SMJC 4824 CHEMICAL PLANT DESIGN

PROJECT

INDIVIDUAL REPORT

DESIGN OF MULTI-TUBULAR CATALYTIC

REACTOR (R-101)

LECTURER : DR. LIEW PENG YEN

No. Name Matric Number

1 BRANDON YONG HUA YIIK A17MJ0177

1
 ABSTRACT

Ethylene oxide is very flammable and reactive. Hence, a suitable reactor should be
selected to produce ethylene oxide. The most-used reactor for the oxidation of ethylene
reaction is a multi-tubular catalytic reactor (R-101). Catalyst is often used in increasing rate of
chemical reaction and a good catalyst is somethings that shows high activity and selectivity
for production of the desired product. Silver catalyst will be used in R-101 to facilitate the
chemical reactions and maximize the production of ethylene oxide. Besides, silver catalyst
can help in enhancing the reactor efficiency and lower the activation energy of the reactions
occurred in R-101. Multi-tubular catalytic reactor is ideal for ethylene oxide production due to
its mild operating condition for silver catalyst. Besides, its sequential oxidation of ethylene
oxide will promote low per-pass conversion to ensure high selectivity of product. It is also
ideal reactor due to its good heat transfer efficiency. Manual calculation of mass and energy
balance of R-101 has been illustrated. Volume of reactor is calculated beforehand and
residence time is assumed as 8 minutes. The design pressure and design temperature of R-101
are 23.97 bar and 514 ˚F respectively. Stainless steel 304 is being selected as material of
construction as it contains chromium which can help to prevent oxidation and ease for
cleaning and welding process. Besides, it able to withstand high temperature and very durable
compared to other materials. Ellipsoidal head has been selected for mechanical design of R-
101 as it is cost effective closure. The surface of the reactor is insulated with mineral wool to
maintain the temperature inside the reactor. Various kind of stresses are analysed and
calculated. Straight cylindrical skirt support is being selected as it is suitable for vertical
vessel and able to support higher weight load. The base ring thickness calculated to be 8.68
mm and 16 pieces of M14 bolts with area of 154mm2 will be used. Regarding the control
system, ratio controller and feedback controller are used to control ratio of reactants, internal
temperature, and internal pressure of R-101. Besides, HAZOP study of R-101 has been
carried out. The mechanical drawing of R-101 have been clearly presented in this report. The
details and specifications of R-101 has been summarised in the equipment specification sheet.

2
 TITLE PAGE
ABSTRACT 2
TABLE OF CONTENTS 3
LIST OF TABLES 5
LIST OF FIGURES 6
CHAPTER 1 Design of Multi-tubular Catalytic Reactor (R-101)
1.1 Process Description 7
1.2 Reactor Selection 8
1.3 Catalyst Selection 9
1.4 Material Balance 10
1.4.1 Assumption of Chemical Design 10
1.4.2 Mass Balance for R-101 11
1.5 Energy Balance 15
1.5.1 Reactive Reaction 15
1.5.2 Energy Balance for R-101 16
1.6 Volume of Multi-tubular Catalytic Reactor (R-101) 19
1.7 Weight of Catalyst 19
1.8 Mechanical Design for Multi-tubular Catalytic
20
Reactor (R-101)
1.8.1 Design Pressure, Pd 21
1.8.2 Design temperature, Td 22
1.8.3 Material of construction 22
1.8.4 Maximum Allowable Stress 23
1.8.5 Welded Joint efficiency 24
1.8.6 Head and Closure 25
1.8.7 Wall thickness with Corrosion Allowance 26
1.8.8 Weight of Multi-tubular Catalytic Reactor 29
1.8.9 Weight of Insulation 30
1.8.10 Total Weight Excluding the Skirt Support 31
1.8.11 Analysis of stress 31
1.8.12 Reactor support 36

3
 1.8.12.1 Skirt Support 36
1.8.13 Cooling Jacket Design 41
1.8.14 Base Ring and Anchor Bolt Design 42
1.8.15 The Engineering Drawing of R-101 46
1.9 Process Control and Safety 48
1.9.1 Process Control System 48
1.10 HAZOP Study 51
1.11 Equipment Specification Sheet 54

REFERENCE 57

4
 LIST OF TABLES

TABLE NO. TITLE PAGE

Table 1.1 Operating Conditions for Multi-tubular Catalytic Reactor 8
Table 1.2 Mass Balance of Multi-tubular Catalytic Reactor (R-101) 14
Table 1.3 Energy Balance of Multi-tubular Catalytic Reactor (R-101) 18
Table 1.4 Typical Maximum Allowable Stress For Different Materials 23
Table 1.5 Maximum Allowable Joint Efficiency 24
Table 1.6 Calculation of volume of MTO reactor 19
Table 1.7 Calculation of weight of SAPO-34 catalyst 20
Table 1.8 Maximum allowable stress of different materials at various 24
temperature
Table 1.9 Maximum Allowable Joint efficiency 25
Table 1.10 Calculation of weight of insulation 30
Table 1.11 Table of assumptions of skirt support for R-101 37
Table 1.12 Control system of Multi-tubular Catalytic Reactor (R-101) 50
Table 1.13 HAZOP study on Multi-tubular Catalytic Reactor (R-101) 52
Table 1.14 Equipment Specification Sheet 54

5
 LIST OF FIGURES

NO. TITLE PAGE

Figure 1.1 Schematic Diagram of Multi-tubular Catalytic Reactor 9
Figure 1.2 Ellipsoidal head for cylindrical vessels 25
Figure 1.3 Single plate with gusset 42
Figure 1.4 Cross-sectional Engineering Drawing of R-101 46
Figure 1.5 Top View Engineering Drawing of R-101 47
Figure 1.6 Control System Design for R-101 50

6
 CHAPTER 1

DESIGN OF MULTI-TUBULAR CATALYTIC REACTOR (R-101)

1.1 Process Description

Partial oxidation of ethylene is being carried out with the aim to produce ethylene
oxide. The most-used reactor for the oxidation of ethylene reaction is a multi-tubular catalytic
reactor. The reaction system involves multi-tubular catalytic reactor (R-101). The reactor feed
consists of ethylene and oxygen with mass fraction of 0.5 and 0.5 respectively. Silver will be
used as catalyst for reactor (R-101) to increase the reactor efficiency and lower the activation
energy of the reactions occurred in reactor (R-101) such as production of ethylene oxide from
ethylene through partial oxidation and production of undesired carbon dioxide and water from
combustion of ethylene. According to previous studies, the selectivity of the ethylene oxide
formation found to be in the range between 85% and 90% while the conversion rate of
ethylene to ethylene oxide was found to be approximate 25% (Perzon, 2015) under more
severe conditions (the temperature is 240°C and the pressure is 20 bar). Similar finding is
observed in (Zahedi et al., 2011). The reactions occurred in ethylene oxide reactor (R-101) are
exothermic which release heat energy (Richard et al., 2018). Negative value of change in
enthalpy will be obtained. Besides, common cooling medium such as water will be used on
the shell side of the reactor (R-101) which then can be reuse in production of low-pressure
steam. The suitable operation conditions for reactor R-101 are summarized in the table 1.1
below.

7
 Table 1.1 Operating conditions for Multi-tubular Catalytic Reactor (R-101)

Aspects Description
Type of Reactor Multi-tubular Catalytic Reactor
Reactant Ethylene (C2 H4 ) and Oxygen (O2 )
Product Ethylene Oxide (C2 H4 O)
Temperature 240 ˚C
Pressure 20 bar
Catalyst Used Silver

1.2 Reactor Selection

Ethylene oxide is very flammable and reactive (Dinh, 2008). Hence, a suitable reactor
should be selected to produce ethylene oxide. Multi-tubular catalytic reactor (R-101) is
commonly used to produce ethylene oxide. Multi-tubular catalytic reactor is a shell and tube
type reactor which will be operate at 240 ˚C and 20 bar (Perzon, 2015). The reactions will be
occurred in the tubes side which packed with catalyst (Aryana et al., 2009). The main purpose
of this reactor R-101 is to produce ethylene oxide from raw materials such as ethylene and
oxygen. Ethylene oxide synthesis process is an exothermic reaction where the heat is released
throughout the chemical reactions occurring in R-101. Multi-tubular catalytic reactor is ideal
for ethylene oxide production due to its mild operating condition for silver catalyst. Besides,
its sequential oxidation of ethylene oxide will promote low per-pass conversion to ensure high
selectivity of product (Digiulio, 2018). Similar finding is observed in (Bernardo & Clarizia,
2012). Multi-tubular catalytic reactor is also ideal due to its good heat transfer efficiency.

