Technological Institute of the Philippines

NEUTRALIZER

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EQUIPMENT No. (TAG) N-101

NEUTRALIZER DATA DESCRIPT. (FUNC.) Neutralizer
SHEET SHEET No.1
OPERATING DATA 1
CH2O, C2H4O, H2O, HCOONa,
Components 2
C5H12O4, C2H3NaO2, CH3COOH
Operating Temperature 60.0oC 3
Operating Pressure 101.325 kPa 4
TECHNICAL DATA 5
PRESSURE VESSEL DESIGN 6
Inside Diameter 1.97 m 7
Shell Thickness 10 mm 8
Vessel Diameter 1.99 m 9
End Closure Type Torispherical 10
Head and Base Thickness 10.85 mm 11
Material of Stainless Steel
Joint Factor 1.0 12
Construction Type 304
Knuckle Inside Crown
0.12 m 1.97 m 13
Radius Radius
Total Height 2.72 m Total Volume 7.48 m3 14
AGITATOR 15
Type of impeller Three-Blade Marine Propeller 16
Impeller Diameter 0.66 m 17
Blade width 0.13 m 18
Blade length 0.17 m 19
No. of Baffles 4 20
Impeller speed 350 rpm 21
3
Agitation Circulation Rate 0.85 m /s 22
Motor Power 7.9 kW 23
Baffle Width 0.20 m Mixing Time 33 seconds 24
JACKET 25
Thickness 12.94 mm Length 2.08 m 26
Material of Carbon Steel (SA
Nozzle Diameter 0.5 inch 27
Construction 285, Grade C)
STIFFNESS RINGS DESIGN 28
Stiffness Ring Width 1.1 m 29
Number of Stiffness Rings 2 30
Spacing Between Rings 0.95 31

N-101: NEUTRALIZER

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Objective: To neutralize excess sodium hydroxide to avoid unwanted reactions

Data and Assumptions:

1. Mass flow rate of feed is 5531.5910 kg/hr (Refer to Material balance)
2. 20% Volumetric allowance

CALCULATION OF CYLINDRICAL TANK

Using Aspen V8.8 for transport properties of the feed streams,

Stream Temperature Pressure Density Viscosity

No. (°C) (kPa) (kg/m3) (cP)
S9 11.4 101.325 842.178 0.389033
S10 95 101.325 977.63 0.865077
S11 95 101.325 830.739 0.377383

V feed =V s 9+ V s 10
4095.92 kg 108.69 kg
V feed = +
kg kg
842.178 3 977.63 3
m m
V feed =4.97467 m3

Considering a safety factor of 20% (Peters & Timmerhaus, 1991)

V cylinder =4.97467 m 3 x 1.20

V cylinder =5.9696 m3

Determination of Vessel-straight-side height and diameter:

The vessel-straight-side-height to diameter ratio is 0.75 – 1.5 [CITATION
Placeholder4 \l 13321 ], therefore Hc = Dt
π
V R=( Area)( Height )= D 2 H
4
π
5.9696 m3= ( D3 )
4
Di=1.9662 m
H c =D i=1.9662m

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DESIGN FOR SHELL THICKNESS:

Basis:
1. The liquid depth is approximately equal to the diameter of the tank
[ CITATION McC93 \l 13321 ].
2. For Stainless Steel Type 304, corrosion allowance is 8.89 mm
(Couper, Penney, Fair, & Walas, 2012)
3. Maximum Allowable Working Pressure Stainless Steel Type 304 is
150 N/mm2 [ CITATION RKS051 \l 13321 ].
4. Double butt Joint is used with efficiency of 0.7

Working stress:
SW = SU x Fm x Fr x Fs
Where: Su: minimum specified tensile strength, 565 MPa
Fm: material factor, 1.00 for Grade A material
Fa: radiographing factor, 1.00 since relieving is not employed
Fr: stress relieving factor, 1.00 since relieving is not employed
Fs: factor of safety, 0.25 for temperature less than 315.56°C

Sw = 565,000,000 Pa x (1.0) x (1.0) x (0.25)

Sw = 141,250,000 Pa

Design Pressure:
The design pressure is 5 -10% or the working pressure [ CITATION
RKS051 \l 13321 ].
Pi=101.325 kPa ( 1.10 )
Pi=111.4575 kPa

Substituting values to the shell thickness equation:

The equation for shell thickness [ CITATION RKS051 \l 13321 ]:

Pi D
t s= +C
2 S w e−P i
Where:
t s=Thickness of the Shell
Pi=Internal Pressure
D=Internal Diameter
E=Efficiency of the joint
Sw =Maximum Allowable Stress

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C=Corrosion Allowance

1000 mm
t s=
(
( 111457.5 Pa ) 1.9662 m x
1m ) +8.89 mm
2(141,250,000 kPa)(0.7)−( 111457.5 Pa )
t s=9.9988 mm

The total shell diameter of the cylinder is:

Dt =Di +2t s
Dt =1.9662 m+2( 9.9988× 10−3 m)
D t =1.9862 m

DESIGN FOR AGITATOR

Three-blade marine propeller is the impeller type of the agitator for low-
viscosity mixture (less than 3 Pa·s) (Geankoplis, 1995).

