International Journal on Advances in Engineering Technology and Science

Volume: 2, Issue: 2, March-April 2016, e-ISSN: 2455-3131

Process Design for Hydrogenation of Palm Oil

Bhavika J. Parmar, Prof. S. M. Dutta, Prof. S. B. Thakore
Chemical Engineering Department, L D College of Engineering, Ahmedabad

Abstract— This paper presented here is study about jet

loop reactor technology for hydrogenation amination
alkylation. A Jet Loop Reactor consists of a reaction
autoclave, a circulation pump, a heat exchanger, a
venturi type ejector similar to Stirred Tank Reactor but
is arranged in a completely different way. Jet Loop
Reactor gives excellent performance on a faster
reaction scheme in the fully saturated hydrogenation
process in palm oil refinery.

Keywords— Jet Loop Reactor, Venturi Type Ejector, Fig. 1 Process flow design for Hydrogenation of Palm Oil
Hydrogenation Process, Palm Oil Recovery

II. APPLICATIONS OF JET LOOP REACTOR

I. INTRODUCTION The various industrial applications of Jet Loop Reactor

are as follows:
The Loop Reactor consists of a reaction autoclave, a
circulation pump, a heat exchanger and a venturi type  Hydrogenation of castor oil and fatty acids.
ejector. This system requires the same number of elements  Reduction of adiponitrile to hexamethylene diamine.
as that of a stirred vessel system, but is arranged in a
 Amination of aldehyde to amine.
completely different way.
 Low-pressure synthesis of methanol.
 Biological treatment of wastewaters.
The reaction vessel of a Loop Reactor does not need
baffles and is normally built with a larger L/D than the  Reduction of carbonyl group and acid chlorides.
stirred vessel and is thus lower in cost, especially for high-  Biodesulphurisation of petroleum
pressure reactions.
Advantages
The external heat exchanger are built as large as needed
and is not limited by the reactor’s working volume. The Jet Loop Reactor possess several benefits which makes
full heat exchanger area is available, also if the reactor is it substantial for various industrial applications, these
operated with reduced working volumes. benefits include; Firstly, it promotes a faster reaction rate
by exerting its higher mass transfer rate & mixing intensity
The circulation pump allows high power input per m3 as compare to continuous stirred tank reactor (CSTR).
working volume in those cases where high mass transfer Secondly, absence of moving parts in jet loop reactors
rates have to be achieved. eliminates the sealing problems and allows easier operation
at elevated pressure. Third, Length to diameter ratio of jet
Pump designs with mechanical seals that can be reactor is higher than same of agitated vessel, thus it
operated at pressures of up to 200 bar g. A unique impeller requires less cost particularly for high pressure reactions.
and a special hydrodynamic pump house profile allow Next, the external heat exchanger can be built as needed
pumping of liquids with a high solid content and high gas and can have accurate temperature control even if the
loads, without the aid of an inducer and thus avoiding reactor is operated with reduced working volumes.
abrasion problems where heterogeneous catalysts are used. Moreover, the maximum power input per unit volume is
often a limiting factor, especially for large reactors with an
agitator. Since there is no agitator in the jet reactor, this
The down flow Jet Mixer is a high performance gassing
limitation does not exist. Lastly, the circulation pump can
tool. The ability to finely disperse very small gas bubbles
provide very high power per m3 of working volumes if it is
to the liquid with a gas-liquid ratio between 0.5 and 2.0, or
required to achieve the desired mass transfer rate.
even more, makes this an ideal tool for gas-liquid reactions.

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Bhavika J. Parmar et al, Process Design for Hydrogenation of Palm Oil

