Technological Institute of the Philippines

MULTI TUBULAR
FIXED BED REACTOR
R-01
Technological Institute of the Philippines
 Technological Institute of the Philippines

SPECIFICATION SHEET
Equipment Name: MULTI-TUBULAR FIXED BED
REACTOR
Equipment Code: R - 01
Objective: The multi – tubular fixed bed reactor is
used for the alkylation of Benzene and
Propylene to produce Cumene using zeolie
– based catalyst.
Vessel Type Fixed Bed Reactor
Operation Continuous
OPERATING DATA
Operating Temperature 257.5 oC
Operating Pressure 3.54 MPa
Design Pressure 3.894 MPa
Inlet Flowrate 41096.66 kg/day
Retention Time 300 s
Material of Construction Carbon Steel
DESIGN DATA
Volume of Reactor 0.4329 m3
Volume of Reactor with 20% 0.5195 m3
Allowance
Weight of the Catalyst 432.8850 kg
Height of Cylinder 6 m
Height of Torispherical Head 0.1186 m
and Bottom
Total Height of Reactor 6.0277 m
Shell Thickness 13.8269 mm
Tank Outside Diameter 0.6405 m
Tank Inside Diameter 0.6129 m
TUBE SIDE
Inlet Temperature 170 oC
Outlet Temperature 257.50 oC
Number of Tubes 196 tubes
Tube Length 5 m
Diameter of Tubes Di 22 mm
Do 26 mm
Cross Sectional Area of Tube 0.00038 m2
Volume of 1 tube 0.00265 m3
Heat Transfer Coefficient 87.7580 W/m2 K
Pressure Drop 211.127 Pa
SHELL SIDE
Inlet Temperature 28 oC
Outlet Temperature 65.5 oC
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Mass of Cooling Water 5664.24 kg/day

Baffle Spacing 0.1225 m
Number of Baffles 49 Baffles
Heat Transfer Coefficient 55.6627 W/m2 K
Pressure Drop 7922.2589 Pa
NOZZLE SIZING
Feed Inlet Nozzle Diameter 50.2190 mm
Feed Outlet Nozzle Diameter 37.2876 mm
Cooling Water Nozzle 45 mm
Diameter
Cooling Water Outlet Nozzle 45 mm
Diameter
CATALYST PROFILE
Type of Catalyst Zeolite
Bulk Density 1000 kg/m2
Porosity 0.5
Particle Size 3 mm
Shape Spherical
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DESIGN CALCULATIONS ON MULTI-TUBULAR FIXED BED REACTOR

Fixed Bed Reactor:

Fixed bed reactors are most commonly used reactors. It is usually consists of a
cylindrical vessel packed with solid catalyst. It is relatively easy and inexpensive to
construct, to operate, to maintain, and to scale up. It is even more practical due to its
suitability to any types of catalysts such as powder, pellets, spheres, etc.
(Hasani et al 2014)

Basis (Dimian et al, 2008):

1. The reactor is operated isothermally at steady state.
2. The reaction is in first order based on propylene.
3. There is uniform velocity with no radial variation (but there is axial variation)
reaction rate.

OPERATING CONDITIONS
Operating pressure
𝐎𝐩𝐞𝐫𝐚𝐭𝐢𝐧𝐠 𝐏𝐫𝐞𝐬𝐬𝐮𝐫𝐞 = 𝟑. 𝟓𝟒 𝐌𝐏𝐚
Design Pressure
Design pressure is set to be 10% higher than normal operating pressure (Green and
Perry, 2008).

Design Pressure = 1.10(Poperating pressure )

Design Pressure = 1.10(3.54 MPa)

𝐃𝐞𝐬𝐢𝐠𝐧 𝐏𝐫𝐞𝐬𝐬𝐮𝐫𝐞 = 𝟑. 𝟖𝟗𝟒 𝐌𝐏𝐚

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Maintaining Temperature
The reactor was usually operated at 150 to 300 degrees Celsius (Hasani et al, 2014).

𝐎𝐩𝐞𝐫𝐚𝐭𝐢𝐧𝐠 𝐓𝐞𝐦𝐩𝐞𝐫𝐚𝐭𝐮𝐫𝐞 = 𝟏𝟓𝟎 − 𝟑𝟎𝟎 °𝐂

REACTION KINETICS

Reactor Design Equation

C3 H6 + C6 𝐻6 → 𝐶9 𝐻12

The surface chemical reaction seems to follow the Eley – Rideal (ER) mechanism, in
which the adsorption of propylene is predominant over benzene, as represented by the
equation:
𝑘0 𝐾𝑝 𝑐𝑝
𝑟𝐴 =
1 + 𝐾𝑝 𝑐𝑝

In which k0 is the surface reaction constant, Kp the adsorption constant of propylene, and
cp its bulk propylene concentration. The mentioned reference supplies experimental
values for 𝑘1 = 𝑘0 𝑘𝑝 but not for 𝑘𝑝 . Because on the interval of interest 𝑘1 𝑐𝑝 ≪ 1 we
may assume a pseudo first – order reaction. (Dimian et al, 2008).

