Individual Design (13243)

MUHAMMAD MUHAIMIN BIN ABD RAHMAN (13243)
PDP II SEPTEMBER 2013 INDIVIDUAL DESIGN
GROUP NO 18
FINAL YEAR DESIGN PROJECT SHEET
PRODUCTION OF AMMONIA AND JOB CODE
UREA PLANT DESIGNER
MUHAMMAD MUHAIMIN BIN
ABD RAHMAN
DETAILED DESIGN OF
MAJOR EQUIPMENT
UREA REACTOR (R-201)
AND
DESIGN OF MINOR EQUIPMENT

HEAT EXCHANGER (E-12)
COMPRESSOR (K-102)
DOC PREPARED REVIEWED

DESCRIPTION BY BY DATE
NO
01 GENERAL DESCRIPTION MAR
02 SPECIFICATION SHEET MAR
03 MECHANICAL DESIGN MAR
04 OPERATING PROCEDURE MAR
05 COSTING MAR
06 MINOR EQUIPMENT DESIGN (E-12) MAR
07 MINOR EQUIPMENT DESIGN (K-102) MAR
INFORMATION CONTAINED IS OUR PROPERTY AND MUST NOT BE USED BY OR CONVEYED TO ANY PERSON
WITHOUT AUTHORITY
TABLE OF CONTENT
CHAPTER 1
GENERAL DESCRIPTION
1.1 INTRODUCTION
Reactors are the equipment which helps to convert the raw materials into desired products. They
are compulsory to the plant where the reaction occurs. There is a lot of factors will affect the
performance of the process conditions. For example, operating temperatures and pressures,
quantity of raw materials and products produced. Chemical reactors are where the conversion of
desired valuable chemicals from lower chemicals occurs through chemical reaction.
In order to select a reactor, several criteria need to be taken into consideration. Among those
criteria are:
1. Operating conditions
2. Feed condition
3. Reactor types
4. Type of catalyst
5. Size of reactor
For this project, the reactor that is selected is the Urea Reactor R-201. This reactor converts
Ammonia and Carbon Dioxide into Ammonium Carbamate and at the same time converting
Ammonium Carbamate into Urea.
1.2 DESIGN METHODOLOGY

The design methodology is divided into 2 major sections which are the process design and
mechanical design. The process design will determine the reactor sizing and also the selected
optimized pressure and temperature for the reaction to occur. The second section which is
mechanical design will determine the mechanical structure of the reactor such as the design
stress pressure, the operating pressure of the reactor, the reactor head, nozzle and pipe sizing and
many more.
In summary, the major steps for the overall design are as follows:
1. Selecting major equipment (Urea Reactor R-201).
2. Select the suitable reactor type.
3. Determine the optimum operating conditions.
4. Perform calculation based on rate of reaction to obtain volume and length of the reactor.
5. Obtain data from iCON simulation.
6. Determine reactor sizing.
7. Do reactor mechanical design.
8. Technical Drawing for the reactor.
9. Start-up and Shutdown Procedures description.
1.3 REACTOR TYPE

There are two major types of reactor, which are CSTR and PFR reactor. These two reactors are
different according to its ability and mechanism. According to AUTHOR, there are several
criteria that will be considered upon selecting the type of reactor. The criteria are:
1. Phase
2. Operating Conditions
3. Feed Conditions
4. Catalyst
5. Size
Table 1.1 summarized the major criteria that involved in selecting the reactor.
Table 1.1: Major Criteria Involved In Selecting the Reactor
CSTR Plug Flow Reactors

- Used for liquid phase reactions - Normally used for gas phase reactions.
- Organic chemical industries. - High pressure conditions.
- No back mixing required due to
reversible reactions.
Therefore, the type of reactor that is selected is the Plug Flow Reactor.
1.4 PROCESS DESCRIPTION

The manufacturing of urea can be simplified into the chemical equation as stated below:
𝐶𝑂2 + 2𝑁𝐻3 ↔ 𝑁𝐻2 𝐶𝑂𝑂𝑁𝐻4
𝑁𝐻2 𝐶𝑂𝑂𝑁𝐻4 ↔ 𝑁𝐻2 𝐶𝑂𝑁𝐻2 + 𝐻2 𝑂
At the same time, the byproduct will form which is undesirable to the product. The chemical
equation of the byproduct is as follows:
2𝑁𝐻2 𝐶𝑂𝑁𝐻2 ↔ 𝑁𝐻2 𝐶𝑂𝑁𝐻𝐶𝑂𝑁𝐻2 + 𝑁𝐻3
However, in urea reactor, there is no formation of byproduct thus it can be removed from the
process design. For the reactor, the first reaction which converts Ammonia into Ammonium
Carbamate is very fast and highly exothermic. The second reaction which is the formation of
urea, the reaction is slow and requires heat as it involves dehydration of ammonium carbamate.
Therefore, the heat from the first reaction will be absorbed by the second reaction.For the
process temperature, the production of urea works optimally between 180 oC to 190oC.
1.5 FEED AND PRODUCT CONDITIONS

