1.

0 SIZING AND COSTING

1.1. MEDIUM PRESSURE DECOMPOSER
1.1.1. Introduction
The purpose of this section is to further stripping of NH3, CO2 and the left Carbamate. it is
divided into 2 parts: top separator, where the released Flash gases are condensed and recycled
to the reactor before the solution enters the tube bundle, where the last carbamate is
decomposed and required heat is supplied by means of steam saturated at 4.5 atm.

1.1.2. Design Calculation

Table 4.1: Medium Pressure Decomposer Specification Sheets

Equipment Specification Sheet

Identification Medium Pressure
Decomposer
Function: To separate the feed stream into gas and liquid products.

Process Specification/Operating Condition

Liquid Flow Rate, FL 15421.38 kg/h
Vapor Flow Rate, FV 21479.87 kg/h
Density of liquid, ρL 1178.696 kg/m3
Density of vapor, ρV 21.526 kg/m3
Surface Tension,σ 65.00 dyne/cm
Temperature, To 140.00 ˚C
Pressure, Po 18 atm
Equipment Properties
Type Vertical vessel
Bare-module Factor, FBM 2.45
Material of Construction Carbon Steel
Density, ρcarbon steel 7861.0929 kg/m3
Material Factor, FM 1.00
Maximum Allowable Stress, S 15000 psi
Vessel Internal Diameter, DT 0.983 m
Vessel Height, L 18.8711 m
Wall thickness to withstand internal
0.0101 m
pressure, tP
Average vessel wall thickness, tV 0.0614 m
Corrosion Allowance, tc 0.003175 m
Shell Thickness, ts 0.0646 m
Weight, W 1031.613 kg
 Cost of Pressure Vessel
Cost of empty vessel, Cv $ 6683.60
Added cost, CPL $ 2907.15
f.o.b Purchase cost, Cp $ 9545.75

Density of Urea = 1230 kg/m3

Density of biuret = 1467 kg/m3

Density of water = 1000 kg/m3

Density of Liquid (ρl) = (0.7611 x 1230) + (0.00776 x 1467) + (0.231 x 1000)

= 1178.696 kg/m3

P × Mwt
Density of NH3 (gas) =
RT

4.5× 17
=
0.0082× 353

= 2.64 kg/m3

P × Mwt
Density of CO2 (gas) =
RT

4.5 × 44
=
0.0082× 353

= 6.8 kg/m3

P × Mwt
Density of Carbamate =
RT

4.5 ×78
=
0.0082× 353

= 12.126 kg/m3

Density of gases (ρv) = 2.64 + 6.8 + 12.126

= 21.526 kg/m3

Mass flow rate of gases = 4531.755 kg/hr

Qv = mass flow rate of gases/ density of gases (ρv)

 = 4531.755/21.526

= 75.854 m3/hr

= 0.0210 m3/sec

Mass flow rate of liquid = 89409.39 kg/hr

QL = 89409.39 /1178.696

= 210.524 m3/hr

= 0.0584 m3/sec

1
ρl−ρv
Ut = 0.07 × (
ρv ) 2

1
1178.696−21.526
= 0.07 × ( 21.526 ) 2

= 0.513 m/sec

Without demister,

Uv = 0.15 ut, Uv = 0.0769 m/sec

4 ×Qv
Dv = = 0.983 m
π ×Uv

Qv
A= = 0.0210/0.0769
Uv

= 0.7596 m2

Setting time = 10 min = 600 sec

Volume held in the vessel = 600 x 0.0584

= 35.087 m3

V 35.087
Liquid height (HL) = =
A 0.7596

=16.643 m

Feed height (Hf) = 0.5 x Dv = 0.491 m

Vapor or gas height (Hv) = Dv = 0.983 m

Total height = 0.983 + 0.491+16.643

= 18.8711 m

Figure x.x Low Pressure Decomposer Design Sumamry

Vessel Costing Purchase Cost, Cp

Step 1 : Calculate the design pressure, Pd.

