EH2418F

DESIGN PROJECT II (JULY 2018)

PRODUCTION OF 100, 000 METRIC TONNES OF ETHANOL PER YEAR

CHAPTER 7: ETHANOL SEPARATION TOWER (T-101)

STUDENT NAME

ZURHAFEFEE BINTI ZABIDI 2014473438

SUPERVISOR:
PROF MADYA HASNORA JAFRI

FACULTY OF CHEMICAL ENGINEERING

UNIVERSITI TEKNOLOGI MARA
SHAH ALAM
 TABLE OF CONTENT PAGE
7.4 Ethanol separation tower 3
7.4.1 Introduction 3
7.4.2 Chemical process design of T-101 3
7.4.2.1 Physical properties 4
7.4.2.2 Tower and Plate designation 4
i. Calculation Tdew and bubble 5
ii. Calculation stages Mc –Cabe Thiele 9
iii. Calculation actual stages 13
iv. Feed point location 15
v. RMM and density 16
vi. Column sizing 19
vii. Provisional plate design 24
viii. Weir dimension 25
ix. Plate pressure drop 28
x. Downcomer design 32
xi. Downcomer residence time 32
xii. Perforated area 33
7.4.3 Mechanical design for T-101 36
7.4.3.1 Design Pressure & Temperature 36
7.4.3.2 MOC and Maximum Allowable Stress 36
7.4.3.3 Welded Joint Efficiency & Corrosion Allowance 37
7.4.3.4 Minimum wall thickness 38
7.4.3.5 Types of domed heads 39
7.4.3.6 Dead weight of vessel 41
7.4.3.7 Wind loading 43
7.4.3.8 Analysis of stress 44
7.4.3.9 Design of Vessel Support 48
7.4.3.10 Bolt and Flange Design 50
7.4.4 Reference 56

2
 7.4 ETHANOL SEPARATION TOWER, T-101
7.4.1 INTRODUCTION
Ethanol separation tower or denoted as T-101 in ethanol production plant is used to
separate the main product which is ethanol from the wastewater. There are total of four components
involve in this separation, but since the amount of unreacted ethylene and diethyl ether are too
small (less than 0.001 kmol/h), hence these two components are neglected in calculation and this
separation is considered as binary distillation. In this separation, the light key component which is
the component that is desired to keep out of the bottom product is ethanol. On the other hand,
heavy key component that is desired to keep out of the top product is water.

7.4.2 CHEMICAL PROCESS DESIGN OF ETHANOL SEPARATION TOWER

7.4.2.1 Physical Properties
The physical properties used in this calculation are as follows:

A) Boiling Point, Molecular Weight and Density

Table 1: Table of boiling point, molecular weight and density for each component at 25°C and 1 atm

Molecular
Boiling Density
No Component weight Reference
Point (°C) (kg/m³)
(kg/kmol)
(National Center for
1 Ethanol 78.29 46 789 Biotechnology Information,
2018)
2 Water 100 18 998 (Sinnot, 2005)

B) Antoine Equation
𝐵
ln 𝑃 𝑠𝑎𝑡 (𝑘𝑃𝑎) = 𝐴 −
𝑇 (𝐾) + 𝐶

Table 2: Table of Antoine Parameter

No Component Formula A B C Reference

1 Ethanol C2H5OH 16.90 3795.17 -42.232 (B.E. Poling, 2001)
2 Water H2O 16.39 3885.70 -42.980 (B.E. Poling, 2001)

3
 C) Viscosity

Table 3: Viscosity of the mixture

No Component VIS A VIS B Reference

1 Ethanol 686.64 300.88 (Reid, 1977)
2 Water 658.25 283.16 (Reid, 1977)

7.4.2.2 Tower and Plate Designation

The block diagram and stream summary of T-101 is presented as follows

DISTILLATE
Ethanol (A)
Water (B)

FEED

Ethanol (A)
Water (B)

BOTTOM
Ethanol (A)
Water (B)

Figure 1: Ethanol separation tower, T-101

Table 4: Table of stream flow at T-101

Feed Distillate Bottom

Pressure (kPa) 250 200 240
Temperature (ºC) 309.33 360.1 384.65
Mole Mole Mole Mole Mole Mole
Component fraction flowrate fraction flowrate fraction flowrate
(xf) (Fxf) (xd) (Dxd) (xb) (Bxb)
Ethanol 0.15 271.81 0.91 258.22 0.03 13.59
Water 0.85 494.99 0.09 24.75 0.97 470.24
TOTAL 1.00 766.80 1.00 282.97 1.00 483.83

4
 In order to design tower, there are few parameters need to be considered such as physical
properties and equation used for the calculation. Several steps need involved in tower designation
and a good assumption must also be made to justify the calculation.

i) Calculation temperature at Tdew and Tbubl

Firstly, in order to design distillation column, temperature at dew point and bubble point is
calculated. Dew temperature referred to distillate temperature while bubble temperature referred
to feed and bottom temperature. The value of dew temperature and bubble temperature need to be
iterated to obtain the most approximate value. The first guess for dew and bubble temperature are
taken from HYSYS.

The vapour pressure of each component need to be determined in order to calculate dew
temperature and bubble temperature followed by equilibrium constant, K and relative volatility, α.
Antoine equation is used to determine the vapour pressure at the iterated temperature. The value
of A, B and C is the Antoine constant and can be found in Table 2.

The Antoine equation can be illustrated as follows (B.E. Poling, 2001).

𝐵 Eq 7.1
ln 𝑃 𝑠𝑎𝑡 (𝑘𝑃𝑎) = 𝐴 −
𝑇 (𝐾) + 𝐶

Next, the value of equilibrium constant K need to be calculated by using below formula
where Ki is the equilibrium constant for each component and P is the operating pressure
(Geankoplis, 2014).

𝑃 𝑠𝑎𝑡 Eq 7.2
𝐾=
𝑃

5
Bubble point (feed)
By using goal seek method in excel programme, with constant operating pressure at feed,
the value of the bubble temperature is iterated and shown in table below.

Table 5: Operating Condition at feed

OPERATING CONDITION
Design pressure Bubble
250 395.25
(kPa) temperature (K)

Table 6: Calculation of Bubble point at feed

Component Mole fraction, ln Psat Psat K-value Ʃy = xi ki

xf
Ethanol 0.15 6.15 466.45 1.87 0.28
Water 0.85 5.36 212.03 0.85 0.72
1.00
Hence, the bubble temperature of feed is 395.25K

Dew point (distillate)

By using goal seek method in excel programme, with constant operating pressure at feed,
the value of the dew temperature is iterated and shown in table below.

Table 7: Operating condition at distillate

OPERATING CONDITION
Design pressure Dew temperature
200 372.50
(kPa) (K)

Table 8: Calculation of Dew Point at distillate

Mole fraction,
Component ln Psat Psat K-value Ʃx = yi/ki
xf
Ethanol 0.91 5.40 222.43 1.11 0.82
Water 0.09 4.60 99.01 0.50 0.18
1.00
Hence, the dew temperature of distillate is 375.25K

6
Bubble point (bottom)
By using goal seek method in excel programme, with constant operating pressure at feed,
the value of the bubble temperature is iterated and shown in table below.

Table 9: Operating condition at bottom

OPERATING CONDITION
Design pressure Bubble
240 398.25
(kPa) temperature (K)

Table 10: Calculation of Bubble point at bottom

Mole fraction,
Component ln Psat Psat K-value Ʃx = yi/ki
xf
Ethanol 0.03 6.24 510.68 2.13 0.06
Water 0.97 5.45 232.73 0.97 0.94
1.00

Hence, the bubble temperature of bottom is 375.25K

After the value of of K is obtained, the value of relative volatility for each component is
then calculated. The equation is as shown below (Geankoplis, 2014).

𝐾𝑖
𝛼= Eq 7.3
𝐾𝐻𝐾

where 𝐾𝑖 is the equilibrium constant for each component and 𝐾𝐻𝐾 is the equilibrium constant for
Heavy Key. In this separation, heavy key component is water since it is the lowest volatility
compared to ethanol. The value of relative volatility is given in table below.

Table 11: Relative Volatility at distillate

Relative Volatility (Distillate)

Relative
Component Mole fraction, yi K-value
volatilty
Ethanol 0.91 1.11 2.25
Water 0.09 0.50 1

7
 Table 12: Relative Volatility at bottom

Relative Volatility (Bottom)

Relative
Component Mole fraction, xi K-value
volatilty
Ethanol 0.03 2.13 2.19
Water 0.97 0.97 1

The average relative volatility is given by:

Eq 7.4
𝛼𝑎𝑣𝑔 = √(𝑡𝑜𝑝 𝛼) (𝑏𝑜𝑡𝑜𝑚 𝛼)

Table 13: Average relative volatility

Relative Volatility
Component Top Bottom Average
Ethanol 2.25 2.19 2.22
Water 1.00 1.00 1.00

Next, the value of 𝑅𝑚𝑖𝑛 is determined next using Underwood & Fenske equation (Sinnot, 2005).

