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1 : REACTOR DESIGN:
In this project, the reactor is used for carrying the reaction
between the reactants, ethanol and acetic acid. The temperature of the reaction medium is
critical and is controlled by using saturated steam heat transfer through coils.
WHAT IS REACTOR?
Chemical Reactors are vessels that are designed to provide residence
times for reactants so that chemical reaction occur among them.
Selection Criteria of Reactor:
Conversion
Selectivity
Productivity
Yield
Heat exchange
Mixing
Catalyst Distribution
Hold-up Time
Availability
Energy utilization
Safety
Economics
MODE OF OPERATION :
Batch
Continuous
MODE OF OPERATION
BATCH
PHASES IN CONTACT :
LIQUID-LIQUID
Mixing of Reactants
Good Temperature Control
High heat and mass transfer efficiencies
Useful for slow reactions requiring large hold up time
Less Man power requirements
Product Vapours
C2H5OH 0.432 %
Ethanol stream
CH3COOH 7.34 %
Acetic 82.2 %
CH3COOC2H5 62.28 %
Acid stream 1273.363 Kg /hr H2O 29.94 %
95.2 %
13923.764 Kg/ hr
1537.896 Kg /hr
Recycle Stream
C2H5OH 0.394 %
CH3COOH 9.99 %
CH3COOC2H5 69.050 %
H2O 20.557 %
83 °C 11112.503 kg / hr
107 kPa 435.38 Kg / hr
120 °C
198.5 kPa
Steam
Condensate
E-27
Mixing Pattern
DESIGNING :
General design parameters for all the parts of a CSTR are ;
Reaction Vessel
Rate of reaction
Residence time
Volume of reactor
Reactor Length
Reactor Diameter
Mixing Agitator
Selection
Specifications
Power consumption
Heat Transfer System
Selection
Specifications
STANDARD DESIGN PROCEDURE FOR REACTOR
1. Calculate molar flow rate from given mass flow rates
2. Calculate volumetric flow rate from molar flow rate
3. Calculate initial concentration from volumetric flow rate
4. Calculate the concentration for given conversion
5. Calculate the rate of reaction by the given kinetic equation
6. Calculate the residence time
7. Calculate the reactor volume
8. Calculate the actual volume of reactor
9. Calculate the dimensions of reactor.
Reaction Equation: 83 °C
CH3COOH + C2H5OH <==========> CH3COOC2H5 + H2O
107 KPa
Rate Equation:
The reaction is elementary with the rate law as:
-rAcet. = k1CAcet.CAlc – k2 CWaterCEster
As we know that ,
molar. Flow rate = mass. Flow rate / mol.wt ------------------ (1)
X A
C Ao r A
------------------(5)
Ref : Octave Laevenspiel , “Chemical Reaction Engineering “,3rd Ed.
So, by putting all the values in the above equation,we have
t = 2.955 * 0.615 / 0.000768
t= 2365.8 Sec
or
t= 39.43 min
Thus the volume of the reactor is :
V= t * VFR
So
V= 0.657 * 13.101
V = 8.61 m3
For CSTR ;
L/D = 1–3
.
Ref : Coulson & Richardson , “Chemical Engineering “ Vol : 6
For convenience of boiling and agitation, I have selected,
L / D = 1.5
Thus
(π/4)D2L = (π/4)*1.5D3
Thereby;
π/4*1.5D3 = 8.61 m3
So,
D = 1.94 m
And L = 2.91 m
But to accommodate the volume of the vapours rising from the surface of
the reactor vessel, we have taken the liquid as it fills 50 % of the reactor’s
total volume.
Thus keeping the same diameter as evaluated before but to accommodate
the double the volume, the height required will be ;
L = 5.83 m
With this the volume of the reactor is;
V = 17.22 m3
Wall Thickness :
P ri
t = + Cc -------------------(6)
SEj - 0.6 P
P = Pressure of system
ri = Radius of shell
S = Allowable Stress of material
Ej = Efficiency of joint
Cs = Corrosion allowance
By putting the values available ,
t = 6.5 mm ( 0.0065 m )
MIXING AGITATOR
SELECTION :
Axial impeller:
Used for
• Dispersion of miscible liquids.
• Heat transfer enhancement.
• Promotion of chemical reaction.
• Suspension of solids.
Radial impeller:
Used for
• Necessary and sufficient turbulence and mixing radially.
SIZE OF IMPELLER:
Ref : Peters M. S & Timmerhaus K.D , Plant Design & Economics For Chemical
Engineers “, 5th Ed, MnGraw Hill Inc.
