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hat are the cases to use PBT ?

For less dense and less viscous reaction mass we prefer PBT, the mixing with
PBT shall be axial, which will allow the mass to pump from bottom to top
uniformly.

For detailed selection of reactor with agitator click here

Will PBT generate top pumping or bottom pumping or both ?

PBT will generate top pumping i.e., lifting mass from bottom to top.

Lets take an example of 100 L SS Reactor with PBT agitator design, in general
we consider 80% occupancy for a reactor. Water as medium. Basic dimensions:
Internal Dia - 48 cm, Height - 58 cm, Shell thickness - 0.6 cm.

Let's start the design [majority of the design calculations were of thumb rules],

Dish height = 0.2 x inner dia = 0.2 x 48 = 9.6 cm,

Impeller Dia = 40 % sweep = 0.4 x 58 = 19.2 cm,

Blade width = Impeller Dia / 5 = 19.2 / 5 = 3.84 cm,

Blade thickness = Vessel thickness / 2 = 0.6 / 2 = 0.3 cm,

Liquid level = ((((1000 x liquid vol.)-(0.0809 x Inner dia^3))x4) / (3.141 x Inner

dia^2)) + Dish heigh = 48.9 cm

Impeller count = Liquid level x density / impeller dia = 48.89 x 1 / 19.2 = 2.54
~3
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Distance between impeller = Impeller Dia = 19.2 cm,

Volume of reactor = (((3.141 x Inner dia^2 x Vessel height)/4)+(0.0809 x Inner

dia^3))/1000 = 113.9 Lts,

Tip Speed = 3.141 x 19.2 x 140 / 60 x 100 = 1.41 m/sec,

Distance between reactor bottom and impeller = Liquid height / 7 = 48.9 / 7 =

6.99 cm,

Liquid density = 1000 Kg/m3,

Liquid viscosity = 0.0008 Kg-m/sec,

Reynolds number = RPS x impeller dia ^2 x density / viscosity = 107365,

Power number = 2.5 [As per generic agitator curves],

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Power req. for agitation = Np x density x Impeller Dia^5 x RPS^3 = 8.24 W =
0.011 HP,

Transmission losses = 20%,

Gland losses = 10%,
Gear box losses = 10%,
Agitation power required after considering losses = 0.011 x (20+10+10)/100 =
0.015 HP,

Power with 70% efficiency, i.e., 0.015 / 0.7 = 0.022 HP,

/** Mixing dynamics calculation shall be updated in a short time **/

Baffles Design:

Number of baffles = 4 (say)

Baffle width = Internal dia / 12 = 4 cm,

Baffle height = Vessel height x 0.8 = 46.4 cm,

Baffle thickness = 0.5 - 1 cm,

Bottom clearance = Baffle width / 5 = 0.8 cm,

Distance between baffle and shell = Inner dia / 24 = 2 cm.

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That's it ....!!!

These are some of the aspects related to design of PBT agitator.

If any queries, feel free to comment / message me ......!!!

Comments are most appreciated .....!!!

Types of Agitators, Agitator's Design and Significance

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Ajay Kumar Kalva 6 years ago agitator, design

Hello readers.....!!
Today i gonna give you a description that limits upto my knowledge, and most
of you may find it useful, about the Industrial Agitators, Types of Agitators,
their Power Numbers, Design Equations and their significance in production.

Introducing or discovering the types of agitators in pharma field is certainly a

revolution because different agitators will have different purposes and different
advantages, but most commonly used agitators are Anchor, Propeller, Turbine,
Paddle etc., and still these agitators are sub divided into types, for example
Round Anchor and Anchor combined with Gate are two types of Anchor.

So, for knowing the types of agitators and their significance you don't need any
basic knowledge, but just an idea that
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"what is an agitator ?, And what it can do ??"

"What is the difference between Agitation and Mixing ??"
Agitator : An agitator is something which is used to stir liquid or mixture of
liquids.

Also Read:

How to Select a Condenser?

What Does a TR exactly means?
How to Calculate the Energy of Steam?

What it can do ?? : It can be used in various operations, in a pharma industry it

can be used in multiple operations like reactions, work up's, drying, filtration,
etc.,

Difference between Agitation and Mixing :

Agitation is the process of keeping a mixture that has been mixed in the proper
mixed state required for the 'end' product.
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Mixing refers to the actual stirring of different liquids and/or materials to blend
them together into an end product or mixture. Once this mixture is 'mixed' it
may require agitation to keep the mixture in the proper 'mixed' state.

So, Now i'll go into our topic,

There are two types of Agitators commonly used,

1. Mechanical Agitators, 2. Electronically Controlled Agitators, I'll demonstrate

commonly used Mechanical Agitators.

Recommended For You:

How to Select Motor Capacity of an Agitator?

How to do Scale Up calculations?
How to Design an Industrial Column?

Paddle Agitators: This is one of the most primary types of agitators with blades
that reach up to the tank walls. Paddle agitators are used where an uniform
laminar flow of liquids is desired.
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Anchor Agitators : This simple agitator consists of a shaft and an anchor type
propeller and can be mounted centrally or at an angle. It is mainly used in
reactors.

Radial Propeller Agitators : Radial agitators consist of propellers that are

similar to marine propellers. They consist of two to four blades that move in a
screw like motion, propelling the material to be agitated parallel to the shaft.

Propeller Agitators : A propeller agitator is shaped with blades tapering

towards the shaft to minimize centrifugal force and produce maximum axial
flow. Propeller agitators are popular for simple mixing jobs.
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Turbine Agitators : Yet another type of process agitator is the turbine agitator.
Turbine agitators can create a turbulent movement of the fluids due to the
combination of centrifugal and rotational motion.

Helical Agitators : These agitators have blades with a twisted mechanism, just
like the threads of a screw. The curves result in a vigorous motion of the fluids
to be agitated. Helical agitators are most useful for mixing viscous liquids.
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A simplified brief description has been tabulated below.