1 𝑋𝑑,𝐿𝐾 𝑋𝑑,𝐻𝐾
𝑅𝑚𝑖𝑛 = ( − 𝛼𝑎𝑣𝑔 [ ]) Eq 7.5
(𝛼𝑎𝑣𝑔 − 1) 𝑋𝑓,𝐿𝐾 𝑋𝑓,𝐻𝐾

According to Geankoplis (2014), the value of reflux ratio is 1.5 of the minimum reflux ratio
which can be shown as

𝑅 = 1.5𝑅𝑚𝑖𝑛 Eq 7.6

1 0.91 0.09
𝑅𝑚𝑖𝑛 = ( − 2.22 [ ])
(2.22 − 1) 0.15 0.85
𝑅𝑚𝑖𝑛 = 4.78
𝑅 = 1.5(4.78)

𝑅 = 7.17

8
 ii) Calculation to determine number of stages using Mc-Cabe Thiele method

The relatively volatility is given by (Geankoplis, 2014):

𝑦𝐴 𝑥𝐵
𝑎= Eq 7.7
𝑥𝐴 𝑦𝐵

This gives a relation between the ratio A and B in the vapour to that in the liquid. Since with
binary mixture 𝑦𝐵 = 1- 𝑦𝐴 and 𝑥𝐵 = 1 - 𝑥𝐴 then:

𝑦𝐴 1 − 𝑥𝐴
𝑎=( )( )
1 − 𝑦𝐴 𝑥𝐴
𝑎𝑥𝐴
𝑦𝐴 =
1 + (𝑎 − 1)𝑥𝐴

Relative volatility, 𝑎 = 2.22

2.22 𝑥
𝑦=
1 + 1.22 𝑥

Table 14: Liquid and vapour mole fraction of component A

𝑥𝐴 𝑦𝐴
0 0.00
0.1 0.20
0.2 0.36
0.3 0.49
0.4 0.60
0.5 0.69
0.6 0.77
0.7 0.84
0.8 0.90
0.9 0.95
1 1.00

9
 Vapour-liquid equilibrium curve
1
0.9
Mole fraction of A in vapour phase, y

0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
Mole fraction of A in liquid phase, x

Figure 2: Vapour-Liquid Equilbrium (VLE) Diagram

Material balance to determine operating line

Table 15: Parameter for Feed, Distillate, Bottom & Reflux Ratio

Parameter Value
Feed Molar Flow Rate (kmol/h),F 766.8
Distillate Molar Flow Rate (kmol/h), D 282.97
Bottom Molar Flow Rate (kmol/h), B 483.83
Reflux Ratio, R 7.17

Above feed point:

(i) Vapour flow rate:

Vn = D (R + 1)
Vn = 282.97 (7.17 + 1)
Vn = 2311.87 kmole/hr

10
 (ii) Liquid down flow

Ln = Vn − D
Ln = 2311.87 − 282.97
Ln = 2028.90 kmole/hr

Below feed point:

(iii) Liquid flow rate

Lm = Ln + F
Lm = 2028.90 + 766.8
Lm = 2795.70 kmole/hr

(iv) Vapour flow rate

Vm = Lm – B
Vm = 2795.70 - 483.83
Vm = 2311.87 kgmole/hr

Operating line
Top operating line (Geankoplis, 2014)
𝐿𝑛 𝐷 Eq 7.8
𝑦𝑛 = 𝑥𝑛+1 + 𝑥𝑑
𝑉𝑛 𝑉𝑛
2028.90 282.97
𝑦𝑛 = 𝑥𝑛+1 + 𝑥
2311.87 2311.87 𝑑
𝑦𝑛 = 0.88 𝑥𝑛+1 + 0.11

Bottom operating line (Geankoplis, 2014)

𝐿𝑚 𝐵 Eq 7.9
𝑦𝑚 = 𝑥𝑚+1 + 𝑥𝑏
𝑉𝑚 𝑉𝑚
2795.70 483.83
𝑦𝑛 = 𝑥𝑛+1 + 𝑥
2311.87 2311.87 𝑏
𝑦𝑛 = 1.21 𝑥𝑛+1 + 0.0063

11
 1
VAPOUR-LIQUID EQUILIBRIUM
0.9

Top operating line

0.8

0.7 q-line

0.6

0.5

0.4

0.3

0.2
Bottom operating line
0.1

0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1

Xb Xf Xd

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 iii) Calculation to determine number of actual stages

In order to determine the number of actual stages, plate efficiency must be determined. The
O’Connell correlation shown can be used to estimate the overall column efficiency. The equation
correlated with the product of the relative volatility of the light key and the molar average viscosity
of the feed with estimated at the average column temperature. The equation is shown below
(Eduljee, 1958).
Eq 7.10
𝐸𝑜= 51 − 32.5 log(𝜇𝑎 𝛼𝑎 )

Where 𝜇𝑎 = the molar average liquid viscosity, mNs/m2

𝛼𝑎 = average relative volatility of the light key

The average viscosity can be found by using equation below where T is the average temperature
(Sinnot, 2005).
Eq 7.11
1 1
log 𝜇 = 𝑉𝐼𝑆 𝐴 × ( − )
𝑇 (𝐾) 𝑉𝐼𝑆 𝐵

The value for VIS A and VIS B is given in table 3.

Average temperature can be calculated as follows:

(𝑇 𝑎𝑡 𝑡𝑜𝑝 + 𝑇 𝑎𝑡 𝑏𝑜𝑡𝑡𝑜𝑚) Eq 7.12

𝑇=
2

360.1 + 384.65
𝑇 (𝐾) =
2

𝑇 = 372.375 𝐾

13
The average viscosity is calculated and shown in table below

Table 16: Viscosity of the mixture

Mole
Average Molar viscosity,
Component fraction,
viscosity, μ μxf
xf
Ethanol 0.36 0.15 0.05
Water 0.28 0.85 0.24

The molar average liquid viscosity is calculated by

0.05 + 0.24
𝜇𝑎 =
2
𝜇𝑎 = 0.145

Substituting this value for Eo

𝐸𝑜= 51 − 32.5 log(0.145)(2.22)

𝐸𝑜= 66.98%

Hence, the efficiency of this plate is 66.98%

Number of actual stages

The actual number of stages, N is the number of stages required for the column. Number
of ideals stages is 10 from the Mc-Cabe-Thiele method, one stage will be the reboiler, so the
number of actual stage is given by (Geankoplis, 2014):

𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑖𝑑𝑒𝑎𝑙 𝑠𝑡𝑎𝑔𝑒𝑠

𝐸𝑜 = Eq 7.13
𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑎𝑐𝑡𝑢𝑎𝑙 𝑠𝑡𝑎𝑔𝑒𝑠

10 − 1
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑎𝑐𝑡𝑢𝑎𝑙 𝑠𝑡𝑎𝑔𝑒𝑠 =
0.6689

Hence, the number of actual stages are 13

14
 iv) Determination of feed point location

The feed point location is calculated to determine in which stage feed enter the column. The
given equation to calculate the feed point location are as follow (Kirkbride, 1944).

2
𝑁𝑟 𝐵 𝑋𝑓,𝐻𝐾 𝑋𝑏,𝐿𝐾 Eq 7.14
log ( ) = 0.206 𝑙𝑜𝑔 [( ) ( )( ) ]
𝑁𝑠 𝐷 𝑋𝑓,𝐿𝐾 𝑋𝑑,𝐻𝐾

𝑁𝑟 = number of stages above the feed, including any partial condenser

𝑁𝑟 = number of stages below the feed, including the reboiler

𝑋𝑓,𝐻𝐾 = concentration of the heavy key in the feed

𝑋𝑓,𝐿𝐾 = concentration of the light key in the feed

𝑋𝑏,𝐿𝐾 = concentration of the light key in the bottom product

𝑋𝑑,𝐻𝐾 = concentration of the heavy key in the top product

𝑁𝑟 483.83 0.85 0.03 2

log ( ) = 0.206 𝑙𝑜𝑔 [( )( )( ) ]
𝑁𝑠 𝐷282.97 0.15 0.09

𝑁𝑟
( ) = 1.02
𝑁𝑠

Thus,

𝑁𝑟 = 1.02 𝑁𝑠

Overall number of trays,

𝑁𝑟 + 𝑁𝑠 = 13

𝑁𝑠 = 13 − 𝑁𝑟

15
Substituting into above equation,

𝑁𝑟 = 1.02 (13 − 𝑁𝑟)

𝑁𝑟 = 6.43 ≈ 6 (𝑁𝑜 𝑜𝑓 𝑠𝑡𝑎𝑔𝑒𝑠 𝑎𝑏𝑜𝑣𝑒 𝑓𝑒𝑒𝑑 𝑝𝑙𝑎𝑡𝑒)

Thus,

𝑁𝑠 = 6.56 ≈ 7 (𝑁𝑜 𝑜𝑓 𝑠𝑡𝑎𝑔𝑒𝑠 𝑏𝑒𝑙𝑜𝑤 𝑓𝑒𝑒𝑑 𝑝𝑙𝑎𝑡𝑒)

v) Determination of Relative Molar Mass and Density

The following table shows the mole fraction, molecular weight and liquid density for each
component.

