Ethylene Fixed Bed Reactor Equipment Design

Technological Institute of the Philippines
TUBULAR FIXED
BED REACTOR
R-002
TUBULAR FIXED BED REACTOR
Physical and Chemical Parameters

Catalytic Multi Tube, Fixed Bed, Heat
TYPE
Exchanger
OPERATION CONTINOUS
Catalyst Specification
CC
Shape Column (pelletized)
Dimension Φ2×2-10mm
Pore Volume ≥0.25ml/g
Bulk Density ~0.72 kg/l
Specific Surface Area ≥250m2/g
Crushing Strength ≥98 N/cm2
Attrition <1 wt.%
Pore Size ~5A
Binder Type Pseudo-Boehmite
Binder wt.% 30wt.%
Max Temperature 853.15K
Materials of Construction
Metal Alloy Material Austenitic Stainless Steel
Materials of Construction Stainless Steel 316
Standard (In Tube Side) ASTM A312
Tube Specifications
Schedule Number SCH NO. 40S (Standard)
Nominal Diameter ND 26.623 mm
Nominal Pipe Size NPS 1 inch
Tube Length Lt 7 ft 2.1336 m
Inside Diameter I Dt 1.049 inch 26.645 mm
Outside Diameter O Dt 1.315 inch 33.401 mm
Thickness xt 0.133 inch 3.378 mm
Allowable Operating Conditions in using Stainless Steel 316

Maximum Allowable
973.15K
Temperature
2
Maximum Allowable
35 bar
Pressure
Material of Construction Stainless Steel 316

N 220
Design Strength
mm2
Ultimate Tensile N 520
Strength mm2
N 200,000
Young’s Modulus
mm2
Elongation % 40
Thermal Design
Tube and Shell Side Specifications
Tube Side
kg
Mass Flowrate 1,604.16
hr
kmol
Molar Flowrate 89.02
hr
Mean Temperature 320 ℃
Pressure 100 kPa
kg
Density 0.3669 3
m
kJ
Specific Heat Capacity 2.0231
kg
−5 kg
Viscosity 2.11 x 10
ms
Watt
Thermal Conductivity 0.04565
mK
3
Shell Side
kg
Mass Flowrate 411.3311
hr
kmol
Molar Flowrate 9.62
hr
Pressure 101.325 kPa
kg
Density 1.2309 3
m
J
Specific Heat Capacity 1,851.91
kg K
kg
Viscosity 1.2739 x 10−5
ms
Watt
mK
Shell Side Temperature Profile
Shell Side
Inlet Temperature 150 ℃
Outlet Temperature 280 ℃
4
Tubular Fixed Bed Reactor
Catalytic fixed-bed reactors are the most important type of reactor for the
synthesis of largescale basic chemicals and intermediates. In these reactors, the reaction
takes place in the form of a heterogeneously catalyzed gas reaction on the surface of
catalysts that are arranged as a so-called fixed bed in the reactor.
Ethylene Formation from Ethanol Dehydration Using ZSM-5 Process
The dehydration of ethanol is a process used to produce ethylene.
The main reaction in the process is:
Ethanol → Ethylene+Water C 2 H 6 O (g ) → C2 H 4 ( g )+ H 2 O (g )
Ethanol is converted in a reactor packed with catalyst to produce ethylene and
water. Typically, the reaction reaches a conversion of 98.50% with ZSM-5 zeolite catalyst
(ACS Omega 2017, American Chemical Society).
Main Reaction:
5
C 2 H 6 O ( g ) k 1 C 2 H 4 ( g ) + H 2 O ( g)
→
Side Reaction:
2 C2 H 6 O ( g ) k 2 , k 3 C 4 H 10 O(g )+ H 2 O ( g)
↔
From Material Balance
Considering the side reaction:
2 C2 H 6 O ( g ) k 2 C 4 H 10 O(g ) + H 2 O ( g )
↔
Reaction 2 C ↔ E +¿ W
I 0.08 0.02 0.02

C -2x +x +x
E 0.08-2x 0.02+x 0.02+x
−Ea
RT
K= A e
For Diethyl Ether:
mol J
A=1.72 x 10−5 E =2.16 x 10 4
g ∙ min a mol
T =280 ℃
4 J
)[ ]
−2.16 x 10
mol
−Ea J
mol ( 8.314 mol ∙ K )(280+273.15 ) K
K= A e RT
(
= 1.72 x 10
g ∙ min
−5
e
6
mol
K=1.5694 x 10−7
g ∙ min
Source: Catalytic Conversion of Ethanol to Ethylene over ZSM-5 Zeolite Catalyst by