DETERMINATION OF THE WEIGHT OF CATALYST

𝑋𝐴
𝑑𝑋𝐴
𝑊 = 𝐹𝐴𝑂 ∫ (𝐿𝑒𝑣𝑒𝑛𝑠𝑝𝑖𝑒𝑙, 1999)
0 −𝑟𝐴
In terms of volume of pellets
𝑋𝐴
𝑑𝑋𝐴
𝑉𝑝 = 𝐹𝐴𝑂 ∫
0 −𝑟𝐴

𝑘0 𝐾𝑝 𝑐𝑝
𝑟𝐴 =
1 + 𝐾𝑝 𝑐𝑝
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Where
𝑘1 = 𝑘0 𝑘𝑝

And
−52564
𝑘1 = 6510 exp [ ] (𝐷𝑖𝑚𝑖𝑎𝑛 𝑒𝑡 𝑎𝑙, 2008)
𝑅𝑇
Therefore the final rate expression
− 𝑟𝐴 = 𝑘1 𝐶𝑝
𝐽
−52564
𝑘1 = 6510 exp [ 𝑚𝑜𝑙 ]
𝐽
(8.314 ) (257.5 + 273.15)𝐾
𝑚𝑜𝑙 𝐾
𝑚𝑜𝑙
𝑘1 = 43.5759
𝑚3 𝑠
For bulk concentration of Propylene Cp
𝐶𝑝𝑜 (1 − 𝑋𝐴 )
𝐶𝑝 =
(1 + 𝜀𝐴 𝑋𝐴 )
Where
𝑋𝐴 = 0.96
𝐶𝑝 = 𝑚𝑜𝑙 𝑜𝑓𝑝𝑟𝑜𝑝𝑦𝑙𝑒𝑛𝑒 𝑝𝑒𝑟 𝐿𝑖𝑡𝑒𝑟𝑠 𝑜𝑓 𝑠𝑜𝑙𝑢𝑡𝑖𝑜𝑛

Residence time according to Dimian et al, 2008, 5 mins.

𝑘𝑔 1 𝑑𝑎𝑦 1ℎ𝑟
𝑘𝑔 𝐶3 𝐻6 = (3974.174 )( )( ) (5 min) = 𝟏𝟑. 𝟕𝟗𝟗𝟐 𝒌𝒈 𝑪𝟑 𝑯𝟔
𝑑𝑎𝑦 24 ℎ𝑟 60𝑚𝑖𝑛

𝑘𝑔 𝐶3 𝐻6 = 𝟏𝟑. 𝟕𝟗𝟗𝟐 𝒌𝒈 𝑪𝟑 𝑯𝟔

1000 𝑔 1 𝑚𝑜𝑙
𝑚𝑜𝑙𝑒𝑠 𝐶3 𝐻6 = 13.7992 𝑘𝑔 𝐶3 𝐻6 ( )( ) = 𝟑𝟐𝟖. 𝟓𝟓𝟐𝟕 𝒎𝒐𝒍𝒆𝒔 𝑪𝟑 𝑯𝟔
1 𝑘𝑔 42 𝑔

𝑚𝑜𝑙𝑒𝑠 𝐶3 𝐻6 = 𝟑𝟐𝟖. 𝟓𝟓𝟐𝟕 𝒎𝒐𝒍𝒆𝒔 𝑪𝟑 𝑯𝟔

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Bulk Density at 257.5 oC

Bulk Density, kg/m3

Benzene 545.4056
Propylene 36.4059
Propane 38.5277
Total 225.1705371

𝑘𝑔 1 𝑑𝑎𝑦 1 ℎ𝑟
𝑇𝑜𝑡𝑎𝑙 𝑓𝑙𝑜𝑤 𝑜𝑓 𝐼𝑛𝑙𝑒𝑡 = (41096.3463 )( )( ) (5 𝑚𝑖𝑛)
𝑑𝑎𝑦 24 ℎ𝑟 60 𝑚𝑖𝑛

𝑇𝑜𝑡𝑎𝑙 𝑓𝑙𝑜𝑤 𝑜𝑓 𝐼𝑛𝑙𝑒𝑡 = 𝟏𝟒𝟐. 𝟔𝟗𝟓𝟔 𝒌𝒈

𝑚3
𝑉𝑖𝑛𝑙𝑒𝑡 = 142.69566 𝑘𝑔 ( )
225.17 𝑘𝑔

𝑉𝑖𝑛𝑙𝑒𝑡 = 𝟎. 𝟔𝟑𝟑𝟕 𝒎𝟑 = 𝟔𝟑𝟑. 𝟕𝟐 𝑳

Therefore
328.5527 𝑚𝑜𝑙𝑒𝑠 𝐶3 𝐻6
𝐶𝑝𝑜 = = 0.5184 𝑀
633.72 𝐿

𝐶𝑝𝑜 = 𝟎. 𝟓𝟏𝟖𝟒 𝑴

𝑉𝑋𝐴=1 − 𝑉𝑋𝐴=0
𝜀𝐴 =
𝑉𝑋𝐴=0
Chemical Reaction
C3 H6 + C6 𝐻6 → 𝐶9 𝐻12
C3H6 C6H6 C9H12 Inert (Propane) Total
At VXA=0 0.1652 0.8261 0 0.0087 1
At VXA=1 0.8261 0.0087 0.8348
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Therefore
0.8348 − 1
𝜀𝐴 = = −0.1652
1
𝜀𝐴 = −𝟎. 𝟏𝟔𝟓𝟐

From the previous equation:

𝑋𝐴
𝑑𝑋𝐴
𝑉𝑝 = 𝐹𝐴𝑂 ∫
0 −𝑟𝐴
𝑋𝐴
𝑑𝑋𝐴
𝑉𝑝 = 𝐶𝑝𝑜 𝑉𝑜 ∫
0
𝑘1 𝐶𝑝𝑜 (1 − 𝑋𝐴 )
(1 + 𝜀𝐴 𝑋𝐴 )
𝑉𝑜 𝑋𝐴 (1 + 𝜀𝐴 𝑋𝐴 )
𝑉𝑝 = ∫ 𝑑𝑋𝐴
𝑘1 0 (1 − 𝑋𝐴 )

