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STUDENTS NAME:
HANEARYTHA LITAD CHARLES
2014679702
SUPERVISOR:
MS CHRISTINA VARGIS
EQUIPMENT DESIGN
3.3.1 INTRODUCTION
289
Figure 3.2 Plug Flow Reactor Schematic.
Source: Excerpted by special permission from Chem. Eng., 63(10), 211 (Oct.
1956). Copyright 1956 by McGraw-Hill, Inc., New York, NY 10020.
There are several assumptions that have been made in order to design the
reactor:
290
3.3.4 SELECTION OF EQUIPMENT
There are many types of reactor that can be applied to produce the
Tetrafluoroethylene through the pyrolysis of Chlorodifluoromethane. Basically,
the types of reactor that can be used in the worldwide for the pyrolysis of
Chlorodifluoromethane are Tubular Flow Reactor and Packed Bed Reactor. For
this plant, Tubular Flow reactor was chosen as it does not require any catalyst.
Below are the comparisons of three types of reactor that are commonly used for
continuous production.
291
3.3.5 DESIGN INPUT PARAMETER
Inlet Outlet
Condition Stream 4 Stream 5
Temperature ( C) 450 810
Pressure (kPa) 705 655
Phase vapor vapor
Table 3.3 Inlet and outlet stream of the Pyrolysis reactor R-101.
Table 3.4 Properties and volumetric flow rate of reactant and product.
Description Values
3.66 kg/m3
Density of Chlorodifluormethane
1122.301 m3/hr
Total volumetric flow rate at inlet stream
1.52 kg/m3
Density of Tetrafluoroethylene
1.49 kg/m3
Density of Hydrogen Chloride
1122.301 m3/hr
Total volumetric flow rate at outlet stream
292
3.3.6 DESIGNING PROCEDURE OF TUBULAR FLOW REACTOR (PFR).
Figure below shows the flow chart of the chemical design of the Tubular Flow
Reactor (R-101).
Step 1: Determination of
the Chemical Reaction rate
Law.
Step 2:Determination of
the Reaction Rate
Constant.
Step 4: Determination of
residence time
Step 5: Determination
diameter and height of
reactor.
Figure 3.3 Steps in determining the chemical design of Pyrolysis Reactor (R-101)
293
Step 1: Determination of the Chemical Reaction Rate Law
Forward Reaction:
22 2 = 2 + 2, = [2 ]2
2 + 2 , = [ ]2
Reverse Reaction:
2 = 2 + 2 22 , = [2 = 2 ][]2
+ 2 2, = [ ][ ]2
= +
= [ ]2 + [ ][ ]2
= [2 2]
1
=1+ 1
2
= 0.5
294
Concentration of each component
A stoichiometry table was constructed as below in order to find the concentration of each component that exists in the reactor.
Chlorodifluoromethane, 2 A = (1 )
=
(1+ )
Tetrafluoroethylene, 2 4 D = (1 )
=
(Product) (1+ )
Hydrogen Chloride, C = (1 )
=
(By-product) (1+ )
The concentration of Component B does not included in the stoichiometry table due to very small concentration and it is also an
intermediate product.
Where,
, = Molar flow rate of each component,
, = Concentration of each component,
3
295
1. Component A (Chlorodifluoromethane)
In order to find the initial concentration of chlorodifluoromethane, the molar
flowrate of reactant at inlet of reactor is divided with the density of reactant.
Initial concentration:
0 = 47.50 1122.30 3
0 = 0.04232
3
Final Concentration:
= 0.04232 (1 0.95)
3
= 0.002116
3
2. Componenent D (Tetrafluoroethylene)
In this reaction, Tetrafluoroethylene only exist in the outlet stream. Therefore,
there is no initial concentration of Tetrafluoroethylene at the inlet stream. The
final concentration of Tetrafluoroethylene can be obtained by multiplying the
molar fraction with the molar flowrate of Chlorodifluoromethane at inlet stream
and conversion of 95%.
