Appendix 8.5 Equipment Summary & Specification Sheets 59
EQUIPMENT NR. : NAME : REACTORS, COLUMNS & VESSELS SUMMARY R0 Monolith Reactor R02 Riser Regenerator C0 Depropanizer C04 Deethanizer C05 PP splitter Tray Column Tray Column Tray Column Pressure [bara] :.9 / 2 / 2 6.8 / 6.7 24.2 / 24 0.0 /.0 Temp. [ o C] : 596 / 600 84 / 682 (2) 47.4 / 89.2 62. / 60.9 9.0 / 30.4 Volume [m 3 ] : Diameter [m] : L or H [m] : Internals Tray Type : Tray Number : Fixed Packing Type : Shape : Catalyst Type : Shape : Number Series : Parallel : Materials of Construction () : 7 3 0 Monolith Honeycomb 400 cpsi PtSnK/γAl 2 O 3 0.9 5 0.9 8.0 Sieve Trays 26.0 9.8 Sieve Trays 29.98+.98 (3) 39.6+36.6 (3) Sieve Trays 9 2 (3) Trays: SS34 Column: CS Trays: SS34 Trays: SS34 Column: CS Column: CS () SS = Stainless Steel; CS = Carbon Steel (2) Temperatures of incoming air and outgoing effluent. The temperature of incoming solids is 596 o C. (3) The PP splitter is split in two towers Project IDNumber : CPD3300 Date : January 2th 2004 60
EQUIPMENT NR. : NAME : REACTORS, COLUMNS & VESSELS SUMMARY V0 Reflux accumulator C0 V02 Flash vessel for water separation V03 Reflux accumulator of C04 V04 Reflux accumulator of C05 Horizontal Horizontal Horizontal Horizontal Pressure [bara] : 6.2 2.0 23.8 0.0 Temp. [ o C] : 47.4 30 62 9 Volume [m 3 ] : Diameter [m] : L or H [m] : Internals Tray Type : Tray Number : Fixed Packing Type : Shape : Catalyst Type : Shape : Number Series : Parallel : Materials of Construction (2) : 63.62 () 9.0 5.8 ().3 3.9 49. () 2.5 0.0 34.0 () 5.3 5.8 CS SS CS CS () Effective volume for residence time of 0 minutes. (2) SS = Stainless Steel; CS = Carbon Steel Project IDNumber : CPD3300 Date : January 2th 2004 6
HEAT EXCHANGERS SUMMARY EQUIPMENT NR. : NAME : E0 C0 Condenser E02 Heat exchanger E03 Heat exchanger E04 Heat exchanger E05 C0 Reboiler Substance Tubes : Shell : Floating Head Floating Head Floating Head Floating Head Floating Head Cooling W. nc 3 Exhaust air nc 3 nc 3 /C 3 =/H 2 O nc 3 nc 3 /C 3 = nc 3 Duty [kw] : 467 7022 4898 3050 0607 Heat Exchange area [m 2 ] : 92 49 424 2262 84 Number Series : Parallel : Pressure [bara] Tubes : Shell : Temperature In / Out [ o C] Tubes : Shell : 6.7 20.0/37.0 47.0/47.0 Special Materials of Construction (2) : Other : Praat geen poep 2 2.2.0 682.2/70.9 60.9/248.2 () Bare tube surface. (2) SS = Stainless Steel; CS = Carbon Steel. 2.2.55 595.9/498.3 248.2/378.9 3 2.2 25.0 70.9/46.6 20.4/60.9 nc 3 /C 3 =/H 2 O nc 4 /nc 3.55 6.8 394.5/83.3 89.2/89.2 Project IDNumber : CPD3300 Date : January 2 st 2004 62