Vo as mol/s
MW of Total Inlet entering
Total Molecular Weight g/mol
Benzene 0.826086957 78 64.43478
Propylene 0.165217391 42 6.93913
Propane 0.008695652 44 0.382609
TOTAL 1 71.75652

𝑘𝑔 1 𝑑𝑎𝑦 1 ℎ𝑟 1000 𝑔 1
𝑉𝑜 = (41096.3463 )( )( )( )( )
𝑑𝑎𝑦 24 ℎ𝑟 3600 𝑠 1 𝑘𝑔 71.75652𝑔
𝒎𝒐𝒍
𝑉𝑜 = 𝟔. 𝟐𝟖𝟕𝟎
𝒔
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Substituting the values from the above equation

𝑉𝑜 𝑋𝐴 (1 + 𝜀𝐴 𝑋𝐴 )
𝑉𝑝 = ∫ 𝑑𝑋𝐴
𝑘1 0 (1 − 𝑋𝐴 )
𝑚𝑜𝑙
6.2870 0.96
(1 + ((−0.1652)𝑋𝐴 ))
𝑉𝑝 = 𝑠 ∫ 𝑑𝑋𝐴
𝑚𝑜𝑙 0 (1 − 𝑋𝐴 )
43.5759 3
𝑚 𝑠
𝑉𝑝 = 𝟎. 𝟒𝟑𝟐𝟗 𝒎𝟑

Density of Zeolite is 1000 kg/m3 (Dimian et al, 2008)

Therefore
1000 𝑘𝑔
𝑊 = 0.4329 𝑚3 ( ) = 432.8850 𝑘𝑔
𝑚3

𝑊 = 𝟒𝟑𝟐. 𝟖𝟖𝟓𝟎 𝒌𝒈

Catalyst Profile
Catalyst Profile of Zeolite (Dimian et al, 2008)
Type of Catalyst Zeolite
Form of Catalyst Spherical
Bulk Density 1000 kg/m3
Particle Diameter 3 mm
Porosity/Void Fraction 0.5

Volume of Catalyst
𝐖
𝐕𝐩 =
𝛒𝐁
Where:
W = Weight of the catalyst
ρb = Bulk density of catalyst
Vp = Volume of catalyst
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432.8850 kg
𝐕𝐩 =
kg
1000 3
m

𝐕𝐩 = 𝐕𝐑 (𝐭𝐡𝐞𝐨) = 𝟎. 𝟒𝟑𝟐𝟗 𝐦𝟑

Residence Time

The residence time is 5 minutes (300 seconds) (Dimian et al, 2008)

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REACTOR SIZING

Basis (Hasani et al, 2014):

4. A typical contact tube length is in the range of 5 to 7 meters.
5. Internal diameter is generally from 20 to 30 mm.
6. The contact tubes usually have a wall thickness of around 1 to 3 mm.

Tube dimensions based on assumptions are:

 Length of one tube is 5 m.
 Tube inside diameter is 22 mm.
 Tube outside diameter is 26 mm.

Cross Sectional Area of Tube using dO:

𝛑
𝐀𝐜 = (𝐝 )𝟐
𝟒 𝐎
π
Ac = (0.026 m)2
4
𝐀 𝐜 = 𝟎. 𝟎𝟎𝟎𝟓𝟑𝟎𝟗 𝐦𝟐
Volume per tube, Vtube
𝐕𝐓𝐔𝐁𝐄 = 𝐀 𝐂 𝐋
VTUBE = 0.0005309 m2 × 5 m

𝐕𝐓𝐔𝐁𝐄 = 𝟎. 𝟎𝟎𝟐𝟔𝟓 𝐦𝟑

Number of tubes, NT
𝐕𝐓𝐡𝐞𝐨
𝐍𝐓(𝐓𝐡𝐞𝐨) =
𝐕𝐓𝐮𝐛𝐞
0.4329 m3
NT =
0.00265 m3
𝐍𝐓 = 𝟏𝟔𝟑. 𝟎𝟔𝟕𝟎 ≈ 𝟏𝟔𝟒 𝐭𝐮𝐛𝐞𝐬
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Cross Sectional Area of Tube using di:

𝛑
𝐀𝐜 = (𝐝𝐢 )𝟐
𝟒
π
Ac = (0.022 m)2
4
𝐀 𝐜 = 𝟎. 𝟎𝟎𝟎𝟑𝟖𝟎𝟏 𝐦𝟐

Total Gas Flow Area, Aflow

𝐀 𝐟𝐥𝐨𝐰 = 𝐍𝐓(𝐓𝐡𝐞𝐨) × 𝐀 𝐜

Aflow = 164 tubes × 0.0003801 m2

𝐀 𝐟𝐥𝐨𝐰 = 𝟎. 𝟎𝟔𝟐𝟑𝟒𝟐 𝐦𝟐

Reactor Volume
A volumetric Allowance of 20% is considered for coolant flow and clearances. (Couper,
2012)
𝐕𝐑 (𝐚𝐜𝐭𝐮𝐚𝐥) = 𝟏. 𝟐 × 𝐕𝐑 (𝐭𝐡𝐞𝐨)

VR (actual) = 1.2 × 0.4329 m3

𝐕𝐑 (𝐚𝐜𝐭𝐮𝐚𝐥) = 𝟎. 𝟓𝟏𝟗𝟓 𝐦𝟑

Recalculation of the number of tubes

𝐕𝐀𝐜𝐭𝐮𝐚𝐥
𝐍𝐓(𝐀𝐜𝐭𝐮𝐚𝐥) =
𝐕𝐓𝐮𝐛𝐞
0.5195 m3
No. of tubes =
0.00265 m3
𝐍𝐨. 𝐨𝐟 𝐭𝐮𝐛𝐞𝐬 = 𝟏𝟗𝟓. 𝟔𝟖𝟎𝟑 ≈ 𝟏𝟗𝟔 𝐭𝐮𝐛𝐞𝐬
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Bundle Diameter
Using Bundle diameter equation (Sinnot, 2005)

