Chapter 1 - First Reactor

Production of n-propanol Chapter I
1-1

CHAPTER I

FIXED BED REACTOR UNIT DESIGN

1.1 CHEMICAL DESIGN

In order to design a fixed bed reactor, below is the algorithm of the steps taken for
chemical design of fixed bed reactor.

1-2

1.1.1 Types Of Reactor
Accordingly, classifications of reactor are classified using following factors which
are:
1. Form of energy supplied
2. Phases in contact
3. Catalytic or noncatalytic
4. Batch or continuous
5. Packed or suspended bed
The first reactor involved process of hydroformylation which is reaction between
olefin and syngas with catalyst. Fixed bed, slurry or trickle bed reactor are common
reactor for hydroformylation in the industry itself. Factors that are considered in
order to select the best reactor such as catalyst and phases involved in the reaction.
Decisions must be made in terms of type of reactor, concentration, temperature and
pressure of optimum condition, phases involve and also catalyst used. Proper
reactor design should have atleast stoichiometry of the participating reactions,
thermal and physical properties, heat of reaction, rate of reaction, composition,
temperature and pressure, stability and controllability of the process, heat transfer
and mass transfer.(Reference: Gilbert F.F, Chemical Reactor Analysis and Design,
1990). Table below show the advantages and disadvantages of fixed bed and fluid
or slurry bed.

Table 1.1 Advantages and disadvantages of reactors.
Types of Reactor Advantages Disadvantages
Fixed Bed Reactor - Simple to design.
- High efficiency.
- Low cost.
- Low maintenance.
- Little loss or attrition.
- High ratio of catalyst to
reactants.
- No moving parts to
wear out.
- Heat can be added or
remove.
- Less heat transfer in fixed
bed reactor.
- Non uniform flow pattern.
- Swelling of the catalyst
and deformation of
reactor.
- Regeneration or
replacement of catalyst is
difficult and need
shutdown.
- High pressure drop for
1-3

- Can be operated
adiabatically.
- Only practical and
economical reactor at
high pressure.
- Efficient-long residence
time and achieve near
complete reaction.
small beads or pellets.
Fluid Bed And
Slurry Reactor
- Frequent regeneration
of the catalyst.
- Rapid mixing of solids
in beds means uniform
gas composition.
- Efficient temperature
control.
- Small diameter
particles in fluid
minimize pore
diffusional resistance.
- High heat transfer
rates.
- Complicated.
- Extensive investment and
high maintenance.
- Low residence time and
conversion maybe limited.
- Attrition and loss of
catalyst.

Sources: Garton R.D, U.S Patent 7851221,2010

From the differences above, it has been decided that fixed bed reactor is
better for hydroformylation process because it is efficient but easy to conduct, to
maintain and cheaper than others reactor. Besides that, it is also because catalyst
that has been used is in solid phase.

Hydroformylation of ethylene, carbon monoxide and hydrogen will produce
propanal and ethane with the help of rhodium catalyst. The reaction is exothermic
and corrosive. Because of the reaction is exothermic and may occur temperature
oscillation, the temperature must be controlled well. This is because temperature
oscillation can affect product quality, catalyst degradation and unsafe reactor
operation. Besides that, the types of the reaction and reaction order must be
considered to make sure all the reaction follows the right rules. (Coulson &
Richardsons, 1999).
1-4

Reaction of the process is considered as heterogenous reactions because all
the reactant and product is in gas phase meanwhile catalyst in the solid form.
Rhodium also is characterized as heterogenous catalyst since the reactant and
catalyst in different forms. The flow is characterized as plug flow since there are
tubes in the fixed bed reactor to place catalyst.

1.1.2 Stream Condition
Generally, the fixed bed is design to produce propanal with rhodium as catalyst at
temperature 100
o
C and pressure 1000 kPa respectively. The reactor is catalytic
reactor with rhodium as catalyst in the tubes and water as a cooling on the shell
side. This reactor operated at vertical position. Table below shows conditions of the
hydroformylation process.

Figure 1.1 Inlet and Outlet Streams of Reactor

1-5

Table 1.2 Conditions of inlet and outlet streams of reactor.
Inlet Outlet
Temperature,
o
C 100 170
Pressure, kPa 1000 1000
Phase Vapor Vapor

Table 1.3 Components mole flows and mass flows of inlet and outlet streams.
Components
Inlet Outlet
Mole flows,
kmol/h
Mass flows,
kg/h
Mole flows,
kmol/h
Mass flows,
kg/h
Ethylene 641.93 18 008.58 192.58 5402.60
Carbon
monoxide
2888.60 80912 2503.40 70124
Hydrogen 2889 5824.22 2439.60 4918.30
Propanal - - 385.16 22370
Ethane - - 64.19 1930.30

1.2 REACTION
1.2.1 Reaction Rate
The reaction invoved in the fixed bed reactor:

ethane opanal Hydrogen monoxide Carbon Ethylene + + + Pr
(1.1)

6 2 6 3 2 4 2
H C O H C H CO H C + + +
(1.2)

E D C B A
C C C C C + + +
(1.3)

To ensure the validity of the reaction and equations used in designing the reactor,
this assumption has been made:
- The reaction is in steady state.
- The reaction order is valid for the reactions above like in the journal.
- Irreversible reaction.
The general reaction rate for this reaction is like equation below.
C B A
A
A C C kC
dt
dC
r = |
.
|
\
|
=
(1.4)

1-6

The order of reaction is important in order to calculate reaction rate of the
hydroformylation process. The information below is from the journal of
Hydroformylation, Hydrogenation, and lsomerization of Olefins over Polymer-
Immobilized Rhodium Complexes by Hirochimi Arai:

Table 1.4 Reactivity of Olefins
Olefin Product
Reaction order
Rate
(10
-5
mol
hr.g cat)
Activation
energy(kcal/mol)
Olefin H
2
CO
C
2
H
4
C
3
H
6
O 1.1 0.8 -0.5 43.1 10.2
C
2
H
4
C
2
H
6
1.1 0.8 -1.3 181 8.9
Where the W/F=10 g.cat.hr/mol;feed mole ratio,olefin:H
2
:CO=3:3:1 and W=weight of
catalyst is 0.15 gram (Source:Hiromichi Arai,1978)

From the in formations given, reaction rate of the process will become;
For propanal :
8 . 0 5 . 0 1 . 1
C B A
A
A
C C kC
dt
dC
r

= |
.
|
\
|
=
(1.5)

For ethane :
8 . 0 3 . 1 1 . 1
C B A
A
A
C C kC
dt
dC
r

= |
.
|
\
|
=
(1.6)

1.2.2 Reaction Constant
In order to find value of reaction constant,k of the equation, concentration of every
component is calculated and then it will be substitute into equation 1.5 an 1.6
together with reaction rate,-r
A
. The result of the calculation is shown below.

