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MIDDLE EAST TECHNICAL UNIVERSITY
CHEMICAL ENGINEERING DEPARTMENT
ChE 418
CHEMICAL ENGINEERING DESIGN I
FINAL REPORT
SUBMITTED BY: GROUP I
Yousef Alsharif
lkin Aliyev
Kanan Atakyev
Fariyaz Rustamov
SUBMITTED TO: Prof.Dr.HAYRETTN YCEL
Assist. MERVE INAR AKKU
DATE OF SUBMISSION: 21.05.2014
TABLE OF CONTENTS
Abstract
Table of Contents
List of Tables
List of Figures
Nomenclature
1. Introduction
2. Design Basis
3. Process Flow Diagram
4. Process Description
5. Pipeline Design
6. Plant Layout
13
7. Equipment Design
14
8. Economic Evaluation
24
9. Discussion
28
10. Conclusion
32
11. References
33
12. Appendices
34
12.1. Physical and Chemical Properties
34
12.2. Equilibrium restriction for DME synthesis
35
12.3. Safety Considerations
36
12.4. Sustainability Considerations
41
12.5. Material and Energy Balance Calculations
43
12.6. Equipment Design for reactor
50
12.7. Cost Calculations and Equipment Cost Data
75
Abstract
In this report, design of a dimethyl ether production plant is done by considering, raw materials to use,
equipment specifications, utilities needed, economic analysis and safety issues. It is supposed to provide
the plant with 60000 metric tons of methanol as a feed. Methanol dehydration reaction is known to be a
catalytic reaction so a packed bed reactor with aluminum silicate as a catalyst is used. The process starts
by pre-heating the methanol feed up to the boiling point then re-heat up to 250 0C and sent to the reactor.
The feed is given as liquid methanol with 99.5% wt. methanol. Since the methanol dehydration reaction is
an exothermic reaction, the temperature in the reactor increases up to 365.5 0C approximately to give 80%
conversion. Finally the exit stream of the reactor is sent to separation towers in order to get the desired
product (DME) with 99.7 % wt.
Feed preparation for the DME separation column is handled at temperature of 90.7 0C and pressure of
10.4 bars by using condenser with a heat duty of 10274.8 MJ/hr. Amount of feed to the DME separation
column is 282 kmol/hr. In DME separation column, 99.6 mole percent of DME is achieved in a top
product stream. In order to have such a high purified product, 8 trays and a reboiler are used with an
efficiency of 39%. Number of trays is found 7 by ChemCad simulation that confirms the result. Tray
spacing is calculated as 0.762 m by using data from ChemCad simulation. In methanol separation column
99.5 mole percent of methanol is achieved in a top product stream that is sent through a recycle stream as
a feed to the reactor. In order to have such a high purified methanol, 27 trays and a reboiler are used with
an efficiency of 91.5%. Also, methanol separation column is simulated by using ChemCad that gave the
same number of trays as a result. Also, tray spacing is calculated as 0.6 m by using data from ChemCad
simulation and finally the height of the column was determined as 18.9 m.
Economic evaluation analysis for the preliminary DME production plant design is carried out to
estimate the feasibility of the plant. At the very beginning of this analysis, total fixed capital and working
capital investments are estimated as 5,460,980 and 17,289,470$ respectively that gives a total
manufacturing capital of 22,750,450$. Then the total manufacturing cost is estimated as 30,807,022$.
Throughout these economic analyses the percentage net return on investment is estimated as 27%, 21.6%
and16.2% for 100%, 80% and 60% production capacities respectively. Finally the rate on investment
(ROI) is found as 27%.
List of Tables
Table 2.1: Design basis for the dimethyl ether production

Table 7.1. Equipment Schedule Sheet
Table 8.1: Manufacturing Capital

Table 8.2: Non-Manufacturing Capital Investment
Table 8.3: Manufacturng Cost Sheet
Table 8.4: Estimate Of Annual Earnings & Return
Table 12.1.1: Reaction conditions for DME synthesis
Table 12.1.2: Physical properties of DME
Table 12.5.1: Composition of feed and product
Table 12.5.2.1: Amount of each species in each stream
Table 12.5.2.3: Explanation of symbols that used in diagram
Table 12.5.2.4: Molar flow rates of each stream
Table 12.6.1: Parameters and its values
Table 12.6.2: Description of the first heat exchanger streams and their temperatures
Table 12.6.3: Description of the second heat exchanger streams and their temperatures
List of Figures
Figure 1.1: Methods of production
Figure 3.1: Flow diagram of DME production.
Figure 12.2.1 Stoichiometric equilibrium conversion of DME and methanol synthesis
Figure 12.5.1: Input- output diagram of the plant
Figure 12.5.2.2: Diagram of the reactor
Figure 12.5.2.3: Flow diagram of feed preparation
Figure 12.6.1: CHEMCAD simulation for the feed preparation.
Figure 12.6.2: Schematic draw of the first heat exchanger
Figure 12.6.3: Schematic draw of the second heat exchanger
Figure 12.6.4 : Block diagram for the DME Tower
Figure 12.6.5.Gillilan correlation (1968 , McGraw-Hill)
NOMENCLATURE
Symbols
Definition
Area
Concentration of Species i
Heat Capacity
Diameter
Nominal Inside Diameter
Overall Column Efficiency
Correction factor
Molar flow rate of species i
Liquid-Vapor Flow Factor
Height
Heat of Vaporization
Heat of Reaction
Specific Reaction Rate
Length
Mass Flow Rate

Moleculer Weight of Species i
Number of Stages
Molar Flow Rate

Pressure
Feed condition (liquid ratio)

Heat Duty
Volumetric Flow Rate

Ideal Gas Constant
R
Rmin
Reflux Ratio
Minimum Reflux Ratio
Rate of Reaction
Residence Time
Temperature
Temperature Difference
Log-mean Temperature
Overall Heat Transfer Coefficient
Volume
Catalyst Weight
Drive Power
Shaft Power
Conversion
Greek Symbols
Relative Volatility
Viscosity
Liquid Density
Vapor Density
Flooding Velocity
Overall Efficiency
Drive Efficiency
Shaft Efficiency
ii
1. INTRODUCTION
The production of high purity DME became one of the most important issues of the world
industry in recent years. The reason of increasing demand to DME is its potential as a clean fuel
for diesel engines due to its higher combustion quality, lower concentration of particulates and
mono-nitrogen oxides in emission, low engine noise, high fuel economy and high efficiency [6].
There are two main methods of DME production; an indirect synthetic method using the
dehydration reaction of methanol, and a direct synthetic method from natural gas, coal bed
methane and synthetic gas made from coal, biomass and so on as shown in Figure1.1.
Figure 1.1
Although, both methods are available, indirect synthetic method is preferred more widely
due to its simple process and relatively low startup cost. Methanol dehydration reaction shown
below is used in this process.
2 CH3OH
CH3-O-CH3 + H2O
In order to perform this reaction aluminum silicate catalyst is used. Between 250- 400 C it is
suitable for reaction in terms of catalyst activity temperature and side reactions. Conditions in the
reactor must provide these conditions. It is an exothermic reaction which results in increase of
temperature in adiabatic tubular catalyst reactor.
In order to design process for indirect method of dimethyl ether (DME) production from
methanol, certain steps should be considered. Generally process design should be started with
the determination of design basis and then encompass desired production rate, product
composition are decided. Overall material and energy balances are performed by referring predetermined design basis information. Overall process could be briefly generalized by four steps;
feed preparation, reactor, DME separation and methanol separation. In the first part, aim is to
bring the inlet stream of reactor to the desired conditions in terms of temperature, pressure and
phase of reactants by using a tank, pumps and heat exchangers. In the reactor, reaction takes
place and the desired conversion should be achieved. After the reactor distillation columns are
used to obtain desired product.
2. DESIGN BASIS
Table 2.1: Design basis for the dimethyl ether production
Feed: Methanol
Purity (wt %) (rest is water)
99.5
Product: Dimethyl ether

Purity ,wt % balance is methanol
99.7
Capacity of the plant

Methanol feed rate, mt/year
60 000
Stream time, h/year
8320
Utilities Available
Steam
High Pressure Steam (sat), bar g.
40
Medium Pressure Steam (sat), bar g.
10
Low Pressure Steam (sat), bar g.
Cooling Water
Available Cooling Water Tower max. values
4 bar, 25 C
CW Return max. Values
1.8 bar, 40 C
Fuel
Natural gas
Electricity
All voltages and phases are suitable

for electric drives.
Materials Handling
Methanol
Delivered by pipe to battery limits

and stored
Dimethyl ether
Stores
3. PROCESS FLOW DIAGRAM OF DIMETHYL ETHER PRODUCTION BY METHANOL DEHYDRATION
Figure 3.1: Flow diagram of DME production.
Process flow diagram given in Figure 2.1 displays DME production, feed preparation with preheater
and heat exchanger for the reactor and two separation towers which are simulated with ChemCad
v6.3.1. For the sake of simplicity the reboiler and condenser are embedded in to towers.
4. PROCESS DESCRIPTION
Plant that is considered to be designed, has a capacity to use 60,000 metric tons of DME as a feed per
year. Production method is catalytic dehydration of methanol over an acid zeolite catalyst. A packed
bed reactor (R-201) which is filled with solid catalyst particles is used to produce dimethyl ether.
Fresh methanol, Stream 1, is combined with recycled reactant, Stream 13, and pre-heated by the first
heat exchanger (E-201).Then this mixture is vaporized by the second heat exchanger, E-202, prior to
being sent to a fixed-bed reactor (R-201) operating between 250C and 370C. The stream leaving
reactor, Stream 7, is then cooled (E-203) prior to being sent to the first of two distillation columns: T201 and T-202. DME product is taken overhead from the first column (Stream 10). The second column
separates the water from the unused methanol. The methanol, Stream 13, is recycled back to the front
end of the process, and the water is sent to wastewater treatment to remove trace amounts of organic
compounds.
5. PIPELINE DESIGN
In order to find the optimum pipe diameter following equations were used.
For turbulent flow in steel pipes, (NR>2100)
Di 1 in
Di,opt = 3.9 (qf0.49)*( 0.13)
Di < 1 in
Di,opt = 4.7 (qf0.49)*( 0.14)
For viscous flow in steel pipes, (NR <2100)
Di 1 in
Di,opt = 3.0 (qf0.36) * (0.18)
Di < 1 in
Di,opt = 3.6 (qf0.4) * (0.2)
= fluid density b/ft3
qf = fluid flow rate ft3/s

= fluid viscosity lb/ft.s
Pipeline for Stream: 1
Assume that pipe diameter is greater than 1 in and turbulent flow.
49
=317
= 0.000363
= 2.17 in
=0.2144
=
= 5273 >>> 2100
Nominal size of pipe, in =1/8 Schedule no= 40 , Wall thickness, in = 0.068

Pipeline for Stream 2:

49.343
=317.875
= 0.00036
=
=0.2145
=
= 5266 >>> 2100

Pipeline for Stream : 3

43.52
=396
= 0.00016
=
7
=
=
= 12078>>> 2100
Pipeline for stream:4

0.736
=396
= 1.18*10^-5
=1.388
=
=
= 4732 >>> 2100

0.5549
=421
= 1.36*10^-5
= 1.375in
=0.708
=
= 3314 >>> 2100

0.651
=421
= 1.19*10^-5
=1.404 in
8
=
=
= 4354 >>> 2100
Assume that pipe diameter is greater than 1 in and laminar flow.

