Proyecto Capstone Desing, Ejercicios de Diseño Capstone

¡Descarga Proyecto Capstone Desing y más Ejercicios en PDF de Diseño Capstone solo en Docsity! SECOND STAGE OF CAPSTONE DESIGN AUTHORS ISAIAS ARIZA JIMENEZ ANDRES FELIPE GUEBELY MARTELO LAURA MARCELA MERCADO GUERRERO MANUEL ALEJANDRO SUAREZ BALLESTEROS JUAN CARLOS VERGARA VILLADIEGO TUTOR JOSE ANGEL COLINA MARQUEZ SUBJECT PLANT DESIGN CARTAGENA DE INDIAS UNIVERSITY OF CARTAGENA CHEMICAL ENGINEERING 25/10/2021 PROJECT: PRODUCTION AND RECOVERY OF STYRENE FROM ETHYLBENZENE DEHYDROGENATION Target: 80000 TPY (basis: 8000 h of continuous production) Raw material: Liquid ethylbenzene Styrene is a monomer belonging to the group of aromatic hydrocarbons whose appearance ranges from colorless to oily yellow liquid which evaporates easily and has a sweet odor. Its molecular chemical formula is C8H8, it has a molecular mass of 104.2 g/mol, a boiling point of 145°C and a melting point of -30°C. Styrene is apolar, can be dissolved in some liquids, but is poorly soluble in water. Styrene is a product widely used worldwide having multiple applications, some of these are: polystyrene which is frequently used in packaging and automotive components and appliances, expanded polystyrene (EPS), also known as white cork, used both in insulation and packaging in construction, there are also the ABS and SAN copolymers used for the manufacture of toys, small appliances, medical devices, etc., styrenic rubbers used in the manufacture of tires, hoses, shoe soles, among others, and unsaturated polyester resins (UPR) used in construction, furniture, impact-resistant surfaces (floors, kitchens, bathrooms, etc.). Styrene has some health risks among which we can highlight: Irritation of the skin, eyes, throat and nose, rashes, headache and dizziness, it can also be carcinogenic so care must be taken with its handling and exposure for which established safety protocols must be followed. ECONOMIC ASPECTS OF STYRENE IN COLOMBIA  Total imports in Colombia  Total imported: 636,188,463 U$.  Quantity imported: 505,392,466 kilograms  Unit price: 1,259 U$/kg  Number of imports of the product styrene in Colombia: 290250 MAIN IMPORTERS IN COLOMBIA:  Americas Styrenics de Colombia  LTDA 68.4% (428,588,096 U$)  AJOVER SAS 9.5% (59,427,649 U$)  AJOVER SA 22.1% (138,748,789 U$) MAIN COUNTRIES OF ORIGIN:  United States 99.5%  United Kingdom 0.5% PRODUCTION VOLUME AND FOREIGN TRADE (TONS) Process Flow Diagrams (PFD) Figure 2. Process Flow Diagrams for the Production and Recovery of Styrene from Ethylbenzene Dehydrogenation. Table.1. Identifying Process Equipment Tag Equipment type T-101 Distillation tower (Ethylbenzene, Styrene, Benzene, Toluene) T-102 Distillation tower (Benzene, Toluene) T-103 Distillation tower (Ethylbenzene, Styrene) R-101 Reactor V-101 Three-phase separator TK-101 Storage Tank (Hydrogen, Methane and Ethylene) TK-102 Storage Tank (Benzene) TK-103 Storage Tank (Toluene) TK-104 Storage Tank (Styrene) E-101 Heat Exchanger E-102 Heat Exchanger E-103 Heat Exchanger E-104 Heat Exchanger E-105 Heat Exchanger E-106 Heat Exchanger E-107 Condenser E-108 Reboiler E-109 Condenser E-110 Reboiler E-111 Condenser E-112 Reboiler H-101 Fired Heater MX-101 Mixer MX-102 Mixer MX-103 Mixer KV-101 Divider Detailed description of the process 1. Preheating The reaction material, liquid phase ethylbenzene (stream 1), enters at a temperature of 25°C and a pressure of 200 kPa into the heat exchanger (E-101) where the temperature is increased from 25°C to 125°C, then exits the heat exchanger (stream 2) and passes to the mixer (MX-101) where it enters a recirculated (stream 24) which has a temperature of 125°C with a composition of 99% ethylbenzene and 1% styrene, coming from the distillation tower (T-103). The mixture coming from the mixer (MX-101) passes to the exchanger (E-102) (stream 3) where its temperature is increased from 125°C to 171.111°C, when leaving the exchanger (stream 4) it enters a steam mixer (MX-102) to increase its temperature up to 600°C using the superheated steam (stream 8) which has a temperature of 620°C, coming from a divider (KV-101). All these temperature increases are performed to meet the reaction conditions, finally the mixture comes out with a composition of 55% water, 44,89551% ethylbenzene and 0,104489% styrene (stream 10) and enters the reactor (R-101). 