8
 Figure 1.1 Schematic Diagram of Multi-tubular Catalytic Reactor (Hiremath et al., 2001)

1.3 Catalyst Selection

Catalyst is often used in increasing rate of chemical reaction and a good catalyst is
somethings that shows high activity and selectivity for production of the desired product
(Smith, 2005). Silver catalyst will be used in multi-tubular catalytic reactor (R-101) to
facilitate the chemical reactions and maximize the production of ethylene oxide. Silver is
selected as catalyst due to its high selectivity for ethylene oxide (Aryana et al., 2009). Silver
catalyst can help in enhancing the reactor efficiency and lower the activation energy of the
reactions occurred in reactor (R-101) such as production of ethylene oxide from ethylene
through partial oxidation and production of undesired carbon dioxide and water from
combustion of ethylene. Ideally, a catalyst does not change and should have eternal life
(Couper, 2012). However, this is not possible in real life and the catalysts need to be
regenerated or replaced when the catalysts have lost so much of its initial activity. Moreover,
the deactivation time of catalysts depends on the process, and it may vary from a few seconds
to several years (Moulijn et al., 2010). In ethylene glycol production plant, catalyst used in
ethylene oxide reactor (R-101) for a period will become deactivated catalysts or known as
spent catalysts. (Clifford, 1997) stated that a spent catalyst is a catalyst that no longer exhibits
the necessary activity or cannot perform its original duty. The deactivated or spent catalysts
are considered as hazardous materials which can harm the environment and these materials
need to undergo proper waste management to prevent the undesired consequences.

9
1.4 Material Balance

Material balance is vital and need to be conducted before operation of any unit
operations to track the components that move in or out of a system. The equation of mass
balance for reactive reaction is shown as below:

Total mass input + Generation – Total mass output – Consumption = Accumulation

1.4.1 Assumption of Chemical Design

In designing the multi-tubular catalytic reactor (R-101), several assumptions are made
beforehand to simplify the calculation. The assumptions are shown as follows:

1. Feed flow rate = 85,000 kg/hr

2. Reactor operates in steady sate condition
3. Ethylene conversion = 0.25
4. Oxygen conversion = 0.50
5. Mass fraction of ethylene = 0.50
6. Mass fraction of oxygen = 0.50

10
1.4.2 Mass Balance for Multi-tubular Catalytic Reactor (R-101)

First, all the components are listed in the table. The inlet of reactor is calculated first
based on the mass fraction of reactants. In this case, mass fractions of ethylene and oxygen
are assumed as 0.5 and 0.5 respectively. The mass flow rate for inlet streams S5 and S10 will
be 42,500 kg/hr of ethylene and 42,500 kg/hr of oxygen respectively. Then, mole flow rate
can be calculated by dividing mass flow rate with molecular weight of ethylene and oxygen.

𝑘𝑔 1 𝑘𝑚𝑜𝑙 𝑘𝑚𝑜𝑙
𝑛 C2 H4,O = 85,000 𝑥 0.5 𝑥 = 1514.946282
ℎ𝑟 28.0538 𝑘𝑔 ℎ𝑟

𝑘𝑔 1 𝑘𝑚𝑜𝑙 𝑘𝑚𝑜𝑙
𝑛 O2,O = 85,000 𝑥 0.5 𝑥 = 1328.174807
ℎ𝑟 31.9988 𝑘𝑔 ℎ𝑟

Since we know that ethylene conversion and oxygen conversion are 0.25 and 0.50
respectively, we can calculate the outlet stream molar flow rate for ethylene and oxygen.

𝑘𝑚𝑜𝑙 𝑘𝑚𝑜𝑙
𝑛 C2 H4 = (1 − 0.25) 𝑥 1514.946282 = 1136.209711
ℎ𝑟 ℎ𝑟

𝑘𝑚𝑜𝑙 𝑘𝑚𝑜𝑙
𝑛 O2 = (1 − 0.50) 𝑥 1328.174807 = 664.0874033
ℎ𝑟 ℎ𝑟

In order to calculate the material balance, extend or reactions approach will be used.
First, we need to determine the extent of reaction 1 and 2 in order to find the remaining outlet
stream flow rate. There are two extent of reactions in this reactor as two different chemical
reactions occur in this reactor.

2 C2 H4 + O2 → 2 C2 H4 O - reaction 1, ξ1

C2 H4 O + 2.5 O2 → 2 CO2 + 2H2 O - reaction 2, ξ2

Next, all the material balance equations are listed to determine the ξ1 and ξ2.

11
 𝑛 C2 H4 = 1514.946282 − 𝜉1

𝑛 O2 = 1328.174807 − 0.5 𝜉1 − 2.5 𝜉2

𝑛 C2 H4 𝑂 = 𝜉1 − 𝜉2

𝑛 CO2 = 2 𝜉2

𝑛 H2 𝑂 = 2 𝜉2

As we know that

𝑘𝑚𝑜𝑙
𝑛 C2 H4 = 1136.209711
ℎ𝑟
Thus, 𝜉1 can be solved through mathematical calculation. At last, we got that 𝜉1 =
𝑘𝑚𝑜𝑙
378.7366 .
ℎ𝑟
𝑘𝑚𝑜𝑙
Then 𝜉2 can be calculated and 𝜉2 found to be 189.8876 .
ℎ𝑟

After we get the value for 𝜉1 𝑎𝑛𝑑 𝜉2 , the outlet stream flow rate can be calculated using the
material balance equations which mentioned before.

𝑘𝑚𝑜𝑙
𝑛 C2 H4 = 1514.946282 − 𝜉1 = 1136.2097
ℎ𝑟

𝑘𝑚𝑜𝑙
𝑛 O2 = 1328.174807 − 0.5 𝜉1 − 2.5 𝜉2 = 664.0874
ℎ𝑟

𝑘𝑚𝑜𝑙
𝑛 C2 H4 𝑂 = 𝜉1 − 𝜉2 = 188.8489
ℎ𝑟

𝑘𝑚𝑜𝑙
𝑛 CO2 = 2 𝜉2 = 379.7753
ℎ𝑟

𝑘𝑚𝑜𝑙
𝑛 H2 𝑂 = 2 𝜉2 = 379.7753
ℎ𝑟

After that, convert the outlet molar flow rate to mass flow rate by multiple the molar flow rate
with molecular weight.

12
 𝑘𝑚𝑜𝑙 𝑘𝑔 𝑘𝑔
𝑛 C2 H4 = 1136.2097 𝑥 28.0538 = 31875
ℎ𝑟 𝑘𝑚𝑜𝑙 ℎ𝑟

𝑘𝑚𝑜𝑙 𝑘𝑔 𝑘𝑔
𝑛 O2 = 664.0874 𝑥 31.9988 = 21250
ℎ𝑟 𝑘𝑚𝑜𝑙 ℎ𝑟

𝑘𝑚𝑜𝑙 𝑘𝑔 𝑘𝑔
𝑛 C2 H4 𝑂 = 188.8489 𝑥 44.0532 = 8319.3994
ℎ𝑟 𝑘𝑚𝑜𝑙 ℎ𝑟

𝑘𝑚𝑜𝑙 𝑘𝑔 𝑘𝑔
𝑛 CO2 = 188.8489 𝑥 44.0090 = 16713.5309
ℎ𝑟 𝑘𝑚𝑜𝑙 ℎ𝑟

𝑘𝑚𝑜𝑙 𝑘𝑔 𝑘𝑔
𝑛 H2 𝑂 = 188.8489 𝑥 18.0150 = 6841.6519
ℎ𝑟 𝑘𝑚𝑜𝑙 ℎ𝑟

Thus, we can calculate the mass flow rate of outlet stream (S11),

Outlet stream = 31875 + 21250 + 8319.3994 + 16713.5309 + 6841.651929

𝑘𝑔
= 84999.3824 ℎ𝑟

13
The summary of the mass balance at multi-tubular catalytic reactor (R-101) is shown in Table 1.2.

Table 1.2 Mass Balance of Multi-tubular Catalytic Reactor (R-101)

Input Output
Operating conditions
S5 S10 S11
Phase V V V
Temperature (K) 513 513 513
Pressure (bar) 20 20 20
Input Output
Components S5 S10 S11
kmol/hr kg/hr kmol/hr kg/hr kmol/hr kg/hr
Ethylene (C₂H₄) 1514.935482 42500 0 0 302.9870963 8500
Oxygen (O₂) 0 0 1328.166505 42500 664.0832526 21250
Ethylene oxide (C₂H₄O) 0 0 0 0 1188.7048 52366.01085
Carbon dioxide (CO₂) 0 0 0 0 46.48724798 2045.903784
Water (H₂O) 0 0 0 0 46.48724798 837.4677723
Total 1514.935482 42500 1328.166505 42500 2248.749606 84999.3824

14
1.5 Energy Balance

After performing the material balance for the components involved in reactions,
energy balance needed to be performed to calculate the enthalpy flow and change in enthalpy
for the inlet streams (S5 & S10) and outlet stream (S11). Information such as temperature,
states and pressure for each stream are required to calculate the energy balance for the
processes involved in reactor (R-101).