Table 17: Molecular weight, mole fraction and liquid density of ethanol and water

Composition
Molecular Weight Density
Component Feed,
(kg/kmol) (kg/m3)
Xf Distillate, Xd Bottom, Xb
Ethanol 46 0.85 0.91 0.03 789
Water 18 0.15 0.09 0.97 998

Relative molecular mass

𝑅𝑀𝑀 = ∑(𝑚𝑜𝑙𝑒 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛 × 𝑚𝑜𝑙𝑒𝑐𝑢𝑙𝑎𝑟 𝑤𝑒𝑖𝑔ℎ𝑡) Eq 7.15

Liquid density

𝜌𝐿 = ∑ 𝑋𝑓,𝑖 𝜌𝑖 Eq 7.16

Vapour density

𝑅𝑀𝑀𝑑 𝑇𝑆𝑇𝑃 𝑃𝑂𝑃

𝜌𝑉 = ∑ × × Eq 7.17
𝑉𝑆𝑇𝑃 𝑇𝑂𝑃 𝑃𝑆𝑇𝑃

16
Where the value of VSTP, TSTP and PSTP are given by

Table 18: Condition for volume, pressure & temperature at STP

VSTP 22.4 m3/kmol

TSTP 273 K
PSTP 1 atm

Relative molar mass and density at feed

𝑅𝑀𝑀 𝑓𝑒𝑒𝑑 = (0.85 × 46) + (0.15 × 18)

𝑅𝑀𝑀 𝑓𝑒𝑒𝑑 = 41.8 𝑘𝑔/𝑘𝑚𝑜𝑙

Liquid density feed

𝜌𝐿 𝑓𝑒𝑒𝑑 = (0.85 × 789) + (0.15 × 998)

𝜌𝐿 𝑓𝑒𝑒𝑑 = 820.35 𝑘𝑔/𝑚³

Vapour density at feed

41.8𝑘𝑔/𝑘𝑚𝑜𝑙 273𝐾 2.47𝑎𝑡𝑚

𝜌𝑉 𝑓𝑒𝑒𝑑 = 3
× ×
22.4𝑚 /𝑘𝑚𝑜𝑙 309.33 𝐾 1 𝑎𝑡𝑚

𝜌𝑉 𝑓𝑒𝑒𝑑 = 4.07𝑘𝑔/𝑚³

Relative molar mass and density at distillate

𝑅𝑀𝑀 𝑓𝑒𝑒𝑑 = (0.91 × 46) + (0.09 × 18)

𝑅𝑀𝑀 𝑓𝑒𝑒𝑑 = 43.48 𝑘𝑔/𝑘𝑚𝑜𝑙

Liquid density distillate

𝜌𝐿 𝑓𝑒𝑒𝑑 = (0.91 × 789) + (0.09 × 998)

𝜌𝐿 𝑓𝑒𝑒𝑑 = 807.81 𝑘𝑔/𝑚³

17
Vapour density at distillate

43.48 𝑘𝑔/𝑘𝑚𝑜𝑙 273𝐾 1.97𝑎𝑡𝑚

𝜌𝑉 𝑓𝑒𝑒𝑑 = × ×
22.4 𝑚3 /𝑘𝑚𝑜𝑙 360.1 𝐾 1 𝑎𝑡𝑚

𝜌𝑉 𝑓𝑒𝑒𝑑 = 2.90 𝑘𝑔/𝑚³

Relative molar mass and density at bottom

𝑅𝑀𝑀 𝑓𝑒𝑒𝑑 = (0.03 × 46) + (0.97 × 18)

𝑅𝑀𝑀 𝑓𝑒𝑒𝑑 = 18.84 𝑘𝑔/𝑘𝑚𝑜𝑙

Liquid density bottom

𝜌𝐿 𝑓𝑒𝑒𝑑 = (0.03 × 789) + (0.97 × 998)

𝜌𝐿 𝑓𝑒𝑒𝑑 = 991.73 𝑘𝑔/𝑚³

Vapour density at bottom

18.84 𝑘𝑔/𝑘𝑚𝑜𝑙 273𝐾 2.37 𝑎𝑡𝑚

𝜌𝑉 𝑓𝑒𝑒𝑑 = × ×
22.4 𝑚3 /𝑘𝑚𝑜𝑙 384.65 𝐾 1 𝑎𝑡𝑚

𝜌𝑉 𝑓𝑒𝑒𝑑 = 1.41 𝑘𝑔/𝑚³

Summary of RMM, liquid and vapour density

Table 19: Summary of RMM, vapour and liquid density

RMM ρv ρl
Feed 41.8 4.07 820.35
Top 43.48 2.90 807.81
Bottom 18.84 1.41 991.73

18
 vi) Determination of column sizing

Plate spacing

Taller spacing between successive trays raises capacity, leading to a smaller tower diameter
but also raises tower height. In tower with larger than 1.5m diameter, tray spacing is typically 600
mm and is large enough to permit a worker to crawl between trays (Robert H. Perry, 2008).

Determination of column diameter

FLV is defined as liquid-vapour flow factor and need to be calculated to obtain the column
diameter. Note that all the calculation involves in estimating the column diameter needs to be done
for distillate and bottom. This is because, the column diameter value will depend on the most
appropriate value which is either the diameter at distillate or diameter at bottom. The formula of
FLV is:

𝐿𝑤 𝜌𝑉 Eq 7.18
𝐹𝐿𝑉 = √
𝑉𝑤 𝜌𝐿

𝐿𝑤 = liquid mass flow rate, kg/s

𝑉𝑤 = vapour mass flow rate, kg/s

Liquid-vapour flow factor, FLV at top

2028.90 2.90
𝐹𝐿𝑉 = √
2311.87 807.81

𝐹𝐿𝑉 = 0.053

Liquid-vapour flow factor, FLV at bottom

2795.70 1.41
𝐹𝐿𝑉 = √
2311.87 991.73

𝐹𝐿𝑉 = 0.046

19
 By considering the chosen tray spacing and 𝐹𝐿𝑉 value, by using figure below, the value of
K1 can be obtained. K1 value will be used to calculate flooding velocity, 𝑈𝑓 in the next step.
Figure below shows the relationship between K1 value and FLV based on tray spacing for sieve
trays type.

Figure 3: K1 vs FLV to calculate flooding velocity

Thus, at 0.6m tray spacing

𝑇𝑜𝑝 𝐾1 = 0.105

𝐵𝑜𝑡𝑡𝑜𝑚 𝐾1 = 0.110

Calculation of flooding velocity

𝜌𝐿 − 𝜌𝑉
𝑈𝑓 = 𝐾1 √ Eq 7.19
𝜌𝑉

Value of uf is used to calculate vapour velocity, 𝑈𝑣 by using flooding consideration. The

normal flooding occur is around 70% to 90%. However, for design purpose, flooding of 80% to
85% is commonly being used (Sinnot, 2005). The formula of flooding percentage can be shown
as follows:

20
 𝑈𝑣 Eq 7.20
% 𝑓𝑙𝑜𝑜𝑑𝑖𝑛𝑔 =
𝑈𝑓

Rearranging the equation

𝑈𝑣 = % 𝑓𝑙𝑜𝑜𝑑𝑖𝑛𝑔 × 𝑈𝑓

𝑈𝑣 = vapour velocity, m/s

𝑈𝑓 = flooding velocity, m/s

For top column

807.99 − 2.90
𝑈𝑓 = 0.105√
2.90

𝑈𝑓 = 1.75 𝑚/𝑠

𝑈𝑣 = 85% × 1.75 𝑚/𝑠

𝑈𝑣 = 1.49 𝑚/𝑠

For bottom column

993.67 − 1.41
𝑈𝑓 = 0.110√
1.41

𝑈𝑓 = 2.91 𝑚/𝑠

𝑈𝑣 = 85% × 2.91 𝑚/𝑠

𝑈𝑣 = 2.48 𝑚/𝑠

21
Calculation for maximum volumetric flow rate (Sinnot, 2005).

𝑘𝑚𝑜𝑙
𝑀𝑜𝑙𝑒 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 𝑜𝑓 𝑣𝑎𝑝𝑜𝑢𝑟 ( ) × 𝑅𝑀𝑀 Eq 7.21
𝑉𝑚𝑎𝑥 = ℎ
𝜌𝑉 × 3600

For top column

2311.87 × 43.48
𝑉𝑚𝑎𝑥 =
2.90 × 3600

𝑉𝑚𝑎𝑥 = 9.63 𝑚3 /𝑠

For bottom column

2311.87 × 18.84
𝑉𝑚𝑎𝑥 =
1.41 × 3600

𝑉𝑚𝑎𝑥 = 8.55 𝑚3 /𝑠

Calculation of net area, An (Sinnot, 2005).

𝑉𝑚𝑎𝑥 Eq 7.22
𝑁𝑒𝑡 𝑎𝑟𝑒𝑎 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 =
𝑈𝑣

For top column

9.63 𝑚3 /𝑠
𝑁𝑒𝑡 𝑎𝑟𝑒𝑎 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 =
1.49 𝑚/𝑠

𝑁𝑒𝑡 𝑎𝑟𝑒𝑎 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 = 6.48 𝑚²

For bottom column

8.55 𝑚3 /𝑠
𝑁𝑒𝑡 𝑎𝑟𝑒𝑎 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 =
2.48 𝑚/𝑠

𝑁𝑒𝑡 𝑎𝑟𝑒𝑎 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 = 3.45 𝑚²

22
 The downcomer area and plate spacing must be below the outlet weir to avoid from column
flooding. Thus, to calculate the downcomer area, an assumption of 10% from total area is taken
(Sinnot, 2005). The value will then change depending on the detailed plate designation. From this
assumption, the value of column area can be determined.

