1.

1 Main Process Sizing

1.1.3 Separator
Separator is a device that functions to separate two fractions by using the
flash separation principle under conditions of constant pressure and temperature.
The separator in this pyrolysis plant is used to separate between gas and oil product.
The specification of separator is shown in table below.

Table 1.1 Separator Specification

Equipment Specifications
Equipment Name Separator
Equipment Code S-101
Function To separate between gas and oil
product
Type Vertical cylindrical tank
Material Low alloy steel SA-204 Grade A
Operating Condition
Pressure (kPa) 200
Temperature (℃) 464
Construction Data
Max. allowable stress, f (psi) 16,250
Efficiency (%) 80
A min (m2) 0.122
D min (m) 1.236
D v (m) 1.388
HLLL (m) 0.381
HH (m) 0.922
HS (m) 0.369
HL IN (m) 0.383
HD (m) 0.649
HME (m) 0.457
HT (m) 3.161
Total Vessel Height (m) 3.315
H/D 3
Shell thickness (in) 3/16
Head & Bottom thickness (in) 3/16
Head Height (in) 3.038
Type of Head & Bottom Flanged and Dished Head
(Torispherical)
 Figure 1.1 Mechanical Drawing of Separator

1.2 Supporting Process Sizing

1.2.4 Furnace
A furnace is a device used for high-temperature heating. The heat generated
by the furnace is flowed directly to the reactor R-101 reactor before the pyrolysis
process takes place. The specification of separator is shown in table below.

Table 1.2 Furnace Specification

Equipment Specifications
Equipment Name Furnace
Equipment Code H-101
Function To heat the pyrolysis reactor at
an initial stage until it reaches a
temperature of 300℃
Type Rectangular box type furnace
Inner Case Material SS-304
Furnace Wall Material Fire Brick
Operating Condition
Q Total (Btu/hr) 71 x 106
Entering Fluid Temperature (℉) 357
Fluid gas Temperature out (℉) 1439
Mass Flow Rate (lb/h) 195,394
Construction Data
Furnace Efficiency (%) 75%
Length (ft) 38.5
Height (ft) 39
Width (ft) 19
Number of tube 79
Tube Specification 6-5/8 in. OD Schedule 80 pipe

Figure 1.2 Mechanical Drawing of Furnace

1.3 Utility Sizing
1.3.2 Nitrogen Generator Sizing
In this plant, nitrogen is used as carrier gas in fluidized bed reactor. Nitrogen
will be utilized in Pressure Swing Adsorber plant.
1.3.2.1 Pressure Swing Adsorption Unit
Table 1.3 Adsorber Specification

Equipment Specifications
Equipment Name Pressure Swing Adsorption Unit
Equipment Code D-201
Function To separate nitrogen from
ambient air
Type Vertical vessel
Material Carbon steel, SA-283 Grade C
Operating Condition
Temperature in (℃) 60
Pressure (bar) 20
Flow Rate (kg/day) 6373.301
Safety Factor 25%
Construction Data
Desiccant Carbon Molecular Sieve
Type Head Elliptical (Ellipsoidal head)
Diameter of Column (m) 1.245
Shell Thickness (in) 1
1
8
Head Thickness (in) 3
16
Height of Head (m) 0.311
Height of Column (m) 2.490
 Figure 1.3 Mechanical Drawing of PSA Unit

Appendix C. Separator
Separator is a device that functions to separate two fractions by using the
flash separation principle under conditions of constant pressure and temperature.
The separator in this pyrolysis plant is used to separate between gas and oil product.
The specification of separator is shown in table below.
Based on vessel function, the type used is vertical vessel, because it is
applied for the separation of fluid-gas fluid types.

