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7/24/2019 Tk21 Report Assignment2
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UNIVERSITAS INDONESIA
RENEWABLE BIODIESEL FROM
CRUDE PALM OIL, JATROPHA OIL, NYAMPLUNG OIL
REPORT ASSIGNMENT 2
GROUP 21
GROUP PERSONNEL:
DANAR ADITYA S. (1206263401)
DENNY SETYADARMA (1206263351)
HASANNUDIN (1206230725)
MUHAMMAD HAFIZ AL RASYID (1206219161)
TITEN PINASTI (1306482054)
CHEMICAL ENGINEERING DEPARTMENT
FACULTY OF ENGINEERING
UNIVERSITAS INDONESIA
DEPOK
2015
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EXECUTIVE SUMMARY
In order to design renewable diesel plant, we have to make Piping and
Instrumentation Diagram and Equipment Sizing. Piping and Instrumentation
Diagram known as P&ID is one of some objectives in this assignment. It is the
completion of Process Flow Diagram made in first assignment. It makes P&ID is
more detail than PFD. P&ID is used in manufacturing the renewable biodiesel
plant. Valves and some controllers also connected to the P&ID. P&ID is a used by
process engineer in communicating with other engineer from another discipline.
With this P&ID, we expect the other engineer can understand the whole plant
system easily. In this P&ID we separate it to some pages based on process to
make easy in attaching the valves and controller. There are 4 pages containing of
Degumming, Bleaching, Steam Methane Reforming, Hydrothreating.
After designing P&ID, We need to calculate the specification of the
process equipment being used in a plant known as equipment sizing. This is
another objective of this assignment There are equipment specifications,
equipment sizing, equipment calculations used in making renewable biodiesel
plant in this second assignment. Equipment needed in this plant are 5 tanks, 4
pumps, heat exchanger, reactor, three phase separator. These data is used for
manufacturing in plant design. Sizing of equipment based on rule of thumbs of the
equipment and industrial calculation method by using manual calculation and
software.
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TABLE OF CONTENTS
EXECUTIVE SUMMARY .................................................................................... ii
TABLE OF CONTENTS ....................................................................................... iii
LIST OF FIGURES ................................................................................................ v
LIST OF TABLES ................................................................................................. vi
CHAPTER 1 ........................................................................................................... 1
CONTROL AND INSTRUMENT DESIGN .......................................................... 1
1.1.
Plant Control Tabulation .......................................................................... 1
1.2.
Piping and Instrument Diagram ..............Error! Bookmark not defined.
1.3.
Start up, Normal and Shutdown Procedure ............................................ 12
1.3.1.
Start Up Procedure .......................................................................... 12
1.3.1.1.
Start Up Procedures for Each Section ..................................... 13
1.3.2.
Shut Down Procedure ..................................................................... 14
CHAPTER 2 ......................................................................................................... 15
EQUIPMENT SIZING ......................................................................................... 15
2.1.
Main Equiment ....................................................................................... 15
2.1.1.
Storage Tank ................................................................................... 15
Crude Palm Oil Storage Tank T-101 ................................................................ 15
Jatropha Oil Storage Tank T-101 ...................................................................... 16
Nyamplung Oil Storage Tank T-101 ................................................................ 17
Renewable Biodiesel Storage Tank T-102........................................................ 18
Degumming Tank V-101 .................................................................................. 19
Shift Converter Reactor R-102 ......................................................................... 20
Absorber Column V-103 ................................................................................... 21
2.2.
Supporting Equipment ............................................................................ 24
Heat Exchanger E-101 ...................................................................................... 24
Heat Exchanger E-102 ...................................................................................... 25
Heat Exchanger E-103 ...................................................................................... 26
Cooler E-104 ..................................................................................................... 29
CONCLUSION ..................................................................................................... 38
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REFERENCES ..................................................................................................... 39
APPENDIX ........................................................................................................... 40
Storage Tank ..................................................................................................... 40
Crude Palm Oil Storage Tank ........................................................................... 41
Jatropha Oil Storage Tank ................................................................................ 41
Nyamplung Oil Storage Tank ........................................................................... 42
Renewable Biodiesel Storage Tank .................................................................. 42
Degumming Tank ............................................................................................. 48
Hydrotreating Reactor Sizing ........................................................................... 52
Shift Converter Reactor R-102 ......................................................................... 60
Absorber Calculation ........................................................................................ 62
Heat Exchanger Design Procedure ................................................................... 70
Heat Exchanger E-101 ...................................................................................... 75
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LIST OF FIGURES
Figure A.1. Types of head of storage tank ............................................................ 44
Figure A.1. Power Number ................................................................................... 51
Figure B.1. Fixed Bed Reactor ............................................................................. 53
Figure B.2. Polymath Programming ..................................................................... 55
Figure B.3. Polymath Programming Result .......................................................... 56
Figure B.4. Polymath Programming Graph .......................................................... 56
Figure B.5. Equation used for the design or sizing of fixed bed reactor .............. 61
Figure B.6. Design for Various Packing............................................................... 64
Figure B.7. Flooding Line Graph .......................................................................... 65
Figure C.1. Shell and Tube Overall Coefficient ................................................... 71
Figure C.2. Air Cooled Exchangers and Immersed Oil Overall Coefficient ........ 71
Figure C.3. Coomon Tube Layouts ....................................................................... 72
Figure C.4. Heat exchangers tube-layouts ............................................................ 72
Figure C.5. Type of Heat Exchanger Baffles ........................................................ 73
Figure C.6. Temperature Correction Factor : two shell passes ; four or multiple
passes .................................................................................................................... 76
Figure C.7. Tube Sheet Layouts (square pitch) .................................................... 77
Figure C.8. HE Layouts ........................................................................................ 78
Figure C.9 jH Factor ............................................................................................. 83
Figure E.1 Impeller shapes related to specific speed ............................................ 92
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LIST OF TABLES
Table 1.1. Tabulation of degumming process ......................................................... 1
Table 1.2. Tabulation of bleaching process ............................................................ 2
Table 1.3. Tabulation of hydrotreating process ...................................................... 2
Table 1.4. Tabulation of steam methane reforming process ................................... 4
Table 1.7. Startup procedure ................................................................................. 12
Table 1.8. Emergency Shutdown .......................................................................... 14
Table 2.1 Specification Data of Storage Tank ...................................................... 15
Table 2.2. Specification Data of Storage Tank ..................................................... 16
Table 2.3 Specification Data of Storage Tank ...................................................... 17
Table. 2.4. Specification Data of Storage Tank .................................................... 18
Table. 2.5. Specification Data of Degumming Tank ............................................ 19
Table. 2.6. Specification Data of Shift Converter Reactor ................................... 20
Table. 2.7. Specification Data of Absorber Column ............................................. 21
Table. 2.8. Specification Data of Steam Methane Reformer ................................ 22
Table. 2.9. Specification Data of Hydrotreating Ractor Design ........................... 23
Table. 2.10. Specification Data of Heat Exchanger E-101 ................................... 24
Table. 2.11. Specification Data of Heat Exchanger E-102 ................................... 25
Table. 2.12. Specification Data of Heat Exchanger E-107 ................................... 26
Table. 2.13. Specification Data of Heat Exchanger E-105 ................................... 27
Table. 2.14. Specification Data of Heat Exchanger E-106 ................................... 28
Table. 2.15. Specification Data of Fired Heater E-103 ......................................... 29
Table. 2.16. Specification Data of Fired Heater E-104 ......................................... 30
Table 2.18. Specification Data of Compressor C-102 .......................................... 33
Table 2.19. Specification Data of Pump P-101 ..................................................... 34
Table 2.20. Specification Data of Pump P-102 ..................................................... 35
Table 2.21. Specification Data of Pump P-103 ..................................................... 36
Table 2.22. Specification Data of Pump P-104 ..................................................... 37
Table A.1. List of Materials that Selected for Each Storage Tank ....................... 40
Table B.1. Sizing Shift Converter Reformer ........................................................ 62
Table B.2. Composition of the Incoming Gas ....................................................... 63
Table B.2. Steam Methane Reformer ................................................................... 69
Table C.1. Composition Properties ....................................................................... 79
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CHAPTER 1
CONTROL AND INSTRUMENT DESIGN
1.1. Plant Control Tabulation
Table 1.1. Tabulation of degumming process
No DeviceControl
Variable
Manipulated
Variable
Location
of Control
Valve
Sequence of
Instrumentation
Degumming Process
1 T-101 Level of Oil
Tank
Flow of crude
oil
After pump
and before
heater
If the level of tank is
low, valve before
heater will be closed
and the other valve
will be opened. It
make the oil go back
until the level is
normal enough
2 E-101 Temperature
outlet of
Heat
Exchanger
Temperature
heating fluid
Inlet of the
heater
Increase the flow of
heating fluid if the
temperature of oil
going to degumming
tank does not react
the set point
3 V-101 Level of
Degumming
Tank
Flow of
degummed
oil
After pump If the level of mixing
tank is low, valve
before heater will be
closed and the other
valve will be opened.