Bundle Diameter Constants (Coulson and Richardson’s Chemical Engineering Design

Vol. 6, 4th Ed, Table 12.4, p. 649)

Using triangular pitch:

 K1 = 0.319
 n1 = 2.142

Using Eq. 12.13, Bundle Diameter Equation (Coulson and Richardson’s Chemical
Engineering Design Vol. 6, 4th Ed, p. 648)

𝐍𝐓(𝐀𝐜𝐭𝐮𝐚𝐥) 𝟏/𝒏𝟏
𝐃𝐛 = 𝐝𝐨 ( )
𝐊𝟏

196 1/2.142
Db = 26 mm ( )
0.319
𝐃𝐛 = 𝟓𝟐𝟎. 𝟗𝟐𝟖𝟑 𝐦𝐦 ≅ 𝟎. 𝟓𝟐𝟎𝟗 𝐦
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Shell Diameter
Using Figure 12.10, Bundle-Shell Clearance for Pull Through Floating Head (Coulson
and Richardson’s Chemical Engineering Design Vol. 6, 4th Ed, p. 647)

BDC = 92 mm
Ds = BDC + Db
Ds = 92 mm + 520.9283mm

𝐃𝐬 = 𝟔𝟏𝟐. 𝟗𝟐𝟖𝟑 𝐦𝐦 = 𝟎. 𝟔𝟏𝟐𝟗 𝐦

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Check L/D Ratio: (Control Volume only)

L
2≤ ≤ 30
D
5m
2≤ ≤ 30
0.6129 m
2 ≤ 8.1579 ≤ 30
*Therefore L/D ratio is acceptable.

*Add 1 m height for Vapor entrance and exit

Total length = 5 m + 1 m

𝐓𝐨𝐭𝐚𝐥 𝐥𝐞𝐧𝐠𝐭𝐡 = 𝟔 𝐦
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DETERMINATION OF HEAT TRANSFER COEFFICIENT

SHELL SIDE COEFFICIENT

From Energy Balance:
𝐤𝐉
𝐐𝐓 = −𝟐𝟒𝟔. 𝟖𝟖
𝐬
𝐈𝐧𝐥𝐞𝐭 𝐓𝐞𝐦𝐩𝐞𝐫𝐚𝐭𝐮𝐫𝐞 = 𝟐𝟖 ℃
𝐎𝐮𝐭𝐥𝐞𝐭 𝐓𝐞𝐦𝐩𝐞𝐫𝐚𝐭𝐮𝐫𝐞 = 𝟔𝟓. 𝟓 ℃

Water Coolant Physical Properties

Density, kg/m3 988.5816
Viscosity, Pa-s 0.000639573
Thermal Conductivity, W/m-K 0.000639573
Specific Heat, kJ/kg-K 4.184265
(Green and Perry, 2008)

Calculating the mass of cooling medium required

Cooling medium: Water
Qtotal = ṁCp ∆T
Qtotal
ṁ=
Cp ∆T
𝑘𝐽
246.88 𝑠
ṁ=
𝑘𝐽
(4.184265 ) (338.65 − 301.15)𝐾
𝑘𝑔 𝐾

𝐤𝐠
ṁ𝐜𝐨𝐨𝐥𝐢𝐧𝐠 𝐰𝐚𝐭𝐞𝐫 = 𝟏. 𝟓𝟕𝟑𝟒
𝐬
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Taking Baffle Spacing of 0.2DS

Optimum baffle spacing will usually be between 0.2 to 0.5 of shell diameter (Coulson
and Richardson’s Chemical Engineering Design Vol. 6, 4th Ed.).

𝐥𝐁 = 𝟎. 𝟑 × 𝐃𝐬
lB = 0.2 × 621.9283mm
𝐥𝐁 = 𝟏𝟐𝟐. 𝟓𝟖𝟓𝟕 𝐦𝐦

Take Tube Pitch as 1.25Do

𝐩𝐭 = 𝟏. 𝟐𝟓 × 𝐃𝐎
pt = 1.25 × 26 mm
𝐩𝐭 = 𝟑𝟐. 𝟓𝟎 𝐦𝐦

Cross Flow Area

(𝐩𝐭 − 𝐝𝐎 )𝐃𝐒 𝐥𝐁
𝐀𝐬 =
𝐩𝐭
(32.50 mm − 26 mm)(621.9283 mm)(122.5857 mm)
As =
32.50 mm
𝐀 𝐬 = 𝟎. 𝟎𝟏𝟐𝟕𝟕 𝐦𝟐

Equilateral Pitch Arrangement

𝟏. 𝟏𝟎
𝐝𝐞 = (𝐩𝐭 𝟐 − 𝟎. 𝟗𝟏𝟕 𝐝𝐨 𝟐 )
𝐝𝐨
1.10
de = ((32.50 mm)2 − 0.917 (26 mm)2 )
26 mm
𝐝𝐞 = 𝟏𝟖. 𝟒𝟔𝟏𝟑 𝐦𝐦 = 𝟎. 𝟎𝟏𝟖𝟒𝟔 𝐦
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Shell Side Mass Velocity

𝐦̇
𝐆𝐒 =
𝐀𝐬
kg
1.5734 s
GS =
0.01277 m2
𝐤𝐠
𝐆𝐒 = 𝟏𝟐𝟑. 𝟏𝟗𝟑𝟓
𝐦𝟐 ∙ 𝐬
Reynold’s Number
𝐆𝐒 𝐝𝐞
𝐑𝐞 =
𝛍
kg
123.1935 × 0.01846 m
Re = m2 − s
kg
0.000639573 m − s

