Crystallizer

1) Design Data: Be specific on this section. Indicate the operating conditions: Operating Pressure
and Operating Pressure. Indicate Design Conditions: Design Pressure and Design Temperature.

Operating Pressure = 0 barg or 1.0 barA

Operating Temperature = 20 deg C

Design Temperature between -30 degC and 345 degC is 25 degC + Maximum Operating
Temperature. (Analysis, Synthesis and Design of Chemical Processes, Fourth Edition, p. 368)
Therefore

Design Temperature = 20 + 25 = 45 deg C

Design Pressure is 10% or 1.7 bar over the maximum operating pressure or 3.5 barg (Industry
Standard, minimum pressure to send the process fluid to flare during emergency)

Design Pressure = 3.5 barG

In vessel thickness calculation

P = 3.5 barg + (Density of Fluid)(g/gc)(height of Liquid)

Assume full liquid for the vessel.

Corrosion Allowance = 3.0 mm for Carbon Steel

= 0.0 mm for Stainless Steel

Based on ASME (American Society of Mechanical Engineers) Code minimum vessel thickness
should be 1.5 mm. For distillation columns, Carbon steel = 6 mm minimum thickness, Stainless
Steel = 5 mm.

2) Please redesign the equipment.

Many inconsistencies
a) Spec Sheet indicated Cooling Water Temperature In = 70 deg C and Out = 20 deg C. Process
Fluid is 15 to 25 deg C.
b) PFD shows a Cooling Water Entering at 15 to 20 deg C and leaving at 25-30 deg C.
Please do not give range in cooling water inlet and outlet temperature. Use 30 for inlet and
40 for outlet. The maximum outlet temperature of cooling water is 45 deg C. Beyond 45 deg
C, cooling water will start to scale.

Moreover, your drawing in spec sheet is not consistent with PFD. Your CW is in the Tube
side while Process Fluid is in the Shell Side, but your drawing shows the opposite. Usually
CW is allocated in tube side to meet the 1 m/s minimum velocity criteria for cooling water to
prevent biological fouling, the minimum 1 m/s is difficult to achieve in shell side unless the
number of baffles is increased, which will result in exceeding the allowable pressure drop of
70 kPa (typical value of allowable pressure drop). If you want to keep the drawing, change
the fluid allocation, SS for cooling water (increase the baffle and check for the velocity if
min. 1 m/s is achieved), TS for process fluid.
c) In your calculation, the values used in LMTD are also different from your PFD and Spec
Sheet.

d) Please be consistent with the values. My time is being wasted in checking these
inconsistencies. Wrong input values will result to inaccurate equipment size.

e) Why do you add insulation to your vessel? What is the purpose of insulation? The operating
temperature 25 deg C a little lower compared to the ambient temperature (30 deg C) in
here in the Philippines. You are cooling the process fluid to aid crystal formation, adding
insulation is not practical and not economical. You are just adding capital cost to your
equipment. Remove all calculations with regard to insulation since it has no USE.

f) I attached Heat Exchanger Sample Data Sheet for your perusal. Please check the e-mail
attachment.
g) Shell Inside Diameter is less than 300 mm, NOTE: You must report the shell diameter in
terms o SHELL INSIDE DIAMETER (Shell ID), to differentiate it with OUTSIDE DIAMETER.
Chemical/Process Engineers will specify Shell ID while Mechanical Engineers will calculate
the thickness of the equipment based on Design Pressure.

Shell inside diameter increment should be 50 mm increment. In your initial design, shell ID is
< 300 mm. Therefore you must use Pipe Size (meaning fabricators cannot construct
vessels/equipment with < or = to 300 mm Inside Diameter, therefore they will use pipe to
fabricate the equipment).
 Use any of these 3 Pipe Sizes when designing your heat exchanger.

h) We still don’t understand why Pump is included in Crystallizer Design. Pump calculation
requires Source and Destination pressure, Difference in elevation, and Difference in velocity
head. (Mechanical Energy Balance equation is used in fluid mechanics to design the head of
the pump and to determine the power required).

Fluidized Bed

a)

6 m and 0.5 dimension of the bed is OK. But you need to account the T/T (Tangent to Tangent) length of
the Vessel or the cylindrical length of the vessel, please indicate the inside diameter of the reactor to
your drawing.

Height from bottom and height from top = 1/3*6 = 2 m.

Height from Bottom = 2 m

Height from Top = 2 m

T/T Length = 10 m
Reactor Dimension = 300 mm ID x 10,000 mm T/T Length

b) Kindly indicate the operating and design conditions based on my previous comment in crystallizer,
use the formula for DP (Design Pressure) and DT (Design Temperature) calculations.

c) Use the design conditions to calculate the thickness of the equipment.

Rotary Drum Filter

a) Design is OK, except for the specification on Pump.