Plant Design of Dimethyl Ether Production from Natural Gas

UNIVERSITAS INDONESIA
PLANT DESIGN OF DIMETHYL ETHER PRODUCTION
FROM NATURAL GAS BY DIRECT SYNTHESIS
Report Assignment 2
GROUP TK-03
GROUP PERSONNEL:
DIVA MEISYA PUTRIADI
(2006535590)
FAAH LATIFAH
(2006530904)
HANA NUR ARIFAH
(2006467425)
MUHAMMAD ERZADITYA ZHAFRAN
(2006576035)
MUHAMMAD FACHRY ARRIFQI
(2006575644)
DEPARTMENT OF CHEMICAL ENGINEERING
FACULTY OF ENGINEERING
UNIVERSITAS INDONESIA
OCTOBER 2023
EXECUTIVE SUMMARY
Dimethyl ether (DME) is an environmentally friendly substitute for diesel
and liquefied petroleum gas (LPG). DME shares many characteristics with LPG,
but it is simpler to manage, condense, transport, and store. Notably, DME offers
advantages over LPG, as it is more environmentally friendly, non-hazardous, and
possesses a lower calorific value.
The production of DME from natural gas undergoes 3 main processes,
which are pre-treatment process (to produce syngas), synthesis process (to produce
DME and MeOH), and DME purification process (to purify the DME and MeOH)
respectively. The production plant also consists of 6 utility areas, which are water
utility, steam utility , air utility , fuel utility, and waste treatment utility.
This assignment will present the dimensions, material, usage, and the other
important aspects of plant equipment design. Sizing calculations are done through
several equations, which adheres to a set of rules of thumbs and heuristics for each
equipment that are sourced from literatures. The operating conditions are put in
based on simulation results from the previous assignment. The sizing calculations
differ from one equipment to the other, based on their own equation methods. For
the utility sections, the previous assignment’s after HEN calculations are applied
and ran through a simulation in order to accurately size its equipments.
The main equipments in this process are 3 reactors, 2 in pre treatment
process and 1 in DME synthesis (fixed bed reactor). There are also a 5 heat
exchangers, 8 heaters and coolers, 2 PSA (pressure swing adsorption), 2 distillation
columns. The utility units consist of a series of compressors, tanks, basins, boiler,
mixer, pump, filter, separator, adsorber, distillation column. All these equipment’s
require sizing calculations, though there are some units that do not need sizing
calculations they are provided by standard manufacture.
All the equipment is designed using a few calculations and estimates
following the rule of thumb and the state of the process to find out what
specifications can meet plant capacity. The process of designing this tool is called
sizing, which in this process is carried out in various ways starting from manual
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calculations to software assistance for a more detailed engineering design. The data
needed to start the sizing process is the type of material that flows in each stream
along with its flow rate and density, viscosity, temperature, pressure, vapor fraction,
and all other operating data.
For some major and quite important equipment, after getting the data design
specification, it can be continued by doing mechanical drawing using the
appropriate scales from said specification. This goal is to be able to assist in
determining a more specific plant layout. In this plant, some of the tools drawn are
Steam Pre-Reforming, Steam Methane Reforming, and DME Synthesis reactor type
packed bed. There are also distillation column and pressure swing adsorption.
After knowing all the specifications of each of these tools, the plant will be
more efficient in starting its operations because each tool has been designed as well
as possible to achieve the best operating conditions and capacity of the plant in
producing a product.
In conclusion, it is worth emphasizing that the sizing of all equipment in this
DME plant has meticulously adhered to all existing standards, ensuring utmost
safety in its operations. Every aspect of the facility, from the reactors to the storage
units, has been designed and calibrated with precision, guaranteeing not only
efficiency but also compliance with industry regulations. With these rigorous
measures in place, we can confidently assert that our DME plant operates at the
pinnacle of safety and reliability, meeting and even surpassing all established
benchmarks.
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TABLE OF CONTENTS
EXECUTIVE SUMMARY ................................................................................... ii
TABLE OF CONTENTS ..................................................................................... iv
LIST OF FIGURES ............................................................................................. vi
LIST OF TABLES .............................................................................................. vii
CHAPTER 1 MAIN EQUIPMENT SIZING AND SPECIFICATION ........... 1
1.1
Steam Pre-Reforming Process ............................................................... 1
1.1.1 Heat Exchanger (HE-101) ................................................................... 1
1.1.2 Heater (E-101) ..................................................................................... 4
1.1.3 Steam Pre-Reforming Reactor (R-101) ............................................... 5
1.2
Steam Methane Reforming Process ...................................................... 8
1.2.1 Heater (E-102) ..................................................................................... 8
1.2.2 Steam Methane Reforming Reactor (R-102) ....................................... 9
1.3
DME Direct Synthesis Process ............................................................ 12
1.3.1 Heat Exchanger - Cooler ................................................................... 12
1.3.2 Heat Exchanger (E-105) - Heater ...................................................... 15
1.3.3 Compressor ........................................................................................ 17
1.3.4 DME Synthesis Reactor (R-103) ....................................................... 18
1.4
Purification and Recycle Process ........................................................ 21
1.4.1 Expander (K-104) .............................................................................. 21
1.4.2 Cooler (E-104) ................................................................................... 21
1.4.3 Pressure Swing Adsorption (V-101).................................................. 22
1.4.4 Pressure Swing Adsorption (V-102).................................................. 24
1.4.6 Distillation Column (T-101) .............................................................. 26
1.4.7 Distillation Column (T-102) .............................................................. 27
1.4.8 Heat Exchanger (HE-105) ................................................................. 29
1.4.9 Heater (E-108) ................................................................................... 30
CHAPTER 2 UTILITY EQUIPMENT SIZING AND SPECIFICATION ... 32
2.1
Water Utility ......................................................................................... 32
2.1.1 Pump (P-201) ..................................................................................... 32
2.1.2 Screens (TK-201) .............................................................................. 33
2.1.3 Flash Mixer Basin (M-201) ............................................................... 33
2.1.4 Flocculator (M-202) .......................................................................... 35
2.1.5 Sedimentation Tank (TK-202)........................................................... 36
2.1.6 Filter Package (F-201) ....................................................................... 37
2.1.7 Mixer (M-203) ................................................................................... 38
2.1.8 Decant Basin Tank (TK-203) ............................................................ 39
2.1.9 Water Recovery Basin Tank (TK-204) ............................................. 40
2.2
Steam Utility.......................................................................................... 41
2.2.1 Boiler (B-401).................................................................................... 41
2.2.2 Compressor (K-401) .......................................................................... 42
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2.2.3 Compressor (K-402)............................................................................. 42
2.2.4 Cooler (E-401) ................................................................................... 43
2.2.5 Separator (V-401) .............................................................................. 44
2.3
Air Utility .............................................................................................. 44
2.3.1 Filter (F-501) ..................................................................................... 44
2.3.2 Compressor (K-501) .......................................................................... 45
2.3.3 Adsorber ............................................................................................ 46
2.4
Fuel Utility............................................................................................. 47
2.5
Wastewater Treatment Utility............................................................. 48
2.5.1 Distillation Column (T-301) .............................................................. 48
2.5.2 Water Storage (TK-301) .................................................................... 49
CHAPTER 3 CONCLUSION ............................................................................ 51
REFERENCES .................................................................................................... 53
APPENDIX .......................................................................................................... 54
APPENDIX A ................................................................................................... 54
APPENDIX B .................................................................................................... 59
APPENDIX C .................................................................................................... 62
APPENDIX D ................................................................................................... 67
APPENDIX E .................................................................................................... 69
APPENDIX F .................................................................................................... 72
APPENDIX G ................................................................................................... 75
APPENDIX H ................................................................................................... 77
APPENDIX I ..................................................................................................... 80
APPENDIX J ..................................................................................................... 82
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LIST OF FIGURES
Figure 1. 1 Heat Exchanger (HE-101) Design ....................................................... 3
Figure 1. 2 Pre-Reforming Reactor (R-101) Design .............................................. 7
Figure 1. 3 Steam Methane Reforming Reactor (R-102) Design......................... 11
Figure 1.4 DME Synthesis Reactor (R-103) Design ............................................ 20
Figure 1.5 Pressure Swing Adsorption (V-101) Desig ........................................ 25
Figure 1.6 Distillation Column Design ................................................................ 29
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LIST OF TABLES
Table 1.1 Heat Exchanger (HE-101) Specification ................................................ 1
Table 1.2 Heat Exchanger (HE-101) Specification (cont’d) .................................. 2
Table 1.3 Heater (E-101) Specification .................................................................. 4
Table 1.4 Pre-Reforming (R-101) Specification .................................................... 5
Table 1.5 Pre-Reforming (R-101) Specification (cont’d) ...................................... 6
Table 1.6 Heater E-102 Specifications ................................................................... 8
Table 1.7 Heater E-102 Specifications (cont’d) ..................................................... 9
Table 1.8 Steam Methane Reforming Reactor (R-102) Specifications .................. 9
Table 1.9 Steam Methane Reforming Reactor (R-102) Specifications (cont’d) .. 10
Table 1.10 HE-102 Specification ......................................................................... 12
Table 1.11 HE-103 Specification ......................................................................... 13
Table 1.12 E-103 Specification ............................................................................ 14
Table 1.13 Intercooler (E-104) Specifications ..................................................... 15
Table 1.14 Heater (E-101) Specification .............................................................. 16
Table 1.15 Compressor (K-101) Specifications ................................................... 17
Table 1.16 Compressor (K-102) Specifications ................................................... 18
Table 1. 17 R-103 Specifications ......................................................................... 19
Table 1. 18 Expander (K-104) Specifications ...................................................... 21
Table 1.19 Cooler (E-104) Specifications ............................................................ 22
Table 1.20 Specification of Distillation Column T-101 ....................................... 23
Table 1.21 Specification of Pressure Swing Adsorption V-102........................... 24
Table 1. 22 Cooler (E-107) Specifications ........................................................... 26
Table 1. 23 Distillation Column (T-101) Specifications ...................................... 27
Table 1.24 Distillation Column (T-102)............................................................... 28
Table 1. 25 Heat Exchanger (HE-105) Specifications ......................................... 29
Table 1. 26 Heat Exchanger (HE-105) Specifications (cont’d) ........................... 30
Table 1.27 Heater (E-108) Specifications ............................................................ 30
Table 2.1 Pump (P-201) Specification ................................................................. 32
Table 2.2 Screens (TK-201) Spesification ........................................................... 33
Table 2.3 Flash Mixer Basin (M-201) Specifications .......................................... 34
Table 2.4 Flocculator (M-202) Specifications...................................................... 35
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Table 2.5 Flocculator (M-202) Specifications (cont’d) ........................................ 36
Table 2.6 Sedimentation Tank (TK-202) Spesification ....................................... 36
Table 2.7 Sedimentation Tank (TK-202) Spesification (cont’d) ......................... 37
Table 2.8 Filter Package (F-201) Specifications .................................................. 37
Table 2.9 Filter Package (F-201) Specifications (cont’d) .................................... 38
Table 2.10 Mixer (M-203) Specifications ............................................................ 38
Table 2.11 Mixer (M-203) Specifications (cont’d) .............................................. 39
Table 2.12 Decant Basin Tank (TK-203) Specifications ..................................... 40
Table 2. 13 Water Recovery Basin Tank (TK-204) Design ................................. 40
Table 2. 14 Water Recovery Basin Tank (TK-204) Design (cont’d) ................... 41
Table 2.15 Boiler (BL-601) Spesification ............................................................ 41
Table 2.16 Boiler (BL-601) Spesification (cont’d) .............................................. 42
Table 2. 17 K-401 Specifications ......................................................................... 42
Table 2. 18 K-402 Specifications ......................................................................... 43
Table 2. 19 E-401 Specifications.......................................................................... 43
Table 2.20 ............................................................................................................. 44
Table 2. 21 K-501 Specifications ......................................................................... 45
Table 2.22 Boiler (B-701) Spesification .............................................................. 46
Table 2.23 Diesel Generator ................................................................................. 47
Table 2.24 TK-301 Spesification ......................................................................... 49
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CHAPTER 1
MAIN EQUIPMENT SIZING AND SPECIFICATION
1.1
Steam Pre-Reforming Process
1.1.1
Heat Exchanger (HE-101)
Heat is transferred from the hot side to the cold side using heat exchangers.