1.5.1 Reactive Reaction

To determine the specific enthalpy of the components, the formula below was used:

𝑇
𝐻𝑥 = 𝐻𝑓, 𝑥 +∫ 𝐶𝑝𝑑𝑇
𝑇𝑟𝑒𝑓

Where:

𝐻𝑥 = specific enthalpy of component x (kJ/kmol)

𝐻𝑓,𝑥 = specific heat formation of the component x (kJ/kmol)

Cp = specific heat capacity at constant pressure for component x (kJ/mol.K)

T = temperature of the reactor

Tref = reference temperature, 298.15 K

15
The general formula used to calculate the total enthalpy flow of each stream is shown below:

𝛥Ḣ = ∑ Ḣ𝑡

Where

𝛥Ḣ = total enthalpy flow rate of each stream (kJ/hr)

For reactive reactions, the net heat change in enthalpy flow rate was calculated by using the
equation below:

𝑄 = Ḣ𝑜𝑢𝑡 + Ḣ𝑟𝑒𝑎𝑐𝑡𝑖𝑜𝑛 − Ḣ𝑖𝑛

Q = heat duty

Ḣ𝑜𝑢𝑡 = total enthalpy flow rate of outlet stream (kJ/kg)

Ḣ𝑖𝑛 = total enthalpy flow of inlet stream (kJ/kg)

Ḣ𝑟𝑒𝑎𝑐𝑡𝑖𝑜𝑛 = total enthalpy of reaction (kJ/kg)

1.5.2 Energy Balance for Multi-tubular Catalytic Reactor (R-101)

The regression coefficients for particulate chemical components can be found in Perry`s
Chemical Engineering Handbook 9th Edition. After listed down all the relevant regression
coefficients for the components involved in reactions, the specific heat capacity, heat of
formation, heat of vaporisation and heat of reaction can be calculated using formulas shown
below.

Specific heat capacity of each component

𝐶3 𝐶5
∫ 𝐶𝑝 𝑑𝑇 = 𝐶1 𝑇 + 𝐶2 𝐶3 𝑐𝑜𝑡ℎ( ) − 𝐶4 𝐶5 𝑡𝑎𝑛ℎ( )
𝑇 𝑇

16
Where 𝐶1 , 𝐶2 , 𝐶3 , 𝐶4 and 𝐶5 are the regression coefficients for chemical compound and
temperature are in Kelvin (K).

Heat of vaporization
2
𝛥Ḣ𝑣𝑎𝑝 = 𝐶1 (1 − 𝑇𝑟 )(𝐶2+𝐶3𝑇𝑟 +𝐶4𝑇𝑟 )

Where;

𝛥Ḣ𝑣𝑎𝑝 = heat of vaporisation (kJ/kmol)

𝑇
𝑇𝑟 = where 𝑇𝑐 = critical temperature
𝑇𝑐

Heat of formation

𝛥Ḣ𝑓 = 𝐴 + 𝐵𝑇 + 𝐶𝑇 2

Where;

𝛥Ḣ𝑓 = enthalpy of formation (kJ/kmol)

A, B and C are the regression coefficients for particulate chemical compounds

Heat of reaction

𝛥𝐻𝑟 = ∑(𝑛𝛥𝐻𝑓 )𝑝𝑟𝑜𝑑𝑢𝑐𝑡 − ∑(𝑛𝛥𝐻𝑓 )𝑟𝑒𝑎𝑐𝑡𝑎𝑛𝑡

Several assumptions are made when calculating the energy balance, which are:

1. Reference temperature, 𝑇𝑟𝑒𝑓 = 298.15K (25°C)

2. Reference pressure, 𝑃𝑟𝑒𝑓 = 1 atm
3. The heat of mixing pressure is negligible
4. Assume ideal gas condition

17
The summary of the energy balance at multi-tubular catalytic reactor (R-101) is shown in Table 1.3.

Table 1.3 Energy Balance of Multi-tubular Catalytic Reactor (R-101)

Input Output
S5 S10 S11
Comp
onents Flow ΔHºf Flow ΔHºf Flow ΔHºf
T sat CpDT H1 CpDT H1 CpDT H1
(kmol/h (J/kmol (kmol/h (J/kmol (kmol/h (J/kmol
(K) (J/kmol) (J/hr) (J/kmol) (J/hr) (J/kmol) (J/hr)
r) ) r) ) r) )
Ethyle
176.99 1514.93 1.15E+0 5.25E+ 9.70 1.15E+0 5.25E+ 0.00 302.987 1.15E+0 5.25E+ 1.94E
ne 0
74829 5482 7 07 E+10 7 07 E+00 0963 7 07 +10
(C₂H₄)
Oxyge 95.491 6.48E+0 0.00E+ 0.00 1328.16 6.48E+0 0.00E+ 8.61 664.083 6.48E+0 0.00E+ 4.31E
0
n (O₂) 55773 6 00 E+00 6505 6 00 E+09 2526 6 00 +09
Ethyle
ne - - - -
294.17 1.36E+0 0.00 1.36E+0 0.00 1188.70 1.36E+0
oxide 0 5.26E+ 0 5.26E+ 5.26E+ 4.64E
41816 7 E+00 7 E+00 4761 7
(C₂H₄ 07 07 07 +10
O)
Carbo
n - - - -
199.95 8.95E+0 0.00 8.95E+0 0.00 46.4872 8.95E+0
dioxid 0 3.94E+ 0 3.94E+ 3.94E+ 1.79E
46919 6 E+00 6 E+00 4798 6
e 08 08 08 +10
(CO₂)
- - - -
Water 385.46 6.49E+0 0.00 6.49E+0 0.00 46.4872 6.49E+0
0 2.42E+ 0 2.42E+ 2.42E+ 8.23E
(H₂O) 87968 7 E+00 7 E+00 4798 7
08 08 08 +09
- - - -
TOTA 1514.93 1.05E+0 9.70 1328.16 1.05E+0 8.61 2248.74 1.05E+0
6.35E+ 6.35E+ 6.35E+ 4.88E
L 5482 8 E+10 6505 8 E+09 9606 8
08 08 08 +10

18
1.6 Volume of Multi-tubular Catalytic Reactor (R-101)

The volume of multi-tubular catalytic reactor (R-101) can be calculated by using

equation 1.1. Volume flow rate of R-101 is collected from simulation data by ASPEN PLUS
which is 101.0553 m3/min. The residence time of R-101 is assumed as 8 minutes.

Volume of vessel = Volume flow rate x Residence Time (1.1)

Volume of vessel, V = 101.0553 m3/min × 8 min

= 808.4424 m3

1.7 Weight of Catalyst

The outlet mass flow rate of R-101 can be obtained from mass balance which is
84999.3824 kg/hr. The weight of catalyst can be calculated by using equation 1.2. Take
reaction rate as 9 hours.

𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 (1.2)

Weight of catalyst, Wc = 𝑟𝑒𝑎𝑐𝑡𝑖𝑜𝑛 𝑟𝑎𝑡𝑒

Wc = 84999.3824 kg/hr / 9 hr
= 9444.3758 kg
= 92649.3266 N

19
1.8 Mechanical Design for Multi-tubular Catalytic Reactor (R-101)

Mechanical design is vital in ensuring an equipment to be installed well and operate

smoothly. Hence, it is very important in choosing suitable material for robust equipment
design at designated temperature and pressure as tensile strength of material can be affected
by temperature and other factors. The tensile strength of materials increases as temperature
increases. In following sections, factors in mechanical design for multi-tubular catalytic
reactor (R-101) such as design pressure, design temperature, material of construction,
maximum allowable stress, welded joint efficiency, head and closure, wall thickness with
corrosion allowance, weight of reactor, weight of insulation, total weight excluding skirt
support, analysis of stresses, reactor support, cooling jacket design, base ring and anchor bolt
design will be discussed.