Inlet of reactor R-201:
Average inlet temperature: 180.6°C
Average inlet pressure: 12,680 kPa
Table 1.2: Urea Reactor Inlet Composition
Component Flow Rate Mass Flow Rate Mass Flow Rate Mass
(kg/h) Fraction (kg/h) Fraction (kg/h) Fraction
Ammonia 209.125 100.00 169.31 23.78 0.00 0.00
Water 0.00 0.00 0.00 0.00 0.00 0.00
Ammonium Carbamate 0.00 0.00 542.82 76.22 0.00 0.00

Urea 0.00 0.00 0.00 0.00 0.00 0.00
Carbon Dioxide 0.00 0.00 0.00 0.00 91.67 100.00
Outlet of reactor R-201:

Average outlet temperature: 189.6°C
Average outlet pressure: 13,124 kPa
Table 1.3: Urea Reactor Outlet Composition
Component Flow Rate Mass Flow Rate Mass

(kg/h) Fraction (kg/h) Fraction
Ammonia 314.56 31.45 1.67 12.9
Water 110.73 11.07 0.00 0.00
Ammonium Carbamate 205.65 20.56 0.00 0.00
Urea 369.12 36.92 0.00 0.00
Carbon Dioxide 0.00 0.00 11.275 87.1
CHAPTER 2
PROCESS DESIGN
2.1 SUMMARY OF UREA REACTOR PROPERTIES
Before developing the process design for Urea Reactor, the properties of urea reactor is first
summarized in table 2.1. The data included in the table are obtained from the simulations of the
process and also calculated in previous chapter. From the data, the sizing of the urea reactor
could be determined.
Table 2.1: Properties of Urea Reactor
Operating Temperature 190oC
Operating Pressure 13 210 kPa
Overall Feed Flow rate 1012.925 kg/hr
Volumetric Flow rate 5911.905 m3/hr
Composition of Carbamate 0.5359
Catalysts None
2.2 REACTOR SIZING

2.2.1. Volume Of The Reactor
Based on previous chapter, the type of reactor that is selected is plug flow reactor. Urea reactor
contains numbers of trays on top of one another which combines altogether will form complete
plug flow reactor. According to Froment et. al. (2011), the equation to calculate the volume of
reactor is given by:
𝑥𝐴
𝑉 𝑑𝑥𝐴
= ∫
𝐹𝐴𝑂 0 −𝑟𝐴
Where,
𝑉 = Volume of the reactor
𝐹𝐴𝑂 = Feed flow rate
𝑟𝐴 = Rate of reaction
𝑥𝐴 = Reactant composition
The rate of reaction, rA, is given by the formula:
−𝑟𝐴 = 𝐴 𝐶𝐴
𝐶𝐴 = 𝐶𝐴0 − 𝑥𝐴
The formula of rate of reaction is substituted back into the volume of reactor where:
𝑥𝐴
𝑉 𝑑𝑥𝐴
=∫
𝐹𝐴𝑂 0 𝐴 𝐶𝐴𝑂 − 𝑥𝐴
𝑥𝐴
𝑉 𝐶𝐴𝑂 𝑑𝑥𝐴
= ∫
𝐹𝐴𝑂 0 − 𝑥𝐴
𝑉
= [−ln − 𝑥𝐴 ]
𝑣0
In order to obtain the volume of the reactor, the equilibrium constant, k is calculated using
Arrhenious equation.
𝐸
= 0 (− )
𝑅𝑇
Where,
= 2 𝑟
Thus, the volume of reactor is,

𝑉
= [− ln − 0 5 59 ]
59 905 2
𝑉 = 072 89 𝑚3
2.2.2. Diameter And Height Of The Reactor
From the volume of the urea reactor, the diameter of the reactor can be determined. Using the
ratio of diameter to height 5:1, the diameter of reactor is:
𝜋
𝑉 = 𝐷2 𝐻
𝐻 = 5𝐷
𝜋
072 89 = 𝐷2 5𝐷
5𝐷3 = 65 86
𝐷 =6 9𝑚
Using the same ratio diameter to height, the height of diameter is:
𝐻 = 5𝐷
𝐻=5 6 9
𝐻= 2 𝑚
2.2.3. Residence Time Of Reactor
The residence time of reactor can be calculated using the equation:

𝑉
=
𝑣0
072 89
=
59 905
=0 5 𝑟
2.2.4. Number Of Stages Required
Based on the heights of the reactor, the number of stages of the plug flow reactor can be
calculated. It is assumed that the trays used are sieve trays with spacing between them are
assumed to be 2.5m. Therefore,
𝐻
𝑁=
2
𝑁=
25
𝑁 = 2 976
𝑁
CHAPTER 3
MECHANICAL DESIGN
3.1. DATA FOR MECHANICAL DESIGN
Table 3.1: Data Required
Working Temperature 190°C
Design Temperature 210°C
Working Pressure 13210 kPa
Design Pressure 14531 kPa
Material of Construction Stainless Steel 321
Design Stress 135000 kPa
Yield Strength
3.2. DETERMINATION OF SHELL THICKNESS

