FLUIDIZED BED REACTOR

TABLE CONTENTS

1.1 Introduction 2
1.2 Design Pressure and Temperature 5
1.3 Materials of Construction (MOC) 7
1.4 Maximum Allowable Stress 9
1.5 Welded Joint Efficiency and Construction 14
Categories
1.6 Corrosion Allowance 17
1.7 Design Loads 18
1.8 Minimum Practical Wall Thickness 26
1.9 Vessel Supports 33
2.0 Flanged Joints 40
2.1 Design of Fluidized Bed Reactor 42
2.2 Conclusion 44
2.3 References 45

1
 FLUIDIZED BED REACTOR

1.1 INTRODUCTION

1.1.1 Acrylic Acid

Acrylic acid is an organic compound with the formula CH2=CHCO2H.

This is simplest unsaturated carboxylic acid. (ACRYLIC ACID | CH2=CHCOOH
- PubChem)

IUPAC name Prop-2-enoic acid

Other name acroleic acid,
ethylenecarboxylic acid, propene
acid, propenoic acid, vinyl formic
acid.
Molecular formula C3H4O2
Molar mass 72.06266 g/mol
Appearance colourless liquid
Density 1.051 g/mL
Melting point 14 °C
Boiling point 141 °C
Table 1

1.1.2 Production of Arcylic Acid via the Catalytic Partial Oxidation of

Propylene.

2
 FLUIDIZED BED REACTOR

The ultimate aim for the consultation project is to produce Acrylic Acid.
Acrylic acid and its derivatives are very useful in many applications. Acrylic
acid is commonly used for surface coating, textiles, diapers, personal cares
and water treatment industries. There are several chemical pathways to
produce AA, but the most common one is via the partial oxidation of
propylene. The usual mechanism for producing AA utilizes a two-step process
in which propylene is first oxidized to acrolein and then further oxidized to
AA. Each reaction step usually takes place over a separate catalyst and at
different operating conditions. (Turton)

The reaction stoichiometry is given below:

Several side reactions may occur, most resulting in the oxidation of

reactants and products.

The main production of the process was to produce acrylic acid. The
side products for this production were water, acetic acid and carbon dioxide.
The production rate for this process was to produces 50,000 metric tons per

3
 FLUIDIZED BED REACTOR

year of 99.9% by mole of Arcylic acid. The reactor used for the production of
this acrylic acid was by using the fluidized bed reactor.

4
 FLUIDIZED BED REACTOR

1.2 DESIGN PRESSURE AND TEMPERATURE

In designing pressure vessel, there are some considerations must be

taken. The vessel must be designed to withstand the maximum pressure
which will subjected to any operation in industrial production. The
temperature and pressure of the vessel is taken from the equipment
summary table as attached in the appendices. Furthermore, for the
production of acrylic acid from propylene, the design pressure is taken 15%
and 10% above the normal working pressure, to avoid spurious operation of
the relief valve during minor process upsets.

a) Design pressure:

For 15% design

Pressure → 3 bar

= 3 bar × 115%

= 3.45 bar

For 10% design

Pressure → 3 bar

= 3 bar × 110%

= 3.30 bar

5
 FLUIDIZED BED REACTOR

Besides that, design temperature is also taken 15% and 10% above the
normal working temperature. Under the ASME BPV Code, The maximum
design temperature at which the maximum allowable stress is evaluated
should be taken as the maximum working temperature of the material, with
due allowance for any uncertainty involved in predicting vessel wall
temperature. Moreover, the design temperature of the vessel must not be
less than the maximum fluid temperature at the design pressure. The design
temperature of the vessel is calculated as followed:

b) Design temperature:

For 15% design

Temperature → 251.65 ℃ (Upennedu, 2016)

= 251.65 ℃ × 115%

= 289.42 ℃

Therefore: temperature = 289.42 ℃ = 552.96 ℉

For 10% design

Temperature → 251.65 ℃ (Upennedu, 2016)