2. Overheating The incoming water (stream 5) and the recirculated water (stream 18) from the three-phase separator (V-101) enters the mixer (MX-103), reaching a temperature of 50ºC. This mixture enters the boiler (H-101) (stream 6), which operates at constant pressure, where its temperature rises to the saturation temperature, thus producing saturated steam, which subsequently undergoes a superheating process because a higher temperature is required with respect to the boiler's operating range (it should be noted that superheating is an operation that occurs in conjunction with the boiler). In the superheat process the temperature of the saturated steam is increased to a range between 580°C - 630°C, where it becomes superheated steam (stream 7). 3. Reactor In the Reactor (R-101) where the dehydrogenation reaction of ethylbenzene is carried out, which works at a pressure of 200 kPa, a gaseous mixture enters (stream 10), which reacts with the catalyst (Iron Oxide III). This reaction takes place at high temperatures (580°C - 630°C) so superheated steam is injected (stream 9) through the reactor jacket in order to maintain a constant temperature. The reaction leaving the reactor (R-101) at a temperature of 600°C (stream 12) had a conversion of 71.277%, generating the following products: styrene, toluene, benzene, hydrogen, methane and ethylene, as well as unreacted ethylbenzene and water. The reaction has a selectivity of 95% and comes out with a composition of water 55%, styrene 32%, ethylbenzene 10.6666%, toluene 1.06666%, benzene 0.71111%, hydrogen 0.53888%, methane 0.0094445% and ethylene 0.0072223%. Reactions: Design Heat Exchanger When designing heat exchangers some restrictions must be taken into account, among these is the percentage of excess area, taking into account that the ideal range would be between 5% and 25%, if it exceeds 25% it is considered that the exchanger is oversized and if it is less than 5% it is considered that the exchanger is small, an ideal value for this percentage would be around 15%. Another important factor in determining whether the heat exchanger is adequate to perform its function is the pressure drop, which should not exceed 10 psi, otherwise the exchanger is not suitable for operation.  Heat Exchanger (E-101) To increase the temperature of ethylbenzene from 25°C (Stream 1) to 125°C (Stream 2), a heat exchanger (E-101) using steam at a pressure of 8 bar (800 kPa) (low pressure steam) was chosen. Steam enters the heat exchanger (E-101) into the shell side with a temperature of 170,411°C, while ethylbenzene enters into the tube side. The heat exchanger (E-101) was designed with CHEMCAD 7 software, obtaining the following results: Simulation: Heat Exchanger E-101 FLOW SUMMARIES Stream No. 1 2 3 4 Stream Name Stream 1 LPS Stream 2 LPS Temp F 77.0000 338.7398 257.0000 330.0000 Pres psia 29.0000 116.0200 29.0000 116.0200 Enth MMBtu/h -1.1900 -12.474 0.77130 -14.435 Vapor mole frac. 0.00000 1.0000 0.00000 0.00000 Total lbmol/h 224.9449 122.1011 224.9449 122.1011 Total lb/h 23881.7305 2199.6506 23881.7305 2199.6506 Total std L ft3/hr 438.8038 35.2351 438.8038 35.2351 Total std V scfh 85361.80 46334.75 85361.80 46334.75 Flow rates in lbmol/h Ethylbenzene 224.9449 0.0000 224.9449 0.0000 Water 0.0000 122.1011 0.0000 122.1011 SUMMARY REPORT General Data: Heat Transfer Data: Exch