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TABLE CONTENTS
1.1
1.2
1.3
1.4
1.5
Introduction
Design Pressure and Temperature
Materials of Construction (MOC)
Maximum Allowable Stress
Welded Joint Efficiency and
Categories
1.6 Corrosion Allowance
1.7 Design Loads
1.8 Minimum Practical Wall Thickness
1.9 Vessel Supports
2.0 Flanged Joints
2.1 Design of Fluidized Bed Reactor
2.2 Conclusion
2.3 References
Construction
2
5
7
9
14
17
18
26
33
40
42
44
45
Acrylic Acid
Prop-2-enoic acid
acroleic
ethylenecarboxylic
acid,
acid,
propene
C3H4O2
72.06266 g/mol
colourless liquid
1.051 g/mL
14 C
141 C
The main production of the process was to produce acrylic acid. The
side products for this production were water, acetic acid and carbon dioxide.
The production rate for this process was to produces 50,000 metric tons per
3
Temperature 251.65
(Upennedu, 2016)
= 251.65
115%
= 289.42
= 552.96
(Upennedu, 2016)
= 251.65
110%
= 276.84
= 530.307
Acrylic acid is a substance that will react readily with free radicals and
electrophilic or nucleophilic agents such as (example). It might be polymerize
in the presence of acids such as sulphuric acid, chlorosulfonic acid, alkalis
such as ammonium hydroxide, amines such as ethylenediamine, iron salts,
elevated temperature, light peroxide are formed when oxygen was sparged
into acrylic acid. Moreover, the presence of oxygen is required for the
stabilizer to function effectively. Besides that, acrylic acid should not be
handled under an inert atmosphere. (Kimyasanalcom, 2016)
Polymerization of acrylic acid can occur of it is rethawed under
inappropriate temperature and it is a strong corrosive agent to many metals
such as unalloyed steel, copper and brass. (Kimyasanalcom, 2016). Besides
that, metal ions can initiate polymerization and acrylic acid, especially in the
presence of water, will easily corrode carbon steel and similar metals.
Corrosion and subsequent polymerization initiated by metal ions cannot only
be caused by inappropriate material but also by accidental introduction of
incompatible metals into the system such as gaskets, maintenance tools,
carbon steel bolts and nuts. (European basic acrylic monomer group, 2012)
Thus, it is best choice to use stainless steel (AISI Type 304L) as the
material for fluidized bed reactor. This type of stainless steel is chosen
because it can withstand the design pressure and temperature. It can be
exposed continuously without appreciable scaling about 899 . Besides
that, it also have very good draw ability and the combination of low yield
strength and high elongation permits successful forming of complex shapes.
7
Analysis of stresses
For 10% design,
P = 0.33 N/mm2
t= 10.8mm
Di = 3600 mm
Pressure Stresses
Longitudinal stress, L = PDi / 4t
L =
(0.33)(3600)
4 (10.8)
= 27.5 N/mm2
(0.33)(3600)
= 55 N/mm2
2(10.8)
Wz / [ (Di + t) t ]
w =
173.641000
(3600+10.8)(10.8)
= 1.417 N/mm2
Bending stresses
Do = Di + 2t
Do = 3600 + 2(10.8) = 3621.6 mm
b = (M/Iv)[ Di/2 + t]
740000
3600
+10.8 = 6.71*10-3 N/mm2
b = ( 1.9971011 )(
2
Iv =
64
( Do4 Di4 )
Iv =
64
Longitudinal Stress
10
26.09 N/mm2
Upwind
26.076 N/mm2
Downwind
t= 11.2mm
P = 0.345 N/mm2
Di = 3600 mm
(N/mm2)
L = 27.723
h = 55.446
2. Dead weight stresses
w = 1.409
3. Bending stresses
b = 0.00647
4. Longitudinal Stress
(upwind)z = 26.320
(downwind)z = 26.308
Greatest difference between 29.138
principal stresses
Analysis of stresses
1. Pressure Stresses
12
26.320 N/mm2
Upwind
26.308 N/mm2
Downwind
13
Pi = 3.3 bar
Ti = 276.837 C which is equivalent to 530.3066 F
Interpolation
14
Maximum
(F)
Stress (ksi)
500
12.9
530.3066
700
11.7
Allowable
S 12.9
530.3066 500
11.7 12.9
700 500
S 12.718ksi
S 12.718 103 psi
1Pa
0.000145 psi
S 8.77110 7 Pa
15
Pi = 3.45 bar
Ti = 289.43 C which is equivalent to 552.956 F
Interpolation
Temperature
Maximum
(F)
Stress (ksi)
500
12.9
552.956
700
11.7
Allowable
S 12.9
552.956 500
11.7 12.9
700 500
S 12.582ksi
S 12.582 103 psi
1Pa
0.000145 psi
S 8.6772 107 Pa
Corrosion Allowance = 4 mm
t=11.2mm
Wv =
240CwDm(Hv+0.8Dm)t
Cw = 1.08
Dm = (Di + t
10-3)
= 3.6m + (11.2
10-3m)
= 3.61m
Hv = 10m
t = 11
3.61m](11.204
10-3m)
Rm
T
70.866
0.441
= 160.69
=0.875(
ro
)
Rm
8
= 0.875 ( 70.866
= 0.099
Based on the appendix (graph for Nozzles load),
=150,000
( 2TP )( R T2 )
=[
2 ( 50.038 )
0.441
[70.866
]
0.441
2
19
FRRF =
=
Rm
(S y )
(70.886)2
(31,20016,031.56)
150,000
= 507.86 lbf
= 2259.06 N
2001)
for 2 nozzles = 4518.13 N
Weight of nozzles= 4.518kN
3.
