tk21 report assignment2

7/24/2019 Tk21 Report Assignment2

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UNIVERSITAS INDONESIA

RENEWABLE BIODIESEL FROM

CRUDE PALM OIL, JATROPHA OIL, NYAMPLUNG OIL

REPORT ASSIGNMENT 2

GROUP 21

GROUP PERSONNEL:

DANAR ADITYA S. (1206263401)

DENNY SETYADARMA (1206263351)

HASANNUDIN (1206230725)

MUHAMMAD HAFIZ AL RASYID (1206219161)

TITEN PINASTI (1306482054)

CHEMICAL ENGINEERING DEPARTMENT

FACULTY OF ENGINEERING


DEPOK

2015


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EXECUTIVE SUMMARY

In order to design renewable diesel plant, we have to make Piping and

Instrumentation Diagram and Equipment Sizing. Piping and Instrumentation

Diagram known as P&ID is one of some objectives in this assignment. It is the

completion of Process Flow Diagram made in first assignment. It makes P&ID is

more detail than PFD. P&ID is used in manufacturing the renewable biodiesel

plant. Valves and some controllers also connected to the P&ID. P&ID is a used by

process engineer in communicating with other engineer from another discipline.

With this P&ID, we expect the other engineer can understand the whole plant

system easily. In this P&ID we separate it to some pages based on process to

make easy in attaching the valves and controller. There are 4 pages containing of

Degumming, Bleaching, Steam Methane Reforming, Hydrothreating.

After designing P&ID, We need to calculate the specification of the

process equipment being used in a plant known as equipment sizing. This is

another objective of this assignment There are equipment specifications,

equipment sizing, equipment calculations used in making renewable biodiesel

plant in this second assignment. Equipment needed in this plant are 5 tanks, 4

pumps, heat exchanger, reactor, three phase separator. These data is used for

manufacturing in plant design. Sizing of equipment based on rule of thumbs of the

equipment and industrial calculation method by using manual calculation and

software.


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TABLE OF CONTENTS

EXECUTIVE SUMMARY .................................................................................... ii

TABLE OF CONTENTS ....................................................................................... iii

LIST OF FIGURES ................................................................................................ v

LIST OF TABLES ................................................................................................. vi

CHAPTER 1 ........................................................................................................... 1

CONTROL AND INSTRUMENT DESIGN .......................................................... 1

1.1.

Plant Control Tabulation .......................................................................... 1

1.2.

Piping and Instrument Diagram ..............Error! Bookmark not defined.

1.3.

Start up, Normal and Shutdown Procedure ............................................ 12

1.3.1.

Start Up Procedure .......................................................................... 12

1.3.1.1.

Start Up Procedures for Each Section ..................................... 13

1.3.2.

Shut Down Procedure ..................................................................... 14

CHAPTER 2 ......................................................................................................... 15

EQUIPMENT SIZING ......................................................................................... 15

2.1.

Main Equiment ....................................................................................... 15

2.1.1.

Storage Tank ................................................................................... 15

Crude Palm Oil Storage Tank T-101 ................................................................ 15

Jatropha Oil Storage Tank T-101 ...................................................................... 16

Nyamplung Oil Storage Tank T-101 ................................................................ 17

Renewable Biodiesel Storage Tank T-102........................................................ 18

Degumming Tank V-101 .................................................................................. 19

Shift Converter Reactor R-102 ......................................................................... 20

Absorber Column V-103 ................................................................................... 21

2.2.

Supporting Equipment ............................................................................ 24

Heat Exchanger E-101 ...................................................................................... 24

Heat Exchanger E-102 ...................................................................................... 25

Heat Exchanger E-103 ...................................................................................... 26

Cooler E-104 ..................................................................................................... 29

CONCLUSION ..................................................................................................... 38


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REFERENCES ..................................................................................................... 39

APPENDIX ........................................................................................................... 40

Storage Tank ..................................................................................................... 40

Crude Palm Oil Storage Tank ........................................................................... 41

Jatropha Oil Storage Tank ................................................................................ 41

Nyamplung Oil Storage Tank ........................................................................... 42

Renewable Biodiesel Storage Tank .................................................................. 42

Degumming Tank ............................................................................................. 48

Hydrotreating Reactor Sizing ........................................................................... 52

Shift Converter Reactor R-102 ......................................................................... 60

Absorber Calculation ........................................................................................ 62

Heat Exchanger Design Procedure ................................................................... 70

Heat Exchanger E-101 ...................................................................................... 75


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LIST OF FIGURES

Figure A.1. Types of head of storage tank ............................................................ 44

Figure A.1. Power Number ................................................................................... 51

Figure B.1. Fixed Bed Reactor ............................................................................. 53

Figure B.2. Polymath Programming ..................................................................... 55

Figure B.3. Polymath Programming Result .......................................................... 56

Figure B.4. Polymath Programming Graph .......................................................... 56

Figure B.5. Equation used for the design or sizing of fixed bed reactor .............. 61

Figure B.6. Design for Various Packing............................................................... 64

Figure B.7. Flooding Line Graph .......................................................................... 65

Figure C.1. Shell and Tube Overall Coefficient ................................................... 71

Figure C.2. Air Cooled Exchangers and Immersed Oil Overall Coefficient ........ 71

Figure C.3. Coomon Tube Layouts ....................................................................... 72

Figure C.4. Heat exchangers tube-layouts ............................................................ 72

Figure C.5. Type of Heat Exchanger Baffles ........................................................ 73

Figure C.6. Temperature Correction Factor : two shell passes ; four or multiple

passes .................................................................................................................... 76

Figure C.7. Tube Sheet Layouts (square pitch) .................................................... 77

Figure C.8. HE Layouts ........................................................................................ 78

Figure C.9 jH Factor ............................................................................................. 83

Figure E.1 Impeller shapes related to specific speed ............................................ 92


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LIST OF TABLES

Table 1.1. Tabulation of degumming process ......................................................... 1

Table 1.2. Tabulation of bleaching process ............................................................ 2

Table 1.3. Tabulation of hydrotreating process ...................................................... 2

Table 1.4. Tabulation of steam methane reforming process ................................... 4

Table 1.7. Startup procedure ................................................................................. 12

Table 1.8. Emergency Shutdown .......................................................................... 14

Table 2.1 Specification Data of Storage Tank ...................................................... 15

Table 2.2. Specification Data of Storage Tank ..................................................... 16

Table 2.3 Specification Data of Storage Tank ...................................................... 17

Table. 2.4. Specification Data of Storage Tank .................................................... 18

Table. 2.5. Specification Data of Degumming Tank ............................................ 19

Table. 2.6. Specification Data of Shift Converter Reactor ................................... 20

Table. 2.7. Specification Data of Absorber Column ............................................. 21

Table. 2.8. Specification Data of Steam Methane Reformer ................................ 22

Table. 2.9. Specification Data of Hydrotreating Ractor Design ........................... 23

Table. 2.10. Specification Data of Heat Exchanger E-101 ................................... 24





Table. 2.15. Specification Data of Fired Heater E-103 ......................................... 29

Table. 2.16. Specification Data of Fired Heater E-104 ......................................... 30

Table 2.18. Specification Data of Compressor C-102 .......................................... 33

Table 2.19. Specification Data of Pump P-101 ..................................................... 34




Table A.1. List of Materials that Selected for Each Storage Tank ....................... 40

Table B.1. Sizing Shift Converter Reformer ........................................................ 62

Table B.2. Composition of the Incoming Gas ....................................................... 63

Table B.2. Steam Methane Reformer ................................................................... 69

Table C.1. Composition Properties ....................................................................... 79


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CHAPTER 1

CONTROL AND INSTRUMENT DESIGN

1.1. Plant Control Tabulation

Table 1.1. Tabulation of degumming process

No DeviceControl

Variable

Manipulated

Variable

Location

of Control

Valve

Sequence of

Instrumentation

Degumming Process

1 T-101 Level of Oil

Tank

Flow of crude

oil

After pump

and before

heater

If the level of tank is

low, valve before

heater will be closed

and the other valve

will be opened. It

make the oil go back

until the level is

normal enough

2 E-101 Temperature

outlet of

Heat

Exchanger

Temperature

heating fluid

Inlet of the

heater

Increase the flow of

heating fluid if the

temperature of oil

going to degumming

tank does not react

the set point

3 V-101 Level of

Degumming

Tank

Flow of

degummed

oil

After pump If the level of mixing

tank is low, valve

before heater will be

closed and the other

valve will be opened.