It make the oil go
back until the level is
normal enough
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Table 1.2. Tabulation of bleaching process
No DeviceControl
Variable
Manipulated
Variable
Location
of
Control
Valve
Sequence of
Instrumentation
Bleaching Coloumn
1 E-102 Temperature
outlet of Heat
Exchanger
Temperature
heating fluid
Inlet of
the heater
Increase the flow of
heating fluid if the
temperature of oil
going to adsorber
coloumn does not
react the set point
2 V-102 Level of
Bleaching
Tank
Flow of
bleached oil
After
pump
If the level of adsorber
coloumn is low, valve
before heater will be
closed and the other
valve will be opened.
It make the oil go backuntil the level is
normal enough
Table 1.3. Tabulation of hydrotreating process
No Device Control
Variable
Manipulated
Variable
Location
of Control
Valve
Sequence of
Instrumentation
Hydrotreating Reactor
1 E-107 Temperature
outlet of
Heat
Exchanger
Temperature
of heating
fluid
Inlet of
the heater
Increasing the flow of
heating fluid if the
temperature of oil
going to hydrogenation
reactor does not reach
the set point
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Table 1.3.Tabulation of hydrotreating process (Contd)
2 C-102 Flow of
Hydrogen
Pressure
outlet of
Compressor
Before
entering
compresso
r
If the pressure outlet of
comprossor is
decreasing, the valve
will be closed slowly
in order to make the
flow of hydrogen
entering the
compressor decrease.
3 R-104 Flow
Control
Flow of
Bleached Oil
Before the
reactor
Increasing or
decreasing the flow of
degummed oil if the
flow of oil going to
reactor is not suitable
4 R-104 Pressure of
hydrothreati
ng reactor
pressure
safety valve
Pressure
Relieve
If the pressure is to
high, the pressure
safety valve will be
opened to release theexcess gas until the
normal pressure. If the
reactor does not
release the gas, the
reactor will be hold
the over pressure and
the equipment will be
broken soon.
5 R-104 Level of
Hydrotreatin
g Reactor
Flow of
Green Diesel
outlet
After
hydrotreat
ing reactor
If the level is too low,
the valve will be
closed slowly until the
normal level.
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Table 1.4. Tabulation of steam methane reforming process
No DeviceControl
Variable
Manipulate
d Variable
Location of
Control
Valve
Sequence of
Instrumentation
Steam Methane Reformer
1 C-101 Flow of Gas
Inlet
Separator
Pressure
outlet of
Compressor
Before
entering
compressor
If the pressure outlet
of comprossor is
decreasing, the valve
will be closed slowly
in order to make the
flow of hydrogen
entering the
compressor decrease.
2 E-103 Temperatur
e outlet of
Heat
Exchanger
Temperature
of heating
fluid
Inlet of the
heater
Increasing the flow
of heating fluid if the
temperature of oil
going to the next
process does notreach the set point
3 E-104 Temperatur
e outlet of
Heat
Exchanger
Temperature
of heating
fluid
Inlet of the
heater
Increasing the flow
of heating fluid if the
temperature of oil
going to the next
process does not
reach the set point
4 E-105 Temperatur
e outlet of
Heat
Exchanger
Temperature
of heating
fluid
Inlet of the
heater
Increasing the flow
of heating fluid if the
temperature of oil
going to the next
process does not
reach the set point
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Table 1.6 Tabulation of steam methane reforming process (Contd)
5 E-106 Temperatur
e outlet of
Heat
Exchanger
Temperature
of heating
fluid
Inlet of the
heater
Increasing the flow
of heating fluid if the
temperature of oil
going to the next
process does not
reach the set point
6 R-101 Pressure Flow of gas
outlet
After
reactor
If the pressure is too
low, the valve will
be closed slowly
until the normalcoloumn level.
7 R-101 Pressure Pressure
safety valve
Pressure
Relieve
If the pressure is too
high, the pressure
safety valve will be
opened to release the
excess gas until the
normal pressure. If
the coloumn does not
not release the gas,
the coloumn will be
hold the over
pressure and the
equipment will be
broken soon.
8 R-102 Pressure Flow of gas
outlet
After
reactor
If the pressure is too
low, the valve will
be closed slowly
until the normal
coloumn level.
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Table 1.6 Tabulation of steam methane reforming process (Contd)
9 R-102 Pressure Pressure
safety valve
Pressure
Relieve
If the pressure is too
high, the pressure
safety valve will be
opened to release the
excess gas until the
normal pressure. If
the coloumn does not
not release the gas,
the coloumn will be
hold the overpressure and the
equipment will be
broken soon.
10 R-103 Pressure Flow of gas
outlet
After
reactor
If the pressure is too
low, the valve will
be closed slowly
until the normal
coloumn level.
11 R-103 Pressure Pressure
safety valve
Pressure
Relieve
If the pressure is too
high, the pressure
safety valve will be
opened to release the
excess gas until the
normal pressure. If
the coloumn does not
not release the gas,
the coloumn will be
hold the over
pressure and the
equipment will be
broken soon.
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Table 1.6 Tabulation of steam methane reforming process (Contd)
12 V-103 Pressure Flow of gas
outlet
After
reactor
If the pressure is too
low, the valve will
be closed slowly
until the normal
coloumn level.
13 V-103 Pressure Pressure
safety valve
Pressure
Relieve
If the pressure is too
high, the pressure
safety valve will be
opened to release the
excess gas until thenormal pressure. If
the coloumn does not
not release the gas,
the coloumn will be
hold the over
pressure and the
equipment will be
broken soon.
1.2. Process & Instrumental Design
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Steam
DATESIGNATURENAME
GROUP 21NAME
CORRECTED BY
PICTURE NO.
NO REVISION WITHOUT SCALE
P&ID DEGUMMING UNIT
RENEWABLE BIODIESEL FROM CPO,
JATROPHA OIL & NYAMPLUNGS OIL
DEPARTEMEN TEKNIK KIMIA
FAKULTAS TEKNIK
UNIVERSITAS INDONESIA
Condensate
T-101
Crude Oil Tank
P-101
Feed Pump
E-101
Heat Exchanger
V-101
Degumming tank
P-102
Feed Pump
Fosforic Acid
Gum
CPO /
NYAMPLUNG /JATHROPA LT
P-101
101101
101
M
102102
102
M
101
101
LT
101
1
2
34
5
6
7
8
9V-96
T-101
E- 101
V-101
P- 102
LIC
FIC
PI FT TT
LIC
FIC
PI FT
LIC
DegummedOil
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DATESIGNATURENAME
GROUP 21NAME
CORRECTED BY
PICTURE NO.
NO REVISION WITHOUT SCALE
P&ID BLEACHING UNIT
RENEWABLE BIODIESEL FROM CPO,
JATROPHA OIL & NYAMPLUNGS OIL
DEPARTEMEN T EKNIK KIMIA
FAKULTAS TEKNIK
UNIVERSITAS INDONESIA
E-102
Heat Exchanger
V-102
Bleaching Unit
P-103
Pump
Steam
Condensate
BleachedOil
Degummed Oil
103103
103
M
102
102
102
1
2
4
5
3
6
102
E- 102
V-102
P-103
TIC
TT
LT
FIC
PI FT
LIC
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DATESIGNATURENAME
GROUP 21NAME
CORRECTED BY
PICTURE NO.
NO REVISION WITHOUT SCALE
P&ID HYDROTHREATING UNIT
RENEWABLE BIODIESEL FROM CPO,
JATROPHA OIL & NYAMPLUNGS OIL
DEPARTEMEN TEKNIK KIMIA
FAKULTAS TEKNIK
UNIVERSITAS INDONESIA
E-107Heater
R-104Hidrotreating Reactor
V-108Green Diesel Tank
C-102Compressor
BleachedOil
Steam
Condensate
Hydrogen
107
1
2
5
6
4
7
3
107
102
102
102
E-107
R-104
C-102
104
TT
FIC
PIC
PT
PIC
FC
Excess Reactant11
104PT
104PIC
V-108
104
104
LT
LIC
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1.3. Start up, Normal and Shutdown Procedure
1.3.1. Start Up Procedure
Start up actions occurs every day beside Saturday and Sunday, this
makes 330 days plant startup per year. Startup will be explained step by step in
Table 1.7 below.
Table 1.7. Startup procedure
No Procedure DescriptionSafety
Precautions
1
All piping and instrument
are completed as P&ID.
Electrical set start up. All
electrical cords are
connected and no faulty
cord.
Instrument set start up
2
Ensure functionality of
control valves,
controllers, emergency
shutdown system, etc.
All equipment and
instrument set start up
3Install and activate
electrical systemElectrical set start up
All electrical
cords are
connected and no
faulty cord
4 Activate steam utilitiesHeater start up for
heating water utilities
Desired
temperature has
been reached
5 Pre-treatment startup
Pre-treatment
equipment start up to
produce CPO from
palm fruit, nyamplung,
jathropa
All pre treatment
equipment is safe
to operate
6 Activate plant process Starting all controller
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instrument and checking
alarm panel
on plant and checking
alarm function
7Activate main process
equipment
Starting reactor and
other process
equipment after CPO
level is adequate for
process
All equipment
connected and no
leakage
1.3.1.1.Start Up Procedures for Each Section
Start-up procedures in this system are divided into four parts based on
the number of units in our plant. Below are the procedures:
a. Degumming Unit
1. Check all of the systems are installed correctly
2. Check the controller of the system
3. Check the temperature at 65C and the process lasts for 15 minutes
b. Bleaching Unit
1. Check all of the systems are installed correctly
2.