Class/Type C/CEL Effective Transfer Area 120.87 Shell I.D. 0.83 Area Required 106.91 Shell in Series/Parallel 1/1 COR LMTD 149.81 Number of Tubes 53 U (Calc/Service) 122.45/108.32 Tube Length 12.00 Heat Calc 2.22 Tube O.D./I.D. 0.0625/0.0517 Heat Spec 1.96 Excess % 13.05 Tube Pattern TRI60 Foul(S/T) 1.500E-003/1.500E-003 Tube Pitch 0.08 Del P(S/T) 0.23/3.63 Number of Tube Passes 4 SS Film Coeff 1743.34 Number of Baffles 0 SS CS Vel 0.51 Baffle Spacing 0.00 TW Resist 0.000862 Baffle Cut, % Diameter 15 TS Film Coeff 354.09 Baffle Type NOBF TS Vel 4.69 Baffle space def. Edge-Edge Thermodynamics: K: NRTL H: Latent Heat D: Library Number of Components: 2 Calculation Mode: Design Engineering Units: Temperature F Flow/Hour (lb/h)/h Pressure psia Enthalpy MMBtu Diameter/Area ft/ft2 Length/Velocity ft/(ft/sec) Film Btu/hr-ft2-F Fouling hr-ft2-F/Btu TEMA SHEET 1 2 Customer Ref No. 3 Address Prop No. 4 Plant Loc. Date Rev 5 Service of Unit Item 6 Size 0.8ft x 12.0ft Type CEL (Hor/Vert) H Connected in 1 Para 1 Seri 7 Surf/Unit(G/E) 124.9/120.9 ft2; Shell/Unit 1.000000 Surf/Shell 124.9/120.9 ft2 8 PERFORMANCE OF ONE UNIT 9 Type of Process Horiz Cond Sensible 10 Fluid Allocation Shell Side Tube Side 11 Fluid Name LPS Stream 1 12 Flow 2199.7 23881.7 lb/h 13 Liquid 0.0 23881.7 lb/h 14 Vapor 2199.7 0.0 lb/h 15 NonCondensable 0.00000 0.00000 lb/h 16 Steam 2199.7 0.0 lb/h 17 Evap/Cond 2199.7 0.0 lb/h 18 Density 0.25/55.98 / 0.25/56.29 0.00/53.91 / 0.00/48.16 lb/ft3 19 Conductivity 0.02/0.39 / 0.02/0.39 0.00/0.07 / 0.00/0.06 Btu/hr-ft-F 20 Specific Heat 8.28/18.79 / 8.28/18.73 0.00/43.74 / 0.00/53.73 Btu/lbmol-F 21 Viscosity 0.02/0.16 / 0.02/0.16 0.00/0.64 / 0.00/0.26 cP 22 Latent Heat 882.54 0.00 Btu/lb 23 Temperature(In/Out) 338.739/330.000 77.000/257.000 F 24 Operating Pressure 116.02 29.00 psia 25 Fouling Factor 0.001500 0.001500 hr-ft2- F/Btu 26 Velocity 0.51 4.69 ft/sec 27 Press Drop Allow/Calc 10.000/0.226 10.000/3.628 psi 28 Heat Exchanged 1.961e+000 MMBtu/h; MTD(Corrected): 149.81 F 29 Transfer Rate, Service: 108.3 Calc: 122.5 Clean: 206.1 Btu/hr- ft2-F 30 CONSTRUCTION DATA/SHELL Sketch 31 Shell Side Tube Side 32 Design/Test Press psia 0.000000/Code 0.000000/Code 33 Design Temperature F 0.000 0.000 34 No. Passes per Shell 1 4 35 Corrosion Allowance ft 0.000 0.000 36 Connections IN ID ft 0.172 0.206 37 Size & OUT ID ft 0.087 0.206 38 Rating 39 Tube No. 53 OD 0.063 ft;Thk. 0.0054 ft;Length. 12.00 ft;Pit. 0.078 ft; Ptn. 60 40 Tube Type Bare Material MONEL SB-163-400 41 Shell A-240-317L 0.83 ID 0.92 OD ft Shell Cover 42 Channel or Bonnet A-285-C Channel Cover 43 Tubesheet Stationary A-285-C Tubesheet Floating 44 Floating Head Cover Impingement Protection: Yes 45 Baffles Cross A-285-C Type NOBF Cut(Diam) 0 Spacing C/C 0.00 ft 46 Baffles Long Seal Type 47 Supports Tube C.S. U-Bend 48 Bypass Seal Arrangement Tube-Tubesheet Joint 49 Expansion Joint No. Type 50 Rho-V2-Inlet Nozzle 2698.77 Bundle Entrance Bundle Exit 51 Shell Side Tube Side 52 Gasket Floating Head 53 Code Requirements Tema Class C 54 Weight/Shell 55 Remarks: Pressure drop shown is total pressure drop. 56 57 Taking into account different economic factors, we sought to design a heat exchanger that would operate under optimum conditions and at the lowest possible cost. In designing the heat exchanger (E-101), we chose a triangular layout for the heat exchanger. The sizing that was determined for the tubes and shell of the heat exchanger (E-101) resulted in the number of tubes required for this equipment is 53 tubes and the number of passes through the tubes is 4 passes, which indicates that the equipment is not very large, also 2199.6506 lb/h (997.447 kg/h) of low-pressure steam is used to increase the temperature of 23881.7305 lb/h (10832.57 kg/h) of ethylbenzene, which is a reasonable value to use with respect to the amount of ethylbenzene that enters, concluding