CHAPTURE 01: INTRODUCTION

For biodiesel production process mass and energy balances were calculated along its process.
At start jatropha oil is introduced to esterification and concentrated sulfuric acid and
methanol are used as other raw materials. Material and energy balance was carried out for
esterification and then output from esterification is introduced to the transesterification.
Sodium hydroxide and methanol are used as raw materials for transesterification. The output
from transesterification is then neutralized by phosphoric acid in neutralization. After that in
decanter, glycerol is separated from fatty acid methyl esters (FAME). Then both streams are
introduced to separate distillation columns to recover methanol in liquid streams. The FAME
after methanol recovery is introduced to washing stage to remove soap and salts produced
along the process. After that FAME is subjected to evaporation process, to remove remaining
moisture in it to meet the ASTM standards.
Unit operations of the plant

Esterification
Transesterification
Neutralizing
Decantation
Distillation
Washing
Evaporation

1.1 PLANT OPERATION

Plant is operated 24 hours per day and 330 days per year. Required demand is 9188200 kg in
annually.
Demand for biodiesel per annum

9,188,200 kg

Number of operating days per annum

330

Daily production of biodiesel

27,843.03 kg

Number of working hours per day

24

Hourly production of biodiesel

1,160.13 kg
1.2 TRANSESTERIFICATION REACTOR OPERATION

Operating condition (Ebtisam et al, 2013)

Temperature =60C
Pressure

=Atmospheric pressure (1atm)

Assumptions

Transesterification occurs at Steady state (no accumulation) and there are no losses

There are three reactions inside the reactor.

Reaction of triglyceride in Jatropha oil with methanol to form fatty acid methyl esters

and glycerol.
Reaction of fatty acid with NaOH to form soap and water.
Reaction of H2SO4 with NaOH to form water and Na2SO4.

These three reactions occur inside the transestrification reactor. After the esterification unit,
the mixture is forward to the trasestrification reactor and also NaOH is delivered to the reactor
and NaOH is used as the catalyst to produce fatty acid methyl esters. The mass balance of the
transestrification unit is shown below.
INPUT/ (Kg/h)

OUTPUT/ (Kg/h)

FFA
Triglyceride

11.955
1017.35

FAME
Methanol
NaOH
H2SO4
Water

3
174.583
698.063
12.759
11.955
12.496

TOTAL

1939.16

Reactor
1 atm
60C
Reactor

FFA
Triglyceride
FAME
Methanol
NaOH
water
Na2SO4
Glycerol
Soap
TOTAL

0.239
23.399
1171.054
585
1.31
22.331
17.322
105.883
12.628
1939.166

Fig 1.1 Total mass balances for transesterification

CHAPTER 02: TRANSESTRIFICATION REACTOR DESIGN
Transesterification reactor is designed to meet the applicable safety standards and to comply
with mechanical, technical and safety standards for chemical plant design. General design
2

procedure of the reactor (Coulson & Richardson, Chemical Engineering Design, volume 06,
page 381-390) is considered.

Collect together all the kinetic and thermodynamic data on the desired reaction and the
side reactions.
Identify the predominant rate controlling mechanism.
Kinetics
Mass and heat transfer
Reactor type
Select the reactor type and sizing of the reactor.
Estimate the performance of the reactor.
Select the suitable material of construction.
Make the mechanical and civil design for the reactor.
Auxiliary equipment design (Plate & frame heat exchanger).
Collect the detail of safety, environment, social and economic assessment.
Draw the piping and instrumentation diagram.

2.1 TRANSESTERIFICATION REACTION KINETICS

There are three reactions inside the reactor.

Reaction of triglyceride in Jatropha oil with methanol to form fatty acid methyl esters

and glycerol.
Reaction of fatty acid with NaOH to form soap and water.
Reaction of H2SO4 with NaOH to form water and Na2SO4.

To be able to design a suitable reactor for biodiesel production, the kinetic mechanisms and
reaction rate constants have to be determined effectively. But, main reaction of
transesterification reaction which is Reaction of triglyceride in Jatropha oil with methanol to
form fatty acid methyl esters and glycerol is considered.
Transesterification reaction is a consecutive and reversible reaction being driven by excess
methanol and NaOH catalyst.

Where k1, k3 and k5 are rate constants for forward reactions and k2, k4 and k6 are rate
constants for reverse reactions. ROH is methanol. RCO2R1, RCO2R2 and RCO2R3 are fatty
acid esters. TG is Triglyceride. DG is diglyceride. MG is monoglyceride. ME is methyl ester
and GL is glycerol.
The three consecutive transesterification reactions can either be equilibrium reactions, reverse
or forward reactions depending on the working conditions, the chosen catalyst and molar ratio
of methanol to oil. The kinetic rate constants were written as a function of reaction time
(Okullo et al, 2011).

d[TG]/dt

= K2[DG][ME]-K1[TG][ROH]

d[DG]/dt

= K4[MG]][ME]-K3[DG][ROH]+K1[TG][ROH]-K2[DG][ME]

= K6[GL][ME]-K5[MG][ROH]+K3[DG][ROH]-K4[[MG][ME]

d[MG]/d
t

Pseudo assumptions,
d[DG]/dt
d[MG]/d

= 0

= 0

Considering equation 2
4

[DG]

= K1[TG][ROH]+K4[MG][ME]
K2[ME]+K3[ROH]
considering equation 3

[MG]

= K6[GL][ME]+K3[DG][ROH]
K5[ROH]+K4[ME]

Equation 5 is adding to 4

[DG]

1
K2[ME]+K3[ROH]

K1[TG][ROH]+K4[ME]{K6[GL][ME]+K3[DG][ROH]}
K5[ROH]+K4[ME]

[DG]

K1[TG][ROH]{K5[ROH]+K4[ME]}+K4[ME]+K6[GL][ME]
{K5[ROH]+K4[ME]}{K2[ME]+K3[ROH]-K4[ME][ROH]

By adding [DG] value for the equation 1

d[TG]/d
t

=
=

K2[DG][ME]-K1[TG][ROH]

K2[ME]-K1[ROH]
=

K1[TG][ROH]{K5[ROH]+K4[ME]}+K4[ME]+K6[GL][ME]
{K5[ROH]+K4[ME]}{K2[ME]+K3[ROH]-K4[ME][ROH]

[TG]

Overall mass balance to the reactor

Assumption
The reacting mixture is to be well mixed
The properties of the exit stream are the same as the properties of the reacting mixture within the reactor
In CSTR reactor per unit time

Mass of TG entering =

Mass of TG leaving+ Mass of Accumulated+ Mass of Disappearing

At steady state ,
Accumulation is zero

F TGo MTG

F TGf MTG + (-rTG) MTG V + d/dt(CTGf MTG V)

FTG0-FTGf
(-r TG) at [TGf]

FTG0
FTGf
-r TG
MTG
CTGf
(-r) TG at exit

=
=
=
=
=
=

The number of moles of TG per unit time entering the CSTR

The number of moles of TG per unit time leaving the CSTR
Molar rate of TG
Molar mass of TG
Molar concentration of TG at the exit
d[TG]/dt

(-r) TG at exit

K1[TG][ROH]{K5[ROH]+K4[ME]}+K4[ME]+K6[GL]

