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Pandya - Nitric Acid Plant Design
Pandya - Nitric Acid Plant Design
DESIGN PROJECT
SHIVAM PANDYA
UNIT 1 INTRODUCTION
PROCESS DESCRIPTION:
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PROCESS EQUIPMENT:
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REACTOR The reactor is a pressure vessel operating in the range
1050 kPa to 1100 kPa. The design pressure should be about 1400
kPa. The vessel must be designed to ensure even passage of the
feed gas mixture over the platinum/rhodium catalyst gauze. A
‘Random Pack’ flow distributor (Englehard Industries) would be
suitable. The catalyst gauze and accompanying platinum filter
gauze are fixed in position by lateral supports across the width of
the reactor. The catalyst gauze and filter gauze are both 80 mesh,
plain weave-type sheets (about 25 of each for a total mass of 24
kg). In the reaction section, the walls of the reactor should be
lined with refractory material to prevent wear on the outer walls.
The bottom section of the reactor is jacketed. Air is preheated in
this jacket prior to mixing with ammonia. The bottom section of
the reactor also contains a shell and tube-type heat exchanger.
This exchanger provides the final stage of tail-gas preheating.
Tail gas enters at 235°C and the reaction gases leave the
exchanger section of the reactor at 645°C. The reactor shell,
jacket and associated heat exchanger are all constructed from
mild steel. Reactor exchanger heat-transfer area = 72m2.
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WASTE-HEAT BOILER A shell and tube-type exchanger
required to heat pressurized (4000 kPa) hot water from 117°C to
a saturated vapour at 250°C. Design pressure on the tube side is
approximately 5000 kPa. The waste-heat boiler cools reaction
gases from 595°C to 280°C. It is made from mild steel. Waste-
heat boiler heat-transfer area = 110 m2.
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Bleaching Column The bleaching column is a smaller sieve tray-
type column. Impure acid runs down the column from the top tray
and air is bubbled up through the liquor to remove dissolved
nitrogen oxides. The acid from the base of the column is the final
desired 60%(wt.) product.
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UNIT 2 MATERIAL AND ENERGY
BALANCE
Ammonia Requirement :
Air Requirement :
Tail Gas :
tail gas = 28521 kg
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Air 35638 Kg Tail Gas 28521 Kg
PROCESS
Ammonia 2008 Kg Total Product
BASIS 1 HOUR
Make-up Water 2542 Kg (7000 Kg HNO3 +
4667 Kg H2O
Compresser :
= 72226717 kJ
=11118026 kJ
= 35638×1.05 × (180−45 )
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= 5051686 kJ
= 5051686/4.184× ( 40−20 )
= 60370 kg
Ammonia Vaporizer :
Ammonia Superheater :
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Heat Duty To Superheat Ammonia = m Cp (Tout – Tin)
=2008×2.25 × 142
= 641556 kJ
= 308 kg
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UNIT 3 STEAM SUPERHEATER
DESIGN
The floating head also enables easy withdrawal of the tube bundle for
cleaning purposes. This may prove very advantageous, not because the
streams suffer from fouling, but because platinum carryover from the reactor
may be deposited on thewalls of the tubes.
Allocation
The reaction-gas stream is allocated to the tube side for several reasons:
(b) This stream will have the largest tendency for fouling.
(c) It is the higher temperature stream and therefore heat losses are
minimized by passage through the tubes rather than the shell.
(d) It has the highest flowrate, and typically if the lowest flowrate stream is
allocated to the shell side a better result is achieved.