that, the use of this equipment will not generate very high economic costs. Based on the results provided by the CHEMCAD 7 software, it was determined that the heat exchanger (E-101) complies with the established restrictions, since the reported 30 CONSTRUCTION DATA/SHELL Sketch 31 Shell Side Tube Side 32 Design/Test Press psia 0.000000/Code 0.000000/Code 33 Design Temperature F 0.000 0.000 34 No. Passes per Shell 1 2 35 Corrosion Allowance ft 0.000 0.000 36 Connections IN ID ft 0.256 0.206 37 Size & OUT ID ft 0.115 0.505 38 Rating 39 Tube No. 660 OD 0.063 ft;Thk. 0.0054 ft;Length. 20.00 ft;Pit. 0.078 ft; Ptn. 60 40 Tube Type Bare Material 1 Carbon Steel 41 Shell A-285-C 2.25 ID 2.33 OD ft Shell Cover 42 Channel or Bonnet A-285-C Channel Cover 43 Tubesheet Stationary A-285-C Tubesheet Floating 44 Floating Head Cover Impingement Protection: Yes 45 Baffles Cross A-285-C Type NOBF Cut(Diam) 0 Spacing C/C 0.00 ft 46 Baffles Long Seal Type 47 Supports Tube C.S. U-Bend 48 Bypass Seal Arrangement Tube-Tubesheet Joint 49 Expansion Joint No. Type 50 Rho-V2-Inlet Nozzle 4297.19 Bundle Entrance Bundle Exit 51 Shell Side Tube Side 52 Gasket Floating Head 53 Code Requirements Tema Class C 54 Weight/Shell 55 Remarks: Pressure drop shown is total pressure drop. 56 57 Taking into account different economic factors, we sought to design a heat exchanger that would operate under optimum conditions and at the lowest possible cost. In designing the heat exchanger (E-102), we chose a triangular arrangement for the heat exchanger. The sizing that was determined for the tubes and shell of the heat exchanger (E-102) resulted in the number of tubes required for this equipment is 660 tubes and the number of passes through the tubes is 2 passes, also 6471.9912 lb/h (2935.6458 kg/h) of medium pressure steam is used to increase the temperature of 31104.0703 lb/h (14108. 569 kg/h) of the mixture, these values obtained for this equipment are due to the fact that in the process there is a phase change in the mixture (liquid phase to vapor phase), so the costs of the exchanger are higher compared to the previous one. Based on the results provided by the CHEMCAD 7 software, it was determined that the heat exchanger (E-102) complies with the established restrictions, since the reported pressure drop showed values lower than 10 psi and the excess area was 8.53 %, so it can be concluded that the equipment is in optimal conditions to comply with its operation.  Heat Exchanger (E-103) To decrease the temperature of the vapor mixture from 600°C (stream 12) to 370°C (stream 13), a heat exchanger (E-103) using water at a pressure of 4.826 bar (482.6 kPa) as the coolant was chosen. The water enters the heat exchanger (E-103) into the tube side with a temperature of 25°C, while the mixture enters into the shell side. The heat exchanger (E-103) was designed with CHEMCAD 7 software, obtaining the following results: Simulation: Heat Exchanger E-103 FLOW SUMMARIES Stream No. 1 2 3 4 Stream Name Stream 12 Water Stream 13 Water Temp F 1112.0000 77.0000 698.0000 320.0000 Pres psia 29.0000 70.0000 29.0000 70.0000 Enth MMBtu/h -169.26 -94.628 -185.18 -78.714 Vapor mole frac. 1.0000 0.00000 1.0000 1.0000 Total lbmol/h 2591.6895 770.4193 2591.6897 770.4193 Total lb/h 69120.1563 13879.1025 69120.1719 13879.1025 Total std L ft3/hr 1241.5964 222.3222 1241.5966 222.3222 Total std V scfh 983490.75 292357.63 983490.81 292357.63 Flow rates in lbmol/h Ethylbenzene 69.4457 0.0000 69.4457 0.0000 Styrene 212.3671 0.0000 212.3671 0.0000 Water 2110.2473 770.4193 2110.2478 770.4193 Toluene 8.0019 0.0000 8.0019 0.0000 Benzene 6.2923 0.0000 6.2923 0.0000 Methane 0.4067 0.0000 0.4067 0.0000 Ethylene 0.1779 0.0000 0.1779 0.0000 Hydrogen 184.7502 0.0000 184.7502 0.0000 SUMMARY REPORT General Data: Heat Transfer Data: Exch Class/Type C/AEL Effective Transfer Area 