UNIVERSITI TEKNOLOGI MALAYSIA

PRODUCTION OF STYRENE FROM BENZENE AND

BIOETHYLENE
INDIVIDUAL EQUIPMENT DESIGN
FLASH COLUMN (V-103)
GROUP 5

NAME MATRIC NUMBER

AMIR REDHA BIN EZUDDIN A17MJ0013

0
TABLE OF CONTENTS

NO CONTENT PAGE
1 INTRODUCTION 3
2 CHEMICAL DESIGN 4
2.1 Mass and Energy Balance 4
2.2 Settling Velocity 7
2.3 Column Diameter 7
2.4 Column Height 8
2.5 Design Pressure 9
3 MECHANICAL DESIGN 8
3.1 Cylindrical Minimum Thickness 10
3.2 Design of Column Domed Head 11
3.3 Design of Column Dead Weight 11
3.4 Design of Wind Loading 13
3.5 Stresses Analysis 13
3.6 Elastic Stability (Buckling Check) 16
3.7 Vessel Support Design 17
3.8 Base Ring and Anchor Bolts Design 19
3.9 Feed Inlet Nozzle 21
3.10Top Product Nozzle Sizing 21
3.11Bottom Product Nozzle Sizing 22
4 Control and Safety 23
4.1 Process Control of Flash Column 23
4.2 HAZOP Study on Flash Column 24
5 Summary Flash Column 25
5.1 Equipment Specification Sheet 27
6 Mechanical Drawing of Flash Column 28
References 35

1
 List of Figures
Figure No Title Page
Figure 3.5 Stress Analysis 15
Figure 4.1 Control and Safety 23

List of Table
Table No Title Page
Table 2.1 Mass and Energy Balance 4
Table 2.2 Mass and Energy Balance 6
Table 4.2 HAZOP Study Flash 24
Column
Table 5.0 Summary of Flash Column 25
Table 5.1 Equipment Specification 27
Sheet

2
Introduction:
Flash column or two-phase separator is use in industry to separates vapor and liquid by density
gradient (Vijayan et al., 2020). According to(Morales and Alvarez, 2017), flash distillation is
preliminary step of separation between liquid and vapor before enter more complicated
separation. In this production, we will separate the liquid mixture into benzene and carbon
dioxide.

Two-phase separator have two kinds of version either vertically or horizontally (Svrcek and
Monnery, 1993).This separator also works based on temperature (Kiss, 2013). Vapor and liquid
separation usually complete it cycle or stages by 3 steps which first steps are use an inlet diverter
as the biggest droplets fall on the diverter due to the motion of the liquid formed in the vapor.
Next, gravity separation of smaller droplets occur which occur at disengagement area. The third
step which mist elimination as the tiny droplets merge to generate larger droplets that will
separate by gravity.

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2.0 CHEMICAL DESIGN
Design assumption
1) No reactive mechanism occurs
2) Uniform flow in process
3) Constant Density in stream line
4) No change in mass
5) Steady state condition

2.1 Mass and Energy Balance

Pressure, P = 2.0265 bar

Temperature, T =343.15 K

Vapor Density, 𝜌𝑣 = 3.315 kg/m3

Liquid Density, 𝜌𝑙 = 856 kg/ m3

Vapor Flowrate,𝑀𝑣 =4104.17 kg/hr

Liquid Flowrate, 𝑀𝑙 =28665.89 kg/hr

ξ for light key = 0.99

ξ for heavy key = 0.01
Light key component is carbon dioxide
Heavy key component is benzene
According to (Mohamed Noor et al., 2010) the general equation of material balance is:

Input + Generation – Output – Consumption = Accumulation

𝑚𝑖𝑛 = 𝑚𝑜𝑢𝑡
Where,
𝑚𝑖𝑛 = 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 𝑎𝑡 𝑖𝑛𝑙𝑒𝑡
𝑚𝑜𝑢𝑡 = 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 𝑎𝑡 𝑜𝑢𝑡𝑙𝑒𝑡
To obtain split fraction:

4
 𝛼𝜉 𝑛
𝜉𝑖 = 1+(𝛼𝑖 −1)𝜉
𝑖 𝑛

Where;
𝛼𝑖 = 𝑟𝑒𝑙𝑎𝑡𝑖𝑣𝑒 𝑣𝑜𝑙𝑎𝑡𝑖𝑙𝑖𝑡𝑦 𝑜𝑓 𝑡ℎ𝑒 𝑐𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡 𝑖
𝜉𝑛 = 𝜉 of the key component

Table 2.1
𝑣𝑖 = 𝜉𝑖 × 𝑛𝑖
Where;
𝑘𝑚𝑜𝑙
𝑣𝑖 = 𝑜𝑢𝑡𝑝𝑢𝑡 𝑚𝑜𝑙𝑎𝑟 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 𝑜𝑓 𝑐𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡 𝑖 ( )
ℎ𝑟
𝜉𝑖 = 𝑠𝑝𝑙𝑖𝑡 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝑐𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡 𝑖
𝑛𝑖 = input molar flow rate of component (kmol/hr)

Molar flowrate of the bottom product can be obtained by applying the following equation:
𝑙𝑖 = 𝑛𝑖 − 𝑣𝑖

Energy Balance:

5
 Table 2.2
ΔH = Q = 𝐻𝑜𝑢𝑡 − 𝐻𝑖𝑛
Q = 29317225.44 +(-36120572.84) – (-6803347.39) = -7.45×10−9 𝑘𝐽/ℎ𝑟

6
2.2 Settling Velocity, (𝒖𝒕 )
𝜌𝑙 − 𝜌𝑣 0.5
𝑢𝑡 = 0.07 [ ]
𝜌𝑣

856−3.315 0.5
𝑢𝑡 = 0.07 [ ]
3.315

=1.12 m/s

Where;

𝑢𝑡 = settling velocity, m/s

𝑢𝑡 = liquid density, kg/ 𝑚3

𝜌𝑣 = vapour density, kg/ 𝑚3

2.3 Column Diameter (𝑫𝒗 )

Vapour flowrate one of major consideration when determining the column diameter. To avoid a
high pressure drop and severe liquid entrainment, the vapour velocity must be sufficient.

Vapour volumetric flowrate:

𝑀
𝑉𝑣 = 3600𝑣×𝜌
𝑣

4104.17 𝑘𝑔/ℎ𝑟
𝑉𝑣 = 3600 ×3.315 𝑘𝑔/𝑚3

=0.344 𝑚3 /s

7
Minimum vessel diameter,

4𝑉
𝐷𝑣 = √𝜋𝑢𝑣
𝑡

4(0.344)
=√𝜋 (1.12×0.15)

=1.612m

2.4 Column Height (𝑯𝒗 )

Liquid volumetric flowrate,

𝑀 𝑙
𝑉𝑙 = 3600×𝜌
𝑙

28665.89 𝑘𝑔/ℎ𝑟
=3600×856 𝑘𝑔/𝑚3

=9.302×10−3 𝑚3 /s

Liquid level is relied on hold-up times and 10 minutes is appropriate and suitable for the process
𝑠
𝑉ℎ𝑒𝑙𝑑 = 𝑉1 × (10 min × 60 𝑚𝑖𝑛)

𝑠
𝑉ℎ𝑒𝑙𝑑 = 9.302×10−3 𝑚3/s × (10 min ×60 𝑚𝑖𝑛)

𝑉ℎ𝑒𝑙𝑑 = 5.58 𝑚3

8
According to (Hall, 2012),liquid depth required, ℎ𝑣 , can be obtained by follow this formula;

𝑣𝑜𝑙𝑢𝑚𝑒 ℎ𝑒𝑙𝑑−𝑢𝑝
ℎ𝑣 = 𝑣𝑒𝑠𝑠𝑒𝑙 𝑐𝑟𝑜𝑠𝑠−𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎

5.58
ℎ𝑣 = (𝜋×1.6122 /4)

ℎ𝑣 = 2.73m

Increase to 0.3 to allow space for positioning the level controller.

