Fundamentals of Design (Student)
Fundamentals of Design (Student)
Fundamentals of Design (Student)
DESIGN DEVELOPMENT
Design Procedure:
Initial idea or plan
Define the scope of design and its specific objective
General specification and pertinent laboratory or Ch.E data and Infos from the
evaluation of design
Traditional Design Process
The Design Process
Final Design
Modern Design Process:
Types of Design:
Preliminary Design -Basis for determining whether further work should
be done and minimum time is required
Detailed Design -Cost-profit potential is specified, exact specification
not yet given and drafting work is minimized.
Firm Process Design -complete specifications are presented for all
components which include blue prints and sufficient infos to immediate
development for construction. Accurate costing should also be made.
Feed Preparation
Product Purification
Product Storage
Wastes
Sales
Design Documentation:
Calculation Sheets: Design calculations, costing, computer print-out
Drawings : Flow sheets, piping and instrumentation diagrams, layout
diagrams, site plans, equipment details, architectural
drawings, design sketches
Specification Sheet: All process equipment
Bases for Design Documentation:
Basis used in design computations, assumptions and approximations made.
(Material and Energy balance, yield, reaction rates, time cycle, % composition)
Computer Aided Design (CAD) methods for flowsheets, piping and
instrumentation, mechanical and civil work
Raw material and product specifications
(Quantity, quality and values of materials)
Operating Information ,data sheet, process and operating manuals
(Temperature, Pressure, Fuel to be used and other process conditions)
Specification Sheet for equipment
Flow Diagram: use to show the sequence of equipment and unit operation in the
overall process and it is a simplified visualization of manufacturing procedures which also
indicate the quantities of material and energy transfer.
Process Literatures:
Given the large scale of the application, the alkylbenzenesulfonates have been prepared by
many methods.[In the most common route, benzene is alkylated by long chain monoalkenes
(e.g. dodecene) using hydrogen fluoride as a catalyst. The purified dodecylbenzenes (and
related derivatives) are then sulfonated with sulfur trioxide to give the sulfonic acid. The
sulfonic acid is subsequently neutralized with sodium hydroxide.
This process involves reaction of dodecene with benzene in the presence of aluminum
chloride catalyst; fractionation of the resulting crude mixture to recover the desired boiling
range of dodecylbenzene; sulfonation of the dodecyl- benzene and subsequent
neutralization of the sulfonic acid with caustic soda; blending the resulting slurry with
chemical “builders”; and drying. Dodecene is charged into a reaction vessel containing
benzene and alu- minum chloride. The reaction mixture is agitated and cooled to maintain
the reaction temperature of about 115°F maximum. An excess of benzene is used to
suppress the formation of by-products. Aluminum chloride requirement is 5 to 10 wt% of
dodecene.
After removal of aluminum chloride sludge, the reaction mixture is fractionated to recover
excess benzene (which is recycled to the reaction vessel), a light alkylaryl hydrocarbon,
dodecylbenzene, and a heavy alkylaryl hydrocarbon.
Sulfonation of the dodecylbenzene may be carried out continuously or batch-wise under a
variety of operating conditions using sulfuric acid (100 percent), oleum (usually 20 percent
SO2), or anhydrous sulfur trioxide. The optimum sulfonation temperature is usually in the
range of 100 to 140°F depending on the strength of acid employed, mechanical design of
the equipment, etc.
Removal of the spent sulfuric acid from the sulfonic acid is facilitated by adding water to
reduce the sulfuric acid strength to about 78 percent. This dilution prior to neutralization
results in a final neutralized slurry having approximately 85 percent active agent based on
the solids. The inert material in the final product is essentially Na2SO4.
The sulfonic acid is neutralized with 20 to 50 percent caustic soda solution to a pH of 8 at
a temperature of about 125°F. Chemical “builders” such as trisodium phosphate,
tetrasodium pyrophosphate, sodium silicate, sodium chloride, sodium sulfate,
carboxymethyl cellulose, etc., are added to enhance the detersive, wetting, or other desired
properties in the finished product. A flaked, dried product is obtained by drum drying or a
bead product is obtained by spray drying.
A literature search indicates that yields of 85 to 95 percent have been obtained in the
alkylation step, while yields for the sulfonation process are substantially 100 percent, and
yields for the neutralization step are always 95 percent or greater. All three steps are
exothermic and require some form of jacketed cooling around the stirred reactor to
maintain isothermal reaction temperatures.
Benzene
Dodecene Water
𝐀𝐥𝐂𝐥𝟑
Water Sodium Dodecylbenzene
𝐇𝟐 𝐒𝐎𝟒 Sulfonate
𝐍𝐚𝐎𝐇
Benzene
Dodecene Alkylation Sulfonation
Separation Separation
𝐀𝐥𝐂𝐥𝟑 Reaction Reaction
Water
Neutralization
NaOH Purification Sodium Dodecylbenzene
Reaction
Sulfonate
Dodecene
Benzene Benzene
Dodecene
AlCl3
Dist. Dist.
Column Column
Reactor
H2 0
Settler
AlCl3
Sludge Spray
Dryer
Oleum NaOH
H2 O
Detergent
Separator Product
Heavy
Alkylated HC Spent Acid Builders
C. OPERATION DIAGRAM (QUANTITATIVE)
Benzene Q Q
Q Dodecylbenzene Q
Neutralization Liquid-liquid Sulfonation
Reactor Sulfonic Separator Reactor
Acid
Water
Detergent
Mixer Spray Dryer
Solution
Q
Other ingredients (Builders) Solid Detergent Product (to storage & packaging)
QUANTITATIVE FLOW DIAGRAM
Raw Materials Processing Products
AlCl 3
1,758 lbs.
Oleum Sulfonator
43,951 lbs.
(75,596 lbs.)
EQUIPMEN SYMBOLS
(Plant Design and Economics for Ch.E. by Peters and Timmerhaus)
EQUIPMENT SYMBOLS
(Plant Design and Economics for Ch.E. by Peters and Timmerhaus)
CHEMICAL ENGINEERING DESIGN by G. Towler and R. Sinnot
CHEMICAL ENGINEERING DESIGN by G. Towler and R. Sinnot
Specification Sheet of an equipment
• A datasheet or a document that summarizes the performance and other
technical characteristics of an equipment in sufficient detail to be used
by a design engineer.
• A properly prepared equipment specification will define the
performance requirements of the equipment, materials of construction,
fabrication methods and procedures, test and inspection requirements,
etc. Proper definition of these items will ensure that the equipment
supplied will meet the performance requirements of the plant.
• The specification is the primary means of communicating and
documenting the design, materials, fabrication, testing, etc.
requirements for the equipment
• Some of the problems associated with equipment can be traced back to
improper or poor specification of the equipment. Equipment purchased
without a detail specification relies on the vendor to supply their
standard equipment or to fabricate according to their own procedures.
When this is done, the supplied equipment may not perform as required
and be totally unsuitable for use in an acid plant environment