DESIGN FOR A HIGH TEMPERATURE SHIFT CONVERTER

7- LITERATURE REVIEW

7.1 PROBLEM STATEMENT

To design a High temperature shift converter that will convert the reacted part of the CO to CO2,

which is easier to remove and increase the H 2 yield with a flow rate of 41,043.67kg/hr operating at

conditions of 713K and 27bars.

7.3INTRODUCTION

Reactors form a major operating unit in a chemical process plant by providing desirable conditions

for a chemical reaction to occur in a safe and controllable manner. A typical examples of a kind of

reactor is the High temperature shift converter. The High temperature shift converter can be

approximated to several adiabatic reactors.

The High temperature shift reaction technology is an essential step in modern ammonia plants. Efficient

and reliable shift conversion is required to ensure that the highest yield of hydrogen can be obtained from

the reformed hydrocarbons.

Hence, good performance of the shift catalyst and attainment of equilibrium CO slip from the catalyst

system is critical for the efficient and economic operation of the plant to maximize the hydrogen

production from the plant. As well as maximizing the hydrogen production, the water gas shift reaction

also maximizes the CO2 production from an ammonia plant. In addition, carbon oxides, both carbon
monoxide and carbon dioxide (COx), are a poison to the ammonia synthesis catalyst and, therefore, must

be removed. CO is converted into CO2 for easier removal in the CO2 removal system. (Gaber, 2018)

7.4 MAIN OBJECTIVE

To design a High temperature shift converter as a unit.

7.5 SPECIFIC OBJECTIVES

1. To specify both the type of High temperature shift converter and its material of construction.

2. To perform detailed chemical and mechanical engineering calculations of the High temperature

shift converter.

3. To give a detailed mechanical engineering drawing for the selected High temperature shift

converter

7.6 EQUIPMENT SELECTION

7.6.1REACTOR TYPE

Reactors are often classified by their mode of operations, the number of phases present with the

inclusion of a catalyst or not and its end product usage.

Classification by mode of operation

1. Batch reactors

Batch reactors are essentially tanks in which there is stirring of the reactants using internal impellers,

or a pump around loop where some of the reactants is removed and externally regurgitated back to

the reactor. Temperature is regulated by internal cooling surfaces (coils or tubes), jackets, reflux

condensers, or pump-around loops that pass through a heat exchanger. The reactants are introduced

into the reactor and operated at the right conditions until the targeted conversion is reached.

2. Continuous reactors

An alternative to batch processes is to feed the reactants continuously into the reactor at a point,

allow the reaction to take place and withdraw the products at another point. There must be an equal

flow rate of reactants and products. This is to prevent total emptying of the reactor or overflow.

Continuous processes are installed when large quantities of chemicals are being produced. It is

important that the reactor operates for several months without shutdown. The products tend to be

more of a consistent quality than that of a batch process because of reaction parameters (residence

time, temperature and pressure) are better controlled than in batch operations. They also produce less

waste and require lower storage of both raw materials and products resulting in a more efficient

operation.
3. Continuous Stirred Tank Reactor

In a continuous-flow stirred-tank reactor (CSTR), reactants and products are continuously added and

withdrawn. In practice, mechanical or hydraulic agitation is required to achieve uniform composition

and temperature, a choice strongly influenced by process considerations. Because the compositions

of mixtures leaving a CSTR are those within the reactor, the reaction driving forces, usually the

reactant concentrations, are necessarily low. Therefore, except for reaction orders zero- and negative,

a CSTR requires the largest volume of the reactor types to obtain desired conversions. However, the

low driving force makes possible better control of rapid exothermic and endothermic reactions.

When high conversions of reactants are needed, several CSTRs in series can be used. Equally good

results can be obtained by dividing a single vessel into compartments while minimizing back-mixing

and short-circuiting. The larger the number of CSTR stages, the closer the performance approaches

that of a tubular plug-flow reactor.