3.75
=421
= 0.000139
=
= 0.431
=
= 1709 <<< 2100

47.35
=151
= 0.00012
=1.546 in
=0.2012
=
= 10199 >>> 2100

1.31
=270
= 7.03*10^-5
= 1.26 in
= 0.541
10
= 1063 <<< 2100

0.98
=396
= 9.72*10^-6
=
=
=
= 7377 >>> 2100
11

55
=73
= 9.92*10^-5
= 1.136in =
=0.1799
=
= 9457 >>> 2100

0.677
=78
= 9.28*10^-6
= 0.66in
= 0.568
=
= 2286 >>> 2100

2.48
= 421
= 0.000158
= 1.67in
= 0.48
=
= 1048 <<< 2100
12
6. Layout (Plot Plan)
13
7.1. EQUIPMENT SCHEDULE
Table 7.1. Equipment Schedule Sheet
Item No.
No.
Required
of Equipment Name
Size(Each)
V-101
Methanol Storage Tank
73.01 m3
V-102
Methanol Feed Drum
7.64 m3
V-103
DME Reflux Drum
2.15 m3
V-104
DME Storage Tank
61.15 m3
V-105
Methanol Reflux Drum
0.72 m3
P-101A/B
Methanol Feed Pump
9.48 kw
P-102 A/B
DME Tower Pump
2.16 kw
P-103 A/B
Methanol Tower Pump
8.10 kw
R-101
Reactor
4.8 m3
E-101
Reactor Preparation Preheater
85 m2
E-102
Reactor Preparation Heater
153.2 m2
E-103
Separator Feed Prep. Condenser
26.3 m2
E-104
DME Tower Condenser
122 m2
E-105
DME Tower Reboiler
30.16 m2
E-106
Methanol Tower Condenser
12.68 m2
E-107
Methanol Tower Reboiler
14.88 m2
E-108
Waste Water Cooler
43.6 m2
T-109
DME Distillation Tower
8.36 m3
T-110
Methanol Distillation Tower
25.26 m3
14
SIEVE TRAY COLUMN SPECIFICATION SHEET

Page 1 of 3
Item No.
Name
:
:
T-101
By
DME Separation Column
: Group I
Date:
20-03-2014
Number Required :
Function:
DME Purification
Reboiler
Material Balance:
Feed
Overhead
Bottoms
Reflux
Vapor
Phase, % vapor
30% vapor Vapor (100%)
Liquid (0%)
kg/h
mol/h
281000
112000
169500
Mean MW.
Operating Conditions:
Top
Feed Plate
Bottom
Temperature, C
47.7
90.7
152
Pressure, bar
10.4
10.4
10.4
Reflux & Stage Calculation:

Method of Calculation
Gilliland correlation (Wankat,2011)
Minimum equilibrium stages (inc. reboiler)

Minimum reflux ratiol (L/D)
0.202
Operating reflux ratio
0.755
Feed, % vapor
30% vapor
Req'd equilibrium stages at oper. reflux

7 stages (chemcad simulation)
(inc. reboiler )
Above feed
Below feed
Total
7 stages
15
Est. Overall plate efficiency, %
0.39
Calculated plates
9 stages
Page 2 of 2
Column Design:
Materials of construction
Column Shell
Trays
Internal diameter, cm
61
Normal tray spacing, cm
61
Feed tray numbers:

Normal
Optional
Column height
(N-1) tray spacings
(9-1)*0.61m=4.88 m
Disengagement space above top plate, m

Extra space at feed trays
Normal sump height
Disengagement space above sump
Skirt height
Total column height,m
Vessel design temp., C
Vessel design press., barg.
Wall thickness, cm
Includes corrosion allow., cm
Insulation required (Yes or No)
Tray Design:
Trav type
16
Tower ID to fit, m
Total tower cross-section area, m
Normal tray spacing, m

Number liquid passes
Perforations :
Hole diameter, cm
Total hole area per tray, m
Overflow weir height, cm

Downcomer apron clearance, cm
Downcomer location (Side or Center)
Side downcomer each
Center downcomer total
Overflow weir lengths, cm
Side downcomer each
Center downcomer each
Areas, m
Downcomer, each pass

Downcomer, total
Downcomer, % of tower
Net tower area
Tray active area

Hole area/active area
Weir length/tower diameter
(for side downcomer)
Downcomer width/tower diameter
Page 3 of 3
Tray Dynamics Calculations :
Top Tray
Bottom Tray
Pressure, bar g.
Temperature, C
Loading:
Vapor load,
kg/hr
17
m /h
Liquid Ioad, kg/h
3
m /h
L/V ratio, kg/kg
Properties :
Vapor density, kg/m
Liquid density, kg/m
Liquid surface tens., N/m

Liquid visc., cp.
Load Factors
FLV
LW
VW
V
L
Kl, chart ( = 20 )
K, flood (with = )
Pressure drop:
Per tray, cm liquid
barg.
Total, for column, cm liquid
Flooding criteria:
Actual Uf, cm/s
Flood Uf, cm/s
% vapor flooding
Entrainment ratio (liquid):
= kg entrain/kg downflow
Weep point:
Weep Uf, cm/s
Actual Uf, cm/s
Weep Uf, % actual
Mise. dynamic factors
Liquid crest over weir, cm
Liquid gradient
Mean height of froth, cm
18
Downcomer capacity:
Height clear liquid in downcomer,cm
Height froth (Assume =0.5), cm
% downcomer floor
Downcomer residence time, s (min.=3 sec)
Ratio, min./actual res.time
SIEVE TRAY COLUMN SPECIFICATION SHEET

Page 1 of 3
Item No.
Name
:
:
T-102
By
Methanol Separation Column
: Group I
Date:
20-03-2014
Number Required :
Function:
Methanol Recycling
Reboiler
Material Balance:
Feed
Overhead
Bottoms
Reflux
Vapor
Phase, % vapor
Liquid
(0%vapor)
Vapor (100%)
Liquid (0%)
169500
55000
114500
kg/h
mol/h
Mean MW.
Operating Conditions:
Top
Feed Plate
Bottom
Temperature, C
152
139
181
Pressure, bar
10.4
10.4
10.4
Reflux & Stage Calculation:
McCabe-Thiele method
Method of Calculation
Minimum equilibrium stages (inc. reboiler)
Minimum reflux ratiol (L/D)
1.251
19
Operating reflux ratio
1.251
Feed, % vapor
Liquid (0% vapor)
Req'd equilibrium stages at oper. reflux

28 stages
(inc. reboiler )
Above feed
23
Below feed
Total
28
Est. Overall plate efficiency, %
91.5
Calculated plates
27 + reboiler
Page 2 of 2
Column Design:
Materials of construction
Column Shell
Trays
Internal diameter, cm
61
Normal tray spacing, cm
61
Feed tray numbers:

Normal
23
Optional
23
Column height
(N-1) tray spacings
(28-1)*0.61m= 16.47m
Disengagement space above top plate, m

Extra space at feed trays
Normal sump height
Disengagement space above sump
Skirt height
Total column height,m
Vessel design temp., C
20
Vessel design press., barg.

Wall thickness, cm
Includes corrosion allow., cm
Insulation required (Yes or No)
Tray Design:
Trav type
Tower ID to fit, m
Total tower cross-section area, m
Normal tray spacing, m

Number liquid passes
Perforations :
Hole diameter, cm
Total hole area per tray, m
Overflow weir height, cm

Downcomer apron clearance, cm
Downcomer location (Side or Center)
Side downcomer each
Center downcomer total
Overflow weir lengths, cm
Side downcomer each
Center downcomer each
Areas, m
Downcomer, each pass

Downcomer, total
Downcomer, % of tower
Net tower area
Tray active area

Hole area/active area
Weir length/tower diameter
(for side downcomer)
Downcomer width/tower diameter
21
Page 3 of 3
Tray Dynamics Calculations :
Top Tray
Bottom Tray
Pressure, bar g.
Temperature, C
Loading:
Vapor load,
kg/hr
3
m /h
Liquid Ioad, kg/h
3
m /h
L/V ratio, kg/kg
Properties :
Vapor density, kg/m
Liquid density, kg/m
Liquid surface tens., N/m

Liquid visc., cp.
Load Factors
FLV
LW
VW
V
L
Kl, chart ( = 20 )
K, flood (with = )
Pressure drop:
Per tray, cm liquid
barg.
Total, for column, cm liquid
Flooding criteria:
Actual Uf, cm/s
Flood Uf, cm/s
% vapor flooding
Entrainment ratio (liquid):
= kg entrain/kg downflow
Weep point:
Weep Uf, cm/s
22
Actual Uf, cm/s

Weep Uf, % actual
Mise. dynamic factors
Liquid crest over weir, cm
Liquid gradient
Mean height of froth, cm
Downcomer capacity:
Height clear liquid in downcomer,cm
Height froth (Assume =0.5), cm
% downcomer floor
Downcomer residence time, s (min.=3 sec)
Ratio, min./actual res.time
23
8. Economic Evaluation
Estimate Of Capital Requirements
Table 8.1: Manufacturing Capital
I. Manufacturing Capital
Item
Equipment Name
No.
No.
Reqd.
Total
Cost ($)
3
1
1
3
1
435000
9130
4920
375000
22303
27700
16745
1
1
1
25300
15300
15500
15600
E-108
METHANOL STORAGE TANK

DME REFLUX DRUM
METHANOL REFLUX DRUM
DME STORAGE TANK
REACTOR PREPERATION
PREHEATER
REACTOR PREPERATION
HEATER
SEPERATOR FEED
PREPERATION CONDENSER
DME TOWER CONDENSER
DME TOWER REBOILER
METHANOL TOWER
CONDENSER
METHANOL TOWER
REBOILER
WASTE WATER COOLER
18500
P-201
P-202
P-203
FEED PUMP
DME REFLUX PUMP
METHANOL REFLUX PUMP
1
1
1
17946
2564
3462
T-101
DME TOWER
10700
T-102
METHANOL TOWER
35000
7376
1058046
V-101
V-102
V-103
V-104
E-101
E-102
E-103
E-104
E-105
E-106
E-107
R-201 REACTOR
Total Process Equipment
Total Mfg. Capital
Based on Lang Factor = 4
Contingency at 10%
4232184
423218
24
Table 8.2: Non-Manufacturing Capital Investment
II. Non-Manufacturing Capital Investment
Proportionate share existing capital

estimated at 25 % mfg. cap.
III. Total Fixed Capital Investment
Sum of I & II
IV. Working Capital

Raw Material Inventory
Goods in Process
Finished Product Inventory
Stores Supplies
All other Items
Total Working Capital
V. Total Fixed & Working Capital Investment
Sum of III & IV
Total
Cost ($)
1058046
5460980
13826504
(included in utilities)
42865000
12696
4286500
17289470
22750450
25
Table 8.3: Manufacturng Cost Sheet
Manufacturng Cost Sheet

LOCATION: ZMT
Design: DME Plant per Yr. (8320 h)
Mfg. Capital: 3222313 $
UNIT
QUANTIT
Y
$/UNIT
$/YEAR
$/kgDME
Methanol
mt
60000
220
13200000
0.3081
Catalyst
mt
3.12
18000
56160
0.00131
13256160
0.3094
56160
0.0013
RAW MATERIALS
GROSS R.M. COST

NET MATERIAL COST
QUANTIT
Y
$/UNIT
$/YEAR
$/kg
Mt
61243.5
14
857409
0.020
Steam (hps)
Mt
37681.3
16.5
621742
0.146
Steam (lps)
Mt
1141728.6
12.5
14271608
0.334
Electricity
kWh
164236.8
0.11
18066.05
0.0003
Cooling Water
1000 m3
23384
0.00055
15792209
0.5
Labor
380160
0.0063
Supervision
192000
0.0032
200256
0.0033
253931
0.0059
84643
0.0019
DIRECT EXPENSE
UNIT
Steam (mps)
1558.9
15
TOTAL UTILITIES
Payroll Charges
(35%Labor and supervision)
Repairs (6% of Mfg. Cap/year)

Product Control
Factory supplies
(2% of Mfg. Cap/year)
Laboratory
26
Technical service
Royalty
Depreciation
( 8% of Mfg. Cap/year)
338574
0.0079
Factory Indirect Expense
( 4% of Mfg. Cap/year)
169287
0.0039
TOTAL MANUFACTURING COST
0.721
Table 8.4: Estmate Of Annual Earnings & Return
Estmate Of Annual Earnings & Return

Production at % of Capacity
60%
80%
100%
Annual Production Rate, ton/yr
25719
34292
42865
DME Sales Price, $/mt
1000
1000
1000
Gross Sales Income
25719
34292000
42865000
Manufacturing Cost
18484213
24645618
Gross Profit
7234787
9646382
Sare Expenses at 10% Sales
2571900
3429200
Net Income Before Income Taxes
4662887
6217182
7771478
Income Taxes at 20% Net Income
932577
1243436
1554295
Net Annual Earning
3730310
4973746
6217183
13650270
18200360
22,750,450
16.2%
21.6%
27 %
I. Gross Sales
II. Less Manufacturing Cost
III. Less SARE
IV. Less Income Taxes
V. Return on Total Investment