Minimum shell thickness, t s can be determined by using the equation:
𝑃𝐷 𝐷𝑖
𝑠 = + 𝐶𝐶
2𝑆𝐽 − 0 6𝑃𝐷
Where,
𝑃𝐷 = Design Pressure
𝐷𝑖 =Inside Diameter
𝐽 = Joint Factor
𝑆 = Design Stress
𝐶𝐶 = Minimum Corrosion Allowance
According to Sinnot (2005), a minimum corrosion allowance should be taken into account. For
carbon and steel, the minimum corrosion allowance is 2mm. For the value of J, the value is 1
assuming that joints are fully radiographed. The value of S is assumed to be 8370000Pa.
Therefore, the reactor shell thickness is
2 0×6 9
𝑠 = + 0 002
2 5000 −06 5
= 0 29𝑚
3.3. DESIGN OF HEAD AND CLOSURE
3.3.1. Selection of Closure
Based on McKetta Jr (1992), there are three common types of head closure, which are
hemispherical head, ellipsoidal head and torispherical head. In choosing the head closure of the
reactor, it is important to consider about the pressure of the vessel so that the head can withstand
the pressure. Between the three head closure, the ellipsoidal head is the selected type. Althought
it is more expensive than torispherical, but it is stronger than torispherical head.
3.3.2. Thickness Calculation: Top and Bottom Closure
Design at domed ends can be calculated as

𝑃𝑖 𝐷𝑖
=
2𝑆𝐽 − 0 2𝑃𝑖
Where,
2 0×6 9
=
2 5000 −02 2 0
=0 2 𝑚
3.4. DESIGN OF BOLTED FLANGED JOINTS
3.4.1. Design of Gasket
Table 1: Gasket Material Detail Specification
Parameters Properties
Material of Construction Soft steel
Gasket factor, m 4.25
Min. design seating stress, Y 10100 psi or 69655.17 kPa
Min. actual gasket width 0.01 m
Ratio of do to di (gasket diameter)
𝑑𝑜 − 𝑃𝑚
=√
𝑑𝑖 −𝑃 𝑚+
69655 7 − 5 25
=√
69655 7 − 5 25 +
= 6
Gasket inner diameter, di,

𝐷𝑜 + 𝑚 𝑚 𝑚 𝑑 = 6 9+00 = 65𝑚
To find gasket outer diameter, do,

𝑑𝑜
𝑑𝑜 = ( ) 𝑥 𝑑𝑖 = 6 × 65 = 06𝑚
𝑑𝑖
To find gasket width, W,

𝑑𝑜 − 𝑑𝑖 0
𝑊= = = 2 05 𝑚
2 2
To find basic gasket seating width, bo,
𝑑𝑜 − 𝑑𝑖 2 05
𝑜 =2 = = 0 𝑚
2 2
To find diameter at location of gasket load reaction, G,

𝑑𝑜 + 𝑑𝑖
𝐺= 8 55 𝑚
2
3.4.2. Design of Flange Bolts
Table 5 shows the gasket specification.
Table 2: Gasket Specification
Parameters Properties
Bolt grade ASTM A193 B8M
Bolt yield strength 80000 psi or 5551.3 MPa
Bolt allowable stress 57.3 MN/m2
Bolt Loads
Under atmospheric condition, Wm1
𝑊𝑚 = 𝜋 𝐺
= 2 0 8 55 69655 7
= 927 6 𝑁
Under operating condition, Wm2
𝜋
𝑊𝑚2 = 𝜋2 𝑚𝐺𝑃 + 𝐺 2𝑃
= 785 6 𝑁
Minimum bolting area

𝑊𝑚2
𝐴𝑛 =
𝑆𝑔
785 6
=
57 000
= 0 0 𝑚2
3.5. LOADING ANALYSIS

3.5.1. Dead Weight Loading of Vessel
3.5.1.1. Weight of Shell
Weight of the shell can be calculated as:

𝑊𝑉 = 2 0𝐶𝑉 𝐷𝑚 𝐻𝑉 + 0 8𝐷𝑚 𝑚
Where,
𝐶𝑉 = Factor to account for the weight of nozzles, manholes, internal support
= 1.5 for distillation columns or similar vessels)
𝑚 = Mean wall thickness =0.329 m
𝐷𝑚 = Mean Diameter of Vessel = 𝐷𝑖 + 𝑚 = 6 8 + 0 29 = 6 8 9 𝑚
𝐻𝑉 = Height of cylindrical section = 32.44 m
By substituting the value, the weight of shell is:

𝑊𝑉 = 2 0 5 6 8 9 ( 2 + 0 8 6 8 9 )0 29
= 0605 77 𝑁
3.5.1.2. Weight of Insulation Material
Table X summarizes the properties of insulation material

Table X: Properties of Insulation Material
Information Properties
Insulation material Mineral wool
Thickness of insulation material,𝑥𝑤 0.1 m
Density 130 kg/m3
The weight of insulation can be calculated as

