CH 3060 PLANT AND EQUIPMENT DESIGN

Assignment 1

NAME : U.L.S.U.Perera
INDEX NO: 130439G
Introduction
The report designs a crystallizer for Sodium Nitrate aqueous solution. The crystallizer should
crystalize the Sodium Nitrate into its solid form. Sodium Nitrate is a white crystalline solid which is
soluble in water. It is a naturally occurring mined product, and it is mainly used as fertilizers, materials
inside explosives. Therefore large scale of production can be widely seen. It is not combustible but
accelerates the combustion due to the release of oxygen in decomposition with the supply of heat. This
release of Oxygen increase the corrosion rate. So that considerations of materials for fabrication is a
must. Sodium nitrate can be produced in different methods. Most common method is dissolving the
crushed material in hot water and filtering. Finally the aqueous solution is undergone crystallization
process. It is done in a prilling tower or a crystallizer. The ultimate objective of this report is to design
a crystallizer which is most suitable and economical for the above conditions and constraints.

Data given

Operating conditions;

Absolute pressure - 1.4 atm = 20.7543psi

Temperature - 55oC = 131F = 328K
Mean diameter is 3.5 m
Length of cylindrical shell is 7 m
Content

1. Material selection

2. Calculation of the Design Pressure (P Design) and Temperature (T Design)

3. Calculation of the wall thickness of the shell economical and safe to P Design & T Design

4. Selection of the suitable ends and calculation of their wall thicknesses

5. Required Openings for the vessel and compensation for them
6. Propose suitable support type for the vessel
7. Description of fabrication procedure

8. Technical drawings of the designed vessel including welding symbols

 1. Material Selection

Vessels, designed, fabricated and inspected to meet ASME code division1 requirements are marked
with U. There are three categories:
U-68
U-69
U-70

U-68
For any content including lethal gases and liquids (Heavy duty vessels).No limit for operating
temperature. Pressure up to 15000- psi.

U-69

For any content except lethal gases and liquids (Ammonia, chlorine, propane, natural fuel gas are not
lethal) (Moderate load vessels). Temperature limit 700 F. Pressure below 400 psi

U-70
For nontoxic gases and liquids (Light duty vessels).temperature limit 250 F. Pressure below 100 psi.

According to the values of pressure 1.4 atm ( 20.7543 psi below than 100psi) and temperature 55oC
=131F (below than 250F) and the non-toxcity of the chemical component Sodium Nitrate aqueous
solution. U-70 will be most suitable.

The materials that are used in pressure vessel construction are:

Steels
Nonferrous materials such as aluminum and copper
Specialty metals such as titanium and zirconium
Nonmetallic materials, such as, plastic and composites

And most commercial steels are classified under four groups.

1. Plain carbon steels
2. Low-alloy steels
3. High-alloy steels
4 .Clad steel
Material Important characteristic
Steels Plain Low carbon steel( cheap
carbon mild steel) Available in a wide range of standard forms and
steels sizes;
Easily worked and welded.
It has good tensile strength and ductility.
Not resistant to corrosion.

Medium Carbon Increased hardness and tensile strength.

steel Decreased ductility,
More difficult machining.
High carbon steel These steels can be challenging to weld
Low alloy steels greater strength
Resistance to atmospheric environments
No resistance to liquid corrosives
No resistance to acid or alkaline solutions
High alloy martensitic can be hardened by heat treatment
steels generally used in mildly corrosive environments
(Stainless (atmospheric, fresh water, and organic exposures
steel) )
ferritic Fairly easy to machine.
Welding is not a problem (requires skilled
operators).
Corrosion resistance is good(except reducing
acids such as HCl)

austenitic the most corrosion-resistant

tough and ductile.
can be fabricated by all standard methods. But
not easy to machine
Clad steel has sufficient strength required of structural
materials resistance to heat and corrosion
low cost than similar products made entirely of
the cladding material.