Total Fixed & Working Capital
% Net Return on Investment
27
9. Discussion
The objective of this study is to make preliminary design for a plant which produces DME by
using 60,000,000 kg /year methyl alcohol with 99.5 % purity, used as start point for material
balance in the process.and with a stream time of 8320 h/year. In order to achieve this aim, one
reactor, two distillation towers with condensers and reboilers, four heat exchangers, three
pumps, 2 drums, 6 storage tanks are designed. While equipment necessary for the process is
designed, material and energy balance, design heuristics and Chemcad simulation are used.
Indirect method, that is, dehydration of methanol is used in this plant to produce DME.
Methanol needed for the process is bought as raw material whose purity is 99.5 %wt. Silica
alumina is used as catalysis in this process. The aim is defined as DME production with purity of
99.7 %wt . Natural gas is used as fuel. To begin with, horizontal arrangement is preferred for
streams in liquid phase. While energy balance is performed around the drum, heat of mixing is
neglected due to the fact that it is expected to be low compared to the flow enthalpies.
Secondly, pumps are designed according to heuristic to be able to calculate power consumed
both for shaft and driver work. While pumps are designed efficiency is determined by
considering volumetric flow rate and pressure difference around pump according to flow
diagram is used in calculation. For pump, shaft work is found as 8.17 kW and efficiency is found
as 0.45. Spare must be considered for all three pumps so two pumps are provided for each
pumping purpose. While reactor is being designed, expected conversion which is 0.8 is
considered at first. According to conversion and needed production rate, material balance
around reactor is performed. In addition, energy balance around reactor is conducted and it is
assumed that reactor is adiabatic. Temperature calculation gives us outlet temperature of
reactor as 365.5 0C. Since the chosen catalyst is deactivating above 4000C, calculated outlet
temperature is considered to be in appropriate range. In addition, it is a significant point that in
working temperature range silica alumina is active. While performing material balance feed is
assumed as pure methanol. It is a
reasonable assumption since water entering reactor is negligible with respect to
methanol. Furthermore, in the recycle stream only methanol exists. Considering volume value
of different types of reactor packed bed reactor is more advantageous to use in this process.
28
Silica alumina is an effective catalyst for dehydration reaction of methanol so it is chosen as

catalyst. Weight of catalyst is calculated as 3350 kg.
Reactor volume is estimated as 4.8 m3. In this calculated volume, expected conversion which is
about 0.8 can be achieved.By using calculated volume and cross sectional area values, length of
reactor can also be found. Furthermore, thickness of the reactor is calculated as 1.04 cm and
construction material of reactor is chosen as carbon steel. Working pressure of reactor and
maximum allowable stress of the material are considered while determining the thickness and
material of the reactor. In order to make feed ready to enter the reactor, it must be heated
since methanol is stored at 45C. To achieve this aim, a preheater is designed whose function is
to heat
methanol from 45 C to 154 C. Steam is preferred as heating medium. After that, another heat
exchanger is designed to rise the temperature of methanol from 154 C to 250 C where reactor
effluent is used as heating medium, so that, steam does not needed for this heat exchanger. As
a result, it can be mentioned as beneficial for economic aspect. At the e it of this heat
exchanger, reactor effluent is obtained at 260 C. Therefore, cooling of reactor effluent to 100 C
for the entrance of separation unit is also made easier and less cooling water is required than it
would be if no heat integration is used. Cooling water is available at 25 C so cooling medium is
fed to exchanger at 25 C. Maximum allowable temperature to which cooling water can be
reached is 40 C so e it temperature of cooling medium is fixed at 40 C. In addition, another heat
exchanger is needed to cool waste water for environmental aspects. While heat transfer area
calculations are conducted, overall heat transfer coefficients are determined with respect to
nature of process. In order to obtain DME as a product from rector effluent, DME separation
tower is designed. In addition, separation of methanol from water methanol mixture is
necessary to recycle methanol to reactor. Hence, methanol separation tower is designed. Sieve
trays are used for economic purposes. Furthermore, R/Rmin is chosen as 1.3 by taking into
consideration design heuristics and economic aspects. In addition for both columns flooding
and weeping are checked and it is seen that there is no such a risk. First of all, DME-Methanol
tower is designed by using Chemcad simulation program. Because there are three components
in the first column, hand calculation is difficult to conduct. At first short cut method is used and
then some information is derived from that simulation. SCDS simulation method is used with
the help of short cut column simulation results. Chemcad simulation gives ideal number of
29
stages as 7 and bu hand calculation is found 9. In order to obtain actual number of stage
overall efficiency is calculated by using Gilliland correlation. Overall efficiency and actual
number of stages are found as 42.8 % and 21 respectively. Moreover, minimum number of
stages and feed point location are determined by hand calculation for first column. The results
are found as 5 and 4 stages respectively which are close to each other. Feed enters the tower
from the middle of the tower. Secondly, methanol and water mixture which is bottom product
of first column is fed to the second tower. For this column both hand calculation that is, McCabe-Thiele method, design heuristics, sizing equations and Chemcad simulation are done. It is
neglected that there is a trace amount of DME in the feed of second column. Ideal number of
stages is calculated by using McCabe-Thiele method. Mc-Cabe-Thiele method involves its own
assumptions which are molal over flow, negligible heat loss and it states that for a mole of
vapor which condenses there is a mole of liquid which vaporize. Mc-Cabe-Thiele method gives
28 ideal numbers of stages which is consistent with Chemcad result. Overall efficiency and
actual number of stages are found as 90.3 and 31 respectively. Heuristic revealed at reference
list for column design are used to compute total column height and diameter. It is seen that
both tower height and tower height / diameter ratio are within the safe zone and satisfy design
parameter. Column diameter is calculated by hand as 0.76 m.
Economic analysis is crucial since it is the main factor to determine the success of a project.
Economic analysis reveals the amount of profit under operating condition of a plant. Both
capital investment cost and production cost must be examined for a successful economic
analysis. While economic analysis is being conducted, 2012 September CEPCI values were used
to calculate purchasing cost of the equipment used in DME production plant. Chemcad
program was used to calculate estimate cost of pumps and CapCost software was used for all
other equipment. It is necessary to specify properties of equipment such as volumes, heat
transfer areas, diameters and construction materials to be able to use this program. Moreover,
Lang factor method was used for total manufacturing capital. When working capital is
considered the main aim was to decrease it as much as possible. To satisfy this aim just in time
operation and good planning were provided to the DME production plant. The important
function of just in time operation is to get rid of wasteful activities which increases the working
capital but does not contribute the value of the product. Hence, raw material inventory and
working process inventory were ignored while working capital calculation was done. In
30
addition, heat integration is applied by using reactor effluent to heat feed in the process to
decrease cost of utility. It is effect can be seen by the help of net present value method. If heat
integration was not applied, net present value would be lower. Construction material of
equipment is selected as carbon steel. It is stated that Stainless steel and carbon steel are
typically used in methanol plants. [6]]. However, for long term operations stainless steel is a
better construction material.
DME production preliminary design is analyzed economically according to the net income and
rate of return on investment results in order to ensure the feasibility of the design. The total
manufacturing capital is approximately estimated as 22750450$ that is the summation of total
fixed capital and working capital investments while total manufacturing cost is estimated as
30,807,022$.
The net annual profit is estimated as for 100% capacity working plant. However, as it is known
that in real industries it is impossible to operate a plant with 100% capacity. Therefore, the rate
of return on investment for 60% and 80% are estimated as 16.2% and 21.6% respectively.
Regarding all the calculations required for the economic analysis done in results part, it may
be concluded that producing DME from methanol is quite feasible.
31
10. Conclusion
The aim of the project is to make preliminary design for DME production including economic
analysis. One reactor, two distillation towers with condensers and reboilers, four heat exchangers,
three pumps, two drums and six storage tanks are designed and pipeline is constructed according
to heuristics and main results are summarized in specification sheets. Either material or energy
balance is performed for each equipment. Reactor is designed as a packed bed reactor to carry out
dehydration reaction of methanol. Two of heat exchangers are available to prepare feed before the
entrance of reactor. One of the heat exchangers prepares the reactor effluent for the feed of
separation unit. The function of other exchanger is cooling waste water which appears at the exit
of separation tower. Two pumps are placed to continue the flow of liquids at desired pressure to
separation towers from drums and one of the pumps is placed in order to send methanol to feed
preheater from methanol storage tank. Storage tanks are constructed in the process so as to make
certain amount of feed and product available at any time. Drums exist at the exit of condensers of
both separation towers to keep reflux for a certain time. Pipeline is built between all equipment to
convey materials in a safe way during process. Hence, DME is obtained with purity of 99.7 wt%. The
designed plant aims to use 60,000 metric tons of Methanol, with 99.5 % purity, as a feed per year and
having stream time of 8320 h/year. Finally, economic analysis was performed in order to confirm
the feasibility for DME production preliminary plant design. Total fixed capital investment, working
capital investment, total manufacturing capital and total manufacturing cost were estimated
accordingly. Then, the net annual profit was approximately estimated as 6,217,183$/year with 27%
return on investment when 100% capacity (full) is considered. However, in real life it is impossible
to perform with such capacity. Therefore, rates of return on investment for 60% and 80% are
estimated as 21.6% and 16.2% respectively. To conclude, it is reasonable to move a detailed design
since preliminary design has given acceptable return on investment, according to interest rate in
Turkey.
32
11. References
[1] Timmerhaus, K. D., Peters, M. S. & West R. E. (2003). Plant Design and Economics for
Chemical Engineers, 5th ed. New York: McGraw-Hill.
[2] Sinnot, R.&Towler G.(2009). Chemical Engineering Design, 5th ed. Oxford: Elsevier.
[3] Turton, T., Bailie, R.C, Whiting, W.B. and Shaeiwitz, J.A.,(2009) Analysis, Synthesis and
Economics of Chemical Processes, 3rd ed., New Jersey: Prentice Hall.
[4] Dougles, J.M.., Conceptual Design of Chemical Processes, (1988) New York: McGraw
Hill.
[5]
Seider, W.D.., Seader, J.D..,LewinD.R.(2004) Product and Process Design
Principles,Synthesis, Analysis and Evaluation. 2nded. New York: John Wiley &Sons
[6] Keith O., Trevor C., Cetane Number in Diesel Fuel Automotive Fuels Reference
Book, SAE ISBN 1-56091-589-7 (1995) evergreenamerika.com
[7] Plant Design And Economics For Chemical Engineers, Max S. Peters, Klaus D.
Timmerhaus, Ronald West.,5th edition,2002
[8] Turton, R., Bailie, R. C., & et al, R. C. (2013). Analysis, synthesis, and design of
chemical processes. (4th ed). Upper Saddle River, N.J.: Pearson Education, Inc.
[9] ME: Multi-Use, Multi-Source Low Carbon Fuel nternational DME association,
http://www.aboutdme.org/ (01.12.2012)
[10] Retrieved from http://www.igu.org/html/wgc2006/pdf/paper/add10696.pdf
33
12. Appendices
12.1 Physical and Chemical Properties of methanol and dimethyl ether
DME from synthesis gas (CO+H2)
2CH3OHCH3OCH3+H2O
(Methanol Dehydration Reaction)
The required pressure for DME synthesis reaction and catalyst ratio (W/F) that is defined as the
catalyst weight (kg) to the reactant gas flow rate (kg.mole/h) are shown in the below table,
Table 12.1.1. Reaction conditions for DME synthesis
0
Reaction condition Temperature ( C ) Pressure ( Mpa )Fed syn-gas(H2/CO) ratioW/F ((kg.h)/kg)
Experimental
240 - 280
3.0 - 7.0
0.5 - 2.0
3.0 - 8.0
Standard
260
5
1
4
Physical properties of dimethyl ether.