𝐑𝐞 = 𝟑𝟓𝟓𝟓. 𝟗𝟖𝟑𝟗
Prandtl’s Number
𝐂𝐏 𝛍
𝐏𝐑 =
𝐤
J kg
4.1843 × 0.000639573 m − s
kg − K
PR =
W
0.0006 m − ℃

𝐏𝐑 = 𝟒. 𝟏𝟖
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Heat Transfer Factor

For 25% Baffle Cut

Figure 9.6.3. Shell-Side Heat Transfer Factor (Coulson and Richardson’s

Chemical Engineering Design Vol. 6, 4th Ed, Figure 12.29, p. 672)
𝐣𝐡 = 𝟎. 𝟐𝟖

Nusselt Number
𝟏
𝐍𝐮𝐬 = 𝐣𝐡 𝐑 𝐞 𝐏𝐫𝟑
1
Nus = (0.28)(3555.9839)(4.18)3
𝐍𝐮𝐬 = 𝟏𝟔𝟎𝟒. 𝟒𝟒
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Heat Transfer Coefficient

Using Eq. 12.25, Nusselt Number – Heat Transfer Coefficient Equation (Coulson and
Richardson’s Chemical Engineering Design Vol. 6, 4th Ed, p. 674)

𝐍𝐮𝐬 𝐤 𝐬
𝐡𝐬 =
𝐝𝐞
W
(1604.44) (0.0006
hs = m − K)
0.01846 m
𝐖
𝐡𝐬 = 𝟓𝟓. 𝟓𝟖𝟒𝟑
𝐦𝟐 −𝐊

TUBE SIDE COEFFICIENT

Reactor Inlet and Outlet
Using DWSIM: Raoult’s Law Property Package
Properties of the Inlet and Outlet of the Reactor
Density (kg/m3) 57.6668 52.7032
Viscosity (Pa-s) 1.5199E-05 1.4995E-05
Specific Heat (kJ/kg-K) 1.9109 2.0666
Conductivity (W/m-K) 0.0350 0.0391

Average Density
𝛒𝐢𝐧 + 𝛒𝐨𝐮𝐭
𝛒𝐚𝐯𝐞 =
𝟐
57.6668 + 52.7032 kg
ρave = ( ) 3
2 m
𝐤𝐠
𝛒𝐚𝐯𝐞 = 𝟓𝟓. 𝟏𝟖𝟓
𝐦𝟑
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Average Viscosity
μin + μout
μave =
2
1.5199E − 05 − 1.4995E − 05
μave = ( ) Pa ∙ s
2
𝛍𝐚𝐯𝐞 = 𝟏. 𝟓𝟎𝟗𝟕𝐄 − 𝟎𝟓 𝐏𝐚 ∙ 𝐬

Total Flowrate of Gas

𝐤𝐠
𝐓𝐨𝐭𝐚𝐥 𝐅𝐥𝐨𝐰𝐫𝐚𝐭𝐞 𝐨𝐟 𝐆𝐚𝐬 = 𝟎. 𝟒𝟕𝟓𝟕
𝐬

Tube Side Mass Velocity

𝐦̇
𝐆𝐭 =
𝐀𝐜
0.4757
𝐺=
0.0620

𝒌𝒈
𝑮 = 𝟕. 𝟔𝟕𝟑𝟒
𝒎𝟐 𝒔

Linear Velocity
𝐆𝐬
𝐮𝐓 =
𝛒𝐚𝐯𝐞
kg
7.6734
2∙s
uT = m
kg
55.185 3
m
𝐦
𝐮𝐓 = 𝟎. 𝟏𝟑𝟗𝟎
𝐬
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Reynold’s Number
𝐆𝐭 𝐝𝐢
𝐑𝐞 =
𝛍
kg
7.6734 × 0.022 m
Re = m2 − s
kg
1.50967E − 05 m − s

𝐑𝐞 = 𝟏𝟏𝟏𝟖𝟐. 𝟐𝟒𝟑𝟕

Prandtl’s Number
𝐂𝐏 𝛍
𝐏𝐑 =
𝐤
J kg
1.98873 × 1.50967E − 055 m − s
kg − K
PR =
W
0.0349585 m − K

𝐏𝐑 = 𝟎. 𝟖𝟏𝟎𝟕
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For 25% Baffle Cut

Figure 9.6.3. Tube-Side Heat Transfer Factor (Coulson and Richardson’s

Chemical Engineering Design Vol. 6, 4th Ed, Figure 12.29, p. 672)

𝐣𝐡 = 𝟎. 𝟎𝟎𝟓
Nusselt Number
𝟏
𝐍𝐮𝐬 = 𝐣𝐡 𝐑 𝐞 𝐏𝐫𝟑
1
Nus = (0.005)(11182.2437)(0.81072)3
𝐍𝐮𝐬 = 𝟓𝟐. 𝟏𝟑𝟒𝟐
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Heat Transfer Coefficient

Using Eq. 12.25, Nusselt Number – Heat Transfer Coefficient Equation (Coulson and
Richardson’s Chemical Engineering Design Vol. 6, 4th Ed, p. 674)

𝐍𝐮 𝐤 𝐭
𝐡𝐭 =
𝐝𝐢
W
(52.1342) (0.0370
ht = m − K)
0.022 m
𝐖
𝐡𝐭 = 𝟖𝟕. 𝟕𝟓𝟖𝟎
𝐦𝟐 −𝐊

The controlling heat transfer coefficient is the shell side, since the heat transfer
coefficient of shell side is lower than the tube side.

Calculating overall heat transfer coefficient based on R.K. Sinnott. Coulson’s and
Richardson’s Chemical Engineering Design Vol. 6.

