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2461283.51
4.1840
14720.595kg/hr
Energy oI entering water mC
p
dT14720.7154.18(30)
1845977.661kj/hr
Energy oI water leaving mC
p
dT14720.7154.18(70)
4307281.209kj/hr
10.1.4 FLASH EVAPORATOR
74
Flash
evaporator
3627833 63k[/hr
413k
2948270 74k[/hr
423k
1361347 891k[/hr
373k
210614 33k[/hr
373k
Enthalpy oI entering stream 5627835.653kj/hr
Stream entering mc
p
dT m
m*4.13*100(m2258.4)
Water leaving m*4.13100
210614.3599kj/hr
Enthalpy oI NH mC
p(NH)
dT
4329.016*2.35*(423-273)
1525978.14kJ/hr
Enthalpy oI CO
2
0.959*5690.251(423-273)
818542.6064kJ/hr
73
Enthalpy oI H
2
O mCpdT m
218.75*4.312*1423.2731(218.75*2113.2)
` 603750kJ/hr
Total 6037501525978.14818542.6064
2948270.746kJ/hr
C
p(urea)
1.762,C
p(acetic acid)
2.3
C
mix
(0.39221.679)(0.50982.3)(0.0984.312)
2.2884kj/hr
Enthalpy oI bottom stream 2.288411156.25(423-273)
3830498.438kj/hr
Energy balance.
Entering leaving
5627835.653(m4.13100) m 3830498.438(m4.13100)2948270.1746
m2256.9 1150933.531
m509.9621kg/hr
Substituting m` value we get, mc
p
AT m
m*4.13*100(m2258.4)
1361547.891kj/hr
Entering leaving-0.
9.1.5.Decomposer:
76
NH
2
COONH
4
heat NH
3
CO
2,
dH-84kj/mol
Enthalpy oI stream entering 3830498.438
Heat oI reaction (-84/78)56787.510
3
-6125000kj/hr
Enthalpy oI product stream leaving t bottom,
C
pmix
5468.752.1696(402-273)
1530585kj/hr
Enthalpy oI stream top stream.
Enthalpy oI NH mc
p
AT m
Here 317.00586 at 129
0
c
2479.1611.07129(2479.16317.0058)
77
4326223.114kg/hr
Enthalpy oI CO
2
mc
p
AT
3208.30.942129
389866.1998kj/hr
Total NH
3
CO
2
4326223.114 389866.1998
4716089.314kj/hr
Enthalpy oI steam leaving entering mc
p
AT m
1436.07204.31151.8(1436.0722109)
11190835.68kj/hr
Enthalpy oI condensate leaving m4.31151.8
4049.874.31151.2
2649659.846kg/hr
Energy balance,
Entering leaving
3830498.438(m2109)(m4.31151.8)-6125000-8541175.876-2109
1530585(m4.31654.248)4716089.314
m(2109) 3028675.876
m 4049.87 kg/hr
substituting value oI m` we get,
entering leaving 0
78
10.1.6 PREHEATER
Enthalpy oI product stream entering 1530585Kj/hr
Enthalpy oI product stream leaving,
C
pmix
0.8C
purea
0.2C
PH2O
0.81.681(0.24.277)
2.2O
Enthalpy 2.25468.75135
1683618.75kj/hr
Enthalpy oI Steam entering mc
p
dT m
Enthalpy oI condensate leaving mc
p
dT
Energy balance:
Entering leaving
1530593(m4.312150)(m2256.4) (m4.312150)1683618.75
m2113.2 153033.75
m 72.42kg/hr
79
enthalpy oI steam entering at 150
0
C and 4.760 bar
mc
p
dT m
(72.424.312*150)(72.422113.2)
199879.2kj/hr
Enthalpy oI condenser leaving mc
p
dT
72.424.312150 46841.256kj/hr
80
10.1.7 VACUUM EVAPORATOR
Enthalpy oI stream entering 1683618.75kj/hr
Enthalpy oI stream bottom,
C
pmix
0.991.681(0.014.277)
1.70696
Enthalpy oI stream bottom1.706964419.19135
1018356.373kj/hr
Enthalpy oI top stream mc
p
AT m
(1049.564.277135)(1049.562158.9)
2871905.78kj/hr
Steam entering at 4.76bar mc
p
AT m
81
m4.31150(m2113.2)
Water leaving mc
p
AT
Energy balance:
Entering leaving
1683618.75 (m4.31150)(m2113.2)
2871905.781018356.373()m4.31150)
m 2206643.403
m 1049.218911kg/hr
ThereIore,
Steam entering at 4.76bar m4.31150(m2113.2)
2881730.929kg/hr
Water leaving mc
p
AT
675087.526kg/hr
substituting value oI m` we get,
entering leaving 0
82
10.1.8 ENERGY FLOW DIAGRAM FOR UREA
83
10.2 FORMALDEHYDE
10.2.1 VAPORIZER
Enthalpy oI air entering mC
p
AT
13351.91.005 (303-273)
402559.785KJ/hr
Enthalpy oI methanol entering 5237.572.566(303-273)
403188.1386kj/hr
Enthalpy oI mixture leaving
84
Enthalpy oI methanol leaving mC
p
(337.7-273) m. mC
p
(393-
337.7)
5237.572.7164.75237.571101.8755237.571.60155.3
7153197.083 KJ/hr
Enthalpy oI air leaving 1.003213351.9(393-273)
1607355.13kj/hr
Total mixture leaving 7153197.0831607355.13
8760552.216kj/hr
Heat balance:
Entering leaving
402559.785 403188.1386 mC
p
AT m mC
p
AT 8760552.216
m 7954804.292
m 7954804.292/2113.2
m 3764.341Kg/hr
Enthalpy oI steam entering at 150C and 4.76bar mC
p
AT m
3764.341 4.312 150
3764.341 2113.2
7971037.237KJ/hr
Enthalpy oI condensate leaving mC
p
AT
5685.058204 4.312 150
16231.84 KJ/hr
83
10.2.2 REACTOR
CH
3
OH O
2
7HCHOH
2
O, AH -37Kcal/mol
CH
3
OH 3/2 O
2
72H
2
0CO
2,
AH -162Kcal/mol
Heat oI reaction 1 37 4.18 145.833 1000
22554531.78 kj/hr
86
Heat oI reaction 2 162 4.18 16.204 1000
10972700.64 kj/hr
Total heat oI reaction 33527232.42kj/hr
Enthalpy oI mixture inlet 8760552.216 kj/hr
Enthalpy oI water entering m 4.216(373-273)
Enthalpy oI steam leaving m 4.216100 m 2270
Enthalpy oI product leaving :
C
pmix
0.2354 1.353 0.5509 1.0396 0.9698 0.0384 0.0028 2.116
0.1726 2.207
1.3155kj/hr
Enthalpy 18589.521 1.315 340
8311374.839 kj/hr
Energy balance;
8760552.216 33527232.42 412.6 m 2691.16 m 8311374.83
m 14967.58141 kg/hr
Enthalpy oI water entering m 4.216(373-273)
6310332.323 kj/hr
Enthalpy oI steam leaving m 4.216100 m 2270
40286742.12 kj/hr
87
10.2.3 HEAT EXCHANGER
Enthalpy oI entering gas 8311374.839 kj/hr
Cp
mix
0.23541.0250.550981.03520.03840.95450.00281.557
0.17362.177
1.227 kj/kg
Enthalpy oI product gas leaving 18589.5211.227110
2509027.649kj/hr
Heat removed Q 5802347.19
Enthalpy oI water entering at30C mC
p
dTm4.1830
Enthalpy oI water leaving at 80C mC
p
dTm4.1880
Energy balance
Water required Q/4.1850
5802347.19/4.1850
27762.43kg/hr
88
AIter substituting 'm
o
value we get
Enthalpy oI water entering at30C
mC
p
dT27762.434.18303481408.314kj/hr
Enthalpy oI water leaving at 80C
mC
p
dT27762.434.18809283755.504kj/hr
10.2.4 ABSORBER
Enthalpy oI steam entering 2509027.649kj/hr
Heat evolved by absorption 4375 62.75/30 9151.042 KJ/hr
89
C
Pmix
0.9304 1.03184 0.0605 0.84325
1.019kj/kgk
Enthalpy oI exit gas 10953.739 1.019 50
558093.021kj/hr
Enthalpy oI bottom:
C
pmix
.3732 3.107 .6222 4.177 0.00446 2.633
3.77kj/kgk
Enthalpy oI bottom 11719.051 3.77 (323-273)
2209041.114kj/hr
Enthalpy oI water entering 4083.329 4.178 (303-273)
511804.4564kj/hr
Enthalpy oI water entering in coolerm 4.178 (303-273)
125.34m
Enthalpy oI water leaving in cooler m 4.178 (311-273)
Energy balance:
Entering leaving
2509027.649 9151.042 511804.4569125.34m 558093.0021 2209041.114
158.726m
m 7873.031567kj/hr
Enthalpy oI water entering in cooler m 4.178 (303-273)
986805.7766kj/hr
90
Enthalpy oI water leaving in cooler m4.178(311-273)
1249654.809kj/hr
10.2.5 ENERGY FLOW DIAGRAM FOR FORMALDEHYDE
91
10.3 UREA FORMALDEHYDE RESIN
10.3.1 REACTOR
Enthalpy oI Iormaldehyde entering 2209041.144kj/hr
Enthalpy oI urea Ieed entering 108356.373kj/hr
Heat oI reaction 64 4375/60
466.667kj/hr
Total heat input 2209041.144 108356.373 466.667
3232064.154kj/hr
Product leaving :
C
pmix
0.37953 1.67 3.25 10
-3
2.85 0.61722 4.2
92
3.24kj/kgk
Enthalpy oI product 16138.24 3.24 (363-273)
4705911.076kj/hr
ENERGY BALANCE
m 1473846.864
m 1473846.864/2256.9
m 653.0404192kj/hr
enthalpy oI Steam entering mC
p
AT m
1749103.459kj/hr
Enthalpy oI condensate leaving mC
p
AT
275256.5367kj/hr
10.3.2 HEAT EXCHANGER
93
Enthalpy oI inlet stream 4705911.076 kj/hr
Cp
mix
0.37953*1.670.00325*2.560.61722*4.18
3.22 kj/kg
Enthalpy oI outlet stream 3.22*16138*35
1818779.761 kj/hr
Enthalpy oI water entering m
o
*4.18*(303-273)
125.4m
o
kj/hr
AIter substituting 'm
o
value we get
Enthalpy oI water entering3936997.247 kj/hr
Enthalpy oI water leavingm
o
*4.18*52
217.36m
o
kj/hr
AIter substituting 'm
o
value we get
Enthalpy oI water leaving6824128.562 kj/hr
Energy balance:
entering-leaving0
4705911.076125.4m
o
1818779.761217.36m
o
m
o
31395.51234kg/hr
94
10.3.3 MIXER:
Enthalpy oI inlet product stream 1818779.761 kj/hr
Enthalpy oI stream cellos Iiller m
o
cpA
4166.667*1.4*(303-273)
175000.014 kj/hr
Enthalpy oI stream outlet 20304*cp
mix
*A
cp
mix
0.30165*1.670.49056*4.181.4*0.205210.00258*2.8
2.85 kj/hr
Enthalpy oI stream outlet stream 2.85*20304.908*(T-273)
energy balance;
93
1818779.761175000.01457868.99(T-273)
T34.45I
Enthalpy oI outlet stream 1993780.669 kj/hr
9.3.4 DRIER:
Enthalpy oI product entering 1993780.66kj/hr
C
pmix
1.67 .5892 1.4 0.4 4.18 10
-3
1.59kj/kgk
Enthalpy oI product leaving 1.59 10395.623 68
1123974.75kj/hr
96
Humidity oI inlet air,H1 0.01805kg moisture/dry air
At 303k wet bulb temperature 298k
Humidity oI outlet air,H2 0.0832kg moisture/dry air
At 393k wet bulb temperature 322.8k
Enthalpy oI air entering 1.006 (303-273)0.01805 2556.16
76.323kj/kgdry air
Fresh air 151295.4873Kg/kg oI dry air
Total 7.323 151295.4873
11547779.36kj/hr
Enthalpy oI exhaust air 1.006 322.8-273 2591.5 0.0832 1.006 1.84 0.0832
(393-322.8)
340.125kj/kg dry air
Total340.125 151295.4873 52.384 2.74 64.7 52.384 1.601(2393-337.1)
51473301.98kj/hr
Heat supplied by heater Q
Energy balance