K2[ME]-

[ME]
{K5[ROH]+K4[ME]}{K2[ME]+K3[ROH]}-K4[ME][ROH]

K1[ROH][TG]

Table 2.1: The input stream of reactor

Molecular
Compone

weight/

nt

(Kg/Kmol)
863.820
32.000
289.950
92.020

TG
ROH
ME
GL

Flow rate

Molar flow

Volumetric

Density/

at input

rate/

flow rate/

(Kg/m3)
908.004
828.300
829.517
1254.900

/(Kg/hr)
1017.353
698.063
174.565
0.000

(Kmol/hr)
1.178
21.814
0.602
0.000

Concentratio

(m3/hr)
1.120
0.843
0.210
0.000

n/(Kmol/m3)
1.051
25.884
2.861
0.000

Table 2.2: The output Stream of the reactor

Compone

Molecular

Density/

Flow rate

Molar flow

Volumetri

Concentrati

nt

weight/

(Kg/m3)

at input/

rate/

c flow

on/

(Kg/hr)

(Kmol/hr)

rate/

(Kmol/m3)

(Kg/Kmol)

TG
ROH
ME
GL

863.820
32.000
289.950
92.020

908.004
828.300
829.517
1254.900

23.399
585.000
1170.937
105.883

0.027
18.281
4.038
1.151

(m3/hr)
0.026
0.706
1.412
0.084

1.051
25.884
2.861
13.637

Table 2.3: Rate constants of the reactions (Okullo et al,2011)

Rate
constant(L/mol.s)
K1
K2
K3
K4
K5
K6

Value
0.050
0.110
0.215
1.228
0.242
0.007

d[TG]/d
t

-0.511
0.511

-0.511

2.252

m3

Volume

2.25

m3

d[TG]/d

The reactor is the only place in the process where chemical conversion occurs. Reactors can
be grouped into two broad categories, batch reactors and continuous reactors. In the batch
reactor, the reactants are fed into the reactor at the determined amount. The reactor is then
closed, and the desired reaction conditions are set. The chemical composition within the
reactor changes with time. The construction materials are an important consideration for the
reactor and storage tanks. Key reactor variables that dictate conversion and selectivity are
7

temperature, pressure, reaction time (residence time), and degree of mixing. In general,
increasing the reaction temperature increases the reaction rate and, hence, the conversion for a
given reaction time.
Two reactors within the continuous reactor category are continuous stirred tank reactors
(CSTRs) and plug flow reactors (PFRs). For CSTRs, the reactants are fed into a well-mixed
reactor. The composition of the product stream is identical to the composition within the
reactor. Hold-up time in a CSTR is given by a residence time distribution. The plug flow
reactors (PFRs) model is used to describe chemical reactions in continuous, flowing systems.
A PFR is a vessel through which flow is continuous,
usually at a steady state, and configured so that conversion of the chemicals and other
dependent variables are functions of position within the reactor rather than of time. For PFRs,
the reactants are fed into one side of the reactor. The chemical composition changes as the
material moves in plug flow through the reactor (Praptijanto A, 2011).
Transesterification reactor will be designed and fabricated according to the British Standard
PD 5500.
2.2 HEADS AND CLOSURES
The ends of a cylindrical vessel are closed by heads of various shapes. The principal types
used are:
1. Flat plates: Cheapest type formed head to manufacture and limited to low pressure
and small diameter vessels.
2. Hemispherical heads: The strongest shape and capable of resisting about twice the
pressure of the torisherical heads of the same thickness.
3. Ellipsoidal heads: Cost is very high and use for very high pressure
4. Torispherical heads: The most commonly used end close for vessels when operating
high pressure.
Standard torispherical heads (dished ends) are the most commonly used
end closure for vessels up to operating pressures of 15 bar. The operating
pressure of the reactor is 60C and the boiling point of the methanol is
64.8 C. Therefore, there is a vapor pressure inside the reactor. So that
torispherical heat is selected for the heat of the reactor (Coulson &
Richardson,2005, vol 6, 815-819).
Torispherical shape is better suitable than flat shape as the bottom of the reactor. Because of
hydrostatic pressure should carry the reactor. Otherwise reactor can be failure.
8

2.3 MIXING AND AGITATION

Agitation is a means whereby mixing of phases can be accomplished and by which mass and
heat transfer can be enhanced between phases or with external surfaces.
The dimensions of the liquid content of a vessel and the dimensions and arrangement of
impellers, baffles and other internals are factors that influence the amount of energy required
for achieving a needed amount of agitation or quality of mixing.
Mixing occurs through the bulk flow of the liquid and, on a microscopic scale, by the motion
of the turbulent eddies created by the agitator. Bulk flow is the predominant mixing
mechanism required for the blending of miscible liquids and for solids suspension. Turbulent
mixing is important in operations involving mass and heat transfer which can be considered as
shear controlled processes (Coulson & Richardson,2005, vol 6, 794-802).

2.3.1 Mixing Flow patterns (Coulson & Richardson 2005, vol 6, 460-476).
(i) Axial flow
Impeller makes an angle of less than 90o with the plane of rotation thus resultant
flow pattern towards the base of the tank (i.e. marine impellers).
More energy efficient than radial flow mixing.
More effective at lifting solids from the base of the tank.
(ii) Radial flow
Impellers are parallel to the axis of the drive shaft.
The currents travel outward to the vessel wall & then either upward or downward.
Higher energy is required compared to axial flow impellers.
(iii) Tangential flow
The current acts in the direction tangent to the circular path around the shaft.
Usually, it produce vortex (disadvantageous) & swirling the liquid.

Fig 2.1 Flow patterns

of Axial and

Radial

2.3.2 Vortex
If solid particles present within tank; it tends to throw the particles to the outside by
centrifugal force.
Power absorbed by liquid is limited.
At high impeller speeds, the vortex may be so deep that it reaches the impeller.

Fig.2.2 Vortex in liquid

Method of preventing vortex
- baffles
- impeller in an angular off-center position
2.3.3 Baffles
10

Except at very high Reynolds numbers, baffles are needed to prevent vortexing and rotation of
the liquid mass as a whole.
Four radial baffles at equal spacing are standard; six are only slightly more effective, and three
appreciably less so. When the mixer shaft is located off center (one-fourth to one-half the tank
radius), the resulting flow pattern has less swirl, and baffles may not be needed, particularly at
low viscosities.
Basic impeller actions are either axial or radial, but, as Figure 4 shows, radial action results in
some axial movement by reason of deflection from the vessel walls and baffles. Baffles
contribute to turbulence by preventing swirl of the contents as a whole and elimination of
vortexes; offset location of the impeller has similar effects but on a reduced scale.

Fig.2.3: Agitator flow patterns. (a) Axial or radial impellers without baffles produce vortexes.
(b) Off center location reduces the vortex. (c) Axial impeller with baffles. (d) Radial impeller
with baffles.
2.4 IMPELLER TYPES
The most suitable agitator for a particular application will depend on the type of mixing
required, the capacity of the vessel, and the fluid properties, mainly the viscosity.
The three basic types of impeller which are used at high Reynolds numbers (low viscosity)
They can be classified according to the predominant direction of flow leaving the impeller.

