Project
Project
Project
Introduction....................................................................................................... 2
Process Description........................................................................................... 3
Block Diagram................................................................................................... 4
Process Design Basis......................................................................................... 5
Overall Material Balance................................................................................... 6
Design of column, reboiler and condenser......................................................7
Equipment List................................................................................................. 15
PFD, Piping and Instrumentation Diagram and Plot plan..............................16
Line Sizing....................................................................................................... 17
Pump Hydraulic Calculations..........................................................................19
Introduction
The instructions given in the following pages are for the design of 100 MT/day Liquid N2O4
plant.
Process Description
Raw liquid N2O4 containing a small amount of Nitric acid is branched off from
the discharge of N2O4 pump P-1 and fed to N2O4 distillation column T-1
through a flow control valve.
The distillation column is provides with stripping and rectification sections
and has beds of intalox saddles.
The heat required for the vaporization of N2O4 is supplied by indirect steam
in the thermosyphon reboiler E-1. Saturated LP steam at 3 kg/cm2 g pressure
will be utilized for this purpose. The temperature at the bottom of the column
is maintained at approx. 25 degC.
Pure N2O4 vapors leaving the top of the column at approx 21 degC are
condensed and sub cooled to 0 degC in condenser E-2 using brine. A
controlled quantity of condensed N2O4 is fed back to the column as reflux for
proper rectification. The quantity of reflux required depends upon the purity
of product obtained.
The bottom product containing N2O4 and nitric acid is returned to tank D-2
by gravity.
Excess N2O4 from the condenser is drawn off as product and is led to
collecting tank D-3 from where it can be transferred to the main storage
tanks using transfer pumps. If there is no draw-off from D-3 to main storage,
the product overflows into D-1.
Block Diagram
Feed
TPD
95 % (w/w)
N2O4
Temperature 0
degC
Distillatio
n
Distillate
100 TPD
99.9 % (w/w)
N2O4
Temperature
0 degC
Bottoms
84 % (w/w)
N2O4
Temperature
25 degC
Temperature 0 degC
Quality 95% (w/w)
LP Steam
Pressure 3 Kg/cm2 g
Temperature Saturated
Brine
Pressure 4 Kg/cm2 g
Temperature -13 degC
Inst Air
100 TPD
4
400 TPD
400+10
0=
500 TPD
Above vapor value is the vapor leaving the enriching section. But the vapor flow
through the
enriching section will be more than above value because cold reflux is
used.
Taking material and energy balance at top end of enriching section to find the
vapor flow in
enriching section,
Vapor in enriching section - Vapor flow out of enriching section = Vapor condensed
Also,
Heat of vaporisation at 21 degC X Vapor condensed = Sensible heat rise of reflux
(i.e 400 TPD)
from 0 to 21
degC
Heat of vaporisation of n2o4 and hno3 at 21 degC is 75.04828 and 148.4839
Kcal/Kg respectively
Taking weighted average,
Heat of vaporisation of vapor mixture at 21 degC is
equal to
