CHEMICAL ENGINERING DEPARTMENT

S4 NATIONAL DIPLOMA
CHEMICAL PROCESSES DESIGN PRINCIPLES
CPD3111
MAIN PROJECT

Ntsako Jason Maluleke

201209457

Xitsunduxo Gladwin Nukeri

201125145

Bongani Abel Mkansi

201220511

November 3, 2014

Md. Tyson Makua (P.hd)

East Coast Developments
85 HARRISON, JOHANNESBURG 2001
Subject: Submission of production of di-methyl ether (DME)
Dear Sir,
We are pleased to submit the report that you asked for & gave us the authorization
to work on DME production and costs estimations, we tried our best to work on it
carefully and sincerely to make the report informative.
The study we conducted enhanced our knowledge to make an executive report. This
report has given us an exceptional experience that might have immense uses in the
future endeavours and I sincerely hope that it would be able to fulfil your
expectations.
We have put our sincere effort to give this report a presentable shape and make it as
informative and precise as possible. We thank you for providing us with this unique
opportunity.

Sincerely yours,

MKANSI BA

Signature

MALULEKE NJ

Signature

NUKERI XG

Signature

4. Abstract
Dimethyl ether (DME) is a sustainable substitute for diesel fuel. Its
application involves both the chemical and automotive industries. In recent
years the global market for DME has increased especially in emerging
countries like China. The trend indicates increasing future demands in this
project, natural gas (e.g. from biomass) and carbon dioxide (e.g. from power
plants) are utilized as raw materials in a dry reforming process to produce
syngas. Syngas production is followed by direct DME synthesis, in which
conventional methanol synthesis and DME synthesis are integrated into a
one-step process over a functional catalyst, resulting in a simplified overall
process design. The literature search shows that DME is produced by the
catalytic dehydration of methanol over zeolite catalyst, the required
methanol is obtained from synthesis gas which is obtained from organic
waste. Construction of plant with 50,000 metric-tons/y (50,000,000 kg/y)
capacity. The objective of this project is to evaluate and analyse process
design, costs and especially with respect to sustainability and environmental
impact.

5. Introduction

Over the mid-to-long term, energy consumption in the African region is

expected to increase substantially during the 21st century. In realizing
sustained growth in this region in the future, energy supply and
environmental problems associated with mass energy consumption
will be major problems. High expectations are placed on dimethyl
ether (DME) as a new fuel which can be synthesized from diverse
hydrocarbon sources, including natural gas, can be handled as easily
as liquefied petroleum gas (LPG), and causes a small load on the
environment. Thus, if DME can be produced and distributed at low cost
and in large quantities, this fuel can make an important contribution to
solving the energy supply problems and environmental problems
resulting from expanded energy consumption expected in Asia in the
future.

Our plant will be located in Umlwazi (Kwazulu Natal province) where

the product will be easily transported even to the other South African
countries through ships as Umlwazi is next to the sea. Since
production of DME is in high demand we have conducted a survey
across, we found out that the best method to use indirect method by
dehydration reaction of methanol. While most of the DME is currently
produced by the indirect method, technical development of the direct
method has been carried out expecting its higher efficiency because
the methanol itself is synthesized from the synthesis gas.

Problem statement
Introduction
Dimethyl ether (DME) is used primarily as a propellant. It is miscible with
most organic solvents and has high solubility with water. Recently, the use of
DME as a fuel additive for diesel engines has been investigated due to its
high volatility (desirable for cold starting) and high cetane number.
As an engineering team, you are asked by the management to design a DME
process in order to produce 50,000 metric-tons/y (50,000,000 kg/y).
The literature search shows that DME is produced by the catalytic
dehydration of methanol over zeolite catalyst. The reaction is as follows:
2CH3OH CH3OCH3 + H2O
In the temperature range of normal operations, there are no side reactions.
Process Description
Fresh methanol, Stream 1, is combined with recycled reactant, Stream 8, and
vaporized prior to being sent to a fixed bed reactor, operating at 350C. The
reactor effluent, Stream 4, is then cooled prior to being sent to the first of
two distillation columns. DME product is taken overhead from the first
column. The second column separates water from the unreacted methanol.
The methanol is recycled back to the front end of the process, while the
water is sent to waste treatment to remove trace amounts of organic
compounds.

