EXECUTIVE SUMMARY

CHAPTER 1

INTRODUCTION

1.1 Introduction

Mechanical design is the process of engineering design. It is used to determine the suitable
measurement for the equipment in the chemical plant before the plant start operating. In this
chapter, the mechanical design for acrylonitrile plant has been discussed by shown the detail
calculation for reactor.

In this chapter, the calculation of reactor as mention above are been done in order to find
out the overall calculation that are related to build the equipment in a plant. Besides that the main
reason for this mechanical design calculation are done to find out the value of designing equipment
based on the value obtain. So, this is as an early step for the confirmation of all the calculation
consideration before building the real equipment in a plant. The value obtains in each component
calculation also can have been considered in the logical of the value for o real building of the
equipment.

Then, the details of the mechanical design, control strategies and Hazard and Operability
(HAZOP) Study of the equipment are explained in this chapter.

1
1.2 Review Background

Mechanical Design for Reactor

Chemical reactors are vessels designed to contain chemical reactions. It is the site of
conversion of raw materials into products and is also called the heart of a chemical process. The
design of a chemical reactor where bulk drugs would be synthesized on a commercial scale would
depend on multiple aspects of chemical engineering. Since it is a very vital step in the overall
design of a process, designers ensure that the reaction proceeds with the highest efficiency towards
the desired output, producing the highest yield of product in the most effective way. Reactors are
designed based on features like mode of operation or types of phases present or the geometry of
reactors. They are thus called:

Batch or Continuous depending on the mode of operation.

Homogeneous or Heterogeneous depending upon the phases present.

They may also be classified as:

Stirred Tank Reactor
Tubular Reactor
Packed Bed Reactor
Fluidized Bed Reactor

Depending upon the flow pattern and manner in which the phases make contact with each other.
Thus, the reactor that being choose for the Acrylonitrile production is Plug Flow Reactor (PFR).

2
1.3 Plug Flow Reactor (PFR) Model (Fogler et al.,1999)

In a PFR, one or more fluid reagents are pumped through a pipe or tube. It is also referred
to as Tubular Flow Reactors (TFRs). The characteristics of PFR are as follows:
PTRs may have several pipes or tubes in parallel. The reactants are charged continuously
at one end and products are removed at the other end.
The chemical reaction proceeds as the reagents travel through the PFR.
In this type of reactor, the reaction rate is gradient, where at the inlet to the PFR the rate is
very high, but as the concentrations of the reagents decrease and the concentration of the
product(s) increases the reaction rate slows. Normally a steady state is attained.
Both horizontal and vertical operations are common.
When heat transfer is needed, individual tubes are jacketed or shell and tube construction
is used. In the latter case, the reactants may be on either the shell or the tube side.
The reactant side may be filled with solid particles, either catalytic (if required) or inert, to
improve interphase contact in heterogeneous reactions.
Large diameter vessels with packing or trays may approach plug flow behavior and are
widely employed.
Some of the configurations in use are axial flow, radial flow, multiple shell with built in
heat exchangers, horizontal, vertical and so on.

Some important aspects of the PFR are:

All calculations performed with PFRs assume no upstream or downstream mixing, as
implied by the term plug flow.
Reagents may be introduced into the PFR at locations in the reactor other than the inlet. In
this way, a higher efficiency may be obtained, or the size and cost of the PFR may be
reduced.
A PFR typically has a higher efficiency than a CSTR of the same volume. That is, given
the same space-time, a reaction will proceed to a higher percentage completion in a PFR
than in a CSTR.

3
 For most chemical reactions, it is impossible for the reaction to proceed to 100%
completion. The rate of reaction decreases as the percent completion increases until the point
where the system reaches dynamic equilibrium (no net reaction, or change in chemical species
occur). The equilibrium point for most systems is less than 100% complete. For this reason a
separation process such as distillation often follows a chemical reactor in order to separate any
remaining reagents or by products from the desired product. These reagents may sometimes be
reused at the beginning of the process, such as in the Haber process.

