12 Equipment Compilation PDF

PAMANTASAN NG LUNGSOD NG MAYNILA
University of the City of Manila

College of Engineering and Technology
Department of Chemical Engineering
TABLE OF CONTENTS
ROLLER CRUSHER DEHULLER ....................................................................................................................3
MIXER SETTLER EXTRACTOR ................................................................................................................... 15
DISTILLATION COLUMN .......................................................................................................................... 28
EVAPORATOR ............................................................................................................................................... 43
CRYSTALLIZER .............................................................................................................................................. 57
GAS ABSORPTION COLUMN .................................................................................................................. 77
GAS ADSORPTION COLUMN…………………………………………………………………………………………..98
ACID HYDROLYZER………………………………………………………………………………………………….……108
ROTARY DRYER………………………………………………………………………………………………………….….128
COOLING TOWER………………………………………………………………………………………………………….140
STIRRED BATCH EXTRACTOR………………………………………………………………………………………..146
SHELL AND TUBE HEAT EXCHANGER……………………………………………………………………………162
CHE 513 – Equipment Design (Lec)

COMPILATION OF 12 EQUIPMENT 2
C.B. Baoas | A.C.M. Garcia P.G.C. Santos | M.M. Sarmient
ROLLER CRUSHER
DESIGN DESCRIPTION
Roller Crusher is used to crush the Tamarind seed shells to obtain the kernel inside.
The Roller Crusher employs double crushing rolls and a series of two vibrating screens of
different mesh sizes. The seeds are fed into a hopper and will be nipped to crush the shells
and will be subjected to vibration through the vibrating screens to separate the shells
from the kernel. The first screen will be used to separate large fragments from the small
fragments and the kernel. The second screen will have a small mesh opening and will be
used to separate the smaller fragments of shells from the kernels.
DESIGN SELECTION
Roll crusher is used in the process because it provides an efficient removal of the
Tamarind Seed shells because it provides the necessary cracking of the shells without
breaking the kernels inside. Vibrating screens are installed to separate the kernels from
the cracked shells, which happens because of the differences in densities of the shell
fragments and the kernels with the help of the vibrating motion of the screens.
PARTS AND FUNCTIONS

Feeding Hopper
Dehulling
Chamber
Vibrating Screens

Parts Functions
Feeding Hopper This serves as the inlet of the seeds in the equipment. It is
trapezoid in shape and accommodates the whole seeds from
which the shells are to be removed.
Vibrating
This separates the kernel from the shells.
Screens
Dehulling This is where the seeds are dehulled and it accommodates the
Chamber roller crushers.
DESIGN ASSUMPTIONS
1. The mass of the seeds to be dehulled is 5560 kg/ batch. (Basis: Material Balance)
2. The mass of the Tamarind Seed kernel recovered from the Roller Crusher is 2610.42
kg/batch. (Basis: Material Balance)
3. The mass of the Tamarind Seed shells removed by the Roller Crusher is 2943.67
kg/batch. (Basis: Material Balance)
4. The average seed diameter is approximately 4.2 in (10.67 cm). (Basis: Experiment)
5. The average kernel diameter is approximately 4.0 in (10.16 cm). (Basis: Experiment)
6. The bulk density of the Tamarind Seed is 1170 kg/m3. (Basis: Experiment)
7. Assume continuous and steady feeding condition.
8. Assume work index equal to that of calcined clay which is equal to 1.43 kW/metric
ton since the shells are easy to crack, thus requiring a low work index. ( Table 12.2
page 342 of Couper J. R., Chemical Process Equipment Selection and Design, 2 nd
ed.)

DESIGN CONSIDERATIONS
Roll Crusher
1. The distance between the rolls is taken as the average between the Tamarind
Seed diameter and Tamarind kernel diameter, which is equal to 4.1 in. This is
to ensure that the rolls will only crush the shells leaving the kernel inside
unaffected.
2. The diameter of the two rolls is equal with each other.
3. The diameter and the width of the rolls is equal to 2:1 (Source: Couper J. R.,
Chemical Process Equipment Selection and Design, 2nd ed. Page 342).
4. The angle of nip usually used for ordinary materials is 32 degrees. (Source:
Brown G. G., Unit Operations, page 36)
5. The dimensions of light duty crushers vary between 228 mm and 760 mm.
(Source: Gupta and Yan, Introduction to Mineral Design and Operation page
143)
6. The normal speed of operation of roller crushers ranges between 50-200 rpm.
(Source: Couper J. R., Chemical Process Equipment Selection and Design, 2 nd

ed. Page 370).
Vibrating Screen
1. Screen capacity for vibrating screens has a range of 0.023 kg/ft2-s to 0.347 kg/
ft2-s. (Source: Brown G. G., Unit Operations page 13)

2. The length to the width ratio of the screen is 2:1 and the inclination is 30
degrees. (Source: Felin, M. Screeners, Encyclopedia of Chemical Engineering

Equipment)

3. The typical shaft speed for vibrating screens are 650-1100 rpm and the stoke
value varies between 1/8”- 5/8”. (Source: Metso, Operating Green and Efficient
Vibrating Screens)
DESIGN REQUIREMENTS
Roll Crusher Design
1. Hopper Volume
2. Roll Dimension
3. Roll Speed
4. Capacity
5. Power Requirement
Vibrating Screen Design
1. Screen Area
2. Screen Dimensions
3. Power Requirement of Screen
DESIGN CALCULATIONS
1. Hopper Volume
The hopper volume is calculated because the volume must be enough to hold the
required mass of seeds per operation. It is calculated as:
𝑚𝑓
𝑉𝐻 =
𝜌𝑏
Where: VH= hopper volume
mf= mass of feed

b= bulk density of the seeds
5560 𝑘𝑔
𝑉𝐻 = = 4.75 𝑚3
1170 𝑘𝑔/𝑚3

2. Roll Dimension
The roll diameter is computed by rearranging the equation given by Brown, G. G.

Unit Operations page 36:
𝐴 𝐷𝑟 + 𝐷𝑝
cos =
2 𝐷𝑟 + 𝐷𝑓
𝐷𝑓 − 𝐷𝑝
𝐷𝑟 =
𝐴
1 − cos( )
2
Where: Dr= Roll Diameter
Dp = Diameter of the Particle

Df = Feed Diameter
A= Nip Angle
10.67 𝑐𝑚 − 10.414 𝑐𝑚
𝐷𝑟 = = 6.6084 𝑐𝑚 = 0.0661 𝑚
32
1 − cos ( 2 )
According to the design consideration the ratio of roll diameter to roll width is 2:1,
then:
W= 2(Dr)= 2(6.6084 cm)= 13.2169 cm= 0.1322 m
However, according to Gupta, the diameters of a light duty crusher vary between
228 mm and 760 mm, while the face lengths between 250 mm and 460 mm. Therefore,
the diameter to be used is 228 mm diameter because the Roller Crusher has a smaller
capacity and 456 mm.
3. Roll Speed
According to the design consideration, the normal speed of operation roll crushers
is 50-200 rpm. Getting the average which is equal to 125 rpm and according to Gupta and
Yan, page 147, the speed operation of commercial light duty rolls is 130-300 rpm,
therefore 130 rpm is used.
4. Capacity
The capacity of roller crushers is calculated using the equation given by Brown in
Unit Operations page 36:
𝑇 = 60(𝜋𝐷𝜔)𝐿𝐷𝑃 𝜌𝑏
Where: T= crusher capacity
D= diameter of rolls
L= width of rolls
Dp= distance between the rolls
𝜔= roll speed
𝜌𝑏 = bulk density of the seeds
𝑚 𝑟𝑒𝑣𝑜𝑙𝑢𝑡𝑖𝑜𝑛𝑠 𝑘𝑔
𝑇 = 60 (𝜋 × 0.228 × 130 ) × 0.456𝑚 × 0.1041𝑚 × 1170 3
𝑟𝑒𝑣𝑜𝑙𝑢𝑡𝑖𝑜𝑛𝑠 𝑚𝑖𝑛 𝑚
𝒌𝒈
= 𝟓𝟏𝟕𝟏. 𝟔𝟓
𝒉𝒓
The power requirement of the rolls is computed using the equation given by Gupta
and Yan:
𝑃 = 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 × 𝑅𝑒𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑅𝑎𝑡𝑖𝑜 × 𝑊𝑜𝑟𝑘 𝐼𝑛𝑑𝑒𝑥
𝑘𝑔
5171.65
= ℎ𝑟 × 4.2 𝑖𝑛 × 1.43 𝑘𝑊
𝑘𝑔 4.1 𝑖𝑛 𝑡𝑜𝑛
1000 𝑚𝑒𝑡𝑟𝑖𝑐 𝑡𝑜𝑛
= 7.5758 𝑘𝑊/ℎ = 𝟏𝟎. 𝟏𝟓𝟗𝟑 𝒉𝒑

Vibrating Screen Design
1. Area of the Screen
The area of the screen is computed as:

𝑚𝑎𝑠𝑠 𝑜𝑓 𝑓𝑒𝑒𝑑
𝐴=
𝑠𝑐𝑟𝑒𝑒𝑛 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 × 𝑑𝑒ℎ𝑢𝑙𝑙𝑖𝑛𝑔 𝑡𝑖𝑚𝑒
According to Brown, screen capacity for vibrating screens has a range of 0.023
kg/ft2-s to 0.347 kg/ ft2-s. Getting the average, 0.185 kg/ ft2-s is used as the screen
capacity.
5560 𝑘𝑔
𝐴=
𝑘𝑔 𝑠𝑒𝑐
0.185 × 30 min × 60 𝑚𝑖𝑛
𝑓𝑡 2 − 𝑠
= 16.6967 𝑓𝑡 2 = 1.5512 𝑚2
Use: 1.6 m2
2. Screen Dimensions
The length and width ratio considered is 2
𝐴=𝐿 × 𝑊
𝐴 = 2𝑊
1.5512 = 2𝑊
W= 0.77 m
L= 1.55 m
Use: 0.8m width and 1.6m length
3. Power Requirement of Screens

The power requirement for vibrating screens is calculated in order to determine
the minimum motor power for circular motion vibrating screens:

0.2𝑛(𝑚𝑅)
𝑃𝑜𝑤𝑒𝑟 𝑅𝑒𝑞𝑢𝑖𝑟𝑒𝑚𝑒𝑛𝑡 =
97400𝐿𝑅𝑇
Where: mR= total static moment of counterweight assemblies
N= screen speed (rpm)

LRT= motor locked rotor torque in a decimal form; For vibrating equipment the
general recommendation is that the motor should have a min LRT of 200%
Based on the design consideration, the typical shaft speed for vibrating screens are
650- 1100 rpm. Getting the average, it is equal to 875 rpm.
0.2 × 875 × (5560 × 1.6)
𝑃𝑜𝑤𝑒𝑟 𝑅𝑒𝑞𝑢𝑖𝑟𝑒𝑚𝑒𝑛𝑡 =
97400(2)
= 7.9918 𝑘𝑊 = 10.72 ℎ𝑝
USE: 11 hp
DESIGN SPECIFICATION
Roller Crusher

Operating Data
Number of Units 1
Materials Handled Tamarind Seeds
Residence Time 60 minutes
Operating Temperature 26.6- 30ºC
Materials of Construction Carbon Steel
Design Data
Parameters Proposed Design Existing Design
Roll Crusher
Hopper Volume 4.75 m3
Roll Diameter 228 mm 228- 760 mm
Roll Width 456 mm 250-460 mm
Roll Speed 130 rpm 130-300 rpm
Capacity 5171.65 kg/h (5.17ton/hr) 2-8 ton/hr
Power Requirement 10.15 hp 5.5-15 hp
Vibrating Screen
Screen Area 1.6 m2
Screen Length 1.6 m 1- 2 m

Screen Width 0.8 m 0.5-2 m
Power Requirement 11 hp 5.5- 20 hp
Equipment Supplier
Supplier Name Joyal Crusher Inc.
Supplier Address Shanghai, China
Accessories and Auxilliary Parts
Vibrating Screens

DESIGN CONFIGURATION
Design Configuration
Hopper Volume= 4.75 m2

Capacity= 5171.65 kg/hr
Screen Area= 1.6 m2
Power Requirement= 10.16 hp
0.8 m
228 mm

MIXER SETTLER EXTRACTOR
DESIGN DESCRIPTION
The mixer settler extractor is a stage-wise extractors in which the liquids are contracted in
the mixing tank and then separated in the settling tank. It is designed to separate the
ethyl levulinate from the humins by addition of an immiscible liquid, in this case, toluene.
DESIGN OPERATION
The filtered ethyl levulinate solution is loaded into the mixer settler and a toluene is added
to the mixer. Mixture stays in the mixing tank for 10 minutes until it is evenly mixed. The
mixture is heated up to 90°C. Subsequently, the mixture is discharged in a settler where
the ethyl levulinate is settled at the top layer, while the humins deposits at the bottom.
DESIGN SELECTION
The selection guide given in Chemical Engineering Design: Principles, Practice, and
Economics of Plant and Process Design, Second Edition by Sinnot and Towler (2013) is
used to select the type of equipment most likely suitable to the process.
Since the operation requires 10 minutes of contact between the liquids thus there is no
minimum contact time essential and no possibility for stable emulsions in mixing the
solvent and feed. Moreover, small number of stages is considered and the area of the
headroom is assumed to be limited to be more practical. Following the selection guide
gave the mixer settler extractor as the suitable equipment.
PARTS AND FUNCTIONS

1. A mixing chamber where a mechanical agitator brings in intimate contact the feed
solution and the solvent to carry out the transfer of solute(s).
2. The mechanical agitator is equipped with a motor which drives a mixing and
pumping turbine. This turbine draws the two phases from the settlers of the
adjacent stages, mixes them, and transfers this emulsion to the associated settler.
3. A settling chamber where the two phases separate by static decantation.
4. Coalescence plates facilitate the separation of the emulsion into two phases (heavy
and light).
5. The two phases then pass to continuous stages by overflowing the light phase and
heavy phase weirs. The height of the heavy phase weir can be adjusted in ordeer
to position the heavy/light interphase in the settling chamber based on the density
of each one of the phases.
DESIGN DATA AND ASSUMPTIONS
1. Entering ethyl levulinate solution is 1,962.59 kg. (Basis: Material Balance)

2. Entering toluene is 785.03 kg. (Basis: Material Balance)
3. The density of ethyl levulinate is 996 kg/m3.
4. The viscosity of ethyl levulinate feed is 0.2013 kg/m-s.
5. The density of toluene solvent is 865 kg/m3 at 25 °C. (www.sigmaaldrich.com).
6. The viscosity of toluene solvent is 0.38 cp (www.Engineeringtoolbox.com).
1. The safety factor for the extractor is 20% therefore having a filling capacity of 80%
(Plant Design and Economics for Chemical Engineers by Peters and Timmerhaus,
Table 6, page 37).
2. The mixer tank is fabricated using lap-welded joints. The efficiency of lap-welded
joints is 80% (Plant Design and Economics for Chemical Engineers, 5 th ed., Peters
and Timmerhaus, Table 12, page 555)
3. The corrosion allowance is 0.35 inch. (Rules of Thumb for Chemical Engineers, 4 th
edition, page 458).

4. The type of impeller used is turbine flat blade impeller which is mainly used for low
liquid viscosities and low tank volume. The impeller is assumed to have 10% of the
volume of the dilution tank (Chemical Engineering Design Volume 6, 4 th ed, page
42).
5. The number of baffles is usually 4; the number of impeller blades ranges from 4 to
16 but is generally 6 to 8 (Unit Operations of Chemical Engineering, 6 th ed by
Mccabe, page 241).
6. It is assumed that the material of construction for the reactor is stainless steel,
which is suitable for steam as the jacketed fluid and aqueous solution as the fluid
in the vessel (Chemical Process Equipment: Selection and Design, Couper et al.,
Table 17.11, 3rd ed, page 638)
7. The material of construction for the shaft is stainless steel 416 which is mainly used
for parts requiring considerable machining during fabrication. (Plant Design and
Economics for Chemical Engineers, 5th ed., Peters and Timmerhaus Table 4, page
428)
8. Settling tank basin floor area of 41 Lpm per m2 of flow. (Settling Tanks Retrieved
from: http:/goo.gl/8y8hJz)
9. 250 to 410 Lpm per m width of weir for outflow. (Settling Tanks Retrieved from:
http:/goo.gl/8y8hJz)
10. Submerge inlet weir 15% of basin water depth. (Settling Tanks Retrieved from:
11. Use 25 cm wide weirs and use rounded edges. (Settling Tanks Retrieved from:
12. Maximize length of settling chamber as much as possible. (Settling Tanks Retrieved
from: http:/goo.gl/8y8hJz)
DESIGN REQUIREMENTS
1. Capacity of the Mixing
2. Mixing Tank Diameter
3. Mixing Tank Height
4. Shell Thickness
5. Head and Bottom Thickness

6. Impeller Design
a. Impeller Diameter
b. Impeller Height
c. Impeller Width
d. Impeller Elevation
e. Impeller Length
7. Baffle Design
a. Baffle Width
9. Settling Tank Dimensions
a. Settling Tank Depth
b. Settling Tank Length
c. Settling Tank Width
DESIGN CALCULATIONS
1. Capacity of Mixing Tank
1,962.6 𝑘𝑔 785.03 𝑘𝑔
𝑉= 3
+ = 2.87 𝑚3
996 𝑘𝑔 /𝑚 865 𝑘𝑔 /𝑚3
The volume for a filling capacity of 80% would be:
2.87 𝑚3
𝑉= = 3.59 𝑚3
0.80
Considering the safety factor:
𝑉 = 3.59 𝑚3 + (0.20)(3.55𝑚3 ) = 4.31 𝑚3
𝑉 = 4.35 𝑚3
2. Mixing Tank Diameter
𝑉 = 𝑉𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟 + 𝑉ℎ𝑒𝑚𝑖𝑠𝑝ℎ𝑒𝑟𝑖𝑐𝑎𝑙𝑏𝑜𝑡𝑡𝑜𝑚 + 𝑉ℎ𝑒𝑚𝑖𝑠𝑝ℎ𝑒𝑟𝑖𝑐𝑎𝑙ℎ𝑒𝑎𝑑

𝜋𝐷2 ℎ 𝜋𝐷3 𝜋𝐷3

+ + 𝑉=
4 12 12
Since: 𝐻 = 3𝐷, the tank diameter would then be:
5𝜋𝐷3 𝜋𝐷3
4.35 𝑚3 = +
4 12
𝐷 = 1.03 𝑚
𝐷 = 1.05 𝑚
3. Mixing Tank Height
𝐻𝑡 = 3𝐷 = 3(1.05 𝑚) = 3.15 𝑚
𝐻 = 3.15 𝑚
4. Shell Thickness
Using eq 4-3, p. 85, Process Equipment Design by Rushton
𝑃𝐷
𝑡𝑠 = +𝐶
2𝑆𝑒 − 𝑃
where:
𝑡𝑆 = 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑜𝑓 𝑡ℎ𝑒 𝑝𝑙𝑎𝑡𝑒
𝑃 = 𝐼𝑛𝑡𝑒𝑟𝑛𝑎𝑙 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒
𝐷 = 𝐼𝑛𝑡𝑒𝑟𝑛𝑎𝑙 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟
𝑆 = 𝐴𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑊𝑜𝑟𝑘𝑖𝑛𝑔 𝑆𝑡𝑟𝑒𝑠𝑠
𝑒 = 𝐸𝑓𝑓𝑖𝑐𝑖𝑖𝑒𝑛𝑐𝑦
𝐶 = 𝐶𝑜𝑟𝑟𝑜𝑠𝑖𝑜𝑛 𝐴𝑙𝑙𝑜𝑤𝑎𝑛𝑐𝑒
Using eq 4-1, p.84, Process Equipment Design by Rushton:
𝑆 = 𝑆𝑢 𝑥𝐹𝑚𝑥𝐹𝑎𝑥𝐹𝑟𝑥𝐹𝑠
where:
𝑆𝑢 = 90000 𝑝𝑠𝑖 (𝑆𝑡𝑒𝑒𝑙 𝑃𝑟𝑜𝑑𝑢𝑐𝑡 𝐷𝑎𝑡𝑎 𝑆ℎ𝑒𝑒𝑡 𝑓𝑜𝑟 𝑆𝑡𝑎𝑖𝑛𝑙𝑒𝑠𝑠 𝑆𝑡𝑒𝑒𝑙 𝑇𝑦𝑝𝑒 304)
𝐹𝑚 = 1.00 𝑓𝑜𝑟 ℎ𝑖𝑔ℎ 𝑡𝑒𝑛𝑠𝑖𝑙𝑒 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ 𝑠𝑡𝑎𝑖𝑛𝑙𝑒𝑠𝑠 𝑠𝑡𝑒𝑒𝑙𝑠
𝐹𝑎 = 𝐹𝑟 = 1.00 𝑠𝑖𝑛𝑐𝑒 𝑟𝑎𝑑𝑖𝑜𝑔𝑟𝑎𝑝ℎ𝑖𝑛𝑔 𝑎𝑛𝑑 𝑠𝑡𝑟𝑒𝑠𝑠 𝑟𝑒𝑙𝑖𝑒𝑣𝑖𝑛𝑔 𝑖𝑠 𝑛𝑜𝑡 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑
𝐹𝑠 = 0.25 (𝑇𝑎𝑏𝑙𝑒 4.2, 𝑃𝑅𝑜𝑐𝑒𝑠𝑠 𝐸𝑞𝑢𝑖𝑝𝑚𝑒𝑛𝑡 𝐷𝑒𝑠𝑖𝑔𝑛 𝑏𝑦 𝑅𝑢𝑠ℎ𝑡𝑜𝑛, 𝑝. 84)

𝑆 = 90000 𝑥 1.00 𝑥 1.00 𝑥 1.00 𝑥 0.25 = 22500 𝑝𝑠𝑖

Computing for the internal pressure:
𝜌𝑔𝐻
𝑃=
𝑔𝑐
𝑘𝑔
= 54 𝑙𝑏/𝑓𝑡 3
𝜌 = 865
𝑚3
𝑙𝑏 𝑚 3.2808 𝑓𝑡 2
(54 3 ) (9.8067 2 ) (3.15𝑚) ( 1 𝑚 )
𝑓𝑡 𝑠
𝑃=
𝑙𝑏 − 𝑓𝑡 𝑖𝑛2
(32.175 2 )(144 2 )
𝑙𝑏𝑓 − 𝑠 𝑓𝑡
𝑃 = 1.18 𝑝𝑠𝑖
Computing for the shell thickness:
𝑃𝐷
𝑡𝑠 = +𝐶
2𝑆𝑒 − 𝑃
𝑙𝑏 3.2808 𝑓𝑡 12𝑖𝑛
(1.18 2 ) (1.05 𝑥 𝑥 )
𝑖𝑛 1𝑚 1 𝑓𝑡
𝑡𝑠 = + 0.35 𝑖𝑛
𝑙𝑏 𝑙𝑏
[2 (22500 2 ) (0.8) − 1.18 2 ]
𝑖𝑛 𝑖𝑛
𝑡𝑆 = 0.35 𝑖𝑛 = 8.89 𝑚𝑚
𝑡𝑠 = 8.90 𝑚𝑚
Using eq. 4-8, p 86, Process Equipment Design by Rushton for hemispherical head and
bottom:
𝑃𝐷
+𝐶 𝑡 =
4𝑆𝑒
𝑙𝑏 3.2808 𝑓𝑡 12𝑖𝑛
(1.18 2 ) (1.05 𝑥 𝑥 )
𝑖𝑛 1𝑚 1 𝑓𝑡
𝑡 = + 0.35 𝑖𝑛
𝑙𝑏
[4 (22500 2 ) (0.8)]
𝑖𝑛
𝑡 = 0.35 𝑖𝑛 = 8.89 𝑚𝑚
𝑡 = 9.00 𝑚𝑚
6. Impeller Design

a. Diameter of Impeller
𝐷𝑎
= 0.4
𝐷𝑇
(p. 241, Unit Operations of Chemical Engineering by Mccabe, 6th ed)
where:
𝐷𝑎 = 𝐼𝑚𝑝𝑒𝑙𝑙𝑒𝑟 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑚
𝐷𝑇 = 𝑇𝑎𝑛𝑘 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑚
Computing for Impeller Diameter:
𝐷𝑎 = 0.4(1.05𝑚)
𝐷𝑎 = 0.42 𝑚
𝐷𝑎 = 0.45 𝑚
b. Height Impeller
𝐻
=1
𝐷𝑇
(p.241, Unit Operations of Chemical Engineering by Mccabe, 6th ed)
where:
𝐻 = 𝐻𝑖𝑒𝑔ℎ𝑡 𝑜𝑓 𝐼𝑚𝑝𝑒𝑙𝑙𝑒𝑟, 𝑚
Computing for the Height of Impeller:

𝐻 = 1(1.05 𝑚)
𝐻 = 1.15 𝑚
c. Width of Impeller
𝑊 1
=
𝐷𝑎 5
where:
𝑊 = 𝑊𝑖𝑑𝑡ℎ 𝑜𝑓 𝐼𝑚𝑝𝑒𝑙𝑙𝑒𝑟, 𝑚

Computing for the Width of Impeller:

0.4485𝑚
𝑊=
5
𝑊 = 0.088 𝑚
𝑊 = 0.10 𝑚
d. Elevation of Impeller
𝐸 1
=
𝐷𝑇 3
where:
𝐸 = 𝐸𝑙𝑒𝑣𝑎𝑡𝑖𝑜𝑛 𝑜𝑓 𝐼𝑚𝑝𝑒𝑙𝑙𝑒𝑟, 𝑚
Computing for the Elevation of Impeller:
1.05𝑚
𝐸=
3
𝐸 = 0.35 𝑚
e. Length of Impeller
𝐿 1
=
𝐷𝑎 4
where:
𝐿 = 𝐿𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝐼𝑚𝑝𝑒𝑙𝑙𝑒𝑟, 𝑚
Computing for the Length of Impeller:

0.45 𝑚
𝐿=
4
𝐿 = 0.11 𝑚
𝐿 = 0.15 𝑚
9. Baffle Design
a. Width of Baffle

𝐽 1
=
𝐷𝑇 12
where:
𝐽 = 𝑊𝑖𝑑𝑡ℎ 𝑜𝑓 𝐵𝑎𝑓𝑓𝑙𝑒, 𝑚
Computing for the Width of Baffle:

1.05 𝑚
𝐽=
12
𝐽 = 0.09 𝑚
𝐽 = 0.10 𝑚
𝑛𝐷𝑎2 𝜌
𝑁𝑅𝑒 =
𝜇
(Eq. 9.17, p. 253, Unit Operations of Chemical Engineering by Mccabe, 6th ed.)
Where:
𝑁𝑅𝑒 = 𝑅𝑒𝑦𝑛𝑜𝑙𝑑𝑠 𝑁𝑢𝑚𝑏𝑒𝑟
𝑟𝑒𝑣
𝑛 = 𝑅𝑜𝑡𝑎𝑡𝑖𝑜𝑛𝑎𝑙 𝑆𝑝𝑒𝑒𝑑,
𝑠
𝜇 = 𝑉𝑖𝑠𝑐𝑜𝑠𝑖𝑡𝑦 𝑜𝑓 𝑡ℎ𝑒 𝑓𝑒𝑒𝑑
𝐷𝑎 = 𝐼𝑚𝑝𝑒𝑙𝑙𝑒𝑟 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟
𝜌 = 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑡ℎ𝑒 𝑆𝑜𝑙𝑢𝑡𝑖𝑜𝑛
Computing for 𝑁𝑅𝑒 :

𝑟𝑒𝑣 1 𝑚𝑖𝑛 𝑘𝑔
(250 𝑚𝑖𝑛 𝑥 60 𝑠 ) (0.45 𝑚)2 (865 3 )
𝑚
𝑁𝑅𝑒 =
𝑘𝑔
0.2013
𝑚−𝑠
𝑁𝑅𝑒 = 3,955. 4280
(Fig. 3.4-5, p. 159, Principles of Transport Process and Separation Processes, Geankoplis,
4th Ed)

𝐴𝑡 𝑁𝑅𝑒 = 3,955.4280; 𝑁𝑝 = 1
𝑃
𝑁𝑝 = 3 5
𝑛 𝐷𝑎 𝜌
(Equation 9.12a, p.251, Unit Operations of Chemical Engineering by Mccabe, 6th Ed)
where:
𝑁𝑝 = 𝑝𝑜𝑤𝑒𝑟 𝑛𝑢𝑚𝑏𝑒𝑟
𝑃 = 𝑃𝑜𝑤𝑒𝑟, 𝑘𝑤
𝑘𝑔
𝜌 = 𝑑𝑒𝑛𝑖𝑠𝑡𝑦 𝑜𝑓 𝑡ℎ𝑒 𝑠𝑜𝑙𝑢𝑡𝑖𝑜𝑛, 3
𝑚
𝑟𝑒𝑣
𝑛 = 𝑟𝑜𝑡𝑎𝑡𝑖𝑜𝑛𝑎𝑙 𝑠𝑝𝑒𝑒𝑑,
𝑠
𝐷𝑎 = 𝑖𝑚𝑝𝑒𝑙𝑙𝑒𝑟 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑚
Computing for the power consumption:

𝑃 = 𝑁𝑝 𝑛3 𝐷𝑎5 𝜌
𝑟𝑒𝑣 1𝑚𝑖𝑛 3 𝑘𝑔
) (0.45𝑚)5 (856 3 )
𝑃 = (1) (250
𝑥
𝑚𝑖𝑛 60 𝑠 𝑚
𝑃 = 1247.1024 𝑊 = 1.2471 𝑘𝑊
𝑃 = 1.67 ℎ𝑝
11. Settling Tank Dimensions
From Settling Tanks retrieved from: hhtp://goo.gl/8y8hJz
Description Dimensions
Typical Range
Rectangular
Depth, m 3-5 3.5
Length, m 15-90 25-40
Width. m 3-24 6-10
The typical dimension for rectangular settling tank is used:

For the:
Settling Tank Depth: 3.5 m
Settling Tank Length: 32.50 m

Settling Tank Width: 8 m
MIXER SETTLER
FUNCTION To separate the desired product from the undesired product
SELECTION Since the operation requires 10 minutes of contact between
the liquids thus there is no minimum contact time essential
and no possibility for stable emulsions in mixing the solvent
and feed. Moreover, small number of stages is considered
and the area of the headroom is assumed to be limited to be
more practical.
DESIGN PARTS
DESIGN DATA
Capacity 4.35 m3 Shell Thickness 8.9mm
Tank Diameter 1.05 m Head Thickness 9 mm
Tank Height 3.15 m Bottom Thickness 9 mm
Impeller Diameter 0.45 m Settling Tank Depth 3.5 m
Impeller Height 1.15 m Settling Tank Length 32.5 m
Impeller Width 0.10 m Settling Tank Width 8m

OTHER DESIGN INFORMATION

Materials Handled Toluene Auxiliaries Gate
and Ethyl Valve,
Levulinate Centrifugal
Solution Pump
Material of Stainless
Construction Steel 304

DISTILLATION COLUMN
Design Problem
Design a distillation column to separate 1798 kg/batch

of miscella (composed of hexane and rubber seed oil)
producing 1652kg/batch of distillate and 146kg/batch
of bottoms product with an operating temperature of
70 °C.
DESIGN DESCRIPTION
Distillation is the most common form of separation

technology in the chemical industry. This operation
utilizes vapor and liquid phases at essentially the same
temperature and pressure for the coexisting zones. Various kinds of devices such as
random or structed packings and plates or trays are used to bring the two phases into
intimate contact. Trays are stacked one above the other and enclosed in a cylindrical
shell between hold-down and support plates, the distillation column operates at the
liquid mixture that is to be processed known as the feed and this is introduced usually
somewhere near the middle of the tower to a tray known as the feed tray. The feed tray
divides column into a top (enriching or rectification) section and a bottom (stripping)
section. The feed flows down the column where it is collected at the bottom in the
reboiler. The heat is supplied to the reboiler to generate vapor. The source of heat input
can be any suitable fluid, although in most chemical plants this is normally steam.
DESIGN SELECTION
A distilling column is selected for the separation of oil and hexane from the collected
miscella. The use of distillation columns, in this case simple distillation, is based on the
idea that it is applicable for separating compounds having boiling point difference
greater than 25°C as applied for oil and hexane. Additionally, because the boiling points
of the two is greater than 100°C relatively pure substances can be acquired. Simple
distillation unit is cheaper than any other distillation column, and the efficiency would
not be compromised since the miscella can be easily separated from each other. With
the application of heat coming from the steam, the more volatile component, hexane,

will be vaporized and further condensed for recovery. The oil, being the heavier
component, will be left in the bottom of the column.
PARTS AND FUNCTION
DESIGN PARTS AND FUNCTION

A
A Gas It serves as the exit stream of
Discharge the evaporated liquid
B Reflux Inlet This is where the liquid from B

the reflux drum enters E
C Liquid Inlet It evenly distributes the

liquid in the column
D Tray It is the where the heat C F

transfer between liquid and
gas occurs
D G
CUT AWAY VIEW
E Liquid It distributes the liquid from

Distributor the reflux to the adsorption
H
column
I
F Liquid It collects the Liquid and
Collector prevents entrainment as it J
goes down along the trays
G Downcomer It serves as the pathway for

liquid to transfer to another
tray
H Gas Suction It is the entrance for the

steam
I Shell It serves as the body holding

the internal parts
J Liquid It serves as the exit stream

Discharge for the desired product

DATA AND ASSUMPTIONS
1. The entering feed is 1798 kg/batch of miscella (Basis: Material Balance)
2. The amount of distillate is 1652 kg/batch and the bottoms product is 146 kg/batch
(Basis: Material Balance)
3. The amount of hexane in the initial miscella is 1653 kg/batch (Basis: Material Balance)
4. The density of oil is 857 kg/m³ and that of hexane is 655 kg/m³ (Basis: Material
Balance)
5. The operating temperature of hexane is 70 °C (Basis: Boiling point of Hexane)
6. The heat requirement is 490,707.36kJ/batch (Basis: Energy Balance)
7. The steam requirement is 175.05kg/batch (Basis: Energy Balance)
1. The material of construction to be used is Type 316 which possesses increased

strength at higher temperatures and excellent corrosion resistance (Basis: Chemical
Resistance Chart)
2. Tray column is to be used to handle a wider range of liquid and gas flow rates, and to
provide good liquid distribution under all operating conditions for higher efficiency
(Basis: Chemical Engineering Design Volume 6, by Richardson and Coulson, page 588)
3. The insulation is lamella mats since it has low thermal conductivity and excellent
water-repellent properties. (Basis: Industrial Column Insulation)
4. For columns above 1 m diameter, plate spacings of 0.3 to 0.6m will normally be used,
use mean 0.45m (Basis Chemical Engineering Design, Volume 6, by Richardson and
Coulson, page 557)
5. The plate thickness is usually 1 in (2.54 cm), weir height is 2 in( 5.08cm), and the
spacing is triangular with ¾ spacing (Basis : Principles of Transport Processes by
Geankoplis, pg 727.)

6. The minimum corrosion allowance considered is 0.15 in since it is not a highly

corrosive condition.
DESIGN REQUIREMENTS
1. Vapor Velocity
2. Vapor Flow Rate
3. Column Capacity
4. Column Area
5. Column Diameter
6. Number of Plates
7. Column Height
8. Shell Thickness
9. Thickness of Insulation
DESIGN CALCULATION
1. Vapor Velocity
The equation used for computing the maximum allowable vapor velocity is given by
Chemical Engineering Design, Volume 6, by Richardson and Coulson, page 557
1
𝜌𝐿 − 𝜌𝑉 2
𝜇= (−0.171𝑙𝑙2 + 0.27𝑙𝑙 − 0.047) ( )
𝜌𝐿
Where:
μ= maximum allowable vapor velocity
ρ𝑉 = density of vapor
ρ𝐿 = density of liquid

l𝑙 = Plate Spacing
Computing for Density of liquid mixture:

𝑀𝑎𝑠𝑠 𝑜𝑓 𝐿𝑖𝑞𝑢𝑖𝑑 𝑀𝑖𝑥𝑡𝑢𝑟𝑒
ρ𝐿 = ρ𝑎 ρ𝑏
m𝑎 + m𝑏
Where :
ρ𝑎 = 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑜𝑖𝑙
m𝑎 = 𝑚𝑎𝑠𝑠 𝑜𝑓 𝑜𝑖𝑙
ρ𝑏 = 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 ℎ𝑒𝑥𝑎𝑛𝑒
m𝑏 = 𝑚𝑎𝑠𝑠 𝑜𝑓 ℎ𝑒𝑥𝑎𝑛𝑒
1798
ρ𝐿 =
857 655
146 + 1652
ρ𝐿 = 286. 9293𝑘𝑔/𝑚3
From Geankoplis, Appendix 2-9 (page 857), the density of vapor at 70 °C is
ρ𝑔 = 0.1983 𝑘𝑔/𝑚3
Given ρ𝐿 = 286. 9293𝑘𝑔/𝑚3; l𝑙 = 0.45 𝑚

1
286.9293 − 0.1983 2
𝜇𝑣 = (−0.171(0.45)2 + 0.27(0.45) − 0.047) ( )
286.9293
𝒎
𝝁𝒗 = 𝟎. 𝟑𝟗𝟖𝟔
𝒔
2. Vapor Flowrate
Computing for the Vapor Flowrate

𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒
V𝑓 =
𝑣𝑎𝑝𝑜𝑟 𝑑𝑒𝑛𝑠𝑖𝑡𝑦
1798𝑘𝑔 1𝑏𝑎𝑡𝑐ℎ
( ∗ 3600𝑠 )
V𝑓 = 𝑏𝑎𝑡𝑐ℎ
0.1983 𝑘𝑔/𝑚3
V𝒇 = 𝟐. 𝟓𝟏𝟖𝟔 𝒎𝟑 /𝒔
3. Capacity of the Column
Computing for the Capacity of the column

𝑚
𝑉=
ρ
1798𝑘𝑔
𝑉 = 𝑏𝑎𝑡𝑐ℎ
286.9293
𝑉 = 6.264 𝑚3
𝑆𝑎𝑓𝑒𝑡𝑦 𝐹𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 20%
Source: Design and Rating of Trayed Distillation Columns
𝑉 = 6.264𝑚3 𝑥 1.2
𝑉 = 7.5196 𝑚3
𝑽 = 𝟕. 𝟔 𝒎𝟑
4. Cross Sectional Area of the Column
𝑉𝑎𝑝𝑜𝑟 𝐹𝑙𝑜𝑤 𝑅𝑎𝑡𝑒

𝐴=
𝑉𝑎𝑝𝑜𝑟 𝑉𝑒𝑙𝑜𝑐𝑖𝑡𝑦
𝑚3
2.5186 𝑠𝑒𝑐
𝐴= 𝑚
0.3986 𝑠𝑒𝑐
𝐴 = 6.3186 𝑚2
𝑨 = 𝟔. 𝟑𝟐 𝒎𝟐
5. Column Diameter

𝜋 2
𝐶𝑜𝑙𝑢𝑚𝑛 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = 𝐷
4
4𝐴
𝐷=√
𝜋
4(6.3186)
𝐷=√
𝜋
𝐷 = 2.8364 𝑚
𝑫 = 𝟑. 𝟎𝟎 𝒎
6. Number of Plates
Computing for the vapor and liquid compositions:

𝟏𝟔𝟓𝟑 𝟏𝟔𝟓𝟐
𝒙𝒂 = 𝒙𝒂 =
𝟏𝟕𝟗𝟖 𝟏𝟕𝟗𝟖
𝒙𝒂 = 𝟎. 𝟗𝟏𝟗𝟒 𝒚𝒂 = 𝟎. 𝟗𝟏𝟖𝟖
𝒙𝒃 = 𝟏 − 𝟎. 𝟗𝟏𝟗𝟒 = 𝟎. 𝟎𝟖𝟎𝟔 𝒚𝒃 = 𝟏 − 𝟎. 𝟗𝟏𝟖𝟖 = 𝟎. 𝟎𝟖𝟖𝟏𝟐
𝑦𝑎
𝑥𝑎
𝛼𝐴𝐵 =𝑦
𝑏
𝑥𝑏
0.9188
𝛼𝐴𝐵 = 0.0806 = 1.9920
0.08812
0.9194
𝑥𝐹 = 0.9194
𝑥𝑏 = 0.0812
1652
𝑥𝐷 = = 0.9994
1653
𝑈𝑠𝑖𝑛𝑔 𝐹𝑒𝑛𝑠𝑘𝑒 𝐸𝑞𝑢𝑎𝑡𝑖𝑜𝑛

𝑥 (1 − 𝑥𝐵 )
𝑙𝑛 ( 𝐷 )
𝑥𝐵 (1 − 𝑥𝐷 )
𝑁𝑚𝑖𝑛 =
𝑙𝑛(𝛼𝐴𝐵 )
0.9994(1 − 0.0812)
𝑙𝑛 ( )
0.0812(1 − 0.9994)
𝑁𝑚𝑖𝑛 =
𝑙𝑛(1.9920)
𝑁𝑚𝑖𝑛 = 3.2847 𝑝𝑙𝑎𝑡𝑒𝑠
𝑁𝑚𝑖𝑛 = 4 𝑝𝑙𝑎𝑡𝑒𝑠
𝐶𝑎𝑙𝑐𝑢𝑙𝑎𝑡𝑖𝑛𝑔 𝑉𝑜𝑙𝑎𝑡𝑖𝑙𝑖𝑡𝑦 (𝐴)
𝛼𝐴𝐵 𝑥𝐹
1=
𝛼𝐴𝐵 − 𝐴
𝐴 = 𝛼𝐴𝐵 − 𝛼𝐴𝐵 𝑥𝐹
𝐴 = 1.9920 − 1.9920(0.9194)
𝐴 = 0.1606
𝑈𝑠𝑖𝑛𝑔 𝑈𝑛𝑑𝑒𝑟𝑤𝑜𝑜𝑑 𝐸𝑞𝑢𝑎𝑡𝑖𝑜𝑛
𝛼𝐴𝐵 𝑥𝐷
𝑅𝑚𝑖𝑛 + 1 =
𝛼𝐴𝐵 𝑥𝐷
1.9920(0.9994)
1.9920 − 0.1606
𝑅𝑚𝑖𝑛 = 2.0687
𝑨𝒄𝒄𝒐𝒓𝒅𝒊𝒏𝒈 𝒕𝒐 𝑮𝒆𝒂𝒏𝒌𝒐𝒑𝒍𝒊𝒔, 𝒑𝒂𝒈𝒆 𝟔𝟔𝟎, 𝒕𝒉𝒆 𝒐𝒑𝒕𝒊𝒎𝒖𝒎 𝒓𝒆𝒇𝒍𝒖𝒙 𝒓𝒂𝒕𝒊𝒐 𝒇𝒐𝒓 𝒍𝒐𝒘𝒆𝒔𝒕 𝒄𝒐𝒔𝒕
𝒊𝒔 𝒃𝒆𝒕𝒘𝒆𝒆𝒏 𝟏.𝟐 𝒕𝒐 𝟏.𝟓 𝑹𝒎. 𝑼𝒔𝒊𝒏𝒈 𝒕𝒉𝒆 𝒎𝒆𝒂𝒏, 𝒘𝒆 𝒖𝒔𝒆 𝟏.𝟑𝟓𝑹𝒎
𝑅 = 1.35𝑅𝑚𝑖𝑛
𝑅 = 1.35(2.0687)
𝑅 = 2.7928
Using Gilliand Correlation

𝑁 − 𝑁𝑚𝑖𝑛 𝑅 − 𝑅𝑚𝑖𝑛
,
𝑁+1 𝑅+1
𝑅 − 𝑅𝑚𝑖𝑛 2.7928 − 2.0687
= = 0.1550 ≈ 0.16
𝑅+1 2.7928 + 1
𝑁 − 𝑁𝑚𝑖𝑛
= 0.48
𝑁+1
𝑁 − 3.3880
= 0.48
𝑁+1
𝑁 = 7.4385
𝑵 = 𝟖 𝒑𝒍𝒂𝒕𝒆𝒔
To determine feed location

0.206
𝑁𝑅 𝑋𝐹,𝐻𝐾 𝐵 𝑋𝐵 2
=( ( )( ) )
𝑁𝑆 𝑋𝐹,𝐿𝐾 𝐷 𝑋𝐷
Where:
𝑁𝑅 = 𝑟𝑒𝑐𝑡𝑖𝑓𝑦𝑖𝑛𝑔 𝑠𝑒𝑐𝑡𝑖𝑜𝑛
𝑁𝑅 = 𝑠𝑡𝑟𝑖𝑝𝑝𝑖𝑛𝑔 𝑠𝑒𝑐𝑡𝑖𝑜𝑛
𝑋𝐹,𝐻𝐾 = 𝑐𝑜𝑚𝑝𝑜𝑠𝑖𝑡𝑖𝑜𝑛 𝑜𝑓 ℎ𝑒𝑎𝑣𝑦 𝑐𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡 𝑖𝑛 𝑡ℎ𝑒 𝑓𝑒𝑒𝑑
𝑋𝐹,𝐿𝐾 = 𝑐𝑜𝑚𝑝𝑜𝑠𝑖𝑡𝑖𝑜𝑛 𝑜𝑓 𝑙𝑖𝑔ℎ𝑡 𝑐𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡 𝑖𝑛 𝑡ℎ𝑒 𝑓𝑒𝑒𝑑
𝐵 = 𝐵𝑜𝑡𝑡𝑜𝑚𝑠 𝑃𝑟𝑜𝑑𝑢𝑐𝑡
𝐷 = 𝐷𝑖𝑠𝑡𝑖𝑙𝑙𝑎𝑡𝑒 𝑃𝑟𝑜𝑑𝑢𝑐𝑡
0.206
𝑁𝑅 0.115 146 0.0812 2
=( ( )( ) )
𝑁𝑆 0.885 1652 0.9994
𝑁𝑅
= 0.4165
𝑁𝑆
𝑁𝑅 + 𝑁𝑆 = 8

𝑁𝑅 = 8 − 𝑁𝑆
8 − 𝑁𝑆
= 0.4165
𝑁𝑆
𝑁𝑆 = 4.46477
𝑵𝑺 = 𝟓
𝑇ℎ𝑒 𝑓𝑒𝑒𝑑 𝑝𝑙𝑎𝑡𝑒 𝑖𝑠 𝑡ℎ𝑒 5𝑡ℎ 𝑝𝑙𝑎𝑡𝑒
7. Column Height
𝐼𝑛 𝑜𝑟𝑑𝑒𝑟 𝑡𝑜 𝑐𝑎𝑙𝑐𝑢𝑡𝑎𝑡𝑒 𝑡ℎ𝑒 𝑐𝑜𝑙𝑢𝑚𝑛 ℎ𝑒𝑖𝑔ℎ𝑡, 𝑡ℎ𝑒 𝐻𝐸𝑇𝑃( ℎ𝑒𝑖𝑔ℎ𝑡 𝑒𝑞𝑢𝑖𝑣𝑎𝑙𝑒𝑛𝑡 𝑜𝑓 𝑝𝑙𝑎𝑡𝑒 𝑡𝑜𝑤𝑒𝑟)
𝐹𝑟𝑜𝑚 𝐸𝑞 11.5 −
8 𝑜𝑓 𝐺𝑒𝑎𝑛𝑘𝑜𝑝𝑙𝑖𝑠 (𝑝𝑔 727), 𝑡ℎ𝑒 𝐻𝐸𝑇𝑃( ℎ𝑒𝑖𝑔ℎ𝑡 𝑒𝑞𝑢𝑖𝑣𝑎𝑙𝑒𝑛𝑡 𝑜𝑓 𝑝𝑙𝑎𝑡𝑒 𝑡𝑜𝑤𝑒𝑟)
𝑐𝑎𝑛 𝑏𝑒 𝑐𝑎𝑙𝑐𝑢𝑙𝑎𝑡𝑒𝑑
𝑇
𝐻𝐸𝑇𝑃 =
𝐸𝑜
Where
𝑇 = 𝑇𝑟𝑎𝑦 𝑆𝑝𝑎𝑐𝑖𝑛𝑔
𝐸𝑜 = 𝑂𝑣𝑒𝑟𝑎𝑙𝑙 𝑇𝑟𝑎𝑦 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
𝐴𝑐𝑐𝑜𝑟𝑑𝑖𝑛𝑔 𝑡𝑜 𝐺𝑒𝑎𝑛𝑘𝑜𝑝𝑙𝑖𝑠, 𝑝𝑔 728, 𝑡ℎ𝑒 𝑚𝑜𝑠𝑡 𝑡𝑦𝑝𝑖𝑐𝑎𝑙 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 𝑎𝑟𝑒 𝑏𝑒𝑡𝑤𝑒𝑒𝑛 40 𝑡𝑜 80%
𝑈𝑠𝑖𝑛𝑔 𝑡ℎ𝑒 𝑚𝑒𝑎𝑛 𝑣𝑎𝑙𝑢𝑒 𝑓𝑜𝑟 𝑡𝑟𝑎𝑦 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 𝑤𝑒 𝑔𝑒𝑡 60%, 𝐶𝑎𝑙𝑐𝑢𝑙𝑎𝑡𝑖𝑛𝑔 𝑓𝑜𝑟 𝑡ℎ𝑒 𝐻𝐸𝑇𝑃:
0.45
𝐻𝐸𝑇𝑃 =
0.65
𝐻𝐸𝑇𝑃 = 0.75𝑚
𝑇ℎ𝑒 𝑐𝑜𝑙𝑢𝑚𝑛 ℎ𝑒𝑖𝑔ℎ𝑡 (𝐸𝑞 11.5 − 5 𝑜𝑓 𝐺𝑒𝑎𝑛𝑘𝑜𝑝𝑙𝑖𝑠, 𝑝𝑎𝑔𝑒 727)
𝐻 = 𝐻𝐸𝑇𝑃 𝑥 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑝𝑙𝑎𝑡𝑒𝑠
𝐻 = 0.75𝑚 𝑥 8
𝐻 = 6𝑚
8. Shell Thickness
𝐹𝑟𝑜𝑚 𝑆𝑖𝑛𝑛𝑜𝑡, 𝑅. 𝐾 (2005)𝑒𝑞𝑢𝑎𝑡𝑖𝑜𝑛 13.39𝑎, 𝑝𝑔 813

𝑃𝐷
𝑡𝑠 = +𝐶
2𝑙𝑓 − 𝑃
Where:
𝑡𝑠 = 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑜𝑓 𝑡ℎ𝑒 𝑝𝑙𝑎𝑡𝑒
𝑃 = 𝐼𝑛𝑡𝑒𝑟𝑛𝑎𝑙 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒
𝐷 = 𝐼𝑛𝑡𝑒𝑟𝑛𝑎𝑙 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟
𝑙 = 𝑤𝑖𝑒𝑙𝑑 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
𝑓 = 𝑑𝑒𝑠𝑖𝑔𝑛 𝑠𝑡𝑟𝑒𝑠𝑠
𝐶 = 𝐶𝑜𝑟𝑟𝑜𝑠𝑖𝑜𝑛 𝐴𝑙𝑙𝑜𝑤𝑎𝑛𝑐𝑒
𝐹𝑟𝑜𝑚 𝑆𝑖𝑛𝑛𝑜𝑡, 𝑅. 𝐾 (2005)𝑒𝑞𝑢𝑎𝑡𝑖𝑜𝑛 13.39𝑎, 𝑝𝑔 812
𝑓 = 165 𝑁/𝑚𝑚2
Computing for Internal Pressure