Figure C.1 Algorithm to Choose Storage Tank Type Horizontal/Vertical

 Evans (1980) proposed a stepwise design procedure for sizing dimension of
vertical vapor-liquid separators. The steps are outlined as follows:
1. Vapor-liquid separation factor
The first step is to calculate a vapor-liquid separation factor, the equation is
wl ρ 0.5
= ( ρv ) (C-1)
wv l
where, ρl = density of liquid (kg/m3)
ρv = density of vapor (kg/m3)
wl = liquid flow rate (kg/s)
wv = vapor flow rate (kg/s)
These variables are obtained from the Aspen simulation results.
2. Maximum vapor velocity
ρl −ρv 0.5
(uv )max = K v ( ) (C-2)
ρv
With, K v = 0.35 with mist eliminator
K v = 0.1 without mesh mist eliminator
3. Minimum vessel-cross sectional area
Qv
Amin = (u (C-3)
v )max
Where Qv , (m3/s) Vapor volumetric flow rate can be directly found from the
Aspen simulation results.
4. Vessel Diameter
Dmin = (4 . Amin . π) 0.5 (C-4)
Here to find the final vessel diameter, it is needed to decide whether to put
a mist eliminator or not. The gas that rises to the top of the vessel actually still
contains a little liquid so removing the liquid requires mist eliminator. So, it was
decided to put a mist eliminator. If a mist eliminator is there, 3 to 6 inches must be
added to the Dmin value. If 6 inches (0.1524 m) were added
DV = Dmin + 0.1524 m (C-5)
5. Liquid depth required
Variable of Ql , (m3/s) liquid volumetric flow rate can be directly found from
the Aspen simulation results.
Calculate volume held in vessel VH in m3 with the equation below
VH = TH . Ql (C-6)
Select hold up time TH , min from Table C.1
 Table C.1 Liquid hold up and surge times

Holdup time Surge time

Service (NLL-LLL), min (NLL-HLL), min
-Unit feed drum 10 5
-Separator:
Feed to column 5 3
Feed to other drum or
tankage
With pump or through 5 2
exchanger
Whitout pump 2 1
Feed to fired heater 10 3
-refinery product
accumulator: 3 2
Reflux only +3 +3
Reflux and product
-column bottoms:
feed to another column 5 2
feed to other drum or
tankage 5 2
with pump or through 2 1
exchanger 5-8 2-4
without pump
feed to fired boiler
-compressor suction/ interstage scrubber:
3min between HLL(HLA) and HLSD
1min from bottom tangent line to HLA
-flare knockout drum :
30 min to HLL
-fuel gas knockout drum:
1 ft. in the incoming fuel gas line
Between NLL and HLSD

For separator equipment with system feed to other drum or tankage, with pump or
through exchanger, Hold up time (TH ) selected is 5 min = 300 s. This gives the
height from low liquid level to normal liquid level (liquid depth required)
Volume held up VH
H𝐻 = Vessel cross sectional area = π (C-7)
D 2
4 v
6. Surge Height
From Table C.1 for separator equipment with system feed to other drum or tankage,
with pump or through exchanger, surge time (TS ) selected is 2 min = 120 s.
Calculate surge volume VS in m3 with the equation below
VS = TS . Ql (C-8)
This gives the height from normal liquid level to high liquid level (or high-level
alarm)
Surge Volume VS
H𝑆 = Vessel cross sectional area = π (C-9)
D 2
4 v
7. Low Liquid Level Height
Obtain low liquid level height HLLL from Table C.2.

Table C.2 Low liquid level height

Vertical
Vessel Horizontal
LLL
diameter LLL
< 300psia > 300psia
≤ 4 ft 15 in 6 in 9 in
6 ft 15 in 6 in 10 in
8 ft 15 in 6 in 11 in
10 ft 6 in 6 in 12 in
12 ft 6 in 6 in 13 in
16 ft 6 in 6 in 15 in

