Ministry of Higher Education

And Scientific Research

University Of Technology Chemical Engineering Department

Equipment Design With The Aid Of Computer

Third Year By

Dr.Khalid A.Sukkar 2008-2009

Equipments Design with the Aid of Computer Programming

Theoretical 2 hr/week Tutorial 1 hr/week Practical 3 hr/week :Using Simulation by HYSYS Program.

References . 1- Ludwig E.E. (1999) Applied Process Design for Chemical and Petrochemical

Plants, Volume 1, Third Edition, Butterworth-Heinemann. 2- Ludwig E.E. (1999) Applied Process Design for Chemical and Petrochemical

Plants, Volume 3, Third Edition, Butterworth-Heinemann. 3- Peters, M. S., and Timmerhaus K. D. (1991). Plant Design and Economics for

Chemical Engineers, 4th edition, McGraw Hill. 4- McCabe, W., Smith, J. and Harriott, P. (2004). Unit Operations of Chemical

Engineering, 7th Edition, McGraw Hill. 5- Perry, Robert H. and Green, Don W. (1984). Perry's Chemical Engineers'

Handbook, 6th Edition, McGraw-Hill. 6- Kister, Henry Z. (1992). Distillation Design, 1st Edition, McGraw-Hill. Part (A) 1. Process Planning:

Scheduling and flow sheet design. Flow sheet types and designation. Block diagram. Process flow sheet. Piping and instruments diagram. Utility flow sheet. Equipment layout and plot plan. Project evaluation. Feasibility studies. Site selection. Project cost estimation. (6hrs) 2. Piping networks and pumps:

Pipe fittings, valves. Steam traps. Piping design standards. Piping material and selection. Pump specifications and data sheets. Optimum diameter. Types of pumps. Hydraulic characteristics for centrifugal pumps. (6hrs)

3. Vessels and Tanks: Types of vessels. Flash drums. LPG tanks. Criteria in vessel design. Stress

considerations. Design of tall vertical vessel. Design of pressure vessels. Supports and foundations (6hrs) 4. Heat transfer equipment:

Types of exchangers and applications. Exchanger ratings. Exchanger design. Exchanger specification sheets. Furnaces. Convection and radiation zones. Types of fuels. Burners and arrangements. Steam boilers, types of boilers. (6hrs) 5. Mass Transfer Equipment:

Types of columns. Plate and packed Types of plates and packing. Design features. Pressure drops in columns. (6hrs) Part (B) : Complete equipment design of each of the following units: 1. Pressure vessels, pumps and compressors:

Flash drum. Gas-liquid separator, LPG storage tanks. Cyclone separators. Gas movers and compressors. Pumps. Piping network. etc. (8hrs) 2. Heat Equipment:

Shell and tube heat exchangers. Plate heat exchanger. Boilers. Furnaces. Vaporizers. Air coolers. Coil type heaters. Condensers. etc. (10hrs) 3.Mass transfer equipment and reactors:

Distillation column. Absorber. Extractor. Dryer. Absorption towers. Leaching equipment. Scrubbers. Stripping towers. Reactors. (12hrs)

DesignsEquipment the Aid of Computer Programming ith w

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Equipment Design

Process design is the design of processes for desired physical and/or chemical transformation of materials. Process design is central to chemical engineering and it can be considered to be the summit of chemical engineering, bringing together all of the components of that field.

Process design can be the design of new facilities or it can be the modification or expansion of existing facilities. The design starts at a conceptual level and ultimately ends in the form of fabrication and construction plans.

in Chemical Engineering Field Transport Processes 1- Momentum Transfer (Fluid Flow)

2- Heat Transfer

3- Mass Transfer

and reaction kinetic and mechanism

:e equipments are classified tothngineering Ehemical C in, nThe

1- Fluid flow equipments (such as: pipes, pumps, storage tanks and vessels…..)

2-Heat transfer equipments ((such as: coolers, heat exchangers, boilers, reboilers,

heaters, condensers, furnaces, …….)