= 251.65 ℃ × 110%

= 276.84 ℃

Therefore: temperature = 276.84 ℃ = 530.307 ℉

6
 FLUIDIZED BED REACTOR

1.3 MATERIALS OF CONSTRUCTION

Acrylic acid is a substance that will react readily with free radicals and
electrophilic or nucleophilic agents such as (example). It might be polymerize
in the presence of acids such as sulphuric acid, chlorosulfonic acid, alkalis
such as ammonium hydroxide, amines such as ethylenediamine, iron salts,
elevated temperature, light peroxide are formed when oxygen was sparged
into acrylic acid. Moreover, the presence of oxygen is required for the
stabilizer to function effectively. Besides that, acrylic acid should not be
handled under an inert atmosphere. (Kimyasanalcom, 2016)

Polymerization of acrylic acid can occur of it is rethawed under

inappropriate temperature and it is a strong corrosive agent to many metals
such as unalloyed steel, copper and brass. (Kimyasanalcom, 2016). Besides
that, metal ions can initiate polymerization and acrylic acid, especially in the
presence of water, will easily corrode carbon steel and similar metals.
Corrosion and subsequent polymerization initiated by metal ions cannot only
be caused by inappropriate material but also by accidental introduction of
incompatible metals into the system such as gaskets, maintenance tools,
carbon steel bolts and nuts. (European basic acrylic monomer group, 2012)

Thus, it is best choice to use stainless steel (AISI Type 304L) as the
material for fluidized bed reactor. This type of stainless steel is chosen
because it can withstand the design pressure and temperature. It can be

exposed continuously without appreciable scaling about 899 ℃ . Besides

that, it also have very good draw ability and the combination of low yield
strength and high elongation permits successful forming of complex shapes.

7
 FLUIDIZED BED REACTOR

Stainless steel does not readily corrode, rust or stain with water as normal
steel does. However, it is not fully stain-proof most noticeably under low
oxygen, high salinity or in poor circulation environment. There will be
different grades and surface finishes of stainless steel to be chosen in order
to suit the alloy with the environment. (Aksteelcom, 2016)

Stainless steel is an alloy of iron and carbon and often found in

materials used in construction and tools which contain minimum of 10.5%
chromium. Then, the chromium in stainless steel will reacts with oxygen in
the air to produce a very thin, inert, chromium rich oxide film on the surface
of the steel. The presence of this layer will cause the stainless steel to be
more resistance to corrosion. (Aalcocouk, 2016)

This passive film is not like coatings such as paint and if it is

damaged by abrasion or mechanical means such as cutting, it will reforms
and continues to protect the steel. Furthermore, the material selection for
this fluidized bed reactor is stainless steel because of its corrosion resistance
and aesthetic appearance. Moreover, it is very vital to understand the factors
in selecting the best material both in grade and surface finish respectively.
Choosing the most suitable material will increase the performance of the
equipment and increase the product yield. (Aalcocouk, 2016)

Carbon steel cannot be used for this reactor because it will readily
rust when it get exposed to air and moisture. When the moisture react with
the air, it will produce a layer of iron oxide which known as rust and it will
form more rust if it is continuously exposed to air. Layers of rust will tend to
flake and fall away. In the presence of water and acrylic acid, they will readily
react with the carbon steel and corrosion occur. Different with carbon steel,
stainless steel has sufficient chromium to form a passive film of chromium
oxide which will prevents further surface corrosion by preventing oxygen

8
 FLUIDIZED BED REACTOR

diffusion to occur on the steel surface and eventually blocked the corrosion
from spreading into the metal’s internal structure and due to similar size of
the steel and oxide ions, the bond are very strong and it will attached
strongly onto the surface. (Aalcocouk, 2016)

1.4 MAXIMUM ALLOWABLE STRESS

Analysis of stresses

For 10% design,

t= 10.8mm P = 0.33 N/mm2 Di = 3600 mm

Pressure Stresses

Longitudinal stress, ƠL = PDi / 4t

(0.33)(3600)
ƠL = 4 (10.8) = 27.5 N/mm2

Circumferential stress, Ơh = PDi / 2t

(0.33)(3600)
Ơh = 2(10.8) = 55 N/mm2

Dead weight stresses

- Due to weight of the vessel, its contents and any attachments.