1993780.66911547779.36Q51473301.981123974.75
Q39055710.76kj/hr
1
10.3.5 COOLING ROOM
Enthalpy oI entering stream1123974.759 kj/hr
Enthalpy oI product
cp
mix
1.59 kj/hr
97
1.59*10395.623*(303-273)
495871.2171 kj/hr
Enthalpy oI cool air enteringm
o
*1.0051*(293-273)
=
Enthalpy oI cool air balancem
o
*1.005*(323-273)
Energy balance:
1123968.812m
o
*1.005*(293-273)495868.5936m
o
*1.005*(323-273)
30.15m
o
628103.5419
m
o
20832.62162 kg/hr
Enthalpy oI cool air entering418735.6946 kg/hr
Enthalpy oI cool air leaving1046839.233 kg/hr
98
10.3.6 BALL MILL
(p/m
o
) 0.3162W
I
(1/V
b
)-(1/V
a
)
P 0.3162 m
0
W
i
(1/V
b
)-(1/V
a
)
0.316210291.6712.73(1/V)-(1/V)
P 17347.69066 W17.3477 kw
99
10.3.7 ENERGY FLOW DIAGRAM FOR UREA FORMALDEHYDE RESIN
100
DESICA OF EQUIPMEA1S
101
CHAP1ER 11
11 DESIGN OF EQUIPMENTS
11.1 DESIGN OF SHELL AND TUBE HEAT EXCHANGER
11.1.1PROCESS DESIGN
FLOW TYPE - Counter current heat exchanger
SHELL SIDE FLUID
COMPONENT WEIGHT(KG/HR) PERCENTAGE
Urea 4375 20.39
Ammonium carbamate 5687.5 26.50
NH
3
4397.016 20.49
CO
2
5690.251 26.51
Water 1312.5 6.12
TUBE SIDE - water
TEMPERATURE CONDITION
Inlet temperature oI urea mixture T
H1
185 c
Outlet temperature oI urea mixture T
H2
140 c
Temperature 0I water inlet 30 c
Temperature 0I water outlet 70 c
T
Havg
185+140
2
162.5 c T
Cavg
70+30
2
50 c
ENERGY BALANCE
Enthalpy oI inlet urea solution mC
Pmix
(T
H1
-273)
21462.2672.0373(185)8089139.163kj/hr
Enthalpy oI outlet urea solution mC
Pmix
(T
H2
-273)
21462.2672.0373(140)5627835.653kj/hr
102
Heat removed Irom urea solution(8089139.163-5627835.653)kj/hr
2461303.51kj/hr
Water Ilow rate M
Q
CpdT
2461303.51
4.1840
14720.714kg/hr
Volumetric Ilow rate
14720.714
988.03
14.899m
3
/hr
LMTD
(185-70)-(140-30)
In
18S-0
140-30
112.481c
ASSUME U
D
500W/M
2
K(BINAY K DUTT ,PAGE NO:297,TABLE NO;8.2)
A
2461303.51
UdTIm
2461303.51
500112.481
43.764m
2
Select / inch 16BWG tubes id15.7mm,od19mm L3.5m
1-2 pass
Outer surIace area oI tubes nd
o
Ln.0193.5.2089
No.oI tubes required
43.764
.2089
210
From table
No.oI oI tubes 220
Shell diameter 20
1
4
inch51.435
TUBE SIDE CALCULATION
1)Flow per pass
4
.0157
2
110.0213
2)Velocity
14.899
3600.o213
.1943m/s
3)NRe
dVp
.0157.1943988.03
610
-4
5023.33510
3
103
4)J
h
i
d
i
hIdI
k
(
cp
k
)
-1/3
18
(Irom binay k dutt page no;294,Iig8.11(a))
cp
k
4.18610
-4
.624
10004.019
5) h
i
18.6244.019
.333
.0157
1137.44w/m
2
k979.61kcal/hrm
2
k
SHELL SIDE CALCULATION
P25.4mm ,C(25.4-19)mm6.410
-3
m, B.1m
D
s
51.435cm20/inch
1)Flow area a
s
CBDs
p
6.410
-3
0.151.43510
-2
.0254
.01296
2)G
s
w
as
=
21462.267
.01296
16.56039kg/m
2
h
d
0
19mm
3)D
4(P
2
-d0
2
4)
0
4(.0254
2
-.019
2
4)
.019
.0385m
4)NRe
DHGs
=
.03851656039.12
36001.9310
-S
917638.2573
5)J
h
i
d
i
hIdI
k
(
cp
k
)
-1/3
780
(Irom binay k dutt page no;295,Iig8.12(b))
cp
k
1.9551.9310
-S
.1572
1000.24
h
i
780.1572.24
.333
.0385
1979.2021w/m
2
k
1704.58kcal/hrm
2
k
104
OVERALL HEAT TRANSFER COEFFICIENT CALCULATION
1
0
1
h
R
do
1
R
di
1h
R
do
1.0210
-4
hr.m
2
/kcal(Irom binay k dutt page no;294
R
di
3.0710
-4
hr.m
2
/kcal
1
0
1
1704.58
1.0210
-4
1.213.0710
-4
1.21
979.61
2.29510
-3
U435.67Kcal/hrm
2
k505.86w/m
2
k
R
11-12
t2-t1
185-140
70-30
1.125
S
t2-t1
11-t1
70-30
185-30
.258
F
t
.98
(A)
lm
112.481.98110.231k
Area required
0tLM1
2461283.51
110.231505.86
44.1395
Area available n.0192203.545.96
Percentage excess area
45.96-44.14
44.14
1004.12%
103
PRESSURE DROP CALCULATION
TUBESIDE TUBE SIDE CALCULATION
G
t
14720.714
3600.0213
=191.97kg/m
2
sec
L3.5m , n2, p
t
988.03, d
i
.0157m, =1, g9.8m
2
/sec, NRe5023.33, I610
-3
Tube side pressure drop A
]ut
2
Ln
2gptdI
610
-3
191.97
2
3.52
2988.089.8.0157
5.09kg/m
2
7.3510
-3
psi
Return loss Ar4n
v
2
pt
2g
42.19432988.03
29.8
15.22kg/m
2
.022psi
Total pressure drop AAr7.3510
-3
.022.029psi
SHELL SIDE PRESSURE DROP
As
]sus
2
s(Nb+1)
2gpsq
NRe917638.258, I
s
2.310
-2
D
s
.51435m, p
s
619.40, B.10m, N
p
3.5
.10
-134
As
2.310
-2
460.010
2
.5143535
29.8619.40.03851
187.453.271psi
106
10.1.2 MECHANICAL DESIGN
1) SHELL THICKNESS
t
s
P
2]]+P
c
J85%,
Operating pressure P1.792N/mm
2
Design pressure P1.7921.11.9712N/mm
2
D514.35, I95N/mm
2
, C3mm
t
s
1.9712514.35
295.85+1.9712
39.20=
outer diameter oI shell D
s
2t
s
514.35210534.35mm
2) NOZZLE THICKNESS
Nozzle diameter75mm, J1
C3mm
t
s
P
2]]-P
c
1.971275
2951-1.9712
33.79=4mm
3) HEAD THICKNESS
t
s
PRcw
2]]
w/(3In )
R
c
514.35mm, R
nk
51.435mm
w/(3.. )1.54
t
s
P
2]]-P
t
s
1.9712514.351.54
2.8595
9.66mm=10mm
107
4) TRANSVERSE BAFFLES
Spacing between baIIle.10mm
BaIIle cut 25
BaIIle thickness 6mm (standard)
5) TIE ROD AND SPACES
No. oI tie rods6
Diameter oI tie rod10mm
6) FLANGE 1OINT
Minimum gasket width N24mm
7) FLANGE THICKNESS
Seating stress 5.34kg/cm
2
Gasket outer diameter 514.35210534.35mm
Gasket inner diameter514.35mm
Gasket mean diameter
514.35+534.35
2
524.35mm
b
0
N/224/212, m3.75
b2.5Vbo =2.5V8.64mm
W
m1
nbGY
a
n8.64524.3553.40760.00KN
W
m2
n2bG
m
Pn/4G
2
P
n28.64524.353.751.9712 n/4524.35
2
1.9712
210415.0702425660.2703
636075.3405N
K
1
.3+
1.SWm1hG
HG
108
H
G
-u
2
37.5mm, H n/4G
2
P n/4524.35
2
1.9712425660.2703N
Bbolt circle diameter
K
1
.3+
1.S600003.S
42S660.2S24.3S
= .
t
I
G_
P
K]
C 524.35_
1.972
2.0395
356mm
8) CHANNEL AND CHANNEL COVER
t
I
G_
kP
K]
k.3(Ior ring type Gasket ) P.1143N/m
2
t
I
524.35_
.3.1143
95
9.86=10mm
9) FLANGE 1OINT (BETWEEN TUBE SHEET CHANNEL)
G524.35mm
Ring gasket width(w)22mm
Seating stress Y
a
126.60kg/mm
2
Gasket outer diameter 514.35210534.35mm
Gasket inner diameter514.35mm
Gasket mean diameter
514.35+534.35
2
524.35mm
b
0
W/822/82.75mm
2
, m3.75
b= b
0
W
m1
nbGY
a
n2.75524.35126.60573505.4437N
W
m2
n2bG
m
Pn/4G
2
P
n22.75524.353.75.11143 n/4524.35
2
.11143
5552.6224062.15729614.777N
109
A
m1
m1
]u
573505.4437
140.6
4078.986mm
2
A
m2
m2
]u
29614.777N
140.6
210.637m
2
d
o
_
4
18.02mm
No oI bolt
un ut
2b0
524.35
212
22bolts
Using M48 BOLT
Pitch diameter44.681mm
Minor diameter41.795mm(I33139)
Actual bolt area n(
44.682+41.7985
2100
)294cm
2
Minimum pitch diameterGN2db524.3522248642.35mm
Hence bolt diameter is chosen as650mm
10)FLANGE THICHNESS
K
1
.3+
1.SWm1hG
HG
H
G
-u
2
37.5mm, H n/4G
2
P n/4524.35
2
.11143B24062.157
Bbolt circle diameter
K
1
.3+
1.SS3S0S.4433.S
24062.1SS24.3S
=.35
t
I
G_
P
K]
C 524.35_
.11143
.3595
333.35=
11) NOZZLE INLET AND OUTLET DIAMETR
Inlet diameter oI nozzle 75mm
t
n
P
2]]-P
c t
n
.1114375
2951-.11143
33.044
110
Minimum thickness5mm
Outer diameter oI nozzle752585mm
10.1.3 SUPPORT FOR SHELL AND TUBE HEAT EXCHANGER
Length oI the heat exchanger, L
s
4.25m
Inner diameter oI Shell, D
i
514.35mm
Outer diameter oI Shell, D
o
534.35mm
Thickness oI Shell, t
s
10 mm
Outer diameter oI tube, d
o
19 mm
Inside diameter oI tube,di 15.7mm
Number oI tubes, N
t
220
Density oI Steel,p
s
7850 Kg /m
3
Density oI urea in shell, p
l
619.40Kg /m
3
Density oI water in tube, p
t
988.03Kg /m
3
Volume oI Shell body, V (H/ 4) ( D
o
2
D
i
2
) x L
0.0577 m
3
Weight oI Shell body, W
s
V x p
s
.05777850
452 Kg
Volume oI Tubes, V
t
(H/ 4 ) ( d
o
2
d
i
2
) x L x N
t
0.0693 m
3
Total Weight oI Tubes, W
t
V
t
x p
s
543.62 Kg
Volume oI Head, V
h
0.087 D
i
3
0.0118m
3
Weight oI Head, W
h
V
h
x p
s
92.93Kg
Weight oI Liquid, W
l
(H/ 4) (d
i
2
) x L x N x p
s
147.28 Kg
111
Total Weight, W W
s
W
t
W
h
W
l
1235.83Kg
1235.83 x 9.81
12.12KN
Depth oI head, H 250 mm
Q (W/2)
6.06 KN
Now, we calculate,
Distance oI saddle center line Irom shell end ,
A 0.4 x R
i
0.4 x (514.35/2)
102.87 mm
1. LONGITUDINAL BENDING MOMENTS
Radius, R 0.2572 m
Depth oI head, H 0.250 m
The bending moment at the supports is
M
1
QA | 1 (A/L) (R
2
- H
2
) / 2 AL}/1 4H/3L}|
603.77 N-m
The bending moment at the center oI the span is given by
M
2
(Q L / 4)|1 2 ( R
2
- H
2
) / L
2
}/1 4H / 3L} - ( 4A / L) |
1478.85 N-m
2. STRESS IN SHELL AT THE SADDLE
For 0 120
0
k
1
0.107
k
2
0.192
Thickness oI shell, t 10mm
I
1
M1/( k
1
H R
2
t)
272x 10
5
N/m
2
I
2
M1/( k
2
H R
2
t)
151 x 10
4
N/m
2
112
3. STRESS IN THE SHELL AT MID- SPAN
The stress at the mid span is I
3
, which is either tensile or compressive depending on
the position oI the Iiber. The resultant tensile stresses ( including the axial stress
due to internal pressure ) should not exceed the permissible stress, and the resultant
compressive stress should not exceed the permissible compressive stress
I
3
M
2
/(H R
2
t )
7.11 x 10
5
N/m
2
Axial Stress in Shell due to internal pressure
I
p
(P x D
i
)/ (4 t)
2.5x 10
7
N/m
2
All combined stresses ( I
p
I
1
) , ( I
p
I
2
) , and ( I
p
I
3
) are well within allowable
limits. Hence, the given parameters can be considered Ior design.