Where,
Da = Diameter of Impeller
Dt = Inside vessel diameter of the reactor
C = Height of central shaft from bottom
L = Length of the turbine blades
W = Height of the turbine blades
B = Thickness of the reactor vessel
Z = Height of the Impeller shaft in the reactor
Thus putting the values and taking a vessel thickness of 0.1 m, giving both
the mechanical strength and safety margin.
So,
(1) Diameter of the Impeller = Da = 1.94 / 3
= 0.65 m
(2) Height of central shaft from bottom= C
= 0.65 m
(3) Length of the turbine blades = L
= 0.25 * 0.65
= 0.155 m
(4) Height of the turbine blades = W
= 0.2 * 0.95
= 0.13 m
POWER REQUIRENENTS:
= (0.65)2*(90/60)*(881.03) / (0.5133*10-3)
= 1.088 * 107
(2) Froude number:
Fr = Da* Nr2 / g ------------------ (8)
= 0.149
From Equ. 12-42 ofMax S. Peters “Plant design and Economics for chemical
Engineers” , we have :
P = Ø Frm Nr3 Da5ρ --------------- (9)
where
= - 0.126
The power function as determined from the Fig : 12-40 corresponding to
Reynold’s No. of 1.088 * 107 , for unbaffled reactor is ,
Ø = 1.0
Now, putting all the values of parameters in the above mentioned equ.
We have
P = (1.0) *(0.149)-0.126 * (90/60)3 * (0.65)5 * (881.03 * 10-3)
P = 0.44 kW
Function :
To provide heat the incoming reactants to 83 oC , and to evaporate the
reaction mixture thoroughly to provide Rectifier’s feed .
Selection :
Usually the heating systems are commonly observed in two following
configurations:
1. Coils
2. Jacketing
Q = 7.287 * 106 KJ / hr
Areas of heat transfer will be calculated separately for both the zones
and then summed to give total HT area.
Calculate the sensible heat transfer rate to the reaction mixture.
Reactants Products
o
63 C 83 oC
mCp▲T1 mCp▲T2
Reactants HR Products
o
25 C 25 oC
Then,
Q sensible = - mCp▲T1 + ▲HR + mCp▲T2
------------------- (11)
Q sensible = m. Λ
------------------(12)
Where λ = specific latent heat of saturated steam.
3. Calculate Overall Heat transfer coefficient (Ud):
1 / Ud = 1 / ho + 1 / hio + x / km + Rd
4. Calculate LMTD for the pre-heating zone:
5. Find HT area A1, required for sensible heat transfer:
6. Now same steps are repeated for vaporization zone heat transfer area
with different correlations and equations.
7. Total area of Heat transfer is then,
8. Select a suitable standard coil pipe size and find its length required that
will provide this HT area.
9. Assume a suitable coil diameter. Those will not interrupt mixing and
then find the external length per turn.
10. Find the No. of turns required of specific diameter by :
No. of Turns = Length of Coil
------------------(15)
π * Diameter of Coil
Calculations:
1. Q sensible :
m = 107.98 Kg / hr
3. Overall heat transfer coefficient Calculations :
ho = 834.51 W/ m2-K
Rd = 6 * 10-4 m2-K/ W
Then ,
1 / Ud = 1 / ho + 1 / hio + x / km + Rd
-------------------------------(17)
Ud = 487.695 W/ m2-K
4. LMTD :
= ( 120 – 63.16 ) – (120 – 83)
= 46.21 oC
5. Sensible HT Area :
A1 = Qsensible
(Ud) (LMTD)
A1 = 10.55 m2
6. Q Latent :
= 6.992 * 106 Kj / hr
7. Steam required :
= 6.992 * 106 / 2202.2
= 317.51 Kg / hr
8. Overall HT coefficient :
With reference to table 14-5 , Max S. Peters; K.D. Timmerhaus;
R.E.West.
Uc for steam as heating media and light organics as vaporizing
medium is given as :
= 1000 W / m2-K
With a Dirt factor of 6 * 10-4 m2-K/ W .
.Thus,
Ud = 625 W / m2-K
9. Latent HT Area :
= 6992213.5 / 625 * 37
= 30.24 m2
10 . Total HT Area :
= 10.55 + 30.24
= 40.79 m2
11. Now we take the pipes for coils as standard 2” Schedule 40 IPS steel
pipes and that the diameter of the coil turn is 3 ft (0.914 m).
