CHAPTER 4:

MTBE REACTOR

CONTENTS

TITLE
CHAPTER 4

PAGE

MTBE REACTOR
4.1 CHEMICAL ENGINEERING DESIGN
OF REACTOR
4.1.1Catalyst

97
98

4.1.2 Tube side

103

4.1.3 Shell

105

4.1.4 Condition Calculation

106

4.2 MECHANICAL DESIGN OF REACTOR 112

4.2.1 Design Consideration

112

4.2.2 The Design of Thin Walled Vessels

Under Internal Pressure

113

4.2.3 Design of Vessels Subject to

Combined Loading

116

4.2.4 Vessel Support

121

4.2.5 Base Ring and Anchor Bolt Design

124

4.2.6 Bolt Flanged Joint

127

4.2.7 Pipe Sizing

129

4.2.8 Compensation for Opening and

Branch Connections

130

CHAPTER 4

MTBE REACTOR

4.1

CHEMICAL ENGINEERING DESIGN OF REACTOR

The major equipment in the MTBE process plant is reactor, where the conversion of

reactant to products takes place. The reactor use is fixed bed reactor which operates
isothermally. The fixed bed reactor consists of a number of tubes packed with catalyst
particles and operated at vertical position. The condition of the reactor is plug flow reactor
where the reactants flow through the tube without back mixing with concentration changing
down the tube as a result of the reaction.
The amount of catalyst required can be determined by calculating the rate of
reaction. The catalyst effectiveness factor must be taken into account in overall rate constant
calculation because the intra- particle diffusion has a great effect on the rate of reaction.

Feed

Cooling
Water Outlet

Cooling
water inlet
Product

Figure 4.1: Fixed Bed Reactor

4.1.1

Catalyst
The catalyst used for this process is sulfonic ion resin which is having 16000 hours

operating life, longer life compared to other catalyst.

Catalyst properties:
Diameter of catalyst (dp) = 0.04 mm
Bulk density (b) = 700 kg/ m3
Surface area (Sa) = 100 m2/ g
Total voidage (b) = 0.54
Void fraction (p) = 0.32
Pore volume (V) = 4.7 x 10-7 m3/ g
Specific surface area (O) = 0.020 m2/ g
4.1.1.1 Particle solid density
From Perrys:

b
1
700 kg / m3
1 0.32

= 1029 kg/ m3
4.1.1.2 Pore radius of catalyst
Brunauer -Emmet-Teller (BET) showed that the pore radius is related to the specific
surface area, O perunit mass to the pore volume, V by the equation below: ( G.H Osborn,
1961)

r = 2.7

V
O

= 6.35 x 10 -5 m
4.1.1.3 Effective Diffusivity
Knudsen diffusion

Dk =

8r
3

RT
2M

= 4.68 cm2/ s

4.1.1.4 Thiele Modulus

From Levenspiel, Thiele Modulus for sphere is given by: (Octave Levenspiel, 1999)
= 1.1
4.1.1.5 Effectiveness factor,
From Perrys:

3
2

1
tanh

= 0.93
4.1.1.6 Reaction Rate
For a reversible first order reaction on exothermic conditions, the rate of reaction for
the suphonic cation exchange resin catalyst is:
CH3OH + CH3C(CH3)CH2
A

(CH3)3CH2COCH3
C

-rB = k1CB k2Cc

A1 = 6.5 x 105

R = 8.314 J/ mol.K

A2 = 1.36 x 108

Tin = 65oC = 338 K

E1 = 4.74 x 104

Tout = 200oC = 473 K

E2 = 7.04 x 104

Pin = 2 bar
Pout = 10 bar
K1 = A1 e(-E1/ RT)
= 3.07 x 10-2 hr-1
K2 = A1 e(-E2/ RT)
= 2.285 hr-1
By using ideal gas law for isobutylene :

CBO =

PBO
RT

= 71.17 mol/m3

Density (kg/m3)
600
791.5
998.2
312

Component
C4H8
CH3OH
H2O
PO

Input flowrate = 61335.1630 kg/hr

Volume of mixture = 93.20 m3/hr

Density of mixture =

M
V
61335.1630kg / hr
93.20m3 / hr

= 658.10 kg/m3

CCO =

F
V

F = mole flowrate of the feed

V = volume of the feed

CCO =

1401.2048
93.20

= 15.03 mol/m3

M=

CCO
CBO

= 0.211
-rB = k1CB k2Cc
= k1(CBO CBOXB) k2(MCBO + CBOXB)
= -196.77

Volume flowrate (m3/hr)

64.75
28.04
0.23
0.18

4.1.1.7 Weight of catalyst

x

W
dx

F o rB
W = weight of catalyst needed
F = molar flowrate of the feed
X = conversion of reactant
x

dx
r
0 B

W F

1401.2048
0.999
196.77

= 7.11 m3

= 7.11 m3 x 700 kg/ m3

= 4977 kg

4.1.1.6 Pressure Drop

For gas-liquid reaction at high pressure, the change in pressure may effects the
global rate significantly. Also, the pressure drop is needed for designing pumping equipment
which usually estimates the economic structure of a reactor system. For packed bed, the
pressure drop may be estimated from the Ergun equation as below:

dP
L

fu 2
d' p

Where:
f = friction factor

1.75

1501 b

Re

1 b

3
b

u = superficial linear velocity

= density of fluid
L = depth of the bed
dp = effective particle diameter = 5 x 10-4 m
i.