Turbine impeller
Propeller
11

Paddle, anchor and helical ribbon agitators

Table 2.4 Impeller types and applications

Impeller type
Propeller
The three-bladed mixing propeller

Application
Axial flow impellers
Maximum flow is achieved at axis of agitator
Maximum vessel size is 1m3
Maximum speed is 415 rev/minute
Diameter of propeller is 15-30% of vessel

diameter
Relatively high speeds (up to 1800rpm) with
low viscosity fluids, up to about 4000CP

Turbine impeller

mixing duties up to 100,000CP/(100 Pa.s)

The turbine with flat vertical blades

12

The turbine with flat horizontal

blades

Radial-flow devices
Suitable for processes controlled by turbulent
mixing (shear controlled processes)

Curved blade turbines

Effectively disperse fibrous materials without

fouling

Shrouded turbines

Emulsification and dispersion

For more viscous fluids

13

Turbine with blades are inclined 45o

(Pitch turbine)

Axial-flow devices
Suitable for bulk fluid mixing
Especially effective for heat exchange with
vessel walls

Anchor paddles

Gate paddles

For more viscous fluids

Good for top to bottom liquid circulation
High power requirement

For more viscous fluids

Speed range 5-300rpm
Used for large size vessels
Agitator size almost touching vessel wall
Normally used for reaction vessel having jacket
by providing good heat transfer area

14

A preliminary selection of the agitator type is based on the liquid viscosity and tank volume.
The viscosity of the liquid is shown in below table 2.2.
Table 2.5 The viscosity values of components and average viscosity of the mixture before
reactor
Component

Viscosity

Mass fraction of

(i)/(mpas)

component/Wi

FFA
Palmitate
Stearate
Oleate
Linoleate
Triglycerides
Trilaurate
Trimyristate
Tripalmitoleate
tripalmitate
tristearate
trioleate
trilinoleate
FAME
Methyl palmitate
Methyl stearate
Methyl oleate
Methyl linoleate
Others
Sulfuric
Methanol
Water

Average viscosity of the mixture

(%Wi)/i

8.3
9.5
9.5
9.5

0.00099
0.00008
0.00225
0.00287

0.00012
0.00000
0.00024
0.00030

13.5
24
25
25
28
28
28

0.00037
0.00062
0.00687
0.07782
0.02276
0.16802
0.25163

0.00003
0.00003
0.00028
0.00311
0.00081
0.00600
0.00899

2.508
3.225
2.638
2.266

0.01465
0.00121
0.03281
0.04194

0.00584
0.00038
0.01244
0.01851

5.4
0.543
0.91

0.00620
0.36236
0.00648

0.00115
0.66734
0.00713
0.73270

1
w

1/0.73270

1.365 mPas

Table 2.6: The viscosity values of components and average viscosity of the mixture after the
reactor

15

Components

Viscosity

Mass fraction of

(i)/(mpas)

component/(Wi)

FFA
Palmitate
Stearate
Oleate
Linoleate
Triglycerides
Trilaurate
Trimyristate
Tripalmitoleate
tripalmitate
tristearate
trioleate
trilinoleate
FAME
Methyl laurate
Methyl myristate
Methyl palmitoleate
Methyl palmitate
Methyl stearate
Methyl oleate
Methyl linoleate
Others
Methanol
Water
Sodium sulphate
Glycerol
Soap
Sodium hydroxide
Total

(%Wi)/ i

8.30
9.50
9.50
9.50

1.98610-5
1.65510-6
4.46910-5
5.71010-5

2.39310-6
1.74210-7
4.70410-6
6.01010-6

13.50
24.00
25.00
25.00
28.00
28.00
28.00

8.55210-6
1.90510-6
8.14710-5
1.09310-4
1.73210-2
6.97410-3
2.42210-4

6.33510-7
7.93810-8
3.25910-6
4.37410-6
6.18610-4
2.49110-4
8.65110-6

1.47
1.95
2.51
2.51
3.23
2.64
2.27

9.03510-2
2.32510-2
1.96210-1
3.62410-4
6.64410-3
2.86510-1
6.04010-4

6.14110-2
1.19310-2
7.82310-2
1.44510-4
2.06010-3
1.08610-1
2.66510-4

0.54
0.91
3.50
10.80
9.50
3.30

Average viscosity of mixture

3.01710-1
5.55610-1
1.15210-2
1.26510-2
8.93310-3
2.55210-3
-2
5.46010
5.05610-3
6.51210-3
6.85510-4
6.75710-4
2.04810-4
1.013
0.840
= (1/0.840)
= 1.190mpa/s

The average viscosity of mixture is 1.19 mpas

The average viscosity of the mixture inside the transesterification reactor is equal to the outlet
viscosity of the mixture from reactor.
The average viscosity of mixture inside the reactor is 1.19 mpas
Identify the impeller type by using the agitation selection guide which is shown in Fig 2.4
graph.

16

Fig.2.4 Agitator selection guide

Considering the standards of impellers, six flat horizontal blades, Rushton turbine impeller
and 4 baffles are used for the continuous stirred tank reactor.

17

Fig.2.5: Six flat horizontal blades, Rushton turbine impeller

2.5 STANDARD DIMENSIONS OF THE TURBINE IMPELLER
Considering the standards of turbine impeller, dimensions of the reactor was calculated.

Fig.2.6: Standard Dimensions of the turbine impeller

By considering the hemispherical shape of bottom
Volume of the Hemisphere
=

(2/3D3)

Volume of the cylinder

/8
((d2/4)(D

))
((d2/4)(D)) + (2/3D3)/8

V of cylinder
V

2.252

m
3

1.373

Ht
= 1.962
m
Summary of the dimensions of the transesterification reactor
18

Dt
Ht
H
Da
J
W
E
L

=
=
=
=
=
=
=
=

Tank diameter
height of tank
Liquid level in tank
Impeller diameter
Baffle width
Impeller width
Impeller elevation above tank bottom
Impeller length

= 1.373 m
= 1.962 m
= 1.373 m
= 0.458 m
= 0.114 m
= 0.092 m
= 0.458 m
= 0.114 m

2.6 AGITATOR POWER CONSUMPTION

The shaft power required to drive an agitator can be estimated using the following
dimensionless equation, the derivation of which is given in Coulson & Richardson, 2005, Vol
6, page 473.
Pa

N
da
g

= Shaft power
= Fluid density
= Fluid viscosity
= Agitator speed
= Agitator diameter
= Gravitational acceleration= 9.81

W
Kg/m3
Ns/m2
s-1
m
m/s2

Table 2.7 Density of the input stream and output stream in reactor

Input to the reactor

Component
FFA
Palmitate
Stearate
Oleate
Linoleate
Total FFA

Output from reactor

Volume

Mass flow

Volume

Density /

Mass flow

flow rate/

rate/

flow rate/

(kg/m3)

rate/(kg/h)

(m3/hr)

(kg/h)

(m3/hr)