9
 FLUIDIZED BED REACTOR

Ơw = Wz / [ ╥(Di + t) t ]

173.64∗1000
Ơw = ╥ (3600+10.8)(10.8) = 1.417 N/mm2

Bending stresses

Do = Di + 2t

Do = 3600 + 2(10.8) = 3621.6 mm

Ơb = ±(M/Iv)[ Di/2 + t]

740000 3600
+10.8 ¿ = ± 6.71*10-3 N/mm2
Ơb = ± ( 1.997∗1011 )( 2

Where M : total bending moment at the plane

Iv : second moment area of the vessel about the plane of bending

╥
Iv = 64 ( Do4 – Di4 )

╥
Iv = 64 ( 3621.64 – 36004 ) = 1.997*1011 mm4

Longitudinal Stress

10
 FLUIDIZED BED REACTOR

Ơz = ƠL + Ơw ± Ơb

Since Ơw is compressive, thus the value will be negative.

Upwind :

Ơz = ƠL +( -Ơw ) + Ơb

Ơz = 27.5 + ( -1.417 ) + 0.00671 = 26.09 N/mm2

Downwind :

Ơz = ƠL +( -Ơw ) - Ơb

Ơz = 27.5 + ( -1.417 ) - 0.00671 = 26.076 N/mm2

26.09 N/mm2 26.076 N/mm2

Upwind Downwind

Thus, the greatest difference between the principal stresses is at the

downwind side of the vessel, which is:

55.00 – 26.076 = 28.924 N/mm2

Comparing with the design stress;

Maximum allowable design stress = 87.71 N/mm2

Greatest difference stress = 28.924 N/mm2

11
 FLUIDIZED BED REACTOR

As the maximum allowable design stress is more than the greatest difference
between principal stresses, the vessel design is valid.

For 15% design,

t= 11.2mm P = 0.345 N/mm2 Di = 3600 mm

Analysis of stresses (N/mm2)

1. Pressure Stresses ƠL = 27.723
Ơh = 55.446
2. Dead weight stresses Ơw = 1.409
3. Bending stresses Ơb = ± 0.00647
4. Longitudinal Stress (upwind)Ơz = 26.320
(downwind)Ơz = 26.308
Greatest difference between 29.138
principal stresses

12
 FLUIDIZED BED REACTOR

26.320 N/mm2 26.308 N/mm2

Upwind Downwind

Comparing with the design stress;

Maximum allowable design stress = 86.77 N/mm2

Greatest difference stress = 29.138 N/mm2

As the maximum allowable design stress is more than the greatest difference
between principal stresses, the vessel design is valid.

13
 FLUIDIZED BED REACTOR

1.5 WELDED JOINT EFFICIENCY AND CONSTRUCTION

Maximum Allowable Stress

1st Trial: 10% of operating condition

 Pi = 3.3 bar

 Ti = 276.837 °C which is equivalent to 530.3066 °F

Interpolation

14
 FLUIDIZED BED REACTOR

Temperature Maximum Allowable

(°F) Stress (ksi)

500 12.9

530.3066 S

700 11.7

S  12.9 530.3066  500


11.7  12.9 700  500

S  12.718ksi

S  12.718 103 psi

Conversion of unit from psi to Pa

1Pa
S ( Pa)  12.718 103 psi 
0.000145 psi

S  8.77110 7 Pa

2nd Trial: 15% of operating condition

15
 FLUIDIZED BED REACTOR

 Pi = 3.45 bar

 Ti = 289.43 °C which is equivalent to 552.956 °F

Interpolation

Temperature Maximum Allowable

(°F) Stress (ksi)

500 12.9

552.956 S

700 11.7

S  12.9 552.956  500


11.7  12.9 700  500

S  12.582ksi

S  12.582 103 psi

Conversion of unit from psi to Pa

1Pa
S ( Pa)  12.582 103 psi 
0.000145 psi

S  8.6772  107 Pa

1.6 CORROSION ALLOWANCE

16
 FLUIDIZED BED REACTOR

Corrosion allowance is very important as an estimation of how much

thickness need to be added to the equipment in order to avoid it from being
corroded, eroded or scaled. The commonly minimum corrosion allowance
used is 2 mm for normal condition. However, for this process the substances
used are very corrosive, hence higher corrosion allowance need to be used
instead of 2 mm. Due to this reason, the corrosion allowance chosen for this
process is 4 mm due to the high corrosive substances used. This is mainly for
safety purpose.

