Mechanical Design Details for Reactor R-4 and Associated Equipment

APPENDIX F
F.1 Mechanical Design For Reactor, R-4 Appendix F-2

F.2 Mechanical Design For Flash Drum, F-7 Appendix F-9
F.5 Mechanical Design For Storage Tank – Nitrogen Appendix F-34
F.6 Mechanical Design For Storage Tank – Hydrogen Appendix F-35
F.7 Mechanical Design For Storage Tank – Ammonia Appendix F-36
F.1 Mechanical Design For Reactor, R-4
Design Pressure
The reactor must be designed to withstand the maximum pressure to which it
is likely to be subjected in operation. For reactor under internal pressure, the design
pressure is taken as 10% of the working pressure to avoid spurious operation during
minor process upsets.
Pi = 1 atm x 1.1 = 1.1 atm
= 1.114575 bar = 0.1114575 N/mm2
Design Temperature
The strength of metals decreases with increasing temperature. Therefore, the
maximum allowable design stress will depend on the material temperature. The
design temperature is taken as the maximum working temperature in the reactor.
T= 60C = 333.15 K
Material Of Construction
For design purposes, it is necessary to decide a value for the maximum
allowable stress that can be accepted in the material of construction. It has been
stated that the material of construction is stainless steel, 18 Cr/ 8 Ni, unstabilised
(304). The reasons are very clear that it has to withstand the internal high pressure (in
tube side). Besides it has to withstand the sudden changes (reaction) that take place
in it.
From Table 13.2, Chemical Engineering Volume 6 (page638), for 18 Cr/ 8 Ni,
Design stress, f at 60C = 145 N/mm2
Tensile strength = 510 N/mm2
Corrosion Allowance
The corrosion allowance is the additional thickness of metal added to allow
for material lost by corrosion and erosion. From Chemical Engineering Volume 6
(page 641), the minimum corrosion is taken as 2 mm.
 Welded Joint Efficiency

From Table 13.3, Chemical Engineering Volume 6 (page 639), welded joint
efficiency is taken as 1.0 implies that the joint is of double-welded butt type and
with 100% degree of radiography.
J = 1.0
Appendix F-2
Design for Shell Wall Thickness
There will be a minimum shell wall thickness required to ensure that any vessel
is sufficiently rigid to withstand its own weight. From Chemical Engineering
Volume 6, for a vessel diameter between 1 m to 2 m, its wall thickness (include
corrosion allowance of 2mm) should not less than 7 mm.
For a cylinder shell, the minimum thickness required to resist internal pressure is
determine from the equation (given in the BS 5500):
Pi D s
e
2f  Pi
Where,
e = wall thickness
Ds = internal diameter = 1.6797 m
Pi = design pressure = 0.1114575 N/mm2
f = design stress = 145 N/mm2
0.1114575 N / mm 2 x1.6797  1000mm
e  0.6458mm
2 x145N / mm 2  0.1114575 N / mm 2
Corrosion Allowance Thickness
Let the corrosion allowance thickness = 2mm,
The shell wall thickness = 0.6458 + 2 = 2.6458 mm
This value is lower than minimum thickness; hence the value of 7 mm should be
taken instead of 2.6458 mm in order to ensure that the vessel is sufficiently rigid to
withstand its own weight.
Hence, diameter of reactor, Dr = Ds + 2e = 1.6937 m
Baffles Thickness
The baffles used would be in the form of flat stainless steel plate. Thickness of the
plate,
Pi
t bf  0.5FD bf
f
Where,
Dbf = diameter baffle = Ds- cs = 1.6797 – 0.0016 = 1.6781 m
F = factor equal to 1.00 for a fixed plate
Therefore,
0.1114575
t bf  0.5 1 1.6781 = 0.02326 m = 23.2626 mm
145
Appendix F-3
Domed Head (Torispherical)
The ends of a cylinder vessel are closed by heads of various shapes. The
principal types used are flat plates and formed flat heads, hemispherical heads,
ellipsoidal heads and torispherical heads. For reactor, R-4, closure of type
torispherical is selected because it will usually prove to be the most economical
closure to be used.
Torispherical head is used because the pressure is 1.01325 bar and it is