Superficial linear velocity

L = 4.88 m
D = 2.0 m

Q
A

U=

93.20 m3 / hr
2 m 4.88 m
4

= 3.377 x 10-3 m/s

ii.

Reynolds number

Re =

ud

= 658.10 (3.377 x 10-3) (5x10-4)

1.89 x 10-3
= 0.59
iii.

Friction factor

1.75

1501 b

Re

f=

1.75

1 b

3
b

1501 0.54

0.59

f=

1 0.54

0.54 3
b

f = 346.76
iv.

Pressure drop

dP
L

fu 2
d' p

= 346.76 (3.377 x 10-3)2 (658.10)

5 x 10-4
= 5204.90 N/m3
4.1.1.9 Height of the bed
The preferred lengths of the tubes length are 6 ft, 8 ft, 12 ft, 16 ft, 20 ft and 24 ft
( Coulson and Richardson,1999). The height of the bed is taken as 16 ft (4.88m). The height

of the bed is selected to suit the criteria that the optimum value of pressure drop is between
5 to 15% of the total pressure.

dP)
Pressure drop (-

= 5204.90 N/m3x 4.88m

= 25399.95 N/m2

4.1.1.10 Volume of catalyst bed

W
p
Vp =

4977 kg
1029kg / m3
=
= 4.84 m3

4.1.2

Tube Side

4.1.2.1 Total cross section of the tube

= volume of catalyst bed
Height of the bed
= 4.84 m3
4.88 m
= 0.99 m2
4.1.2.2 Tube diameter (O.D)
The standard dimensions for steel tube diameter is in the range of 16 mm to 50 mm.
The smaller diameters (16 mm to 25 mm) are preferred for most duties. Larger tubes are
easier to clean by mechanical methods and would be selected for heavily fouling fluids.
Therefore the tube diameter of 50 mm is choose as they will give more compact and
therefore cheaper.
4.1.2.3 Wall thickness
A 2.0 mm of wall thickness is the standard wall thickness for 50 mm tube diameter
that are given in BS 3274 used in this reactor.
4.1.2.4 Inside diameter
DI = 50 mm 2(2.0mm)

= 0.046 m
4.1.2.5 Total number of tube

cross section of one tube =

D 2 I
4
3.142 0.046
4

= 1.66 x 10-3 m2
nt = Total cross section of tube
cross section of one tube

0.99m 2
1.66 x10 3

= 596 tubes
4.1.2.6 Tube arrangements
The tubes are usually arranged in an equilateral triangular, square or rotated square
pattern. Since this process required high heat transfer to maintain isothermal condition in the
reactor, the triangular arrangement is recommended. (Please refer APPENDIX D10)
4.1.2.7 Tube pitch
The recommended tube pitch (distance between tube centre) is 1.25 times the tube
outside diameter.
Pt = 1.25 x O.D
= 0.0625 m
4.1.2.8 Tube side passes
Since the inlet flow rate is very high, this exchanger is build with one tube passes.
4.1.2.9 Bundle diameter
The bundle diameter will depend not only on the number of tubes but also the
number of the tubes passes. For triangular patterns;

N
Db d o t
k1

1
n1

where :
Nt = number of tubes
Db = bundle diameter
Do = tube outside diameter

596
Db 0.05

0.319

1
2.142

= 1.68 m

4.1.2.10 Holding time

Vtube =

x0.0462 x 4.88

= 8.11 x 10-3 m3
Voutlet = 83.77 m3/hr

th =

8.11x103
83.77

= 0.35 s
4.1.3

Shell

4.1.3.1 Shell types

A single shell pass type is used
4.1.3.2 Shell diameter
The shell diameter must be selected to give as close as fit to the tube bundle as in
practical to reduce bypassing round the outside of the bundle. The clearance required
between the outermost tubes in the bundle and the shell inside diameter will depend on the
type of exchanger and manufacturing tolerances. The split ring floating head type is used in
this reactor.
From figure 12.10 (Coulson & Richardson vol.6);(Please refer APPENDIX D7)
Ds Db = 100 mm
= 100 mm + 1680 mm
= 1.780 m

4.1.3.3 Baffles
Baffles are used in the shell to increase the fluid velocity and to improve the rate of
the heat transfer. 25% baffles cut is used for this shell.
4.1.3.4 Baffle spacing
The baffle spacing used range from 0.2 to 1.0 shell diameters. The optimum spacing
usually between 0.3 to 0.5 times the shell diameter.
Bs = 0.4 x 1.780 m
= 0.712 m
4.1.3.5 Number of baffles