𝑊𝐼 = 𝜌𝑉𝐼
Where
𝑉𝐼 = 𝜋𝐷𝑂 𝐼 𝐻
Therefore,
𝑊𝐼 = 𝜌𝜋𝐷𝑂 𝐼 𝐻
= 0 2 6 82 0 2 98
= 8865 02 𝑁
= 88 65 𝑁
3.5.1.3. Total Reactor Weight
𝑊𝑇 = 𝑊𝑉 + 𝑊𝐼
= 0605 77 + 88 65
= 069 2 𝑁
3.5.2. Wind Loading
Dynamic wind pressure, Pw = 1280N/m2

Vessel Thickness = 0.329 m
Insulation Thickness, xw = 0.1 m
Thus, in order to calculate the mean diameter including insulation, D m the equation below is
used,
𝐷𝑚 = 𝐷𝑖 + 2 + 𝑥𝑤 = 6 8 + (2 0 29 + 0 )=7 𝑚
To find loading (per linear meter),
𝐹𝑤 = 𝑃𝑤 𝐷𝑚 = 280 × 7 = 9 95 𝑁⁄𝑚
=9 𝑁 𝑚
3.6. BOTTOM STRESS ANALYSIS

3.6.1. Pressure Stress
The longitudinal and circumferential stresses due to pressure are given by:
𝑃𝐷𝑖
𝜍𝐿 =
= 65 × 04 𝑃
𝑃𝐷𝑖
𝜍𝐻 =
2
= 0 × 05 𝑃
3.6.2. Dead Weight Stress
𝑊
𝜍𝑤 =
𝜋 𝐷𝑖 +
= × 03 𝑃
3.7. SKIRT SUPPORT DESIGN
3.7.1. Skirt Thickness
The type of support that will be used is the skirt support with cylindrical shell welded to the base
of the vessel.
The thickness of the skirt,t s is chosen to be 0.35 m, since the thickness of the vessel is 0.325 m.
3.7.2. Bending Stress in Skirt
Bending stress in skirt is calculated by using

4M S
 bs 
DS  t S t S DS
7
=
6 9+0 5 0 5 6 9
76 6 𝑃
3.7.3. Dead Weight Stress in Skirt
The dead weight of the skirt,

WT
 ws 
 DS  t S t S
069 2
=
2 6 9+0 5 0 5
= 975 56 𝑃
CHAPTER 5
REACTOR SPECIFICATION SHEET
CHAPTER 5
COSTING
The costing for reactor is based on the cost correlation method of reactors (Douglas, 1988).
Purcha sec ost,$ 

M & S  [101.9D1.066H 0.82 ( Fc)]
280
Where,
M&S = Ratio indices = 575.4
D = Reactor diameter, ft = 21.29 ft.
H = Height,ft. = 106.403 ft.
Fm = Material factor (carbon steel) = 1.00
Fp = pressure factor = 7.12
Fc = correction factor =Fm x Fp = 7.12
Thus,
Purchase cost = $ 68,572.88
CHAPTER 6
OPERATING MANUAL AND PROCEDURE
6.1 Scope and Objectives

This procedure provides operating instruction for the R-201 system, inclusive of operation
instructions for system start-up and shutdown.
6.2 Applicable Documents

Material Safety Data Sheet (MSDS)
6.3 Material & Equipment

Special equipment or materials are required to perform these procedures.
6.4 Safety & Health

No safety or health issues which require special attention are associated with operation of the
Urea Reactor.
6.5 Standard Operating Condition (SOC)

Table 6.1: Standard operating condition (R-201)
Loop ID Normal Set Point (R-201)
Temperature 190˚C
Pressure 13210 kPa
6.6 Procedures
6.6.1 Reactor Pre-Start up Procedures
No. Procedures Checklist

Ensure that inventory is available at each unit operation. Note
1
that reactor will be last unit operation to start up.
Verify vessel readiness such as all maintenance and I&E
works completed, the reactor is clean and rinse with process
2
water if necessary, man way closed, all blinds are removed
and proper gasket are installed.
3 Line up cooling water into shell-side of R-201.
4 Line up all transmitters and stroke all control valves
5 Close, plug and cap all bleeders.

Place the reactor temperature indicator (TI) and pressure
6
indicator (PI) in service.
Purge reactor with high pressure N2 until the vent of O2 is
7
lower than 6%.
Pressure up the reactor with high-pressure Nitrogen to15000
8
kPa and perform leak check on all flanges.
Pressure up the reactor to 10000 kPa and check flanges for
9
leaks.
6.6.2 Initiation of Reactor
No. Procedures Checklist
1 Set reactor operating condition at 13210 kPa and 190˚C.
2 Stop circulation. Allow reactor effluent to pass through.

