Integrated Design Initiative

2nd Year
Semester II, Academic Session 2016-2017

Brief Description

The purpose of this initiative is to develop the students generic skills and ability to integrate all
phases of a design project. These include problem formulation, feasibility study including
geotechnical assessment of the site, conceptual design including architectural plans, preparation
of design specifications, timelines, construction schedules, design options such as choice of
material and structural form, load estimation, analysis including manual and computational
methods via IT tools, the design of structural elements, process control and automation elements,
process optimization, safety elements and sustainability issues.

The integrated design initiative span from the course taught in Semester 1, first year until
Semester 2, 3rd year. The elements of process design are embedded in selected courses from 1st
year until 3rd year.

Project Topic

Production of Dimethyl Ether (DME)

Objective

To design the appropriate heat transfer unit assigned from the available process parameters and
conditions.

Outcomes

Able to
Understand the process flow of the process from raw materials to production of DME
Identify process components and conditions for all the streams in the system
Identify available heat transfer units in the process
Identify the important process design parameters required in designing a heat transfer unit
Apply the basic design methods in designing a heat transfer unit
Design the assigned heat transfer unit

1

Tasks

Based on the information given below:

1. Identify and list all the heat exchanger units available in the chemical plant.
2. Based on the given process flow diagram (PFD) and process flowsheet, redraw the
process flow diagram in block diagram formats with proper stream flows. Label each of
the block diagrams to its appropriate units of operation and its tagging number. List down
all the components (and its phases), process conditions and mass or volumetric flow rates
of all the streams available in the PFD.
3. Accordingly, design the heat exchanger unit assigned to your group based on all the
information given below.
3.1 Draw a schematic diagram of the heat exchanger unit and label the equipment and
streams accordingly (with its process components and process conditions)
3.2 Calculate the heat transfer area required and the rate of heat transfer to satisfy the heat
transfer requirement.
3.3 Suggest the appropriate type of heat exchanger and its configuration for your assigned
unit.
3.4 Approximate the total size of your unit based on your calculations in (3.2) and (3.3).

2

 DIMETHYL ETHER PRODUCTION

1.0 Manufacturing Routes

Synthesis of DME through 2 step process/Indirect method

In brief the synthesis of DME through 2 step process consists of 3 reaction steps which are
methanol synthesis reaction, dehydration of methanol and shift reaction. Without the shift
reaction, the reaction can be carried out through the reaction (d) which is theoretical obtained
by combining reaction (a) and (b). Due to the reason that methanol synthesis encourages the
shift reaction (c), the total reaction is likely to precede either reaction (d) or (e).

The total reaction is highly exothermic; thus, the excess reaction heat must be removed
efficiently and the reaction temperature must be controlled carefully in order to avoid the
deactivation of the catalyst used.

Table 1: Reaction of DME Synthesis and its reaction heat

Reaction Reaction heat (kcal/mol-DME)
(a) 2CO+4H22CH3OH 1. methanol synthesis +43.4
(b) 2CH3OHCH3OCH3+H2O 2. dehydration of methanol +5.6
(c) CO+H2OCO2+H2 3. shift reaction +9.8
(d) 3CO+3H2CH3OCH3+CO2 4. possibly total reaction 1 +49.0
(e) 2CO+4H2CH3OCH3+H2O 5. possibly total reaction 2 +58.8

3

 1.1 Process Flow Diagram

M-101 C-101 E-101 R-101 E-102 T-101 C-102 E-103

Syngas feed mixer Syngas feed compressor Syngas feed condenser Methanol synthesis reactor Methanol condenser Methanol separation Column Recycle syngas compressor Methanol heater

11

35 30
30
38 25
25

12
10 9 Flare
C-102

8 30
25

Notes
Pressure
25 50 Temperature
1 100

CO/CO2 1 7 Stream No

25 25 80
1 1
5
60
E-102

167 50
T-101
H2 2 3
60 250

4 6
C-101 R-101

30
E-101 12
25

60 E-106
80

14

21 MeOH
30
80
DME 66
10
13
10
17
30

R-102 T-103
E-103 P-101
50 15
15 50
250 40 20
100

16

10 10
30 40 96
E-104 15
18 19
T-102 22 Water

E-105 P-102 E-107

E-103 P-101 R-102 E-104 T-102 E-105 P-102 T-103 E-106 E-107
Methanol feed heater Centrifugal pump DME synthesis reactor DME cooler DME separation column Unreacted Methanol heater Centrifugal pump Methanol distillation column Condenser Reboiler
DME Plant
Drawn By: Mohamad Nasrul Hadi
Check By:
Approved By:
Date: 4th April 2010
Revision:

