MANUFACTURE OF NITROTOLUENE

FROM TOLUENE

Submitted by
M.SRIRAM
810016239041
PETROCHEMICAL TECHNOLOGY
6.ENERGY BALANCE

6.1THE MIXER
Inlet temperature=15⁰C
Outlet temperature=30⁰C
Reference temperature=25⁰C

Components Flow Specific Temp Heat

rate heat Q
capacity(cp)
Kg/h KJ/kgK °C kJ/h
Heat entering the
mixer

Nitric acid 1151 1.72 15 19797.2

Sulfuric acid 2338 1.38 15 32264.4
Cycle acid 10820 1.9256 20 104174.96

Total input=156236.5
Heat leaving the
mixer

Mixed acid 14309 1.9256 30 137767.052

Total Output = 137767.052
6.2REACTOR

Reference temperature=25⁰C
Inlet temperature=30⁰C
Outlet temperature=35⁰C

INPUT
Component Flow rate Specific heat Temp Heat (Q)
Kg/h capacity (cp) ⁰C kJ/h
KJ/KgK
Toluene 1000 1.13 15 11300
Mixed acid 14309 1.9256 30 137767.052
Total input=149067.052

OUTPUT
Component Flow rate Specific heat Temp Heat (Q)
Kg/h capacity (cp) ⁰C kJ/h
KJ/KgK
Nitrated product 15309 1.425 35 218153.25
Total output=218,153.25

6.3COOLER
Inlet temperature=50⁰C
Outlet temperature=20⁰C
Reference temperature=25⁰C
INPUT
Component Flow rate Specific heat Temp Heat (Q)
Kg/h capacity (cp) ⁰C kJ/h
KJ/KgK
Spent acid 10820 1.9256 50 416699.84

OUTPUT
Component Flow rate Specific heat Temp Heat (Q)
Kg/h capacity (cp) ⁰C kJ/h
KJ/KgK
Cycle acid 10820 1.9256 20 104174.96

6.4WASH TOWER COMPLEX

Inlet temperature=50⁰C
Outlet temperature=15⁰C
Reference temperature=25⁰C
INPUT
Component Flow rate Specific heat Temp Heat (Q)
Kg/h capacity (cp) ⁰C kJ/h
KJ/KgK
Mononitrotoluene 1488 1.8 50 66690

OUTPUT
Component Flow rate Specific heat Temp Heat (Q)
Kg/h capacity (cp) ⁰C kJ/h
KJ/KgK
Washed 1451 1.8 15 26118
Mononitrotoluene
6.5 DISTILLATION COLUMN
Inlet temperature=15⁰c
Outlet temperature=92⁰c
Reference temperature=25⁰c

INPUT
Component Flow rate Specific heat Temp Heat (Q)
Kg/h capacity (cp) ⁰C kJ/h
KJ/KgK
Washed 1451 1.8 15 26118
Mononitrotoluene
Steam 40psi 510 1.9 130 101745
Total input=127863
OUTPUT
Component Flow rate Specific heat Temp Heat (Q)
Kg/h capacity (cp) ⁰C kJ/h
KJ/KgK
Mononitrotoluene 1367 1.8 92 164.8602
Mononitrotoluene 0.058 1.8 120 9.918
Residue
Fore runnings 0.027 1.8 15 0.486
Steam 510 1.9 130 101745
Total output=101920.264

6.6 CONDENSER
The vapour rising to the condenser amounts is
=1367/137
=9.97kgmol/h
The latent heat λv=49825.3kJ/kgmol
Therefore condenser loading = m*λv
=9.97*49825.3
=497161.935kJ/h
The water is used @ 18⁰C and 30⁰C
=497161.935/(30-18)*4.187
=7915kg/h
Inlet temperature=18⁰C
Outlet temperature=30⁰C
Reference temperature=25⁰C
INPUT
Component Flow rate Specific heat Temp Heat (Q)
Kg/h capacity (cp) ⁰C kJ/h
KJ/KgK
Mononitrotoluene 1367 1.8 92 164.8602
Vapour
Cooling water 7915 4.187 18 237980.735
Total input=238145.595
OUTPUT
Component Flow rate Specific heat Temp Heat (Q)
Kg/h capacity (cp) ⁰C kJ/h
KJ/KgK
Mononitrotoluene 1367 1.8 92 164.8602
Liquid
Cooling water 7915 4.187 30 331401.05
Total output=331565.915
6.7 RESIDUE COOLER