411.16 Shell I.D. 1.27 Area Required 337.51 Shell in Series/Parallel 1/1 COR LMTD 592.98 Number of Tubes 192 U (Calc/Service) 79.52/65.27 Tube Length 11.00 Heat Calc 19.39 Tube O.D./I.D. 0.0625/0.0517 Heat Spec 15.91 Excess % 21.82 Tube Pattern TRI60 Foul(S/T) 1.000E-003/2.000E-003 Tube Pitch 0.08 Del P(S/T) 6.29/4.33 Number of Tube Passes 2 SS Film Coeff 120.63 Number of Baffles 0 SS CS Vel 119.78 Baffle Spacing 0.00 TW Resist 0.000253 Baffle Cut, % Diameter 15 TS Film Coeff 1970.70 Baffle Type NOBF TS Vel 48.99 Baffle space def. Edge-Edge Thermodynamics: K: NRTL H: Latent Heat D: Library Number of Components: 8 Calculation Mode: Rating Engineering Units: Temperature F Flow/Hour (lb/h)/h Pressure psia Enthalpy MMBtu Diameter/Area ft/ft2 Length/Velocity ft/(ft/sec) Film Btu/hr-ft2-F Fouling hr-ft2-F/Btu TEMA SHEET 1 2 Customer Ref No. 3 Address Prop No. 4 Plant Loc. Date Rev 5 Service of Unit Item 6 Size 1.3ft x 11.0ft Type AEL (Hor/Vert) H Connected in 1 Para 1 Seri 7 Surf/Unit(G/E) 414.7/411.2 ft2; Shell/Unit 1.000000 Surf/Shell 414.7/411.2 ft2 8 PERFORMANCE OF ONE UNIT 9 Type of Process Sensible Forced Evap 10 Fluid Allocation Shell Side Tube Side 11 Fluid Name Stream 12 Water 12 Flow 69120.2 13879.1 lb/h 13 Liquid 0.0 13879.1 lb/h 14 Vapor 69120.2 0.0 lb/h 15 NonCondensable 0.00000 0.00000 lb/h 16 Steam 38016.1 0.0 lb/h 17 Evap/Cond 0.0 13879.1 lb/h 18 Density 0.05/0.00 / 0.06/0.00 0.16/62.22 / 0.15/57.19 lb/ft3 19 Conductivity 0.05/0.00 / 0.03/0.00 0.02/0.35 / 0.02/0.40 Btu/hr-ft-F 20 Specific Heat 15.64/0.00 / 13.96/0.00 8.23/18.01 / 8.25/18.55 Btu/lbmol-F 21 Viscosity 0.03/0.00 / 0.02/0.00 0.01/0.92 / 0.01/0.18 cP 22 Latent Heat 0.00 911.21 Btu/lb 23 Temperature(In/Out) 1112.000/697.999 76.999/320.000 F 24 Operating Pressure 29.00 70.00 psia 25 Fouling Factor 0.001000 0.002000 hr-ft2- F/Btu 26 Velocity 127.85 48.99 ft/sec Number of Tube Passes 2 SS Film Coeff 106.60 Number of Baffles 0 SS CS Vel 80.71 Baffle Spacing 0.00 TW Resist 0.000231 Baffle Cut, % Diameter 15 TS Film Coeff 1448.78 Baffle Type NOBF TS Vel 23.16 Baffle space def. Edge-Edge Thermodynamics: K: NRTL H: Latent Heat D: Library Number of Components: 8 Calculation Mode: Design Engineering Units: Temperature F Flow/Hour (lb/h)/h Pressure psia Enthalpy MMBtu Diameter/Area ft/ft2 Length/Velocity ft/(ft/sec) Film Btu/hr-ft2-F Fouling hr-ft2-F/Btu TEMA SHEET 1 2 Customer Ref No. 3 Address Prop No. 4 Plant Loc. Date Rev 5 Service of Unit Item 6 Size 1.3ft x 12.0ft Type CEL (Hor/Vert) H Connected in 1 Para 1 Seri 7 Surf/Unit(G/E) 452.4/448.9 ft2; Shell/Unit 1.000000 Surf/Shell 452.4/448.9 ft2 8 PERFORMANCE OF ONE UNIT 9 Type of Process Sensible Forced Evap 10 Fluid Allocation Shell Side Tube Side 11 Fluid Name Stream 13 Water 12 Flow 69120.2 6560.6 lb/h 13 Liquid 0.0 6560.6 lb/h 14 Vapor 69120.2 0.0 lb/h 15 NonCondensable 0.00000 0.00000 lb/h 16 Steam 38016.1 0.0 lb/h 17 Evap/Cond 0.0 6560.6 lb/h 18 Density 0.06/0.00 / 0.08/0.00 0.16/62.22 / 0.15/57.19 lb/ft3 19 Conductivity 0.03/0.00 / 0.02/0.00 0.02/0.35 / 0.02/0.40 Btu/hr-ft-F 20 Specific Heat 13.96/0.00 / 12.89/0.00 8.23/18.01 / 8.25/18.55 Btu/lbmol-F 21 Viscosity 0.02/0.00 / 0.02/0.00 0.01/0.92 / 0.01/0.18 cP 22 Latent Heat 0.00 911.22 Btu/lb 23 Temperature(In/Out) 698.000/482.000 77.000/320.000 F 24 Operating Pressure 29.00 70.00 psia 25 Fouling Factor 0.001000 0.002000 hr-ft2- F/Btu 26 Velocity 90.24 23.16 ft/sec 27 Press Drop Allow/Calc 10.000/5.327 10.000/2.282 psi 28 Heat Exchanged 7.522e+000 MMBtu/h; MTD(Corrected): 284.50 F 29 Transfer Rate, Service: 58.9 Calc: 72.1 Clean: 95.7 Btu/hr- ft2-F 30 CONSTRUCTION DATA/SHELL Sketch 31 Shell Side Tube Side 32 Design/Test Press psia 0.000000/Code 0.000000/Code 33 Design Temperature F 0.000 0.000 34 No. Passes per Shell 1 2 35 Corrosion Allowance ft 0.000 0.000 36 Connections IN ID ft 1.271 0.087 37 Size & OUT ID ft 1.104 0.256 38 Rating 39 Tube No. 192 OD 0.063 ft;Thk. 0.0054 ft;Length. 