Tasks
1. Draw the process flow diagram (PFD) with a stream table showing the
material balance;
2. Determine the per-pass conversion of methanol assuming that the reactor
operates at equilibrium;
3. Size and estimate the purchase cost of the process equipment;
4. Estimate the capital cost using detailed factorial method;
5. Estimate the operating cost;
6. Perform cash-flow analysis and determine the whether the process is
economically viable. If yes, determine when the project will break even.

Catalyst and reactor information

The process uses a crystalline silicon-aluminum oxide catalyst, called a
zeolite. This particular catalyst performs well in the 200C-to-400C range,
but deactivates rapidly if heated above 400C. The design will use a single
packed bed reactor. Reactor sizing is out scope and will be covered at the
BTech level. However, for costing purposes, the reactor will be assumed to
account for 25% of the total purchase cost of the equipment.
Supplemental Information

Feed and Product Prices

Methanol $ 0.60 per gallon
Dimethyl ether $ 0.43 per pound

Utility Costs
Low Pressure Steam (618 kPa saturated) $6.62/1000 kg
Medium Pressure Steam (1135 kPa saturated) $7.31/1000 kg
High Pressure Steam (4237 kPa saturated) $8.65/1000 kg
Natural Gas (446 kPa, 25C) $3.00/GJ
Fuel Gas $2.75/GJ
Use this price for fuel gas credit
Electricity $0.06/kW h
Boiler Feed Water (at 549 kPa, 90C) $2.54/1000 kg
Cooling Water $0.16/GJ
Refrigerated Water $1.60/GJ
Available at 516 kPa and 10C
Return pressure 308 kPa

Return temperature is no higher than 20C

Deionized Water $1.00/1000 kg
Available at 5 bar and 30C
Refrigeration $60/GJ

6. Process Flowsheet and Material balances

Overall Mass Balance

Methanol
Water

kmol/h
Input
260.812
4627.387

Output
0.982
4757.301

kg/h
Input
8356.93
83362.367

Dimethyl Ether

129.915

Total

4888.198

4888.198

91719.297

Overall Mass Balance

Methanol
Water

kmol/h
Input
260.812
4627.387

Output
0.982
4757.301

kg/h
Input
8356.93
83362.367

Dimethyl Ether

129.915

Total

4888.198

4888.198

91719.297

Output
31.477
85702.77
3
5985.042
91719.29
7

Output
31.477
85702.77
3
5985.042
91719.29
7

7. Process Description
Appendix A is a preliminary process flow diagram (PFD) for the dimethyl
ether production process. The raw material is methanol, which may be
assumed to be pure. The feed is pumped to the mixed where it is mixed with
the recycle then passed to the vaporizer where it is heated, vaporized, and
superheated and then sent to the reactor in which dimethyl ether (DME) is
formed. The reactor effluent is cooled and partially condensed in a heat
exchanger, and it is then sent to the first separation section called distillation
column. Pure DME is produced in the top stream (distillate), with methanol
and water in the bottom stream (bottoms). In the second distillation column
the distillate contains methanol for recycle, and the bottoms contains waste
water. The desired dimethyl ether production rate is 5985.0415kg/hr.

Process Details
Feed Stream
Stream 1: methanol, from storage tank at 1 atm and 25C, may be assumed
pure
Effluent Streams
Stream 9: dimethyl ether product, required 5985.0415kg/hr. may be assumed
pure
Stream 10: waste water stream, may be assumed pure in material balance
calculations with 2340.4082 kg/hr, and is not pure, so there is a cost for its
treatment

Equipment
Pump
The pump increases the pressure of the feed plus recycle to a minimum of 15
atm.
Heat Exchanger 1:
This unit heats, vaporizes, and superheats the feed to 153.78C at 42.37
atm. The source of energy for heating must be above 153.78C.
Reactor:
The following reaction occurs: methanol dimethyl ether
2CH3OH CH3OCH3 + H2O
The reaction is equilibrium limited. The conversion per pass is 80% of the
equilibrium conversion at the pressure and exit temperature of the reactor.
Based on the catalyst and reaction kinetics, the reactor must operate at a
minimum of 15 atm. The reactor operates isothermally, and, since the
reaction is exothermic, the reactor effluent temperature will be 350C.
Heat Exchanger 2:
This unit cools and partially condenses the reactor effluent. The valve before
this heat exchanger reduces the pressure. This exit pressure may be at any
pressure below the reactor pressure, but must be identical to the pressure at
which it operates.

