PILOT PLANT R

Basic requirements :-
1 MINIMUM CHARGING -

2 MAXIMUM WORKING -
CAPACITY

3 CONICAL BOTOM

4 L/D

5 BAFFLES REACHING
ALOMOST NEAR BOTTOM

6 MATERIAL OF CONSTRUCTION

7 BOTTOM DISCHARGE FLUSH

VALVE

8 ARRANGEMENT FOR STEAM/

NITROGEN/AIR BLANKETING,
SPARGING. ROTAMETERS FOR
AIR/NITROGEN FLOW
MEASUREMENT

9 MANHOLE SIZE AND SHAPE.

10 JACKETS

11 COIL

12 STIRRER
13 TEMPERATURE INDICATOR

14 Pressure indicators

Reactor to operate be

Suitable for WR vaccu

PILOT PLANT REACTOR
Prepared by - GAURAV KAKAD.
NMIMS (MPSTME)
MBA-TECH(CHEM)-207

30 lit, sufficient for mixing and temperature indication

500 liters

Large -1.5

SS316

Suitable for addition of powder RM directly

in the liquid without falling on stirrer/baffles/
reactor wall.

Steam/water/oil : split in at least 3 levels

with air flush arrangement.

Steam/water/oil circulation

Variable speed drive, mechanical seal,

connection of ammeter to note current drawn during
reaction

Changeable from PADDLE/ TURBINE/ ANCHOR/ GATE/ PITCHED BLADE

 etc to handle from thin to viscous, pasty , consistency, emulsification etc.

At 3 levels, digital

Digital

to operate between 3 torr - 10 kg/cm^2

e for WR vaccum pump + Steam jet ejector system.

DESIGNING OF A REACTOR VESSEL IS DIVIDED IN TO FOLLOWING PARTS

1. SHELL
2. HEAD (TOP AND BOTTOM)
3. JACKETS
4.COILS
5. AGITATOR
6. SHAFT
7. BAFFLES
8. NOZZLES AND FLANGES

DESIGNING OF A
1 VOLUME OF THE VESSEL = 500 LIT.
As per the standard condition, volume of the reacto
must be 35% more than the actual capacity,

DESIGNING VOLUME OF THE REACTOR = 500*1

2 L/D = 1.5

3 Diameter of the shell = 0.830m or 830mm

4 Length of the shell =1.245m or 1245 mm

5 Internal pressure = 0.98 N/mm^2 ( 10 kg/cm^2)

design internal pressure = 0.98 + 10% of 0.98
total design internal pressure = 1.078 N/mm^2

6 Design external pressure = 0.945 N/mm^2 aprro

7 Permissible stress = 130 N/mm^2

8 As per the internal design pressure

thickness of the shell (t) = 4.038 mm
5 mm or more can be used.

9 As per design external pressure

thickness of the shell (t') = 3.772 mm (less than
OWING PARTS

GNING OF A SHELL

volume of the reactor

ctual capacity,

E REACTOR = 500*1.35 = 675 LIT. = .675 m^3

m or 830mm

or 1245 mm

m^2 ( 10 kg/cm^2)
8 + 10% of 0.98
= 1.078 N/mm^2

945 N/mm^2 aprroximately equal to 1N/mm^2

772 mm (less than design internal pressure, not applicable)
 HEAD DESIGN

→ Torispherical head - AT TOP

1 Crown radius = 830mm

knuckle radius = 49.8 mm
stress intensification factor ( W ) = 1.77

2 As per design internal pressure

thickness of the head(t) = 8mm to 9mm

3 As per design external pressure

thickness of the head(t') = 9.72 mm
10 mm or more can be used

(since t'>t,
therefore thickness of the head in de

→ Conical head- at bottom (α= 45 degree, apex angle)

1 Diameter of the head = 830mm

2 As per design internal pressure

thickness of the head(t) = 6mm to 7mm

3 As per design external pressure

thickness of the head(t')= 5.505 mm to 6 mm

(since t'<t, thickness of head by external desi

→Elliptical head

1 Diameter of the head = 830mm

2 As per design internal pressure

thickness of the head(t) = 6.022 mm to 7 mm

3 As per design external pressure

thickness of the head (t') = 5.633 mm to 6 mm
 (since t'<t , thickness of the head by external

→ Hemispherical head

1 Diameter of the head = 830mm

2 As per design internal pressure

thickness of the head(t) = 2mm to 3mm

3 As per design external pressure

thickness of the head(t')= 1.877 mm to 2.5 mm

(since t'< t , thickness of the head by externa

 DESIGN

(FLANGE LENGTH = 3*10 = 30mm)

W ) = 1.77

m to 9mm

s of the head in design internal pressure is not applicable)

gree, apex angle)

(flange length = 7*3.5 = 24.5 )

m to 7mm

05 mm to 6 mm

ad by external design pressure is not applicable)

(flange length = 7*3.5 =24.5 )

22 mm to 7 mm

633 mm to 6 mm
e head by external design pressure is not applicable)

(flange length = 20mm)

m to 3mm

77 mm to 2.5 mm

he head by external design pressure is not applicable)

 Agitator

ASSUMPTIONS : -

1 LIQUID INSIDE THE REACTOR IS FUEL OIL

VISCOSITY= 8081*10^-3 POISE
DENSITY=0.99*10^3 KG/M^3

→ TURBINE AGITATOR

1 DIAMETER OF THE AGITATOR=277 mm

2 BLADE LENGTH = 1/4 th of agitator dia

blade length = 69.25 mm to 70 mm

3 REYNOLD'S NOS is 7.833

Power number
Np=9 (from power curve)

