Tutorial 4 - Solution

RDCHB2- Tutorial 4
Based on the PFD and flow stream information of the above ( production of Benzene via the hydrodealkylation of Toluene production Using
Heuristic estimate the size of the equipment and other operating parameters for the following units . Compare your results on those provided on
Table 2.
a. V-102
b. E-105
c. P-101
d. C-101
e. T-101
f. H-101
Figure 1.5
Table 1.5 Stream table
Table 1.7
Solution
. V-102 High-Pressure Phase Separator
From Table 11.6, the following heuristics are used:
Rule 3 → Vertical vessel
Rule 4 → L/D between 2.5 and 5 with optimum at 3.0
Rule 5 → Liquid holdup time is 5 min based on 1/2 volume of vessel
Rule 9 → Gas velocity u is given by
pl
√
u=k (
pv
¿−1)m/s ¿
where k = 0.0305 for vessels without mesh entrainers

Rule 12 → Good performance obtained at 30%–100% of u from Rule 9; typical value is 75%
From Table 1.5,
Vapor flow = Stream 8 = 9200 kg/h, P = 23.9 bar, T = 38°C
Liquid flow = Streams 17 + 18 = 11,570 kg/h, P = 2.8 bar, T = 38°C
ρv = 8 kg/m3 and ρl = 850 kg/m3 (estimated from Table 1.7)
From Rule 9, u = 0.0305[850/8 – 1]0.5 = 0.313 m/s
Use uact = (0.75)(0.313) = 0.23 m/s
Now mass flowrate of vapor = uρυπD2/4 = 9200/3600 = 2.56 kg/s
Solving for D, D = 1.33 m
From Rule 5, the volume of liquid = 0.5 LπD2/4 = 0.726L m3
5 min of liquid flow = (5)(60)(11,570)/850/3600 = 1.13 m3
Equating the two results above, L = 1.56 m
From Rule 4, L/D should be in the range 2.5 to 5. For this case L/D = 1.56/1.33 = 1.17
Because this is out of range, change to L = 2.5D = 3.3 m.
Heuristics from Table 11.6 suggest that V-102 should be a vertical vessel with D = 1.33 m, L =3.3 m
From Table 1.7, the actual V-102 is a vertical vessel with D = 1.1 m, L = 3.5 m
It should be concluded that the design of V-102 given in Chapter 1 is consistent with the heuristics given in Table
11.6. The small differences in L and D are to be expected in a comparison such as this one.
b. E-105 Product Cooler
From Table 11.11 use the following heuristics:
Rule 1: Set F = 0.9
Rule 6: min. ΔT = 10°C
Rule 7: Water enters at 30°C and leaves at 40°C
Rule 8: U = 850 W/m2°C
It is observed immediately from Table 1.5 and Figure 1.5 that Rule 6 has been violated because
ΔTmin = 8°C.
For the moment, ignore this and return to the heuristic analysis:
ΔTlm = [(105 – 40) – (38 – 30)]/ln[(105 – 40)/(38 – 30)] = 27.2°C
Q = 1085 MJ/h = 301 kW (from Table 1.7)
A = Q/UΔTlmF = (301,000)/(850)/(27.2)/(0.90) = 14.46 m2
From Rule 9, Table 11.11, this heat exchanger should be a double-pipe or multiple-pipe design.
Comparing this analysis with the information in Table 1.7 shows
Heuristic: Double-pipe design, area = 14.5 m2
Table 1.7: Multiple-pipe design, area = 12 m2
Again, the heuristic analysis is close to the actual design. The fact that the minimum approach
temperature of 10°C has been violated should not cause too much concern, because the actual
minimum approach is only 8°C and the heat exchanger is quite small, suggesting that a little extra area
(due to a smaller overall temperature driving force) is not very costly.
c. P-101
From Table 11.9, use the following heuristics:
Rule 1: Power(kW) = (1.67)[Flow(m3/min)]ΔP(bar)/ε
Rules 4–7: Type of pump based on head
From Figure 1.5 and Tables 1.5 and 1.7,
Flowrate (Stream 2) = 13,300 kg/h
Density of fluid = 870 kg/m3
ΔP = 25.8 – 1.2 = 24.6 bar = 288 m of liquid (head = ΔP/ρg)
Volumetric flowrate = (13,300)/(60)/(870) = 0.255 m3/min
Fluid pumping power = (1.67)(0.255)(24.6) = 10.5 kW