L
Nb 1
Bs

4.88
Nb 1
0.712
Nb = 6 baffles
4.1.3.6 Cross flow area

Pt OD

x Ds x Bs
Pt

As =

62.5 50
6

x 1780 x 712 x10

62.5

= 0.2535 m2
4.1.3.7 Volume of reactor

VR =

Ds
4

x bed height

= 12.15 m3
4.1.4

Condition Calculation

4.1.4.1 Tube side

Feed = 61335.1630 kg/hr
Outside diameter = 0.050 m
Inside diameter = 0.046 m
Pitch = 0.0625 m
Length = 4.88 m
Number of tubes = 596
Passes = 1
Cross section of one tube = 0.00166 m2
Total cross section = 0.99 m2

4.1.4.1.1

Heat transfer coefficient in tube side

Gmax =

M
Amin

Where;
Gmax = maximum mass flowrate
M = total mass flowrate
Amin = total minimum free flow area
Gmax = 61335.1630 kg/hr
0.99 m2
= 61954.7101 kg/hr
= 17.21 kg/s

Re =

DGmax

Where;
D = outside diameter
= average viscosity

Re =

0.05017.21
1.89 x10 3

= 455.29
L/D = 4.88 m / 0.046m
= 106.09
From figure 12.23 (Coulson & Richardson vol.6);
Heat transfer factor, jh = 8 x 10-3 (Please refer APPENDIX D1)

hi d i

jh Re Pr 0.33
kf

0.14

= w
Neglect

Cp
kf
Pr =

= 84.45

L
4.88

d i 0.046
= 106.09

hi

kf
di

x jh Re Pr 0.33

0.21989
0.33
x 8 x10 3 455.29 84.45
0.046

= 75.267 W/m2.K
4.1.4.1.2

Correction for tube heat transfer coefficient

The heat transfer coefficient that calculated is based on the inside diameter. In order
to obtain heat transfer coefficient that based on outside diameter, correction is;

hc

hi Di
Do

41.39 x 0.046
0.050

= 69.247 W/m2.K
4.1.4.1.3

Tube side pressure drop

From figure 12.24 for Re=3154,

Jf = 1.8 x10-1 (Please refer APPENDIX D2)

P = 8jf

L ut 2

d
i 2

= 33.981 N/m2
4.1.4.2 Shell side
Flow area = 0.2535 m2
Inside diameter = 1.780 m
Baffle spacing = 0.712 m

4.1.4.2.1

Shell side heat transfer coefficient

Shell side mass velocity, Gs

= Ws
As
Ws = fluid flowrate on the shell side
Gs = 61335.1630 kg/hr
0.2535 m2
= 67.209 kg/m2.s
4.1.4.2.2

Shell side equivalent diameter

For an equilateral triangular pitch arrangements,

De =

2
P
1 d
4 t x 0.87 Pt o
2 4
2
d o
2

= 0.037 m

4.1.4.2.3

Reynolds Number

Gs de

Re =

67.209 0.037
1.89 x10 3

= 2045
4.1.4.2.4

Heat transfer factor

From figure 12.29 (Coulson & Richardson vol. 6)

Jh = 1.5 x 10-1 (Please refer APPENDIX D3)

4.1.4.2.5

Heat transfer coefficient

hs d e

jh Re Pr 3
kf

w
1

Neglect

0.14

hs

kf
de

x jn Re Pr

1
3

1
0.21989
x 1.5 x10 1 1315.73 84.45 3
0.037

= 5145.90 W/m2.K
4.1.4.2.6

Overall heat transfer coefficient

The overall heat transfer coefficient can be determined from Fourier equation. By
neglecting the wall effect, the equation is;

U0

U0

hi o ho
hi o hi

75.267 5145.90
75.267 5145.90

= 74.182 W/m2.K
4.1.4.2.7

Friction factor

From figure 12.30 (Coulson & Richardson vol.6)

Jf = 7.0 x 10-2 (Please refer APPENDIX D4)
4.1.4.2.8

Pressure drop

Ps = 8jf

Neglect

Ds

de

L u s 2

Bs 2 w

0.14

Ps = 8 (7.0 x 10-2)

1.780 4.88 658.10 0.054

2
0.037 0.712

Ps = 632.139 N/m2

4.1.4.2.9

Total heat transfer area

A = DoLNt
= (4.88)(596)(0.05)
= 456.922 m2

4.1.4.2.10

Design overall coefficient

Let dirt factor,Rd = 0.001

1
1

Rd
Ud Uo

1
0.001
74.182

Ud = 69.059 W/m2.K
Overall heat transfer,
Q = UdATm

Log Mean Temperature Different (LMTD)

22598.17 J / s
69.059 W / m 2 K x 456.922 m 2
Tm =
= 716.16 K
TLMTD = To - TL
ln(To / TL)
By trial and error, outlet temperature of cooling water = 155 oC
4.1.4.2.11 Reactors cooling system
Cooling water is flow outside the reactor tubes where the reaction took place. This is to
maintain a constant operating temperature and to prevent any excessive heating happen.
Mass of cooling water enter,
mfCp(T1 T2) = mcCp(t2 t1) = Q
mc = 39.673 kg/s

