DETAILED DESIGN OF

MAJOR EQUIPMENT
HIGH TEMPERATURE CO SHIFT
CONVERTER (R-1103)
And
DESIGN OF MINOR EQUIPMENT
FLASH SEPERATOR (V-1105)
COMPRESSOR (K-1106)
By

ALI ABDURAHMAN JAMA

12956

Group Num: 2

Bachelor of Engineering (Hons)

(Chemical Engineering)

Dec 2013

i
Table of Contents
CHAPTER ................................................................................................................................. 5
GENERAL DESCRIPTION..................................................................................................... 5
1.1 Introduction ........................................................................................................................... 5
1.2 Design methodology ............................................................................................................. 5
1.3 CO shift converter selection................................................................................................... 6
1.3.1 Packed Bed Reactor ........................................................................................................... 6
1.3.2 Flow arrangement .............................................................................................................. 7
1.3.3 Thermal and bed arrangement ........................................................................................... 7
1.4 Operating conditions: ............................................................................................................ 8
1.4.1 Feed stream (S22) into R0302: .......................................................................................... 8
1.4.2 Outlet stream (S23) from R0302: ..................................................................................... 8
CHAPTER 2 .................................................................................................................................. 9
PROCESS DESIGN...................................................................................................................... 9
2.1 Reactor volume calculation ................................................................................................ 10
2.2 Reactor diameter, DR ......................................................................................................... 14
2.3 Reactor Height ................................................................................................................... 14
2.4 Heat Removal System of Reactor ...................................................................................... 15
2.5 Support of the reactor ........................................................................................................ 15
2.6 Pressure drop across the reactor ........................................................................................ 18
CHAPTER 3 ............................................................................................................................... 19
MECHANICAL DESIGN ........................................................................................................ 19
3.1 Reactor Design ................................................................................................................. 19
3.1.1 Reactor Design Pressure ............................................................................................... 19
3.1.2 Reactor Design Temperature ........................................................................................ 19
3.1.3 Reactor Cylindrical Shell Thickness ............................................................................ 19
3.2 Reactor Closures (Head and Closure) .............................................................................. 21

ii
3.3 Height of Reactor ........................................................................................................... 22
3.4 Design of Bolted Flange Joints ...................................................................................... 22
3.4.1 Gasket Design ............................................................................................................. 22
3.5 Reactor Weight .............................................................................................................. 23
3.5.1 Weight of shell ............................................................................................................ 24
3.5.2 Total Weight of Baffles Plate ..................................................................................... 24
3.5.3 Weight of Tubes ..........................................................................................................25
3.5.4 Weight of Fluid in Reactor ......................................................................................... 25
3.5.5 Weight of Insulation Material .................................................................................... 26
3.6 Wind Loading ................................................................................................................ 26
3.7 Analysis of Stress at bottom...........................................................................................27
3.7.1 Pressure Stresses ........................................................................................................ 27
3.7.2 Dead weight stress ..................................................................................................... 27
3.7.3 Bending Stress ........................................................................................................... 27
3.8 Reactor Support............................................................................................................. 29
3.9 Nozzles Sizing................................................................................................................30
3.9.1 Inlet and Outlet Nozzle ............................................................................................. 30
4.1 OPERATING MANUAL PROCEDURE .................................................................... 31
4.1.1 SCOPE AND OBJECTIVES .................................................................................... 31

iii
4.1.2 MATERIAL AND EQUIPMENT .................................................................................... 31
4.1.3 Safety & Health .................................................................................................................31
4.1.4 Procedures ........................................................................................................................ 31
4.1.5 DRAWING ...................................................................................................................... 32
CHAPTER 4 ................................................................................................................................. 33
4.1 Flash Separator (V-1105) ............................................................................................................35

4.2 Compressor (K-1105)...42

REFERENCES ......................................................................................................................... 46

List of Figure
Figure 1: Box diagram of R-1103 ............................................................................................. 9
Figure 2: Friction factor ............................................................................................................18

List of Table
Table 1Feed stream composition............................................................................................... 8
Table 2: Product stream composition ........................................................................................ 8
Table 3: Specification for the calculation of pressure drop ..................................................... 17
Table 4: Selection of Materials for Reactor Components........................................................ 20

iv
 CHAPTER 1
GENERAL DESCRIPTION

1.1 Introduction

CO shift conversion process for producing a gaseous mixture of hydrogen and carbon dioxide
from a CO-rich feed gas. The function of CO Shift Conversion is to convert traces of CO into
CO2 and increase H2 yield by reaction with steam. Here the same reaction occurs twice. CO
converter is divided into two stages which are in high and low temperature. Here, the high
temperature CO shift converter will be focused. Reliable operation is the key to the performance
of the whole plant.

1.2 Design methodology

1. Select the major equipment High temperature CO shift converter, R-1103

2. Justify the type of CO shift converter that is suitable for the process.

3. Determine the optimum operating conditions.

4. Perform calculation based on rate of reaction to obtain the volume of the CO shift converter.

5. The value from calculation is used as input data in ICON.

6. Size the reactor accordingly

7. Obtain the necessary parameters from reactor sizing calculation and proceed with equipment
mechanical design.

8. Reactor Cost and the utilities needed.

9. Perform technical drawing of the designed CO shift converter.

10. Perform start up and shut down procedures for the CO shift converter.

5
1.3 CO shift converter selection
1.3.1 Packed Bed Reactor

The catalytic water gas shift conversion process is well known and is commonly used in
processes which manufacture hydrogen gas. In the water gas shift reactor, carbon monoxide is
combined with water to yield carbon dioxide and hydrogen according to the following formula:

CO + H2O <=> H2 + CO2

This process is exothermic and is limited by the chemical equilibrium. This reaction, commonly
known as the water gas shift reaction, is highly exothermic, liberating about 16,700 BTUs for
each pound mole of carbon monoxide converted. Water gas shift reactors are often used to
reduce the amount of carbon monoxide present in a gas stream typically composed of water
vapor, methane, carbon monoxide, carbon dioxide and hydrogen. In these systems, natural gas,
or some other suitable hydrocarbon gas, is first reformed in a catalytic hydrocarbon reformer to
yield a mixture of hydrogen, carbon dioxide and small amounts of carbon monoxide. This gas
mixture is commonly referred to as reformate. The reformate gas is then introduced into the
water gas shift reactor, where the carbon monoxide concentration is reduced in order to avoid
poisoning by the carbon monoxide of the catalyst employed in the fuel cells and to produce
additional hydrogen fuel. In many instances, the reformate stream exiting the water gas shift
reactor is introduced into a selective oxidizer, which further reduces the level of carbon
monoxide present in the stream. The conventional water gas shift reactor is an adiabatic bed in
which the process gas temperature increases as the amount of carbon monoxide is reduced by the
water gas shift reaction. Practically speaking, due to equilibrium limitations, catalyst activity, 7
and catalyst thermal limits, conventional water gas shift reactors are generally incapable of
reducing the carbon monoxide concentration of a reformate stream much below 0.8%.The carbon
monoxide concentration of a reformate stream can be reduced below 0.8% through the use of a

6
second adiabatic catalyst bed. However, because of equilibrium limitations, a second adiabatic
bed would necessarily operate at a lower temperature relative to the first bed. As a result, the
catalyst activity in the second adiabatic bed would be so low that the size of the catalyst bed
necessary to achieve any meaningful reduction in carbon monoxide concentration would be
prohibitively large from an economic and efficiency standpoint. It is a further object of the
present invention to provide a water gas shift conversion process which reduces the
concentration of carbon monoxide in a reformate stream in order to avoid poisoning of the
catalyst employed in the associated fuel cell or cells to which the reformate stream is introduced.
It is a still further object of the present invention to provide a water gas shift conversion process
which utilizes one adiabatic reactor bed and one cooled reactor bed.

1.3.2 Flow arrangement

The first division is with respect to flow arrangement. Most fixed-bed reactors are operated with
axial flow of fluid down the bed of solid particles. In this case, R-1102 is operated with axial
flow of gas.

1.3.3 Thermal and bed arrangement

For axial flow of fluid, the division for thermal considerations is between adiabatic and non-
adiabatic operation. In adiabatic operation, there is attempt that made to adjust the temperature
within the bed by means of heat transfer. In CO shift conversion, the operation is adiabatic. Heat
transfer for control of temperature is accomplished outside the bed. Thus the reactors are single
stage reactors and not tubular reactors.

1.4 Operating conditions:

Operating Temperature: 400 C

Operating Pressure: 30bar (3040.5 kPa)

7
 Components Fraction Flow Rate (Kmole/hr)
Methane 0.0014 5.48
Water 0.3396 1328.85
Hydrogen 0.3829 1498.3
Carbon Dioxide 0.0819 320.47
Carbon Monoxide 0.0505 197.60
Nitrogen 0.1436 562
Total 1 3913
Table 1: Feed Stream Composition

1.4.1 Feed stream into R01103:

Inlet Temperature: 400 C

Inlet Pressure: 29.5bar (2989 kPa)
Molar flow: 3913 kmole/hr

Components Fraction Flow Rate (Kmole/hr)

Methane 0.0014 5.48
Water 0.2992 1170.8
Hydrogen 0.4234 1656.76
Carbon Dioxide 0.1223 478.6
Carbon Monoxide 0.0101 39.52
Nitrogen 0.1436 562
Total 1 3913
Table 2: Product Stream Composition

1.4.2 Outlet stream from R1103:

Outlet Temperature: 400 C
Inlet Pressure: 29.5bar (2989 kPa)
Molar flow: 3913 kmole/hr

8
 CHAPTER 2
PROCESS DESIGN

2.1 Reactor volume calculation

The reactor for the High Temperature CO Shift Converter in ammonia plant can be represented in
the flowing box diagram shown in Figure 2.1:

IN Out
High Temperature Shift
Converter R-1103
CH4, H2O, CO2, CH4, H2O, CO2,
CO, H2, N2 CO, H2, N2

Figure 1: Box diagram of R-1103

In the high temperature CO shift Reactor, the water gas shift reaction takes place as:

CO + H2O <=> H2 + CO2

A+BC+D

CO is taken as basis. So the concentration for CO can be calculated as below:

FA FA0 (1 x)

Flow of CO, FA will be divided with volumetric flow, v to obtained the concentration of CO,
CAo

FA FA0 (1 x)

v v

From equation 3.38 in Fogler third edition (1999), we assume that:

v v0 (1 x)

9
So, CA is calculated as below:

FA0 (1 x)
CA
v0 (1 x)

is calculated as below as taken from Fogler:

d c b 1 1 1
= y A0 y A0 ( 1) y A0 ( 1) 0
a a a 1 1 1

So CA=?

Po
CA y Ao
RT0

3040
C A0 * 0.0505 0.0275Kmole / m 3
8.314 * 673

Put the CA0 value in this equation (80% conversion of CO):

C A0 (1 x) 0.0275 * (1 0.8)
CA 0.0055Kmole / m 3
(1 x) 1 0

For concentration of H2O, CB the value same steps used from previous calculation of CA except
need to find value of B :

F B 0 1328.85
B 6.725
F A0 197.6

b
FB FA0 ( B x)
a

b
FA0 ( B x)
FB a

v v

10
 b
FA0 ( B x)
C B a
v 0 (1 x)

b
C A0 ( B x)
C B a
(1 x)

0.0275(6.72 0.8)
C B 0.1628Kmole / m 3
(1 0)

For the concentration of CO2, CC the same steps used from the above calculation.