12.00 ft;Pit. 0.078 ft; Ptn. 60 40 Tube Type Bare Material 1 Carbon Steel 41 Shell A-285-C 1.27 ID 1.35 OD ft Shell Cover 42 Channel or Bonnet A-285-C Channel Cover 43 Tubesheet Stationary A-285-C Tubesheet Floating 44 Floating Head Cover Impingement Protection: Yes 45 Baffles Cross A-285-C Type NOBF Cut(Diam) 0 Spacing C/C 0.00 ft 46 Baffles Long Seal Type 47 Supports Tube C.S. U-Bend 48 Bypass Seal Arrangement Tube-Tubesheet Joint 49 Expansion Joint No. Type 50 Rho-V2-Inlet Nozzle 3667.19 Bundle Entrance Bundle Exit 51 Shell Side Tube Side 52 Gasket Floating Head 53 Code Requirements Tema Class C 54 Weight/Shell 55 Remarks: Pressure drop shown is total pressure drop. 56 57 Taking into account different economic factors, we sought to design a heat exchanger that would operate under optimum conditions and at the lowest possible cost. In designing the heat exchanger (E-104), we chose a triangular layout. The sizing that was determined for the tubes and shell of the heat exchanger (E-104) resulted in the number of tubes required for this unit being 192 tubes and the number of passes through the tubes is 2 passes, indicating that the unit is not very large, also 6560.5503 lb/h (2975.816 kg/h) of water is used to decrease the temperature of 69120.1563 lb/h (31352.375 kg/h) of the mixture, which is a reasonable value to use with respect to the amount of mixture that enters, concluding that, the use of this equipment will not generate very high economic costs. Based on the results provided by the CHEMCAD 7 software, it was determined that the heat exchanger (E-104) complies with the established restrictions, since the reported pressure drop showed values lower than 10 psi and the excess area was 22.42 %, so it can be concluded that the equipment is in optimal conditions to comply with its operation.  Heat Exchanger (E-105) To decrease the temperature of the vapor mixture from 250°C (stream 14) to 104.444°C (stream 15), a heat exchanger (E-105) using water as the coolant was chosen. The water enters the heat exchanger (E-105) into the tube side with a temperature of 20°C, while the mixture enters into the shell side. The heat exchanger (E-105) was designed using CHEMCAD 7 software, obtaining the following results: Simulation: Heat Exchanger E-105 FLOW SUMMARIES: Stream No. 6 8 9 10 Stream Name Stream 14 Water Stream 15 Water Temp F 482.0000 68.0000 220.0000 200.0000 Pres psia 29.0000 14.7000 29.0000 14.7000 Enth MMBtu/h -192.70 -2037.5 -232.09 -1998.2 Vapor mole frac. 1.0000 0.00000 0.30577 0.00000 Total lbmol/h 2591.6897 16566.9453 2591.6890 16566.9453 Total lb/h 69120.1719 298453.5000 69120.1563 298453.5000 Total std L ft3/hr 1241.5966 4780.7729 1241.5963 4780.7729 Total std V scfh 983490.81 6286801.50 983490.56 6286801.50 Flow rates in lbmol/h Ethylbenzene 69.4457 0.0000 69.4457 0.0000 Styrene 212.3671 0.0000 212.3671 0.0000 Water 2110.2478 16566.9453 2110.2471 16566.9453 Toluene 8.0019 0.0000 8.0019 0.0000 Benzene 6.2923 0.0000 6.2923 0.0000 Methane 0.4067 0.0000 0.4067 0.0000 Ethylene 0.1779 0.0000 0.1779 0.0000 Hydrogen 184.7502 0.0000 184.7501 0.0000 SUMMARY REPORT General Data: Heat Transfer Data: Exch Class/Type C/AEL Effective Transfer Area 3264.06 Shell I.D. 2.75 Area Required 2862.06 Shell in Series/Parallel 1/1 COR LMTD 92.84 Number of Tubes 858 U (Calc/Service) 148.23/129.98 Tube Length 20.00 Heat Calc 44.92 Tube O.D./I.D. 0.0625/0.0517 Heat Spec 39.39 Excess % 14.05 Tube Pattern TRI60 Foul(S/T) 1.000E-003/2.000E-003 Tube Pitch 0.08 Del P(S/T) 7.34/8.87 Based on the results provided by the CHEMCAD 7 software, it was determined that the heat exchanger (E-105) complies with the established restrictions, since the reported pressure drop showed values lower than 10 psi and the excess area was 14.05 %, so it can be concluded that the equipment is in optimal conditions to comply with its operation.  