4.2

MECHANICAL DESIGN OF REACTOR

4.2.1

Design Consideration

4.2.1.1 Design pressure

For vessels under internal pressure, the design pressure is normally taken as the
pressure at which the relief device is set. This will normally be 5 to 10 percent above the
normal working pressure, to avoid spurious operation during minor process upsets. The
design pressure is taken as 10% above the operating pressure.
PD = (PI -Po ) x 1.1

= (10-1 ) x 1.1
= 9.9 bar
4.2.1.2 Design temperature
The maximum allowable design stress is depended on the temperature of material
because the strength of metals decreases with increasing temperature. The design
temperature at which the design stress is evaluated is taken as the maximum working
temperature of the material, that is T = 200 oC
4.2.1.3 Material
A suitable material must take into account the suitability of material for fabrication as
well as the compatibility of the material with the process environment since the maximum
working temperature at this reactor is
200 oC because it will oxidize rapidly at high temperature. Stainless steel is recommended in
construction of vessel tubes and shell.
4.2.1.4 Design stress (nominal design strength)
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
without failure under standard test conditions. By using stainless, the design stress is given
as 115 N/mm2 (Please refer APPENDIX D5)

4.2.1.5 Welded joint efficiency

The strength of a welded joint will depend on the type of joint and the quality of the
welding. For reactor, the joint factor is taken as 1.0 which implies that the joint is equally as
strong as the virgin plate. This highest category, requires 100% non destructive testing
welds.
4.2.1.6 Corrosion allowance
The corrosion allowance is the additional thickness of metal added to allow for
material lost by corrosion and erosion. For carbon and low- alloy steels, where severe
corrosion is not expected, a minimum corrosion allowance of 2.0 mm is used since the
influent and effluent gas of the reactor is not corrosive.

4.2.2

The Design of Thin Walled Vessels Under Internal Pressure

4.2.2.1 Cylinders shell minimum practical wall thickness

A minimum wall thickness is required to ensure that any vessel is sufficiently rigid to
withstand its own weight, and any incidental loads. For a cylindrical shell the minimum
thickness required to resist internal pressure can be determined from equation below:

Pi Di
4 Jf 1.2 Pi

where:
e = minimum wall thickness, m
Pi = internal pressure, N/mm2
f = design stress, N/mm2
J = joint efficiency
Di = internal diameter of shell, mm
e=

1 N/mm2 (1780mm)
2 (115 N/mm2)-1N/mm2

= 7.773 mm
By adding corrosion allowance of 2 mm,

9.773 mm

4.2.2.2 Heads and closure

The ends of a cylindrical vessel are closed by heads of various shapes. The
commonly types used are:
i.

Domed heads
a. Hemispherical heads
b. Ellipsoidal heads
c. Torispherical heads

ii.

Flat heads

Design equations and charts for the various types of domed heads are given in the
codes and standards and values for design constant C p and the nominal plate diameter D e of

flat end closures are given in the design codes and standards for various arrangements of
flat end closures. The selection of head depends on the thickness required for the head
which contributed to cost.
a) Torispherical heads.
The minimum thickness of head can be calculated from equation below:

Pi Rc Cs
2 fJ Pi Cs 0.2

where :
Cs = stress concentration factor for torispherical
heads

1
3
4

Rc
Rk

Rc = crown radius = shell outside diameter

Rk = Knuckle radius
Where Rc / Rk should not be less than 0.06 and to avoid buckling; crown
radius Rc should not be greater than diameter of the cylinder section.
For formed head (no joints in the head), the joint factor J is taken as 1.0.
Rc = 1.78 m
Rk = 0.06 Rc
= 0.1068 m

Cs

1
Rc
3

4
Rk

= 1.771 m
Add corrosion allowance of 2 mm

1.773 m

b) Ellipsoidal heads with major and minor axis ratio of 2:1. The minimum
thickness required can be determined by equation below:

e
e=

Pi Di
2 Jf 0.2 Pi
1 N/mm2 (1780mm)
2 (115 N/mm2)-0.2(1N/mm2)

= 7.746 mm
Add corrosion allowance of 2 mm
e = 9.746 mm
c)

Flat heads
The minimum thickness required is given by equation below:

e C p De

Pi
f

Where Cp = a design constant, dependent on the edge

constraint
De = nominal plate diameter
f = design stress
For bolted cover with a full face gasket (to avoid leakage) take Cp = 0.4 and
De equal to the bolt circle diameter, take as approximately 1.7 m

e 0 .4 x 1 .7 x

10 x 10 5
1.15 x 10 8

= 0.063 m
Add corrosion allowance of 2 mm;

= 65 mm

This shows the inefficiency of flat head. It would be better to use a flanged
domed head.

4.2.3

Design of Vessels Subject To Combined Loading

Pressure vessels are subjected to other loads in addition to pressure and must be

designed to withstand the worst combination of loading without failure. A trial thickness must
be assumed (based on that calculated for pressure alone) and the resultant stress from all
loads to ensure that the maximum allowable stress intensity is not exceeded at any point.