= 10.18m2
20
6.
Insulation
The insulating material used is Mineral Wool because it is made of
porous material that traps air making it one of the best insulating
materials. Due to the flammability of Acrylic Acid, it is preferable than
the other 2 materials like Foam glass and Calcium silicate because it is
incombustible and will not be induced by fire. Moreover, it has high
resistance to heat flow making it the most suitable insulating material
to be chosen.
Mineral wool insulation ranges from 3.7 inch to 4.2 inch (94mm to
107mm) of thickness.
Density of mineral wool = 130kg/m3
3
Volume of insulator = 3.6 m10 m (94 10 m)
= 10.63m3
3
3
2
Weight of insulator = 10.63 m 130 kg /m 9.81m/ s
= 13,556.44 kgm/s2 or 13,556.44 N
To allow for fittings, therefore the weight of insulator needs to be
doubled
= 13.56kN
Weight of catalyst
Only the weight of catalyst is calculated because the process only
involves gas phase, therefore weight of liquid is not required.
The use of catalyst in the catalytic partial oxidation of propylene to
produce acrylic acid is to propel the oxidation steps.
The catalyst used in this reaction is Vanadium Oxide, V2O5.
21
dx r A
=
dw F AO
r A=k C 2AO (1x )2
2
dx k C AO (1x)
=
dW
F AO
0.9
k C AO
1
dx=
dW
(1x
2
)
0
0 F AO
2
1 0.9 k C AO
[
] =
[W ]W
0
2
F AO
( 1x ) 0
-9 =
W = 452 g of catalyst
W = 0.45kg
W = 0.45kg
9.81m/s2
Weight of catalyst
= 4.43 N
Wz = 179.01 kN
b) ) For 10% design, t= 10.8mm
Major sources of Dead Weight
1. The vessel shell
2. The vessel fittings
3. Internal fittings : plates (plus
fluid on the plates)
4. External fittings : ladders,
Weight (kN)
130.24
4.07
12.22
-
platforms
22
27.11
4.43 10
-3
173.64
Pw = 0.06Uw2
The plant is located in Gelang Patah, Johor and the wind speed at that
particular area is 5 miles per hour which is equals to 8.047 km/h.
23
t=11.2mm
1.7.3
a)
Wind Loading
t=11.2mm
b)
t= 10.8mm
and
pressure
must
higher
than
operating
25
Temperature )
Pressure,
Pi
(N/m2)
10%
276.84
15%
289.42
330000
345000
8.771x107
8.6772x107
1.0
1.0
4
3.6
t=
t=
Pi D i
2 SE1.2 Pi
330 10 N
(3.6 m)
2
m
330 103 N
m2
)
26
C Pi
Assume Ct=D
is constant
= 0.1
e
SE
So De =
27
t=(3.6 m)
0.1
330 103 N
m2
t=
t=
Pi D i
4 SE0.4 Pi
330 10 3 N
( 3.6 m)
m2
330 103 N
m2
t=0.0034 m=3.4 mm
t=
P i Di
2 SE0.2 Pi
28
t=
330 10 N
(3.6 m)
m2
330 103 N
m2
t=0.0068 m=6.8 mm
Assume Rc = Di
t=
330 10 3 N
(0.885)
(3.6 m)
m2
3
N
( 8.771 107 N /m2 ) ( 1.0 )0.1 330 10
2
t=0.0119 m=11.9 mm
Therefore, the most suitable head is torispherical since its thickness can fit
the cylindrical shell of reactor.
b.