3- Mass transfer equipments (such as: distillation column, absorption column, leaching,

dryer, crystallizer, …….)

4- Reaction units (such as: CSTR, tubular reactor, fixed bed reactor, fluidized bed reactor,

biological reactor (fermenter),

Petroleum refinery

Tray in a distillation column Reboiler

Oil Refinery

Chemical plant near the river

Chemical Engineer (Process Engineer)

He has the following responsibilities:-

1. Prepares studies of process cycles and systems for various product productions.

2. Prepares economic studies associated with process performance.

3. Design and /or specifies items of equipment required to define the process flow sheet

or flow system.

4. Evaluates competitive bids for equipment.

5. Evaluates operating data for existing or test equipment.

6. Guides flow sheet draftsmen in detailed flow sheet preparation.

Flow Sheet –Types There are several types of flow sheets:-

1- Pictorial Flow Diagram

2- Block Diagram

a) Usually used to set for the a preliminary or basic processing concept with

out details,

b) The blocks represent the steps of process without details.

c) Each block represents a manufacturing step in the process.

d) It is used in survey studies to management, research summaries and

process proposals.

3. Process Flow Diagram (PFD)

A. Used to present the heat and mass balances of the process.

B. Show all production steps, starting from raw material to final products.

C. Show the operating conditions of each production step in the process (operating conditions

are: Temperature, Pressure, Flowrate, -----).

D. Show the type and quantities of utilities that required for the process (such as: water,

steam, O2, H2, -----)

E. Shows the process equipments and their conction pipes.

F. Gives some details for the main process equipments (such as: distiallion column: its

diameter, height, type of internals (trays or packing types), material of construction,

thickness, ---)

G. Show the main control system (type of instruments) required for the process.

H. Used as data base for Piping and Instrumentation Diagram (PID ) and for equipment

schedule (equipment summary).

3. Piping and instrument diagram (PID)

1) Prepared by chemical engineer with the aid of mechanical and control

Engineers.

2) Regarded as a data base for mechanical engineer for manufacturing of vessels,

Heat exchangers, Machines and controllers.

3) This diagram flows the PFD configuration.

4) Show piping details (diameter, length, type of flowing material, material of

construction, flow direction, design pressure, type of instillation and pipe position

in the process.

5) Show the position of measurement points for T, P and sample point.

6) Show all equipment in the process with details.

7) Used as data base for preparation of detailed design.

4. Utility Diagram (UD)

A. Utilities are:-cooling water, steam, air, O2, N2, H2, Flue gas, fire

water…….)

B. This diagram shows the quantities of required utilities for each

production step.

C. Show the operating conditions of utilities tat to be supplied

(specification, T, P……)

D. This diagram regarded as a Complementary diagram for ( PID) and

(PFD).

Model

1- It is a small three dimensional sample of the original plant shows all

instruments, pipes and carrying pipes.

2- It has a great advantage in the designing faults correction of instruments

location and pipes; directions and pathways before project establishing.

2- Useful in the training purposes as well as explaining the project to the

visitors after its done.

Three dimensional plant models

Plot Plans (Plant layout)

Actual north Pipe Racks

Control

room

H.E

H.E

H.E

Input of raw material Out put of products

S

W N

S

West north

Horizontal storage tank

Vertical storage tank

Power station

W

E

E

Furnaces

Towers

Symbology and Designation ا������و�� ��� �(�م� �1 ا��Rا��م�ز ا��

Symbology divination

W

Rw

Tw

Sw

S

S150

S400

V

M

A

SA

Water

River water

Treated water

Sea water

Low pressure steam

150 Psi steam

400 Psi steam

Vent

Methan

Air

Sulfuric acid

Data sheet or Schedule or Equipment summary

Pumps

-Section pressure

-Discharge pressure

- Net Position Section Head (NPSH)

-Quality of flow

-Type of fluid

-Type of material of Construction

-Physical properties of fluid (µ, ρ, -----)

Vessel

-Length

-Diameter

-Material of construction

-Operating pressure

-Design pressure

-Test pressure

-Internal (trays or packing, -----------)

