CHEMICAL ENGINERING DEPARTMENT S4 NATIONAL DIPLOMA CHEMICAL PROCESSES DESIGN PRINCIPLES CPD3111 MAIN PROJECT
Ntsako Jason Maluleke
201209457
Xitsunduxo Gladwin Nukeri
201125145
Bongani Abel Mkansi
201220511
November 3, 2014
Md. Tyson Makua (P.hd) East Coast Developments 85 HARRISON, JOHANNESBURG 2001 Subject: Submission of production of di-methyl ether (DME) Dear Sir, We are pleased to submit the report that you asked for & gave us the authorization to work on “DME production and costs estimations”, we tried our best to work on it carefully and sincerely to make the report informative. The study we conducted enhanced our knowledge to make an executive report. This report has given us an exceptional experience that might have immense uses in the future endeavours and I sincerely hope that it would be able to fulfil your expectations. We have put our sincere effort to give this report a presentable shape and make it as informative and precise as possible. We thank you for providing us with this unique opportunity.
Sincerely yours,
MKANSI BA
Signature
MALULEKE NJ
Signature
NUKERI XG
Signature
4. Abstract Dimethyl ether (DME) is a sustainable substitute for diesel fuel. Its application involves both the chemical and automotive industries. In recent years the global market for DME has increased especially in emerging countries like China. The trend indicates increasing future demands in this project, natural gas (e.g. from biomass) and carbon dioxide (e.g. from power plants) are utilized as raw materials in a dry reforming process to produce syngas. Syngas production is followed by direct DME synthesis, in which conventional methanol synthesis and DME synthesis are integrated into a one-step process over a functional catalyst, resulting in a simplified overall process design. The literature search shows that DME is produced by the catalytic dehydration of methanol over zeolite catalyst, the required methanol is obtained from synthesis gas which is obtained from organic waste. Construction of plant with 50,000 metric-tons/y (50,000,000 kg/y) capacity. The objective of this project is to evaluate and analyse process design, costs and especially with respect to sustainability and environmental impact.
5. Introduction •
Over the mid-to-long term, energy consumption in the African region is expected to increase substantially during the 21st century. In realizing sustained growth in this region in the future, energy supply and environmental problems associated with mass energy consumption will be major problems. High expectations are placed on dimethyl ether (DME) as a new fuel which can be synthesized from diverse hydrocarbon sources, including natural gas, can be handled as easily as liquefied petroleum gas (LPG), and causes a small load on the environment. Thus, if DME can be produced and distributed at low cost and in large quantities, this fuel can make an important contribution to solving the energy supply problems and environmental problems resulting from expanded energy consumption expected in Asia in the future.
•
Our plant will be located in Umlwazi (Kwazulu Natal province) where the product will be easily transported even to the other South African countries through ships as Umlwazi is next to the sea. Since production of DME is in high demand we have conducted a survey across, we found out that the best method to use indirect method by dehydration reaction of methanol. While most of the DME is currently produced by the indirect method, technical development of the direct method has been carried out expecting its higher efficiency because the methanol itself is synthesized from the synthesis gas.
Problem statement Introduction Dimethyl ether (DME) is used primarily as a propellant. It is miscible with most organic solvents and has high solubility with water. Recently, the use of DME as a fuel additive for diesel engines has been investigated due to its high volatility (desirable for cold starting) and high cetane number. As an engineering team, you are asked by the management to design a DME process in order to produce 50,000 metric-tons/y (50,000,000 kg/y). The literature search shows that DME is produced by the catalytic dehydration of methanol over zeolite catalyst. The reaction is as follows: 2CH3OH CH3OCH3 + H2O In the temperature range of normal operations, there are no side reactions. Process Description Fresh methanol, Stream 1, is combined with recycled reactant, Stream 8, and vaporized prior to being sent to a fixed bed reactor, operating at 350°C. The reactor effluent, Stream 4, is then cooled prior to being sent to the first of two distillation columns. DME product is taken overhead from the first column. The second column separates water from the unreacted methanol. The methanol is recycled back to the front end of the process, while the water is sent to waste treatment to remove trace amounts of organic compounds.