Check the controller of the system
3. Check substances that give color to the oil
4. Check all the equipment safe to operate
c. Hydrotreating
1. Check all of the systems are installed correctly
2.
Check the controller of the system
3. Processes implement reactions of hydrotreatment promoted by catalysts
Nickel Molybdenum with buffer Alumina4. The hydrotreatment reactions are generally carried out in the presence of
hydrogen
5.
Check temperature at 300C and pressure at 2 atm
d. Steam Methane Reforming
1. Check all of the systems are installed correctly
2. Check the controller of the system
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3. Check the steam flow from its temperature whether it is suitable or not for
entering the steam methane reformer
4.
Reduced localized temperature
1.3.2. Shut Down Procedure
Manual shutdown. Manual shut down occur every end of year. It
occurs according to procedure:
1.
Decrease the flow rate of feed CPO, Nyamplung oil, and Jathropa oil
gradually until the flows stop
2. Let all the flue gas flow until there is no excess flue gas in the piping line
3.
Turn off all the equipment, such as heat exchanger, steam methane
reformer, and pump.
4. Uninstall the catalyst from all unit.
Emergency shutdown. Emergency shutdown only happen if theres
special condition occurs. Emergency shutdown relies on plant process control
instrument and alarm. The condition and procedure are shown in Table 1.8.
Table 1.8. Emergency Shutdown
No Condition Procedure
1Reactor temperature condition
reach too high or too low
Shut the ball valve that related to the flow,
and maintenance or change with reserve
equipment if available
2Reactor flow condition reach
too high
3
Hydrotreating temperature
condition reach too high or
too low
4Steam Methane Reforming
flow condition reach too high
5 Pump failures
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CHAPTER 2
EQUIPMENT SIZING
2.1. Main Equiment
2.1.1. Storage Tank
2.1.1.1.Crude Palm Oil Storage Tank T-101
Table 2.1 Specification Data of Storage Tank
Identification
Item : Storage Tank
Item Number : T-101
Name of Equipment : Crude Palm Oil Storage Tank
Item Amount : 10
Function : Storing of Crude Palm Oil
Composition
Crude Palm Oil: 100%
Operation Data
Capacity : 44.70 ton/hr
Pressure : 2.576 atm
Temperature : 25oC
Storage Time : 7 days
Specification Design
Type :Cylindrical Tank with Ellipsoidal Top
and Flat Bottom
Joint : Double Welded Butt Joint
Material : SA-283, Grade C
Volume : 949 m3
Diameter Tank : 7.48 m
Height Tank : 16.21 m
Wall Thickness : 0.97 inch
Head Thickness : 1.40 inch
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2.1.1.2.Jatropha Oil Storage Tank T-101
Table 2.2. Specification Data of Storage Tank
Identification
Item : Storage Tank
Item Number : T-101
Name of Equipment : Jatropha Oil Storage Tank
Item Amount : 10
Function : Storing of Jatropha Oil
Composition
Crude Palm Oil: 100%
Operation Data
Capacity : 44.70 ton/hr
Pressure : 2.5645 atm
Temperature : 25oC
Storage Time : 7 days
Specification Design
Type :Cylindrical Tank with Ellipsoidal Top
and Flat Bottom
Joint : Double Welded Butt Joint
Material : SA-283, Grade C
Volume : 968 m3
Diameter Tank : 7.53 m
Height Tank : 16.32 m
Wall Thickness : 0.97 inch
Head Thickness : 1.40 inch
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2.1.1.3.Nyamplung Oil Storage Tank T-101
Table 2.3 Specification Data of Storage Tank
Identification
Item : Storage Tank
Item Number : T-101
Name of Equipment : Nyamplung Oil Storage Tank
Item Amount : 10
Function : Storing of Nyamplung Oil
Composition
Crude Palm Oil: 100%
Operation Data
Capacity : 44.70 ton/hr
Pressure : 2.565 atm
Temperature : 25oC
Storage Time : 7 days
Specification Design
Type :Cylindrical Tank with Ellipsoidal Top
and Flat Bottom
Joint : Double Welded Butt Joint
Material : SA-283, Grade C
Volume : 961 m3
Diameter Tank : 7.51 m
Height Tank : 16.27 m
Wall Thickness : 0.97 inch
Head Thickness : 1.40 inch
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2.1.1.4.Renewable Biodiesel Storage Tank T-102
Table. 2.4. Specification Data of Storage Tank
Identification
Item : Storage Tank
Item Number : T-102
Name of Equipment : Renewable Biodiesel Storage Tank
Item Amount : 2
Function :Storing of Renewable Biodiesel
Product
Composition
Crude Palm Oil: 100%
Operation Data
Capacity : 37,88 ton/hr
Pressure : 1.863 atm
Temperature : 25oC
Storage Time : 7 days
Specification Design
Type :Cylindrical Tank with Ellipsoidal Top
and Flat Bottom
Joint : Double Welded Butt Joint
Material : SA-283, Grade C
Volume : 640 m3
Diameter Tank : 3.83 m
Height Tank : 8.94 m
Wall Thickness : 0.64 inch
Head Thickness : 0.80 inch
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2.1.1.5.Degumming Tank V-101
Table. 2.5. Specification Data of Degumming Tank
Identification
Item Mixer Tank
Item number V-101
Equipment name Degumming Tank
Number of Unit 1
Function Reacting phosporic acid with gum
Mode Operation Continue
Composition (%)
Oil 11.39 kg/h
Phosporic Acid 27,005.35 kg/h
Operating condition Capacity 45,560 kg/h
Pressure 168.2 kPa
Temperature 64.12 oC
Spesification Design Type Ellipsoidal vertical tank
Material Stainless Steel 316
Volume 59.33 m3
Diameter tank 3.19 m
Height tank 8.51 m
Height of cylinder 6.38 m
Height of ellipsoidal 1.06 m
Wall thickness 4.29 mm
Head thickness 4.29 mm
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Table. 2.5. Specification Data of Degumming Tank (Contd)
Stirrer Design Impeller type Axial four blade
Number of impeller 1
Impeller diameter 1.06 m
Impeller level width 0.213 m
Impeller to bottom 1.06 m
Diameter stick 0.353 m
Diameter baffle 0.266 m
Impeller speed 2 rps
Utilities Power 0.114 kW/h
2.1.2. Reactor
2.1.2.1.Shift Converter Reactor R-102
Table. 2.6. Specification Data of Shift Converter Reactor
Identification
Item Shift Converter
Item Number R-102
Function: To produce syngas from Natural Gas and SteamType of Reactor Multitubular Packed Bed Reactor
Operating Condition
Pressure bar 4,16
Temperature oC 427
Dimension
Reaction Rate kgmol/kg cat.h 0,378978
Residence Time min 10,73Volume Reactor m3 16,35581
Catalyst Weight kg 0,57
No. of Tubes 8
Tube Diameter cm 1,733461
Diameter cm 173,3461
Height m 6,933845
Thickness cm 5,0225
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2.1.2.2.Absorber Column V-103
Table. 2.7. Specification Data of Absorber Column
Identification
Name Absorber Column
Item Number V-103
Function To separating H2and CO2from Shift
converter unit
Number of unit 1
Material Carbon Steel SA-283 Grade C
Type Packing
Packing Width and Height
Tower Diameter 12.60 m
Height of packing 20.51 m
Permissible tensile stress 950 kg/cm2
Mechanical Design
Working pressure 101300 N/m2
Design pressure,p 106365 N/m2
0.106365 N/mm2
Permissible stress 95 N/mm2
Joint Efficiency (j) 0.85
Corrosion allowance 3 mm
Outer diameter, Do 12.659 m
Input Amine. T 150 oC
Input CO2, T 75oC
Output Amine, T 80 oC
Output CO2, T 95oC
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2.1.2.3.Steam Methane Reformer R-101
Table. 2.8. Specification Data of Steam Methane Reformer
Identification
Item Steam Methane Reformer
Item Number R-101
Function: To produce syngas from Natural Gas and
Steam
Type of Reactor Multitubular Packed Bed Reactor
Operating Condition
Pressure bar 4,5
Temperature oC 760
Dimension
Reaction Rate kgmol/kg cat.h 4,08045
Residence Time min 10,73
Volume Reactor m3 57,39
Catalyst Weight kg 523.23
No. of Tubes 8
Tube Diameter cm 2,63
Diameter cm 263,41
Height m 10,54
Thickness cm 5,0225
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2.1.2.4.Hydrotreating Reactor Design
Table. 2.9. Specification Data of Hydrotreating Ractor Design
Unit: CRV-100 Hydrotreating Reactor
Function:To Produce Green Diesel via
Triglycerides and Hydrogen
Operating Condition
Type of Reactor Packed Bed Reactor
Pressure bar 34.378
Temperature oC 300
Catalyst Volume m3 8.33
DimensionResidence Time s 8.62
Volume m3 10.42
Number of Tubes 414
Tube Diameter in 1.968
Diameter m 1.744
Height m 4.366
Thickness mm 5
Shell Thickness mm 4.9
Material Stainless Steel 316 SS
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2.2. Supporting Equipment
2.2.1. Heat Exchanger
2.2.1.1.Heat Exchanger E-101
Table. 2.10. Specification Data of Heat Exchanger E-101
Equipment Specification
Equipment Name Heat Exchanger
Equipment Code E-101
FunctionIncrease the temperature of CPO
before entering degumming process
Amount 1
Material Carbon Steel
Type Shell and Tube
Operating Data
Shell Tube
Flow Rate kg/h 10000.00 4594.85
Temperature Inlet C 155.00 25.00
Temperature Outlet C 134.00 65.00
Operating Pressure kPa 300.00 200.00
Construction Data
LMTD C 99.1969
UA W/m C 5.7046
Duty kW 122.1208
Heat Transfer Area m 4.1637
Number of Passes 1-2
Shell ID m 0.49
Tube Arrangement Triangular
Number of Tubes 220
Tube Length m 4.00
Tube OD m 0.0191
