MAJOR EQUIPMENT DESIGN

DISTILLATION COLUMN

(ETHYL-BENZENE RECOVERY)
Process Design

For calculation simplification let us assume the feed entering the distillation or E-B
recovery column in binary mixture.
Mol. Wt. of E-B = 106
Mol. Wt. of styrene = 104
i.e. xF = 0.267 ; xD = 0.495 ; xW = 0.049

CALCULATION FOR q :-
The benzene toluene tower is been operated under 160 mm Hg pressure. (from Dryden)
So the reboiler must be operated at an equilibrium temperature. Assuming the reboiler
acts as an ideal stage.
i.e. PT = x1*P1° + x2*P2°
where x1 and x2 are the mole fraction of styrene and EB recovery tower.
Hence, feed temperature calculated = 95.0°C

∴, q = (Hv – Hf)/( Hv – Hl)

i = 4.35 Tci*(1-Pri)0.69 * log Pri/(1-Tri-1)

Where P* = 50 mm Hg

Critical Point Data Pc,kPa Tc,°C

Styrene 3810 369

Ethyl Benzene 3701 343.05

And T* = 63.138°C
VW = 36275 J/mol
(% -PRO
Now, in gaseous state2 Cp = 138.737 kJ/kmol°k(styrene)
At 70°C Cp = 151.745 kJ/kmol°k ( EB )
_
= 36698.19 kJ/kmol
_
Cp = 142.21 kJ/kmol°k
q = 0.876
So, slope of the q line = q/(q-1)
= -7.0645
So, from the graph reflux ratio is calculated.
Intercept: 0.13 = xD/(R+1)
Rmin = 2.81
Let, the reflux ratio be maintained 1.4 times the minimum,
i.e. R = 3.93
So, the conditions of the distillation column are specified.

ENRICHING SECT STRIPPING SECT

Top Bottom Top Bottom
Temp. liquid, °C 61.25 63.2 63.2 65.1
Temp. vapor, °C 62.0 64.6 64.6 65.2
Liq. Flow rate, kmol/hr 482.22 482.22 701.73 701.73
Vapor. Flowrate,kmol/hr 604.923 604.923 573.35 573.85
Vapor density,kg/m3 0.251 0.248 0.248 0.247
Liquid density,kg/m3 850.94 855.44 855.44 861.06
Avg. mol.wt. (vapor.) 104.99 104.68 104.68 104.091
Avg. mol wt. (liq.) 104.99 104.534 104.534 104.098
Mole fraction, x 0.495 0.267 0.267 0.049
Mole fraction, y 0.495 0.340 0.340 0.049
/* !*!/ 0.0136 0.0135 0.021 0.021
Surface WHQVLRQ1 dyne/cm 30.217 30.795 30.795 31.37

ENRICHING SECTION
Tray spacing

ts = 500 mm

Hole diameter

dh = 10 mm.

Tray thickness

Tt = 0.6dh = 9 mm.

Plate diameter calculation

! bottom = 855.44 kg/m3.

!J) bottom = 0.248 kg/m3.

! top = 850.94 kg/m3.

!J top = 0.251 kg/m3.

(L/G)*(!g!l)0.5 = 0.0136 (max. at top)

(From Perry 7th edition fig. 14-25)

csb = 0.095 m/s.

unf = csb 10.2 > !1 - !g !g ]0.5

unf = 6.0064 m/s.

where σ = 30.217 mN/m.

un = 0.82 unf = 4.925 m/s.

Net area for gas flow

Volumetric gas flow rate
An = Ac – Ad = = 14.27 m2.
un

Weir length = 0.75Dc

Ac = 0.785 Dc2
Ad = 0.088 Dc2
Substituting and evaluating,
Dc = 4.5 m.
Lw = 3.375 m.
Ac = 15.904 m2.
Ad = 1.782 m2.

Active area
Aa = Ac – 2Ad = 12.34 m2.
Acz = 2 ( Lw x 0.2 ) = 1.35 m2.
. = 82.8° and = 97.2°
Awz = 0.635 m2.
Ap = Aa – Acz – Awz
= 10.355 m2.

Total hole area

( Ah/Ap) = 0.1
Ah = 1.0355 m2.
No. of holes = 13200

Weir height
hw = 8 mm.

Check for weeping

hd = head loss due to dry force.