Table 1.5 Concentration of initial reactant
Component
Molar
flowrate,mol/hr
Mass flowrate,
mol/hr
Concentration,
mol/m
3
C
2
H
4
0.0643 1.8032 0.4120
CO 0.0214 0.6002 0.6941
H
2
0.0643 0.12990 0.5027
Value of concentration and reaction rate is substituted into equation 1.5 and 1.6 to
get k
exp
and then substitute the value into Arrhenius equation to find k
o.

1-7

Arrhenius equation
RT
E
o
a
k k

= exp
exp
(1.7)

Where:
E
a
= activation energyfor components, cal/mol
R = constant, 1.987 cal/mol.K
T = temperature of the components,K
The results of the calculation recorded in the table below.

Table 1.6 Reaction constant
Components K
exp,
hr
-1
K
o,
hr
-1
Propanal 8.74 x 10
8
926.78
Ethane 4.75 x 10
8
2906.30

1.2.3 Initial Concentration

1.2.3.1 Mixture Density

Density of the reactants at the initial streams must be treated as mixture not by
single component density.

c c b b a a mixture
x x x + + =
(1.8)

3
/ 117 . 1
) 06 . 0 085 . 0 ( ) 77 . 0 184 . 1 ( ) 17 . 0 178 . 1 (
m kg
mixture
=
+ + =

(References: www.wikibook.org)

1.2.3.2 Reactants Volume Flow Rate

In order to calculate volume flow rate of the reactants, total mass flow rate is divided
by density mixture.

density mixture
hr kg flowrate mass total in rate Flow
1
/ , =
(1.9)

1-8

hr m
kg
m
hr kg in rate Flow
/ 96 . 93769
11704 . 1
1
/ ) 2241 . 5824 80912 576 . 18008 (
3
3
=
+ + =

1.2.3.3 Determination of Initial Concentration

Initial concentration of ethylene, carbon monoxide and hydrogen can be determined
by molar flow rate of each component divide by volume flow rate of the inlet.
3
,
1
/ ,
m in rate flow
hr
hr kmol rate flow molar C
AO
=
(1.10)
3
3
/ 0068458 . 0
, 96 . 93769
1
/ 93 . 641 m kmol
m
hr
hr kmol C
AO
= =
3
3
/ 0308052 . 0
, 96 . 93769
1
/ 6 . 2888 m kmol
m
hr
hr kmol C
BO
= =
3
3
/ 030809 . 0
, 96 . 93769
1
/ 2889 m kmol
m
hr
hr kmol C
CO
= =

Table 1.7 Initial concentrations of components
Components Initial concentration,kmol/m
3

Ethylene,C
AO
0.0068458
Carbon monoxide,C
BO
0.0308052
Hydrogen,C
CO
0.0308090

1.2.4 Volume Reactor
1.2.4.1 Reaction Rate at Different Conversion
The reaction between syn gas and ethylene will produce two products which are
propanal and ethane. In order to find the volume of the reactor for the reaction,
reaction rate of both products should be calculated and a graph of 1/reaction rate
versus conversion should be draw. The area under the graph represent the value of
volume of reactor divide by initial ethylene molar flowrate like shown
below.(Sources:Hiromichi Arai)

AO
F ethylene of flowrate molar Initial
V reactor of Volume
graph the under Area
,
,
=
(1.11)

1-9

Sample of calculation:
Concentaration of propanal at X
a
= 0.2 by adapting equation 1.5.
8 . 0 5 . 0 1 . 1
C B A
A
A
C C kC
dt
dC
r

= |
.
|
\
|
=

hr m kmol r
A
. / 736 . 15 ) 65 . 24 ( ) 62 . 26 ( ) 48 . 5 )( 78 . 926 (
3 8 . 0 5 . 0 1 . 1
= =

Reaction rate of every product is calculated by using equation 1.5 and 1.6. The
results are shown in the Table 1.8 below.

Table1.8 Reaction rate at different conversion

Conversion
Reaction rate
propanal,
kmol/m
3
.hr
Reaction rate
ethane,
kmol/m
3
.hr
Reaction rate
combine,r
A
kmol/m
3
.hr
1/r
A
,m
3
.hr/kmol
0 21.507 4.346 25.853 0.0387
0.2 15.736 3.801 19.537 0.0512
0.4 10.519 3.198 13.717 0.0729
0.6 5.962 2.508 8.470 0.1181

1.2.4.2 Determination Volume of Reactor
Then, the graph or 1/r
a
versus conversion is drawn like the graph below and area
under the graph is calculated by using Simpsons rule.

Figure 1.2 Area Under The Graph
1-10

8
) (
) (
4 3 2 1
fx fx fx fx
a b graph the under Area
+ + +
=
(1.12)

kmol hr m graph the under Area / . 0396825 . 0
8
1181 . 0 ) 0729 . 0 0512 . 0 ( 3 0387 . 0
) 0 6 . 0 (
3
=
(
+ + +
=

Based on the facts that volume of reactor is area under the graph times initial
concentration of ethylene, thus the volume of reactor is

3
47 . 25 93 . 641 0396825 . 0 m reactor of Volume = =

1.2.5 Diameter of Reactor

Formula of volume of reactor is shown below.

L
D
V
Length Area reactor of Volume
=
=
4
2
t
(1.13)

Besides, the relation of height of reactor with the diameter shown
below.(Biegler,1997)
4 =
D
L
(1.14)

Thus, it makes the formula of reactor volume become
3
2 2
4
4 4
D D
D
L
D
reactor of Volume t
t t
= = =

Thus, the diameter of reactor is
3
, D V reactor of Volume t = (1.15)
m D
D
2
47 . 25
3
=
=
t

1.2.6 Length of Reactor
Because of the relationship between diameter and length of reactor is 4 =
D
L

Thus, length of reactor become

m L 8 2 4 = =

1-11

1.2.7 Residence Time
Residence time is the time taken for the reactants to contact with each other in order
to form the products. In this case, contact time between ethylene, carbon monoxide
and hydrogen.
sec 986 . 0
96 . 93769
67 . 25
, Re
= =
=
t
u
t
o
r
V
time sidence
(1.16)
Table 1.9 Summary of Reactor Design
Items Values
Volume reactor,V
r
25.47 m
3

Height reactor 8 m
Diameter reactor 2 m
Residence time, 0.986 s

1.3 CATALYST
1.3.1 Catalyst Selection
Catalyst selection is very important in the hydroformylation process. This is because
catalyst plays a big role in production of propanal. Besides, catalyst in the fixed bed
reactor should be in the form of solid and it will be placed in the tube along the
reactor. Because of the solid catalyst the catalyst bed is arrange in tube
arrangement to give more time contact between solid catalyst and reactant gas. The
amount of catalyst needed in the reactor depend on the production rate and lifetime
of the catalyst. In this process, rhodium will be used as the catalyst and it is
classified as heterogenous catalyst since it has different phase with reactant. The
total surface area of solid catalyst has an important effect on the reaction rate which
is the smaller the catalyst particle size, the larger the surface area for a given mass
of particles. Usually this kind of catalyst needs support from the second material that
may enhance the effectiveness of the catalyst and reaction process.
1-12