4

 1.2 Flowsheets of Temperature, Pressure and Phase Change Condition

From
C-102

35 bar
o
H2 25 C
1 bar C-101
o
25 C Phase,
Pressure & Syngas R-101 CH3OH E-102
M-101 60 bar E-101 50 bar
1 bar Temperature (H2 & CO) Temperature Syngas Temperature
No change o Temperature
25 C change &Pressure change
167 C
o change o
100 C
60 bar change 50 bar
o
CO
o
80 C 250 C
1 bar
o Continue
25 C
to T-101

Recycle C-102
syngas to Pressure & Purge
M-101 35 bar Temperature 30 bar Syngas
o change o
38 C 25 C 30 bar
o
25 C

CH3OH T-101
Continue Syngas Temperature&
from E-102 Pressure
50 bar change
o
100 C

30 bar Continue
to E-103
o
25 C

5

 CH3OH
30 bar
o
25 C E-103 CH3OH P-101 CH3OH R-102 E-104
Temperature & 50 bar 50 bar
Temperature Temperature o
Temperature o
100 C
Continue change 30 bar change 60 bar Pressure 250 C change
from o
80 C
o
80 C change
T-101
Continue to
T-102

CH3OCH3
E-106
10 bar Temperature
o
30 C change
1 bar
o
T-102 76 C
CH3OH
Temperature
CH3OCH3 CH3OH
and pressure 15 bar
change o T-103
50 bar 30 C 1 bar
o Temperature & o
100 C 66 C
Pressure
change
Continue
from E-105
H 2O
CH3OH E-105 CH3OH P-102 E-107
Temperature Temperature Temperature
change change change 1 bar
10 bar 10 bar 1 bar o
99 C
o o o
30 C 40 C 95 C

6

 1.3 List of Heat Exchangers in PFD with Justifications

Equipment Materials of Operating Purpose/ Orientation Justifications or special feature

construction conditions usage
E-101 Carbon Steel Ti=167oC to reduce Horizontal It is a shell and tube heat exchanger.
Syngas Feed To = 80oC temperature It is used to reduce temperature of the
Cooler P = 60 bar of the syngas syngas
from syngas It is preferred as it is easier to be cleaned. (
feed Max S. Peters & Klause D. Timmerhaus,
compressor 1991)
E-102 Carbon Steel Ti=250oC - to reduce Horizontal It is a shell and tube heat exchanger.
Methanol To = 100oC temperature It is used to reduce temperature of the
Feed Cooler P = 50 bar of the methanol
methanol It is preferred as it is easier to be cleaned.
from (Max S. Peters & Klause D. Timmerhaus,
methanol 1991)
synthesis
reactor
E-103 Carbon Steel Ti = 25oC - to increase Horizontal It is used to increase the non-corrosive
Methanol To = 80oC temperature streams which flow out from methanol flash
Heater P = 30 bar of methanol drum
from It is preferred as it is easier to be cleaned.
methanol (Max S. Peters & Klause D. Timmerhaus,
flash drum 1991)
It is use to increase temperature of the
methanol
E-104 Carbon Steel Ti = 250oC - to reduce Horizontal It is used to increase the non corrosive
DME Cooler To= 100oC temperature streams which flow out from DME
P = 50 bar of DME synthesis reactor
from It is preferred as it is easier to be cleaned.
DME (Max S. Peters & Klause D. Timmerhaus,
synthesis 1991)
reactor It is use to reduce temperature of the DME