Table 12.1.2. Physical properties of DME
Properties
Dimethyl
ether
Chemical formula
CH3OCH3
Boiling point (K)
247.9
Liquid density (K)
0.67
Specific gravity
1.59
Vapor pressure (atm)
6.1
Heat of vaporization (kJ/kg)
467
Igntion temperature ( K)
623
Cetane number
Net calorific value (106J/kg)
55 - 60
28.9
34
12.2 Equilibrium restriction for DME synthesis

Since it is known that methanol synthesis reaction is an equilibrium restricted reaction, in other
words; the equilibrium conversion of synthesis gas (CO+H2) is strongly affected by pressure,
temperature and stoichiometric ratio [H2/CO] as can be seen in the figure 1.2.1
Figure 12.2.1 Stoichiometric equilibrium conversion of DME and methanol synthesis
35
12.3: SAFETY CONSIDERATIONS

Safety is the control of recognized hazards to achieve an acceptable level of risk. It includes the
inherent safety, hazards and operability analysis
(HAZOP), material hazards and fire
protection. This can take the form of being protected from the something that causes health or
economical losses. The design process is based on the material, fire protection and explosion
considering plant, unit layout, storage tanks, distillation towers, reactors and piping system. In
order to process operation friendly and economic, process requirements, environmental
regulations, location and process materials should be taken consideration. Furthermore, so as
to provide good plant operating written instruction in the use of substances and the risk
involves. [8]The adequate training of personnel should be provided about devices and plant
operations. Protective clothing should be supported personnel. Also, housekeeping and
personal hygiene should be checked regularly. Regular medical checkups on employees and
chronic effects of materials should be considered. Preventative and total productive
maintenance strategy should be applied to equipment. Moreover emergency trainings should
be done regularly. Steam traps and security valves should be equipped especially when
handling high pressure steam. [8] Another important consideration is shipping regulations of
DME. The detailed information is given below.
Shipping regulations
Proper shipping name: Dimethyl ether
Hazard class number: 2.1 (Flammable gas)
UN identification number: UN 1033
Packing group: p 200
36
Dot labels required: Flammable gas
Marine pollutant: DME is not classified as a marine pollutant
DME packages: Packages should be implemented in reusable/returnable pressure containers

which have the following properties:
o Steel cylinders (70 100 Ibs)
o Tank trucks (30,000 35,000 Ibs)
o Tank cars (100,000 + Ibs)
Transport on vehicles where load space is not separated from the drivers compartment should
be avoided. Vehicle driver should be aware of the potential hazards of load and should know
what to do in the event of an accident or an emergency. Before transporting DME containers
should be firmly secure. Cylinder valve should be checked to be closed and not leaking. Valve
protection device must be correctly fitted. Adequate ventilation must be provided. Applicable
regulations should be complied [9]. Under the process hazard analysis requirement, it should
be completed that one of the analysis techniques listed:
o What if
o Checklist
37
o FMEA
o FTA
o HAZOP
HAZOP is chosen for this design as the process hazard analysis method since it is the most
widely used method in the chemical process industries.
38
15.3. HAZOP STUDY
Table 15.1. Hazop Study for Reactor

Guide Word
Deviation
Cause
Consequences
Action
No
No flow
-Blockage in line
-Decrease in production rate

until no production
-Cleaning of lines
-No methanol in storage tank
-Level control system
-Feed pipe rupture
-Maintenance of pipes
-Supply pipe rupture
-Automatic valve
-Valve is closed
-Automatic pump
-Pump is closed
More of
Higher flow at reactor entrance

and feed
-More amount of opening of valve
-Lower temperature in feed to

the reactor
-Automatic valve
-Explosion
-Check reactor conditions

(Catalyst
efficiency,
temperature, pressure)
-Low conversion in previous pass

-Increase in quantity of
methanol in recycle stream
Less of
Less rate of flow at entrance and

feed
-Less amount of opening of valve
-Low product rate
-Automatic valve
-Low recovery of methanol in

methanol tower
-Higher temperature in feed to

reactor
-Temperature control
reactor feed preparation
at
39
As well as
-Impurities in feed stream
-Problems in raw material
-Low conversion rates
-Water in recycle system
-Fouling in pipes
-Decrease
product
in
quality
of
-Quality control of raw

material and product
- Maintenance of pipes
-Impurities mix with feed

stream to reactor
Part of
-Higher methanol fraction
-High quality of feed
-Less methanol fraction
-Less quality of feed
-More pure DME production

than intended
- Quality control of feed

stream and product
-Less pure DME production

than intended
Reverse
-Reverse of flow
-No probable cause
-Decrease in production rate

until no production
-Consider interlock in feed

stream
Other than
-Liquid raw material replaced

phase feed
-Wrong connection during plant

modification
-Explosion
-Better management
change procedure
of
40
12.4: SUSTAINABILITY CONSIDERATIONS

Sustainability is an important consideration for chemical plants and industry. Everything that we
need for our survival and well-being depends, either directly or indirectly, on our natural
environment. Sustainability creates and maintains the conditions under which humans and nature can
exist in productive harmony, that permit fulfilling the social, economic and other requirements of
present and future generations. Sustainability is important to making sure that we have and will
continue to have, the water, materials, and resources to protect human health and our environment. [2]
For these reasons, plants and companies are asked to report their pollution prevent activities with the
waste management hierarchy with the steps which are: (from most to the least desirable) [10]
1. Source reduction
2. In-process recycle
3. On-site recycle
4. Off-site recycle
5. Waste treatment
6. Secure disposal
7. Release to environment
There are some physical properties which has influence on environmental pollutions. They are
melting point, boiling point, vapor pressure, Henrys law constant, Octanol-water partition
coefficient, water solubility, soil sorption coefficient, bio-concentration factor.
[10]
The most
important issues while trying to reduce the impact on environment while designing chemical plant
are to minimize generation of waste product from reactor, design separation systems for maximum
recovery and minimum energy usage, minimize effluent streams containing waste, minimize leaks
during the storage and transfer operations.
[10]
Unreacted raw materials need to be separated and
recycled. It helps not to put extra chemicals to environment while it is reducing the cost. If they were
not recycled, they will lead subsequent reaction, emission or combustion all of which are
undesirable.
[10]
In the production of DME, there is a recycle from the reactor for unreacted
materials.
39
Heat integration is another important issue to be considered from the environmental point of view
since heating and cooling operations release extra carbon dioxide to the environment. It is important
since extra energy consumption is a disadvantage for both environment and economics.
[10]
Heat
integration is done also for the process of DME.

Another important issue is about the separation units. Since no perfect separation exists, there are
always trace contaminants in any pure stream. The aim of pollution preventing is to minimize these
trace contaminants.
[10]
In DME production, 2 separation column is used. In distillation extra trace
contaminants do not exist. However, it requires heating and cooling both of which gives carbon
dioxide to environment. Thus, distillation columns need to be designed such that they use minimum
energy for heating and cooling. The heat integration of boilers and condensers are also done in DME
production design.
Another issue is the storage tanks which introduce the emission problem. If there are volatile liquids
in storage tanks there will be a vapor which is in equilibrium with it liquid. When liquid is pumped
through these tanks from the bottom, there will be an elevation of liquid. The vapor of volatile
material needs to be collected and recycled to the tanker truck which provides liquid to the tank. The
ventilation of vapor to the atmosphere is a wrong action the take.
[10]
There are storage tanks of
methanol and DME as volatile liquid storages. Boiling points for methanol and DME are 337.6 and
247.9 in Kelvin, respectively. They are volatile liquids. Thus, the emission of them needs to be
considered as explained above.
Finally, there is a product of waste water inside DME production process. That waste water
contains methanol since before it is collected there is a separation column. As it is stated before
there is no perfect separation. Thus, that waste water from the second separation unit will contain
trace amount of methanol in it. In the overall calculations it is neglected since it is a preliminary
design. However, in real operations there will be trace amount of alcohol in it. It is wrong to release
it to the environment directly. There needs to be a waste water treatment unit. After the waste
water treatment that clean water can be used for other purposes in plant.
40
12.5 : Material and Energy Balance Calculations
OVERALL MATERIAL BALANCE

12.5.1 Input-Output Diagram of the Plant
Product
OVERALL
Feed
PROCESS
Water
C
Figure 12.5.1: Input- output diagram of the plant
The symbols on the diagram show the total mass flow rate of feed, product and byproduct water.
Compositions of these are given in table 4.1.1 and 4.1.2.
Table 12.5.1 Composition of feed and product
Feed- A
Species
Compositon
Methanol
99.50%
Water
0.50%
Product -B
Species
Compositon
Methanol
0.30%
DME
99.70%
41
12.5.2 Overall Material Balances

The calculations are made based on process design basis. Overall process is selected as a
system and amount of methanol is selected as basis to make material balance calculations.
System: Overall Process
Basis: 60000 mt/year of methanol as feed (A)
Overall material balance:
A=B+C
Material balance on specie A :
(
Two equations and two unknowns (B & C)

Using above equations for B and :
B = 43002 mt/year
C = 16998 mt/year
Mass flow rates are converted from mt/year to kmol/h using stream time which is 8320h/year to be
used in simulation of the overall process in ChemCad. Results are shown in table 4.2.1. Molecular
weight of methanol is 32 ton/tmol and 46 ton/tmol for DME.
Table 12.5.2.1: Amount of each species in each stream
Feed
Species
Methanol
Water
Product
Methanol
DME
Waste Water
Water
Flow
rate(kmol/h)
224.2
2
0.485
112
113.2
42
MATERIAL AND ENERGY BALANCES FOR REACTOR AND REACTOR FEED

PREPARATION
Material Balance around Reactor
To make this calculation, flow rates of entering and leaving species to the reactor must be
known. It is assumed that amount of material that enters the process enters to the process and amount
of material that leaves from process also leaves the reactor. However there is difference in the amounts
because of the recycle of methanol. So, firstly recycle is calculated using the values in table 4.2.1. To do
that, reactor is selected as a system and amount of recycle methanol is symbolized with R which is
achieved at 80% conversion.
System: Reactor
Basis: 288.1 kmol/h of feed
)
(
)
)
R = 69.8 kmol/h
Then molar flow rates of each stream are calculated. Diagram and the results are shown in
figure 5.1.1 and table 5.1.2.
Normally 313.3kmol/h methanol enters the process. However amount of methanol that enters
to the reactor is summed with recycle methanol.
Figure 12.5.2.2: Diagram of the reactor
3
1
2CH3OH
CH3OCH3 + H2O
2
5
43
Table 12.5.2.3 : Explanation of symbols that used in diagram

Symbol
Streams
Methanol input the reactor
Water input to the reactor
Methanol leaving the reactor(unreacted)
DME leaving the reactor
Waste water leaving reactor
Table 12.5.2.4 Molar flow rates of each stream

Stream
Flow rate(kmol/h)
m1
279.2
m2
2.0
m3
56
m4
112
m5
159.1
44
Reactor Feed Preparation
Material Balance
Firstly, feed preparation part was considered as a black box. By doing so, the overall energy that
should be fed to the reactor inlet was calculated.
n1=224.2 kmol/h
n5=279.2 kmol/h
n2=2.0 kmol/h
n6=7.94 kmol/h
Feed Preparation
T1=250C
T3=2500C
P1=1 bar
P3=14.7 bar
n3=55 kmol/h
n4=5.94 kmol/h
P2=13.5 bar
T2=1210C
Figure 12.5.2.3: Flow diagram of feed preparation
n1 : Methanol flow rate of stream 1

n2 : Water flow rate of stream 1
n3 : Methanol flow rate of stream 2 (recycle from reactor)
n4 : Water flow rate of recycle
n5: Methanol flow rate of stream 3
n6: Water flow rate of stream 3
P1 , P2 , P3 : Pressure values of stream 1, 2, 3 respectively
T1, T2, T3 : Temperature values of stream 1, 2, 3 respectively
Overall material balance by choosing system as whole feed preparation:

n1 + n2 + n3+ n4= n5 + n6
(1)
45
Balance on species of methanol and water will be as below since there is no reaction in feed
preparation unit:
n1 + n3 = n5
(2)
n2+ n4= n6
(3)
Energy Balance
By using those equations, flow rates of methanol and water in each stream were calculated and shown
on the flow diagram. As it can be seen from the diagram, there is no unknown material around reactor.
By knowing that values, an overall energy balance can be written as below:
[In] [Out] + [Generation] = [Accumulation]
(4)
Hin Hout = Q + W
(5)
=Q+W
(6)
W=0
((
)
)
=Q
(8)
=Q
)
(
(7)
(
)
)
)
(9)
where
[3]
n1=224.2kmol/h; n2=2.0kmol/h; n3=55kmol/h; n4=5.94kmol/h n5=279.2kmol/h; n6=7.94kmol/h