𝐷
𝐻𝑣 = ℎ𝑣 + 2𝑣 + 𝐷𝑣 +0.3 m

1.612
𝐻𝑣 = 2.73 m + + 1.612 + 0.3 m
2

𝐻𝑣 = 5.45 𝑚

2.5 Design Pressure ( 𝑷𝒊 )

Vessel need to build strong and high resistance to the maximum pressure along the process. 10%
above operation pressure are amount or value that take into the consideration for design pressure
(Sinnott and Towler, 2013).

𝑃𝑖 = P × 1.1

𝑃𝑖 = 2.0265 bar × 1.1

𝑁
𝑃𝑖 = 2.22 𝑏𝑎𝑟 𝑜𝑟 0.222
𝑚𝑚2

Tensile Strength = 360 N/𝑚𝑚3

Design stress, f = 130 N/𝑚𝑚3

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3.0 MECHANICAL DESIGN

3.1 Cylindrical Minimum Thickness (𝑒𝑚𝑖𝑛(𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟) )

𝑃 𝐷
𝑖 𝑖
e = 2 𝑓−𝑃
𝑖

Where,

e = minimum thickness, mm

𝑃𝑖 = Design pressure.𝑁/𝑚𝑚2

𝐷𝑖 = internal diameter, mm

J = Joint factor

f = Design stress, 𝑁/𝑚𝑚2

𝑁
0.222 ×(1.615𝑥1000)𝑚𝑚
𝑚𝑚2
e= 𝑁
2 ×130 −0.222
𝑚𝑚2

e = 1.38mm (round off to 1.40 mm)

Carbon steel are being consider for this process and 2 mm of minimum corrosion allowance have
been applied for material undergo erosion and corrosion.

𝑒min(𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟)=2+1.40

𝑒min(𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟)=3.40𝑚𝑚

10
3.2 Design of Column Domed Head

Domed heads came out with various version which are ellipsoidal, hemispherical and tori
spherical. According to (Zheng et al., 2020), tori spherical and ellipsoidal heads are applied for
internally pressurized vessel and those head have quite similar design. In this article and research
also state that ellipsoidal heads have higher buckling resistance. Ellipsoidal heads also have
benefit in term of economical. Ratio of 2:1 are being used for major and minor axis in build
ellipsoidal heads (Seipp et al., 2017).

Ellipsoidal Head

𝑃𝑖 𝐷𝑖
e=
2𝐽𝑓−0.2 𝑃𝑖

𝑁
0.222 ×(1615𝑚𝑚)
𝑚𝑚2
e= 𝑁
2×1×130 −0.2 (0.222)
𝑚𝑚2

e = 1.38mm (round off to 1.40 mm)

minimum allowance of 2 mm is added as corrosion and erosion is taken into consideration.

Minimum allowance is works based on temperature (Stewart, 2008). Thus, thickness of the
ellipsoidal head is;

1.40 mm + 2mm = 3.40 mm

e = 3.40 mm

3.3 Design of Column Dead Weight:

𝐷𝑚 = 𝐷𝑖 + 𝑡 × 10−3

𝐷𝑚 = 1.612 𝑚 + (3.40 × 10−3 )𝑚

𝐷𝑚 = 1.62𝑚

11
Weight of Vessel, 𝑊𝑣 can be obtained as below;

Consider, 𝐶𝑣 = 1.08

𝑊𝑣 = 240 𝐶𝑉 𝐷𝑚 (𝐻𝑣 + 0.8 𝐷𝑚 )t

𝑊𝑣 = 240 × 1.08 ×1.62m × (5.44m +0.8×1.62 m)3.40 mm

𝑊𝑣 = 9600 N (9.60kN)

Weight of insulation:

Mineral wool density, 𝜌𝑤𝑜𝑜𝑙 = 130 𝑘𝑔/𝑚3, mineral wool with thickness = 75mm @ 0.075m

𝐻
𝑉𝑖 = π [ (𝐷𝑖 + 𝑡𝑖 )2 – Dm2] × 4𝑣

5.44
𝑉𝑖 = π [(1.62m + 0.075 m)2 – (1.62)2] × 4

𝑉𝑖 = 1.012 𝑚3

Weight of insulation is,

𝑊𝑖 = 𝑉𝑖 𝜌𝑤𝑜𝑜𝑙 g

𝑘𝑔 9.81𝑚
𝑊𝑖 = 1.012𝑚3 × 130 ×
𝑚3 𝑠2

𝑊𝑖 = 1291𝑁

2×𝑊𝑖 =2583N

Total Dead Weight (W);

W= 9.60 + 2.58kN

W= 12.18 kN

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3.4 Design of Wind Loading

Wind loading is design to withstand any kind of wind speed at the plant operation. The
fluctuating wind will result high pressure which will cause severe damage to structure of column
(Mendis et al., 2007).