7

E-105 Carbon Steel Ti = 30oC - to increase Horizontal It is used to increase the non corrosive
Methanol To = 40oC temperature streams which flow out from DME flash
Heater P = 10 bar of methanol drum
from DME It is preferred as it is easier to be cleaned.
flash drum (Max S. Peters & Klause D. Timmerhaus,
1991)
It is use to increase temperature of the
methanol
E-106 Stainless Steel Ti = 76oC - to heat and Horizontal The top product of distillation column T-103
Condenser To = 66oC evaporate is condensed by cooling water stream
P = 1 bar the top The product stream that enters the shell side
product contains corrosive concentration of methanol
which is It is chosen as it is easier to clean and suitable
methanol for fouling liquids (Max S. Peters & Klause
from D. Timmerhaus, 1991)
methanol It can be also be used for high temperature
distillation and pressure
column
E-107 Stainless Steel Ti = 95oC - to heat and Horizontal It is a shell and tube heat exchanger type
Reboiler To = 99oC evaporate It is used with distillation column to vaporize
P = 1 bar the bottom a fraction of bottom product which is water
product Steam flows through the tube bundle and exits
which is as condensate
water from The tubes is submerged in a pool of water
the where boiling takes place
methanol It is less expensive than other types of reboiler
distillation if the bundle is installing in the column base
(Max S. Peters & Klause D. Timmerhaus,
1991)

8

2.0 Mass Balance and Energy Balance of Selected Heat Exchangers Unit and Other Related
Unit of Operations

2.1 Cooler (E-101)

178299.36
kg/hr 178299.36 kg/hr
167 OC 80OC
60 bar 60 bar

Stream No. Inlet Outlet

3 4
Mass flow rate (kg/hr) Carbon monoxide 115564.40 115564.40
Carbon dioxide 46225.76 46225.76
Hydrogen 16509.20 16509.20
Composition (mass %) Carbon monoxide 64.81 64.81
Carbon dioxide 25.93 25.93
Hydrogen 9.26 9.26
Molar flow rate (kmol/hr) Carbon monoxide 4127.30 4127.30
Carbon dioxide 1050.59 1050.59
Hydrogen 8254.6 8254.6
Temperature (oC) 167 80
Pressure (bar) 60 60
Enthalpy (kJ/kg) Carbon monoxide 10.90E6 32.35E6
Carbon dioxide 45.48E6 12.92E6
Hydrogen 196.61E6 59.14E6
Heat Duty (kJ/hr) -148.58E6

2.2 Cooler (E-102)

E-102
183358.8 183358.86 kg/hr
6 kg/hr 100OC
250OC 50 bar
50 bar

Stream No. Inlet Outlet
5 6
Mass flow rate (kg/hr) Carbon monoxide 46225.76 46225.76
Carbon dioxide 46225.76 46225.76
Hydrogen 6603.68 6603.68
Methanol 79245.44 79245.44
Water 5058.22 5058.22
Composition (mass %) Carbon monoxide 25.21 25.21
Carbon dioxide 25.21 25.21
Hydrogen 3.60 3.60
Methanol 43.22 43.22

9

 Water 2.76 2.76
Molar flow rate (kmol/hr) Carbon monoxide 5778.22 5778.22
Carbon dioxide 1050.59 1050.59
Hydrogen 3301.84 3301.84
Methanol 2476.42 2476.42
Water 281.01 281.01
Temperature (oC) 250 100
Pressure (bar) 50 50
Enthalpy (kJ/kg) Carbon monoxide 10.90E6 32.35E6
Carbon dioxide 45.48E6 12.92E6
Hydrogen 196.61E6 59.14E6
Methanol
Water
Heat Duty (kJ/hr) 48.58E6

2.3 Cooler (E-104)

84303.66
kg/hr
E-104
84303.66 kg/hr
25OC
80OC
30 bar
30 bar


Stream No. Inlet Outlet
11 12
Mass flow rate (kg/hr) Methanol 79245.44 79245.44
Water 5058.22 5058.22
Composition (mass %) Methanol 94 94
Water 6 6
Molar flow rate (kmol/hr) Methanol 2476.42 2476.42
Water 281.01 281.01
Temperature (oC) 25 80
Pressure (bar) 30 30
Enthalpy (kJ/kg) Methanol 2.5E3 16.62E6
Water 1.87E3 13.43E6
Heat Duty (kJ/hr) 30.05E6

