Detailed Design of Reactor :

Dimensions :
Volume of the liquid in reactor = VL = 1.3759 m3
Taking 25 % Vapour space
Volume of the reactor = V =1.7199 m3
Taking Diameter = D = 1 m = 1000 mm
V = *D2*H/4 + 2*0.081*D3

1.7199 = 3.14*(1)2*H/4 + 2*0.081*(1)3

We get Height of the Jacket = H = 2 m = 2000 mm

H/D = 2 .
We get Liquid Level in reactor by taking V = VL

1.3759 = 3.14*(1)2*L/4 + 2*0.081*(1)3

L iquid level = 1.55 m
Residence time in reactor :
Two reactions are taking in place in the reactor. Both reactions are of second order while first reaction is endothermic and
second reaction is exothermic.
1. First reaction takes place at 550C at 1 atm.
Concentration of Phenylacetic Acid = Ca =1.5844 Kmol/m3
Concentration of SOCl2 = Cb = 1.5844 Kmol/m3
At 550 C k1 = 0.1527 m3/Kmol/min.

1
Xa
1 Ca
(
)
k 1 1Xa
1
0.99
=
1
1.5844
0.1527
10.99

t1 =

= 407.19 mins

2. Second reaction takes place at 800C at 1 atm.

Concentration of Phenylacetyl chloride = Cc = 1.73359 Kmol/m3
Concentration of Benzene = Cd = 6.93327 Kmol/m3
At 800 C k2 = 0.005065 m3/Kmol/min.
t2 =

1
M Xc
ln (
)
( M 1 )Cck 2
M (1 Xc)

1
40.99
ln(
) = 163.028 mins
( 41 )1.733590.005065
4(10.99)

Total time for reaction = 407.19 + 163.028 = 570.218 mins = 9.504 hrs
Time for Charging & discharging = 1 hrs
Cumulative time = 10 Hours and 30 mins
Shell design
Material of Construction: as Aluminum chloride and dry hydrochloric gas is corrosive to stainless steel and carbon steel .
Hence from Corrosion Chart, we have chosen Hastelloy C-276 as MOC which compatible with all the constituents taking
part in reaction.
1) Designing considering internal pressure
Internal Pressure = 1 atm = 0.101325 N/mm2
Internal Design Pressure = p = 1.1 * Internal Pressure = 1.1 * 0.101325 = 0.1115 N/mm2
Maxximum Working Temperature = 80oC
Design Temperature = 80 + 90 oC
Shell inside diameter =Di =1000 mm
Allowable stress for shell and head material= f =174.676 N/mm2
Density of shell and head material = = 8890 Kg/m3
Material of construction = Hastelloy C-276
Joint efficiency = J = 0.8
Corrosion allowance = ca =2 mm
At Design Temperature
Poissons ratio = u = 0.32
Modulus of elasticity = 203000 N/mm2
Thickness of shell =

p Di
2 fj p

= 0.1115*1000/ (2*174.676*0.85 0.1115)

t = 0.3755 mm
for rigidity of the vessel thickness of vessel should be 3 mm
t = 3 mm
Thickness of shell + Corrosion Allowance = 3 + 1.5 = 4.5 mm
ts = 4.5 mm
Do=Di+ 2*t = 1000 + 2*4.5 =1009 mm 1010 mm
D = (Do+Di)/2 = (1000+1010)/2 = 1005 mm
The stress induced in the vessel due to various types of loadings are as follows:
i) Stresses in the circumferential or tangential direction due to the internal pressure
Ft =

P(Di +t) 0.1115(1000+3)

=
2t
2 3

= 18.632 N/mm2 (tensile)

ii) Stresses in the longitudinal or axial direaction
a) Due to internal pressure
FL1 =

P(Di +t) 0.1115(1000+3)

=
4t
4 3

= 9.316 N/mm2 (tensile)

b) Due to the weight of the vessel and its content in vertical vessels

W
( Di+t ) t

FL2=

Weight of the content = 1800 Kgs

Weight of shell = *D*H*t* =3.14 * 1005 * 2000 *4.5 *8890 * 10-9 = 281.93 Kgs
Crown radius = Rc = 1000 mm
Knuckle Radius = Rk =0.06 Rc = 0.06 * 1000 = 60 mm
Straight flange legth = s.f = 40mm
B=1.024*Do+0.67*Rk +2*s.f = 1.024*1010+0.67*60+2*40 = 1154.44 mm
Weight of the shell = *B2*t*/4 = 3.14*1154.442*4.5*8890 * 10-9/4 = 46.5 Kg
Outer Gasket Radius =Go=1.04m
Inner Gasket Radius =Gi=1.02 m
Thickness of flange =tf=0.026 m all values considering 5 mm shell thickness
Density of flange material(carbon steel) = f=7850 Kg/m3
Weight of the flange = 2** [Go2-Gi2]* tf *f /4
=2*3.14*[1.042-1.022]*0.026*7850/4 =13.202 Kgs
Therefore the weight of the vessel includes nozzles, manhole and support is considered to be 25% of sum of Weight of
shell, torisperical head and flange.
Weight of vessel = 1.25*(281.93+46.5+13.202)= 427.053 Kgs
Total Weight of vessel = weight of vessel + weight of content
= 427.053+1800 = 2227.053 Kgs = 21839.823 N