𝑁𝑒𝑡 𝐴𝑟𝑒𝑎, 𝐴𝑛 Eq 7.23

𝐶𝑜𝑙𝑢𝑚𝑛 𝐴𝑟𝑒𝑎, 𝐴𝑐 =
0.9

For top column

6.48 𝑚²
𝐶𝑜𝑙𝑢𝑚𝑛 𝐴𝑟𝑒𝑎, 𝐴𝑐 =
0.9

𝐶𝑜𝑙𝑢𝑚𝑛 𝐴𝑟𝑒𝑎, 𝐴𝑐 = 7.20 𝑚²

For bottom column

3.45 𝑚²
𝐶𝑜𝑙𝑢𝑚𝑛 𝐴𝑟𝑒𝑎, 𝐴𝑐 =
0.9

𝐶𝑜𝑙𝑢𝑚𝑛 𝐴𝑟𝑒𝑎, 𝐴𝑐 = 3.84 𝑚²

Therefore, diameter of column is given by:

4𝐴𝑐
𝐷= √ Eq 7.24
𝜋

For top column

4(7.20)
𝐷= √
𝜋

𝐷 = 3.03 𝑚

23
For bottom column

4(3.84)
𝐷= √
𝜋

𝐷 = 2.21 𝑚

Therefore, the most suitable diameter for the design of column is 3.03 m

vii) Provisional plate design

The following area terms are used in the plate design. In order to calculate the column diameter,
an estimate of net area is required. The downcomer area is assuming as 12% of total, and assume
that hole area is 10% (Sinnot, 2005).

Table 20:Provisional plate design

Column diameter, Dc 3.03 𝑚

Column Area, Ac 4𝐷𝑐 ²

= 7.21 𝑚²
𝜋

Downcomer Area, Ad 0.12 𝐴𝑐 = 0.87 𝑚²

Net Area, An 𝐴𝑐 − 𝐴𝑑 = 6.34 𝑚²

Active Area, Aa 𝐴𝑐 − 2𝐴𝑑 = 5.47 𝑚²

Hole Area, Ah 0.1 𝐴𝑎 = 0.55 𝑚²

Number of holes

Take diameter hole as 5 mm

𝜋𝑑² 𝜋(0.005)²
𝐴𝑟𝑒𝑎 𝑜𝑓 𝑜𝑛𝑒 ℎ𝑜𝑙𝑒 = = = 1.96 × 10−5
4 4

𝐻𝑜𝑙𝑒 𝑎𝑟𝑒𝑎 0.55

𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 ℎ𝑜𝑙𝑒𝑠 = = = 28 011 ℎ𝑜𝑙𝑒𝑠
𝐴𝑟𝑒𝑎 𝑜𝑓 𝑜𝑛𝑒 ℎ𝑜𝑙𝑒 1.96 × 10−5

24
 viii) Weir dimension
Calculation to determine weir height

Weir height is used to determine the volume of liquid on plate and is to determine the plate
efficiency. Higher weir height will increase plate efficiency. However, it will also increase the
plate pressure drops (Sinnot, 2005).

Determination of weir length

Weir length, 𝐼𝑤 will depends on the percentage of downcomer area. According to Sinnot
(2005), a good initial value used is 0.75 x Dc which is equivalent to 12% downcomer area.

𝐴𝑑
× 100% = 12% Eq 7.25
𝐴𝑐

The relationship between weir length and downcomer area can be shown in Figure 4

Figure 4: Relation between downcomer area and weir length

25
Therefore,
Eq 7.26
𝐼𝑤 = 0.75 𝐷𝑐
𝐼𝑤 = 2.27 𝑚
Calculation of Lmax

𝑀𝑜𝑙𝑎𝑟 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 𝑜𝑓 𝑙𝑖𝑞𝑢𝑖𝑑 × 𝑅𝑀𝑀 Eq 7.27

𝐿𝑚𝑎𝑥 =
3600
2795.69 𝑘𝑚𝑜𝑙𝑒/ℎ × 18.84𝑘𝑔/𝑘𝑚𝑜𝑙𝑒
𝐿𝑚𝑎𝑥 =
3600
𝐿𝑚𝑎𝑥 = 14.63 𝑘𝑔/𝑠

Check weeping rate

Calculation of weir crest is calculated as follows (Sinnot, 2005).

𝐿𝑤 2/3 Eq 7.28
ℎ𝑜𝑤 = 750 ( )
𝜌𝑙 (𝐼𝑤 )
Where ℎ𝑜𝑤 = weir liquid crest, mm
𝐿𝑤 = liquid flow rate, kg/s
𝜌𝑙 = liquid density, kg/m³
𝐼𝑤 = weir length, m

By taking 70% turndown ratio, the minimum liquid flowrate can be obtained as follows (Sinnot,
2005).
𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 Eq 7.29
𝑇𝑢𝑟𝑛𝑑𝑜𝑤𝑛 𝑟𝑎𝑡𝑖𝑜 =
𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒
𝐿𝑚𝑖𝑛 = 0.7 × 14.63 = 10.24 𝑘𝑔/𝑠
Therefore,

𝐿𝑤 2/3 Eq 7.30
ℎ𝑜𝑤,𝑚𝑖𝑛 = 750 ( )
𝜌𝑙 (𝐼𝑤 )
2/3
10.24
ℎ𝑜𝑤,𝑚𝑖𝑛 = 750 ( )
991.73(2.27)

26
 ℎ𝑜𝑤,𝑚𝑖𝑛 = 20.59 𝑚𝑚 𝑙𝑖𝑞𝑢𝑖𝑑
Thus,
ℎ𝑤 + ℎ𝑜𝑤 = 50 + 20.59 = 70.59 𝑚𝑚

From the summation of ℎ𝑤 and ℎ𝑜𝑤 , a constant K2 can be obtained from the below graph
correlation.

Figure 5: Weep point correlation

From the graph, the value of K2 obtained is 30.5

Calculation of minimum vapour velocity through holes based on hole area can, Ub

The equation to calculate minimum vapour velocity through holes are as follows (Sinnot, 2005)

𝐾2 − 0.9(25.4 − 𝑑ℎ ) Eq 7.31
ŭℎ = [ ]
(𝜌𝑣 )1/2
Where,
ŭℎ = Minimum vapour velocity through holes (based on hole area), m/s
𝐾2 = constant, depending on the depth of clear liquid on plate, m/s

27
𝑑ℎ = Hole diameter, mm
𝜌𝑣 = Density of vapour, kg/m³

30.5 − 0.9(25.4 − 5)
ŭℎ = [ ]
(1.41)1/2
ŭℎ = 10.22 𝑚/𝑠
However, a certain condition need to be fulfilled to determine whether information in estimating
the value of plate dimension is correct or not. The condition need to be fulfilled is that:

ŭℎ < 𝑎𝑐𝑡𝑢𝑎𝑙 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦

Where
𝑚3
𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑣𝑎𝑝𝑜𝑢𝑟 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒(
𝑚
𝑎𝑐𝑡𝑢𝑎𝑙 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 ( ) = 𝑠 )
𝑠 𝐴ℎ (𝑚2 )
𝑚3
𝑚 (0.7 × 9.63 )
𝑎𝑐𝑡𝑢𝑎𝑙 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 ( ) = 𝑠 = 12.33 𝑚
𝑠 0.55 𝑚² 𝑠

𝑚 𝑚
10.22 < 12.33
𝑠 𝑠
The condition is acceptable and the minimum operating rate is above the weep point.

ix) Calculation of plate pressure drop

Pressure drop is one of the important criteria in plate designation. Higher pressure drop
may cause higher efficiency however it is not god for the distillation process. According to
(Branan, 2005), the pressure drops across plate for sieve trays cannot exceed 22% of the space
between the trays.

28
Dry plate pressure drop
𝑢ℎ 2 𝜌𝑣 Eq 7.32
ℎ𝑑 = 51 ( )
𝐶𝑜 𝜌𝑙
Where
𝑢ℎ = Maximum vapour velocity through holes, m/s
𝐶𝑜 = Function of plate thickness, hole diameter and hole to perforated area ratio
𝜌𝑣 = density of vapour, kg/m³
𝜌𝑙 = density of liquid, kg/m³

Calculation maximum vapour velocity through holes, 𝑢ℎ

𝑚3 Eq 7.33
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑣𝑎𝑝𝑜𝑢𝑟 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 ( 𝑠 )
𝑢ℎ =
𝐴ℎ (𝑚2 )

Since 𝐶𝑜 is the function of plate thickness, hole diameter and hole to perforated area ratio, it can
be defined as the following

2
𝐴ℎ 𝑑ℎ
= 0.9 ( ) Eq 7.34
𝐴𝑝 𝐼𝑝

The value of 𝐼𝑝 must be in the range of 2.5 to 4.0 of hole diameter hence, the value of 3 is chosen
to calculate 𝐼𝑝
Eq 7.35
𝑃𝑖𝑡𝑐ℎ ℎ𝑜𝑙𝑒, 𝐼𝑝 = 3 × 𝑑ℎ

The value of 𝐶𝑜 can be determined in the figure below

29
 Figure 7: Discharge coefficient for sieve plates

𝑚3
9.63 𝑠 𝑚
𝑢ℎ = = 17.61
0.55 𝑚2 𝑠

To determine value of 𝐶𝑜 , take the ratio of plate thickness and hole diameter to be 1 and the
𝐴ℎ
pitch hole and ratio of is given by:
𝐴𝑝

𝑃𝑖𝑡𝑐ℎ ℎ𝑜𝑙𝑒, 𝐼𝑝 = 3 × 5 = 15

𝐴ℎ 5 2
= 0.9 ( ) × 100% = 10%
𝐴𝑝 15

Hence, the value of 𝐶𝑜 is 0.84.