Tasks 1. Draw the process flow diagram (PFD) with a stream table showing the material balance; 2. Determine the per-pass conversion of methanol assuming that the reactor operates at equilibrium; 3. Size and estimate the purchase cost of the process equipment; 4. Estimate the capital cost using detailed factorial method; 5. Estimate the operating cost; 6. Perform cash-flow analysis and determine the whether the process is economically viable. If yes, determine when the project will break even.
Catalyst and reactor information The process uses a crystalline silicon-aluminum oxide catalyst, called a zeolite. This particular catalyst performs well in the 200°C-to-400°C range, but deactivates rapidly if heated above 400°C. The design will use a single packed bed reactor. Reactor sizing is out scope and will be covered at the BTech level. However, for costing purposes, the reactor will be assumed to account for 25% of the total purchase cost of the equipment. Supplemental Information •
Feed and Product Prices Methanol $ 0.60 per gallon Dimethyl ether $ 0.43 per pound
•
Utility Costs Low Pressure Steam (618 kPa saturated) $6.62/1000 kg Medium Pressure Steam (1135 kPa saturated) $7.31/1000 kg High Pressure Steam (4237 kPa saturated) $8.65/1000 kg Natural Gas (446 kPa, 25°C) $3.00/GJ Fuel Gas $2.75/GJ Use this price for fuel gas credit Electricity $0.06/kW h Boiler Feed Water (at 549 kPa, 90°C) $2.54/1000 kg Cooling Water $0.16/GJ Refrigerated Water $1.60/GJ Available at 516 kPa and 10°C Return pressure ≥ 308 kPa
Return temperature is no higher than 20°C Deionized Water $1.00/1000 kg Available at 5 bar and 30°C Refrigeration $60/GJ
6. Process Flowsheet and Material balances
Overall Mass Balance Methanol Water
kmol/h Input 260.812 4627.387
Output 0.982 4757.301
kg/h Input 8356.93 83362.367
Dimethyl Ether
0
129.915
0
Total
4888.198
4888.198
91719.297
Overall Mass Balance Methanol Water
kmol/h Input 260.812 4627.387
Output 0.982 4757.301
kg/h Input 8356.93 83362.367
Dimethyl Ether
0
129.915
0
Total
4888.198
4888.198
91719.297
Output 31.477 85702.77 3 5985.042 91719.29 7
Output 31.477 85702.77 3 5985.042 91719.29 7
7. Process Description Appendix A is a preliminary process flow diagram (PFD) for the dimethyl ether production process. The raw material is methanol, which may be assumed to be pure. The feed is pumped to the mixed where it is mixed with the recycle then passed to the vaporizer where it is heated, vaporized, and superheated and then sent to the reactor in which dimethyl ether (DME) is formed. The reactor effluent is cooled and partially condensed in a heat exchanger, and it is then sent to the first separation section called distillation column. Pure” DME is produced in the top stream (distillate), with methanol and water in the bottom stream (bottoms). In the second distillation column the distillate contains methanol for recycle, and the bottoms contains waste water. The desired dimethyl ether production rate is 5985.0415kg/hr.
Process Details Feed Stream Stream 1: methanol, from storage tank at 1 atm and 25°C, may be assumed pure Effluent Streams Stream 9: dimethyl ether product, required 5985.0415kg/hr. may be assumed pure Stream 10: waste water stream, may be assumed pure in material balance calculations with 2340.4082 kg/hr, and is not pure, so there is a cost for its treatment
Equipment Pump The pump increases the pressure of the feed plus recycle to a minimum of 15 atm. Heat Exchanger 1: This unit heats, vaporizes, and superheats the feed to 153.78°C at 42.37 atm. The source of energy for heating must be above 153.78°C. Reactor: The following reaction occurs: methanol dimethyl ether 2CH3OH → CH3OCH3 + H2O The reaction is equilibrium limited. The conversion per pass is 80% of the equilibrium conversion at the pressure and exit temperature of the reactor. Based on the catalyst and reaction kinetics, the reactor must operate at a minimum of 15 atm. The reactor operates isothermally, and, since the reaction is exothermic, the reactor effluent temperature will be 350°C. Heat Exchanger 2: This unit cools and partially condenses the reactor effluent. The valve before this heat exchanger reduces the pressure. This exit pressure may be at any pressure below the reactor pressure, but must be identical to the pressure at which it operates.
