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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
ACKNOWLEDGEMENT
First and foremost, thank you to Allah S.W.T for giving us the strength to finish up this
project report. Without Your Willingness we would not be able to complete this project.
It would be impossible to acknowledge adequately all the people who have been
influential, directly or indirectly in forming this project.
We would like to take this opportunity to express our deepest gratitude to our
supervisors, Encik Mohd Imran Bin Zainuddin and Puan Sunita Binti Jobli who has
given us his constant encouragement constructive advises and his patient in
monitoring our progress in this project.
Our appreciation and special thanks goes, Puan Hasnora Binti Jafri, Puan Junaidah
Binti Jai, Encik Aziz Bin Ishak for supplying the valuable information and guidance for
this project.
We greatly indebted to Encik Napis Bin Sudin for his cooperation and willingness to be
interviewed and for provide us with invaluable information and for his resourcefulness
in gathering material.
Special thanks owe to Puan Masni Bt Ahmad for her willingness to be interviewed and
for the painstaking care she has shown in assisting us throughout the project.
We also would like to express our appreciation to the Malaysia Industrial Development
Authority (MIDA), Pusat Informasi Sirim Berhad, Petronas Resource Center, Jabatan
Perangkaan Malaysia and Tiram Kimia Sdn.Bhd. (Kuala Lumpur) for their generous
supply of relevant documents and material needed research.
Last but not least to all my lecturers, family, friends and collegues for their
encouragement and kind support when we need it most.
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
ABSTRACT
The purpose for this MTBE or Methyl tertiary Butyl Ether plant is to produce 300,000
metric tonne/year. MTBE is the simplest and most cost effective oxygenate to produce,
transport and deliver to customers. The additive works by changing the oxygenate /
fuel ratio so that gasoline burns cleaner, reducing exhaust emissions of carbon
monoxide, hydrocarbons, oxides of nitrogen, fine particulates and toxic. Two units will
be considered which are the fluidizations, (Snamprogetti) Unit and the Etherification
Unit. The raw materials used are isobutane, methanol, and water as feedstock. In
addition, two types of catalysts are chromia alumina catalyzed compound in
Snamprogetti Unit, while sulphonic ion exchanged resin catalyzed is used in the MTBE
reactor. A good deal of catalyst has been devoted to improve the activity, selectivity,
and the lifetime of the catalysts.
Design Project 2 also includes Process Control, Safety, Economic Evaluation, Process
Integration and as well as Waste Treatment, which are considered as group works.
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
CONTENTS
TITLE PAGE
DECLARATION II
CERTIFICATION III
ACKNOWLEDGEMENT V
ABSTRACT VI
LIST OF TABLES
LIST OF FIGURES
LIST OF NOMENCLATURES
REPORT 1
1.1 Introduction 1
1.2 Historical Review of MTBE Production Process 2
1.2.1 UOP Oleflex Process 3
1.2.2 Philips Star Process 3
1.2.3 ABB Lummus Catofin Process 3
1.2.4 Snmprogetti Yartsingtez FBD Process 4
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
3.5 Supply 14
3.6 Market Price 15
3.6.1 Methanol 15
3.6.2 Isobutane 16
3.6.3 Catalyst 16
3.6.4 Conclusion 16
3.7 Economic Analysis 17
3.7.1 Break Even Analysis 17
3.7.2 Data Calculation1 20
5.1 Introduction 34
5.2 Stack gas 35
5.2.1 Gas Emission treatment 35
5.3 Wastewater Treatment 35
5.3.1 Wastewater characteristic 35
5.3.1a) Priority pollutants 36
5.3.1b) Organic 36
5.3.1c) Inorganic 37
5.3.1d) pH and Alkalinity 37
5.3.1e) Temperature 38
5.3.2 Liquid waste treatment 38
5.3.2a) Equalization treatment 38
5.3.2b) Solid waste treatment 39
5.3.3 Waste Minimization 41
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
6.1 Introduction 42
6.2 Material Safety Data Sheet 43
6.2.1 Isobutane 43
6.2.1.1 Product Information 43
Physical & Chemical Properties 43
6.2.1.2 Immediate Health Effects 44
6.2.1.3 First Aid Measure 44
6.2.2 N-Butane 44
6.2.2.1 Handling and Storage 45
6.2.3 Methanol 45
6.2.4 MTBE 46
6.2.4.1 Physical State and Appearance46
6.2.4.2 Physical Dangers 46
6.2.4.3 Chemical Dangers 47
6.2.4.4 Inhalation Risks 47
6.2.5 TBA 47
6.2.5.1 Recognition 48
6.2.5.2 Evaluation 48
6.2.5.3 Controls 48
6.3 Hazard Identification & Emergency Safety & Health Risk 49
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
8.2.6 Mixer 80
8.2.7 Expander 1 81
8.2.8 Cooler 1 82
8.2.9 Distillation Column 1 84
8.2.10 Cooler 2 86
8.2.11 Pump 3 87
8.2.12 Extraction Column 88
8.2.13 Pump 4 89
8.2.14 Pump 5 91
8.2.15 Distillation Column 2 92
8.2.16 Cooler 3 93
CHAPTER 9 HYSYS 95
APPENDICES
REPORT 2
CONTENTS
PAGE
1.1 Introduction 1
1.2 Estimation of Cost Diameter of Reactor 3
1.3 Calculation of TDH Height 4
1.4 Minimum Fluidization Velocity 4
1.5 Calculation for Terminal Velocity 5
1.6 Find the Value Kih 8
1.7 Find the value Eo 9
1.8 Calculation of Solid Loading 10
1.9 Calculation for Holding Time 12
1.10 Calculation for Pressure Drop 14
1.11 Determine the Direction and Flowrate 15
1.12 Design of Cyclone 17
1.13 Calculation for Mechanical Design 21
2.2 Mechanical Design
2.2.1 Introduction 58
2.2.2 Design stress 59
2.2.3 Welded Joint Efficiency 59
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
3.1 Introduction 78
3.2 Selection f Construction Material 79
3.3 Chemical Design 79
3.3.1 Determine the Number of Plate 81
3.3.2 Determination of Number of Plate 88
3.3.3 Physical Properties 89
3.3.4 Determination of Column Diameter 89
3.3.5 Liquid Flow Arrangements 90
3.3.7 Plate Layout 91
3.3.8 Entrainment Evaluation 91
3.3.9 Weeping Rate Evaluation 94
3.3.13 Number of Holes 95
3.3.14 Column size 96
3.4 Mechanical Design
3.4.1 Material construction
3.4.2 Vessel Thickness 98
3.4.3 Heads and closure 98
3.4.4 Total Column Weight 99
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
APPENDICES
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
5.4 By taking D = 500 mm, the selected tube nozzle is: 149
5.5 Standard Flange for Inlet isobutene 150
5.6 Standard Flange for Outlet isobutene 151
5.7 Standard Flange for Inlet Steam 151
5.8 Standard Flange for Outlet Steam 151
5.9 Using Ds = 600mm, the Standard Steel Saddles
for Vessels up to 1.2m 152
5.10 Summary of Mechanical Design For
Heat Exchanger in Series 153
Chapter 2
2.1 Parameter at Heat Exchanger 151
2.2 Parameter at Catalytic Cracking Fluidized Bed Reactor 152
2.3 Parameter at Compressor 153
2.4 Parameter at Condenser 154
2.5 Parameter at Separator 154
2.6 Parameter at Fixed Bed Reactor 155
2.7 Parameter at MTBE Distillation Column 156
2.8 Parameter at Liquid-liquid Extraction Column 157
2.9 Parameter at Distillation Column 158
2.10 Parameter at Mixer 159
2.11 Parameter for Expander 160
Chapter 3
3.1 Important Features in a HAZOP Study 170
Chapter 4
4.1 Labor Cost 189
4.2 Estimation Cost of Purchase Equipment 197-198
4.3 Annual Cash flow Before Tax 200
4.4 Annual Cash flow After Tax 201
4.5 Present Worth Value 202
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Chapter 5
5.1 Shows the process data for each stream. 210
5.2 Interval Temperature for ΔTmin = 10oC 211
5.3 Ranked order of interval temperature 212
5.4 Problem Table 213
Chapter 6
6.1 Parameter Limits for Wastewater and Effluent under the Environmental Quality
Act 1974 208
6.2 Functions of Pumps in the Waste Treatment Plant 215
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Chapter 2
2.1 Control Scheme for the Heat Exchanger 156
2.2 Control Scheme for Catalytic Cracking
Fluidized Bed Reactor 157
2.3 Control Scheme for the Compressor 158
2.4 Control Scheme for the Condenser 159
2.5 Control Scheme for the Separator 160
2.6 Control Scheme for the Fixed Bed Reactor 161
2.7 Control Scheme for the MTBE Distillation Column 162
2.8 Control Scheme for the Liquid-liquid Extraction Column 163
2.9 Control Scheme for the Distillation Column 164
2.10 Control Scheme for the Mixer 165
2.11 Control Scheme for the Expander 166
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Chapter 3
3.1 Methyl tert-Butyl Ether (MTBE) Plant Layout 180
3.2 Methyl tert-Butyl Ether (MTBE) Plant Evacuation Routes 181
3.3 PID before HAZOP 182
3.4 PID after HAZOP 183
Chapter 4
4.1 Cumulative Cash Flow (RM) Versus Year 203
Chapter 5
5.1 Diagrammatically representation of process stream 210
5.2 Intervals and streams 211
5.3 Heat Cascade 212
5.4 Grid for 4 stream problem 213
5.5 Grid for 4 Stream Problem 214
5.6 Proposed Heat Exchanger Network 216
Chapter6
6.1 The Sludge Treatment System 229
6.2 Waste Treatment Plant Layout 231
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Ar - Archimedes number
a - acceleration
b - dimension
C - constant
CD - drag coefficient
c - concentration
D - system diameter
d - particle diameter
E, - field intensity
F - cross-sectional area
Pr - Fronde number
g - gravitational acceleration
H - height
K - precipitation constant ,
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
µg - Gas viscosity
τ - Time for complete conversion of reactant particle
∆p - Pressure drop
Ret - dpU ρg / µ
t - time
Greek Symbols
ε - voidage in freeboard
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
ρg - gas density
ρp - particle density
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
CHAPTER 1
1.1 INTRODUCTION
Methyl tertiary butyl ether (MTBE) is produced by reacting isobutene with methanol
over a catalyst bed in the liquid phase under mild temperature and pressure. Isobutene
can be obtained from stream cracker raffinate or by the dehydrogenation of isobutane
from refineries. Ether in general is a compound containing an oxygen atom bonded to
two carbon atoms.
In MTBE one carbon atom is that of a methyl group – CH3 and the other is the central
atom of a tertiary butyl group, -C (CH3)). At room temperature, MTBE is a volatile,
flammable, colorless liquid with a distinctive odour. It is miscible with water but at high
concentrations it will form an air-vapour explosive mixture above the water, which can
ignite by sparks or contact with hot surfaces.
MTBE has good blending properties and about 95% of its output is used in gasoline as
an octane booster and an oxygenate (providing oxygen for cleaner combustion and
reduced carbon monoxide emissions). It is also used to produce pure isobutene from
C4 streams by reversing its formation reaction. It is a good solvent and extractant.
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
The MTBE plants actually consist of six units: Isomerization Unit (including
deisobutanizer), Dehydrogenation Unit, MTBE Unit, Methanol Recovery Unit,
Oxygenate Removal Unit and Olefin Saturation Unit. A common offsite utility system
will be incorporated to distribute the required utilities to each unit. There are four
method of producing MTBE implemented under license as the following:
1. UOP-Oleflex Process
2. Phillips STAR Process
3. ABB Lummus Catofin Process
4. Snamprogetti-Yarsingtez FBD (SP-Isoether) Process.
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
The UOP-Oleflex process uses multiple side-by-side, radial flow, moving-bed reactors
connected in series. Preheated feed and interstage heaters supply the heat of reaction.
The reaction is carried out over platinum supported on alumina, under near isothermal
conditions. The catalyst system employs UOP's Continuous Catalyst Regeneration
(CCR) technology. The bed of catalyst slowly flows concurrently with the reactants and
is removed from the last reactor and regenerated in a separate section. The
reconditioned catalyst is then returned to the top of the first reactor. The typical
processes involved are the deisobutenization, the isomerisation and the
dehydrogenation process that has been commercial in Malaysia.
The second one is the Philips Steam Active Reforming (STAR) Process. The Phillips
Steam Active Reforming (STAR) Process uses a noble metal-promoted zinc aluminate
spinel catalyst in a fixed-bed reactor. The reaction is carried out with steam in tubes
that are packed with catalyst and located in a furnace. The catalyst is a solid,
particulate noble metal. Steam is added to the hydrocarbon feed to provide heat to the
endothermic reaction, to suppress coke formation, and to increase the equilibrium
conversion by lowering partial pressures of hydrogen and propane.
The ABB Lummus Catofin Process uses a relatively inexpensive and durable
chromium oxide–alumina as catalyst. This catalyst can be easily and rapidly
regenerated under severe conditions without loss in activity. Dehydrogenation is
carried out in the gas phase over fixed beds. Because the catalyst cokes up rapidly,
five reactors are typically used. Two are on stream, while two are being regenerated
and one is being purged. The reactors are cycled between the reaction and the
reheat/regeneration modes, and the thermal inertia of the catalyst controls the cycle
time, which is typically less than 10 minutes. The chromium catalyst is reduced from
Cr6+ to Cr3+ during the dehydrogenation cycle. The raw materials used to produce
MTBE by using this method are butanes, hydrogen and as well as recycled isobutene
from the system itself. In this process, there is an isostripper column, which separates
the heavies, and the light ends from which then could produce MTBE.
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
CHAPTER 2
PROCESS SELECTION
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Suitable process, which is gives a lot of profit and less problem is an important in order
to determinant for the success of a plant. This chapter will briefly discuss the best
process selected based on a few criteria. It covers general consideration, detailed
consideration for process selection and conclusion on the process selection.
From the processes mentioned earlier, there are many ways to produce MTBE. It is
essential to choose the best method that will be used to produce MTBE. The selection
of the method must consider the safety of the plant, minimum waste or by product
generated, efficient and economical. Snamprogetti-Yarsingtez SP- Isoether FBD
process will be chosen as the method to produce MTBE. More detailed reasons for the
selection of this process are: High conversion (greater than 98 %) with few by-products
compared to other process. From the economy aspect,Snamprogetti-Yarsingtez FBD
Process can reduce the cost of setting up the plant as it can be implied in any of typical
MTBE-produced plant, known as “Financial Safety Net”.(When an MTBE plant faces an
oversupplied MTBE market, Isoether makes it possible to switch production from
MTBE to a superior Alkylate.). As for the safety aspects of the plant, as the
Snamprogetti-Yarsingtez FBD is a safe process as it just use the fluidize bed to the
process of producing MTBE. The process operates under low pressure and has a low-
pressure drop and this means that the fluidized bed is physically not harmful to anyone.
As for the temperature, it operates under uniform temperature profile. As the
temperature is not high, this means that the process is not as dangerous as other high-
temperature-operated process. But, precautions should be taken seriously all the time,
as we do not know when an accident could happen even in the safest place. As for the
waste by using the Snamprogetti-Yarsingtez FBD Process, the product of the process
is only MTBE and other effluent and as well as flue gas which are not harmful to the
environment.
Table 1.1 The comparison of the UOP-Oleflex, Philips Star, ABB Lummus Catofin and
Snamprogetti- Yartsingtez SP-Isoether FBD process.
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Endothermic
The main feature of this process is that the catalyst filled annuli are connected in such a way
that small, discrete amounts of catalyst can be withdrawn from the bottom of a reactor,
and sent to the top of the reactor. Catalyst withdrawn from the bottom of the reactor is
sent to a separate regeneration section for regeneration prior to being sent to the top of
the reactor. The catalyst is recirculated from the reactor to the regeneration section on
a 30–60-min cycle. The reactor and regeneration sections are totally independent of
each other. The regeneration section can be stopped, even for several days, without
interrupting the dehydrogenation process in the reactor section. The vaporized
isobutane is fed along with fresh catalyst to the first, called reactor, and the spent
catalyst is separated from the products and sent to the regenerator, where air (O 2) is
added to oxidize the carbon. The reactor cracks the isobutane and forms coke on the
catalyst. Then in the regenerator the coke is burned off and the catalyst is sent back
into the reactor. The “magic” of this process is that the reactor-regenerator combination
solves both the heat management and coking problems simultaneously. Burning off the
coke is strongly exothermic, and this reaction in the regenerator supplies the heat
(carried with the hot regenerated catalyst particles) for the endothermic cracking
reactions in the reactor.
The process operates under low pressure and has a low-pressure drop and
uniform temperature profile. Products that have been produced from this unit are
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
The MTBE unit includes two sections such as the main reaction section and the
finishing reaction. In the main reaction section, 98% conversions of isobutene occurs
mainly in the main reactor which are designed to provide the mechanical ands thermal
conditions required by the expanded catalyst bid technology.
Reactions occur in this unit are:
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
This column includes a separation column yielding MTBE product at the bottom and
(isobutene, isobutene, normal butane, water and DME) with methanol entrained by
azeotropy at the top. The reaction section bed is contained in the upper part of this
column. An excess of methanol is maintained corresponding to the amount leaving the
tower in the azeotrope. The required methanol is passed through guard beds and
filtered prior to being charged to the catalytic column to achieve final conversion.
Bottom MTBE product and the other by-product such as TBA, DME is sent to rundown
tanks under level control after cooling in feed/bottom exchanger and trim cooler.
In this unit methanol will extract from the isobutene, isobutene, normal butane to
produce C4 raffinate from the overhead of the column and at the bottom, methanol and
water are produced. C4 raffinate from this unit we decided to sell to the Korea.
CHAPTER 3
ECONOMIC SURVEY
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
The MTBE market has been in strong continuous growth since 1992. For instance, the
1998 world consumption was approximately 19.5 million tonnes, about double that of
1992, representing an annual growth rate of about 12%. Present trends indicate a mild
growth in 2000, up to 20 million tonnes, with US consumption slightly declining and
other parts of the world growing (EEA 2000). The MTBE’s role in U.S. gasoline grew
rapidly through 1995 given away in figure 3.1.
Figure 3.1 MTBE’s role in U.S. gasoline grew rapidly through 1995
(Sources: Local Issues, Global Implications)
Most Asia countries such as South Korea, Japan, Hong Kong, Taiwan, China, Malaysia,
Singapore, Philippines and Thailand, have already phased lead out of their gasoline pool
and are replacing it with oxygenates such as MTBE. Due to MTBE’s relative ease in
blending into gasoline, easy transportation and storage, as well as relatively cheap and
abundant supply, MTBE is the most widly use oxygenate in Asia.
However, the use of MTBE in gasoline blending is not mandatory for countries
like South Korea and Thailand. South Korea, for instance, requires a 1.3% - 2.3%
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
oxygenate content in gasoline during the winter, compared to a minimum of 0.5% for
the summer. In other Asian Countries, MTBE is mainly use as an octane booster to
replace lead. (source: features mtbe asias.html).
3.3 DEMAND
World demand of MTBE mod scenario is about 4.1 mil ton per annum consumption in
US West Coast at stake due to the legislation from 1998 to 2010. It has as an impact
on 80% of PETRONAS MTBE exports to the US. This mod scenario is representing in
figure 3.2.
In Europe, MTBE demand is estimated about 60,000 b/d. MTBE use in Europe
is essentially confined to Octane enhancement, and about 6,000 b/d is exported to the
United States. Eastern Europe currently consumed about 10,000 b/d of MTBE.
In Asia, demand for MTBE in this region is expected to grow at much more
rapid rate than elsewhere in the world. The rate will taper off late in decade from about
12% per year to about 8% by the turn of the century, since the early rapid growth has
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
been fed by the lead phase down which should be nearly complete by 2000. Throughout
the period, the region will be a net importer of MTBE, mostly obtained from the Middle
East. The trade balance of MTBE in Asia and Pacific is expected to be in table 3.1.
(Sources: MTBE annual Report)
Capacities listed are the average available during the year. Details for 1995 and 1999
of MTBE Balance for Asia and Pacific are shown in table 3.2. These data are also
shown graphically in figure 3.3 which indicate for MTBE supply and demand Asia and
Pacific. (Sources: MTBE annual Report)
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Demand for MTBE expected to be marginally firmer in the near future as Asian
Countries such as Indonesia and India are working totally phase out lead from their
gasoline pool. Supply on other hand is expected to remain abundant, as Asia is able to
produce about 3 million Mt/yr of MTBE for its Captive consumption. In addition to this,
Asia attracts a regular supply of about 500,000 ton/yr of MTBE from Middle Eastern
and Europe sources.(Reference: features mtbe asias.html).
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Commercial production of MTBE started in Europe in 1973 and in the US in 1979. Total
worldwide production capacity in 1998 was 23.5 million tones and the actual production
was 18 million tones
The annual production volume of MTBE in the year 2000 in the Europe was
2,844,000 tons. About 129,000 tonnes was imported and about 479 000 tonnes were
exported outside the Europe in the year 2000 ((Dewitt & Company Inc. 2002). The
majority of the exported volume (> 83%) was exported to USA and Canada. The
majority of exported volume (> 80%) was transported as non-blended MTBE and
minority as a component of petrol (blended). The annual consumption of MTBE within
the Europe was hence 2,495,000 tons in the year 2000 (see table below). For the future
no substantial increase in MTBE usage is expected. (Dewitt & Company Inc. 2002).
Table 3.3: Production, import, export and consumption in Europe in year 2000
(tonnes/year) souces: (Dewitt & Company Inc. 2002).
Production Import into Europe Export outside Europe Consumption
2 844 000 129 000 479 000 2 495 000
The world's MTBE industry today is operating at about 80% of capacity. The US
is by far the largest market, having about 43% of the production capacity but
consuming 63% of total global output. On stability, the Middle East is the swing
producer, exporting more than 50,000 bbl/day to the US and elsewhere.
3.5 SUPPLY
DeWitt’s Company estimates for local production of MTBE a summarized in table 3.4.
Most of plants unit are refinery-based units taking isobutylene from FCCU units, or as
Raffinate I from olefins plants. Since olefin plants in the region a mostly naphtha-
based, they produce significant quantities of C4 olefins for this purpose. There is one
butane-based plant in Malaysia. Table 3.4 also shown for MTBE plants suppliers to
Asia and Pacific.
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
3.6.1 Methanol
Price of methanol, as feedstock in Asia is $240 - $280 /ton. While in Europe, the prices
is $265 - $270 / ton free on board (fob) Rotterdam. In U.S. the price of methanol is 76
cts – 77cts/ gal in fob.
Global Methanol demand is expected to increase to 3.5 % per year over the
next 5 years, compared to 1.0% - 1.5% growth in 2002 and 2003. Those lower growth
rates are attributable to the phase-out of Methyl tert-butyl ether (MTBE) as oxygenate
in gasoline in California, and slower economic growth in China caused by SARS.
Methanol growth in China is forecast at 7% - 8.5% per year, fueled by formaldehyde
and acetic acid demand. (Chemicals Week)
3.6.2 Isobutane
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
3.6.3 Catalyst
Price of Chromia catalyst Compound – USD60 000/Rottedam (Rdam) from the existing
plant. (En Mohd. Napis, from MTBE plant, Gebeng )
3.6.4 Conclusion
Our company will import the methanol and isobutane as feedstock, from Petronas
Malaysia and United State (US) respectively. Methanol feedstock will be supplied from
Gurun, Kedah production capacity of 66,000 ton/year. For the second feedstock,
isobutane (instrument grade) will be supplied by Chevron Phillips Chemical Company
LP, 10001 Six Pines Drive, The Woodlands, Texas, US by shipping method.
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
consumption of MTBE has increased significantly and many new facilities have been
constructed to support the growing market (Kirschner, 1996; Riddle, 1996).
MTBE production will increase in future in Asia, Asia Pacific, Middle East and
Europe even though MTBE is banned in California but not in the entire nation of the
United States.
An economic analysis used to smooth the progress of based on existing plant. This
analysis is important to ensure that the chemical plants converge and the economics is
satisfactory before the plant operate. All the data taken from MTBE Annual 1994,
DeWitt & Company Incorporated, 16800 Greenpoint Park, Suite 120 N, Houston,
Texas, that given by Petronas Library, KLCC.
When chemical engineers determine outlay for any type commercial process, they
want these costs to be enough accuracy to provide reliable decision. To accomplish
this, they must have a complete understanding of the many factors that can affect
costs. Break-even analysis is important to ensure that the plant can give profit before
the plant can run.
The objective of break even analysis is to find the point, in dollars or in ringgits
and units, at which costs equal revenues. This point is the break even point. Break
even analysis requires an estimation of fixed costs, variable costs and revenue.