Tube BWG 14.0000
Tube Pitch m 0.0254
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2.2.1.2.Heat Exchanger E-102
Table. 2.11. Specification Data of Heat Exchanger E-102
Equipment Specification
Equipment Name Heat Exchanger
Equipment Code E-102
FunctionIncrease the temperature of CPO
before entering bleaching process
Amount 1
Material Carbon Steel
Type Shell and Tube
Operating Data
Shell Tube
Flow Rate kg/h 10000.00 5138.21
Temperature Inlet C 155.00 64.23
Temperature Outlet C 134.00 100.00
Operating Pressure kPa 300.00 200.00
Construction Data
LMTD C 62.0925
UA W/m C 32.0492
Duty kW 122.1208
Heat Transfer Area m 6.7828
Number of Passes 1-2
Shell ID m 0.30
Tube Arrangement Triangular
Number of Tubes 32
Tube Length m 8.00
Tube OD m 0.0191
Tube BWG 14.0000
Tube Pitch m 0.0238
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2.2.1.3.Heat Exchanger E-103
Table. 2.12. Specification Data of Heat Exchanger E-107
Equipment Specification
Equipment Name Heat Exchanger
Equipment Code E-107
FunctionIncrease the temperature of oil before
entering the reactor
Amount 1
Material
Type Shell and Tube
Operating Data
Shell Tube
Flow Rate kg/h 90000.00 41928.91
Temperature Inlet C 400.00 102.44
Temperature Outlet C 294.84 300.00
Operating Pressure kPa 800.00 700.00
Construction Data
LMTD C 141.1967
UA () W/m C 20.2749
Duty () kW 5504.0209
Heat Transfer Area m 165.4549
Number of Passes 1-2
Shell ID m 0.49
Tube Arrangement Triangular
Number of Tubes 264
Tube Length m 12.00
Tube OD m 0.0191
Tube BWG 14
Tube Pitch m 0.0238
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2.2.1.4. Heat Exchanger
Table. 2.13. Specification Data of Heat Exchanger E-105
Equipment Specification
Equipment Name Heat Exchanger
Equipment Code E-105
Function
Decrease the temperature of shift
product before entering absorption
process
Amount 1
Material Carbon Steel
Type Shell and Tube
Operating Data
Shell Tube
Flow Rate kg/h 2135.00 36787.10
Temperature Inlet C 430.00 25.00
Temperature Outlet C 38.00 41.50
Operating Pressure kPa 340.00 100.00
Construction Data
LMTD C 110.5275
UA () W/m C 743.3854
Duty () kW 727.5363
Heat Transfer Area m 27.5850
Number of Passes 1-2
Shell ID m 0.39
Tube Arrangement Triangular
Number of Tubes 154
Tube Length m 4.00
Tube OD m 0.0191
Tube BWG 14.0000
Tube Pitch m 0.0238
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2.2.1.5.Heat Exchanger
Table. 2.14. Specification Data of Heat Exchanger E-106
Equipment Specification
Equipment Name Heat Exchanger
Equipment Code E-106
Function
Decrease the temperature of
methanator feed before entering
reactor
Amount 1
Material Carbon Steel
Type Shell and Tube
Operating Data
Shell Tube
Flow Rate kg/h 18000.00 1845.43
Temperature Inlet C 280.00 138.00
Temperature Outlet C 262.75 260.00
Operating Pressure kPa 340.00 100.00
Construction Data
LMTD C 57.2235
UA () W/m C 743.3854
Duty () kW 269.8557
Heat Transfer Area m 18.4039
Number of Passes 1-2
Shell ID m 0.30
Tube Arrangement Triangular
Number of Tubes 90
Tube Length m 4.00
Tube OD m 0.0191
Tube BWG 14.0000
Tube Pitch m 0.0238
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2.2.1.6.Fired Heater E-103
Table. 2.15. Specification Data of Fired Heater E-103
Equipment Specification
Equipment Name Fired Heater
Equipment Code E-103
FunctionIncrease the temperature of mixed
feed before entering reformer process
Amount 1
Material Stainless Steel
Type Shell and Tube
Operating Data
Shell
Flow Rate kg/h 2135.00
Temperature Inlet C 140
Temperature Outlet C 760
Operating Pressure kPa 500
Radiant Section
Tube OD in 8.626
Tube Thickness in 0.05118
Number of Tubes
(Radiant) -40
Number of Tubes (Shield) - 12
Combustion (Fraction
Excess Air) -0.15
Firebox Diameter ft 19.98
Flue Gas Temperature R 2077,1Emmisivity - 0.5087
Radiation Heat Transfer Btu/hr 3.37 x 107
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Table. 2.15. Specification Data of Fired Heater E-103 (Contd)
Convection Section
Tube BWG 14.0000
Tube Pitch m 0.0238
Wall Temperature 959Number of Rows - 5
Number of Tubes per Row - 4
Flue Gas Temperature 1472LMTD 430.28Convection Heat Transfer Btu/hr 3.37 x 107
2.2.1.7.Fired Heater E-104
Table. 2.16. Specification Data of Fired Heater E-104
Equipment Specification
Equipment Name Fired Heater
Equipment Code E-104
FunctionIncrease the temperature of shift feed
before entering water-gas-shift
process
Amount 1
Material Stainless Steel
Type Shell and Tube
Operating Data
Shell
Flow Rate kg/h 2135.00
Temperature Inlet C 760
Temperature Outlet C 1050
Operating Pressure kPa 500
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Table. 2.16. Specification Data of Fired Heater E-104 (Contd)
Radiant Section
Tube OD in 8.626
Tube Thickness in 0.05118
Number of Tubes
(Radiant) -40
Number of Tubes (Shield) - 12
Combustion (Fraction
Excess Air) -0.15
Firebox Diameter ft 19.98
Flue Gas Temperature R 2077,1Emmisivity - 0.5087
Radiation Heat Transfer Btu/hr 3.37 x 107
Convection Section
Tube BWG 8.626
Tube Pitch m 0.5
Wall Temperature
959
Number of Rows - 5
Number of Tubes per Row - 4
Flue Gas Temperature 1472LMTD 430.28Convection Heat Transfer Btu/hr 3.37 x 107
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2.2.2. Compressor
2.2.2.1.Compressor C-101
Table 2.17. Specification Data of Compressor C-101
Equipment Specification
Name Feed Methane Compressor
Code C-101
Function To help methane flow to feed mixer
Total 1
Vendor Ingersoll Rand
Model UP5 22-7
Type Rotary Screw Air Compressor
Material Carbon Steel
Frequency (Hz) 50
Nominal Power (kW) 22
Flow (m3/min) 3.54
Length/Width/Height (cm) 128/92/105
Weight (kg) 540
Operation Data
Flow rate (m3/h) 2.672
Mass flow (kg/h) 800
Suction Pressure (kPa) 520
Discharge Pressure (kPa) 824
Temperature Inlet (oC) 20
Temperature Outlet (oC) 63.25
Power (kW) 21.6
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2.2.2.2.Compressor C-102
Table 2.18. Specification Data of Compressor C-102
Equipment Specification
Name Hydrogen Compressor
Code C-102
Function To help hydrogen flow from methanator
to hydrogenation reactor
Total 1
Vendor Ingersoll Rand
Model M300-2S
Type Rotary Screw Air Compressor
Material Carbon Steel
Frequency (Hz) 50
Nominal Power (kW) 300
Flow (m3/min) 60.2
Length/Width/Height (cm) 400/193/215
Weight (kg) 5540
Operation Data
Flow rate (m3/h) 5.391
Mass flow (kg/h) 1578
Suction Pressure (kPa) 241
Discharge Pressure (kPa) 544.9
Temperature Inlet (oC) 280
Temperature Outlet (oC) 440.7
Power (kW) 290.2
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2.2.3. Pump
2.2.3.1.Pump P-101
Table 2.19. Specification Data of Pump P-101
Equipment Specification
Name Oil Feed Pump
Code P-101
Function To help oil to flow to heat exchanger then
mixer
Number of unit 1
Type Centrifugal Pump
Operation Data
Liquid Volume Flow (m3/h) 49.96
Temperature (oC) 25
Suction Pressure (kPa) 101.3
Discharge Pressure (kPa) 202.6
Head (ft) 54.714
NPSHA (ft) 0.111
Efficiency 0.75
Hydraulic Power (kW) 2.35
BHP (kW) 3.14
Spesific Speed (rpm) 1327.109
Jenis Impeller Radial Vane
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2.2.3.2.Pump P-102
Table 2.20. Specification Data of Pump P-102
Equipment Specification
Name Refined Oil Pump
Code P-102
Function To help refined oil to flow to heat exchanger
then adsorption column
Number of unit 1
Type Centrifugal Pump
Operation Data
Liquid Volume Flow (m3/h) 50.76
Temperature (oC) 64.15
Suction Pressure (kPa) 66.85
Discharge Pressure (kPa) 168.2
Head (ft) 54.724
NPSHA (ft) 0.111
Efficiency 0.75
Hydraulic Power (kW) 2.39
BHP (kW) 3.19
Spesific Speed (rpm) 1336.109
Jenis Impeller Radial Vane
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2.2.3.3.Pump P-103
Table 2.21. Specification Data of Pump P-103
Equipment Specification
Name Refined Bleached Oil Pump
Code P-103
Function To help oil to flow to heat exchanger then
hydrogenation column
Number of unit 1
Type Centrifugal Pump
Operation Data
Liquid Volume Flow (m3/h) 49.96
Temperature (oC) 100
Suction Pressure (kPa) 101.3
Discharge Pressure (kPa) 2758
Head (ft) 960.21
NPSHA (ft) 0.111
Efficiency 0.75
Hydraulic Power (kW) 39.699
BHP (kW) 52.932
Spesific Speed (rpm) 151.618
Jenis Impeller Radial Vane
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2.2.3.4.Pump P-104
Table 2.22. Specification Data of Pump P-104
Equipment Specification
Name Green Diesel Pump
Code P-104
Function To help green diesel to flow
Number of unit 1
Type Centrifugal Pump
Operation Data
Liquid Volume Flow (m3/h) 34.01
Temperature (oC) 349.4
Suction Pressure (kPa) 101.3
Discharge Pressure (kPa) 202.6
Head (ft) 54.714
NPSHA (ft) 0.111
Efficiency 0.75
Hydraulic Power (kW) 1.6
BHP (kW) 2.138
Spesific Speed (rpm) 1094.523
Jenis Impeller Radial Vane
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CONCLUSION
Each equipment is sized to suit the need of the process. The main aspects
considered are volume, height, diameter, and energy.