Thus a shell and tube Heat Exchanger with the above speciIications is designed
113
10.1.4 DATA SHEET
Address Coimbatore institute oI technology,Coimbatore-14
Service oI Unit urea heat exchanger
Sell side pass 1 Tupe side pass 2
PERFORMANCE OF ONE UNIT
FLUID ALLOCATION SHELL SIDE TUPE SIDE
FLUID NAME UREA MIIXTURE WATER
FLUID QUANTITY
TEMPERATURE IN/ OUT 185C 140C 30C 70C
DENSITY KG/M
3
619.40 619.40 988.03 988.03
VISCOSITY, CP 1.9310
-5
1.9310
-5
610
-4
610
-4
SPECIFIC HEAT,KJ/KGK 2.0373 2.0373 4.18 4.18
TERMAL CONDUTIVITY, W/MK .15727 .15727 .624 .624
PRESSURE,ATM.IN/OUT 17 17 1 1
VELOCITY,M/SEC - .1943
PRESSURE DROP,PSI .029 .271
FOULING RESISTANCE,
hr.m
2
k/kcal
1.0210
-4
3.0710
-4
HEAT EXCHANGED, kj/hr 2461303.51 LMTD 110.231
Over all heat transIer coeIIicient, W/m
2
k 505.86
MECHANICAL DESIGN
Length oI the oI tupes, L 3.5m
SHELL DIAMETER 514.35mm
SHELL THICKNESS 10mm
NOZZLE THICKNESS 4mm
HEAD THICKNES 10mm
SPACING BETWEEN BAFFLES .10m
NO.OF. TIE RODS 6
DIAMETER OF TIE ROD 10mm
MINIMUM GASKET WIDTH 24mm
FLANGE THICKNESS 5mm
RING GASKET THICJNESS 22Mm
BOLT DIAMETER 525mm
TUBE DIAMETER, IN/OUT 15.7mm 19mm
CORROSION ALLOOWENCE 3mm
NO.OF.BOLTS 22
TOTAL WEIGHT OF HEATEXCHANGER 12.12KN
114
11.2DESIGN OF EVAPORATOR
11.2.1 PROCESS DESIGN
Enthalpy entering stream16836.75kj/hr
Enthalpy oI bottom product
Cp
mix
0.991.6810.014.227
1.70696kj/hr
Enthalpy oI bottom product 1.70694419.19135
1018356.373kj/hr
Enthalpy oI top productm%c
pA
tm%
1049.56 4.227 1351049.56 2158.9
2871905.78kj/hr
Steam entering at 4.76 barm%c
pA
tm%
m%4.31150m%2113.2
m%(4.311502133.2).(1)
Water leaving m%c
pA
t
m%4.31150....(2)
ENERGY BALANCE
Enteringleaving
1683618.75m%1504.31m%2113.22871905.781018356.373m%4.3
1150
m%1049.218911kg/hr
Substituting m% in equ (1) and (2) we get
113
Steam entering1049.218911(4.311502113.2)
2881730.929 kg/hr
Water leaving1049.2189114.31150
675087.526 kg/hr
Now, entering leaving
1683618.752881730.9292871905.781018356.373675087.526
0
HEAT TRANSFER AREA
AS
s
/UAT
1049.2189112158.9 1000
1000150 3600
41.94m
2
Tube OD76.2mm
Thickness2.86mm
3mm
NO OF TUBES
AnnD
o
L
nA/nD
o
L
41.94/(n76.210
-3
1.82)
n97 tubes
PITCH
P
t
1.5D
o
1.576.210
-3
114.3mm
116
ANNULAR AREA
A
N
NP
t
2
97114.3
2
1.267m
2
DOWNTAKE AREA
A
D
0.5n/4D
I
2
n
0.5n/470.210
-3
97
0.1877m
2
EVAPORATOR DIAMETER
(A
D
A
N
)1.05
(0.18871.267)1.05
(n/4)D
2
1.527
D
2
. (n)
D1.39m
Height oI steam chest1.5m
Height oI vapour space1.5m
HEIGHT OF CONICAL BOTTOM
Volumetric Ilowrate4375 Ior 60 mins
For 5 mins(4375510
-3
)/60
0.3645m
3
/hr
117
(n/3)rh0.3645
h(0.36453)/(n0.695
2
)
h0.7207m
HEIGHT OF DISHED HEAD
H
i
R
i
- (R
i
-0.5D
i
)(R
i
0.5D
i
-2r
i
)
0.5
R
i
1.39m
r
I
0.139m
D
i
1.37m ,h
i
0.272m
Total height oI the evaporator1.51.50.72070.272
3.9927m
10.2.2 MECHANICAL DESIGN
1) THICKNESS OF THE SHELL
tPDi/2IJ-P (3.04x10
5
x1.01x1.39)/(2x550x10
6
x0.85-3.04x1.01x10
5
)0.456mm
Corrosion allowance 0.45622.456mm
Available standard thickness 5mm
To determine the maximum internal pressure
P2IJt/D
0
-t (2x550x10
6
x0.85x3x10
-3
)/(1.39-3x10
-3
)2.02x10
6
N/m
2
Maximum internal pressure is obtained by dividing P by 1.05
P
i
max 2.02x10
6
/1.05 1.92x10
6
N/m
2
It can easily withstand a pressure oI 2.02x10
6
N/m
2
t/D
i
t/D
0
-2t 3/(1390-2x3)) 0.00216
the ratio is much less than 0.25 and hence the equations are correctly applied.
118
2) HEAD DESIGN
TYPE- dished head
CALCULATION OF THICKNESS
tPD
0
C/2IJ solution oI this equation will require iteration as C is also a Iunction
oI t. As the Iirst approximation,
R
i
R
0
D
0
1.39 ; r
0
0.06x1.39
h
0
R
0
-b(R
0
-D
0
/2)(R
0
D
0
/2-2r
0
)
h
0
0.4274m
D
0
2
/4R
0
1.39
2
/4x1.39 0.3475m
b(D
0
r
0
/2) b(1.39x0.06x1.39/2)0.2407
Out oI the 3 quantities calculated above b(D
0
r
0
/2) is the best. ThereIore the
eIIective external height oI thehead is equal to b(D
0
r
0
/2) i.e., h
E
0.2407m. Irom
this
H
E
/D
0
0.2407/1.39 0.1732
As the diameter oI vessel(1.39m) is not very large, head can be Iabricated Irom a
single plate and hence J1.
Cstress concentration Iactor
t/D
0
PC/2IJ (3.04x10
5
x1.01xC)/(2x550x10
6
x1) 2.791x10
-4
C
Irom table 4.1(A) oI Bhattacharya, various values oI t/D
0
C are tried Ior h
E
/D
0
0.17
to match the above relationship. It is Iound that Ior t/D
0
0.002 and C3.425 gives
t/D
0
C 5.83x10
-4
which is a good approximation. From the above Iinding the
corroded head thickness is obtained as,
t/D
0
0.002 or t0.002x1.390.00278m
Blank diameter oI the plate Ior Iorming the head:
Blank diameter: D
0
D
0
/42(2/3) r
i
2S
I
119
13901390/42(2/3)x(0.06x1390)2x40
(S
I
40mm---Bhattacharya)
1.558mm
DESIGN OF NOZZLE (OPENINGS)
Outside diameter oI the shell1.39m
Maximum working pressure2.02x10
6
N/m
2
Wall thickness oI shell 3mm
Corrosion allowance2mm
Weld joint eIIiciency Iactor (Class I) 1
Allowable stress 0.25m
Outside diameter oI nozzle (seamless)0.25m
Nozzle wall thickness0.016m
Inside protrusion oI nozzle-not desired
Length oI the nozzle above surIace0.1m
Area to be compensated:
A(d2C)t
r
d(0.25-2x0.016)m0.218m
C2x10
-3
m
t
r
pD
0
/2IJp
where pdesign pressure2.02x10
6
N/m
2
D
0
1.39m ,I550x10
6
N/m
2
Nozzle diameter0.25m
120
J1(opening is assumed away Irom welded joint)
ThereIore t
r
2.54mm
A(0.2182x0.002)x0.002545.67x10
-4
m
2
Area available Irom shell Ior reinIorcement
A
S
(d2C)(t
S
-t
r
-C)(0.218(2x0.002))(0.03-0.00254-0.002) 5.65x10
-3
Area available Irom nozzle Ior reinIorcement
A
n
A
0
(no inside protrusion)2H
1
(t
n
-t
r
l
-C)
t
n
0.016m
t
r
l
pD
0
/2IJp (2.02x10
6
x0.25)/(2x550x1)2.02*10
6
0.2498mm
H
1
b(d2C)(t
n
-C)b(0.218(2x0.002))(0.016-0.002)0.0557m
Actual length oI nozzle above shell surIace is larger than 0.054m.
Hence A
n
2x0.0557(0.016-0.0002-0.002)1.53x10
-3
m
2
ReinIorcement area available Irom shell and nozzle is
(A
s
A
n
)( 5.65x10
-3
1.53x10
-3
)4.14x10
-3
m
2
Area remained to be compensated NIL
DESIGN OF FLANGE FOR EVAPORATOR
(I)DESIGN OF GASKET AND BOLT SIZE
The Ilange is made oI carbon steel with a stainless steel lining (raised Iace) in the
Iorm oI a ring. A Ilat asbestos gasket oI 1400 mm internal diameter and 1440 mm
external diameter and 3 mm thickness is used to cover the raised Iace.
From Table 7.1 (Bhattacharya),
Gasket Iactor m 2
121
Minimum design seating stress11.2 MN/m
2
Basic gasket seating width b
o
0.5(1440-1400)/210 mm
EIIective gasket seating width b2.5(b
o
)
0.5
2.5(10)
0.5
7.9 mm
W
m1
a 7.9 (14401400)/2 11.2394714.7275 N
W
m2
a 2 7.9 (14401400)/2 2 2.02 a/4 ((14401400)/2)
2
2.023483785.732 N
A
m1
W
m1
/I
a
394714.72/587067.24 cm
2
A
m2
3483785.73/5450639.226 cm
2
Number oI BoltsG/b
o
2.51420/10 2.5 57 bolts
Diameter oI bolt(639.226 4/57a)
0.5
3.77 cm
We use M18 bolts.
Pitch Diameter16.376 mm
Minor Diameter14.480 mm
ACTUAL BOLT AREA
a/4(16.376
2
14.48
2
/2 100) 57106.95 cm
2
A
b
2aY
a
GN/I
a
2a 1390 11.2 10/58.7166.63 cm
2
(NWidth oI gasket)
Hence the bolt area suggested is satisIactory.
Pitch oI bolts4.75 1885.6 mm
PITCH CIRCLE DIAMETER (B)
85.6 57/a1553.09 mm
Outside diameter oI IlangePitch circle diameter2 diameter oI the bolt
1553.09 2 181.589 m
122
FLANGE THICKNESS
K1/(0.31.5W
m
h
G
/HG)1/(0.3(1.5 3483785.732 (1553.09-1420)/a/4 2
1400
2
2.02 1390))
2.623
t
I
G(p/K
I
)
0.5
c1420(2.02/2.623 95)
0.5
128.96 mm
DESIGN OF NOZZLE (OPENINGS)
Outside diameter oI the shell1.39m
Maximum working pressure5.72x10
6
N/m
2
Wall thickness oI shell 3mm
Corrosion allowance2mm
Weld joint eIIiciency Iactor (Class I) 1
Allowable stress 55010
6
N/m
2
Outside diameter oI nozzle (seamless) 0.25m
Nozzle wall thickness0.016m
Inside protrusion oI nozzle-not desired
Length oI the nozzle above surIace0.1m
Area to be compensated:
A (d2C) t
r
d (0.25-2x0.016) m0.218m
C2x10
-3
m
t
r
pD
0
/2IJp
where pdesign pressure2.02x10
6
N/m
2
123
D
0
0.47m
I550x10
6
N/m
2
J1(opening is assumed away Irom welded joint)
ThereIore t
r
2.547mm
A(0.2182x0.002)x0.0024315.65x10
-4
m
2
AREA AVAILABLE FROM SHELL FOR REINFORCEMENT
A
S
(d2C)(t
S
-t
r
-C)(0.218(2x0.002))(0.03-0.002431-0.002) 5.65x10
-3
Area available from nozzle for reinforcement
A
n
A
0
(no inside protrusion)2H
1
(t
n
-t
r
l
-C)
t
n
0.016m
t
r
l
pD
0
/2IJp (5.72x10
6
x0.25)/(2x550x10) 0.458mm
H
1
b(d2C)(t
n
-C)b(0.218(2x0.002))(0.016-0.002)0.0557m
Actual length oI nozzle above shell surIace is larger than 0.054m.
Hence A
n
2x0.0557(0.016-0.001293-0.002)1.508x10
-3
m
2
ReinIorcement area available Irom shell and nozzle is
(A
s
A
n
)( 5.67x10
-3
1.398x10
-3
)7.15x10
-3
m
2
Area remained to be compensated NIL
124
10.2.3 SUPPORT DESIGN FOR EVAPORATOR
TYPE: Skirt support.
1) MATERIAL: IS-2062-1962 Gr St 42-W. I96MN/M
2
. E210
5
MN/M
2
The minimum weight oI the vessel with two heads and shell will be-
W
min
n(D
i
t
a
)t
a
(H-4)V
s
2(7500)
D
i
1.39m
t
a
0.014m
H3.72m
V
s
speciIic weight oI shell material
778509.81n/m
3
77000n/m
3
77kn/m
3
W
min
n(1.390.014)0.014(3.72-4)772(7.5)
13.66KN
W
max
W
s
W
i
W
l
W
a
W
s
weight oI shell
W
max
4W
min
413.66KN 54.67KN
Period oI vibration at minimum dead weight is
T
min
(6.3510
-5
)(H/D)
1.5
(W
min
/t
a
)
0.5
6.3510
-5
(3.72/1.39)
1.5
(13.66/0.014)
0.5
3.6810
-3
sec 0.5sec
Hence K
1
CoeII to determine wind load 1
123
Period oI vibration at maximum daed weight
T
max
(6.3510
-5
)(H/D)
1.5
(W
max/
t
a
)
0.5
6.3510
-5
(54.67/0.014)
0.5
T
max
0.017 sec 0.5 sec
Hence K
2
1
2) WIND LOAD:
P
w
K
1
K
2
p
w
H
d
For min weight condition, D1.4m.
For max weight condition, D1.5m.
Hence P
w
(min)110003.721.4
5208N
P
w
(max)110003.721.5
5580N
3) MINIMUM AND MAXIMUM WIND MOMENTS
M
w
(min)P
w
(min)H/2
5.2083.72/2
9.68 KJ
M
w
(max)P
w
(max) H/2
5.583.72/2
10.37KJ
II the thickness oI the skirt is expected to be small, Assume D
i
D
o
1.4m
2
Wm(min)4M
w
(min)/nD
2
t
49.68/n1.4
2
t
126
6.2810
-
3/t NM/M
2
2
W
m
(max)410.37/n1.4t
6.7310
-3
/t NM/M
2
4) MINIMUM AND MAXIMUM DEAD LOAD STRESSES
2
W(min)W(min)/nDt
13.6610
-3
/n1.4t
0.0031/t MN/M
2
2
W(max)54.6710
-3
/n1.4t
0.0124/t MN/M
2
2
(tensile)
2
Wm(min)-
2
W(min)
0.00318/t MN/M
2
2
(tensile) IJ
960.7
67.2MN/M
2
J0.7 Ior double welded joint but joint Ior class 3 const.
67.20.00318/t
t1mm
2
(compression)
2
W(max)
2
W
m
(max)
(0.006730.0124)/t
0.01919/t
2
(compression)0.125Et/D
o
0.125210
5
t/1.5
127
1.610
4
t
1.610
4
t0.01913/t
t2mm
As per IS:2825-1969,minimum corroded skirt thickness is 7mm.providing 1mm
corrosion allowance a standard 8mm thick plate can be used Ior skirt.
5) DESIGN OF SKIRT BEARING PLATE
F
c
W(max)/A M
w
(max)/Z
W(max)54.67 KN
An(D
o
-l)l , ZnR
m
2
l
F
c
0.05467/n(1.4-l)l 0.010374/(1.4-l)l
The allowable compressive strength oI concrete Ioundation varies Irom 5.5 to 9.5
MN/M
2,
Assuming F
c
5.5 MN/M
2
,l7.5mm
As the required width oI the bearing plate is very small, a 100mm width is
selected i.e. l0.1mm.
6) THICKNESS OF BEARING PLATE
t
bp
l(3 F
c
/I)
0.5
l100mm , F
c
1.85
t
bp
100(31.85/96)
t
bp
25mm.
