II.

EQUIPMENT DESIGN

A. SPECIFICATION SHEET
IDENTIFICATION
Name of Equipment Fluidized Bed Reactor
Code F-1 Unit/s Required 1
APPLICATION SERVICE
To combust spent coffee grounds to combustion gas
OPERATING CONDITION
Mode of Operation Batch
Temperature 343 C
Pressure 8 atm
Time of reaction 1.98 hrs
Fluidization Velocity 0.75 m/hr
Power Requirement 2,250 hp
MATERIALS HANDLED
Composition Spent coffee grounds, compressed air

Density of Mixture 1,993.16 kg/m3

Mass of Feed 9,938.08 kg
Mass of Fluidized Gas 9,847.74 kg
CONSTRUCTION DETAILS
VESSEL
Material of Construction ASME SA-302, Grade B
Orientation Horizontal
Design Capacity 2,400 m3
Type of Joint Double V Butt Joint
Joint Efficiency 0.90
Diameter 9.46 m
Length 28.33 m
Shell Thickness 3 in
Head Thickness 4 in
BED DESIGN
Fluidizing Bed Activated carbon
Model A-BAC SP
Density of activated carbon 600 kg/m3
Diameter of particle 0.638 mm
Mass of Bed 530.22kg
Location of Bed
from the bottom of the tank 3.15 m
from the top of the tank 6.27 m
Height of Bed 0.027 m
Height expansion of Bed 0.037 m
Volume of Bed 0.88 m3
Pressure drop of Bed 41.34 Pa
INSULATION DESIGN
Insulating Material Alumina Bricks
Thermal conductivity
2.7

Thickness 31 cm
B. FLUDIZED BED REACTOR
Summary of Assumptions:

1. Using Modelling & Simulation of Fluidized-Bed Boilers & Gasifiers for Carbonaceous Solids

by Souza-Santos activation energy and frequency factor in this reaction are taken respectively

at E/R = 13,597 K and A = 5.16 x 1010 /hr.

2. Crone CKS uses activated carbon for fluidizing bed/medium in its reactor

3. A BAC SP is the type of activated carbon that will be ued in this reactor.

4. Activated carbon is spherical so, =0.45, and s =1.

5. The shell is assumed to be cylindrical while the head is assumed to be torispherical.

Summary of Equations:

Density of mixture

1
=

=1

Arrhenius Equation

Residence time

1 1
=
1

Viscosity of Gases

gas= A TB/(1+ C/T +D/T2)

 Minimum Fluidization Velocity

( )0.934 ()0.934 ( )1.8

umf (in m/s) =
7770( )0.87 ( )0.066

Volumetric flow rate

/
vo =

Area of the reactor

Area of the reactor =

Diameter of the reactor

4
Diameter of the Reactor =

Length of the reactor

Volume of the reactor

Length, l =
unit area

Volume of bed

Volume of Bed =

Height expansion on bed

(1 )
l= lm
(1)

Pressure
2
150 (1 )2 1.75 (1 )
= 3 + 3
2 2

Thickness of the shell

ts = + C for P 0.385Se
0.6
 C. Detailed Equipment Design Computations:

MW Mass Feed xi Density Volumetric Feed No. of

Component (kg/kmol) rate () rate moles
(kg/day) (kg/m3) (m3/day) (kmol)
Spent Coffee 121.58
6.58 800.00 0.08 350 2.29
Grounds
Air 29.00 9,138.08 0.92 4.59 1,990.87 315.11

Total 9,938.08 1.00 4.98 1,993.16 436.69

Reaction Involved:

CH1.73N0.04O0.48 + 2O2 CO2 + 0.04NO2 + 0.33O2 + 0.87H2O

I. CAPACITY DETERMINATION

Density of mixture

The density of a mixture of can be estimated as:

(Elementary Principles of Chemical Processes by Felder p. 189)

1
=

=1

1 0.08 0.92
= +
350 4.59

mixture = 4.98 kg/m3 =0.30 lb/ft3

Vmixture = 1,993.16 m3

Moles of the Reactant = 436.69 kmol

For the rate constant, k

(Modelling & Simulation of Fluidized-Bed Boilers & Gasifiers for Carbonaceous Solids by
Souza-Santos p.141)

A = 5.16 x 1010 /hr

E/R = 13,597 K

T = 616.15 K

Therefore,

13,957 K
k =5.16 x 109 /hr e( 616.15 K )

Rate constant = k = 1.34/hr = 0.0223/min

Conversion: 93%, first order reaction

1 1
=
1

1 1
=
1.34/ 1 0.93

tresidence = 1.9845 hr = 119.07 min

Volume of Feed = 1,993.16 m3

Volume of Reactor = 1,993.16 m3 (from brochure, Volume of reactor = 2,400 m3)

For Combustion Gas:
(Outlet/Product Side)

Component MW Mass (kg) No. of moles

N 28 7008.82 250.32
NO 30 27.68 0.92
NO 46 22.85 0.50
CO 44 1,457.42 33.12
CO 28 18.93 0.68
O 32 1086.40 33.95
HO 18 222.84 12.38
Flying Ash 22 2.80 0.13
Total 248 9,847.74 332