By moving heat from systems where it is not needed to systems where it can be
used, heat exchangers can increase a system's energy efficiency. HE-101 to
preheating stream feed for Pre-Reforming reactor is shown in Table 1.1.
Table 1.1 Heat Exchanger (HE-101) Specification
Equipment Specification
Equipment Name
Heater
Equipment Code
E-101
Type
Shell and Tube
Operating Condition
Data
Shell Side
Tube Side
Fluid Flow (kg/h)
17000,0
102257,4
Temperature in (oC)
203
380
Temperature out (oC)
358
373
Operating pressure (kPa)
3040
3300
1
4
0,0005
0,0005
No. of passes
Fouling factor (m2 oC/W)
Heat Duty (MW)
1,903
∆T LMTD (oC)
71,969
Overall U (W/m2 oC)
748,242
Design Specification
Type of unit
Fixed tube
Material
SA-240
Heat Transfer Area (m2)
35,347
Tube OD (mm)
19,050
1
2
Table 1.2 Heat Exchanger (HE-101) Specification (cont’d)
Design Specification
Tube Length (m)
4,572
Shell ID (m)
0,813
Tube Pitch (mm)
24
Tube Thickness (mm)
3,048
Number of tubes
32
Tube arrangement
Triangular
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Figure 1. 1 Heat Exchanger (HE-101) Design
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1.1.2
Heater (E-101)
Heat is transferred from the hot side to the cold side using heat exchangers.
By moving heat from systems where it is not needed to systems where it can be
used, heat exchangers can increase a system's energy efficiency. The detail
specification Heater dryer is shown in Table 1.3
Table 1.3 Heater (E-101) Specification
Equipment Name
Equipment Specification
Heater
Equipment Code
E-101
Type
Shell and Tube
Operating Condition Data
Shell Side
Tube Side
Fluid Flow (kg/h)
17000,0
22545,4
Temperature in (oC)
358
1000
Temperature out (oC)
550
600
Operating pressure (kPa)
3040
3040
1
2
0,0005
0,0025
No. of passes
Fouling factor (m2 oC/W)
Heat Duty (MW)
2,505
∆T LMTD (oC)
291,014
Overall U (W/m2 oC)
299,302
Design Specification
Type of unit
Fixed tube
Material
SA-240
Heat Transfer Area (m2)
28,760
Tube OD (mm)
19,050
Tube Length (m)
3,658
Shell ID (m)
0,650
Tube Pitch (mm)
24
Tube Thickness (mm)
3,048
Number of tubes
66
Tube arrangement
Triangular
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1.1.3
Steam Pre-Reforming Reactor (R-101)
Pre-Reforming reactor is reactor that process light hydrocarbon to form a
syngas, especially for C2H6 and C3H8. This reactor type is fixed bed reactor with
catalyst NiO/Al2O3.
The detail specification and mechanical drawing Pre-
Reforming Reactor is shown in Table 1.4
Table 1.4 Pre-Reforming (R-101) Specification
Specification Design
Type
Fixed Bed Reactor
Material
SA-516 All
Maximum Allowable Stress Value (pa)
3000000
Residence Time (s)
5,26516704
Volume (m3)
3,0772
Tank Height (m)
10
Shell Thickness (m)
0,0144
Design Temperature (oC)
800
Design Pressure (KPa)
7000
Reactor Diameter (m)
6,2610
Tube Design
Total Tube
80
Total Tube Length (m)
10
Tube Diameter (m)
0,07
Tube Area (m2)
0,0038
Tube Volume (m3)
0,0385
Catalyst (Ni/Al2O3 )
Density (kg/m3)
1767
Catalyst Volume in Reactor (m3)
1,85
Total Catalyst Weight (kg)
Porosity
3262,45
0,4
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Table 1.5 Pre-Reforming (R-101) Specification (cont’d)
Head Design
Type of Head
Elipsodial
Material
SA-516 All
Maximum Allowable Stress Value (kPa)
13790
Radius (m)
0,0350
Head Thickness (m)
0,0084
Corrosion Allowance (m)
0,0038
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Figure 1. 2 Pre-Reforming Reactor (R-101) Design
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1.2
Steam Methane Reforming Process
1.2.1
Heater (E-102)
In steam methane reforming (SMR), a heater serves as a vital component,
supplying the required heat energy to drive the highly endothermic reaction
between methane and steam, which produces hydrogen and syngas. This heater
elevates the reactants' temperature to the optimal range (typically 700°C to
1000°C). The detail specification of heater E-102 is shown in Table 1.6.
Table 1.6 Heater E-102 Specifications
Equipment Specification
Equipment Name
Heater
Equipment Code
E-102
Type
Shell and Tube
Operating Condition
Data
Shell Side
Tube Side
Fluid Flow (kg/h)
102300,0
6000,0
Temperature in (oC)
744
1000
Temperature out (oC)
800
780
Operating pressure (kPa)
2000
101
1
6
0,0002
0,0005
No. of passes
Fouling factor (m2 oC/W)
Heat Duty (MW)
4,121
∆T LMTD (oC)
84,068
Overall U (W/m2 oC)
89,768
Design Specification
Type of unit
Fixed tube
Material
SA-240
Heat Transfer Area (m2)
546,125
Tube OD (mm)
19,050
Tube Length (m)
3,658
Shell ID (m)
0,650
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Table 1.7 Heater E-102 Specifications (cont’d)
Design Specification
1.2.2
Tube Pitch (mm)
24
Tube Thickness (mm)
3,404
Number of tubes
416
Tube arrangement
Triangular
Steam Methane Reforming Reactor (R-102)
The SMR reactor is a crucial unit in hydrogen and syngas production. It
operates at high temperatures, typically between 700°C and 1000°C, enabling the
endothermic reaction between methane and steam to produce hydrogen and carbon
monoxide. This reactor's design and operation are pivotal for optimizing gas yields
and maintaining temperature control, making it integral in diverse industrial
applications. The details of this reactors can be seen in Table 1.5 and Figure 1.2.
Table 1.8 Steam Methane Reforming Reactor (R-102) Specifications
Specification Design
Type
Fixed Bed Reactor
Material
Stainless Steel SA-240
Maximum Allowable Stress Value (pa)
3000000
Residence Time (s)
0,0001
Volume (m3)
2,6865
Tank Height (m)
10
Shell Thickness (m)
0,0144
Design Temperature (oC)
800
Design Pressure (KPa)
2000
Reactor Diameter (m)
5,5498
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Table 1.9 Steam Methane Reforming Reactor (R-102) Specifications (cont’d)
Tube Design
Total Tube
90
Total Tube Length (m)
10
Tube Diameter (m)
0,065
Tube Area (m2)
0,0033
Tube Volume (m3)
0,0298
Catalyst (Ni/Al2O3 )
Density (kg/m3)
1767
Catalyst Volume in Reactor (m3)
1,61
Total Catalyst Weight (kg)
2848,19
Porosity
0,4
Head Design
Type of Head
Material
Elipsodial
Stainless Steel SA-240
Maximum Allowable Stress Value (kPa)
13790
Radius (m)
0,0350
Head Thickness (m)
0,0084
Corrosion Allowance (m)
0,0038
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Figure 1. 3 Steam Methane Reforming Reactor (R-102) Design
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1.3
DME Direct Synthesis Process
1.3.1
Heat Exchanger - Cooler
Heat is transferred from the hot side to the cold side using heat exchangers.
By moving heat from systems where it is not needed to systems where it can be
used, heat exchangers can increase a system's energy efficiency. The heat exchanger
here is used to reduce the fluid temperature to 100°C so that it can be compressed
by the compressor.
Table 1.10 HE-102 Specification
Unit:
Data
Type of Fluid
Fluid Stream
Fluid Flow
Temperature in
Temperature out
Operating pressure
No. of passes
Fouling factor
Heat Duty
LMTD
Overall U
Type of unit
Heat Transfer Area
Tube OD
Tube Length
Shell ID
Tube Pitch
Tube Thickness
Number of tubes
Tube arrangement
Heat Exchanger
HE-102
Operating Condition
Shell Side
Tube Side
Chilled Water Hot Mixture
Cold Fluid
Hot Fluid
102300
102.300
370
749,1
744,11
390
2.000
1.950
1
8
0,0002
0,0002
170207,3083
68,01606678
46,977
Dimension
Fixed tube
8.342
19
5
0,889
24
3,048
3486,26837
Triangular
Unit
kg/h
°C
°C
kPa
m2 °C/W
kW
°C
W/m2 °C
m2
mm
m
m
mm
mm
tubes
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Table 1.11 HE-103 Specification
Heat Exchanger
Unit:
HE-103
Operating Condition
Data
Shell Side
Tube Side
Unit
Type of Fluid
Cold Mixture
Hot Mixture
Fluid Stream
Cold Fluid
Hot Fluid
Fluid Flow
102300
102.300
kg/h
Temperature in
190
380
°C
Temperature out
390
210
°C
Operating pressure
7.000
1.950
kPa
No. of passes
1
8
Fouling factor
0,0002
0,0002
m2 °C/W
Heat Duty
179960,7608
kW
LMTD
34,58679199
°C
Overall U
49,264
W/m2 °C
Dimension
Type of unit
Fixed tube
19.271
m2
Tube OD
19
mm
Tube Length
5
m
Shell ID
0,86709504
m
Tube Pitch
24
mm
Tube Thickness
3,048
mm
Number of tubes
8257,607078
tubes
Tube arrangement
Triangular
Heat Transfer Area
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Table 1.12 E-103 Specification
Cooler
Unit:
E-103
Operating Condition
Data
Shell Side
Tube Side
Unit
Type of Fluid
Cold Mixture
Hot Mixture
Fluid Stream
Cold Fluid
Hot Fluid
Fluid Flow
5984,382935
102.300
kg/h
Temperature in
20
201,43
°C
Temperature out
25
100
°C
Operating pressure
100
1.950
kPa
No. of passes
1
8
Fouling factor
0,002
0,0002
m2 °C/W
Heat Duty
862128,7033
kW
LMTD
128,0049057
°C
Overall U
273,190
W/m2 °C
Dimension
Type of unit
Fixed tube
16.838
m2
Tube OD
19
mm
Tube Length
5
m
Shell ID
0,86709504
m
Tube Pitch
24
mm
Tube Thickness
3,048
mm
Number of tubes
7214,993408
tubes
Tube arrangement
Triangular
Heat Transfer Area
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Table 1.13 Intercooler (E-104) Specifications
Intercooler
Unit:
E-104
Operating Condition
Data
Shell Side
Tube Side
Unit
Type of Fluid
Cold Mixture
Hot Mixture
Fluid Stream
Cold Fluid
Hot Fluid
Fluid Flow
296137
102.300
kg/h
Temperature in
20
198,8
°C
Temperature out
25
100
°C
Operating pressure
100
3.650
kPa
No. of passes
1
4
Fouling factor
0,002
0,0002
m2 °C/W
Heat Duty
862128,7033
kW
LMTD
120,3511769
°C
Overall U
W/m2.C
W/m2 °C
Dimension
Type of unit
Fixed tube
Heat Transfer Area
9.452
m2
Tube OD
19
mm
Tube Length
5
m
Shell ID
0,86709504
m
Tube Pitch
24
mm
Tube Thickness
3,048
mm
Number of tubes
8100,561139
tubes
Tube arrangement
Triangular
1.3.2
Heat Exchanger (E-105) - Heater
Heat is transferred from the hot side to the cold side using heat exchangers.