The main sources of load to consider are;

a. Pressure
b. Dead weight of vessel and contents
c. Wind
d. Earthquake
e. External loads imposed by piping and attached equipment.
4.2.3.1 Stresses Analysis
4.2.3.1.1

Stresses resulting from internal pressure

The longitudinal and circumferential stresses due to pressure are given by:

PDi
4t

= (1 N/mm2)(1780 mm)
4(9.773)
= 45.534 N/mm2

PDi
2t

= (1 N/mm2)(1780 mm)
2(9.773)
= 91.067 N/mm2
4.2.3.1.2

Dead weight stress

The major sources of dead weight loads are:

a. The vessel shell
b. The vessel fittings: manways, nozzles
c. Internal fittings; ladders,platforms,
piping.
4.2.3.1.2.1

Weight of cylindrical vessel

The approximate weight of a cylindrical vessel with domed ends, and uniform wall
thickness, can be estimated from the following equation:

Wv C v m Dm g H v 0.8Dm t x10 3

For a stainless steel vessel, the equation reduces to:

Wv 240C v Dm H v 0.8Dm t

where;
Wv = total weight of the shell, excluding internal
fittings
Cv = a factor to account for the weight of nozzles
manways, internal supports,etc, Cv is taken as
1.08 for vessel with only a few internal fittings.
Hv = Height between tangent lines
t = wall thickness
g = gravitational acceleration, 9.81m/s2
m = density of vessel material, kg/m3
Dm = mean diameter of vessel
= ( Di + t x10-3)
= (1.780 + 9.773 x 10-3)
= 1.790 m
Wv =240 (1.080)(1.790)(4.88 + 0.8(1.790))9.773
= 28.62 kN
4.2.3.1.2.2

Weight of tubes

From Perrys (Robert H. Perry,1997), the mass per length of steel tube is equal to
1.905 kg/m.
The weight of one tube = 1.905 x 4.88
= 9.2968 kg
Total weight of tubes = 596 x 9.2968
= 54.353 kN

4.2.3.1.2.3

Weight of insulation

For high operating temperature, mineral wool is normally used as insulator.

Density of mineral wool = 130 kg/m3
The thickness of insulator = 75 mm
Approximate volume of insulation; = DiHvt
Vi = (1.780)(4.88)(75 x 10-3)
= 2.047 m3
Weight of insulator = Vig

= 130 (2.04)(9.81)
= 2.61 kN
4.2.3.1.2.4

Weight of catalyst

Weight of catalyst, Wc = 48.824 kN

4.2.3.1.2.5

Total weight

Total weight, WT = Wv + Wt + Wi + Wc
= 134.408 kN
4.2.3.1.2.6

Calculation of dead weight stress

The dead weight stress can be calculated by equation below:

w
=

WT
Di t t
134.408
(1780 + 9.773)9.773

= 2.446 N/mm2
4.2.3.1.3

Bending stress

4.2.3.1.3.1

Wind loads

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.

Pw 0.07U w

where ; Pw = wind pressure, N/m2

Uw = wind speed, km/hr

Pw

= 0.07 (160)
= 1792 N/m2

The loading per unit length of the column can be obtained from the wind pressure by
multiplying by the effective column diameter

Fw Pw Deff

= 3494.40 N/mm2
where Fw = Loading per unit length
= Pwx(mean diameter including insulation)
Deff = Effecting column diameter, the outside
diameter plus allowance for the thermal
insulation.
= 1.780 + 2(9.773+75)x10-3
= 1.950 m
4.2.3.1.3.2

Bending moment

For a uniformly loaded cantilever, the bending moment at any plane is given by:

Mx

WX 2
2

= 3494.40 (4.88)2
2
= 41608.52 Nm
where X = distance measured from the free end (Hv)
W = Fw = load per unit length (N/m)

4.2.3.1.3.3

Calculation for bending stress

The bending stresses will be compressive or tensile, depending on location, and are
given by;

M x Di

Iv 2

= 0.106 N/mm2
where Iv = second moment of area of the vessel
about the place of bending

I v

4
4
Do Di
4

= 3.522 x 10 11 mm4

Do

Outside diameter of vessel

Di 2t

= 1780 + 2(9.7730
= 1799.55 mm
4.2.3.1.3.4

Principle stresses

The resultant longitudinal stress is :

z L w b
w
z
z

is compressive and therefore negative

(upwind) = 45.534 2.446 +0.106 =43.194 N/mm2
(downwind)= 45.534 -2.446 -0.106 =42.982N/mm2

As there is no torsional shear stress, the principal stresses will be z and h.

h = 43.406 N/mm2
The greatest principal stresses that acted on the vessel is 0.212N/mm 2 which is well below
the maximum allowable design stress.
4.2.3.1.3.5

Check Elastic Stability (Buckling)

A vessel design must be checked to ensure that the maximum value of resultant axial
stress (compressive) does not exceed the critical value at which buckling will occur. For steel
cylindrical vessels, the critical buckling stress is given by:

t
Do

c 2 x 10 4

= 2 x 10-4 (9.773/1780)
= 109.81 N/mm2
The maximum compressive stress will occur when the vessel is not under pressure.