Fixed costs are costs that continue even if no units are produced. Examples
include depreciation, taxes, debt, and mortgage payments. Variable costs are those
that vary with the volume units produced. The major components of variable costs are
labor and materials. However, others cost, such as the portion of the utilities that varies
with volume, are also variable cost. The different between selling price and variable
cost is contribution. Only when total contribution exceeds total fixed cost will there be
profit.
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Table 3.6 showed that the cost of production of MTBE based on existing plant
producing 500,000 ton/year. From table 3.6, given data, break-even analysis can be
calculated to know the break-even point figure. Figure below indicate that break-even
chart, where it has been calculated by using excel that shown in table 3.8 and based
on the data given from table 3.6.
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
From the break even chart figure above, the value of break-even point at the
existing capacity of 500,000 ton/year is 185,629.85 tons in units and RM
244,679,817.14 in Ringgit Malaysia (RM). This value indicates the minimum units and
values needed to be sold. The given capacity of 500,000 tons/year can give profit to
the company. The margin of safety (MOS) calculated from the graph, which is
314,370.15 tons and RM414,373,182.86. Margin of safety (MOS) in percentage of
sales is 62.87%. The sale is allowed to drop about 62.87% before the company will
incurred a loss.
In other word, at selling 300,000 tons/year capacity will also give profit to our
company. The margin of safety from the graph for 300,000 ton/year calculated is
114,370.15 tons and RM150,751,982.86. The margin of safety (MOS) as percentage of
sales is 38.12%. The sale is allowed to drop about 38.12% before the company will
incurred a loss. All the data calculation is shown in the next section.
41
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
All the data based on 500,000 tons/year producing MTBE from existing plant.
Tables 3.7 represent cost per unit ton converted into Ringgit Malaysia (RM), taking
data’s directly from the table 3.6.
42
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Beside that, margin of safety and percentage of sale can be calculated as follows:
43
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Table 3.9 shown that the calculation of break-even point by using excel.
44
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
CHAPTER 4
45
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
The location of the plant can have a crucial effect on the profitability of a project and the
scope for future expansion. Many factors must be considered when selecting a suitable
site. A good location is required to optimise the production of the plant. It is important to
know that, not all Malaysian industrial park caters the need of a chemical plant. Also not
all industrial park allows the building of chemical plants. Our industrial parks are divided
into categories such as: -
1. Light industrial
2. Medium industrial
3. Heavy industrial
4. General industrial
5. Hi-tech industrial
All the information about plant locations are based on the data gathered from the
Malaysian Industrial Development Authority (MIDA). And we refer detail information on
important factors that need to be considered in the site selection. In the process of
selecting the location, we did some evaluation. Among the principle factors considered
are:
For materil that are produced in bulk quantities, such as cement, fertilizer, raw material
of petrochemical product, where the cost of product per tone is relatively low and the
cost of transport a significant fraction of the sales price, the plant must located close to
the primary market. This consideration will be less important for low volume production,
high priced products; such as pharmaceuticals, plastisizer and etc. in an international
46
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
market, there may be an advantage to be gained by locating the plant within an area
with preferential tariff agreement.
The availability and price of suitable raw materials will often determine the site location.
Plant producing bulk chemicals are best located close to the source of the major raw
material, where this is also close to the marketing area.
The transport of materials and products to and from the plant will be an overriding
consideration in site selection. If practicable, a site that we are consider that close to at
least two major forms of transport: road, rail, waterway or a sea port. Road transport
being increasing used, and is suitable for local distribution from central warehouse. Rail
transport will be cheaper for the long distance transport of bulk chemicals
. Air transport is convenient and efficient for the movement of personnel and
essential equipment and supplies and the proximity of the site to a major airport also
considered.
Labour that will be needed for construction of the plant and its operation. Skilled
construction workers will usually be brought in from outside the site area, but there
should be an adequate pool of unskilled labour available locally and labour suitable for
training to operate the plant. Skill tradesman will be needed for plant maintenance.
Local trade union customs and restrictive practices will have to be considered when
assessing the availability and suitability of the local labour for requirement and training
.
4.2.5 Availability of Utilities
47
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Chemical processes invariably require large quantities of water for cooling and general
process used and the plant must be located near a source of water of suitable quality.
Process water may be drawn from a river, wells or purchased from a local authority.
At some site, the cooling water required can be taken from a river or lake or
from the sea; at other locations cooling towers will be needed.
All industrial processes produce waste products and full consideration must be given to
the difficulties and cost of their disposal. The disposal of toxic and harmful effluents will
be covered by local regulations and the appropriate authorities must be consulted
during the initial site survey to determine the standards that must be met.
The proposed plant must fit in with and be acceptable to the local community. Full
consideration must be given to the safe location of the plant so that it does not impose
a significant additional risk to the community.
On a new side, the local community must be able to provide adequate facilities
for the plant personnel: schools, banks, housing and recreational and cultural facilities.
48
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Sufficient suitable land must be available for the proposed plant for future expansion.
The land should ideally be flat, well drained suitable load-bearing characteristics. A full
site evaluation should be made to determine the need for piling or other special
foundations.
Capital grants, tax concessions and other inducements are often given by government
to direct new investment to preferred locations such as areas of high unemployment.
The availability of such grants can be the overriding factor in site selection.
Our process is a petrochemical base process; therefore we choose to locate our plant in a
petrochemical complex. The reason is quite simple; a petrochemical complex could
simplify the formation and the maintenance of a chemical plant. It could also cut the daily
operation cost and saving us the hassle of transportation.
In Malaysia there are only three such places, known as the Integrated
Petrochemical Complexes. These complexes are situated in each of the site below:
Other than the above factors, the capacity of plant was also taken into consideration in
determining the suitability of site. Plant capacity will determine how big the space required
to build the plant and the storage area and also the mode of transportation to be use.
The manufacture of MTBE is classified as a petrochemical project. Several
locations of industrial area particular at Teluk Kalong Industrial Area in Terengganu,
Tanjung Langsat Industrial Area in Johor and Bintulu Industrial Area, Sarawak that we are
refer for location.
49
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Teluk Kalong Industrial Estate located 9.6 km from Kemaman. Total area available
167.46 hectares. The price of land in ranges RM 0.46 to RM 4.18 per Feet Square.
This area is proposed for petrochemical and heavy industry petrochemical.
1. Airport facilities
• Terengganu major industrial locations are serve by 3 airports
- Kuantan
- Kerteh
- Kuala Teregganu
• Kuala Teregganu
2. Port Facilities
• Kemaman Port, Kerteh Port and Kuantan Port
Tanjung Langsat is designed as hub for heavy/medium industries with all the
necessary infrastructure and service facilities. 91.43 km distance from Johor Baharu.
The infrastructure works such as the Pasir Gudang – Segamat Highway. Sungai
Johore Bridge and dedicated Port in Tanjung Langsat. Tanjung Langsat Industrial
Complex is a sprawling area just a stone’s through from Pasir Gudang Industrial Area.
A total hectare still available is 1,085.95. Selling price is RM8 to RM22 square feet. In
term of seaport two seaports are currently being constructed at Tanjung Pelepas,
50
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
located 40 km west of Johore Baharu city and Tanjung Langsat located 10 km east of
the Johore Port. Tenaga Nasianal Berhad (TNB) provides electricity.
Two airports in the 50km radius. There is the Sultan Ismail International Airport
(common known locally as Senai Airport) in Johore Baharu and the Changi
International Airport in Singapore. The Sultan Ismail International Airport, which is
located about 30km to the north west of JB city, is currently being expended and
upgrades to become the regional airport for southern peninsular Malaysia.
4.3.3 Bintulu
The distance from nearest town is 224.29 km from Sibu. Type of industries is light and
medium petrochemical. Area available is 77 hectares. Selling price RM2.5 to RM10 per
feet square. Electricity supplies by Sarawak Electricity Supply Cooperation (SESCO).
51
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Land Price
2
RM 0.46 - 4.18 RM 8.00 - 22.00 RM 2.50 - 10.00
(RM/ft )
Sarawak Electrycity
Electricity
Tenaga National Berhad Tenaga National Berhad Supply Cooperation
Supply (SESCO)
Bukit Shah Water Syarikat Air Johor and
Water Supply Syarikat Air Sarawak
Treatment Logi Air Sg. Layang
Kuala Terengganu-
Kuantan-Kuala Lumpur- North-South Highway
Major Road : Bintulu -
Road Facilities Kuala Terengganu-Kerteh- from Bukit Kayu Hitam to
Sibu and Bintulu - Miri
Teluk Kalong-Kuantan- Singapore-
Kuala Lumpur
Kuala Terengganu Airport Senai International
Airport Facilities Bintulu Airport
Kerteh Airport Airport
Kemaman Port,
Port Facilities Kerteh Port Pasir Gudang Port Bintulu Port
Kuantan Port
RM 1.68 (0-20 m 3) RM 0.95 (0 -25 m 3)
Water Tariffs
3
RM 1.15 RM2.24 (more than RM1.20 (more than
(RM/m ) 20 m 3) 25 m 3)
(Source: MIDA)
A few proposed plant sites were narrowed down based on the above factors (table 4.2).
Table 4.2 is a summary of location and factors being considered. After detailed study of
52
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
the factors, each was given weightage and was estimated. The result tabulated in table
4.2 for the purpose of comparison.
Tanjung
Telok Kalong
Langsat Bintulu
Weightage Industrial
Industrial Industrial Area
Area
Area
Marketing Area 10 8 7 7
Raw Material 10 8 9 9
Transport 10 8 7 6
Availabillity of
10 8 8 7
Labour
Utilities 10 8 9 7
Total Land
10 8 9 8
Available
Climate 10 9 9 9
Price of Land 10 9 5 7
Local
Community 10 6 8 9
Consideration
Incentives 10 8 8 8
TOTAL 100 80 79 77
Table 4.3 The Electricity Tariffs (Industrial Tariff) for Peninsular Malaysia and Sarawak
53
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
(Source: MIDA)
54
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
4.4 CONCLUSION
Based on the factor weightage studied, it can be concluded that Telok Kalong Industrial
Estate is the most suitable and practical location to choose as a site for MTBE plant.
The philosophy of in situ consumption of much of the production MTBE,
together with remaining product aimed directly at the export market and also makes the
need for port facilities of paramount importance. The Tanjung Langsat and Bintulu
Industrial Area are not impressive for MTBE plant. There are many other reasons
influences our decision including:
• Nearest of the Kuantan Port, Kemaman Port and Kerteh Port facilities is more
convenient and economically for export and import purposes.
• Excellent and consistent support from bulky oil, gas and chemical supplier from
Kerteh.
Constantly upgrading existing and developing new infrastructure, facilities and supporting
industries. These include the construction of roads; to increase accessibility to and from
the estates are scheduled.
55
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
CHAPTER 5
ENVIRONMENTAL CONSIDERATION
5.1 INTRODUCTION
Nowadays, environmental issues become very important. Besides this, a good waste
treatment system is also important in order to reduce and minimize
environmental pollutants. The chemical waste in the form of solid, liquid and
gases must be treated before being discharged into sewage, drain and
atmospheres.
Any chemical plant to be set up in Malaysia must follow the rules and
regulations under the Department of Environment (DOE) Malaysia, which includes the
Environmental Quality Act 1974. Under Environmental Quality Act (Sewage and
Industrial Effluents) Regulation 1979 and Environment Quality Act (Clean Air) 1978.
The plant owner or waste generator must ensure that waste generated disposed
appropriately to prevent environmental pollution. The proper and suitable methods
should be implemented in dealing with the waste disposal. Kualiti Alam Sdn. Bhd is
one of the licensed contractors specialized in the industrial waste disposal in Malaysia.
MTBE plant is not excluded from these regulations. As our plant produces
MTBE and other byproducts like raffinate but generally they are not hazardous to the
environment and human if safety measures are taken into consideration. These
environmental considerations depend on the location of our plant. The plant will follow
the Standard B of water quality measurement and also need some waste treatment
facilities to minimize the pollution from our plant.
56
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
STACK GASES
Direct flame combustion was used to burn the excess gas. Flare is usually open ended
combustion unit. Therefore, the combustion process will be controlled by flow
rate of gases mixture to prevent incomplete combustion.
Stack gas means the product of combustion process usually occur at machine or
generator. It is usually the fuels used occurred in the complete combustion
process, but it produced unwanted gas such as carbon monoxide, sulphur oxide
and other gases.
In our MTBE plant, the stack gases is only Hydrogen and it is stored in a
special tank before being sold to interested company at market price.
57
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Recently, greatest concern has been for this class of substances for the reasons given
previously. These materials are treated on an individual-substance basis for regulatory
control. Thus each industry could receive a discharge permit that lists an acceptable
level for each priority pollutant.
5.3.1(b) Organics
The organic composition of industrial wastes varies widely, primarily due to the
different raw materials used by each specific industry. These organics include proteins,
carbohydrates, fats and oils, petrochemicals, solvents, pharmaceutical, small and large
molecules, solids, and liquids. Another compilation is that a typical industry produces
many diverse waste streams. Good practice is to conduct a material balance
throughout an entire production facility. This survey should include a flow diagram,
location and sizes of piping, tanks, and flow volumes, as well as an analysis of each
stream.
58
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
brewery, and numerous other industrial wastes containing complex organics have been
satisfactorily treated biologically, but proper testing and evaluation is necessary.
5.3.1(c) Inorganics
The inorganics is most industrial wastes are the direct result or inorganic compounds in
the carriage water. Soft-water sources will have lower inorganics than hard-water or
saltwater sources. However, some industrial wastewaters can contain significant
quantities of inorganics which result from chemical additions during plant operation.
Many food processing wastewaters are high in sodium.
Wastewaters should have pH values between 6 and 9 for minimum impact on the
environment. Wastewaters with pH values less than 6 will tend to be corrosive as a
result of the excess hydrogen ions. On the other hand, raising the pH above 9 will
cause some of the metal ions to precipitate as carbonates or as hydroxides at higher
pH levels. Alkalinity is important in keeping Ph values at the right levels. Bicarbonate
alkalinity is the primary buffer in wastewaters. It is important to have adequate alkalinity
to neutralize the acid waste components as well as those formed by partial metabolism
or organics.
59
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
5.3.1(e) Temperature
Most industrial wastes tend to be on the warm side. For the most part, temperature is
not a critical issue below 37oC if wastewaters are to receive biological treatment. It is
possible to operate thermophilic biological wastewater-treatment systems up to 65oC
with acclimated microbes. Low-temperature operations in northern climates can result
in very low winter temperatures and slow reaction rates for both biological treatment
systems and chemical treatment systems.
Liquid treatment generally is necessary in any plant. In our plant, we also have liquid
treatment but in general, we only state the general method, as our plant does not
produce any significant liquid waste. In any liquid waste treatment, we need
equalization treatment. The equalization treatment is an initial procedure in liquid waste
treatment. The purpose of equalization is to minimize and control the fluctuation in
liquid waste characteristic. Besides it provides the suitable and optimum condition for
biological and chemical treatment. It also provides adequate damping to minimize the
chemical consumption. The procedure will occur in the equalization tank. The size of
tank and time of equalization process depend on the liquid waste amount.
The Activated Sludge process will be used for this treatment. It is carried out in
Aerobic condition. The main purpose of activated sludge process is to remove soluble
and insoluble organic matter that converted into flocculants microbial suspension and
settable microbial. It also permits the use of gravitational solid liquid separation
technique for the above requirement.
The organic matter where measured in the form of BOD and COD serves as
food and energy source for microbial growth. It converts the pollutant into microbial cell
60
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
and oxidized end product such as CO2 and H2O by microbial activities. Therefore,
Submersible Aerator as mixing device will supply the oxygen and nutrient into aeration
tank and therefore improves the quality of the liquid. (Howard et. al, 1985)
The solid waste treatment will be minimized by regenerating the catalyst. Regeneration
processes depend on the characteristic of catalyst after whole reaction. Licensed
contractor will dispose the solid waste to follow the DOE regulation. By the way,
the scheduled maintenance activities will be implemented.
Dewatering system will be used to solidify and extract the catalyst. Therefore,
clarifier and filter press were used in these treatments. Clarifier is used to clarify any
impurities before going through the filters. The size of equipment depends on the flow
rate and holding time of these processes. Maintenance activities will be scheduled
based on the availability of workers and machines. Skilled and experienced workers
will do the maintenance activities, (Bailed, 1995).
61
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Industrial
Process
Waste
Reduction
Waste
Generation
Re-use
Storage
Transfer/ Processing/
Transport Recovery
Collection
Recycling/
Disposal
Reuse
62
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Waste minimization means the optimization process to minimize the waste come out of
the plant. It will be done by source reduction and recovery of the sources. The source
reduction refers to preventative measured taken to reduce the amount of waste, which
produced in this process. Recovery of the sources is aimed to reuse the excess
methanol to produce the MTBE.
The most important is by improving the product yield and this means
minimization of waste generation. It will be accomplished through improvement in
catalyst efficiency and proper maintenance activities.
63
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
CHAPTER 6
SAFETY CONSIDERATION
6.1 INTRODUCTION
For years, those employed in the chemical industry have known that the safe operation of
chemical plant is essential to the industry’s continued ability to survive. The human,
political and financial costs of having accidents are just too high for the chemical
industry to not exhibit excellence in their efforts to operate plants in safe and
environmentally responsible ways. The chemical industry has an outstanding record in
both transportation safety and the safe operations of its processes. That effort has
resulted in a dramatic and steady decline in releases and waste produced at chemical
sites.
Actions that should be taken to avoid serious chemical plant accidents are as follows:
1. In most cases involving large volumes of highly hazardous chemicals, excess
flow valves are in place that would stop a rapid flow of the chemicals
2. When highly hazardous chemicals are involved, processes have fixed
protection, as well as trained emergency response teams that could handle the
incident.
3. Appropriate reaction control or inhibiting systems are in place to interrupt
runaway reactions if cooling, heating and pressure relief are not considered
adequate.
4. Control systems are designed to detect heat or pressure of a chemical reaction
and to control that reaction.
5. Work more closely with local and state law enforcement groups.
64
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
65
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Eye: Because the liquid product evaporates quickly, it can have a severe chilling effect
on eyes and can cause local freezing of tissues (frostbite). Symptoms may include
pain, tearing, reddening, swelling and impaired vision.
Skin: Because the liquid product evaporates quickly, it can have a severe chilling
effect on skin and can cause local freezing of tissues (frostbite). Symptoms may
include pain, itching, discoloration, swelling, and blistering. Not expected to be harmful
to internal organs if absorbed through the skin.
Ingestion: Material is a gas and cannot usually be swallowed.
Inhalation: This material can act as a simple asphyxiant by displacement of air.
Symptoms of asphyxiation may include rapid breathing, in coordination, rapid fatigue,
excessive salivation, disorientation, headache, nausea, and vomiting.
Convulsions, loss of consciousness, coma, and/or death may occur if exposure to high
concentrations continues.
Eye: Flush eyes with water immediately while holding the eyelids open. Remove
contact lenses, if worn, after initial flushing, and continue flushing for at least 15
minutes. Get immediate medical attention.
Skin: Skin contact with the liquid may result in frostbite and burns. Soak contact area
in tepid water to alleviate the immediate effects and get medical attention.
Ingestion: No specific first aid measures are required because this material is a gas
and cannot usually be swallowed.
Inhalation: For emergencies, wear a niosh approved air-supplying respirator. Move
the exposed person to fresh air. If not breathing, give artificial respiration. If breathing is
difficult, give oxygen. Get immediate medical attention.
6.2.2 N-Butane
N-Butane synonym with I-Butane, Butane, and Normal Butane is a flammable gas. N-
Butane is heavier than air and may travel considerable distance to an ignition source.
66
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
N-Butane is listed under the accident prevention provisions of section 112(r) of the
Clean Air Act (CAA) with threshold quantity (TQ) of 10000 pounds.
Protect cylinders from physical damage. Store in cool, dry, well- ventilated area away
from heavily trafficked areas and emergency exits. Do not allow the temperature where
cylinders are stored to exceed 130oF. Cylinders should be stored upright and firmly
secured to prevent falling or being knocked over. Full and empty cylinders should be
segregated. Use a “first in first out” inventory systems to prevent full cylinders from
being stored for excessive periods of time. Never carry a compressed gas cylinder or a
container of a gas in cryogenic liquid form in an enclosed space such as a car trunk,
van or station wagon. A leak cans re4sult in a fire, explosion, asphyxiation or a toxic
exposure.
6.2.3 Methanol
Methanol synonyms with Methyl alcohol and in chemical family alcohol with the
formula CH3OH. Methanol is a clear, colourless, mobile, volatile, flammable liquid and
it’s soluble in water, alcohol and ether.
67
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Reactivity Data:
Stability : Medium
Conditions to avoid : Oxidizing materials
Incompatibility : Sulfo-chromic mixtures
Special Precautions
Precaution to be taken in handling and storing Methanol: store in iron or steel
containers or tanks. Small quantities can be stored in reinforced glass containers.
6.2.4 MTBE
MTBE is chemically stable; it does not polymerize, nor will decompose under normal
conditions of temperature and pressure. Unlike most ether, MTBE does not tend to
form peroxides (auto-oxidize). The physical state of MTBE is that MTBE is in the form
of liquid at room temperature (25oC). It is a colourless liquid with the billing point at
68
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
55.2oC 131.4oF. The freezing point of MTBE is –108.6oC –163.5oC. The density of
MTBE at 25oC is 735g/cm3.
MTBE is non-reactive. It does not react with air, water, or common materials of
construction. The reactivity of MTBE with oxidizing materials is probably low. However,
without definitive information, it should be assumed that MTBE reacts with strong
oxidizers, including peroxides.
MTBE is highly flammable and combustible when exposed to heat or flame or spark,
and it is a moderate fire risk. Vapours may form explosive mixtures with air. It is
unstable in acid solutions. Fire may produce irritating, corrosive or toxic gases. Runoff
from fire control may contain MTBE and its combustion products.
Occupational exposure limits (OELs)
Routes of Exposure
Like other ethers, inhalation of high levels of MTBE by animals or humans results in the
depression of the central nervous system. Symptoms observe red in rats exposed to
4000 or 8000 ppm in air included labored respiration, ataxia, decreased muscle tone,
abnormal gait, impaired treadmill performance, and decreased grip strength. These
symptoms were no longer evident 6 hours after exposure ceased. A lower level of
MTBE, 800ppm did not produce apparent effects (Daughtrey et al., 1997).
69
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
6.2.5.1 Recognition
6.2.5.2 Evaluation
70
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
6.2.5.3 Controls
Safety & Health Risks vary with the type of industry & the magnitude of the emergency.
The severity of the risk too will vary with especially where there are chemicals,
combustible gases, potential for fire & explosion etc. These hazards may not only pose
a danger to the health of working in a particular plant but also the adjacent community.
In the event of a major disaster property both within and outside the plant will be
damaged. The real and potential hazards at the work place must be identified and the
Safety & Health Risks that they pose assessed. This will require a close scrutiny of all
71
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
work place buildings, their design, electrical wiring, transport and storage facilities, the
work processes, workstation design, safe operating procedures, list of chemicals
substances used, their quantity, storage, daily transfer, safe usage and disposal.
MSDS’s of the chemical too have to be studied as regards their toxicity, volatility, and
their potential for a fire and/or explosion and adverse health affects both short term and
long term.
The best action plan is prevention from an emergency. This is where one has to
work closely with operation personnel to make sure that all operations are safe and
comply with OSH Legislations. All persons at work are aware of the safe procedure
and also follow those procedures. Unfortunately in the real world, mostly human
factors- accident & emergency do occur. This is why emergency response plans have
to be written up, communicated to all concerned and tested for effectiveness.
Depending on the gravity the workplace emergency can be categorized in to Level 1,
Level 2, or Lever 3 emergency.
Level 1 Emergency- the first responder without having to call the disaster
response team or outside help can effectively manage such incident. Examples; a
small fire easily smothered, chemical spill easily contained and cleaned, injury minor
and treated at site by rendering first aid.
72
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Level 3 Emergency- these are major disaster that are difficult to contain even
with trained personnel and outside help. Examples, spill that cannot be properly
contained or abated even by highly trained team and the use of sophisticated special
equipment. Fire involving toxic material that is too large to control and are to burn. This
may require the evacuation of civilians across jurisdictional boundaries
73
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
CHAPTER 7
MASS BALANCE
100 kgmole/hr S2
74
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
iC4H10 C4H8 + H2
Balanced Based upon the stoichoimetric ratio with 65% conversion of iC4H10 to obtain
C4H8.