By moving heat from systems where it is not needed to systems where it can be
used, heat exchangers can increase a system's energy efficiency. The detail
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specification and mechanical drawing for each heat exchanger is shown in Figure
1.14
Table 1.14 Heater (E-101) Specification
Equipment Specification
Equipment Name
Heater
Equipment Code
E-101
Type
Shell and Tube
Operating Condition
Data
Shell Side
Tube Side
Fluid Flow (kg/h)
102257,4
551612,1
Temperature in (oC)
682
1000
Temperature out (oC)
800
725
Operating pressure (kPa)
7000
3300
4
2
0,0025
0,0025
No. of passes
Fouling factor (m2 oC/W)
Heat Duty (MW)
42,137
∆T LMTD (oC)
91,764
Overall U (W/m2 oC)
186,383
Design Specification
Type of unit
Fixed tube
Material
SA-240
Heat Transfer Area (m2)
2463,679
Tube OD (mm)
19,050
Tube Length (m)
6,096
Shell ID (m)
1,084
Tube Pitch (mm)
24
Tube Thickness (mm)
3,048
Number of tubes
3378
Tube arrangement
Triangular
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1.3.3
Compressor
The compressor is responsible for increasing the pressure of the feed gases
from their initial pressure to the desired reaction pressure. This compression ensures
that the reaction proceeds at the required conditions for optimal DME production.
Because the desired pressure increase is relatively high, multistage compressors,
namely K-101 and K-102, are used. With a compression ratio of 1.87, here are their
specifications.
Table 1.15 Compressor (K-101) Specifications
Equipment Specification
Equipment Name
Gas Compressor
Equipment Code
K-101
Increased the gas
Function
pressure from stream
109
Type
Centrifugal
Amount
1,00
Material
Carbon Steel
Operation Data
Inlet Temperature (K)
373,00
Discharge Temperature (K)
570,49
Inlet flow rate (kg/h)
102.300,00
Design Specification
Compression ratio
1,87
Compressor Head (m)
104.365,46
Efficiency (%)
0,77
Pressure inlet (kPa)
1.950,00
Pressure outlet (kPa)
3.650,00
Power (kW)
38.148,26
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Table 1.16 Compressor (K-102) Specifications
Equipment Specification
Equipment Name
Gas Compressor
Equipment Code
K-102
Increased the gas pressure
Function
from stream 111
Type
Centrifugal
Amount
1,00
Material
Carbon Steel
Operation Data
Inlet Temperature (K)
373,00
Discharge Temperature (K)
579,58
Inlet flow rate (kg/h)
102.300,00
Design Specification
1.3.4
Compression ratio
1,92
Compressor Head (m)
109.415,69
Efficiency (%)
0,77
Pressure inlet (kPa)
3.650,00
Pressure outlet (kPa)
7.000,00
Power (kW)
39.994,25
DME Synthesis Reactor (R-103)
A fixed bed reactor for direct dimethyl ether (DME) synthesis operates at a
pressure of 70 bar and a temperature of 800°C. In this type of reactor, the reactants
and catalyst are placed in a fixed position, allowing the reaction to occur as the
gases pass through the stationary catalyst bed. The high pressure and elevated
temperature are essential for promoting the chemical reactions necessary for DME
synthesis. In this type of reactor, the reactants and the Cu-ZnO-Al2O3 catalyst are
placed in a fixed position, allowing the reaction to occur as the gases pass through
the stationary catalyst bed.
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In this setup, methanol (CH3OH), the primary reactant, is fed into the
reactor under high pressure. Inside the reactor, the methanol molecules come into
contact with the Cu-ZnO-Al2O3 catalyst, initiating a chemical transformation.
Table 1. 17 R-103 Specifications
Specification Design
Type
Material
Maximum Allowable Stress Value (pa)
Residence Time (s)
Fixed Bed Reactor
Inconel 625 (Paduan Kromium-Nikel)
1199998030
0,566
Volume (m3)
Tank Height (m)
Shell Thickness (m)
8,655
9,000
0,038
Design Temperature (oC)
Design Pressure (KPa)
Reactor Diameter (m)
800
7000
9,961
Tube Design
Total Tube
Total Tube Length (m)
Tube Diameter (m)
Tube Area (m2)
Tube Volume (m3)
100
90
0,35
0,0961625
0,8654625
Catalyst (Cu/ZnO/Al2O3)
Density (kg/m3)
Catalyst Volume in Reactor (m3)
Total Catalyst Weight (kg)
Porosity
1300
5
6750,6
0,4
Head Design
Type of Head
Elipsodial
Material
Inconel 625 (Paduan Kromium-Nikel)
Maximum Allowable Stress Value (kPa)
11999980,303
Radius (m)
2,804
Head Thickness (m)
0,009
Corrosion Allowance (m)
0,004
Jacket Design
Duty Required (W)
1173611,000
Temperature Operation ( C)
800
Coolant
Water (25 C)
Heat Transfer Coefficient (W/m K)
156,4673846
Diameter Jacket (m)
10,96
Jacket Length (m)
9,00
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Figure 1.4 DME Synthesis Reactor (R-103) Design
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1.4
Purification and Recycle Process
1.4.1
Expander (K-104)
Expander are mechanical devices used to decrease pressure in a variety of
compressible fluids or gases, the most common of which being air. The compressor
will be used in this procedure to facilitate gas transfer. The detail specification of
compressor is shown in Table below
Table 1. 18 Expander (K-104) Specifications
Equipment Specification
Equipment Name
Gas Expander
Equipment Code
K-103
Function
To reduce gas solution pressure
Type
Centrifugal
Amount
1
Material
Carbon Steel
Operating Data
Inlet Temperature (K)
1,105.25
Discharge Temperature (K)
895.70
Inlet FLow Rate (kg/h)
1,704.29
Design Specification
Compression Ratio
0.47
Compressor Head (m)
-260,476.80
Efficiency (%)
0.73
Pressure inlet (kPa)
6,950.00
Pressure outlet (kPa)
3,300.00
Power (kW)
-1,673.10
1.4.2
Cooler (E-104)
The function of a cooler is to reduce the temperature of a substance,
typically a fluid or gas, by transferring heat from the substance to the surroundings.
The detail specification of E-104 is shown in Table 1.13
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Table 1.19 Cooler (E-104) Specifications
Equipment Specification
Equipment Name
Cooler
Equipment Code
E-104
Type
Shell and Tube
Operating Condition
Data
Shell Side
Tube Side
Fluid Stream Inlet
CW in
110
Fluid Stream Outlet
CW out
111
Fluid Flow (kg/h)
253568
101500
o
Temperature in ( C)
25
199
Temperature out (oC)
Operating pressure
(kPa)
No. of passes
Fouling factor (m2
o
C/W)
Heat Duty (MW)
∆T LMTD (oC)
54
100
101
3650
1
2
0,0003
0,0002
14,980
100,834
Overall U (W/m2 oC)
297,688
Design Specification
Type of unit
Fixed tube
Material
SS-316
Heat Transfer Area
499,051
(m2)
Tube OD (mm)
20,000
Tube Length (m)
4,880
Shell ID (m)
0,686
Tube Pitch (mm)
25
Tube Thickness (mm)
0,710
Number of tubes
814
Tube arrangement
Triangular
TEMA Type
BEP
1.4.3
Pressure Swing Adsorption (V-101)
This unit procedure simulates the performance of a adsorption column that
handles gaseous streams. To determine the column volume, we used FlexPDE to
find the time needed where the DME and Methanol concentration that is wanted are
achieved.
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Table 1.20 Specification of Distillation Column T-101
Equipment Specification
Adsorption Column
V-101
To separate DME and Methanol from
Function
mixture (H2, CH4, and H2)
Operating Data
Adsorbent requirement (kg/h)
SAPO-34 Zeolite
o
Temperature ( C)
47
Pressure (bar)
32
Breaktrough time (h)
1
Adsorption Capacity (kg N2/kg
Adsorbent)
1.64
Bulk density (kg/m3)
700
Bed porosity
0.4
Mass flow (kg/h)
8182.41
Adsorbent requirement (kg/h)
4989.28
Adsorbent Size (µm)
2
Langmuir's Constant
308
Construction Data
Material
Carbon Steel SA-516
Rasio L/D
3.33
Column Diameter (m)
3
Column Height (m)
10
3
Column Volume (m )
2.93
Shell Thickness (m)
0.050
Head and Bottom
Type
Hemispherical
Head Thickness (m)
0.028
Bottom Thickness (m)
0.028
Equipment Name
Equipment Code
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1.4.4
Pressure Swing Adsorption (V-102)
This unit procedure simulates the performance of a adsorption column that
handles gaseous streams. To determine the column volume, we used FlexPDE to
find the time needed where the Nitrogen concentration that is wanted are achieved.
The detail specification of distillation column is shown in Table 1.21.
Table 1.21 Specification of Pressure Swing Adsorption V-102
Equipment Specification
Equipment Name
Adsorption Column
Equipment Code
V-102
To separate N2 from air
Function
Operating Data
Adsorbent requirement (kg/h)
Activated Carbon
o
Temperature ( C)
52
Pressure (bar)
20
Breaktrough time (h)
0.30
Adsorption Capacity (kg N2/kg
Adsorbent)
0.088703668
Bulk density (kg/m3)
1.520527357
Bed porosity
0.360
Mass flow (kg/h)
951.46
Adsorbent requirement (kg/h)
10726.30
Adsorbent Radius (cm)
0.105
Langmuir's Constant
3.42
Construction Data
Material
SA-516
Rasio L/D
3.142857143
Column Diameter (m)
1.75
Column Height (m)
5.500
Column Volume (m3)
13.222
Shell Thickness (m)
0.023
Head and Bottom
Type
Hemispherical
Head Thickness (m)
0.015
Bottom Thickness (m)
0.015
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Figure 1.5 Pressure Swing Adsorption (V-101) Desig
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1.4.5
Cooler (E-107)
A cooler, in the context of reducing the temperature of a gas or gas solution,
is a device or system designed to remove heat from the gas, causing its temperature
to decrease. Coolers are commonly used in various industrial and scientific
applications to achieve specific temperature targets for gases or gas mixtures.
Table 1. 22 Cooler (E-107) Specifications
Unit
Data
Type of Fluid
Fluid Stream
Fluid Flow
Temperature in
Temperature out
Operating pressure
No. of passes
Fouling factor
Heat Duty
LMTD
Overall U
Type of unit
Heat Transfer Area
Tube OD
Tube Length
Shell ID
Tube Pitch
Tube Thickness
Number of tubes
Tube arrangement
1.4.6
E-107
Operating Condition
Shell Side
Tube Side
Chilled Water
Hot Mixture
Cold Fluid
Hot Fluid
1555863.485
16,770
20
30
25
0
100
500
1
4
0.0003
0.0001
9047.77835
10.77152185
659.70
Dimension
Fixed tube
1,273
100
5
0.53975
125
10
208
Triangular
Unit
kg/h
°C
°C
kPa
m2 °C/W
kW
°C
W/m2 °C
m2
mm
m
m
mm
mm
tubes
Distillation Column (T-101)
In the process of distilling liquid mixtures, a distillation column plays a vital
role by effectively dividing the mixture into its constituent parts or fractions, driven
by differences in their volatility. A distillation column is employed to reclaim the
solvent. Distillation is particularly advantageous for liquid mixtures with high
relative volatilities, where there exists a significant gap in volatility between the
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desired product and any impurities. The specific details about the distillation
column in Table below.
