e

The Republic of Sudan

Al-Neelain University

Faculty of Engineering

Chemical Engineering Department

Design of diesel hydro-treating unit

DHT

A Project Submitted in Partial Fulfillment of the Requirements

for the Bachelor Degree (Honors) in Chemical Engineering

Supervisor:
Dr. Saif Al-Din Jala Al-Din
Prepared by:
1. Elyas Yagoub Galal Elnour
2. Mohamed Ali Salih Ibrahim
3. Odai Elmubarak Gismalla Saed
4. Ethar Fath-Al-rahman Haju Al-amein

November 2023

I
 ‫األية‬
‫قال تعالي ‪:‬‬
‫( وقل ربي زدني علما )‬
‫صدق هللا العظيم‬

‫‪I‬‬
II
III
IV
 Table of Contents
‫االية‬...……………………………………………….............……………………… I
Dedication...………………………………………………..………...…...………...ii
Acknowledgement …………………………...……………..…………..………... iv
Table of contents…………………...…………………………..……………….......v
List of Table ...……………………………………….…………..……….………...xi
List of Figure ………………………………………………….……………….…..ix
Abstract ……………………………………………….…………….………….…xiii
‫………المستخلص‬...……………………………………………..……..................…xiv
Chapter one: Introduction and literature review
1.1 Introduction ………………………………………………..………………..1
1.2 Historical Background……………………………………………….……….1
1.3 Classification of Diesel fuels ……………………………….………………..2
1.4 Composition of diesel fuel ……………………………….…………………..3
1.5 Diesel Fuel Production Processes…………………………..………………...3
1.5.1 Petroleum diesel Process……………………………….…………………..3
1.5.2 Synthetic diesel process ………………………………………………..…..4
1.5.3 Biodiesel process …………………………………………………...……...5
1.5.4 Diesel Hydro treating Processes …………………………………….……..5
1.6 Introduction to Hydro treating Process……………………………...……….6
1.7 Hydro treating process configurations………………………………..……...6
1.8 HYDROTREATING CATALYSTS …………………………….…………...8
1.9 Chemistry of Hydro treating Process …………………………….………….9
1.10 Hydro-treating Reactions…………………………………………………...9
1.11 Process description ………………………………………………….…….12
Chapter two Material Balance
2.1 Introduction ………………………………………………………………...14
2.2 Overall material balance …………………………………………………...16
2.3 partial Material balance …………………………………………………….17
2.3.1Material balance around mixture ………………………………………...17

V
2.3.2 Material balance around Reactor …………………………………………….17
2.3.3Material balance around mixture valve ……………………………………….18
2.3.4 Martial balance around cold High pressure
Separator drum …………………………………………………………………….18
2.3.5 Martial balance around low pressure
Separator drum …………………………………………………………………….19
2.3.6 Martial balance around striping column ……………………………………19
Chapter three Energy Balance
3.1 Introduction to Energy Balance ………………………………………………..21
3.1.2 Assumption considered ………………………………………………………21
Conservation of energy……………………………………………………… 21
3.2 partial Energy Balance ………………………………………………………...22
3.2.1 Energy balance around reactor ………………………………………………22
3.2.2 Energy balance around reactor furnace ……………………………………... 23
3.2.3Energy balance around column furnace ……………………………………...23
3.2.4 Energy balance around first heat exchanger………………………………... 24
3.2.5 Energy balance around second heat exchanger ……………………………...25
3.2.6 Energy balance around 3th heat exchanger………………………………….. 26
3.2.7 Energy balance around air cooler …………………………………………….27
3.2.8 Energy balance around water cooler …………………………………………28
3.2.9 Energy balance around striping column ……………………………………...29
3.2.10 Energy balance around
Striper heat exchanger ……………………………………………………………...30
Chapter four Process Design
4.1 Introduction …………………………………………………………………….32
4.2 Design of Distillation column …………………………………………………32
4.2.1 Selection of column type …………………………………………………….33
4.2.2 Design procedure and calculations …………………………………………...33
4.2.3 Design calculation ……………………………………………………………34
4.3 Heat exchanger design ………………………………………...………………39
4.3.1 Introduction to heat exchanger design ………………………………………39

VI
4.3.2The principal types of heat exchanger ………………………………………39
4.3.3 Design procedure …………………………………………………………….39
3.3.4Design objective ……………………………………………………………..40
3.3.5 Design calculation …………………………………………………………...40
4.4 Reactor design ………………………………………………………………...48
4.4.1 Introduction to reactor design ……………………………………………….48
4.4.2 Requirements of industrial chemical reactor design ………………………..49
4.4.3 design calculation …………………………………………………………..50
Chapter five Process Control
5.1 Introduction …………………………………………………………………...54
5.1.2Process ……………………………………………………………………...54
5.1.3Process Control ……………………………………………………………...54
5.1.4Control Loop ………………………………………………………………..54
5.1.5Process Variable ……………………………………………………………..55
5.2 Applications of control in DHT unit …………………………………………55
5.2.1 Steam stripping column control …………………………………………….55
5.2.2 Reactor variables control …………………………………………………..56
5.2.3 Heat exchanger control …………………………………………………….57
Chapter six Safety and Environment
6.1 Introduction …………………………………………………………………..61
6.1.2 Safe work is a work without any damage / loss to …………………………61
6.1.3 To prevent loss ……………………………………………………………..61
6.1.4Common hazard in a plant ………………………………………………….61
6.1.5 Fire hazards of diesel ………………………………………………………..61
6.2 Diesel hydro treating unit safety ……………………………………………...62
6.2.1 Safety characteristics and safety measures of the device …………………...62
6.2.2 Safety measures of the device ……………………………………………….62

VII
6.3 Environmental considerations ……………………….……………………….63
6.3.1 Measures for discharge and control of three wastes
in hydrogenation device ………………………………………………………….63
[Link] Waste gas ………………………………………………………………….63
[Link] Waste liquid Sewage ……………………………………………………..63
[Link] Dirty oil …………………………………………………………………...64
[Link] Waste residue ……………………………………………………………..64
Chapter seven Plant location and Layout
7.1 Introduction …………………………………………………………………68
7.1.1 Plant Location and Site Selection …………………………………………..68
7.1.2 Location, with respect to the marketing area ……………………………….68
7.1.3 Raw material supply ………………………………………………………..68
7.1.4 Transport facilities …………………………………………………………68
7.1.5Availability of labor …………………………………………………………69
7.1.6 Availability of utilities ……………………………………………………...69
7.1.7 Availability of suitable land ………………………………………………..69
7.2 Environmental impact and effluent disposal …………………………………70
7.2.1 Local community considerations …………………………………………..70
7.2.2 Climate ……………………………………………………………………..70
7.2.3 Political and strategic considerations ………………………………………70
7.3 Site Layout: ………………………………………………………………….70
7.4 Plant Layout: ………………………………………………………………...72
7.4.1The process requirements …………………………………………………..72
7.4.2 Convenience of operation …………………………………………………..72
7.4.3 Convenience of maintenance ………………………………………………72
7.4.4 Safety ……………………………………………………………………….73
7.4.5 Future expansion ……………………………………………………………73
7.5 Modular construction ………………………………………………………….73

VIII
7.6 General considerations ………………………………………………………...73
7.6.1 Buildings ……………………………………………………………………..74
7.6.2 Plant expansion ………………………………………………………………74
7.6.3 Other services ………………………………………………………………..74
7.6.4 Wind direction ………………………………………………………………..74
7.6.5 Storage facilities ……………………………………………………………...75
7.7 DHT unit layout ………………………………………………………………..75
7.7.1 Scope ………………………………………………………………………...75
7.7.2 Site of feed storage …………………………………………………………...75
7.7.3 Site of process equipment ……………………………………………………75
7.7.4 Site of products ………………………………………………………………75
7.8Control room consideration …………………………………………………….75
Chapter eight Cost Estimation
8.1 Introduction …………………………………………………………………….78
8.1.1 The actual production capacity ………………………………………………78
8.1.2 Installed capacity …………………………………………………………….78
8.2 Factors Affecting Investment and Production Costs ………………………….78
8.3 Accuracy of Estimates: ………………………………………………………..79
8.4 Capital Investment Cost ………………………………………………………..79
8.5 Operation cost ………………………………………………………………….81
8.5.1Variable operation cost ………………………………………………………..81
8.5.2 Fixed operation cost ………………………………………………………….83
8.6 Total annual income ……………………………………………………………84
8.7 Net profit ……………………………………………………………………….84
8.8 Taxes of net profit ………………………………………………………………84
8.9 Annual net profit ……………………………………………………………….84
8.10 Payback period ………………………………………………………………..84
Chapter nine Recommendation and Conclusion
9.1 Conclusion………………………………………………………………………86
9.2 References ……………………………………………………………………...87
9.3 Appendices ……………………………………………………………………..89

IX
Appendixes of Tables
Table (A-1) Typical overall coefficient …………………………………………….89
Table (A-2) Fouling factors (coefficients) typical values: …………………………89
Table (A-3) stander dimensions of steel tube : ……………………………………90
Table (A-4) conductivity of metals ……………………………………………….90
Table (A-5) typical tube arrangement …………………………………………….90
Appendixes of Figures:
Figure (B-1) Erbar Maddox correlation . …………………………………………..91
Figure (B-2) flooding velocity sieve plate . ……………………………………….91
Figure (B-3) tube side heat transfer factor …………………………………………92
Figure (B-4) Temperature correction factor: one shell pass; two or
more even tube passes. ………………………………………………………..…..92
Figure (B-5) shell side heat transfer factor, segmental baffle ……………………93
Figure (B-6) shell side friction factor, segmental baffle ………………………….93
Figure (B-7) shell bundle clearance ……………………………………………….93

X
 LIST OF TABLE
Table (1.1) Properties of diesel fuel ……………………………………………….3
Table (1.2) Process parameters : …………………………………………...……..11
Table (1.3) Row feed from RFCC to DHT unit Properties : …………………......11
Table (2.1): Stream lines codes. ………...………………………………………….15
Table (2.2): summary of general material balance: ……………………………….16
Table (4.1) Feed specifications ……………………………………………………34
Table (4.2 ) Average relative volatility (αav) ……………………………………...34
Table (4.3) calculated using trial and error method …………………………….35
Table (4.4) Summery of Distillation column design calculation ………………….38
Table ( 4.5 ) Enthalpy and mass flow rate ………………………………………..40
Table ( 4.6) fluids properties ……………………………………………………...41
Table ( 4.7 ) illustrated exchanger layout …………………………………………43
Table ( 4.8 ) Heat exchanger design summary ……………………………………46
Table (4.9 ) Design summary in shell &tube sides: ………………………………47
Table (4.10) Design summary of reactor : ………………………………………..52
Table (5.1) Indices for DHT Process control ………………………………………59
Table ( 6.1 ) diesel hazards specification …………………………………………..61
Table (6.2) Environmental department measurement and control …………………65
Figure (7.1) plant layout …………………………………………………………...76
Table (8.1) equipment prices ……………………………………………………….80
Table (8.2) below represent utilities required for DHT unit ……………………….82

XI
LIST OF FIGURES
Figure ( 1.1 ) diesel fuel from simple distillation column ………………………….4
Figure ( 1.2 ) Synthetic diesel process ……………………………………………..4
Figure ( 1.3 ) Biodiesel process flow sheet ……………………………………….. .5
Figure ( 1.4 ) Diesel Hydro treating flow sheet …………………………………...5
Figure ( 1.5 ) DHT unit a cold separator layout …………………………………...7
Figure ( 1.6 ) DHT unit hot separator layout ………………………………………7
Figure (1.7 ) DHT flow scheme ……………………………………………………12
Figure (2.1) DHT flow scheme ……………………………………………………14
Figure (4.2 ) schematics drawing of hydro treating reactor ……………………….49
Figure ( 5.1 ) a level transmitter (LT) ……………………………………………...54
Figure (5.2 ) Model of stripper top control ………………………………………...55
Figure (5.3 ) Model of stripper bottom control …………………………………….56
Figure (5.3) stripper bottom temperature control …………………………………..56
Figure (5.5) DCS Screen of heater and Reactor control …………………………...57
Figure (5.6) model reactor bed temperature control ……………………………….57
Figure (5.7) Conventional Process Control ………………………………………..58
Figure (5.8) Digital Process Control ………………………………………………58

XII
 Abstract
Through this research, we expect the results to be useful in improving the quality of
diesel and reducing its impact on the environment. Consequently, this will contribute
to enhancing the performance of heavy transport engines and developing the trans-
portation industry as a whole.
Heavy transport engines are considered essential components in modern countries
seeking to boost their economy. It is known that these engines operate on diesel fuel,
the properties of which are important in the ability of these engines to perform their
function effectively and to preserve their parts from damage and corrosion. There-
fore, in this research, we shed light on the hydrogen diesel processing unit and im-
proving the specifications of the diesel produced from it. We studied the raw materi-
al coming from the fluid catalytic cracking unit, and designed a reactor capable of
producing low-sulfur diesel, which is a major cause of engine damage and corrosion.
We then conducted a study of the process flow diagram from the reactor to the distil-
lation column to obtain the best flow diagram economically and for easy material
flow between different unit equipment. We performed material and energy balances,
and designed three pieces of equipment (reactor, heat exchanger, and distillation col-
umn). We studied the costs, profitability, and payback period, as well as ensuring
control of the designed equipment and compliance with safety and environmental
regulations at the unit site.