Corrosion Allowance = 4 mm

1.7 DESIGN LOADS

17
 FLUIDIZED BED REACTOR

1.7.1 Dead Weight of Reactor

a) For 15% design, t=11.2mm

Major sources of dead weight are:

1. The vessel shell

 Since the MOC for this equipment is Carbon Steel, therefore for a steel
vessel the equation shown below is applied:

Wv =
Cw = 1.08 240CwDm(Hv+0.8Dm)t

Dm = (Di + t × 10-3)

= 3.6m + (11.2 × 10-3m)

= 3.61m

Hv = 10m

t = 11

For a steel vessel

Wv = 240 (1.08) (3.61m) [10m + 0.8 × 3.61m](11.204 × 10-3m)

Weight of vessel = 135.16kN

2. Vessel fittings

18
 FLUIDIZED BED REACTOR

 There are 2 nozzles embedded to the reactor which are the inlet and
outlet nozzles respectively.
 i) Rm = 70.886 inch
ii) T = 0.425 inch
iii) ro = 8 inch
iv) P = 50.038 pounds per inch square
v) Sy = 31,200 psi

Rm = Mean Radius of Shell, inches

T = Shell Thickness, inches
ro = Nozzle Outside Radius, inches
P = Design Pressure, pounds per square inch (psi)
Sy = Yield Strength of Material at Design Temperature, pounds per
square inch (psi)

Rm
 γ=
T
70.866
γ=
0.441
γ = 160.69

ro
 β=0.875( )
Rm

8
= 0.875 ( 70.866 ¿

= 0.099

 Based on the appendix (graph for Nozzles load), α =150,000

 σ= ( 2TP )( R − T2 )
m

2 ( 50.038 ) 0.441
=[ ¿ [70.866− ]
0.441 2

19
 FLUIDIZED BED REACTOR

= 16, 031.56 psi

2
Rm
 FRRF = (S y −σ )
α

(70.886)2
= ×(31,200−16,031.56)
150,000
= 507.86 lbf
= 2259.06 N (Based on handbooks of Megyesy,
2001)

for 2 nozzles = 4518.13 N

Weight of nozzles= 4.518kN

3. Internal fittings: plates (plus the fluid on the plates)

 Based on Nelson (1963), for contacting plates, steel, including typical

liquid loading of 1.2kN/m2 plate area.

 Weight of plates:
2
π ×(3.6 m)
Plate area = 4 = 10.18m2

 Weight of a plate including liquid on it

= 1.2kN/m2 × 10.18m2
= 12.22 kN
Since there is only one porous plate in a fluidized bed reactor so,
Weight of the plate = 12.22kN

4. External fittings: (Ladders, Platforms, piping)

 For the design of the reactor, there will be no ladders attached to it

since it involves reaction with very high temperature and pressure.
 There is no platforms design for the reactor as it will be directed to the
ground.

20
 FLUIDIZED BED REACTOR

5. Auxiliary equipment that is not self-supported

 Agitators are not needed in a fluidized bed reactor unlike in a

Continuous Stirred Tank Reactor, CSTR.

6. Insulation

 The insulating material used is Mineral Wool because it is made of

porous material that traps air making it one of the best insulating
materials. Due to the flammability of Acrylic Acid, it is preferable than
the other 2 materials like Foam glass and Calcium silicate because it is
incombustible and will not be induced by fire. Moreover, it has high
resistance to heat flow making it the most suitable insulating material
to be chosen.
 Mineral wool insulation ranges from 3.7 inch to 4.2 inch (94mm to
107mm) of thickness.
 Density of mineral wool = 130kg/m3
−3
 Volume of insulator = π × 3.6 m×10 m ×(94 ×10 m)
= 10.63m3
3 3 2
 Weight of insulator = 10.63 m ×130 kg /m × 9.81m/ s
= 13,556.44 kgm/s2 or 13,556.44 N
 To allow for fittings, therefore the weight of insulator needs to be
doubled
= 13.56kN × 2
Weight of insulator = 27.11 kN

7. Weight of catalyst

 Only the weight of catalyst is calculated because the process only

involves gas phase, therefore weight of liquid is not required.
 The use of catalyst in the catalytic partial oxidation of propylene to
produce acrylic acid is to propel the oxidation steps.
 The catalyst used in this reaction is Vanadium Oxide, V2O5.