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(645−380)−(595−250)
= ln
645−380
595−250
∆ T LMTD = 303℃
The proposed design uses one shell pass with two tube passes, therefore:
= 0.385
= 0.329
= 300℃
Reaction Gas
Saturated steam
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Temperature out (t2) 380°C
B. Provisional area
Heat duty
A = U ∆T
lm
586× 1000
= 100× 300
= 19.5 m2
19.5
= 0.175
= 112
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( )
1
Nt n
Tube bundle diameter, Db = D0 k
1
( )
1
112
=38.1× 0.249
2.207
= 607 mm
Clearance = 62 mm
Shell inside diameter = Tube bundle diameter +¿Clearance
=669 mm
Tube side heat transfer coefficient
( )
0.14
μ
Nu = 0.021 Re 0.8
Pr 0.33
μw
[ ( ) ]
0.14
kf 0.33 μ
ho= d jh ℜ Pr μw
e
0.0475
ho = −3
[ 0.0037 × 60540 ×2.04 0.33 ]
28× 10
W
h0 = 480 2
m K
1
U =
1 d 0 1 + d 0 ln
+
h0 di hi
d0
( )
d i + F i+ F o
2 kw
−3
1 38 1 + 38× 10 ln
= 534 + 32 h
i
38
32 +0.002+0.001 ( )
2 × 45
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W
U = 135 2
m K
[ () ]
∆ Pt = 8 j f
L
di
+2.5
ρ u2
2
[ ( ) ]
2
1.83 5.7 ×34.3
= 8 ×0.0027 0.032 + 2.5 2
= 26 kPa
Shell Side Pressure drop
∆ P s=8 j f
( )( )
Ds
De
Lt ρu 2
Bs 2
= 8× 0.36× ( )(700
28 0.305)
1.83 27.5× 2.92
2
= 50 kPa
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HEAT EXCHANGER SPECIFICATION SHEET
Operation Type Continuous
Model Type Shell and Tube
Construction Material Carbon Steel
Heat Duty 586 kW
Pass Per Unit 1 Shell - 2 Tube Pass
Number of Tubes 112
Tube Length 6 ft
Tube Outer Diameter 38 mm
Tube Wall Thickness 31 mm
Shell Wall Thickness 3.5 mm
Bundle Diameter 607 mm
Shell Diameter 669 mm
Tube Pitch 25 mm
Baffle Cut Per Cent 25
Heat Exchanger Area 19.5 m2
Overall Heat Transfer Coefficient 135 W/m2 K
Tube Side Fluid
Flow Rate 31706 kg/h
Components Reaction Gas
Fouling Coefficient 500 W/m2K
Inlet Outlet
Temperature 918 K Temperature 868 K
Pressure 1035 kPa Allowable Pressure Drop 50 kPa
Shell Side Fluid
Flow Rate 5775 kg/h
Components steam
Fouling Coefficient 1000 W/m2K
Inlet Outlet
Temperature 523 K Temperature 653 K
Pressure 4000 kPa Allowable Pressure Drop 50 kPa
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UNIT 4 PUMP CALCULATION
To specify the pump for delivery of 60% wt. ‘red’ nitric acid from the
absorption column to the bleaching column.
Temperature 65°C
Piping Specification
= 2.63 x 10-3/2
= 1.31 x 10-3 m2
= 41 mm
This value is compared with the result achieved by applying the ‘economic
pipe diameter’ formula for stainless steel.
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Optimum diameter = 226 G0.53 ρ -0.35
=33mm
Accept the larger value as a conservative This suggests that pipe of nominal
pipe size 1.5, schedule number 80 S. This piping is 48 mm (1.9 in.) o.d. and
38 mm (1.5 in.) i.d.
= 1.13 x 10-3 m2
= 2.3 m/s
(urnax) = (1 .2)2 u
= 3.3 m/s
= 2.22 kPa/m
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Accept the higher value and design for a maximum flowrate at 20% above
the normal (average) flow, therefore:
= 3.2 kPa/m
Pump Power
P = Q Hρg
= 2.63×10 -3×34×1350×9.8
= 1183 W
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PUMP SPECIFICATION SHEET
Design Data
Pipe Material Cast Iron
Pipe Diameter 0.04 m
Pipe Schedule Number 40
NPSH 69.38 m
Temperature 353 K
Inlet Pressure 946 kPa
Outlet Pressure 1287 kPa
Power Required 1.6 hp
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