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‘Your Fingertips on
Corbuston cae
Cover David Whacter
Iageseurce: toMechanical Design Aspects for
High-Performance
Agitated Reactors
An understanding of the mechanical design
helps in specifying, maintaining and
revamping agitated reactor systems
IM. Siataus, HJ, Weis, W Himmelabach ond Sith
[wAsmarasi
=a
tnt te ee
See’ | a
arenes =
maa
Bato
steed tank retetor with r=
Mating mizer remains te bok
Nan of heehee! proses
dhatooe (CPD, While mixing ie
considered « materetachndly,
‘tear that cntnued tehnelapeal de
“lopment eater achieve the
Sntnotthonet dsgn demanded by
‘rer lnctesingefilency meds
‘Ae worldwide competion free
‘he CPI tera the pratt of
‘hee profuetion pani ven more
Smporan for proces detlopers and
Plant deign engineers to understand
The mechanical design aspects of a
{ated recone Proce denis oe
fin imei procedure of semical
‘tad there regirements on
‘the oe band and plato chanical
rstretenson he oer Chemical ad
technical eaglners Work together
{oreach the commen gl of opti
‘eactor design. Ad this knoe
tls important er lant operators and
tinintenanes engineers Ofen here
{enced to bons tho plant capacity
nd proces ocr y revamp ad
odifentions ofthe reactor: Oni
tearm of the mache) ond.
tins inthe exiting reaetor wl pe
‘eat eapensive flores
‘his rte ves an veviw of the
mechanical design anpect of pated,
Higtperfranee reactors that.
Ip im endenvers to spec, latin
‘ud also rte equpment. The a
cle is addressed to proces develop
fm plant designers, lane operators
tod ialatenance” engineer Fit,
the ator sc te eopoants are
agate on all rector
‘Sterna and on he wena
inci te sel stretare
In alton, the rile x= FIGURE 4 Mary ace re ota wit eion-
‘in retouene end vires gameplan oregon apeteaten
ion" phenoment aad bow
thee te cnadered: Mechel eae
pln eral rl eulg in safe
fd conomie operation of paar
feed vectors. Thr dale deserP-
tio, however, wold caso the spe
‘thir erie fr moe on mechanical
‘eas ee Alehanical ‘Sens, Chem,
Beng Decor 208, pp 36-12,
Process intensificntion
Higher prods in he CPL ca be
ine a8 higher entpot pr plant vk
‘es eer a a mate con-
$Sumptins ager with rede was,
‘dtr pdt quai nein fo
thon rinks oa als ee io
ead to reluoel mctnance Apr
from the ned, speciltycemals
prcrs also expect high ety
In prodctin fr ter ne market
The suns a th equipment roan
facture to ll thee euiements of
hp ins can be summarized
‘procs itm
‘anaiderahe progress. in proces
‘oteminton far mining bas alee
nen acieed ands til angoing 2
(One example in agated guild
eoctre 12 Bulk chemical reactors
tften caver gasce With inert compe:
‘ents cha ner wit a ad
Feu lare reactor witha capacity
Sn oxen of 1,000 2 Tel nina
us aperai regis preci ning
ube interaction Bebren station
Tdredynamies andthe saperine
‘ice qui and pae-food and outlet
‘rea ih he reoction Kinet fr
‘ptimum proces rl
Tor svceasul rector desi,
‘xideratin ns to be gien to the
Felatonsizbeewn al leant pe-
ameter Ths includes not aly the
Operating andten, adh os ta
ature, pressure aad tid proper
Fee but ale en az and spe al
Internal canpoents eae nbs
feed and lt pipes. sarge and
heatingan-cmling eaupeent) and
structural ponents sath as siendy
bearings), wel ar power Input oF
‘gation nea. Agtaton not nly
klies te proces rors, bat i also
{he source fal! mami ods that,
‘gust be cotsdored for the desi of
‘he actor uit Te abviou thatthehe tow pars
to
een ea
‘asa
Frieeo Fee
ee eee eee
se or eel a eae
‘ihncomporens phe cor ont meacss""*hysmueten aah on
conditions of intensified preceees | components, variety of aly
eed anew, integrated appronch fr | equipment also nds to be consié-
‘eastor dig, which cottders the | ered For example yesel uppers