Ouyang J., Song Q. 2009
Calculating the value of x from ICE table

[ Products ]
K=
[ Reactants ]
[ E ] [ W ] ( 0.02+ x ) ( 0.02+ x )
K= =
[ C ]2 ( 0.08−2 x )2
( 0.02+ x )( 0.02+ x )
1.5694 x 10−7=
( 0.08−2 x )2
x=−5.62 x 10−19 ≈ 0
Side Reaction Suppression

The change is almost zero or negligible, therefore the second or side reaction can be
neglected. Here 𝑘2 = 𝑘3 = 0, and only the first reaction proceeds. Dehydration of ethanol
to ethylene behaves like this because the catalyst suppresses the undesired reactions
sufficiently so that single reaction behavior is approached.
Considering the main reaction
7
C 2 H 6 O ( g ) k 1 C 2 H 4 ( g ) + H 2 O ( g)
→
Conversion: 98.50%
Sources:
Catalytic Conversion of Ethanol to Ethylene over ZSM-5 Zeolite Catalyst by Ouyang J.,
Song Q. 2009
Theoretical Investigation of Ethanol Conversion to Ethylene over ZSM-5 by

Ruangpornvisuti V. 2011
STREAM IN
Molar Mass
Flowrate Flowrate Mass
Compound Formula (kmole/hr) Mole Fraction (kg/hr) Fraction
C2H5O 390
Ethanol H 8.48197 0.88 .76450 0.95
20
Water H2O 1.14132 0.12 .56655 0.05
411
Total 9.62 1.00 .33105 1.00
STREAM OUT
Molar Mass
Flowrate Flowrate Mass
Compound Formula (kmole/hr) Mole Fraction (kg/hr) Fraction
C2H5O
0.08482 0.00472 3.90764 0.00950
Ethanol H
Water H2O 9.51727 0.52938 171.50114 0.41694
Ethylene C2H4 8.35474 0.46472 234.35055 0.56974
Diethylethe C4H10 0.02120 0.00382

r O 0.00118 1.57171
8
TOTAL 17.97803 1.00000 411.33105 1.00000
From Material Balance:

Composition of Inlet and Outlet Stream
Rate Law:
k PC 2 H6 O
−r E=
1+k C 2 H4 PC 2 H4 +k H O P H O
2 2
Parameter Values:
3.5 x 10−3 mol

at m2
gcat
k=
min
2.69 x 10−3
kC H =
2 4
atm
3.81 x 10−3
k H O=
2
atm
9
( 3.5 x 10−3 ) PC H O 2
mol
6
−r E=
1+ ( 2.69 x 10 ) PC H + ( 3.81 x 10 ) PH O g cat . min
−3 −3
2 4 2
Mole Balance:
dx −r E
=
dW F E o
Since the reaction is in gas phase;

Calculating for ε:
C 2 H 6 O ( g ) k 1 C 2 H 4 ( g ) + H 2 O ( g)
→
Simplifying the chemical reaction

A=C2 H 6 O 2 P= All products
A →2 P
(assumption: there is no inert in the feed)
ε =( Purity of feed ) ( stoichiometric coefficient of product −stoichiometric coefficient of reactant

stoichiometric coefficient of reactant )
ε =( 1 ) ( 2−1
1 )
ε =1
Getting the Partial pressures of the species

For the reactant:
1− x P 1−x P
P E=C E RT =C E R T E o o [ ]( ) [ ]( )
1+ εx Po
=P E
1+ εx
o
Po
For the products
10
θC H + x θC H + x
PC H =C E R T E
2 4 o o[ 1+εx
2 4
]( ) [
P
Po
=P E
1+εx
o
2 4
]( )
P
Po
θH O + x θH O + x
P H O =C E R T E
2 o o [ 2
1+ εx ]( ) [
P
Po
=P E
1+ εx
o
2
]( )
P
Po
nethanol
P E =( x ethanol ) ( PT )=
o ( n total)( PT )
PE = o ( 8.48197
9.62 )
( 1 atm )=0.88 atm
P E =0.88 atm
o
Calculating θ for each product:

yi
θi =
y limiting reactant
yC H 0.46472
θC 2 H4
= = 2
=0.528094
yC H O 2
0.88 6
θC 2 H4 =0.52809
yH O 0.52938
θH O= 2
= =0.60157
2
yC H 2 6 O 0.88
θ H O =0.60157
2
Catalyst Weight
W x
FE
∫ dW =∫ −r E
o
0 0
x
FE
W =∫ o
0 −r E
11
x
FE
W =∫ −3
o
0 ( 3.5 x 10 ) P C H O 2 mol6

