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42
Figure 3.13
3.5.10.9.1
Mechanical properties
ii.
iii.
Corrosion resistance
iv.
v.
vi.
vii.
Cost
The basic material of construction that are used in the fatty acid industry is one of
the 300 series stainless steels. Based on NPCS Board of Consultants& Engineer, the
common construction material for vessel for splitting of oils and distillation column is
stainless steel (grade 316). Type 304 stainless steel may be used in fatty chemical
processing at temperatures up to 150C and Type 316 stainless steel is used above that
temperature (Rice, E.E., 1979). At high temperature, fatty acid are very corrosive to
carbon steel. Type 304 stainless steel is not much more resistant than type 316 stainless
steel. Since the operating temperature is above 300C, stainless steel 316 is the best
suitable for material of construction. The table 3.10 show the general properties of
stainless steel 316.The trade name stainless steel 316 covers a range of nickel,
chromium and molybdenum. The components in stainless steel have the following
functions:
a
Table 3.10 General properties of stainless steel 316 (Source: Davis J.R.,
1994)
43
7.90g/cm3
0.50 kJ/kg.K
1392-1444C
14.6 W/m.K
17.5m/m.K
Density
Specific heat
Melting point range
Thermal conductivity@20C
Coefficient of heat expansion
3.5.10.9.2
Design Pressure
The design pressure normally be 5% to 10% above the normal working pressure to
prevent spurious operation of the relief valve during minor process upsets (Sinnot, R.K.,
2005).
Design pressure, take as 10% above l.4 bar = 1.4 bar x 1.1
= 1.54 bar
= 0.154 N/mm2
3.5.10.9.3
Design Temperature
= 651.2 x 1.1
= 716.3 K
By interpolation from the table 3.11, the maximum allowable stress = 105 N/mm2
Table 3.11
Material
Strength
0-50
(N/mm2)
520
175
Tensile
115
110
Mo 2 percent (316)
3.5.10.9.4
Vessel Thickness
The minimum thickness of column required and other designs are calculated based on
equation below;
t=
Pi D i
( 3.46)
2 SE1.2 Pi
95
44
Therefore, minimum thickness required,
t=
0.154 x 2330
2 x 105 x 11.2 x 0.154
1.71mm
A much thicker wall is needed at the column base to withstand the wind and dead
weight loads. As a first trial, divide the column into five sections, with the thickness
increasing by 2 mm per section. Try 10, 12, 14, 16 and 18 mm.
3.5.10.9.5
The rough estimate of the weight of vessel by using the average thickness 14 mm.
Take
14 103 = 2.344 m
Hw = 26 m
t = 14 mm
45
Weight of plates
Plate area=
2
d=
2
2
4
4 (2.33 ) = 4.26 m
= 46 x 5.11 = 235.06 kN
Insulation
252
235
Insulation
36
Total
523 kN
46
3.5.10.9.6
Wind loading
Take dynamic wind pressure as 1280 N/m2, corresponding to 160kph (100 mph).
Mean diameter, including insulation, Deff = Dc + 2(tshell + tinsulation )
(3.48)
W =P w Deff
(3.49)
M x=
Wx
3.5.10.9.7
3213
x 262=1,085,994 Nm
2
Analysis of stress
Pressure stresses:
L=
h=
Pi D
(3.44 )
4t
Pi D
( 3.50)
2t
w =
wv
(3.51)
( Di +t ) t
3
523 x 10
=3.94 N /mm2 ( compressive)
(2330+18)18
Bending stresses:
47
Do = 2330 + (2 x 18) = 2366 mm
I v=
64
(Do4-Di4)
I v=
(3.52)
b =
M Di
+t (3.53)
Iv 2
b =
( )
14. 04 N /mm 2
The resultant longitudinal stress is
3.54
z L + w b )
15.08
9.96
13.08
9.96
Upwind
Down-wind
48
The greatest difference between the principal stresses will be on the downwind side
(9.96-(-15.08)) =25.04 N/mm2
below the maximum allowable design stress
3.5.10.9.8
c =2 x 10 4
t
N /mm2 (3.55)
Do
( )
c =2 x 10 4
18
( 2366
)=152.16 N /mm
The maximum compressive stress will occur when the vessel is not under pressure =
3.94 +14.04 = 17.98, well below the critical buckling stress. So, the design is
satisfactory.