20
1.8.1 Design Pressure, Pd

A reactor should be designed to resist the maximum pressure that can be exerted through
operation. The design pressure (also known as the maximum permissible working pressure or
MAWP) is used to establish the relief system for a reactor under internal pressure. The
maximum difference between internal and external pressure is used to calculate design
pressure for vessels that will be exposed to external pressure. To evaluate the design pressure,
operating pressure of system should be evaluated by engineer first. Design Pressure would
typically be 5 to 10% above the normal working pressure to prevent unnecessary operation
during minor process defeats (Sinnott & Towler, 2020) .

For catalytic reactor, design pressure can be calculated by equation 1.3:

Pd = exp{0.60608+0.91615[ln(Po)]+0.0015655[ln(Po)]2} (1.3)
Where:
Po = operating pressure (psig)

Pd = design pressure (psig)

Operating pressure, Po = 20 bar

= (20 × 14.504) psi

= 290.08 psig
Since operating pressure is within the range 10 < Po < 1000 psig,
Design pressure, Pd = exp{0.60608+0.91615[ln(Po)]+0.0015655[ln(Po)]2}
= exp{0.60608+0.91615[ln(290.08)]+0.0015655[ln(290.08)]2}
= 347.7018 psig
= 23.97 bar
= 2.397 N/mm2

21
1.8.2 Design temperature, Td

The design temperature is often used to determine the maximum permissible stress, S.
To achieve an economically and mechanically feasible wall thickness, materials must have
adequate strength at the design temperature. Since the strength of metals decreases as
temperature rises, the maximum permissible stress will be largely depending on the
temperature of the material. The maximum design temperature at which the maximum
acceptable stress is measured should be used as the material's maximum working temperature,
with any uncertainty in estimating reactor wall temperatures considered. The lowest
temperature required in service should be taken as the minimum design metal temperature
(MDMT). The design temperature can be calculated by adding 50 ˚F to the operating
temperature (Couper, 2012).

Operating temperature, To = 240 ˚C = 464 ˚F

Design temperature, Td = 464 ˚F + 50 ˚F

= 514 ˚F
= 267.78 ˚C

1.8.3 Material of construction

The suitability of the material for fabrication (particularly welding) as well as the
material's compatibility with the process environment must be considered when choosing a
suitable material. The operating conditions of the multi-tubular catalytic reactor (R-101) are
240 ˚C (464 ˚F) and 20 bar. Stainless steel 304 is being selected as construction material
because it contains chromium which can help to prevent oxidation and ease for cleaning and
welding process (Green & Perry, 2008). Besides, stainless steel 304 has the ability of high
temperature resistant and able to withstand the temperature up to 700 ˚C continuously and it is
very durable compared to other materials (Seider et al., 2016).

22
1.8.4 Maximum Allowable Stress

The allowable stress used to calculate the minimum vessel wall thickness is
determined by the tensile and yield properties of the material at room and design temperatures.
For design purposes, a value for the allowable maximum stress (nominal design strength) that
can be accepted in the construction material must be determined. This can be calculated by
adding up the maximum stress which can be resisted by particular materials without failing
under normal test conditions by a suitable safety factor. The safety factor compensates for any
uncertainty in the design methods, packing, material quality, and workmanship (Sinnott &
Towler, 2020).

Table 1.8 Typical Maximum Allowable Stress for different materials (Towler & Sinnott, 2013)

Operating temperature of R-101 is 464˚F, hence the maximum allowable stress, S can be
obtained by doing linear interpolation.

464 − 300 𝑆 − 15
=
500 − 300 12.9 − 15

Maximum Allowable stress, S = 13.278 ksi = 13278 psi = 91.55 N/mm2

23
1.8.5 Welded Joint efficiency

Welded joints are needed in various forms when construct a vessel (Towler & Sinnott,
2013). The strength of a welded joint in relation to the strength of the base metal is referred to
as joint efficiency. With a Joint Efficiency of 1.00, the weld is considered to be smooth and
has the same strength as the base metal. Joint efficiency is a consideration that must be
considered in both head and shell measurements. It measures how closely a finished weld
joint resembles the consistency of the seamless parent material. Visual inspection and non-
destructive testing are used to ensure that welds are sound (radiography). The amount of
radiography needed by the design code will determine the value of the joint efficiency used in
design. Based on the table 1.9, the double-welded butt joint or similar joint used in the
construction of the multi-tubular catalytic reactor (R-101) has a radiographic inspection
degree of 1.0.

Table 1.9. Maximum Allowable Joint Efficiency (Towler & Sinnott, 2013)

24
1.8.6 Head and Closure

Heads of different sizes, such as flat flanged, conical with or without knuckle,
hemispherical heads, ellipsoidal heads, and torispherical heads, are used to cover the ends of a
cylindrical vessel (Bhattacharyya, 2013). As compared to the torispherical head, the
ellipsoidal head is normally the most cost-effective closure. Since the height of the head is
just a quarter of the diameter, the shape is more cost-effective. The radius of the main and
minor axes varies. For this rector style, an ellipsoidal domed head was chosen. The minimum
thickness available for this ratio is:

𝑃 𝐷
𝑑 𝑖 (1.4)
Thickness of head = 2𝑆𝐸−0.2𝑃
𝑑

Where:

S is Maximum Allowable Stress

E is Welded Joint efficiency = 1

(2.397)(8013.89)
Thickness of head = 2(91.55)(1)−0.2(2.397)

= 105.19 mm

Figure 1.2 Ellipsoidal head for cylindrical vessels (Couper, 2012)

25
1.8.7 Wall Thickness with Corrosion Allowance

The corrosion allowance is the extra thickness of metal applied to compensate for
material loss due to corrosion and erosion, also known as scaling. Corrosion is a dynamic
phenomenon, and it is impossible to have precise guidelines for calculating the corrosion
allowance needed in all situations. The allowance should be based on previous experience
with the construction material under similar service conditions to the proposed design.
Minimum corrosion allowance of 2 mm should be used in the case of non-corrosive
conditions whereas in severe corrosive conditions, 4 mm corrosion allowance is highly
recommended but 3.175 mm (0.125 inch) corrosion allowance has been used in this R-101.

A minimum wall thickness would be needed to ensure that any vessel is rigid enough
to withstand its own weight as well as any incidental loads. Internal pressure is the most
significant factor in high-pressure vessels. The wall thickness of low-pressure vessels is
designed to withstand vacuum. To calculate wall thickness of the reactor. Inside and outside
diameter for reactor should be calculated first-hand. To calculate diameter, a ratio assumption
on the L:D should be made. The ratio is:

Length, L: Diameter, D = 2:1

By using the ratio of L:D, the inside diameter can be calculated using the equation

𝐷𝑖 2 (1.5)
Volume of reactor, V = 𝜋 𝐿
4

1
4× 808.4423 m3
Internal diameter, Di = [ ]3
𝜋×2

= 8.0139 m
= 315.5076 inch
Thus, the height of the diameter can be calculated by the ratio assume with the inner diameter:

Length, L = 2 × Di
= 2× 8.0139 m
= 16.03 m
= 631.02 inch

26
The thickness to withstand internal pressure, tp can be calculated using equation below:

𝑃 𝐷
𝑑 𝑖 (1.6)
Thickness to withstand internal pressure, tp = 2𝑆𝐸−1.2𝑃
𝑑

𝑃 𝐷
𝑑 𝑖
Thickness to withstand internal pressure, tp = 2𝑆𝐸−1.2𝑃
𝑑

(347.7018 psig)(315.5076 inch)

= 2(13278)(1)−1.2(347.7018 psig)

= 4.1969 inch

Where,
tp = thickness to withstand internal pressure (inch)
𝑃d = Vessel internal design pressure (psig)
𝐷𝑖 = Shell inside diameter (inch)
E = Maximum allowable joint efficiency
S = Maximum allowable stress (psi)

Outer diameter, Do = 𝐷𝑖 + 2Tw (1.7)