855.425
853.209
866.698
801.391
833.305

1.926
0.160
4.333
5.536
11.955

0.00225
0.00019
0.00500
0.00691
0.01435

0.039
0.003
0.087
0.111
0.239

0.00005
0.00000
0.00010
0.00014
0.00029
19

Triglycerides
Trilaurate
Trimyristate
Tripalmitoleate
tripalmitate
tristearate
trioleate
trilinoleate
Total Triglycerides

933.776
883.857
907.680
914.488
906.832
900.764
911.035
908.004

0.721
1.203
13.236
149.908
43.853
323.679
484.754
1017.353

0.00077
0.00136
0.01458
0.16393
0.04836
0.35934
0.53209
1.12043

0.017
0.028
0.304
3.448
1.009
7.445
11.149
23.399

0.00002
0.00003
0.00034
0.00377
0.00111
0.00826
0.01224
0.02577

Methyl Esters
Methyl laurate
Methyl myristate
Methyl palmitoleate
Methyl palmitate
Methyl stearate
Methyl oleate
Methyl linoleate
Total Methyl esters

836.132
834.284
828.154
739.267
820.213
828.315
844.848
829.517

26.118
6.721
56.722
0.105
1.920
82.805
0.175
174.565

0.03124
0.00806
0.06849
0.00014
0.00234
0.09997
0.00021
0.21044

175.190
45.086
380.475
0.703
12.882
555.431
1.171
1170.937

0.20952
0.05404
0.45943
0.00095
0.01571
0.67056
0.00139
1.41159

1169.600
1496.700
983.200
985.200
1254.900
1163.500
828.300
828.300

0.000
12.759
12.496
0.000
0.000
11.955
698.063
1939.163

0.00000
0.00852
0.01271
0.00000
0.00000
0.01027
0.84277
2.29443

17.322
1.310
22.331
12.628
105.883
0.000
585.000
1939.166

0.01481
0.00088
0.02271
0.01282
0.08438
0.00000
0.70627
2.27950

Na2SO4
NaOH
Water
soap
glycerol
H2SO4
methanol
Average
Density
of
stream at input
Density
of

the
845.162
the

stream at output

850.697

Considering the Tip speed various mixing duties from (L.M Rose, 1981, Chemical reactor
design in practice, Page 201).
Table 2.8: Tip speed for various mixing duties
Duty
Normal mixing
Heat transfer duty
High shear two phase dispersion duty

Tip speed/(m/s)
2.5-3.3
3.5-5.0
5.0-6.0

High shear two phase dispersion duty is selected for tip speed.
20

Velocity of the tip

Angular velocity
Tip speed

V
W
N

Agitator speed
Diameter of impeller
Viscosity
Density

N
Da

=
=
=

5 m/s
21.85 rad/s
3.48 1/s
=
=
=
=

3.48
0.458
0.001
850.7

1/s
m
Ns/m2
kg/m3

Fig. 2.7: Power correlations for baffled turbine impellers, for tank with 4 baffles (Coulson &
Richardson, 2005, page 475)
Considering the Fig.2.7, power number was taken. Power number is 5.
So that using the equation of power number, shaft power was calculated.
Shaft power, Pa =
3592.1
W
Power/volume
=
1.59
Kw/m3
According to the Degree of mixing and power input /unit volume (L.M Rose, 1981, Chemical
reactor design in practice, Page 202), calculated shaft power was corrected. Degree of
agitation High is achieved.
Table 2.9: Degree of mixing and power input/unit volume
Power input /unit

Degree of agitation

Application area
21

volume KW/m3
0.005
0.1
0.3
1.0

achieved
Gentle
Mild
Moderate

Blending
Blending , Homogenous reaction
Homogenous reaction with the heat

High

transfer requirement
Homogenous reaction,
Two

2.0

Intense

phase

system,

gas/liquid,

liquid/liquid
Two phase

system,

gas/liquid,

liquid/liquid
Summary

Ht
Dt

Db

V
Dt
Ht
H
Da
J
W
E
L
Pa
N

=
=
=
=
=
=
=
=
=
=
=
=
=

Volume of the reactor

Tank diameter
height of tank
Liquid level in reactor
Impeller diameter
Baffle width
Impeller width
Impeller elevation above tank bottom
Impeller length
Shaft power
Agitator speed
Viscosity of the mixture
Density of the mixture

= 2.25 m3
= 1.373 m
= 1.962 m
= 1.373 m
= 0.458 m
= 0.114 m
= 0.092 m
= 0.458 m
= 0.114 m
= 3592.1 W
= 3.48 1/s
= 0.001 Ns/m2
=850.7 Kg/m3

22

Chapter 03: MECHANICAL DESIGN FOR REACTOR

Pressure vessel mechanical design procedure is considered to the transesterification reactor for
mechanical design. (Coulson & Richardson, 2005, Chemical Engineering Design, vol 6, 4

th

edition, page 794-819).

3.1 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 per cent above the normal working
pressure, to avoid spurious operation during minor process upsets.
Vessel top pressure
Hydrostatic pressure

Vessel bottom pressure

Vessel Pressure
Factor
Design Pressure

1 bar
Htg
1.962 850.67 9.81
0.164 bar
1 + 0.164 bar
1.164 bar

=
=
=
=
=
=

10%
1.1(Vessel pressure 1)
0.18 bar
0.18 bar

=
=
=
=

3.2 DESIGN TEMPERATURE

The strength of metals decreases with increasing temperature. So the maximum allowable
design stress will depend on the material temperature. The design temperature at which the
design stress is evaluated should be taken as the maximum working temperature of the
material (Page 810).

Average reactor temperature

Design temperature

=
=
=

333 K
(333-273) C
60 C

3.3 MATERIALS
Pressure vessels are constructed from plain carbon steels, low and high alloy steels, other
alloys, clad plate, and reinforced plastics. Selection of a suitable material must take into
23

account the suitability of the material for fabrication as well as the compatibility of the
material with the process environment.
Therefore, Stainless steel 18 Cr/8 Ni / ASTM standard: A351 CF8/ Japanese Industrial
Standard: SUS 304 is selected as the vessel design material.
3.4 DESIGN STRESS
For design purposes it is necessary to decide a value for the maximum allowable stress
(Nominal design strength) that can be accepted in the material of construction.
Using British Standard, PD 5500, the nominal design strengths (allowable design
Stresses) data,
Design stress for the stainless steel for design temperature at 60C = 161 N/mm2
3.5 WELDED JOINT EFFICIENCY
This depends on the Welded joint factor (J). The joint factor used in design will depend on the
type of joint and amount of radiography required by the design code. Using standard typical
values,
Double-welded butt or equivalent type and spot degree of radiography welded.
Therefore, welded joint factor (J) = 0.85
3.6 CORROSION ALLOWANCE
The corrosion allowance is the additional thickness of metal added to allow for material lost
by corrosion and erosion, or scaling.
Standard valve for allowance
Maximum valve for allowance
Minimum value for allowance

= 2 mm
= 4 mm
= 1 mm

Considering the design maximum valve for allowance is selected.

3.7 DESIGN LOADS
A structure must be designed to resist gross plastic deformation and collapse under all

24

the conditions of loading. Therefore, the entire loads act on the reactor is considered. The
major loads can be present like this.

