Distillation Towers (Columns) presentation on Types, governing Equations and ...Hassan ElBanhawi
Based on my 8 years of experience in Oil & Gas industry I can claim that you can find here All what you need to know about Columns. This is an introduction to understand more about their:-
-Types
-Basic Principles and equations
-Distillation System
-P&ID Symbols
-Worked Example
You can find also more at:
http://hassanelbanhawi.com/staticequipment/columns/
All the data and the illustrative figures presented here can be found through two reference books:-
ENGINEERING DATA BOOK by Gas Processors Suppliers Association
Process Technology - Equipment and Systems by Charles E. Thomas
Thank you.
Troubleshooting in Distillation Columns
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 FLOW DIAGRAM FOR TROUBLESHOOTING
5 GENERAL APPRAISAL OF PROBLEM
5.1 Is the Problem Real?
5.2 What Is the Magnitude of the Problem?
5.3 Is it the Column or the Associated Equipment which is Causing the Problem?
6 PROBLEMS IN THE COLUMN
6.1 Capacity Problems
6.2 Efficiency Problems
7 PROBLEMS OUTSIDE THE COLUMN
7.1 Effect of Other Units on Column Performance
7.2 Column Control System
7.3 Improper Operating Conditions
7.4 Auxiliary Equipment
8 USEFUL BACKGROUND READING
9 BIBLIOGRAPHY
FIGURES
1 FLOW DIAGRAM FOR TROUBLESHOOTING
2 DETERMINATION OF COLUMN CAPACITY
Distillation Towers (Columns) presentation on Types, governing Equations and ...Hassan ElBanhawi
Based on my 8 years of experience in Oil & Gas industry I can claim that you can find here All what you need to know about Columns. This is an introduction to understand more about their:-
-Types
-Basic Principles and equations
-Distillation System
-P&ID Symbols
-Worked Example
You can find also more at:
http://hassanelbanhawi.com/staticequipment/columns/
All the data and the illustrative figures presented here can be found through two reference books:-
ENGINEERING DATA BOOK by Gas Processors Suppliers Association
Process Technology - Equipment and Systems by Charles E. Thomas
Thank you.
Troubleshooting in Distillation Columns
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 FLOW DIAGRAM FOR TROUBLESHOOTING
5 GENERAL APPRAISAL OF PROBLEM
5.1 Is the Problem Real?
5.2 What Is the Magnitude of the Problem?
5.3 Is it the Column or the Associated Equipment which is Causing the Problem?
6 PROBLEMS IN THE COLUMN
6.1 Capacity Problems
6.2 Efficiency Problems
7 PROBLEMS OUTSIDE THE COLUMN
7.1 Effect of Other Units on Column Performance
7.2 Column Control System
7.3 Improper Operating Conditions
7.4 Auxiliary Equipment
8 USEFUL BACKGROUND READING
9 BIBLIOGRAPHY
FIGURES
1 FLOW DIAGRAM FOR TROUBLESHOOTING
2 DETERMINATION OF COLUMN CAPACITY
Get full Course here:
www.ChemicalEngineeringGuy.com/Courses
The BASIC Aspen HYSYS Course will show you how to model and simulate Processes (From Petrochemical, to Ammonia Synthesis and Polymerisation).
Analysis of Unit Operation will help you in order to optimise the Chemical Plant.
This is helpful for students, teachers, engineers and researchers in the area of R&D and Plant Design/Operation.
The course is didactic, with a lot of applied theory and Workshops/Study cases.
At the end of the course you will be able to setup a simulation, run it, get results and more important, analysis of the process for further optimization.
Chemical Engineers
Process Engineers
Students related to engineering fields
Teachers willing to learn more about process simulation
Petrochemical Engineers
Types of Distillation & column internalsBharat Kumar
More:- https://chemicalengineeringworld.com
Distillation is a method of separating the components of a solution which depends upon distribution of the substances between a gas and liquid phase, applied to cases where all components are present in both phases.
* What is distillation ?
* Types of Distillation
* Batch Distillation
* Azeotropic Distillation
* Flooding
* Priming
* Coning
* Weeping
* Dumping
* Packed Column
* Tray column
* Reflux Ratio
* Relative volatility
* Distillation column
Distillation is a method of separating mixtures based on differences in volatility (volatility is the tendency of a substance to vaporize. Volatility is directly related to a substance's vapor pressure.) of components in a boiling liquid mixture. Distillation is a unit operation, or a physical separation process, and not a chemical reaction
This is course on Plant Simulation will show you how to setup hypothetical compounds, oil assays, blends, and petroleum characterization using the Oil Manager of Aspen HYSYS.
You will learn about:
Hypothetical Compounds (Hypos)
Estimation of hypo compound data
Models via Chemical Structure UNIFAC Component Builder
Basis conversion/cloning of existing components
Input of Petroleum Assay and Crude Oils
Typical Bulk Properties (Molar Weight, Density, Viscosity)
Distillation curves such as TBP (Total Boiling Point)
ASTM (D86, D1160, D86-D1160, D2887)
Chromatography
Light End
Oil Characterization
Using the Petroleum Assay Manager or the Oil Manager
Importing Assays: Existing Database
Creating Assays: Manually / Model
Cutting: Pseudocomponent generation
Blending of crude oils
Installing oils into Aspen HYSYS flowsheets
Getting Results (Plots, Graphs, Tables)
Property and Composition Tables
Distribution Plot (Off Gas, Light Short Run, Naphtha, Kerosene, Light Diesel, Heavy Diesel, Gasoil, Residue)
Oil Properties
Proper
Boiling Point Curves
Viscosity, Density, Molecular Weight Curves
This is helpful for students, teachers, engineers and researchers in the area of R&D, specially those in the Oil and Gas or Petroleum Refining industry.
This is a "workshop-based" course, there is about 25% theory and about 75% work!
At the end of the course you will be able to handle crude oils for your fractionation, refining, petrochemical process simulations!
Distillation is one of the widely used separation method in most of the Chemical Process Industries. Improper design/ operation & maintenance leads to various troubles like reduced plant capacity, poor quality of separated products, high energy consumption, etc. This presentation is for learning about the troubleshooting of packed type distillation systems. Through conceptual aspects of the overall distillation system, reader can easily identify the various causes of probable troubles and will be able to suggest their remedial measures.