Impeller Diameter, Da
Dt 1.9862 m
Da = =
3 3
Da =0.6621m
Impeller Elevation, E:
D t 1.9862 m
E= =
3 3

E=0.6621 m
Impeller Blade Width, Bw:
D t 1.9862 m
Bw = =
15 15

Bw =0.1324 m

Impeller Blade Length, BL:

D a 0.6621m
BL = =
4 4
BL =0.1655 m

Area Swept by the Tips of Impeller Blades,

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A P=π Da B w =¿
A P=π (0.6621 m)( 0.1324 m)
A P=0.2754 m

For viscosities less than 2.5 – 5.0 Pa·s, baffles are installed to prevent turbulence
and assist swirling of the mixture.

Baffle width, J:
D t 1.9862 m
J= =
10 10
J=0.1986 m

Number of Baffles (Geankoplis,1995) = 4

Baffle Spacing: 90 degrees around the vessel

The impeller speed for this agitation equipment type is 350 rpm (5.8333 rps)
with a gear drive (Perry & Green, 2008).

Agitattor Circulation Rate, Q

Q
NQ=
N D a3

For marine propeller type, NQ = 0.5 (Geankoplis, 1995)

Q=N Q N Da3

Q = 0.5 × 5.8333 × 0.66213

Q = 0.8464 m3/s

POWER REQUIREMENT:
Calculating for Reynolds Number:
N D a2 ρ
N ℜ=
μ
N ℜ=5.8333rps ¿ ¿

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N ℜ=5628341.06

Figure 1 Power correlations for various impellers and baffles

Mixing Time, tT
Da 1
For propeller with = with NRe ≥ 105, ntT = 190
Dt 3
190
t T=
5.8333 rps
tT = 32.5714 s

Since the Reynolds number is greater than 10,000, the agitation is turbulent. The
value of power number necessary for the calculation of power requirements is
equal to KT of the impeller to use

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Figure 2 Constants KL and KT for Baffled Tanks

Solving for Power Requirement:

K T ρ N 3 D5a
P=
gc
P=0.32 x 5.833 33 ¿ ¿
P=10155.65344 Watts ≈ 10. 1557 kW

Taking 85 % motor efficiency:

10.1557 kW
Pmotor =
0.85
Pmotor =11.9478 kW

Propeller mixers are readily available up to 2.2 kW in the industry (Perry &
Green, 2008)

DESIGN FOR HEAD AND BOTTOM THICKNESS:

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For less than 10 bar operation, torispherical end closure is economical to use
(Types of Vessel Head, 2013). Using the design equation for pressure vessel
adopted from ASME for torispherical head and base:

0.885 P R c
t hb= +C
S w e+0.1 P

Where:
t hb=Head∧bottom thickness
Pi=Internal Pressure
Rc =Crown radius
e=Efficiency of the joint
S= Maximum Allowable Stress
C=Corrosion Allowance
Where Crown Radius, Rc =Di
Substituting the values to the head and bottom thickness equation:
1000 mm
t hb=
(
0.885(111457.5 Pa) 1.9662 m x
1m ) +8.89 ×10−3 m
( 141,250,000 Pa ) ( 0.7 )−111.4575 kPa(0.1)

t hb=¿ 10.8517 mm

Knuckle Radius
The ratio of the knuckle to crown radius should not be less than 0.06, to
avoid buckling (Towler & Sinnott, 2013)

R K =0.06 D i
R K =0.06(1.9662 m)
R K =0.1180 m

The stress concentration factor as a function of the knuckle and crown radii must
be taken into account in the design of the heads for the bending and shear
stresses caused by the differential dilation that will occur at torispherical end
closure:

P Rc C s
e=
2 S w J + P(C s −0.2)

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where, C s=Stress concentration factor for torispherical head

J = joint factor, 1.0
Rc
C s=
1
4( √ )
3+
RK

Solving for Cs:

1 1.9662 m
C s=
4 ( √
3+
0.1180 m )
C s=1.7706
P Rc C s
e=
2 S w J + P(C s −0.2)