𝒅
𝟏 𝟏 𝟏 𝒅𝒐 𝒍𝒏 ( 𝒐 ) 𝒅𝒐 𝒅𝒐
𝒅𝒊
= + + +( )+( )
𝑼𝒐 𝒉𝒐 𝒉𝒐𝒅 𝟐𝒌𝒘 𝒅𝒊 𝒉𝒊𝒅 𝒅𝒊 𝒉𝒊

Given the fouling factor coefficient of 5000 W/m2 K for organic vapor and thermal
conductivity of tube material carbon steel 45 W/m K (R.K. Sinnott. Coulson’s and
Richardson’s Chemical Engineering Design Vol. 6)
 Technological Institute of the Philippines

0.026
𝟏 1 1 0.026𝑙𝑛 (0.022) 0.026
= + + +( )
𝑼𝒐 55.5843 𝑊 5000 2
𝑊 𝑊
2 (45 2 ) (0.022)5000 2
𝑊
𝑚2 𝐾 𝑚 𝐾 𝑚 𝐾 𝑚 𝐾

0.026
+( )
𝑊
(0.022)87.7580 2
𝑚 𝐾

𝐖
𝑼𝒐 = 𝟑𝟏. 𝟑𝟎𝟔𝟔
𝐦𝟐−𝐊

From Energy Balance:

𝐐𝐓 = −𝟐𝟒𝟔. 𝟖𝟖 𝐤𝐖

TUBE SIDE
Inlet Temperature 443.15 K (170°C)
Outlet Temperature 530.65 K (257.5°C)
SHELL SIDE
Inlet Temperature 301.15 K (28°C)
Outlet Temperature 338.65 K (65.5°C)

Type of Operation: Counter-current

∆T1 = (170 − 28)℃ = 142℃
∆T2 = (257.5 − 65.5)℃ = 192℃
∆𝐓𝟏 − ∆𝐓𝟐
∆𝐓𝐋𝐌 =
∆𝐓
𝐥𝐧 (∆𝐓𝟏 )
𝟐

(142 − 192)℃
∆TLM =
142
ln (192)

∆𝐓𝐋𝐌 = 𝟏𝟓𝟖. 𝟖𝟗 ℃
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Heat Transfer Area

𝐐𝐓
𝐀=
𝐔∆𝐓𝐋𝐌
1000 W
246.88 kW ×
A= 1 kW
W 1K
31.3066 × 158.89 ℃ × 1 ℃
m2 −K
𝐀 = 𝟒𝟗. 𝟔𝟑𝟏𝟎 𝐦𝟐

DETERMINATION OF THE NUMBER OF BAFFLES

Tube Sheet Thickness

𝐅 𝐆𝐏 𝐏
𝐭 𝐭𝐬 = √
𝟑 𝐤𝐟

Where:
F = 1.0 (Floating Type Tube Sheet)
P = Operating Pressure = 3.54 N/mm2
GP = DS

Design Stress (f) = 93.5 N/mm2 (Carbon Steel)

𝟎. 𝟗𝟎𝟕
𝐤=𝟏−
𝐏 𝟐
( 𝐭)
𝐝𝐨
0.907
k= 1−
0.0325 2
( 0.026 )

𝐤 = 𝟎. 𝟒𝟏𝟗𝟓𝟐
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Calculating the Tube Sheet Thickness

N
1.0 × 612.9283 mm 3.54 2
t ts = √ mm
3 N
0.41952 × 93.5
mm2

𝐭 𝐭𝐬 = 𝟔𝟏. 𝟑𝟕𝟕𝟑 𝐦𝐦 = 𝟎. 𝟎𝟔𝟏𝟒 𝐦

NOZZLE SIZING

As per Engineering Standard for Process Design (Standard Code IPS-PR-880)