For the fixed bed, the common catalyst size is between 0.1 to 10 mm and it
preferrable if the size is between 0.5 to 5 mm. (Reference: Smith J.M, Chemical
Engineering Kinetics, 1981). Below are the properties of the rhodium catalyst
Table 1.10 Properties of Catalyst
Items Values
Particle density,
p
12.41 g/cm
3
or 12 410 kg/m
3

Bulk density,
b
573 kg/m
3

Diameter particle, d 5 mm or 5 x 10
-3
m
Surface area, S
A
150 m
2
/g or 1.5 x 10
5
m
2
/kg
Pore volume 0.55 ml/g or 5.5 x 10
-4
m
3
/kg
(Reference: www.en.wikipedia.org/rhodium)

1.3.2 Volume Catalyst
Volume of catalyst can be determined by using below formula. The voidage for the
rhodium in the fixed bed is varying from 0.3-0.5.
) 1 ( c =
r c
V V
(1.17)

3
735 . 12 ) 5 . 0 1 ( 47 . 25 m V
c
= =

1.3.3 Weight of Catalyst
Weight of the catalyst needed in the hydroformylation process can be calculated by
using equation below.
b c c
V W =
(1.18)
kg W
c
16 . 7297 ) 573 735 . 12 ( = =

1.4 HEAT EXCHANGER IN REACTOR
1.4.1 Logarithmic Mean Temperature, T
lm

Because of hydroformylation reaction is exothermic reaction, certain amount of heat
will be released during the reaction occured. The system should be treated and
controlled as isothermal sytem is desired in order to form the product. In order to
control the temperature from being exceed the desired temperature, cooling water
system is needed in the reactor. Catalyst is put in the tube and reactant gas will be
flow in through the tube. The heat released will be transfer to the cooling water at
the shell side and flow out from the reactor. By doing this, temperature of the
reaction in the tube can be maintained at 100
o
C and cooling water inlet at 25
o
C will
1-13

be absorb the heat flow out at 50
o
C. Fluid allocation in the tube and shell is
summarized in the table 1.11 below.
Table 1.11 Allocation of fluids in the heat exchanger
Allocation Tube Shell
Fluid Catalyst and reactant gas Cooling water
Temperature
symbol
t
1
t
2
T
1
T
2
Temperature,
o
C
100 100 25 50

In order to determine temperature differences between fluid, logarithmic mean
temperature should be calculated using equation below.
( ) ( )
( )
( )
1 2
2 1
1 2 2 1
ln
t T
t T
t T t T
T
lm

= A
(1.19)
(Source: Coulson & Richardson, 1999)
Where T
lm
is log mean temperature differences.
( ) ( )
( )
( ) 100 50
100 25
ln
100 50 100 25

= A
lm
T
66 . 61 = A
lm
T

1.4.2 True Temperature Differences
The usual practice in the design of shell and tube exchangers is to estimate the
"true temperature difference" from the logarithmic mean temperature by applying a
correction factor to allow for the departure from true counter-current flow: (Source:
Coulson & Richardson, 1999)
lm t m
T F T A = A
(1.20)

Where T
m
is true temperature differences and F
t
is temperature correction factor.
To determine value of F
t
value of R and S has to calculate first.

1-14

1 2
2 1
t t
T T
R
=
(1.21)
0
100 100
50 25
=
= R
1 1
1 2
t T
t t
S
=
(1.22)

0
100 25
100 100
=
= S
Therefore, from the Figure A.1 (Appendix A), value of F
t
= 1.
Thus,
66 . 61 66 . 61 1 = = A
m
T

1.4.3 Determination of Heat Transfer Area
As mention above, to keep the temperature maintained, heat released from the
reaction need to be transferred outside the reactor and it is related to the amount of
heat transfer area available or needed in the reactor. Total area needed for heat
transfer is calculated using equation given. (Reference: Coulson &
Richardson,1999)

lm
T UA Q A =
(1.23)

Rearrange the equation
lm
T U
Q
A
A
=

Where
Q=heat released from the reaction, 13 102.78 kJ/s
U=Overall heat transfer through stainless steel, 680 W/m
2.
K
(Sources: www.engineeringtoolbox.com)
Thus, area needed to transfer 13 102.78 kW of heat is
2
5 . 312
66 . 61 68 . 0
78 . 13102
m A =
=

1-15

1.4.4 Mass of Cooling Water
Cooling water amount needed in order to control the temperature in the reactor to
gain desired product is calculated using given equation.

T mC Q
p
A =
(1.24)

Rearrange the equation and get the mass of cooling water
s kg m / 6 . 122
) 25 50 ( 2736 . 4
78 . 13102
=

=

Table 1.12 Summary of Cooling System
Items Values
Logarithmic mean temperature,T
lm
61.66
True temperature differences, T
m
61.66
Heat transfer area 312.5 m
2

Mass of Cooling Water 122.6 kg/s

1.5 TUBES
1.5.1 Tube dimensions
To calculate the number of tube there are certain calculations needed to be done.
As refer to Table A.1(Appendix A), the standard dimensions of tube used in the
industry was given. (Coulson & Richardsons,1999). Assume that;

Table 1.13 Dimension for tubes
Outside diameter, D
o
(m) 0.05
Length, L (m) 8
Wall thickness, t (m) 0.002
Inside diameter, D
i
(m) 0.046

1-16

Length of the tubes is the same as length of the reactor. (Coulson & Richardsons,
1999). The diameter of fixed bed reactor should be less than 5 or 7 cm in other to
give stable thermal stability and efficient heat removal from the tubes. (Sources:
Heat Exchanger for Carrying Out An Exothermic Reaction, Anne Boer 2007)

1.5.2 Determination of Area
From the information on the Table 1.13, surface area of one tube, A
s
can be
determined using equation given:
L D A
o
t = (1.25)
2
26 . 1 8 05 . 0 m A = = t

1.5.3 Number of Tubes
Number of tubes needed is closely related to the amount of heat need to be
removed from the system. Tubes needed in this process are
tube one of Area
needed area transfer heat Total
tubes of Number =
(1.26)

tubes N
t
248
26 . 1
5 . 312
= =

1.5.4 Tube Pitch
Tube pitch, P
t
is a length of distance between two tubes. The recommended tube
pitch is 1.25 times the tube outside diameter, D
o
.(Coulson & Richardsons, 1999). A
larger tube pitch leads to a larger overall shell diameter which leads to a more
expensive heat exchanger. (Sources: wikipedia.com)
o t
D P = 25 . 1
(1.27)
m P
t
0625 . 0 05 . 0 25 . 1 = =


1-17

1.5.5 Tube Arrangement

Figure 1.3: Tube patterns

There are four patterns that can be use in order to arrange the tubes which are
triangular (30), rotated triangular (60), square (90) and rotated square (45) like
figure shown above. Triangular and rotated square arrangement gives higher heat
transfer compared to square arrangement. Meanwhile, square patterns are
employed where high fouling is experienced and cleaning is more regular. Because
of the reaction involve in hydroformylation process is very exothermic, it is the best
to choose triangular arrangement. (Figure 12.9, Coulson & Richardsons, 1999).