Distillation Column 1: This distillation column separates DME from methanol and water. The separation may be assumed to be perfect, i.e., pure DME is produced in the distillate. The temperature of the distillate is the temperature at which DME condenses at the chosen column pressure. Distillation Column 2: This distillation column separates methanol for recycle from water. For this semester only, the separation may be assumed to be perfect. However, since we know this cannot be true in practice, the water stream is actually a waste water stream, and there is a cost for its treatment. The temperature of the distillate is the temperature at which methanol condenses at the chosen column pressure. Other Equipment: For two or more streams to mix, they must be at identical pressures. Pressure reduction may be accomplished by adding a valve. All of these valves are not necessarily shown on the attached flowsheet, and it may be assumed that additional valves can be added as needed at no cost. Flow occurs from
higher pressure to lower pressure. Pumps increase the pressure of liquid streams, and compressors increase the pressure of gas streams
8. Energy balance and Utility Requirements Overall Energy Balance Feed Streams Product Streams
MJ/h Input -6.57E+06
6.57E+0 6
Total Heating Total Cooling Power Added Power Generated
5949.63 -10007.7 24.5302 0
Total
-6.57E+06
Steam
Output
6.57E+0 6
sell/100 0 kg Flow rate (kg/hr) Cost ($)
8.60 6,549.84 468,766.4 5
Gibbs Reactor Summary Equip. No. Name Thermal mode Reaction Phase Temperature C Heat duty MJ/h Overall Heat of Rxn (MJ/h) Approach DT C
Electricity Heat Duty (MJ/h) Evaporat or Reactor
11,979.40 1,804.03
Condens or
9,628.69
Coloumn 1
-4,244.98
Coloumn 2
-883.48
Total (MJ/hr) Total (KW/hr) Cost ($)
152,156,59 5.22 42,265,720. 89
4 2 1 350 10864.91 02 3123.151 9 0.01
2,535,943.2 5 Cooling water Cost ($/GJ) 0.16 Heat Duty 9,628.69 (MJ/hr) Heat Duty (MJ) 80,129,986 .47 Heat Duty (GJ) 80,129.99 $ 12,820.80
9. Unit description •
•
•
•
•
Pump •
The pump increases the pressure of the feed plus recycle to a minimum of 15 atm.
•
For sizing the pump refer to appendix 5
Heat exchanger1 •
This unit heats, vaporizes, and superheats the feed to 153.78°C at 42.37 atm. The source of energy for heating must be above 153.78°C. The heating source used is the low pressure steam.
•
For sizing we used chemcad to simulate and get the heat area required (appendix 3)
•
Material of construction we used carbon steel for tube and carbon steel for shell side, carbon steel has the highest value heat transfer coefficient. The feed will take the shell side and the low pressure steam will take the tube side.
Heat exchanger 2(condenser) •
This unit cools and partially condenses the reactor effluent. The valve before this heat exchanger reduces the pressure. This exit pressure may be at any pressure below the reactor pressure, but must be identical to the pressure at which it operates. Water is used to cool down the temperature of the reactor effluent.
•
For sizing we used chemcad to simulate and get the heat area required (appendix 4)
•
Material of construction we used carbon steel for tube and carbon steel for shell side, carbon steel has the highest value heat transfer coefficient. The reactor effluent will take the tube side and the cooling water will take the shell side.
Distillation column 1 •
This distillation column separates DME from methanol and water. The separation may be assumed to be perfect, i.e., pure DME is produced in the distillate. The temperature of the distillate is the temperature at which DME condenses at the chosen column pressure.