Design pressure
Maximum weight of the vessel and contents
Wind loads
External loads imposed by piping and attached equipment

3.7.1 Pressure Loading

For a cylindrical shell the minimum thickness required to resist internal pressure can be
determined from equation which given in the British Standard PD 5500.

E
Pi
e
Di
f
J

=
=
=
=
=
=
=

(PiDi)/(2Jf-Pi)
Design pressure
Required minimum thickness
Internal diameter
Design stress
Welded joint factor

Therefore the required minimum thickness of the cylindrical vessel is calculated

Pi
=
0.018 N/mm2
Di
=
1.373 m
f
=
161 N/mm2
J
=
0.85
e
=
(0.0181.3731000)/(20.85161-0.018)
=
0.090 mm
Adding the corrosive allowance, 4mm
The required thickness of the reactor, t
t
=
(4+0.09)
mm
=
4.090
mm
t
=
4.09 mm

According to the minimum practice wall thickness, wall thickness of the vessel taken as 7mm.
Because of vessel diameter is between 1-2 m ranges. (Coulson & Richardson, 2005, page
814).
Minimum wall thickness = 7 mm
3.7.1.1 Heads & Closures
25

Torisherical heads

There are two junctions in a torispherical end closure: that between the cylindrical section
and the head, and that at the junction of the crown and the knuckle radii.
The stress concentration factor is a function of the knuckle and crown radii.
e

[piRcCs]/[2fJ+Pi(Cs-0.2)]
stress concentration factor for

Cs

=
torispherical heads
=
1/4(3+(Rc/Rk)^0.5)
Rc
=
Crown radius
Rk
=
knuckle radius
Rk/Rc > 0.06, avoid buckling
Rc not be greater than the diameter of the cylindrical section
Rc = Di
=
1.373 m
Rk= 6% of Rc
=
0.082 m
J
=
Welded factor
=
0.85
f
=
Design stress
=
161 N/mm2
Pi
=
Design pressure
=
0.018 N/mm2
Cs
=
1.771
e

=
[piRcCs]/[2fJ+Pi(Cs-0.2)]
=
0.0002 m
e
=
0.160 mm
Adding corrosion allowance
4 mm
e
=
4.160 mm
According to the minimum practice wall thickness, wall thickness of the vessel taken as 7mm.
Because of vessel diameter is between 1-2 m ranges. (Coulson & Richardson, 2005, page
814).
Minimum wall thickness = 7 mm
3.7.2 Weight Loads (Coulson & Richardson, 2005, page 835).
The major sources of dead weight loads are:

The vessel shell.

The vessel fittings: man ways, nozzles.
Internal fittings: plates (plus the fluid on the plates); heating and cooling coils.
External fittings: ladders, platforms, piping.
26

Auxiliary equipment which is not self-supported; condensers, agitators.

Insulation.

3.7.2.1 Weight of vessel shell

The weight of the vessel and fittings can be calculated from the
preliminary design sketches. The weights of standard vessel components:
heads, shell plates, man ways, branches and nozzles, are given in various
handbooks. For preliminary calculations the approximate weight of a
cylindrical vessel with domed ends, and uniform wall thickness, can be
estimated from the following equation.
Wv

CvPmDmg(Hv+0.8Dm)t10-3

Wv
Cv

=
=
=
=
=
=
=
=
=

Total weight of the shell, excluding internal fittings

A factor to account for the weight of nozzles, man ways, internal supports,
1.08 for vessels with only a few internal fittings
1.15 for several man ways and with plate support rings, or equivalent fittings
Height, or length, between tangent lines (the length of the cylindrical
Gravitational acceleration, 9.81 m/s2,
Wall thickness, mm
Density of vessel material, kg/m3
Mean diameter of vessel = (Di + t 10 -3) m

Hv
g
t
Pm
Dm

For the steel vessel, reduced above equation

Wv
=
240 CvDm(Hv + 0.8Dm) t

Cv
Hv
Pm
t
Dm

=
=
=
=
=

1.08
1.962
8000
7
1.38

Wv

704.18 N
704.2

Wv

m
Kg/m3
mm
m

3.7.2.2 Wight of ladder

Plain steel ladder is used as the external ladder
Standard value
= 150 N/m
Length
=

1.75 m
27

Total ladder weight

262.50 N

Total weight

966.68 N

3.7.3 Wind Load

Wind loading will only be important on tall columns installed in the open.
Columns and chimney-stacks are usually free standing, mounted on skirt
supports, and not attached to structural steel work. Under these conditions
the vessel under wind loading acts as a cantilever beam.
A wind speed of 160 km/h (100 mph) can be used for preliminary design
studies, equivalent to a wind pressure of 1280 N/m2.

Fw

PwDeff

Fw
Pw
Deff

=
=
=

Loading per unit length of the column

Wind pressure
Effective column diameter

An allowance 0.4 m should be added for a caged ladder.

Pw
=
1280 N/m2
Deff
=
1.29+ 2(7+75)*(10^-3)
=
1.537 m
Fw

=
=

Bending moment at bottom tangent line

Mx
=
Mp
=
x
=
Mx

=
=
=

12801.537
1967.45 N/m

Wx2/2
Bending moment at bottom tangent line
Loading per linear meter
1967.45(1.962^2)/2)
3785.03 Nm
3785 Nm

3.8 INSULATION

28

D2

D1

D1
D2
h1
h2
h3
h4
k1
k2

Cp

U
L
T1
T2

=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=

Inlet diameter
Outlet diameter
Convection heat transfer coefficient of bio diesel
Conduction heat transfer coefficient of stainless steel
Convection heat transfer coefficient of water
Radiation heat transfer coefficient of stainless steel
Thermal conductivity of bio diesel
Thermal conductivity of stainless steel
Emissivity of stainless steel
Specific heat
Viscosity
Overall heat transfer coefficient
Length of the vessel
Inside temperature
Outside temperature
Stefan boltsman constant

=
=
=
=

1.373 m
1.387 m
17 W/m.k
284 W/m.k

=
=
=
=
=

0.125
16
0.44
2.15
1.19

W/m.k
W/m.k
KJ.kg/C
mpas

=
=
=
=

1.962
333
278
5.67(10^-8)

m
K
k
w/m2K4

Calculation of convection heat transfer coefficient of bio diesel

Nusselt number is the dimensionless heat transfer coefficient defined as
Nu

hD/k

Re
=
991887.80 (From previous calculation)
The Prandtl number is defined as
Pr
=
Cp /k
=
20.468
For the turbulent flow
Nu

0.023 Re0.8 Pr n
29

0.3

Nu

3566.32

h1

324.68

h4

=
=

(T12+T22)(T1+T2)
2.86
W/m.k

W/m.k

Resistance diagram

R3
R1

R2

R4

By considering thermal resistance diagram

1/U

= R1+R2+ Rt

1/Rt

= 1/R3 +1/R4

R3
R4

= 1/(h3Ao)
= 1/(h4Ao)

1/Rt

= [1/h3 D2L ]+[ 1/h4 D2L]

=
2445.08
=
0.0004 K/W m

Rt

=
=

R1

= 1/h1Ai
=

=
0.026 K/W m

R2

= ln(D2/D1)/2KL
5.1410-5 K/W m

1/U

1/h3 D2L
1/h4 D2L

1/h1 D1L

0.027
30

37.708 W/m2k

5C cooling water is used for the cooling water jacket.