1.5.6 Pressure Drop in the Tubes
Pressure drop in the tube side is calculated using equation below which is known
as Ergun equation.
|
|
.
|
\
|
(
(
+
|
|
.
|
\
|
|
|
.
|
\
|
= A

2
5 . 2 8
2
t
m
w i
f p t
u
D
L
j N P

(1.28)
Where
N
p
= Number of pass,1
L = Length of tube, 8m
D
i
= Inside diameter, 0.046 m

1-18

1.5.6.1 Determination of Mixture Density
c c b b a a mixture
x x x + + =
(1.29)

3
/ 117 . 1
) 06 . 0 085 . 0 ( ) 77 . 0 184 . 1 ( ) 17 . 0 178 . 1 (
m kg
mixture
=
+ + =

1.5.6.2 Determination Area of One Tube

i
D tube one of Area =
4
t
(1.30)

2
0361 . 0 046 . 0
4
m tube one of Area = =
t


1.5.6.3 Determination of Total Area
tube one of Area tubes of Number area Total =
(1.31)

2
96 . 8 0361 . 0 248 m area Total = =


1.5.6.4 Determination of Mass Velocity
area Total
rate flow Mass
velocity Mass =
(1.32)

s m kg velocity Mass
2
/ 25 . 3
96 . 8
096 . 29
= =
1.5.6.5 Determination of Linear Velocity
density Mixture
velocity Mass
u velocity Linear
t
= ,
(1.33)

s m u velocity Linear
t
/ 91 . 2
117 . 1
25 . 3
, = =

1-19

1.5.6.6 Determination of Viscosity Mixture
k k j j i i mix
x x x + + =
(1.34)

) 45 . 0 10 04 . 1 ( ) 45 . 0 10 75 . 1 ( ) 1 . 0 10 26 . 1 (
5 5 5
+ + =

mix

s m kg
mix
. / 10 38 . 1
5
=
1.5.6.7 Determination of Reynold Number
i t
D u
= Re
(1.35)

4
5
10 08349 . 1 9 . 10834
10 38 . 1
046 . 0 91 . 2 117 . 1
Re = =

=


1.5.6.8 Determination of Friction Factor
From the Figure A.2 (Appendix A) (Coulson & Richardsons, 1999), friction factor at
Reynold number 1.08349 x10
4
is
j
F
= 4.5 x 10
-3

Value
m
w
|
|
.
|
\
|
is neglected
Substitutes all the values into the equation,
|
|
.
|
\
|
(
(
+
|
|
.
|
\
|
|
|
.
|
\
|
= A

2
5 . 2 8
2
t
m
w i
f p t
u
D
L
j N P

( )( )
Pa P
t
41
2
91 . 2 117 . 1
5 . 2
046 . 0
8
) 10 5 . 4 ( 8 1
2
3
=
|
|
.
|
\
|
(
+
|
.
|
\
|
= A

1.5.7 Tube Side Passes and Shell Types
The flow of the fluid can be design whether single passes(1-1 parallel flow), 2
passes tube side (1-2 crossflow) or 2 passes tube side). Cocurrent flow is when both
fluid are in the parallel and countercurrent when the flow is from opposite end.
(Coulson & Richardsons, 1999) For this reactor, single pass tube and single pass
shell are used.
1-20

1.5.8 Bundle Diameter
Bundle diameter, D
b
is calculated based on the arrangement of the tube which is in
this process it is triangular pattern by using equation below.
1
1
1
n
t
o b
k
N
D D
(
=
(1.36)

Where k
1
and n
1
are constant and value of D
o
and D
b
in millimeter,mm. (Coulson &
Richardsons, 1999). Value of k
1
and n
1
get from Table A.2 (Appendix A). From the
table the chosen value of k
1
and n
1
are 0.319 and 2.142 respectively for triangular
pitch. Thus bundle diameter can be calculated.
142 . 2
1
319 . 0
248
50
(
=
b
D

m mm D
b
12 . 1 11 . 1118 = =

1.5.9 Tubes in Centre Row
The number of tubes in the centre row can be calculated using given equation.
(Coulson & Richardsons, 1999)
tubes
P
D
row center in Tubes
t
b
18 92 . 17
0625 . 0
12 . 1
= = = =
(1.37)

1.5.10 Baffles
Baffles are used in the shell to direct the fluid stream across the tubes, to increase
the fluid velocity and so improve the rate of transfer. It also to hold the tubes from
bend when the heat is released from the reaction in the tubes. Baffles spacing is no
closer than 20% of shells inner diameter. The optimum spacing is 0.3 to 0.5 times
the shells inner diameter. The space between them cannot be too closed because it
will cause increase in pressure change, P and can cause redirection of the flow.
1-21

Number of baffles need in the reactor is calculated using following equation.

1 =
s
b
B
L
N
(1.38)

Where;
N
b
= number of baffles
L = length or height of reactor, 8 m
B
s
= baffles spacing, 0.5 from shell diameter, 2 m

baffles N
b
7 1
2 5 . 0
8
=
=


1.6 SHELL
1.6.1 Shell Diameter, D
s

The diameter of shell is calculated using equation below.
clearance diameter bundle D D
b s
+ =
(1.39)

Where bundle diameter clearance is estimate from Figure A.3 (Appendix A)
(Coulson and Richardsons, 1999) .From the figure, bundle diameter clearance is
0.018 m.
m D
s
138 . 1 018 . 0 12 . 1 = + =
1.6.2 Shell Side Equivalent Diameter,D
e

Shell side equivalent diameter is calculated based on the tube arrangements choose
for the reactor which is square arrangement. The equation is shown below.
2
4 2
1
86 . 0
2
4
2
o
o
t
t
e
D
D
P
P
D
t
t
(
=
(1.40)

2
) 05 . 0 (
4
) 05 . 0 (
2
1
) 0625 . 0 86 . 0 (
2
0625 . 0
4
2
t
t
(
(

=
e
D
mm D
e
88 . 8 =

1-22

1.6.3 Pressure Drop in Shell

1.6.3.1 Determination of Density and Viscosity of Water
Because of the inlet and outlet temperature of cooling water is not the same the
properties should be taken at the mean temperature.

C e temperatur Mean
O
5 . 37
2
50 25
=
+
= (1.41)

The density and viscosity of water at 38
o
C is get by interpolation and the result
shown in the following table.

Table 1.14 Water Properties
Items Value
Density, kg/m
3
992.8
Viscosity, Ns.m
2
0.682 x 10
-3

Sources: simetric.co.uk and engineeringtoolbox.com

1.6.3.2 Determination of Area
Area of available at shell can be determined by using following equation.

t
s s o t
s
P
B D D P
A Area
) (
,

= (1.42)

Substitutes all the values into equation above,

2
4 . 0
0625 . 0
) 1 )( 2 )( 05 . 0 0625 . 0 (
m A
s
=
=


1.6.3.3 Determination of Mass Velocity
Mass velocity can be calculated by using following equation.

s
s
s
A Area
W flowrate Mass
G velocity Mass
,
,
, = (1.43)

Substitutes all the values.