•
For tray spacing and baffle cuts refer to appendix 2
Distillation column 2
•
•
This distillation column separates methanol for recycle from water. For this semester only, the separation may be assumed to be perfect. However, since we know this cannot be true in practice, the water stream is actually a waste water stream, and there is a cost for its treatment. The temperature of the distillate is the temperature at which methanol condenses at the chosen column pressure
•
For tray spacing and baffle cuts refer to appendix 2
Other equipment
•
For two or more streams to mix, they must be at identical pressures. Pressure reduction may be accomplished by adding a valve. All of these valves are not necessarily shown on the attached flowsheet, and it may be assumed that additional valves can be added as needed at no cost. Flow occurs from higher pressure to lower pressure. Pumps increase the pressure of liquid streams, and compressors increase the pressure of gas streams
10. Specification sheet 1. Distillation columns SCDS Rigorous Distillation Summary Equip. No. Name No. of stages 1st feed stage Condenser mode Condenser spec Cond comp i pos. Reboiler mode Reboiler spec. Reboiler comp i Est. dist. Rate (kmol/h) Est. reflux rate (kmol/h) Est. T top C Est. T bottom C Est. T 2 C Calc cond duty MJ/h Calc rebr duty MJ/h Initial flag Calc Reflux mole (kmol/h) Calc Reflux ratio Calc Reflux mass kg/h Column diameter m Tray space m Thickness (top) m Thickness (bot) m No of sections No of passes (S1) Weir side width m Weir height m
8
9
13 7 5 129.914 7 3 5 48.6315
20 11 5 48.1452
1 131.729 7
1 5 129.914 4 2 51.2819
150.755
83.4697
31.4828
112.930 9 165.550 9 123.699 4 4327.96 14 4444.46 97 6 87.6667
141.559 2 32.9164 5679.14 75 1434.21 06 6 180.227 8 1.382 8293.28 91 0.9144 0.6096 0.0048 0.0063 1 1 0.1397 0.0508
1.7258 2808.91 99 0.6096 0.6096 0.0032 0.0119 1 1 0.1016 0.0508
System factor Optimization flag Calc. tolerance
1 1 0.0005
1 1 0.0002
2. Heat exchangers Heat Exchanger Summary Equip. No. Name 1st Stream T Out C 2nd Stream T Out C 1st Stream VF Out Calc Ht Duty MJ/h
3
LMTD (End points) C
225 1 11979.42 38 136.9068
LMTD Corr Factor Utility Option: 1st Stream Pout atm 2nd Stream Pout atm
1 1 15 41.2657
3. Pump Pump Summary Equip. No. Name Output pressure atm Efficiency Calculated power MJ/h Calculated Pout atm Head m Vol. flow rate m3/h Mass flow rate kg/h NPSH available m Cost estimation flag Install factor Basic pump cost $ Basic motor cost $ Total purchase cost $ Total installed cost ($) Request NPSH calc 4. Reactor Gibbs Reactor Summary
1 17 0.7 24.5302 17 209.372 7 10.584 8356.92 97 10.9108 1 2.8 4352 690 5042 14118 1
6 135 55 9628.71 48 187.532 6 1 1 15 1
Equip. No. Name Thermal mode Reaction Phase Temperature C Heat duty MJ/h Overall Heat of Rxn (MJ/h) Approach DT C
4 2 1 350 10864.91 02 3123.151 9 0.01
5. Mixer Mixer Summary Equip. No. Name Output Pressure atm
2 15
6. Valve Valve Summary Equip. No. Name Pressure out atm
5 7
11. Equipment Cost Summary Summary of Equipment Cost : Equipment : Cost ($) Pump 18000285 Evaporiser 163439.8 919 Reactor 188515.7 Condensor 16343.98 919 Valve 500 Dist. 39,895.95 Coloumn 1 Dist. 16334 Coloumn 2 Total ($)
18425314
.53
12. Fixed-Capital Investment Summary
13. Important considerations Environmental problems • The plant emission has been evaluated based on the conceptual design of the plant. The key result is that the plant will abide by all environmental regulations and not discharge any material which is harmful to the environment. Furthermore, by treating the flue gas from the plant, which is currently discharged to the atmosphere, the combined emissions from both plants will be much less, and thus the overall environmental impact is improved. Short half-life in atmosphere.