*Lines

-size

-Schedule

-Material of construction

-operating pressure

-Design pressure

-Test pressure

-Type of flowing fluid and physical properties

Pressure Types in Design Work - Design pressure

- Operating pressure

- Test pressure

Design pressure = Operating pressure + 20% (Operating pressure)

Test pressure = 2×Design pressure

Activity analysis

Activity analysis Time%

Process design calculations

Conferences and consultion

Supervision

Preparation of chart

Marking, chart and reviewing

Group meeting

Literature

Coffee breaks

others

35-52

13-29

4-15

1-3

9-12

1-3

0.5-2

4-6

5-10

Estimated Equipment Calculation Man-Hours Man–hour: - for a specific calculation vary with process equipment, process system,

physical properties and familiarity of process engineer with design work.

Estimated total Job process Engineering =Estimated equipment Man-hours

0.45

Man –hour patterns

Assignment of Personnel It is important to plan ahead for the proper assignment of qualified engineering to various

projects as they arise.

The consideration selected for engineering works:-

1. Basic ability to understand the process under consideration.

2. Compatibility with the project engineer and other key decision making

representatives with whom they will be in daily contact.

There are two approaches to developing personnel

1. The generalist approached

2. The specialist approach

COST

Pb= Pa ( Cb/ Ca )0.6

Where:-

Pb:- cost of plant or section of plant of new capacity "b"

Pa:- cost of plant or section of plant of original capacity "a"

Cb:- capacity of plant or section of new requirements.

Ca:- capacity of plant or section of original requirements

Design of Drums There are three main types of drums:-

A. Liquid Surge Drums

B. Liquid -Liquid Separators

C. Vapoure-Liquid Separators or Vapour-Two Liquid Separators

Liquid Surge Drums

Surge time (ts)

ts: - depends on a functionality and location of surge drum.

Position of Surge Drum ts

A. Distillation reflux drum

B. Surge drum between two distillation column

C. Feeding a furnaces or reactor

D. Checking drum or drum feeding unite

5 minute

8 minute

12 minute

20 minute

Liquid surge time (ts) :- should be corrected for:-

1. Operators experience = ts×1 for fully experience

= ts ×1.5 for inexperience

2. Correction for the type of instrumentation

= ts×1 for fully instrumented

= ts ×1.5 for poorly instrumented

Design Surge Drum

-Length

-Diameter

-Material of construction (function temperature)

-Thickness

-Nozzle (location and size)

- Length/Diameter ratio (L/D) : it is related to pressure

Three ranges of (L/D)

(L/D)=1.5 for low pressure range (1.5-3) bar

(L/D)= 3 for pressure range (4-42) bar

(L/D)= 5 for pressure greater than 42 bar

Material of Construction it is Depends on Temperature

-For operating temperature -45 to 200 0C we used carbon steel (C.S) where, its

Tensile Strength (F) =950 Kg/cm2

-For operating temperature -45 to -104 0C we used 3(2

1 ) Nickel where, its

Tensile Strength (F) =1150 Kg/cm2

-For operating temperature -104 to -196 0C we used stainless steel where its

Tensile Strength (F) =1400 Kg/cm2

Liquid –liquid Separators (For two immiscible liquids)

Mechanism of Liquid-Liquid Separation

In separation of two liquids of marked densities differences, separation will occur by

settling. Therefore, the droplets of heavy phase (water droplet) will have a tendency to

full down and out of light phase under the influence of gravitational forces. The heavy

droplets accelerate until frictional force balance the gravitation force, at this point the

heavy droplet will continue to full down (phase out ) of the light phase at a constant

velocity which is the (terminal velocity ) until it reach the interface.

An analogy mechanism applies to separation of light phase droplets that may be present

in heavy phase (water) except that in this case the motion is up wards and the drag

frictional forces opposed by bouncy force.

Vapoure-Liquid Separators or Vapour-Two Liquid

Separators

Design of Bubble Cap Trays