W
21839.823
=
( Di+t ) t 3.14 ( 1000+3 ) 3

FL2=

= 2.646 N/mm2 (Compressive)

c) Due to wind loads in vertical direction vessels
Wind pressure = p1 = 2000 N/mm2
3

Period of vibration = 6.35 *10-5 *

T= 0.015 secs
k1= 1
k2= 0.7

.. As T< 0.5
.. for cylindrical surface

The wind acting on the vessel

Pw=k1*k2*p1*H*Do =1* 0.7 *2000 *2 *1.01 = 2825.2 N
Bending movement due to wind load
Mw= Pw*

H
= 2825.2*2000/2 = 2825200 N/mm2
2

The corresponding bending stress in the axial direction

FL3=

H 2 * W 2 =6.35 *10-5 *
2 2 * 21839 2
)
( )
(
)
(
)
D
t
1.01
3

4 Mw
42825200
=
2
2
Di t 3.141000 3

= 1.199 N/mm2 (Tensile or Compressive)

Total resultant stress in longitudinal direction

fLR (tensile) = FL1+ FL2+ FL3 = 9.316 - 2.646+1.199 = 7.869 N/mm2

fLR (Compressive) = FL1+ FL2+ FL3 = -9.316 + 2.646 +1.199 = -5.471 N/mm2
iii) Stress due to torque from offset piping
T= torque about the vessel axis = 3000000 N-mm
fs =

2T
2 3000000
=
Dit ( Di+t) 3.1410003(1000+ 3)

= 0.6350 N/mm2
The equivalent resultant stress induced in vessel
FR(tensile) =

F t F tF
2

LR

+ F LR2 +3F 2s

18.6322 18.6327.869+7.8692 +30.6350 = 16.259 N/mm2

Permissible compressive stress = fc =

1
E
t
1
203000
3
=
2
2
12 3 ( 1u ) Do
12 3 ( 10.32 ) 1006
2
2
2
61.30 N/mm

( )

As FR(tensile) < Ft (Permissible Tensile Stress)

fLR (tensile) < Ft (Permissible Tensile Stress)
fLR (Compressive) < Fc (Permissible compressive stress)
Considering internal pressure thickness of 3 mm of shell acceptable for safe design
2) Designing considering external pressure
External pressure = 2 atm = 0.20265 N/mm2
External Design Pressure = 1.1 * External Pressure = 1.1 * 0.20265 = 0.2229 N/mm2

for Standard Torispherical Head

RCi = 1000 mm
Rki = 6% of RCi = 60 mm

Depth of the Head = RCi

( Rci Di2 )(Rci+ Di2 2 Rki )

1000
(1000+
260)
( 1000 1000
)
2
2

= 1000 -

= 169.34 mm

170 mm

L iquid level is upto 1.55 m = 1550 mm

Hence straight length of jacket = 1550 -170 = 1380 mm

1400 mm

Hence Unsupported length = L = 1400 +

1
170=1456.66
3

1460 mm

Initially assuming thickness t = 5 mm , hence

t /Do= 5/(1000+2*5) = 0.00495
L/D0= 1460/(1000+2*5) = 1.46

Critical buckling pressure

2.42 E
pc =

3
2 4

t 52
Do

[( ) ( ) ]

L
t
(1u )
0.45
Do
Do

1
2

2.42203000 0.00495 2

3
2 4

(10.32 ) (1.46 )0.45 ( 0.00495 )

1
2

= 0.650 N/mm2

0.2229 N/mm2

Allowable pressure pa = pc/4 = 0.650/4 = 0.162

pa p , Design is not safe and thickness has to increased. Choosing t = 6mm

t /Do= 6/(1000+2*6) = 0.005923
L/D0= 1460/(1000+2*6) = 1.4427

Critical buckling pressure

pc =

t 52
2.42 E
Do
3
2 4

[( ) ( ) ]

( 1u ) L 0.45 t
Do

Do

1
2

2.42203000 0.005923

5
2

( 10.322 ) 4 ( 1.4427 )0.45 ( 0.005923 ) 2

= 1.12 N/mm2
Allowable pressure pa = pc/4 = 1.12/4 = 0.28 0.2229 N/mm2
Since pa p , design is safe and t = 6 mm is selected.

Checking for elastic stability

Do/L = 0.693

K= 0.5625

M=2.46
m

Critical Pressure against Elastic Failure pa = KE

t
)
Do

= 0.379
Since pa

= 0.5625*203000*

0.2229 N/mm2

p , design is safe for elastic stability

Determination of safe external pressure against plastic deformation

U=Out-of- Roundnes = 2%*100
fc = 174.676 N/mm2

0.005932.46

t
)
Do

Safe External Pressure against Plastic Deformation = pa = 2fc

1
1.5 U (10.2
1+
100(

Do
)
L

t
)
Do

= 2*174.676*0.005923

1
1.52( 10.20.693 )
1+
100 ( 0.0059 )
= 0.387
Since pa

0.2229 N/mm2

p , design is safe for plastic deformation.

