Reaction Kinetics:

C6H6 + 4.5O2

K1

C4H2O3 + 2CO2 + 2H2O

(R1)

C6H6 + 4.5O2

K2

6C0 + 3H2O

(R2)

C4H2O3 + 3O2

K3

4C02 + H2O

(R3)

r1 (Kmole/kgcat.sec) = k1CB
r2 (Kmole/kgcat.sec) = k2CB
r3 (Kmole/kgcat.sec) = k3CMAN

K1 = 0.0595 (m3/Kgcat.sec)
K2 = 0.01288 (m3/Kgcat.sec)
K3 = 0.0207 (m3/Kgcat.sec)

Weight of catalyst
On the basis of first reaction

1
W
1

1   ln

  X 
F K C
1  X

Where,
Reactant Flow rate, F
= 9.836 x 10-3 (kmole/sec)
Reaction Constant, K1
= 0.0595 (m3/Kgcat.sec)
Reactant Concentration, C = 0 .000566 (Kmole/m3)
Fractional Volume Change,  = - 0.091
Conversion (First Rex), XA = 0.73

So,



9.836 x 10  3
1

1  0.091ln
 0.091 x 0.73
0.0595 x 0 .000566
1  0.73

W = 3670.18 Kgcat

Type and volume of Catalyst

A mixture of V2O5 (70%) and MoO3 (25-30%) having average particle size of 5mm
is used as catalyst in the process
Bulk density of catalyst, c = 1200 Kg/m3

Bed void fraction, = 0.4

Volume of catalyst

= 3670.18/1200
= 3.058 m3

Reaction Volume:
Vr = Vcat / (1 - )
= 3.058 / (1 - 0.4)
= 5.097 m3

Tube length and diameter

Assuming tube length of 2.5 m and taking the diameter of tube to prevent deviation from
plug flow assumption. Dt/Dp > 10
Where,

Dt = diameter of tube
Dp = diameter of particle
Tube Dimensions:
Tube outside diameter do = 60.45 mm
Tube inside diameter di = 52.50 mm (Schedule No. 40)
Total number of tubes Nt

 

!"
#4 . %& ' . (

= 5.097 / (/4 x 0.052502 x 2.5)

= 940

So,

Tube layout
Assuming triangular pitch arrangement then

P
Where P

So,

= 1.25do

= tube pitch

do

= outside tube diameter

= 0.07556 m

Number of tubes at bundle diameter

N+  ,

4N-  1

3

ND = number of tubes at bundle diameter

Where,

ND = 35
Shell Inside diameter:

So,

So,

D i = P[N D + 1]

Shell inside diameter,

Di = 2.75 m

Shell Height:
Length of tube

2.5 m

Leaving 20 % spacing above and below

= 2 (0.2 2.5) + 2.5

So height of shell

= 3.5 m

PRESSURE DROP
Tube side pressure drop
Using Eurgen equation.

P 1 G 150(1 )

= 3
+ 1.75G
L D P f g c
DP

= bed void fraction = 0.4

DP = particle diameter = 0.5 cm

f = feed density = .0012 g/cm3

= viscosity of feed = 3.19 x 10-4 g/cm. Sec

gc

= 980.67 cm/sec2

= length = 2.5 m = 250 cm

./012345&4( 6477 81(95&0:, < 

Total flow area

= Nt . /4. di2

311% 6477 3(9= 2401

0904( 3(9= 4214

= 940 x /4 x 0.052502
= 2.039 m2
Total mass flow rate = 19.44 kg/sec
So,

Interfacial mass velocity

= 0.9533 g/cm2.sec

Putting values in above eq. gives

P = 655.32 gm/cm2
And 1033.074 g/cm2 = 1 atm

P = 0.634 atm

So

Shell side pressure drop:

Heat duty

Q = 2.76 x 107 Kj/hr

Cooling media
Molten salt mixture of Sodium Nitrate (60%) and Potassium Nitrate (40%) is used
to recover heat from the reactor
Specific heat capacity of salt mixture, Cp

