Design of a 90 MTPD Methanol Production Plant

May, 2023

A design project submitted to the Department of Chemical Engineering, BUET in

partial fulfillment of the requirements of the degree of Bachelor of Science in
Chemical Engineering

Submitted By

Abir Podder (1702009)

Mahmudur Rahman (1702017)
Bimol Nath Roy (1702026)
Bilash Devnath (1702056)

Supervised By
Dr. Nafisa Islam
Associate Professor
Department of Chemical Engineering

Bangladesh University of Engineering and Technology (BUET)

Dhaka, Bangladesh
 Acknowledgement

We would like to express our sincerest gratitude to our supervisor Dr. Nafisa Islam,
Associate Professor, Department of Chemical Engineering, BUET, for her constant
guidance and supervision of our works throughout the course. Her inception, skill,
patience and care helped us to finish this work.

We would also like to thank our other teachers for their valuable insights regarding
process design.

i
 Abstract

In terms of various applications in the modern world, methanol holds significant

importance as a chemical. It is widely used across the world, including Bangladesh,
where its usage is experiencing a growth parallel with industrial development. A 90
MTD methanol plant is to be built in Anwara, Chittagong, Bangladesh, with a working
day of 330 days. The primary raw materials for this plant will be liquefied natural gas
(LNG) imported from Qatar. A comprehensive project description was provided,
establishing the design basis to be aligned with climatic conditions, soil characteristics,
socio-economic factors, and existing environmental regulations. The material and
energy balance were conducted for the entire process. Sizing of all equipment were
followed by relevant codes and standards, and detailed mechanical designs for four
equipment units, accompanied by piping and instrumentation diagrams, were
thoroughly prepared.

ii
 Table of Contents

Acknowledgement .......................................................................................................... i

Abstract ..........................................................................................................................ii

Table of Contents ......................................................................................................... iii

List of Tables ...............................................................................................................vii

List of Figures ............................................................................................................ viii

Chapter 01: Introduction ................................................................................................ 1

Chapter 02: Project Definition ....................................................................................... 4

2.1 Definition of the Project....................................................................................... 4

2.2 Raw Material Specifications and Source ............................................................. 4

2.3 Product Specification ........................................................................................... 4

2.4 Plant Location and Area....................................................................................... 5

Chapter 03: Design Basis ............................................................................................... 6

3.1 Geological Data ................................................................................................... 6

3.2 Meteorology ......................................................................................................... 6

3.2.1 Ambient Temperature ................................................................................... 6

3.2.2 Atmospheric Pressure ....................................................................................... 6

3.2.3 Humidity ....................................................................................................... 6

3.2.4 Wind .............................................................................................................. 6

3.3 Utility Conditions................................................................................................. 7

3.3.1 Water Quality ................................................................................................ 7

3.3.2 Air Quality .................................................................................................... 7

3.4 Climate Conditions .............................................................................................. 7

3.4.1 Ambient Conditions in Summer ................................................................... 7

3.4.2 Ambient Condition in winter ........................................................................ 7

3.5 Developing Constrains ......................................................................................... 8

iii
Chapter 04: Selection of Process ................................................................................... 9

4.1 Process Selection ................................................................................................. 9

4.2 Process Description ............................................................................................ 10

4.2.1 Regasification and Compression of LNG ................................................... 10

4.2.2 Syngas Production (Primary and Secondary Reformer) ............................. 10

4.2.3 Methanol Synthesis ..................................................................................... 11

4.2.4 Methanol Purification - Low-End and High-End Distillation Column ...... 12

Chapter 05: Environmental Assessment ...................................................................... 14

5.1 Hazard Analysis ................................................................................................. 14

5.2 Environmental Effect ......................................................................................... 15

Chapter 06: Process Block Diagram (PBD)................................................................. 17

Chapter 07: Process Flow Diagram (PFD) .................................................................. 18

Chapter 08: Material and Energy Balance ................................................................... 19

8.1 Re-gasifier (E-101) ............................................................................................ 19

8.2 Split into Feed and Fuel NG .............................................................................. 20

8.3 Mixing (Feed NG and Steam) ............................................................................ 21

8.4 Compressor (C-101)........................................................................................... 22

8.5 Heat Exchanger (E-102) .................................................................................... 23

8.6 Primary Reformer (R-101) ................................................................................. 24

8.7 Secondary Reformer (R-102) ............................................................................. 26

8.8 Heat Exchanger (E-103) .................................................................................... 28

8.9 Waste Heat Boiler .............................................................................................. 29

8.10 Compressor (C-102)......................................................................................... 30

8.11 Cooler (E-104) ................................................................................................. 31

8.12 Flash Separator (V-101)................................................................................... 32

8.13 Compressor (C-103)......................................................................................... 33

8.14 Mixing of Recycle with Reactor Feed ............................................................. 34

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 8.15 Methanol Synthesis Reactor (R-103) ............................................................... 35

8.16 Heat Exchanger (E-105) .................................................................................. 36

8.17 Cooler (E-106) ................................................................................................. 37

8.18 Flash Separator (V-102)................................................................................... 38

8.19 Purge Splitter ................................................................................................... 39

8.20 Light End Distillation Column (T-101) ........................................................... 40

8.21 Cooler (E-107) ................................................................................................. 41

8.22 Heavy End Distillation Column (T-102) ......................................................... 42

Chapter 09: List of Equipment and Sizing ................................................................... 43

9.1 Major Equipment List and Sizing ...................................................................... 43

9.2 List of Auxiliaries, Offsites and Package Units ................................................. 44

9.2.1 Auxiliary and offsite facilities .................................................................... 44

9.2.2 Package Unit ............................................................................................... 44

Chapter 10: Process Licensor and Vendor List............................................................ 45

10.1 Process Licensor .............................................................................................. 45

10.2 Vendor List ...................................................................................................... 45

Chapter 11: Detailed Design of Heavy End Distillation Column ................................ 46

Chapter 12: Detailed Design of Flash Separator.......................................................... 74

Chapter 13: Detailed Design of Primary Reformer ..................................................... 94

Chapter 14: Detailed Design of Methanol Synthesis Reactor ................................... 108

Chapter 15: Economic Analysis................................................................................. 125

15.1 Estimation of Total Capital Investment ......................................................... 125

15.2 Determination of Operating Cost ................................................................... 127

15.3 Determination of Revenues............................................................................ 129

15.4 Calculation of Depreciation Cost by Sinking Fund Method .......................... 129

15.5 Net Income Calculation ................................................................................. 129

15.6 Cash Flow Diagram ....................................................................................... 129

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 15.7 Feasibility Analysis ........................................................................................ 130

Chapter 16: Plant Layout and Equipment Layout...................................................... 133

16.1 Plant Layout ................................................................................................... 133

16.2 Equipment Layout .......................................................................................... 133

References .................................................................................................................. 134

Appendices ................................................................................................................. 136

Appendix A: MATLAB Code for MSR ................................................................ 136

Workload Distribution ............................................................................................... 138

vi
 List of Tables

Table 1:Raw material composition ................................................................................ 4

Table 2: IMPCA reference specification ....................................................................... 5
Table 3: Major water properties of Karnaphuli river water ........................................... 7
Table 4: Hazard analysis of chemicals in Methanol plant ........................................... 14
Table 5: Design Parameter for High End Distillation Column (T-102) ...................... 67
Table 6: Kinetic parameters equations for the rate equations [1] .............................. 109
Table 7: Kinetic parameters values for the rate equations ......................................... 110

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 List of Figures

Figure 1: Historical construction of methanol production [2] ....................................... 2

Figure 2: Methanol production expressed in MM ton per year of production from 1975
to 2016 ........................................................................................................................... 2
Figure 3: Process Block Diagram of the Methanol Plant ............................................ 17
Figure 4: Process flow diagram of the methanol plant ................................................ 18
Figure 5: Chart for estimating values of Csb (±10%) .................................................. 50
Figure 6: Side View of Distillation Column ................................................................ 68
Figure 7: Top View of Distillation Column ................................................................. 69
Figure 8: Side View of Sieve Tray .............................................................................. 69
Figure 9: Top View of Sieve Tray ............................................................................... 70
Figure 10: Side View of Skirt Support ........................................................................ 70
Figure 11: Piping and Instrumentation Diagram for Distillation Column ................... 71
Figure 12: Front View of Flash Separator ................................................................... 89
Figure 13: Cross Sectional View of Flash Separator ................................................... 90
Figure 14: P&ID of Flash Separator ............................................................................ 91
Figure 15: Front sectional view of PRF ..................................................................... 104
Figure 16: Top view of PRF ...................................................................................... 104
Figure 17: P&ID for PRF ........................................................................................... 105
Figure 18: Molar Flow rate of Methanol vs Weight of Catalyst................................ 111
Figure 19: Detailed design of methanol synthesis reactor ......................................... 122
Figure 20: Cross section of shell with tube bundle inside and their dimensions ....... 123
Figure 21: P&ID of the methanol synthesis reactor................................................... 124
Figure 22: Sensitivity analysis for the Cash flow of Methanol production plant ...... 132
Figure 23: Plant layout ............................................................................................... 133
Figure 24: Equipment Layout .................................................................................... 133

viii
 Chapter 01: Introduction

Over the last century, fossil fuels and natural gases have been our primary energy
sources. Unfortunately, these resources are nonrenewable and thus scarce. This causes
volatility in the global market, which in turn causes volatility in fuel prices. Fossil fuels
are primarily responsible for greenhouse gas (GHG) emissions such as CO2, CH4 and
N2O are greenhouse gases that contribute to global warming. Nowadays, the main
competitors appear to be methanol. Methanol can be utilized as a handy energy carrier
for hydrogen storage and transit, as an easily transportable fuel, and as a solvent and
C1 building block in the chemical industry to produce intermediates and synthetic
hydrocarbons such as polymers and single-cell proteins. For all these reasons, methanol
is considered to be the transition molecule from fossil fuels to renewable energies.

Methanol, or methyl alcohol, is an organic compound, CH3OH, with a molecular

weight equal to 32.042 g/mole. It is only slightly soluble in fat and oil and represents
one of the most important chemical raw materials. Indeed, the primary use of methanol
is in the chemical industry, as either a feedstock, solvent, or cosolvent. Methanol
appears as a colorless fairly volatile liquid with a faintly sweet pungent odor like that
of ethyl alcohol. Completely mixes with water. The vapors are slightly heavier than air
and may travel some distance to a source of ignition and flash back. Any accumulation
of vapors in confined spaces, such as buildings or sewers, may explode if ignited. Used
to make chemicals, to remove water from automotive and aviation fuels, as a solvent
for paints and plastics, and as an ingredient in a wide variety of products.
Approximately 65% of the methanol produced worldwide is consumed to produce
acetic acid, methyl and vinyl acetates, methyl methacrylate, methylamines, methyl-tert
butyl ether (MTBE), fuel additives, and other chemicals. The remaining portion is
converted into formaldehyde and the resulting products [1].

The most amazing and promising application of methanol is probably its use as a fuel.
Methanol is often blended with gasoline in many countries to improve performance.
Around the world, fossil fuel storage is rapidly depleting. Furthermore, fossil fuel is
directly responsible for Pollution of the environment Methanol, on the other hand, is a
clean fuel with a higher efficiency than gasoline. conventional fuels and more suitable
for engine longevity Furthermore, our fuel stations are easily accessible. be transformed
into methanol stations as a result, the use of methanol as a clean fuel is increasing.
1
 Figure 1: Historical construction of methanol production [2]

Before the development of the modern industrial era, methanol, also called wood spirit,
was prepared by wood heating in anaerobic condition. The wood distillation process
provided an extract that contained many impurities besides methyl alcohol. The process
was improved in the 1660s by scientist Sir Robert Boyle. He carried out a purification
of the extract, called wood vinegar, by a reaction with milk of lime (an aqueous
suspension of calcium hydroxide). However, this was not marketed for about two
centuries. The exact composition of the wood vinegar remained unknown until the
1800s, when J.V. Liebig and J.B.A. Dumas independently identified the methanol
molecule. The first breakthrough in methanol synthesis, however, came in 1923 from a
German company called Badische Anilin and Soda Fabrik (BASF). The BASF process
is a metal-based catalytic hydrogenation at high pressure developed by that company.
This technology began to be exported, and in 1927, it was introduced in the United
States by both DuPont and the Commercial Solvents Corporation. The BASF process
not only marked the beginning of industrial methanol production, but it also remained
the dominant technology for more than 45 years [2].

Figure 2: Methanol production expressed in MM ton per year of production from

1975 to 2016
2
Methanol began to be used in a variety of fields as industrial production increased. An
oil embargo imposed by the Organization of Petroleum Exporting Countries (OPEC) in
the United States and the Netherlands in 1973 heightened interest in methanol as a new
alternative automobile fuel. However, while these studies were ongoing, the United
States Clean Air Act was passed in 1990. This authorized the reduction of ozone and
carbon monoxide emissions caused by methanol combustion. As a result, the use of
methanol as a fuel was prohibited. When it was discovered that methyl alcohol can also
be used as a fertilizer in agriculture for a wide range of products in the 1990s, market
demand increased once more. Today, global consumption of methyl alcohol is around
92Mt/year, and production has increased by about 1433% since 1975 [3].

3
 Chapter 02: Project Definition

2.1 Definition of the Project

A methanol plant with a daily production capacity of 90 metric tons of methanol and
an annual capacity of 27,000 metric tons of methanol with 300 working days is planned
to be set up at Anwara, Chittagong. LNG imported from Qatar will be used as the raw
material. With all the utilities, offices, and other facilities included, the factory will have
a land area of around 35 acres.

2.2 Raw Material Specifications and Source

Methane as raw material is availed from imported LNG (liquefied natural gas). The
government is negotiating with Qatar seeking long-term contracts for the import of
liquefied natural gas (LNG)[4] as prices have abnormally climbed in international spot
markets. Recently, the LNG prices in the spot markets have gone up so high that the
government finds it too much of an expense to accommodate, for which it was seeking
long-term contracts.

Table 1:Raw material composition [4]

Composition (%)
Source
CH4 C2H6 C3H8 C4 + N2 CO2

Qatar 96.91 2.37 0.44 0.15 0.13 0.00

2.3 Product Specification

Methanol product composition: 99.85 wt% or 99.73 mole%

Our product specification meets IMPCA (International Methanol Producers and

Consumers Association) defined specification. Most of the worldwide methanol sold is
also IMPCA specified product. The reference product specifications are given below-

4
Table 2: IMPCA reference specification

Test Unit Method Limits

Clear and free of
Appearance IMPCA 003-98
suspended matter
Purity on dry basis % W/W IMPCA 001-14 Min 99.85
Acetone mg/kg IMPCA 001-14 Max 30
Ethanol mg/kg IMPCA 001-14 Max 50
Colour Pt-Co ASTM D1209-11 Max 5
Water % W/W ASTM E1064-12 Max 0.100
Distillation Range at 760 Max 1.0 to include
℃ ASTM D1078-11
mm Hg 64.6° +/- 0.1°
Specific Gravity 20°/20° ASTM D4052-11 0.7910-0.7930
Potassium Permanganate
minutes ASTM D1363-11 Min 60
Time test at 15 ℃
Chloride as Cl - mg/kg IMPCA 002-98 Max 0.5
ASTM D 3961-98
Sulphur mg/kg Max 0.5
ASTM D 5453-12
Hydrocarbons ASTM D 1722-09 Pass test
Carbonisable Substances
(Sulfuric Acid Wash Pt-Co ASTM E 346-08 Max 30
Test)
Acidity as Acetic acid mg/kg ASTM D 1613-12 Max 30
Iron in solution mg/kg ASTM E 394-09 Max 0.10
Non-Volatile Matter mg/1000ml ASTM D 1353-13 Max 8

2.4 Plant Location and Area

Proposed industry is located at Anwara, an upazila of Chittagong district in the Division

of Chittagong, Bangladesh. It comprises the Korean Export Processing Zone (Korean
EPZ) and Chinese Economic and Industrial Zone (CEIZ). It is located at 22.2167°N
91.9111°E. It has 38,008 households and a total area of 164.13 km2

5
 Chapter 03: Design Basis

3.1 Geological Data

Load bearing capacity of soil: 0.38 ton/ft2

Corrosion tendency of soil: moderate

Basis for surface drainage system: yearly maximum rainfall condition

Seismic condition: maximum earthquake 6.5 in Richter scale

3.2 Meteorology

3.2.1 Ambient Temperature

Absolute maximum temperature: 39℃

Absolute minimum temperature: 15℃

3.2.2 Atmospheric Pressure

Annual average atmospheric pressure: 101.3 kPa

Maximum average atmospheric pressure 103.3 kPa

Minimum average atmospheric pressure 99 kPa

Design average atmospheric pressure 103.3 kPa

3.2.3 Humidity

Annual average relative humidity 80%

Maximum monthly average relative humidity: 95%

Minimum monthly average relative humidity: 65%

3.2.4 Wind

Wind direction: Generally, wind flows from north-east to south-east during winter and
from south to north during summer.

6
Wind velocity: 68 m/s, 10 m above ground level 88 m/s, 40 m above ground level This
high wind velocity occurs during cyclone.

3.3 Utility Conditions

3.3.1 Water Quality

The secondary data of Karnaphuli river water have been collected from BUET, CUET,
Environmental Science (CU), DU and BCSIR.

Table 3: Major water properties of Karnaphuli river water

Oil and
Temperature Chloride TDS COD Salinity
pH Grease
(℃) (ppm) (ppm) (ppm) (%)
(ppm)
7.21-
30.5-31.1 35 155 31 2.25 3.5
7.64

3.3.2 Air Quality

The concentration of Standard Particulate Matter (SPM) in industrial area is 250μg/m3,

which was significantly higher than the standard value. Due to site clearance/
preparation, construction activities, excavation, exhaust from construction
vehicles/machinery the air quality is degrading day by day.

