3.

4(a)Process Design of Reactor

Reactions taking place are as follows:

Temperature of reactor= 167 C
Pressure of the reactor= 31.2 barg

Kinetics of 1st reaction

Activation energy= 35.64 kJ/mol
A1= 9.044
K01 = A1 exp (-E1/RT)
K1= 5.311 x 10-4

Kinetics of 2nd reaction

Activation energy= 29.4 kJ/mol
A2= 9.28
K02=A2 * exp(-E1/RT)
K2= 3*10-3

Kinetics of 3rd reaction

Activation energy= 119.7 kJ/mol
A3= 2.2 * 1011
K03 = A3 exp (-E1/RT)
K3= 1.354 * 10-3

Kinetics of 4th reaction

Activation energy= 356.393 kJ/mol
A4= 7.32*107
K04 = A4 exp (-E1/RT)
K4= 9.36*10-4

Kinetics of 5th reaction

Activation energy= 372.187 kJ/mol
A5= 1.816*109
K05 = A5 exp (-E1/RT)
K5= 10.56*10-3

So, Final rate of consumption of ethylene per Kg of catalyst:

Reaction :1

Reaction:2

Reaction 3:

Reaction:4

From reactor equation of Packed bed reactor:

W = FA0 dX/(sum of all rate of reactions) [Ref: Fogler, Reaction Engineering]

FA0= 265.8017 kmol/hr

Now, Reactor is Tube and Shell reactor.

From reactor design equation,

W = 4337 kg of catalyst.

Catalyst bulk density = 0.5 kg/L

Particle size = 5 mm :

Porous Volume = 0.8 L/Kg

Void fraction = 0.4

Catalyst density = 833 Kg/m3

So,
Volume of reactor = Weight of catalyst/Bulk density
= 8674.656 L = 86.7 m3

Selected Reactor Length = 10.01 m

Tube Diameter = 3.7 cm

Tube outside diameter = 4 cm

Volume per tube = 108.5 L

Number of tubes required = 799

Total height of reactor = 11.01 m (10 % margin)

Design of Stabilizer

Step 1: Product Specification

Components 9 13 14

Butane 0.982869 0.806373 0.982184

Iso-Pentane 23.02581 0.40635 23.03792

N-Pentane 10.20585 0.022796 10.21014

CycloPentane 1.859525 0 1.860439

2,2-Dimethylbutane 60.74692 0 60.78118

2,3-Dimethylbutane 19.8698 0 19.88122

2-Methylpentane 55.90909 0 55.89082

3-Methylpentane 29.85815 0 29.87209

N-hexane 16.94609 0 16.95523

Methyl 10.46642 0 10.47053

CycloPentane

cyclohexane 10.40247 0 10.40658

benzene 0 0 0

heptane 12.39379 0 12.39856

Hydrogen 13.04249 11.3609 13.04934

Methane 2.126542 2.027181 0.09936

Ethane 1.780722 1.689584 0.091138

Propane 5.607583 5.353586 0.253997

i-Butane 5.315212 4.901782 0.413431

Step 2: Determination of Relative Volatilities

The following table gives the value of relative volatilities of the compounds at an average of
temperature of top and bottom.

Components(kmol/hr ktop kbottom top bottom avg

)

