JOSHI’s

Process Equipment Design

 JOSHI’s
Process Equipment Design
Fifth Edition

V V Mahajani
S B Umarji

(An Imprint of Laxmi Publications Pvt. Ltd.)

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PROCESS EQUIPMENT DESIGN

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 Dedicated to

Late Shri M V JOSHI

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 Preface to the
Fifth Edition

This edition of the book, like the previous edition, is dedicated to late Professor MV Joshi, who was
the architect and the author of this book.
This edition brings you few updates and additions, like chapter 12 gives you a new write up on
hydrocyclone, in Auxiliary Process Vessels; Chapter 14 gives a write up on Jet Mixer and Eductor, in
Mixers; and Appendix J, gives a calculation of volume of a horizontal tank, with formulae, and so on.
We are very much thankful to Dr VV Chavan, Managing Director, Mamko Design and
Engineering Private Ltd Mumbai 400 063 for pictures of Jet Mixers and hydrocyclone. His
suggestions on brief write up of these items are thankfully acknowledged. Suggestions by Professor
(Dr) S P Deshmukh of ICT (UDCT) Mumbai 400 019 were very much valuable.
We acknowledge with thanks the support of our friends and student community and now look
forward to their comments and suggestions for the next edition.

V V Mahajani
S B Umarji
 Preface to the
Fourth Edition

This revised edition is dedicated to late Professor M V Joshi who was the main architect and the
author of this book.
The emphasis in this fourth revised edition is on mechanical design, as in the earlier editions, and
not on process design. In this edition, an attempt has been made to eliminate all types of errors
missed out in earlier editions. The chapters have been revised wherever necessary. The reference list
at the end of each chapter has been updated with some very old references being deleted. The chapter
on ‘Agitators’ (Chapter 14) has been renamed as ‘Mixers’ taking into account static mixers also.
All numerical problems have been reworked on to make them more comprehensive without
altering the main definition. Illustrations have been presented to appreciate equipment, particularly
the mechanically agitated reactor.
We take this opportunity to thank all those who gave feedback to bring forth this revision.
Our thanks are due to Dr P D Vaidya and research scholars, Mr T L Gunale for going through
illustrations and the revision, and Mr M S Talekar for updating literature search. Their constructive
suggestions from the students’ point of view have been invaluable.
We thank Mr S M Mokashi, former Managing Director of Xytel India Ltd and Director (then)
Davy Powergas India Ltd, for making the opening Chapter 1 more appealing. Our sincere thanks are
due to Dr V V Chavan, Director, Mamko Design and Engineering Pvt Ltd, Mumbai for their inputs on
static mixers. We thank with equal sincerity Mr Kekatpure of Evergreen Technologies Pvt Ltd
Mumbai for permitting to use photographs of structured packings and mist eliminators.
We also thank Professor (Dr) J B Joshi, Director, Institute of Chemical Technology, Matunga,
Mumbai, where this revision was designed and executed.
N Preface to the Fourth Edition

We also wish to express our sincere gratitude to the entire team of Macmillan Publisher India Ltd,
in particular Mr Suresh Gopal, Senior Editorial Consultant and Ms Garima Rao, the Development
Editor, for their enormous help and cooperation.
Finally, we would like to acknowledge the support of the student community to further improve
this book.

Mumbai V V Mahajani
S B Umarji
 Preface to the
Third Edition

During the last ten years, several engineering institutions have started offering courses in chemical
engineering. During this period, a large number of chemical industries have been set up, leading to
the application of a variety of chemical equipment. This has caused an increased demand for this
book both by students and design engineers. To meet this growing demand, the second edition of the
book was reprinted three times.
However, keeping in view the developments in this field, it was necessary to incorporate some
significant and essential features of process equipment in the original text. Hence, the second edition
of the book has been thoroughly revised and updated by certain additions and alterations wherever
necessary. In the present edition, certain additions relating to items of equipment such as filters,
dryers, evaporators, etc., have been made. A chapter on auxiliary process equipment has been
incorporated. These items of equipment are functionally essential as a complement to the main items
of equipment, data sheets have also been included. A chapter on process flow sheets has been
included, since it is desirable for an equipment designer to understand not only the function of the
equipment but also its location, necessary piping and instrumentation in overall process.
Lately, computer aided design has become a specialized topic of study, and many good books are
available in this area. Hence, in the present edition the chapter on computer aided design has been
deleted. SI units have been used in all numerical problems and tables.
While preparing this edition, information has been obtained from various sources such as
textbooks, handbooks, journals, etc. Indebtedness to these sources is freely acknowledged. Special
mention must be made of the help received from Mr S M Mokashi and Mr V R Thakur of Davy
Powergas India Pvt Ltd for which the authors are grateful to them. Thanks are due to Mr Anand
Kulkarni for preparing some of the sketches, and to Prof P K Jadhav for checking the numerical
problems.
M V Joshi
V V Mahajani
 Preface to the
Second Edition

The response to the first edition of the book was most encouraging, both from the students and
design engineers from the field of chemical engineering. To fulfil the demand, the book was re-
printed in 1979. The purpose of this edition is to update the previous text and to revise certain topics,
based upon the comments received from experts in the field.
Certain changes will be found in most chapters. In particular, greater emphasis has been laid on
topics pertaining to corrosion and its prevention and pressure vessel codes. Pressure vessels form
the most important component of chemical equipment. Codes on pressure vessels have been evolved
by different countries. The design engineer has, therefore, a wide choice. The information given in
this volume will help him to understand the basic difference in the design approach adopted by four
important codes. With these additions it is expected that this edition will provide a sound basis for the
study of the fundamentals of the subject and will be of some value to practicing engineers.
In the preparation of this edition, information has been obtained from various sources such as
textbooks, handbooks, journals, etc. Indebtedness to these sources is freely acknowledged. Special
mention must be made of the help received from Shri J P Roy, for which the author is grateful to
him. Thanks are due to Shri V R Laud, who prepared the sketches and Shri S R Tuvekar who typed
the manuscript.
M V Joshi
V V Mahajani
 Preface to the
First Edition

There are at present only a few books available on the subject of process equipment design. The
scope of these books is essentially limited to design of pressure vessel components and some
machine elements. However, if the subject is to be made sufficiently comprehensive, much more
emphasis is needed on design and construction features of different items of equipment. The present
book is an attempt to fill this gap. It is expected to satisfy the long-felt need for a more
comprehensive book, which sets out to embrace a wider field, viz., application of fundamental
principles of machine design to specific items of equipment and elaborate details of construction
illustrated through sketches and drawings. The book is intended both for the undergraduate students
of chemical engineering and for practicing engineers in the chemical industry. It is the outcome of
experience gained by the author in classrooms and industry.
Chemical industries involve problems in process design, unit operations, equipment design and
overall plant design. In a design of a chemical plant these problems cannot be segregated. However,
in spite of their interdependence, these problems may be advantageously segregated for study and
development because of different principles involved in each. Process problems are primarily
physicochemical in nature. Unit operation problems are for the most part physical, while equipment
design problems are to a large extent mechanical. The fundamentals and theory of chemical
engineering process design and unit operations are well covered in a number of books and
handbooks. Overall sizing of equipment and its components is no doubt determined by the above
considerations. Equipment design is, therefore, essentially limited to mechanical aspects of design
and construction features of process equipment.
The first few chapters are devoted to a review of materials of construction, corrosion and
protective coatings, stresses arising out of different loading conditions and factors which influence
design. An outline of the design features of some machine elements, which form a part of chemical
equipment, is presented in Chapter 5. Chemical equipment may be classified on the basis of certain