It make the oil go

back until the level is

normal enough


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Table 1.2. Tabulation of bleaching process

No DeviceControl

Variable

Manipulated

Variable

Location

of

Control

Valve

Sequence of

Instrumentation

Bleaching Coloumn

1 E-102 Temperature

outlet of Heat

Exchanger

Temperature

heating fluid

Inlet of

the heater

Increase the flow of


temperature of oil

going to adsorber

coloumn does not

react the set point

2 V-102 Level of

Bleaching

Tank

Flow of

bleached oil

After

pump

If the level of adsorber

coloumn is low, valve

before heater will be

closed and the other

valve will be opened.

It make the oil go backuntil the level is

normal enough

Table 1.3. Tabulation of hydrotreating process

No Device Control

Variable

Manipulated

Variable

Location

of Control

Valve

Sequence of

Instrumentation

Hydrotreating Reactor

1 E-107 Temperature

outlet of

Heat

Exchanger

Temperature

of heating

fluid

Inlet of

the heater

Increasing the flow of


temperature of oil

going to hydrogenation

reactor does not reach

the set point


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Table 1.3.Tabulation of hydrotreating process (Contd)

2 C-102 Flow of

Hydrogen

Pressure

outlet of

Compressor

Before

entering

compresso

r

If the pressure outlet of

comprossor is

decreasing, the valve

will be closed slowly

in order to make the

flow of hydrogen

entering the

compressor decrease.

3 R-104 Flow

Control

Flow of

Bleached Oil

Before the

reactor

Increasing or

decreasing the flow of

degummed oil if the

flow of oil going to

reactor is not suitable

4 R-104 Pressure of

hydrothreati

ng reactor

pressure

safety valve

Pressure

Relieve

If the pressure is to

high, the pressure

safety valve will be

opened to release theexcess gas until the

normal pressure. If the

reactor does not

release the gas, the

reactor will be hold

the over pressure and

the equipment will be

broken soon.

5 R-104 Level of

Hydrotreatin

g Reactor

Flow of

Green Diesel

outlet

After

hydrotreat

ing reactor

If the level is too low,

the valve will be

closed slowly until the

normal level.


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Table 1.4. Tabulation of steam methane reforming process

No DeviceControl

Variable

Manipulate

d Variable

Location of

Control

Valve

Sequence of

Instrumentation

Steam Methane Reformer

1 C-101 Flow of Gas

Inlet

Separator

Pressure

outlet of

Compressor

Before

entering

compressor

If the pressure outlet

of comprossor is

decreasing, the valve

will be closed slowly

in order to make the

flow of hydrogen

entering the

compressor decrease.

2 E-103 Temperatur

e outlet of

Heat

Exchanger

Temperature

of heating

fluid

Inlet of the

heater

Increasing the flow

of heating fluid if the

temperature of oil

going to the next

process does notreach the set point

3 E-104 Temperatur

e outlet of

Heat

Exchanger

Temperature

of heating

fluid

Inlet of the

heater

Increasing the flow


temperature of oil

going to the next

process does not

reach the set point

4 E-105 Temperatur

e outlet of

Heat

Exchanger

Temperature

of heating

fluid

Inlet of the

heater

Increasing the flow


temperature of oil

going to the next

process does not

reach the set point


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Table 1.6 Tabulation of steam methane reforming process (Contd)

5 E-106 Temperatur

e outlet of

Heat

Exchanger

Temperature

of heating

fluid

Inlet of the

heater

Increasing the flow


temperature of oil

going to the next

process does not

reach the set point

6 R-101 Pressure Flow of gas

outlet

After

reactor

If the pressure is too

low, the valve will

be closed slowly

until the normalcoloumn level.

7 R-101 Pressure Pressure

safety valve

Pressure

Relieve


high, the pressure


opened to release the

excess gas until the

normal pressure. If

the coloumn does not

not release the gas,

the coloumn will be

hold the over

pressure and the

equipment will be

broken soon.


outlet

After

reactor


low, the valve will

be closed slowly

until the normal

coloumn level.


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safety valve

Pressure

Relieve


high, the pressure




normal pressure. If



the coloumn will be

hold the overpressure and the

equipment will be

broken soon.


outlet

After

reactor


low, the valve will

be closed slowly

until the normal

coloumn level.


safety valve

Pressure

Relieve


high, the pressure




normal pressure. If



the coloumn will be

hold the over

pressure and the

equipment will be

broken soon.


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12 V-103 Pressure Flow of gas

outlet

After

reactor


low, the valve will

be closed slowly

until the normal

coloumn level.

13 V-103 Pressure Pressure

safety valve

Pressure

Relieve


high, the pressure



excess gas until thenormal pressure. If



the coloumn will be

hold the over

pressure and the

equipment will be

broken soon.

1.2. Process & Instrumental Design


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Steam

DATESIGNATURENAME

GROUP 21NAME

CORRECTED BY

PICTURE NO.

NO REVISION WITHOUT SCALE

P&ID DEGUMMING UNIT

RENEWABLE BIODIESEL FROM CPO,

JATROPHA OIL & NYAMPLUNGS OIL

DEPARTEMEN TEKNIK KIMIA

FAKULTAS TEKNIK


Condensate

T-101

Crude Oil Tank

P-101

Feed Pump

E-101

Heat Exchanger

V-101

Degumming tank

P-102

Feed Pump

Fosforic Acid

Gum

CPO /

NYAMPLUNG /JATHROPA LT

P-101

101101

101

M

102102

102

M

101

101

LT

101

1

2

34

5

6

7

8

9V-96

T-101

E- 101

V-101

P- 102

LIC

FIC

PI FT TT

LIC

FIC

PI FT

LIC

DegummedOil


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DATESIGNATURENAME

GROUP 21NAME

CORRECTED BY

PICTURE NO.


P&ID BLEACHING UNIT



DEPARTEMEN T EKNIK KIMIA

FAKULTAS TEKNIK


E-102

Heat Exchanger

V-102

Bleaching Unit

P-103

Pump

Steam

Condensate

BleachedOil

Degummed Oil

103103

103

M

102

102

102

1

2

4

5

3

6

102

E- 102

V-102

P-103

TIC

TT

LT

FIC

PI FT

LIC


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DATESIGNATURENAME

GROUP 21NAME

CORRECTED BY

PICTURE NO.


P&ID HYDROTHREATING UNIT



DEPARTEMEN TEKNIK KIMIA

FAKULTAS TEKNIK


E-107Heater

R-104Hidrotreating Reactor

V-108Green Diesel Tank

C-102Compressor

BleachedOil

Steam

Condensate

Hydrogen

107

1

2

5

6

4

7

3

107

102

102

102

E-107

R-104

C-102

104

TT

FIC

PIC

PT

PIC

FC

Excess Reactant11

104PT

104PIC

V-108

104

104

LT

LIC


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1.3. Start up, Normal and Shutdown Procedure

1.3.1. Start Up Procedure

Start up actions occurs every day beside Saturday and Sunday, this

makes 330 days plant startup per year. Startup will be explained step by step in

Table 1.7 below.

Table 1.7. Startup procedure

No Procedure DescriptionSafety

Precautions

1

All piping and instrument

are completed as P&ID.

Electrical set start up. All

electrical cords are

connected and no faulty

cord.

Instrument set start up

2

Ensure functionality of

control valves,

controllers, emergency

shutdown system, etc.

All equipment and

instrument set start up

3Install and activate

electrical systemElectrical set start up

All electrical

cords are

connected and no

faulty cord

4 Activate steam utilitiesHeater start up for

heating water utilities

Desired

temperature has

been reached

5 Pre-treatment startup

Pre-treatment

equipment start up to

produce CPO from

palm fruit, nyamplung,

jathropa

All pre treatment

equipment is safe

to operate

6 Activate plant process Starting all controller


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instrument and checking

alarm panel

on plant and checking

alarm function

7Activate main process

equipment

Starting reactor and

other process

equipment after CPO

level is adequate for

process

All equipment

connected and no

leakage

1.3.1.1.Start Up Procedures for Each Section

Start-up procedures in this system are divided into four parts based on

the number of units in our plant. Below are the procedures:

a. Degumming Unit

1. Check all of the systems are installed correctly

2. Check the controller of the system

3. Check the temperature at 65C and the process lasts for 15 minutes

b. Bleaching Unit


2.