tajtator andvesa sone uit | emul tke the form fa se betchet
reg design. Heat rchangers can
Design of agitated reactors |e divided into external aod intra
‘The dengn of apttar tnd reactors | type, The designe an ntrnal heat
starts by defining the prcess per | exchanger canbe lsd as plato,
mance and’ operating condsions | ert or tbe bundle There ee any
(Figure 1. The rele are the base | more aspect tobe considered te
‘engineering dete forthe rear an | ameter of th manhole erstriced
fgtatorinloing the main dimen-| by mechani or ructral need for
‘Hs ofall components impel type, | example this wool hae re
‘number efimpellrs, use and sped or | pct on the impeller desen to ensure
wer input respectively as deserbed | thatthe impels cold be inverted
In dealin several references (1) | into the ren If the tal too
‘Thesedaa are tbeinpt orth design | smal the impeller hub canbe of
work ofthe mechani enginere | epitdlamped deen or the blades
"he neat step is ta find the deal | maybe old
‘lance between the prose requ
rents and an easels machanesi | Computer-aided engineering
telacion ofthe ves agitator system. |The se ef caput forenoon
‘Aste opitatornemnertedviatheag: | parse har developed api over
Stator mounting Benge the vel wn | the let wo dade that be
‘gator eannet be tented ax parts | ene an dispense tl fe he me
‘mts beense ther dig mutually | bank dsign fags econ ad
lnueace ead her. Figure 2 shows | internal capone There the ue
imnavervow ofthe gecral reser. | of numeral simulta for exangle
‘ousand sts its key components. | computatinal fd dyeaioe (CFD)
"In adition to thoe hey agitate | sed fate clement nals (FEA), has
on
become anor se bx 40.
‘Thecompletow pattern inagiated
reators aa be emputed od val
ina with CPD calealations: Not oly
door this fata the understand
tng. of hydralyanmic. mechanisms,
‘it CFD daa also be ud the
Aetemination of the heat tensor
efits af ample hen exchange
‘rm Hydraulic ad such as pres
Alsen and ens based on ea
‘how votes ae celated ty CED,
fd then used se np fr FEA
"The mechani! beni of struc
tam such ae natural freuen,
ewer and dfemations canbe
‘eertaned wih FEA. The genera
Aeentages of tuner imaltions
inetd the flbwing
‘Reduced deopment tine, for
{aoe tine te market
‘Applicaton specie dimensioning
ff ymca ap their emgonets fa
faving i ing, energy end money
‘ Imprnement of plant saety
‘Iara re iit and operation
sf better planning of shutdown
nd maltenance nerve
+ Prevention fptentl eat and
‘nent dks a neal stage‘mera
Siete ermal ent
‘unto rane
seen epi
‘Seen i grime aon
bung impor prces
+ Foamy sul re tia nanerid ses rade he
+ Baked oor tino ec
None nln lows an nope of perma ep
+ Sain nnd pana raped
SE Seeger yy a
hes ase ei sel rt esse ie be es
Sintvenonsee er
‘Loads acting on the system
the eration and definition a te
‘leant ods ating uate seu
‘his especialy true fr ming. 2
gy demic proces in whieh
sides the atc ods considerable dy
‘ami fc cn alo bave gear
‘acts o he veel seractare
Fandanentl for wrolabl design
isthe eae awledge af the nuber
‘od naar ft tate and amie
forse and omens acting on the
ence and ie itera component
Ut hat exchanger, edn de
lta Typiea state loud ae weg,
‘eel presure and the racer te
posters wh tu ea ce
"The dymicydzaulie freee are
senate by the gitar alata
{liyat the impeller blades Doyen
fn the blade geomet, which etn
the flow diraion, there are Thee
The with axa fw deton
{howe with al ow dete
{howe ‘with oth aa and radia
fw dresion
igure $ shows a CFD-alulated
oapshot th ow pattern around»
Hat bade dis turbine, To undertand
the dynaaie nature of ing
sideration ho ob given to he fact
‘hat the earbulen few arse
Hie a tuneton of Une tod ie a
rotationally symmetric or in other
‘wor the forsee nting on each nd
Tidal Bide re not dea.