4. Plug Flow Reactor

A Plug flow reactor (PFR) is a tube (or pipe) through which reactants flow and is converted to

product. The PFR may have a varying diameter along the flow path. In such a reactor, there is a

continuous gradient (in contrast to the stepped gradient characteristic of a CSTR) of concentration in

the direction of flow. Both horizontal and vertical orientations are common. When heat transfer is

needed, individual tubes are jacketed, or a shell-and-tube construction is used. The reaction side may

be filled with solid catalyst or internals such as static mixers (to improve interphase contact in

heterogeneous reactions or to improve heat transfer by turbulence). Some of the configurations in use

are axial flow, radial flow and multi shell with built-in heat exchangers. Relatively slow reactions are
best conducted in a stirred tank reactor battery. A plug flow reactor is used when heat transfer is

needed, where high pressures and/or high (or low) temperatures occur, and when relatively short

reaction times suffice.

Classification by type of Reaction

In a reactor, a catalytic reaction or a non-catalytic can be performed. Catalytic reactors are normally

performed in tubular reactors employing plug flow. Catalytic reactors are classified into three types,

namely:

1. Fixed bed reactors:

A heterogeneous catalyst is often used where gas flow through a solid catalyst, which is often in the

form of small pellets, to increase the surface area. This is described as a fixed bed. Non-uniform

packing of catalyst may cause channeling that could lead to poor heat transfer, poor conversion, and

catalyst deactivation due to hot spots. The bed is loaded by pouring and manually packing the

catalyst or by sock loading.

2. Moving Beds

In a moving-bed reactor, the catalyst, in the form of large granules, circulates by gravity and gas lift

between reaction and regeneration zones.

3. Fluidized Beds
Fluidized beds are reactors in which small particles (with average size below 0.1 mm) are fluidized

by the reactant gases or liquids. Advantages of fluidized beds are temperature uniformity, good heat

transfer, and the ability to continuously remove catalyst for regeneration. Disadvantages are solids

back mixing, catalyst attrition, and recovery of fines. Baffles have been used often to reduce back

mixing.

7.6.2 JUSTIFICATION

The most appropriate reactor to undertake the conversion of CO to CO 2 is a tubular reactor also called a

plug flow reactor. The tubular reactor can be fluidized, moving or fixed based on the specific type of

catalyst used. For easy recoverability of the catalyst through regeneration and for a longer catalyst life, a

fixed bed catalytic multi-tubular reactor (packed bed reactor) is chosen among the wide range of

alternatives. The fixed bed catalytic multi-tubular reactor is chosen due to its numerous merits as

enumerated below;

1. High conversion rate per weight of the catalyst.

2.More contact between the reactant and the catalyst than other alternatives hence lower residence

time.

3. Low cost of construction, operation and maintenance.

4. Effective at high temperatures.

5. More product is formed due to increased contact between reactants and catalyst.
 6. Operated at high velocities, enabling little or no back mixing(Walas, 1959).

In a fixed bed catalytic multi-tubular reactor, it is difficult for temperature to be controlled. This is

accounted for by the inclusion of a heat exchange system to regulate the temperature in the reactor at

6500C.

7.6.3 EQUIPMENT DESCRIPTION

High temperature shift converter performance can be improved by the use of sieve trays which are

efficient. The trays improve the redistribution of unreacted carbon dioxide inside the liquid phase rich in

free ammonia. They also reduce the back mixing phenomenon. They give an increase in production of

hydrogen.

This reaction occurs more efficiently when the temperature is kept between 370°C and 440°C.It is in

this temperature range that the catalyst’s activity is at its maximum. Consequently, the conversion of

CO to CO2 and selectivity of hydrogen are both maximized.

The reaction occurs in the form

CO + H2O ↔ CO2 + H2 + heat.

The reaction is an exothermic reaction and the cooling fluid widely used is water. The recommended

temperature is 350˚C.
Thus the shift converter reactor is divided into a number of compartments, mostly separated with

sieve trays. The trays have various functions, and in particular.

1. Distribute the reactants as evenly as possible along the reactor section, to prevent

back-mixing;

2. Enhance mixing of the gaseous- and liquid phases; and

Reasons for choosing sieve trays

1. Sieve trays are easier to install.

2. They are less expensive as compared to the other trays.

3. They improve redistribution of unreacted carbon dioxide inside the liquid phase

which is rich in free ammonia.