Heat Exchanger (E-106) To decrease the temperature of the vapor-liquid mixture from 104.444°C (stream 15) to 70°C (stream 16), a heat exchanger (E-106) using water as the coolant was chosen. The water enters the heat exchanger (E-106) into the tube side with a temperature of 25°C, while the mixture enters into the shell side. The heat exchanger (E-106) was designed using CHEMCAD 7 software, obtaining the following results: Simulation: Heat Exchanger E-106 FLOW SUMMARIES Stream No. 9 11 12 13 Stream Name Stream 15 Water Stream 16 Water Temp F 220.0000 77.0000 158.0000 190.0000 Pres psia 29.0000 14.7000 29.0000 14.7000 Enth MMBtu/h -232.09 -777.36 -244.96 -764.49 Vapor mole frac. 0.30577 0.00000 0.090369 0.00000 Total lbmol/h 2591.6890 6328.9419 2591.6895 6328.9419 Total lb/h 69120.1563 114015.8828 69120.1563 114015.8828 Total std L ft3/hr 1241.5963 1826.3617 1241.5964 1826.3617 Total std V scfh 983490.56 2401698.25 983490.75 2401698.25 Flow rates in lbmol/h Ethylbenzene 69.4457 0.0000 69.4457 0.0000 Styrene 212.3671 0.0000 212.3671 0.0000 Water 2110.2471 6328.9419 2110.2473 6328.9419 Toluene 8.0019 0.0000 8.0019 0.0000 Benzene 6.2923 0.0000 6.2923 0.0000 Methane 0.4067 0.0000 0.4067 0.0000 Ethylene 0.1779 0.0000 0.1779 0.0000 Hydrogen 184.7501 0.0000 184.7502 0.0000 SUMMARY REPORT General Data: Heat Transfer Data: Exch Class/Type C/CEL Effective Transfer Area 4412.47 Shell I.D. 3.25 Area Required 4080.99 Shell in Series/Parallel 1/1 COR LMTD 30.83 Number of Tubes 1163 U (Calc/Service) 102.33/94.64 Tube Length 20.00 Heat Calc 13.92 Tube O.D./I.D. 0.0625/0.0517 Heat Spec 12.88 Excess % 8.12 Tube Pattern TRI60 Foul(S/T) 1.000E-003/2.000E-003 Tube Pitch 0.08 Del P(S/T) 0.86/2.13 Number of Tube Passes 8 SS Film Coeff 243.31 Number of Baffles 0 SS CS Vel 0.67 Baffle Spacing 0.00 TW Resist 0.000203 Baffle Cut, % Diameter 15 TS Film Coeff 592.99 Baffle Type NOBF TS Vel 1.69 Baffle space def. Edge-Edge Thermodynamics: K: NRTL H: Latent Heat D: Library Number of Components: 8 Calculation Mode: Design Engineering Units: Temperature F Flow/Hour (lb/h)/h Pressure psia Enthalpy MMBtu Diameter/Area ft/ft2 Length/Velocity ft/(ft/sec) Film Btu/hr-ft2-F Fouling hr-ft2-F/Btu TEMA SHEET 1 2 Customer Ref No. 3 Address Prop No. 4 Plant Loc. Date Rev 5 Service of Unit Item 6 Size 3.3ft x 20.0ft Type CEL (Hor/Vert) H Connected in 1 Para 1 Seri 7 Surf/Unit(G/E) 4567.1/4412.5 ft2; Shell/Unit 1.000000 Surf/Shell 4567.1/4412.5 ft2 8 PERFORMANCE OF ONE UNIT 9 Type of Process Horiz Cond Sensible 10 Fluid Allocation Shell Side Tube Side 11 Fluid Name Stream 15 Water 12 Flow 69120.2 114015.9 lb/h 13 Liquid 46114.5 114015.9 lb/h 14 Vapor 23005.7 0.0 lb/h 15 NonCondensable 383.91751 0.00000 lb/h 16 Steam 8466.6 0.0 lb/h 17 Evap/Cond 20716.8 0.0 lb/h 18 Density 0.12/56.31 / 0.04/57.27 0.00/62.22 / 0.00/60.33 lb/ft3 19 Conductivity 0.02/0.21 / 0.07/0.18 0.00/0.35 / 0.00/0.39 Btu/hr-ft-F 20 Specific Heat 4.29/23.24 / 25.11/19.41 0.00/18.01 / 0.00/18.09 Btu/lbmol-F 21 Viscosity 0.01/0.27 / 0.01/0.41 0.00/0.92 / 0.00/0.32 cP 22 Latent Heat 483.59 0.00 Btu/lb 23 Temperature(In/Out) 220.000/157.999 77.000/190.000 F 24 Operating Pressure 29.00 14.70 psia 25 Fouling Factor 0.001000 0.002000 hr-ft2- F/Btu 26 Velocity 0.67 1.69 ft/sec 27 Press Drop Allow/Calc 10.000/0.863 10.000/2.128 psi 28 Heat Exchanged 1.288e+001 MMBtu/h; MTD(Corrected): 30.83 F 29 Transfer Rate, Service: 94.6 Calc: 102.3 Clean: 157.4 Btu/hr- ft2-F 30 CONSTRUCTION DATA/SHELL Sketch 31 Shell Side Tube Side 32 Design/Test Press psia 0.000000/Code 0.000000/Code 33 Design Temperature F 0.000 0.000 34 No. Passes per Shell 1 8 35 Corrosion Allowance ft 0.000 0.000 36 Connections IN ID ft 1.000 0.421 37 Size & OUT ID ft 0.835 0.421 38 Rating 39 Tube No. 1163 OD 0.063 ft;Thk. 0.0054 ft;Length. 