7.

PROCESSEQUIPMENTDESIGN

1.ROTARYDRIER

Feed

(NH4)2SO4+H20 Hotair
Spentair
Product
Moist(NH4)2SO4

Amountofwaterinfeed=212.5
kg/hrDrysolidinfeed=10417kg/hr
Watercontentinproduct=105.25kg/hr
Hence water dried in drier = 107.25
kg/hrInletairtemperature=150C
Outletairtemperature=85C
Inlettemperatureoffeed=30C
Dischargetemperature=80C
Assumingwetbulbtemperatureof80C,70%humidityofair.
Thetemperatureoftheairleavingthedriershouldbeselectedonthebasisofaneconomic
balancebetweendriercostandfuelcost.Ithasbeenthatrotarydriersaremosteconomically
operatedwhenthetotalnumberoftransferunits(NTU)rangefrom1.5to2.0.Assuming
NTU=1.5.

NTU=ln[[tg1tw]/[tg2tw]]

1.5=ln[{15080}/{tg280}]
tg2=95.62C
Heatbalance
Cpof (NH4)2SO4=1.63kJ/kgC
Cpofwater=4.187kJ/kgC

Temperaturedetail

Feed Air
Inlet 30C 150C
Outlet 80C 85C

Heatrequiredtorisethefeedto45C,
10417x1.63x(4530)+105.25x(4530)=261326.4kJ
Considering55kgofwaterofevaporation,
HeatrequiredtoHYDSRUDWH NJ RI ZDWHU P

=55x2400
=132000kJ
Heatrequiredtosuperheattheproductto80C,10417
x1.63x(8045)+27x1.9(8045)=596085kJ

totalheatrequiredtoraisetheproducttodischargetemperature,
Qt=261326.4+132000+596085
=989412kJ
/07' DFURVV WKH GU\HU Wm

=
Wm [(15030)(8580)]
Ln[(15030)(8530)]
Theminimumvelocityofairissetbasedontheparticlesize.Airflowrateof
100lb/hr.ft3is sufficientfor420microns.Hencethiswillbeusedinapplication.The
minimumvelocityisusedsinceitgivesthesmallestpossiblesizeofdrier.
Amountofairrequired:
M=(Qt/CpW
1= 989412/(15085)
1= 15221.72kg/hr
Themaximumamountofwaterpresentinthisamountwateris60%
i.e.9133.03kg/hr
Anextraamountof10%ofthisquantitytoaccounttheheat
losses.1.1x15221.72=16743.89kg/hr.
Ifthevelocityofairis1000lb/hr.ft=4880kg/hr.m3

Areaofdrier=(16743.89/4880)3.431m2

Diameterofthedryer= [ e

=2.09m.
Diameterofdryer=2.09m.

Lengthoftransferunithasbeenrelatedtomassvelocityanddiameterbyfollowing
relation,Ltu=0.0064xCpx(G)0.84x2.04
=7.36m.
Lengthofthedrier=Ltux
NTU=7.36x1.5
=11.05m.
Followingdimensionsforthedrierare
chosen.L=12m;D=2m
L/D=12/2
=6
L/Dshouldrangeinbetween410.Hencethedesignissafe.
2.SHELLANDTUBEHEATEXCHANGER

200C
1)Temperaturedetail:
waterin
Coldfluid Hotfluid150c

Inlet 150c 970c

Waterout
Outlet 350c 200

97OC
2.Heatload

Hotfluid: (Aq.Ammonia)
Q4=mxCpx W

Wherem=1453kg/nr=3.98kg/sec.
Cp=2.57KJ/kg

QH=3.98x2.57[9720}
QH=799.99k.j
Ba+QH=Qc=Q=799KJ

WhereQH=heatloadofhotfluid
Qc=heatloadofcoldfluid.
Coldfluid:(Water)
Qc=MCxCpx.t
WhereMC=tobedetermined.
Cp=Spheatofwater.

799=MCx4.184(35.15)
MC=9.548kg/sec.