F C 0 320.47
C 1.6218
F A0 197.6

c
C A0 ( C x)
CC a
(1 x)

0.0275(1.6218 0.8)
CC 0.066 Kmole / m 3
(1 0)

Finally, for the concentration of H2, (CD) also the same steps used from the above calculation.

F D 0 1498.3
D 7.6
F A0 197.6

d
C A0 ( D x)
C D a
(1 x)

0.0275(7.6 0.8)
CD 0.231Kmole / m 3
(1 0)

11
The desired reaction is reaction (1).The rate law for reaction (1) is given by:

rA K AC AC B

Rate constant of CO is calculated using formula below taken from Holmes (Case Study 105)
because the catalyst that used in high temperature shift converter is Cr-Fe Oxide.

Since the operating Temperature is 400 C (1212 R), KA can be calculated:

K A exp(15095 8820 / T )

K A exp(15.95 8820 / 1212) 5841.67

So, the rate of law for the equation (1) is as below:

rA 5841.67 * 0.0055 * 0.1628 5.23

Assume the reactor is Plug Flow Reactor (PFR), because the volume of reactor before the
catalyst is placed must be determined. Below is the calculation to determine the volume of PFR:

x
dx
VRe actor FA0
0
rA

0.8
dx
FA 0 K
0 AC AC B

0.8
dx
FA 0 b
0 K A C A0 (1 x)C A0 ( B x)
a

After Integration and Simplification it will give you as flowing:

12
 0.8
FA 0 dx

K A C 2 A0 b
0 (1 x)( B x)
a

0.8
FA 0 dx

K A C 2 A0 b
0 (1 x)( B x)
a

0.8
197.6 dx
2

(5841.670(0.0275 ) 0 (1 x)(6.725 x)

=48.01(0.26) = 12.5 m 3

Volumetric flow rate into each reactor is obtained from iCON simulation = 121 m3/hr. Thus, the
space time for R-3 is calculated as,

V 12.5
0.103305hr 371s
v0 121

R-1103 has a contact time of 371s. The space velocity is then the reciprocal of space time = 1135
hr-1. This value is well within the space velocity range obtained from literature. From literature
(Ullmans (1985)), the contact time in both reactors are taken to be 0.5 to 3s.The void fraction in
a packed bed is defined as the volume of voids in the bed divided by the total volume of the bed.
Assume the void fraction of the catalyst bed as 50% of the total volume of reactor, = 0.4.
Therefore, actual reactor volume for Packed Bed Reactor (PBR):

Vbed 12.5
VPFR 31.25 m 3
0.4

The volume of catalyst can be determined when the volume of bed time 2/3. This is because,
from Douglas, it is stated that the volume of catalyst used is 2/3 from the volume of bed.

V Catalyst 2 / 3Vbed 2 / 3(12.5) 8.30m 3

To get the mass of catalyst, the volume of catalyst must be times the bulk density of the Cr-Fe
Oxide. The bulk density of this catalyst is 1200m3/kg (1.2kg/L).

13
 M Catalyst VCatalyst * bulkdensity 8.3 *1200 9960kg

2.2 Reactor diameter, DR

Practically, the reactor diameter must be selected to give know the dimension of the reactor.
From this diameter, the height of reactor also can be determined.

D 2 R H
VPFR
4

From Douglas, the ratio of height to diameter is given as 1:3. Therefore

H 3D R

Substitute in the equation above, we can calculate the DR and rearrange the equation:

D 2 R 3DR
VPFR
4

After rearrangement it will give you as following:

4VPFR 3 4 * 31.25
DR 3 2.37m
3 3

2.3 Reactor Height

The diameter of reactor is calculated as 2.36 m. So, the height of reactor can be calculated using
the same formula. The height of the reactor is calculated as below:

H 3D R 3 * (2.36) 7.1m

14
2.4 Heat Removal System of Reactor

Since the reaction is exothermic and adiabatic due to the reaction transforming CO to CO2, heat
must be removed so that the temperature will not increase too high which will affect the reaction
at the next reactor which is low temperature CO shift converter. Heat is removed from the
reactor by cooling it with cooling water. However, the adiabatic process using 18 single stage
packed bed reactor. So, the temperature of reactant is using cooler and heater outside the feed
and product stream. Therefore, there are no inside cooling or in the reactor.

2.5 Support of the reactor

Reactor vessel shall be supported either in vertical or horizontal position which also depends on
the type of process involved. There are few types of vertical reactor vessel support design that
commonly used in industry such as bracket or lug support, leg support and ring support. For this
Continuous Stirred Tank Reactor (CSTR) vessel support design, bracket support is selected as it
is usually being applied in industry. The bracket may rest on the building structural steel work, or
the vessel may be supported on legs. The advantages of using bracket as the vessels support are
(i) it is easily constructed which can be designed using the usual methods for structural
steelwork. The next advantage is (ii) it can be attached to the vessels with a minimum length of
the weld stream. In addition, the bracket must be designed to resist the load due to any bending
moment which cause by wind or other loads. Figure 2 below is the sketch of a bracket support
arrangement.