−3 −3
2 4 2
Calculating for F E o
kmol
F E = 8.48197
o ( hr )( 1000 mol
1 kmol )( 1 hr
60 min )=141.36617
mol
min
mol
F E =141.36617
o
min
Substituting F E : o
mol
x 141.36617
min
W =∫ dx
0 ( 3.5 x 10−3 ) P C H O 2
mol6

−3 −3
2 4 2
Source: Fogler, H. (2011). Essentials of Chemical Reaction Engineering. Boston: Pearson

Education, Inc.
mol
0.9850 141.36617
min
W= ∫ 1−x P
0
( 3.5 x 10−3 ) ( P E ) o [ ]( )
1+εx Po mol
θC H + x θH O+ x g cat . min
( [
1+ ( 2.69 x 10−3 ) P E o
2
1+ εx
4
]( )) (
P
Po [ [
+ 3.81 x 10−3 ) P Eo
2
1+ εx ] ( )]
P
Po
dx
Substituting the values:

ε =1
θC 2 H4 =0.52809
θ H O =0.60157
2
12
mol
0.9850 141.36617
min
W= ∫ 1−x P
0
( 3.5 x 10−3 ) ( P E ) o [ ]( )
1+εx Po mol
( [
1+ ( 2.69 x 10−3 ) P E o
2
1+ εx
4
]( ))P
Po
+ ( 3.81 x 10−3 ) P E
[ [
1+ εx o
2
] ( )]
P
Po
dx
P
, where P=Po
Po
mol
0.9850 141.36617
min
W= ∫ dx
1−x
0 −3
( 3.5 x 10 ) ( P E ) o [ ]
1+ εx mol
( [
1+ ( 2.69 x 10−3 ) P E o
2
1+ εx
4
])
+ ( 3.81 x 10−3 ) P E
1+ εx [ [ o
2
]]
mol
0.9850 141.36617
min
W= ∫ dx
0
( 3.5 x 10−3 ) ( 0.88 ) 1−x [ ]
1+(1)x mol
0.52809+ x 0.60157+ x g cat . min
( [
1+ ( 2.69 x 10−3 ) ( 0.88 )
1+(1) x ])
+ ( 3.81 x 10−3 ) ( 0.88)
1+(1) x [ [ ]]
Simplifying:
13
mol
0.9850 141.36617
min
W= ∫ dx
0
( 3.5 x 10−3) ( 0.88 ) 1−x
[ ] 1+ x mol
0.52809+ x 0.60157+ x g cat . min
( [
1+ ( 2.69 x 10−3 ) ( 0.88 )
1+ x ]) [ [
+ ( 3.81 x 10−3 ) ( 0.88)
1+ x ]]
W =193,691.7508 g cat
1 kg cat
W =( 193,691.7508 g cat ) ( 1,000 g cat )
=193.69175 kg cat
W =193.69175 kg cat
Source: Fogler, H. (2011). Essentials of Chemical Reaction Engineering. Boston: Pearson

Education, Inc
Catalyst Specification
CC
Shape Column (pelletized)
Dimension Φ2×2-10mm
Pore Volume ≥0.25ml/g
Bulk Density ~0.72 kg/l
Specific Surface Area ≥250m2/g
Crushing Strength ≥98 N/cm2
Attrition <1 wt.%
14
Pore Size ~5A

Binder Type Pseudo-Boehmite
Binder wt.% 30wt.%
Max Temperature 853.15K
Figure ZSM-5 Zeolite Catalyst
Source: ZSM-5 Catalyst by ACS Material-Advanced Chemical Supplier
Reactor Volume in Tube Side
kg
Catalyst Bulk Density ρ B=720
m3
Void Fraction φ=0.45
Void fraction is taken from Morphology and gas permeance of ZSM-5-type zeolite
membrane formed on a porous α-alumina support tube by Kusakabe, Yoneshige, Murata,
Morroka 1996.
15
Calculating for the volume (V R (¿ Tube Side) ¿
M Catalyst
V R ( ¿ Tube Side )=
ρcatalyst ( 1−φ )
193.69175 kg cat
V R ( ¿ Tube Side )=
kg
( )
720 3 ( 1−0.45 )
m
V R ( ¿ Tube Side )=0.48912 m 3
Source:
Fogler, H. (2011). Essentials of Chemical Reaction Engineering. Boston: Pearson

Education, Inc
Mechanical Design
c
Metal Alloy Material Austenitic Stainless Steel
Materials of Construction Stainless Steel 316
Standard (In Tube Side) ASTM A312
Stainless steel has a high chromium content which acts as a protective layer against
corrosion and rust. Stainless steel is one of the cheapest materials next to carbon steel
with maximum service temperature of 760⁰C. It is also applicable to high pressure
applications. While Carbon has low resistance to corrosion and is only limited to less than
5 bar and 500⁰C which is not applicable to the working temperature and pressure in the
16
reactor. It is also high in carbon that when exposed to moisture can corrode and rust
quickly.
Source:
Fogler, H. (2011). Essentials of Chemical Reaction Engineering. Boston: Pearson

