Sample Full Report Design 2 PDF

DESIGN PROJECT 2 (CPB 30803)
FINAL REPORT
DESIGN OF METHANOL PLANT WITH A CAPACITY OF

100, 000 METRIC TONNES PER YEAR
NUR ZARINA BINTI MOHD ZAIRI 55201113636

NURUL AIN NABILAH BINTI
55201113501
ZUHAIMI
MUHAMMAD ADZFAR BIN KHAIRI
55201113625
AZARI
MOHAMED ZAKARIA BIN
55201113602
ABDULLAH
MOHAMAD RIDHWAN BIN AZLI 55201113730
SUPERVISOR: MDM SALEHA BINTI ATAN
L01-P11
SECTION OF CHEMICAL ENGINEERING TECHNOLOGY

UNIVERSITI KUALA LUMPUR
MALAYSIAN INSTITUTE OF CHEMICAL
AND BIOENGINEERING TECHNOLOGY
JANUARY 2016
i
EXECUTIVE SUMMARY
Methanol is a chemical building block used to produce formaldehyde, acetic acid and a
variety of other chemical intermediates. Methanol is also widely considered a leading candidate
as the fuel of choice for vehicular fuel-cell applications. Methanol production usually requires
three steps which is Syngas preparation, Methanol synthesis and Methanol purification. The
chemical that use in the production is hydrogen and carbon monoxide. Mostly methanol is
produced from natural gas. The process selection chosen was Lurgi low-pressure process
because Lurgi technology has an economic advantage over high-pressure processes due to
decreased compression cost at lower pressure. The synthesis technology is more efficient and
only consumes 3-5% less natural gas per ton of pure methanol with lower investment and
operating cost for syngas compression. It also maximizes medium pressure steam production;
thus minimizing overall utility costs and pay out time. The major equipment used in this process
is methanol reactor, steam reformer, separator and three distillation column. Each of the
equipment listed have their own function and important process that being carried out. . The
success or failure of any industry mostly depends on the right selection of the site for it. In order
to choose the most suitable site, several factors other than the physical aspect of the site are to
be considered. The site chosen for methanol plant is in Kerteh, Terengganu since it possessed
the best characteristics and factor of building a plant. The rate of return of this project is 14.28%
with payback period of 3 years. During the next five years, the European and North American
markets are not expected to experience any significant increase in demand volume. Yet, a large
amount of capacity is likely to be added in the US, as it has access to cheap and abundant natural
gas feedstock. Thus, methanol demand is expected to grow significantly in next few years.
ii
LIST OF TABLES
TABLE TITLE PAGE

NO.
2.1 Major equipment list 9
2.2 Methanol reactor specification data sheet 14
2.3 Steam reformer specification data sheet 23
2.4 Flash drum specification data sheet 25
2.5 Scale Value for Distillation Column 1 27
2.6 Distillation column 1 specification data sheet 29
2.7 Scale up values in kmol/hr for distillation column 2 31
2.9 Scale up value for distillation column 3 34
3.1 List of guide words 46
3.2 HAZOP for Reactor 48
4.1 Annual Production of Methanol (Methanol Market
57
Services Asia, 2014)
4.2 List of Material and its Price 60
4.3 Estimation of Fixed and Total Capital Investment Cost 64
4.4 Manufacturing Cost of Summary 65
4.5 Total Product Cost 66
4.6 Pay-back Time 68
iii
LIST OF FIGURES
FIGURE TITLE PAGE

NO.
1.1 Process flow diagram for production of methanol 4
2.1 Tube layout 13
2.2 Geometry of methanol reactor 16
2.3 Process control for methanol reactor 17
2.4 Control loop for level control 18
2.5 Control loop for temperature control 18
2.6 Control loop for pressure control 19
2.7 Side-fired (radiant wall) steam reformer 22
2.8 Three stages of distillation column 26
2.9 Schematic diagram for Distillation Column 1 27
2.10 McCabe – Thiele graph for methanol distillation column 1 28
3.1 Heat exchanger network 38
3.2 Control loop for level control 40
3.3 Control loop for temperature control 40
3.4 Control loop for pressure control 41
3.5 Initial process flow diagram for production of methanol 43
3.6 Finalize and detailed Process flow diagram for production of
44
methanol
3.7 Piping and Instrumentation diagram for production of methanol 45
4.1 Graph of cumulative cash position showing effects of cash flow
with time for an industrial operation neglecting time value of 54
money (Peter & Timmerhouse, 1991)
iv
4.2 Global Methanol Production in 2013 (Merchant Research &

56
Consulting Ltd, 2014)
4.3 Methanol Demand by Major Region (Methanol Market Service
58
Asia, 2014)
4.4 Tax Rate of Company in Malaysia 2016 66
4.5 The Graph of Profit versus Time 69
v
TABLE OF CONTENTS
EXECUTIVE SUMMARY i
LIST OF TABLES ii
LIST OF FIGURES iii
CHAPTER 1 1
INTRODUCTION 1
1.1 Background 1
1.2 Process Selection 2
1.3 Plant Side Consideration 2
1.4 Process Flow Diagram 4
CHAPTER 2 5
DETAILED DESIGN EQUIPMENT 5
2.1 Summary 5
2.2 Introduction 5
2.3 Process Description 6
2.4 Mechanical Design Features of Major Process Unit 9
2.5 Reactor Design 9
2.5.1 Choice of Methanol Reactor 9
2.5.2 Description 10
2.5.3 Function 10
2.5.4 Sizing 10
vi
2.5.5 Reactor Dome Closure 11
2.5.6 Number of Tube 11
2.5.7 Baffle Spacing 12
2.5.8 Number of Baffle 12
2.5.9 Heat Transfer to Vessel 12
2.5.10 Tube Pitch 13
2.5.11 Tube Arrangement 13
2.5.12 Methanol Reactor Specification Data Sheet 14
2.5.13 Geometry of Methanol Reactor 16
2.5.14 Choice of Material 17
2.5.15 Process Control and Instrumentation 17
2.5.15.1 Level Control (Cascade Control) 18
2.5.15.2 Temperature Control (Cascade Control) 18
2.5.15.3 Pressure Control (Cascade Control) 19
2.6 Other Major Equipment (Individual Task) 21
2.6.1 Steam Reformer 21
2.6.1.1 Description 21
2.6.1.2 Structure of Steam Reformer 21
2.6.1.3 Choice of Material 22
2.6.2 Flash Drum (Separator) 24
2.6.2.1 Function 24
2.6.2.2 Choice of Material 24
2.6.3 Distillation Column 26
2.6.3.1 Function 26
vii
2.6.3.2 Arrangement 26
2.6.3.3 Distillation Column 1 27
2.6.3.3.1 Mechanical Design of Distillation Column 1 28
CHAPTER 3 37
SUPPLEMENTARY DESIGN 37
3.1 Summary 37
3.2 Introduction to Heat Integration 37
3.2.1 Defining Hot Stream and Cold Stream Utilities 37
3.3 Process Control and Instrumentation 40
3.3.1 Level Control (Cascade Control) 40
3.3.2 Temperature Control (Cascade Control) 40
3.3.3 Pressure Control (Cascade Control) 41
3.3.4 Piping and Instrumentation Diagram 43
3.4 Hazard Operability Study (HAZOP) For Reactor 46
3.4.1 Introduction to HAZOP Study in Reactor 46
3.4.2 The Technique 52
CHAPTER 4 53
ECONOMIC EVALUATION AND COST OPTIMIZATION 53

viii
4.1 Summary 53
4.2 Introduction 53
4.3 Supply and Demand 54
4.3.1 Global Production of Methanol 55
4.3.2 Global Demand of Methanol 57
4.3.3 Current and Future Price 58
4.4 Major Equipment Cost Estimation 60
4.5 Economical Investment 61
4.5.1 Capital Investment 62
4.5.1.1 Fixed Capital Investment 62
4.5.1.2 Working Capital 63
4.6 Profitability Analysis 65
4.6.1 Manufacturing Cost 65
4.6.2 Revenue from Sales of Methanol 66
4.6.3 Pay-Back Period 67
4.7 Conclusion 70
APPENDIX 72
A Calculation of Equipment Design 72
A.1 Methanol Reactor 72
A.2 Steam Reformer 79
A.3 Flash Drum 83
A.4 Distillation Column 1 85

ix
B Calculation of Economic Analysis 102
B.1 Equipment Cost Estimation 102
B2. Capital Cost Estimation 103
B3. Profitability Analysis 104
REFERENCES 107
1
CHAPTER 1
INTRODUCTION
1.1 Background
Methanol is derived from natural gas and one of hydrocarbon which comprised of
carbon, hydrogen and oxygen. Its chemical formula is CH3OH and also known as methyl alcohol
or wood alcohol which is colorless, neutral, polar, flammable, water-soluble liquid with mild
alcoholic odor. Its freezing point is at -97.8°C while the boiling is 64.7°C and a density of 791
kg/m3 at 20°C.
Methanol can be produced from variety of source such as natural gas, coal,
biomass and petroleum. Methanol also can be produce by the reaction of hydrogen with carbon
monoxide or carbon dioxide at high temperature and pressure over a catalyst. It is also been
called as wood alcohol because it was made from distilling wood in previous time (Methanex
Corp., 2006).
Besides that, Methanex company producing methanol by using a catalytic

process with natural gas and steam as the feedstock. The natural gas is catalytically reformed to
carbon oxides and hydrogen. The resulting synthesis gas mixture is circulated under pressure
and moderate temperature in the presence of a metallic catalyst and converted to crude methanol
which is then being distilled to yield commercial methanol. Natural gas is the most common
raw material used to produce methanol. Small amounts of methanol are produce naturally in the
human body, in animals, plants and bacteria. It also occurs in small amounts in fresh fruit and
vegetables (Methanex Corp., 2006).
2
According to a report by Nian (2013), Methanol demand in the global market is

burgeoning with a 23% increase from 2010 to 2012 to 61 million tons and an expected increase
to 137 million tons in 2022. However, its raw material which is natural gas faces both supply
limitation and volatility. Natural gas is a non-renewable energy that is expected to deplete as
early as 37 years depending on the level of conservativeness while gas infrastructure in Europe
is fragmented and inconsistent. Therefore, currently there are researches on substituting natural
gas with biogas or other renewable resources.
1.2 Process Selection
Nowadays, there are several ways of producing methanol with different process
technology in this world. All of the process technology have their own advantages and
disadvantages. It is important to choose the most efficient process in order to have a good and
almost perfect production of methanol. Methanol can be produce by using several process like
Lurgi low‐pressure methanol synthesis process, ICI low‐pressure methanol process, Haldor
Topsøe methanol process and the MGC low‐pressure process. Based on this process provided,
lurgi low-pressure is chosen as the best method on producing methanol. This is because Lurgi
technology has an economic advantage over high-pressure processes due to decreased
compression cost at lower pressure. Besides that, Lurgi technology does not require a complex
reactor design and the temperature control can be carried out by flowing boiling water on the
shell side. Another Lurgi technology advantages is pressurized steam is produced which benefits
for energy savings. The steam produced is used for heating the reactor feed and as a reboiler in
methanol distillation process. Last but not least, by using this technology the methanol yield is
more than 99% can be produced.
1.3 Plant Side Consideration
In terms of plant site location for this methanol plant, a lot of principal factors must be
considered. The principal factors to be considered are location, raw material supply, transport
facilities, availability of labor, availability of utilities (water, fuel, and power), availability of
3
suitable land, environmental impact and effluent disposal, local community considerations,
climate, political and strategic considerations. For the site location for the methanol plant, there
are several possible options for the site location which include a ‘hot spot’ for chemical plant
within two regional states which are Kerteh, Terengganu and Kimanis, Sabah. Finally, Kerteh,
Terengganu has been identified to be the most suitable site location for methanol plant based on
its attractive land price, well-established facilities, good transportation facilities and the various
incentives given by the Terengganu state government.
4
1.4 Process Flow Diagram
Figure 1.1: Process flow diagram for production of methanol

5
CHAPTER 2
DETAILED DESIGN EQUIPMENT
2.1 Summary
The objective in this chapter is to study about the detailed equipment design, heat
exchanger network, process control and instrumentation for reactor and HAZOP for methanol
reactor. In a typical methanol plant, the reactor is the main component followed by steam
reformer, separator and 3 stages of distillation column. For reactor design, the volume was
calculated and determined based on space time from literature review. In terms of mechanical
design of reactor, it include types of reactor, material of reactor and geometry of reactor. The
design also cover the specification of tubes, size of tubes and the number of tubes also was
calculated as well as diameter of reactor. In terms of heat transfer equipment, the heat balance
was calculated and the specification of cooling media was determined. The cooling media
flowrate also was calculated by using the heat exchanger equation. All the design parameter was
summarized into a specification data sheet with the drawing of reactor. Besides reactor, other
major equipment was designed by student individually where each equipment have its own
volume, diameter and length of equipment. For distillation column, calculation for number of
tray, height of tray and feed tray position are shown detail in the appendix using short cut
methods such as McCabe Thiele.
2.2 Introduction
The Lurgi Low pressure methanol production process had been choosing based on
economic and operational advantages. The Lurgi process was developed to take full advantage
of low process pressure. From the point of advantage, low pressure will give benefit to the
6
production methanol where it can produce a high quality methanol. From the point of cost, the
lower cost were used allow it to used small size of equipment throughout the process.
In a typical plant, methanol production is carried out in two steps. The first step is to
convert the feedstock natural gas into a synthesis gas stream consisting of carbon monoxide,
carbon dioxide (CO2), water (H2O) and hydrogen. This is usually accomplished by the catalytic
reforming of feed gas and steam. Partial oxidation is another possible route. While for the second
step, the catalytic synthesis of methanol was from the synthesis gas. Each of these steps can be
carried out in a number of ways and various technologies offer a spectrum of possibilities which
may be most suitable for any desired application.
This section will discussed about the process description production of methanol from
Lurgi process and major component used to produce methanol from natural gas. There are four
major process steps uses for produce methanol which is Feed Purification Process, Synthesis
Gas from Natural Gas, Methanol Synthesis and Methanol Purification.
2.3 Process Description
The method of Lurgi low pressure processes are favorites in application among
worldwide industries. This is because the low pressure process is low in investment and
production cost, improved operational reliability and greater flexibility in the choice of plant
size. The two main raw materials used are natural gas (96% methane) to provide the carbon and
hydrogen components and water to provide the oxygen component. These raw materials
undergo a series of chemical reactions to produce crude methanol which is then purified to yield
refined methanol, having a purity exceeding 99.9%.
The plants operate continuously 24 hours a day in a production process that can be
divided into two separate processes which is synthesis gas production and conversion of
synthesis gas to methanol. For the synthesis gas production, the reformer is the main unit and
for the synthesis of methanol, the units consist of reactor, separator, topping column and
7
distillation column. There are four major process steps uses for produce methanol which is Feed
Purification Process, Synthesis Gas from Natural Gas, Methanol Synthesis and Methanol
Purification (J. Jackson., 2006).
Firstly, two main feedstocks which is natural gas and water require purification before
use. This process is called feed purification. Natural gas contains low levels of sulphur
compounds and undergo a desulphurization process to reduce the sulphur to levels of less than
one part per million. Next, the impurities in the water are reduced to undetectable or parts per
billion levels before being converted to steam and added to the process. It is very important to
removes it because if these impurities is not removed it can result in reduced heat efficiency and
significant damage to major pieces of equipment (J. Jackson., 2006).
Then, reforming process will takes place. Reforming is the process which transforms the
methane (CH4) and the steam (H2O) to intermediate reactants of hydrogen (H2), carbon dioxide
(CO2) and carbon monoxide (CO). Carbon dioxide is also added to the feed gas stream at this
stage to produce a mixture of components in the ideal ratio to efficiently produce methanol. This
process is carried out in a reformer furnace which is heated by burning natural gas as fuel. The
nickel catalyst is packed in vertical tubes. Heat for endothermic reaction is supplied by
combustion gas. The reaction temperature is maintained in the range of 400 oC to 500oC. High
temperature alloy steel is used for the tubes and the steel wall of the furnace. The effluent
reformer gas is then cooled to 250oC through heat exchanger (J. Jackson., 2006).
CH4 + H2O  CO + 3H2