Maximum compressive stress =

w b

= 2.552 N/mm2

which is well below the critical buckling stress and maximum allowable design stress.
4.2.4

Vessel Support
The method used to support a vessel will depend on size, shape and weight of the

vessel, the design temperature and pressure, the vessel location and arrangement: the
internal and external fittings and attachments.
Since the design reactor is a vertical vessel, a skirt support is recommended as it
does not impose concentrated loads on the vessel shell. Supports will impose localized
loads on the vessel wall, and the design must be checked to ensure that the resulting stress
concentrations are below the maximum allowable design stress.
4.2.4.1 Skirt supports
A skirt support consists of a cylindrical or conical shell welded to the base of vessel.
A flange at the bottom of the skirt transmits the load to the foundations. Openings must be
provided in the skirt for access and for any connecting pipes.
4.2.4.2 Skirt thickness
The skirt thickness must be sufficient to withstand the dead weight loads and bending
moments imposed on it by the vessel; it will not be under the vessel pressure.
4.2.4.3 Structure of skirt
The skirt is not required to withstand the pressure in the vessel and in the condition
of the fluid, then the selection of material is not limited to steels permitted by the pressure
vessel codes. A straight cylindrical skirt of plain carbon steel with design stress 105 N/mm 2 is
used.
4.2.4.4 Height of the skirt
The height of the skirt is taken as I m

4.2.4.5 Stresses analysis on skirt

The resultant stresses in the skirt will be:
s(tensile) = bs - ws
s(compressive) = bs + ws
where bs = bending stress in the skirt

4M s
Ds t s t s Ds

ws = the dead weight stress in the skirt

W
Ds t s t s

where Ms = maximum bending moment

W = total weight of the vessel and contents
Ds = inside diameter of skirt
ts = skirt thickness
The skirt thickness should be such that under the worst combination of wind and dead
weight loading the following design criteria not exceeded

s tensile f s J sin s
ts
Ds

s compressiv e 0.125 E

sin s

where fs = maximum allowable design stress for the skirt material,

normally taken at ambient temperature.
J = weld joint factor, if applicable
s= base angle of a conical skirt (80o to 90o)
4.2.4.6 Calculation of bending stress at the base of the skirt
Wind loading, Fw = 3494.40 N/m
Bending moment at base of skirt,
Ms = Fw x (Hv + Hs)2
= 3494.40 x (4.88 + 1)2
= 60408.39 Nm
Where Hv = Height of vessel
Hs = Height of skirt
4.2.4.7 Calculation of bending stress in the skirt
Weight of vessel = 134.408 kN

bs =

4M s
Ds t s t s Ds

bs =

4(60408.39 x 103)
(1780 + 18)18(1780)

= 1.335 N/mm2

ws =

W
Ds t s t s

ws = 134.408 x103
(1780 + 18)18
= 1.322 N/mm2

Maximum
Maximum

s compressiv e

s tensile

= 1.335 + 1.322 = 2.657 N/mm2

= 1.335 1.322 = 0.013 N/mm2

Take joint factor J as 0.85 because type of joint is double welded butt and requires less nondestructive testing but places some limitations on the materials which can be used and the
maximum plate thickness, and Youngs Modulus 200000N/mm2.
Criteria for design:

s tensile f s J sin

s tensile
s tensile

0.85(105) sin 90o

89.25N/mm2

ts
Ds

s compressiv e 0.125 E

s compressiv e
s compressiv e

sin

0.125 (200000)(18/1780)sin 90o

252.81 N/mm2

Both criteria are satisfied, add 2 mm for corrosion, gives a design thickness of 20 mm.
4.2.5

Base Ring and Anchor Bolt Design

The loads carried by the skirt are transmitted to the foundation slab by the skirt base
ring (bearing plate). The moment produced by the wind and other lateral loads will tend to
overturn the vessel: this will be opposed by the couple set up by the weight of the vessel and
the tensile load in the anchor bolts.
Since reactor is considered as small vessels, the simplest type rolled angle rings is
recommended.
Scheimans method can be used for preliminary design.
4.2.5.1 Calculation for area of bolt
The anchor bolts are assumed to share the overturning load equally, and the bolt
area required is given by:

Ab

4M s

N b f b Db

where Ab = area of one bolt at the root of the thread,mm2

Nb = number of bolts
fb = maximum allowable bolts stress, N/mm2 :
typical design value 125 N/mm2 (18,000 psi)
Ms = bending (overturning) moment at the base, Nm
W = weight of the vessel, N
Db = bolt circle diameter, m
Scheiman gives several guide rule for selecting the anchor bolts.
a. Bolts smaller than 25 mm (1 in) diameter should not be used.
b. Minimum number of bolts 8
c. Use multiples of 4 bolts.
d. Bolt pitch should not be less than 600 mm (2 ft)
Let the pitch circle diameter = 0.49 m
Circumference of bolt circle = 1540 mm
Number of bolts required, at minimum recommended bolt spacing
= 1540
600
= 2.57
Since the minimum number of bolts is 8, therefore 8 bolts are used.
Take bolts design stress =125 N/mm2