15
2.6 Pressure drop across the reactor
There are pressure drops across the reactor with a pressure difference from the inlet and outlet
stream of reactor. The pressure drop across the reactor is calculated based on the pressure drop
equation given by (Silla, 2004) as shown below.
L u2
P 8 J f ( )
de 2
Given,
P = pressure drop across the reactor
Jf = friction factor (obtain from Table 12.24 from Coulson & Richardson, Vol 6, 2004)
de = equivalent diameter

16
Specifications and steps of Pressure Drops Calculation Several values which are calculated in
the design reactors will be used for the specification of the calculation for pressure drop across
reactor. Therefore, the values calculated and parameters involved for the calculation are
tabulated in Table below.
Table 3: Specification for the calculation of pressure drop
Flowrate of mixture into reactor, Fao Density of inlet fluid to reactor, fluid
Fao =2777 kg/hr fluid = 1142.89 kg/m3

Diameter of channel into reactor, d Viscosity of fluid entering the reactor,

d = 0.08 m
= 0.003965 Pa.s
Total height of vessel (include heads) Equivalent diameter, de
L = 8.8 m de = 3.66 m

Determination of Reynolds number (Re)

First step is to find the cross sectional area of inlet channel (A) using equation stated below.
D 2
A
4
Hence, the area of inlet channel is 0.0050265 m2

The value of area calculated and other parameters obtained as stated in table above will be used
to find the inlet fluid velocity (u) by using equation:
F
v
A *P if

Thus, the inlet fluid velocity (v) is 1.54 m/s

Therefore we need to calculate Reynolds number by using the flowing equation:
d
Re
u
The above equation will give you 35, 469.53 (more than 2100, thus it is turbulent flow). So, by
using the value of the Re you need to use the graph to get the value of Jf

17
 Figure 2: Friction factor
Based on the figure shown above, the friction factor (jf) is found to be as 0.06. therefore we
substitute the Previous equation to get the value pressure drop.
L u2
P 8 J f ( )
de 2
Which will give you P = 509.70 Pa = 0.51 kPa
The pressure drop across reactor is 0.51 kPa whereby, it is lesser than 101.33 kPa (1 atm). Refer
to the standard guideline, pressure drop lesser than 101.33 kPa (1 atm) is considered feasible to
be applied in industry.

18
 CHAPTER 3

MECHANICAL DESIGN
3.1 Reactor Design
3.1.1 Reactor Design Pressure

The pressure is calculated after considering 5% safety factor for internal pressure. Thus,
Operating Pressure, P = 2989 kPa (absolute)
Thus design pressure,
Pd = 2989 x 1.05 = 3138.45 kPa

3.1.2 Reactor Design Temperature

Tdes = Top (1.05)

Where Tdes = Design Temperature
Top = Operating Temperature = 400C
Taking into account a 5% factor of safety,
Design Temperature = 1.05 x 400C = 420 C

3.1.3 Material of Construction

One of the important things that need to be considered when designing equipment is the
materials that are used to construct the equipment. The importance of selecting the best material
when constructing the equipment is to ensure that the equipment will have longer life-span and
to prevent any mechanical damages from happening in the future. There are many factors that
should be considered when choosing the material of construction, but the major factors are
usually the ability to resist corrosion, cost and mechanical strength. Materials that have been
selected for the components of the reactor are summarized in the table 4 below.

19
 Equipment Material Specification
Shell Stainless Steel type 340
(IS:1570-1961, 05 Cr 18, Ni 11, Mo 3)
Closure Stainless Steel type 340
(IS:1570-1961, 05 Cr 18, Ni 11, Mo 3)
Bolt 18-8 Cr-Ni Steel
Flange Stainless Steel type 340
(IS:1570-1961, 05 Cr 18, Ni 11, Mo
3,)
Gasket Asbestos filled with corrugated metal
jacket for stainless steel (Based on
IS:2825-1969)
Brackets Carbon Steel, IS : 2002-1962 Grade
2A
Table 4: Selection of Materials for Reactor Components

3.1.4 Reactor Cylindrical Shell Thickness

On the reactor side, syngas at an average temperature of 420C will be circulating. As syngas is
corrosive, stainless steel Stainless Steel (Type 340, IS: 1570-1961) is chosen as material of
fabrication for reactor as it is also can sustain wide temperature condition from 0C to 500C

The minimum shell thickness can be calculated as flowing is:

p i *D i
t c
(2 fj pi )
Where Di = internal diameter
f = design stress
t = minimum thickness required
Pi = internal pressure
J = welding efficiency = 0.9 for Class 1: Single welded butt joint with backing strip
c = corrosion allowance

Design stress of stainless steel (Type 340, IS: 1570-1961):

f (max temp=600C) = 3.80 x 108 N/mm2
Inside diameter of shell, DR = Di = 2.36 m
t = (2989x103) (2.36) / [2 (3.80x108) (0.9) 2989x 103] + c
= 0.0103 m + c

20
 = 10.3mm + c
2mm corrosion allowance will be used. Therefore:
t = 10.3 mm + 2 mm=12.3mm
The above equation is only valid if and only if it satisfy the equation below
D0 t
1.5 And 0.25
Di Di

D0 Di 2 * t 2.36 2 * 0.0123 2.3846m

D0 2.3846
1.01 1.5 Which mean it is valid.
Di 2.36
t 0.0123
0.0052 0.25 Which means valid.
Di 2.36

3.2 Reactor Closures (Head and Closure)

p *R C *C s
t c
2 fj p(C s 0.2)

1 RC
Cs (3
4 RK

Where:
J = joint factor = 0.9
f = design stress = 100 N/mm2
P = 2989x103 Pa
Rc = crown radius = should be greater than D0
Rk = knuckle radius = 0.06Rc
Rk/Rc should not be less than 0.06
D0 Di 2 * t 2.36 2 * 0.0123 2.3846m

1 2.3846
Cs (3 ) 1.77
4 0.06 * 2.3846
p * RC * C s
t c
2 fj p(C s 0.2)
t = (2989x103) (2.3846) (1.77) / [2 (3.80x108) (0.9) + 2989x103 (1.77 0.2)]

21
 = 0.0183 m
=18.3mm
Adding allowance, t = 18.3mm + corrosion allowance + thinning of torus during fabrication
t = 18.3mm + 4 mm + 0.06x7.28 mm
= 22.755 mm

Volume of dish, V = 0.0847 Di

= 0.0847 x 2.363
= 1.11 m3

3.3 Height of Reactor

Height of the closure is also assumed, ho + Sf = 0.6 m
Thus, the total height of the reactor = height of closures + heigh of reactor = 2(0.6) + 7.08
= 8.28 m

3.4 Design of Bolted Flange Joints

Gasket and bolts are designed for both top and bottom closure flanges. Flanges are also designed
accordingly. Welding neck flanges are used here because it is suitable for extreme service
conditions such as high temperature. It has long tapered hub between flange ring and weld joint.
This helps reduce discontinuity stress between flange and joint. It is commonly used for
removable vessel heads for ease of access.