HEAT EXCHANGERS SUMMARY EQUIPMENT NR. : NAME : E06 Heat exchanger E07 C04 Reboiler E08 C04 Reboiler E09 Heat exchanger E0 R0 effluent cooler Substance Tubes : Shell : Floating Head Floating Head Floating Head Floating Head Floating Head nc 3 /C 3 =/H 2 O nc 3 /C 3 = nc 3 /C 3 =/H 2 O nc 3 /C 3 = nc 3 /C 3 =/H 2 O nc 3 /C 3 = nc 3 /C 3 =/H 2 O Light ends Duty [kw] : 522 49 26 89 327 Heat Exchange area [m 2 ] : 288 5 469 20 668 Number Series : Parallel : Pressure [bara] Tubes : Shell : Temperature In / Out [ o C] Tubes : Shell : Special Materials of Construction (2) : Other :.55 25 498.3/394.5 60.9/00.0.55 25.0 83.3/00.0 60.9/60.9 (3) Bare tube surface. (4) SS = Stainless Steel; CS = Carbon Steel. 5 2.2 25.0 225.0/70.9 60.9/60.9 2.2 2.2 70.9/69.8 62.5/5.0 nc 3 /C 3 =/H 2 O Cooling W. 2.2 69.8/29.9 20/40 Project IDNumber : CPD3300 Date : January 2 st 2004 63
HEAT EXCHANGERS SUMMARY EQUIPMENT NR. : NAME : E C04 Reboiler E2 C04 feed cooler E3 C04 Condenser E4 Heat pump Reboiler E5 Heat pump trim cooler Substance Tubes : Shell : Floating Head Floating Head Floating Head Floating Head Floating Head nc 3 /C 3 = nc 3 /C 3 = nc 3 /C 3 = Cooling W. Refrig. (N 2 ) Light ends nc 3 /C 3 = + nc 3 /C 3 =/C 4 Duty [kw] : 456 2073 535 (3) 39702 887 Heat Exchange area [m 2 ] : 927 736? 4393 3088 Number Series : Parallel : Pressure [bara] Tubes : Shell : Temperature In / Out [ o C] Tubes : Shell : Special Materials of Construction (2) : Other : 25.2 25.0 74.5/69.0 60.9/60.9 46.6/30.0 20.0/37.0 25.2 Shell : SS?? 24.0. Bare tube surface. 2. SS = Stainless Steel; CS = Carbon Steel. 3. Cost estimation based on energy consumption ($/MJ) <72.0 62.0/62.0 5 8.0.0 54.0/4.0/.0 C 3 = Cooling W. 3 7.0 4/29.5 9.5/3 Project IDNumber : CPD3300 Date : January 2 st 2004 64
HEAT EXCHANGERS SUMMARY EQUIPMENT NR. : NAME : E6 Exhaust air cooler E7 C 4 + cooler E8 C04 Reboiler Substance Tubes : Shell () : Floating Head Floating Head Thermosyphon C 4 + nc 3 /C 3 = L.P. Exhaust Air Cooling W. Cooling W. Duty [kw] : 357? (Small) 5349 Heat Exchange area [m 2 ] : 50? (Small) 83 Number Series : Parallel : Pressure [bara] Tubes : Shell : Temperature In / Out [ o C] Tubes : Shell : Special Materials of Construction (2) : Other :.2 70.9/39.9 20.0/40.0 6.8 89.0/5.0? 25.0. L.P. = Low pressure steam 2. SS = Stainless Steel; CS = Carbon Steel. 60.9/60.9 90.0/33.5 Project IDNumber : CPD3300 Date : January 2 st 2004 65
PUMPS & COMPRESSORS SUMMARY EQUIPMENT NR. : P0 P02 P03 P04 P06 NAME : C0 Reflux pump Bottom C02 Bottom C03 Bottom C05 C04 Reflux pump Type : Centrifugal Centrifugal Centrifugal Centrifugal Centrifugal Number : 2 2 2 2 2 Medium transferred : nc 3 TEG/water TEG nc 3 nc 3 / Light ends Capacity [kg/s] : 6.67 0.4 [m 3 /s] : 33.4?? 0.04? Density [kg/m 3 ] : 427?? 469? Pressure [bara] Suct. / Disch. : 6.2/8.0??.0/20.0 24.8/25.0 Temperature In / Out [ o C] : 47.0/47.0?? 30.0/30.0 62.0/62.0 Power [kw] Theor. :?? Actual : 6.8?? 3.52 3.46 Number Theor. : Actual : 2 () 2 () 2 () 2 () 2 () Special Materials of Construction : MS casing MS casing MS casing MS casing MS casing Other : () One installed spare included. Project IDNumber : CPD3300 Date : January 2 st 2004 66