The main equipment that uses multiple units to accommodate the process are
storage tank, hydrotreating reactor and unit separator.
The supporting equipment that used are pump, compressor, heat exchanger
and cooler.
The complete main equipment and its intrumentation is depicted in P&ID
The controller needed to be arranged based on the risk of the variable that
being controlled.
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REFERENCES
Branan. 2012.Rules of Thumb for Chemical Engineer.5 thedition. USA: Stephen
Hall.Brownell, L.E & Edwin H.Y. 1959. Process Equipment Design: Vessel Design.
John Wiley & Sons.
Walas, S.M. 1990. Chemical Process Equipment. Selection and Design.
Massachusetts Institute of Technology: Butterworth-Heineman Series in Chemical
Engineering.
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APPENDIX A
A.1. Storage Tank
In the process of producing renewable biodiesel, because of not continues
supplies, storage tank are needed to store the raw materials and product. We have
to determine the size and dimension based on the flow rate of each material that
goes in and out the storage tanks.
We use three different types of storage tank to store three different type
crude oil for process that is crude palm oil, jatropha oil and nyamplung oil.
Moreover, we need storage tank for renewable diesel produced.
Material Selection
The raw material storage tanks form are cylindrical tanks because a
cylinder shape has a great structural strength and easier to fabricate. The top end
of storage tanks use ellipsoidal shape, while the bottom end is flat and stand
directly upon the ground. We use carbon steel as the material for storage tanks.
Table A.1. List of Materials that Selected for Each Storage Tank
No. Storage Tank Material Specification
1. Crude Palm Oil Storage Tank SA-283, Grade C2. Jatropha Oil Storage Tank SA-283, Grade C
3. Nyamplung Oil Storage Tank SA-283, Grade C
4. Renewable Biodiesel Storage Tank SA-283, Grade C
A.1.1. Volume of Storage Tank
For sizing the storage tanks, we estimate that the capacity of crude oil
storage tanks are able to fulfill the needs of material for a week depending on the
supply attendants. So, we determine one week as a batch.
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Crude Palm Oil Storage Tank
Crude Palm Oil mass flow rate is 44700 kg/hour. So the storage tanks have
to store 7,509,600 kg/batch crude palm oil. The calculation of storage tanks
volume needed to store :
= = 7,509,600kgweek879.3 kgm
= 8540.43 mweekTo store the crude palm oil, we will use 10 storage tank. so, the crude palm oil
volume per tank is :
=8,540.43 m
week10 =854.04 m
week
To calculate the total volume of storage tanks, safety factor has to be
considered. Safety factor of the tank is 10% of the total volume. This is based
on literature saying that for tanks which volume is above 3,8 m 3, only 90%
volume is filled.
= 854.04 mweek0.9 = 948.94 m
week
Jatropha Oil Storage Tank
Jatropha Oil mass flow rate is 44700 kg/hour. So the storage tanks have to
store 7,509,600 kg/batch jatropha oil. The calculation of storage tanks volume
needed to store :
= = 7,509,600kgweek862 kg
m
= 8711.83 mweekTo store the jatropha oil, we will use 10 storage tank. so, the jatropha oil
volume per tank is : = 8,711.83 m
week10 =871.18 m
weekTo calculate the total volume of storage tanks, safety factor has to be
considered. Safety factor of the tank is 10% of the total volume. This is based
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on literature saying that for tanks which volume is above 3,8 m 3, only 90%
volume is filled.
= 871.18 m
week0.9 = 967.98 mweek Nyamplung Oil Storage Tank
Nyamplung Oil mass flow rate is 44700 kg/hour. So the storage tanks have
to store 7,509,600 kg/batch nyamplung oil. The calculation of storage tanks
volume needed to store :
= = 7,509,600 kgweek869 kgm = 8641.66 mweekTo store the nyamplung oil, we will use 10 storage tank. so, the nyamplung oil
volume per tank is : = 8,641.66 m
week10 =864.17 m
weekTo calculate the total volume of storage tanks, safety factor has to be
considered. Safety factor of the tank is 10% of the total volume. This is basedon literature saying that for tanks which volume is above 3,8 m 3, only 90%
volume is filled.
= 864.17 mweek0.9 = 960.18 m
week
Renewable Biodiesel Storage Tank
Renewable biodiesel produced have mass flow rate is 37880 kg/hour. For,
renewable biodiesel we determine 1 day for a batch. So the storage tanks have
to store 909,120 kg/batch renewable biodiesel. The calculation of storage tanks
volume needed to store :
= = 909,120kgweek790 kgm
= 1150.78 mweek
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To store the renewable biodiesel product, we will use 2 storage tank. so, the
renewable biodiesel volume per tank is :
= 1150.78 m
week2 =575.39 mweekTo calculate the total volume of storage tanks, safety factor has to be
considered. Safety factor of the tank is 10% of the total volume. This is based
on literature saying that for tanks which volume is above 3,8 m 3, only 90%
volume is filled.
=575.39 mweek
0.9 = 639.32m
weekA.1.2. Diameter and Height of Storage Tank
Based on rule of thumb, the ratio of height and diameter of tank for
cylindrical tanks is 2:1. Therefore, H = 2D. The volume of cylinder can be
calculated as :
= 1
4 = 1
2
The shape of tanks top cover is ellipsoidal and the bottom cover is flat, with
major axis ratio of 2:1. The volume of heads (cover and pedestal) is . The tank
volume is:
= 2
24 = 13
24
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Figure A.1. Types of head of storage tank
(Source:Perrys Chemical Engineering Handbook, 1999)
We use the equation of cylinder tank volume to determine the diameter of
cylinder.
= 2413 The height of tank is an addition of cylinder and head of tank height. The cylinder
height is 2D as stated before. The head height is D/6.
Crude Palm Oil Storage Tank
Using the equation, the diameter of tank is :
= 2413 = 28540.4313 = 7.48 The cyclinder height is:
= 2 = 2 7.48 = 14.96
The head height is:
= 6 = 7.48 6 =1.247 The total height is:
= =16.207
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Jatropha Oil Storage Tank
Using the equation, the diameter of tank is :
= 2413
= 28711.8313
= 7.53 The cyclinder height is:
= 2 = 2 7.53 = 15.06 The head height is:
= 6 = 7.53 6 =1.255 The total height is:
= =16.315 Nyamplung Oil Storage TankUsing the equation, the diameter of tank is :
= 2413 = 28641.6613 = 7.51 The cyclinder height is:
= 2 = 2 7.51 = 15.02
The head height is:
= 6 = 7.51 6 =1.252 The total height is:
= = 16.27 Renewable Biodiesel Storage Tank
Using the equation, the diameter of tank is :
= 2413 = 21150.7813 = 3.83 The cyclinder height is:
= 2 = 2 3.83 = 7.66 The head height is:
= 6 = 7.66 6 =1.27 The total height is:
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= = 8.937 A.1.3. Design Pressure
Pressure design of storage tank determines the type of storage tank used.