Health and safety •
DME has been proven to be stable in the presence of LPG under normal storage conditions. Equipment to store, transport, bottle, dispense and use DME are substantially similar to those required for LPG. Significant studies into materials compatibility, and the thermal and chemical properties of such blends in China, Japan and Korea provide clear guidelines for safe handling and use.
•
Waste water is pretreated and remove all materials that can be easily collected from waste water before they damage or clog the pumps. Objects that are commonly removed during pretreatment include trash, tree limbs, leaves and other large objects. On our plant we will use the device known as the American Petroleum Institute oil-water separator which is designed to separate oil and suspended solids from the waste water effluents.
•
Non toxic, non-carcinogenic and Approved as consumer product propellant
14. Operating Cost and Economic Analysis •
The fixed capital cost has to be installed over a 3-year period (2014-2016) in steps of 50%, 30% and 20%. Just prior to start-up, 15% of fixed capital is required as working capital. The production cost (excluding capital charges) is estimated as 0.593283616 $/kg and the selling price 1.08 $/kg. The plant capacity of 50,000,000 kg/y is reached in the third year of operation as follows: in the first year the plant operates at 50% capacity, second year at 75% capacity and third year at full capacity. The estimated life of the project is 15 years. The interest rate is 15% and tax of 30%
15. Conclusions and recommendations DME is a very promising new, multi-purpose fuel, manufactured from methanol. It has many opportunities and many driver are dependent on DME as a fuel and a significant global DME effort has evolved led by Asia. If the DME production is successful it would be the first DME production in AFRICA. DME community has joined forces for advancement of DME
16. Acknowledgement We would like to thank our tutor Samson for fruitful discussions and guidance during our project. Especially your comments and advice concerning the project writing process was most beneficial. We would also like to thank our fellow classmates and B-Tech students from University Of Johannesburg for useful discussions from time to time. I hope we can continue exchanging research ideas and results.
A special thanks goes to Professor Jalama Kalala from University Of Johannesburg of Department of Chemical Engineering for his supervision on our project and for interesting discussions.
17. Bibliography • • • •
•
Perry, R. H. and D. Green, eds., Perry’s Chemical Engineering Handbook (7th ed.), McGraw-Hill, New York, 1997. Felder, R. M. and R. W. Rousseau, Elementary Principles of Chemical Processes (3rd ed.),Wiley, New York, 2000 Dimethyl Ether Technology and Markets 07/08-S3 Report, ChemSystems, December 2008. http://www.japantransport.com/conferences/2006/03/dme_detailed_informati on.pdf, Conference on the Development and Promotion of Environmentally Friendly Heavy Duty Vehicles such as DME Trucks, Washington DC, March 17, 2006 DuPont Talks About its DME Propellant,” Aerosol Age, May and June, 1982
• • • • • • •
Bondiera, J., and C. Naccache, “Kinetics of Methanol Dehydration in Dealuminated H-Mordenite: Model with Acid and Base Active Centres,” Applied Catalysis, 69,139-148 (1991). T. A. Semelsberger, R. L. Borup, H. L. Greene, "Dimethyl Ether (DME) as an Alternative Fuel," J. Power Sources 156, 497 (2006). C.-J. Yang and R. B. Jackson, "China's Growing Methanol Economy and Its Implications for Energy and the Environment," Energy Policy 41, 878 (2012). Fei JH, Yang MX, Hou ZY, Zheng XM (2004) Effect of the addition of manganese and zinc on the properties of copper-based catalyst for the synthesis Of syngas to dimethyl ether. Energy Fuel 18:1584 Jun KW, Lee HS, Roh HS, Park SE (2003) highly water-enhanced H-ZSM-5 catalysts for dehydration of methanol to dimethyl ether. Bull Korean Chem Soc 24:104 University Of Johannesburg :Chemical Engineering S4, process design notes(2014) “Liquid Phase Dimethyl Ether Demonstration in the LaPorte Alternative Fuels Development Unit,” DOE Topical Report, Cooperative Agreement No. DE-FC22 92PC90543, January 2001.
