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Equipments Design PO/Styrene Plant. Done By: Salem Alkanaimsh. Prof. M. Fahim Eng. Yousef Ismael. Agenda. Reactor Design. Heat Exchangers Design. Distillation Columns Design. Pumps Design. Compressors Design. Reactor Design. Chemical reactors are the heart of chemical processes.

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equipments design po styrene plant

Equipments DesignPO/Styrene Plant

Done By:

Salem Alkanaimsh

Prof. M. Fahim

Eng. Yousef Ismael

  • Reactor Design.
  • Heat Exchangers Design.
  • Distillation Columns Design.
  • Pumps Design.
  • Compressors Design.
reactor design
Reactor Design
  • Chemical reactors are the heart of chemical processes.
  • Reactors can be divided into:
  • Batch reactors.
  • Continues reactors.
  • CSTR.
  • PFTR.
  • Example: Petroleum Refinery.
reactor design1
Reactor Design

Finding The rate equation:

Design Equation

reactor design2
Reactor Design

Thickness of Reactor

Diameter and length of reactor


t: thickness of reactor.

P: internal pressure .

ri: radius of the vessel .

Ej: joint efficiency .

S: stress of carbon steal .

Cc: corrosion allowance

heat exchanger design
Heat Exchanger Design
  • Definition.
  • Service.
  • Exchanger.
  • Condenser.
  • Heater.
  • Type.
  • Shell and tube.
  • Air cooled HX.
shell and tube hx
Shell and Tube HX
  • Tubes.
  • Pattern of Tubes.
  • Shell and nozzle.
  • Baffles.
shell tube heat exchanger design
Shell & Tube Heat Exchanger Design.
  • Assumptions:
  • Shell and tube heat exchanger counter flow is used because it is more efficient than the parallel flow.
  • The value of the overall heat transfer coefficient was assumed based on the fluid assigned in both sides.
  • The outer, the inner diameter , the length of the tube, and the number of passes were assumed.
  • For a good design :
  • The assumed overall heat coefficient has to be equaled to the calculated overall heat transfer coefficient.,
  • The pressure drop in the tube side has to be lower than 1 bar.
  • The pressure drop in the shell side has to be lower than 1 bar.
shell tube heat exchanger design1
Shell & Tube Heat Exchanger Design.

Log mean Temperature

Heat Load


T1 is temperature of inlet hot stream. (oC)

T2 is the temperature of outlet hot stream. (oC)

.t1 is the temperature of inlet cold stream. (oC)

.t2 is the temperature of outlet cold stream. (oC).

shell tube heat exchanger
Shell & Tube Heat Exchanger

Number of tubes

Heat Transfer Area

Shell and Bundle diameter

Where ;

Nt is the number of tubes.

K1, n1 are constants.

Db is the bundle diameter (mm)

Ds is the shell diameter. (mm)

shell tube heat exchanger design2
Shell & tube heat exchanger Design

Tube Side Heat Transfer Coefficient

Shell side heat Transfer Coefficient


is the density of fluid (kg/m3).

is the thermal conductivity (W/m.C).

is specific heat (kJ/kg.k).

Re is the Reynolds number.

Pr is the Prandtl number.

Nu is the Nusselt number.

is the convective heat transfer coefficient (W/m2.C).


.pt is the tube pitch (mm).

.lB is the baffle spacing (mm).

As is the cross flow area (m2)

us is the velocity (m/s).

de is the equivalent diameter for triangular arrangement (mm).

jh is the heat transfer factor

hs is the convective heat transfer coefficient (W/m2.C).

shell tube heat exchanger design3
Shell & Tube Heat Exchanger Design.

Overall Heat Transfer coefficient

Shell Side Pressure Drop


Tube side pressure Drop

Where; D is the shell diameter in m

Rj is internal radius in (in).

P is the operating pressure in psi

S is the working stress (psi).

E is the joint efficiency

distillation column
Distillation column
  • A separation unit based on the difference between a liquid mixture and the vapor formed from it.
  • It can be subdivided according to:
  • How complex the unit is:
  • Simple Distillation.
  • Flash distillation.
  • Fractionation.
  • The internal Design of the column:
  • Tray Column.
  • Packing Column.
distillation column design

Column Efficiency.

Tray spacing.

Flooding Percentage.

Down Comer Area.

Hole area( 0.1 of Active area).

Weir height ( 40~100)mm.

Hole diameter (10 mm).

Plate Thickness (10~30 mm).

Turn down Percentage (70%)

Good Design:

No weeping.

Down comer back up is less than half ( plate thickness+ weir height).

No entrainment.

Calculated percentage flooding equal to the assumed one.

Residence time exceeds 3 secs.

Distillation Column Design.
distillation column design1
Distillation Column Design.

Actual Number of trays

Column Diameter

Where; FLV is the vapor-liquid flow factor.

is the density in (kg/m3).

is the surface tension in (mN/m).

uf is the velocity of vapor in (m/s).

D is the column diameter (m).

distillation column design2
Distillation Column Design

Provisional Plate design

Liquid Flow Pattern

distillation column design3
Distillation Column Design

Checking Weeping

Down Comer Back up

Residence time

distillation column design4
Distillation column design

Estimating the Thickness



Number of holes

pump design
Pump Design
  • Definition.
  • Suction Calculations.
  • Discharge Calculations.
  • NPSH.
pump design1
Pump Design.

Actual Head of pump

Water horse Power


compressor design
Compressor Design
  • Definition.
  • Types:
  • Centrifugal.
  • Axial.
  • Reciprocating.
  • Compression:
  • Adiabatic.
  • Isothermal.
  • Intercooler stage
  • Pressure Ratio (PR).

Reduce temperature and work required.

compressors design
Compressors Design.


Efficiency =0.8 Isentropic Compression

Thank you All for

Paying Attention