Pressure Relief Systems
BACKGROUND TO RELIEF SYSTEM DESIGN Vol.1 of 6
The Guide has been written to advise those involved in the design and engineering of pressure relief systems. It takes the user from the initial identification of potential causes of overpressure or under pressure through the process design of relief systems to the detailed mechanical design. "Hazard Studies" and quantitative hazards analysis are not described; these are seen as complementary activities. Typical users of the Guide will use some Parts in detail and others in overview.
Safety is the most important factor in designing a process system. Some undesired conditions might happen leading to damage in a system. Control systems might be installed to prevent such conditions, but a second safety device is also needed. One kind of safety device which is commonly used in the processing industry is the relief valve. A relief valve is a type of valve to control or limit the pressure in a system by allowing the pressurised fluid to flow out from the system.
The purpose of this document is to present a potential design to the client to build an acetic acid (CH3COOH) plant in the United Kingdom. The plant will have the capacity to produce 400,000 tonnes per annum of acetic acid base product from a feedstock of methanol and carbon monoxide. As an overview, the methanol carbonylation process is highly efficient in that it produces acetic acid with more sought after selectivity and purity.
Environmental Impact Assessment has been proven successful in outlining the main environmental issues in relation to this project. The general location considerations linked to the potential pollution produced (odours, noise, traffic) has been analysed, justifying the measures that will be put in place to minimize them. The handling of raw materials and the final product both on and off site has been studied in depth in order to outline the features and add-ups that can be applied to reduce the impact on the environment.
In addition to environmental methodologies, principles of process control and instrumentation have been applied throughout the design stage of this project with the aim of creating a process that is ultimately safe, that complies with all the necessary safety regulations, efficient, that will not suffer unnecessary downtime to avoidable failures and maintenance being carried out on key piece of process equipment and not suffer performance impairments due to poor design, as well as being economically stable, linked to the plants efficiency, an efficient plant will bring a certain amount of economic stability in addition to ensuring unnecessary equipment or instrumentation is not put in place.
Economic evaluation of this project indicates viability, the return of investment is 53% and the net profit of £1,378,000,000 is very lucrative figure for a 20-year investment. The project payback time of 2 years demonstrates that this project is highly feasible and has the potential to attract numerous investors.
B E Project - Manufacturing of Phosphoric AcidAniket Mali
A method is disclosed for the manufacture of phosphoric acid directly from phosphate rock slurry in a reaction vessel with additional sulphuric acid to produce dehydrate calcium sulphate (gypsum). The gypsum is separated from the recovery solution via filtration and removed as a by-product. Design of equipments like reactor, sedimentation tank and evaporator is done.
Get full Course here:
www.ChemicalEngineeringGuy.com/Courses
The BASIC Aspen HYSYS Course will show you how to model and simulate Processes (From Petrochemical, to Ammonia Synthesis and Polymerisation).
Analysis of Unit Operation will help you in order to optimise the Chemical Plant.
This is helpful for students, teachers, engineers and researchers in the area of R&D and Plant Design/Operation.
The course is didactic, with a lot of applied theory and Workshops/Study cases.
At the end of the course you will be able to setup a simulation, run it, get results and more important, analysis of the process for further optimization.
Chemical Engineers
Process Engineers
Students related to engineering fields
Teachers willing to learn more about process simulation
Petrochemical Engineers
Types of Distillation & column internalsBharat Kumar
More:- https://chemicalengineeringworld.com
Distillation is a method of separating the components of a solution which depends upon distribution of the substances between a gas and liquid phase, applied to cases where all components are present in both phases.
* What is distillation ?
* Types of Distillation
* Batch Distillation
* Azeotropic Distillation
* Flooding
* Priming
* Coning
* Weeping
* Dumping
* Packed Column
* Tray column
* Reflux Ratio
* Relative volatility
* Distillation column
Distillation is a method of separating mixtures based on differences in volatility (volatility is the tendency of a substance to vaporize. Volatility is directly related to a substance's vapor pressure.) of components in a boiling liquid mixture. Distillation is a unit operation, or a physical separation process, and not a chemical reaction
This is course on Plant Simulation will show you how to setup hypothetical compounds, oil assays, blends, and petroleum characterization using the Oil Manager of Aspen HYSYS.
You will learn about:
Hypothetical Compounds (Hypos)
Estimation of hypo compound data
Models via Chemical Structure UNIFAC Component Builder
Basis conversion/cloning of existing components
Input of Petroleum Assay and Crude Oils
Typical Bulk Properties (Molar Weight, Density, Viscosity)
Distillation curves such as TBP (Total Boiling Point)
ASTM (D86, D1160, D86-D1160, D2887)
Chromatography
Light End
Oil Characterization
Using the Petroleum Assay Manager or the Oil Manager
Importing Assays: Existing Database
Creating Assays: Manually / Model
Cutting: Pseudocomponent generation
Blending of crude oils
Installing oils into Aspen HYSYS flowsheets
Getting Results (Plots, Graphs, Tables)
Property and Composition Tables
Distribution Plot (Off Gas, Light Short Run, Naphtha, Kerosene, Light Diesel, Heavy Diesel, Gasoil, Residue)
Oil Properties
Proper
Boiling Point Curves
Viscosity, Density, Molecular Weight Curves
This is helpful for students, teachers, engineers and researchers in the area of R&D, specially those in the Oil and Gas or Petroleum Refining industry.
This is a "workshop-based" course, there is about 25% theory and about 75% work!
At the end of the course you will be able to handle crude oils for your fractionation, refining, petrochemical process simulations!
Distillation is one of the widely used separation method in most of the Chemical Process Industries. Improper design/ operation & maintenance leads to various troubles like reduced plant capacity, poor quality of separated products, high energy consumption, etc. This presentation is for learning about the troubleshooting of packed type distillation systems. Through conceptual aspects of the overall distillation system, reader can easily identify the various causes of probable troubles and will be able to suggest their remedial measures.
