1

Project Advisors:
Prof. Dr. M. Zafar Noon
Sir Mohsin Ali Kazmi
Group Members:
Ateeq-Ur-Rehman 04-Chem-118
Rizwan Masood 04-Chem-114
Tariq Mahmood 04-Chem-16
Muhammad Rizwan 04-Chem-36

2
Synopsis
 Introduction
 Process Selection
 Capacity
 Overall Plant Flow sheet
 Overall Material Balance
 Overall Energy Balance
 Individual Equipment Design

3
Introduction
Vegetable fats and oils are substances derived from
plants that are composed of triglycerides.
Nominally, oils are liquid at room temperature, and
fats are solid.

What Is Hydrogenation?
 Un-saturation bond reduction
 Decreasing Iodine Value of Oil
 Increasing Melting Point of oil

4
Objective
Energy per gram is higher
 9 kcal per gram

Remove objectionable constituent

 Free Fatty Acid 0.6 to 0.005%
 Phosphatides 2 to 0.035%
long shelf life
 3-6 month
Making fat suitable for manufacture of margarine
 Decreasing hardness of fat
For Cooking

5
Processes
2 types of process involves in oil processing
 Refining
 Hydrogenation
Refining:
The process in which we are removing
objectionable constituents from oil.
 Neutralizing
 Bleaching
 Deodorizing

Hydrogenation:
Addition of hydrogen to generate saturation in the presence
of catalyst
Process Selection
Process Alternatives:
1) Batch Process
2) Continuous Process

Factors Effecting on selection

High product yield.
Amount of FFA. Content
Simplicity of operation and low maintenance Cost
Small scale production
Cost
7
Process Selection
Batch Process

Reasons:

FFA contents
Low Level of Production
Low Capital Investment
Supply of Raw Material

8
Capacity

Import Required in (2005-2006) = 0.42 MMTY

Import In (2006-2007) = 0.35 MMTY (Ref 1)

Avg. Plant size = 40 – 80 MTD

Selected capacity = 60 MTD

REFERENCE
9
HYSIS DIADRAM
10
 OVERALL MATERIAL BALANCE

Material In Material out

1) Crude Oil = 15000 Kg 1) Saturated Fat = 14250 Kg
2) H3PO4 Sol = 45 Kg 2) From Degumming = 840 Kg
3) NaOH Sol = 52 Kg 3) From Neutralizer = 3630 Kg
4) H2O = 3950 Kg 4) Bleacher Discharge = 453.2 Kg
5) Activated Earth = 150.3 Kg 5) From Hydrogenator = 20.7 Kg
6) H2 Hydro = 200.5 Kg 6) Deodorizer Discharge = 228 Kg
7) Ni-Catalyst = 10.025 Kg
8) Citric Acid = 4.35 Kg
-------------------- -------------------
Material In = 19412 Kg Material Out = 19411 Kg
11
OVERALL ENERGY BALANCE

Unit Heat In Unit Heat Out

(KJ) (KJ)
Neutralizer 523803 Hydrogenator 2866000

Bleacher 1567824 Filter Dreain 1264

Heat Exchanger 1 1074
Cooler 2467695
Heat Exchanger 2 1852
Hydrogenator 2866000 Product 444163

Deoderizer 818570
Total Heat = 5779120
Total Heat In =5779123 Out
 Individual Process Designing

1) Rizwan Masood Designing of Neutralizer

04-Chem-114
2) Tariq Mehmood Designing of Bleacher
04-Chem-16
3) M. Rizwan Designing of Heat Exchanger
04-Chem-36
4) Ateeq Ur Rehman Designing of Reactor
04-Chem-118

13
Reactor Design
By
Hafiz Ateeq Ur Rehman
04-Chem-118

14
Synopsis
 Introduction of Hydrogenation
 Reaction Mechanism
 Steps of Hydrogenation
 Factors Affecting Hydrogenation
 Importance of Reactor
 Reactor Material Balance
 Reactor Energy Balance
 Reactor Design