Viscosity of Gases:

gas= A TB/(1+ C/T +D/T2) (Pa-s) ; T = 273.15 + 343 = 616.15 K

Component xi A B C D
-7
N 0.7117 6.5592X10 0.6081 54.714 - 2.9944X10-5
-6
NO 0.0028 1.467X10 0.5123 125.4 - 3.2744X10-5
-6
CO 0.1480 2.148X10 0.46 290 - 2.8040X10-5
-6
CO 0.0019 1.1127X10 0.5338 94.7 - 2.9745X10-5
-6
O 0.1103 1.101X10 0.5634 96.3 - 3.5516X10-5
-8
HO 0.0226 1.7096x10 1.1146 - - 2.1985X10-5
th
Ref: Ch.E. Handbook, 8 Ed by Perry and Green
NO2 = 130X10-6 Pa-s
(Properties of Gases by Isidoro Martinez, http://webserver.dmt.upm.es/~isidoro/dat1/eGAS.pdf)
XNO2 = 0.0023

ave= (0.7117)(2.9944X10-5) + (0.0028)(3.2744X10-5) + (0.0023)(130X10-6) +

(0.1480)(2.8040X10-5) + (0.0019)(2.9745X10-5) + (0.1103)(3.5516X10-5) +

(0.0226)(2.1985X10-5)

ave = 3.03X10-5 Pa-s

 II. VESSEL DESIGN

Gas Phase Density

Total moles of Gas Mixture = 332kgmole

Total wt. of Gas Mixture = 9,847.74 kg

gasat 8 atm and 343 C

usinggas =

9,847.74
( )(8105 )
332
gas = 8.314 3 1000
= 4.69 kg/m30.2930 lb/ft3
( )( )(616.15 )

Minimum Fluidization Velocity: (ChE HB 6th Ed. 20-54; Wen and Yu Correlation)

( )0.934 ()0.934 ( )1.8

umf (in m/s) = ; using SI units
7770( )0.87 ( )0.066

Based onthe study High Quality Biodiesel from Spent Coffee Grounds by Mirsa et. al, Dp for

spent coffee ground is 0.638mm.

(4.89 4.69)0.934 (9.8)0.934 (0.638103 )1.8

umf= = 2.08x10-4m/s 0.75 m/hr
7770(3.03X105)0.87 (4.69)0.066

Volumetric flow rate

9847.74
/ 3
vo = = 1.99
= 52.7552 .
4.69 3

Area of the reactor

3
52.76
Area of the reactor = =
m = .
0.75 hr
Diameter of the reactor

A=70.35 m2

2
70.35 m2=
4

4 4(70.35 m2)
Diameter of the Reactor = =

Diameter of the Reactor =9.46 m

Length of the reactor

Volume of the reactor

Length, l =
unit area

Vcalculated = 1,993.16 m3

1,993.16 m3
Length = = 28.33 m
70.35 m2

III. AUXILLARY DESIGN

Bed Design

Fluidizing Bed/ Medium

Crone CKS uses activated carbon for fluidizing bed/medium in its reactor.
Mass of bed
(Modelling & Simulation of Fluidized-Bed Boilers & Gasifiers for Carbonaceous Solids by
Souza-Santos)

0.625
Mass of bed needed=800.00 kg SCG * = 530.22 kg activated carbon
0.943

Volume of bed

, =600 kg/m3

530.22
Volume of Bed = =
600 3

Volume of the Bed = 0.884 m3 .

Height of bed

For a horizontal cylinder, the volume may be calculated using:

= [ 2 2 arccos ( ) + ( ) ((2 ))]

Reference: http://www.hagra.nl/glossary/convertors/horizontal-tank-volume-calculator.html

Using the construction details above and solving for h:

Height of bed (lm)=0.027 m

Area = W x L

Liquid height

r
r-h

w/2
Solving for W:

( )2 = 2 ( )2
2

( )2 = 4.372 (4.37 0.027)2
2

= 0.97

A = 0.97 m x 28.33 m = 27.48 m2

Height expansion of bed

Using equation of 7.58 for height of bed in Unit Operations of Chemical Engineering by

Mccabe and Smith, 6th ed. = 0.60 , based on the Fig 7-11.

(1 )
l= lm
(1)

(10.45)
l=0.027 m*
(10.60)

Height expansion of bed (l)=0.037125 m .

Location of the bed

From Albrights Chemical Engineering Handbook by Lyle F. Albright

1 1
H from the bottom= ( ) = (9.46) = 3.15
3 3

H from the top=

H from the top= 9.46m -0.037m-3.15m

Hfrom the top= 6.27 from the top

Pressure

Using Ergun equation for fluidized bed system, equation 7.50 Unit Operations of

Chemical Engineering by Mccabe and Smith, 6th ed.

2
150 (1 )2 1.75 (1 )
= 3 + 3
2 2

where =0.45 and s=1 for spheres

2
150(3.03x105 Pas)(2.08x104 m/s)(10.45)2 1.75(4.98 /3 )(2.08104 /) (10.45)
= +
2.41 (1)2 (0.638103 )2 (0.45)3 (1)(0.638103 )0.453

= .