𝐻𝜌𝑔
𝑃=
𝑔𝑐
3.2808𝑓𝑡 𝑘𝑔 2.205𝑙𝑏 1𝑚 3 32.2𝑓𝑡

(6.0𝑚) ( ) (286.9293 ) ( ) ( ) ( 2 ) 1𝑓𝑡 2
1𝑚 𝑚3 1𝑘𝑔 3.28𝑓𝑡 𝑠
𝑃= ( )
𝑙𝑏 − 𝑓𝑡 12𝑖𝑛
32.2 𝑚
𝑙𝑏𝑓 − 𝑠 2
𝑙𝑏𝑓
𝑃 = 16.1533
𝑖𝑛2
𝑃𝐷
𝑡𝑠 = +𝐶
2𝑙𝑓 − 𝑃
𝑙𝑏𝑓 3.2808𝑓𝑡 12𝑖𝑛
(2.5𝑚) (
16.1533
𝑖𝑛2 1𝑚 ) ( 1𝑓𝑡 )
𝑡𝑠 = + 0.15𝑖𝑛
𝑁 645.16𝑚𝑚2 1𝑙𝑏𝑓 𝑙𝑏𝑓
2(0.85)(165 ( ) (4.4482𝑁) − 16.1533 2
𝑚𝑚2 1𝑖𝑛2 𝑖𝑛
𝑡𝑠 = 0.1391 𝑖𝑛 ≈ 3.5331 𝑚𝑚
𝑼𝒔𝒆 𝒕𝒔 = 𝟒𝒎𝒎

9. Insulation Material
W
𝑇ℎ𝑒𝑟𝑚𝑎𝑙 𝐶𝑜𝑛𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 𝑜𝑓 𝐿𝑎𝑚𝑒𝑙𝑙𝑎 𝑀𝑎𝑡 𝑖𝑠 0.0527 at 70°C
mK
(𝑆𝑜𝑢𝑟𝑐𝑒: 𝑅𝑜𝑐𝑘𝑤𝑜𝑜𝑙 𝐿𝑎𝑚𝑒𝑙𝑙𝑎 𝑀𝑎𝑡 𝐷𝑒𝑠𝑖𝑔𝑛)
𝑘𝐽 𝐵𝑇𝑈
𝐻𝑒𝑎𝑡 𝑅𝑒𝑞𝑢𝑖𝑟𝑒𝑚𝑒𝑛𝑡 = 490,707.36 = 465,100.84
𝑏𝑎𝑡𝑐ℎ 𝑏𝑎𝑡𝑐ℎ
𝑂𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 𝑇𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑖𝑠 70°𝐶
∆𝑇 = 70°𝐶 − 25°𝐶 = 45°𝐶
∆𝑇 = 113°𝐹
𝑈𝑠𝑖𝑛𝑔 𝑒𝑞𝑢𝑎𝑡𝑖𝑜𝑛 10.8 𝑝𝑎𝑔𝑒 284 𝑜𝑓 𝑈𝑛𝑖𝑡 𝑂𝑝𝑒𝑟𝑎𝑡𝑖𝑜𝑛𝑠 𝑜𝑓 𝐶ℎ𝑒𝑚𝑖𝑐𝑎𝑙 𝐸𝑛𝑔𝑖𝑛𝑒𝑒𝑟𝑖𝑛𝑔,
6𝑡ℎ 𝑒𝑑𝑖𝑡𝑖𝑜𝑛 𝑏𝑦 𝑀𝑐𝐶𝑎𝑏𝑒, 𝑆𝑚𝑖𝑡ℎ 𝑎𝑛𝑑 𝐻𝑎𝑟𝑟𝑖𝑜𝑡
𝑄 ∆𝑇
= 𝑘( )
𝐴 𝑥
∆𝑇
𝑄 = 𝐴𝑘 ( )
𝑥
𝑊ℎ𝑒𝑟𝑒: 𝑥 = 𝑇ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑜𝑓 𝑙𝑎𝑦𝑒𝑟 𝑜𝑓 𝑖𝑛𝑠𝑢𝑙𝑎𝑡𝑖𝑜𝑛
𝑊
𝐾 = 0.0527
𝑚𝐾
𝐵𝑇𝑈
𝐶𝑜𝑛𝑣𝑒𝑟𝑡𝑖𝑛𝑔 𝑡ℎ𝑒𝑟𝑚𝑎𝑙 𝑐𝑜𝑛𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 𝑡𝑜
𝑓𝑡 − ℎ𝑟 − 𝐹
𝐵𝑇𝑈
𝑊 𝑓𝑡 − ℎ𝑟 − 𝐹
𝑘 = 0.0527 (6.9335 )
𝑚𝐾 𝑊
𝑚𝐾
𝐵𝑇𝑈
𝑘 = 0.3657
𝑓𝑡 − ℎ𝑟 − 𝐹
2
2 3.28𝑓𝑡 𝐵𝑇𝑈
𝐵𝑇𝑈 𝑏𝑎𝑡𝑐ℎ 3.73𝑚 ( ) (0.3657 ) (113𝐹)
1𝑚 𝑓𝑡 − ℎ𝑟 − 𝐹
465,100.84 ∗ =
𝑏𝑎𝑡𝑐ℎ 1ℎ𝑟 𝑥
𝑥 = 0.04877 𝑓𝑡 = 0.01487𝑚
𝑥 = 14.87𝑚𝑚
𝑼𝒔𝒆 𝟏𝟓𝒎𝒎
𝐹𝑟𝑜𝑚 𝑡ℎ𝑒 𝑡𝑎𝑏𝑙𝑒 7.8 𝑜𝑓 𝐶ℎ𝑒𝑚𝑖𝑐𝑎𝑙 𝑃𝑟𝑜𝑐𝑒𝑠𝑠 𝐸𝑛𝑔𝑖𝑛𝑒𝑒𝑟𝑖𝑛𝑔 𝐷𝑒𝑠𝑖𝑔𝑛 𝑎𝑛𝑑 𝐸𝑐𝑜𝑛𝑜𝑚𝑖𝑐𝑠 𝑏𝑦 𝐻𝑎𝑟𝑟𝑦 𝑆𝑖𝑙𝑎
4.18 ℎ𝑝
𝑝𝑔 388 𝑡ℎ𝑒 ℎ𝑒𝑎𝑡 𝑡𝑟𝑎𝑛𝑠𝑓𝑒𝑟 𝑝𝑜𝑤𝑒𝑟 𝑖𝑛 𝑎 𝑑𝑖𝑠𝑡𝑖𝑙𝑙𝑎𝑡𝑖𝑜𝑛 𝑐𝑜𝑙𝑢𝑚𝑛 𝑖𝑠 .
1000𝑔𝑎𝑙
𝑇ℎ𝑢𝑠, 𝑐𝑜𝑚𝑝𝑢𝑡𝑖𝑛𝑔 𝑓𝑜𝑟 𝑡ℎ𝑒 𝑝𝑜𝑤𝑒𝑟 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑚𝑒𝑛𝑡
264.1720 𝑔𝑎𝑙 4.18ℎ𝑝
𝑃 = 7.6 𝑚2 𝑥 ( 3
)𝑥( )
𝑚 1000 𝑔𝑎𝑙
𝑃 = 8.3922 ℎ𝑝
𝑼𝒔𝒆 𝑷 = 𝟖. 𝟒𝟎 𝒉
Identification
Number of Units Required 1
Materials Handled Miscella (Oil-Hexane Mixture)
Function To separate the dissolved hexane from the

miscella and recover the rubber seed oil
Materials of Construction Stainless Steel Type 316
Operating Temperature 70 C
Heat Requirement 490,707.36 kJ/batch
Steam Requirement 175.05 kg/batch
Design Data
Parameter Proposed Design Existing Design
Column Capacity 7.60 𝑚3 4-10 𝑚3

Column Area 6.32 𝑚2 4-8.00 𝑚2
Column Diameter 3.00 m 2-4 m
Plate Spacing 0.45m 25 in
Plate Thickness 1 in (2.54 cm) 1.5 in
Weir Height 2 in (5.08 cm) 2 in
Number of Plates 8 -
Column Height 6m -
Shell Thickness 4mm 3-10mm
Insulation 15mm 10-40mm

Thickness
Power 8.4 hp -
Requirement

0.45m
2.5cm
6m
5cm
3m
EVAPORATOR
DESIGN PROBLEM
Design an evaporator that will vaporize water from a sulfuric acid solution entering at
25C with a heat capacity of 2.82 kJ / kg C.

DESIGN PROCEDURE
1. Determine first the properties of the feed solution: density, viscosity, and heat
capacity.
2. Determine the mass flow rates and the operating temperature according to the
feed and outlet conditions.
3. Choose the appropriate evaporator type for the given conditions.
4. Calculate the steam economy and the overall heat transfer area.
5. Then, compute for the number of tubes as well as the tube dimensions and tube
pitch.
6. Calculate the dimensions of the Downcomer and the total area of the tube sheet.
7. Calculate the overall dimensions of the evaporator.
8. Determine the number of baffles to be used in the entrainment section.
9. Calculate the insulation and proper shell thickness with respect to the internal
pressure.
10. Determine all the necessary ancillary equipment such as circulation pumps.
DESIGN DESCRIPTION
The short tube evaporator uses vertical tubes rather than horizontal in its operation. The
short tube evaporator contains tubes inside the shell that will support the heating up of
the feed to 100 degrees celsius. The tubes are usually about 2 in. to 3 in. diameter and
have a length of 1.2 m to 1.8 m for short tube evaporator (Perry’s Chemical Engineering
Handbook, 7th ed.). The entrainment separator to be used is in a form of baffles placed
at the top of the drum, diameter of the drum may be the same as that for the calendria
(Joshi’s Process Equipment Design by VV. Mahajani, SB. Umarji). The liquid is inside the
tubes and the steam condenses outside the tubes. It will be used to evaporate the water
from the solution.
DESIGN SELECTION
The selection of the most suitable evaporator type for a particular application will
depend on the following factors (Plant Design and Economics for Chemical Engineers,
5th ed., Peters and Timmerhaus):
1. The throughput required.
2. The viscosity of the feed and the increase in viscosity during evaporation.

3. The nature of the product required; solid, slurry, or concentrated solution.
4. The heat sensitivity of the product.
5. Whether the materials are fouling or non-fouling.
6. Whether the solution is likely to foam.
7. Whether direct heating can be used.
The following figure summarizes the types of evaporators suitable for each feed
condition.
Source: Plant Design and Economics for Chemical Engineers, 5th ed., Peters and
Timmerhaus
PARTS AND FUNCTIONS

1. Downcomer - Return passage from above the top tube sheet to below the bottom
tube sheet.
2. Tubes- To support the desired temperature of 100oC
3. Steam Inlet- Where supplied steam enters the evaporator.
4. Calendria- The body of the evaporator.
5. Feed Inlet- Where the feed solution enters.
6. Evaporator Drum-Contains the entrainment separator and baffles.
7. Vapor Outlet- Where vaporized water exits the evaporator.
1. The mass flow rate of entering solution is 385.55 kg/batch.
2. The feed temperature is 25oC.
3. The supplied steam temperature is 150oC.

4. The steam requirement is 117.42 kg/batch.
5. The feed heat capacity is 2.82 kJ / kg –OC.
6. The operating temperature of the evaporator is 100oC .
1. The efficiency of the lap-welded joints is 70% (Plant Design and Economics for
Chemical Engineers, 5th ed., Peters and Timmerhaus).
2. The height to diameter ratio of the evaporator tank is 2 (Perry’s Chemical

Engineering Handbook, 7th edition)
3. The materials of construction are stainless steel Type 316 (Plant Design and
Economics for Chemical Engineers, 5th ed., Peters and Timmerhaus)
4. The insulating material used for the reactor is calcium silicate and the thermal
conductivity is 0.44 𝐵𝑡𝑢𝑓𝑡2ℎ𝑟℉. (Principles of Transport Processes and Phenomena
by Geankoplis)
5. The head and bottom shell is hemispherical shape.
6. The diameter of the evaporator drum is the same as that for the calendria. (Joshi’s
Process Equipment Design by VV. Mahajani, SB. Umarji)
7. The shell thickness of the evaporator drum is the same as that for the calendria, and
top and bottom shell. (Joshi’s Process Equipment Design by VV. Mahajani, SB.
Umarji)
8. The corrosion allowance for non-corrosive conditions is 0.15 in. (Rules of Thumb for
Chemical Engineers 4th ed., by Branan)
9. The diameter of the evaporator is equal to the height of head and bottom shell.
10. The maximum allowable tensile stress for stainless steel at temperature up to 650oF
is 9,000psi (Process Equipment Design, Hesse.)
11. The typical overall coefficients for short tube vertical evaporator are: for natural
circulation = 1,100 – 2800 W/m2-K (Transport Processes and Unit Operations,
Geankoplis)

12. The tubes are usually about 2 in. to 3 in. diameter for short tube evaporator (Perry’s
Chemical Engineering Handbook, 7th ed.,)
13. Tube length may vary from less than 1.2 m to 1.8 m in the short tube evaporator
(Perry’s Chemical Engineering Handbook, 7th ed.,)
14. The tube arrangement is triangular pitch.
15. A safety factor of 15% is considered for the evaporator. (Plant Design and
Economics by Peters and Timmerhaus)
DESIGN REQUIREMENTS
1. Steam Economy
2. Heat Transfer Area
3. Number of Tubes
4. Length and diameter of the tubes
5. Tube pitch
6. Downcomer Area
7. Downcomer Diameter
8. Total Area of the tube sheet
9. Evaporator Dimensions
10. Baffle Design
11. Shell Thickness
12. Insulation

DESIGN CALCULATIONS
1. Steam Economy
kg. vapor vaporized
Steam Economy =
kg of steam
77.13 kg vapor
Steam Economy =
117.42 kg Steam
𝐒𝐭𝐞𝐚𝐦 𝐄𝐜𝐨𝐧𝐨𝐦𝐲 =0.66
2. Heat Transfer Area
𝑄=𝑈𝐴(𝑇𝑠−𝑇1)
Where:
Ts = temperature of steam
T1 = temperature of product
According to design consideration, the typical overall coefficients for short

tube vertical evaporator are: for natural circulation = 1,100 – 2800 W/m2-K
(Transport Processes and Unit Operations, Geankoplis). Use 1,100 W/m2-K.
3. Number of Tubes
4. Length and diameter of the tubes

The length of the tube used is 1.2 m (Perry’s Chemical Engineering
Handbook). The diameter of the tube used is 2.0 in (0.0508 m) (Perry’s Chemical
Engineering Handbook).

Use: L= 1.2 m ; Doutside, tube = 2.0 in
5. Number of Tubes
6. Tube pitch
7. Downcomer Area
8. Downcomer Diameter
9. Total Area of Tube Sheet in the Evaporator

10. Evaporator Dimensions
Height of Evaporator:
From the design consideration, H = 2D;
Adding the height of the top and bottom shell
Volume of Evaporator:
Since the height and the diameter of the evaporator is given we can compute for its
volume.
Considering a 15% safety factor:

11. Baffle Design
Baffle Width:
Number of Baffles:
The number of baffles is usually 4 (Unit Operations of Chemical Engineers, 6th ed., by
McCabe). This number of baffles is used for liquid with low viscosity (Geankoplis,
2012)
Use: NB= 4
12. Shell Thickness
Shell Thickness formula (Process Equipment Design, Hesse and Rushton, Eq. 4-3, page
85):
Allowable Working Stress formula (Rules of Thumb 4th ed.):

Where Su – workable pressure (9,000 psi) for temperature of -20oF to 650oF (Process
Equipment Design, Hesse and Rushton).
Computing for the height of the liquid inside the evaporator:
Internal Pressure:

13. Insulation
The operating temperature of the evaporator is 100oC and the temperature

surrounding is assumed to be 25oC.
From the energy balance:
Using equation 10.8, pg. 294, Unit operations of Chemical Engineering, 6th ed., by
McCabe, Smith, and Harriott:
Arranging the equation,
Where x is the thickness of the layer of insulation,



CRYSTALLIZER
DESIGN PROBLEM
A batch of 16,253.54kg of potassium nitrate solution at 95°C coming from a
reactor needs to be purified. Cooling water is accessible at 10°C. Design a separation

equipment that would yield pure potassium nitrate crystals. Potassium nitrate has a
steep solubility curve with respect to temperature.
DESIGN DESCRIPTION
A simple cooling tank crystallizer is designed in order to purify 16,253.54kg of
potassium nitrate solution. The entirety of the batch is fed to the tank. After which,
agitation and cooling is commenced. The agitator increases the rate of heat transfer and
keeps the crystals formed in suspension. The residence time is taken as the total time
needed to bring the solution down to the desired temperature and to allow for crystal
growth. At the end of the process, the magma is pumped out of the tank while agitation
is still present. The magma is transported to a centrifuge to recover the pure potassium
nitrate crystals.
DESIGN SELECTION
Since the mode of operation is batch, continuous crystallizers such as the forced-
circulation crystallizer and scraped-surface crystallizers are eliminated. Furthermore, the
solubility of potassium nitrate is remarkably dependent on temperature, thus, the

cooling crystallization method is much more appropriate.
DESIGN PARTS AND FUNCTION

Table 3.1 and Figure 3.7 show the main parts and function of each part of agitated
tank crystallizer.
Figure 3.7 Parts of the Agitated Tank Crystallizer
Table 3.1 Parts and Functions of the Agitated Tank Crystallizer
Parts Functions
Transfers mechanical rotation to the impeller

1 Agitator Motor
turbines
2 Feed Inlet Feeding port of the crystallizer

3 Cooling Water Inlet Inlet port of the cooling jacket
4 Cooling Jacket Removes heat from the crystallizing solution
5 Tank Body Contains the crystallizing solution
6 Product Outlet Outlet port of the magma
7 Cooling Water Outlet Outlet port of the cooling water
Transfers momentum to the fluid, allowing for

8 Impeller increased heat transfer rate and keeping the
crystals in suspension
1. The mass of potassium nitrate solution is 16,253.54 kg/batch (Material Balance).

2. The mass of potassium nitrate crystals is 521.59 kg/batch (Material Balance).
3. The density of the input solution is 1.08 kg/L (Experiment).

4. The feed inlet temperature in the crystallizer is 95°C and its outlet temperature is
20°C.
5. The cooling water inlet temperature is 10°C and its outlet temperature is 75°C
6. The mass flowrate of cooling water is 3322.09 kg/h (Energy Balance)

7. The specific heat of water and the solution is 4.108 kJ/kg-°C and 3.56 kJ/kg-°C
respectively (Perry’s Chemical Engineers’ Handbook 8th Edition, Section 2).

1. The safety factor for agitated batch crystallizers is 20% (Plant Design and
Economics for Chemical Engineers by Peters and Timmerhaus, Table 3-1, p. 82).
2. Conical bottom is used for this type of crystallizer when it is desired that
precipitates flow freely to the bottom outlet nozzle (Rule of Thumb for Chemical
Engineers, 5th ed., Hall, pp.149)

3. The ratio of H/D of cylindrical body is 1.5 (Giulietti et al, Industrial Crystallization
and Precipitation from Solutions: State of the Technique, 2001).

4. the ratio of H/D of conical bottom is 1 (Giulietti et al, Industrial Crystallization and
Precipitation from Solutions: State of the Technique, 2001).

5. Double welded butt is used with an efficiency of 85% (Chemical Engineering
Design, Principles, 2nd ed., Sinnott, pp.574)

6. The material of construction is Stainless Steel Type 302 since this type can be used
for non-corrosive applications (Plant Design and Economics for Chemical

Engineers, 4th ed., Peters and Timmerhaus, Table 4, page 426).
7. The maximum allowable internal pressure S, for stainless steel type 302 is 13,700
psi at 95°C (Plant Design and Economics for Chemical Engineers, 4th ed.,
Timmerhaus, pp.537)
8. The shell has a rigidity factor of 0.38 inches and a corrosion factor of 0.15 inches
(Couper, Chemical Process Equipment, p.xix)

9. The power input for blending operations is 0.35hp/1000gal (Couper, Rules of
Thumb for Chemical Engineers, p.xvii)

10. The number of baffles is usually 4 (Unit Operations of Chemical Engineers 7th ed,
McCabe et al., 2005, pg. 241). This number of baffles is used for liquid with low
viscosity (Geankoplis, 2012, pg. 159). Also, with the pitched blade turbine (4 blades),
the number of standard baffles is 4.
11. The type of impeller used is turbine flat blade impeller which is mainly used for low
liquid viscosities. (Sinnott, Chemical Engineering Design Vol. 6, 4th ed., p. 42).
12. The power number for pitched turbine impeller (45°) is 1.35 (McCabe and Smith,
Unit Operations for Chemical Engineers, 5th Edition, p.293)
DESIGN REQUIREMENTS
1. Rate of Cooling 8. Power Requirement
2. Residence Time
3. Crystallizer Capacity
4. Crystallizer Dimensions
a. Diameter
b. Height
5. Wall Thickness
a. Shell
b. Head
c. Cone Bottom
6. Agitator Design
a. Number of Impellers
b. Impeller Diameter
c. Blade Width
d. Impeller Elevation
e. Shaft Height
f. Impeller Speed
7. Baffle Design
DESIGN CALCULATIONS
1. Rate of Cooling
The rate of cooling is calculated using the heat balance equation,

̇
𝑄𝑐𝑜𝑜𝑙𝑖𝑛𝑔 = −[𝑚̇𝐶𝑝 (𝑇𝑖 − 𝑇𝑜 )]𝑐𝑜𝑜𝑙𝑖𝑛𝑔 𝑤𝑎𝑡𝑒𝑟
𝑘𝑔 1 4108 𝐽
̇
𝑄𝑐𝑜𝑜𝑙𝑖𝑛𝑔 = −3322.09 × × × (10°𝐶 − 75°𝐶)
ℎ 3600𝑠 𝑘𝑔°𝐶
̇
𝑸𝒄𝒐𝒐𝒍𝒊𝒏𝒈 = 𝟐𝟒𝟔, 𝟒𝟎𝟔. 𝟖𝟎𝑾
2. Residence Time
𝑄𝑓𝑒𝑒𝑑 𝑠𝑜𝑙𝑢𝑡𝑖𝑜𝑛
𝑡𝑟𝑒𝑠𝑖𝑑𝑒𝑛𝑐𝑒 =
̇
𝑄𝑐𝑜𝑜𝑙𝑖𝑛𝑔
[𝑚𝐶𝑝 (𝑇𝑖 − 𝑇𝑜 )]𝑓𝑒𝑒𝑑 𝑠𝑜𝑙𝑢𝑡𝑖𝑜𝑛

̇
𝑄𝑐𝑜𝑜𝑙𝑖𝑛𝑔
𝑘𝑔 3560 𝐽
16253.54 × × (95°𝐶 − 20°𝐶)
𝑏𝑎𝑡𝑐ℎ 𝑘𝑔°𝐶
246,406.80𝑊
𝑠 ℎ𝑟
𝑡𝑟𝑒𝑠𝑖𝑑𝑒𝑛𝑐𝑒 = 17611.91 ×
𝑏𝑎𝑡𝑐ℎ 3600𝑠
𝑡𝑟𝑒𝑠𝑖𝑑𝑒𝑛𝑐𝑒 = 4.89ℎ
Use: 5 hours
3. Crystallizer Capacity
𝑚
𝑉ℎ𝑜𝑙𝑑 𝑢𝑝 = ( )
𝜌 𝑓𝑒𝑒𝑑 𝑠𝑜𝑙𝑢𝑡𝑖𝑜𝑛

16253.54 𝑘𝑔
𝑉ℎ𝑜𝑙𝑑 𝑢𝑝 = ( )
𝑘𝑔
1080 3
𝑚 𝑓𝑒𝑒𝑑 𝑠𝑜𝑙𝑢𝑡𝑖𝑜𝑛
𝑉ℎ𝑜𝑙𝑑 𝑢𝑝 = 15.0496𝑚3
Applying 20% of safety factor,
𝑉𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = 1.20 (𝑉ℎ𝑜𝑙𝑑 𝑢𝑝 )
𝑉𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = 1.20 (15.0496𝑚3 )
𝑉𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = 18.0595𝑚3
Use: 18.1 m3
4. Crystallizer dimensions
a. Diameter
The following relations will be used for determining the tank diameter.
𝑉𝑐𝑟𝑦𝑠𝑡𝑎𝑙𝑖𝑧𝑒𝑟 = 𝑉𝑠ℎ𝑒𝑙𝑙 + 𝑉𝑡𝑜𝑟𝑖𝑠𝑝ℎ𝑒𝑟𝑒 + 𝑉𝑐𝑜𝑛𝑒
𝜋 2 1 𝐷2
𝑉𝑐𝑟𝑦𝑠𝑡𝑎𝑙𝑖𝑧𝑒𝑟 = 𝐷𝑖 ℎ𝑠ℎ𝑒𝑙𝑙 + 0.0809𝐷𝑖 3 + 𝜋 ℎ
4 3 4 𝑐𝑜𝑛𝑒
where
Di is the tank’s internal diameter

hshell is the tank height
hcone is the cone height
From Industrial Crystallization and Precipitation from Solutions: State of
the Technique by Giulietti et al (2001), the ratio of H/D = 1.5 is for the
cylindrical body, the ratio of H/D = 1 is for the conical bottom.