3.4 Climate Conditions

3.4.1 Ambient Conditions in Summer

Maximum dry bulb temperature: 39℃

Maximum wet bulb temperature: 34℃

Minimum dry bulb temperature: 25℃

Minimum wet bulb temperature: 22℃

3.4.2 Ambient Condition in winter

Maximum dry bulb temperature: 21℃

7
Maximum wet bulb temperature: 16℃

Maximum relative humidity: 60%

Minimum dry bulb temperature: 10℃

Minimum wet bulb temperature: 7℃

Minimum relative humidity: 50%

Minimum dry bulb temperature: 10℃

Minimum wet bulb temperature: 7℃

Minimum relative humidity: 50%

3.5 Developing Constrains

1. Difficult communications in most areas because of long linear, hill ranges with
steep slopes. Roads are expensive to build and to maintain.
2. Low soil fertility especially in areas used for jhum cultivation.
3. Heavy monsoon rainfall.

8
 Chapter 04: Selection of Process

4.1 Process Selection

Synthesis of methanol can be achieved by mainly two approaches.

From synthesis gas (CO + H2): Production of methanol from the synthesis gas is the
most common and conventional way in the present world. Syn gas is produced by
reforming natural gas, coal or biomass with steam. This is the most profitable process
and most of the methanol industries in the world follow this process.

From the hydrogenation of CO2: In this process CO2 is captured from different
sources and reacted with H2. H2 is produced from the electrolysis of water. The energy
required for hydrolysis is supplied by using any renewable source of power. This is the
latest technology for the production of methanol and can be considered as a renewable
process [5].

In our problem, we followed the synthesis gas procedure to produce methanol.

Synthesis gas can be produced in various methods. By using catalytic methods such as
partial oxidation, steam reforming, and dry reforming of methane, synthesis gas is
produced from natural gas. In our case, we are using methane and steam to produce
steam gas. This method is also known as “Wet Reforming”.

According to the current scenario of our country, it is not feasible to production

methanol from the hydrogeneration of CO2. For this process, CO2 is to be extracted
from different source and H2 is to be produced from the hydrolysis reaction. Both of
these initial processes are very expensive and needs strict supervision. This process
might be a cleaner one, but for a developing country like Bangladesh it is not efficient
[6].

The steam reforming process is efficient enough in many aspects. It has a hydrogen
yield of more than 50%. This ensures a high ratio of syngas production (H2/CO = 3)
[7]. The process is endothermic, and the heat must be supplied to the reformer to
continue the reaction. The heat that is generated from the combustion of natural gas.
The exhaust gas from the combustion is used to preheat different process materials.
Hence, this process is energy efficient. Moreover, the process can go on smoothly
although it might be in a transient phase.

9
In case of dry reforming, methane reacts with CO2 to produce methanol. CO2 is
captured from different sources. This process yields a very low syngas ratio (H2/CO =
1) [8]. Besides, during the reforming process due to highly endothermic nature of the
reaction, coke is formed and deposited on the bed of catalyst. This decreases the activity
of the catalyst. Moreover, there is a significant rate of byproduct formation in this
process.

By taking all these things into consideration, steam reforming (wet reforming) is used
because these results in huge profits, lesser emission and greater efficiency.

4.2 Process Description

4.2.1 Regasification and Compression of LNG

The process of using and transporting liquefied natural gas (LNG) requires the step of
regasification. LNG stands for liquefied natural gas, which is natural gas that has been
cooled to a temperature of -162°C, at which point it turns into a liquid and can be
transported and stored more effectively. The LNG must be transformed back into a
gaseous state to be used for power production, industrial activities, or as a fuel for
automobiles, though, once it has arrived at its destination. This process is known as
regasification.

Regasification typically involves heating the LNG using seawater or other types of heat
exchangers. This process raises the temperature of the LNG, causing it to return to its
gaseous state. The gas is then sent through a series of compressors to increase its
pressure, making it suitable for storage or transport through pipelines.

4.2.2 Syngas Production (Primary and Secondary Reformer)

Syngas, or synthesis gas, is a mixture of carbon monoxide (CO) and hydrogen (H2) that
can be produced through a variety of methods, including the use of primary and
secondary reformers. The primary reformer is responsible for converting natural gas,
or other hydrocarbon feedstocks, into syngas by breaking down the hydrocarbons
through a process called steam methane reforming (SMR). The secondary reformer, on
the other hand, is used to further purify and increase the concentration of hydrogen in
the syngas.

10
The primary reformer, also known as the steam methane reformer (SMR), is the key
unit in the production of syngas. It is a large, high-temperature reactor that uses steam
and a catalyst to convert natural gas or other hydrocarbon feedstocks into a mixture of
CO and H2. The process takes place at high temperatures, typically between 800 and
1400 °C, and high pressures, typically between 30 and 60 bar. In the primary reformer,
natural gas is mixed with steam and passed over a catalyst, usually nickel, which
catalyzes the reaction between the methane and the steam to produce CO and H2. This
reaction is exothermic and produces a large amount of heat, which is used to generate
steam for the process. The syngas produced by the primary reformer contains CO, H2,
and various impurities such as CO2, N2, and CH4.

The Secondary reformer, also known as the shift converter, is used to purify and
increase the concentration of hydrogen in the syngas. It is a large, high-temperature
reactor that uses a catalyst to convert CO into CO2 and H2. The process takes place at
high temperatures, typically between 400°C and 600°C, and high pressures, typically
between 1 and 5 bar. In the secondary reformer, the syngas produced by the primary
reformer is passed over a catalyst, usually iron or cobalt, which catalyzes the reaction
between the CO and the steam to produce CO2 and H2. This reaction is also exothermic
and produces a large amount of heat, which is used to generate steam for the process.
The syngas produced by the secondary reformer contains CO, H2, and very low
impurities such as CO2, N2, and CH4.

4.2.3 Methanol Synthesis

Methanol synthesis is the process of converting syngas (a mixture of carbon monoxide

and hydrogen) into methanol. This process typically takes place in a methanol synthesis
reactor, which is a high-pressure and high-temperature reactor that uses a catalyst to
convert syngas into methanol. The process is typically carried out at a pressure of
around 30-60 bar and a temperature of around 180-220°C.

The primary reactant in the methanol synthesis process is syngas, which is typically
produced by steam methane reforming (SMR) or coal gasification. The syngas contains
a mixture of CO and H2, which are then converted into methanol in the methanol
synthesis reactor. The methanol synthesis reactor is typically a fixed-bed reactor, which
is filled with a catalyst, usually copper-chromium-zinc (Cu-Cr-Zn) or copper-zinc (Cu-
Zn) based. The syngas is then passed through the reactor, where it comes into contact
11
with the catalyst, which catalyzes the reaction between the CO and H2 to produce
methanol. The overall reaction can be represented by the following equation:

CO + 2H2 → CH3OH + Heat

The methanol synthesis reaction is exothermic, which means it produces heat, which
can be recovered and used to generate steam for the process. The methanol produced
by the methanol synthesis process is typically around 99% pure, and it is then cooled,
distilled, and further purified to remove any remaining impurities. The methanol
produced through the synthesis process can be used as a feedstock to produce various
chemicals, such as formaldehyde, acetic acid, and dimethyl ether. It can also be used as
a fuel for power generation, and as a feedstock to produce liquid fuels such as gasoline
and diesel.

4.2.4 Methanol Purification - Low-End and High-End Distillation Column

Methanol separation in a low-end distillation column involves the use of a distillation

process to separate methanol from a mixture of other compounds. The process begins
with the feed mixture being heated and vaporized, and then the resulting vapor is fed
into the distillation column. The column is designed with a series of trays or plates that
facilitate the separation of the components in the mixture based on their differences in
boiling points. As the vapor moves up the column, it meets the trays or plates, which
act as condensation and re-vaporization points. The more volatile components, such as
methanol, will condense and re-vaporize at the lower trays or plates, while the less
volatile components will condense and re-vaporize at the higher trays or plates.

The condensed liquid, or distillate, from the lower trays or plates will contain a high
concentration of methanol and is collected as the desired product. The liquid that does
not vaporize and remains on the trays or plates is known as the residue and typically
contains the less volatile components. In a low-end distillation column, the goal is to
separate methanol from other components with similar boiling points. This can be
achieved by carefully selecting the operating conditions, such as the temperature and
pressure, to ensure that the methanol is efficiently separated from the other components.
Additionally, the use of a high-performance distillation column, such as a packed
column or a plate column, can also improve the efficiency of the separation process.
Light components will be present in the distillation column's top product. Methanol and

12
other heavy substances will be present in the distillation column's bottom product. The
bottom product is fed to another distillation column to obtain the necessary composition
of methanol. Most of the methanol will be found in the top product of the second
distillation column.

13
 Chapter 05: Environmental Assessment

5.1 Hazard Analysis

Chemicals involved in methanol production plant –

• Raw Materials- CH4, C2H6 (in Natural Gas), Air, Steam

• Intermediate Products- CO, CO2, H2
• Product- CH3OH
• Catalysts- Ni
• Catalyst Promoter- Al2O3

Table 4: Hazard analysis of chemicals in Methanol plant

Components PEL/TLV LD50/LC50 Potential of fire

and explosion

CH3OH 200 ppm LD50 – Rat Fire and explosion

5600 mg/kg

CH4 1000 ppm Not classified Fire and explosion

C2H6 1000 ppm LC50 Inhalation - Fire and explosion

Rat 658 mg/l/4h

CO 25 ppm LC50 Inhalation - Fire and explosion

Rat 1880 ppm/4h

CO2 5000 ppm LC50 Inhalation Explosion

Human

49500 ppm/.5h

Steam Not Applicable LC50 Inhalation - Explosion

Rat 820000
ppm/4h

14
 H2 Asphyxiant Not Classified Fire and explosion

Ni 1.5mg/m3 LC50 – Fish Not Flammable

>100mg/L

Al2O3 15 mg/m3 LC50 - Rat Not Flammable

>5 mg/l/4h

Control Measures to be taken:

• Ventilate area or move container to a well-ventilated area. Flammable vapors

may spread from the leak and could explode if reignited by sparks or flames.
Explosive atmospheres may linger. Before entering the area, especially
confined areas.

• Check the atmosphere with an appropriate device. Prevent it from entering

sewers, basements, and work pits, or any place where its accumulation can be
dangerous.

• Use self-contained breathing apparatus where needed.

• Remove all sources of ignition if safe to do so.

• Reduce vapors with fog or fine water spray, taking care not to spread liquid with
water. Shut off flow if safe to do so.

5.2 Environmental Effect

Methanol does not pose a significant hazard for aquatic or terrestrial life, except in the
case of spillage. Contamination of soil, water, and the atmosphere can be avoided by
proper methods of storage, handling, transport, and waste disposal.

Human Hazard: Air emissions from diverse industrial and residential solvent use,
methanol production, end-product manufacturing, and bulk storage and handling losses
are the main sources of methanol exposure for the general public. Air pollution levels
in the general population are currently 10,000 times lower than occupational norms.
Methanol inhalation exposure at work is normally modest, although it can be higher in

15
less controlled environments. Ingestion of methanol-containing products, whether by
accident or on purpose, is associated with a high rate of illness and fatality.

Methanol irritates the eyes, skin, and lungs. Longer-term occupational exposure to
lower quantities of methanol has been linked to a variety of eye problems. Acute oral
and inhalation exposures to large quantities of methanol, as well as percutaneous
absorption to a lesser extent, have resulted in central nervous system depression,
blindness, coma, and death. Methanol contact with the skin on a regular or extended
basis can cause dermatitis. Methanol in liquid form defats the skin. It's a good extracting
solvent, but it can harm the skin's permeability barrier.

Fire Hazard: Methanol burns with an undetectable or mild blue flame and is highly
flammable. Heat, sparks, or flames can ignite methanol, and the vapor can travel to the
source of ignition and flash back.

There should be no ignition sources near methanol storage or consumption, such as

open fires, sparks, or smoking. Methanol should not come into contact with oxidants.
Methanol must be used and stored in cold, enclosed spaces with enough ventilation and
explosion-proof electrical and lighting equipment. Small fires can be fought with dry
chemicals, carbon dioxide, water spray, alcohol-resistant foam or, if these are not
available, by dilution with plenty of water. Large fires can be attacked with water spray,
fog, or alcohol-resistant foam. Water spray should be used to cool down containers in
the fire area.

Spillage and Disposal: Evacuate the hazardous area, collect the leaking liquid in
sealable containers, or construct a dike well ahead of the liquid spill to allow for later
disposal. Spilled liquids should be flushed with sufficient volumes of water, and run-
off should not be allowed to enter waterways directly. The liquid can be absorbed into
sand or vermiculite and transported into suitable containers for relatively small spills
(approximately 25 liters). The spillage place should be carefully cleaned with water.
Personnel should only visit the hazard area when absolutely necessary, wearing
protective clothing appropriate for the degree of spillage. Complete protective
equipment, including self-contained breathing apparatus, can provide further personal
protection.

16
 Chapter 06: Process Block Diagram (PBD)

Fuel NG Air, 5% Excess

Air
LNG 30℃, 1 atm
Re- 450℃, 1 atm
gasifier
30℃, 1 bar
Feed NG Wet Synthesis Gas
Synthesis Gas
Primary (10% CH4) (0.5 % CH4) Waste Heat
Preheated Secondary
Reformer Reformer Recovery
Steam at 450℃, 600℃, 15.5 bar 900℃, 15 bar
150℃, 1 bar 16 bar

Exhaust Gas, 420℃

Purge Recycle

Methanol Synthesis Dry Synthesis Wet Synthesis Gas

Reactor Gas (0.5 % CH4)
Flash Flash
Separator (220℃, 52.6 bar) Separator
60℃, 26 bar

Water
Liquid to Condensate
Methanol Light Ends Methanol
Recovery
Light End Heavy End
Distillation Distillation
Column Column
25℃, 12 bar 50℃, 3 bar

Heavy Ends

Figure 3: Process Block Diagram of the Methanol Plant

17
Chapter 07: Process Flow Diagram (PFD)

Figure 4: Process flow diagram of the methanol plant

18
 Chapter 08: Material and Energy Balance

All the material balances are done in excel and then energy balances are taken from
Aspen HYSYS Simulation.

8.1 Re-gasifier (E-101)

3
0

1 Re-Gasifier 2
9

4
0

Inlet (mole%) Outlet (mole%)

Stream No.
01 03 02 04
Temperature (℃) -161 33 30 15
Pressure (Bar) 1 1 1 1
Mass Flow (kg/h) 2681 31500 2681 31500
Molar Flow (kmol/h) 161.709 1750 161.709 1750
CH4 0.9691 - 0.9691 -
C2H6 0.0237 - 0.0237 -
C3H8 0.0044 - 0.0044 -
C4H10 0.0015 - 0.0015 -
N2 0.0013 - 0.0013 -
H2O - 1.00 - 1.00
Total (kg/h) 34181 34181
Heat Flow (kJ/h) -14588514 -499818167 -12140336 -502266345
∆Q 2448178 kJ/h

19
8.2 Split into Feed and Fuel NG

5
9

2 Splitter 6
9

Inlet (mole%) Outlet (mole%)

Stream No.
02 05 06
Temperature (℃) 30 30 30
Pressure (Bar) 1 1 1
Mass Flow (kg/h) 2681 2072.40 608.6
Molar Flow (kmol/h) 161.709 125 36.709
CH4 0.9691 0.9691 0.9691
C2H6 0.0237 0.0237 0.0237
C3H8 0.0044 0.0044 0.0044
C4H10 0.0015 0.0015 0.0015
N2 0.0013 0.0013 0.0013
Total (kg/h) 1502.36 1502.36

20
8.3 Mixing (Feed NG and Steam)

7
9

5 Mixer 8
9

Inlet (mole%) Outlet (mole%)

Stream No.
05 07 08
Temperature (℃) 30 150 117
Pressure (Bar) 1 1 1
Mass Flow (kg/h) 2072.40 6744.3 8816.7
Molar Flow (kmol/h) 125 375 500
CH4 0.9691 - 0.24228
C2H6 0.0237 - 0.00593
C3H8 0.0044 - 0.00110
C4H10 0.0015 - 0.00037
N2 0.0013 - 0.00032
H2O - 1.00 0.75000
Total (kg/h) 8816.7 8816.7

21
8.4 Compressor (C-101)

8 Compressor 9
9

Inlet (mole%) Outlet (mole%)

Stream No.
08 09
Temperature (℃) 117 221.5
Pressure (Bar) 1 16
Mass Flow (kg/h) 8816.7 8816.7
Molar Flow (kmol/h) 500 500
CH4 0.24228 0.24228
C2H6 0.00593 0.00593
C3H8 0.00110 0.00110
C4H10 0.00037 0.00037
N2 0.00032 0.00032
H2O 0.75000 0.75000
Total (kg/h) 8816.7 8816.7
Heat Flow (kJ/h) -98492372 -90299709
∆Q 8192663 kJ/h

22
8.5 Heat Exchanger (E-102)

12
0

9 Heat Exchanger 11
9

14
0

Inlet (mole%) Outlet (mole%)

Stream No.
09 12 11 14
Temperature (℃) 221.5 750 450 420
Pressure (Bar) 16 1 16 1
Mass Flow (kg/h) 8816.7 11469.9 8816.7 11469.9
Molar Flow (kmol/h) 500 414.03 500 414.03
CH4 0.24228 - 0.24228 -
C2H6 0.00593 - 0.00593 -
C3H8 0.00110 - 0.00110 -
C4H10 0.00037 - 0.00037 -
N2 0.00032 0.7187 0.00032 0.7187
H2O 0.75000 0.1804 0.75000 0.1804
O2 - 0.0091 - 0.0091
CO2 - 0.0918 - 0.0918
Total (kg/h) 20286.6 20286.6
Heat Flow (kJ/h) -96777919 -22933365 -91976230 -27735054
∆Q 4801689 kJ/hr

23
8.6 Primary Reformer (R-101)

12

11 Primary Reformer 13

6 10

Inlet (mole%) Outlet (mole%)

Stream No.
11 06 10 13 12
Temperature (℃) 450 30 30 600 750
Pressure (Bar) 16 16 1 15.5 1
Mass Flow (kg/h) 8816.7 606.9 10863 8816.7 11469.9
Molar Flow
500 36.709 376.64 662.02 414.03
(kmol/h)
CH4 0.24228 0.9691 - 0.0732 -
C2H6 0.00593 0.0237 - - -
C3H8 0.00110 0.0044 - - -
C4H10 0.00037 0.0015 - - -
N2 0.00032 0.0013 0.79 0.0002 0.7187
H2O 0.75000 - - 0.4074 0.1804
O2 - - 0.21 - 0.0091
CO - - - 0.0857 -
CO2 - - - 0.0367 0.0918
H2 - - - 0.3968 -
Total (kg/h) 20286.6 20286.6
Heat Flow (kJ/hr) -9.198E+7 -2.755E+6 5.197E+4 -7.175E+7 -2.305E+7
∆Q 2.029E+7 kJ/h

24
Reactions Considered in Primary Reformer:
1. CH4 + H2O ⇋ CO + 3H2 Conversion: 60%
2. CO + H2O ⇋ CO2 + H2 Conversion: 30%
3. C2H6 + 2H2O ⇋ 2CO + 5H2 Conversion: 100%
4. C3H8 + 3H2O ⇋ 3CO + 7H2 Conversion: 100%
5. C4H10 + 4H2O ⇋ 4CO + 9H2 Conversion: 100%

Assumptions:
1. Conversion of CH4 and CO are assumed 60% and 30% respectively.
2. Assumed that all the C2H6, C3H8. C4H10 have been reacted.