Nonferrous material (Al & Cu) Remarkable corrosion resistance

Low strength
Relatively low service temperature
Required insulation due to high thermal
conductivity of Cu (to minimize energy loss)
Specialty metals ( titanium and Good corrosion resistance (including HCl)
zirconium) High cost
In industry zirconium is used where resistance to
hot and boiling acids is required: nitric,
sulphuric, and particularly hydrochloric
 Nonmetallic material ( plastic & Can be used in relatively low temperatures
composited)

As NaNO3 accelerated corrosion due to the emission of O2 with the thermal decomposition it is
not suitable to use corrosive materials such as Carbon steel. Due to the high cost Zerconium and
titanium can be rejected. Al also cant be used because it reacts with NaOH and corrode. ( due to the
presence of NaNO3 and H2O there is a possibility to the above reaction to be happen). As low alloy steel
is not resistant to liquid corrosives it is also can be rejected. Plastics like PVC, Polyolefine are not
suitable due to their poor thermal stability. Polypropylene is high creep and poor U.V resistance. GRP
(Glass fiber reinforced plastics) has excellent properties favorable to steel but not used for fabrication of
pressure vessels. Therefore most suitable materials would be stainless steel and clad steel.

By considering the most economical (low cost) and quality products clad steel would be the most
suitable material for this fabrication. The combination of low carbon steel with austenitic steel gives
several products with varying qualities. According to ASME standards SA-240 specifications of
stainless steel, 304L is selected due to the presence of low C percentage (since it get cheap, high
strength). This material has furnishes the necessary resistance to corrosion, abrasion, or oxidation, the
backing material contributes structural strength and improves the fabrication.

2. Calculation of design pressure and temperature

Basic idea of the design:

The concentrated aqueous Sodium Nitrate solution is sprayed into the space at the top of the prilling
tower. The droplets of concentrated sodium nitrate descend through the tower against a rising current of
air introduced at the bottom of the prilling tower by means of fans. Solidified droplets of sodium nitrate
or prills drop from the prilling tower onto conveyor for removal to storage in.

Design Pressure
Assumption:

No water or liquid is accumulated at the bottom of the vessel.

External pressure is equal to atmospheric pressure (atmospheric pressure is 1 atmosphere)
Internal pressure (absolute pressure): 1.4 atmosphere

As the internal pressure is greater than the external pressure this is an internal pressure vessel.
Therefore the design pressure can be calculated as
P design = P max. operating by gauge + (10)% extra
P design = (1.4 1) x 101325 + (10) % extra
P design = 44583 Pa
Design Temperature
The Sodium Nitrate solution is non-directly heated and the highest temperature of it is as 55C at the
top of the tower.
Then,
T design = T highest temperature of body + 10C
T design = 55 + 10
T design = 65oC (149F)

3. The wall thickness of the shell economical and safe to PDesign & TDesign

For the cylindrical part,

Pdesign D
tactual
2 design

D= mean diameter= 3.5 m

P design= 44583Pa
The selected weld joint is double V grove welded butt joint. Therefore the welded joint efficiency;

- Welded joint efficiency = 0.7 (no radiography of the joints)

design - Stress of the vessel= 17100psi= 117 900 349.5 Pa @ 149F (from the tables given in ASME
SEC 2 part D)
Therefore,
t actual = 9.454 x 10-4 m
= 0.95 mm

As we used SA-240 where no corrosion occurs, c = 0

Then,

Pdesign D
tactual c
2 design

Therefore t actual= 0.95mm

According to standards the minimum thickness should be (ASME SEC 8)

D Do t


Pdesign Do
tactual 2 c
design 0.6 Pdesign

tactual = 0.9452 mm ( according to ASME SEC 8)

As t actual < t minimum,, this value is also less than the minimum thickness required. So, minimum wall
thickness related to the diameter is considered as the wall thickness.
Therefore, wall thickness = t = 12mm.
4. Selection of the suitable ends and calculation of their wall thicknesses

The heads may be of various types such

as:
Flat
Flanged only
Torispherical
Hemispherical
Ellipsoidal
Conical
Toriconical

When selecting heads, the diameter of the vessel, inside pressure, and the internal chemical
components should be considered. Therefore tori spherical head is chosen for the crystallizer.