21
 FLUIDIZED BED REACTOR

dx −r A
 =
dw F AO

−r A=k C 2AO (1−x )2

2 2
dx k C AO (1−x)
=
dW F AO
0.9 W 2
1 k C AO
∫ (1−x 2
dx=∫ dW
0 ) 0 F AO

2
−1 0.9 k C AO
[ 2
] = [W ]W
0
( 1−x ) 0 F AO

(49.43 m 3/g .cat . min)

-9 = ×[W −0]
2482.2m 3/min

W = 452 g of catalyst

 W = 0.45kg
W = 0.45kg × 9.81m/s2
Weight of catalyst = 4.43 N

The total weight, Wz

= 135.16kN + 12.22kN + 27.11kN + (4.43 × 10-3 )kN + 4.518
Wz = 179.01 kN

b) ) For 10% design, t= 10.8mm

Major sources of Dead Weight Weight (kN)

1. The vessel shell 130.24
2. The vessel fittings 4.07
3. Internal fittings : plates (plus 12.22
fluid on the plates)
4. External fittings : ladders, -
platforms

22
 FLUIDIZED BED REACTOR

5. Auxiliary equipment that is not -

self- supported: Agitators
6. Insulation 27.11
7. Weight of catalyst 4.43 ×10 -3

Total Weight, Wz 173.64

1.7.2 Dynamic Wind Pressure

Pw = 0.06Uw2

The plant is located in Gelang Patah, Johor and the wind speed at that
particular area is 5 miles per hour which is equals to 8.047 km/h.

23
 FLUIDIZED BED REACTOR

a) For 15% design, t=11.2mm

 In order to increase the drag, therefore 0.06 is applied in the above

equation instead of 0.05

 Pw = 0.06 × (8.047 km/h)2 = 3.885 N/m

b) ) For 10% design, t= 10.8mm

 In order to increase the drag, therefore 0.06 is applied in the above

equation instead of 0.05

 Pw = 0.06 × (8.047 km/h)2 = 3.885 N/m2

1.7.3 Wind Loading

a) For 15% design, t=11.2mm

 Mean diameter, Deff (including insulator)

= 3.6m + [2(11.2 + 94) × 10-3m]
=3.8104m

 Loading (per linear meter) =3.885 N/m2 × 3.8104m

= 14.80 N/m

 Bending moment at bottom tangent line

Mx = 14.80/2 × 102
= 740.0 Nm

24
 FLUIDIZED BED REACTOR

 Wind Loading = 740.0 Nm

b) For 10% design, t= 10.8mm

 Mean diameter, Deff (including insulator)

= 3.6m + [2(10.8 + 94) × 10-3m]
=3.8096m

 Loading (per linear meter) =3.885 N/m2 × 3.8096m

= 14.80 N/m

 Bending moment at bottom tangent line

Mx = 14.80/2 × 102
= 740.0 Nm

 Wind Loading = 740.0 Nm

1.8 MINIMUM PRACTICAL WALL THICKNESS

Design of Thin Walled Vessel under Internal Pressure

Assumptions

1. The reaction is occurred in reactor.

2. Design temperature and pressure must higher than operating

temperature.

3. Shape of reactor is cylindrical.

4. Two different percentages of design temperature and pressure are

compared to evaluate their effects.

25
 FLUIDIZED BED REACTOR

Informations from previous calculation.

Percentage of design 10% 15%

℃ 276.84 289.42
Temperature ¿ )
Pi 330000 345000
Pressure, (N/m2)
Maximum allowable stress, S 8.771x107 8.6772x107
(N/m2)
Maximum Allowable Joint 1.0 1.0
Efficiency, E (dimensionless)
Corrosion allowance (mm) 4
Di 3.6
Diameter, (m)

1.8.1 Cylindrical shell of reactor

Minimum thickness of shell is so crucial as to resist internal pressure.

a. For 10% design

Pi D i
t=
2 SE−1.2 Pi

t=
( 330× 10 N
m
2 )
(3.6 m)