111457.5 Pa x 1.9662 m x 1.7706

e=
2(141,250,000 Pa)(1.0)+111457.5 Pa(1.7706−0.2)

e = 1.3727 mm

Calculating for the volume of the torispherical head and base volume

Vhead = 0.0847Di3 + 0.25πDi2(SF)

Where: SF = straight flange, 3.5th

Vhead = 0.0847(1.9662)3 + 0.25π(1.9662) 2(3.5 x 10.8517×10-3)

Vhead = 0.7545 m3
Vbase = Vhead = 0.7545 m3

CALCULATION OF OVERALL TANK DIMENSIONS

Calculating the total volume of the mixer
Vtotal = Vcylinder + Vbase + Vhead =
Vtotal = 5.9696 + 0.7545 + 0.7545 m3
Vtotal = 7.4786 m3

Calculating the total height of the mixer

Htotal = Di + 2(0.1935Dt – 0.455th)
Htotal = 1.9662 + 2[(0.1935 x 1.9862) – (0.455 x 0.1085)]
Htotal = 2.7249 m

HEAT TRANSFER IN THE VESSEL:

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From energy balance, the amount of heat that must be absorbed by the
water to maintain the reaction temperature is 24.6515 kW. To check whether the
use jacket will be enough to remove the heat, calculate for Q J using the table
below:

Table 5.6.12.2 Approximate STR Overall Heat-Transfer Coefficients

[ CITATION Har031 \l 13321 ].

From the table, the overall heat transfer range for steam with aqueous solution as
the agitated liquid is 70 - 130 BTU/hr-oF-ft2. Assuming Uj = 70 BTU/hr-oF-ft2

5.768 W /m 2. K
UJ = 70 BTU/hr-oF-ft2 ( ¿=¿397.46W/m2·K
BTU /hr −o F−ft 2

From the table the jacket area is:

Table 5.6.12.3 Standard Stirred Tank Reactors [ CITATION Har031 \l 13321 ],

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The volume of the tank is 7.2461 m 3 or 1914.2237 gal, from the figure above the
jacket area is,
A J =191 ft 2 ≈ 17.7445m 2

( T 1−t 2 ) −(T 2−t 1)

∆ T lm=
( T 1−t 2 )
ln
(T 2−t 1)

( 333.15−323.15 )−(333.15−303.15)
∆ T lm=
(333.15−323.15)
ln
(333.15−303.15)

∆ T lm=18.2048

Solving for the amount of heat that can be transferred to the jacket:

Q J =U J A J ∆ T lm

W
Q J =397.46 2
( 17.7445 m2 ) ( 18.2048 ) K
m ∙K

QJ =128,393.2712W ≈ 128.3933 kW

Since the QJ is enough to produce the heat needed by the reactor, the use of
cooling coil is not needed.
MECHANICAL DESIGN OF JACKET:

A secondary shell for jacket is typically fabricated with a 2-3” space from the
primary vessel (Pressure Vessel FAQs, 2013):

Solving for the inside diameter of the jacket:

D ji=1.9862 m+2 ¿
D ji=2.13856 m

Considering the material to be used is Carbon Steel (SA 285, Grade C). Using
the following formula for working stress:
SW = Su x Fm x Fr x Fs

where: Su: minimum specified tensile strength, 380 MPa (ASME SA285 Grade
C, 2014)

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Fm: material factor, 0.92 for Grade C material

Fa: radiographing factor, 1.00 since radiographing is not employed
Fr: stress relieving factor, 1.00 since relieving is not employed
Fs: factor of safety, 0.25 for temperature less than 315.56°C

Sw = 380,000,000 Pa x (0.92) x (1.0) x (0.25)

Sw = 87,400,000 Pa

The design pressure for jacket must be at least 520 kPa. Using the following
equation to calculate shell thickness with a corrosion allowance of 3.81 mm for
noncorrosive water stream (Couperm Penney, Fair, & Walas, 2012) and
efficiency joint 0,70 fior double-welded butt joint since radiographing is not
employed (Sinnot, 2005)

Substituting values to the shell thickness equation:

PJ DJ
t J= +C
2 S w e−PJ
1000 mm
t J=
(
( 520 ,000 Pa ) 2.1386 m x
1m )
+3.81 mm
2(87,400,000 Pa)( 0.70)−( 520,000 Pa )

t J =12.9371 mm

The outside diameter of the jacket is:

D jo =D ji + 2t j
D jo =2.1386 m+2 ( 0.0129 m )
D jo =2.1644 m

Area covered by the jacket:

A J = Abase + A covered ∈shell

A J =0.264 π D ji 2 +π D ji L

17.7445 m2=0.264 π (2.13856 m)2 + π (2.13856 m)(L)