ρg
= k1 + k2 v 2h
ρ1
k1 = 0
k2 = 50.8/Cv2
Ah Tt
= 0.1 :
Aa d h = 0.5
From pg. 18-5 fig. 18-14 Perry
cv = 0.74 * ( Ah/Aa ) + exp (0.29 (Tt/Dh)-0.56)
= 1.03
k2 = 47.88
hd = 75.16 mm
how = Height of liquid crest formed
2
3
q
how = 664 * Fw where q = 16.5 x 10-03 m3/s.
Lw
Fw = 1.01
how = 19.31 mm
hσ = (409σ)/ ρ1dh = 1.452 mm.
hd + hσ = 76.612 mm.
hw + how = 27.32 mm.
Ah/Aa = 0.1
From Perry fig. 18-11 pg. 18-7
hd + hσ > graphical value.
∴ weeping does not occur.

Down comer flooding

Down comer back up :-
hdc = ht + hw + how + hda + hhg
hhg = hydraulic gradient
ht = total pressure drop across plate
hda = head loss due to liquid flow under down comer apron
Again,
ht = hd + h1
hd = 128.15 mm.
h1 = βhds
=0.0825*ln(q/Lw)-0.269*lnFvh + 1.679
hds = hw + how + hhg/2
1000fu f2 L f
hhg =
grh
h f Df
rh =
h f + Df
Again, f is a function of Reynold’s number.
Where,
rh u f ρ1
Nreh. =
µ1
Where,
1000q
uf =
h 1D f
Df = (Dc+Lw)/2 = 3.9375 m
Fga = Ua(ρg/ ρl)0.5
hf = h1 / φt = 123.083 mm.
3= exp(-12.55 Ks0.91)
Ks= Ua>!g/(!l-!g)]0.5
=0.0978 [Ua= gas vel. Through active area= 5.70 m/s]
hence,3=0.2201
And
hl 3>Kw & T32/3]
where, C= 0.0327+ 0.0286*exp[-0.1378hw]
=0.0327+ 0.0286*exp[-0.1378*8]
= 0.04219
hl=27.09 mm of clear liquid
Uf=0.1549 m/s
Rh=0.11584 m
la= [Σxi i1/3]3
= 0.484 cp
Nreh.=31540
From PERRY fig 14.34( 7th ed)
f= 0.02
Lf =2.976 m
hhg= 1.25 mm of clear liq
hds= 27.925 mm
ht= 83.08 mm clear liq

q
hda = 162.5
Ada

hap = hds – c
c= 14 mm.
hap = 13 mm.
Ada = Lwhap = 0.04387 m2
hda = 23.42 mm.

hdc= 135.05 mm of clear liq

h’dc = hdc 3t PP ZKHUH 3t= 0.5

h’dc < ts
∴ hence no flooding occur.

Column efficiency
Eog Æ Emv Æ E oc
Eog = 1 – exp( - Nog)
1
N og =
1 λ
+
Ng Nl
where, P*P/P

for gas phase transfer unit

Ng= kg D
For sieve plate
Kga= 316*Dg1/2*(1030*f+ 867*f2)/ hl0.5
= 636.9 m/s
where; Dg= 5.4*105 m/s
g= ε*hf*Aa/1000Q
φ = hl/hf and, ε= 1-φ
∴, φ= 0.2201
and, ε = 0.7799
∴ g=0.01678 s
∴, Ng= 10.67 m
For liquid transfer unit
N1 = k1aθ1

(
k1a = 3.875 × 10 D1
8
) (0.40Uaρ
0.5 0.5
g + 0.17 )
= 1.434 m/s [Dl= 3.08*109 m/s]

Residence time
θ1 = (1-ε)*hf*Aa/1000q
= 20.23 s
∴, Nl =29.017 m

In Enriching section

mL
λ top =
G top

m = slope of equilibrium curve at the top.