Butane 3.56157 7.5463 18.81442 11.55351 15.18396

Iso-Pentane 1.67309 4.09136 8.838299 6.263938 7.551118

N-Pentane 1.34103 3.11547 7.084152 4.769835 5.926993

CycloPentane 0.751485 2.28964 3.96981 3.505476 3.737643

2,2-Dimethylbutane 0.8859 2.34427 4.679873 3.589115 4.134494

2,3-Dimethylbutane 0.7087 1.96677 3.743793 3.011157 3.377475

2-Methylpentane 1.6687 1.8616 8.815108 2.85014 5.832624

3-Methylpentane 0.611 1.70776 3.227681 2.614608 2.921144

N-hexane 0.49323 1.25409 2.605547 1.920032 2.262789

Methyl CycloPentane 0.5343 1.39064 2.822504 2.129092 2.475798

cyclohexane 0.3745 0.957863 1.978341 1.466504 1.722422

heptane 0.1893 0.653161 1 1 1

Hydrogen 1758.88 1766.88 9291.495 2705.122 5998.308

Methane 147.745 205.211 780.4807 314.1813 547.331

Ethane 32.4483 56.7322 171.412 86.85791 129.135

Propane 10.3815 20.7987 54.84152 31.84314 43.34233

i-Butane 4.78923 10.3708 25.29968 15.87786 20.58877

Step 3: Determination of Reflux Ratio

Here, q=0.85
On Solving, = 1.8
Rm + 1 = 3.8
Rm = 2.8
So, actual R is:
R=1.25*Rm=3.5

Step 4: Determination of Number of stages

Nm=11.6
Rm/(Rm+1)=0.736
Rm=2.8
R=1.25*Rm=3.5

R/R+1 =0.777

Nm/N=0.3885
N=30

Feed plate location

Nr/Ns=0.875
Ns+Nr=30
Nr=14(Above the Feed)
Ns=16(Below the Feed)
D=26.5691kMol/hr
B=231.74 kMol/hr

Step 5: Slope of operating line & density calculation

Calculation of non-key flows

Rectifying section

Components i di li=di/(i-1) vi=li+di

Butane 15.18396413 0.8063 0.056845885 0.863145885

Iso-Pentane 7.551118492 0.4063 0.062019944 0.468319944

N-Pentane 5.926993418 0.02271 0.004609302 0.027319302

CycloPentane 3.737642752 0 0 0

2,2-Dimethylbutane 4.134494153 0 0 0

2,3-Dimethylbutane 3.377474718 0 0 0

2-Methylpentane 5.832623923 0 0 0

3-Methylpentane 2.921144483 0 0 0

N-hexane 2.262789359 0 0 0

Methyl 2.475798088 0 0 0
CycloPentane

cyclohexane 1.722422461 0 0 0

Heptane 1 0 0 0

Hydrogen 5998.308345 11.36 0.001894183 11.36189418

Methane 547.3310306 2.027 0.003710205 2.030710205

Ethane 129.1349777 1.6895 0.013185315 1.702685315

Propane 43.34233287 5.3535 0.126433752 5.479933752

i-Butane 20.58877235 4.9017 0.250230076 5.151930076

Li = 0.5189 kmol/hr

Vi= 27.085kmol/hr
Stripping section

Components i bi vi' li'=bi+vi'

Butane 15.18396 0.982 12.26169 13.24369

Iso-Pentane 7.551118 23.037 19.65843 42.69543

N-Pentane 5.926993 10.21 5.77815 15.98815

CycloPentane 3.737643 1.86 0.54903 2.40903

2,2- 4.134494 60.78 20.48791 81.26791

Dimethylbutane

2,3- 3.377475 19.88 5.156004 25.036

Dimethylbutane

2-Methylpentane 5.832624 55.89 30.84828 86.73828

3-Methylpentane 2.921144 29.87 6.473442 36.34344

N-hexane 2.262789 16.95 2.713002 19.663

Methyl 2.475798 10.47 1.861622 12.33162

CycloPentane

cyclohexane 1.722422 10.4 1.220446 11.62045

Heptane 1 12.39 0.804545 13.19455

Hydrogen 5998.308 13.04 1.456 14.496

Methane 547.331 0.099 3.457 3.556

Ethane 129.135 0.0911 4.56943 4.66053

Propane 43.34233 0.2539 9.5833 9.8372

i-Butane 20.58877 0.4134 5.54833 5.96173

Li = 399.043kmol/hr

Vi = 132.42kmol/hr

Flows rates of combined keys:

L = R*D-Li
 =72.96kmol/hr

V = (R+1)*D - Vi
=92.435kmol/hr

L=(R+1)D-Li
=306.56kmol/hr

V=(R+1)*D-Vi
=109.46kmol/hr

Slope of upper operating line

= L/ V = 0.782

Slope of bottom operating line

= L/ V = 2.8

Top Density and surface tension:

v = 2.57 kg/m3
l = 650.35 kg/m3

= 0.015 N/m
Bottom Density and surface tension:
v= 2.23 kg/m3
l = 784.56 kg/m3
= 0.0177 N/m

Step 6: Plate Design

Column Diameter = 2.27 m

Column Area, Ac = 4.0486 m2
Downcomer Area
Ad = 0.12 * 4.0486
= 0.486 m2
Net Area, An = Ac - Ad
= 3.56 m2
Active Area = Aa = Ac - 2Ad
= 3.076 m2
Hole Area (Take 10% Aa as first trial)
An = 0.3076 m2
Weir length = 0.76 * 2.27
= 1.725 m
Take, Weir height =50 mm
Hole Diameter = 5 mm
Plate thickness = 5 mm

DESIGN OF DEHEXANIZER
Composition:

Components 14 15 16 2

Butane 0.982184 0.134079 0 0

Iso-Pentane 23.03792 19.84468 0 0

N-Pentane 10.21014 8.195523 0 0

CycloPentane 1.860439 1.768616 0 0

2,2-Dimethylbutane 60.78118 55.34947 0.001508 0.918778

2,3-Dimethylbutane 19.88122 10.37917 0.06921 8.593536

2-Methylpentane 55.89082 20.95249 0.33577 29.88831

3-Methylpentane 29.87209 4.87894 0.575605 20.8624

N-hexane 16.95423 0.219529 1.402467 14.55669

Methyl CycloPentane 10.47053 0.073093 1.753769 8.197122

cyclohexane 10.40658 0 4.029237 4.593901

benzene 0 0 0 0

heptane 12.39836 0 6.910918 2.549132

Hydrogen 13.04934 0 0 0

Methane 0.09936 0 0 0

Ethane 0.091138 0 0 0

Propane 0.253997 0 0 0

i-Butane 0.413431 0.170626 0 0

Step 2: Determination of Relative Volatilities

The following table gives the value of relative volatilities of the compounds at an average of
temperature of top and bottom.

Components ktop kbottom top bottom avg

Butane 3.56 7.54 18.83598 11.54671 15.19134

Iso-Pentane 1.673 4.09 8.851852 6.2634 7.557626

N-Pentane 1.341 3.1157 7.095238 4.771363 5.933301

CycloPentane 0.751 2.289 3.973545 3.50536 3.739452

2,2-Dimethylbutane 0.8859 2.3442 4.687302 3.589893 4.138597

2,3-Dimethylbutane 0.708 1.9667 3.746032 3.011792 3.378912

2-Methylpentane 0.668 1.861 3.534392 2.849923 3.192157

3-Methylpentane 0.61 1.707 3.227513 2.614089 2.920801

N-hexane 0.49 1.254 2.592593 1.920368 2.25648

Methyl 0.534 1.39 2.825397 2.128637 2.477017

CycloPentane

cyclohexane 0.374 0.957 1.978836 1.465544 1.72219

heptane 0.189 0.653 1 1 1

Hydrogen 1758.88 1766.88 9306.243 2705.789 6006.016

Methane 147.74 205.2 781.6931 314.242 547.9675

Ethane 32.44 56.72 171.6402 86.86064 129.2504

Propane 10.38 20.789 54.92063 31.83614 43.37839

i-Butane 4.789 10.37 25.33862 15.88055 20.60959

Step 3: Determination of Reflux Ratio

Here, q=0.937
On Solving, = 5.3

Rm + 1 = 2.4
Rm = 1.4
So, actual R is:
R=1.25*Rm=1.75

Step 4: Determination of Number of stages

Nm=25.4
Rm/(Rm+1)=0.583
Rm=1.4
R=1.25*Rm=1.75

R/R+1 =0.6363

Nm/N=0.31841
N=80

Feed plate location

Nr/Ns=0.0.4545
Ns+Nr=80
Nr=25(Above the Feed)
Ns=55(Below the Feed)
D=121.96kMol/hr
B=15.079 kMol/hr

