Equipment Design Part 1

Sugarmill.co.
in Page 1 of 50
Thickness obtained by code or formula is only main value of thickness and requires
to be increased to allow for the factors affecting the use of vessels, mentioned
below are these factors:
i. Corrosion allowance
ii. Addition allowance is to be provided to take care of stresses due to:
iii. Input load and fluctuating pressure
iv. Weight of vessel and its content under operating condition
v. Due to ladders, piping, walls, etc.
vi. Wind loads when are required
vii. Reaction of support and reinforcement
viii. Thermal stresses
The max gauge pressure that is permitted for vessel in operation is determined by
the technical requirement of the process. It is generally not more than 10% excess
of normal pressure.
Pw = Pnormal × 101
Pdesign = Pw × 1.05
Generally it is 5% more than the max. Working pressure

Sugarmill.co.in Page 2 of 50
Normally the corrosion allowance for mild steel is taken as 1.5 mm till the thickness
of 20 - 25 mm, but for chemical use corrosion is taken as 8
The joint efficiency depends on the following factors:
i. Class of vessel
ii. Radio graphic inspection of welding joint
iii. Type of joint
iv. Quality control over fabrication pressure
The clandria shell thickness is given by the following formula:
PDi
t min = +C
200 fJ − P
tmin = clandria shell thickness

P = Design pressure in kg/mm2
f = Allowable stress
Di = inner dia. Mm
J = Joint efficiency 70%
C = Corrosion allowance
Tube plate thickness t1 is:
.025 P
t1 = FG
f
P = Design Pressure in kg/cm2

f = allowable stress in kg/cm2
G = main gasket dia.in mm
F = factor verifying with heat exchanger
For fixed type plate shell, the thickness is calculated for both shell tube plate, F is
calculated by:
k
F= For shell side pressure
2 + 3k
2+k
F= For tube plate side
2 + 3k
E s .t s D .t s 1
k=  
Et .t t d  − t t N
Where:
Et = Young modulus of tube = 0.95 × 106 kg/cm2 for brass

2.9 × 106 kg/cm2 for m.s
Es = Young modulus of shell = 1.9× 106 kg/cm2 for m.s

ts = shell thickness
tt = tube thickness
D0 = out dia. of shell
do = out dia. of tube
N = Number of tubes
Determination of CylinderThickness
Longitudinal stresses:
di P
For calculation of the longitudinal stress for the above cylinder

d i 2  2
A1 = , F1 = d i  P
4 4
Hence the longitudinal (fe) stress is given by:
F1 Pd i
f = =
A1 t
Hoop stresses:
Hoop stresses are circumferential stresses, when fh > fe cylinders are designed for
Hoop stresses
A2 = 2× (t × l), F2 = P × di × l
F2 Pd i t Pd i
fh = = =
A2 2(t  l ) 2t
F2 t
P
where:
fh = Hoop stress (allowable stress)

di = inner dia. of the cylinder
t = thickness of the shell.
In many vessels which subjected to internal pressure, the basic stress is:
Pd i
fh =
2t
Which taken place the base for calculation of pressure vessels, we use:
PD PD
f = , t=
2t 2f
Where:
P = the internal pressure acting inside the vessel

D = mean dia. of the vessel
f = allowable stress of material of construction
Design of Pressure Vessel As Per IS – 2825 – 1969
For unfired pressure vessels, for any cylindrical shape of vessel, we can say
uniformly stressed if:
D0 / Di ≤ 1.5 Ø
t / Di ≤ 0.25
We have a basic equation for thickness of cylinder can be:
Pd
t=
2t
But considering the joint efficiency and corrosion allowance this formula can be
modified to:
PD
t= +C
2tJ
J = joint efficiency = 0.7

C = corrosion allowance =1.5
D = Di + t
P(Di + t )
t= +C
2 fJ
 P  PDi
t 1 −  = +C
 2 fJ  2 fJ
PDi
t= +C
2 fJ − P
P in kg/mm2 , Di in mm, f in kg/mm2 , J welded joint eff. = 70%
P
Di
t = 100 +C
P
2 fJ −
100
PDi PDo
t= +C or t= +C
200 fJ − P 200 fJ + P
P in kg/cm2, Do outer dia. D = Do – t
Design Of Pressure Vessel Under External Pressure

As Per IS 2825 – 1969
Vapor body of evaporator or pan are subjected to vacuum i.e. they are externally
pressurized, hence are critical, the shell thickness of such parts can not be
calculated as
Per normal formula of:
PDi
t= +C
200 fJ − P
as this formula is driven on basis of internal pressure acting inside the cylinder,
but when vessel is subjected to vacuum, the force is exerted by the external
pressure, hence in such cases, the thickness will be calculated as for unfired
pressure vessel working under external pressure, referring to IS – 2825 – 1969
the procedure of calculation is as follow:
1. t = thickness of the vessel

2. l = height of the vessel (height of space)
3. di= vessel inner dia.
4. do = vessel outer dia.
5. calculate the ratio Do/ti , l/Do
6. find out the factor ß form the chart of carbon & alloy steel at temperature
T0 C given on page 182 of book of IS – 2825 – 1969, for operating
temperature 1500C
7. calculate allowable working pressure using the following formula:
factor
fw =  1.033kg / cm 2
14.22(D0 / t )
In case of calculated value of Pw < 1.03 then we have to assume the thickness
greater than the thickness earlier assumed.
Juice Heaters Design