Heat capacities can be approximated by equations provided in the Perrys Chemical Engineers
handbook :
Cp1 = a1 + b1T + c1T2 + d1T3
(10)
Cp2 = a2 + b2T + c2T2 + d2T3
(11)
a1=19.038 b1=0.09146 c1=-1.218*10-5 d1=-8.034*10-9

a2=29.163 b2=0.01449 c2=-0.202*10-5
46
T1 = 318 K;
T2 = 427 K;
T3 = 523 K
Hvap,water:Latent heat of vaporization of water =40.7 kJ/mol

Hvap,meth:Latent heat of vaporization of meth =35.3 kJ/mol
The values were also taken from Perrys Chemical Enginners handbook and the data is interpolated to
satisfy the current process. It is found that the mixture changes its phase at 427K and the second heat
exchanger is required to heat the preheated mixture up to 523 K.
Heat of vaporization for each specie is multiplied by flow rates in order to find overall latent heat.
Plugging data into equation (9) and solving for :
=Q
13.6404*10 kJ/h = 13640 MJ/h
13,640 MJ/h is required for heat exchangers to provide energy to heat the inlet materials to reactor at
inlet temperature of 2500C.This calculated value is very close to the obtained total heat duty from the
ChemCad simulation, which is given as report in the Appendix section.
Chemcad simulation is more reliable since it uses different algorithms into account therefore total heat
is taken as the duty found in Chemcad as 12558.1 MJ/h and divided it into two heat exchangers ; as
10989 MJ/h for the first one and 1569 MJ/h for the second one.
47
12.6 EQUIPMENT DESIGN FOR REACTOR AND REACTOR FEED PREPARATION

Design of Reactor
Synthesis of DME from methanol dehydration is catalytic reaction. So reactor is designed that it
gives chance to use catalyst. Because of that reason a Packed Bed Reactor is chosen. Although PBR has
difficulties with temperature control, it allows designer to get highest conversion per weight of catalyst
of any catalytic reactor.
Selection of catalyst is crucial at that point. The most important property of solid catalyst for
gas phase reaction is physical structure of it because catalytic substance is usually located on the
surface of the solid. Therefore, large surface areas of the catalyst are usually required to achieve the
desired conversion. Large areas are obtained by using solids containing micropores and mesopores of
the order of nanometer in size. Typically, these catalyst particles are made from more or less inert
solids such as alumina, silica and alumina silicate. Hence amorphous alumina treated with 10% silica.
Several assumptions are made and listed below in order to be able to design such a reactor.
Assumptions;
Methanol is an ideal gas.
Standard heat of reaction is taken 298 oK. (Reference)
There are no side reactions.
Design temperature is assumed as 640 oK.
Design pressure is assumed 15 bar.
Single pass conversion is 0.8.
Maximum allowable internal pressure is 20 bar
Maximum working temperature is 4000 C since catalyst deactivates above that value.
48
Approaching the problem

The procedure listed below illustrates the design of the packed bed reactor for DME synthesis
from methanol dehydration.
Step 1.In order to design the reactor firstly type of reactor is decided. Since the reaction is a
catalytic reaction, packed bed reactor is chosen.
Step 2. Material balance around reactor:
It is provided in the section 5.1 .
Step 3. In order to find reactor outlet temperature and catalyst weight, design equation for PBR
is applied.
)(
Step 4. Using catalyst weight, volume of reactor is calculated using bulk density of catalyst.
Step 5. Using rule of thumb [1] for reactor design, cross-sectional area, length and diameter is
determined.
Step 6. Carbon steel (double-welded butt joints with spot examined) is chosen as a
construction material of the reactor.
Step 7. Thickness of reactor shell is calculated.

( )
49
where;
X : Single pass conversion
FA0: Molar flow rate of methanol
W: Weight of catalyst
Hrxn : Heat of reaction
Dp : Catalyst particle diameter
D : Reactor diameter
L: Length of reactor
t: Thickness of reactor
ri: Inside radius of shell before corrosion allowance is added
S : Maximum allowable working stress
Ej: Efficiency of joint expressed as a fraction
P: Maximum allowable internal pressure
Cc: Allowance for corrosion
Calculations done for design of Packed Bed Reactor

Equations (Eq. 6.1.1-1 and 6.1.1-2) used in order to design the reactor that is considered to be
adiabatic, so convection term in Eqn. 6.1.1-2 is eliminated and becomes;
(
)(
50
Where;
(
( )
Table 12.6.1 Parameters and its values

Parameter
Value
k0(kmol/m3.cat*h*kPa)
1.21*106
Ea (kJ/mol)
80.40
Hrxn
-11770
Cp(methanol)
19.038 + 0.09146T - 1.218*10-5T2 - 8.034*10-9T3
Cp(water)
29.163 + 0.01449T 0.202*10-5T2
Cp(DME)
17.01+ 0.179T - 5.2*10-5T2 - 1.9*10-9T3
catalyst(kg/m3)
700
CA and FA0 must be calculated in order to calculate weight of catalyst used.

CA can be calculated using Ideal Gas Law.
P*V = n*R*T
Po*yA = CAo*R*To
Where Po = 14.7 bar, yA = 0.995, To = 523.15 oK, R = 0.083 m3*bar / kmol*K
CA0 = 0.337 kmol/m3

Using Eq 6.1.1-1, Eq 6.1.2-1, Eq 6.1.2-2, Eq 6.1.2-3 and the values that is given in table 6.1.2.1,
polymath code is written which is given in appendix 8.1. To achive 80% conversion of methanol,
polymath gives the results as
Toutlet = 638.65 K =365.50 oC

W = 3350 kg
From Eqn 6.1.1-3, volume of catalyst is calculated.
51
= 4.80 m3
Then by using Eqn 6.1.1-4 and Eq 6.1.1-5, dimension of reactor is found. To apply this relations particle
size should be decided. Since it is known that the dimension of catalyst particle size for fixed bed
reactor is between 2-5 mm[3], it can be chosen as 3 mm.
To determine this parameter, for some of diameter, length is calculated. Diameter is selected between
50 mm and 2000 mm. Calculated length are varied between 3332.5 m and 2.1 m. Then for practical
usage, 0.7 m is selected for diameter.
(
(
)
)
L=12.50 m
Eqn. 6.1.1-7 is used for calculation of shell thickness of the packed bed reactor, carbon steel, doublewelded butt joints with spot examined.
Efficiency of joints of carbon steel material is given as 0.85 and designed temperature of the reactor is
stated as 365.5 0C. For carbon steel maximum allowable working stress is given as 827.37 bar. Also
maximum allowable working pressure is 20 bar. For carbon steel corrosion allowance values are
between 0.254 mm and 0.381 mm for a 10 years life [1]. So it is selected as 0.3175 mm.
(
(
) (
) (
)
) (
t = 10.44 mm = 0.01044 m
52
Design of Reactor Feed Preparation
Figure 12.6.1: CHEMCAD simulation for the feed preparation.
Vessel (V-101) (Drum)

From Table 11.6 in textbook [3] is being used while designing our vessel (V-101):
Liquid drums are usually horizontal:
Since our feed coming to vessel is in liquid phase, we choose our vessel as
horizontal.
Knockout drums placed ahead of compressors should hold no less than 10 times the
liquid volume passing per minute:
It is selected 15 times the liquid volume passing per minute which is 0.152 m3/min
in our system, so volume of our vessel is selected 2.28 m3.
By using the optimum ratio of length to diameter, which is 3, D=1.0 m and L=3.0 m.
53
Pump (P-101)
According to design heuristics for pumps that is stated in table 11.9 [3], power for pumping
liquids is determined by;
W=(1.67)[Flow(m3/min)][P(bar)]/
Here, is the fractional efficiency which is equal to sh as stated in Table 11.5. [3]
The flow rate of stream which comes from the storage vessel is 9.12 m3/h stream at 1bar and
25oC. And shaft efficiency is estimated as 0.45 from Table 11.9. [3]
Following the heuristics;
(
) (
)
)
Then, drive efficiency is calculated by using the relation in Figure 8.7 in the textbook. For electric drive;
( )
( )
( )
(0.8424)
)
(
Then drive power is calculated by;
Heat Exchangers
As it is shown in the procedure of DME production, pre-heating processes is achieved by two
steps. In order to have more efficient heating process, firstly feed in liquid phase must be changed to
gas phase, then it must be heated to the desired temperature. That is why two seperate heating
processes is applied. Shell and tube heat exchanger is selected for each heating steps. Because the
average temperature of the first heater is less than that of second heater, first one is operated at
moderate pressure while the second is operated at high pressure.
Equipment Selection First Heat Exchanger

Heat duty value for the first heat exchanger of feed preparation part can be found after doing
the necessary balance calculations,. This value is estimated to be around 10988.72 MJ/h from the
54
ChemCad simulation, which is given as report in the Appendix section. Then we can use the general
heat exchanger equation 6.2.3.1.1.
(6.2.3.1.1)
Here, F is choosed as 1.0 since phase change is occuring. Also overall heat transfer coefficient,
U, is taken as 280 W/m2K, from table 11.11 [3] which is valid for liquid to liquid system. Water steam
inlet is assumed as liquid at the high pressure for the heat exchanger.
Saturated steam
T= 250 oC
Feed Preparation Inlet

T= 45oC
First Heat Exchanger

(Counter-Current & ShellTube)
Heated Feed
T= 154oC
Superheated steam
T= 250 oC
Figure 12.6.2: Schematic draw of the first heat exchanger
We can write equation 6.2.3.1.2 to find logarithmic mean temperature difference and then we
can find the overall area (A) of the heat exchanger. The first exchanger is designed to work with
medium pressure steam. It is assumed that water steam enters the equipment at 250oC superheated
steam and leaves as saturated and at 250oC. The latent heat of steam is used for feed heating. So, feed
enters the exchanger at 45oC and leaves at 154oC.
55
(6.2.3.1.2)
Table 12.6.2: Description of the first heat exchanger streams and their temperatures
) (
Feed preparation inlet
45 oC
Heated stream of the feed
154 oC
Superheated steam inlet
250 oC
Saturated steam outlet
250 oC
Equipment Selection Second Heat Exchanger

For the second heat exchanger, which is used to heat the vapor mixture to reactor inlet
temperature, same procedure is used. Heat duty value for the second heat exchanger of feed
preparation section is estimated to be around 2030 MJ/h from the textbook [3]
F is choosed as 0.9 since no phase change is occuring. Also overall heat transfer coefficient, U,
is taken as 30 W/m2K, which is valid for gas to gas systems.
56
The second heat is exchanger is designed different than the first one. It uses reactor outlet for
the heating fluidng. Hot reactor stream enters the equipment at 365.5 oC and it is assumed that it
leaves at 250 oC.
Cooled reactor steam

T= 250 oC
Second Heat Exchanger

Heated feed from 1st H.E.
o
T= 154 C
(Counter-Current & ShellTube)
Final Stream
T= 250oC
Hot reactor outlet

T= 365.5oC
Figure 12.6.3: Schematic draw of the second heat exchanger
Table 12.6.3: Description of the second heat exchanger streams and their temperatures
Heated feed from 1st H.E.
154 oC
Final stream from feed prep.
250 oC
Hot stream from reactor outlet
365.5 oC
Cooled stream of the reactor outlet
250 oC
57
) (
According to Heuristics: (table 11.11)[3]
Due to boiling, pressure drop is chosen 0.1 bar for first heat exchanger. Also for
other services, pressure drop is chosen 0.4 bar within the range of 0.2-0.62 bar.[3]
F is selected 1.0 for the first heat exchanger due to phase change and 0.9 for the
second one. [3]
Overall heat transfer coefficient, U, is selected 280 W/m2K which is applicable liquid
to liquid systems (medium pressurized steam is liquid as well as feed) for the first
exchanger and is selected 30 W/m2K which is applicable for gas to gas systems for
the second heat exchanger. [3]
Tubes are standard that have 1.9 cm OD, on a 2.54 cm triangle spacing, 4.9 m long
for both exchangers. So first heat exchanger has340 tubes, and the second one has
728 tubes, approximately. [3]
Again due to heuristics, shell diameter of the first exchanger is calculated as 89cm,
and the shell diameter of the second heat exchanger is calculated as 130cm,
approximately. [3]
58
Separation Columns:
Separator Feed Preparation Condenser