So,
= 2.0401 m2/m
Therefore,
Length of pipe required = 40.79 / 2.0401
= 19.99 m
13. Per turn length for HT:
= π * Dia of coil turn ------------------(18)
= π * .914
= 2.871 m
14. No. of Turns required :
= 19.99 / 2.871
= 6.96
~ 7 Turns
Definition:
Decanters are the equipments used to separate liquids where there is a difference
in density between the liquids for the droplets to settle readily.
It is a continuous gravity separator vessel that does not run full and lighter phase
overflows from top or near the top of the vessel.
Types of Decanters:
Basically the decanters also have the same conventional types based upon the
process, which are:
Batch Decanters
Continuous Decanters
But it must be known that the design steps in both cases remain same.
Types: on the basis of Fluids nature:
Continuous gravity settlers
Centrifugal Decanters
Basically the selection is made between continuous gravity settler and centrifugal
decanter through following procedure:
1. If density ratio between the liquids is about unity, then centrifugal one is the best.
2. If there is much difference between the liquid densities, the gravity settlers are
used.
Conditions of Operation:
4. Viscosities:-
a) Aqueous Layer (centipoise) = µH = 0.58178
b) Ester-rich Layer (centipoise) = µL = 0.4044
a) Aqueous Layer (kg/m-sec) = µH = 0.00058178
b) Ester-rich Layer (kg/m-sec) = µL = 0.0004044
5.Temperature:
= 40°C
6. Pressure:
= 101.3 KPa
If,
Q L= lighter phase flow rate.
Q H= heavier phase flow rate.
ρ L= density of lighter phase.
ρ H= density of heavier phase.
Then,
When:
a) θ < 0.3, Lighter phase is dispersed phase.
b) θ > 3.3, Heavier phase is dispersed phase.
Here,
θ = 8.213
Hence,
Dispersed Phase: Heavier (Aqueous) Phase.
Viscosity of Continuous Phase (cp) : 0.4044
Thus,
the area of the interface is
= volume flow rate of continuous phase/settling velocity
= 1.889 m2
Piping Calculations:
1. Ref :Peters M. S & Timmerhaus K.D , Plant Design & Economics For
Chemical Engineers “, 5th Ed, Ch 12 ,McGraw Hill Inc.
Putting values,
D i (m) = 0.10212
b) Outlet pipes:
Since, the height of the overflow leg has been calculated on the basis of the frictionless
flow so the flow of liquids through discharge pipes may be considered as laminar flow,
Thus,
1. Identification D-1
2. Function Separation on the basis of gravity
3. operation Continuous
4. Shape Cylinderical
5. No. Required 1
6. Temperature 40 °C
7. Pressure 101.3 Kpa
8. Separation Time (hr) 0.3709
9. Diameter (m) 1.364
10 . Length (m) 6.819
11 . Total depth of liquid in
the
decanter (m) 1.146
12 . height of interface (m/sec) 0.573
13 . height of heavy liquid
overflow
leg (m) 1.082
14 . Settling velocity (m/sec) 0.0033
15 . Area Of interface (m2) 1.889
16 . Material of construction Stain- less steel
17 . Head type Torispherical
Piping
18 . Sizes ( m)
inlet pipe 0.1021
Light discharge 0.0880
Heavy discharge 0.0338
4.4:COOLER DESIGN :
In our project the cooler is actually a shell and tube heat exchanger, which has been
selected by using following criteria table:
Heat exchangers have been developed with different approaches to these four
fundamental design factors. Three principal types of heat exchangers
STEP 1:-
Duty (heat transfer rate) calculated
Q =m Cp ∆T
=13105 * 2.22 * (71 – 40)
=9.00 ×105 KJ/hr
STEP 2:-
PHYSICAL PROPERTIES
For Rectified top product (condensed) :
PROPERTIES INLET MEAN OUTLET UNITS
Temperature 71 55.5 40 °C
Specific heat 2.27 2.22 2.17 KJ/kg°C
(C)
Thermal .216 .213 .210 KJ/hr m2
conductivity (k) 0C
Density (r) 901 908 915 Kg/m3
Viscosity (m) 3.06x10- 3.73x10- 4.40x10-4 Kg/m.