15
Hydrogenation
“Treatment of an oil with hydrogen and a suitable
catalyst to decrease the number of double bonds
and increase the degree of saturation.”
Catalyst Activity
Defined as iodine value decrease per unit of time during a
hydrogenation under a specific set of conditions.
Reaction Result
 Saturation of double bonds
 Migration of double bonds
 Trans-fatty acid formation

16
Hydrogenation
Postulated Schematic Diagram of Hydrogenation

REFERENCE
17
 Hydrogenation
Chemical Reaction
Oil + Catalyst Oil-Catalyst Complex
Oil-Catalyst Complex + H2 Hydrogenated Oil + Catalyst

Steps in Hydrogenation:
 Transfer and/or diffusion
 Adsorption
 Hydrogenation/isomerization
 Desorption
Transfer and adsorption steps are critical steps in controlling
the degree of isomerization and selectivity of reactions.
18
Steps in Hydrogenation
Transfer:
Transfer of reactants and products to and from the bulk of the
liquid oil phase and outside surface of the catalyst.

Diffusion:
Diffusion of reactant into the pores of the catalyst. Diffusion
of products out of the pores of catalyst.

19
Steps in Hydrogenation
Hydrogenation Scheme

Linoleic acid Oleic acid

Linolenic acid Stearic acid

Isolinoleic acid Isooleic acid

20
Steps in Hydrogenation
Selectivity
Preferential hydrogenation of more unsaturated acids with
minimum formation of completely saturated fatty acids.
Linoleic acid : Oleic acid
Very selective hydrogenation 50 : 1
Non-selective hydrogenation 4:1

Reactor Importance
 Heart Of Plant
 Main Reaction Take Place

21
 Hydrogenation
Factors Affecting Hydrogenation
Selectivity Ratio Trans-Content Reaction Rate

Temperature

Pressure

Agitation

Catalyst

22
Material Balance Around Hydrogenator

REFERENCE
23
Energy Balance Around Hydrogenator

Soybean oil inlet condition = 150 ◦C

Specific heat of oil Cp = 1.93 KJ/Kg◦C (Ref 1)

Specific heat of Hydrogen = 14.84 KJ/Kg◦C
Specific heat of steric acid = 2.30 KJ/Kg◦C
Specific heat of water = 4.2 KJ/Kg◦C
Mass of Soybean oil = 14322 Kg
Mass of Hydrogen added = 200.5 Kg
Mass of steric acid formed = 14236 Kg

REFERENCE
24
Energy Balance Around Hydrogenator

Chemical Reaction
At 150 ◦C Soybean oil + H2 → Steric Acid
▲h1 ↓ ↑ ▲h2
▲hr
At 25 ◦ → Steric Acid
Soybean oil + H2 ▲hr

So heat produce during reaction,

Q = ▲h1 + ▲h2 + ▲Hr
Q = 2866000 KJ

25
Mass Flow rate of Water
Assume
1) Cooling water enter at ambient temperature i.e
25◦C
2) Cooling water exit at 29◦C
Tw = Texit – T in
= 29 – 25 = 4 ◦C
Heat of reaction ▲Hr = mwat*Cp*Tw
mwat = 85297 Kg/Batch
mwat = 12.64 Kg/Sec

26
Reactor Design
Standard Designing steps

 Calculate Volume of reactor

 By suggesting “L/D”, find
dimensions of reactor
 Wall thickness of reactor
 RPM of agitator
 Power required for agitator
 Overall heat transfer coefficient
 Pressure loss in coil
 Specification Sheet

27
Reactor Design
Volume of Reactor

Mass of Ni- catalyst MNi = 10.025 Kg

Mass of Soybean oil Moil = 14322 Kg
Density of Soybean oil ρoil = 915.67 Kg/m3 (Ref 1)
Density of Ni catalyst ρNi = 8900 Kg/m3 (Ref 2)

Volume of oil Vo = 15.64 m3

Volume of Ni VNi = 0.00112 m3

REFERENCE
28
Volume of Reactor Conti….

