Acrolein Project Final PDF

A PROJECT ON
“Production of Acrolein”
Submitted in partial fulfilment of the requirement for
the Degree of Bachelor of Technology
----------- Submitted -----------
By
PANKAJ RANA AMIT AGRAWAL

(U15CH077) (U15CH101)
B. TECH. IV (Chemical) 8th Semester (2018-19)
Guided by
Dr. Sanjay R. Patel
Associate Professor, ChED
CHEMICAL ENGINEERING DEPARTMENT
Sardar Vallabhbhai National Institute of Technology
Surat-395007, Gujarat, INDIA
-
Sardar Vallabhbhai National Institute of Technology
Surat-395007, Gujarat, INDIA
CHEMICAL ENGINEERING DEPARTMENT
CERTIFICATE
This is to certify that the following students Pankaj Rana (U15CH077) and
Amit Agrawal (U15CH101) of B.Tech. IV have successfully completed the project entitled
“Production of Acrolein” during year 2018-19 and their work is satisfactory.
PANKAJ RANA AMIT AGRAWAL

(U15CH077) (U15CH101)
Dr. Sanjay. R. Patel
Associate Professor, ChED

(Project Guide)
DEPARTMENT OF CHEMICAL ENGINEERING
S. V. National Institute of Technology, Surat
Pankaj Rana (U15CH077) and Amit Agrawal (U15CH101), registered in Chemical

Engineering Department of S.V.N.I.T. have successfully completed the project entitled
“Production of Acrolein” during year 2018- 2019. The report is presented before the
following members of the Committee.
Name Sign
1) Examiner-1 Dr. CHETAN M. PATEL NKKL
2) Examiner-2 Dr. A. K. MUNGRAY
3) Examiner-3 Dr. G. C. JADEJA
The Project entitled “Production of Acrolein” is submitted to the Head (ChED)

along with this certificate.
Place: SVNIT, Surat
Date: 09/05/2019
Dr. Mausumi Mukhopadhyay

(Professor, ChED)
Head of Chemical Engineering Department
ACKNOWLEDGEMENT
We would like to express deep sense of gratitude to our guide Dr.
Sanjay R. Patel (Associate Professor, Department of Chemical
Engineering, SVNIT, Surat) for his valuable guidance and motivation, and
for his extreme cooperation to complete our project work successfully.
We would also like to thank all the academic and non-academic staff for
cooperating us in completing this project.
In addition, we would also like to thank the department for including
project in the curriculum. Finally, we would like to express our heartfelt
thanks to God then our beloved parents and our friends for their constant help
and wishes for the successful completion of the project preliminary.

CONTENT
SR.NO. DESCRIPSTIPN PAGE NO.
1 INTRODUCTION OF ACROLEIN 6
2 PROCESS AND CAPACITY SELECTION 12
3 PROCESS DESCRIPTION 15
4 MATERIAL BALANCE 19
5 ENERGY BALANCE 26
6 THERMODYNAMICS AND KINETICS 34
7 EQIPMENT DESIGN (MAJOR & MINOR) 37
8 P AND I DIAGRAM 67
9 COST ESTIMATION 68
10 PLANT LOCATION 76
11 PLANT LAYOUT 80
12 MATERIAL SAFETY DATA SHEET 84
13 SAFETY ISSUES AND ENVIRONMENTAL IMPACTS 91
14 APPENDICES 96
15 REFRENCES 104
6
CHAPTER NO: 1
INTRODUCTION OF ACROLEIN
1.1 Acrolein
Acrolein is the basic compound in the series of unsaturated aldehydes. Its
chemical formula is C3H4O and chemical name is 2-propanol. Acrolein is
colourless and highly volatile liquid and soluble in many organic liquids.
1.2 History and origin
Acrolein is highly toxic and flammable material with extreme lachrymatory

properties. Degussa has produced Acrolein commercially since 1938.The process
was based on vapors phase condensation of acetaldehyde and formaldehyde.
By following the Degussa method of acrolein production the first plant to

manufacture acrolein first started in 1942. In 1945 shell started the production of
acrolein by pyrolysis of di-allyl ether, a by-product of synthesis of allyl alcohol by
saponification of allyl chloride. In 1959 shell began producing acrolein by partial
oxidation of propylene.
Acrolein, low mole weight aldehyde containing a C=C solid bond, is a clear to
yellow, flammable, poisonous liquid with a disagreeable odour; boiling at 52.7
0
C; soluble in water, alcohol, and ether; causing tears. Commercial acrolein is
produced by gas-phase oxidation of propylene in the presence of bismuth or

molybdenum oxide. It is also produced as a by-product during the production of
acrylic acid or acrylonitrile.
7
1.3 Methods of Manufacturing
 It was produced commercially starting in 1938 by the vapor-phase condensation of

acetaldehyde & formaldehyde.
 In 1959, the direct oxidation of propylene in presence of a catalyst became the

preferred commercial process, & variations of this process are the only methods
currently used commercially.
 The acetaldehyde-formaldehyde route was last used in the USA in 1970.
 Manufactured: By oxidation method i.e.
(A) by oxidation of acetaldehyde;
(B) by oxidation of propylene in liquid phase;
(C) by oxidation of propylene in vapor phase;
(D) by oxidation of allyl alcohol;
 By heating glycerol with magnesium sulphate.
 Prepared industrially by passing glycerol vapors over magnesium sulphate heated

0
to 330-340 C.
8
1.4 properties of acrolein
1.4.1 Physical properties of acrolein

Molecular weight 56.06 kg/kg mole
Odour Extreme sharp, pungent and disagreeable
Colour Colourless or yellowish
0
Boiling point 52.5 C at 760 mmHg
0
Melting point -88 C
3 0 3 0
Density 0.8389 g/cm at 20 C, 0.8621 g/cm at 0 C
0
Heat capacity 2139 kJ/kg.K (17 to 44 C, liquid)
0
1200 kJ/kg.K (300 C, vapor)
Standard heat of -74.483 kJ/mole

formation
Heat of combustion -29098 kJ/kg
Heat of vaporization 542.191 kJ/kg
Heat of -80.4 kJ/mole

polymerization
0
PH 6 in 10% solution in water at 25 C
0
Surface tension 0.024N/m at 20 C
Vapor density 1.94 (Air =1)
0
Viscosity 0.35 cp at 20 C
9
1.4.2 Chemical properties
CH2=CH-CHO the carbonyl group in the conjugate with the C=C bond is present
in molecule of acrolein because of its two functional group; acrolein is highly

reactive, easily polymerized compound. Its reactive centre can be reacted
selectively and simultaneously. The reaction of acrolein can be understood as
typical of olefin activated for nucleophilic attack by influence of electron
attracting carbonyl group or as a reaction of aldehyde that is unsaturated.
The tendency of acrolein to polymerize is very great; the acrolein can only be
stored in the presence of considerable amounts of stabilizers. In spite of the
presence of stabilizer, small amounts of polymerization catalysts which are able to
initial radical, anionic or cationic propagating polymerization are sufficient to
cause highly polymerization reaction.
1.5 Uses and applications of acrolein
Some of direct and indirect uses of acrolein are
Manufacturing of Acrylic Acid
The largest single use for acrolein is as an isolated intermediate in the

manufacturing of acrylic acid, most of which is converted to its lower alkyl esters.
Preparation of Polyester Resin
Acrolein is used in the preparation of polyester resin, polyurethane, propylene

glycol, acrylic acid, acrylonitrile and glycerol.
10
Production of Methionine
Acrolein is basic raw material for the production of essential amino acid
methionine because of lack of methionine in many nutrient protein compounds with the
average biological demand, it is necessary to add methionine to the natural food
materials for boilers to improve their biological efficiency which is a protein supplement
used in animal feed.
Manufacturing of Glycerol
The chemical reduction of acrolein via alkyl alcohol is the technical process for
the manufacturing of synthetic glycerol.
Microbiological Activity of Acrolein
In biological systems one may expect rapid reactions with any reactive N-H, S-H,
O-H or C-H bond which would lead to molecular modification. In the subsurface
injection of waste waters, the addition of 6-10 ppm acrolein controls the growth of
microbes in the food lines thereby preventing plugging and corrosion.
The microbiological activity is further utilized in protecting the liquid fuel against
microorganism. About <500 is in jet fuels or distillate feed tank bottoms. The di
alkyl acetyls of acrolein are also effective in such cases; as a biocide in oil wells
and liquid petrochemical fuels. The growth of algae, aquatic weeds and molluscs
in recirculation process water is controlled by acrolein.
Slime Formation
Slime formation is a serious problem in paper manufacturer: acrolein at 0.4 to 0.6

ppm is effective slimicide in this application.
11
Acrolein as Tissue Fixative
Acrolein has received quite a bit of attention as a tissue fixative. This property of acrolein
has been utilized for preservation of red blood cells. Acrolein may be used to cross link
inverses at pH 7 to give a water insoluble product which possesses constant activity for
inversion of sucrose for the period of 12 weeks. Acrolein is sometimes used as a fixative
in preparation of biological specimens for electron microscopy.
Immobilization of Enzymes
Conversion of acrolein into polymers or copolymers processing pendant aldehyde

groups provides polymers which have been utilized for Immobilization of
enzymes.
Other uses
o Acrolein has been used to make modified food starch.
o In the cross-linking of protein collagen in leather tanning.
o In the manufacture of colloidal forms of metals.
o In the production of perfumes.

12
CHAPTER NO: 2
PROCESS AND CAPACITY SELECTION
2.1 Process Selection

Acrolein can be produced by different methods.
2.1.1 Vapor phase condensation
Acrolein was first produced commercially in the 1930s through vapor phase
condensation of formaldehyde and acetaldehyde.
2.1.2 Vapor phase oxidation
Acrolein was then produced in 1940s by vapor phase oxidation of propylene using
cuprous oxide catalyst; however, this method was not used at first due to the poor
performance of cuprous oxide catalysts.
2.1.3 Partial oxidation of propylene

Acrolein is being produced by partial oxidation of propylene using mixed catalyst
now days from 1960s and to produce acrolein by this method using bismuth-
molybdate based catalyst is important one. This is most favoured and most
economical method. By the critical study of the processes, catalytic oxidation of
propylene has proved to be the most attractive in terms of raw material and high
yield of acrolein than any other process. This process is attractive because of the
availability of highly active and selective catalysts and the relatively low cost of
propylene.
The process that we have chosen for the production of acrolein is by the
“Partial oxidation of propylene”.
13
2.2 Capacity Selection
Market trends /Demands
Acrolein as a chemical product is rarely sold in large amounts on open market.