From previous calculation
Q
=
A

Heat transfer surface area

58.01 MJ/h
16113.889 W
7.770 m2

7.770 m2

3.9 ANALYSIS OF STRESS

3.9.1 Primary stresses
The longitudinal and circumferential stresses due to pressure (internal or external),
given by
Longitudinal stress h
= PDi/2t
Circumferential stress L = PDi/4t
P
= Design pressure
= 0.018 N/mm2
Di
= Inlet diameter
= 1.373 m
t
= Wall thickness
=
7 mm
Therefore,
h
= (0.0181.3731000/27)
=
1.766 N/mm2
L

= (0.0181.3731000/47)
=
0.883 N/mm2

3.9.2 Dead weight stress

The direct stress w due to the weight of the vessel, its contents, and any attachments.
The stress will be tensile (positive) for points below the plane of the vessel supports,
and

compressive

(negative)

for

points

above

the

supports.

The

dead-weight stress will normally only be significant, compared to the magnitude of

the other stresses, in tall vessels (Coulson & Richardson, 2005, page 831-833).

31

Fig.3.1: Stress in a cylindrical shell under combined loading

w
W
Di
t

=
=
=
=

Therefore
,
w

W/((Di+t)t)
Total weight of the supported by the vessel at the plane
Internal diameter
Wall thickness at the bottom

0.032 N/mm2

3.9.3 Bending stresses

Bending stresses resulting from the bending moments to which the vessel
is subjected. Bending moments will be caused by the following loading
conditions:

The wind loads on tall self-supported vessels

Seismic (earthquake) loads on tall vessels

32

The dead weight and wind loads on piping and equipment which is
attached

to

the vessel, but offset from the vessel centre line

For horizontal vessels with saddle supports, from the disposition of
dead-weight
load

The bending stresses will be compressive or tensile, depending on location, and are
given by
b
= ( M/Iv )(Di/2+ t)
M
= Total bending moment
Iv
= Second moment of area of the vessel
t
= Base vessel wall thickness
Di
= Inlet diameter
Iv
Do

=
=

(/4)(Do4-Di4)
Outlet diameter base of the vessel

Di
Do
Do
Iv

=
=
=
=

1373.08
(1349.44+27)
1387.08
1.15611E+11

b
b

=
=

((3785.031000)/1.1510^11)(1373.08/2 + 7)
0.023
N/mm2

Therefore,

Therefore,

mm
mm
mm
mm4

3.9.4 Torsion shear stress

Torsional shear stresses resulting from torque caused by loads offset from
the vessel axis. These loads will normally be small, and need not be
considered in preliminary vessel designs.

33

3.10 PRINCIPLE STRESSES

1
2

=
=

1/2[h + z + ((h-z)2 + 42)0.5]

1/2[h + z -( (h-z)2 + 42)0.5]

z
=
Total longitudinal stress
z
=
L + wb
z should be counted as positive if tension , negative if compressive

=
Torsional shear stress, is not usually significant
3
=
The third principal stress, that in the radial direction
usually be negligible for thin-walled vessels
As an approximation it can be taken as ,half of the pressure loading
=
0.5 P
using above calculation,
h
=
1.766
N/mm2
L
=
0.883
N/mm2
w
=
-0.032
N/mm2
b
=
0.023
N/mm2
b
=
0.02
N/mm2

For up wind
z
z

=
=

L + w + b
0.874
N/mm2

For down wind

z

=
L + w-b
=
0.828
N/mm2
The greatest difference between the principle stress will be on the up wind side
1
=
1/2[h + z + ((h-z)2 + 42)0.5]
=
1.76
N/mm2
2

=
=

1/2[h + z -( (h-z)2 + 42)0.5]

0.43
N/mm2

=
0.5P
=
0.009
N/mm2
3.11 ALLOWABLE STRESS INTENSITY
The maximum intensity of stress allowed will depend on the particular
theory

of

failure

adopted in the design method. Using this criterion, the maximum stress
intensity at any point is taken for design purposes as the numerically
greatest value of the following.
34

1-2

1.329

N/mm2

1-3

1.757

N/mm2

2-3

0.428

N/mm2

The vessel wall thickness must be sufficient to ensure the maximum stress
intensity does not exceed the design stress (nominal design strength) for
the material of construction, at any point.
The vessel wall thickness must be sufficient to ensure the maximum stress intensity does not exceed
the design stress (nominal design strength) for the material of construction, at any point.
13
Well below the maximum allowable stress
3
N/mm2
Therefore, Design valves are OK
3.12 CHECK ELASTIC STABILITY (BUCKLING)

Under conditions where the resultant axial stress z due to the combined loading is
compressive, the vessel may fail by elastic instability (buckling). Failure can occur in a thinwalled process column under an axial compressive load by buckling of the complete vessel, as
with a strut (Euler buckling); or by local buckling, or wrinkling, of the shell plates. Local
buckling will normally occur at a stress lower than that required to buckle the complete
vessel. A column design must be checked to ensure that the maximum value of the resultant
axial stress does not exceed the critical value at which buckling will occur.
For a curved plate subjected to an axial compressive load the critical buckling stress c
is given by
Critical buckling stress

=
=

210^4(t/Do)
101.443 N/mm2

Compressive stresses

=
=
=

w+b
-0.054 N/mm2
0.054 N/mm2

N/mm2

Well below the critical buckling stress

So design is satisfactory

35

3.13 VESSEL SUPPORTS

The method used to support a vessel will depend on the size, shape,
weight of the vessel the design temperature, pressure, the vessel location,
arrangement,

the

internal

and

external

fittings

and

attachments.

Horizontal vessels are usually mounted on two saddle supports. Skirt

supports are used for tall, vertical columns. Brackets, or lugs, are used for
all types of vessel. The supports must be designed to carry the weight of
the vessel and contents, and any super imposed loads, such as wind loads.
Supports will impose localised 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. Supports should be designed
to allow easy access to the vessel and fittings for inspection and
maintenance.
3.13.1 Skirt support
A skirt support consists of a cylindrical or conical shell welded to the base
of the vessel. Skirt supports are recommended for vertical vessels as they
do not impose concentrated loads on the vessel shell; they are particularly
suitable for use with tall columns subject to wind loading.
The resultant stresses in the skirt will be
bss (tensile)
s(compressive)
Where bs
ws

=
=
=
=
=
=

ws
bs+ws
Bending stress in the skirt
4Ms/(Ds + ts)tsDs
Dead weight stress in the skirt
W/(Ds+ts)ts
maximum bending moment, evaluated at the base of the skirt (due

Ms

to
wind, seismic and eccentric loads)
Ds
=
Inside diameter of the skirt , at the base
ts
=
Skirt thickness
The skirt thickness should be such that under the worst combination of wind and
dead-weight loading the following design criteria are not
exceeded
36

s (tensile)

fsJsin(s)

s(compressive)

0.125 E (ts/Ds)sin(s)

fs

J
s

=
=

Try a straight cylindrical stress(s)

Carbon steel
Design stress
fs
Young modules
E

maximum allowable design stress for the skirt material

normally taken atambient temperature, 20C
Welded joint factor
Base angle of a conical skirt , 80 to 90
=