XIII
 ‫الملخص‬
‫و‬
‫جودة الج زج ل وتجلجلج جث تج ج ج ه‬ ‫من خالل هذا البحث نتوقع أن تكون النتائج مجدج ج ة ف تجحج ج ج و‬
‫ي‬
‫و‬
‫بالتال سي اهم ذلك يف تعزي أداء مجحجا جات الجنجلجث الجقجلج جث وتجوجريجا عجنجاعجة الجنجلجث‬ ‫ي‬ ‫عىل البيئة‪ .‬و‬
‫كث‪.‬‬
‫و‬
‫تعت ر محا ات الجنجلجث الجقجلج جث مجن الجكجكجونجات األسجاسج جة يف الج ول الجحج زجقجة الج ي ي س ج إل تجعجزيج‬
‫اقتصادها ‪.‬ومن الكعاوف أن هذه الكحا ات تعكث بوقود ال ز ل الذي تعجتج ر خصجائصجم مج جكجة‬
‫و‬
‫يف ق ج رة هججذه ال جك جحججا ججات عججىل أداء وظ ج جد جت ج ججا ب جد جعججال ج ججة و ال جح جدججاظ عججىل أ ج ائ ج ججا مججن ال جت جل ج‬
‫والتآكث ‪.‬ولجذلجك قجكجنجا وف هجذا الجبجحجث بجطج جلج ج الضجوء عجىل وحج ة مجعجالج جة دزج ل الج ج ج رو ج ج و‬
‫ي‬
‫وتح ج و مواعدات ال ز ل الكنت من ا ‪.‬قكنا ب راسة الكواد الخام الجلجادمجة مجن وحج ة الجتجكج ج ج‬
‫الجبج ر يج‬ ‫الجحجدج ي لجلج ججوائججث وقجكجنجا بجتجصجكج ججم مجدججاعججث قججادر عجىل إنجتجاج وقجود الج زج ل مجنجخجدج‬
‫تج ج‬ ‫سببا رئي ً ا لتجلج الجكجحجاك وتجآ كجلجم ‪.‬قجكجنجا بجعج ذلجك بجر جااء دراسجة لجكجخجوج‬ ‫ً‬ ‫والذي يع‬
‫اقجتجصجادي ول ج جولجة‬ ‫ت‬
‫العكل ة من الكداعث إل عكود التلو ج للحصول عىل أ ضث مخو‬
‫الكواد ب ج و مع ات الوح ة الكختلدة ‪.‬قكنا بر ااء موازنة الكواد والواقة وقكنا بجتجصجكج جم‬ ‫ت‬

‫‪XIV‬‬
 Chapter one
INTRDUCTION

XV
1.1 Introduction :
Diesel fuel , also called diesel oil, is any liquid fuel specifically designed for use in a
diesel engine, a type of internal combustion engine in which fuel ignition takes place
without a spark as a result of compression of the inlet air and then injection of fuel.
Therefore, diesel fuel needs good compression ignition characteristics.
The most common type of diesel fuel is a specific fractional distillate of petroleum
fuel oil, but alternatives that are not derived from petroleum, such as biodiesel, bio-
mass to liquid (BTL) or gas to liquid )GTL) diesel are increasingly being developed
and adopted. To distinguish these types, petroleum derived diesel is sometimes
called petro diesel.
1.2 Historical Background:
In German before the Second World War the hydrogenation technology of modern
times originated from the high pressure hydrogenation process of coal and coal tar,
which appeared, and had been put into widely application in 1926.
In 1949, the platinum reforming technology appeared. That requires the feedstock
being refined to get sulfur content of less than 1 ppm. On the other hand, it provides
a great deal of free hydrogen gas.
All these accelerated the development of hydro refining technology; After 1950 , the
auto-industry progressed rapidly. Therefore, the consumption of gasoline in USA
and kerosene and diesel in EU and Japan increased rapidly. The straight run fractions
could not meet the requirement of consumption and quality simultaneity, so hydro-
cracking process which can neatly produce naphtha or mid-distillates was born. In
1959, the first hydro cracking process was opened out.
In 1960，most of residue was burn off as industrial fuel and thus a large amount of
SOx sent to air, the pollution became more and more severity. USA, Japan and many
of European countries adopted measure to limit the sulfur content of fuel oil, so resi-
due HDS process had been studied.

1
In 1967, the first residue HDS unit was commercialized in Japan.
In 1970，in order to obtain more quantity of diesel fuel, EEC relaxed the limitation
of FBP of diesel fuels, while the increase of pour point was not allowed. Hence,
along with the increase of needs on low pour point and colorless middle fractions,
the hydro dew axing process for middle fractions had been applied. The successful
application of hydro-dew axing on medium fractions provided an example for lube
oils. Before long, in 1981, the first hydro-dew axing unit for lube oil production had
been put into application.
1.3 Classification of Diesel fuels :
Diesel fuels are classified 1D, 2D, and 4D. Low speed, stationary units use 4D fuels.
4D fuel is not appropriate for most mobile equipment. On-highway and mobile
equipment use 1D and 2D fuels. High speed diesel engines use either 1D or 2D
fuels. Important characteristics of diesel fuels are its viscosity, pour point, and cetane
number. The primary differences between 1D and 2D fuel are the pour point and the
viscosity.
Pour point is the lowest temperature at which a liquid will flow. Viscosity is the re-
sistance of a liquid to flow. A 1D fuel is designed for cold weather operation; thus, it
is less viscous and has a lower pour point. A 2D fuel is used in warmer weather be-
cause it has a higher viscosity and pour point. The higher viscosity provides better
lubrication qualities for the moving parts of the fuel injection system. Because 2D
fuels contain more heating value bar liter , they are able to deliver more power per
gallon. This is critical to diesel engine fuel economy. The higher LCV rating a diesel
fuel has, the greater power yield per liter ; thus, higher mpg will result. Cetane rating
is the diesel equivalent to gasoline's octane rating. Unlike an octane rating, which
rates gasoline's resistance to spontaneous ignition, the cetane rating number (usually
40 to 55 for medium to high speed engines) notes the relative ease with which diesel
fuel ignites. The higher the cetane number, the easier the fuel ignites; the higher the
octane number, the more resistant the fuel is to ignition. Each manufacturer usually
specifies a minimum or maximum cetane rating and the suggested operating temper-
ature for 1D and 2D fuels .

2
Table (1.1) Properties of diesel fuel :
Properties Refined diesel oil
Item Calculated value Value provided Kh.R
Distillation range Kh.R specifications
IBP 196
10% 226 223
30% 253 253
00% 277 277
70 % 307 306
90 - 90 % 335 335
Density (10 Co) kg/L 0.8923 Max 0.9
Sulfur ( w%) 0.008 Max .05 ASTM
Nitrogen ppm 45 Min 45
Cetane number 56
2
Viscosity mm /s 0.2
Ash (w%) 0.002 0.01 Max
O
Freezing point C -4

1.4 Composition of diesel fuel :

Diesel fuel is very complex mixture of thousands of compounds with carbon number
between 9 and 23
( number of carbon atom bar hydrocarbon molecule ) most of these compounds are
number of paraffinic ,
naphthenic or aromatic classes of hydrocarbons, these three classes have different
chemical and physical
properties ,the different proportion of three classes is one of the factors that make
one diesel fuel different
from another , it influences fuel properties and effects its performance.
1.0 Diesel Fuel Production Processes
Diesel fuel produced by several processes some of them are:
1.0.1 Petroleum diesel Process
Petroleum diesel, also called petro diesel , fossil diesel, or mineral diesel, is the most
common type of diesel fuel. It is produced from the fractional distillation of crude
oil between 250 and 350 °C at atmospheric pressure, resulting in a mixture of carbon
chains that typically contain between 9 and 23 carbon atoms per molecule.
3
 Figure ( 1.1 ) diesel fuel from simple distillation column
1.0.2 Synthetic diesel process :
Synthetic diesel can be produced from any carbonaceous material, including bio-
mass, biogas, natural gas,
coal and many others. The raw material is gasified into synthesis gas, which after
purification is converted
by the Fischer–Tropsch process to a synthetic diesel.
The process is typically referred to as biomass-to-liquid (BTL), gas-to-liquid (GTL)
or coal-to liquid
(CTL), depending on the raw material used.
Paraffinic synthetic diesel generally has a near-zero content of sulfur and very low
aromatics content, reducing unregulated emissions of toxic hydrocarbons, nitrous
oxides and particulate matter (PM).

Figure ( 1.2 ) Synthetic diesel process

4
1.0.3 Biodiesel process :
Biodiesel is produced from vegetable oils, yellow grease, used cooking oils, or ani-
mal fats. The fuel is produced by transesterification a process that converts fats and
oils into biodiesel and glycerin (a co product). Approximately 100 pounds of oil or
fat are reacted with 10 pounds of a short-chain alcohol (usually methanol) in the
presence of a catalyst (usually sodium hydroxide [NaOH] or potassium hydroxide
[KOH]) to form 100 pounds of biodiesel and 10 pounds of glycerin (or glycerol).

Figure ( 1.3 ) Biodiesel process flow sheet

1.0.4 Diesel Hydro treating Processes :
Is process to produce diesel by treating the gas oil feed stock came form (fluid cata-
lytic cracker ( FCC ) or
delayed Coker unit ) by hydrogen in present of catalyst .

Sour

Figure ( 1.4 ) Diesel Hydro treating flow sheet

5
1.6 Introduction to Hydro treating Process:
Hydro treating is a process to catalytically stabilize petroleum products by convert-
ing olefins to paraffin's or remove objectionable elements from products or feed-
stock by reacting them with hydrogen. Stabilization usually involves converting un-
saturated hydrocarbons such as olefins and gum-forming unstable diolefins to paraf-
fin's. Objectionable elements removed by hydro treating include sulfur, nitrogen, ox-
ygen, halides, and trace metals. Hydro treating is applied to a wide range of feed-
stock, from naphtha to reduced crude. When the process is employed specifically for
sulfur removal, it is usually called hydrodesulphurization. To meet environmental
objectives, it also may be necessary to hydrogenate aromatic rings to reduce aro-
matic content by converting aromatics to paraffin's.
1.7 Hydro treating process configurations:
Different process design and flow schemes can be employed for DHT depending on
the process objectives and characteristics of the feed being processed. One typical
process design in distillate for DHT unit is a cold separator layout and hot separator
layout a flow scheme is shown in Figure ( 5,6). Each layout has its own set of ad-
vantages and disadvantages. The hot separator layout is attractive in terms of energy
conservation as the major part of the of the stripper feed comes from the hot separa-
tor and only a small amount of hydrocarbon needs to be condensed and reheated be-
fore it is sent to the stripper column. On the other hand, the H2 purity in recycle gas
is lower in the hot separator layout. As a result, to achieve the same H2 partial pres-
sure in the reactor, the hot separator layout requires a higher operating pressure for
the unit compared to the cold separator layout. In terms of H2S concentration in treat
gas, if no amine scrubber exists in the unit, then the hot separator layout will have
2.8-3.2 times more H2S in the treat gas compared to the cold separator layout. As
H2S is an inhibitor for HDS reactions, high concentration of H2Sin treat gas will re-
quire more catalyst or higher operating pressure. Furthermore, H2 solubility loss is
higher in the hot separator layout because of the higher operating pressure and tem-
perature in which gas liquid separation takes place in the hot separator. As a result,
the hydrogen make-up requirement increases in a hot separator layout. From the
above-mentioned points, it is clear that proper selection between the two layouts is
of utmost importance for optimum plant performance. cold separator layout it was
taken in this research to it economic performance .
6
 L6 HM

L7 C1

L8
L 12

L 14
L 10
L 20
L L 13

L0 L4 L 11
L 17
L 16
Sour water
L9 L 10
L 19

L 24

L 18

L1 L2 L 21
L 22

L 23

Figure ( 1.0 ) DHT unit a cold separator layout

Figure ( 1.6 ) DHT unit hot separator layout

7
1.8 HYDROTREATING CATALYSTS :
Catalysts developed for hydro treating include tungsten and molybdenum sulfides on
alumina. These metals are considered the hydrogenating catalysts but their properties
are modified by adding either cobalt or nickel sulfides. Nickel sulfide, nickel thio-
molybdate, tungsten and nickel sulfides, and vanadium oxide are also hydrogenation
catalysts . Cobalt and molybdenum sulfide on alumina catalysts are in most general
use today because they have proven to be highly selective, easy to regenerate, and
resistant to poisons. Usually, when purchased the metals are in the oxide state, and
they must be activated by converting the hydrogenation metals from the oxide to the
sulfide form. The most economic catalysts for sulfur removal contain cobalt and mo-
lybdenum sulfides (CoMo) on alumina supports. If, however, the removal of nitro-
gen is a significant consideration, catalysts composed of nickel-cobalt-molybdenum
or nickel-molybdenum (NiMo)
compounds supported on alumina are more efficient.
Nitrogen is usually more difficult to remove from hydrocarbon streams than sulfur,
and any treatment that reduces excess nitrogen concentration to a satisfactory level
usually will effectively remove excess sulfur. Nickel-containing catalysts generally
require activation by presulfiding with carbon disulfide, mercaptans, or dim ethyl
sulfide before bringing up to reaction temperature. However, some refiners activate
cobalt molybdenum catalysts by injecting the sulfiding chemical into the oil feed
during start-up . The sulfiding reaction is highly exothermic, and care must be taken
to prevent excessive temperatures during activation to prevent permanent catalyst
deactivation. Cobalt-molybdenum catalysts are selective for sulfur removal, and
nickel-molybdenum catalysts are selective for nitrogen removal, although both cata-
lysts will remove both sulfur and nitrogen . Nickel molybdenum catalysts have a
higher hydrogenation activity than cobalt-molybdenum, which results, at the same
operating conditions, in a greater saturation of aromatic rings. Simply stated, if sul-
fur reduction is the primary objective, then a cobalt-molybdenum catalyst will re-
duce the sulfur a given amount at less severe operating conditions with a lower hy-
drogen consumption than a nickel-molybdenum catalyst. If nitrogen reduction or ar-
omatic ring saturation is desired, nickel-molybdenum catalyst is the preferred cata-
lyst.