Whilst there are producers that sell certain amounts of it, the chemical is
immediately used in the production of other chemicals due to its instability and
safety hazards.
In the case of this project, we will be designing a plant that will produce Acrolein,
which will be piped out directly to the neighbouring plant that uses Acrolein to
produce other chemicals. This allows a small scale plant to be designed whilst
avoiding the problem of transporting Acrolein.
Whilst plant will be producing Acrolein, the price and market of chemical is fully
dependent on products it is used to create and as such market analysis must be
extended to these chemicals. There are six main products that are produced using
Acrolein. These are polyurethane, methionine, Polyester resins, acrylonitrile and
acrylic acid.
Acrolein is not a staple import/export product and due to its overall lack of value
unless further processed, the market is centre around countries and areas with
facilities that process the chemical further.
This can be seen when trying to source prices for Acrolein alone. The majority of
the manufacturers selling Acrolein are doing so from mainland China. Looking at
the change in market share and Acrolein exports, being imported into the USA,
over the past few years, this viewpoint is only reinforced.
14
Figure 2.1. Dominant exporters of acrolein in the world with respect to number of
shipments
Figure 2.2. Dominant exporters of acrolein in the world with respect to

market share changes
15
CHAPTER NO: 3
PROCESS DESCRIPTION
Acrolein is prepared industrially by oxidation of propene. The process uses air as the
source of oxygen and requires metal oxides as heterogeneous catalysts.
CH2CHCH3 + O2 → CH2CHCHO + H2O
500,000 tons of acrolein are produced in this way About annually in North America,
Europe, and Japan.
Additionally, all acrylic acid is produced via the transient formation of acrolein.
The main challenge is in fact the competing over oxidation to this acid.
Propane represents a promising but challenging feedstock for the synthesis of acrolein
(and acrylic acid).
3.1 Process Description
 Propylene (Stream 2), steam (Stream 4) and compressed air (Stream 6) are
mixed and heated to 250°C.
 The resultant stream (Stream 8) is sent to a catalytic packed bed reactor

where propylene and oxygen react to form acrolein.
 The reactor effluent is quickly quenched to 50°C with deionized water

(Stream 10) to avoid further homogeneous oxidation reactions.
16
 Stream 12 is then sent to an absorber, T-101, where it is scrubbed with

water and acrolein is recovered in the bottoms (Stream 15).
 The off gas, Stream 14, is sent to an incinerator for combustion. Stream 15
is then distilled in T-102 to separate acrolein and propylene from water
and acrylic acid.
 The bottoms (Stream16) consisting of wastewater and acrylic acid are sent
to waste treatment.
 The distillate (Stream 17) is sent to T-103 where propylene is separated

from acrolein and the remaining water in the system.
 The distillate from T-103 contains 98.4% propylene.
 The bottoms (Stream 19) are then sent to T-104 where acrolein is
separated from water.
 Stream 21 is sent to waste treatment, and the distillate (Stream 20)

consists of 98% pure acrolein.
17
Figure 3.1 Process flow diagrams

18
Table 3.1. Equipment Description
Equipment No. Equipment Name Equipment No. Equipment Name
C-101 Feed air P-103A/B Reflux pump
compressor
E-101 Reactor preheater P-104A/B Reflux pump
Packed
E-102 Condenser R-101 bed
reactor
E-103 Reboiler T-101 Acrolein absorber
E-104 Condenser T-102 Water distillation
tower
E-105 Reboiler T-103 Propylene
distillation tower
E-106 Condenser T-104 Acrolein
distillation tower
E-107 Reboiler V-101 Reflux vessel
P-101A/B Water pump V-102 Reflux vessel
P-102A/B Reflux pump V-103 Reflux vessel

19
CHAPTER NO: 4
MATERIAL BALANCE
From capacity selection data as per the referred literatures, we have to
produce acrolein based on the below mentioned capacity. So we will do
material balance according to our capacity.
The production of Acrolein per annum = 50,000 tonnes / year
Considering shut down of the plant = 30 days / year

Working days for the plant = 365-30 = 335 days / year
Then production per day = 50,000/335 tonnes / Day
= 150 tonnes / Day
Our plant has capacity of 150 tonnes / Day to produce Acrolein.
DETAILED MATERIAL BALANCE
Basis: 150 TPD of Acrolein.
CH2=CHCH3 + O2  CH2 = CHCHO + H2O

Propylene Acrolein
Compound Molecular weight (gm/mol)

Propylene 42
Acrolein 56
Oxygen 32
20
Propylene required to produce 150 TPD of Acrolein
1 kmol of C3H6 - 1 kmol of Acrolein

42 kg/hr of C3H6 - 56 kg/hr of Acrolein
C3H6 required to produce 150 TPD of Acrolein

= 150 x (42/56) = 112.5 TPD of C3H 6
At a yield of 79% kmol of C3H6 required = 112.5/0.79

= 142.4 TPD
= 141.27 kmol/hr
Oxygen required:
1 kmol of C3H6 requires 1 kmol of O2
Hence O2 required = 1 x 141.26 kmol/ hr
= 141.26 kmol/ hr
Material Balance Across Reactor (R-101)

21
Oxidation of Propylene to Acrolein
CH2=CHCH3 + O2  CH2 = CHCHO + H2O

Propylene Acrolein
Feed Composition: C3H6: Air: Steam: 1: 7.75: 3.75

Contact time = 3.6 sec
Average temperature = 3550C
Overall conversion of C3H6 = 100%
Conversion to acrolein = 70%
C3H6 feed = 141.27 kmol/hr

Steam fed = 529.725 kmol/hr
Air fed = 141.27 x 7.75 = 1094.7 kmol/hr
O2 entering = 230 kmol/hr
N2 in = N2 out = 864.7 kmol/ hr
O2 used in the reactor = 141.26 kmol/hr
O2 left unreacted = 88.74 kmol/hr
Acrolein produced = 141.27 x 0.7 = 98.842 kmol/hr
Steam produced = 98.842 kmol/hr
Total steam leaving the reactor = 628.567kmol/hr

22
Material Balance Across Absorber (T-101)

Feed is entering at the bottom of the absorber.
Acrolein = 98.842 kmol/hr
O2 = 88.74 kmol/hr
N2 = 864.7 kmol/hr
Steam = 628.567 kmol/hr
Propylene = 2.83 kmol/hr
Acrylic acid =9.8842 kmol/hr
Acrolein is absorbed using water as Solvent.
Gases O2, N2 and small amount of steam leave the absorber at the top.
Assumptions: 90% of the steam entering gets solvent

Water entering at the top = 565.71 kmol/hr
Off gases leaving at the top:
N2 = 864.7 kmol/hr
O2 = 88.74 kmol/hr
Product liquid leaving at the bottom of the absorber to recovery section:

Acrylic acid =9.8842 kmol/hr
Propylene =1.13 kmol/hr
Water = 1082.85 kmol/hr
Mol fraction of Acrolein in the product stream = 0.082= 8.2%

Weight fraction of Acrolein in the product stream = 0.203= 20.3%
23
Material Balance across Water Distillation Column ( T– 102)
Feeds Entering from the feed tray Location

Acrylic acid = 9.8842 kmol/hr
H2O = 1082.85 kmol/hr
According to conversion data available from the literatures
Top Products
100% propylene goes to top

94.6% Acrolein goes to top
Bottom Products
100% acrylic acid goes to bottom

99.8% water goes to bottom
Hence amount of Products leaving the water distillation column
Top Products
Propelyne = 1.13 kmol/hr
H2O = 2.15 kmol/hr
Bottom Products
Acetic acid = 9.8842 kmol/hr
H2O = 1080.7 kmol/hr

24
Material Balance across Propylene Distillation Column ( T–103)
H2O = 2.15 kmol/hr
Top Products
100% acrolein goes to top

98.8% propylene goes to top
Bottom Products
100% water goes to bottom

90%acrolein goes to bottom
1.2% propylene goes to bottom
Top Products
Bottom Products
H2O = 2.15 kmol/hr

25
Material Balance across Acrolein Distillation Column ( T–104)

H2O = 2.15 kmol/hr
Top Products
98% acrolein goes to top
99.67% propylene goes to top
2% water goes to top
Bottom Products
98% water goes to bottom
2%acrolein goes to bottom
Top Products
H2O = 0.043 kmol/hr
Bottom Products
H2O = 2.105 kmol/hr
Hence from above calculations Acrolein produced = 150 TPD at

98% purity.
26
CHAPTER NO: 5 ENERGY BALANCE
Energy balance across Reactor (R-101)
Energy Balance (Steam)

From Literature,
T avg = 373 + 298 / 2

= 335.5K
Q air = 0
Q propylene = 0
Cp = 34.698 kJ/kg.k
Q = m ×Cp× (T in-T ref)

= 529.725×34.698× (298-373)
= -1378594.913 KJ
Q in = -1378594.913 KJ
Cp acr = 70.5 KJ/Kg.k
27
Q acr = m ×Cp×(Tin-Tout)
= 522627.05 KJ
Cp N2 = 29.4 kJ/kg.k
Q N2 = m ×Cp×(Tin-Tout)
=1214803.965 KJ
Cp O2 = 29 kJ/kg.k
Q O2 = 207427.6 KJ
H r = H f product - H f react
H r = 295.9 KJ/Kmol
Q out = 1971423.065 KJ
H r + Q = Q out - Q in
Q = 3419126.8 KJ
28
Energy balance across Absorber (T-101)
Q in = Q out = 1971423.1 KJ
Q acr = m ×Cp× (T in-T out)
Cp acr = 155.79 kJ/kg.k
Q acr = 4579303.91 KJ
Cp N2 = 29.4 kJ/kg.k
Q N2 = m ×Cp×(Tin-Tout)
Q N2= 7536819.158 kJ
Cp O2 = 29 kJ/kg.k
Q o2 = 348528.46 KJ
H r = 242.51 KJ/kmol
Q out = 12464651.5 KJ
Hr + Q = Q out -- Q in
Q = 10492985.92 KJ
29
Energy balance across Heat Exchanger(E-101)
Energy Balance (Steam)

From Literature,
Qair = 0
Q propylene = 0
Tavg = 373 + 298 / 2
= 335.5 K
Cp= 34.698 kJ/kg.k
Q = m ×Cp× (Tin - Tref)

= 529.725×34.698× (298-373)
= -1447999.54 KJ
Qin = -1447999.54 KJ
Qout = Qacr + QN2 + QO2
Q acrolein = 549191.5 KJ
QN2 =1214803.965 KJ
QO2 =207427.6 KJ
Hr = Hf product - Hf react
Hr=295.9 KJ/Kmol
30
Qout =1971423.065 KJ
Hr + Q = Qout- Qin
Q=3419126.8 KJ
Energy balance across Heat Exchanger (E-102)

Qin = Qout = 1971423.1 KJ
Qacrolein = m ×Cp×(Tin-Tout)
Cpacrolein = 155.79 kJ/kg.k
Qacrolein = 4579303.91 KJ
QN2 = m ×Cp×(Tin-Tout)
QN2 = 7536819.158 kJ
Qo2=348528.46 KJ
Hr= 242.51 kJ/kmol
Qout=12464651.5 KJ
Hr + Q = Qout - Qin
Q=10492985.92 KJ
31
Energy balance across the Water Distillation Tower
Refrence Temperature
TRef. = 298.15 K
Stream No./Name 15 16 17
Temperature(k) 310.15 373.15 302.15
Flow Rate
(kmol/hr) 1082.85 1080.7 91.98
CP (KJ/Kg) 70.5 155.79 29.4
Heat load (kJ/hr) 991745.6 4480530.449 2768.57
By applying same energy balance equation as given above we can find the
Load generated across condense and reboiler
Q condenser = 308.2 kJ/hr
Q reboiler = -97272 kJ/hr
32
Energy balance across the Propylene Distillation Tower
TRef. = 298.15 K
Temperature(k) 302.15 299.15 338.15
Flow Rate
(kmol/hr) 91.979 9.179 82.782
CP (KJ/Kg) 29.4 27.6 34.698
Heat load (kJ/hr)