cheaper than ellipsoidal head and hemispherical head. The vessel domed ends design
will be calculated as follows for the torispherical ends closure:
Pi R c Cs
e
2fJ  Pi (C s  0.2)
Where,
Cs = stress concentration factor for torispherical heads
J = Joint factor = 1.0
Rc = crown radius. Assume same with Dr = 1.6937 m
Rk = knuckle radius. Assume 6 % of Rc = 0.101622 m
The ratio of the knuckle to crown radii should not be less than 0.06, to avoid
buckling and the crown radius should not be greater than the diameter of the
cylindrical section.
1 Rc
Cs  (3  )
4 Rk
= 1.77062
Domed minimum wall thickness,
0.1114575 N / mm 2 x1693.7 mm
e  0.65056 mm
(2 x145N / mm 2 x1)  0.1114575(1.77062  0.2)
= 0.65056 mm + 2 mm (Corrosion Factor)

= 2.65056 mm
Take the same thickness as shell wall thickness, hence thickness of domes head
= 7 mm.
e
Flange
Appendix F-4
Outside Diameter for Shell
Let insulation thickness = 75mm, hence
Shell outside diameter = Dr + 2(75x10-3)
= 1.8437 m
» 1.9 m
Weight Loads
Weight Load of Shell
Wv = 240CvDm (Hv + 0.8Dm) t
= 240(1.15)(Ds+t´10-3)[L+0.8(Ds+t´10-3)]t
= 240(1.15)(1.6797+7x10-3 )[5.58+0.8(1.6797+7x10-3)]7
= 22580.7359 N
Where,
Wv= total weight of the shell, excluding internal fittings, such as plates, N
Cv = a factor to account for the weight of nozzles, manways, internal supports
= 1.15
Hv = height, or length between tangent lines (the length of the cylindrical section), m
t = wall thickness, mm
Dm = mean diameter of vessel = (Ds + t x 10-3), m
Weight Load of Pipe
For Stainless Steel, 2inch, Schedule 40, weight of a pipe = 3.66lb/ft (Peter
and Timmerhaus, 1991), hence, for 320 pipes,
Wp = No. of pipes ´ Weight of pipe/length ´ L ´ 9.81
= 320´3.66/0.3048´0.4536´5.58´9.81
= 95409.6611 N
Weight of Insulation Material
Fibreglass (density=100kg/m3) is used as insulation material. The thickness of it
= 75 mm.
Approximate volume of insulation = p´1.9´75´10-3´ 5.58
= 2.4980 m3
Wi = Volume of insulation material ´ density of material ´ 9.81
= 2.4980´100´9.81
= 2450.538 N
Weight Load of Fluid (Shell Side)
Appendix F-5
Wfs = mass flowrate (shell side) ´9.81
= 43.4312´9.81
= 426.06 N
Weight Load of Fluid (Tube Side)
Wft = mass flowrate (tube side) ´9.81
= (4988.8699/3600)´9.81
= 13.5947 N
Weight Load of Catalyst
Wc = 5318.0886 kg ´ 9.81
= 52170.4492 N
Total Weight Load
Total Weight load, W = Wv + Wp + Wi + Wfs + Wft + Wc
= (22580.7359 + 95409.6611+ 2450.538 + 426.06 +13.5947 + 52170.4492) N
= 173051.0389 N = 173.051 kN
Reactor Support
The reactor will be place as horizontally vessel because the diameter of the reactor is
greater than 1.2 m. As for the support of the reactor, saddle support has been chosen
as the support material.
Analysis of Stresses (saddle supports)

At bottom tangent line
Pressure stresses
The longitudinal and circumferential stresses due to pressure given by:
PD s 0.101325 1.6797 10 3
L  = = 6.0784 N/mm2
4t 47
PD s 0.101325 1.6797  10 3
h  = = 12.1568 N/mm2
2t 2 7
Dead weight stress