𝑃𝑤 =1280 N/m2

Mean diameter, including insulation:

𝐷𝑚(𝑤𝑖𝑡ℎ 𝑖𝑛𝑠) = [𝐷𝑚(𝑛𝑜 𝑖𝑛𝑠) + 2(𝑡 + 𝑖𝑛𝑠𝑢𝑙𝑎𝑡𝑖𝑜𝑛) × 10−3 )

𝐷𝑚(𝑤𝑖𝑡ℎ 𝑖𝑛𝑠) =[1.612 + 2(3.40+0.075) ×10−3)

𝐷𝑚(𝑤𝑖𝑡ℎ 𝑖𝑛𝑠) = 1.62 m

Wind Loading, 𝐹𝑤 = 𝑃𝑤 × 𝐷𝑚

𝐹𝑤 = 1280 N/m2 × 1.62 m

𝐹𝑤 = 2074 N/m

Bending moment at bottom tangent line, 𝑀𝑥

𝐹𝑤 (𝐻𝑣 )^2
𝑀𝑥 = 2

𝑁
2074 𝑚 × (5.45𝑚)2
𝑀𝑥 =
2

𝑀𝑥 = 30802Nm @ 30.80 kN/m

3.5 Stresses Analysis

Pressure stress;

𝑃𝑖 𝐷 𝑖
𝜎ℎ = 2𝑡

𝑁
0.222 ×(1612𝑚𝑚)
𝑚𝑚2
𝜎ℎ = 2 (3.40𝑚𝑚)

𝑁
𝜎ℎ = 52.85 𝑚𝑚2

13
 𝑃𝑖 𝐷𝑖
𝜎𝐿 =
4𝑡

𝑁
0.222 × 1615𝑚𝑚
𝜎𝐿 = 𝑚𝑚2
4 (3.40𝑚𝑚)

𝑁
𝜎𝐿 = 26.43 𝑚𝑚2

Dead Weigh Stress ( 𝜎𝑤 ):

𝑊
𝜎𝑤 = 𝜋 (𝐷 +𝑡)𝑡
𝑖

(13.29𝑘𝑁 ×1000)𝑁
𝜎𝑤 = 𝜋(1615+3.4𝑚𝑚)3.4𝑚𝑚

𝑁
𝜎𝑤 = 0.71 𝑚𝑚2 (tensile)

Bending Stress (𝜎𝑏 )

𝐷𝑜 = 𝐷𝑖 + 2t

𝐷𝑜 = 1612𝑚𝑚 + 2(3.40𝑚𝑚)

𝐷𝑜 = 1619mm

Second Moment Area, 𝐼𝑣

𝜋
𝐼𝑣 = (Do 4 – Di 4)64

𝜋
𝐼𝑣 = (1619𝑚𝑚4 -1612𝑚𝑚4 ) 64

𝐼𝑣 = (5.8 × 109 𝑚𝑚4)