3 Increase feed of ammonia to 100%.
The system is stabilized, after air, steam are heated up to the

4
standard operating condition (refer to SOC).
6.6.3 Hot Hold and Shut Down of Reactor
No. Procedure Steps Checklist
1 Notify Wastewater Unit, Utilities Unit and Shipping Unit.
2 Reduce the rate of air entering reactor to 70% of feed rate.
3 Shut down by gradually reducing the hot stream flow rate.
4 Reduce reactor feed further to 50% of feed rate, then to 30%.
5 Isolate feed to the reactor.

To HOT HOLD the reactor, block all isolation valves,
control valves. Manual block valves for molten salt and air
6
fed. Verify at field that all isolation and control valves are
closed. This is to put reactor on HOT HOLD.
To SHUT DOWN the reactor, block all isolation valves,
control valves. Manual block valves for air feed at inlet
7
reactor. Verify at field that all shutoff and control valves are
closed.
Open both man ways of the reactor and inspect the
8
cleanliness inside the reactor. Access the need of washing.
Prepare the reactor for washing with process water if
10
required.
If reactor is clean, then proceed with blinding and prepare
11
vessel for maintenance.
If reactor is not clean, then close the man ways and perform
12
washing with process water.
CHAPTER 7
MINOR EQUIPMENT
7.1 HEAT EXCHANGER
7.1.1 Introduction
Heat exchangers are equipment that used to transfer heat between hot and cold. They have
separate passages for two streams and operate continuously. The heat exchanger that is selected
for this report is the E-12. The function of E-12 is to cool down water from the compressor from
187.5’C to 30’C before entering another compressor. It is supplied with cooling water for this
purpose. The type of heat exchanger that is selected is the shell and tube heat exchanger. It is the
most commonly used type of heat-transfer equipment. The advantages of this type of heat
exchanger are:
1. The configuration gives a large surface area in a small volume
2. Good mechanical layout: a good shape for pressure operation
3. Uses well-established fabrication techniques
4. Can be constructed from a wide range of materials
5. Easily cleaned
6. Well-established design procedures
7.1.2 Heat Exchanger Sizing
Design of an exchanger is based on calculations. The steps of a typical heat exchanger are given
as below:
1. Define the duty: heat-transfer rate, fluid flow-rates, and temperatures.

2. Collect together the fluid physical properties required: density, viscosity, thermal
conductivity.
3. Decide on the type of exchanger to be used.
4. Select a trial value for the overall coefficient, U.
5. Calculate the mean temperature difference, Tm.
6. Calculate the area required.
Table 7.1 summarized the properties of the fluids that flow through the heat exchanger shell and
tube.
Table 7.1: Properties of Fluid

Shell Side Tube Side
Fluid Compressed Air Cooling Water
Flow Rate (kg/hr) 20000 19437.8
Temperature in (°C) 187.5 10
Temperature out (°C) 30 50
Specific heat (kJ/kg.°C) 1.0318 4.18
Heat transfer (kW) 902.778
Density (kg/m3) 2.463 1000
Viscosity (Pas) 0.00002578 0.0008
Viscosity (cP) 0.02578 0.8
Thermal conductivity (W/m.K) 0.03684 0.59
Molecular weight (MW) 28.85 18
Passes 1 2
The type of heat exchanger selected is shell and tube exchanger using u-tube. The configuration
chosen is horizontal. The flow rate of water inside the tube side of the heat exchanger is
calculated from the equation:
𝑄 = 𝑚𝐶𝑝 𝑇
𝑄
𝑚=
𝐶𝑝 𝑇
902778
=
8 × 50 − 0
= 5 99
= 9 78
𝑟
In order to determine the heat transfer area (A), several calculations are done. The log mean
temperature (∆Tm) is calculated using the equation:
𝑇 − 2 − 𝑇2 −
𝑇𝑚 =
𝑇 − 2
𝑇2 −
87 5 − 50 − 0 − 0
=
87 5 − 50
0− 0
= 60 95 𝐶
From the data in table 1, R and S value can also be calculated by:
𝑇 − 𝑇2
𝑅=
− 2
= 9
2 −
𝑆=
𝑇 −
= 02
The true temperature difference is then calculated by using the correction factor, Ft. From the
table, the value of Ft is 0.87. Therefore, the true value can be calculated as
𝑇𝑚 = 𝐹 𝑇𝑚
= 0 87 × 60 95
= 5 02 𝐶
It is needed to assume the initial value for the overall heat transfer coefficient. Based on the table
by Sinnot (2005), the initial value can be set to 30 W/m².°C.
Therefore, the required area for heat transfer, A is
𝑄
𝐴=
𝑈 𝑇𝑚
= 567 525 𝑚
7.1.3 Tube Sides
Table 7.2 summarized the details of the material and the dimension that is selected for the
construction of the tube side of the heat exchanger.
Table 7.2
Material Stainless Steel