4. Maintenance cost is less.

7.6.4 CATALYSTS SELECTION

The gas shift water conversion is an essential step in modern ammonia plants. Efficient and reliable

shift conversion is required to ensure that the highest yield of hydrogen can be obtained by reformed

hydrocarbons. Hence good performance of the catalyst and attainment of equilibrium slip from

catalyst system is critical for efficient and economic operation of plant.

The High temperature shift converter catalyst is comprised of Iron oxide, with chromium oxide

stabilizing agent to reduce the rate of sintering of the active iron crystallites at high temperatures.

More recently, copper has been added to the formulation to increase the activity per unit bed vol ume and
to provide protection against catalyst over-reduction at low steam–gas ratios. Operating temperature for

High temperature shift catalysts are between 310 oC to 460oC,and at this Temperature the new

catalysts should be able to reduce the CO level in the reactor.

The volume of the catalyst bed is is 2.63m3as calculated below.

7.7 MATERIAL OF CONSTRUCTION

The material for construction of the reactor is stainless steel. Stainless steel is the most frequently

used corrosion resistant material in the chemical industry. Its major constituent elements are
chromium; which above 12% impacts corrosion resistance to the alloy and nickel which is added to

improve corrosion resistance in non-oxidizing environments. Other elements in minor amounts

include carbon, copper, molybdenum, selenium, tantalum and titanium. There is a wide range of

stainless steel with compositions tailored to give the properties required for specific applications.

These are divided into three broad classes:

Ferritic: 13-20% Cr, <0.1% C, with no nickel

Austenitic: 18-20% Cr, >7% Ni

Martensitic: 10-12% Cr, 0.2-0.4% C, up to 2% Ni

For the construction of the High temperature shift converter, Austenitic stainless steel will be used.

Its uniform structure is the structure desired for corrosion resistance. It has the significant mechanical

properties which include high tensile strength, relative case of fabrication (welding, annealing),

higher toughness (fracture resistance), and hardness (wear resistance). It has the property to

withstand high pressures.

Table 7.1 Mechanical properties of Stainless Steel 316 (at room temperature).

Property Value

Tensile strength >510N/mm2

Modulus of elasticity >220kN/mm2

Hardness, Brinell 160

Specific gravity 8.0

7.8 CHEMICAL ENGINEERING CALCULATIONS

7.8.1 MATERIAL BALANCE

Mass balance on the R-4

COMPONENT REACTANT PRODUCT COMPOSITION(%)

STREAM(kg/hr) STREAM(kg/hr)

CARBON MONOXIDE 14,736.84 4,421.84 10.77

CARBON DIOXIDE 3,638.25 19,847.54 48.36

HYDROGEN 3,037.5 3,774.28 9.2

NITROGEN 10,157.4 10,157.4 24.75

STEAM 9,473.68 2,842.603 6.93

TOTAL 41,043.67 41,043.67 100

CARBON OXIDES

CARBON OXIDES R-4 NITROGEN

NITROGEN HYDROGEN

HYDROGEN STEAM

STEAM
DESIGN PARAMETERS

Operating Temperature = 440 oC = 713K

Operating Pressure = 27bar

REACTION

CO + H2O ↔ CO2 + H2 + heat. ∆ H 0 =−41.1 KJ /mol

Reactor for urea production contains a number of trays so that each trays acts like a completely plug flow

reactor. Due to number of trays above one another it achieves plug flow reactor.

7.8.2 REACTION KINECTICS

Rhodes et al. (1995) explained the associative mechanism of Cu – Chromite as a Langmuir Hinshelwood

process with the reaction.