Material of Construction

ASME SA-302, Grade B by Peters and Timmerhaus

Sw = 115800 psi; Fm = 1.0; Fr = 1.06; Fa = 1.12; e = 1.0 for seamless

Sult= Sw x Fm x Fs x Fr x Fa

Sult = 115800 psi x 1 x 1.06 x 1.12

Sult = 137477.76 psi

Thickness of the shell

For cylindrical shells from Plant design and Economics by Peters and Timmerhaus,p.554

ts = + C for P 0.385Se
0.6

take C = 1/16 for corrosion allowance

Pmax= ( ) + Poperating condition

9.8
530.22( )
2
= +810,600Pa
27.482

14.7
Pmax= 810,789.09 Pa ( )=117.63 psi
101325

3.25 3.2808 12
(117.63 )( )( ) ( ) 1
2
ts = (137477.76)(0.9)117.63(0.6)
+
16

ts = 3.12

Note: e = 0.9 is valid since the thickness exceeds to 5/8 in.

Head Design

For torispherical head from Plant design and Economics by Peters and Timmerhaus,p.554

0.885
th = + for r = knuckle radius=6% inside crown radius and not less than 3t
0.1

Do = Di + 2ts

3.2808 12
Do= (9.5 m) ( )( )+ 2(0.12 in)
1 1

Do = 374.25 in
Crown Radius, Cr = L =374.25 6 = 368.25 in

Knuckle Radius = Kr = 0.06Do = 0.06 (374.25) = 22.46 in; e = 1.0 for seamless head

0.885(117.63 )(374.25 ) 1
th = +
137477.76(1.0)0.1(117.63 ) 16

th= 4.28 in4 in

Heating System Design

Q = UAT

Based on the energy balance, QR= 2,923,709.86 kJ

4,210,985.63 kJ 1
= = 1,476,621 1,399,566.76 /
1.98

Insulation Design

Crone CKS Liquid-cooled systems are used for high-temperature pre-heating, stress relieving.

(Reference:Crone CKS,info@fhcrone.nl)

For maintaining this condition, the suggested insulating material is to bealumina brick with

= 2.7 (Reference: Ch.E. Handbook, Perry and Green Table 2-326);

For the stainless steel of ASME SA-302 Grade B

= 12.4 (Reference: Ch.E. Handbook, Perry and Green Table 2-328)

 (1 )
Q=
+

3.2808 2
(9,46)(28.33)( ) (649.4086)
1,399,566.76 / = 1
1
3.25 ( 12 )
+
2.7 12.4

= 1.0198 = 0.310 31.00

IV. EQUIPMENT SIZING

From Silla:

Power = Volume x ;
1000

1000 0.2642 3.25

Power = 2400 m3 x x x
1 3 1 1000

Power = 2060.76 hp = 1,544.04 kW

Standard Electric-Motor Size

(Reference: Chemical Process Engineering, Design and Economics by Harry Silla. 2003)

=
 A. SPECIFICATION SHEET

IDENTIFICATION
Name of Equipment Fixed Bed Tubular Reactor
Code R-1 Unit/s Required 3
APPLICATION SERVICE
To oxidize N2 and NO gases, and convert NO2 to N2O4.
OPERATING CONDITION
Mode of Operation Continuous
Temperature 800 C
Pressure 8 atm
Time of reaction 5.8243 s
MATERIALS HANDLED
Composition N2, NO, NO2, CO, CO2, O2, H2O
Density of Mixture 1.194 kg/m3
Mass of Feed 8,372.72 kg
CONSTRUCTION DETAILS
VESSEL
Material of Construction AISI 309
Orientation Horizontal
Type Cylindrical
Design Capacity 58.61 m3
Type of Joint Double V Butt Joint
Joint Efficiency 1.0
Shell Diameter 2.75 m
Length 12.50 m
Shell Thickness 5.75 mm
Head Thickness 7.00 mm
Pressure Drop 6.06 Pa
PIPE
Number of Pipes 824
Pipe Diameter 0.4992 m
Number of Pass 8
Pressure Drop 30.14 Pa
PIPE
Number of Baffles 6
Baffle Length 2.25 m
Baffle Spacing 0.55 m
INSULATION DESIGN
Insulating Material Alumina Bricks

Thermal conductivity 2.7

Thickness 13.50 mm
CATALYST
Name of Catalyst Tungsten Oxide (WO3)
Volume 9.737 m3
Width of Bed 2.00 m
POWER REQUIREMENT
Power 60 hP
B. Equipment Drawing

Plug Flow Reactor

Catalyst Bed Width = 2.0 m

Volume = 9.737 m3

Baffles total = 6

BS = 0.55 m BL = 2.25 m

2.75 m

30%
Oxygen
Volume = 40.88 m3
XInsulation = 13.5 mm
Heated
Decarbonized
Flue Gas
12.50 m
D = 2.75 m

TH = 7.0 mm
Do = 0.0603 m
TS = 5.75 mm
C = 0.0151 m

Pt = 0.0754 m

Total Power requirement

= 60 hP

Length of Electrode = 3.7 m

 C. Detailed Computations:

MW Mass Feed Density Volumetric Feed No. of yi

Component rate () rate moles
(kg/day) (kg/m3) (m3/day)
N2 28 7,008.82 1.145 250.315 0.8395
6,121.24
NO 30 27.68 1.34 0.9227 3.0947x10-3
20.66
NO2 46 22.85 2.62 0.4967 1.6659x10-3
8.72
CO2 44 4.08 1.799 0.0927 3.1091x10-4
2.27
CO 28 0.05 1.14 1.786 x10-3 5.9901x10-6
0.04
O2 32 1,086.40 1.308 33.95 0.1139
830.58
H2O 18 222.84 0.804 12.38 0.0415
277.16
Total 8,372.72 7,010.67 298.1598 1