PUMPS & COMPRESSORS SUMMARY EQUIPMENT NR. : P07 P08 P09 P0 K0 NAME : C05 Reflux pump Discharge V02 pump LPG feed pump Bottom C0 R0effluent compressor Type : Centrifugal Centrifugal Centrifugal Centrifugal Centrifugal Number : 2 2 2 2 Medium transferred : C 3 = Water LPG + C 4 nc 3 /C 3 =/H 2 O Capacity [kg/s] : 23 3.29 9.7 0.39 9.0 [m 3 /s] : 0.25 38 0.09 07 8.8/.9 Density [kg/m 3 ] : 50 980 502 579 2.2/9.9 Pressure [bara] Suct. / Disch. : 0.0/0.5 2.0/5.0 7.0/20.0 6.8/20.0.55/2.2 Temperature In / Out [ o C] : 9.0/9.0 30.0/30.0 5.0/5.0 89.0/89.0 00.0/225.0 Power [kw] Theor. : Actual : 4.43 0.7.68 0.23 4857 Number Theor. : Actual : 2 () 2 () 2 () 2 () Special Materials of Construction : MS casing MS casing MS casing MS casing MS casing Other : () One installed spare included. Project IDNumber : CPD3300 Date : January 2 st 2004 67
EQUIPMENT NR. : NAME : PUMPS & COMPRESSORS SUMMARY K02 C02 Overhead compressor K03 C05 Overhead compressor K04 Air compressor T0 Expander overhead C0 T02 Expander Bottom C04 Type : Centrifugal Centrifugal Centrifugal Number : Medium transferred : nc 3 /C 3 = C 3 = Air nc 3 nc 3 /C 3 = Capacity [kg/s] : 5.66 34.0 3.55 6.0 5.35 [m 3 /s] : 0.68/0.35 6.45/3.75.25/7.33 0.44/3.64 0.37/0.69 Density [kg/m 3 ] : 22.9/44.5 20.77/35.78.205/.85 36.8/4.39 44.5/22.2 Pressure [bara] Suct. / Disch. :.8/25.2 0.0/8.0.0/2.35 6.2/2.2 24.0/ Temperature In / Out [ o C] : 30.0/75.0 9.0/54.0 5.0/02.0 47.0/20.0 00.0/75.0 Power [kw] Theor. : Actual : 873 530 97 0 39 Number Theor. : Actual : Special Materials of Construction : MS casing MS casing MS casing MS casing MS casing Other : Project IDNumber : CPD3300 Date : January 2 st 2004 68
EQUIPMENT NR. : NAME : PUMPS & COMPRESSORS SUMMARY T03 Expander propylene product Centrifugal Type : Number : Medium transferred : C 3 = Capacity [kg/s] : 8.68 [m 3 /s] : 0.42/0.46 Density [kg/m 3 ] : 20.7/8.7 Pressure [bara] Suct. / Disch. : 0.0/9.0 Temperature In / Out [ o C] : 9.0/5.0 Power [kw] Theor. : Actual : 32 Number Theor. : Actual : Special Materials of Construction : MS casing Other : Project IDNumber : CPD3300 Date : January 2 st 2004 69
DISTILLATION COLUMN SPECIFICATION SHEET EQUIPMENT NUMBER : C0 NAME : Depropanizer General Data Service : distillation Column Type : tray Tray Type : sieve Tray Number () Theoretical : 2 Actual : 26 Feed (actual) : 4 Tray Distance (HETP) [m] : 0.6 Tray Material : SS34 (2) Column Diameter [m] : 0.9 Column Material : CS (2) Column Height [m] : 8 Heating : reboiler (3) Process Conditions Stream Details Feed Top Bottom Reflux Temp. [ o C] : 2.7 : 47.4 : 89.2 : 47.4 Pressure [bara] : 7 : 6.7 : 6.8 : 6.7 Density [kg/m 3 ] : 489 : 37 : 436 : 37 Mass Flow [kg/s] : 6.4 : 6.0 : 0.4 : 5.8 Composition mol% wt% mol% wt% mol% wt% mol% wt% Propylene Propane Ethane Butene Butane 0.6 96.0.8 0.2.4 0.6 96.2.2 0.2.8 0.6 97.6.8 0.0 0.0 0.6 98..3 0.0 0.0 0.0 20.2 0.0 8.8 7.0 0.0 6.2 0.0 9.0 74.8 Trays (4) Number of sieve holes : Active Tray Area [m 2 ] : Weir Length [mm] : 0.77 Diameter of chute pipe / hole / [mm] : Column Internals Packing Type : Material : Volume [m 3 ] : Length [m] : Width [m] : Height [m] : () Tray numbering from top to bottom. (2) SS = Stainless Steel; CS = Carbon Steel. (3) Reboiler is E05; can operate with LP steam but also as heat exchanger. (4) Tray layout valid for whole column. Not Applicable Project IDNumber : CPD3300 Date : January 2th 2004 70
HEAT EXCHANGER SPECIFICATION SHEET EQUIPMENT NUMBER : E0 In Series : NAME : C0 Overhead Condenser In Parallel : none General Data Service : Condenser Type : Floating Head Position : Horizontal Capacity [kw] : 467 Heat Exchange Area [m 2 ] : 92 Overall Heat Transfer Coefficient [W/m 2 o C] : 300 Log. Mean Temperature Diff. (LMTD) [ o C] : 6.9 Passes Tube Side : 4 Passes Shell Side : 2 Correction Factor LMTD (min. 0.75) : 0.99 Corrected LMTD [ o C] : 6.7 Process Conditions Shell Side Medium : Propane/Ethane Mass Stream [kg/s] : Mass Stream to Condense [kg/s] : Average Specific Heat [kj/kg o C] : Heat of Evap. / Condensation [kj/kg] : Temperature IN [ o C] : Temperature OUT [ o C] : Pressure [bara] : Material : 3.8 5.8 292 47 47 6.2 CS () Tube Side Water 63.62 3.279 20.0 37.0 SS (). SS = Stainless Steel; CS = Carbon Steel. Project IDNumber : CPD3300 Date : January 2 th 2004 7
HEAT EXCHANGER SPECIFICATION SHEET EQUIPMENT NUMBER : E8 In Series : NAME : C04 Reboiler In Parallel : none General Data Service : Reboiler Type : Thermosyphon Position : Vertical Capacity [kw] : 5349 Heat Exchange Area [m 2 ] : 83 Overall Heat Transfer Coefficient [W/m 2 o C] : 300 Log. Mean Temperature Diff. (LMTD) [ o C] : 97.3 Passes Tube Side : Passes Shell Side : Correction Factor LMTD (min. 0.75) :.0 Corrected LMTD [ o C] : 97.3 Process Conditions Medium : Mass Stream [kg/s] : Mass Stream to Evaporize [kg/s] : Condense [kg/s] : Average Specific Heat [kj/kg o C] : Heat of Evap. / Condensation [kj/kg] : Temperature IN [ o C] : Temperature OUT [ o C] : Pressure [bara] : Material : Shell Side LP steam 5.34 5.34.88 2200 90.0 33.5 4.0 SS () Tube Side Propane / Propylene 24.7 24.7 798.0 6.7 (2) 6.9 (2) 25 CS () () SS = Stainless Steel; CS = Carbon Steel. (2) Actual temperature change is zero since propane/propylene evaporates Project IDNumber : CPD3300 Date : January 2 th 2004 72