Wv 22580.7359
w = =   (1.6797  10 3  7) 7 = 1.912 N/mm2
  (D s  t ) t
The longitudinal bending stress at the mid-span of the vessel is given by:
M L1 Ds 4M L1
 b1  x 
Ih 2 D s 2 t
Appendix F-6
Where,
ML1 = Longitudinal bending stress at the mid-span
Ih = Second moment of area of the shell
Assume that the load per unit length is due to weight of vessel alone,
2
wL1
M L1 
2
w = Total Weight load x 1000/5.58 = 31012.731 N
L1 = L / 2 = 5.58/2 = 2.79 m
ML1= 31012.731(2.79)2/2 = 120703.0997 Nm
4M L1 4 120703.0997
 b1  = = 7781566.931N/m2 = 7.7816 N/mm2
  1.6797   7  10 3
2 2
D s t
The resultant axial stress due to bending and pressure will be given by:
Pi D s 4M L1
z   2
4t D s t
Pi D s 0.1114575 1.6797  10 3
= = 6.6863 N/mm2
4t 4  7
z (upwind)= (6.6863 + 7.7816) N/mm2 = 14.4679 N/mm2

z (downwind)= (6.6863 – 7.7816) N/mm2 = -1.0953 N/mm2
As assume that there is no torsional shear stress, the principal stresses will be z and
Pi 0.1114575
h. The radial stress is negligible,    0.05573 N / mm 2 .
2 2
14.4679 1.0953
12.1568
12.1568
Up-wind
Down-wind
The greatest difference between the principal stresses will be on the down-wind side,
Appendix F-7
= h - z (downwind) = 12.1568 – (-1.0953) = 13.2521 N/mm2. This value is well
below the maximum allowable design stress (145 N/mm2). Thus, the design is
satisfactory.
The theoretical optimum position of the supports to give the least maximum bending
moment will be the position at which the maxima at the supports and at mid-span are
equal in magnitude. For uniformly loaded beam, the position will be at 21% of the
span, in form each end. Therefore:
L2 = 0.21 x L = 0.21 x 5.58 = 1.1718 m from each end
The longitudinal bending stress at the supports,
4M L 2
b2 
C h Ds 2 t
Where,
Ch = an empirical constant; varying from 1.0 for a completely stiff shell to about 0.1
for a thin, unstiffened shell
2
wL 2 31012.731  (1.1718) 2
M L2    21292.02679 Nm
2 2
For completely stiff shell,
4  21292.02679
b2 = 1    (1.6797) 2  7 10 3 = 1372668.407 N/m2 = 1.3727 N/mm2
Elastic stability (buckling)
Under condition where the resultant axial stress z, due to the combined
loading is compressive, the vessel may fail by elastic instability (buckling). Failure
can occur in a thin –walled process column under an axial compressive load by
buckling of the complete vessel, as with a strut, or by local buckling, or wrinkling, of
the shell plates. The critical buckling stress c is given by:
E  t 
c   

31 v 2
 R
 p


With stainless steel at ambient temperature, E = 340,000 N/mm2, a safety factor of 12

will be used and the radius of curvature, Rp = Dr
 t   7 
 c  3.4 x10 4    3.4 x10 4    140.5208N / mm
2
 Dr   1693.7 
The maximum compressive stress will occur when the vessel is not under
pressure.
Maximum compressive stress = w + b1
Appendix F-8
= (1.912 + 7.7816) N/mm2
= 9.6936 N/mm2
9.6936 < 140.5208, well below the critical buckling stress. So design is
satisfactory.
Saddle Support
The standard steel saddle supports is given in Fig. 13.26b, Chemical Engineering,
Vol. 6 (page 673). The design and dimension of the support for the reactor can be
predicted by interpolation.
Vessel Max. Dimensions (m) mm
diam. weight Bolt Bolt
(m) (kN) V Y C E J G t2 t1 diam. holes
1.8 380 1.08 0.2 1.59 0.71 0.405 0.14 12 10 24 30
1.84 397.498 1.102 0.2 1.629 0.73 0.415 0.14 12 10 24 30
2 460 1.18 0.2 1.77 0.8 0.45 0.14 12 10 24 30
The total weight for the designed reactor is 173.051 kN which is less than the
maximum weight of the standard saddle support. Therefore the saddle support
dimension could be used.
F.2 Mechanical Design For Flash Drum, F-7
This calculation is shown according to equations and data from Chemical

engineering, Vol. 6, page 735-781. End result is presented in tabulate form in chapter
5 along with the equipment drawings.
Pressure = 89.94 atm