Inlet temperature=120⁰c
Outlet temperature=40⁰c
Reference temperature=25⁰C

INPUT
Component Flow rate Specific heat Temp Heat (Q)
Kg/h capacity (cp) ⁰C kJ/h
KJ/KgK
Mononitrotoluene 58 1.8 120 9918
Residue
Cooling water 7915 4.187 15 331401.05
Total input=341319.05

OUTPUT
Component Flow rate Specific heat Temp Heat (Q)
Kg/h capacity (cp) ⁰C kJ/h
KJ/KgK
Mononitrotoluene 58 1.8 40 1566
Residue
Cooling water 7915 4.187 20 165700.525
Total output=167266.525

6.8 DISTILLATION COLUMN 2

6.8.1 FEED PREHEATER
Inlet temperature=92⁰C
Outlet temperature=133⁰C
Reference temperature=25⁰C

INPUT
Component Flow rate Specific heat Temp Heat (Q)
Kg/h capacity (cp) ⁰C kJ/h
KJ/KgK
Mononitrotoluene 1367 1.8 92 164860
Feed
Steam 90psi 83.58 1.9 180 24614
Total input=189474

OUTPUT
Component Flow rate Specific heat Temp Heat (Q)
Kg/h capacity (cp) ⁰C kJ/h
KJ/KgK
Hot 1367 1.8 133 265744.8
Mononitrotoluene

Steam 90psi 83.58 1.9 160 21438.27

Total output=287182.8

6.8.2 PRODUCT COOLER

Inlet temperature=133⁰C
Outlet temperature=35⁰C
Reference temperature=25⁰C
INPUT
Component Flow rate Specific heat Temp Heat (Q)
Kg/h capacity (cp) ⁰C kJ/h
KJ/KgK
Hot 803 1.8 133 156103.2
Mononitrotoluene

Cooling water 7915 4.187 15 331401.05

Total input=487504.7

OUTPUT
Component Flow rate Specific heat Temp Heat (Q)
Kg/h capacity (cp) ⁰C kJ/h
KJ/KgK
Cool 803 1.8 133 14454
Mononitrotoluene

Cooling water 7915 4.187 35 331401.05

Total output=345855.05

6.8.3 RESIDUE COOLER

Inlet temperature=120⁰C
Outlet temperature=80⁰C
Reference temperature=25⁰C
INPUT
Component Flow rate Specific heat Temp Heat (Q)
Kg/h capacity (cp) ⁰C kJ/h
KJ/KgK
Mononitrotoluene 483 1.8 120 82593
Residue

Cooling water 7915 4.187 15 331401.05

Total input=413994.05
OUTPUT
Component Flow rate Specific heat Temp Heat (Q)
Kg/h capacity (cp) ⁰C kJ/h
KJ/KgK
Residue 483 1.8 80 47817
Mononitrotoluene

Cooling water 7915 4.187 35 331401.05

 Total output=379218.05

6.8.4 REBOILER
INPUT
Component Flow rate Specific heat Temp Heat (Q)
Kg/h capacity (cp) ⁰C kJ/h
KJ/KgK
Mononitrotoluene 483 1.8 133 93895
feed

Reflux 4015 1.8 117 664884

Steam 510 1.9 160 130815
Total input=889594

OUTPUT
Component Flow rate Specific heat Temp Heat (Q)
Kg/h capacity (cp) ⁰C kJ/h
KJ/KgK
Mononitrotoluene 4498 1.8 117 744868
vapour

Mononitrotoluene 483 1.8 150 108675

residue
Condenste 510 160 1.9 130815
Total output=984358

DESIGN OF EQUIPMENTS
 DESIGN OF REACTOR

Continuous Stirred Tank Reactor:

 Stirred tank reactors consist of a tank fitted with a mechanical agitator and a cooling jacket
or coils. They are operated as batch reactors or continuously. Several reactors may be used
in series.
 The stirred tank reactor can be considered the basic chemical reactor, modelling on a large
scale the conventional laboratory flask. Tank sizes range from a few filters to several
thousand liters.
 They are used for homogeneous liquid-liquid and liquid-gas reactions, and for reactions that
involve finely suspended solids, which are held in suspension by the agitation.
 As the degree of agitation is under the designer’s control, stirred tank reactors are
particularly suitable for reactions where good mass transfer or heat transfer is required.
 When operated as a continuous process, the composition in the reactor is constant and the
same as the product system, and, except for very rapid reactions, this will limit the
conversion that can be obtained in one stage.
 The power requirements for agitation will depend on the degree of agitation require and will
range from about 0.2kW/m3 for moderate mixing to 2kW/m3 for intense mixing.
Design Procedure:

 Volume of the reactor is calculated using volumetric flow rate and residence time.
 Diameter of the reactor is found from V= π r 2L
 Diameter of the agitator Da and baffle width are calculated from the diameter of the
reactor.
 Length and height of the blade are found using agitator diameter.
 Diameter of the hub is calculated using the relation Dh=Da-2L
 Diameter of the shaft is calculated from the diameter of the hub.
 The shaft power required to drive an agitator is found using the relation
PA=NP*row*N3*Da5
 Thickness of the cylindrical part is determined using the formula t=pD/2fj+ C
Design Calculation

Calculation of Reactor Volume:

Residence time τ= 2h
Volumetric flow rate v0 = (1000/867)+(14309/1670)
= 1.153+8.568
v0 = 9,72 m3/h of feed
Volume of the feed V= v0*τ
= 2*9.72
V = 19.44 m3
Let us assume that the reactor contains 80% liquid
Actual Volume of the Reactor = 19.44/0.8
V= 24.3 m3 of the Reactor

Calculation of reactor Diameter:

V= π r 2L = 24.3m3
L =2D
Diameter D = 1.28m
Length L = 1.3711m

Design of Agitator:
Diameter of reactor D = 1.28 m
Diameter of agitator Da = D/3
Da = 0.426
Baffle Width:
J = D/12
J = 1.28/12
J= 0.106 m
Length of the Blade:
L=Da/4
L= 0.1065 m
Height of the Blade:
W= Da/5
W=0.426/5
W= 0.0852m
Height of the liquid:
Height of the liquid= H=D= 1.28m
Diameter of the Hub:
Dh= Da – 2L
Dh= 0.426 - 2*(0.1065)
Dh = 0.213m
Diameter of the Shaft:
Ds=Dh/2
Ds= 0.213/2
Ds= 0.1065
Calculation of the cylindrical part:
Thickness t = (p D / 2 f j) + C

Where operating pressure = 1.033 kg/cm2

Design pressure p = 1.033*1.1 = 1.1363 kg/cm2

Diameter of the vessel D = 1.28 m = 1280mm

Joint efficiency J = 0.85

Permissible shear stress f = 1350 kg/cm3

Corrosion allowance c = 2mm

Thickness of the vessel t= ((1.1363*1280)) / (2*1350*0.85))+2

t =(1454/2295)+2

t = 2.63mm
Design Summary:

1. Diameter of reactor = 1.28 m

2. Volume of reactor = 24.3m3
3. Height of the reactor = 1.3711 m
4. Diameter of the agitator = 0.426m
5. Baffle width = 0.106 m
6. Length of the blade = 0.1065m
7. Height of the blade = 0.0852m
8. Diameter of the hub = 0.213 m
9. Diameter of the shaft = 0.1065 m
10. Thickness of the vessel = 2.63 mm

DESIGN OF CONDENSER

Inlet temperature of cooling water = 18oC

Outlet temperature of cooling water = 29.4oC
Liquid inlet Temperature =92o C
Liquid outlet Temperature = 92 o C

Mononitrotoluene to be condensed, m =25tons/day

=1367.67 kg/h.