Therefore the thickness of 6mm is acceptable based on external pressure .

Thickness after considering corrosion allowance = 6 +1.5 = 7.5 mm
Thickness by considering Internal design pressure = 4.5 mm
Thickness by considering External design Pressure = 7.5 mm
Choosing the maximum thickness for shell , hence thickness of shell ts = 7.5 mm
Do =Di + 2*ts = 1000 + 2*7.5 = 1015 mm
Head Design
We have top and bottom torisperical ends. While there is no external pressure acting (only atmospheric pressure on the
top end, there is a jacket pressure acting on bottom dished end.
i) top head (internal pressure only)
For Standard Torispherical Head
Crown Radius = RCi = 1000 mm
Knuckle Radius = Rki = 6% of RCi = 60 mm
Stress Intensification factor =W= 0.25 (3 +
= 0.25(3 +

p Rc W
2 fJ
0.111110001.77
= 0.6622 mm
2174.6760.85

Rci
) )
rk
1000
) = 1.77
60

Thickness of head th =
=

for rigidity of the vessel thickness of head should be 3 mm

th = 3 mm
Thickness of head + Corrosion Allowance = 3 + 1.5 = 4.5 mm
th = 4.5 mm
Rco = Rci + 2th = 1000 + 2* 4.5 = 1009 mm
Rko= Rki + 2th = 60 + 2* 4.5 = 69mm
External Depth of the Head = RCo
= 1010 -

1010 mm
70 mm

( Rco Do2 )( Rco+ Do2 2 Rko)

1010
(1010+
270)
( 1010 1010
)
2
2

= 176.70 mm

180 mm

Minimum straight flange length = max(3* th ,20) = max(3*4.5 ,20)

= max(13.5,20)= 20 mm
y = th-ts = 7.5 4.5 = 3 mm
Minimum tapering length, l = 3y = 9 mm

ii) The bottom torisperical end

a)

As a rule of thumb, we use the design pressure, pi = 1.67 pE Hence pi=1.67 * 0.20265=0.3384 N/mm2

Thickness of head th =

p Rc W
+ corrosion allowance
2 fJ
0.338410001.77
=
+ 1.5 = 2.01*1.5 = 3.51 mm
2174.6760.85

4 mm

b) By considering the buckling pressure 2 times the external design pressure

1

Thickness of head th = 4 Rc

{3(1u2) }4

=4*1000

p + corrosion allowance
2E

{3(10.32 )}
2

1
4

0.2229
= 4.176 + 1.5 = 5.6763 mm 6 mm
2203000

Therefore thickness of bottom end th = 6mm

Rco = Rci + 2th = 1000 + 2* 6 = 1012 mm
Rko= Rki + 2th = 60 + 2* 6 = 72 mm
External Depth of the Head = RCo
= 1015 -

1015 mm
75 mm

( Rco Do2 )( Rco+ Do2 2 Rko)

1015
(1015+
275)
( 1015 1015
)
2
2

= 179.92 mm

180 mm

Minimum straight flange length = max(3* th ,20) = max(3*6 ,20)

= max(18,20)= 20 mm
y = th-ts = 7.5 - 6 = 1.5 mm
Minimum tapering length, l = 3y = 4.5 mm

Flange Design
Since the operating pressure is low and temperature is below 200C, we use the wide faced flange to join the head and
the shell by Lap Joint.
MOC for flange is glass-lined carbon steel, bolts is 18-8 Cr-Ni and gasket material is Teflon (PTFE).
i) Gasket Design
Gasket seating stress y = 11 N/mm2
Gasket factor m = 2.75
Gasket inner diameter, Gi = Do+10 = 1015+10 = 1025 mm

Go
ymp
112.750.1115
= 1.00526 mm
=
=
Gi
y( m+1 ) p
11 (2.75+ 1 )0.1115

Go =1.00526 * 1025 = 1030.39 mm

Width of the gasket,

N=

GoGi
=
2

1030.391025
2

= 2.692 mm

But minimum width of gasket = 10 mm

Go=Gi + 2N =1025 + 2*10 = 1045 mm
Basic seating width, bo = N/2 =10/2 = 5mm
As bo < 6.3 mm
Effective width of gasket, b = bo = 5 mm
Mean gasket diameter G = Gi + N = 1025 + 10 =1035mm
ii)Bolt Design
Under atmospheric conditions,
Bolt load,Wm1 Ag y=Gby= 3.14*1035*5*11 = 178744.5 N
Permissible stress under atmospheric conditions, fa = 131.8 N/mm2
Area, Am1 = Wm1/fa = 178744.5/131.8 = 1356.179818 mm2
Under operating conditions, Bolt load, Wm2

2 GbmP+ G2 p
4

= 2*3.14*1035*5*2.75*0.1115 + 0.25*3.14*10352 *0.1115

= 103687.115 N
Permissible stress at operating conditions, fb= 110.7 N/mm2
Bolt Area, Am2 = Wm2/fb = 103687.115/110.7 = 936.6496386 mm2
Final bolt area, Am = greater of Am1 and Am2 = 1356.1799 mm2