Check the controller of the system

3. Check substances that give color to the oil

4. Check all the equipment safe to operate

c. Hydrotreating


2.

Check the controller of the system

3. Processes implement reactions of hydrotreatment promoted by catalysts

Nickel Molybdenum with buffer Alumina4. The hydrotreatment reactions are generally carried out in the presence of

hydrogen

5.

Check temperature at 300C and pressure at 2 atm

d. Steam Methane Reforming


2. Check the controller of the system


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3. Check the steam flow from its temperature whether it is suitable or not for

entering the steam methane reformer

4.

Reduced localized temperature

1.3.2. Shut Down Procedure

Manual shutdown. Manual shut down occur every end of year. It

occurs according to procedure:

1.

Decrease the flow rate of feed CPO, Nyamplung oil, and Jathropa oil

gradually until the flows stop

2. Let all the flue gas flow until there is no excess flue gas in the piping line

3.

Turn off all the equipment, such as heat exchanger, steam methane

reformer, and pump.

4. Uninstall the catalyst from all unit.

Emergency shutdown. Emergency shutdown only happen if theres

special condition occurs. Emergency shutdown relies on plant process control

instrument and alarm. The condition and procedure are shown in Table 1.8.

Table 1.8. Emergency Shutdown

No Condition Procedure

1Reactor temperature condition

reach too high or too low

Shut the ball valve that related to the flow,

and maintenance or change with reserve

equipment if available

2Reactor flow condition reach

too high

3

Hydrotreating temperature

condition reach too high or

too low

4Steam Methane Reforming

flow condition reach too high

5 Pump failures


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CHAPTER 2

EQUIPMENT SIZING

2.1. Main Equiment

2.1.1. Storage Tank

2.1.1.1.Crude Palm Oil Storage Tank T-101

Table 2.1 Specification Data of Storage Tank

Identification

Item : Storage Tank

Item Number : T-101

Name of Equipment : Crude Palm Oil Storage Tank

Item Amount : 10

Function : Storing of Crude Palm Oil

Composition

Crude Palm Oil: 100%

Operation Data

Capacity : 44.70 ton/hr

Pressure : 2.576 atm

Temperature : 25oC

Storage Time : 7 days

Specification Design

Type :Cylindrical Tank with Ellipsoidal Top

and Flat Bottom

Joint : Double Welded Butt Joint

Material : SA-283, Grade C

Volume : 949 m3

Diameter Tank : 7.48 m

Height Tank : 16.21 m

Wall Thickness : 0.97 inch

Head Thickness : 1.40 inch


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2.1.1.2.Jatropha Oil Storage Tank T-101

Table 2.2. Specification Data of Storage Tank

Identification

Item : Storage Tank

Item Number : T-101

Name of Equipment : Jatropha Oil Storage Tank

Item Amount : 10

Function : Storing of Jatropha Oil

Composition


Operation Data



Temperature : 25oC




and Flat Bottom



Volume : 968 m3






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2.1.1.3.Nyamplung Oil Storage Tank T-101

Table 2.3 Specification Data of Storage Tank

Identification

Item : Storage Tank

Item Number : T-101

Name of Equipment : Nyamplung Oil Storage Tank

Item Amount : 10

Function : Storing of Nyamplung Oil

Composition


Operation Data



Temperature : 25oC




and Flat Bottom



Volume : 961 m3






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2.1.1.4.Renewable Biodiesel Storage Tank T-102

Table. 2.4. Specification Data of Storage Tank

Identification

Item : Storage Tank

Item Number : T-102

Name of Equipment : Renewable Biodiesel Storage Tank

Item Amount : 2

Function :Storing of Renewable Biodiesel

Product

Composition


Operation Data

Capacity : 37,88 ton/hr


Temperature : 25oC




and Flat Bottom



Volume : 640 m3






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2.1.1.5.Degumming Tank V-101

Table. 2.5. Specification Data of Degumming Tank

Identification

Item Mixer Tank

Item number V-101

Equipment name Degumming Tank

Number of Unit 1

Function Reacting phosporic acid with gum

Mode Operation Continue

Composition (%)

Oil 11.39 kg/h

Phosporic Acid 27,005.35 kg/h

Operating condition Capacity 45,560 kg/h

Pressure 168.2 kPa

Temperature 64.12 oC

Spesification Design Type Ellipsoidal vertical tank

Material Stainless Steel 316

Volume 59.33 m3

Diameter tank 3.19 m

Height tank 8.51 m

Height of cylinder 6.38 m

Height of ellipsoidal 1.06 m

Wall thickness 4.29 mm

Head thickness 4.29 mm


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Table. 2.5. Specification Data of Degumming Tank (Contd)

Stirrer Design Impeller type Axial four blade

Number of impeller 1

Impeller diameter 1.06 m

Impeller level width 0.213 m

Impeller to bottom 1.06 m

Diameter stick 0.353 m

Diameter baffle 0.266 m

Impeller speed 2 rps

Utilities Power 0.114 kW/h

2.1.2. Reactor

2.1.2.1.Shift Converter Reactor R-102

Table. 2.6. Specification Data of Shift Converter Reactor

Identification

Item Shift Converter

Item Number R-102

Function: To produce syngas from Natural Gas and SteamType of Reactor Multitubular Packed Bed Reactor

Operating Condition

Pressure bar 4,16

Temperature oC 427

Dimension

Reaction Rate kgmol/kg cat.h 0,378978

Residence Time min 10,73Volume Reactor m3 16,35581

Catalyst Weight kg 0,57

No. of Tubes 8

Tube Diameter cm 1,733461

Diameter cm 173,3461

Height m 6,933845

Thickness cm 5,0225


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2.1.2.2.Absorber Column V-103

Table. 2.7. Specification Data of Absorber Column

Identification

Name Absorber Column

Item Number V-103

Function To separating H2and CO2from Shift

converter unit

Number of unit 1

Material Carbon Steel SA-283 Grade C

Type Packing

Packing Width and Height

Tower Diameter 12.60 m

Height of packing 20.51 m

Permissible tensile stress 950 kg/cm2

Mechanical Design

Working pressure 101300 N/m2

Design pressure,p 106365 N/m2

0.106365 N/mm2

Permissible stress 95 N/mm2

Joint Efficiency (j) 0.85

Corrosion allowance 3 mm

Outer diameter, Do 12.659 m

Input Amine. T 150 oC

Input CO2, T 75oC

Output Amine, T 80 oC

Output CO2, T 95oC


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2.1.2.3.Steam Methane Reformer R-101

Table. 2.8. Specification Data of Steam Methane Reformer

Identification

Item Steam Methane Reformer

Item Number R-101

Function: To produce syngas from Natural Gas and

Steam

Type of Reactor Multitubular Packed Bed Reactor

Operating Condition

Pressure bar 4,5

Temperature oC 760

Dimension

Reaction Rate kgmol/kg cat.h 4,08045

Residence Time min 10,73

Volume Reactor m3 57,39

Catalyst Weight kg 523.23

No. of Tubes 8

Tube Diameter cm 2,63

Diameter cm 263,41

Height m 10,54

Thickness cm 5,0225


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2.1.2.4.Hydrotreating Reactor Design