1-23

s m kg G
s
. / 5 . 306
4 . 0
6 . 122
2
= =

1.6.3.4 Determination of Velocity
Velocity, u
s
be determined by using the following equation.

,
,
,
Density
G velocity Mass
u Velocity
s
s
= (1.44)

s m u
s
/ 3987 . 0
8 . 992
5 . 306
= =


1.6.3.5 Determination of Reynold Number
Reynold number is determined in order to determine shell side friction factor at the
Appendix A.

i s
D u
= Re
(1.45)

5
3
10 98 . 8
10 682 . 0
) 2 3087 . 0 8 . 992 (
Re =

=


1.6.3.6 Determination of Friction Factor
Based on the Table A.4 (Appendix A) the friction factor, j
F
is 2.5 x 10
-2
.

Pressure drop in the shell side can be determining using equation below.
(Coulson and Richardsons, 1999)
m
w
s water
s e
s
f s
u
B
L
D
D
j P

|
|
.
|
\
|
|
|
.
|
\
|
|
|
.
|
\
|
|
|
.
|
\
|
= A

2
8
2
(1.46)

Since
w
= thus
m
w
|
|
.
|
\
|
is neglected and equation becomes

|
|
.
|
\
|
|
|
.
|
\
|
|
|
.
|
\
|
= A
2
8
2
s water
s e
s
f s
u
B
L
D
D
j P

1-24

kPa Pa P
s
787 . 9 9787
2
) 3087 . 0 )( 8 . 992 (
1
8
10 88 . 8
138 . 1
10 5 . 2 ( 8
2
3
2
= =
|
|
.
|
\
|
|
.
|
\
|
|
.
|
\
|
= A

Table 1.15 Summary of Chemical Design for Fixed Bed Reactor.

Items Values
Volume of reactor, V
r

25.47 m
Height of reactor
8 m
Diameter of reactor
2 m
Residence time,
0.986 s
Volume of catalyst, V
c

12.735 m
3
Weight of catalyst, W
c

7297.16 kg
Mass of cooling water
122.6 kg/s
Outside diameter of tube, D
o

0.05 m
Thickness tube, t
0.002 m
Number of tubes, N
b

248
Tubes pitch, P
t

0.0625 m
Tubes pressure drop, P
t

41 Pa
Bundle diameter, D
b

1.12 m
Number of Baffles, N
b

7
Shell diameter, D
s
1.138 m
Shell side equivalent diameter, D
e
8.8 x 10
-3
m
Shell pressure drop, P
s

9.79 kPa

1-25

1.7 MECHANICAL DESIGN
1.7.1 Introduction
In the mechanical design chapter, the vessel is design based on the functions of the
vessel, process materials and services, operating temperature, operating pressure,
materials of constructions, vessel dimensions and orientation, types of vessel heads
to be used, opening and connections required and specifications of heating and
cooling jackets or coils.(Coulson and Richardson, 1999)

1.7.2 Design Pressure
The pressure of the vessel should be design to withstand the pressure involved in
the process. For safety reason, design pressure is designed 10% above the working
pressure. Pressure involved in the hydroformylation reactor is 1000kPa or 10 bar.
mm N bar P P P
atm a g
/ 1 . 1 11 1 . 1 ) ( = = =
(1.47)
Where
P
g
= Gauge pressure
P
a
= Absolute pressure
P
atm
= Atmospheric pressure

(Source: Coulson & Richardson, 1999 and www.differentbetween.net)

1.7.3 Design Temperature
For the design temperature, the vessel should design at the maximum working
temperature of the material due to allowance for any uncertainty involved in the
predicting the vessel temperature. Besides that, maximum allowable design stress
also depends on the temperature of the material. The strength of the materials will
decrease with the increasing temperature. For the hydroformylation process, the
working temperature is 100
o
C and the process is exothermic, corrosive and reactive.
So, the best material should be choose in order to make sure all this problem can be
control and reduce. The design temperature will be 100
o
C same as working
temperature.

1.7.4 Materials of Construction
There are various kinds of materials that can be chosen as a material to construct
the vessel such as carbon steel, stainless steel, nickel, copper, aluminums and
1-26

many more. Factors that affect the material should be considered in order to choose
the best material for the construction. Characteristics that must be observed like
mechanical properties, effect of high and low temperatures, corrosion resistance,
ease of fabrication, availability in standard sizes and most important one is cost of
the material. The most economical material always been chosen because it satisfies
both process and mechanical requirements. This material will give the lowest cost
over the working life of the plant, allowing for maintenance and replacement. Other
factors that taken into consideration such as product contamination and process
safety. For the fixed bed reactor, the material use is stainless steel due to the
exothermic process, corrosive and reactive reaction involves. There are three types
of stainless steel which are SS 304, SS321 and SS 316. Stainless steel 304 will be
used based on commonly used in the industry and economic saves.

1.7.5 Design Stress
A maximum allowable stress that can be accepted in the material of construction is
necessary to decide for design purpose in which the material could be expected to
withstand failure under standard test condition. Table A.4 (Appendix A) shown that
design stress for the stainless steel at various temperature.

1.7.6 Minimum Wall Thickness
From Table A.3 (Appendix A), tensile and design stress for stainless steel 304 are
Tensile strength: 510 N/mm
2

Design stress: 145 N/m
2

Cylindrical section
i
i i
P f
D P
e
=
2
(1.48)
Where
P
i
= Internal pressure
D
i
= Internal diameter of shell
f = Design stress
e = Minimum wall thickness


1-27

From the chemical design of reactor, diameter of reactor is equivalent to diameter of
shell. So, D
i
= 2m = 2000 mm.
( )
1 . 1 ) 145 ( 2
2000 1 . 1
= e

mm e 6150 . 7 =
Add corrosion allowance for 4 mm
mm e 616 . 11 4 6150 . 7 = + =
Round up the cylindrical section mm 12 ~

1.7.7 Design Domed Heads
There are different types of heads and closure available on the market;
1. Flat plates and formed flat heads.
2. Hemispherical heads.
3. Ellipsoidal heads.
4. Torispherical heads.
Torisphere Head
Crown radius, R
C
= D
i
= 2 meter
Knuckle radius, R
k
= 6 percent R
c
= 0.12 meter
A head of this size would be formed by pressing: no joints, so J=1

|
|
.
|
\
|
+ =
K
C
S
R
R
C 3
4
1
(1.49)
77 . 1
12 . 0
2
3
4
1
=
|
|
.
|
\
|
+ =
S
S
C
C

Substitute value of C
s
into the minimum wall thickness equation.
( ) 2 . 0 2 +
=
S i
S C i
C P fJ
C R P
e
(1.50)
( )( )( )
mm e
e
508 . 13
) 2 . 0 77 . 1 ( 1 . 1 ) 145 ( 2
77 . 1 2000 1 . 1
=
+
=

1-28


Ellipsoidal head
For the ellipsoidaal head, the calculation shown below.
i
i i
P Jf
D P
e
2 . 0 2
=
(1.51)
) 1 . 1 )( 2 . 0 ( ) 145 ( 2
) 2000 )( 1 . 1 (
= e

mm e 60 . 7 =


From the proof of the calculation, ellipsoidal head has been chosen as the head of
the reactor. This is due to the cost, strength and the thickness required for the head.
Ellipsoidal head is commonly used for the vessel having operating pressure above
15 bar. The calculation shows ellipsoidal head is the most saving cost with the small
thickness needed. The thickness of the domed head for the vessel taken will be the
same as the wall thickness which is 12 mm.