PFRs are used to model the chemical transformation of compounds as they are transported
in systems resembling pipes. Plug flow reactors are used for some of the following applications:
Large scale reactions
Fast reactions
Homogeneous or Heterogeneous Reaction
Continuous Production
High Temperature Reactions

4
 Table 1.1: Specification Data Sheet.

Plug flow reactor data Equipment no: Plug flow reactor (R-401)
sheet
Operating Data
No. Required 1 Capacity 50 m3
Specific gravity of content 0.73 Computed (yes or no)
Shell
Content Propylene,Ammonia,Oxygen,Nitrogen,Water,Acrylonitrile
Length 8.5 m
Max. working pressure 1 atm
Temperature 400oC
Material Stainless Steel
Joint factor 1.0
Corrosion allowance 2 mm
Shell thickness 25.0 mm
Shell diameter 2.8 m
Actual volume, m3/h 10454.8076 m3/h

Type of support Saddle

Distance of tangent to 1.3 m
saddle support
Tube
Outer diameter 2.985 inch
insider diameter 2.435 inch
Wall thickness 0.180 inch
Number of tube required 1750
Area of tube 0.00352 m2
Length of tube 8.5 m
Molar flow ,gmol/s 192.400 gmol/s
Mass flow ,g/s 5792.6846 g/s
Surface tube 6.61m2

5
 CHAPTER 2

MECHANICAL DESIGN

& HAZOP STUDY

2.1 Material Balance around Reactor

PLUG
FLOW
REACTOR

Figure 2.1 Material Balance of Reactor

6
Table 2.1 Material Entering Reactor

Inlet 1 Inlet 2 Inlet 3 Mass

Mass Mass
Component Mass in Mass in Mass in Fraction
Fraction Fraction
(kg/hr) (kg/hr) (kg/hr)
C3H6 91.48 0.085 - - - -
NH3 - 109.77 0.1026 - -
O2 - - - 182.5056 0.1705
N2 - - - 686.5574 0.6415

2.2 Volume of Reactor

2.2.1 Total Volumetric Flow rate at Reactor Inlet

a) Volumetric Flow rate of Propylene (C3H6)

.
= (Eq.2.1)
.

101325 42.08

= 3.
8.314 673.15
.

= 761.852 g/m3

V = m/p (Eq.2.2)

3849.478 /
=
761.852 /3

V = 5.0528 m3/s

7
b) Volumetric Flow rate of Ammonia (NH3)

.
= (Eq.2.3)
.

101325 17.031

= 3.
8.314 673.15
.

= 308.344 g/m3

V = m/p (Eq.2.4)

1869.493 /
=
308.344 /3

V = 756.063 m3/s

c) Volumetric Flow Rate of Oxygen (O2)

.
= (Eq.2.5)
.

101325 32

= 3.
8.314 673.15
.

= 579.355 g/m3

V = m/p

5840.18 /
=
579.355 /3

V = 10.0805 m3/s

8
d) Volumetric Flow Rate of Nitrogen (N2)

.
=
.

101325 28.0134

= 3.
8.314 673.15
.

= 507.178 g/m3

V = m/p

19232.807 /
=
507.178 /3

V = 37.921 m3/s

2.2.2 Total Volumetric Flow rate at Inlet

V total = (5.0528 m3/s) + (6.063 m3/s x 2) + (10.085 m3/s) + (37.921 m3/s)

V total = 59.1173 m3/ s

Hence, Volume = 59.1173 m3/ s

9
 Figure 2.2 Reaction order of process (J.R Hopper et al., 1993)

k value is 0.40556 sec-1. Its proven that first order by k unit which sec-1 .

First order to propylene

Zero order to ammonia and oxygen

Residence time is 20 seconds

-ra = kca
k1 = 0.40556
-ra = kca
-ra = 0.40556(0.2321)
= 0.0941
Fa0 = 91.48 kg/hr
V0 = 59.1173 m3/s
= ya0
= 0.0425
x = 0.98
T0 = 400oC (673.15K)
T = 130oC (403.15K)
k = 0.40556 sec-1

10

Step 1 (Mole Balance) : VPFR = FA0 0
Step 2 (Rate Law) : -rA = kCA
0 (1)
Step 3 (Stochiometry) = CA = =
0 (1+)
Combine all step and derive it by using Intergral Derivation Table from Reaction Engineering
Chapter 4 Notes.
0 (1)(x) In1
VPFR = 0 = (0) ((1) ) (Eq.2.6)
(1)

0 (1)(x) In1
VPFR = = (0) ((1) )
(1)

59.1173 403.15 (10.0425)(0.98)(0.0425)1

VPFR = 0.40556 = (0673.15) ( (10.98)
)
(10.98)

= 4081.4195 m3

The calculation formula taken from lecture notes.