λtop = 1.296
Nog = 6.3105
− N og
E og = 1 − e
Eog = 0.998
Murphee stage efficiency
(PY >H[S (RJ-1]

= 2.041
The very high value of Emv (over 1 )suggest there is high liquid entrapment takes place
under such high vacuum. While the previous calculation suggest the liquid hold up
and point efficiency, under such situation for safe design we made an assumption, i.e.,
Eog ≈ Emv .
∴, Emv= 0.998
now,
Ea 1
 = 
Emv 1+ Emv*[ψ /(1-ψ)]

)RU FRUUHVSRQGLQJ /*!J!l)

0.5
and 82% flooding value
ψ= 0.22
∴, Ea= 0.7788

log{1 + E a (λ − 1)}
Eoc =
log λ
Eoc = 0.80
Ideal no. of trays
Again, by definition Eoc = 

Actual no. of trays

∴,the actual number of trays in the enriching section= 7/0.8= 9 trays

Stripping section
Tray spacing
ts = 500 mm

Hole diameter

dh = 15 mm.

Tray thickness

Tt = 0.6dh = 9 mm.

Plate diameter

!1) bottom = 861.06 kg/m3.

!g) bottom = 0.247 kg/m3.

!1) top = 855.44 kg/m3.

!g) top = 0.248 kg/m3.

(L/G)*(!g!l)0.5 = 0.021` (max. at top)

From Perry 7th edition fig. 14-25

csb = 0.085 m/s.

unf = csb 10.2 > !1 - !g !g ]0.5

unf = 5.44 m/s.

where σ = 31.27 mN/m.

un = 0.80 unf = 4.462 m/s.

Net area for gas flow

Volumetric gas flow rate

An = Ac – Ad = = 15.08 m2.
un

Weir length = 0.75Dc

Ac = 0.785 Dc2
Ad = 0.088 Dc2
Substituting and evaluating,
Dc = 4.65 m.
Lw = 3.49 m.
Ac = 16.98 m2.
Ad = 1.903 m2.

Active area
Aa = Ac – 2Ad = 13.174 m2.
Acz = 2 ( Lw x 0.25 ) = 1.86 m2.
. = 82.8° and = 97.2°
Awz = 0.66 m2.
Ap = Aa – Acz – Awz
= 10.654 m2.
Total hole area
( Ah/Ap) = 0.1
Ah = 1.0654 m2.
No. of holes = 13565

Weir height
hw = 6 mm.

Check for weeping

hd = head loss due to dry force.

ρg
= k1 + k2 v 2h
ρ1
k1 = 0
k2 = 50.8/Cv2
Ah Tt
= 0.1 : = 0.5
Aa dh
From pg. 18-5 fig. 18-14 Perry
cv = 0.74 * ( Ah/Aa ) + exp (0.29 (Tt/Dh)-0.56)
= 1.03
k2 = 47.85
hd = 55.32 mm
how = Height of liquid crest formed
2
3
q
how = 664 * Fw where q = 23.8 x 10-03 m3/s.
Lw

Fw = 1.01
how = 24.12 mm
hσ = (409σ)/ ρ1dh = 1.5 mm.
hd + hσ = 56.82 mm.
hw + how = 30.12 mm.
Ah/Aa = 0.1
From Perry fig. 18-11 pg. 18-7
hd + hσ > graphical value.
∴ weeping does not occur.

Down comer flooding

Down comer back up :-
hdc = ht + hw + how + hda + hhg
hhg = hydraulic gradient
ht = total pressure drop across plate
hda = head loss due to liquid flow under down comer apron
Again,
ht = hd + h1
hd = 55.32 mm.
h1 = βhds
=0.0825*ln(q/Lw)-0.269*lnFvh + 1.679
hds = hw + how + hhg/2

1000fu f2 L f
hhg =
grh
h f Df
rh =
h f + Df
again f is a function of Reynold’s number.
Where,
rh u f ρ1
Nreh. =
µ1
Where,
1000q
uf =
h 1D f
.Df = (Dc+Lw)/2 = 4.07 m
Fga = Ua(ρg)0.5
hf = hl / 3 = 148.0 mm.
3= exp(-12.55 Ks0.91)
Ks= Ua>!g/(!l-!g)]0.5
=0.0869 [Ua= gas vel. Through active area= 5.70 m/s]
Hence,3=0.2567
And
hl 3>Kw & T32/3]
where, C = 0.0327+ 0.0286*exp[-0.1378*hw]
= 0.0327+ 0.0286*exp[-0.1378*6]
= 0.04521
hl = 37.38 mm of clear liquid
Uf = 0.1539 m/s
Rh = 0.1379 m
l = [Σxi i1/3]3
= 0.482 cp
Nreh. = 37534
From PERRY fig 14.34( 7th ed)
f= 0.02
Lf = 3.057 m
hhg= 1.1 mm of clear liq
hds = 30.67 mm
ht = 65.72 mm clear liq
q
hda = 162.5
Ada

hap = 14 mm.
Ada = Lwhap = 0.04886 m2
hda = 39.2 mm.

hdc= 136.14 mm of clear liq

h’dc = hdc 3t = 272.28 mm. ZKHUH 3t= 0.5

h’dc < ts ∴ hence no flooding occur.