Pressure Relief Systems
BACKGROUND TO RELIEF SYSTEM DESIGN Vol.1 of 6
The Guide has been written to advise those involved in the design and engineering of pressure relief systems. It takes the user from the initial identification of potential causes of overpressure or under pressure through the process design of relief systems to the detailed mechanical design. "Hazard Studies" and quantitative hazards analysis are not described; these are seen as complementary activities. Typical users of the Guide will use some Parts in detail and others in overview.
Safety is the most important factor in designing a process system. Some undesired conditions might happen leading to damage in a system. Control systems might be installed to prevent such conditions, but a second safety device is also needed. One kind of safety device which is commonly used in the processing industry is the relief valve. A relief valve is a type of valve to control or limit the pressure in a system by allowing the pressurised fluid to flow out from the system.
The purpose of this document is to present a potential design to the client to build an acetic acid (CH3COOH) plant in the United Kingdom. The plant will have the capacity to produce 400,000 tonnes per annum of acetic acid base product from a feedstock of methanol and carbon monoxide. As an overview, the methanol carbonylation process is highly efficient in that it produces acetic acid with more sought after selectivity and purity.
Environmental Impact Assessment has been proven successful in outlining the main environmental issues in relation to this project. The general location considerations linked to the potential pollution produced (odours, noise, traffic) has been analysed, justifying the measures that will be put in place to minimize them. The handling of raw materials and the final product both on and off site has been studied in depth in order to outline the features and add-ups that can be applied to reduce the impact on the environment.
In addition to environmental methodologies, principles of process control and instrumentation have been applied throughout the design stage of this project with the aim of creating a process that is ultimately safe, that complies with all the necessary safety regulations, efficient, that will not suffer unnecessary downtime to avoidable failures and maintenance being carried out on key piece of process equipment and not suffer performance impairments due to poor design, as well as being economically stable, linked to the plants efficiency, an efficient plant will bring a certain amount of economic stability in addition to ensuring unnecessary equipment or instrumentation is not put in place.
Economic evaluation of this project indicates viability, the return of investment is 53% and the net profit of £1,378,000,000 is very lucrative figure for a 20-year investment. The project payback time of 2 years demonstrates that this project is highly feasible and has the potential to attract numerous investors.
B E Project - Manufacturing of Phosphoric AcidAniket Mali
A method is disclosed for the manufacture of phosphoric acid directly from phosphate rock slurry in a reaction vessel with additional sulphuric acid to produce dehydrate calcium sulphate (gypsum). The gypsum is separated from the recovery solution via filtration and removed as a by-product. Design of equipments like reactor, sedimentation tank and evaporator is done.
This presentation is about my academic project on generating electricity using thermoelectric generator (TEG), to harvest the thermal energy dissipated by combustion gases. The current project discusses the optimal design of the thermoelectric generator (TEG) and the design is conducted analytically based on the idea of air cooled TEG system using fins and an experimental system is fabricated and tested by attaching to exhaust pipe of a two wheeler IC engine for the heat source to verify the validity of the proposed system.
Automobile Management System Project Report.pdfKamal Acharya
The proposed project is developed to manage the automobile in the automobile dealer company. The main module in this project is login, automobile management, customer management, sales, complaints and reports. The first module is the login. The automobile showroom owner should login to the project for usage. The username and password are verified and if it is correct, next form opens. If the username and password are not correct, it shows the error message.
When a customer search for a automobile, if the automobile is available, they will be taken to a page that shows the details of the automobile including automobile name, automobile ID, quantity, price etc. “Automobile Management System” is useful for maintaining automobiles, customers effectively and hence helps for establishing good relation between customer and automobile organization. It contains various customized modules for effectively maintaining automobiles and stock information accurately and safely.
When the automobile is sold to the customer, stock will be reduced automatically. When a new purchase is made, stock will be increased automatically. While selecting automobiles for sale, the proposed software will automatically check for total number of available stock of that particular item, if the total stock of that particular item is less than 5, software will notify the user to purchase the particular item.
Also when the user tries to sale items which are not in stock, the system will prompt the user that the stock is not enough. Customers of this system can search for a automobile; can purchase a automobile easily by selecting fast. On the other hand the stock of automobiles can be maintained perfectly by the automobile shop manager overcoming the drawbacks of existing system.
Student information management system project report ii.pdfKamal Acharya
Our project explains about the student management. This project mainly explains the various actions related to student details. This project shows some ease in adding, editing and deleting the student details. It also provides a less time consuming process for viewing, adding, editing and deleting the marks of the students.
Quality defects in TMT Bars, Possible causes and Potential Solutions.PrashantGoswami42
Maintaining high-quality standards in the production of TMT bars is crucial for ensuring structural integrity in construction. Addressing common defects through careful monitoring, standardized processes, and advanced technology can significantly improve the quality of TMT bars. Continuous training and adherence to quality control measures will also play a pivotal role in minimizing these defects.
Overview of the fundamental roles in Hydropower generation and the components involved in wider Electrical Engineering.
This paper presents the design and construction of hydroelectric dams from the hydrologist’s survey of the valley before construction, all aspects and involved disciplines, fluid dynamics, structural engineering, generation and mains frequency regulation to the very transmission of power through the network in the United Kingdom.
Author: Robbie Edward Sayers
Collaborators and co editors: Charlie Sims and Connor Healey.
(C) 2024 Robbie E. Sayers
Final project report on grocery store management system..pdfKamal Acharya
In today’s fast-changing business environment, it’s extremely important to be able to respond to client needs in the most effective and timely manner. If your customers wish to see your business online and have instant access to your products or services.
Online Grocery Store is an e-commerce website, which retails various grocery products. This project allows viewing various products available enables registered users to purchase desired products instantly using Paytm, UPI payment processor (Instant Pay) and also can place order by using Cash on Delivery (Pay Later) option. This project provides an easy access to Administrators and Managers to view orders placed using Pay Later and Instant Pay options.
In order to develop an e-commerce website, a number of Technologies must be studied and understood. These include multi-tiered architecture, server and client-side scripting techniques, implementation technologies, programming language (such as PHP, HTML, CSS, JavaScript) and MySQL relational databases. This is a project with the objective to develop a basic website where a consumer is provided with a shopping cart website and also to know about the technologies used to develop such a website.