Outside diameter, do (m) 0.02
Inside diameter, di (m) 0.016
Wall thickness, Lt (m) 0.00165
Tube length (m) 4.88
Conductivity Factor, kw (W/m.°C) 16
Heat transfer factor, jh (25% cut) 0.024
From the data, the area of the tube is calculated using equation:
𝐴 = 𝑑𝑜 𝜋
= 0 07𝑚
From the equation X, the number of tubes can be calculated by using equation:
𝐴
𝑁 =
𝐴
= 85
Then, the tube side mass velocity, Gt can be calculated using the formula:
𝐺 =
𝐴
= 29 0 7 𝑚
The tube side velocity is then can be calculated based on formula:
𝐺
𝑣 =
𝜌
= 0 029𝑚
The value for Reynolds number and Prandtl number then can be calculated.
Reynolds number, Re
𝜌𝑣 𝑑𝑖
𝑅 = = 580 9
Prandtl number, Pr
𝐶 𝑤 𝑤
𝑃𝑟 = = 5 668
𝑤
The tube side heat transfer coefficient, ht can be calculated using:
𝑤 𝑅 𝑃𝑟 3
=
𝑑𝑖
= 970 𝑊 𝑚 𝐶
It is necessary to calculate the shell diameter for the purpose of calculation in shell side. It is first
need to calculate the bundle diameter, Db of the shell. The calculation for the bundle diameter is
based on calculation:
⁄𝑛
𝑁
𝐷 = 𝑑𝑜 ( )
Based on AUTHOR, the value for k1 and n1 can be used based on the number of passes in heat
exchanger. The value is set to be 0.249 and 2.207 for k1 and n1 respectively due to 2 passes.
Therefore the value of Db
𝐷 = 5𝑚
After that, it is needed to determine the value of bundle diameter clearance. It is assumed that the
type of floating head is to be U-tube floating head. Therefore, the value based on the table by
Sinnot (2005) is 0.019m.
Thus the value for the shell diameter is
𝐷𝑠 = 𝐷 + 𝐷𝐶
= 5+00 9
= 5 𝑚
7.1.4 Shell Sides
For the calculation in the shell sides, table 7.3 summarized the necessary data for the
calculations.
Table 7.3: Data for Calculation of Shell Side Heat Exchanger
Material Stainless Steel

Arrangement Triangular
Shell diameter, Ds (m) 1.154
Baffle spacing, lB (m) 0.231
Tube pitch, pt (m) 0.025
Tube outside diameter, do (m) 0.02
Heat transfer factor, jh (25% cut) 0.0028
The cross flow area, As is calculated using equation:
− 𝑑𝑜 𝐷𝑠
𝐴𝑠 =
= 0 005 𝑚
Shell side mass velocity, G s can be calculated using the following equation:
𝑠
𝐺𝑠 =
𝐴𝑠
= 0 266 𝑚
Then, the equivalent diameter, de is represented by
2
𝑑 = − 0 9 7𝑑02
𝑑𝑜
= 00 6𝑚
The value for Reynolds number and Prandtl number then can be calculated.
Reynolds number, Re
𝐺𝑠 𝑑
𝑅 = = 59096 57
Prandtl number, Pr
𝐶 𝑤 𝑤
𝑃𝑟 = = 0 722
𝑤
Finally, the shell side heat transfer coefficient, hs can be calculated using the formula:
𝑤 𝑅 𝑃𝑟 3
𝑠 =
𝑑
= 7 262 𝑊 𝑚 𝐶
7.1.5 Overall Heat Transfer Coefficient
From the data calculated for the tube and shell side, it is now possible to calculate the overall
heat transfer coefficient, Uo. The necessary data for the calculation is summarized in table 7.4.
Table 7.4: Data for Heat Transfer Coefficients
Outside fluid film coefficient, ho (W/m2 K) 374.262

Inside fluid film coefficient, hi (W/m2K) 970.343
Outside dirt coefficient (fouling factor), hod (W/m2 K) 6000
2
Inside dirt coefficient (fouling factor), hid (W/m K) 3000
Thermal conductivity of the tube wall material, k w (W/m2 K) 16
Tube inside diameter, di (m) 0.016
Tube outside diameter, do (m) 0.02
The heat transfer coefficient is then calculated based on the formula given:
𝑑
𝑑𝑜 ln ( 𝑑𝑜 ) 𝑑0 𝑑0
𝑖
= + + + × + ×
𝑈0 𝑠 𝑜 2 𝑤 𝑑𝑖 𝑖 𝑑𝑖 𝑖
= 0 00 68
𝑈𝑜
𝑈𝑜 = 2 5 2𝑊 𝑚 𝐶
It is calculated that the overall heat transfer coefficient is 202.081 W/m².°C. The value is
acceptable since it is greater than the initial value assumed earlier which is 30 W/m².°C.
7.1.6 Heat Exchanger Specification Sheet
HEAT EXCHANGER DATA SHEET Equipment No E-12