Ms = 60408.39 Nm
Take W= operating value = 134.408 kN

Ab

4M s

N b f b Db

Ab

1 4 60408.39

134.408 x10 3

8125
0.49

= 359 mm2
From BS 4190 : 1967, M24 bolts with root area of 353 can be used.
Bolt root diameter = (353 x 4/ )1/2
= 21.20 mm
4.2.5.2 Calculation for minimum thickness of base ring
The base ring must be sufficiently wide to distribute the load to the foundation. The
total compressive load on the base ring is given by:

4M s

Fb

Ds

Ds

4 60408.39

Fb

1.780

134.408 x10 3

1.780

= 48304.81 N/m
where Fb = the compressive load on the base ring, Newtons per
linear metre
Ds = skirt diameter, m
The minimum width of the base ring is given by:

Lb

Fb 1
x
f c 10 3

where Lb = base ring width, mm

fc = the maximum allowable bearing pressure on the
concrete foundation pad, which will depend on the mix
used, and will typically range from 3.5 to 7 N/mm2 (500 to
1000 psi)
Taking bearing pressure as 5 N/mm2

Lb

Fb 1
x
f c 10 3

= (48304.81/5) x (1/103)
= 9.66 mm
Actual width required = Lr + ts + 50 mm
= 64 + 18 + 50
= 132 mm
From M24 (BS 4190 : 1967), Lr = 64
Actual bearing pressure on concrete foundation:

f c

48304.81 / 132 x 103

= 0.366 N/mm2
The minimum thickness is given by:

t b Lr x 3 f c f r
where tb = Base ring thickness, mm
Lr = The distance from the edge of the skirt to the outer edge
of the ring, mm
fc = Actual bearing pressure on base , N/mm2
fr = Allowable design stress in the ring material, typically
140 N/mm2

t b Lr x 3 f c f r
= 64 ((3 x 0.366)/140)1/2
= 5.67 mm
4.2.6

Bolt Flanged Joint

Flanged joints are used for connecting pipes and instruments to vessels, for manhole

covers, and for removable vessel heads when ease of access is required. Flanges may also
be used on the vessel body, when it is necessary to divide the vessel into sections for
transport or maintenance.
4.2.6.1 Selection of Flange

Since the operating temperature of the reactor is to be considered high, welding

neck flanges are recommended which are suitable for extreme service conditions such as
high temperature. They will normally be specified for the connections and nozzles on
process vessels and process equipment. They have a long tapered hub between the flange
ring and the welded joint. This hub provides a more gradual transition from the flange ring
thickness to the pipe wall thickness, thereby decreasing the discontinuity stresses and
consequently increasing the strength of the tube flange.
4.2.6.2 Selection of Gaskets
Gaskets are used to make a leak-tight joint between two surfaces. It is impractical to
machine flanges to the degree of surface finish that would be required to make a satisfactory
seal under pressure without a gasket. Gaskets are made from semi-plastic materials; which
will deform and flow under load to fill the surface irregularities between the flange faces, yet
retain sufficient elasticity to take up the changes in the flange alignment that occur under
load. An Iron or soft steel is recommended for this vessel since they are normally used for
higher temperature.
4.2.6.3 Flange Faces
The raised face, narrow faced which is probably the most commonly used types of
flange are used for all the flanges.
4.2.6.4 Flange Design
The bolts hold the flange faces together, resisting the forces due to internal pressure
and gasket sealing pressure. As these forces offset, the flange is subject to a bending
moment. A flange assembly must be sized so as to have sufficient strength and rigidity to
resist this bending moment.

M op
The total moment

acting on the flange is given by:

M op H d hd H t ht H g hg
Hg
where

= gasket reaction (pressure force) =

Ht

G 2b mPi

= pressure force on the flange face =

= total pressure force =

Hd

H Hd

4 G 2 Pi

= pressure force on the area inside the flange

4 B 2 Pi

= mean diameter of the gasket

= inside diameter of the flange

2b
b

= effective gasket pressure width

= effective gasket sealing width

The minimum required bolt load under the operating condition is given by:

Wm1 H H g
The moment Matm is given by:

M atm Wm 2 hg
where Wmz is the bolt load required to seat the gasket, given by:

Wm 2 yGb
where y is the gasket seating pressure (stress)
The flange stresses are given by:
Longitudinal hub stress,hb = F1M
Radial flange stress, rd = F2M
Tangential flange stress,hb = F3M F4rd
Where M is taken as Mop or Matm, whichever is the greater.F1 and F4 are the flange
type and dimensions, are obtained from equations and graphs given in BS5500.
The design criteria of flange are:

hb 1.5 f fo
rd f fo
1 2 hb rd f fo
1 2 hb tg f fo
f fo
where

is the maximum allowable design stress for the flange material at the

operating conditions.
4.2.7

Pipe Sizing

The pipe diameter can be obtained from the following equation below:
Carbon steel pipe;
doptimum = 293 G0.53 -0.37
Stainless steel pipe;
doptimum = 260 G0.52 -0.37
where d = optimum diameter of the pipe, mm
G = flow rate of fluid in the pipe, kg/s
= density of fluid, kg/m3
Equation below can be used to calculate the thickness where the pipe diameter is
considerably large.

