Plant Design Project II

FINAL YEAR DESIGN PRO1ECT

DESIGN OF 202,000 TONES PER ANNUM
ETH!ENE O"IDE P!ANT
GROUP NO #$
SHEET %&'#
(O) *ODE
DESIGNER
+UMARAGURU
A&!
GUNASEGARAN,
GURU-
DETAILED DESIGN OF
MA1OR EQUIPMENT
ETHYLENE OXIDE PURIFIER COLUMN
C-702
PREPARED ). +UMARAGURU A&! GUNASEGARAN
DO*
NO
DES*RIPTION PREPARED )
RE/IE0ED
)
DATE
0% INTRODU*TION GURU 2#&0$&01
02 PRO*ESS DESIGN GURU 2#&0$&01
0# ME*HANI*A! DESIGN GURU 2#&0$&01
0$
SPE*IFI*ATION SHEET 2 DETAI!ED
DRA0ING
GURU 2#&0$&01
03 *OSTING GURU 2#&0$&01
04
OPERATING MANUA! ,START
UP&SHUTDO0N-
GURU 2#&0$&01
0' REFEREN*ES GURU 2#&0$&01
TABLE OF CONTENT
1 GENERAL DESCRIPTION
%
Plant Design Project II
%5% Process Descri6tion775755555555555555555555555555555555555555555555555555555555555553
%52 Selection *riteria 8or P9ri8ier *ol9:n7775777777774
%5# Design Met;o<olog=755555555555555555555555555555555555555555555555555555555555555555555'
2 PROCESS DESIGN OF ETHYLENE OXIDE PURIFIER COLUMN
25% M9lti>co:6onent Distillation 77777777777777551