Table 1. 23 Distillation Column (T-101) Specifications
Mass Flow Rate
Molar Flow Rate
Equipment Specification
Distillation Column
T-101
To separate DME from H2O & Methanol
Continuous
Water, DME, Methanol
Operating Condition
16,767.76
kg/h
618.56
kgmole/h
Volumetric Flow Rate
51.71
m3/h
Reflux Ration
Condenser Pressure
Reboiler Pressure
5.00
400.00
800.00
kPa
kPa
Item
Code
Function
Mode of Operation
Material Handled
Condenser Temperature 10.00
o
Reboiler Temperature
o
170.00
32.00
Design Specification
Column Shape
Cylindrical
Material
Carbon Steel
Plate Type
SA-516 All
Type
Tray
Type of Tray
Sieve
Tray Spacing
0.550
Column Height
17.6000
Column Inside Diameter 1.5000
Shell Thickness
0.0090
Top Head Type
Hemispherical
Top Head Thickness
0.0072
Bottom Head Type
Hemispherical
Bottom Head Thickness 0.0072
C
C
Number of Stage
1.4.7
m
m
m
m
m
m
Distillation Column (T-102)
In the process of distilling liquid mixtures, a distillation column plays a vital
role by effectively dividing the mixture into its constituent parts or fractions, driven
by differences in their volatility. A distillation column is employed to reclaim the
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solvent. Distillation is particularly advantageous for liquid mixtures with high
relative volatilities, where there exists a significant gap in volatility between the
desired product and any impurities. The specific details about the distillation
column in Table 1.24.
Table 1.24 Distillation Column (T-102)
Mass Flow Rate
Molar Flow Rate
Equipment Specification
Distillation Column
T-102
To separate Methanol from solution
Continuous
Water and Methanol
Operating Condition
8,585.00
kg/h
440.90
kgmole/h
Volumetric Flow Rate
10.24
m3/h
Reflux Ration
Condenser Pressure
Reboiler Pressure
10.00
101.30
1,000.00
kPa
kPa
Item
Code
Function
Mode of Operation
Material Handled
Condenser Temperature 66.85
o
Reboiler Temperature
o
176.70
35.00
Design Specification
Column Shape
Cylindrical
Material
Carbon Steel
Plate Type
SA-516-70
Type
Tray
Type of Tray
Sieve
Tray Spacing
0.610
Column Height
21.3360
Column Inside Diameter 0.6734
Shell Thickness
0.0079
Top Head Type
Hemispherical
Top Head Thickness
0.0078
Bottom Head Type
Hemispherical
Bottom Head Thickness 0.0078
C
C
Number of Stage
m
m
m
m
m
m
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Figure 1.6 Distillation Column Design
1.4.8
Heat Exchanger (HE-105)
Heat transfer occurs through the utilization of heat exchangers, which
transport heat from the warmer side to the cooler side. This process enhances the
energy efficiency of a system by redistributing heat from areas where it is surplus
to areas where it can be put to good use. The specific information for each heat
exchanger displayed in Table 1.25.
Table 1. 25 Heat Exchanger (HE-105) Specifications
Unit
Data
Type of Fluid
Fluid Stream
Fluid Flow
Temperature in
Temperature out
Operating pressure
No. of passes
Fouling factor
HE-105
Operating Condition
Shell Side
Tube Side
Chilled Water
Hot Mixture
Cold Fluid
Hot Fluid
84540
102,300
52
372.877
380
65.059
2,000
3,300
1
8
0.0002
0.0002
Unit
kg/h
°C
°C
kPa
m2 °C/W
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Table 1. 26 Heat Exchanger (HE-105) Specifications (cont’d)
Unit
HE-105
Operating Condition
235039.0808
30.76084535
45.844
Dimension
Fixed tube
25,470
25
8
1.4224
32
1.651
4990
Triangular
Heat Duty
LMTD
Overall U
Type of unit
Heat Transfer Area
Tube OD
Tube Length
Shell ID
Tube Pitch
Tube Thickness
Number of tubes
Tube arrangement
1.4.9
kW
°C
W/m2 °C
m2
mm
m
m
mm
mm
tubes
Heater (E-108)
The recycled stream from stream 124 is sent to heater (E-108) to increase
the heat before sent back into Steam Methane Reforming Reactor. The specification
for heater is shown in Table 1.26.
Table 1.27 Heater (E-108) Specifications
Equipment Specification
Equipment Name
Heater
Equipment Code
E-108
Type
Shell and Tube
Operating Condition
Data
Shell Side
Tube Side
Fluid Flow (kg/h)
84540,0
6000,0
Temperature in (oC)
370
700
Temperature out (oC)
383
500
Operating pressure (kPa)
2000
101
1
2
0,0002
0,0005
No. of passes
Fouling factor (m2 oC/W)
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Heat Duty (MW)
4,388
∆T LMTD (oC)
209,790
Overall U (W/m2 oC)
71,270
Design Specification
Type of unit
Fixed tube
Material
SA-240
Heat Transfer Area (m2)
293,507
Tube OD (mm)
19,050
Tube Length (m)
3,658
Shell ID (m)
0,650
Tube Pitch (mm)
24
Tube Thickness (mm)
3,404
Number of tubes
671
Tube arrangement
Triangular
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UTILITY EQUIPMENT SIZING AND SPECIFICATION
2.1
Water Utility
2.1.1
Pump (P-201)
A pump is a mechanical tool used to move various fluids down pipes from
one place to another. The specification for each pump are shown in Table 2.1
Table 2.1 Pump (P-201) Specification
Equipment Specification
Pump
Equipment Code
P-201
Function
To pump water into
screen tank
Equipment Specification
Type
Rotary Pump
Material
Carbon Steel ST372/SS304
Type of Component
Water
Operating data
Data
Units
Fluid
Value
Water
Temperature
°C
29
Pressure In
bar
0,81
Pressure Out
bar
2,50
Mass Flow
kg/hr
5100
Data
Units
Value
NPSHa
m
7,91
NPSHr
m
7,86
Head
m
25,65
FHP
W
267,39
BHP
W
356,52
Design Specification
32
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2.1.2
Screens (TK-201)
The specifications of Screens can be seen in Table 2.2.
Table 2.2 Screens (TK-201) Spesification
Equipment Specification
Screen Filter
Equipment Code
TK - 201
To separate sand and
Function
other fine particles out of
water
Equipment Specification
Automatic Water Screen
Type
Filter
Model
A520
Carbon Steel ST37Material
2/SS304
Type of Component
Water
Operating data
Data
Units
Value
Temperature
°C
25
Pressure
bar
2.5
Mass Flow
kg/hr
5100
Design Specification
Data
Units
Value
Filter Flow
m³
2000
Filtration Area
cm²
21760
Weight
kg
1570
Available Filtration
micron
50
Bacwash tTime
s
20 ~ 30
Filtered Water
%
1~3
Voltage
V
380
Filter Element
Stainless Steel 304
2.1.3
Flash Mixer Basin (M-201)
A coagulant is used to aggregate particles into flocs, and the choice of
coagulant type and dosage depends on jar test results. Ferric sulfate (Fe2(SO4)3)
was used in this treatment. Rapid mixing, facilitated by a static mixer in the
conveyance pipe, ensures even coagulant dispersion. A minimum of two mixers
should be provided. The specifications can be seen in the table below.
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Table 2.3 Flash Mixer Basin (M-201) Specifications
Mixer
Code
M-201
Combines Water, polymer, and
Function
coagulant before going into
flocculator
Operating Condition
Storage Time (days)
330
Flowrate (kg/h)
5089,85
Capacity (m3)
1,90
Temperature (oC)
29
Pressure (bar)
1,01
Specification Design
Type
Vertical Cylinder tank
Material
Stainless Steel 316
Inside Diameter (m)
1,15
Tank Height (m)
1,72
Head Type
Torispherical Head
Head Height (m)
0,19
Total Height (m)
1,91
Shell Thickness (m)
0,004
Head Thickness (m)
0,94
Agitator
Impaller Type
Pitch Blade
Number
1
Diameter (m)
0,382404525
Shaft Diameter (m)
0,047800566
Distance from Tank Bottom (m)
0,382404525
Rotation Speed (rpm)
100
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2.1.4
Flocculator (M-202)
Flocculation aids in the creation of flocs, which are subsequently separated
during sedimentation and filtration. Unlike coagulation, which uses rapid mixing to
disperse the coagulant into the feed water, flocculation employs gentle stirring to
improve contact between the coagulant and feed water, facilitating the development
of flocs. The specification for flocculator is shown below.
Table 2.4 Flocculator (M-202) Specifications
Equipment Identification
Equipment Name
Flocculation Tank
Equipment Number
M-202
Aggregating contaminants
Function
into flakes or “flocs”
Mode of Operation
Continuous
Cylindrical tank with flat-
Type
dished head
Operating Condition
Flow Rate (kg/hour)
5618,70
Pressure (bar)
1,00
Temperature (Celcius)
29
Residence time (hour)
1
Component
Mass percent
Dam Water
90,59
Sludge
9,41
Design Specification
Tank Volume (L)
7583,97
Safety factor
20%
Height of Fluid (m)
5,81
Pressure design (atm)
1,87
Material
CS SA-516
Tank Diameter (m)
3,56
Tank Height (m)
7,75
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Table 2.5 Flocculator (M-202) Specifications (cont’d)
Design Specification
Cylinder Height (m)
5,34
Type of head
standard / flat-dished head
Head Height (m)
1,20
Wall Thickeness (mm)
8,87
Head Thickeness (mm)
11,09
Impeller Design
2.1.5
Impeller type
Axial Flow Pitched blade turbine
Impeller diameter (m)
1,42
Width of leaf impeller (m)
0,28
Impeller to bottom (m)
1,78
Baffle width (m)
0,30
Impeller speed (rpm)
200,00
Motor power (Kwh)
322,58
Sedimentation Tank (TK-202)
A sedimentation tank is a hydraulic structure designed to separate
suspended particles from water through gravitational settling. It harnesses the
principles of gravity and fluid dynamics to effectively remove solid particles that
are denser than water. The tank operates as a quiescent basin where water is allowed
to rest for an extended period, enabling particles to settle to the bottom due to their
own weight. The specification for sedimentation tanks are shown in Table 2.5.
Table 2.6 Sedimentation Tank (TK-202) Spesification
Equipment Specification
Equipment Name
Storage Tank
Equipment Code
TK-202
Type of Fluid/ Solid
Water
Horizontal/ Vertical
Vertical with Concrete
Supports
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Table 2.7 Sedimentation Tank (TK-202) Spesification (cont’d)
Equipment Specification
Open/ Close Vessel
Close Vessel
Vessel Head Type
Torispherical Type
Material Type
SA-283C
Number Equipment
1
L/D
0,8
Design Specification
2.1.6
Flowrate (kg/h)
5089,85
Tank Volume (m3)
940,60
Height (m)
8,93
Diameter (m)
11,17
Temperature ( C )
29,00
Pressure Design (kPa)
121,60
Filter Package (F-201)
In this water treatment plant, a dual-media filter (anthracite and sand) is used
for rapid filtration to achieve a finished water quality with very low turbidity (≤0.3
NTU) and effective removal of cryptosporidium (4-log removal). Raw water flows
through the treatment processes by gravity, moving from coagulation and
flocculation to sedimentation, and finally to the filtration unit. The specification for
filter package are shown below.