8
Actually, nickel-tungsten is most effective for nitrogen removal and saturation of ar-
omatic rings to reduce aromatic content but is much more expensive than nickel-
molybdenum and is, therefore, seldom used in fuels refineries. The ability to adjust
pore size to concentrate pores around a particular diameter has a great impact on the
hydro treating activity both at start-of-run (SOR) and as the catalyst ages. Reactions
taking place in the hydro treating of gas oils [(200 to 566°C)] generally require a
minimum pore size to overcome most diffusion restrictions. Pores that are larger
than necessary lend little to improving diffusion characteristics, and as the pore di-
ameters of the catalyst increase, the surface area decreases (at constant pore vol-
ume).
Activity generally decreases with surface area, and loss in pore volume occurs in the
smallest diameter pores first. Highest activity retention is maintained if the pore vol-
ume is concentrated in a very narrow range of pore diameters. At the hydro treating
severity to reduce sulfur in LCO to 0.05 wt%, the performance of high activity Ni-
Mo and Co-Mo catalysts appears to be equivalent. Catalyst consumption varies from
(0.003 to 0.02 kg/m3) feed depending upon the severity of operation and the gravity
and metals content of the feed.
1.9 Chemistry of Hydro treating Process :
The chemistry of hydro treating and hydro cracking is commonly taken together and
termed hydro processing and is similar for both sections of the hydro processing
unit. The conversions in hydro processing can be classified into desirable and unde-
sirable reactions. The desirable reactions are desulfurization and denitrogenating ,
saturation (i.e., hydrogen addition to olefin and aromatic molecules). Undesirable
reactions are contaminant poisoning (metals deactivating the catalyst) as well as
coking of the catalyst.
1.10 Hydro-treating Reactions:
The hydro treating reactions that take place are the removal of sulfur, nitrogen, organ
metallic compounds, oxygen, and halide.

9
10
Table (1.2) Process parameters :

Item Value

Feed 5000 kg/hr

Hydrogen to oil ratio 400 Nm3 H2 / m3 oil a1

Reactor temperature To 260 Co

Type of catalyst nickel-molybdenum (NiMo)

Hydrogen consumption to oil ratio 39.0162 Nm3 H2 / m3 oil a2

Reactor pressure 8.25 Mpa

Table (1.3) Row feed from RFCC to DHT unit Properties :

Properties
Item
Distillation range 204
10% 228
20% 242
30% 254
05% 278
70% 309
80% 323
90% 337
Sulfur ppm 600
D , kg/m3 856
Nitrogen 283
Freezing point -2
Bromine value mgBr/100g 15.4
Cetane index 33.4

11
1.11 Process description :
The feed enters the feed surge drum from which it is pumped through a bank of feed/
effluent exchangers, is mixed with recycle gas, is heated to reaction temperature, and
enters the reactor. Reactor effluent is passed through a bank of feed/ effluent ex-
changers and a fin fan cooler and then enters the separator. The gas is recovered and
sent to a recycle gas compressor and recycled to the reactor. The liquid product is
then directed to a flash drum, where any light gases are recovered overhead while
the hydrocarbon is routed to a stripper to remove any dissolved hydrogen sulfide and
ammonia in the product as well as any wild naphtha formed. The stabilized product
is then sent to blending or storage. Wash water is added to the reactor effluent just
upstream of the air fin cooler to absorb the ammonia produced in order to avoid pre-
cipitation of ammonium hydrosulfide salts in the colder sections for the plant.

L6 HM

L7 C1

L8
L 12

L 14
L 10
L 20
L L 13

L0 L4 L 11
L 17
L 16
Sour water
L9 L 10
L 19

L 24

L 18

L1 L2 L 21
L 22

L 23

Figure (1.7 ) DHT flow scheme

12
 Chapter two

Material Balance

13
2.1 Introduction
Mass balances are nothing more than the application of the conservation law for
mass: “Matter is neither created nor destroyed”. Just what this statement means in
practice and how you can use the concept to solve problems of varying degrees of
complexity requires some extensive explanation. The general expression of a mass
balance takes the following form.
Accumulation=input − output + generation − consumption (2.1)
For continuous process at steady state accumulation equal zero. The equation can be
reduced to:
Input − Output = Generation−Consumption (2-2)
If there is no chemical reaction generation and consumption equal zero. The equa-
tion can be reduced to:
Input = output (2.3)
The project studies the Diesel hydro treating unit , the feed is RFCC gas oil and the
unit capacity is 5000 kg/hr, the flow sheet is illustrated in figure (2.1). The unit
stream lines are named in table (2.1).

L6 HM

L7 C1

L8
L 12

L 14
L 10
L 20
L3 L 13

L0 L4 L 11
L 17
L 16
Sour water
L9 L 10
L 19

L 24

L 18

L1 L2 L 21
L 22

L 23

Figure (2.1) DHT flow scheme

14
Table (2.1): Stream lines codes.

Stream information NO
FCC gas oil feed stream from surge drum L1

Pump effluent L2
Hydrogen stream to Mixture fed with gas oil L3
Fed to HX-1 L4

HX-1 product to furnace L5

Furnace effluent to reactor fed L6
Total hydrogen fed to reactor L7
Hydrogen quench for reactor L8
Reactor effluent to HX-1 L9
HX-1 product to HX-2 L10
HX-2 product L11
Injection of Wash water L12
Stream fed to Air cooler L13
Air cooler product to CHPS L14
Hydrogen recycle to compressor L15
CHPS sour water L16
CHPS product to LPS L17
LPS sour water L18
Fuel gas to refinery L19
LPS product to HX-2 L20
HX-2 product to stripping column fed L21
Steam inject to stripper L22
Treated diesel L23
Naphtha +LPG L24
Makeup hydrogen MH
Compressed hydrogen C1

15
2.2 Overall material balance:

For a steady-state process, the accumulation term will be zero. Except in nuclear
processes mass is neither generated nor consumed; but if a chemical reaction takes
place a particular chemical species may be formed or consumed in the process. If
there is no chemical ,reaction the steady state, balance reduces to

Material out = Material in

RFCC gas oil 5000
kg/hr H2, H2s, NH3 = ?

Fuel gas ( c1 ,c2 ,c3 )= ?

DHT Naphtha+ LPG = ?

Hydrogen 210.05
kg/hr
Treated Diesel = ?

1. Feed (RFCC gas oil ) = 5000 kg/hr

Total Hydrogen fed to DHT unit = 210.05 kg/hr
2. ( H2, H2s, NH3 ) = 3.98% of total feed
( H2, H2s, NH3 ) = 0.0398* 5210.05 = 207.53 kg/hr
3. Fuel gas ( c1 ,c2 ,c3 ) = 1.92% of total feed
Fuel gas ( c1 ,c2 ,c3 ) = 0.0192* 5210.05 = 99.95 kg/hr
4. Naphtha+ LPG = 17.41% of total feed
Naphtha+ LPG = 0.1741 * 5210.05 = 906.97 kg/hr
5. Treated Diesel = 76.67% of total feed
Treated Diesel = 0.76.67 * 5210.05 = 3995.6 kg/hr
Table (2.2): summary of general material balance:

Component Mass % Mass flow rate kg/h

Feed
FCC gas oil 95.97% 0000
Hydrogen 4.03% 210.00
Total 100% 0210.00
Product
H2, H2s , NH3 3.98% 207.03
Fuel gas 1.92% 99.90
Naphtha+ LPG 17.41% 906.97
Treated Diesel 76.67% 3990.6
Total 100% 0210.00
16
2.3 partial Material balance :
2.3.1Material balance around mixture :

L2
L4
L3

H2 feed = 400 Nm3/m3 oil or = 0.04201 kg/kg oil

H2total fed to reactor = 0.04201*L2 = 0.04201*5000 = 210.5 kg/hr
L 3 = 0.6*H2total = 06*210.5 =126.03 kg/hr
Input = output
L2 + L3 = L4
L4 = 5000 + 126.03 = 5126.03kg/hr

2.3.2 Material balance around Reactor :

L3
L6
L7

L8

L9
Input = output
L6 + L8 = L9
L7 = L3 + L8
L7 = H2 feed = 400 Nm3/m3 oil or = 0.04201 kg/kg oil
L7 = 0.04201 kg/kg oil * 5000 kg oil/hr = 210.050 kg/hr
L8 = 0.4 * L7 = 0.4*210.05 = 84.02 kg/hr
L6 = 5126.03 kg/hr
L9 = ?
L9 = L6 +L8
L9 = 5126.03 + 84.02 = 5210.05 kg/hr
17
2.3.3Material balance around mixture valve

L 11 L 13

L 12

Input = output
L13 = ?
L13 = L11 + L12
L12 = 0.055* L1
L12 = 0.055 * 5000 = 275 kg/hr
L13 = L11+ L12 = 5210.05 + 275 = 5485.05 kg/hr

2.3.4 Martial balance around cold High pressure

Separator drum :
L 10

L 14 L 17

L 16

Input = output
L14 = L15 + L16 + L 17
L15 = 3.3% * L14 = .033* 5485.05 = 179.93 kg/hr
L16 = 4.6% * L14 = 0.046 * 5485.05 = 252.3123 kg/hr
L17 = ?
L17 = L14 - L15 - L 16
L18 = 5485.05 - 252.3123 - 179.93 = 5052.81 kg/hr
18
2.3.0 Martial balance around low pressure
Separator drum : L 19

L 17 L 20

L 18

Input = output
L17 = L18 + L19 + L 20
L19 = 2% * L17 = .02* 4997.57 = 99.95 kg/hr
L18 = 1%* L17 = 0.01* 5052.81 = 50.5281 kg/hr
L20 = ?
L20 = L17 - L18 - L 19
L20 = 5052.81 - 50.5281 - 99.95 = 4902.57 kg/hr
2.3.6 Martial balance around striping column :

L 24

L 21 L 22

L 23
Input = output
L21 + L 22 = L23 + L24
L22 = 3%L21 = 0.03*4902.57 = 147.0771 kg/hr
L23 = 81.5%L21 = 0.815*4902.57 = 3995.6 kg/hr
L24 = ?
L24 = L21 + L22 - L23
L24 = 4902.57 + 147.0771- 3995.6 = 1054.0471 kg/hr
19
 Chapter three
Energy Balance

20
3.1 Introduction to Energy Balance:
Energy can be separately conserved in all but nuclear processes. Energy can exist in
several forms: heat, mechanical energy, electrical energy, and it are the total energy
that is conserved. Energy balance around a unit or equipment equilibrates the exiting
and entering forms of energy. In process design, energy balances are made to deter-
mine the energy requirements of the process: the heating, cooling, and power re-
quired in plant operation.
3.1.2 Assumption considered:
1. Steady- state operation conditions.
2. Reference temperature Tref = 25° C.
3. = ( − )
4. SG of RFCC gas oil ≈0.856
Conservation of energy:
A general equation can be written for the conservation of energy
Energy out = Energy in + Generation – Consumption – Accumulation
At steady state conditions, there is no accumulation of heat, the above equation can
be written as:
Energy out = Energy in + generation – Consumption

21
3.2 partial Energy Balance:
3.2.1 Energy balance around reactor :

Q1
T1= 260o

Qr

Q2
T2 = 300o

Q1 = Q2 + Qr
Qr = ?
Given , M1 = M1 = 5210.05 kg/hr
Q1 = M1 * H1
H1at (T1= 260 Co , or 533 K and SG = 0.856 ) = 847.96 kj/kg
Q1 = 5210.05 * 581.45 = 4,417,936.2613 kj/hr
Q2= M2 * H2
H2 at (T2= 300Co , or 573 K and SG = 0.9 ) = 928.51 kj/kg
Q2= 5210.05 * 928.51 = 4,837,583.53 kj/hr
Qr = Q1- Q2
Qr = 4,417,936.2613 - 4,837,583.53 = -419,647.264 kj/hr

22
3.2.2 Energy balance around reactor furnace

Q1
T1 = 219.75

Q4
Qload T2 = 260

Q1 + Qload = Q2
Given , M1 = M2 = 5210.05 kg/hr
Q1 = 3,843,672.7116
Q2 = M2 * H2
H2 at (T2 = 260 Co , or 533 K and SG = 0.856 ) = 847.96 kj/kg
Q2 = 5210.05 * 581.45 = 4,417,936.2613 kj/hr
Qload = Q2 - Q1
Qload = 4,417,936.2613 - 3,843,672.7116 = 574,263.5497 kj/hr

3.2.3Energy balance around column furnace

Q1
T1 = 135

Q4
Qload T2 = 191.7

Q1 + Qload = Q2
Given , M1 = M2 = 4902.57 kg/hr
Q1 = 1,340,763.431
Q2 = M2 * H2
H2 at (T2 = 191.7 Co , or 464.7 K and SG = 0.9 ) = 406.49 kj/kg
Q2 = 4902.57 * 406.49= 1,992,889.3248 kj/hr
Qload = Q2 - Q1
Qload = 1,992,889.3248 - 1,340,763.431 = 652,125.8938 kj/hr

23
3.2.4 Energy balance around first heat exchanger

Q1
T1 = 300o

Q3
T3= 122.9o Q4
T4 = ? o

Q2
T2 = 204o

Q1 + Q3 = Q2 + Q4

Q4= ?

