3.2.

3 Mechanical Design of Separator

3.2.3.1

Design Pressure

It is known that the design pressure must be designed to withstand the maximum
pressure to which it is likely to be subjected in operation. The design pressure is
normally taken as the pressure at which the relief device is set. This will normally
be 5 to 10% above the normal operating pressure (Sinnot and Towler,2009).
Therefore, the design pressure

Pi

will operate 10% above the operating

pressure as a safety factor.

Operating pressure = 1atm = 1.013bar

Pi=1.1 x 7.90
Pi=8.69
Pi=0.869 N /m m2
Design Temperature = 105 C
105 C = 378K; at 378K, Maximum Allowable Design Stress is 16.48ksi by doing
interpolation (from Table 3.21)
Temperature (K)
300
378
500

Maximum Allowable
Stress
15.0
14.2
12.9

15.0x 300378
=
x 12.9 378500
14.18 ksi

S, Maximum Allowable Design Stress

N
mm2
1 ksi

6.8948
14.18ksi X

= 97.77

N
mm2

E, Welding Efficiency = 1

3.2.3.2

Material for Construction

The process chemicals which deal with nitric acid and sulfuric acid solution are
corrosive chemical. Hence, according to Sinnot and Towler (2009) the most
suitable material use to construct the separator is stainless steel 304 which it is
highly corrosive resistance.

3.2.3.3 Maximum Allowable Design Stress

According to Table 3.21, the typical maximum allowable design stress,S after
being interpolate at 105oC (378K) for Stainless Steel 304L is 14.18ksi (97.77

N
mm2 ).

Table 3.21 Typical Maximum Allowable Stresses

3.2.3.4

Minimum Wall Thickness, t

In order to ensure that vessel is sufficient to rigid to withstand its own weight and
any incidental load, there will be a minimum wall thickness. According to Sinnot
and Towler, 2009,the minimum thickness equation is :

t=

P i Di
2 SEPi

................................................................................

(3.2.23)
where,
t

= minimum thickness of the plate required

Pi

= internal pressure, 0.869 N/mm2

Di

= internal diameter, 1190 mm

= design stress, 97.77 N/mm2

= Joint efficiency,1

N
(74.9 mm)
2
mm
t=
=0.33 mm
N
N
2 97.77
(1 ) 0 . 869
2
2
mm
mm

0 . 869

Taking into consideration that the corrosion allowance is 2mm

t=0.33m m+ 2 mm = 2.33

3 mm

3.2.3.5 Head and Closure

There are several types of head and closure of a cylindrical vessel including
hemispherical, ellipsoidal, torispherical and flat plate. According to Sinnot and
Towler (2009), the most suitable head and closure for vassel in which the the
operating pressure less than 15 bar is torispherical and ellipsoidal head. Since the
operating pressure is 5 bar both of it were chose to be compared with.

Figure 3.1: Domed heads. (a) Hemispherical. (b) Ellipsoidal. (c) Torispherical

a)

Ellipsoidal Head

The calculation of minimum thickness of ellipsoidal head was based on equation

below:

t=

P i Di
2 SE0.2 Pi

................................................................ (3.2.24)

N
0 . 869
(74.9 mm)
(
mm )
t=
=0.33 mm
N
N
2 97.77
( mm )(1)0.2(0 . 869 mm )
2

Taking into consideration that the corrosion allowance is 2mm

t=0.33 mm+2 mm = 2.33

b)

3 mm

Torispherical Head

The calculation of minimum thickness of torispherical head was based on

equation below:

t=

0.885 Pi Rc
2 SE0.2 Pi

.......................................................................... (3.2.25)

Where:

74.9 mm

Crown Radius, Rc = Di =

N
(74.9 mm)
mm2
t=
=0.295 mm
N
N
2 97.77
(1)0.2 0 . 869
2
2
mm
mm

0.885 0 . 869

Taking into consideration that the corrosion allowance is 2mm

t=0.295 mm+2 mm = 2.295mm

3.2.3.6
a)

3 mm

Dead weight of Vessel

Weight of Shell

,WV

For preliminary calculation the approximate weight of a cylinder steel vessel with
domed end, and uniform wall thickness can be calculate by using the following
equation:

W V =240 CW D M ( H V + 0.8 D M ) t

............................................. (3.2.26)

Where:

The average wall thickness, t

This value is calculated based on 5 separated section where build up by
adding 2mm, from vessel minimum thickness as a much thicker wall will be
needed at the column base to withstand the wind and dead weight load.

t=

3+ 5+7+9+11
5

t=7 mm @0.007 m
The mean diameter of vessel, DM

DM =Di+ t
DM =0.0749 m+ 0.007 m
DM =0.0819 m

A factor, Cw
Take 1.08 for vessels with only a few internal fittings.

b)

Height or length between tangent lines, Hv

Take 2.685 m as the height (as calculated in chemical design section)

Therefore,

W V =240 ( 1.08 ) 0.0819 m ( 2.685 m+0.8 (0.0819 m) ) 7 mm

W V =408.73 N @0.409 kN

3.2.3.7 Weight of Insulation,

Wi

Generally, all equipment in the contact section of an acid plant is insulated for
the purpose of heat conservation and process temperature maintenance.
Insulating material : Mineral wool
Mineral wool density

: 130 kg/m3

Insulation thickness

: 70mm (Harish, 2011)

a)

Approximate volume of insulation,

V i= Dv H v t i

Vi

..................................... (3.2.27)

V i= ( 0.23 m )( 2.685 m )( 0.07 m)

V i=0.1358 m

b)
Weight of insulation
W insulator =i g V i

W insulator = 12.72

kg
m
9.81 2 (0.1358 m3)
3
m
s

)(

W insulator =16.95 N

c)

Coupling weight for fittings,

W i=2 x W insulator

Wi

................................................... (3.2.28)

W i=2 x 16.95 N
W i=33.89 N @0.0339 kN

3.2.3.8.

Weight of Demister,

Wd

Stainless steel 304L wire mesh is selected as material of construction of demister

pad due to its excellent resistance against acid, alkali, heat and corrosion.

a)

Approximate volume of demister pad,

D

( d 2)t d

V d =( )
4

............................................................ (3.2.29)

Where:

Dd =Diameter of demister pad , 1.04m

t d=Height of demister pad , 0.15m

0.23 m
( 2)0.15 m

V d =( )
4

Vd

V d =0.027 m

b)

Weight of demister pad,

W d =d V d g

Wd

.................................................................................. (3.2.30)

W d =( 7850 ) (0.027) ( 9.81 )

W d =2079.23 N @ 2.08 kN

c)

W Total

Total Vessel Weight,

W Total =W V

Wi

W Total =0.409 kN

Wd

................................................. (3.2.31)

0.0339 kN

2.08 kN

W Total =2.523 kN

3.2.3.9

Wind Load

A vessel must be designed to withstand the weight bending stress cause by the
highest wind speed that is likely to be encountered at the site during the life of
the plant. For a preliminary design, a wind speed of 160km/h can be used
equivalent to wind pressure PW, 1280N/m2.

a)

Mean diameter, Dm
t

insulator+
t wall average )
+2(
D m=D v

...................................... (3.2.22)

D m=0.23 m+(0.07 m+ 0.007 m)

Dm=0.307 m

b)

Loading (per linear meter), Fw

F w =Pw D m ................................................................. (3.2.23)

F w =1280 N /m x 0.307 m
F w =4169.38 N /m

c)

Bending moment, Mx
Hv
( 2)
F
M x =( w )
2

........................................................ (3.2.24)

2.685 m
( 2)
4169.38 N / m
M x =(
)
2

M x =5597.39 N . m

3.2.3.10 Analysis of the Stresses

The stress analysis of separator is analyzed to determine the stress exert on a
body vessel. This section will show the analysis of primary stress, dead weight
stress, bending stress and resultant and longitudinal stress.

a)

Longitudinal,

and Circumferential Pressure Stress,

Longitudinal pressure stress,

Use the maximum thickness

h=

Pi D i
2t

............................................................................. (3.2.25)

N
0.869
(0.0749 m)
(
mm )
=
2

h =4.65

2( 0.007 m)

N
mm2

Circumferential Pressure Stress,

 L=

Pi Di
4t

....................................................................... (3.2.26)

N
0 . 869
( 0.0749 m)
(
mm )
=
2

4 (0.007 m)

L =4.65

b)

N
mm2

Dead Weight Stresses,

It is a direct stress due to the weight of the vessel, its content and any
attachment. The weight dead stress is significant compared to the other stress.