= 0.379 kg/s
7
Latent heat of vaporization of MNT, λv,MNT = 4.6 x 10 J/kmol.
= 335.766 kJ/kg
HEAT BALANCE

Qw = QMNT
mw * Cpw (∆T)w = mMNT * λMNT
mw = 0.379 x 335.766 x103
=1.45kg/s
Q = (m * λ)MNT

3
= 0.379 x 335.766 x 10
= 95827.73 W
LMTD CALCULATIONS

LMTD = (T1- t2) – (T2 - t1) / ln [(T1- t2)/(T2 - t1)]

=68.141⁰C
NTU = to – ti / LMTD
= 29.4 - 18 / 68.14
=0.56
The correction factor is found to be 0.29

Therefore, Tm = FT LMTD
= 0.29 * 68.14
= 19.78 °C
ROUTING OF FLUIDS

Shell side Condensing vapors of

Mononitrotoluene

Tube side cooling water

ESTIMATED HEAT TRANSFER AREA

Assume (Uo) = 200 W/m2°C

A=Q/U(LMTD)
=93420/200*19.78
=2.4212 m2
Using 5/8 inch OD, BWG tubes: OD = do = 0.015875 m
ID = di = 0.012573 m

Heat Transfer area = a = πdo = π * 0.015 = 0.049 m2/m length

Length, L = 6ft = 1.77 m

Allowing 50 mm thickness for tube sheets

Le = 1.72 m

Heat transfer area for one tube,A1 = 3.14 * 0.015 * 1.72

= 0.0887 m2/tube
Number of tubes, Nt = (A / A1) = 2.4212 / 0.0887 = 28 tubes.

Taking number of tubes = Nt= 48

SHELL ID
Shell ID = Lb + Cs
Nt= C{(Lb/Pt)2}
48= 0.86(Lb/0.025)2
Lb= 0.18677 = 186.77 mm
Cs = 93mm
Shell ID = 279.77 mm
TUBE PASSES
(π/4)(Di)2*(Nt/Np)*(v)= ⱱ
(π/4)*(0.0125)2*(48/Nt)*(1.5)= 1.45/1000
Number of passes = Np = 2
Therefore
2
A corrected = 48 x 0.0887 = 4.2576 m

TUBE SIDE

Properties of water at 32oC

3
Density = ρ t = 995.026 kg/m

Viscosity = μ t = 8.57 * 10-4 N/M2

Thermal Conductivity = К t =0.614 W/mK
Specific heat = CPt = 4.18 kJ/Kg K

Total flow area,

2 2
At = (Nt/Np) πdi/4 = (48/2) * [π * (0.012573) / 4] = 0.0029797 m

hi di / кt = 0.023 (Re)0.8(Pr)0.33(µ/µw)0.33

0.8 0.4
hi = (0.614/0.012573) x 0.023 x (7114.9) (5.83)

hio=(3469.04)(0..0158)

hio= 2744.5 W/m2 oC

OVERALL HEAT TRANSFER COEFFICIENT

Wall thickness, x = 0.015875 – 0.01257

-3
= 3.3 x 10 m

К w = 45 W/moC (for steel)

D w = [0.015875 + 0.012573] / 2 =0.014224 m
-4
Dirt factor, Rw = 5.823 x 10 m/JsoC
 2
(Uo)d = 213.7 W/m °C
Area available, Aa = 3.14*Do*Le*Nt
=3.14*0.015*1.72*48
=3.88m2

% excess area = {(3.88 – 3.45)/3.45} * 100

=12.46%

DESIGN SUMMARY

Heat duty of the heat exchanger = 95.827 kW

Area required for heat transfer = 3.45 m2
Area available for heat transfer = 3.88m2
Percentage Excess area = 12.46 %
Number of tubes = 48
Number of passes on tube side = 2
Number of passes on shell side = 1
Shell ID = 254 mm
Film heat transfer coefficient tube side = hio = 2744.5 W/m2 ºC
Film heat transfer coefficient shell side = hc = 555.64 W/m2 ºC