25
8.7 Secondary Reformer (R-102)

17

13 Secondary Reformer 15

Inlet (mole%) Outlet (mole%)

Stream No.
13 17 15
Temperature (℃) 600 450 900
Pressure (Bar) 15.5 1 15
Mass Flow (kg/h) 8816.7 11033 19849.7
Molar Flow (kmol/h) 662.02 380.97 1056.8
CH4 0.0732 - 0.0015
N2 0.0002 0.78 0.2813
H2O 0.4074 - 0.3345
O2 - 0.21 -
CO 0.0857 - 0.0703
CO2 0.0367 - 0.0507
H2 0.3968 - 0.258
Inert - 0.01 0.0036
Total (kg/h) 19849.7 19849.7
Heat Flow (kJ/hr) -7.160E+7 1.290E+4 -8.343E+7
∆Q 1.184E+7

26
Reactions Considered in Secondary Reformer:

1. H2 + 0.5O2 ⇋ H2O Conversion: 10%

2. CH4 + 1.5O2 ⇋ CO + 2H2O Conversion: 60%

3. CH4 + 2O2 ⇋ CO2 + 2H2O Conversion: 60%

4. CH4 + H2O ⇋ CO + 3H2 Conversion: 80%

5. CO + H2O ⇋ CO2 + H2 Conversion: 50%

Assumptions: All the conversion percentage were assumed.

27
8.8 Heat Exchanger (E-103)

17
0

15 Heat Exchanger 18
9

16
0

Inlet (mole%) Outlet (mole%)

Stream No.
15 16 18 17
Temperature (℃) 900 30 775 450
Pressure (Bar) 15 1 15 1
Mass Flow (kg/h) 19849.7 11033 19849.7 11033
Molar Flow (kmol/h) 1056.8 380.97 1056.8 380.97
CH4 0.0015 - 0.0015 -
N2 0.2813 0.78 0.2813 0.78
H2O 0.3345 - 0.3345 -
O2 - 0.21 - 0.21
CO 0.0703 - 0.0703 -
CO2 0.0507 - 0.0507 -
H2 0.258 - 0.258 -
Inert 0.0036 0.01 0.0036 0.01
Total (kg/h) 30882.7 30882.7
Heat Flow (kJ/h) -83425345 8615 -88281155 4864425
∆Q 4855810 kJ/hr

28
8.9 Waste Heat Boiler

B2

18 Waste Heat Boiler 19

9

B1

Inlet (mole%) Outlet (mole%)

Stream No.
18 B1 19 B2
Temperature (℃) 775 30 170 400
Pressure (Bar) 15 1 15 1
Mass Flow (kg/h) 19849.7 30456 19849.7 30456
Molar Flow (kmol/h) 1056.8 1692 1056.8 1692
CH4 0.0015 - 0.0015 -
N2 0.2813 - 0.2813 -
H2O 0.3345 1.00 0.3345 1.00
CO 0.0703 - 0.0703 -
CO2 0.0507 - 0.0507 -
H2 0.258 - 0.258 -
Inert 0.0036 - 0.0036 -
Total (kg/h) 50305.7 50305.7
Heat Flow (kJ/h) -88299972 -408977668 -110355405 -386922235
∆Q 22055433 kJ/hr

29
8.10 Compressor (C-102)

19 Compressor 20

Inlet (mole%) Outlet (mole%)

Stream No.
19 20
Temperature (℃) 170 250
Pressure (Bar) 15 26
Mass Flow (kg/h) 19849.7 19849.7
Molar Flow (kmol/h) 1056.8 1056.8
CH4 0.0015 0.0015
N2 0.2813 0.2813
H2O 0.3345 0.3345
CO 0.0703 0.0703
CO2 0.0507 0.0507
H2 0.258 0.258
Inert 0.0036 0.0036
Total (kg/h) 19849.7 19849.7
Heat Flow (kJ/h) -110355405 -107701238
∆Q 2654167 kJ/h

30
8.11 Cooler (E-104)

20 Cooler 21

Inlet (mole%) Outlet (mole%)

Stream No.
20 21
Temperature (℃) 250 60
Pressure (Bar) 26 26
Mass Flow (kg/h) 19849.7 19849.7
Molar Flow (kmol/h) 1056.8 1056.8
CH4 0.0015 0.0015
N2 0.2813 0.2813
H2O 0.3345 0.3345
CO 0.0703 0.0703
CO2 0.0507 0.0507
H2 0.258 0.258
Inert 0.0036 0.0036
Total (kg/h) 19849.7 19849.7
Heat Flow (kJ/h) -120625716 -144164689
∆Q 23538973 kJ/h

31
8.12 Flash Separator (V-101)

21 Flash Separator 22

23

Inlet (mole%) Outlet (mole%)

Stream No.
21 23 22
Temperature (℃) 60 60 60
Pressure (Bar) 26 26 26
Mass Flow (kg/h) 19849.7 6236.4 13613.3
Molar Flow (kmol/h) 1056.8 346.45 710.35
CH4 0.0015 - 0.0022
N2 0.2813 - 0.4186
H2O 0.3345 1.00 0.0100
CO 0.0703 - 0.1047
CO2 0.0507 - 0.0754
H2 0.258 - 0.3839
Inert 0.0036 - 0.0054
Total (kg/h) 19849.7 19849.7
Heat Flow (kJ/h) -128718362 -98413048 -30305314

32
8.13 Compressor (C-103)

22 Compressor 24

Inlet (mole%) Outlet (mole%)

Stream No.
22 24
Temperature (℃) 60 176
Pressure (Bar) 26 60
Mass Flow (kg/h) 13613.3 13613.3
Molar Flow (kmol/h) 710.35 710.35
CH4 0.0022 0.0022
N2 0.4186 0.4186
H2O 0.0100 0.0100
CO 0.1047 0.1047
CO2 0.0754 0.0754
H2 0.3839 0.3839
Inert 0.0054 0.0054
Total (kg/h) 13613.3 13613.3
Heat Flow (kJ/h) -30510865 -28031587
∆Q 2479278 kJ/h

33
8.14 Mixing of Recycle with Reactor Feed

33
9

24 Mixer 25
9

Inlet (mole%) Outlet (mole%)

Stream No.
24 33 25
Temperature (℃) 176 170 172.1
Pressure (Bar) 60 52.6 54
Mass Flow (kg/h) 13613.30 42039.54 55652.84
Molar Flow (kmol/h) 710.35 1519.05 2229.40
CH4 0.0022 0.0048 0.0038
N2 0.4186 0.9233 0.7435
H2O 0.0100 0.0005 0.0036
CH3OH - 0.0054 0.0035
CO 0.1047 0.0506 0.0699
CO2 0.0754 0.0036 0.0291
H2 0.3839 - 0.1370
Inert 0.0054 0.0118 0.0095
Total (kg/h) 55652.84 8816.7

34
8.15 Methanol Synthesis Reactor (R-103)

Methanol Synthesis
25 26
Rector

Inlet (mole%) Outlet (mole%)

Stream No.
25 26
Temperature (℃) 172.1 220
Pressure (Bar) 54 52.6
Mass Flow (kg/h) 55652.84 55652.84
Molar Flow (kmol/h) 2229.40 1982.45
CH4 0.0038 0.0043
N2 0.7435 0.8361
H2O 0.0036 0.0336
CH3OH 0.0035 0.0662
CO 0.0699 0.0458
CO2 0.0291 0.0033
H2 0.1370 0.0000
Inert 0.0095 0.0107
Total (kg/h) 55652.84 55652.84
Heat Flow (kJ/h) -3.922E+7 -4.246E+7
∆Q 3.24E+6

Reactions Considered in MSR:

1. CO2 + 3H2 ⇋ CH3OH + H2O

2. CO + H2O ⇋ CO2 + H2

3. CO + 2H2 ⇋ CH3OH

35
8.16 Heat Exchanger (E-105)

32

26 Heat Exchanger 27

33

Inlet (mole%) Outlet (mole%)

Stream No.
26 32 27 33
Temperature (℃) 220 35 130 170
Pressure (Bar) 52.6 52.6 52.6 52.6
Mass Flow (kg/h) 55652.84 42039.54 55652.84 42039.54
Molar Flow (kmol/h) 1982.45 1519.05 1982.45 1519.05
CH4 0.0043 0.0048 0.0043 0.0048
N2 0.8361 0.9233 0.8361 0.9233
H2O 0.0336 0.0005 0.0336 0.0005
CH3OH 0.0662 0.0054 0.0662 0.0054
CO 0.0458 - 0.0458 -
CO2 0.0033 - 0.0033 -
H2 0.0000 - 0.0000 -
Inert 0.0107 0.0118 0.0107 0.0118
Total (kg/h) 97692.38 97692.38
Heat Flow (kJ/h) -4.374E+7 -1.260E+7 -4.939E+7 -6.924E+6
∆Q 5.65E+6 kJ/hr

36
8.17 Cooler (E-106)

27 Cooler 28

Inlet (mole%) Outlet (mole%)

Stream No.
27 27
Temperature (℃) 130 35
Pressure (Bar) 52.6 52.6
Mass Flow (kg/h) 55652.84 55652.84
Molar Flow (kmol/h) 1982.45 1982.45
CH4 0.0043 0.0043
N2 0.8361 0.8361
H2O 0.0336 0.0336
CH3OH 0.0662 0.0662
CO 0.0458 0.0458
CO2 0.0033 0.0033
H2 0.0000 0.0000
Inert 0.0107 0.0107
Total (kg/h) 55652.84 55652.84
Heat Flow (kJ/h) -4.939E+7 -5.520E+7
∆Q 5.81E+6 kJ/h

37
8.18 Flash Separator (V-102)

28 Flash Separator 29

30

Inlet (mole%) Outlet (mole%)

Stream No.
28 29 30
Temperature (℃) 35 35 35
Pressure (Bar) 52.6 52.6 52.6
Mass Flow (kg/h) 55652.84 50520.56 5132.28
Molar Flow (kmol/h) 1982.45 1793.35 189.10
CH4 0.0043 0.0048 -
N2 0.8361 0.9233 0.0095
H2O 0.0336 0.0005 0.3470
CO 0.0458 0.0506 0.0002
CO2 0.0033 0.0036 0.0006
CH3OH 0.0662 0.0054 0.6426
Inert 0.0107 0.0118 0.0001
Total (kg/h) 55652.84 55652.84
Heat Flow (kJ/h) -6.379E+7 -1.554E+7 -4.825E+7

38
8.19 Purge Splitter

31
9

29 Splitter 32
9

Inlet (mole%) Outlet (mole%)

Stream No.
29 31 32
Temperature (℃) 35 35 35
Pressure (Bar) 52.6 52.6 52.6
Mass Flow (kg/h) 50520.56 8481.02 42039.54
Molar Flow (kmol/h) 1793.35 274.30 1519.05
CH4 0.0048 0.0048 0.0048
N2 0.9233 0.9233 0.9233
H2O 0.0005 0.0005 0.0005
CO 0.0506 0.0506 0.0506
CO2 0.0036 0.0036 0.0036
CH3OH 0.0054 0.0054 0.0054
Inert 0.0118 0.0118 0.0118
Total (kg/h) 55652.84 55652.84

39
8.20 Light End Distillation Column (T-101)

35

Light End Distillation

34
Column

36

Inlet (mole%) Outlet (mole%)

Stream No.
34 35 36
Temperature (℃) 25 50 150
Pressure (Bar) 12 12 12
Mass Flow (kg/h) 5132.28 166.12 4966.16
Molar Flow (kmol/h) 189.10 7.55 181.55
N2 0.0095 0.2364 -
H2O 0.3470 0.6612 0.3341
CO 0.0002 0.0048 -
CO2 0.0006 0.0142 -
CH3OH 0.6426 0.0820 0.6659
Inert 0.0001 0.0016 -
Total (kg/h) 5132.28 5132.28
Heat Flow (kJ/h) -48439912 -1544579 -44307448
∆Q 2587885 kJ/h

40
8.21 Cooler (E-107)

37 Cooler 38

Inlet (mole%) Outlet (mole%)

Stream No.
37 27
Temperature (℃) 110 50
Pressure (Bar) 3 3
Mass Flow (kg/h) 4966.16 4966.16
Molar Flow (kmol/h) 181.55 181.55
H2O 0.3341 0.3341
CH3OH 0.6659 0.6659
Total (kg/h) 4966.16 4966.16
Heat Flow (kJ/h) -83425345 -88281155
∆Q 4855810 kJ/h

41
8.22 Heavy End Distillation Column (T-102)

39

Heavy End Distillation

38
Column

40

Inlet (mole%) Outlet (mole%)

Stream No.
38 39 40
Temperature (℃) 50 64.5 91.5
Pressure (Bar) 3 1 1
Mass Flow (kg/h) 4966.16 3750.00 1216.16
Molar Flow (kmol/h) 181.55 117.15 64.40
H2O 0.3341 0.0027 0.9373
CH3OH 0.6659 0.9973 0.0627
Total (kg/h) 5132.28 5132.28
Heat Flow (kJ/h) -46340285 -27797463 -17896462
∆Q 646360 kJ/h

42
 Chapter 09: List of Equipment and Sizing

9.1 Major Equipment List and Sizing

Equipment
Equipment Type Equipment Duty Heat Duty/Sizing
Tag
PRF Feed Compressor C-101 2223 kW
Syngas Compressor C-102 737 kW
Compressor
MSR Feed
C-103 688 kW
Compressor
Re-gasifier for LNG E-101 677 kW
For Preheating the
E-102 1333 kW
Feed NG and Steam
Air Preheater for
E-103 1350 kW
Secondary Reformer
Heat Exchanger Syngas Cooler E-104 6503 kW
Heating the Recycle
E-105 1567 kW
Before Mixing
MSR Product Cooler E-106 1614 kW
Cooler between
E-107 1348 kW
Distillation Column
Pumping Water for
Pump P-101
Regasifier
Primary Reformer R-101 5620 kW
Secondary Reformer R-102 3290 kW
Reformer/Reactor
Methanol Synthesis
R-103 900 kW
Reactor
Syngas to Flash D = 0.77 m
V-101
Separation L = 1.9 m
Separator
Product to Flash D = 1.22 m
V-102
Separator L = 4.27 m
No. of Tray: 10
Distillation Light End Distillation
T-101 Condenser: 104 kW
Column Column
Reboiler: 822 kW

43
 Heavy End
T-102
Distillation Column
Storage Tank for
Tank TK-101
Methanol
Heat Recovery
Waste Heat Boiler WHB-101 6125 kW
Unit

9.2 List of Auxiliaries, Offsites and Package Units

9.2.1 Auxiliary and offsite facilities

• Laboratory
• Housing Colony (Accommodations) and utilities
• Maintenance
• Garage
• Warehouse

9.2.2 Package Unit

• Water supply and Water treatment

• Cooling water and distribution system
• Fire water system
• Steam generation and Power generation
• Compressed air system Inert gas generation
• Refrigeration system
• Yard piping
• Waste disposal system etc.

44
 Chapter 10: Process Licensor and Vendor List

10.1 Process Licensor

The plant has two major operations. One is to syngas production and the other one is
methanol synthesis from syn gas. Both of the processes are designed under the same
licensor in this design. Licensor of the processes are listed below-

Syn Gas Production: Haldor Topsoe

Methanol Synthesis: Haldor Topsoe

10.2 Vendor List

List of Vendors –

1. Primary and Secondary Reformer: Haldor Topsoe

2. Flash Separator – Honeywell UOP
3. Methanol Synthesis Reactor – Johnson Matthey
4. Distillation Column – Honeywell UOP
5. Compressor – Siemens
6. Pump – Aliaxis Utilities and Industry
7. Heat Exchanger – HRS Heat Exchanger
8. ETP – Excel Filtration Private Limited

45
Chapter 11: Detailed Design of Heavy End Distillation Column

Prepared By-

Abir Podder
1702009
Department of Chemical Engineering
Bangladesh University of Engineering and Technology

46
Design of Distillation Column (T-102)

39

Heavy End Distillation

38
Column

40

Inlet (mole%) Outlet (mole%)

Stream No.
38 39 40
Temperature (℃) 50 64.5 91.5
Pressure (Bar) 3 1 1
Mass Flow (kg/h) 4966.16 3750.00 1216.16
Molar Flow (kmol/h) 181.55 117.15 64.40
H2O 0.3341 0.0027 0.9373
CH3OH 0.6659 0.9973 0.0627
Total (kg/h) 5132.28 5132.28

Supplied data-

Initial feed stream at 50℃ and 3 bar,

F = 4966.16 kg/h = 181.55 kmol/h

Mole fractions in feed, zH2O = 0.3341 and zCH3OH = 0.6659

Data obtained from material balance-

Top flow, D = 3750 kg/h = 117.15 kmol/h

Bottom flow, B = 1216.16 kg/h = 64.40 kmol/h

H2O as heavy key and CH3OH as light key components.

