Production of 10,000MT/Yr

of n-Butyraldehyde by
hydroformylation of
propylene

Design of Stripper

Asma Shafique
(2018-CH-49)

University of Engineering & Technology Lahore 1

Table of Content

1. Introduction
2. Choice Between Tray & Packed Column
3. Selection of packing Type
4. Material Balance & Property Data
5. Design approach
6. Calculation of Diameter & Height of Column
7. Calculation of Pressure Drop
8. Material Selection
9. Calculation of Mechanical Design
10.Instrumentation & Costing
11.Environmental Impact Assessment (EIA)
12.HAZOP ANALYSIS

2
2
Introduction
Stripper
It is a Unit Operation, where one or more components of a liquid stream are removed by
being placed in contact with a gas stream that is insoluble in the liquid stream. Stripping
works on the basis of mass transfer.

Significance of Equipment
The organic phase containing the crude aldehydes and
propylene is stripped with synthesis gas(Mass Stripping
Agent) to remove dissolved propylene(olefin), which is
recycled to the reactor. So the required separation is being
brought about by stripper.

https://www.academia.edu/38701203/Butanal 3
Is Stripper really a good choice for our Process?

Mass fraction of Normal Feed

Process key component in Separating Agent Capacity Limits Advantages
feed set by
Equipment(kg/s)

Strips volatile component from

General Ranges Liquid Stripping Vapor 10^-4 to 50 liquid, simple operating conditions
For Stripper 10^-3 to 0.75

Our Process data 0.0271 Syn Gas 0.402 Strips propylene from crude
butanals.

Plant Design and Economics for Chemical Engineers 5th edition. 4

Types of Stripping Columns

Tray Column Packed Column

If the liquid causes fouling, or For corrosive liquids a packed
contains solids, it is easier to column will usually be cheaper
make provision for cleaning in a than the equivalent plate
plate column. column.

For large column heights, weight Packing should always be

of the packed column is more considered for small diameter
than plate column. columns <0.6m where plates are
difficult to install.

It is easier to make provisions for Packed column are suitable for

cooling in plate column. foaming liquids. Tray Column Packed Column

5
Our Selection
Packed Column

• Provide a large surface area, a high interfacial area

between the gas and liquid.
• Have an open structure: low resistance to gas flow.
• Promote uniform liquid and gas distribution on the
packing surface.
• It is more efficient.
• Packed towers are better for corrosive liquids.
• Packed towers are better at handling foaming systems.
• Flow parameter was in between.
Plant Design and Economics for Chemical Engineers 5th edition. 6
Selection of Packing Type
Random Packing

 Increased surface area for Types of Packing

vapor/liquid contact.
 Maximize surface-to-volume ratio.
 Minimizes pressure drop. Random Packing Structured Packing
 Uniform liquid distribution.
 Highly Cost Effective.
 Made of Ceramics, Metal or Plastic
 Easy Transport and Storage

7
Packing Selected

38mm Intalox Ceramic Saddle

Reasons:
 One of the most efficient packings
 Little tendency to nest and block areas of bed
 Gives a fairly uniform bed
(m^-1)
 Higher flooding point
 Lower pressure drop

Chemical Engineering Design by Sinott & Towler 8

Material & Energy Balance
Around Stripper

Components VIN LIN LOUT VOUT

CO (kg/hr) 519 0 0 519
H2 (kg/hr) 37.67 0 0 37.67
Propylene (kg/hr) 0 39.23 0.38 38.9
n-Butanal (kg/hr) 0 1336.25 1036.5 299.8
i-Butanal (kg/hr) 0 72.11 51.1 21.1
CH4 (kg/hr) 3 0 0 3
Temperature (C) 210 40 115 44
Pressure(Bar) 50 49.96 49.95 49.99
Heat Flow(kJ/hr) -2.92E+07 -4.69E+07 -4.35E+07 -3.26E+07

9
Chemical Design Calculations & Strategy

DESIGN APPROACH

1. Diameter of column
2. HETP of packing
3. Number of transfer units for the required separation
4. Height of overall transfer units
5. Total height of column
6. Flooding velocity
7. Verifying the pressure drop across the column
8. Mechanical Design