90

=
=

135 N/mm2
210^5 N/mm2

The maximum dead weight load on the skirt will occur when the vessel is full of liquid
weight

=
=
=

/4 1.373^2 1.962 850.79.81

24239.3
4 N
24.24 KN

Wight of the vessel above calculation

=
=

966.68 N
0.97 KN

Total weight

25.21 KN

Wind loading

=
=

1967.46 N/m
1.97 KN/m

Bending moment at base of skirt

=
=
=

2 m
1.97(2+1.96)/2
15.438 KNm

As the 1st trial , take the skirt thickness as the same as that of the bottom section of the vessel, 7 mm
bs

1.482 N/mm2

ws

test

0.799 N/mm2

ws

operating

0.022 N/mm2

bs + ws (test)
2.281 N/mm2

Maximum s compressive

37

Maximum s tensile

=
=

bs- ws
(operating)
1.460 N/mm2

Take the joint factor J

Fs
Criteria for design

=
=

0.85
135 N/mm2

s tensile

114.75

1.460

114.75

Therefore criterion is accepted

s
compressive

127.451

2.281

127.451

Therefore criterion is accepted

Both criteria is satisfied.

3.14 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 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. A variety of base ring designs is used with skirt supports. The
simplest types, suitable for small vessels, are the rolled angle and plain flange rings.
The anchor bolts are assumed to share the overturning load equally, and
the

bolt

area

required is given by

38

Ab

1/(Nbfb) [(4 Ms)/Db-W]

Ab
Nb
fb

=
=
=
=
=
=
=

Area of one bolt at the root of the thread, mm2

Number of bolts
Maximum allowable bolt stress, N/mm2
Typical design value 125 N/mm2 (18,000 psi)
Bending (overturning) moment at the base, Nm
Weight of the vessel, N
Bolt circle diameter, m

Ms
W
Db
Guide rules

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).

Approximate pitch circle diameter

Cirmferance of bolt circle
Number of bolt required at minimum recommended bolt spacing

Closest multiple of 4
Bolt design stress

Bolt root diameter

=
2 m
2000
=
=
= 2000/600
=
10.5
12
= bolts
=
125 N/mm2

Ms

3785 N/m
966.6
8 N

Ab

=
=

4.402 mm2
2.367 mm

Bolts smaller than 25 mm, value is ok

Total compressive load on the base ring per unit length
Fb
= [(4 Ms/Ds2)+ W/Ds]
=
2780.5 N/m
The minimum width of the base ring is given
by
Lb
= (Fb/fc)(1/1000)
= Base ring width, mm
fc
= the maximum allowable bearing pressure on the concrete foundation pad,
39

which will depend on the mix used, and will typically range from 3.5 to
7 N/mm2
Take the bearing pressure 6N/mm2
Lb

=
0.4634
=
The required thickness for the base ring is found by treating the ring as a cantilever beam.
The minimum thickness is
given by
tb
= Lr(3 Fc/fr)^0.5
Lr
tb
fc
fr

=
=
=
=

the distance from the edge of the skirt to the outer edge of the ring, mm;
Base ring thickness, mm,
Actual bearing pressure on base, N/mm2,
Allowable design stress in the ring material, typically 140 N/mm2

Actual width required

Fc

= Lr+ts+50 mm
= 100+21+50
=
171 mm
=
16.261 N/mm2

tb
tb

=
=

59.0 mm
59 mm

4.0 SAFETY STUDY

4.1 Chemicals
The main chemicals used in this process that present safety concerns are the acid catalyst, the
base catalyst and the alcohol, which are sulfuric acid, sodium hydroxide and methanol,
respectively.

40

Sulfuric acid

Sulfuric acid is a colorless, odorless, and highly-corrosive material. The main acute exposure
hazard is severe burns to skin and eyes. It is more harmful than other strong acids due to the
dehydrating nature of the chemical, which releases extra heat, causing secondary burns. It will
cause temporary or permanent blindness if contacted with eyes in either liquid or vapor form.
Long term exposure also causes lung damage, vitamin deficiency and potentially cancer.

Sodium hydroxide

Sodium hydroxide is a caustic base and white solid that is typically available in flakes or
pellets.
It is a highly corrosive alkali that will decompose living tissue on contact. It also causes
secondary burns, as the decomposition reaction is highly exothermic. Aqueous sodium
hydroxide is more dangerous than solid, although solid NaOH will also exhibit some
corrosive behavior if there is any water present.

Methanol

Methanol is a colorless, flammable liquid with a distinct odor. If ingested, methanol will be
metabolized to formic acid, which damages the central nervous system and causes blindness
or death. The adverse health effects associated with methanol all occur internally. While
contact with skin will not cause external damage, it may provide a route for the chemical to
enter ones central nervous system. Methanol is highly flammable and easily ignites.

4.2 Storing chemicals

Sulfuric acid
Sulfuric acid must be stored in a vessel made of a non-reactive reactive material, such as
glass.
Great care should be taken that the acid does not contact the operators skin. Proper personal
protective equipment (PPE) for handling sulfuric acid includes safety goggles, face shield,
41

boots and gloves. Material safety data sheets can be used for more information. If sulfuric acid
does contact the skin, any contaminated clothing must be removed and the affected person
must wash the acid off under a safety shower for at least 15 minutes. Medical attention must
be sought immediately. When diluting the sulfuric acid the acid must be added to the water
instead water added to the acid. This way, the high heat capacity of water will absorb the heat
released as the chemicals mix.

Sodium hydroxide

Sodium hydroxide must also be stored in a non-reactive vessel, preferably the container in
which it was delivered. Keep sealed tightly in a cool, dry, well-ventilated area. When handling
sodium hydroxide, the same PPE should be worn as for sulfuric acid. If an operator needs to
create the sodium hydroxide solution, a respirator should also be worn. The same procedure as
for the sulfuric acid should also be followed if sodium hydroxide contacts skin.

Methanol

Methanol must be stored in a cool, dry, well-ventilated area away from any potential sparks. If
the methanol does ignite, water will not extinguish the fire. A fire extinguisher will be
necessary. If an operator must come into contact with the methanol, the same PPE as for
sulfuric
acid must be worn. If the area is not well ventilated, a respirator must also be worn. If
methanol is ingested, the exposed person must drink two glasses of water and seek medical
attention immediately. If methanol contacts any part of the body, the same procedure used for
sulfuric acid must be followed.
4.3 Safety and environmental considerations
All vessels/tanks and other equipment for the biodiesel plant are designed to meet the
applicable safety standards and to comply with mechanical, technical and safety standards for
chemical plant design and local regulations. The entire production process is programcontrolled. The process visualisation allows monitoring of the process and intervention if
required. The process equipment for the biodiesel production line (such as vessels, machines,
pipelines, instruments etc.) will be made of stainless steel or other resistant materials fulfilling
the respective mechanical, technical and safety standards.