Pi Di
2 f Pi

where Di = optimum diameter of pipe.

4.2.7.1 Calculation of Pipe Diameter
i.

Feed Stream
Flow rate = 17.04 kg/s
Density of the stream = 658.10 kg/m3
Stainless steel is recommended for the construction of the pipe.
For stainless steel,
doptimum= 260(17.04)0.52(658.10)-0.37
= 104.06 mm

ii.

Inlet and Outlet Stream for Cooling Water

Stainless steel is recommended for the construction of this pipe
For stainless steel pipe,
doptimum = 260 (39.673)052(998.20)-0.37
= 136.92 mm

4.2.8

Compensation for Openings and Branch Connections

The presence of openings and branches weakens the shell and give rise to stress

concentrations. Sufficient reinforcement must be provided to compensate for the weakening

effect of the opening.

The equal area method is chosen because it is the simplest method used for
calculating the amount of reinforcement required and experience has proved it to be
satisfactory for a wide range of application.
I. Feed stream
From Perrys Handbook,
For d = 104.06 mm
Nominal pipe size = 127.00 mm
Outside diameter = 141.30 mm
Nominal wall thickness = 19.05 mm
Minimum thickness of branch , e1 = PiDi
(2f-Pi)
= 0.454 mm
The nominal pipe wall thickness is above minimum thickness of branch, so no
reinforcement of the branch is required.
II. Cooling Water Stream
For d = 136.92 mm
Nominal pipe size = 127.00 mm
Nominal wall thickness = 2.767
Minimum thickness of branch, e1 = 0.60 mm
The nominal pipe wall thickness is above the minimum thickness of branch, so
no reinforcement of the branch is required.
4.2.8.1 Manholes
The maximum length of manhole is dependent on the manhole diameter. The length
is perpendicular distance fro the face of the opening including lining or any projection of the
branch within the vessel.
Type of branch connection: flush nozzle
Inside diameter = 598.50 mm
Nominal size = 600 mm
Outside diameter = 609.60 mm
Nominal wall thickness = 5.54 mm
4.2.8.1.1

Compensation for manholes

Actual thickness
ta = (do di) / 2

= 5.55 mm
Minimum thickness
e1 = PiDi
(2f-Pi)
= 2.614 mm
Distance, N = 2.5 ta
= 13.875 mm
Length, S = di /2
= 299.25 mm
Area removed, X = edi
2
= (7.773)(598.5)
2
= 2326.07 mm2
Compensation area, Y = Nta Ne1 + Stc
= 40.737 +299.25tc
tc is the thickness for compensation
Area X = Area Y
2326.07 = 40.737 +299.25tc
tc = 7.637 mm

4.2.1.8.2

Flat end closure for manholes

Flat plates are used to blank off flange connections, and as covers for manholes and
inspection parts. Flat end closures are blind flanges, bolted cover with a full face gasket,
The thickness required will be depend on the degree of constraint at the plate
periphery. The minimum thickness required is given by:
e = CpDe(Pi/f)1/2
where Cp = design constant = 0.4
De = bolt circle diameter = 490 mm

f = design stress, 115 N/mm2

Minimum thickness for flat end closures, e = 18.277 mm
Add 2 mm for corrosion allowance, e = 20.277 mm

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Coulson and Richardson. 1999. Chemical Engineering Volume 6.

Butterworth Heinemann.
Coulson and Richardson. 1971,Chemical Engineering Volume 3.
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Massimo Morbidelli. 2001. Catalyst Design- Optimal Distribution of Catalyst
in Pellets reactors and membranes. Cambridge University Press.
Page 124-130.
M.J Slater. 1992. Ion Exchange Advances-Proceedings of IEXs. Elsevier
Science Publisher Limited.
G.H. Osborn. 1961. Synthetic Ion Exchange. London Chapman and Hall
Limited. Page 1-17.
Robert C. Reid. The Properties of Gases and Liquid. Fourth Edition.
McGraw Hill Inc..Page 433.
James M. Douglas. 1998. Conceptual Design of Chemical Process.
McGraw Hill International Editions. Page 329.
Michael Streat. 1988. Ion Exchange for Industry. Ellis Herwood Limited.
Page 585.
M. Necati Ozisik. 1985. Heat Transfer-A Basic Approach. McGraw Hill Book
Page 385-397

Company.

Octave Levenspiel. 1999. Chemical Reaction Engineering. John Wiley and

Sons. Page 367-509.
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McGraw Hill.