Column efficiency
Eog Æ Emv Æ E oc
Eog = 1 – exp( - Nog)
1
N og =
1 λ
+
Ng Nl
where, P*P/P

for gas phase transfer unit

Ng= kg D
For sieve plate
Kga= 316*Dg1/2*(1030*f+ 867*f2)/ hl0.5
= 521.2 m/s
where; Dg = 5.434*10-5 m/s
g= ε*hf*Aa/1000Q
φ = hl/hf and, ε= 1-φ
∴ φ = 0.2567
∴ g = 0.02128s
∴ Ng= 11.09 m
For liquid transfer unit
Nl = klaθl

(
Kla = 3.875 × 10 8 D1 ) (0.40Uaρ
0.5 0.5
g + 0.17 )
= 1.314 m/s [Dl= 3.1624*10-9 m/s]
Residence time
θl = (1-ε)*hf*Aa/1000q
= 21.02 s
∴, Nl = 27.62 m

mL
λ top =
G top

m = slope of equilibrium curve at the top.

λavg = 0.948
Nog = 6.3105
− N og
E og = 1 − e
Eog = 0.99
Murphee stage efficiency
The very high value of Emv (over 1 )suggest there is high liquid entrapment takes place
under such high vacuum. While the previous calculation suggest the liquid hold up
and point efficiency, under such situation for safe design we made an assumption, i.e.,
Eog ≈ Emv .
∴, Emv= 0.99
now,
Ea 1
 = 
Emv 1+ Emv*[ψ /(1-ψ)]
)RU FRUUHVSRQGLQJ /*!g/!l)
0.5
and 80% flooding value
ψ= 0.22
∴, Ea= 0.833
log{1 + E a (λ − 1)}
Eoc =
log λ
Eoc = 0.83

∴,the actual number of trays in the enriching section= 15/0.83= 18 trays

∴ The entire length = actual no. of trays * tray spacing

of the tower
= (18.0 + 9.0)*0.5 m
= 13.5 m

MINOR EQUIPMENT DESIGN

Condenser
(Process Design)

The condenser to be designed over here is been placed after the reactor in the process.
The stream coming out of the reactor contains steam as well as some non-condensable
gases (like hydrogen) and organic vapors.
The gas out of the reactor is passed through the vaporizer where the gas temperature falls
from 600 to 454oC. Even at this temperature, the load on the condenser is very high, so to
make the process more economical a boiler is positioned in between the vaporizer and
condenser in order to recover the waste heat from the flue gas stream.
Therefore, after the super heat recovery the stream is entering the reactor at its normal
boiling point temperature. The condenser is operated under atmospheric pressure. Hence,
the normal boiling point of the mixture is calculated 90oC.
To perform the given operation the load is very high for a single condenser, so to avoid
overloading of the condenser two condenser of identical performance are put in series.

HOT GAS IN (1000C) CONDENSATE OUT(90OC)

condenser

HOT WATER OUT(45OC) COLD WATER IN(25OC)

• Hot condensing gases enters at 100oC temperature and leaves at 90oC (I.e.,
effective boiling condensing gases)
• Cold fluid enters at 25oC and leaves at 40oC.
INITIAL CALCULATION:
Average latent heat of condensation of the condensing vapor = 1299.24 kJ/kg
Total mass of the condensing vapour feed into each condenser=9.27 kg/s.
Specific heat of water at 300C =4.184 kJ/kg
Mass of process water required=
9.27*1299.24/(4.184*(45-25)) kg/s.
= 190.68 kg/s