2768.57 162.825 66807.52
Q reboiler = -292.18 kJ/hr
33
Energy balance across the Acrolein Distillation Tower
TRef. = 298.15 K
Temperature(k) 338.15 325.15 378.15
Flow Rate
(kmol/hr) 82.782 81.1826 2.105
CP (KJ/Kg) 34.698 30.2 58.9
Heat load (kJ/hr) 66807.52 40959.95 12662.4
Q reboiler = -181.18 kJ/hr
34
CHAPTER 6
Kinetics and Thermodynamics Data
Simple Kinetics Expression for Acrolein
 Rate expression is first order in propylene and half order in oxygen
r  k  C p  CO2
1
2 kmol / kg cat  sec


k  5.1778  106 exp(16206.5 / T ) m 3 rxtr / kgcat  sec kmol 3
 m
 1
2 

Reaction Kinetics
 Real reaction kinetics can be describe as below
( )
( )
( )
( )
35
THERMODYNAMICS DATA
Physical State at 15° C and 1 atm: Liquid
Molecular Weight: 56.1
Boiling Point at 1 atm: 127°F = 53°C =326°K
Freezing Point: –125°F = –87°C = 186°K
Critical Temperature: (est.) 489°F = 254°C = 527°K
Critical Pressure: (est.) 737 psia = 50.0 atm = 5.08 MN/m2
Specific Gravity: 0.843 at 20°C (liquid)
Liquid Surface Tension: 24 dynes/cm = 0.024 N/m at 20°C
Liquid Water Interfacial Tension: (est.) 35 dynes/cm = 0.035 N/m at 20°C
Vapor (Gas) Specific Gravity: 1.94
Ratio of Specific Heats of Vapor (Gas): 1.1487
Latent Heat of Vaporization: 216 Btu/lb = 120 cal/g = 5.02 X 105 J/kg
Heat of Combustion: –12,500 Btu/lb = –6,950 cal/g = –290 X 105 J/kg
Heat of Decomposition: Not pertinent
Heat of Solution: Not pertinent
Heat of Polymerization: (est.) –50 Btu/lb = –28 cal/g = –1.2 X 105 J/kg
Heat of Fusion: Not available
Limiting Value: Not available

36
SATURATED LIQUID DENSITY LIQUID HEAT CAPACITY
British Thermal unit

Temperature (oF) Pounds per cubic
foot
o
Temperature ( F) per Pound
20 53.710
0 0.522
30 53.480 10 0.524
40 53.250 20 0.527
50 53.020 30 0.529
60 53.790 40 0.534
LIQUID THERMAL CONDUCTIVITY
SATURATED VAPOR PRESSURE

British Thermal unit
inch per hour square
Temperature (oF) foot- F Temperature (oF) Pounds per sq. inch
0 0.522 40 3.398
10 0.524 50 4.358
20 0.527
60 5.537
30 0.529
70 6.971
40 0.534
80 8.701
37
CHAPTER NO: 7
DESIGNING OF EQUIPMENTS
7.1 Design of Shell and Tube Heat Exchanger
7.1.1 Design Calculations

Design/Problem Statement
Design a shell and tube heat exchanger to heat a feed mixture of,
• Propylene = 141.27kmol/hr = 1.65 Kg/s
• Steam =529.72kmol/hr =2.65 Kg/s
• Air = 1094.7kmol/hr =8.82 Kg/s
o o 2
From 413K (140 C) to 523K (250 C) at pressure 203KN/m (KPa) and heated
o o
by Dowtherm oil from 673K (400 C) to 530K (257 C).
Design Steps of Shell and Tube Heat Exchanger

The design steps of shell and tube heat exchanger are given below:
Part (A) Thermal Design
Part (B) Hydraulic Design
Part (C) Mechanical Design
PART [A] Thermal design of Shell & Tube Heat Exchanger
Step 1: Specification
38
Hot Fluid [Dowtherm A]

o
Inlet temperature = 673k (400 C)
o
Outlet temperature = 530k (257 C)
Cold Fluid [Feed Mixture]

o
Inlet temperature = 413k (140 C)
o
Outlet temperature = 523k (250 C)
Step 2: Physical Properties
Mean Temperature feed mixture (Tm)

= (523+413)/2
= 468K (195oC)
Heat Capacity (Cp):
o
Cp of Propylene at mean temperature = 12.25kJ/Kg. C
o
Cp of Steam at mean temperature = 2.01543kJ/Kg. C
o
Cp of Air at mean temperature = 1.02202kJ/Kg. C
Density:
3
Density of Propylene at mean temperature = 2.21Kg/m
3
Density of Steam at mean temperature = 7.106Kg/m
3
Density of Air at mean temperature = .754Kg/m
Viscosity:
Viscosity of Propylene at temperature = .004003Kg/m.S
Viscosity of Steam at mean temperature =1.59x10-5Kg/m.S
Viscosity of Air at mean temperature = .008637Kg/m.S
Thermal Conductivity (K):
“K” of Propylene at mean temperature = 3.82x10-5KJ/m.S.oC
“K” of Steam at mean temperature =3.33x10-5KJ/m.S.oC
“K” of Air at mean temperature =3.825x10-5KJ/m.S.oC

39
Physical Properties of Dowtherm “A”:
o
Mean temperature (Tm) = (673+530)/2 = 601.5k (328.5 C)
3
Density of Dowtherm at mean temperature = 15.60Kg/m
o
Cp of Dowtherm at mean temperature = 2.049KJ/Kg. C
-5 o
“K” of Dowtherm at mean temperature = 2.99x10 KJ/m.S. C
-5
Viscosity of Dowtherm at mean temperature =1.16x10 Kg/m.S
Heat Duties
Heat duty of cold fluid
Heat duty can be calculated by formula given below.
Q = (m1Cp1+m2Cp2+m3Cp3) * ΔTm
So using the values of m1, m2, m3 and Cp1, Cp2, Cp3, ΔTm
Q = 118.08KJ/s
Mass flow rate of hot fluid

m = Q/Cp T
Where
Q = 118.08KJ/s
o
Cp = 2.049KJ/Kg. C
o o
T = (400-257) C = 143 C
m = 0.4031Kg/s
Step 3: Overall Heat Transfer Coefficient
As our feed is Air and Gas mixture at low pressure. So let us assume overall heat
transfer coefficient,
2o
U = 6W/m C
OR
2 o
= .006KJ/m S C
40
Step 4: Calculation of Tavg
Our Heat exchanger is 1-2 pass shell and tube heat exchanger
T1= 400 oC T2=257 oC
t2=250 oC t1=140 oC
As (T1/T2) = 1. 28 which is less than 2 so we will calculate here just

Tavg rather than ΔTlm for calculation heat transfer area.
Tavg = ( T1 + T2 )/2
= [(T1–t2) + (T2-t1)]/2
After calculation Tavg = 133.5 oC
Step 5: Calculation of Heat Transfer Area
Heat transfer area can be calculated by formula given below

Q = U A Tavg
A = Q / (U * Tavg)
2
A = 147.4m
Step 6: Layout, Tube Sizing & Allocation

Heat exchange fluid is allocated toward the shell & feed stream toward tube
sides due to corrosive nature.

Floating head shell and tube heat exchanger with split rings & 1-2 pass.

Tubes are “Cupro-Nickel”.

Using Triangular Pitch as shell side fluid is clean.
 inch
Alternative Selection is (3/4 x14 BWG)
Suppose Assuming L = 4m, O.D = do = 20mm, I.D. = di =16mm

41
Step 7: Calculation of Number of tubes
Area of Single Tube = π do L

=0.2512 m2
No. of tubes required Nt = Total Heat Transfer Area/Area of single tube

= 604
Calculation of tube side velocity ut:
2 -4 2
Tube cross section Area = (π/4) .di = 2.01x10 m
Tubes per pass = Total tubes/2 = 302
Area per pass = (Tubes per pass) x (cross sectional area)

2
= 0.061m
Volumetric flow rate = mass flow rate/density
Where,
3
ρ = 3.675Kg/m
Mass flow rate= 0.4031Kg/s
So after adding values

3
Volumetric flow rate = 0.1097 m /sec
Tube side velocity = Volumetric flow rate/Area per pass

= 1.79 m/s (acceptable)
Deduction:
According to rule of thumbs and conventions it is well known that the

velocity in the tubes should be between (0.92-3.02) m/sec.
So our 1-2 pass selection is acceptable.

42
Step 8: Calculation of Shell Diameter
As shell side fluid is clean so we will use Triangular pitch (Pt).

Pt = 1.25d0 = 1.25 * 0.02 = 0.025 m
n1 = 2.207
K1 = 0.249
Where n1 and k1 are fouling factor co-efficient.
1/ n1
Bundle diameter Db = do (Nt/K1)
= 0.683m
By using split ring floating head Heat Exchanger,
Clearance diameter = 65mm = .065m
Shell side Diameter = Bundle diameter + clearance diameter
= 0.683 + 0.065 = 0.748m
Step 9: Tube side heat transfer coefficient

It can be calculated from the given below formula,
0.33 0.14
hi di / Kf = jh Re Pr (µ/µw)
.14 .14
Where .(µ/µw) or .(µ/µw) =1
Kf (of mixture) Cp(of mixture) µ(of mixture) L di

-5 o 0
3.314x10 KJ/m.S. C 1.9178Kg/Kg. C .002881Kg/m.S 4m .016m
Re =(ρ.ut.di)/µ = 24
For (L/di) = 250 and Re = 24, from graph of tube side heat transfer factor (Jh),
-2
Jh = 3.4x10
Pr = (Cp.µ)/Kf = 166.723
So after putting all these values into above formula gives the Tube side Heat transfer
coefficient is,
2 o
hi = 50.7W/m . C
43
Step 10: Shell side heat transfer coefficient
Shell side heat transfer coefficient can be calculated by formula given below
1/3 0.14
hs de/ kf = jh.Re. Pr (µ/µw)
Neglecting (µ/µw).14 or = 1
Selecting Baffles
25% Cut Segmental Baffles.
Calculating Baffle spacing
According to the TEMA standards the allowed baffle spacing is 0.2Ds
Baffle Spacing lg= Ds/5 = 0.748/5 = 0.1496m
Selecting tube pitch

Tube pitch Pt = 1.25d0 = 1.25 * 0.02 = 0.025 m = 25mm
Calculating cross flow area (As)

2
As = (Pt – d0) x Ds x lg / Pt = 0.0224m
Calculating mass velocity (Gs)
Gs = mass of hot fluid / As = 18.02Kg/s.m
Calculating Equivalent Diameter (De)
2 2
De = 1.10/do (Pt - .917do ) = .014201m
Calculating Reynolds's Number (Re)

Re = Gs de / µ = 22050.09
Calculating Prandtl Number (Pr)

Pr = Cpµ/Kf = .7949
Calculating Jh factor
As baffle cut is 25 so from the graph of shell side heat transfer factor ,
-3
Jh = 4x10
44
Calculating shell side heat transfer coefficient

As,
1/3 .14
hs de/ kf = jh. Re. Pr (µ/µw)
.14
Neglecting (µ/µw) and after putting values we have shell side heat
transfer coefficient.
2 o
hs = 172.1W/m . C
Step 11: Calculation of overall heat transfer coefficient Uo

