CHAPTER VI

MECHANICAL DESIGN OF REACTOR

6.1 PROCESS DESCRIPTION

The reactor used in the production of phosphoric acid is continuously-stirred tank rector
(CSTR). The reaction involved is

3 H
2
SO
4
(l) + Ca
3
(PO
4
)
2
(s) + 6 H
2
O (l) 2 H
3
PO
4
(l) + 3 CaSO
4
.2H
2
O(s)

Phosphoric acid and gypsum are products of the reaction. The reaction occurred at
temperature of 80C and pressure of 1.5 bar. Figure 6.1 shows the reactants and products
of the reactor.


R-1


Figure 6.1 Reactor R-100





H
2
SO
4

Ca
3
(PO
4
)
2

H
2
O
H
3
PO
4

CaSO
4
.2H
2
O
R-100
Stream 7 Stream 8
44


6.2 MATERIAL SELECTION

The construction material for fermenter is a stainless steel type 304 which is an austenitic
iron. Type 304 has a minimum of 18% chromium, 8% nickel, and combined with a
maximum of 0.08% carbon. It is defined as a Chromium-Nickel austenitic alloy. It
contains the minimum chromium, Cr and nickel, Ni that give a stable austenitic structure.
It also has lowest price compared to other stainless steel. Type 304 has characteristics
such as good in forming and welding, corrosion or oxidation resistance, excellent
toughness, and ease of cleaning.

6.3 DESIGN SPECIFICATION

The operating pressure, P
O
for fermenter is 1atm (14.70 psi and 1.01325 bars)
which is same as the atmospheric pressure, P
atm
. Therefore, the fermenter is designed
subject to internal pressure. The operating temperature, T
o
is 65
o
C (150 F). Since P
o,abs

P
atm
, the pressure vessel is designed under internal pressure.

Nominal thickness, t
nominal
= 10 mm
Corrosion allowance, CA = 2 mm

Figure 6.2 shows the shape of the vessel and its dimension.
Top - ellipsoidal head with a radio of 2:1
Shell cylindrical
Bottom - ellipsoidal head with a radio of 2:1
45

h/3
h/3
Di
hs
ho
ho


Figure 6.2 Dimensions of Pressure Vessel


6.3.1 Dimension calculation

From Superpro, volumetric flow rate of the outlet stream of the reactor is 546.77 L/h. At
1.5 days time, the capacity of the reactor is

V =

= 19.68 m
3


For chemical plant, D
i
: H = 1: 4, H = 4Di,
3
2 2
4
4 4
i i
i i
D D
D
H
D
V t
t t
= = =

3 3
68 . 19
i
D m t =
Internal diameter, D
i
= 2.5 m = 8.2 ft = 98.43 in
H
L
46


Vessel height, H = 4D
= 10 m = 32.81 ft = 393.70 in

Other dimensions can be determined from the given D
i
and H
For the ellipsoidal height with a ratio of 2:1(major axis: minor axis), h D
i
2 2 = ,
Ellipsoidal height, f t m in
in D
h
i
o
05 . 2 6251 . 0 61 . 24
4
43 . 98
4
= = = = =
Shell height, ( ) ft m in in in h H h
o s
71 . 28 75 . 8 48 . 344 61 . 24 2 70 . 393 2 = = = = =
Support line, in
in
in
h
h L
o
s
89 . 360
3
61 . 24
2 48 . 344
3
2 = |
.
|

\
|
+ = |
.
|

\
|
+ =

Table 6.1 Dimensions of The Vessel
Part Dimension(ft) Dimension (in) Dimension (m)
Internal diameter
Height
Ellipsoidal height
Shell height
8.20
32.81
2.05
28.71
98.43
393.70
24.61
344.48
2.50
10.00
0.63
8.75





6.4 WALL THICKNESS OF REACTOR

The wall thickness, t for each part of the pressure vessel has to be calculated in order to
get the minimum wall thickness, t
min
under internal pressure.



47

6.4.1 Top Ellipsoidal Head

From ASME Code Sec II Part D Table 1A, maximum allowable stress, S for stainless
steel Type 304 is 20000 psi while the joint efficiency, E is 1.0.

