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Design
Design
DETAILS
Introduction
To produce desired product at commercial level we cannot used laboratory equipment.
For this we required equipment of large capacity and if production capacity is very large then
we have to use multiple equipment of same or different capacity. Also, we have to keep
equipment in spare if any equipment needs any maintenance so that we can use that spare
equipment without affecting production very much.
Selection of MoC for the equipment is an important task. Because of some material to
be handled in equipment it will damage the MoC or there is chances of failure of equipment.
This selection of MoC is done based on the duty of equipment and the operating condition like
temperature and pressure.
In this chapter all equipment used in plant is given with its capacity and number, MoC,
for which purpose it is used.
Raw brine tank 4 2300 m3 RCC with coal tar To store raw brine
epoxy lined
Purified brine 2 2300 m3 RCC with coal tar To store purified brine
tank epoxy lined
Conclusion
Out of all the equipments listed above, the major equipment that can be considered is
Absorber tower & it’s process & mechanical design are shown in the next chapter. Also the
minor equipments that can be considered are Storage tank & Centrifugal pump & it’s process
design are also explained in next chapter.
EQUIPMENT
DESIGN
Introduction
In previous chapter we have seen various equipment used in the soda ash plant. As a
chemical engineer we should aware about designing of an equipment. The design of these
equipment is done to get the maximum performance of the equipment under given extreme
condition. In this chapter we are going to see how detailed designing of an equipment is done.
Process design includes calculation of volume and residence time in reactor design,
calculation of number of trays in tray column design, calculation of height of packing required
for packed tower design, calculation of overall heat transfer coefficient and area for heat
transfer in heat exchanger design, calculation of NPSH, power consumption and capacity
required in pump design, calculation of volume for storage vessel design, etc.
From process design, after getting the process data like maximum and minimum operating
pressure and temperature, nature of the material to be handled mechanical design is done. It
includes calculation of diameter, height and thickness of vessel, thickness of head, calculation
of number of plates required, designing of nozzle, flange, gasket, no. of bolts, design of
support, design of jacket or coil, design of agitator, etc. Also, from nature of material to be
handled in equipment material of construction is selected for that equipment.
Temperature 35oC
Absolute pressure at free surface of liquid at source 101.325 kPa
Z 5m
Z’ 6m
Density 1200 kg/m3
μ 0.001291 Pa*sec
1
.
1
9
Therefore, turbulent flow
f = 0.079 / (Re)^0.25 = 0.00346
Frictional loss in suction pipe =
4*f*L*v2 / 2*g*D
=
4*0.0
0346
*11.5
*(1.1
985)2
/
2*9.8
1*0.2
43
=
0.048
m
=
(2
*0
.4
5
+
1*
6)
*
(1.
19
85
)2 /
2*
9.8
1
=
0.
50
51
m
NPSHA = hs – Pv
NPSHR = 3 m
(b) Storage
tank
To keep production, continue without any interruption from material quantity point of
view we have to keep some extra quantity of material in stock in excess of required quantity
for the production. For this we have to store this material in a container that is called storage
tank. Storage tank is used to store solids, liquid & gases during interval between raw material
supplied & production, between production & transportation, also used as an intermediate
stage in the process. Storage tank is of two types:
(1) Fixed roof storage tank
(2) Floating roof storage tank
Let us, consider we have to store raw brine equivalent to 12 hours production requirement.
Capacity 2300 m3
D/H 2.5
Density of raw brine 1200 kg/m3
Temperature 350C
MoC CS Grade 2A
Density of MoC 7800 kg/m3
J 0.85
V = 2300 m3
π/4*D2*H = 2300
H = (2300*4 / π*(2.5)2)1/3
H = 7.769 m
D = 2.5*H = 2.5*7.769 =
19.423 m
Periphery = π*19.426 =
60.988 m
No. of plate per course (X) =
(60.998 – 0.002X) / 1
X=
60.87
= 61
plate
No. of course (Y) = (7.769 –
0.002Y) / 1
Therefore, height of tank = 8*1 = 8 m
Total no. of plates required = 61*8 = 488 plates
From economic point of view, we will not all use all 488 plates of same thickness.
2 7 12 7.363
3 6 10 6.018
4 5 9 5.345
5 4 8 4.673
6 3 8 4.673
7 2 8 4.673
8 (top most) 1 8 4.673
Let us assume tr = 5 mm
Pressure created by dead load and live load (P)
= tr *ρm + 125
= 0.005 *7800 +
125
= 164 kgf /m2
tr = (D /sinθ) *(P /0.204*E)1/2 + C.A.
= 19423 /sin (9.46) *(164 /0.204*2*1010)1/2 + 1.5
= 25.19 mm
Here tr > 12 mm, we have to use structural roof.