The juice obtained from the sugar cane mill consist of impurities & sediments, and
to treat this juice in clarifier it becomes difficult when the juice is at the ambient
temperature, hence it is necessary to heat the juice to reduce its viscosity, due to
reduction in viscosity there is proper settlement of impurities, coloring matters and
sediment. The properly clarified juice improves the ICUMSA index of the sugar;
hence the juice has to be heated in heat exchanger, the principle of working of
juice heater based on:
Heat given by steam or vapor = heat absorbed by juice
The heat exchanger used in the sugar industry, are of the shell and tube
construction, the heating media used is either steam or bleeding vapor from
evaporator bodies.
1. juice heaters are used for raw juice heating, sulphated juice heating and
clear juice heating
2. steam economy is obtained by using, bleed vapor from evaporator for juice
heating application, the bleed vapor being at lower pressure, it has more
latent heat
3. the effectiveness hence is largely a function of heat transfer coefficient
between heating and receiving components
4. the major factor influencing the heat transfer are:
i. juice velocity 1.5 to 2 m/sec.
ii. scaling
Determination of Heating Surface for Juice Heaters
Thi
steam
∆te
∆ti juice
Tce
∆t
Tci
Ti = Thi − Tci
Te = The − Tce
Thi = Tce
T = Tce − Tci
Heat given out by steam = Heat absorbed by juice
S .k .t m = Q j  C j  t
Where:
S = heating surface in mm2

k = Heat transfer coefficient in kcal m2/hr
∆ tm = LMTD log mean thermal difference
Qj = quantity of juice in kg/hr
Cj = specific heat of juice = 0.9
∆ t = rise in juice temperature
t i − t e
t m =
t
log i
t e
Q jC j T − Tci
S=  log e
k T − Tce
Determination of Calendria Diameter for Juice Heater

To get the required juice heating surface, we have tow method of tube fittings in
the calendria of juice heater
Triangle method
600
600 60
0
3 2
The area is given by A= P = 0.866 P 2
2
The Square Method:
Area is given by: A = P2

From above it is clear that the area required for fitting the tube will be lost in
Rhomus type of arrangement that is the square type of arrangement. To get the
required area we will be required to fit N number of tube hence the total area.
Area = N×0.886 ×P2

D 2 = N  0.866 P 2 _______________(1)
4
Thus in equation No (1) area corresponding to diameter (D) is only for drilled tube
for achieving the heating surface (S) to take care for the required by partition
place, non condensable gases, connection, stay bolts and welding, we have to
consider the factor ß, which is for evaporator or pan is 0.8 to 1.0 for juice heaters
0.6 to 0.8, considering a factor of 0.6 equation No (1) becomes:
 0.866 P 2  N
D2 =
4 0.6
D = 1.36  P  N
Where: D = dia. of the calendria

Determination of Number of Passes

And Number of Tubes Per Pass
Leff.
E
Total length = leff. + 2t + 2E
S = d m  l eff .  N
di + do
dm =
2

Q= d i  n  velocity
2
n = number of tubes per pass

N= total number of tubes
Ratio N/n = number of passes
Problem:
Calculate the heating surface of a juice heater for 1250 TCD plant to raise the juice
temperature from 35o C to 75o C, for raw juice heating application.2and body of
quadruple at 96o C and 3rd of quadruple at 84o C.
Solution:
T = 96o C
Tci = 75o C
ti = 35o C
Q jC j T − Tci
S=  log e
k T − Tce
T = 96o C, Tci = 35o C, Tce =75o C, C j= 0.9
K = coefficient of heat transfer in kcal m2/hr

0.8
 1.8 
k = 6T  
 vt 
vt velocity of juice to tube and it is taken as 1.8 m/sec

0.8
 1.8 
 k = 6  96  = 576 Kcal m2/hr
 1.8 
Qj = Quantity of juice in kg/hr
1250TCD
Qj = = 56.81 MT/hr
22hr
Considering:
Qj =57 MT/hr = 57×103 kg/hr
57  10 3  0.9 96 − 35
S =  log e = 94.97m 2
576 96 − 75
Heating surface of the juice heater is 95 m2
Question 2:
Calculate the number of passes for the above juice heater of 95 m2 heating
surface; assume the tube size of 45 mm Do ×SWG thick and total length of 400
mm also tube plate thickness 25 mm.
Ans.
25
Top thick
t plate
400
Bottom
5 tube plate
leff. = 400 mm, E = 5 mm, t = 25 mm, 16 SWG =1.6 mm
dm =Do – thick (SWG) = 45 – 1.6 = 43.5 mm = 0.0435 m
S = d m  l eff .  N
95 = 3.14 ×0.0435 × 4 × N
95
N= = 173.789 Nos.
3.14  4  0.0435
Total number of tubes is 173.389 Nos. say 174 Nos.
n number of tubes per pass


Q = A v =  di  v  n
2
v = juice velocity in tubes, taken as 1.5 m/sec2
di = 45 - 2×1.6= 41.8 mm = .00428 m
57
Q= = .01553 m3/sec
1.06  3600
0.01553
n = = 7.5