‘he result of thin nal Dow
shawn oa the left aid of Figure & ie
4 tree laded impeller The
tierence of the tangential
fore iF) at each Had (at
a>
tine leeds to teulsngra- FIGURE
alte Wit tickaown
lover radial re io
he distance beweon impale and
shat bearing, the bending moment
(a) can be eleclte by the fo
My=Rol o
‘The sum of al tangential fren in
fun generates a trgue (Mf) around
he after shat
Mather ®
or axially pumping impellers, an
al fre) rae tech ine,
Feeding toa eral xin thrust =
fod the flowing
a=W ®
‘The rel fa abuetorysale
fore mearoremnt sing sppropste
fealeuperitar or CFD are then usd
the opt forthe eben analy
‘eof the illaiae ds.
gute 5 depicts laboratory-scale
‘pale shalt which i egulpped wit
rnin ups fr bending moment
Sod tonoe measurement. The force
eaten can te ebalnd by using
‘Ameraoles concent
"The fore cents (Cp) are in
dlsdaal for cock impeller type and
‘oanty the magni of xi, an-
fet and rafal ores independent
the pelle damser Ie ema
fete the Slleving tren
Radial are coin
abl towed oer
* Axil ore soon Cy)
* Mangut fore eatin)
adil tree and arg are the pe
sary opt Sta fr he calelton of
the shat dame
Large sat ameter, as well as
large and pensive ect seal
‘warings ahah tee maybe
quien the eae of log and oer
hing agate tht depending on
the popes of the tra mats
"aT climate thse disadvantages,
the ue of tom steady bare
‘wich i an diol bearings he
halt end the tank, abrnted by
{he promt id — en be consid
“he ext advantages of belt
steady bewing restated in
‘able 1. Foeexampl, for 1Oamlong
haf the mansfacorng conta he
Complete aptatr canbe reduced by
soprocimanly $08, Svings can Ie
{chine ty te etn a the sha
diameter fo 24D mm to 18D,
ormpated Sn sal which would
nly provi a 10% saving The appl
ations that easily be rm ea
Iarngs de Oth large and tl
rectors, sha blk che reat
tra redo od large ry tar
tetas.
"While btom stasdy bearing offers
comerdl advantage forthe oi
ren sn aee ae sther apes
ensien ining te flowing:TABLET. suMMARY OF COST SAVINGS ACHIEVED BY INSTALLATION OF
'ABOTION STEADY SEARING FORTWO VESSELAGIIATOR DESIONS
+ A btom bering i a wearing part
{Higher som of wneahip (mainte:
‘nace spare parts and 0 on)
+ Wearing pet material Selecta as
tobe carly enalered
‘The veel design must withstand
the indued roe
‘A igh level of rcision is roid
far the alignment of the bearing to
the agittor kat aie
‘The val bl and he rneto inter.
tal ae exposed to considerable by
Aral lod. In earbulent conden
‘hone frees ean be elated Ey the
folowing equation:
cure tt “
Where cs the dag count, ps
he gid density, isthe proetad
ston of iterer baile, ed pipe or
‘ter and ithe low velo The
‘lermiaaion of ¢ i conducted by
‘measurements together with CFD
CCayputaton. Figure 6 tlustrates the
premurednebution oa bale ne
ion alot rom the velo el
‘The resus of such elelatins and
‘aperinett re he basing the
Saleeqoet mechanic dimensioning
‘fa vee internal companet
"The bara fen meting all
reactor ‘smpmnonts ate. primarily
fenertad by the agitator, Exceave
rations strane end defrmatone
‘internal eompanert and hr sp
ports canbe eausod by a weak vessel
rvctare and by Ineafientsxng
‘he flawing topics dicues oppor
‘le toed thee na
Vibration and resonance
When existing reactor are upgraded
torech higher producti set
fal to anerea the rononane fet
tmensoning of the veaelagiator
yom fra high eel of operational
Safe. Carles modifications can
‘hit the natural queries nto the
fra! ange and ream operaional
Problens. Fiat the relevant eet
ton spectra mist e ler Enon,
‘extation can be coud ther by
‘aft apd, posing hades or at.