252 Si?ing o8 *ol9:n Internals77777777777575777%'
3 MECHANICAL DESIGN
#5% Selection o8 Material o8 *onstr9ction 77777777777#'
#52 *o:@ine< !oa<ing on /essel 777757777777777$0
#5# 0in< !oa<ing7777777777777557577775755$#
#5$ Anal=sis o8 Stresses 777777777777777777$#
#53 /essel SAirts an< S966ort757777777777777755$3
#54 Design o8 Flanges7777777777777777557755$B
#5' Flange 8or Man;oles777777777777777775555$1
#5B Design o8 No??les7777777777777777575753$
4 SPECIFICATION SHEET AND DRAWING(S)
$5% S6eci8ication S;eet 7777777777777777755 4%
$52 Tec;nical Engineering DraCing 77777777777754#
5 COSTING 77777777557777777777777777775554$
6 OPERATING MANUAL (START UP/SHUTDOWN)77777777754B
7 REFERENCES777777777777777777757775575755'2
8 APPENDIX777777777777777777777755577755555'#
LIST OF TABLES
2
Plant Design Project II
Ta@le %. Distri@9tion o8 *o:6onent
Ta@le 2. Antoine Para:eters
Ta@le #. DeC Point *alc9lation ,Distillate--
Ta@le $. )9@@le Point *alc9lation ,)otto:-
Ta@le 3. )9@@le Point *alc9lation ,Fee<-
Ta@le 4. Tra= Pro8ile In8or:ation 8ro: i*ON
Ta@le '. S9r8ace Tension 8or eac; *o:6onent
Ta@le B. )olt Si?e
Ta@le 1. )olt Si?e
Ta@le %0. )olt Si?e
Ta@le %%. )olt Si?e
LIST OF FIGURES
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Plant Design Project II
Fig9re %. Design Met;o<olog= 8or P9ri8ier *ol9:n *>'02
Fig9re 2. E@@ar Ma<<oD *orrelation
Fig9re #. Floo<ing Eelocit= ,R. K. Sinnott, 1993-
Fig9re $. Selection o8 !iF9i< FloC Arrange:ent ,RK Sinnott, 1993-
Fig9re 3. 0eir lengt; correlation ,RK Sinnott, 1993-
Fig9re 4. 0ee6 Point *orrelations
Fig9re '. Disc;arge *oe88icient SieEe Plates
Fig9re B. Entrain:ent *orrelation 8or SieEe Plates
Fig9re 1. Relation @etCeen Angle S9@ten<e< @= *;or<, *;or< Heig;t an< *;or< !engt;
Fig9re %0. Trial !a=o9t
Fig9re %%. DoCnco:er )acA96
Fig9re %2. Met;o<olog= 8or Mec;anical Designs
Fig9re %#. Toris6;erical Diagra:
Fig9re %$. Elli6soi<al Diagra:
Fig9re %3. P9rc;asing *ost o8 /ertical *ol9:ns
Fig9re %4. P9rc;ase< *ost o8 Tra=s in Tra= *ol9:n
Fig9re %'. Installe< *ost o8 /ario9s In<9strial Ins9lations 8or *ol9:ns, ToCers an< TanAs5
$
Plant Design Project II
1.0 INTRODUCTION
1.1 General Description
Et;=lene ODi<e P9ri8ier *ol9:n, *>'02 ;aEe @een selecte< in t;is <etaile< <esign
since it is t;e 8inal :ajor 9nit o6erations 9se< in t;e Et;=lene ODi<e 6ro<9ction 6lant5
)asicall=, t;e 89nction o8 t;is <istillation col9:n, *>'02 is to recoEer Et;=lene ODi<e 8ro:
Cater5
T;e entire @otto: 6ro<9ct 8ro: *>'02, C;ere t;e :ajor co:6onent is Cater, Cill @e
sent to t;e Caste Cater treat:ent5 T;e to6 6ro<9ct C;ic; is Et;=lene ODi<e is recoEere< an<
sent to storage tanA
SieEe tra= :et;o< ;as @een selecte< to <esign t;e <istillation col9:n5 )ase< on t;e
calc9lations res9ltsG t;ere are 20 tra=s in t;e col9:n to ac;ieEe< t;e <esire< 6ro<9ct F9alit=
Cit; t;e ass9:6tions o8 $1 H tra=s e88icienc=5 T;e ;eig;t o8 col9:n is %353 : Cit; inner
<ia:eter o8 05B4 :5 Stainless steel is c;osen as t;e <esign an< tra= :aterial as t;e :ost cost>
saEing :aterial co:6are< to ot;er :aterial5
3
Plant Design Project II
1.2 Selection Criteria
)e8ore t;e 6roject is carrie< o9t, st9<ies an< researc;es ;aEe @een con<9cte< in
consi<ering a 8eC alternatiEes s9c; as t;e se6aration :et;o< an< ot;er 6ossi@le alternatiEes5
T;e j9sti8ications o8 eac; selection are state< in t;is c;a6ter5
1.2.1 Separation Method Selection
Distillation :et;o< is c;osen <9e to it a@ilit= to 6ro<9ce a 6ro<9ct Cit; ;ig; 69rit=
as state< in o9r clientIs reF9ire:ent5 Distillation 6rocess can also ;an<le a Ci<e
range o8 t;ro9g;69t, C;ereas :an= ot;er alternatiEes can ;an<le onl= loC
t;ro9g;69t5 T;e a@ilit= o8 <istillation 6rocess to ;an<le a Ci<e range o8 8ee<
concentrations is also a 6l9s 6oint since o9r 8ee< consists o8 :9lti>co:6onent
:iDt9re5
1.2.2 Justification for Tray Column
Accor<ing to *o9lson an< Ric;ar<sonIs j9sti8ications, tra= col9:ns generall=
6roEi<e satis8actor= o6eration oEer a Ci<e range o8 liF9i< an< Ea6or loa<ings5 T;e
Ea6or an< liF9i< rates can Ear= in<e6en<entl= oEer a @roa< range an< t;e col9:n can
o6erate satis8actoril=5 T;9s, it is c;osen 8or o9r <istillation col9:n eF9i6:ent5