(0.418) 2
 1.5
4
Hence number of tubes per pass is 7
Total No.oftubes 174

No.ofpasses = = = 24.87
No.oftubeperpas 7
No. of passes is taken as 26, No. of tubes per pass 7, hence the actual No. of tubes
is:
N
= 7  N = 26  7 = 182 Nos.
n
Question 3:
Calculate the calendria dia. and calculate the shell thickness for juice heater of the
proceeding juice heater.
Ans:
The calendria dia. is given by:
D = 1.36  P  N
P P P
A B
P = pitch, AB = legmen 10 mm
P =Do + lig.10 =45 + 10 = 55 mm
D = 1.36  55  182 = 1010mm = 1.010 m
Calendria thickness tc
PDi
tc = +C
2000 fJ − P
P = 60 m head from mixed juice pump = 6 kg/cm2
f = allowable stress = 9.8 kg/mm2
J = Joint efficiency = 70%
C = corrosion allowance = 1.5
6  1010
tc = + 1.5 = 6mm
200  9.8  0.7 − 6
tc = 6 mm say 8 mm
out side dia. of the calendria = 1010 + 8×2 = 1026 mm

Question 4:
Calculate the juice pipe line size for the same heater
Ans:

Q= (D )p
2
vj
4
vj = juice velocity = 1.5 m/sec
Dp =juice pipe dia.
Cane + water = juice + bagasse
TCD =1250
TCH = 57 MT/hr
Assume imbibitions is 25% on fiber, fiber = 14%
Hence MJ% cane
100 + 35 = MJ +30
MJ = 105% cane
57 1
Q=  = 0.016378 m3/sec
1.06 3600
0.016378
Dp = = 0.117m = 117 mm

 1.5
4
Hence pipe line size is 150 mm
Question 5:
Calculate the vapor pipe line size

Ans:
Heat taken by juice = Heat given by steam
Q jC j
T = hl  weightofsteam
k
hl = enthalpy of steam at 96o C
Weight of steam = 4375 kg of steam
The specific weight of steam at 96o C = 1.905 m3/kg

Volume of vapor from second body = (d v )2  vv
4
4375  1.905 
= (d v )  30
2
3600 4
dv = 0.314 mm , taken as 16 mm
Question 6:
Calculate the pipe line dia. for condensate collection tank.
Ans:
Q =A.v

= (d c )  vc
4375 2
1000  3600 4
Condensate velocity vc = 0.6 m/sec
From above dc condensate pipe dia = 0.051 m = 51 mm ×2 Nos.

Question 7:
Calculate tube plate thickness for the same juice heater
Ans:
E s t s Do − t s 1
k=   
Et t t d o − t t N
Es = 1.9×106 kg/cm2
Et = 2.9 ×106 kg/cm2 for m.s
ts = 8 mm
tt =1.6 mm (tube thickness)
Do =1026 mm (calendria out side dia.)
do = 45 mm (tube out side dia.)
N = 182 total number of tube
Hence k = 0.4236
2+k
F= = 0.7409 = 0.8607
2 + 3k
10 mm 10 mm
Sealing ring of
25 mm width
1026
G = Do + 2  10 + 25 = 1026 + 45 = 1071mm
0.25P .025  6
t = FG = 0.8607  1071 = 36.25mm
f 980
Hence the tube plate thickness is 36.25 mm
Question 8:
Draw the drawing for the above juice heater and the calculation made
Evaporators Design
Calculation of Pressure and Temperature

For Quadruple Effect Evaporators
P1 P2 P3 P4 P5
∆P1 ∆P2 ∆P3 ∆P4
turbine
condenser P5
For the quadruple effect evaporator set the following proportional of the pressure
drop across the bodies are applicable:
11
P1 = P
40
10.3
P2 = P
40
9.7
P3 = P
40
9.0
P41 = P
40
Where P = P1 − P5
Problem 1:
For a quadruple effect evaporator set take P1 = 1kg/cm2, T1 =120o C, P5 = - 635

mm of Hg, calculate the pressure and temperature in each body
Solution:
P1 = 1kg/cm2 = 760 mm of Hg
∆P = P1 – P5 = 760 – (-635) = 1395 mm of Hg
First body:
11 11
P1 = P =  1395 = 383 mm of Hg
40 40
∆P1 =P1 – P2 , P2 =760 – 383 = 377 mm of Hg
377
P2 = = 0.5kg / cm 2
760
P2 = 1.0 + 0.5 = 1.5 kg/cm2 Abs.
From stem tables at 1.5 kg/cm2 Abs., T2 = 1110 C
∆T1 =T1 – T2 = 120 – 111 =9oC