8. Height from height liquid level to centerline of inlet nozzle

For this, it must be decided whether put an inlet diverter or not. The feed
stream to the separator is typically a high velocity turbulent mixture of gas and
liquid. Because of this high velocity, the fluids enter with a high momentum and
from an inlet diverter, the direction of the flow can be abruptly changed by
absorbing the momentum of the liquid. That allows the liquid and gas to separate.
The inlet diverter also referred as the primary separation section. So, considering
that an inlet diverter is to be used
HL IN = 12 + dN (𝑖𝑛𝑐ℎ) (C-10)
dN is the nozzle diameter, inlet or outlet, vapor or liquid as specified. dN is
calculated as
4 *Q m
dN ≥ ( )1 / 2 , ft. (C-11)
 * 60 /  m
Qm = Ql + Qv , ft 3 /sec (C-12)
ρm = (ρl . λ ) + ρv ( λ − 1) lb/ft 3 (C-13)
Ql
λ = (Ql + Qv )
(C-14)
The disengagement height from the centerline of the inlet nozzle to the bottom of
the mist eliminator pad.
With a mist eliminator
1
HD = 24 + 2 dN (𝑖𝑛𝑐ℎ) (C-15)
Since there is a mist eliminator; for the mist eliminator pad = 6 inch = 0.1524m.
From top of the mist eliminator to the top tangent line of vessel= 1ft = 0.3048m
HME = 0.1524 + 0.3048 = 0.4572 m (C-16)
Total Height
HT = HLLL + HH + HS + HL IN + HD + HME (C-17)
Brownell & Young (1959) proposed a stepwise design procedure for sizing
vessel thickness of vertical vapor-liquid separators. The steps are outlined as
follows:
1. Determine Material
Determination of vessel material is based on temperature conditions in
vessels. Low alloy steel material SA-204 Grade A was chosen because it has a high
temperature range which is in the range of 650-1000℉, operating temperature of
464℃ (867.2℉) so that it is still within the range of material criteria.
2. Shell Volume
To calculate the volume of shell using the equation
π
Vshell = 4 D2 H (C-18)

3. Shell Thickness
To calculate the thickness of a shell using the equation
P . ri
ts = f . +C (C-19)
E−0.6 P

Where,
ts : minimum required thickness of the shell (in)
P : working pressure (psia)
f : maximum allowable stress (psia)
From Table 13.1 for low alloy steel 204 Grade A, f = 16,250 psia
(Brownell & Young, 1959)
E : welded-joint efficiency
From Table 13.2 for double-welded but joint, E = 80% (Brownell &
Young, 1959)
ri : inside radius of the shell (in)
1
C : corrosion factor (8 in)

From the calculation, the thickness of the shell is obtained t s = 0.186 in, so that
3
thickness is used 16 in according to the nominal size thickness standard.

4. Head & Bottom Design

The shape of the head & bottom used is torispherical flanged and dished
head. This type of head is to accommodate the possibility of rising temperatures in
the tank so that it causes a rise in pressure in the tank, due to the increase in ambient
temperature being more than 1 atm. For torispherical flanged and dished heads, the
allowable pressure ranges from 15 psig (1,0207 atm) to 200 psig (13,6092 atm).

Figure C.2 Dimensional relationships for flanged and dished heads (Torispherical)
(Source: Brownell & Young, 1959)
5. Minimum head thickness
Determine the stress-intensification factor, w for torispherical dished head using the
equation
1 r
w= x (3 + √rc ) (C-20)
4 1

Where,
w : stress-intensification factor
rc : Crown radius (in)
r1 : Knuckle radius (in)
Determine the thickness of the head by using the equation
P . rc . w
th = 2 . +C (C-21)
f . E−0.2 P
From the calculation, the thickness of the head is obtained t h = 0.093 in, so that
3
thickness is used 16 in according to the nominal size thickness standard. From this

data, using Table 5.7 (Brownell & Young, 1959) obtained inside-corner radius, icr
3 ¼ in and from Table 5.8 (Brownell & Young, 1959) obtained standard straight
flange, sf = 0.5 in.
6. Depth of Dish
ID
b = rc − √(r − icr)2 − ( 2 − icr)2 (C-22)

7. Height of Head
OA = t h + b + sf (C-23)
Then, the total height of vertical separator is
OA = Htotal = H + (2 . OA) (C-24)

Table C.3 Separator Specification

Variable Name Separator Unit
Specification
W Liquid 0.163 kg/s
W Vapor 1.45 kg/s
ρ Liquid 3.497 kg/m3
ρ Vapor 0.035 kg/m3
Kv 0.350 constant
v vapor max 3.441 m/s
A min 0.122 m2
D min 1.236 m
Dv 1.388 m
HLLL 0.381 m
HH 0.922 m
HS 0.369 m
HL IN 0.383 m
HD 0.649 m
HME 0.457 m
HT 3.161 m
H/D 3.000 dimensionless
P 29.0075 psia
ts 3/16 in
th 3/16 in
b 2.351 in
 OA 3.038 in
HTotal 3.315 m