Let, thickness of conical roof plate = 6.35 mm
Slope of conical roof (θ) = 3.5763o
Pressure created by dead load and live load (P)
= 0.00635 *7800 + 125
= 174.53 kgf/m2
Size of curb angle = 75*75*10 mm
Max. rafter spacing on periphery ring (l)
= tr*(2*f /P)1/2
= 0.00635*(2*980*104 /174.53)1/2
= 2.128 m
Minimum no. of rafters between in between outer most polygon & periphery,
Rafter selection,
Total load of rafter per unit length,
W = P *(x + l’) /2
= 174.53 *(0.333 + 1.5254)/2
= 162.22 kg /m= W*lr 2 /8
Mmax
lr =Maximum bending
19.423 /2*(2 + 1) moment
*[2 – cos(360 /2*10)]
induced in rafter,
= 3.395 m
Gas absorption is a mass transfer operation in which one or more species is removed from
a gaseous stream by dissolution in a liquid solvent. There may be different purpose of
absorption processs. In our plant absorption process is carried out to absorb ammonia in brine
solution. Absorption is a separation operation and it is carried out mainly in packed column.
Designing of absorber column means we have to calculate height of column and diameter
of column.
Let us consider to absorb NH3 from 1960.2 kmol/hr gas stream into the brine solution.
Process design:
y2 = 0.0786 x2 = 0.00154
NH3
Absorber
L1 = 15415.6 kmol/hr
G1 = 1960.2 kmol/hr
(1)
y1 = 0.65 x1 = 0.0788
Where, (y – y*) LM = [(y1 – y1*) – (y2 – y2*)] /ln ((y1 – y1*) / (y2 – y2*))
Where, (1 – y*) LM = [(1 – y1) – (1 – y1*)] /ln ((1 – y1) /(1 – y1*))
1 – y1 = 1 – 0.65 = 0.35
Height of column,
Diameter calculation:
Packing selected: plastic pall ring
Size = 89 mm
Bulk density = 64
kg/m3 a = 85 m2/m3
Fp = 52 m-1
G = 1960.2 kmol/hr
= 11.57 kg/s.
L = 15415.6 kmol
/hr = 92.1 kg/s.
= 92.1 /11.57
*(0.905 /1200)1/2
= 0.2186
From graph,
At flooding K4 = 2.4
Therefore, K4 = 1.1
Percentage flooding
= (1.1 /2.4)1/2 *100 =
67.7%
K4 =
[13.1*(V)2*Fp*(μL/ρL)0.1] /
(ii) Various axcial stress induced in shell plate material at a distance X from the top of shell.
fd(liq + packing)X =
3.14/4*(2.367)2*120*1000 /3.14*2.372*(5 –
2)
= 23620*[X – 0.9]
= 2.362X – 2.126
kgf/cm2
(4) stress due to dead load of attachment
= 0.6713X kgf/cm2
1.069 kgf/cm2
Maximum compressive stress induced in the shell plate material at a distance X from the
top of shell.
Take, X = 11.52 m
Therefore, upto 11.52 m from top we can keep thickness of
shell equal to 5 mm.
(i)Circumferential stress and axial stress induced in shell plate material at a distance X from
the top of shell due to internal pressure.
(ii) Various axcial stress induced in shell plate material at a distance X from the top of shell.
= 14160*[X – 0.9]
= 1.416X – 1.2744 kgf/cm2
(4) stress due to dead load of attachment
Maximum tensile stress induced in the shell plate material at a distance X from the top of
shell.
Maximum compressive stress induced in the shell plate material at a distance X from the
top of shell.
Take, X = 20.33 m
Therefore, upto 20.33 m from top we can keep thickness of shell equal to 7 mm.
(i)Circumferential stress and axial stress induced in shell plate material at a distance X from
the top of shell due to internal pressure.
(ii) Various axcial stress induced in shell plate material at a distance X from the top of shell.
fd(liq + packing)X =
3.14/4*(2.367)2*120*1000 /3.14*2.379*(12
– 2)
= 7065*[X – 0.9]
= 0.7065X – 0.6358
kgf/cm2
(4) stress due to dead load of attachment
= 0.2X kgf/cm2
kgf/cm2
Maximum tensile stress induced in the shell plate material at a distance X from the top of
shell.
Maximum compressive stress induced in the shell plate material at a distance X from the
top of shell.
Take, X = 42.47 m
Conclusion
From this chapter, we have concluded that designing of pump means we have to find out
power requirement and NPSH available. For designing of storage tank we have to find out
thickness of plate for different course as well as selection of rafter for fixed roof tank. For
designing of absorption column, we have to find height of column and diameter of column.