Table 2.8 Filter Package (F-201) Specifications
Equipment Specification
Filter Package
Equipment Code
Function
F-201
To separate sand and other
fine particles out of water
Equipment Specification
Type
Model
Automatic Water Screen
Filter
A520
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Table 2.9 Filter Package (F-201) Specifications (cont’d)
Equipment Specification
Material
Carbon Steel ST37-2/SS304
Type of Component
Water
Operating data
Data
Units
Value
Temperature
°C
29
Pressure
bar
1
Mass Flow
kg/hr
5039,85
Design Specification
Data
Units
Value
Filter Flow
m³
2000
Filtration Area
cm²
21760
Weight
kg
1570
Available Filtration
micron
50
Backwash Time
s
20 ~ 30
Filtered Water
%
1~3
Voltage
V
380
Filter Element
2.1.7
Stainless Steel 304
Mixer (M-203)
In the water treatment process, disinfection of the filtered water was
accomplished by applying liquid sodium hypochlorite (NaOCl) through
chlorination. A detention period of at least one hour at the average design flow rate
or 30 minutes during peak hourly flow, whichever was longer, was employed. The
specifications of the mixer for this process can be seen in Table 2.10.
Table 2.10 Mixer (M-203) Specifications
Mixer
Code
Function
M-203
Combines Water, soda ash, and NaOCl
before going into storage tank
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Table 2.11 Mixer (M-203) Specifications (cont’d)
Operating Condition
Storage Time (days)
330
Flowrate (kg/h)
5009,008
Capacity (m3)
2,37
Temperature (oC)
29
Pressure (bar)
1,01
Specification Design
Type
Vertical Cylinder tank
Material
Stainless Steel 316
Inside Diameter (m)
1,24
Tank Height (m)
1,85
Head Type
Torispherical Head
Head Height (m)
0,21
Total Height (m)
2,06
Shell Thickness (m)
0,003
Head Thickness (m)
0,95
Agitator
Impaller Type
Pitch Blade
Number
1
Diameter (m)
0,412164123
Shaft Diameter (m)
0,051520515
Distance from Tank Bottom (m)
0,412164123
Rotation Speed (rpm)
100
2.1.8
Decant Basin Tank (TK-203)
The decant basin tank in water treatment plays a vital role in the separation
of settled solids from water. It clarifies water by allowing suspended solids to settle,
resulting in improved water quality and reduced turbidity. Additionally, it regulates
flow, assists in sediment removal, and may serve as temporary water storage before
advancing to subsequent treatment processes or distribution. The specifications of
Decant Basin Tank are presented in Table 2.12
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Table 2.12 Decant Basin Tank (TK-203) Specifications
Equipment Specification
Name
Decant Basin Tank
Code
TK-203
Treat the sedimentation sludge and
Function
impurities generated from sedimentation
tank and filter package
Operation Data
Mass Flow Rate (kg/h)
160,00
Volumetric Flow Rate (m3/h)
0,16
Clarifier Volume (m3)
0,3520
Detention Time (h)
2
Surface Overflow rate (L/m2h)
383,79
Weir Overflow Rate (L/mh))
254,47
Solids Loading Rate (kg/m2day)
163,38
Construction Data
Clarifier Height (m)
1,2
D2/D1
0,67
y (m)
2,40
D1 (m)
0,73
D2 (m)
0,49
Clarifier Volume
0,3520
2.1.9
Water Recovery Basin Tank (TK-204)
These tanks are designed to capture, store, and potentially treat water from
various sources, making it available for reuse or controlling its flow for various
purposes. This scientific narration provides an overview of the operation and
significance of a Water Recovery Basin Tank. The detail of specification basin tank
is shown in Table 2.13
Table 2. 13 Water Recovery Basin Tank (TK-204) Design
Equipment Specification
Equipment Name
Storage Tank
Equipment Code
TK-204
Type of Fluid/ Solid
Water
Vertical with Concrete
Horizontal/ Vertical
Supports
Open/ Close Vessel
Close Vessel
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Table 2. 14 Water Recovery Basin Tank (TK-204) Design (cont’d)
Equipment Specification
Vessel Head Type
Flat type
Material Type
SA-283C
Number Equipment
L/D
Design Specification
Flowrate (kg/h)
Tank Volume (m3)
Height (m)
Diameter (m)
Temperature ( C )
Pressure Design (kPa)
2.2
Steam Utility
2.2.1
Boiler (B-401)
1
0,8
80,00
14,35
2,25
2,81
29,00
121,60
Boilers heat water and produce steam or hot water for heating purposes. The
detail specification of boiler is shown in Table 2.29.
Table 2.15 Boiler (BL-601) Spesification
Equipment Spesification
Equipment Name
Boiler
Equipment Code
B-601
Type of Fuel
Biomass Fuel
Operation Data and Properties
Mass flow rate (kg/h)
10,000.00
LHV (kj/kg)
20,340.00
qv (kW/m3)
200
3
qf (kW/m )
2,130
3
qb (kW/m )
1,400
2
Fgrate (m )
26.53
Construction Data
Inner Case Material
SS-316
Furnace Wall
Fire Brick
V (m3)
282.50
Hfu+Hb
10.65
b (m)
4.91
Hb (m)
1.96
Hfu (m)
8.69
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Table 2.16 Boiler (BL-601) Spesification (cont’d)
Construction Data
a (m)
α
β
γ
E (m)
d (m)
2.2.2
5.40
30.00
45.00
50.00
0.80
0.49
Compressor (K-401)
Boilers heat water and produce steam or hot water for heating purposes. The
detail specification of boiler is shown in Table below.
Table 2. 17 K-401 Specifications
Equipment Specification
Equipment Name
Gas Expander
Equipment Code
K-401
Function
Compress steam to boiler
Type
Amount
Material
Centrifugal
1.00
Carbon Steel
Operation Data
Inlet Temperature (K)
Discharge Temperature (K)
Inlet flow rate (kg/h)
Design Specification
Compression ratio
Compressor Head (m)
Efficiency (%)
Pressure inlet (kPa)
Pressure outlet (kPa)
Power (kW)
172.56
268.81
9,789.38
1.89
6,258.51
0.76
840.00
1,587.00
221.79
2.2.3 Compressor (K-402)
Boilers heat water and produce steam or hot water for heating purposes. The
detail specification of boiler is shown in Table below.
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Table 2. 18 K-402 Specifications
Equipment Specification
Equipment Name
Gas Expander
Equipment Code
K-402
Function
Compress steam to boiler
Type
Amount
Material
Centrifugal
1.00
Carbon Steel
Operation Data
Inlet Temperature (K)
Discharge Temperature (K)
Inlet flow rate (kg/h)
Design Specification
Compression ratio
Compressor Head (m)
Efficiency (%)
Pressure inlet (kPa)
Pressure outlet (kPa)
Power (kW)
2.2.4
269.54
380.82
9,789.38
1.89
9,246.21
0.76
1,587.00
3,000.00
327.67
Cooler (E-401)
Table 2. 19 E-401 Specifications
Equipment Specification
Equipment Name
Equipment Code
Function
Data
Type of Fluid
Fluid Stream
Fluid Flow
Cooler
E-401
Decrease Steam Temperature
Operating Condition
Shell Side
Tube Side
Chilled Water
Hot Mixture
Cold Fluid
Hot Fluid
1155565.656
16,770
Unit
kg/h
Temperature in
Temperature out
Operating pressure
No. of passes
20
25
100
1
384.1
250
3,000
4
°C
°C
kPa
Fouling factor
Heat Duty
0.009
0.009
m2 °C/W
kW
6923.554596
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LMTD
Overall U
289.3960073
34.04
Type of unit
Dimension
Fixed tube
Heat Transfer Area
Tube OD
Tube Length
Shell ID
Tube Pitch
Tube Thickness
Number of tubes
Tube arrangement
703
100
5
0.53975
125
10
114.7533695
Triangular
2.2.5
°C
W/m2 °C
m2
mm
m
m
mm
mm
tubes
Separator (V-401)
Boilers heat water and produce steam or hot water for heating purposes. The
detail specification of boiler is shown in Table 2.29.
Equipment Specifications
Name
Material
Code
Separator
Carbon Steel SA-516 All
V-301
Operation Condition
Mass flow (kg/h)
Mass density (kg.m3)
Temperature (K)
9789.375603
882.0818589
333.15
Pressure (kPa)
840
Construction Data
Diameter (m)
Height (m)
Thickness (m)
Allowable working stress (psia)
Joint efficiency (%)
Roof thickness (m)
2.3
Air Utility
2.3.1
Filter (F-501)
2.320144158
3.633983352
0.003690002
20560
90
0.0073664
Table 2.20
Equipment Specification
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Equipment Name
Equipment Number
Function
Air Filter
F-801
Remove solid in Gas Waste feed
Klean Environmental
Technology Co., Lt
BSG-216 Series
Galvanized Steel/SS304
Operation Data
25°C
8 bar
4000 m3/h
Construction Data
870 mm
2060 mm
1561 mm
1.8 kW
492 kg
Supplier
Model
Filter Cell
Temperature
Maximum Pressure
Capacity
Length
Width
Height
Power Consumption
Net Weight
Source: Alibaba.com
2.3.2
Compressor (K-501)
.
Table 2. 21 K-501 Specifications
Equipment Specification
Equipment Name
Gas Compressor
Equipment Code
C-601
Function
Type
To compress air going into
adsorption unit
Centrifugal
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Amount
1.00
Material
Carbon Steel
Operation Data
Inlet Temperature (K)
303.00
Discharge Temperature (K) 462.61
Inlet flow rate (kg/h)
856.69
Design Specification
2.3.3
Compression Ratio
3.00
Compressor Head (m)
10,527.25
Efficiency (Ep)
80.00
Pressure inlet (kPa)
88.00
Pressure outlet (kPa)
264.00
Power (kW)
41.42
Adsorber
Adsorber is used to removing water or liquid in compressed air. The air is
then used for boiler feed to produce steam.
Table 2.22 Boiler (B-701) Spesification
Equipment Name
Equipment Code
Function
Material Handled
Type
Pressure
Temperature
Adsorbent
Adsorbent radius
Mass Flow Rate
Langmuir's Constant
Maximum concentration
in surface
Equipment Specification
Adsorber
V-501
Removing H2O in compressed air
O2, N2, H2O
Operating Condition
Packed Bed Adsorber
1.03 bar
30°C
Silica Alumina
15 mm
856.69
kg/h
5.13
2200.7
mol/m3
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Material
Vessel Diameter
Vessel Height
Volume
Shell Thickness
Construction Data
CS SA-516
0.4
1.1
0.13816
m
m
m3
1.257
in
0.032
m
31.926
mm
Head Type
Head Thickness
Torispherical
1.262
in
0.032
m
32.061
mm
Bottom Type
Head Thickness
Torispherical
1.262
in
2.4
0.032
m
32.061
mm
Fuel Utility
In situations such as power failures, an electric generator becomes
necessary. Diesel generators represent one type of electrical generator that can be
utilized for this purpose. The illustration and specifications of the diesel generator
can be found in below.
Table 2.23 Diesel Generator
Model
LTM-2000GF
Power
2000kw/2500kva
Frequency
50Hz (60Hz is available)
Voltage
230/400V (can be customized)
Optional Type
Open/soundproof/trailer
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Size
8300*2950*2700mm
Weight
24000kg
Cylinders
20 in line arrangement
Bore*Stroke
170*210mm
Displacement
95.4L
Lubrication Oil Capacity
390L
Fuel Consumption at 100% Load
193g/kw.h
Figure 2.1 Diesel Generator
(Source : Fetting Power, Inc., n.d.)