CO + H2O  CO2 + H2
Next is methanol synthesis. After removing excess heat from the reformed gas, it is being
compressed before being sent to the methanol production stage in the synthesis reactor. Here
the reactants are converted to methanol and separated out as crude product with a composition
of methanol (68%) and water (31%). Traces of by-products are also formed. 85% of carbon
8
dioxide is being convert and the conversion for carbon monoxide gas is 60% (Aasberg-Petersen.,
2001).
CO + 2H2  CH3OH
CO + H2O  CO2 + H2
CO2 + 3H2  CH3OH + H2O
The synthesis gas however results in a build-up of inert gases in the system and this is
continuously sent to the reformer where it is burnt as fuel. The crude methanol formed is
condensed and sent to the methanol purification step which is the final step of the process. The
reaction is highly exothermic the enhanced pressure would result in more favorable equilibrium
that called Le Chatlier’s principle. Ether (CH3OCH3) is produced by decomposition of 5 % of
methanol merge at reactor effluent together with unreacted gases which is CO, CO2, H2, N2 CH4,
methanol (CH3OH) and water (H2O). Then, 25oC of the exit gases are separated in high pressure
separator where methanol is condensed at the bottom of separator. The liquid methanol is drawn
off and the residual gases are recycled back to reformer (Charlotte Stub Nielsen., 2001).
Crude methanol as removed from the synthesis section contains water and impurities,
which must be removed before the product is ready to commercial use. Purification is achieved
by two stages of distillation which are topping column to separate the more volatile components
contained in the crude methanol; it receives the crude methanol and separates the light
components (light ends) at the top and aqueous solution at the bottom. The first column or
topping column need to be at 445oF, 750 psi, have 15 trays, and the feed need to be above 5 th.
By product from the topping column will recycled back to the reactor in order to save cost for
the plant. Then, purification followed with refinery column to remove the water and the heavier
organic material and also to yield product with a purity of 99% methanol as Grade AA refined
methanol. Second column carries out the actual distillation, obtaining refined methanol at the
top and by product of the most synthesis reaction at the bottom. The second column need to be
at 445oF, 750psi same as topping column and have 33 trays; feed need to be at 13 th tray to obtain
the correct purity of methanol. Water from the refining column bottom is cooled by the crude
9
methanol feed to the extraction column before being recycled or discharged to the wastewater
pond system. The methanol process is tested at various stages and the finished product is stored
in a large secured tankage area off the plant until such time that it is ready to be delivered to
customers. Since 70% of the product is sold on the overseas market, it is shipped by ocean going
tankers while local sales are made via pipelines and drums.
2.4 Mechanical Design Features of Major Process Unit
Table 2.1: Major equipment list
No Name of equipment
1 Methanol reactor
2 Steam reformer
3 Separator
4 Distillation column (1, 2, and 3)
5 Heat exchanger
2.5 Reactor Design
2.5.1 Choice of Methanol Reactor
The choice of the methanol reactor is the Lurgi Methanol Reactor which is boiler water
reactor (BWR). Boiler water reactor is a type of plug flow reactor where the operation concept
is quiet similar with the operation of heat exchanger. There are other options that are interesting,
but the Lurgi reactor is believed to have a high level of temperature control. The choice is also
based on the fact that the methanol industry has a very high level of experience with the Lurgi
Methanol reactor, among others (Meyers, 2005).
10
2.5.2 Description
In this process, the syngas (H2, CO, CO2, CH4, and H2O) feed was introduced into
reactor. The methanol synthesis is stimulated as an equilibrium reactor where methanol reaction
and the water shift reaction takes place during this stage. In the production of methanol from
syngas, there are several reactions that will have to be considered:
CO + 2H2 CH3OH
CO2 +3H2 CH3OH + H2O
These reactions occur simultaneously inside of the reactor during methanol synthesis step. In
the reactor there will be a Cu/Zn/Al catalyst to drive the overall reaction toward methanol. The
amount CO2 activates the catalyst and it also deactivates it, so an adequate amount of CO 2 must
be allowed into the reactor. In order to ensure that the catalyst life can stay at a reasonable time,
the temperature of the reactor need to stay at 871.11 oC and pressure at 21.71 atm. This
isothermal reactor is the most efficient type where this reactor are low by-product production
formation due to almost isothermal reaction conditions, high reaction heat recovery, and easy
temperature control by regulating steam pressure .The reacted gas will then go through several
pieces of equipment until it reaches the distillation column for purification of the product.
2.5.3 Function
It is the only place in the process where raw materials are converted into products, and
reactor design is a vital step in the overall design of the process.
2.5.4 Sizing
A fixed bed reactor (FBR) was used as the basis for the methanol reactor. The catalyst
used was the common Cu/ZnO. The total length of reactor with dome closure is 9.425m and the
11
number of tubes was calculated to 278 tubes, each with a diameter of 0.073152m. More detailed
dimensioning calculations are given in the appendix A.
2.5.5 Reactor Dome Closure
The reactor has a top and bottom head closure, the choice of head closure used
in this design is the hemispherical type. These have been chosen as they can withstand
very high pressure, and since the reactor design pressure will be higher than the operating
pressure, it is viable to use this type of head closure.
The dimensions of hemispheres are very simple, since it is half of a circle; the
radius from the center of the circle to all edges of the hemisphere will be the same. The reactor
diameter was calculated earlier to be 1.885 meters; hence the radius of the hemisphere
will be 0.9425 meters. The dimension of the hemispherical head closure is shown in the
appendix using the formula below:
2 3
𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 ℎ𝑒𝑚𝑖𝑠𝑝ℎ𝑒𝑟𝑒 = 𝜋𝑟
3
2.5.6 Number of Tube
To calculate the number of tube, the outside and inside diameter of the tube need to be
assumed as well as the length of the tube and not based on the previous reactor calculation. The
number of tube is 278 using the formula below and detail calculation can be refer in appendix.
Based on the Steel Pipes Dimensions - ANSI Schedule 40:
 Outside diameter= 0.073152𝑚
 Tube length= 18𝑚
(Source: http://www.engineeringtoolbox.com/ansi-steel-pipes-d_305.html)
12
𝑉𝑟𝑒𝑎𝑐𝑡𝑜𝑟
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑡𝑢𝑏𝑒 =
𝑉𝑡𝑢𝑏𝑒
2.5.7 Baffle Spacing
The calculated baffle spacing was 0.754m using the formula below. The range of baffle
spacing used is around 0.2 to 1.0. The minimum spacing usually 0.3 0.5 times the shell diameter.
The calculation is begin with taking 0.4 as the baffle spacing value. The edge distance between
the outer tubes limit (OTL) and the baffle diameter has to be sufficient to prevent tube
breakthrough due to vibration.
𝐵𝑆 = 0.4𝐷
2.5.8 Number of Baffle
The number of baffle was determined and it was 10. Baffle is a plate or mechanical
device designed to restrain or regulate the flow of a fluid where number of baffle:
𝑇𝑢𝑏𝑒 𝑙𝑒𝑛𝑔𝑡ℎ
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑏𝑎𝑓𝑓𝑙𝑒 = −1
𝐵𝑎𝑓𝑓𝑙𝑒 𝑠𝑝𝑎𝑐𝑖𝑛𝑔
2.5.9 Heat Transfer to Vessel
From the material balance calculated, the Q obtain is negative and it shows that the
reaction is exothermic. In term of cooling process, the amount of water is needed to maintain
the temperature of the reaction and absorb the excess heat produce during the reaction occur.
𝑘𝑔
The mass flowrate of water, ṁ ( 𝑠 ) is 52.93160 and to determine the amount of water needed
for cooling, the formula used is:
𝑄 = ṁ𝐶𝑝 𝑑𝑇
13
2.5.10 Tube Pitch
From Chemical Engineering, Volume 6, Fourth edition Chemical Engineering Design

by R. K. Sinnott, the recommended tube pitch (distance between tube centers) is 1.25 times the
tube outside diameter where the calculated tube pitch is 0.09144m using the formula below. For
the minimum spacing (pitch), Segmental baffles normally should not be closer than 1/5th of
shell diameter (ID) or 50.8 mm (2in) meanwhile for maximum spacing (pitch), Spacing does
not normally exceed the shell diameter. Tube support plate spacing determined by mechanical
considerations e.g. strength and vibration.
𝑇𝑢𝑏𝑒 𝑝𝑖𝑡𝑐ℎ (𝑃𝑡 ) = 1.25 × 𝑡𝑢𝑏𝑒 𝑜𝑢𝑡𝑠𝑖𝑑𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟
2.5.11 Tube Arrangement
The chosen tube arrangement is triangular because triangular pattern provides a more
robust tube sheet construction.
Figure 2.1: Tube layout

14
2.5.12 Methanol Reactor Specification Data Sheet
Table 2.2: Methanol reactor specification data sheet
EQUIPMENT SPECIFICATION SHEET

General Information
Type of equipment Methanol reactor
Function It is the only place in the process where raw
materials are converted into products, and reactor
design is a vital step in the overall design of the
process.
Number of Unit 1
Material of construction Carbon steel
Operating Information
Operating Pressure 50 – 60bar
Operating Temperature 250 - 260°C
Operating Condition Continuous
Feed flow rate 3460.0367 mol/hr
Column Design Information
Reactor volume without catalyst 14.028
bed (m3)
Reactor volume with catalyst 21.03
bed (m3)
Total reactor volume (m3) 24.53698
Volume of catalyst bed (m3) 7.01
Diameter of reactor (m)
Reactor dome closure (𝑚3 ) 3.50698
Volume of Hemisphere (𝑚3 ) 1.753491
7.54
15
Length of cylindrical section

(m) 1.885
Length of hemispherical head
(m) 9.425
Total length of reactor (m) 278
Number of tube 0.073152
Outside diameter of tube (m) 4.13665
Area of tube (m2) 0.07565
Volume of tube (m3) 0.754
BS (m) 10
Number of baffle Triangular
Tube arrangement 52334.27
Heat transfer to vessel, Q (kw) 214.65071
∆𝑇𝑚 (k) 0.0079
Shell thickness (m) 0.09144
Tube pitch (m)
Overall heat transfer coefficient, 188.32350
𝑤
U (𝑚2 .𝑘)
Mass flowrate of water, 52.93160

𝑘𝑔
ṁ( )
𝑠
Costing Information
Purchase Cost RM 683,009.00
Installation factor 2.1
Total equipment cost RM 697,352.189
16
2.5.13 Geometry of Methanol Reactor
Figure 2.2: Geometry of methanol reactor

17
2.5.14 Choice of Material
The material for the methanol reactor was chosen to be carbon steel. Since the process
streams at this stage are only gasses, corrosion is not believed to be a problem. Due to the
temperature conditions at about 250°C, metal dusting not comes into consideration. This leads
to a construction material of carbon steel, which is the least expensive material (Peters, 2003).
2.5.15 Process Control and Instrumentation
Figure 2.3: Process control for methanol reactor

18
2.5.15.1 Level Control (Cascade Control)
Level Flow Output Output Reactor

Liquid
Controller Controller Valve Flow Level
level
Process
Figure 2.4: Control loop for level control
 Reactor Level is affected by changes in output flow rate.

 Control Strategy: handle reactor level by adjusting the flow rate of the product output.
 If a disturbance in output flow rate occurs, FC will act quickly to hold the output flow
rate at its Set Point.
Control system measures Reactor level and compares it to set point level of the reactor. Then
uses the resulting error signal as the input to a controller for output flow rate
2.5.15.2 Temperature Control (Cascade Control)
Temperat Flow Steam Steam Reactor

Temperature
ure Controller Valve Flow Temperat
Controller Process ure Level
Figure 2.5: Control loop for temperature control

19
 Reactor Temperature is affected by changes in reactant feed Temperature.

 Control Strategy: handle reactor temperature by adjusting the flow rate of the steam on
the steam jacket.
 Primary control loop (TT & TC).
 Secondary (FT & FC).
 The hot steam is used by MASTER controller (TC) to establish the set point for
SLAVE loop controller.
 Secondary measurement is fuel steam flow rate.
 If a disturbance in steam supply occurs, FC will act quickly to hold the Steam flow rate
at its Set Point.
 Control system measures Jacket Temperature and compares it to set point temperature
of the reactor. Then uses the resulting error signal as the input to a controller for steam
makeup.
 PRINCIPAL: the 2ndmanipulated variable is located closed to potential disturbance &
react quickly
2.5.15.3 Pressure Control (Cascade Control)
Pressure Gas Flow Gas Valve Gas Flow Reactor

Pressure
Controller Controller Process Pressure
Level
Figure 2.6: Control loop for pressure control
 Reactor Pressure is affected by changes in gas flow rate.

 Control Strategy: handle reactor pressure by adjusting the flow rate of the gas.
20
 If a disturbance in gas flow rate occurs, FC will act quickly to hold the gas flow rate at
its Set Point.
Control systems measures Reactor pressure and compare it to set point level of the reactor.
Then uses the resulting error signal as the input to a controller for gas flow rate.
21
2.6 Other Major Equipment (Individual Task)
2.6.1 Steam Reformer (Mohamed Zakaria Bin Abdullah)
Reforming is the process which transforms the methane (CH4) and the steam (H2O) to
intermediate reactants of hydrogen (H2), carbon dioxide (CO2) and carbon monoxide (CO).
2.6.1.1 Description
In this process, natural gas is combine with steam under heat to produce synthesis gas,
which consist of hydrogen, carbon monoxide, and carbon dioxide. The process to transform the
methane and steam water to intermediate reactants of hydrogen (H2), carbon dioxide (CO2) and
carbon monoxide (CO). Carbon dioxide is also added to the feed gas stream to produce a mixture
of components in the ideal ratio to the efficiently produce methanol.
2.6.1.2 Structure of Steam Reformer
A steam reformer is similar to a big furnace, with vertical tubes loaded with catalyst, see
figure 7.2. The feed of natural gas and steam is mixed in a manifold at the inlet. The feed is then
injected into the catalyst filled tubes. The reformer is heated by burners, usually located at the
top or at the sides of the reformer. The reformer can be divided into a radiant section, convective
section and stack section. Heat transferred into the catalytic tubes is mostly done in the radiant
section, with radiation. Approximate 50 % of the heat created by the burners is transferred into
the tubes.
22
Figure 2.7: Side-fired (radiant wall) steam reformer
2.6.1.3 Choice of Material
Due to the high temperature levels in the steam reformer, heat resistant stainless steel
was chosen to be the material of construction. Stainless steel types like 309 and 310, which
contain some nickel and chromium can be used for such high temperature application (Peters,
2003).
23
Table 2.3: Steam reformer specification data sheet

General Information
Type of equipment Steam reformer
Function Transforms the methane (CH4) and the steam
(H2O) to intermediate reactants of hydrogen (H2),
carbon dioxide (CO2) and carbon monoxide (CO).
Number of Unit 1
Material of construction Heat resistant stainless steel
Operating Pressure 50-80 bar
Operating Temperature 850°C-860°C
Heat flux 𝑊
19329.64814
𝑚2
Volume of steam reformer 22.35945𝑚3
Volume of steam reformer 22.35945𝑚3
without catalyst bed
Volume of catalyst bed 11.17973𝑚3
Total of volume steam reformer 33.53918𝑚3
with catalyst bed
Diameter of steam reformer 2.20176𝑚
Length of steam reformer 8.80704𝑚
Number of tube 182
Outside diameter of tube 0.1143𝑚
Internal diameter of tube 0.102362 𝑚
Volume of tube 0.18469𝑚3
24
Costing Information
Purchase Cost RM 2,011,725.00
Total equipment cost RM 2,041,900.875
2.6.2 Flash Drum (Separator) (Mohd Ridhwan Bin Azli)
2.6.2.1 Function
A separator is used to separate dispersed liquid in a gas stream. It is important that the
dimension of the separator is large enough so that liquid can settle in the bottom of the tank.
When designing the separator size, a hold-up time of 10 minutes was assumed (O4). Two
separators were used in the plant design, each equipped with demisters, to ensure good
separation and to decrease equipment cost. When using a demister the vessel height can be
reduced (Peters, 2003). The separator located after the methanol reactor to separate the final
product (methanol) from the recycle. Detailed descriptions of the calculations are given in the
appendix.
2.6.2.2 Choice of Material
The construction material of separator was chosen to carbon steel with nickel-alloy
clad. The nickel-alloy clad was added due to the water content in the actual process streams.
Nickel exhibits high corrosion resistance to most alkali and increases toughness and improves
low temperature properties and corrosion resistance of the material (Peters, 2005).
25
Table 2.4: Flash drum specification data sheet