HEAT EXCHANGER SPECIFICATION SHEET EQUIPMENT NUMBER : E5 In Series : NAME : Heat pump trim cooler In Parallel : none General Data Service : Heat Exchanger Type : Floating Head Position : Horizontal Capacity [kw] : 887 Heat Exchange Area [m 2 ] : 3088 Overall Heat Transfer Coefficient [W/m 2 o C] : 300 Log. Mean Temperature Diff. (LMTD) [ o C] : 0.2 Passes Tube Side : 4 Passes Shell Side : 2 Correction Factor LMTD (min. 0.75) : 0.94 Corrected LMTD [ o C] : 9.59 Process Conditions Shell Side Medium : Cooling water Mass Stream [kg/s] : Mass Stream to Evaporize [kg/s] : Condense [kg/s] : Average Specific Heat [kj/kg o C] : Heat of Evap. / Condensation [kj/kg] : Temperature IN [ o C] : Temperature OUT [ o C] : Pressure [bara] : Material () : 56.62 4.8 9.5 3 SS () Tube Side Propylene 56.62 4.75 4 30.0 7.0 SS () () SS = Stainless Steel; CS = Carbon Steel. Project IDNumber : CPD3300 Date : January 2 st 2004 73
CENTRIFUGAL PUMP SPECIFICATION SHEET EQUIPMENT NUMBER : P09 Operating : NAME : C0 LPG Pump Installed Spare : Service : LPG Transfer pump Type : Centrifugal Number : Operating Conditions & Physical Data Pumped liquid : LPG Temperature (T) [ o C] : 5 Density (ρ) [kg/m 3 ] : 502 Viscosity (η) [N s/m 2 ] : 2*0 8 Vapour Pressure (p v) [bara] : 7 at Temperature [ o C] : 5 Power Capacity (Φ v ) [m 3 /s] : 0.09 Suction Pressure (p s ) [bara] : 7 Discharge Pressure (p d ) [bara] : 9.7 Theoretical Power [kw] : 5.3 { = Φ v ( p d p s ) 0 2 } Pump Efficiency [] : 0.7 Power at Shaft [kw] :.7 Construction Details () RPM : 3500 Drive : Electrical Type electrical motor : Tension [V] : 380 Rotational direction : Clock Foundation Plate : Combined / Flexible Coupling : Yes Pressure Gauge Suction : No Pressure Gauge Discharge : Yes Min. Overpressure above p v /p m [bar] : 0. Pump House : MS Pump Rotor : HT Steel Shaft : HT Steel Special provisions : none Construction Materials (2) Nominal diameter Suction Nozzle [ ] : Discharge Nozzle [ ] : Cooled Bearings : No Cooled Stuffing Box : No Smothering Gland : Yes If yes Seal Liquid : Yes Splash Rings : Yes / No Packing Type : Mechanical Seal : Yes N.P.S.H. [m] : 3.7 Wear Rings : Shaft Box : Operating Pressure [bara] : 7.3 Test Pressure [bara] : () required to prevent any leakage; singlestage pump (2) MS = Mild Steel; HT Steel = High Tensile Steel Project IDNumber : CPD3300 Date : January 2th 2004 74
COMPRESSOR SPECIFICATION SHEET EQUIPMENT NUMBER : K03 Operating : NAME : C05 Overhead compressor Installed Spare : Service : Heat pump gas compressor Type : Centrifugal, polytropic Number : Operating Conditions & Physical Data Pumped liquid : Propylene Temperature In / Out (T) [ o C] : 9.0 / 54 Power Capacity (Φ v ) [m 3 /s] : 6.45 Pressure In [bara] : 0 Discharge Pressure (p d ) [bara] : 8 Actual Power [kw] : 530 Efficiency [] : 0.73 Construction material : CS Construction Material Project IDNumber : CPD3300 Date : January 2th 2004 75