2
Am= d b n
4
Where db = bolt diameter and n = no of bolts
No of bolts, n = G/25 = 1035/25 =41.4 = 44 bolts (multiple of 4)
Using equation for bolt area,
1356.1799 = 3.14*0.25* d b2 *44
we get, bolt diameter db = 6.266mm 8 mm.
Area per bolt = 1356.1799/44 = 30.822 mm2
Ab for 8M bolt = 0.51*db2.09 = 0.51*82.09 = 39.36 mm2 > greater than required.
Bolt circle diameter, BCD = Go+2db+12 = 1035+2*8 +12 = 1073 mm 1080 mm

B
n

Bolt Spacing =

= 3.14*1080/44= 77 mm

ii)Flange Design
Flange diameter Df = BCD + 2db +12 = 1080+ 2*8 +12 = 1108
Flange thickness,

tf =G

mm 1110 mm

P
Kf

Permissible stress of flange material = 95 N/mm2

Where factor

K=

1
1
1.5 Wmh =
1.5103687.11522.5
0.3+
0.3+
HG
93725.90741035

= 2.9755

Radial distance

h=

BCDG 10801035
=
= 22.5 mm
2
2

H= G2 p =
4

Hydrostatic force on gasket,

Flange thickness,

tf =G

P
0.1115
=1035
=20.55 mm 22 mm
Kf
2.975595

Hence, the thickness of flange is 22 mm.

Width of flange =

1035 20.1115 = 93725.90744 N

4

Df Do
2

= (1110 1015)/2 = 47.5 mm

Process Design for agitator

Selection of Agitator :
Volume of the liquid in reactor = VL = 1.3759 m3
Power Requirement baffled agitated tanks, Power requird for heat transfer and liquid-liquid mixing is
1-1.5 KW/m3 (From Coulson& Richardson's Chemical Engineering Volume 6:Chemical Engineering Design, Table No. 10.4)
Hence Power Required for agitation in reactor should be between 1.38 2.10 KW.
Viscosity of first reaction mixture at 50oC = 0.63739 mPa.S
Viscosity of Second reaction mixture at 80oC = 0.32456 mPa.S
Hence Flat Blade Turbine is suitable for agitation in reactor from agitation selection guide based on volume of liquid and
viscosity.(From Coulson& Richardson's Chemical Engineering Volume 6:Chemical Engineering Design, Figure 10.57)
Determination of Dimensions of agitator :
Type of Impeller : 6 blade Flate blade turbine
Diameter of flat blade turbine is between 1/3 to 1/6 of the tank diameter.
Diameter of agitator = Da = Di /3 = 1000/3 = 333.33 mm
Width of blade = Da/5 = 330/5 =66 mm
Thickness of blade = 6 mm
Speed of the impeller = 250 rpm
Number of baffles in reactor = 4
For first reaction taking place in tank :
Properties of Reaction mixture:
1.Density = mix 1= 1059.96 Kg/m3
2.Specific Heat = Cpmix1 =1.721 KJ/Kg.K
3.Viscosity = mix 1= 0.63738697 mPa.s

330 mm

4.Thermal conductivity = kmix1= 0.33827 W/m.K

250 330 2

1059.96
2
Reynolds Number = NRe = nDa mix 1
60 1000
=
mix 1
0.63738697103

= 754581.87

At NRe = 754581.87 , Power Number Np = 4 (from Process Drawing and Eqipment I , figure 4.7 )

Prandle Number = NPr =

C p mix 1mix 1
K mix 1

1.72110000.6373910
0.33827

= 3.2428

Npmix 1N 3Da 5
g75
250 3 330
41059.96

=
60
1000
9.8175

Power Required to agitate reaction mixture 1 = P1 =

( )(

= 1.8247 hp = 1.4231 KW

As P1 lies between the range of 1.38 2.10 KW, Selected agitator is sufficient for heat transfrer and mixing for reaction
mixture 1.

For Second reaction taking place in tank :

Properties of Reaction mixture:
1.Density = mix 2= 1277.5918 Kg/m3
2.Specific Heat = Cpmix2 = 1.5644975 KJ/Kg.K
3.Viscosity = mix 2= 0.3243632 mPa.s
4.Thermal conductivity = kmix2= 0.1146771W/m.K

Reynolds Number = NRe =

nDa 2 mix 2
=
mix 2

250 330 2

1277.5918
60 1000

0.324363210

= 1787216.55

At NRe = 1787216.55 , Power Number Np = 4 (from Process Drawing and Eqipment I , figure 4.7 )

Prandle Number = NPr =

C p mix 2mix 2
K mix 2

1.564510000.3243632103
0.1146771

Power Required to agitate reaction mixture 1 = P2 =

Npmix 2N 3Da 5
g75

= 4.42517

250
330

60
1000
9.8175

( )(

41277.5918

= 1.95835124 hp = 1.524

KW
As P2 lies between the range of 1.38 2.10 KW, Selected agitator is sufficient for heat transfrer and mixing for reaction
mixture 2.
Assuming 10% gland loss and 20% Transmission loss
We get total power = 1.95835(1+0.1+0.2) = 2.5458 hp
Considering fitting losses use 3 hp motor