Agitator Type Applications Advantages Disadvantages

* Mixing of Solids,
* Slurry Mixing,
* Heavy duty,
* Used during * Power
* Apt for Slow
Crystals Consumption is
Paddle operation,
forming phase very high,
* Can have 2 or 4
during * Inefficient Mixing
blades
Super saturated
Cooling
* Liquids and Gas
Turbine * Generates high
reactions, * Not preferred for
*Straight Blade Radial Flow,
* Highly used solvents with
*Pitched Blade * Highly used for
during Reaction high viscosity[NM
*Curved Blade dispersion
and Extraction T 20 cP]
*Disk Blade operations
Operations.
* Have to use in
addition to other * Uniform mixing * Not preferred for
Screw type agitators. of High viscous im-miscible
* Mostly used in masses. solvents.
Food processing.
Helical Blade * Most Probably * Can handle
* Low possibility
*Ribbon Type used in Paint Visco-elastic
for Radial mixing
*Helical Screw industry. liquids efficiently
* Highly used in * Increase possible * Required high
Pharma Industry heat transfer rate in Efficiency Gearbox,
Anchor
for Several reactors, from * Required high
Operations reactor heat Power.
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transfer surface to
Mass.
* Provides efficient
Mixing and * Not preferred
* Highly used for
agitation control, when both liquids
Gate blending
* Can handle and gases combine
Operations
Psuedo-plastic involves
liquids.
* Need to be
* Will increase the operated at high
* Suitable for
homogeneity, speed to avoid solid
GLR's, ANFD's,
* Can be used in settlings in reactors.
Propeller can handle
two different * Need to be
Corrosive materials
patterns for drying operated at low
with Glass lining.
and pressing. speeds in drying
operations.

Diameter of Agitator: Usually the diameter of agitator depends on the Diameter

of the vessel,

It is generally 1/3rd the diameter of the tank for Marine Propeller, Axial flow
turbine, Turbo Propeller, Disc Blade turbine, Flat Blade turbine, Backward
Blade turbine.

It is generally 4/5th of the diameter of the tank for Paddle, Anchor, Gate.

Type of Agitators and their functions:

Marine Propeller is generally an item produced by casting process in a foundry

and it has 3 or 4 blades. Cast agitators have two basic advantages, uniformity of
material and hard surface. These have tapering blades, and angle of blade varies
from root to tip. This produces maximum axial flow. The diameter of Marine
Propeller impeller is 15% to 30% of diameter of tank. These have tip speeds
between 300 to 500 meters per minute.

Axial Flow Turbine, Turbo Propeller and Flat Blade Turbine have blades
ranging from 3 to 6. These have tip speeds between 200 to 300 meters per
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minute. The diameter of impeller is 25% to 60% of tank diameter. For Axial
Flow Turbine and Turbo Propeller, the angle of blade varies from 30 degrees
(for less viscous liquids) to 60 degrees (for more viscous liquids). Standard
angle is 45 degrees. Power requirement increases with higher pitch angle. For
Flat Blade Turbine, the length of blade is 25% of diameter, and disk diameter is
60% to 70% of the diameter of impeller.

Paddle, Anchor, or Gate have only 2 blades. These extend close to the tank
wall and have tip speeds between 80 to 150 meters per minute. These push and
rotate the liquid in a laminar flow. There is no axial or radial mixing. The width
of blade is 1/8th or 1/10th of the agitator diameter.

Number of Agitators:

There can be many number of agitators connected to a shaft, and it can be

calculated as

Number of agitators = (Maximum liquid height x specific gravity) /

Diameter of tank.
Gap between two Agitators = Liquid height / (Number of impellers - 0.5).
Basic Design Equations for a Vertical Vessel and Agitator:

Vessel Volume = (pi x vessel dia x vessel dia x vessel length) / 4.0
Agitator Shaft length = vessel length + (vessel dia x 0.25)
For Rectangular Tanks,
Tank Volume = Vessel Length x Vessel Breadth x Vessel Height

Agitator Shaft length = Vessel Height

Based on geometry of vessel, many factors for impeller can be decided.

Agitator Power Pumping Impeller

Agitator
Speed Number Factor Diameter
Marine 100 - * 0.3 for 3 * 0.33 for 3 1/3rd of tank
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bladed
impeller, bladed,
300
Propeller * 0.33 for 4 * 0.34 for 4 dia
RPM
bladed bladed.
impeller
* 1.35 for 3 * 0.6 for 3
bladed, bladed,
* 1.4 for 4 * 0.69 for 4
100 -
Axial Flow bladed, bladed, 1/3rd of
300
Turbine * 1.45 for 5 * 0.78 for 5 tank dia
RPM
bladed, bladed,
* 1.6 for 6 * 0.87 for 6
bladed. bladed.
* 1.35 for 3 * 0.6 for 3
bladed, bladed,
* 1.4 for 4 * 0.69 for 4
100 -
Turbo bladed, bladed, 1/3rd of tank
300
Propeller * 1.45 for 5 * 0.78 for 5 dia
RPM
bladed, bladed,
* 1.6 for 6 * 0.87 for 6
bladed. bladed.
100 -
Disc Blade 1/3rd of
300 5.0 0.7 - 0.8
Turbine tank dia
RPM
100 -
Flat Blade 1/3rd of tank
300 5 0.7 - 0.85
Turbine dia
RPM
Backward 100 -
1/3rd of tank
Blade 300 5 0.65 - 0.85
dia
Turbine RPM
80% of
Paddle 50 RPM 5 0.03
tank dia
80% of
Anchor 50 RPM 5 0.07
tank dia
80% of
Gate 50 RPM 5 1
tank dia

AGITATOR COMPARISON CHART:

Today, the major concerns of the chemical and pharmaceutical industries are
improving performance and reducing production costs. Agitation, mixing and
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heat transfer are major factors in maximizing the efficiency of a process. The
various blade designs in our agitator product range have undergone significant
research and testing, making it possible to use a scientific approach to agitation
and heat exchange techniques that will optimize your process. The chart below
illustrates the different types of blades available and the characteristics of each.
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That's it.........!! Cheers..... if you understand,

Excel Sheet has been simulated for design of Agitator and you can download it
here,

DOWNLOAD HERE

Any Queries feel free to ask,

Comments are most appreciated.!