Second body:
10.3 110.3
P2 = P =  1395 = 359 mm of Hg
40 40
∆P2 =P2 – P3 , P3 =377 – 359 = 18 mm of Hg
18
P3 = = 0.0236kg / cm 2
760
P3 = 1.0 + 0.0236 = 1.0236 kg/cm2 Abs.
From stem tables at 1.0236 kg/cm2 Abs., T3 =
∆T2 =T2 – T3
Third body:
9.7 9.7
P3 = P =  1395 = 339 mm of Hg
40 40
∆P3 =P3 – P4 , P4 =18 – 339 = - 321 mm of Hg
− 321
P4 = = −0.422kg / cm 2
760
P4 = 1.0 + (-0.422) = 0.577 kg/cm2 Abs.
From stem tables at 0.577 kg/cm2 Abs., T4 = 84 0 C
∆T3 =T3 – T4
Fourth body:
9.0 9.0
P4 = P =  1395 = 314 mm of Hg
40 40
∆P4 =P4 – P5 , P5 = - 321 – 314 = - 635 mm of Hg
− 635
P5 = = −0.836kg / cm 2
760
P5 = 1.0 + (-0.836) = 0.164 kg/cm2 Abs.
From stem tables at 0.164 kg/cm2 Abs., T5
∆T4 =T4 – T5
Problem 2:
Calculate the pressure and temperature for the five body’s evaporator, P1
= 1 kg/cm2, P6 = -635 mm of Hg, T1 = 120o C, take the pressure drop as follows:
11
P1 = P
50
10.5
P2 = P
50
10.0
P3 = P
50
9.5
P4 = P
50
9.0
P5 = P
50
Solution:
Actual pressure drop a cross the evaporator set is:
∆ P = P1 – P6 =760 – (- 635) = 1395 mm of Hg
First body:
11 11
P1 =  P =  1395 = 306 mm of Hg
50 50
∆P1 = P1 – P2 , P2 = 760 – 306 = 454 mm of Hg
454
P2 = = 0.597 kg/cm2
760
P2 = 1 + 0.597 = 1.597 kg/cm2Abs.
Second body:
10.5 10.5
P2 =  P =  1395 = 292 mm of Hg
50 50
∆P2 = P2 – P3 , P3 = 454 – 292 = 162 mm of Hg
162
P3 = = 0.0213 kg/cm2
760
P3 = 1 + 0.0213 = 1.0213 kg/cm2Abs.
Third body:
10.0 10.0
P3 =  P =  1395 = 279 mm of Hg
50 50
∆P3 = P3 – P4 , P4 = 162 – 297 = -117 mm of Hg
− 117
P4 = = −0.154 kg/cm2
760
P4 = 1 + (- 0.154) = 0.846 kg/cm2Abs.
Fourth body:
9.5 9.5
P4 =  P =  1395 = 256 mm of Hg
50 50
∆P4 = P4 – P5 , P5 = -117 – 256 = -373 mm of Hg
− 373
P5 = = −0.491 kg/cm2
760
P5 = 1 +( -0.491) = 0.509 kg/cm2Abs.
Fifth body:
9.0 9.0
P5 =  P =  1395 = 251 mm of Hg
50 50
∆P5 = P5 – P6 , P6 = -373 – 251 = -624 mm of Hg
− 624
P6 = = −0.821 kg/cm2
760
P6 = 1 + (-0.821) = 0.179 kg/cm2Abs.
Determination of calendria Diameter of evaporator body
D = Diameter of the calendria
d = Diameter of the centre down take = 0.2 D
Heating surface = 0.866 P2 N
P = pitch
We have the requirement for any heating surface by fitting N number of tubes
At = 0.866P2N __________ (1)

Now the area of the center down take

Ad = (0.2 D )2 ___________ (2)
4
Again the diameter of the calendria can be expressed in

Ac = D 2 _____________ (3)
4
Now we can write down
Ac = At + Ad
 
D 2 = 0.866 P 2 N + (0.2 D) 2
4 4
D 2 = 1.1485P 2 N __________ (4)
Considering the additional area required for stay bolts, connection for removal of
non condensable gases we have to consider a factor ß which is 0.9 for evaporator,
Hence
1.1485  P 2  N
D =
2
factor = 0.9
Sizing of evaporator
Diameters:
D1 = Calendria diameter (to be calculated)

D2 = Centre down take diameter = 0.2 D1
D3 = Vapor space diameter = D1
D4 = dome diameter = 2d1
d1 = Vapor / steam entry (to be calculated)
Heights:
H1 = 2d1
D3 − D4
H2 = tan 30 o
2
H3 = 2 to 2.5 H4
H4 = calendria height is given

H5 = typically 200 mm
D2 − D5
H6 =
2
H7 = typically 200 mm
H1
D4 H2
D3 H3
D2
H4
D1
H5
H6
H7
Sizing of Catch – all

Diameters
d1 = vapor out let (to be calculated)
d2 = umbrella diameter = 2d1
d3 = diameter of inner cylinder
d4 = diameter of intermediate cylinder
d5 = dome diameter = 1.8 d1
Heights
d1
h1 =
4
d1
h2 =
4
h3 = 2d1
h4 = 0.21 d1
h5 = 1.8 d1
d5
h2 d4
d3 d1
h5
h3
h4
h1
d2
Catch – all Proportional

Problem:
Design evaporator body having 600 mm2 heating surface, tube size of 45 mm
OD,18 SWG and total length of 2000 mm, assume the evaporator body as the third
effect of a quadruple set with in let vapor of 100o C and out let vapor of 84o, also
assume that the tube plate thickness is 25 mm and E = 5 mm
Solution:
1.Number of tubes
Heating surface
H .S = d m l eff  N
leff = lT -2( E+t) = 2000 – 2(25 + 5) = 1940 mm
SWG 18 = 1.22
dm = dt – tt = 45 – 1.22 = 43.78 mmm
600 = 3.14 × 0.04378 × 1.940 × N
N =2248
Considering stay bolts and non condensable gasses connection of 4 & 8