Now heat capacity of distillate at 0 deg C is
equal to
Now heat capacity of distillate at 21 deg C is
equal to
Avg heat capacity is
equal to
75.12 Kcal/K
172 g
0.198
728 Kcal/Kg.degK
0.200
991 Kcal/Kg.degK
0.199
86 Kcal/Kg.degK
22348
.01 Kg per day
22.34
801 TPD
422.3
48 TPD
522.3
48 TPD
566.8
935 TPD
522.3
48 TPD
44.54
549 TPD
The maximum L/G ratio is obtained at bottom of column. Also maximum gas and
liquid flows
are at bottom of column
Vapor and Liquid densities at 25 degC and prevailing pressure are as
follows
Compnt
n2o4
hno3
Comp
Liquid
Vapor
Unit
89.6476 0.23242
2
2 lb per cuft
94.2580
4
0.1614 lb per cuft
n2o4
0.84
hno3
0.16
0.98549
8
0.01450
2
0.00937
0.00169
7
90.3547
4
52074.4
7
4.24012
0.08985
2
0.23094
8
47982.5
5
Den
mix
Flow
lb per
cuft
lb per
hr
90.12
379
1.002
563
1.001
28
1.086
669
For above value of function the corresponding value of ordinate from graph for a
pressure drop
of .05 inH2O per ft of packing is .003
For 25mm ceramic intalox saddle
packing, Cf =
J=
Liquid
viscosit
y
1.54E08
gc=
98
1.502
4.18E
+08
0.395
977 cP
3.141
593
19453
1
441.0
567 lb/sqrft.hr
Gas flow=
Therfore column cross
108.7
section =
9 sqft
10.10
=
7 sqmtr
Plate dimensions
Therfo
re
Dia=
1.772
454 meter
pi X diameter =
5.56832
8 meter
18.2687
9 feet
Following plate dimensions are available at leading indian alluminium plate manfg
Hindalco
Al
Alloys
Temper
1050
1060
1070
1080 F and O
1100
1200
3003
3105
8011
Thickne
ss
mm
6-200
Lengt
h
mm
10007000
Width
mm
5001550
522.3
48 TPD
47990 Lb per
=
.72 hr
A circulation ratio of 4:1 shall be used because Alluminium alloy MOC is used and
alluminium
nitrate salt will get deposited on tubes for smaller
ratios.
3/4 in OD tubes 16 BWG on a triangular pitch of 1 inch shall be
used.
Let initial guess of tube length as 6
feet.
Heat of vaporisation of n2o4 and hno3 at 25 degC is 75.04828 and 148.4839
Kcal/Kg respectively
Weigthed average Heat of vaporisation for wt fraction of n2o4 =
.84 is
Heat of
vaporisation =
84.0 Kcal/Kg
Therefore, Heat of Duty, Q = 84 X
522.348 =
18282 Kcal/h
18 r
56.12 sq.mtr
972 =
32571
.3 Kcal/hr.m2
603.9
558 sq.ft
Heat transfer area for 3/4 in OD tube per unit length is 0.1963 sq.ft per
ft of length
Therefore, No of 6ft tube
512.7
lengths =
829
Nearest tube count for 1-Pass, 3/4 in OD tube on 1 in triangular
pitch is,
Shell ID, 27 inch; Total tube count 559
Check for pressure drop,
Static pressure of
z3.rhoavg =
2.3L
. log vo
144
144(vo - vi)
vi
psi
reboiler
Vapor density =
Liquid density =
0.23094
8 lb per cuft
90.3547
4 lb per cuft
Substuting above,
Static pressure of reboiler leg
=
Specific volum
=
Specific volum
=
4.329
972
0.011
067
0.057
524 psi
At 25 deg C,
viscos,
nu =
ID of
tube =
Nre=DG/
nu
friction
fac
Avg.sp.v
olm
delta P
=
0.03 lb/hr.ft
0.0517 ft
352742.
6
0.00011 sq.ft per sq.in
2.17052
0.00472
1 psi
0.062
245 psi
3.764
781 psi
Since Driving force is much more than Total resistance a circulation ratio of 4:1 is
assured.
At Nre
=
352742
Coulborn factor, jH
=
Thermal condu, k=
sp heat capacity,
Cp=
k(Cp.nu/k)^1/3 =
700
0.16268
5
0.21058
8
0.05509
1
hi = (jH.k/D)(Cp.nu/k)^1/3 =
745.9
165
0.02008 hr.sqft.degF/Bt
2 u
where,
lambda = heat of vaporisation, Btu/lb
=
=
=
=
135.0
869
1.000
964
90.02
211
0.083
496
4.18E
+08
69.8
8.6
0.200
991
45930 lb/hr
62045
41 Btu/hr
559
G' =
506.202
5 lb/hr.ft
2022.
Re = 4 X 506.2025/1.001 =
86
This is the lowest value of Re on Colburns curve. So any change in loading from
above value will
only increase Re and shall increase condensing
coefficient.