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Hoffmann, M.R., Martin, S.T., Choi, W. and Bahnemann, D.W. (1995) Environmental Applications of Semiconductor Photocatalysis. Chemical Reviews, 95, 69-96.
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STEPHENSON, R. M. Introduction to the Chemical Process Industries, 1966 (New York: Reinhold Publishing Corporation).
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J. H. GARVIE, Chem. Proc. Engng, Nov. 1967, pp. 55 65. Synthesis gas manufacture
18. Appendix Appendix A 1. Calculation of mass flowrates of DME, methanol and water: Mass Flowrate of DME
=6008.17 kg/hr
2CH3OH → CH3OCH3 + H2O Mass flowrate of water = =2457.89 kg/hr Mass flowrate of methanol = = 8739.16 kg/hr 2. Distillation column information Unit type : SCDS Unit name: Eqp # 8
Stg 1 2 3 4 5 6 7 8 9 10 11 12 13
Temp C 31.5 32.9 42.8 73.9 92.4 98 105.9 109.1 113.9 120.3 127 132.8 139
Mole Reflux ratio
1.382
Total liquid entering stage
7
Pres atm 7 7 7 7 7 7 7 7 7 7 7 7 7
* Net Flows * Liquid Vapor kmol/h kmol/h 180.23 164.47 310.64 114.84 294.88 88.15 245.25 85.08 218.56 79.44 215.49 222.33 209.86 221.98 41.13 221.73 40.78 221.84 40.53 222.33 40.64 222.57 41.13 41.37
at
105.396
Pres atm 7 7 7 7 7
* Net Flows * Liquid Vapor kmol/h kmol/h 87.67 89.03 138.46 88.42 139.83 87.54 139.22 86.45 138.34
C
Feeds kmol/h
Produ kmol 130.4
311.61
181.2
222.404
kmol
Feeds kmol/h
Produ kmol 50.8
Unit type : SCDS Unit name: Eqp # 9
Stg 1 2 3 4 5
Temp C 112.8 123.7 124.7 125.4 126.2
6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
127.3 128.7 130.7 133.3 136.4 139.6 140.2 141 142.4 145.4 150.3 156.2 161 163.7 164.9
Mole Reflux ratio
1.726
Total liquid entering stage
11
•
7 7 7 7 7 7 7 7 7 7 7 7 7 7 7
85.07 83.36 81.29 79 76.89 258.1 257.76 256.93 255.32 252.89 250.54 249.41 249.3 249.45
at
138.087
137.24 135.87 134.15 132.08 129.79 127.69 127.69 127.36 126.53 124.92 122.49 120.14 119.01 118.9 119.05
C
181.2
130.4
257.988
Heat exchanger 1 (vaporizer) 3.1
TABULATED ANALYSIS FOR HEAT EXCHANGER 1 Overall Data: Area Total (m²) Area Required (m²) Area Effective (m²) Area Per Shell (m²) Weight LMTD C 141.65 Shellside Data: Rho V2 IN kg/m-sec2 Avg. SS Vel. m/sec Film Coef. (W/m²K) Allow Press. Drop (atm) Inlet Nozzle Size
19.53
% Excess
-1.94
19.15
U Calc.
