Fundamentals of Design (Student)

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Design – is a creative activity, a synthesis, the putting together, of ideas to achieve a desired

purpose. It is the conversion of an ill-defined requirement into a satisfied customer. In the


design of chemical process, the need is the public need for the product, the commercial
opportunity, as foreseen by the sales and marketing organization.

DESIGN DEVELOPMENT

Principal responsibilities of a Chemical Engineer:


 Design of chemical Plants
 Construction of Chemical Plants
 Operation of Chemical Plants

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

Objective (Design Specification)

Collection of Data, Physical Properties,


And Design Methods

Generation of Possible Designs

Selection and Evaluation


(Optimization)

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.

Three Types of Chemical Engineering Project / Design Works:


 Modification, and Additions, to existing plant; usually carried out by the plant
design group.
 New production capacity to meet growing sales demand, and the sale of
established processes by contractors. Repetition of existing designs, with only
minor design changes.
 New processes, developed from laboratory research, through pilot plant, to a
commercial process. Even here, most of the unit operations and process
equipment will use established designs.
ANATOMY OF A CHEMICAL MANUFACTURING PROCESS

Storage of Raw Materials

Feed Preparation

Recycle of unreacted material


Reaction

By - products Product Separation

Product Purification

Product Storage
Wastes

Sales

Production of Biodiesel using an Alkaline Catalyst


Two (2) Phases of Design work in Chemical Manufacturing process
 Phase 1 Process design, which covers the steps from the initial selection of
the process to be used, through the issuance of the process flow sheet, and include
the selection, specification, and chemical engineering design of equipment. The
work will be mainly done by chemical engineers. This may also include the
preparation of the piping and instrumentation diagram.
 Phase 2 The detailed mechanical design of equipment, the structural, civil
and electrical design; and the specification and design of the ancillary services. This
work will the responsibility of special design groups , having expertise in the whole
range of engineering discipline.

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

General Classification of Equipment:


 Columns ( Separation /Purification equipment)
 Vessels (Handling/Preparation/ Storage Equipment/ Separation/Purification)
 Reactors (Reaction Equipment)
 Heat Exchangers and Furnaces (Heat Transfer Equipment)
 Pumps, compressors and transport equipment
 Instrument (Process Control Equipment)
 Special Equipment ( Purification, separation)

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.

General type of flow diagram:


 Qualitative -indicates flow of material, unit operations involved,
equipment necessary and operating information such as temperatures and
pressures .
 Quantitative -shows quantities of materials required for process operation
 Combine-detail -shows the qualitative flow process and serves as a base
reference for giving equipment specifications, quantitative data and simple
calculations. It also shows location of temperature and pressure regulators and
indicators as well a local critical control valves and special instrument with
corresponding defined code numbers.

Flow Diagram Synthesis and Development


A. Input/Output Diagram
B. Function Diagram
C. Operation Diagram
D. Final flowsheet Diagram
Manufacture of Sodium dodecylbenzenesulfonate (SDS)
Sodium dodecylbenzenesulfonate is a series of organic compounds with the formula
C12H25C6H4SO3Na. It is a colourless salt with useful properties as a surfactant. It is usually
produced as a mixture of related sulfonates. It is a major component of laundry detergent.
Most sodium dodecylbenzenesulfonates are a member of
the linear alkylbenzenesulfonates, meaning that the dodecyl group (C12H25) is unbranched.
This dodecyl chain is attached at the 4-position of the benzenesulfonate group. Linear
dodecyl-4-benzenesulfonate anions can exist in six isomers (ignoring optical isomers),
depending on the carbon of the dodecyl group that is attached to the benzene ring. The
isomer shown below left is 4-(5-dodecyl) benzenesulfonate (4 indicating the position of
the benzene ring, 5 indicating the position on the dodecane chain). Branched isomers, e.g.
those derived from tetramerized propylene, are also known (below right) but are not as
widely used because they biodegrade too slowly.

4-(5-Dodecyl) benzenesulfonate, a linear dodecylbenzenesulfonate

A branched dodecylbenzenesulfonate, which has been phased out in developed countries.