CO(g) → CO(ads)
H2O(g) → H2O(ads)

CO(ads) +H2O(ads) →[*] →CO2(ads) + H2(ads)

CO2(ads) → CO2(g)

H2(ads) → H2(g)

Using the Langmuir-Hinshelwood model

p [ CO 2 ] p [ H 2 ]
k K co K H 20 [ p [ CO ] p [ H 2 O ] − ]
K eq ρ cat
r A= ×
(1+ K co p [ CO ] + K H 20 p [ H 2O ] + K CO 2 p [ CO 2 ] )
2
60

Equilibrium Constant K eq =exp ⁡¿ -4.33)=8.0887

Rate constant k =exp ( 1.987 ×T 1.987 )

−29364 40.32
+ 0.6475mol /g cat . min

K CO =exp ( 1.987
−3064
× T 1.987 )
+
6.74
=3.4189

K H 20=exp ( 1.987 ×T 1.987 )

−6216 12.77
+ =7.6845 , K CO 2 =exp ( 1.987 × T 1.987 )
−12542 18.45
+ =1.5412

p [ CO ] =12.4416 ×10 Pa
5

p [ CO2 ] =3.0726 × 10 Pa
5

p [ H 2 O ] =8.6427× 105 Pa

p [ H 2 ] =2.8431× 10 Pa
5
 3
ρcat =4.561 g/cm (Singh and Saraf,1977)

mol
r A =0.00236 3
cm s

r is rate of reaction (mol/cm3s), Pi is partial pressure of species (Pa), ρcat is density of catalyst(g cat/cm3),

T is temperature(K) ,Criscuoli et al. (2000).

Weight of Catalyst

For a packed bed reactor, the weight of the catalyst is calculated from the rate of reaction

as(Fogler, 1981),
F AO
d FA
w c= ∫
FA
rA

F AO
1
w C= ∫ d F A
rA F A

1
w C= [ F −F A ]
r A AO

w C =weight of catalyst

r A =Rate of reaction

F AO=Input of CO into the reactor

F A=Output of CO ¿ reactor
 WC=
0.00236
1
mol
3
[
× (146.198−43.867)
mol
s ]
cm s

W C =3118.33 kg

Therefore, the weight of the catalyst is 3118.33 kg .

Volume of Catalyst Bed

Volume of the catalyst bed is calculated from the solid density of the catalyst and the height of

the catalyst. The bulk solid density of an of Iron oxide is 995kg/m3. (Sun et al., 2015).

W c = ρb V B

W c −Weig h t of catalyst

ρb −Solid density

V B−Volume of catalyst bed

w c 3118.33
V B= = = 3.134m3
ρB 995

∴The volume of the catalyst bed is 3.134m3

Volume of Reactor

Pressure drop depends very strongly on the void fraction ( ε) of the packing. Hollow ylinders of

thin wall thickness are the preferred standard form for packing catalyst and has a void fraction of

0.6-0.8 (Eigenberger, 1992).

The volume of the reactor is related by the volume of the catalyst bed and the void fraction. The

void fraction also influences the pressure drop across the reactor, for a minimum amount of

pressure drop across the reactor, the packings must be uniformly arranged hence a higher void

fraction is required. Using void fraction of 0.8(Eigenberger, 1992).

V B=V R (1−ε)

V B−Volume of catalyst bed

V R−Reactor volume

ε −Void fraction

VB
V R=
(1−ε )

3.134
V R=
(1−0.8)

3
V R=15.67 m
Where ,vo= volumetric flowrate of liquid

V = volume of reactor

Density of the mixture = 995kg/m3

Calculation for Input Stream.

Mass flowrate of feed intothe reactor

Now, =
Density of the mixture

F ¿ RT
Volumetric flow rate=
P

146.198 ×8.314 × 713

V̇ =
2700000
 3
m
¿ 0.320979
s
3
15.67 m
τ=
m3
0.320979
s

τ =48 s

Length and diameter of reactor

Aspect ratio = 2.0 (Stanbury et al, 1995)

Height of reactor = H

Diameter of reactor = D

H
So =2.0
D

H=2D

π D2
Volume = xL
4

π d2
15.67= x 2D
4

15.67
D3= =2.152m
1.5707
D = 2.2m

Length of reactor =2D = 2x 2.152 = 4.31m

L = 4.5m

1
Space Velocity( )
τ

Volumetric flow rate of f eed

Space velocity=
Volume of t h e reactor

1 0.320979
( )=
τ 15.67

1 1
( )=0.0205
τ s

7.8.3 TRAY DESIGN

The trays to be used will be stainless steel which is the same material of construction as the column and

have the same diameter as that of the reactor. The holes on the trays will be punched mechanically. The

hole sizes mostly vary from 2.5 to 12 mm. 5 mm will be used .(Perry, 2008)
Number of trays

Lengt h of reactor
Number of trays =
Plate spacing

4.5 m
Number of trays = = 1.8
2.5 m

Tube Diameter and Length

For a packed bed reactor, the tube diameter varies between 3 inches and 4.5inches the length of the tube

also varies between 40 feet and 50 feet.