= 91.14 bar
= 9.114 N/mm2
Temperature = -23 C
DFlash = 0.5577m
= 557.5 mm
LFlash = 2.7885m
Appendix F-9
= 2788.5 mm
Skirt Height = 1.5m
1. Design Pressure
For safety purpose, the design pressure will operate 10% above the operating
pressure was chosen.
Design Pressure, Pi
= 9.114 bar x 1.1
= 100.254 bar
= 10.0254 N/mm2
2. Material Used
Material of construction: Carbon Steel (CS) is chosen as the material for flash for
safety purpose. From Chemical Engineering Volume 6 (Table 13.2), the strength
property of this material is:
Design Stress, f = 145 N/mm2 at temperature –23  C
Tensile Strenght = 360N/mm2
3. Welded Join Efficiency
Taking the factor as 1.0 implies that the joins is equally as strong as the virgin plate :
this achieve by radio graphing the complete weld length and cutting out and
remarking any effect. The lower joint factor will results in a thicker and heavier
vessel.
4. Corrosions Allowance
From Chemical Engineering Volume 6 the min corrosion of 2 mm has been chosen,
where several corrosion is not expected.
Min corrosion = 2 mm
5. Min Wall Thickness
Thickness of the vessel is given as ei
Pi Di
ei 
2 f  Pi
where,
ei = minimum wall thickness, mm
Pi = vessel internal design pressure
= 10.0245 N/mm2
Appendix F-10
f = typical design stresses for plat ( from Table 13.2 in Chemical Engineering
Volume 6)
= 145 N/mm2
Di = shell inside diameter
= 0.5577 m
ei = 19.9703 mm
Therefore, the wall thickness = ei + corrosion allowance
Wall thickness = 21.9703 mm
A much thickness wall will be needed at the column base to withstand the wind and
dead weight loads. For the first trial, divide the column into 5 section with thickness
increasing by 2 mm per section.
Section 1 = 21.9703 mm
Average thickness = 25.9703 mm
6. Design Of The Domed Head
Domed Head
Type : Ellipsoidal head
J :1
Minimum thickness required
Pi Di
ei 
2 jf  0.2 Pi
ei = 19.4141 mm
Head thickness = 21.4141 mm
Divide the column in to 5 section with increasing by 2 mm per section as shown in
cylindrical section above.
Appendix F-11
Average thickness, t = 27.4141 mm
= 0.02741 m
The height of ellipsoidal head is related to column diameter and it is expressed as
D
h
4
h = 0.1394 m
= 139.425 mm
7. Weight Loads
Loading on vessel
Loading sources of vessel also includes dead weight of vessel, content, wind external
loads imposed by piping and attached equipment.
Dead weight of vessel
where,
t = 24.4141 mm
Cv = a factor to account for the weight of nozzles, manways, internal
support = 1.15
Di = 0.5577 m
Dm = mean diameter of vessel
= Dm  Di  t  103
= 0.5851 m
Hv = height of vessel between tangent lines
Wv = total weight of the shell, excluding internal fitting, such as plates, N
Weight of Vessel
wv  240Cv Dm  H v  0.8 Dm  t
= 14.417 kN
= 14417.40477 N
Weight of insulation
From Chemical Engineeering Volume 6
Type of insulating material : mineral wool
Density : 130 kg/m3
Thickness, ti : 75 mm
Approximate volume of insulating
D m H v t i
Wi = rmaterial Vmaterial g
Appendix F-12
= 490.3329 N
= 0.4903329 kN
Total weight = Shell + Insulation
= 14904.7377 N
8. Wind Loading
Take the dynamic wind pressure as, Pw = 1280 N/mm2
Mean diameter, Dm = Dm  Di  2 t  t i  10 3 
= 0.76253 m
Where,
t = average diameter
ti = thickness of insulation
Wind loading (per linear meter) = Fw  Pw  D w
= 976.0361 N/m
Hv 2  Fw
Bending moment at bottom tangent lines = Mx 
2
= 3794.6978 Nm
9. Stress Analysis
Pressure stress
Pi Di
n  = 101.976 N/mm2
2t
Pi Di
l  = 50.9880 N/mm2
4t
Dead weight stress

wv
w  = 0.2958 N/mm2
  Di  t  t
where Wv = total weight

Bending stress
Do  Di  2t = 612.5282 mm
= 0.612528 m
Second moment of area of vessel
  Do4  Di4 
Iv  = 2.162E+09 mm4
64
The bending stress which will be compressive are tensile are given
Appendix F-13
D 
M x i  t
 2  = 0.53766 N/mm2
b  
lv
Resultant longitudinal stress

 z l w b = 51.8215N/mm2 upwind
= 50.7426 N/mm2 downwind
The greatest difference between the principle stresses, on the downwind
= 51.2299 N/mm2
Well below is design stress for carbon steel = 145 N/mm2
Elastic stability (bucking)
2  10 4  t 
c  = 895.1134 N/mm2
Do
10. Vessel Support