Table. 2.9. Specification Data of Hydrotreating Ractor Design

Unit: CRV-100 Hydrotreating Reactor

Function:To Produce Green Diesel via

Triglycerides and Hydrogen

Operating Condition

Type of Reactor Packed Bed Reactor

Pressure bar 34.378

Temperature oC 300

Catalyst Volume m3 8.33

DimensionResidence Time s 8.62

Volume m3 10.42

Number of Tubes 414

Tube Diameter in 1.968

Diameter m 1.744

Height m 4.366

Thickness mm 5

Shell Thickness mm 4.9

Material Stainless Steel 316 SS


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2.2. Supporting Equipment

2.2.1. Heat Exchanger

2.2.1.1.Heat Exchanger E-101

Table. 2.10. Specification Data of Heat Exchanger E-101

Equipment Specification

Equipment Name Heat Exchanger

Equipment Code E-101

FunctionIncrease the temperature of CPO

before entering degumming process

Amount 1

Material Carbon Steel

Type Shell and Tube

Operating Data

Shell Tube

Flow Rate kg/h 10000.00 4594.85

Temperature Inlet C 155.00 25.00

Temperature Outlet C 134.00 65.00

Operating Pressure kPa 300.00 200.00

Construction Data

LMTD C 99.1969

UA W/m C 5.7046

Duty kW 122.1208

Heat Transfer Area m 4.1637

Number of Passes 1-2

Shell ID m 0.49

Tube Arrangement Triangular

Number of Tubes 220

Tube Length m 4.00

Tube OD m 0.0191

Tube BWG 14.0000

Tube Pitch m 0.0254


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FunctionIncrease the temperature of CPO

before entering bleaching process

Amount 1


Type Shell and Tube

Operating Data

Shell Tube

Flow Rate kg/h 10000.00 5138.21




Construction Data

LMTD C 62.0925

UA W/m C 32.0492

Duty kW 122.1208



Shell ID m 0.30


Number of Tubes 32

Tube Length m 8.00

Tube OD m 0.0191

Tube BWG 14.0000

Tube Pitch m 0.0238


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FunctionIncrease the temperature of oil before

entering the reactor

Amount 1

Material

Type Shell and Tube

Operating Data

Shell Tube

Flow Rate kg/h 90000.00 41928.91




Construction Data

LMTD C 141.1967

UA () W/m C 20.2749

Duty () kW 5504.0209



Shell ID m 0.49


Number of Tubes 264

Tube Length m 12.00

Tube OD m 0.0191

Tube BWG 14

Tube Pitch m 0.0238


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2.2.1.4. Heat Exchanger





Function

Decrease the temperature of shift

product before entering absorption

process

Amount 1


Type Shell and Tube

Operating Data

Shell Tube

Flow Rate kg/h 2135.00 36787.10




Construction Data

LMTD C 110.5275

UA () W/m C 743.3854

Duty () kW 727.5363



Shell ID m 0.39


Number of Tubes 154

Tube Length m 4.00

Tube OD m 0.0191

Tube BWG 14.0000

Tube Pitch m 0.0238


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28


2.2.1.5.Heat Exchanger





Function

Decrease the temperature of

methanator feed before entering

reactor

Amount 1


Type Shell and Tube

Operating Data

Shell Tube

Flow Rate kg/h 18000.00 1845.43




Construction Data

LMTD C 57.2235

UA () W/m C 743.3854

Duty () kW 269.8557



Shell ID m 0.30


Number of Tubes 90

Tube Length m 4.00

Tube OD m 0.0191

Tube BWG 14.0000

Tube Pitch m 0.0238


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2.2.1.6.Fired Heater E-103

Table. 2.15. Specification Data of Fired Heater E-103


Equipment Name Fired Heater


FunctionIncrease the temperature of mixed

feed before entering reformer process

Amount 1

Material Stainless Steel

Type Shell and Tube

Operating Data

Shell

Flow Rate kg/h 2135.00

Temperature Inlet C 140

Temperature Outlet C 760

Operating Pressure kPa 500

Radiant Section

Tube OD in 8.626

Tube Thickness in 0.05118

Number of Tubes

(Radiant) -40

Number of Tubes (Shield) - 12

Combustion (Fraction

Excess Air) -0.15

Firebox Diameter ft 19.98

Flue Gas Temperature R 2077,1Emmisivity - 0.5087

Radiation Heat Transfer Btu/hr 3.37 x 107


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Table. 2.15. Specification Data of Fired Heater E-103 (Contd)

Convection Section

Tube BWG 14.0000

Tube Pitch m 0.0238

Wall Temperature 959Number of Rows - 5

Number of Tubes per Row - 4

Flue Gas Temperature 1472LMTD 430.28Convection Heat Transfer Btu/hr 3.37 x 107

2.2.1.7.Fired Heater E-104

Table. 2.16. Specification Data of Fired Heater E-104


Equipment Name Fired Heater


FunctionIncrease the temperature of shift feed

before entering water-gas-shift

process

Amount 1

Material Stainless Steel

Type Shell and Tube

Operating Data

Shell

Flow Rate kg/h 2135.00

Temperature Inlet C 760

Temperature Outlet C 1050

Operating Pressure kPa 500


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Table. 2.16. Specification Data of Fired Heater E-104 (Contd)

Radiant Section

Tube OD in 8.626

Tube Thickness in 0.05118

Number of Tubes

(Radiant) -40

Number of Tubes (Shield) - 12

Combustion (Fraction

Excess Air) -0.15

Firebox Diameter ft 19.98

Flue Gas Temperature R 2077,1Emmisivity - 0.5087

Radiation Heat Transfer Btu/hr 3.37 x 107

Convection Section

Tube BWG 8.626

Tube Pitch m 0.5

Wall Temperature

959

Number of Rows - 5

Number of Tubes per Row - 4

Flue Gas Temperature 1472LMTD 430.28Convection Heat Transfer Btu/hr 3.37 x 107


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2.2.2. Compressor

2.2.2.1.Compressor C-101

Table 2.17. Specification Data of Compressor C-101


Name Feed Methane Compressor

Code C-101

Function To help methane flow to feed mixer

Total 1

Vendor Ingersoll Rand

Model UP5 22-7

Type Rotary Screw Air Compressor


Frequency (Hz) 50

Nominal Power (kW) 22

Flow (m3/min) 3.54

Length/Width/Height (cm) 128/92/105

Weight (kg) 540

Operation Data

Flow rate (m3/h) 2.672

Mass flow (kg/h) 800

Suction Pressure (kPa) 520

Discharge Pressure (kPa) 824

Temperature Inlet (oC) 20

Temperature Outlet (oC) 63.25

Power (kW) 21.6


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2.2.2.2.Compressor C-102

Table 2.18. Specification Data of Compressor C-102


Name Hydrogen Compressor

Code C-102

Function To help hydrogen flow from methanator

to hydrogenation reactor

Total 1

Vendor Ingersoll Rand

Model M300-2S

Type Rotary Screw Air Compressor


Frequency (Hz) 50

Nominal Power (kW) 300

Flow (m3/min) 60.2

Length/Width/Height (cm) 400/193/215

Weight (kg) 5540

Operation Data

Flow rate (m3/h) 5.391

Mass flow (kg/h) 1578

Suction Pressure (kPa) 241

Discharge Pressure (kPa) 544.9

Temperature Inlet (oC) 280

Temperature Outlet (oC) 440.7

Power (kW) 290.2


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2.2.3. Pump

2.2.3.1.Pump P-101

Table 2.19. Specification Data of Pump P-101


Name Oil Feed Pump

Code P-101

Function To help oil to flow to heat exchanger then

mixer

Number of unit 1

Type Centrifugal Pump

Operation Data

Liquid Volume Flow (m3/h) 49.96

Temperature (oC) 25

Suction Pressure (kPa) 101.3


Head (ft) 54.714

NPSHA (ft) 0.111

Efficiency 0.75

Hydraulic Power (kW) 2.35

BHP (kW) 3.14

Spesific Speed (rpm) 1327.109

Jenis Impeller Radial Vane


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2.2.3.2.Pump P-102



Name Refined Oil Pump

Code P-102

Function To help refined oil to flow to heat exchanger

then adsorption column

Number of unit 1


Operation Data


Temperature (oC) 64.15



Head (ft) 54.724

NPSHA (ft) 0.111

Efficiency 0.75


BHP (kW) 3.19




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2.2.3.3.Pump P-103



Name Refined Bleached Oil Pump

Code P-103

Function To help oil to flow to heat exchanger then

hydrogenation column

Number of unit 1


Operation Data


Temperature (oC) 100


Discharge Pressure (kPa) 2758

Head (ft) 960.21

NPSHA (ft) 0.111

Efficiency 0.75


BHP (kW) 52.932




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2.2.3.4.Pump P-104



Name Green Diesel Pump

Code P-104

Function To help green diesel to flow

Number of unit 1


Operation Data


Temperature (oC) 349.4



Head (ft) 54.714

NPSHA (ft) 0.111

Efficiency 0.75


BHP (kW) 2.138




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CONCLUSION

Each equipment is sized to suit the need of the process. The main aspects

considered are volume, height, diameter, and energy.

The main equipment that uses multiple units to accommodate the process are

storage tank, hydrotreating reactor and unit separator.