17.61 2 1.41
ℎ𝑑 = 51 ( ) = 31.99 𝑚𝑚 𝑙𝑖𝑞𝑢𝑖𝑑
0.84 991.73

30
Calculation of residual head
12.5 × 10³ Eq 7.36
ℎ𝑟 =
𝜌𝑙
12.5 × 103
ℎ𝑟 =
991.73
ℎ𝑟 = 12.60 𝑚𝑚 𝑙𝑖𝑞𝑢𝑖𝑑

Therefore, total pressure drop can be calculated as below

Eq 7.37
ℎ𝑡 = ℎ𝑑 + (ℎ𝑤 + ℎ𝑜𝑤,𝑚𝑎𝑥 ) + ℎ𝑟

ℎ𝑡 = 31.99 + (50 + 26.12) + 12.60 = 120.18 𝑚𝑚 𝑙𝑖𝑞𝑢𝑖𝑑

By converting the total pressure drop to Pa, equation below is used

ΔP = 9.81 × 10−3 ℎ𝑡 𝜌𝑙 Eq 7.38

ΔP = 9.81 × 10−3 × 120.71 × 991.73 = 1174.37 𝑃𝑎 = 0.012 𝑏𝑎𝑟

Checking whether the pressure drop is suitable or not

No of trays: 13 (theoretical)
Tray spacing: 600 mm
𝑃 Eq 7.39
< 22% 𝑇𝑠
𝑆𝐺 × 𝑇𝑛 × 𝑇𝑠
𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑙𝑖𝑞𝑢𝑖𝑑
𝑆𝐺 = = 0.99
𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟
120.71
< 0.22 × 0.6
0.99 × 13 × 600
0.016 < 0.132
Therefore, the value is said to fulfil the condition is acceptable.

31
 x) Determination of downcomer design

Calculating downcomer backup in clear liquid using equation below (Sinnot, 2005).
ℎ𝑏 = ℎ𝑡 + (ℎ𝑤 + ℎ𝑜𝑤 ) + ℎ𝑑𝑐 Eq 7.40

Where ℎ𝑑𝑐 can be calculated as follows:

𝐿𝑤𝑑 2 Eq 7.41
ℎ𝑑𝑐 = 166 ( )
𝜌𝑙 𝐴𝑚
𝐿𝑤𝑑 = Liquid flowrate in downcomer (assume same as liquid rate across the trays), kg/s
𝐴𝑚 = Either downcomer area, Ad or clearance area under downcomer, Aap (which is smaller), m²

2
14.63
ℎ𝑑𝑐 = 166 ( )
991.73 × 0.0908

ℎ𝑑𝑐 = 4.38 𝑚𝑚
Therefore,
ℎ𝑏 = 115.18 𝑚𝑚 + (50𝑚𝑚 + 20.59 𝑚𝑚) + 4.38 𝑚𝑚
ℎ𝑏 = 190.15 𝑚𝑚 ≈ 0.19𝑚
By comparing ℎ𝑏 value with tray spacing
1
ℎ𝑏 < (𝐼 + ℎ𝑤 )
2 𝑡
1
0.19 𝑚 < (0.6 𝑚 + 0.05𝑚)
2
0.19 𝑚 < 0.325 𝑚
Therefore, the condition is said to be fulfilled.

xi) Calculating downcomer residence time, tr

𝐴𝑑 ℎ𝑏 𝜌𝑙 Eq 7.42
𝑡𝑟 =
𝐿𝑤𝑑
(0.86)(0.196)(991.73)
𝑡𝑟 = = 11.45 𝑠
(14.63)
32
 xii) Calculation for perforated area

Perforation area can be reduced by the obstruction that is caused by the support rings and
beams as well as the use of calming zones. Calming zones are the unperforated strips of the inlet
and outlet sides of the plate. The recommended value is between 100 mm to 1500 mm and taking
50 mm as normal value used (Sinnot, 2005).

𝐼𝑤 2.27 Eq 7.43
= = 0.75
𝐷𝑐 3.03

Figure 8:Relation between angle subtended by chord, chord height and chord length

Therefore, 𝜃 = 105°
𝐴𝑛𝑔𝑙𝑒 𝑠𝑢𝑏𝑡𝑒𝑛𝑑𝑒𝑑 𝑏𝑦 𝑡ℎ𝑒 𝑒𝑑𝑔𝑒 𝑜𝑓 𝑡ℎ𝑒 𝑝𝑙𝑎𝑡𝑒 = 180° − 105° = 75°

Calculating mean length for underperforated edge strips, Lus

𝑎𝑛𝑔𝑙𝑒 𝑠𝑢𝑏𝑡𝑒𝑛𝑑𝑒𝑑 𝑏𝑦 𝑡ℎ𝑒 𝑒𝑑𝑔𝑒 𝑜𝑓 𝑡ℎ𝑒 𝑝𝑙𝑎𝑡𝑒(°) Eq 7.44

𝐿𝑢𝑠 = (𝐷𝑐 − 𝑊𝑢𝑠 )π ×
180°
75°
𝐿𝑢𝑠 = (3.03 − 0.05)π × = 3.90 𝑚
180°

33
Calculating area of unperforated edge strips, Aus
Eq 7.45
𝐴𝑢𝑠 = 𝑊𝑢𝑠 × 𝐿𝑢𝑠
𝐴𝑢𝑠 = 0.05𝑚 × 3.90𝑚 = 0.19𝑚²

Calculating mean length of calming zone, Lcz

𝐿𝑐𝑧 = 𝐼𝑤 + 𝑊𝑢𝑠 Eq 7.46

𝐴𝑢𝑠 = 2.27𝑚 × 0.05𝑚 = 2.32 𝑚

Calculating area of calming zone, Acz

Eq 7.47
𝐴𝑐𝑧 = 2(𝐿𝑐𝑧 × 𝑊𝑢𝑠 )
𝐴𝑐𝑧 = 2(2.32𝑚 × 0.05𝑚) = 0.232 𝑚²

Calculating total area of perforation, Ap,

Eq 7.48
𝐴𝑝 = 𝐴𝑎 − 𝐴𝑢𝑠 − 𝐴𝑐𝑧

𝐴𝑝 = 5.47 − 0.19 − 0.232 = 5.04𝑚²

By calculating the ratio of hole area, Ah and perforated area, Ap, and then referring to
figure below, the ratio of pitch hole to hole diameter. lp/dh can be obtained.

𝐴ℎ
= 0.11
𝐴𝑝

Figure 9: Relation between hole area and pitch

34
 The normal value of 𝑙𝑝/𝑑ℎ is between 2.5 to 4. If the value is in this range, the calculation
is acceptable otherwise, all the calculation need to be repeated and recalculated. From the graph,
the value of 𝑙𝑝/𝑑ℎ is 2.9 hence the calculation is acceptable.

CHEMICAL DESIGN SPECIFICATION SHEET

Main Properties
Diameter 3.03 m
Area 7.195 m²
Tray spacing 0.6 m
No. of trays 13
Height 9.8 m
Feed Location 7
Liquid flow arrangement
Cross-flow (single pass)
Material of Construction

Stainless Steel 316

Plate properties
Downcomer Area,
0.86 m² Pitch hole, Ip 20 mm
Ad
Active Area, Aa 5.47 m² Weir length, Iw 2.27 m

Net Area, An 6.33 m² Plate thickness 5 mm

Hole Area, Ah 0.55 m² Plate Pressure Drop 0.012 bar

Downcomer
Weir Height, Hw 50 mm 11.45 s
residence time, tr

No. of holes 28 018 Perforated Area 5.04 m²

35
 7.4.3 MECHANICAL DESIGN OF ETHANOL SEPARATION TOWER

7.4.3.1 Determination of Design Pressure and Temperature

Design Pressure and Temperature need to be higher than temperature and pressure
operating. Therefore, 10% margin is used for design temperature and pressure (Sinnot, 2005).

110
𝐷𝑒𝑠𝑖𝑔𝑛 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = × 𝑂𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒 Eq 7.49
100

110
𝐷𝑒𝑠𝑖𝑔𝑛 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = × 2.5 𝑏𝑎𝑟 = 2.75 𝑏𝑎𝑟
100

2.75 𝑏𝑎𝑟 ≈ 0.275 𝑁/𝑚𝑚²

110
𝐷𝑒𝑠𝑖𝑔𝑛 𝑇𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 = × 𝑂𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 𝑇𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 Eq 7.50
100

110
𝐷𝑒𝑠𝑖𝑔𝑛 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = × 111.5°𝐶 = 122.65 °
100

122.65 °𝐶 ≈ 395.8 𝐾

7.4.3.2 Determination of Material of Construction used and its Maximum

Allowable Stress
Material of Construction (MOC) must be chosen wisely so that the material can withstand
temperature and pressure operating condition. There are many types of MOC such as carbon steel,
stainless steel, alloy and others.

Since one of the component involved in the separation is ethanol and said to be highly
corrode, thus, carbon steel is not suitable for material of construction. Hence, the MOC chosen is
stainless-steel 316.

The maximum allowable stress is determined based on MOC as well as the design pressure
and temperature. Below is the table for maximum allowable stress value.

36
 Figure 10: Typical design stress for plate

To get the design stress at suitable material of construction, interpolation was made at the
design temperature.

Temperature (°C) Maximum allowable stress (N/mm²)

100 150
122.65 S
150 135

150 − 100 135 − 150

=
150 − 122.65 135 − 𝑆

𝑆 = 143.205 𝑁/𝑚𝑚²

7.4.3.3 Determination of Welded Joint Efficiency and Corrosion Allowance for

tower
Welded joint strength will depend on the quality of welding as well as type joint. The
common values of welded joint efficiency are listed in the table below. A value of 1 shows that
the welded joint is strong enough for the plate. The higher the degree of radiography, the higher
the quality of welded joint (Sinnot, 2005).