Distillation Column 1:
This distillation column separates DME from methanol and water. The
separation may be assumed to be perfect, i.e., pure DME is produced in the
distillate. The temperature of the distillate is the temperature at which DME
condenses at the chosen column pressure.
Distillation Column 2:
This distillation column separates methanol for recycle from water. For this
semester only, the separation may be assumed to be perfect. However, since
we know this cannot be true in practice, the water stream is actually a waste
water stream, and there is a cost for its treatment. The temperature of the
distillate is the temperature at which methanol condenses at the chosen
column pressure.
Other Equipment:
For two or more streams to mix, they must be at identical pressures. Pressure
reduction may be accomplished by adding a valve. All of these valves are not
necessarily shown on the attached flowsheet, and it may be assumed that
additional valves can be added as needed at no cost. Flow occurs from

higher pressure to lower pressure. Pumps increase the pressure of liquid

streams, and compressors increase the pressure of gas streams

8. Energy balance and Utility Requirements

Overall Energy Balance
Feed Streams
Product Streams

MJ/h
Input
-6.57E+06

6.57E+0
6

Total Heating
Total Cooling
Power Added
Power Generated

5949.63
-10007.7
24.5302
0

Total

-6.57E+06

Steam

Output

6.57E+0
6

sell/100
0 kg
Flow
rate
(kg/hr)
Cost ($)

8.60
6,549.84
468,766.4
5

Gibbs Reactor Summary

Equip. No.
Name
Thermal mode
Reaction Phase
Temperature C
Heat duty MJ/h
Overall Heat of Rxn
(MJ/h)
Approach DT C

Electricity
Heat Duty
(MJ/h)
Evaporat
or
Reactor

11,979.40
1,804.03

Condens
or

9,628.69

Coloumn
1

-4,244.98

Coloumn
2

-883.48

Total
(MJ/hr)
Total
(KW/hr)
Cost ($)

152,156,59
5.22
42,265,720.
89

4
2
1
350
10864.91
02
3123.151
9
0.01

2,535,943.2
5
Cooling water
Cost
($/GJ)
0.16
Heat
Duty
9,628.69
(MJ/hr)
Heat
Duty (MJ)
80,129,986
.47
Heat
Duty (GJ)
80,129.99
$
12,820.80

9. Unit description

Pump

The pump increases the pressure of the feed plus recycle to a

minimum of 15 atm.

For sizing the pump refer to appendix 5

Heat exchanger1

This unit heats, vaporizes, and superheats the feed to 153.78C at

42.37 atm. The source of energy for heating must be above
153.78C. The heating source used is the low pressure steam.

For sizing we used chemcad to simulate and get the heat area
required (appendix 3)

Material of construction we used carbon steel for tube and carbon

steel for shell side, carbon steel has the highest value heat transfer
coefficient. The feed will take the shell side and the low pressure
steam will take the tube side.

Heat exchanger 2(condenser)

This unit cools and partially condenses the reactor effluent. The
valve before this heat exchanger reduces the pressure. This exit
pressure may be at any pressure below the reactor pressure, but
must be identical to the pressure at which it operates. Water is
used to cool down the temperature of the reactor effluent.

For sizing we used chemcad to simulate and get the heat area
required (appendix 4)

Material of construction we used carbon steel for tube and carbon

steel for shell side, carbon steel has the highest value heat transfer
coefficient. The reactor effluent will take the tube side and the
cooling water will take the shell side.

Distillation column 1

This distillation column separates DME from methanol and water.

The separation may be assumed to be perfect, i.e., pure DME is
produced in the distillate. The temperature of the distillate is the
temperature at which DME condenses at the chosen column
pressure.

For tray spacing and baffle cuts refer to appendix 2

Distillation column 2

This distillation column separates methanol for recycle from water.

For this semester only, the separation may be assumed to be
perfect. However, since we know this cannot be true in practice,
the water stream is actually a waste water stream, and there is a
cost for its treatment. The temperature of the distillate is the
temperature at which methanol condenses at the chosen column
pressure

For tray spacing and baffle cuts refer to appendix 2

Other equipment

For two or more streams to mix, they must be at identical pressures.