Process Design for Jacket

L iquid level is upto 1.55 m = 1550 mm
Hence straight length of jacket = h = 1550 -170 = 1380 mm
Diameter of vessel = D =1015 mm
Rk= 60 mm
Straight flange length = 20 mm

1400 mm

Dh+ (1.67Rc+ 0.67Rk +2sf )

2
= 10151400+ ( 1.67(1015+26)+0.6760+220 ) /4

Area available for heat transfer =

= 6.992 m2
Spacing between Jacket and shell = sp = 50 mm
Inner diameter of jacket = Dji = Do + 2* sp = 1015 + 2*50 = 1115 mm
Pitch of the spiral baffle in Jacket = pt = 100 mm
Cross section of channel = sp * pt = 50*100 = 5000 mm2 =0.005 m
Equivalent Diameter of Jacket =

4Cross Sectional Area

Wetted perimeter

4sppt
2( sppt)

45000
= 66.67
2( 50+ 100)

mm
Center Diameter of Jacket = Dc =

Do+ Dji
2

1015+1115
2

= 1040 mm

1) Considering Heat transfer during Reaction 1

First reaction takes place at 550C at 1 atm.
Volume of the reaction mixture =
Concentration of Phenylacetic Acid = Ca =1.5844 Kmol/m3
Concentration of SOCl2 = Cb = 1.5844 Kmol/m3
At 550 C k1 = 0.1527 m3/Kmol/min.
-ra = 0.1527 [Ca] [Cb]

dCa
dt

= 0.1527 * 1.5844*1.5844 = 0.383326 Kmol/m3/min

Moles of Phenylacetic Acid consumed =

dNa
dt

dCa
dt

* V = 0.383326*1.3759

= 0.527418762 Kmol/min = 145925.24 Kmol/hr

Heat of Reaction = HR1T =145925.24 KJ/Kmol (Endothermic)

Heat Required at the starting of the reaction Q1 = HR1T *

dNa
dt

= 145925.24*145925.24 KJ/hr
= 4617822.567 KJ/hr
To provide 4617822.567 KJ/hr of heat , We are using Condensing Stream at 2 atm as hot utility.
Saturation Temperature of Stream at 2 atm = 121oC

Log mean temperature difference =

( 12155 )(12127)
= 79.176 K
12155
ln (
)
12127
Q1
4617822.567 /3.6
=
= 2317.058 W/m2.K
79.1766.992046
TmA

Tm=

Overall heat transfer coefiicient required =

i) Agitator-side heat transfer coefficient for reaction 1

For Vessel containing 6 bladed flat blade turbine and 4 baffles , Nusselt Number is given by
Nussult Number = Nu1 = 0.74

0.667

0.33

N N Pr

= 0.74 *754581.870.667 *3.2428345430.33

= 9083.789193

K1
* Nu1 =
D

Heat transfer coefficient = hi1 =

0.338271000
* 9083.789 = 3027.379931 W/m2C
1015

ii) Jacket-side heat transfer coefficient

Properties of stream at 2 atm and 121oC :
1.Latent of of condensation = = 2202.557 KJ/Kg

v = 1.129 Kg/m3
3.Liquid Density = l = 942.935 Kg/m3
2.Vapour Density =

4.Specific Heat = Cp = 2.175 KJ/Kg.K

5.Viscosity = = 0.23205 mPa.s
6.Thermal conductivity = k = 0.68365 W/m.K
7. NPr 1.04281
Mass flow rate of stream required

m
=

4617822.567
2202.557

= 2096.57 Kgs/hr

2096.57 /3600
=
= 2.7819 Kg/s.m
De 3.1466.67103
4
42.78191000
= 47953.45831
NRe =
=

0.23205
As NRe 47953.45831 and NPr 1.04281 by Nusselt Condensation Model
=

We get

hj

k l ( lv ) g

1
3

= 0.385

942.935( 942.9351.129 )9.81

hj=0.3850.68365
3 2
(0.2320510 )
hj= 14342 W/m2K

1
3

(From Coulson& Richardson's Chemical Engineering Volume 6:Chemical Engineering Design, Table
No. 12.43)
Overall heat transfer coefficient for first reaction mixture = U1=

1
1 1
+
hi hj

1
1
1
+
3027.38 14342

2499.726 W/m2K

2) Considering Heat transfer during Reaction 2

First reaction takes place at 800C at 1 atm.
Volume of the reaction mixture =
Concentration of Phenylacetyl Chloride = Cc =1.73359 Kmol/m3
Concentration of Benzene = Cd = 6.93327 Kmol/m3
At 550 C k2 = =0.005065 m3/Kmol/min.
-ra = 0.1527 [Cc] [Cd]

dCa
dt

0.005065 * 1.73359 *6.93327 = 0.060878502 Kmol/m3/min

dNc
dt

Moles of Phenylacetyl Chloride consumed =

dCc
dt

* V = 0.060878502 *1.26154

= 0.076800665 Kmol/min = 4.608 Kmol/hr

Heat of Reaction = HR2T = - 380249.8 KJ/Kmol (Exothermic)
Peak rate of heat evoluation Q2 = HR2T *

dNa
dt

= - 380249.8 *4.608 KJ/hr

= 1752206.254 KJ/hr
We need to remove this heat to maintain temperature at 80oC. This can be done by circulating cooling water
through the jacket.
Inlet temperature of cooling water = 27oC
Outlet temperature of cooling water = 37oC
Log mean temperature difference =