Input Output
Stream S2 S5
Component MW Molar flow Mass flow kg/hr Molar flow Mass flow kg/hr
kg/kgmole kgmole/hr kgmole/hr
C4H8 56 - - 64.74 3625.44
H2 2 - - 64.74 129.4
iC4H10 58 99.6 5776.8 34.86 2021.88
n C4H10 58 0.4 23.2 0.4 23.4
Total 5800 5800
75
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
7.2 SEPARATOR
Input Output
Stream S9 S10 S11
Component MW Molar flow Mass flow Molar flow Mass flow Molar flow Mass flow
kg/kgmole kgmole/hr kg/hr kgmole/hr kg/hr kgmole/hr kg/hr
C4H8 56 - - - - 64.74 3625.44
H2 2 - - 64.74 129.4 64.74 129.4
iC4H10 58 99.6 5776.8 - - 34.86 2021.88
n C4H10 58 0.4 23.2 - - 0.4 23.4
Total 5800 129.4 5670.6
7.3 MIXER
0.3596 CH3OH
0.6404 H2O
76
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Input Output
Stream S13 S27 S14
Component MW Molar flow Mass flow Molar flow Mass flow Molar flow Mass flow
kg/kgmole kgmole/hr kg/hr kgmole/hr kg/hr kgmole/hr kg/hr
CH3OH 32 71.214 2278.848 0.146 4.67 71.36 2283.52
H2O 18 - - 0.26 4.68 0.26 4.685
Total 2278.848 9.356 2288.205
77
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
98%
C4H8 + CH3OH conv. C5H12O + C4H8 + CH3OH
64.74 71.214 63.44 1.3 7.92
unconverted
kgmole/hr kgmole/hr
64.74 kgmole/hr
1 C4H8
R
e kgmole/hr
ac C4H8
to
r CH3OH
64.74 kgmole/hr C5H12O
1 CH3OH
Input Output
Component MW Molar flow Mass flow Molar flow Mass flow
78
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
98%
2CH3OH conv. C2H6O + H2O + 2CH3OH
7.92 3.88 3.88 0.16
unconverted
kgmole/hr kgmole/hr
R
7.92 kgmole/hr e kgmole/hr
ac CH3OH
1 CH3OH
to
r C2H6O
H2O
Input Output
79
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Component MW Molar flow Mass flow Molar flow Mol Mass flow
kg/kgmole kgmole/hr (kg/hr) (kgmole/hr) Fraction (kg/hr)
From 1st reaction, kgmole/hr of C4H8 remain is 1.3 and 3.88 kgmole/hr of H2O is
obtained in 2nd reaction.
Since C4H8 is limiting reactant to react with H2O, only 1.3 kgmole/hr of H2O needed to
react with C4H8
1.3 kgmole/hr
1 C4H8
80
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
R
e 4.166 kgmole/hr
ac 0.3058C4H8
to
r 0.3058C4H10O
4.14 kgmole/hr 0.688H2O
1 H2O
Input Output
Component MW Molar flow Mass Molar Mass Molar Mass
kg/kgmole kgmole/hr flow flow flow flow flow
(kg/hr) kgmole/hr (kg/hr) kgmole/hr (kg/hr)
C4H8 56 1.3 72.8 - - 0.026 1.456
H2O 18 - - 4.14 74.52 2.866 51.588
C4H10O 74 1.274 94.276
R
e S15 = 100.676 kgmole/hr
ac 0.0002 C4H8
to
r 0.3261 iC4H10
0.0037 nC4H10
0.0015CH3OH
0.5934 C5H12O
S14 = 71.36 kgmole/hr
0.0119 C4H10O
1 CH3OH
0.0363 C2H6O
0.0268 H2O
82
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Input Output
S18 S20 S21 S23
Mass Mass Mass Mass
MW Molar flow Molar flow Molar flow Molar flow
Component flow flow flow flow
kg/kgmole (kgmole/hr) (kgmole/hr) (kgmole/hr) (kgmole/hr)
(kg/hr) (kg/hr) (kg/hr) (kg/hr)
C4 H8 56 0.026 1.456 - - 0.026 1.456 - -
iC4H10 58 34.86 2021.88 - - 34.86 2021.88 - -
n C4H10 58 0.4 23.2 - - 0.4 23.2 - -
CH3OH 32 0.149 4.768 - - - - 0.149 4.768
C5H12O 88 - - - - - - - -
C2H6O 46 3.88 178.48 - - 3.88 178.48 - -
C4H10O 74 - - - - - - - -
H2O 18 1.006 18.108 12.029 216.522 - - 13.035 234.63
Total 40.321 2247.892 12.029 216.522 39.166 2225.016 13.184 239.398
S3
S17 S18
S9
S11
r tion
or or ction mn
cto or mn extrac colu
rea ct
rat act extra
liquid
colu ation
ytic Re liquid
–
pa
ea ation
d-
Liquid Distill
tal Se Distill
Ca R Liqui
85
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Input
S4 S13 S20
Molar flow Mass flow Molar flow Mass flow Molar flow Mass flow
kgmole/hr (kg/hr) (kgmole/hr) (kg/hr) (kgmole/hr) (kg/hr)
5800 2278.848 216.522
Total input 8295.37
Output
S10 S16 S26 S21
Molar flow Mass Mass Mass Mass
Molar flow Molar flow Molar flow
(kgmole/hr flow flow flow flow
(kgmole/hr) (kgmole/hr) (kgmole/hr)
) (kg/hr) (kg/hr) (kg/hr) (kg/hr)
129.48 5710.828 230.046 2225.016
Total
8295.37
output
With a basis 100 kgmole/hr of feed at stream S2, the product at stream S12 acquired is
5658.934 kg/hr.
86
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
= 6.785005854
≈ 6.785
CHAPTER 8
ENERGY BALANCE
The equation that we used to calculate the power Q or W at each equipment is:
87
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
To calculate ∆H, first we need to find the Cp values for every component in each of the
stream. To find the Cp values, we need to use this equation to find the values of Cp
C P
o
= a + bT + cT2 + dT3
The values of a, b, c and d are taken from Appendix D, Coulson and Richardson
Chemical Engineering, Volume 6. If the temperature and pressure is more than the
critical temperature and pressure of the component, we need to find the (C p – Cpo) for
that specific component. But as for all of our temperatures and pressures none of them
exceed the critical temperature and pressure; we need not to find the (Cp – Cpo).
T2
∆H = ∫ C
T1 P
dT x (n)
Should there is any reaction in the process; we need also to find the values of ∆HR
which takes place in the equipment. The equation, which we used to find ∆HR is:
and if the equipment has ∆KE and ∆PE, we also need to calculate the values by using
this equation:
so, after we have calculated all the values of the energy for each and every of the
stream, we then can calculate the value of Q or W.
And for this sample of calculations, listed are the values of constants in the ideal gas
heat capacity equation based on R. K Sinnot, Coulson & Richardson, Chemical
Engineering, Volume 6, Third Edition, Butterworth Heinemann:
88
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Component a b c d Delta HF
kJ/kmol.K kJ/kmol
-1 -4 -8
C5H12O 2.53 5.14 x 10 -2.60 x 10 4.30 x 10 -292990
CH3OH 2.12 x 101 7.09 x 10-2 2.59 x 10-5 -2.85 x 10-8 -201300
H2O 32.243 1.93 x 10-3 1.06 x 10-5 -3.60 x 10-9 -242000
C4H8 -2.994 3.53 x 10-1 -1.98 x 10-4 4.46 x 10-8 -130
i-C4H8 16.052 2.8043 x 10-1 -1.091 x 10-4 9.098 x 10-9 -16900
i-C4H10 -1.39 3.85 x 10-1 -1.85 x 10-4 2.90 x 10-8 -134610
C4H10O -4.86 x 10 7.17 x 10-1 -7.08 x 10-4 2.92 x 10-7 -312630
1
(Methods of calculations are based on, Coulson & Richardson, Chemical Engineering,
Volume 6, page 78).
S2
T = -150C
P = 750 Kpa
(liquid)
S1
T = -180C
P = 450
Calculations are Kpa
based on Yunus A. Cengel, Micheal A. Boles, Thermodynamics:
(Liquid)
An Engineering Approach, WCB/Mc Graw-Hill, 1989, page, 354-355.
Assumptions:
1. Steady operating conditions exist
2. Kinetic and potential energy negligible
3. The process is to be isentropic
Specific volume:
Isobutane = 0.255 m3/mol
n-butane = 0.263 m3/mol
89
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
(Data of these specific volumes are based on Coulson & Richardson, Chemical
Engineering, Volume 6, Third Edition, Butterworth Heinemann, page 947)
Isobutane
0.255m3/mol x 1000mol/kmol x 1kmol/58kg = 9.11 m3/kg
n-butane
0.263m3/mol x 1000mol/kmol x 1kmol/58kg = 4.53 m3/kg
Vavg = (9.11 + 4.53) m3/kg / 2 = 6.82 m3/kg
(Which remains essentially constant during the process)
2
∴Win = ∫ Vdp
1
= V1 (P2 − P1 )
= 6.82m 3 /kg(750 − 450)kpa(1k J/1kpa.m 3
)
= 6.82(300)
= 2046.00kJ/ kg
∴2046kJ/kg x 39353kg/hr
= 80516238kJ /hr = 22365.62kW
S2 S3
T = -15 oC T = 117 oC
P = 750Kpa P = 450Kpa
(Liquid) (Gas)
Stream 2
90
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
∑ ∆H =
-692.86
Stream 3
∑ ∆H =
1910.51
T2
∫ C
T2
T1 P
dT = ∫
T1
a + bT + cT 2 + dT 3
= 10100 kJ/kmol
∆H = 10100 kJ/kmol x 675.786 kmol/hr
= 6825438.6 kJ/hr
= 1902.85 kW (for i-C4H10)
And as for n-C4H10, the ∆H = 7.66 kW
So ∑ ∆H = 1910.51
Energy balance,
91
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Q=( ∑ H) out –( ∑ H) in
= 1910.51- (-692.86)
= 2603.37kW
Steam flowrate, Q = mCpΔT
Cp of isobutane, 2155 J/kg oC (Elementary Principles of Chemical Processes, W.
Rousseau et. al)
Q
m=
Cp ∆T
2603370 J/s
=
2155J/g o C x (117 - (-15)) o
C
= 9.152g/s
S3 S4
T = 117 oC T = 250 oC
P = 450 kPa P = 325 kPa
(Gas) (Gas)
Stream 3
∑ ∆H =
1910.51
Stream 4
92
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
∑ ∆H =
5378.03
T2
∫ C
T2
T1 P
dT = ∫
T1
a + bT + cT 2 + dT 3
= 28500 kJ/kmol
∆H = 28500 kJ/kmol x 675.786 kmol/hr
= 19259901 kJ/hr
= 5349.97 kW (for i-C4H10)
And as for n-C4H10, the ∆H = 21.46 kW
So ∑ ∆H t = 5371.43kW
ou
Energy balance,
Q=( ∑ H) out –( ∑ H) in
= 5371.43- (1910.51)
= 3460.92kW
93
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Q
m=
Cp ∆T
3460920 J/s
=
2155J/g o C x (250 - 118) o C
= 12.17g/s
S5
Air Out
S4
T=250oC
P=325kPa S6
(gas) Air In
S7
T=180oC
P=110kPa
(Liquid)
Stream 4
∑ ∆H =
5378.03
Stream 7
94
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
∑ ∆H =
3856.66
To calculate the value of ∆HR:
1) i-C4H10 →C4H8 + H2
so,
∆ĤR = (∆ĤF C4H8) + (∆ĤF H2) -(∆ĤF i-C4H10)
= (-130) + (0) – (-134610)
= 134480 kJ/kmol
therefore,
Although there is stream flow, but the ∆KE is too small and negligible and there is also
now work so, W is zero and as for the ∆PE, the value is neglected, as it is also too
small.
Now we calculate the value of Q,
95
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
S7 S8
T = 1800C T = 1930C
P = 110 Kpa P = 120 Kpa
(Gas) (Gas-liquid)
T7 = 453K T8 =?
P7 = 1.1 bar P8 = 1.2 bar
T4 = 453K, P4 = 1.1 bar, P8 = 1.2 bar is based on the literature review of process
Snamprogetti fluidized bed.
By assuming polytropic and ideal gas condition:
T7= T6(P7/P6)m (Coulson & Richardson, Chemical Engineering, Volume 6, page 85)
96
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
To find Ep(efficiency),
1117.76kmo l 453 1
Flow rate = x22.4x x
3600s 273 0.5
= 23 .08 m 3 / s
From Figure 3.6, Coulson & Richardson, Chemical Engineering, Volume 6, page 83,
Ep = 75%
m = α – (1/ αEp) = 1.07-(1/1.07 (0.75) ) = 0.3690
To determine T6,
T8 = T7(P8/P7)m = 453(1.2/1.1)0.3690 = 466.83K (193oC)
Tc and Pc for H2, isobutene, isobutane and n-butane, Tc = 417.07K, Pc = 38.17 bar
Trmean = (T7 + T8)/2Tc = (453+ 466.83K)/2(417.07) = 1.10 K
Prmean = (P5 + P6)/2Pc = (1.1+1.2)/2(38.17) = 0.030 bar
From Figure 3.8, Compressibility factors (Coulson & Richardson, Chemical
Engineering, Volume 6, page 87).
Z = 1.00
Then find n, n = 1/(1-m) = 1/(1-0.3456) = 1.53
Polytropic work = zRT1(n/n-1)x((P1/P2)(n-1/n) – 1)
0.53
1.53 1.2 1.53
= 1.00 (8.314 )( 453 )( 0.53 ) x −1
1.1
= 332.69 kJ/kmol
Actual work = Polytropic work / Ep
= 332.69 /0.75
= 443.60 kJ/kmol
Compressor power = 443.60 kJ/kmol x 1117.76 kmol/hr x 1hr/3600s
= 137.73 kW
Therefore the compressor power required to increase the pressure from 1.1 bar to 1.2
bar is 137.73kW.
S8 S9
T = 193oC T = 530C
P = 120 Kpa P = 100 Kpa
97
(Liquid) (Liquid)
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Stream 8
∑ ∆H =
4090.20
Stream 9
∑ ∆H =
75.61
Energy balance,
Q=( ∑ H) out –( ∑ H) in
= 75.61– 4090.20
= -4014.59 kW (heat is being released to the surrounding)
98
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Q
m=
mCp ∆T
4014590J/s
=
4.184J/g o C x (193 - 53.3) o
C
=6869.36 g/s
S10
T = 53.3oC
P = 90 kPa
(gas)
S9
T= 53.3oC
P= 100kPa
(liquid-gas)
S11
T=53.3oC
P=100kPa
Stream 9
99
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
∑ ∆H =
621.57
Stream 10
∑ ∆H =
H2 4.39x102 0.00 298 326.3 99.88
Stream 11
∑ ∆H =
512.99
Energy balance,
Q=( ∑ H) out –( ∑ H) in
= (512.99)-(621.57+99.88)
= -208.46 (heat is being released to the surroundings)
S14
T = 27oC
P = 100kPa
(liquid)
S15
T = 101oC
100
P = 2000kPa
(liquid)
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
The pressure increases from 100kPa to 2000kPa. As there is a heat exchanger (heater)
in the MTBE reactor.
Stream 11
Component Flowrates ∆ĤF To T, K ∆H
Kmol/hr kJ/Kmol K kJ/hr
C4H8 439.26 -16910 298 326.3 321.92
i-C4H10 236.53 -134610 298 326.3 188.89
n-C4H10 2.71 -126230 298 326.3 2.18
∑ ∆H =
512.99
Stream 14
Component Flowrates ∆ĤF To T, K ∆H
Kmol/hr kJ/Kmol K kJ/hr
CH3OH 4.84x102 -2.01x104 298 300 11.81
H2O 1.76 -2.42x105 298 300 -4.79
∑ ∆H =
7.02
Stream 15
Component Flowrates ∆ĤF To T, K ∆H
Kmol/hr kJ/Kmol K kJ/hr
C5H12O 4.30x102 -2.93x105 298 374 1339.10
CH3OH 1.09 -2.01 x105 298 374 1.07
101
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
∑ ∆H =
1962.32
Q=( ∑ H) out –( ∑ H) in
102
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Although there is stream flow, but the ∆KE is too small and negligible and there is also
now work so, W is zero and as for the ∆PE, the value is neglected, as it is also too small
Now we calculate the value of Q
S13
T = 270C
P = 115 Kpa
(liquid)
S12
T = 270C
P = 110 Kpa
(Liquid)
Assumptions:
Specific volume:
103
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Methanol
0.118m3/mol x 1000mol/kmol x 1kmol/32kg = 3.6875 m3/kg
Vavg = 1.78 m3/kg
Which remains essentially constant during the process
2
∴Win = ∫ Vdp
1
= V1 (P2 − P1 )
= 3.6875m 3 /kg(115 −110)kpa(1k J/1kpa.m 3
)
= 18 .44 kJ/kg
∴18.44kJ/kg x 15462 kg/hr
= 285080.63k J/hr = 79.19 kW
S13 S14
T= 27oC T= 27oC
P=115kPa P= 115kPa
(liquid) (liquid)
S29
T=27oC
P=130kPa
(liquid)
Stream 13
Component Flowrates ∆ĤF To T, K ∆H
Kmol/hr kJ/Kmol K kJ/hr
∑ ∆H =
CH3OH 4.83 x102 -2.01 x102 298 300 11.79
104
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Stream 29
Component Flowrates ∆ĤF To T, K ∆H
Kmol/hr kJ/Kmol K kJ/hr
1 5
CH3OH 9.91 x10 -2.01 x10 298 300 0.02
5
H20 1.76 -2.42 x10 298 300 0.03
∑ ∆H =
0.06
Stream 14
∑ ∆H =
11.84
S15 S16
T = 1010C T = ?0C
P = 2000 kPa P = 450 Kpa
(liquid) (Gas-liquid)
105
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
T16= T15(P16/P15)m (Coulson & Richardson, Chemical Engineering, Volume 6, page 85)
0.125(Cp, M TBE+ Cp, TBA + Cp, DM E+ Cp, methanol+ Cp, H2 + Cp, butene+ Cpisobu
Cpmean=
(1000− 453)
0.125(1510 00 + 126000 + 70700 + 44900 + 23500 + 113000 + 126000 + 113000)
= = 153.37kJ/k mol.K
1000 − 374
So , α = CPm/CPm – R = 153.37/(153.37-8.314) = 1.06
106
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
To find Ep(efficiency),
53999.92km ol 374 1
Flow rate = x22.4x x
3600s 273 0.5
= 920 .61m 3 / s
From Figure 3.6, Coulson & Richardson, Chemical Engineering, Volume 6, page 83,
Ep = 85%
m = α – 1/ αEp = (1.06-1/1.06 (0.85)= 0.0665
To determine T6,
T16 = T15(P16/P15)m = 374(0.45/2.0)0.0665 = 338.68K (65.6oC)
Tc = 417.07K, Pc = 38.17 bar
Trmean = (T15 + T16)/2Tc = (374+ 228.68K)/2(417.07) = 0.723 K
Prmean = (P15 + P16)/2Pc = (2+0.45)/2(38.17) = 0.0321 bar
Z = 0.8
Then find n, n = 1/(1-m) = 1/(1-0.0665) = 1.07
Polytropic work = zRT1(n/n-1)x((P15/P16)(n-1/n) – 1)
0.07
1.07 2 1.07
= 1.00 (8.314 )( 374 )( 0.07 ) x −1
0.45
= 4872.06 kJ/kmol
S16 S17
T = 193oC T = 64.50C
P = 120 Kpa P = 100 Kpa
(Liquid) (Liquid)
107
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Stream 16
∑ ∆H =
5298.44
Stream 17
∑ ∆H =
1084.15
Energy balance,
108
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Q=( ∑ H) out –( ∑ H) in
= 1084.15– 5298.44
= -4214.29 kW (heat is being released to the surrounding)
Q
m=
mCp ∆T
4214290J/s
=
4.184J/g o C x (193 - 64.5) o
C
=7838.44 g/s
S19
P = 305 Kpa
T = 53.3 oC
(gas)
S17
P = 450 Kpa
T =64.5 oC
( liquid )
S18
P = 400 Kpa
T = 103.3oC
( liquid )
Sample of Calculations:
R = L/D
Overall:
(NL), L = D x 1.5
109
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
= 451.779 x 2.5
= 1129.45 kmol/hr
(NV), V = L + D
= 1129.45+ 451.779
= 1581.23 kmol/hr
Stream 17
∑ ∆H =
1084.15
Stream 19
∑ ∆H =
611.21
Stream 18
110
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
∑ ∆H =
481.17
Energy balance,
Q=( ∑ H) out –( ∑ H) in
S19 S20
T = 53.3oC T = 400C
P = 305 Kpa P =100 Kpa
(Liquid) (Liquid)
∑ ∆H =
611.21
Stream 20
111
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
-2.01
CH3OH 1.01E+00 x105 298 313 0.19
-2.42
H2O 6.83E+00 x105 298 313 0.96
-1.69
i-C4H8 1.76E-01 x104 298 313 0.07
-1.84
(CH3)2O 2.63E+01 x105 298 313 7.33
-1.35
I-C4H10 2.37E+02 x105 298 313 98.29
-1.26
N-C4H10 2.71E+00 x105 298 313 1.14
∑ ∆H =
107.97
Energy balance,
Q=( ∑ H) out –( ∑ H) in
= 107.97– 611.21
= -503.24 kW
S22
T = 270C
P = 30 kPa
(liquid)
S21
T = 270C
P = 25 kPa
(Liquid)
112
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Assumptions:
7. Steady operating conditions exist,
8. Kinetic and potential energy negligible
9. The process is to be isentropic
Specific volume:
Water = 0.056m3/mol
(Data of these specific volumes are based on Coulson & Richardson’s)
(Which remains essentially constant during the process)
Water
0.056m3/mol x 1000 mol/kmol x 1 kmol/18kg = 3.11 m3/kg
Which remains essentially constant during the process.
2
∴Win = ∫ Vdp
1
= V1 (P2 − P1 )
= 3.11m 3 /kg(30 − 25)kpa(1kJ /1kpa.m 3 )
= 3.11(5)
= 15.55kJ/kg
∴15.55kJ/kg x 1469kg/hr
= 22851 kJ/hr = 22.85kW
113
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
S22 S23
T=27oC T=40oC
P=30kPa P=250kPa
(liquid) (liquid)
S20
T=40oC
P=100kPa S25
(liquid) T=27oC
P=100kPa
(liquid)
∑ ∆H =
107.97
Stream 22
-2.42
∑ ∆H =
H2O 8.16E+01 x105 298 300 1.53
114
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Stream 23
∑ ∆H =
106.83
Stream 25
∑ ∆H =
1.68
Energy balance,
Q=( ∑ H) out –( ∑ H) in
= (106.83+1.68) – (107.97+1.53)
= -0.91 kW
S24
T = 40OC
P=
300 Kpa
(liquid)
115
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
DME
0.178m3/mol x 1000mol/kmol x 1kmol/46kg = 3.87 m3/kg
butene
0.240m3/mol x 1000mol/kmol x 1kmol/56kg = 4.29 m3/kg
Isobutane
0.255m3/mol x 1000mol/kmol x 1kmol/58kg = 9.11 m3/kg
n-butane
0.263m3/mol x 1000mol/kmol x 1kmol/58kg = 4.53 m3/kg
Vavg = (3.87 + 4.29 + 9.11 + 4.53) m3/kg / 4 = 5.45 m3/kg
116
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
2
∴Win = ∫ Vdp
1
= V1 (P2 − P1 )
= 5.45m 3 /kg(300 − 250)kpa(1k J/1kpa.m 3
)
= 5.45(50)
= 272.50kJ/k g
∴272.50kJ/k g x kg/hr
= 4113932.50 kJ/hr = 1142.76kW
S26
T = 27OC
P=
150 Kpa
( liquid
) on Yunus A. Cengel, Micheal A. Boles, Thermodynamics: An
Calculations are based
Engineering Approach, WCB/Mc Graw-Hill, 1989, page, 354-355.