Initial concentration
0 = 0
Final concentration:
= 0.5783 0.04232 3
(0.95) = 0.0232
3
= 0.0232
3
296
Initial concentration
0 = 0
Final concentration:
= 0.4217 0.04232 3
(0.95) = 0.0169
3
Rate of Reaction
The main reaction that involves in the Tubular Flow Reactor is the pyrolysis of
Chlorodifluoromethane to produce Tetrafluomethane and Hydrogen Chloride.
The kinetics of pyrolysis of chlorodifluoromethane that been studied by Percy B.
Chinoy et al., (1987) and states that equations below be applied to obtained the
reaction rate constant of the pyrolysis of Chlorodifluoromethane that occur in the
Tubular Flow Reactor.
. 1
1 ( 1 ) = 1013.84 exp (55.79 )
22 2 = 2 + 2 at T = 1083K (810 C)
= [2 ]2
. 1
( 1 ) = 1013.84 exp (55.79 (1.987103 )(1083))
= .
297
Step 3: Determination Volume of Reactor
The volume of reactor is the functions of the inverse of the reaction rate. Table
3.6 Shows the rate data to plot Levenspiel plot.
Thus from table 6, it can be concluded that 10.9761 m 3 volume of Tubular Flow
Reactor needed for the pyrolysis of Chlorodifluoromethane with 95 % conversion.
Although the conversion of reaction is 100 % at 810 and 655 kPa (Ebnesajjad,
2016), the volume of reactor needed for that conversion is very large and this will
contribute to high cost of equipment. Therefore, volume of 10.9761 m 3 was
taken as the volume of the reactor with optimum conversion which is 95 %.
298
Graph of Conversion, X Versus 1/-ra
0.6
0.5
0.4
1/-ra
0.3
0.2
0.1
0
0 0.2 0.4 0.6 0.8 1
Conversion, X
The reactant spent inside the reactor before converting into product.
=
0
10.9761 3
=
3 1
1122.3
3600
= .
Diameter of reactor
3
=
3 10.9761
=
= .
299
Height of reactor
4
=
2
4(10.9761)
=
(1.517)2
= .
Step 6: Calculating the Velocity of the gas reactant across the reactor
0
=
( )
3
0.3117
=
(1.517)2 /4
= .
From Table 12.3 (Colson & Richardsons Chemical Engineering), below is the
standard tube diameter and length that was chosen for the Tubular Flow Reactor:
Inside diameter, Di = 46 mm
Outside diameter, DO = 50 mm
Length of Tube = 6.10 m
Volume of a tube
02
=
4
(50 103 )2
= 6.10
4
= .
300
Number of tube required
The tube in the Tubular Flow Reactor will be arranged in Triangular pitch, =
1.25 . The information of number of passes and constant, K 1 and N1 were
obtained from Table 12.4 (Coulson Richardsons Chemical Vol.6 Chemical
Engineering Design).
No. passes =4
K1 = 0.175
N1 = 2.285
= 1 ( ) 1
Where;
: Number of tubes
: bundle diameter, mm
: Tube outside diameter, mm
1517 2.285
= 0.175( )
50
The pressure drop for gases flowing through pipes without packing / catalyst can
be neglected (H. Scott Fogler, Element of Chemical Reaction Engineering Fourth
Edition 2006). For the pyrolysis of Chlorodifluoromethane the pressure drop can
be neglected as there is no catalyst being used for the reaction.
301
Table.3.7 Summary of Chemical design for Pyrolysis Reactor R-101
Parameter Value
Volume of reactor 10.9761 m3
302
3.3.7 MECHANICAL DESIGN
Step 4:
Step 1: Design Step 2: Design Step 3: Material
Corrosion
Pressure Temperature of construction
allowance
Step 6:
Step 8: Weight Step 7: head and Step 5: Welded
Minimum wall
load closure Joint efficiency
thickness
Step 17:
Manhole design
Figure 3.5 The flow chart of the mechanical design for Pyrolysis reactor (R-101)
303
Step 1: Design Pressure
Operating pressure,
1
= 705 103
1 105
= 7.05
Designed pressure,
= (7.05 1) 1.1
= 6.655
= 0.6655
2
Design Temperature,
= 810
304
Step 3: Material of construction
Table 3.8 Maximum allowable stresses. source : ASME sec II part D version
2010
Corrosion allowance is the additional thickness that is allowed for the material to
loss through corrosion, erosion or scaling (Coulson Richardsons Chemical,
Vol.4). The corrosion allowance for this reactor will be 4.00 mm as it will be
operated at more severe condition (very high temperature).