( 8027 )(8037)
= 47.82588367 K
8027
ln (
)
8037
Q2
1752206.25/3.6
=
= 1454.0257 W/m2.K
47.825886.9992
TmA

Tm=

Overall heat transfer coefficient required =

i) Agitator-side heat transfer coefficient for reaction 2

For Vessel containing 6 bladed flat blade turbine and 4 baffles , Nusselt Number is given by
Nusselt Number = Nu2 = 0.74

Heat transfer coefficient = hi2=

0.33
= 0.74 *1787216.55.667 *4.425167845.33 = 17889.19153
N 0.667
N Pr

K2
* Nu2 =
D

ii) Jacket-side heat transfer coefficient

0.1146771000
* 17889.19153= 2021.163159 W/m2C
1015

Properties of cooling water at 32oC :

1.Liquid Density = l = 995.0312 Kg/m3
2.Specific Heat = Cp = 4.1795 KJ/Kg.K
3.Viscosity = = 0.715 mPa.s
4.Thermal conductivity = k = 0.618695 W/m.K
5. NPr 4.827081415

1752206.254
Q
=
= 41923.8247 Kgs/hr
( 3727 )4.1795
TCp
m

41923.825
Velocity of cooling water =
=
= 2.340732119 m/s
A
3600958.6370.005
De
995.03122.3407366.66
NRe =
=
= 217300.2482

0.715
Mass flow rate of stream required

m
=

Nusselt Number relation for spiral baffled jacket is given by

De
66.67
1+3.5
Dc
Nu = 0.027*
) = 0.027*
1040
)
0.8
0.33
0.8
0.33
N N Pr
121853.1638 5.17177
1+ 3.5

= 1034.038328

K2
* Nu1 =
De

0.6186951000
* 1034.038328 = 9596.315359 W/m2C
66.66
1
1
Overall heat transfer coefficient for reaction mixture 2 = U2 = 1
=
1 =
1
1
+
+
hi hj
2021.613 9596.315
Heat transfer coefficient = hi2 =

1669.529153 W/m2K
For both reaction mixture Deigned Overall heat transfer coefficient is higher than required Overall heat transfer
coefficient , Hence area covered by jacket is sufficient for heat transfer.
Mechanical Design of agitator
i) Shaft Design
Liquid level in Reactor = 1550 mm
Diameter of agitator = 330 mm
Width of blade = Da/5 = 330/5 =66 mm
Thickness of blade = 6 mm
Speed of impeller = 250 rpm
Generally agitator is mounted such that distance equal to one agitator is kept below agitator upto the tank bottom , while
distance of 2 agitator diameter is kept upto the liquid level. If this liquid level is more than 2 agitator diameter , more
than one agitor are required.
Hence we require two agitator.
Material of Construction = Hastelloy C-276
Permissible stress for shaft= fs =125 N/mm2
Elastic limit in Tension =fb = 248 N/mm2
Modulus of elasticity = 203000 N/mm2
Position of impeller from bearing support

a) impeller one = 1250 mm

b) impeller two = 1900 mm
Shaft subjected to twisting moment only

nP4500 234500
=
10000= 171974.52 N-mm
2 N
23.14250

Rated motor torque = Tr =

Maximum torque = Tm = 1.5 Tr = 1.5 *171974.52 = 257961.781 N-mm

3
3
d . fs =
d 145
16
16
d = 20.85 mm

Shaft subjected to bending moment only

Resistance force to maximum torque = Fm =

Tm
257961.781
=
= 2084.53 N
0.75 R b 0.753300.5

Bending movement by shaft to impeller 1 = Mm1= Fm1 * l1= 2084.53 * 1250 = 2605662.5 N-mm
Bending movement by shaft to impeller 2 = Mm2= Fm2 * l2= 2084.53 * 1900 = 3960607 N-mm
Total bending movement = Mm = Mm1 + Mm2 = 2605662.5 + 3960607 = 6566269.5 N-mm
=

3
3
d . fb =
d 248
32
32
d = 64.619 mm

Shaft subjected to Combined Twisting Moment and Bending moment

According to maximum shear stress theory for ductile materials, the equivalent twisting moment T e
is given by
Te =
M 2m +T 2m = 6566269.52+ 257961.7812 = 6571334.676 N-mm

3
3
d . fs =
d 145
16
16
d = 61.353 mm

According to maximum normal stress theory for brittle materials, the equivalent twisting moment M e
is given by

