7.

3 DESIGN OF FIXED BED CATALYTIC REACTOR:

PROCESS DESIGN:
This is a vertical tube fixed bed catalytic reactor with catalyst packed inside the tubes and
coolant flowing in shell.
Reaction:
C6H5CH2CH3

C6H5CH=CH3 + H2

This is an endothermic reaction with reaction inlet temperature (RIT) = 6600C.

7.3.1 Catalyst:
UOP Hydrobon F 105 (93% Fe2O3, 4% G2O3, 2% KOH, 1% MoO3)
All % are weight %.
Density = 1440 kg/m3

Porosity ( ) = 0.3
7.3.2 Coolant:
Coolant is a mixture of two very stable compounds biphenyl (C12H10) and diphenyl (C12H10O).
These compounds have practically the same vapor pressure, so can easily be handled as single
compound.
Freezing point = 12oC
Atmosphere boiling point = 257oC
Average molecular weight = 166 g/mol
Colour = clear to light yellow
Liquid phase = 15oC - 257oC
Vapour phase = 257oC - 400oC
7.3.3 Feed:
Component

Flow rate (kg/hr)

Ethylbenzene

13638.225

Styrene

4296.975

Steam

52165

Total

70100.20

Production rate of styrene = 12559.68 kg/hr

Reaction inlet temperature = 6600C

Reaction outlet temperature = 6000C

Type of reactor: vertical tube reactor exchanger type in which catalyst is placed inside the tube.
Reaction is endothermic: It is carried out in adiabatic manner. Dowtherm A is to be circulated
in liquid form on shell side to maintain the adiabatic condition.
Heat of formation of styrene = 86.99*103 J/mol product.
The global rate was given as
1
r p=k p E p p H
K S

------------------- Equation (1)

Where PE = partial pressure of Ethylbenzene

PH = partial pressure of hydrogen
PS = partial pressure of styrene
The reactor is operated at mean pressure of 1.2 bar and temperature of 6600C.
Fractional conversion of Ethylbenzene = 0.65
At 6600C,
k = 6.6*10-6 kmol/kg catalyst.bar
K = 0.1 bar
Feed rate of Ethylbenzene = 13638.225/106*3600 = 0.035740 kmol/s
Let W= mass of the catalyst, kg
Xa
dXa
W
0 ra
FAo
For fixed bed,
=
------------------- Equation (2)
Where FAo = molar flow rate of reactant
XA = fractional conversion of reactant
-rA = rate of reaction
BASIS: I kmol Ethylbenzene entering at 1.2 bar
According to reaction,
C6H5CH2CH3
T = 0 moles
1
T = t moles
1-x

C6H5CH=CH3
0
x

H2
0
x

Moles of steam = 18 (steam to hydrocarbon ratio)

Total moles = 18 + 1 x + x + x = 19 + x
Component
Ethylbenzene
Styrene
Hydrogen
Steam
Thus equation (1) becomes

Mole fraction
(1 - x)/(19 + x)
x/(19 + x)
x/(19 + x)
18/(19 + x)

Partial Pressure
(1 - x)*P/(19 + x)
x*P/(19 + x)
x*P/(19 + x)
18*P/(19 + x)

 (1 x ) P
x 2.P 2
19 x (19 x) 2.K

-rA = k
Put P = 1.2 bar and K = 0.1 bar
(1 x) * 1.2 x 2 * 14.4
19 x (19 x)2

-rA = k
1.2k
1 x 19 x 12 x 2
19 x 2
=

1.2k
19 18x 13x2
19 x 2

------------------- Equation (3)

Using Equation (3) in (2),

W
FAo

0.65

0.65

dXa
ra

1
1.2k

19 x 2dx

1.2k 19 18 x 13 x 2

=
0.65

1
1.2 * 13k

1
15.6k
1
15.6k

0.65

361 x 2 38 x dx

0.65

361 x 2 38 x dx

1.462 1.385 x x2
0

1
1.2 * 13k

1
15.6k

361 x 2 38 x dx
131.462 1.385 x x 2

x 2 1.385 x 1.462
0

0.65

0.65

36.615 x 362.462
dx
x 0.7009 x 2.0859

139.273
102.658
dx

x 0.7009 x 2.0859

0.65

36.615 x 362.462
dx
x 2 1.385 x 1.462

1
15.6k

[x + 139.273*ln(x - 0.7009) 102.658*ln(x + 2.0859)]

1
392.441
15.6k
15.6k
=
[0.65 365.244 27.847] =
Putting k = 6.6*10-6 kmol/(kg catalyst bar s)
392.441
W
FAo
15.6 * 6.6 *10 - 6
=
FAo = 0.035740 kmol/s
W = 10477.94 kg

Volume of catalyst = W/ = 10477.94/1440 = 7.276 m3

Porosity ( ) = 0.3
V
1
Volume occupied by catalyst, VC =
= 10.395 m3
7.3.4 Tube Side Calculations:
Let the length of the tubes be taken as 24 ft.
Internal diameter, di = 46 mm
Outer diameter, dO = 50 mm

Volume of 1 tube = di2L/4 = 0.012157 m3

No. of tubes (Nt)= VC/Volume of 1 tube = 10.395/0.012157 = 856
Mole fractions of feed stream are:
Ethylbenzene = 0.1946
Styrene = 0.0613
Steam = 0.7441
Molecular weight of feed, MF = 0.1946*106 + 0.0613*104 + 0.7441*18
MF = 37.3078 kg/kmol
Mass flow rate of feed = 70100.2 kg/hr = 19.4723 kg/s
Mass velocity = Mass flow rate of feed/Area of tube = 11716.89 kg/m2.s
We know,
hi = 1.51(G)0.95/(di)0.42 = 1.51(11716.89)0.95/(46)0.42 = 2218.147 W/ m2.K
From heat of formation = 86.99*103 J/mol product
Moles of styrene formed = 12559.68*103/104*3600 = 33.546 mol/s