2.5
Wastewater Treatment Utility
2.5.1
Distillation Column (T-301)
The purpose of this distillation is to purify water to >99%, making it
reusable for generating steam in the feed process
Table 2.13 Air Filter (F-801) Spesification
Item
Code
Function
Mode of Operation
Material Handled
Mass Flow Rate
Molar Flow Rate
Volumetric Flow Rate
Reflux Ratio
Equipment Specification
Distillation Column
T-301
purify water to >99%
Continuous
Water, MeOH
Operating Condition
8258
kg/h
430.7
kgmole/h
9.867
m3/h
20
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Condenser Pressure
Reboiler Pressure
Condenser Temperature
Reboiler Temperature
Number of Stage
Column Shape
Material
Plate Type
Type
Type of Tray
Tray Spacing
Column Height
Column Inside Diameter
Shell Thickness
2.5.2
800
800
130,5
180
50
Design Specification
Cylindrical
Carbon Steel
SA-516-70
Tray
Sieve
0.4
50
2.54
0.0124
kPa
kPa
o
C
o
C
m
m
m
m
Water Storage (TK-301)
The water storage is used to temporarily store water before it is transferred
to the steam generator. This water storage is in the form of an excavated pond in
the ground because it contains only 100% water.
Table 2.24 TK-301 Spesification
Equipment Identification
Water Storage
Equipment Name
Equipment Number
TK-301
Number of unit
1
Function
Water Storage
Mode of Operation
Continuous
Type
Pond
Material
Component
Mass Flow (kg/hr)
Waste Water from 301
1138,12
Clean Dam Water from 304
5000,00
Total
6138,12
Operating Condition
Flow Rate (kg/hour)
6138,12
Pressure (atm)
1,00
Temperature (Celcius)
25,00
Design Specification
Volume (L)
8,18
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Length (m)
Wide (m)
Depth (m)
3,00
1,36
2,00
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CONCLUSION
Based on the whole design of the equipment, some important conclusions
are listed as follow.
1. The sizing of equipment that handle solid is done by comparing and taking
reference from credible source of manufacture. While any process unit that
handle fluid will be sized using calculation which also require engineering
software such as Aspen Hysys, Aspen Exchanger, Polymath, and FlexPDE.
2. The main process can be divided into 4 different section which is steam prereforming, steam methane reforming, DME synthesis, and purification.
3. In the pre-treatment process there are 1 Heater, 1 heat exchanger, and 1 Reactor.
4. In the Steam methane reforming process there are 1 cooler, 1 heater, 1
Compressor for increasing pressure in order to achieve better absorption
process, 1 reactor for make a syngas to being a feed on next process.
5. In the DME synthesis process there is a multistage compressor (2 compressors
and 1 intercooler) to create an inlet temperature of 800 C with a pressure of 70
bar. The DME synthesis reactor is a Fixed Bed Reactor whose design has been
simulated on a polymath. The length of the reactor to achieve maximum
conversion of 60% is 9m with a volume of 9.96 m3 with a total of 100 tubes.
6. The Fixed bed reactor is sized using Polymath in order to obtain Light
hydrocarbon concentration profile, the using the equation we had from
empirical experiment, the working volume can be determined. Thus, the rest
column sizing can be done using ratio, rule of thumb, or benchmarking with
real unit.
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7. In the distillation process, there are 1 Expander, 2 Coolers, 1 Heater, 1 heat
exchangers, 2 distillation columns and 2 PSA for purifying DME until it reaches
99% concentration.
8. The water utility can be differentiated into cooling water utility, hot water
utility, steam utility as well as air utility.
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REFERENCES
Alibaba.com (2022) Good price 100kw 125KVA gas turbine generating units - buy
generators natural gas,natural gas power generator,gas generator product
on
Alibaba.com.
Available
at:
https://www.alibaba.com/product-
detail/Good-price-100kw-125KVA-Gasturbine_1600160835126.html?spm=a2700.7724857.normal_offer.d_title.16
4e6804qBsMhI (Accessed: October 26, 2023).
Branan, C.R. (2005) “Compressors,” Rules of Thumb for Chemical Engineers, pp.
124–133. Available at: https://doi.org/10.1016/b978-075067856-8/50006-2.
Branan, C.R. (2005) “Heat exchangers,” Rules of Thumb for Chemical Engineers,
pp. 29–58. Available at: https://doi.org/10.1016/b978-075067856-8/50002-5.
Branan, C.R. (2005) “Pumps,” Rules of Thumb for Chemical Engineers, pp. 116–
123. Available at: https://doi.org/10.1016/b978-075067856-8/50005-0.
Branan, C.R. (2005) “Separators/accumulators,” Rules of Thumb for Chemical
Engineers, pp. 142–152. Available at: https://doi.org/10.1016/b978075067856-8/50008-6.
Cheremisinoff, N.P. (2000) “Distillation Equipment,” Handbook of Chemical
Processing
Equipment,
pp.
162–243.
Available
at:
https://doi.org/10.1016/b978-075067126-2.50005-0.
Kim, Y., 2016. Energy Efficiency Improvement in a Modified Ethanol Process from
Acetic Acid. Entropy, 18(12), p.422.
Perry, Robert H. 1999. Perry’s Chemical Engineers’ Handbook. McGraw-Hill
Companies, Inc.
Sander, R. (2015) "Compilation of Henry's law constants (version 4.0) for water as
solvent", Atmospheric Chemistry and Physics, 15(8), pp. 4399-4981. doi:
10.5194/acp-15- 4399-2015.
Towler, G. P. and Sinnott, R. K. (2008) Chemical engineering design: principles,
practice and economics of plant and process design. Amsterdam; Boston:
Elsevier/Butterworth Heinemann.
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APPENDIX
APPENDIX A
HEAT EXCHANGER
Type: Shell and tube heat exchanger
Total unit HE = 5 , Total Unit Heater and Cooler = 8
Step of calculation:
➢
Define the properties of each cold and hot streams, including temperature
and density of fluid.
➢
Assume value of overall coefficient
➢
Calculate LMTD
𝐿𝑀𝑇𝐷 =
(𝑇1 − 𝑡2 ) − (𝑇2 − 𝑡1 )
𝑇 −𝑡
𝑙𝑛 𝑇1 − 𝑡2
2
1
(A.1)
➢ Calculate Caloric Temperature
𝑇𝑐 =
𝑇1 + 𝑇2
2
(A.2)
𝑡𝑐 =
𝑡1 + 𝑡2
2
(A.3)
After knowing all of the temperature conditions, the temperature difference
factor (Ft) is calculated. Based on rule of thumb, there is a minimum Ft value that
will be only around 0.65. Ft value determined by using R and P factor. Here is the
calculation of R and P factor.
𝑅=
𝑇1 + 𝑇2
2
(A.4)
𝑃=
𝑡2 − 𝑡1
𝑇2 − 𝑡1
(A.5)
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Figure A.1. Correction Factor for STHE
➢ Calculate Flow Area
𝐴=
𝑄
𝑈. 𝐿𝑀𝑇𝐷
(A.6)
➢ Determining the construction of heat exchanger data that will be used for
fermentative DME plant.
1) Tube
Number of tubes, tube cross sectional area, area per pass, volumetric flow,
and tube side velocity needs to be calculated again for another type of
exchanger.
Table A.1. Tube Properties
Use 3/4 in (19.05 mm) tube, 1.6 mm thickness, 4.88 m long
OD =
19.05 mm
thickness =
3.048 mm
ID =
12.954 mm
Tube length =
4.8768 m
Area per tube =
0.291715546 m²
Number of tubes =
7346 tubes
Tube cross sectional area =
0.00029 m²
Area per pass =
2.14894 m²
Volumetric flow =
28,24540 m³/s
Tube side velocity =
13 m/s
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2) Shell
Taking 1.25 times of the OD tube, details about pitch can be determined
by reading the data from Table D.2
Table A.2. Constant for different type of pitch
Table A.3. Shell Properties
Tube pitch, Pt =
31.75 mm
ID shell =
25.60 in
Pitch Type =
Number of Tube Pass in Shell =
Triangle
8
K1 =
0.037
n1 =
2.675
Tube bundle diameter, Db =
2440.9 mm
Num of tubes in center row, Nr =
Shell diameter =
77 tubes
650.32 mm
Trial baffle spacing =
130 mm
Cross flow area, As =
16916 mm2
Equivalent diameter =
18 mm
Volumetric flow rate =
28.24 m3/s
Shell side velocity =
1669 m/s
➢ Calculate tube heat transfer coefficient
Reynold’s Number
Cold Fluid: tube side, steam stream
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𝐷𝐺
μ
(A.7)
𝐿
𝑡𝑢𝑏𝑒 𝑙𝑒𝑛𝑔𝑡ℎ (𝑚)
=
𝐷
𝐼𝐷 (𝑚𝑚)𝑥 1000
(A.8)
𝑅𝑒 =
Then read Re and L/D to get jh
Figure A.2. Tube Side Heat Transfer Factor
➢ Calculate shell heat transfer coefficient
Reynold’s Number
Hot Fluid: Shell side, CO2 stream
𝑅𝑒 =
𝐷𝐺
μ
(A.9)
Read Re and baffle cut from Figure D.3. to determine jh of shell
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Figure A.3. Shell-side Heat Transfer Factor
➢ Calculate overall heat transfer coefficient
Predicting fouling factor for both cold and hot fluid using table D.4
Table A.4. Table for Selecting Fouling Factor
➢ Trial and error the assumed U by checking the error between the U from
calculation and the U from assumption.
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APPENDIX B
PRE-REFORMING REACTOR
To determine the sizing calculation reactor, several steps have to be done,
1. Determine the species involved in the reaction and the reaction pathways,
in case of syngas reforming from Light Hydrocarbon here are the pathways:
→ 𝐶𝑂 + 3𝐻2
(Reaction 1)
𝐶2𝐻6 + 2𝐻2𝑂 → 2𝐶𝑂 + 5𝐻2
(Reaction 2)
𝐶3𝐻8 + 3𝐻2𝑂 → 3𝐶𝑂 + 7𝐻2
(Reaction 3)
𝐶𝐻4 + 𝐻2𝑂
→ 𝐶O2 + 𝐻2
𝐶𝑂 + 𝐻2𝑂
(Reaction 4)
2. Derive the rate equation for each reaction
𝑃
𝑟1 =
𝑃
𝑃
𝐾1
2.5 𝐶𝑂
𝑘1 ( 𝐶𝐻42.5𝐻2𝑂 − 𝑃𝐻2
)
𝑃𝐻2
(Reaction 1)
𝐷𝐸𝑁 2
−0.54 −0.33 0.2
𝑟2 = 𝑘2𝑃𝐶2𝐻6
𝑃𝐻2𝑂 𝑃𝐻2
(Reaction 2)
𝑟3 = 𝑘3𝐶𝐶3𝐻8
(Reaction 3)
𝑃
𝑃
𝑟4 = 𝑘4𝑃𝐶𝑂 𝑃𝐻2𝑂 (1 − 𝐾4𝑃𝐶𝑜2 𝑃𝐻2 )
𝐶𝑜 𝐻2𝑜
(Reaction 4)
3. Do the calculations to gain the conversion of the reaction and the
information for length the reactor using Polymath plus Website
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Figure B. 1 Polymath Calculation
4. Calculate the residence time and size of the reactor
𝑡𝑟 =
𝑉𝑟𝑒𝑎𝑐𝑡𝑜𝑟
𝑄
𝑉𝑟𝑒𝑎𝑐𝑡𝑜𝑟 = 𝐿𝑒𝑛𝑔𝑡ℎ × 𝐴𝑟𝑒𝑎 𝑜𝑓 𝑡𝑢𝑏𝑒 × 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑡𝑢𝑏𝑒
5. Determine the vessel and head type based on this criterion
Figure B. 2 Material Selection Sheet
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Figure B. 3 Material Head Selection
6. Calculate the thickness head and vessel
Figure B. 4 Calculation Head Thickness
Figure B. 5 Formula to Calculate Vessel Thickness
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APPENDIX C
DME SYNTHESIS REACTOR
Design Equation for multitube fixed bed reactor:
Where –rA is the rate of CO hydrogenation reaction as a rate limiting step
in a series of reactions that occur in methanol synthesis reactors with the
following kinetic equation:
Table C.1 Reaction rate equations and estimated kinetic parameters (Park,
2020)
Table C.2 Estimated kinetic parameters for MeOH (Park,2020)
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Table C.3 Estimated kinetic parameters for DME (Park, 2020)
Simulation results using polymath as toolkit:
Figure C.1 Polymath Script for DME Synthesis
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Figure C.1 Polymath Script for DME Synthesis (cont’d)
From the graph can be obtained, for conversion by 60% then the mass of the
reactor length required is 9 m.