Density of feed

total mass
feed =
total volume
8,372.72 kg
feed =
7,010.67 m3

feed = 1.194kg/m3
Vfeed = 7,010.67 m3
Moles of the Reactant = 298.1598 kgmol

For the initial concentration of N2

Mass = 7,008.82 kg
 =

= 0.8395(28) + 3.0947x103 (30) + 1.6659x103 (46) +

3.1091x104 (44) + 5.9901x106 (28) + 0.1139(32) + 0.0415(18)

MWave = 28.08 kg/kmol

Vfeed = 7,010.67 m3

=

7,008.82 kg
28.08 kg/kmol
=
7,010.67 m3
= . kgmol/m3 = . mol/L

For the rate constant, k

(Ref: Evaluated Kinetic Data for Combustion Modeling: Supplement II by Baulch, D. L, et al)
WO3
For N2 + O2 2NO

k = 2.3649 x 104

For the reaction time t R

( + )
= ( + ) ( ) + +

(2.3649 x 104 )(0.0356 ) = 2(0.3006)(1 0.3006) ln(1 0.9999) +
(1 0.3006)2 (0.9999)
(0.3006)2 (0.9999) +
1 0.9999
= = 5.8143
 Volume Computation

1
=

1
5.8143 = 3
7,010.67
24 60 60

1 = 47.178 3

For the initial concentration of NO

Mass = NOfeed +NOformed

Mass = 27.68 kg + 15,018.90 kg

Mass = 15,046.58 kg

= 0.8395(28) + 3.0947x103 (30) + 1.6659x103 (46) +

3.1091x104 (44) + 5.9901x106 (28) + 0.1139(32) + 0.0415(18)

MWave = 28.08 kg/kmol

Vfeed = 7,010.67 m3

=

15,046.58 kg
28.08 kg/kmol
=
7,010.67 m3
= . kgmol/m3 = . mol/L
For the rate constant, k
(Ref: Gas-phase oxidation of nitric oxide: chemical kinetics and rate constant by Mayumi M.)

530
= 1.2103 ()

Where
k = rate constant (L/mol-s)
T = 800 C = 1073 K
530
= 1.2103 1073

= 732.26

For the reaction time t R

( + )
= ( + ) ( ) + +

(732.26 )(0.0764 ) = 2(0.44)(1 0.44) ln(1 0.96) +
(1 0.44)2 (0.96)
(0.44)2 (0.96) +
1 0.96
= = .

Volume Computation

2
=

2
0.1662 = 3
7,010.67
24 60 60

2 = 1.349 3

For the initial concentration of NO2

Mass = NO2feed +NO2formed

 Mass = 22.85 kg + 22,148.57 kg

Mass = 22,171.42 kg

= 0.8395(28) + 3.0947x103 (30) + 1.6659x103 (46) +

3.1091x104 (44) + 5.9901x106 (28) + 0.1139(32) + 0.0415(18)

MWave = 28.08 kg/kmol

Vfeed = 7,010.67 m3

=

22,171.42 kg
28.08 kg/kmol
=
7,010.67 m3
= . kgmol/m3 = . mol/L

For the rate constant, k

(Ref: Evaluated Kinetic Data for Combustion Modeling: Supplement II by Baulch, D. L, et al)
For 2 NO2 N2O4

k = 103.97

For the reaction time t R

( + )
= ( + ) ( ) + +

(103.97 )(0.1126) = 2(0.001255)(1 + 0.001255) ln(1 0.3333) +
(1 + 0.001255)2 (0.3333)
(0.001255)2 (0.3333) +
1 0.3333
= = 0.0428
 Volume Computation

3
=

3
0.0428 = 3
7,010.67
24 60 60

3 = 0.347 3

Volume of the Catalyst Determination

Space Velocity
(from Zhang, J. et. al Novel Approach for High Efficient Catalyst, 2012)
1
= 0.01 1

1
=

3 1 1
0.01 7,010.67 20 3600
=

= 9.737 3

= 1 + 2 + 3 +

= 47.178 3 + 1.349 3 + 0.347 3 + 9.737 3

= 58.611 3

Dividing the reactor:

58.611 3
one reactor =
3
one reactor = 19.537 3
Since L/D = 200 (Ref: Chapter 6: Rules of Thumb in Engineering Practice by D.R. Woods,2007)
Selection of pipe:
 Nominal pipe size = 2 in
Schedule no. = 80
Inside Diameter = 0.0493 m
Outside Diameter = 0.0603 m
Thickness = 0.006 m
Flow area of one tube = 0.0019 m2

3 4
=
( )

3 4(19.537 3 )
=
200

= 0.4992

= 200
= 200(0.4992 )
= 99.84 100

Number of Pipes

PFR 2
Required Flow area for = = (0.4992 )2 = .
pass 4 4
PFR
Required Flow area for pass
. =