Outer diameter, Do = 𝐷𝑖 + 2Twall

= 315.5076 inch + 2(4.3219 inch)
= 324.1514 inch
= 8233.4456 mm
= 8.2334 m

27
 0.22(Do+18)L2 (1.8)
Thickness to withstand wind load, tw (inch) = 𝑆Do2

0.22(Do+18)L2
Thickness to withstand wind load, tw (inch) = 𝑆Do2

0.22(324.1514+18)631.022
= (13278)(324.1514 )2

= 0.02 inch

(𝑡𝑝 +𝑡𝑤) (1.9)

Average thickness, tv = 2

(4.1969+0.02)
Average thickness, tv = 2

= 2.1085 inch

Taking the corrosion allowance, tc of 0.125 inch,

Shell thickness, Ts = tv +tc (1.10)

Shell thickness, Ts = tv +tc

= 2.1085 inch + 0.125 inch
= 2.2335 inch
= 56.7309 mm

Wall thickness, Twall = tp +tc

= 4.1969 inch + 0.125 inch
= 4.3219 inch
= 109.78 mm

28
1.8.8 Weight of Multi-tubular Catalytic Reactor (R-101)

To prevent failure in the worst-case circumstance, the reactor configuration must be

subjected to combined loading. The following are the main sources of dead weight loads:

a) The vessel shells

b) The vessel fittings, manway, nozzles.
c) Internal fitting plates/pipe
d) External fitting ladder, platform, piping.
e) Auxiliary equipment.
f) The weight of the liquid to fill the vessel.
For cylindrical vessel with domed ends, and uniform wall thickness, the total weights of the
shell (excluding internal fitting) is:

𝑊𝑣 = 𝐶𝑤 𝜋 𝜌𝑚 𝐷𝑚 𝑔 (𝐻𝑣 + 0.8𝐷𝑚) Ts × 10-3

For a steel vessel such as stainless steel, the above equation has been reduced to equation 1.11.
𝑊𝑣 = 240𝐶𝑤𝐷𝑚(𝐻𝑣 + 0.8𝐷𝑚)Ts (1.11)

𝑊𝑣 = 240𝐶𝑤𝐷𝑚(𝐻𝑣 + 0.8𝐷𝑚)Ts
= 240(1.15)(5.84)[17.49 + 0.8(5.84)](9.33× 10−3)
= 332.56kN
= 332559.81 N
Where:
𝑊𝑣 = total weight of the shell, excluding internal fittings
𝐶𝑤 = a factor account for the weight of nozzles, manways, internal supports, etc; which can be
taken as 1.15.
𝐷𝑚 = mean diameter of vessel
= (𝐷𝑖 + Ts) m
= (8.01 + 0.06) = 8.07 m
𝐻𝑣 = height or length, between tangent lines, 16.03 m
Ts = shell thickness, 0.06 m

29
1.8.9 Weight of Insulation

Insulation of reactor will help to keep the desired temperature inside reactor and can
eliminate heat conductivity as well as reduce heat transfer. Well insulated reactor is very
energy efficient and at the same time can reduce noise pollution. Mineral wool is effective
insulating materials that ensure that the temperature of outer wall of the reactor is lower
which is very crucial for safety purpose. The calculation of weight of insulation has been
summarized in table 1.8.

Table 1.10 Calculation of weight of insulation

Parameters Calculations
Insulating material Mineral wool
Density, 𝜌𝑚 (kg/m3) 130 kg/m3
Thickness of mineral wool, 𝑡𝑚 (m) 0.1
Volume of insulation (m3) Vi = 𝜋(𝐷𝑜 )(𝐿)(𝑡𝑚 )
= 𝜋(8.23)(16.03)(0.1)
= 41.4461 m3
Weight of Insulation (N) Wi = 𝜌𝑚 Vi
= (130)(41.4461)
= 5387.993 𝑘𝑔
= 52856.21 𝑁

30
1.4.10 Total Weight Excluding The Skirt Support

It is important to take note that total weight of the reactor is largely corresponding to
the cost. Moreover, total weight will also affect the mechanical stability of the reactor. The
total weight of reactor consists of weight of catalyst, vessel, and insulation.

Total weight of reactor excluding skirt support, Wt = Wc + Wi + Wv (1.12)

= (92649.33 + 52856.21 + 332559.81)𝑁

= 478065.35 𝑁

1.8.11 Analysis of stress

Pressure stresses
The hoop and longitudinal stresses due to pressure are calculated by equation 1.13 and 1.14

𝑃𝑑 𝐷𝑖 (1.13)
ℎ𝑜𝑜𝑝 𝑠𝑡𝑟𝑒𝑠𝑠, 𝜎ℎ =
2𝑇𝑠

𝑃𝑑 𝐷𝑖
𝜎ℎ =
2𝑇𝑠

(2.397)(8013.9)
= 2×56.73

= 169.30 𝑁/𝑚𝑚2

𝑃𝑑 𝐷𝑖 (1.14)
Longitudinal stress, 𝜎𝐿 = 4𝑇𝑠

𝑃𝑑 𝐷𝑖
𝜎𝐿 =
4𝑇𝑠

(2.397)(8013.9)
= 4×56.73

= 84.65 𝑁/𝑚𝑚2

31
Dead weight stress

𝑊𝑡 (1.15)
𝐷𝑒𝑎𝑑 𝑤𝑒𝑖𝑔ℎ𝑡 𝑠𝑡𝑟𝑒𝑠𝑠, 𝜎𝑤 =
𝜋(𝐷𝑖 + 𝑇𝑠 )(𝑇𝑠 )
𝑊𝑡
𝜎𝑤 =
𝜋(𝐷𝑖 + 𝑇𝑠 )(𝑇𝑠 )

478065.35
= 𝜋(8013.9+56.73)(56.73)

= 0.33 𝑁/𝑚𝑚2

The longitudinal bending stress at the mid-span of the vessel is given by the equation 1.16:

𝑀 𝐷𝑖 (1.16)
Longitudinal bending stress, 𝜎𝑏 = ( 2 + 𝑇𝑠 )
𝑙𝑣

Where,
M = Longitudinal bending stress at the mid-span
lv = Second moment of area of the shell

Before calculating the longitudinal bending stress, second moment of area, 𝒍𝒗

𝜋 (1.17)
𝑆𝑒𝑐𝑜𝑛𝑑 𝑚𝑜𝑚𝑒𝑛𝑡 𝑎𝑟𝑒𝑎, 𝑙𝑣 = (𝐷 4 − 𝐷𝑖 4 )
64 𝑜
𝜋
𝑙𝑣 = (𝐷 4 − 𝐷𝑖 4 )
64 𝑜
𝜋
= (8233.4456 4 − 8013.94 )
64

= 2.3115 × 1013 𝑚𝑚4

It is assumed that the load per unit length is due to the weight of vessel alone,

wL1 2
𝐿𝑜𝑛𝑔𝑖𝑡𝑢𝑑𝑖𝑛𝑎𝑙 𝐵𝑒𝑛𝑑𝑖𝑛𝑔 𝑠𝑡𝑟𝑒𝑠𝑠, M =
2
𝑊𝑡
𝑤= 𝐿

478065.35
= 16.03

32
 = 29823.17 𝑁/𝑚

𝐿
𝐿1 =
2
16.03
= 2

= 8.015 m

29823.17(8.015)2
𝑀=
2

= 957923.58 𝑁𝑚

With the value of longitudinal bending stress and second moment of area, 𝜎𝑏 can be
calculated by equation below.