D
( i+t) t
W
W= v

W =

.................................................... (3.2.27)

408.73 N
(74.9mm+ 7 mm)7 mm

W =0.713 N /mm2

c)

Bending Stresses,

Bending moment is a vital in stress analysis as this stress will cause by the wind
load of tall self supported vessels, dead weight and wind loading on piping and
equipment

Outer Diameter, Do

Do=Di +2 t ...................................................... (3.2.28)

D o=0.0749m+2(0.007 m)

Do=0.0899m @89.9 mm

Second Bending Moment,

Do
4
( 4Di )

I v=
64

Iv

..................................................... (3.2.29)

89.9 mm
( 474.9 mm 4)

I v=
64
10

I v =0.74 x 1 0 mm

Bending Stresses,

b =

Mx
Iv

D
(
( ) 2 +t )
i

................................................... (3.2.30)

7487.29 x 10 3 N . m 74.9 mm
b =
+7 mm
2
0.47 x 1 010 mm4

)(

b = 0.071 N /mm2

d)

The resulted longitudinal stress,

z= L + w b

...................................................... (3.2.31)

where w , is compressive and therefore negative value

z (upwind ) = 4.65

N
N
N
0.713
+ 0.071
=5.434 N /m m2
2
2
2
mm
mm
mm

)(

z ( downwind ) = 4.65

)(

N
N
N
0.713
0.071
=3.866 N /m m2
2
2
2
mm
mm
mm

)(

)(

The difference between the principles stresses will be on the down-wind side:

difference = h z (downwind)

.................................. (3.2.32)

difference =(5.4343.866) N /mm

difference =1.568 N /mm2

Because of this value smaller than design stress, 112.38 N/mm 2 it means the
design is satisfactory.

e)

Critical Elastic Stability,

The critical buckling stresses are given as:

t
Do

7 mm
89.9 mm

c = 2 x 1 04 x

c = 2 x 1 04 x

............................................................. (3.2.33)

c =1557.29 N /m m2

The maximum compressive stress will occur while the vessel is not under
pressure;

w b =

( 0.713+ 0.071 ) N
=0.784 N /mm2
2
mm

resulting a value which is less than critical buckling stress, thus the design is
acceptable.

3.2.3.11.

Vessel Support

Type of support used usually depends on the orientation of the vessel. There are
some factors need to be considered during the support design including the
weight of the vessel and contents, and any superimposed loads. The support
design also must have easy access to the vessel and fitting for maintenance and
inspections (Sinnot and Towler, 2009). In this design, the skirt support are
recommended as the vertical vessels support because this type of support are
the most economical (Brownell and Young, 1959) and they do not impose
concentrated loads on the vessel shell (Sinnot and Towler, 2009).
Type of Support

: Straight cylindrical skirt

Base angle of a conical skirt, s

Material of Construction

: 90
: Stainless steel 304

Design Stress

: 137.9 N/mm2 at ambient temp. 20 C

Youngs Modulus

: 193000N/mm2

Approximate Skirt Weight, W

a)

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

W =

Approximate Weight, W

2
D H g
64 i l v

................................................... (3.2.34)

0.23 m
1000 kg
9.81 m
( 2)
( 2.685 m ) (
)
3
2
m
s

W =
64

W =297.38 N @ 0.297 kN

W total

Total Weight,

W total=W v +W

........................................................... (3.2.35)

W total =0.409 kN +0.297 kN

W total=0.706 kN

Bending moment of the skirt base,

H
1
F w ( v+ H s)
2

M s=

Ms

................................................................. (3.2.36)

where

Hs

is the skirt height, and take its value as 1m height

1

4169.38 N / m(2.685 m+1 m)

M s=
2

M s=7682.08 Nm @7.682 kN

Bending stresses in skirt,

bs

As first trial, take skirt thickness,ts as the same as bottom of vessel,7mm

bs =

bs =

4Ms
( D i +t s ) ( D i t s )

............................................................. (3.2.37)

4(7682.08) Nmm
( 61 mm+7 mm ) ( 61mm x 7 mm )

 bs =0.34 N /mm

ws =

Dead Weight in the Skirt,

W
( Di + t s) ( t s )

ws (test )=

ws

................................................................ (3.2.38)

25.40 kN
( 61mm+7 mm )( 7 mm )

ws (test )= 0.017N/ mm2

ws (operating)=

35.16 Nx 103
( 61 mm+7 mm ) ( 7 mm )

ws (operating)= 23.51N/ mm2

Resulting the maximum stress in the skirt,

Maximum , s (Compressive )= ws ( test ) + bs

Maximum , s (Compressive )=0.017 N /m m2+ 0.34 N /mm2
Maximum , s (Compressive )=0.357 N /m m