respectively, the total number of tubes will be:
Total number of tubes = 2248 + 4+ 8 = 2260
2. Tube plate diameter (dt):
d t = 1.13  P  N
P =do + ligament = 45 +10 =55 mm
d t = 1.13  55  2260 = 2955 mm
Taking margin of 10% dt =1.1× 2955 = 3250
3. Vapor space length
Vapor space length = 2.0 to 2.5 × tube length
Vapor pace length = 2.5 × 2955 = 3250 mm
4. Center down take diameter
Center down take diameter = 0.2 D = 0.2 × 3250 = 650 mm
5. Calendria shell thickness
PDi
tc = +C
200 fJ − P
3  3250
tc = + 1.5 = 8.6mm
200  9.8  0.7 − 3
6. Design of vapor space
The vapor space is acted upon by external pressure, the design of vapor space has
to be carried out with respect to external pressure as per IS 2825 – 1969.
Assuming vapor space thickness as t = 12 mm , Do =3250 + 2 × 12 = 3274
l 5000
= = 1.5
Do 3274
Do 3274
= = 273
t 12
Allowable working pressure (Pw)
Factor
Pw =
D
14.22 o
t
From the chart on page 182 of IS – 2825 – 1969, factor ß for l/Do = 1.5, Do/t
= 273 at 150o C, ß = 3250
3250
Pw = = 0.84
14.22  272
Pw = 0.84 < 1.033 kg/cm2 Not acceptable
We have to increase the thickness t2 = 14 mm
Do = 3250 + 2 × 14 = 3278 mm
l 5000
= = 1.5
Do 3278
Do 3278
= = 234
t 14
Hence factor ß corresponding to l/Do = 1.5 & Do/t = 234 is 4500

4500
Pw = = 1.3
14.22  234
Pw = 1.3 > 1.033, hence the thickness 14 mm is acceptable
Design of conical bottom:
As per IS – 2825 – 1969 the angle of inclination  for conical section to vessel
axis y – y should not be more than 70o. if this condition is satisfied, the conical
bottom design can be:
i. Let us assume the thickness for the bottom cone t = 14 mm, we find l/Do, Do/t
as follows
Di − d1 1  3250 − 500  1
L=  =  = 1463
2 sin 70  2  sin 70
Do =3250 - 2×14 =3278 mm

l 1463
= = 0.45
Do 3278
Do 3278
De = = = 9584mm
cos  cos 70
Do 9584
= = 685
t 14
Factor 9000
Pw = = = 0.92 kg/cm2
De 14.22  685
14.22 
t
Pw =0.92 < 1.033 , hence the assumed thickness is not acceptable, we have to
increase the thickness and repeat the calculations, take the thickness 16 mm
Do = 3250 + 2×16 = 3282 mm
Do 3282
De = = = 9596
cos  cos 70
l 1463
= = 0.45
Do 3282
De 9596
= = 600
t 16
From IS chart factor ß is found 10500
Factor 10500
Pw = = = 1.23
De 14.22  600
14.22 
t
Pw = 1.23 > 1.033 kg/cm 2 ,
Hence the thickness 16 mm is acceptable
8. Calculation of vapor inlet and out let diameter
Inlet vapor pipe diameter
The heating surface = 600 mm2
Evaporation rate 25 kg / m3 / hr (for third body)
Weight of vapor generated = heating surface × evaporation rate
Wt = 600 ×35 = 1500 kg/hr

Volume of vapor at the inlet = Wt of vapor × vapor specific volume
At inlet T = 100o C and vapor specific volume = 1.673 m3/kg
Q = A × V = (15000/3600) × 1.673 = 6.9708 m3/sec
Velocity of vapor = 30 m/sec

6.9708 = (d in )2  30
4
Hence the vapor inlet pipe diameter is 544 mm taking margin of 10%, inlet dia.
= 600mm
Out let vapor pipe diameter
Out let vapor temperature 84o C
Vapor specific volume at 84o C = 2.936 m3/kg
Volume of out let vapor = (15000/3600) × 2.936 = 12.23 m3/sec
Q = A ×V = 12.23

12.23 =  (d out )  30
2
Hence the vapor out let pipe diameter is 720 mm, taking margin of 10%, out let
dia.= 792 mm say 800 mm
9. Tube plate thickness
0.25 P
t t = FG
f
G = 3282
k
F=
2 + 3k
E s t s Do − t s 1
k=   
E t tt d o − tt N
1.9  10 6 16 3282 − 16 1
k=    = 0.28
2.9  10 1.22 45 − 1.22 2260
6
0.28
F= = 0.2
2 + 3  0.28
0.25
t t = 0.2  3282 = 24.8
980
9. Draw the complete engineering sketch for the above evaporator body,
complete evaporator body and catch - all
For catch – all
Vapor out let dia. is calculated, d1 = 800 mm
Umbrella dia, d2 = 2d1 = 2 × 800 = 1600 mm
Diameter of outer cylinder, d5 = 1.8 d1 = 1.8 × 800 = 1440 mm
Design of Vacuum Pans
Definitions used in pans boiling
1. Syrup:
Syrup is the concentrated juice discharged from evaporators
2. Graining – Grain making:
It is the process of initialing the growth of crystals in the sugar solution
3. Proof:
This is synonymous to high concentration when sugar crystals are formed and
grown
4. Footing
It is the quantity of mass. enough to cover the volume of tube before the strike of
pan
5. Masscuite
It is the mixture of sugar and sugar crystal and mother liquor
6. Seed Magma:
It is consist of more sugar grains mingled with syrup or molasses
7. Cutting:
Transferring of masscuite from one pan to another
8. Pan circulation
While controlling the pan boiling process two very important parameters are to be
considered circulation and temperature
The speed of masscuite traveling through the tubes of well designed pan of
calendria type with its down take 15% of pan diameter was calculated and found
as below:
Time(hr) 1st 2nd 3rd 4th 5th 6th