III. DESIGN FOR HYDROGENATION OF PALM OIL IV. INPUT PARAMETERS FOR THE DESIGN

Hydrogenation of palm oil is carried out to produce The presented design of jet reactor incorporates charge
(hydrogenated fat) in the presence of nickel catalyst in of 1t palm oil 64 IV for a product specification of 10 IV,
batch reactor. In which iodine value of the mass is reduced 24 ̊C melting point (max).
from 64 to 10. The batch reactor has a jacket for heating
the initial charge with circulating hot oil. Cooling The following data is taken into consideration:
requirements are met by passing cooling water in internal
coils.  Average molar mass of soybean oil is 270
 Average chain length of fatty acids is 16.98
In a newly developed jet loop reactor, it is planned to  Average exothermic heat of reaction is 0.942 kcal /kg
complete the reaction in 3 hours by improving mass or 3.941 kJ /kg
transfer in the reactor and cooling the mass in external heat  Hydrogen feed rate is from 110 to 125 Nm3/h
exchanger, thereby maintaining near isothermal condition.  Bleed rate is 1 to 2 Nm3/h
Palm oil, having iodine value (IV) of 64 is to be Thermic fluid or oil is used as both, heating medium in
hydrogenated in the jet reactor at 5 bar g and 195 ̊ C. starting of reaction and cooling medium in running of
initially the charge is heated from 50 ̊ C to 160 ̊ C with the reaction.
circulating hot oil external heat exchanger.
Cooling water is available at 2 bar g and 32 ̊ C. A rise
Hydrogen is introduced in hot palm oil and pressure is of 5 ̊ C is permitted over here. Cooling water is used for
maintained in the reactor at 5 bar g. reaction is exothermic cooling the oil from 80 ̊ C to 70 ̊ C in oil cooler (HE-2) of
and the temperature of mass increases. Cold oil flow in the oil cycle.
external heat exchanger controls the temperature at 195 ̊ C
as per the requirement; IV reduction is desired up to 10 The following average properties of fluids for the
when the reaction is considered over. design are taken:
Thereafter hydrogenated mass is cooled to 110 ̊ C in
Properties Palm oil or Circulating oil
about 1.5 h before it is discharged to filter. 150 kg spent
hardened fat (thermic fluid)
nickel catalyst is charged with palm oil while fresh 5 to 10 Density, 0.856 0.71
kg nickel catalyst is charged at intervals in the reactor kg / L
under pressure. A bleed is maintained from the system to Specific heat, kJ 2.56 2.95
purge out water vapour and non-condensable. /(kg ̊ C)
Viscosity, mPa s 2.387 0.5
Thermal 0.1664 0.1
conductivity,
W/(m ̊ C)

V. DESIGN OF JET LOOP REACTOR

S.No Properties Design Equation Results
1 Volume of inside the jet reactor VL = π/4 Di 2 hi + inside volume of torispherical head 11.682 m3
hL= 1.5 Di
2 Diameter of Reactor VL = π/4 Di 2 hi +0.084672 Di3 + π/4 Di 2 SF 2.1 m
3 Total height of reactor H = 2*Di 4.2 m
Design of Shell and Tube Heat Exchanger used for cooling of Palm Oil (HE – 1)
4 Heat Duty Required Øc = average heat of reaction× IV reduction× kg of 196.99 kW or
reaction / mass reaction time 425628 kJ/h
5 Mean temp. difference ∆T=∆Tlm × Ft 117.1459 ̊ C
Ft = 1
6 Tube side mass velocity (kg/m2·s) Gt= utρ 1284 kg / m2s
ut=1.5 m / s
7 Tube side flow area (m2) at = m̊ / Gt 0.0126719m2
8 Total number of tube at= Nt/ NP × π/4. Di2 Number of tube side passes = 1 34
9 Tube side Reynold’s Number Ret = dt Gt/ µ 11886
10 Tube side Prandtl’s Number Pr=Cpµ /k 36
11 Tube side heat transfer coefficient hidi /kf=0.023 Re0.8Pr0.33(µ/µw)0.14 1028.339 W/m2 ̊ C
25.4 mm (1 in) OD and 31.75 (1.25 in) triangular pitch; Type of baffle =25 % cut segmental
Baffle spacing , Bs =150mm
12 Shell side flow area As = (Pt– do)/Pt × Ds × Bs 7.62 × 10 -3 m2

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 International Journal on Advances in Engineering Technology and Science
Volume: 2, Issue: 2, March-April 2016, e-ISSN: 2455-3131