Operating pressure = 1.01325 bar = 14.7 psi
Design pressure, P
D
= P
o
+ 0.433h
= 14.7 + 0.433(2.05)
= 15.5877 psi

From ASME Code UG-32 part (D),
Thickness, t =

= 0.03836 in

6.4.2 Cylindrical shell

Design pressure, P
D
= P
o
+ 0.433h
= 14.7 + 0.433(30.76)
= 28.0191 psi





From ASME Code UG-27 Part (C),
For circumferential stress, thickness, t =

= 0.0690 in
48

For longitudinal stress, thickness, t =

= 0.03447 in

6.4.3 Bottom Ellipsoidal Head
Design pressure, P
D
= P
o
+ 0.433h
= 14.7 + 0.433(32.81)
= 28.9067 psi
From ASME Code UG-32 Part (D),
Thickness, t =

= 0.071 in

6.4.4 Wall Thickness
t
calc
= 0.071 in = 1.80mm
By considering corrosion allowance, CA of 2mm,
t
user
= t
calc
+ CA
= 1.80mm + 2mm
= 3.80mm
t
min
= t
nominal
CA
= 10mm 2mm
= 8mm
= 0.3150 in
Table 6.2 Design Pressure and Wall Thickness of The Vessel
Part Design pressure (psi) Wall thickness (in) Wall thickness (m)
Top ellipsoidal head
Cylindrical shell
Bottom ellipsoidal head
15.5877
28.0191
28.9067
0.03836
0.06900
0.07100
0.000974
0.001753
0.001803

49


6.5 MAXIMUM ALLOWABLE WORKING PRESSURE

The maximum allowable working pressure of pressure vessel, MAWP is determined by
calculating part by part under internal pressure.

6.5.1 Top ellipsoidal head
From ASME Code UG-32 Part (D),
P =

= 127.9279 psi

MAWP vessel = 127.9279 0.433(2.05)
= 127.0403 psi

6.5.2 Cylindrical shell
From ASME Code UG-27 Part (C),
For circumferential stress,
P =

= 127.5071psi


MAWP vessel = 127.5071 0.433(30.76)
= 114.1880 psi

For longitudinal stress,
P =

50

=

= 256.6505 psi
MAWP vessel = 256.6505 0.433(30.76)
= 243.3314psi

6.5.3 Bottom ellipsoidal head
From ASME Code UG-32 Part (D),
P =

= 127.9279psi

MAWP vessel = 127.9279 0.433(32.81)
= 113.7212 psi


Table 6.3 MAWP of The Vessel
Part MAWP (psi)
Top ellipsoidal head
Cylindrical shell
Bottom ellipsoidal head
127.0403
114.1880
113.7212

In conclusion, MAWP vessel is 113.7212 psi, smallest value is chosen.



6.6 COMBINED LOADING
6.6.1 Primary Stresses

51

For a cylindrical vessel, primary stresses which are required to achieve static equilibrium
are due to the following sources:
a) Longitudinal and circumferential stresses due to pressure
b) Direct stress
c) Bending stresses
d) Torsional shear stresses

Some assumptions are made for the calculation of primary stress.
Assumptions :
- Liquid level is three quarter of the effective length of the column.
- Hydrostatic pressure is considered at the bottom of the column.
- Liquid density in the column is equal to water (1000kg/m
3
)
- Safety factor of 10% is considered.

Column height, H = 32.81 ft = 10 m
Liquid level =

(10) = 7.5m
P
gage
= P
abs
P
atm

Where P
abs
=P
atm

P
gage
= 0

Design pressure, P = gh
= (1000)(9.81)(7.5)
= 73575 N/m
2

= 0.0736 N/mm
2

By considering safety factor of 10%, design pressure, P = 1.10(0.0736) = 0.08096 N/mm
2

(a) Longitudinal (
L
o ) and circumferential (
h
o ) stresses
2
/ 0595 . 28
071 . 0 4
) 43 . 98 ( 08096 . 0
4
mm N
t
D P
i
L
=

= o
52

2
/ 1190 . 56
071 . 0 2
) 43 . 98 ( 08096 . 0
2
mm N
t
D P
i
h
=

= o

(b) Direct stress (
w
o )
( )t t D
W
i
w
+
=
t
o
For a steel vessel, ( )t D H D C W
m v m v v
8 . 0 240 + =
With m H m t D D C
v i m v
4008 . 6 , 5019 . 2 0018 . 0 5001 . 2 , 15 . 1 = = + = + = =
( )( ) N W
v
6125 . 10443 8 . 1 5019 . 2 8 . 0 4008 . 6 5019 . 2 15 . 1 240 = + =
( )( )
2
/ 7382 . 0
8 . 1 8 . 1 1 . 2500
6125 . 10443
mm N
w
=
+
=
t
o