Given M1 = M2= M3 = M4 =5210.05 kg/hr

Q1 = 4,837,583.53 kj/hr

Q3 = M3 * H3

H3 at (T3 = 122.9 Co , or 395.9 K and SG = 0.856 ) = 246.422 Kj/Kg

Q3 = 5210.05 * 246.422 = 1,283,870.9411 kj/hr

Q2 = M2 * H2

H2 at (T2 = 204 Co , or 477 K and SG = 0.9 ) = 437.19 Kj/Kg

Q2 = 5210.05 * 437.19 = 2,277,781.7595 kj/hr

Q4 = Q1 + Q3 - Q2

Q4 = 4,837,583.53 + 1,283,870.9411 - 2,277,781.7595 = 3,843,672.7116 kj/hr

H4 = Q4 /M4 = 3,843,672.7116 /5210.05 = 737.742 Kj/Kg

T4 at ( H4 = 737.742 Kj/Kg , and SG = 0.856 ) = 492.75 Ko or 219.75 Co

24
3.2.0 Energy balance around second heat exchanger

Q1
T1 = 204o

Q2
T2 = 111o Q4
T4 = ? o

Q3
T3= 184o

Q1 + Q2 = Q3 + Q4

Q4 = ?

Given , ( M1 ,M3 ) = 5210.05 , ( M2 , M4) = 4902.57 kg/hr

Q1 = 2,277,781.7595 kj/hr

Q3 = M3 * H3

H3 at (T3 = 184 Co , or 457 K and SG = 0.9) = 387.78 Kj/Kg

Q3 = 5210.05 * 387.78= 2,020,353.189 kj/hr

Q2 = M2 * H2

H2 at (T2 = 111Co , or 384 K and SG = 0.9) = 220.19 Kj/Kg

Q2 = 4902.57 * 220.19 = 1,083,334.86 kj/hr

Q4 = Q1+ Q2 - Q3

Q4 = 2,277,781.7595 + 1,083,334.86 - 2,020,353.189 = 1,340,763.431 kj/hr

H4 = Q4 /M4 = 1,340,763.431 /4902.57 = 273.48 Kj/Kg

T4 at ( H4 = 273.48 Kj/Kg , and SG = 0.9 ) = 408 Ko or 135 Co

25
3.2.6 Energy balance around 3th heat exchanger

Q1
T1 = 184o

Q2
T2 = 40o Q4
T4 = ? o

Q3
T3 = 110o

Q1 + Q2 = Q3 + Q4

Q4 = ?

( M1 , M2 , M3 ,M4 ) = 5210.05 kg/hr

Q1 = M1 * H1

H1 at (T1 = 184 Co , or 457 K and SG = 0.9) = 387.78 Kj/Kg

Q1 = 5210.05 * 387.78= 2,020,353.189 kj/hr

Q2 = M2 * H2

H2 at (T2 = 40 Co , or 313 K and SG = 0.856 ) = 75.9 Kj/Kg

Q2 = 5210.05 * 75.9 = 395,400.96 kj/hr

Q3 = M3 * H3

H3 at (T3 = 110 Co , or 383 K and SG = 0.9 ) = 217.25 Kj/Kg

Q3 = 5210.05 * 217.25 = 1,131,883.362 kj/hr

Q4 = Q1 + Q2 - Q3

Q4 = 2,020,353.189 + 395,400.96 - 1,131,883.362 = 1,283,870.7865 kj/hr

H4 = Q4 /M4 = 1,283,870.7865 /5210.05 = 246.422 Kj/Kg

T4 at ( H4 = 246.422 Kj/Kg , and SG = 0.856 ) = 395.9 Ko or 122.9 Co

26
3.2.7 Energy balance around air cooler

Qair
Tair = 00o

Q1 Q2
T1 = 110o T2 = 02o

Q1 = Q2 + Qair

Qair = ?

Given (M1 ,M2 ) = 5210.05 Kg/hr

Mari = ?

Q1 = 1,131,883.362 kj/hr

Q2 = M2* H2

H2 at (T2 = 52 Co , or 325 K and SG = 0.9) = 97.34 Kj/Kg

Q2 = 5210.05 * 97.34 = 507,146.267 kj/hr

Qair = Q1- Q2

Qair = 1,131,883.362 - 507,146.267 = 624,737.095 kj/hr

Qair = Hair * Mair

Hair at Tair = 55 Co = 0.718 Kj/Kg

Mair = Qair /Hair

Mair = 624,737.095 / 0.718 = 870,107.37 Kg/hr

27
3.2.8 Energy balance around water cooler

QH2o = ?
Δ T = 15 Co

Q1 Q2
T1 = 02o T2 = 40o

Qout5 = Qout6 + Q

QH2o = ? MH2o = ?

Given (M1 ,M2 ) = 5210.05 Kg/hr

MH2o = ?

Q1 = 507,146.267 kj/hr

Q2 = M2* H2

H2 at (T2 = 40 Co , or 313 K and SG = 0.9) = 74.02 Kj/Kg

Q2 = 5210.05 * 74.02 = 385,647.901 kj/hr

QH2o = Q1 - Q2

QH2o = 507,146.267 - 385,647.901 = 121498.366 kj/hr

QH2o = MH2o * cp * Δ T

MH2o= QH2o /cp * Δ T

CpH2o = 4.18 Kj/Kg.C , Δ T = 15 Co

MH2o = 121498.366 / ( 4.18 * 15 ) = 1987.77 Kg/hr

28
3.2.9 Energy balance around striping
column :
Q3
T3 = 120 o

Q1 Qs
T1 = 191.65 o Ts = 240o

Q2
T2 =180o

Q1 + Qs = Q2 + Q3

Qs = ?

Given M1 = 4902.57 Kg/hr , M2 = 3995.6 kg/hr , M3 = 1054.0471 kg/hr , MH2o =

147.0771 Kg/hr

Q1 = 1,992,889.3248 kj/hr

Q2 = M2 * H2

H2 at (T2 = 185 Co , or 469 K and SG = 0.9) = 305.5 Kj/Kg

Q2 = 3995.6 * 305.5 = 1,220,655.8 kj/hr

QH2o = MH2o * HH2o

HH2o at T = 240 Co , p = 10 bar = 2921Kj/kg

QH2o= 147.0771 * 2921= 429,612.2091 kj/hr

Q3 = Q1 + QH2o - Q2

Q3 = 1,992,889.3248 + 429,612.2091 - 1220,655.8 = 1,201,854.73 kj/hr

29
3.2.10 Energy balance around
Striper heat exchanger
Q2
T2= 180o

Q1
T1 = 40o Q4
T4 = ?o

Q3
T3 = 66o

Q1 + Q2 = Q3 + Q4

Q4= ?

Given ( M1 , M4 )= 4902.57 Kg/hr ,

M2 , M3 = 3995.6 kg/hr ,

Q2 = 1,220,655.8 kj/hr

Q1 = M1 * H1

H1 at (T1 = 40 Co , or 313 K and SG = 0.9) = 74.02Kj/Kg

Q1 = 4902.57 * 74.02 = 362,888.2314 kj/hr

Q3 = M3 * H3

H3 at (T3 = 66 Co , or 359 K and SG = 0.9) = 125.19 Kj/Kg

Q3 = 3995.6 * 166.22 = 500,209.164 kj/hr

Q4 = Q1 + Q2 - Q3

Q4 = 362,888.2314 + 1,220,655.8 - 500,209.164 = 1,083,334.86 kj/hr

H4 = Q4 /M4

H4 = 1,083,334.86 / 4902.57 = 220.99 Kj/Kg

T4 at ( H4 = 220.99 Kj/Kg , and SG = 0.9 ) = 384 Ko or 111 Co

30
 Chapter four
Process Design

31
4.1 Introduction:
Process design establishes the sequence of chemical and physical operations; operat-
ing conditions; the duties, major specifications, and materials of construction (where
critical) of all process equipment (as distinguished from utilities and building auxil-
iaries); the general arrangement f equipment needed to ensure proper functioning of
plant; line sizes; and principles instrumentation. The process design is summarized
by a process flow sheet, a material and energy balance, and set of individual equip-
ment specifications. Varying degree of thoroughness of a process design may be re-
quired for different purpose. Sometimes only a preliminary design and cost estimate
are needed t evaluate the advisability of further research on a new process or a pro-
posed plant expansion or detailed design work; or a preliminary design may be
needed to establish the approximate funding for a complete design and construc-
tions. A particularly valuable function of preliminary design is
that it may reveal lack of certain data needed for final design. Data of costs of indi-
vidual equipment are supplied in this book, but the complete economics of process
design is beyond its scope.
4.2 Design of Distillation column
The typical vapor-liquid contacting operations include distillation, absorption, strip-
ping, leaching and humidification. Distillation and absorption are two most widely
used mass transfer processes in chemical industries. Design of plate column for ab-
sorption and distillation involves many common steps of calculation such as deter-
mination of number of theoretical plates, column diameter, plate hydraulic design,
etc. In. The vapor and liquid streams leaving the tray are in equilibrium under the
ideal condition. The separation in distillation is based on the relative volatility of
the components.

32
4.2.1 Selection of column type:
1/ Plate or Packed
Packed towers (columns) are also used as the contacting devices for gas absorption,
liquid-liquid extraction and distillation. The gaseous mixture is allowed to contact
continuously with the u liquid counter-currently in a packed column. The liquid
flows downward over the packing surface, and the gaseous mixture flows upward
through the space in the packing. The performance of the column strongly depends
on the arrangement of the packing to provide good liquid and gas contact throughout
the packed bed. The solute gas is absorbed by the fresh solvent (liquid) entering at
the top of the tower where the lean gas leaves system. The liquid enriched with ab-
sorbed solute gas, leaves the column bottom through the exit port. In a plate tower,
the liquid and gas are contacted in stage-wise manner on the trays; while gas-liquid
contact is continuous in a packed column. There are always some uncertainly to
maintain good liquid distribution in a packed tower. For this reason, it is difficult to
accurately estimate the packed tower efficiency.
4.2.2 Design procedure and calculations:
1. Feed specifications.
2. Specify key and non-key components.
3. Calculate minimum theoretical stages using fenske equation
4. Calculate minimum reflux ratio using Underwood equations
5. Calculate actual theoretical stages for specified reflux ratio using.
Gilliland correlations.
6. Calculations of the column Efficiency and the number of real stages
7. Calculate the height of the column.
8. Calculate feed stage location using kirbride equation.
9. Calculate column diameter (top and bottom).
10. Selection of liquid – flow arrangement.
11. Provisional plate design.
[Link] calculations.
13. Plate pressure drop (column pressure drop).