𝑀𝑥 𝐷𝑖
𝜎𝑏 = ± [ +t]
𝐼𝑣 2

30674 𝑁/𝑚𝑚 1615𝑚𝑚

𝜎𝑏 = [ +3.40]
5.8×109 𝑚𝑚4 2

𝑁
𝜎𝑏 = 4.29 ×10−3 𝑚𝑚2

14
Resultant Longitudinal Stress (𝜎𝑧 ):

𝜎𝑧 = 𝜎𝐿 +𝜎𝑊 + 𝜎𝑏

For upwind,

𝜎𝑧(𝑢𝑝𝑤𝑖𝑛𝑑) = 𝜎𝐿 +𝜎𝑤 + 𝜎𝑏

𝑁
𝜎𝑧(𝑢𝑝𝑤𝑖𝑛𝑑) = (26.36 + 0.77 +4.28 ×10−3 ) 𝑚𝑚2

𝑁
𝜎𝑧(𝑢𝑝𝑤𝑖𝑛𝑑) = 27.134 𝑚𝑚2

For downwind,

𝜎𝑧(𝑑𝑜𝑤𝑛𝑤𝑖𝑛𝑑) = 𝜎𝐿 +𝜎𝑤 ̶ 𝜎𝑏

𝑁
𝜎𝑧(𝑑𝑜𝑤𝑛𝑤𝑖𝑛𝑑) = (26.36 + 0.77 − 4.28 ×10−3 ) 𝑚𝑚2

𝑁
𝜎𝑧(𝑑𝑜𝑤𝑛𝑤𝑖𝑛𝑑) = 27.130
𝑚𝑚2

Figure 3.5 Upwind and Downwind analysis

The greatest difference of principal stress is considered on down-wind side;

𝜎𝑑 = 𝜎ℎ − 𝜎𝑧

15
 𝑁 𝑁
= 52.85 𝑚𝑚2 − 27.130 𝑚𝑚2

𝑁
= 25.72 𝑚𝑚2

Thus, the value is the below the design’s maximum permitted stress.

3.6 Elastic Stability (Buckling) Check

The equation for the critical buckling stress, 𝜎𝑐 :

𝑡
𝜎𝑐 = 2 × 104 (𝐷 )
𝑜

𝑁
2×104
𝑚𝑚2
𝜎𝑐 = (3.40mm)
1619𝑚𝑚

𝑁
𝜎𝑐 = 41.92 𝑚𝑚2

Thus, we need to evaluate maximum stress in order to identify whether the vessel or column
have good design of pressure by applying following formula

𝑁 𝑁
𝜎𝑤 + 𝜎𝑏 = 0.77 𝑚𝑚2 + (4.28 ×10−3 )
𝑚𝑚2

𝑁
=0.7743 𝑚𝑚2

𝑁
The design is satisfactory as the value below the maximum stress of 41.92 𝑚𝑚2

3.7 Vessel Support Design

The design need to overcome high stress and device failure by reducing the stress that revolve in
the column (Williams and Seipp, 2007)

Straight cylindrical skirt, e = 90°

Material of construction = Plain carbon steel

16
 1
𝑊𝑤 = 4 [ π 𝐷𝑖 2 𝐻𝑣 ] 𝜌𝑤 g
1 𝑘𝑔 𝑚
𝑊𝑤 = 4 [ π (1.612 m) ×2 × 5.45m] (1000 𝑚3 )(9.81𝑠2 )

𝑊𝑤 = 1.36 × 105 N
Thus, total weight is
𝑊𝑇 = 𝑊𝑣 + 𝑊𝑤
𝑊𝑇 = 9616.8N + 1.36 × 105 N
𝑊𝑇 = 1.45 ×105 N
Bending moment at the base of skirt, 𝑀𝑠
𝐹𝑤 ×(𝐻𝑣 +8)^2
𝑀𝑠 = 2

2073 × (5.44 + 8)^2

𝑀𝑠 =
2
𝑀𝑠 = 1.87×105 Nm
For the first trial, consider the skirt thickness as the same as that of the bottom section of the
vessel,3.40 mm.
Bending stress in skirt can be obtain,𝜎𝑏𝑠 by applying this formula:
4 𝑀𝑠
𝜎𝑏𝑠 =
𝜋(𝐷𝑠 + 𝑡)𝑡𝐷𝑠
4(1.87 × 105 × 1000𝑚𝑚)
𝜎𝑏𝑠 =
𝜋(1615 + 3.40𝑚𝑚)(3.40 × 1615𝑚𝑚)
𝜎𝑏𝑠 = 26.95 𝑁/𝑚𝑚2

Dead weight stress in skirt;