1.2.3 Justification of Sieve Tray
SieEe tra= ;as t;e a<Eantages o8 loCest relatiEe cost ,si:6lest constr9ction-, loCest
6ress9re <ro6, an< increase< ca6acit= 8or a giEen toCer <ia:eter5 Alt;o9g; t;e sieEe
tra= generall= ;as ;ig;er ca6acit=, its :ain <isa<Eantage is t;at it is s9sce6ti@le to
Cee6ing or <9:6ing o8 liF9i< t;ro9g; t;e ;oles at loC Ea6or 8loC rate an< its
t9rn<oCn ca6acit= is li:ite<5
Deter:ination o8 o6ti:9: o6erating region, i5e5 :aDi:9: an< :ini:9: Ea6or an<
liF9i< loa< is cr9cial to ens9re sa8e col9:n o6eration an< aEoi< con<ition s9c; as
8loo<ing, Cee6ing an< entrain:ent5
4
Plant Design Project II
1.2.4 Reboiler Selection
+ettle re@oiler is a<o6te< 8or a66lication <9e to t;e ease o8 control an< no tCo 6;ase
8loC or circ9lation o8 liF9i< t;ro9g; t;e eDc;anger is reF9ire<5 !iF9i< 8ro: t;e
@otto: tra= is graEit= 8e< to t;e re@oiler 8ro: a <raC o88 on t;e @otto: o8 t;e tra=5 A
Ceir :aintains t;e liF9i< leEel in t;e re@oiler s9c; t;at t;e t9@e @9n<le is alCa=s
s9@:erge<5 T;e Ea6or is 6i6e< @acA to t;e col9:n to 6roEi<e stri66ing Ea6or 8or t;e
@otto: tra=5 D9e to t;e Ea6or <isengage:ent reF9ire:ent, Aettles are constr9cte<
Cit; as eD6an<e< s;ell5
1.2. Condenser Selection
T;e selection o8 a 6artial or total con<enser is 8iDe< @= t;e reF9ire:ent o8 t;e
oEer;ea< 6ro<9ct5 A total con<enser is 9se< 8or a liF9i< 6ro<9ct an< a 6artial
con<enser 8or a Ea6or 6ro<9ct5 HoCeEer, t;e liF9i< 6ro<9ct can @e 6ro<9ce< as a
Ea6or an< s9@seF9entl= coole< to 6ro<9ce a liF9i< 6ro<9ct5 In t;e <esign o8 t;e
Et;=lene ODi<e 69ri8ier col9:n ,*>'02-, t;e total con<enser is a<o6te< as it is
econo:icall= attractiEe, as t;e cost o8 6artial con<enser relatiEel= :ore eD6ensiEe
since it Cill ;aEe to @e co:6ensate< against t;e cost o8 a<<itional <oCnstrea:
eF9i6:ent s9c; as a<<itional cooler5
'
Plant Design Project II
1.3 Design Methodology
In <esigning t;e Et;=lene ODi<e 69ri8ier col9:n ,*>'02-, C;ic; is a @inar=
<istillation col9:n, a s=ste:atic 6roce<9re Cas i:6le:ente<5 Fig9re % @eloC s9::ari?es
t;e :et;o<olog= in <esigning t;e <istillation col9:n5
Figure 1: Design Methodology for Purifier Column C-!"
Step 1
Pre6aring i*ON si:9lation o8 t;e oEerall 6lant 6rocess
Step 2
Select t=6es o8 <istillation col9:n, re@oiler an< con<enser to @e 9se<5
Step 3
*alc9late t;e col9:n o6erating con<ition J @otto: @9@@le 6oint, oEer;ea<
<eC 6oint an< 8ee< @9@@le 6oint
Step 4
Pre6are a 6reli:inar= 6rocess <esign to <eter:ine Re8l9D Ratio an<
N9:@er o8 Tra=
Step
*alc9late t;e col9:n o6erating region @= 9sing Stic;l:air an< Fair
:et;o< to 6reEent 96set insi<e col9:n s9c; as 8loo<ing an< ot;ers
Step !
*alc9late t;e <i:ension o8 t;e *>'02 <istillation col9:n
Step "
Pre6are t;e tec;nical engineering <raCing,s- an< tra= col9:n
s6eci8ication s;eet
Step #
Per8or: start 96 an< s;9t <oCn 6roce<9res 8or *>'02
B
Plant Design Project II
T;is section 6resente< <etaile< 6rocess <esign o8 Et;=lene ODi<e 69ri8ier col9:n C;ic;
incl9<es <eter:ination o8 col9:n o6erating 6ara:eters an< si?ing o8 col9:n internals5
2.0 PROCESS DESIGN OF ETHYLENE OXIDE PURIFIER COLUMN
(C-702)
2.1 MULTI-COMPONENT DISTILLATION
2.1.1 Determination of Column Operating Condition
To esti:ate t;e <eC an< @9@@le 6oints, it is ass9:e t;at not;ing ;eaEier t;an ;eaE= Ae=
a66ears at <istillate an< not;ing lig;ter t;an lig;t Ae= in @otto:5 T;e s9::ar= o8
co:6onent <istri@9tion is as @eloC.
Ta@le %. Distri@9tion o8 *o:6onent
Component Feed Mole
fraction
Distillate
flow
(kmol/h)
Mole
fraction
Bottom
flow
(kmol/h)
Bottom
Et;=lene Gl=col 135B3B3 050'31 05%#$B4 050022 135'2#4$ 05114##
0ater 05B'2B %500E>%00 05B'2'1 %500E>%00 254%E>04 25'2E>0B
Generall=, <eC an< @9@@le 6oints are esti:ate< 9sing t;e 8olloCing eF9ations.
)9@@le Point .
0 5 %
i i i
# K y
77777775,EF5F>%-
DeC Point .
0 5 % &
i i i
K y #
777777555,EF5F>2-
K
i
is t;e Ea6or>liF9i< eF9ili@ri9: constant or <istri@9tion coe88icient 8or co:6onent i5 T;e
eF9ili@ri9: <ata are o8ten re6resente< @=,
P P K
i i
&
C;ere P
i
is 6artial 6ress9re o8 eac;
co:6onent <eter:ine< @= Antoine EF9ation an< P is col9:n o6erating 6ress9re5
Antoine EF9ation.
C K $
%
& P