2.3 Tubes

Plug Flow Reactors are known to have tubes running through in the vessel. There are
various types of tubes used in the industries and the common types of tubes are fixed tube sheet,
floating head and U tube. The characteristics of these common types of tubes are given in table
1.1.

11
 Table 2.2 : Characteristic of common types of Tubes, obtained from (Design et al., 2000.)
Shell and Tube Advantages
Exchangers
Fixed tube sheet Provides maximum heat
transfer area for a given shell
and tube diameter.
Provides for single and multiple
tube passes to assure proper
velocity. Less costly than
removable bundle designs.
Floating-head Floating tube sheet allows for
differential thermal expansion
between the shell and the tube
bundle.
Both the tube bundle and the
shell side can be inspected and
cleaned mechanically.
U-tube U-tube design allows for
differential thermal expansion
between the shell and the tube
bundle as well as for individual
tubes.
Both the tube bundle and the
shell side can be inspected and
cleaned mechanically.
Less costly than floating head
or packed floating head
designs.
Limitations
Shell side / outside of the tubes are
inaccessible for mechanical
cleaning.
No provision to allow for
differential thermal expansion
developed between the tube and
the shell side. This can be taken
care by providing expansion joint
on the shell side.
To provide the floating-head cover
it is necessary to bolt it to the tube
sheet.
The bolt circle requires the use of
space where it would be possible
to place a large number of tubes.
Tubes cannot expand
independently so that huge thermal
shock applications should be
avoided. Packing materials
produce limits on design pressure
and temperature.
Because of U-bend some tubes are
omitted at the centre of the tube
bundle. Because of U-bend, tubes
can be cleaned only by chemical
methods.
No single tube pass or true
countercurrent flow is possible.
Tube wall thickness at the U-bend
is thinner than at straight portion of
the tubes. Draining of tube circuit
is difficult when positioned with
the vertical position with the head
side upward.
12
 Based on the above characteristics, the type of tube chosen in the PFR is fixed tube sheet
because it is the simplest and cheapest type where the tube sheet is welded to the shell and no
relative movement between the shell and tube bundle is possible.

2.4 Length of Tubes

According to the TEMA standard, the preferred tube length used are 6 ft. (1.83 m), 8 ft
(2.44 m), 12 ft (3.66 m), 16 ft (4.88 m) 20 ft (6.10 m), 24 ft (7.32 m) , (SINNOTT, 2005). Longer
tubes reduce the shell diameter and expense of higher shell pressure drop (Design et al., n.d.).
Thus, for the PFR with a volume of 4081.4195 m3, the preferred length of tube is 7.32 m.

2.5 Number of Tubes

The number of tubes can be calculated by using the following formula (R.K.Sinnot..et
al,.2005):

Number of tube = (Eq 2.7)

To know the volume of tube, it is necessary to know the diameter of the tubes. The tube
diameter is determined from Nominal Pipe Size Table: Steel Pipes Dimension ANSI Schedule
80. From the table, it is assumed that the pipe size for the reactor tube is 24 inches.

21.56 inch = 0.5476 m

Volume of one tube = 4 (2 )() (Eq.2.8)

=4 (0.54762 )(7.32)

=1.724 m3

13
Hence, number of tubes is 4081.4195 m3 / 1.724 m3

Number of tubes = 2367 tubes

Table 2.3 Table of Steel Pipes Dimension ANSI Schedule 80

14
2.6 Tube Arrangement

Generally there are two types of tube arrangement which are triangular pattern and also
square pattern. In this design calculation, the triangular pattern was taken into consideration
because it provides a more robust tube sheet construction.

Figure 2.3 Arrangements of Tubes(R.K.Sinnot..et al,.2005).

Tube pitch is defined as (R.K.Sinnot..et al,.2005):

PT = do+ C

PT = tube pitch

do = tube outside diameter

C = clearance

15
2.7 Tube Passes

The number of passes is chosen to get the required tube side fluid velocity to obtain greater
heat transfer co-efficient and also to reduce scale formation. The tube passes vary from 1 to 16.
The tube passes of 1, 2 and 4 are common in application. The partition built into exchanger head
known as partition plate (also called pass partition) is used to direct the tube side flow. In this
design calculation, 1 tube pass is chosen for further calculations (Primo..et al,.2012).