1
Taking outer diameter to be 3 inches and length to be 45 feet. Taking inner diameter to be
2

3inches(Blythe and Sampson, 1973).

Tube outer diameter( D¿¿ T (out))¿ ,

3.5inches

3.5 ×2.54
D T ( out )= =0.0889 m
100

Tube inner diameter ( DT ( ¿ ) ),

2.5inches

2.5 ×2.54
DT ( ¿ )=
100

D T ( ¿ )=0.0635 m

Tube Length LT ,
45feet

LT =¿ 45 ×0.3048=13.716m ¿

Therefore, the tube outer diameter, inner diameter and length are 0.0889m, 0.0635m and 13.716m

respectively.

Total Number of Tubes

For a packed bed reactor, the total number of tubes is calculated from the volume of the

reactor(Eyalarasan et al., 2013).

[ ]
2
π D T LT
V R=n
4

V R=Volume of reactor

D T =Diameter of tube

LT =Lengt h of tube

3
15.67 m =n [ n ×0.0889 2 × 4.5
4 ]
15.67=n ×0.02793

25.059
n=
0.0851375

n=561tubes

∴The total number of tubes in the reactor is 561 tubes.

Table 7.2 Specification sheet

DESIGN PARAMETER VALUE

Operating pressure 10 bar

Operating temperature 713K

Volume of the reactor 16m3

Diameter of the reactor 2.2m

Length of the reactor 4.5 m

Residence time 48s

Plates used Sieve trays

Number of sieve trays 2

7.9 MECHANICAL ENGINEERING DESIGN CALCULATIONS

Shaft design

The agitator shaft will be made from a standard AISI 304L stainless steel (18Cr/8Ni) material that is

austenitic grade. Austenitic grade steels are non-magnetic and provide excellent corrosion and heat

resistance with good mechanical properties over a wide range of temperatures and respond very well

to forming operations.

Table 7.3 Mechanical properties of AISI 304L stainless steel (18Cr/8Ni)

 Propert Value Unit

Density 8030 Kg/m3

Poisson ratio 0.28

Elastic modulus 195 GPa

Shear modulus 77 GPa

Tensile strength 510 MPa

Yield strength 205 MPa

Elongation 46 %

Reduction 50 %

Hardness 201 Brinell

Allowable shear stress, σs 41.4 MPa

Allowable tensile stress, 68.9 MPa

σt

Determination of power required

10 KW
Power =
m3

10 KW
Power required = × 24 =240.0Kw
m3

Motor efficiency is 85%

 240
Power required = =282.3529 kW
0.85

Design of impeller

Pitched-blade turbines are used on top-entry agitator instead of propellers when a high mixed

circulation rate is desired and the power consumption is more than 3hp (Perry et al, 1999).For this

reactor, 45° pithed blade turbine impellers are used.

Impeller diameter (d ) a

3 3
da = × D = ×2.4818=0.74454 m
10 10

Impeller speed

P = Np × ρ × N × d (Dahlstrom et al., 2006)

m
3 3

ρm = density of the mixture

N p = power number

d = diameter of impeller

P = power required

For a pitched 4-blade turbine inclined at 45° N p = 1.4 (Warren L.McCabe, Julian C. Smith, 1993)
 √
N= 3
282.35 ×103
1.4 × 995 ×0.74454
3
=7.8896rps

Preq 282.35
τc = = =5695.77N/m
2 πN 2 π ×7.8896

Design torque input ɽdes = τc × service factor

Using a service factor of 1,

τdes = 5695.77N × 1 = 5695.77 N/m

Maximum force on shaft (Fmax)