This document will discuss each of the underlying technologies to create and implement an e- commerce website.
Welcome to WIPAC Monthly the magazine brought to you by the LinkedIn Group Water Industry Process Automation & Control.
In this month's edition, along with this month's industry news to celebrate the 13 years since the group was created we have articles including
A case study of the used of Advanced Process Control at the Wastewater Treatment works at Lleida in Spain
A look back on an article on smart wastewater networks in order to see how the industry has measured up in the interim around the adoption of Digital Transformation in the Water Industry.
Cosmetic shop management system project report.pdfKamal Acharya
Buying new cosmetic products is difficult. It can even be scary for those who have sensitive skin and are prone to skin trouble. The information needed to alleviate this problem is on the back of each product, but it's thought to interpret those ingredient lists unless you have a background in chemistry.
Instead of buying and hoping for the best, we can use data science to help us predict which products may be good fits for us. It includes various function programs to do the above mentioned tasks.
Data file handling has been effectively used in the program.
The automated cosmetic shop management system should deal with the automation of general workflow and administration process of the shop. The main processes of the system focus on customer's request where the system is able to search the most appropriate products and deliver it to the customers. It should help the employees to quickly identify the list of cosmetic product that have reached the minimum quantity and also keep a track of expired date for each cosmetic product. It should help the employees to find the rack number in which the product is placed.It is also Faster and more efficient way.
Event Management System Vb Net Project Report.pdfKamal Acharya
In present era, the scopes of information technology growing with a very fast .We do not see any are untouched from this industry. The scope of information technology has become wider includes: Business and industry. Household Business, Communication, Education, Entertainment, Science, Medicine, Engineering, Distance Learning, Weather Forecasting. Carrier Searching and so on.
My project named “Event Management System” is software that store and maintained all events coordinated in college. It also helpful to print related reports. My project will help to record the events coordinated by faculties with their Name, Event subject, date & details in an efficient & effective ways.
In my system we have to make a system by which a user can record all events coordinated by a particular faculty. In our proposed system some more featured are added which differs it from the existing system such as security.
Democratizing Fuzzing at Scale by Abhishek Aryaabh.arya
Presented at NUS: Fuzzing and Software Security Summer School 2024
This keynote talks about the democratization of fuzzing at scale, highlighting the collaboration between open source communities, academia, and industry to advance the field of fuzzing. It delves into the history of fuzzing, the development of scalable fuzzing platforms, and the empowerment of community-driven research. The talk will further discuss recent advancements leveraging AI/ML and offer insights into the future evolution of the fuzzing landscape.
Hybrid optimization of pumped hydro system and solar- Engr. Abdul-Azeez.pdffxintegritypublishin
Advancements in technology unveil a myriad of electrical and electronic breakthroughs geared towards efficiently harnessing limited resources to meet human energy demands. The optimization of hybrid solar PV panels and pumped hydro energy supply systems plays a pivotal role in utilizing natural resources effectively. This initiative not only benefits humanity but also fosters environmental sustainability. The study investigated the design optimization of these hybrid systems, focusing on understanding solar radiation patterns, identifying geographical influences on solar radiation, formulating a mathematical model for system optimization, and determining the optimal configuration of PV panels and pumped hydro storage. Through a comparative analysis approach and eight weeks of data collection, the study addressed key research questions related to solar radiation patterns and optimal system design. The findings highlighted regions with heightened solar radiation levels, showcasing substantial potential for power generation and emphasizing the system's efficiency. Optimizing system design significantly boosted power generation, promoted renewable energy utilization, and enhanced energy storage capacity. The study underscored the benefits of optimizing hybrid solar PV panels and pumped hydro energy supply systems for sustainable energy usage. Optimizing the design of solar PV panels and pumped hydro energy supply systems as examined across diverse climatic conditions in a developing country, not only enhances power generation but also improves the integration of renewable energy sources and boosts energy storage capacities, particularly beneficial for less economically prosperous regions. Additionally, the study provides valuable insights for advancing energy research in economically viable areas. Recommendations included conducting site-specific assessments, utilizing advanced modeling tools, implementing regular maintenance protocols, and enhancing communication among system components.