2.8 Tube Bundles

Tube bundles are also known as tube stacks are designed for applications according to
customer requirements, including direct replacements for existing units. There are two types of
tube bundles:

a) Fixed Tube Sheet. A fixed-tube sheet heat exchanger has straight tubes that are secured at both
ends by tube sheets welded to the shell.

b) U-Tube. As the name implies, the tubes of a U-tube heat exchanger are bent in the shape of a
U and there is only one tube sheet in a U-tube heat exchanger.

In this design calculation, Fixed Tube sheet is chosen.

The bundle diameter can be estimate by using following formula (R.K.Sinnot..et al,.2005):

= ( )1/ (Eq 2.8)
1

Constants for the triangular pitch is shown in figure 2.3.

Figure 2.4 Constants for Triangular Pitch , obtained from (Primo, 2012).

16
Hence, the bundle diameter is,

NT = 2367

n for pass 1 = 2.142

K1 for 1 pass = 0.319

Do = 0.6096 m

Db = 0.6096 ( 2367/0.319)1/2.142

Db = 39.097 m

2.9 Shell (Reactor)

2.9.1 Height of Shell (reactor)

Allowance of the reactor height is 20% - 50% of the shell height.

In this system assuming the allowance for shell is 50% of the tube height.

So

= 7.32 + 0.5(7.32) = 10.614 (Eq 2.9)

(R.K.Sinnot..et al,.2005)

2.9.2 Diameter of Shell (Reactor)

Diameter of the shell is calculated by using the Harvey equation. Harvey equation is:

[( 1 )2 ] ( 1 )(1 +4 )
= (Eq 2.10)
1.23 ( )2

(R.K.Sinnot..et al,.2005)

Where = = 2367

= = ?

= = 1.25 0.6096 = 0.762

17
The tubes used in triangular form. For triangular form

1 = 1.08, 2 = 0.9, 3 = 0.69, 4 = 0.8

= = 1

By putting all these values in the Harvey and solving, we have

= = 42.30

2.9.3 Verification of the assumptions

All the values assumed can be verified from the length to diameter ratio of the given reactor
and the pressure drop calculations. If the value of length to diameter ratio and pressure drop lies
within the limit of the fixed bed plug flow reactor then the design is accepted, otherwise we must
perform the calculations again with the different assumptions

For the plug flow reactor, the length to diameter ratio lies between 0-5.

For the desired reactor (R.K.Sinnot..et al,.2005)

Length = 10.614 m

Diameter = 42.30 m

Length to diameter ratio for desired reactor = 10.983.34

= 0.251

For the desired reactor, the length to diameter ratio is 0.251 lies between the allowable
limit. So, the design is satisfactory.

18
2.10 Design Pressure

The reactor must be designed to withstand the maximum pressure to which it is likely to
be subjected in operation. For reactor under internal pressure, the design pressure is taken as 10%
of the working pressure to avoid spurious operation during minor process upsets. (R.K.Sinnot..et
al,.2005)

Pi = 1 atm x 1.1 = 1.1 atm

2.11 Design Temperature

The strength of metals decreases with increasing temperature. Therefore, the maximum
allowable design stress will depend on the material temperature. The design temperature is taken
as the maximum working temperature in the reactor.

T= 400C = 673.15 K

2.12 Material of Construction

For design purposes, it is necessary to decide a value for the maximum allowable stress
that can be accepted in the material of construction. It has been stated that the material of
construction is stainless steel, 18 Cr/ 8 Ni Ti, stabilised (321). The reasons are very clear that it
must withstand the internal high pressure (in tube side). Besides it should withstand the sudden
changes (reaction) that take place in it.

From Table 13.2, Chemical Engineering Volume 6 (page812), for 18 Cr/ 8 Ni Ti,

Design stress, f at 400C = 120 N/mm2

Tensile strength = 540 N/mm2

19
2.13 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. This is determined
by applying a suitable design stress factor (factor of safety) to the maximum stress that the
material could be expected to withstand without failure under standard test conditions. The design
stress factor allows for any uncertainty in the design methods, the loading, the quality of the
materials, and the workmanship.

According to (Boardman, n.d.), the stress factor, f at 400C for the pearlitic steel is 1000
mPa which equals to 1.1 N/mm2. .