Speed (cm/sec) 46.6 19.2 4.6 0.9 0.6 0.3
It was calculated in the tubes of calendria pan for getting equilibrium, temperature
corresponding to the rube, lowered by superposed hydrostatic head and of the
weight of the masscuite, to this we must add the boiling point elevation of purity
and density of masscuite.
9. Natural circulation
When the level of strike is low the circulation are generated are reduced due to
the bubbles formation in the tube. This reduces the masscuite in the tube
compared to balance in masscuite in the centre down take, which has bubble due
to difference in specific gravity of the column; this generates the natural circulation
of masscuite from center down take to tube and from tube to center down take
10. Mechanical circulation
By Vertical screw pump of the same diameter as down take with 4 to 6 vanes
driven by a heavy shaft centered in down take by appropriate bearing, it is
necessary to chose proper diameter and rpm based on peripheral speed
11. Boiling point / rise elevation
It is the difference between the temperature of the boiling solution and that of the
vapor leaving the pan
12. Definition of graining volume
This denotes the min. volume of masscuite which must be introduce into pan
before turning on the steam, to avoid caramelizing and deteriorate the color of
sugar in the actual practice the masscuite should be taken above top of tube plate
by 1 to 2 inch, that the syrup can be circulated through centre down take, this also
is called footing, it is expressed in percentage of volumetric capacity of pan,
generally taken as 35% to 37%.
Approximate Proportionality with respect to

Calendria diameter and vapor entry diameter:
Diameters:
D1 = calendria diameter (to be calculated)
D2 = Center down diameter = 45% - 50% D1
D3 = vapor space diameter = D1
D4 = 2d1
D5 = suitable to masscuite out let = 700 mm for 40 MT pan

= 900 mm for 60 MT pan
d1 = vapor out let (to be calculated)

d2 = vapor/steam inlet (to be calculated)
D4
D1 H5
H4
30o
D3 H3
H2
d2 D2
H1
D1
H6
17o to 25o H7
D5
Universal H8
joint
Bevel gear
pairs
Approximate Proportionality Diameters and Heights

with Respect to Calendria diameter and Vapor out let.
Heights
H1 = Calendria shell height (to be calculated)
H2 = Strike level (to be calculated)
H3 = vapor space height = 1500 – 2000 mm
D3 − D4
H 4= tan 20 o or 30 o
2
H5 = 1.75d1
H6 = 150 to 175 mm it should be minimum

D1 − D5
H7 = tan 17 o or 25 o
2
H8 = 150 – 175 mm
Number of tubes and Pan Calendria diameter
B C h
D2
D
Form the above geometry:

H = P sin 60o = 0.866 P
Hence the area required to accommodate one tube is:
= The area of Rhobmus ∆ ABC
= 2 (Area ∆ ABC)
= 2(1/2 × h ×P)
= 0.866 P2 ________________ (1)
The area required to accommodate N number of tubes to form the pan heating
surface
 
D1 = 0.866 P 2 N +
2
(0.45D1 )2
4 4
When the center down take diameter is equal = 45 % D1, the total number of tube
is given by:
D1 = 1.24  P 2  N
When the center down take diameter is equal to 55% D 1, the total number of
tubes is given by:
D1 = 1.32  P 2  N
Design of vacuum pan

Deign a low head vacuum pan of 80 MT capacity assume the necessary design
S
data, tube size OD, t, ligament, expansion allowance, ratio
V
Assumptions:
1. tube size – 120 mm OD ×16 SWG × 750 mm total length
2.  mass. = 1.43
3. ligament = 16 mm
S
4. = 6.6
V
5. expansion allowance = 5 mm
Dm = OD – thickness = 102 – 16 SWG= 102 – 1.626 = 100.4 mm
P = OD + ligament = 102 + 16 = 118 mm
1. Number of tubes:
Pan capacity =  × V, hence 80 = 1.4 × V
80
V = = 56 m3
1.43
S
Heating surface to volume ratio = 6.6 (for low head pans)
V
Heating surface S = V × 6.6 = 56 × 6.6 = 369.6
Heating surface S = Dm  l eff  N
Effective length leff = 750 – 2 × (30 + 5) = 680 mm= 0.680 m

Hence 369.6 = 3.14 × 0.1004 × 0.680 × N
Hence number of tubes = 1724 Nos.
2. Calandria diameter:
Dcal = 1.24  P  N
N number of holes required for tubes + non condensable gasses connection +

stay bolts
N = 1724 + 10 + 8 = 1742
Dcal = 1.24  118  1742 = 6107
Considering 5% margin:
Dcal = 1.05 × 6107 = 6412 mm
3. Height of vapor space
Considering 42% graining volume above top tube plate, the volume remains equal
to
(1 – 0.42) = 58% of the working volume
58% Hs
Hence the volume above top tube plate 58% of the working volume
58
 56 = 32.48 m3
100

4
(D cal
= Dvaporspace )
2
 H s = 32.48
Hence the height of the vapor space = 1006 mm = 1.006 m

Height of strike level required is 2000 mm to avoid the entrainment in vapor which
is recommended by Hugot, hence total height of the vapor space is:
Hs = strike level + 2000 = 1006 +2000 = 3006 mm = 3.006 m
4. Center down take:
Dc/d.take = 45% Dcal

Dc/d.take = 0.45 × 6412 = 3000 mm =3 m
5. Calandria thickness:
PDi
t cal = +C
200 fJ − P
P = 3kg/cm2
Di = 6412 mm
f = 9.3 kg/cm2
J = 0.7
C = 1.5
Hence the thickness of the Calandria shell is:
3  6412
t cal = + 1.5 = 15.55 mm
200  9.8  0.7 − 3
Considering weight of mass; Stay bolts load, vapor connections, condensate

connections, tcal = 18.0 mm
6. Thickness of vapor space:
Let us assume the thickness of the vapor space is tv = 18 mm