Massofcoldwaterrequiredtoremovetheheatassociated=9.548kg/sec.

2)LMTDCalculation,
t

T1=97c t2=35c
T2=20c t1=15c

Tlmtd =(9735) (2018)/ln((9735)/(2015)

CorrectionfactorFr

R=(T1T2) S=(t2 t 1)
(t2t1) (T1t1)

R=(9720) S= (3515)
(3515) (9715)
R=3.85 S= 0.2439
Fromperry6th.cd.page10.27
Considering2shellpass,4tablepassi.e.,2.4exchanger.

FT=0.8

CorrectedLMTD=22.63x0.8=18.10

0
Wlmtd=18.10

3)Rountingoffluid:

CleanerfluidiswaterShellside.
UncleanfluidisAq.Ammonia.Tubeside

4)HeatTransferArea:

Referenceperry,page(1044)Udforwaterinshellside,inorganicsolventintubesideis
rangingbetween(100250)BTU/(F.Ft2.hr)

Rangeis=(567.831419.57)
JCm2.s
3=73.57m
TotalHeatTransferArea(HTA)=799x10
2

(600x18.10)
Choosel6BWGtubes.
OD=(5/8)=0.01587m
ID=0.495 P

Lengthoftube=16ft=4.8768
Heattransferarea=0.1636ft2/ft2length=
0.04986m2/m.length.
Heattransferareaofovertube=0.04968x4.8768
2
=0.2431m
Tube

Nooftube=73.57=302
0.2431
Nearesttubecountfromperry,page1113is274.andcorrespondingshelldiameter
(inner)=438mm.

ShellID=438mm.
Correctedheattransferarea=274x0.243
=66.60m2

correctedUd=799x103
66.60 x18.1
2.
2= k
662.0W/m

5) Fluidvelocitycheck

a)Tubeside: (aqammonia)

Numberofpasses=4
Availableflowarea=xdi2xNT
4 NP
2= x(0.01257)2x274
4 4
at=0.0085m2
VelocityoffluidinthetubeVt=Mt
 fxdt

Vt=3.98x 1x 1
832 0.0085
Vt=0.563m/s

b)Shellside: (water)

shellID,Ds=438mm
Lcbafflecut =0.25xDs
Ls,bafflespacing=0.5Ds=0.219m
Sm=(p1Do)LsxDs
p1
Sm=Grosssectionalareaatcentreofshell
Nb=Noofbaffles,L=lengthoftube

p1=13inchessquarepitch=0.0206m
16

Sm=((0.02060.0158)x0.219)x0.438
0.0206
Sm=0.02235m2

Shellsidevelocity,Vs= Ms
SsxSm
=9.548
997.04x0.02235

= 0.4284m/s
No.ofbaffles
Nb+1=Totallengthoftube
 Bafflespacing

=4.8768/0.2
=22.2623

Nb=22

6)Filmtransfercoefficient
m 10
2
14.78
a)Tubeside
K=0.219
w/m0km2
Richardson
&coulson
NRC=
fVtD
At550c
M
1= 832
S=832kg/ x
m3 0.56
Cp 3x
= 0.01
257
2.5
7 1.26 x
KJ/ 10
3
kg
0
k 2=467
M 3
= NPr=
1.2 MCp
6
m
K

Ns 2.57x103x
/ 1.26x
 =1.26x
(Pageno:270 3
10 NS
297)

3
 =14.78
Fromperrypage(1029)jH=0.02
NNh=jHxNRCx(NPr)NNh
=0.02x4673x14.78
NNh=229.35
But,hidi=NNh
k
hi=229.35x0.219
0.01257
2
=3995.83 w/m 0k
20
hi=3995.83 w/m
k