Overall heat transfer heat transfer coefficient can be calculated from
following formula.
Uo = the overall coefficient based on the outside area of the tube,

20
W/m C
2 o 2o
ho = Outside fluid film coefficient, W/m C =172.1 W/m C
2o 2 o
hi = Inside fluid film coefficient, W/m C = 50.7 W/m C
do = Tube outside diameter, m = .02m
di = Tube inside diameter, m = .016m

o 2 o
Kw =Thermal conductivity of the tube wall material, W/m C, = 50 W/m C
2o 2o
hid = Inside dirt coefficient, W/m C = 5000 W/m C
2o 2o
hod = Outside dirt coefficient (fouling factor), W/m C =5000 W/m C
2o
So after adding values into formula we have, Uo = 8.2 W/m C
We will use this Corrected heat transfer coefficient in further calculations.
Corrected Heat Transfer Area

2
Corrected heat transfer area is given as A = 107.86m
45
Part B: Hydraulic Design
Step 12: Calculation of Pressure Drops
Tube Side Pressure Drop

Pressure drop on tube side is calculated from given formula,
[ ( )( ) ]
-m -m
Again Neglecting (µ/µw) or. (µ/µw) =1
-1
Where, Jf =Friction factor = 3.1x10
Np = No. of tube passes =2
After putting values to above formula, tube side pressure drop is calculated as,
 Pt= 3.06kpascal or .443 psi
Shell Side Pressure Drop:

Pressure drop on tube side is calculated from given formula,
( ) ( )( )
-m -m
Again Neglecting (µ/µw) or. (µ/µw) =1
Where, us = Gs/ρ = 1.49m/s

lB =baffle spacing
-2
From graph for 25% Baffle cut, Jf = 4.8x10
After putting values to above formula, shell side pr. drop is calculated as,
Ps= 5.43kpascal or .787 psi
46
PART [C] MECHANICAL DESIGN OF HEAT EXCHANGER
(a) Shell Side:
Material carbon steel

(Corrosion allowance = 3mm)
Number of shells =1
Number of passes =2
Working pressure = 1 atm = 0.101 N/mm2

Design pressure = 1.1 x 0.101 = 0.11 N/mm2
Temperature of the inlet = 673 K
Temperature of the outlet = 530 K
Permissible Strength for Carbon steel = 95 N/mm2
b) Tube side:
Number of tubes = 604

Outside diameter = 20 mm
Inside diameter = 16 mm
Length = 4 m
Feed =Water
Pitch = 3/4 inch = 0.019 m
Working Pressure =1 atm = 0.101 N/ mm2
Design Pressure =0.11 N/mm2
Inlet temperature = 413 K
Outlet temperature = 523 K
Shell Side Thickness:
ts = Shell thickness
47
P = design pressure =0.11 N/ mm2

Di = Inner diameter of shell = 0.748 m
f = Allowable stress value = 95 N/mm2
J = Joint factor = 0.85
ts = 0.11 x 0.748 = 0.509 mm

(2 x 95 (0.85) –0.11)
Minimum thickness = 6 + 3 = 9 mm (Including corrosion allowance)
∴ ts = 10 mm ( According to market availability )
Head Thickness
(Torrispherical head)
th = thickness of head
W = ¼ {3 + (Rc/Rk) 1/2}
Where, RC = Crown radius

= Outer diameter of shell
= 768 mm
Rk = knuckle radius = 0.06 RC
⇒W = ¼ {3 + (Rc / 0.06 Rc) 1/2}

= 1.77
⇒ th = 0.11 x 768 x 1.77 = 0.9258 mm

2 x 95x 0.85
Minimum shell thickness should be = 10 mm
∴ th = 10mm
48
Flanges Thickness
Loose type except lap-joint flange.

Design pressure (p) =0.11 N/mm2
Flange material: Carbon Steel
Bolting steel: 5% Cr-Mo steel.
Gasket material = Asbestos composition
Shell side diameter = 748 mm
Shell side thickness =10 mm
Outside diameter of shell = 748 + 10 x 2 = 768 mm
Determination of gasket width:
[ ]
( )
Where, y = Yield stress

m = gasket factor = 2.75
Gasket material chosen is asbestos with a suitable binder for the operating
conditions.
Gasket thickness = 10mm
y = 2.60 x 9.81 = 25.5 N/mm2

1/2
do = 25.5 - 0.11 (2.75) = 1.002

di 25.5 – 0.11 (2.75 +1)
Inside diameter of gasket di = outside diameter of shell + 5 mm

= 768 + 5mm = 773 mm
Outside diameter of the gasket

do = 1.002 (773)
= 774.564 mm
49
Minimum gasket width = 774.564 - 773 = 0.773 mm

2
But minimum gasket width = 6mm
∴ G = 768 + 2 x 6 = 780 mm (diameter at the location of gasket load reaction)
Estimation of bolt loads:
Load due to design pressure (H) = π G2 P

4
H = π (0.780)2 (0.11)
4
= 5.356 x 10-2 MN
Load to keep the joint tight under operating conditions.

Hp = π G (2b) m p
where, b= Gasket width = 6mm = 0.006m

⇒ Hp = π (0.78) (2 x 0.006) x 2.75 x 0.11
= 8.89 x 10-3 MN
Total operating load (Wo) = H + Hp

= 5.5 x 10-2 MN
Load to seat gasket under bolt –up condition = Wg

Wg = π G b y
= π x 0.78 x 0.006 x 25.5
Wg = 0.373 MN
⇒ Wg > W0
∴ Wg is the controlling load

∴ Controlling load = Wg = 0.3737 MN
50
Calculation of minimum bolting area:
Minimum bolting area (Am) = Ag = Wg

Sg
Sg = Tensile strength of bolt material (MN/m2) Consider ,

5% Cr-Mo steel, as design material for bolt
At 673 K, Sg = 138 x 10 6 N/m2 = 138 MN/m2
⇒ Am = 0.3737 = 3.71 x 10-- 3 m2

138
Calculation for optimum bolt size:
g1 = go /0.707 = 1.415 go
where, gl = thickness of the hub at the back of the flange

go = thickness of the hub at the small end = 10 + 2.5 =12.5mm
Selecting bolt size: M18x2

R = Radial distance from bolt circle to the connection of hub & back of flange
R = 0.027 m
C = Bolt circle diameter = ID + 2 (1.415 go + R)
= 748 +2 (1.415 (12.5) + 27) = 0.858 m
Actual flange outside diameter (A) = C + bolt diameter + 0.02

= 0.858 + 0.018 + 0.02
= 0.896 m2
Calculation of the flange thickness;
t2 = (M CF Y) / (B SFO)
Y = 17, CF = 1, B = 0.768 m
SFO = Nominal design stresses for the flange material at design temperature.
SFO = 100 MN
M = moment under operating conditions = 0.01365 MJ
51
t2 = (0.01365 x 1 x 17) / (0.768 x 100) = 0.0104 m2

t = 0.102 m
Bs = Bolt spacing = π C = π (0.858) = 0.0612 m

n 44
where, n = number of bolts = 44
CF = Bolt pitch correction factor

= [Bs / (2d + t)]1/2
= [0.0612 / (2 x 0.018 + 0.102)]1/2
CF = 0.623
∴ t = 0.102 x 0.623 = 0.0635 m
Let us take t = 65 mm.
Tube sheet thickness: (Cylindrical Shell)
t1s = Gc √ KP / f
Where, Gc = mean gasket diameter for cover.

P = design pressure.
K = 0.25 (when cover is bolted with full faced gasket)
f = permissible stress at design temperature.
⇒ t1s = 0.24 x [(0.25 x 0.11) / ( 95)]1/2

= 4.083 x 10-3 m = 4.083 mm
Considering corrosion allowance 3mm,

t1s = 8 mm
.
52
7.1.2 Specification Sheet of shell and tube heat exchanger
Unit Shell & tube heat exchanger
No. of shell passes 1
No. of tube passes 2
2
Heat Transfer area 147.4m
Diameter of shell 0.748m
Pitch 25mm
No. of tubes 604
Type of tube used 14BWG
No of baffles &type 12 (25%cut baffle)
OD & ID of tube 20mm & 16mm
Pt on shell side 3.06Kpascal or .443Psi
Ps on tube side 5.43kpascal or .787Psi

53
7.2 Design of Distillation Column
From material balance across Acrolein Distillation Tower
Feed Composition & Flow Rates (F)

Component Mass Flow Rate Molar Flow Rate Mass Fraction
(Kg/hr) (Kgmol/hr)
Acrolein 4635.8 82.782 0.98
Propylene 90.3 2.15 0.0191
Water 0.18 0.01 0.000039
Top Product Composition and Flow Rates (D)
Component Mass Flow Molar Flow Mass Fraction

Rate Rate(Kgmol/hr)
(Kg/hr)
Acrolein 4582.3 81.1826 0.999
Propylene 0.42 0.01 0.0000916
Water 0.774 0.043 0.000168
\
Bottom Product Composition & Flow Rates (B)
Component Mass Flow Molar Flow Mass Fraction

Rate Rate(Kgmol/hr)
(Kg/hr)
Acrolein 92.68 1.655 0.7098
Propylene 0 0 0
Water 37.89 2.105 0.2902
Since the liquid is feeding at its bubble point Temperature Hence

feed is saturated liquid.
54
Selection of key components

Light key (LK) Acrolein
Heavy key (HK) Water
Calculation of Relative Volatility
( Thermodynamics Data)
Component Top Bottom Average

α
Ki αDi=Ki/KHK Ki αBi=Ki/KHK
Acrolein 0.9698 5.615 3.5475 3.514 4.442
Propylene 30.68 177.6 59.818 59.216 102.5
Water 0.1727 1 1.0094 1 1
Calculation of minimum reflux ratio (Rm)
As Liquid is at its Bubble Point, so q = 1.

By trial and error, ɵ = 1.4
Using Equation of Min. Reflux Ratio,
Where, α = Relative volatility of component w.r.to reference (heavy key)

xd = Concentration of component in top product
xf= Concentration of component in feed
ɵ = Root of equation at Rm
R m = 0.414
55
Actual reflux ratio (R)

R = (1.2 - 1.5) R m
R = 1.5 R m = 0.621
Minimum Number of Plates ( Nm )
By Fenske Equation,
{( ) ( )}
( )
(αAB)AVG. = Avg. relative volatility of light key with respect to heavy key = 4.442
A = Light Key
B = Heavy Key
By putting the value we get,
Nm = 6.41
Theoretical No. of Plates
Gilliland related the number of equilibrium stages and the reflux ratio and the no. of
equilibrium stages with a plot that was transformed by Eduljee into the below relation.
Theoretical No. of Plates can be calculated by “Kirk Bride” relation,
* ( ) +
Putting the values in above equation we get,
N = 14
Hence, Min. Number of plates required is 6.41 (near 7).
And Theoretical no. of plates required is 14 plates.