Agitators Curves for reference:

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Note: Some of the Data Interpreted here is not of my own, but from a generous
Genius "Satish Lele"
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[How To] Select Condenser Capacity for a Reactor
Ajay Kumar 4 years ago Calculations, Condenser, design, reactor

Dear All.......!!!
Good Evening, Hope you all are good, Thanks for the support that i'm receiving
for maintaining this blog, wish this'll continue all time.

Recently i've received a common query from Mechie (Mech. Engineer / Project
Engineer) and one of my colleague,

And i think some of us also will have the same, to address their query today i'm
posting this here, this may be a basic post but i've taken some time to think over
it and to make it best possible solution.

But before going to that there is some basic stuff, which need to be accepted by
all those who are reading this post, or else there may be slightly
misunderstanding erupted in-between.

What is a reactor ?
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Reactor is a vessel having an agitator and other accessories which are intended
for measuring and maintaining it in safe condition.

What are the operations that can be carried in a reactor ?

The main operation is reaction, apart from that it can be used for extraction,
concentration, crystallization and many more.

What are the sub components of a reactor ?

The notable sub components of a reactor are condenser, collection receiver,

safety valve, rupture disc, etc.

What is the main duty of a condenser ?

The main duty of a condenser is to condense the vapour, to deliver exactly the
main purpose is to remove the latent heat of vapour. Apart from that the
condenser will perform some unofficial duty by removing some of the sensible
heat from the condensed liquid.

That's it....!!! Now lets begin the calculation.

Also Read:
[How to] Map equipments for a manufacturing process
[How to] Determine Overall Heat transfer Coefficient practically ?

Lets consider a case where a 10 KL SS reactor is available and we need to select

a condenser for that reactor.

Step - 1: Select a solvent having high volatility.

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Step - 2: Calculate the maximum boil-up of the selected solvent.

Step - 3: Calculate the Condenser Capacity for that boil-up.

That's it ...!! your job is done.