𝑊𝑤
𝜎𝑤𝑠(ℎ𝑦𝑑𝑟𝑎𝑢𝑙𝑖𝑐 𝑡𝑒𝑠𝑡) =
𝜋(𝐷𝑠 + 𝑡𝑠 )𝑡𝑠
1.46 ×105
𝜎𝑤𝑠(ℎ𝑦𝑑𝑟𝑎𝑢𝑙𝑖𝑐 𝑡𝑒𝑠𝑡) =𝜋(1615+3.40)3.40

=8.40 𝑁/𝑚𝑚2
9616.81
𝜎𝑤𝑠(𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔) = 𝜋(1615+3.40)3.40

=0.55 𝑁/𝑚𝑚2

17
Maximum 𝜎𝑠
Compressive = 𝜎𝑏𝑠 + 𝜎𝑤𝑠 (test)
=26.80 + 8.44
𝑁
= 35.35 𝑚𝑚2

Tensile = 𝜎𝑏𝑠 – 𝜎𝑤𝑠 (operating)

= 26.80 – 0.55
𝑁
=26.40 𝑚𝑚2

Consider the joint factor, as 0.85 (Bamatov et al., 2020).

𝑡𝑠
𝜎𝑠(𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑜𝑛 𝑠𝑡𝑟𝑒𝑠𝑠) ≯ 0.125 𝐸 ( ) 𝑠𝑖𝑛∅
𝐷𝑠
𝑁 3.40
35.35 𝑚𝑚2 ≯ 0.125 (200000) (1612)sin 90°
𝑁 𝑁
35.24 ≯ 52.73 𝑚𝑚2
𝑚𝑚2

𝜎𝑠(𝑡𝑒𝑛𝑠𝑖𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠) ≯ 𝑓𝑠 𝐽𝑠𝑖𝑛∅

𝑁 𝑁
26.40 𝑚𝑚2 ≯0.85(130 𝑚𝑚2 ) sin 90°
𝑁 𝑁
26.40 ≯110.5 𝑚𝑚2
𝑚𝑚2

From calculation, both conditions are satisfied. 2 mm value is added as considering corrosion of
the wall. Thus, skirt thickness is 5.40 mm.

18
3.8 Base Ring and Anchor Bolts Design
Assumption;
Pitch circle diameter,𝐷𝑏 =1.8m
Circumference of bolt circle =1800π
1800𝜋
Number of bolts required at minimum = = 9.42
600

recommended bolt spacing

Closest multiple of 4 =8
Bolt design stress (typical design value), = 125 𝑁/𝑚𝑚2
W=operating value = 1.36×105 N
Anchor bolt tensile force are also consider the baseplate with the conditions (Redwood, 2011).
Anchor bolt forces are travel to the column flange via plat that connected to the flange. Tensile
forces are influence by distribution of forces across base plate (Zdravkov, 2017).
1 4𝑀
𝐴𝑏 = 𝑁 [ 𝐷 𝑠 – w]
𝑏 𝑓𝑏 𝒃

Where,
𝐴𝑏 = Area of bolt,𝑚𝑚2
𝑁𝑏 = Number of bolts
𝑓𝑏 = Design stress of bolts, 𝑁/𝑚𝑚2
𝑀𝑠 = 𝐵𝑒𝑛𝑑𝑖𝑛𝑔 𝑚𝑜𝑚𝑒𝑛𝑡 𝑎𝑡 𝑏𝑎𝑠𝑒 𝑜𝑓 𝑠𝑘𝑖𝑟𝑡, 𝑁𝑚
𝐷𝑏 = Pitch circle diameter, m
W = weight of vessel, N

1 4 ×1.87×105
𝐴𝑏 = 8×125 [ – 1.36×105 ]
1.8

𝐴𝑏 = 281 𝑚𝑚2
Value of bolt diameter is obtained by applying those formula:

281𝑚𝑚2 ×4
Bolt root diameter = √ 𝜋

Bolt root diameter = 19m

Total compressive load on the base ring per unit length

19
 4𝑀 𝑊
𝐹𝑏 = (𝜋 × 𝐷 𝑠^2) + (𝜋 𝐷 )
𝑠 𝑠

4 (1.87 ×105 ) 1.36×105

= + (𝜋 (1.615𝑚)
𝜋(1.615𝑚)2

= 1.2 × 105 N/m

By applying the bearing pressure, 𝑓𝑐
= 5 N/𝑚𝑚2
Base ring width,𝐿𝑏 , is obtained by applying equation:
𝐹𝑏
𝐿𝑏 =
𝑓𝑐