As a trial, a straight cylindrical skirt used. The vessel vertically stress therefore the
type of support used is skirt.
Material of construction : Carbon steel
Design stress, f : 135 N/mm2
Young Modulus, e : 200000 N/mm2
The maximum dead weight load on the skirt will occur when vessel full of water
Approximate weight
  Di2  H v   H 2o  g
W =
4
= 6683.2412 N
= 6.6832 kN
Weight of vessel = 14471.4048 N
Total weight = 21100.6460 N
= 21.1006 kN
Skirt height
Bending moment, skirt base, M=Mx
Fw   H v  1
2
M  = 25118.8546 Nm
Di
= 25.1189 kNm
Bending stress skirt
Appendix F-14
4M s
 bs  = 3.5746888 N/mm2
  D s  t s  t s Ds
Dead weight on the skirt

w
 ws  test   = 0.1326069 N/mm2
  Ds  t s  t s
w
 ws  operating   = 0.2957950 N/mm2
  Ds  t s  t s
max  s  compressive    bs   ws  test  = 3.7072958 N/mm2

max  s  tensile   bs   ws  operating  = 3.2788939 N/mm2
Take the join factor, J =1
Criteria for design
 s  tensile   f s JSin 3.2788939 < 145 N/mm2
 t 
 s  compression   0.125E  s  Sin 3.7072958 < 1228.8915 N/mm2
 Ds 
11. Base Ring And Anchor Bolts

Pitch circle diameter : 2.2 m
Circumference of bolt circle : 2200  = 6912.4
Closest of 4, Nb : 12
Ms : 25118.8546 Nm
Wv (operating pressure) : 14907.738 N
Bolt design stress, fb : 125 N/mm2
The area of one bolts is given by
1  4M s 
Ab     W  = 20.5086 mm2
N b f b  Db 
Bolt root diameter

Ab  4
d = 5.1097 mm

Total compressed load on based ring per length

4M s w
Fb   = 111321.5810 N/m
D 2
s
D s
Take the beaming, fc = 5 N/mm2

Base ring
Appendix F-15
Fb
Lb  = 22.2643 mm
1000 f c
The minimum available standard bolt size

Bolt size : M24
Root are : 353 mm
Lr : 76 mm
fr : 140
Actual width required
Lr + ts + 50 = 153.4141 mm
Actual beaming pressure on concrete foundation
fc = 0.72563 N/mm2
Base thickness
3 fc
tb  Lr = 9.47692 mm
fr
12. Nozzle Feed Sizing

Material : Carbon steel
Design stress : 145 N/mm2
Operating pressure : 100.254 bar
Corrosion allowance : 2 mm
Optimum duct diameter, dopt

d opt  226G 0.50  0.35
Density : 666.13 kg/m3

Flowrate : 11.87 kg/hr
dopt = 79.9996 mm
Nozzle thickness, tno
psdopt
tno
20d  ps = 2.673202 mm
Thickness of nozzle = 4.6732 mm
13. Top Product Nozzle
Material : Carbon Steel
Design pressure : 145 N/mm2
Appendix F-16
dopt = 187.7424 mm
Nozzle thickness, tno = 6.2734 mm
14. Bottom Product Nozzle
dopt = 42.3535 mm


