Project Title

Production of
Toluene
Diisocyanate

1
Designing Team
Project Advisor:
 Prof Dr. M.Mehmood Ahmed

Team members:
Arshad Mehmood
M. Adnan Farooq
Amir Usman
Liaqat Ali
Hafiz Saqib Islam

2
Process Description,
Block and Process
Flow Diagram

3
 Process FlowChart

Start
96.7% Pure TDI
4850Kgs/H
(486.73 Kg/hr ofr TDI)
Recycle Solvent

Section 100 Phosgenation

125 deg C, 135 PSI Section 400 TDI Resicue (By-Product)
Yield:85.%
(Basic upon TDA feed) Evaporation (89.05 Kg/hr)

Section 200 Section 300

Degassing Fractionation

Gases

Section 500
Separation of By-Product
Gases HCl 3% wt

CoCl2 for recycle

4
 18

10 10 19
7 F-210
7 REACTION PHASE
SEPARATOR

9
18
PURE SOLVENT 11 12
STORAGE TANK 9 F-211
11
14
L-113 E-113 SECONDARY 14
SEPARATOR
TOLUENE
DIAMINE E-312
REACTOR 13
STORAGE TANK 8
R-110
13
1 15
E-112
O- F-311 17
DICHLOROBENZE 6
NE STORAGE Distillation
TANK
5
column 16
E-311 D-310 16
4 5

3
2
2 3 E-111 HEAT
EXCHANGER PHOEGENE
L-111 21
L-112 STORAGE TANK
E-313

20 20
24
E-411 24

V-410
E-412
22
23 23 Heater

5
Material and Energy
Balance

6
Material Balance
From TDA From DLB To From CoCl2 To E-213 or
Component
Storage Storage E-111 Storage R-110

TDA 4086 4086

DLB 16344 16344 18063.5

CoCl
2 25140 10.86

TDI 28.9

HCL

Res

7
Material Balance
To To Section 500 To To Section 500 To
Component
D-210 or from D-210 D-211 or from D-211 D-310

TDA

DLB 34711 3609.4 3110116 295 30806.6

CoCl
2 18644 12820 5824 5805.8 18.2

TDI 5000 45.012 4987.7 26 4961.7

HCL 4675 4349.1 325.9 325.9

Res 643.3 643.3 643.3

8
Material Balance
To
To E-312 To Section To TDI To V-410
Component Residue
or D-314 500 Storage Or E-313
Storage

TDA 12712.5

DLB 30776 30.6 30.6

CoCl
2 18.2 7.34

TDI 49.6 20.7 62.08 4850 4912.08

HCL

Residue 643.3 643.3

9
Energy Balance
Heat Load T or ΔT
Unit Unit Name Utility
KJ/hr C

E-111 TDA solution Heater 9.8x105 105-145 Saturated Steam

E-112 CoCl2 Heater 7.5x105 25-75 Saturated Steam

Column feed
E-311 2.7x106 115-190 Saturated Steam
Pre-heater

E-312 Reflux Condenser 1.12x107 165 Cooling Water

E-313 Re-boiler 1.12x107 252 Thermal Fluid

V-410 Evaporator 1.5x106 252--270 Thermal Fluid

Product
E-411 1.3x106 270-252 Cooling Water
Condenser

10
Separator Design

11
Separator Design
 Selection of a separator
 Designing procedure
 Designing assumptions
 Sizing of a horizontal separator
 Diagram
 Design summary
 Specification sheet

12
Selection of a Separator
 Basic objectives that dictate the selection procedure.
1. Separate the gases from the liquid as efficiently as
possible.
2. Minimize the liquid carryover and maximize the liquid in the
separator.
 There are many types of commercial separators available
i.e.
Vertical separators.
Horizontal separators.
Spherical separators.
 A basic comparison for these different types of separators
and a preliminary selection is given ahead.