Pressure reduction may be accomplished by adding a valve. All of
these valves are not necessarily shown on the attached flowsheet,
and it may be assumed that additional valves can be added as
needed at no cost. Flow occurs from higher pressure to lower
pressure. Pumps increase the pressure of liquid streams, and
compressors increase the pressure of gas streams

10. Specification sheet

1. Distillation columns
SCDS Rigorous Distillation
Summary
Equip. No.
Name
No. of stages
1st feed stage
Condenser mode
Condenser spec
Cond comp i pos.
Reboiler mode
Reboiler spec.
Reboiler comp i
Est. dist. Rate
(kmol/h)
Est. reflux rate
(kmol/h)
Est. T top C
Est. T bottom C
Est. T 2 C
Calc cond duty MJ/h
Calc rebr duty MJ/h
Initial flag
Calc Reflux mole
(kmol/h)
Calc Reflux ratio
Calc Reflux mass kg/h
Column diameter m
Tray space m
Thickness (top) m
Thickness (bot) m
No of sections
No of passes (S1)
Weir side width m
Weir height m

13
7
5
129.914
7
3
5
48.6315

20
11
5
48.1452

1
131.729
7

1
5
129.914
4
2
51.2819

150.755

83.4697

31.4828

112.930
9
165.550
9
123.699
4
4327.96
14
4444.46
97
6
87.6667

141.559
2
32.9164
5679.14
75
1434.21
06
6
180.227
8
1.382
8293.28
91
0.9144
0.6096
0.0048
0.0063
1
1
0.1397
0.0508

1.7258
2808.91
99
0.6096
0.6096
0.0032
0.0119
1
1
0.1016
0.0508

System factor
Optimization flag
Calc. tolerance

1
1
0.0005

1
1
0.0002

2. Heat exchangers
Heat Exchanger Summary
Equip. No.
Name
1st Stream T Out C
2nd Stream T Out C
1st Stream VF Out
Calc Ht Duty MJ/h

LMTD (End points) C

225
1
11979.42
38
136.9068

LMTD Corr Factor

Utility Option:
1st Stream Pout atm
2nd Stream Pout atm

1
1
15
41.2657

3. Pump
Pump Summary
Equip. No.
Name
Output pressure atm
Efficiency
Calculated power MJ/h
Calculated Pout atm
Head m
Vol. flow rate m3/h
Mass flow rate kg/h
NPSH available m
Cost estimation flag
Install factor
Basic pump cost $
Basic motor cost $
Total purchase cost $
Total installed cost
($)
Request NPSH calc
4. Reactor
Gibbs Reactor Summary

1
17
0.7
24.5302
17
209.372
7
10.584
8356.92
97
10.9108
1
2.8
4352
690
5042
14118
1

6
135
55
9628.71
48
187.532
6
1
1
15
1

Equip. No.
Name
Thermal mode
Reaction Phase
Temperature C
Heat duty MJ/h
Overall Heat of Rxn
(MJ/h)
Approach DT C

4
2
1
350
10864.91
02
3123.151
9
0.01

5. Mixer
Mixer Summary
Equip. No.
Name
Output Pressure atm

2
15

6. Valve
Valve Summary
Equip. No.
Name
Pressure out atm

5
7

11. Equipment Cost Summary

Summary of Equipment
Cost :
Equipment : Cost ($)
Pump
18000285
Evaporiser
163439.8
919
Reactor
188515.7
Condensor
16343.98
919
Valve
500
Dist.
39,895.95
Coloumn 1
Dist.
16334
Coloumn 2
Total ($)

18425314

.53

12. Fixed-Capital Investment Summary

13. Important considerations

Environmental problems
The plant emission has been evaluated based on the conceptual design of
the plant. The key result is that the plant will abide by all environmental
regulations and not discharge any material which is harmful to the
environment. Furthermore, by treating the flue gas from the plant, which is
currently discharged to the atmosphere, the combined emissions from
both plants will be much less, and thus the overall environmental impact is
improved. Short half-life in atmosphere.