Torispherical head

D outer diameter of the vessel

R- radius of the crown Di =3.488
r- knucle radius Dm= 3.5
h- height of the flange D= Douter=3.512
t- thickness
R=D = 3.5 + (2 x 0.012) = 3.512m
There are 3 different equations available for calculate h value.

= ( ) ( + 2)
2 2
 = 3.512 (3.512 1.756) (3.512 + 1.756 (2 0.06 3.512)) = 0.595

2 3.5122
= 4 = 43.512 = 0.878

3.512 0.06 3.512

= = = 0.608
2 2

Therefore minimum value of he is 0.595 m

p DC ; Do = D, C-shape factor depends on effective external head height he

t design o
2 design
= 44583 3.512 /(2 117900349.5 0.7)
= (9.486 ) 10000
t/Do
h e/ Do 0.00075 0.0005 0.001 0.002 0.005 0.01 0.02 0.04
0.15 5.34 5.50 5.18 4.55 2.66 2.15 1.95 1.75
0.20 2.55 2.60 2.5 2.3 1.7 1.45 1.37 1.32
0.25 1.48 1.50 1.46 1.38 1.14 1 1 1
0.30 0.98 1.00 0.97 0.92 0.77 0.77 0.77 0.77
0.40 0.59 0.59 0.59 0.59 0.59 0.59 0.59 0.59
0.50 0.55 0.55 0.55 0.55 0.55 0.55 0.55 0.55

But he/Do = 0.595/3.512= 0.169 =0.17

Using the interpolation,
t/Do
h e / Do
0.00075 0.0005 0.001 0.002 0.005 0.01 0.02 0.04
0.15 5.34 5.50 5.18 4.55 2.66 2.15 1.95 1.75
0.17 4.22 4.34 4.108 3.65 2.28 1.87 1.72 1.58
0.20 2.55 2.60 2.5 2.3 1.7 1.45 1.37 1.32

When C=3.65,
t= 3.46 x 10-3
t=7.00 x 10-3
When C=4.108
t= 3.89 x 10-3
t= 3.502 x 10-3
Therefore the actual C value;
(3.502-3.89)/(C- 4.108 ) = (3.46-7)/(3.65-C)
C= 4.063
= 0.9459 103 = 3.84mm

Usually the vessel material (stainless steel (clad steel)) is used to fabricate the head, so that corrosion
allowance is 0.
Therefore,
tactual of the head = 3.84mm

h dished section
B
A Welding
h Knuckle section

Flanged section (cylinder)

a
R

R - Crown radius,
C
r Knuckle radius
D Outer diameter
t Thickness of the head
h Height of knuckle section
OC = R = 3.512m
BC = R - r
=3.512 (0.06 3.512) = 3.3
AB = (Din / 2) - r
= 1.744 (0.06 3.512) = 1.533
AC = (BC2 - AB2)
 AC =3.3 2 1.5332 = 2.92
h = OC AC= 3.512 -2.92 = 0.592
Sin = AC/ BC
= 2.92/3.3 = 0.885

= 62.250
h = r sin
=(0.06 3.512) 0.885 =0.186 m

Since thickness of the wall 3.84mm < 25mm;

Dblank = D + D /42 + 2/3 r + 2H flanged
Where,
Hflanged can be specified by the customer. But it should not be less than 2/3 of total height.
Htotal = hDished + hflanged + hknuckle
2
= [ + + knuckle ]
3
2
= [ + 0.592 + 0.186]
3
= 1.556

Therefore; Dblank
= 3.512 + (3.512/42) + 2/3 (0.06 x3.512) + 21.556 m
Dblank = 6.848 m

Conical bottom
Since this is a crystallizer usually Conical or toriconical ends are used to facilitate the smooth flow and
removal of solids from process. In this design conical end is chosen.