0.19572
. = = 103 /
0.00192

. = 103(8) =
 Length of Shell

=
.
100
= = .
8

Bundle Diameter

Selection:
Tube arrangement = Fixed and U-Tube
Tube Pitch = Triangular (Pt =1.25 Do)
Pt = Do + C
Pt = tube pitch; Do = tube outside diameter; C = clearance

(Ref: Chapter 12, Chemical Engineering Design Volume 6, Coulson et. al,1983)

P = 1.25 = 1.25(0.0603 m) = 0.0754

k 1 = 0.0365; n1 = 2.675
1
n1
D = ( )
k1
1
824 2.675
D = 0.0603 ( ) = .
0.0365
= 0.0754 0.0603 = 0.0151 m 15.1 mm
 Diameter of Shell

Since Bundle Diameter (Db) is 2.3379 m, Diameter of the shell is 2.75 m

Baffle Length

= 0.75 = 0.75(2.75) = 2.06 .

Number of Baffles
12.5
= = 5.56
2.25

Baffle Spacing
1
= (2.75 ) = .
5

(Ref: Perrys Chemical Engineering Handbook 8th Ed. Chapter 11)

Material of Construction

Total Operating Pressure: = 9

Maximum Allowable Pressure = 1.2 Pmax
Maximum Allowable Pressure = 1.2(9 atm) = 10.8 atm

Minimum Wall Thickness of the Pipe

= +
0.6
Where:
P = Maximum Allowable Internal Pressure, atm
S = Maximum Allowable Working Stress, atm
e = efficiency of joints expressed as a fraction
C = Allowance for corrosion, m
r = inside radius of shell before corrosion allowance is added, m
From Perrys Chemical Engineering Handbook 8th ed, Table 25-11
AISI 309 UNS S30900: S = 95,001.20 psi = 6,462.67 atm
2.75
(10.8 )( )
2
= + 0.003
(6,462.67 )(0.9) 0.6(10.8)
= 0.00556 = 5.56 .

Head Design

For torispherical head from Plant design and Economics by Peters and Timmerhaus,p.554
0.885
th = + for r = knuckle radius=6% inside crown radius and not less than 3t
0.1

Do = Di + 2ts
Do= (2.75 m) + 2(0.00575 m)
Do = 2.7615 3.00 m
Crown Radius, L = Cr = Do -0.1524m = 2.7615 m 0.1524 m = 2.6091 m
Knuckle Radius = Kr = 0.06Do = 0.06 (2.6091) = 0.1565 m; e = 1.0 for seamless head
0.885
= +
0.1
0.885(10.8)(2.6091 )
= + 0.003
(6,462.67 )(1) 0.1(10.8)
= 0.0069 = 6.90 .

Pressure Drop
2
= [8 ( ) + 2.5]
2
3
= 2.472 10
Using Figure 12.24 Coulson and Richardson Chemical Engineeing Design Vol 6, 4th ed
Jf = 0.0070
12.5 1.194kg/m3 (0.209/)2
= 8 [8(0.0070) ( ) + 2.5]
0.00493 2

= 30.14

Shell Side

Equivalent Diameter

Using Eq 12.23 & Fig.12.30 Coulson & Richardson Chemical Engineering Design Vol. 6, 4th ed
1.1 2
= ( 0.917 2 )

1.1
= [(0.0754)2 0.917(0.0603)2 ]
0.0603
= 0.0429
2
= [8 ( ) ( ) + 2.5]
2
Jf = 0.057

0.4492 12.5 1.194kg/m3 (0.209/)2

= 8 [8(0.057) ( )( ) + 2.5]
0.0429 2.25 2

= 6.06 Pa

Heating System Design

Based on the energy balance, QR= 5,286,931.80 /

21,880,522.50 1
= = 3,763,225.58 12,840,608,200 /
5.8143
Equipment Sizing

Reference: Chemical Process Engineering, Design and Economics by Harry Silla. 2003

=
1000
1000 0.2642 3.25
= 58.61 3
13 1 1000
= 50.33 37.53

Standard Electric-Motor Size

(Reference: Chemical Process Engineering, Design and Economics by Harry Silla. 2003)

Length of Electrode
12.5
= = .
3
 Insulation Design

Insulating material: Alumina Bricks

= 2.7 (Reference: Ch.E. Handbook, Perry and Green Table 2-326);

For the stainless steel of AISI 309

= 10.8 (Reference: Ch.E. Handbook, Perry and Green Table 2-328)

(1 )
Q=
+

3.2808 2
(2.75)(12.5)( ) (147286)
12,840,608,200 / = 1
1
0.1969 ( 12 )
+
2.7 10.8