3.4.1 Gasket Design

The raised-faced flanges are applied in the design wherein the gasket is held in place by friction
between the gasket and flange surface. This is the most commonly used type of flange whereby
the flanges are simple, inexpensive and both the connecting flanges are identical to each other.
Besides, it is good for low pressure services but care should be taken as there is possibility of
gasket blowing out. For this reactor design, gasket made of asbestos with a suitable binder and
1.6 mm thick is recommended.

22
From Table 13.4 (Sinnott, 1999)

Material of gasket = Asbestos with a suitable binder (1.6 mm thick)

Gasket factor, m = 2.75
Min design seating stress, y = 25.5 MN/m2
Min actual gasket width = 10mm
Shell outside diameter, B = 2.404 m
Shell thickness, go = 0.022 m
Gasket diameter ratio,

d0 y PD m

di y PD (m 1)

Substituting the equation with previous values which will give

d0 y PD m
1.708
di y PD (m 1)

Gasket inner diameter, di = 2.404m + go

= 2.404 + 0.022
= 2.426 m
Hence,
Gasket outer diameter, do = di x gasket diameter ratio
= 2.426 mx 1.708
= 4.145 m

d 0 d i
Minimum Gasket width = = 0.859 m
2

Taking even gasket width, N = 0.859 m = 859.28 mm

Outside diameter of gasket where gasket reaction acts, G = di + N

= 2.426 + 0.859
= 3.285 m

23
3.5 Reactor Weight

The major sources of dead weight loads are:

1. The vessel shell

2. The vessel fittings, man way, nozzles.

3. Internal fitting plates.

4. External fitting ladder, platform, piping.

5. Auxiliary equipment.

6. The weight of the liquid to fill the vessel.

3.5.1 Weight of shell

Total weight of shell can be calculated by this formula:

( )

Wv is total weight of the shell,

Cv is a factor (1.15) accounting for weight of nozzles, manways, internal supports,
Hv is the height between tangent lines,(total height) = 8.28 m
g is the gravitational factor, 9.81m/s2
t is the wall thickness =22.75
Dm is the mean diameter of the vessel (outer diameter,m)
Dm =(Di + tx10-3), m = 2.39 m

( )( )( ( ))( )

3.5.2 Total Weight of Baffles Plate

Number of plates = 10
Plate diameter = 2.05146 m

24
Baffle cut = 25%
b = angle subtended by the baffle chord, rads = 2.1 rads

D 2b b D
Baflearea 2( ) ( b 25% Db ) 2 tan b jak 1.1885 m 2
4 2 2 2
Weight of plate = 1.2 kN/m2 (Table 34, Mechanical Design Handbook)
Total weight of baffle = 1.1885 x 1.2 kN/m2
= 1.426 kN
3.5.3 Weight of Tubes
Number of tubes = 589
Weight per feet of tube = 5.8 lb/ft = 81.4 N/m [32] from table D-13, Timmerhaus
Length of tube = 6.096 m
Total weight of tubes = 589 (6.096) (81.4)
= 292.27 kN

3.5.4 Weight of Fluid in Reactor

Total weight of fluid in reactor comprises of the weight of fluid, catalyst and coolant. On the
tube side, the volume of fluid and catalyst are calculated.
Volume of fluid = Volumetric Flow rate x Residence Time =12.5 m 3
Density of fluid = 16.3040 kg/m3
Weight of fluid = 12.44 x 16.3040 x 9.81
= 1.99 kN

Weight of catalyst = 9960 x 9.81

= 97.71 kN
Maximum Volume of Cooling water = volume of shell - volume occupied by tubes
= /4 (2.36)2 (7.096) 589 [ /4 (0.0605)2 (6.096)]
= 31.04 10.32 = 20.72 m 3
Cooling water = 1003 kg/m3
Weight of cooling water = 20.72 (1003) (9.81)
= 203.873 kN

25
Total weight of fluid = 1.99 kN + 97.71 kN + 203.873 kN = 303.572 kN
3.5.5 Weight of Insulation Material

Insulating material = mineral wool

Density = 130 kg/ m 3
Thickness = 100 mm
Approximate volume of insulation = (Do) ( t insulation) (L)

= (4.145)(0.100)(6.096)
= 7.938 m 3
Weight of insulation = 7.938 x 130 x 9.81
= 10.123 kN
Total Weight of Reactor = (130.72 + 1.426 + 292.27 + 303.572 + 10.123) kN
= 738.11 kN

3.6 Wind Loading

2
Wind pressure Pw = KU w
= 0.05 x 160 2
= 1280 N/m2
Loading per unit length, Fw = PwDeff
t insulation
Deff = Do + 2 + 0.4
=4.145 + 2(0.1) + 0.4
=4.745 m
Fw = 1280 x 4.745
= 6.074 kN/m

Bending moment at the bottom,

M = Fw X2/2
= 6.074 x 7.09 2 / 2
= 152.92 kNm

26
3.7 Analysis of Stress at bottom
3.7.1 Pressure Stresses
The longitudinal and circumferential stresses due to pressure given by
pD i 2.989 N / mm 2 * 2.36(10 3 )
L 77.52 N / mm 2
4t 4 * 22.75
pD i 2.989 N / mm 2 * 2.36(10 3 )
h 155 N / mm 2
2t 2 * 22.75