Ordinate from Colburns curve for above Re is
0.15
Therefor, condensing
coefficient =
187.9
769 Btu/hr.sqft.F
539.3
291 sq.ft
0.055
388 feet
5.025 sq.fee
098 t
19386
1.8 Btu/hr
Therefore,
Subcooling film coefficient =
LMTD =
21.8428
9 =
4739.
914 Btu/hr.sqft.F
71.31
721 degF
Equipment List
EQUIPMENT LIST FOR
PLANT SECTION
ITE
M
DESIGNATION
T-1
N2O4
PRODUCTION
TOWER
E-1
CONDENSER
E-2
REBOILER
NUM
BER
a b
MEDIU
M
TECHNICAL
DATA
1 -
N2O4,
HNO3
H = 5000
MM
D = 1780
MM
N2O4,
BRINE
N2O4,
HNO3
STEAM
D-1
N2O4 FEED
TANK
P-1
A,B
N2O4 FEED
PUMP
1 N2O4
P-2
A,B
REFLUX PUMP
1 N2O4
N2O4
MATERI
AL
DRIV
E
REM
ARKS
AL 99.5
A = 61.2
SQ.MTR
Q=
1.6E+6
KCAL/HR
SHELL :
AL 99.5
A = 61.2
SQ.MTR
Q=
1.8E+6
KCAL/HR
SHELL :
AL 99.8
AL 99.5
F = 5.1
CU.MTR/HR
H = 21
mLC
SS 304
L
E.MO
TOR
F = 14.7
CU.MTR/HR
H = 8 mLC
SS 304
L
E.MO
TOR
V = 210
CU.MTR
D = 4100
MM
L = 16000
MM
TUBE :
AL 99.5
TUBE :
AL 99.8
Line Sizing
Line sizing:
The Feed pump suction:
From pump rated flow equal to 5.1 cu.mtr per hr
Selecting velocity as 0.6 m/s,
The diameter is equal to 54.88 mm.
Select DN 50 Sch 40 pipe.
The Feed pump discharge:
From pump rated flow equal to 5.1 cu.mtr per hr
Selecting velocity as 1.6 m/s,
The diameter is equal to 33.6 mm.
Select DN 40 Sch 40 pipe.
For vapor line from column to condenser:
Vapor flow from material balance = 500 TPD = 20833 kg per hr
At top temperature vapor density = 3.6 kg per cu.mtr
Therefore, volumetric flow rate = 5787 cu.mtr per hr
Selecting vapor velocity = 15 m/s
Diameter = 370 mm
Select DN 400 Sch 40 pipe.
For condenser outlet line as reflux pump suction:
Condensate mass flow = 20833 kg per hr
Condensate density = 1470 kg per cu.mtr
Therefore, volumetric flow rate = 14.7 cu.mtr per hr
Selecting velocity = 0.6 m/s
Diameter = 94 mm
Select DN 90 Sch 40 pipe.
For reflux pump discharge:
For volumetric flow rate = 14.7 cu.mtr per hr
Reflux pumps:
Condensate mass flow = 20833 kg per hr
Condensate density = 1470 kg per cu.mtr
Therefore, volumetric flow rate = 14.7 cu.mtr per hr
Selecting velocity = 1.6 m/s
Diameter = 94 mm
Select DN 50 Sch 40 pipe.
Rated flow through pump = 14.7 cu.mtr per hr
For ease of maintenance and operation reflux pumps shall be located on first
floor at elevation of 5 mtr from grade.
The elevation of reflux point from grade is 12 mtr.
The pump head will be calculated for 12-5 = 7 mtr discharge elevation.
The available positive suction head shall be avoided for this calculation.
Calculating total discharge head,
Selected discharge velocity = 1.6 m/s
The fittings in discharge line can be estimated by following,
Selecting straight length of pipe as 7 meters,
Le/L = 1 + (0.347d^0.5 + 0.216) Fc
Where d = pipe NB inches.
Fc = Correction factor = 1.0