1.7.8 Design of Vessel Subject To Combined Loading
Pressure vessels are subject to other loads in addition to pressure and must be
designed to withstand the worst combination of load without failure. The main
sources of load to be considered are:

1. Dead weight of vessel and contents
2. Wind

1.7.8.1 Dead Weight of Vessel
For the steel vessel, equation below is applied to calculate dead weight of vessel.
( )t D H D C W
m v m v v
8 . 0 240 + =
(1.52)
Where
W
v
= Total weight of the shell
C
v
= Weight factor take as 1.15
H
v
= Height or length between tangent line
D
m
= Mean diameter of vessel, D
m
= D
i
+ (t x 10
3
)

1-29

For this section, to get the rough estimate of weight of this vessel the average of
thickness is found by using five different section in the column increasing with 2 mm

per section. The value of 10, 12, 14, 16, until 18 mm. Average thickness 14 mm is
estimated as the thickness of the weight of the vessel.( Coulson & Richardson,
1999)

Mean diameter of vessel, D
m

m D
t D D
m
i m
014 . 2 014 . 0 2 = + =
+ =
(1.53)

Dead weight of vessel, W
v

v
W ( )t D H D C
m v m v
8 . 0 240 + =

( )( ) ( ) ( )14 014 . 2 8 . 0 0 . 8 014 . 2 15 . 1 240 + =

N 28 . 74795 =
v
W kN 795 . 74 =

1.7.8.2 Weight of Tubes

g L D D N W
m i o t t
t ) (
2 2
= (1.54)

Where
N
t
= Number of tubes
D
o
= Outer tube diameter
D
i
= Inner tube diameter
L= Length of tube
m
= Density of vessel material, Stainless steel
g = Gravitational acceleration, 9.81 m/s
2

From chemical design of reactor, those information was calculated earlier.
Table 1.16 Calculate values
Items Values
N
t
248 m
D
o
0.05 m
D
i
0.026 m
L 8 m
m
8030 kg/m
3
g 9.81 m/s
2

1-30

Substitute all the values into equation 1.54.

N W
W
t
t
6566 . 188541
) 81 . 9 )( 8030 )( 8 )(( 046 . 0 05 . 0 ( 248
2 2
=
= t

1.7.8.3 Weight of Cooling Water
Weight of cooling water must be calculated to identify how many cooling water hit
need.

Vg W
cw
= (1.55)
V
cw
= Volume of cooling water
m
= Gravitational acceleration

Thus,
N W
W
cw
cw
36 . 72162
8 . 992 81 . 9 41 . 7
=
=

1.7.8.4 Weigth of Catalyst

g m W
cat cat
= (1.56)
14 . 71585
81 , 9 16 . 7297
=
=
cat
cat
W
W

1.7.8.5 Insulator

Weight of insulation
For the insulation purpose mineral wool material is chose. Density of wool is
3
/ 130 m kg (Coulson & Richardsons, 1999). By taking the thickness of wool use for
to insulation is mm 75 Table A.5 (Appendix A).
N W
W
g v W
insulator
insulator
insulator
77 . 4807
81 . 9 130 77 . 3
=
=
=
(1.57)

1-31

kN W
W W W W W
insulation weight catalyst weight tubes weight vessel weight W
T
ins c t v T
vessel total
73 . 339 77 . 4807 71585 66 . 188541 28 . 74795 = + + + =
+ + + =
+ + + =

1.7.8.6 Wind
A vessel installed in the open must be designed to withstand the weight bending
stress caused by wind loading. The wind loading is a function of the wind velocity,
air density and the shape of structure. A wind speed of 160 km/hr is used for
preliminary design.
For a cylindrical column, the following semi-empirical equation can be used to
estimate the wind pressure.
2
05 . 0
w w
U P =
(1.58)

Where
P
w
= Wind pressure
U
w
= Wind speed, 160 km/h

2 2
/ 1280 ) 160 ( 05 . 0 m N P
w
= =

Then, D
eff
must be calculate before determine the F
w
which is loading per linear
meter.

eff
D ( )
insulation i
t t D + + = 2
(1.59)

( )
m D
D
eff
eff
178 . 2
075 . 0 014 . 0 2 2
=
+ + =

Loading, (per linear meter),
w
F ( )
eff wind
D P = (1.60)

Where
P
wind
= 1280 N/m
2

1-32

It will become,
( )
2
/ 84 . 2787
) 178 . 2 ( 1280
m N F
F
D P F
w
w
eff wind w
=
=
=

Bending moment at bottom tangent line
x
M ( )
2
2
v
w
H
F
=
(1.61)
Where
F
w
= Loading per linear meter
H
v
= Height or length between tangent lines
From equation 1.61, bending moment is
( )
m N M
M
H
F
M
x
x
v
w
x
. 06 . 89210
) 8 (
2
84 . 2787
2
2
2
=
=
=

1.7.9 Analysis of Stress
1.7.9.1 Longitudinal and Circumferential Pressure Stress
t
D P
i i
L
2
= o (1.62)

( )
( ) 14 2
2000 1 . 1
=

2
/ 57 . 28 mm N =

Where
P
i
= Internal diameter
D
i
= Internal diameter of shell

t
D P
i i
H
4
= o (1.63)

( )
( ) 14 4
2000 1 . 1
=

2
/ 29 . 39 mm N =

1-33

1.7.9.2 Dead Weight Stress
( )t t D
W
i
v
w
+
=
t
o (1.64)

Where
W
v
= Dead weight of vessel
t = Thickness
( )
2
/ 84438 . 0
14 14 2000
28 . 74795
mm N
w
w
=
+
=
o
t
o

1.7.9.3 Bending Stress
mm D
t D D
o
i o
2028 ) 14 ( 2 2000
2
= + =
+ =
(1.65)
Second bending moment
( )
4 4
64
i o v
D D I =
t
(1.66)

Where
I
v
= Second bending moment
D
o
= Outer diameter
D
i
= Inner diameter
( )
4 10
4 4
10 49 . 4
2000 2028
64
mm x I
I
v
v
=
=
t

|
.
|
\
|
+
|
|
.
|
\
|
= t
D
I
M
i
v
x
b
2
o (1.67)
Where
M
x
= Bending moment
I
v
= Second bending moment
D
i
= Internal diameter
1-34

2
9
3
/ 015 . 2 14
2
2000
10 49 . 4
10 06 . 89210
mm N
b
=
|
.
|
\
|
+
|
|
.
|
\
|

= o
The total longitudinal stress is
b w L z
o o o o + =
(1.68)

w
o is compressive therefore negative
( )
2
/ 73 . 77 015 . 2 84438 . 0 57 . 78 mm N upwind
z
= + = o
( )
2
/ 71 . 75 015 . 2 84438 . 0 57 . 78 mm N downwind
z
= = o

The greatest different between the principal stresses will be on the down wind side
2
2 2
/ 73 . 77
/ 84437 . 0 / 57 . 78
mm N
mm N mm N
=
=

Because of this value smaller than design stress, 145 N/mm
2
it means the design is
satisfactory.