Figure C.2 Profile of CO Conversion to Reactor Length
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Figure C.3 Profile of MeOH and DME Molar Flow to Reactor Length
To find the total reactor volume, the equation is needed
𝑉𝑡𝑜𝑡𝑎𝑙 = 𝑁 𝑥 𝐿 𝑥 𝐴𝑡 = 8.654 𝑚3
Then the reactor diameter is obtained from the following equation:
𝐷=√
4𝑥𝑉𝑥𝐿
𝜋
Obtained D = 9.96 m
The design of the reactor thickness must take into account the operating
pressure as well as the additional pressure tolerance factor to ensure process
safety. In all calculations of reactor thickness also included a corrosion
tolerance factor of 0.15 in. By using the following formula (Bronell and
Young):
ta =
P.ri
+c
SE − 0.6 P
The reactor thickness was obtained at 0.038 m
Then the need for a catalyst can be calculated by the following equation:
Obtained catalyst weight 6750.6075kg
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and the volume of catalyst filling the reactor is
= 5,192 m3
In whizzing the reactor jacket, to get the U value and Q value taken from
the simulation results, then using the following equation:
𝑄 = 𝑈 𝑥 𝑁 𝑥 𝐴𝑡 𝑥 𝑑𝑒𝑙𝑡𝑎 𝑇
𝑈 = 156 𝑊/𝑚𝐾
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APPENDIX D
COMPRESSOR
There are several steps to sizing a compressor stated below:
1. Find out physical properties of the stream which will go into the pump and the
information needed in the calculation (pressure inlet, temperature inlet,
compression ratio, flow rate, molecular weight and tip speed).
2. Determine the type of the compressor. To accomplish this step, we use the
“general range of application of compressor” graph as shown in Figure D.1.
Figure D.1. General Range of Application for Compressor
(Source: Kern, 2010)
3.
Calculate the specific gravity and isentropic heat capacity ratio:
𝑆𝐺 =
𝑀𝑊𝑔𝑎𝑠
𝑀𝑊𝑎𝑖𝑟
𝛾 = 1.3 − (0.31)(𝑆𝐺 − 0.55)
(D.1)
(D.2)
4.
Calculate the compressor speed:
5.
𝑇1𝑍𝑎 𝑅
𝑃2 𝛾−1
(D.3)
[( ) 𝛾 − 1]
𝛾−1
( 𝛾 )(𝑀𝑊) 𝑃1
Input data (Flow rate, Tip speed, Conversion factor, Efficiency polytropic,
∆ℎ =
Polytropic heat capacity ratio).
6.
Calculate efficiency isentropic:
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𝑃2 𝛾−1
(𝑃 ) 𝛾 − 1
𝐸𝑖𝑠𝑒𝑛 = 1 𝑛−1
𝑃
(𝑃2 ) 𝑛 − 1
1
(D.4)
7. Calculate the actual flowrate:
𝑚3
𝑠𝑡𝑑 𝑑
𝑃𝑠 𝑇1
𝑞=(
) ( ) ( ) 𝑍𝑎
86400 𝑃1 𝑇𝑠
(D.5)
8. Calculate compression power (kW/stage):
𝛾−1
𝑘𝑊
𝐴
𝛾
𝑃𝑠
𝑃2 𝛾
= ( )(
)(𝑞) ( ) (𝑇1 ) [( )
− 1] (𝑍𝑎)
𝑠𝑡𝑎𝑔𝑒
𝐸 𝛾−1
𝑃1
𝑃1
(D.6)
9. Calculate diameter of impeller and compressor speed:
𝑞
60 𝜇
𝑑= √
;𝑁 =
0.05𝜇
𝑑𝜋
(D.7)
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APPENDIX E
PRESSURE SWING ADSORPTION
The design of an adsorption column is accomplished through the utilization of the
FlexPDE. To effectively model the adsorption process, a number of factors must be
taken into account and computed beforehand. The subsequent section outlines the
steps involved in these calculations.
1. Input Operating Parameters
Table H.1. Physical Properties of The Adsorbent
Volumetric Flow Rate (m3/s)
Adsorption temperature (K)
Total bed porosity
Fluid density (kg/m3)
Q
Temp
dc
Et
Column pressure (bar)
Rho
Adsorbat Fraction in Feed
Ptot
Column diameter (m)
FraksiA
2. Calculated Operating Parameters
Table H.1. Physical Properties of The Adsorbent
Column area (m2)
Superficial fluid velocity (m/s)
Dispersion coefficient (m2/s2)
Adsorbate concentration in
(mol/m3)
Ac
uz
Dz
feed CAin
3. Input Kinetic Parameters
Table H.1. Physical Properties of The Adsorbent
Partial pressure (bar)
PA
Maximum adsorption capacity of n0A
monolayer (moles of adsorbate/kg
adsorbent)
Langmuir exponential factor (m3/mol) KA
4. Calculated Kinetic Parameters
Table H.1. Physical Properties of The Adsorbent
Mass balance (adsorption isotherm)
kPA
Absorbed adsorbate concentration qA
(oles of adsorbate/kg adsorbent)
5. Input Sizing
Table H.1. Physical Properties of The Adsorbent
Column length (m)
L
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Breakthrough time (h)
BT
Simulation end time (s)
tfinal
6. Input Equations with initial value CA = 0
CA: (Et+Rho*kPA)*dt(CA)-Dz*dxx(CA)+uz*dx(CA)=0
7. Run the Program
The result shown in the graph below.
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Figure E.1 Shell Side Heating Factor
(Source: Sinnot, 2005)
1. Calculate heat transfer coefficient
The overall heat transfer coefficient can be calculated by equation:
𝑑𝑜
𝑑𝑜. ln ( ) 𝑑𝑜
1
1
1
1
𝑑𝑜 1
𝑑𝑖 +
=
+
+
×
+
× … (24)
𝑈 ℎ𝑜 ℎ𝑜𝑑
2𝑘𝑤
𝑑𝑖 ℎ𝑖𝑑 𝑑𝑖 ℎ𝑖
Where
ho = hs = heat transfer coefficient (fluid shell), W/m2.C
hi = heat transfer coefficient (fluid tube), W/m2.C
hod = fouling factor for fluid shell, W/m2.C
hid = fouling factor for fluid tube, W/m2.C
kw = thermal conductivity of tube material, W/m.C
di = inside diameter of tube, m
do = outside diameter of tube, m
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APPENDIX F
DISTILLATION COLUMN
To sizing the height and diameter of the distillation column can be done using
HYSYS by this following steps
1. Determine the condenser pressure, reboiler pressure, type, material,and
dimension of the packing based on the ethanol production process and
literature
2. Determine the number of stages and reflux ratio using a shortcut method
3. Determine the diameter column, tray spacing for trayed distillation using
short cut distillation in HYSYS, and section packing height for distillation.
4. Determine the vessel and head type based on this criterion.
Vessel Type
Pressure (Psi)
Hemispherical
15-400
Eliptical
200-400
Flanged
14.7
Torispherical
15-200
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Flanged standard dished & flanged
Low pressure (vacuum)
shallow dished heads
Head Type
Pressure (Psi)
Spherical
10-200
Cylindrical
1-400
Rectangular
14.7
Bullet Tank
15
5. Determine the material and plate of the vessel
6. Calculate the circumferential stress (longitudinal joints) thickness with
equation
𝑡=
𝑃𝑖 𝐷𝑖
2𝑆𝐸 − 1.2𝑃𝑖
Calculate the longitudinal stress (circumferential joints) thickness with
equation
𝑡=
𝑃𝑖 𝐷𝑖
4𝑆𝐸 − 0.8𝑃𝑖
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7. Choose the minimum thickness and then calclulate the final thickness with
equation
𝑡𝑑 = 𝑡𝑚𝑖𝑛 + 𝐶𝐴
8. Calculate the head thcinkness using hemispherical head equation
𝑡=
𝑃𝑅
+ 𝐶𝐴
2𝑆𝐸 − 0.2𝑃𝑖
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APPENDIX G
PUMP
To determine the sizing calculation and pump type, several steps have to be done,
1. Find out all physical properties of the streams (stream in and stream out),
such as pressure inlet (Pin), pressure outlet (Pout), vapor pressure (Pvap), the
density of the fluids (ρ), mass flowrate (ṁ), temperature (T), and length of
the pump (L).
2. Determine the type of the pump based on pumps’ heuristic, which is
concluded below.
Table G. 1 Criteria for selecting type of pump
Pump Type
Max Head (ft)
Centrifugal
Flowrate (GPM)
Min
Max
5500
15
11000
Axial
40
20
100000
Rotary
50000
1
5000
Reciprocating
1000000
10
10000
All of the pumps in the process area and utility area use the
centrifugal pump.
3. Set the pump efficiency of 75% due to many medium and larger centrifugal
pumps to offer efficiencies of 75% to 93%.
4. Assume the pipe length, either from instrument to pump or pump to another
instrument.
5. Assume there are no fittings, and the velocity difference is neglected due to
its’ small number (V2=0).
6. Determine the head of the pump using the equation below,
ℎ𝑒𝑎𝑑 = ∆𝑧 =
(𝑟𝜔)2 (𝐷𝜋𝑁)2 ∆𝑃
=
=
… (1)
2𝑔
2𝑔
𝜌𝑔
7. Determine W theoretical and W actual using the equation below
𝑊𝑡ℎ𝑒𝑜𝑟𝑖𝑡𝑖𝑐𝑎𝑙 =
−𝑑𝑊∞ −𝑑𝑊𝑝𝑜𝑚𝑝𝑎
𝑃
𝑣2
=
= ∆ ( + 𝑔𝑧 + ) + 𝐹 … (2)
𝑑𝑚
𝑑𝑚
𝜌
2
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𝑊𝑎𝑐𝑡𝑢𝑎𝑙 =
𝑊𝑡ℎ𝑒𝑜𝑟𝑖𝑡𝑖𝑐𝑎𝑙
𝜂
8. Determine NPSHa and NPSHr value using the equation below,
𝑁𝑃𝑆𝐻𝑎 =
𝑃1(𝑎𝑡𝑚)
𝜌𝑔
−
𝑁𝑃𝑆𝐻𝑟 =
𝑃𝑣𝑎𝑝
𝜌𝑔
− (𝑍2 − 𝑍1 ) −
𝑃2(𝑠𝑢𝑐𝑡𝑖𝑜𝑛) − 𝑃𝑣𝑎𝑝
𝜌𝑔
𝑉2 2 𝐹
− … (3)
2𝑔 𝑔
… (4)
Suction cavitation occurs when NPSHa is smaller than NPSHr. Therefore,
the NPSHa value must be bigger, with a ratio of 1.1-1.2 for chemical
processes and a minimum ratio of 1.0 for electric power generation.