Health and safety

DME has been proven to be stable in the presence of LPG under normal
storage conditions. Equipment to store, transport, bottle, dispense and use
DME are substantially similar to those required for LPG. Significant studies
into materials compatibility, and the thermal and chemical properties of such
blends in China, Japan and Korea provide clear guidelines for safe handling
and use.

Waste water is pretreated and remove all materials that can be easily
collected from waste water before they damage or clog the pumps. Objects
that are commonly removed during pretreatment include trash, tree limbs,
leaves and other large objects. On our plant we will use the device known as
the American Petroleum Institute oil-water separator which is designed to
separate oil and suspended solids from the waste water effluents.

Non toxic, non-carcinogenic and Approved as consumer product propellant

14. Operating Cost and Economic Analysis

The fixed capital cost has to be installed over a 3-year period (2014-2016)
in steps of 50%, 30% and 20%. Just prior to start-up, 15% of fixed capital
is required as working capital. The production cost (excluding capital
charges) is estimated as 0.593283616 $/kg and the selling price 1.08 $/kg.
The plant capacity of 50,000,000 kg/y is reached in the third year of
operation as follows: in the first year the plant operates at 50% capacity,
second year at 75% capacity and third year at full capacity. The estimated
life of the project is 15 years. The interest rate is 15% and tax of 30%

15. Conclusions and recommendations

DME is a very promising new, multi-purpose fuel, manufactured from methanol.
It has many opportunities and many driver are dependent on DME as a fuel and a
significant global DME effort has evolved led by Asia. If the DME production is
successful it would be the first DME production in AFRICA. DME community has
joined forces for advancement of DME

16. Acknowledgement
We would like to thank our tutor Samson for fruitful discussions and guidance
during our project. Especially your comments and advice concerning the
project writing process was most beneficial.
We would also like to thank our fellow classmates and B-Tech students from
University Of Johannesburg for useful discussions from time to time. I hope
we can continue exchanging research ideas and results.

A special thanks goes to Professor Jalama Kalala from University Of

Johannesburg of Department of Chemical Engineering for his supervision on
our project and for interesting discussions.

17. Bibliography

Perry, R. H. and D. Green, eds., Perrys Chemical Engineering Handbook (7th

ed.), McGraw-Hill, New York, 1997.
Felder, R. M. and R. W. Rousseau, Elementary Principles of Chemical
Processes (3rd ed.),Wiley, New York, 2000
Dimethyl Ether Technology and Markets 07/08-S3 Report, ChemSystems,
December 2008.
http://www.japantransport.com/conferences/2006/03/dme_detailed_informati
on.pdf, Conference on the Development and Promotion of Environmentally
Friendly Heavy Duty Vehicles such as DME Trucks, Washington DC, March 17,
2006
DuPont Talks About its DME Propellant, Aerosol Age, May and June, 1982

Bondiera, J., and C. Naccache, Kinetics of Methanol Dehydration in

Dealuminated H-Mordenite: Model with Acid and Base Active Centres,
Applied Catalysis, 69,139-148 (1991).
T. A. Semelsberger, R. L. Borup, H. L. Greene, "Dimethyl Ether (DME) as an
Alternative Fuel," J. Power Sources 156, 497 (2006).
C.-J. Yang and R. B. Jackson, "China's Growing Methanol Economy and Its
Implications for Energy and the Environment," Energy Policy 41, 878 (2012).
Fei JH, Yang MX, Hou ZY, Zheng XM (2004) Effect of the addition of
manganese and zinc on the properties of copper-based catalyst for the
synthesis Of syngas to dimethyl ether. Energy Fuel 18:1584
Jun KW, Lee HS, Roh HS, Park SE (2003) highly water-enhanced H-ZSM-5
catalysts for dehydration of methanol to dimethyl ether. Bull Korean Chem
Soc 24:104
University Of Johannesburg :Chemical Engineering S4, process design
notes(2014)
Liquid Phase Dimethyl Ether Demonstration in the LaPorte Alternative Fuels
Development Unit, DOE Topical Report, Cooperative Agreement No. DE-FC22
92PC90543, January 2001.

Hoffmann, M.R., Martin, S.T., Choi, W. and Bahnemann, D.W. (1995)

Environmental Applications of Semiconductor Photocatalysis. Chemical
Reviews, 95, 69-96.