1.18 ×105 𝑁/𝑚

= 5×103 𝑁/𝑚𝑚

= 24.1 mm
Consider 𝐿𝑟 = 76 mm, thus the actual width needed is obtained by applying this formula;
𝑊𝑎 = 𝐿𝑟 + 𝑡𝑠 + 50 mm
= 76 mm + 3.40mm +50mm
= 129.4mm
Actual bearing pressure on concrete foundation, 𝑓′𝑐
𝐹
𝑓′𝑐 = 𝐴𝑐𝑡𝑢𝑎𝑙𝑏𝑤𝑖𝑑𝑡ℎ

1.18 ×105
= 129 ×103

= 0.93 𝑁/𝑚𝑚2
Minimum thickness for base ring,𝑡𝑏 , is obtained as follows;

3 𝑓′𝑐
𝑡𝑏 = 𝐿𝑟 √ 𝑓𝑟

3 (0.91𝑁/𝑚𝑚2 )
= 76 mm √ 140 𝑁/𝑚𝑚2

=10.61 mm

20
3.9 Nozzles Design
In the flash column, there are three nozzles being consider which are feed inlet nozzle, top
product nozzle and bottom nozzle.
Feed inlet nozzle
G = 32770.06 kg/hr @ 9.102 kg/s
Density, ρ = 23.21
𝐷𝑜𝑝𝑡(𝑡𝑜𝑝) = 293𝐺 0.53 𝜌−0.37
𝑘𝑔 0.53 𝑘𝑔3 −0.35
= 293(9.102 ) (23.21 )
𝑠 𝑚

= 314.21mm
𝑃𝐷𝑜𝑝𝑡
𝑡𝑡𝑜𝑝 =
20𝜎𝑑 + 𝑃
𝑁
0.222 ×314.21
𝑚𝑚2
= 𝑁
20 (146.6 )+0.222
𝑚𝑚2

=0.024
2 mm is added for corrosion allowance which will give 2.02 mm thickness

3.10 Top Product Nozzle Sizing

Flow rate, G = 4104.17 kg/hr. @1.14 kg/s
Density, ρ = 3.315
𝐷𝑜𝑝𝑡(𝑡𝑜𝑝) = 293𝐺 0.53 𝜌−0.37
𝑘𝑔 0.53 𝑘𝑔3
= 293(1.14 ) (3.315 𝑚 )−0.35
𝑠

= 206.47 mm
𝑃𝐷𝑜𝑝𝑡
𝑡𝑡𝑜𝑝 =
20𝜎𝑑 + 𝑃
𝑁
0.222 ×206.47
𝑚𝑚2
= 𝑁
20 (146.6 )+0.222
𝑚𝑚2

=0.016
2 mm is added for corrosion allowance which will give 2.02 mm thickness

21
3.11 Bottom Product Nozzle Sizing
Flow rate, G = 28665.89 kg/hr. @7.96 kg/s
Density, ρ = 856 kg/𝑚3
𝐷𝑜𝑝𝑡(𝑡𝑜𝑝) = 293𝐺 0.53 𝜌−0.37
𝑘𝑔 0.53 𝑘𝑔3
= 293(7.96 ) (856 𝑚 )−0.35
𝑠

= 82.80 mm
𝑃𝐷𝑜𝑝𝑡
𝑡𝑡𝑜𝑝 =
20𝜎𝑑 + 𝑃
𝑁
0.222 ×82.80
𝑚𝑚2
= 𝑁
20 (146.6 )+0.222
𝑚𝑚2

=6.2 ×10−3 𝑚𝑚
2 mm is added for corrosion allowance which will give 2.01mm thickness.