Hybrid optimization of pumped hydro system and solar- Engr. Abdul-Azeez.pdf
FYDP Sem 2
1. Lim Kah Huay A132816
Low Bee Chan A132764
Sonia Dilip Patel A/P Dilip Kumar A133115
Fatin Atikah Binti Kassim A132739
Jamilah Binti Ahmad A133159
Muhammad Khairil Azim bin Abdullah A133275
PRODUCTION OF BIOETHANOL FROM GLYCEROL
USING Enterobacter aerogenes TISTR1468
Group KB4
2. 2
CONTENT
1. Introduction
2. Summary of Production
3. List of improvement work
4. Heat integration
5. PFD after heat integration
6. Piping and Instrumentation
7. P&ID after HAZOP
8. Detailed Unit & Mechanical Design
9. Waste Management
10. Process Hazard Analysis
11. Plant Layout
12. Conclusion
3. SUMMARY OF PRODUCTION
Specifications Description
Product Bioethanol
Microorganism used Enterobacter aerogenes TSITR
1468
Processes involved • Micro-aerobic fermentation
• Stripping
• Binary Distillation
• Extraction
• Flash Vaporization
Production basis (per hour) 3676.47 kg
Bioethanol sale price (RM / kg) 3.04
Return on investment, ROI 0.25
Payback period, PBP 3.46 years
Net present value, NPV RM 10.37 million
Discounted cash flow rate of return, DCFRR 0.19
Site location Pengerang, Johor
3
4. List of Improvement Work
4
CHAPTERS PROBLEM CORRECTION DONE
Chapter 3 - PFD • Size of bioreactors in series
doesn’t shows its
effectiveness in improving
productivity of fermentation
process
• Mass flow rate of medium
from distillation column to
condensers and reboilers are
too big
• Stream tables lacks of data
• Bioreactors
arrangement in parallel
• Re-calculation of mass
balance
• Edited stream table data
Chapter 5 - Heat
integration
Mistakes in inlet and outlet
temperature
Corrected pinch analysis
with heat recovery
integrated in PFD
To be continued…
5. 5
CHAPTERS PROBLEM CORRECTION DONE
Chapter 6 – Piping and
Instrumentation
• Control loops with
electrical signal were
not drawn correctly and
some loops were not
complete
• Relief valve for after
HAZOP study was not
done
• Mistakes in P&ID
drawing
• Complete drawing of
controllers for the entire
plant
• Sizing calculated and
type of valve
determined
• Improved drawing with
second layer of safety
incorporated
Chapter 7 – Detailed
Process Design
Design calculation had
some mistake since inlet
and outlet of stream
changed
All the design calculation
had been calculated and
redesign for all unit
Chapter 8 - Mechanical
Design
The calculation for the
design and mechanical
drawing are not complete
All the calculation design
and drawing AUTOCAD
is done
…continue
List of Improvement Work
To be continued…
6. 6
CHAPTERS PROBLEM CORRECTION DONE
Chapter 10 – Production
Hazard Analysis
HAZOP was incomplete
and did not consider P&ID
HAZOP done after
complete P&ID drawing
Chapter 11 – Site Location
and Plant Layout
Plant layout need to
reconstruct, details were
not drawn out clearly and
wrong arrangement of unit
operations in plant layout
Completed plant layout
drawing
List of Improvement Work
…continue
10. DESIGN OF RELIEF VALVE
Location Type Function A (mm2)
F-101 Spring-loaded To prevent the rupture of vessel due to
overpressure during process and
sterilization
20 921.57
F-102 Spring-loaded To prevent rupture of vessel due to
overpressure during process and
sterilization
18 673.24
F-103 Spring-loaded To prevent rupture of vessel due to
overpressure during process and
sterilization
21 879.60
C-101 Spring-loaded To avoid damage to C-101 due to
overpressure
17 614.22
C-102 Spring-loaded To avoid damage to C-101 due to
overpressure
16 392.17
C-103 Spring-loaded To avoid damage to C-101 due to
overpressure
15 670.20
C-104 Spring-loaded To avoid damage to C-101 due to
overpressure
17 986.11
10
12. DETAIL UNIT &
MECHANICAL DESIGN
i. Seed Fermenter, F-101
ii. Stripping Column, C-01
iii. Binary Distillation Column, C-102
iv. Extractive Column, C-103
v. Flash Drum, C-104
vi. Cooling Tower
vii. Heat Exchanger, E-103
12
14. Detailed Design Fermenters
Design Parameters F-101 F-102 & F-103
Tank diameter, Dt 1.91 m 3.50 m
Tank height, Ht 5.72 m 10.49 m
Working volume, V 16.35 m3 100.86 m3
Design of Cooling Jacket
Height of jacket 2 m 3.5 m
Spacing between jacket
and vessel wall
50 mm 50 mm
Overall heat transfer
coefficient, U
500.63 W/m.°C 201 W/m.°C
Pressure drop, ∆P 0.42 kPa 0.16 kPa
Design of Impeller
Type of impeller Axial flow 3 blades
hydrofoil
Axial flow pitched-blade
45°impeller
Impeller diameter, Da 0.98 m 1.05 m
Depth of impeller in
vessel, H
1.96 m 3.50 m
To be continued… 14
15. 15
Design Parameters F-101 F-102 & F-103
Height of impeller above vessel floor, C 0.65 m 1.17 m
Impeller width, W 0.20 m 0.13 m
Length of impeller width, L 0.25 m 0.26 m
Diameter of impeller base, Dd 0.65 m 0.70 m
Baffle width, J 0.16 m 0.29 m
Power number, Np 0.3 1.6
Flow number, Nq 0.55 0.85
Impeller speed 0.10 rps 0.01 rps
Power, P 0.3057 W 0.0008 W
Sparger ring diameter, Ds 1.08 m 1.15 m
Sparger location above vessel floor, S 0.49 m 0.53 m
Mixing time, tT 6.67 s 2041.06 s
Circulation rate, Q 0.05 m3/s 0.29 m3/s
…Continue
Detailed Design Fermenters
16. 16
MECHANICAL DESIGN
SEED FERMENTER, F-101
Process Description
Microaerobic continuous fermentation with an aeration rate of 0.5
vvm, medium consistently mixed by agitator.