For Inlet fluids (Liquid or Gas) ρv2 = 1000

For Outlet Gas ρv2 = 3600
For Outlet Liquids v = 1 m/s

Inlet Feed Nozzle

Density 57.6668
ρv2 1000

kg
1000
v=√ m − s2
kg
57.6668 3
m
𝐦
𝐯 = 𝟒. 𝟏𝟔𝟒𝟑
𝐬

Nozzle inlet diameter, ɗi

𝐦̇
𝐀=
𝛒𝐯

𝑘𝑔
0.4757 𝑠
A=
kg 𝑚
(57.6668 3 ) (4.1643 𝑠 )
m

𝐀 = 𝟎. 𝟎𝟎𝟏𝟗𝟖𝟎 𝒎𝟐
 Technological Institute of the Philippines

4(0.001980) 𝑚2
Nozzle inlet diameter = √
𝜋

ɗ𝐢 = 𝟎. 𝟎𝟓𝟎𝟐𝟏𝟗 𝐦 ≈ 𝟓𝟎. 𝟎𝟐𝟏𝟗 𝐦𝐦

Outlet Feed Nozzle

Density, kg/m3 52.7032

ρv2 3600

kg
3600
v=√ m − s2
kg
52.7032 3
m
𝐦
𝐯 = 𝟖. 𝟐𝟔𝟒𝟖
𝐬

Nozzle outlet diameter, ɗo

𝐦̇
𝐀=
𝛒𝐯

𝑘𝑔
0.4757 𝑠
A=
kg 𝑚
(52.7032 3 ) (8.2648 𝑠 )
m

𝐀 = 𝟎. 𝟎𝟎𝟏𝟎𝟗𝟏 𝒎𝟐

4(0.001091) 𝑚2
Nozzle inlet diameter = √
𝜋

ɗ𝐢 = 𝟎. 𝟎𝟑𝟕𝟐𝟖𝟕𝟔 𝐦 ≈ 𝟑𝟕. 𝟐𝟖𝟕𝟔 𝐦𝐦

 Technological Institute of the Philippines

Spacing Available for Baffles

Lb = L − 2t ts − Dn,in − Dn,out

Lb = 5 m − 2(0.061377m) − 0.050219 m − 0.037288 m

𝐋𝐛 = 𝟓. 𝟕𝟖𝟗𝟕𝐦

Number of Baffles

Lb
= Nb − 1
lb

5.7897
= Nb − 1
0.1226

𝐍𝐛 = 𝟒𝟖. 𝟐𝟑 ≈ 𝟒𝟗 𝐛𝐚𝐟𝐟𝐥𝐞𝐬

PRESSURE DROP TUBE SIDE

For the calculation of pressure drop for packed tubes, Ergun Equation is used. (Eq. 2.3
Fixed Bed Reactor by Gerhart, E.)
Ergun Equation
∆𝐏𝐭
= 𝐟𝟏 𝐯𝐆 + 𝐟𝟐 𝐯𝐆 𝟐
𝐋

(𝟏 − ∅)𝟐
𝐟𝟏 = 𝟏𝟓𝟎𝛍 [ 𝟑 ]
∅ 𝐃𝐩 𝟐

−5
kg (1 − 0.5)2
f1 = 150 (1.50967 × 10 )[ ]
m − s (0.5)3 (0.003 m)2

𝐤𝐠
𝐟𝟏 = 𝟓𝟎𝟑. 𝟐𝟐𝟑𝟑
𝐦𝟑 − 𝐬
 Technological Institute of the Philippines

kg (1 − ∅)
f2 = 1.75 ( 3 ) [ 3 ]
m ∅ Dp

kg (1 − 0.5)
f2 = 1.75 (55.185 ) [ ]
m3 (0.5)3 (0.003 m)

𝐤𝐠
𝐟𝟐 = 𝟏𝟐𝟖𝟕𝟔𝟓
𝐦𝟒

Velocity inside the tubes

𝐅𝐓𝐨
𝐯𝐆 =
𝐕𝐩
𝛒𝐚𝐯𝐞 (𝐃 )
𝐬

kg
0.6337 s
vG =
kg 0.4329
55.185 3 (0.6129 m)
m
𝐦
𝐯𝐆 = 𝟎. 𝟎𝟏𝟔𝟐𝟓𝟗𝟖
𝐬

Pressure Drop
∆Pt kg m kg m 2
= (503.2233 3 ) (0.0162598 ) + (128765 3 ) (0.01662598 )
L m −s s m s
∆Pt kg
= 42.2254 2
L m − s2
kg
∆Pt = 5 m × 42.2254
m2 − s 2
14.7 psi
∆Pt = 211.127 Pa ×
101325 Pa
∆𝐏𝐭 = 𝟎. 𝟎𝟑𝟎𝟔 𝐩𝐬𝐢

*For Pressure Drop across tubes: Maximum allowable pressure drop ∆Pt < 10psi.
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PRESSURE DROP SHELL SIDE

𝐆𝐜𝐨𝐨𝐥𝐚𝐧𝐭
𝐯=
𝛒𝐜𝐨𝐨𝐥𝐚𝐧𝐭
kg
123.1935
v= m2
−s
kg
988.5816 3
m
𝐦
𝐯 = 𝟎. 𝟏𝟐𝟒𝟔
𝐬
Pressure Drop
For a 25% Baffle cut

Figure 9.6.3. Shell-Side Heat Friction Factor (Coulson and Richardson’s

Chemical Engineering Design Vol. 6, 4th Ed, Figure 12.30, p. 673)

Shell side friction factor: 𝐣𝐟 = 0.095

(Eq. 12.26, Chemical Engineering Design, 4th ed., by Sinnott, R.K)
𝐃𝐬 𝐋 𝛒𝐯 𝟐 𝛍 −𝟎.𝟏𝟒
∆𝐏𝐬 = 𝟖𝐣𝐟 ( ) ( ) ( )( )
𝐝𝐞 𝐥𝐁 𝟐 𝛍𝐰
Neglecting viscosity correction factor:
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kg m 2
(988.5816 ) (0.1246
0.6219 m 5m m3 s)
∆Ps = 8(0.095) ( )( )( )
0.01846 m 5.7897 mm 2

14.7 psi
∆Ps = 7899.9549 Pa ×
101325 Pa
∆𝐏𝐬 = 𝟏. 𝟏𝟒𝟔𝟏 𝐩𝐬𝐢

*For Pressure Drop across shell side: Maximum allowable pressure drop ∆Pt <
10psi.
SHELL THICKNESS

𝐏𝐃 𝐃𝐢
𝐭 𝐬𝐩 = +𝑪
𝟐𝐉𝐟 − 𝐏𝐃
Where:
P = design pressure, N/mm2
D = inside diameter, mm
J = Joint Efficiency
f = design stress, N/mm2
C = corrosion allowance, mm

Reference:
 Joint Efficiency of a Double-welded butt : @ 100% degree of radiography = 1.0
*Using Table 13-3 (Sinnot, R.K. “Chemical Engineering Design,” 4th Ed., p. 813.)