Appendix L. Furnace
An industrial furnace or direct fired heater, is an equipment used to provide
heat for a process or can serve as reactor which provides heats of reaction. Furnace
designs vary as to its function, heating duty, type of fuel and method of introducing
combustion air. However, most process furnaces have some common features.
Fuel flows into the burner and is burnt with air provided from an air blower.
There can be more than one burner in a particular furnace which can be arranged in
cells which heat a particular set of tubes. Burners can also be floor mounted, wall
mounted or roof mounted depending on design. The flames heat up the tubes, which
in turn heat the fluid inside in the first part of the furnace known as the radiant
section or firebox. In this chamber where combustion takes place, the heat is
transferred mainly by radiation to tubes around the fire in the chamber.
The option for material of furnace is carbon steel, stainless steel, or titanium.
Carbon steel is used for low temperature. Stainless steel is used for elevated
temperature. Titanium is used for high temperature. The process take place until
>1000℃. It is considered as elevated temperature stainless steel material will be
choosen. To be specific, the kind of stainless steel material used is SS-310 which
are has good chemical resistance and heat resistance. It also has affordable price.
The outer walls are constructed using firebricks that can withstand temperatures up
to 1500℃. From Figure L.1, selection of Firebrick H-W Karundal XL because it
has low thermal conductivity so it fits with our insulation system. The next
consideration because it has affordable price that actually will be counted in
economic analysis later.
 Figure L.1 Material Properties of Outer Wall
(Source: GPSA, 2004)

Walas, et al. (2012) proposed a stepwise design procedure for sizing

furnace. The steps are outlined as follows:
1. Choose a tube diameter corresponding to a cold oil velocity of 5-6 ft/sec. tube
diameter based on data Characteristics of Tubing (From Standards of the Tubular
Exchanger Manufacturers Association, 8th Ed., 1999).
2. Find the ratio of center-to-center spacing to the outside tube diameter. Usually
this is determined by the dimensions of available return bends, either short or
long radius. Short radius return bends have 12 in. center-to-center.
3. Specify the desired thermal efficiency. This number may need modification after
the corresponding numbers of tubes have been found. Basic specifications on the
process such as overall thermal efficiency, η = 75%.
4. Specify the excess combustion air. From basic specification on the process,
fraction excess air = 0.25.
5. Calculate the total heat absorbed, given the enthalpies of the inlet and outlet
process streams and the heat of reaction.
 Qtotal = ṁ (∆H) (L-1)
6. Calculate the corresponding heat release.
Qtotal
Qn = (L-2)
η

7. Assume that 75% of the heat absorption occurs in the radiant zone. Then,
equation for radiant heat absorption is
Qn
QR = (L-3)
0.75

8. Specify the average radiant heat flux, which may be in the range of 8000–20,000
Btu/(hr)(sqft). This value may need modification after the calculation of Step 28
has been made.
Q Btu
(A) rad = 10,000 (Average) (L-4)
hr .ft2

9. Find the needed tube surface area from the heat absorbed and the radiant flux.
QR
A= Q (L-5)
( )rad
A

10. Take a distance of about 20 ft between tube banks. A rough guide to furnace
dimensions is a requirement of about 4 cuft/sqft of radiant transfer surface, but
the ultimate criterion is sufficient space to avoid flame impingement.
11. Choose a tube length, L between 30 and 60 ft or so, so as to make the box
dimensions roughly comparable. The exposed length of the tube, and the inside
length of the furnace shell, is 1.5 ft shorter than the actual length. the required
number of tubes, N will be known with equation below
A
Total Tube Length = (L-6)
1.7344

Assumed that 40 ft tube length, so it will have an exposed length of 38.5 ft.