= 0.0440 = 0.0134 13.50

.
For Catalyst Bed Width and Diameter:
= = 2.50
2
=
4

9.737 3 = (2.75)2
4
= 1.64 .
 A. SPECIFICATION SHEET

IDENTIFICATION
Name of Equipment Bleaching Tower
Equipment Code T-3
Equipment Type Air Stripping Tower
Number of Units Required 1
APPLICATION SERVICE
To remove dissolved NOx from the red nitric acid
OPERATING CONDITIONS
Mode of Operation Continuous
Capacity 1.20 m3
Feed Flow Rate 41002.11 kg/day
Product Flow Rate 38952.00 kg/day
Operating Temperature 50 C
Operating Pressure 8 atm
Power Consumption 4.84 kW
Materials Handled Red nitric acid and air
STRIPPING SYSTEM
Stripping Medium Air
Stripping Time 6.48 secs
Air Inlet Temperature 30 C
Air Outlet Temperature 50 C
Air Pressure 8 atm
Air Velocity 1.29 m/s
Air Mass Flow Rate 24132.08 kg/hr
CONSTRUCTION DETAILS
Shell Design
Material of Construction Stainless Steel, AISI 304
Joint Type Double welded U-butt joint
Inside Diameter 0.5000 m
Outside Diameter 0.5045 m
Height 8m
Shell Thickness 2.25 mm
Head Thickness 4.00 mm
Number of trays 15
Number of holes 1871
B. EQUIPMENT DRAWING

BLEACHING TOWER

TH = 4.00 mm

L = 8.5m Number of Trays = 15

TS = 2.25 mm
Summary of Assumptions:

1. Tray Efficiency (E) = 0.50 (an appropriate E is in the range of 0.4 to 0.6 U.S. ACE, 2001)

from MWH's Water treatment Principles and Design by Crittenden, p. 1100

2. Initial plate spacing (z) = 0.5 m (plate spacings of 0.3 to 0.6 m will normally be used) from

Chemical Engineering Design by Coulson and Richardson vol. 6, p. 557

3. Turn-down ratio for sieve trays = 85% (50% to 120% of design capacity from Chemical

Engineering Design by Coulson and Richardson vol. 6 Chapter 11)

4. Weir height (hw) = 45 mm (from Chemical Engineering Design by Coulson and Richardson

vol.6: for columns operating above atmospheric pressure the weir heights will normally be

between 40 to 50 mm (recommended))

Summary of Equations:

Stripping Tower Design

Theoretical Number of Sieve Trays

1 1
+1 (1 )+

log [ ]
+1

=
log

Where:

Xo = concentration of NOx in the inlet red nitric acid

Xn = concentration of NOx in the treated nitric acid

Yn+1 = concentration of volatiles in the air entering the stripping tower

m = slope of equilibrium curve

S = stripping factor
 (from Mass-Transfer Operations 3rd ed. by Treybal, R., p.275-313)

Slope of Equilibrium Curve

Where:

H = Henrys constant

Pt = ambient pressure

(from Design of Aeration Towers to Strip Volatile Contaminants from Drinking

Water, Journal AWWA by Kavanaugh and Trussell, p.684-692)

Stripping Factor

= ( )

Where:

G = molar flow rate of inlet air

L = molar flow rate of inlet red nitric acid

(from: Process Design Manual for Stripping of Organics by Shulka and Hicks)

Actual Number of Sieve Trays

Where:

E = tray efficiency

Flooding Velocity

Where:
 uf = flooding vapour velocity

K1 = a constant obtained from Figure 11.27 of Chemical Engineering

Design by Coulson and Richardson vol. 6, p. 568

L = density of liquid

V = density of vapor

Tower Height

= (( 1) ) + (3 )

Where:

Nact = actual number of trays

z = plate spacing

(from Conceptual Design of Distillation, Absorption, and Stripping Systems by

Reppich)

Weir Liquid Crest

2/3
= 750 ( )

Where:

Lw = liquid flow rate

lw = weir length

(Francis Weir Formula from Chemical Engineering Design by Coulson and

Richardson vol. 6)

Minimum Vapor Velocity

[2 0.90(25.4 )]
=
( )1/2

Where:
 K2 = constant obtained from figure 11.30 of Chemical Engineering

Design by Coulson and Richardson vol. 6, p. 571

dh = hole diameter

Dry Plate Drop

2
= 51 ( ) ( )

Where:

Co = orifice coefficient from figure 11.34 of Chemical Engineering

Design by Coulson and Richardson vol. 6, p. 576

Residual Head

12.5 103
=

Pressure Drop

= 9.81 103

Clearance Area under the Downcomer

Where:

hap = height of the bottom edge of the apron above the plate

Headloss in Downcomer

2
= 166 ( )

Where:

Lwd = maximum liquid flowrate

Downcomer Residence Time


=

Where:

hbc = clear liquid back-up

Vessel Design

Material of Construction:

Using Stainless Steel, AISI 304

(Ref.: Perrys ChE handbook 8th Ed., Table 25-11 p.25-36)

Type of Joints: Double Welded U-Butt Joint

(Ref.: PED by Hesse et. Al., eqn. 4-1, p. 84)

Where:

Su = 565 MPa (from Perrys Chemical Engineering Handbook 8th ed.,

Table 25-11)

Fm = 1.0,material factor or grade of steel

Fa = 1.0,not radiographed

Fr = 1.06,stress relieving factor

Fs = 1.0,factor of safety

(Ref.: PED by Hesse et. Al., p. 81)

Shell Thickness:
(Ref.: from eq. 4-3 page 85 of PED by Hesse et. al.)

= +
2
Where:
p = internal pressure
D = inside diameter
S = maximum allowable working stress
e = efficiency of longitudinal joint, 0.8 welding efficiency for API-ASME code
for ts>5/8 (page 84 of PED by Hesse et. al.)