J = joint efficiency
𝐉 = 1.0

Reference:
 Design Stress of Carbon Steel: @ 257.5 °C (530.65𝐾) = 93.5 N/mm2
*Using Table 13-2 (Sinnot, R.K. “Chemical Engineering Design,” 4th Ed, p. 812.)

f = Design stress
𝐍
𝐟 = 𝟗𝟑. 𝟓
𝐦𝐦𝟐
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For Corrosion Allowance

Corrosion allowance, C = 2 mm (Sinnot, Chemical Engineering Design, 2005)

𝐂 = 𝟐 𝐦𝐦

Substituting the values

N
(3.54 ) ( 621.9283 mm)
t sp = mm2 + 2 mm
N N
2(1) (93.5 ) − (3.54 )
mm2 mm2

𝐭 𝐬𝐩 = 𝟏𝟑. 𝟖𝟐𝟔𝟗 𝐦𝐦 ≈ 𝟎. 𝟎𝟏𝟑𝟖𝟐𝟔𝟗 𝐦

HEAD AND BOTTOM THICKNESS

For Torispherical Head and Bottom

𝐏𝐃 𝐑 𝐜 𝐂𝐬
𝐭𝐡 = +𝐂
𝟐𝐉𝐟 + 𝐏𝐃 (𝐂𝐬 − 𝟎. 𝟐)

Where
PD = design pressure, N/mm2
Rc = crown radius, m
Cs = stress concentration factor for torispherical heads
J = Joint Efficiency
f = design stress, N/mm2
C = corrosion allowance, mm
Crown Radius

R c = Ds

𝐑 𝐜 = 𝟎. 𝟔𝟏𝟐𝟗𝟐𝟖 𝐦

Knuckle Radius
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R k = 0.06Ds

R k = 0.06(0.612928 m)

𝐑 𝐤 = 𝟎. 𝟎𝟑𝟔𝟕𝟖 𝐦

Stress Concentration, Cs

1 Rc
Cs = (3 + √ )
4 Rk

1 0.612928 m
Cs = (3 + √ )
4 0.03678 m

𝐂𝐬 = 𝟏. 𝟕𝟕𝟎𝟔

Computing for Head and Bottom Thickness,

N
(3.54 ) (621.928)mm (1.7706)
th = mm2 + 2 mm
N N
2(1) (93.5 ) + (3.54 ) (1.7706 − 0.2)
mm2 mm2

𝐭 𝐡 = 𝟐. 𝟎𝟏𝟗𝟗𝟓 𝐦𝐦 ≈ 𝟎. 𝟎𝟎𝟐𝟎𝟐𝟎 𝐦

Since tsp > th, tsp will be the wall thickness for the vessel and heads for
uniformity.

∴ 𝐭 = 𝟏𝟑. 𝟖𝟐𝟔𝟗 𝐦𝐦

Total Tank Diameter/Outside Tank Diameter, Do

Do = DT = Di + 2t

DT = 0.612928 m + 2(0.013826 m)

𝐃𝐓 = 𝟎. 𝟔𝟒𝟎𝟔 𝐦
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Height of Torispherical Head, Hhead

The height of the head (Berg Group, 2016)

Where: R = crown radius (mm)

Da = tank diameter (mm) = Dt
h1 = straight flange height (mm)
h2 = dished height (mm)
h12 = head height (mm)
s = wall thickness (mm) = t

𝐇𝐇𝐞𝐚𝐝 = 𝟑. 𝟓𝐭 + 𝟎. 𝟏𝟗𝟑𝟓𝐃𝐓 − 𝟎. 𝟒𝟓𝟓(𝐭)

HHead = 3.5(13.8269 mm) + 0.1935(618.9682)mm

− 0.455(13.8269 mm)

𝐇𝐇𝐞𝐚𝐝 = 𝟏𝟏𝟖. 𝟔𝟒𝟑𝟕 𝐦𝐦 ≈ 𝟎. 𝟏𝟏𝟖𝟔 𝐦

Total Tank Height, Htank

Htank = Hcylinder + HHead

Htank = 6 m + 2(0.0138)m
𝐇𝐭𝐚𝐧𝐤 = 𝟔. 𝟎𝟐𝟕𝟕 𝐦
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NOZZLE SIZING

As per Engineering Standard for Process Design (Standard Code IPS-PR-880)

For Inlet fluids (Liquid or Gas) ρv2 = 1000

For Outlet Gas ρv2 = 3600
For Outlet Liquids v = 1 m/s

Inlet Feed Nozzle

Density 988.5816
ρv2 1000

kg
1000
v=√ m − s2
kg
988.5816 3
m
𝐦
𝐯 = 𝟏. 𝟎𝟎𝟓𝟖
𝐬
Nozzle inlet diameter, ɗi
𝐦̇
𝐀=
𝛒𝐯

𝑘𝑔
1.5734 𝑠
A=
kg 𝑚
(988.5816 3 ) (1.0058 𝑠 )
m

𝐀 = 𝟎. 𝟎𝟎𝟏𝟓𝟖 𝒎𝟐

4(0.00158) 𝑚2
Nozzle inlet diameter = √
𝜋

ɗ𝐢 = 𝟎. 𝟎𝟒𝟒𝟖𝟖𝟕 𝐦 ≈ 𝟒𝟒. 𝟖𝟗 𝐦𝐦
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Outlet Feed Nozzle

Density 988.5816
ρv2 1000

kg
1000
v=√ m − s2
kg
988.5816 3
m
𝐦
𝐯 = 𝟏. 𝟎𝟎𝟓𝟖
𝐬
Nozzle inlet diameter, ɗi
𝐦̇
𝐀=
𝛒𝐯

𝑘𝑔
1.5734 𝑠
A=
kg 𝑚
(988.5816 3 ) (1.0058 𝑠 )
m

𝐀 = 𝟎. 𝟎𝟎𝟏𝟓𝟖 𝒎𝟐

4(0.00158) 𝑚2
Nozzle inlet diameter = √
𝜋

ɗ𝐢 = 𝟎. 𝟎𝟒𝟒𝟖𝟖𝟕 𝐦 ≈ 𝟒𝟒. 𝟖𝟗 𝐦𝐦