1) Add 20% vol of liquid for gas space (Ref 3)

2) Add 10% vol of liquid for coil & agitator space
3) Add 10 % void space for head space (Ref 4)

So Total volume

Vt = 1.4(Vo) + VNi
= 21.9 m3
REFERENCE
29
 Reactor Design
Dimensions of Reactor
(Assume) L/D =2 (Ref 3)
Vt = π /4 *Di2*L
Di = 2.4 m
L = 2*Di = 4.8 m
Working height = 4.4 m
Wall Thickness
t = PDi/2 ∕ (SEj - 0.6P) + Cc (Ref 5)
= 6.2 mm =0.0062 m
Now outside diameter
Do = Di + 2t = 2.412 m
REFERENCE
30
Reactor Design
Baffles specification
Baffle width = 0.1 * Di (Ref 6)
= 0.24 m
= 0.75 ft = 9.05 in
Baffle height should be 21 in less than
the total tank height (Ref 3)
Baffle Height = L – 21/39.37
= 3.83 m

No of baffles = 4 (90◦ Apart)

REFERENCE
31
Agitator calculations
Impeller Dimensions
Di = Inside diameter of reactor = 2.4 m
Dp = Diameter of paddle = Di/3 (Ref 3)
Dp = 0.8 m
Blade Length BL = Dp/4 = 0.2 m (Ref 6)
Blade width Bw = Dp/5 = 0.16 m
No. of impeller = 3
No. of blades = 6 (60 Apart)
Height of 1st (top) Impeller = 9 in below liquid level (Ref 3)
= 3.5 m
Height of 2nd (middle) impeller ~ Di = 2.4 m
Height of 3rd (bottom) impeller = Di/3 = 0.8 m (Ref 6)
REFERENCE
32
 Agitator calculations
RPM of Agitator
Diameter of paddle Dp = 0.8 m

Typical Impeller Tip Speed For turbine (Ref 7)

Impeller Tip speed =1200 ft/min

π *Dp*N = 366m/min
N = 366/ π *Dp
N = 146 rpm

REFERENCE
33
 Agitator calculations
Power Requirement
NRe = ( Dp2*N* ρoil)/ μoil
NRe = 118833
Pa = Kt*N3*Dp5* ρoil (Ref 6)
Power = (power of each impeller)*(No. of impeller) (Ref
7)
Pf = 49.7 KW
Pp = 7 KW
Pa = Pf + Pp = 56.7 KW
Pa = 1.1 ( 56.7) =REFERENCE
62.4 KW = 83.7 hp 34
 Vertical Helical Coil Design

 In order to maintain temperature of reactor at 150 C, cooling

water coil are required

Coil Configuration
Di = Inside diameter of reactor = 2.4 m
Dc = Coil Diameter = 0.7*Di = 1.68 m (Ref 8)
Standard outside diameter of 14 BWG tube is (Ref 9)
do = 1.5 in = 0.038 m
Inside diameter di = 1.33 in =0.034 m

REFERENCE
35
 Coil Configuration
Tube Side Heat Transfer Coefficient

hi = Jh * (kw/Di) * (NPr) 0.33*(μ/ μw)0.14 (Ref 9)

Specific heat of water Cpw = 4.2 KJ/Kg C
Density of water ρw = 994 Kg/m
Viscosity of water μw = 0.80cp = .0008 Pa Sec
Thermal conductivity Kw = 0.62 W/m C
Outside diameter of tube do = 0.038 m
Inside diameter of tube di = 0.034 m
Flow area per tube at = 1.40 in2 =0.0009 m2
From energy balance mw = 12.64 Kg/Sec
36
REFERENCE
Tube Side Heat Transfer Coefficient
Mass Velocity = G = mw/ at
= 14044 Kg/m2 Sec
NRe = (G*din) / μw = 596988
JH = 1150 (Ref 9)
NPr = Cpw*μw/Kw
= 5.43
μ/ μw = 1
So, hi = 36588 W/m2 C
For coil in helical form, multiply hi by (Ref 9)
1 + 3.5(di/Dc)
so
hio = {1+3.5(di/Dc) }* hi
hio = 36958 W/m2 C
REFERENCE
37
 Coil Configuration
Heat Transfer Coefficient on Agitated Side
hodo/Ko = 0.17(NRe)0.67(NPr)0.37(μ/μw)0.54(Dp/Di)0.1(do/Di)0.5 (Ref 7)