The supporting equipment that used are pump, compressor, heat exchanger

and cooler.

The complete main equipment and its intrumentation is depicted in P&ID

The controller needed to be arranged based on the risk of the variable that

being controlled.


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REFERENCES

Branan. 2012.Rules of Thumb for Chemical Engineer.5 thedition. USA: Stephen

Hall.Brownell, L.E & Edwin H.Y. 1959. Process Equipment Design: Vessel Design.

John Wiley & Sons.

Walas, S.M. 1990. Chemical Process Equipment. Selection and Design.

Massachusetts Institute of Technology: Butterworth-Heineman Series in Chemical

Engineering.


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APPENDIX A

A.1. Storage Tank

In the process of producing renewable biodiesel, because of not continues

supplies, storage tank are needed to store the raw materials and product. We have

to determine the size and dimension based on the flow rate of each material that

goes in and out the storage tanks.

We use three different types of storage tank to store three different type

crude oil for process that is crude palm oil, jatropha oil and nyamplung oil.

Moreover, we need storage tank for renewable diesel produced.

Material Selection

The raw material storage tanks form are cylindrical tanks because a

cylinder shape has a great structural strength and easier to fabricate. The top end

of storage tanks use ellipsoidal shape, while the bottom end is flat and stand

directly upon the ground. We use carbon steel as the material for storage tanks.

Table A.1. List of Materials that Selected for Each Storage Tank

No. Storage Tank Material Specification

1. Crude Palm Oil Storage Tank SA-283, Grade C2. Jatropha Oil Storage Tank SA-283, Grade C

3. Nyamplung Oil Storage Tank SA-283, Grade C

4. Renewable Biodiesel Storage Tank SA-283, Grade C

A.1.1. Volume of Storage Tank

For sizing the storage tanks, we estimate that the capacity of crude oil

storage tanks are able to fulfill the needs of material for a week depending on the

supply attendants. So, we determine one week as a batch.


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Crude Palm Oil Storage Tank

Crude Palm Oil mass flow rate is 44700 kg/hour. So the storage tanks have

to store 7,509,600 kg/batch crude palm oil. The calculation of storage tanks

volume needed to store :

= = 7,509,600kgweek879.3 kgm

= 8540.43 mweekTo store the crude palm oil, we will use 10 storage tank. so, the crude palm oil

volume per tank is :

=8,540.43 m

week10 =854.04 m

week

To calculate the total volume of storage tanks, safety factor has to be

considered. Safety factor of the tank is 10% of the total volume. This is based

on literature saying that for tanks which volume is above 3,8 m 3, only 90%

volume is filled.

= 854.04 mweek0.9 = 948.94 m

week

Jatropha Oil Storage Tank

Jatropha Oil mass flow rate is 44700 kg/hour. So the storage tanks have to

store 7,509,600 kg/batch jatropha oil. The calculation of storage tanks volume

needed to store :

= = 7,509,600kgweek862 kg

m

= 8711.83 mweekTo store the jatropha oil, we will use 10 storage tank. so, the jatropha oil

volume per tank is : = 8,711.83 m

week10 =871.18 m

weekTo calculate the total volume of storage tanks, safety factor has to be



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volume is filled.

= 871.18 m

week0.9 = 967.98 mweek Nyamplung Oil Storage Tank

Nyamplung Oil mass flow rate is 44700 kg/hour. So the storage tanks have

to store 7,509,600 kg/batch nyamplung oil. The calculation of storage tanks


= = 7,509,600 kgweek869 kgm = 8641.66 mweekTo store the nyamplung oil, we will use 10 storage tank. so, the nyamplung oil

volume per tank is : = 8,641.66 m

week10 =864.17 m

weekTo calculate the total volume of storage tanks, safety factor has to be

considered. Safety factor of the tank is 10% of the total volume. This is basedon literature saying that for tanks which volume is above 3,8 m 3, only 90%

volume is filled.

= 864.17 mweek0.9 = 960.18 m

week

Renewable Biodiesel Storage Tank

Renewable biodiesel produced have mass flow rate is 37880 kg/hour. For,

renewable biodiesel we determine 1 day for a batch. So the storage tanks have

to store 909,120 kg/batch renewable biodiesel. The calculation of storage tanks


= = 909,120kgweek790 kgm

= 1150.78 mweek


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To store the renewable biodiesel product, we will use 2 storage tank. so, the

renewable biodiesel volume per tank is :

= 1150.78 m

week2 =575.39 mweekTo calculate the total volume of storage tanks, safety factor has to be



volume is filled.

=575.39 mweek

0.9 = 639.32m

weekA.1.2. Diameter and Height of Storage Tank

Based on rule of thumb, the ratio of height and diameter of tank for

cylindrical tanks is 2:1. Therefore, H = 2D. The volume of cylinder can be

calculated as :

= 1

4 = 1

2

The shape of tanks top cover is ellipsoidal and the bottom cover is flat, with

major axis ratio of 2:1. The volume of heads (cover and pedestal) is . The tank

volume is:

= 2

24 = 13

24


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Figure A.1. Types of head of storage tank

(Source:Perrys Chemical Engineering Handbook, 1999)

We use the equation of cylinder tank volume to determine the diameter of

cylinder.

= 2413 The height of tank is an addition of cylinder and head of tank height. The cylinder

height is 2D as stated before. The head height is D/6.

Crude Palm Oil Storage Tank

Using the equation, the diameter of tank is :

= 2413 = 28540.4313 = 7.48 The cyclinder height is:

= 2 = 2 7.48 = 14.96

The head height is:

= 6 = 7.48 6 =1.247 The total height is:

= =16.207


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Jatropha Oil Storage Tank


= 2413

= 28711.8313

= 7.53 The cyclinder height is:

= 2 = 2 7.53 = 15.06 The head height is:


= =16.315 Nyamplung Oil Storage TankUsing the equation, the diameter of tank is :


= 2 = 2 7.51 = 15.02

The head height is:


= = 16.27 Renewable Biodiesel Storage Tank



= 2 = 2 3.83 = 7.66 The head height is:



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46


= = 8.937 A.1.3. Design Pressure

Pressure design of storage tank determines the type of storage tank used.

Height of fluid in the tank is calculated as follows:

= The pressure of the tank is:

= In calculating the design pressure, we assuming that the pressure safety factor is

15%. = 1 1 5 % 1 Crude Palm Oil

= 854.0416.207948.94 = 14.59 = 879.3 9,81 14.59 = 1.24 =115% 11.24 =2.576 Jatropha Oil

= 871.1816.315967.98 = 14.68 = 862 9,81 14.68 = 1.23 =115% 11.23 = 2.5645 Nyamplung Oil

= 864.1716.27960.18 = 14.64

= 869 9,81 14.64 = 1.23

=115% 11.23 = 2.5645 Renewable Biodiesel

= 575.398.937639.32 = 8.04 = 790 9,81 8.04 = 0.62 =115% 10.62 =1.863


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A.1.4. Wall and Head Thickness

To calculate the wall and head thickness, there are several data we needs

to be determined such as corrosion factor, maximum allowable stress, joint

efficiency, and equipment age. These data determined based on the material

selected for each storage tank. Carbon steel has a bigger corrosion factor than

stainless steel, since carbon steel is more prone to corrosion. Corrosion factors of

stainless steel are also different depending on the grade of stainless steel.

Calculation of storage tanks wall thickness is based on circumferential

stress (longitudinal joint). We can use the following formula (Towler, 1990):

=

0.6

While head thickness of storage tank could be calculated with the following

formula:

= 20.2 where,

t = material thickness

P = pressure gauge

R= shell radius

Di= shell inner diameter

K = ellipsoidal formula factor

S = maximum allowable stress

E = joint efficiency = 0.85

C = corrosion factor = 0.015

A = planned equipment age = 30 year

Crude Palm Oil

= 37.86147.2412,6500.850.637.86 0.01530=0.969 = 37.86294.481.833212.6500.850.237.86 0.015 30 = 1.40


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Jatropha Oil

= 37.69148.2312,6500.850.637.69 0.01530=0.971

= 37.69296.461.833212.6500.850.237.69 0.01530=1.40 Nyamplung Oil

= 37.69147.8312,6500.850.637.69 0.01530=0.969

=37.69295.661.833

212,6500.850.237.69 0.01530=1.40 Renewable Biodiesel

= 27.3875.3912,6500.850.627.38 0.01530=0.642 = 27.38150.781.833212,6500.850.227.38 0.01530

= 0.802

A.2. Degumming Tank

Volume

Flow rate into the tank 46560 kg/h, to gain the volume we could divide the mass

rate with total density.