(b)Shellside
at250c
C=995.045kg/m3
Cp=4.184kj/kg0k
M=0.95x103poise
k=1.42w/mk

NRC=fxVs xD (D=tubeoutsidedia)
M
1= 995.04 x 0.4254 x
0.015870.095x103
2= 7620

NPr=MxCp
K
 1= 0.95x103 x
4.18 x 103
1.42
2= 2.8
Fromperry,page(1029),jH=1x103

NNh=1x103x7620x(2.8)

=10.74
but,hodo=NNh
k
ho=10.74x1.42=960w/m2k
0.01587

ho=960w/m2k

Overallheattransfercoefficient

1=1+Dox1+Doln(Do/Di)+1
UohoDi hi 2kw hdirt

Forstainlesssteelkw=
45hdirt=0.003

1/Uo=1/960+(0.01587/0.012257x1/3995.53)
+0.01587ln(0.01587/0.01257)/(2x45)+1/0.003
Uo=243.096w/m20k
7)Pressuredropcalculation:

1) Tubeside
1 PL=4fLV
2xfxg
2gDibut,

f=0.079xRc0.25

1= 0.079x(4673)0.25
2= 0.0095
PL = 4x0.0095x4.8768x(0.563)2 x832
2x0.01257
PL =1.943aKpa

Pt =2.5( fxVt2)
2
Pt =2.5( 832x(0.563)2) =0.3796KPa
2
Ptotal 1S [ PL + Pt )

1= 4x1.9439+0.3796

2 Ptotal=9.294KPa

3 Ptotal is less than 70 Kpa hence design is

satisfactory.

2) shellside
Shellsidepressuredropiscalculatedusingbellsmethod
(Perry:page1026to1031)
NRC=7620
Fromfigure10.25(a)page1031frictionfactor
fkfk=0.19

(i)Pressuredropacrosscrossflowsection Pc
0.4
Pc=bxfk xw2xN cx(Mw/Mb)
f.f2m
b=2x103
w=9.54kg/s
Sm=0.02235m2
Nc=Dsx12(Lc/Ds)/Pp
WhereDs=shell1D=0.438m
Lc=0.1095
Pp=pitchparallel(cross)flow= 13in =0.0206m
16
Nc=0.43812(0.1096 /0.438)
0.0206
Nc=16
Pc = 2x103 x0.19x9.54x16
2
10.4
997.04x0.02235

=0.0252KPa
(ii)Endzonepressuredrop3c

3c PL 1+(Ncw / Nc)

Ncw=0.8lc
Pp=0.8x0.1095
0.0206
1= 4
Pc =0.0252x1+ 4
16

3c=0.0315KPa

(iii)Pressuredropinwindowzone,Pw

2
Pw=bxw
2+0.6klcw
fmxSwxf
b=5x104
Sm=0.02235m2
Ncw=4
w=9.84kg/s
S=997.045kg/m2
AreaforflowthoughwindowSw=SwgSwt
Swg,fromfig(1018),page(1029),perryhandbook.

Swg=0.029
Swt=NT(1Fc)Do
8
1= 274x(10.68)x(0.0158)2
8

Swt=0.0085

Sw=0.0290.0029

Sw=0.0205m2
PressuredropatwindowzonePw
=5x104x(9.54)2x(2+0.6x4)/0.02235x0.0205x997.045
Pw =0.386Kpa

Totalpressuredropatshellside,PTwouldbegivenby
PT =2x Pc + (Nb 1)x Pc +Nb Pw

1 PT=2x0.0315+(221)x0.0252+22x0.386
2 PT=9.08Kpa

Totalpressuredropatshellsideislessthan70Kpahence,shell&heatexchangerdesign
issatisfactory.
 8. MECHANICALDESIGNOFPROCESSEQUIPMENTS

1. MECHANICALDESIGNOFROTARYDRIER

1. Flightdesign:
Numberofflights=3xD.
=3x2.09

=6.277flightsarerequiredusinglipangleof
45.Radialheightistakenas1/8ofdiameter,
Radialheight=2.09/8
=0.2615m.