13
 Vertical Horizontal Spherical
Function
configuration configuration configuration
For small
For low gas For high gas leases at
Usage
liquid ratio liquid ratio moderate
pressure
Large fluid Large gas Capacity rated
Capacity
capacity capacity low
Handling
foreign Rated no 1 Rated no 2 Rated no 3
materials
Separation
Rated no 2 Rated no 1 Rated no 3
efficiency
Maintenance
Very difficult Accessible Average
and inspection
Coast/ unit & Average & Least &
Highest & easy
installation most difficult average
Overall ranking Rated no2 Rated no 1 Rated no3 14
Selection of a Separator
 The basic selection states the use of a horizontal
separator.
 The following factors point towards the use of a horizontal
separator.
1. Horizontal separators are more suitable for two phase
separation than any other type.
2. They can handle the highest gas liquid ratio.
3. They have larger gas capacities.
4. They are rated no1 on the bases of their efficiency.
5. They are rated no1 in relation to their maintenance and
inspection.
6. They have the lowest coast per unit.
7. The installation coast is not prohibitively high.

15
Design Assumptions
The basic assumptions of design are as follows.
 No foaming takes place or the retention time is drastically
increased.
 The cloud point of the liquid and the hydrate point of the gas
are below the operating temperature.
 The smallest separable liquid drops are spherical ones
having a minimum diameter of 100microns.
The above assumptions are necessary owing to the reason that
otherwise the design equation become too complex without
any effective improvement in the design accuracy.

16
Sizing of a Horizontal Separator
 The sizing procedure for a horizontal separator is
somewhat complex however the following points are
followed
1. Assume various values for the dia and calculate the
effective length of the separator using the gas capacity
equation and determine the seem to seem length from
D
Ls  Lg  ft
12
2. For each of the assumed values of D, determine the
effective length and the seem to seem length from the
liquid capacity equation, from

4
Ls  Lo ft
3

17
Sizing of a Horizontal Separator
 For each of the values of D used, compare the values of the
gas effective length and the liquid effective length to
determine whether gas constraint or liquid constraint governs
the design, the larger one will be the governing dimension.
 Select reasonable combination of D and L such that the
slenderness ratio is in the range of 3-5.

18
Separator Diagram
Gas outlet

Feed inlet Mist eliminator

Assumed liquid level
Splash plate 0.1524 m

0.381 m min

0.61 m min

Separator head Vortex breaker

19
Design Summary
1

  g  Cd  
2

Lg D  37Qg  TZ    
 p  
    d
 l g  m 

Calculation of gas flow rate

yields Q g  2 .08 m 3
sec 
Calculation of compressibility factor using following EQ
1 4.9340  h  0.08664Pr
Z     where h 
1 h Tr
1.5
 1  h  ZTr
Z(phosgene) = 0.8764 yields Z=0.624
Calculation of gas and liquid densities

yields g  18. 73  kg m 3

and  l  1202.8  kg m3  20
Design Summary
 Calculation of drag coefficient from the following sequence of
equations and employing an iterative technique.
3 24
Cd  0.34  0.5

Re Re
 g d mU
Re  0.0049
g
1

 l   g  d m 
2

U  0.01186   
 g  C 

  d 

yields drag coefficient = 0.4016

 Values for temperature and pressure are provided by the
process description as being
pressure = 758.214 Kpa
21
Temperature = 135 oC
Design Summary
 LD = 61.59 (m,cm)
 Liquid capacity constraint equation

Ql t R
D Ll 
2

0.00273
Ql=0.6 m3/sec
tR= 5 min
hence
D2L = 1025.23 m3
Using
D2L = 1025.23 m3 and LD = 61.59 (m,cm)
and using D=0.78m as a first estimate

22
Design Summary
For the first estimate of D
Lg= 0.8 m and Ls= 1.6 m
Ll= 11.73 m and Ls= 16 m

Hence the liquid capacity dictates the design

seem to seem length of the separator = 6.09 m

diameter of the separator = 1.3 m

23
Specification Sheet
 Identification
item – separator
item no – F - 210
no required – 1
 Function
separation of gas liquid mixture from the reactor effluent
 Operation
continuous
 Design data
Diameter = 1.3 m
seem to seem length = 4.56 m

24
Specification sheet
 Identification
item – separator
item no – F - 211
no required – 1
 Function
separation of gas liquid mixture from the primary separtor
 Operation
continuous
 Design data
Diameter = 1.2m
seem to seem length = 5.95m

25