33
4.2.3 Design calculation:
Table (4.1) Feed specifications

COMPONENT Top mass wt% Bottom mass wt%

flow flow
rate kg rate kg
LPG 158.107 0.15 0 0.0
Naphtha ( Lk ) 843.237 0.8 11.98 0.003
Diesel ( Hk ) 52.7 0.05 3983.61 0.997
Total 1054.0471 1 3995.6 1
COMPONENT Top relative volatility (α) Bottom relative volatility (α)
LPG 307.44685 90.586975
Naphtha ( Lk ) 27.99855 13.75387
diesel( Hk ) 1 1

Table (4.2 ) Average relative volatility (αav) : -

COMPONENT Average relative volatility (αav)

LPG 199.01691
naphtha 20.87621
diesel 1

Minimum number of stages calculations

Nm = (XLk / XHk )d *( XHk / XLk )b
( αLk)

Nm = (0.8/0.05)d *( 0.997/0.003)b = 2.8 ≈ 3

( 20.87621 )

34
Table (4.3) calculated using trial and error method

COM-
PONEN
αi Xif
%
αi * αi - Ѳ Xid
∑ (Xid * αi) / ( αi - θ ) ∑ (Xif* αi) / ( αi - θ )
≈0
Ѳ
Xif
T
LPG 199.0 0.0 5.970 195.01 0.15 0.153076656 0.030615331 4
1691 3 5074 691
Naphtha 20.87 0.1 3.548 16.876 0.8 0.989616034 0.210293407 4
( Lk ) 621 7 9557 21
Diesel 1 0.8 0.8 -3 0.05 -0.016666667 -0.266666667 4
( Hk )
Total 1 1 1.126026023 -0.02575 close

1/ minimum reflex ratio

Rm + 1 = ∑ (Xid * αi) / ( αi - θ ) , Rm + 1 = 1.126026023 , Rm = 0.126026023

Rm / Rm + 1 = 0.11

2/ Total reflex ratio

Take R = 1.2 * Rm = 1.2 * 0.126026023 = 0.151

R/R+1 = 0.13

3/ number of theoretical stages

From figure ( B-1) at Appendixes

Nm / N = 0.14 , N = Nm / 0.14 = 3 / 0.14 = 21 stage

4/ the column Efficiency and the number of real stages

column Efficiency = 89% ( from Khartoum refinery company manual )

number of real stages = N / = 21 / 0.89 = 24 stage

0/ Calculations of feed stage location using kirbride equation :

Log (Nr/Ns) = 0.206 log ( B/D* (Xifh/XifL)* (XibL/Xidh)2 )

Log (Nr/Ns) = 0.206 log ( 3995.6/ 882.24 * ( 0.8/0.15)*( 0.003/0.05)2 ) = -0.2456

Nr/Ns= 0.589

Feed plate = number of real stages /(1+Nr/Ns) = 24 / ( 1+0.589) = 15

35
6/ Top diameter calculations

Given :- = 750 kg/m3 , = 0.163 , Plate spacing = 0.6mm

Mwt (average molecular weight for top section) = 106.9 kmol /kg
V = 1054.0471 Kg/hr
From ideal gas law PV = n RT we can estimate

= = 2.955*106.9 = 8.2744 kg/m3

0.0821* 465

FLV = = 0.163 √ 8.2744 /750 = 0.0171

√ /

From FLV = 0.0171 , plate spacing 0.6 mm we estimated that K= 0.1

using entrainment flooding chart (B-2).

Uf = K√( - / ) , Uf = 0.1 √ ( 750—8.2744 )/ 8.2744 = 0.94679 m/s

Design velocity U = 0.85*Uf

U = 0.85*0.94679 = 0.805 m/s

Q max = V = 1054.0471* 106.9 = 3.77 m3/s

8.2744 * 3600

Net area required (An) = Q max = 3.77 = 4.9632 m2

U 0.805

Actual tower cross sectional area At = = 6.165 m2

0.9
0.5 0.5
Top section DT = ( 4
) = ( 4*6.165 ) = 2.802 m

36
7/ Bottom diameter calculations

’
Given :- = 893.2 kg/m3 , ’ = 27.2 , Plate spacing = 0.6mm

Mwt (average molecular weight for Bottom section) = 230.637 kmol /kg
V = 147.077 Kg/hr
From ideal gas law PV = n RT we can estimate

= 1.43 kg/m3

’
FLV = √ / = 27.2 √ 1.43 /893.2 = 1.088
’

From FLV = 1.088, plate spacing 0.6 mm we estimated that K= 0.032

using entrainment flooding chart (B.2).

Uf = K√( - / ) , Uf = 0.032 √ ( 893.2 - 1.43 )/ 1.43 = 0.8 m/s

Design velocity U = 0.85*Uf

U = 0.85*0.8 = 0.68 m/s

Q max = V = 147.077 * 230.637 = 6.59 m3/s

1.43 * 3600

6.59
Net area required (An) = Q max = 0.68 = 9.7 m2
U

Actual tower cross sectional area At = 0.9

= 10.766 m2

0.5 0.5
4
Bottom section DT = ( ) = ( 4*10.766
= 3.7 m
)
Selection of liquid – flow arrangement.
Top liquid flow rate = / = 172*106.9 / 750*3600 = 0.0068 m3/s
bottom liquid flow rate = / = 3995.6*230.637 / 893.2*3600 = 0.286 m3/s
we estimated that single pass cross-flow sieve plate is chosen for this tower.

37
8/ Provisional Column and plate design.

1. Column (tower) diameter (Dc) = 4 m

2. Column cross sectional area (At) = 0.708 * Dc2= 12.566 m2

3. Down comer area (AD) = 0.1* (At) = 0.1 * 12.566 = 1.2566 m2

4. Net area (AN) = At - AD = 12.566 - 1.2566 =11.31 m2

5. Weir length (lw) = 0.73 * Dc = 0.73 * 4 = 2.92 m

6. Weir height (hw) = 60 mm is considered

7. Active area (Aact) = At – 2 * AD = 12.566 – 2*1.2566 = 10.0528m2

8. Consider hole diameter ( dh ) = 6 mm, the plate thickness = hole ( dh ) = 6 mm

9. AH( Holes Area) = 0.1* (At) = 0.1 * 12.566 = 1.2566 m2

10. Number of Holes Nh = ( Holes Area / Area of one hole )

Area of one hole = ( * dh2 / 4) = (m

Nh = 1.2566 / 

11. column height Ch = ∗ + (( - )+ ) / +0.2 Ch

N = number of real stages = 24 , C = plate spacing = 0.6m

Ch - 0.2 Ch= 24 * 0.6 + ((24-1)+0.6) /10 = 17 m

Table (4.4) Summery of Distillation column design calculation
Distillation column design
Minimum theoretical 7 Column cross sectional 5.306m2
stags area (At)
Minimum reflux ratio 0.126 Plate spacing 0.6 m
Actual theoretical stages 21 Plate type sieve
Column efficiency 89% Flow arrangement Cross-flow
Column height 17 Net area (AN) 11.31 m2
Feed stage 15 Weir length (lw) 2.92 m
Column Top 2.802 m Weir height 60mm
2
diameter Bottom 3.7 m Active area 10.0528m
38
4.3 Heat exchanger design
4.3.1 Introduction to heat exchanger design:
Heat exchangers are devices that facilitate the exchange of heat between two
fluids that are at different temperatures while keeping them from mixing with
each other. Heat exchangers are commonly used in practice in a wide range
of applications, from heating and air-conditioning systems in a household, to
chemical processing and power production in large plants. Heat exchangers
differ from mixing chambers in that they do not allow the two fluids involved
to mix.
4.3.2The principal types of heat exchanger are:
1- Double - pipe exchanger: the simplest type, used for cooling and heating.
2-Shell and tube exchangers: used for all applications.
3-Plate and frame exchangers (plate heat exchangers): used for heating and
cooling.
4-Plate-fin exchangers.
5- Spiral heat exchangers.
6-Air cooled: coolers and condensers.
7-Direct contact: cooling and quenching.
8-Agitated vessels.
9-Fired heater.
4.3.3 Design procedure:
1-Define the duty: heat-transfer rate, fluid flow-rates, and temperatures.
2- Collect the fluid physical properties required: density, viscosity, and
thermal conductivity.
3-Decide on the type of exchanger to be used.
4-Select a trial value for the overall coefficient, .
5- Calculate the mean temperature difference, .
6- Calculate the area required.

39
7- Decide the exchanger layout.
8- Calculate the individual coefficients.
9- Calculate the overall coefficient and compare with the trial value. If the
calculated value differs significantly from the estimated value, substitute the
calculated for the estimated value and return to step 6.
10- Calculate the exchanger pressure drop; if unsatisfactory return to steps 7
or 4 or 3 in that order of preference.
11- Optimize the design: repeat steps 4 to 10, as necessary, to determine the
cheapest exchanger that will satisfy the duty. Usually this will be the one
with the smallest area.
3.3.4Design objective:
To design shell and tube heat exchanger to raise the temperature of FCC gas oil by
using diesel outcome from reactor .
3.3.0 Design calculation: T1 = 184 co

t1 = 40 co t2 = 122.9 co

T2 = 110 co
1-Defined duty: heat-transfer rate, fluid flow-rates, and temperatures.

Table ( 4.0 ) Enthalpy and mass flow rate

FLUID Hin (kj/kg) Hout (kj/kg) m (kg/hr)

Diesel 387.78 ( T1 = 184 co ) 217.25 ( T2 = 110 co ) 5210.05

FCC gas oil 75.9 ( t1 = 40 co ) 246.422 ( t2 = 122.9 co ) 5210.05

40
Table ( 4.6) fluids properties

FLUID k (w/m.℃) μ(mNs/m2) ρ (kg/m3) Cp (kJ/kg.℃)

Residue 0.145 0.5344 893.2 2.003

FCC gas oil 0.122 0.324 856 1.05

2-Heat exchanger duty:

= × ( Hout - Hin )

= 5210.05 × (246.422 - 75.9) = 888428.15 /ℎ

= 246,785.6
3-Collect the fluid physical properties required: density, viscosity, thermal conductiv-
ity.
4-Decide on the type of exchanger to be used:
Shell and tube heat exchanger
0-Select a trial value for the overall coefficient U:
From Appendix table (A.1) = 155 / 2.℃

6- Calculate the mean temperature difference :

∆ =(∆ -∆ )/ (∆ /∆ )

= -

= -
T1 =Hot fluid temperature inlet.
T2 = Hot fluid temperature outlet.
t1 = Cold fluid temperature inlet.
t2= Cold fluid temperature outlet.
ΔT1=184 - 122.9 =61.1 ℃

ΔT2=110 - 40 =70 ℃

∆ = ( 61.1 - 70 ) / ( 61.1 / 70 ) = 64.67 ℃

41
7- Calculate the area required:
A= / ∗∆
∆ = ×∆
R= - / - , R = 184 - 110 / 122.9 - 40 = 0.89
S= - / - , S = 122.9 - 40 / 184 - 40 = 0.575
From Appendix figure ( B.4 ) F=0.97
ΔTm = 0.97×64.67 =62.73 ℃
A = 246,785.6 / 155 * 62.73 = 25.4 m2
8-Decide the exchanger layout.
Outside diameter 20 mm, inside diameter 16 mm, tube long 5 m and put
diesel in tube and FCC gas oil in shell on squared arrangement, carbon steel.
area of the tube
=× ×
=  × 20*10-3 × 5 = 0.314 m2
Number of tube
Nt = A/At = 25.4 / 0.314 = 82 tube
Number of tube per pass
For two passes=82/2= 41
Tube Cross section Area
Tia = (  × I2 ) / 4 = (  × 0.0162 ) / 4 = 0.000201 m2
Area per pass
Area per pass =41 ×0.000201 = 0.00824 m2
Volumetric flow rate = M/ = 5210.05 / 893.2*3600 = 0.00162 m3/s
Tube velocity:
= / = 0.00162 / 0.00824 = 0.1965 m/s
Tube Reynolds Number:
= ∗ ∗ / = ( 893.2*0.1965 *0.016 )/0.5344 *10-3 = 5.26*103

Tube Prenatal number:

Pr = ∗ /k = 2.003*103 * 0.5344 *10-3 / 0.145 = 7.38

42
Tube side Nusselt number:
= × × . ×( / ) .
/ =5/0.02 =250
From Appendix figure (B.3) ℎ factor = 3.8*10-3
Nu = 3.3*10-3 *5.1318*103 *(7.38 )0.33 = 38.66
(μ/μw)0.14 The viscosity correction factor will normally only be significant
for viscous liquids.
bundle diameter
= do * ( nt/k1 )1/n1
Table ( 4.7 ) illustrated exchanger layout
Tube Number of K1 n1 Pt(1.20do)
arrangement passes
Squared 2 passes 0.156 2.291 0.025
Db= 0.02 × (84 / 0.156)1/2.291 = 0.308 m
Use spelt ring floating head type
From Appendix figure ( B-7) bundle diametrical clearance = 52
Shell diameter (Ds)
Ds = Db + 52 = 308+52 = 360 mm = 0.36 m
Baffle spacing (lB):
= 0.35 × = 0.35 × 0.36 = 0.126 m = 126 mm
Shell cross section area
As = ( - )∗ ∗ /
As = ( (0.025 - 0.02 )*0.36 *0.126 ) /0.025 = 0.00907 m2

Volumetric flow rate of shell

s = M/ = 5210.05 / 856 *3600 = 0.00169 m3/s
Shell side velocity:
= / As = 0.00169 / 0.00907 = 0.1863 m/s
hydraulic diameter (de):
= . /do ( - . do2 )
de= (1.27/0.02) ×(0.0252-0.785×0.022) =0.0197 m

43
shell side Reynolds :
= ∗ s∗ o / = ( 856 *0.1863 *0.0197 )/0.324*10-3 = 9.7 *103
shell Prenatal number:
Pr = ∗ /k = 1.05 *103 * 0.324*10-3 / 0.122= 2.788
shell ℎ factor:
From Appendix figure ( B-5 )
Choose baffle cut 25% from figure
ℎ = 6*10-3
shell side Nusselt number:
= × × .

