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Contents
1 Process overview
1.1 Problem statement . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Process flow diagram . . . . . . . . . . . . . . . . . . . . . . .
3
3
4
Mass balance
2.1 Mass balance over reactor . . . . . . . . . . . . . . . . . . . .
2.2 Mass balance over absorber . . . . . . . . . . . . . . . . . . .
2.3 Actual vs. theoretical comparison . . . . . . . . . . . . . . . .
5
5
6
7
3 Energy Balance
3.1 Heat of reaction . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Actual vs Theoretical comparison . . . . . . . . . . . . . . . .
8
8
9
14
29
Chapter 1
Process overview
Formaldehyde is a simplest form of aldehyde produced industrially by catalytic oxidation of methanol.It is an important precursor to many industrial
process like formation of pyridine, production of industrial resins etc. Its
chemical formula is CH2 O and the name is derived from its similarity and
relation to formic acid. In this plant Metal Oxide is used as a catalyst which
provides higher yield & selectivity and amount of methanol in product is
very less compared to Silver catalyst.The high yield & selectivity comes at
cost of higher air flow rate. Reaction occur in this process is
1
CH3 OH + 12 O2 HCHO + H2 O
Hrxn = 159 KJ/mol
The reaction is exothermic and heat generated in this process is carried out
by cooling oil and used to generate steam.Also this process involves a side
reaction which leads to the formation of Carbon Monoxide.
1.1
Problem statement
1.2
Chapter 2
Mass balance
Percentage yield of formaldehyde = 93%
Percentage of CO in Stream 9 = 1.2%
Methanol feed in Stream 3 = 1340Kg/hr
Methanol feed in Stream 7 = 1700Kg/hr
Air Input, Stream 1 = 6000N m3 /hr
Flow rate of stream 2 = 14425N m3 /hr
2.1
1 +2
100
nM 6 = nM 5 nM 5
nF 6 = nF 5 + nM 5
1
100
nC6 = nC5 + nM 5
2
100
nW 6 = nW 5 + nM 5
nO6 = nO5 nM 5
1 +2
100
1 +2
200
nN 6 = nN 5 where,
M Methanol, F Formaldehyde, C Carbon Monoxide, W Water
and N Nitrogen
2.2
to sparingly soluble gases like nitrogen and oxygen, we use water to make
approx. 48 wt% formaldehyde solution.The basis for mass balance across
absorber is
95% absorption of formaaldehyde
0.8 wt% Methanol in stream 12
0.8 wt% Methanol in stream 12 72% absorption of methanol (Hit & trial
method)
So, nF 12 = 0.95 nF 10
nM 12 = 0.72 nM 10
nW 12 = nW 10 + nW 11
ni13 = ni10 + ni11 ni12
i = M,F,W,O,C&N
where, M Methanol, F Formaldehyde, C Carbon Monoxide, W
Water and N Nitrogen
2.3
Chapter 3
Energy Balance
3.1
Heat of reaction
Oxygen
Water(g)
0
-241.8 KJ/mol
CH3 OH + 21 O2 HCHO + H2 O
0
Hrxn
= Hf0 (P roducts) Hf0 (Reactants)
0
= 156.718KJ/mol
Hrxn
By Hesss Law,
Hrxn (T = 300C) = 156.424KJ/mol
Similarly for,
HCHO + 21 O2 CO + H2 O
Hrxn (T = 300C) = 233KJ/mol
CO
-110.5 KJ/mol
Heat carried by oil from reactor-1 and reactor-2 is used to heat the water
in in boiler.
m
=
3.2
Ho1 + Ho2
2455.5
Process gas heater is used to heat the process gas to desired temperature
rquired in reactor. But due to its small size compared to designed one, desired
value of temperature is not obtained. Some portion of heat liberated by the
reaction is consumed in heating the process gas to desired temperature. So,
it decreases the amount of steam production compared to designed process.
To increase the temperature of process gas to desired value, an introduction
of heat exchanger is proposed as given below:
9
Proposal
Product from reactor-2 i.e. stream-9 can be splitted to heat both inlet of
reactor-1 and reactor-2. In this case 1 baffle is ther on shell side to increase
heat transfer coefficient and reduce area.
Heat exhanger would be Shell & Tube type and designing of this heat exchanger is done in the next chapter.
10
Chapter 4
Heat Exchanger Design
4.1
Petukhov-Kirillov correlation:
Friction factor, f = (1.58ln(Re) 3.28)2
f
2
Nusselt No., Nu =
N uK
di
4.2
Tube-pitch = PT
Clearance, C = PT - do
Baffle spacing = B
Shell diameter = Ds
As =
Ds CB
PT
11
Gs =
As
K
De =
1
Uo A o
1
hi Ai
ln(ro /ri )
2Ks L
1
ho Ao
12
4.3
Results
Proposal 2
Material of Construction
Tube OD
BWG
Tube thickness
Pitch
Number of tubes
Length
Shell ID
Shell thickness
Tube-side velocity
Shell-side velocity
Tube-side pressure
Shell-side pressure
Tube pressure drop
Shell pressure drop
Overall heat transfer cefficient
Area
Heat transfer rate
LMTD
No. of Baffles
HX-1
Stainless steel
1 in
16
0.065 in
1.25 in
538
4m
33 in
6 mm
22.59 m/s
9.11 m/s
1.25 atm
0.75 atm
0.017 Kg/cm2
0.03 Kg/cm2
37.81 W/m2.K
171.6 m2
1067500 KJ/hr
45.68 K
1
13
HX-2
Stainless steel
1 in
16
0.065 in
1.25 in
538
4m
33 in
6 mm
22.59 m/s
9.11 m/s
1.25 atm
0.75 atm
0.017 Kg/cm2
0.03 Kg/cm2
37.95 W/m2.K
171.6 m2
1025107 KJ/hr
43.71 K
1
Chapter 5
Process Safety Considerations
If gas composition lies in flammability limit and ignition energy is provide,
it will catch fire but if compositio lies outside the region of flammability, no
matter how much ignition energy we provide, gas will not catch fire.
Problem:
Stream
Fuel %
Oxygen %
5
6
8
9
6.36 5.88 12.8 11.98
14.5 11
9.5
6.5
14
15
16