𝑀 𝐷𝑖 (1.18)
𝜎𝑏 = ± ( + 𝑇𝑠)
𝑙𝑣 2

957923.58 8013.9
𝜎𝑏 = ± ( + 56.74)
2.3115 × 1013 2

𝜎𝑏 = ± 1.6841 × 10−4 𝑁/𝑚𝑚2

The resultant longitudinal stress is:

𝜎𝑧 = 𝜎𝐿 + 𝜎𝑤 ± 𝜎𝑏 (1.19)
𝜎𝑤 is compressive and therefore negative

𝜎𝑧 (𝑢𝑝𝑤𝑖𝑛𝑑) = 𝜎𝐿 − 𝜎𝑤 + 𝜎𝑏

= 84.65 − 0.33 + 1.6841 × 10−4

= 84.32 𝑁/𝑚𝑚2

𝜎𝑧 (𝑑𝑜𝑤𝑛𝑤𝑖𝑛𝑑) = 𝜎𝐿 − 𝜎𝑤 − 𝜎𝑏

= 84.65 − 0.33 − 1.6841 × 10−4

= 84.32 𝑁/𝑚𝑚2

33
As there is no torsional shear stress, the principal stresses will be σz and σh. The greatest
difference between the principal stresses will be on the downwind side:

𝑁 𝑁 𝑁 𝑁
169.3 𝑚𝑚2 − 84.32 𝑚𝑚2 = 84.98 𝑚𝑚2 < 76.3𝑚𝑚2 , 𝑑𝑒𝑠𝑖𝑔𝑛 𝑠𝑡𝑟𝑒𝑠𝑠 (acceptable)

Check elastic stability (buckling) (Sinnott et al, 2005):

𝑇
Critical buckling stress, 𝜎𝑐 = 2 × 104 × 𝐷𝑠
𝑜

56.74
= 2 × 104 × 8233.4456

= 137.83 N/mm2

∑ 𝜎𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒 = 𝜎𝑤 + 𝜎𝑏

= 0.33 + 1.6841 × 10−4

𝑁
= 0.33 𝑚𝑚2

𝑁 𝑁
Hence, the design is considered safe as ∑ 𝜎𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒 = 0.33 𝑚𝑚2
< 𝜎𝑐 = 137.83 𝑚𝑚 2

The region that will enhance the supports and mid-span to be equal in magnitude will be the
potential most desirable location of the supports that produces the lowest bending moment.
For a uniformly loaded beam, the location would be approximately 21% of the total span
measured from each end. Thus,

𝐿2 = 0.21 × 𝐿

= 0.21 × 16.03

= 3.37 𝑚 from each end

34
The longitudinal bending stress at the supports is calculated using equation 1.20.

4ML2 (1.19)
σb2 = 2
Ch πDi Ts

Ch = an empirical constant varying from 1.0 for a completely stiff shell to about 0.1 for a thin,
unstiffened shell
𝑤𝐿2 2
𝑀𝐿2 =
2
(29823.17 )(3.37)2
= 2

= 169349.38 𝑁𝑚

For a completely stiff shell, the longitudinal bending stress can be calculated

4 (169349.38)
𝜎𝑏2 =
(1)𝜋(8.0139)2 (0.05673)
= 59182.18 N/m2
= 0.0592 𝑁/𝑚𝑚2

Therefore, for a completely stiff shell, the longitudinal bending stress is 0.0592 𝑁/𝑚𝑚2

35
1.8.12 Reactor Support

Reactor support is the support system that designed to withstand the weight of the
vessel and its contents, as well as any additional loads, such as wind in order to maintain the
stability of reactor vessel. Many factors must be considered, including the vessel's scale,
shape, and weight. Saddle support, skirt support, and brackets supports are the three forms of
reactor support. Saddle support is usually installed on the horizontal vessel. Skirt support is
used in the tall and vertical column. Brackets supports is the most common support as it can
be used in all types of vessel (Sinnott & Towler, 2020).

It is important to conduct a thorough analysis of the stresses that have been caused in
order to provide sufficiently good and cost-effective supports. In a chemical processing plant,
support failure may result in major hazards. In this design of reactor support, the skirt support
is appealing because it causes the least number of local stresses due to mechanical loads
acting at the vessel's junction. Skirt supports should be considered over bracket supports if the
bending moment is likely to be significant. Thus, for multi-tubular catalytic reactor (R-101),
as it is vertical vessel with the ratio of L:D = 2:1, skirt support is highly recommended and
being used as the support system.

1.8.12.1 Skirt Support

A skirt support is made up of a cylindrical or conical shell that is welded to the

vessel's base (Sinnott & Towler, 2020). For vertical vessels, skirt supports are recommended
because they do not place concentrated loads on the vessel shell. A straight cylindrical skirt
support is used as support system as it is able to withstand higher weight loads. Carbon steel
is chosen as material of construction of skirt support instead of stainless steel because carbon
steel is stronger and more durable. Moreover, carbon steel is cheaper as it has lower material
factor. There are several assumptions have been made for the skirt supports.

36
 Table 1.11. Table of assumptions of skirt support for R-101

Type Straight cylindrical skirt (𝜃=90°)

Material construction Carbon steel
Conditions Ambient temperature and pressure
Maximum allowable stress, fs 101.7 N/mm2
Young’s modulus, E 200000 N/mm2
Skirt support diameter, Ds 8.0139 m
Skirt thickness, ts 40 mm
Skirt support height, Hs 3m
Total weight of reactor excluding skirt support, Wt 478065.35 N
For safety purpose, add more 10% to Wt 525871.89 N

Assume wind loading as 0.5% of Wt

𝑊𝑖𝑛𝑑 𝑙𝑜𝑎𝑑𝑖𝑛𝑔, 𝐹𝑤 = 0.05/100 × 𝑊𝑡 (1.20)

𝑊𝑖𝑛𝑑 𝑙𝑜𝑎𝑑𝑖𝑛𝑔, 𝐹𝑤 = 0.5% × 𝑊𝑡

= 2390.33 N

Bending moment at the base of the skirt is shown below:

(𝐷𝑖 + 𝐻𝑠 )2 (1.21)
𝑀𝑠 = 𝐹𝑤 ×
2

Where:

𝐹𝑤 is wind loading (N)

𝐷𝑖 is internal diameter (m)

𝐻𝑠 is height of skirt (m)

(𝐷𝑖 + 𝐻𝑠 )2
𝑀𝑠 = 𝐹𝑤 ×
2

37
 (8.0139+3)2
= 2390.33 × 2

= 144980.6774 𝑁𝑚

= 144.98 𝑘𝑁𝑚

The maximum amount dead weight load on the skirt is produced when the vessel is full of
water. The approximate weight of skirt has been calculated using equation 1.22.

𝜋
Approximate weight of skirt, Wapprox = × (𝐷𝑖 )2 × 𝜌 × 𝑔 × 𝐿 (1.22)
4

𝜋
Approximate weight of skirt, Wapprox = × (𝐷𝑖 )2 × 𝜌 × 𝑔 × 𝐿
4
𝜋
= × (8.0139)2 × 1000 × 9.81 × 16.03
4

= 7931955.131 𝑁
= 7931.96 𝑘𝑁

Total weight including the skirt support, WT = Wt + Wapprox

= 478065.35 + 7931955.13
= 8410020.48 N

Since the Wapprox > total weight of reactor (catalyst, vessel, and insulation),Wt. It is reasonable
case as the weight of skirt support is able to withstand the total weight of reactor and would
not collapse. The skirt thickness must be sufficient to withstand the dead weight loads and
bending moments imposed on it by the vessel; it will not be under the vessel pressure.

4𝑀𝑠 (1.23)
Bending stress in the skirt, 𝜎𝑏𝑠 = 𝜋(𝐷𝑖 +𝑡𝑠 )𝑡𝑠 𝐷𝑖

4𝑀𝑠
Bending stress in the skirt, 𝜎𝑏𝑠 = 𝜋(𝐷𝑖 +𝑡𝑠 )𝑡𝑠 𝐷𝑖
4(144980.6774 )
= 𝜋(8013.9+40)(40)(8013.9)

= 7.15 × 10−5 𝑁/𝑚𝑚2

38
 W𝑇 (1.24)
dead weight stress in skirt, 𝜎𝑤𝑠 (𝑡𝑒𝑠𝑡) = 𝜋(𝐷𝑖 +𝑡𝑠 )𝑡𝑠

W𝑇
dead weight stress in skirt, 𝜎𝑤𝑠 (𝑡𝑒𝑠𝑡) = 𝜋(𝐷𝑖 +𝑡𝑠 )𝑡𝑠
8410020.48
= 𝜋(8013.9+40)(40)

= 8.31 𝑁/𝑚𝑚2

𝑊 (1.25)
dead weight stress in skirt, 𝜎𝑤𝑠(operating) = 𝜋(𝐷 +𝑡𝑡
𝑖 𝑠 )𝑡𝑠

𝑊
dead weight stress in skirt, 𝜎𝑤𝑠(operating) = 𝜋(𝐷 +𝑡𝑡
𝑖 𝑠 )𝑡𝑠

478065.35
= 𝜋(8013.9+40)(40)

= 0.47 𝑁/𝑚𝑚2

Maximum 𝜎𝑤𝑠 (compressive) = 𝜎𝑏𝑠 + 𝜎𝑤𝑠 (𝑡𝑒𝑠𝑡) (1.26)