Education, Inc
Sinnott, R. (2005). Coulson & Richardson's Chemical Engineering Design (4th ed., Vol.
VI). Oxford: Elsevier Butterworth-Heinemann
Material Alloy Material Specification
17
Source:
316 Stainless Steel: Properties, Fabrication and Applications AZO Materials, Inc
Stainless Steel 316 is also compatible to the chemical component in the reactor tube side
Tube Length and Tube Nominal Size

American Society for Testing and Materials Standard ASTM A312 Standard Specification
for Seamless, Welded, and Heavily Cold Work Austenitic Steel Pipes.
Tube Specifications
18
Tube Length Lt 7 ft 2.1336 m

Inside Diameter I Dt 1.049 inch 26.645 mm
Outside Diameter O Dt 1.315 inch 33.401 mm
Thickness xt 0.133 inch 3.378 mm
Tube Nominal Size Standard

I Di
A reasonably flat velocity profile is assured for values of 10 or more with a
d catalyst
maximum deviation of 20%.
I Dt 26.645 mm
= =13.3225
d catalyst 2 mm
I Dt
=13.3225>10 ( satisfies the 10−20 % deviation )
d catalyst
Source:
Rase, H. F. (1990). Fixed-Bed Reactor Design and Diagnostics Gas-Phase Reactions.

Boston: Butterworth Publisher. Page 123
Reactor Diagram
19
Tube Length Standard
The height of the tube is limited to at least ½ D and not more than 25 ft (7.62 m) to avoid
Lt
crushing the catalyst. The ratio of the tube length to the mean diameter is equal to
d catalyst
or greater than fifty.
Source:
Chaudhari, R. V.; Ramachandran, P. A. (March 1980). "Three phase slurry reactors". AIChE
Journal. 26 (2): 177–201
Fogler, H. Scott (2006). Elements of chemical reaction engineering (4th ed.). Upper Saddle
River, NJ: Pearson Education International/Prentice Hall PTR. p. 850
Catalyst Diameter d catalyst =2 mm
Tube Length Lt =2.1336 m
Calculating for the ratio of Tube length and Catalyst Diameter:
Lt
=
( 2.1336 m ) ( 10001 mmm ) =1066.8
d catalyst 2 mm
Lt
=1066.8>50 ∴ It satisfies the condition
d catalyst
Allowable Operating Conditions in using Stainless Steel 316
20

Maximum Allowable
973.15K
Temperature
Maximum Allowable
35 bar
Pressure
∴ It satisfies the alowable operating conditions
Source:
Chaudhari, R. V.; Ramachandran, P. A. (March 1980). "Three phase slurry reactors". AIChE
Journal. 26 (2): 177–201
Fogler, H. Scott (2006). Elements of chemical reaction engineering (4th ed.). Upper Saddle
River, NJ: Pearson Education International/Prentice Hall PTR. p. 850
Tube Arrangement
The square pitch pattern arrangement in the reactor is the most appropriate for easy
cleaning of equipment. The advantage of square pitch is that the tubes are accessible for
external cleaning and cause a lower pressure-drop when shell-side fluid flows
perpendicularly to the tube axis.
Figure: Tube Pitch
21
Calculating the Number of Tubes
Tube Length Lt =2.1336 m
Volume V R ( ¿ Tube Side )=0.48912 m 3
Inside Diameter of Tubes I Dt =26.645 mm
V R ( ¿ Tube Side )
nt =
π 2
( I D t ) ( Lt )
4
0.48912 m 3
nt = 2
=411.13
π 1m
4[( 26.645 mm ) (
1000mm )] (2.1336 m)
nt =411.13 tubes ≈ 412tubes
nt =412tubes
Tube Pitch (distance between tube centers)
Pt =( 1.25 ) ( O Dt )
Pt =( 1.25 ) (33.401 mm ) =41.75125 mm
Pt =41.75125 mm
Standard: Recommended minimum clearance between tubes for square pattern
arrangement is 0.25 in. (6.4 mm)
Pt =41.75125 mm ≫ 6.4 mm
∴ It satisfies the minimum clearance between tubes
22
Source
VI). Oxford: Elsevier Butterworth-Heinemann.
Tube Bundle Diameter
1
nt
Dbundle =( O Dt ) ( )
K1
n
1
Constant for Calculation of Tube Bundle Diameter
23
For Square pitch for only one pass at k 1∧n1 :
k 1=0.215
n1 =2.207
1
nt
Substituting to the equation Dbundle =( O Dt )
K1( ) n
1
1
288
Dbundle =( 33.401 mm ) ( 0.215 ) 2.207
Dbundle =1025.78 mm
D bundle =( 1025.78 mm ) ( 10001mmm )=1.026 m