The P/s value = 44583/ (117900349.5*0.7)= 0.54 x 10-3


1 103 2 103 3 103 4 103 5 103 6 103

13o 18o 22o 25o 28o 31o

By assuming the interpolation method is applicable to get the value.

0.002 0.001 0.001 0.00054

=
(18 13) (13 )

= 10.7
According to the calculated value value would be less than 13o. Since its not practical to use such a
small value since it will unnecessarily increase the height of the vessel.
Therefore lets assume the semi apex angle is 60o

Then,
According to ASME SEC 8 division 1, the following equation is used to determine its thickness.

P design= 44583Pa
Pdesign Di
design= 117 900 349.5 Pa
2 cos design 0.6Pdesign .
t theoretical
Di= (3.488)
44583 3.488
=
2 cos(60) (117900349.5 0.7 0.6 44583)

=1.89 mm
Because of the corrosion resistant of material, suggested corrosion allowance is also 0. Therefore,
tactual= t theoretical +c
tactual= 1.89mm

And place reinforcement around cone-cylinder junction (this is because the higher value of semi apex
angle than )

8t

8tc
Di2 tan
p
A 1
8

; A reinforced area
 44583 3.52 (60) 10.7
= (1 )=
117 900 349.5 0.7 8 60
A=1.177 x10-3 m2
If the thickness of the reinforcement is tr,
Then,

= 2((8 ) + (8 ))

0.001177 = 16( 0.012 +0.00189)

tr = 0.0053m
= 5.3 mm

5. Required Openings for the vessel and compensation for them

According to ASME SEC 8 division 1, under openings and reinforcements following rules are
have been stated.
For vessels 60 in. (1 500 mm) inside diameter and less, one-half the vessel diameter, but not to exceed
20in. (500 mm); for vessels over 60 in. (1 500 mm) inside diameter, one-third the vessel diameter, but
not to exceed 40 in. (1 000 mm)
For the designing crystallizer there are

1. inlet
2. two inlets for air fan
3. outlet for product
4. outlet for air
5. manhole
For all the openings except manhole, protruded nozzle will be used.
As the diameter of the vessel is 3.5m. Lets take the diameters as follow,

Inlets for air fan and the outlet for air: 0.5m
Inlet for aqueous solution: 0.5m
The above two openings will be longitudinal as shown below. (one of the opening for the fan and
the feed inlet will be longitudinal.)

L
Lets assume L = 3.5m then,
For no interactions to happen,

L d Do tactual c
d diameter of the largest opening
c- corrosion allowance = 0

(3.5 0.5) > 3.512(0.012 0)

3 > 0.205
As 3 > 0.205, there is no interactions to each other.

Lets consider the two air outlets. They will be horizontally positioned.

Assume = 2

Then for no interactions to happen,

L d Do tactual c
d diameter of the largest opening

( 2 ) > (0.012 0)

5.02 > 0.205

Therefor no interactions from these two too.
Compensation for inlet feed, inlet and outlet of air (2 inlet fans and air outlet).

d= 0.5 m
tactual = 3.512
c= 0

ttheroticle =
2

= 44583x 3.5/2x0.7x117 900 349.5

= 0.945mm

Area removed : A1 d 2c t theoretical c

A 1 = (0.5 +0)x(0.000945) = 4.725 x10-4 m2

Excess Area in the Shell

2 = ( ) ( + 2)
2 = (0.012 0.000945 0) (0.5 + 2 0)
2 = 0.00553

An excess area in the nozzle :