Casing plate thickness oI 25mm is required. As the plate thickness required is
larger than 20mm,gussets may be used to reinIorce the plate.
From table no 10.1 (battacharya) Ior 1/b1,M
max
M
y
-0.119 F
c
l
2
-0.1191.850.1
2
128
-2.210
3
MJ
t
bp
(6M
max
/I)
0.5
(62.210
-3
/96)
0.5
1.1810
-2
M
II gussets are used at 100mm spacing, bearing plate thickness oI 12mm will be
suIIicient. thereIore rolled angle bearing plate oI size
100mm100mm12mmwith 62 gussets may be used. II no oI gussets are reduced
thicker plate will be required.
F
min
W(min)/A - M
w
(min)/Z
0.01366/0.1n(1.4-0.1)
2
- 0.00968/0.1n(1.4-0.1)
2
F
min
0.0152MN/M
2
J W(min)R/M
w
0.0152(1.4-0.1)0.1/0.00968
J0.183
As this value is less than 1.5 the vessel will not be steady by its own weight ,
thereIore anchor are to be used-
P
bolt
n (min )A
0.0152n(1.4-0.1)0.1 MN
6.210
-3
MN
II hot rolled carbon steel is selected Ior bolts, table 5.7 gives I53.5 MN/M
2
( a
r
n) I P
bolt
6.210
-3
MN
a
r
n6.210
-3
/53.5
11.6mm
2
Where , a
r
root area oI bolt
129
nno oI bolts
For M
121.5
bolts a
r
63mm2, this indicates that 1 such anchor bolt is more than
suIIicient Ior this purpose. But as the wind may blow Irom any side eight such
bolts are to be used equally distributed.
10.2.4 DATA SHEET
Address Coimbatore institute oI
technology,coimbatore-14
Design unit EVAPORATOR
Design DETAILS
Inlet Ieed rate 5468.75kg/hr
Bottom product 4419.19 kg/hr
Top product 1049.56kg/hr
Inlet temperature 135c
Outlet temperature 135c
Height oI the column 3.9927m
Diameter oI column 1.39mm
Water Ilow rate 1049.218911kg/hr
Pressure oI column 60cm.Hg
Pressure oI water 4.76 bar
Tube OD 76.2mm
Thickness oI tube 3mm
No.oI tubes 97
Pitch 114.3mm
Annular area 1.267m
2
Downtake area 0.1877m
2
Height oI steam chest 1.5m
Thickness oI shell 5mm
Number oI Bolts 57 bolts
Diameter oI bolt 3.77 cm
Thickness oI Ilange 128.96 mm
130
10.3. ABSORBER DESIGN
10.3.1 PROCESS DESIGN.
Temperature inside the scrubber 50%c
STREAM COMPONENT ACROSS ABSORBER
Component Reactor exit gas Absorber outlet gas Bottom product
Kg/hr Mass Kg/hr Mass Kg/hr Mass
CHOH 52.384 0.28 - - 53.384 0.446
O - 0 - - - -
N 10240.823 55.04 10240.283 93.05 - -
HO 3208.338 17.26 - - 7291.667 62.222
HCHO 4.375 23.54 - - 4375 37.332
CO 712.976 3.84 712.976 6.508 - -
CO - 0 - - - -
H - 0 - - - -
CH - 0 - - - -
(CH)CO - 0 - - - -
18589.521 10953.799 11719.051
Total entering 18589.521 Kg/hr.
Total moles oI Iormaldehyde absorbed4375/30 145.833 Kmol/hr.
Heat oI solution 62.75Kg/mol.
Total heat evolved by absorption145.833*62.75*1000
9151041.667 KJ 2541.9546 kW
Total heat to be removed by coolers
131
Total enthalpy in Heat generated due to absorption - Total enthalpy out.
2509027.649 9151041.667 5119804.4564 - 558093.0021 - 2209041.114
2612.4276 KW.
Flow rate oI Iresh water Ied at the top oI tower 7291.667 3208.33
4083.337 Kg/hr
Average temperature oI absorption in entire tower 30%C.
The temperature oI Iormaldehyde solution leaving the topmost section50%C.
Enthalpy oI solution leaving the topmost section Enthalpy oI Iresh water
Heat oI solution *Iormaldehyde absorbed in top section.
(4083.337/3600) C
L
(50 0) (4083.3374.1868(30 0))
(1 - w&/100) 3600
62.710 4083.337 4083.337
303600 1 - w&/100
W& Mass oI Iormaldehyde in solution leaving the 1
st
section.
SpeciIic heat oI Iormaldehyde solution is given by
C
L
4.1868(1 0.0534W (0.004 0.00001W )t)
t 50 0 25%C & W W&
2
4.1868(1 0.0534W& 0.1 0.00025W&)
4.1868 (1.1 0.04975W&).
132
4.60548 0.2082W&
1.1342 (4.0548 0.2082 W&) 50 142.46
1 0.01 W&
0.581*4083.337(1/(1-0.01 W&) 1)
W& 3.5(by trial and error)
Heat duty oI Iirst intercooler:
u
1
m %C
L
(50 30)
m% 4083.337
1 (0.01 *3.5)
4231.437Kg/hr.
1.1753Kg/sec.
C
L
4.604598 (0.2082 * 3.5)
C
L
3.87678KJ/Kg%C
u
1
1.1753 * 3.87678 * (50 30)
u
1
91.12 Kw.
Steam leaves the Iirst intercooler and enters at the top oI second section which is
3.5(by mass) Iormaldehyde solution at 30%C.
This stream is mixed with recirculated stream.
Let recirculation ratio R.
Mass Ilow rate oI recirculated stream R * 1.1753.
133
Total mass Ilow rate oI HCHO solution Ieed to the top oI second section
(R 1)*1.1753.
by mass oI HCHO in liquid solution leaving second section 37.332.
Mass Ilow rate oI Iormaldehyde solution leaving the second section
R * 1.1753 (4083.337/3600) (R * 1.1753 1.8098) Kg/sec.
1 - (37.33/100)
This stream leaves at 50%C.
Enthalpy balance around second section:
(1.1753 * R 1.8098) C
L
(50 0) 1.1753R C
L
`
* (30 0) -1.1735 C
L
*(40
0)
(62.75 * 1000) / 30 * (1.8098 1.1753)
Where,
C
L
4.1868( 1-0.00534 * 37.33 ( 0.004 (0.00001 * 37.33))25)
4..5636 KJ/Kg%C.
C
L
` 4.1868( 1-0.00534 * 37.33 ( 0.004 ( 0.00001 * 37.33))15)
4.9812KJ/Kg%C.
C
L
4.1868( 1-0.00534 * 3.5 ( 0.004 ( 0.00001 * 3.5))15)
4.01164KJ/Kg%C.
(1.17531.8098)*4.5636 * 50 - 1.1753 * 4.9812R * 30( 1.1753 * 4.01164) * 40
1327.1625.
228.18(1.1753R 1.8098) 175.632R 188.595 1327.1625
268.1799R 412.960 175.632R 188.595 1327.1625
134
92.5479R 725.6075
R 7.8403
Amount oI recirculated stream back to the top oI second section
7.8403*1.1753
9.2147kg/sec.
Second cooler cools this stream Irom 50%C to 30%C.
u
2
m%C
L
(50-30)
C
L
4.186|1- 0.00534*37.33( 0.0040.00001*37.33) ((5030)/2)|
3.556kJ/kg%C
u
2
655.459kw
Let cooling water enters at 30%C and leaves at 37%C.
Mass Ilow rate oI cooling water required.
m%w 655.459
4.1868*(37-30)
22.364kg/sec.
80513.349kg/hr
80.674m
3
/hr.
Let the temperature oI cooling water Irom top section intercooler 39%C
u
1
91.12kw.
m%
1
* 4.1868*(39-37)
m%
1
10.88kg/sec
remaining m%
2
22.364 10.88
11.482kg/sec will be used by gas cooler.
133
CALCULATION FOR HEAT DUTY OF GAS COOLER
Reactor and exit gas is at 110%C. This cooled Irom 110%C to 30 %C in cooler.
(a). Dew point temperature calculation:
Mass oI water in reactor exit gas 17.26.
Molar Ilow rate oI reactor exit gas (52.384/32) (10240.823/28)
(3208.338/18) (4375/30)
(712.976/44).
707.659Kmol/hr.
Moisture content oI gas mixture (3208.338/18)
707.659 (3208.338/18)
0.3366Kmol water/Kmol dry gas.
At dew point,
P
V
/(P
t
P
V
) 0.3366.
P
V
/(135 P
V
) 0.3366.
45.441 0.3366P
V
P
V
P
V
33.9974 Kpa
At 72%C temperature vapour pressure oI water is 33.9974Kpa. Hence dewpoint oI
gas mixture is 72%C.
136
Heat duty oI cooler,
u
3
273.15+100
273.15+30
%P
1
dt
_ (8. -.) + _ (8.
2
- .`)
b u
2
_ (8.
3
- .
c
) _ (8.
4
- 303.15
4
)
3 4
_ ,
aI
_ ,
bI
_ ,
cI
_ aie taken
dI
Irom reIerence.
u
3
47588.5(80) 2267.1 * 10
-3
(54904) 15211.7 * 10
-6
2 3
(28388461.4) 5816.3 * 10
-9
(1.3105 * 10
10
)
4
3807080 62236.4292 1439 5.586 19055.65)
3869733.507Kj/hr
1074.925Kw
Total heat to be removed by two intercoolers and one gas cooler
u
1
u
2
u
3
91.12 655.459 1074.925
1821.504 Kw
u
3
11.482 * 4.1868 *(t
0
-37)
1074.925
137
t
0
59.36%C - outlet temperature oI cooling water Irom gas cooler.
Calculation oI number oI trays required:
Flow rate oI Iresh water at top L
2w
4083.337Kg/hr.
L
2
L
s
4083.337/18 226.852Kmol/hr.
x
2
0, X
2
x
2
/(1-x
2
) 0
Mass Ilow rate oIexit gas at top 10953.799Kg/hr.
G
2
w 10953.799Kg/hr
Molar Iolw rate oI gas mixture at outlet oI absorber,
G
2
(10240.823/28) (712.976/44)
381.9476kmol/hr
Let concentration oI Iormaldehyde in outgoing gas mixture is 120ppm.
y
2
120 * 10
-6
0.00012
Y
2
y
2
/(1-y
2
) 0.00012
n
I
moles oI HCHO in liquid solution entering to 2
nd
section
n
I
(9.2174 *0.3733) (1.1753*0.035)
30
0.1160kmol/sec
Moles oI water in same solution;
N
w
9.2174* (1- 0.373) 1.1753 *(1-0.035)
18
0.3839kmol/sec
x
2
`
0.1160
138
0.116 0.3839
0.2320
Y
2
`
x
2
`
/(1- x
2
`
)
0.3021
Formaldehyde absorbed in the top section
G
s
(Y
2
`
- y
2
) ((4083.337)/(1-0.035)) 4083.337
30
4.936 Kmol/hr
G
3
G
2
(1 y
2
)
381.9476(1 0.00012)
381.9017 Kmol/h
381.9017(y
2
`
0.00012) 4.936
y
2
`
0.013044
y
2
`
y
2
`
/(1Y
2
`
)
0.0128
At the base oI the tower,
G
1
52.384 7291.667 4375
32 18 30
G
1
552.562 Kmol/hr.
Mole Iraction oI HCHO in gas mix.
y
1
(4375/30)
552.562
139
0.2639
Y
1
Y
1
/(1-Y
1
) 0.3585
Flow rate oI liquid solution leaving the tower
L
1w
R * 101753 * 3600 11719.051
L
1w
44881.987Kg/hr (R 7.8403)
Average molar mass oI product solution
M
av
100
(37.332/30) (62.22/18) (0.446/32)
21.208Kg/mol
L
1
44881.987/21.208
2116.276Kmol/hr.
Mole Iraction oI HCHO in this solution
x
1
44881.9987 *( 0.3733/30 )
2116.276
x
1
0.2638
X
1
x
1
/(1-x
1
) 0.3585
Mass oI HCHO at top oI second section
x
2
` *30 * 100
( x
2
` * 30)( 1 x
2
`)*18
0.2320*30*100
(30*0.2320)(0.768 * 18)
33.487.
Average mass percentage oI HCHO in second section
140
(33.48 37.33)/2
35.4086 .
Average temperature oI absorption 50C.
Partial pressure oI HCHO in atmosphere air over HCHO solution is given by
Lacy`s empirical equation.
Log pv 9.942 0.953 *(0.488)
w/10
2905/T
T 50273 323K.
W 35.4086
pv 1.9torr
At atmospheric pressure,
Equation constant m (1.91/760)
(35.4/30)/((35.4/30)(100-35.4)/18)
m 0.0101
Value oI m Ior second section is 0.0101.
Y YX 0.0101X 0.0101XY
Y 0.9899XY 0.0101X 0
(Y 0.002),
0.022 0.001979X 0.0101X 0
Y X
0 0
0.002 0.2462
0.004 0.6514
141
0.006 1.442
0.008 3.668
0.01
0.0101 -
Average mass oI HCHO Ior top section,w 3.5/2 1.75
Average temperature oI absorption (5030)/2 40C
Logpv 9.942-0.953(0.488)
1.75/10
(2905/313)
Pv 0.67 torr
m (0.67/760)
(1.75/30)/((1.75/30)(100-1.75)/18)
m 0.0833
equation data Ior 1
st
equation,
Y/(1Y) 0.0833(X/1X)
Y XY 0.0833X 0.0833XY
Y 0.9167XY- 0.0833X 0
X Y
0 0
0.0121 0.011
0.0245 0.002
0.0372 0.003
0.0502 0.004
142
0.0771 0.006
0.1053 0.008
0.1448 0.01
For the 1
st
section operating line starts Irom (0,0.00012) to (x,0.013044)
X x/(1-x) &
x (3.5/30) 0.0212
(3.5/30) (100-3.5)/18
X 0.02165
x 2.2
For 2
nd
section operating lines starts Irom (0.3032,0.013) & terminates at
(0.3585,0.35)
n
2
1 but assumed as 1
Total number oI trays required Ior the desired separation, n
T
3.2
Tower diameter calculations:
At the base oI second section
G
1w
18589.21 kg/hr
L
1w
44881.987 kg/hr
Average molecular mass oI gas mixture that enters the tower
M
av
(18589.21/552.562) 33.638 kg/mol
Liquid vapour Ilow rate F
LV
Ior sieve tray tower,
F
LV
L
w
/G
w
(p
V
/p
L
)
L
1w
L
w
44801.987 kg/hr
G
w
G
1w
1858
9.21 kg/hr
143
p
V
pm
AV
/RT 135 * 33.638/8.314*(27350)
1.6909 kg/m
3
p
L
1
_
i
/p
Li
1
(0.000446/780) (0.622/988) (0.3733/815)
919.243Kg/m
3
F
LV
(44881.987/18589021) * (1.6909/919.243)
1/2
0.1035
For tray spacing S 0.45m.
