Equipment Design: Production of Phthalic Anhydride Via Vapor-Phase Catalytic Oxidation of O-Xylene

EQUIPMENT DESIGN
PRODUCTION OF
PHTHALIC ANHYDRIDE VIA
VAPOR-PHASE CATALYTIC OXIDATION OF O-XYLENE
PRODUCTION OF PHTHALIC ANHYDRIDE VIA VAPOR-PHASE CATALYTIC OXIDATION OF O-XYLENE
C-04 DESIGN
COLUMN CONDENSER
SPECIFICATION SHEET
Shell and Tube Heat Exchanger
Operation
Functional Description
Type
Configuration
Continuous
Total condenser
TEMA AES Removable tube bundle, split clamp-ring floating
head
Horizontal, with condensation
Design Code
Shell
Fluid Circulating
Materials of Construction
Type
Pass
Tube
Vapor
Stainless Steel, type 304
TEMA Type E
1
Water
Stainless Steel, type 304
Plain, seamless
2
Tube Layout
BWG
Pitch Type
Tube OD-3/4 in. TEMA std.
Tube ID
Tube Length
Tube Pitch (1.25 x Tube OD)
Number of Tubes (Design)
Tubes per pass
12
Square
19 mm
15 mm
0.762 m
23.75 mm
16
8
Shell Layout
Shell ID-8 in.
Shell Thickness
Shell OD
Baffle Spacing
Number of Baffles
Shell Cover Type
0.2033 m
2.2 mm
.2065 m
0.1016 m
7
Standard Torispherical Head
COLUMN CONDENSER
318
= 10502.84
2 = 50
1 = 199
2 = 60
1 = 30
From Overall Energy Balance:

= 46.11
mass of cooling water, = 0.08
Shell Side: Reaction Gases

1 = 199 C
2 = 60 C
Tube Side: Water

1 = 30 C
2 = 50 C
Log Mean Temperature Difference:

=
(1 2 ) (2 1 )
1 2
)
2 1
ln(
(199 50) (60 30)

19950
ln( 6030 )
= 74.247
Eq. 12.4. Page 655. Sinnot, R. K. Coulsons and Richardsons Chemical Engineering Design Vol. 6.
COLUMN CONDENSER
319
Dimensionless Temperature Ratio:2

=
=
1 2 199 60
=
= 6.95
2 1
50 30
2 1
50 30
=
= 0.1183
1 1 199 30
Correction Factor:
(1)
( 2 + 1)ln[(1)]
2[+1(2 +1)]
( 1)ln[
2[+1+(2 +1)]
= (, ) = 0.82
True Temperature Difference:

Corrected LMTD:
= 4
= 0.895(74.247)
= .
Assume Overall Heat Transfer Coefficient:
, =
Eq. 12.6 & Eq. 12.7. Page 655. Sinnot, R. K. Coulsons and Richardsons Chemical Engineering Design Vol. 6.
4
5
Table 12.1 Page 637. Sinnot, R. K. Coulsons and Richardsons Chemical Engineering Design Vol. 6.
3
COLUMN CONDENSER
320
Heat Transfer Area:

=
0,
1000
)
1
9.67 (
(200 2 ) (74.25)
= .
Surface area of a single tube:

Use smallest diameter for greater heat transfer area with a normal minimum of 3/4"od tube due to
cleaning considerations and vibration. in od tubes can be used on shorter tube lengths say < 4ft.
=
= (0.019 )(0.762)
= .
Number of Tubes:
1
= ( ) (
)
.
0.7279 2
= (
0.045
1
) ( ) = 16
1
COLUMN CONDENSER
321
Using TEMA Standard:7

( )
Shell inside diameter, = 0.2033
Tube Bundle Diameter:8

For square pitch,
1 = 0.156
1 = 2.291
1
1
= ( ) 9
1
1
16 2.291
= (0.019) (
)
0.156
= .
Number of Tubes in Center Row:10

= . (. ) = .
, =
0.1434
=
= 6.04
0.02375
,
Table 9. Page 841. Kern D. Q. Process Heat Transfer. (1965).