An Ao Ai
Ao excess area in the outer nozzle
Ai excess area in the internal nozzle
A0 excess area in the outer nozzle
Ao= (tn ttheoretical c)x2H1
,
=
2
44583 0.52
= = 0.00014m ; assumed tn as 0.02m
2117900349.50.7

Assume H1,a= 0.5m

Ai= excess area in the internal nozzle

Ai= (tn -2c) x 2H2
Assume H2,a= 0.5m
By considering boundary limits

H1 d 2ctn c for outer nozzle

H2 d 2ctn 2c for internal nozzle
1 = (0.5 + 0)(0.02 0) = 1 = 0.01 < 0.5=H1,a
H1= 0.01 will be used for calculations
Therefore Ao= (tn ttheoretical c) x 2H1= (0.02-0.00014-0) x 2x 0.01 = 3.972x10-4m2

2 = (0.5 + 0)(0.02 0) = 0.01 < 0.5= H2

H2 = 0.01 will be used for calculations
Therefore Ai= (tn -2c) x 2H2 = (0.02-0)x (2x0.01) =0.0004m2
Area for reinforcement Ar = A1- Ao -Ai
= 4.725 x10-4 3.972x10
-4
-0.0004= -3.247x10-4
Therefore no reinforcement is required.
Therefore the two air fans and the air outlet have same dimensions for openings.

Manhole
Lets take the diameter for the manhole as 0.8m. (According to ASME standard mentioned above as
the diameter is 3.5m and should not exceed 1m). For no interactions between the manhole and the air
inlet will consider for following calculations.

Assume = 4

Then for no interactions to happen,

L d Do tactual c
d diameter of the largest opening

( 4 ) > (0.012 0)

1.758 > 0.205

Therefor again no interactions from these two too.
 = 0.8
= 0.012
Area Removed A1
1 = ( + 2) ( )

=
2
44583 3.5
= = 0.945
2 0.7 117900349.5

1 = (0.8 + 2 0) (0.000945)
1 = 0.0007562
Excess Area in the Shell

2 = ( ) ( + 2)

2 = (0.012 0.000945 0) (0.8 + 2 0)

2 = 0.008844 2

Area for Reinforcement

= 1 2
=0.000756 0.008844
=-0.0081 2
As this is again a negative value no need of reinforcements.
Compensation for Outlet of product
Assumuption: as the angle is 60o and the nozzle is surrounded by flat surface. ( = 60). Therefore the
effect of the thickness would be 0.00189 x Cos60. That means the tactual and

t therotical = 0.000945

Then the calculation will be same as inlet.

Lets assume the diameter of the opening as 0.8m

Therefore,
d= 0.8m
tactual = 0.000945m
c= 0

ttheroticle = 0.000945 ; has calculated above.

Area removed : A1 d 2c t theoretical c

A 1 = (0.8 +0) x (0.000945 + 0) = 0.000756

Excess Area in the Shell

2 = ( ) ( + 2)
 2 = (0.000945 0.000945 0) (1 + 2 0)
2 = 0 2
A0 excess area in the outer nozzle
Ao= (tn ttheoretical c) x 2H1
,
=
2
44583 0.82
= 2117900349.50.7 = 0.000221 m; assumed tn as 0.02m

Assume H1,a= 0.5m

Ai= excess area in the internal nozzle

Ai= (tn -2c) x 2H2
Assume H2,a= 0.5m
By considering boundry limits

H1 d 2ctn c for outer nozzle

H2 d 2ctn 2c for internal nozzle
1 = (0.8 + 0)(0.02 0) = 1 = 0.016 < 0.5=H1,a
H1= 0.016 will be used for calculations
Therefore Ao= (tn ttheoretical c) x 2H1= (0.016-0.000221-0) x 2x 0.016 = 5.05x10-4m2

2 = (0.8 + 0)(0.02 0) = 0.016 < 0.5= H2

H2 = 0.016 will be used for calculations
Therefore Ai= (t n -2c) x 2H2 = (0.02-0) x (2x0.016) =0.0006.4m2
Area for reinforcement A r = A1- A o -Ai
= 0.000756 0.000505-0.00064= -3.89 x10-4m2
Therefore no reinforcement is required.
 6. Suitable support types for the vessel
As there is a bottom product that should be taken out, the suitable support will be bracket supports or
lugs.