42

4.4 HAZOP Analysis for transesterification reactor

HAZOP is a standard technique for the danger analysis to preparation the security setting on
the new system or existing to measure the presence of potential dangers. HAZOP purpose is to
review a process or operating system systematically, to determine deviations from the
potential dangers. HAZOP is studying the possibility of deviation from normal operation.
HAZOP has a systematic character structure or have a high level structure that relies on guide
words. HAZOP can be applied to various systems and application procedures, which is
emphasized as an interpreter of the dangers and techniques as early predictor, so as to produce
good quality and also HAZOP can be used together in safety hazard identification process, the
operating system is continuous and jointly review the procedures used to set the operating
system. So that HAZOP is used for Transesterification reactor to identify deviations from the
normal operation.
Input 02
NaOH
Water

Input 01
FFA
Triglyceride
FAME
Methanol
H2SO4
Water

Reactor
1 atm

Reactor
60C

Output 01
FFA
Triglyceride
FAME
Methanol
NaOH
water
Na2SO4
Glycerol
Soap

Most critcal parameters of the input stream are flow, temperature and pressure.
So the guide word are No,Less, more, reverse and part of
Node: Input flow

43

Parameter: flow
Guide

Deviation

Causes

Consequences

Action required

word
No

No flow

Valve closed

No reaction

Alarm system for open the

Mal function of valve

valve manually

Pump failure

Arrow indicator on pipe

Pipe breakage

line

No

output

in

Backup pump system

esterification
Less

Less flow

Reqular

Valve partially closed

Reation rate reduced

maintaince

and

Inspection
Alarm system for open the

Leakage on the pipe Reactor temperature valve manually

line

reduced

Arrow indicator on pipe

Pump the feed at low

line

rates

Backup pump system

Reqular

More

More flow

maintaince

and

Inspection
Alarm system for open the

Discharge valve fully Pressure build up

open than required set Reactor temperature valve manually

valve

incresed

Arrow indicator on pipe

Pump the feed at high Reactor

rates

solution line

Volume incresed

Reqular

No desired output

Inspection

Toxic
vapour
Reverse

Part of

Reverse flow

maintaince

and

methanol Turn off pump

may

relesed
Pressure build inside Reaction

be
rate Reqular

maintaince

and

the reactor

reduced

Pump dameged

Temprature

Operator failure

reduced

Alarm system for closed

Pipe breakage

the valve manually

reaction

or

Inspection
is Turn off pump

Operator training
Reduce the yeild of Testing the composition

Contaminatio

No

partially reaction of bio deisel

out put of esterification init

transestrification unit

Closed

Soap formation

the

feed
44

valve

mannually

Node

: Input flow line

Parameter

: Temperature

Guid

Deviation

Causes

Consequences

Low

Preheater failure

No

temperatur

Insulation of the pipe failure reaction

Less flow feed to the reactor No

Action required

e
word
Less

required Proper maintain and Inspection

Alarm

system

for

manual

desired operating

No desired output form output

Backup preheater

esterification unit

Control temperature system &

recycling line to the preheater

More

High

No desired output form No

temperatur

esterification unit

High flow feed to the No

reactor

desired Alarm

output

system

for

operating the feed valve

required and cooling system

reaction
Toxic methanol
vapor produced

Node

: Input feed line

Parameter

: Pressure

Guid

Deviation

Causes

Consequences

Action required

e
word
45

manual

Less

Low

Pump the flow at low rates

pressure

No

desired Pressure control system to the

reaction

reactor

Toxic methanol Proper Inspection

vapor produced

Alarm

system

for

manual

operating
More

More

Pump the flow at high rates No

pressure

Operator training
desired Pressure control system to the

reaction

reactor

Temperature

Proper Inspection

increased

Alarm

system

for

manual

feed

valve

for

manual

operating

Most critical parameter of the cooling system are flow and temperature
The most critical guide words are No, Less and more
Node

: Cooling water line

Parameter

: Flow

Guid

Deviation

Causes

Consequences

Action required

No flow

Mal function of valve

Runaway

Stop

Valve fully closed

reaction

automatically

Pump failure

No desired out Alarm

No chill water produced

put

e
word
No

the
system

operating
Backup pump system
Maintance and operation

Less

Less flow

Partially closed the valve

Toxic methanol Stop

Leakage the line

vapor produced

Pump the feed at low rates

No

Block the valve

output
reaction

the

feed

valve

for

manual

automatically

desired Alarm

system

and operating
Backup pump system
46

Maintance and operation

More

More flow

Discharge valve is fully No

open than the desired valve

reaction

Pump the feed at high rates

output

desired Alarm

system

for

manual

feed

valve

and operating
Stop

the

automatically
Operator training
Proper

operation

and

inspection
Node

: Cooling water line

Parameter

: Temperature

Guid

Deviation

Causes

Consequences

Action required

Low

Failure of chilling Reduced the reactor Alarm

temperature

system

e
word
Less

temperature

system

for

manual

for

manual

operating
Operator training

No desired output
More

Proper operation

High

Failure of chilling Increased the reactor Alarm

temperature

system

temperature

system

operating

Toxic methanol vapor Stop the feed valve to the

released

reactor

No desired reaction Operator training

and output

Proper operation

47

5.0 REFERANCE

Anchor Institute, 2012, Agitation & Mixing Dharmsinh Desai University.

Coulson & Richardson, 2005, Chemical Engineering Design, volume 06, 4 th edition.

Couper J.R, Peneey W.R, Fair J.R, Walas, S.M, 2010, Chemical Process Equipment
Selection and design, second edition.

Cheremisinoff, N.P, 2000, Handbook of Chemical Processing Equipment, Boston

Oxford Auckland Johannesburg Melbourne New Delhi.

Davis R.S, 2010, Design and Scale-Up of Production Scale Stirred Tank Fermentors,
Utah State University.

L.M Rose, 1981, Chemical reactor design in practice, Page 200-204.

Okullo A, Temu A. K, Ntalikwa, J.W, 2011, Transestrification Reaction Kinetics Oil

for Biodiesel Production.

48

Praptijanto A, 2011, Sonochemistry approach for a new process biodiesel production

from jatropha curcas oil.

Perry, R. H., Green, D. W. and Maloney, J. O, 1997, Perrys Chemical Engineers

Handbook, 7th edition. (McGraw-Hill).

49

50

References

Anchor Institute, 2012, Agitation & Mixing Dharmsinh Desai University.

Coulson & Richardson, 2005, Chemical Engineering Design, volume 06, 4 th edition.
Couper J.R, Peneey W.R, Fair J.R, Walas, S.M, 2010, Chemical Process Equipment

Selection and design, second edition.

Cheremisinoff, N.P, 2000, Handbook of Chemical Processing Equipment, Boston

Oxford Auckland Johannesburg Melbourne New Delhi.

Davis R.S, 2010, Design and Scale-Up of Production Scale Stirred Tank Fermentors,

Utah State University.

L.M Rose, 1981, Chemical reactor design in practice, Page 200-204.
Okullo A, Temu A. K, Ntalikwa, J.W, 2011, Transestrification Reaction Kinetics Oil
for Biodiesel Production.

Praptijanto A, 2011, Sonochemistry approach for a new process biodiesel production

from jatropha curcas oil.

Perry, R. H., Green, D. W. and Maloney, J. O, 1997, Perrys Chemical Engineers

Handbook, 7th edition. (McGraw-Hill).

51