Height of fluid in the tank is calculated as follows:
= The pressure of the tank is:
= In calculating the design pressure, we assuming that the pressure safety factor is
15%. = 1 1 5 % 1 Crude Palm Oil
= 854.0416.207948.94 = 14.59 = 879.3 9,81 14.59 = 1.24 =115% 11.24 =2.576 Jatropha Oil
= 871.1816.315967.98 = 14.68 = 862 9,81 14.68 = 1.23 =115% 11.23 = 2.5645 Nyamplung Oil
= 864.1716.27960.18 = 14.64
= 869 9,81 14.64 = 1.23
=115% 11.23 = 2.5645 Renewable Biodiesel
= 575.398.937639.32 = 8.04 = 790 9,81 8.04 = 0.62 =115% 10.62 =1.863
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A.1.4. Wall and Head Thickness
To calculate the wall and head thickness, there are several data we needs
to be determined such as corrosion factor, maximum allowable stress, joint
efficiency, and equipment age. These data determined based on the material
selected for each storage tank. Carbon steel has a bigger corrosion factor than
stainless steel, since carbon steel is more prone to corrosion. Corrosion factors of
stainless steel are also different depending on the grade of stainless steel.
Calculation of storage tanks wall thickness is based on circumferential
stress (longitudinal joint). We can use the following formula (Towler, 1990):
=
0.6
While head thickness of storage tank could be calculated with the following
formula:
= 20.2 where,
t = material thickness
P = pressure gauge
R= shell radius
Di= shell inner diameter
K = ellipsoidal formula factor
S = maximum allowable stress
E = joint efficiency = 0.85
C = corrosion factor = 0.015
A = planned equipment age = 30 year
Crude Palm Oil
= 37.86147.2412,6500.850.637.86 0.01530=0.969 = 37.86294.481.833212.6500.850.237.86 0.015 30 = 1.40
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Jatropha Oil
= 37.69148.2312,6500.850.637.69 0.01530=0.971
= 37.69296.461.833212.6500.850.237.69 0.01530=1.40 Nyamplung Oil
= 37.69147.8312,6500.850.637.69 0.01530=0.969
=37.69295.661.833
212,6500.850.237.69 0.01530=1.40 Renewable Biodiesel
= 27.3875.3912,6500.850.627.38 0.01530=0.642 = 27.38150.781.833212,6500.850.227.38 0.01530
= 0.802
A.2. Degumming Tank
Volume
Flow rate into the tank 46560 kg/h, to gain the volume we could divide the mass
rate with total density.
=
= 46560 kgh
872
= 53.39 So, the volume tank is 53.39 m3. Base on literature if volume above 3,8
3volume of each tank only filled 90%. The headspace is 10% thus the workingvolume which calculated before is 90%. The use of headspace is a safety unit for
sudden increment volume.
= 53.390.9 = 59.33 Diameter and height of mixing tank
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Comparison of high tank with tank diameter (Hs: D) = 2:1. The volume will be
represented by using ellipsoidal shape, the diameter and height of tank could be
calculated.
= 14 = 14 2Cover and pedestal tank of ellipsoidal shape with major to minor axis ratio of 2:1,
so high head is h=16(Walas, 1990). Volume of 2 cover is:= 14 2 = 14 16 2 = 112
Tank volume is:
= = 14 2 112 = 712 Tank diameter is: = 127 = 1259.337 = 3.19
Height of cylinder is Hs= 2D = 6,38 m
Height of cover ellipsoidal is Hh = = 1.06
Height tank is Ht = Hs + (2xHh) = 6.38 + (2x1.06) = 8.51
Pressure Design
Height of fluid in the tank
= = 53.39 8.5159.33 = 7.66
Pressure
= = 872 9.8 7.66 = 0.646 = 9.494 Thick of Wall and HeadMaterial choosen is stainless steel because condition of solution must be at pH
4,5. Avoiding corrosion, stainless steel used for this case
Thick of wall
Assumption of corrosion factor is (C) = 0,0042 in/year
Allowable working stress is (S) = 16.250 lb/in2 (Walas, 1990)
Assumptions connection efficiency is (E) = 0,85
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Planned of tool age (A) = 30 years
Thick of cylinder is
= 0.6
= 9.49462.9916.2500.850.69.494 0.0042 30 = 0.169 = 4.29 Thick wall head (cap)
Assumption of corrosion factor is (C) = 0,0042 in/year
Allowable working stress is (S) = 16.250 lb/in2 (Walas, 1990)
Assumptions connection efficiency is (E) = 0,85
Planned of tool age (A) = 30 years
Thick of wall head is
= 0.2 = 9.49462.9916.2500.850.29.494 0.0042 30 = 0.169 = 4.29 Impeller
Type: axial four blade, this kind of impeller is chosen based on literature, if
viscosity < 5000 cp propeller is common used. This solution has 79 cpAssumption of rotation speed (N): 120 rpm = 2 rps
Assumption of 80% efficiency motors
Mixer is designed with the following standards: (Walas, 1988)
Da : Dt = 1 : 3 Dt : J = 12
W : Da = 1 : 5 where:
Da : Db = 6 : 1 Da = stirrer diameter
C : Dt = 1 : 3 Dt = the diameter of the tank
Db = stick diameter
W = width of leaf stirrer
C = the distance from bottom of the tank
Reynold number is
= Stirrer diameter is
= =
3.19 = 1.06
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Stirrer leaf widhth is = = 1.06 = 0.213 Strirrer height from the bottom = = 3.19 = 1.06 Diameter of stick = = = 1.06 = 0.353 Diameter baffle = = 3.19 = 0.266 Where
Da = diameter impeller (ft)
N = rotation speed (rps)
= density (lb/ft3) = viscosity (lb/(ft.s))
= 0.35324.490.05 =63.40
Figure A.1. Power Number
(Source: Walas, 1990)
Then, the power is
= 1 0 = 1 03 4 . 4 9 2 1.06 = 0.114 /
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APPENDIX B
B.1. Hydrotreating Reactor
Fixed-Bed Reactors (FBRs) are the most commonly used reactor systems
in commercial hydrotreating operations. They are easy and simple to operate.
However, the simplicity of operation limits their use to the HDS of light feeds.
For example, in case of naphtha hydrodesulfurization, the reaction is carried out in
two-phases (gas-solid) fixed-bed reactors since at the reaction conditions the
naphtha is completely vaporized. On the contrary, for heavier feeds three phases
are commonly found: hydrogen, a liquid-gas mixture of the partially vaporized
feed, and the solid catalyst. The latter system is called a trickle-bed reactor (TBR),
which is a reactor in which a liquid phase and a gas phase flow co-currently
downward through a fixed bed of catalyst particles while reactions take place.The
gas is the continuous phase, and the liquid is the disperse phase (Quann et al.,
1988). A schematic representation of the phenomena occurring in a TBR based on
three-film theory is presented in Figure 3.3 (Korsten and Hoffmann, 1996;
Bhaskar et al., 2004). It is common to assume that mass transfer resistance in the
gas film can be neglected and that no reaction occurs in the gas phase, so that for
the reactions to occur, the hydrogen has to be transferred from the gas phase to the
liquid phase, whose concentration is in equilibrium with the bulk partial pressure
and then adsorbed onto the catalyst surface to react with other reactants. The gas
reaction products are then transported to the gas phase, while the main liquid
hydrotreated reaction product is transported to the liquid phase.
In Hydrotreating Reactor there will be two main reaction which are
reaction of tryglycerides and H2also reaction between tryglicerides and H2, those
reaction can be combine into one that will produce the green diesel itself. Thevolume of reactor is equal to the amount of catalyst used. It is because common
reactor for hydrotreating reactor is fixed bed reactor. In this process, catalyst used
is Nickel-Molybdenum alumina supported.
The material for the hydrotreating reactor was chosen to be Stainless Steel
316 SS. Due to the temperature conditions at about 250C, metal dusting not
comes into consideration. This leads to a construction material of carbon steel,
which is the least expensive material (Peters, 2003). However, since the process
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streams at this stage produce some amount of CO2, sweet corrosion is believed to
be a problem. That is why we chose Stainless Steel as a material for hydrotreating
reactor.
Figure B.1. Fixed Bed Reactor
Source: Handbook of Petroleum Processing
1. Hydrotreating Reactor (CRV-100)
Catalyst Weight
2 21 3 3 6 2 , =
k1= 0.008554 m3kmol-1 s-1
Assumption:
Rate law of these reaction follow one order rate reaction in Packed Bed
Reactor. Equation for rate law in Packed Bed Reactor is
= Where:
=
/
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Equation for one order rate reaction:
= So = / The derivation of equation
= / =
= = 1
=
= 1 = = 1 1
= = 1
So,
= . 1 1 . 1
= 1 1
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This equation will be used to determine how much catalyst needed for each
reaction.