3.7.2 Dead weight stress

Wv 738.11 *10 3
w 4.35 N / mm 2
( D i t )t (2.36 *10 22.75)22.75
3

3.7.3 Bending Stress

The longitudinal bending stress at the mid-span of the vessel is given by:
M Di
b t
Lv 2

Lv (D 0 D i )
4 4

64
Where,
M = Longitudinal bending stress at the mid-span
Iv = Second moment of area of the shell

Lv (2404 4 2360 4 ) 1.17 *1011 mm 4
64
0.166 *10 9 2360
b 9
22.75
1.17 *10 2
= 1.705N/mm2

Resultant longitudinal stress, z = L + w b
w is compressive, thus the value will be a negative value.
z (upwind)= (77.52 4.35 + 1.705) N/mm2 = 83.6 N/mm2
z (downwind)= (77.52 4.35 - 1.705) N/mm2 = 80.16 N/mm2

27

As assume that there is no torsional shear stress, the principal stresses will be z and h
P 0.84015
Radial stress is negligible, i 0.42 N / mm 2
2 2

Prior to determine the maximum stress,

1 = h = 155N / mm2
2 = z (upwind) = 83.6 N/mm2
= z (downwind) = 80.16 N/mm2
3 = P/2 = 0.42 N/mm2

Therefore apply to get the maximum stress:

( 1 - 2 ) up = 71.4 N/mm2
( 1 - 2 ) down = 74.84 N/mm2
( 1 - 3 ) = 154.58 N/mm2

Therefore, the maximum stress = 74.84N/mm2 (< 118 N/mm2, valid)

This value is well below the maximum allowable design stress, f (118N/mm2). Thus, the design
is satisfactory.

3.7.4 Elastic stability (buckling)

If the resultant axial stress, z due to the combined loading is negative, the reactor may fail due
to elastic instability (buckling). The condition for this not to take place is the maximum
compression stress, c must be more than the critical buckling stress c max .

c max w b( ve)
= -4.35 1.705= -6.055N/mm2
t
c 2 *10 4 ( ) = 2 x 10 4 (22.75/2404) = 183.028 N/mm2
D0
The maximum compression stress is 6.055 N/mm2< 183.028 N/mm2, well below the critical
buckling stress. So design is satisfactory.

28
3.8 Reactor Support
Reactor will be placed vertically. Cylindrical skirt support is used. The skirt thickness must be
sufficient to withstand the dead weight loads and bending moments imposed on it by the vessel;
it will not be under the vessel pressure. From Sinnot (2000),
The resultant stresses in the skirt will be:

s (tensile) bs ws
And s (compressive) bs ws where bs is the bending stress in the skirt.
4M s
bs
( D s t s )t s D s
ws The dead weight stress in the skirt,

W
ws
( D s t s )t s
Where Ms = maximum bending moment, evaluated at the base of the skirt (due to wind, seismic
and eccentric loads,
W = total weight of the vessel and contents,
Ds = inside diameter of the skirt at the base,
ts = skirt thickness.

As first trial take the skirt thickness as the same as the shell thickness, 39.35 mm
ts = 22.75 mm
Ds = 3.038 m (=Di shell)
W = 738.11kN
Wind loading = Fw = 6.074 kN/m
Ms, Bending moment at the base of the skirt = (6.074*(3.414+0.02275)2)/2 = 36kNm

bs =0.2366N/mm2
ws =2.9033 N/mm2
s (tensile) bs ws = -2.6667 N/mm2
s (compressive) bs ws =3.1399 N/mm2

29
The skirt thickness should be such that under the worst combination of wind and dead-weight
loading the following design criteria are satisfied:
s (tensile) f s J sin s

ts
s ( compressive) 0.125E ( ) Sin s
Ds

where fs = maximum allowable design stress for the skirt material at ambient temperature,
J = weld joint factor
s = base angle of a conical skirt, normally 80 to 90
E = Young modulus of the material = 200,000 N/mm2 for plain carbon steel.

s (tensile) = -2.6667 N/mm2 < 83.7 N/mm2 which means satisfied

22.75
s ( compressive) 0.125 * 200,000( ) Sin90
3038
3.1399 N/mm2< 323.82 N/mm2 which means satisfied

3.9 Nozzles Sizing

Four nozzles are designed according to each stream specifications: Feed stream nozzle, reactor
product outlet nozzle, molten salt (coolant) inlet, and molten salt outlet.

3.9.1 Inlet and Outlet Nozzle

d/D 0.5

d=diameter of nozzle

D=diameter of vessel

Suggest d=0.55

30
4.1 OPERATING MANUAL PROCEDURE

4.1.1 SCOPE AND OBJECTIVES

This procedure provides operating instruction for the HTS Reactor System; Included are
operation instructions for system start-up and shutdown.

4.1.2 MATERIAL AND EQUIPMENT

Special equipment or materials are required to perform these procedures.

4.1.3 Safety & Health

No special safety or health issues are associated with operation of the HTS Reactor.

4.1.4 Procedures

4.1.4.1 Reactor Pre-start up Procedures

Procedure Steps Checklist
1 Ensure that inventory is available at each unit operation. Note that
reactor will be last unit operation to start up.
2 Verify Vessel Readiness for startup, i.e., all maintenance and I&E
works completed, the reactor is clean and rinse with process water
as necessary, man way close, and all blind are removed and proper
gasket are installed.
3 Line up cooling water to shell-side of R-1103
4 Line up all transmitter and stroke all control valve
5 Close, plug and cap all bleeders
6 Place the reactor temperature indicators (TI) and pressure
indicator (PI) in service
7 Purge reactor with high pressure N2 until vent O2 is less than 6%

31
4.1.4.2 Initiate the reactor
Procedure Steps Checklist
1 Introduce the molten salt flow rate to reactor shell side up to 20%
of design rate. Increase reactor inlet temperature slowly to 200C.
2 Increase the molten salt flow rate to reactor shell side up to 50%.
3 Stop circulation
4 Adjust the IPA-water feed flowrate. Adjust the reactor
temperature profile reactor outlet pressure.
5 Increase IPA feed to 100%.
6 When the system steadies out, IPA-water feed is heated up to the
standard operating condition. Refer to SOC.