τ des 5695.77
Fmax = = =3477.3005N
2.2 d 2.2 ×0.74454

Shaft length Ls

Ls = H – C = 5 - 0.74454 = 4.25546m

Maximum bending moment

M= Fmax × Ls = 3477.3005× 4.25546

M= 14797.51319m

Equivalent bending moment, Meq =√ M 2+ τ des2

Meq =√ 14797.513192+5695.77 2

Meq =15855.857m
Shaft diameter, ds

Minimum shaft diameter for shear stress d ss =

√
3 16 M eq
π σs

√
dss = 3
16 × 15855.857
π × 41.4 ×10
6 =0.124945m

Minimum shaft diameter for tensile stress, d ts=

√
3 16 M eq
π σt

√
dts= 3
16 × 15855.857
π × 68.9 ×106
=0.105433

Since dss ˃˃ dts , the shaft diameter is taken to be 0.124945m

Design Pressure

Vessels subject to external pressure are to be designed to resist the maximum differential pressure

that is likely to occur during operation. From the chemical design analysis, the design pressure is

taken as 10% of the operating pressure.

110
×27 ¯¿ 29.7 ¯¿
100

Design Temperature

The strength of materials decreases with temperature. The maximum operational temperature is

713K. For design purposes, a tolerance of about 20°C is allowed. The maximum operational

temperature is therefore 733K.

7.10 MATERIAL FOR CONSTRUCTION

A material suitable for the construction must be chosen. The material chosen must be compatible

with the process conditions. Carbon and alloy steel are generally good for the construction of

pressure vessels. (Sinnot, 1999). However, the material for construction of the reactor is stainless

steel. Stainless steel is the most frequently used corrosion resistant material in the chemical industry.

Its major constituent elements are chromium; which above 12% impacts corrosion resistance to the

alloy and nickel which is added to improve corrosion resistance in non-oxidizing environments.
Other elements in minor amounts include carbon, copper, molybdenum, selenium, tantalum and

titanium.

Corrosion Allowance

Corrosion or scaling in equipment’s such as this reactor is inevitable. An additional thickness is

therefore added to the constructional material to allow for the material lost by scaling or corrosion.

The allowance is based on experience with the material of construction under previous service

conditions like that intended for the design.

The reactor to be designed must overcome gross plastic deformation and collapse under all

conditions of loading. Two major categories of loads are identified. The major loads include:

 Design pressure: including any significant static head of liquid.

 Maximum weight of the vessel and content under operating conditions.

 Maximum weight of the vessel and contents under hydraulic test conditions.

 Wind loads

 Earthquake (seismic) loads.

 Loads supported by, or reacting on, the vessel.

Weight loads (Subsidiary loads)

 Local stresses caused by supports, internal structures, and connecting pipes.

 Shock loads caused by water hammer or by surging of the vessel contents.

 Bending moments caused by eccentricity of the centre of the working pressure relative to the

neutral axis of the vessel.

 Stresses due to temperature differences and differences in the coefficient of expansion of

materials.

 Loads caused by fluctuations in temperature and pressure.

Minimum Practical Wall Thickness

There will be a minimum wall thickness required to ensure that any vessel is sufficiently rigid to

withstand its own weight and any incidental loads. The ASME BPV Code Sec. VIII D.1 specifies a

minimum wall thickness of 1/16 inch (1.5 mm) not including corrosion allowance, and regardless of

vessel dimensions and material of construction. As a general guide, one can refer to a table of values

based on the vessel diameter. (Sinnot, 1999).

Material of construction of vessel: Stainless steel 304L

Design stress of stainless steel 304L = 131MPa (Atlas,2008)

7.11 Calculatoins

Thickness of Cylindrical Section

For the cylindrical section, the minimum thickness required to resist internal pressure can be

determined from equation

PiDi
e=
2 f −Pi

Where:

e is the thickness of the cylindrical section, mm

f is the design stress at 713K, 131N/mm 2

Di is the internal diameter of vessel. mm

Pi is the internal pressure of the vessel, N/mm 2

 3
2.7 ×2.152 ×10
e= =22.408 m
2(131)−2.7

e=22.408 m

Allowing for 4mm for corrosion the thickness becomes 26.408mm.