Figure 1.4 Upwind and Downwind Vessel

1.7.10 Vessel Support Design
Vessel support is very important to support the vessel or reactor whether it is in
vertical or horizontal position. There are two types of support which are saddle and
skirt. Skirt support is used when the vessel is in vertical meanwhile saddle is used
when the vessel in horizontal position. Factors that will be considered in choosing
the right support is based on the size, shape, weight of the vessel, design
1-35

temperature, design pressure , vessel location and internal and external fittings and
attachment. Besides the supports should be designed to allow easy access to the
vessel and fittings for inspection and maintenance.
Skirt supports for reactor at ambient temperature:
Type of support : Straight cylindrical skirt (
0
90 =
s
u )
Material construction : Stainless Steel 304
Design stress :
145 N/mm
2

Youngs Modulus :
200 000N/mm

Skirt height, H
s
: Ellipsoidal head
2
12
25 . 0
+ =
i
D
(1.69)
= 2.003 m m 3 ~

Approximate weight, g H D W
L v i Approx

t
4
= (1.70)
Where
D
i
= Internal diameter
H
v
L
= Density water,992.8 kg/m
3
g = Gravitational accelaration, 9.81 m/s

( ) ( )( )( ) 81 . 9 8 8 . 992 2
4
2
t
=
Approx
W

kN N W
Approx
39 . 122 122388 = =

Therefore, total weight of the vessel under operating condition
approx vessel total total
W W W Weight Total + = ,
(1.71)
kN N W
total
12 . 462 462120 122390 339730 = = + =

Test the skirt thickness if the skirt thickness is same as vessel wall thickness.

1.7.10.1 Bending Moment at Base of the Skirt
( ) ( ) 2 /
2
s v w s
H H F M + = (1.72)

1-36

Where
M
s
= Bending moment at base of the skirt
F
w
= Loading per linear meter
H
v
H
s
= Skirt height

( ) ( ) 2 3 8 8 . 2787
2
+ =
s
M
m kN M
m N M
s
s
/ 67 . 168
/ 9 . 168661
=
=

1.7.10.2 Bending Stress of Skirt

( )
s s s s
s
skirt b
D t t D
M
+
=
t
o
4
(1.73)

Where
D
s
= Inside diameter of the skirt at the base
t
s
= Skirt thickness

( )
( )( )( )
2
3
/ 81 . 3
14 2000 14 2000
10 32 . 168664 4
mm N
skirt b
skirt b
=
+

=
o
t
o

1.7.11 Base Ring and Anchor Bolts
A variety of base ring design is used with skirt support to make the wind load and
other lateral loads do not overturn the vessel. The simplest types suitable for small
vessels are the rolled angle and plain flange rings. Scheiman gives the following
guide rules which can be used for the selection of the anchor bolts.
1. Bolts smaller than 25 mm (1 in.) diameter should not be used.
2. Minimum number of bolts 8.
3. Use multiples of 4 bolts.
4. Bolt pitch should not be less than 600 mm (2 ft).
From previous calculation
Approximate pitch circle mm t t D D
insulation i Approx
2178 ) ( 2 = + + =
(1.74)

(Sources:Coulson & Richardsons, 1999)
1-37

By following Scheiman rules for selection of anchor bolts, number of bolt required, at
minimum recommended bolt spacing determine by

bolts
D
required bolts of Number
Approx
12 4 . 11
600
) 2178 (
600
~ = = =
t
t
(1.75)
Closet multiple of 4 = 12 bolts
Bolt design stress for design value is 125 N/mm
2

At W
opert
= 462.12 kN and the anchor bolts is calculated using below formula.

(
= W
D
M
f N
A
b
s
b b
b
4 1
(1.76)
Where
A
b
= Area of one bolt at the root of the thread
N
b
= Number of bolts
f
b
= Maximum allowable bolt stress, 125 N/mm
2
D
b
= Bolt circle diameter
W = Weight of the vessel
(
= W
D
M
f N
A
b
s
b b
b
4 1

(
= 339730
2178
) 2 . 168662771 ( 4
) 125 12 (
1
x
A
b

2
3219 . 85 mm A
b
=

1.7.11.1 Bolt root diameter

mm
A
b
4228 .. 10
) 3219 . 85 ( 4 4
= = =
t t
(1.77)

As area of one bolt at the root of the thread is 85.3219
2
mm from Figure A.4
(Appendix A) bolt size use is M24 bolts (BS 4190: 1967) .

1-38

1.7.11.2 Total Compressive Load on the Base Ring
(
(
+ =
s
s
s
b
D
W
D
M
F
t
t
2
4
(1.78)
Where
F
b
= Compressive load on the base ring per unit length
D
s
= Skirt diameter

( )
( )
( )
m kN F
F
b
b
/ 76 . 107
2
339730
2
77 . 168662 4
2
=
(
+ =
t
t

1.7.11.3 Bearing Ring Width
Bearing pressure range is 5 . 3 to
2
/ 7 mm N (Coulson & Richardsons, 1999).
Therefore take the bearing pressure as
2
/ 5 mm N

3
10
1
=
b
b
b
f
F
L
(1.79)
Where
L
b
= Base ring width
F
b
= Compressive load on the base ring per unit length
f
b
= Maximum allowable bolt stress, 125 N/mm
2

mm L
L
b
b
55 . 21
10 5
10 76 . 107
3
3
=

=

Therefore, the actual width (all the characteristic find at Appendix A (Table A.5
Anchor Bolt Chair Design) bolt size use is M24 bolts (BS 4190: 1967)
mm
t L
s s
128
50 14 64
50
=
+ + =
+ + =
(1.80)

Actual bearing pressure on concrete foundation
84 . 0
10 128
10 76 . 107
3
3
'
=
=
c
f N/mm
2
(1.81)
1-39

1.7.11.4 Ring Thickness
Therefore, ring thickness is
140
3
'
c
r b
f
L t =
(1.82) ( )
( )
mm t
b
58 . 8
140
84 . 0 . 0 3
64 = =