13 Shell side mass velocity Gs = m̊s/ As 876.350 kg/m2s

14 Shell side velocity us = GS / ρ0 1.2342 m/s
15 Shell side equivalent diameter de= 1.1 / do (pt2 - 0.907do2) 18.3147 mm
16 Shell side Reynold’s numbers Re = de Gs/ µo 32100.175
17 Shell side Prandtl’s numbers Pr= CPoµ0 / k0 14.75
18 Shell side heat transfer coefficient hode / k0 = 0.36 Re0.55 Pr0.33 (µ/µw)0.14 1438.080 W / m2 ̊
C
Thermic fluid (oil) side fouling coefficients, hod=5000 W/m2 0C
Palm oil side fouling coefficients, hid=3000 W/m2 0C
Tube material = SS 316
Thermal conductivity of tube material kw = 16.26 W/m2 0C
19 Overall heat transfer coefficient 1/U0 = 1/h0 + 1/hod+ doln (do/di)) /2 × kw + ( do/ di) × 1 / 399.2075 W/m2 ̊ C
hod + ( do / di) × 1/hi
20 Heat transfer area required A = U0 Øc/∆Tm 4.21248 m2
21 Length of tube Lt= Ar/ nt π do 1.5526 m
22 Heat Transfer Area Provided A=Nt πdoL 5.4261 m2
Taking Length of tube = 3m
23 % excess heat transfer area (A / Ar-1) × 100 28.81 %
Re = 11886 and 25 % cur segmental baffles
Jf = 0.047
24 Tube side pressure drop ∆pr =Np [8 Jf (L / di) ( μ / μw)-m + 2.5] ρ ut2 / 2 7.323 kPa
25 Shell side pressure drop ∆ps= 8 Jf (DS / de ) ( L / Bs ) (ρ us2/ 2) (μ/μw)-m 53.97 kPa
Parameters of Shell and Tube Heat Exchanger used for preheating of Palm Oil before Reaction (HE -1)
26 Time required for heating the palm oil from 50 to 160 7600 s
27 K2 Constant UA / m̊CLH= 0.04530 1.0463
K2=e(UA/m̊CLH)
28 Temperature of heating medium ln [(t1-t1')/( t1-t2')] = m̊CLH/ m̊CLC( K2 - 1 / K2) Ѳ 321.605477 ̊ C
inlet, t1
Design of cooler of oil cycle (HE – 2)
BEM type fixed tube sheet
Tube side fluid : cooling water
Shell side fluid oil : (Thermic oil)
Cooling water inlet temp. = 32 ̊ C
Cooling water outlet temp. = 37 ̊ C
29 Cooling water flow rate ϕc = m̊CL∆t 33877.73 kg/h
30 Mean Temperature Difference ∆Tm=∆Tlm × Ft 40.04 ̊ C
R=[(t1-t2’)/( t2-t1’)] = 2
S = [(t2-t1) / ( t1-t1’)] = 0.1042
Ft=0.99
31 Volumetric flow rate of water Density of water at 34.5 0C =994.202 kg/m3 9.465 × 10-3 m3/h
V=
32 Tube side flow area at = V / ut 6.3102 × 10-3 m2
2
33 Number of tubes at = ( Nt/ Np) × (Π /4) di 66
Np = 2 (selected)
di = 15.748 mm
do = 19.05 mm
For 25.4 mm triangular pitch , Np= 2 , shell ID = 305mm
34 Tube side Reynold’s numbers Re = diut ρ/μ 32171.3
35 Tube Side Prandtl’s numbers Pr= CL µ/ k 4.867
36 Heat Transfer Coefficient of Tube hidi /k= 0.023 Re0.8 Pr0.33(µ/µw)0.14 6340.7 W/m2 ̊ C
Side Viscosity of water, μ = 0.73 cp, thermal conductivity
of water, k = 0.626 W/m ̊ C
37 Shell side flow area As =[(Pt– do )/Pt] × Ds × Bs 9.5312 × 10-3
Pt = 25.4, do = 19.05 Ds = 305 mm
Bs = 125
38 Shell side mass velocity Gs = m̊o/ As 700.62 kg/m2s
39 Shell side velocity us = Gs/ ρo 0.9867 m/s
40 Shell side equivalent diameter de= 1.1 / do (pt2 - 0.907do2) 18.25 mm

© 2016, IJAETS 3
Bhavika J. Parmar et al, Process Design for Hydrogenation of Palm Oil

41 Shell side Reynolds numbers Re = de Gs/ µ 25572.63

42 Shell side Prandtl’s number Pr= CP µ/ k 14.75
43 Shell side heat transfer coefficient hode / k0 = 0.36 Re0.55 Pr0.33 (µ/µw)0.14
44 Overall heat transfer coefficient Thermic fluid (oil) side fouling coefficient, hod= 5000 682.2290 W/ m2 ̊ C
W / m2 ̊ C
Tube material = mild steel
kW = 50 w / m2 ̊ C
1/U0 = 1/h0 + 1/hod+ doln (do/di)) /2 × kw + ( do/ di) × 1 /
hod + ( do / di) × 1/hi
45 Heat transfer area required A = U0 Øc/∆Tm 7.2110 m2