From Rules 4–7, pump choices are multistage centrifugal, rotary, and reciprocating. Choose
reciprocating to be consistent with Table 1.7. Typical ε = 0.75.
Power (shaft power) = 10.5/0.75 = 14.0 kW → compares with 14.2 kW from Table 1.7.
d. C-101
Rule 2: Wrev adiab = mz1RT1[(P2/P1)a–1]/a
From Table 1.7, flow = 6770 kg/h, T1 = 38°C = 311 K, mw = 8.45, P1 = 23.9 bar, P2 = 25.5
k = 1.41 (assume) and a = 0.2908
m = (6770)/(3600)/(8.45) = 0.223 kmol/s
Wrev adiab = (223)(1.0)(8.314)(311){ (25.5/23.9)0.2908 – 1)/0.2908 = 37.7 kW using a
compressor efficiency of 75%
Wactual = (37.7)/(0.75) = 50.3 kW → This checks with the shaft power requirement given in
Table 1.7.
e. T-101
Rule 5: Optimum reflux in the range of 1.2–1.5Rmin
Rule 6: Optimum number of stages approximately 2Nmin
Rule 7: Nmin = ln{ [x/(1 – x)]ovhd/[x/(1 – x)]bot}/ln α
Rule 8: Rmin = {F/D}/(α – 1)
Rule 9: Use a safety factor of 10% on number of trays.
Rule 14: Lmax = 53 m and L/D < 30
Rule 2: Fs = uρυ 0.5 = 1.2 → 1.5m/s(kg/m3) 0.5
Rule 3: ΔPtray = 0.007 bar
Rule 4: εtray = 60 – 90 %
xovhd = 0.9962, xovhd = 0.0308, αovhd = 2.44, αbot = 2.13, αgeom ave = (αovhdαbot)0.5 = 2.28
Nmin = ln{ [0.9962/(1 – 0.9962)]/[0.0308/(1 – 0.0308)]}/ln (2.28) = 10.9
Rmin = {142.2/105.6}/(2.28 – 1) = 1.05
Range of R = (1.2 →1.5)Rmin = 1.26 → 1.58
Ntheoretical ≈ (2)(10.9) = 21.8
εtray = 0.6
Nactual ≈ (21.6/0.6)(1.1) = 40 trays
ρυ = 6.1 kg/m3
u = (1.2 → 1.5)/6.10.5 = 0.49 → 0.60 m/s
Vapor flowrate (Stream 13) = 22,700 kg/h
Vol. flowrate, v = 1.03 m3/s
Dtower = [4v/πu]0.5 = [(4)(1.03)/(3.142)/(0.49 → 0.60)]0.5 = 1.64 – 1.48 m
ΔPtower = (Nactual)(ΔPtray) = (40)(0.007) = 0.28 bar
A comparison of the actual equipment design and the predictions of the heuristic methods are given below.
From Tables 1.5 and 1.7 and From
Figure 1.5 Heuristics
Tower diameter 1.5m 1.48-1.64m
Reflux ratio, R 1.75 1.26-1.58
Number of Trays 42 40
Pressure drop, ΔP 0.30bar 0.28bar
f. H-101
Rule 13: Equal heat transfer in radiant and convective sections
Radiant rate = 37.6 kW/m2, convective rate = 12.5 kW/m2
Duty = 27,040 MJ/h = 7511 kW
Area radiant section = (0.5)(7511)/(37.6) = 99.9 m2 (106.8 m2 in Table 1.7)
Area convective section = (0.5)(7511)/(12.5) = 300.4 m2 (320.2 m2 in Table 1.7)
From the earlier worked examples, it is clear that the sizing of the equipment in Table 1.7 agrees well with the
predictions of the heuristics presented in this chapter. Exact agreement is not to be expected. Instead, the heuristics
should be used to check calculations performed using more rigorous methods
and to flag any inconsistencies.
In this chapter, a number of heuristics have been introduced that allow the reasonableness of the results of
engineering calculations to be checked. These heuristics or guidelines cannot be used to determine absolutely
whether a particular answer is correct or incorrect. However, they are useful guides that allow the engineer to flag
possible errors and help focus attention on areas of the process that may require special attention. Several heuristics,
provided in the tables at the end of this chapter, were used to check the designs provided in Table 1.5 for the
toluene hydrodealkylation process.

Tutorial 4 - Solution

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Tutorial 4 - Solution

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RDCHB2- Tutorial 4

where k = 0.0305 for vessels without mesh entrainers

Reflux ratio, R 1.75 1.26-1.58

Pressure drop, ΔP 0.30bar 0.28bar

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