20.00 ft;Pit. 0.078 ft; Ptn. 60 40 Tube Type Bare Material 1 Carbon Steel 41 Shell A-285-C 3.25 ID 3.33 OD ft Shell Cover 42 Channel or Bonnet A-285-C Channel Cover 43 Tubesheet Stationary A-285-C Tubesheet Floating 44 Floating Head Cover Impingement Protection: Yes 45 Baffles Cross A-285-C Type NOBF Cut(Diam) 0 Spacing C/C 0.00 ft 46 Baffles Long Seal Type 47 Supports Tube C.S. U-Bend 48 Bypass Seal Arrangement Tube-Tubesheet Joint 49 Expansion Joint No. Type 50 Rho-V2-Inlet Nozzle 1703.81 Bundle Entrance Bundle Exit 51 Shell Side Tube Side 52 Gasket Floating Head 53 Code Requirements Tema Class C 54 Weight/Shell 55 Remarks: Pressure drop shown is total pressure drop. 56 57 Taking into account different economic factors, we sought to design a heat exchanger that would operate under optimum conditions and at the lowest possible cost. In designing the heat exchanger (E-106), we chose a triangular arrangement. The sizing that was determined for the tubes and shell of the heat exchanger (E-106) resulted in the number of tubes required for this unit being 1163 tubes and the number of passes through the tubes is 6 passes, furthermore 114015.8828 lb/h (51716.7345 kg/h) of water is used to lower the temperature of 69120.1563 lb/h (31352.375 kg/h) of the mixture, these values obtained for this equipment are due to the fact that in the process another partial phase change occurs in the mixture, reducing the vapor fraction in the mixture from 30.577% to 9.03609% (vapor phase to liquid phase). Ethylene 0 0 0 0 0 0 0 Hydrogen 0 0 0 0 0 0 0 Stream number 8 9 10 11 12 13 14 Temperature (°C) 620 620 600 620 600 370 250 Pressure (kPa) 200 200 200 200 200 200 200   Mass flow (kg/h) 17243,806 17243,806 31352,375 17243,806 31352,375 31352,375 31352,375 Component Mass flow (%)   Ethylbenzene 0 0 0,44896 0 0,1067 0,1067 0,1067 Styrene 0 0 0,00104 0 0,32 0,32 0,32 Water 1 1 0,55 1 0,55 0,55 0,55 Toluene 0 0 0 0 0,01067 0,01067 0,01067 Benzene 0 0 0 0 0,00711 0,00711 0,00711 Methano 0 0 0 0 0,0000944 0,0000944 0,0000944 Ethylene 0 0 0 0 0,0000722 0,0000722 0,0000722 Hydrogen 0 0 0 0 0,0053889 0,0053889 0,0053889 Component Mass flow (kg/h)   Ethylbenzene 0 0 14075,809 0 3344,253 3344,253 3344,253 Styrene 0 0 32,760 0 10032,760 10032,760 10032,760 Water 17243,806 17243,806 17243,806 17243,806 17243,806 17243,806 17243,806 Toluene 0 0 0,000 0 334,425 334,425 334,425 Benzene 0 0 0,000 0 222,950 222,950 222,950 Methano 0 0 0,000 0 2,961 2,961 2,961 Ethylene 0 0 0,000 0 2,264 2,264 2,264 Hydrogen 0 0 0,000 0 168,954 168,954 168,954 Stream number 15 16 17 18 19 20 21 Temperature (°C) 104.444 70 70 70 70 65 70 Pressure (kPa) 200 200 200 200 200 200 200   Mass flow (kg/h) 31352,375 31352,375 174,180 17243,806 13934,389 557,376 220,628 Component Mass flow (%)   Ethylbenzene 0,1067 0,1067 0 0 0,24 0 0 Styrene 0,32 0,32 0 0 0,72 0 0 Water 0,55 0,55 0 1 0 0 0 Toluene 0,01067 0,01067 0 0 0,024 0,6 0,02 Benzene 0,00711 0,00711 0 0 0,016 0,4 0,98 Methano 0,0000944 0,0000944 0,017 0 0 0 0 Ethylene 0,0000722 0,0000722 0,013 0 0 0 0 Hydrogen 0,0053889 0,0053889 0,97 0 0 0 0 Component Mass flow (kg/h)   Ethylbenzene 3344,253 3344,253 0 0 3344,253 0 0 Styrene 10032,760 10032,760 0 0 10032,760 0 0 Water 17243,806 17243,806 0 17243,806 0 0 0 Toluene 334,425 334,425 0 0 334,425 334,43 4,413 Benzene 222,950 222,950 0 0 222,950 222,95 216,215 Methano 2,961 2,961 2,961 0 0 0 0 Ethylene 2,264 2,264 2,264 0 0 0 0 Hydrogen 168,954 168,954 168,954 0 0 0 0 Stream number 22 23 24 25 Temperature (°C) 85 115 125 140 Pressure (kPa) 200 200 200 200   Mass flow (kg/h) 336,748 13377,013 3276,003 10101,010 Component Mass flow (%)   Ethylbenzene 0 0,25 0,99 0,01 Styrene 0 0,75 0,01 0,99 Water 0 0 0 0 Toluene 0,98 0 0 0 Benzene 0,02 0 0 0 Methano 0 0 0 0 Ethylene 0 0 0 0 Hydrogen 0 0 0 0 Component Mass flow (kg/h)   Ethylbenzene 0 3344,253 3243,243 101,010 Styrene 0 10032,760 32,760 10000,000