M 2m +T 2m
1
M m +
Me =
=
2
1

2
3
d . fb =
=
32

(6566269.5+ 6566269.52+ 257961.7812) = 6568802 N-mm

3
d 248
32
d = 64.627 mm

Hence Selecting maximum diameter

Shaft Diameter = 65 mm
Design of Shaft Based on Critical Speed

Deflection of shaft due to 1st impeller =

Critical speed for 1st impeller Nc1 =

1 =

2084.531900
3203000
65 4
64

= 2.689 mm

946
1

Deflection of shaft due to 2nd impeller =

F m 1l
3 EI

3
1

2 =

946
2.689
F m 2l 32
3 EI

= 576.75 rpm

2084.531250 3
3203000
4
65
64

=0.76334 mm

Critical speed for 2nd impeller Nc2 =

946
2

946
0.763

= 1081.87 rpm

1
1
1
1
1
= 2 + 2
+
=
2
2
NC NC1 NC2
576.75 1081.87 2
Nc=508.49 rp m
Actual speed is 250 rpm is 49.17% of critical speed, Hence selected shaft size of 65 mm is
satisfactory.
ii) Hub and Key Design
Key material : Hastelloy C-276
Permissible stress for shaft= fs =145 N/mm2
Permissible crushing stress =fc = 290 N/mm2
Hub diameter of agitator = 2d = 2*65 = 130 mm
Length of hub = 2.5d = 2.5*65 = 162.5 mm 163 mm
Length of key = 1.5 d= 1.5*65 = 97.5 98 mm
Tangential force acting at the circumference of the shaft F is given by

Tm
t
=l b f s=l f c
d /2
2
257961.781
98t
=98b145=
290
=
65
2
2
b=t=0.55

F=

but practically b = t =

d
4

65
=16.25 17 mm
4

Use 17mm x 17 mm x 33 mm long key

iii) Blade design
Blade Material : Hastelloy C-276
Rb =Radius of blade = 165 mm
Rh = Radius of hub = 65 mm
bt = Blade Thickness = 6 mm
bw = Blade Width = 66 mm

Stress in the blade is given by

F m (0.75 Rb Rh )
2084.53 (0.7516565)
2
=
b tbw
6662
6
6

f=

= 28.114 N/mm2 which is well within the

endurance limit and yield point stress of Hastelloy C-276.

iv) Stuffing Box and Gland Design
Stuffing box material = Hastelloy C-276
Diameter of shaft d < 100 mm
Clearancw between shaft and stuffing box
c = 0.2d + 5 mm = 0.2*65+ 5mm = 18 mm
Internal diameter of stuffing box
d1 = d + 2c = 65 + 2*18 = 101 mm
length of gland and corresponding stuffing box length upto metal lip
l = d1 = 101 mm
Thickness of gland flange
h=

d
65
+12.5 mm =
+12.5=20.625 mm
8
8

21mm

Thickness of stuffing box body

t=

pd 1
0.2225101
+6=
+6 = 6.064 7 mm
2f
2174.676

Using 4 numbers of studs

Load on gland F =
=

3,14
2
2
2
2
p ( d 1d ) =
0.2225 ( 101 65 ) = 1043.78 N
4
4
2
3.14 2
d nf t =
d b4174.676
4 b
4

d b=1.379 mm but minium diameter of Bolts is 16 mm

Using 16M stud.
Thickness of stuffing box flange = 1.75 db = 1.75*16 = 28 mm
v) Design of Coupling
We are using split muff or clamp coupling made up of Hastelloy C-276.
Outer diameter of the muff = 2.5 d = 2.5*65 = 162.5 mm 163 mm
Length of muff ( minimum) = 3.5 d = 3.5*65 = 227.5 mm 228 mm
As shaft diameter d is less than 100 mm,
Number of bolts, n = 6
Coefficient of friction between muff and shaft =
Torque transmission capacity of the coupling
Tm =

2
n d d2b f t = 257961.781 N/mm2
16

=0.25

3.14
0.25665d 2b174.676
16

db = 4.95 mm 5 mm
Jacket Design
Material of Construction of Jacket = Carbon steel
Permissible stress of carbon steel = 90 N/mm2
Spacing between jacket and shell, jacket width wj = 50 mm
Jacket internal diameter Dij = Do + 2*wj =1015+2*50 = 1115mm
Jacket side Length, Lj = 1550 m
Jacket shell thickess, tj