330 ×103 N
2 ( 8.771 ×107 N /m 2 ) (1.0 )−1.2 ( m2 )
26
 FLUIDIZED BED REACTOR

t=0.0068 m=6.8 mm

After adding corrosion allowance,

t=6.8 mm+ 4 mm

t=10.8 mm

1.8.2 Design heads and closures

1.8.2 i) Flat plated that formed flat heads

Assume Ct=D e
SE√
C Pi
is constant = 0.1

So De =

Assume C is constant = 0.1

So De = Di

27
 FLUIDIZED BED REACTOR

√
330× 103 N

t=(3.6 m)
0.1
( m2 )
( 8.771× 107 N /m2 N /m2 ) (1.0 )

t=0.069 m=69 mm

1.8.2 ii) Hemispherical head

Pi D i
t=
4 SE−0.4 Pi

330 ×10 3 N

t=
( m2 )
( 3.6 m)

330× 103 N
4 ( 8.771 ×107 N / m2 ) ( 1.0 )−0.4 ( m2 )

t=0.0034 m=3.4 mm

1.8.2 iii) Ellipsoidal head

P i Di
t=
2 SE−0.2 Pi

28
 FLUIDIZED BED REACTOR

t=
( 330× 10 N
m2 )
(3.6 m)

330 ×103 N
2 ( 8.771 ×107 N /m2 ) (1.0 )−0.2 ( m2 )

t=0.0068 m=6.8 mm

1.8.2 iv) Torispherical head

0.885 P R
t=Assumei Rc c = Di
SE−0.1 Pi

Assume Rc = Di

330 ×10 3 N

t=
(0.885) ( m2 )
(3.6 m)

(
( 8.771× 107 N /m2 ) ( 1.0 )−0.1 330 ×10
2
N
m )

t=0.0119 m=11.9 mm

Therefore, the most suitable head is torispherical since its thickness can fit
the cylindrical shell of reactor.

1.8.3 Cylindrical shell of reactor

b. For 15% design

Pi D i
t=
2 SE−1.2 Pi

29
 FLUIDIZED BED REACTOR

345 × 103 N

t=
( m2 )(3.6 m)

345 ×103 N
2 ( 8.6772 ×107 N / m2 ) (1.0 )−1.2
( m2 )
t=0.0072 m=7.2 mm

After adding corrosion allowance,

t=7.2 mm+4 mm

t=11.2 mm

1.8.4 Design heads and closures

1.8.4 i) Flat plated that formed flat heads

Assume Ct=D e
C Pi
is constant
SE √
= 0.1

30
 FLUIDIZED BED REACTOR

So De =

Assume C is constant = 0.1

So De = Di

√
345 ×10 3 N

t=(3.6 m)
0.1
( m2 )
( 8.6772× 107 N /m2 ) ( 1.0 )

t=0.0718 m=71.8 mm

1.8.4 ii) Hemispherical head

Pi D i
t=
4 SE−0.4 Pi

345 ×10 3 N

t=
( m2 )
(3.6 m)

345× 103 N
4 ( 8.6772 ×107 N /m2 ) (1.0 )−0.4 ( m2 )

t=0.0036 m=3.6 mm

1.8.4 iii) Ellipsoidal head

P i Di
t=
2 SE−0.2 Pi
31
 FLUIDIZED BED REACTOR

345× 103 N

t=
( m2 )
(3.6 m)

345 ×103 N
2 ( 8.6772 ×107 N / m2 ) (1.0 )−0.2 ( m2 )

t=0.0072 m=7.2 mm

1.8.4 iv) Torispherical head

0.885 P R
t=Assumei Rc c = Di
SE−0.1 Pi

Assume Rc = Di

345 ×10 3 N

t=
(0.885) ( m2 )
(3.6 m)

(
( 8.6772× 107 N /m2 ) ( 1.0 )−0.1 345 ×10
2
N
m )

t=0.0127 m=12.72 mm

Therefore, the most suitable head is torispherical since its thickness can fit
the cylindrical shell of reactor. In conclusion, different percentages of design
pressure and temperature do not affect the shape of head of reactor.

1.9 VESSEL SUPPORTS

32
 FLUIDIZED BED REACTOR

A skirt support is one of the accessories in designing process

equipment. It is more recommended to vertical vessels as they do not
impose concentrated loads on the vessel shell. Although the wind load for
this process is not that huge, it still need support at the bottom of the reactor
to secure it. The material of construction chosen for the skirt support is
carbon steel.