Now, lets begin,

Step - 1: Solvent selection based on boiling point,

Below is the list of solvent and their boiling points [from my database],

B.P. B.P.
Solvent Name Solvent Name
(°C) (°C)
(N N) Dimethy Amino ethyl
95 Di Cyclo Hexyl Amine 255
Acrylate
(R)-Glycidyl Butyrate 90 Di Ethyl Oxalate 186
(S)-3-Chloro 1-Propanethiol 144 Di Isopropyl Adipate 125
1-(Trimethylsilyl)-1-Propyne 95 Di Isopropyl Ether 67
1,1,3,3-Tetramethoxy Propane 183 Di N-butyl Sebacate (Diester) 349
1,1,3,3-Tetramethyl Guanidine 158 DI Water (Acidified with HCl) 100
1,1-Dichloro-3,3-Dimethyl Butane 146 Dibenzyl Phosphite 110
1,2-Dibromoethane 131 Dibutyl Phthalate 340
1,2-Dimethoxyethane 82 Dicyclopentadiene 170
1,2-Dibromo Methane 96 Diethanolamine 268
1,3 - Difluoro Benzene 82 Diethyl Carbonate 126
1,4-Dimethyl Piperazine 131 Diethyl Ether 34.6
1,4-Dibromobutane (DBB) 63 Diethyl Ethoxymethylene Malonate 278
1,4-Dichloro Butane 161 Diethyl Malonate 199
1,4-dioxane 101.3 Diethyl Phthalate 296
1,6-Dibromohexane 243 Diethyl Sulphate 208
1,8-Diazabicyclo(5.4.0)undec-7-ene 80 Diethylamine 55
10-Undecenoyl Chloride 120 Diethylene Glycol 244
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1-Acetopapthone 302 Diethyl-L-Tartarate 280
1-Aminopiperidine 146 Diisopropyl Amine 84
1-Bromo 2-Fluoro Benzene 78 Dimethoxyethane 64.5
1-Bromo 4-Fluoro Benzene 150 Dimethyl Carbonate 90
1-Bromo-2,4,6-Trifluorobenzene 140.5 Dimethyl Formamide 153
1-Bromo-2-Fluoroethane 71 Dimethyl Sulfoxide (DMSO) 189
1-Bromo-3,4,5-Trifluorobenzene 47 Dimethylsulfide 37
1-Bromo-3-Chloro Propane 144 Diphenyl Phosphine 280
1-Bromo-4-chloro Butane 80 Dowtherm A 257
1-Bromopentane 130 Ethane Sulfonyl Chloride 177
1-Chloroethyl Chloroformate 118 Ethanol 78.3
1-Dodecanethiol 143 Ethyl Acetate 77
1-Fluoro Naphthalene 215 Ethyl Aceto Acetate 180
1-Methylimidazole 198 Ethyl Acrylate 99
1-Phenyl Ethyl Isocyanate 55 Ethyl Bromoacetate 159
2,4-Dichloro Fluoro Benzene 143 Ethyl Chloro Acetate 143
2,2,2-Trifluoro Ethanol 77 Ethyl Chloroformate 93
2-Fluoronitrobenzene 116 Ethyl Iodide 69
2-(2-Chloro Ethoxy) Ethanol 79 Ethyl isocyano acetate 195
2-(2-Thienyl) Ethanol 108 Ethyl Methyl Ketone 78
2-(2-Thienyl) Methylamine 95 Ethyl Nipecotate 102
2-(3-Amino Propylamino)-Ethanol 250 Ethyl Nipecotate 102
2,2,4-Trimethyl Pentane 99 Ethyl Oxalyl Chloride 135
2,3-Dimethyl Pyrazine 156 Ethyl Propiolate 120
2,3-Lutidine 162 Ethylbromodifluroacetate 112
2,3,4- Trifluoroaniline 92 Ethylene Di Chloride 83.5
2,3,Dihydro Benzofuran 188 Ethylhexyl Stearate >200
2,3-Benzofuran 173 Eucalyptus Oil 174
2,4-Dichloro Benzylamine 83 Euxyl K 100 100
2,5 Norbornadiene 89 Fluoro Benzene 85
2,5-Bis(Trifluoromethyl) Aniline 70 Formamide 210
2,5-Dichlorothiophene 146 Formic Acid 100.8
2,5-Dimethoxy Tetrahydrofuran 145 Fuming Nitric Acid 86
2,6-Lutidine 143 Furfuryl Alcohol 170
2,6-Difluoro Aniline 51 Gamma-Butyro Lactone 206
2,6-Difluoro Nitrobenzene 91 Glutarldehyde 50 % Solu. (198595) 187
2,6-Dimethyl Aniline 214 Glycerol BP 290
2-Acetyl Butyro Lactone 107 Hexa methyl Disilazane 125
2-Acetyl Thiophene 214 Hexane 69
2-Aminomethyl Pyridine 202 Hexene 64
2-Amino Thiophenol 70 Hexylene Glycol 198.3
2-Bromo Ethanol 149 HF/Pyridine(70%) -
2-Bromo Biphenyl 297 Hydrazine Hydrate 118
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2-Butyl Alcohol 99.5 Hydrobromic Acid 124
127-
2-Chloro Ethanol Hydrochloric Acid 50.5
136
2-Chloro Ethyl isocyanate 135 Hydrogen Peroxide 150.2
2-Chloro Pyridine 170 Iso Butanol 108
2-Fluoro Toluene 113 Iso Butylchlororformate 128.8
2-Fluorobenzyl Bromide 84 Iso Butyraldehyde 63
2-Methoxy 1-Propanol 130 Iso Propyl Acetate 89
2-Methyl Tetrahydrofuran 78 Iso Propyl Bromide 59
2-Methyl-1-Butanol 132 Iso Propyl Chloride 34
150-
2-MethylaminoEthanol Isoamyl Alcohol 132
159
2-Methylfuran 63 Isonicotinaldehyde 77
2-Phenyl Ethylamine 197 Isoparaffin 115
2-Pyridinecarboxaldehyde 181 Isopropenyl Acetate 94
2-Pyrrolidinone 245 Isopropyl Alcohol 82
2-Tetra Hydrofuroic Acid 128 Isopropyl Myristate BP 192.6
3,2-Dimethoxy Propane 81 Isovaleraldehyde 90
3 4 Difluoronitro Benzene 76 Lactic Acid 122
3- Chloro Aniline 230.5 m-Chloropyridine 148
3-Methyl-2-Butanone 94.2 Methacryloyl Chloride 95
3,3-Dimethyl Piperidine 136 Methane Sulfonic Acid 100
3,3-Dimethylbutyraldehyde 104 Methanol 63.9
3,4 Dichloro Benzoyl Chloride 242 Methyisobutylketone 116.8
3,4 dimethyl Benzylamine 178 Methyl Acetoacetate 169
3,4,5-Trimethoxy Toluene 117 Methyl Acrylate 80
3,4,5-Trimethoxybenzyl Alcohol 228 Methyl Cellosolve 124.4
3,4-Dihydropyran 86 Methyl Chloroacetate 130
3,5-Lutidine 169 Methyl Cyanoacetate 204
3-Amino-1-Propanol 187 Methyl Formate 31.5
3-Bromo-5-Fluorobenzonitrile 210 Methyl Iodide 42.5
3-Bromoanisole 210 Methyl Propyl Ketone 100
3-Butyn-1-ol 128.9 Methyl Tert-Butyl Ether 54
3-Chloro Benzaldehyde 213 Methylene Chloride 40
3-Chlorobenzy Bromide 109 Mono Isopropyl Amine 32
3-Cyclohexene-1-Methanol 80 Mono methyl amine - 40 % 48
3-Methoxy Benzaldehyde 143 Monoethylene Glycol 198
3-Methoxy Thiophenol 223 Morpholine 128.9
3-Methoxypropyl Amine 109 N- Benzylethanolamine 153
3-N,N,Dimethylamino Acrolein 279 n Butyl Acetate 126.5
4 -Amino Butyric Acid 60 N N Diethyl Aniline 217
N N N N-Tetramethyl
4-(Trifluoromethoxy)aniline 73 120
Ethylenediamine
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4-Amino-1-Butanol 206 N, O-Bis Trimethyl Silyl Acetamide 71
4-Chloro Ethylacetoacetate 209 N,N Diisopropylethylamine 127
4-Chlorobutyryl Chloride 173 N,N-Diisopropyl Carbodiimide 145
4-Ethylmorpholine 139 N,N-Dimethyl Acetamide 164
4-Fluoro Acetophenone 196 N,N-Dimethyl Aniline 192
4-Fluoro Aniline 188 N,N-Dimethyl Benzylamine 178
4-Fluoro Nitrobenzene 205 N,N-Dimethyl Eththylenediamine 104
4-Fluorobenzoyl Chloride 82 N,N-Dimethyl Propylene Urea 146
N,N-
4-Isobutylacetophenone 107 102
Dimethylformamidedimethylacetal
4-Methoxy Phenyl Acetone 145 n-Butanol 117.2
4-Methoxybenzyl Chloride 117 n-Butyl Amine 78
4-Methyl Acetophenone 226 N-Ethyl Piperzine 157
4-Methylthio Benzaldehyde 89-90 n-Heptane 98.4
4-Phenyl 1-Butanol 140 N-Hexyl Amine 131
4-Phenylbutyric Acid Nitrile 97 N-Isopropyl Aniline 206
5 Fluoro Benzaldehyde 181 Nitric Acid 86
5-Ethyl-2-Methylpyridine 178 Nitrobenzene 210.8
5-Fluoro-2-Nitrotoluene 97 Nitromethane 101.2
Acetic Acid 118 N-Methyl 2- Pyrrolidinone -
Acetic Anhydride 140 N-Methyl Morpholine 115
Acetoin 148 N-Methylaniline 196
Acetone 56 N-Methylpiperazine 138
Acetonitrile 81 n-Pentane 36.1
Acetophenone 201.7 n-Pentyl Amine 104
Acetyl Chloride 51 n-Propanol 97.4
Acrolein 52 n-Propyl Bromide 71
Acrolein Diethyl Acetal 125 O Toluidine 199
209-
Acrylonitrile 77.3 o-Chloro Benzaldehyde
215
Acryloyl Chloride 74-76 Ortho Phosphoric Acid 135
Allyl Bromide 71.3 Oxalyl Chloride 63
138-
Aniline 184 o-Xylene
143
Anisole 154 Petroleum Ether 30
Benzaldehyde 179 Phenyl Acetone 100
Benzene 80 Phenyl Chloro Formate 135
Benzene Sulphonyl Chloride 251 Phenylacetonitrile 234
Benzhydryl Chloride 140 Phenylchloroformate 74
Benzoyl Chloride 197 Phosphorous Tribromide 175
Benzyl Acetoacetate 275 Phosphorous Trichloride 74.2
Benzyl Acrylate 228 Phosporous Oxychloride 105.8
Benzyl Alcohol 203 Pinacolone 106
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Benzyl Amine 184 Piperidine 106
Benzyl Bromide 198 Pivaloyl Chloride 105
Benzyl Chloride 175 p-Methoxybenzyl Cyanide 286
Benzyl Chloro Formate 103 p-Methyl Benzaldehyde 204
Benzyl Ethyl Malonate - 85% 138 Propargylamine 83
Bis (Trimethylsilyl) Acetylene 136 Propionaldehyde 46
Bis(Trimethylsilyl)
145 Propionic Acid 141.1
Trifluoroacetamide BSTFA
Boron Trifluoride Diethyl Etherate 126 Propionic Anhydride 167
Bromine 58.78 Propionitrile 97.2
Bromo Benzene 156 Pyridine 115.5
Bromo Ethane 38 Pyridine-4-Carboxaldehyde 77
Bromo Nitro Methane 146 Pyrrole 130
Bromochloromethane 68.1 Pyrrolidine 87
Bromoform 149.50 R(+)-Glycidol 61
Sodium Methoxide Methanol
Bromotrimethyl Silane 77 69
Solution
Butyryl Chloride 102 Sulfuric Acid 315
Carbon Tetra Chloride 76.8 Sulfuryl Chloride 69.3
Chloro Acetaldehyde 85 Tert-Butyl Bromo Acetate 50
Chloro Acetic Acid 189 Tertiary Butanol 82
Chloro Acetonitrile 124 Tertiary Butyl Acetate 96
Chloro Acetyl Chloride 105 Tertiary Butylamine 46
Chloro Benzene 131 Tetra Ethyl Ortho Carbonate 159
Chloro Butane 78.5 Tetrahydro-4H-Pyran-4-One 166
Chloroform 60 Tetrahydrofuran 66
Chlorosulfonyl Acetylchloride 71 Thiazolidine 72
Chloro Sulphonic Acid 151 Thionyl Chloride 79
Collidine 171 Thiophene 84.14
Cyclohexane 80.7 Titanium Tetrachloride 136.4
Cyclohexanone 155.6 Titanium Isopropoxide 220
Cyclohexyl Isocyanate 168 Toluene 110.6
Cyclohexylamine 134.5 Tributyl Tin Chloride 171
Cyclopropane Carboxylic Acid 182 Tributylamine 216
Cyclopropylamine 49 Triethyl Ortho Formate 146
Decyl Oleate 363 Triethyl Phosponoacetate 118
Di Benzyl Amine 300 Triethyl Silane 107
Trimethylsilyl Trifluoromethane
77 Triethyl Silyl Chloride (TESCI) 142
Sulphonate
Tri-n-Butylamine 216 Triethylamine 89
Valeronitrile 139 Trifluoroacetic Acid 72.4
Valeryl chloride 125 Trimethyl Chloro Silane 58
Valeryl Chloride (Pentanoyl 125 Trimethyl Ortho Formate 101
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Chloride)