C
I
0.03
Flooding velocity, V
F
C
F
(p
L
/0.02)
0.2
*( p
L
-p
v
/p
V
)
0.5
p
L
surIace tension oI liquid N/m
_o
i
x
i
0.26o
F
0
0.74o
water
o
0
1/4
|P
i
|(o
L
` o
G
`
)
| P
i
| Ior HCHO 15.5 66 81.5
p
G
`
p
M
/RT 135 * 130 /8.314 *(27350) 1.5Kg/m
3
o
0
1/4
81.5 * (815 -1.5) * 10
-3
/30 2.21
o
0
23.85dyns/cm 23.85 * 10
-3
N/m
p
L
0.26 *23.85 *10
-3
(0.74 *70 *10
-3
)
58 * 10
-3
N/m
144
V
I
(0.03 *0.058)/0.02 ((919.243 1.6909)/1.6909)
0.5
2.026m/sec
Let actual velocity oI gas vapour mixture through tower
V
1
0.66V
I
0.66 *2.026
1.33m/sec
Volumetric Ilow rate at bottom(oI gas mixture)
q
v1
G
1w
/p
v
(18589.21/3600)/1.6909
3.05m
3
/sec.
Net area oI tray required at bottom
A
n
q
v1
/V
3.053/1.33 2.296m
2
Let down corner area A
d
0.12A
c
Where, A
c
inside cross sectional area oI tower
A
n
A
c
-A
d
A
c
-0.12A
c
0.88 A
c
0.88A
c
2.296m
2
A
c
2.609
(n/4) D
i
2
2.609
D
i
1.822 m
TOWER DIAMETER REQUIRED AT THE BASE OF TOP SECTION
143
At the base oI top section, L
w
1.1753Kg/sec
Gas Ilow rate at the base oI Iirst section,
G
w
Gas Ilow rate at the top oI Iirst section L
w
solvent Ilow rate at top
10953.799 (1.1753 *3600)- 4083.33
13181.262kg/hr
3.66Kg/sec.
Molar Ilow rate oI gas mixture at the entrance oI Iirst section,
G G
s
(10.013)
386.905Kmol/hr
M
av
13181.262/386.905
34.068Kg/Kmol
p
v
pM
av
/RT
(135 *34.068)/8.314 *(50273)
1.712Kg/m
3
p
L
1
_(w
i
/p
w
)
1
(0.035/815) ((1 0.035)/983.2)
976.148 Kg/m
3
F
Lv
L
w
/G
w
(p
v
/p
l
)
1/2
1.1753/3.66(1.712/976.148)
1/2
0.01344
For tray spacing S 0.45m
146
C
I
0.05
SurIace tension oI 3.5 HCHO solution
o
L
_o
i
x
i
oF
0
x(1-x)o
at
X (3.5/30)/((3.5/30)(96.5/18))
0.0212
o
L
0.0212 * 23.84 *10
-3
(1-0.0212) *70 *10
-3
0.069N/m.
Flooding velocity:
V
I
c
I
(o
l
/0.02)
0.2
|(o
L
o
V
)/ o
V
|
0.5
0.05 *(0.069/0.02)
0.2
|(976.148-1.712)/1.712|
0.5
1.528m/sec.
For 66 Ilooding,
V 0.66 * 1.528 1.008m/sec|
Volumetric Ilow rate oI gas mixture at the base oI Iirst section
q
v
3.66/1.712
2.1707 m
3
/sec
Net area oI tray required
A
n
q
v
/V 2.137/1.008 2.12m
2
n/4(D
i
)
2
2.12
D
i
1.642 m
Checking of weeping for bottom section:
147
The minimum design vapour velocity through holes to avoid weeping is given by,
U
h
k 0.9(25.4 d
n
)
p
G
U
h
minimum gas velocity through holes, m/sec
K constant.
d
n
Hole diameter, minimum.
Let d
n
5mm
p
G
1.6909 Kg/m
3
Height oI weir h
w
50mm
Height oI liquid crest over the weir,
H
ow
750|L
w
/p
L
p
w
|
2/3
L
w
44881.987Kg/hr 12.46 kg/sec
p
L
919.243
L
w
length oI weir.
For, A
d
/A
c
0.12
L
w
/D
i
0.76
L
w
0.76 * 1.822
1.3847 m.
h
ow
750|12.46/(919.243 * 1.3847)|
2/3
34.32 mm
h h
ow
50 34.32 84.32
k 30.8(table 8.19)
148
U
n
30.8 0.9(25.4-5)
V.99
9.566 m/sec
Maximum hole area required
A
hm
3.053/9.566
0.3191 m
2
A
hm
/A
c
0.3191/2.609 0.1223
Let A
h
0.08A
c
0.08 * 2.609 0.2087 m
2
V
w
3.053/ 0.2087
14.62 m/sec
Actual velocity oI gas through holes V
w
~9.566m/sec
Hence weeping will not take place.
Checking of weeping for top section:
For the trays oI top section. Let hole diameter d
n
5mm.
Height oI weir h
w
50mm.
Height oI liquid crest over the wire
h
ow
750|L
w
/p
L
L
w
|
2/3
L
w
1.1753 Kg/sec
976.148 Kg/m
3
.
For A
d/
A
c
0.12
L
w
/D
i
0.76
Length oI weir:
149
L
w
0.76 *1.642
1.2479m
h
ow
750 (1.1753/976.148*1.2479)
2/3
7.323mm
For h
w
h
ow
50 7.323
57.323mm, k 30.2
Minimum vapour velocity required through holes to avoid weeping,
U
h
k-0.9(25.4-d
h
)
p
G
30.2 0.9(25.4-5)
V.
9.048m/sec under weeping conditions
Maximum hole area which can be provided,
A
hm
2.137/9.048
0.2361m
2
A
hm
/A
c
0.2361
(n)(1.642)
2
0.1115
Let A
h
/A
c
0.1
A
h
0.1A
c
0.2117m
2
130
Actual velocity oI gas through holes
V
h
2.137/0.2117
10.0917m/s ~9.048m/sec
Hence weeping will not take place.
Checking oI downcomer Ilooding Ior bottom section
Where, h
t
total tray pressure drop,mm L
c
H
tc
head loss in downcomer,mmL
c
h
d
51(V
n
/C
o
)
2
(p
G
p
L
)
where, C
o
oriIice coeIIicient can be determined by Iig 8.20.
Let plate thickness 5mm
Plate thickness/hole diameter 5/51
A
h
/A
p
=A
h
/A
a
A
h
A
c
-2A
d
A
h
A
c
-2*0.12A
c
A
h
/0.76A
c
0.1/0.76 0.1315
C
o
0.875
h
d
51*(10.0917/0.875)
2
*(1.1712/919.243)
12.63mmL
c
Residual pressure drop:
h
r
(12.5 *10
3
)/p
L
(12.5*10
3
)/919.243
131
13.58mmL
c
h
t
12.63(84.32)13.58 110.53mm
h
b
5034.31110.53h
dc
Head loss in diameter,
h
dc
166|L
wd
/p
L
A
m
|
2
166|12.46/(919.243A
m
|
2
A
m
A
d
(0.47m
2
)
Or,
A
ap
(0.04*1.2479) 0.0499m
2
A
ap
h
ap
Lw
h
ap
h
w
-(5 to 10mm)
h
dc
166|12.46/(919.243*0.0499)|
2
12.248mm
h
b
50110.5312.248
207.098mm
Sh
w
45050
500mm
h
b
~ 0.5(Sh
w
)
hence downcomer Ilooding will take place. To avoid Ilooding, let tray spacing in
bottom section S600mm
Ior,
F
LV
0.1456
C
F
0.09
132
Flooding velocity,
V
F
0.09(0.069/0.02)
0.2
|(976.148-1.712)/1.712|
0.5
2 .7506m/sec
V
1
0.66V
I
1.815m/sec
q
v
3.66/1.712
2.137m
3
/sec
A
n
.137/1.815
1.1774m
2
n/4D
i
2
1.1774
D
1
1.502 (nearly same as top section)
Length oI weir 0.76*1.502 1.422m
h
dw
750(12.46/919.243*1.2479)
2/3
36.78mm
h
w
h
ow
5036.78 86.78mm
k30.8(Iig 8.19)
minimum vapour velocity required through holes,
u
h
k-0.9(.4-d
h
)
p
G
30.8-0.9(25.4-5)
V.
133
9.507m/s under weeping conditions
Let A
h
/A
c
0.1
A
h
0.1*
4
(.)
2
0.1771m
2
Actual gas velocity through holes,
V
h
2.137/0.1771
12.066m/s ~U
h
9.507m/s
Hence weeping will not take place.
CHECKING OF DOWNCOMER FLOODING
Dry plate pressure drop,
h
d
51(V
h/
c
o
)
2
p
G/
p
L
plate thickness 5/5 1
hole diameter
A
h
/A
p
A
h
/0.76A
c
0.1/0.76
0.1315
C
o
0.87(Iig 8.20)
h
d
51*(12.066/0.87)
2
*(1.712/919.243)
18.26mmL
c
h
t
18.26 5036.7813.58
118.62mm
h
b
5036.78118.62h
dc
134
A
m
A
ap
0.04*1.1422
0.0456m
2
h
dc
166(12.46/919.243*0.0456)
2
14.667mmL
c
h
b
220.067mmL
c
Sh
w
60050 650mm
h
ap
h
ap
-5mm 45mm
A
m
A
ap
0.045*1.422
0.0513m
2
h
dc
14.667mm
h
b
220.0670.5 (60050)
downcomer Ilooding will not take place.
DOWNCOMER RESIDENCE TIME
T
A
d
h
b
p
L
L
wd
0.12*2.12*0.220*919.243
12.46
4.129sec ~3sec (satisIactory)
CHECKING OF DOWNCOMER FLOODING IN TOP SECTION
Dry plate pressure drop.
h
d
51(V
h
/w) p
G/
p
L
plate thickness/ hole diameter 5/5 1
133
A
h/
A
p
A
h
/0.76A
c
0.1/0.76 0.1315
C
o
0.87
h
d
51(10.0917/0.87)
2
*(1.717/976.148)
12.03mm
RESIDUAL PRESSURE DROP
h
r
12.5*10
3
/976.148
12.805mm
h
t
12.035012.8057.323
82.158mm
L
w
1.3847m
A
ap
0.045**1.347
0.062m
2
Head loss in downcomer,
h
dc
166|L
wd
/p
L.
A
m
|
2
166 |1.1753/(976.148*0.062)|
2
0.0626mm
H
h
50 7.32382.1586.06
139.541mm
Sh
w
45050 500mm
h
b
0.5(500)
Downcomer Ilooding will not take place.
Downcomer residue time
r
A
d
h
b
p
L
136
L
wd
0.12 (n) -1.5
2
*0.139*976.14
1.175
24.485 (satisIactory)
ESTIMATION OF HEIGHT
Tray eIIiciency 0.33
Actual number oI trays 3.2/0.33 10
Plate thickness 5mm
Plate openings 600mm
Take height oI dished head.510m
Total height 2*(dished head height) 9(600)(5*10)
2(510)(9*600)(5*10)
6.470m
10.3.2MECHANICAL DESIGN OF ABSORBER
1.THICKNESS OF FLANGE
tpD
i
/(2Ij-p) ,p3 bar,I Ior c-steel550MN
310
5
1.0131.822/(255010
6
0.85)-(31.01310
5
)
0.5922mm
Corrosive allowance0.59232mm
2.5923mm
Available thickness5mm
137
TO DETERMINE MAX INPUT PRESSURE
P2Ijt/D
o
-t
2*(550*10
6
)*0.85*3*10
-3
/1.832-0.003
1.50810
6
N/M
2
HEAD DESIGN
TYPE : DISHED HEAD
CALCULATION OF THICKNESS
tpD
o
c/2Ij
1
st
approximation
R
i
R
o
D
o
1.822m
r
o
0.06*1.822
0.1093m
h
o
R
o
- (R
o
-D
o
/2)*(R
o
D
o
/2-2r
o
)
h
o
0.3085m
D
o
2
/4801.822
2
/4*1.822
0.455m
(D
o
R
o
/2)
0.5
(1.822*0.1093/2)
0.5
0.3155m
H
o
is least, hence H
E
0.3085m
H
E
/D
o
0.3085/1.822 0.1693
J1
t/D
o
pc/2Ij
381.013*10
5
c/2*550*10
6
*1
138
`2.762*10
-4
c
C3.452
t/D
o
0.002
t0.002*1.822
3.644*10
-3
m
This is the corroded head thickness
DESIGN OF FLANGE
DESIGN OF GASKET AND BOLT SIZE
MATERIAL: carbon steel with a stainless steel lining
GASKET: Ilat asbestos oI 1822 mm ID & 1900 mm OD , 3mm thickness , gasket
Iactor0.2mm
Basic gasket sealing width b
o
0.5*(1862-1822)/2
EIIective gasket sealing width b2.5Vbo
2.5V9.
7.905mm
W
m1
n*7.9*(18621822)/2*11.2
512017.27N
W
m2
n*2*7.9*(18621822)/2*2*3n/4*((18221862)/2)
2
3
8543073.01N
A
m1
512017.27/587087.22 cm
2
A
m2
8543073.01 /54501567.53cm
2
NUMBER OF BOLTS
G/2.5b
o
139
1861/(2.5*10)
75 bolts
Diameter oI bolts((639.226/57)*(4n))
0.5
3.77cm
We use M18 bolts .