46 Tube length L r= A r/ n t π d o 1.82560 m

47 Area Available A=Nt πdoL 7.89984 m2
tube length L = 2 m
48 % excess heat transfer area (A / Ar-1) × 100 9.5598 %
49 Tube side pressure drop For Re = 32171.3 and 25 % cut segmental baffles 13547 kPa
Jf = 0.0035
∆pr =Np [8 Jf (L / di) ( μ / μw)-m + 2.5] ρut2/2
50 Shell side pressure drop ∆ps= 8 Jf (DS / de )( L / Bs) (ρ us2/ 2) (μ/μw)-m 31.791 kPa

REFERENCES
VI. DISCUSSION
[1] R.J.Malone, Herzog-Hart Corp., (1980). “Loop reactor
technology improves catalytic hydrogenation”, Boston, Mass.
The time required for hydrogenation of Palm Oil with [2] Ogawa.s,h.yamaguchi,s.tone and t.otake (1983). “Gas liquid
Continuous Stirred Tank Reactor takes 8 to 10 hours, while mass transfer in the jet reactor with liquid jet ejector”, J. H.
it takes 3 hours with Jet Loop Reactor. The design Chemical Engineering, Japan.
parameters for two heat exchangers in the process are well [3] N. N. Dutta And K. V. Raghavan, Chemical Engineering
calculated citing their benefits over Conventional method of Division, Regional Research Laboratory, 1986, Jorhat-785
Jacket or coil Heat transfer methods. The use of external 006 (India)
heat exchangers eliminates the disadvantage of limited [4] Dirix and van der wiele, (1990). “Mass transfer in jet loop
reactor volume. Furthermore, the ease of recycle of product reactor”, Akzo research laboratories Arnhem corporation
research, process technology department, Netherlands.
in the reactor loop increases the product consistency and [5] M. Velan, T. K. Ramanuj, (1992), “Gas - liquid mass
purity. The formation of smaller bubbles in the reaction transfer in a down flow jet loop reactor”, Department of
increases the surface area for reaction hence, promoting chemical Engineering, Indian Institute of Technology,
better reaction rates. The design calculations show a venturi Madras, India.
type compact jet reactor with Diameter of 2.1 m and having [6] Ch. Viala, B. S. Poncina, G. Wilda, N. Midouxa,
Length 4.2 m, i.e., L/D ratio as 2, is sufficient for the “Experimental and theoretical analysis of the hydrodynamics
hydrogenation reaction of 1 ton of Palm Oil. The reactor in the riser of an external loop airlift reactor”, A Laboratoire
volume thus obtained is 11.682 m3. des Sciences du Genie Chimique, CNRS-ENSIC-INPL 1,
rue Grandville, BP 451, F-54001 Nancy Cedex, France
[7] W. Ludwig A, R. G. Szafran, A. Kmiec, J. Dziak,
Further calculation shows that, two BEM type fixed tube “Measurements of flow hydrodynamics in a jet-loop reactor
Shell and Tube Heat Exchanger used for cooling and using PIV method”, Wroclaw University of Technology,
preheating of Palm Oil and for cooling of thermic fuel. The Faculty of Chemistry, Department of Chemical Engg.,
dimensions of first being, 34 tubes of 25.4 mm (1 in) OD, Wybrzeze Wyspianskiego St. 27,50-370 Wroclaw, Poland
3m long and 31.75mm (1.25 in) triangular pitch, 25 % cut [8] Thakore S. B., Bhatt. B. I., “Introduction To Process
segmental type baffle with 150mm and spacing, 1 pass. Engineering And Design”, 2nd Ed., Tata McGraw Hill, 2010
[9] Pangarkar, Vishwas, Govind, “Design Of Multiphase
The dimensions of second heat exchanger being, 66 Reactors”
tubes of 25.4 mm (1 in) OD, 2m long and 15.048mm (1 in)
ID and 19.04 OD triangular pitch, 25 % cut segmental type
baffle with 150mm and spacing, 2 pass, 305mm Shell Inner
Diameter.

The results of calculations meet the TEMA standards,

thus giving most suitable process design.

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