From the above mentioned listing, Petroleum Ether is highly volatile i.e., B.P. is
30°C,

So, Step - 1 is done.

Now, lets move to Step - 2.

Step - 2: Boil-up calculation,

This is somewhat crucial step in the whole process.

To generate maximum boil-up the utility in reactor jacket shall be Saturated

steam,
Jacket pressure: 0.2 Kg/Cm2. Temperature: 105.1 °C,[Refer Steam Tables]

A 10 KL SS reactor will have an Heat transfer area of 19.8 Sq.m,[Use this

Spreadsheet to calculate the HT Area - Learn it here]
Lets consider 70% occupancy, The effective HT area will be 13.86 Sq.m.

The boil-up shall be calculated based on the formula: M x ƛ = U x A x LMTD.

Petroleum Ether Properties:

Specific heat, Cp: 0.22 KCal/Kg.K,

Latent heat, ƛ: 85 KCal/Kg,
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You might also like:
[How to] Arrange pumps [ Series VS Parallel ]
What does a TR actually means ?

LMTD calculation: (ΔT1 - ΔT2) / ln(ΔT1/ΔT2)

ΔT1 = 105.1 - 30 = 75.1°C, ΔT2 = 105.1 - 35 = 70.1°C,

LMTD = (75.1 - 70.1) / ln(75.1/70.1) = 72.46°C.

Lets consider U = 250 KCal/Sq.m.hr.K,

U x A x LMTD = 250 x 13.86 x 72.46 = 251073 KCal.

M = 251073 / 85 = 2954 Kgs.

So, the boil-up is 2954 Kgs.

Step - 2 is successful.
Lets move to Step - 3.

Step - 3: Condenser Capacity calculation,

Lets use the basic formula,

(M x Cp x dT) + (M x ƛ) = U x A x LMTD.

Lets calculate,
(M x Cp x dT) + (M x ƛ) = (2954 x 0.22 x 5) + (2954 x 85) = 254340 KCal.
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For a condenser we'll consider U as 400 KCal/Sq.m.hr.K,

LMTD calculation: (ΔT1 - ΔT2) / ln(ΔT1/ΔT2),

Consider Chilled water as condenser utility,

Inlet utility temp.: 8°C, Outlet utility temp.: 15°C,

You might also like:

[How to] Design an Agitator ?
What capacity motor is suitable for reactor ?

ΔT1 = 30 - 8 = 22°C, ΔT2 = 30 - 15 = 15°C,

LMTD = ( 22 - 15 ) / ln( 22 / 15 ) = 18.276°C.