= 60.76 bar
= 6.076 N/mm2
Temperature = -41.85 C
DFlash = 0.7418 m
= 741.8 mm
Appendix F-17
LFlash = 3.7092 m
= 3709.2 mm
Skirt Height = 1.5m
1. Design Pressure
Design Pressure, Pi
= 6.076 bar x 1.1
= 66.8411 bar
= 6.6841 N/mm2
2. Material Used
Design Stress, f = 145 N/mm2 at temperature –41.85  C
vessel.
Pi Di
ei 
2 f  Pi
where,
Appendix F-18
= 6.6841 N/mm2
Volume 6)
= 145 N/mm2
= 0.7481m
ei = 17.5009 mm
Domed Head
J :1
Pi Di
ei 
2 jf  0.2 Pi
ei = 17.1767 mm
Appendix F-19
= 0.02518 m
D
h
4
h = 0.1885 m
= 185.45 mm
7. Weight Loads
Loading on vessel
where,
t = 25.1767 mm
support
Di = 0.7481 m
= Dm  Di  t  103
= 0.7670 m
Weight of Vessel
wv  240Cv Dm  H v  0.8 Dm  t
= 23.038 kN
= 23038.41828 N
Density : 130 kg/m3
Appendix F-20
D m H v t i
= 854.9529 N
= 0.8549529 kN
= 23893.3712 N
8. Wind Loading
= 0.94215 m
Where,
= 1205.9563 N/m
Hv 2  Fw
2
= 8295.8724 Nm
9. Stress Analysis
Pressure stress
Pi Di
n  = 98.4700 N/mm2
2t
Pi Di
l  = 49.2348 N/mm2
4t
Dead weight stress

wv
w  = 0.3938 N/mm2
  Di  t  t

Bending stress
Do  Di  2t = 792.1530 mm
= 0.792153 m
Appendix F-21
  Do4  Di4 
Iv  = 4.466E+09 mm4
64
D 
M x i  t
 2  = 0.73572 N/mm2
b  
lv

 z l w b = 50.3643 N/mm2 upwind
= 49.5767 N/mm2
2  10 4  t 
c  = 635.6513 N/mm2
Do
10. Vessel Support

Approximate weight
  Di2  H v   H 2o  g
W =
4
= 15727.8408 N
= 15.7278 kN
= 15.7509 kN
Skirt height
F   H v  1
2
M  w = 36052.7998 Nm
Di
Appendix F-22
= 36.0528 kNm
4M s
 bs  = 3.2042447 N/mm2
  D s  t s  t s Ds

w
 ws  test   = 0.2592284 N/mm2
  Ds  t s  t s
w
 ws  operating   = 0.3938138 N/mm2
  Ds  t s  t s

Criteria for design
 t 
 Ds 

Ms : 36052.7998 Nm
1  4M s 
Ab     W  = 27.7714 mm2
N b f b  Db 
Bolt root diameter

Ab  4
d = 5.9460 mm


4M s w
Fb   = 93661.6267 N/m
D 2
s
D s
Appendix F-23
Base ring
Fb
Lb  = 18.7323 mm
1000 f c

Bolt size : M24
Root are : 353 mm
Lr : 76 mm
fr : 140
Lr + ts + 50 = 151.1767 mm
fc = 0.61955 N/mm2
Base thickness
3 fc
tb  Lr = 8.75687 mm
fr

d opt  226G 0.50  0.35

dopt = 67.1539 mm
psdopt
tno
20d  ps = 1.512936 mm
Appendix F-24
dopt = 207.8144 mm
dopt = 10.0452 mm


= 60.76 bar
= 6.076 N/mm2
Temperature = -23.29 C
DFlash = 0.5380m
= 538.0 mm
Appendix F-25
LFlash = 2.6901m
= 2690.1 mm
Skirt Height = 1.5m
1. Design Pressure
Design Pressure, Pi
= 6.076 bar x 1.1
= 66.8411 bar
= 6.68411 N/mm2
2. Material Used
Design Stress, f = 145 N/mm2 at temperature –23.29  C
vessel.
Pi Di
ei 
2 f  Pi
where,
Appendix F-26
= 6.68411 N/mm2
Volume 6)
= 145 N/mm2
= 0.5380 m
ei = 12.6927 mm
Domed Head
J :1
Pi Di
ei 
2 jf  0.2 Pi
ei = 12.4576 mm
Appendix F-27
= 0.02046 m
D
h
4
h = 0.1345 m
= 134.5 mm
7. Weight Loads
Loading on vessel
where,
t = 20.4576 mm
support = 1.15
Di = 0.5380 m
= Dm  Di  t  103
= 0.5585 m
Weight of Vessel
wv  240Cv Dm  H v  0.8 Dm  t
= 9.891 kN
= 9891.21892 N
Density : 130 kg/m3
Appendix F-28
D m H v t i
= 451.4799 N
= 0.4514799 kN
= 10342.6997 N
8. Wind Loading
= 0.72892 m
Where,
= 933.0114 N/m
Hv 2  Fw
2
= 3375.9330 Nm
9. Stress Analysis
Pressure stress
Pi Di
n  = 87.890 N/mm2
2t
Pi Di
l  = 43.9452 N/mm2
4t
Dead weight stress