STEPHENSON, R. M. Introduction to the Chemical Process Industries, 1966

(New York: Reinhold Publishing Corporation).

J. H. GARVIE, Chem. Proc. Engng, Nov. 1967, pp. 55 65. Synthesis gas
manufacture

18. Appendix
Appendix A
1. Calculation of mass flowrates of DME, methanol and water:
Mass Flowrate of DME

=6008.17 kg/hr

2CH3OH CH3OCH3 + H2O

Mass flowrate of water =
=2457.89 kg/hr
Mass flowrate of methanol =
= 8739.16 kg/hr
2. Distillation column information
Unit type : SCDS
Unit name:
Eqp #
8

Stg
1
2
3
4
5
6
7
8
9
10
11
12
13

Temp
C
31.5
32.9
42.8
73.9
92.4
98
105.9
109.1
113.9
120.3
127
132.8
139

Mole
Reflux
ratio

1.382

Total
liquid
entering
stage

Pres
atm
7
7
7
7
7
7
7
7
7
7
7
7
7

* Net Flows *
Liquid
Vapor
kmol/h
kmol/h
180.23
164.47
310.64
114.84
294.88
88.15
245.25
85.08
218.56
79.44
215.49
222.33
209.86
221.98
41.13
221.73
40.78
221.84
40.53
222.33
40.64
222.57
41.13
41.37

at

105.396

Pres
atm
7
7
7
7
7

* Net Flows *
Liquid
Vapor
kmol/h
kmol/h
87.67
89.03
138.46
88.42
139.83
87.54
139.22
86.45
138.34

Feeds
kmol/h

Produ
kmol
130.4

311.61

181.2

222.404

kmol

Feeds
kmol/h

Produ
kmol
50.8

Unit type : SCDS

Unit name:
Eqp #
9

Stg
1
2
3
4
5

Temp
C
112.8
123.7
124.7
125.4
126.2

6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

127.3
128.7
130.7
133.3
136.4
139.6
140.2
141
142.4
145.4
150.3
156.2
161
163.7
164.9

Mole
Reflux
ratio

1.726

Total
liquid
entering
stage

11

7
7
7
7
7
7
7
7
7
7
7
7
7
7
7

85.07
83.36
81.29
79
76.89
258.1
257.76
256.93
255.32
252.89
250.54
249.41
249.3
249.45

at

138.087

137.24
135.87
134.15
132.08
129.79
127.69
127.69
127.36
126.53
124.92
122.49
120.14
119.01
118.9
119.05

181.2

130.4

257.988

Heat exchanger 1 (vaporizer)

3.1

TABULATED ANALYSIS FOR HEAT EXCHANGER 1

Overall Data:
Area Total
(m)
Area Required
(m)
Area Effective
(m)
Area Per Shell
(m)
Weight LMTD C 141.65
Shellside Data:
Rho V2 IN kg/m-sec2
Avg. SS Vel. m/sec
Film Coef. (W/mK)
Allow Press. Drop
(atm)
Inlet Nozzle Size

19.53

% Excess

-1.94

19.15

U Calc.

18.78

U Service (W/m-K)

1039.74

18.78

Heat Duty (MJ/h)

9.63E+03

(W/m-K)

1019.61

LMTD CORR Factor 0.9670 CORR LMTD C 136.98

2302.40 Press. Drop (Dirty) atm
0.43
8.95
2518.4
Calc. Press. Drop
7
(atm)
0.34
Press. Drop/In Nozzle
(atm)
0.15
Press. Drop/Out

0.25
0.02
0

kmol

(m)
Outlet Nozzle Size
(m)
Rho V2 IN (kg/msec)
Tubeside Data:
Film Coef. (W/mK)
Allow Press. Drop
(atm)
Inlet Nozzle Size
(m)
Outlet Nozzle Size
(m)
Interm. Nozzle
Size (m)
Velocity
(m/sec)
Clearance Data:
Baffle
(m)
Tube Hole
(m)
Bundle Top Space
(m)
Bundle Btm Space
(m)

0.13
2302.4

(m)
(m)
(m)

195.45
0.43

8704.8
0.34
0.15
0.15
0
2.1

0.0063
0.0008
0

Calc. Press. Drop

(atm)
Press. Drop/In Nozzle
(atm)
Press. Drop/Out
Nozzle (atm)
Mean Temperature
(C)
Mean Metal
Temperature (C)