Assumptions: 1) Straight cylindrical skirt of Carbon Steel where the angle is

90°

2) Young modulus of 200,000 N/mm2

3) Height of Skirt Support is assumed to be 1.98 m

(based on the reference from table in Design of Skirt Support

section)

Skirt Support for 15% of operating condition

 The maximum dead weight load on the skirt will occur when the
vessel is full of water.

 Maximum Allowable Stress = 8.6409×107 Pa = 86.6409 N/mm2 (For

CS)

  
  3.6  10  1000  9.81  998,666 N  999kN
2

 4 
 Approximate Weight =

 Total weight of the vessel = 179.01 kN

 Total Weight = 999 + 179.01 = 1178.01 kN

 Wind loading = 14.80 N/m = 0.0148 kN/m

33
 FLUIDIZED BED REACTOR

(10  1.98) 2
0.0148   1.0621kNm
2
 Bending moment at the base of skirt =

 Thickness of the reactor = 11.2 mm (with corrosion allowance)

 As the first trial, the reactor thickness is divided into 5 sections

which are; 11.2 mm, 13.2mm, 15.2 mm, 17.2 mm, 19.2 mm

 As the first trial, take the skirt thickness as the same as 15.2 mm.

Calculation of Bending stress of the Skirt

4Ms
bs 
 ( Ds  tsk )tskDs
4(1.0621 10 3  10 3 )
bs 
 (3600  15.2)  15.2  3600
bs  0.006835 N / mm 2

Calculation of Dead weight Stress in the Skirt

Wv Wv
ws(Operating )  ws(Trial ) 
 ( Ds  tsk )tsk  ( Ds  tsk )tsk
179.01103 1178.01 103
ws  ws 
 (3600  15.2)  15.2  (3600  15.2)  15.2
ws  1.0368 N / mm2 ws  6.8229 N / mm2

 Noted that: Trial condition is when the vessel full of water for hydraulic
test. In estimating total weight, the weight of liquid on the plates has

34
 FLUIDIZED BED REACTOR

been counted twice. The weight has not been adjusted to allow for this as
the error is small and on the ‘safe side’.

Maximumˆs (Compressive)  0.006835  6.8229  6.8297 N / mm2

Maximumˆs(Tensile )  0.006835  1.0368  1.0030 N / mm2

 Take the joint efficiency E as 1.0

 Hence, the design must obeys the following criteria:

1st Criteria

ˆs (Tensile )  SsE sin 

 1.0030  (86.6409)(1sin 90)
 1.0030  86.6409

2nd Criteria

tsk
ˆs (Compressive)  0.125 Ey( ) sin 
Ds
15.2
ˆs (Compressive)  0.125  200,000  ( ) sin 90
3600
6.8297  105.556

 As a conclusion, both of the criteria are satisfied. Since the thickness

already included the corrosion allowance, so the design thickness of the
skirt support is 15.2 mm for 15% of operating condition.

35
 FLUIDIZED BED REACTOR

Skirt Support for 10% of operating condition

 The maximum dead weight load on the skirt will occur when the
vessel is full of water.

 Maximum Allowable Stress = 8.7502×107 Pa = 87.502 N/mm2 (For

CS)

  
  3.6  10  1000  9.81  998,666 N  999kN
2

 4 
 Approximate Weight =

 Total weight of the vessel = 173.64 kN

 Total Weight = 999 + 173.64 = 1172.64 kN

 Wind loading = 14.80 N/m = 0.01480 kN/m

 Bending moment at the base of skirt =

(10  1.98) 2
0.01480   1.0621kNm
2

 Thickness of the reactor = 10.8 mm (with corrosion allowance)

 As the first trial, the reactor thickness is divided into 5 sections

which are; 10.8 mm, 12.8 mm, 14.8 mm, 16.8 mm, 18.8 mm

 As the first trial, take the skirt thickness as the same as 14.8 mm.