47
Minimum number of stages required-

Relative volatility is respect to heavy key. So,

αCH3OH = 4.04 and αH2O = 1 [5]

From Fenske equation, [1]

𝑥𝑙𝑘
( )𝑑𝑖𝑠𝑡
ln [ 𝑥ℎ𝑘
𝑥𝑙𝑘 ]
( )𝑏𝑜𝑡
𝑥ℎ𝑘
Nmin = ln 𝛼 𝑙𝑘/ℎ𝑘

0.9973
( )𝑑𝑖𝑠𝑡
0.0027
ln [ 0.0627 ]
( )𝑏𝑜𝑡𝑡𝑜𝑚
0.9373
= ln 4.04

= 6.1711

So, the minimum number of equilibrium stages is 6.1711.

Minimum reflux ratio-

From Underwood Equation, [2]

𝛼𝑖 𝑧𝑖
1 – q = ∑𝑛𝑖=1 𝛼𝑖−𝜃

Here, q is the quality of feed which is found to be = 1 (from HYSYS simulation)

By putting values and solving we get,

4.02 × 0.6659 1 × 0.3341

0= +
4.02 − θ 1−θ

θ = 1.335

𝛼𝑖 𝑥𝐷𝑖
Rmin + 1 = ∑𝑛𝑖=1 𝛼𝑖−𝜃

By calculation, we get

4.02 × 0.9973 1 × 0.0027

Rmin + 1 = +
4.02 − 1.335 1 − 1.335

48
Rmin = 0.473

Actual reflux ratio-

Assuming, R = 1.5Rmin implies

R = 1.5×0.473 = 0.7095

Diameter of the column-

𝐿𝑜
Reflux ratio, R = 𝐷

R = 0.7095 and D = 117.15 kmol/h

Lo
So, 0.7095 = 117.15

L0 = 83.118 kmol/h

Now, V = L0 +D

= (83.118 + 117.15) kmol/h

= 200.268 kmol/h

Now vapor density is obtained with the help of ideal gas relationship-

𝑃𝑀
Vapor density, 𝜌 = 𝑅𝑇

M = molecular weight of the gas

= (0.3341 × 18) + (0.6659 × 32)

= 27.32 gm

Now inserting the values 𝜌v = 3.091 kg/m3

𝜌L = 802.8 kg/m3 (from HYSYS)

49
 L V
FLV = V √ρL

83.118 3.091
= 200.268 √802.8

= 0.0257

Assuming, tray spacing = 0.50 m

L V
Using Figure 15-5 (Timmerhaus) [4], X- axis ( V √ρL) and tray spacing, Csb can be

calculated.

Figure 5: Chart for estimating values of Csb (±10%)

Here Csb = 0.08

So, the Souders Brown co-efficient, Csb = 0.08 m/s.

Now, the surface tension for the feed, 𝜎 = 39.70 dyne/cm

So, net vapor velocity at flood condition,

50
 𝜎 𝜌𝑙−𝜌𝑣 0.5 39.70 0.2 802.8−3.091 0.5
Vnf = Csb × (20)0.2 × ( ) = 0.08 × ( ) ×( ) = 1.47 m/s
𝜌𝑣 20 3.091

Assuming 80 % of flooding, [1]

Actual vapor velocity, Vn = 0.8 × Vnf = 0.8 × 1.47

= 1.176 m/s

Average molecular weight of the mixture = (0.0027 × 18) + (0.9973 × 32)

= 31.962

𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒

Volumetric flow rate of the vapor, mv = 𝑣𝑎𝑝𝑜𝑟 𝑑𝑒𝑛𝑠𝑖𝑡𝑦

200.268 × 31.962
= m3/s
3.091 × 3600

= 2.077 m3/s

𝑚𝑣
An = 𝑣𝑛

2.077
So net area, An = 1.176 = 1.766 m2

Assuming, Downcomer area (Ad) = 15% of Active area (Ac) [1]

Net area, An = 0.85Ac

1.766 = 0.85Ac

Ac = 2.077 m2

𝜋𝐷 2
The cross-sectional area of the column, Ac =
4

𝜋𝐷 2
1.651 = 4

D = 1.626 m

Therefore, the diameter of the column is 1.626 m

51
Actual number of stages required-

From the Gilliland Equation, [1]

𝑁 − 𝑁𝑚𝑖𝑛 𝑅 − 𝑅𝑚𝑖𝑛 0.566

= 0.75[1 − ( ) ]
𝑁+1 𝑅+1

𝑁 − 6.1711 0.7095 − 0.473 0.566

= 0.75[1 − ( ) ]
𝑁+1 0.7095 + 1

⸫ N = 13.493 theoretical stage

Assuming tray efficiency to be 85%

13.493
Actual number of stages = 0.85

= 15.87

So, the number of actual stages is 16.

Feed Stage Calculation-

𝑥𝑙𝑘
( )𝑑𝑖𝑠𝑡
𝑥ℎ𝑘
ln [ 𝑥𝑙𝑘 ]
( )𝑓𝑒𝑒𝑑
𝑥ℎ𝑘
NFopt = ln 𝛼 𝑙𝑘/ℎ𝑘

0.9973
( )𝑑𝑖𝑠𝑡
0.0027
ln [ 0.6659 ]
( )𝑓𝑒𝑒𝑑
0.3341
= ln 4.04

= 3.74

𝑁𝐹𝑜𝑝𝑡 𝑁𝐹
For feed stage, =
𝑁𝑚𝑖𝑛 𝑁

𝑁𝐹𝑜𝑝𝑡 × 𝑁
 NF = 𝑁𝑚𝑖𝑛
3.74 × 16
 NF = 6.1711

 NF = 9.6968
 NF = 10

So, the feed stage is 10th stage.

52
Height of column-

Actual column height, Hc = (the actual number of trays, Nact – 1) × the plate spacings,
Hs + ∆H

 H = the height required for phase disengagement + liquid holdup needed for surge
capacity + liquid height in the base of the column [must be high enough above the
elevation of the bottom of pump to provide the necessary net positive suction head
(NPSH) requirements for this pump]

An additional from 10% to 20% more height than that required should be added for the
requirements of  H. Here, taking 15%.

actual number of stages Nc = 16

Tray spacing = 0.50 m

So, Hc = (16 - 1) × 0.5 × 1.15

Hc = 8.625 m

Therefore, the Height of the column is 8.625 m.

Shell thickness-

Carbon steel is used as the construction material for its strength and ability to hold
higher temperature pressure.

Maximum allowable stress, 𝑓s = 955 kg/cm2

Assuming welding efficiency, 𝑗 = 0.85

The specific gravity of carbon steel = 7.7

Design pressure, P = 1.5 × operating pressure

= 1.5 × 3 × 1.0329 𝑘𝑔𝑐𝑚-2

= 4.6481 𝑘𝑔𝑐𝑚-2

53
Column diameter, D = 1.626 m = 162.6 cm

Consider, for carbon steel, minimum corrosion allowance = 3 mm

P×D
So, shell thickness, 𝑡s = + C [6]
2 × fs × j−P

4.6481 × 162.6
=2 × 955 × 0.85 − 4.6481 + 0.3

= 0.767 cm

= 7.67 mm

We may assume 8 mm thickness as a precaution.

Head design

A hemispherical head is selected. [7]

𝑃𝐷
Thickness of head 𝑡ℎ = 4𝑓 𝑗
𝑠

4.6481 × 1.626 × 1000

=
4 × 955 × 0.85

= 2.324 mm

For precaution, take the head thickness as 4 mm.

Tray specification-

A tray column is used for high liquid flow rate. Sieve, valve, and bubble cap tray are
common type of tray. Of these tray types, the sieve tray is the choice in many distillation
separations since its tray fundamentals are well established, entailing minimal risk. In
addition, the sieve trays are low-cost relative to many other tray types. Again, wide
variations of flow rates can be considered in this tray. Overall sieve tray efficiency is
between 60 to 80 percent. So, the selected tray is sieve tray.

According to Applied process design, Ludwig, Earnest E. [3], For 0.50 m tray
spacing, table 8.20 suggests-

54
Allowable liquid flow rate through downcomer, v = 0.53 ft/s = 0.16 m/s

This velocity is suggested for light components like methanol.

Feed stage liquid flow rate = 8.64 m3/hr

= 0.0024 m3/s

𝐹𝑒𝑒𝑑 𝑠𝑡𝑎𝑔𝑒 𝑙𝑖𝑞𝑢𝑖𝑑 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒

Downcomer area, Ad = 𝐴𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑙𝑖𝑞𝑢𝑖𝑑 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 𝑡ℎ𝑟𝑜𝑢𝑔ℎ 𝑑𝑜𝑤𝑛𝑐𝑜𝑚𝑒𝑟 [3]

0.0024
= 0.16

= 0.015 m2

Number of holes in a tray-

Assuming hole diameter is 0.01 m. For a plate there is one downcomer on the plate and
top down comer also affected to bottom plate. Therefore, two down comer areas needed
to be reduced from active area. So,

Aa = Ac - 2Ad

= 1.626 – 2 × 0.015

= 1.596 m2

Assuming holes area is 15% of active area.

Ah = 0.15Aa

= 0.15 × 1.596

= 0.2394 m2

𝜋
Area of a hole = 4 × (0.01)2

55
 =7.854 × 10-5 m2

0.2394
Number of holes = 7.854 × 10−5

= 3049

Tray thickness-

Tray spacing = 0.5 m

Hole diameter do = 0.01 m

Assume, pitch of equilateral triangular form. It is most preferable.

Pitch size
= 2.5 to 4 [4]
𝐻𝑜𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟

Pitch size, Pt = 3.5 × hole diameter

= 3.5 × 0.01

= 0.035 m

tray thickness
Now, = 0.3 [3]
ℎ𝑜𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟

Tray thickness, Tt = 0.3 × 0.01 = 0.003 = 3 mm

Skirt Support Design

Assuming uniform thickness, the skirt's shell is built to withstand the combined stress
of the vessel's dead weight, wind load, and seismic load.

Stress due to dead weight-

∑𝑊
𝑓𝑑 = [6]
𝜋𝐷𝑠𝑘 𝑡𝑠𝑘

Here-

56
𝑓𝑑 = stress due to dead weight,

W = dead weight of vessel contents and attachments

𝑡s𝑘 = thickness of the skirt.

𝐷s𝑘 = diameter of the skirt (outside diameter of the shell)

= 𝐷 + 2 × 𝑡s

= (1.626 + 2 × 0.007) m

= 1.64

Volume of cylindrical section of the column,

𝜋
V1 = 4 × (Do2- Di2) × H

𝜋
= × (1.642-1.6262) × 9.625 (adding extra 1m with the height for spherical head)
4

= 0.345 m3

𝜋
Volume of trays, V2 = Actual number of stages × × tray diameter2 × tray thickness
4

= 0.0997 m3

Total volume = V1 + V2

= 0.272 + 0.0997

= 0.3717 m3

Density of carbon steel, 𝜌cs = 7700 𝑘𝑔/𝑚3

Weight of the tower, W1 = (0.3717 × 7700) kg

= 2862.09 kg

Assuming weight of attachments (pipe, ladder, platform, insulation etc.) is 20% of the
tower weight.

So, W2 = 2862.09 × 0.2

57
 = 572.418 kg

Assume the column is 5% filled with water having density 1000 kg/m3

𝜋
Inside volume of the column = 4 ×Di2×H

= 17.91 m3

Weight of the water = 17.91 × 1000 × 0.05

= 895.5 kg

So total dead weight, ∑W = (2862.09 + 572.418 + 895.5) kg

= 4330.008 kg

Now by putting the values we have-

840.42
𝑓𝑑 =
𝑡𝑠𝑘

Stress due to bending moment due to wind flow-

𝑀𝑤
fwb = 𝑍

4𝑀𝑤
fwb = 𝜋 × 𝐷𝑠𝑘 × 𝑡𝑠𝑘 [6]

Z = Modulus section for skirt cross-section

𝑡𝑠𝑘 = thickness of the skirt

𝐻
Again, Mw = 𝜌 × 2

𝜌 = 𝑘PH𝐷𝑜

k = shape factor, for cylindrical shape (0.7)

= 0.7
P = wind pressure (40 to 100 kg/m2)
= 70 kg/m2

By putting the values we have-

58
 4𝑀𝑤
fwb = 𝜋𝐷
𝑠𝑘 𝑡𝑠𝑘

𝐻
4×𝜌×
2
= 𝜋𝐷𝑠𝑘 𝑡𝑠𝑘

𝐻
4 × kPHDo ×
2
= 𝜋𝐷𝑠𝑘 𝑡𝑠𝑘

2320.57
= 𝑡𝑠𝑘

Stress due to seismic load

8𝑤𝐶𝐻
fsb = [6]
3𝜋𝑡𝑠𝑘 𝐷 2

C = Seismic coefficient = 0.1 (0.1 to 0.3)

W = Total weight of the column

H = Height of the column

The total weight of the column = 4330.008 kg

Putting the values we have-

1178.634
fsb = 𝑡𝑠𝑘

Skirt thickness calculation-

Stress due to seismic load is greater than wind load.

So maximum tensile stress at the bottom of the skirt, = 𝑓sb – 𝑓d

1178.634 840.42
= –
𝑡𝑠𝑘 𝑡𝑠𝑘

338.214
= 𝑡𝑠𝑘

Permissible tensile strength = 565 MPa = 5.7 × 107 kg/m2

338.214
tsk = 5.7 × 10^7

= 0.059 mm

Maximum compressive stress at the bottom of the skirt, = 𝑓s𝑏 + 𝑓𝑑

59
 1178.634 840.42
= +
𝑡𝑠𝑘 𝑡𝑠𝑘

2019.054
= 𝑡𝑠𝑘

Permissible compressive strength = 248 MPa = 2.5×107 kg/m2

2019.054
tsk = 2.5 × 10^7

= 0.081 mm

The calculated skirt thickness is too low.

We may assume the skirt thickness to be = 5 mm

Insulation

Material: Fiber glass

Thickness = 100 mm

Density of insulation = 112.13 kg/m3

Thermal conductivity of fiber glass at 30˚C, k = 0.038 W/m˚C

Convection heat transfer co-efficient of air, h = 3 W/ m2˚C

Critical radius of insulation, rc = k/h

=12.67 mm

𝐷
Inner radius of insulation, ri = 2 + ts

1.626
= + 8 × 10-3
2

= 0.821 m

Outer radius of insulation, ro = 0.821 +100 × 10-3 m

= 0.921 m

Vessel temperature, Ti = 91.5˚C

60
Outer temperature, T = 30˚C

Heat transfer with insulation,

q 2π(Ti −T)
= r
ln o
L ri 1
+
k ro h

2π(91.5 − 30)
= ln0.921
0.821+ 1
0.038 0.921 × 3

= 114.10 W/m

q
Heat transfer without insulation, L = 2πri h(Ti − T)

= 2π × 0.821 × 3 × (100 - 30)

= 951.74 W/m

Therefore, insulation sufficiently reduced heat loss.