PDi
0.2225 1115
+ c=
+3=4.6238 mm 5 mm
2 fJP
2 90 0.850.2225

Jacket outside diameter = Dij + tj = 1115 + 2*5 = 1125 mm

Jacket closure = trc = 2t rj = 2*5 = 10 mm
Or

trc

0.866 wj

trc must be greater of the two,

Jacket Head thickness = th

Pj
f

0.86650

0.2225
=2.1529
90

t rc=10 mm
pRcW
0.2225 1115 1.77062
+c=
+3=5.87 mm 6 mm
2 fJ
2 90 0.85

Sf = max{3*th or 20} = max{3*6 or 20} = max{18,20} = 20 mm

y = th-ts = 6 - 5 = 1 mm
Minimum tapering length, l = 3y = 3 mm
Head height =

hij =1115

1115
1115+
2 0.061115 )=188.81 mm 190 mm
( 1115 1115
)(
2
2

Support Design
The vessel has a moderate diameter of 1.125 m along with jacket and an aspect ratio of 2. Hence, we use lug or bracket
support.
Brackets are made of structural steel
Permissible stresses for structural steel: Tensile = 140N/mm2
Compressive = 125N/mm2
Bending = 155 N/mm2
n = Number of brackets = 4 since the diameter of vessel is 1.125 m
C = Clearance between vessel bottom and ground = 500mm
Total height of the vessel H = L+2ho+hoj+clearance between vessel bottom and the ground
= 2+2*0.180+0.190+0.5
= 3.05 m
Pw = Total wind force acting on the vessel = 2825.2 N (from shell design)
Dbc = Diameter of anchor bolt circle = 1275 mm
W = Total vessel weight with its contents and attachments =2227.053 Kgs = 21839.823 N
The maximum compressive load on the most remote bracket due to wind and dead load,

4 Pw ( HC ) W 42825 ( 1200500 ) 21839.823

+
=
+
= 9067.226709 N
n Dbc
n
41275
4

P=

R= Vessel shell radius = 562.5 mm

t = vessel shell thickness = 6 mm
a = Lever arm for load P from the bolt circle = (Dbc Djo)/2 = (1275-1125)/2 = 75 mm
A = Width of horizontal compression plate = 200 mm
h = Height of gusset plate = 150 mm
= Poissons ratio = 0.3

3 (12 ) 4 3 (10.32 )
=
=0.022126044
R2t 2
562.52 62

The approximate axial bending induced in the vessel wall

3 Pa R2
fa=
2 ( 12 ) Ah
0.022126 39067.226775562.52

= 42.6874 N/mm2
2
2 ( 10.2 )200150
Maximum stress in vessel wall due to internal pressure

fp=

PD 0.2225 1125
=
=20.859 N /mm 2
2t
2 6

Combined stress = fa + fp = 63.5475 N/mm2 which is less than the allowable tensile stress of the material (140 N/mm 2), hence
backing plate is not required.

i)

Design of Horizontal plate

a = effective width of horizontal plate = 175 mm
B = Legth of Horizontal plate = 200 mm

Maximum stress on horizontal plate

p=

P 9067.2267
=
=0.259 N / m m 2
aB 175 200

Maximum stress in horizontal plate

2

f =0.7 p

B
a
200
175
2680.6725
=0.7 0.259

=
2
4
4
2
4
4
2
T h B +a
Th
200 +175
Th

Permissible bending stress for structural steel = 155 N/mm2

Thickness of horizontal plate

Th=

Use 5 mm thick horizontal plate.

ii) Design of Gusset plate

Bending moment for each gusset plate

2680.6725
=4.15868 mm
155

M=

Pl
=
2

9067.2267

( 12751125
)=
2

340021.002 N-mm

The maximum stress at the edge of the gusset plate when edge is at an angle =45

fmax=

M 1
M
1
340021.002
1
128.1789
=
=

=
2
2
Z cos T g h cos
cos 45
Tg
150
Tg
6
6

Permissible stress = 155 N/mm2

Thickness of the gusset plate

Tg=

128.1789
=0.8269 mm
155

Use plate thickness 5 mm

iii)

Design of column support for bracket

Selecting standard channel section ISMC 175 having size 175*75 mm.
Area of cross section A=24.38 cm2
Modulus of section Zyy=22800 mm3
Radius of gyration ryy = 22.3 mm
Height of bracket from foundation L=1200 mm
Effective length of column le=L/2 = 1200/2 = 600 mm
Slenderness ratio

= 600 =26.9058
ryy 22.3

The maximum combined stress due to compressive load and eccentricity

f=

( ) ]+ nZ =

P
1+ a
nA
ryy

Pe

9067.227
1
75
N
1+
( 26.91 )2 +9067.227
=33.9045
2
2438
7500
22800
mm

Bending stress in the column due to wind

Pw L
1200
n 2 2825.7
2
fw =
=

=18.59 N /m m2
Z
4
22800
Total combined stress = f + fw =33.9045+18.59 = 52.4946 N/mm2
The total combined stress is less than the permissible compressive stress of the material (125N/mm 2), hence the channel
selected is satisfactory.

iv)

Design of base plate for column

Area to be provided by the base plate,

Ap=

P
9067.227
=
=2266.807 mm2
4
fc ( concrete )

That is around 48 x 48 mm square plate, but since the column has dimensions 175 x 75 we provide 225 x 125 mm
rectangular plate.

225175
12575
=25 mm and B=
=25 mm
2
2
9067.227
=0.3224 N /m m2
Pressure intensity on the underside of the base plate w=
225 125
Projections beyond overall dimensions

The minimum thickness of the base plate

A=

3 w 2 B2
3 0.3224
2 52
2
tb=
A
=
25
=1. 71 mm
fb
4
155
4

We use a 5 mm thick plate.