56
Calculation of actual number of stages

Using O’ Connell’s Correlation for overall tray efficiency,
[ ( )]
Average temperature of column = 351.65k
Feed viscosity at average temperature

2
= avg 0.267mNs/m
Eo = 49%
So, No. of actual trays = Nact = 14-1/0.49= 27
Location of Feed Plate
( )
[ ] [( ) ( ) ( ) ]
( )
ND = No. of stages above the feed plate
NB = No. of stages below the feed plate
B = molar flow rates of bottom
D = molar flow rate of distillate
XLK=mole fraction of light key component
XHK=mole fraction of heavy key component
From which, NB = 16 and ND = 11

57
Determination of Column Diameter
Top Conditions Bottom Conditions
Ln = 2846.63 kg/hr Lm= Ln + F = 7572.91kg/hr
Vn = 7430.58 kg/hr Vm= Vn = 7430.58 kg/hr
TD=325.15 k TB=378.15 k
Mavg = 55.5 Mavg =18.35
3 3
Liquid density = ρL = 808.4 kg/m Liquid density = ρL = 953.7kg/m
3 3
Vapor density = ρV =1.8 kg/m Vapor density = ρV =0.60 kg/m
Surface Tension = σ = 0.01988 N/m Surface Tension= σ = 0.05798N/m
Assuming Total Pressure drop across the entire column is ∆Pt = 30.00 KPa.
Flow Parameter
( )( )
Ln = liquid flow rate in kg/sec
Vn= Vapor flow rate in kg/sec
FLV = Liquid Vapor Factor (Top) = 0.018
FLV = Liquid Vapor Factor (Bottoms) = 0.033

58
Calculation of flooding velocity

Assumed tray spacing = 0.45
( )
Where,
Uf = flooding velocity in m/sec
K1= constant
From graph of K1 vs. FLV
Top K1=0.08
Bottom K1=0.082
0.2
Correction for surface tension K1 × [σ/0.02]
Where σ in N/m. Now,
Top K1=0.0801
Bottom K1=0.1
Top Uf = 1.695 m/sec
Bottom Uf =3.985 m/sec
Assuming 90% flooding of Actual vapor velocity
At Top Uf = 1.525 m/sec
At Bottom Uf = 3.525 m/sec
Maximum volumetric flow rate of vapors ( mv )

= (mass vapor flow rate) / (3600 × vapor density)
3
mv = 0.78 m / s (Top)
mv = 2.226 m3 / s (Bottom)
59
Net area required = An = mv / U

2
= 0.51 m (Top)
= 0.621 m2 (Bottom)
Assume that downcommers occupies 15% of cross sectional Area (Ac) of column.
Ac = An + Ad
Where, Ad = downcommer area
Ac = An + 0.15(Ac)
Ac = An / 0.85
2
Ac=0.601m (Top)
2
Ac=0.730m (Bottom)
2
Ac =π/4D
D = (4Ac/π)
D = 0.87meter (Top)
D = 0.96meter (Bottom)
Since bottom diameter is larger so calculations will be based on bottom conditions.
Hence column diameter is D = 0.96meter.
Liquid flow arrangement
Maximum liquid flow rate = (Liquid mass rate)/ (3600) × (Liquid density) Max
Liquid Rate is at the bottom of column
3
So, Maximum liquid flow rate = 0.0030m /sec
From Appendix B figure 11, cross flow single pass plate is selected.
60
Provisional Plate Design
Column Diameter Dc= 0.96 m
2
Column Cross-sectional Area (Ac) = 0.730 m
2
Down comer area Ad = 0.15Ac = 0.109 m
2
Net Area (An) = Ac - Ad = 0.621 m
2
Active area Aa = Ac-2Ad = 0.512 m
2
Hole area Ah take 6% of Aa = 0.06 × 0.512 = 0.0307 m
Weir length
Ad / Ac = 0.109 / 0.730 = 0.149
Lw / dc = 0.80 (From graph of Ad / Ac vs. Lw / dc)
Lw = 0.96*0.80= 0.768 m
Weir length should be 60 to 85% of column diameter which is satisfactory.
Take weir height, hw 50 mm
Hole diameter, dh 5 mm
Plate thickness 5 mm (Carbon Steel)

61
Check Weeping
Uh (min) = [ K2 – 0.9(25.4-dh)] / ρv0.5
Where, Uh (min) is the minimum design vapor velocity.
The vapor velocity at weeping point is the minimum velocity for the stable operation.
In order to have K2 value we have to 1st find how (depth of the crest of liquid over
the weir).
Where how is calculated by following formula:
how(max) = 750 (Lm/ ρL Lw)

2/3
Taking minimum liquid rate at 70% turn down ratio of maximum liquid rate
At Maximum rate (how) = 16.170 mm Liquid

At Minimum rate (how) = 12.73mm Liquid
hw + how = 50 + 12.73 = 62.73 mm Liquid
K2 = 30.2 (From graph of K2 vs. hw + how )
So, U (min) = 15.66 m/sec
Now taking maximum volumetric flow rate (vapors) at 70% turn down ratio
Actual minimum vapor velocity = minimum vapor rate / Ah
UActual = 21.8 m/sec > U (min) = 15.66 m/sec
So minimum vapor rate will be well above the weep point.

62
Plate Pressure Drop (P.D)

To find the pressure drop across the column we requires,
I.
Dry plate P.D (orifice loss)
II.
P.D due to static head of liquid
III.
Residual P.D (bubbles formation result in energy loss + froth formed in operating
plates)
(1) Dry Plate Drop
Max. Vapor velocity through holes (Uh) = 29.7 m/sec

2
Active Area = Aa = 0.512 m
Ah/Aa = Ah/Ap = 0.059
Where Ap is the perforated area.
C0 = 0.82 (From graph of (C0 vs. (Ah/Ap × 100) )
2
hd = 51(Uh / Co) (ρv / ρL)
= 42.09 mm liquid
(2) Reisdual Drop

hr = 12.5 × 1000 / ρL
= 13.1 mm liquid
Total Plate Pressure Drop
ht = hd + hr + (hw +how)
= 117.92 mm liquid
Total pressure drop,

-3
∆Pt = 9.81 × 10 ×(ht) × ρL × Nact
= 29787.36
= 29.78 KPa
Hence, Assumed and calculated pressure drop are almost equal.

63
Downcomer Liquid backup / Liquid height in downcomer
Caused by P.D over the plate and resistance to flow in the downcomer itself.
hdc = 166 ×(Lw / ρL × Aap)2
Take hap = hw -10 = 40 mm = 0.04
Area under apron = hap×Lw

2
= 0.031 m
2
As Aap is less than Ad = 0.109 m . So use this value of Aap in the following equation:
hdc = 166 ×(Lw / ρL × Aap)2

= 1.041 mm
hb = (hw+ how) + ht + hdc

= 241mm
= 0.241m
hb < ½ (Tray spacing + weir height)

0.241 m < 0.25 m
So tray spacing of 0.45m is acceptable
Residence time
tr = (Ad × hbc × ρL ) / L(max)
tr = 8.00 sec
It should be > 3 sec.
So, result is satisfactory.

64
Entrainment
Actual velocity (based on net area) (un)
= Maximum volumetric flow rate / Net area

= 2.871 m/sec Velocity at flooding condition uf
= 3.586 m/sec
So Percent flooding = un / uf = 0.80 = 80%
Liquid flow factor = FLv =0.033
Fractional entrainment (ψ) = 0.05

(From graph of Fractional entrainment (ψ) vs. FLv)
Well below the upper limit of (ψ) which is 0.1.

Below this effect of entrainment on efficiency is small.
Number of holes
2 2
Area of 1 Hole = (π/4) × D hole = 0.0000196 m
2
Area of N Holes = 0.0307 m
Number of Holes = 1566.3
Height of Distillation Column
Height of column Hc
= (Nact -1)Hs+ ∆H+ plates thickness
No. of plates = 27 and Tray spacing Hs = 0.45 m
∆H= liquid hold up and vapor disengagement
∆H=0.55+0.55=1.1 m
Total thickness of trays = 0.005× 27 = 0.135 m
Height of column = (26 ×0.45) + 1.1+0.135

= 12.9 meters
65
7.2.2 Specification Sheet of Distillation Column
DESIGN DATA
No. of trays 27 Weir height 50mm
Pressure drop per 1.1kPa Weir length 0.7688 m

tray
No of Holes 1567 Minimum Reflux 0.414

Ratio
Height of column 12.9m Reflux ratio 0.621
Column-Diameter 0.96m Hole size 5mm
Tray spacing 0.45m Entrainment 0.05
Tray thickness 5mm Hole area 0.0307 m2
Flooding 80 % Active area 0.512m2

66
7.3 DESIGN OF STORAGE TANK
Storage Tank Diameter (Di): 15 m
Storage Tank Height (H) : 10 m
Pressure at the bottom of tank,
P=1.268 * (10 – 0.3) * 9.8 = 0.12053 N/mm2
Permissible Stress (f): 142 N/mm2
Joint Efficiency (J): 0.85
Thickness required (t) = (P*Di) / (2 * f * J)
= 120.53 * 15000 / 2 * 142 * 0.85
= 7.349 = 8 mm
Now, Assuming t = 6 mm,
6 = P * 15000 / 2 * 142 * 0.85
P = 0.1287 N/mm2
H = 8.0785 m
Remaining Height is (10 – 8.075) = 1.092 m
Height of one Plate = 1.8 m
No. of 8 mm plates required = 2

67
Height of Two Plates = 3.6 m
Height Left = 10-3.6 = 6.4 m
Now, Assuming t = 4 mm,
4 = P * 15000 / 2 * 142 * 0.85
P = 0.643 N/mm2
H = 5.48 m
Remaining Height is (6.4 – 5.48) = 0.92
No. of plates required = 1
Height required = 8.4 – 1.8 = 6.6 m
The remaining Height of 6.6 m will be completed using 2 mm plates.
No. of 2 mm plates = 4
Storage tank will require 2 plates of 6 mm thickness,

1 plate of 4 mm thickness and
4 plates of 2 mm thickness.
Total Height = 7 *1.8 = 12.6 mm
The Excess Height will be used for overlapping between Plates.

68
CHAPTER NO: 09 COST ESTIMATION

Cost of designed Equipments
Cost is being calculated by using following formula,
Cost of Equipment in year A = Cost of Equipment in year B ×

(Cost Index in year A/Cost Index in year B)
We will use Marshall and Swift Equipment Cost Index (MS) for Cost Estimation
throughout the procedure.
(1) Heat Exchanger

For carbon steel shell, stainless steel tubes and floating head,
Purchased cost of shell & tube Condenser (2012) = 98, 00,000 Rs.
Using Marshall & Swift equipment cost index,
Cost index in year 2012 = 1200

Cost of Condenser in 2018 = 98, 00,000 × 1700/1200 = 1, 38, 84,000 Rs.
(2) Reactor
For carbon steel shell, stainless steel tubes and fixed head,
Purchased cost of multi-tubular reactor (2012) = 17,36,000 Rs.

69
Cost of multi-tabular Reactor in 2018 = 17,36,000 × 1700/1200
= 24,60,000 Rs.
(3) Absorber
Material of construction = Carbon steel
Purchased cost of Absorber (2012) = 92,40,000 Rs.
Cost of Absorber in 2018 = 92,40,000 × 1750/1100

(Includes column internal support and distribution)
=1,47,00,000
(4) Distillation Column
Material of construction = Carbon steel
Purchased cost of Distillation Column (2012) = 10,94,800 Rs.
Cost of Column in 2018 = 10, 94,800 × 1500/1092 = 15, 03,900 Rs.