Assumptions:
4. Steady operating conditions exist,
5. Kinetic and potential energy negligible
6. The process is to be isentropic
Specific volume:
Water = 0.056 m3/mol
Methanol = 0.118m3/mol
(Data of these specific volumes are based on Coulson & Richardson’s)
Water
0.056 m3/mol x 1000mol/kmol x 1kmol/18kg = 4.26 m3/kg
Methanol
0.118m3/mol x 1000mol/kmol x 1kmol/32kg = 3.6875 m3/kg
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
= V1 (P2 − P1 )
= 3.974m 3 /kg(150 −100)kpa(1k J/1kpa.m 3
)
= 3.974(50)
= 198.7kJ/kg
∴198.7kJ/kg x 1624.32kg/ hr
= 322752.384 kJ/hr = 322 .75 kW
S28
T=530C
P=100kPa
(liquid)
S26
T=27oC
P=150kPa
(Liquid)
S27
T=30oC
P=70kPa
Sample of Calculations: (liquid)
R = L/D
Overall:
(NL), L = D x 1.5
= 88.44 x 1.5
= 132.66 kmol/hr
(NV), V = L + D
118
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
= 132.66 + 88.64
= 221.30 kmol/hr
Stream 26
∑ ∆H =
-4.77
Stream 27
∑ ∆H =
-235.48
Stream 28
∑ ∆H =
-240.26
Energy balance,
Q=( ∑ H) out –( ∑ H) in
= (-235.48+(-240.26))– (-4.77)
= -470.97 kW
S28 S29
T = 53oC T = 270C
P = 100Kpa P = 130 Kpa
(Liquid) (Liquid)
119
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Stream 28
∑ ∆H =
-240.26
Stream 29
Component Flowrates ∆ĤF To T, K ∆H
Kmol/hr kJ/Kmol K kJ/hr
CH3OH 9.91E-01 -2.01 x105 298 300 0.02
H20 1.76E+00 -2.42 x105 298 300 0.03
∑ ∆H =
0.06
Energy balance,
Q=( ∑ H) out –( ∑ H) in
= 0.06– (-240.26)
= 240.32 kW
Q
m=
mCp ∆T
240320 J/s
=
4.184J/g o C x (53 - 27) o C
= 2209.15 g/s
120
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
CHAPTER 9
121
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
HYSYS
There are two method that was used in calculating the mass balance and energy
balance for the process which is:
i) Manual calculation
ii) Hysys simulation
Hysys program was used to see whether the design could be run or not. Using
Hysys the calculation of the process was calculated automatically when the parameter
that needed was insert. Then if the parameter that was insert is logic so Hysys program
can calculated the result and the equipment can converge. If the data that was inserted
was illogical the equipment cannot converge and the calculation cannot be done.
At the back of this page show the simulation using Hysys that was converge
and include with the manual log book.
REFERENCES
Alber V.G Hahn (1970). The Petrochemical Industry – Market & Economics, USA
Mc Graw Hill Book Company. 363- 372.
122
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
123
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
124
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
DESIGN
PROJECT II
125
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
SECTION 1
1.1 INTRODUCTION
A bed of solid particles can be fluidized by a stream of gas through it. The fluidization
of solids in a stream of gas occurs only if the gas velocity achieved a certain value
which is called minimum fluidization velocity Umf. Once the gas velocity achieved this
value, the bed expands and pressure drop across the fluidized bed remains constant
once fluidization occurred.
In this commercial fluidized-bed catalytic cracking reactor, catalysts flow up through the
reaction regeneration section in a riser type of flow regime. The over head catalyst
captured by cyclones is returned to the hopper where it is fluidized with air to recapture
any entrained hydrocarbon vapor. The catalyst was then discharged from the hopper,
down through a standpipe. The solids flow through the standpipe was controlled by
slide valve located at the base. From there, the solids went into the riser where they
are carried by stream of air to the regenerator vessel.
The regenerator operation in these plants resembled that of the reactor except for the
system’s use of air instead of oil vapor. A portion of the catalyst from the regenerated
catalyst hopper was returned to the regenerator through catalyst fresh feed
exchangers. This action controlled the regenerator temperature and served to preheat
the feed. Another bypass line from the hopper to the regenerator was used to control
the dense bed level or holdup in the regenerator. Catalyst from the regenerated
catalyst hopper flowed through a standpipe back into riser where the feed was injected.
The commercial cracking catalysts used most widely is silica-alumina. High content
catalysts are characterized by higher equilibrium activity level and surface area. These
126
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
catalysts could be offered at a lower price. An advantage of this catalyst grade is that a
lesser amount of adsorbed, unconverted, heavy products on the catalyst were carried
over to the stripper zone and regenerator. As a result, a higher yield of more valuable
products and also smoother operation of the regenerator was achieved.
Basically the design of the fluidized bed system can be divided into several sections:
1. Reaction vessel which included:
Fluidized bed portion
Gas disengaging space or freeboard
Gas distributor
2. Solids feeder or flow control
3. Solids discharge
4. Dust separator for the exit gas
5. Instrumentation and control
6. Gas supply
127
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
The fluidized bed diameter depends on the operating gas velocity. A larger diameter is
required for a low gas velocity while for a high gas velocity, a small diameter is
required.
However the gas velocity must exceed the terminal velocity (Ut) of the particle
transport of solid particles may occur. The operating velocity should be between
minimum fluidization velocity and terminal falling velocity to maintain fluidization of
solids.
d p2 g ( ρ p − ρg )
Operating gas velocity, Uo =
18 µg
39353
= m3/s
1.484 ×3600
= 7.366 m3/s
Q
Cross sectional area, A =
V
7.366
=
0.388
= 18.985 m2
128
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
4×A
Diameter of bed, D =
π
4 ×18 .985
=
π
= 4.9164 m
≈5m
According to M. Rhodes (1998), the TDH region is considered as the region where
located above the bed surface to the top of disengagement zone. While the
disengagement zone is the region above the splash zone or region just above the bed
surface in which the upward flux and suspension concentration of fine particles
decrease with increasing in height.
There are so many correlations that can be used to find the TDH value. For this
design Amitin et al. (1968) was used.
TDH ( F ) = 7.740968 ≅ 8m
U mf D p ρ f
Re =
µ
129
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Ar = 150
(1 − ε ) Re + 1.75 1
Re 2
And (1.2)
ε 3
ε 3
By rearranging the equation (1.2) above we can get the new equation for minimum
fluidization, Umf. As a result, the equation is becomes:
U mf D p ρ f µ
Re = = (1135 .7 + 0.0408 Ar ) 0.5 − 33 .7
µ ρg d p
1.15 ×10 −5
U mf = −6
(1135 .7 + 0.0408 × 72 .44 ) 0.5 − 33 .7
1.484 × 80 ×10
U mf = 0.00425 m / s
The value of Re t need to be calculated first, then the value of U t can be calculated.
The range of particle size is 65 μm to 95 μm. The mean particle size is 250 μm.
−6
When d p = 80 ×10 m
4 ρ g ( ρ p − ρ g ) gd p
3
2
C D Ret = 2
3 µg
C D Re t
2 4 1.484 × (1282 − 1.484 ) × 9.81 × 80 ×10 −6
= ×
( ) 3
3 1.15 ×10 −5 ( 2
)
2
C D Re t = 96.227883
2 CD
From the chart of C D Re t and vs Reynolds number, for value of
Re t
130
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
2
C D Re t = 96.227883 the value of Re t = 3
ρg U t d p
Re t =
µg
1.484 ×U t ×8 ×10 −6
3=
1.15 ×10 −5
U t = 0.290599 ms −1
131
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
−6
when d p = 85 ×10 m
4 ρ g ( ρ p − ρ g ) gd p
3
2
C D Re t =
3 µ2
C D Re t
2 4 1.484 × (1282 −1.484 ) × 9.81 × 85 ×10 −6
= ×
( ) 3
3 (
1.15 ×10 −5
2
)
2
C D Re t = 115.421775 5
2 CD
From the chart of C D Re t and vs Reynolds number from figure 1.1 for value
Re t
2
of C D Re t = 115.421775 5 the value of Re t = 3.5
ρg U t d p
Re t =
µg
U t = 0.3190899 ms −1
132
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Using the correlation for estimating entrainment rates are reported in the literature. The
entrainment rate can be expressed by the following equation, as follows:
Ei∞ = K i∞ Xi (1.4)
Where Ki∞ is the elutriation rate constant for which numerous correlations have
been reported. Table 2.2 from Appendix lists various published correlations
for the elutriation rate constant.
The constant, af, in equation (1.2) is independent of the bed’s composition and can be
evaluated from experimental data for Fi as a function of h. Following Chen et al. (1979),
is the entrainment rate of particles at the bed surface, where:
133
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
3.07 ×10 −9 ρ g
3.5
g 0 .5
Eo
= (U − U )
mf
2..5
Ad eqmt µ 2 .5
Eo = (18 .98 )( 5)
(1.15 ×10 −5 ) 2..5
Eo = 10.676 kg/m2s
The following correlation is used to calculate the value of E i*∞ by using three different
investigators which is :
0.25
v U mf
0.5
E i∞
= A +130 exp −10 .4 t
ρg U U U −U mf
2
v
E i∞ = 331 − t
U
From this correlation we find that the average of the correlation for these three
investigators, shown in the table below:
134
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
= 4.36537385 kg/m 2 s
R = Σ Ri = Σ RmRi
Fm Fi
m Bi =
( F − R ) + K i∞ A
135
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
10 .93 × 0.0045
+
(10 .93 − R ) + 2.35123708 8 ×18 .98
RT
Eih =
A
0.5641475
=
18.98
= 0.0297 kg / m 2 s
Rti = Kih* A
2.35123708 8 ×1 8.98
= 404.8578835 kg/s
Ri = Kih A. Xi
= 55.90386 kg/s
136
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
The outlet concentration of a plug flow reactor is related to the inlet concentration of the
reactant by the same equation as in a batch reactor with the same residence time -.
For an equilibrium reaction between A and B, is first order.
Based on studied of Khabtou, S., Chevreau, T., and Lavalley, J.C., Micropor. Mat. 3,
133 (1994), express the rate per catalyst mass instead of reactor volume.
1 0.75 0.35
k mA = − ⋅ ⋅ ln 1 − 0.35 −
151 .92 0.75 +1 0.75
= 4.785 ×10 −3 m 3 kg −1
hr −1
137
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
[A] is experssed in concentration in mol/m3, K the rate mol m-3 s-1, kA in s-1.
τ = 2256.48/ 4.785x10-3
τ = 417574.39 hr
τ = 115.99 s
when the total holding time are calculate then the weight of the bed of fluidized bed can
be calculated. The formula used is as below:
W Bed
t=
FB 0
830 WBed
=
3600 39353
W Bed = 95679.7761 7 kg
The equation that can be used to calculate the pressure drop across the bed is:
138
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
ρg
W Bed − W Bed
ρp
( − ∆p ) =
A
1.484
( 95679.78 × 9.81 ) − ( 95679.78 ×9.81 ) ×
( − ∆p ) = 1282
18 .985
According to Kunii and Levenspield, the pressure drop across the distributor ∆p d is
10% from the value of pressure drop across the bed when fluidized ∆PB . So the value
of ∆p d is:
( ∆p d ) = 10 %( − ∆p B )
According to Kunii and Levenspield (1991), to determine the number of holes in the
Re t = 250344
1.11 Determine the direction and flow rate of gas passing between the vessels.
139
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Assuming that in fluidized flow the apparent weight of the solids will be supported by
the gas flow, the equation below gives the pressure gradient for fluidized bed flow:
( − ∆P ) = (1 − ε ) × ( ρ − ρ ) × g
p g
H
= 7411.499 Pa / m
Since the actual pressure gradient is well below that for fluidized flow, the standpipe is
operating in packed bed flow.
The pressure gradient in packed bed flow is generated by the upward flow of gas
through the solids in the standpipe. The Ergun equation above provides the
relationship between gas flow and pressure gradient in packed bed.
Knowing the required pressure gradient, the packed bed voidage and the particle and
gas properties, equation below can solve for IUrelI, the magnitude of the relative gas
velocity:
( − ∆P ) µ (1 − ε )
= 150 2
2
!U ! +
1.75
ρ f (1 − ε ) 2
rel !U rel !
H x sv ε 2
x sv ε
140
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Gp
Solid flux, = = U p (1 − ε ) ρ p
A
55 .9
Up = = 0.072715 m /s
(1 −0.41 ) ×1282
Therefore the gas flows upwards at a velocity of 0.21829 m/s relative to the standpipe
walls. The superficial gas velocity is therefore :
From the continuity for the gas, mass flow rate of gas,
Mf = ε U f ρp A
= -0.10431 kg/s
So, for the standpipe operate as required, 0.10431 kg/s of gas must flow from the lower
vessel to the upper vessel.
Size a cyclone separator for removing particles above 80µ m in diameter entrained in a
flue gas stream. The following information is supplied:
141
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
α = 0.21
β
= 0.66
dp = 0.00008 m
gas volumetric flow = 1.8 m3/s
particle density = 1282 kg/m3
gas density = 1.484 kg/m3
viscosity gas = 0.0000115 Ns/m
kinematic viscosity v = 0.0000278 m2/s
inlet gas velocity = 0.388 m/s
specific wall thickness δ = 5 mm
All dimensions of a cyclone of any design are selected depending on the width of inlet
duct b or on the diameter of cyclone Dc. The problem is to properly select one of these
dimensions from which the other dimensions are proportionally evaluated.
The cyclone diameter, settling velocity, gas velocity, and parameters of the suspension
to be separated are all interrelated parameters. Therefore, we select a preliminary
diameter for approximate calculations and then refine our estimate to a more exact
design.
b = α DC and hin = β DC
Vsec
bh = (1.5)
Win
142
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
where win is the inlet gas velocity; which for a primary cyclone operation is typically 18
to 22 m/s. Expressing b and hin in terms of diameter DC, equation above is rearranged
to solve for the cyclone diameter:
0.5 0.5
Vsec 1.8
DC =
w
=
in 0.21 × 0.66 ×18
= 0.85 m
4 Vsec 4 × 1.8
Wd = = = 8.5m / s
πDd 2
3.142 × 0.52 2
Specifying a wall thickness δ = 5 mm for the gas discharge pipe, its outside diameter
will be:
The width of the circular gap between the pipe and cyclone shell is:
Dc Dd ,out
= − = 0.45 − 0.265 = 0.185 m
2 2
The height of the circular gap from a spiral surface to the lower edge of discharge pipe
is:
The calculated dimensions of the cyclone can be checked by comparing the particle
settling time:
143
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Rc − Rd ,out
τ0 = =
wo wo
2 π Rav n
τ=
wg
where Rc and Rd,out are the radii of the cyclone and discharge pipe, respectively; n =
number of gas rotations around the discharge pipe (we may assume n = 1.5)
Vsec 1 .8
wg = = = 13 .9 m / s
H 0.7 × 0.185
w g2 13.9
2
a= = = 542 m / s 2
Rav 0.357
a 542
Ks = = = 55 .2
g 9.81
In this case, the centrifugal field in the cyclone is 55.2 times more intensive than the
gravitational.
144
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
g d 3 ρ p − ρg
Ar = ×
ν2 ρg
= 77.44
S1 = Ar x 1 x Ks = 72.44 x 55.08843
= 3999
Because 3.6 < S1 < 82,500 the flow regime through the cyclone is transitional.
Therefore, the theoretical velocity of the particles is:
(
α ρf 2
w = 0.22 d
)
0.333
(
α ρf 2
= 0.22 d
)
0.333
µρ
µρ
= 4.638 m / s
The particles have a shape factor ofψ = 0.77 and the gas inlet gas stream contains a
low volume of solid particles. Based on the operating conditions specified, the settling
velocity is
145
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
τ0 = = 0.0518s
w
Since τ0 < τ the diameter of the cyclone selected is acceptable and we may now
specify the other dimensions as based on the recommended proportions.
As a final calculation for the design, we evaluate the hydraulic resistance of the
cyclone:
1
∆ P= C D ρ win2 Where CD is the typical number of cyclone.
2
For mechanical design, the temperature and pressure are imperative properties in
calculate the thickness and the stress of the material. For that reason, the safety factor
also required as safeguard and determined by certain consideration such as corrosion
factor, location and process characteristic.
From Hysys data, the operating temperature inlet into the reactor is 250oC and
regenerator is 180oC. The design temperature is related to the operating temperature.
The design pressure and temperature for this reactor are showed as follow:
Reactor
1. Design Pressure
Operating pressure = 2.89 bar
= 0.289 N/mm2
146
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
2. Material Construction
The material used is stainless steel (18Cr/8Ni, 304). For this material, the design stress
at 200 ºC, R.K.Sinnot (1999).
Design stress, f = 115 N/mm2
Diameter vessel, Di = 5.0 m
Tensile strength, = 510 N/mm2
3. Vessel Thickness
Pi Di
e = 2 jf − Pi
(0.3179 )( 5000 )
=
2(1)(115 ) − (0.3179 )
= 7 mm + 4 mm
= 11 mm
From R.K.Sinnot (1999), this value should not be less than 12 mm (including 2 mm of
corrosion allowance). For vessel diameter around 5 m, this take e = 15 mm. A much
thicker wall will be needed at the column base to withstand the wind and dead weight
loads.
147
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
1 Rc
Cs = 3+
4 Rk
1 5 .0
= 3 +
4
0 .3
= 1.77
Pi Di
e =
2 Jf − Pi ( Cs − 0.2)
( 0.3179 )( 5000 )
=
2(1)(115 ) − 0.3179 (1.77 − 0.2 )
= 11 mm
5. Column Weight
Where,
Dm = mean diameter, m
= (Di + t)
Cv = a factor, take 1.15
148
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
To get a rough estimate of the weight of this vessel is by using the average thickness,
11mm
Therefore,
Dm = 5 + 2 x 0.011
= 5.022 m
So,
Weight of insulation, WI
Volume of insulation
= π x Dm x Hv x thickness of insulation
= π (5.022) (7.622) (0.075)
= 9.018967m3
Weight of insulation, WI
= Volume of insulation x ρ x g
= 9.018967 x 130 x 9.81
= 11501.89N
= 11.50189kN
149
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
WB = 95679.78 x 9.81
= 938618.6 N
= 938.6186 kN
Weight of cyclone
For Regenerator
1. Design Pressure
Operating pressure = 2.6 bar
= 0.26 N/mm2
For safety reason take pressure 10% above operating pressure
Design Pressure, Pi = 0.26 N/mm2x 1.1
= 0.286 N/mm2
Design Temp. , T = 180ºC
2. Material Construction
The material used is stainless steel (18Cr/8Ni, 304). For this material, the design stress
at 200 ºC, R.K.Sinnot (1999).
150
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
3. Vessel Thickness
Pi Di
e = 2 f − Pi
(0.286 )( 6500 )
=
2(1)(121 ) − (0.286 )
= 8 mm + 4 mm
= 12 mm
This section covers the choice of closure to be used in the design. Basically there are
two types of ends, which are domed ends. A standard torispherical heads and
ellipsoidal heads as well as the flat heads are calculated in order to select the most
economical head regarding its thickness. All the calculation is by referring to the R.K.
Sinnot, Coulson and Richardson Vol.6 page 815-817
1 Rc
Cs = 3+
4 Rk
1 6.5
= 3 +
4
0.39
= 1.77
Pi Di
e =
2 Jf − Pi ( Cs − 0.2)
151
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
( 0.286 )( 5000 )
=
2(1)(121 ) − 0.286 (1.77 − 0.2 )
= 14 mm
5. Column Weight
Where,
Dm = mean diameter, m
= (Di + t)
Cv = a factor, take 1.15
Hv = height or length between tangent lines, m
t = wall thickness, m
To get a rough estimate of the weight of this vessel is by using the average thickness,
12 mm
Therefore,
Dm = 6.5 + 2 x 0.012
= 6.524 m
So,
152
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
thickness = 75 mm
Volume of insulation
= π x Dm x Hv x thickness of insulation
= π (6.524) (8) (0.075)
= 12.29745 m3
Weight of insulation, WI
= Volume of insulation x ρ x g
= 12.29745 x 130 x 9.81
= 15682.94N
= 15.68294kN
Weight of bed
Weight of cyclone
Volume of cyclone in reactor = 2.438 m3
Weight of cylone = 2.438 x 9.81 x 1282
= 30661.31 N
= 30.661 kN
There fore,
Total weight = Wv +WI +WB + Wc
= 0.2856 + 31.36588 + 736.3405 + 30.661
= 798.652 kN
153
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
6. Wind Loads
Take,
For a smooth cylindrical column stack, the following semi-empirical equation can be
used to estimate wind pressure.
Pw = 0.05Uw2
= 0.05(160)2
= 1280 N/m2
Fw = Pw Deff]
Where,
Therefore,
Fw = 1280 x 6.68
= 8550.4 N/m
Bending Moment
Fw ( X ) 2
Mx =
2
154
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Where,
Therefore,
8550 .4 (18 ) 2
Mx =
2
= 1385164.8 Nm
= 1385.1648 kNm
7. Analysis of Stress
Pi Deff
σ h =
2t
(0.286 )( 6680 )
=
2(12 )
= 79.6033N/mm2
155
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
= 7.2958 N/mm2
Bending Stress,
M Di
σ b = ± + t
Iv 2
where,
Iv =
π
64
(Do
4
− Di
4
)
Iv = second moment of area
which,
Di = 6500 mm
Do = (6500+ 2(12))
= 6524 mm
so,
π
Iv =
64
(6524 4
− 6500 4 )
Therefore,
1385164 .8 ×1000 6500
σ b = ± + 12
1.3013 ×10 12
2
= ± 3.47 N/mm2
The resulted longitudinal stress, σ z is:
σ z(upwind) = σ L - σ w + σ b
156
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
σ z(downwind) = σ L - σ w - σ b
8. Elastic Stability
t
σ 1 = 2 x 104
D
m
12
= 2 x 104
6512
= 36.855 N/mm2
Maximum compressive stress will occurs when the vessel not under pressure
=σ w + σ b
= 7.2958 + 3.472
= 10.768 N/mm2
Wind load,
Fw = 8550.4 N/m
= 8.5504 kN/m
157
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
( H v + H skirt ) 2
Ms = Fw
2
(18 + 2 ) 2
= 8.5504
2
= 1710.08 kNm
As a first trial, take skirt thickness as same as the thickness of the bottom section of
the vessel, ts = 12 mm
Therefore,
4(1710 .08 )(1000 )(1000 )
σ =
bs
[π ( 6500 +12 ) (12 )( 6500 )]
= 4.287 N/mm2
Dead weight stress in the skirt,
2W
σ =
ws
[π ( D s + t s ) t s ]
Where,
158
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
= 14.592 N/mm2
= 7.2958 N/mm2
= 14.592 + 4.287
= 18.879 N/mm2
159
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Where ,
Therefore,
Both criteria are satisfied, add 2 mm for corrosion, give design thickness of 150 mm
160
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
5000 π
Minimum number bolt required, Nb =
600
= 26.18
Closest multiple of 4 = 28
Bending moment at base skirt, Ms = 212.101 kNm
Total weight of vessel, W = 236.7534 kN
Area of bolt,
1 4M s
Ab = − W … E.1.19
N b f b Db
1 4( 212 .101 )(1000 )
= − (184 .046 )(1000 )
28 (125 ) 3. 0
= 28.22 mm2
28 .22 × 4
d =
π
= 6 mm
4M s W
Fb = +
πDs
2
πDs
Fb 1
Lb = × 3
fc 10
161
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
55 .12 ×10 3
=
4 ×10 3
= 13.78 mm
Where,
Therefore,
Nozzle thickness,
Ps d opt
t =
20 σ + Ps
Where,
Therefore
162
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
( 2.74945 )(118 )
t =
20 (30 ) + 2.74945
= 0.2 mm
Where,
Therefore,
Nozzle thickness,
Ps d opt
t = σ
20 σ + Ps
163
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Where
Therefore
( 2.74945 )(1000 )
t =
20 (30 ) + 2.74945
= 2 mm
Design Pressure
Reactor Operating Pressure 2.89 bar
0
Reactor Operating Temperature 160 C
Reactor Design Pressure 3.179 bar
164
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
0
Reactor Design Temperature 200 C
Regenerator Operating Pressure 2.6 bar
0
Regenerator Operating Temperature 150 C
Regenerator Design Pressure 2.86 bar
0
Regenerator Design Temperature 180 C
Safety Factor 0.10
Design of Domed Ends
Types Torispherical head
Crown Radius 6.5 m
Knuckle Radius 0.039 m
Joint Factor 1
Stress Concentration Factor 1.77
Minimum Thickness 14 mm
Corrosion Allowance 4 mm
Column Weight
Dead Weight of Vessel 389 kN
Weight of Bed 736.34 kN
Weight of cyclone 30.66 kN
Weight of Insulation 31.366 kN
Total Weight reactor and regenerator 1791.11 kN
Wind Pressure 1280 N/m2
Loading 8550.4 N/m
Bending Moment 1385.1648 kNm
REFERENCES
Dolignier J. C, Marty E., Martin G. & Delfosse L., 1998, Modelling of gaseous pollutants
emission in circulating fluidized bed of municipal refuse. Elsevier Science
Ltd(77): 1399-1409
Gregory et al, 1985, The design of distributor for gas-fluidized bed, Powder
Technology. (42): 100-145
165
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Sinclair, J.L. and R. Jackson, “Gas-Particle Flow in a Vertical Pipe with Particle-Particle
Interactions, AIChE J., 35, 1473-1486 (1989)
Wei, F., Wang, Z., Jin, Y., Yu, Z. and W. Chen, “Dispersion of Lateral and Axial Solids
in a Cocurrent Downflow Circulating Fluidized Bed”, Powder Technology, 81, 25-
30 (1994)
Zhang, H., Zhu, J-X., “Hydrodynamics in Downflow Fluidized Beds (2): Particle Velocity
and Solids Flux Profiles”, Chemical Engineering Science, 55, 4367-4377 (2000)
166
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Wei, F., R. Xing, Z. Rujin, L. Guohua, J. Yong, “A Dispersion Model for Fluid Catalytic
Cracking Riser and Downer Reactors”, Ind. Eng. Chem. Res., 36, 5049-5053
(1997)
Yang Y.L., Y. Jin, Z.Q. Yu, Wang, Z.W., “Investigation on Slip Velocity Distribution in
the Riser of Dilute Circulating Fluidized Bed”, Powder Tech., 73, 67-73 (1992)
http://thor.tech.chemie.tu_muenchen.de/~tc2/eng/teaching/industr_chem_process/crac
king%20lecture%201.pdf
http://www.refiningonline.com/EngelhardKB/npra/NPR8851.htm
http://iglesia.cchem.berkeley.edu/ChemicalCommunications_1764_2003.pdf
http://www.caer.uky.edu/energeia/PDF/vol10-3.pdf
http://www.netl.doe.gov/publications/proceedings/96/96ps/ps_pdf/96ps3_2.pdf
http://tetra.mech.ubc.ca/CFD03/papers/paper29AF3.pdf
http://www.netl.doe.gov/products/r&d/annual_reports/2001/stpt/cfb%20operating
%20regimes%20cork.pdf
http://www.flotu.org/~weifei/twophase-ces.pdf
http://www.gtchouston.com/articles/GTC%20online%20reprint%2011-99.pdf
167
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
SECTION 2
2.1.1 INTRODUCTION
168
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Fixed bed reactors are the most important type of the reactor for the synthesis of large
scale basic chemicals and intermediates. In these reactors, the reaction takes place in
the form a heterogeneous catalyst. In addition to the synthesis of valuable chemicals,
fixed bed reactors have been increasingly used in recent years to treat harmful and
toxic substances. The most common arrangement is the multi tubular fixed bed reactor,
in which the catalyst is arranged in the tubes, and the heat carrier circulates externally
around the tubes. Fixed bed reactor for industrial synthesis are generally operated in a
stationary mode under constant operating conditions over prolonged production runs,
and design therefore concentrates on achieving an optimum stationary operation.