Molar flow Tryglycerides : = 144 /Molar flow Hidrogen : = 570 /
= = 144144570 =0.2017 / = y. = 0.20173 1 1 1 =0.4034
Feed volume flow :
=4,351 Bulk density, = 3200 /
Then we use polymath to determine conversion vs catalyst weight:
Figure B.2. Polymath Programming
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Figure B.3. Polymath Programming Result
Figure B.4.Polymath Programming Graph
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As the result of the polymath, the higher catalyst weight, the higher of
conversion. Therefore, we choose the conversion is 18% because the high
conversion needs a lot of catalyst. As we know that catalyst is expensive and the
lifetime is just about one year. For example, for 85% conversion needs 500,000 kg
catalyst, that is too much. So we just need 18% conversion plus we will recycle
the methane that is not converted into the syngas. At 18% conversion, we need
catalyst 37,000 kg.
Dimension of Reactor
Volume of catalyst that fills the reactor can be calculated as follow:
= = 30,000 kg3600 kg/m = 8.33 Then we assume that the catalyst fills 80% of reactor volume. So we can estimate
the reactor volume needed as follow:
= 10080 8.33 = 10.42 Assume that L:D = 2.5:1 (Rule of Thumbs)
14 = 10.42 14 2.5 = 10.42 = 16.672 = 1.744
The length is
= 2 = 4.36 Retention Time
= = 10.42
4,351 m/h 36001 =8.62Wall thickness can be obtained by using method in Wallas.
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Thickness t = P x RSxE0,6P CA Corrosion Allowance
Head Thickness t =P x D
2SxE0.2P CA
With : P = operation pressure (Psig)
Pc = pressure because of catalyst weight
R = reactor radius (inch)
E = Joint efficiency, it assumed that the joint effieciency is 0.8
S = allowable stress
Due to the high pressures and temperatures in the primary reformer tubes,
a 25% chromium-20% nickel alloy is the preferred tube material. The
allowable stress is very dependent on the material that used for the vessel.
From the Perrys Chemical engineer handbook the allowable stress for the
conrete is 9.8 Mpa or 145,054 psi.
The pressure because of catalyst is :
= = = 30,0009.80.251.744 = 123,287 = 17.87 Thickness t = 14517.87 34.33145,0540.80.614517.87 0.15 = 0.198
= 5 Head Thickness t = 145 4.1 x 68.662x145,054x0.81.8x145 0.15 = 0.193 = 4.9
Tubes calculation
The maximum conventional heat flux through primary reformer tube walls
is approximately 5,921.176 kcal/ ft2hr with industry averages. Using this value
and the heat duty through the reformer calculated by Aspen, the primary reformer
tube size was calculated as follows:
= = 8.89510 5,921.176 = 15,174.35
Then, number of tubes needed is
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= 413.4 414 Height of tube
Based on rule of thumbs, height of reactor is 1.25 times of tubes, so
= 11.25 = 11.25 4.36 = 3.488 Pinch tube selection and diameter of tubes
We choose square pinch of tubes because it is more easy to be cleaned.
The arrangement is at the picture below
Where :
= = 1.5 As we know, diameter of reactor is 1.744 m2, then the length of square is allowing
at phytagoras rule :
= 2 =1.744
= 1.7442 = 1.7442
= 1.233 Assuming the cover of the shell size is 10 cm = 0.01 m
Then tube line is
= 1 . 2 3 3 20.01 = 1.213
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As we know that the number of tubes are 414, so
=
414= 1.213 1 1.213 1
4 1 4 = 1.213
414= 1.213
414= 1.213
20.347=1.213
19.347=1.213 = 0.0627 So, we can calculate diameter of tubes
= 1.25 = 0.06271.25 = 0.05 = 1.968 B.2. Shift Converter Reactor R-102
Water Gas Shift (WGS) is reversible reaction. So both the forward and
reverse reaction is with thermodynamic equilibrium. The true dimensionless
equilibrium constant can predict from Gibbs free energy as denoted by the
following reaction.
=All fixed Bed catalytic reactor assumed to behave like ideal plug flow reactor.
Equation used for the design or sizing of fixed bed reactor is:
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Figure B.5. Equation used for the design or sizing of fixed bed reactor
Here is process condition, mole fraction, and molar flow of feed of water gas shift
reactor from Aspen Hysys simulation.
Feed Flowrate :187,5 kgmol/h
0,052083 kgmol/s
R 8,314
P 4,16 bar
T 1050 K
Species Fraksi mol P parsial K
CO2 0,055 0,2288 0
H2O 0,2237 0,930592 0,908513
H2 0,5735 2,38576 9,59E-05
CO 0,1178 0,490048 0,252871
= 1
= 1 0,2528710,490048 9,59E052,38576 00,2288 0,9085130,9305922,38576 =1,4785
Constant rate law
kj = 34.21
Rate Law
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R1= 0,3799 kgmol/kg cat. S
The Calculation for sizing shift converter reformer is using Microsoft Excel and
the result is shown in the sizing table
Table B.1. Sizing Shift Converter Reformer
weight of catalyst 0,57 kg cat
Cat Vol 13,90244 m3
Vol Reactor 16,35581 m3
A Reaktor total 0,016889 ft2
Tube 100
D Reaktor 1,733461 m
173,3461 cm
L 6,933845 m
D tube 1,733461 cm
1,06 in
Residence time 0,018924 h
69,14921 s
1,152487 min
thickness 1,977392 in
5,0225 cm
thicknes head 3,829613 in
9,6478 cm
TUBE THICKNESS 0,129954 in
B.3. Absorber Calculation
The calculation manually doing which it will be suited to the rule of thumb.
Firstly, should do design the absorber by know the composition of incoming
gas from model simulation we have done.
Basis: 1 hour of operation
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Table B.2. Composition of the Incoming Gas
Component Kmols Fraction Molecular Weight
Methane 84.72 0.03 16
Hydrogen 1799.7352 0.6373 2H2O 451.5576 0.1599 18
CO 152.496 0.054 28
CO2 335.4912 0.1188 44
TOTAL 2824 1
1. The average of molecular weight of the incoming gas
=
MW = 6422.906 kg/kmols
2. Density of gas mixture
Given that Tin= 38oC, so the density of gas mixture will be calculated
by following:
gas = 251.7014855 Kg/m33. Amine and gas Flowrate Calculation
CO2absorbed = 335.4912 kmoles = 14761.6128 kgs
Total CO2absorbed by amine = 1003.2 Kgs
Based on the calculation:
0.407667 W needs 13758.41 Kgs
Then The value of W = 9.37477 Kgs/s
Amine flowrate (A ) = 9.37477 Kgs/s
Densitas (A)= 1040 Kg/m3
Gas Flowrate (G) = 5038.413 Kgs/s
Densitas (G)= 251.7015 Kg/m3
4. Column Selection
In this case of absorber, there are two kind of column, tray column
and packing column. We have choosen packing column for the reason:
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The gas material which enter to the absorber column is a
corrosive gas.
From economic side, packing column is cheaper than tray column.
The pressure drop result of packing column is lower than tray
column. The contact between gas and liquid in packing column is
more perfect due to the higher area contact.
5. Material Selection
Then choose the following packing as given in the Richardson and
Coulson as seen in the Figure below
Figure B.6. Design for Various Packing
Based the table, the material selected is Racing Rings Ceramic,
because if it compared to the other material, Rashing Rings ceramic is
the best on because of it has corrosif endurance, it will be good to the
corrosif liquid.
Material = 3Ceramic. Rasching Rings
Nominal Size = 76 mm
Bulk Density = 561 kg/m3
Surface area = 68 m2/m3
Packing factor = 65 m-1
Voidage = 75%
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6. Diameter Calculation
The calculationof it is based on Richardson and Coulson, volume 6.
Firstly we have to calculate below
= { }.FLV = 0.0009154
Then we have to plot the result to the flooding line graph to get the value
K4. From the plot of K4 Vs FLV. We get K4 at the flooding line 3.2
Figure B.7. Flooding Line Graph
G*= 49.913 Kg/m2s
Designing for a pressure drop of 42 mm water per m of packing. We
Have
K4 = 2.1
% Loading = 81.00925873%
G* = 40.4342758 Kg/m2s
Cross Section Area required
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A = 124.60
Diameter required
D = 12.6 m
Hence the diameter which is calculated from this approach is 12.6 meter
7. Diameter Calculation
The number stage of packing column absorbtion tower can be
calculated by using the graph below from Richard and Coulson. From the
graph, we get the number of stage is about two stages.
8. Height of Packing Calculation
Volumetric Flowrate entering gas
= 20.017 m3/s
Gas Velocity at the bottom of tower
= 0.16 m/s
Mass Flowrate at the top of tower = 4439.84 Kgs/s
Volumetric Flowrate at the top of tower
= 17.64 m3/s
Gas velocity at the top of tower
= 0.14 m s
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Liquid Flow
= 0.075 Kgs/ m2/s
Then We have to calculate the co-relation by the formula below
KG = 0.136
Area of Packing/ft height
A = 8597.9151 m
Height of Packing require
H = 20.51 m
9. Height of Packing Calculation
Inner Diameter = 12.60 meter
Height of pack req = 20.51 meter
Skirt Height = 2 meter
Density of mat column = 7700 kg/m3
Wind pressure = 130 kg/m2
Material Selection
Carbon Steel
Permissible tensile stress (f) = 950 kg/cm2
Thickness of shell = 3.008 mm
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B.4. Steam Methane Reformer R-101
Before calculating the volume of the reactor, we should calculate the rate of
reaction by the kinetic equation of Steam Methane Reforming below (Datta, et al.