Crown radius, Rc = D/2 = 0.813 m

Knuckle radius, Rl = 0.1Rc = 0.0813 mm

Inside depth of dish, = (𝑅𝑐 - √(𝑅𝑐 − 𝑅𝑙 )2 − (𝑅𝑐 − 𝑅𝑙 − 𝑡)2 ) [4]

= (0.813 - √(0.813 − 0.0813)2 − (0.813 − 0.0813 − 0.008)2 )

= 0.705 m

Height of the cylindrical portion of column, H = tower height – 2 × inside depth of dish

= (8.625 – 2 × 0.705) m

= 7.215 m

Surface area for insulation of cylinder, S1 = πDH

= π × 1.626 × 7.215 m

= 36.86 m2

61
Surface area for insulation in tori-spherical head, S2 = 1.084D2

= 2.87 m2

Total surface area, S = S1 + 2S2

= 42.6 m2

Volume of insulation = (42.6 × 0.1) m2

= 4.26 m3

Weight of insulation = 4.26 m3 × 112.13 kg/m3

= 477.67 kg

Nozzle Design

Feed nozzle calculation

Volumetric flowrate of feed, Qf = 1.66 × 10-3 m3/s [from Hysys]

4Qf
Dn = √0.75π

4 × 1.66 × 10−3
=√ m
0.75 × π

= 0.05 m

Material of construction: Carbon steel

Specific gravity = 7.7

Maximum allowable stress, fs = 955 kg/cm2

Assuming welding efficiency, j = 0.85

Design pressure, P = 1.5 × operating pressure

= 1.5 × 3 × 1.0329 𝑘𝑔𝑐𝑚-2

= 4.6481 𝑘𝑔𝑐𝑚-2

62
Nozzle diameter, Dn = 0.05 m = 50 mm (internal diameter)

P×𝐷
Thickness, tsn = 2 × fs × 𝑛j−P + C

4.6481 × 50
= 2 × 955 × 0.85 − 4.6481 + 0.3

= 0.44 mm

Here, corrosion allowance, C = 0.3 mm

Top vapor nozzle calculation

Volumetric flowrate of feed, Qv = 1.31 × 10-3 m3/s [from Hysys]

4Qv
Dn = √0.75π

4 × 1.31 × 10−3
=√ m
0.75 × π

= 0.047 m

Material of construction: Carbon steel

Specific gravity = 7.7

Maximum allowable stress, fs = 955 kg/cm2

Assuming welding efficiency, j = 0.85

Design pressure, P = 1.5 × operating pressure

= 1.5 × 3 ×1.0329 𝑘𝑔𝑐𝑚-2

= 4.6481 𝑘𝑔𝑐𝑚-2

Nozzle diameter, Dn = 0.047 m = 47 mm (internal diameter)

P×𝐷
Thickness, tsn = 2 × fs × 𝑛j−P + C [6]

4.6481 × 47
= 2 × 955 × 0.85 − 4.6481 + 0.3

63
 = 0.43 mm

Here, corrosion allowance, C = 0.3 mm

Reflux nozzle calculation

Volumetric flowrate of reflux liquid, QL = 9.29 × 10-4 m3/s [from Hysys]

4QL
D = √0.75π

4 × 9.29 × 10−4
=√ m
0.75 × π

= 0.04 m

Material of construction: Carbon steel

Specific gravity = 7.7

Maximum allowable stress, fs = 950 kg/cm2

Assuming welding efficiency, j = 0.85

Design pressure, P = 1.5 × operating pressure

= 1.5 × 3 × 1.0329 𝑘𝑔𝑐𝑚-2

= 4.6481 𝑘𝑔𝑐𝑚-2

Nozzle diameter, Dn = 0.047 m = 40 mm (internal diameter)

P×𝐷
Thickness, tsn = 2 × fs × 𝑛j−P + C

4.6481 × 40
= 2 × 955 × 0.85 − 4.6481 + 0.3

= 0.41 mm

Here, corrosion allowance, C = 0.3 mm

64
Bottom liquid nozzle calculation

Volumetric flowrate of reflux liquid, QL = 3.48 × 10-4 m3/s [from Hysys]

4QL
D = √0.75π

4 × 3.48 × 10−4
=√ m
0.75 × π

= 0.024 m

Material of construction: Carbon steel

Specific gravity = 7.7

Maximum allowable stress, fs = 950 kg/cm2

Assuming welding efficiency, j = 0.85

Design pressure, P = 1.5 × operating pressure

= 1.5 × 3 × 1.0329 𝑘𝑔𝑐𝑚-2

= 4.6481 𝑘𝑔𝑐𝑚-2

Nozzle diameter, Dn = 0.024 m = 24 mm (internal diameter)

P×𝐷
Thickness, tsn = 2 × fs × j𝑛− P + C

4.6481 × 24
= 2 × 955 × 0.85 − 4.6481 + 0.3

= 0.37 mm

Here, corrosion allowance, C = 0.3 mm

Boil-up nozzle calculation

Volumetric flowrate of reflux liquid, QL = 1.014 × 10-3 m3/s [from Hysys]

4QL
D = √0.75π

65
 4 × 1.014 × 10−3
=√ m
0.75 × π

= 0.041 m

Material of construction: Carbon steel

Specific gravity = 7.7

Maximum allowable stress, fs = 950 kg/cm2

Assuming welding efficiency, j = 0.85

Design pressure, P = 1.5 × operating pressure

= 1.5 × 3 × 1.0329 𝑘𝑔𝑐𝑚-2

= 4.6481 𝑘𝑔𝑐𝑚-2

Nozzle diameter, Dn = 0.041 m = 41 mm (internal diameter)

P×𝐷
Thickness, tsn = 2 × fs × j𝑛− P + C

4.6481 × 41
= 2 × 955 × 0.85 − 4.6481 + 0.3

= 0.42 mm

Here, corrosion allowance, C = 0.3 mm

66
Design Parameter

Table 5: Design Parameter for High End Distillation Column (T-102)

Column height 8.625 m

Column diameter 1.626 m

Column thickness 8 mm

Tray type Sieve tray

No. of trays 16

Feed stage 10th stage

Tray spacing 0.5 m

Tray thickness 3 mm

Weir length 0.3 m

Downcomer area 0.015 m2

Insulation material Fiber glass

Insulation thickness 100 mm

Insulation area 42.6 m2

Column weight 4330.008 kg

Reboiler duty 7.301 × 106 kJ/h

Condenser duty 6.655 × 105 kJ/h

67
Mechanical Drawing

Figure 6: Side View of Distillation Column

68
Figure 7: Top View of Distillation Column

Figure 8: Side View of Sieve Tray

69
 Figure 9: Top View of Sieve Tray

Figure 10: Side View of Skirt Support

70
Figure 11: Piping and Instrumentation Diagram for Distillation Column

71
Specification Sheet
Item: Distillation column Prepared by: Abir Podder
Item no.: T-102 Checked by:
Quantity: 01 Approved by:
Operation Purification of Methanol
Operating conditions
Operation mode Continuous
Operating temperature (℃) 50
Operating pressure (bar) 3
Reflux ratio 0.7095
Flow type Cross flow
Flow conditions
Feed Distillate Bottom Products
Flowrate (kg/h) 4966.16 3750 1216.16
Temperature (℃) 50 64.5 91.5
Pressure (bar) 3 3 3
Column specifications
Column height 8.625 m
Column diameter 1.626 m
Number of trays 16
Feed stage 10
Support type Skirt support
Column internals specifications
Tray type Sieve tray
Stage efficiency 80%
Tray spacing 0.5 m
Weir length 0.38 m
Hole diameter 0.01 m
Number of holes 3049
Shell Insulation Tray
Materials of construction Carbon steel Fiber glass Stainless steel
Thickness (m) 0.008 0.1 0.003

72
Reference:

[1] Wankat, P. (1988). Equilibrium Staged Separation. (pp. 276-282, 388, 445) New
Jersey: Prentice Hall

[2] A.J. V. Underwood Chem. Eng. Prog. 44:603(1948)

[3] Ludwig, E., & Coker, A. (2007). Applied process design for chemical and
petrochemical plants (3rd ed., pp. 135-217). Burlington, MA [etc.]: Gulf Professional
Publishing.

[4] Peters, M., Timmerhaus, K., & West, R. (1981). Plant design and economics for
chemical engineers (5th ed., pp. 769-782). Auckland: McGraw-Hill International Book.

[5] Green, D., & Southard, M. Perry's chemical engineers' handbook (4th ed., pp. 120).

[6] Matos, D. (2022). MECHANICAL DESIGN OF DISTILLATION COLUMN.

[7] Joshi, M. (1976). Process equipment design (pp. 128, 139-140). Delhi, India:
MacMillan India.

73
 Chapter 12: Detailed Design of Flash Separator

Prepared By-

Mahmudur Rahman
1702017
Department of Chemical Engineering
Bangladesh University of Engineering and Technology

74
Design of Flash Separator

21 Flash Separator 22

23

Inlet (mole%) Outlet (mole%)

Stream No.
21 23 22
Temperature (℃) 60 60 60
Pressure (Bar) 26 26 26
Mass Flow (kg/h) 19849.7 6236.4 13613.3
Molar Flow (kmol/h) 1056.8 346.45 710.35
CH4 0.0015 - 0.0022
N2 0.2813 - 0.4186
H2O 0.3345 1.00 0.0100
CO 0.0703 - 0.1047
CO2 0.0507 - 0.0754
H2 0.258 - 0.3839
Inert 0.0036 - 0.0054
Total (kg/h) 19849.7 19849.7

Feed stream pressure calculation:

Water has dominant composition; therefore,

𝐵
𝑙𝑜𝑔10 𝑃𝑠𝑎𝑡 = 𝐴 −
𝑇+𝐶

2354.731
= 6.20963 −
(273 + 60) + 7.559

= −0.7035

75
So, partial pressure of stream-21 at 600 C, Psat = 0.1979 bar = 2.87 psia
Molecular weight of vapor, 𝑀𝑣
= 0.0022 × 86 + 0.4186 × 28 + 0.0100 × 18 + 0.1047 × 28
+ 0.0754 × 44 + 0.3839 × 2.016

= 18.959 𝑔/𝑚𝑜𝑙𝑒

𝑃𝑀
𝐷𝑒𝑛𝑠𝑡𝑖𝑦 𝑜𝑓 𝑣𝑎𝑝𝑜𝑟, 𝜌𝑣 =
𝑅𝑇

2.6 × 106 × .018959

=
8.314 × (273.15 + 60)

𝐾𝑔
= 17.79
𝑚3

= 1.11 𝑙𝑏/𝑓𝑡 3

𝐾𝑔
𝐷𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝐿𝑖𝑞𝑢𝑖𝑑(𝑤𝑎𝑡𝑒𝑟) 𝑎𝑡 60℃, 𝜌𝐿 = 983 𝑚3 = 61.37 𝑙𝑏/𝑓𝑡 3 (Lide et al., 2003)

𝐾𝑑𝑟𝑢𝑚 = exp [𝐴 + 𝐵 ln(𝐹𝑙𝑣 ) + 𝐶 ln(𝐹𝑙𝑣 ) 2 + 𝐷 ln(𝐹𝑙𝑣 ) 3

+ 𝐸 ln(𝐹𝑙𝑣 ) 4 ] … . (1)

Where, 𝐾𝑑𝑟𝑢𝑚 is the drum boiling constant, is a parameter used in the analysis and
design of industrial distillation columns, which are commonly used to separate mixtures
of liquids based on differences in their boiling points. The parameter is used to model
the rate of liquid-vapor mass transfer in the drum section of a distillation column, which
is the section where the liquid and vapor phases are in equilibrium and the liquid is
being boiled.

The constants are (Blackwell, 1984): A = −1.877478097, C = −0.1870744085, E =

−0.0010148518 B = −0.8145804597, D = −0.0145228667

76
 𝑊𝐿 𝜌𝑣
𝐹𝑙𝑣 = √ … . (2)
𝑊𝑉 𝜌𝐿

𝑘𝑚𝑜𝑙𝑒 𝐾𝑔 1𝑙𝑏
WL (lb liquid/hr) = 346.45 × 18 𝑘𝑚𝑜𝑙𝑒 × .453 𝐾𝑔
ℎ𝑟

𝑙𝑏
= 13766
ℎ𝑟

𝑘𝑚𝑜𝑙𝑒 𝐾𝑔 1𝑙𝑏
Wv (lb vapor/hr) = 710.35 × 18.959 𝑘𝑚𝑜𝑙𝑒 × .453 𝐾𝑔
ℎ𝑟

𝑙𝑏
= 29729
ℎ𝑟

13766 18.959
𝐹𝑙𝑣 = √
29729 18

= 0.475

From (1), 𝐾𝑑𝑟𝑢𝑚 = 0.254

permissible vapor velocity, uperm ft/sec :The permissible vapor velocity is a parameter
used in the design of flash separator to ensure that the vapor flow rate does not exceed
a certain limit that could lead to flooding or other operational problems.

𝜌𝐿 − 𝜌𝑣
𝑢𝑝𝑒𝑟𝑚 = 𝐾𝑑𝑟𝑢𝑚 √
𝜌𝑣

983 − 17.79
= 0.254 × √
17.79

= 1.87 𝑓𝑡/𝑠

𝑓𝑡 3600 𝑠 𝑙𝑏𝑚
𝑙𝑏 𝑚𝑜𝑙𝑒𝑠 𝑢𝑝𝑒𝑟𝑚 ( ) ( ) 𝐴𝑐 (𝑓𝑡 2 ) 𝜌𝑣 ( )
𝑠 ℎ𝑟 𝑓𝑡3
Vapor mass flow rate, 𝑉 ( )= 𝑙𝑏𝑚 … (3)
ℎ𝑟 𝑀𝑊𝑣𝑎𝑝 ( )
𝑙𝑏𝑚𝑜𝑙𝑒

77
 𝑙𝑏 𝑚𝑜𝑙𝑒𝑠 710.35 𝑘𝑔 − 𝑚𝑜𝑙𝑒𝑠 1 𝑙𝑏
𝑉( )= × = 1568.1 𝑙𝑏 𝑚𝑜𝑙𝑒𝑠/ℎ𝑟
ℎ𝑟 ℎ𝑟 0.453 𝑘𝑔

𝑉(𝑀𝑊𝑣 )
From (3), 𝐴𝑐 = 𝑢
𝑝𝑒𝑟𝑚 (3600) 𝜌𝑣

𝑙𝑏𝑚𝑜𝑙𝑒𝑠 𝑙𝑏𝑚
1568.1 × 18.959
= ℎ𝑟 𝑙𝑏𝑚𝑜𝑙𝑒
𝑓𝑡 3600𝑠
1.87 𝑠 × × 1.11 𝑙𝑏/𝑓𝑡 3
ℎ𝑟

= 3.97 𝑓𝑡 2

4×𝐴𝑐
Vessel inside diameter, 𝐷 = √ 𝜋

4 × 3.97
=√
𝜋

= 2.25 𝑓𝑡

EN 13445 recommends an overdesign factor of at least 1.1 for most pressure vessels.
(107_FICHIER_0, n.d.)

Considering overdesign, D = 2.5 ft

Nozzle diameter calculation:

Minimum required nozzle diameter, DN

QM = QL + QV = 7.44 + 0.06 = 7.5 ft3/s

78
 𝑄𝐿 0.06
𝜆= = = 0.008
𝑄𝐿 + 𝑄𝑉 7.44 + 0.06

𝜌𝑀 = 𝜌𝐿 × 𝜆 + 𝜌𝑉 × (1 − 𝜆) = 61.37 × 0.008 + 1.11 × (1 − 0.008)

𝑙𝑏
= 1.59208
𝑓𝑡 3

1
Therefore, = .26 𝑓𝑡 ≥ 𝑑𝑁
4×𝑄𝑀 ×𝜌𝑀 .5

𝑑𝑁 ≤ 0.26 𝑓𝑡

As a general rule of thumb, we want to increase the nozzle diameter by 10-20% above
the minimum required value to ensure adequate flow velocity and to avoid excessive
pressure drop in the system.(Kupdf.Net_crane-Technical-Paper-410, n.d.)

Let, dN = 0.312 ft; by 20% increment.

The outlet liquid nozzle diameter may range from approximately 0.7 to 0.9 times the
inlet nozzle diameter. The outlet vapor nozzle diameter may range from approximately
1.1 to 1.3 times the inlet nozzle diameter.(Rousseau, 1987)

Outlet liquid nozzle diameter = 0.8 × 0.312 𝑓𝑡 = 0.25 𝑓𝑡

Outlet vapor nozzle diameter = 1.1 × 0.312 𝑓𝑡 = 0.34 𝑓𝑡

Height Calculation:

𝑊𝑉
Vapor volumetric flow rate, 𝑄𝑉 = 3600 𝜌𝑣

29729
=
3600 × 1.11

𝑓𝑡 3
𝑄𝑉 = 7.44
𝑠

𝑊𝐿
Liquid volumetric flow rate, 𝑄𝐿 = 3600 𝜌𝐿

13766
=
3600 × 61.37

79
 𝑓𝑡 3
𝑄𝐿 = 0.06
𝑠

Taking hold-up time for separator TH = 5 minutes

Liquid hold-up volume, VH = 5 × 60 × 0.06 = 18 𝑓𝑡 3

Taking surge time as Ts = 3 minutes

Surge volume, VS = 3 × 60 × 0.06 = 10.8 𝑓𝑡 3

2.5 2
𝐶𝑟𝑜𝑠𝑠 − 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒 𝑜𝑓 𝑡ℎ𝑒 𝑣𝑒𝑠𝑠𝑒𝑙 = 𝜋 × ( )
2

= 4.9 𝑓𝑡 2

Assuming, low liquid level, HLLL = 1 ft

Height from low liquid level to normal liquid level,

18 𝑓𝑡 3
𝐻𝐻 =
4.9 𝑓𝑡 2

= 3.67 𝑓𝑡

𝑉
Height from normal liquid level to high liquid level, 𝐻𝑠 = 𝜋 𝑆2
𝐷
4

10.8
=𝜋
2
4 × 2.5

= 2.2 𝑓𝑡

The empirical formula, 𝑯𝑳𝑰𝑵 = 𝟏𝟐 + 𝟎. 𝟓 × 𝑫𝑵 is widely used in the industry for

estimating the height from the high liquid level to the centerline of the inlet nozzle for

80
horizontal vessels. However, its origin is not well documented, and it is unclear who
first proposed it or how it was derived.