Feed= 282 kmole/hr
Feed= 282 kmole/hr
T= 90.7 0C
T= 260 0C
P= 10.4 bar
P= 10.4 bar
q= 0.70
q= 1
XDME = 0.3968
XDME = 0.3968
XMethanol = 0.1979
XMethanol = 0.1979
Xwater =0.4053
Xwater =0.4053
Energy balance around Feed Preparation Condenser
According to the CHEMCAD simulation, the heat duty required for condensation is 10274.8
MJ/hr.
Then the amount of water required for cooling from 260 0C to 90.7 0C is calculated as shown
below,
10274.8*1000 kJ/hr = m *4.18 kJ/kg. 0C*(40-25) 0C

m = 163872 kg/hr = 9104 kmole/hr.
(
) (
(
(
)
)
)
= 127.7 0C
Q = U A F Tlm
A=
= 26.29 m2
59
Partial reboiler of DME separation column:

The heat duty of the partial reboiler is taken from ChemCad DME Tower simulation, which is
3465.86 MJ/h. Overall heat transfer coefficient is taken as 1140 W/m2.K due to boiling, and the
correction factor as 1.0 since is a phase change occurs. In this case a high pressure steam of 41
bar at 252 0C is used as utility.
Steam out
T = 180 0C
Saturated vapor
T= 152 oC
Saturated liquid
Partial Reboiler
T= 152 C
Steam in
T= 180 oC
= undetermined
Q = U A F Tlm
3465.86 MJ/h = (1140 W/m2 .K). A . (1) . (252 152) K
(3465.86 * 10^6)/(3600) J/s = (1140 W/m2 .K). A. (1). (180 152) K
A = 30.16 m2
(
= 2032.76 kg/h
60
Total condenser of DME separation column:

The heat duty of the total condenser is taken from ChemCad DME Tower simulation, which is
4479.2 MJ/h. Overall heat transfer coefficient is taken as 850 W/m2.k due to condensation and
the correction factor is taken as 1.0 a phase change occurs. In this case low pressure steam is
used as utility.
(
) (
(
(
)
)
)
= 12 0C
Q = U A F Tlm
A=
= 122 m2
consumption rate of cooling water can be calculated from the following formula,
Q = mwater* cp* T
mwater =
= 71438.6
kg/hr
Partial reboiler of methanol separation column:

The heat duty of the partial reboiler is taken from ChemCad methanol Tower simulation, which
is 4275.5 MJ/h. Overall heat transfer coefficient is taken as 1140 W/m2.K due to boiling, and the
correction factor as 1.0 since is a phase change occurs. In this case a high pressure steam of 40
bar at250 0C is used as utility.
= undetermined
Q = U A F T
4275.5 MJ/h = (1140 W/m2). A . (1) . (250 180) 0C
(4275.5 * 10^6)/(3600) J/s = (1140 W/m2.K). A. (1). (250 180) 0C
A = 14.88 m2
(
= 2496 kg/h
61
Total condenser of methanol separation column:

The heat duty of the total condenser is taken from ChemCad DME Tower simulation, which is
4124.9 MJ/h. Overall heat transfer coefficient is taken as 850 W/m2.K due to condensation and
the correction factor is taken as 1.0 a phase change occurs. In this case low pressure steam is
used as utility.
(
) (
(
(
= 106.32 0C
)
)
Q = U A F Tlm
A=
= 12.68 m2
Q = mwater* cp* T
mwater =
= 65787.87
kg/h
Wastewater cooler from the bottom of methanol tower:

The wastewater from the bottom of methanol tower is cooled from 191 0C to 40 0C by using a
heat exchanger. A chemcad simulation is conducted to estimate the heat duty that is
1386.17MJ/h. Overall heat transfer coefficient is taken as 850 W/m2.K because a phase change
occurs l. The correction factor is taken as 0.9 as there is no phase change occurs.
(
) (
(
(
)
)
)
= 55.96 0C
Q = U A F Tlm
A=
= 43.6 m2
Q = mwater* cp* T
mwater =
= 23492.2
kg/hr
62
DESIGN OF DISTILLATION TOWERS
i) DME Tower Stage Calculations

There are two distillation columns necessary for the dimethyl ether production from methanol
dehydration. In this process, first one is called DME Tower and DME is taken as top product
and remaining methanol-water mixture is sent to the second column, which is Methanol Tower.
Number of stage calculations for the first tower is carried out by Shortcut Method and method of
attack is given as below;
Method of Attack:
1) Identify the properties of inlet and outlet streams such as flow rate, composition,
temperature, pressure and feed condition (q).
2) Indicate the distillation system as multicomponent and selecting light key as methanol and
heavy key as water.
3) Using SCDS column profile (appendix) obtained from Chemcad relative volatility for light
key (DME) is calculated with respect to heavy key (methanol) and average volatility is found
by equation X.5.1 :
4) For multicomponent system the minimum number of stages (Nmin) is calculated by Fenske
(
equation X.5.2:
)(
(
)
)
5) Taking into account CMO and constant relative volatilities (

Underwood equation (X.5.3) will be used to calculate
(
= ),
: (Wankat,2011, p251)
6) Determine the minimum reflux ratio (Rmin ) using both graphical method and Underwood
equation (Wankat,2011, p250) :
63
7)Then, the reflux ratio (R) is calculated ,in both ways, at the pinch point which is the
intersection point of q-line and rectifying section operating line on the equilibrium line of
methanol. The second way to calculate Reflux ratio is to use thumb rule taking ratio of
as 1.3 .
Operating line for rectifying section:
yn+1 =
( )
(
Operating line for feed stream:
yn+1 = (
( )
)
Operating line for stripping section:
Ym+1 =
( )
( )
( )
Determine R using the common relation between R and Rmin which is;
(1.2)R min< R < (1.5)Rmin
8) Again using operating lines of each sections, determine theoretical stages by graphical
method.
64
Theoretical
stage
number
,N,
will
also
be
calculated
by Kirkbride
equation
6) Determine overall efficiency of column using OConnells correlation :
E0 = 51-(32.5*log(a a)
Where; a is the average liquid viscosity estimated at the average column temperature and a is the
average relative volatility of light key to the heavy key
7) Using overall efficiency, determine actual number of stage.
E0 =
* 100
D = 112 kmole/hr
ii) DME Tower Diagram
T= 47.7 0C
P= 10.4 bar
q=0
Feed= 281 kmole/hr
XDME = 0.996
T= 90.7 C
XMethanol = 0.0043
P= 10.4 bar
Xwater = ~ 0
q= 0.704
XDME = 0.397
B = 169.5 kmole/hr
XMethanol = 0.198
T= 152 0C
Xwater =0.405
P= 10.4 bar
Vapor fraction = 0.0

1) System is defined as in the Figure 11.5.1
q value is found as 0.704 from ChemCad simulation (SCDS Simulation)
XDME = 0.00147
XMethanol = 0.326
Xwater =0.673
65
2) Light Key (LK) is selected as DME

Heavy Key (HK) is selected as Methanol
3) Relative volatilities with respect to stage number were obtained by Chemcad .(Appendix)
Relative volatilities of light key for top and bottom stages are as follows:
4)
)(
(
)(
)
)
5)
;
value was calculated by trial-error method .The root that was found is valid and reasonable
since the value is in between the volatilities of heavy and light key.
6)
7)
8)
66
Plugging computed data into Gilliland correlation (Wankat,2011) and solving for N
Figure 12.6.5.Gillilan correlation (1968 , McGraw-Hill)
9) Solving for feed location using Kirkbride equation (X.5.5).
(
(
)
)
(
(
)
)
Feed tray is found as 4th tray.

Both stage number and feed stage number is consistent with the Chemcad simulation and
exactly these numbers were found by short-cut method calculation and simulation.
67
10)
11)
68
ii) Methanol Tower Stage Calculations

In methanol tower which is the second separation unit of the dimethyl ether production
from methanol dehydration, methanol is taken as a top product and water is taken as bottom
product. To make these calculations, some assumptions are made. These are;
Binary mixture system
Recovery of methanol is 96%
Recovery of water is 99%
Design pressure of column is 10.4 bar
Constant molar overflow throughout the column.
Number of stage calculations for the second tower is carried out by McCabe-Thiele
method and method of attack is given as below;
Method of Attack:
1) Identify the properties of inlet and outlet streams such as flow rate, composition,
temperature, pressure and feed condition (q).
2) Indicate the distillation system select light key as methanol and heavy key as water.
3) Determine the minimum reflux ratio (Rmin ) using graphical method. Then, the reflux ratio (R)
is calculated at the pinch point which is the intersection point of q-line and rectifying section
operating line on the equilibrium line of methanol.
Operating line for rectifying section:
yn+1 = (
( )
)
Operating line for feed stream:
yn+1 = (
( )
)
Operating line for stripping section:
69
Ym+1 =
( )
( )
( )
4) Determine R using the common relation between R and Rmin which is;
(1.2)R min< R < (1.5)Rmin
5) Again using operating lines of each sections, determine theoretical stages by graphical
method.
6) Determine overall efficiency of column using OConnells correlation.
E0 = 51-(32.5*log(a a)
7) Using overall efficiency, determine actual number of stage.
E0 =
* 100
D = 55 kmole/hr
T= 139 0C
P= 10.4 bar
q=1
Feed= 169.5
kmole/hr
XDME = 0.0005
T= 152 0C
XMethanol = 0.995
P= 10.4 bar
Xwater =0.000
q= 1
XDME = 0.0002
B = 114.5 kmole/hr
XMethanol = 0.327
T= 181 0C
Xwater =0.672
P= 10.4 bar
Vapor fraction = 0.0
XDME = 0.0
XMethanol = 0.0012
Xwater =0.9988
70
Calculation of ideal stages:

The number of ideal stages for methanol water separation is determined by using McCabeThiele method. The equilibrium data of methanol at 10.4 bar is obtaind from CHEMCAD
simulation.
Firstly, Rmin is calculated at the pinch point which is the intersection point of rectifying op.line
and q-line at the equilibrium line as it is seen in figure. Since the feed is saturated liquid, q =1.
Hand Drawn is provided

on the next page.
= 0.442
Rmin = 1.251
The actual operating reflux ratio (R) is calculated using the relation below.
1.2 Rmin< R <1.5 Rmin
So, R is found as 1.625
Secondly, operating line equations for the methanol separation column are found as it is
illustrated below,
Rectifying section
Stripping section
Stripping section
Rectifying Section:
The operating line is yn+1 = (
( )
)
71
= 0.995
Point 1. at
so, yn+1 =
Point 2. at
=0
so, , yn+1 = (
= 0.379
Using these two points, the operating line for rectifying can be drawn.
Feed Section:
The operating line is yn+1 = (
At x = xfeed = 0.327
( )
)
so, yn+1 =
= 0.327
In fact, q of the methanol separation column is ( q = 1) that is a saturated liquid.

Stripping Section:
( )
The operating line is Ym+1 = (

At
( )
= 0.0012
so, Ym+1 =
Now using these information from the three sections, number of stages can be determined as it is
drawn in the figure.
THE HAND DRAWN is provided in the
next page
Number of ideal stage is calculated as 22
21 stages + 1 reboiler
The stage number is directly proportional to the purification of methanol.99.5% mole of

methanol is recycled and 99.8% mole is taken waste. Taking into consideration the
environmental aspects the design is optimized to give the least mole percentage of methanol in
waste water.
The overall column efficiency is determined using OConnells correlation. Average
temperature of the bottom and top streams is calculated as 145.50C.The terms a and a are
calculated at the average temperature. Average relative volatility is 0.304 and individual
viscosity values are as 0.194 and 0.184.
The average viscosity is calculated as :
(
(
(
)
)
(
(
)
)
Substituting these values into OConnells correlation, overall efficiency is found as :
72
12.7 Cost Calculations including Equipment Cost Data

ECONOMIC ANALYSIS FOR PUMPS
Now, purchased equipment cost can be obtained by using the equation A.1 in the textbook
( )
( )) ( )
where A is shaft power.