D bundle =1.026 m
Shell Inside Diameter
Using Split-ring floating head for clearance in fixed bed reactor
24
Figure Clearance based on bundle diameter
At Split-ring floating head at 0.80300m
Clearance=73 mm
ID s=D bundle + clearance
1m
ID s=1.026 m+ ( 73 mm ) ( 1000mm )=1.099 m
25
ID s=1.099 m
Shell Design Pressure
OP-Operating Pressure of cooling water
(From Energy Balance the cooling water operates at 1 atm)
DP shell =( 1+0.10 ) ( OP )
DP shell =( 1+0.10 ) ( 1atm )=1.10 atm
DP shell =1.10 atm
Sources
Perry's Chemical Engineers' Handbook (8th ed.). New York: The McGraw-Hill
Companies, Inc
Material of Construction Stainless Steel 316

N 220
Design Strength
mm2
Ultimate Tensile N 520
Strength mm2
N 200,000
Young’s Modulus
mm2
Elongation % 40
26
Corrosion Allowance
Pi ID s
e= +C
2 f −P i
Most design codes and standards specify a minimum allowance of C=1.0 mm
e=
( 1.10 atm ) ( 0.101325
1 atm
m m2 (
)1.099 m)
1000 mm
(
1m ) +1.0 mm
N
(2)(220
N
mm
2
)−( 1.10 atm ) ( 0.101325
1 atm
mm
2
)
e=1.28 mm
Source
British Stainless-Steel Association. (n.d.). Comparison of Structural Design in Stainless
Steel and Carbon Steel
Minimum Practical Wall Thickness
27
Since the calculated shell thickness does not meet the standard for wall thickness. The
minimum practical wall thickness will be used instead. The values include a corrosion
allowance of 1.28 mm.
t shell will be based ¿ ID s +corrosion allowance
1m
1.099 m+ ( 1.28mm ) ( 1000 mm )
=1.10 m
∴ t shell=5 mm
Shell Outside Diameter
OD s=ID s +2 t shell
OD s=1.099 m+ ( 2 ) (5 mm ) ( 10001 mmm )=1.109 m

OD s=1.109 m
Choice of Heads and Closures
28
A hemispherical head is the strongest shape; capable of resisting about 30 Bar.
Hemispherical heads are domed heads and used for high pressures.
Figure Heads and Closures
Source
Heigh of Heads and Closures
29
ID s 1.099 m
Lhead = = =0.55 m Lhead =0.55 m
2 2
Heads and Closures Thickness
Hemispherical head thickness calculation is based on American Society of Mechanical
Engineers Standard ASME (para UG-27(d) of ASME Section VIII Division 1 2011 edition
code book).
(DP)(R)
t head= +C
2 fJ −0.2(DP)
Joint Efficiency Table
Source: Sinnott, R. (2005). Coulson & Richardson's Chemical Engineering Design (4th
ed., Vol. VI). Oxford: Elsevier Butterworth-Heinemann
Heads and Closures Design Pressure
(Using Double-welded butt)
30
DP head=( 1+0.10 )( OP )
DP head=( 1+0.10 )( 1 atm )
DP head=1.10 atm
t head=
( 1.10 atm ) ( 0.101325
1 atm
mm2 (
)
0.55 m )
1000 mm
(
1m ) +1 mm
N
(
( 2 ) 220
N
mm2
( 0.7 )
)
−0.2 ( 1.10 atm ) (
0.101325
1atm
mm2
)
t head=1.19 mm
Height of Reactor
Lreactor =Lt + ( 2 ) ( Lhead ) + ( 2 ) ( t head )
Lreactor =2.1336 m+ ( 2 )( 0.55 m ) + ( 2 )( 1.19 mm ) ( 10001 mmm )