A = 254340 / (400 x 18.276) = 21.11 Sq.m.

Considering 20 % excess as safety, A = 21.11 x 1.2 = 25.34 ~26 Sq.m.

So, the required condenser capacity required for 10 KL SS reactor is 26 Sq.m

That's it......!!!

Hope you all got it, if any queries feel free to comment / message.

Comments are most appreciated........!!!

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[How To] Design a Scrubber [ Packed column ] (UPDATED) as on 07.02.2020

Ajay Kumar 4 years ago Calculations, design, pressure calculation, scrubber

Hello Readers, Good day all.........!!!

After many days i'm back with much more awaited post, i.e., designing a
Scrubber which shall be used for safe venting of vapours / gases from reactors /
vessels.

This post was requested by Mr. Nitin kheese a long back ago, and may be i
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think he should have forgotten also, and Mr. Nitin sorry for being late over this
query.

Before getting into the topic lets start with some basic stuff,

What is Scrubber & Whats its purpose ?

A scrubber is an object used for cleaning something unwanted thing, and in

Pharma terminology i..e, our words, it is simply a combination of blower system
and absorption system.

What is absorption ?

Absorption is simply grabbing a vapour/ gas or liquid into another liquid by

means of holding them in the voids spaces available in this another liquid. Also
there is some term which is called adsorption, which is same but instead of
another liquid, a solid comes into play.

You may also like:

[How to] Calculate Product assay in liquid ?
Alternative for Reaction calorimetry

What is blower ?

This term is the main heart of the scrubber, without a blower a scrubber is
simply a re-circulation column. Blower is used to blow out the vapours / gases
those are produced in a reaction reactor or to remove the unwanted vapours
generated because of breathing losses in storage vessels.

What are the major components of the scrubber ?

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There are majorly 4 major components according to me,

1. Blower,
2. Re-circulation pump,
3. Column,
4. Collection / holding tank.

If anyone have any other major components, then kindly comment / message
me, i'll add those here.

What is the principle of scrubber ?

May be i should have posted this question at the top, but sorry for not 😆, the
principle of scrubber is gas liquid absorption.

What is Packing factor, Fp ?

Packing factor is the ration of packing surface area per unit volume to cube of
the packing's void fraction.
Holds the unit of m-1.

You may also like:

[How to] Calculate rate of distillation in batch reactor ?
Calculate density of Reaction mass

What are the types of packing's used in scrubbers ?

Usually, there may be many packing's, but i know only three sort,

1. Super intallox,
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2. Intallox saddles,
3. Pall rings.
4. Random packing's

Again there will be sub categories based on the MOC, like ceramic, metal,
Plastic, etc.

By now, basic stuff is completed,

Lets start out show,

Design calculations of Scrubber,

Out of these let us start from the damn basic thing, i.e., Collection / holding
tank.

Usually a collection tank is nothing but a vessel which contains water / caustic
lye,
Directly i've mentioned water / caustic lye because usually in a pharma field we
will use that.

If the fumes that were sucked by blower are acid then we will go for lye, and if
other than that we will go with water, also the selection depends on the
solubility.

Lets have an example, the reaction that's is carried out in the reactor generates
1000 Kgs of spent in form of vapour per hour and the component to be scrubbed
is HCl vapour, which is produced at a rate of 70 Kg/hr and the volume percent
of HCl vapour is ~6%(v/v). Scrubbing medium is 20% caustic solution.

Lets start,
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For performing the design calculations, there will be some of the considerations
that we have to made, especially for the packing materials
As the saddles would be cheap, for ensuring cost effectiveness, i'm considering
intallox saddles.

Input Data:

Packing type : Intallox saddles,

Packing size : 25 mm,
Packing MOC : PP,
Gas pressure drop per m of bed : 15 mmWC / m of bed, [Considered Value]
Packing factor, Fp : 21 / m, [Considered value]
Characteristic packing factor, Cf : 32 [ refer below table ],
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You may also like:

[How to] Prepare installation qualification ?
[How to] Prepare Operational qualification ?
As the vapour requires a medium, we have to consider the carrier gas i.e., air
along with the desired component which need to be scrubbed.

Carrier Gas properties :

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Gas flow rate (Air) : 1000 Kg/hr = 0.2778 Kg/sec,
Gas entry pressure : 1.00 atm,
Gas temperature at entry : 30 degC,
Gas mol. wt. : 29 g/mole

Component to be scrubbed :

Component flow rate : 70 Kg/hr,

% component in gas : 6%
Molecular wt. of component : 36.5

For scrubbing HCl fumes, i've selected Caustic solution 20%, but i should be
able to calculate the theoretical amount of caustic required in this case. So, i
would like to perform the material balance:

HCl NaOH NaCl H2O

36.5 40 58.5 18.02
70.00 76.71 112.19 34.56
1.92 1.92 1.92 1.92

As per the material balance, HCl moles is 1.92, so theoretically caustic required
is 1.92 moles, which is equivalent to 76.71 Kgs, so i'll round it off to 77 Kgs.
Scrubbing medium properties :

Scrubbing medium : 20% caustic,

Liquid flow rate : 77 Kg/hr = 0.0214 Kg/sec
Liquid density : 1100 Kg/Cu.m
Liquid Viscosity : 3.5 Cp = 0.0035 N.Sec/Sq.m,
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Gas Density Calculation :

Average molecular wt. of gas = 29.45 g/mole,

Gas in flow rate = 0.2778 / 29.45 = 0.0094 Kmol/sec,
= (Kmole/sec) x (T in K / 273.15) x ( 1 atm / pr. in atm) x (22.414/1),
= 0.234499 Cu.m/Sec.

You may also like:

[How to] Prepare design qualification ?
[How to] Evaluate User Requirement Specification ?

So, now we have determined total of three flowrates for the gas,
1. Molar flow rate = 0.0094 Kmol/Sec,
2. Volumetric flow rate = 0.234499 Cu.m/Sec,
3. Mass flow rate = 0.2778 Kg/Sec,

Gas Density = Mass flow rate / Volumetric flow rate = 1.1846 Kg/Cu.m,

As of now basic detailing regarding flowrates is done, and we need to go

calculating the cross sectional area of the tower /column.