Total Tube Length Total Tube Length

Total N = = (L-7)
exposed length 38.5

12. Select the number of shield tubes between the radiant and convection zones so
that the mass velocity of the flue gas will be about 0.3–0.4 lb/(sec)(sqft free cross
section). Usually this will be also the number of convection tubes per row.
To calculate flue gas mass rate, GF
106 GF
= [840 + 8.0x, with fuel oil] , lb/MBtu heat release (L-8)
Qn

106 GF
Qn
= [822 + 7.78x, with fuel gas] , lb/MBtu heat release (L-9)
 Where, x = fraction excess air
Then, flue gas velocity is
GF (12)
Total G = (exposed length)(3600 s)(27.98)
(L-10)

13. The convection tubes usually are finned

14. The cold plane area is
Acp = (exposed length) (center − to − center spacing)(number of tubes exclusive of the shield tubes) (L-11)

15. The refractory area Aw is the inside surface of the shell minus the cold plane
area Acp of Step 14
Aw = 2[W(H + L) + (H x L)] − Acp (L-12)

where W, H, and L are the inside dimensions of the shell

Figure L.2 Mean beam length

(Source: Walas, et al., 2012)

The ratio of length, width, and height between 1-2-1. By using this ratio, the
calculation of length, width, and height is complete.
16. The absorptivity α is obtained from equation below
α = 1 − [0.0277 + 0.0927 (x − 1)](x − 1) (L-13)

where,

(center−to−center spacing)
x= (outside tube diameter)

when only single rows of tubes are used. For the shield tubes, α =1
17. The sum of the products of the areas and the absorptivity in the radiant zone is
α AR = Ashield + α Acp (L-14)
18. For the box-shaped shell, the mean beam length L is approximated by
1
2
𝐿 = 3 (𝑓𝑢𝑟𝑛𝑎𝑐𝑒 𝑣𝑜𝑙𝑢𝑚𝑒)3 (L-15)
19. The partial pressure P of CO2 +H2O is given in terms of the excess air by
𝑃 = 0.288 − 0.229𝑥 + 0.090𝑥 2 (L-16)
Where :
x = fraction excess air
20. The product PL is found with the results of Steps 18 and 19
21. The mean tube wall temperature (Tt) in the radiant zone is given in terms of the
inlet and outlet process stream temperatures by
𝑇𝑡 = 100 + 0.5(𝑇1 + 𝑇2 ) (L-17)
22. The temperature of the gas leaving the radiant zone (Tg) is found by combining
the equations of the radiant zone heat transfer (L-19) and the radiant zone heat
balance (L-20)
With the approximation usually satisfactory, the equality is
𝑄𝑛 𝑄𝑔 𝑇𝐺 +460 4 𝑇𝑡 +460 4
(1 − 0.02 − 𝑄 ) = 1730 [ ( ) −( ) ] + 7(𝑇𝑔 − 𝑇𝑡 ) (L-18)
α𝐴𝑅 𝐹 𝑛 1000 1000

Where
Radiant zone heat transfer (L-19) :
𝑄𝑅 𝑇𝑔 +460 4 𝑇𝑡 +460 4
= 1730 [ ( ) −( ) ] + 7(𝑇𝑔 − 𝑇𝑡 ) (L-19)
α𝐴𝑅 𝐹 1000 1000

Radiant zone heat balance (L-20) :

𝑄𝑅 𝑄 𝑄 𝑄 𝑄 𝑄𝑔
= α𝐴𝑛𝐹 (1 + 𝑄𝑎 + 𝑄𝑓 − 𝑄𝐿 − 𝑄 ) (L-20)
α𝐴𝑅 𝐹 𝑅 𝑛 𝑛 𝑛 𝑛

Where :
QR = enthalpy absorbed in the radiant zone
Qa = enthalpy of the entering air
Qf = enthalpy of the entering fuel
QL = enthalpy loss to the surroundings
Qg = enthalpy of the gas leaving the radiant zone
Qa and Qf are neglected if there is no preheat
𝑄𝐿
= 0.02–0.03
𝑄𝑛