Thickness of head

The reactor will be covered with a torispherical plate both at the top and the bottom. The equation

below can be used to calculate the minimum thickness required.

PiDi
e=
2 fj−Pi(0.25)

Where:

“e” is the thickness of the cylindrical section, mm

“f” is the design stress at 50°C, N/mm 2

Di is the internal diameter of vessel, mm

Pi is the internal pressure of vessel

J is taken as 1

3
2.7 ×2.152 ×10
e= =22.234 m
2 (131 ×1 ) −2.7 ( 0.25 )
Allowing 4mm for corrosion, thickness becomes 26.234mm

Thickness for torispherical head is the same as that of torispherical bottom = 26.234mm

Weight of vessel

Total weight of stainless steel vessel excluding internal fittings is given as:

W v =ρm CV D m ( Hv+0.8 Dm ) t(Sinnott , 2005)

Where:

Wv is the total weight of the shell, excluding internal fittings, N

Cv is a factor to account for weight of nozzles, man ways, internal supports, etc. Cv=1.15 for

distillation columns, or similar vessels, with several man ways and with plate support rings, or

equivalent fittings and 1.08 for reactors and vessels with less internal fittings.

Dm = mean diameter of vessel = (D i +tx 10−3)m

H is the height or length, between tangent lines (the length of cylindrical section), m

𝜌𝑚= density of vessel material, kg/m3 = 8030 kg/m3

t is the wall thickness, mm

Dm = (2.152+26.408×10 ) = 2.178408m
-3

Wv = 8030×1.08×2.178408[5+(0.8×2.178408)]0.0298

Wv = 3694.11N = 3.7kN
Calculating dead weight

Mass flow rate of steam = 9473.68kg/hr

Mass flowrate of cooling water= 2842.60kg/hr

Weight of fluid = 12316.28× 9.81 = 120822.7068= 120.8kN

Total dead weight = (3.7 + 120.8)

Total dead weight = 124.5KN

7.11.1 Analysis of stresses

The longitudinal and circumferential stresses due to pressure (internal or external) are given by:

Longitudinal stress

P Di
σ h= (Sinnott, 2005)
2t

2.7 ×2152
σ h= =¿110MPa
2× 26.408
Circumferential stress

P Di
σ L= (Sinnott, 2005)
4t

2.7 ×2152
σ L= =55 MPa
4 × 26.408

Dead weight stress

The direct stress due to the weight of the vessel, its component and any attachment is given by:

W
σ w=
π ( D i+ t)t

Where:

σw is the direct stress, N/mm2

W is the total weight which is supported by the vessel

W 124500
σ w= = =0.6973 MPa
π ( D i+ t)t π ( 2152 ) 26.408

The bending stress is given by:

M di
σb=± ( +t)
lv 2

Where:

M is the total bending moment at the plane being considered

Iv is the second bending moment of area of the vessel about the bending plane
But,

π
lv = (D04- Di4)
64

Do is the outside diameter =Di+2(t) =2152 +2(26.408)= 2204.816m

π
lv = (2204.84- 21524)=1.055033×10 11 mm4
64

Dynamic wind pressure

Pw =0.05u2w

Wind velocity (uw) for most engineering design is 160 km/hr

Pw = 0.05(160) = 1280N/m
2 2

Wind loading

The loading per unit length of the column can be obtained from the wind pressure by multiplying the

effective column diameter, the outside diameter plus an allowance for the thermal insulation and

attachments, such as pipes and ladders.

Loading (per length meter), F = P D eff

w w
Pw is the wind pressure, taken as 1280 N/m 2

D = 2152+ 2(26.403) = 2204.816mm

eff

F = 1280 × 2.204 = 2821.12N/m

w

Bending moment at the bottom tangent line

Fw H2
M= (Sinnott, 1999)
2

F is the load per unit length.

w

2821.12× 4.52
M= = 28563.84Nm
2

Hence, the bending stress

M di
σb=± ( +t)
lv 2

3
28563.84 × 10 2152
σb=± 11
( + 26.408)
1.055 ×10 2

σb=± 0.2984 MPa

The resultant longitudinal stress is:

σ z =σ l +σ w ± σ b

σz is compressive and therefore negative

σ z (Upward )=55+0.6973+0.2984=¿ 56 MPa

σ z ( Downward )=55+ 0.6973−0.2984=¿ 55.3989MPa

Greatest differential stress

σ h−σ z ( downward )=110−¿55.3989= 54.6011MPa which is less than the design stress of 131MPa.