Since Po is between 10 psig to 1000 psig,

Pd = exp[0.6068 + 0.91615 (ln Po) + 0.00015655 (ln Po)2]

= exp[0.6068 + 0.91615 (ln 264.527) + 0.00015655 (ln 264.527)2]

= 305.1868 psig

Step 2 : Calculate the design temperature, Td

Td = To + 50 oF

= (140 + 273.15) + 50

= 463.15 oF
Step 3 : Since Td is within range of -20 oF to 650 oF, carbon steel SA-285, grade C
is selected.
Therefore, maximum allowable stress, S = 15000 psi

Step 4 : By assuming weld efficiency, E = 1,

Calculate cylindrical shell wall thickness, tp,

PD D T
tp =
2 SE−1.2 P D

305.1868 ×0.983
=
(2 ×15000 ×1)−(1.2× 305.1868)

= 0.0101 m

Step 5 : Calculate necessary thickness to withstand wind load or earthquake at the

bottom of the column, t W.

0.22 ( 0.983+ 18 ) L2
tw =
SD20

0.22(0.983+18)18.8711 2
=
15000 ×0.9832

= 0.1026 m

Step 6 : Calculate the average vessel wall thickness, tv.

2t p +t w
tv =
2

2(0.0101)+ 0.1026
=
2

= 0.0614 m

Step 7 : Calculate final vessel thickness, ts

ts = tv + tc

= 0.0614 + 0.003175
 = 0.0646 m

Step 8 : Calculate the weight, W

Where ρcarbon steel = 7861.0929 kg/m3

W = π (DT + Ts) (L + 0.8DT) Ts ρcarbon steel

= π (0.983 + 0.002157) (18.8711 + 0.8 (0.983)) (0.002157) (7861.0929)

= 1031.613 kg

Step 9 : Calculate cost of empty vessel, Cv

Cv = exp[5.336 + 0.4599(ln W) + 0.00582(ln W)2]

= exp[5.336 + 0.4599(ln 1031.613) + 0.00582(ln 1031.613)2]

= $ 6683.60

Step 10 : Calculate the added cost, CPL

CPL = 2275Di 0.2094

= 2275(3.225) 0.2094

= $ 2907.15

Step 11 : Calculate the f.o.b purchase cost, CP

where Material Factor, FM for carbon steel is 1.0.

CP = FMCV + CPL

= (1 x 6683.60) + 2907.15

= $ 9545.75

Notes: The above steps are then repeated to calculate the f.o.b purchase cost for Low Pressure
Decomposer
 1.2. LOW PRESSURE DECOMPOSER
1.2.1. Introduction
The purpose of this section is to further stripping of NH3, CO2 and the left Carbamate. it is
divided into 2 parts: top separator, where the released Flash gases are condensed and recycled
to the reactor before the solution enters the tube bundle, where the last carbamate is
decomposed and required heat is supplied by means of steam saturated at 4.5 atm.

1.2.2. Design Calculation

Table 4.1: Medium Pressure Decomposer Specification Sheets

Equipment Specification Sheet

Identification Low Pressure Decomposer
Function: To separate the feed stream into gas and liquid products.

Process Specification/Operating Condition

Liquid Flow Rate, FL 93941.14 kg/h
Vapor Flow Rate, FV 4531.755 kg/h
Density of liquid, ρL 1178.696 kg/m3
Density of vapor, ρV 21.526 kg/m3
Surface Tension,σ 65.00 dyne/cm
Temperature, To 80.00 ˚C
Pressure, Po 4.5 atm
Equipment Properties
Type Vertical vessel
Bare-module Factor, FBM 2.45
Material of Construction Carbon Steel
Density, ρcarbon steel 7861.0929 kg/m3
Material Factor, FM 1.00
Maximum Allowable Stress, S 15000 psi
Vessel Internal Diameter, DT 0.983 m
Vessel Height, L 18.8711 m
Wall thickness to withstand internal
0.0101 m
pressure, tP
Average vessel wall thickness, tV 0.0614 m
Corrosion Allowance, tc 0.003175 m
Shell Thickness, ts 0.0646 m
Weight, W 1031.613 kg
Cost of Pressure Vessel
Cost of empty vessel, Cv $ 6683.60
Added cost, CPL $ 2907.15
f.o.b Purchase cost, Cp $ 9545.75