𝜋 2 𝜋 2
𝐷𝑖 (1.5𝐷𝑖 ) + 0.0809𝐷𝑖 3 +
𝑉𝑐𝑟𝑦𝑠𝑡𝑎𝑙𝑙𝑖𝑧𝑒𝑟 = 𝐷 (𝐷𝑖 )
4 12 𝑖
𝜋 𝜋
18.0595𝑚3 = 𝐷𝑖 2 (1.5𝐷𝑖 ) + 0.0809𝐷𝑖 3 + 𝐷𝑖 2 (𝐷𝑖 )
4 12
𝐷𝑖 = 2.2815𝑚
Use: 2.30 m
b. Height
The total height of the crystallizer is calculated as the sum of the heights of
the heads and the shell. Furthermore, the height to diameter ratio of the
torisphere is obtained from Perry’s Chemical Engineers’ Handbook, 7 th ed.,

Table 10-65, sec. 10-140
ℎ𝑐𝑟𝑦𝑠𝑡𝑎𝑙𝑙𝑖𝑧𝑒𝑟 = ℎ𝑠ℎ𝑒𝑙𝑙 + ℎ𝑡𝑜𝑟𝑖𝑠𝑝ℎ𝑒𝑟𝑒 + ℎ𝑐𝑜𝑛𝑒
ℎ𝑐𝑟𝑦𝑠𝑡𝑎𝑙𝑙𝑖𝑧𝑒𝑟 = 1.5𝐷𝑖 + 0.1577𝐷𝑖 + 𝐷𝑖
ℎ𝑐𝑟𝑦𝑠𝑡𝑎𝑙𝑙𝑖𝑧𝑒𝑟 = 1.5(2.2815𝑚) + 0.1577(2.2815𝑚) + 2.2815𝑚
ℎ𝑐𝑟𝑦𝑠𝑡𝑎𝑙𝑙𝑖𝑧𝑒𝑟 = 6.0635𝑚
Use: 6.1 m
5. Wall Dimension
a. Shell Thickness
The shell thickness is calculated from the formula given by Towler, Chemical
Engineering Design (pp. 579)

𝑃𝐷
𝑡𝑠 =
2𝑆𝑒 − 𝑃
where:
t = thickness (m),

P = internal pressure (Pa),

D = internal diameter of shell (m),
S = allowable working stress

e = efficiency (0.85 for double welded butt joint),
The total pressure is calculated as the fluid head and atmospheric

pressure,
𝑃ℎ𝑒𝑎𝑑 = 𝜌𝑔ℎ𝑙𝑖𝑞𝑢𝑖𝑑 + 𝑃𝑎𝑡𝑚
The liquid level is calculated as,
(𝑉𝑓𝑒𝑒𝑑 − 𝑉𝑙𝑖𝑞𝑢𝑖𝑑 𝑖𝑛 𝑐𝑜𝑛𝑒 )

ℎ𝑙𝑖𝑞𝑢𝑖𝑑 = + ℎ𝑙𝑖𝑞𝑢𝑖𝑑 𝑖𝑛 𝑐𝑜𝑛𝑒
𝐴𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛,𝑠ℎ𝑒𝑙𝑙
(15.0496𝑚3 − 3.1091𝑚3 )
ℎ𝑙𝑖𝑞𝑢𝑖𝑑 = + 2.2815𝑚
2.2815𝑚 2
𝜋( )
2
ℎ𝑙𝑖𝑞𝑢𝑖𝑑 = 2.9207𝑚
The hydraulic head is then,
𝑘𝑔 𝑚
𝑃ℎ𝑒𝑎𝑑 = (1080 3
) (9.81 2 ) (2.9207𝑚) + 101325 𝑃𝑎
𝑚 𝑠
𝑃ℎ𝑒𝑎𝑑 = 132269.23𝑃𝑎
Calculating for the shell thickness,

(132269.23𝑃𝑎)(2.2815𝑚)
𝑡𝑠 =
101325 𝑃𝑎
2 (13,700 𝑝𝑠𝑖 × (132269.23𝑃𝑎)
14.7 ) (0.85) −
1000𝑚𝑚
×
𝑚
𝑡𝑠 = 1.8813 𝑚𝑚
Adding the rigidity and corrosion factor, the actual shell thickness is
calculated as,
𝑡𝑎𝑐𝑡𝑢𝑎𝑙 = 𝑡𝑠 + 𝑡𝑟𝑖𝑔𝑖𝑑𝑖𝑡𝑦 + 𝑡𝑐𝑜𝑟𝑟𝑜𝑠𝑖𝑜𝑛
25.4𝑚𝑚
𝑡𝑎𝑐𝑡𝑢𝑎𝑙 = 1.8813 𝑚𝑚 + (0.38𝑖𝑛 + 0.15𝑖𝑛) ×
𝑖𝑛
𝒕𝒂𝒄𝒕𝒖𝒂𝒍 = 𝟏𝟓. 𝟑𝟒𝟑𝟑𝒎𝒎
Use = 16 mm
b. Head Thickness
The formula for head thickness of the tori sphere is obtained from Chemical
Engineering Design by Towler (p. 581),

0.885𝑃𝐿
𝑡𝑡𝑜𝑟𝑖𝑠𝑝ℎ𝑒𝑟𝑒 =
2𝑆𝐸 − 0.1𝑃
where:
t = thickness (in),
P = internal pressure (psi),

L = crown radius (in)
S = allowable working stress,

E = efficiency (0.80 for double welded butt joint),

0.885(19.1893 𝑝𝑠𝑖)(89.8227 𝑖𝑛)

𝑡𝑡𝑜𝑟𝑖𝑠𝑝ℎ𝑒𝑟𝑒 =
2(13,700 𝑝𝑠𝑖)(0.85) − 0.1(19.1893 𝑝𝑠𝑖)
𝑡𝑡𝑜𝑟𝑖𝑠𝑝ℎ𝑒𝑟𝑒 = 0.0655 𝑖𝑛
calculated as,
𝑡𝑡𝑜𝑟𝑖𝑠𝑝ℎ𝑒𝑟𝑒,𝑎𝑐𝑡𝑢𝑎𝑙 = 𝑡ℎ𝑒𝑎𝑑 + 𝑡𝑟𝑖𝑔𝑖𝑑𝑖𝑡𝑦 + 𝑡𝑐𝑜𝑟𝑟𝑜𝑠𝑖𝑜𝑛

25.4 𝑚𝑚
𝑡𝑡𝑜𝑟𝑖𝑠𝑝ℎ𝑒𝑟𝑒,𝑎𝑐𝑡𝑢𝑎𝑙 = (0.0655 + 0.38 + 0.15)𝑖𝑛 ×
𝑖𝑛
𝑡𝑡𝑜𝑟𝑖𝑠𝑝ℎ𝑒𝑟𝑒,𝑎𝑐𝑡𝑢𝑎𝑙 = 13.5275 𝑚𝑚
Use: 14 mm
c. Cone Bottom Thickness
The formula for head thickness of the cone is obtained from Process
Equipment Design by Hesse and Rushton (p. 86),
𝑃𝑀
𝑡𝑐𝑜𝑛𝑒 =
2 cos(𝜃) 𝑆𝐸
where:
t = thickness (in),
P = internal pressure (psi),
M = mean diameter (in)

Θ = angle of cone (53.13° for 1:1 h/d ratio of cone)
S = allowable working stress

E = efficiency (0.85 for double welded butt joint),
89.8227𝑖𝑛 + 0
(19.1893 𝑝𝑠𝑖) ( )
𝑡𝑐𝑜𝑛𝑒 = 2
2 cos(53.13°) (13,700 𝑝𝑠𝑖)(0.85)

𝑡𝑐𝑜𝑛𝑒 = 0.0617 𝑖𝑛
calculated as,
𝑡𝑐𝑜𝑛𝑒,𝑎𝑐𝑡𝑢𝑎𝑙 = 𝑡ℎ𝑒𝑎𝑑 + 𝑡𝑟𝑖𝑔𝑖𝑑𝑖𝑡𝑦 + 𝑡𝑐𝑜𝑟𝑟𝑜𝑠𝑖𝑜𝑛

25.4 𝑚𝑚
𝑡𝑐𝑜𝑛𝑒,𝑎𝑐𝑡𝑢𝑎𝑙 = (0.0617 + 0.25 + 0.15)𝑖𝑛 ×
𝑖𝑛
𝑡𝑐𝑜𝑛𝑒,𝑎𝑐𝑡𝑢𝑎𝑙 = 13.5237 𝑚𝑚
Use: 14 mm
6. Agitator Design
a. Number of Impellers
As given by Joshi in Process Equipment Design in p. 415, the number of

agitators can be computed as:
(ℎ𝑙𝑖𝑞𝑢𝑖𝑑 )(𝑆𝐺𝑎𝑣𝑒 )
𝑁𝑖𝑚𝑝𝑒𝑙𝑙𝑒𝑟 =
𝐷𝑖
(2.9207𝑚)(1.080)
𝑁𝑖𝑚𝑝𝑒𝑙𝑙𝑒𝑟 =
2.2815𝑚
𝑁𝑖𝑚𝑝𝑒𝑙𝑙𝑒𝑟 = 1.3826
Use: 2 impellers
b. Impeller Diameter
The values for the impeller diameter is given by McCabe and Smith in Unit
Operations for Chemical Engineers, 5th Edition, p.242-243.

𝑑𝑖𝑚𝑝𝑒𝑙𝑙𝑒𝑟 1
=
𝑑𝑡𝑎𝑛𝑘 3
𝑑𝑖𝑚𝑝𝑒𝑙𝑙𝑒𝑟 1
=
2.2815𝑚 3
𝑑𝑖𝑚𝑝𝑒𝑙𝑙𝑒𝑟 = 0.7605𝑚
Use: 0.77m
b. Blade Width
𝑤𝑏𝑙𝑎𝑑𝑒 1
=
𝑤𝑏𝑙𝑎𝑑𝑒 1
=
2.2815𝑚 5
𝑤𝑖𝑚𝑝𝑒𝑙𝑙𝑒𝑟 = 0.4563𝑚
Use: 0.46m
c. Impeller Elevation
𝐶𝑖𝑚𝑝𝑒𝑙𝑙𝑒𝑟 1
=
𝐶𝑖𝑚𝑝𝑒𝑙𝑙𝑒𝑟 1
=
2.2815𝑚 3
𝐶𝑖𝑚𝑝𝑒𝑙𝑙𝑒𝑟 = 0.7605𝑚
Use: 0.77m
d. Shaft Height
ℎ𝑠ℎ𝑎𝑓𝑡 = ℎ𝑡𝑎𝑛𝑘 − 𝑐𝑖𝑚𝑝𝑒𝑙𝑙𝑒𝑟
ℎ𝑠ℎ𝑎𝑓𝑡 = 6.0635𝑚 − 0.7605𝑚
ℎ𝑠ℎ𝑎𝑓𝑡 = 5.303𝑚
Use: 5.4m
e. Impeller Speed
The impeller speed is calculated using the power number equation given
by Walas (Chemical Process Equipment Selection and Design by Walas,
p.290)
1.523 × 1013 × 𝑃
𝑁𝑃 =
𝑁 3 𝑑5𝑆
where, NP = power number (1.35, McCabe, p.293)
N = impeller speed (rpm)

d = impeller diameter (in)

S = liquid’s specific gravity

P = power input (0.35hp/1000gal)
0.35ℎ𝑝 𝑔𝑎𝑙
1.523 × 1013 × (15049.6 𝐿 × × )
1000 𝑔𝑎𝑙 3.7854 𝐿
1.35 =
39.37 𝑖𝑛 5
𝑁 3 (0.77𝑚 × 𝑚 ) (1.080)
𝑁 = 82.8034 𝑟𝑝𝑚
Use: 90 rpm
7. Baffle Design
The width of the baffle would be calculated according to the equation also
indicated by Geankoplis (2012) in Table 3.4-1, pg. 158.
𝑤𝑏𝑎𝑓𝑓𝑙𝑒 1
=
𝐷𝑖 12
𝑤𝑏𝑎𝑓𝑓𝑙𝑒 1
=
2.2815𝑚 12
𝑤𝑏𝑎𝑓𝑓𝑙𝑒 = 0.1901𝑚
Use: 0.20m
The power number for pitched turbine impeller (45°) is 1.35 (McCabe and
Smith, Unit Operations for Chemical Engineers, 5th Edition, p.293)
1.523 × 1013 × 𝑃
𝑁𝑃 =
𝑁3 𝑑5𝑆
Where:
Np = power number (dimensionless)
P = power
S = specific gravity
N = rotational speed
Da = impeller diameter
1.523 × 1013 × 𝑃
1.35 =
39.37 𝑖𝑛 5
(90 𝑟𝑝𝑚)3 (0.77𝑚 ×
𝑚 ) (1.080)
𝑃 = 1.7868 ℎ𝑝
Use: 2 hp
AGITATED VESSEL CRYSTALLIZER
Operating Data
Number of Units 1
Holding Capacity 1 batch
Materials of Construction Stainless Steel 302
Materials Handled Potassium Nitrate Acid Solution

Feed
Density 1,080 kg/m3
Operating Temperature 95oC to 25oC
Operating Pressure atmospheric
Rated Capacity 20,000 kg/batch
Amount of Cooling Water 3,200 kg/h
Vessel Data
Proposed Existing
Tank Capacity 18.10 m3 0.5 – 50 m3
Tank Diameter 2.30 m 1.0 – 3.0 m
Tank Height 6.10 m 2.4 – 9 m

Thickness of Cylinder Body 16 mm Up to 40 mm
Thickness of Conical Bottom 14 mm Up to 40 mm
Thickness of Torispherical Up to 40 mm
14 mm
Head
Four-Blade Pitched Four-Blade Paddle

Type of Agitator
Blade (45°)
Number of Impellers 2 At least 2
Impeller Diameter 0.77 m 0.4 – 1.0 m
Blade Width 0.46 m 1.0 – 3.0 m
Impeller Elevation 0.77 m 0.4 – 1.0 m
Shaft Height 5.4 m Up to 0.20 m
Impeller Speed 90 rpm 0.15 – 0.80 m
Number of Baffles 4 Up to 0.25 m
Baffle Width 0.20 m Up to 0.25 m
Power Requirement 2 hp 1.5 - 20.0 hp
Existing Equipment
Supplier Tork Philippines, Inc.
No. 174 Ermin Garcia Street, Barangay E.

Supplier Address
Rodriguez, Cubao, Quezon City
Auxiliaries
Pump Centrifugal Pump
Instrumentation and Control Temperature and Level Sensor
Maintenance Manhole with Sight Glass
Figures 3.8 and 3.9 show the design configuration of the agitated crystallizer
tank and its agitation system
Figure 3.8 Tank Configuration (figures in meters)

Figure 3.9 Impeller Configuration (figures in meters)
GAS ABSORPTION COLUMN

DESIGN PROBLEM
Design an equipment that will be used for the recovery of sulphur dioxide
from stack gases. A solution of sulphite-bisulphite liquid is circulated through the
absorption tower to absorb the So2. The following is a list of conditions, assumptions,
and data on which the design of an absorber is based.
• 100,000 ft3 gas per minute at 300oF and 1 atm are to be treated.
• The entering gas contains 0.3 percent by volume SO2.
• The average molecular weight of the entering gas is 29.4.
• The mole percent SO2 in the exit gas is to be 0.01 percent.
• The entering and exit pressures of the absorption column may be assumed to
be 1 atm for purposes of calculating the SO2 pressures.
The zinc oxide process will be used for recovering the SO2. In the process, a
solution of H2O, NHSO3, is circulated through the absorption tower to absorb the
SO2. This mixture is then treated with ZnO, and the ZnO¬3 formed is filtered off,
dried, and calcined to yield practically pure SO2. The ZnO from the calciner is reused,
and the sulphite-bisulfite from the filter is recycled.
The absorption tower will contain non-staggered wood grids of the following
dimensions:
• Clearance = 1.5 in
• Height = 4 in
• Thickness = 0.25 in
• Free cross-sectional area = 85.8%
• Active absorption are per cubic foot of volume (a) =13.7 ft2/ft3
The average density of the gas at the tower entrance can be assumed to be
0.054 lb/ft3. The sulphite-bisulfite liquid has a density of 70 lb/ft3 and can be
considered as having a zero equilibrium SO2 vapor pressure at both the inlet and
outlet of the tower.
The sulphite-bisulfite must be supplied at rate of 675 lb(h)(ft2) of column cross

sectional area.
The optimum design can be assumed to be that corresponding to a minimum

total power cost for circulating the liquid and forcing the gas through the tower. You

may assume that this optimum that would be obtained if fix charges were also
considered.
The following simplified equations are applicable for grids of the dimensions
to be used:
Kg = 0.00222(G0)
∆ℎ𝜔
= 0.23x10-7 (G0)1
𝐿
Where:
Kg = molar absorption coefficient,lbmole of component absorbed/(h)(ft2)(atm)kg

mean
G0 = superficial mass velocity of gas in tower, lb/(h)(ft2)
∆ℎ𝜔 = pressure drop through tower, in of water (in H2O)
L = height of tower, ft
The liquid is put into absorption tower by means of a nozzle at the top of the
tower. The pressure just before the nozzle is 35 psig. Assume the pump for the liquid
must supply power to lift the liquid to the top of the tower and compress the liquid
to 35 psig. Use a 10 percent safety factor on the above pumping-power requirements
to take care of the friction in the lines and other minor losses.
The gas blower has an overall efficiency of 55 percent and the pump has an
overall efficiency of 65 percent.

GAS ABSORPTION TOWER
DESIGN SELECTION
The packed column filled with non-staggered wood grid was selected to
promote contact between two fluids. The open structure of grids is recommended
for high gas rates, where low pressure drop is very essential (Coulson, p. 519).
DESIGN DESCRIPTION
A gas absorption tower consists of a column filled with non-staggered wood

grid packing. The column of the tower is fabricated from stainless steel which is
applicable to variety of feedstock such as abrasives, corrosives, flammable, explosive
or toxic.
The liquid feed is introduced at the top of the tower using a nozzle. The liquid
used to absorb sulphur dioxide is a solution of water, sodium bisulphate and sodium
sulphate. The stack gas is blown from bottom of the tower. By virtue of gravity, the
liquid will flow down and the gaseous product will rise up. This will promote contact
between the two fluids which is enhanced by the presence of non-staggered wood
grids. Sulphur dioxide will be dissolved in the sulphite-bisulphite solution. The
gaseous will be discharged at a certain level above of the tower.
PARTS AND FUNCTIONS
Packed Tower Absorber Internals
A schematic drawing of a countercurrent packed

tower is shown to the right. In this figure, the packing
is separated into two sections. Corrosion resistant
alloys or plastic materials such as polypropylene are
required for column internals when highly corrosive
solvents or gases are used. A basic packed tower unit
is comprised of:
Column/tower shell
The tower shell may be made of steel or plastic,

or a combination of these materials depending on
the corrosiveness of the gas and liquid streams, and the process
operating conditions. One alloy that is chemical and temperature resistant
or multiple layers of different, less expensive materials may be used. The shell
is sometimes lined with a protective membrane, often made from a corrosion
resistant polymer. For absorption involving acid gases, an interior layer of
acid resistant brick provides additional chemical and temperature resistance.
Mist eliminator
At high gas velocities, the gas exiting the top of the column may carry off
droplets of liquid as a mist. To prevent this, a mist eliminator in the form
of corrugated sheets or a layer of mesh can be installed at the top of the
column to collect the liquid droplets, which coalesce and fall back into the
column.
Liquid distributors
A liquid distributor is designed to wet the packing bed evenly and initiate
uniform contact between the liquid and vapor. The liquid distributor must
spread the liquid uniformly, resist plugging and fouling, provide free space
for gas flow, and allow operating flexibility. Large towers frequently have a
liquid redistributor to collect liquid off the column wall and direct it toward
the center of the column for redistribution and enhanced contact in the
lower section of packing. Liquid redistributors are generally required for
every 8 to 20 feet of random packing depth.
Distributors fall into two categories:
 gravitational types, such as orifice and

weir types Orifice-type distributors
typically consist of flat trays with a
number of risers for vapor flow and
perforations in the tray floor for liquid
flow. The trays themselves may present a
resistance to gas flow. However, better

contact is generally achieved when

orifice distributors are used.
 pressure-drop types, such as spray

nozzles and perforated pipes. Spray
nozzles are the most common
distributors, but they may produce a fine
mist that is easily entrained in the gas
flow. They also may plug, and usually
require high feed rates to compensate
for poor distribution.
packing materials, packing support, and may include a packing restrainer
Packing Materials
 provides a large surface area for mass transfer

 made of plastic (polyethylene, polypropylene, polyvinylchloride), ceramic or
metal
 Sizes range from 1 to 4 inches each

 Design depends on corrosiveness of gas, scrubbing liquid, size of absorber,
static pressure drop and cost

1. The volumetric flow gas into the tower is 100,000 ft3 per minute.
2. The inlet and outlet pressure is maintained at 1 atm.
3. There is 0.3%v of sulphur dioxide in the inlet of the gas and 0.01%v of sulphur
dioxide in the outlet gas.
4. The mass flow of liquid solution is 675 lb per hour cross-sectional area of the
column.
5. The density of the inlet gas is 0.054 lb/ft3 while that of the liquid is 70 lb/ft3.
1. The major absorption coefficient for sulphur dioxide in sodium

carbonate/sodium sulphate is 12 lbmoles/hr(ft2)(atm) (p. 114, Rule of Thumb
of the Chemical Engineer, 4th Ed by Carl Branan, 2005).
2. The gas absorber will be operated in a countercurrent flow because it
provides the highest theoretical removal efficiency because gas with the
lowest pollutant concentration contacts liquid with the lowest pollutant
concentration. This serves to maximize the average driving force for
absorption throughout the column.
3. The solubility of sulphur dioxide in the absorbing liquid is based on the
Chemical Engineers Handbook 5th Edition by McGraw-Hill, 1973).
From Chemical Engineers handbook 5th ed. by McGraw-Hill,1973
SO2 Percent 0.05 0.1 0.15 0.2 0.3 0.5 0.7 1.0 1.5
w/w
solution
Partial 1.2 3.2 5.8 8.5 14.1 26 39 59 92

pressure,
Gas
mmHg
4. The determination of the optimum number of grids can be done using a pilot
testing but Coulson recommends to use a table which shows the relationship
flow ratio to the number of grids. (p.606, Chemical Engineering Design Volume
6, Sinnott et.al.).
m
0.5 0.6 0.7 0.8 0.9 1.0
(Gm/Lm)
NOG 3.7 4.1 6.3 8 10.8 19.0
From the table, it can be observed that the optimum m (Gm/Lm) = 0.6 to 0.8, as
would be expected. Below 0.6 there is only a small decrease in the number of
stages required with increasing liquid rate; and above 0.8 the number of stages
increases with decreasing liquid rate.
5. Stainless steel only requires a visual inspection of the welds thus uses 80%
joint efficiency since the limits is initially placed on the nominal design stress
(p.813 Chemical Engineering Design Volume 6, Sinnott et.al.).
6. The corrosion allowance used is 1.16 in. (p.xix, Chemical Process Equipment,
Selection and Design, Couper at.al.)
DESIGN REQUIREMENTS
1. Efficiency of the Absorption Tower

2. Superficial Mass Velocity of Gas
3. Pressure Drop in the Tower
4. Number of Wood Grids
5. Cross-sectional Area Required
6. Diameter of the Column
7. Height of the Tower
8. Column Thickness
DESIGN CALCULATIONS
1. Efficiency of the Absorption Tower
Since the properties of the influent gas is identified and the properties of the
desired concentration of the effluent gas is also presented, the overall efficiency of
the absorption tower can be calculated as follows:

𝑌𝑖 − 𝑌𝑜
× 100 = 𝑒
𝑌𝑖
Where,
Yi = is the initial concentration of sulphur dioxide in the feed gas
Yo = is the initial concentration of sulphur dioxide in the discharge gas
E = removal efficiency of sulphur dioxide
2. Superficial Mass Velocity of Gas
The superficial mass velocity in the absorption tower is the maximum loading rate of
the feed gas into the tower. This is based on the motor absorption coefficient of
sulphur dioxide in the absorbing liquid introduced which is made up of sulphite-
bisulphite liquid. The major absorption coefficient for sulphur dioxide in sodium
carbonate/sodium sulphate is 12 lbmoles/hr(ft2)(atm) (p. 114, Rule of Thumb of the
Chemical Engineer, 4th Ed by Carl Branan, 2005).
The design engineers used the following equations for the calculation of the
superficial mass velocity using the data of molar absorption coefficient.
𝐾𝑔 = 0.00222𝐺𝑂0.8
Where,
Kg = molar absorption coefficient, lbmole of component absorbed/hr (ft2)(atm)
Go = superficial mass velocity of gas in tower, lb/hr(ft2)

𝑙𝑏𝑚𝑜𝑙𝑒
12 = 0.00222𝐺𝑂0.8
ℎ𝑟. 𝑓𝑡 2 . 𝑎𝑡𝑚
lb 2
𝐺𝑂 = 46,348 (ft )
hr
Use: Go = 46,348 lb/hr-ft2

3. Pressure Drop in the Tower
The pressure drop in tower is the difference of the pressure from the inlet to the
outlet. The pressure drop is the primary factor to be considered in the determination
of the height of the packed bed using the following equation:
∆ℎ𝑤
= 0.23 × 10−7 𝐺𝑂1.8
𝐿
Where,
GO = superficial mass velocity of gas in tower, lb/hr(ft2)
∆𝐻 = pressure drop through tower, in of water (in H2O)
It was assumed by the design engineers that the inlet and outlet pressure is
maintained at atmospheric pressure. Thus, this shows that the computation will be
based on the partial pressure difference brought by the removal of sulphur dioxide
from the stack gas. Using the solubilty of sulphur dioxide presented in the Chemical
Engineers handbook 5th ed. by McGraw-Hill,1973, the partial pressure of sulphur
dioxide in a given concentration can be determined.
From Chemical Engineers handbook 5th ed. by McGraw-Hill,1973
SO2 Percent 0.05 0.1 0.15 0.2 0.3 0.5 0.7 1.0 1.5
w/w
solution
Partial 1.2 3.2 5.8 8.5 14.1 26 39 59 92

pressure,
Gas
mmHg
The partial pressure of sulphur dioxide in the inlet is based on 0.3% while that in the
outlet is based on 0.01%. The summary of the concentration together with the partial
pressure in the inlet gas and outlet gas is presented below:

Part Percentage of Sulphur Partial Pressure

Dioxide (mmHg)
Inlet Gas 0.3% 14.1
Outlet Gas 0.01% 0.4
The pressure drop can now be calculated by subtracting the partial pressure in the
outlet to the partial pressure at the inlet.
∆ℎ𝑤 = 𝑃𝑜 − 𝑃𝑖
∆ℎ𝑤 = 10.4 𝑚𝑚𝐻𝑔 − 14.1𝑚𝑚𝐻𝑔 = 13.7 𝑚𝑚𝐻𝑔
29.92 𝑖𝑛 𝐻2𝑂
∆ℎ𝑤 = 13.7 𝑚𝑚𝐻𝑔 ( ) = 0.5393 𝑖𝑛 𝐻2𝑂
760 𝑚𝑚𝐻𝑔
Use: ∆𝒉𝒘 =0.54 in H2O
4. Height of the Packed Column
The height of the packed bed depends on the pressure drop. In order to calculate
for the total height, the following equation is recommended by the design engineers:
∆ℎ𝑤
= 0.23 × 10−7 𝐺𝑂1.8
𝐿
Where,
GO = superficial mass velocity of gas in tower, lb/hr(ft2)
∆𝐻 = pressure drop through tower, in of water (in H2O)
Substituting the values to the given equation,

0.54 𝑖𝑛 H2O 𝑙𝑏 1.8
= 0.23 × 10−7 (46,348 )
𝐿 ℎ𝑟. 𝑓𝑡 2
L = 0.0937 ft
Use: L = 1 ft

5. Number of Wood Grids
The number of grids is equivalent to the number of stages in a plate absorption

column. The determination of the optimum number of grids can be done using a
pilot testing but Coulson recommends to use a table which shows the relationship
of flow ratio to the number of grids (p.606, Chemical Engineering Design Volume 6,
Sinnott et.al.).
m
0.5 0.6 0.7 0.8 0.9 1.0
(Gm/Lm)
NOG 3.7 4.1 6.3 8 10.8 19.0
From the table, it can be observed that the optimum m (Gm/Lm) = 0.6 to 0.8, as would
be expected. Below 0.6 there is only a small decrease in the number of stages
required with increasing liquid rate; and above 0.8 the number of stages increases
with decreasing liquid rate.
Use: NOG=8
6. Cross Sectional Area Required
The calculation of the cross-sectional area is a trial and error method based on the
flow of sulphite-bisulphite liquid. The first step is to evaluate the empirical
relationship which correlates the liquid and vapour flow rates, system physical
properties and packing characteristics, with the gas mass flow-rate per unit cross-
sectional area as presented in the figure (p. 603, Chemical Engineering Design
Volume 6, Sinnott et. Al.):

The first term is k4 which is defined as:

𝜇
13.1(𝑉𝑤∗ )2 𝐹𝑝 (𝜌𝐿 )0.1
𝐿
𝑘4 =
𝜌𝑉 (𝜌𝐿 − 𝜌𝑉 )
Rearranging,
𝑘4 𝜌𝑉 (𝜌𝐿 − 𝜌𝑉 ) 1
𝑉𝑤∗ = ( 𝜇 )2
13.1𝐹𝑝 (𝜌𝐿 )0.1
𝐿
Where: Vw* =gas mass flow rate per unit column cross-sectional area, kg/m2
Fp = packing factor, characteristic of the size and type of packing, 170
µL = liquid viscosity, N.s/m2

ρL, ρv = liquid and vapour densities, kg/m3
The second term id FLV which is defined as:
𝐿∗𝑤 𝜌𝑉
𝐹𝐿𝑉 = √
𝑉𝑤∗ 𝜌𝐿
Where: Lw* = liquid mass flow rate per unit column cross-sectional area, kg/m2
Vw* = gas mass flow rate per unit column cross-sectional area, kg/m2
ρL, ρv = liquid and vapour densities, kg/m3
To start the trial and error method, first assume that the column cross-sectional area
is 1.6 m2
675 𝑙𝑏 𝑙𝑏
0.054 3
ℎ(1.6 𝑚2 ) 𝑓𝑡
𝐹𝐿𝑉 = √ = 5.10𝑥10−5
𝑓𝑡 3 60 𝑚𝑖𝑛 0.054 𝑙𝑏 1 𝑙𝑏
100,000 𝑚𝑖𝑛 ( )( )( ) 70 3
ℎ𝑟 𝑓𝑡 3 1.6 𝑚2 𝑓𝑡
From the figure,
𝑘4 = 0.6
𝑘4 𝜌𝑉 (𝜌𝐿 − 𝜌𝑉 ) 1
𝑉𝑤∗ = ( 𝜇 )2
13.1𝐹𝑝 (𝜌𝐿 )0.1
𝐿
𝑙𝑏 3.28 𝑓𝑡 3 𝑙𝑏 0.054 𝑙𝑏 1 𝑘𝑔 3.28 𝑓𝑡 3

0.6(0.054 3 ) ( 1 𝑚 ) (70 3 − )( )( 1 𝑚 ) 1
𝑓𝑡 𝑓𝑡 𝑓𝑡 3 2.2046 𝑙𝑏
𝑉𝑤∗ = ( )2
10−3 0.1
13.1(170)( )
𝑙𝑏 1 𝑘𝑔 3.28 𝑓𝑡 3
70 3 ( )( 1 𝑚 )
𝑓𝑡 2.2046 𝑙𝑏
𝑘𝑔
𝑉𝑤∗ = 1
𝑚2 𝑠
Then the column cross-sectional area can be determined.

675 𝑙𝑏 1 𝑘𝑔 1ℎ 1 𝑚𝑖𝑛 675 𝑙𝑏 1 𝑘𝑔 1ℎ 1 𝑚𝑖𝑛

( )(60 𝑚𝑖𝑛)(60 𝑠𝑒𝑐 ) ( )(60 𝑚𝑖𝑛)(60 𝑠𝑒𝑐 )
𝐴= ℎ 2.2046 𝑙𝑏 = ℎ 2.2046 𝑙𝑏
𝑉𝑤∗ 𝑘𝑔
1 2
𝑚 𝑠
= 0.085𝑚2
2 0.054 3
ℎ(0.085 𝑚 ) 𝑓𝑡
𝐹𝐿𝑉 = √ = 1.09𝑥10−3
𝑓𝑡 3 60 𝑚𝑖𝑛 0.054 𝑙𝑏 1 𝑙𝑏
100,000 𝑚𝑖𝑛 ( )( )( ) 70 3
From the figure,

𝑘4 = 1.5
𝑘4 𝜌𝑉 (𝜌𝐿 − 𝜌𝑉 ) 1
𝑉𝑤∗ = ( 𝜇 )2
13.1𝐹𝑝 (𝜌𝐿 )0.1
𝐿
𝑙𝑏 3.28 𝑓𝑡 3 𝑙𝑏 0.054 𝑙𝑏 1 𝑘𝑔 3.28 𝑓𝑡 3

1.5(0.054 3 ) ( 1 𝑚 ) (70 3 − )( )( 1 𝑚 ) 1
𝑓𝑡 𝑓𝑡 𝑓𝑡 3 2.2046 𝑙𝑏
𝑉𝑤∗ = ( )2
10−3 0.1
13.1(170)( )
𝑙𝑏 1 𝑘𝑔 3.28 𝑓𝑡 3
70 3 ( )( 1 𝑚 )
𝑓𝑡 2.2046 𝑙𝑏
𝑘𝑔
𝑉𝑤∗ = 1.62
𝑚2 𝑠
( )(60 𝑚𝑖𝑛)(60 𝑠𝑒𝑐 ) ( )(60 𝑚𝑖𝑛)(60 𝑠𝑒𝑐 )
𝐴= ℎ 2.2046 𝑙𝑏 = ℎ 2.2046 𝑙𝑏
1.62 2
𝑚 𝑠
= 0.052𝑚2
2 0.054 3
ℎ(0.052 𝑚 ) 𝑓𝑡
𝐹𝐿𝑉 = 3 √ = 1.78𝑥10−3
𝑓𝑡 60 𝑚𝑖𝑛 0.054 𝑙𝑏 1 𝑙𝑏
100,000 𝑚𝑖𝑛 ( )( )( ) 70 3
From the figure,

𝑘4 = 0.01

𝑘4 𝜌𝑉 (𝜌𝐿 − 𝜌𝑉 ) 1
𝑉𝑤∗ = ( 𝜇𝐿 0.1 )2
13.1𝐹𝑝 (𝜌 )
𝐿
𝑙𝑏 3.28 𝑓𝑡 3 𝑙𝑏 0.054 𝑙𝑏 1 𝑘𝑔 3.28 𝑓𝑡 3

0.01(0.054 ) ( ) (70 − )( ) (
𝑓𝑡 3 1𝑚 𝑓𝑡 3 𝑓𝑡 3 2.2046 𝑙𝑏 1𝑚 ) 1
𝑉𝑤∗ = ( )2
10−3
13.1(170)( )0.1
𝑙𝑏 1 𝑘𝑔 3.28 𝑓𝑡 3
70 3 ( )( 1 𝑚 )
𝑓𝑡 2.2046 𝑙𝑏
𝑘𝑔
𝑉𝑤∗ = 0.1322
𝑚2 𝑠
( )(60 𝑚𝑖𝑛)(60 𝑠𝑒𝑐 ) ( )(60 𝑚𝑖𝑛)(60 𝑠𝑒𝑐 )
𝐴= ℎ 2.2046 𝑙𝑏 = ℎ 2.2046 𝑙𝑏
0.1322 2
𝑚 𝑠
𝐴 = 0.6432𝑚2
0.054 3
ℎ(0.6432 𝑚2 ) 𝑓𝑡
𝐹𝐿𝑉 = √ = 1.44𝑥10−4
𝑓𝑡 3 60 𝑚𝑖𝑛 0.054 𝑙𝑏 1 𝑙𝑏
100,000 𝑚𝑖𝑛 ( )( )( ) 70 3
From the figure,

𝑘4 = 0.001
𝑘4 𝜌𝑉 (𝜌𝐿 − 𝜌𝑉 ) 1
𝑉𝑤∗ = ( 𝜇 )2
13.1𝐹𝑝 (𝜌𝐿 )0.1
𝐿
𝑙𝑏 3.28 𝑓𝑡 3 𝑙𝑏 0.054 𝑙𝑏 1 𝑘𝑔 3.28 𝑓𝑡 3

0.001(0.054 3 ) ( ) (70 3 − )( )( ) 1
𝑓𝑡 1𝑚 𝑓𝑡 𝑓𝑡 3 2.2046 𝑙𝑏 1𝑚
𝑉𝑤∗ = ( )2
10−3 0.1
13.1(170)( )
𝑙𝑏 1 𝑘𝑔 3.28 𝑓𝑡 3
70 3 ( )( 1 𝑚 )
𝑓𝑡 2.2046 𝑙𝑏
𝑘𝑔
𝑉𝑤∗ = 0.008504
𝑚2 𝑠


( )(60 𝑚𝑖𝑛)(60 𝑠𝑒𝑐 ) ( )(60 𝑚𝑖𝑛)(60 𝑠𝑒𝑐 )
𝐴= ℎ 2.2046 𝑙𝑏 = ℎ 2.2046 𝑙𝑏
0.008504 2
𝑚 𝑠
𝐴 = 9.9996 𝑚2
2 0.054 3
ℎ(9.9996 𝑚 ) 𝑓𝑡
𝐹𝐿𝑉 = 3 √ = 9.25𝑥10−6
𝑓𝑡 60 𝑚𝑖𝑛 0.054 𝑙𝑏 1 𝑙𝑏
100,000 ( )( )( ) 70 3
𝑚𝑖𝑛 ℎ𝑟 𝑓𝑡 3 1.6 𝑚2 𝑓𝑡
From the figure,
𝑘4 = 0.00158
𝑘4 𝜌𝑉 (𝜌𝐿 − 𝜌𝑉 ) 1
𝑉𝑤∗ = ( 𝜇 )2
13.1𝐹𝑝 (𝜌𝐿 )0.1
𝐿
𝑙𝑏 3.28 𝑓𝑡 3 𝑙𝑏 0.054 𝑙𝑏 1 𝑘𝑔 3.28 𝑓𝑡 3

0.00158(0.054 ) ( ) (70 − )( ) (
𝑓𝑡 3 1𝑚 𝑓𝑡 3 𝑓𝑡 3 2.2046 𝑙𝑏 1𝑚 ) 1
𝑉𝑤∗ = ( )2
10−3 0.1
13.1(170)( )
𝑙𝑏 1 𝑘𝑔 3.28 𝑓𝑡 3
70 3 ( )( 1 𝑚 )
𝑓𝑡 2.2046 𝑙𝑏
𝑘𝑔
𝑉𝑤∗ = 0.052
𝑚2 𝑠
( )(60 𝑚𝑖𝑛)(60 𝑠𝑒𝑐 ) ( )(60 𝑚𝑖𝑛)(60 𝑠𝑒𝑐 )
𝐴= ℎ 2.2046 𝑙𝑏 = ℎ 2.2046 𝑙𝑏
0.052 2
𝑚 𝑠
𝐴 = 1.62 𝑚2
Use: A=1.62 m2
7. Diameter of the Column
The diameter of the column can be calculated based on the computed column cross-
sectional area.
𝜋 2
𝐴= 𝐷
4
Where,
A = column cross-sectional area
D = diameter of the column

𝜋 2
1.62 𝑚2 = 𝐷
4
𝐷 = 1.43 𝑚
Use: D=1.45 m
8. Height of the Tower
The height of the tower is normally calculated based on the mechanical

constraints of the design of an absorption column. A specific design of the height of
the tower based on the height of the packed and the column according to gas
absorption vendor is presented below:
𝐻𝑡𝑜𝑤𝑒𝑟 = 1.4𝐻𝑝𝑎𝑐𝑘𝑒𝑑 𝑏𝑒𝑑 + 1.02𝐷 + 2.81
3.28 𝑓𝑡
𝐻𝑡𝑜𝑤𝑒𝑟 = 1.4(1 𝑓𝑡) + 1.02(1.45 𝑚) ( ) + 2.81 = 9 𝑓𝑡 = 2.76𝑚
1𝑚
Use:H=2.8 m
9. Shell Thickness
The shell thickness will be calculated using Equation 4-3, page 85, Process Equipment
Design by Hesse and Rushton:
𝑃𝐷
𝑡𝑠 = +𝐶
2𝑆𝑒 − 𝑃
Where,
ts - thickness of the plate
P - internal pressure
D - inside diameter
S - allowable working stress, 10,500 pis

e - efficiency of joint , 80% for welded joint efficiency

C - corrosion allowance , 1/16 in

1000 𝑚𝑚
101325 Pa(2.76 m)(
t𝑠 = 1m ) +
1 2.54 𝑐𝑚 1000 𝑚𝑚
( )( )
101325 Pa 16 1 in 1 cm
2(10500 psi)( 14.7 psi )(0.25)(0.8) − 101325 Pa
t 𝑠 = 11.28 𝑚𝑚
Use: 𝐭 𝒔 = 12 mm
GAS ABSORPTION COLUMN
OPERATING DATA
Method of Operation Batch
No. of Required Units 1
Residence Time 60 mins
Compound Gas Liquid
Feed Density 0.054 lb/ft3 70 lb/ft3
Amount Charged 100,000 ft3/min 675 lb/hr.(m2)
Compound Gas Effluent Liquid Effluent

Discharge
Concentration 0.01% N/A
Operating Temperature 300°F
Operating Pressure 101.325 kPa
Maximum Allowable Stress 714.285 kPa
TECHNICAL DATA
Parameters Proposed Existing
Efficiency 97% 95-98%
Pressure Drop 0.54 in H2O -

COLUMN SHELL
Vessel Shape Cylindrical Cylindrical
Area 1.65 m2 -
Diameter 1.45 m 1.0-4.0 m
Height 2.80 m -
Thickness 12 mm -
PACKING
Type of Packing Wood Grids Wood Grids
Height of Packed Bed 1 ft -
Number of Grids 8 -
MATERIALS OF CONSTRUCTION
Column Stainless Steel Type 304
SUPPLIER INFORMATION
Company Name Peiyang Chemical Equipment Co., LTD
Xincheng Building, An Shanxi Rd, Nankai

Company Address
District, Tianjin, China
Contact Number +86-022-87890750
E-mail tiantim@peiyangchem.com
Price Php 471,000


FIXED- BED ADSORPTION TOWER
DESIGN DESCRIPTION
Fixed bed operation is the oldest form of column contact adsorption. It

operates as batch units or as beds of adsorbent through which the feed fluid passes,
with periodic interruption for regeneration. A bed of adsorbent is held in place inside
the column, and the solution to be treated flows over, through, and around it. The bed
must be taken off line to replace or regenerate the spent adsorbent.
DESIGN SELECTION
The fixed bed unit was chosen because it is the most commonly used and
suitable for simple applications like decolorizing. The main advantages of fixed bed
system are the simplicity of equipment needed and they are relatively inexpensive to
fabricate.

The final selection of the adsorber type was based on the table, Physical Properties of
adsorates form Perry’s Chemical Engineers Handbook. It can be seen there that carbon
adsorbates are the most favorable with respect to % internal porosity, surface area,
sorptive capacity and pore diameter. (Smaller the pores, the higher the sorptive
capacity. Since carbons were the final choice, a selection between granular and
powdered activated carbon is made. Granular activated carbon was chosen because it
can be easily regenerated by putting it in a furnace while the regeneration process for
powdered activated is tedious.
PARTS AND FUNCTIONS
1. Support system
Means of preventing the particle or adsorbents from passing through.
2. Bed of Adsorbent
The surface where the mass transfer occurs.
3. Heat exchange jacket
Supplies heat in the adsorption process.
4. Pump
Necessary for delivering the feed to the adsorber.
5. Influent solution tank
Storage for the feed.

6. Effluent solution tank
Storage for the product.
7. Inlet temperature stabilization stream
8. Outlet temperature stabilization stream
1. A negligible amount of impurity is considered since decolorization process is

involved.
2. The mass of the feed which is a mother liquor is, 1325.983 kg. The mass of the
adsorbent is 7.956 kg.
3. The density of the feed is, 1.521 kg/L and the feed of the adsorbent is 0.25
kg/L.
DESIGN CONSIDERATION
1. A Stainless Steel Type 316 is used as the material of construction to avoid

negative effect of materials handled and for higher corrosion resistance
(Peters and Timmerhaus’ Plant Design and Economics for Chemical Engineers
4th ed, p. 423.)
2. Granular activated carbon was used as the adsorbent since it is the most
suitable and has high % internal porosity, surface area, sorptive capacity and
pore diameter. (Properties of Adsorbates, Perry’s ChE Handbook, Table No.
16-3, page 9-9)
3. A vertical cylindrical tank is employed since it is the most common type of
adsorption unit commercially available. (Peters and Timmerhaus’ Plant Design
and Economics for Chemical Engineers 4th ed, p. 715.)
4. A height to diameter ratio of 4:3 is used. (Peters and Timmerhaus’ Plant
Design and Economics for Chemical Engineers 4th ed, p. 715.)
5. A fixed bed adsorption system is chosen because it consist of fixed bed
granular adsorbent through which the mother liquor passes, thus provides an
easy carbon regeneration.

DESIGN REQUIREMENTS
1. Volume of the bed

2. Volume of the tower
3. Height of the tower
4. Diameter of the tower
5. Shell thickness
6. Depth of head
7. Surface area of head
8. Volume of Head
DESIGN CALCULATION
From the material balance:

𝑀𝑚𝑜𝑡ℎ𝑒𝑟 𝑙𝑖𝑞𝑢𝑜𝑟=1325.983𝑘𝑔
𝑀𝑎𝑐𝑡𝑖𝑣𝑎𝑡𝑒𝑑 𝑐𝑎𝑟𝑏𝑜𝑛 =7.956 𝑘𝑔
From the experiment:

𝑘𝑔
𝜌𝑚𝑜𝑡ℎ𝑒𝑟 𝑙𝑖𝑞𝑢𝑜𝑟 = 1.521
𝐿
From table 16-3, p16-9 of Perry’s Chemical Engineer’s Hand Book:
Bulk density of activated carbon = 0.25 kg/ L
1. Volume of the bed
1 1000𝑚3
𝑉𝑚𝑜𝑡ℎ𝑒𝑟 𝑙𝑖𝑞𝑜𝑢𝑟 = 1325.983 𝑘𝑔 ( )( )
𝑘𝑔 1𝐿
1.521 𝐿
𝑉𝑚𝑜𝑡ℎ𝑒𝑟 𝑙𝑖𝑞𝑢𝑜𝑟 = 0.8718 𝑚3
1000𝑚3
1
𝑉𝑎𝑐𝑡𝑖𝑣𝑎𝑡𝑒𝑑 𝑐𝑎𝑟𝑏𝑜𝑛 = 7.956 𝑘𝑔 ( )( )
𝑘𝑔 1𝐿
0.25 𝐿
𝑉𝑎𝑐𝑡𝑖𝑣𝑎𝑡𝑒𝑑 𝑐𝑎𝑟𝑏𝑜𝑛 = 0.0318 𝑚3
𝑉𝑇 = 𝑉𝑚𝑜𝑡ℎ𝑒𝑟 𝑙𝑖𝑞𝑢𝑜𝑟 + 𝑉𝑎𝑐𝑡𝑖𝑣𝑎𝑡𝑒𝑑 𝑐𝑎𝑟𝑏𝑜𝑛

𝑉𝑇 = 0.8718 + 0.0318
𝑉𝑇 = 0.9036 𝑚3
2. Volume of the tower
A 100% free board is allotted in the adsorption tower, thus
𝑉𝑇𝑜𝑤𝑒𝑟 = 0.9036 (1) + 0.9036 (1)
𝑉𝑇𝑜𝑤𝑒𝑟 = 1.8072 𝑚3
3. Tower height and diameter

From the assumption,
ℎ 𝑑 4
= ;ℎ = ( )𝑑
4 3 3
𝜋 2
𝑉= 𝑑
4
𝜋 4
1.8072 𝑚3 = ( 𝑑) (𝑑 2 )
4 3
𝑑 = 1.99 𝑚 ; 𝑑 = 2𝑚
ℎ = 2.667 𝑚 ; ℎ = 3𝑚
4. Plate thickness
Plate design: For shell thickness of a vertical cylindrical vessel
From eqn (4-3), p.85 of Process Equipment Design by Hesse and Rushton
𝑃𝐷
𝑡𝑠 = +𝐶
2𝑆𝑤 𝑒 − 𝑃
Where:
𝑡𝑠 = 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑜𝑓 𝑝𝑙𝑎𝑡𝑒
𝑃 = 𝑖𝑛𝑡𝑒𝑟𝑛𝑎𝑙 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒
𝐷 = 𝑖𝑛𝑡𝑒𝑟𝑛𝑎𝑙 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟
𝑆𝑤 = 𝑎𝑙𝑙𝑜𝑤𝑎𝑙𝑏𝑒 𝑤𝑜𝑟𝑘𝑖𝑛𝑔 𝑠𝑡𝑟𝑒𝑠𝑠
𝑒 = 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
𝐶 = 𝑐𝑜𝑟𝑟𝑜𝑠𝑖𝑜𝑛 𝑎𝑙𝑙𝑜𝑤𝑎𝑛𝑐𝑒
For the maximum allowable stress, use equation 4-1, p 84 of Process

Equipment Design by Hesse and Rushton,
𝑆𝑤 = 𝑆𝑢 𝐹𝑚 𝐹𝑎 𝐹𝑟 𝐹𝑠
𝑊ℎ𝑒𝑟𝑒:
18700𝑙𝑏
𝑆𝑢 = 𝑖𝑛2 (For stainless steel 316, from Plant Design by Peters
and Timmerhaus, p 538)
𝐹𝑚 = 1.00 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 𝑓𝑎𝑐𝑡𝑜𝑟 (For high tensile strength stainless
steels,
p 84 of Process Equipment Design by Hesse and Rushton)

𝐹𝑎 = 1.0 (Stress relieving factor, from process equipment design
by Hesse and Rushton, p. 81)
𝐹𝑟 = 1.0 (Radiograph factor, from Process Equipment Design by
Hesse and Rushton, p 81.)
𝐹𝑠 = 25% 𝑆𝑎𝑓𝑒𝑡𝑦 𝐹𝑎𝑐𝑡𝑜𝑟 (From table 4-2, p 84, Process Eqpt
Design by Hesse & Rushton)
For working pressure:
𝑔
𝑃 = 𝑃𝑜𝑝𝑡 𝐻𝜌 𝑔𝑐 (Since g is numerically equal to 𝑔𝑐 and 𝑃𝑜𝑝𝑡= 0 since tank is not vented)
𝑙𝑏
𝑓𝑡 1.521𝑘𝑔 62.4 𝑓𝑡 3 𝑓𝑡 2
𝑃 = 3𝑚 (3.28 ) ( )( )( )
𝑚 𝐿 1 𝑘𝑔 144 𝑖𝑛2
𝐿
𝑙𝑏
𝑃 = 6.486
𝑖𝑛2
Therefore, 𝑆𝑤 = 18,700 𝑋 1.0 𝑋 0.25
𝑙𝑏
𝑆𝑤 = 4675
𝑖𝑛2
For double butt joint:
E= 0.8 (It is the maximum efficiency for that type of joint, p 85, Process
Equipment Design ng Hesse & Rushton)
For corrosion allowance:
C= 0.05 X 10 years = 0.5 in (From table 23-2, Corrosion Data on Construction

Material, Perry’s Chemical Engineer’s Handbook, p 23-21)
Therefore, the shell thickness is

𝑙𝑏 3.28 𝑓𝑡 𝑖𝑛
(6.486 2 ) ( 2𝑚) ( 𝑚 ) (12 )
𝑖𝑛 𝑓𝑡
𝑡𝑠 = + 0.5
𝑙𝑏 𝑙𝑏
2 (4675 2 ) (0.8) − 6.486 2
𝑖𝑛 𝑖𝑛
𝑡𝑠 = 0.568 𝑖𝑛