(c) Bending stresses (
b
o )
|
.
|

\
|
+ = t
D
I
M
i
v
b
2
o
With M = total bending moment
I = second moment of area of the vessel about the plane of bending

( )
( )
Nm M
m N D P W m N P
m t D D D m H x
Wx
M
eff w w
i o eff V
40 . 65649
2
4008 . 6 736 . 3204
/ 736 . 3204 5037 . 2 1280 , / 1280
, 5037 . 2 0018 . 0 2 5001 . 2 2 , 4008 . 6
2
2
2
2
=

=
= = = =
= + = + = = = =
=

( ) ( )
4 4 4 4 4
011070 . 0 5001 . 2 5037 . 2
64 64
m D D I
i o v
= = =
t t

2
/ 4240 . 7 0018 . 0
2
5001 . 2
011070 . 0
40 . 65649
mm N
b
= |
.
|

\
|
+ = o
53


(d) Torsional shear stresses (t )
The torsional shear stresses can be neglected in preliminary vessel design because
these loads will normally be small. 0 = t

Total longitudinal stresses for upwind and downwind
( )
2
/ 2217 . 36 4240 . 7 7382 . 0 0595 . 28 mm N upwind
b w L z
= + + = + + = o o o o
( )
2
/ 3737 . 21 4240 . 7 7382 . 0 0595 . 28 mm N downwind
b w L z
= + = + = o o o o

Table 6.4 Primary Stress
Primary stress Value (N/mm
2
)
Longitudinal stress
Circumferential stress
Direct stress
Bending stress
28.0595
56.1190
0.7382
7.4240


6.6.2 Principal Stresses
Since 0 = t ,
1
=
h
= 56.1190 N/mm
2


2
=
z
= 28.0595 N/mm
2


3
= 0.5P = 0.5(0.08096) = 0.04048 N/mm
2


6.6.3 Maximum Allowable Stress Intensity

2
= 28.0595 N/mm
2

1

3
= 56.0785 N/mm
2

3
= 28.01902 N/mm
2

The maximum allowable stress, S for stainless steel type 304 is 20000 psi or 137.895
N/mm
2
.
( )
max
o A = 56.0785 N/mm
2

54

( ) S < A
max
o
Thus, the design is safe.


6.6.4 Elastic Stability
Critical buckling stress,
( )
|
|
.
|

\
|

=
p
c
R
t
v
E
2
1 3
o
For steel at ambient temperature, E = 200000 N/mm
2
with a safety factor of 12, the
2 4 4
/ 3994 . 14
1 . 2500
8 . 1
10 2 10 2 mm N
D
t
o
c
= |
.
|

\
|
=
|
|
.
|

\
|
= o
( )
2
max
/ 1622 . 8 7382 . 0 4240 . 7 mm N
w b
= + = + =

o o o
( )
c
o o <

max

Thus, the design is safe.

From the analysis of combined loading, the material we chose has fulfilled both
requirements of maximum stress intensity and elastic stability.
( ) S < A
max
o and ( )
c
o o <

max
.
Therefore, the design is safe.








6.7 VESSEL SUPPORT ANALYSIS
The pressure vessel designed is a vertical cylindrical vessel. For vertical cylindrical
vessel, there are two types of skirts which are straight skirt and conical skirt. In this case,
55

we chose straight skirt. A skirt support consists of a cylindrical or conical shell welded to
the base of the vessel. A flange at the bottom of the skirt transmits the load to the
foundations. Openings must be provided in the skirt for access and for any connecting
pipes where the openings are normally reinforced. The skirt may be welded to the bottom
head of the vessel, welded flush with the shell or welded to the outside of the vessel. In
this case, we chose skirt welded flush with the shell which is the most commonly used.
Skirt supports are recommended for vertical vessels as they do not impose concentrated
loads on the vessel shell and particularly suitable for use with tall columns subject to
wind loading.

6.7.1 Skirt Thickness
The skirt thickness must be sufficient to withstand the dead-weight loads and bending
moments imposed on it by the vessel and it will not be under the vessel pressure.
The resultant stresses in the skirt are:
( )
ws bs s
tensile o o o =
( )
ws bs s
e compressiv o o o + =
with bending stress in the skirt,
( )
s s s s
s
bs
D t t D
M
+
=
t
o
4

and dead weight stress in the skirt,
( )
s s s
ws
t t D
W
+
=
t
o
The skirt thickness must be adequate to endure the dead-weight loads and bending
moment imposed on it by the vessel and it will not be lower the vessel pressure.
Assume skirt support height, h
s
= 1m, skirt thickness, mm t
s
20 =
m N W
N W
m D D
m h H x
V
i s
s
/ 216 . 2345
7409 . 6822
8288 . 1
3152 . 8 1 3152 . 7
=
=
= =
= + = + =