9. Determine the FHP and BHP using the equation below.
𝐹𝐻𝑃 =
−𝑑𝑊𝑝𝑢𝑚𝑝
𝑚 = 𝐻𝑔𝑚 … (5)
𝑑𝑚
𝐹𝐻𝑃
𝐵𝐻𝑃 =
… (6)
𝜂
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APPENDIX H
MIXER
The sizing and calculation for mixing tank is almost the same as storage tank, but
with the addition of determining and sizing the impeller needed for optimal mixing.
1. For calculating or sizing of vessel (volume, diamter, height, thickness), first
we need to calculate the total volume needed base on volume flow rate (
𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤𝑒𝑟𝑎𝑡𝑒 × 𝑚𝑖𝑥𝑡𝑢𝑟𝑒 𝑑𝑒𝑛𝑠𝑖𝑡𝑦) and the mixture viscosity (for
impeller calculation)
2. Calculate the pressure inside the vessel, based on hydrostatic pressure, gas
pressure, and safety factor (20%) using Equation below:
𝐻𝑓 =
𝑣𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑙𝑖𝑞𝑢𝑖𝑑 𝑖𝑛𝑠𝑖𝑑𝑒 𝑡𝑎𝑛𝑘 𝑥 𝑡𝑎𝑛𝑘 ℎ𝑒𝑖𝑔ℎ𝑡
𝑡𝑎𝑛𝑘 𝑣𝑜𝑙𝑢𝑚𝑒
𝑃 = 𝑃ℎ𝑦𝑑𝑟𝑜 + 𝑃𝑔𝑎𝑠 + 𝑃𝑠𝑎𝑓𝑒𝑡𝑦
3. Choose the type of head used on the vessel base on the pressure
Figure H.1 Pressure Vessel Head
(Source: Pressure Vessel Engineering,2021)
4. Choose the best suited material for the vessel based on the price, strength,
and corrosion resistance.
5. Calculate the thickness of the vessel based on pressure (P), inside diameter
(ri), allowable stress (f) based on material type, joint efficiency (E), and
corrosion factor (C).
𝑡=
𝑃 𝑥 𝑟𝑖
+𝐶
𝑓𝐸 − 0,6𝑃
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6. Calculate the thickness of the vessel head based on head type, pressure (P),
inside diameter (ri), allowable stress (f) based on material type, joint
efficiency (E), and corrosion factor (C).
7. Calculate the sizing and power needed for impeller in mixing tank. Choose
the most suitable type of impeller for our case.
Figure H. 2 Impeller Type
(Source: Handbook of Industrial Mixing, 2004)
8. Determine the size of impeller using rule of thumb
Figure H. 3 Vessel Distance Sizing
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(Source: Fluid Mixing and Gas Dispersion in Agitated Tanks, 1991)
9. Calculate the power needed using the Equation D.4. Neglect Froude number
because we can use baffle in our tank to prevent vortex.
𝑁𝑝 =
𝑃
𝜌𝑁 3 𝐷 5
Figure H. 4 Power Number
(Source: Chemical Engineering Design, 2005)
10. Use Reynold’s Number to find the power number and calculate the power
needed for the impeller.
𝜌𝑁𝐷 2
𝑁𝑅𝑒 =
𝜇
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APPENDIX I
BOILER
Boiler is used to generate steam for utilities. The simulation and calculation
is done using ASPEN HYSYS and benchmarking and vendor data collecting
method. Boiler in this plant is used to produce steam to support the mixing of natural
gas. First, the method of the furnace need to be determined using the qv equation
below
𝑞𝑣 =
𝑚𝑐 𝐿𝐻𝑉 𝑘𝑊
𝑉
𝑚3
The mc variable is the design fuel consumption rate. The value of qv can ve
determined through the rule of thumb below.
The next step is to determine the Hfu + Hb and the heat transfer area in boiler
(Fgrate) using this equation
𝑞𝑓 =
𝑚𝑐 𝐿𝐻𝑉 𝑘𝑊
𝐹𝑔𝑟𝑎𝑡𝑒 𝑚3
𝐻𝑓𝑢 + 𝐻𝑏 =
𝑉
𝐹𝑔𝑟𝑎𝑡𝑒
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After that, we need to determine the width and depth of the furnae (a and b
constans). Then, we can determine the valua of qb
𝑏=√
𝐹𝑔𝑟𝑎𝑡𝑒
1.1
𝑎 = 1.1𝑏
𝑞=
𝑚𝑐 𝐿𝐻𝑉 𝑘𝑊
[
]
2(𝑎 + 𝑏)𝐻𝑏 𝑚3
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APPENDIX J
TANK
Vessel or tank that we will use is for sedimentation tank, decant basin tank,
and water recovery basin tank. Calculation the sizing of tank or vessel is described
below.
Step 1: Determine the Storage Tank Type
•
Tank Size Criteria
Table J.1 Tank Size Criteria
Criteria
Volume
Pressure
Phase
Function
•
Large Vessel (H/D < 1)
V>25000 US Gal
Low Pressure, Atmospheric Pressure
Liquid
Storage
Small Vessel (H/D>1)
V< 25000 US Gal
High Pressure (>500 psig)
Gas
Storage or Process
Tank Orientation Criteria
Table J.2 Tank Orientation Criteria
Volume
<1000 gal
1000-10000 gal
> 10000 gal
•
Orientation
Vertical Tanks on Legs
Horizontal Tanks on concrete supports
Vertical Tanks on concrete foundation
Tank Shapes Criteria
Table J.3 Tank Shapes Criteria
Pressure
5-200 psig
150-250 psig
2.5-7.5 psig
~14.69 psig
•
Type
Cylindrical
Spherical
Oval
Rectangular
Tank Type
Table J.4 Storage Tank Type
Tank Size
Tank Orientation
Tank Type
Large Vessel
Vertical tank with concrete foundation
Cylindrical
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Step 2: Determine Top Head and Bottom Head Type
Table J.5 Selection of Top and Bottome Head Type
Head Type
Pressure (psi)
Hemispherical
15 – 400
Eliptical
200 – 400
Flanged
14,7
Torispherical
15 – 200
Flanged standard dished & flanged
shallow dished heads
Low Pressure (vacuum)
Table J.6 6Top Head and Bottom Head Type
Top Head
Bottom Head
Torispherical Type
Figure J.1 Torispherical Head
(Source:ASME VII UG-32)
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Step 3: Determine Tank Material
Figure J.2 Material Selection
•
Storage Tank Material : Carbon Steel SA-516
Step 4: Determine Tank Dimension
•
Tank Capacity
𝑉𝐿 =
𝑉𝑇 =
𝑚̇
… (25)
𝜌
𝑉𝐿
… (26)
% 𝑆𝑡𝑜𝑟𝑎𝑔𝑒 𝐹𝑢𝑙𝑙
Where,
•
VL
= Liquid volume (m3)
VT
= Tank Volume (m3)
m
= Liquid Mass Flowrate (kg/h)
ρ
= Liquid Density (kg/m3)
Tank Diameter
Shell Volume
𝐷2
𝑉𝑠 = 𝜋 ( ) 𝐿 … (27)
2
Where
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𝑉𝑆
= Shell Volume (m3)
𝐷
= Diameter (m)
𝐿
= Tank Height (m)
Head Volume
𝑉𝐻 =
1
𝜋(𝐻𝐻 2 )(3𝑟𝑐𝑟𝑜𝑤𝑛 − 𝐻𝐻 ) … (28)
4
Where
𝑉𝐻 = Head Volume (m3)
𝐻𝐻 = Head Height (m)
𝑟𝑐𝑟𝑜𝑤𝑛 = Crown Head Radius (m)
Total Volume = 𝑉𝑇 = 𝑉𝑠 + 2𝑉𝐻 … (29)
By using goal seek in Excel the diameter is obtained.
•
Tank Height
Tank height can be obtained with known L/D = 0.8 (Eyer, 1965). Then, tank
height can be calculated using calculation below.
Shell Height
𝐿 = 1.5𝐷…(30)
Head Height
𝐻𝐻 = 0.169𝐷…(31)
Total Height
𝐻𝑇 = 𝐻𝑠 + 2𝐻𝐻 … (32)
Step 5: Determine Pressure Design
To calculate pressure design, fluid height needs to be calculated using this ratio
formula.
𝐹𝑙𝑢𝑖𝑑 ℎ𝑒𝑖𝑔ℎ𝑡 =
𝐹𝑙𝑢𝑖𝑑 𝑣𝑜𝑙𝑢𝑚𝑒
× 𝑉𝑒𝑠𝑠𝑒𝑙 ℎ𝑒𝑖𝑔ℎ𝑡 … (33)
𝑉𝑒𝑠𝑠𝑒𝑙 𝑣𝑜𝑙𝑢𝑚𝑒
Based on Towler and Sinnott (2012), the design pressure is normally be 5% to 10%
above the normal working pressure. When deciding the design pressure, the
hydrostatic pressure is the base of the column should be added to operating pressure.
Thus, these equations should be used.
𝑃ℎ = 𝜌 × 𝑔 × 𝐹𝑙𝑢𝑖𝑑 ℎ𝑒𝑖𝑔ℎ𝑡 … (34)
𝑃𝑎𝑏𝑠 = (𝑃𝑜 + 𝑃ℎ) … (35)
Using the 10% margin, the pressure design can be obtained using this equation.
𝑃𝑑 = (100% + 10%)(𝑃𝑎𝑏𝑠) … (36)
Where,
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Ph
= Hydrostatic pressure (Pa)
Pabs
= Absolute Pressure (Pa)
Po
= Operating pressure (Pa)
Pd
= Design pressure (Pa)
Step 6: Tank Thickness
To calculate thickness, cylindrical shell and torispherical head thickness
equation is used. The equations based on Walas (2010) is written below.
𝑃𝑅
+ 𝐶 … (37)
𝑆𝐸 − 0.6𝑃
0.885 𝑃 𝑟𝑐𝑟𝑜𝑤𝑛
𝑆𝑡𝑎𝑛𝑑𝑎𝑟𝑑 𝑑𝑖𝑠ℎ ℎ𝑒𝑎𝑑 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 =
+ 𝐶 … (38)
𝑆𝐸 − 0.1𝑃
𝑃 𝑟𝑐𝑟𝑜𝑤𝑛 𝑊
𝑇𝑜𝑟𝑖𝑠𝑝ℎ𝑒𝑟𝑖𝑐𝑎𝑙 ℎ𝑒𝑎𝑑 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 =
+ 𝐶 … (39)
2𝑆𝐸 − 0.2𝑃
𝐶𝑦𝑙𝑖𝑛𝑑𝑟𝑖𝑐𝑎𝑙 𝑠ℎ𝑒𝑙𝑙 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 =
Where,
𝑃
= Pressure (psi)
R
= Radius (inch)
𝑟𝑐rown = Crown Radius (inch)
S
= Maximum Allowable Stress (psi)
W
)
= 4 (3 + √ 𝑐𝑟𝑜𝑤𝑛
𝑖𝑐𝑟
𝐸
= Joint Efficiency
𝐶
= Corrosion Allowance
1
𝑟
Allowable stress and joint efficiency obtained from the figure below.
Figure J.3 Allowable Stress Data
(Source: Towler and Sinott, 2012)
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Figure J.4 Joint Efficiency Data
(Source: Towler and Sinott, 2012)
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