Brackets, or lugs, can be used to support vertical vessels. The bracket may rest on the building
structural steel work, or the vessel may be supported on legs

Brackets
Supported on legs

Or
Brackets Supported from
steel-work

But there are certain circumstances to be considered,

Load in the vessel and the total load

Wind effect
The surrounding environment
Height of the vessel

The advantages of using these types of supports may be,

Easy construction
Easy attachments
Minimum welds
 7. Description of fabrication procedure

Mainly pressure vessels are fabricated by

welding---UW
forging ----UF
brazing ----UB

Stainless steel is available in at market such as

Plates
Sheets
Pipe
Strip
Bars
Forgings
.

Since this vessel is having moderate diameter its suitable to use stainless steel plates and
sheets for the fabrication procedure.

Shell fabrication
Fabrication includes the following steps,
1. Cutting the required section.
2. Crimping process
3. Heating
4. Rolling
5. Welding

1. Cutting the required section

To obtain the optimum results from the vessel the fabrication should be well furnished. The
height, diameter, openings should be placed accurately according to the design. This can be
done by lasser cutting method. In this method the metal is heated and then burnt by the
laser beam, cutting the metal sheet.
 2. Crimping process
This is done prior to rolling. This sets the correct radius on the ends of the plate and eliminates the
waste of the excess material. And it enhance the plate rolling roundness and efficiency.

3. Heating
Heating is done before the plate is moved to the rolling mill. This process makes easier the rolling of
the plate.
4. Rolling

The rollers work the plate to the proper radius.

 5. welding

When the plate is formed into cylinder using rollers, its possible to use various types of
welding methods. In the crystallizer I have designed for double V grove welded but joint.

The openings, heads, nozzles and all will be undergone welding.

As the selected weld type doesnt have limitations it can be used

for any welding of joints.

After the welding post heating process is done at most of the time to further protections.

Fabrication of heads & closers

Since the vessel is designed to use as a crystallizer, obviously bottom should be fabricated in conical or
tori-conical shape. For head, tori-spherical head is selected. The same material can be used to fabricate
the heads and the bottom too. ( the selected material has enough strength and qualities to overcome
these designs too.)
However for the welding of nozzles to the crystallizer I have suggested the following weld joints.
(references ASME sec 8)
For the joints between pressure vessel and conical bottom, nozzle and conical bottom
the following welding is suggested. (ASME sec 8)
8. Technical drawings of the designed vessel including welding symbol.
With welding symbols.
 References

W. (n.d.). Joining Welders since 1995. Retrieved June 15, 2016, from
http://www.welding.com/weld_symbols_welding_symbols.asp

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https://www.asme.org/shop/standards/new-releases/boiler-pressure-vessel-code/pressure-
vessels

2004 ASME Boiler and Pressure Vessel Code Section II Part D: Materials. (2004). New York:
The American Society of Mechanical Engineers.

2007 ASME Boiler and Pressure Vessel Code: Rules for Construction of Pressure Vessels.
(2008). New York: American Society of Mechanical Engineers

Carbon Steel Pressure Vessel Plates for Moderate and Lower Temperature Service. (n.d.).
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Pressue Vessel Steel ASTM A516 Grade 60/65/70. MACSTEEL.

10. BOILER QUALITY PLATES ASTM A 516 GR. 55/ 60 / 65 / 70. (n.d.). Retrieved July 21,
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india/astm-a-516.html

11. DIYTrade. (2013, April 07). Retrieved August 10, 2015, from Torispherical Head Cap :
http://www.diytrade.com/china/pd/11565454/torispherical_head_cap.html#normal_im