Glycerol and ammonium phosphate serve as raw material of carbon
and nitrogen source respectively
Fermentation output consists of bioethanol and carbon dioxide
Material of Construction
Carbon Steel SA 537
17. 17
Design Specifications Details
Operating Pressure 1 atm (15 psia)
Operating Temperature 37 C (310 K)
Corrosion Allowance 2 mm
Vessel Layout Vertical
H/D ratio 3:1
Volume
Torispherical Head (Top and Bottom Design)
Crown radius, R (m) 1.81
Knuckle radius, a (m) 0.19
Distance from the center of the torus to the center of the torus
tube, c (m)
0.76
Height from the base of the dome to the top, h (m) 0.38
Cylindrical Shell (Shell Design)
4.96
Effective Length, L (m) 5.21
18. 18
Vessel Parts Dimensions (mm)
Torispherical Top 5.72
Cylindrical Shell 8.89
Torispherical Bottom 5.72
Overall 11
Minimum Wall Thickness
Design of Cooling Jacket
Design Parameters Details
Type Type 1 (confined entirely
to the cylindrical shell)
Closure Type (b-2)
Material of Construction Carbon Steel SA537
Jacket Space 50 mm
0.91 mm
2.91 mm
Corner radius of torus closures 5.84 mm
20. 20
Design Parameters Details
Type of support Bracket support
Type of bracket Double gusset Type 1
Type of beam Wide-flange
Number of legs 4
47 kN
Standard wide flange
beam leg type base plate
W6
21. 21
Flanged Joint Design
Design Parameters Details
Type of flanged joint Welding neck flange
Flange faces Gasket between bolt
circle
Outside diameter of
flange (mm)
Stream 2&4 – 107.95
Stream 3&5 – 152.4
Stream 1&6 – 228.6
22. DISTILLATION COLUMN (C-101)
SONIA DILIP PATEL (A133115)
C-101
D-101
H-101
BIOETHANOL
BIOMASS
WATER
55% Bioethanol
45%Water
WASTEWATER
TREATMENT/ STILLAGE
S14
S16
S18 S17
S20
S19
S21
Parameter Dimension
Column design Tray
Diameter, DT (m) 1.913
Height, H (m) 9.772
Tray spacing(m) 0.457
Number of actual stages 17
Design of plate Sieve plate
Plate spacing (m) 0.457
Downcomer area 0.2725m2
Active area 1.726m2
Holes area, 0.173m2
Number of holes 8805
22
23. MECHANICAL DESIGN OF C-101
SONIA DILIP PATEL (A133115)
• Material used
SS-308
• Properties
Source : MIT Department of Civil and Environment 1999
Element Content (%)
Iron, Fe 66
Chromium, Cr 20
Nickel, Ni 11
Manganese, Mn 2.0
Silicon, Si 1.0
Carbon, C 0.080
Phosphorus, P 0.045
Sulfur, S 0.030
Properties Metric
Density 8 g/cm3
Tensile strength 585 MPa
Yield strength 240 MPa
Poisson’s ratio 0.27-0.30
23
24. • Design parameter for C-101
Parameter Value (SI unit) Value (English unit)
Temperature, T 100 OC 212 OF
Operating pressure (gage), P0 101.325 kPa 15 psig
Height of vessel , H 9.3262 m 367.1732’’, 30.5978’
Inside diameter of vessel, Di 1.91 m 75.1969’’,6.6224’
Height of cylinder shell, Hcylinder 7.772 m 305.9843”, 25.4987’
Height of torispherical heads, Htoris 0.3688 m 14.5197”, 1.2100’
Torispherical head
24
25. • Combine loading
Primary Stress Value (N/mm2)
3.6226
7.2453
-0.7885
Criterion met. Design is satisfied.
25
26. Vessel Support
Straight Cylindrical skirt.
Criterion satisfied, 2 mm CA added. Final skirt thickness = 12 mm
26
27. • Base ring and Anchor Belt Design
Nb = 4 bolts
Bolt size = nominal diameter (BS 4190: 1967)
Bolt used = M24 with root area = 353 mm2.
• Flanged Joint
Welding Neck Flange
27
29. DISTILLATION COLUMN (C-102)
LOW BEE CHAN (A132764)
Parameter Dimension
Column design Tray
Diameter, DT (m) 1.524
Height, H (m) 26.50
Tray spacing(m) 0.46
Number of actual stages 53
Design of plate Sieve
Plate spacing (m) 0.457
Downcomer area (m2) 0.146
Active area (m2) 0.925
Holes area (m2) 0.0925
Number of holes 4720
29
30. Mechanical Design Of Stripping Column C-102
LOW BEE CHAN A132764
Process Description:
Purify ethanol-water mixture to form azeotrope with 95.63% ethanol and
4.37% water (by weight)
Material Selection:
Austenitic Stainless Steel 304L
Design Specification:
• External pressure vessel
• Cylindrical shell
• Torispherical heads
31
32. VESSEL SUPPORT DESIGN
Resultant Stresses (N/mm2)
<
STRAIGHT SKIRT SUPPORT
Skirt thickness (mm) 20
Skirt height (mm) 2000
Base Ring and Anchor Bolt Design
Number of bolts 12
Actual width 220mm
Minimum thickness 50mm
M56 bolts (BS 4190: 1967)
32
33. FLANGE DESIGN
Parameter
S26
feed
S27
top
S29
refluxed
S31
bottom
S32
reboiled
Flow rate (kg/s) 0.4233 4.314 3.356 1.054 4.314
Density (kg/m3) 846.389 1.507 770.216 796.255 1.429
Optimum diameter 34.103 614.71 97.20 54.47 625.19
Nominal pipe size 50.8 660.4 101.6 101.6 660.4
Flange class 150 150 150 150 150
Outside flange diameter,
O
152.4 831.85 228.6 228.6 831.85
Thickness of flange, Tf 17.526 63.5 22.352 22.352 63.5
Diameter of hub, X 77.724 708.152 134.874 134.874 708.152
Chamfer beginning
diameter, A
60.452 609.6 114.3 114.3 609.6
Length through Hub, Y 61.976 127 74.676 74.676 127
Bore 52.578 355.6 102.362 102.362 355.6
Number of bolts 8 8 8 8 8
• Welding Neck Flange
33
34. DESIGN SUMMARY
Parameter Value
Operating temperature 100
Operating pressure (atm) 1
Material of construction Austenitic stainless steel Type 304L
Vessel internal diameter (m) 1.524
Vessel height (m) 2.65
Type of head and bottom Torispherical
Type of vessel Cylindrical
Vessel wall thickness (mm) 18
Stress analysis (N/mm2) (Δσ)max S < , (7.7128 < 137.89) [Safe]
Elastic stability (N/mm2)
Type of vessel support Straight conical skirt
Type of flanged joint Welding neck flange
Flange faces Gasket between bolt circle
Flange diameter (mm) 50.8, 101.6, 660.4
34
35. Specifications H-101 H-103
Pitch pattern Square pitch Square pitch