5. Thickness of head
For standard dished head
𝑃𝐿𝑊
𝑡ℎ = 2𝑆 (Equation 4-6 of Process Eqpt Design ng Hesse & Rushton)
𝑤𝑒
𝑊ℎ𝑒𝑟𝑒:
L= crown radius (𝐷0 − 6)
W= factor dependent in the ratio of knuckle radius to crown radius
P= operating pressure
Sw = allowable working stress
E= efficiency
Since Di = 2m or 78.72 in
Do = Di + 2ts
Do=78.72 in + 2(0.568in)
Do =79.856 in
L=Do-6
L=79.856-6
L= 73.856in
Knuckle radius:
Kr=6% Do
Kr=0.06(79.856 in)
Kr=4.791 in
Kr= 4.791 in / 73.856 in
Kr= 0.06
W= 1.80 (From table 4-3 of Process Eqpt Design by Hesse & Rushton, p
87)
Therefore,
𝑙𝑏
6.486 (73.856 𝑖𝑛)(1.8)
𝑡ℎ = 𝑖𝑛2
4675𝑙𝑏
2( ) (0.8)
𝑖𝑛2
𝑡ℎ𝑒𝑎𝑑 = 0.112 𝑖𝑛
𝑡𝑏𝑜𝑡𝑡𝑜𝑚= 0.112 𝑖𝑛
(since the bottom of the tank is also dished)
6. Depth of Head:
For a dished head, equation 4-14 by Process Eqpt Design by Hesse &
Rushton,
𝑑2
ℎ = 𝐿√𝐿2 −
4
78.722
ℎ = 73.856 𝑖𝑛 √(73.856 𝑖𝑛)2 − √
4
ℎ = 11.36 𝑖𝑛
7. Volume of Head
For a dished head, equation 4-15 of Process Eqpt Design by Hesse & Rushton,
𝑉 = 1.05ℎ2 (3𝐿 − ℎ)
𝑉 = 1.05 (11.36 𝑖𝑛)2 ( 3𝑥73.856 − 11.36)
1𝑓𝑡 3
𝑉 = 28483.62 𝑖𝑛3 𝑥 ( )
12 𝑖𝑛
𝑉 = 16.48 𝑓𝑡 3
8. Surface area of the head
For a dished head, equation 4-14 of Process Eqpt Design by Hesse &
Rushton,
A=6.28 hL
A= 6.28(11.36 in) (73.856 in)
A= 5268.946 𝑖𝑛2
A= 39.59 𝑓𝑡 2
DESIGN SPECIFICATIONS
Equipment Adsorption Tower
Duty Decolorize the organic matter in the mother liquor
No. Required 1
Type Fixed-bed
Adsorbate Granular Activated Carbon
Volume of Bed 𝑉𝑇 = 0.9036 𝑚3
Volume of Tower 𝑉𝑇𝑜𝑤𝑒𝑟 = 1.8072 𝑚3
Dimensions 𝑑 = 2𝑚
ℎ = 3𝑚
Plate Thickness 𝑡𝑠 = 0.568 𝑖𝑛

Head Thickness 𝑡ℎ𝑒𝑎𝑑 = 0.112 𝑖𝑛

𝑡𝑏𝑜𝑡𝑡𝑜𝑚= 0.112 𝑖𝑛
Depth of Head ℎ = 11.36 𝑖𝑛
Volume of Head 𝑉 = 16.48 𝑓𝑡 3
Surface Area of the A= 39.59 𝑓𝑡 2
Head
Material of Stainless Steel 316
Construction
Connections 2 in sch 40 inlet pipe,2 in sch 40 leading to the
mixing tank
Supplier Reedchem Industries, A. Rivera, Tondo
Cost P 65,000

ACID HYDROLYZER
DESIGN PROBLEM
Design a tank reactor to facilitate acid hydrolysis of 2,739.2365 kg/batch of
alpha-cellulose produced from cassava peels using 41,088.5475 kg/batch of 2.00M of

Sulfuric Acid at a temperature of 120 oC.
DESIGN SELECTION
Acid hydrolyzer in the form of a batch reactor is selected to operate the acid
hydrolysis of alpha-cellulose to obtain levulinic acid because according to Table 7.2 of

Silla (2003), pg. 377, agitated batch reactors are commonly used for liquid-solid
reactions. The reactor is composed of a cylindrical vessel with an ellipsoidal head and
bottom which is suitable for relatively lower working pressures and giving enough
vapor space since heating is involved in the process.
DESIGN DESCRIPTION
Acid hydrolyzer is a batch stirred tank reactor used for the acid hydrolysis of
alpha-cellulose produced from Cassava Peels with sulfuric acid. This stainless steel
reactor consists of a tank with an agitator and integral heating system. The agitator
inside the tank ensures uniform mixing of the reactants while the heating system (the
half coil jacket) allows the steam to pass through to provide heat for the reactor. The
feed charge at top of the tank and a discharge at the bottom. Inside the reactor, alpha-
cellulose will be reacted with sulfuric acid solution in order to convert the alpha-
cellulose into levulinic acid.

1. It is assumed that the system is a constant pressure batch process and a

constant volume reaction.
2. The amount of alpha-cellulose entering the hydrolyzer is 2,739.2365 kg/batch

(based from the Material Balance).
3. The amount of 2.00 M sulfuric acid solution entering the hydrolyzer is

41,088.5475 kg/batch (based from the Material Balance).
4. The bulk density of α-cellulose is 450 kg/m3 (Adelakun et al., 2007).

5. The density of 2.00 M sulfuric acid solution at 120°C is 1050.19 kg/m3 (Perry’s
Chemical Engineering Handbook 8th Edition, Table 2-103, Page 2-113).

6. The reaction temperature is 120 °C and the residence time is 90 minutes
(based from the experiment).

7. The heat for the hydrolyzer is 3,864,028.8670 kJ/batch (based from Energy
Balance).
8. The thermal conductivity of calcium silicate is 0.063 W/m-K at 110oC (0.44
Btu/hr-ft2-°F) (www.Engineeringtoolbox.com).
1. A vertical cylindrical tank with an ellipsoidal top and bottom will be
constructed.
2. The material of construction to be used is type 317 stainless steel which
provides increased strength at elevated temperatures and corrosion-resistant

against sulfuric acid (http://goo.gl/KvCscb, p.1).
3. The filling capacity of the reactor is 80% of the volume (20% safety factor) for
batch reactors with major variables for operational design such as rate of

reaction and equilibrium state, and major variables characterizing capacity

such as volume and residence time (Plant Design and Economics for Chemical
Engineers, 4th ed. by Timmerhaus, p. 37, Tb. 6).

4. The corrosion allowance for known corrosive conditions is 0.35 in. (Rules of
Thumb for Chemical Engineers, Branan, Fourth Edition, page 458).

5. The corrosion allowance for the wall thickness of reactor vessels is 1/8 in
(3.175mm) (Plant Design and Economics for Chemical Engineers, 4th ed. by
Timmerhaus, p. 732).
6. The height of tank body to internal diameter ratio is 1:1 (Unit Operations of
Chemical Engineers 6th ed, McCabe et al., 2001, pg. 241).
7. The efficiency of the double-welded butt joints is 80% based upon a material
factor Fm of 1.00. This type of welded joint was selected because they are
stronger than single-welded joints and may be used for either longitudinal or
circumferential seams (Process Equipment Design, Hesse and Rushton, page
84).
8. The number of baffles is usually 4. (Unit Operations of Chemical Engineers 6th
ed, McCabe et al., 2001, pg. 241)

9. Pitched-blade turbine with four blades is used for solid-liquid mixtures
(Principle of Transport Processes and Separation Processes, Geankoplis, p.155).

10. The rotational speed of pitched-blade turbine impeller is commonly at 20-150
rev/min which mostly used for liquids of moderate viscosity, thus an average
rotational speed of 85 rpm is assumed to be used (Unit Operations of
Chemical Engineers 6th ed, McCabe et al., 2001, pg. 240).

11. The power number for four-bladed pitched-blade turbine is 1.27 (Rules of
Thumb for Chemical Engineers, Fifth Edition, page 261)

DESIGN PARTS AND FUNCTIONS
Parts Function
Feed Inlet It is where the feed enters into the reactor.
Motor It is responsible to operate the agitator.
Baffle It is installed inside the reactor to promote mixing and thus, increase
heat transfer and the chemical reaction rate.

Vessel It is where the reaction takes place. The vessel is jacketed with half
coil in its outer part for the purpose of heating and made up of
stainless steel type 316.
Agitator It applies the mixing action to suspend the solids in the solution.
DESIGN REQUIREMENTS
1. Order of Reaction 12. Power Requirement
2. Rate Constant
3. Residence Time
4. Reactor Volume
5. Tank Diameter
6. Tank Height
7. Shell Thickness

9. Impeller Design
a. Impeller Diameter
b. Impeller Height
c. Impeller Elevation
d. Impeller Width
e. Impeller Length
10. Baffle Design
a. Baffle Width
b. No. of Baffle
11. Tank Insulation

DESIGN CALCULATIONS
1. Order of Reaction (values used in the calculation are based on the performed
experiments)
Acid Hydrolysis of Alpha-Cellulose from Cassava Peels:
𝐶6 𝐻10 𝑂5 + 𝐻2 𝑂 ⃗⃗⃗⃗⃗⃗⃗⃗⃗⃗⃗⃗
𝐻 2 𝑆𝑂4 𝐶5 𝐻8 𝑂3
Let:
• A = α-Cellulose
• B = Water
• C = Glucose
A+B C
𝑚𝑎𝑠𝑠 𝑜𝑓 𝛼 − 𝑐𝑒𝑙𝑙𝑢𝑙𝑜𝑠𝑒 𝑚𝑎𝑠𝑠 𝑜𝑓𝑎𝑐𝑖𝑑 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 𝑚𝑎𝑠𝑠 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟

𝑉0 = + +
𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝛼 − 𝑐𝑒𝑙𝑙𝑢𝑙𝑜𝑠𝑒 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑎𝑐𝑖𝑑 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟
From the experiment:
194.07 𝑔 0.175 ∗ 2911.05 𝑔 (1 − 0.175) ∗ 2911.05 𝑔

V= 𝑔 + 𝑔 + 𝑔 = 3.3180 𝐿
450 𝐿 1050.19 𝐿 1000 𝐿
Solving for CA at t = 0;
1 1
𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝐴 194.07𝑔 (162.16𝑔) (1)
𝐶𝐴 𝑜 = = = 0.3607 𝑀
𝑣𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑠𝑜𝑙𝑢𝑡𝑖𝑜𝑛 3.3180 𝐿

MASS TRANSFER EQUIPMENT 106
C.B. Baoas | A.C.M. Garcia P.G.C. Santos | M.M. Sarmiento
Using the same method for solving CA at t=60, 90, 120, 150, 180 minutes,
Table 1. Data of Rate Contansts for Acid Hydrolysis of Cassava Peels
Time (min) Mass of α-cellulose (g) CA (mol/L) k
0 194.07 0.36 M -
60 66.74 0.11 M 19.8 x 10-3
90 72.46 0.13 M 11.3 x 10-3
120 72.09 0.13 M 8.48 x 10-3
150 65.78 0.12 M 7.32 x 10-3
180 52.18 0.10 M 7.12 x 10-3
(Chemical Reaction Engineering, 3rd Ed. by Levenspiel, p. 41, Eq. 11)
From the study conducted by Ajani et al. (2011) entitled, “A Comparative Kinetic
Study of Acidic Hydrolysis of Wastes Cellulose from Agricultural Derived Biomass”, the
hydrolysis of cellulose using an acidic media like sulfuric acid follows first order of
reaction.
2. Rate Constant

Then, the rate constant, k, can be calculated using the average k constant shown in the
table 5.44.
𝒌 = 𝟎. 𝟎𝟎𝟏𝟎𝟖/𝒎𝒊𝒏𝒖𝒕𝒆
3. Residence Time
From the experiment, the residence time used is
Use t = 90 minutes
4. Reactor Volume
Using the upscaled values for feed of hydrolyzer:
𝑚𝑎𝑠𝑠 𝑐𝑒𝑙𝑙𝑢𝑙𝑜𝑠𝑒 + 𝑚𝑎𝑠𝑠 𝐻2 𝑆𝑂4 𝑆𝑜𝑙𝑢𝑡𝑖𝑜𝑛

𝑉=
𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑠𝑜𝑙𝑢𝑡𝑖𝑜𝑛
Where:
Density of solution= (𝑥𝑐𝑒𝑙𝑙𝑢𝑙𝑜𝑠𝑒 )(𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑐𝑒𝑙𝑙𝑢𝑙𝑜𝑠𝑒) + (𝑥𝐻2 𝑆𝑂4 )(𝐷𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝐻2 𝑆𝑂4 )
2,739.2365
𝑥𝑐𝑒𝑙𝑙𝑢𝑙𝑜𝑠𝑒 = = 0.0625
2,739.2365 + 41,088.5475
41,088.5475
𝑥𝐻2 𝑆𝑂4 = = 0.9375
2,739.2365 + 41,088.5475
𝑘𝑔 𝑘𝑔
𝐷𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑠𝑜𝑙𝑢𝑡𝑖𝑜𝑛 = (0.0625) (450 ) + (0.9375) (1840 )
𝑚3 𝑚3
𝑘𝑔
𝐷𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑠𝑜𝑙𝑢𝑡𝑖𝑜𝑛 = 1753.125
𝑚3
2,739.2365 + 41,088.5475
𝑉=
1753.125 𝑘𝑔/𝑚3

𝑉 = 24.9998 𝑚3
Applying 20% safety factor:
𝑉 = 24.9998 𝑚3 (1.20) = 29.9998 𝑚3
Use 30 m3 as Reactor Volume
5. Tank Diameter
The following relations will be used for determining the tank diameter.
𝑉 = 𝑉𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟 + 𝑉𝑒𝑙𝑙𝑖𝑝𝑠𝑜𝑖𝑑𝑎𝑙 𝑏𝑜𝑡𝑡𝑜𝑚 + 𝑉𝑒𝑙𝑙𝑖𝑝𝑠𝑜𝑖𝑑𝑎𝑙 ℎ𝑒𝑎𝑑
𝜋 4 4 𝐷2
𝑉𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟 = 4 𝐷2 𝐻; 𝑉𝑒𝑙𝑙𝑖𝑝𝑠𝑜𝑖𝑑 = 3 𝜋𝑎𝑏𝑐 = 3 𝜋 ℎ
4
where
• D is the tank diameter
• H is the tank height

• a,b,c are the ellipsoid radii
• h is the head elliptical depth.
Since H = D and h = 1/4 of the inner diameter of the head (or D) in standard ellipsoidal
tanks, based from Process Equipment Design by Hesse and Rushton, page 86,
𝜋 2 4 𝐷2 𝜋 2 4 𝐷2 𝐷 𝜋
𝑉 = 𝐷 𝐻+ 𝜋 ℎ= 𝐷 (𝐷) + 𝜋 ( ) = 𝐷3
4 3 4 4 3 4 4 3
𝜋 3
29.9998 𝑚3 = 𝐷
3

𝐷 = 3.0598 𝑚
𝑼𝒔𝒆 𝑫 = 𝟑. 𝟏𝟎 𝒎
6. Tank Height
Height of tank body (cylinder):
𝐻 = 𝐷 = 3.0598 𝑚
Height of head and bottom:
𝐷 3.0598 𝑚
ℎℎ𝑒𝑎𝑑 = ℎ𝑏𝑜𝑡𝑡𝑜𝑚 = = = 0.765 𝑚
4 4
Use H head = H Bottom = 0.80 m
Total height of the tank:
𝐻𝑡𝑜𝑡𝑎𝑙 = 𝐻 + ℎℎ𝑒𝑎𝑑 + ℎ𝑏𝑜𝑡𝑡𝑜𝑚 = 3.10 + 0.80 + 0.80
𝑯𝒕𝒐𝒕𝒂𝒍 = 𝟒. 𝟕𝟎 𝒎
7. Shell Thickness
Shell thickness formula (Pressure Vessel Design Manual 4th Edition, Table 2-1, page 39):
𝑃𝑅𝑖
𝑡𝑠 = +𝐶
𝑆𝑒 − 0.6𝑃
Where,
• ts - thickness of the shell

• P - internal pressure
• Ri - inside radius
• S - allowable working stress

• e - efficiency of joint
• C - corrosion allowance
Allowable Working Stress formula (Rules of Thumb 4th Edition, page 456):
1
𝑆= 𝑆𝑢
4
1
𝑆 = (89,800 𝑝𝑠𝑖) = 22,475 𝑝𝑠𝑖
4
Computing for the height of the liquid of the tank:
𝜋 2 1 4 𝐷2
𝐷 𝐻+ ( 𝜋 ℎ) = 𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 ℎ𝑦𝑑𝑟𝑜𝑙𝑦𝑧𝑒𝑑 𝑚𝑖𝑥𝑡𝑢𝑟𝑒
4 2 3 4
𝜋 2 (3.0598)2
(3.0598)2 𝐻 + [ 𝜋 (0.765)] = 24.9998 𝑚3
4 3 4
𝐻 = 2.8899 𝑚
Computing for internal pressure:
𝑘𝑔 2.2046 𝑙𝑏𝑚 1 𝑚3 𝑙𝑏𝑚

𝜌 = 1753.125 3 × × = 109.4428
𝑚 1 𝑘𝑔 35.3147 𝑓𝑡 3 𝑓𝑡 3
𝑙𝑏𝑚 3.2808 𝑓𝑡 𝑓𝑡
𝜌𝐻𝑔 109.4428 𝑓𝑡 3 𝑥 2.8899 𝑚 𝑥 1𝑚 𝑥 32.1740 2
𝑠
𝑃= = 2 = 7.2059 𝑝𝑠𝑖
𝑔𝑐 𝑙𝑏 ∙ 𝑓𝑡 144 𝑖𝑛
32.1740 𝑚 2 𝑥
𝑙𝑏𝑓 ∙ 𝑠 1 𝑓𝑡 2

Taking into account 25 psi safety factor for pressure (Rules of Thumb 4 th Edition, page
456):
𝑃 = (7.2059 + 25)𝑝𝑠𝑖 = 32.2059 𝑝𝑠𝑖
Computing for shell thickness:
𝑃𝑅𝑖
𝑡𝑠 = +𝐶
𝑆𝑒 − 0.6𝑃
3.0598 𝑚 39.3701 𝑖𝑛
32.2059 𝑝𝑠𝑖 𝑥 𝑥 25.4 𝑚𝑚
𝑡𝑠 = 2 1𝑚 + 0.35 𝑖𝑛 = 0.3559 𝑖𝑛 𝑥
(22,475 𝑝𝑠𝑖 𝑥 0.7) − 0.6(32.2059 𝑝𝑠𝑖) 1𝑖𝑛
𝑡𝑠 = 9.0399 𝑚𝑚
Use: 9.10 mm
Using Equation 4-8, page 86 of Process Equipment Design by Hesse and Rushton for
ellipsoidal head and bottom:
𝑝𝐷
𝑡= +𝐶
4𝑆𝑒
(32.2059 𝑝𝑠𝑖)(3.0598 𝑚)
𝑡= + 0.35 𝑖𝑛 = 0.3516 𝑖𝑛 = 8.93 𝑚𝑚
4(22,475 𝑝𝑠𝑖)(0.70)
Use: 8.95 m

9. Agitator Design
Figure 3. Design of Agitator Respective to the Tank
(Table 3.4-1, pg. 158, Principles of Transport Processes and Unit Operations, Geankoplis, 4th
edition)
a. Diameter
For the agitator diameter, the following relation shown in figure 5. is applied.
𝐷𝑎 1
=
𝐷𝑡 3
where Da = agitator diameter and Dt = tank diameter. The agitator diameter therefore is,
𝐷𝑎 1
=
3.0598 𝑚 3
𝐷𝑎 = 1.0199 𝑚
𝑼𝒔𝒆 𝑫𝒂 = 𝟏. 𝟎𝟓 𝒎

b. Height
𝐻
=1
𝐷𝑡
where H = agitator height
𝐻 = 3.0598 𝑚
𝑼𝒔𝒆 𝑯 = 𝟑. 𝟏𝟎 𝒎
c. Elevation
The relation presented in Table 3.4-1, pg. 144, of Geankoplis (2012) is used to calculate the
agitator elevation.
𝐶 1
=
𝐷𝑡 3
where C = agitator elevation
𝐶 1
=
3.0598 𝑚 3
𝐶 = 1.0199 𝑚
𝑼𝒔𝒆 𝑪 = 𝟏. 𝟎𝟓 𝒎
d. Width of blade
blade width
𝑊 1
=
𝐷𝑎 5

where W = impeller width
𝑊 1
=
1.2167 𝑚 5
𝑊 = 0.2433 𝑚
𝑼𝒔𝒆 𝑾 = 𝟎. 𝟐𝟓 𝒎
e. Length of blade
blade length.
𝐿 1
=
𝐷𝑎 4
𝐿 1
=
1.0199 𝑚 4
𝐿 = 0.255 𝑚
𝑼𝒔𝒆 𝑳 = 𝟎. 𝟑𝟎 𝒎
10. Baffle Design
a. Baffle Width
The width of the baffle would be calculated according to the equation also indicated by
Geankoplis (2012) in Table 3.4-1, pg. 158.
𝐽 1
=
𝐷𝑇 12
where 𝐽 = 𝑊𝑖𝑑𝑡ℎ 𝑜𝑓 𝑡ℎ𝑒 𝑏𝑎𝑓𝑓𝑙𝑒 𝑖𝑛 𝑚 and 𝐷𝑇 = 𝑇𝑎𝑛𝑘 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑖𝑛 𝑚.

Computing for the width of baffle:
3.0598 𝑚
𝐽= = 0.255 𝑚
12
𝑼𝒔𝒆 𝑱 = 𝟎. 𝟑𝟎 𝒎
b. Number of Baffles
The number of baffles is usually 4 (Unit Operations of Chemical Engineers 6th ed, McCabe
et al., 2001, pg. 241). This number of baffles is used for liquid with low viscosity (Geankoplis,
2012, pg. 159).
𝑵𝑩 = 𝟒
11. Tank Insulation
𝑘𝐽
𝑄 = 3,864,028.8670 ≈ 3,66,2378.317 𝐵𝑡𝑢/𝑏𝑎𝑡𝑐ℎ
𝑏𝑎𝑡𝑐ℎ
The operating temperature at the hydrolyzer is 120°C and the temperature of the
surrounding is assumed to be at 25 °C
∆𝑇 = (120 − 25)°𝐶 = 95°𝐶 ≈ 203°𝐹
Using Equation 10.8, pg. 294, Unit Operation of Chemical Engineering, 6th Ed., by McCabe,
Smith, and Harriott
𝑄 ∆𝑇
=𝑘
𝐴 𝑥

∆𝑇
𝑄 = (2𝜋𝑟𝐻)𝑘
𝑥
Where x is the thickness of the layer of insulation
10.2005 𝑓𝑡 𝐵𝑡𝑢
𝐵𝑡𝑢 1 𝑏𝑎𝑡𝑐ℎ 2𝜋( )(15.4199 𝑓𝑡)(0.44 2 )(203°𝐹)
2 𝑓𝑡 · ℎ𝑟 · °𝐹
3,662,378.317 𝑥 =
𝑏𝑎𝑡𝑐ℎ 1.5 ℎ𝑟 𝑥
𝑥 = 0.0181 𝑓𝑡 ≈ 5.5099 𝑚𝑚
Use x = 5.55 mm
𝑃
𝑁𝑝 =
𝜌𝑁 3 𝐷𝑎 5
Where:
▪ Np - power number (dimensionless)

▪ P - power
▪ ρ - density
▪ N - rotational speed
▪ Da - impeller diameter
𝑃 = 𝑁𝑝 𝜌𝑁 3 𝐷𝑎 5
3 5 𝑘𝑔 𝑟𝑒𝑣 1 𝑚𝑖𝑛 3
𝑃 = 𝑁𝑃 𝜌𝑁 𝐷𝑎 = 1.27 × 1753.125 3 × (85 × ) × (1.0199 𝑚)5
𝑚 𝑚𝑖𝑛 60 𝑠
𝐽
𝑃 = 6985.6623
𝑠
𝑃 = 6.9857 𝑘𝑊 ≈ 9.3679 ℎ𝑝
𝑼𝒔𝒆 𝑷 = 𝟗. 𝟓𝟎 𝒉𝒑

ACID HYDROLYZER
Operating Data
Number of Units 1
Holding Capacity 1 batch
Materials of
Stainless Steel 317
Construction
Residence Time 1.5 hours
Alpha-cellulose and sulfuric acid
Materials Handled
Feed solution
Density 1753.125 kg/m3
Operating Temperature 120oC
Operating Pressure 222.05 kPa
Rated Capacity 43,827.7840 kg
Vessel Data
Proposed Existing
3
Tank Capacity 30 m 0.5 – 60 m3
Tank Height 4.70 m 2.4 – 8.4 m
Shell Thickness 9.10 mm Up to 40 mm
Head and Bottom Thickness 8.95 mm Up to 40 mm
Blade Diameter 1.05 m Up to 4 m
Agitator Elevation 1.05 m Up to 4 m
Blade Height 3.10 m Up to 6 m
Blade Width 0.25 m 0.10-0.80 m
Blade Length 0.30 m 0.10-0.90 m
Baffle Width 0.30 m 0.10-0.90 m
No. of Baffles 4 3–4
Tank Insulation 5.55 mm At least 3.0 mm
Power Requirement 13 hp 0.5 - 21.0 hp
Existing Equipment
Weihai Borui Chemical Machinery Mfg
Supplier
Corporation Limited
Supplier Address Beiguan Village, Shandong, China
Price Php 50,000-3,000,000

Auxilliaries
Motor Electric Motor
Instrumentation and Control Temperature and Level Sensor

ROTARY DRYER
DESIGN PROBLEM
In order to avoid microbial degradation and provide better product quality and process
efficiency in subsequent processes, the moisture content of the raw material copra meal
must be reduced from 12.3% to 4.7%. Design an equipment for the drying process suitable
for drying 580.00 kg/batch of copra meal.
DESIGN DESCRIPTION
A rotary dryer consists of a cylinder, rotated upon suitable bearings and usually slightly
inclined to the horizontal. The dryer is tilted so that the solids gradually work their way
from the feed end to discharge end. Copra meal, the material to be dried is fed at the
upper end, and the dried copra meal is discharged from the lower end. The rotary dryer
is equipped with flights on the interior for lifting and showering the solids through the
gas stream during passage through the rotating cylinder. The drying medium is
introduced at the lower end and leaves at the upper end, flowing countercurrent to the
solid.
DESIGN SELECTION
Among the different types of dryer, a countercurrent direct-heat rotary dryer was
selected as it is the most suitable type of drying equipment for granular solid materials
greater than 100 mesh or 0.147mm at most capacities. Additionally, this type of dryer is
suitable for low and medium temperature operations and the countercurrent flow of gas
and solids gives greater heat-transfer efficiency. (Perry’s Chemical Engineering
Handbook, 7th edition, page 12-40, 12-52 and 12-53).