6*10-3 *9.7*103 *(2.788 )0.33 = 81.59

8- Calculate the individual coefficients:
h = (Nu × k)/d
tube side coefficients:
ℎ = (38.66×0.145 )/ (0.016) = 350.356 W/m.℃
shell side coefficients:
ℎ = (81.59 ×0.122)/0.0197 = 505.32 W/m.℃

9- Calculate the overall coefficient and compare with the trial value. If
0 <((Uac -Uass)/Uass)< 30%

Move to next step if not back to step 6 and calculate required area by using
Uac

Actual over all heat transfer coefficient (Uac)

1/Uact = ( 1/ho ) + ( 1/hod ) + ( (do * ln (do/di))/2kw + do/di * (( 1/hid ) + ( 1/hi )

Where:
=the overall coefficient based on the outside area of the tube, W/m2 ℃
ℎ =outside fluid film coefficient, W/m2℃
ℎ =inside fluid film coefficient, W/m2 ℃

44
ℎ =outside dirt coefficient (fouling factor), W/m2℃
ℎ =inside dirt coefficient, W/m2℃
=thermal conductivity of the tube wall material, W/m℃
=tube inside diameter m
=tube outside diameter m
Fouling factor.
From appendix table (A.2 ) , ( A.4 )
For tube ( 1/hid ) = 0.0005 m2℃/W
For shell side ( 1/hod ) = 0.0002m2℃/W
Thermal conductivity (kw)
kw = 45 W/m℃
1/Uact = ( 1/000.32 ) + ( 0.0002 ) + ( (0.02* ln (0.02/0.016))/2*40) + 0.02/0.016 *
(( 0.0000 )

+ ( 1/300.306)

Uact = 100.73

Check the error

Error= (100.73 –155)/155 =0.048 %

Error in the allowable range.

45
9 - Calculate the exchanger pressure drop:

Tube side pressure drop:

∆ = [ 8* *( L/di) + 2.5 ] * 2/2

∆ ≡ tube side pressure drop

≡ number of tube side passes

≡ tube side velocity

L ≡ length of one tube

from Appendix figure ( B-6) =5.8*10-3

∆ = 2 [ 8*5.8*10-3 *( 5/0.016) + 2.5 ] 893.2*0.19652/2 = 586.304 N/m2 =

0.586 Kpa

Shell side pressure drop

∆ =8 Jf * (Ds /de ) *(L/ ) *( / )0.14 * ( *us2 ) * 0.5

from Appendix figure (B-5) =5× 10-2

∆ = 8 *5* 10-2 * (0.36 /0.0197) *(5/0.126).* ( 856*0.18632 ) * 0.5

∆ =4308.88 pa = 4.308 Kpa

Table ( 4.8 ) Heat exchanger design summary:

Material of Thickness mm Passes .( / . ℃) .( / . Error

construction ℃)
Carbon Steel 9.5 2 155 155.7 0.4 %

46
 Table (4.9 ) Design summary in shell &tube sides:

Tube side Shell side

Parameter Value Parameter Value
Fluid Diesel Fluid FCC gas oil
do (mm) 20 ( ) 0.00907
di (mm) 16 ( ) 308
A (m2) 26.22 ( ) 360
L (m) 5 lB( ) 126
82 ( / ) 0.1863
( / ) 0.1965 ( ) 19.7
Pt (m) 0.025 81.59
K1 0.156 9700
n1 2.291 2.788

de (mm) 16 6*10-3
Re 5.26 *103 ( / . ℃) 505.32
7.38 ∆ (Kpa) 4.308
3.8*10-3
( / . ℃) 350.356
∆ (Kpa) 0.586

47
4.4 Reactor design:
4.4.1 Introduction to reactor design:
The reactors used in hydro treating processes are down flow, fixed-bed catalytic re-
actors. They are usually cylindrical vessels fabricated from 2Y.
Cr-1 Mo material with austenitic stainless steel weld overlay or liner, for added cor-
rosion protection, closed at the upper and lower ends by curved heads provided with
flanged connections The opening at the top of the reactor is used to introduce the
feed and to fill the vessel with catalyst. The opening at the bottom of the reactor is
used as an outlet for the liquid product. Prevents the escape of catalyst particles. At
the opening on top of the reactor is an inlet nozzle that disperses the feed entering
the reactor. Below the inlet nozzle is a vapor/liquid distribution tray that facilitates
the uniform spreading of fluid over the top of the first catalyst bed. The reactor may
contain up to five or six catalyst beds separated by quench zones. Such a multi bed
arrangement of the catalyst allows cooling and uniform redistribution of fluids exit-
ing one catalyst bed prior to entering the next catalyst bed. Each bed of catalyst rests
on a perforated plate or screen. Such a support permits fluids to exit the bottom of
the catalyst bed and to enter the next bed after passing through a quench zone.
Ranching rings or ceramic balls are placed on top of the bed to keep the catalyst in
place. Layers of inert granular material are also placed at the bottom of each catalyst
bed. The catalyst beds may be of the same or of different sizes. The catalyst particles
may be in extruded, pilled, or spherical form.

48
 Figure (4.2 ) schematics drawing of hydro treating reactor
4.4.2 Requirements of industrial chemical reactor design:
1. The chemical factors and the kinetics of the reaction.
2. Resident time and reactor volume.
3. The mass transfer factors, with heterogeneous reactions, the reaction rate
may be controlled by the rate of diffusion of the reacting species, rather
than the chemical kinetics.
4. The heat transfer factors.
5. The operating condition, Allowable temperature, pressure drop.
6. The safety factors, the confinement of hazardous reactants and products
and the control of the reaction and the process conditions.
7. Material of construction and size characteristics.
8. Economic factor.

49
4.4.3 design calculation
1/ Reactor length:
R = (4.6 * * )/( * )
R≡ ℎ. .
≡ ( ),( 3 / 3 .)
≡ , ⁄ .
≡ - - , ⁄ .
≡ , 2⁄ 3 .
Given:
( ) ≈ 0.35 3/ 3

= 6.7 ⁄ = 0.067 ⁄
= 1.19 ∗ 10-2 ⁄
= 0.5 2⁄m3

R = (4.6 * 0.35 * 0.067 ) / ( 1.19 ∗ 10-2 * 0.5 ) = 16 m

2/Reactor area:
R = (4.6 * V ) / ( * )
A ≡ Reactor area , 2.

̇ ≡ volume flow rate , 3⁄ℎ .

̇ = 5210.5 Kg/hr / 856 kg/m3 = (6.087 m3/hr)/3600 s = 0.0017 m3/s
R = (4.6 * 0.0017 ) / ( 1.19 ∗ 10-2 * 0.5 ) = 1.316 m2
3/ Reactor volume:
=R ∗ R

= 16 * 1.316 = 21 m3
4/ Reactor Diameter:
DR = √ (4 ∗ R ) / , √ (4 ∗ 1.316 ) / = 1.3 m
0/Shell Thickness:
s =(( )/( - ))+
s≡ ℎ ℎ , mm.
≡ max 12 ⁄ 2.

50
 ≡ 1300 .
≡ 105 ⁄ 2.
≡ 80%.
≡ (stainless steel (18%Cr-8%Ni)type 304 , 2 ).
s = ((12*1300)/(2*105*.8 - 12 ))+ 2 = 102 mm = 0.102 m
6/ Catalyst:
TYPE OF CATALYST ARE USED:
1. Ni-Mo
Mass of catalyst in reactor:
Mc = ̇*

Mc ≡ Mass of catalyst

̇ ≡ Reactor volume 21 m3

 ≡ , 642.73 ⁄
Mc = 21*642.73 =13500 kg = 13.5 ton
Three bed of catalyst in reactor
- = 4.5
- = 4.5
- = 4.5

51
Table (4.10) Design summary of reactor :

Feed FCC gas oil 0000 kg⁄hr

product Diesel, Naphtha , Dry gases , LPG 85%of feed

Catalyst Bed-1 (Ni Mo) = 4.5

(NiMo) Bed-2 (Ni Mo) = 4.5

Bed-3 (Ni Mo) = 4.5

Design Data:

Number of beds =3

Pressure = 60 bar ( KRC manual)

Material of construction = Stainless steel

Diameter = 1.3 m

Height = 16m

Maximum allowable pressure drop = 1 bar

Shell Thickness = 0.102 m

Closure = ellipsoidal

Catalyst dia. = 6.35 mm

Catalyst density = 642 kg/ m3

52
 Chapter five
Process Control

53
0.1 Introduction:
Control in process industries refers to the regulation of all aspects of the process.
Precise control of level , temperature, pressure and flow applications.
0.1.2Process:
Process as used in the terms process control and process industry, refers to the
methods of changing or refining raw materials to create end products.
0.1.3Process Control:
Process control refers to the methods that are used to control process variables when
manufacturing a product.
0.1.4Control Loop:
Control loops in the process control industry work in the same way, requiring three
tasks to occur:
-Measurement
- Comparison
- Adjustment
In Figure ( ), a level transmitter (LT) measures the level in the tank and transmits a
signal associated with the level reading to a controller (LIC). The controller com-
pares the reading to a predetermined value, in this case, the maximum tank level
established by the plant operator, and finds that the values are equal. The controller
then sends a signal to the device that can bring the tank level back to a lower level a
valve at the bottom of the tank. The valve opens to let some liquid out of the tank.
Many different instruments and devices may or may not be used in control loops
(e.g., transmitters, sensors, controllers, valves, pumps), but the three tasks of meas-
urement, comparison, and adjustment are always present.

Figure ( 0.1 ) a level transmitter (LT)

54
0.1.0Process Variable:
A process variable is a condition of the process fluid (a liquid or gas) that can
change the manufacturing process in some way
Common process variables include:
-Pressure
-Flow
-Level
-Temperature
-Density
- PH (acidity or alkalinity)
- Mass
-Conductivity
0.2 Applications of control in DHT unit:
0.2.1 Steam stripping column control:

Figure (0.2 ) Model of stripper top control

1/ The pressure of steam stripping column is controlled actually by adjusting the gas

discharge capacity of reflux drum.

2/ Reflux drum level controlled by adjusting the flow rate of light product.

3/ Top temperature is controlled by adjusting the flow rat of cold reflux.

55
 Figure (0.3 ) Model of stripper bottom control
1/ Stripping steam flow rate controlled according to specification of diesel product.
2/ Semi treated diesel flow rate to stripper controlled by level control. Also level.
3/ The bottom temperature of column controlled by decrease the flow rate of the
bottom recycle if the temperature of the bottom is less and increase the flow rate of
the bottom recycle if the temperature of the bottom is more

Figure (0.3) stripper bottom temperature control

0.2.2 Reactor variables control:

The main variables which were needed controlling and adjustments are pressure and
temperature, so as to obtain desired conversion, and to prevent the reactor from
damage, also the product specifications.

56
 Figure (0.0) DCS Screen of heater and Reactor control

Controlling reactor bed temperatures:

Set point = 300 – 340 ± 50 C (between the entrance, beds to leave).

Measuring element: set of three thermocouples for each point, due the importance,

and accuracy needing, spare if there is damage due to mild conditions.

-Final element control: Pneumatic valve.

- Action:

Increase flow in of quench hydrogen when temperature increase, and decrease when

it decrease.

Figure (0.6) model reactor bed temperature control

57
0.2.3 Heat exchanger control:

Diesel

RFCC gas oil RFCC gas oil

Diesel

Figure (0.7) Conventional Process Control.

Diesel

RFCC gas oil RFCC gas oil

Diesel

Figure (0.8) Digital Process Control.

58
Table (0.1) Indices for DHT Process control

59
 Chapter six
Safety and Environment

60
6.1 Introduction:
The success of plant is around quality, teamwork and professionalism. Part of this
professionalism is the commitment to performing the job safely. It takes effort to
keep safety foremost in mind during every job task. Safety is each employee’s re-
sponsibility and performing each task safely makes everyone’s job easier in the long
run.
6.1.2 Safe work is a work without any damage / loss to:
-People.
- Equipment.
- Materials.
- Environment.
6.1.3 To prevent loss:
-Stop unsafe act.
- Remove unsafe condition.
- Maintenance.
6.1.4Common hazard in a plant:
- Fire.
- Explosion.
- Toxic release.
- Chemical hazard.
- Electrical hazard.
- Other physical Hazard (Heat, radiation, Noise…).
6.1.0 Fire hazards of diesel:
Table ( 6.1 ) diesel hazards specification
Properties Diesel
Flash point 125 ºf
Auto ignition 545 ºf
Burning rate 4 mm/min
Fire extinguishing agent Dry chemical, foam, carbon
dioxide
Hazard classification 1. Flammable liquid.
2. class 3 group III

61
6.2 Diesel hydro treating unit safety:
6.2.1 Safety characteristics and safety measures of the device:
Safety characteristics of the device.
Hydrogenation device is a high temperature and high pressure production device
with inflammable and explosive hydrogen.
6.2.2 Safety measures of the device:
All parts of the device will be set with reliable pressure discharge systems; the
inflammable and explosive gas will be discharged into airtight torch system; and the
dirty oil will be discharged into the slop oil tank in the device according to its prop-
erties.
1/ To guarantee production safety, important parts (for example, compressor, heating
furnace, and reactor, etc.) of the device will be set with automatic interlocking pro-
tection systems.
2/ The device will be set with emergency pressure discharge system in the reaction
part; when the circulating hydrogen compressor fails, the reactor bed over tempera-
tures or the device inside has serious fire, start up the emergency pressure discharge
system, so that the reaction system can discharge pressure so as to ensure equipment
and personnel safety.
3/ All key equipments (such as compressors and feeding pumps, etc.) in the device
should be prepared with standby machines to ensure the device’s safety production.
4/ To ensure device safety, the device inside should also be installed with detecting
and alarm facilities for inflammable and poisonous gas.
5/ All bearing structural steel frames, brackets, skirt supports, and pipe racks should
be installed with refractory bricks according to the concerning regulations.
6/ The high pressure separator should be set with Low-Low liquid level self-
protection interlocking system to prevent the high-component gas from flowing into
the low pressure separator and ensure the normal operation of low pressure separa-
tor.
7/ All pipelines and equipments with appearance temperature bigger than 60c and
possibly touched by personnel should be scald avoided and heat preserved.