37
 Figure 11: Table of welded joint efficiency

Corrosion allowance is an additional thickness to metal in case the wall of vessel corrodes
due to components flow. For carbon and low-alloy steel, corrosion allowance of 2 mm is
recommended to be used. In any case that have higher component concentration, a larger corrosion
allowance of 4 mm is recommended to be used (Sinnot, 2005).

7.4.3.4 Determination of minimum wall thickness

Minimum wall thickness is the thickness of vessel that is suitable for the vessel to support
its weight and any other loads. Minimum wall thickness can be calculated based on equation below
(Sinnot, 2005).

𝑃𝑖 𝐷𝑖
𝑡= Eq 7.51
2𝑆𝐸 − 1.2𝑃𝑖

Where 𝑃𝑖 is design pressure, N/mm2

𝐷𝑖 is diameter of the column, m

𝑆 is maximum allowable stress, N/mm2

𝐸 is welded joint efficiency

(0.275)(3030)
𝑡=
2(143.21)(1) − 1.2(0.275)

𝑡 = 2.91 𝑚𝑚

By adding corrosion allowance of 2mm

𝑡 = 2.91 𝑚𝑚 + 2𝑚𝑚

𝑡 = 4.91 𝑚𝑚 ≈ 5𝑚𝑚
38
 7.4.3.5 Determination of types of domed head used
The choice of heads and closure are important for covers of manways. Besides, it must be
chosen to withstand the operating pressure. There are three types of domed head which is
hemispherical, ellipsoidal, and torispherical. The types of head used need to be determine by
calculating its thickness. The thickness should be almost the same as the minimum wall thickness
calculated previously. The thickness for the types of head used can be calculated as follow.

 Hemispherical head

Hemispherical head is the strongest closure for domed head. It is used for high pressure
vessel and the cost is also much higher compared to other two closure. For cylinder-shaped vessel,
by taking Poisson’s ratio as 3 for steel, the thickness can be calculated as follows. The same
equation is to be used for spherical shaped vessel (Sinnot R. a., 2009).

𝑃𝑖 𝐷𝑖
𝑡= Eq 7.52
4𝑆𝐸 − 0.4𝑃𝑖

(0.275)(3030)
𝑡=
4(143.21)(1) − 0.4(0.275)

𝑡 = 1.45 𝑚𝑚

By adding corrosion allowance

𝑡 = 1.45 𝑚𝑚 + 2𝑚𝑚 = 3.45 𝑚𝑚

39
  Ellipsoidal head

Ellipsoidal head can also be used for high pressure vessel. For pressure above 15 bar,
ellipsoidal head is more recommended to be used (Sinnot R. a., 2009). The thickness of Ellipsoidal
head can be calculated as follows.

𝑃𝑖 𝐷𝑖 Eq 7.53
𝑡=
2𝑆𝐸 − 0.2𝑃𝑖

(0.275)(3030)
𝑡=
2(143.21)(1) − 0.2(0.275)

𝑡 = 2.91 𝑚𝑚

By adding corrosion allowance

𝑡 = 2.91 𝑚𝑚 + 2𝑚𝑚 = 4.91 𝑚𝑚

 Torispherical head

Torispherical head is commonly used for vessel operating up to 15 bar. It can also be used for
higher pressure, however, for pressure above 10 bar, the cost of this closure will be higher (Sinnot
R. a., 2009). The thickness of Ellipsoidal head can be calculated as follows:

40
 0.885𝑃𝑖 𝑅𝑐 Eq 7.54
𝑡=
𝑆𝐸 − 0.1𝑃𝑖

0.885(0.275)(3030)
𝑡=
(143.21)(1) − 0.1(0.275)

𝑡 = 5.15 𝑚𝑚

By adding corrosion allowance

𝑡 = 5.15 𝑚𝑚 + 2𝑚𝑚 = 7.15 𝑚𝑚

Since ellipsoidal has the similar thickness as the minimum wall thickness, thus,
ellipsoidal head will be chosen for the closure.

7.4.3.6 Determination dead weight of vessel

For a preliminary design calculation, the approximate dead weight of vessel including the
domed heads can be calculated as follows (Sinnot, 2005).
Eq 7.55
𝑊𝑣 = 𝐶𝑤 𝜋𝜌𝑚 𝑔(𝐻𝑣 + 0.8𝐷𝑚 )𝑡

Where 𝑊𝑣 = total weight of shell including external and internal fittings, N

𝐶𝑤 = a factor to account for weight of nozzles, manways and internal supports where 1.08 for vessel
with only few fittings and 1.15 for distillation columns or similar vessel with several manways,
plate support rings or equivalent fittings.

𝐻𝑣 = height or length of vessel, m

𝜌𝑚 = density of vessel material, kg/m3

𝑔 = gravitional acceleration, 9.81 m/s

𝑡 = wall thickness, m

𝐷𝑚 = mean diameter of vessel (Di + t × 10-3), m

41
However, for vessel using steel as MOC, the above equation can be rewrite as

𝑊𝑣 = 240𝐶𝑤 𝐷𝑚 𝑔(𝐻𝑣 + 0.8𝐷𝑚 )𝑡 Eq 7.56

The total weight of vessel will be affected by the types of insulation used. There many
types of insulation but the most commonly used is foam glass, mineral woo, fiberglass and calcium
silicate. Below are the types of insulation and their densities.

Table 21: Table of insulation used and their densities

Types of insulation Density (kg/m3)

Foam glass 150
Mineral wool 130
Fiberglass 100
Calcium Silicate 200

Dead weight of vessel

𝑊𝑣 = 240(1.15)(3.03 + 0.005)(9.81)(9.8 + 0.8(3.03 + 0.005))5

𝑊𝑣 = 51214.53 𝑁 ≈ 51.21 𝑘𝑁

Calculating weight of plate

𝜋𝐷2 𝜋(3.03)²
𝑃𝑙𝑎𝑡𝑒 𝑎𝑟𝑒𝑎 = = = 7.21𝑚²
4 4

𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑝𝑙𝑎𝑡𝑒 𝑖𝑛𝑐𝑙𝑢𝑑𝑖𝑛𝑔 = 𝑤𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑓𝑖𝑡𝑡𝑖𝑛𝑔 × 𝑝𝑙𝑎𝑡𝑒 𝑎𝑟𝑒𝑎

𝑘𝑁
𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑝𝑙𝑎𝑡𝑒 𝑖𝑛𝑐𝑙𝑢𝑑𝑖𝑛𝑔 𝑙𝑖𝑞𝑢𝑖𝑑 = 1.2 × 7.21 𝑚2 = 8.65𝑘𝑁
𝑚²

For 13 plates

𝑇𝑜𝑡𝑎𝑙 𝑤𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑝𝑙𝑎𝑡𝑒 = 13 × 8.65 𝑘𝑁 = 112.49 𝑘𝑁

42
Calculating weight of insulation

Types of insulation used is mineral wool which have density 130 kg/m3. By taking
thickness of insulator to be 50mm,

Eq 7.57
𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑖𝑛𝑠𝑢𝑙𝑎𝑡𝑖𝑜𝑛 = 𝜋𝐷𝑖 𝐻𝑣 × 𝑡𝑤

𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑖𝑛𝑠𝑢𝑙𝑎𝑡𝑖𝑜𝑛 = 𝜋 × 3.03 × 9.8 × (50 × 10−3 ) = 4.66 𝑚³

Thus, weight of insulation

Eq 7.58
𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑖𝑛𝑠𝑢𝑙𝑎𝑡𝑖𝑜𝑛 = 𝑉𝑖 × 𝜌𝑚 × 𝑔

𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑖𝑛𝑠𝑢𝑙𝑎𝑡𝑖𝑜𝑛 = 4.66 × 130 × 9.81 = 5.95 𝑘𝑁

This value is double to allow fitting. Hence,

𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑖𝑛𝑠𝑢𝑙𝑎𝑡𝑖𝑜𝑛 = 11.9 𝑘𝑁

𝑇𝑜𝑡𝑎𝑙 𝑤𝑒𝑖𝑔ℎ𝑡 = 𝐷𝑒𝑎𝑑 𝑤𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑣𝑒𝑠𝑠𝑒𝑙 + 𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑝𝑙𝑎𝑡𝑒 + 𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑖𝑛𝑠𝑢𝑙𝑎𝑡𝑖𝑜𝑛

𝑇𝑜𝑡𝑎𝑙 𝑤𝑒𝑖𝑔ℎ𝑡 = 51.21 𝑘𝑁 + 112.49 𝑘𝑁 + 11.9 𝑘𝑁 = 175.6 𝑘𝑁

7.4.3.7 Calculating wind loading

The calculation of wind loading will be significant to a tall vessel due to the wind pressure.
The vessel which allow wind loading will act as cantilever beam and thus, the bending moment
can be calculated as follows:

𝑊𝑥 2 Eq 7.59
𝑀𝑥 =
2

Where 𝑥 = height of vessel

𝑊 = wind load per unit length, N/m

The value of W will depend on the wind pressure at certain condition. According to Sinnot
et al. (2009), for preliminary design, a wind speed of 160 km/h can be used. Thus, by using this
value, the dynamic wind pressure can be calculated as follows:
43
 Eq 7.60
𝑃𝑤 = 0.05 𝑢𝑤 ²

Where 𝑢𝑤 is wind velocity, m/s

Therefore, by utilizing all the values calculated by using equation above, loading, W can
be calculated as (Note that W = Fw):
Eq 7.61
𝐹𝑤 = 𝑃𝑤 × 𝐷𝑚𝑒𝑎𝑛

Where D mean is mean diameter and can be calculated as follows

𝐷𝑚𝑒𝑎𝑛 = 𝐷𝑖 + 𝐷𝑖 (𝑡𝑣 + 𝑡𝑖𝑛𝑠 )