wv
w  = 0.28812 N/mm2
  Di  t  t

Bending stress
Do  Di  2t = 578.9150 mm
= 0.578915 m
Appendix F-29
  Do4  Di4 
Iv  = 1.401E+09 mm4
64
D 
M x i  t
 2  = 0.69736 N/mm2
b  
lv

 z l w b = 44.9306 N/mm2 upwind
= 44.3544 N/mm2
2  10 4  t 
c  = 706.7562 N/mm2
Do
10. Vessel support

Approximate weight
  Di2  H v   H 2o  g
W =
4
= 5999.9575 N
= 6.0000 kN
= 6.0098 kN
Skirt height
F   H v  1
2
M  w = 23614.6203 Nm
Di
Appendix F-30
= 23.6146 kNm
4M s
 bs  = 4.8911131 N/mm2
  D s  t s  t s Ds

w
 ws  test   = 0.1671465 N/mm2
  Ds  t s  t s
w
 ws  operating   = 0.2881263 N/mm2
  Ds  t s  t s

Criteria for design
 t 
 Ds 

Ms : 23614.6203 Nm
1  4M s 
Ab     W  = 21.7286 mm2
N b f b  Db 
Bolt root diameter

Ab  4
d = 5.2595 mm


4M s w
Fb   = 109983.746 N/m
D 2
s
D s
Appendix F-31
Base ring
Fb
Lb  = 21.9967 mm
1000 f c

Bolt size : M24
Root are : 353 mm
Lr : 76 mm
fr : 140
Lr + ts + 50 = 146.4576 mm
fc = 0.75096 N/mm2
Base thickness
3 fc
tb  Lr = 9.64092 mm
fr

d opt  226G 0.50  0.35
dopt = 43.5616 mm
psdopt
tno
20d  ps = 0.981465 mm
Appendix F-32
dopt = 43.5895 mm
dopt = 42.3535 mm
F.5 Mechanical Design For Storage Tank – Nitrogen
The storage tank will be designed as a horizontal cylinder tank with fixed-
cone roof. The ratio of height to the diameter of the tank will be taken as 0.5 because
of the diameter is below 60 ft.. The dimension of each tank will be as follows:
Design volume Storage Tank 1 = θ D2Hs
4
Where,
D = Diameter of storage tank
HL = Height liquid in storage tank
VL = 662066.8731kg
805 kg/m3
The liquid volume of the tank = 822.4433 m3
(assume 10% of liquid vaporized)
Vstorage = Vvapor X VL
Appendix F-33
= 1.1 VL
= 904.6876 m3
The diameter of the tank, D = (4V / 0.5 θ)1/3
= ( 4 X 904.6876 / 0.5 θ)1/3
= 13.2067 m
= 43.3291 ft
The height of the tank, Hs = 0.5 X 13.2067 m
= 6.6034 m
Vv = θ D2 / 4 [ Hs - HL +1/3 HR]
Since HR = (D/2) tan θ, hence :
Vv = θ D2 / 4 [ Hs - HL + D/6 (tan θ)]
Let θ = 10 o
0.1 x (904.6876) = θ x(13.2067)2 /4 x [ 6.6034 - HL + (13.2067/6(tan θ)]
HL = 4.98 m
Accoording to the table, clearly that the minimum wall thickness is 3/16 inch
(Refer to sizing and costing of storage tank)
t = D
400 sin θ
= 43.3291 ft
400 sin 100
= 0.6238 in
= 1.5845 cm
= 15.85 mm
Because of the roof thickness is 15.85 mm, the thickness of shell wall is also 15.85
mm.
F.6 Mechanical Design For Storage Tank – Nitrogen
Appendix F-34
of the diameter is below 60 ft.. The dimension of each tank will be as follows:
4
Where,
VL = 134,095.4863 kg
71 kg/m3
The liquid volume of the tank = 1,888.6688 m3
= 1.1 VL
= 2,077.5357 m3
= ( 4 X 2,077.5357 / 0.5 θ)1/3
= 17.4238m
= 57.1649 ft
= 8.7119 m
Vv = θ D2 / 4 [ Hs - HL +1/3 HR]
Vv = θ D2 / 4 [ Hs - HL + D/6 (tan θ)]
Let θ = 10 o
0.1 x (2,077.5357) = θ x(17.4238)2 /4 x [8.7119 - HL + (17.4238 /6(tan θ)]
HL = 6.91 m
t = D
400 sin θ
= 57.1647 ft
400 sin 100
= 0.823 in
= 2.0904 cm
Appendix F-35
= 20.904 mm
mm.
F.7 Mechanical Design For Storage Tank – Ammonia
of the diameter is above 60 ft.. The dimension of each tank will be as follows:
4
Where,
VL = 134095.4863kg
639 kg/m3
The liquid volume of the tank = 2,861.646 m3
= 1.1 VL
= 3,147.8106 m3
= ( 4 X 3,147.8106 / 0.4 θ)1/3
= 21.5576 m
= 70.727 ft
= 8.623 m
Vv = θ D2 / 4 [ Hs - HL +1/3 HR]
Vv = θ D2 / 4 [ Hs - HL + D/6 (tan θ)]
Let θ = 10 o
Appendix F-36
0.1 x (2,077.5357) = θ x(21.5576)2 /4 x [8.623 - HL + (21.5576 /6(tan θ)]
HL = 6.82 m
t = D
400 sin θ
= 70.727ft
400 sin 100
= 1.018 in
= 2.5863 cm
= 25.86 mm
mm.
Appendix F-37