However, the non stationary dynamic operation mode is also great importance for
industrial operation control.
The heart of fixed bed reactor and the site of the chemical reaction is the catalyst. The
processes taking place on the catalyst may formally be subdivided into the following
separate steps:
1. Mass transfer of reactants from the main body of the fluid to the gross exterior
surface of the catalyst particle.
2. Molecular diffusion /Knudsen flow of reactants from the exterior surface of the
catalyst particle into the interior pore structure.
6. Transfer of products from the interior catalyst pores to the gross exterior
surface of the catalyst by ordinary molecular diffusion/Knudsen flow.
7. Mass transfer of products from the exterior surface3 of the particle into the bulk
of the fluid.
169
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
For industrial use, a particle size is a compromise between the speed of the exchange
reaction (which is greater with small beds) and high flow rates (which require coarse
particles to minimize the head loss). Standard resins contain particle with diameter
from 0.3 to 1.2 mm, but coarser or finer grades are available. For the MTBE production
process, the fine sulphonic ion exchange resin particles with its size less than 1.0 mm
have to be enveloped in various conceivable shapes
ρp = ρb
1-εb
= 810
1 - 0.32
= 1191.2 kg/m3
170
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Vg = εp
ρp (2.1)
= 0.32
1191.2
= 0.268 cm3/g
r = 2. Vg
Sa (2.2)
= 2 * 0.268
45 x 104
= 1.194 x10-5 m
171
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
98
= 0.013 cm2/ s
k1
CH3C(CH3)=CH2(B) + CH3OH CH3C(CH3)2OCH3 (M)
K2
Reaction kinetics:
According to Yang et al, the forward reaction of reaction above is first order with
respect to the isobutylene concentration and zero order with respect to the methanol
concentration, respectively, and the reverse reaction is first order with respect to the
MTBE concentration as shown below:
172
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
A1 A2 E1(J/mole) E2(J/mole)
= 0.0165 / min
= 0.00071/ min
The main side reactions are the dimerization of isobutylene to diisobutylene, and the
hydration of isobutylene to tert-butyl-alcohol (TBA) as shown below:
The kinetic study shows that reaction (3) can only take place when the addition of
methanol is unsufficient. Since the methanol addition is carefully arranged to allow the
molar ratio of methanol to isobutylene to be higher than 0.8, the reaction (3) can be
173
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
neglected. For reaction (4), the minor water in hydrocarbon and methanol feedstock is
consumed in the pre-reactor before it is fed into reactor. Therefore, reaction (4) can
also neglect. The products of the two side reaction are considered in the vapor-liquid
equilibrium calculation, whereas the reaction kinetics is not included in the calculation.
-rB = k1CB – k2CM
CBo = Pi /RT
W = ∫ dX
F r 2.7)
174
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
For isothermal operation, heat may be supplied or removed continuously along with the
reaction path. In order to accomplish effective heat transfer with the packed bed, the
width of the bed must be small. In other words, isothermal reactors usually consist of a
number tube arranged as in large heat exchangers with the catalyst inside the tubes
and the cooling or heating medium outside the tubes.
For the fixed bed reactor to be designed so that reactants remain isothermal, the rate
of heat required for the exothermic reaction must be exactly balance the heat transfer
from the heating medium. For any isothermal reaction of positive order, the reaction
rate falls as the reaction approaches equilibrium. Therefore a more rapid heating is
need at the reactant entrance than the reactant exit. Therefore the reactors have to be
designed as co-current to match the requirement and heat transfer.
= 2998
810
= 3.70 m3 (2.8)
Pressure drop is an important variable in the rate equations. The maximum allowable
pressure drop criteria below have to be concerned.
1. The resulting force must not be exceeding the crushing strength of the
particle. For the down flow bed this force created by the pressure drop is
transmitted by contacting solid to the bottom of the bed.
2. Mass velocity through the bed must be high enough to minimize interphase
gradients and assure good distribution. Incremental increases in pressure
175
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
drop however should not exceed savings release from improved reactor
performance. In many bed systems the maximum economical pressure drop
is in the range of 3 to 5% of the total pressure.
(ΔP) = ƒ u2 ρf
L d’p (2.9)
Re = d’p u ρf = d’p G
μf μf (2.10)
From the criteria shown above, the optimum value of pressure drop is between 3 to
15% of the total pressure. Let the height of bed equals to 4 m, the pressure drop in the
bed is 4240 N/m2 which is equal to 4.2% of the operating pressure. Therefore, the
height of bed is taken as 4m
Total cross section area of the tube can be obtained by dividing the volume of the bed
with the height of the bed.
At = 3.70
176
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
= 0.925 m2 (2.11)
If the tube diameter to particle diameter ratio is less than 10, the effect of wall can
become predominate, the void fraction and thus fluid velocity near the wall become
more dominant. However, if high value of tube to particle diameter ratio is obtained, the
heating effects through the tube wall will not be efficient. Therefore, tube with the inside
diameter Di =0.1143m and thickness 0.005m is used in this reactor, where the ratio is
approximately 11.5.
The inside diameter of the tube (Di) = 0.1143 – 2 x 0.005
= 0.1043 m
The cross section of the tube is then obtained from the equation:
At = π Di 2 /4
= 0.009 m2 (2.12)
Total number of tube can then obtained by dividing the total cross section area of one
tube.
Nt = 0.925
0.009
177
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
From reference (Process Heat Transfer’s book), the pitch of the tube is recommended
to be 1.25 times of the outside tube diameter Do.
Therefore,
Pitch of the tube (Pt) = 1.25Do
= 1.25 x 0.1143
= 0.143 m
(2.14)
2.1.9.12 Bundle Diameter
The bundle diameter depends not only on the number of tubes but also can also on the
number of tube passes. For a single pass heat exchanger type reactor, the bundle
diameter can be obtained from the empirical equation base on standard tube layout as
shown:
Where n1 and K1 = constant for use in the equation above given in reference (Process
Heat Transfer’s book). For single pass, n1 and K1 is given as 2.142 and 0.319
respectively. Hence,
= 1.70 m
2.1.9.13 Number of Tubes In the Centre Row
= 1.70/ 0.143
178
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
By using split ring floating head type from Fig 12.6 in Reference (Chem. Eng. Vol.6’s
book),
Ds – Db = 95.14 mm
Where Ds = Shell Diameter
Ds = 1.7 + 0.09
= 1.79 m
2.1.10 Baffles
Baffles are used in the shell to direct the fluid stream across the tubes, increase the
fluid viscosity and create turbulence so as to improve the rate of heat transfer. The
baffles used in this reactor are a common type i.e the single segmented baffles with
baffles cut 35 %.
The optimum baffles spacing will usually be between 0.3 to 0.5 times of the shell
diameter. Here, it is taken as 0.3 times of the shell diameter.
Bs = 0.3 Ds
= 0.3 x 1.79
179
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Nc = L -1
Bs
= 4 (2.18)
As = (Pt – Do) * Ds * Bs
Pt (2.19)
The flow pattern in the shell of a segmental baffled heat exchanger type of reactor is
complex, and this makes the prediction of the shell side heat transfer coefficient and
pressure drop much more difficult than for the tube side. However, Kern has developed
a method base on experimental work on commercial exchangers with standard
tolerances and gives a reasonably satisfactory prediction of the heat transfer coefficient
and pressure drop for standard design.
Mass velocity, Gs
Ws
Gs =
As
2.211
G =
0.218
G s =10.14 kg / m 2 s
(2.20)
180
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Gs
us =
ρ
10.14
us =
1209
u s = 0.01 m / s
(2.21)
= 0.084 m (2.22)
Reynolds number
G s d as
Re =
µ
Re = 2505
Prandtl number
CP µ
Pr =
kf
Pr =12.3
Choose buffle cut of 35%, from figure 12.30 (Coulson & Richardson’s Chemical
Engineering), we can obtained
Jf =1.3 x 10-1
181
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
k f jf Re Pr 1 / 3
hs =
de
h s = 763.2 W / m 2 o
C
Reynolds number
Re = 2505
(2.26)
∆P =8.93kPa
182
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
t1 + t 2
t mean =
2
53 + 27 (2.27)
t mean =
2
t mean = 80 o C
velocity, Gt = (2.211)/(0.927)
= 2.05 kg / sm2
v = 0.002 kg / ms
Reynolds number, Re
ρν d i
Re =
µ
Re =1000
183
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Heat transfer factor figure 12.31 (Coulson & Richardson’s Chemical Engineering),
Jh = 2 x 10-2
Pr =12.3
Tube side coefficient, hi can be calculated using equation below.
jh k f Re Pr 0.33
hi =
di
h i = 393 W / m o C
[ ] ρ 2µ
2
184
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Since the tube side heat transfer coefficient calculated is based on the inside diameter
of the tube, correction has to be done to obtain the heat transfer coefficient for outside
diameter of tube.
HO = hI . Di
Do
= 192 W/ moC (2.32)
Uc = HO . hS
HO + hS
= 100.1 W/ moC (2.33)
TLMTD = Ti –To
ln(Ti-To)/(Ti-To) (2.35)
= 45 oC
From this value can get mc = 39.63 kg/s where CPc=4220 and ti-t2 =135 oC
2.2.1 INTRODUCTION
185
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
the plant, especially the reactor vessels. However, the chemical engineer will be
responsible for developing and specifying the elementary design information for the
reactor, and need to have a general appreciation of pressure vessel design to work
effectively with the specialist designer.
Therefore, the design of wall thickness, head, column support, flange joint,
reinforcement and maximum allowable pressure are considered here.
Material of construction:
In this design, reference will mainly be based on the current British Standard BS 5500
and Bs 1515 where the current addition of Bs 5500 covers vessels fabricated in carbon
steel. The most common types used in the petroleum industry are Types 304, 316,321,
and 347.Because of their inherent high temperature strength propertied and high
corrosion resistance, they are particularly suitable for use in this process, in areas of
moderate and high temperature, and where substantial resistance such as in heater
tubes, reactors, reactor effluent exchangers and piping. In this design, material of
construction: can be constructed by using carbon steel. Type 304
DESIGN STRESS
It is necessary to decide a value for the maximum allowable stress that can be
accepted in the material of construction, for example, it can withstand without failure
under standard test conditions. The nominal design strengths (allowable design stress)
for the range of materials covered are listed in BS 5500. By using carbon steel (semi
killed or silicon Killed), the design stress is given, σD as 125 N /mm2 at design
temperature.
The strength of a welded joint will be depending on the type of joint and the quality of
the welding. The soundness of welds is checked by visual inspection and non
destructive testing (radiography).
For the reactor, it is assumed that the joint is equally as strong as the virgin plate; this
is achieved by radio graphing the complete weld length and cutting out and remarking
186
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
any defects. Therefore, the non destructive testing is assumed to be 100% and the
joint efficiency, J is taken as 1.0.
1. Corrosion and erosion or scaling will cause material lost, so an additional thickness
of material called “corrosion allowance” must be added to be calculated wall
thickness.
The minimum thickness of cylindrical section of shell to resist the internal pressure can
be determined by using equation below:
e = PD DIs
2J σD - PD
= 2.0*1.8
2.125-2
= 0.015 m (2.36)
By adding corrosion allowance 2 mm,
e = 0.015 + 0.002m
= 0.017 m
1. Hemispherical heads
2. Ellipsoidal heads
3. Torispherical heads
187
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
The selection of head depends on the cost and the thickness required for the head.
The design equations and charts for the various types of domed head are given in the
codes and standards (BS 5500) used in this design.
A standard dished head (torisphere) is used as first trial. The crown radius of this head
equals to the diameter of the shell, DIS. On the other hand, the knuckle radius is taken
as 6% of the crown radius. Since this type of head is formed by pressing, no joint is
needed. Therefore, the joint factor is taken as 1.
For the torispherical head, the minimum thickness of the head can be determined from
equation below:
eh = P D RC CS
2 J TD + PD(CS – 0.2) (2.37)
Therefore,
eh = 2.0 x1.8 x1.771
2 x 1x125 + 2.0 (1.771 - 0.2)
= 0.025 m
However, for a standard ellipsoidal head,
eh = PDDIs
2J σD - 0.2PD
= 0.014 m (2.39)
Therefore, an ellipsoidal head would probably be the most economical to be used. For
convenience, the thickness is taken to be as same of wall thickness 17 mm.
188
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
LOADING STRESSES
Wv = 39000 N
= 39 KN
189
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
From BS 3059, the mass per length of tubes is equal to 13.5 kg/ m for carbon steel.
Therefore, the weight of one tube
= 13.5 x 3 x g
= 4.529 * 104 N
≈ 45 KN (2.40)
Weight of Insulation
To avoid heat loss from the surface of the shell, mineral wool is used as the insulator.
From (Chem. Eng. Vol. 6’s book),
= 1.803 x103 N
190
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Weight of Catalyst
Total Weight
Since only 4 baffles are used in the reactor, their weight is neglected compared to
others.
W = Wv + Wi + Wt +Wc
= 1.1x 105 N
Wind Loading
Fw = P w Dm
= 1300 x2.18 m
= 2.8 x 103 N/m (2.42)
Therefore, the bending moment at bottom tangent line can be determined from
equation below:
Mx = Fw L2
191
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
2 (2.43)
= 2.8 x 103 x 42
2
= 2.24 x104 N
Uniform thickness is used for analyzing stresses in the column. If it is found satisfactory
at the bottom of the vessel which is the highest loading point, then the entire column
structure is feasible.
At bottom tangent line, the longitudal and circumferential stresses due to pressure is
given by:
Longitudal, σL = P i Di
4t
= 2.0 x1.8
4 x 0.017 (2.44)
= 53 N /mm2
Circumrerential, σh = P i Di
4t
= 2.0 x1.8
2 x 0.017
= 106 N /mm2
The direct stress is mainly due to the weight of vessel, its contents and any attachment
which is often called the dead weight stress. The stress is compressive since it is at the
bottom of the vessel to support the direct loading.
192
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
= 1.1 x 105
Л (1800 + 17) x 17 (2.45)
= 1.13 N /mm2 (compressive)
Bending Stress
The second moment of area of the vessel about the plane of bending,
Iv = Л (18344 – 18004)
64
= 4.0 x1010 mm4
σb = ± Mx (Di /2 + t) (2.47)
Iv
= ± 0.51 N/mm2
σZ = σ L + σW + σb
For upwind,
σZ = 53 – 1.13 + 0.51
= 52.38 N/mm2
For downwind,
193
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Radial Stress
= Pi = 2.0
2 2 (2.48)
= 1.0 N/mm2
Since radial stress obtained is a small value and there are torsional stress in the
system, therefore the principle stress will be σZ and σh
194
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
The value obtained is well bellow the maximum allowable design, 125 N/mm2.
2.2.11 CHECK ELASTIC STABILITY
The design of this vessel have to be checked to ensure that the maximum value of the
resultant axial stress does not exceed the critical value at which buckling will occur.
By applying a factor of safety of 12, the critical buckling stress gives:
σC = 2x104 (t/Do)
= 185.4 N/mm2 (2.49)
The maximum compressive stress will occur when the vessel is not under pressure,
= σ W + σb
= 1.13 + 0.51
= 1.64 N/mm2
The method used to support a vessel will depend on the size, shape and weight of the
vessel; the design temperature and pressure; the vessel location and arrangement;
and the internal and external fittings and attachment. Since the reactor is a vertical
vessel, skirt support is used in this design.
195
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
A skirt support consists of a cylindrical or conical shell welded to the base of the
vessel. A flange at the bottom of the skirt transmits the load to the foundations. The
skirt may be welded to the bottom, level of the vessel.
Skirt supports are recommended for vertical vessels as they do not imposed
concentrated loads on the vessel shells; they are particularly suitable for use with tall
columns subject to wind loading.
2.2.13 SKIRT THICKNESS
The skirt thickness must be sufficient to withstand the dead weight loads and bending
moments imposed on it by the vessel; it will not be under the vessel pressure.
The resultant stresses in the skirt will be:
= 4Ms
Л(Ds + ts) tsDs (2.50)
= W
Л(Ds + ts) ts
196
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
The skirt thickness should be such that under the worst combination of wind and dead
weight loading the following design criteria are followed:
Where fs is the maximum allowable design stress for the skirt material, normally taken
at ambient temperature, 20oC.
197
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
σS = σbS + σWS
Both criteria are satisfied, add 2mm for corrosion allowance, and give a design
thickness of 22 mm.
198
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
The loads carried by the skirt are transmitted to the foundation slab by the skirt base
ring (bearing plate). The moment produced by wind and other lateral loads will tend to
overturn the vessel. Since the reactor can be considered as the small vessel, the
simplest types, rolled angle ring are used. The preliminary design of base ring is done
by using Scheiman’s short cut method.
The anchor bolts are assumed to share the overturning load equally, and the bolt area
required is given by:
= 1 (4.Mbs – W) (2.53)
Nbfb Db
Scheiman gives the following guide rules which can be used for the selection of the
anchor bolts.
1. bolts smaller than 25 mm diameter should not be used
2. minimum number of bolts = 8
3. use multiples of 4 bolts
4. bolts pitch should not be less than 600 mm
The base ring must be sufficiently wide to distribute the load to the foundation. The
total compressive load on the base ring is given by:
Where Fb is the compressive load on the base ring and Ds = skirt diameter, m
The minimum width of the base ring is given by:
199
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Lb = fb 1
fc 103 (2.55)
Lb = 28255
5 x103
= 5.65 mm
This is the minimum width required; actual width will depend on the chair design
Where Lr = the distance from the edge of the skirt to the outer edge of the ring, mm
= 64 mm (from BS 4190:1967)
f’c = 28255
136 x103
= 0.21 N/mm
tb = 64 ( 3 x 0.21) ½ (2.56)
140
200
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
= 4.3 mm
All process vessels will have opening for connections, man ways, sight holes, hand
holes and instrument fittings. The presence of an opening weakens the shell, and gives
rise to stress concentrations. The stress at edge of a hole will be considerably higher
than the average stress in the surrounding plate. To compensate for the effect of an
opening, the wall thickness is increased in the region adjacent to the opening.
Sufficient reinforcement must be provided to compensate for the weakening effect of
opening without altering the general dilation pattern of the vessel opening.
Pipe size for inlet and outlet of the reactor are all less than 10 mm, therefore, the
reinforcement area can be usually is provided by increasing the wall thickness of the
branch pipe. This already done on piping, where extra thickness is provided, thus no
compensation area needed.
Flanged joints are used to connect pipes and instruments to vessels and from
removable vessel heads when ease of access is required. Flanges may also be used
on the vessel body, when it is necessary to divide the vessel into section for transport
or maintenance. Flanged joints are also used to connect pipes to other equipment,
such as pumps, valves.
201
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Have a long tapered lub between the flange ring and the welded joint. This gradual
transition of the section reduces discontinuity stresses between flange and branch,
and increases the strength of the flange assembly.
Welding neck flanges are suitable for extreme service conditions, where the flange
is likely to be subjected to temperature, shear and vibration loads.. For this reactor,
the welding neck flanges are suitable for use in connecting the inlet and outlet
piping of reactor.
b) Gasket
Gaskets are used to make a leak tight joint between two surfaces. It is impractical to
machine flanges to the degree of surface finish that would be required to make a
satisfactory seal under pressure without a gasket. Gasket are made from “semi plastic”
materials, which will deform and flow under load to fill the surface inequalities between
the flange faces, yet retain sufficient elasticity to take up the changes in the flange
arrangement that occur under load.
Several factors must be considered when selecting a gasket material:
1. The process condition: pressure, temperature, corrosive nature of
process fluid.
The raised face, narrow feed flange are used for all the flanges. Where the flange has
a plain face, as for the flange faces mentioned above, the gasket is held in place by
friction between the gasket and flange surface.
202
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Reactor Design
Catalyst weight required 2998 kg
203
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
204
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
205
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
SECTION 3
3.1 INTRODUCTION
MTBE is our main product that needs to be separated. For individual design,
MTBE distillation column was chosen. The characteristics required in the chosen types
of distillation column are the separation objective satisfied in the column, the cost of
construction and the design of the selected distillation column.
R e lief Va lve
C on den se r
T=53.3oC
T=6 4.5oC
TC
LC
206
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Materials chosen are based on the characteristics of the component in the distillation
column, the location and the environmental consideration of the MTBE plant. Stainless
steel 304 is used in construction of the MTBE distillation column - ‘The stainless steels
are the most frequently used corrosion resistant materials in the chemical industry’ –
Coulson & Richardson, Chemical Engineering, Volume 6, page 295.
Carbon steel is used in skirt support material and the insulation material used is
fiberglass. The selection is based on the chemical and mechanical design as stated in
Coulson & Richardson, Chemical Engineering, Volume 6. Most parameters used in
design were referred to mass, energy balance data and also data generated by
Chemical Engineering Simulation Software; HYSIS Version 3.2. Other materials
chosen were based on the British Standard BS 5500, BS4505 and BS 750.
207
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
T (K) kPa
kmol/hr
i-C4H10 313 337.5 450 34.860 0.3261
n-C4H10 313 337.5 450 0.400 0.0037
C4H8 313 337.5 450 0.026 0.0002
DME 313 337.5 450 3.880 0.0363
CH3OH 313 337.5 450 0.160 0.0015
H2O 313 337.5 450 2.866 0.0268
* The T(K) is the stream temperature, while the Operating T(K) temperature is the
temperature which should be achieved by controlling the pressures.
208
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
The components in the feed to the MTBE distillation column are i-C4H10, n-C4H10, C4H8,
DME, CH3OH, H2O, MTBE and TBA, and the feed is assumed as multicomponents
feed. By using the Hengstebeck’s and McCabe-Thiele method, the number of stages
required and the position of the feed in the MTBE distillation column can be
determined.
The vapor pressure can be determined by using the Antoine’s equation as follows:
B
Log10 P* = A - (3.1)
T +C
Ki = P* x P (3.2)
209
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
yi
Ki = (3.3)
xi
In this case, MTBE is as the heavy key and i-C4H10 is as the light key components. By
using goal seek in the excel programme, the value of the bubble point at bottom
column = 103.3oC and dew point at the top column is = 53.3 oC, from the values of Ki
related to the pressure, the values of relative volatilities could be determined, listed are
values of the relative volatilities for components at the top and bottom of the distillation
column.