General Information
Type of equipment Separator (Flash Drum)
Function To separate dispersed liquid in a gas stream. It is
important that the dimension of the separator is
large enough so that liquid can settle in the bottom
of the tank.
Number of Unit 1
Material of construction Carbon Steel with nickel alloy clay
Operating Pressure 3 - 4 bar
Operating Temperature 140 °C – 145 °C
Height of the tank 6.0 m
Height related to velocity 1.525 m
Height related to flooding level 0.91 m
Height related to liquid level 3.565 m
control
Volume of flash drum 10.780 m3
Diameter of separator 1.5 m
Wall Thickness 31.242 mm
Overall Thickness 34.442 mm
Costing Information
26
2.6.3 Distillation Column
2.6.3.1 Function
A distillation column is used to separate different components in a fluid, by using their

difference in boiling point.
2.6.3.2 Arrangement
Since the outlet stream from the last separator contains many different components, a
minimum of two distillations had to be used to obtain the desired product specification but in
this design three column distillations were used to obtain a high purity of methanol. The column
arrangement used was the conventional arrangement described by R. Sinnot et.al known as the
stripper and re-run column. The light components are separated in the first column, followed by
a separation of mostly methanol and water in the last 2 column. Detailed descriptions of the
calculations are given in the appendix.
Figure 2.8: Three stages of distillation column

27
2.6.3.3 Distillation Column 1 (Nurul Ain Nabilah Binti Zuhaimi)
D = 383.2363 kmol/hr
XD = 0.96
T = 75 °C
P = 60 atm
Stripping Enriching
Section Section
F = 1985.8255 kmol/hr
XF = 0.1996
W = 1588.8806 kmol/hr
Xw = 0.04
T = 112 °C
P = 65 atm
Figure 2.9: Schematic diagram for Distillation Column 1
Table 2.5: Scale Value for Distillation Column 1
Input / Output
Substances Distillate (kmol/hr) Bottom (kmol/hr)
Stripper (kmol/hr)
H2O 1 589.3621 15.3295 1 525.3254
CH3OH 396.9068 367.9068 63.5552
Total 1 985.8255 383.2363 1 588.8806
28
Figure 2.10: McCabe – Thiele graph for methanol distillation column 1

29
2.6.3.3.1 Mechanical Design of Distillation Column 1
Table 2.6: Distillation column 1 specification data sheet
Vapor Liquid Contacting Column

Equipment Label : T-100 Equipment Name : Distillation Column 1
Process Data
Enriching Stripping
Column Section
Section Section
Methanol Vapor Flow kg/h 15 977.70304 15 977.70304
Methanol Liquid Flow kg/h 8 006.388 49 311.5584
Top of Section Operating °C 70-85
Temperature
Pressure atm 60.00
Vap Density kg/m3 2.13
Liq Density kg/m3 740.50
Liq Surface Tension dyn/c 21.00
m
Bottom of Operating °C 90-115
Section Temperature
Pressure atm 65.00
Vap Density kg/m3 4.67
Liq Density kg/m3 714.00
Liq Surface Tension dyn/c 19.00
m
Construction Material
Enriching Stripping
Column Section
Section Section
Tray Of Stages Number 9 6
30
Shell Material Carbon Steel

Shell Height m 10.50
Shell Diameter m 1.82
Shell Thickness mm 6.00
Operating Temperature °C 110.00
Design Temperature °C 121.00
Test Pressure kg/cm2 1.1362
Tray Type Sieve Tray
Tray Material Stainless Steel
Tray Diameter m 1.50 1.30
Tray Section m 0.50 0.50
No. Holes 6078 4467
Hole Diameter mm 5.00 5.00
Hole Pitch mm 15.00 15.00
Tray Thickness mm 3.00 3.00
Weir Length m 1.20 0.98
Weir Height mm 50.00 50.00
Insulator
Insulation Materials Asbestos
Insulation Thickness mm 75
Density Of Insulation kg/m3 575
31
2.6.3.4 Distillation Column 2 (Nur Zarina Binti Mohd Zairi)
Distillate: 369.1052 kmol/hr
Feed: 383.236 kmol/hr
CH3OH: 10.6224
Bottom: 22.6963 kmol/hr
2.11: Schematic diagram for Distillation Column 2
Input = Output
F=D+B
From previous calculated mass balance,
Table 2.7: Scale up values in kmol/hr for distillation column 2
Substances Input/Feed Distillate Bottom

H2O 15.3295 7.3807 22.2426
CH3OH 367.9068 361.7245 0.4537
Total 383.236 369.1052 22.6963
32

General Information
Type of equipment Distillation Column 2
Function To separate methanol and water in order to obtain
the highest purity of product (methanol).
Number of Unit 1
Material of construction Stainless steel
Operating Pressure 101.33-267 kPa
Feed flow rate 11574.07 kg/hr
Number of trays 8
Feed tray 5th tray from above
Tray spacing 1.0 m
Column diameter 2.5 m
Column Cross Sectional Area 5 m2
Column Height 9.11352 m
Liquid flow patent Cross flow (single path)
Costing Information
33
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1

34
2.6.3.5 Distillation Column 3 (Muhammad Adzfar Bin Khairi Azari)
Distillate: 361.6933 kmol/hr
Feed: 369.236 kmol/hr
CH3OH: 10.4439
Bottom: 18.227 kmol/hr
Figure 2.13: Schematic diagram for Distillation Column 3
Input = Output
F=D+B
Table 2.9: Scale up value for distillation column 3
Substances Input/Output Distillate Bottom

H2O 7.3807 3.6159 18.0448
CH3OH 361.7245 358.0774 0.1823
Total 369.1052 361.6933 18.227
35

General Information
Type of equipment Distillation Column 3
Function To separate methanol and water in order to obtain
the highest purity of product (methanol).
Number of Unit
Operating Pressure 101.33-267 kPa
Feed flow rate 11574.07 kg/hr
Number of trays 9
Number of actual trays 15
Area of distillation column 4.158 m2
Column diameter 2.5 m
Volume of distillation column 43.6897 m3
Column Height 10.5156 m
Liquid flow patent Cross flow (single path)
Costing Information
36
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1

37
CHAPTER 3
SUPPLEMENTARY DESIGN
3.1 Summary
In this chapter, the heat exchanger network (heat integration) was proposed with added
diagram for the plant the conserve energy for example using the waste heat from the reactor to
pre-heat the reactant. The pipe line and instrumentation for the whole process is shown in the
piping and instrumentation diagram. All the instrumentation, pumps, valve and pipe line was
identified to build a P&ID drawing. Process instrumentation and control for reactor also was
defined with diagram. Last but not least is the HAZOP study for the reactor.
3.2 Introduction to Heat Integration
Heat exchanger network (HEN) design is a very important part of the chemical process
design; typically 20-30% energy saving can be realized by improved HEN design (Linnhoff,
1983). In the following the minimum number of heat exchanger units in the process, minimum
amount of utility requirement and different heat exchanger networks will be proposed.
3.2.1 Defining Hot Stream and Cold Stream Utilities
It is essentially two hot streams to be cooled and four cold streams to be heated and
figure below shows the heat integration proposed for the methanol plant design:
38
Figure 3.1: Heat exchanger network
 The synthesis gas from the steam reformer is to be cooled from 860°C to 30°C.
 The product out from the methanol reactor is to be cooled from 260°C to 30°C.
 The natural gas feed is to be heated from -0.26°C to 250°C.
 The methane rich gas from the prereformer is to be heated from 250°C to 860°C
 The methanol reactor feed is to be heated from 41°C to 260°C.
Heat exchangers used for preheating process streams in the reformer section was all
assumed to be included in the heat recovery section of the steam reformer, where heat from the
hot flue gas were exchanged. This was mostly done to ensure an easy startup after shutdown.
For the methanol synthesis part, the preheating of the methanol reactor feed was done
using heat from the reactor outlet. It was assumed to be wise to separate the reformer part and
the synthesis part to ensure no complications could occur during startup procedure. Because of
the relative large exchanger size, a flat plate heat exchanger was used. In terms of cooling and
heating, water will flow in the shell side to maintain the reaction temperature in the reactor thus
removing the waste heat from the reactor. The hot water from the reactor then will be used for
steam generation and not only that the steam produced is used for heating the reactor feed and
as a reboiler in methanol distillation process. Moreover, the heat recovered from the hot syngas
is used to preheat methanol reactor feed as well as to vaporize recycled water/condensate for
39
steam reforming reaction. However, natural gas preheating for the steam methane reformer is
not subjected to process heat exchange as this will cause difficulty in achieving steady state
during start up; hence the duty will be provided by LPS. Crude methanol feed to the distillation
column is preheated using LPS as the methanol reactor effluent stream is used to generate MPS
and LPS for plant-wide heating purposes and there are no other hot process streams in close
proximity for process heat exchange.
To ensure good heat recovery, heat from hot reactor outlet was used to preheat the input
stream. However, since the methanol reactor is in isothermal, the inlet temperature would be the
same as the outlet temperature. In reality, the inlet temperature of the reactor would be smaller
than the outlet temperature, but since the reaction is exothermic one would experience a rapid
increase to the desired temperature by controlling the amount of cooling, and the reactor would
be approximately isothermal. The proposed solution was to add a heater at the reactor inlet,
heating the inlet stream to the desired temperature of 260°C.
40
3.3 Process Control and Instrumentation
3.3.1 Level Control (Cascade Control)
Level Flow Output Output Reactor

Liquid
Controller Controller Valve Flow Level
level
Process
Figure 3.2: Control loop for level control
 Reactor Level is affected by changes in output flow rate.

 Control Strategy: handle reactor level by adjusting the flow rate of the product output.
 If a disturbance in output flow rate occurs, FC will act quickly to hold the output flow
rate at its Set Point.
Control system measures Reactor level and compares it to set point level of the reactor. Then
uses the resulting error signal as the input to a controller for output flow rate
3.3.2 Temperature Control (Cascade Control)
Temperat Flow Steam Steam Reactor

Temperature
ure Controller Valve Flow Temperat
Controller Process ure Level
Figure 3.3: Control loop for temperature control

41
 Reactor Temperature is affected by changes in reactant feed Temperature.

 Control Strategy: handle reactor temperature by adjusting the flow rate of the steam on
the steam jacket.
 Primary control loop (TT & TC).
 Secondary (FT & FC).
 The hot steam is used by MASTER controller (TC) to establish the set point for
SLAVE loop controller.
 Secondary measurement is fuel steam flow rate.
 If a disturbance in steam supply occurs, FC will act quickly to hold the Steam flow rate
at its Set Point.
 Control system measures Jacket Temperature and compares it to set point temperature
of the reactor. Then uses the resulting error signal as the input to a controller for steam
makeup.
 PRINCIPAL: the 2ndmanipulated variable is located closed to potential disturbance &
react quickly
3.3.3 Pressure Control (Cascade Control)
Pressure Gas Flow Gas Valve Gas Flow Reactor

Pressure
Controller Controller Process Pressure
Level
Figure 3.4: Control loop for pressure control
 Reactor Pressure is affected by changes in gas flow rate.

 Control Strategy: handle reactor pressure by adjusting the flow rate of the gas.
42
 If a disturbance in gas flow rate occurs, FC will act quickly to hold the gas flow rate at
its Set Point.
Control systems measures Reactor pressure and compare it to set point level of the reactor.
Then uses the resulting error signal as the input to a controller for gas flow rate.
43
3.3.4 Piping and Instrumentation Diagram
Figure 3.5: Initial process flow diagram for production of methanol

44
Figure 3.6: Finalize and detailed Process flow diagram for production of methanol
45
Figure 3.7: Piping and Instrumentation diagram for production of methanol

46
3.4 Hazard Operability Study (HAZOP) For Reactor
3.4.1 Introduction to HAZOP Study in Reactor
Hazard and Operability Study (HAZOP) is a formal systematic examination of a

processing plant for identifying hazards, failures and operability problems, and assessing the
consequences from such mal-operation (OSHA Website). Hazard identification is the process
of recognizing that hazard exists and defining its characteristics as it is essential to identify the
hazards and reduce the risk in advance of an accident. The objectives of the HAZOP study are
stated as follow:
 Identification and assessment of major hazards potential in the process equipment which
is reactor.
 Suggesting measures to reduce risk by reducing hazard and probability.
A list of guide words used in this HAZOP study is shown as below:
Table 3.1: List of guide words
Guide Words Meanings Comments

No or Not Complete negation of No part of the intention is
intention. achieved (e.g: no flow or
reverse flow).
More of, Less of Quantity increases or These refer to quantities and
decreases in activity. properties such as flow rates
and temperatures as well as
activities like ‘HEAT’ and
‘REACT’.
Part of Incomplete performance of Only some of the intentions
an activity. are achieved, some or not.
47
Sooner/ Later than When activity occurs at the No part of the original
wrong time relative to intention is achieved.
others. Something quite different.
Other than Complete substitution. No part of the original
intention is achieved.
Something quite different.
48
Table 3.2: HAZOP for Reactor
Parameter Guide Word Causes Consequences Present Protection Recommendation Action

Temperature More Good Heating  No process hazard.  Temperature  Non-returnable valve must be
Part of the gauge and install.
requirement. indicator.  Arrow indicator provided in the
 It will accelerate the  Sight glass any pipe.
distillation process. provided.  Insulation material which can
 No process will take  Safety valve withstand high temperature
place. Process provided. install outside the reactor.
delayed.  Cooling and  Periodic checking on the
chilling performance of the gauge and
arrangement indicator.
with alternative  If emergency, immediately
provided. shutdown the equipment and
Less Poor Heating  Emergency cool down the reactor by
Dump for spraying the water to the
methanol reactor.
provided.  Install alarm to alert the person
in-charge.
49
Pressure More  Inlet or outlet  Failure in reactor  Sign on open  Install pressure relief valve at
valve blockage and close the the inlet and outlet pipeline,
in error. valve fully. upper reactor.
 Incorrect  Install High Pressure Alarm to
pressure being alert the person in-charge.
set.  Periodic checking on the
 Vapour lock. performance of the gauge and
indicator.
 Install safety valve.
Flow Less  Leaking  Lower production rate None  Periodic inspection on the
throughout the will take place. pipeline to check any leakage.
pipeline.  Decrease the quality  Isolate the valve to prevent
 Valve is not and purity of the leakage.
fully opened or product (methanol).  Install flowrate indicator
closed. together with sight gauge to
 Low material monitor the flow in the pipeline
flow. and the content of the liquid in
the reactor.
 Install an emergency fully open
valve to top-up water in case
50
there is not enough water in the

reactor.
Contamination  Leaking on the  Contamination in None  Proper maintenance and
water supply reactor. operator alert.
pipeline.  Daily check on the water supply
 From the water to the reactor and also in the
reservoir. water reservoir.
Power failure  Failure in  Process disturbance. Captive power
electrical plant provided
system.
Others Equipment Failure  Valve cannot fully  Install alarm to alert the person
open or closed. in-charge.
 Pipeline blockage due  Install safety valve along the
to fouling factor. pipeline.
 Valve indicator to show either
valve is fully function.
 Put tag- out and tag-in sign to
ensure the valve is fully
checked.
51
The reaction is exothermic, and a cooling system is provided to remove the excess energy
of reaction. If the cooling flow is interrupted, the reactor temperature increases, leading to an
increase in the reaction rate and the heat generation rate. The result could be a runaway reaction
with a subsequent increase in the vessel pressure possibly leading to a rupture of the vessel. The
temperature within the reactor is measured and is used to control the cooling water flow rate by
a control valve.
Performing a HAZOP on this process with the assigned task of considering runaway
reaction episodes would lead to a completed form. The process is already small enough to be
considered a single section. Four study nodes are cooling water line, stirring motor, monomer
feed line, and reactor vessel.
The HAZOP analysis would reveal the following potential process modifications:
1. Installation of a cooling water flow meter and low flow alarm to provide an immediate
indication of cooling loss.
2. Installation of a high temperature alarm to alert the operator in the event of cooling
function loss.
3. Installation of a high temperature shutdown system that would automatically shut down
the process in the event of a high reactor temperature. The shutdown temperature would
be higher than the alarm temperature to provide the operator with the opportunity to
restore cooling before the reactor is shut down.
4. Installation of a check valve in the cooling line to prevent reverse flow. A check valve
could be installed both before and after the reactor to prevent the reactor contents from
flowing upstream and to prevent the backflow in the event of a leak in the coils.
5. Periodic inspections and maintenance of the cooling coil to insure its integrity.
6. Evaluation of the cooling water source to consider any possible interruption and
contamination of the supply.
In the event that the cooling water system fails (regardless of the source of the failure),
the high temperature alarm and emergency shutdown system prevents a runaway. The review
52
committee performing the HAZOP decided that the installation of a back-up controller and
control valve was not essential. The high temperature alarm and shutdown system prevents a
runaway in this event.
Similarly, a loss of cooling water source or a plugged cooling line would be detected by
either the alarm or emergency shutdown system. The review committee suggested that all
cooling water failures be properly reported. In the event that a particular cause occurs repeatedly
then additional process modifications are warranted.
3.4.2 The Technique
A HAZOP is organized by dividing the unit to be analyzed into nodes. A node represents
a section of the process where a significant process change takes place. For example, a node
might cover the transfer of material from one vessel to another through a pump. In this case the
process change is the increase in pressure and flow that occurs across the node.
Another node might include an overhead air-cooler on a distillation column. Here