2.14 Corrosion Allowance

The corrosion allowance is the additional thickness of metal added to allow for material
lost by corrosion and erosion. From Chemical Engineering Volume 6 (page 641), the minimum
corrosion is taken as 1 mm.

Welded Joint Efficiency

From Table 13.3, Chemical Engineering Volume 6 (page 639), welded joint efficiency is
taken as 1.0 implies that the joint is of double-welded butt type and with 100% degree of
radiography.

J = 1.0

20
2.15 Designs for Shell Wall Thickness

There will be a minimum shell wall thickness required to ensure that any vessel is
sufficiently rigid to withstand its own weight. From Chemical Engineering Volume 6, for a vessel
diameter between 1 m to 2 m, its wall thickness (include corrosion allowance of 2mm) should not
less than 7 mm.

For a cylinder shell, the minimum thickness required to resist internal pressure is determine from
the equation (given in the BS 5500):

Pi D s
e (Eq 2.11)
2f Pi

(R.K.Sinnot..et al,.2005)

Where,

e = wall thickness

Ds = internal diameter = 42300 mm

Pi = design pressure = 1.1 N/mm2

f = design stress = 120 N/mm2

1.1N / mm2 x 42300mm

e 194.74mm
2 x120 N / mm2 1.1N / mm2

2.16 Corrosion Allowance Thickness

Let the corrosion allowance thickness = 195 mm,

The shell wall thickness = 195 + 1 = 196 mm

Hence, diameter of reactor, Dr = Ds + 2e = 42.692 m

21
2.17 Baffle Thickness

The baffles used would be in the form of flat steel plate. Thickness of the plate,
(R.K.Sinnot..et al,.2005)

Pi
t bf 0.5FDbf (Eq 2.12)
f

Where,

Dbf = diameter baffle = Ds- cs = 42.3 2.0304 = 40.2696 m

F = factor equal to 1.00 for a fixed plate

Therefore,

1.1
t bf 0.5 1 40.2696 = 2.0304 (Eq 2.13)
120

2.18 Domed Head

The ends of a cylinder vessel are closed by heads of various shapes. The principal types
used are flat plates and formed flat heads, hemispherical heads, ellipsoidal heads and torispherical
heads. For reactor, R-4, closure of type torispherical is selected because it will usually prove to be
the most economical closure to be used.

Torispherical head is used it is cheaper than ellipsoidal head and hemispherical head. The
vessel domed ends design will be calculated as follows for the torispherical ends closure
(R.K.Sinnot..et al,.2005):

Pi R c Cs
e (Eq 2.14)
2fJ Pi (Cs 0.2)

22
Where,

Cs = stress concentration factor for torispherical heads

J = Joint factor = 1.0

Rc = crown radius. Assume same with Dr = 42.692 m

Rk = knuckle radius. Assume 6 % of Rc = 25.6152 m

The ratio of the knuckle to crown radius should not be less than 0.06, to avoid buckling and the
crown radius should not be greater than the diameter of the cylindrical section.

1 Rc
Cs (3 ) (Eq 2.15)
4 Rk

= 1.073

Domed minimum wall thickness,

1.1N / mm 2 x42.692mmx1.073
e 0.625 mm
(2 x(120) N / mm 2 x1) 1.1(1.073 0.2)

= 0.6348 mm + 1 mm (Corrosion Factor)

= 1.6348 mm

Take the same thickness as shell wall thickness, hence thickness of domes head

= 1.6348 mm.

23
r1 = DR = 42.692 m

r2 = 25.6151 m

3.5

3.5 210

h = 735 mm

2 = 0.1935 0 0.455

Where,

0 = + 2( )

Assume insulation thickness = 0.075 mm, thus

D0 = 42.842 m

Hence,
2 = 0.1935 42.842 0.455 0.21

h2 = 8.1944 m

24
2.19 Weight Loads

2.19.1 Weight Load of Shell (R.K.Sinnot..et al,.2005)

Wv = 240CvDm (Hv + 0.8Dm) t

= 240(1.15)(42.962+0.195)[10.614+0.8(42.962+0.195)0.195

= 100601.66 N

Where,

Wv= total weight of the shell, excluding internal fittings, such as plates, N

Cv = a factor to account for the weight of nozzles, mean ways, internal supports

= 1.15

Hv = height, or length between tangent lines (the length of the cylindrical section), m

t = wall thickness, mm

Dm = mean diameter of vessel = (Ds + t), m

25
2.19.2 Weight Load of Pipe
For Steel, 24inch, Schedule 80, weight of a pipe = 441.99 kg/m, hence, for 2367 pipes,
(R.K.Sinnot..et al,.2005)

Wp = No. of pipes Weight of pipe/length L 9.81

= 2367441.9910.6149.81

= 1.089 x 108 N

2.19.3 Weight of Insulation Material

Fibreglass (density=100kg/m3) is used as insulation material. The thickness of it
= 75 mm.