Pitch dia16.376 mm
Bolt dia14.48 mm
ACTUAL BOLT AREA
n/4*(16.376
2
14.48
2
)/2*57
106.95 cm
2
A
b
(2n/58.7)*1390*11.2*10
166.63 cm
2
Hence bolt area suggested is satiaIactory
Pitch oI bolts4.75*18
85.6mm
Pitch circle dia(B):
(85.6*57)/n
1553.09mm
Outside dia oI Ilangepitch circle (2*dia oI bolt)
1553.092*18
1.589m
FLANGE THCKNESS T
f
K1/(0.31.5*(W
m
h
g
/H
g
)
160
1/(0.31.5*3483785.732*(1553.09-1420)/2)
4
-
2
*2.03*1390
2.623
T
I
G(p/k
I
)
0.5
c
1420*(2.03/2.623*95)
0.5
T
I
128.16mm
10.3.3 SUPPORT DESIGN FOR ABSORBER
TYPE: Skirt support.
MATERIAL: IS-2062-1962 Gr St 42-W. I96MN/M
2
. E210
5
MN/M
2
The minimum weight oI the vessel with two heads and shell will be-
W
min
n(D
i
t
a
)t
a
(H-4)V
s
2(7500)
D
i
1.822m
t
a
0.014m
H5.842m
V
s
speciIic weight oI shell material
778509.81n/m
3
77000n/m
3
77kn/m
3
W
min
n(1.8220.014)0.014(5.842-4)772(7.5)
26.45KN
W
max
W
s
W
i
W
l
W
a
161
W
s
weight oI shell
W
max
4W
min
426.45KN 105.81KN
Period oI vibration at minimum dead weight is
T
min
(6.3510
-5
)(H/D)
1.5
(W
min
/t
a
)
0.5
6.3510
-5
(5.842/1.822)
1.5
(26.45/0.014)
0.5
0.015
sec 0.5sec
Hence K
1
CoeII to determine wind load
1
Period oI vibration at maximum daed weight
T
max
(6.3510
-5
)(H/D)
1.5
(W
max/
t
a
)
0.5
6.3510
-5
(5.842/1.822)
0.5
(105.81/0.014)
0.5
T
max
0.031 sec 0.5 sec
Hence K
2
1
WIND LOAD
P
w
K
1
K
2
p
w
H
d
For min weight condition, D1.9m.
For max weight condition, D2m.
Hence P
w
(min)11*10005.8421.9
11099.8N
P
w
(max)11*10008.8421.9
11684N
MINIMUM AND MAXIMUM WIND MOMENTS
162
M
w
(min)P
w
(min)H/2
11.0995.842/2
32.42 KJ
M
w
(max)P
w
(max) H/2
11.6845.842/2
34.12KJ
II the thickness oI the skirt is expected to be small, Assume D
i
D
o
1.9m
2
Wm(min)4M
w
(min)/nD
2
t
432.42*10
-3
/n1.9
2
t
0.011/t Mn/M
2
2
W
m
(max)434.12/n1.9
2
t
0.012/t Mn/M
2
MINIMUM AND MAXIMUM DEAD LOAD STRESSES
2
W(min)W(min)/nDt
26.45*10
-3
/n1.9t
0.0043/t MN/M
2
2
W(max)105.8110
-3
/n1.9t
0.0177/t MN/M
2
2
(tensile)
2
Wm(min)-
2
W(min)
0.00657/t MN/M
2
2
(tensile) IJ
960.7
163
67.2MN/M
2
J0.7 Ior double welded joint but joint Ior class 3 const.
67.20.00657/t
t1mm
2
(compression)
2
W(max)
2
W
m
(max)
(0.0120.0177)/t
0.0299/t
2
(compression)0.125Et/D
o
0.125210
5
t/2
1.2510
4
t
1.2510
4
t0.0299/t
t2mm
As per IS:2825-1969,minimum corroded skirt thickness is 7mm.providing 1mm
corrosion allowance a standard 8mm thick plate can be used Ior skirt.
DESIGN OF SKIRT BEARING PLATE
F
c
W(max)/A M
w
(max)/Z
W(max)105.81KN
An(D
o
-l)l , ZnR
m
2
l
F
c
0.10581/n(1.9-l)l 0.03412/n(1.9-l)l
164
The allowable compressive strength oI concrete Ioundation varies Irom 5.5 to 9.5
MN/M
2,
Assuming F
c
5.5 MN/M
2
,l7.5mm
As the required width oI the bearing plate is very small, a 100mm width is
selected i.e. l0.1mm.
THICKNESS OF BEARING PLATE
t
bp
l(3 F
c
/I)
0.5
l100mm , F
c
1.85
t
bp
100(31.85/96)
0.5
t
bp
24.04mm
Casing plate thickness oI 24.04mm is required. As the plate thickness required is
larger than 20mm,gussets may be used to reinIorce the plate.
From table no 10.1 (battacharya) Ior 1/b1,M
max
M
y
-0.119 F
c
l
2
-0.1191.850.1
2
-2.210
3
MJ
t
bp
(6M
max
/I)
0.5
(62.210
-3
/96)
0.5
1.1810
-2
M
II gussets are used at 100mm spacing, bearing plate thickness oI 12mm will be
suIIicient. thereIore rolled angle bearing plate oI size
100mm100mm12mmwith 62 gussets may be used. II no oI gussets are reduced
thicker plate will be required.
F
min
W(min)/A - M
w
(min)/Z
0.02645/0.1n(1.9-0.1)
2
- 0.03242/0.1[(1.9-0.1)
2
163
F
min
0.0139MN/M
2
J W(min)R/M
w
0.02645(1.9-0.1)0.1/0.03242
J0.01468
As this value is less than 1.5 the vessel will not be steady by its own weight ,
thereIore anchor are to be used-
P
bolt
n (min )A
0.0139n(1.9-0.1)0.1 MN
7.8610
-3
MN
II hot rolled carbon steel is selected Ior bolts, table 7.5 gives I53.5 MN/M
2
( a
r
n) I P
bolt
7.8610
-3
MN
a
r
n7.8610
-3
/53.5
14.6mm
2
Where , a
r
root area oI bolt
nno oI bolts
For M
121.5
bolts a
r
63mm
2
, this indicates that 1 such anchor bolt is more than
suIIicient Ior this purpose. But as the wind may blow Irom any side eight such
bolts are to be used equally distributed.
166
11.3.4. DATA SHEET
Address Coimbatore institute oI technology,
coimbatore-14
design unit absorber column
design details
inlet Ieed rate 18589.521kg/hr
bottom product 11719.051 kg/hr
top product 10953.799kg/hr
inlet temperature 120c
outlet temperature 50c
height oI the column 6.470m
diameter oI column 1.822 m
temperature oI column 50c
pressure oI absorber column 1atm
tray spacing 0.45m
tray eIIiciency 0.33
actual number oI trays 10
plate thickness 5mm
plate openings 600mm
thickness oI Ilange 5mm
maximum inlet pressure 1.50810
6
n/m
2
no.oI bolts 75 bolts
diameter oI bolts 3.77cm
eIIective gasket sealing width 7.905mm
diameter oI bolts 3.77cm
bolt diameter 14.48 mm
167
PLAA1 LOCA1IOA
168
CHAPTER 12
12 PLANT LOCATION
PARAMETER LOCATION A:
Kundaim ,Goa
LOCATION B:
Dewas industrial estate
,Indore(M.P)
1.CLIMATIC
CONDITIONS
Hot, average
temperature35-40%C
Sub tropical ,hot dry
summer, cool and
relatively dry winter,
average
temperature30c,max.
temperature40%C
2.SOURCES OF RAW
MATERIAL
Zurai Industries ltd.(Goa)
Ior urea and easy
availability oI
Iormaldehyde as well.
Vishnupari , Indore-lord
oI urea industries, Terai
Organics-Siliguri (West
Bengal)
3.TRANSPORTATION
COST
Reasonable , less Ior bulk
quantities.
Relaitively cheaper.
4.ACCESS TO MARKET Panaji -Goa, Mumbai ,
Nagpur, Pune and a
number oI local markets.
Indore, Ranchi,Bhopal
,Gwalior, Jabalpur ,
Khandwa , Dewas
5.LINK RAODS Yes Yes, extensive road
networks , 5 major
airports
6.RAILWAYS Yes Yes
7.SEAPORTS Yes No
8.WATER
AVAILABILITY
Easily available Easily available ,
Bhansagar dam on Sone
river, large river basins
and catchment oI many
rivers
9.ELECTRICITY Cheap Cheap
169
10. LABOUR Easily available at low
cost
Easily available at low
cost
11.BANKS AND
FINANCIAL
INSTITUTIONS
Goa, Mumbai, Pune. Bhopal , Dewas , Indore.
12.GOVERNMENT
INFLUENCE
Good Comparatively better
13.COST OF LAND 90 lakhs /acre 65 lakhs /acre
On the basis oI the above Iactors we have chosen Dewas industrial estate
(Indore) as the location Ior the plant.
170
COS1 ES1IMA1IOA
AAD ECOAOMICS
171
CHAPTER 13
13 COST ESTIMATION AND ECONOMICS
Cost oI Urea Formaldehyde plant oI capacity 100 TPD in 1970 is Rs.3000.2
10
5
ThereIore cost oI 250 TPD in 2010 is:
C1 C2 (Q1/Q2)
0.6
3000.2 10
5
(250/100)
0.6
Rs. 5198.9310
5
i.e., Fixed Capital Cost (FCI) Rs. 5.1989310
8
CHEMICAL ENGINEERING PLANT COST INDEX
Cost index in 1970114
Cost index in 2003402
Present cost oI plant (original cost) (present cost index)/(past cost index)
5198.9310
5
(402/114) Rs 1.83330610
9
Fixed capital cost Rs 1.83330610
9
ESTIMATION OF CAPITAL INVESTMENT COST
I. DIRECT COSTS: material and labour involved in actual installation oI
complete Iacility (70-85 oI Iixed-capital investment)
a) Equipment installation instrumentation piping electrical insulation
painting (50-60 oI Fixed-capital investment)
1. PURCHASED EQUIPMENT COST (PEC): (15-40 oI Fixed-capital
investment)
Consider purchased equipment cost 25 oI Fixed-capital investment
i.e., PEC 25 oI 1.83330610
9
0.25 1.83330610
9
Rs. 4.5832610
8
172
2. INSTALLATION, INCLUDING INSULATION AND PAINTING: (25-55
oI purchased equipment cost.)
Consider the Installation cost 40 oI Purchased equipment cost
40 oI 4.5832610
8
0.40 4.5832610
8
Rs.1.8333 10
8
3. INSTRUMENTATION AND CONTROLS, INSTALLED: (6-30 oI
Purchased equipment cost.)
Consider the installation cost 20 oI Purchased equipment cost
20 oI 4.5832610
8
0.20 4.5832610
8
Rs.
9.166510
7
4. PIPING INSTALLED: (10-80 oI Purchased equipment cost)
Consider the piping cost 40 Purchased equipment cost
40 oI Purchased equipment cost 0.40 4.5832610
8
Rs.
1.833310
8
5. ELECTRICAL, INSTALLED: (10-40 oI Purchased equipment cost)
Consider Electrical cost 25 oI Purchased equipment cost
25 oI 4.5832610
8
0.25 4.5832610
8
Rs. 1.1458110
8
B. BUILDINGS, PROCESS AND AUXILIARY: (10-70 oI Purchased
equipment cost)
Consider Buildings, process and auxiliary cost 40 oI PEC
40 oI 4.5832610
8
0.40 4.583.2610
8
Rs. 1.833310
8
C. SERVICE FACILITIES AND YARD IMPROVEMENTS: (40-100 oI
Purchased equipment cost)
Consider the cost oI service Iacilities and yard improvement 60 oI PEC
60 oI 4.5832610
8
0.60 4.5832610
8
Rs. 2.74995610
8
D. LAND: (1-2 oI Iixed capital investment or 4-8 oI Purchased equipment
cost)
Consider the cost oI land 6 PEC 6 oI 4.5832610
8
0.06 4.5832610
8
Rs. 2.749910
7
But presently cost oI 3 acres oI landRs 2.40 10
7
Thus, Direct cost Rs. 1.513557610
10
173
II. INDIRECT COSTS: expenses which are not directly involved with
material and labour oI actual installation oI complete Iacility (15-30 oI
Fixed-capital investment)
A. ENGINEERING AND SUPERVISION: (5-30 oI direct costs)
Consider the cost oI engineering and supervision 10 oI Direct costs
i.e., cost oI engineering and supervision 10 oI 1.5135.57610
10
0.11.5135.57610
10
Rs. 1.5135.57610
9
B. CONSTRUCTION EXPENSE AND CONTRACTOR`S FEE: (6-40 oI
direct costs)
Consider the construction expense and contractor`s Iee 40 oI Direct costs
i.e., construction expense and contractor`s Iee 40 oI 1.513557610
9
0.41.513557610
9
Rs6.0542210
8
C. CONTINGENCY: (5-30 oI Fixed-capital investment)
Consider the contingency cost 30 oI Fixed-capital investment
i.e., Contingency cost 30 oI 10
5
0.3 1.83330610
9
Rs. 5.49991810
8
Thus, Indirect Costs Rs. 1.3067688 10
9
III. FIXED CAPITAL INVESTMENT:
Fixed capital investment Direct costs Indirect costs
2.8203.26410
9
i.e., Fixed capital investment Rs. 2.8203.26410
9
IV. WORKING CAPITAL: (10-20 oI Fixed-capital investment)
Consider the Working Capital 15 oI Fixed-capital investment
i.e., Working capital 15 oI 2.8203.26410
9
0.15 2.8203.26410
9
Rs. 4.2304810
8
V. TOTAL CAPITAL INVESTMENT (TCI):
Total capital investment Fixed capital investment Working capital
(28203.2644230.48) 10
5
i.e., Total capital investment Rs. 3.24337510
9
174
ESTIMATION OF TOTAL PRODUCT COST:
I. MANUFACTURING COST Direct production cost Fixed chargesPlant
overhead cost.