temperature and phase are the process variables that change. Although the strength of the
HAZOP method lies in its clear organization, it is important not to allow the analysis to become
too rigid.
53
CHAPTER 4
ECONOMIC EVALUATION AND COST OPTIMIZATION
4.1 Summary
In this chapter, it will discuss about the economic evaluation and cost optimization. For
the equipment cost, it referred to the detailed design of the equipment such as material cost,
manufacturing cost regarding to the selection of material and geometry of the equipment such
as height, diameter, thickness and others. In this chapter, it also will focus on the economic
potential and estimation. It include the capital investment cost, supply and demand of methanol,
global production of methanol, current and future price of methanol as well as profitability
analysis.
4.2 Introduction
Cost estimation for plant design is important as it must present a process that capable of
operating which will yield a profit. Capital cost must be consisting of direct plant expenses and
indirect expenses. The total investment which consist of fixed capital investment and working
capital investment need of a direct cash expense. Thus, in an analysis of cost in industrial
processes, capital-investment cost, manufacturing costs, general expenses including tax must be
taken into consideration. So, the estimate rate of investment can be acknowledged. The Figure
8.1 shows the example of cash position starting from a plant start to be built till its end of project
or shutdown of the plant. For this plant, it is assumed that the construction period is 2 years.
54
Figure 4.1: Graph of cumulative cash position showing effects of cash flow with time for an
industrial operation neglecting time value of money (Peter & Timmerhouse, 1991)
4.3 Supply and Demand
The main purpose of this project is to provide the current methanol demand and supply
in market. It’s also provide an important opportunities for the world market which it can be
categorized into two categories. The first categories is to provide wide range of possible site to
market for the products and also to find the potential target client to market their products. The
second categories is to attract many investors to invest in the plant that is going to build.
There are few countries that produce methanol in the world such as The United States
Of America and China. The demand of methanol is expected to increase as well as for the
55
demand for the world. Methanol is widely consumed by many countries around the world.
Hence, there is no surprising to know many countries that imported methanol for domestic used.
4.3.1 Global Production of Methanol
Recently, methanol has becoming the favorite of the global economy. Methanol is an
important natural-gas-derived chemical feedstock. The three largest derivatives of methanol are
formaldehyde, methyl tertiary butyl ether (MTBE) and acetic acid. However, methanol is seeing
growing demand in fuel applications such as dimethyl ether (DME), biodiesel and the direct
blending into gasoline. The main use for MTBE is an octane booster and oxygenate in gasoline.
Methanol production process is relatively simple and various source of raw material such as
coal, naphtha and natural gas. Methanol has wide range of uses and its downstream products as
many as several hundred. For methanol industry, China is rank first in worldwide production of
methanol. It’s due to rate of development in China always higher compare to any countries in
past few year.
Beside that one of factor in methanol in high production is methanol has also been used
as an “alternative fuel.” In Europe, methanol is used in the production of biodiesel, which can
replace refinery based diesel for use in transportation. Besides that in China, methanol is used
directly as a blending component of gasoline. This is driven by the need to extend the octane
pool in that country, and also due to economic feasibility as high crude oil and gasoline prices
have encouraged the use of less costly methanol. Methanol has also been considered for direct
combustion in combined cycle power generation facilities. There is also significant
commercialization effort underway in two developmental uses for methanol which is fuel cells
and methanol-to-olefins (MTO or GTO – gas to olefins). Fuel cells can utilize the hydrogen
molecules of methanol (as well as other fuels) to create electricity (and water).
In the worldwide, formaldehyde production is largest consumer of methanol with more

than 34% of world methanol demand. The demand is driven by the construction industry since
formaldehyde is used primarily to produce adhesives for the manufactures of various
56
construction board products. Beside that the demand also driven by the expanding use of
engineering board products such as OSB (oriented strand board).
Overall the global production for methanol is currently lead by china with 47.9% in 2013
with their annual production of methanol is 35 million tonnes followed by other countries like
United States of America Russia , Iran, Saudi Arabia and Trinidad. More detail about the global
methanol production and annual production of methanol is shown in Figure 8.2 and Table 8.1.
Figure 4.2: Global Methanol Production in 2013 (Merchant Research & Consulting Ltd, 2014)
57
Table 4.1: Annual Production of Methanol (Methanol Market Services Asia, 2014)
World 65 million tonnes

Europe 2.6 million tonnes
US 2.8 million tonnes
Middle East 14 million tonnes
S E Asia 4.8 million tonnes
China 35 million tonnes
South America 10 million tonnes
4.3.2 Global Demand of Methanol
Methanol has been use as an alternative fuels. In Europe methanol is used in the process
of production of biodiesel, which can replace refinery based diesel for use in transportation. In
China methanol is used directly as blending component of gasoline. It driven by need to extend
the octane pool in that country, and also due to economic feasibility as high crude oil and
gasoline prices have encourage the use of less costly methanol. On top of that, US-based
consultants Jim Jordan & Associates (JJ&A), has stated that China will be remain as a driving
force for global methanol market. The total demand in China was below 3m tonnes/year and
capacity was around 4m tonnes/year in 2001 but currently both supply and demand has risen
five times from what it was in 2001.
During the next five years, the European and North American markets are not expected
to experience any significant increase in demand volume. Yet, a large amount of capacity is
likely to be added in the US, as it has access to cheap and abundant natural gas feedstock. Thus,
methanol demand is expected to grow significantly in next few years. China consumption in this
period will grow at a CAGR (compound annual growth rate) of approx. 20% per year, while
other regions and countries will show more modest growth around 3% per year.
58
China will keep its leading position in methanol industry, with its higher-than-average
demand growth. It will continue to increase production capacity to fulfill this, and is expected
to add 22.17 million tons per year (mmty) of methanol capacity over the next five years. In
Figure 8.3, it shown the methanol demand by major region.
Figure 4.3: Methanol Demand by Major Region (Methanol Market Service Asia, 2014)
4.3.3 Current and Future Price
In methanol plant design, there are some chemical that important in ensuring the cost of
production is at its optimum level. The chemical that use in methanol plant design are the raw
material and the methanol itself. The chemical that use in the production is hydrogen and carbon
monoxide. For hydrogen gas usually it be selling in a cylinder. Currently the price for cylinder
of hydrogen gas is cylinder is 100$ - 300$ (RM 327.720– RM 983.160). In the future, it is
expected that the price of hydrogen gas will not deviate much from the prices nowadays as the
production of hydrogen usually independent and not affected by other industries.
59
Moving on to carbon dioxide, its price is also based on per cylinders where the price is
70$ to 200$ per cylinder (RM 327.720– RM 655.440). The price of carbon monoxide also is
estimated will not differ much from the prices nowadays as the production of carbon monoxide
usually independent and not affected by other industries. However the federal regulatory has
measures combined with state and regional policies will begin to put economic pressure on CO2-
emitting power plants throughout the U.S. by 2020, and that prices will continue to rise through
2040. Therefore, some research suggest to make a policy for bringing down the costs of captured
CO2 and stimulating its potential uses.
Last but not least the most important chemical which is methanol or methyl alcohol, the
standard value of it is around 435$ - 650$ per Metric Ton. This price is based on the production
of methanol per metric ton, excluding tax for deliveries (shipping). According to Methanex
Corp. the demand of methanol will increase more than 10% per year as the usage of methanol
in many household and daily product will cause the price of this chemical to rise.
60
4.4 Major Equipment Cost Estimation
Table 4.2: List of Material and its Price
Estimated Current Price

Categories Types Ringgit
USD ($)
Malaysia(RM)
Carbon dioxide $75/piece
Raw Material RM 314.25/ piece
(alibaba.com,2014) cylinder
Carbon monoxide $100/piece
RM 419.00/ piece
Hydrogen gas $70/ piece
RM 293.30/piece
Methane $120/ piece
RM 502.80/ piece
Water
- RM 47045.735
(5% of PCE)
Utilities
Electricity
- RM 94091.471
(10% of PCE)
Methanol Synthesis
Reactor $ 60 000 RM 251400.00
(alibaba.com,2014)
Topping Column
$ 60 000 RM 251400.00
(alibaba.com,2014)
Refinery Column
$ 60 000 RM251400.00
(alibaba.com,2014)
Labor Cost - - RM 1,097,120.19
Reactor $ 163 009 per
Equipment RM 683,009.00
(alibaba.com,2014) unit x 1
61
Heat Exchanger $ 835 per unit x

RM 28,000.00
(alibaba.com,2014) 8
Steam reformer (High
quality BV NG steam
$500,000 per RM 2,011,725.00
reforming hydrogen
unit x 1
plant)
(www.alibaba.com)
Separator $ 55 719 per
RM 233,463.00
Mixer $ 169 760 per
RM 711,295.00
Vessel $ 1 789 per unit
RM 22,491.00
(alibaba.com,2014) x3
Compressor $69 928 per unit
RM 293,000.00
Pump $ 2073 per unit
RM 34,760.00
Distillation column $ 10000 per unit
RM 125,700.00
(Alibaba.com,2014) x3
4.5 Economical Investment
Chemical plants are built to make profit, and an estimate of the investment required and
the cost of production, are needed before the profitability of a project can be assessed. Since the
net profit equals total income minus all expenses, it is essential to be aware of the various types
of costs associated with each manufacturing step (Peters, 2003). In the economic analysis of a
chemical plant, the costs for the plant are divided into investment cost and operating cost. In the
following section these costs are considered for the methanol plant.
62
4.5.1 Capital Investment
Before an industrial plant can be put into operation, a large sum of money must be
available to purchase and install the required equipment. Land must be obtained, service
facilities must be made available, and plant must be erected complete with all piping, controls
and services. In addition, funds are required to pay the expenses involved in the plant operation
before sales revenue becomes available. The capital needed to supply the required
manufacturing and plant facilities is called the fixed-capital investment, FCI, while that needed
for the operation of the plant is called working capital, WC. The sum of the fixed capital
investment and the working capital is known as the total capital investment, TCI (Peters, 2003).
4.5.1.1 Fixed Capital Investment
Before an industrial plant can be put into operation, a large sum of money must be
available to purchase and install the required equipment. Land must be obtained, service
facilities must be made available, and plant must be erected complete with all piping, controls
and services. In addition, funds are required to pay the expenses involved in the plant operation
before sales revenue becomes available. The capital needed to supply the required
manufacturing and plant facilities is called the fixed-capital investment, FCI, while that needed
for the operation of the plant is called working capital, WC. The sum of the fixed capital
investment and the working capital is known as the total capital investment, TCI (Peters, 2003).
This costing technique relates all costs back to the purchased cost of equipment evaluated
for some base conditions, which is equipment made of carbon steel and operating at ambient
pressure. Deviations from these base conditions are handled by using multiplying factors that
depends on the following:
 The specific equipment type
 The specific system pressure
 The specific materials of construction
63
4.5.1.2 Working Capital
The working capital for an industrial plant consist of the total amount of money invested
in raw materials and supplies carried in stock, finished products in stock and semi-finished
products in the process of being manufactured, account receivable, cash kept on hand for
monthly payment of operating expenses, accounts payable, and taxes payable.
The ratio of working capital to total capital investment varies with different companies,
but most chemical plants use an initial working capital from 10-20 percent of the total capital
investment (Peters, 2003). In our analysis the working capital was estimated to be 9 percent of
the total capital cost. The total capital investment (TCI) is the sum of the fixed capital investment
end the working capital. Table 8.3 presents the estimate of the obtained total investment cost.
64
Table 4.3: Estimation of Fixed and Total Capital Investment Cost
Range Cost (RM)

Direct cost
Onsite
Purchased equipment cost 18.0% 9 874 081.73
Instrumentation and control 6.0% 3 291 360.58
Piping (installed) 11.0% 6 034 161.06
Electrical and material 5.4% 2 962 224.52
(installed)
Offsite
Building 7.0% 3 839 920.67
Yard improvements 1.3% 713 128.12
Service facilities 6.0% 3 291 360.58
Land 2.3% 1 261 688.22
Total 1 31 267 925.48
Indirect cost
Engineering and supervision 8.0% 4 388 480.77
Construction expenses 9.0% 4 937 040.86
Labor cost 2.0% 1 097 120.19
Contingency 9.0% 4 937 040.86
Total 2 15 359 682.68
TOTAL (1 + 2) 46 627 608.16
Working capital 9% FCI 4 937 040.86
Startup cost 6% FCI 3 291 360.58
Total capital investment 100% FCI 54 856 009.60

(TCI)
65
4.6 Profitability Analysis
4.6.1 Manufacturing Cost
Table 4.4: Manufacturing Cost of Summary
Range Cost (RM)

Total Manufacturing
46 627 608.16
Expenses, AME
General Expenses
Administration Cost 5% FCI 2 742 800.48

Distribution & Selling
8% FCI 4 388 480.77
Expenses
Research &
3% FCI 1 645 680.29
Development
Transportation 2% FCI 1 097 120.19
Total General Expenses,
9 874 081.73
AGE
Total Production Cost, APC AME + AGE 56 501 689.89
Depreciation, AD 15% FCI 8 228 401.44

Total Expenses, ATE APC + AD 59 793 050.47
Revenue from sales Quantity x Price 248 952 000.00
66
4.6.2 Revenue from Sales of Methanol
Table 4.5: Total Product Cost
Item Methanol
Quantity in kg 100 000 000
Total price 248 952 000
Annual Profit = Revenue from sales – Total expenses

= RM 248 952 000.00 - RM 59 793 050.47
= RM 189 158 949.50
According to Lembaga Hasil Dalam Negeri (LHDN):
Figure 4.4: Tax Rate of Company in Malaysia 2016
Thus:
The income taxes is at 24 % of total annual profit.
Income Tax = 0.24 x RM 189 158 949.50
= RM 45 398 147.88
67
Therefore,
Net annual profit after deduction of income tax:
= RM 189 158 949.50 – RM 45 398 147.88
= RM 143 760 801.60
Rate of return, ROR is the annual profit to investment, is a simple index of the performance of
the money invested. The life time, N of the project was assumed to be 10 years. This can be
expressed as follows:
𝑁𝑒𝑡 𝑃𝑟𝑜𝑓𝑖𝑡
Rate of return = 𝑥 100%
𝑁 𝑥 𝐹𝑖𝑥𝑒𝑑 𝐶𝑎𝑝𝑖𝑡𝑎𝑙 𝐼𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡
𝑅𝑀 143 760 801.60