=

= 46560 kgh

872

= 53.39 So, the volume tank is 53.39 m3. Base on literature if volume above 3,8

3volume of each tank only filled 90%. The headspace is 10% thus the workingvolume which calculated before is 90%. The use of headspace is a safety unit for

sudden increment volume.

= 53.390.9 = 59.33 Diameter and height of mixing tank


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Comparison of high tank with tank diameter (Hs: D) = 2:1. The volume will be

represented by using ellipsoidal shape, the diameter and height of tank could be

calculated.

= 14 = 14 2Cover and pedestal tank of ellipsoidal shape with major to minor axis ratio of 2:1,

so high head is h=16(Walas, 1990). Volume of 2 cover is:= 14 2 = 14 16 2 = 112

Tank volume is:

= = 14 2 112 = 712 Tank diameter is: = 127 = 1259.337 = 3.19

Height of cylinder is Hs= 2D = 6,38 m

Height of cover ellipsoidal is Hh = = 1.06

Height tank is Ht = Hs + (2xHh) = 6.38 + (2x1.06) = 8.51

Pressure Design

Height of fluid in the tank

= = 53.39 8.5159.33 = 7.66

Pressure

= = 872 9.8 7.66 = 0.646 = 9.494 Thick of Wall and HeadMaterial choosen is stainless steel because condition of solution must be at pH

4,5. Avoiding corrosion, stainless steel used for this case

Thick of wall

Assumption of corrosion factor is (C) = 0,0042 in/year

Allowable working stress is (S) = 16.250 lb/in2 (Walas, 1990)

Assumptions connection efficiency is (E) = 0,85


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Planned of tool age (A) = 30 years

Thick of cylinder is

= 0.6

= 9.49462.9916.2500.850.69.494 0.0042 30 = 0.169 = 4.29 Thick wall head (cap)

Assumption of corrosion factor is (C) = 0,0042 in/year

Allowable working stress is (S) = 16.250 lb/in2 (Walas, 1990)

Assumptions connection efficiency is (E) = 0,85

Planned of tool age (A) = 30 years

Thick of wall head is

= 0.2 = 9.49462.9916.2500.850.29.494 0.0042 30 = 0.169 = 4.29 Impeller

Type: axial four blade, this kind of impeller is chosen based on literature, if

viscosity < 5000 cp propeller is common used. This solution has 79 cpAssumption of rotation speed (N): 120 rpm = 2 rps

Assumption of 80% efficiency motors

Mixer is designed with the following standards: (Walas, 1988)

Da : Dt = 1 : 3 Dt : J = 12

W : Da = 1 : 5 where:

Da : Db = 6 : 1 Da = stirrer diameter

C : Dt = 1 : 3 Dt = the diameter of the tank

Db = stick diameter

W = width of leaf stirrer

C = the distance from bottom of the tank

Reynold number is

= Stirrer diameter is

= =

3.19 = 1.06


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Stirrer leaf widhth is = = 1.06 = 0.213 Strirrer height from the bottom = = 3.19 = 1.06 Diameter of stick = = = 1.06 = 0.353 Diameter baffle = = 3.19 = 0.266 Where

Da = diameter impeller (ft)

N = rotation speed (rps)

= density (lb/ft3) = viscosity (lb/(ft.s))

= 0.35324.490.05 =63.40

Figure A.1. Power Number

(Source: Walas, 1990)

Then, the power is

= 1 0 = 1 03 4 . 4 9 2 1.06 = 0.114 /


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52


APPENDIX B

B.1. Hydrotreating Reactor

Fixed-Bed Reactors (FBRs) are the most commonly used reactor systems

in commercial hydrotreating operations. They are easy and simple to operate.

However, the simplicity of operation limits their use to the HDS of light feeds.

For example, in case of naphtha hydrodesulfurization, the reaction is carried out in

two-phases (gas-solid) fixed-bed reactors since at the reaction conditions the

naphtha is completely vaporized. On the contrary, for heavier feeds three phases

are commonly found: hydrogen, a liquid-gas mixture of the partially vaporized

feed, and the solid catalyst. The latter system is called a trickle-bed reactor (TBR),

which is a reactor in which a liquid phase and a gas phase flow co-currently

downward through a fixed bed of catalyst particles while reactions take place.The

gas is the continuous phase, and the liquid is the disperse phase (Quann et al.,

1988). A schematic representation of the phenomena occurring in a TBR based on

three-film theory is presented in Figure 3.3 (Korsten and Hoffmann, 1996;

Bhaskar et al., 2004). It is common to assume that mass transfer resistance in the

gas film can be neglected and that no reaction occurs in the gas phase, so that for

the reactions to occur, the hydrogen has to be transferred from the gas phase to the

liquid phase, whose concentration is in equilibrium with the bulk partial pressure

and then adsorbed onto the catalyst surface to react with other reactants. The gas

reaction products are then transported to the gas phase, while the main liquid

hydrotreated reaction product is transported to the liquid phase.

In Hydrotreating Reactor there will be two main reaction which are

reaction of tryglycerides and H2also reaction between tryglicerides and H2, those

reaction can be combine into one that will produce the green diesel itself. Thevolume of reactor is equal to the amount of catalyst used. It is because common

reactor for hydrotreating reactor is fixed bed reactor. In this process, catalyst used

is Nickel-Molybdenum alumina supported.

The material for the hydrotreating reactor was chosen to be Stainless Steel

316 SS. Due to the temperature conditions at about 250C, metal dusting not

comes into consideration. This leads to a construction material of carbon steel,

which is the least expensive material (Peters, 2003). However, since the process


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53


streams at this stage produce some amount of CO2, sweet corrosion is believed to

be a problem. That is why we chose Stainless Steel as a material for hydrotreating

reactor.

Figure B.1. Fixed Bed Reactor

Source: Handbook of Petroleum Processing

1. Hydrotreating Reactor (CRV-100)

Catalyst Weight

2 21 3 3 6 2 , =

k1= 0.008554 m3kmol-1 s-1

Assumption:

Rate law of these reaction follow one order rate reaction in Packed Bed

Reactor. Equation for rate law in Packed Bed Reactor is

= Where:

=

/


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54


Equation for one order rate reaction:

= So = / The derivation of equation

= / =

= = 1

=

= 1 = = 1 1

= = 1

So,

= . 1 1 . 1

= 1 1


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55


This equation will be used to determine how much catalyst needed for each

reaction.

Molar flow Tryglycerides : = 144 /Molar flow Hidrogen : = 570 /

= = 144144570 =0.2017 / = y. = 0.20173 1 1 1 =0.4034

Feed volume flow :

=4,351 Bulk density, = 3200 /

Then we use polymath to determine conversion vs catalyst weight:

Figure B.2. Polymath Programming


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Figure B.3. Polymath Programming Result

Figure B.4.Polymath Programming Graph


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57


As the result of the polymath, the higher catalyst weight, the higher of

conversion. Therefore, we choose the conversion is 18% because the high

conversion needs a lot of catalyst. As we know that catalyst is expensive and the

lifetime is just about one year. For example, for 85% conversion needs 500,000 kg

catalyst, that is too much. So we just need 18% conversion plus we will recycle

the methane that is not converted into the syngas. At 18% conversion, we need

catalyst 37,000 kg.

Dimension of Reactor

Volume of catalyst that fills the reactor can be calculated as follow:

= = 30,000 kg3600 kg/m = 8.33 Then we assume that the catalyst fills 80% of reactor volume. So we can estimate

the reactor volume needed as follow:

= 10080 8.33 = 10.42 Assume that L:D = 2.5:1 (Rule of Thumbs)

14 = 10.42 14 2.5 = 10.42 = 16.672 = 1.744

The length is

= 2 = 4.36 Retention Time

= = 10.42

4,351 m/h 36001 =8.62Wall thickness can be obtained by using method in Wallas.