𝑘𝑚 2 𝑁
𝑃𝑤 = 0.05 (160 ) = 1280
ℎ 𝑚²

𝐷𝑚𝑒𝑎𝑛 = 3.03 + 3.03 ((5 + 75) × 10−3 ) = 3.27𝑚

𝑁 𝑁
𝐹𝑤 = 1280 𝑚² × 3.27𝑚 = 4188.67 𝑚

Hence,

(4188.67)(9.8)2
𝑀𝑥 =
2

𝑀𝑥 = 201140 𝑁𝑚 ≈ 201.4 𝑘𝑁𝑚

7.4.3.8 Analysis of stress

Analysis of stress need to be taken in account to ensure the stresses can withstand the
process system in the vessel. The analysis of stress comprises:

 Pressure Stress

𝑃𝐷𝑖 Eq 7.62
𝐶𝑖𝑟𝑐𝑢𝑚𝑓𝑒𝑟𝑒𝑛𝑡𝑖𝑎𝑙 𝑠𝑡𝑟𝑒𝑠𝑠, 𝜎ℎ =
2𝑡

(0.25)(3030)
𝐶𝑖𝑟𝑐𝑢𝑚𝑓𝑒𝑟𝑒𝑛𝑡𝑖𝑎𝑙 𝑠𝑡𝑟𝑒𝑠𝑠, 𝜎ℎ = = 75.75 𝑁/𝑚𝑚²
2(5)

44
 𝑃𝐷𝑖
𝐿𝑜𝑛𝑔𝑖𝑡𝑢𝑑𝑖𝑛𝑎𝑙 𝑠𝑡𝑟𝑒𝑠𝑠, 𝜎𝐿 =
4𝑡

(0.25)(3030)
𝐿𝑜𝑛𝑔𝑖𝑡𝑢𝑑𝑖𝑛𝑎𝑙 𝑠𝑡𝑟𝑒𝑠𝑠, 𝜎𝐿 = = 37.88 𝑁/𝑚𝑚²
4(5)

 Dead weight stress

𝑊𝑧 Eq 7.63
𝜎𝑤 =
𝜋(𝐷𝑖 + 𝑡)𝑡

Where Wz is the total weight of vessel. For vessel that is above support system, the value of dead
weight stress is said to be compressive (negative). Besides, if the vessel operated below the support
system, it is said to be tensile (positive). Since most vessel will operate above the support system,
the value of dead weight stress is compressive (negative) (Sinnot R. a., 2009).

(51.21 × 103 )
𝜎𝑤 = = 1.07 𝑁/𝑚𝑚²
𝜋(3030 + 5)5

 Bending stress

Bending stress is the result from bending moment occurred at the equipment. The value of
bending stress will be either tensile (positive) or compressive (negative) depends on their location.
Usually, for upwind, the bending stress will be tensile (positive) and at downwind, the bending
stress will be compressive (negative) (Sinnot R. a., 2009). Bending stress can be calculated as
follows:

𝑀 𝐷𝑖 Eq 7.64
𝜎𝑏 = ± ( + 𝑡)
𝐼𝑣 2

Where M is the bending moment occur due to wind loading and Iv is the second moment of area
of the vessel at the bending point. Therefore, Iv can be calculated as follows:

𝜋
𝐼𝑣 = (𝐷4 − 𝐷𝑖 ⁴) Eq 7.65
64 𝑜

45
 𝜋
𝐼𝑣 = (3040⁴ − 3030⁴) = 5.49 × 1010 𝑚𝑚⁴
64

Hence, bending stress

201.14 × 10³ 3030

𝜎𝑏 = ± ( + 5) = ±0.056 𝑁/𝑚𝑚²
5.49 × 1010 2

 Total longitudinal stress

The total of longitudinal stress can be calculated as follows:

𝜎𝑧 = 𝜎𝑙 + 𝜎𝑤 ± 𝜎𝑏 Eq 7.66

𝜎𝑧 (𝑢𝑝𝑤𝑖𝑛𝑑) = 𝜎𝑙 + 𝜎𝑤 + 𝜎𝑏 = 37.88 + (−1.07) + 0.056 = 36.81 𝑁/𝑚𝑚²

𝜎𝑧 (𝑑𝑜𝑤𝑛𝑤𝑖𝑛𝑑) = 𝜎𝑙 + 𝜎𝑤 − 𝜎𝑏 = 37.88 + (−1.07) − 0.056 = 36.79 𝑁/𝑚𝑚²

𝑑𝑖𝑓𝑓𝑒𝑟𝑒𝑛𝑐𝑒 𝑏𝑒𝑡𝑤𝑒𝑒𝑛 𝑝𝑟𝑖𝑛𝑐𝑖𝑝𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠 = 75.75 − 36.79 = 38.95 𝑁/𝑚𝑚²

The value of total longitudinal stress need to be below the design stress. The relationship is given
as follows:

𝑁
𝜎𝑧 < 𝑆 (𝑢𝑛𝑖𝑡 )
𝑚𝑚2

(36.81 + 36.79)𝑁/𝑚𝑚² < 143.205 𝑁/𝑚𝑚²

 Critical buckling stress

In some cases, when the total longitudinal stress which due to combined loading is
compressive (negative), the vessel will experience failure due to buckling (elastic instability).
Thus, for a curve plate, the critical buckling stress can be calculated as follows:

𝐸𝑌 𝑡
𝜎𝑐 = ( ) Eq 7.67
√3(1 − 𝑣 2 ) 𝑅𝑝

46
Where,

𝑣 = Poisson’s ratio

𝑅𝑝 = Radius of curvature, mm

𝑡 = wall thickness, mm

𝐸𝑌 = Young’s Modulus, N/mm2 (Cambridge University Enginering Department, 2003)

The radius of curvature is the radius from the top of curved heads to its centre. The radius
of curvature is illustrated in the figure below:

According the above figure, the terms can be defined as:

𝑟1 = crown radius

𝑟2 = knuckle radius

ℎ1 = straight flange

ℎ2 = height of crown radius

ℎ2 = total internal height

𝑆 = wall thickness

ℎ𝑎 = outer diameter

47
According to the above figure, Rp is denoted as h2

𝑅𝑝 = 0.225𝐷𝑜 − 0.635𝑡 = 0.225(3.04) − 0.635(0.005) = 0.68 𝑚

By taking Young Modulus of 215GPa = 215 000 𝑁/𝑚𝑚²

215 000 5
𝜎𝑐 = ( ) = 956.7𝑁/𝑚𝑚²
√3(1 − (0. 3)2 ) 680

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

𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒 𝑠𝑡𝑟𝑒𝑠𝑠 = 𝜎𝑤 + 𝜎𝑏 Eq 7.68

𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒 𝑠𝑡𝑟𝑒𝑠𝑠 = 1.07 + 0.0056 = 1.08 𝑁/𝑚𝑚²

The maximum compressive stress is below the buckling stress hence the design is satisfied.

7.4.3.9 Determination the Design of Vessel Support

Vessel support is designed according to some factors which are size and shape of vessel,
weight of vessel, design temperature and pressure, vessel location and arrangement and external
and internal fittings (Sinnot R. a., 2009). There are two types of vessel support that are saddle
support and skirt support. Saddle support is usually for short and horizontal vessel and skirt is for
tall and vertical vessel. Support is important for supporting the vessel as well as for ease excess to
vessel and for inspection and maintenance. The design should consider the weight of vessel and
wind loads. For skirt support, the design can either be straight or conical pattern (Sinnot R. a.,
2009). Since distillation column is a vertical vessel, thus the suitable support used is skirt support.

Depending on the types of insulation used for skirt, the dimension of skirt can be obtained.
The height of skirt can be taken as 1.5 x Diameter of bottom (Icarus Corporation, 1998).
Approximate weight need to be calculated by assuming the vessel is full of liquid to estimate the
maximum dead weight of load on skirt. Thus, this can be calculated as follows:

𝜋𝐷𝑖 ²𝐻𝜌𝑔 Eq 7.69

𝐴𝑝𝑝𝑟𝑜𝑥𝑖𝑚𝑎𝑡𝑒 𝑤𝑒𝑖𝑔ℎ𝑡 (𝑁) =
4

48
Where,

𝜌 = Density of Liquid, kg/m3

𝐻 = Height of vessel, m

𝜋(3.03)2 (9.8)(998)(9.81)
𝐴𝑝𝑝𝑟𝑜𝑥𝑖𝑚𝑎𝑡𝑒 𝑤𝑒𝑖𝑔ℎ𝑡 (𝑁) = = 691.83 𝑘𝑁
4

The thickness of skirt need to be sufficient to support the vessel. The thickness of vessel must not
less than 6mm and thus it is first assumed to be 10 mm (Sinnot R. a., 2009). This value may change
after detailed calculation is made. Analysis of stress for skirt can be calculated as follows:

Bending moment of skirt

𝐹𝑤 (𝑓𝑟𝑜𝑚 𝑣𝑒𝑠𝑠𝑒𝑙) × (𝐻 + 𝐻𝑠 ) Eq 7.70

𝑀𝑠 =
2

𝐻𝑠 = 1.5 × 𝐵𝑜𝑡𝑡𝑜𝑚 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = 1.5 × 2.2 = 3.3 𝑚

4.19 × (9.8 + 3.3)

𝑀𝑠 = = 359.41 𝑘𝑁𝑚
2

Bending stress skirt

4𝑀𝑠
𝜎𝑏𝑠 = Eq 7.71
𝜋(𝐷𝑠 + 𝑡𝑠𝑘 )

4(359.41 × 103 × 103 )

𝜎𝑏𝑠 = = 4.97𝑁/𝑚𝑚²
𝜋(3030 + 10)

Dead weight in skirt

𝑊𝑣 Eq 7.72
𝜎𝑤𝑠 =
𝜋(𝐷𝑠 + 𝑡𝑠𝑘 )𝑡𝑠𝑘

Where Wv is the total weight of vessel, N. The dead weight stress need to be calculated for test
condition and operating condition. Test conditions are when the vessel is full of water for hydraulic
test (Sinnot R. a., 2009).