10
Diamter of Column

Calculated Flow Parameter:

FLV=0.98

Calculated ∆Pflood at Fp=51.8ft

∆Pflood =1.823in.H2O/ft
From Graph;
Fc=0.83

“Separation Process Principles” by Seader & Henly 4 th edi. 11

CONTI…

Superficial Velocity( Estimated flooding Velocity uVf ):

uvf=0.297ft/s
Diameter

DT=1.45ft or 0.44m
Calculated Fc at the design velocity
Fc=0.498
Read P drop at FLV and Fc;
∆P=0.12in. H2O/ft
“Separation Process Principles” by Seader & Henly 4 th edi. 12
HETP
Thus, HETP=1.45ft
HETP=0.44m
NTU HOG & NOG
HOG

HOG= 0.68m
Β=L/KV=1/S=0.444
x2=Solute contents in liquid inlet stream mol
fraction = 0.0456
x1=Solute contents in liquid exit stream mol
fraction = 0.0006 NOG= 4.54m
y1=Solute contents in gas at bottom mol fraction
=0 NTU≈7
“Separation Process Principles” by Seader & Henly 4 th edi. 13
Packing Height
lT Pressure Drop
lT=HOG×Nt
∆P = 0.12 in. H2O/ft
lT= 4.751m ∆P = 98.2 Pa/m of packing Height
Height of Column: ∆P = 0.000982bar/m
(Packing height=4.751m)
Height= 5.665m
∆P = 0.010 bar
Flooding Velocity: (60% of Superficial Velocity)
Cross-Sectional Area:
AT=π(D^2)/4
vs= 0.0899m/s AT = 0.152sq.m
vf=

vf= 0.15 m/s

“Separation Process Principles” by Seader & Henly 4 th edi. 14
Liquid Holdup

 Volumetric Flowrates:
QL = , Qv =

QL = 1.93 cum/hr Qv = 0.008 cum/s

 Superficial Velocities:

uL = 12.69 m/h uv = 0.053 m/s

 Reynolds Number:

NReL = 42.183
 Froude Number :

NFrL = 0.00023
“Separation Process Principles” by Seader & Henly 4 th edi. 15
CONTI…

Thus,

ah/a = 0.826

And, Liquid Holdup:

hL = 0.0355m3/m3

“Separation Process Principles” by Seader & Henly 4 th edi. 16

Selection of Material of Construction

 Butyraldehyde is a colorless flammable liquid with an unpleasant smell, and forms

explosive peroxides.
 Suitable Material is Stainless steel and Aluminium.
 Operating Conditions: P = 50 bar
Tmax=210C
 So, Material Selected is Type 304-Stainless Steel (SS-304).

 Low Carbon Variation of Type 302,

minimizes carbide Precipitation
during welding.

Plant Design and Economics for Chemical Engineers 5th edition. 17

Mechanical Design
Minimum Wall Thickness of Shell (t):
For Cylindrical shell

Cc = Allowance for Corrosion = 2mm

P= Design Pressure = 1.1×Operating Pressure = 5500kPa
S=maximum allowable working stress = 77200kPa
ri= inside radius of shell, before corrosion allowance = 0.22m
EJ=efficiency of joints expressed as a fraction = 0.85
t = 21mm
Weight of Shell (M):
M=π×Dc×L×t×ρm
;ρm=8000kg/m3 (SS-304)
M = 1314.9kg
18
Head

Thickness of Head:
t = 20.6mm
2:1 Elliptical head has been selected because it is used for high pressure requirements and its manufacturing is easy as
compared to other types. Material of construction is low alloy steel.