EQUIPMENT PARTS AND FUNCTION
Parts Functions
It can be made from a variety of materials, including carbon
Dryer Shell
steel or special stainless steel alloys.
It is where feedstock is fed into the system, typically by a feed
Wet Feed Inlet
screw or chute.
Air Inlet It is where the entering steam or hot gases enter.
It is used to “pick up” materials, carry it over, and shower it
Material lifters through the stream of gas. It also helps maximize heat transfer
efficiency between the material and the gas.
It includes chain and sprocket, reducer and motor. This is the
Chain Drive
motor behind the actual rotation of the drum. A reducer takes
Assembly
down the speed of the motor for higher torque applications.
Support Roller It supports the weight of the drum which is made of steel.
It adds structural support for the drum, and a place for
Riding Ring pressure to be absorbed. The riding ring rides on the support
roller.
Exhaust Gas It is where the spent gas and hot air exit the system.
Product Discharge It is where the product exits the system.

1. The mass flow rate of entering copra meal to be dried is 580.00 kg/batch (Based
on Material Balance)
2. The production rate of dried copra meal leaving the dryer is 535.92 kg/batch
(Based on Material Balance)
3. The initial moisture content of copra meal is 12.3% (Based on Laboratory Testing
Results from Department of Agriculture)
4. The final moisture content of the dried copra meal is 4.7% (Based on Material
Balance)
5. The density of copra meal is 0.486 g/mL or 486 kg/m3 (Based on Experimental
Study)
6. The heat requirement for the rotary dryer is 167,301.3805 kJ/batch (Based on
Energy Balance)
7. The relative humidity of the air is assumed to 80%

8. Assume an elevation of 0.50 m from the ground
1. Rotary dryers usually operate with 10% to 15% of their volume filled with material
(Perry’s Chemical Engineering Handbook, 7th edition, page 12-55).
2. The length to diameter ratio of the cylinder is 4 (Perry’s Chemical Engineering
Handbook, 7th edition, page 12-52).
3. The diameter of rotary dryer ranges from 1 to 3 m (3 to 10 ft) (Harriot, McCabe
and Smith, Unit Operations in Chemical Engineering, 5th ed., page 796).

4. Rotary dryers are built in sizes up to 9 ft in diameter in standard models with

lengths up to 80 ft (Foust, et al., Principles of Unit Operations, 2nd Ed., page 471).
5. The shell thickness is generally 6 to 8 mm (Joshi, M.V., Process Equipment Design
page 499).
6. The mean mass velocity of the gas that will be used is 13500 kg/m2-h inclusive in
the range of 2000 to 25000 kg/m2-h (Harriot, McCabe and Smith, Unit Operations in
Chemical Engineering, 5th ed., page 795).
7. Rotation speeds of about 4 rpm are used for rotary dryer (Couper, Penney, Fair
and Walas, Chemical Process Equipment: Selection and Design, 3rd Ed, Rules of Thumb:
Drying of Solids page xv).
8. To promote longitudinal travel of the solid, the shell is mounted on a slope of 1

in 40 or 20 (Couper, Penney, Fair and Walas, Chemical Process Equipment: Selection and
Design, 3rd Ed, page 239).
9. The residence time for rotary dryer ranges from 5 to 90 minutes (Couper, Penney,
Fair and Walas, Chemical Process Equipment: Selection and Design, 3rd Ed, Rules of
Thumb: Drying of Solids page xv).
10. The shape of the flights depends upon the handling characteristics of the solids.
For free-flowing materials, a radial flight with a 90° lip is employed (Perry and
Green, Perry’s Chemical Engineers’ Handbook, 7th ed., sec. 12-53).

11. The number of flights is between 2 and 4 times the diameter of the shell in feet
(Couper, Penney, Fair and Walas, Chemical Process Equipment: Selection and Design, 3rd
Ed, page 239).

12. The depth of a flight is between 1/12 and 1/8 of the cylinder diameter (Couper,
Penney, Fair and Walas, Chemical Process Equipment: Selection and Design, 3rd Ed, page
239).
13. A minimum corrosion allowance of 1/16 in. must be provided (Hesse and
Rushton, Process Equipment Design, page 73)
14. From different insulating materials, calcium silicate was selected as this insulating
material is typically used for steam, hot water pipe work, vessels and oven constructions
(Thermal Insulation Handbook, 2011).
15. Materials of construction to be used in the cylinder is stainless steel type 302 with
a density of 7.90 g/cm3 (7900 kg/m3). (Plant Design and Economics for Chemical
Engineers, 4th ed, Table 4 p.426).
6. Flight Geometry
a. Number of
DESIGN REQUIREMENTS
Flights
1. Dryer Volume b. Height of
2. Geometric Flights
Configuration 7. Insulation
a. Dryer Diameter Thickness
b. Dryer Height 8. Power Requireme
c. Dryer Length
d. Dryer Cross Sectional
Area
e. Dryer Shell Thickness
3. Flowrate of Heating Air
4. Residence Time
5. Outlet Humidity

DESIGN CALCULATIONS
1. DRYER VOLUME
Compute for the dryer capacity using the equation:
Using a fill capacity of 12.5%, the total dryer volume is,
2. GEOMETRIC CONFIGURATION
a. Dryer Diameter
The total volume of the dryer is equal to the volume of the cylinder,

b. Dryer Height
The total dryer height of the equipment is usually from the diameter of the dryer
itself and its base support. Thus
c. Dryer Length
The length to diameter ratio of the cylinder is 4.
d. Dryer Cross-Sectional Area
e. Dryer Shell Thickness

The shell thickness is generally 6 to 8 mm
3. FLOW RATE OF HEATING AIR

The flow rate of the heating air can be determined using the cross sectional area and
the mean mass velocity of the gas that will be used.
Where:
• 𝐴 = dryer cross sectional area
• 𝑚̇ 𝑔 = flow rate of the heating air
• 𝐺 = mass velocity of the gas
4. RESIDENCE TIME
The residence time for rotary dryer is calculated using Equation 9.17 (Couper, Penney,
Fair and Walas, Chemical Process Equipment: Selection and Design, 3rd Ed, page 239)
Where:
• θ = residence time
• 𝑘 = coefficient (varies from 3 to 12 for various countercurrent single shell
dryers)
• 𝐿 = length
• 𝑛 = rotation speed in rpm

• 𝐷 = diameter
• 𝑆 = slope
5. OUTLET HUMIDITY
In computing for the outlet humidity, the average rate of mass transfer (m v) and the
inlet humidity of air (Ha), are determined first. The average rate of mass transfer is be
determined by using Equation 24.9 (Harriot, McCabe and Smith, Unit Operations in
Chemical Engineering, 5th ed., page 774),
𝑚̇ 𝑣 = 𝑚̇ 𝑠(𝑋𝐴 − 𝑋𝐵)
Where:
• 𝑚̇ 𝑣 = average rate of mass transfer
• 𝑚̇ 𝑠 = mass flow rate of bone dry solids
• 𝑋𝐴 = initial moisture content
• 𝑋𝐵 = final moisture content
The inlet humidity of air can be determined using the psychrometric chart (Couper,
Penney, Fair and Walas, Chemical Process Equipment: Selection and Design, 3 rd Ed,

page 224), given a relative humidity of 80% and a temperature of 80 C (176 F). Thus,
the inlet humidity is 0.021 lb water/lb dry air.
The outlet humidity, Ha, is then calculated using Equation 24.10 (Harriot, McCabe and
Smith, Unit Operations in Chemical Engineering, 5th ed., page 774),
6. FLIGHT GEOMETRY
a. Number of Flights
The number of flights is 3 times the diameter of the cylinder in feet,
b. Height of Flights
The height of a flight is between 1/8 and 1/12 of the cylinder diameter,
7. INSULATION THICKNESS
The insulation thickness can be calculated by using equation 10.4 (Harriot, McCabe
and Smith, Unit Operations in Chemical Engineering, 5th ed., page 292),
𝑄 ∆𝑇
=𝑘
𝐴 𝑥
Where
• 𝑄 = heat transfer rate
• 𝐴 = cross sectional area normal to the direction of flow of heat
• 𝑘 = thermal conductivity
• ∆𝑇 = temperature difference
• 𝑥 = insulation thickness
The operating temperature of the rotary dryer is 80◦C (176◦F) while the surrounding
environment is assumed to be at ambient temperature of 25◦C (77◦F).
∆𝑇 = (80 − 25)◦𝐶 = 55◦𝐶 = 131◦𝐹

The thermal conductivity for calcium silicate at 80 C is determined using Figure 11-65:
Thermal conductivity of insulating materials (Perry’s Chemical Engineering Handbook,
7th
edition, page 11-69). Thus, the thermal conductivity is 0.4 Btu-in/h-ft2-◦F.
8. POWER REQUIREMENT

The power requirement of a rotary dryer is calculated by using Equation 12-60 (Perry’s
Chemical Engineering Handbook, 7th Ed., page 12-60),
𝑁 [ 4.75 dw +0.1925 𝐷𝑊 + 0.33 𝑊]

𝑏ℎ𝑝 =
100 000
Where:
• 𝑏ℎ𝑝 = horsepower required (1 bhp = 0.75 kW)
• 𝑁 = rotational speed, rpm
• 𝑑 = shell diameter, ft
• 𝑤 = live load (material), lb
• 𝐷 = riding-ring diameter, ft (D = d+2)
• 𝑊 = total rotating load (equipment plus material), lb

The total volume of the cylinder with the thickness is calculated as
𝑉 = 𝜋𝑟2𝐿
𝑉 = 𝜋(0.753 𝑚)2(6.0 𝑚) = 10.6879 𝑚3

The total weight is equal to the sum of the weights of the equipment and the material
to be handled,


Rotary Dryer
Identification
Number of units 1
Materials handled Copra Meal
Function To reduce the moisture content from 12.3% to 4.7%
Residence Time 18.75 mins
Operating Temperature 80°C
Materials of Construction Stainless steel type 302 insulated with Calcium Silicate
Design Data
2
Dryer cross-sectional area 1.80 m –
Dryer diameter 1.50 m 1.0 – 4.6 m
Dryer length 6.00 m 4.0 m – 25.0 m
3
Dryer volume 9.60 m 0.50 – 80 m3
Dryer Height 2.00 m –
Shell Thickness 7 mm 6 – 10 mm
Number of flights 15 10 – 20
Height of flights 0.20m –
Insulation Thickness 1.00 mm 1.00 – 3.00 mm
Rotational Speed 4 rpm 2 – 5rpm
Power Requirement 3.0 hp 2.0 – 10.0 hp
Equipment Supplier
Supplier Name FEECO International Inc.
Supplier Address 3913 Algoma Rd. Green Bay, WI 54311, USA
Supplier Contact Number Phone: (920)468.1000; Fax: (920)469.5110
Supplier Website www.feeco.com
Accessories and Auxiliary parts
Centrifugal fan, Chain Drive Assembly, Support Roller, Product Collector, Resistance
Temperature Detector

AA

COOLING TOWER
Design Problem
3494.94 kg/batch of water is discharged from the condenser and will be used again for
the cooling water needed in the heat exchangers. The water needs to be cooled from
40oC to 29oC. Design a cooling tower that will satisfy the requirements for the cooling
tower.
Design Selection
The induced draft cooling tower was chosen because it produces low entering and high
exiting air velocities, reducing the recirculation in which discharged air flows back into
the air intake. Additionally, it is suitable for all water flows and all weather conditions.
Design Description
The cooling tower is designed to cool water that will be used in the condenser and heat
exchanger. Induced draft tower have fans at the discharge. Location of the fan in the
warm air stream provides excellent protection against icing of the mechanical
components.
Parts and Functions

Parts Function
Structural frames that support the exterior enclosures

Frame and Casing
(casings), motors, fans, and other components
Facilitate heat transfer by maximizing water and air

Fill
contact
Receives the cooled water that flows down through tower

Cold Water Basin
and fill
Capture water droplets entrapped in the air stream that

Drift Eliminators
otherwise would be lost to the atmosphere
Air Inlet The point of entry for the air entering a tower
Equalize air flow into the fill and retain the water within
Louvers
the tower
Nozzles Provides the water sprays to wet the fill
Fans Vary air flow
Design Assumptions
1. Water feed temperature is 40oC.
2. Water feed rate is 3494.94 kg/batch and the density of water at 40 oC is 992.25
kg/m3.
3. Exiting water temperature is 29oC.

4. Air enters the bottom of the tower with a wet bulb temperature of 26oC.
5. The air rate used is 1.5 times the minimum and water flowrate is 100 gal/min.
6. The tower performance is taken 95%.
7. The height of each transfer unit is taken as 0.553 m.

8. The wind velocity is 1.67 m/s.

9. Water concentration is 3 gal/min-ft2 of the ground area.
Design Considerations
1. The type of fill used is film fill because of its low air quality requirement and power
savings due to fewer air and pumping head required.

2. L/G ratio is 1.5 based on the type of the fill.
3. Effective Heat Exchange Area is 150 m2/m2 based on the type of fill.
4. Fill height is 1.2 m based on the type of fill.
5. Pumping head required is 7 m based on the type of fill.

6. The use of forced and induced draft fans in employed.
7. Exiting air velocity is 10.2 m/s.
Design Requirements
1. Area of the tower base

2. Fan power requirement
3. Number of Heat Transfer Units

4. Tower Height
5. Pump Horsepower
Design Calculations
1. Area of the Tower Base
From Perry’s Chemical Engineering Handbook 8th Edition, p. 12-19,
𝑤𝑎𝑡𝑒𝑟 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒

𝑨𝒓𝒆𝒂 =
𝑤𝑎𝑡𝑒𝑟 𝑐𝑜𝑛𝑐𝑒𝑛𝑡𝑟𝑎𝑡𝑖𝑜𝑛

100 𝑔𝑎𝑙/𝑚𝑖𝑛
𝑨𝒓𝒆𝒂 =
𝑔𝑎𝑙
3 ⁄𝑚𝑖𝑛 ∙ 𝑓𝑡 2
𝑨𝒓𝒆𝒂 = 𝟑𝟑. 𝟑𝟑 𝒇𝒕𝟐 = 𝟑. 𝟎𝟗 𝒎𝟐
2. Fan Power Requirement
From Perry’s Chemical Engineering Handbook 8th Edition, p 12-19,
𝑄(ℎ𝑠 )(𝜌)
𝑺𝒕𝒂𝒕𝒊𝒄 𝑨𝒊𝒓 𝑯𝒐𝒓𝒔𝒆𝒑𝒐𝒘𝒆𝒓 (𝑺𝑨𝑯𝑷) =
33,000 (12)
Where:
𝑔𝑎𝑙⁄ 𝑓𝑡 3⁄ 𝐿
𝑄 = 𝑎𝑖𝑟 𝑣𝑜𝑙𝑢𝑚𝑒 = 33.33 𝑚𝑖𝑛 = 4.4559 𝑚𝑖𝑛 ; 𝑢𝑠𝑖𝑛𝑔 ⁄𝐺 𝑟𝑎𝑡𝑖𝑜
𝑓𝑡⁄ 𝑚
ℎ𝑠 = 𝑠𝑡𝑎𝑡𝑖𝑐 ℎ𝑒𝑎𝑑 = 0.470 𝑓𝑡 𝑒𝑞𝑢𝑖𝑣𝑎𝑙𝑒𝑛𝑡 𝑡𝑜 𝑎 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑜𝑓 5.5 𝑠 (1.67 ⁄𝑠)
𝑘𝑔⁄ 𝑙𝑏
𝜌 = 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟 = 992.25 𝑚3 = 62.23 ⁄𝑓𝑡 3
33.33(0.470)(62.23)
𝑺𝒕𝒂𝒕𝒊𝒄 𝑨𝒊𝒓 𝑯𝒐𝒓𝒔𝒆𝒑𝒐𝒘𝒆𝒓 (𝑺𝑨𝑯𝑷) =
33,000(12)
𝑺𝒕𝒂𝒕𝒊𝒄 𝑨𝒊𝒓 𝑯𝒐𝒓𝒔𝒆𝒑𝒐𝒘𝒆𝒓 (𝑺𝑨𝑯𝑷) = 0.0474 ℎ𝑝
𝑺𝒕𝒂𝒕𝒊𝒄 𝑨𝒊𝒓 𝑯𝒐𝒓𝒔𝒆𝒑𝒐𝒘𝒆𝒓 (𝑺𝑨𝑯𝑷) = 𝟎. 𝟎𝟓 𝒉𝒑
3. Number of Heat Transfer Units

Using Psychrometric Chart: H = 0.008
𝒉𝟏 = [1.005 + 1.88(26.7) + 2501.4(0.008)]

𝒌𝑱
𝒉𝟏 = 𝟐𝟏. 𝟒𝟎𝟕𝟐 ⁄𝒌𝒈
Heat Balance: 𝐺(ℎ2 − ℎ1 ) = 𝐿𝐶(𝑇𝑙1 − 𝑇𝑙2 )
196−21.4072
𝒎= = 12.4073
40−26.7
𝑘𝐽
1.5𝐺min (ℎ2 − 21.4072) ⁄𝑘𝑔 = 12.4709 (40 − 26)
𝒌𝑱
𝒉𝟐 = 𝟏𝟑𝟕. 𝟖𝟎𝟐𝟑 ⁄𝒌𝒈
Plotting the values on the Fig. 12-8b in Perry’s Chemical Engineering Handbook 8th
Edition, the value of NTU is 4.
4. Tower Height
𝒁 = 𝐻𝑇𝑈(𝑁𝑇𝑈)
𝒁 = 0.533(4)
𝒁 = 2.132 𝑚
𝒁 = 𝟐. 𝟐𝟎 𝒎
5. Pump Horsepower
𝑔𝑎𝑙
⁄𝑚𝑖𝑛 (ℎ )
𝑡
𝑷=
3960 (𝜇)
𝑔𝑎𝑙
100 ⁄𝑚𝑖𝑛 (6.9948)
𝑷=
3960 (0.95)
𝑷 = 0.1859 ℎ𝑝
𝑷 = 𝟎. 𝟐 𝒉𝒑

Design Specifications
INDUCED DRAFT COOLING TOWER
OPERATING CHARACTERISTICS
Number of Units 1
Operating Temperature 26oC-40oC
Operating Pressure 101.325 kPa (1 atm)
EQUIPMENT SPECIFICATIONS
Design Parameter Proposed Existing
Area of the Tower Base 3.09 m2 4.0 m2
Fan Power Requirement 0.05 hp 0.02 hp
NTU 4 4
Tower Height 2.20 m 2.5 m
Pump Requirement 0.2 hp 0.2 hp

BATCH STIRRED TANK EXTRACTOR
Design Description
Leaching process is the removal of a solute constituent from a solid, by contacting the
solid with a liquid phase which is the solvent. The two phases are in intimate contact and
the solute(s) can diffuse from the solid to the liquid phase which results in the complete
separation of the components which are originally in the solid (Geankoplis, 2003). A
batch stirred tank extractor is used to recover the oil component of rubber seed kernels
using n-Hexane as solvent. The process is conducted at 50oC for a total contact time of
2 hours.
Design Selection
The leaching equipment to be designed needs to provide the following features: 1)

intimate contact between the solids and the solvent; 2) agitation to distribute and supply
unexhausted solvent to the solid particle; 3) sufficient contact time of the solvent to the
solids to provide an effective extraction process; and 4) a safe operation with respect to
the materials inside (e.g. sealed/ covered systems for volatile and flammable solvents).
Dispersed-solids systems like batch stirred tanks and vertical plate extractors are the
most suitable option since they provide agitation enough to aid efficient contact of the
particles with the solvent.
The tank is cylindrical with torispherical top and bottom since it’s dealing with solution
under ambient temperature and the inner pressure is less than 150 psig. Torispherical
heads are used under inner pressure that is less than 150 psig according to Silla, H.
(pg.281). Pitched-blade turbine with four blades at 45o is used due to its application for

liquids or suspensions containing small particles (Principles of Transport Processes and
Unit Operations by Geankoplis, 3rd Edition, pg. 142).
Parts and Functions
Parts Functions
Converts electrical energy into mechanical energy that is

Motor
transmitted to the impeller through the shaft
Impeller and Shaft Provides uniform mixing to the mixture
Outlet Exit Stream
Solids Inlet Inlet of solid reactants
Liquid Inlet Solvent inlet
Tank Consists of the shell and torispherical head and bottom
Leg Provides support to the whole vessel

Data and Assumptions
1. The feed rate of ground rubber seed kernel is 550.70 kg per batch.
2. The feed rate of n-Hexane is 1,652.10 kg (2.5m2) per batch.
3. The density of the ground rubber seed kernel is 0.480 g/cm3 or 480 kg/m3.
4. The density of n-Hexane is 0.660 g/cm3 or 660 kg/m3.

5. The reaction temperature is 50oC and the residence time is 120 minutes.
6. Charging time, TF = 10 minutes.

7. Time of heating to required temperature, TH = 20 minutes.
8. The time of emptying the reactor TE = 10 minutes.

9. The thermal conductivity of calcium silicate is 0.063 W/m-K (0.44 Btu/hr-ft2-oF)
10. The total heat requirement for the process is 1,452,334.68 kJ/batch.
11. The system is a constant pressure batch process and a constant batch process and
a constant volume reaction.

12. Jacket is used as the heating medium for the reactor.
1. A vertical cylindrical tank with torispherical top and bottom is chosen since this
type of closure is the most commonly used end enclosure for vessels up to
operating pressure of 10 bar. (Chemical Engineering Design, Sinott (2005), Volume
6, Fourth Edition, pg. 817)

2. The height of the tank body to internal diameter ratio is 1:1. (Unit Operations of
Chemical Engineers, McCabe et. al. (2001), 6th Edition, pg. 241)
3. For a torispherical head, the crown radius, L, is equals the inside diameter, D, of the
cylindrical vessel. (Table 10-65, Silla (2003), pg. 10-140)

4. Type 302 Stainless Steel (18% Cr, 9% Ni, 0.15% Cmax) is chosen since it is primarily
used for general process equipment. (Plant Design and Economics for Chemical
Engineers by Peters and Timmerhaus, 4th Edition, Table 4, pg. 426)
5. The number of baffles is usually 4. (Unit Operations of Chemical Engineers, McCabe

et. al. (2001), 6th Edition, pg. 241)
6. Impeller’s rotational speed, N = 200 rpm. (Principles of Transport Processes and Unit
Operations by Geankoplis, 3rd Edition, pg. 142)
7. The corrosion allowance is 2.0 mm. (Chemical Engineering Design, Sinnott (2005),
Volume 6, Fourth Edition, pg. 813).
8. The efficiency of the double-welded butt joint is 80% based upon a material factor
Fm of 1.00. This type of welded joint was selected because the are stronger than
single-welded joints and may be used for either longitudinal or circumferential

seams. (Process Equipment Design, Hesse and Rushton, pg. 84)
9. A 20% factor of safety for batch reactor. (Plant Design and Economics for Chemical
Engineers, Timmerhaus, 4th Edition, pg. 37)
10. The filling capacity of the reactor is 80% of the volume, measured at the top
tangent line to allow vapor space. (Rules of Thumb for Chemical Engineers, Hall, 5th
Edition, pg. 150)
Design Requirements
1. Batch Time
2. Capacity of the Tank
3. Tank Diameter
4. Tank Height
5. Shell Thickness

7. Impeller Design
a. Diameter
b. Length
c. Width
d. Elevation
8. Baffle Design
a. Width
9. Tank Insulation
Design Calculations
1. Total Batch Time
Batch time will be equal to the time of filling plus extraction time plus the emptying
time. (From eq’n 7.8.5 of Chemical Process Engineering Design and Economics by
Harry Silla pg. 395)
tB = tF + tH + tR + tE
tB = (10 + 20 + 120 + 10) mins = 160 min
The total batch time is equal to 2 hours and 50 mins.
2. Tank Capacity
Using the upscaled values for feed of extraction process:

550.70 𝑘𝑔 1,652.10 𝑘𝑔
𝑉= + = 3.6505 𝑚3
𝑘𝑔 𝑘𝑔
480 3 660 3
𝑚 𝑚
Applying 20% safety factor,
𝑉 = 3.6505 𝑚3 × 1.20 = 4.3806 𝑚3
For 80% filling capacity,
4.3806 𝑚3
𝑉= = 5.46 𝑚3
0.80
The tank capacity is 5.50 m3
3. Tank Diameter
𝑽 = 𝑽𝒄𝒚𝒍𝒊𝒏𝒅𝒓𝒊𝒄𝒂𝒍 𝒕𝒂𝒏𝒌
𝜋𝐷2 ℎ
𝑉=
4
Since H=D then,
3
𝜋𝐷3
𝑉 = 5.50 𝑚 =
4
𝜋𝐷3
5.50 𝑚3 =
4
𝐷 = 1.91 𝑚
𝑼𝒔𝒆 𝑫 = 𝟐. 𝟎 𝒎
4. Tank Height
Height of the Body,
𝐻𝑇 = 𝐷
𝑯𝑻 = 𝟐. 𝟎 𝒎
Height of Head,
HH = 0.10H
𝐻𝐻 = 0.10 (2.0𝑚)
𝑯𝑯 = 𝟎. 𝟐𝟎 𝒎
Height of Bottom,
HH = 0.10H
𝐻𝐻 = 0.10 (2.0𝑚)
𝑯𝑯 = 𝟎. 𝟐𝟎 𝒎
Total Height of the Tank,