Further complicating the description of the commercial materials, sodium
dodecylbenzenesulfonate is one component of a mixture of compounds that feature
variable alkyl chain lengths aside from C12, mainly ranging from C10-C16.
Dodecylbenzenesulfonate is considered representative of the entire class of compounds,
since the mean number of alkyl carbon atoms in the alkylbenzenesulfonates is 12.

IUPAC Name Sodium Dodecylbenzene Sulfonate


Other Names Dodecylbenzenesulfonic acid,
Sodium salt;
Linear alkylbenzene sulfonate (LAS)

Molecular Formula C18H29NaO3S


Molar Mass 348.48 g mol−1
Solubility in Water 20%
Environmental Consideration:
Biodegradability has been well studied, and is affected by the isomerization (branching).
The salt has an LD50 of 2.3 mg/liter for fish, about 4x more toxic than the branched
tetrapropylenebenzenesulfonate. It is however biodegraded more rapidly. Oxidative
degradation initiates at the alkyl chain.

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.

A. INPUT/OUTPUT DIAGRAM (QUALITATIVE)

Benzene
Dodecene Water
𝐀𝐥𝐂𝐥𝟑
Water Sodium Dodecylbenzene
𝐇𝟐 𝐒𝐎𝟒 Sulfonate
𝐍𝐚𝐎𝐇

B. FUNCTION DIAGRAM (QUALITATIVE)


Recycle 𝑯𝟐 𝑺𝑶𝟒 Recycle

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

Dist. Reactor Reactor Hot


Column H2 O H2O Air

H2 O
Detergent
Separator Product

Heavy
Alkylated HC Spent Acid Builders
C. OPERATION DIAGRAM (QUANTITATIVE)

Recycle (Benzene + Dodecene)

Benzene Q Q

Dodecene Alkylation Solid-Liquid Fractional


Reactor Separator Distillation
𝐀𝐥𝐂𝐥𝟑 Q

𝐀𝐥𝐂𝐥𝟑 𝐒𝐥𝐮𝐝𝐠𝐞 Heavy Alkylates


NaOH Solution

Q Dodecylbenzene Q
Neutralization Liquid-liquid Sulfonation
Reactor Sulfonic Separator Reactor
Acid

Sodium Spent Acid 𝐇𝟐 𝐒𝐎𝟒


Dodecylbenzene
Sulfonate

Water
Detergent
Mixer Spray Dryer
Solution
Q

Other ingredients (Builders) Solid Detergent Product (to storage & packaging)
QUANTITATIVE FLOW DIAGRAM
Raw Materials Processing Products

Benzene Alkylator AlCl3 Sludge


11,145 lbs. 1,758 lbs.
(38,677 lbs.)
1,114
Dodecene Fractionators Heavy Ends
24,016 lbs. 2,402 3,516 lbs.
(31, 645 lbs.)

AlCl 3
1,758 lbs.

Oleum Sulfonator
43,951 lbs.
(75,596 lbs.)

Water Separator 78 % Spent Acid


8,570 lbs. 36,862 lbs.
(47,314 lbs.)
20 %
Caustic Neutralizer
55,085 lbs.

(102,399 lbs.) Water


52,399 lbs.

Spray Dryer Detergent


50,000 lbs.
FINAL PROCESS FLOW DIAGRAM (COMBINED-DETAIL)

MANUFACTURE OF SODIUM DODECYL SULFONATE


(A BIODEGRABLE DETERGENT)
EQUIPMENT/PLANT STANDARD CODE: (Perry’s Ch.E Handbook, 7th Edition)
EQUIPMENT COST CODE:

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

Specification Sheet for equipment should show the following:


1. Identification
2. Function
3. Operation
4. Materials handled
5. Basic design data
6. Essential controls
7. Insulation requirements
8. Allowable tolerances
9. Special information and details pertinent to the particular equipment,
such as materials of construction including gaskets, installation,
necessary delivery date, supports, and special design details or
comments

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