Bulent vortex pet, Resonance
‘fas are often th reason for nie
tnd unsceptale vibrations tha end
to structaral damage of components
‘Ths cn seal in catly planned
Plant shutdowns and could also have
‘Design [Design 2
aoa dometer [mm 5000 | 000
Reactor helgh a 5000 | 1805
Length option sa | mm 5000 | 12600
Number otimpetes = B o
impater clomeier ()__| men 2500 | 2800
Motor power (Pa) 0 [a0
Sha spees OX) 2m fa [es
Shot ire Ne 723000 | 06
Moti of constuction |= tot [si6u
eure pure 6) [bar fre
son omer is) [wn boom beaing [10mm | 180mm
orerang 101mm [240m
Reine agicionpiceior [win bom booing [ors | a
eres rerung ‘woe |oo8
ote [as
'FGURE 7 inte vrs wound vsti) can bo soon ah»
‘Somat it arabe saeco vey ne aN
‘an impact on healt, safety and nv
‘omental
Blade pasting frequencies are de
{ined ype ype and shalt ped
‘Tovrea exetation rqucnce, the
‘evaliet Karan vortex detachment
frequencies (Figure 7, Ht ace fa
‘por diel to detarmin, The erst
‘Requency is decid bythe Strobel
‘umber (S)in Bquatin
fusS-ale ®
Pletseale mesturements cn, once
‘gsm, provide data forth local ve
Iii, bu CPD aultons give
‘nore compesbentive ad diferent
care ofthe etre ow pater,
shown in Figure right).
‘ven ifthe exciton frequencies
are wellknown, the design engineer
‘ao decide which type excitation
{stelevant odorant fora epee
component. This dca has t be
sade on a cae-y-cne ati ith
ae to avid any resonance caused
Uyeolseldence ofeacitaton with mat
ral frequencies
Vibration, which are caused
hy the dymimie nature ofthe x:
ing process are ineitable and ot
detriment a Long as they do ot
iced thecalulaed, ceoptable ine
{Wasity lee. This ensured when
theaystem' natural equenies are
‘cently distanced trom there
vant excitation spetea The dif.
hes between the natal egueney
find eritationfroqueney ie a7 In
the fled o! machine dynamics an
fcceplable mrgin is a7 215-205
tar
if this nton is not uled,
resonance iif = 08) or reenanes
‘tects amply even stall dynam
forces dratially. The mot impor
{tant natra frequency for agitator
inthe Int bending mde ofthe asia
tor sat, shih tho erie haf
peed
Fir fee overhung shaft with one
ee impale the aba length)
fd the tnpeller sass mare the
minting’ parameters iouencng
‘he shat ertial speedeso nt
FIGURE 6: ranured url eqn ofa eat xara sats cone
Eat teeuenees thet mun be vse fro opera
"LGURE 8. cncioase fh an aural Fegercy ing he ig prostes
‘utd eda oonance acs ise ah op
Correlation 6 shows that ove minor
‘hanger the shat length or pale
Fesiton can ead ta deat ange
tthe thls natural foequeney. Far
‘nore sopbistcatod cleat eth
sare roquied to determine the
fact N, when designing comoles
Shaft apstems, ach ex mule i
baller, mateshouldered or tepped
halts nd toten-beaing or hallow
‘aft ction,
‘Operating blow abv the shat
ington components ass be
‘onsidered with regard to ronan
Figure 8 shows measured nara re
(qnmcen of hast eachanger Te i
‘ied pena or erie uence,
‘ost not be ela by the attr
"The aatral eqnciw area
serically determined when using
FEA, however the aecorecy of te
resulta Io tually dependant op he
securacy ofthe input dts. The ms
teria! model at take all dierent
Sperating endtons in asount, Por
aURe 0.1 ic ore
cue ope
‘example, ding «mixing pertion,
‘ene fled with the eral
ie'mied, Depending on the ling
Teel this canna deeenae
the vests naar requenies by up
toavs gure
“The same ipl applies to a=
ternal compovunta when they are
stimerged by liquid or simakane
ner Ti it ns with
heating and conling els and feed
pies were sian decrease of
stra foqucies san be expected
{nd a purely structural, mechanic
‘pprech mould al. Such operating
fendiins are conidored yl
froctare inaction PSD aay.
Si, based the wave equation of
cust [7 all relevant fcc
Mencing the ration bebe ean
‘eke into wzoun by thi pot
ltphgscl appre
Tf otallg or pred paries srw:
‘multe enuf of on ner
Component, te reall mass of ths
‘onpnent wlan. This asin
‘rete leads toa deren ofthe nat
‘al reqonciee. which can change the
Sperating socio during. produc
on oer a peri of woke of noth( TABLE, DECREASE OFTHE TET NATURAL FREGUENGY BUETO SPECIFIC |
‘OPERATING CONDITIONS CTYPICALVALUES)
i ‘ononani | Operating Conation
1a Nature Feauny
(Got vous)
vena ‘ero
‘able 2 shows the inftaene of at
ferent operating cana tha eat | [= aaes
inthe decene of mature! feaueies | Tiled ene
fe invdul components | [reeapipe | Winout seat on auto
7
f
‘Natural requanses ae eulerantex- | | Soe
ciation pcr mut belated |
Sart tated any cenacrence,|[POOTeCones” [Vowel ond pen empty
Tnoomnctin wit alety for ep vel ond pipes es
3
‘nocerace cana on rotrieon of
Ue operating apecdeanes which vld | Gaaiga draing | Ramana modeT
Gricunted reste
lento prov licen
Patigue-proof design
At leat 9 of flares in chan
fal engineering ave due to fatigue
Tend. "Thie means that-macaniel
Breakdowns can ceeor even though
the state strength of the compe.