𝐻𝐿𝐼𝑁 = 12 + 0.5 × 𝐷𝑁

= 12 + 0.5 × 0.312

= 12.156 𝑖𝑛

= 1.013 𝑓𝑡

Disengagement height, 𝐻𝐷 = 36 + 0.5 × 𝐷𝑁

= 36 + 0.5 × .312

= 3.013 𝑓𝑡

Total height of separator, HT = HLLL + HH + HS + HLIN + HD

= 1 + 3.67 + 2.2 + 1.013 + 3.013

= 10.90 ft

Now, L/D = 10.90/ 2.5 = 4.36;

This ratio has to be 4:1 to 6:1 for light liquid loading to act as a Vertical Flash
Separator. (Pell et al., 2008)

Thickness calculations:

Allowable stress for Stainless steel 316 L if spot-examined by the radiograph technique
(Weilding factor = 0.85) between 343 to 393k, S = 82700 KPa (Plant design and
economics Chapter 12 table 12.10)

𝑃×𝑅
𝑇ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 =
𝑆 × 𝐸 − 0.2 𝑃

2.5
2600 × 2
=
82700 × 0.85 − 0.2 × 2600

81
 = 0.0031 𝑚

= 0.01 𝑓𝑡

1 1
Volume of Cylindrical shell = 4 × 𝜋 × (𝐷 + 2𝑡)2 × 𝐻 − 4 × 𝜋 × 𝐷2 × 𝐻

= 0.94 𝑓𝑡 3

1 1 1
Volume of hemispherical head = 2 × {6 𝜋 × (𝐷 + 2𝑡)3 − 6 × 𝜋 × 𝐷 3 }

= 0.0989 𝑓𝑡 3

1
Volume of flat plate = 4 × 𝜋 × 𝐷2 × 𝑡 = 0.04 𝑓𝑡 3

Total volume of material = 0.94 + .0989 + 0.04

= 1.0789 ft3

𝑙𝑏
Amount of material needed = 1.0789 𝑓𝑡 3 × 490 𝑓𝑡 3 = 528.661 lb

= 240 𝑘𝑔
Skirt support design

Skirt design

Selected material

Stainless steel 316 L

Maximum allowable tensile stress = 16700 psi or 1174 kg/cm2

Maximum allowable compressive stress = 22.9-57.6 Mpa or 234 kg/cm2

Stress due to dead load

Dead load of the reactor, Wd = weight of the tubes + shell + catalyst +

attachments

= 240 + 100

= 340 kg

82
Assuming, diameter of the skirt, dsk = outside diameter of the reactor, Do

= 76.5 cm

Let, thickness of the skirt, t sk

Wd
Stress due to dead load, fd = πd
sk tsk

1.42 kg
=
t sk cm2

Stress due to wind pressure

kg
Wind pressure for upto 20 m height = 40 − 100 m2

kg
Taking maximum wind pressure, p = 100 m2

k = 0.7 (for cylindrical vessel)

h = 3.32 m vessel + 2.6 m skirt

Now, force due to wind load, pw = kphDo

= 317.016 kg − wt

kphDo h
Bending moment due to wind load at base, Mw = 2

= 102837 kg − cm

4M
So, wind stress at base, fwb = πD2 tw
o sk

22.37 kg
=
t sk cm2

Stress due to seismic load

C = seismic coefficient

= 0.04, for moderate seismic zone

8
CWH
3
Now, stress due to seismic load at base, fsb = πD2t
o sk

83
 11.68 kg
=
t sk cm2

Considering tensile strength, we get,

maximum allowable tensile strength

= max(fwb , fcb ) − fd
safety factor

Assuming safety factor = 1.2

1174 22.37 1.42

= −
1.2 t sk t sk

t sk = 0.02 cm = 0.2 mm

Considering compressive strength, we get,

maximum allowable compressive strength

= max(fwb , fcb ) + fd
safety factor

Assuming safety factor = 1.2

234 22.37 1.42

= +
1.2 t sk t sk

t sk = 0.122 cm

A thickness of 4 mm can be used.

Skirt bearing

Assuming bolt circle diameter, Db = Dsk + 2l

= 76.5 + 32.5 = 109 cm

π(1094 −76.54 )
Section modulus, z = 32.5×109

= 94810 cm3

Area of contact between the bearing plate and foundation, A = π(1092 − 76.52 )

= 18940 cm2

Bending moment due to wind, Mw = 102837 kg − cm

84
 𝑘𝑔
Assuming, permissible compressive strength in concrete 𝑓𝑐𝑚𝑎𝑥 = 200 𝑐𝑚2

Compressive strength between the bearing plate and concrete foundation

𝑤 𝑀𝑤
𝑓𝑐 = +
𝐴 𝑧

340 102837
= +
18940 94810

𝑘𝑔 𝑘𝑔
= 1.10 2
< 200
𝑐𝑚 𝑐𝑚2

Now,

3𝑓𝑐 0.5
Thickness of the bearing plate, 𝑡𝑏 = 𝑙 × (𝑓 )
𝑐𝑚𝑎𝑥

= 2.09 cm = 20.9 mm

Demister Design:

Assumption:

• Negligible Pressure drop in Demister Pad.

• Separation efficiency 50%
• The vapor stream behaves as an ideal gas.
𝑙𝑏
Gas Density,𝜌𝑣 = 1.11 𝑓𝑡 3

= 0.0178 𝑘𝑔/𝑚3

∑(𝜇𝑖 ×𝑥𝑖 × √𝑀𝑖 )

Gas Viscosity: 𝜇𝑚𝑖𝑥 = ∑(𝑥𝑖 × √𝑀𝑖 )
(Herning and Zipperer equation, n.d.)

Liquid Load: 19864.09 kg/hr

= 5.518 kg/s

85
Component 𝜇𝑖 𝑥𝑖 𝑀𝑖 √𝑀𝑖 𝜇𝑖 × 𝑥𝑖 × √𝑀𝑖 𝑥𝑖 × √𝑀𝑖 𝜇𝑚𝑖𝑥
Methane 0.0000116 0.00223 0.016 0.126491106 0.000000003278 0.000283
Ethane 0.0000000 0.00000 0 0 0.000000000000 0
Propane 0.0000000 0.00000 0 0 0.000000000000 0
n-Butane 0.0000000 0.00000 0 0 0.000000000000 0
CO 0.0000104 0.10470 0.028 0.167332005 0.000000182204 0.01752
CO2 0.0000090 0.07529 0.044 0.20976177 0.000000142132 0.015792
H2O 0.0000115 0.00925 0.018 0.134164079 0.000000014276 0.001241
Hydrogen 0.0000119 0.38425 0.002016 0.044899889 0.000000205306 0.017253 3.5587
Nitrogen 0.0000104 0.41892 0.028 0.167332005 0.000000729023 0.070098
Oxygen 0.0000000 0.00000 0 0 0.000000000000 0
Argon 0.0000094 0.00536 0.04 0.2 0.000000010080 0.001072
Methanol 0.0000000 0.00000 0 0 0.000000000000 0
∑(𝜇𝑖 × 𝑥𝑖 × √𝑀𝑖 ) = ∑(𝑥𝑖 × √𝑀𝑖 ) =
0.000001286299 0.123259

86
Viscosity of individual gases is determined using the above graph at 600 C.

Now, we can proceed with the demister pad thickness calculation.

Determining Allowable Face Velocity:

Let's assume an allowable face velocity of 0.5 m/s. This value can vary depending on
the specific application and design standards.

Calculating Cross-sectional Area:

The cross-sectional area of the demister pad can be calculated using the cross-sectional
area of the flash separator.

𝜋
Cross-sectional Area , 𝐴 = × 2.52
4

= 4.908 𝑓𝑡 2

= 0.46 𝑚2

87
Determining Demister Pad Thickness:

Liquid Load × Gas Density

𝐷𝑒𝑚𝑖𝑠𝑡𝑒𝑟 𝑃𝑎𝑑 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 =
Area × Separation Efficiency × Gas Viscosity

kg 𝑘𝑔
5.518 s × 0.0178 3
= 𝑚
0.46 𝑚2 × 0.50 × 3.5587

= 0.1524 𝑚

= 0.5 𝑓𝑡

So, the estimated demister pad thickness is 0.5 ft

88
Mechanical Drawing

Figure 12: Front View of Flash Separator

89
Figure 13: Cross Sectional View of Flash Separator

90
P&ID of Flash Separator

Figure 14: P&ID of Flash Separator

91
 SPECIFICATION SHEET OF SEPARATOR:

Identification: Date: 05/10/2023

Item: Separator
Item no: V-101
No. required: 2

Function: To separate liquid phase from vapor phase.

Operations Continuous
Materials handled 528.661 lb
Quantity(kmol/hr) 1056.8 kmol/hr
Temperature( 0C) 600 C

Design data:

Pressure 26 bar
Functional 11.4 ft
height
Material of Stainless steel 316 L
construction
Diameter 2.5 ft
Support Skirt
Controls Liquid level at bottom of the separator is controlled by controlling
flow rate of bottom product and liquid inlet is controlled by
controlling recycle flow rate.
Tolerances: TEMA standards.
Comments and drawings: Location and sizes of inlets and outlets are
shown on drawing.

92
References

107_FICHIER_0. (n.d.).

Herning and Zipperer equation. (n.d.). A Slmple and Accurate Method for Calculatlng
Viscosity of Gaseous Mixtures I UNITED STATES DEPARTMENT OF THE
INTERIOR I.

kupdf.net_crane-technical-paper-410. (n.d.).

Lide, D. R., Eleanor Lide David Alston Lide, M., & Grace Eileen Lide David Austell
Whitcomb Kate Elizabeth Whitcomb, J. (2003). CRC Handbook of Chemistry and
Physics, 84th Edition, 2003-2004.

Pell, Melvyn., Dunson, J. B., & Knowlton, T. M. (Ted M. ). (2008). Perry’s chemical
engineers’ handbook. Section 17, Gas-solid operations and equipment. McGraw-Hill.

Rousseau, R. W. (1987). Handbook of separation process technology. J. Wiley.

93
Chapter 13: Detailed Design of Primary Reformer

Prepared By-

Bimol Nath Roy

1702026
Department of Chemical Engineering
Bangladesh University of Engineering and Technology

94
Basic Calculation: Primary Reformer (R-101)

12

11 Primary Reformer 13

6 10

Inlet (mole%) Outlet (mole%)

Stream No.
11 06 10 13 12
Temperature (℃) 450 30 30 600 750
Pressure (Bar) 16 16 1 15.5 1
Mass Flow (kg/h) 8816.7 606.9 10863 8816.7 11469.9
Molar Flow
500 36.709 376.64 662.02 414.03
(kmol/h)
CH4 0.24228 0.9691 - 0.0732 -
C2H6 0.00593 0.0237 - - -
C3H8 0.00110 0.0044 - - -
C4H10 0.00037 0.0015 - - -
N2 0.00032 0.0013 0.79 0.0002 0.7187
H2O 0.75000 - - 0.4074 0.1804
O2 - - 0.21 - 0.0091
CO - - - 0.0857 -
CO2 - - - 0.0367 0.0918
H2 - - - 0.3968 -
Total (kg/h) 20286.6 20286.6

95
Energy Balance:
Energy balance is done considering the reference temperature of 25℃ and 1 bar

Reformer feed gas energy; Input: 11; Output: 13

Tin = 450℃ Tout = 600℃
Component nin Hin nin*Hin nout Hout n out* H out
kmol/hr kJ/mol MJ/hr kmol/hr kJ/mol MJ/hr
CH4 121.1375 -54.75 -6632.28 48.455 -45.39 -2199.37
C2H6 2.9625 -51.33 -152.065 0 -35.22 0
C3H8 0.55 -55.74 -30.657 0 -32.5 0
C4H10 0.1875 -61.67 -11.5631 0 -31.53 0
N2 0.1625 12.69 2.062125 0.1625 17.39 2.825875
H2O 375 -226.72 -85020 269.6903 -220.92 -59580
CO 0 -97.72 0 56.70525 -92.95 -5270.75
CO2 0 -374.68 0 24.30225 -366.97 -8918.2
H2 0 12.355 0 262.6998 16.8 4413.356
Total Hin -91844.5 Total Hout -71552.1

∆Q = -71552.1 - (-91844.5) = 20292.4 MJ/hr

Fuel Gas Energy; Input: 6,10; Output: 12

Tin = 30℃ Tout = 750℃
Component nin Hin nin*Hin nout Hout n out* H out
kmol/hr kJ/mol MJ/hr kmol/hr kJ/mol MJ/hr
CH4 0.9691 -74.67 -72.3627 0 -34.97 0
C2H6 0.0237 -84.4042 -2.00038 0 -17.37 0
C3H8 0.0044 -103.43 -0.45509 0 -6.9399 0
C4H10 0.0015 -124.2 -0.1863 0 1.55 0
N2 8.106149 0.15 1.215922 8.106149 22.22 180.1186
O2 2.155545 0.15 0.323332 0.102645 23.6 2.422422
CO2 0 -393.31 0 1.0357 -358.9 -371.713
H2O 0 -241.661 0 2.0344 -214.85 -437.091
Total Hin -73.4652 Total Hout -626.263

Fuel Gas Energy is calculated for 1 mol of fuel and 5% excess air is considered.

∆Q = n(-626.263) - n(-73.4652) = -552.8n

So, Required Fuel, n = 20292.4/552.8 = 36.709 mol fuel and 5% excess air

96
Reaction Kinetics:

Assumptions:

1. Plug flow.
2. Steady state process.
3. Kinetics other than methane reforming are neglected.

Considering the steam reforming of methane, involves two major reactions-

CH4 + H2O = 3H2 + CO

CO + H2O = CO2 + H2

Reaction kinetics for these two reactions are defined as [1] -

𝑃𝐶𝐻4 𝑃𝐶𝑂 0.5

𝑘1𝐾1 [𝐾1 2.5 − 𝑃𝐻2 𝑃𝐶𝑂 ]
𝑃𝐻2
𝑟1 =
𝐾 𝑃𝐻2𝑂 2
(1 + 𝐾𝐶𝑂 𝑃𝐶𝑂 + 𝐾𝐻2 𝑃𝐻2 + 𝐾𝐶𝐻4 𝑃𝐶𝐻4 + 𝐻2𝑂 𝑃𝐻2 )

𝑃 𝑃𝐻2
𝑘0𝑃𝐶𝑂 𝑃𝐻2𝑂 (1 − 𝑃 𝐶𝑂2
𝑃 𝐾)
𝐶𝑂 𝐻2𝑂 𝑒
𝑟2 =
(1 + 𝐾21𝑃𝐶𝑂 + 𝐾22𝑃𝐻2𝑂 + 𝐾23𝑃𝐶𝑂2 + 𝐾24𝑃𝐻2 )2

Temperature, T = 823 K

Pressure, P = 16 bar

Partial pressures are listed below-

𝑃𝐶𝐻4 = 1.17 bar

𝑃𝐻2𝑂 = 6.52 bar

𝑃𝐻2 = 6.35 bar

𝑃𝐶𝑂 = 1.37 bar

𝑃𝐶𝐻4 = 0.59 bar

97
Values of equilibrium constants are calculated using literature parameters-

Equilibrium Equilibrium
Value Value
Constant Constant
𝑘1 (mol atm0.5 /g h) 382.69 𝑘0 0.5244
𝐾1 (atm2) 0.5234 𝐾21 2.5052
𝐾𝐶𝐻4 (atm-1) 0.1298 𝐾22 0.4864
𝐾𝐻2𝑂 (atm-1) 0.8754 𝐾23 0.1417
𝐾𝐻2 (atm-1) 5.5863 𝐾24 0.3781
𝐾𝐶𝑂 (atm-1) 1.3893

Inserting the parameters in kinetic equation-

r1 = -0.4086 mol/kg catalyst.s

r2 = 0.0094 mol/kg catalyst.s

Effectiveness factor = 0.0017

reaction rate of methane,

-rCH4 = 0.0017×0.4086×3.6 = 0.0025 kmol/kg catalyst.h

Amount of catalyst required = (Amount of methane reacted)/(Rate of reaction for

methane)

=(0.24228×500-0.0732×662.02)/0.0025 = 29072 kg

Catalyst Requirement:

Catalyst Name: 25-4MQ (JM Catalyst) [2]

Size = 13mm×10.5mm×2.7mm [Length × OD × ID]

Void fraction, ℇ = 0.3967

Bulk density, 𝜌𝑏 = 950 kg/m3

Catalyst Surface area = 768.2626 mm2

98
 768.2626
Equivalent spherical diameter, 𝐷𝑒 = √ = 15.60 mm = 0.0156 m
3.1416

Tube Calculation:

Volume of reactor, Vr = Weight of Catalyst/Bulk Density of Catalyst

= 29072/950 = 30.60 m3

Total molar flow of LNG and Steam, nin = 500 kmol/hr

Molar volume of LNG and Steam input, Vmolar = 3.72 m^3/kmol [From Aspen HYSYS]

Total volumetric flow, VTotal = 500×3.72 m^3/hr = 1860 m^3/hr

Taking, 5 in schedule 40 size for tubes,

Tube length, L = 30 ft = 9.144 m

Tube Inner Diameter, ID = 128.1 mm = 0.1281 m

π×ID2 ×L
Volume of one tube, VTube = = 0.117849 m3/pipe
4

No. of tubes = Volume of reator/Volume of one tube = 30.60/0.117849 = 259.67 ~ 260

tubes

Pressure Drop Calculation

Pressure drop can be calculated from the Ergun equation,

∆𝑃 150𝜇 (1 − 𝜀)2 1.75𝜌𝑣𝑠 2 (1 − 𝜀)

= 𝑣𝑠 +
𝐿 𝐷𝑒 2 𝜀3 𝐷𝑒 𝜀3

Where,

∆𝑃 = Pressure drop across packed tube

𝐿 = Height/Length of tube

𝐷𝑒 = Equivalent spherical diameter of particle

𝜇 = Dynamic viscosity of fluid

𝜀 = Void fraction

99
𝑣𝑠 = Superficial velocity

𝜌 = Density of fluid

From Hysys,

Gas density, ρ = 4.746 m3/kg

Viscosity, μ = 2.16×10-5 Pa.s

Considering superficial velocity, 𝑣𝑠 = 1 m/s

150 × 2.16 × 10−5 (1 − 0.3967)2

∆𝑃 = 9.144 × ( × ×1
0.01562 0.39673
1.75 × 4.746 × 12 (1 − 0.3967)
+ × )
0.0156 0.39673

= 47752 Pa ~ 0.50 bar

Fuel Requirement:

From energy balance-

Fuel required = 36.709 kmol/hr

Air required = 376.64 kmol/hr

Mechanical Design:

Tube Thickness Calculation (ASME B31.3 Method):

Material considered: HK 40 Steel

Yield strength = 35000 psi

Safety factor = 3

Allowable stress, S = Yield strength/Safety factor = 35000/3 = 11667 psi = 80.4 MPa

Pressure inside tube, P = 1.6 MPa = 232.06 psi

Pipe wall thickness calculation as per ASME B31.3 method [3]-

tm = t + c

100
where,

tm = Minimum thickness in mm

𝑃𝐷
𝑡=
2(𝑆𝐸𝑊 + 𝑃𝑌)

c = Corrosion allowance in mm

P = Internal design pressure in psi

D = Tube inner diameter in mm

S = Allowable stress in psi

E = Quality factor

W = Weld joint strength

Y = Coefficient from ASME B31.3 table 304.1.1

Taking E = 1, W = 1 and Y = 0.4 and Tube Inner Diameter, D = 128.1 mm

232.06×128.1
𝑡= = 1.264 mm
2(11667×1×1+232.06×0.4)

Taking corrosion allowance, c = 4 mm

Taking an 12.5% error, thickness = (tm/0.875) = (t + c)/0.875 = (1.264+4)/0.875 = 6.015

mm

Which is less than D/6, so according to ASME B31.3, 304.1.2(a) calculated thickness
is justified. Now with available market size, 5 in 40 schedule is taken as it has 6.6 mm
thickness.