Brass, kw (W/m C) 110 110
Floating head Split-ring Split-ring
Shell pass 1 1
Tube pass 4 4
Number of tubes, Nt 998 1596
Outer diameter, do(m) 0.0381 0.0381
Inner diameter, di(m) 0.0168 0.0168
Length of tubes, l (m) 5 7
Tube pitch, Pt (m) 0.0125 0.0125
Heat transfer area, A (m2) 596.96 1336.46
Shell inside diameter, Ds (m) 1.915 2.335
Baffle spacing, lB(m) 0.036 0.036
Baffle cut, (%) 45 45
Tube side coefficient, hi(W/m2∆ C) 12473.48 11138.26
Shell side coefficient, hs(W/m2∆ C) 3310.721 1053.628
Overall coefficient, Uo(W/m2 C) 991.88 603.28
Tube side pressure drop, ∆Pt(kPa) 78.83 44.67
Shell side pressure drop, ∆Ps (kPa) 1.47 14.36
CONDENSER DESIGN
35
36. KETTLE REBOILER DESIGN
Specifications H-102 H-104
Pitch pattern Square pitch Square pitch
Carbon steel, kw (W/m. C) 55 55
Number of U tubes 404 374
Outer diameter, do(m) 0.022 0.0381
Inner diameter, di(m) 0.01688 0.0168
Length of tubes, l (m) 5 4
Heat transfer area, A (m2) 158.78 94.09
Baffle spacing, lB (m) 0.036 0.036
Baffle cut (%) 45 45
Tube side coefficient, hi(W/m2∆ C) 736000 734000
Shell side coefficient, hnb (W/m2∆ C) 28137.52 28565.69
Overall coefficient, Uo (W/m2 C) 1444 1239.23
Tube side pressure drop, ∆Pt (kPa) 174.89 168.6
Shell side pressure drop, ∆Ps (kPa) 14.59 14.36
36
37. EXTRACTIVE DISTILLATION COLUMN (C-103)
JAMILAH AHMAD (A133159)
Material Carbon steel 516
Actual no of stages 27
Diameter of the column (m) 4.68
Height of the column (m) 21.19
CONDENSER H-105
Cooling water flow rate 11409.8
Area required 3.531 m2
Outside diameter 19.05 mm
Inside diameter 14.83 mm
Length 5 m
Number of tube 12
Diameter of the bundle, Db 0.11 m
Shell-side coefficient 1030.137 W/m2oC
Tube-side coefficient 8982.51 W/m2oC
Overall heat transfer cofficient, Uo 649.99 W/m2oC
Total heat load (kW) 771
6.3
Shell side coefficient
Overall heat
transfercoefficient
(W/m2oC)
496
Pressure drop (kPa) 12.1
KETTLE REBOILER H-106
37
38. MECHANICAL DESIGN
EXTRACTIVE COLUMN
JAMILAH AHMAD (A133159)
INTRODUCTION
• Wall thickness required for the vessel
• Pressure exerted by the outside force weather the vessel can
withstand or not.
• Type of top & bottom and shell used for the
vessel
• Type of vessel support to withstand the vessel.
38
39. EXTRACTIVE COLUMN
Parts Value/Description
Main Part:
•Vessel height
•Diameter
•Shell height
•Top & bottom height
•Thickness
•Type of shell
•Type of head & bottom
•Material
• 21.49 m
• 4.68 m
• 19.15 m
• 1.17 m
• 30 mm
• Cylindrical
• Torispherical
• Carbon steel 516
Support
•Type
•Material
•Height
•Thickness
• Straight skirt
• Carbon Steel
• 1.219 m
• 30 mm
Flanges
• Type of flange • Welding neck
39
40. Detailed Design of Flash Drum C-104
KHAIRILAZIM (A133275)
Inlet
(S41)
Vapour Outlet
(S42)
Liquid Outlet
(S43)
h=1.219m
Dv=0.366
Flash drum C-104 is used to separate
the vapour and liquid. For design
calculations it is normally assumed that
the vapour and liquid are in equilibrium
and the vessel is adiabatic
Condition Value
Temperature 100 oC
Pressure 1 atm
Density of Water 958.4 kg/m3
Vapour Density 1.422 kg/m3
From the calculation,
•The diameter must be large enough
•The high of vessel outlet above the
gas inlet should be sufficient for
liquid drops.
•Liquid level will depend on hold up
time necessary for smooth
operations and control
hv=0.283 m3
The conclusion from the calculation,
Minimum vessel diameter,
Dv = 0.366 m
Liquid depth required,
hv = 0.238 m3
Height of the tank,
H = 1.219 m
41. Mechanical Design of Flash Drum C-104
KHAIRILAZIM (A133275)
Parts Value/Description
Main Part:
•Height
•Diameter
•Thickness
•MAWPvessel
1.219 m
0.366 m
3.5 mm
1.714 kPa
Support
•Type
•Material
•Height
•Thickness
Conical skirt
Plain Carbon Steel
0.25 m
3.5 mm
Flanges
•Feed
•Liquid
•Vapour
Welding neck
Welding neck
Welding neck
Design Summary of C-104
41
42. Properties Value
Cooling water flow rate (kg/h) 105458
Water inlet temperature (°C) 37
Water outlet temperature (°C) 28
Ambient wet bulb temperature
(°C)
23.9
Tower characteristic, KaL/V 1.5
Minimum tower area (m2) 17
Height of cooling tower (m) 10.4Source : HarrisonCooling
Tower 2002
FATIN ATIKAH (A132739)
42
43. Number of tube 43
Length tube 4 m
Shell-Side Pressure Drop 78.94 kPa
Tube-Side Pressure Drop 1.84 kPa
Shell-side coefficient 63.94 W/m2oC
Tube-side coefficient 661 W/m2oC
Overall heat transfer
cofficient, Uo
549.47 W/m2oC
Shell and Tube Exchanger
FATIN ATIKAH (A132739)
43
44. Parts Value/Description
Main Part:
•Vessel length
•Height vessel
•Inner diameter
•Outer diameter
4.0 m
0.267 m
0.016 m
0.02 m
Support
•Type
•Material
•Height
•Thickness
Saddle support
Carbon Steel
0.8 m
0.15 m
Flanges Welding neck
Shell and Tube Exchanger
Saddle support Welding neck flanges
FATIN ATIKAH (A132739)
44
45. T-102 Primary Clarifier A-101 Air Blower T-105 Sludge Storage Tank
Check Pond
Wastewater
from production
plant
Air
Flocculants and
Coagulant
T-101
T-102
T-103
A-101
T-104
T-105
1
2
3
4
5
7
8
9
10
6
WASTEWATER MANAGEMENT
ACTIVATED SLUDGE WASTEWATER TREATMENT PLANT
PROCESS FLOW DIAGRAM
Stream 1
Flowrate(m3/day) 892.99
S,BOD (mg/L) 362422.7
X, SS (mg/L) 16792.5
Stream 8
Flowrate (m3/day) 0.47
S,BOD (mg/L) -
X, SS (mg/L) 5850.5
Stream 7
Flowrate (m3/day) 4.25
S,BOD (mg/L) -
X, SS (mg/L) 5850.5
Stream 6
Flowrate(m3/day) 4.72
S,BOD (mg/L) -
X, SS (mg/L) 5850.5
Stream 5
Flowrate (m3/day) 884.29
S,BOD (mg/L) 362422.7
X, SS (mg/L) 5940.5
Stream 4
Flowrate(m3/day) 9.45
S,BOD (mg/L) -
X, SS (mg/L) 11775.7
Stream 3