0.27

Outer Tube Limit

(m)
Outer Tube Clear.
(m)
Pass Part Clear. (m)

0.2908

0
0
40
91.89

0.0457
0

Baffle Parameters:
Number of Baffles
Baffle Type
Inlet Space (m)
Center Space (m)
Outlet Space (m)
Baffle Cut, %
Diameter
Baffle Overlap
(m)
Baffle Cut
Direction
Number of Int.
Baffles
Baffle Thickness
(m)
Shell:
Shell O.D.
Shell I.D.
Bonnet I.D.
Type

Nozzle (atm)
Mean Temperature
(C)
Press. Drop (Dirty)
(atm)

13
Single Segmental
0.191
0.212
0.191
21
0.04
Vertical
0
0.003

0.36
0.34
0.34
AES

Orientation
Shell in Series
Shell in Parallel
Max. Heat Flux
Btu/ft2-hr

H
1
1
0

Imping. Plate

Impingement Plate

Sealing Strip

Tubes:
Number
Length

(m)

102
3.05

Tube O.D.
Tube I.D.

(m)
(m)

0.02
0.016

Tube Type
Free Int. Fl Area
(m)
Fin Efficiency
Tube Pattern

0.002

Tube Pitch

Tube Wall Thk.

(m)
No. Tube Pass
Inner Roughness
(m)

5
Bare
0

(m)

2
1.6E-06

Resistances:
Shellside Film
0.0004
(m-K/W)
Shellside Fouling
0.0001
(m-K/W)
8
Tube Wall (m0.0000
K/W)
4
Tubeside Fouling
0.0001
(m-K/W)
8
Tubeside Film
0.0001
(m-K/W)
1
Reference Factor (Total outside area/inside area based on tube ID)
Pressure Drop Distribution :
Tube Side
Inlet Nozzle
0.0042
(atm)
Tube Entrance
0.0141
(atm)
Tube
(atm)
0.1772
Tube Exit
(atm)
0.0432
End
(atm)
0.0276
Outlet Nozzle
0.0022
(atm)
Total Fric. (atm)
0.2684
Total Grav. (atm)
0
Total Mome.
0.0001
(atm)
Total
(atm)
0.2685
3.2
COSTING OF HEAT EXCHANGER 1
Area Required
Pressure (bar)
Pressure Factor
Type Factor

0
TRIANGULA
R 30
0.025

(m)

19.15
15
1.1
1

1.25

Shell Side
Inlet Nozzle (atm)

0.0206

Impingement

0.0148

(atm)

Bundle
(atm)
Outlet Nozzle (atm)
Total Fric. (atm)
Total Grav. (atm)

0.2431
0.0025
0.2662
-0.0011

Total Mome. (atm)

Total
(atm)

-0.0121
0.2531

Bare Cost ($)

120000

Puchase Cost in 2004 ($)

Puchase Cost in 2014 ($)

132000
163439.8
919

1 US Dollar = 11,02 ZAR

Purchase Cost in 2014
ZAR
3.3
Year

CE
Index
(CEPSI)

2004
2009
2014

1801107.
609

444.2
521.9
550
Heat exchanger 2
4.1
TABULATED ANALYSIS
Overall Data:
Area Total
(m)
Area
Required
(m)
Area
Effective
(m)
Area Per
Shell
(m)
Weight LMTD C 141.65
Shellside Data:
Avg. SS
Vel.
(m/sec)
Film Coef.
(W/m-K)
Allow
Press.
Drop
(atm)
Inlet
Nozzle
Size
(m)

19.53

% Excess

19.15

U Calc.
(W/m-K)

18.78

U Service
(W/m-K)

18.78

Heat Duty
(MJ/h)
LMTD CORR Factor

0.9670

CORR LMT

8.95
2518.47
0.34

Calc. Press.
Drop
(atm)

0.15

Press.
Drop/In
Nozzle
(atm)

Outlet
Nozzle
Size
(m)

0.13

Rho V2 IN
(kg/msec)