2.4 Cooler (E-105)

84304.05 E-105
kg/hr 84304.05 kg/hr
250OC 100OC
50 bar 50 bar

Stream No. Inlet Outlet
14 15

10

 Mass flow rate (kg/hr) Methanol 7924.54 7924.54
Water 25117.36 25117.36
DME 51262.15 51262.15
Composition (mass %) Methanol 9.40 9.40
Water 29.79 29.79
DME 60.81 60.81
Molar flow rate (kmol/hr) Methanol 247.64 247.64
Water 1395.41 1395.41
DME 1114.39 1114.39
Temperature (oC) 250 100
Pressure (bar) 50 50
Enthalpy (kJ/kg) Methanol 0 16.62E6
Water 0 13.43E6
DME
Heat Duty (kJ/hr) 30.05E6

2.5 Heater (E-106)

33035.83 E-106
kg/hr 33035.83kg/hr
30OC 40OC
10 bar 10 bar

Stream No. Inlet Outlet

17 18
Mass flow rate (kg/hr) Methanol 7892.84 7892.84
Water 25117.36 25117.36
DME 25.63 25.63
Composition (mass %) Methanol 23.89 23.91
Water 76.03 76.09
DME 0.08 0.08
Molar flow rate (kmol/hr) Methanol 245.16 245.16
Water 1395.41 1395.41
DME 11.14 11.14
Temperature (oC) 30 40
Pressure (bar) 10 10
Enthalpy (kJ/kg) Methanol 0 16.62E6
Water 0 13.43E6
DME - -
Heat Duty (kJ/hr) 30.05E6

11

 2.6 Methanol Flash Drum (T-101)

98467.39 kg/hr (purge +recycle)

25OC
30 bar

183358.86 kg/hr
100OC
50 bar

84303.66 kg/hr
25OC
30 bar

Stream No. Inlet Outlet

6 8(purge) 9(recycle)
Mass flow rate (kg/hr) Carbon monoxide 46225.76 4622.58 41603.18
Carbon dioxide 46225.76 4022.98 41602.97
Hydrogen 6603.68 661.57 5954.11
Methanol 79245.44 79245.44 (11)
Water 5058.22 5058.22 (11)
Composition (mass %) Carbon monoxide 25.21 49.66 46.66
Carbon dioxide 25.21 43.22 46.66
Hydrogen 3.60 7.12 6.68
Methanol 43.22 94
Water 2.76 6
Molar flow rate Carbon monoxide 5778.22 165.09 1485.83
(kmol/hr) Carbon dioxide 1050.59 91.43 945.52
Hydrogen 3301.84 330.79 2977.06
Methanol 2476.42 2476.42
Water 281.01 281.01
Temperature (oC) 100 25 25
Pressure (bar) 50 30 30
Enthalpy (kJ/kg) Carbon monoxide 32.35E6 0 0
Carbon dioxide 12.92E6 0 0
Hydrogen 59.14E6 0 0
Methanol 6.385E6 0 0
Water 462.45E6 0 0
Heat Duty (kJ/hr) 73.245E6

12

 2.7 Pump (P-101)

84303.66 kg/hr 84303.66 kg/hr

80OC 80OC
30 bar 60 bar

Stream No. Inlet Outlet

12 13
Mass flow rate (kg/hr) Methanol 79245.44 79245.44
Water 5058.22 5058.22
Composition (mass %) Methanol 94 94
Water 6 6
Molar flow rate (kmol/hr) Methanol 2476.42 2476.42
Water 281.01 281.01
Temperature (oC) 80 80
Pressure (bar) 30 60
Enthalpy (kJ/kg) Methanol 0 16.62E6
Water 0 13.43E6
Heat Duty (kJ/hr) 30.05E6

2.8 Methanol Distillation Column (T-103)

7899.35 kg/hr
33035.83kg/hr 66 OC
30 OC 1 bar
10 bar

25142.42 kg/hr
99 OC
1 bar

Stream No. Inlet Outlet

19 20 21
Mass flow rate Methanol 7892.84 7899.35 -
(kg/hr) Water 25117.36 - 25116.79
DME 25.63 - 25.63
Composition Methanol 23.91 100 -
(mass %) Water 76.09 - 100
DME 0.08 - -
Molar flow rate Methanol 246.65 245.42 1.23

13

 (kmol/hr) Water 1395.41 6.98 1388.43
DME 11.14 11.14 -
Temperature (oC) 30 66 99
Pressure (bar) 10 1 1
Enthalpy (kJ/kg) Methanol 0.73E6 1.25E6 -
Water 3.04E6 - 9.99E6
DME - - -
Heat Duty (kJ/hr) 17.83x103

14