Assuming counter current operation ∆Tln = 57.170C

Assuming U heat transfer coefficient = 800 W/m2K
A = Q / (∆Tln) = 261.65 m2.
Assuming, length of pipe is 12 ft.
Tube for the heat transfer purpose is selected:
Tube OD = ¾” , 12 BWG
∴OD : ID= 1.41:1
∴ The total no of tube is calculated= Nt = 1204
From Perry, for 1-2 STHE TEMA P for ¾ in. OD on 1-inch ∆lar pitch
Nt = 1378 for Shell diameter = 1.067 m.
Ucorrected= 700 W/m2K

FILM COEFFICIENT
Shell side - Condensate
The heat transfer coefficient for the shell side given as:
hs = 1.51*[k3*ρ2*g/µ2]1/3 *Nre-1/3
Reynolds number ( NRe )= 4*Γ/µ
Where, Γ= W/(N1/3*L)
W= condensation rate
N= total no of tubes
L= length of each tubes
∴, Γ= 0.02062
Again, µ= 0.347 cp
N.B., all the properties been evaluated at the condensate average temperature.i.e, at
75.62oC.
Therefore, the Reynolds no is calculated= 237.72
Properties are evaluated at 75.62oC.
K = Thermal conductivity = 0.398 w/m.K.
µ = Viscosity = 0.347 x 10-3 cp.
ρ = Density = 892 kg/m3.
hs= 3897 W/m2.K.

TUBE SIDE

Nre= v*ρ*d/µ
ρ = 994 kg/m3
Therefore, velocity of the fluid on the tube side=1.948 m/s
diameter of each tube= 13.51 mm
Reynold’s number (NRe) = 33438

k = 0.61 W/mK
µ = 0.78 cp
cp = 4.184 KJ/kgK
Prandtl number (NPr) = 5.35
For turbulent condition Dittus Bolter equation.

hide
= 0.023 (NRe )0.8 ( NPr )0.33 ( φ )0.14
k

φ = µl/µw

∴,φ= 1.0, since the liquid used is water.

hi = 5996 W/m2K

Calculated Ud = 926.61 W/m2K assuming hd = 1892 W/m2K

∴, Ud > Ucorrected

∴ Design is okay.
PRESSURE DROP CALCULATION

SHELL SIDE

Let us assume, no of baffles(B)=0

as = 0.9683 m2
Gs = 9.57 kg/m2s.
de = 18.29 mm
NRe = 21887
From Perry graph of f v/s/ NRe on log log sheet
f = 0.2452

 2f ( N b + 1)D s G s 
∆Ps =   x 0.5 = 1.369 kPa.(KERN’s method)
 gρ g d e 
since the shell side pressure drop is less than 14 kPa , the design is satisfactory.

TUBE SIDE

NRe = 33438
F = 0.0791 ( NRe )-1/4 = 0.00584
∆Pl = 4*f*L*v2*ρl/2di = 11.82 kPa
∆Pe = 2.5*v2*ρl/2 = 4.700kPa
∆PTotal = 2*(∆Pl + ∆Pe )= 33.04 kPa.
which is very less than permissible value(70 kPa), therefore design is satisfies all the
necessary condition.
MECHANICAL DESIGN OF
DISTILLATION COLUMN
(REF: BROWNELL & YOUNG,CH:10)

a) SPECIFICATION:

1. inside diameter : 4.65 m ( design with the maximum dia for safety)
2. height of disengaging section: 40 cm
3. design pressure: 50 mmHg
4. (since the vessel operated under vacuum, subjected to external
pressure)external pressure: 0.965 kgf/cm2
5. design pressure: 1.033 kgf/cm2
6. design temperature: 70oC
7. shell material: carbon steel(sp. Gr.=7.7) (IS:2002-1962, GRADE I)
8. permissible tensile stress: 950 kgf/cm2
9. insulation material: asbestos
10. density of insulation: 2700 kg/m3
11. insulation thickness: 50 mm
12. tray spacing: 500 mm
13. down comer plate material: stainless steel(sp. Gr.: 7.8)
SHELL THICKNESS CALCULATION:

Let the thickness of the shell= 10 mm

Using stiffener channels of C-60, 18x4, of CSA=18 in2
Wt =51.9 lb/ft
At a distance of 500 mm, (below each tray)

∴, Do = 4.67 m
L = 0.5 m
∴, L/Do = 0.11
&, Do/t = 467 ∴, B= 12000
∴, pallowable= B/( 14.22*( Do/t)), t= 5.71 mm ≈ 6 mm
Which, suggest the thickness is allowable under the operating condition.
Therefore, allowing corrosion correction, thickness choose= 12 mm

HEAD:

Design for torrispherical head.