Design and rating shell and tube heat exchanger by John E. Edwards
8
Table 12.4. Page 649. Sinnot, R. K. Coulsons and Richardsons Chemical Engineering Design Vol. 6.
9
Eqn. 12.3b. Page 648. Sinnot, R. K. Coulsons and Richardsons Chemical Engineering Design Vol. 6.
10
Page 649. Sinnot, R. K. Coulsons and Richardsons Chemical Engineering Design Vol. 6.
8
COLUMN CONDENSER
322
Baffle spacing:
25 % baffle cut11
@ = 16;
= 8 0.2032
= 0.5 = 0.5 (0.2032)

= .
Number of baffles:
= + 112
Where:
= no. of times the flow crosses the tube bundle
0.762
1=
1
0.1016
= .
Check:
= (0.1016 m)(7 baffles) = 0.1016 m < 0.762 m (Tube Length)
Therefore, baffle spacing is acceptable.
11
12
Shell and Tube Heat Exchangers. http://www.thermopedia.com/content/1121/

COLUMN CONDENSER
323
TUBE-SIDE HEAT TRANSFER COEFFICIENT: SINGLE PHASE13
4200(1.35 + 0.02)0.8
14
0.2
Where:
]
2
= inside ceofficient for water [

= water temperature []
m
= water velocity [ ]
s
= tube inside diameter [mm]
Tube-side mean temperature:
=
1 + 2 303.15 + 323.15
=
2
2
= .
Physical properties of water at tube-side mean temperature15

Water
Density
Viscosity
Thermal Conductivity
Specific Heat Capacity
0.0007
0.6304
4.1833

991.2546
13
15
Table 2-305. Thermodynamic Properties of Water. Perry, R.H. and Green, D.W. (2008). Perrys Chemical Engineers
Handbook, 8th Edition. New York: McGraw-Hill
14
COLUMN CONDENSER
324
Tube cross-sectional area:

, =
( )2 = (0.015 )2
4
4
, = .
Tube per pass:
, =
16
=
.
2
, =
Total flow area:

, = , , = 8(0.00017672 )
, = .
Tube-side mass velocity:
0.077
0.0014142
= .
Tube-side linear velocity:
54.49 2

=
=
991.2546
3
= .
COLUMN CONDENSER
325
Tube-side Reynolds number:
(54.46 2 ) (0.015 )
=
=
0.0007
= .
Tube-side Prandtl number:
1000
(0.0014 ) (0.0007 )
=
=
(0.6304 )
= .
Length to diameter ratio:
0.762
=
0.015
= .
Tube-side coefficient:
4200(1.35 + 0.02(40))(0.055)0.8
=
(15 )0.2
= .
COLUMN CONDENSER
326
SHELL-SIDE HEAT TRANSFER COEFFICIENT: SINGLE PHASE16

Shell-side mean temperature:
=
1 + 2 333.15 + 303.15
=
2
2
= .
Physical properties of reaction gases at shell-side mean temperature:17

Reaction Gases
Density
0.001008
0.2272
2.2528271
1248.5288
Viscosity
Thermal Conductivity
Specific Heat Capacity
Clearance between tubes:

= = 0.0254 0.019
= .
Cross flow area:
=
=

18
(0.0064 )(0.2033 )(0.1016 )

0.0254
= .
16
CHEMCAD
18
Eq. 12.21. Page 672. R.K Sinnott. Coulsons and Richardsons Chemical Engineering Design Vol. 6.
17
COLUMN CONDENSER
327
Shell-side mass velocity:
(581.22 24 3600 )
=
=
0.00520 2
= .
Shell-side linear velocity:
1.29 2
=
=
1248.53 3
= .
Shell-side equivalent diameter (hydraulic diameter):19

=
=
1.27 2
( 0.7852 )

1.27
(0.02542 0.785(0.019)2 )
0.019
= .
Shell-side Reynolds number:
(1.29 2 ) (0.0241)

20 =
=
0.001008
= .
19
20
COLUMN CONDENSER
328
Shell-side Prandtl number:
1000
(2.253 ) (0.001008 )
=
=
(0.2272
)
Shell-side coefficient:
Tube loading, condensate flow per unit length of tube:
=
= 1.53
Mean coefficient for a tube bundle:

( ) 1 2
]3 ( )1/6

3
= 0.95 [
1
3
1248.53 3 (1248.53 3 .3922 3 ) (9.81 2 ) 2

6
= 0.95 (0.2272 2 ) [
]
(
6)

3
(0.001008 ) (1.53 )
2
= 368
COLUMN CONDENSER
329
Overall Heat Transfer Coefficient
Estimate:21
tube wall material thermal conductivity, =
outside dirt coefficient, =

inside dirt coefficient, =
Overall Heat Transfer Coefficient,
( )
1
1
1
1
1
=
+
+
+[
]+[
] 22

2

1
1
1
=
+
368
1500
2

(0.019 ) (
2 (16
0.019
0.015
+[
0.019
1
0.015 1500
, = .
]+[
0.019
1
0.015 16582.83
Percent Error23
% = 0% < [
224.96 200
100] < 30%
200
% = . %
Therefore, the assumed overall heat transfer coefficient is acceptable.
21
Table 12.6, page 662 and Table 12.2, page 640. Sinnot, R. K. Coulsons and Richardsons Chemical Engineering
Design Vol. 6.
22
Eq.12.2. Page 635. R.K Sinnott. Coulsons and Richardsons Chemical Engineering Design Vol. 6.
23
Page 684. R.K Sinnott. Coulsons and Richardsons Chemical Engineering Design Vol. 6.
COLUMN CONDENSER
330
PERCENT OVERSURFACE:
% = 15% < [
,
100] < 50%24
Where:
= clean overall heat transfer coefficient
Calculating for
=
= 16582.83
25
= 13091.71
0.015
0.019
Calculating for
=
=

26
+
368 13091.71
368 + 13091.71
= 357.94
Calculating for percent oversurface

% =
357.94 224.96
100
357.94
% = . %
Therefore, the oversurface is acceptable.
24
Page 26. Process Design of Heat Exchanger. NPTEL Chemical Engineering Chemical Engineering Design II
26
25
COLUMN CONDENSER
331
PERCENT OVERDESIGN

% = 0% < [(
) 100] < 10%27
Design area ( = 16)

=
= (0.019)(0.76)(16)
= 0.723 2
Required heat transfer area ( = 15)
=
= (0.019)(0.76)(15)
= 0.68 2
Calculating for percent overdesign

0.723 0.68
% = (
) 100
0.68
% = . %
Therefore, the overdesign is acceptable.
27
Eq. 1.7. Page 26. Process Design of Heat Exchanger. NPTEL Chemical Engineering Chemical Engineering Design
II
COLUMN CONDENSER
332
TUBE-SIDE PRESSURE DROP
2
= [8 ( ) + 2.5] (
) 28
Water
Density
0.0007
0.7659
991.2546
Viscosity
Linear velocity
Reynolds number
24,482.22
Estimate from Figure 12.3029

= 0.38
0.76
= 2 [8(0.0038) (
) + 2.5] (
0.015
(991.2546
3 ) (0.7659
= 1622.46
= .
28
29
Eqn. 12.20. Page 667. R.K Sinnott. Coulsons and Richardsons Chemical Engineering Design Vol. 6.
Figure 12.24. Page 668. R.K Sinnott. Coulsons and Richardsons Chemical Engineering Design Vol. 6.
COLUMN CONDENSER
333
SHELL-SIDE PRESSURE DROP
= {8 (
2
0.14
)( )(
)( )
} 30
Shell-side fluid
Equivalent diameter
0.0241
Baffle spacing, B
0.1016
Density
0.001008
0.01
1248.53
Viscosity
Linear velocity
Reynolds number
30.84
Estimate 31
25 % baffle cut32
= 0.3
(1248.53 3 ) (0.1 )
1
0.2033
0.76
= ( ) {8(0.3) (
)(
)(
) (1)}
2
0.0241 0.1016
2
= 472.71
= .
30
Figure 12.30. Page 674. R.K Sinnott. Coulsons and Richardsons Chemical Engineering Design Vol. 6.
32
Shell and Tube Heat Exchangers. http://www.thermopedia.com/content/1121/
31
COLUMN CONDENSER
334
EFFECTIVENESS OF HEAT EXCHANGER
For one shell pass and two tube passes:

= 2 {1 + + (1 +
2 )0.5
1 + [()(1 + 2 )0.5 ]
}
1 [()(1 + 2 )0.5 ]
1
33
For vapour mixture:

= = (581.22
) (1.2099
)
24 3600
=.
For water:
= = (0.077
= .
) (4.1833
)
Capacity ratio:
, =
=
34
0.0813
0.32
= .
Inside depth of the head:35
= [(
0.5
) ( +
) + 2 ]
2
2
33
Eqn. 11.30a. Page 724. Dewitt, D.P. and Incropera, F.P. Fundamentals of Heat and Mass Transfer. 7th Ed.
Eqn. 11.24. Page 723. Dewitt, D.P. and Incropera, F.P. Fundamentals of Heat and Mass Transfer. 7th Ed.
35
34
COLUMN CONDENSER
335
Where:
= = 203.2520
= 0.06 = 12.1951
= 203.2520
0.5
203.2520
203.2520
[(203.2520
) (203.2520 +
) + 2(12.1951)]
2
2
= .
Effective exchanger length:36

= + 2 = 0.76 + 2(0.0272 )
= .
Area effective:
= = (0.019 )(0.814)(16)
= .
Calculating for NTU:
=
,
37
(224.96 2 ) (0.78 2 )
(0.0813
1000
= .
Effectiveness:
2 )0.5
= 2 {1 + 0.0254(1 + 0.0254
1 + [(2.16)(1 + 0.02542 )0.5 ]
}
1 [(2.16)(1 + 0.02542 )0.5 ]
= . %
36
37
Eqn. 11.24. Page 723. Dewitt, D.P. and Incropera, F.P. Fundamentals of Heat and Mass Transfer. 7th Ed.
COLUMN CONDENSER
336
MECHANICAL DESIGN
Shell
Tube
Material of construction
Stainless Steel, type 304 Stainless Steel, type 304
Allowable stress (Design stress)
95 MPa38
Design pressure:
Take as 10 percent above operating pressure39
= 1.1101.325
= 111.4575
Design temperature:
Take as 10 percent above operating temperature40
= 1.1591.15 (318 )
= 622.95 (349.8 )
SHELL DESIGN
Shell thickness:
For a cylindrical shell, the minimum thickness required to resist internal pressure can be determined
from the equation below based on the maximum allowable stress and corrected for welded joint
efficiency:
=

41
2
Where:
= design stress
= minimum thickness required
= joint factor, range from 0.7 1.0
38
Table 13.2. Page 812. R.K Sinnott. Coulsons and Richardsons Chemical Engineering Design Vol. 6
40
41
Eq. 13.39a. Page 815. R.K Sinnott. Coulsons and Richardsons Chemical Engineering Design Vol. 6.
39
COLUMN CONDENSER
337
Calculating for shell thickness:

=
(. 1114575 )(203.2520)
2(0.7)(95 ) (. 1114575 )
= 0.1705
Add corrosion allowance taken as 3.0 mm:

= 0.1705 + 2.00 = 2.1705
. 42
This value is in accordance to IS: 4503 corresponding to the shell diameter.
Shell outside diameter:

= +
= 203.2520 + 2.2
= .
COVER AND CHANNEL DESIGN

For the shell head design, a torispherical head is selected. According to IS: 4503, the minimum
thickness of the shell cover should be at least equal to the thickness of the shell.
Shell cover thickness:

The required thickness of a torispherical head can be determined from the equation below.
=

43
2 + ( 0.2)
Where:
= stress concentration factor
= crown radius
For torispherical head, stress concentration factor is given by:
42
43
Table CB-3.13. Page 5.3-1. Standards of the Tubular Exchanger Manufacturers Association, 9th Ed.
COLUMN CONDENSER
338
(3 + )
4
Where:
= knuckle radius
Let:
= = 203.2520
= 0.06 = 12.1951
For formed domed heads (no joints in the head), joint factor = 1.0
Calculating for stress concentration factor:

1
203.2520
= (3 +
)
4
12.1951
= 1.7706
Calculating for shell cover thickness:
=
(. 1114575 )(203.2520 )(1.7706)

2(95 )(1) + (. 1114575 )(1.7706 0.2)
= 0.2109

= 0.2109 + 2.00 = 2.2109
.
Use same thickness as for wall in accordance to TEMA standard.
COLUMN CONDENSER
339
Channel cover thickness:

The channel cover material is the same as the shell material. The outside diameter of the channel
shall be the same as that of the shell.
The effective channel cover thickness can be determined from the equation below.
=
1
44
10
Where:
= thickness of the channel cover []
= diameter of the cover [] usually same as the outside shell diameter
1 = factor equal to 0.3 for ring type gasket
= design pressure [
= design stress [
]
2
]
2
Calculating for channel cover thickness:

=
206.4520 0.3 (1.1366)

10
9.6873
= 1.2445

= 1.2445 + 2.00
= .
44
Page 35. IS:4503, section 15.6.1. Indian Standard Specification for Shell and Tube Type Heat Exchangers.
COLUMN CONDENSER
340
Tube sheet thickness:

The tube sheet thickness is calculated based on the bending and considering the design pressure
only. The material is the same as the shell material.
The minimum tube sheet thickness to resist bending can be determined from the equation below.

45
3
For the stationary tube sheet in floating type:

= 146
= 47
Mean ligament efficiency:
=1
=1
0.907
2
( )
48
0.907
0.02375 2
0.019
= 0.4195
Calculating for tube sheet thickness:
(1)(203.2520 ) (. 1114575 )
(0.4195)(95 )
3
= .
45
Eq. 2.5. Page 9. Mechanical Design of Heat Exchanger. NPTEL Chemical Engineering Chemical Engineering
Design II
46
Page 9. Mechanical Design of Heat Exchanger. NPTEL Chemical Engineering Chemical Engineering Design II
47
Page 9. Mechanical Design of Heat Exchanger. NPTEL Chemical Engineering Chemical Engineering Design II
48
Eq. 2.7. Page 9. Mechanical Design of Heat Exchanger. NPTEL Chemical Engineering Chemical Engineering
Design II
COLUMN CONDENSER
341
Impingement plate:
According to IS: 4503, the protection against impingement may not be required for the services
involving non-corrosive, non-abrasive, single phase fluid.
To check for the impingement parameter:
2 < 125
Where:
m
= the linear velocity of the fluid [ ]
s
= fluid density [
]
3
1000
3
2
= (991.2546 3
)
(0.7659
)
1003 3
0.581 < 125

Therefore, impingement protection is not required.
COLUMN CONDENSER
342
NOZZLE DESIGN
Use same nozzle material as for shell. The nozzle thickness is calculated from the stress formula
used in the calculation of shell thickness.
For the nozzle inside diameter:
= 2 49
Nozzle thickness:

=
2
(. 1114575 ) (2
25.4
1
2(0.7)(95 ) (. 1114575 )
= 0.0426

= 0.0426 + 2.00 = 2.0426
.
The pressure at the entry point of both shell-side and tube-side fluids is the same. Therefore, the
same nozzle specification can be used for both.
49
Table 2.3. Page 11. Mechanical Design of Heat Exchanger. NPTEL Chemical Engineering Chemical Engineering
Design II
COLUMN CONDENSER
343

Equipment Design: Production of Phthalic Anhydride Via Vapor-Phase Catalytic Oxidation of O-Xylene

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Equipment Design: Production of Phthalic Anhydride Via Vapor-Phase Catalytic Oxidation of O-Xylene

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EQUIPMENT DESIGN

PRODUCTION OF PHTHALIC ANHYDRIDE VIA VAPOR-PHASE CATALYTIC OXIDATION OF O-XYLENE

PRODUCTION OF PHTHALIC ANHYDRIDE VIA VAPOR-PHASE CATALYTIC OXIDATION OF O-XYLENE

From Overall Energy Balance:

Shell Side: Reaction Gases

Tube Side: Water

Log Mean Temperature Difference:

(199 50) (60 30)

PRODUCTION OF PHTHALIC ANHYDRIDE VIA VAPOR-PHASE CATALYTIC OXIDATION OF O-XYLENE

Dimensionless Temperature Ratio:2

True Temperature Difference:

Assume Overall Heat Transfer Coefficient:

PRODUCTION OF PHTHALIC ANHYDRIDE VIA VAPOR-PHASE CATALYTIC OXIDATION OF O-XYLENE

Heat Transfer Area:

Surface area of a single tube:

PRODUCTION OF PHTHALIC ANHYDRIDE VIA VAPOR-PHASE CATALYTIC OXIDATION OF O-XYLENE

Using TEMA Standard:7

Tube Bundle Diameter:8

Number of Tubes in Center Row:10

Table 9. Page 841. Kern D. Q. Process Heat Transfer. (1965).

PRODUCTION OF PHTHALIC ANHYDRIDE VIA VAPOR-PHASE CATALYTIC OXIDATION OF O-XYLENE

= 0.5 = 0.5 (0.2032)

= no. of times the flow crosses the tube bundle

Shell and Tube Heat Exchangers. http://www.thermopedia.com/content/1121/

PRODUCTION OF PHTHALIC ANHYDRIDE VIA VAPOR-PHASE CATALYTIC OXIDATION OF O-XYLENE

TUBE-SIDE HEAT TRANSFER COEFFICIENT: SINGLE PHASE13

= inside ceofficient for water [

Physical properties of water at tube-side mean temperature15

PRODUCTION OF PHTHALIC ANHYDRIDE VIA VAPOR-PHASE CATALYTIC OXIDATION OF O-XYLENE

Tube cross-sectional area:

Total flow area:

Tube-side linear velocity:

PRODUCTION OF PHTHALIC ANHYDRIDE VIA VAPOR-PHASE CATALYTIC OXIDATION OF O-XYLENE

Tube-side Reynolds number:

PRODUCTION OF PHTHALIC ANHYDRIDE VIA VAPOR-PHASE CATALYTIC OXIDATION OF O-XYLENE

SHELL-SIDE HEAT TRANSFER COEFFICIENT: SINGLE PHASE16

Physical properties of reaction gases at shell-side mean temperature:17

Clearance between tubes:

(0.0064 )(0.2033 )(0.1016 )

PRODUCTION OF PHTHALIC ANHYDRIDE VIA VAPOR-PHASE CATALYTIC OXIDATION OF O-XYLENE

Shell-side mass velocity:

Shell-side linear velocity:

Shell-side equivalent diameter (hydraulic diameter):19

Shell-side Reynolds number:

PRODUCTION OF PHTHALIC ANHYDRIDE VIA VAPOR-PHASE CATALYTIC OXIDATION OF O-XYLENE

Shell-side Prandtl number:

Tube loading, condensate flow per unit length of tube:

Mean coefficient for a tube bundle:

1248.53 3 (1248.53 3 .3922 3 ) (9.81 2 ) 2

PRODUCTION OF PHTHALIC ANHYDRIDE VIA VAPOR-PHASE CATALYTIC OXIDATION OF O-XYLENE

Overall Heat Transfer Coefficient

outside dirt coefficient, =

Overall Heat Transfer Coefficient,

PRODUCTION OF PHTHALIC ANHYDRIDE VIA VAPOR-PHASE CATALYTIC OXIDATION OF O-XYLENE

Calculating for percent oversurface

PRODUCTION OF PHTHALIC ANHYDRIDE VIA VAPOR-PHASE CATALYTIC OXIDATION OF O-XYLENE

Design area ( = 16)

Calculating for percent overdesign

PRODUCTION OF PHTHALIC ANHYDRIDE VIA VAPOR-PHASE CATALYTIC OXIDATION OF O-XYLENE

TUBE-SIDE PRESSURE DROP

Estimate from Figure 12.3029

PRODUCTION OF PHTHALIC ANHYDRIDE VIA VAPOR-PHASE CATALYTIC OXIDATION OF O-XYLENE

SHELL-SIDE PRESSURE DROP