210
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
TOP αi di li = di / (α i-1) Vi = li + di
n-C4H10 2.827497 0.4 0.218878614 0.618878614
C4H8 3.47437 0.026 0.010507724 0.036507724
DME 7.05307 3.88 0.640997055 4.520997055
CH3OH 0.83478 0.149 -0.901828648 -0.75282865
H2O 0.220372 1.006 -1.290358653 -0.28435865
∑ = -1.321803909 ∑ = 4.139
Table 3.6 The Non-Key Flow of the Bottom Stream
BOTTOM αi bi Vi’=α ibi / (α -
LK li’ = vi’ + bi’
α i)
TBA 0.074666 1.27 0.01506000 1.2900
CH3OH 0.83478 0.01 0.001652422 0.0100
H2O 0.220372 1.86 0.066417357 1.9300
∑ = 0.083127984 ∑ = 3.23
Le = L - ∑ li (3.5)
= (2.5 X 40.321) – (- 1.3218)
= 102.1243
Ve = V - ∑Vi (3.6)
= (2.5+1) x 40.321 – 4.139
= 136.985
Le 102 .1243
= (3.7)
Ve 136 .984
= 0.7455
Ve’ = V’ - ∑ Vi’ (3.8)
= (2.5+1) x 40.321 – 0.08313
= 141.04
Le’ = L’ - ∑ li’ (3.9)
= (2.5+1) x 40.321 + 66.59 – 3.23
= 204.48
211
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
flow .LK
Xb = at bottom, (3.11)
flow ( LK + HK )
1
=
(1 +62 .47 )
= 0.016
flow .LK
Xd = at top, (3.12)
flow ( LK + HK )
33 .86
Xd =
(33 .86 +1)
= 0.9713
flow .LK
Xf = at feed, (3.13)
flow ( LK + HK )
34 .86
Xf =
(34 .86 +63 .44 )
= 0.3546
α.x
Y = α from LK component (3.14)
[1 + (α − 1) x]
6.391 x
=
[1 + ( 5.391 ) x]
6.391 x
y=
1 + 5.391 x
x y
212
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
0 0
0.1 0.41527398
0.2 0.61508201
0.3 0.73257407
0.4 0.80992987
0.5 0.86471539
0.6 0.9055511
0.7 0.93716326
0.8 0.96235974
0.9 0.9829137
1.0 1.0000
So from the data as above, the McCabe-Thiele diagram was constructed to determine
the number of plates. The top operating line and the bottom operating line were
determined first before the number of plates required could be calculated.
And from the graph plotted, the number of stages needed for the MTBE
distillation column is 11 with the feed point location is at stage number six from bottom.
213
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
McCabe-Thiele Diagram
0.9
0.8 Top
Operating
Line
0.7
0.6
Number of
Stages
Equilibrium
Curve
0.4
0.3
Bottom
Operating Line
0.2
0.1
0
0 0.2 0.4 0.6 0.8 1
X
214
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
1 X D.L K X D.H K
Rmin =
α −1 −α (3.15)
X F .H K X F .H K
1 33 .86 1.0
= − 6.391
6.391 −1 63 .44 63 .44
= 0.0803
Where,
XD.LK = Light key component at top flow
XD.HK = Heavy key component at top flow
XF.LK = Light key component at feed flow
XF.HK = Heavy key component at feed flow
In the calculation, the optimum reflux ratio as 2.5 was used (based on Coulson
& Richardson, Chemical Engineering, Volume 6, and J.M Coulson, J.F Richardson,
Chemical Engineering, Volume Two, Third Edition) as 0.1204 is too low for the
calculation, based on statement from R. K. Sinnot, Coulson & Richardson, Chemical
Engineering, Volume 6, Butterworth Heinemann, 2001, page 495 – “At low reflux
ratios the calculated number of stages will be very dependent on the accuracy of the
vapor-liquid equilibrium data available. If the data are suspect a higher than normal
ratio should be selected to give more confidence in the design”.
215
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
The Fenske’s equation (1932) can be used to estimate the minimum stages required at
total reflux. The derivation of the equation is for binary system and applies equally to
multicomponents system. But in the design only the calculation of plates using
McCabe-Thiele method as the design plate number was taken into consideration.
x x
log LK HK
Nmin = x HK d x LK b (3.16)
log α LK
33 .86 62 .44
log
= 1.000 1.000
log 6.392
= 4.13
Nmin ≈ 5 stages
Normally after using the Fenske’s Equation, the value of Nmin is given by the equation
below to get the number of stages, NT,
NT = 2 (Nmin)
= 2 (5)
= 10 stages
To get the real number of stages, the efficiency of the process must be considered,
and the efficiency is calculated based on the equation by O’Connell’s (J. Douglas,
1988),
0.5
Eo = (3.17)
( µ α) 0.25
0.5
=
( 0.224 x 6.392 ) 0.25
= 0.457
216
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
NT
N =
Eo
11
=
0.457
= 24.07
≈ 24 plates
The properties consider in this design are liquid flow rate, LW, vapor flow rate, VW, liquid
surface tension, σ, liquid density, ρl and vapor density, ρv. This physical properties
evaluated at the system temperature by using HYSIS generated data or by manual
calculations the from mass and energy balance data. The useful properties data are
from HYSIS, mass and energy balance data is given as below:
The principal factor that determines the columns diameter is the vapour flow-rate. The
vapour velocity must be below that which would cause excessive liquid entrainment or
a high-pressure drop. The equation below which is based on the well-known Souders
and Brown equation, Lowenstein (1961), Coulson & Richardson, Chemical
Engineering, Volume 6, page 556, can be used to estimate the maximum allowable
superficial vapour velocity, and hence the column area and diameter,
217
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
( σ L −σ v)
1/ 2
1/ 2
( 746 .74 −3.8402 )
= 2
−0.171 ( 0.9 ) +0.27 ( 0.9) −0.047
3.8402
= 0.7997 m/s
Where,
u v
= maximum allowable vapour velocity, based on the gross (total)
l t
= plate spacing, m (range 0.5 – 1.5).
4 vw
Dc = (3.19)
π vρu v
4(0.6244 )
Dc =
π(3.8402 )( 0.7997 )
= 0.51 m
Dc = 0.51 x 1.5
= 0.765 m
For safety reason, the approximate diameter was increased 50% more than the
calculated value, as it deals with vapour, which is in high pressure.
218
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
The overall height of the column will depend on the plate spacing. Plate spacings from
0.15 m (6 in.) to 1m (36 in.) are normally used. The spacing chosen will depend on the
column diameter and the operating conditions. Close spacing is used with small-
diameter columns, and where head room is restricted, as it will be when a column is
installed in a building. In the MTBE distillation column, the plate spacing was assumed
0.9 m as it is in the range of 0.5 m to 1 m recommended by Coulson and Richardson,
Chemical Engineering, Volume 6.
Before deciding liquid flow arrangement, maximum volumetric liquid rate were
determined by using equation below,
Lw
VL =
ρ L
(3.20)
38747 .97
VL =
746 .74
VL = 51.89 m3/hr
= 0.0144 m3/s
Based on the values of volumetric flow rate and column diameter, Dc. Figure
11.28 from Coulson & Richardson, Chemical Engineering, Volume 6, page 568.
Therefore, types of liquid flow could be considered as single pass.
The value of downcomer area, active area, hole area, hole size, and weir height were
determined based on above value calculated, trial plate layout column area determined
by using the equation below,
219
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Um
Column area, Ac = (3.21)
Uv (0.9)
4.181
=
0.7997 (0.9)
= 5.81 m2
Down comer area were found by assume 20% of column area and using equation
below,
Down comer Area Ad = 0.2 Ac
= 0.2(5.81 m2)
= 1.162 m2
Net area and active area were determined by using equations below,
Net Area, An = Ac - Ad
= 5.181 -1.162
= 4.02 m2
Hole Area, AH are determine with trial value of 10% active area by equation below,
Hole Area, Ah = 0.10(Aa)
= 0.10(2.857)
= 0.2857 m2
Weir Length, lw was calculated by referring Figure 11.31 from Coulson Richardson,
Chemical Engineering, Volume 6, page 572 which was determined based on the
value of the ratio of Ad/Ac to get the ratio of lw/ Dc .
220
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
0.5
Lw ρv
FLV =
ρl
(3.23)
Vw
0.5
38747 .97 3.8402
=
15251 .95
746 .74
= 0.182
Where FLV is liquid vapor factor.
Based on value of FLV and assumption made for initial tray spacing (0.9m) by
referring to Figure 11.27 from Coulson & Richardson, Chemical Engineering, Volume
6, page 567, the data were used to determine the constant, K1 for the estimation of
flooding velocity. Before that, correction factor are used as equation below:
0.2
σ
K1 = k1 0.02 (3.24)
221
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
0 .2
0.0351
= 0.1
0.02
= 0.112
= 1.56 m/s
Uv
Actual % of flooding = ×100 (3.26)
Uf
0.807
= ×100
1.560
= 51.8%
222
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Weir liquid crest were determined by using values of maximum liquid flow rate
and minimum flow rate based on the process condition and also assumption of
turndown percentage based on the liquid characteristic. Each weir liquid crest value
was determined by using equations as follow, the Francis weir formula (see also
Volume 1, Chapter 5),
2/3
Lw max
Max how = 750
ρl (lw )
(3.27)
2/3
1.5860
= 750
(746 .74 )( 0.88 )
= 13.49 mm liquid
2/3
Lw min
Min how = 750
ρl (lw )
(3.28)
2/3
10 .7633
= 750
(746 .74 )( 0.88 )
= 48.37 mm liquid
Where,
Iw = Weir length, 0.88 (standard)
how = weir crest
Lw = liquid flow rate
At minimum liquid flow rate, the value was determined by adding weir height H w and
weir crest, how the constant, K2 where it is found based on the value by referring to
Figure 11.30 from Coulson & Richardson, Chemical Engineering, Volume 6, page
571.
Minimum vapor velocity Uh, were determined by using the equation as below,
K 2 − 0.90 ( 25 .4 − d h )
Uh = (3.29)
ρv 0.5
223
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Area of hole,
2
πd h
AH = (3.30)
4
π × (0.05 ) 2
=
4
= 1.9634 x 10-3 m2
Ah
Number of Holes = (3.31)
AH
0.2857
=
1.9634 ×10 −3
= 145.49
≈ 146 units (at every sieve plate).
The column height will be calculated based on the equation given below. The equation
determines the height of the column without taking the skirt or any support into
consideration. Its determination is based on condition in the column.
The overall height from the calculation is 10.85 m, but in a real construction it
will be added slightly more (about 10%) because of vapor and liquid area at top and
bottom column. The space for vapor and liquid are required if uncertain condition occur
224
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
in the column, such as over flooding, over vapor pressure or upset in reaction situation.
The calculated result is tabulated in the Table 5.8 as below.
Item Value
Column Diameter, Dc 0.765 m
No of Plates 11 units
Plate Spacing 0.9 m
Plate Thickness 5 mm*
Total Column Height, Ht 12.00 m
Plate Pressure Drop, ht 192.81 mm liquid*
Plate Material SS 304
Down Comer Area, Ad 0.8348 m2
Down Comer Material SS 304
Column Area, Ac 5.181 m2
Net Area, An 4.020 m2
Active Area, Aa 2.857 m2
Hole Area, Ah 0.2857 m2
Number of Holes 146 units
Weir Length 0.612 m
Weir Height (standard) 0.05 m
Resident Time 13.37 seconds*
* For the determination of these values, they are shown in the Appendix section.
In the mechanical design, the temperature and pressure are important properties in
evaluating the thickness and the stress of material. Therefore, the safety factor also is
225
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
The safety factor is usually 10% above the operating pressure and as for this
MTBE distillation column, the operating pressure is 450 kPa. The chosen safety factor
is based on the process characteristics of the system. The design temperature is
related to the operating temperature. Based on the calculated result, the temperature
at the top of the column is 53.3oC and the temperature at the bottom of the column is
107oC.
The material used in the construction of the distillation column is stainless steel
(18Cr/8Ni, 304) as the material is suitable in high temperature and less corrosive. For
this material, the design stress at 150 ºC is obtained from Table 13.2, page 809
Coulson & Richardson, Chemical Engineering, Volume 6.
The minimum thickness of column required and other designs are calculated based on
equation below (Coulson & Richardson, Chemical Engineering, Volume 6, page 812):
226
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Pi Di
e = (3.32)
2Jf − Pi
(0.495 )( 765 )
=
2(1)(145 ) −(0.495 )
= 1.31 mm
e = 1.31 mm + 5 mm
= 6.31 mm
Assumed ≈ 7.00 mm
A much thicker wall is needed at the column base to withstand the wind and
dead weight loads. As a first trial, divide the column into five sections, with the
thickness increasing by 2 mm per section. Try 7, 9, 11, 13 and 15 mm. The average
wall thickness is 11 mm.
227
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Torispherical head had been chosen because of operating pressure below 10 bars and
suitable for liquid vapor phase process in inconsistent high pressure. The calculations
as below is considered,
Total Weight, Tw
Total weight is the summation of the weight of dead weight, the weight of plates and
the weight of insulation. The calculations for the dead weight, the weight of plates and
the weight of the insulation are shown in the Appendix.
Total weight, Wt = W v + Wp + WI
= (28.46 + 68.53 + 10.63) kN
= 107.62 kN
The wind load is calculated based on location and the weather of surrounding.
Therefore, the value of wind speed is assumed as below and wind load is calculated
shown in the appendix. The wind load for the MTBE column is 62.91kN (methods of
calculation in shown in the appendix.
228
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
229
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
230
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
(The method of calculations for other parameters in the vessel support design in shown
in the Appendix section)
Support Data
Type of Support Straight cylindrical skirt
Material of Construction Carbon steel
Design Stress, at T 20ºC (ambient) 135 N/mm2
Skirt Height 2.50 m
Young’s Modulus 200000 N/mm2
σ L 746.74 kg/m3
Approximate Weight, Wapprox 8.418 kN
Total Weight 107.62 kN
Wind Load, Fw 1068.8 N/m2
Skirt Thickness, ts 15 mm
REFERENCES
231
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
SECTION 4
4.1 INTRODUCTION
232
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
extractor types, in the evaluation of which the chemical engineer must primarily depend
on manufacturers’ literature.
To the design, only three components that are considered, - methanol, water
and isobutene- this is because of for most system containing more than four
components, the display of equilibrium data and the computation of stages is very
difficult. In such cases, the requirements are best obtained in the laboratory without
detail study of the equalibria. (Treybal, Mass Transfer Operations, 1987).
Sieve tray (perforated plate) Column were choose for the extraction of these
components. These multistage, countercurrent columns are very effective, both with
respect to liquid-handling capacity and with respect to extraction efficiency, particularly
for system of low interfacial tension, which do not require mechanical agitation for good
dispersion.
There is usually a wide choice of liquids to be used as solvent for extraction operations.
It is unlikely that any particular liquid will exhibit all the properties considered desirable
for extraction, and some compromise is usually necessary. The following factors need
to be considered when selecting a suitable solvent for a given extraction – affinity for
solute, partition ratio, density, miscibility, safety and cost. Based on the factors that
need to be considered water was choosing as a solvent in this system.
233
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Most of the design parameter used were refer to mass balance, energy balance data
and generated by chemical Engineering Simulation Software, HYSIS.
To determine the theoretical stages required, by assuming the minimum solvent to feed
ratio required to remove all the minimum component, so that is the extraction factor, ε =
1(Schweitzer, Separation Handbook). Equation 4.1 was used. The value for X f =
0.0195 kg CH3OH/ kg water, Ys = 1.57 x 10-6 kg CH3OH/ kg water was compute from
the mass balance at this system.
234
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
The number of mass transfer unit, Nor is identical to the number of the theoretical
stages when extraction factor, ε = 1.
Nor = 10 units
The sieve tray sizing was base on the manufacturer’s literature. Usually the tray
spacing is from (6 to 24) in, and perforation diameter, do usually from (0.32 to 0.64) cm
or (1/8 to 1/4) in diameter. By take 2 ft tray spacing, Zt, 0.25 in holes on 0.75 in
triangular spacing. The downcomer area is found with equation 4.4.
2 = 4.5(41.45) Vd2
2(4.18 x 108) 17.35
Vd = 12471 ft/hr
Ad = QD/ Vd (4.5)
= 1254.92 / 12471
= 0.1006 ft2
235
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
To determine the total holes area in a tray used equation 4.6 and set the velocity
through the holes, Uh are kept below 0.8 ft/sec or 2880ft/ hr to avoid formation of very
small droplet.
To find the tray area, by using ratio of the tray area to hole area as state below:
ds = triangular spacing
236
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
=½ (Л/4) (0.25) 2
=0.0245 in2
Number of hole, NH = AHT/AH (4.8)
2 2
= 0.4357ft / 0.0245 in
= 2560 units
Number of tray, NT required and the tower high, HT is determining by using equation
4.9 and 4.10 respectively. The efficiency of the tray is base on assumption of the
column efficiency.
Net area and active are were determined by using equation 4.11 and 4.12 respectively.
237
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
The height equivalent to theoretical stages, (HETS) and height of transfer unit, Hor are
calculated by using equation 4.13 and 4.14 respectively.
HETS = CH / Nf (4.13)
= 29 / 10
= 2.9
Weir crest were determined by using value of maximum flowrate and minimum
flowrate based on process condition. Each weir crest value determine by using
equation 4.15 and equation 4.16 respectively.
2/3
Max how = 750 Lw max / ρD( lw) (4.15)
2/3
= 750 3.8106/ (380.048 x 1.2705)
= 29.73 mm liquid
2/3
Min how = 750 Lw min / ρD( lw) (4.16)
2/3
= 750 0.4512/ (380.048 x 1.2705)
238
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
= 7.17 mm liquid
Orifice coefficient, Co was referring from figure 11.34 Coulson and Richardson Vol. 6
pg 576 and by assuming.
1. Plate thickness : hole diameter =1
2. Ah/Ap =5
239
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
In mechanical design, the temperature and the pressure are important properties in
evaluate the thickness and the stress of material. Therefore, the safety factor also need
as precaution and determined by certain consideration such as corrosion factor,
location and process characteristic.
Based on Hysis data, the operating pressure is 2.75 kPa and the safety factor is
10% above operating pressure. The design temperature related to the operating
temperature. The temperature of column operated in 400C at top of column and 270C at
the bottom of the column. The design pressure and design temperature of the system
as follows:
The material used is stainless steel (18Cr/8Ni, 304). Design stress at 500C is gain from
table 13.2, pg 809 Coulson & Richardson Vol.6.
240
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
= 0.9276 mm
From Coulson & Richardson, value for vessel diameter (m), 1 m, the minimum
wall thickness required should not be less than 5mm including corrosion allowance. A
much thicker wall will be needed at the column base to withstand the wind and dead
weight loads. As a first trial, divide the column into five sections (courses) with
thickness increasing by 2mm per section. Try 10,12,14,16, and 18mm. The average is
14 mm.
Standard torispherical head are the most commonly used end closure for vessel up to
operating pressure of 15 bar. Torispherical head had been choose because of
operating pressure below 10 bar.
241
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
= 0.3025(1011) (3.053)
(2 x 165) + (0.3025(3.053 -0.2))
= 2.821 mm
4.3.4 Column Weight
To get a rough estimate of the weight of this vessel by using the average thickness 14
mm.
Dm = 1.011 + 0.014
= 1.025 m
Hence,
Wv = 240(1.15) (1.025) (9 +0.8(1.025)) 14
= 38933.69N
242
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
= 389 kN
From Nelson (1963) pg 833 in Coulson & Richardson Vol. 6 rough guide to weight of
fittings, take contacting plates, steel including typical liquid loading, 1.2 kN/m2 plate
areas. The total of weight of plate determine by multiply the value with number of tray
design.
243
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
W = Wv + Wp + Wi (4.28)
= 389 + 12.56 + 5.47
= 407.03 kN
244
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
σh = PiDi (4.31)
2t
= 0.3025 (1011)
2 (14)
= 10.92 N/mm2
σL = PiDi (4.32)
4t
= 0.3025 (1011)
4 (14)
= 5.46 N/mm2
4.3.5.2 Dead Weight Stress
σL = W (4.33)
Л (Di + t) t
= 407030
Л (1011 + 14) 14
= 9.03 N/mm2
σb = ± MX / IV ((Di/2) + t) (4.34)
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
σZ (upwind) = σ L - σ W + σb
= 5.46 – 11.15 + 11.89
= 6.2 N/mm2
σZ(downwind) = σL - σW - σb
= 5.46 – 11.15 – 11.89
= -17.58 N/mm2
4.3.5.4 Elastic Stability (Buckling)
The maximum compressive stress will occurs when the vessel is not under pressure:
σ W + σb = 11.15 + 11.89
= 23.04N/mm2
At ambient temperature.
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
The maximum dead weight load on the skirt will occur when the vessel is full of the
mixture.
As a first trial, take the skirt thickness as the same as that of the bottom section of the
vessel, ts = 14 mm.
247
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
= 22.5710 N/mm2
= 0.60 N/mm2
= 9.03 N/mm2
= 0.60 + 22.57
= 23.17 N/mm2
= 22.57 – 9.03
= 13.54 N/mm2
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Both criteria are satisfied; add 2mm for corrosion gives a design thickness of 16 mm.
= 2200 Л / 600
= 11.5
Nbfb Db
249
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Therefore,
Ab = 1 4 (257184) - 407030
12 (125) 2.2
= 40.35 mm2
= 7.17 mm
Fb = 4MS + W (4.43)
Л DS2 Л DS
= 4 (257184) + 407030
Л (1.0112) Л (1.011)
By taking the bearing pressure as 5 N/mm2. The minimum width of the base ring, Lb:
Lb = Fb + 1 (4.44)
Fc 103
= 448.5 x 103
5000
= 89.7 mm
Use M24 bolts (BS 4190:1967) root area = 353 mm2 (Figure 13.30 Coulson &
Richardson Vol. 6)
250
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Where: fr = Allowable design stress in the ring material, typically 140 N/mm2
251
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
20σ + P
The piping sizing for this system are shown in table 4.5
Design Pressure
Operating Pressure 2.75 kPa
0
Operating Temperature 40 C
Design Pressure 0.3025 N/mm2
0
Design Temperature 50 C
Safety Factor 0.10
Design of Domed Ends
Types Torispherical head
Crown Radius 1.011 m
Knuckle Radius 0.061 m
Joint Factor 1
Stress Concentration Factor 3.053
Minimum Thickness 2.821 mm
Column Weight
Dead Weight of Vessel 389 kN
Weight of Plate (per plate) 0.966 kN
Weight of Insulation 2734.11 N
Total Weight 407.03 kN
Wind Pressure 1280 N/m2
Loading 3572.48 N/m
Bending Moment 144.685 kNm
252
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
253
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Control systems are very important in any of the chemical industries. It is essential for
a process to meet the design specification and products purity that imposed by the
designer or by external constrains such as government regulations and standards.
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Process parameters control is to compensate for the process changes with the
existence of external disturbances. Normally, an overall control strategy is design to
meet the following objectives:
1. Ensure stable plant operation conductive to power optimization
2. Maintain product quality according to specification
3. Operate the process and machinery in such a way as to estimate or minimize
the possibility of activating last resort safety measures such as relief valve and
surge system, thus ensuring safe plant operation.
Typically, there are two types of control systems- feedback control and feed
forward control. In this case, the feedforward control is applied; in feedforward control
its take corrective action before they upset the process. In this system also, solvent use
is lighter than the material being extract, the two input indicated are of course
interchanged. Both inputs are on flow control. The light phase is removing from the
tower on LC (level control) or at the top of level maintain with an internal weir. The
bottom stream is removed on interfacial level control (ILC). The relative elevations of
feed and solvent input nozzles depend on the nature of the extraction process. The
temperature of an extraction process ordinarily is controlled by regulating the
temperature of the feed stream.
REFERENCES
255
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
SECTION 5
256
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
INTRODUCTION
Shell and tube heat exchangers are the most versatile type of heat exchangers. They
are used in process industries, in conventional and nuclear power stations as
condensers, in steam generators in pressurized water reactor power plants, in feed
water heaters and in some air conditioning and refrigeration systems. They are also
proposed for many alternative energy applications including ocean, thermal and
geothermal. Shell and tube heat exchangers provide relatively large ratios of heat
transfer area to volume and weight and they can be easily cleaned.
Shell and tube heat exchangers offer great flexibility to meet almost any service
requirement. The reliable design methods and shop facilities are available for their
successful design and construction. Shell and tube heat exchangers can be designed
for high pressures relative to the environment and high pressure differences between
the fluid streams.
Shell and tube heat exchangers are built of round tubes mounted in a cylindrical
shell with the tubes parallel to the shell. One fluid flows inside the tubes, while the other
fluid flows across and along the axis of the exchanger. The major components of this
exchanger are tubes (tube bundle), shell, front-end head, baffles and tube sheets.
Shell types-various front and rear head types and shell types have been standardized
by Tubular Exchanger manufacturers Association (TEMA).
The E-shell is the most common due to its cheapness and simplicity. In this
shell, the shell fluid enters at one end of the shell and leaves at the other end that is
there is one pass on the shell side. The tubes may have a single or multiple passes
and are supported by transverse baffles. This shell is the most common for single-
phase shell fluid applications. With a single-tube pass, a nominal counter flow can be
obtained. The design of a shell and tube heat exchanger is an iterative process
because heat transfer coefficients and pressure drop depend on many geometric
factors, including shell and tube diameters, tube length, tube layout, baffle type and
257
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
spacing and the numbers of tube and shell passes, all of which are initially unknown
and are determined as part of the design process.