691.83 × 103
𝜎𝑤𝑠 (𝑡𝑒𝑠𝑡) = = 7.24 𝑁/𝑚𝑚²
𝜋(3030 + 10)10

49
 51.21 × 103
𝜎𝑤𝑠 (𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔) = = 0.54 𝑁/𝑚𝑚²
𝜋(3030 + 10)10

Resultant stress in skirt

Eq 7.73
𝜎𝑠 (𝑡𝑒𝑛𝑠𝑖𝑙𝑒) = 𝜎𝑏𝑠 − 𝜎𝑤𝑠 (𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔)

𝜎𝑠 (𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒) = 𝜎𝑏𝑠 + 𝜎𝑤𝑠 (𝑡𝑒𝑠𝑡)

𝜎𝑠 (𝑡𝑒𝑛𝑠𝑖𝑙𝑒) = 4.97 − 0.54 = 4.43 𝑁/𝑚𝑚²

𝜎𝑠 (𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒) = 4.97 + 7.24 = 12.21 𝑁/𝑚𝑚²

The thickness of skirt chosen must not exceed the following condition

𝜎𝑠 (𝑡𝑒𝑛𝑠𝑖𝑙𝑒) < 𝑆𝑠 𝐸 sin 𝜃𝑠

4.43 < (143.205)(1) sin 90°

4.43 < 143.205

𝑡𝑠𝑘
𝜎𝑠 (𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒) < 0.125𝐸𝑌 ( ) sin 𝜃𝑠
𝐷𝑠

10
12.21 < 0.125(215 000) ( ) sin 90°
3030

12.21 < 88.70

Therefore, the thickness is 12mm after adding corrosion allowance.

7.4.3.10 Determination of bolt and flange

The selection of anchor bolts is based on the Scheiman guidelines (Sinnot, 2005):
a) Bolts size less than 25 mm

b) Minimum number of bolts is 8

c) Use multiple of 4 bolts

d) Bolt pitch should not less than 600 mm

50
Let the bolt diameter to be 3.5m

𝐶𝑖𝑟𝑐𝑢𝑚𝑓𝑒𝑟𝑒𝑛𝑐𝑒 𝑜𝑓 𝑏𝑜𝑙𝑡 𝑐𝑖𝑟𝑐𝑙𝑒 = 3500 𝜋

Number of bolt required at minimum recommenced bolt spacing

3500 𝜋
𝑁𝑜 𝑜𝑓 𝑏𝑜𝑙𝑡 = = 18.3 𝑏𝑜𝑙𝑡𝑠 ≈ 18 𝑏𝑜𝑙𝑡𝑠
600
Bolt area can be calculated as follows
1 4𝑀𝑠 Eq 7.74
𝐴𝑏 = [ − 𝑊]
𝑁𝑏 𝑓𝑏 𝐷𝑏

Where

𝐴𝑏 = Area of one bolt at the rot pf the thread, 𝑚𝑚2

𝑁𝑏 = Number of bolts

𝑓𝑏 = Maximum allowable bolt stress, N/𝑚𝑚2 (typical value 125 N/𝑚𝑚2)

𝑀𝑠 = bending moment at the base, Nm

𝑊 = Weight of vessel, N

𝐷𝑏 = Bolt circle diameter, m

1 4(359.41 × 103 )
𝐴𝑏 = [ − 175.6 × 10³] = 104.51 𝑚𝑚²
(18)(125) 3.5

105.41 × 4
𝐵𝑜𝑙𝑡 𝑟𝑜𝑜𝑡 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = √ = 11.58 𝑚𝑚
𝜋

The base ring must be wide enough to distribute the load to the foundation. Total compressive
load on base rings is

4𝑀𝑠 𝑊
𝐹𝑏 = [ + ] Eq 7.75
𝜋𝐷𝑠 ² 𝜋𝐷𝑠

Where,

𝐹𝑏 = Compressive Load on base ring, N/m

𝐷𝑠 = Skirt Diameter, m

51
 4(359.41 × 103 ) 175.6 × 10³
𝐹𝑏 = [ + ] = 68291.51 𝑁/𝑚
𝜋(3.03)² 𝜋(3.03)

The minimum width base ring is given below

𝐹𝑏 1 Eq 7.76
𝐿𝑏 = ×
𝑓𝑐 10³

Where,
L𝑏 = Base ring width, mm
𝑓𝑐 = maximum allowable bearing pressure on the concrete (typical vaue 3.5 to 7 N/𝑚𝑚²)

68291.51 1
𝐿𝑏 = × = 13.66 𝑚𝑚
5 10³

52
Flange
Flange can be calculated based on the pipe diameter. The dimension of flange can be obtained
from the figure below (Wade):

Figure 12: Typical standard flange design

The pipe or nozzle diameter can be calculated using the following formula since it is a stainless-
steel type:

𝑑𝑝𝑖𝑝𝑒 = 260𝐺 0.52 𝜌−0.37 Eq 7.76

53
Feed
21412.07
𝑀𝑎𝑠𝑠 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒, 𝐺 = = 5.95 𝑘𝑔/𝑠
3600

𝑑𝑝𝑖𝑝𝑒 (𝑓𝑒𝑒𝑑) = 260(5.95)0.52 (820.35)−0.37 = 55 𝑚𝑚

Distillate
12317.61
𝑀𝑎𝑠𝑠 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒, 𝐺 = = 3.42 𝑘𝑔/𝑠
3600

𝑑𝑝𝑖𝑝𝑒 (𝑑𝑖𝑠𝑡𝑖𝑙𝑙𝑎𝑡𝑒) = 260(3.42)0.52 (2.90)−0.37 = 332 𝑚𝑚

Bottom

9089.45
𝑀𝑎𝑠𝑠 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒, 𝐺 = = 2.52 𝑘𝑔/𝑠
3600

𝑑𝑝𝑖𝑝𝑒 (𝑏𝑜𝑡𝑡𝑜𝑚) = 260(2.52)0.52 (991.73)−0.37 = 33 𝑚𝑚

Table 22:Flange Dimension for T-101

FEED DISTILLATE BOTTOM

d1 76.1 355.6 48.3
D 160 490 130
b 14 22 14
h 32 - 26
d4 110 415 80
f 3 4 3
Bolting M12 M20 M12
Drilling No 4 12 4
d2 14 22 14
k 130 445 100
d3 88 385 62

54
 MECHANICAL DESIGN SPECIFICATION SHEET
Vessel
Internal Diameter 3.03 m
External Diameter 3.04 m
Height 9.8 m
Design Pressure 0.25 N/mm2
Material of Construction Stainless Steel 316
Maximum allowable stress 143.205 N/mm2
Wall thickness 5mm
No of bolts 18
Head and Closure
Types of Closure Elipsoidal
Welding Efficiency (Joint Factor) 1
Minimum thickness 4.91 mm
Corrosion allowance 2mm
Material of Construction
Stainless Steel 316
Column properties
Dead weight of vessel 51.21 kN
Weight of plates 112.49 kN
Weight of insulation 11.90 kN
Wind speed 160 km/h
Wind Pressure 1280 N/m2
Bending moment 201.14 kNm
Insulation Material Mineral Wool
Insulation Thickness 75 mm
Nozzle properties
Diameter of pipe (feed) 55 mm
Diameter of pipe (distillate) 332 mm
Diameter of pipe (bottom) 33 mm
Vessel Support
Type of support Skirt support
Material of construction Stainless Steel
Angle of support 90º
Young’s Modulus 2.0 GPa
Approximate weight 691.83 kN
Bending moment 359.41 kNm
Skirt thickness 12mm
Skirt height 3.3m

55
 References
B.E. Poling, J. P. (2001). The Properties of Gases and Liquids, 5th edition, Appendix A. New
York: McGraw Hil.

Branan, C. (2005). Rules of Thumb for Chemical Engineers. Burlington: Elsevier Inc.

Eduljee, H. E. (1958). Design of sieve-type distillation plates. Brit. Chem. Eng. 53, 14. .

Geankoplis, C. (2014). Transport Processes & Separation Process Principles (Includes Unit
Operation). Pearson Education Limited.

Kirkbride, C. G. (1944). Process design procedure for multicomponent fractionators.

National Center for Biotechnology Information. (2018, May). Retrieved from PubChem
Compound Database; CID=702: https://pubchem.ncbi.nlm.nih.gov/compound/702

Reid, R. C. (1977). The Properties of Gases and Liquids, 3rd edition. McGraw-Hill.

Robert H. Perry, D. W. (2008). Perry's Chemical Engineer Handbook, 8th Edition.

Sinnot, R. (2005). Chemical Engineering Design, Fourth Edition. Coulson and Richardson's
Chemical Engineering Series.

Wade, I. (n.d.). Wade Industrial Steam, Valve & Pipeline Specialist. Retrieved from Wade
Industrial:
http://www.wadeindustrial.co.za/downloads/Wade_Industrial_Flange_Tables.pdf

56