A. FIXED CHARGES: (10-20 total product cost)
i. DEPRECIATION: (depends on liIe period, salvage value and method oI
calculation-about 13 oI FCI Ior machinery and equipment and 2-3 Ior Building
Value Ior Buildings)
Consider depreciation 20 oI FCI Ior machinery and equipment and 10 Ior
Building Value Ior Buildings)
i.e., Depreciation (0.228203.26410
5
) (0.128203.26410
5
)
Rs. 8.4609710
8
ii. LOCAL TAXES: (1-5 oI Iixed capital investment)
Consider the local taxes 5 oI Iixed capital investment
i.e. Local Taxes 0.052.820326410
9
Rs. 1.4101610
8
iii. INSURANCES: (0.4-1 oI Iixed capital investment)
Consider the Insurance 1 oI Iixed capital investment
i.e. Insurance 0.012.820326410
9
Rs2.820310
7
Thus, Fixed Charges Rs. 1.01531610
9
B. DIRECT PRODUCTION COST: (about 60 oI total product cost)
Now we have Fixed charges 5-20 oI total product charges
Consider the Fixed charges 5 oI total product cost
Total product charge Iixed charges/5
Total product charge 10153.16 10
5
/5
Total product charge 10153.1610
5
/0.05
Total product charge (TPC) Rs. 2.03063210
10
i. RAW MATERIALS: (10-50 oI total product cost)
Consider the cost oI raw materials 25 oI total product cost
Raw material cost 25 oI 2.03063210
10
0.25 2.03063210
10
Raw material cost Rs.5.07658 10
9
173
ii. OPERATING LABOUR (OL): (10-20 oI total product cost)
Consider the cost oI operating labour 12 oI total product cost
Operating labour cost 12 oI 2.03063210
10
0.12 2.03063210
10
Operating labour cost Rs.2.4367584 10
9
iii. DIRECT SUPERVISORY AND CLERICAL LABOUR (DS & CL): (10-
25 oI OL)
Consider the cost Ior Direct supervisory and clerical labour 12 oI OL
Direct supervisory and clerical labour cost 12 oI 2.4367584 10
9
0.122.4367584 10
9
Direct supervisory and clerical labour cost Rs. 2924.11 lakhs
iv. UTILITIES: (10-20 oI total product cost)
Consider the cost oI Utilities 12 oI total product cost
Utilities cost 12 oI 2.030632 10
10
0.122.030632 10
10
Utilities cost Rs. 24367.584lakhs
v. MAINTENANCE AND REPAIRS (M & R): (2-10 oI Iixed capital
investment)
Consider the maintenance and repair cost 5 oI Iixed capital investment
i.e. Maintenance and repair cost 0.052.820326410
9
Rs. 1.4101610
8
vi. OPERATING SUPPLIES: (10-20 oI M & R or 0.5-1 oI FCI)
Consider the cost oI Operating supplies 15 oI M & R
Operating supplies cost 15 oI 1.4101610
8
0.15 1.4101610
8
Operating supplies cost Rs 211.52lakhs
vii. LABORATORY CHARGES: (10-20 oI OL)
Consider the Laboratory charges 15 oI OL
Laboratory charges 15 oI 24367.584 10
5
0.1524367.584 10
5
Laboratory charges Rs. 3.6551310
8
viii. PATENT AND ROYALTIES: (0-6 oI total product cost)
Consider the cost oI Patent and royalties 4 oI total product cost
Patent and Royalties 4 oI 2.03063210
10
0.04 2.03063210
10
Patent and
Royalties cost Rs. 8.1225210
8
Thus, Direct Production Cost Rs. 1.1582440810
10
C. PLANT OVERHEAD COSTS (50-70 oI Operating labour, supervision, and
maintenance or 5-15 oI total product cost); includes Ior the Iollowing: general
176
plant upkeep and overhead, payroll overhead, packaging, medical services, saIety
and protection, restaurants, recreation, salvage, laboratories, and storage Iacilities.
Consider the plant overhead cost 60 oI OL, DS & CL, and M & R
Plant overhead cost 60 oI ((2.4367584 10
9
) (2.92411 10
8
)
(1.4101610
8
))
Plant overhead cost Rs. 17221.112 lakhs
Thus, ManuIacture cost Direct production cost Fixed charges Plant overhead
costs.
ManuIacture cost (2.03063210
10
) (1.01531610
9
) (1.7221112 10
9
)
ManuIacture cost Rs. 2.3043747210
10
II. GENERAL EXPENSES Administrative costs distribution and selling
costs research and development costs
A. ADMINISTRATIVE COSTS :(2-6 oI total product cost)
Consider the Administrative costs 5 oI total product cost
Administrative costs 0.05 2.03063210
10
Administrative costs Rs. 1.01531610
9
B.DISTRIBUTION AND SELLING COSTS: (2-20 oI total product cost);
includes costs Ior sales oIIices, salesmen, shipping, and advertising.
Consider the Distribution and selling costs 15 oI total product cost
Distribution and selling costs 15 oI 2.03063210
10
Distribution and selling costs 0.15
Distribution and Selling costs Rs3.04594810
9
C. RESEARCH AND DEVELOPMENT COSTS: (about 5 oI total product
cost)
Consider the Research and development costs 5 oI total product cost
Research and Development costs 5 oI 2.03063210
10
Research and development costs 0.05 2.03063210
10
Research and Development costs Rs. 1.01531610
9
D. FINANCING (INTEREST): (0-10 oI total capital investment)
Consider interest 5 oI total capital investment
i.e. interest 5 oI 3.24337510
9
0.053.24337510
9
Interest Rs. 1.6216810
8
Thus, General Expenses Rs. 5.23874810
9
177
IV. GROSS EARNINGS/INCOME
Wholesale Selling Price oI Urea Formaldehyde per kg Rs.275
Total Income Selling price Quantity oI product manuIactured
Total Income Rs. 2.0625010
10
Gross income Total Income Total Product Cost
(2.0625010
10
) (2.03063210
10
)
Gross Income Rs. 3.186810
8
Let the Tax rate be 45 (common)
Net ProIit Gross income - Taxes Gross income (1- Tax rate)
Net proIit 3186.8 (1-0.45) Rs.1.7527410
8
RATE OF RETURN
Rate oI return Net proIit100/Total Capital Investment
Rate oI Return 1752.7410
5
100/ (32433.7510
5
)
Rate oI Return 6
BREAK-EVEN ANALYSIS
Data available:
Annual Direct Production Cost Rs 2.03063210
10
Annual Fixed charges Rs. 1.01531610
9
Total Annual sales Rs. 2.0625010
10
Wholesale Selling Price Urea Formaldehyde per ton. Rs. 275000
Direct production cost per ton oI Urea Formaldehyde (1.01531610
9
)/
(2.0625010
10
/275000)
Rs. 13537.54 per ton
Let n` TPA be the break even production rate.
Number oI tons needed Ior a break-even point is given by
(1.01531610
9
) (13537.54n) (275000n)
~ n 3883.21 tons/year
Hence, the break-even production rate is 5.1 oI the considered plant capacity.
PAYBACK PERIOD
PPTotal Fixed Investment interest/ Avg Depreciation Net ProIit
28203.26452387.48/8460.971752.74
7.89 years
178
SAFE1Y SHEE1
179
CHAPTER 14
14 SAFETY SHEET
14.1 MATERIAL SAFETY DATA SHEET UREA
SECTION 1: CHEMICAL PRODUCT AND COMPANY IDENTIFICATION
Product Name: Urea
Catalog Codes: SLU1063, SLU1132, SLU1093, SLU1162
CAS#: 57-13-6
RTECS: YR6250000
TSCA: TSCA 8(b) inventory: Urea
CI#: Not available.
Synonym: Carbamide
Chemical Name: carbonyldiamide
Chemical Formula: (NH2)2CO or CH4N2O
SECTION 2: COMPOSITION AND INFORMATION ON INGREDIENTS
COMPOSITION:
Name CAS # by Weight
Urea 57-13-6 100
Toxicological Data on Ingredients: Urea: ORAL (LD50): Acute: 8471 mg/kg
|Rat|. 11000 mg/kg |Mouse|.
180
SECTION 3: HAZARDS IDENTIFICATION
POTENTIAL ACUTE HEALTH EFFECTS
Hazardous in case oI skin contact (irritant), oI eye contact (irritant), oI
ingestion, oI inhalation.
POTENTIAL CHRONIC HEALTH EFFECTS
CARCINOGENIC EFFECTS: Not available.
MUTAGENIC EFFECTS: Mutagenic Ior mammalian somatic cells.
TERATOGENIC EFFECTS: Not available.
DEVELOPMENTAL TOXICITY: Not available.
The substance may be toxic to blood, cardiovascular system. Repeated or
prolonged exposure to the substance can produce target organs damage.
SECTION 4: FIRST AID MEASURES
EYE CONTACT
Check Ior and remove any contact lenses. In case oI contact, immediately Ilush
eyes with plenty oI water Ior at least 15 minutes. Cold water may be used. Get
medical attention.
SKIN CONTACT
In case oI contact, immediately Ilush skin with plenty oI water. Cover the irritated
skin with an emollient. Remove contaminated clothing and shoes. Cold water may
be used.Wash clothing beIore reuse. Thoroughly clean shoes beIore reuse. Get
medical attention.
SERIOUS SKIN CONTACT
Wash with a disinIectant soap and cover the contaminated skin with an anti-
bacterial cream. Seek medical attention.
INHALATION
II inhaled, remove to Iresh air. II not breathing, give artiIicial respiration. II
breathing is diIIicult, give oxygen. Get medical attention.
181
14.2 MATERIAL SAFETY DATA SHEET FOR FORMALDEHYDE
SECTION 1: CHEMICAL PRODUCT AND COMPANY IDENTIFICATION
Product Name: Formaldehyde 37 solution
Catalog Codes: SLF1426
CAS#: Mixture.
RTECS: LP8925000
TSCA: TSCA 8(b) inventory: Formaldehyde; Methyl alcohol;
Water
CI#: Not applicable.
Synonym: Formalin
Chemical Name: Formaldehyde
Chemical Formula: HCHO
SECTION 2: COMPOSITION AND INFORMATION ON INGREDIENTS
COMPOSITION:
NAME CAS # BY WEIGHT
Formaldehyde 50-00-0 36.5-38
Methyl alcohol 67-56-1 10-15
Water 7732-18-5 47-53.5
TOXICOLOGICAL DATA ON INGREDIENTS: Formaldehyde: ORAL
(LD50): Acute: 100 mg/kg |Rat|. 42 mg/kg |Mouse|. 260 mg/kg |Guinea pig|.
MIST (LC50): Acute: 454000 mg/m 4 hours |Mouse|. Methyl alcohol: ORAL
(LD50): Acute: 5628 mg/kg |Rat|.
DERMAL (LD50): Acute: 15800 mg/kg |Rabbit|. VAPOR (LC50): Acute: 64000
ppm 4 hours |Rat|.
182
SECTION 3: HAZARDS IDENTIFICATION POTENTIAL ACUTE
HEALTH EFFECTS
Very hazardous in case oI eye contact (irritant), oI ingestion, . Hazardous in
case oI skin contact (irritant, sensitizer, permeator), oI eye contact (corrosive).
Slightly hazardous in case oI skin contact (corrosive). Severe over-exposure can
result in death. InIlammation oI the eye is characterized by redness, watering, and
itching.
POTENTIAL CHRONIC HEALTH EFFECTS
Hazardous in case oI skin contact (sensitizer).
CARCINOGENIC EFFECTS: ClassiIied A2 (Suspected Ior human.) by ACGIH,
2A (Probable Ior human.) by IARC |Formaldehyde|.
MUTAGENIC EFFECTS: Mutagenic Ior mammalian somatic cells.
|Formaldehyde|. Mutagenic Ior bacteria
and/or yeast. |Formaldehyde|. Mutagenic Ior mammalian somatic cells. |Methyl
alcohol|. Mutagenic Ior bacteria
and/or yeast. |Methyl alcohol|.
TERATOGENIC EFFECTS: ClassiIied POSSIBLE Ior human |Methyl alcohol|.
DEVELOPMENTAL TOXICITY: Not available
The substance may be toxic to kidneys, liver, skin, central nervous system (CNS).
Repeated or prolonged exposure to the substance can produce target organs
damage. Repeated exposure to a
highly toxic material may produce general deterioration oI health by an
accumulation in one or many human organs.
SECTION 4: FIRST AID MEASURES
EYE CONTACT
Check Ior and remove any contact lenses. Immediately Ilush eyes with running
water Ior at least 15 minutes, keeping eyelids open. Cold water may be used. Get
medical attention immediately.
SKIN CONTACT
In case oI contact, immediately Ilush skin with plenty oI water. Cover the irritated
skin with an emollient. Remove contaminated clothing and shoes. Cold water may
be used. Wash clothing beIore reuse. Thoroughly clean shoes beIore reuse. Get
medical attention.
SERIOUS SKIN CONTACT
Wash with a disinIectant soap and cover the contaminated skin with an anti-
bacterial cream. Seek immediate medical attention.
183
INHALATION
II inhaled, remove to Iresh air. II not breathing, give artiIicial respiration. II
breathing is diIIicult, give oxygen. Get medical attention immediately.
SERIOUS INHALATION
Evacuate the victim to a saIe area as soon as possible. Loosen tight clothing such
as a collar, tie, belt or waistband. II breathing is diIIicult, administer oxygen. II the
victim is not breathing, perIorm mouth-to-mouth resuscitation. WARNING: It may
be hazardous to the person providing aid to give mouth-to-mouth resuscitation
when the inhaled material is toxic, inIectious or corrosive. Seek immediate medical
attention.
INGESTION
II swallowed, do not induce vomiting unless directed to do so by medical
personnel. Never give anything by mouth to an unconscious person. Loosen tight
clothing such as a collar, tie, belt or waistband. Get medical attention immediately.
SECTION 5: FIRE AND EXPLOSION DATA
Flammability of the Product: Flammable.
Auto-Ignition Temperature: 430C (806F)
Flash Points: CLOSED CUP: 50C (122F). OPEN CUP: 60C (140F).
Flammable Limits: The greatest known range is LOWER: 6 UPPER: 36.5
(Methyl alcohol)
Products of Combustion: These products are carbon oxides (CO, CO2).