Description Heat Exchanger
Sheet No 1
OPERATING DATA
Total Heat Transfer Area 567.525m2 Type Shell and Tube
Number of Shell Passes 1 Orientation Horizontal
Number of Tube Passes 2
PROCESS DATA
Shell Side Tube Side
Circulating Fluid Air Water
Phase Gas Liquid
Mass flow rate of fluid Kg/hr 20000 19437.8
entering
Fluid velocity m/s 42.33 0.029
Heat transfer coefficient W/m2.K 970.343 340.426
Fouling coefficient W/m2.K 3000 6000
IN OUT IN OUT
Temperature °C 187.5 30 10 50
Heat capacity kJ/kmol.°C 1.0317 4.18
Thermal conductivity W/m.K 0.03684 0.59
Viscosity cP 0.02578 0.8
3
Density Kg/m 2.463 1000
MECHANICAL DATA
Shell-Side Tube-Side
Material Stainless Steel Material Stainless steel
Shell Internal m 1.15 Thermal conductivity W/m2.K 0.59
Diameter
Baffle diameter Length of tube m 4.88
Baffle spacing m 0.23 Outside diameter m 0.02
Inside fouling W/m2.K 3000 Inside diameter m 0.016
Outside fouling W/m2.K 6000 No of tubes 1851
Pressure drop Tube pitch m 0.025
Bundle diameter m 1.135
Pressure drop
7.2 COMPRESSOR
7.2.1 Introduction
Compressors are required to transfer gases from one process unit to another and to compress
them to carry out chemical reactions, separations, and to liquefy gases (Silla, 2003). For this
plant, compressor is used to compress air from atmospheric pressure to a pressure before inserted
into the secondary reformer, R-102. Compressor that is selected for this report is K-102. In
general, there are several most common types of compressors used in industries. Those are
centrifugal compressor, diagonal or mixed-flow compressor, axial flow compressor and
centrifugal compressor.
7.2.2 Basic Operation
There are two main classes of compressors, positive displacement and dynamic. Positive
displacement compressors compress essentially the same volume of gas in a chamber regardless
of the discharge pressure. In a dynamic compressor, a gas is first accelerated to a high velocity to
increase its kinetic energy. Then, the compressor converts kinetic energy into pressure by
reducing the gas velocity, according to the macroscopic energy balance. The C4 from
atmosphere will enter the compressor prior to entering the heat exchanger, E-105 before it enters
another heat exchanger, E-106. The stream needs to increase its pressure from 101.3 kPa to
327.2 kPa. The process stream for compressor K-102 is as follows:
Po = 327.2 kPa
Pi = 101.3 kPa To = 187.5’C
Ti = 30’C
W =333.33 kg/min
7.2.3 Compressor Sizing
The calculations in order to determine the size of the compressor are as follow:
The pressure differences between the inlet and outlet stream,
𝑃 = 𝑃 − 𝑃 = 225 9 𝑃
In order to determine the number of stages of the compressor,
𝑃
= 𝑃
ln 7
272
= 0 = 09
ln 7
Therefore, approximately 1 stage is needed for the compressor.
To determine the theoretical temperature of the compressor, the value of polytropic temperature
exponent need to be found.
𝑁− ⁄𝑁 −
Polytropic temperature exponent, 𝑁 = = ⁄ 𝐸
− 0⁄
= ×08
= 0 2885
02 5
Theoretical outlet temperature, 𝑇𝑜 =𝑇 ( )
0 02 5
= 298 (3 2 2 )
= 9
Z = 1.0
R = 1544/MW
R = 1544/28.966=53.304
To determine the amount of polytropic work required,
𝑅𝑇𝑖 𝑃2
𝐻𝑝𝑜 𝑦 = [ − ]
𝑁− 𝑃
𝑁
5 0 298 272 02 5
= [ 02 5 − ]
0 2885 − 0
0 2885
= 6086 777
𝑊𝐻𝑝𝑜 𝑦
𝐻𝑃 =
𝐸 000
=4610.65 kW
𝑅𝑇𝑖 𝑃2
𝐻 = [ − ]
− 𝑃
𝑁
=34253.72 hp
𝑊𝐻
𝐻𝑃 =
𝐸 000
= 27679.50 hp
7.2.4 Compressor Specification Sheet
COMPRESSOR DATA SHEET EQUIPMENT NO

DESCRIPTION
SHEET NO
GENERAL
COMPRESSOR TYPE NO OF UNITS
LUBRICATION METHOD
COOLING METHOD
OPERATION METHOD continuous parallel
intermitte indoor outdoo
nt
OPERATING CONDITIONS & REQUIREMENTS r
INLET FLOW RATE NORMAL MAXIMUM