The head is under external pressure.
Let, th = 10 mm
Rc = Do = 4.67 m
∴, Rc/(100*th) = 4.67
∴, B= 4000
∴,pallowable= B/(14.22*Rc/th), ∴, th= 17.15 mm(> 10 mm)
Hence, 10 mm thickness is not satisfactory.
Further, iteration suggest the design thickness with a corrosion allowance :th= 15 mm

The approximate weight of the head is calculated= 3000 kg

CHECK FOR SHELL THICKNESS:

Material specification:
Carbon steel (sp. Gr. =7.7) (IS: 2002-1962, GRADE I)
Tensile strength(R20)= 37 kgf/mm2
Yield stress (E20)= 0.55R20

Since, the vessel operated under vacuum, compressive axial stress:

fap= pd/(4*(ts-c)) = 120.6 kgf/cm2

i) Dead wt calculation:

Total dead load can be calculated as:

∑W = head wt+ liquid wt(X)+ wt of the attachment(X)

head wt= 3000 kg

liquid hold up in each tray= ρl*( Aa*hl + Ad*hdc)
= 571 kg ≈ 600 kg
wt of attachment per plate= 1100 kg (approx.)

∴,∑W= (3000+ 3400X) kg

Where, X is the distance in meter from the top tangent.

Further, the wt of the insulation and shell also exerts a compressive stress:
π*di*X*t*ρs + π/4*(D0,ins2 – d02)*X*ρins = 3126.8X kg

∴, total compressive stress on the shell due to dead wt:

fdsx= ∑W/(π*di*(ts-c)) = (2.055+4.47X) kg/cm2

ii) Wind pressure calculation:

Wind load: Pw = 0.0025 Vw2

Where, Pw= wind pr on the column (lb/ft2)
Vw= wind velocity in miles per hour
Let the design wind velocity= 90 mi/hr
Pw = 20.25 lb/ft2 = 98.67 kg/m2

∴Moment at a distance X from the top tangent:

Mwx= ½*Pw*X2*deff = 235.35X2 kg-m

Where, deff= effective outer diameter of the vessel including insulation= 4.77 m

∴, fwx= tensile stress on the upwind side

= Mwx/(π*ro2*(ts-c)) = 0.1386 kg/cm2

STRESS BALANCE FOR THE UPWIND SIDE:

Ft,max = fwx- fdsx- fap

Where, Ft,max= 50% of the maximum allowable stress

= 475 kg/cm2

There for upwind side solution gives: X= 69.1 m (>14m)

STRESS BALANCE FOR THE DOWNWIND SIDE:

FC,max = fwx+ fdsx+ fap

Where, FC,max= maximum allowable compressive stress.

= 1/3* yield stress
= 1/3* 20.25 kgf/mm2

Therefore, the solution to the quadratic equation:

X= 49.27 m (> 14m)
N.B. the wind moment on the downwind side act as a compressive force on the tower.
Since, the thickness of 12 mm with corrosion allowance is enough to with stand the load
of the tower of 14 m height, the thickness of the shell is maintained 12 mm through out the
entire tower length.

SKIRT SUPPORT DESIGN:

Let, we assume skirt material: carbon steel;

IS:2002-1962,GRADE1
Yield stress= 20.35 kgf/mm2
Allowable compressive stress: 9660.31 lb/in2
We design for cylindrical skirt support.
Moreover, it is been attached to the shell at a height of 50 cm from the bottom tangent.
Skirt height selected= 2.0 m
Where, the tangent to tangent distance= 13.5 m
Let, t= thickness of the skirt.
For, X= 13.5 m
Fwb= 24599/t

Further for seismic load: fsb= 8CWH/(πr2t)

Where, for safe design, C=0.1
W= weight of the tower = 20300 lb
&, r= 92 in
∴, fsb= 3226/t
Again, fdb = stress due to dead load at the bottom
= 35.12/t

Therefore the force balance at the bottom of the tower gives: ft,max=( fwb or fsb) - fdb
(upwind side)

fc,max=( fwb or fsb) + fdb (downwind side)

since, fwb > fsb , for safe design we will consider fwb in consideration.