70
Fixed capital investment for 150 tons/day capacity
= (7 * 1, 38, 84,000) + (1 * 24, 60,000)

+ (1 * 1, 47, 00,000) + (3 * 15, 03,900)
= Rs 11, 88, 60,000
9.1 Estimation of total capital investment:
I. Direct cost:
1. Purchased equipment (30% of fixed capital investment)
8
= 0.3 x 1.189 x10
8
= 0.3567 x 10 Rs.
2. Installation, including insulation and painting

(30% of purchased equipment)
8
= 0.3 x 0.3567 x 10
8
= 0.10701 x 10 Rs.
3. Instrumentation and controls, installed (10% of purchased equipment)

8
= 0.1 x 0.3567x10
7
= 0.3567x 10 Rs.
4. Piping, installed (20% of purchased equipment)

8
= 0.2 x 0.3567 x 10
7
= 0.7134 x 10 Rs.
5. Electrical, installed (15% of purchased equipment)

8
= 0.15 x 0.3567 x 10
7
= 0.535x 10 Rs.
6. Buildings (20% of purchased equipment cost )

8
= 0.2 x 0.3567 x 10
7
= 0.7314 x 10 Rs.
71
7. Service facilities and yard improvements: (60% of purchased equipment)

8
= 0.6 x 0.3567x 10
8
= 0.214 x 10 Rs.
8. Land (5% of purchased equipment)
= 0.05 × 0.3567 × 108

7
= 0.1783 x 10 Rs.
9. Yard improvement (10% of purchased equipment)
= 0.1 × 0.3567 × 108
= 0.3567 × 107 Rs.
Direct cost = 98.626 × 106 Rs.
II. Indirect cost:-
1. Engineering and supervision

6
(4% of fixed capital cost) = 4.756 x 10 Rs.
2. Construction expense and contractor’s fee

(10% of fixed capital cost)
6
= 11.89 x 10 Rs.
3. Contingency (5% of fixed capital investment)
=5.945 × 106 Rs.
Indirect cost = 22.591 × 106 Rs.
Fixed capital cost = Direct cost + Indirect cost
=121.217 × 106 Rs.

72
Total capital investment

= fixed capital investment + working capital
Let working capital = 15% of total capital investment

6
Fixed capital investment = 121.217 x 10 Rs.
6
Total capital investment = 142.6 x 10 Rs.
9.2 Estimation of total product cost:
I. Manufacturing cost
A. Fixed charges:
(1) Depreciation (10% of fixed capital investment + 2% of building)

6
= 11.88 x 10 + 0.146x106
6
= 12.026 x 10 Rs.
(2) Local taxes (3% of fixed capital investment)

6
= 3.564 x 10 Rs.
(3) Insurance ( 0.8% of fixed capital investment )

6
= 0.9504 x 10 Rs.
6
Fixed charges = 16.5404 x 10 Rs.
Let fixed charge be 15% of total product cost
Total product cost

6
= 16.5404 x 10 /0.15
6
=110.27 x 10 Rs.
73
B. Direct production cost:
1. Raw materials (15% of total product cost)

6
= 16.54 x 10 Rs.
2. Operating labor (11% of total product cost)

6
= 12.13 x 10 Rs.
3. Direct supervisory and clericallabor (15% of operating labor)

6
= 1.82 x 10 Rs.
4. Utilities (15% of total product cost)

6
= 16.54 x 10 Rs.
5. Maintenance and repairs (5% of fixed capital investment)

6
= 6.061 x 10 Rs.
6. Operating supplies [15% of maintenance and repairs)

6
= 0.9091 x 10 Rs
7. Laboratory charges (15% of operating labor)

6
= 1.82 x 10 Rs.
8. Patents and royalties (3% of total product cost)

6
= 3.3081 x 10 Rs.
Direct production cost = 59.13 × 106

74
C. Plant overhead costs (5% of total product cost)

6
= 5.5135 x 10 Rs.
(1) Manufacturing cost = Fixed charges + direct production cost + plant overhead cost
6
= 524.83 x 10 Rs.
(2) General Expenses:
A. Administrative costs (5% of total product cost)

6
= 55.135 x 10 Rs.
B. Distribution and selling costs (14% of total product cost)

6
= 154.38 x 10 Rs.
C. Research and development costs (5% of total product cost)

6
= 55.135 x 10 Rs.
D. Financing (20% of total capital investment)

6
=220.52 x 10 Rs.
6
General expenses = 485.67 x 10 Rs.
Total product cost

= manufacturing cost + general expenses
6
= 1010.5 x 10 Rs.
Cost of the product
6
= (1010.5 x 10 ) / (5,00, 00,000)
= 20.2 Rs/Kg
75
With a profit margin of 5% = 1.05 x 20.21

= 21.221 Rs/Kg
Gross annual earning (GAE)
2
=21.221 x 54750 x 10
6
= 101.7 x 10 Rs.
Net annual earnings = GAE – Income tax
Income tax = 40% of GAE
6
Net annual earnings = 61.02 x 10 Rs.
Payback period = (total capital investment) / (net annual earnings)
6
= 142.6 x 10
6
61.02 x 10
= 2.33 years
Rate of return = (net annual earnings) / (fixed capital investment)
6
= 61.02 x 10 x 100
118.86 x 106
= 51.33
76
CHAPTER: 10 PLANT LOCATIONS
The location of the plant can have a crucial effect on the profitability of a project,
and the scope for future expansion. Many factors must be considered when
selecting a suitable site, and only a brief review of the principal factors will be
given in this section. The principal factors to be considered are:
1. Location, with respect to the marketing area.

2. Raw material supply.
3. Transport facilities.
4. Availability of labour.
5. Availability of utilities: water, fuel, power.
6. Availability of suitable land.
7. Environmental impact and effluent disposal.
8. Local community considerations.
9. Climate.
10. Political strategic considerations.
Marketing area
For materials that are produced in bulk quantities: such as cement, mineral
acids and fertilizers, where the cost of the product per ton is relatively low and the
cost of transport a significant fraction of the sales price, the plant should be
located close to the primary market.
This consideration will be less important for low volume production, high-
priced products; such as pharmaceuticals. In an international market, there may be
an advantage to be gained by locating the plant within an area with preferential
tariff.
77
Raw materials
The availability and price of suitable raw materials will often determine the site
location. Plants producing bulk chemicals are best located close to the source of
the major raw material; where this is also close to the marketing area.
Transport
The transport of materials and products to and from plant will be an overriding
consideration in site selection. If practicable, a site should be selected that is close
at least two major forms of transport: road, rail, waterway or a seaport.
Road transport is being increasingly used, and is suitable for local distribution
from a central warehouse. Rail transport will be cheaper for the long-distance
transport of bulk chemicals. Air transport is convenient and efficient for the
movement of personnel and essential equipment and supplies, and the proximity
of the site to a major airport should be considered.
Availability of labour
Labour will be needed for construction of the plant and its operation. Skilled
construction workers will usually be brought in from outside the site, but there
should be an adequate pool of unskilled labour available locally; and labour
suitable for training to operate the plant. Skilled tradesmen will be needed for
plant maintenance. Local trade union customs and restrictive practices will have
to be considered when assessing the availability and suitability of the labour for
recruitment and training.
Utilities (services)
The word “utilities” is now generally used for the ancillary services needed in the
operation of any production process. These services will normally be supplied
from a central facility; and will include:
78
1. Electricity: - power required for electrochemical processes, motors,

lightings, and general use
2. Steam for process heating: - The steams required for the process are
generated in the Tube boilers using most economic fuel.
3. Cooling water: - Natural and forced draft cooling towers are generally
used to provide the cooling water required on site.
4. Water for general use: - The water required for the general purpose will be
taken from local water supplies like rivers, lakes and seas. Because of this
reason all the plants located on the banks of river.
5. Dematerialized water: - Dematerialized water, from which all the minerals

have been removed by ion-exchange is used where pure water is needed
for the process use, in boiler feed water.
6. Refrigeration: - Refrigeration is needed for the processes, which require

temperatures below that are provided by the cooling water.
7. Inert-gas supplies.
8. Compressed air: - In an ethylene oxide plant compressed air is one of the

raw materials. It is also needed for pneumatic controllers etc.
9. Effluent disposal facilities: - facilities must be provided for the effective

disposal of the effluent without any public nuisance.
79
Environmental impact, and effluent disposal
All industrial processes produce waste products, and full consideration must be
given to the difficulties and coat of their disposal. The disposal of toxic and
harmful effluents will be covered by local regulations, and the appropriate
authorities must be consulted during the initial site survey to determine the
standards that must be met.
Local community considerations
The proposed plant must fit in with and be acceptable to the local community.
Full consideration must be given to the safe location of the plant so that it does
not impose a significant additional risk to the community. Land (site
considerations) sufficient suitable land must be available for the proposed plant
and future expansion. The land should be ideally flat, well drained and have load-
bearing characteristics. A full site evaluation should be made to determine the
need for piling or other foundations.
Climate
Adverse climatic conditions at site will increase costs. Abnormally low

temperatures will require the provision of additional insulation and special heating
for equipment and piping. Stronger locations will be needed at locations subject to
high wind loads or earthquakes.
Political and strategic considerations
Capital grants, tax concessions, and other inducements are often given by
governments to direct new investment to preferred locations; such as areas of high
unemployment. The availability of such grants can be the overriding consideration
in site selection.
80
CHAPTER 11 PLANT LAY OUT
The economic construction and efficient operation of a process unit will depend
on how well the plant and equipment specified on the process flow sheet is laid
out. The principal factors are considered are: Economic considerations:
construction and operating costs.
 The process requirements

 Convenience of operation
 Convenience of maintenance
 Safety. Future expansion
 Modular construction
Costs
The cost of construction can be minimized by adopting a layout that gives the
shortest run of connecting pipe between equipment, and at least amount of
structural steel work. However, this will not necessarily be the best arrangement
for operation and maintenance.
Process requirements
An example of the need to take into account process consideration is the need to
elevate the base of columns to provide the necessary net positive suction head to a
pump or the operating head for a thermo syphon reboiler.
Operations
Equipment that needs to have frequent attention should be located convenient to

the control room. Valves, sample points, and instruments should be located at
convenient positions and heights. Sufficient working space and headroom must be
provided to allow easy access to equipment.
81
Maintenance
Heat exchangers need to be sited so that the tube bundles can be easily withdrawn
for cleaning and tube replacement. Vessels that require frequent replacement of
catalyst or packing should be located on the outside of buildings. Equipment that
requires dismantling for maintenance, such as compressors and large pumps,
should be places under cover.
Safety
Blast walls may be needed to isolate potentially hazardous equipment and confine
the effects of an explosion. At least two escape routes for operators must be
provided from each level in process buildings.
Plant expansion
Equipment should be located so that it can be conveniently tied in with any future
expansion of the process. Space should be left on pipe alleys for future needs, and
service pipes over-sized to allow for future requirements.
Modular construction
In recent years there has been a move to assemble sections of plant at the plant
manufacturer’s site. These modules will include the equipment, structural steel,
piping and instrumentation. The modules are then transported to the plant site, by
road or sea. The advantages of modular construction are:
 Improved quality control.
 Reduced construction cost.
 Less need for skilled labor on site.
Some of the disadvantages are;