Primary Stresses:

P×D
(i) Horizontal Stress, 𝜎ℎ = 2t
1.6×0.1281
= = 15.527 MPa
2×0.0066

P×D
(ii) Longitudinal Stress, 𝜎𝑙 = 4t

101
 1.6×0.1281
= = 7.763 MPa
4×0.0066

Shell Size:

Assuming tubes are arranged in 10 rows

Tubes per row = 260/10 = 26

Tube outer diameter = 0.1347 m

Length, L = 2 × Wall Gap + Diameter of Support + No. of Tubes × (Tube Gap + Tube
Diameter)

= 2×1.5+0.2696+26×(0.2696+0.1347)m

= 13.7760 m

Width, W = No of Row × ( Row Gap + Tube Diameter)

= 10×(1.5 +0.1347) m

= 16.3470 m

Height, H = Tube height + Allowance = 9.1440 + 2.3470 = 11.4910 m

Thickness for Shell:

From Joshi M.V, Process Equipment Design,

Thickness of firebrick, x1 = 114 mm = 0.114 m

Thickness of insulation brick, x2 = 229 mm = 0.229 m

Thickness of outer carbon steel, x3 = 4 mm = 0.004m

Insulation to Shell Calculation: [4]

Area for heat transfer, A = 2×H(L+W) +2× L×W

= 2×11.4910(13.7760+16.3470)+2×13.7760×16.3470

= 1142.67 m2

Thermal conductivity of fire brick, k1 = 0.98 W/m.℃

102
Thermal conductivity of insulation brick, k2 = 0.32 W/m.℃

Thermal conductivity of carbon steel, k3 = 50.2 W/m.℃

Assuming shell outer surface temperature = 75℃

Heat transfer with insulation,

𝑇𝑖 − 𝑇𝑜
𝑞=
𝑘1 𝑘2 𝑘3
𝑥1 × 𝐴 + 𝑥2 × 𝐴 + 𝑥3 × 𝐴

So,

750 − 30
𝑞= = 65.50𝑊
0.98 0.32 50.2
0.114 × 917.483 + 0.229 × 917.483 + 0.004 × 917.483

Load Calculation:

Density of fire brick = 2270 kg/m3

Density of insulation brick = 604 kg/m3

Density of fire cast iron = 7300 kg/m3

Density of fire HK 40 alloy = 7720 kg/m3

Weight of fire brick = Area × Thickness × Density = 1142.67 × 0.114 × 2270 = 295700
kg

Weight of insulation brick = Area × Thickness × Density = 1142.67 × 0.229 × 604 =

158050 kg

Weight of cast iron = Area × Thickness × Density = 1142.67 × 0.004 × 7300 = 33365
kg

Weight of tubes = No. of tubes × πD × L × Thickness × Density

= 260 × 3.1416 × 0.1347 × 9.144 × 7720 = 7766857 kg

Total Weight = 295700 + 158050 + 33365 + 7766857 = 8253972 kg

Support: Reinforced Concrete Support

103
Mechanical Drawing of Primary Reformer

Figure 15: Front sectional view of PRF

Figure 16: Top view of PRF

104
P&ID for Primary Reformer

Figure 17: P&ID for PRF

105
Specification Sheet

Job No Reference No
Customer Proposal No
Address Date
Plant Location Item: Primary Reformer
Service of Unit Item No: R-101
Code:
Operation: Continuous
Function: Input of air and fuel necessary for combustion and steam-methane
reforming
Tube Specification No of Tubes: 260
Material: HK 40 Alloy
5 inch. 40 Schedule
Length: 30 ft
Catalyst Specification Catalyst Name: 25-4MQ (JM Catalyst)
Size = 13mm×10.5mm×2.7mm
Requirement: 29072 kg
Shell Specification (Without Insulation)
Length: 13.776 m
Width: 16.3470 m
Height: 11.4910 m
Shell Materials and Thickness Fire Brick – 0.114 m
Insulation Brick – 0.229 m
Cast Irom – 0.004 m

106
References:

[1] Amran, U. I., Ahmad, A., & Othman, M. R. (2017). Kinetic based simulation
of methane steam reforming and water gas shift for hydrogen production using
aspen plus. Chemical Engineering Transactions, 56, 1681-1686.

[2] https://matthey.com/documents/161599/440823/JM+Steam+reforming+cataly
sts+product+brochure+%28c2019%29.pdf/

[3] https://designandengg.com/pipe-wall-thickness-calculation-as-per-code-asme-
b31-3/

[4] J.P., H., Heat Transfer. Vol. 8th edition.

107
Chapter 14: Detailed Design of Methanol Synthesis Reactor

Prepared By-

Bilash Devnath
1702056
Department of Chemical Engineering
Bangladesh University of Engineering and Technology

108
PLUG FLOW REACTOR FOR METHANOL SYNTHESIS (R-103)

Assumptions:

• Plug flow
• Steady state
• The kinetics of reactions other than reverse water gas shift and methanol formation
from CO and CO2 are neglected. Kinetics takes into account only the methanol
formation from CO2 therefore, methanol formation reaction from CO is not shown
here
• Catalyst effectiveness remains unchanged

Reactions:

Kinetic model:

Table 6: Kinetic parameters equations for the rate equations [1]

109
Table 7: Kinetic parameters values for the rate equations

Parameters Values
k1 5.8376e-05
k2 6.0721e-05
k3 5.2027e-05
K1 1.9643
K2 2.4305
K3 5.0638
Keq,1 0.0066
Keq,2 0.0065

Reactor sizing calculation:

The mole balances and stoichiometry give,

𝑑𝐹𝐻2
=-3r1+r2+r3=RH2 ………..(1)
𝑑𝑊

𝑑𝐹𝐶𝑂2
=-r1+r2=RCO2 ………………(2)
𝑑𝑊

𝑑𝐶𝐻3𝑂𝐻
=r1+r3=RCH3OH ...…………(3)
𝑑𝑊

𝑑𝐻2𝑂
𝑑𝑊
=r1-r2=RH2O ……………….(4)

110
𝑑𝐹𝐶𝑂
=-r2-r3=RCO …………….(5)
𝑑𝑊

𝑑𝐹𝑁2
=0=RN2 ………………….(6)
𝑑𝑊

𝑑𝐹𝐶𝐻4
=0=RCH4 ………………..(7)
𝑑𝑊

The differential equations are solved using the odesuit45 in MATLAB (Appendix A).
A plot for molar flow rate of the components as a function of catalyst weight gives us
the required weight for the desired conversion.

Initial flow rates:

Component Flow rate (mol/s)

H2 84.84
CO2 18.02
CH3OH 2.16
H2O 2.23
CO 43.29
N2 460.43
CH4 2.35
Total flow rate 613.32

Catalyst requirement:

Figure 18: Molar Flow rate of Methanol vs Weight of Catalyst

111
From the graph, weight of catalyst required to achieve CO2 outlet flowrate is W= 3000
kg

Catalyst Specification:

Catalyst: Cu/ZnO/Al2O3

Catalyst particle shape: cylinder

Catalyst diameter: 10.95 mm

Catalyst particle height: 5.2 mm

Catalyst particle density: Dc = 1190 kg/m3

Reactor specifications:

Void fraction of bed, ϵ = 0.465

Length of tube, L = 7 m

Diameter of tube, D = 0.04 m

Radius of tube, R = 0.02 m

Required tube number:

Catalyst weight required, W = 3000 kg

𝑊 3000
Catalyst volume required, Vc = 𝐷𝑐 = 1190 = 2.52 m3

𝑉𝑐 2.52
Total volume required, Vt = = = 4.71 m3
1−𝑒 1−0.465

Volume of one tube = 𝜋 × 𝑅2 × 𝐿 = 𝜋 × 0.022 × 7 = 0.009 m3

𝑇𝑜𝑡𝑎𝑙 𝑅𝑒𝑎𝑐𝑡𝑜𝑟 𝑉𝑜𝑙𝑢𝑚𝑒 4.71

So, no of tubes = = 0.009 =523.33 ≈ 524
𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑒𝑎𝑐ℎ 𝑡𝑢𝑏𝑒

Cooling fluid:

Qt=Qs= 3.24×106 kJ/hr. =900 kJ/s

Water at inlet temperature, 𝑇1 = 25oC and 1 atm pressure is heated to an exit

temperature,

112
𝑇2 = 50oC remove heat generated in the tube side.

Cp = 4.182 kJ/kg oC

𝑄𝑠 900
mw = 𝐶𝑝(𝑇2−𝑇1) = 4.182(50−25) = 8.61 kg/s

Pressure drop calculation (tube side):

Pressure drop in a packed column reactor is calculated by the Ergun equation,

Density of the mixture was calculated using ideal gas equations. Average molecular
mass of

inlet and outlet mixture are first calculated.

From simulation, gas density and viscosity,

ρin = 35.71 kg/m3

ρout =32.17 kg/m3

ρavg = 33.94 kg/m3

µin =2.3×10-5 kg/m.s

µout =2.5×10-5 kg/m.s

µavg =2.4×10-5 kg/m.s

Catalyst particle shape: cylinder

Diameter, D = 10.95 mm

Height, h = 5.2 mm

Volume, V = 𝜋𝑟2ℎ = 4.89 ×10-7 m3

Surface area, A = 2𝜋𝑟2 + 2𝜋𝑟ℎ = 2.72 × 10-4 m2

6𝑉 6∗4.89∗10^−7
Particle Diameter, Dp = = = 8 mm
𝐴 2.72∗10^−4

113
Mass Flow rate in, min = 55652.84 kg/hr

55625.84
Mass flow rate per tube, mint = = 106.2 kg/hr
524

Tube Diameter, ID = 0.04m

Flow area per tube, at = 𝜋𝑟2 = 𝜋 × 0.022 = 0.001257 𝑚2

𝑚𝑖𝑛𝑡 106.2
Mass Velocity, G = = .001257 =84486.87 kg/hr.m2
𝑎𝑡

Superficial Velocity, Vs =(G/ ρin +G/ ρout)/2 = 2496.08 m/hr = 0.7 m/s

Tube length, L = 7m

Bed porosity, e= 0.465

Pressure drop in the tube calculated using Ergun equation gives,

∆P = 136287.84 = 1.36 bar

Mechanical Design:

Tube diameter and thickness:

Tube internal diameter, ID = 40 mm = 0.04 m

Operating pressure, P= 54 bar

Safety factor, S=1.2

Design pressure, Pd=1.2×54=64.8 bar = 65.26 kg/cm2

Material is stainless steel for tube

Maximum allowable stress for stainless steel SS 304L, F = 1006 kg/cm2

Joint efficiency, J= 1

P×ID 65.26×40
Tube thickness, t = 2𝐹𝐽+𝑃 = 2×1006×1+65.26 = 1.26 ≈ 2 mm

Tube outer diameter, OD = 40 mm + 2×2 mm = 44 mm

Heating area required, A = NT×𝛑×OD×L = 524×3.1416×0.044×7 = 507.03 m2

114
Shell diameter and thickness:

Number of tubes, NT = 524

Bundle diameter, Db = OD×(NT/K)1/n

For 1.25 in triangular pitch of tubes, K = 0.319 and n = 2.142 (Towler)

Db = 1395 mm = 1.395 m

Bundle diametrical clearance = 21 mm

Shell diameter, IDs = 1395 mm + 21 mm = 1416 mm = 1.416 m

Operating pressure, P= 1.01325 bar

Safety factor, S=1.2

Design pressure, Pd=1.2× 1.01325 = 1.216 bar = 1.24kg/cm2

Material for shell is carbon steel

Maximum allowable stress for carbon steel, F = 950 kg/cm2

Joint efficiency, J= 0.8

Corrosion allowances, C = 3 mm

P×ID 1.24×1416
Shell thickness, t = 2𝐹𝐽+𝑃 + C = 2×950×.85+1.24 + 3 = 4.08 mm ≈ 5 mm

Shell outer diameter, OD = 1416 mm + 2×5 mm = 1426 mm = 1.426 m

Shell height:

Tube length, L = 7 m

Leaving 20% spacing above and below, shell height = 2×(0.2×7) + 7 = 9.8 m

Pressure drop shell side:

Baffle cut = 25%

Pitch is taken as 1.25ODt triangular pitch ODt = 44 mm

115
IDs = 1416 mm

Flow rate of water, Ws = 8.61 kg/s

Properties at mean T = 37.5 ˚C,

𝜌 = 993 kg/ m3

𝜇 = 692 × 10-6 kg/m.s

Cp = 4.178 kJ/kg.K

Pt = 1.25×ODt =1.25×44 mm = 55 mm

Baffle spacing, Lb = 0.2×IDs = 0.2×1416 mm = 283.2 mm

(𝑃𝑡−𝑂𝐷𝑡)×IDs×Lb (55−44)×1416×263
Area of cross flow = As = = = 74481.6 mm2 = .0745
𝑃𝑡 55

m2

𝑊𝑠 8.61
Mass Velocity, Gs = = = 115.57 kg/m.s
𝐴𝑠 0.0745

𝐺𝑠 115.57
Linear Velocity, Vs = = = 0.116 m/s
ρ 993

Shell equivalent diameter (hydraulic diameter)

For triangular pitch, de = 1.1(Pt2 – 0.917 × ODt2) / ODt = 1.1(552- 0.917 × 442) = 31.24
mm

𝐺𝑠×de 115.57×31.24×10^−3
Reynolds number, Re = = = 5217
μ 692×10^−6

Shell side friction factor from fig-19.30 of “Chemical Engineering Design Principles”

Elsevier 2nd edition by Gavin Towler page- 1088,

Shell side friction factor jf = 0.045

Pressure drop, ∆𝑃𝑠 = 8jf(IDs/de)(L/Lb)( ρV2/2)

= 8 × 0.045 × (1416/31.24) × (7000/283.2) × (993 ×.1162/2)

= 2.7 kPa

116
 =0.027 bar

Nozzle diameter and thickness:

Nozzle diameter, DN

taking D/DN = 4

Shell inside diameter, D = 1416 mm

DN = 354 mm = 13.94 in

Taking nearest nominal pipe size 14 inch [01]

P×DN
Nozzle thickness, tN = 2𝐹𝐽−𝑃

here, tN = nozzle thickness

Nozzle diameter, DN = 355.6 mm

Maximum allowable stress, F = 950 kg/cm2 and J = 1

Shell side design pressure, P = 1.24 kg/cm2

1.24×355.6
Shell side, tN = 2×950×1−1.24 + 3 mm = 3.23 mm ≈ 4 mm

Tube side design pressure, P = 65.26 kg/cm2

65.26×355.6
Tube side, tN = 2×950×1−65.26 + 3 mm = 15.64 mm ≈ 16 mm

Head thickness:

Selecting torispherical head,

Crown radius taken similar to shell IDs, Rc = 1416 mm

Knuckle radius 6% of IDs, Ri = 0.06×1416 = 84.96 mm

𝑅𝑐
W = (1/4) × (3 + √ 𝑅𝑖 )

1416
= (1/4) × (3 + √84.96 ) = 1.77 mm

Maximum allowable stress, F = 950 kg/cm2 and J = 1

117
 𝑊𝑃𝑅𝑐 1.77× 1.24× 1416
tH = = = 1.64 mm
2𝐹𝐽 2× 950× 1

including corrosion allowances of 3 mm we can use thickness same as shell 5 mm.

Tube sheet thickness:

Minimum tube sheet thickness according to TEMA standard, can be given by

F = 1 for fixed tube sheet

Gp = IDs = 1416 mm for fixed tube sheet

f = 1006 kg/cm2 allowable stress

P = 65.26 kg/cm2

tts = 196 mm

Baffle:

Baffle shape: Segmental with 25% cut

Baffle spacing, Lb = 263 mm

Tube length, L = 7000 mm

Number of baffles, L/Lb = 7000/283.2 = 24.7 ≈ 25

Weight Calculation:

Weight of eacg tube, Wtl = Vtl × 𝜌

Vtl = pi/4 (D02 – Di2) × H

= pi/4 (.0442 - .042) × 7

118
 = 1.85 × 10-3 m3

Wtl = 1.85 × 10-3 m2 × 8000 = 14.8 kg

Total weight of all tubes, Wt = 524×14.8 = 7755.2 kg

Weight of Catalyst = 3000 kg

Weight of Cylindrical shell. Ws = Vs × 𝜌

Vs = pi/4 (D02 – Di2) × H

= pi/4 (1.4262 – 1.4162) × 7

= 156 × 10-3 m3

Ws = 156 × 10-3 m3 × 7700

= 1203 kg

Stress due to dead weight-

∑𝑊
𝑓𝑑 = 𝜋𝐷𝑠𝑘 𝑡𝑠𝑘

Here-

fd= stress due to dead weight,

W = dead weight of vessel contents and attachments

tsk = thickness of the skirt.