Maximum 𝜎𝑤𝑠 (compressive) = 𝜎𝑏𝑠 + 𝜎𝑤𝑠 (𝑡𝑒𝑠𝑡)

𝑁 𝑁
= 7.15 × 10−5 𝑚𝑚2 + 8.31 𝑚𝑚2

= 8.31 𝑁/𝑚𝑚2

Maximum 𝜎𝑤𝑠 (tensile) = 𝜎𝑏𝑠 + 𝜎𝑤𝑠 (𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔) (1.27)

Maximum 𝜎𝑤𝑠 (tensile) = 𝜎𝑏𝑠 + 𝜎𝑤𝑠 (𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔)

𝑁 𝑁
= 7.15 × 10−5 𝑚𝑚2 + 0.47 𝑚𝑚2

= 0.47 𝑁/𝑚𝑚2

Design criteria:
𝜎𝑤𝑠 (tensile) < 𝑓s 𝐽 𝑠𝑖𝑛 𝜃

39
 𝑁
0.47 𝑚𝑚2 < (101.7) (1) sin 90
𝑁
0.47 𝑚𝑚2 < 101.70 (acceptable)

𝜎𝑤𝑠 (compressive) < 0.125 𝐸(𝑡𝑠/𝐷𝑖) 𝑠𝑖𝑛 𝜃

𝑁 40
8.31 𝑚𝑚2 < 0.125 × 200000 (8013.9) sin 90
𝑁
8.31 𝑚𝑚2 < 124.78 (acceptable)

For safety purpose, the skirt thickness should be added with corrosion allowance of 4 mm.

Actual Skirt thickness = ts + corrosion allowance

= 40 mm + 4 mm
= 44 mm

40
1.8.13 Cooling Jacket Design

Cooling water will be used as cooling medium to remove heat generated from reaction
occurred in multi-tubular catalytic reactor (R-101) and to maintain the reactor temperature
with cooling temperature of 25 ˚C (Gupta & Stinespring, 2002). The heat generated from R-
101 can be collected from simulation data by ASPEN PLUS which is 14324.0062 kW. The
required mass flow rate of cooling water is calculated as below:

Given Cp = 4182 J/kg℃

Tin = 25 ℃
Tout = 200 ℃

𝑄̇ = 𝑚̇CpΔT (1.28)

From 𝑄̇ = 𝑚̇CpΔT
14324006.2 = 𝑚̇(4182)(200 − 25)℃
14324006.2
𝑚̇ = (4182)(200−25)℃

= 19.57 𝑘𝑔/𝑠 of cooling water

41
1.8.14 Base Ring and Anchor Bolt Design

There are some criteria in choosing suitable anchor bolts such as size of bolts. Small bolts that
smaller than 25mm cannot be used, the minimum number of anchor bolts is 8, choose closest
multiple of 4 when calculate for required bolts amount, and lastly bolt pitch must exceed
600mm. Figure 1.2 shows one of the flange rings design.

Figure 1.3 Single plate with gusset (Sinnott & Towler, 2020)

Approximate pitch circle diameter, Db = 3 m

Circumference of bolt circle, Cb = 𝜋D𝑏 (1.29)

Circumference of bolt circle, Cb = 𝜋D𝑏

= 𝜋(3000 𝑚𝑚)
= 9424.78 mm

42
Number of bolts required, at minimum recommended bolt spacing is calculated using
equation 1.30.

𝜋D𝑏 (1.30)
𝑁𝑏 =
600

𝜋D𝑏
𝑁𝑏 =
600
9424.78
= 600

= 15.71

Closest multiple of 4, 𝑁𝑏 = 16 bolts

Take bolt design stress, 𝑓𝑏 = 125 𝑁/𝑚𝑚2 , 𝑀𝑠 = 144980.6774 𝑁𝑚 , 𝑊𝑡 = 478065.35 𝑁

1 4𝑀 (1.31)
Bolt area, 𝐴𝑏 = 𝑁 [ 𝐷 𝑠 − 𝑊𝑡 ]
𝑏 𝑓𝑏 𝑏

1 4𝑀
Bolt area, 𝐴𝑏 = 𝑁 [ 𝐷 𝑠 − 𝑊𝑡 ]
𝑏 𝑓𝑏 𝑏

1 4×144980.6774
= [ − 478065.35 ]
16×125 3

= 142.38 𝑚𝑚2

4×𝐴𝑏 (1.32)
Bolt diameter, d = √ 𝜋

4×𝐴𝑏
Bolt diameter, 𝑑 = √
𝜋

4×142.38
= √ 𝜋

= 13.46 𝑚𝑚

43
Total compressive load on the base ring per unit length:
4×𝑀 𝑊 (1.33)
𝐹𝑏 = (𝜋×𝐷2𝑠 + 𝜋×𝐷 )
𝑏 𝑏

4×144980.6774 478065.35
𝐹𝑏 = ( + )
𝜋×32 𝜋×32

= 37418.67 𝑁/𝑚

= 37.42 𝑘𝑁/𝑚

The minimum width of base ring:

Take 𝑓𝑐 = 5 𝑁/𝑚𝑚2
𝐹𝑏 1 (1.34)
𝐿𝑏 = × 103
𝑓𝑐

𝐹𝑏 1
𝐿𝑏 = × 3
𝑓𝑐 10

37418.67 1
= × 3
5 10

= 7.48 mm

Hence use M14 bolts with area of 154 mm2

Actual width required:

L = 𝑡𝑠 + 𝑡𝑖 (1.35)
Actual width required, L = 𝑡𝑠 + 𝑡𝑖

L = 44 + 50

= 94 𝑚𝑚

44
Actual bearing pressure on concrete foundation:

𝐹𝑏 (1.36)
𝑓 ′𝑐 = 𝐿
37418.67
𝑓 ′𝑐 = 94000

= 0.398 𝑁/𝑚𝑚2

Base ring thickness:

Take 𝑓𝑟 = 140 𝑁/𝑚𝑚2

3×𝑓 ′𝑐 (1.37)
𝑡𝑏 = 𝐿𝑟 × √ 𝑓𝑟

3 × 0.398
𝑡𝑏 = 94 × √
140

= 8.68 𝑚𝑚

Thus, the base ring thickness calculated to be 8.68 mm and 16 pieces of M14 bolts with area
of 154mm2 will be used.

45
1.8.15 The Engineering Drawing of Multi-tubular Catalytic Reactor (R-101)

Figure 1.4 Cross-sectional Engineering Drawing of Multi-tubular Catalytic Reactor (R-101)

46
Figure 1.5 Top View Engineering Drawing of Reactor and Base Ring

47
1.9 Process Control and Safety

1.9.1 Process Control System

Process control is aimed to control all the process variables to ensure the plant
operates under optimum condition to produce high quality and high purity of ethylene glycol,
di-ethylene glycol, and tri-ethylene glycol from raw materials. There are some common
variables being controlled by process control system which are pressure, flow, level, and
temperature. Besides, ratio also can be controlled. The main objective of multi-tubular
catalytic reactor (R-101) is to produce ethylene oxide from raw materials which are ethylene
and oxygen. In this reactor (R-101), there are a few considerations need to be taken such as
the inlet flow rate of both ethylene and oxygen and its internal temperature to ensure that the
system operates in optimal conditions. To achieve high productivity of ethylene oxide, the
control loops used in the operation of multi-tubular catalytic reactor (R-101) are:

1. Ratio control: Ratio control is one of the challenging control systems as it is used to
provide accuracy for composition measurement where the evaluation of the
performance is required. This is to ensure quantitative composition to the inlet and
outlet stream for next process, especially for mixer and reactor that required accurate
composition ratio to ensure the reaction occur at optimum condition and generate
products at greater rate.

2. Temperature control: Temperature control is an important controller especially for the

equipment that operates with specific temperature such as reactor, distillation column,
heat exchanger, compressor, and flash column. The temperature control is to ensure
the equipment provides required optimum temperature for the reaction to occur in
order to achieve the standard quality of the output stream. Generally, the mechanism
of temperature control is to response to the temperature changes of an equipment from
the set point value. Temperature acts as indication of composition especially in

48
 separation processes such as distillation column. Temperature control system can
minimize the energy consumption by determining the optimum amount of energy
needed for reaction in order to minimize energy losses.