𝐻 = 𝐻𝑇 + 𝐻𝐻 + 𝐻𝐵
𝐻 = 2.0 + 0.20 + 0.20
𝐻 = 2.40 𝑚
𝑼𝒔𝒆 𝑯 = 𝟐. 𝟒𝟎 𝒎
5. Shell Thickness
𝑷𝒓
𝒕= +𝑪
𝑺𝑬 − 𝟎. 𝟔𝑷
(Plant Design and Economics for Chemical Engineers, Peters and Timmerhaus, pg.
537)
Where:
t = maximum wall thickness, in
P = maximum allowable working pressure, psi

r = inside radius with corrosion allowance, in
S = maximum allowable tensile strength, psi

E = joint efficiency
C = corrosion allowance, in
Using equation 4-1, pg. 84, Process Equipment Design by Hesse and Rushton,
𝑆 = 𝑆𝑢 + 𝐹𝑚 + 𝐹𝑎 + 𝐹𝑟 + 𝐹𝑆
𝑆 = 60,000 × 1.00 × 1.00 × 1.00 × 0.25
𝑺 = 𝟏𝟓, 𝟎𝟎𝟎 𝒑𝒔𝒊
Where:
Su = 60,000 psi (Process Equipment Design, Hesse & Rushton, pg. 81)
Fm = 1.0 for Grade for double welded butt joint (Process Equipment Design,
Hesse and Rushton, pg. 84)

Fa = Fr = 1.00 since radiographing and stress relieving is not required.
Fs = 0.25 (Process Equipment Design, Hesse and Rushton, Table 4.2, pg. 84)
Computing for the internal pressure,
P = Hρg + Patm
Where:
P = maximum allowable working pressure

H = tank height
Ρ = fluid density
g = acceleration due to gravity
Computing for the density of the solution,

550.70 𝑘𝑔 + 1652.10 𝑘𝑔 𝑘𝑔
𝜌= = 603.4242
3.6505 𝑚3 𝑚3
Computing for the pressure,
𝑘𝑔 𝑚
𝑃 = (2.40 𝑚 × 603.4242 3
× 9.81 2 ) + 101,325 𝑃𝑎
𝑚 𝑠
𝑃 = 115,532.0194 𝑃𝑎
For maximum allowable pressure (based from Process Plant Equipment: Operation,
Control, and Reliablity, Michael D. Holloway, pg. 470)

𝑃 = 1.33 (115,532.0194 𝑃𝑎)
𝑃 = 153,657.5858 𝑃𝑎 = 22.2923 𝑝𝑠𝑖
Computing for the Shell Thickness,
𝑃𝑟
𝑡= +𝐶
𝑆𝐸 − 0.6𝑃
𝑙𝑏
(22.2923
2 ) (39.27 𝑖𝑛 + 0.07874 𝑖𝑛)
𝑡= 𝑖𝑛 + 0.07874 𝑖𝑛
𝑙𝑏 𝑙𝑏
(15000 2 )(0.85) − 0.6(22.2923 2 )
𝑖𝑛 𝑖𝑛
𝒕 = 𝟎. 𝟏𝟒𝟕𝟗 𝒊𝒏 = 𝟑. 𝟕𝟓𝟑𝟕 𝒎𝒎
However, for vessel diameter of 1 to 2 m, minimum thickness is 7.0 mm (Coulson,
pg. 814)
𝑼𝒔𝒆 𝒕 = 𝟕𝒎𝒎
Using equation 13.44 in pg. 819 of Chemical Engineering Design, Sinnott (2005),
𝑃𝑇 𝐿𝐶𝑆
𝑡𝑠 = +𝐶
2𝐽𝑓 − 𝑃𝑇 (𝐶𝑠 − 0.2)
Where:
1 𝐿
CS = stress concentration, for torispherical heads, 𝐶𝑆 = 4 (3 + √𝑅
𝐾
L = crown radius
Rk = knuckle radius, Rk = 0.06L
For knuckle radius,
𝑅𝐾 = 0.06𝐿
Since L = D for torispherical head,
𝑅𝐾 = 0.06(2.0 𝑚)
𝑅𝐾 = 0.12 𝑚
From Table 13.2 in pg. 812 of Chemical Engineering Design, Sinnott (2005),
𝑁
𝑓 = 165
𝑚𝑚2
𝑁 𝑚𝑚2 1𝑙𝑏
𝑓 = 165 (645.16 ) ( )
𝑚𝑚2 𝑖𝑛2 4.482𝑁
𝑙𝑏
𝑓 = 23,750.8702
𝑖𝑛2
For stress concentration, CS,
1 𝐿
𝐶𝑆 = (3 + √
4 𝑅𝐾
1 2.0 𝑚
𝐶𝑆 = (3 + √
4 0.12 𝑚
𝐶𝑆 = 1.7706
Converting the length,
3.2808𝑓𝑡 12 𝑖𝑛
𝐿 = (2.0𝑚) ( )( )
1𝑚 1 𝑓𝑡
𝐿 = 78.7392 𝑖𝑛
Solving for tS,
𝑃𝑇 𝐿𝐶𝑆
𝑡𝑠 = +𝐶
2𝐽𝑓 − 𝑃𝑇 (𝐶𝑠 − 0.2)
𝑙𝑏
𝑖𝑛 2 ) (78.7392 𝑖𝑛)(1.7706)
(22.2923
𝑡𝑠 = + 0.07874
𝑙𝑏 𝑙𝑏
2(0.85) (23,750.8702 2 ) − (22.2923 2 ) (1.7706 − 0.2)
𝑖𝑛 𝑖𝑛
𝑡𝑠 = 0.1552 𝑖𝑛 = 3.9419 𝑚𝑚
𝑼𝒔𝒆 𝒕𝒔 = 𝟒𝒎𝒎
7. Impeller Design

(Table 3.4-3.c, Dimension of Turbine and Tank, Principles of Transport Processes
and Unit Operation by Geankoplis, 3rd Edition, pg. 143)

a. Diameter of Impeller
𝐷𝑎
= 0.5
𝐷𝑇
(Table 3.4-1.c, Dimension of Turbine and Tank, Principles of Transport
Processes and Unit Operation by Geankoplis, 3rd Edition, pg. 144)
Where:
Da = impeller diameter, m
DT = tank diameter, m
Computing for Impeller Diameter,
𝐷𝑎
= 0.5
2.0 𝑚
𝐷𝑎 = 1.0 𝑚
𝑼𝒔𝒆 𝑫𝒂 = 𝟏. 𝟎 𝒎
b. Length of Impeller
The length of impeller is 60 to 80% of the tank diameter (Geankoplis, 2003,
pg.141),
𝐿 = 0.70 (𝐷𝑇 )
Where:
L = length of the impeller, m

Computing for the length of the impeller,

𝐿 = 0.70 (2.0𝑚)
𝐿 = 1.40 𝑚
𝑼𝒔𝒆 𝑳 = 𝟏. 𝟒𝟎 𝒎
c. Width of Impeller
For pitched-blade turbine with blades at 45o,
𝑊 1
=
𝐷𝑎 8
(Figure 3.4-4,Principles of Transport Processes and Unit Operation by
Geankoplis, 3rd Edition, pg. 145)

Where:
W = width of the impeller, m

Da = impeller diameter, m
Computing for the width of Impeller,

𝑊 1
=
1𝑚 8
𝑊 = 0.125 𝑚
𝑼𝒔𝒆 𝑾 = 𝟎. 𝟏𝟓 𝒎
d. Elevation of Impeller
𝐶 1
=
𝐷𝑇 3

Where:

C = elevation of impeller, m
Computing for the elevation of impeller,
𝐶 1
=
2.0 𝑚 3
𝐶 = 0.67 𝑚
𝑼𝒔𝒆 𝑪 = 𝟎. 𝟕𝟎 𝒎
8. Baffle Design
a. Width of the Baffle

𝐽 1
=
𝐷𝑇 12

Where:
J = width of the baffle, m

Computing for the width of the baffle,

𝐽 1
=
2.0 𝑚 12
𝐽 = 0.17 𝑚
𝑼𝒔𝒆 𝑱 = 𝟎. 𝟐𝟎 𝒎
Based from Unit Operations of Chemical Engineers by McCabe et. al, the
usual number of baffles are 4 therefore,
NB = 4
9. Tank Insulation
𝑘𝐽 𝐵𝑡𝑢
𝑄 = 1,452,334.68 = 1,376,547.6741
𝑏𝑎𝑡𝑐ℎ 𝑏𝑎𝑡𝑐ℎ
𝐵𝑡𝑢 1 𝑏𝑎𝑡𝑐ℎ 60 𝑚𝑖𝑛𝑠

𝑄 = 1,376,547.6741 × ×
𝑏𝑎𝑡𝑐ℎ 120 𝑚𝑖𝑛𝑠 1 ℎ𝑟
𝐵𝑡𝑢
𝑄 = 688,273.8371
ℎ𝑟
The operating temperature of the batch stirred tank extractor is 50oC and the
temperature of the surrounding is assumed to be 30oC,
∆𝑇 = (50 − 30)℃ = 20℃ = 68℉
Using equation 10.8 in pg. 294 of Unit Operation of Chemical Engineering by
McCabe et. al,
𝑄 ∆𝑇
=𝑘
𝐴 𝑥
∆𝑇
𝑄 = (2𝜋𝑟𝐻)𝑘
𝑥
Where x is the thickness of the layer of insulation,
𝐵𝑡𝑢
𝐵𝑡𝑢 2𝜋(1.64𝑓𝑡)(7.87𝑓𝑡) (0.44 2 ) (68℉)
𝑓𝑡 ∙ ℎ𝑟 ∙ ℉
688,273.8371 =
ℎ𝑟 𝑥
𝑥 = 0.051 𝑓𝑡 = 15.54 𝑚𝑚
𝑼𝒔𝒆 𝒙 = 𝟏𝟔 𝒎𝒎
Referring to Table 7.7 of Silla (2003), pg. 387, the approximate mixer power for
stirred-tank reactors for reaction with heat transfer is 3.25 hp/1000 gal, therefore,
264.1720 𝑔𝑎𝑙 3.25 ℎ𝑝

𝑃 = 5.50 𝑚3 × 3
× = 4.72 ℎ𝑝
1𝑚 1000 𝑔𝑎𝑙
𝑼𝒔𝒆 𝑷 = 𝟒. 𝟕𝟓 𝒉𝒑
Design Specifications

Batch Stirred Tank Extractor
Identification
Number of Units Required 1
Materials Handled Ground Rubber Seed Kernels and Hexane
Function To extract oil from ground rubber seed kernel
Operating Temperature 50oC
Tank Insulation Calcium Silicate
Materials of Construction Stainless Steel Type 302
Design Data
Tank Capacity 5.50 m3 0.5 – 6.0 m3
Tank Height 2.40 m 2.4 – 4.4 m
Shell Thickness 7.0 mm 5.0 mm
Head and Bottom Thickness 4.0 mm 5.0 mm
Four-Bladed Pitched
Type of Impeller Four-Blade Paddle
Turbine
Impeller Diameter 1.0 m 0.70 m
Impeller Elevation 0.70 m 0.50 m
Impeller Width 0.15 m -
Impeller Length 1.40 m -

Baffle Width 0.20 m 0.10 m
Number of Baffles 4 -
Power Requirement 4.75 hp 3-5 hp
Equipment Supplier
Guangzhou Light Industry Machinery Equipment

Supplier Name
Co., Ltd.
Supplier Address Baiyun District, Guangzhou, China
Cost Php 1,010,500.00
Accessories and Auxiliary Parts
Number of Unit/s Level Transmitter, Tachometer, Centrifugal Pump
Guangzhou Light Industry Machinery Equipment

Supplier Name
Co., Ltd.
Supplier Address Baiyun District, Guangzhou, China

SHELL AND TUBE HEAT EXCHANGER (COOLING)
Design Description
Shell and tube heat exchanger is used to cool down the fatty acids coming from
the acid hydrolysis reactor by removing its heat. The design includes tubes, arranged in
bundle, and is enclosed in a single shell. Inside the shell and tube heat exchanger are
baffles which are crossed arranged so that the fluid is forced to flow perpendicular across
the tube bank rather that parallel with it (Principles of Transport Processes and Separation
Processes, by Geankoplis).
Principle Of Operation
The shell and tube heat exchanger is a 1-2 counter flow heat exchanger. An amount of
20,000 kg is fed on the top of shell and tube heat exchanger and flows inside the tubes
in parallel in one pass. The cooling water at 25⁰C enters at the other end and flows
counterflow across the outside of the tubes, causing the removal of heat in the solution.
Cross baffles are used so that the fluid is forced to flow perpendicular across the tube
bank rather than parallel with it. The added turbulence generated by these baffles
increases the shell side heat-transfer coefficient.
Design Selection
Fixed tube heat exchanger is used for cooling because of its applicability in large flows
operation and provides maximum heat transfer area (Perry’s Chemical Engineering
Handbook, 7th ed).
Data And Assumptions
1. The amount of fatty acid mixture is 20,000 kg.

2. The feed enters at 120⁰C and exits at 60⁰C.
3. The density of the feed is 895 kg/m3.
4. Cooling water enters at 20⁰C and exits at 50⁰C.
5. The heat capacity of the feed is 2.10 kJ/kg-K.

1. An allowance of 15% safety factor is used for shell and tube heat exchanger. (Plant
Design and Economics by Peters and Timmerhaus p. 39, Table 6)
2. The overall coefficient is 490 W/m2-K (Chemical Engineering Design by Towler and
Sinnott p. 1052, Figure 19.1).
3. The standard tube length varies from 1.83 m to 6.096 m long, 3.048 m the most
common. (Perry’s Chemical Engineering Handbook 7th ed. Page 11-40).
4. The standard tube diameters 5/8 inch, ¾ inch and 1 inch in outside diameter (Perry’s
Chemical Engineering Handbook 7th ed. Page 11-40).
5. The tube arrangement is triangular pitch.
6. TEMA standards for triangular pitch are 1.25 times the tube outside diameter.
(Perry’s Chemical Engineering Handbook 7th ed. Page 11-41).
7. The material of construction is carbon steel (Perry’s Chemical Engineering Handbook
7th ed. Page 11-43).
8. The L/D ratio found most efficient in commercial practice lies between 4 and 10
(Process Heat Transfer by Kern).
9. The baffle spacing is generally 1/5 of the shell diameter and not less than 50.8 mm
(Perry’s Chemical Engineering Handbook 7th ed. Page 11-42).
10. The corrosion allowance for non-corrosive conditions is 0.15 in. (Rules of Thumb for
Chemical Engineers 4th ed., by Branan)
11. The lap welded joint efficiency is 70% (Process Equipment Design by Hesse and
Rushton).
Design Requirements
1. Mean Temperature Difference 9. Baffle Spacing

2. Heat Duty and Heat Transfer Area 10. Number of Baffles
3. Number of Tubes 11. Shell Thickness
4. Tube Pitch 12. Mass Flow Rate of Cooling Water
5. Bundle Diameter
6. Bundle Diameter Clearance
7. Shell Diameter
8. Shell Length
Design Calculations
1. Mean Temperature Difference

Computing the logarithmic temperature difference:
∆𝑇1 = 120 − 50 = 70
∆𝑇2 = 60 − 20 = 40
∆𝑇2 − ∆𝑇1
∆𝑇𝐿𝑀 =
∆𝑇
ln ∆𝑇2
1
40 − 70
∆𝑇𝐿𝑀 =
40
ln 70
= 53.6082
Computing for correction factor:
𝑇𝑖𝑛 − 𝑇𝑜𝑢𝑡 120 − 60
𝑍= = =2
𝑡𝑜𝑢𝑡 − 𝑡𝑖𝑛 50 − 20
𝑡𝑜𝑢𝑡 − 𝑡𝑖𝑛 50 − 20
𝑌= = = 0.3
𝑇𝑖𝑛 − 𝑡𝑖𝑛 120 − 20
Using the correction factor graph for 1-2 heat exchangers (Figure 4.9-4 page 295,
Principles of Transport Processes and Separation Processes by Geankoplis)
FT=0.88
Computing the mean temperature difference:
∆𝑇𝑀 = 53.6082 × 0.88 = 𝟒𝟕. 𝟏𝟕𝟓𝟐°𝑪
2. Heat Duty and Heat Transfer Area

Calculating the heat duty:
20 000 𝑘𝑔 𝑘𝐽
𝑄 = 𝑚𝐶𝑝 ∆𝑇 = × 2.10 × (120 − 60)
60 𝑠𝑒𝑐𝑜𝑛𝑑𝑠 𝑘𝑔 − 𝐾
25 𝑚𝑖𝑛𝑢𝑡𝑒𝑠 × 1 𝑚𝑖𝑛𝑢𝑡𝑒
= 𝟏𝟔𝟖𝟎 𝒌𝑾
According to the design consideration, the approximate heat transfer
coefficient is 490 W/m2-K. Computing for the heat transfer area:

COMPILATION OF 12 EQUIPMENT DESIGN 159
1000 𝑊
𝑄 1680 𝑘𝑊 ×
𝐴= = 1 𝑘𝑊 = 43.2604 𝑚2
𝑈∆𝑇𝑚 490 𝑊 × 47.1752℃ × 1 𝐾
𝑚2 − 𝐾 1℃
3. Number of Tubes
To calculate for the number of tubes:
𝐴
𝑁=
𝜋𝑑𝑜 𝐿
Where:
N= number of tubes
d0=outside diameter of the tubes
A= heat transfer area
L= length of the heat exchanger
According to the design consideration, the most common standard tube length
would be 10 ft (3.048 m). For the diameter, the standard tube diameter to be used
is 1 inch 12 BWG (25.40 mm).
43.2604 𝑚2
𝑁= = 177.8656 𝑡𝑢𝑏𝑒𝑠
25.40
𝜋 × 1000 𝑚 × 3.048𝑚
= 𝟏𝟕𝟖 𝒕𝒖𝒃𝒆𝒔
4. Tube Pitch
According to Perry’s Chemical Engineering Handbook 7th ed. Page 11-41,
TEMA standards for triangular pitch are 1.25 times the tube outside diameter.
𝑃𝑇 = 1.25𝑑𝑜 = 1.25 × 25.4𝑚𝑚 = 31.75 𝑚𝑚

USE: Pt= 31.8 mm
5. Bundle Diameter
The equation for Bundle Diameter is given by:

𝑁𝑡 𝑛1
𝐷𝑏 = 𝑑𝑜 ( ) 1
𝐾
Values for n1 and K are obtained from
Table 19.4 of Sinnott, Chemical Engineering
Design page 1063.
1
178 2.207
𝐷𝑏 = 25.40 ( )
0.249
= 498.99 𝑚𝑚 = 𝟒𝟗𝟗. 𝟎𝟎 𝒎𝒎
6. Bundle Diameter Clearance
From the figure:
USE: Bc= 13 mm
7. Shell Diameter
𝐷𝑠 = 𝐷𝑏 + 2(𝐵𝑐 )

= 499 + 2(13)
= 525 𝑚𝑚
According to the design consideration, a 15% safety factor must be used for
shell and tube heat exchangers. Therefore,
𝐷𝑠 = 525(1.15) = 603.7384 𝑚𝑚
= 0.6037 𝑚
𝐷𝑠 = 𝟎. 𝟔𝟓 𝒎
8. Shell Length
According to the design considerations, The L/D ratio found most efficient in commercial
practice lies between 4 and 10 (Process Heat Transfer by Kern). Using the average:
𝐿 = 7𝐷𝑠
𝐿 = 7(0.6037) = 4.23 𝑚
USE: L=4.50m
9. Baffle Spacing
1
𝐵𝑠 = × 𝐷𝑠
5
1
𝐵𝑠 = × 603.7384 = 120.75 𝑚𝑚
5
10. Number of Baffles
𝐿
𝑁𝑏 + 1 =
𝐵𝑠
3.048
𝑁𝑏 + 1 =
120.75
1000
3.048
𝑁𝑏 = − 1 = 24 𝑏𝑎𝑓𝑓𝑙𝑒𝑠
120.75
1000
11. Shell Thickness
Shell Thickness formula (Process Equipment Design, Hesse and Rushton):
Allowable working stress formula is:
1
𝑆 = 𝑆𝑢
4
Where Su is 9,000 psi for temperatures -20⁰F to 650 ℉ (Process Equipment Design, Hesse
and Rushton)
1
𝑆 = (9000) = 2250 𝑝𝑠𝑖
4
Internal Pressure:
𝑘𝑔 𝑚
𝑃 = 𝜌𝐻𝑔 + 𝑃𝑎𝑡𝑚 = 895 3
× 0.6037𝑚 × 9.81 2 + 101325 𝑃𝑎 = 106.62𝑘𝑃𝑎
𝑚 𝑠
1000𝑚𝑚
(106.62 𝑘𝑃𝑎)(0.6037𝑚)(
𝑡𝑠 = 1𝑚 ) + 0.15 𝑖𝑛 ×
25.4𝑚𝑚
101.325 𝑘𝑃𝑎 1 𝑖𝑛
2 × 2250 𝑝𝑠𝑖 × 0.70 × 14.7 𝑝𝑠𝑖 − 106.62 𝑘𝑃𝑎
= 3.3601 𝑚𝑚
USE: ts= 3.50 mm
12. Mass Flowrate of Cooling Water
𝑄 = 𝑚𝐶𝑝 ∆𝑇

𝑄 1680𝑘𝑊 𝒌𝒈
𝑚= = = 𝟏𝟑. 𝟑𝟖
𝐶𝑝 (𝑇𝑜𝑢𝑡 − 𝑇𝑖𝑛 ) 𝑘𝐽 𝒔
4.185 (50 − 20)
𝑘𝑔 − 𝐾
DESIGN SPECIFICATIONS
SHELL AND TUBE HEAT EXCHANGER
Operating Data
Number of Units 1
Compound Fatty Acid

Feed
Density 895 kg/m3
Operating Temperature (⁰C) 60-120
Operating Pressure (kPa) 101.325
Rated Capacity (kg) 20,000
Equipment Data
Designed Parameter Proposed Existing
Heat Transfer Area (m2) 43.26 -
Number of Tubes 178 -
Tube Pitch (mm) 31.8 10-50
Bundle Diameter (mm) 499 200-1000
Bundle Diameter Clearance (mm) 13 2-30

Shell Diameter (m) 0.65 Up to 2
Shell Length (m) 4.5 -
Length of Tube (m) 3.048 2-10
Tube Diameter (in) 1 5/8, ¾, 1
Baffle Spacing (mm) 120.75 -
Number of Baffles 24 -
Shell Thickness (mm) 3.5 -
Mass Flowrate of Cooling Water (kg/s) 13.38 -
Existing Equipment
Supplier Bernabe Construction and Industrial Corporation of Asia
Supplier Address Valenzuela City, Philippines
Materials of Construction
Heat Exchanger Shell SS317
Ancillary Equipment
Instrumentation and Control Pump
Level Indicator
Thermocouple

Design Configuration


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PAMANTASAN NG LUNGSOD NG MAYNILA

University of the City of Manila

STIRRED BATCH EXTRACTOR………………………………………………………………………………………..146

SHELL AND TUBE HEAT EXCHANGER……………………………………………………………………………162

CHE 513 – Equipment Design (Lec)

used to separate the smaller fragments of shells from the kernels.

PARTS AND FUNCTIONS

CHE 513 – Equipment Design (Lec)

which the shells are to be removed.

CHE 513 – Equipment Design (Lec)

(Source: Couper J. R., Chemical Process Equipment Selection and Design, 2 nd

ft2-s. (Source: Brown G. G., Unit Operations page 13)

degrees. (Source: Felin, M. Screeners, Encyclopedia of Chemical Engineering

CHE 513 – Equipment Design (Lec)

Roll Crusher Design

Vibrating Screen Design

3. Power Requirement of Screen

mf= mass of feed

CHE 513 – Equipment Design (Lec)

The roll diameter is computed by rearranging the equation given by Brown, G. G.

Dp = Diameter of the Particle

= 7.5758 𝑘𝑊/ℎ = 𝟏𝟎. 𝟏𝟓𝟗𝟑 𝒉𝒑

The area of the screen is computed as:

CHE 513 – Equipment Design (Lec)

3. Power Requirement of Screens

the minimum motor power for circular motion vibrating screens:

CHE 513 – Equipment Design (Lec)

CHE 513 – Equipment Design (Lec)

Materials Handled Tamarind Seeds

Residence Time 60 minutes

Operating Temperature 26.6- 30ºC

Materials of Construction Carbon Steel

Parameters Proposed Design Existing Design

Hopper Volume 4.75 m3

Roll Diameter 228 mm 228- 760 mm

Roll Width 456 mm 250-460 mm

Roll Speed 130 rpm 130-300 rpm

Capacity 5171.65 kg/h (5.17ton/hr) 2-8 ton/hr

Power Requirement 10.15 hp 5.5-15 hp

Screen Area 1.6 m2

Screen Length 1.6 m 1- 2 m

CHE 513 – Equipment Design (Lec)

Screen Width 0.8 m 0.5-2 m

Power Requirement 11 hp 5.5- 20 hp

Supplier Name Joyal Crusher Inc.

Supplier Address Shanghai, China

Accessories and Auxilliary Parts

CHE 513 – Equipment Design (Lec)

Hopper Volume= 4.75 m2

CHE 513 – Equipment Design (Lec)

MIXER SETTLER EXTRACTOR

PARTS AND FUNCTIONS

CHE 513 – Equipment Design (Lec)

DESIGN DATA AND ASSUMPTIONS

1. Entering ethyl levulinate solution is 1,962.59 kg. (Basis: Material Balance)

CHE 513 – Equipment Design (Lec)

CHE 513 – Equipment Design (Lec)

1. Capacity of Mixing Tank

The volume for a filling capacity of 80% would be:

2. Mixing Tank Diameter

𝑉 = 𝑉𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟 + 𝑉ℎ𝑒𝑚𝑖𝑠𝑝ℎ𝑒𝑟𝑖𝑐𝑎𝑙𝑏𝑜𝑡𝑡𝑜𝑚 + 𝑉ℎ𝑒𝑚𝑖𝑠𝑝ℎ𝑒𝑟𝑖𝑐𝑎𝑙ℎ𝑒𝑎𝑑

CHE 513 – Equipment Design (Lec)