2000)
= 1
1
The rate equations that were obtained based on the rate determining steps for
CH4+ H2O = 3H2+ CO. The rate of reaction use a kgmol/kg cat. S unit ( Hoang,
2005).
Where
= 1 Qr = 4,561
With parameter kinetic, equilibrium constant and adsorption constant below.
=
.
1
Reaction rate is rate = 4,08045 kgmol/kgcat.h
With the molar flow of 2135 kgmol/h, we can calculate the total weight of the
catalyst below
Weight of catalyst = 2135/ 4,08045 = 523.23 kg
By using bulk density of Ni/Mo-Al2O4 catalyst at 0.041 g/ml, we can
calculate the catalyst volume. Then, the volume of the reactor is (with 80% of
catalyst volume). After that, we calculate the number of tubes needed. Then,
calculate number of tubes needed. After that, we calculate the diameter and length
of reactor by 1:4 ratio. Then, we calculate the diameter of each tube. From the
literature we read, the construction materials used is a 25% chromium-20% nickel
alloy is preferred tube material (Low-alloy steels SA-203 grade D). The thickness
of reactor can be calculated by using a thickness calculation for tall vertical
vessel. The corrosion allowance is 1/32.
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The value of S can be found onTable 13.1, Process Equipment Design by
Brownell. A welded-joint efficiency (E) of 0.85 is specified by the ASME code.
The material we used for our reactor is Low-alloy steels SA 203 grade D. After
that, we can use a torispherical heads for our reactor design and calculate the head
thickness.
The Calculation for sizing steam methane reformer is using Microsoft Excel and
the result is shown in the sizing table
Table B.2. Steam Methane Reformer
weight of catalyst 2 kg cat
Cat Vol 48,780488 m
3
Vol Reactor 57,388809 m3
A Reaktor total 0,03 ft2
Tube 100
D Reaktor 2,6341016 m
263,41016 cm
L 10,536406 m
D tube 2,6341016 cm
1,06 in
Residence time 0,0287566 h
105,0765 s
1,751275 min
thickness 1,9773921 in
5,0225 cm
thicknes head 3,829613 in
9,6478 cm
TUBE THICKNESS 0,1299539 in
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APPENDIX C
Heat Exchanger Design Procedure
Step 1. Obtain the required thermos-physical properties of hot and cold
fluids at the caloric temperature or arithmetic mean temperature. Calculate
these properties at the caloric temperature if the variation of viscosity
with temperature is large. The detailed calculation procedure of caloric
temperature available is in reference.
r = TT = T TT TStep 2. Perform energy balance and find out the heat duty (Q) of the
exchanger Q = Q = mCt t = mCT TStep 3. Assume a reasonable value of overall heat transfer coefficient
(Uo,assm). The value of Uo,assmwith respect to the process hot and cold
fluids.
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Figure C.1. Shell and Tube Overall Coefficient
Figure C.2. Air Cooled Exchangers and Immersed Oil Overall Coefficient
Step 4. Decide tentative number of shell and tube passes (np). Determine
the LMTD and the correction factor FT. FT normally should be greater
than 0.75 for the steady operation of the exchangers. Otherwise it is
required to increase the number of passes to obtain higher FTvalues.
T =T T T T
ln T TT T
Step 5. Calculate heat transfer area (A) required:
A = QU,LMTD FStep 6. Select tube material, decide the tube diameter (ID = di, OD =
d0), its wall thickness (in terms of BWG or SWG) and tube length (L).
Calculate the number of tubes (nt) required to provide the heat transfer area
(A).
n = AdLCalculate tube side fluid velocity
u = 4 m(n n )d
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Re = 4 m(n n )d 10Step 7. Decide type of shell and tube exchanger (fixed tubesheet, U-tube
etc.). Select the tube pitch (PT), determine inside shell diameter (Ds)
that can accommodate the calculated number of tubes (nt). Use the
standard tube counts table for this purpose.
Figure C.3. Coomon Tube Layouts
Figure C.4. Heat exchangers tube-layouts
Step 8. Assign fluid to shell side or tube side. Select the type of baffle
(segmental, doughnut etc.), its size (i.e. percentage cut, 25% baffles are
widely used), spacing (B) and number. The baffle spacing is usually chosen
to be within 0.2 Dsto Ds.
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Figure C.5. Type of Heat Exchanger Baffles
Step 9. Determine the tube side film heat transfer coefficient (hi) using the
suitable form of Sieder-Tate equation in laminar and turbulent flow regimes.
Estimate the shell-side film heat transfer coefficient (ho) from:
j = hD ck
.
And find the hio from:
h = h IDODStep 10. Calculate overall heat transfer coefficient (Uo,cal)
U = hhh h
With the design overall coefficient is
U = QA TThe dirt factor is calculated from:
R = U UUU
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Step 11. Pressure drop calculation will be the tube side pressure drop (PT)
and the shell side pressure drop (PS). Pressure drop in the straight section
of the tube (frictional loss) (Pt) and return (Pn) due to change of
direction of fluid. So the total of each pressure drop: PT = Pt + Pn
P = fGD N 1 5,221010 DsIf the tube-side pressure drop exceeds the allowable pressure drop for the
process system,
we can decrease the number of tube passes or increase number of tubes per
pass.
P = LfG5,221010 DsIf the shell-side pressure drop exceeds the allowable pressure drop
P = LfG5,221010 Ds
The procedure is the same for all heat exchanger, the calculation is using
Microsoft Excel and the result is shown in the sizing table. Below will be shown
the calculation for one heat exchanger.
Material Selection for Heat Exchanger
For heat exchanger using low pressure and medium pressure steam as
heating fluid , we used carbon steel as material because temperature of process is
not too high. Moreover, Fluid that we used is Oil that cant cause corrosion. We
choose Carbon Steel SA-283 with Grade C because this material is commonly
used. Carbon steel is used because highly durable, low cost and easy tomanufactured.
Due to the high temperature like fired heater used for heating feed to steam
methane reformer. Therefore, carbon steels cannot be used as pipe material
because this material cannot be used in high temperature conditions. Carbon steel
can be used as material for temperature conditions bellow 1400oF. Materials that
can be used as wall material which can also be used in high temperature
conditions are stainless steel. Therefore, the proper material for low pH and high
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T = 155oC
T2= 134oC
t1= 25oC
t2= 65oC
temperature is stainless steel (SS)316L. Grade 316 is the standard molybdenum
bearing grade, second importance to 304 amongst the austenitic stainless steel.
The molybdenum gives 316 better overall corrosion resistant properties than grade
304 particular resist to pitting and crevice corrosion in chlorine environment.
C.1. Heat Exchanger E-101
Heat Balance
CPO, =+ = 45, c = 2200 J/kg-KQ =m.c.T
= 44,700 kg/h) (2200 J/kg-K) (338-298) K
= 3,933,600,000 J/hSteam, = + =148.5, c =4180 J/kg-K
W = = ,,, J/ J/K K=44812,03 kg/h
Determine the LMTD
LMTD = = = 99.2o
C
R = =
= 0.525S =
== 0.308
Determine the temperature difference
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It could be obtained from the graph that shows temperature correction factor. The
available existing graphs are for two shell passes, four, multiple of four tube
passes, etc.
The example graph that is used in this case could be seen below :
Figure C.6. Temperature Correction Factor : two shell passes ; four or multiple passes
(Source: Kern)
The temperature correction factor (FT) that is obtained from Figure C.6 is 1.
The properties of tube and pitch could be obtained from Table and Table
From the following table could be obtained the exact value of tube outer diameter,
square pitch length, shell inner diameter, amount of passes, and the last one in
amount of tubes. Actually there is no calculation done before choosing the value
of tube and pitch properties, but the chosen one should logically makes sense.
In this case, the selected tube OD is 0.75 in = 0.019m
Square pitch length = 1 in = 0.0254 m
Shell inner diameter = 19.25 in = 0.49m
Amount of passes = 2
So that the amount of tubes is 220
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Figure C.7. Tube Sheet Layouts (square pitch)
(Source: Kern)
Besides that, the other tubes properties could be obtainedfrom the following
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Figure C.8. HE Layouts
(Source: Kern)
The table above is used by using the previous selected tube OD. As the tube OD is
considered to be then the BWG value could be obtained. The BWG value is
chosen randomly, so that the following properties that are in the same row could
be obtained.
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The BWG value = 14
The wall thickness = 0.083 in = 0.0021m
Tube inner diameter = 0.584 in= 0.015m
Flow area per tube = 0.268 in2= 1.73 x 10-4m2
Surface/lin (outside) = 0.1963 ft2= 0.018 m2
Surface/lin (i