MECHANICAL DESIGN OF MAJOR EQUIPMENT

HYDROGENATOR :

For the preparation of hydrogen peroxide a hydrogenator is to be designed.

Parts of the hydrogenator are
1.
2.
3.
4.

Shell
Head (top& bottom)
Nozzle
Support

DESIGN OF SHELL:
GIVEN DATA:
Component: cylinder
Material specifications: SA 240 316L LOW
Design temp: 85 deg c
Internal diameter: 2286mm
Internal design pressure: P= 0.230 N/mm^2 @ 85 deg c
Static liquid head = 0.00564 N/mm^2
Corrosion allowance = 0
Radiography: fully radio graphed
Weight of the vessel = 204.21 kg
capacity :3628.33 liters
Weight of operating liquid: 2362.7kg
Weight of top and bottom head = 923.24 kg
Allowable stress:99.904N/mm^2

THICKNESS OF CYLINDRICAL VESSEL:

t = P*D/(2*f*j-p) + c.a
t = (0.230*2286)/((2*1*99.904)-0.230) + 0
t = 2.7002 mm
Standard thickness to be brought from the market availability is 4mm
Check the shell thickness for combined loadings
( 1) Tensile stress generated due to internal pressure:
Ft = {(Di + t)* P}/(2*t)
= {(2286 +4)/(2*4)}*0.230
= 65.8375 N/mm^2
33.359 psi = 230 * 10^3 N/mm^2
1 psi = 6894.69 N/mm^2
14490*6894.69 = 99.9904 N/mm^2
t = (0.23 * 2286) /{( 2 * 99.904*1) 0.230} + 1.5
= {525.78 / (199.808 0.230)} + 1.5
= (525.78 / 199.578) + 1.5
= 2.6344 mm
From market availability, select plate thickness of 4 mm
(2) Longitudinal stress:
fa = f1 + f2 + f3
f1 = (P *Di) / (4 * t)
= (0.230 * 2286) / (4 * 4)
= 32.86 N/mm^2
f 2 = {(weight of operating liquid) +( weight of shell) + ( weight of top head) +

(weight of bottom head)}/ (3.14 *t* (Di + t))

= (2362.7 + 204.21 + 461.2 + 461.2) / (3.14 *4*(2286 + 4))
= 3489.85/ 28762.4 N/mm^2
= 0.1212 N/mm^2
f3=0

(moment is zero)

(3) fa = f 1 + f 2 + f 3
= 32.86 0.1212
= 32.7388 N/mm^2
f s = (2* T)/{(3.14 * t *Di)(Di + t)}
= (2*1478.2*1000)/{(3.14*4*2286)*(2286 + 4)}
= 0.0449 N/mm^2
Resultant tensile stress, f R = [f t^2 - (f a *f t) + f a^2 + (3*f s^2)]^0.5
= [(68.8374^2) (68.8374*158.9) + (158.9^2) + (3*{0.0449^2)}]^0.5
= 57.017 N/mm^2
f R < f allowable, so ,our design is safe.
DESIGN OF HEAD:
GIVEN DATA:
Component : elliptical head
K = (length of major axis) / (length of minor axis)
= 2/1
=2
Material specifications: SA 240 316L LOW
Internal diameter: 2286mm
Internal design pressure: P= 0.230 N/mm^2 @ 85 deg c
Static pressure = 0.0 N/mm^2

Corrosion allowance = 0
Radiography: fully radio graphed
Weight of the top head = 461.62 kg
capacity :1666.34 liters
Forming , fa = 1.5875 mm
Weight of operating liquid: 2362.7kg
Weight of top and bottom head = 923.24 kg
Allowable stress: 99.904N/mm^2
DESIGN THICKNESS OF SEMI-ELLIPSOIDAL HEAD (TOP):
t h = (P*D)/{(2*F*j) (0.2*P)} + CORROSION ALLOWANCE + fa
= (0.23*2286) /{(2*99.904*1) (0.2*0.23)} + 0 + 1.5875
= 2.6303 + 1.5875
= 4.2195 mm
MAXIMUM ALLOWABLE PRESSURE:
P = (2*F*j*th) / {(D + (0.2*th)} + Ps
= (2*99.904*1*4.2195) / {(2286 + (0.2*4.2195)} 0
= 843.089 / 2294.439
= 0.3674 N/mm^2
DESIGN THICKNESS OF SEMI-ELLIPSOIDAL HEAD (BOTTOM):
Internal design pressure: P= 0.230 N/mm^2 @ 85 deg c
Static liquid head = 152.3534 KPa
= 0.152 N/mm^2
Total pressure = Internal design pressure + Static liquid head
= 0.230 + 0.152
= 0.382 N/mm^2