4 4 sec
STEP 4:-
For S & T HE design we’ll have to calculate LMTD.,
LMTD
Tlm = (71-38)-(40-25)/In(71-38)/(40-25)
Tlm = 23 K
Sine for this type of construction, by definition
Ft=1
Now
Tm = Ft x Tlm
Tm = 1x23=23 K
STEP 5:-
HEAT TRANSFER AREA
Q = u AoTm
Ao = Q / u Tm=9.00 x 105 /675*23
Ao = 16.23 m2
Now
Assume (do) Tube outside dia = 1.5in = .0381m
18BWG, length of tube = 6 ft = 1.83 m from table 10 (kern) (di)
Tube inside dia = 1.4 in = 0.036 m
Tube pitch = .049 m
Flow area per tube = 1.54 in2 (from table 10, kern)
STEP 7:-
TUBE SIDE HEAT TRANSFER COEFFICIENT
Since
area of one tube = p do L =3.14x0.0381x1.83
=.22 m2
Nt = no of tubes = Ao / At =16.23 /.22
Nt ≡ 80
Tube Pitch (Pt) = 1.25do
= 1.25x.0381
=.048 m
For 1tube pass, tube per pass = 80
Tube cross sectional area = p / 4 (di2)
= 3.14/4x(.037)2
=1.07x10-3 m2
So area per pass = 80x1.07x10-3
=.281m2
Volumetric flow rate = W / r
=16.25 m3/hr
= 4.5×10-2m3 /s
ut = tube side velocity
= volumetric flow / area per pass
ut = .045/.281=1.1m/s
The velocity is satisfactory between 1 to 2 m/sec
STEP 8:-
TUBE BUNDLE AND SHELL DIA
From table 12.4 for 1-tube pass and type of pitch (Coulson 6)
K1 = .319
n1 =2.142
for type of pitch Pt = 1.25 do
Db = do (Nt / K1)1/n1
= .0381 (265/.319)1/2.142
Tube bundle dia Db = .305 m
For a fixed tube sheet exchanger the typical shell clearance from (fig
12.10 coulson 6)
Shell clearance = .05 m
So,
Ds = Shell inside dia =.360 m
STEP 9:-
Re = r x ut x di / mc
= 1000x0.016x.037/8.1×10-4
= 74000
PRANDTLE NUMBER:-
Pr = C x m / k
=4.2x8x10-4 x3600/.6
=20.16
Now
Find the value of Jh from the graph, fig 12.23 ( Coulson–vol. 6) i.e.
Jh = 3x10-2
hi = Jh Re Pr1/3 (K / do)
hi = 3x10-2 x 74000 x(20.16).33 (.6/.0381)
=942 W/ m2 K
Shell side heat transfer coefficient:
(Ds) = inside dia. of shell
= .360 m
Assume;
take a baffle spacing = Dsx.2
=0.36 x.2=0.212 m
No. of baffles = length of tube / baffle spacing
=1.83/.212=10
(As) = cross flow area
= (Pt – do / Pt) x Ds x Baffle spacing
As
= (.048-.0381/.048)x1.06x.212
= 0.046 m2
SHELL SIDE EQUIVALENT DIA :
de = 4 × (pt2 -.917xdo2 )
de = 0.028 m
Volumetric flow rate on shell side
= 14.41/3600=4.0x10-3 m3 /s
Us =shell-side velocity
= volumetric flow rate / As
=4.0x10-3 /.046
Us = .98m/s
REYNOLD No.
Re = Us x r x de shell / m
= 0.09x910x0.028/3x10-4
= 76440
PRANDTL No.
Pr = CP m / K
= 2.2x 3x10-4x3600/.2
=11.88
Use 25% Cut Segmental Baffles
PRESSURE DROP:
TUBE SIDE PRESSURE DROP:
For Re = 74600
The Jf= 9.8 X10-2 (from Fig 12.24 Coulson 6)
The pressure drop calculated is within allowable limits. Therefore our design
Is both thermally and hydraulically feasible and appropriate.
SPECIFICATION SHEET FOR COOLER
• Unit Cooler (HEAT EXCHANGER)
• Operation Continuous
No. of tubes 80
Centrifugal Pump:
These pumps are most commonly used type in the chemical industry. It can
be constructed in a wide range of corrosion resistant material or lined with rubber or
plastics. It is, in fact, used for almost all pumping operations other than those where a
large head or positive displacement is required.
In centrifugal pumps, the mechanical energy of the liquid is increased by
centrifugal action. The liquid enters through a suction connection concentric with the axis
of a high speed rotary element called the “Impeller”. The impeller carries radial vanes
integrally cased in it. Liquid flows outward in the space between the vanes and casing
and leaves the impeller at a considerable greater velocity with respect to ground than at
the entrance to the impeller. In properly functioning pump, the space between the vanes is
completely filled with liquid flowing without cavitations. The liquid leaving the outer
periphery of the impeller is collected in a spiral casing called the volute and leaves the
pump through a tangential discharge connection. In the volute, the velocity head of the
liquid from the impeller is converted into pressure head. The centrifugal pump may be
single stage or multi stage, propeller, mixed flow and peripheral.