3.5.10.9.9
Stated that the ends of a cylindrical knows as the closed. There are four common types
of closure in cylindrical vessel:
a) Torispherical head
b) Hemispherical heads
c) Ellipsoidal heads
d) Flat head
Table 3.13
49
(Source: Lawate. S., & Deshmukh, B.B., 2015)
Torispherical head
Hemispherical heads
Ellipsoidal heads
Deeper
Major to minor ratio =2:1
Diagram
Shape
Advantage
3.5.10.9.1
Torispherical head
t=
Strongest shape,
capable of resisting
about twice pressure of
torispherical at same
thickness
0.885 Pi Rc
(3.56)
SE0.1 Pi
Where
t=
Pi D i
(3.57)
4 SE0.4 Pi
t=
0.154 x 2330
4 x 105 x 10.4 x 0.154
0.85 mm
Add corrosion allowance 0.85 + 2 = 2.85 mm 3 mm
50
t=
P i Di
(3.58)
2 SE0.2 Pi
t=
0.154 x 2330
2 x 105 x 10.2 x 0.154
1.71mm
Add corrosion allowance 1.71 + 2 = 3.71 mm 4 mm
3.5.10.9.4
Flat heads
Use a full face gasket C=0.25, De = bolt circle diameter, take as approximately 1.7 m
t=D e
CPi
(3.59)
SE
t=1.7 x 103
0.25 x 0.154
=32.55 mm
105 x 1
Type of head
Torispherical head
Hemispherical head
Ellipsoidal head
Flat head
Minimum thickness, t
5m
3m
4m
35 m
So, an ellipsoidal head would probably be the most economical. The thickness as being
same as the thickness of the wall. From the calculation, it shows the inefficiency of a flat
cover. It would be better to use a flanged domed head.
Vessel Support Design
The method used to support a vessel depends on the size, shape and weight of the
vessel, design pressure and temperature. Since distillation column is vertical vessel,
skirt support is used in this design. The material used to design skirt support is carbon
steel because it has higher strength and the toughness.
51
Type of support
Type of material
: Carbon steel
Design stress
: 135 N/ mm
Youngs modulus
: 200 000 N/ mm
Skirt height
:1m
3.
Approximate weight
( 4 Di H ) g
60)
1,087,537.09 N =1088 kN
Weight of vessel
= 523 kN
523+1088 N
Total weight
1611 kN
3.6.10.1
M S=F w
Bending moment
( HV + HS)
M S=3.21
(3.61)
( 26+3 )2
=1350 kNm
2
52
3.6.10.2
As the first trial, skirt thickness is taken as the same as the thickness of the bottom
section of the vessel, ts = 18 mm.
bs =
4 Ms
[ ( Dv +t s ) t s Do ]
(3.62)
3
1350 x 103 x 10
4
bs=
ws (test )=
Total weight
(3.63)
[ ( Ds +t s ) t s ]
1611 x 103
=12.13 N /mm2
(2330 mm+18 mm)(18 mm)
ws ( operating )=
Weight of vessel
(3.64)
[ ( D s+ t s ) t s ]
523 x 103
=3.94 N /mm2
(2330 mm+18 mm)(18 mm)
s ( compressive )= bs + ws =17.45+3.94=21.39 N / mm2
s ( tensile ) = bs ws =17.453.94=13.51 N /mm2
Take joint factor, J = 0.85
53
13.51<114.75
s ( compressive ) <0.125 E y
t sk
sin
Ds
( )
21.39<0.125 ( 200000 )
(3.66)
18
( 2330
) sin 90
21.39<193
Both criteria are satisfied; adding 2mm for corrosion gives a thickness of 20 mm.
3.6.11 Base ring and anchor bolt design
Assume pitch circle diameter = 2.33 m
Circumference of bolt circle = 2330
Recommended spacing between bolts = 650 mm
Minimum number bolts required, Nb = 2330/650 = 11.26
Closest multiple of Nb = 12
Bending moment at base skirt, MS = 1350 kNm (from previous calculation)
Total weight of vessel, Wt = 523 kN (from previous calculation)
Bolt design stress, fb = 125 N/mm2
The bolt area required is given by:
Ab=
1
Nb f b
4Ms
W (3.67)
Db
4 ( 1350 x 1 03 )
1
Ab=
( 523 x 1 03 ) =2222.76 mm2
(12 x 125)
1.4
Use M64 bolts (BS 4190:1967) root area = 2680 mm2
54
4 Ab
4 x 2222.76
=
=53.2mm
Based on guide rules in selecting the anchor bolt, bolts smaller than 25 mm cannot be
used. So, the bolt root diameter is acceptable (Sinnot, R.K., 2005).