+
- ,
log
7777555 ,EF5F>#-
0;ere,
A, ), * K Antoine 6ara:eters
T K Strea: te:6erat9re in +elEin
1
Plant Design Project II
Ta@le 2. Antoine Para:eters
No5 *o:6onent Antoine *oe88icients
A ) *
% Et;=lene Gl=col B5410%4 20035'B ##$5''
2 0ater '5144B% %44B52% 22B500
T;ere are onl= tCo signi8icant co:6onents 8e< to EO 69ri8ier C;ic; are Et;=lene ODi<e an<
0ater5 Ot;er co:6onents are negligi@le an< can @e ignore<5 *ol9:n 6ress9re is taAen as
%%30 APa ,at re@oiler-5T;e <eter:ination o8 @9@@le 6oint at @otto: an< 8ee< ,sat9rate<
liF9i<- an< <eC 6oint o8 <istillate ,sat9rate< Ea6or- is @= trial an< error to satis8= EF9ation %
an< 25
Table 3: Bubble Point Calculation (Feed)
8ee< te:6erat9re,L*- B453
8ee< 6ress9re,APa- %0B0

Component log P`
P`(mmhg
) P`(KPa) Ki
Composition(Xi
) KiXi oi,HK
Et;=lene ODi<e
#512B
B B$BB5403B
%%#%5'2%
0
%50$'
1 0512#$
05041
' %B5$43%
0ater
25442
3 $315'%%B 4%52B11
05034
' 050'31
05032
1 %50000
Table 4: Dew Point Calculation (Distillate)
<istillate te:6erat9re,L*- B25B
%0
Plant Design Project II
<istillate 6ress9re,APa- %030

Component log P`
P`(mmhg
) P`(KPa) Ki Composition(yi) Yi/Ki oi,HK
Et;=lene ODi<e
#5BB4
4 ''025'4'2
%024513%
2
051'B
0 0511B2
%50%1
1 '5342$
0ater
25311
# #1'530%' 3251131
05030
3 050022
050$#
4 %50000
Table 5: Bubble Point Calculation (Bottom)
@otto: te:6erat9re,L*- %B%5#
@otto: 6ress9re,APa- %%00

