Equipment sizing

Process Design:
The sizing of the various equipments in the plant is dealt with as shown below:
REACTOR R-001 Design:
The plant to produce Anthraquinone has one reactor which is of fixed bed type. This reactor is
packed with solid catalyst and has gaseous as well as liquid reactants and products. This reactor
5 2
is operated at 1.01325*10 N/m and 564 K. Its sizing is as shown below:
1. Reactor R 1001:
Sizing of R 001
Type Adiabatic Fixed bed reactor

Material of Construction SS 316 / SS304

Operating Temperature 683 K

Operating Pressure 275 kPa

Catalyst Vanadium Phosphorous Catalyst

Reasons for choice of equipment

 The adiabatic reactor as per literature has the lowest construction cost and operation cost
due to absence of external utility arrangement.
 Fixed bed reactor offers ease of operation over multi-tubular reactor due to low pressure
drop.
 The reaction being highly kinetically favored allowed for use of fixed bed rather than
multi-tubular reactor.
 Gas is considered to be in plug flow. The patent mentions space velocity which is in the
range of 5 per hour.
Design Basis:
Reaction Operating Conditions:
Parameter Value
Feed Flow Rate 0.678 m3 /s

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Inlet Temperature 433

Outlet Temperature 564
Inlet Pressure 1 atm

Catalyst Properties:
Parameter Value
Type Hß modified Zeolite
Specific Surface Area (m2/g) 100 (assumed)
Bed Voidage (Ɛ) 0.5 (assumed)
Particle Diameter (mm) 2 mm (reported in literature)
Density (Kg/m3) 5715.7

Amount of Phthalic Anhydride fed to the reactor = 646.40 Kg/hr

Amount of Benzene fed to the reactor = 8516.82 Kg/hr
Total amount of feed being fed to the reactor = 9163.22 Kg/hr
Space velocity of the catalyst = 0.5 kg phA/ litre of catalyst (bed volume). hr.
Let Diameter (D) of the reactor = 1.8 m
Cross sectional area of the Reactor (Ac) = 2.5434 m2
Amount of Catalyst required (bed Volume) = 9163.22/0.5 = 18326.44 Kg
Volume of Catalyst Required = 3.206 m3
Catalyst bed Volume = Volume of Catalyst Required/Bed Voidage
= 3.206/0.5 = 6.412 m3
Height of Catalyst Bed = Catalyst Bed Volume/Ac = 6.412/2.5434 = 2.52 m
H/D ratio = 1.4
Velocity of the feed = Feed flow rate/ Ac
= 0.678 / 2.5434 = 0.266 m/s

Fluidization Analysis:
Minimum fluidization velocity for the given catalyst arrangement was estimated from following
expression:

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0.0093𝑑𝑝1.82 (𝜌𝑏−𝜌)0.94
Vmf = = 37.37 m/s
µ0.88 𝜌0.6
V<Vmf
Volume of catalyst required = Catalyst bed volume * (1-ε) = 6.64 * (1-0.5) = 3.206 m3
Weight of the catalyst = Volume of catalyst * Density = 3.206 * 5715.7 = 18324 kg
Assuming clearance of 0.5 m from top and bottom,
Height of the reactor = Height of catalyst bed + 2*0.5 = 3.52 m
Volume of the reactor = Cross sectional area * Height = 2.5434 * 3.52 = 8.95 m3

11.2.3 Pressure drop calculation

Allowable pressure drop is estimated after setting up the dimensions of the reactor. Using the
catalyst property data available in literature pressure drop in the fixed bed column is determined.
Pressure drop in this case is estimated using Ergun equation:
𝜟𝑷 𝟏𝟓𝟎µµₒ(𝟏 − Ɛ𝒃)𝟐 𝟏. 𝟕𝟓𝝆µₒ𝟐 (𝟏 − Ɛ𝒃)
= +
𝑳 (∅𝒅𝒑𝟐 )Ɛ𝒃𝟑 ∅𝒅𝒑Ɛ𝒃𝟑
Where, uₒ = superficial velocity
Ɛb= bed porosity
∅ = Shape Factor
𝜟𝑷
So, = 1425.6 N/m3
𝑳

