Anonymous
timer Asked: May 5th, 2020

Question Description

every think in the file , The separation of crude methanol (feed) to produce purified methanol (main product) and tar residue (bottom product) is accomplished by distillation. Crude methanol is pumped to the Distillation column, which vaporizes the methanol/tar mixture. Methanol rises to the top of the column and is condensed in a Condenser, cooled by cooling water before passing to a collection Drum. The methanol product is then pumped to large storage tanks prior to packaging. The bottom product from the distillation column is passed to a Reboiler, which reheats the liquid mixture by means of a heating coil and feeds it back to the distillation column. The bottom product from the Reboiler is pumped to another section of the plant for further processing. During cleaning cycles, the distillation column is inerted with nitrogen to prevent the formation of a flammable mixture inside the column. The process lines contain several control valves, labeled VX and pumps, labeled PX.

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ChE 312 Section 2 ​Term Project Due May 5, 11:59 PM Dr Cimino Spring 2020 In this project, you will analyze the separation process pictured below in ​Figure 1: Figure 1. Process Diagram for the distillation of crude methanol The separation of crude methanol (feed) to produce purified methanol (main product) and tar residue (bottom product) is accomplished by distillation. Crude methanol is pumped to the Distillation column, which vaporizes the methanol/tar mixture. Methanol rises to the top of the column and is condensed in a ​Condenser, cooled by cooling water ​before passing to a collection ​Drum​. The methanol product is then pumped to large storage tanks prior to packaging. The bottom product from the distillation column is passed to a ​Reboiler​, which reheats the liquid mixture by means of a ​heating coil and feeds it back to the distillation column. The bottom product from the ​Reboiler is pumped to another section of the plant for further processing. During cleaning cycles, the distillation column is ​inerted with nitrogen to prevent the formation of a flammable mixture inside the column. The process lines contain several control valves, labeled ​V​X​ ​and pumps, labeled ​P​X​. ChE 312 Section 2 ​Term Project Due May 5, 11:59 PM Dr Cimino Spring 2020 Tasks: 1. (20 pts) As mentioned above, the distillation column uses pure N​2​ for inerting cycles. a. Determine how many pressure purge cycles are necessary to inert the distillation tower to 10 PPM O​2​, if the vessel is a 200 ft tall x 20 ft wide cylinder. Assume the vessel is initially at atmospheric conditions (T = 68F). The N​2 source is 9 atmg, and is regulated down to 2 atmg before being introduced to the column. b. What is the total N​2​ [lbmol] used when purging the column? 2. (30 pts) Design relief systems for the Distillation Column: a. Pump P1 is rated to 400 psig and normally pumps 300 gallons of liquid methanol mixture per minute towards the distillation column. The pump experiences a typical back pressure of 50 psig from the vapor in the column. Determine the diameter of a spring-operated relief in [in] necessary to prevent damage to the pump, if it became deadheaded with an overpressure of 30 psig. Assume pure liquid methanol for your calculations. b. Describe the necessary design elements (pieces of equipment) for handling the effluent from the relief you designed in 2.a. (What are they? How will they work?) c. As mentioned in 1.a, the N​2 source is 9 atmg, and is regulated down to 2 atmg before being introduced to the column. The MAWP of the distillation column is 2.5 atmg. Determine the diameter of a spring-operated relief in [in] necessary to prevent damage to the column if the regulator fails. Note, the backpressure of this device will be 0.1 atmg and the inlet pipe from the inerting system to the column has an inner diameter of 6 inches. Assume atmospheric conditions are the same as they were for Task 1. d. Add drawings of the Reliefs you designed to the P&ID. 3. (20 pts) HAZOP a. Perform a HAZOP study on the distillation column for the variable column temperature, ​T​. Present your results in a table. b. Note, there are currently no safeguards in this process. For “recommended actions”, propose a control safeguard for this variable and update the P&ID illustrating its installation. 4. (30 pts) Risk Analysis a. Valve positioner failures are frequent sources of failure in processes. Calculate the probability P​V that any one of the valves associated with the reboiler will fail within a year of normal operation, using the information in Table 12-1 in the book. ​Note: this problem is equivalent to calculating the probability that ​V3​ fails OR ​V4​ fails. b. The MTBF for a positive displacement pump like ​P1 ​is 2.5 years. Determine the probability P​P+V​ that ​P1​ AND ​V1​ both fail simultaneously in a year’s time. c. Pump P3 is directly exposed to methanol vapor due to a cooling water failure, releasing 100,000 lb​m of methanol to the atmosphere. The event is partially mitigated by the opening of a relief valve on the pump. Use the LOPA method to estimate the TMEF and Risk Level for this scenario. Make sure to list any assumptions you have made when calculating your estimate! ChE 312 Section 2 ​Term Project Due May 5, 11:59 PM Dr Cimino Spring 2020 Project Report Guidelines: This project will be completed individually, and a final typewritten report will be submitted on Canvas. Your report should include the following, in order, in a single PDF file: 1. A cover page, including your name. 2. A table of contents, including page numbers for all of the tasks. 3. For each task, write an introductory paragraph explaining the task at hand, including the equations used, each of which must be typewritten. Make sure that each major equation has an equation number associated with it. For example: y = mx + b ( Eq.1) If the task involves figures (images/plots/etc...), make sure that the images have a label and brief description beneath them. For example: Figure 1. ​A kitten saying hello. Finally, make sure that you make direct references to numbered equations and figures in the body of your report. For example: “The equation of a line is given by (Eq.1) above. Also, there’s totally a picture of a cat in this report - see Figure 1.” Note: ​all of your calculations must be uploaded alongside the report. If you do not include your calculations you will receive no credit. This project will serve as your Final Exam for our course. We will devote several class periods to office hours, during which you’ll be able to ask individual questions, as they arise. ...
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