Lreactor =3.23598 m
Source
L/D Standard
Pressured vessel standard for length/diameter ratio ranges to 2-4
31
Lreactor 3.2360m
= =2.92
OD s 1.109m
Lreactor
=2.92
OD s
length
2<2.92< 4 ∴ It satisfies the standard
diameter
Baffles
Single Segmental Baffle will be used to direct the fluid stream across the tubes, to
increase the fluid velocity and so improves the rate transfer.
Baffle Cut
A baffle cut of 20% will be the optimum, giving good transfer rate, without excessive drop
Figure Baffle Cut
Baffle Spacing (Baffle Pitch)
32
The common standard by manufactures for baffle pitch is 20% of shell inside diameter.
l B =0.2 ID s
l B =0.2 (1.099 m )=0.2198 m
l B =0.2198 m
Number of Baffles
Lt
NB= −1
lB
2.1336 m
NB= −1
0.2198 m
N B =8.71 baffles≈ 9 baffles
N B =9 baffles
Tube Plate Thickness
Pi
t tube plate =( C ) ( ID s )
√ f
Source
Edge support Constant
33
C=0.56
√ ( )
( 1 atm ) 0.101325
1000mm m m2
t tube plate =( 0.56 )( 1.099 m ) ( 1m ) 220
N
mm2
t tube plate =13.21 mm
Source:
3Tubular Exchanger Manufactures Association, Inc. (2007). Standards of the Tubular
Exchanger Manufacturers Association ( 9th Ed.)
Thermal Design
34
Tube and Shell Side Specifications
Tube Side
kg
Mass Flowrate 1,604.16
hr
kmol
Molar Flowrate 89.02
hr
Pressure 100 kPa
kg
Density 0.3669 3
m
kJ
Specific Heat Capacity 2.0231
kg
kg
ms
Watt
mK
Shell Side
kg
Mass Flowrate 411.3311
hr
kmol
Molar Flowrate 9.62
hr
Pressure 101.325 kPa
kg
Density 1.2309 3
m
J
Specific Heat Capacity 1,851.91
kg K
kg
ms
Watt
mK
Shell Side Temperature Profile
Shell Side
Inlet Temperature 150 ℃
Outlet Temperature 280 ℃
Type of Heat Transfer
Counter-current flow heat transfer
35
Log Mean Temperature Difference
( T 1−t2 ) −( T 2 −t1 )
∆ T lm=
( T 1 −t 2 )
ln
[ ]
( T 2 −t 1 )
Shell Side
t 1=150 ℃
t 2=280 ℃
Tube Side
T 1=320 ℃
T 2=300 ℃
( T 1−t2 ) −( T 2 −t1 )
∆ T lm=
( T 1 −t 2 )
ln
[ ]
( T 2 −t 1 )
( 320℃ −280℃ )−( 300 ℃−150 ℃ )

∆ T lm=
( 320 ℃−280 ℃ )
ln
[
( 300 ℃−150 ℃ ) ]
∆ T lm=83.22 ℃
Dimensionless Temperature Ratio
t 1−t 2
R=
T 2−T 1
36
T 2−T 1
S=
t 1−T 1
150 ℃−280 ℃
R=
300 ℃−320 ℃
R=6.5
300 ℃−320 ℃
S=
150 ℃−320 ℃
S=0.1176
Correction Factor for Counter-Current Flow
37
Correction Factor F t=0.95
True Temperature Difference ∆ T m=F t ∆ T lm
∆ T m= ( 0.95 )( 83.22 ℃ )
∆ T m=79.059 ℃
Shell Side Coefficient
Shell Side Cross Flow Area
( pt −ODt ) ID s l b
A s=
pt
( 41.75125 mm−33.401 mm ) ( 1.099 m )( 0.2198 m )