Capacity as volume in head

IDD = inside depth of dish = = 0.11m
Approximate weight of dished portion of head= W =
Da=major axis of an ellipsoidal head = 0.44m , n=1.2

W = 38.94kg

19
 Dead weight loads

Weight of vessel:
Weight of insulations:
 Volume of insulation = πDmHvt
(for cylindrical Shell domed ends, uniform thickness)
Volume of insulation = 0.16 m3
Cv = 1.15 for columns with only a few internal  Weight of insulation = VꝬg
fittings, Weight of insulation = 0.22 kN
Density of material=8000kg/m3
D m = Di + t

Wv = 15.75 kN Wi = 0.22 kN

Total Weight = 15.75 + 0.22 = 15.97 kN

Chemical Engineering Design, Coulson and Richardson Vol. 6, 4th edition 20

 Wind load analysis

At worst wind scenario  Wind Loading:

uw = 160 km/hr

 Wind Pressure: Fw = 616.96 N/m

 Bending moment at bottom target line:

Pw = 1280 Pa
 Effective Diameter:
Deff = Do + 2*t Mx = 9899.9 Nm
Deff = 0.482 m

Chemical Engineering Design, Coulson and Richardson Vol. 6, 4th edition 21

 Stress analysis

 Longitudinal stresses:  Direct stress:

Stress = 27.43 N/mm2

Stress = 0.54 N/mm2
 Circumferential stress:
 Radial stress:

Stress = 54.9 N/mm2 Stress = 2.75 N/mm2

Chemical Engineering Design, Coulson and Richardson Vol. 6, 4th edition 22

 Stress analysis
 Bending stresses:  Total longitudinal stress:

Where
 Upwind stress:

Stress = 33.8 N/mm2

Iv = 3.3 x 10^8 mm4
 Downwind Stress:
And,
Stress = 19.98 N/mm2
Stress = 6.91 N/mm2

Chemical Engineering Design, Coulson and Richardson Vol. 6, 4th edition 23

 Elastic stability check

 Critical buckling stress:  Maximum comprehensive stress:

Stress = 955 N/mm2 Stress = 7.45 N/mm2

As critical buckling stress is greater than maximum comprehensive stress. So,

mechanical design is safe and satisfactory

24
Chemical Engineering Design, Coulson and Richardson Vol. 6, 4th edition
Specifications Sheet
Name of equipment Stripper

Type Packed Column

Type of Packing 0.038m ceramic Intalox saddles

Material of Construction Type 304-Stainless Steel

Pressure drop 98 Pa/m of Packing height

Diameter of Column 0.44m

Area of Column 0.152m^2

NTU 7

HOG 0.68

Height of Column 5.665m

Weight of Shell 1315kg

25
COST ESTIMATION

Purchased Cost = 9×10^3 $

Purchased Cost = 3.9×10^4 $ Fp= 3.2 , Fm = 1.7
Cost = PC×Fp×Fm
Cost = 48960 $

Plant Design and Economics for Chemical Engineers 5th edition. 26

CONTI...

Purchased Cost = 7.5×10^3 $/m

Cost = 35632.5 $
Purchased Cost = 1.1×10^3 $
Packing Fm = 2.2 Total Cost in 2002= 126013 $
Cost = 2420 $ Present Cost = Cost of 2002×(776.9/395.6)
Present Cost = 24748.55 $

https://www.toweringskills.com/financial-analysis/cost-indices/ 27
Control on Stripper

28
Simulation Results

29
CONTI…

30
HAZOP Study
Guide Deviation Possible Causes Consequences Actions Required
Word

None No Flow No flow in Stream coming to Quality and amount of Install low level
the column product will suffer. alarm
-

Line Accidental discharge to Plant shut

fracture the environment (aldehydes down.
are flammable material).

Overfills
More Flow LCV fails (open in Error) Incomplete separation of Install high level
of Aldehydes and Olefins Alarm and Check sizing.

Pressure Isolation valve close in error Full pump Isolation Valve close in error
delivery

31
CONTI…

Temperature Higher pressure in Degradation of the High Temperature

Transfer line solvent quality will Alarm (HTA)
become significant.

Less of Flow Leaking flange of valve Material discharge to Isolate that part of the
the environment plant

Others Maintenance Equipment Line cannot be Install

Failure Completely drained or alarms
purged

https://dokumen.tips/documents/chapter-8-hazop-study.html 32