Qn = total enthalpy released in the furnace

The solution of this equation involves other functions of Tg, namely, the
emissivity ϕ by (L-21), the exchange factor F by (L-22) and the exit enthalpy
𝑄𝑔
ratio by (L-23)
𝑄𝑛
 emissivity of the gas (ϕ) by
ϕ = a + b(PL) + 𝑐(𝑃𝐿)2 (L-21)
(𝑇𝑔 + 460)
𝑧=
100
a = 0.47916 − 0.19847z + 0.022569𝑧 2
b = 0.047029 + 0.0699z − 0.01528𝑧 2
c = 0.000803 − 0.00726z + 0.001597𝑧 2
Where :
PL = product of the partial pressure Eq. (L-16) and beam length (Figure L.2)
Exchange factor (F) by
𝐹 = a + bϕ + 𝑐ϕ2 (L-22)
𝐴𝑤
𝑧=
α𝐴𝑅
a = 0.00064 + 0.0591z + 0.00101𝑧 2
b = 1.0256 + 0.4908z + 0.058𝑧 2
c = − 0.144 − 0.552z + 0.040𝑧 2
𝑄𝑔
Exit enthalpy ratio ( 𝑄 ) by
𝑛

𝑄𝑔 𝑇 𝑇
= [𝑎 + 𝑏 (1000−0.1)] (1000−0.1) (L-23)
𝑄𝑛

a = 0.22048 − 0.35027z + 0.92344𝑧 2

b = 0.016086 + 0.29393z − 0.48139𝑧 2
Where :
z = fraction excess air
23. The four relations cited in Step 22 are solved simultaneously by trial to find the
temperature of the gas. Usually it is in the range 1500–1800°F.
24. After Tg has been found, calculate the heat absorbed QR by Eq. (L-19).
25. Find the heat flux
𝑄 𝑄𝑅
= (L-24)
A 𝐴𝑟𝑎𝑑𝑖𝑎𝑛𝑡

and compare with value specified in Step 8. If there is too much disagreement,
repeat the calculations with an adjusted radiant surface area.
26. By heat balance over the convection zone, find the inlet and outlet temperatures
of the process stream
27. The enthalpy of the flue gas is given as a function of temperature by Eq. (L-23).
The temperature of the inlet to the convection zone was found in Step 23. The
enthalpy of the stack gas is given by the heat balance [Eq. (L-25)], where all the
𝑄𝑠
terms on the right-hand side are known. is given as a function of the stack
𝑄𝑛

temperature Ts by Eq. (L-23). That temperature is found from this equation by

trial.
Enthalpy of the stack gas (Qs), given by the overall heat balance
𝑄𝑠 1
=1+ (𝑄𝑎 +𝑄𝑓− 𝑄𝐿 − 𝑄𝑅 − 𝑄𝑐𝑜𝑛𝑣𝑒𝑐𝑡𝑖𝑜𝑛 ) (L-25)
𝑄𝑛 𝑄𝑛

28. The average temperature of the gas film in the convection zone is given in terms
of the inlet and outlet temperatures of the process stream and the flue gas
approximately by
(𝑇𝑔1 −𝑇𝐿1 )−(𝑇𝑠 −𝑇𝐿0 )
𝑇𝑓 = 0.5[𝑇𝐿1 + 𝑇𝐿0 + (L-26)
ln[(𝑇𝑔1 −𝑇𝐿1 )/(𝑇𝑠 −𝑇𝐿0 )]

The flow is countercurrent

29. Choose the spacing of the convection tubes so that the mass velocity is G = 0.3-
𝑙𝑏
0.4 . Usually this spacing is the same as that of the shield
(𝑠)(𝑓𝑡 2 𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛)

tubes, but the value of G will not be the same if the tubes are finned.
30. The overall heat transfer coefficient is found with Eq. (L-27)
Overall heat transfer coefficient (Uc) in the convection zone
4.5
𝑈𝑐 = (𝑎 + 𝑏𝐺 + 𝑐𝐺 2 )( 𝑑 )0.25 (L-27)
𝑇𝑓
𝑧=
100
a = 2.461 − 0.759z + 1.625𝑧 2
b = 0.7655 + 21.373z − 9.6625𝑧 2
c = 9.7938 − 30.809 + 14.333𝑧 2
Where :
𝑙𝑏
G = flue gas flow rate, (𝑠)(𝑓𝑡 2 𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛)

d = tube outside diameter, in

z = average outside film temperature, oF
31. The convection tube surface area is found by
𝑄𝑐
𝐴𝑐 = (L-28)
𝑈𝑐 (𝐿𝑀𝑇𝐷)
32. Procedures for finding the pressure drop on the flue gas side, the draft
requirements and other aspects of stack design are presented briefly by
Wimpress.