The Joint efficiency for this reactor is 1 as lower joint factor will result in a thicker
and heavier vessel (Sinnot, 2005)
The minimum wall thickness is required to ensure that the vessel can withstand
its own weight and any incidental loads.
305
= +
2 1.2
(0.6655)(1.517 1000)
= +4
2(37.577)(1) 1.2(0.6655)
= .
Where,
= (0.6655 )
2
= (1.517 )
= (37.577 )
2
= (4 )
= (1)
Heads usually serve as closure which positioned at the end of cylindrical vessel.
There are three types of heads that typically used in industries which are
Hemispherical heads, Ellipsoidal heads and Torispherical heads.
1. Hemispherical head
=
4 0.4
(0.6655)(1.517 1000)
=
4(37.577)(1) 0.4(0.6655)
= 6.730
2. Ellipsoidal head
=
2 0.2
306
(0.6655)(1.517 1000)
=
2(37.577)(1) 0.2(0.6655)
= 13.457
= 13.457 + 4 ( )
= 17.457
3. Torispherical head
0.885
=
0.1
0.885(0.6655)(1.517 1000)
=
(37.577)(1) 0.1(0.6655)
= 23.819
The ellipsoidal type of head was chosen as the closure of the reactor because
the thickness is nearly equivalent to the wall thickness which is 18 mm. It is
crucial to select the suitable type of head to avoid any possibility of reactors
failure which might trigger undesired event of accident. Therefore, ellipsoidal
head was chosen as the closure of the reactor.
Weight of vessel
= 240 ( + 0.8 )
Where,
307
= 240(1.15)(1.517)(5.31 + 0.8 1.345) 18 x 10 3 m
= .
Weight of tube
(02 2 )
, =
4
Where,
= .
Volume of insulator
= (1.517)(6.12)(75 103 )
= .
Weight of insulator
= 1
= (130)(2.187)(9.81)
= .
308
Where,
= + +
= .
2
=
2
Where,
2
= 0.05
= 1280 /2
Where,
309
=
Where,
=1.568 m
= (. ) = . /
Thus,
(. )(. )
= = .
=
4
(0.6655)(1.517 1000)
= = 14.02
4(18) 2
=
2
(0.6655)(1.517 1000)
= = 28.04
2(18) 2
310
Dead weight stress
=
( + )
110116
= = 1.268
(1517 + 18)18 2
Bending stress
= ( + )
2
Where,
= (04 4 ) = 1.828 1010 4
64
= 1.596
2
() = 14.02 1.268 + 1.596 = 14.348
2
() = 14.02 1.268 1.596 = 11.156
2
311
14.348 11.156
28.04 28.04
= ()
= 28.04 11.156
= 16.884
The differential stress was found to be below the allowable design stress (fs =
37.75)
= 2 104 ( )
18
= 2 104 ( )
1517 + 2 18
= 231.809 /2
Maximum compressive stress occurred when the vessel is not under pressure,
312
= +
= 1.268 + 1.596
= 2.864
2
From the calculation above, it shows that the maximum compressive stress is
below the critical value and thus it is acceptable.
The type of element that was chosen for the design of furnace is KANTHAL
SUPER 1700. This type of element is generally used in most types of industrial
furnaces for heat treatment for forging, sintering, melting and refining of glass.
This type of element can exceed to temperature of 1700 C. Since the operating
temperature is 810 C of reactor (R-101) (which is below the limit of maximum
temperature), this element can be used for the heating of chlorodifluoromethane
(product) to produce tetrafluoroethylene and hydrogen chloride (by-product).
Table 3.9 The mechanical and physical properties of the KANTHAL SUPER
electrical heating material.