Step 5: Slope of operating line & density calculation

Calculation of non-key flows

Rectifying section

components i di li=di/(i-1) vi=li+di

Butane 15.19134317 0.134 0.009442376 0.143442376

Iso-Pentane 7.557625773 19.84 3.025485242 22.86548524

N-Pentane 5.933300518 8.19 1.660146178 9.850146178

CycloPentane 3.739452426 1.768 0.645384451 2.413384451

2,2-Dimethylbutane 4.138597195 55.34 17.63208101 72.97208101

2,3-Dimethylbutane 3.378911738 10.37 4.359136084 14.72913608

2-Methylpentane 3.192157482 20.94 9.552233436 30.49223344

3-Methylpentane 2.920801024 4.87 2.535400564 7.405400564

N-hexane 2.256480064 0.219 0.174296438 0.393296438

Methyl 2.477016943 0.073 0.049423942 0.122423942

CycloPentane

cyclohexane 1.722189812 0 0 0

Heptane 1 0 0 0
Hydrogen 6006.016027 0 0 0

Methane 547.9675409 0 0 0

Ethane 129.2504274 0 0 0

Propane 43.3783879 0 0 0

i-Butane 20.60958782 0.1706 0.008699826 0.179299826

Li = 39.65 kmol/hr

Vi = 161.56kmol/hr

Stripping section

Components i bi vi' li'=bi+vi'

Butane 15.19134 0 0 0

Iso-Pentane 7.557626 0 0 0

N-Pentane 5.933301 0 0 0

CycloPentane 3.739452 0 0 0

2,2-Dimethylbutane 4.138597 0.0015 0.000506 0.002006

2,3-Dimethylbutane 3.378912 0.069 0.017905 0.086905

2-Methylpentane 3.192157 0.335 0.080965 0.415965

3-Methylpentane 2.920801 0.575 0.124596 0.699596

N-hexane 2.25648 1.402 0.223677 1.625677

Methyl 2.477017 1.753 0.311874 2.064874

CycloPentane

cyclohexane 1.72219 4.029 0.472734 4.501734

Heptane 1 0 0 0

Hydrogen 6006.016 6.91 1.456 8.366

Methane 547.9675 0 3.457 3.457

Ethane 129.2504 0 4.56943 4.56943

Propane 43.37839 0 9.5833 9.5833

i-Butane 20.60959 0 5.54833 5.54833

Li = 40.92kmol/hr

Vi = 25.84kmol/hr

Flows rates of combined keys:

L = R*D-Li
=143.78kmol/hr

V = (R+1)*D - Vi
=173.89kmol/hr

L=(R+1)D-Li
=494.47kmol/hr

V=(R+1)*D-Vi
=208.56kmol/hr

Slope of upper operating line

= L/ V = 0.826

Slope of bottom operating line

= L/ V = 2.375

Top Density and surface tension:

v = 1.57 kg/m3
= 550.35 kg/m3

= 0.015 N/m
Bottom Density and surface tension:
v= 2.23 kg/m3
= 784.56 kg/m3
= 0.0177 N/m
Step 6: Plate Design

Column Diameter = 2.87 m

Column Area, Ac = 3.9486 m2
Downcomer Area
Ad = 0.12 * 4.0486
= 0.546 m2
Net Area, An = Ac - Ad
= 2.66 m2
Active Area = Aa = Ac - 2Ad
= 1.576 m2
Hole Area (Take 10% Aa as first trial)
An = 0.2076 m2
Weir length = 0.76 * 2.27
= 1.725 m
Take, Weir height =50 mm
Hole Diameter = 5 mm
Plate thickness = 5 mm