NRe = ρoil*N*Dp2/ μo
= 118833
NPr = Cpo* μo/ Ko
= 115.8
Dp/Di = 0.33
do/Di = 0.016
So ho = 1496 W/m2 C
Uc = hio*ho / hio+ho
Uc =1413 W/m2 C
REFERENCE
38
Coil Configuration
Dirt coefficient (Recommended)
Rd = 0.0023 m2 C/W
Now 1/Ud = 1/Uc + Rd
Ud = 332 W/m2 C
Coil Length
Q = Ud*A*LMTD
LMTD = (150-25) –(150-40)/In(125/110)
= 117.5 C
Now A = 17.34 m2 = 186 ft2
Surface area per ft of length a = 0.3925 ft2/ft. (Ref 9)
REFERENCE
39
 Coil Length
Length of tube = A/a = 474 ft
Length of one tube = π*Dc
= 5.3 m = 17.3 ft
No of Turn of tube = 474/17.3
= 27 turn
Pressure Drop in Tube side
∆Pcoil = ∆PStr × γ
∆PStr = f × G2×L×n / (5.22 × 1010 × di × s) (Ref 9)
f = Friction Factor = 0.0017
G = Mass Velosity = 14044 Kg/m2 Sec
L = length of one tube = 5.3 m
REFERENCE
40
Pressure Drop in Tube side
n = No of Turns = 27
di = Inside diameter of tube = 0.034 m
s = specific gravity = 0.93

∆PStr = 25 KN/m2 =3.6 psi

γ = 1 + 3.59(di/Dc) = 1.07
∆Pcoil = 4 psi

41
Equipment Slurry Reactor
Function Hydrogenation Of Soybean Oil
Inside Diameter (m) 2.4
Height (m) 4.8
Wall Thickness (mm) 6.2
Outside Diameter (m) 2.412
Height to diameter ratio 2
Design Temperature (K) 423
Operating Temperature (K) 423
Design Pressure (KPa) 202.6
Operating Pressure (KPa) 202.6
Head Torispherical

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Catalyst Nickel
No. of Agitator 3
Types of Agitator 1. Pitched Blade Turbine
2. Flat Blade Turbine
Width of Baffles(m) 0.23

No of Baffles 4
Tube Length(m) 144
No of Turn of Tube 27

43
Thanks

44
 Ref 1
http://www.pakistaneconomist.com/database2/cov.asp

http://www.pakistaneconomist.com/database2/cover/c2002-1.a
sp

http://www.pakistaneconomist.com/pagesearch/Search-Engine
2003/S.E155.asp
http://www.ahl.com.pk/mgil/index_aboutind.htm

Back 45
Reference
Process Engg Calculations Of material & Energy Balance
by Mack Tyner 2nd Edi
Chemical Reactor Design For Process Plant, Rase &
Holmes, Vol 1, Pg # 168

Back 46
Reference
Bailey,s Industrial handbook of oils and Fats 4th vol
Ref2
http://home.fuse.net/clymer/rq/index.html

Back

47
References
1) http://www.simetric.co.uk/si_liquids.htm
2) http://www.qivx.com/ispt/elements/ptw_028.php
3) Chemical Reactor Design For Process Plant, Rase & Holmes,
Vol 2, Pg #173,174
4) Chemical Process Engg by Harry Silla Pg # 377
5) Plant Design and Economics For Chemical Engineers, Edi 5 ,
Peter & Timmerhaus, Table 12-10,Pg # 554
6) Unit Operations Of Chemical Engineering ,Edi 6th , McCabe
& Smith, P # 241,256,Tab 9.2
7) Chemical Reactor Design For Process Plant, Rase & Holmes,
Vol 1, Pg #356,361, 358, fig 8.4,Tab 8.3,8.6

38 35 33 32 31 30 29 28 48
Reference
8) Chemical Engineering Desgn By Coulson & Richardson’s ,
Vol 6
9) Process Heat Transfer By D.Q.Kern, Tab 10, Pg # 843,112
(6.15b),721,148 fig24,

40 37 36 35 49
39
PROCESS DIAGRAM

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