= 144.40 Kj/kmole-K

Temperature difference, T = 20K

Average molecular weight of salt = 94.7 Kg/Kmole
Molten salt required:

Q = m.Cp.T
2.76 x 107 = m x 144.40 x 20
So molten salt flow rate, m = 9556.78 kmol/hr
Mass flow rate, mw = 251.20 Kg/sec
Shell side flow area:

Where,

>?  #4 @AB '   %C ' D

Di = shell inside diameter = 2.72 m

Nt = total number of tubes = 940

do = tube outside diameter= 0.06045 m
Ac = 3.11 m2
Equivalent Diameter:

4@#4 AB '   #%C ' 4D

 G
I
 #%C 12  #AB 12

Putting values in above formula

AE F = 0.06934 m

Shell side mass velocity

= salt flow rate / shell side flow area

= 251.20 / 3.11
= 80.68 kg/m2 - sec
= 1.98 x 10-3 kg/m-sec

Viscosity of molten salt

Reynolds Number

Re =

GDe

= 2826
Friction factor for tube side, fs

Where

= 0.00208

3L <L ' M ?
K 
5.22 N 10 AF E 7 O

PS

= pressure drop

Gs

= shell side mass velocity= 59459.8 lb/ft2/hr

= length of tube = 8.2ft

Nc

= number of passes = 1

De

= Equivalent diameter = 0.2275 ft

= specific gravity = 1.88

= 1

Putting above values

PS

= 0.0027 psi = 1.8 x 10-4 atm

Calculations of Heat Transfer Co-efficient

Shell Side
Using Eagle and Ferguson equation

1501  0.0110Q ! E .R

AF E .'

PC 

tb

= average water temperature of cooling media oF

= 653 oF

De

= Equivalent Diameter = 0.2274 ft

Now to calculate V = velocity of cooling salt in fps

Mass velocity, G = 16.54 lb/ft2/s
Salt density, s
Velocity

= 117.36 lb/ft3

= mass velocity / salt density

= 0.1409 lb/ft

Putting values for shell side heat transfer coefficient

ho

= 332.41 Btu/ hr. ft2 oF

Wall Resistance:

ST 

%B (/%C %B 
2UT

Kw = Thermal conductivity of wall

= 25 Btu/ hr. ft2 oF

Putting the values in above equation:

Rw = 0.00049 ft2-hr-oF/BTU
Tube Side
An equation proposed by LEVA to find heat transfer co-efficient inside the tubes
filled with catalyst particles.

D pG
hiD
= 3.5
k

0.7

Dp
4.6

= tube side mass velocity = 7029.4 lb/hr. ft2

= viscosity of tube side fluid = 0.0772 lb/hr. ft

= 0.0273 Btu/hr. ft. oF

Dp

= diameter of particle = 0.01640 ft

di

= Inside diameter of tube = 0.17225 ft

Putting values in above equation

hi

= 60.36 Btu/hr. ft2 oF

Inside dirt coefficient:

hid = 500 Btu/hr. ft2 oF
Outside dirt coefficient:
hid

= 300 Btu/hr. ft2 oF

Over all H.T. Coefficient:

1
1
%B
%B
1


 ST 

PB PBW
PC % PBW %C
VB

do

= tube outside diameter = 2.38 in

di

= tube inside diameter = 2.067 in

Ui

= overall heat transfer on the basis of inside diameter

By putting the values

Ui

= 44.96 Btu/hr. ft2 oF

Area required for Heat Transfer

>214 S1XY&21% 
Q

= 2.62 x 107 Btu/hr

LMTD = 148.5 o F
So
Area required for Heat Transfer

= 3916.7 ft2
= 363.818 m2

Z
M[\A. VB

Area Available for Heat Transfer

Length of tube, Lt = 2.5 m
Inside Diameter of tube, di = 0.05045 m

\904( 7Y23451 4214 484&(4](1   #%B M

= 940 x x 0.05045 x 2.5

= 372.45 m2
So sufficient area is available for heat transfer