4 CENTRAL DISC = 1/8* 277=34.625mm

5 MOTOR REQUIRED TO MOVE THE AGITATO

THE BLADE ANGLE OF A CURVED BLADE TURBINE A

→ PADDLE AGITATOR
(BLADES OF THESE AGITATORS NORMALL
1 PADDLE DIAMETER= 0.8 Times the tank
PADDLE DIAMETER= 0.8*830=664mm

2 width of the blade =1/4*664=166mm

→ PROPELLER AGITATOR

1 DIAMETER OF PROPELLER AGITATOR= .2

It is shaped wid tapering blade to minimis

and produce a maximum axial flow

Other types of AGITATOR which can be used are:-

1 HELICAL SCREW AGITATOR

2 CONE TYPE AGITATOR

3 RADIAL PROPELLER AGITATOR

4 HIGH SPEED DISC AGITATOR

5 DOUBLE MOTION AGITATOR

S FUEL OIL

GITATOR=277 mm (DIAMETER OF AGITATOR/3)

4 th of agitator diameter
5 mm to 70 mm

8* 277=34.625mm

O MOVE THE AGITATOR= 6-7 hP

ED BLADE TURBINE AGITATOR IS 45⁰

AGITATORS NORMALLY EXTEND CLOSE TO TANK WALLS)

0.8 Times the tank diameter
0.8*830=664mm

1/4*664=166mm

LLER AGITATOR= .2*830=166mm

ring blade to minimise the effect of centrifugal force

mum axial flow

h can be used are:-

CREW AGITATOR

E AGITATOR
OPELLER AGITATOR

D DISC AGITATOR

OTION AGITATOR
 SHAFT

For Shaft design assume power rquired as 6 h

1 Continuous average rated torqu

on the agitator shaft

2 Maximum TORQUE (Tm ) = 214

3 Polar modulus of section of the

cross section

4 Diameter of the shaft (d) = 4.3

we can use a shaft of diameter
ower rquired as 6 hP

s average rated torque(Tc) = 859.43Nm

ator shaft

TORQUE (Tm ) = 2148.59Nm

ulus of section of the shaft (Zp)=16.527 Cm^3

of the shaft (d) = 4.38 cm

e a shaft of diameter upto 5cm to 6cm
 HUB AND KEY DE
1 Hub diameter of agitator= 2*sh

2 length of the key = 1.5*5=7.5

3 permissible stress for key= 130

4 shear stress & crushing = 130N

stress

5 b = 0.73mm to 1mm

6 t = 2mm
AND KEY DESIGN
ter of agitator= 2*shaft dia=2*5=10cm

he key = 1.5*5=7.5cm

e stress for key= 130N/mm^2

ss & crushing = 130N/mm^2

mm to 1mm
 JACKETS and COIL
1 Thickness of the coil = 3 mm

2 diameter of the coil = 540 mm

3 thickness of the jacket=

4 length of the jacket =

BAFFLES

1 Baffle width = 83mm (1/10th

2 Max Baffle height = 1128mm

 TS and COILS
of the coil = 3 mm

of the coil = 540 mm

of the jacket=

he jacket =

h = 83mm (1/10th of tank diameter)

height = 1128mm(baffle height can b kept little more than the max. level
of the liquid inside the tank)
 NOZZLES
1 Number of nozzles required = 15

2 coils requires " 2 nozzles " ( INLET AND OUTLET, AT THE

3 For temp. indicator " 3 nozzles" are required (digital)

1st- on top head of reactor, 2nd- on jacket, 3rd- on bottom he

4 Jacket requires " 2 nozzles " 1 for inlet and other for outlet

5 " 1 nozzle at the bottom of the head " for drain purpose

6 " 1 nozzle at the bottom for removal of product "

7 " 1 nozzle at the top head for pressure indicator purpo

8 " 1 nozzle at the top of the head for rotameter "

9 " 1 nozzle in the middle of the top head, for shaft "

10 " 1 nozzle at the top of the head , as a hand hole" (for a

11 " 2 nozzles for reflux condensors "

 DIMENSIONS

D OUTLET, AT THE TOP OF THE HEAD) (20mm away from the center nozle , diam

uired (digital) 1st- on top head of reactor, 3-4mm away

et, 3rd- on bottom head.) 2nd and third, diameter- 20-25 mm

and other for outlet (20-40mm diameter)

" for drain purpose (20-35 mm diameter)

of product " (140-150mm diameter)

re indicator purpose(digital) " (3-4mm away from the boundry of the he

rotameter " (3-4mm away from the boundry of the he

ead, for shaft " AT the center 0⁰, 6cm.(diameter)

a hand hole" (for addition of powder RM directly in the liquid FROM THE CENTER AT 45-50⁰, 140-150mm
without falling on stirrer/baffles/reactor walls) in 3rd quadrant)
he center nozle , diameter= 30-50mm)

eactor, 3-4mm away from the boundry of the head diameter- 20-25mm in 3rd quadrant.at 5-10⁰ from the cente
eter- 20-25 mm

he boundry of the head, 20-25mm diameter,in first quadrant, at 10-20⁰ from the center.)

he boundry of the head, 20-25mm diameter,in first quadrant, at 5-10⁰ from the center.)

m.(diameter)

AT 45-50⁰, 140-150mm (diameter)

5-10⁰ from the center)