t=
Pi D i
2 SE1.2 Pi
29
t=
345 103 N
(3.6 m)
m2
345 103 N
m2
t=0.0072 m=7.2 mm
C Pi
Assume Ct=D
is constant
= 0.1
e
SE
30
t=(3.6 m)
0.1
345 10 3 N
m2
t=
t=
Pi D i
4 SE0.4 Pi
345 10 3 N
(3.6 m)
m2
345 103 N
m2
t=0.0036 m=3.6 mm
t=
P i Di
2 SE0.2 Pi
31
t=
345 103 N
(3.6 m)
m2
345 103 N
m2
t=0.0072 m=7.2 mm
Assume Rc = Di
(0.885)
t=
345 10 3 N
(3.6 m)
m2
3
N
( 8.6772 107 N /m2 ) ( 1.0 )0.1 345 10
2
t=0.0127 m=12.72 mm
Therefore, the most suitable head is torispherical since its thickness can fit
the cylindrical shell of reactor. In conclusion, different percentages of design
pressure and temperature do not affect the shape of head of reactor.
Assumptions:
90
The maximum dead weight load on the skirt will occur when the
vessel is full of water.
Maximum Allowable Stress = 8.6409107 Pa = 86.6409 N/mm2 (For
CS)
Approximate Weight =
2
3.6 10 1000 9.81 998,666 N 999kN
4
0.0148
Bending moment at the base of skirt =
(10 1.98) 2
1.0621kNm
2
As the first trial, take the skirt thickness as the same as 15.2 mm.
Calculation of Bending stress of the Skirt
bs
4Ms
( Ds tsk )tskDs
4(1.0621 10 3 10 3 )
bs
(3600 15.2) 15.2 3600
bs 0.006835 N / mm 2
ws(Operating )
Wv
( Ds tsk )tsk
ws(Trial )
Wv
( Ds tsk )tsk
179.01103
ws
(3600 15.2) 15.2
1178.01 103
ws
(3600 15.2) 15.2
ws 1.0368 N / mm2
ws 6.8229 N / mm2
Noted that: Trial condition is when the vessel full of water for hydraulic
test. In estimating total weight, the weight of liquid on the plates has
34
1st Criteria
2nd Criteria
tsk
) sin
Ds
15.2
) sin 90
3600
6.8297 105.556
35
The maximum dead weight load on the skirt will occur when the
vessel is full of water.
Maximum Allowable Stress = 8.7502107 Pa = 87.502 N/mm2 (For
CS)
Approximate Weight =
2
3.6 10 1000 9.81 998,666 N 999kN
4
moment
at
the
base
of
skirt
(10 1.98) 2
1.0621kNm
2
As the first trial, take the skirt thickness as the same as 14.8 mm.
36
bs
4 Ms
( Ds tsk )tskDs
bs
4(1.0621 103 10 3 )
(3600 14.8) 14.8 3600
bs 0.00702 N / mm2
ws(Operating )
ws
Wv
( Ds tsk )tsk
173.64 103
(3600 14.8) 14.8
ws 1.033 N / mm 2
ws(Trial )
ws
Wv
( Ds tsk )tsk
1172.64 103
(3600 14.8) 14.8
ws 6.9761N / mm2
Noted that: Trial condition is when the vessel full of water for hydraulic
test. In estimating total weight, the weight of liquid on the plates has
been counted twice. The weight has not been adjusted to allow for this as
the error is small and on the safe side.
37
2nd Criteria
tsk
) sin
Ds
14.8
) sin 90
3600
6.98312 102.778
38
The diameter of the vessel is 3.6 m where the maximum weight that can
be supported is 2500 kN. Hence, the parameters for this design are
approximately to be:
V = 1.98 m
G = 0.150 m
Y = 0.25 m
t2 = 16 mm
C = 3.20 m
t1 = 12 mm
E = 1.40 m
Bolt diameter = 27 mm
J = 0.815 m
Bolt Holes = 33 mm
39
Overall Conclusion
The skirt support is not the top priority in designing this reactor. This is
because the wind load is too small, hence the reactor is secured enough
without the support of a skirt at the bottom of it. Adding the skirt support will
eventually increase the cost of construction of the reactor. However, it still
can be done since the height of the reactor is quite big but the addition of
skirt support is not that significant in designing the reactor.
2.0.1
Flange types
Several different types of flanges are used for various applications. The most
used flange types according to ASME B16.5 are: Welding Neck, Slip On,
Socket Weld, Lap Joint, Threaded and Blind flange.
Most common flange types
from
41
Figure 4
42
Figure 5
43
Figure 6
44
2.3 REFERENCES
45
46