4.1.4.3 Hot Hold and Shut Down the Reactor

Procedure Steps Checklist
Notify Wastewater Unit, Utilities Unit and Shipping Unit
1 Introduce the molten salt flow rate to reactor shell side up to 20%
of design rate. Increase reactor inlet temperature slowly to 200C.
1 Reduce reactor hydrogen and nitrogen rate to 70% of feed rate.
2 Shut down E001, E002, E004, E005 and E006 gradually by
reducing hot stream flow rate.
3 Reduce reactor feed further to 50% of feed rate, then to 30%.
4 To HOT HOLD the reactor, block all isolation valves, control
valves and manual block valves for cooling water, hydrogen, and
nitrogen feed (syngas). Verify at field that all isolation and control
valve are closed. This is to put reactor on HOT HOLD.
To SHUT DOWN the reactor, block all isolation valves,
controlvalves and manual block valves for ethylene, acetic acid
and oxygen feed at mix line. Verify at field that all shutoff
andcontrol valve are closed.

32
 Equipment Specification Sheet
Item Name High Temperature Water Gas Shift Reactor
Item No. R-1103
Supporting calculations Appendix
Author Ali
Subject Specification Data
Total Height 7700mm
Inner diameter 2360mm
Reactor dimension Outer diameter 2382mm
Thickness 22.75mm
Volume 12.5m3
Type Ellipsoidal head
Head closure Thickness 22.75mm
Height 0.6m
Inner diameter 45mm
Minimum thickness 2mm
Corrosion allowance 2mm
Tubes
Actual thickness 4mm
Height 6096mm
Number 589
Type Cr-Fe Oxide
Diameter 6mm
Catalyst
Weight needed 9960kg
Density 1200 kg/m3
Number 4
Baffle Spacing 0.4m
Type Doughnut
Operating pressure 29 bar
Pressure Design pressure 31.9bar
Pressure drop 0.5 bar
Operating temperature 400 C
Temperature
Design Temperature 440 C
Type Stainless Steel 340
Reactor material
Design stress 118 N/mm2
Inlet and outlet nozzle nozzle diameter 0.55m
Inlet phase Vapour
Reactant
Outlet phase Vapour

Molar flow 3913 kmol/h

33
4.1.5 Reactor mechanical Drawing.

34
Chapter 4: Minor Equipment Design

4.1 Vapor Liquid Separator

The separator is used to physically separate the liquid ammonia from the other vapour
components which is present in the stream. The stream entering the separator contains liquid
content because it has been cooled to -6 C.

Table 1: The components being separated

Component Liquid (kmol/hr) Vapour (kmol/hr)

NH3 191.3123 1676.873

H2 11230.64

N2 3748.893

Ar 759.0861

CH4 1494.064

Total 17423.99 1676.873

4.1.2 Type of separator

There are generally two types of configuration for separators which is commonly used. That is
the vertical separator and the horizontal separator. The horizontal separator is used when the
landscape of the site does not allow tall vessels, for example on hilly areas where it is dangerous
to build tall vessels due to wind speed. Hence the vertical separator is chosen as the area chosen
for the building of site is on flat land. Another advantage to choosing a vertical separator is that it
can save the land used. With a horizontal separator, a larger area is need in the plant for the
separator.

For this separator, it is a separator with no moving part. Unlike a cyclone separator or a
centrifugal separator which has moving parts. Hence little maintenance is need. This will hence

35
decrease the maintenance cost in the long run and there will be no moving parts which will wear
out in the long run.

4.1.3 Demister Pad

The separator can be with or without the demister pad. The function of a demister pad is to
remove the liquid entrained in the vapour stream to ensure a dry vapour stream leaves the
separator. Liquid entrainment occurs when there is dynamic process, for example contact of
vapour and liquid during mass transfer operation, or thermal processes such as condensation.

Using a demister pad will allow the separating coefficient to become 99%. The pressure drop
while using a demister pad is small. This pressure drop is negligible.

The separator chosen is the KnitMesh Mist Eliminator (Sulzer Chemtech). This separator can
be made from materials like stainless steel, Alloy, Copper, plastics or glass fiber. The material
chosen for this design is stainless steel. As the component involved, ammonia, is corrosive.

The operational range of this demister pad is that it has low capacity with K-values typically up
to 0.107m/s. It can efficiently separate the droplet size which is up to 2 to 3 m. The estimated
pressure drop is less than 2.5mbar. Hence it can be neglected. This demister pad can be easily
tailor made to the vessel shape and size.

Sizing of the separator

The sizing of the separator can be done based on the following equation:

V = maximum superficial gas velocity

l = liquid density

36
v = vapour density

K = a constant which specific to the separation equipment

K is a function of process parameters such as liquid loading, gas and liquid viscosity, gas
pressure and surface tension. From the chosen demister pad, the K-value is 0.107m/s. The K-
value is reduced by a factor of 2/3. The k-value is then reduced to 0.071m/s. Hence the gas
velocity, v, is 0.15m/s.

The minimum allowable diameter of a vessel can be calculated with the following equation:

Where Dv = minimum vessel diameter, m

Vv = vapour flow rate, m3/s

us =v, if a demister pad is used, and 0.15v for a separator without a demister pad.

Dv = 3.08m, round to 3.1m

Height of the separator

The height of the separator should have a L:D ratio of 3. This ratio represents the optimum ratio.
But a range of 2.5 to 5.0 is also acceptable.