 Higher design costs & more structural steel work.
 More flanged constructions & possible problems with assembly.
82
THE PLANT LAYOUT KEYWORDS
1. Raw material Storage
2. Product Storage
3. Process Site
4. Laboratories
5. Workshop
6. Canteen & Change house
7. Fire Brigade
8. Central Control Room
9. Security office
10. Administrative Building
11. Site for Expansion Project.
12. Effluent treatment plant
13. Power house
14. Emergency water storage
15. Plant utilities

83
A detailed plant layout is drawn and submitted with this thesis report.
This plant layout is just a reference plant layout. There may be a lot of changes
in actual plant layout.
84
CHAPTER 12
MATERIAL SAFETY DATA SHEET (MSDS)
Section 1: Chemical Product
 Product Name: Acrolien

 Chemical Formula: C3H4O
 CAS: 107-02-8
Section 2: hazards identification
 Potential acute health effects.

 very hazardous in case of skin contact (irritant), of eye contact (irritant), of ingestion, of
inhalation. Hazardous in case of skin contact (permeator). Slightly hazardous in case of
skin contact (corrosive), of eye contact (corrosive). liquid or spray mist may produce
tissue damage particularly on mucous membranes of eyes, mouth and respiratory tract.
Skin contact may produce.
 Potential chronic health effects.
 Carcinogenic effects: not classifiable for human.
 Mutagenic effects: mutagenic for mammalian somatic cells. Mutagenic for bacteria
and/or yeast. Teratogenic effects: not available.
 Developmental toxicity: not available. The substance is toxic to lungs, upper respiratory
tract. The substance may be toxic to skin, eyes. Repeated or prolonged exposure to the
substance can produce target organs damage. repeated or prolonged contact with spray
mist
 May produce chronic eye irritation and severe skin irritation. Repeated or prolonged
exposure to spray mist may produce.
85
Section 3: first aid measures
 Eye Contact:
Check for and remove any contact lenses. Immediately flush eyes with running water for at
least 15 minutes, keeping eyelids open. Cold water may be used. Get medical attention
immediately.
 Skin Contact:
In case of contact, immediately flush skin with plenty of water for at least 15 minutes while
removing contaminated clothing and shoes. Cover the irritated skin with an emollient.
Cold water may be used. Wash clothing before reuse. Thoroughly clean shoes before
reuse. Get medical attention immediately.
 Serious Skin Contact:
Wash with a disinfectant soap and cover the contaminated skin with an anti-bacterial cream.
Seek immediate medical attention.
 Inhalation:
If inhaled, remove to fresh air. If not breathing, give artificial respiration. If breathing is
difficult, give oxygen. Get medical attention immediately.
 WARNING: It may be hazardous to the person providing aid to give mouth-to-mouth

resuscitation when the inhaled material is toxic, infectious or corrosive. Seek immediate
medical attention.
 Ingestion: If swallowed, do not induce vomiting unless directed to do so by medical

personnel. Never give anything by mouth to an unconscious person. Loosen tight clothing
such as a collar, tie, belt or waistband. Get medical attention immediately.
 Serious Ingestion: Not available
86
Section 4: Fire and Explosion Data

 Flammability of the Product: Flammable.
 Auto-Ignition Temperature: 220°C (428°F)
 Flash Points: CLOSED CUP: -26°C (-14.8°F). OPEN CUP: -18°C (-0.4°F) (Cleveland).
 Flammable Limits: LOWER: 2.8% UPPER: 31%
 Products of Combustion: These products are carbon oxides (CO, CO2).
 Fire Hazards in Presence of Various Substances: Highly flammable in presence of open
flames and sparks, of heat. Flammable in presence of oxidizing materials.
 Explosion Hazards in Presence of Various Substances:
 Risks of explosion of the product in presence of mechanical impact: Not available. Risks
of explosion of the product in
 Presence of static discharge: Not available. Slightly explosive in presence of heat.
 Fire Fighting Media and Instructions:
 Flammable liquid, soluble or dispersed in water. SMALL FIRE: Use DRY chemical
powder. LARGE FIRE: Use alcohol foam,
 Water spray or fog.
 Special Remarks on Fire Hazards:
 Vapors may form explosive mixtures with air. Vapor may travel considerable distance to
source of ignition and flash back.
 When heated to decomposition it emits toxic fumes of carbon monoxide.
 Special Remarks on Explosion Hazards: Vapors may form explosive mixtures with air.
Section 5: Accidental Release Measures

 Small Spill: Dilute with water and mop up, or absorb with an inert dry material and place
in an appropriate waste disposal container.
 Large Spill: Flammable liquid. Corrosive liquid. Poisonous liquid. Keep away from heat.
Keep away from sources of ignition. Stop leak if without risk. Absorb with DRY earth,
sand or other non-combustible material. Do not get water inside container. Do not touch
 Spilled material. Use water spray curtain to divert vapor drift. Use water spray to reduce
vapors. Prevent entry into sewers.
87
 Basements or confined areas; dike if needed. Call for assistance on disposal. Be careful
that the product is not present at a concentration level above TLV. Check TLV on the
MSDS and with local authorities.
Section 6: Handling and Storage
 Precautions: Keep away from heat. Keep away from sources of ignition. Ground all
equipment containing material. Do not ingest. Do not breathe gas/fumes/ vapor/spray.
Never add water to this product. In case of insufficient ventilation, wear suitable
respiratory equipment. If ingested, seek medical advice immediately and show the
container or the label. Avoid contact with skin and eyes. Keep away from incompatibles
such as oxidizing agents, acids, alkalis.
 Storage: Store in a segregated and approved area. Keep container in a cool, well-
ventilated area. Keep container tightly closed and sealed until ready for use. Avoid all
possible sources of ignition (spark or flame). Do not store above 8°C (46.4°F).
Refrigerate. Sensitive to light.
Section 7: Exposure Controls/Personal Protection

 Engineering Controls:
 Provide exhaust ventilation or other engineering controls to keep the airborne
concentrations of vapors below their respective ethers hold limit value. Ensure that
eyewash stations and safety showers are proximal to the work-station location.
 Personal Protection:
 Face shield. Full suit. Vapor respirator. Be sure to use an approved/certified respirator or
equivalent. Gloves. Boots. Personal Protection in Case of a Large Spill: Splash goggles.
Full suit. Vapor respirator. Boots. Gloves. A self-contained breathing apparatus should be
used to avoid inhalation of the product. Suggested protective clothing might not be
sufficient; consult a specialist BEFORE handling this product.
 Exposure Limits: TWA: 0.1 STEL: 0.3 from ACGIH (TLV) [United States] TWA: 0.23
STEL: 0.69 from ACGIH (TLV) [United States] Consult local authorities for acceptable
exposure limits.
88
Section 8 : Physical and Chemical Properties

 Physical state and appearance: Liquid. (Liquid.)
 Odor: Disagreeable and choking. Piercing. Extremely sharp. Extremely acrid
 Taste: Not available.
 Molecular Weight: 56.06 g/mole
 Color: Colorless to light yellow. p. 4
 pH (1% solution/water): 7 [Neutral.]
 Boiling Point: 52.5°C (126.5°F)
 Melting Point: -88°C (-126.4°F)
 Critical Temperature: 254°C (489.2°F)
 Specific Gravity: 0.8389 (Water = 1)
 Vapor Pressure: 28 kPa (@ 20°C)
 Vapor Density: 1.94 (Air = 1)
 Volatility: Not available.
 Odor Threshold: 0.21 ppm
 Water/Oil Dist. Coeff.: The product is equally soluble in oil and water; log(oil/water) = 0
 Ionicity (in Water: Not available.
 Dispersion Properties: See solubility in water, diethyl ether.
 Solubility: Soluble in cold water, hot water, diethyl ether. Soluble in petroleum ether,
alcohol, oxygenated solvents. Miscible with lower alcohols, ketones, benzene. Solubility
in water: 208 g/kg @ 20 deg. C; 212,000 mg/l @ 25 °C
Section 9: Stability and Reactivity Data
 Stability: The product is stabilized with Hydroquinone. However, it may form unstable
peroxides over time.
 Instability Temperature: Not available.
 Conditions of Instability: Heat, ignition sources, incompatible materials, light.
 Incompatibility with various substances: Reactive with oxidizing agents, acids, alkalis.
 Corrosivity: Non-corrosive in presence of glass.
89
 Special Remarks on Reactivity: Incompatible with amines. Incompatible with oxygen and
peroxides. May polymerize on exposure to light, or in presence of alkali or strong acid
forming disacryl. Incompatible with oleum, ethyleneimine, chlorosulfonic acid,
ammonium hydroxide, 2-aminoethanol, alkalis, strong acids, mineral acids, oxidizers,
ammonia may form shock sensitive peroxides overtime.
 Polymerizes readily unless inhibited (stabilized)
 Special Remarks on Corrosivity: Non-corrosive to iron and steel at room temperature
 Polymerization:
 Will not occur with the product as is. This product is stabilized with Hydroquinone.
However, it will polymerize of not stabilized or in contact with acids (including sulfur
dioxide), alkalis, volatile amines, salts, thiourea, oxidants (air), and on exposure to light
and heat.
Section 10: Toxicological Information

 Routes of Entry: Absorbed through skin. Dermal contact. Eye contact. Inhalation.
Ingestion.
 Toxicity to Animals:
 WARNING: THE LC50 VALUES HEREUNDER ARE ESTIMATED ON THE BASIS
OF A 4-HOUR EXPOSURE. Acute oral toxicity (LD50): 7 mg/kg [Rabbit]. Acute
dermal toxicity (LD50): 200 mg/kg [Rabbit]. Acute toxicity of the vapor (LC50): 18
mg/m3 4 hours [Rat].
 Chronic Effects on Humans:
CARCINOGENIC EFFECTS: 3 (Not classifiable for human.) by IARC.
MUTAGENIC EFFECTS: Mutagenic for mammalian somatic cells. Mutagenic for bacteria
and/or yeast. Causes damage to the following organs: lungs, upper respiratory tract. May
cause damage to the following organs: skin, eyes.
 Other Toxic Effects on Humans:
Very hazardous in case of skin contact (irritant), of ingestion, Hazardous in case of skin
contact (permeator), of inhalation (lung corrosive). Slightly hazardous in case of skin
contact (corrosive), of eye contact (corrosive).
90
 Special Remarks on Toxicity to Animals: Not available.

 Special Remarks on Chronic Effects on Humans:
 May cause adverse reproductive effects. May affect genetic material (mutagenic)
 Special Remarks on other Toxic Effects on Humans: Acute Potential Health Effects:
Skin: Causes severe irritation. May cause skin burns. May be fatal if absorbed through
skin.
 Eyes: Causes severe irritation. May cause corneal burns. It is a lacrimating agent.
Inhalation: May be fatal if inhaled. It causes respiratory tract irritation. It is a severe
pulmonary irritatant. Symptoms may include difficulty breathing (dyspnea), chest
congestion, and bronchospasm. Delayed of acute lung injury (acute pulmonary edema,
emphysema), permanent lung damage may also occur. Nausea, vomiting, and CNS can
also occur. Death may result from acute lung injury and/or respiratory failure.
 Ingestion: May be fatal if swallowed. May produce severe irritation of the mouth, and
gastrointestinal tract. It may also affect behavior/central nervous system (general
anesthetic, somnolence).
Section 11: Ecological Information
 Ecotoxicity: Not available.