Total compressive load on the base ring per unit length,
Fb =
4Ms
D s
W
(3.68)
D s
2.33 2
4 ( 1350 x 1 03 )
Lb =
Fb 1
x
(3.69)
f c 10 3
Where:
Lb =
( 388 x 1 03 )
5 x 1 03
=77.6 mm
55
Actual bearing pressure on concrete foundation:
f 'c=
Fb
(3.70)
actual width
388 x 10 3
2
=2.92 N /m m
133 x 10 3
Base ring thickness,
tb :
The required thickness for the base ring is found by treating the ring as cantilever
beam. The minimum thickness is given by:
t b=Lr
3 '
f (3.71)
fr c
Where:
'
c
3 x 2.92
=19 mm
140
56
provided below the bottom tray and above the top tray, intermediate should be placed no
farther than 30 feet (15 tray) apart (Stewart and Lewis, 2012).
Figure 3.14
d , optimum=260(8.469)0.52 (844.49)0.37=65.25 mm
Distillate
0.52
d , optimum=260( 4.6361)
0.37
(845.35)
=47.68 mm
Bottom
0.52
d , optimum=260(3.833)
0.37
(843.22)
Table 3.14
=43.24 mm
Stream
d, optimum (mm)
Feed
65.25
d, optimum (in)
2.57
57
Distillate
47.68
1.88
Bottom
43.24
1.70
Figure 3.15
Standard flange
58
Table 3.15
59
Table 3.16
Equipment label
T-100
Equipment name
Distillation column
Maximum diameter
2.33
m
Total height
26
m
Operating temperature
378.2
C
Design temperature
416
C
Operating pressure
1.4
bar
Design pressure
1.54
bar
Material of construction
316 stainless steel Vessel thickness
4
mm
HEAD AND CLOSURE
Type
Ellipsoidal
Thickness
4 mm
VESSEL SUPPORT
Type support
Straight Skirt support
Material of construction
Carbon steel
Design stress
135 N/mm2
Skirt height
1m
Skirt thickness
14 mm
COLUMN WEIGHT
Dead weight of vessel
252 kN
Weight of plates
235 kN
Weight of insulation
36 kN
Wind loading
3213 N/m
ANALYSIS OF STRESS
Pressure stress:
4.98 N/mm2
L
9.96 N/mm2
h
3.94 N/mm2
Dead weight stress , w
14.04 N/mm2
Bending stress , b
BASE RING AND ANCHOR BOLT
Bolt diameter
53.2 mm
No. of bolt
12
Actual bearing pressure
2.92 N/mm2
Base ring thickness
19 mm
PIPE SIZE
Feed
65.25 mm
Distillate
47.68 mm
Bottom
43.24
From summary table of mechanical design, the material construction for distillation
column is 316 stainless steel. The material is selected after considering the degree of
60
the corrosion and design temperature that take place in the distillation column.
Ellipsoidal head is selected because it is the most economically than torispherical and
hemispherical head. Skirt support is used for tall, vertical distillation column. A column
must be designed to withstand the highest wind speed that is likely to be encountered at
the site during the life of the plant.
REFERENCES
61
Davis J.R., (1994). Stainless steel. ASM International
Geankoplis C.J., (2003). Transport Processes and separation process principles. Prentice
Hall
Henley, E. J., Seader, J. D. (1981). Equilibrium-stage separation operations in chemical
engineering, New York, John Wiley & Sons.
Lawate S., Deshmukh., B.B.,(2015). Analysis of heads of pressure vessel. International
Journal of Innovative Research in Science, Engineering and Technology, 4(2), 759765
Luyben W.L., (2005) .Process Modelling, simulation and control for chemical engineer.
McGraw Hill
Rice, E.E., (1979). Material of construction in the fatty acid industry. Journal of the American
Oil Chemists Society, 56 (11), 754A758A
Sinnot R.K., (2005). Coulson & Richardsons Chemical Engineering, Chemical Engineering
Design. Butterworth Heinemann
Stewart, M. & Lewis, O.T., (2012). Pressure Vessels Field Manual: Common Operating
Problems and Practical Solutions. Gulf Professional Publishing
Turton R., Bailie R. C., Whiting W.B., (2009) Analysis, Synthesis and Design of Chemical
Processes. Pearson Education International