FIRE HAZARDS IN PRESENCE OF VARIOUS SUBSTANCES
Flammable in presence oI open Ilames and sparks, oI heat. Non-Ilammable
in presence oI shocks, oI oxidizing materials, oI reducing materials, oI combustible
materials, oI organic materials, oI metals, oI acids, oI alkalis.
EXPLOSION HAZARDS IN PRESENCE OF VARIOUS SUBSTANCES:
Non-explosive in presence oI open Ilames and sparks, oI shocks.
184
FIRE FIGHTING MEDIA AND INSTRUCTIONS
Flammable liquid, soluble or dispersed in water.
SMALL FIRE: Use DRY chemical powder.
LARGE FIRE: Use alcohol Ioam, water spray or Iog. Cool containing vessels with
water jet in order to prevent pressure build-up, autoignition or explosion.
SPECIAL REMARKS ON FIRE HAZARDS
Explosive in the Iorm oI vapor when exposed to heat or Ilame. Vapor may travel
considerable distance to source oI ignition and Ilash back. When heated to
decomposition, it emits acrid smoke and irritating Iumes. CAUTION:
MAY BURN WITH NEAR INVISIBLE FLAME (Methyl alcohol)
SPECIAL REMARKS ON EXPLOSION HAZARDS
Reaction with peroxide, nitrogen dioxide, and permIormic acid can cause an
explosion.(Formaldehyde gas)
14.3 SAFTY SHEET FOR UREA-FORMALDEHYDE RESIN
PRODUCT IDENTIFICATION: Hardwood Plywood, Veneer Core PlatIorms,
Uniply, Lumber Core PlatIorms, Particleboard,Medium Density Fiberboard (Urea-
Formaldehyde), Medium Density Overlay
SYNONYMS: VCPF, Blanks, LCPF, 2-Ply, Plywood, PB, MDF, MDO
TRADE NAME: None
DESCRIPTION
This panel products contains a hardwood veneer Iace (occasionally a decorative
soItwood Iace) bondedto wood components such as other
woodveneer,particleboard, or medium density Iiberboard (MDF) using urea-
Iormaldehyde resin.
POTENTIAL AIRBORNE RELEASES
The product may release small quantities oI Iormaldehyde (CAS No.50-00-0) in
gaseous Iorm. Emissionsdecrease through time as the panels age. Manual or
183
mechanical cutting or abrasion processes perIormed onthe product can result in
generation oI wood dust.
FIRE AND EXPLOSION DATA
Flash point.......................................................................................... Not applicable
Autoignition Temperature.................................................................. Not available
(will depend upon duration oI exposure to heat source and other variables)
Explosive Limits in Air...................................................................... See below
under 'Unusual Fire and Explosion Hazards
Extinguishing Media.......................................................................... Water, Carbon
Dioxide, Sand
Special Fire Fighting Procedures....................................................... None
Unusual Fire and Explosion Hazards................................................. Sawing,
sanding or machining can produce wood dust as a byproduct which may present an
explosion hazard iI a dust cloud contacts an ignition source. An airborne
concentration oI 40 grams oI dust per cubic meter oI air is oIten used as the LEL
Ior wood dust.
REACTIVITY DATA
Conditions Contributing to
Instability........................................................................................... Stable under
normal conditions.
Incompatibility................................................................................... Avoid contact
with oxidizing agents. Avoid open Ilame. Product may ignite in excess oI 400
degrees F. Hazardous Decomposition
Products..............................................................................................Thermal and/or
thermal oxidative decomposition can produce irritating and toxic Iumes and gases,
including carbon monoxide, hydrogen cyanide, aldehydes, organic acids and
polynuclear aromatic compounds.
Hazardous Polymerization................................................................. Not applicable
HEALTH EFFECTS INFORMATION
Exposure Limits:
Formaldehyde.....................................................................................OSHA
PELTWA: 0.75 ppm
OSHA PEL-STEL: 2 ppm
ACGIH TLV-CEILING: 0.3 ppm
Exposure Limits (cont`d.):
186
Wood Dust...................................................................................................OSHA
PEL-TWA: 15.0 mg/m3
(total dust);
5.0 mg/m3 (respirable Iraction)
1
See important Iootnote below concerning
OSHA PELs Ior wood dust
Wood Dust (SoItwood)............................................................................... ACGIH
TLV-TWA: 5.0 mg/m3
ACGIH TLV - STEL (15 min.): 10.0 mg/m3
Wood Dust (Certain hardwoods such
as beech and oak).........................................................................................ACGIH
TLV-TWA: 1.0 mg/m3
Eye Contact................................................................................................. Gaseous
Iormaldehyde may cause temporary irritation or a burning sensation. Wood dust
can cause mechanical irritation.
Skin Contact..... ........................................................................................... Both
Iormaldehyde and various species oI wood dust may evoke allergic contact
dermatitis insensitized individuals.
Ingestion...................................................................................................... Not
likely to occur.
Gaseous Iormaldehyde................................................................................ May
cause temporary irritation to eyes, nose and throat. Some reports suggest that
Iormaldehyde may cause respiratory sensitization, such as asthma, and that pre-
existing respiratory disorders may be aggravated by exposure. Formaldehyde is
listed by the International Agency Ior Research on Cancer (IARC) as a probable
human carcinogen. The National Toxicology Program (NTP) includes
Iormaldehyde in the Annual Report on Carcinogens. Formaldehyde is regulated by
OSHA as a potential cancer agent.1 In AFL-CIO v. OSHA 965 F. 2d 962 (11th
Cir. 1992), the court overturned OSHA`s 1989 Air Contaminants Rule, including
the speciIic PELs Ior wood dust that OSHA had established at that time. The 1989
PELs were: TWA - 5.0 mg/m3; STEL (15 min.) - 10.0 mg/m3 (all soIt and hard
woods, except Western red cedar); Western red cedar: TWA - 2.5 mg/m3. Wood
dust is now oIIicially regulated as an organic dust under the Particulate Not
Otherwise Regulated (PNOR) or Inert or Nuisance Dust categories at PELs noted
under the Health EIIects InIormation section oI this MSDS. However, a number oI
states have incorporated provisions oI the 1989 standard in their state plans.
Additionally, OSHA has announced that it may cite companies under the OSH Act
General Duty Clause under appropriate circumstances Ior non-compliance with the
1989 PELs.
187
Gaseous Iormaldehyde (cont`d.)................................................... In studies
involving rats, Iormaldehyde has been shown to cause nasal cancer Irom long-term
exposure to very high concentrations (14 ppm), Iar above those normally Iound in
the workplace using this product.The National Cancer Institute (NCI) conducted an
epidemiological study oI industrial workers exposed to Iormaldehyde (published
June 1986). The NCI concluded that the data provides little evidence that mortality
Irom cancer is associated with Iormaldehyde exposure at the levels experienced by
workers in the
study.
WOOD DUST: May cause nasal dryness, irritation and obstruction. Coughing,
wheezing, and sneezing; sinusitis and prolonged colds have also been
reported.Depending on species, may cause
Respiratory sensitization and/or irritation.IARC classiIies wood dust as a
carcinogen to humans (Group 1). This classiIication is based primarily on IARC`s
evaluation oI increased risk in the occurrence oI adenocarcinomas oI the nasal
cavities and paranasal sinuses associated with exposure to wood dust. IARC did
not Iind suIIicient evidence to associate cancer oI the oropharynx, lung,
hypopharynx, lymphatic, stomach and hematopoietic systems, colon or rectum
with exposure to wood dust. The NTP includes wood dust in The Annual Report
on Carcinogens.
PRECAUTIONS, SAFE HANDLING
Formaldehyde: Provide adequate ventilation to reduce the possible buildup oI
Iormaldehyde gas, particularly when high temperatures occur.
WOOD DUST: Avoid dusty conditions and provide good ventilation.
GENERALLY APPLICABLE CONTROL MEASURES
Ventilation: Provide adequate general and local exhaust ventilation to keep
airborne contaminant concentration levels below the OSHA PELs. Personal
Protective Equipment: Wear goggles or saIety glasses when manuIacturing or
machining the product. Wear NIOSH/MSHA approved respirator when the
allowable exposure limits may be exceeded. Other protective equipment such as
gloves and outer garments may be needed depending on dust conditions.
EMERGENCY AND FIRST AID PROCEDURES
EYES:Flush eyes with large amounts oIwater. Remove to Iresh air. IIirritation
persists, get medcal attention.
188
SKIN: Wash aIIected areas with soap andwater. Get medical advice iI rash or
persistentirritation or dermatitisoccurs.
Inhalation..................................................................................................... Remove
to Iresh air. Get medical advice iI persistent irritation, severe coughing or
breathingdiIIiculty occurs.
INGESTION: Not applicable
189
PID DIACRAM
190
CHAP1ER
15 PID DIAGRAM
191
PLAA1 LAYOU1
192
CHAPTER 16
16 PLANT LAYOUT
The economic construction and operation oI a process unit will depend on
how well the plant equipment speciIied on the process Ilow sheet and laid out.
The principal Iactors to be considered are:
1. Economic consideration: construction and operation cost.
2. The process requirement
3. Convenience oI operation
4. convenience oI maintenance
5. SaIety
6. Future expansion
7. Modular construction
16.1 COSTS:
The cost oI construction can be minimized by adopting a layout that
gives shortest run oI connecting pipes between equipment, and adopting the
least amount oI structural steel work. However, this will not necessarily be
the best arrangement Ior operation and maintenance.
16.2 PROCESS REQUIREMENT
All the required equipments have to be placed properly within process.
Even the installation oI the auxiliaries should be done in such a way that it
will occupy the least space.
193
16.3 OPERATION
Equipment that needs to have Irequent operation should be located
convenient to the control room. Valves, sample points, and instruments should be
located at convenient position and height. SuIIicient workingspace and headroom
must be provided to allow easy access to equipment.
16.4 MAINTENANCE
Heat exchangers need to be sited so that the tube bundles can be easily
withdrawn Ior cleaning and tube replacement. Vessels that require Irequent
replacement oI catalyst or packing should be located on the outside oI buildings.
Equipment that requires dismantling Ior maintenance,
such as compressors and large pumps, should be placed under cover.
16.5 SAFETY
Blast walls may be needed to isolate potentially hazardous equipment, and
conIine the eIIects oI an explosion. At least two escape routes Ior operator must be
provided Irom each level in the process building.
PLANT EXPANSION
Equipment should be located so that it can be conveniently tied in with any
Iuture expansion oI the process. Space should be leIt on pipe alleys Ior Iuture
needs, service pipes over-sized to allow Ior Iuture requirements.
MODULAR CONSTRUCTION:
In recent years, there has been a move to assemble sections oI the plant at
the manuIacturer site. These modules will include the equipment, structural steel,
piping and instrumentation. The modules then transported to the plant site, by road.
194
COACLUSIOA
193
CHAPTER 17
17 CONCLUSION
Thus the project based on manuIacturing oI urea Iormaldehyde resin oI capacity
250 tons per day includes
1 Various method oI production
2 Selection oI suitable method
3 Process description
4 Material balance
5 Energy balance
6 Design oI equipment such as
6.1 Heat exchanger
6.2 Evaporator
6.3 Absorption column
7 Estimation oI cost oI plant and payback period
8 PID diagram
9 Plant layout
In carrying out this subject we have applied
1 Chemical process calculation concepts
2 Process equipment and design process
3 Application oI heat and mass balance principles
4 Economics oI process
5 Instrumentation Process and control
Thus the project covers all aspects required Ior the manuIacturing oI urea
Iormaldehyde resin and could be implemented in reality.
This book also covers the production oI raw materials oI urea Iormaldehyde
resin, selection oI plant location and saIety aspects oI handling oI raw materials
and product
196
ILIOCRAPHY
197
CHAPTER 18
18 BIBLIOGRAPHY
1. B.I.Batt and S.M.Vohra 'Stiochiometry, Tata McGraw Hill International
Editions. (3
rd
Edition)
2. David Himmelblau,Basic Principles and Calculations in Chemical
Engineering, Prentice Hall India, 2004
3. Dryden`s 'Outlines oI Chemical Technology, East-West Press Private
Limited, 2004
4. Faith, Keyes and Clark , Industrial Chemicals,4
th
edition.
5. George T.Austin,Shreve`s Chemical Process Industries, Tata McGraw Hill
International Editions
6. George Stephanopoulos,' Chemical process control,(2005)
7. James A.Kent 'Riegel`s Handbook oI Industrial Chemistry,10
th
edition
8. Jerry L.Atwood and Jonathan 'W.Steed Encyclopedia oI Supramolecule
Chemistry,vol.2
9. John Brydron also discussed about urea Iormaldehyde resins in the journal
oI applied science, vol-77,page no 64-67.
10. Jon Williams ,American Journal oI Pharmacy, page no220.
11. Kenneth W.Britt,Handbook oI Pulp oI Paper Technology, CBS Publishers
(2
nd
Edition)
12 kernuC"process heaL Lransfer" Mcgraw Plll(1930)
13 Keyes and Clark`s has given the details oI Iormaldehyde in Industrial
Chemicals, 4
th
edition.
14 R.S.Khurmi,Staem Tables and humidity charts.
13 klrk and CLhmer(Ld)"encyclopaedla ln chemlcal Lechnology"(volumes
23121422) ,4
th
edition.
16. Robert Salley Synthetic Resins and allied plastics, 2
nd
edition.
17. Peter Timmerhaus, 'Plant Economics and Design Ior Chemical Engineers.
198
18. Robert H.Perry & Don Green, 'Perry`s Chemical Engineer`s Handbook,
McGraw Hill International Editions. (8
th
Edition)
19. Robert E.Treybal,Mass TransIer Operations, Tata McGraw Hill
International editions. (3
rd
Edition)
20. Sami Matar, Lewis F.Hatch 'Chemistry oI Petrochemicals, 2
nd
edition.
21. Timothy E.Long, 'Synthetic Method in step growth polymer, page no 377-
388
22. M.V.Joshi and V.V. Mahajan ,'Process Equipment Design 'by Mc-Millan
India Limited (2
nd
Edition)
23. Warren L.Mc Cabe, Julion.C.Smith, Peter Harriot,Unit operations oI
chemical Engineering, McGraw Hill International Editions. (6
th
Edition)
199