Selection Criteria:-
Many different factors can influence the final choice of a pump for a particular
operation. The following list indicates the major factors that govern pump selection.
1) The amount of fluid that must be pumped. This factor determines the size of
pump (or pumps) necessary.
2) The properties of the fluid. The density and the viscosity; of the fluid influence
the power requirement for a given set of operating conditions, corrosive properties
of the fluid determine the acceptable materials of construction. If solid particles
are suspended in the fluid, this factor dictates the amount of clearance necessary
and may eliminate the possibility of using certain types of pumps.
3) The increase in pressure of the fluid due to the work input of the pumps. The head
change across the pump is influenced by the inlet and downstream reservoir
pressures, the change in vertical height of the delivery line, and frictional effects.
This factor is a major item in determining the power requirements.
Selection:
We have selected centrifugal pumps in our project because of following outstanding
advantages:
1- They are simple in construction and cheap.
2- Fluid is delivered with uniform discharge pressure without pulsation and shocks.
3- There are no valves involved in the pump operation.
4- They operate at high speed(up to 4000 rpm) and therefore, can be coupled
directly to an electric motor(In general, the higher the speed, the smaller the
pump and motor for a given duty).
5- The discharge line may be partly shut off or completely closed off without
changing the pump.
6- They can handle liquid with large amount of solids.
7- They are much smaller than other pumps of equal capacity.
8- Maintenance costs are lower than for other types of pumps.
Design
Function:
To pump the organic layer, from the flow divider, to the top of the rectifier
column,
Potential Head:
The pump has to pump the liquid mixture to the top plate of the rectifier,
which is 12.3 ft above ground (including the support structure for the rectifier)
Head lost by the friction:
Hf = 4f (L/D) ( µ2/gc )
Area of pipe = a = π D2 / 4 = π / 4 * (1/ 12)2
= 0.0055 ft2
= 0.00051 m2
Volumetric flow rate = mass flow rate / density
Volumetric flow rate = 0.00128 m3 / sec
Velocity = 0.00128 / .00051
= 2.51 m/sec
Average Viscosity = 0.937 cp
= 0.000937 Kg/m-sec
Re =ρDu/µ
= 60.85 * 1 *8.224 / (12 * 0.00063)
=675021
Roughness of carbon steel pipe, from graph 13(Kern):
K / D = 0.004 * 12 / 1
= 0.0048
From friction factor chart,
F = 0.008
Now
hfs = 4f▲Lu2 / 2 D gc
= 4 * 0.008 *200 *12 *(8.2244)2 /(2*32.17)
= 8.074 ft
If efficiency = 60 %,
Then power = 0.4 / 0.6
= 0.7 KW
A centrifugal pump of 1 kW will suffice the requirement.
4.6: DESIGN OF STORAGE TANK:
VESSEL DESIGN :
Several head designs are shown by Walas [6], but not all of these are common
designs. The most common head designs are shown in Figure 6.1. According
to Markovitz [7] ellipsoidal heads, where the ratio of the semi-major to semiminor
axis is 2:1, are commonly used when the pressure is greater than 150 psig
(10.3 barg). Below 150 psig, a torispherical head (dished head) is used.
The wall thickness for a 2:1 ellipsoidal head is given by
Ellipsoidal and torispherical vessel heads.
Wall-Thickness Rounding Increments for Pressure Vessels
Pt = Patm + P static
Since,
Pstatic = ρ (g / gc ) h
= 56.16 * 1 * 16
= 898.72 lbf / ft2
= 0.425 atm
Pt = 1 +0.425
= 1.425 atm
Since the design pressure is set at 10-20 % excess over original pressure.So,
PD = 1.425 * 1.1
= 1.567 atm
= 158.7 KN/ m2
(III) Wall Thickness :
P ri
t = + Cc
SEj - 0.6 P
P = Pressure of system
ri = Radius of shell
S = Allowable Stress of material
Ej = Efficiency of joint
Cs = Corrosion allowance
t = 9.75 mm
~ 10 ( 0.01 m )
Identification:
Item Storage Tank
Item No. E-38
No. Requird 2
Function: Storage of Cooled Product from Stripper bottom.
Design Data :