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Thickness t = P x RSxE0,6P CA Corrosion Allowance

Head Thickness t =P x D

2SxE0.2P CA

With : P = operation pressure (Psig)

Pc = pressure because of catalyst weight

R = reactor radius (inch)

E = Joint efficiency, it assumed that the joint effieciency is 0.8

S = allowable stress

Due to the high pressures and temperatures in the primary reformer tubes,

a 25% chromium-20% nickel alloy is the preferred tube material. The

allowable stress is very dependent on the material that used for the vessel.

From the Perrys Chemical engineer handbook the allowable stress for the

conrete is 9.8 Mpa or 145,054 psi.

The pressure because of catalyst is :

= = = 30,0009.80.251.744 = 123,287 = 17.87 Thickness t = 14517.87 34.33145,0540.80.614517.87 0.15 = 0.198

= 5 Head Thickness t = 145 4.1 x 68.662x145,054x0.81.8x145 0.15 = 0.193 = 4.9

Tubes calculation

The maximum conventional heat flux through primary reformer tube walls

is approximately 5,921.176 kcal/ ft2hr with industry averages. Using this value

and the heat duty through the reformer calculated by Aspen, the primary reformer

tube size was calculated as follows:

= = 8.89510 5,921.176 = 15,174.35

Then, number of tubes needed is


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= 413.4 414 Height of tube

Based on rule of thumbs, height of reactor is 1.25 times of tubes, so

= 11.25 = 11.25 4.36 = 3.488 Pinch tube selection and diameter of tubes

We choose square pinch of tubes because it is more easy to be cleaned.

The arrangement is at the picture below

Where :

= = 1.5 As we know, diameter of reactor is 1.744 m2, then the length of square is allowing

at phytagoras rule :

= 2 =1.744

= 1.7442 = 1.7442

= 1.233 Assuming the cover of the shell size is 10 cm = 0.01 m

Then tube line is

= 1 . 2 3 3 20.01 = 1.213


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As we know that the number of tubes are 414, so

=

414= 1.213 1 1.213 1

4 1 4 = 1.213

414= 1.213

414= 1.213

20.347=1.213

19.347=1.213 = 0.0627 So, we can calculate diameter of tubes

= 1.25 = 0.06271.25 = 0.05 = 1.968 B.2. Shift Converter Reactor R-102

Water Gas Shift (WGS) is reversible reaction. So both the forward and

reverse reaction is with thermodynamic equilibrium. The true dimensionless

equilibrium constant can predict from Gibbs free energy as denoted by the

following reaction.

=All fixed Bed catalytic reactor assumed to behave like ideal plug flow reactor.

Equation used for the design or sizing of fixed bed reactor is:


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Figure B.5. Equation used for the design or sizing of fixed bed reactor

Here is process condition, mole fraction, and molar flow of feed of water gas shift

reactor from Aspen Hysys simulation.

Feed Flowrate :187,5 kgmol/h

0,052083 kgmol/s

R 8,314

P 4,16 bar

T 1050 K

Species Fraksi mol P parsial K

CO2 0,055 0,2288 0

H2O 0,2237 0,930592 0,908513

H2 0,5735 2,38576 9,59E-05

CO 0,1178 0,490048 0,252871

= 1

= 1 0,2528710,490048 9,59E052,38576 00,2288 0,9085130,9305922,38576 =1,4785

Constant rate law

kj = 34.21

Rate Law


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R1= 0,3799 kgmol/kg cat. S

The Calculation for sizing shift converter reformer is using Microsoft Excel and

the result is shown in the sizing table

Table B.1. Sizing Shift Converter Reformer

weight of catalyst 0,57 kg cat

Cat Vol 13,90244 m3

Vol Reactor 16,35581 m3

A Reaktor total 0,016889 ft2

Tube 100

D Reaktor 1,733461 m

173,3461 cm

L 6,933845 m

D tube 1,733461 cm

1,06 in

Residence time 0,018924 h

69,14921 s

1,152487 min

thickness 1,977392 in

5,0225 cm

thicknes head 3,829613 in

9,6478 cm

TUBE THICKNESS 0,129954 in

B.3. Absorber Calculation

The calculation manually doing which it will be suited to the rule of thumb.

Firstly, should do design the absorber by know the composition of incoming

gas from model simulation we have done.

Basis: 1 hour of operation


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Table B.2. Composition of the Incoming Gas

Component Kmols Fraction Molecular Weight

Methane 84.72 0.03 16

Hydrogen 1799.7352 0.6373 2H2O 451.5576 0.1599 18

CO 152.496 0.054 28

CO2 335.4912 0.1188 44

TOTAL 2824 1

1. The average of molecular weight of the incoming gas

=

MW = 6422.906 kg/kmols

2. Density of gas mixture

Given that Tin= 38oC, so the density of gas mixture will be calculated

by following:

gas = 251.7014855 Kg/m33. Amine and gas Flowrate Calculation

CO2absorbed = 335.4912 kmoles = 14761.6128 kgs

Total CO2absorbed by amine = 1003.2 Kgs

Based on the calculation:

0.407667 W needs 13758.41 Kgs

Then The value of W = 9.37477 Kgs/s

Amine flowrate (A ) = 9.37477 Kgs/s

Densitas (A)= 1040 Kg/m3

Gas Flowrate (G) = 5038.413 Kgs/s

Densitas (G)= 251.7015 Kg/m3

4. Column Selection

In this case of absorber, there are two kind of column, tray column

and packing column. We have choosen packing column for the reason:


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The gas material which enter to the absorber column is a

corrosive gas.

From economic side, packing column is cheaper than tray column.

The pressure drop result of packing column is lower than tray

column. The contact between gas and liquid in packing column is

more perfect due to the higher area contact.

5. Material Selection

Then choose the following packing as given in the Richardson and

Coulson as seen in the Figure below

Figure B.6. Design for Various Packing

Based the table, the material selected is Racing Rings Ceramic,

because if it compared to the other material, Rashing Rings ceramic is

the best on because of it has corrosif endurance, it will be good to the

corrosif liquid.

Material = 3Ceramic. Rasching Rings

Nominal Size = 76 mm

Bulk Density = 561 kg/m3

Surface area = 68 m2/m3

Packing factor = 65 m-1

Voidage = 75%


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6. Diameter Calculation

The calculationof it is based on Richardson and Coulson, volume 6.

Firstly we have to calculate below

= { }.FLV = 0.0009154

Then we have to plot the result to the flooding line graph to get the value

K4. From the plot of K4 Vs FLV. We get K4 at the flooding line 3.2

Figure B.7. Flooding Line Graph

G*= 49.913 Kg/m2s

Designing for a pressure drop of 42 mm water per m of packing. We

Have

K4 = 2.1

% Loading = 81.00925873%

G* = 40.4342758 Kg/m2s

Cross Section Area required


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A = 124.60

Diameter required

D = 12.6 m

Hence the diameter which is calculated from this approach is 12.6 meter

7. Diameter Calculation

The number stage of packing column absorbtion tower can be

calculated by using the graph below from Richard and Coulson. From the

graph, we get the number of stage is about two stages.

8. Height of Packing Calculation

Volumetric Flowrate entering gas

= 20.017 m3/s

Gas Velocity at the bottom of tower

= 0.16 m/s

Mass Flowrate at the top of tower = 4439.84 Kgs/s

Volumetric Flowrate at the top of tower

= 17.64 m3/s

Gas velocity at the top of tower

= 0.14 m s


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Liquid Flow

= 0.075 Kgs/ m2/s

Then We have to calculate the co-relation by the formula below

KG = 0.136

Area of Packing/ft height

A = 8597.9151 m

Height of Packing require

H = 20.51 m

9. Height of Packing Calculation

Inner Diameter = 12.60 meter

Height of pack req = 20.51 meter

Skirt Height = 2 meter

Density of mat column = 7700 kg/m3

Wind pressure = 130 kg/m2

Material Selection

Carbon Steel

Permissible tensile stress (f) = 950 kg/cm2

Thickness of shell = 3.008 mm


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B.4. Steam Methane Reformer R-101

Before calculating the volume of the reactor, we should calculate the rate of

reaction by the kinetic equation of Steam Methane Reforming below (Datta, et al.

2000)

= 1

1

The rate equations that were obtained based on the rate determining steps for

CH4+ H2O = 3H2+ CO. The rate of reaction use a kgmol/kg cat. S unit ( Hoang,

2005).

Where

= 1 Qr = 4,561

With parameter kinetic, equilibrium constant and adsorption constant below.

=

.