Column Cross-Sectional area Calculation

Now, Assuming complete absorption of the desired HCl vapour into scrubbing
medium,
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Component removed = molar flow rate x % component x mol. wt.
= 0.0094 x (6/100) x 36.5 = 0.0207 Kg/Sec,
Liquid leaving the packing (L') = inlet liquid flow rate + Component removed
= 0.0207 + 0.0214 = 0.0420 Kg/Sec.

(L' / G') x (ρg / ρl)^0.5 = (0.0420/0.2778) x (1.1846/1100)^0.5 = 0.00497,

Use the 0.00497 as ordinate, and pressure drop of 147.1 (N/Sq.m)/m,

find the abscissa from the below graph,

[(G' ^ 2) x Cf x (μl^0.1) x J ] / [ρg(ρl - ρg)gc] = 0.04 [from graph],

Now, Outlet flowrate of gas through the column (G') = [ 0.04 x ρg(ρl-ρg)gc/(Cf
x (μl^0.1) x J)]^0.5,

= 1.6665 Kg/Sq.m.Sec,
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** Pl don't confuse between the initial G' and the current G', the initial G' i.e.,
X-axis will represent the inlet flowrate of gas and the Y - axis G' will represent
the outlet flowrate of gas.

Column cross section area = Gas mass flow rate / G' = 0.2778 / 1.6665 = 0.1667
Sq.m,

Column dia = 0.461 m,

That's it....!!!

07.02.2020
Due to receipt of continuous requests for the blower capacity, hydraulic
power estimation, Flooding % & HETP calculations, extending the post.

Now i'm extending the post a little bit to further explain you to calculate the
blower capacity, hydraulic power requirement, HETP and the amount of
flooding.

Basically, the blower capacity and the hydraulic power is calculated based on
the estimated pressure drop inside the tower,

Pressure Drop Estimation

There will be total 4 types of considerable pressure drops happening inside the
tower,
1. Pressure drop due to dry packing,
2. Pressure drop due to irrigation of liquid over dry packing,
3. Pressure drop due to the internals (packing supports + distributor plate),
4. Pressure drop due to contraction losses of gas.
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Now we have to estimate all four, to get the overall pressure drop.

i. Pressure drop due to irrigated packing = Total packing height x Pressure drop
across packing = 147.1 x 3 = 441.3 N/m2,

ii. For dry packing,

outlet gas flowrate =
(Gas inlet flowrate - Component to be scrubbed) / Column cross-sectional area
= ( 0.2778 - 0.0207 ) / 0.1667 = 1.54 Kg/m2.sec.

Gas outlet pressure = 1 x 101325 - 441.3 = 100883.7 N/m2,

Outlet gas density = (100883.7 / 101325) x (36.5 / 22.414) x (273.15 / 303.15) =

1.46 Kg/m3;

Pressure drop due to dry packing (ΔP / z) = Cd x (G'^2/⍴g);

Cd for 25 NB intallox saddles is 96.7, [Refer top table i.e., properties of

packings],

ΔP / z = 96.7 x (1.54^2 / 1.46) = 157.07 N/m2;

iii. Pressure drop due to internals,

Assuming 25 mmWC = 25 x 9.80665 = 245.17 N/m2.

iv. Pressure drop due to contraction losses,

Lets say, gas velocity be 6 m/sec,
Contraction losses = 1.5 x v^2/2gc = 1.5 x (6^2/(2 x 1)) = 27 N/m2.

Total Pressure drop = 441.3 + 157.07 + 245.17 + 27 = 870.54 N/m2.

Required hydraulic power = Pressure drop x (Total flow - Scrubbed gas flow) /
Outlet gas density
= 870.54 x (0.2778 - 0.0207) / 1.46 = 153.29 N.m/sec = 0.1533 KW,
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Considering 60% efficiency, 0.1533/0.6 = 0.255 KW = 0.34 HP.

Required blower capacity = Hydraulic power x 1714 / (0.1771 x blower

efficiency)
= 0.34 x 1714 / (0.1771 x 0.6) = 5516.54 GPM = 5516.54 x 0.1605 = 885.41
CFM = 1504 m3/hr.

Flooding Estimation across column

Vapour liquid flow factor Flv = (Liquid flowrate/Gas flowrate) x (Gas
density/Liquid density)^0.5
= (0.0214/0.2778) x (1.1846/1100)^0.5 = 0.0025
Norton's correlation curves - Generalized pressure curves

Using the above curve and plotting the flow-factor of ~0.01 at 15 mmWC
curve(based on initial assumption),
K4 = 0.6, K4(flooding) = ~8;

Ideal flooding = (0.6 / 8)^0.5 x 100 = 6.25 %,

Mass flowrate of gas = [K4 x ρV x (ρL - ρV) / (13.1 x Fp x (µL / ρL)^0.1)]^0.5

= [0.6 x 1.1846 x (1100 - 1.1846) / (13.1 x 21 x (0.01/1100)^0.1]^0.5 = 3.01
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Kg/m2.sec,

Ideal column cross sectional area = Inlet gas flow / mass flowrate = 0.2778 /
3.01 = 0.0922 m2,

Actual flooding = Ideal flooding x (Actual cross sectional area / Ideal cross
sectional area)
= 6.25 x (0.1667/0.0922) = 11.3 %.
[For effective scrubbing the flooding should be less than 70%]

HETP Prediction

As per Norton correlation, Ln HETP = n - 0.187 x Lnσ - 0.213 x Ln μ

= 1.1308 - 0.187 x Ln 80 - 0.213 x Ln 1 [σ - Surface tension; μ - Viscosity in
cP]
= 1.1308 - 0.819 - 0 = 0.311.

HETP = 1.365 ft = 0.416 m;

No. of theoretical stages required = Total height of packing bed / HETP =

3/0.416 = 7.21 ~8 stages.
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Overall Heat Transfer Co-Efficient Calculation

Ajay Kumar Kalva 6 years ago Calculations

Hello guys........Hope all are enjoying the start of these weekend !!