2302.40

Tubeside Data:
Film Coef.
(W/m-K)
Allow
Press.
Drop
(atm)
Inlet
Nozzle
Size
(m)
Outlet
Nozzle
Size
(m)
Interm.
Nozzle
Size
(m)
Velocity
(m/sec)
Clearance Data:
Baffle
(m)

8704.80
0.34

Calc. Press.
Drop
(atm)

0.15

Press.
Drop/In
Nozzle
(atm)
Press.
Drop/Out
Nozzle
(atm)
Mean
Temperatur
e
(C)
Mean Metal
Temperatur
e (C)

0.15

0.00

2.10

0.0063

Tube Hole
(m)

0.0008

Bundle
Top
Space
(m)
Bundle
Btm
Space
(m)

0.0000

Baffle Parameters:
Number

Press.
Drop/Out
Nozzle
(atm)
Mean
Temperatur
e
(C)
Press. Drop
(Dirty)
(atm)

Outer Tube
Limit
(m)
Outer Tube
Clear.
(m)
Pass Part
Clear.
(m)

0.0000

13

of Baffles
Baffle
Type
Inlet
Space
(m)
Center
Space
(m)
Outlet
Space
(m)
Baffle
Cut, %
Diameter
Baffle
Overlap
(m)
Baffle Cut
Direction
Number
of Int.
Baffles
Baffle
Thickness
(m)
Shell:
Shell O.D.
(m)
Shell I.D.
(m)
Bonnet
I.D.
(m)
Type
Imping. Plate
Tubes:
Number
Length
(m)
Tube O.D.
(m)
Tube I.D.
(m)
Tube Wall
Thk.
(m)
No. Tube

Single
Segmental
0.191
0.212
0.191
21.000
0.040
Vertical
0
0.003

0.36

Orientation

0.34

Shell in
Series
Shell in
Parallel

0.34
AES
Impingement Plate
102
3.05
0.020
0.016
0.002
2

Max. Heat
Flux Btu/fthr
Sealing Strip
Tube Type
Free Int. Fl
Area
(m)
Fin
Efficiency
Tube
Pattern
Tube Pitch
(m)

Pass
Inner
Roughnes
s
(m)
Resistances:
Shellside Film

0.000001
6

(m-K/W)
0.00040

Shellside Fouling

(m-K/W)

0.00018
Tube Wall
(m-K/W)
0.00004
Tubeside
Fouling
0.00018
(m-K/W)
Tubeside
0.00011
Film
(m-K/W)
Reference Factor (Total outside area/inside area based on tube ID) 1.250
Pressure Drop Distribution:
Tube Side
Inlet
0.0042
Nozzle
(atm)
Tube
0.0141
Entrance
(atm)
Tube
0.1772
(atm)
Tube Exit
0.0432
(atm)
End
(atm)
Outlet
Nozzle
(atm)
Total Fric.
(atm)
Total
Grav.
(atm)
Total
Mome.
(atm)
Total
(atm)

0.0276
0.0022
0.2684
0.0000
0.0001
0.2685

4.2
COSTING OF HEAT EXCHANGER 2

Shell Side
Inlet Nozzle
(atm)
Impingeme
nt
(atm)
Bundle
(atm)
Outlet
Nozzle
(atm)
Total Fric.
(atm)
Total Grav.
(atm)
Total Mome.
(atm)
Total
(atm)

Area
Required
(m)
Pressure
(bar)
Pressure
Factor
Type Factor
Bare Cost ($)

19.15

Puchase Cost
in 2004 ($)
Puchase Cost
in 2014 ($)

13200

15
1.1
1
12000

16343.
99

1 US Dollar = 11,02 ZAR

Purchase
Cost in 2014
ZAR

18011
0.8

4.3

Yea
r

CE
Index
(CEP
SI)

200
4
200
9
201
4

444.
2
521.
9
550

Pump

Pump
Summary
Equip. No.
Name
Output
pressure atm
Efficiency
Calculated
power MJ/h
Calculated
Pout atm
Head m

1
17

0.7
24.5302

17

209.3727

Appendix B

Vol. flow rate

m3/h
Mass flow rate
kg/h
NPSH available
m
Cost
estimation flag
Install factor
Basic pump
cost $
Basic motor
cost $
Total purchase
cost $
Total installed
cost
($)
Request NPSH
calc

10.584

8356.9297

10.9108

2.8
4352

690

5042

14118