A s=
41.75125 mm
A s=0.04831 m2
38
Shell Side Mass Velocity
Ws
Gs =
As
kg 1 hr
G=
( 411.3311 )(
hr 3600 s )
=2.3651
kg
s 2 2
0.04831 m m s
kg
G s =2.3651
m2 s
Shell Side Linear Velocity
Gs
v s=
ρs
kg
2.3651
m2 s
v s=
kg
1.2309 3
m
m
v s=1.9214
s
39
Shell Side Equivalent Diameter
For a square pitch arrangement
1.27 2
d e= [ p −0.785 OD2t ]
OD t t
1.27
d e=
33.401 mm
[ ( 41.75125 mm )2 −0.785 (33.401 mm )2 ]
d e =32.9830 mm
Shell Side Reynold’s Number
G s de
ℜ=
μ
kg 1m
ℜ=
( 2.3651 2
m s) (32.9830 mm )(1000 mm )
=6,123.5649
kg
1.2739 x 10−5
ms
ℜ=6,123.5649
Shell Side Prandtl Number
Cp μ
Pr=
kf
J kg
Pr=
( 1,851.91
kg K )(
1.2739 x 10 −5
ms )
( 0.0286 mWK )( 1W1 J s )
40
Pr=0.8249
Shell Side Heat Transfer Factors for Segmental Baffles
Figure Shell Side Heat Transfer Factors for Segmental Baffles
Baffle Cut 20%
Heat Transfer Factor j h =0.25
Shell Side Coefficient
hs d e μ 0.14
kf ( )
= j h ℜ Pr 1 /3 ⁡
μw
41
Without viscosity correction term
kf
h s=( ) j ℜ Pr
de h
1/3
W
0.0286
h s=
(32.9830 mm
mK
1m
(
1000 mm ) )
(0.25)(6,123.5649)¿
W
h s=1,244.9560
m2 K
Tube Side Coefficient
Cross Sectional Area of Tube
π
¿ A c = I Dt
4
π 26.645 mm 2
¿ Ac =
4 (1000 )
=5.5760× 10−3 m2
Ac =5.5760 × 10−3 m2
Tube Total Flow Area
Af ∧¿ Ac nt
A f =( 5.5760 ×10−3 m2 ) ( 412 )
A f ∧¿ 0.2297 m2
42
Tube Side Mass Velocity
Wt
¿ Gt =
Af
kg hr
¿ Gt =
( 1,604.16 )(
hr 3600 s )
2
0.2297 m
kg
¿ Gt =1.9399 2
m s
Heat Transfer for Spherical Particles in Tube
G0.95
¿ hi=15.1
( )
t
d 0.42
cat ❑
kg 0.95
(( ) ]
( )
1. 9399
m2 s
¿ hi =15.1
2mm 0.42
1000
W
¿ hi=385.42
m2 K
Overall Heat Transfer Coefficient
O Dt
1 1 1
O Dt ln ( ) I Dt O Dt 1 O Dt 1
= + +
U o hs hod 2 kw [
+ ×
I Dt hid][
+ ×
I Dt hi ]
43
Fouling Factors Coefficient
Materials of Construction Specifications
kw W
Stainless Steel 316 Thermal Conductivity 18.47
mC
Outside Dirt h od W
Shell 5,000
Coefficient mC
hi d W
Tube Inside Dirt Coefficient 5,000
mC
44
1 1 1
( 33.401 mm ) ( 10001mmm ) ln ( ( 33.401 mm )
26.645 mm ) 33.401 mm 1
Uo
=
W
1,244.9560 2
m K
+
5,000
W
mC
+
2 ( 18.47
W
mC)
[ +
26.645 mm
×
5,000
W
U o =212.2814
m2 K
Heat Transfer Area
kJ
From Energy Balance: Q=1,401.1503
s
Q=U o AΔ T m
A=
Q
=
( 1,401.1503 kW ) ( 1000 W
kW )
=83.4875 m 2
U o Δ Tm
( 212.2814 mWK ) (79.059 ℃ )
2
A=83.4875 m2
Effectiveness of Heat Transfer
1−exp [−NTU ( 1−Cr ) ]

ε= ( C r <1 )
1−C r exp [ −NTU ( 1−C r ) ]
45
NTU
ε= ( C =1 )
1+ NTU r
Capacity Ratio
C min
C r=
C max
C min =mt C p t
C max=ms C p s
kg hr kJ kJ
(
C min = 1,604.16 )(
hr 3600 s
2.0231 )(
kg
=0.9015
Ks )
kW
C min =0.9015
K
kg 1 hr J kJ
(
C max= 411.3311
hr )( 3600 s )( 1,851.91
kg K )=211.5967
Ks
kW
C max=211.5967
K
kW
0.9015
K
C r= =4.2605 x 10−3
kW
211.5967
K
C r=4.2605 x 10−3
Number of Transfer Unit
Uo A
NTU =
Cmin
46
NTU =
( 212.2814 2
m K )
( 83.4875m 2 )
=19.6593
kW 1000W
( 0.9015
K )(
kW )
NTU =19.6593
1−exp [ −( 19.6593 ) ( 1−4.2605 x 10−3 ) ]

ε=
1−( 4.2605 x 10−3 ) exp [−( 19.6593 ) ( 1−4.2605 x 10−3 ) ]
ε =96.7 %
Mechanical Design for Vessel Openings
Nozzle Diameter for Process Gas
W 0.45
D Nozzle ( Tube )=8.41
ρ0.31
kg 0.45
(1,604.16
)
hr
DNozzle ( Tube )=8.41
kg 0.31
(0.3669 3 )
m
DNozzle ( Tube )=317.7954 mm
DNozzle ( Tube )=3 20 mm
Nozzle Thickness
t Nozzle ( Tube ) =P⋅ D Nozzle (Tube ¿ ¿ +C