= 𝑥 100%
10 𝑥 𝑅𝑀 54 856 009.60
= 14.28 %
The rate of return on the methanol project was calculated to be 14.28 %. The minimum
acceptable rate of return for a new capacity with established market position are suggested to be
somewhere between 8-16% (Peters, 2003). That means that the calculated rate of return are
inside the acceptable limit. This limit corresponds to the rate of earnings that must be achieved
by an investment in order for it to be acceptable for an investor. Since the value of ROR is in
the range that is considered to be among the minimum acceptable, the value might be a bit low.
That corresponds to a somewhat low annual profit for the investment.
4.6.3 Pay-Back Period
Pay-back time is another measure of performance of the capital invested. This

profitability measure the length of the time necessary for the total return to equal the capital
investment. This section is where the year where the companies gain its profit from the
investment. The pay-back time is the times require recovering the original fixed investment from
profit and depreciation. Most recent practice is to base pay-back time on an actual sales
projection. The Table 8.6 and Figure 8.4 shows the profit that company will get year by year.
68
Then, carried out calculation for payback period:

𝑇𝑜𝑡𝑎𝑙 𝐶𝑎𝑝𝑖𝑡𝑎𝑙 𝐼𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡
Payback Period =
𝑁𝑒𝑡 𝑃𝑟𝑜𝑓𝑖𝑡+𝐷𝑒𝑝𝑟𝑒𝑐𝑖𝑎𝑡𝑖𝑜𝑛
𝑅𝑀 54 856 009.60
= 𝑅𝑀 143 760 801.60+𝑅𝑀 8 228 401.44
= 2.7
≈ 3 years
Table 4.6: Pay-back Time
Year Profit (RM)

2016 -111 357 699.50
2017 32 403 102.11
2018 176 163 903.70
2019 319 924 705.30
2020 463 685 506.90
2021 607 446 308.50
2022 751 207 110.10
2023 894 967 911.70
2024 1 038 728 713.00
69
Profit (RM) vs Time
1038728713
894967911.7
751207110.1
607446308.5
463685506.9
319924705.3
176163903.7
32403102.11
2016
-111357699.52017 2018 2019 2020 2021 2022 2023 2024
Profit, RM
Figure 4.5: The Graph of Profit versus Time

70
4.7 Conclusion
All of the basic cost for starting up a plant has been calculated and determined throughout
this chapter. From cost optimization to profit analysis of the plant, all of the factors were taken
into a detailed consideration. The supply and demand for this project were focused on United
States of America and China. With the global demand of Methanol seen to receive broad
attention worldwide, the demand for this material will also increase every year.
While numerous application transform methanol into vital products and commodities
that drive modern life, methanol is also used on its own in a number of applications. Being able
to be used as transportation fuel has made many countries have adopted or are seeking to expand
methanol fueling programs, and it is the fastest growing segment of the methanol marketplace
today. Besides, methanol can be used for electricity generation whereby different companies
were also exploring the use of methanol to drive turbines to create electricity.
There are a number of projects currently underway that are using methanol as the fuel
source to create steam to drive turbines - which is an excellent option for areas rich in resources
other than traditional electricity sources. The price of the raw material used in the production
of methanol such as hydrogen and carbon monoxide were expected will not deviate much from
the prices nowadays as the these material is usually independent and not affected by other
industries. However, another chemical used for this process which is methanol or methyl alcohol
where the prices of it were expected somehow will increase more than 10% per year as the
demand of methanol itself will increase (Methanex Corp.).
The total capital investment (TCI) for this plant is RM54 856 009.60. While for the
profitability analysis, the annual profit of the plant it RM189 158 949.50 with income tax of
24% per year of total annual profit, making the net annual profit after deduction of income tax
is RM143 760 801.60. The rate of return for this project is 14.28% where according to (Peters,
2013) the minimum acceptable rate of return is range between 8-16%. Hence, it can be conclude
71
that the rate of return of this project is considered safe since it is within the said range with the
payback period of 3 years.
72
APPENDIX
A Calculation of Equipment Design
A.1 Methanol Reactor
a) Reactor volume
𝑀𝑜𝑙𝑎𝑟 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒
𝑉𝑜𝑙𝑢𝑚𝑡𝑒𝑟𝑖𝑐 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 =
𝑀𝑜𝑙𝑎𝑟𝑖𝑡𝑦
𝐹𝐴𝑂
𝑉𝑂 =
𝐶𝐴𝑂
𝑌𝐴𝑂 𝑃𝑂
𝐶𝐴𝑂 =
𝑅𝑇𝑂
0.1231(60 𝑎𝑡𝑚)
𝐶𝐴𝑂 =
𝑚3 . 𝑎𝑡𝑚
(8.205 × 10−5 𝑘. 𝑚𝑜𝑙 )(533 𝑘)
𝑚𝑜𝑙
𝐶𝐴𝑂 = 168.88983 3
𝑚
𝐹𝐴 = 𝐹𝐴𝑂 (1 − 𝑋)
𝑘𝑚𝑜𝑙
𝐹𝐴𝑂 = 426.3569
ℎ𝑟
𝐹𝐴𝑂
𝑉𝑂 =
𝐶𝐴𝑂
𝑚𝑜𝑙
426356.9
𝑉𝑂 = ℎ𝑟
𝑚𝑜𝑙
168.88983 3
𝑚
𝑚3
𝑉𝑂 = 2524.46758
ℎ𝑟
Residence time (τ) used is 20 second,
𝑉 = 𝑉𝑂 × 𝜏
73
𝑚3 1ℎ𝑟
𝑉 = 2524.46758 × 20𝑠 ×
ℎ𝑟 3600𝑠
𝑉 = 14.02𝑚3
Volume reactor without catalyst bed= 14.02𝑚3
b) Volume of catalyst bed
1
𝑉𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 = 𝑉
3 𝑟𝑒𝑎𝑐𝑡𝑜𝑟,𝑡𝑜𝑡𝑎𝑙
1
𝑉𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 = (21.03𝑚3 )
3
𝑉𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 = 7.01𝑚3
c) Total of volume reactor with catalyst bed
1
3 𝑟𝑒𝑎𝑐𝑡𝑜𝑟
𝑉𝑟𝑒𝑎𝑐𝑡𝑜𝑟,𝑡𝑜𝑡𝑎𝑙 = 𝑉𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 + 𝑉𝑟𝑒𝑎𝑐𝑡𝑜𝑟
1
𝑉𝑟𝑒𝑎𝑐𝑡𝑜𝑟,𝑡𝑜𝑡𝑎𝑙 = 𝑉 + 𝑉𝑟𝑒𝑎𝑐𝑡𝑜𝑟
1
𝑉𝑟𝑒𝑎𝑐𝑡𝑜𝑟,𝑡𝑜𝑡𝑎𝑙 (1 − ) = 𝑉𝑟𝑒𝑎𝑐𝑡𝑜𝑟
3
𝑉𝑟𝑒𝑎𝑐𝑡𝑜𝑟,𝑡𝑜𝑡𝑎𝑙 =
1
(1 − 3)
2
(3)
14.02𝑚3
2
(3)
𝑉𝑟𝑒𝑎𝑐𝑡𝑜𝑟,𝑡𝑜𝑡𝑎𝑙 = 21.03𝑚3
74
d) Diameter of reactor
Assumption,
Diameter to length ratio (D:L) is (1:4), hence 𝐿 = 4𝐷
𝜋𝐷 2 𝐿
𝑉=
4
Substitute 𝐿 = 4𝐷 into 𝑉𝑟𝑒𝑎𝑐𝑡𝑜𝑟,𝑡𝑜𝑡𝑎𝑙
𝜋𝐷 2 𝐿
𝑉𝑟𝑒𝑎𝑐𝑡𝑜𝑟,𝑡𝑜𝑡𝑎𝑙 = × 4𝐷
4
𝑉𝑟𝑒𝑎𝑐𝑡𝑜𝑟,𝑡𝑜𝑡𝑎𝑙 = 𝜋𝐷 3
Rearrange the equation,
3 𝑉
𝐷=√
𝜋
3 21.03𝑚3
𝐷=√
𝜋
𝐷 = 1.885𝑚
e) Length of reactor
𝐿 = 4𝐷
𝐿 = 4(1.885𝑚)
𝐿 = 7.54𝑚
f) Reactor dome closure
The reactor has a top and bottom head closure, the choice of head closure used
in this design is the hemispherical type. These have been chosen as they can withstand
very high pressure, and since the reactor design pressure will be higher than the
operating pressure, it is viable to use this type of head closure.
75
The dimensions of hemispheres are very simple, since it is half of a circle; the
radius from the center of the circle to all edges of the hemisphere will be the same. The reactor
diameter was calculated earlier to be 1.885 meters; hence the radius of the hemisphere
will be 0.9425 meters. The dimension of the hemispherical head closure is shown below
accordingly.
2 3
𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 ℎ𝑒𝑚𝑖𝑠𝑝ℎ𝑒𝑟𝑒 = 𝜋𝑟
3
𝑟 = 0.9425𝑚
2
𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 ℎ𝑒𝑚𝑖𝑠𝑝ℎ𝑒𝑟𝑒 ℎ𝑒𝑎𝑑 𝑐𝑙𝑜𝑠𝑢𝑟𝑒 = 𝜋0.94253
3
𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 ℎ𝑒𝑚𝑖𝑠𝑝ℎ𝑒𝑟𝑒 = 1.75349𝑚3
There are 2 closures (top and bottom) so total volume of closures= 1.75349𝑚3 × 2 =
3.50698𝑚3
The total volume of reactor = volume of the cylindrical section + volume of dome
closure = 21.03𝑚3 + 3.50698𝑚3 = 24.53698𝑚3
𝐿𝑒𝑛𝑡𝑔ℎ 𝑜𝑓 𝑐𝑦𝑙𝑖𝑛𝑑𝑟𝑖𝑐𝑎𝑙 𝑠𝑒𝑐𝑡𝑖𝑜𝑛 = 7.54𝑚
𝐿𝑒𝑛𝑡𝑔ℎ 𝑜𝑓 ℎ𝑒𝑚𝑖𝑠𝑝ℎ𝑒𝑟𝑖𝑐𝑎𝑙 ℎ𝑒𝑎𝑑 = 0.9425𝑚 + 0.9425𝑚 = 1.885𝑚
Total length of reactor = length of cylindrical section + length of hemispherical head
closures = 7.54𝑚 + 1.885𝑚 = 9.425𝑚
g) Number of tube
assumed as well as the length of the tube and not based on the previous reactor calculation.
Based on the Steel Pipes Dimensions - ANSI Schedule 40:
(Source: http://www.engineeringtoolbox.com/ansi-steel-pipes-d_305.html)
76
𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑡𝑢𝑏𝑒 = 𝜋𝑟 2 ℎ
𝑉𝑡 = 𝜋(0.036576𝑚)2 (18𝑚)
𝑉𝑡 = 0.07565𝑚3
From previous calculation, 𝑉𝑟 = 21.03𝑚3
𝑁𝑡 =
21.03𝑚3
𝑁𝑡 =
0.07565𝑚3
𝑁𝑡 = 277.986 = 278 𝑡𝑢𝑏𝑒
h) Baffle spacing
The range of baffle spacing used is around 0.2 to 1.0. The minimum spacing usually
0.3 0.5 times the shell diameter. The calculation is begin with taking 0.4 as the baffle spacing
value.
𝐵𝑆 = 0.4𝐷
𝐵𝑆 = 0.4(1.885𝑚)
𝐵𝑆 = 0.754𝑚
i) Number of baffle
Baffle is a plate or mechanical device designed to restrain or regulate the flow of a

fluid,
𝐿
𝑁𝐵 = −1
𝐵𝑆
7.54𝑚
𝑁𝐵 = −1
0.754𝑚
77
𝑁𝐵 = 10
Therefore, the number of baffle = 10
j) Heat transfer to vessel
From the material balance calculated, the Q obtain is negative and it shows that the
reaction is exothermic. In term of cooling process, the amount of water is needed to maintain
the temperature of the reaction and absorb the excess heat produce during the reaction occur. To
determine the amount of water needed for cooling, the formula used is:
𝑄 = −52334.27𝑘𝑤
𝑄 = ṁ𝐶𝑝 𝑑𝑇
𝑄
ṁ=
𝐶𝑝 𝑑𝑇
52334.27𝑘𝑤
ṁ=
𝑘𝐽
1.855 𝑘𝑔. 𝑘 (533𝑘)
𝑘𝑔
ṁ = 52.93160
𝑠
k) Overall heat transfer coefficient
𝑄 = 𝑈𝐴∆𝑇𝑚
𝑄
𝑈=
𝐴𝑇𝑚
Where,
𝑄 = 𝐻𝑒𝑎𝑡 𝑏𝑎𝑙𝑎𝑛𝑐𝑒
𝑈 = 𝑂𝑣𝑒𝑟𝑎𝑙𝑙 ℎ𝑒𝑎𝑡 𝑡𝑟𝑎𝑛𝑠𝑓𝑒𝑟 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡
𝐴 = 𝑇𝑜𝑡𝑎𝑙 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑡𝑢𝑏𝑒
∆𝑇𝑚 = 𝐿𝑜𝑔 𝑚𝑒𝑎𝑛
∆𝑇𝑚 =?
78
(𝑇1 − 𝑡2 ) − (𝑇2 − 𝑡1 )
∆𝑇𝑚 =
(𝑇 − 𝑡2 )
ln 1
(𝑇2 − 𝑡1 )
(533𝑘 − 303𝑘 ) − (533𝑘 − 333𝑘)
∆𝑇𝑚 =
(533𝑘 − 303𝑘 )
ln
(533𝑘 − 333𝑘)
30𝑘
∆𝑇𝑚 =
0.13976
∆𝑇𝑚 = 214.65071𝑘
𝑄 =?
𝑄 = 52334.27𝑘𝑤
𝐴 =?
𝐴 = 𝐴𝑟𝑒𝑎 𝑜𝑓 𝑡𝑢𝑏𝑒(𝐴𝑡 ) × 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑡𝑢𝑏𝑒(𝑁𝑡 )
𝐴𝑟𝑒𝑎 𝑜𝑓 𝑡𝑢𝑏𝑒, 𝐴𝑡 = 𝜋 × 𝐷 × 𝐿
𝐴𝑡 = 𝜋 × 0.073152𝑚 × 18𝑚
𝐴𝑡 = 4.13665𝑚3
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑡𝑢𝑏𝑒, 𝑁𝑡 = 278 𝑡𝑢𝑏𝑒
Therefore,
𝐴 = 4.13665𝑚3 × 278 𝑡𝑢𝑏𝑒
𝐴 = 1149.9887𝑚2
𝑈 =?
𝑄
𝑈=
𝐴𝑇𝑚
52334270𝑤
𝑈=
1149.9887𝑚2 (214.65071𝑘)
𝑤
𝑈 = 188.32350 2
𝑚 .𝑘
79
l) Tube pitch
From Chemical Engineering, Volume 6, Fourth edition Chemical Engineering Design