Flowrate(m3/day) 883.54
S,BOD (mg/L) 362422.7
X, SS (mg/L) 5016.8
Stream 2
Flowrate (m3/day) 892.99
S,BOD (mg/L) 362422.7
X, SS (mg/L) 16792.5
Stream 10
Flowrate (m3/day) 879.57
S,BOD (mg/L) 45
X, SS (mg/L) 90
Stream 9
Flowrate(m3/day) 9.92
S,BOD (mg/L) -
X, SS (mg/L) 12290.9
Flocculation
tank
Sludge
storage tank
Aeration
tank
Secondary
clarifier
Primary
clarifier
46.51 m3
60 min
93.02 m3
SL: 40m3/m2.day
188. 06 m3
Length: 8.17 m
Width: 3.8 m
Height: 3m
93.02 m3
Length: 9.3 m
Width: 5 m
Height: 2 m
45
47. Process Hazard Analysis
Components Hazardous
Properties
Glycerol • Flammable
• Explosion
• Toxic
Ammonium phosphate • Toxic
Oxygen • Flammable
• Toxic
Ethanol • Fire
• Explosion
• Toxic
Carbon dioxide • Explosion
• Toxic
Nitrogen • Toxic
Hazard Identification
Legal Acts Requirement
1. Environmental Quality Act
(EQA) 1974
2. Occupational Safety and Health
Act (OSHA) 1994
3. Factory and Machinery Act
(FMA) 1967
Methods for PHA:
1. HAZOP analysis
2. FMEA
Set of organized and systematic assessments of the potential hazards associated with an
industrial process. A PHA provides information intended to assist managers and employees
in making decisions for improving safety and reducing the consequences of unwanted or
unplanned releases of hazardous chemicals.
47
48. FMEA method
- Systematic process to identify potential failures to fulfill the intended function,
to identify possible failure and locate the failure impacts
- Example of the method is shown in Seed Fermenter F-101
Component Failure mode Failure effects Symptom Safeguard Action
Level control
valve
Valve fails open
Valve fails
closed
Fluid will
exceed the level
of storage tank
causing
overflow and
rupture the tank
Liquid overflow None Schedule
inspection and
maintenance
required
Pure glycerol
valve
Valve fails open No glycerol in
the tank. Product
produce does
not meet the
specification.
The reaction is
not complete
None Daily check
Temperature
control valve
Valve fails open High
temperature in
the tank. It will
effect product
reaction
No cooling
water is supply
to the tank
Low level alarm Daily check
Process Hazard Analysis
48
49. Component Failure mode Failure effects Symptom Safeguard Action
Heat exchanger Tube failure High pressure and
could cause a cause
a major fire
Odors at the
cooling tower
None Daily check and
schedule
maintenance
Centrifugal pump Pump stop Loss of power
which cause
mechanical failure
Risk of upstream
process pump
damage due to
overpressure
None Preventive
maintenance
Temperature
control valve
Heater failure Electric device
failure. Loss of
electric power
May cause over
temperature which
will rupture the
wall
None Schedule
inspection and
maintenance
Condenser(Cooler) Power failure Unable to cool the
outlet stream
Very high
temperature is
flowing out
None Back-up power
supply generator
Level control valve Valve fails open
Valve fails closed
Fluid will exceed
the level of storage
tank causing
overflow and
Liquid overflow None Schedule
inspection and
maintenance
required
- FMEA analysis for Distillation Column C-101
49
50. PROCESS HAZARD ANALYSIS
HAZOP Analysis
• HAZOP Analysis is to identify how a process deviation can be prevented
or mitigate to minimize the potential hazard. Example of the analysis is
in the distillation column.
Project name : Process Plant Design
Process : Bio ethanol production
Part : Distillation Column
Study node Process parameter
Deviations
(guide words)
Possible causes Possible consequence Action required
Stream 28 Flow NO Pipe broken or plugging Loss of feed into column/not achieve into
desired output.
Level decrease in distillation column.
Off specification product.
1. Schedule inspection
and maintene.an
LOW 1. Pipe partial plugged or leakage. 1. Level decrease in distillation
column.
2. Off specification product.
3. Back flow of material.
Install check valve.
HIGH 1. High pressure from source 1. Flooding in distillation column. 1. Install bypass line with
manual valve.
Distillation column Level HIGH 1. Output pipe blockage. Overpressure of reflux drum.
Condensed liquid flow back to
distillation.
1. Install high level alarm
2. Scheduling inspection
LOW Pipe partial clogged & leakage. Level decrease in the vessel
The valve closed.
Back flow of material.
1. Scheduling inspection
2. Install valve.
Temperature HIGH 1. Low incoming flow from H-101
cause overheating.
Off specification product. Install temperature sensor.
LOW 1. H-101 malfunction.
2. High incoming flow through H-
101.
Low level inside reboiler.
Off specification product.
1. Scheduling inspection
2. Install temperature sensor.
50
51. 51
A high yield and potential for ethanol as fuel from Enterobacter
aerogenes. Pengerang has been the best location judging from the
coming development as Asia’s largest storage terminal.
Production rate of 3276 kg/hr and high demand in 2018 (projection) will
leave a very stable economic growth for ethanol.
65% saving of energy through pinch and heat exchanger installation will
further bloom the net profit.
Mechanical calculations and drawings for main utilities provide a clearer
insight of the sizing and supports.
Safety has been of top consideration through FMEA and HAZOP
performed. Layers of control aspect will further enhance the safety and
continuous operation of ethanol plant.
Waste management has been of top priority and calculations from waste
treatment plant designed is able to lower down pollutants to allowable
limits.