62
8/ High and low pressure transformer rooms and power distribution rooms should be
far away from the noise area, high temperature and high pressure area, and
inflammable and explosive area with indoors installed with air conditioning
facilities.
6.3 Environmental considerations:
Vigilance is required in both the design and operation of process plant to ensure that
legal standards are met and that no harm is done to the environment.
Consideration must be given to:
1/ All emissions to land, air, water.
2/ Waste management.
3/ Smells.
4/ Noise.
5/ The visual impact.
6/ Any other nuisances.
7/ The environmental friendliness of the products.

6.3.1 Measures for discharge and control of three wastes in hydrogenation device:
[Link] Waste gas:
1/ The gases containing H2S produced during the device’s production process mainly include low
pressure separator gas and steam stripping tower top gas. The low-component gas will be dis-
charged into the fuel gas pipe network; before the steam stripping tower top gas is discharged into
the gas compressor of the heavy oil catalytic cracking device, it should be made desulfurization.
2/ The heating furnace smoke during device’s normal production will use high altitude discharge
measures through chimney; the smoke only contains very small amount of SO2and NOx, therefore,
the smoke discharge complies with discharge standard.
3/ The waste gas produced during catalyst regeneration contains the harmful gases such as SO2 and
CO2 , etc. This design will use the means of nitrogen--air regeneration and consider the measures
of alkaline liquor injection for neutralization; the discharged gas only contains a small amount of
CO2, which will not pollute the environment
[Link] Waste liquid Sewage
1/ Acid sewage: The sulfurous and ammoniac sewage discharged from the high pressure separator,
the low pressure separator and the steam stripping tower top return tank will be delivered from the
device into the sulfurous sewage steam stripping device for treatment.
2/ Domestic sewage: A small amount of domestic sewage produced from the device will be deliv-
ered out of the device for treatment.

63
3/ Rainwater discharge will separate from the fresh water and dirty water so as to re-
duce the oil-bearing sewage quantity discharged from the device as possible and re-
duces the load of the sewage treatment plant.
[Link] Dirty oil:
Unqualified oil: The unqualified oil produced during the device’s startup, shutdown
or normal production will be delivered into the unqualified oil tank in the factory
through a special unqualified oil pipeline for reprocessing and treatment.
[Link] Waste residue:
During the device’s normal production process, waste residue will not be produced,
and waste residue will be discharged only during catalyst nitrogen regeneration
(about once per two years), the high pressure separator will discharge the waste alka-
line liquor containing Na2 CO3 and Na2 SO3 from the device into the factory sys-
tem for treatment. The inactive catalyst and waste active carbon should be contained
in barrels and buried deeply after being unloaded or delivered to the waste catalyst
treatment plant.
Wastes” discharge – examination indices of environmental protection depart-
ments:
1/ Oil content in the sewage of the device < 100mg/l.
2/ PH value 6-9.
3/ Sulfurous sewage and outside delivered industrial water should not be discharged
into the effluent sewer.
4/ Waste residue should be poured in the places recognized and specified by the en-
vironmental protection departments.

64
6.4 Environmental protection statistics table:-
Table (6.2) Environmental department measurement and control

65
66
 Chapter seven
Plant location and Layout

67
7.1 Introduction
7.1.1 Plant Location and Site Selection:
The geography location of the final plant must be taken into consideration when a
process design is developed.
The location of the plant can have a crucial effect on the profitability of a project,
and the scope for future expansion. Many factors must be considered when selecting
a suitable site. The principal factors to consider are:
7.1.2 Location, with respect to the marketing area:
For materials that are produced in bulk quantities where the cost of the product per
tone is relatively low and the cost of transport represent a significant fraction of the
sales price, the plant should be located close to the primary market. This considera-
tion will be less important for low volume production, high-priced products. In an
international market, there may be an advantage to be gained by locating the plant
within an area with preferential tariff agreements; such as the European Community
(EC).
7.1.3 Raw material supply:
The availability and price of suitable raw materials will often determine the site loca-
tion. Plants producing bulk chemicals are best located close to the source of the ma-
jor raw material.

7.1.4 Transport facilities:

The transport of materials and products to and from the plant will be an overriding
consideration in site selection. If practicable, a site should be selected that is close to
at least two major forms of transport: road, rail, waterway (canal or river), or a sea
port. Road transport is being increasingly used, and is suitable for local distribution
from a central warehouse. Rail transport will be cheaper for the long-distance
transport of bulk chemicals. Air transport is convenient and efficient for the move-
ment of personnel and essential equipment and supplies, and the proximity of the
site to a major airport should be considered.

68
7.1.0Availability of labor:
Labor will be needed for construction of the plant and its operation. Skilled construc-
tion workers will usually be brought in from outside the site area, but there should be
an adequate pool of unskilled labor available locally; and labor suitable for training
to operate the plant. Skilled tradesmen will be needed for plant maintenance. Local
trade union customs and restrictive practices will have to be considered when as-
sessing the availability and suitability of the local labor for recruitment and training.
7.1.6 Availability of utilities:
Chemical processes invariably require large quantities of water for cooling and gen-
eral process use, and the plant must be located near a source of water of suitable
quality. Process water may be drawn from a river, from wells, or purchased from a
local authority. At some sites, the cooling water required can be taken from a river or
lake, or from the sea; at other locations cooling towers will be needed. Electrical
power will be needed at all sites. A competitively priced fuel must be available on
site for steam and power generation. And utilities may include:
- Electricity.
- Steam, for process heating.
- Cooling water.
- Water for general use.
- Demineralized water.
- Compressed air.
- Inert-gas supplies.
- Refrigeration.
- Effluent disposal facilities.
7.1.7 Availability of suitable land:
Sufficient suitable land must be available for the proposed plant and for future ex-
pansion. The land should ideally be flat, well drained and have suitable load-bearing
characteristics. A full site evaluation should be made to determine the need for piling
or other special foundations.

69
7.2 Environmental impact and effluent disposal:
All industrial processes produce waste products, and full consideration must be giv-
en to the difficulties and cost of their disposal. The disposal of toxic and harmful ef-
fluents will be covered by local regulations, and the appropriate authorities must be
consulted during the initial site survey to determine the standards that must be met.
An environmental impact assessment should be made for each new project, or major
modification or addition to an existing process.
7.2.1 Local community considerations:
The proposed plant must fit in with and be acceptable to the local community. Full
consideration must be given to the safe location of the plant so that it does not im-
pose a significant additional risk to the community. On a new site, the local commu-
nity must be able to provide adequate facilities for the plant personnel: schools,
banks, housing, and recreational and cultural facilities.
7.2.2 Climate:
Adverse climatic conditions at a site will increase costs. Abnormally low tempera-
tures will require the provision of additional insulation and special heating for equip-
ment and pipe runs. Stronger structures will be needed at locations subject to high
winds (cyclone/hurricane areas) or earthquakes.
7.2.3 Political and strategic considerations:
Capital grants, tax concessions, and other inducements are often given by govern-
ments to direct new investment to preferred locations; such as areas of high unem-
ployment. The availability of such grants can be the overriding consideration in site
selection .
All the above factors should be considered simultaneously in selecting the optimal
plant location.
7.3 Site Layout:
The physical layout of plant should be design to print co-ordination between the op-
eration of the process equipment and the use of storage and material handling equip-
ment (buildings should be laid out to give the most economical flow of materials and
personnel around the site). Hazardous processes must be located at a safe distance
from other buildings.

70
Consideration must also be given to the future expansion of the site. The ancillary
buildings and services required on a site, in addition to the main processing units
(buildings), will include: :
1/ Storages for raw materials and products: tank farms and warehouses. Maintenance
workshops.-
2/ Stores, for maintenance and operating supplies.
3/ Laboratories for process control.
4/ Fire stations and other emergency services.
5/ Utilities: steam boilers, compressed air, power generation, refrigeration, trans-
former stations.
6/ Effluent disposal plant.
7/ Offices for general administration.
8/ Canteens and other amenity buildings, such as medical centers.
9/ Car parks .
When roughing out the preliminary site layout, the process units will normally be
sited first and arranged to give a smooth flow of materials through the various pro-
cessing steps, from raw material to final product storage. Process units are normally
spaced at least 30 m apart; greater spacing may be needed for hazardous processes.
The location of the principal ancillary buildings should then be decided. They should
be arranged so as to minimize the time spent by personnel in traveling between
buildings .
Administration offices and laboratories, in which a relatively large number of people
will be working, should be located well away from potentially hazardous processes.
Control rooms will normally be located adjacent to the processing units, but with po-
tentially hazardous processes may have to be sited at a safer distance. The sitting of
the main process units will determine the layout of the plant roads, pipe alleys and
drains. Access roads will be needed to each building for construction, and for opera-
tion and maintenance .

71
Utility buildings should be sited to give the most economical run of pipes to and
from the process units. Cooling towers should be sited so that under the prevailing
wind the plume of condensate spray drifts away from the plant area and adjacent
properties. The main storage areas should be placed between the loading and un-
loading facilities and the process units they serve. Storage tanks containing hazard-
ous materials should be sited at least 70 m (200 ft.) from the site boundary.
7.4 Plant Layout:
The economic construction and efficient operation of a process unit will depend on
how well the plant and equipment specified on the process flow-sheet is laid out.
The principal factors to be considered are :
Economic considerations: construction and operating costs
The cost of construction can be minimized by adopting a layout that gives the short-
est ran of connecting pipe between equipment, and the least amount of structural
steel work. However, this will not necessarily be the best arrangement for operation
and maintenance.
7.4.1The process requirements:
An example of the need to take into account process considerations is the need to
elevate the base of columns to provide the necessary net positive suction head to a
pump or the operating head for a thermo siphon Reboiler.
7.4.2 Convenience of operation:
Equipment that needs to have frequent operator attention should be located conven-
ient to the control room. Valves, sample points, and instruments should be located at
convenient positions and heights. Sufficient working space and headroom must be
provided to allow easy access to equipment.
7.4.3 Convenience of maintenance:
Heat exchangers need to be sited so that the tube bundles can be easily withdrawn
for cleaning and tube replacement. Vessels that require frequent replacement of cata-
lyst, packing or cleaning should be located on the outside of buildings. Equipment
that requires dismantling for maintenance, such as compressors and large pumps,
should be placed under cover.

72
7.4.4 Safety:
Blast walls may be needed to isolate potentially hazardous equipment, and confine
the effects of an explosion. At least two escape routes for operators must be provided
from each level in process buildings .
7.4.0 Future expansion:
Equipment should be located so that it can be conveniently tied in with any future
expansion of the process. Space should be left on pipe alleys for future needs, and
service pipes over-sized to allow for future requirements.
7.0 Modular construction:
In recent years there has been a move to assemble sections of plant at the plant man-
ufacturer's site. These modules will include the equipment, structural steel, piping
and instrumentation. The modules are then transported to the plant site, by road or
sea .
The advantages of modular construction are:
1/ Improved quality control.
2/ Reduced construction cost.
3/ Less need for skilled labor on site.
4/ Less need for skilled personnel on overseas sites
Some of the disadvantages are:
5/ Higher design costs.
6/ More structural steel work.
7/ More flanged connections.
8/ Possible problems with assembly, on site.
7.6 General considerations:
Open, structural steelwork, buildings are normally used for process equipment;
closed buildings are only used for process operations that require protection from the
weather .

73
The arrangement of the major items of equipment will usually follow the sequence
given on the process flow-sheet: with the columns and vessels arranged in rows and
the ancillary equipment, such as heat exchangers and pumps, positioned along the
outside.
Other allowance are made for certain types of hazards, certain steps have to be fol-
lowed:
Locating ignition sources up wind (based on prevailing wind description) from
points of possible release of flammable. Materials providing adequate access ways
for the movement of equipment and people inside the processing plant area.
Great precaution should be taken to ensure, the safety of equipment building areas
and people working.
7.6.1 Buildings:
It always as fundamental in the chemical engineering industries that buildings
should be built around the process area, instead of the process being made to fit
building of conventional design.
7.6.2 Plant expansion:
Future expansion of plant should always be kept in mind and allowance is made for
any thought of multiplying the number of units or increasing the size of the prevail-
ing units.
7.6.3 Other services:
A plant must be prepared for the convenience of its employees and general adminis-
trative staff. Room is made for recreational activities such as rest room, cafeteria,
and change room for workers. Providing a medical facility is importance for safety
of employees and to take care of any sudden emergencies that might be happened.
Other important parts needed for plant efficient operation are administrative offices,
laboratories, workshops and stores.
7.6.4 Wind direction:
Wind direction will determine the general of many things. All equipment that spill
flammable should be located down wind. Plant offices, central lab, fire station, pow-
er house, cafeteria, store house, parking, main water pump should be located upwind
side.