C = corrosion allowance, 1/16 in

Head Thickness

= +
4
(Ref.: from eq. 4-3 page 85 of PED by Hesse et. al.)
Outside Diameter:

= 2 +

Optimum Pipe Diameter

= 260 0.52 0.37

(from Chemical Engineering Design by Coulson and Richardson vol. 6, p. 221)

Pressure drop in the line due to friction

= 0.125 1.84 0.16 1 4.84

Genereaux formula from Chemical Engineering Design: SI edition 5th ed by R.K. Sinnott

p. 261

Work Done by the Pump

 2
= + + +
2

Where:

g = acceleration due to gravity

z = elevation

P = system pressure difference

Pf = pressure drop due to friction

v = velocity difference

Power Requirement

=
3.670 105

(from Perrys Chemical Engineering Handbook 6th ed. equation 10-52)

 C. DETAILED EQUIPMENT DESIGN COMPUTATIONS

STRIPPING TOWER DESIGN

Operating Conditions:

Tair,i = 30C

Tair,f = 50C

THNO3,i = 30C

THNO3,f = 50C

Density In, Mass In Volume In

(kg/m3) (kg/day) (m3/day)
HNO3 1,353.30 23,371.20 17.27
N2O4 1,440.00 2,050.11 1.42
H2O 995.70 15,580.80 15.65
Total 1193.95 41,002.11 34.34
Density In Mass In Volume In
, (kg/m3) (kg/day) (m3/day)

N2 1.251 19064.34 15239.28

O2 1.429 5067.74 3546.35
Total 1.285 24132.08 18785.63

Where:

Mass In and Mass Out: from material balance

Density, (kg/m3) = Mass / Volume

 Density, (kg/m3): from Perrys Chemical Engineering Handbook, 8th ed., pp. 2-96 to 2-

125

Theoretical Number of Sieve Trays:

1 1
+1 (1 )+

log [ ]
+1

=
log

For N2O4:

106
24 2,050.11 kg 1
( )= = 1000 = 59697.64
34.34 3

1

( ) = 0.001

+1 ( )=0 ; there is no NO in the air entering the tower

6615
log(24 ) = = 21.98 ; = 103,085.81
+ 86.88 + 303 24
H at 5% weight 30C = 0.75 kmol/m3-bar

3 2,050.11 1 100
= 3
= 2,086.96
0.75 92 42 1

2086.96 kPa
= = = 20.6
101.325

kg 1 1
20,501.06day2460
( )
29
= ( ) = 20.6 = 11.18
1 1
41,002.112460
( kg )
31.4734kgmole
 For MW of red nitric acid:

Mass In ni = mass/MW yi = ni/nt MWred HNO3 =

(kg/day) yi*MW
HNO3 27922.96 370.97 0.2947 18.5654
N2O4 1764.83 22.28 0.0177 0.5310
H2O 18572.24 865.6 0.6876 12.3770
Total 48264.16 1258.855 1 31.4734

59697.64 1 1
1 1
log [( ) (1 ) + ] log [( ) (1 9.7727) + (9.7727)]
0.001
= = = 7.37
log log(9.7727)

Actual Number of Sieve Trays:

7.81
= = = 14.75 15
0.5

Nact = 15

Where:

E = 0.50 (an appropriate E is in the range of 0.4 to 0.6 U.S. ACE, 2001) from

MWH's Water treatment Principles and Design by Crittenden, p. 1100

Flooding Velocity

Solving for Ki:

 Initial plate spacing (z) = 0.5 m (plate spacings of 0.3 to 0.6 m will normally be

used) from Chemical Engineering Design by Coulson and Richardson vol.

6, p. 557

41002.11 1.2884 3
= =
= 0.06570
20501.06 1193.95 3

From figure 11.27 of Chemical Engineering Design by Coulson and Richardson

vol. 6, p. 568, Ki = 0.05

1193.95 1.2884
= 0.05 = 1.5213
1.2884

From Chemical Engineering Design by Coulson and Richardson vol. 6 Chapter 11:
Net Vapour Velocity

= 0.85 = 1.5213 0.85 = 1.2931

Net Column Cross-sectional Area

15912.09 3

= = 243600

= 0.1424 2
1.2931

An = 0.1424 m2

Total Column Area (Ac) = An / (1 - 0.12) = 0.1618 m2

Downcomer Area (Ad) = 0.12 * Ac = 0.0194 m2

Active Area (Aa) = Ac - 2* Ad = 0.1230 m2

Hole Active Area (Ah) = 0.10 * Aa = 0.0123 m2

Tower Diameter

4 4 0.16182
= = = 0.455

D = 0.5 m 1.64 ft

Tower Height

= (( 1) ) + (3 ) = 8.5

H = 8.5 m 27.9 ft
Weir Length

Using Fig11.31 of Chemical Engineering Design by Coulson and Richardson vol.6, p.573

0.0194
100 = 100 = 12
0.1618

= 0.765

Weir length (lw) = 0.765 * D = 0.3473 m

Weir Liquid Crest

2/3
= 750 ( )

1 1
max = 41002.11 = 0.4746
24 3600

min = ( )(max ) = 0.85 0.4746 = 0.4034

Where:

Turn-down ratio for sieve trays = 85% (50% to 120% of design capacity from

Chemical Engineering Design by Coulson and Richardson vol. 6 Chapter 11)

2/3

2/3 0.4746

max = 750 ( ) = 750 ( ) = 8.2064
1193.95 3 0.3473

2/3

2/3 0.4034

min = 750 ( ) = 750 ( ) = 7.3637
1193.95 3 0.3473

Weir height (hw) = 45 mm (from Chemical Engineering Design by Coulson and

Richardson vol.6: for columns operating above atmospheric pressure the weir heights

will normally be between 40 to 50 mm (recommended))

Vapor Velocity

[2 0.90(25.4 )]
=
( )1/2

+ = 45 + 7.3637 = 52.36
From figure 11.30 of Chemical Engineering Design by Coulson and Richardson vol.6,

p. 571, K2 = 30

[30 0.90(25.4 5)]

= 1 = 10.25
(1.2884) 2

3
= = 0.1842

3
0.850.1842
= = = 12.72
0.0123 2

3
0.1842

= = = 14.97
0.0123 2
Dry Plate Drop

2
= 51 ( ) ( )

From figure 11.34 of Chemical Engineering Design by Coulson and Richardson vol. 6,

p. 576, Co = 0.84

14.97 2 1.2884
= 51 ( ) ( ) = 17.48
0.84 1193.95

Residual Head

12.5 103 12.5 103

= = = 10.47
1193.95
Total Pressure Drop

= + + + = 80.32

= 9.81 103 = 9.81 103 80.32 1193.95 = 940.74
3

= . .

Height of the Bottom Edge of the Apron above the Plate

hap = hw 5 mm = 40 mm

Clearance Area under the Downcomer

= = 40 103 0.3473 = 0.0139 2

Head Loss in Downcomer

2

2 0.4746

= 166 ( ) = 166 ( ) = 0.1359
1193.95 3 0.0139

Back-up in Downcomer

hb = hw + how + ht + hdc =0.1328 m

1 1 45
( + ) = (0.5 + ) = 0.2725
2 2 1000

hb < 0.2725 m; acceptable plate spacing

Percent Flooding

% =

Where:
3
0.2174
= = = 1.2785
0.142

1.2931
% = = 100 = 85%
1.5213

0.1424
Number of Holes= = 5 2 = 1566.14
( )
1000

Downcomer Residence Time

2
0.0194 0.1328 1193.95 3
= = = 6.49
0.4746

tr = 6.49 s

Capacity of Equipment
(34.34 + 15912.09 )3
= = 6.49
24 3600
V = 1.20 m3
VESSEL DESIGN

Material of Construction:

Using Stainless Steel, AISI 304

Type of Joints: Double Welded U-butt joint

(from PED by Hesse et. Al., eqn. 4-1, p. 84)

(from Perrys Chemical Engineering Handbook 8th ed., Table 25-11)

= 565

(from PED by Hesse et. Al., p. 81)

= 1.0,

= 1.0,

= 1.06,

= 1.0,

= 565 1.0 1.0 1.06 1.0 = 598.9 = 85557.761

Shell Thickness:

Based from eq. 4-3 page 85 of PED by Hesse et. al.)

= +
2
Where: p = internal pressure = 9 atm =132.3 psi

D = inside diameter

S = maximum allowable working stress

e = efficiency of longitudinal joint, 0.8 welding efficiency for API-ASME

code for ts>5/8 (page 84 of PED by Hesse et. al.)

C = corrosion allowance, 1/16 in

3.28 12
132.3 (0.50 ) 1
1 1
= +
(2 85557.76 0.8) 132.3 16

= . = . .

Head Thickness

3.28 12
132.3 (0.50 1 1 ) 1
= + = +
4 (4 85557.76 0.8) 16

thead = 0.1575 in = 4.00 mm

Outside Diameter

= 2 +

= 2(0.00225) + 0.50

= .

Piping Specification

Where:

Velocity of fluid flow = 2 m/s, from Chemical Engineering Design by Coulson and
Richardson vol. 6, p. 218
 34.34 3

= 243600


= 2.0 104 2
2

4 4 2.0 104 2
= = = 0.0159 = 0.626

41002.11 0.52
= 260 ( ) 1193.950.37 = 0.0128 = 0.504
24 3600

From table 10-22 of Perrys Chemical Engineering Hanbook, 8th ed., p. 10-78;

Most suitable nominal pipe size (in.) = , schedule number = 40S

Pressure drop in the line due to friction

= 4.13 1010 1.84 0.16 1 4.84

Genereaux formula from Chemical Engineering Design: SI edition 5th ed by R.K. Sinnott p. 261

http://www.viscopedia.com/fileadmin/_processed_/csm_nitric_acid_60__ueberarb._2f1089ab08.

png
Red nitric acid @ 30C = 0.00205 Pa s

10
41002.11 1.84
= 4.13 10 0.002050.16 1193.951 12.834.84 = 14.12
24 3600

Work Done

2
2 14,120 2 22 2

= + + + = [9.81 (9) + 0 + + ]
2 1193.95 3 2 2

= 10211.33

Power Requirement

= = . .
1000