By using Table A.1, equipment cost data in textbook and substituting k1, k2 and k3 values into
eqn. 6, purchased equipment cost can be obtained for pump 1 as following:
(
))
By substituting equipment cost data in the textbook into eqn.6, purchased equipment cost can be
obtained for pump 2 as following:
(
))
By substituting equipment cost data in the textbook into eqn.6, purchased equipment cost can be
obtained for pump 3as following:
(
))
73
Utility Cost
Estimation for Pumps
All pumps are working with electricity. The price of electricity is given as 0.11 $/kwh. Then,
annual electricity cost will be found for each pump by the following procedure;
Where;
Celect is the annual electricity cost
P is the power of the pump
t is the annual working time of pump, 8320 h/year
Pr is the price of electricity, 0.11 $/kwh
Then, the following table shows the electricity cost for each pump;
Pumps
Power (kW)
Celect ($/year)
P-201A/B
8.17
7413
P-202A/B
2.16
1977
P-203A/B
9.48
8676
DISTILLATION TOWERS
CAPCOST program is used for finding the equipment costs of the towers. The required
parameters are taken from the previous progress report as;
Table1 Parameters of separation columns
Diameter (m)
Column 1
Column 2
(T-101)
(T-102)
0.76
0.76
74
Height (m)
6.22
18.9
P (bar)
10.4
10.4
Material of
Carbon
Carbon
Construction
Steel
Steel
Tray type
sieve
sieve
No. of trays
28
Purchased equipment costs of towers found as followed;

Table2Purchased equipment costs of towers from CAPCOST
Towers
Tower
Height
Description
(meters)
(meters)
6.22
0.76
18.9
0.76
36 Carbon Steel
T-101
Sieve Trays
30 Carbon Steel
T-102
Sieve Trays
Diameter Tower Pressure

MOC
Carbon
Steel
Carbon
Steel
Purchased
(barg)
Equipment Cost
10.4
10,700 $
10.4
35,000 $
REACTOR
Reactor is taken as pressurized vessel. CAPCOST program is used also for finding the
equipment cost of the reactor. The required parameters are taken from the previous progress
report as;
Diameter (m)
0.72
Height (m)
12.5
P (bar)
14.7
Material of
Carbon
Construction
Steel
75
Purchased equipment cost of reactor found as followed;

Table3 Purchased equipment cost of reactor from CAPCOST
Vessels
R-101
Orientation
Vertical
Length/Height Diameter
(meters)
(meters)
12.5
0.72
MOC
Carbon
Steel
Pressure
(barg)
14.7
Purchased
Equipment
Cost
7,376 $
Utility Cost for Reactor

The silica-alumina (zeolite zsm-5) catalyst, which is used in the reactor, is planned to be
changed annualy. The cost of the catalyst is considered as a utility cost.
The unit price of the catalyst is found as 18 $/kg. The required amount of catalyst for one year
can be calculated by using volume of the packed-bed section of the reactor and the bulk density
of the catalyst.
, where,
And the annual cost of the catalyst is found as;
REFLUX DRUMS
There are two reflux drums for each separation columns condenser section. These drums are
relatively small vessels. From the heuristics for towers, reflux drums are horizantal with a liquid
holdup of 30 min half full [1]. The required parameters for CAPCOST program are found as
followed;
First the volume of drums are found;
76
For Drum 1 (V-103)
For Drum 2 (V-104)
By taking length/diameter ratio as 3 from heuristics, founded diameter and height shown in the
table below;
Table4 Parameters of drums
Drum 1
Drum 1
(V-103)
(V-104)
Diameter (m)
1.48
0.97
Height (m)
4.44
2.91
P (bar)
10.4
10.4
Material of
Carbon
Carbon
Construction
Steel
Steel
From CAPCOST, purchased equipment costs of drums are found as followed;

Table5 Purchased equipment costs of drums from CAPCOST
Vessels
Orientation
Length/Height Diameter
(meters)
(meters)
V-103
Horizontal
4.44
1.48
V-104
Horizontal
2.91
0.97
MOC
Carbon
Steel
Carbon
Steel
Pressure
(barg)
Purchased
Equipment
Cost
10.4
9,130 $
10.4
4,920 $
77
VESSELS
In our plant we need equipment for storage. Vessels are used to meet this need. For the feed
part, if there is something wrong with the flow of methanol, methanol stored in the vessels will
be sent to the reactor and keeps the operation going. For the outlet part produced DME should
be stored if it cannot be saled as soon as it comes out. We need those vessels for the storage of
one day so calculations for the volume of the vessels done accordingly.
Methanol Storage Vessel
We need the volumetric flow rate of methanol per day to find the vessel volume needed.
Volumetric flow rate of methanol is found by dividing its mass flow rate to its density. Density
is taken from chemcad results.
Since it is the daily flow rate, it is equal to the capacity of the vessel.
V101=220 m3
From the heuristics,
78
DME Storage Vessel

DME produced per day is calculated from material balance and found as,
Volumetric flow rate of methanol is found by dividing its mass flow rate to its density. Density
is taken from chemcad results.
Since it is the daily flow rate, it is equal to the capacity of the vessel.
V105=183.56
From the heuristics,
Storage vessels costs are found from CAPCOST program:

79
Vessels
Orientation
Length/Height Diameter MOC
Pressure Purchased
(meters)
(barg)
(meters)
Equipment
Cost
V-101
Vertical
13.6
4.53
Carbon
145,000 $
124,000 $
Steel
V-105
Vertical
12.8
4.27
Carbon
Steel
COST CALCULATIONS INCLUDING EQUIPMENT COST DATA

RATE OF RETURN ON INVESTMENT
Rate of return on investment (ROROI) represents the nondiscounted rate at which money is
made from the fixed capital investment.
Net Annual Earnings = (Gross Profit-SARE expenses)*(1-Income Taxes)
SARE expenses = 0.1*Gross Sales
Gross Profit = Gross Sales Total Manufcturing Cost
Total Fixed Capital Investment = Total Manufacturing Capital + Non-Manufacturing

Capital
Total Manufacturing Capital = Purchase Equipment Cost * Lang factor
Lang factor=4
Non-Manufacturing Capital = 0.25* Total Manufacturing Capital
Working Capital = 0.03*Total Manufacturing Capital+0.10*Gross Sales+0.50*Raw

Material Inventory+0.50*Finished Product Inventory
80
Table6 Utilities Cost Data
Steam
High Pressure (40 bar g, sat)
16.50 $/mt
Medium Pressure (10 bar g, sat)
14.00 $/mt
Low Pressure (4 bar g, sat)
12.50 $/mt
Electricity
0.11 $/kwh
Cooling Water
15.00 $/1000 m3
Manufacturing cost factors
Labor Wage Rate
15.00 $/year
Supervision Salary Rate
4000 $/month
Payroll Charges
35% of labor and supervision
Repairs
6% of Mfg.Cap/year
Factory Supplies
Laboratory
Product Control
Assume 2%of Mfg.Cap/year
Technical Service
Royalty
Depreciation
8% of Mfg.Cap/year
Factory ndirect Expense

(Property Taxes, Insurance, Other
4% of Mfg.Cap/year
Distrbutable Expenses)
81
ECONOMIC ANALYSIS
All the equipment costs are added for the total equipment cost (based on the equipment cost
list),
Total Equipment Cost= 1058046 $
By using Lang Factor for calculation of total cost,
Taking Lang factor as 4.0
Total Manufacturing Capital=1058046 $ * 4.00 = 4232184 $/year
If the contingency was considered as 10% of Total Manufacturing Capital, then Total
Manufacturing Cost Estimate was found;
Contingency 4232184 $* 10% =423218 $
TMC estimate : 4232184 $ + 423218 $= 4655402 $ (which is 1.1 of Total manufacturing cap)
Additionally, Non-Manufacturing Capital Investment was evaluated as 25% of Total

Manufacturing Capital.
Non-manufacturing Fixed Capital Investment (NMFCI) = 4232184 * 0.25=805578 $
Fixed Capital investment (FCI)=TMC+NMFCI=4655402 $ + 805578 $= 5,460,980 $
Price of methanol=0.22$/kg
Store supplies were given as 3% of Total Manufacturing Capital. Then,

Store supplies=0.03 * 4232184=12696 $
Gross sales= $ 42865000
All other items=42865000 * 0.1=4286500 $
Working Capital
(
Working Capital= 0.03*4232184+0.1*42865000+12862504+13500=17,289,470 $
82
Thus, manufacturing capital is calculated by summing up fixed capital and working capital as
given below :
MC=17,289,470 $ + 5,460,980 $= 22,750,450 $
Total MANUFACTURING COST ESTIMATION

Labor and Supervision Cost
Manufacturing cost consists of labor, supervision, repairs , factory supplies, laboratory, product
control, technical service, royalty, factory indirect expenses and depreciation.
Labor
A correlation is used to find the number of workers in the plant.
NOL=(6.29+31.7p+0.23Nnp)0.5
Nnp=1 reactor+2 columns+4 heat exchangers
Nnp=7
NOL=(6.29+0.23x7)0.5=2.81
Plant operates 24h/day 365days/year therefore,
Total operation hour=365x24=8760 h/year
A worker works 8 hours a day 6 days a week and 48 weeks a year, therefore;
Working hour of a worker in a year=8hours/dayx6days/weekx48weeks/year=2304 h/year
Number of workers= (8760h/year/2304h/year)x2.81=10.6811workers
Wage Rate=15.00$/h
Labor Cost=11x15.00$/hx2304h/year=380160$/year
Supervision
We need engineers as well as workers in our plant.
Number of engineers can be assumed as 1/3rd of number of workers, therefore;
Number of engineers in the plant =11/3=3.674 engineers
Supervision cost= 4000 USD/month x 4 x 12=192000 $/year
83
Payroll charges
It will be 35% of Labors and Supervision factor.
Payroll ch= (380160+192000) *0.35=200256 $/year
Repair factors
Assuming it constitutes 2 % of Mfg. Cap./year :
Repair fac=4232184 $ * 0.02= 84644$/year
Depreciation (Straight Line)
By depreciating equipment cost for ten straight years:
Depreciation=Equipment cost/10 years= 1058046/10=105805 $/year
Factory Indirect Expense
FIE=4232184 $ * 0.08=169287$/year
Hence, sum of all these gives the total manufacturing cost.
Total Manufacturing Cost
=Raw material inventory + Total utility cost + Labor cost + Supervision+ Payroll expenses +
Repairs cost + Product control cost +Depreciation +Indirect expenses
ANNUAL EARNINGS AND RETURN

Price of DME= 1$/kg
Produced DME in ton : 112kmol/hr * 0.046 ton/kmol* 8320 days/hr=42,865 ton
Gross profit=Sales revenue Manufacturing cost

GP=
Until that point, Sales-Administration-Research-Engineering expenses are not covered by any of the
previous percentage factors. To determine net gross profit, SARE expenses is taken 10% of annual
income than subtracted from gross profit to find net gross profit.
(
)
To calculate the income tax, tax rate is taken 20%.
( )
84
ROI=27%
12.8. Polymath program needed for calculation of catalyst weight and reactor outlet temperature.
d(X)/d(W) = (-rA / r) / Fa0
X(0) = 0
d(T)/d(W) = (rA / r) * Hrxn / (Cpa * Fa0)
T(0) = 523.15
r = 700 # density of the catalyst
Fa0 = 288.13 # kmol/h
rA = -k * exp(-Ea / (R * T)) * Ca * R * T
Ea = 80480
Ca = Ca0 * (1 - X) * (523.15 / T)
Ca0 = 0.337 # kmol/m3
R = 8314e-3
k = 1210000
Hrxn = -11770 + (8097e-3 + 11e-3 * T - 2966e-8 * T ^ 2 + 1417e-11 * T ^ 3) * (T - 298)
Cpa = (19038e-3) + (9146e-5) * T - (1218e-8) * T ^ 2 - (8034e-12) * T ^ 3
W(0) = 0
W(f) = 3350
85
86
87
8.2. ChemCad Report for the Heat Exchangers

CHEMCAD 6.3.1
Simulation: First Heat Exchanger
Time: 18:21:24
EQUIPMENT SUMMARIES
Date: 12/16/2013
Heat Exchanger Summary

Equip. No.
Name
1st Stream dp bar
1st Stream T Out C
Calc Ht Duty MJ/h
LMTD Corr Factor
1st Stream Pout bar
1
0.1000
155.0000
10998.7197
1.0000
15.3000
CHEMCAD 6.3.1
Simulation: Second Heat Exchanger
Time: 18:27:29
EQUIPMENT SUMMARIES
Date: 12/16/2013
Heat Exchanger Summary