Maximum , s (Tensile )= bs ws (operating)

2

Maximum , s (Tensile )=0.34 N /m m 23.51 N /mm

Maximum , s (Tensile )=23.17 N /mm2

Take the joint efficiency E as 1.Cateria for design:

Maximum , s (Tensile )< S s E sins

23.17 N
<137.9 ( 1 ) sin 90
2
mm
23.17<137.9

.......................................... (3.2.39)

Maximum , s (Compressive ) <0.125 E y (

ts
) sin s
Ds

0.357 N /m m2 <0.125(193000 N /m m2)(

7 mm
) sin 90
61mm

0.357<2768.44

Both criteria are satisfied, add 2mm for corrosion, and give the design thickness,

t s=7+2=9 mm

3.2.3.12.

Pipe Size Selection for Nozzle

Optimum diameter for the pipe can be calculated using the following equation
below.

D opt =226 G0.5 0.35

.................................... (3.2.40)

Where,

Dopt =Optimum Diameter

G=Flow Rate , kg/s

Density , kg /m3

Feed inlet nozzle sizing

The calculation for the theoretical diameter of inlet nozzle, D 1 is:

mix=

mix=

W l +W v
Ql +Qv

.............................................................. (3.2.41)

( 317.38+303.95 ) kg /hr
3
m
0.0086
x 3600 s
s

mix=20.068

kg
m3

The calculation of feed pipe optimal diameter is:

Dopt =0.226 G 0.5 mix0.35

Dopt =( 0.226 ) ( 390.18 /3600 0.5 ) (20.0680.35 )
Dopt =0.023 m

Gas outlet nozzle sizing

The calculation of gas outlet optimal diameter is:

Dopt =0.226 G0.5 v 0.35

D opt =( 0.226 ) ( 390.18 /3600 0.5 ) (9.9370.35)
D opt =0.033 m

Liquid outlet nozzle sizing

The calculation of gas outlet optimal diameter is:

0.5

0.35

Dopt =0.226 G l

Dopt =( 0.226 ) ( 390.18 /3600 0.5 ) (931.80.35)

Dopt =0.0068m

3.2.3.13.

Standard Flange

Standard flanges will be specified for most applications. Standard flanges are
available in a range of types, sizes and materials and are used extensively for
pipes, nozzles and other attachments to vessels body. Flanges used in this design

were chosen from the standard flanges. The standard flanges are adapted from
Standard Flanges of Steel welding neck flange.

Table 3.22: The standard flanges are adapted from Standard Flanges of Steel
Pipe
A
B
C

3.2.3.14.

Feed Inlet
Gas Outlet
Liquid Outlet

D optimum
(mm)
26
29
29.4

Nominal Size
Use
30
30
30

Manways for Column Access

Manholes are design for entrance into vessel column. It should be position so that
it can be accessed to the internal parts of the column. It should be sufficiently
large to allow workers to rapidly climb out through them without cutting
themselves. According Rahimi (2011), normally manway is 0.6m. therefore, in
this separator design we take 0.03m as manways diameter.

Table 3.23: Mechanical Design for Separator

Pressure Vessel
Operating Pressure, Po
0.790 N/mm2
Design Pressure, P1
0.869 N/mm2
Operating Temperature
105oC
Design Temperature
816 oC
Column Material
Stainless Steel 304
Safety Factor
10%
Design Stress
97.77N/mm2
Head and Closure
Types
Torispherical Head
Crown Radius, Rc
0.749 m
Joint Factor, J
1
Minimum thickness, e
3 mm
Column Weight
Dead weight of Vessel, Wv

0.409 kN

Weight of Insulation, Wi

0.0339 kN

Weight of Demister,Wd

2.08 kN

Total Weight, Wt

2.523 kN

Bending Moment, Mx

5597.39 N . m

Insulation Material
Insulation Thickness

Mineral Wool
70 mm

Skirt Support
Type of Support
Straight Cylindrical Skirt
Material of Construction
Stainless Steel
Youngs Modulus
193000N/mm2
Bending Moment, Mx
Skirt Thickness, ts
Skirt Height, Hs

7.682 kN
7 mm
1m