For the bending stress in the skirt,
bs
o
56

Maximum bending moment, Nm
Wx
M
s
1085 . 81077
2
3152 . 8 216 . 2345
2
2 2
=

= =
( )( )( )
2 2
/ 698 . 1 / 311 . 1698047
8288 . 1 018 . 0 018 . 0 8288 . 1
1085 . 81077 4
mm N m N
bs
= =
+

=
t
o

For the dead weight stress in the skirt,
ws
o
( )
2 2
/ 06533 . 0 / 598 . 65330
018 . 0 018 . 0 8288 . 1
7409 . 6822
mm N m N
ws
= =
+
=
t
o

Therefore, resultant stresses
( )
2
/ 63267 . 1 06533 . 0 698 . 1 mm N tensile
s
= = o
( )
2
/ 76333 . 1 06533 . 0 698 . 1 mm N e compressiv
s
= + = o

The skirt thickness under the worst combination of wind and dead weight loading should
follow the below design criteria:
( ) u o sin J f tensile
s s
< and ( ) u o sin 125 . 0
|
|
.
|

\
|
<
s
s
s
D
t
E e compressiv
Assumptions:
- Weld joint factor, J = 1.0
- Base angle,
o
s
90 = u
- Maximum allowable design stress,
2
/ 145 mm N f
s
=
- Youngs modulus,
2
/ 200000 mm N E =

2
/ 145 90 sin 0 . 1 145 sin mm N J f
o
s s
= = u
2
/ 06 . 246 90 sin
8288 . 1
018 . 0
200000 125 . 0 sin 125 . 0 mm N
D
t
E
o
s
s
s
=
|
.
|

\
|
=
|
|
.
|

\
|
u
( )
2 2
/ 145 / 63267 . 1 sin mm N mm N where J f tensile
s s
< < u o
( )
2 2
/ 06 . 246 / 76333 . 1 sin 125 . 0 mm N mm N where
D
t
E e compressiv
s
s
s
<
|
|
.
|

\
|
< u o
57

Since both criteria are satisfied, the assumed value of skirt thickness m t
s
018 . 0 = is
acceptable. With corrosion allowance of 4 mm, the design skirt thickness, m t
s
022 . 0 = .

6.7.2 Base Ring and Anchor Belt Design

Approximate pitch circle diameter = 2.2 m.
Circumference of bolt circle = 2200
Number of bolts required, at minimum recommended bolt spacing, N
b

Closest multiple of 4 = 12 bolts
Take bolt design stress = 125 N/mm
2

The bending moment at the base, M
s
= 81077.1085 Nm
The weight of the vessel, W = 6822.7409 N

The area of one bolt at the root of the thread, A
b
,

58


Since the bolt root diameter is smaller than 25mm, straight skirt cannot be used and we
change it to the conical skirt.
Total compressive load on the base ring per unit length,

Taking the bearing pressure as 5 N/mm
2
, the minimum width of the base ring, L
b

Take the skirt bottom diameter as 3m,

Keep the skirt thickness the same as that calculated for the cylindrical skirt. Highest
stresses will occur at the top of the skirt where the values will be close to those calculated
for the cylindrical skirt. sin 78.95 = 0.98, so this term has little effect on the design
criteria.



6.8 FLANGED JOINT DESIGN
There are several different types of flange used for various applications. In this case, the
flanged joint design we chose is lap-joint flanges. Lap-joint flanges are used in pipe work.
59

They are economical when used with expensive alloy pipe like stainless steel. This is
because the flanges can be made from low-cost carbon steel. Usually, a short lapped
nozzle is welded to the pipe but with some schedules of pipe the lap can be formed on the
pipe itself and this will give a cheap method of pipe assembly.

At stream 7, lap-joint flange is chosen.
Total mass flow rate of H
2
SO
4
= 1.3889 kg/s, density of H
2
SO
4
= 1840 kg/m
3

For liquid flow, the optimum diameter of a flange,

From Appendix E, nominal size of flange to be used is 80mm. From the appendix,
outside diameter of pipe for 80mm flange size is 88.9mm. Thus, it can be concluded that
the outside diameter of the pipe is 88.9mm.


6.9 DESIGN DRAWING

Figure 6.3 shows the standard and detailed engineering drawing of mechanical design of
pressure vessel using Autocad software.