18.78
U Service (W/m²-K)
1039.74
18.78
Heat Duty (MJ/h)
9.63E+03
(W/m²-K)
1019.61
LMTD CORR Factor 0.9670 CORR LMTD C 136.98 2302.40 Press. Drop (Dirty) atm 0.43 8.95 2518.4 Calc. Press. Drop 7 (atm) 0.34 Press. Drop/In Nozzle (atm) 0.15 Press. Drop/Out
0.25 0.02 0
kmol
(m) Outlet Nozzle Size (m) Rho V2 IN (kg/msec²) Tubeside Data: Film Coef. (W/m²K) Allow Press. Drop (atm) Inlet Nozzle Size (m) Outlet Nozzle Size (m) Interm. Nozzle Size (m) Velocity (m/sec) Clearance Data: Baffle (m) Tube Hole (m) Bundle Top Space (m) Bundle Btm Space (m)
0.13 2302.4
(m) (m) (m)
195.45 0.43
8704.8 0.34 0.15 0.15 0 2.1
0.0063 0.0008 0
Calc. Press. Drop (atm) Press. Drop/In Nozzle (atm) Press. Drop/Out Nozzle (atm) Mean Temperature (°C) Mean Metal Temperature (°C)
0.27
Outer Tube Limit (m) Outer Tube Clear. (m) Pass Part Clear. (m)
0.2908
0 0 40 91.89
0.0457 0
0
Baffle Parameters: Number of Baffles Baffle Type Inlet Space (m) Center Space (m) Outlet Space (m) Baffle Cut, % Diameter Baffle Overlap (m) Baffle Cut Direction Number of Int. Baffles Baffle Thickness (m) Shell: Shell O.D. Shell I.D. Bonnet I.D. Type
Nozzle (atm) Mean Temperature (°C) Press. Drop (Dirty) (atm)
13 Single Segmental 0.191 0.212 0.191 21 0.04 Vertical 0 0.003
0.36 0.34 0.34 AES
Orientation Shell in Series Shell in Parallel Max. Heat Flux Btu/ft2-hr
H 1 1 0
Imping. Plate
Impingement Plate
Sealing Strip
Tubes: Number Length
(m)
102 3.05
Tube O.D. Tube I.D.
(m) (m)
0.02 0.016
Tube Type Free Int. Fl Area (m²) Fin Efficiency Tube Pattern
0.002
Tube Pitch
Tube Wall Thk. (m) No. Tube Pass Inner Roughness (m)
5 Bare 0
(m)
2 1.6E-06
Resistances: Shellside Film 0.0004 (m²-K/W) Shellside Fouling 0.0001 (m²-K/W) 8 Tube Wall (m²0.0000 K/W) 4 Tubeside Fouling 0.0001 (m²-K/W) 8 Tubeside Film 0.0001 (m²-K/W) 1 Reference Factor (Total outside area/inside area based on tube ID) Pressure Drop Distribution : Tube Side Inlet Nozzle 0.0042 (atm) Tube Entrance 0.0141 (atm) Tube (atm) 0.1772 Tube Exit (atm) 0.0432 End (atm) 0.0276 Outlet Nozzle 0.0022 (atm) Total Fric. (atm) 0.2684 Total Grav. (atm) 0 Total Mome. 0.0001 (atm) Total (atm) 0.2685 3.2 COSTING OF HEAT EXCHANGER 1 Area Required Pressure (bar) Pressure Factor Type Factor
0 TRIANGULA R 30 0.025
(m²)
19.15 15 1.1 1
1.25
Shell Side Inlet Nozzle (atm)
0.0206
Impingement
0.0148
(atm)
Bundle (atm) Outlet Nozzle (atm) Total Fric. (atm) Total Grav. (atm)
0.2431 0.0025 0.2662 -0.0011
Total Mome. (atm) Total (atm)
-0.0121 0.2531
Bare Cost ($)
120000
Puchase Cost in 2004 ($) Puchase Cost in 2014 ($)
132000 163439.8 919
1 US Dollar = 11,02 ZAR Purchase Cost in 2014 ZAR 3.3 Year
CE Index (CEPSI)
2004 2009 2014 •
1801107. 609
444.2 521.9 550 Heat exchanger 2 4.1 TABULATED ANALYSIS Overall Data: Area Total (m²) Area Required (m²) Area Effective (m²) Area Per Shell (m²) Weight LMTD C 141.65 Shellside Data: Avg. SS Vel. (m/sec) Film Coef. (W/m²-K) Allow Press. Drop (atm) Inlet Nozzle Size (m)
19.53
% Excess
19.15