22
4.0 Control and Safety
4.1 Control System and Safety of Flash Column (V-103)

Figure 4.1

Control System of Flash Column (V-103)

Controlled Manipulated Disturbance Type of Set Point
Variable variable Controller
Pressure of the Flowrate of Inconsistent feed Feedback 2.0265 bar, if the
column stream 36 flow rate of controller pressure above
stream 35 this values the
alarm will be
activated
Liquid level in Outlet Stream 37 Inconsistent Feedback 5% height to
the column flow rate from flow rate controller prevent drum
the column by from drying and
valve adjustment 50% height to
prevent from
flooding.

23
 4.2 HAZOP Study on Flash Column
Project: Styrene Production of Styrene for Flash Column (V- Date: 26 April 2021
103)
Node Description: Separator that separate gas phase and liquid phase by gravity Node intention:
settling. The gas phase will direct to top column and liquid mixture at bottom Liquid mixture will form
column at outlet stream and
carbon dioxide is flow to
the top of column
GW (Guide Word) Cause Consequences Safeguards Recommendation
• Leakage of the • Low • Pressure • Regular inspection of
pipeline efficiency of Indicator safety valve
separation Controller • Monthly monitoring
Low Pressure (PIC)
• Pressure
Alarm Low
(PAL)
• High • Rupture of • Pressure • Regular inspection of
temperature in the column Indicator safety valve
the column Controller • Monthly monitoring
High Pressure (PIC)
• Pressure
Alarm High
(PAH)
• Pipe clogged • Low desired • Level • Regular inspection
and leakage at product Indicator
Low Liquid Level the inlet stream produce at Controller
outlet stream (LIC)
• Level Alarm
Low (LAL)
High Liquid Level • Valve • Flooding • Level
malfunction in the Indicator • Monthly
column Controller monitoring
• Level
Alarm
High
(LAH)
Table 4.2 HAZOP STUDY FLASH COLUMN

24
5.0 Summary of Flash Column (V-103)

Parameter Data
Operating Condition
Temperature 343.15 K
Pressure 2.0265 bar
Cylindrical shell Design
Domed Head Type Ellipsoidal Head
Minimum wall thickness 3.40 mm
Total Weight of Column
Weight of Vessel 12.18 kN
Type of Material Insulation Mineral wool
Mineral wool thickness 75 mm
Weight of Insulation 1.291 kN
Total Dead Weight 12.18 kN
Stress of Column
Pressure Stress 𝑁
52.85 𝑚𝑚2

Longitudinal stress 𝑁
26.43 𝑚𝑚2

Dead Weight Stress 𝑁

0.71 𝑚𝑚2

Bending Stress 𝑁
4.29 ×10−3 𝑚𝑚2

Resultant longitudinal Stress 𝑁

27.134 𝑚𝑚2
(upwind)
Resultant longitudinal Stress 𝑁
27.130 𝑚𝑚2
(downwind)
Difference of Principal Stress 𝑁
25.72 𝑚𝑚2

Critical buckling stress 𝑁

41.92 𝑚𝑚2

Base Ring Anchor Bolts

Area 281 𝑚𝑚2

25
 Diameter 18 m
Type of bolt size M24
Design of Nozzle
Feed nozzle diameter 314.21 mm
Top product nozzle diameter 206.47 mm
Bottom product nozzle 82.80 mm
diameter
Summary Flash Column (V-103)

26
5.1 EQUIPMENT SPECIFICATION SHEET

EQUIPMENT SPECIFICATION SHEET

Identification: Flash Column
Item no: V-103
Function: To separate liquid mixture to liquid and gas
Specification Data Design Sizing Data
Type of vessel Vertical Height 5.45 m
Material Construction Carbon Steel Inner Diameter 1.612
Operating Condition Data Vessel thickness 3.40 mm
Temperature 343.15 K Domed head type Ellipsoidal
Operating pressure 2.0265 bar Domed head thickness 3.40 mm
Vessel support Data Skirt thickness 3.40 mm
Material construction Carbon steel Base ring thickness 10.61mm
Bolt size M24 Base ring width 24.1 mm
Number of bolts 8 bolts
Table 5.1 Equipment Specification Sheet

27
6.0 Mechanical Drawing of Flash Column (V-103)

28
29
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31