Approximate volume of insulation = 42.8427510-3 10.614

= 107.142 m3

Wi = Volume of insulation material density of material 9.81

= 107.1421009.81

= 105106.302 N

2.19.4 Weight Load of Fluid (Shell Side)

Wfs = mass flowrate (shell side) 9.81

= 30.7919589.81

= 302.069 N

26
2.19.5 Weight Load of Fluid (Tube Side)
Wft = mass flowrate (tube side) 9.81

= (30.791958)9.81

= 302.069 N

2.19.6 Total Weight Load

Total Weight load, W = Wv + Wp + Wi + Wfs + Wft

= 1.091 X 108 N

2.20 Reactor Support (Saddles)

The reactor will be place as horizontally vessel because the diameter of the reactor is
greater than 1.2 m. As for the support of the reactor, saddle support has been chosen as the support
material. (R.K.Sinnot..et al,.2005)

27
2.21 Analyses of Stresses

a) Pressure Stresses

The longitudinal and circumferential stresses due to pressure given by (R.K.Sinnot..et

al,.2005):

PD s 1.0 42.3
L = = 54.231 N/mm2
4t 4 0.195

PD s 1.0 42.3
h = = 108.462 N/mm2
2t 2 0.195

b) Dead Weight Stress

Wv 100601.66
w = = = 0.01214 N/mm2
(D s t ) t (42300 0.195) 0.195

The longitudinal bending stress at the mid-span of the vessel is given by (R.K.Sinnot..et
al,.2005):

M L1 Ds 4M L1
b1 x (Eq 2.15)
Ih 2 Ds 2 t

Where,

ML1 = Longitudinal bending stress at the mid-span

Ih = Second moment of area of the shell

Assume that the load per unit length is due to weight of vessel alone,

2
wL 1
M L1
2

w = Total Weight load x 1000/10.614 = 1.028 x 109 N

L1 = L / 2 = 10.614/2 = 5.307 m

28
ML1= 1.028 x 109 (5.307)2/2 = 1.448 x 1010 Nm

4M L1 4 1.448 x1010
b1 = 3 = 52.84 N/mm
2
D s t 42.3 195 10
2 2

The resultant axial stress due to bending and pressure will be given by (R.K.Sinnot..et al,.2005):

Pi D s 4M L1
z (Eq 2.16)
D s t
2
4t

Pi D s 1.1 42.3
= = 59.654 N/mm2
4t 4 0.195

z (upwind)= (59.654 + 52.84) N/mm2 = 112.494 N/mm2

z (downwind)= (59.654 - 52.84) N/mm2 = 6.814 N/mm2

As assume that there is no torsional shear stress, the principal stresses will be z and h.

112.494 N/mm2 6.814 N/mm2

108.462 N/mm2 108.462 N/mm2

Up-wind
Down-wind

The greatest difference between the principal stresses will be on the down-wind side, = h
- z (downwind) = 108.462 6.814 = 101.648 N/mm2. This value is well below the maximum
allowable design stress (120 N/mm2). Thus, the design is satisfactory.