2. FEED PREHEATER (BENZENE) – SIZING AND DESIGN (STHE)

Sizing of S001:
Type Shell and tube
Heat Duty 5159192 kJ/hr = 1433108 KJ/sec
Temperature of process fluid (tube side) In: 298K Out: 433 K
HTF (Shell Side) Reactor Outlet Stream
Process fluid flow rate 2.365 Kg/s
Temperature of HTF In: 450 K Out: 393 K
Log Mean Temperature Difference 45.33K
Dirty Heat Transfer Coefficient (assumed) 1200W/(m2.K)

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Heat Transfer Area 26.345 m2

MOC (Shell/Tube) Carbon Steel

Q
No of Passes Uassumed (W/m2K) Area (m2)
(KJ/sec)
1 1433108 1200 26.345834
2 1433108 1200 26.345834
4 1433108 1200 26.345834
6 1433108 1200 26.345834

Tube Tube od Length

od(inch) (m) Thickness Tube id Length(ft) (m) N-No of tubes
0.5 0.0127 0.0004 0.0123 18 5.4864 120
0.5 0.0127 0.0004 0.0123 18 5.4864 60
0.5 0.0127 0.0004 0.0123 18 5.4864 30
0.5 0.0127 0.0004 0.0123 18 5.4864 20

EQUIPMENT SIZING:

3.AUTOCLAVE (PHTHALIC ANHYDRIDE) – S002

Sizing of S002:
Type Shell and tube
Heat Duty 156204 kJ/hr
Temperature of process fluid (tube side) In: 298 K Out: 433 K
HTF (Shell Side) Reactor output stream
Process fluid flow rate 0.4315Kg/s
Temperature of HTF In: 450 K Out: 393 K
Log Mean Temperature Difference 45.33K
Dirty Heat Transfer Coefficient (assumed) 300W/(m2.K)
Heat Transfer Area 3.19 m2
MOC (Shell/Tube) SS 316

4. HOT CHAMBER (HC001)

Sizing of HC001 :

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Type Vertical
Duty Product Streams Separation
Operating pressure 1 atm
Temperature of Process Fluid IN: 564K OUT: 450K
Volume 42.4 m3
Height 6m
Diameter 3m
Heat Duty 941449.6 KJ/hr
Type DPHE
HTF Cooling Water
HTF Flow rate 15.062 m3/hr
Temperature of HTF IN: 298 K OUT: 313 K

5.FILTER – F001
Amount of Anthraquinone present on filter media = 500 kg/hr
Volume of Phthalic Anhydride = 27.8/ 480.6 = 0.38 m3/ hr
Assuming that the cake formed on the filter medium has a thickness of 10 cm
Area of filter medium = 3.8 m2
Sizing of F001:

TYPE Agitated Nutsche Filter

Cake thickness assumed 10 cm
Filter medium Area 3.8 m2
Material of Construction SS 316
Max. Temperature 150 0C
Max. Pressure 1 atm

6. HOT WATER CHAMBER- HC-002

Sizing of HC-002 :

Duty Phthalic Anhydride separation

Material
Duty of construction MS

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Reacting Fluid flow rate Water – 48 L/hr

Volume 0.5 m3

7. DRYER – D-001
Amount of to be dried = 500 kg/hr = 500/1308 = 0.38 m3 /hr
Amount of water present = 0.008 m3/hr
Total volume of contents = 0.388 m3
Assuming thickness of bed = 5 cm
Area = 7.76 m2
Design volume = 0.5 m3
Sizing of D1001:

TYPE PNEUMATIC DRYER

volume 0.5 m3
Material of Construction SS 316
Max. Temperature 110 0C
Max. Pressure 1 atm