U Calc. (W/m²-K)
18.78
U Service (W/m²-K)
18.78
Heat Duty (MJ/h) LMTD CORR Factor
0.9670
CORR LMT
8.95 2518.47 0.34
Calc. Press. Drop (atm)
0.15
Press. Drop/In Nozzle (atm)
Outlet Nozzle Size (m)
0.13
Rho V2 IN (kg/msec²)
2302.40
Tubeside Data: Film Coef. (W/m²-K) Allow Press. Drop (atm) Inlet Nozzle Size (m) Outlet Nozzle Size (m) Interm. Nozzle Size (m) Velocity (m/sec) Clearance Data: Baffle (m)
8704.80 0.34
Calc. Press. Drop (atm)
0.15
Press. Drop/In Nozzle (atm) Press. Drop/Out Nozzle (atm) Mean Temperatur e (°C) Mean Metal Temperatur e (°C)
0.15
0.00
2.10
0.0063
Tube Hole (m)
0.0008
Bundle Top Space (m) Bundle Btm Space (m)
0.0000
Baffle Parameters: Number
Press. Drop/Out Nozzle (atm) Mean Temperatur e (°C) Press. Drop (Dirty) (atm)
Outer Tube Limit (m) Outer Tube Clear. (m) Pass Part Clear. (m)
0.0000
13
of Baffles Baffle Type Inlet Space (m) Center Space (m) Outlet Space (m) Baffle Cut, % Diameter Baffle Overlap (m) Baffle Cut Direction Number of Int. Baffles Baffle Thickness (m) Shell: Shell O.D. (m) Shell I.D. (m) Bonnet I.D. (m) Type Imping. Plate Tubes: Number Length (m) Tube O.D. (m) Tube I.D. (m) Tube Wall Thk. (m) No. Tube
Single Segmental 0.191 0.212 0.191 21.000 0.040 Vertical 0 0.003
0.36
Orientation
0.34
Shell in Series Shell in Parallel
0.34 AES Impingement Plate 102 3.05 0.020 0.016 0.002 2
Max. Heat Flux Btu/ft²hr Sealing Strip Tube Type Free Int. Fl Area (m²) Fin Efficiency Tube Pattern Tube Pitch (m)
Pass Inner Roughnes s (m) Resistances: Shellside Film
0.000001 6
(m²-K/W) 0.00040
Shellside Fouling
(m²-K/W)
0.00018 Tube Wall (m²-K/W) 0.00004 Tubeside Fouling 0.00018 (m²-K/W) Tubeside 0.00011 Film (m²-K/W) Reference Factor (Total outside area/inside area based on tube ID) 1.250 Pressure Drop Distribution: Tube Side Inlet 0.0042 Nozzle (atm) Tube 0.0141 Entrance (atm) Tube 0.1772 (atm) Tube Exit 0.0432 (atm) End (atm) Outlet Nozzle (atm) Total Fric. (atm) Total Grav. (atm) Total Mome. (atm) Total (atm)
0.0276 0.0022 0.2684 0.0000 0.0001 0.2685
4.2 COSTING OF HEAT EXCHANGER 2
Shell Side Inlet Nozzle (atm) Impingeme nt (atm) Bundle (atm) Outlet Nozzle (atm) Total Fric. (atm) Total Grav. (atm) Total Mome. (atm) Total (atm)
Area Required (m²) Pressure (bar) Pressure Factor Type Factor Bare Cost ($)
19.15
Puchase Cost in 2004 ($) Puchase Cost in 2014 ($)
13200
15 1.1 1 12000
16343. 99
1 US Dollar = 11,02 ZAR Purchase Cost in 2014 ZAR
18011 0.8
4.3
•
Yea r
CE Index (CEP SI)
200 4 200 9 201 4
444. 2 521. 9 550
Pump • • • • • • • • •
Pump Summary Equip. No. Name Output pressure atm Efficiency Calculated power MJ/h Calculated Pout atm Head m
• • • • •
1 17
• •
0.7 24.5302
•
17
•
209.3727
• • • • • • • • • • •
Appendix B
Vol. flow rate m3/h Mass flow rate kg/h NPSH available m Cost estimation flag Install factor Basic pump cost $ Basic motor cost $ Total purchase cost $ Total installed cost ($) Request NPSH calc
•
10.584
•
8356.9297
•
10.9108
•
1
• •
2.8 4352
•
690
•
5042
•
14118
• •
1