2 f −P
47
t Nozzle ( Tube ) =
(100 Kpa ) ( 0.001
Kpa
mm2
) (317.7954 mm)
+1.0 mm=1.0722mm
N
(
2 220
N
mm2
−(100 Kpa )
0.001
)
Kpa
m m2
( )
t Nozzle ( Tube )=1.0722mm
Nozzle Diameter for Cooling Water
W 0.45
D Nozzle ( Shell )=8.41
ρ 0.31
0.45
kg
DNozzle ( Shell ) =8.41

[( 411.3311
hr )]
0.31
kg
( 1.2309
m3 )
D Nozzle ( Shell ) =118.3622 mm
D Nozzle ( Shell ) =120 mm
Nozzle Thickness
P⋅ D Nozzle ( Shell )
t Nozzle ( Shell )= +C
2 f −P
t Nozzle ( Shell )=
(10 1.325 Kpa ) ( 0.001
Kpa
mm2
) (118.3622 mm)
+1.0 mm=1.0273 mm
N
(
2 220
N
m m2
−(101.325
)
Kpa )
0.001
Kpa
mm2
( )
48
t Nozzle ( Shell )=2 mm
49
50
51

Ethylene Fixed Bed Reactor Equipment Design

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Ethylene Fixed Bed Reactor Equipment Design

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Technological Institute of the Philippines

TUBULAR FIXED BED REACTOR

Physical and Chemical Parameters

Schedule Number SCH NO. 40S (Standard)

Material of Construction Stainless Steel 316

Tube and Shell Side Specifications

Tubular Fixed Bed Reactor

catalysts that are arranged as a so-called fixed bed in the reactor.

Ethylene Formation from Ethanol Dehydration Using ZSM-5 Process

The dehydration of ethanol is a process used to produce ethylene.

The main reaction in the process is:

Ethanol is converted in a reactor packed with catalyst to produce ethylene and

(ACS Omega 2017, American Chemical Society).

From Material Balance

Considering the side reaction:

I 0.08 0.02 0.02

Source: Catalytic Conversion of Ethanol to Ethylene over ZSM-5 Zeolite Catalyst by

Calculating the value of x from ICE table

Side Reaction Suppression

sufficiently so that single reaction behavior is approached.

Considering the main reaction

Theoretical Investigation of Ethanol Conversion to Ethylene over ZSM-5 by

Water H2O 9.51727 0.52938 171.50114 0.41694

Ethylene C2H4 8.35474 0.46472 234.35055 0.56974

Diethylethe C4H10 0.02120 0.00382

TOTAL 17.97803 1.00000 411.33105 1.00000

From Material Balance:

3.5 x 10−3 mol

Since the reaction is in gas phase;

Simplifying the chemical reaction

ε =( Purity of feed ) ( stoichiometric coefficient of product −stoichiometric coefficient of reactant

Getting the Partial pressures of the species

For the products

Calculating θ for each product:

1+ ( 2.69 x 10 ) PC H + ( 3.81 x 10 ) PH O g cat . min

1+ ( 2.69 x 10 ) PC H + ( 3.81 x 10 ) PH O g cat . min

Source: Fogler, H. (2011). Essentials of Chemical Reaction Engineering. Boston: Pearson

Substituting the values:

Source: Fogler, H. (2011). Essentials of Chemical Reaction Engineering. Boston: Pearson

Pore Size ~5A

Figure ZSM-5 Zeolite Catalyst

Source: ZSM-5 Catalyst by ACS Material-Advanced Chemical Supplier

Reactor Volume in Tube Side

Void Fraction φ=0.45

membrane formed on a porous α-alumina support tube by Kusakabe, Yoneshige, Murata,

Calculating for the volume (V R (¿ Tube Side) ¿

V R ( ¿ Tube Side )=0.48912 m 3

Fogler, H. (2011). Essentials of Chemical Reaction Engineering. Boston: Pearson

with maximum service temperature of 760⁰C. It is also applicable to high pressure

Fogler, H. (2011). Essentials of Chemical Reaction Engineering. Boston: Pearson

Material Alloy Material Specification

Tube Length and Tube Nominal Size

Tube Length Lt 7 ft 2.1336 m

Tube Nominal Size Standard

Rase, H. F. (1990). Fixed-Bed Reactor Design and Diagnostics Gas-Phase Reactions.

Tube Length Standard

or greater than fifty.

Fogler, H. Scott (2006). Elements of chemical reaction engineering (4th ed.). Upper Saddle

River, NJ: Pearson Education International/Prentice Hall PTR. p. 850

Catalyst Diameter d catalyst =2 mm

Tube Length Lt =2.1336 m

Calculating for the ratio of Tube length and Catalyst Diameter:

Allowable Operating Conditions in using Stainless Steel 316

Schedule Number SCH NO. 40S (Standard)