3. Pressure control: Pressure control are usually being used in the system that involved
vapor or gases phase as liquid and solid are hardly being compress. Pressure control is
designed to manage the stress given by gases produced by the equipment that involve
reaction or compromise with lot of gases such reactor, distillation column, flash
column, and compressor. Pressure control system are very important in ensuring plant
can be run smoothly and avoid equipment from increasing temperature due to
increasing pressure. Hence, it is very crucial to have pressure controller after
equipment to ensure the pressure is being maintain at the controllable range.

The control system for the reactor (R-101) is designed with the following control objectives:
1. To control ratio of ethylene to oxygen at stream 5 and 10, respectively by
manipulating inlet flowrate of stream 5.
2. To control temperature in reactor R-101 by manipulating inlet flowrate of cooling
medium of cooling jacket.
3. To control pressure of reactor R-101 by manipulating outlet flowrate of stream 11.

49
 Figure 1.6 Control system design for multi-tubular catalytic reactor (R-101)

Table 1.12 Control system of multi-tubular catalytic reactor (R-101)

Controlled Disturbance Manipulated Type of Set Point

Variable Variable Controller

Ratio of Flowrate at Inlet flowrate of Ratio Ratio of ethylene to

ethylene to stream 5 ethylene at stream controller oxygen is 0.5:0.5
oxygen 5

Internal Temperature of Inlet flowrate of Feedback T=240℃, if

temperature of stream 5 and cooling medium at controller temperature ±10℃
reactor stream 10 reactor jacket of set point, alarm is
activated

Internal Pressure at Pressure of reactor Feedback P=20 bar, if pressure

pressure of stream 11 R-101 at outlet controller ±10 bar, valve will
reactor stream 11 open or close

50
1.10 HAZOP Study

The objectives are being proposed after a detailed study on the reactor.

1. Product quality control

▪ To maintain optimum temperature for favor reaction conditions.
▪ To enhance the productivity of reactor by maintaining the parameters at optimum level.

2. Operational constraints
▪ To ensure the reactor must not be flooded.
▪ To ensure reactor pressure maintained at desire level for high selectivity of ethylene
oxide.
▪ To ensure the temperature always maintained at optimum conditions for reaction to
take place in reactor smoothly.
▪ To ensure the flow rate of reactant and product at standard condition to avoid
overpressure or backflow.

51
 Table 1.13 HAZOP Study on Multi-tubular Catalytic Reactor (R-101)

PROJECT: PRODUCTION OF ETHYLENE GLYCOL FROM ETHYLENE Date: 16/04/2021

NODE: MULTI-TUBULAR REACTOR Subsystem intention: To produce ethylene oxide
NO PARAMETER GUIDEWORD DEVIATION CAUSES CONSEQUENCES SAFEGUARDS RECOMMENDATION
1. Temperature Low Low 1. Valve (V-112) 1. Reaction affected 1. Temperature 1. Inspection and
Temperature malfunction and less products Indicator functionality check
2. Heater (E-104 & produced Controller (TIC- regularly
106) malfunction 2. Cannot achieve 004 & TIC-006) 2. Maintenance and
optimum reaction 2. Temperature monitoring regularly
temperature Alarm Low
3. Temperature
Transmitter
High High 1. Valve (V-112) 1. Reaction affected 1. Temperature 1. Inspection and
Temperature malfunction and less products Indicator Controller functionality check
2. Heater (E-104 & produced (TIC-004 & TIC- regularly
106) malfunction 2. Cannot achieve 006) 2. Maintenance and
optimum reaction 2. Temperature monitoring regularly
temperature Alarm High
3. Temperature
Transmitter
2. Pressure Low Low Pressure 1. Pipeline leakage 1. Product could 1.Pressure Indicator 1. Inspection and
back flow into Controller (PIC-003) functionality check
reactor 2. Pressure Alarm regularly
Low 2. Maintenance and
3. Pressure monitoring regularly
Transmitter

52
 High High Pressure 1. Outlet valve (V- 1. Can lead to 1.Pressure Indicator 1. Inspection and
113) malfunction reactor rupture Controller (PIC-003) functionality check
2. Pressure Alarm regularly
High 2. Maintenance and
3. Pressure monitoring regularly
Transmitter
3. Flow Low Low Flow 1. Pipe leakage or 1. Low productivity 1. Ratio 1. Inspection and
clogged as less reactant Controller functionality check
enters the reactor (RC-001) regularly
2. Flow 2. Maintenance and
Transmitter monitoring regularly
3. Flow
Indicator
Controller
(FIC-003)
High High Flow 1. Valve (V-107) 1. Overpressure in 1. Ratio 1. Inspection and
malfunction reactor Controller functionality check
(RC-001) regularly
2. Flow 2. Maintenance and
Transmitter monitoring regularly
3. Flow
Indicator
Controller
(FIC-003)

53
1.11 Equipment Specification Sheet

Table 1.14 Equipment specification sheet

Equipment Specification Sheet

Item no. Multi-tubular reactor R-101
To produce ethylene oxide from ethylene and
Function oxygen
Orientation Vertical
Material of construction Stainless steel 304
Operating Data
Inlet Outlet
Stream
S5 S10 S11
Temperature (K) 513.00 513.00 513.00
Pressure (bar) 20 20 20
Composition (kg/hr)
Ethylene (C₂H₄) 42500.00 0.00 8500.00
Oxygen (O₂) 0.00 42500.00 21250.00
Ethylene oxide (C₂H₄O) 0.00 0.00 52366.01
Carbon dioxide (CO₂) 0.00 0.00 2045.90
Water (H₂O) 0.00 0.00 837.47
Total mass flow rate (kg/hr) 42500.00 42500.00 84999.38
Operating Conditions
Operating Pressure, Po (bar) 20 Operating temperature, To (⁰C) 240
Operating pressure, Po
(psig) 290.08 Operating temperature, To (⁰F) 464
Design Pressure (bar) 23.97 Design Temperature, Td (⁰C) 267.78
Design Pressure (psig) 347.7 Design Temperature, Td (⁰F) 514
101055.29 26696.067
Flow rate , Q (l/min) 25 Flow rate, Q (GPM) 13
Catalyst
Type of Catalyst Silver
Weight of Catalyst (N) 92649.3266
Insulation
Insulation Material Mineral Wool
Density (kg/m3) 130
Insulation Thickness (m) 0.1
Insulation Volume (m3) 41.4461

54
 Shell Specification
Weld Joint Efficiency 1 Maximum allowable stress (psi) 13278
L:D ratio 2 Length, L (m) 16.0278
Internal diameter, Di (m) 8.0139 Outer diameter, Do (m) 8.2334
Thickness to withstand Thickness to withstand wind
4.1969 0.02
internal pressure, tp (inch) load, tw (inch)
Average wall thickness, tv
2.1085 Shell thickness ,Ts (inch) 2.2335
(inch)
Corrosion allowance, tc
0.125 Shell thickness, Ts (mm) 56.7309
(inch)
33900.082
Mass of Vessel, Wv (kg) Weight of Vessel, Wv (N) 332559.81
57
Corrosion allowance, tc
3.175 Internal diameter, Di (inch) 315.5076
(mm)
33903.320
Material density, Ib/in3 0.298 Shell thickness ,Ts
07
5387.9928
Mass of Insulation (kg) Weight of Insulation (N) 52856.21
64
92649.326
Mass of Catalyst (kg) 9444.3758 Weight of Catalyst (N)
6
48732.451 478065.34
Total Mass, Wt (kg) Total Weight, Wt (N)
23 66
Head and Closure
Type Ellipsoidal head
Diameter to Height Ratio 1 to 4
Head thickness (mm) 105.19
Reactor Support
Type Straight cylindrical skirt (θ=90°)
Material Carbon Steel
Maximum Allowable Stress, fs (N/mm2) 101.7
Wind Loading, Fw (N) 2390.33
Skirt Support Diameter, Ds 8.0139
Skirt Thickness, ts (mm) 40
Skirt Support Height, Hs (m) 3
Actual Skirt Thickness, ts (mm) 44
Total Weight including Skirt Support, WT
8410020.48
(N)
Cooling Jacket Design
Cooling Medium Cooling Water
Cooling Temperature 25
Mass flow rate (kg/s) 19.57
Base Ring and Anchor Bolts

55
Base Ring Thickness, tb (mm) 8.68
Bolt Diameter, d (mm) 13.46
Number of Bolts Required, Nb 16
Type of Bolt M14

56
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