1

Reaction rate is rate = 4,08045 kgmol/kgcat.h

With the molar flow of 2135 kgmol/h, we can calculate the total weight of the

catalyst below

Weight of catalyst = 2135/ 4,08045 = 523.23 kg

By using bulk density of Ni/Mo-Al2O4 catalyst at 0.041 g/ml, we can

calculate the catalyst volume. Then, the volume of the reactor is (with 80% of

catalyst volume). After that, we calculate the number of tubes needed. Then,

calculate number of tubes needed. After that, we calculate the diameter and length

of reactor by 1:4 ratio. Then, we calculate the diameter of each tube. From the

literature we read, the construction materials used is a 25% chromium-20% nickel

alloy is preferred tube material (Low-alloy steels SA-203 grade D). The thickness

of reactor can be calculated by using a thickness calculation for tall vertical

vessel. The corrosion allowance is 1/32.


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The value of S can be found onTable 13.1, Process Equipment Design by

Brownell. A welded-joint efficiency (E) of 0.85 is specified by the ASME code.

The material we used for our reactor is Low-alloy steels SA 203 grade D. After

that, we can use a torispherical heads for our reactor design and calculate the head

thickness.

The Calculation for sizing steam methane reformer is using Microsoft Excel and

the result is shown in the sizing table

Table B.2. Steam Methane Reformer

weight of catalyst 2 kg cat

Cat Vol 48,780488 m

3

Vol Reactor 57,388809 m3

A Reaktor total 0,03 ft2

Tube 100

D Reaktor 2,6341016 m

263,41016 cm

L 10,536406 m

D tube 2,6341016 cm

1,06 in

Residence time 0,0287566 h

105,0765 s

1,751275 min

thickness 1,9773921 in

5,0225 cm

thicknes head 3,829613 in

9,6478 cm

TUBE THICKNESS 0,1299539 in


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APPENDIX C

Heat Exchanger Design Procedure

Step 1. Obtain the required thermos-physical properties of hot and cold

fluids at the caloric temperature or arithmetic mean temperature. Calculate

these properties at the caloric temperature if the variation of viscosity

with temperature is large. The detailed calculation procedure of caloric

temperature available is in reference.

r = TT = T TT TStep 2. Perform energy balance and find out the heat duty (Q) of the

exchanger Q = Q = mCt t = mCT TStep 3. Assume a reasonable value of overall heat transfer coefficient

(Uo,assm). The value of Uo,assmwith respect to the process hot and cold

fluids.


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Figure C.1. Shell and Tube Overall Coefficient

Figure C.2. Air Cooled Exchangers and Immersed Oil Overall Coefficient

Step 4. Decide tentative number of shell and tube passes (np). Determine

the LMTD and the correction factor FT. FT normally should be greater

than 0.75 for the steady operation of the exchangers. Otherwise it is

required to increase the number of passes to obtain higher FTvalues.

T =T T T T

ln T TT T

Step 5. Calculate heat transfer area (A) required:

A = QU,LMTD FStep 6. Select tube material, decide the tube diameter (ID = di, OD =

d0), its wall thickness (in terms of BWG or SWG) and tube length (L).

Calculate the number of tubes (nt) required to provide the heat transfer area

(A).

n = AdLCalculate tube side fluid velocity

u = 4 m(n n )d


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Re = 4 m(n n )d 10Step 7. Decide type of shell and tube exchanger (fixed tubesheet, U-tube

etc.). Select the tube pitch (PT), determine inside shell diameter (Ds)

that can accommodate the calculated number of tubes (nt). Use the

standard tube counts table for this purpose.

Figure C.3. Coomon Tube Layouts

Figure C.4. Heat exchangers tube-layouts

Step 8. Assign fluid to shell side or tube side. Select the type of baffle

(segmental, doughnut etc.), its size (i.e. percentage cut, 25% baffles are

widely used), spacing (B) and number. The baffle spacing is usually chosen

to be within 0.2 Dsto Ds.


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Figure C.5. Type of Heat Exchanger Baffles

Step 9. Determine the tube side film heat transfer coefficient (hi) using the

suitable form of Sieder-Tate equation in laminar and turbulent flow regimes.

Estimate the shell-side film heat transfer coefficient (ho) from:

j = hD ck

.

And find the hio from:

h = h IDODStep 10. Calculate overall heat transfer coefficient (Uo,cal)

U = hhh h

With the design overall coefficient is

U = QA TThe dirt factor is calculated from:

R = U UUU


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Step 11. Pressure drop calculation will be the tube side pressure drop (PT)

and the shell side pressure drop (PS). Pressure drop in the straight section

of the tube (frictional loss) (Pt) and return (Pn) due to change of

direction of fluid. So the total of each pressure drop: PT = Pt + Pn

P = fGD N 1 5,221010 DsIf the tube-side pressure drop exceeds the allowable pressure drop for the

process system,

we can decrease the number of tube passes or increase number of tubes per

pass.

P = LfG5,221010 DsIf the shell-side pressure drop exceeds the allowable pressure drop

P = LfG5,221010 Ds

The procedure is the same for all heat exchanger, the calculation is using

Microsoft Excel and the result is shown in the sizing table. Below will be shown

the calculation for one heat exchanger.

Material Selection for Heat Exchanger

For heat exchanger using low pressure and medium pressure steam as

heating fluid , we used carbon steel as material because temperature of process is

not too high. Moreover, Fluid that we used is Oil that cant cause corrosion. We

choose Carbon Steel SA-283 with Grade C because this material is commonly

used. Carbon steel is used because highly durable, low cost and easy tomanufactured.

Due to the high temperature like fired heater used for heating feed to steam

methane reformer. Therefore, carbon steels cannot be used as pipe material

because this material cannot be used in high temperature conditions. Carbon steel

can be used as material for temperature conditions bellow 1400oF. Materials that

can be used as wall material which can also be used in high temperature

conditions are stainless steel. Therefore, the proper material for low pH and high


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T = 155oC

T2= 134oC

t1= 25oC

t2= 65oC

temperature is stainless steel (SS)316L. Grade 316 is the standard molybdenum

bearing grade, second importance to 304 amongst the austenitic stainless steel.

The molybdenum gives 316 better overall corrosion resistant properties than grade

304 particular resist to pitting and crevice corrosion in chlorine environment.

C.1. Heat Exchanger E-101

Heat Balance

CPO, =+ = 45, c = 2200 J/kg-KQ =m.c.T

= 44,700 kg/h) (2200 J/kg-K) (338-298) K

= 3,933,600,000 J/hSteam, = + =148.5, c =4180 J/kg-K

W = = ,,, J/ J/K K=44812,03 kg/h

Determine the LMTD

LMTD = = = 99.2o

C

R = =

= 0.525S =

== 0.308

Determine the temperature difference


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It could be obtained from the graph that shows temperature correction factor. The

available existing graphs are for two shell passes, four, multiple of four tube

passes, etc.

The example graph that is used in this case could be seen below :

Figure C.6. Temperature Correction Factor : two shell passes ; four or multiple passes

(Source: Kern)

The temperature correction factor (FT) that is obtained from Figure C.6 is 1.

The properties of tube and pitch could be obtained from Table and Table

From the following table could be obtained the exact value of tube outer diameter,

square pitch length, shell inner diameter, amount of passes, and the last one in

amount of tubes. Actually there is no calculation done before choosing the value

of tube and pitch properties, but the chosen one should logically makes sense.

In this case, the selected tube OD is 0.75 in = 0.019m

Square pitch length = 1 in = 0.0254 m

Shell inner diameter = 19.25 in = 0.49m

Amount of passes = 2

So that the amount of tubes is 220


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Figure C.7. Tube Sheet Layouts (square pitch)

(Source: Kern)

Besides that, the other tubes properties could be obtainedfrom the following


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Figure C.8. HE Layouts

(Source: Kern)

The table above is used by using the previous selected tube OD. As the tube OD is

considered to be then the BWG value could be obtained. The BWG value is

chosen randomly, so that the following properties that are in the same row could

be obtained.


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The BWG value = 14

The wall thickness = 0.083 in = 0.0021m

Tube inner diameter = 0.584 in= 0.015m

Flow area per tube = 0.268 in2= 1.73 x 10-4m2

Surface/lin (outside) = 0.1963 ft2= 0.018 m2

Surface/lin (i

tk21 report assignment2

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