Hence the reactor will be able to withstand the stresses acting on it.

7.12 Reactor support

The method used to support a vessel depends on the size, shape, and weight of the vessel, the design

temperature and pressure; the vessel location and arrangement; and the internal and external fittings

and attachments. Horizontal vessels are usually mounted on two saddle supports. Skirt supports are

used for tall, vertical columns whilst brackets or lugs are used for all types of vessel. Supports should

be designed to allow easy access to the vessel and fittings for inspection and maintenance (Sinnott,

1999).

In view of the effect of the total dead weight loads and bending moment of the heater which has a

substantial value, a leg support is the most suitable support. This is because the support will be so

strong to withstand the total weight of the Shift converter(reactor). The vessel will have 4 legs.
Stress on support

W 124500
σ w= = =0.6973 MPa
π ( D i+ t)t π ( 2152 ) 26.403

Types of Flange and Selection

Several different types of flange are used for various applications. The principal types used in the

process industries are:

1. Welding-neck flanges.

2. Slip-on flanges hub and plate types.

3. Lap-joint flanges.

4. Screwed flanges.

5. Blank, or blind, flanges.

Welding-neck flanges have a long-tapered hub between the flange ring and the welded joint. This

gradual transition of the section reduces the discontinuity stresses between the flange and branch and

increases the strength of the flange assembly. Welding-neck flanges are suitable for extreme service

conditions; where the flange is likely to be subjected to temperature, shear and vibration loads. They
will normally be specified for the connections and nozzles on process vessels and process equipment.

So, the selected flange is welding neck flange.(Sinnott, 2005).

Gaskets

Gaskets are used to make a leak-tight joint between two surfaces. It is impractical to machine flanges

to the degree of surface finish that would be required to make a satisfactory seal under pressure

without a gasket. Gaskets are made from "semi-plastic" materials; which will deform and flow under

load to fill the surface irregularities between the flange faces yet retain enough elasticity to take up

the changes in the flange alignment that occur under load. The corrugated metal, asbestos inserted

(soft steel) gasket is selected.

Table 7.3 Summary of mechanical engineering design

Parameter Value

Material of construction Stainless steel 304L

Design pressure 29.7

(bar)

Design Temperature (K) 733

Allowable design stress ((MPa) 131

Reactor wall thickness (mm) 27

Longitudinal stress (MPa) 110

Circumferential stress (MPa) 55

Dead weight stress (MPa) 0.6973

Bending stress (MPa) 0.2984MPa

Reactor support type Leg

0.6973

Stress on support(MPa)

Number of legs 4

7.13 REFERENCES

Perry, R. and D.W., G., (2008). Perry’s Chemical Engineering Handbook.8th ed . McGraw- Hill

Book Co, New York.

Walas, S.M. (1990) Chemical Process Equipment Selection and Design, Butterworth- Heinemann,

Oxford.

Engineering Toolbox (2018) Density of stainless steel type 304L [Online]. Available from: <http

://www.engineeringtoolbox.com> [Accessed 2020 January 22].

R.K.Sinnot. Chemical Engineering Design, vol. 6, 4th edition. Coulson & Richardson's, Elsevier,

2005.

Sinnott, R.K. (1999). Chemical Engineering Design. In Coulson, J. and Richardson, J. Coulson and

Richardson's Chemical Engineering. 3rd ed. Vol. 6. Butterworth-Heineman.

Damien Vannier(2011).Kinetic study of High temperature water shift reaction. .[online] Available

from: <https://pdfs.semanticscholar.org/38da/10609d422fec7f57658a56b86825ba11753b /en>

[Accessed 18/01/20]

Criscuoli A, A Basile and E Drioli, “An analysis of the performance of membrane reactors for

the water gas shift reaction using gas feed mixtures” , Catalysis Today, 56, 2000, 53- 64