74
 7.6.0 Storage facilities:
Tank farms and warehouses that contain non-hazardous, nonflammable and non-
explosive material should be located up wind of the plant. Facilities do not fit with
above category should be located down wind and should be located at least 75m far
from any processing area.
7.7 DHT unit layout:
7.7.1 Scope:
This unit set as an expansion of a refinery, for this it is location was determined be-
fore starting the construction, because of the above reasons mentioned.
7.7.2 Site of feed storage:
It must be found in strong fence with at least 9 meter height, for each one (naphtha &
diesel) 4 tanks at least and suitable distance from process and from each one for
safety considerations and cleaning.
7.7.3 Site of process equipment:
A process is divided into the following sections:
Feed equipment (pump, filter, and surge drums).
Reactor equipment (reactor, furnace, and heat exchangers).
Separator equipment (high pressure and low pressure drums).
Striper equipment ( fractionation and stabilization columns)
The space between one and the other must be suitable as shown in figure (6.1), for
respect ions of safety and maintaining considerations.
7.7.4 Site of products:
As the same of feed storage properties. (For the main products) with three tanks for
product.
7.8Control room consideration:
Located between tanks and the process with the following considerations:
1. Concrete construction.
2. Wind direction (leakage of gas).
3. Good air conditioning, for computers and other controlling devices.
4. Good lighting.

75
Figure (7.1) plant layout

76
 Chapter eight

Cost Estimation

77
8.1 Introduction :
An acceptable plant design must present a process that is capable of operating under
conditions which will yield a profit. Since net profit equals total income minus all
expenses, it is essential that the chemical engineer be aware of the many different
types of costs involved in manufacturing processes. Economic analysis and cost esti-
mation are done to determine profitability of plant depending on production capacity
of the plant which determined by demand and market survey. Two types of produc-
tion capacities are known.
8.1.1 The actual production capacity:
Which is the capacity achieved at the existing situation.
8.1.2 Installed capacity:
Which can be achieved from a technical point according to equipment specifica-
tions.
A capital investment is required for any industrial process, and determination of the
necessary investment is an important part of a plant design project.
8.2 Factors Affecting Investment and Production Costs :
When a chemical engineer determines costs for any type of commercial process, the-
se costs should be of sufficient accuracy to provide reliable decisions. To accomplish
this, the engineer must have a complete understanding of the many factors that can
affect costs. For example:
Sources of Equipment.
Price fluctuations.
Operating Time and Rate of Production.
Company policies.
Governmental regulations.
And other factors affecting costs and the engineer must keep up-to date of this fac-
tor.

78
8.3 Accuracy of Estimates:
The accuracy of any estimate will depend on the competence of the people involved,
the completeness of the design information, the proper feedback of actual costs, and
the subsequent updating of all cost data. It has been noted before that it takes a while
for an engineer to get a qualitative and quantitative understanding of any process.
This is also true for a cost estimator. For this reason, many companies have the pro-
cess engineers do the capital cost estimating at the preliminary design stages. This
saves time, since a cost estimator does not need to go through this gestation period.
However, the process engineer must then spend some time keeping up with the ad-
vances in cost engineering. He must also receive feedback about the accuracy of his
estimates.
In any profession it is important that the people involved see the results of their
handiwork. If a mistake is made and the person making it never hears about it, he
will probably make it again. Presumably he did what he felt was right the first time,
Why should he change his ways unless he is corrected? For this reason it is im-
portant that each company have a procedure for gathering cost data while the plant is
being built. At its completion an analysis of the costs should be compared with all
the cost estimates made. The estimator should then be apprised of the results, and
some method should be used to update the factors involved in the cost estimates. On-
ly in this way can accurate cost estimating occur. Good cost estimations don’t just
happen. They require careful work and skilled judgment, and they cost money1.

8.4 Capital Investment Cost:

Is calculated according to cost indices as:

79
1/ Estimation of equipment:
Table (8.1) equipment prices

NO Equipment Item No of Equipment Cost ($) in year 2018

1 Reactor 1 2,285,452.5
2 Column 1 64,80
3 Drum or vessel 10 3,322
4 Furnace 2 254,432
0 Heat exchanger 12 262,515.5
6 Air cooler 8 325,977.3
7 Compressor 4 425,968.6
8 Pump 14 262,927.9
9 Filter 3 615,909.3
10 Total 4,492,058

Total cost of equipment in year 2018

Therefore the total cost of equipment in year 2023 equal:-
Index for 2018 = 105.977
Index for 2023 = 106.077
Cost equipment in 2023 = 4,492,058 * 106.077/105.977
= 4,496,296.71 $
2/ Cost of installation:
Cost of installation = 15% of cost of equipment
= 0.15*4496296.71 = 674,444.5065$
3/ Cost of instrumentations and control:
Cost of instrumentations and control = 20% of cost of equipment
= 0.2*4496296.71 = 899,259.342$
4/ Cost of pipes and valves:
Cost of pipes and valves = 30% of cost of equipment
= 0.3* 4496296.71 = 1,348,889.013$
0/ Electric system:
Electric system = 10% of cost of equipment
0.1 *4496296.71 = 449629.671 $

80
6/ Serves:
Serves = 30% of cost of equipment
= 0.3*4,496,296.71 = 1,348,889.013$
7/ Buildings:
Buildings = 3.5% of cost of equipment
= 0.035*4,496,296.71 = 157,370.38485 $
8/ Land:
Land = 2% of cost of equipment
= 0.02*4,496,296.71 = 89,925.9342 $
9/ Fixed capital:
Fixed capital equal the sum of the above costs:
Fixed capital = 9,464,704.56 $
10/ Working cost:
Working cost = 12% of fixed cost
= 0.12* 9,464,704.56 = 1,135,764.5472 $
11/ Total investment required:
= fixed capital + working cost
= 9,464,704.56 + 1,135,764.5472= 10,600,469.1072 $
8.0 Operation cost:
Operation cost consists of the following:
Fixed operation cost.
Variable operation cost.
8.0.1Variable operation cost:
1/ Raw material:
Consist of the following materials, they are:
Hydro treating catalyst:
Price of hydro treating catalyst = 28000 $/ton
Annual cost = 28000*13.5 = 378,000 $
Thermal cracked – untreated diesel cost:
Thermal cracked - untreated diesel price is too cheap due to its bad specifications, it
uses as furnace fuel or blended with, so the ton price is 553$.
Annual cost = 2.47*8000 = 19,760 $

81
Cost = 553*8000 = 4,424,000 $
Hydrogen cost:
The price = 2.47 $/kg
2/ Miscellaneous cost:
Miscellaneous cost = 5% maintenance
Maintenance cost = 10% total investment required
=0.05 x 0.1× 5,564,616.8
3/ Utilities:
Table (8.2) below represent utilities required for DHT unit

NO Auxiliary materi- Required t/ Total Price Cost $

al hr. $

1. Fuel gas 233 kg/hr. - - -

2. Fresh water 1 t/hr. 8000 1.6 12,800

3. Demineralized water 0.5 t/hr. 4000 2.5 10,000

4. Cooling water 7.18 t/hr. 57,440 2.8 160,832

0. Electric consumption 3.148 kw/hr. 25,184 0.15 3777.6

6. Steam 1.66 hr. 13,280 20 265,600

7. Total - - - 453,009.6

Remark:
Operation time 8000 hr. / year.
Fuel gas generated = fuel gas consumed.
4/ Total variable operation cost: Cvc:
= 0,302,093 $

82
8.0.2 Fixed operation cost:
1/ Labor cost:
Working time Tow shifts (30 labors).
Average cost assumed: 2.5 $/hr.
Operating labor cost = 2.5*30*8000 = 600,000 $
2/ Supervision:
SV = 20% of labor cost
SV = 0.2*600,000 = 120,000 $
3/ Plant over head:
[Link] = 50% of labor cost
[Link] = 0.5*600,000 = 300,000 $
4/ Capital change:
C.C = 15% of total investment required.
C.C = 0.15* 5,564,616.8032 = 834692.52048$
0/ Insurance:
Insurance = 1% of total investment required.
Insurance = 0.01* 5,564,616.8032 = 55,646.168 $
6/ Local taxes:
L .T = 2% of total investment required.
L .T = 0.02* 5,564,616.8032 = 111,292.336$
7/ Royalties:
Royalties = 1% of total investment required.
Royalties = 0.01* 5,564,616.8032 = 55,646.168 $
8/ Maintenance:
M.T = 10% of total investment required.
M.T = 0.1 * 5,564,616.8032 = 556,461.68 $
9/ Total fixed operation cost:
Total fixed operation (production) cost = 2,633,738.87 $

83
8.6 Total annual income:
Refined diesel:
Selling price of refined diesel = 1300 $/ton
Refined diesel = 3.9 ton/hr
Annual income from refined diesel = 3.9 ton/hr.
3.9*1300*8000 = 40,560,000 $
8.7 Net profit:
Net profit = total annual income − total operation cost.
Total operation cost =
Total variable operation cost + total fixed operation cost
=0,302,093 + 2,633,738.87 = 7,936,331.87$
Net profit = total annual income − total operation cos
= 40,560,000 - 7,432,139 = 33,127,861$
8.8 Taxes of net profit:
Taxes of net profit are equal to 40% of net profit.
Taxes of net profit = 0.4 * 33,127,861= 13,251,144.4 $
8.9 Annual net profit:
Annual net profit = net profit − taxes.
Annual net profit = 33,127,861 -13,251,144.4 = 19,876,716.6 $
8.10 Payback period:

Payback period =

Year = 9,464,704.56 / 19,876,716.6 = 0.5 year

Summery of cost estimation:
Table (8.3) Summery of Cost

Items Value $
Total fixed cost 9,464,704.56
Total production ( operation ) cost 7,936,331.87

Total annual income 40,560,000

Annual net profit 19,876,716.6
Payback period 0.5 year
84
 Chapter nine
Recommendation and Conclusion

85
9.1 Conclusion
In this research we treat the cracked diesel of RFCC unit which contains, sulfur, ni-
trogen, oxygen, and unsaturated compound by using hydrogen which is produced in
continuous catalytic reforming unit (CCR) and pressure swing adsorption unit
(PSA).
The result is to obtain diesel that is anticorrosive, with desired Cetane number, and
high performance to keep the environment and improve combustion rate of diesel.
We calculate mass and energy balance based on the 5000kg of feed.
We designed three equipment's, one is hydro-treating stripper, heat exchanger and
hydro-treating fixed bad reactor . Control is done for these equipment's. Also we
modeling digital control for reactor and stripper.
We study cost estimation of the project and discovered that the payback period
(PBP) which is (0.5) year.
In the final we take care of the layout of the plant, safety and environment consider-
ation of (unit).

9.2 Recommendation:
We use in this project real data from practical operation so we recommend to build
new DHT with counties regeneration reactor to reduce cost of regeneration.
According to our study of diesel hydro-treating unit we found the hydrogenation
process suitable to treat most petroleum cuts with respect to cost. So we recommend
in future treating virgin naphtha from CDU.

86
9.2 References

1. J.M. Coulson and J.F. Richardsons, ”Chemical Engineering Vol.1”, Fourth Edi-

tion, Oxford, Boston, Johannesburg, Melboume, New Delhi, and Singapore, 1996

2. J.M. Coulson and J.F. Richard sons, “Chemical Engineering Vol.2” Second Edi-

tion, New York, Toronto, and Germany, 1993.

3. J.M. Coulson and J.F. Richard Songs “Chemical Engineering vol.6”, Second Edi-

tion, New York, 1993.

4. J .[Link] Hust, J.H. Harker, “Process Design Plant”, Mc-Graw-Hill Company,

1979.

5. Khartoum Refinery Company, Operating Rules for Diesel Hydrogenation

Plant,l999

6. L. Bryce Andersen, Leonard [Link], “Introduction to Chemical Engineering”,

Mc-Graw-Hill Company, New York, Toronto, London, 1976.

7. Engineering encyclopedia – Aramco company, 1999.

8. Robert [Link] , hand book of petroleum refining processes , Mc Graw – Hill,

3rd edition ,.

9. W . L Nilsson, Petroleum refinery engineering– 4th edition.

10. Ronald William Missen , Charles , A Mims , Bradley, A Saville. John Willy,

Introduction to chemical reaction engineering and kinetics, & Sons Inc – New York.

87
11. P . Trambouze, Petroleum refining four material and equipments –,

institute France petroleum publications ( I F P ).

[Link] Arnold and Maurice Stewart et al: ''Surface Production Opera-

tions '',Volume 1, Design of Oil-Handing System and Facilities, Gulf P

Web site:

[Link]

13. petroleum refining technology and economics fifth edition

14. M .R. Riazi characterization and properties of petroleum fractions

88
9.3 Appendices
1. Appendixes of Tables:
Table (A-1) Typical overall coefficient:

Table (A-2) Fouling factors (coefficients) typical values:

89
Table (A-3) stander dimensions of steel tube :

Table (A-4) conductivity of metals :

Table (A-0) typical tube arrangement :

90
 2. Appendixes of Figures:
Figure (B-1) Erbar Maddox correlation :

Figure (B-2) flooding velocity sieve plate :

91
Figure (B-3) tube side heat transfer factor :

Figure (B-4) Temperature correction factor: one shell pass; two or more even tube passes:

92
Figure (B-0) shell side heat transfer factor, segmental baffle :

Figure (B-6) shell side friction factor, segmental baffle :

93
Figure (B-7) shell bundle clearance :

94