Q = HR * moles product formed/s = 86.99*103 * 33.546 = 2918.17 kW

7.3.5 Shell Side Calculations:

Since vapors are formed in large quantity, square pitch is used in tube sheets. They are easy to
clean as well as heavy end formation.
Pitch, Pt = 1.25*do = 1.25*50 = 62.5 mm
So K1 = 0.215, n1 = 2.207 (from table in Coulson & Richardson Volume 6)
Bundle Diameter, Db = do(Nt / K1)1/n1
1/2.207

Db = 50(856/0.215)
= 2139 mm = 2.139 m
From Fig 12.10 in Coulson & Richardson Volume 6 for pull through floating head type,
Ds - Db = 98 mm
Shell diameter, Ds = 2.237 m
Baffle diameter, lB = Ds/5 = 0.4474 m
No. = (6/ lB) + 1 = 14.0
Area of shell, AS = (Pt - do)DSlB/Pt = 0.2002 m2
Coolant inlet temperature = 25oC
Coolant outlet temperature = 255oC
Average temperature = 140oC
Cp of coolant at 140oC,
Cp = 1.814 + (1.954 - 1.814)*(140 - 105)/ (155 - 105) = 1.912 kJ/kg.K
Where Cp105oC = 1.814 kJ/kg.K, Cp155oC = 1.954 kJ/kg.K

Q = m*Cp* T

2918.17 = m*1.912*(255 25)

m = 6.636 kg/s
Mass velocity in shell, GS = m/AS = 6.636/0.2002 = 33.147 kg/m2.s
Viscosity at 140oC,

= 0.91 + (0.56 0.91)*(140 - 105)/(155 - 105) = 0.665 cP

Reynolds Number, NRe = GS de/ = 55.66*0.014201/0.186*10-3 = 4249.6

Equivalent diameter, de = 1.27(Pt2 0.765d02)/d0 = 0.0493 m
NRe = 33.147*0.0493/ (0.665*10-3) = 2457.36
From Fig 12.29 in Coulson & Richardson Volume 6, for baffle cut = 25 %,
Jh = 1.2*10-2
Thermal conductivity, K = 0.1251 + (0.1171 0.1251)*(140 - 105)/ (155 - 105)
K = 0.1195 W/m.K

Prandtl number, Pr = Cp /K = 10.64

Using equation, Nu = hSde/K = Jh*Re*Pr1/3
hS = 1.2*10-2*2457.36*10.641/3*0.1195/0.0493 = 1572.12 W/m2.K
Taking copper as material of construction, w at 140oC = 392 W/m.K
As neither fluid is heavily fouling, so from table in chapter 12, Coulson & Richardson Volume 6

hid = 5000 W/ m2
1
U

1
ho

1
hc

1
hd

1
hod

and hod = 5000 W/ m2

+ d0*ln

d o /d i
2w

d o /d i
2w

50 * 10 - 3
2 * 392

50

46

do
di

1
hid

do
di

1
hi
1
U

1
1572.12

1
hc

1
hd

1
5000

ln

do
di

50 * 1
46 * 5000

50 * 1
46 * 2218.147
UO = 645.654 W/m2

MECHANICAL DESIGN:
We choose a stainless steel vessel with welded joints which has an operating pressure range
of 5 atm (73.5 psi).
Data:
SU: Ultimate tensile strength = 55000 psi
Fm: Material factor = 1
FR: Radiographic factor = 1.12
FA: Stress relieving factor = 1.06
FS: % minimum tensile strength = 0.25
Working Stress S = SU*Fm*FR*FA*FS = 55000*1*1.12*1.06*0.25 = 16324 psi
7.3.6 Thickness of Shell:
Taking a single welded vee butt joint,
pDi
2 Se p
Thickness of shell, t =
+C
Where C: Corrosion Allowance = 1/16 in
Di: Inside diameter of shell = 2.237 m = 88.07 in
p: Maximum allowable pressure = 73.5 psi
S: Maximum allowable tensile stress = 16324 psi
e: Efficiency of joint = 0.7

73.5 * 88.07
1
2 * 16324 * 0.7 73.5 16
t=
+
= 0.347 in
tmin = (88.07+100)/1000 = 0.188 in
We use standard 5/16 in thick shell.
Outer diameter of shell = 88.49 in
7.3.7 Thickness of Tube:
Diameter of tubes = 50 mm = 1.969 in
pDi
73.5 * 1.969
1
2 Se p
2 * 16324 * 0.7 73.5 16
Thickness of tube, t =
+C=
+
= 0.069 in
tmin = (1.969+100)/1000 = 0.102 in
So we take t = 1/8 in (standard)
Outside diameter of tube = 2.094 in
7.3.8 Head Selection and Design:
For pressures ranging between 0-200 psi we use standard dished heads.

LW
2 Se

t=
L: crown radius = Di 6 = 88.07 6 = 82.07 in
k: knuckle radius = 0.06Di = 5 in
W: factor from ratio of knuckle radius to crown radius = 1.5
73.5 * 82.07 * 1.5
2 * 16324 * 0.7

t=
= 0.396 in
We use standard 5/12 in thickness.
Outside diameter = 88.49 in