The theoretical optimum position of the supports to give the least maximum bending
moment will be the position at which the maxima at the supports and at mid-span are equal in

29
magnitude. For uniformly loaded beam, the position will be at 21% of the span, in form each end.
Therefore:

L2 = 0.21 x L = 0.21 x 10.614 = 2.229 m from each end

The longitudinal bending stress at the supports,

4M L 2
b2
C h Ds 2 t (Eq 2.17)

Where,

Ch = an empirical constant; varying from 1.0 for a completely stiff shell to about 0.1 for a thin,
unstiffened shell

wL2 (1.091x10^8) (2.229) 2

2
M L2 2.708 x10^8 Nm
2 2

For completely stiff shell,

4 (2.708 x10^8)
b2 = = 9.88 x 105 N/m2
1 (42.3) 2 0.195

2.22 Elastic stability (buckling)

Under condition 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 thin walled
process column under an axial compressive load by buckling of the complete vessel, as with a
strut, or by local buckling, or wrinkling, of the shell plates. The critical buckling stress c is given
by (R.K.Sinnot..et al,.2005):

E t
c

3 1 v2 R
p

(Eq 2.18)

30
 With steel at ambient temperature, E = 340,000 N/mm2, a safety factor of 12 will be used
and the radius of curvature, Rp = Dr

t 195
c 3.4 x10 4 3.4 x10 4 136.548 N / mm
2

Dr 42.842

The maximum compressive stress will occur when the vessel is not under pressure.

Maximum compressive stress = w + b1

= (0.01214 + 52.84) N/mm2

= 52.852 N/mm2

52.852 < 136.55, well below the critical buckling stress. So, design is satisfactory.

31
2.23 Design of Saddles

The saddles must be designed to withstand the load imposed by the weight of the vessel
and contents (Megyesy et al.,2001). The standard steel saddle supports is given in Fig. 13.26b,
Chemical Engineering Design, Vol. 4 (page 864).
However, since the diameter of the reactor is 8.935 m and the standard values for the steel
saddles are not available in the reference. Hence, the values were just assumed.

Figure 2.5 Design of the Saddle with the assumption of dimensions

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2.23.1 Original Design of PFR Reactor

Figure 2.6 : PFR Reactor Frame

Figure 2.7 Side and Front View of Designed Reactor PFR with Scale of Side View of PFR
(Scale 1mm=50mm) Front View of PFR (Scale 1mm = 20mm) by eDraw Software.

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2.23.2 PFR Reactor with dimensions

Figure 2.8 : Skecth up Pro software with measurement

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Table 2.4 : Full Scale Complete Data Sheet of Calculated PFR

EQUIPMENT SPECIFICATION SHEET

Identification: Plug Flow Reactor

Function : To produce Carbon Black

General design considerations: Plug Flow Reactor for Acrylonitrile production

Material Stainless steel, 18 Cr/ 8 Ni Ti, stabilised (321)
Design pressure 1 atm 10% above operating pressure

Design joint efficiency 1.0

Design stress, f 120 N/mm2
Corrosion allowance 1 mm
Minimum thickness 194.74 mm E=PiDi/(2f-Pi) for cylindrical
shell, given in BS5500
Inner diameter (1 Tube) 0.5476 m
Outer diameter (1 Tube) 0.6096 m
Total vessel weight 1.091 X 108 N
Pressure stress, L 54.231 N/mm2
Pressure stress, h 108.462 N/mm2
Dead weight stress 0.01214 N/mm2
Bending stress 52.84 N/mm2
Longitudinal stress,
z(upwind) 112.494 N/mm2
z(downwind) 6.814 N/mm2
Critical buckling stress 52.852 N/mm2

Head (Closure)
Type Torispherical, welded
Minimum thickness 0.6348 mm Design for 1.6348 mm

Vessel Support
Type of Support Saddle
Support Drawing Dimensions
V 21.6 m
Y 0.25 m
C 9.0 m
E 3.4 m
J 1.815 m
G 0.15 m
t2 20 mm
t1 14 mm

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2.24 Hazard and Operability (HAZOP) of Reactor

HAZOP study is a systematic method of uncovering if a process can cope with deviations
from indented design goals. The goal is to uncover situations where deviations from design intend
may lead to undesired events. HAZOP is a structured technique in which a multi-discipline team
performs a systematic study of a process using guide words to discover how deviations from the
design intent can occur in equipment, actions, or materials, and whether the consequences of these
deviations can result in a hazard.

There are various parameters like flow, temperature, pressure, liquid, level, composition
and any other variable affecting the process.