In the production of MTBE, a heater is the most important heat exchanger in the
system. Therefore this chapter is going to describes details for this heater and the
design of this piece of equipment.
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Heater is used in the process to heated the raw material of MTBE consist of
isobutane and a bit of normal butane. Isobutane and normal butane from the storage is
in liquid form. The heating process is because to produce the isobutane and normal
butane in the gases form before this material is feed to the Snamprogetti Fluidized Bed
Reactor. Here the mixtures of this component initially are in the liquefied gas form at
temperature of -15 oC. It will be heated in the Heater (E-100) and Heater (E101) until it
converted into gas form at temperature of 250 oC using steam. For this heat exchanger
we use the counter current process. The temperature difference between liquid and
gas phase is quit big, so we need two heat exchanger in series. The shell and tube
heat exchanger is the floating head type.
T = 250OC T = 350OC
STEAM IN STEAM IN
O T = 250 OC
T = 117 C
E100 E101
STEAM OUT STEAM OUT
T = 120 OC T = 250OC
The chemical engineering design for the heat exchanger is also known as thermal. The
design requires the calculation of the heat transfer area required. From this value,
design features of the unit such as the tube and shell size, tube counts and layout is
determined. In addition, then pressure loss of the fluids across the unit is also
calculated by determined the pumping capacity required. The calculation of the design
259
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
is base on the first heat exchanger (E100). The chemical design is based on Bell’s and
Kern method. Bell’s method accounts for the major bypass and leakage streams. Kern
method was based on experimental work on commercial exchangers with standard
tolerances and will give a reasonably satisfactory prediction of heat-transfer coefficient
for standard design.
Where
∆ Tm = true temperature difference
260
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Where
∆ Tlm = log mean temperature difference
T1 = inlet shell-side fluid temperature
T2 = outlet shell-side fluid temperature
t1 = inlet tube-side temperature
t2 = outlet tube-side temperature
the temperature correction factor can be obtain by using figure 12.19 (Coulson &
Richardson’s Chemical Engineering)
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
T1 - T2
R= (5.3)
t 2 - t1
(250 - 120)
R=
(117 - (-15))
R = 0.98
t 2 - t1
S= (5.4)
T1 - t1
(117 - (-15))
S=
(250 - (-15))
S = 0.50
∆Tm = Ft ∆Tlm
0
∆Tm = ( 0.82 )(134 .00 C)
0
∆Tm = 109.88 C
From table 12.1 (Coulson & Richardson’s Chemical Engineering), we take overall
Coefficient, U = 300 W/m2 0 C
Duty for this heat exchanger is obtain from the energy balance. The duty is,
Q = 3109542.883 W
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Q
A= (5.5)
U∆Tm
3109542.88 3
A=
(300 )(109 .88 )
A = 94.33 m2
From table 12.3 (Coulson & Richardson’s Chemical Engineering), we take standard
pipe of:
Inside diameter, di = 16 mm
Outside diameter, do = 20 mm
Length of pipe is assumed as 16 ft.
Length, L = 4.88 m
Area of the pipe can be calculated using equation below
area = Lπ D (5.6)
area = (4.88)(3.142)(0.02)
area = 0.3067 m2
Using the area needed from the duty and area for each tube, the number of
Tube, Nt that we get is,
A
Nt = (5.7)
a
94.33
Nt =
0.3067
Nt = 307.56
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
The tubes in heat exchanger are usually arranged in an equilateral triangular, square
or rotated pattern. The triangular and rotated square patterns give higher heat transfer
rates. Here we use the triangular pattern.
Bundle diameter
Db = do (Nt / K1 )1 / n1 (5.8)
From table 12.4 (Coulson & Richardson’s Chemical Engineering), for 1.25 triangular
pitch, number of passes = 2, then we can obtain
K1 = 0.249
n1 = 2.207
Db = do (Nt / K1 )1 / n1
Db = 0.50m
Shell diameter, Ds
Ds = 0.50 + 0.093
= 0.60m
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
- 15 + 117
t mean =
2
t mean = 51 o C
Reynolds number, Re
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
ρ ν di
Re = (5.16)
µ
Re = 59047.87
Heat transfer factor figure 12.31 (Coulson & Richardson’s Chemical Engineering),
Jh = 4.1 x 10-3
Prandtl number,
Cp µ
Pr = (5.17)
kf
(2.010 x 10 3 )(1.55263 x 10 - 5 )
Pr =
0.0306575
Pr = 1.0180
jhk f Re Pr 0.33
hi = (5.18)
di
hi = 466.62 W / mo C
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Take baffle spacing as 1/3 from the shell diameter, so Baffle spacing:
lB = Ds / 3 (5.19)
= 0.60 / 3
= 0.20 m
Flow area, As
A s = 0.0240 m2
Mass velocity, Gs
Ws
Gs = (5.22)
As
10.9314
Gs =
0.0240
Gs = 455.48 kg / m 2 s
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Gs
us = (5.23)
ρ
455.48
us =
485
us = 0.9391 m / s
1.10
de = (0.025 2 - 0.917(0.02 )2 )
0.02
de = 0.0142 m
(455.48)(0 .0142)
Re =
0.00013000 5
Re = 49750.52
Prandtl number
CpIsobutane μIsobutane
Pr = (5.26)
kf
(2155)(0.0 00130005)
Pr =
0.07
Pr = 4.0023
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Choose baffle cut of 25%, from figure 12.30 (Coulson & Richardson’s Chemical
Engineering), we can obtained
Jf = 2.70 x 10-2
k f jf Re Pr 1 / 3
hs = (5.27)
de
hs = 10513.35 W / m2 o
C
1 1 1 d ln(d o /di ) 1
= + + o + ( do /di ) + 1 (do /di ) (5.28)
Uo hs hod 2k w hid hi
1
= 0.0039738 m2 o
C/W
Uo
Uo = 322.85 W / m2 o
C
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
ρiμi 2
∆Pt = Np [ 8 jf (L/d i )(μ/μ W )- m + 2.5 ] (5.29)
2
∆Pt = 66921.86 N / m2
Reynolds number
Re = 49750.52
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
271
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
60000. In addition, the design also complies with the American Society of mechanical
Engineers (ASME) Boiler and Pressure Vessel Code, Section VIII, Division 1.
For the design of tube and shell parts, a safety factor of 10% is included to determine
the design pressures.
Operating pressure = 1.1 bar
10% above the pressure for safety
Pi = 1.1 x 10
= 11 bar
= 1.1 N / mm2
For the shell side and tube side the operating temperature is at 250 oC, so:
Shell-side design temperature = 1.1x 250 oC
= 275 oC
Adding 2 oC for uncertainties in temperature prediction
TD = 275 + 2
= 277 oC
For the heater design, pull through floating head exchanger is chosen as the
exchanger type. Internal floating head is versatile than other type and also suitable for
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
high temperature different between shell and tubes. The tube for internal floating head
also can be rod from end to ends and the bundle are easier to clean.
The minimum thickness of the cylindrical section of the shell to stand the pressure can
be obtained from the calculation below.
PiDi
e= (5.30)
2jf - Pi
Where,
Pi = design pressure
Di = shell diameter
F = design stress (from table 13.2, Coulson & Richardson’s Chemical Engineering)
(1.1)(600)
e=
2(1)(85) - (1.1)
PiDi
σh = (5.31)
2t
(1.1)(600)
σh =
2(6)
σ h = 55.00 / mm 2
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
PiDi
σh = (5.32)
4t
σ h = (1.1)(600) / 4(6)
σ h = 27.50 N / mm 2
Minimum thickness of the tube wall can be calculated using the equation (5.30):
PiDi
e=
2jf - Pi
(1.1)(600)
e=
2(1)(85) - (1.1)
e = 3.91 mm
PiR c Cs
e= (5.33)
2jf + Pi (Cs - 0.2)
Rc = crown radius
Rk = knuckle radius
Cs = stress concentration factor for torispherical head
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
[
Cs = 1/4 3 + R c / Rk ] (5.34)
Rc = Ds = 600 mm
Rk = 0.06(500) = 36 mm
Cs = 1.77
(1.1)(600) (1.77)
e=
2(1)(85) + 1.1(1.77 - 0.2)
e = 6.80 mm
where
Cp = a design constant, depend on the edge constraint (0.45)
De = nominal plate diameter
f = design stress
e = (0.45)(600)(1.1/85)1/2
= 30.72 mm
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
where
Wv = total weight of the shell
Cv = 1.08 for vessels with only few internal fitting
Wv = (1.08)π (7700)(0.602)(9.81)(4.88+0.8(0.602))(2 x 10-3)
= 1654.45 N
Weight of tubes
2
W t = 308 π(0.02 - 0.016 2 )(4.88)(77 00)(9.81)
W t = 51362.08 N
Weight of insulation
Material used = mineral wool insulation
Insulation thickness = 50 mm = 0.05 m
Density = 130 kg / m3
Approximate volume of insulation
V = πH v [ (r + r1 )2 - r 3 ] (5.38)
V = π (4.88) [ (0.60 + 0.05) - (0.50)2 2
]
V = 2.64 m3
W t = Vρ g (5.39)
W t = (2.64)(130 )(9.81)
W t = 3366.79 N
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
277
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
278
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
(From Perry R.H and Green, Don (1984), “Perry’s Chemical Engineer’s Handbook”, 7th
Edition, McGraw-Hill Book)
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Flanges used in this design are chosen from the standard flanges. Here standard
flanges are adapted from the British standard (BS 4504), nominal pressure 10 bar.
280
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Table 5.9: Using Ds = 600mm, the standard steel saddles for vessels up
to 1.2m :
281
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
5.2.15 Baffles
282
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
REFERENCES
283
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
284
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Perry R.H and Green, Don, “Perry’s Chemical Engineer’s Handbook”, 7th
Edition, McGraw-Hill Book Company, Singapore, 1984.
Sinnott, R. K., Coulson & Richardson, “Chemical Engineering Volume 6,
Chemical Engineering Design”, Butterworth Heinemann, 1999.
Peters, max Stone, “Plant Design and Economics for Chemical Engineers”,
2nd Edition, McGraw-Hill Chemical Engineering Series, 1968.
CHAPTER 2
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
2.1 INTRODUCTION
All processes are subject to disturbances that tend to change operating conditions,
compositions and physical properties of the streams. In order to minimize those ill
effects that could result from such disturbances, chemical plants are implemented with
substantial amounts of instrumentation and automatic control equipment. In critical
cases and in especially large plants, moreover, the instrumentation is computer
monitors for convenient, safety and optimization.
In control situations, the demand for speed of response may not be realizable
with an overly elaborate mathematical system. Moreover, in practice, not all
disturbances are measurable and the process characteristics are not known exactly.
Accordingly, feedforward control is supplemented in most instances with feedback. In a
well-designed system, typically, 90% of the corrective action is provided by feed
forward and 10% by feedback with the result that the integrated error is reduces by a
factor 10%. The main types of instrument used for chemical process plants are flow
controller, temperature controller, pressure controller and level controller.
The most important objectives of the designer when specifying control and
instrumentation schemes are:
286
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
• To keep the process variables within known safety operating limits and
within allowable limits.
• To detect dangerous situations as they develop and to provide alarms
and automatic shut down system.
• To provide interlocks and alarms to prevent unsafe operating
procedures.
2. Production Specification
• To achieve the design product output
• To produce the desired quality of final product
• To keep the product composition within the specified quality
standards.
3. Economics
• To operate at the lowest production cost, commensurate with the other
objectives.
• The operation of the plant must conform to the market condition, which
is availability of raw materials and demand of the final product.
4. Environmental Regulations
• Variable controlled must not exceed the allowable limits set by various
federal and state laws.
5. Operational Constraint
• Various type of equipments used in chemical plant have constrains
inherent to their operation. Such constraints should be satisfied
throughout the operation of plant.
• Control systems are needed to satisfy all these operational constrains.
287
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
288
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Figure 2.2: Control Scheme for Catalytic Cracking Fluidized Bed Reactor
Variable
1. To control flow Flow of gas Change in flow Control flowrate of the Stream S4
inside phase in phase to of gas in phase Input stream S4 by
reactor reactor of reactor controlling V3
2. To control solid Solid in and Change of solid Control solid in and 95679.8kg
flow to relate out in the flow rate moving solid out in the
speed and flow rate reactor and to reactor and reactor and
regenerator regenerator regenerator
3. To control flow rate of Change of feed Control pressure by 2.89 bar
pressure between feed into reactor flow rate opening or closing
reactor and and regenerator valve by adjusting V5
regenerator
4. To control Temperature in Change of Control temperature 180oC
temperature reactor and temperature by opening or closing
in reactor regenerator In reactor and valve at the air feed
regenerator V4 and product V6
S7
289
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
S8
290
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
291
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
292
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
V29
V13
Variable
To regulate Cooling Reactant feed Control temperature Set the
reactor water make temperature and by V13 temperature
temperature up rate composition at 53.3 oC
To maintain Pressure in Pressure feed to Control the pressure Pressure at
constant the fed of the reactor in the reactor by 1 bar
pressure at the stream S15 control of V29
feed stream
293
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
294
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
295
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
296
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
297
PRODUCTION OF 300,000 METRIC TON MTBE PER YEAR
38
PRODUCTION OF 300,000 METRIC TON MTBE PER YEAR
39
PRODUCTION OF 300,000 METRIC TON MTBE PER YEAR
Legend
- Process Flow PC - Pressure Control ILC - Interfacial Level Control
TC
- Control Flow FC - Flow Control LC - Level control
- Temperature Control TI - Temperature Indicator DPC - Differential Pressure Control
40
PRODUCTION OF 300,000 METRIC TON MTBE PER YEAR
41
PRODUCTION OF 300,000 METRIC TON MTBE PER YEAR
REFERENCES
Luyben, W. l., (1990), Process Modelling simulation and Control for Chemical
Engineers, 2nd Edition, McGraw-Hill Chemical Engineering Series
42
PRODUCTION OF 300,000 METRIC TON MTBE PER YEAR
CHAPTER 3
SAFETY CONSIDERATION
3.1 INTRODUCTION
Any organization has a legal and moral obligation to safe guard the health and
welfare of its employees and the public. Safety is also good business: the good
management practices needed to ensure safe operation would also ensure efficient
operation.
Safety and loss prevention in process design can be considered under the
following broad headings :( Coulson and Richardson’s Volume 6)
1. Identification and assessment of the hazards
2. Control of the hazards; for example by containment of flammable and toxic
materials
3. Control the process. Prevention of hazardous deviation in the process
variables, (pressure, temperature, flow) by provision of automatic control
system interlocks, alarms, trips, together with good operating practices and
management.
4. Limitation of the loss. The damage and injury caused if an incident occurs,
pressure relief, plant layout, provision of fire-fighting equipment.
In Malaysia, The Occupational Safety and Health Act, 1994 is a tool which
provided a new legal and administrative as a driving force to promote, encourage
and stimulate the high quality standards of health and safety at work place. Both
parties such as employers and employees must give their support and cooperate to
43
PRODUCTION OF 300,000 METRIC TON MTBE PER YEAR
comply the law and not misuse safety in order to increasing the promotion of safety
awareness and effective safety organization and performance in companies.
HAZOP stands for “hazard and operability studies.” This is asset of formal hazard
identification and elimination procedures designed to identify hazard to people,
process plants and the environment. The techniques aim to stimulate in a
systematic way the imagination of designers and people who operate plants or
equipment so they can identify potential hazard. In effect, HAZOP studies make the
assumption that hazard or operating problem can arise when there is a deviation
from the design or operating intention. Corrective actions can then be made before
a real accident occurs.
When using the operability study technique to vet a process design, the
action to be taken to deal with a potential hazard will often be modification to the
control system and instrumentation, the inclusion of additional alarms, trips or
interlock. If major hazard are identified, major design changes may be necessary,
alternatives processes, material and equipment. In order to have a safe process
successfully producing to specification to the required product, a sound control
system is necessary but not sufficient. (Coulson & Richardson’s, 1999).
44
PRODUCTION OF 300,000 METRIC TON MTBE PER YEAR
45
PRODUCTION OF 300,000 METRIC TON MTBE PER YEAR
Safe procedures must be well known for the start up and shut down of plant and
deviations from normal operating conditions. Whenever process conditions are
changed, opportunities are presented for hazardous situations to arise. Building up
the process consistency may reduce the investigating breakdown and malfunction,
availability, the design cycle, operability, flexibility including blending and recycling
experience and known how personnel.
The start-up and shutdown of the plant must proceed safely and easily, yet
be flexible enough to be carried out in several ways. The operating limits of the
plant must not exceed and dangerous mixtures must not be formed because of
abnormal states of concentration, temperature, phase, reactant, catalyst and
products.
46
PRODUCTION OF 300,000 METRIC TON MTBE PER YEAR
condense in unplanned location causing process levels to get out of control and
other problems. The ignition of fuel to heat the high temperature fluid during start-up
must be designed to accomplish this safely Some typical errors that could occur
during start-up of the plant include :
1. Wrong routing, involving failure to ensure that correct valves are closed.
This is especially crucial in the adsorption section where three different
processes are occurring at any one time.
2. Drain valves are left open resulting in loss of material and possibly
endangering the lives of workers.
3. Valves left closed resulting in over pressure in the vessel.
4. Failure to complete purging cycle before admission of fuel air mixture.
5. Backflow of material from high pressure to low pressure system.
6. Setting of wrong valves for operating parameters such as jacket
temperature in the reactor and reflux in the distillation column.
The study of the plant start up and shut down must include investigation of the
operating limits, transient operating conditions, process dynamics, contamination
and added material, emissions, hot standby and emergency shut down with plant
protection control systems and alarms.
The operating limits of the plant are imposing by mechanical, electrical, civil and
process design. Where necessary, it has to be introduce additional equipment,
sampling points, instrumentation and lines, and identify their use on the engineering
line diagram,
The transient operating conditions must be studied to safe time and operating cast.
The process dynamics that to be investigated includes excessive heat transfer
47
PRODUCTION OF 300,000 METRIC TON MTBE PER YEAR
when more or less floe in either energy exchanging streams through activations and
warming of catalyst when the flow of reactant starts to entrance of contamination
and others
Materials are added by operations may not be tolerated in part of the system or
clean material may be needed for the start up of the plant. Residues or unwanted
products such as out of specification may be discharged or hold in tank for further
treatment.
Time is save during restart up if plant are kept partially working such as when other
unit operation are ceased to function temporarily, the converter can be left in hot
standby conditions.
Special plant protection known as process trip system or emergency shut down
system is design to affect the emergency shut down through the push button by
operator or from automatic activation of a relay when necessary. The trip systems
should be reliable and operate when required to avoid a nuisance shut down of
plant.
3.3.2 Start up and Shut down Procedure for the Main Equipment
3.3.2.1 Reactor
48
PRODUCTION OF 300,000 METRIC TON MTBE PER YEAR
3. There are two vessel types of bed supports that can be used; (1) has a
support grid permanently installed about 2 inches below the throat of the
lower manway; or (2) uses a level bed of washed gravel, ceramic balls, or
pawl rings. The bed support must be leveled.
4. Close and secure the bottom manway.
5. Through the top manway, load the remaining feed to level as stated in the
EPS. During the latter stages of loading level off the cone of the filled
product bed and continue loading until finished.
6. Close and secure the top manway.
Start-Up Procedure
2. Switch the column power source lever to the "on" position. Turn the Reboiler
Heater Control knob clockwise. This prevents over heating of the reboiler.
3. Turn on the cold water supply ( CWS )valve until the computer stops telling
the user to increase the volume of the CWS valve.
7. Turn on the feed and reboiler pumps as applicable. The pump settings can
be adjusted on the computer.
49
PRODUCTION OF 300,000 METRIC TON MTBE PER YEAR
This will result in damage to the heaters. If the heaters are exposed turn off the
column, this allows the vapor in the column to condense and return to the
reboiler. If the liquid level is still below the heaters, more liquid must be added to
the reboiler.
Shut-Down Procedure
3. Turn off the CWS valve when the temperature of the distillate is below the
boiling point of the light component of the mixture.
5. Shut off the computer, by selecting the "Shut-down" option from the Special
menu.
Start Up Procedure
3. When the liquid level in the column reaches the top right nozzle(water in
nozzle), turn the water flowrate down to the desired setpoint. Turn on and
set the feed flowrate to the desired setpoint by adjusting the pump speed,
and close the top water vent.
4. Allow the interface to form between the top mesh and the top left nozzle.
50
PRODUCTION OF 300,000 METRIC TON MTBE PER YEAR
Start up Procedure
When putting a heat exchanger in operation, open the vent connections and
slowly start to circulate the cold medium only. Be sure that the entire cold side
of the exchanger is completely flooded before closing its vents. The hot medium
should then be gradually introduced until all passages are filled with fluid. Then
close the hot side vents and slowly bring the unit up to its operating
temperature.
It is expected that every person who working in this plant will act responsibly in any
Department of Emergency. ERP procedures were state in Appendix: Safety. In most cases,
the observer of an emergency is faced with decision to leave the scene to summon help or
stay and provide help. The basic rule is as follows.
“Unless we are sure that we are not putting ourselves in any danger and we know we can
make a difference, summon help.
General Procedures
51
PRODUCTION OF 300,000 METRIC TON MTBE PER YEAR
When alarm system is activated whether by break glass or by smoke detector, the
alarm that is siren sound will be triggered throughout plant. The following general
procedures should be followed if there is no immediate emergency in your area.
52
PRODUCTION OF 300,000 METRIC TON MTBE PER YEAR
3.4.3 Fires:
• If the fire alarm sounds or a fire broke out in the plant, turn off any electrical
equipment that been operating and evacuate the building immediately.
Close all doors to help prevent fires from spreading. Exit via stairwells.
• Call 994 to give location and extent of fire and notify the management to
report the fire :
State if there are any special circumstances, such as the presence of
dangerous chemicals.
• Don’t attempt to fight a fire unless we have been trained in fire extinguisher
use and the fire is very small :
When fighting a fire, always position ourselves between the exit and the fire
to ensure an escape route. IF THE FIRE CANNOT BE CONTAINED, GET
OUT QUICKLY!
• Injuries :
53
PRODUCTION OF 300,000 METRIC TON MTBE PER YEAR
For life – threatening emergencies, CALL 991 for medical aid and for
transportation to hospital and at same time notify the management as listed
on the Notification Lists. For less serious injuries or illness, first aid can be
obtained at the nearest clinic. Report all injuries to the management.
• Equipment failures :
Any equipment failures, which may harm or injured the workers, should be
reported to the Production Supervisors or the management for further action
to be taken.
The process units and ancillary buildings should be laid out to give the most
economical flow of material and personnel around the site. Hazardous process
must be located at a safe distance from other buildings. Consideration must be also
being given to the future expansion of the site. The ancillary buildings and services
required on site, in addition to the main processing units (building) will include:
(Coulson and Richardson’s 1999)
1. Storage for raw materials and products; tank farms and warehouses
2. Maintenance workshop
3. Stores, for maintenance and operating supplies
4. Laboratories for process control
5. Fire stations and other emergency services
6. Utilities: steam boilers, compressed air, power generation, refrigeration,
transformer stations.
7. Effluent disposal plant
8. Offices for general administration
9. Canteens and other amenity buildings, such as medical centres
10. Car parks
Normally, the process units will be sited first and arranged to give a smooth
flow of materials through various processing steps, from raw material to final
product storage. It is normally spaced at least 30 apart and for hazardous
processes, the greater spacing may be needed. Then, the principal ancillary
buildings to be located and arranged in order to minimize the time spent by the
personnel in travelling between the buildings. The administration offices and
54
PRODUCTION OF 300,000 METRIC TON MTBE PER YEAR
laboratory should be located well away from potentially hazardous processes since
a many people be in here. The control rooms normally are located adjacent to the
process units but if it with the potentially hazardous processes has to be sited at
safer distance.
Besides that, the layout of the plant roads, pipe alleys and drains also must
be considered to locate the main process units. Easy access roads will be needed
to each building for construction and for operation and maintenance. The utilities
buildings should be sited to give most economical run of pipes to and from the
process units. Finally, the main storage areas should be placed between loading
and unloading facilities and the process units they serve. Storage tanks containing
hazardous materials should be sited at least 70 m (200 ft) from the site boundary.
There are 7 principal factors to be considered :
1. Economic considerations: construction and operating costs.
2. The process requirements.
3. Convenience of operation.
4. Convenience of maintenance.
5. Safety.
6. Future expansion.
7. Modular construction.
55
PRODUCTION OF 300,000 METRIC TON MTBE PER YEAR
56
PRODUCTION OF 300,000 METRIC TON MTBE PER YEAR
Legand
Evacuation Routes
57
PRODUCTION OF 300,000 METRIC TON MTBE PER YEAR
58
PRODUCTION OF 300,000 METRIC TON MTBE PER YEAR
59
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
REFERENCES
Clarles A.Wentz, 1998. Safety, Health and Environmental Protection. United State of
America:McGraw-Hill.