Therefore, the minimum allowable thickness calculated= 2.3 in = 58 mm

SKIRT BEARING PLATE:

η= ES/EC
where, Es= modulus of steel
Ec= modulus of concrete

Let, η= 10.
∴, let, fs= 20000 psi
fc= 1200 psi (from table: 10.1, BROWNELL & YOUNG)
1
∴, k=  = 0.375
1 + fs/(η fc)

Let, width of the bearing plate, t3= 1 ft

2kd + t3
∴, fc,max = fc,bolt circle * ()
2kd

Where, d= 184 in
fc,bolt= 1104 psi

Again (from table 10.2, BROWNELL & YOUNG)

At k= 0.375 Cc= 1.7025
Ct= 2.2785
Z= 0.4215
J= 0.7835

∴, t1= A/πd; A= bolt area

let assume the circle in which 24 bolts of 21/2 in diameter.
∴, area per bolt = 3.72 sq in
∴, t1= 0.154 in
∴, Ft = fs*t1*r*Ct
⇒ 30700 = fs*0.154*92*2.2785
⇒ fs= 951 psi

∴, Fc= Ft+ W = 51000 lb.

Again t2= 11.846 in

Fc = (t2 + ηt1)*r*fc*Cc ⇒ fc = 24.324 psi

∴,k= 0.2036
thus iterating with new values finally we get,
k= 0.269
Cc= 1.340
Ct= 2.571
Z= 0.450
J= 0.778
∴, the max compressive stress in bolt & concrete
fs,compression= η*fc = 305.8 psi
Where, fc,max induced= 34.286 psi
This is a safe value.

Therefore, the thickness of the bearing plate,

⇒ t4 = l*√( 3*fc,max/fallowable) = 1 in

where, l= outer radius of bearing plate

MECHANICAL DESIGN OF CONDENSER

SHELL SIDE:

MATERIAL :
Carbon steel (corrosion allowance= 3 mm)
Permissible strength for carbon steel= 95 N/mm2
Number of shell= 1
Number of tube passes= 2
Condensing fluid type: Mixed vapor
Working pressure= 1 atm
= 0.101 N/mm2
Design pressure= 0.11 N/mm2
Temperature of inlet= 1000C
Temperature of outlet= 900C
Design temperature= 950C

TUBE SIDE:
Number of tubes= 1378
Out side diameter= 19.05 mm
Inside diameter= 13.51 mm
Length of each pipe= 3.63 m
Pitch ∆lar = 1”
Feed= water
Working pressure= 1 atm
Design pressure= 0.11 N/mm2
Inlet temperature= 250C
Outlet temperature= 400C

SHELL SIDE DESIGN:

P*Di
Shell thickness ( ts ) = ___________ + c
2*f*J - P
P = design pressure = 1.1 kg/cm2.
D = diameter of shell = 1.067 m
F = 95 N/mm2.
J= joint efficiencies= 0.85
c = corrosion allowance = 3 mm.
ts = 10 mm.
Take shell thickness as 10 mm.
Head thickness:
Assume torrispherical head.
P*RC*W
Th = ___________
2*f*J
RC = crown radius = DC
Where,
W = ¼*(3+√(Rc/Rk))= 1.77
Rk= knuckle radius (6% of Rc)
∴; Th= 1.28 mm
Standard minimum thickness =6 mm
Let, Th= 10mm (with corrosion allowance)

SINCE THERE IS NO BAFFLE IS USED TIE RODS AND SPACERS ARE NOT
REQUIRED.

FLANGES:
Loose type except lap joint flange is designed.
Design pressure= 10N/mm2
Flange material: IS:2004-1962 class2
Bolting steel= 5% Cr Mo steel
Gasket material= asbestos composition
Shell inside diameter=1067 mm
Shell thickness =10 mm
Shell outside diameter= 1087 mm

Determination of gasket thickness:

D0/Di = √ ((y – p*m)/(y –p(m+1))
Where,
m Æ gasket factor
y Æ minimum design seating stress
Assuming gasket thickness of 10 mm (from IS:2825-1969)
y= 25.50 MN/m2
m= 2.75
∴, Do = 1094 mm
∴, minimum gasket width= 1mm
a gasket width of 6 mm is selected.
∴, diameter at the location of gasket load:
G = di + N
= 1104 mm

Estimation of bolt load:

Load due to design pressure

H = (π*G2/4)*p = 0.1053 MN

Load to keep the joint tight under operation:

Hp = π*G*N*m*p = 12.5*10-3 MN

Total operating load:

Wo = Hp+H = 0.1179 MN

Load to seat under bolting condition:

Wg = π*G*b*y = 0.5306 MN
∴, Wg > Wo , therefore Wg is the controlling load.
Calculation of minimum bolting area:
Am = Ag =Wg/Sg
For 5% Cr Mo steel at the design pressure Sg= 138 MN/m2
∴, Am= 3.84*10-3 m2

Calculation for optimum bolt size.

g1 = go/ (0.707) = 1.415go
Let we select the bolt size: M18*2 , R=0.027
Now, C= id+ 2*(1.415go + R)
= 1156 mm ≈ 1160 mm (where, go = 12.5 mm)

∴, 1.16m is the bolt circle diameter

Where, 18 mm is the bolt diameter

∴, flange outside diameter is calculated:

A= C + bolt diameter + 0.02m
= 1.20 m (SELECTED)

CHECK THE GASKERT WIDTH:

The total number of bolts on the flange= 44

And, the root area of each bolt = 1.54* 10-4 m2
Ab* Sg/ π*G*N = 22.46 < 2y
Hence, the condition is satisfied.

• FLANGE OPERATING CONDITIONS:

A) for operating condition: Wo = W1 +W2 + W3

Where W1 = π*B2*p/4 = 0.01021 MN

W2 = H – W1 = 0.0032 MN
W3 = Wo – H = 0.0125 MN

Total moment on flange,

Mo = W1*a1 + W2*a2 + W3*a3
Where, a1 = (C-B)/2 =0.0365 m
a3 = (C-G)/2 = 0.028 m
a2 = (a1+a3)/2 =0.03225 m

∴, Mo = 4.18* 10-4 MJ

B) FOR BOLTING UP CONDITION:

(IS:2825- 1969)(EQN:4.6,P:56)

Mg =W*a3
Where, W=(Am + Ab)*Sg/2 = (5.308*10-3)*Sg =0.732 Nm

∴, Mg =0.0205 MJ
since, Mg>Mo , Mg is the moment under operating condition.

CALCULATION OF FLANGE THICKNESS:

t2 = M*Cf*Y/(B*ST)
Where, K= A/B =1.103
∴, Y=17
Let, CF =1 (bolt pitch correction factor)

Again, SF= allowable stress for flange material

= 100 MN
∴, t= 0.056 m
Actual bolt spacing,= π*1.16/44 = 0.082 m
Bolt pitch correction:
CF= √(Bs/(2*D +t))= 0.944 ∴, t= 0.054 m ≈ 60 mm
TUBE SHEET THICKNESS CALCULATION:
Tube sheet thickness ( t ) = FG*(0.25*p/f)0.5
= 0.0188 m
∴, considering corrosion allowance= (t) = 21 mm

CHANNEL DESIGN
Channel thickness:
Tc= GC (k*p/f)0.5 = 21 mm (k= 0.3 for ring type gasket)
Covers are assumed flat and welded to channel.

SUPPORT DESIGN
Material low carbon steel
Saddle type of support is designed.
Length= 3.63 m
Vessel diameter= 1.067 m
Knuckle radius= 64.02 mm
Total head depth = √(Do*r0/2)
= 185 mm
∴, A= 0.5*R = 267 mm
Maximum weight of shell, attachments and contents = 25543 kg.
A = 0.267 m
L = 3.36 m
H=0
R = 0.5335 m
Q = W/2*( L + 4/3*H)= 49510.84 kg-m.

Longitudinal bending moment;

M1= Q*A[ 1- (1-A/L+(R2-H2)/2A*L)/(1+4*H/3L)]
= 152.62 kg-m
Bending moment at the centre of the tubes:
M2 = QL/4[ (1+2(R2-H2)/L2)/(1+4*H/3L)- 4H/L]
= 345.12 kg-m
M1
f1 = = 1.7068 kg/cm2.
πR t
2

R = 0.5335 m
t = 0.010 m
M2
f2 = = 0.3849 kg/cm2.
πR t
2

fmax = 950 kg/cm2.

fp = ( pD )/ 4t = 293.4 kg/cm2.
All these values are less than 950.
∴ Design is satisfactory.