King Fahd University Of Petroleum & Minerals College of Engineering Sciences and Applied Engineering Chemical Engineering Department CHE 495 - Integrated Design Course Production of Formaldehyde from Methanol Integrated Final Report Done by team 3: Mohammed Ahmad Sanhoob ID: 200723450 Abdullah Al-Sulami ID: 200848200 Fawaz Al-Shehri ID: 200763230 Sabil Al-Rasheedi ID: 200715130 Course Instructor: Dr. Reyad Shawabkeh December 29th, 2012 Table of Contents PAGE EXCUTIVE SUMMARY ..................................................................................................................…..................V 1. LITERATURE REVIEW OF THE PRODUCTION PROCESS ………………................…….……………..1 1.1. Summary of the project ....................................................................................…................2 1.2. Problem Information .......................................................................................…................3 1.3. Initial Block Diagram .........................................................................................…..............5 1.4. Kinetic Data for the Problem ……………………………………………….................…….9 1.5. Safety nad Environment precautions ……………………….............…………………10 1.6. Preliminary cost of material………………………………..............………………………13 2. MASS BALANCE………………………..…………………………………………................…................................ 14 2.1. First Run ………………………………………………………………..............…………….……………….… 16 2.1.1. Mass balance around the reactor........................................................................…...16 2.1.2. Mass balance around the absorber....................................................................…...18 2.1.3. Mass balance around the distillation column....................................…...............22 2.2 Second Run..............................................................................................................................…...............24 2.2.1. Mass balance around mixing point of streams 2, 3 and 15………..............…24 2.2.2. Mass balance around mixing point of streams 6, 7 and 8..............….............24 2.2.3. Mass balance around the reactor........................................................................…...25 2.2.4. Mass balance around the absorber...................................................................…....26 2.2.5. Mass balance around the distillation column....................................…...............27 2.2.6. Mass balance around mixing point of streams 17, 18 and 19…...................28 3. ENERGY BALANCE………………………………………………………………………………................…………35 3.1. Mixing point of streams 1, 2 and 3..........................................................…..............35 3.2. Pump P-101......................................................................................................…..............37 3.3. Pump E-101.......................................................................................................….............38 3.4. Compressor C-101...................................................................................................…....39 3.5. Heat exchanger E-102……………………………………….…….............……………….40 3.6. Mixing point of streams 6, 7 and 8..........................................................…..............40 3.7. Heat exchanger inside the reactor.....................................................................…...42 3.8. Throttle..........................................................................................................................…...43 3.9. Absorber.............................................................................................................…..............44 3.10 Heat exchanger E-103.................................................................................….............45 3.11. Distillation tower T-101…………………………….............….…………… ………….46 3.12. Pump P-102...............................................................................................................…...48 3.13. Pump P-103.....................................................................................................................49 3.14 Mixing point of streams 17, 18 and 18.................................................….............50 3.15 Heat exchanger E-106.................................................................................….............51 Energy Balance Data Sheet...............................................................................................…...............51 I 4. PROCESS SIMULATION................................................................................................................…................52 4.1. VALIDATION...................……………….………………………………………...................................................53 4.1.1 Flowrate Spreadsheet......................................................................................................…................ 54 4.1.2 Energy Spreadsheet..............................................................................................................................57 4.1.3 Discussion of Mass Balance..............................................................................................................58 4.1.4 Discussion of Energy Balance..........................................................................................................59 4.2. SIMULATION.................................................................................................................….............................60 WATER FEED VARIATION TO THE ABSORBER.................................................................................63 VARIATION OF INLET TEMPERATURE TO THE ABSORBER........................................................64 4.3. ALTERNATIVE PROCESS............................................................................................................................66 4.3.1 Reactor’s Cooler (E-100)...................................................................................................................69 4.3.2 Productivity of the Process................................................................................................................69 4.3.3 Reactor’s Volume....................................................................................................................................69 4. EQUIPMENT SIZING………………………………………………………………………….................……………70 EQUIPMENT & LINING LIST……………...........................................................................................……….71 REACTION DESIGN……....................................................................................................................................72 6.1. Reactor Design Equation……..………………………………….........………...........................................72 6.2. Mole BALANCE…………………………………………….........………………………………………….…….73 6.3. Net Rate Law………………………………………………………………………………….........……….…….74 6.4. Rate Law..........................................................................................................................................….........74 6.5. Stoichiometry…………………………………………………………………………….........……………….…76 6.6. Combination.....................................................................................................................................…........77 6.7. Pressure Drop...............................................................................................................................…..........78 6.8. Energy Balance….......................................................................................................................................80 6.9. Heat Exchanger inside the reactor…………………………………………………………........……….83 6.10. Arrangement of The Tubes..............................................................................................................., 88 6.11. Other Parameters Evaluation……………………………………………........………………………….89 6.11.1. Evaluating the number and height of the tubes...................................…...................89 6.11.2. Evaluating the Volume of the reactor.......................................................…...................89 6.11.3. Evaluating the height of the reactor.........................................................…....................89 6.11.4. Evaluating the width of the reactor,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,…...................89 6.12. Results....………………………………………………………………………..................,,,,,,,,,,,,.............……90 6.12.1. POLYMATH REASULTS...........................................................................................…...........90 6.12.1.1. Differential equations................................................................…......................90 II 6.12.1.2. Explicit equations…………………………………………………........................…90 6.12.1.3. The result of the differential and explicit equations…..........................93 6.12.1.4. Graphs...................................................................................................…..................94 6.12.2. HEAT EXCHANGER RESULTS........................................................................…..................96 6.13. Selection of The Material…………….........………………………………………………………………97 6.14. COMPARING THE PRODUCTS...................................................................................................…...98 6.15. Summary Table ……………………………………………........……………………………………………98 5. ABSORBER DESIGN………………………………….................................……………................………………..99