Do for the vapor space = Dcal + 2 × tvl = 6448 mm
L = vapor space height = Hs = 3006 mm
Hence
Do 6448
= = 358..2
tv 18
L 3006
= = 0.466
Do 6448
Referring IS charts the factor ß = 7500
factor
Pallowable = = 1.38  1.033
Do
14.22 
t
Hence the assumed thickness is accepted, tv = 18 mm
7. Design of the bottom cone
6412
2707
20o
70o
L
1000
Let us assume the thickness of the bottom cone tb1= 20 mm.

cone out side diameter Do
Do= Dcal + 2 × tb1 = 6412 + 2 × 20 = 6492 mm
Cone effective diameter De

Do 6492
De = = = 18866
cos  cos 70
Do 18866
= = 943
t b1 20
L 2880
= = 0.1542
Do 1866
Referring to IS charts, factor ß = 4500
factor 4500
Pw = = = 0.333  1.033 kg/cm2
Do 14.22  943
14.22 
t b1
Since the calculated allowable working pressure is less than the atmospheric
pressure, the assumed thickness must be increased, assume a greater thickness
and repeat the calculation until you get Pallowable greater than the atmospheric
pressure.
8. Vapor inlet
We have the heating surface of the pan which is 396.6 m2, the rate of evaporation
at the start of the strike 58 kg/m2hr (STD), hence vapor generated:
Vapor generated = heating surface × rate of evaporation

= 396.6 × 58 = 21437 kg/hr
1.1  21437
Considering 10% = = 6.55 kg/sec
3600
Let us assume the pan is boiling all the vapor, the specific volume of vapor @ 100 o
C is 1.673 m3/kg and the vapor velocity is 30 m/sec
Hence volume of the vapor generated = 6.55 × 1.673 = 10.938 m3/sec


10.938 = (d in )2  velocity =   (d in )2  30
4 4
The vapor inlet pipe diameter is 0.682 m, taken 700 mm
9. Vapor outlet pipe:
The specific volume of out let vapor @ 55o C is 9.584 m3/kg, outlet vapor velocity
48 m/sec
Outlet vapor = 6.55 × 9.584 = 62.749 m3/sec


62.749 =  (d out )  48
2
4
The vapor outlet pipe diameter is 1290 mm
10. Condensate outlet
Vapor required by pan is equal to condensate available which is equivalent to 6.55

kg/sec going to the condenser, considering the velocity at the pipe section 0.6
m/sec, which is equivalent to 60 m/sec, hence

6550 = (d condensate )2  60
4
dcondensate = 11.78 cm , the standard diameter 125 mm
11. Condensate collection pipe:

3 (125)2 =  (d coll . )2
4 4
hence the diameter of the condensate collection pipe is 250 mm
Condensate collection pipe
11. Draw the complete sketch of this vacuum pan, considering all the
dimensions that we have calculated.
Design of flange and determination of No. bolts
Herein is the procedure for designing a flange thickness and determining number
of bolts, the flange to be used for a pressure vessel, the following data may be
considered
Data:
Allowable stress for bolts material (5% Cr, 1% Mo) steel of 1047 kg/cm2
Design temperature 115o C
Design pressure 6 kg/cm2
Procedure:
1. Gasket out side diameter
We have a relation for gasket which is:
1
d o  y − Pm  2
= 
d i  y − P(m + ) 
From the above relation do can be calculated, where:

y = minimum design stress kg/cm2

m = gasket factor = 2.5 for rubber with asbestos
P = design pressure kg/cm2
di = pressure vessel shell inside diameter (given in cm )
2. Gasket width
The gasket width (N) is given by:
do − di
N=
2
The gasket basic width (b) is given by:
N
b=
2
3. Gasket pitch circle diameter (PCD):
The gasket pitch circle diameter is given by:

PCD = di + N
4. Estimation of number of bolts:
To estimate the number of bolts we have to determine the gasket controlling load
in order to calculate the minimum bolting area and number of bolts
a. Hydrostatic end force (H):


H= G2P
4
Where:
H = hydrostatic force (kg)

G = gasket PCD (cm)
P = design pressure (kg/cm2)
b. Total joint contact surface component (H p):

H p = 2  G  m  b  P
Where:
b = basic gasket width
G = gasket PCD
P = design pressure
c. Total load:
wo = H + Hp
d. Load required sealing the gasket (wg):

The load required to seal the gasket under bolting condition is given by:
wg =   G  b  y
Compare between wo and wg the greater load should be the controlling load (wc)
e. minimum bolting area :

wc
A=
Sb
Area per bolt Ab :

A
Ab =
N1
Where N1 is the number of bolts (to be assumed)


