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Title: United Arab Emirates University College Of Engineering Chemical Engineering Department Graduation Pr


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United Arab Emirates UniversityCollege Of
EngineeringChemical Engineering
DepartmentGraduation Project II
The Design of Formaldehyde Production Plant
  • Group Members
  • Abrar Abdalla Ahmed 200002089
  • Ayisha AL-Marzouqi 200002243
  • Huda Tag Hamza 200004386
  • Noora Al-Mulla 200002122

3
Objectives
1- Design a formaldehyde plant
2- Economical, Environmental safety
4
Layout
First semester
Second semester
1- Design Sizing of Equipment
2- Hazard Operability Study
3- Cost and Economical Evaluation
4- Conclusion
5
First semester
Requirements
1- Raw material
2448.5 kg/hr
2- Power Energy
2.3107 kJ/hr
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Second semester
Distillation column
88oC
35oC
Tail gas
water
Absorption column
Reactor
Steam
145 oC
Converter
Distillation Column
Cooling Water
Absorber
Air washer
88oC
145 oC
Air
110 oC
160oC
Methanol superheater
64.7oC
35oC
Methanol vaporizer
37 CH2O1 CH3OH
Fresh methanol
Recycled methanol
8
Design Sizing of equipments
Absorption Column
Distillation Column
Reactor
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Reactor Unit
Methanol Water Air
Steam
200 oC
23.7 CH2O 9 CH3OH 45.5 H2O 13.5 N2 H2 ,
CO2 , CO , C2H4O2
Water
30 oC
11
Reactor Design
Fixed catalyst bed
Heat exchanger
12
Assumptions
Main design parameters
1- Depth 2- Diameter 3- pressure drop 4-
Catalyst weight
1- Mass transfer limited 2- Isothermal 3-
Adiabatic
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Silver catalyst bed
14
Bed depth
Concentration of methanol
Feed velocity
Mass transfer coefficient
Catalyst area/bed volume
Z 3 cm
15
Ac V / v
1.58 m
Bed diameter
Mass velocity
Volumetric Flow rate
16
Ergun equation
25.7 kpa
Pressure drop
porosity of catalyst
diameter of particle in the bed
catalyst bed depth
superficial velocity
258 kg
Catalyst weight
porosity of catalyst
volume of solids
density of silver catalyst
17
Heat exchanger
18
Heat exchanger design
Steam
200 oC
Water
30 oC
19
Shell diameter
Bandel diameter
1.57 m
1.58 m
No. of tubes
Bandel diameter
Tube diameter
20
U 700 W/m2.oC
Q U A ?Tlm
Q 57418.5 Kw
Dtube 48 mm
Aheat transfer 306 m2
Ltube 3.64 m
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Absorption Unit
Tail gas
Gas Out
Liquid In
Water
Formaldehyde Methanol Other gases
Gas In
Liquid Out
Formaldehyde water and methanol
23
Absorber Design
Methylene glycol
Water
Assumption
Main design parameters
1- Diameter 2- Height 3- Flooding 4- Liquid hold
up
Methylene glycol- Methanol system
Formaldehyde
24
Absorber Design
1 m
Column Height
Column Diameter
Z HPacking 18 m
D 0.9 m
Z HTotal 20 m
Gas density
Gas flow rate
Drag coefficient
1 m
25
Liquid hold up
hL 0.11 m3/m3
26
Flooding
Flooding velocity 3.1 m/s
Gas velocity 1.99 m/s
UG lt Uf
No flooding
27
Liquid distributor velocity 1.15 m/s
Packing size 50 mm
No. of holes 108
Liquid re- distributors
Pressure drop 22 mmH2O/m
Wetting rate 3.75810-5 m3/m2.s
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Distillation Unit
Vapor
99 Methanol 1 methylene glycol
91 Methylene glycol 9 Methanol
Liquid mixture
99 Mehtylene glycol 1 methanol
Liquid
30
Distillation Design
Main design parameters
Assumption
Methanol- Water system
1- Diameter 2- Height 3- Weeping 4- Entrainment
31
Distillation Design
dome
0.35 m
Column Diameter
Column Height
Htotal Hvessel Hdomes
Hvessel Plate spacing NA Hdomes 2 1.2
plate spacing
HTotal 10.60 m
D 1.65 m
32
Description
Gas out
Liquid in
Feed
Liquid out
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Section in distillation column
Liquid flow
Gas flow
Perforated tray
34
Weeping
Gas velocity lt liquid velocity
Min. actual gas velocity 9.29 m/s
Min. design gas velocity 7.67 m/s
9.29 m/s gt 7.67 m/s
Hole Diameter
Vapor density
Plate spacing
No weeping
Max. Volumetric Flow rate
Hole area
35
Entrainment
Gas velocity gt liquid velocity
Percentage flooding 10
Plate spacing 0.35 m
0.0015 lt 0.1
No entrainment
36
No. of holes 12584 holes
No. of trays 28 trays
Total pressure drop 43.97 mm liquid
Height 10.60 m
Diameter 1.65 m
Plate spacing 0.35 m
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Feed to the reactor
Intention
Reactor
Guide Word
More
Flow
Deviation
Causes
  • Control systems failure
  • - Pump 1 failure
  • Filter failure
  • Blower failure

Consequences and actions
High reactor temperature
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Cost
Operation manpower
Total purchase cost 703,976
Total salary 224,907 /year
41
Economical Evaluation
Pay back time
3 years
42
References
  • 1- A. L. Hines, Mass transfer fundamentals and
    applications, Oklahoma state university,
    Prentice Hall P T R, Englewood Cliffs, New
    Jersey.
  • 2- C.J. Geankoplis, Transport process and unit
    operation, third edition, university of
    Minnesota, Prentice Hall P T R, Englewood Cliffs,
    New Jersey, 1993.
  • 3- J.M. Coluson, Chemical engineering, volume
    two, Pergamon Press, new yourk.
  • 4- KOPIA, Standard Proposal For Formalin Plant,
    SP-034.
  • 5- M. S. Peters, Plant design and economics fro
    chemical engineers., Fourth
  • edition, McGraw-Hill, New yourk, 1991.

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Blocked Pipeline
Line 11
Blower damage
Blocked filter
Pump damage
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