The parameters that needed to be study are as follow:

Temperature

Flow

Pressure

36
2.24.1 HAZOP Analysis

Table 2.5 Reactor Feed HAZOP analysis

Guide
Item Deviation Causes Consequences Action
Word
- Process shut down
immediately to proper
No flow of Valve No production
None inspection and maintenance
coal tar oil failure
- Install flow indicator

-Incomplete
production - Proper shut down immediately
No Flow of Valve -Temperature to proper inspection and
None
Air Failure of reaction maintenance.
cant be - Install flow indicator
achieved
Isolation
Failure of
valve
More More pressure reaction in Install High Pressure Alarm
Reactor close in
reactor
error
-Leaking Less
flange of production Process shut down immediately to
valve yield proper inspection and
Less Flow
-Low maintenance
material
flow
Leakage
Contam Contamination Contamination
of tube Proper maintenance and operator
ination of process in PFR
in product in
alert
fluid. reactor
reactor
Pipelines
Equipme cannot be
Others Maintenance nt completely Install alarm
Failure drained or
purged

37
Table 2.6 HAZOP for Reactor Product.

Guide
Item Deviation Causes Consequences Action
Word
Failure of control
Process shut down immediately to
None No Product valve to open or No production
flow proper inspection and maintenance
blockage

-Overfilled Process shut down immediately to

More feed - Valve opening
More -Temperature in proper inspection and maintenance
flow malfunction
Reactor mixer elevated
Quality and
Less feed - Pipe leakage Process shut down immediately to
Less product will
flow - Column leakage proper inspection and maintenance
decrease.
Others Maintenance Equipment Failure Pipelines cannot Install alarm
be completely
drained or
purged

38
 CHAPTER 3

CONTROLS AND INSTRUMENTATION IN REACTOR

3.1 Introduction

Control system is an important aspect in the process. The control system depends on the
type of instrument used. In some case, the instrument that is used is not suitable to control the
variables, so it must be cared to have a best operation system. The design for the process control
in the production of Acrylonitrile plant is implemented based on this guide rule:

(a) Identify the control loops that are obviously needed for steady plant operation as
level, flow, pressure and temperature control.
(b) Identify the key process variables that need to be controlled to achieved the
specified the product quality. Control loops using direct measurement of control
variables, are included where possible if it is not practicable, dependent variable
shall be elected (Sinnot et al., 1999).

Control system in the plant is mainly used for:

Safety.
Operability to ensure that flows and holdup are maintained at chosen values within
operating ranges.
To control product quality, process energy consumption

39
3.2 Control Strategy

The type of control strategy used for PFR reactor is cascade control strategy. Cascade
control is widely used in the chemical process industries and especially in cases where there may
be nonlinear behavior in the dynamics of the control loop and it is easy to determine and correct
any unintentional disturbance presence. The cascade control shown in Figure 3.1 above shows
stream 1 temperature is measured using a temperature transducer. The temperature reading is sent
to temperature controller which manipulate the flow to cool or heat the reactor feed resulting no
sluggish response of the temperature. There are several advantages of using cascade control in the
system such as large improvement in performance when the secondary is much faster than primary.
It is a simple technology with PID algorithms and use of feedback at all levels where primarily
zero offset for step-like disturbances. Cascade system is also known as the best control strategy
to be applied or this case and it is because the secondary loop which is called the slave works four
times faster than the master to correct any wrongs in the process (Green W. Don et al., 2000).

Figure 3.1: Cascade control strategy.

40
 REFERENCES

Fogler, H.S. (1999) Elements of Chemical Reaction Engineering. Prentice Hall of India, New
Delhi.

Green W. Don & Perry R. H. (2000). Perrys Chemical Engineers Handbook. Seventh Edition
Kansas. McGraw Hill,

J.R.Hopper, C.L.Yaws, T.C.Ho and M.Vichailak, Waste Minimization By Process Modification,

1995 (page 5)

Morari, M, and E.Zafiriou, E. 1999 Robust Process Control Prentice Hall

Shell Lubricants. (2010). Shell Heat Transfer Oil S2: High Performance Heat Transfer Liquid.
Retrieved from http://epoxyoil.com/downloads/shell_heat-transfer-oil.pdf

Sinnott, R. K., Coulson & Richardson (1999). Chemical Engineering Volume 6, Chemical
Engineering Design, Butterworth Heinemann.

Towler, G. Sinnott, R. (2012) Chemical Engineering Design. Oxford, United Kingdom: Elsevier
Ltd.

*ARRANGE FROM A-Z

41
APPENDIX

Figure 2.9 Screenshot of Side View with its Measurement- Edraw

42
Figure 2.10 Screenshot of Front View with its Measurement- Edraw

43