Round off to = 10 mm

1.7.12 Piping Selection, Flanges and Manholes
The capital cost of a pipe run increases with diameter, whereas the pumping costs
decrease with increasing diameter. The most economical pipe diameter will be the
one which gives the lowest annual operating cost. Therefore piping selection is
important. By using the Institution of Chemical Engineers, IChemE (1987) equation
updates in mid-1992 and modification from Fanning pressure drop equation give the
equation of optimum diameter (Coulson & Richardsons, 1999). In the fixed bed
reactor which going through hydroformylation process, there are only one pipe of
inlet and one pipe of outlet. This is because no product in the liquid phase formed
from the reaction. Three different reactant will mix and feed to the reactor using one
pipe only.
For stainless steel, the pipe sizing can determine by using following formula
d
optimum
= 260 G
0.52

-0.37
(1.83)

where
d = optimum diameter of the pipe, mm
G = flow rate of fluid in the pipe, kg/s
= density of fluid, kg/m
3

At stream 7a(Feed stream)
G = 104 745.0874 kg/h
= 5.259 kg/m
3
d
optimum
= 260 (29.1)
0.52
(5.259)
-0.37

d
optimum
= 811 mm

1-40

At stream 7(Outlet stream)
G = 104 744.82456 kg/h
= 5.081 kg/m
3
d
optimum
= 260 (29.1)
0.52
(5.081)
-0.37

d
optimum
= 822 mm

At stream 7b(Inlet stream of cooling water)
G = 122.6 kg/s
= 992.8 kg/m
3
d
optimum
= 260 (122.6)
0.52
(992.8)
-0.37

d
optimum
= 247 mm

For the flanges, there several types of flanges that can be used for various
applications which are:

1. Welding neck flanges
2. Slip on flanges, hub and plate types
3. Lap- joint flanges
4. Screwed flanges
5. Blank/ blind flanges

In this design, the flanges measurement is taken at the standard flanges (BS 4504)
that based on the nominal pressure and outer diameter of pipe. The measurement
of the flanges can be referring at the Appendix A (Table A.6 Standard Flanges (BS
4504). Summarization of the dimension is shown on the table below. Meanwhile for
the manholes, the standard size is applied which is 800 mm. Manholes is important
for maintenance purposes.

Figure 1.5 Dimensions in flanges
1-41

Table 1.17 Summaries of Flanges Dimensions
Nominal size 800
Pipe o-d (d
1
) 812.8
Flange
D 975
b 24
h
1
70
Raised face
d
4
880
f 5
Bolting M27
Drilling
No 24
d
2
30
k 920
d
3
842
h
2
16
r 12

1-42

Table 1.18 Summary of Mechanical Design

Types Packed Column
Design Pressure 1100 N/mm
2
Plate
Material Stainless Steel 304
Tensile Strength 510 N/mm
2
Design Stress 145 N/mm
2

Cylindrical Section 12 mm
Column Weight
Mean Diameter 2.014 m
Dead Weight 74.795 kN
Weight of Insulation 4.807 kN
Weight of Tubes 188.54 kN
Weight of Catalyst 71.59 kN
Total weight 339.73 kN
Wind Loading
Mean Diameter 2.178 m
Loading 2.78 kN/m
Vessel Support
Straight cylindrical Skirt 90
o
C
Material Stainless Steel
2

Skirt Height 3 m
1-43

Total Weight 462.12 kN
Wind Loading 2.1478 kN
Bending Moment 168.67 kN
Thickness 18 mm
Anchor bolts
Bolts 12 bolts
2

Area 85.3219 mm
2

Bolts Root Diameter 10.4228 mm
2

Types M24 bolts(BS 4190:1967)
Piping Sizing
Gas in 811 mm
Gas out 822 mm
Cooling system 247 mm
Flanges Steel welding neck flanges (BS
4504)
Manholes 800 mm

1-44

REFERENCES

Sinnott, R. K., Coulson & Richardson, 1999 Chemical Engineering Volume 6,
Chemical Engineering Design, Butterworth Heinemann,. pg (634-686)

Smith J.M.1981. Chemical Engineering Series, Chemical Engineering Kinetics 3
rd

Edition, Mc Graw Hill, Singapore.

Froment J.F and Kenneth B.B. 1990.Chemical Reactor Analysis and Design 2
nd

Edition, Wiley Series, United States of America.

Levenspiel Octave.1972.Chemical Reaction Engineering 2
nd
Edition, John Wiley
and Sons, United States of America.

U.S. Pat. 20070053807 (8 March 2007). Boer A, Maria F.J, Schrauwen to Shell Oil
Company.

U.S. Pat. 7,005,456 (28 Feb 2006). Josephus J.H to BP Exploration Operating
Company Limited.

U.S Pat 7,588,739 (15 Sept 2009). Sugiyama.M, Ando.Y and Taniguchi.Y to
Mitsubishi Company Limited.

U.S Pat 7,771,674 (10 Aug 2010). Suzura.T, Mori.Y, Tanaka.T amd Abe.T to
Sumimoto Chemical Company Limited.

U.S Pat 7,705,060 (27 Apr 2010). Hoek.A and Kueh.P to Shell Oil Company.

U.S Pat 7,851,221 (14 Dec 2010). Garton R.D, Woods D.G, Korstem H.G,
Ossterrieth P.J and McClaine.B to Exxon Mobil Chemical.

Journal of Catalyst (9 Dec 1976). Arai.H to University of Tokyo.

1-45

http://www.bioweb.sungrant.org viewed on 10 Jan 2011

http://www.psenterprise.com viewed on 10 Jan 2011
Heat Exchanger, http://www.wikipedia.org viewed on 10 Jan 2011

Heat Exchanger-Tube Pitch, http://www.process_facility.com viewed on 10 Jan
2011

Density of Water, http://www.simetric.co.uk viewed on 12 March 2011

Viscosity of Water, http://www.engineering.toolbox.com viewed on 12 March 2011

1-46

APPENDIX A

1-47

Figure A.1 Temperature Correction Factor: One Shell Pass; Two Or More Even
Tube Passes, Source Coulson & Richardsons, Chemical Engineering, Volume 6

1-48

Figure A.2 Tube Side Friction Factor , Source Coulson & Richardsons, Chemical
Engineering, Volume 6

Figure A-3 Shell Bundle Clearance, Source Coulson & Richardsons, Chemical

1-49

Figure A-4 Shell Side Friction Factors, Segmental Baffles, Source Coulson &
Richardsons, Chemical Engineering, Volume 6

Table A.1 Standard Dimension For Steel Tubes, Source Coulson & Richardsons,
Chemical Engineering, Volume 6

1-50

Table A.2 Constant Value, Source Coulson & Richardsons, Chemical Engineering,
Volume 6

Table A.3 Typical Design Stress for Plate, Source Coulson & Richardsons,
Chemical Engineering, Volume 6

Table A.4 Density of Insulating Material, Source Coulson & Richardsons, Chemical

1-51

Table A.5 Anchor Bolt Chair Design, Source Coulson & Richardsons, Chemical

1-52

Table A.6 Standard Flanges ( BS 4504), Source Coulson & Richardsons, Chemical

Chapter 1 - First Reactor

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Chapter 1 - First Reactor

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Production of n-propanol Chapter I

is neglected and equation becomes

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