So total dead weight, ∑W

= Weight of all tubes + Weight of Catalyst + Weight of Cylindrical Shell

=(7755.2 + 3000 + 1203) kg

= 11958.2 kg

Dsk = diameter of the skirt (outside diameter of the shell)

= 𝐷 + 2 × 𝑡𝑠

119
 = (1.426 + 2 × 0.005) m

= 1.436m

Now by putting the values we have-

2650.7
𝑓𝑑 =
𝑡𝑠𝑘

Stress due to bending moment due to wind flow-

𝑀𝑤
fwb = 𝑍
4𝑀𝑤
fwb = 𝜋×𝐷𝑠𝑘×𝑡𝑠𝑘
Z = Modulus section for skirt cross-section
tsk = thickness of the skirt
𝐻
Again, Mw = 𝜌 × 2
𝜌 = 𝑘PH𝐷𝑜
k = shape factor, for cylindrical shape (0.7)

= 0.7
P = wind pressure (40 to 100 kg/m2)
= 70 kg/m2

By putting the values we have-

4𝑀𝑤
fwb = 𝜋𝐷
𝑠𝑘 𝑡𝑠𝑘

𝐻
4× 𝜌 ×
2
= 𝜋𝐷
𝑠𝑘 𝑡𝑠𝑘

𝐻
4× kPHDo×
2
= 𝜋𝐷𝑠𝑘 𝑡𝑠𝑘

2975.04
= 𝑡𝑠𝑘

Stress due to seismic load

8𝑤𝐶𝐻
fsb =3𝜋𝑡 2
𝑠𝑘 𝐷

C = Seismic coefficient = 0.1 (0.1 to 0.3) ,W = Total weight of the column , H = Height
of the column

The total weight of the column = 11958.2 kg

4891.8
Putting the values we have- fsb = 𝑡𝑠𝑘

120
Skirt thickness calculation-

Stress due to seismic load is greater than wind load.

So maximum tensile stress at the bottom of the skirt, = 𝑓sb – 𝑓d

4891.8 2650.7
= –
𝑡𝑠𝑘 𝑡𝑠𝑘

2241.1
= 𝑡𝑠𝑘

Permissible tensile strength = 565 MPa = 5.7×107 kg/m2

2241.1
tsk = 5.7×10^7
= 0.039 mm

Maximum compressive stress at the bottom of the skirt, = 𝑓s𝑏 + 𝑓𝑑

4891.8 2650.7
= +
𝑡𝑠𝑘 𝑡𝑠𝑘

7542.5
= 𝑡𝑠𝑘

Permissible compressive strength = 248 MPa = 2.5×107 kg/m2

7542.5
tsk = 2.5×10^7

= 0.3 mm

The calculated skirt thickness is too low.

We may assume the skirt thickness to be = 5 mm

Reference:
[1] Nestler, F., Schütze, A. R., Ouda, M., Hadrich, M. J., Schaadt, A., Bajohr, S.,
& Kolb, T. (2020). Kinetic modelling of methanol synthesis over commercial
catalysts: A critical assessment. Chemical Engineering Journal, 394, 124881.

121
Mechanical Drawing

Figure 19: Detailed design of methanol synthesis reactor

122
Figure 20: Cross section of shell with tube bundle inside and their dimensions

123
P&ID for Methanol Synthesis Reactor

Figure 21: P&ID of the methanol synthesis reactor

124
 Chapter 15: Economic Analysis

15.1 Estimation of Total Capital Investment

Purchased Equipment Cost

Equipment Number Equipment Name Cost

C-101 Compressor $580,000
C-102 Compressor $252,500
C-103 Compressor $300,000
E-101 Heat Exchanger $23,500
E-102 Heat Exchanger $23,500
E-103 Heat Exchanger $23,500
E-104 Heat Exchanger $23,500
E-105 Heat Exchanger $26,000
E-106 Heat Exchanger $26,000
E-107 Heat Exchanger $23,500
P-101 Pump $5,000
R-101 Primary Reformer $1,245,000
R-102 Secondary Reformer $415,000
R-103 Methanol Synthesis Reactor $615,000
T-101 Light End Distillation Column $41,000
T-102 Heavy End Distillation Column $50,500
TK-101 Storage Tank $154,500
V-101 Flash Separator $123,000
V-102 Flash Separator $190,500
WHB-101 Waste Heat Boiler $50,000
Total Purchased Equipment Cost $4,191,500

Methanol synthesis reactor cost was taken from ‘Matches’ [9] and other equipment
costs are taken from ‘MHHE’ [10] . All the cost are normalized for the cost index of
2023. Cost index of 2023 is calculated by extrapolating the cost index data of 2002 and
2021.

125
Cost index of 2002 = 390.4

Cost index of 2021 [11] = 722.8

Cost index of 2023 = 390.4 + (2023-2002)(722.8-390.4)/(2021-2002) = 757.8

Estimation of Capital Investment [12]

Items Factor Cost

Direct cost
Purchased equipment 1 $4,191,500
Purchased equipment installation 0.47 $1,970,005
Instrumentation and control 0.36 $1,508,940
Piping (Installed) 0.68 $2,850,220
Electrical (Installed) 0.11 $461,065
Building 0.18 $754,470
Yard improvement 0.1 $419,150
service facilities 0.7 $2,934,050
Land 0.06 $251,490
Total direct cost 3.66 $15,340,890
Indirect cost
Engineering and supervision 0.33 $1,383,195
construction & expenses 0.41 $1,718,515
Legal expanses 0.04 $167,660
Contractor’s fee 0.22 $922,130
Contingency 0.44 $1,844,260
Total indirect cost 1.44 $6,035,760
Fixed capital investment 5.1 $21,376,650
Working capital investment 0.89 $3,730,435
Total Capital investment 5.99 $25,107,085

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15.2 Determination of Operating Cost

Let, total production cost = C

Estimation of Total Production Cost

Manufacturing cost = Direct Production Cost + Fixed Charges + Plant Overhead Cost

Direct Production Cost

No Components Costs ($)

01. Raw Material (10-80% of total product cost) 0.23C

02. Operating Labor (10-20% of total product cost) 0.15C

Direct Supervisory and Clerical Labor (10-20% of total

03. 0.10C
product cost)

04. Utilities (10-20% of total product cost) 0.15C

05. Maintenance and Repairs (2-10% of total product cost) 0.02C

06. Operating Supplies (0.5-1% of total product cost) 0.005C

07. Laboratory Charges (10-20% of total product cost) 0.024C

08. Patents and Royalties (0-6% of total product cost) 0.005C

Total Direct Production Cost 0.684C

Fixed Charges (10-20% of total production cost)

1. Depreciation (depends on life period, salvage value and method of calculation

about 10% of fixed capital investment for machinery and equipment and 2-3% of
building value for buildings) = 0.07FCI
2. Local Taxes (1-4% of fixed capital investment) = 0.01 FCI
3. Insurance (0.4-1% of fixed capital investment) = 0.004 FCI

127
Plant Overhead (5-15% of total production cost) = 0.05C

(60-70% of cost for operating labor, supervision, and maintenance, or 5-15% of total
production cost); includes costs for the following: general plant upkeep and overhead,
payroll overhead, packaging, medical services, safety and protection, restaurants,
recreation, salvage, laboratories, and storage facilities. Thus,

Manufacturing Cost = 0.684C + 0.084FCI + 0.05C = 0.734C + 0.084FCI

General Expenses

1. Administrative Costs (2-5 % of total product cost) = 0.02C

2. Distribution and Selling Costs (2-20 % of total product cost) = 0.04C
3. R&D Costs (About 5% of total product cost) = 0.02C
4. Financing (0-10 % of total capital investment) = 0.03TCI

General Expenses = Administrative Costs + Distribution and Selling Costs + R&D

Costs

Thus,

General Expenses = 0.08C + 0.03TCI

Hence, Total Production Cost = Manufacturing Cost + General Expenses

or, C = 0.73 C + 0.084 FCI + 0.08 C + 0.03TCI

or, C = 0.81C + 0.084×$21,376,650 + 0.03×$25,107,085

or, C = $13,415,006.05

Total Production Cost = $13,415,006.05/year

(Assuming this production cost includes raw materials cost, utility cost, maintenance
cost etc.)

128
15.3 Determination of Revenues

Daily methanol production = 90 MT

Yearly methanol production = 29700 MT

Market price of methanol = $555/ MT [https://www.methanex.com/about-

methanol/pricing/]

Revenue = 29700×555 = $16,483,500/year

15.4 Calculation of Depreciation Cost by Sinking Fund Method

Project Life = 20 years

Salvage value at the end of the project life = 10% of Fixed Capital Investment

= 0.1 × $21,376,650

= $2,137,665

15.5 Net Income Calculation

Yearly Revenue $16,483,500

Total Production Cost -$13,415,006.05
Gross Annual Earning $3,068,493.95
Tax (30%) $920,548.185
Net Income (After Tax) $2,147,945.765

15.6 Cash Flow Diagram

129
15.7 Feasibility Analysis

Let, MARR = 12%

Assumption: The useful life of the plant is 20 years. So, n = 20

15.7.1 PW Method

PW = -Total capital investment + Annual income (P/A, 12%, 20) + Salvage value (P/F,
12%, 20)

Present Worth = -$8,841,520.38

The plant is not economically justified because of PW<0.

15.7.2 IRR Method

Let, Internal Rate of Return, IRR = i%

PW = -Total capital investment + Annual income (P/A, i%,20) + Salvage value (P/F,
i%,20)

For IRR, considering PW = 0,

The equation for present worth is solved for finding the IRR.

IRR = 6.0929%

The plant is not economically justified because of IRR < MARR.

15.7.3 ERR Method

Let, External Rate of Return, ERR = i%

Assuming, External reinvestment rate per period, ϵ = MARR = 12% per year

Present Worth of negative cash flow, PW (12%) = $25,107,085

Future Worth of positive cash flow, FW (12 %) = Annual revenue (F/A, 12%, 20) +
Salvage value = $156,902,403.6

ERR calculation,

FW = PW(1+ i)n

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$156,902,403.6 = $25,107,085(1+i)20

So, i = 9.595 %

The plant is not economically justified because of ERR < MARR.

15.7.4 Payback Period

Cumulative PW Cumulative PW
EOY Net Cash Flow
(0%) (12%)

0 -$25,107,085 -$25,107,085 -$25,107,085

1 $2,147,945.77 -$22,959,139 -$23,189,276

2 $2,147,945.77 -$20,811,193 -$21,476,947

3 $2,147,945.77 -$18,663,248 -$19,948,082

4 $2,147,945.77 -$16,515,302 -$18,583,023

5 $2,147,945.77 -$14,367,356 -$17,364,221

6 $2,147,945.77 -$12,219,410 -$16,276,005

7 $2,147,945.77 -$10,071,465 -$15,304,383

8 $2,147,945.77 -$7,923,519 -$14,436,864

9 $2,147,945.77 -$5,775,573 -$13,662,293

10 $2,147,945.77 -$3,627,627 -$12,970,712

11 $2,147,945.77 -$1,479,682 -$12,353,229

12 $2,147,945.77 $668,264 -$11,801,905

13 $2,147,945.77 $2,816,210 -$11,309,651

14 $2,147,945.77 $4,964,156 -$10,870,139

15 $2,147,945.77 $7,112,101 -$10,477,717

16 $2,147,945.77 $9,260,047 -$10,127,341

17 $2,147,945.77 $1,1407,993 -$9,814,505

18 $2,147,945.77 $13,555,939 -$9,535,187

19 $2,147,945.77 $15,703,885 -$9,285,796

20 $4,285,610.77 $19,989,495 -$8,841,520

131
From the table,

Simple payback period = 12 years

The discounted payback period is higher than the study period. Hence the plant is not
economically feasible.

15.7.5 Sensitivity Analysis

20000000

10000000

0
-100 -50 0 50 100
Present Worth ($)

-10000000

-20000000

-30000000

-40000000

Deviation (%)
Investment Revenue Study Period MARR

Figure 22: Sensitivity analysis for the Cash flow of Methanol production plant

As the sensitivity analysis suggests, lowering the investment or MARR will make the
project economically feasible but might not be possible in real life. Also, increasing the
annual revenue by 60% will make the project economically viable and can be done with
process optimization.

132
 Chapter 16: Plant Layout and Equipment Layout

16.1 Plant Layout

Figure 23: Plant layout

16.2 Equipment Layout

Figure 24: Equipment Layout

133
 References

[1] Dalena, F., Senatore, A., Basile, M., Knani, S., Basile, A., & Iulianelli, A.
(2018). Advances in methanol production and utilization, with particular
emphasis toward hydrogen generation via membrane reactor technology.
Membranes, 8(4), 98.

[2] https://afdc.energy.gov/files/pdfs/mit_methanol_white_paper.pdf

[3] Kliman, M. L. (1983). Methanol, natural gas, and the development of

alternative transportation fuels. Energy, 8(11), 859-870.

[4] Alam, F., Saleque, K., Alam, Q., Mustary, I., & Chowdhury, H. (2019).
Indigenous and imported natural gas and the economic growth of Bangladesh:
The challenges ahead. Energy Procedia, 160, 18-25.

[5] F. Dalena, A. Senatore, A. Marino, A. Gordano, M. Basile, and A. Basile,

“Chapter 1 - Methanol Production and Applications: An Overview,” in
Methanol, A. Basile and F. Dalena, Eds. Elsevier, 2018, pp. 3–28. doi:
https://doi.org/10.1016/B978-0-444-63903- 5.00001-7

[6] IRENA AND METHANOL INSTITUTE, Innovation Outlok: Renewable

Methanol. 2021.

[7] H. Zou, S. Chen, J. Huang, and Z. Zhao, “Effect of impregnation sequence on

the catalytic performance of NiMo carbides for the tri-reforming of methane,”
International Journal of Hydrogen Energy, vol. 42, no. 32, pp. 20401–20409,
2017, doi: https://doi.org/10.1016/j.ijhydene.2017.06.203.

[8] A. Kleinert, A. Feldhoff, T. Schiestel, and J. Caro, “Novel hollow fibre

membrane reactor for the partial oxidation of methane,” Catalysis Today, vol.
118, no. 1, pp. 44–51, 2006, doi: https://doi.org/10.1016/j.cattod.2005.11.097

[9] https://www.matche.com/equipcost/FiredHeater.html

[10] http://www.mhhe.com/engcs/chemical/peters/data/

[11] https://www.chemengonline.com/2021-cepci-updates-december-prelim-and-
november-final/

134
[12] Culberson, O. L. (1982). PLANT DESIGN AND ECONOMICS FOR
CHEMICAL ENGINEERS, By Max S. Peters, Klaus D. Timmerhaus. Chemical
Engineering Education, 16(4), 205-205.

135
 Appendices

Appendix A: MATLAB Code for MSR

1. File Name: ‘equationset.m’

function dFdW= equationset(W,F)

dFdW = zeros(7,1)
%F(1) = Fh2
%F(2) = Fcd
%F(3) = Fm
%F(4) = Fw
%F(5) = Fcm
%F(6) = Fmt
%F(7)= Fn2
FT = F(1)+F(2)+F(3)+F(4)+F(5)+F(6)+F(7);
%required data
R=8.314 %J/k.mol
T=493 %K
Po =54 %bar
k1=1.09*(10^5)*exp(-87500/(R*T))
k2=9.64*10^11*exp(-152900/(R*T))
k3=4.89*10^7*exp(-113000/(R*T))
K1=2.16*10^-5*exp(46800/(R*T))
K2=7.05*10^-7*exp(61700/(R*T))
K3=6.37*10^-9*exp(84000/(R*T))
a1=7.44140*10^4;
a2=1.89260*10^2;
a3=3.2443*10^-2;
a4=7.0432*10^-6;
a5=-5.6053*10^-9;
a6=1.0344*10^-12;
a7=-6.4364*10^1;
lnkp1=(a1+a2*T+a3*T^2+a4*T^3+a5*T^4+a6*T^5+a7*T*log(T))/(R*T);
kp1=exp(lnkp1)
b1=-3.94121*10^4;
b2=-5.41516*10^1;
b3=-5.5642*10^-2;
b4=2.5760*10^-5;
b5=-7.5694*10^-9;
b6=1.0161*10^-12;
b7=1.8429*10^1;
lnkp2=(b1+b2*T+b3*T^2+b4*T^3+b5*T^4+b6*T^5+b7*T*log(T))/(R*T);
kp2=exp(lnkp2)
Ph2 = Po*(F(1)/FT);
Pcd = Po*(F(2)/FT);
Pm = Po*(F(3)/FT);
Pw = Po*(F(4)/FT);
Pcm = Po*(F(5)/FT);

%reaction rates= equations

denominator = (1+K1*Pcm+K2*Pcd)*((Ph2^.5)+K3*Pw);

136
r1 = (k1*K2*(Pcd*(Ph2^1.5)-
Pm*Pw/((Ph2^1.5)*kp1)))/(.1*denominator);
r2 = (k1*K2*(Pcd*Ph2-(Pw*Pcm/kp2)))/(denominator);
r3 = (k3*K1*(Pcd*(Ph2^1.5)-
Pm*Pw/((Ph2^1.5)*kp1)))/(.1*denominator);

dFdW(1) = -3*r1+r2-2*r3;
dFdW(2) = -r1-r2;
dFdW(3) = r1+r3;
dFdW(4) = r1+r2;
dFdW(5) = r2-r3;
dFdW(6) = 0;
dFdW(7) = 0;
end

2. File Name: ‘CatWtPlot.m’

clc
clear all
close all
F1 = [84.84,18.02,2.16,2.23,43.29,460.43,2.35];
F2=F1; %mol/s
[W,F] = ode45('kinetics',[0 4000],F2);
plot(W,F(:,3),'LineWidth',1)
grid on
xlabel('weight of catalysts, kg')
ylabel('Molar flow rate of Methanol, mol/s')

137
 Workload Distribution

Project Title: Design of a 90 MTPD Methanol Supervised by

Production Plant Dr. Nafisa Islam
Individual
St. ID Name Individual Work Equipment Signature
Design
Design Basis, Selection of
High End
Process and Process
Abir Distillation
1702009 Description, Energy
Podder Column
Balance, Economic
(T-102)
Analysis
Introduction, Material
Balance, Equipment Flash
Mahmudur
1702017 Sizing, Economic Separator
Rahman
Analysis, Environmental (V-101)
Assessment
Process Flow Diagram,
Energy Balance, Primary
Bimol
1702026 Equipment Sizing, Reformer
Nath Roy
Process Licensor, (R-101)
Economic Analysis
Project Definition,
Methanol
Process Block Diagram,
Bilash Synthesis
1702056 Material Balance, Plant
Devnath Reactor (R-
and Equipment Layout,
103)
Vendor List

138