by R. K. Sinnott, the recommended tube pitch (distance between tube centers) is 1.25 times the
tube outside diameter:
𝑇𝑢𝑏𝑒 𝑝𝑖𝑡𝑐ℎ (𝑃𝑡 ) = 1.25 × 𝑡𝑢𝑏𝑒 𝑜𝑢𝑡𝑠𝑖𝑑𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟
𝑃𝑡 = 1.25 × 0.073152
𝑃𝑡 = 0.09144𝑚
A.2 Steam Reformer
a) Volume of steam reformer
𝑀𝑜𝑙𝑎𝑟 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒
𝑉𝑜𝑙𝑢𝑚𝑡𝑒𝑟𝑖𝑐 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 =
𝑀𝑜𝑙𝑎𝑟𝑖𝑡𝑦
𝐹𝐴𝑂
𝑉𝑂 =
𝐶𝐴𝑂
𝑌𝐴𝑂 𝑃𝑂
𝐶𝐴𝑂 =
𝑅𝑇𝑂
0.785(80 𝑎𝑡𝑚)
𝐶𝐴𝑂 =
𝑚3 . 𝑎𝑡𝑚
(8.205 × 10−5 )(1133 𝑘)
𝑘. 𝑚𝑜𝑙
𝑚𝑜𝑙
𝐶𝐴𝑂 = 675.54012 3
𝑚
𝐹𝐴 = 𝐹𝐴𝑂 (1 − 𝑋)
𝑘𝑚𝑜𝑙
𝐹𝐴𝑂 = 2718.8475
ℎ𝑟
𝐹𝐴𝑂
𝑉𝑂 =
𝐶𝐴𝑂
𝑚𝑜𝑙
2718847.5
𝑉𝑂 = ℎ𝑟
𝑚𝑜𝑙
675.54012 3
𝑚
80
𝑚3
𝑉𝑂 = 4024.70189
ℎ𝑟
Residence time (τ) used is 20 second,
𝑉 = 𝑉𝑂 × 𝜏
𝑚3 1ℎ𝑟
𝑉 = 4024.70189 × 20𝑠 ×
ℎ𝑟 3600𝑠
𝑉 = 22.35945𝑚3
Volume of steam reformer without catalyst bed= 22.35945𝑚3
b) Volume of catalyst bed
1
1
𝑉𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 = (33.53918𝑚3 )
3
𝑉𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 = 11.17973𝑚3
c) Total of volume steam reformer with catalyst bed
1
3 𝑟𝑒𝑎𝑐𝑡𝑜𝑟
𝑉𝑟𝑒𝑎𝑐𝑡𝑜𝑟,𝑡𝑜𝑡𝑎𝑙 = 𝑉𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 + 𝑉𝑟𝑒𝑎𝑐𝑡𝑜𝑟
1
𝑉𝑟𝑒𝑎𝑐𝑡𝑜𝑟,𝑡𝑜𝑡𝑎𝑙 = 𝑉 + 𝑉𝑟𝑒𝑎𝑐𝑡𝑜𝑟
1
𝑉𝑟𝑒𝑎𝑐𝑡𝑜𝑟,𝑡𝑜𝑡𝑎𝑙 (1 − ) = 𝑉𝑟𝑒𝑎𝑐𝑡𝑜𝑟
3
1
(1 − 3)
2
(3)
81
22.35945𝑚3
2
(3)
𝑉𝑟𝑒𝑎𝑐𝑡𝑜𝑟,𝑡𝑜𝑡𝑎𝑙 = 33.53918𝑚3
d) Diameter of steam reformer
Assumption,
Diameter to length ratio (D:L) is (1:4), hence 𝐿 = 4𝐷
𝜋𝐷 2 𝐿
𝑉=
4
Substitute 𝐿 = 4𝐷 into 𝑉𝑟𝑒𝑎𝑐𝑡𝑜𝑟,𝑡𝑜𝑡𝑎𝑙
𝜋𝐷 2 𝐿
𝑉𝑟𝑒𝑎𝑐𝑡𝑜𝑟,𝑡𝑜𝑡𝑎𝑙 = × 4𝐷
4
𝑉𝑟𝑒𝑎𝑐𝑡𝑜𝑟,𝑡𝑜𝑡𝑎𝑙 = 𝜋𝐷 3
Rearrange the equation,
3 𝑉
𝐷=√
𝜋
3 33.53918𝑚3
𝐷=√
𝜋
𝐷 = 2.20176𝑚
e) Length of steam reformer
𝐿 = 4𝐷
𝐿 = 4(2.20176𝑚)
𝐿 = 8.80704𝑚
82
f) Number of tube
assumed as well as the length of the tube and not based on the previous reactor calculation.
Based on the Steel Pipes Dimensions - ANSI Schedule 40, the nominal size of tube used in
industry:
 Inner diameter= 0.102362𝑚
(Source: http://www.owlnet.rice.edu/~ceng403/nh3ref97.html)
𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑡𝑢𝑏𝑒 = 𝜋𝑟 2 ℎ
𝑉𝑡 = 𝜋(0.05715𝑚)2 (18𝑚)
𝑉𝑡 = 0.18469𝑚3
From previous calculation, 𝑉𝑟 = 33.53918𝑚3
𝑉𝑠𝑡𝑒𝑎𝑚 𝑟𝑒𝑓𝑜𝑟𝑚𝑒𝑟
𝑁𝑡 =
33.53918𝑚3
𝑁𝑡 =
0.18469𝑚3
𝑁𝑡 = 181.59716 = 182 𝑡𝑢𝑏𝑒
g) Heat flux (𝒒𝒂𝒗𝒈 )
Reaction in steam reformer is endothermic where it shows that heat is supplied to the
steam reformer. When heat is supplied, calculation of rate of heat pass through a surface area
is needed:
𝑄 = 𝑁𝑡 . 𝐴. 𝑞𝑎𝑣𝑔
𝑄 = 𝑁𝑡 . 𝜋. 𝐼𝐷. 𝐿. 𝑞𝑎𝑣𝑔
Where,
83
𝑄 = 𝐻𝑒𝑎𝑡 𝑏𝑎𝑙𝑎𝑛𝑐𝑒
𝑁𝑡 = 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑡𝑢𝑏𝑒
𝐼𝐷 = 𝐼𝑛𝑛𝑒𝑟 𝑑𝑖𝑎𝑚𝑡𝑒𝑟 𝑜𝑓 𝑡𝑢𝑏𝑒
𝐿 = 𝐿𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑡𝑢𝑏𝑒
𝑞𝑎𝑣𝑔 = 𝐻𝑒𝑎𝑡 𝑓𝑙𝑢𝑥
𝐴 = 𝐴𝑟𝑒𝑎 𝑜𝑓 𝑖𝑛𝑛𝑒𝑟 𝑡𝑢𝑏𝑒
𝑄
𝑞𝑎𝑣𝑔 =
𝑁𝑡 . 𝜋. 𝐼𝐷. 𝐿
20363690 𝑊
𝑞𝑎𝑣𝑔 =
182. 𝜋. 0.102362𝑚. 18𝑚
𝑊
𝑞𝑎𝑣𝑔 = 19329.64814 2
𝑚
A.3 Flash Drum
Assumption: Diameter = 1.5 m (Refer to Wankat)

a) Height of the tank
ℎ𝑡𝑜𝑡𝑎𝑙
=4
𝐷
ℎ𝑡𝑜𝑡𝑎𝑙 = 4(1.5𝑚)
= 6.0𝑚
b) Height related to velocity
1
ℎ𝑣 = 36 𝑖𝑛𝑐ℎ + (𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟𝑓𝑒𝑒𝑑𝑙𝑖𝑛𝑒)
2
1
= 36 𝑖𝑛𝑐ℎ + (48.0315 𝑖𝑛𝑐ℎ)
2
= 60.02 𝑖𝑛𝑐ℎ
= 1.525 𝑚
84
c) Height related to flooding level
1
ℎ𝑓 = 12 𝑖𝑛𝑐ℎ + (𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟𝑓𝑒𝑒𝑑𝑙𝑖𝑛𝑒)
2
1
= 12 𝑖𝑛𝑐ℎ + (48.0315 𝑖𝑛𝑐ℎ)
2
= 36.016 𝑖𝑛𝑐ℎ
= 0.91 𝑚
d) Height related to liquid level control
ℎ𝑡𝑜𝑡𝑎𝑙 = ℎ𝑣 + ℎ𝑓 + ℎ𝑙
ℎ𝑙 = ℎ𝑡𝑜𝑡𝑎𝑙 − ℎ𝑣 − ℎ𝑓
= 6.0m - 1.525m - 0.91m
ℎ𝑙 = 3.565 m
e) Volume of flash drum
𝐿
𝑉 = 𝜋𝐷 2
4
6.0 𝑚
= 𝜋(1.5𝑚)2
4
= 10.780 𝑚3
f) Shell thickness
Diameter = 1.5 m
= 4.92 ft.
1
Wall Thickness = (4.92 𝑓𝑡)
4
= 1.23 inch
85
= 31.242 mm
Overall thickness = Wall Thickness + Corrosion allowance
= 31.242 mm + 3.2 mm
= 34.442 mm
A.4 Distillation Column 1
Enriching section
1) Tray spacing, 𝑡𝑠 = 500 𝑚𝑚
2) Hole diameter, 𝑑ℎ = 5.0 𝑚𝑚
3) Pitch, 𝐼𝑝 = 3𝑑ℎ = 3 × 5 = 15.0 𝑚𝑚
4) Tray thickness, 𝑡𝑇 = 0.6 , 𝑑ℎ = 3.0 𝑚𝑚
𝐴𝑟𝑒𝑎 𝑜𝑓 ℎ𝑜𝑙𝑒 𝐴
5) = 𝐴ℎ = 0.10
𝐴𝑟𝑒𝑎 𝑜𝑓 𝑝𝑖𝑡𝑐ℎ 𝑝
𝐿 𝜌𝑔 0.5
6) Plate diameter, 𝐷𝑐 = (𝐺 ) (𝜌 ) = 0.0286 , 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑎𝑡 𝑏𝑜𝑡𝑡𝑜𝑚
𝐿
∴ Flooding check at bottom

𝐶𝑠𝑏,𝑓𝑙𝑜𝑜𝑑 = 0.29 𝑓𝑡/𝑠
𝐶𝑠𝑏,𝑓𝑙𝑜𝑜𝑑 = 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 𝑝𝑎𝑟𝑎𝑚𝑒𝑡𝑒𝑟, 𝑓𝑡/𝑠
𝑓𝑡 𝑚
𝑈𝑛𝑓 = 𝐺𝑎𝑠 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑡ℎ𝑟𝑜𝑢𝑔ℎ 𝑛𝑒𝑡 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑓𝑙𝑜𝑜𝑑, 𝑜𝑟
𝑠 𝑠
0.5
20 0.2 𝜌𝑔
𝐶𝑠𝑏,𝑓𝑙𝑜𝑜𝑑 = 𝑈𝑛𝑓 ( ) ( )
𝜎 𝜌𝐿 − 𝜌𝑔
0.5
𝜎 0.2 𝜌𝐿 − 𝜌𝑔 𝑓𝑡 𝑚
𝑈𝑛𝑓 = 𝐶𝑠𝑏,𝑓𝑙𝑜𝑜𝑑 ( ) ( ) = 5.4594 = 1.664
20 𝜌𝑔 𝑠 𝑠
86
Consider, 80% flooding

𝑈𝑛 = 0.8𝑈𝑛𝑓 = 1.3312 𝑚/𝑠
𝑈𝑛 = 𝐺𝑎𝑠 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦
15 977.70304 𝑘𝑔
ℎ𝑟 𝑚3
Volumetric flow rate of vapor = 𝑘𝑔 = 2.0891
3600 𝑠 × 2.1245 𝑚 3
𝑠
𝑉𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 𝑜𝑓 𝑣𝑎𝑝𝑜𝑟 2.0891
Net area, 𝐴𝑛 = = = 1.5693 𝑚2
𝑈𝑛 1.3312
𝐿𝑤
Let = 0.75
𝐷𝑐
𝐿𝑤 = Weir Length
𝐷𝑐 = Column Diameter
𝜋
Area of column, 𝐴𝑐 = 4 𝐷𝑐2 = 0.785𝐷𝑐2
𝜃𝑐 𝐿𝑤 𝐷𝑐
𝑆𝑖𝑛 ( ) = ( ) ( ) = 0.75
2 2 2
𝜃𝑐 = 97.2°
𝜋 𝜃 𝐿𝑤 𝐷𝑐 𝜃𝑐
Area of down corner, 𝐴𝑑 = ( 4 . 𝐷𝑐2 . 360
𝑐
− . . 𝑐)
2 2
= 0.0882𝐷𝑐2
𝐴𝑛 = 𝐴𝑐 − 𝐴 𝑑
1.5693 = 0.785𝐷𝑐2 − 0.0882𝐷𝑐2
𝐷𝑐 = 1.5007 𝑚
𝐷𝑐 ≅ 1.5 𝑚
∴ 𝐴𝑑 = 0.0882 × 1.52 = 0.19845𝑚2
𝜋
𝐴𝑐 = × 1.52 = 1.7671 𝑚2
4
𝐴𝑛 = 𝐴𝑐 − 𝐴𝑑 = 1.7671 − 0.19845 = 1.56865 𝑚2
Active area, 𝐴𝑎 = 𝐴𝑐 − 2𝐴𝑑 = 1.7671 − 2(0.19845) = 1.3702 𝑚2
𝐿𝑤 1.2
= = 0.8
𝐷𝑐 1.5
𝐿𝑊 = 0.75𝐷𝐶
𝐿𝑊 = 1.125 𝑚
𝐿𝑊 ≅ 1.2 𝑚
87
∴ 𝜃𝑐 = 106.26°
𝐴𝑐𝑧 = 2(50𝑚𝑚) × 𝐿𝑤 = 2 × (50 × 10−3 ) × 1.2 = 0.12 𝑚2
𝐴𝑐𝑧 0.12
= = 0.0679
𝐴𝑐 1.7671
𝐴𝑐𝑧 = 6.79 %. 𝐴𝑐
𝛼 = 𝜋 − 𝜃𝐶 = 180 − 106.26 = 73.74°
𝐴𝑤𝑧 is the waste zones area.
𝜋 𝛼 𝜋 𝛼
𝐴𝑤𝑧 = 2 ( . 𝐷𝑐2 − . (𝐷𝑐 − 0.06)2 . ) = 0.0568 𝑚2
4 360 4 360
𝐴𝑤𝑧 0.0568
= = 0.0321
𝐴𝑐 1.7671
𝐴𝑤𝑧 = 3.21 %. 𝐴𝑐
𝐴𝑝 = Area of perforation
𝐴𝑝 = 𝐴𝑐 − 2𝐴𝑑 − 𝐴𝑐𝑧 − 𝐴𝑤𝑧
= 1.7671 − 2(0.19845) − 0.12 − 0.0568
= 1.1934 𝑚2
7) 𝐴ℎ = Area of holes
𝐴ℎ = 0.1𝐴𝑝 = 0.11934 𝑚2
𝑛ℎ = Number of holes
4×0.11934
𝑛ℎ = 𝜋×(5×10−3)2 = 6078
8) ℎ𝑤 = 𝑤𝑒𝑖𝑟 ℎ𝑒𝑖𝑔ℎ𝑡 = 50 𝑚𝑚
9) Weeping check: Sieve tray

a) Ref:1, pg: 18-9, eq:18-6
𝜌𝑔 2
ℎ𝑑 = 𝐾1 + 𝐾2 ( )𝑈
𝜌𝐿 ℎ
𝐾1 = 0, for sieve tray
𝑈ℎ = Linear gas velocity through holes
88
ℎ𝑑 = Pressure drop across dry hole (mm liquid)

50.8
𝐾2 =
𝐶𝑣2
𝐶𝑣 = Discharge co − efficient
𝐴ℎ
For = 0.0893
𝐴𝑎
𝑡𝑇
= 0.6
𝑑ℎ
𝐶𝑣 = 0.74
50.8
∴ 𝐾2 = = 92.77
0.742
15 977.70304
𝑈ℎ,𝑡𝑜𝑝 = = 15.54 𝑚/𝑠 (𝑚𝑖𝑛𝑖𝑚𝑢𝑚)
2.394 × 3600 × 0.11934
2.394
ℎ𝑑 = 0 + 92.77 ( ) (15.542 ) = 72.97 𝑚𝑚 𝑜𝑓 𝑐𝑙𝑒𝑎𝑟 𝑙𝑖𝑞𝑢𝑖𝑑
735
15 977.70304
𝑈ℎ,𝑏𝑜𝑡𝑡𝑜𝑚 = = 20.05 𝑚/𝑠 (𝑚𝑎𝑥𝑖𝑚𝑢𝑚)
1.855 × 3600 × 0.11934
1.855
ℎ𝑑 = 0 + 92.77 ( ) (20.052 ) = 92.73 𝑚𝑚 𝑜𝑓 𝑐𝑙𝑒𝑎𝑟 𝑙𝑖𝑞𝑢𝑖𝑑
746
𝜎
b) ℎ𝜎 = 409 ( )
𝜌𝐿 𝑑ℎ
ℎ𝜎 = Head loss due to the bubble formation

21
ℎ𝜎 = 409 ( ) = 2.1077 𝑚𝑚 𝑜𝑓 𝑐𝑙𝑒𝑎𝑟 𝑙𝑖𝑞𝑢𝑖𝑑
815 × 5
2
𝑞 3
c) ℎ𝑜𝑤 = 𝐹𝑤 664 ( )
𝐿𝑤
ℎ𝑜𝑤 = Height of crest over weir