37
The height of the separator can be defined as such:

demister pad

0.4m minimum

Dv

Dv 1.0m minimum

0.6m minimum

Liquid level

Height of separator = 7.8m

Ratio L:D =

= 2.5196, which is within the acceptable range

38
4.1.4 Mechanical design

The design pressure is 10% above the operating pressure.

Design pressure = 115*1.1 = 126.5bar = 1.265N/mm2

Design temperature is 10% above the operating temperature.

Design temperature = -6C * 1.1 = -6.6C

Material used is carbon steel. Carbon steel is used because it is able to withstand the temperature
and pressure. As compared to other materials like stainless steel, it is a lot more economical.

39
 SEPARATOR SPECIFICATION
Item Name: Vapour liquid separator V-1105 Item No.
Author: Ali Abdurahman
Fluid Name: Ammonia, Nitrogen, Hydrogen, Argon, Methane
Inlet Flow (kmol/h) 19100.87
Vapour outlet flow(kmol/h) 17423.99
Liquid outlet flow (kmol/h) 1676.87
Temperature (C) -6
Operating Pressure (bar) 115
Design Pressure (bar) 126.5
Pressure Drop Allow/ Calc. (bar) 0
Material of Construction Carbon Steel
OD 3.132m, ID 3.1m, Length 8.575m
Sketch (bindle/Nozzle Orientation)

40
4.1.5 Calculation

Vessel design

Data of liquid

Density,l =39.63kg/m3

Flowrate =35.35m3/hr

Mr =17.11

Table 1: Liquid composition of stream

Components Molar flowrate(kmol/hr) Composition

NH3 1676.87 1.000
Total 1676.87 1.000
Data of vapour

Density,v =4.361kg/m3

Flowrate =4067m3/hr

Mr =10.73

Table 2: Vapour composition of stream

Components Molar flowrate(kmol/hr) Composition

NH3 191.31 0.011
H2 11,230.64 0.645
N2 3,748.89 0.215
Ar 759.09 0.044
CH4 1494.06 0.085
Total 17,423.99 1.000

K =2/3 x 00.107m/s=0.071m/s

= 0.15m/s

Cross-sectional area of drum, =7.45m2

41
 Diameter of Drum,

= 3.08m, round to 3.1m

The liquid level depends on the holdup time. Allow a minumum of 10minutes hold up.

Volume held in the vesssel = 5.89 x 10-4 x (10 x 60) = 5.89m3

Liquid depth required, hv =

=
( )

= 0.78m

Increase to 1m to allow space for positioning the lever controller.

42
4.2 Carbon Dioxide, CO2 Compressor (K-1106)

Compressor is used to transfer and compress gases from one process unit to another to
carry out chemical reactions, separation and to liquefy gases. In this Ammonia and Urea
production plant, K-1106 is located in between the CO2 Regenerator and the Urea Reactor. The
original purpose is to compress product gas coming out of the regenerator to an increased
pressure into the Urea production reactor. The type of compressor will be utilized in this plant is
a multistage centrifugal compressor. A positive displacement compressor will usually be used to
compress same volume of gas in a chamber regardless of the discharge pressure.

4.2.1 The pressure differences between inlet and outlet stream,

( )

4.2.2 Number of stages of the compressor, q

( ) ( )

4.2.3 Polytropic temperature exponent, m

Polytropic Efficiency,

( )

4.2.4 Theoretical Outlet Temperature,

( ) ( )

4.2.5 Polytropic exponent, n

43
4.2.6 Amount of Polytropic work, -W

( ) [( ) ]

( )( )( )( ) [( ) ]

Compressibility factor,

4.2.7 Actual Work Required,

4.2.8 Shaft Power

( )

44
 COMPRESSOR LOAD-SHEET
Item Name: Compressor Item No. K-1106
Supporting Calcs. On page: 42-43 Author Ali Abdurahman
Compressor Type Centrifugal
Spared by Driver
Stage No. 1
Process Material Carbon Dioxide
Mw 44
Cp 103.4
Cp/Cv 1.087
Temperature (K) 423.15
Suction Pressure (bar) 64
Z 1
Discharge Pressure (bar) 171.72
kmol/h 384.2
Normal Capacity kg/h 16900
Actual m3/h 20.4
kmol/h 422.62
Maximum Capacity kg/h 18590
Actual m3/h 22.44
Estimated Efficiency Adiabatic/ Polytropic 0.78
Estimated Power (kW) 370.2
Total Power (kW) 370.2
Notes:

45
REFERENCES

1. Branam, C., Rules of Thumn for Chemical Engineers, 3rd Edition, Gulf Professional
Publishing Company

2. Fair, J. R., Stichmair, J. G., Principles and Practice of Separation, (1998), John Wiley &
Sons Ltd

3. Smith, R., Chemical Process Design and Integration, University of Manchester, (2005),
John Wiley & Sons Ltd

4. Geankopolis, C. J., Transport Processes ans Separation Process Principles, Fourth

Edition, Prentice Hal

5. SINNOT, R. K. (2003).CHEMICAL ENGINEERING DESIGN Butterworth Heinemann.

6. Sinnot, R . K., Coulson & Richardsons Engineering Volume 6, 3rd Editions,

Butterworth-Heinemann

7. Geankopolis, C. J., Transport Processes ans Separation Process Principles, Fourth

Edition, Prentice Hall

8. Fair, J. R., Stichmair, J. G., Principles and Practice of Separation, (1998), John Wiley &
Sons Ltd

9. Douglas, J. M. (1988). CONCEPTUAL DESIGN OF CHEMICAL PROCESSES.

McGraw-Hill Book Company.

46
Reactor Outlet= nozles Issued For Revision PREPARED BY:
D = Shell Inside Diameter ALi
t = Reactor Wall Thickness
H = Height of Reactor
AMMONIA AND UREA PLANT
METHANATOR
GROUP 2 SCALE: NTS SHEET NO. 1 REVISION= A1