Ab =
2
db
4
db is the bolt diameter
PCD = G + N + 2× 1.5 + db + clearance

DESIGN OF JUICE SULPHITER
Design juice sulphiter for 2000 TCD capacity plant for white sugar plantation
Solution
TCH = 2000/ 24 = 83.33 T/Hr
Volume of juice per hour [mixed juice% cane= 100%]
= weight of juice / specific gravity of juice
= 83.33/1.06 = 8.61 m3/Hr
Assuming retention time of 8 minutes, then the volume of juice per 8 minutes is
given by = [78.61× 8]/60 = 10.48 m3/ min and this is known as active volume or
working volume
Active volume =[ 3.14/4]× DR2 ×H
Where DR= reaction tank diameter
H = working height [ assume H =2.8 m
10.48 =[3.14/ 4]× DR2×2.8 , hence DR = 2.18 m = 2180 mm
Reabsorbtion tank diameter Da = 0.4 to 0.5 DR
Da = 0.4×2180 = 872 mm
Shell thickness of reaction tank t ={ [ P×Di]/[200 f j – P]} + C
Where P = pressure at which the tank is tested = 3 kg/cm2
Di = internal diameter of tank in mm
f = allowable stress in kg/ cm2
j = weld joint efficiency = 0.7
c = correction allowance = 1.5 mm
t = {[3×2180] / [200×9.8×0.7 – 3]} +1.5 = 6.26 mm
Take the thickness = 8 mm
The diameter of the reabsorbition tank is taken as = 5 mm
DESIGN OF SYRUP SULPHITER

Deign a syrup sulphiter for 2000 TCD capacity plant for white sugar plantation
Solution
TCH = 2000/24 = 83.33T/Hr
Syrup% cane = 25% [standard evaporation in evaporator is 75%]
Hence syrup quantity Q = 83.33×0.25 =20.83 T/Hr
Volume of syrup = 20.83/1.3 = 16.02 m3/Hr
Where 1.3 = specific gravity of syrup
Assuming retention time of 12 minutes, then the volume of syrup in 12 minutes is
given by:-
Active volume = [16.02×12]/ 60 = 3.204 m3/min
Assuming working height of H = 1.5m
Then active volume = [3.14/4]× DR2 ×1.5 = 3.204
DR = 1.65 m = 1650 mm
Take Da = 1700 mm
Diameter of reabsorbtion tank Da = 0.45 DR = 0.45× 1700 = 765 mm
Reaction vessel shell thickness:-
ts = [P Di/(200 f j – P)] + C
t = [3×1700/(200×9.8×0.7)] + 1.5 = 5.225 mm
take shell thickness = 6 mm
Height above syrup column H1= 0.9× H =0.9×1500 = 1350 mm
Syrup inlet and outlet pipe size
Syrup flow rate = cross sectional area ×velocity of juice
Q = 16.02/3600 = 0.00445 m3/s
Assuming velocity of juice v = 0.4 m/s
0.00445 = (3.14/4)×dP2×0.4, then dP = 0.119 m = 119mm
take the diameter of the pipe = 125 mm.

Equipment Design Part 1

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Equipment Design Part 1

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Sugarmill.co.

Generally it is 5% more than the max. Working pressure

The joint efficiency depends on the following factors:

The clandria shell thickness is given by the following formula:

tmin = clandria shell thickness

Tube plate thickness t1 is:

P = Design Pressure in kg/cm2

Et = Young modulus of tube = 0.95 × 106 kg/cm2 for brass

Es = Young modulus of shell = 1.9× 106 kg/cm2 for m.s

For calculation of the longitudinal stress for the above cylinder

Hence the longitudinal (fe) stress is given by:

fh = Hoop stress (allowable stress)

P = the internal pressure acting inside the vessel

Design of Pressure Vessel As Per IS – 2825 – 1969

We have a basic equation for thickness of cylinder can be:

J = joint efficiency = 0.7

P in kg/mm2 , Di in mm, f in kg/mm2 , J welded joint eff. = 70%

P in kg/cm2, Do outer dia. D = Do – t

Design Of Pressure Vessel Under External Pressure

1. t = thickness of the vessel

Juice Heaters Design

Heat given by steam or vapor = heat absorbed by juice

Determination of Heating Surface for Juice Heaters

Ti = Thi − Tci

Te = The − Tce

Heat given out by steam = Heat absorbed by juice

S = heating surface in mm2

Determination of Calendria Diameter for Juice Heater

The Square Method:

Area is given by: A = P2

Area = N×0.886 ×P2

Where: D = dia. of the calendria

Determination of Number of Passes

Total length = leff. + 2t + 2E

n = number of tubes per pass

Ratio N/n = number of passes

T = 96o C, Tci = 35o C, Tce =75o C, C j= 0.9

K = coefficient of heat transfer in kcal m2/hr

vt velocity of juice to tube and it is taken as 1.8 m/sec

Qj = Quantity of juice in kg/hr

Heating surface of the juice heater is 95 m2

leff. = 400 mm, E = 5 mm, t = 25 mm, 16 SWG =1.6 mm

dm =Do – thick (SWG) = 45 – 1.6 = 43.5 mm = 0.0435 m

Total number of tubes is 173.389 Nos. say 174 Nos.

n number of tubes per pass

v = juice velocity in tubes, taken as 1.5 m/sec2

di = 45 - 2×1.6= 41.8 mm = .00428 m

Hence number of tubes per pass is 7

Total No.oftubes 174

The calendria dia. is given by:

P =Do + lig.10 =45 + 10 = 55 mm

D = 1.36  55  182 = 1010mm = 1.010 m

P = 60 m head from mixed juice pump = 6 kg/cm2

f = allowable stress = 9.8 kg/mm2

J = Joint efficiency = 70%

C = corrosion allowance = 1.5

out side dia. of the calendria = 1010 + 8×2 = 1026 mm

vj = juice velocity = 1.5 m/sec

Dp =juice pipe dia.

Cane + water = juice + bagasse

Assume imbibitions is 25% on fiber, fiber = 14%

Hence MJ% cane

Hence pipe line size is 150 mm