Component log P` P`(mmhg) P`(KPa) Ki
Composition(Xi
) KiXi oi,HK
Et;=lene ODi<e
$5B0#
3
4#40#5$1'
#
B$'15'4B
1
'5'0B
1 0500#4
0502'
B %5%3B'
0ater
#5B1%
0 ''B%5%1B4
%0#'5$0'
B
051$#
% 05114$
051#1
' %50000
2.1.2 Minimum Number of Stages (Fenske Equation)
FensAe eF9ation is 9se< to esti:ate t;e :ini:9: stages reF9ire< at total re8l9D5 T;e relatiEe
Eolatilities are esti:ate< at t;e 8ee< @9@@le 6oint, C;ic; giEes a ro9g; in<ication o8 t;e
aEerage col9:n te:6erat9re5 T;e FensAe eF9ation is re6resente< as.
'K
(
'K
)K
d
)K
'K
#
#
#
#
*
log
log
:in
1
]
1

1
]
1

'K
(
'K
)K
d
)K
'K
#
#
#
#
*
log
log
:in
1
]
1

1
]
1

7777775 ,EF5F>$-
1 B 5 B
:in
*
%%
Plant Design Project II
0;ere,
N
:in
K :ini:9: n9:@er o8 stages at total re8l9D
M
!+
K aEerage relatiEe Eolatilit= o8 t;e lig;t Ae= Cit; res6ect to t;e ;eaE= Ae=
K ,M
to6
M
@otto:
-
%&2
K 251402
D
!+,
D
H+
K lig;t an< ;eaE= Ae= concentrations
2.1.3 To Estimate the Minimum Reflux Ratio, R
min
T;e :ini:9: re8l9D ratio is a g9i<e in c;oosing a reasona@le re8l9D ratio 8or an
o6erating col9:n an< in esti:ating t;e n9:@er o8 6lates nee<e< 8or a giEen se6aration at
certain Eal9es o8 t;e re8l9D ratio5 Accor<ing to M+C,(e, Smith ,nd ),rriott -"!!1., t;e
<esire< se6aration 9s9all= re8ers to t;e a:o9nt o8 lig;t Ae= recoEere< in t;e <istillate an<
t;e a:o9nt o8 ;eaE= Ae= recoEere< in t;e @otto:s5 Ass9:ing 11 H lig;t Ae= recoEere<
in t;e <istillate an< 11 H ;eaE= Ae= recoEere< in t;e @otto:s5
R
min
J T;e :ini:9: re8l9D ratio
/ /al9e 8or Eario9s 8ee< con<itions.
!iF9i< @eloC @oiling 6oint ,/ N %-
!iF9i< at @oiling 6oint ,/ K %-
!iF9i< O Ea6or ,0 P / P %-
Sat9rate< Ea6or ,/ K 0-
Since 8ee< is Ea6or at @oiling 6oint, t;ere8ore / K05
For sat9rate< Ea6or, 9n<erCoo<Is eF9ation 8or t;e :ini:9: re8l9D ratio is.>
( ) ( ) %
%
%
% & %
:in