2.Thicknessofdryer:
Letxbethethicknessofdrier.
Mildsteelcanbeusedsinceitcanwithstandtemperatureupto
200C.Density=7688.86kg/m3.
D2D1=2x.
Volumeofmildsteel=(D22/4D12/4)xL

=((D1+2x)2/4D12/4)x
L=DLx.

Weightofdryer=x12.24x2.09xxx7688.86
=0.626x106xkg.
Assumeholdup=0.2
Volumeofdrierfilledwithmaterial=D2Lx0.2
4
 2
= x2 x12.x0.2
4
=7.53m3.

Weightofmaterialatanytime =7.53x1049.2
= 11219.7kg.

Thedryerissupportedovertwotensionrollassemblies,20ftapart.Itis
uniformlydistributedload.
Maximumbendingmoment=WL/8=M.
6
M=(0.626x10 x/8+11219.7/9)x12

=0.939x106x+
16829.5Weknowthat
M=fxZ.
26 =x(D24D14)/32D2.
1= 0.785x3+12.59x2+67.31x.

f=1800psi.Take
factorofsafety=5.

6 =3.6x105lb/ft3.
=1.75767x104kg/m2.
ThusM=fxZonsimplificationbecomes,
1.38x106x3+22.13x106x2+113.264x106x0.819=0

x=15mm
 3.Diameterofthefeedpipe:

Feedrate=10417+212.9=10629.9kg/hour
Densityoffeed=1410kg/m3
3
Hencevolumetricfeedrate=10629.9/1410=7.534m /hrAssuming
0
thevelocityofair=150m/hr,forchuteinclinationof60

Crosssectionoffeedchute=7.53/150=0.050m2
Diameteroffeedchute=(C.S.A.x4/)=(0.050x4/)
=0.252m
4.BHPtodrivethedrier:

BHP=rx(4.75xdxw+0.1925xdxw+0.33w)/1000
Where,
w=weightofthedrier+weightofthematerial+weightofthe
insulation.

w=x12x2x0.01x7688.86+/4x(2212x0.1x1410)
w=28.65.65x103kg

HPofblower:
Temperatureofatmospheric=300C
Humidityinair=16743.89kg/min=915.5ft3/min
Volumeofthisair,Q=279.05/29x22.4x303/298

1= 219.9m3/min
2= 718.9ft3/min
 HPofblower=0.000157xQx(headdevelopedbywater)
=0.000157x718.9x10
=1.2hp
5.HPofexhaustfan

Outlettemperatureofdrier=95.620C
Humidityofoutletair=0.65x0.00726
Totalquantityofairgoingout=16743.9kg/hr=279.05kg/min
Volumeofthisair=(279.05/29)x22.4x(368.62/298)
3 3
=406.9m /minor1335.13ft /min.
HPofexhaustfan=0.000517x1335.13x16
=6.90hp

6.Diameterofoutletandinletpipe

0
Atinletconditionsof150 Candhumidityof0.002
thevolumeofairhandled=219.2x423/303
=306m3/minor5.1m3/sec.

Assumingairvelocity=25m/s,
C.S.Aofinletpipe=5.1/25=0.20m2
Inletpipediameter=0.504m
Atoutletconditionsof95.620C
Thevolumeofairhandled=219.2x368/313
=4.43m3/sec
C.S.Aofoutletpipe=4.43/25=0.178m2
Outletpipediameter=0.476m
2.MECHANICALDESIGNOFHEATEXCHANGER

(1) Shellsidedetails
Material:carbonsteel
Numberofshellpasses:
2Workingfluid:water
2
Working pressure: 0.1N/mm
2
Designpressure:0.11N/mm
0
Inlettemperature:15 C
Outlettemperature:350C
Permissible stress for carbon steel:
95N/mm2Shellinnerdiameter:438mm

(2) Tubesidedetails
Numbertubes:274
Numberofpasses:4
Outsidediameter:
15.87mmInsidediameter:
12.57mm.Length:4.88m
Pitchtriangular:13/16inch
2
Workingpressure:0.1N/mm
2
Designpressure:0.11N/mm
0
Inlettemperature:97 COutlet
0
temperature:20 C
 SHELLSIDE