 BOD5 and COD: Not available.
 Products of Biodegradation: Possibly hazardous short term degradation products are not
likely. However, long term degradation products may arise.
 Toxicity of the Products of Biodegradation: The products of degradation are less toxic
than the product itself.
 Special Remarks on the Products of Biodegradation: Not available
Section 12: Disposal Consideration
 Waste Disposal: Waste must be disposed of in accordance with federal, state and local
environmental control regulations.
91
CHAPTER NO: 13
SAFETY ISSUES AND ENVIRONMENTAL IMPACTS
13.1Hazards Identification
13.1.1Potential Acute Health Effects
Acrolein is very hazardous in case of skin contact (irritant), of eye contact

(irritant), of ingestion, of inhalation. Liquid or spray mist may produce tissue
damage particularly on mucous membranes of eyes, mouth and respiratory tract.
Skin contact may produce burns. Inhalation of the spray mist may produce severe
irritation of respiratory tract, characterized by coughing, choking, or shortness of
breath. Severe over-exposure can result in death. Inflammation of the eye is
characterized by redness, watering, and itching. Skin inflammation is
characterized by itching, scaling, reddening, or, occasionally, blistering.
13.1.2 Potential Chronic Health Effects
Acrolein is mutagenic for mammalian somatic cells and for bacteria and/or yeast.
The substance is toxic to lungs, upper respiratory tract. The substance may be
toxic to skin, eyes. Repeated or prolonged exposure to the substance can produce
target organs damage. Repeated or prolonged contact with spray mist may
produce chronic eye irritation and severe skin irritation. Repeated or prolonged
exposure to spray mist may produce respiratory tract irritation leading to frequent
attacks of bronchial infection. Repeated exposure to a highly toxic material may
produce general deterioration of health by an accumulation in one or many human
organs.
92
13.2Fire and Explosion Data
Flammability of the Product: Flammable.
Auto-Ignition Temperature: 220°C (428°F)
Flammable Limits: LOWER: 2.8% UPPER: 31%
Products of Combustion: These products are carbon oxides (CO, CO2).
Fire Hazards in Presence of Various Substances:

Acrolein is highly flammable in presence of open flames and sparks, of heat also in
presence of oxidizing materials.
Explosion Hazards in Presence of Various Substances:

There is a risk of explosion of the product in presence of mechanical impact and slightly
explosive in presence of heat.
Fire Fighting Media and Instructions:

Flammable liquid, soluble or dispersed in water. In case of small fire use dry chemical
powder while for large fire alcohol foam, water spray or fog may be used.
Special Remarks on Fire Hazards:

Vapors may form explosive mixtures with air. Vapor may travel considerable distance to
source of ignition and flash back. When heated to decomposition it emits toxic fumes of
carbon monoxide, peroxides.
Special Remarks on Explosion Hazards:

Vapors may form explosive mixtures with air.
93
13.3Accidental Release Measures
Small Spill:
Dilute with water and mop up, or absorb with an inert dry material and place in an
appropriate waste disposal container.
Large Spill:
Acrolein is flammable, corrosive and Poisonous liquid. Keep it away from heat also from
sources of ignition. Absorb with dry earth, sand or other non-combustible material. Do
not get water inside container. Do not touch spilled material. Use water spray curtain to
divert vapor drift. Use water spray to reduce vapors. Prevent entry into sewers, basements
or confined areas; dike if needed. Call for assistance on disposal.
13.4 Handling and Storage
Precautions:
Acrolein should be kept away from sources of ignition. Ground all equipment containing
material. Do not ingest. Do not breathe gas/fumes/ vapor/spray. Never add water to this
product. In case of insufficient ventilation, wear suitable respiratory equipment. If
ingested, seek medical advice immediately and show the container or the label. Avoid
contact with skin and eyes. Keep away from incompatibles such as oxidizing agents,
acids, alkalis.
Storage:
It should be stored in a segregated and approved area. Keep container in a cool, well-
ventilated area also keep it tightly closed and sealed until ready for use. Avoid all possible
sources of ignition (spark or flame). Do not store above 8°C (46.4°F).
94
13.5 Exposure Controls/Personal Protection
Engineering Controls:
Provide exhaust ventilation or other engineering controls to keep the airborne
concentrations of vapors below their respective threshold limit value. Ensure that eyewash
stations and safety showers are proximal to the work-station location.
Personal Protection:
Face shield, full suit and vapor respirator should be used. Be sure to use an
approved/certified respirator with gloves and boots.
Personal Protection in Case of a Large Spill:

A self-contained breathing apparatus should be used to avoid inhalation of the product.
Suggested protective clothing might not be sufficient; consult a specialist before handling
this product.
13.6First Aid Measures
Eye Contact:
Check for and remove any contact lenses. Immediately flush eyes with running water for
at least 15 minutes, keeping eyelids open. Cold water may be used. Get medical attention
immediately.
Skin Contact:
In case of contact, immediately flush skin with plenty of water for at least 15 minutes
while removing contaminated clothing and shoes. Cover the irritated skin with an
emollient. Cold water may be used. Wash clothing before reuse. Thoroughly clean shoes
before reuse. Get medical attention immediately.
95
Serious Skin Contact:
Wash with a disinfectant soap and cover the contaminated skin with an anti-bacterial
cream. Seek immediate medical attention.
Inhalation:
If inhaled, remove to fresh air. If no breathing is possible, give artificial respiration. If

breathing is difficult, give oxygen. Get medical attention immediately.
Serious Inhalation:
Evacuate the victim to a safe area as soon as possible. Loosen tight clothing such as a
collar, tie, belt or waistband. If breathing is difficult, administer oxygen. If the victim is
not breathing, perform mouth-to-mouth resuscitation.
WARNING: It may be hazardous to the person providing aid to give mouth-to-mouth

resuscitation when the inhaled material is toxic, infectious or corrosive. Seek immediate
medical attention.
Ingestion:
If swallowed, do not induce vomiting unless directed to do so by medical personnel.

Never give anything by mouth to an unconscious person. Loosen tight clothing such as a
collar, tie, belt or waistband. Get medical attention immediately.
96
APPENDICES
Fouling factor (Coefficients) typical values

(Coulson Richardson Vol. 06, Table 12.2, Page 640)
Fouling factor (Coefficients) typical values

97
GRAPHS
Relation between Reynolds number and friction factor with respect to

baffle cut
(Coulson Richardson Vol. 06, Figure 12.30, Page 674)

98
Figure 2. Overall Coefficients

99
Figure 3. Tube patterns

Figure 4. Tube side heat transfer factor

100
Figure 5. Shell side heat transfer factor, segmental baffles

Figure 6. Generalized pressure drop correlation

101
Figure 7. Flooding velocity, sieve plates

Figure 8. Selection of liquid flow arrangement

102
Figure 9. Weep point correlation (Eduljee, 1959)

Figure 10. Relation between down comer area and weir length
103
Figure 11. Discharge coefficients, sieve plates

Figure 12. Entrainment correlation for sieve plate

104
REFERENCES
a. “Acrolein and Derivatives,” Kirk-Othmer Encyclopedia of Chemical

Technology, 4th ed., vol. 10, pp. 232-247.
b. McCabe, W.L, Smith, J.C., & Harriot, P., “Unit Operation of Chemical
Engineering”, McGraw Hill, 7th ed., Inc., 2017.
c. Coulson J.M. and Richardson J.F., “Chemical Engineering”, Vol. 6,

Butterwort Heminann, 2006.
d. R.H. Perry, Don Green, “Perry’s Chemical Engineer’s Handbook”, McGraw-

Hill, 7th ed.
rd
e. J.M. Smith, “Chemical Engineering Kinetics”, McGraw Hill, 3 ed., 2014.
f. Max S.Peters, Klaus D.Timmerhaus, Ronald E.West,” Plant Design And

th
Economics for Chemical Engineers”, McGraw Hill, 5 ed.
rd
g. O. Levenspiel, “Chemical Reaction Engineering”, 3 ed‟s., John Wiley and
Sons, 2006.
h. https://slideplayer.com/slide/4724863/
i. https://slideplayer.com/slide/6534558/

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A PROJECT ON

----------- Submitted -----------

PANKAJ RANA AMIT AGRAWAL

B. TECH. IV (Chemical) 8th Semester (2018-19)

CHEMICAL ENGINEERING DEPARTMENT

Sardar Vallabhbhai National Institute of Technology

Surat-395007, Gujarat, INDIA

Surat-395007, Gujarat, INDIA

CHEMICAL ENGINEERING DEPARTMENT

PANKAJ RANA AMIT AGRAWAL

Dr. Sanjay. R. Patel

Associate Professor, ChED

S. V. National Institute of Technology, Surat

Pankaj Rana (U15CH077) and Amit Agrawal (U15CH101), registered in Chemical

1) Examiner-1 Dr. CHETAN M. PATEL NKKL

2) Examiner-2 Dr. A. K. MUNGRAY

3) Examiner-3 Dr. G. C. JADEJA

The Project entitled “Production of Acrolein” is submitted to the Head (ChED)

Dr. Mausumi Mukhopadhyay

We would like to express deep sense of gratitude to our guide Dr.

Sanjay R. Patel (Associate Professor, Department of Chemical

for his extreme cooperation to complete our project work successfully.

cooperating us in completing this project.

In addition, we would also like to thank the department for including

project in the curriculum. Finally, we would like to express our heartfelt

and wishes for the successful completion of the project preliminary.

SR.NO. DESCRIPSTIPN PAGE NO.

2 PROCESS AND CAPACITY SELECTION 12

6 THERMODYNAMICS AND KINETICS 34

7 EQIPMENT DESIGN (MAJOR & MINOR) 37

12 MATERIAL SAFETY DATA SHEET 84

13 SAFETY ISSUES AND ENVIRONMENTAL IMPACTS 91

chemical formula is C3H4O and chemical name is 2-propanol. Acrolein is

1.2 History and origin

Acrolein is highly toxic and flammable material with extreme lachrymatory

By following the Degussa method of acrolein production the first plant to

produced by gas-phase oxidation of propylene in the presence of bismuth or

1.3 Methods of Manufacturing

 It was produced commercially starting in 1938 by the vapor-phase condensation of

 In 1959, the direct oxidation of propylene in presence of a catalyst became the

 The acetaldehyde-formaldehyde route was last used in the USA in 1970.

 Manufactured: By oxidation method i.e.

(A) by oxidation of acetaldehyde;

(B) by oxidation of propylene in liquid phase;

(C) by oxidation of propylene in vapor phase;

(D) by oxidation of allyl alcohol;

 By heating glycerol with magnesium sulphate.

 Prepared industrially by passing glycerol vapors over magnesium sulphate heated

1.4 properties of acrolein

1.4.1 Physical properties of acrolein

Odour Extreme sharp, pungent and disagreeable

Colour Colourless or yellowish

Standard heat of -74.483 kJ/mole

Heat of combustion -29098 kJ/kg

Heat of vaporization 542.191 kJ/kg

Heat of -80.4 kJ/mole

Vapor density 1.94 (Air =1)

1.4.2 Chemical properties

in molecule of acrolein because of its two functional group; acrolein is highly

1.5 Uses and applications of acrolein

Some of direct and indirect uses of acrolein are

Manufacturing of Acrylic Acid

The largest single use for acrolein is as an isolated intermediate in the