Four-shank 1700 elements was chosen for this reactor because it is the best
choise for horizontally mounted elements (AB, 1999). The advantage of having
Four-shank 1700 elements is that fewer elements needed if compared to two-
shank elements and making four-shank element more economical. For this
design, KANTHAL SUPER 1700 9/18 was chose with the following standard
specifications;
313
Lu = 450 mm
Le = 450 mm
B = 400 mm
a = 3 x 60 mm
= + ( 2)
+ ( 2)
= 1.703
314
By referring to the standard steel saddles (adapted from Bhattacharyya, 1976) in
figure 3.7, vessel diameter of 1.8 m will be taken into consideration as the
standard vessel diameter shows the closest size with the DiameterTotal of Reactor
(R-101).
There are several guideline that was given by Scheiman for proper selection of
anchor bolt:
1. Bolt that have diameter that smaller than 25 mm should not be used.
2. Minimum number of bolt being used is 8.
3. Use multiple bolt of 4
4. Bolt pitch (distance between bolts) should be less than 600 mm.
315
Figure 3.8 Typical flange ring design. a) Rolled Angle b) Plain flange ring c)
Double ring with Gusset or bolt chair design (R.K. Sinnot, 2005)
1 4
= [ ]
Where,
: Number of bolt
1 4(66.247 103 )
= [ 96.746 103 ]
(12)(125) 1.5
= 53.28 2
316
Figure 3.9 Anchor bolt chair design
Based on the above calculation, M24 bolt size was chosen as it is the lowest root
area from the table.
Bolt spacing
(1500)
=
8
= 589.04
4
= [ 2 + ]
= . /
1
= +
103
Where,
56952.632 1
= +
7 103
= .
317
The minimum thickness
3
=
Where,
= The distance from the edge of skirt to outer edge of the ring (Assume to
be 150 mm)
56952.7
=(150
+ 13 + 50) 103
= 0.2674 N/mm2
3(0.2674)
= 150
140
= 11.35
318
Bolted flanged joints
Figure 3.10 Flange types and faces (a) Full-face (b) Gasket within bolt circle (c)
Spigot and socket (d) Ring type joint.
There are various types of flange that available and used in industries in a range
of types, sizes and materials and flange is usually used for pipes, nozzles and
other attachments to pressure vessels. The standard that is provided is based
on pressure, temperature and material of construction.
319
Step 16: Design of nozzle
1. Inlet (Reactant)
Where,
= 293(1.141)0.53 (3.66)0.37
= 194 200
By referring to Figure 4, the nominal size of flange that suitable for that size is
200 mm.
2. Outlet (Product)
Where,
= 293(1.141)0.53 (1.50)0.37
= 270 300
By referring to Figure 4, the nominal size of flange that suitable for that size is
300 mm.
320
Step 17: Design of manhole
Actual thickness
= (0 )/2
= (1.703 1.517)/2
= 0.093 = 93
Minimum thickness
1 = /(2 )
1 = (0.6655)(1517)/(2(37.75) 0.6655)
1 = 13.49
Distance
Lengths
1517
= = = 758.5
2 2
Area removed
13.49 1517
= = = 10,232 2
2 2
321
Compensation area
= 19.152
322
Table 3.10 Summary of Mechanical design
Parameter Value
Operating pressure 6.55 bar
Design pressure 0.6105 N/mm2
Material of construction Stainless steel
Weight load
weight of vessel 34.758 kN
weight of tube 59.199 kN
weight of insulator 2.789 kN
Total weight of vessel 96.746 kN
Wind loading
Wind load per unit length reactor 1994.24 N/m
Bending moment any plane vessel 37346.5 N/m
Analysis of stress
Longitudinal pressure stress 17.810 N/mm2
Circumferential pressure stress 35.620 N/mm2
Dead weight stress 1.548 N/mm2
Longitudinal stress upwind 17.838 N/mm2
Longitudinal stress downwind 14.686 N/mm2
Elastic stability
Critical bulking stress 168.502 N/mm2
Max compressive stress 3.124 N/mm2
Vessel support
Type of support Saddle support
Material Carbon steel
Nozzle
Inlet diameter 200 mm
Outlet diameter 300 mm
323
REFERENCES
324