𝐹𝑤 = weir constriction correction factor
𝐿
𝑞 = 𝜌𝑡 = 𝑚3 /𝑠 = liquid flow per serration
𝐿
8 006.388
𝑞= = 3.0258 × 10−3 𝑚3 /𝑠
735 × 3600
89
𝑞1
= 1.5789 (Ref. ? , pg: 18 − 11, fig: 18 − 16)
(𝐿𝑤 )2.5
𝐿𝑤
= 0.8
𝐷𝑐
𝐹𝑤 = 1.02
2⁄
3.0258 × 10−3 3
ℎ𝑜𝑤 = 1.02(664) ( ) = 12.55 𝑚𝑚 of clear liquid
1.2
ℎ𝑑 + ℎ𝜎 = 72.97 + 2.1077 = 75.0777 𝑚𝑚
ℎ𝑤 + ℎ𝑜𝑤 = 50 + 12.55 = 62.55 𝑚𝑚
𝐴ℎ
For = 0.0893 & ℎ𝑤 + ℎ𝑜𝑤 = 62.55 𝑚𝑚,
𝐴𝑎
(Ref: ? , pg: 18 − 7, fig: 18 − 11)
ℎ𝑑 + ℎ𝜎 = 16 𝑚𝑚 < 75.0777 𝑚𝑚
Since design value is greater than the required, weeping will not occur.
10) Flooding check

Since the maximum flow rate is at the bottom,
flooding is checked at the bottom.
ℎℎ𝑔
ℎ𝑑𝑠 = ℎ𝑤 + ℎ𝑜𝑤 + (For Sieve trays)
2
ℎℎ𝑔 = Liquid gradient across plate (mm liquid) (Neglected)
(ℎ𝑜𝑤 )𝑏𝑜𝑡𝑡𝑜𝑚 = 12.42 𝑚𝑚
ℎ𝑑𝑠 = Calculated height of clear liquid over the dispersers.
ℎ𝑑𝑠 = 50 + 12.42 = 62.42 𝑚𝑚
𝑈𝑎 = Linear gas velocity through active area.
15 977.70304 𝑓𝑡
𝑈𝑎 = = 1.353
3600 × 2.394 × 1.3702 𝑠
1 1 1
𝐹𝑔𝑎 = 𝑈𝑎 (𝜌𝑔 )2 = 1.353 (2.394)2 = 2.0934 (𝑚⁄𝑠)(𝑘𝑔⁄𝑚3 )2
= 1.7163 (𝑓𝑡⁄𝑠)(𝑙𝑏⁄𝑓𝑡 3 )0.5
(Ref: ? , pg: 18 − 10, fig: 18 − 15)
90
Aeration factor (𝛽) = 0.58

Relative froth density (∅𝑡 ) = 0.20
ℎ11 = 𝛽ℎ𝑑𝑠 = 0.58 × 62.42 = 36.2036 𝑚𝑚
ℎ11 36.20
ℎ𝑓 = = = 181 𝑚𝑚
∅𝑡 0.20
𝑞𝑏 2
ℎ𝑑𝑎 = 165.2 ( ) (Ref. 1, Pg: 18 − 10, eq: 18 − 14)
𝐴𝑑𝑎
ℎ𝑑𝑎 = Head loss under the downcomer.
𝐴𝑑𝑎 = Minimum area of flow under the downcomes apron.
ℎ𝑎𝑝 = ℎ𝑑𝑠 − 𝑐 = 62.42 − 25.4 = 37.02 𝑚𝑚
𝐴𝑑𝑎 = 𝐿𝑤 × ℎ𝑎𝑝 = 1.2 × (37.02 × 10−3 ) = 0.0444 𝑚2
𝐿𝑏 8 006.388
𝑞𝑏 = = = 2.9812 × 10−3 𝑚3 /𝑠
𝜌𝐿 746 × 3600
2
2.9812 × 10−3
ℎ𝑑𝑎 = 165.2 ( ) = 0.75 𝑚𝑚
0.0444
ℎ𝑡 = Total head lossacross the plate.
ℎ𝑡 = ℎ𝑑 + ℎ11 = 92.73 + 36.2036 = 128.9336 𝑚𝑚
ℎ𝑑𝑐 = ℎ𝑡 + ℎ𝑤 + ℎ𝑜𝑤 + ℎℎ𝑔 + ℎ𝑑𝑎 (Ref: 1, eg: 18 − 3, pg: 18 − 7
= 128.9336 + 50 + 12.42 + 0 + 0.75
= 192.1036 𝑚𝑚
Taking (∅𝑑𝑐 ) average = 0.50 ; ∅𝑑𝑐 = Relative froth density &
ℎ1𝑑𝑐 = Actual back − up
192.1036
ℎ1𝑑𝑐 = = 384.2072 𝑚𝑚 < 500 𝑚𝑚
0.5
Hence flooding will not occur.
11) Column Efficiency: average conditions

0.5 +105𝑤
0.776+0.00457ℎ𝑤 −0.238𝑈𝑎 𝜌𝑔
a) 𝑁𝑔 = 0.5 (Ref: 1, pg: 18 − 15)
(𝑁𝑠𝑐,𝑔 )
𝑁𝑔 = Gas phase transfer unit

91
𝜇𝑔 0.0088 × 10−3
𝑁𝑠𝑐,𝑔 = = = 0.7966
𝜌𝑔 𝐷𝑔 2.1245 × (5.2 × 10−6 )
𝑁𝑠𝑐,𝑔 = Gas phase schmidt number

15 977.70304
𝑈𝑎 = = 1.5247 𝑚/𝑠
3600 × 2.1245 × 1.3702
𝐿𝑤 + 𝐷𝑐 1.2 + 1.5
𝐷𝑓 = = = 1.35 𝑚
2 2
𝑚3
𝐷𝑓 = Width of flow rate ( )
𝑠𝑚
𝑞
𝑊=
𝐷𝑓
8 006.388
𝑞= = 3.0034 × 10−3 𝑚3 /𝑠
740.5 × 3600
3.0034 × 10−3 𝑚3
𝑊= = 2.2247 × 10−3
1.35 𝑚. 𝑠
𝑁𝑔
0.776 + 0.00457(50) − 0.238(1.5247)(2.1245)0.5 + 105(2.2247 × 10−3 )
=
(0.7966)0.5
= 0.7946
b) 𝑁𝐿 = 𝐾𝐿𝑎 𝑄𝐿 (Ref: 1, pg: 18 − 15, eq: 18 − 36)

𝑁𝐿 = Liquid phase transfer units
𝐾𝐿𝑎 = Liquid phase trasnfer coefficient (𝑚⁄𝑠)
𝑄𝐿 = Residence time of liquid in frotn or spray zone
(𝐷𝐿 )𝑎𝑣𝑒𝑟𝑎𝑔𝑒 = 6.9549 × 10−9 𝑚2 ⁄𝑠
𝐾𝐿𝑎 = (𝐷𝐿 )0.5(0.40𝑈𝑎 𝜌𝑔 0.5 + 0.17) (Ref: 1, pg: 18 − 16, eg: 18 − 40(a))
𝐾𝐿𝑎 = (3.875 × 108 × 6.9549 × 10−9 )0.5(0.40 × 1.5247 × 2.12450.5
+ 0.17)
= 1.7384 𝑚/𝑠
ℎ𝐿 𝐴𝑎
𝑄𝐿 = (Ref: 1, pg: 18 − 16, eq: 18 − 39)
1000𝑞𝑏
92
37.26 × 1.3702
𝑄𝐿 = = 17.13 𝑠
1000 × (2.9812 × 10−3 )
𝑁𝐿 = 1.6759 × 17.13 = 28.71
𝑚𝑡𝑜𝑝 = 0.425
𝑚𝑏𝑜𝑡𝑡𝑜𝑚 = 0.625
𝐺𝑚 768.1588
= = 1.9956
𝐿𝑚 384.9225
𝐺𝑚
𝜆𝑡 = 𝑚𝑡𝑜𝑝 ( ) = 0.848
𝐿𝑚
𝐺𝑚
𝜆𝑏 = 𝑚𝑏𝑜𝑡𝑡𝑜𝑚 ( ) = 1.2473
𝐿𝑚
̅̅̅̅̅̅
𝜆𝑎𝑣𝑔 = 1.0476
𝜆 = Stripping factor
1
𝑁𝑜𝑔 = (Ref: 1, pg: 18 − 15, eq: 18 − 34)
1 𝜆
𝑁𝑔 + 𝑁𝐿
1
= = 0.7721
1 1.0476
+
0.7946 28.54
−(𝑁)
𝐸𝑂𝐺 = 1 − 𝑒𝑜𝑔 (Ref: 1, pg: 18 − 15, eq: 18 − 33)
𝐸𝑂𝐺 = 1 − 𝑒 −0.7721 = 0.58
c) Murphee plate efficiency: Emv

𝑍1 2
𝑁𝑝𝑒 =
𝐷𝐸 𝑄𝐿
𝑍1 = Length of liquid travel, m
= 𝐷𝑐 cos(𝜃𝐶 ⁄2) = 1.5 cos(106.26⁄2) = 0.9 𝑚
𝐷𝐸 = Eddy diffusivity
= 6.675 × 10−3 (𝑈𝑎 )1.44 + 0.922 × 10−4 ℎ1 − 0.00562
= 6.675 × 10−3 (1.353)1.44 + 0.922 × 10−4 (36.2036) − 0.00562
= 8.0342 × 10−3 𝑚2 ⁄𝑠
93
0.92
𝑁𝑝𝑒 = = 5.886
8.0342 × 10−3 × 17.13
𝜆𝐸𝑂𝐺 = 1.0476 × 0.58 = 0.6076
𝐸𝑚𝑣
From (Ref: 1, pg: 18 − 18, fig: 18 − 29a), = 1.3
𝐸𝑂𝐺
∴ 𝐸𝑚𝑣 = 1.3 × 0.58 = 0.754
d) Overall column efficiency
𝑁𝑡ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙
𝐸𝑂𝐶 =
𝑁𝑎𝑐𝑡𝑢𝑎𝑙
log(1 + 𝐸𝑎(𝜆 − 1))
𝐸𝑂𝐶 = (Ref: 1, pg: 18 − 17, eq: 18.46)
log(𝜆)
𝐸𝑎 = Murphee plate efficiency corrected to liquid entrainment
𝐸𝑎 1
= (Ref: 1, pg: 18 − 13, eq: 18 − 37)
𝐸𝑚𝑣 1 + 𝐸 ( 𝜓 )
𝑚𝑣 1 − 𝜓
𝜓 = Fractional entrainment
𝐿 𝜌𝑔 0.5 8 006.388 2.1245 0.5
For ( ) = ( ) = 0.0268
𝐺 𝜌𝑙 15 977.70304 740.5
For 80% flood,
From (Ref: 1, fig: 18 − 22, pg: 18 − 44)
𝜓 = 0.11
1
𝐸𝑎 = 0.754 ( ) = 0.6897
0.11
1 + 0.754 ( )
1 − 0.11
log(1 + 0.6897(1.0476 − 1))
𝐸𝑂𝐶 = = 0.6932
log(1.0476)
𝑁𝐴 = Actual trays;
𝑁𝑇 = Theoretical trays.
𝑁𝑇 5
𝑁𝐴 = = = 7.21 ≅ 8 𝑡𝑟𝑎𝑦𝑠
𝐸𝑂𝐶 0.6932
Height of enriching section = 8 × 0.5 = 4 m
94
Stripping Section
1) Tray spacing, 𝑡𝑠 = 500 𝑚𝑚

2) Hole diameter, 𝑑𝑛 = 5 𝑚𝑚
3) Pitch, 𝑙𝑝 = 15 𝑚𝑚
4) Tray thickness, 𝑡𝑟 = 3 𝑚𝑚
𝐴ℎ
5) = 0.10
𝐴𝑝
6) Plate diameter, 𝐷𝑐
𝐿 𝜌𝑔 0.5
( ) ( ) = 0.0728 (maximum of bottom)
𝐺 𝜌𝐿
𝐶𝑠𝑏 𝑓𝑙𝑜𝑜𝑑 = 0.27 𝑓𝑡/𝑠
𝑚
𝑈𝑛𝑓 = 1.3288
𝑠
Consider, 80% flooding
𝑈𝑛 = 1.0631 𝑚/𝑠
Volumetric flow rate of vapor = 2.4337 𝑚3 /𝑠
Net area, 𝐴𝑛 = 2.2892 𝑚2
Column diameter, 𝐷𝑐 = 1.82 𝑚
𝐿𝑤 = 1.4 𝑚
𝐴𝑑 = 0.2922 𝑚2
𝐴𝑐 = 2.6016 𝑚2
𝐴𝑛 = 2.3094 𝑚2
𝐴𝑎 = 2.0172 𝑚2
𝐿𝑤
= 0.7692
𝐷𝑐
𝜃𝑐 = 100.57°
𝐴𝑐𝑧 = 0.14 𝑚2 (5.4% 𝑜𝑓 𝐴𝑐 )
𝐴𝑤𝑧 = 0.0622 𝑚2 (2.3% 𝑜𝑓 𝐴𝑐 )
𝛼 = 79.43°
95
𝐴𝑝 = 1.815 𝑚2
𝐴ℎ = 0.1815 𝑚2
𝑛ℎ = 9244
7) ℎ𝑤 = 50 𝑚𝑚
8) Weeping check (top):

a) ℎ𝑑,𝑡𝑜𝑝 = 50.35 𝑚𝑚 𝑜𝑓 𝑐𝑙𝑒𝑎𝑟 𝑙𝑖𝑞𝑢𝑖𝑑
ℎ𝑑,𝑏𝑜𝑡𝑡𝑜𝑚 = 62.44 𝑚𝑚 𝑜𝑓 𝑐𝑙𝑒𝑎𝑟 𝑙𝑖𝑞𝑢𝑖𝑑
b) ℎ𝜎 = 1.94 𝑚𝑚 𝑜𝑓 𝑐𝑙𝑒𝑎𝑟 𝑙𝑖𝑞𝑢𝑖𝑑
c) ℎ𝑜𝑤 = 24.50 𝑚𝑚 𝑜𝑓 𝑐𝑙𝑒𝑎𝑟 𝑙𝑖𝑞𝑢𝑖𝑑
ℎ𝑤 + ℎ𝑜𝑤 = 74.50 𝑚𝑚
ℎ𝑑 + ℎ𝜎 = 52.29 𝑚𝑚
From graph, ℎ𝑑 + ℎ𝜎 = 16 𝑚𝑚 < 52.29 𝑚𝑚
∴ There is no weeping
9) Flooding check (Bottom)

ℎ𝑜𝑤 = 26.77 𝑚𝑚
ℎ𝑑𝑠 = 76.77 𝑚𝑚 ; 𝛽 = 0.58 ; ∅𝑡 = 0.20
ℎ11 = 44.53 𝑚𝑚
ℎ𝑓 = 222.65 𝑚𝑚
ℎ𝑎𝑝 = 51.37 𝑚𝑚
𝐴𝑑𝑎 = 0.0719 𝑚2
ℎ𝑑𝑎 = 3.76 𝑚𝑚
ℎ𝑡 = 106.97 𝑚𝑚
ℎ𝑑𝑐 = 185.39 𝑚𝑚
ℎ𝑑𝑐 1 = 370.78 𝑚𝑚 < 500 𝑚𝑚
∴ There is no flooding
10) Column efficiency

96
a) 𝑁𝑔 = 1.5873
b) 𝑄𝐿 = 8.8427 𝑠
𝑁𝐿 = 15.1866
𝑁𝑂𝐺 = 1.4233
𝐸𝑂𝐺 = 0.7591
c) Murphee plate efficiency
𝑍𝐼 = 1.1619
𝐷𝐸 = 6.8829 × 10−3 𝑚2 /𝑠
𝑁𝑝𝑒 = 22.2194
𝜆𝐸𝑂𝐺 = 0.8371
𝐸𝑚𝑣
= 1.5
𝐸𝑂𝐺
𝐸𝑚𝑣 = 1.1387
d) Overall column efficiency
𝐸𝑎 = 1.0871
𝐸𝑜𝑐 = 1.0826
9
𝑁𝐴 = = 8.313 ≅ 9
1.0826
Height of stripping section = 9 × 0.5 = 4.5 m
∴ Total height of column = Enriching section + Stripping section

= 4.0 + 4.5 = 8.5 meter
1. The mole fraction values for each stream was calculated and was simplified in Table
below.
Mole Fraction Calculated value(s)
XF 0.96
XD 0.98
97
XB 0.02
2. Minimum Reflux Ratio