ent othe yield steegth,bnsat|
teen reached The caiman ese fr
th pe of allure le mireracing
Which eauted by yee loading The
‘veal een lovel wl aot case &
‘amponen to fi, a requ
Fepeatd tees Intensity range —
‘rhc canbe eavaed when opereting 3
$n reooanescondiens — Wl
‘Dynamic bade are indeed.
result of eto rain in nearly
{ated racer Wa ropa o fate, | (na The aoe nents tenet eeocton
‘rector the aitatr mounting lenge),
‘rhe conecions between the ese
‘ery strcurlcanpmnet usa | atl ene ren comput motes eae ee a eae
Sell andthe support ofall ternal
in these cial sras sich asthe
sgiotor ange, tank be otra
Componente ike halls or best x
‘hangers he stentenaity i n,
‘termined by using FEA. Tose cn
(ited rele deine the paratter
for Gtigue proa-ompenent dsm,
fing into acnant th highly
‘amie character of mining prosesce || FE-mom le parecer wt
ae ne oper
‘he design must then be verled
implant ih iterator ok | HOURS 8 tte een nd cig cetrentine nd roe
‘ches ASME ‘esos met seneger nae
ands os
Practical examples persed by the btm ingle whieh | enters dey into dhe tion lt of
Iydrogenction reactor Figure 10 e 8 xneve trtine. The hydrogen, | this tari, leing to an stan
tows reuctr tp that i tpl | which isnot instantanaay Gave | taneou miming of sling hy
Sted et the redetion of nitegrups | und canvere, aes tothe heed of | dragen adhe uid reactant Sach
to'make taluene diamine aoline and | th recor and ecumlates, Hence | reason arhigly eather tre
her compounds The mee i a co | taut be permanecty recreate, | fren efsot bet exchanging ze,
Uncously operated, 50am hydrogenn | wich le adueved by sl inducing |S pevded br ra eight abe nd
tion reso with ¢sambioe!psing | Carbine via toe ith lang coupling | To casa Sow ete impel int
‘eat The aa foed in eficentiy di | anda low sf Th gud ed alo | thew nls ends ome aec esbmeged [35% snmergnd sok momered 7x nmeres oth omen]
fi generate, whieh in cum pose
Aynamie la onthe het exebenger,
a ‘andl and tinal ees,
A “The general approsdh to character
ie |_| | singe forthe mechani
‘nsoning ofthe ben exchanges
| ao can be sen in Figure 1 The feet.
tags ef ed shows sconceptonl de
| sem ofthe ox exchanger A aye ie
‘uly rebut invita reais by 0
‘ovina er
‘OURE 13,7 ting mvt trce aur ecuonce ofa womans. | tals The snpliston enhsece
‘SKownrorsas computed fae loot hace
ssrpaytes, , | the eality of the analgss ad the
evn surdcndo | gual ath els there reducing
computation tie conlderay, THs
prepress trans tho al
onthe implles and shaf that must | sign into un eequte numerical com
Featae Aspe powerinptbetween |b accmadated by the agitator | puter model gure 1, male Take
and 1DEWin? i required to see | Dane and vee ad. The salts in | lng inte seat al relevant boondary
1 conven af over 89% in sucha | thie pel recor ar of «overhung | conditions (omens, lads ant so
Slngestage crnanas recor Por | design and ot supported by wteady | on) the tude i spa f cle.
50m? reocior volume, ts euats to | earings which are prone to abrasion | ing natal gino, tess and
2600600 KW elt power Byracie typically cstaletn, ssh | deformations. The rule of «muda
“This igh power lve sess re-| at Raney aie. In sdton to the | analy azewhown onthe righ ide
spctively high lads sting as foros | high pawer level a intense fai ow | of Figure 1
Could it be Mauer
your missing link? re
laboratory testing facty or
se return retreat
q Transferring potent or
toxic
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