Mechanical Design Details for Reactor R-4 and Associated Equipment

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Mechanical Design Details for Reactor R-4 and Associated Equipment

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APPENDIX F

F.1 Mechanical Design For Reactor, R-4 Appendix F-2

 Welded Joint Efficiency

Torispherical head is used because the pressure is 1.01325 bar and it is

= 0.65056 mm + 2 mm (Corrosion Factor)

Analysis of Stresses (saddle supports)

Dead weight stress

z (upwind)= (6.6863 + 7.7816) N/mm2 = 14.4679 N/mm2

Elastic stability (buckling)

With stainless steel at ambient temperature, E = 340,000 N/mm2, a safety factor of 12

F.2 Mechanical Design For Flash Drum, F-7

This calculation is shown according to equations and data from Chemical

Pressure = 89.94 atm

Dead weight stress

where Wv = total weight

Resultant longitudinal stress

10. Vessel Support

Dead weight on the skirt

max  s  compressive    bs   ws  test  = 3.7072958 N/mm2

11. Base Ring And Anchor Bolts

Bolt root diameter

Total compressed load on based ring per length

Take the beaming, fc = 5 N/mm2

The minimum available standard bolt size

12. Nozzle Feed Sizing

Optimum duct diameter, dopt

Density : 666.13 kg/m3

F.3 Mechanical Design For Flash Drum, F-10

This calculation is shown according to equations and data from Chemical

Pressure = 59.97 atm

Dead weight stress

where Wv = total weight

Resultant longitudinal stress

10. Vessel Support

Dead weight on the skirt

max  s  compressive    bs   ws  test  = 3.4634731 N/mm2

11. Base Ring And Anchor Bolts

Bolt root diameter

Total compressed load on based ring per length

Take the beaming, fc = 5 N/mm2

The minimum available standard bolt size

12. Nozzle Feed Sizing

Density : 686.81 kg/m3

F.4 Mechanical Design For Flash Drum, F-12

This calculation is shown according to equations and data from Chemical

Pressure = 59.97 atm

Dead weight stress

where Wv = total weight

Resultant longitudinal stress

10. Vessel support

Dead weight on the skirt

max  s  compressive    bs   ws  test  = 5.0582596 N/mm2

11. Base Ring And Anchor Bolts

Bolt root diameter

Total compressed load on based ring per length

Take the beaming, fc = 5 N/mm2

The minimum available standard bolt size

12. Nozzle Feed Sizing

F.5 Mechanical Design For Storage Tank – Nitrogen

F.6 Mechanical Design For Storage Tank – Nitrogen

F.7 Mechanical Design For Storage Tank – Ammonia

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