Today i wanna add a full stop for many peoples fantasies of 'U' value
calculation, the most common line that i heard from many engineers was
Consider U as 150 for Reactors and 450 for Condensers, in return if you ask
them what are the units for those 150 and 450, many of them will take some
strategic time out as in IPL.

An Engineer is the one who holds the ability to deal any of the situation with
a smart work, but not the one who follow the Thumb blindly, i'm not criticizing
the Thumb, as many cases i too prefer the Thumb rules in practical cases but my
intention is An Engineer should be able to derive the U value if needed.
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And for that we need to know some basics, before going into topic.

What are Heat Transfer Co-Efficient?

Heat transfer coefficient is a quantitative characteristic of convective heat

transfer between a fluid medium (a fluid) and the surface (wall) flowed over by
the fluid.

Also Read:

How to Design a Condenser?

How to Select a Pump , Motor, Line Sizings ?

What is Overall Heat Transfer Co-efficient?

Overall Heat Transfer Co-efficient is the combination of the possible Individual

Heat Transfer Co-efficient, which are due to the following Heat Transfer
modes,
1. Rate of convective heat transfer from Fluid to Medium Wall, and

2. Conductive Heat Transfer from Medium Walls one end to other end,

3. Convective Heat Transfer from Medium wall to inside Fluid.

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Credits: TLV.com

What is Thermal Conductivity?

Thermal Conductivity of a material characterizes the Rate of Heat Transfer of a

material, whether the heat is flowing in or out.

The thermal conductivity - k - for some typical materials (varies with

temperature)

 Polypropylene PP : 0.1 - 0.22 W/mK

 Stainless steel : 16 - 24 W/mK
 Aluminum : 205 - 250 W/mK
 Glass lining : 1.2 W/mK
What are the units of Overall Heat Transfer Co-efficient and How are they
derived?

British Units for U are Btu/(hr-ft2°F) , SI units for U are Watts/Sq.m .°K or
KCal/Sq.m .sec.°K

They are basically derived from the formula Q = U x A x LMTD,

where Q holds the units Watts , A - Sq.m, LMTD - °K or °C.

So, that's how U units were derived.

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Credits: engineersedge.com

What will be the Trend of Convective Heat Transfer Co- efficients?

The Convective Heat Transfer Trend will be as follows:

Fluid Convective heat transfer coefficient (h)

Water about 1000 W/(m2°C)

Hot Water 1000 – 6000 W/(m2)°C

Steam 6000 – 15000 W/(m2°C)

The convection heat transfer coefficient - h - depends on

1. The type of fluid - gas or liquid,

2. The flow properties such as velocity,
3. Other flow and temperature dependent properties.
Convective heat transfer coefficient for some common fluids:

 Air - 10 to 100 W/m2K

 Water - 500 to 10 000 W/m2K
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So, I think right now you acquired some courage to drive the fantasy of 'U'
value calculation from your mind. And, i'll start the main show now.

Recommended Read:
How To Select a Condenser?
Determine the Power Required for an Operation?
Industrial Distillation Column Design Steps

U value Calculation:

For calculation of U value we need some basic data regarding the Jacket fluid
properties, Vessel Mass properties, Jacket properties, Equipment Physical data
etc.

General Data includes: Vessel Dia, Vessel MOC, Vessel wall thickness.

For Calculating Overall Heat Transfer Coefficient we need Individual Heat

Transfer Co-efficients used in the following co-relation.

1 / U = ( 1 / hj ) + ( Fj ) + ( X/K ) + Fv + ( 1/hi )
The hj, hi need to be calculated primarily,

Jacket Side Heat Transfer Co-efficient Calculation:

For Calculation of hj , we need to know Pipe coil ID, Flowrate in pipe, Fouling
factor Fj, Fluid properties[Density, Viscosity, Specific heat, Conductivity],

With an example i'll illustrate here,

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Let pipe ID is 2", Flowrate(Q) is 10 Cu.m/hr, Fouling factor(Fj) = 0.0002

h.m2.°C/Kcal,

Density (rho) 1000 Kg/Cu.m, Viscosity(μ) 0.01 cP, Specific heat (Cp) 0.9
KCal/Kg.°C, Conductivity(k) 0.2 KCal/m.h.°C,
Viscosity @ wall is (μw) = 0.01 cP

Velocity, V = Q/A = 2.7410 m/sec

Reynold's number, Nre = D x V x rho / μ =17638677,
Prandtl's number, Npr = Cp x μ / k = 0.2093

using the below co-relation ,

hj x D / K = 0.023 x ( Nre ^ 0.8 ) x ( Npr ^ 0.33 ) x (( μ/μw)^0.14)

hj = 27202.81 Kcal/h.m2.°C

Also Read:

Agitation Scale up
How to find Reactor Heat Transfer Area?

Vessel Side Heat Transfer Co-efficient Calculation:

For this calculation we need to know the inside fluid properties, which includes
Density, Viscosity, Conductivity, Specific Heat, Viscosity @ wall.

Within an example i'll illustrate here,

Agitator RPM 36, Agitator Dia 36", Density (rho) 900 Kg/Cu.m, Viscosity(μ)
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2cP, Specific Heat(Cp) 1KCal/Kg.°C, Conductivity (k) 0.5 KCal/m.h.°C,
Viscosity @wall (μw) 1 cP, Fouling factor(Fv) 0.0002 h.m2.°C/Kcal,

Reynold's number, Nre = N x D^2 x rho / μ = 313548,

Prandtl's number, Npr = Cp x μ / k = 14.4

Now, Individual Heat Transfer Co-efficient hi is Calculated by following co-

relation,

hi x D / K = 0.53 x (Nre ^0.66) x ( Npr ^ 0.33) x (( μ/μw)^0.24)

hi = 1441.16 Kcal/h.m2.°C

So, Now our task came to an end,

U value Calculation,

1 / U = 1/hj + Fj + X/K + Fv + 1/hi

1 / U = 1/27202.8 + 0.0002 + 0.0007 + 0.0002 + 1/1441.2

U = 537.019 Kcal/h.m2.°C

That's it............Task Completed Cheers....!!