1.Shellthickness

ts=PD/(2fJ+P)
1= 0.11x438/(2x95x0.85+0.11)
1= 0.31

Minimumthicknessofshellmustbe=6.0mm
Includingcorrosionallowanceshellthicknessis8mm

2.Headthickness.
Shallowdishedandtorispherical

w=1/4x(3+ 5c/RK)
= 1/4x(3+ 5c/.06Rc)
= 1.77

t=PRcW/2fJ
1= 0.11x305x1.77/(2x95x0.85)
2= 0.528mm.
minimumshellthicknessshouldbe10mmincludingcorrosionallowance.

3.TransverseBaffles

Bafflespacing=0.8xDc
=350mm
numberofbaffles,
Nb+1=L/LS=4.88/0.350=14
Nb=13
Thicknessofbaffles,tb=6mm

4.TieRodsandspacers:
Tierodsareprovidedtoretainallcrossbafflesandtakesupportplates
accurately.Forshelldiameter,300500mm
DiameterofRod=
9mmNumberofrods=4

5.Flanges

Designpressure=0.11N/mm2
FlangematerialIS:20041962,class2
Boltingsteel:5%CrMosteel
Gasketmaterial:asbestoscomposition
Shellinsidediameter=438mm.
Shellthickness:8mm=go
Outsidediameterofshell:446mm
Allowablestressofflangematerial:100MN/m2
Allowablestressofboltingmaterial=138MN/m2
Shellthicknessofflange=10mm.
Outsidediameterofflange=325mm.

6.Determinationofgasketwidth
dO/di=[(yPm)/(yP(m+1))]0.5
 Assumeagasketthicknessof10mm
y=minimumdesignyieldseatingstress=25.5MN/m2

m=gasketfactor=2.75
dO/di=[(44.850.11x2.75)/(44.850.11(2.75+1))]0.
5
dO/di=1.001=1.001
dO=1.001x0.438=0.4385m
Minimumgasketwidth=(0.43850.438)/2=.
00075.TakinggasketwidthofN=0.010m
do=0.458m.
Basicgasketseatingwidth,bo=5mmDiameter
oflocationofgasketloadreactionis
G=di+N
=0.438+0.01
=0.448m

7.EstimationofBoltloads.
Loadduetodesignpressure
H=G2P/4
1= 3.14x0.4482x0.11/4
2= 0.01756MN
Loadtokeepjointtightunderoperation

0.5
b=2.5(b0) =6.12mm.
Hp=G(2b)mp
1= 3.14 x0.448 x (2 x0.00612) x2.75
x0.11
2= 0.00656MN
Totaloperatingload
Wo=H+Hp
=0.01755+0.00656
 =0.0241MN.

Loadtoseatgasketunderboltingcondition
Wg=Gby
1= 3.14x0.448x6.12x103x25.5
2= 0.862MN.
Wg>Wo,controllingload=0.8620MN

8.Calculationofoptimumboltingarea

Am=Ag=Wg/Sg
1= 0.862/138
2= 6.246103m2
Calculationofoptimumbolt
sizeBoltsize,M18X2
Actualnumberofbolts=20
Radialclearancefromboltcircletopointofconnectionofhubornozzleandbackof
flange=R=0.027m
C=ID+2(1.415g+R)=325
+2[1.41x0.008+0.027]=
0.726m
Boltcirclediameter=0.40163m.
UsingboltspacingBs=45mm
C=nBs/3.14=44x0.045/3.14=0.63
HenceC=0.726
Calculationofflangeoutsidediameter
Letboltdiameter=18mm.
A=C+boltdiameter
+0.02=0.716+0.018+0.02
 =0.764m.