Appendix P. Pressure Swing Adsorption Unit

PSA is a technology used to separate some gas species from a mixture of
gases under pressure according to the species’ molecular characteristics and affinity
for an adsorbent material. Pressure Swing Adsorption (PSA) does this by trapping
oxygen from the compressed air stream using adsorption. Adsorption takes place
when molecules bind themselves to an adsorbent, in this case the oxygen molecules
attach to a Carbon Molecular Sieve (CMS). For sizing dimension of vertical
pressure swing adsorption unit, the steps are outlined as follows:
1. Determine Material
Determination of column material is based on temperature conditions in column.
One of the most widely used steels for general purpose in the construction of
pressure vessel is carbon steel material SA-283 Grade C. This steel has good
ductility and forms, welds, and machines easily. It is also one of the most
economical steels suitable for pressure vessels.
2. Calculate the amount of adsorbent required
data known:
Carbon Molecular Sieve
Bulk density : 680 g/l
Adsorption capacity : 16 kg gas/ 100 kg adsorbent
N2 Flow rate : 6373.301 kg/day
The amount of adsorbent
100 kg adsorbent
the amount of adsorbent= N2 flow rate x (P-1)
16 kg gas

Safety Factor : 25%

Porosity of design column, 𝜀 : 0.45
Then, to calculate the amount of adsorbent required, as shown as the equation below
the amount of adsorbent required = amount of adsorbent x (1 + 𝑆𝐹) (P-2)
3. Calculate dimension of column
From Eq. (P-1) and (P-2), the volume of column, Vt can be calculated as
 the amount of adsorbent required
the amount of adsorbent
Vt= (P-3)
(1−𝜀)
Ratio between height of column and diameter of column (Hs : D) is 3:2
As we know that
π 3π
Vt = 4 x D2 x Hs = x D3 (P-4)
8

Then, diameter, D and height, Hs of column can be calculated by

3 8V
D = √ 3πt (P-5)
3
Hs = 2 x D (P-6)

4. Calculate thickness of shell

To calculate the thickness of a shell using the equation
P. D
ts = 2 . + nC (P-7)
s . E−1.2 P

Where,
ts : minimum required thickness of the shell (in)
P : working pressure (psia)
s : maximum allowable stress (psia)
From Table 13.1 for carbon steel SA-283 Grade C, s= 12,650 psia
(Brownell & Young, 1959)
E : welded-joint efficiency
From Table 13.2 for double-welded but joint, E = 80% (Brownell &
Young, 1959)
D : diameter of column (in)
1
C : corrosion factor (8 in)

n : life time (10 years)

From the calculation, the thickness of the shell is obtained t s = 1.252 in, so that
1
thickness is used 1 8 in according to the nominal size thickness standard.

5. Head & Bottom Design

Ellipsoidal head is the most common type, this head as the name suggests is
formed by elliptical space. Usually the most common type is 2: 1 ellipsoidal,
between vertical and horizontal diameters the ratio is around 2: 1. While for the
ratio between head height (Ht) and column diameter (D) is 1: 4 This type of head
has a high pressure range of> 200 psig, in the PSA process, the operating condition
of the pressure that occurs is 20 atm or comparable to 293,919 psig, making it
suitable to use an ellipsoidal type head

Figure P.1 Dimensional relationships for Ellipsoidal

(Source: Brownell & Young, 1959)

To calculate the thickness of a head using the equation

P. D
t = 2. (P-8)
s . E−1.8 P
3
From the calculation the thickness of the head is used 16 in according to the nominal

size thickness standard.

To calculate the height of a head using the equation
1
Ht = 4 x D (P-9)

Then, total height of column is

𝐻𝑇 = 𝐻𝑆 + 𝐻𝑡 (P-10)

REFFERENCE
Brownell, L. and Young, E. (1976). Equipment design. New York: Wiley.
Walas, S. (2012). Chemical process equipment. Amsterdam: BH, Butterworth-
Heinemann, an imprint of Elsevier.