L=2.0766 m

JACKET NOZZLE SIZING:

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We use the following formula to solve for the diameter of nozzle in the
jacket.
ṁ
A=
ρv

The density of the entering water is 992.827 kg/m 3. From the energy balances,
flow rate of steam is 0.1618 kg/s. Assuming the velocity of water to be 1 m/s,
the cross- sectional area of nozzle is:

ṁ
Area=
ρv
kg
Anozzle
ṁ
= =
( 0.2946 )
s
ρv
( 992.827 mkg )(1 ms )
3

Anozzle =0.0002 m2

4 x 0.0002
Pipe diameter=
√
2

Pipe diameter=0.0194 m

Therefore, use 0.5-inch Nominal Pipe size Schedule 40.

DESIGN OF STIFFNESS RINGS

Stiffness rings are installed on vessels which are influenced by an external
pressure. The external pressure is caused by either the operating pressure is
under vacuum or the tank is jacketed (Sinnott, 2005). These rings help prevent
buckling of the vessel.
Table 2
Jacketed Vessel Diameter, Do 2.1644 m

Radius of Jacket, RJ 1.0693 m 42.0976in

Thickness of Jacket, tj 12.9371 mm 0.5093 in

Young Modulus of Elasticity of

1.97136 x 1011 Pa
Jacket, E

Effective Length of Tank, L 2.07656 m

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Design Jacket Pressure 520000 Pa

Width of the stiffness ring, tr

t r=0.78¿

t r=0.78¿

t r=0.0917 m

Spacing between the two rings, Ls

L−2t r 2.07656 m−2(0.0917 m)

Ls = =
2 2

Ls =0.9465 m
Stiffness rings spacing should not exceed the critical spacing, Ls

Do
Ls ≤ 1.11Do (
√ tr
)

2.1644 m
0.9465 m ≤ 1.11( 2.1644 m) (
√ 0.0917 m
)

0.9465 m ≤ 11.6697 m

Therefore, the spacing is effective

The load per unit length on a ring, Fr

Fr = PJ × L s =

Fr = 520000 Pa × 0.9465 m

Fr = 492203.5976 N/m

The critical load to cause buckling in a ring under a uniform radial load, Fc

24 E I r
F c=
D3o

π D o t 3r
Where: Ir = second moment of inertia,
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2 πE t 3r
F c= 2
Do

2 π (1.97136 x 1011 Pa)(0.0917 m)3

F c=
(2.1644 m)2

Since Fr < Fc buckling would not occur

The critical pressure that would lead to buckling, Pc

Pc =K c E ¿

Using the figure above to determine Kc at the following parameters

Ls 0.9465 m
= =0.3692
Do 2.1644 m

Do 2.1644 m
= =23.7919
t r 0.0917 m

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Pc = 75,0554,857.6 Pa
Since PJ << Pc therefore buckling would not occur, making the stiffening act as
effective support rings.

REFERENCES

ASME, A. S. (2013). ASME Section I & VIII Fundamentals. ASME

International.
Dabir Viswanath, T. G. (2007). Viscosity of Liquids: Theory, Estimation,
Experiment, and Data. Netherlands: Springer.
Dream, R. F. (1999). Heat Transfer in Agitated Jacketed Vessel. Chemical
Engineering, 90-96.
Geankoplis, C. J. (1995). Transport Processes and Unit Operations 3rd Ed.
Prentice Hall.
K.V. Selvakumar, A. U. (2014). Extraction of Silica from Burnt Paddy Husk.
International Journal of ChemTech Research.
McCabe. (1993). Unit Operations of Chemical Engineering 5th Ed.
Paul, E. L.-O. (2004). Handbook of Industrial Mixing: Science and Practice.
New Jersey: John Wiley and Sons Inc.
Perry, G. (2008). Perry's Chemical Engineers' Handbook, 8th Ed.
R. Sinnott, G. T. (2005). Coulson and Richardson's Chemical Engineering
Design, 4th Ed.
S.M. Walas, J. C. (2012). Chemical Process Equipment: Selection and Design.
Oxford: Butterworth-Heinemann.
Silla, H. (2003). CHEMICAL PROCESS ENGINEERING Design and
Economics. New York: Marcel Dekker, Inc.
Sinnott, R. (2005). Coulson and Richardsons' Chemical Engineering Design Vol
6, 4th Ed.
Surface Area of Tank Heads. (2015). Mankato: MID-STATES MECHANICAL
SERVICES INC.
Timmerhaus, M. S. (1991). PLANT DESIGN AND ECONOMICS FOR
CHEMICAL ENGINEERS . Singapore: McGraw-Hill Book Co. .

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