Checkforgasketwidth
AbSG/(GN)=1.54104x44x138/(3.14
x0.44862)=66.43<2xy.
whereSGistheAllowablestressforthegasketmaterial

9.Flangemomentcomputation:

(1) Foroperatingcondition
Wo=W1+W2+W3
W1=B2P/4
1= x0.4462x0.11/4
2= 0.0173MN
W2=HW1
=0.017560.0173
=1.6104MN.
W3=WoH=Hp
=0.00672MN.
Mo=Totalflangemoment
Mo=W1a1+W2a2+W3a3
a1=(CB)/2=(0.7260.446)/2
a1=0.14ma3=(C
G)/2=(0.7260.448)/2
a3=0.1395m
a2=(a1+a3)/2=(0.14+0.1390.)/2
=0.139m
Mo=0.01739x0.140+1.60104x0.1395x0.00672+0.139
Mo=3.391103MNm
 (b)Forboltingcondition
Mg=Wa3
W=(Am+Ab)xSg/2

W=(6.2461003+6.76103)x138/2
W=0.897MN
Mg=0.0.897x0.139
=0.125MNm

Mg>Mo,HencemomentunderoperatingconditionMgiscontrolling,Mg=M

10.Calculationofflangethickness

t2=MCFY/(BSF),SFistheallowablestressfortheflange
materialK=A/B=0.764/0.446=1.71
ForK=1.71Y=4.4
AssumingCF=1

t2=0.125x1x4.4/(0.446x100)
t=0.11m

ActualboltspacingBS=C/n=(3.14)(0.776)/(44)=
0.052m11.BoltPitchCorrectionFactor
CF=[Bs/(2d+t)]0.5
1=(0.052/(2x0.018+0.11)1/2
2= 0.596
CF=0.772
Actualflangethickness=CFxt
1= 0.11x0.772
2= 0.085m
3= 85mm.
12.ChannelandchannelCover
th=Gc(KP/f)
1=0.446x(0.25x0.11/95)
2= 0.00767m=7.67mm
th=8mmincludingcorrosionallowance

13.Tubesheetthickness
tts=FG(0.25P/f)
1= 1x0.448(0.3x0.11/95)
2= 0.0084=8.84mm
tts=9mmincludingcorrosionallowance.

14.Saddlesupport
Material:lowcarbonsteel
Totallengthofshell:4.88m
Diameterofshell:4.38mm

Knuckleradius:6%ofcrownradius=26.28
mmTotaldepthofhead(H)=(Doro/2)

=(438
x26.28/2)H=
75.86mm
A=0.5R=0.5x438/2=109.5mm.
weightofvesselandcontents=weightof(shell+tube)
weightofthesteel=7600kg/m3.
Weightofshell=Dx0.008x7600xL
1= 83.67x4.88

2= 408.30kg

Weightoftube=(19.05100312.271003)x4.88x7600x274
=1480kg

weightofwater=0.012242x4.88995x274=
626.19kg
weightofvesselandcontentsW=2215.69kg

15.LongitudinalBendingMoment

M1=QA[1(1A/L+(R2H2)/(2AL))/(1+4H/(3L))]
Q=W/2(L+4H/3)
1= 2215.6/2x(4.88+4x0.07586/3)
2= 5518kgm
M1=598.05kgmkgm

16.Bendingmomentatcenterofthespan

M2=QL/4[(1+2(R2H2)/L)/(1+4H/(3L))4A/L]
M2=6014.4kgm
17.Stressesinshellatthesaddle
(a)Atthetopmostfibreofthecrosssection
f1=M1/(k1R2t) k1=k2=1
=598.06/(3.14x0..2192x0.01)
=35.22kg/cm2
Thestressesarewellwithinthepermissiblevalues.
Stressintheshellatmidpoint
f2=M2/(k2R2t)=6014.4/(1x0.21920.01)
 =399.07kg/cm2

Axialstressintheshellduetointernal
pressurefp=PD/4t
1= 0.11x438/(2x10)
2= 225.53kg/cm2
f2+fp=624.64kg/cm2
thesumf2andfpiswellwithinthepermissiblevalues.