Equip. No.
Name
1st Stream dp bar
1st Stream T Out C
Calc Ht Duty MJ/h
LMTD Corr Factor
1st Stream Pout bar
1
0.4000
250.0000
1569.3738
1.0000
14.7000
88
89
CHEMCAD 6.3.1
Page 1
Simulation: Full_Scheme_DME_Simulation
STREAM PROPERTIES
Stream No.
Name
- - Overall - Molar flow kmol/h
Mass flow kg/h
Temp C
Pres bar
Vapor mole fraction
Enth MJ/h
Tc C
Pc bar
Std. sp gr. wtr = 1
Std. sp gr. air = 1
Degree API
Average mol wt
Actual dens kg/m3
Actual vol m3/h
Std liq m3/h
Std vap 0 C m3/h
- - Vapor only - Molar flow kmol/h
Mass flow kg/h
Average mol wt
Actual dens kg/m3
Actual vol m3/h
Std liq m3/h
Std vap 0 C m3/h
Cp kJ/kg-K
Z factor
Visc N-s/m2
Th cond W/m-K
- - Liquid only - Molar flow kmol/h
Mass flow kg/h
Average mol wt
Actual dens kg/m3
Actual vol m3/h
Std liq m3/h
Std vap 0 C m3/h
Cp kJ/kg-K
Z factor
Visc N-s/m2
Th cond W/m-K
Surf. tens. N/m
CHEMCAD 6.3.1
Date: 05/21/2014
1
feed
226.0020
7213.5295
25.0000
1.0000
0.0000
-54097.
240.1335
81.4581
0.801
1.102
45.0671
31.9180
790.3986
9.1264
9.0012
5065.5286
226.0020
7213.5295
25.7216
15.5000
0.0000
-54084.
240.1335
81.4581
0.801
1.102
45.0671
31.9180
789.7075
9.1344
9.0012
5065.5286
281.4517
8985.1616
110.8411
15.2000
0.0000
-65149.
240.0204
81.3963
0.801
1.102
45.1014
31.9243
697.2007
12.8875
11.2141
6308.3585
281.4517
8985.1616
250.0000
15.1000
1.000
-54567.
240.0204
81.3963
0.801
1.102
45.1014
31.9243
11.8008
761.4013
11.2141
6308.3585
281.4517
8985.1616
31.9243
11.8008
761.4013
11.2141
6308.3585
1.9222
0.9393
1.753e-005
0.0431
226.0020
7213.5295
31.9180
790.3986
9.1264
9.0012
5065.5286
2.5399
0.0022
0.0005406
0.2007
0.0223
226.0020
7213.5295
31.9180
789.7075
9.1344
9.0012
5065.5286
2.5440
0.0333
0.0005409
0.2005
0.0223
STREAM PROPERTIES
Stream No.
Name
- - Overall - -
Time: 15:45:17
281.4517
8985.1616
31.9243
697.2007
12.8875
11.2141
6308.3585
3.2792
0.0290
0.0002388
0.1764
0.0145
Page 2
Date: 05/21/2014
Time: 15:45:17
Molar flow kmol/h

Mass flow kg/h
Temp C
Pres bar
Vapor mole fraction
Enth MJ/h
Tc C
Pc bar
Std. sp gr. wtr = 1
Std. sp gr. air = 1
Degree API
Average mol wt
Actual dens kg/m3
Actual vol m3/h
Std liq m3/h
Std vap 0 C m3/h
Mass flow kg/h
Average mol wt
Actual dens kg/m3
Actual vol m3/h
Std liq m3/h
Std vap 0 C m3/h
Cp kJ/kg-K
Z factor
Visc N-s/m2
Th cond W/m-K
Mass flow kg/h
Average mol wt
Actual dens kg/m3
Actual vol m3/h
Std liq m3/h
Std vap 0 C m3/h
Cp kJ/kg-K
Z factor
Visc N-s/m2
Th cond W/m-K
Surf. tens. N/m
CHEMCAD 6.3.1
281.4525
8985.1900
340.9631
13.9000
1.000
-54566.
204.0864
44.9646
0.753
1.102
56.3859
31.9244
8.8889
1010.8312
11.9307
6308.3762
281.4525
8985.1900
259.7677
13.9000
1.000
-56123.
204.0864
44.9646
0.753
1.102
56.3859
31.9244
10.4274
861.6876
11.9307
6308.3762
281.4519
8985.1608
100.0000
13.9000
0.2563
-65403.
204.0867
44.9645
0.753
1.102
56.3858
31.9243
60.1097
149.4794
11.9306
6308.3638
281.4525
8985.1900
31.9244
8.8889
1010.8312
11.9307
6308.3762
2.2158
0.9778
2.024e-005
0.0548
281.4525
8985.1900
31.9244
10.4274
861.6876
11.9307
6308.3762
2.0503
0.9606
1.770e-005
0.0439
72.1304
3151.7115
43.6947
22.4123
140.6244
4.6140
1616.7046
1.6601
0.8736
1.223e-005
0.0262
209.3216
169.5254
5833.4490
3835.7481
27.8684
22.6264
658.7736
758.4805
8.8550
5.0571
7.3167
4.2821
4691.6595
3799.6823
3.3380
4.0685
0.0207
0.0116
0.0002071
0.0001792
0.1853
0.3153
0.0101
0.0212
Page 3
STREAM PROPERTIES
Stream No.
Name
Mass flow kg/h
Temp C
Pres bar
Vapor mole fraction
Enth MJ/h
Tc C
Pc bar
169.5254
3835.7481
152.4593
10.4000
0.0000
-44026.
309.8234
129.2361
0.896
0.781
26.4668
22.6264
758.4805
5.0571
4.2821
3799.6823
Date: 05/21/2014
Time: 15:45:17
9
DME
10
11
waste water
12
111.9265
5149.4123
47.7170
10.4000
1.000
-20571.
127.2906
53.6864
281.4517
8985.1616
154.0000
15.1000
1.000
-56123.
240.0204
81.3963
114.0757
2064.1150
180.4249
10.4000
0.0000
-31202.
372.7922
218.7304
55.4497
1771.6326
138.4342
10.4000
1.000
-11065.
239.5604
81.1443
Std. sp gr. wtr = 1

Std. sp gr. air = 1
Degree API
Average mol wt
Actual dens kg/m3
Actual vol m3/h
Std liq m3/h
Std vap 0 C m3/h
Mass flow kg/h
Average mol wt
Actual dens kg/m3
Actual vol m3/h
Std liq m3/h
Std vap 0 C m3/h
Cp kJ/kg-K
Z factor
Visc N-s/m2
Th cond W/m-K
Mass flow kg/h
Average mol wt
Actual dens kg/m3
Actual vol m3/h
Std liq m3/h
Std vap 0 C m3/h
Cp kJ/kg-K
Z factor
Visc N-s/m2
Th cond W/m-K
Surf. tens. N/m
CHEMCAD 6.3.1
0.673
1.589
78.6722
46.0071
21.0511
244.6153
7.6485
2508.6812
0.801
1.102
45.1014
31.9243
15.7549
570.3085
11.2141
6308.3585
111.9265
5149.4123
46.0071
21.0511
244.6153
7.6485
2508.6812
1.4982
0.8521
1.046e-005
0.0200
281.4517
8985.1616
31.9243
15.7549
570.3085
11.2141
6308.3585
1.6854
0.8617
1.446e-005
0.0312
0.801
1.103
45.2413
31.9503
10.8465
163.3364
2.2129
1242.8299
55.4497
1771.6326
31.9503
10.8465
163.3364
2.2129
1242.8299
1.6468
0.8953
1.381e-005
0.0286
114.0757
2064.1150
18.0943
881.9093
2.3405
2.0693
2556.8517
4.3973
0.0077
0.0001477
0.6638
0.0413
Page 4
STREAM PROPERTIES
Stream No.
Name
Mass flow kg/h
Temp C
Pres bar
Vapor mole fraction
Enth MJ/h
Tc C
Pc bar
Std. sp gr. wtr = 1
Std. sp gr. air = 1
Degree API
Average mol wt
Actual dens kg/m3
Actual vol m3/h
Std liq m3/h
Std vap 0 C m3/h
0.998
0.625
10.3527
18.0943
881.9093
2.3405
2.0693
2556.8517
13
281.4519
8985.1599
90.6595
10.4000
0.2969
-65403.
204.0868
44.9646
0.753
1.102
56.3858
31.9243
39.7213
226.2054
11.9306
6308.3638
Date: 05/21/2014
Time: 15:45:17

Mass flow kg/h
Average mol wt
Actual dens kg/m3
Actual vol m3/h
Std liq m3/h
Std vap 0 C m3/h
Cp kJ/kg-K
Z factor
Visc N-s/m2
Th cond W/m-K
Mass flow kg/h
Average mol wt
Actual dens kg/m3
Actual vol m3/h
Std liq m3/h
Std vap 0 C m3/h
Cp kJ/kg-K
Z factor
Visc N-s/m2
Th cond W/m-K
Surf. tens. N/m
83.5497
3651.7291
43.7073
16.7073
218.5706
5.3457
1872.6537
1.6317
0.8996
1.179e-005
0.0247
197.9022
5333.4308
26.9498
698.5734
7.6347
6.5850
4435.7101
3.3462
0.0150
0.0002354
0.2072
0.0137

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MIDDLE EAST TECHNICAL UNIVERSITY

CHEMICAL ENGINEERING DEPARTMENT

3. Process Flow Diagram

12.1. Physical and Chemical Properties

12.2. Equilibrium restriction for DME synthesis

12.3. Safety Considerations

12.4. Sustainability Considerations

12.5. Material and Energy Balance Calculations

12.6. Equipment Design for reactor

12.7. Cost Calculations and Equipment Cost Data

Table 2.1: Design basis for the dimethyl ether production

Table 8.1: Manufacturing Capital

Figure 12.6.6 : Block diagram for the DME Tower

Mass Flow Rate

Molar Flow Rate

Feed condition (liquid ratio)

Volumetric Flow Rate

Product: Dimethyl ether

Capacity of the plant

Stream time, h/year

Medium Pressure Steam (sat), bar g.

Low Pressure Steam (sat), bar g.

CW Return max. Values

All voltages and phases are suitable

Delivered by pipe to battery limits

3. PROCESS FLOW DIAGRAM OF DIMETHYL ETHER PRODUCTION BY METHANOL DEHYDRATION

Figure 3.1: Flow diagram of DME production.

For turbulent flow in steel pipes, (NR>2100)

Di,opt = 3.9 (qf0.49)*( 0.13)

Di,opt = 4.7 (qf0.49)*( 0.14)

For viscous flow in steel pipes, (NR <2100)

Di,opt = 3.6 (qf0.4) * (0.2)

= fluid density b/ft3

qf = fluid flow rate ft3/s

= 5273 >>> 2100

Nominal size of pipe, in =1/8 Schedule no= 40 , Wall thickness, in = 0.068

Assume that pipe diameter is greater than 1 in and turbulent flow.

= 5266 >>> 2100

Nominal size of pipe, in =1/8 Schedule no= 40 , Wall thickness, in = 0.068

Assume that pipe diameter is greater than 1 in and turbulent flow.

Nominal size of pipe, in =1/8 Schedule no= 80 , Wall thickness, in = 0.095

Pipeline for stream:4

= 4732 >>> 2100

Nominal size of pipe, in =1/8 Schedule no= 40 , Wall thickness, in = 0.068

Pipeline for Stream : 5

= 3314 >>> 2100

Nominal size of pipe, in =1/8 Schedule no= 40 , Wall thickness, in = 0.068

Pipeline for Stream : 6

= 4354 >>> 2100

Nominal size of pipe, in =1/8 Schedule no= 40 , Wall thickness, in = 0.068

Pipeline for Stream : 7

Assume that pipe diameter is greater than 1 in and laminar flow.

= 1709 <<< 2100

Nominal size of pipe, in =1/8 Schedule no= 40 , Wall thickness, in = 0.068

Pipeline for Stream : 8

= 10199 >>> 2100

Nominal size of pipe, in =1/8 Schedule no= 80 , Wall thickness, in = 0.095

Pipeline for Stream : 9

Assume that pipe diameter is greater than 1 in and laminar flow.

= 1063 <<< 2100

Nominal size of pipe, in =1/8 Schedule no= 40 , Wall thickness, in = 0.068

Pipeline for Stream : 10

Assume that pipe diameter is greater than 1 in and turbulent flow.