INLET TEMPERATURE
OUTLET TEMPERATURE
INLET PRESSURE
OUTLET PRESSURE
DESIGN PRESSURE
MOLECULAR WEIGHT
RELATIVE HUMIDITY
SELF CONDITIONS/UTILITIES
AIR QUALITY Saliferous Salt Laden Corrosive
ALTITUDE ABOVE SEA LEVEL
AMBIENT TEMPERATURE Normal
Max
Min
REQUIRE TROPICALIZATION Yes No
REQUEST WINTERIZATION Yes No
COOLING WATER SUPPLY PRESSURE
TEMPERATURE
COOLING WATER RETURN PRESSURE
TEMPERATURE
COOLING WATER FLOW
RATE
AUXILIARIES TO BE SUPPLIED
Electric Motor Driver Diesel Engine Driver
Gear Unit/Accessories Guards
Inlet Filter/Silencer Blow-Off/Silencer
Inter Cooler/Water Cooled After Cooler/Water Cooled
Inter Cooler/Air Cooled After Cooler/Air Cooled
Outer Filter/Accessories Dual Dryer/Accessories
Air Reservoir/Accessories Safety Relief Valves
Barring Gear Noise Abatement Shroud
Air Reservoir/Accesories
Common Skid (Compressor Package/Dryer/Filter Reservoir)
Spreader Bar and Sling Assembly
ELECTRIC MOTOR DRIVER
Motor Rated Power
Winding Configuration Delta Star
Space Heater Yes Power kW
Voltage V
No
Power Factor Safety Factor
Motor Type Squirrel Cage Synchronous
Operation Method Direct On Line Soft Starting
Rotation Viewing at CW CCW
Motor Fan
REFERENCES
[1] Chemical Engineering Plant Cost Index, http://www.che.com/pindex/DBLS.txt?
[2] H. Scott Fogler (2001), ‘Elements of Chemical Reaction Engineering’, 3 rd Ed., Prentice
Hall Inc, New Jersey.
[3] Molten Salt Data, http://ras.material.tohoku.ac.jp/~molten/
[4] Gael D. Ulrich (1984), ‘A Guide To Chemical Engineering Process Design and
Economics’, John Wiley and Sons, Inc., New York.
[5] Robert J Farrauto, Calvin H Bartholomew (1997) ‘Fundamentals of Industrial Catalytic
Processes’ 1st Edition, Chapman and Hall; Chapter 1: Introduction and Fundamental
Catalytic Phenomena, Table 1.2.
[6] R.K.Sinnott (2005) ‘Chemical Engineering Design’ 4th Edition, Choulson &
Richardson’s; Volume 6.
[7] R.H Perry & D.W Green (1997), ‘Perry’s Chemical Engineering Handbook’, 7th Ed., Mc
Graw Hill, USA.
[8] James M. Douglas (1988), ‘Conceptual Design of Chemical Processes’, International
Edition, Mc Graw Hill Inc, New York
[9] Max S. Peters, Klaus D. Timmerhaus, Ronald E. West (2003), ‘Plant Design and
Economics for Chemical Engineers’, 5th Ed., McGraw Hill, US.

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MUHAMMAD MUHAIMIN BIN ABD RAHMAN (13243)

PDP II SEPTEMBER 2013 INDIVIDUAL DESIGN

DESIGN OF MINOR EQUIPMENT

DOC PREPARED REVIEWED

1.2 DESIGN METHODOLOGY

1.3 REACTOR TYPE

CSTR Plug Flow Reactors

1.4 PROCESS DESCRIPTION

1.5 FEED AND PRODUCT CONDITIONS

Ammonium Carbamate 0.00 0.00 542.82 76.22 0.00 0.00

Outlet of reactor R-201:

Component Flow Rate Mass Flow Rate Mass

Operating Temperature 190oC

Operating Pressure 13 210 kPa

Overall Feed Flow rate 1012.925 kg/hr

Volumetric Flow rate 5911.905 m3/hr

Composition of Carbamate 0.5359

2.2 REACTOR SIZING

Thus, the volume of reactor is,

2.2.2. Diameter And Height Of The Reactor

The residence time of reactor can be calculated using the equation:

2.2.4. Number Of Stages Required

3.1. DATA FOR MECHANICAL DESIGN

Table 3.1: Data Required

Working Temperature 190°C

Design Temperature 210°C

Working Pressure 13210 kPa

Design Pressure 14531 kPa

Material of Construction Stainless Steel 321

Design Stress 135000 kPa

3.2. DETERMINATION OF SHELL THICKNESS

Design at domed ends can be calculated as

Table 1: Gasket Material Detail Specification

Ratio of do to di (gasket diameter)

Gasket inner diameter, di,

To find gasket outer diameter, do,

To find gasket width, W,

To find basic gasket seating width, bo,

To find diameter at location of gasket load reaction, G,

Minimum bolting area

3.5. LOADING ANALYSIS

Weight of the shell can be calculated as:

By substituting the value, the weight of shell is:

3.5.1.2. Weight of Insulation Material

Table X summarizes the properties of insulation material

The weight of insulation can be calculated as

3.5.1.3. Total Reactor Weight

3.5.2. Wind Loading

Dynamic wind pressure, Pw = 1280N/m2

To find loading (per linear meter),

3.6. BOTTOM STRESS ANALYSIS

3.6.2. Dead Weight Stress

Bending stress in skirt is calculated by using

The dead weight of the skirt,

Purcha sec ost,$ 

6.1 Scope and Objectives

6.2 Applicable Documents

6.3 Material & Equipment

6.4 Safety & Health

6.5 Standard Operating Condition (SOC)

6.6.1 Reactor Pre-Start up Procedures

No. Procedures Checklist

4 Line up all transmitters and stroke all control valves