R.K.Sinnot, 1999. Chemical Engineering Design. Coulson & Richardson’s Chemical
Engineering 3rd Edition. Volume 6. Britain; Butterworth Heinemann.
Robert H. Perry, Don W. Green, 1998 Perry’s Chemical Engineer’s Handbook, Seventh
Edition, McGraw-Hill.
http://www.sulfatreat.com/Documents/HTML/St/startup.html
http://www.amberjet.com/IP/start_up.htm
http://www.sulfatreat.com/Documents/PDF/SulfaTreat/ST-Start_Up_Procedure.pdf
http://chem.engr.utc.edu/Webres/435F/Proc.htm
http://www.eng.buffalo.edu/Courses/ce428/Distillation/procedure.htm
http://users.rowan.edu/~savelski/uol/liqliq.html
http://pharmaflo.com/heatexch/
60
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
CHAPTER 4
ECONOMIC EVALUATION
INTRODUCTION
61
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
In this chapter, the costing of equipment which has been designed will be
estimated and the feasibility of MTBE production will be evaluated by
profitability analysis to make sure the project is economically attractive.
There are some general assumptions to this chapter;
62
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
300000 tonne
i. MTBE = 37878.76 kg/h =
year
Price: RM 1.320/kg
37878 .76 kg 24 hr 365 day RM 1.320
= × × × ×0.90
hr day year kg
= RM 394199710/yr
= RM 5219612/yr
= RM 6253560/yr
87541714/yr
= RM 434363/yr
63
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Capital cost estimates are essentially “paper and pencil” studies. The cost of making
an estimate indicates the personnel hours required in order to complete the estimate.
The capital needed to supply the necessary manufacturing and plant facilities is called
the fixed capital investment (FC), while the additional investment needed for the plant
operation (for plant start-up and operation to the point when income is earned) form the
working capital (WC).
Capital cost estimates for chemical process plants are often based on an estimate of
the purchase cost of the major equipment items required for the process, the other
costs being estimated as factors of the equipment cost. The accuracy of this type of
estimate will depend on what stage the design has reached at the time estimate is
made and on the reliability of the data available on equipment cost.
The cost of the purchased equipment is used as the basis of the factorial method of cost
estimation and must be determined as accurately as possible. It should preferably be
based on recent prices paid for similar equipment.
Calculation of total module cost and gross roots cost (based on table 4.2)
Where,
CTC = total capital cost
CFC = fixed capital cost
CWC = working capital cost
CL = cost of land & other non-depreciable costs
64
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
CFC = CGR - CL
= RM 31292629 - RM 12000000
= RM 19292629
Working capital is the additional investment needed over and above the fixed capital to
start the plant up and operate it to the point when income is earned.
Working capital cost = 5% of fixed capital costs
Thus,
Total capital cost (CTC) = CFC + CL + CWC
= RM 19292629+ RM 12000000+ RM 964631
= RM 32257260
65
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
The cost of manufacturing (COM) can be determined when the following costs are
known or can be estimated:
1. Fixed Capital Investment (FCI): (CTM or CGR)
2. Cost of Operating Labor (COL)
3. Cost of Utilities (CUT)
4. Cost of Waste Treatment (CWT)
5. Cost of Raw Material (CRM)
66
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
48 week 5 shift
1 operator = ×
Year week
240 shift
=
Year
Thus,
Operating Labor = 4.125 operators x 3.45 operator per shift
= 14.23 operator
= 15 operator
67
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Since, assuming the plants operating days per year = 330 days
So,
no . of day ' s plant operates per year
Steam factor (SF) = no . of days per year
330
= = 0.90
365
1. Heater (E-100)
Duty = 3109542 J s = 11 .16 G J hr
From table 8.5 (W.R Wan Daud, Princip Reka bentuk Proses Kimia, 2002, page
285) cost of heater RM 19.6 / GJ.
Thus ,
Yearly cost = (Q) (C steam) (t)
GJ 19 .6 hr day
= 11 .16 × RM × 24 ×365 ×0.90
hr GJ day yr
= RM 1724515
2. Heater (E-101)
Duty = 3423874 J s = 12 .24 G J hr
From table 8.5 (W.R Wan Daud, Princip Reka bentuk Proses Kimia, 2002, page
285) cost of cooling water RM 0.6 / GJ.
Thus ,
Yearly cost = (Q) (C steam) (t)
GJ 19 .6 hr day
= 12 .24 × RM × 24 ×365 ×0.90
hr GJ day yr
= RM1891403
68
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
3. Compressor (C-100)
Power (shaft) = 137.73kW
Effeciency of drives, ξdr = 92.28% (refer to table 3.7) Appendix
Power output
Electric Power, Pr =
ξdr
137 .73
=
0.9228
= 149.25 kW
Yearly cost =
0.228 hr day
149 .25 kW × ×24 ×365 ×0.90
kWh day yr
= RM 268285
4. Cooler 1 (E-102)
Duty = 4014590 KJ s = 14 .4 GJ hr
From table 8.5 (W.R Wan Daud, Princip Reka bentuk Proses Kimia, 2002, page
285) cost of cooling water RM 0.6 / GJ.
Thus ,
Yearly cost = (Q) (C steam) (t)
GJ 0.6 hr day
= 14 .4 × RM × 24 ×365 ×0.90
hr GJ day yr
= RM 68118
5. Cooler 2 (E-103)
Duty = 4204290 J s = 15 .12 G J hr
From table 8.5 (W.R Wan Daud, Prinsip Reka bentuk Proses Kimia, 2002, page
285) cost of cooling water RM 0.6 / GJ.
Thus ,
Yearly cost = (Q) (C steam) (t)
GJ 0.6 hr day
= 15 .12 × RM × 24 ×365 ×0.90
hr GJ day yr
= RM71524
69
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
6. Cooler 3 (E-104)
Duty = 503240 J s = 1.8 G J hr
From table 8.5 (W.R Wan Daud, Princip Reka bentuk Proses Kimia, 2002, page
285) cost of cooling water RM 0.6 / GJ.
Thus ,
Yearly cost = (Q) (C steam) (t)
GJ 0.6 hr day
= 1.8 hr × RM GJ ×24 day ×365 yr ×0.90
= RM 8514
7. Cooler 4 (E-105)
Duty = 240320 J s = 0.72 G J hr
From table 8.5 (W.R Wan Daud, Princip Reka Bentuk Proses Kimia, 2002,
page 285) cost of cooling water RM 0.6 / GJ.
Thus ,
Yearly cost = (Q) (C steam) (t)
GJ 0.6 hr day
= 0.72 × RM × 24 ×365 ×0.90
hr GJ day yr
= RM 3406
8. Pump 1(P100)
Power (shaft) = 327.94kW
Effeciency of drives, ξdr = 93.71% (refer to table 3.7) Appendix
Power output
Electric Power, Pr =
ξdr
327 .94
=
0.9371
= 349.95kW
Yearly cost =
0.228 hr day
349 .95 kW × × 24 ×365 ×0.90
kWh day yr
= RM 629053
70
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
9. Pump 2(P101)
Power (shaft) = 79.19kW
Effeciency of drives, ξdr = 91.58% (refer to table 3.7) Appendix
Power output
Electric Power, Pr =
ξdr
79 .19
=
0.9158
= 86.47kW
0.228 hr day
Yearly cost = 86 .47 kW × × 24 ×365 ×0.90
kWh day yr
= RM 155434
= RM 47258
71
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Yearly cost =
0.228 hr day
718 .93 kW × × 24 ×365 ×0.90
kWh day yr
= RM 1292314
0.228 hr day
344 .56 kW × × 24 ×365 ×0.90
kWh day yr
= RM 619366
= RM 120439579/yr
72
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
RM 9.5 1 tonne
3. Catalyst (Alumina silica) = 95679 kg × ×
tonne 1000 kg
= RM909
73
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
74
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
75
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Profitability is used as the general term for the measure of the amount of profit
that can be obtained from a given situation. Profitability therefore, is the common
denominator for all business activities.
The economic feasibility of this plant is evaluated using the Discounted Cash Flow
Analysis (DCF), which is the most frequently used method of economic evaluation in
the chemical industry. This method measures the profitability of the project taking into
account the time value of money. From this method, the internal rate of return (IRR) of
the project can be determined which indicates the feasibility of the project. The value of
IRR is calculated using the information obtained in the sections.
76
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
77
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Year Gross Expenses Investment Depreciation Taxable Taxes (RM) After Tax Cumulative
Income (RM) & Salvage Cost Basis * Income (RM) Taxes rates Cash Flow Cash Flow
(RM) Value (RM) MACRS = 38% (RM) (RM)
Rates
1 2 3 4 (5)=(1)+(2)- (6)=(5)*0.38 (7)=(1)+(2)+
(4) (3)-(6)
0 -19292629 -19292629
0 -964631 -964631
0 -12000000 -12000000 -32257260
1 493648959 -477332286 2756916.69 13559756.32 5152707.4 11163965.6 -21093294.4
2 493648959 -477331168 4724764.84 11593026.16 4405349.94 11912441.06 -9180853.34
3 493648959 -477331168 3374280.81 12943510.19 4918533.871 11399257.13 2218403.789
4 493648959 -477332286 2409649.36 13907023.64 5284668.982 11032004.02 13250407.81
5 493648959 -477331168 1722831.77 14594959.23 5546084.508 10771706.49 24022114.3
6 493648959 -477331168 1720902.50 14596888.49 5546817.627 10770973.37 34793087.67
7 493648959 -477332286 1722831.77 14593841.23 5545659.668 10771013.33 45564101
8 493648959 -477331168 860451.25 15457339.75 5873789.104 10444001.9 56008102.9
9 493648959 -477331168 0 16317791 6200760.58 10117030.42 66125133.32
10 493648959 -477332286 0 16316673 6200335.74 10116337.26 76241470.58
11 493648959 -477331168 0 16317791 6200760.58 10117030.42 86358501
12 493648959 -477331168 0 16317791 6200760.58 10117030.42 96475531.42
13 493648959 -477332286 0 16316673 6200335.74 10116337.26 106591868.7
14 493648959 -477331168 0 16317791 6200760.58 10117030.42 116708899.1
15 493648959 -477331168 0 16317791 6200760.58 10117030.42 126825929.5
15 1929262.9 1929262.9 733119.902 1929262.9 128755192.4
15 12964631 12964631 141719823.4
78
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
MARR is the rate set by an organization to designate the lowest level that makes an
investment acceptable. For a risky investment, MARR should be set higher.
However, for public purpose (government, public utility), MARR is lower. For this
proposed plant, MARR that has been selected is 15%.
MARR = 15%
PW = RM 33178940.2
This project is attractive and acceptable because PW > 0
79
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
150000000
125000000
100000000
Cumulative 75000000
Cash Flow 50000000
(RM) 25000000
0
-25000000 0 2 4 6 8 10 12 14 16
-50000000
Year
80
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
In theory, the Minimum Attractive Rate of Return (MARR) is chosen higher than the
rate expected from the bank or some safe investment that involved minimal
investment risk. The MARR for after taxes is selected at 15%. (Analysis, and
Design of Chemical Processes)
IRR is a method that produces an annual rate of profit, or return, resulting from an
investment and compared with the MARR. In determining the internal rate of return,
trial and error has been done based on the MARR that mentioned before. By trial
and error, the IRR for this plant has been found as 34.94%.
81
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
= 33178940.2 (0.17102)
= RM 5674262.32
82
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
By interpolation,
By interpolation,
= 2 + (0.03) years
83
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
= 2 year 1 month
4.4 CONCLUSION
Based on this chapter, the economic evaluation of MTBE plant are made
through study in all aspect including feasibility study, process synthesis and flow
sheeting and designed of major equipment.
From the cash flow analysis, the payback period for the MTBE plant is about 2
years. Furthermore, it should be stated that the present work is primarily illustrated
based on the method of engineering economic analysis of chemical processes.
PW is positive value so the project is attractive and acceptable same as when IRR
is bigger than MARR.
REFERENCES
84
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Perry R.H and Green, Don, “Perry’s Chemical Engineer’s Handbook”, 7th
Edition, McGraw-Hill Book Company, Singapore, 1984.
Sinnott, R. K., Coulson & Richardson, “Chemical Engineering Volume 6,
Chemical Engineering Design”, Butterworth Heinemann, 1999.
Peters, max Stone, “Plant Design and Economics for Chemical
Engineers”, 2nd Edition, McGraw-Hill Chemical Engineering Series, 1968.
85
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
CHAPTER 5
5.1 INTRODUCTION
There are four streams to consider the problem of integrating the utilization of
energy. Two hot streams which require cooling and two cold streams that have to
be heated. Each streams starts from a source temperature Ts, and is to be heated
or cooled to a target temperature, Tt. The heat capacity of each stream is shown as
CP.
CP is given by:
CP = mCp
(5.1)
86
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Heat
Stream number Type Heat capacity Ts(oC) Tt (oC) Load
Cp(KW/ oC) (KW)
1 HOT 3.2 180 50 416
2 HOT 1.3 150 30 156
3 COLD 2 20 140 240
4 COLD 4 75 135 240
The heat load shown in the table is the total heat required to heat or cools the
stream from the source to target temperature. The stream are shown
diagrammatically below,
The problem table is a numerical method for determining the pinch temperature and
the minimum utility requirements. Firstly, it needs to convert the actual stream
temperature Tact into the interval temperatures Tint.
87
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
350
300
250
C
o
200
Temperature
Hot Stre am s
150 Cold Stre am s
100
50
0
1 2 3 4
2
Enthalpy,1 0kW
The heat balance for the streams falling within each temperature interval:
For the nth interval:
ΔHn = (∑CPc - ∑CPh) (ΔTn)
(5.2)
88
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
175
Interval 1: 145
1 4
Interval 2: 140
2 3
Interval 3: 80
Interval 4: 45
Interval 5: 25
Cascading the heat from one interval to the next implies that the temperature
difference is such that the heat can be transferred between the hot and cold
streams. A negative value in the column indicates the temperature gradient is in the
wrong direction and that the exchange is not thermodynamically possible.
∑CPc - ∑CPh
o o
Interval Tint, C ΔT ,C
n (Kw/oC) ΔHn (KW) surplus/deficit
89
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
175
3 80 60 2.1 126 D
4 45 35 -2.0 -87.5 S
5 25 20 1.0 14 D
Interval temperature
Rank oC
Cold stream = 80 – 5
(5.4)
= 75oC
CP
90
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
(KW/ oC)
o o
85 C75 C
180oC 50 oC
3.2
1
150 oC 30 oC
1.3
2
140 oC 20 oC
2.0
3
135 oC 75 oC
4.0
4
For maximum energy recovery (minimum utility consumption) the best performance
is obtained if no cooling is used above the pinch. This means the hot streams
above the pinch should be brought it the pinch temperature solely by exchange with
the cold streams.
CP hot ≤ CP cold
Applying this condition at the pinch, stream 1 can be matched with stream 4, but not
with 3.
Matching streams 1 and 4 and transferring the full amount of heat required to bring
stream 1 to the pinch temperature gives;
ΔHex = CP (T pinch - Ts)
(5.5)
= 304 kW
This will also satisfy the heat load required to bring stream 4 to its target
temperature.
91
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Stream 2 can be matched with stream 3, whilst satisfying the heat capacity
restriction. Transferring the full amount to bring stream 3 to the pinch temperature:
ΔHex = CP (T pinch- Ts)
= 97.5 kW
The heat required to bring stream 3 to its target temperature, from the pinch
temperature, is:
ΔH = 2.0(140-75)
= 130 kW
So a heater will have to be included to provide the remaining heat load:
ΔHhot = 130-97.5 kW
(5.6)
= 32.5 kW
Stream 1 is matched with stream 3 transferring the full amount to bring stream 1 to
its target temperature; transferring:
ΔHex = 3.2(85-50)
= 112 kW
Stream 3 requires more heat to bring it to pinch temperature; amount needed:
ΔH = 2.0(75-20)-85kW
= 25 kW
So transferring 25 kW will raise the temperature from the source temperature to:
20+ 25/2 =32.5 kW
and gives a stream temperature difference on the outlet side of the exchanger of:
85-32.5 = 52.5 kW
So the minimum temperature difference condition, 10oC will not be violet by this
match.
Stream 2 will need further cooling to bring its to its target temperature, so a cooler
must be included; cooling required.
ΔHcold = 1.3 (85-50)-25
= 73.5 kW
92
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
The proposed network for maximum energy recovery is shown in Figure 5.5
1 B C
2 A D
A
D 3
B C 4
The network shown in figure 5.5 was designed to give the maximum heat recovery,
and therefore give the minimum consumption, and cost of the hot and cold utilities.
In figure 5.5 it is clear that there is scope for reducing the number of exchangers.
Exchanger D can be deleted and the heat loads of the cooler and heater increased
to bring stream 2 and 3 to their target temperatures. Heat would across the pinch
and the consumption of the utilities would be increased
For complex networks a more general expression is needed to determine the
number of exchangers:
93
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
In a final design, there are 3 exchangers, rather than 4 before the process
integration and pinch technology, with the minimum heating and cooling loads, 32.5
kW and 73.5 kW, respectively, match those predicted from the problem table,
compare with the loads for heating and cooling before process integration: 416 kW
and 240 kW.
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
CHAPTER 6
WASTE TREATMENT
6.1 INTRODUCTION
In the MTBE plant, the wastes are only the in liquid form and gas form. The liquid
will be treated in the wastewater treatment plant. The hydrogen gas leaving the
reactor is sent to a gas cylinder which it is then sold to interested company at
market price. The treatment processes and systems employed by the MTBE plant
is the typical processes and systems based on Howard S. Peavy, Donald R. Rowe,
George Tchobanoglous; Environmental Engineering, McGraw-Hill, 1985 and
David H. F. Liu, Bela G. Liptak, Wastewater Treatment, Lewis Publishers, 1999.
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
In the design of the wastewater treatment plant for the production of MTBE,
the COD value used is based of the COD value of wastewater from other plants
that are in operation. The COD value of 3000 mg/l will be used for design purposes.
The design of the plant consists of preliminary, primary and secondary treatment
where each treatment unit chosen is based on the characteristics of the influent to
be treated. Before being treated, all the wastewater is channeled to the holding
tank. It is then ferried for screening and the next process is the primary settling
tank. The effluent leaving this tank is sent to the active sludge reactor. After that, it
will be sent to the secondary settling tank. Finally, the effluent undergoes
adsorption by activated carbon before leaving the wastewater treatment plant.
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
5 1 5 7
NO3- + CH3OH N2 + CO2+ H2O +OH-
6 2 6 6
Theoretically, each milligram per liter of nitrate should require 1.9 mg/L of
methanol. Under treatment plant conditions, however about 3.0 mg/L of methanol is
required for each milligram per litre of nitrate, making this process an expensive
one.
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
Table 6.1 Parameter Limits for Wastewater and Effluent Under the Environmental
Quality Act 1974.
PARAMETER UNIT STANDARD A STANDARD B
o
Temperature C 40 40
pH - 6.0-9.0 5.5-9.0
BOD5 at 20oC mg/l 20 50
COD mg/l 50 100
Suspended solid mg/l 50 100
Mercury mg/l 0.005 0.05
Cadmium mg/l 0.01 0.02
Chromium Hexavalent mg/l 0.05 0.05
Arsenic mg/l 0.05 0.10
Cyanide mg/l 0.05 0.10
Lead mg/l 0.10 0.5
Copper mg/l 0.20 1.0
Manganese mg/l 0.20 1.0
Nickel mg/l 0.20 1.0
Tin mg/l 0.20 1.0
Zinc mg/l 1.0 1.0
Boron mg/l 1.0 4.0
Iron mg/l 1.0 5.0
Phenol mg/l 0.001 1.0
Free Chlorine mg/l 1.0 2.0
Sulfide mg/l 0.5 0.5
Oil and grease mg/l None 10
* Both standards could be used and acceptable, but only one is chosen, Standard B
for the wastewater treatment for the MTBE plant.
The design of the wastewater treatment plant consists of the holding tank, the
design of the screening device, then the design of the settling tank, the design of
the primary and secondary sedimentation tanks, and lastly the design for the
activated sludge process.
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
The next step is the sludge treatment which consists of the sludge
thickening by centrifugation, condensation by using heat treatment and lastly
dehydration by using vacuum filter.
Since the gas produced only hydrogen and no other gases, so the gas
needs no treatment. The hydrogen gas produced is stored to be sold to interested
companies like MOX Sdn. Bhd..
The purpose of the holding tank is to hold and accumulate the wastewater
before it undergoes further treatment. The design of the holding tank is as follows:
m 3 24 hr
Wastewater flow rate = 1.5642 ×
hr day
m3
= 37 .54
day
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
2
1 Q
hL = (6.1)
C( 2g ) A
2
1 4.345 x10 −4
Thus, h L =
0.6 ×2 ×9.81 9
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
0.391
=
0.8
= 0.70 m
3.1284
= 2×
2
= 2.50 m
The activated sludge process is a treatment process that involves the production of
a living or active microorganism which is used to stabilize the waste aerobically. A
completely mixed reactor is used in this process. This reactor is used as it is
suitable for general wastewater treatment and it has a high efficiency (85-95%) to
reduce high COD or BOD. This process involves a completely mixed reactor
followed by a secondary sedimentation tank. Part of the sludge from the secondary
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
sedimentation tank is recycled to the influent reactor. The design for the reactor is
as follows:
m3
Average flow rate = 1.5642
hr
Holding time = 3 hr
Tank Volume = Average flow rate × Holding time
m3
= 1.5642 ×3hr
hr
= 4.693 m 3
4.69
=
2
= 1.53 m
By assuming that 1kg COD requires 1kg of oxygen, thus 112.62 kg/day COD
requires 112.62 kg O2/day. The aerator used is a mechanical aerator with an
oxygen transfer rate of 1.8 kg O2/day.
kg 1day
Oxygen needed per hour = 112 .62 ×
day 24 hr
kg
= 4.69
hr
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
4.69 kg day
Thus, power needed =
1.8 hr kg
= 2.61 kW
An aerator unit provides 10kW of power. Thus, one unit is sufficient to provide
enough power for the activated sludge process.
Wastes from the sludge treatment system, for example the filtrate from the
vacuum filter, are sent to the influent treatment plant to undergo further treatment.
Dehydrated sludge is sent to the sludge dump site. The flow chart for the sludge
treatment is shown in Figure 6.1. Although the treatment is expensive, it is
necessary for our plant.
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
S l udge P la nt
C EN TR IFU G ATIO N H EA T
TH IC K EN IN G TR E ATM EN T
F iltrate to influen t pl an t
Pump Function
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
LEG END
Pum p
S lu d g e f ro m p r im a ry
P R IM A R Y s e d im e n t a t io n t a n k to b e
1 1
S E D IM E N T A T IO N T A N K t re a t e d
S lu d g e f ro m s e c o n d a ry
2 s e d im e n t a t io n t a n k to b e
r e c y c le d
S lu d g e f ro m s e c o n d a ry
s e d im e n t a t io n t a n k to b e
3
t r e a te d
W a s t e w a te r f r o m s lu d g e
t r e a tm e n t s y s te m to in flu e n t
4
p la n t
F lo w
S lu d g e F lo w
S E T T L IN G T A N K W a ste w a te r
F lo w
POW ER HOUSE
A E R A T IO N T A N K
S C R E E N IN G D E V IC E
2 3
S LU D G E TR EA TM E N T PR O C E SS
SECO NDARY
S E D IM E N T A T IO N T A N K
H O L D IN G T A N K
105
PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
x
= K f Ce1 n
m
Where x/m = amount adsorbate absorbed per unit weight of absorbent (activated
carbon)
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
x 1
log = log K f + log Ce
m n
x X C t
= b = Q Ci − b b [8.34 lb Mgal .( mg L ) ]
m b M c 2 Mc
x
Where = field breakthrough adsorption capacity, lb/lb or g/g
m b
Equation above was developed assuming that Ci is constant and that the effluent
concentration increases linearly with time from 0 to Cb value. The time breakthrough
can be calculated using the rearranging equation above. From the test data by
Freundlich adsorption isotherm plotted,
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
x 3.56
= 0.0015 Ce
m
x
= 0.0015(3.250)3.56
m 0
( x / m) b M c
tb =
Q (Ci − Cb / 2[8.34 Ib / Mgal .( mg / L)]
Therefore, results from our study based on Freundlich adsorption isotherm the
activated carbon in our design waste treatment column vessel can long lasting for
56 day. Therefore, our estimation is changing the activated carbon in the vessel
waste treatment in every 56 day to make sure the efficiency capacity of adsorption
carbon is in the maximum capacity.
REFERENCES
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PRODUCTION OF 300,000 METRIC TON OF MTBE PER YEAR
109