t h = (P*D)/{(2*F*j) (0.2*P)} + CORROSION ALLOWANCE + fa

= (0.382*2286) /{(2*99.904*1) (0.2*0.382)} + 0 + 1.5875
= 4.3721 + 1.5875
= 5.9596 mm
MAXIMUM ALLOWABLE PRESSURE:
P = (2*F*j*th) / {(D + (0.2*th)} + Ps
= (2*99.904*1*5.9596) / {(2286 + (0.2*5.9596)} 0
= 1190.7757/2287.1919
= 0.5206 N/mm^2
DESIGN OF INLET NOZZLE OF HYDROGENATOR:
GIVEN DATA:
Located on SHELL
Nozzle material specification : SA 312 TP316L WELD HIGH
Nozzle orientation = 0 degrees
Corrosion allowance = 0
Spot radiography = 0.85
Inner diameter of shell = 2286 mm
Inner diameter of nozzle = 52.5018 mm
Nozzle thickness = 3.9116 mm
As = di*(ts ts corrosion allowance)
ts = (P*Di)/{(2*F*j) P)} + corrosion allowance
= (0.23*2286)/{(2*99.904*0.85) (0.23)} + 0
= 3.099 mm
A = 52.5018*(4-3.099-0) + 0
= 47.304 mm^2

A1 = di*ts
= 52.5018*3.099
= 162.7552 mm^2
H1 = 2.5*tn
= 2.5*3.9116
= 9.779 mm
tn = (P*di)/{(2*F*j) P)} + corrosion allowance
= (0.23*52.5018)/{(2*99.904*1) 0.23)}
= 0.07119 mm
An = {(2*H1)*(tn-tn- corrosion allowance)}
= {(2*9.779)*(3.9116-0.07119-0)}
= 38.404 mm^2
A= A + An
= 47.304 + 38.404

= 85.708 mm^2
A1 A = 162.7552 85.708
= 77.047 mm^2
So, area required for compensation = 77.047 mm^2
DESIGN OF SKIRT SUPPORT:
Material: SA 240 316L LOW
Left end outer diameter= 90.3937 in.(2296 mm)
Right end outer diameter=90.3937 in (2296 mm)
Overall length=11.81102 in (300 mm)
Corrosion inside = 0

Corrosion outside = 0
Weld joint efficiency top, E=0.6
Weld joint efficiency bottom, Eb=0.6
Nominal thickness=0.3149606 in (8mm)
Estimated skirt weight, new=305.3 lb (138.4818 kg)
Estimated skirt weight, corroded= 305.3 lb (138.4818 kg)
Insulation on skirt weights=9.7 lb (4.399846 kg)
SKIRT ALLOWABLE STRESSES
Allowable tensile stress St = 14490*1.2
= 17,388 psi
= 119.884 N/mm2
Factor A = 0.125/(r/t)
= 0.125/ (45.19685/ (0.3149606))
= 8.7108 * 10-4
From table, Factor B = 9214
Allowable buckling stress, Sb = 9214*1.2
= 11056.8 psi
= 76.233 N/mm^2
Allowable compression, Sc = lesser of Sb , St
= 11056.8 psi
= 76.233 N/mm^2
SKIRT REQUIRED THICKNESS, TENSILE STRESS AT BASE:
Governing loading is seismic in the vaccum condition
t = {-W/(3.14*Di*St*E)} + {(48*M)/(3.14*Di^2*St*E)}

= -{149897.8/(3.14*90.07874*17388*0.6)} +
{(48*935841.1)*(3.14*90.07874^2*17388*0.6)}
= 0.05079 + 0.1689
= 0.2196 in
= 5.5803 mm
SKIRT REQUIRED THICKNESS, TENSILE STRESS AT TOP:
t = {-W/(3.14*Di*St*E)} + {(48*M)/(3.14*Di^2*St*E)}
= - {149582.8/ (3.14*90,07874*17388*0.6)} +
{(48*907717.3)*(3.14*90.07874^2*17388*0.6)}
= 0.05069 + 0.1639
= 0.2145 in
= 5.4506 mm
SKIRT REQUIRED THICKNESS, COMPRESSIVE STRESS AT BASE:
Governing loading is seismic in the vaccum condition
t = {-W/(3.14*Di*Sc)} + {(48*M)/(3.14*Di^2*Sc)}
= -{149897.8/(3.14*90.07874*11056.8)} + {(48*935841.1)*(3.14*90.07874^2*11056.8)}
= 0.04793 + 0.1589
= 0.2068 in
= 5.2535 mm
SKIRT REQUIRED THICKNESS, TENSILE STRESS AT TOP:
t = {-W/(3.14*Di*St*E)} + {(48*M)/(3.14*Di^2*St*E)}
= - {149582.8/ (3.14*90,07874*11056.8)} +
{(48*907717.3)*(3.14*90.07874^2*11056.8)}
= 0.04783 + 0.1547
= 0.2025 in

= 5.1443 mm
SKIRT REQUIRED THICKNESS, LARGEST OF THE ABOVE PLUS CORROSION
ALLOWANCE:
= max {5.5803 mm, 5.4506 mm, 5.2535 mm , 5.1443 mm} + 0
= 5.5803 mm + 0
= 5.5803 mm