VESSEL SPECIFICATION SHEET EQUIPMENT NUMBER : R0 In Series : NAME : Reactor In Parallel : none General Data Service : Reaction Type Position : Monolith : Vertical Internals : Honeycomb monolith Heating/Cooling medium : none Type : Quantity [kg/s] : Press./Temp. s [bara/ o C] : Vessel Diameter (ID) [m] : 3 Vessel Height [m] : 0 Vessel Tot. Volume [m 3 ] : 7 Vessel Material : SS (2) Other : Downward solid and gas flow through honeycomb monolith Process Conditions Stream Data Gas Feed Solid Feed Bottom Effluent Temperature [ o C] 378.9 676 596 Pressure [bara] 2.9 Density [kg/m 3 ].62 6689 98.9 Mass Flow [kg/s] 6.0 279 295 Composition mol% wt% mol% wt% mol% wt% Propylene Propane Hydrogen Water Methane Ethane Ethylene Butene Butane Carbon monoxide SOC () Spent SOC () 0.98 0.02 0.98 0.02 () SOC and Spent SOC fractions are solid phase fractions (2) SS = Stainless Steel.00.00 0.36 0.26 0.04 0.32 0.0 0.0 0.92 0.08 0.46 0.35 0.0 0.7 0.0 0.93 0.07 Project IDNumber : CPD3300 Date : January 2 st 2004 76
VESSEL SPECIFICATION SHEET EQUIPMENT NUMBER : R02 In Series : NAME : Riser regenerator In Parallel : none General Data Service : Reaction Type Position : Riser reactor : Vertical Internals : Open Heating/Cooling medium : none Type : Quantity [kg/s] : Press./Temp. s [bara/ o C] : Vessel Diameter (ID) [m] : 0.9 Vessel Height [m] : 5 Vessel Tot. Volume [m 3 ] : 9.53 Vessel Material : SS (2) Other : Upward bound solid and gas flow. Process Conditions Stream Data Gas Feed Solid Feed Top Effluent Temperature [ o C] 02 593 682 Pressure [bara] 2.35.35 Density [kg/m 3 ] 0.064 6689 72.52 Mass Flow [kg/s] 4 276 290 Composition mol% wt% mol% wt% mol% wt% Propylene Propane Hydrogen Water Oxygen Nitrogen Butane Carbon monoxide SOC () Spent SOC () 0.2 0.79 0.23 0.77 () SOC and Spent SOC fractions are solid phase fractions (2) SS = Stainless Steel 0.92 0.08 0.93 0.07 0.0 0.99.00 0.0 0.99.00 Project IDNumber : CPD3300 Date : January 2 st 2004 77
CYCLONE SPECIFICATION SHEET EQUIPMENT NUMBER : S0 Operating : 2 NAME : Reactor effluent separator Installed Spare : Service : GasSolid separation Type : High Flowrate Stairmand cyclone Number : 2 Operating Conditions & Physical Data Gas Solid : Propane/Propylene/Water/Carbonmonoxide : SOC/ Spent SOC Gas flowrate [kg/s] : 9.0 [m 3 /s] : 2.9 Gas density [kg/m 3 ] : 0.866 Solid flowrate [kg/s] : 276 [m 3 /s] : 0.279 Particle size [µm] : 60 Design pressure drop [Pa] : 500 Characteristic velocity [m/s] : 8.47 Temperature [ o C] : 596 Operation pressure [bara] :.9 Cyclone diameter [m] :.0 Cyclone height [m] : 4.04 Particle cut size [µm] : 6.2 Efficiency : 0.99 () Construction material : CS Construction Material () Remaining solids separated by additional filter Project IDNumber : CPD3300 Date : January 2th 2004 78