𝑋𝑑−𝑌∗
Rmin = 𝑌∗ −𝑋∗
= 0.1
3. Rectifying line is obtain by calculating it by using this formula:
1
ROL = 𝑅𝑚𝑖𝑛+1 (𝑋𝑑) = 0.09
4. While for stripping operating line (SOL), the line was obtained by the intersection
between q-line and ROL to XB point.
5. Determination of Actual Number of Trays

Nactual = Ntheory / 𝜀
= 8 / 0.6
= 13.333 ≈ 13
6. Feed plate location
𝑋𝑑
( )𝑙𝑘
𝑋𝑓
Ratio = 𝐼𝑛 𝑋𝑑
( )ℎ𝑘
𝑋𝑓
𝑋𝑓
( )𝑙𝑘
𝑋𝑏
𝐼𝑛 𝑋𝑓
( )ℎ𝑘
𝑋𝑏
= 0.587
7. the value is used to calculate the feed plate location:
𝑛𝑜 𝑜𝑓 𝑎𝑐𝑡𝑢𝑎𝑙 𝑡𝑟𝑎𝑦
Feed tray = 1
1+ (𝑟𝑎𝑡𝑖𝑜 𝑜𝑓 𝑟𝑒𝑐𝑡𝑖𝑓𝑦𝑖𝑛𝑔 𝑎𝑛𝑑 𝑠𝑡𝑟𝑖𝑝𝑝𝑖𝑛𝑔
)
98
13
= 1
1+ 0.587
= 4.808 ≈ 5𝑡ℎ 𝑡𝑟𝑎𝑦
8. Area of Distillation Column 2
𝜋𝐷2
Area = 4
𝜋 (2.5)2
= 4
= 4.908 𝑚2 ≈ 5 𝑚2
9. Dimensions of the Column (Height)
Htower = 2.3 * Nactual

= 2.3 * 13
0.3048 𝑚
= 29.9 ft * 1 𝑓𝑡
= 9.11352 m ≈ ±9 𝑚
10. Volume of Distillation Column 2
𝐿
𝑉 = 𝜋𝐷 2
4
9.11352 𝑚
= 𝜋 (2.5𝑚2 )( )
4
= 44.74 𝑚3
1. Mole fraction of methanol

99
361.7245
= 369.1057
= 0.97
2. Mole fraction of methanol in the distillate, xD = 0.99
Table : moles value for McCabe thiele
xD 0.99
xF 0.97
xB 0.02
3. Min reflux ratio
𝑋𝐷 − 𝑦 ∗
𝑅𝑚𝑖𝑛 = ∗
𝑦 − 𝑥∗
0.99 − 0.98
=
0.98 − 0.97
=1
4. Reflux ratio
𝑅𝑎𝑐𝑡𝑢𝑎𝑙 = 𝑅𝑚𝑖𝑛 × 1.31
= 1 × 1.31
= 1.31
5. Construct upper and Lower Operating Line
𝑅 𝑋𝐷
𝑦𝑛+1 = 𝑥+
𝑅+1 𝑅+1
1.31 0.99
= 𝑥+
1.31 + 1 1.31 + 1
100
= 0.5671𝑥 + 0.42857
6. While for stripping operating line (SOL), the line was obtained by the intersection
between q-line and ROL to XB point
7. Determination of Number of stage
N = 24.
8. Determination of Actual Number of Trays
𝑁𝑡ℎ𝑒𝑜𝑟𝑦
𝑁𝑎𝑐𝑡𝑢𝑎𝑙 =
𝜀
24
=
0.6
= 40
9. Area of distillation column
*assumption column diameter is 2.3 m

𝜋𝐷 2
𝑎𝑟𝑒𝑎 =
4
𝑎𝑟𝑒𝑎 = 4.1548𝑚 ≈ 4𝑚
10. Principal Dimension of the column (height)
𝐻𝑡𝑜𝑤𝑒𝑟 = 2.3 × 𝑁𝑎𝑐𝑡𝑢𝑎𝑙

𝐻𝑡𝑜𝑤𝑒𝑟 = 2.3 × 40
0.3048𝑚
𝐻𝑡𝑜𝑤𝑒𝑟 = 92 𝑓𝑡 ×
1𝑓𝑡
𝐻𝑡𝑜𝑤𝑒𝑟 = 28.0416 𝑚 ≈ 28𝑚 𝑖𝑛 ℎ𝑒𝑖𝑔ℎ𝑡
101
11. Volume of distillation column
𝐿
𝑣 = 𝜋𝐷 2
4
28.0416𝑚
𝑣 = 𝜋(2.3𝑚)2
4
𝑣 = 116.506𝑚3
102
B Calculation of Economic Analysis
B.1 Equipment Cost Estimation
Reactor $ 163 009 per

Equipment RM 683,009.00
Heat Exchanger $ 835 per unit x
RM 28,000.00
(alibaba.com,2014) 8
Steam reformer (High
quality BV NG steam
$500,000 per RM 2,011,725.00
reforming hydrogen
unit x 1
plant)
(www.alibaba.com)
Separator $ 55 719 per
RM 233,463.00
Mixer $ 169 760 per
RM 711,295.00
Vessel $ 1 789 per unit
RM 22,491.00
Compressor $69 928 per unit
RM 293,000.00
Pump $ 2073 per unit
RM 34,760.00
Distillation column $ 10000 per unit
RM 125,700.00
(Alibaba.com,2014) x3
Total RM 4,143,443.00
103
B2. Capital Cost Estimation
Range Cost (RM)

Direct cost
Onsite
Purchased equipment cost 18.0% 9 874 081.73
Instrumentation and control 6.0% 3 291 360.58
Piping (installed) 11.0% 6 034 161.06
Electrical and material 5.4% 2 962 224.52
(installed)
Offsite
Building 7.0% 3 839 920.67
Yard improvements 1.3% 713 128.12
Service facilities 6.0% 3 291 360.58
Land 2.3% 1 261 688.22
Total 1 31 267 925.48
Indirect cost
Engineering and supervision 8.0% 4 388 480.77
Construction expenses 9.0% 4 937 040.86
Labor cost 2.0% 1 097 120.19
Contingency 9.0% 4 937 040.86
Total 2 15 359 682.68
TOTAL (1 + 2) 46 627 608.16
Working capital 9% FCI 4 937 040.86
Startup cost 6% FCI 3 291 360.58
Total capital investment 100% FCI 54 856 009.60

(TCI)
104
B3. Profitability Analysis
a) Manufacturing Cost
Range Cost (RM)

Total Manufacturing
46 627 608.16
Expenses, AME
General Expenses
Administration Cost 5% FCI 2 742 800.48

Distribution & Selling
8% FCI 4 388 480.77
Expenses
Research &
3% FCI 1 645 680.29
Development
Transportation 2% FCI 1 097 120.19
Total General Expenses,
9 874 081.73
AGE
Total Production Cost, APC AME + AGE 56 501 689.89
Depreciation, AD 15% FCI 8 228 401.44

Total Expenses, ATE APC + AD 59 793 050.47
Revenue from sales Quantity x Price 248 952 000.00
b) Revenue from Sales of Methanol
Item Methanol
Quantity in kg 100 000 000
Total price 248 952 000
105
Annual Profit = Revenue from sales – Total expenses

= RM 248 952 000.00 - RM 59 793 050.47
= RM 189 158 949.50
According to Lembaga Hasil Dalam Negeri (LHDN):
Figure 4.3: Tax Rate of Company in Malaysia 2016
Thus:
The income taxes is at 24 % of total annual profit.
Income Tax = 0.24 x RM 189 158 949.50
= RM 45 398 147.88
Therefore,
Net annual profit after deduction of income tax:
= RM 189 158 949.50 – RM 45 398 147.88
= RM 143 760 801.60
c) Rate of Return
𝑁𝑒𝑡 𝑃𝑟𝑜𝑓𝑖𝑡
Rate of return = 𝑥 100%
𝑁 𝑥 𝐹𝑖𝑥𝑒𝑑 𝐶𝑎𝑝𝑖𝑡𝑎𝑙 𝐼𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡
𝑅𝑀 143 760 801.60

= 𝑥 100%
10 𝑥 𝑅𝑀 54 856 009.60
106
= 14.28 %
d) Payback Period
𝑇𝑜𝑡𝑎𝑙 𝐶𝑎𝑝𝑖𝑡𝑎𝑙 𝐼𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡

Payback Period =
𝑁𝑒𝑡 𝑃𝑟𝑜𝑓𝑖𝑡+𝐷𝑒𝑝𝑟𝑒𝑐𝑖𝑎𝑡𝑖𝑜𝑛
𝑅𝑀 54 856 009.60
= 𝑅𝑀 143 760 801.60+𝑅𝑀 8 228 401.44
= 2.7
≈ 3 years
Year Profit (RM)

2016 -111 357 699.50
2017 32 403 102.11
2018 176 163 903.70
2019 319 924 705.30
2020 463 685 506.90
2021 607 446 308.50
2022 751 207 110.10
2023 894 967 911.70
2024 1 038 728 713.00
107
REFERENCES
Text Books and Scientific Papers
Aasberg-Petersen, K., Hansen., J.-K.B., Christensen, T.S., Dybkjaer, I., Christensen, P. S.,
Nielsen, C. S., Madsen, S. E. L. W. and Rostrup-Nielsen, J.R.: Technologies for large-scale
gas conversion. Applied Catalysis A: General, 221, 379-387, 2001
Bussche, K.M.V. and Froment, G. F.: A Steady-State Kinetic Model for Methanol Synthesis
and the Water Gas Shift Reaction on a Commercial Cu/ZnO/Al 2O3 Catalyst. Journal of
Catalysis, 161, 1-10, 1996
Chang, C.-H. and Tsai, W.-T.: “Carburization behavior under the pits induced by metal
dusting in
304L and 347 stainless steels”, Department of Materials Engineering and Science, National
Cheng Kung University, Taiwan, 2008
Erikson, T., “Teknologiledelse, Økonomiske betraktninger”, Gyldendal Norsk Forlag AS,

Oslo, 2005.
Hohmann, E.C.: “Optimum Networks for Heat Exchange”, Ph.D. Thesis, University of
Southern California,1971
Lee, C.-J., Youngsub, L. Kim, H.S. and Han C.: Optimal Gas-To-Liquid Product Selection
from Natural Gas under Uncertain Price Scenerios. Ind. Eng. Chem. Res., 48, 794-800, 2009
Lee, S.: Methane and its Derivatives, Marcel Dekker Inc., New York, 1997
Linnhoff, B and Hindmarsh, E: “The Pinch Design Method for Heat Exchanger Networks”,
38,5 , 745-763, 1983
108
Lødeng, R.: “A Kinetic Model for Methane Directly to Methanol”, Ph.D. Thesis, NTNU, 1991
Meyers, R.A.: “Handbook of Petrochemicals Production Processes”, RR Donneley, USA,

2005
Olah, G.A., Goeppert, A. and Prakash, G.K.: Beyond Oil and Gas: The Methanol Economy,
Wiley-VCH, Darmstad, 2006
Peters, M.S., Timmerhaus, K.D. and West, RE.: Plant Design and Economics for Chemical
Engineers”, 5th ed., McGraw-Hill, New York, 2003
Sell, C.S.: “A Fragnant Introduction to Terpenoid Chemistry”, TJ International Ltd, Cornwall,

2003
Sinnot, R. and Towler, G.: Chemical Engineering Design, 5th ed., Elsevier Ltd., UK, 2009
Skogestad, S.: “Prosessteknikk, Masse- og energibalanser”, 2nd ed., Tapir Akademisk Forlag,
Trondheim, 2003
Smith, R.: “Chemical Process Design and Integration”, John Wiley and Sons Ltd.,
Chippenham, 2005
Tijm, P.J.A., Waller, F. J. and Brown, D.M.: Methanol technology developments for the new
millnium. Applied Catalysis A: General, 221, 275-282, 2001
Trimm, D.L. and Wainwright, M.S.: “Steam Reforming and Methanol Synthesis”, Catalysis
today, 6, 261-278, 1996
Turton, R., Bailie, R.C., Whiting, W.B. and Shaeiwitz, J.A.: “Analysis, Synthesis, and Design
of Chemical Processes”, Prentice Hall, Massachusetts, 2009
109
Weissermel, K. and Arpe, H.-J.: Industrial Organic Chemistry, 4th ed., Wiley-VCH, Darmstad,
2003
"Carburization behavior under the pits induced by metal dusting in

304L and 347 stainless steels"
Chia-Hao Chang,Wen-Ta Tsai
Internet Adresses
1. http://www.uhde.eu/archive/upload/uhde_brochures_pdf_en_6.00.pdf
2. http://chemelab.ucsd.edu/methanol/memos/ZSM-5.html
3. http://www.lurgi.com/website/fileadmin/pdfs/brochures/Br_MegaMethanol.pdf
4. http://www.statoil.com/en/OurOperations/TradingProducts/Methanol/Pages/default.asx
5. http://www.statoil.com/en/InvestorCentre/AnalyticalInformation/InternalGasPrice/Pa
es/default.aspx
6. http://www.ssb.no/emner/10/08/10/elkraftpris/
7. http://maps.google.com/
8. http://www.ineosparaform.com/55-Methanol_price.htm
9. http://people.clarkson.edu/~wilcox/Design/heurist.pdf
Other References
1. Personal conversation with supervisors

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DESIGN PROJECT 2 (CPB 30803)

DESIGN OF METHANOL PLANT WITH A CAPACITY OF

NUR ZARINA BINTI MOHD ZAIRI 55201113636

SUPERVISOR: MDM SALEHA BINTI ATAN

SECTION OF CHEMICAL ENGINEERING TECHNOLOGY

TABLE TITLE PAGE

FIGURE TITLE PAGE

4.2 Global Methanol Production in 2013 (Merchant Research &

LIST OF FIGURES iii

1.2 Process Selection 2

1.3 Plant Side Consideration 2

1.4 Process Flow Diagram 4

DETAILED DESIGN EQUIPMENT 5

2.3 Process Description 6

2.4 Mechanical Design Features of Major Process Unit 9

2.5 Reactor Design 9

2.5.1 Choice of Methanol Reactor 9

2.5.5 Reactor Dome Closure 11

2.5.6 Number of Tube 11

2.5.7 Baffle Spacing 12

2.5.8 Number of Baffle 12

2.5.9 Heat Transfer to Vessel 12

2.5.10 Tube Pitch 13

2.5.11 Tube Arrangement 13

2.5.12 Methanol Reactor Specification Data Sheet 14

2.5.13 Geometry of Methanol Reactor 16

2.5.14 Choice of Material 17

2.5.15 Process Control and Instrumentation 17

2.5.15.1 Level Control (Cascade Control) 18

2.5.15.2 Temperature Control (Cascade Control) 18

2.5.15.3 Pressure Control (Cascade Control) 19

2.6 Other Major Equipment (Individual Task) 21

2.6.1 Steam Reformer 21

2.6.1.2 Structure of Steam Reformer 21

2.6.1.3 Choice of Material 22

2.6.2 Flash Drum (Separator) 24

2.6.2.2 Choice of Material 24

2.6.3 Distillation Column 26

2.6.3.3 Distillation Column 1 27

2.6.3.3.1 Mechanical Design of Distillation Column 1 28

2.6.3.4 Distillation Column 2 31

2.6.3.4.1 Mechanical Design of Distillation Column 2 32

2.6.3.5 Distillation Column 3 33

2.6.3.5.1 Mechanical Design of Distillation Column 3 35

3.2 Introduction to Heat Integration 37

3.2.1 Defining Hot Stream and Cold Stream Utilities 37

3.3 Process Control and Instrumentation 40

3.3.1 Level Control (Cascade Control) 40

3.3.2 Temperature Control (Cascade Control) 40

3.3.3 Pressure Control (Cascade Control) 41

3.3.4 Piping and Instrumentation Diagram 43

3.4 Hazard Operability Study (HAZOP) For Reactor 46

3.4.1 Introduction to HAZOP Study in Reactor 46

3.4.2 The Technique 52

ECONOMIC EVALUATION AND COST OPTIMIZATION 53

4.3 Supply and Demand 54

4.3.1 Global Production of Methanol 55

4.3.2 Global Demand of Methanol 57

4.3.3 Current and Future Price 58

4.4 Major Equipment Cost Estimation 60

4.5 Economical Investment 61

4.5.1 Capital Investment 62