36
 FLUIDIZED BED REACTOR

Calculation of Bending stress of the Skirt

4 Ms
bs 
 ( Ds  tsk )tskDs
4(1.0621 103 10 3 )
bs 
 (3600  14.8)  14.8  3600
bs  0.00702 N / mm2

Calculation of Dead weight Stress in the Skirt

Wv Wv
ws(Operating )  ws(Trial ) 
 ( Ds  tsk )tsk  ( Ds  tsk )tsk
173.64 103 1172.64 103
ws  ws 
 (3600  14.8)  14.8  (3600  14.8) 14.8
ws  1.033 N / mm 2 ws  6.9761N / mm2

 Noted that: Trial condition is when the vessel full of water for hydraulic
test. In estimating total weight, the weight of liquid on the plates has
been counted twice. The weight has not been adjusted to allow for this as
the error is small and on the ‘safe side’.

Maximumˆs(Compressive)  0.00702  6.9761  6.98312 N / mm2

Maximumˆs(Tensile )  0.00702  1.0033  0.9963 N / mm2

37
 FLUIDIZED BED REACTOR

 Take the joint efficiency E as 1.0

 Hence, the design must obeys the following criteria:

1st Criteria

ˆs(Tensile )  SsE sin 

 0.9963  (87.502)(1sin 90)
 0.9963  87.502

2nd Criteria

tsk
ˆs (Compressive)  0.125 Ey( ) sin 
Ds
14.8
ˆs (Compressive)  0.125  200,000  ( ) sin 90
3600
6.98312  102.778

 As a conclusion, both of the criteria are satisfied. Since the thickness

already included the corrosion allowance, so the design thickness of the
skirt support is 14.8 mm for 10% of operating condition.

Design of the Skirt Support

38
 FLUIDIZED BED REACTOR

Figure 1: The design parameters for Skirt Support (text book)

 The diameter of the vessel is 3.6 m where the maximum weight that can
be supported is 2500 kN. Hence, the parameters for this design are
approximately to be:

V = 1.98 m G = 0.150 m

Y = 0.25 m t2 = 16 mm

C = 3.20 m t1 = 12 mm

E = 1.40 m Bolt diameter = 27 mm

J = 0.815 m Bolt Holes = 33 mm

39
 FLUIDIZED BED REACTOR

Overall Conclusion

The skirt support is not the top priority in designing this reactor. This is
because the wind load is too small, hence the reactor is secured enough
without the support of a skirt at the bottom of it. Adding the skirt support will
eventually increase the cost of construction of the reactor. However, it still
can be done since the height of the reactor is quite big but the addition of
skirt support is not that significant in designing the reactor.

2.0 FLANGED JOINTS

2.0.1 Flange types

Several different types of flanges are used for various applications. The most
used flange types according to ASME B16.5 are: Welding Neck, Slip On,
Socket Weld, Lap Joint, Threaded and Blind flange.

Most common flange types

Figure 2: Type of flanges

For the designed reactor, the flat flange can be used to connect the head of
the reactor with the cylindrical body. The torispherical shape which also a
formed dome head that made with a short straight cylindrical section. This
section called as flange or skirt. This flange was to ensure that the weld line

40
 FLUIDIZED BED REACTOR

is away from the point of discontinuity between head and cylindrical section
of vessel. (Sinnott) The closure head was bolted to the flange.

Figure 3: Torispherical head with flange

Flanges can also be used to connect to the pipeline of the feed line into the
reactor and at the bottom of the reactor to in output pipeline. The best type
of flange used was lap-joint flanges, as this type of flange is the most
suitable for pipework. They are economical when used with the expensive
alloy such as stainless steel. (Sinnott)

Explore the World of Piping. (n.d.). Retrieved june 3, 2016, from

http://www.wermac.org/flanges/flanges_welding-neck_socket-weld_lap-
joint_screwed_blind.html

Sinnott, R. K. (n.d.). chapter 13- mechanical design of process equipment. In

R. K. Sinnott, chemical engineering design (p. 1040).

41
 FLUIDIZED BED REACTOR

2.1 DESIGN OF FLUIDIZED BED REACTOR

Figure 4

42
 FLUIDIZED BED REACTOR

Figure 5

43
 FLUIDIZED BED REACTOR

Figure 6

44
 FLUIDIZED BED REACTOR

2.2 CONCLUSION

2.3 REFERENCES

45
 FLUIDIZED BED REACTOR

1.

46