1
1
]
1

,
_

f
D
f
D
y
#
y
#
R

7777775 ,EF5F>3-

( ) ( ) %
0512#$ %
0511B2 %
0512#$
0511B2 1402 5 2
% 1402 5 2 & %
:in

1
]
1

,
_

R
R
min
K 05'3%1
%2
Plant Design Project II
2.1.4 To Estimate the Optimum Reflux Ratio,R and the Ideal Number of
Stages,$
An i:6ortant s;ortc9t :et;o< to <eter:ine t;e t;eoretical n9:@er o8 stages reF9ire<
8or an o6erating re8l9D ratio, R is t;e e:6irical correlation o8 0r(,r ,nd M,ddo#
giEen in Fig9re %5 In Fig9re %, t;e o6erating re8l9D ratio R is correlate< Cit; t;e
:ini:9: R
min
o@taine< 9sing 1nder2ood :et;o<, t;e :ini:9: n9:@er o8 stages
*
min
o@taine< @= t;e Fens3e :et;o<5
Re8erring to Fig9re %, Er@ar>Ma<<oD correlation ,Er@ar an< Ma<<oD, %14%-, to o@tain Eal9e
o8 *
min
4*5
Fig9re 2. Er@ar>Ma<<oD correlation ,0r(,r ,nd M,ddo#, 1951.
%#
Plant Design Project II
It ;as @een s;oCn 8or :an= cases t;at t;e o6ti:9: re8l9D ratio is @etCeen %52Rmin to %53Rmin5
T;ere8ore taAe R K %53QRmin
R K %53Q05'3%1
R K %5%2'1
R &,RO%- K053#0
R min& ,RminO%- K05$21
N:&N K 05$3 ,8ro: t;e gra6;-
* K 20 stages ,in+luding re(oiler.
2.1.5 To Estimate Feed-Point Location
1
1
]
1

,
_

,
_

,
_

,
_

2
,
,
,
5
log 204 5 0 log
)K d
'K (
'K f
)K f
s
r
#
#
#
#
D
%
*
*
777777557557 ,EF5F>4-
*r > N9:@er o8 stages a@oEe t;e 8ee<
*s > N9:@er o8 stage @eloC t;e 8ee<
% > Molar 8loC @otto: 6ro<9ct ,8ro: Ta@le F>3-
D > Molar 8loC to6 6ro<9ct ,8ro: Ta@le F>3-
#
f,)K
> *oncentration o8 t;e ;eaE= Ae= at 8ee< ,8ro: Ta@le F>3-
D
f,'K
> *oncentration o8 t;e lig;t Ae= at 8ee< ,8ro: Ta@le F>3-
#
d,)K
> *oncentration o8 t;e ;eaE= Ae= in t;e to6 6ro<9ct ,8ro: Ta@le F>3-
D
(,'K
> *oncentration o8 t;e lig;t Ae= in t;e @otto: 6ro<9ct ,8ro: Ta@le F>3-
Since 8ro: t;e calc9late< Eal9esG
R K %5%2'1
* K 20 stages
% K 14540 Ag:ole&;r
D K 3B25#0 Ag:ole&;r
#
f,)K
K 050'31
D
f,'K
K 0512#$
%$
Plant Design Project II
#
d,)K
K 050022
D
(,'K
K 0500#4
S9@stit9te all t;e Eal9es o@taine< into EF5F>4.
1
1
]
1

,
_

,
_

,
_

,
_

2
0022 5 0
00#4 5 0
12#$ 5 0
0'31 5 0
#0 5 3B2
40 5 14
log 204 5 0 log
s
r
*
*
[ ] 0#43%# 5 0 log 204 5 0 log

,
_

s
r
*
*
214 5 0 log

,
_

s
r
*
*
303B 5 0

,
_

s
r
*
*
*
r
O *
s
K %1 ,eDcl9<ing re@oiler-
*
s
K %254%B
Fee< tra= location K %#
t;
tra=
%3
Plant Design Project II
2.2 PLATE HYDRAULIC DESIGN
2.2.1 Operating Range
Satis8actor= o6eration Cill onl= @e ac;ieEe< oEer a li:ite< range o8 Ea6or an< liF9i<
8loC rates5 *are89l col9:n <i:ensioning reF9ires <eter:ination o8 t;e entire o6erating
region an< t;e 6ro6er selection o8 t;e o6erating 6ara:eters so t;at a sa8et= :argin can
@e :aintaine< Cit; res6ect to t;is li:it 8or liF9i< an< gas loa<s5
2.2.2 Plate Design Procedure
A trial an< error a66roac; ;as @een 9se< in 6late <esign. starting Cit; a ro9g; 6late
la=o9t, c;ecAing Ae= 6er8or:ance 8actors an< reEising t;e <esign, as necessar=, 9ntil a
satis8actor= <esign is ac;ieEe<5
a) To Estimate the Column Diameter, %c
T;e 6rinci6al 8actor t;at <eter:ines t;e col9:n <ia:eter is t;e Ea6or 8loC>rate5
)ase< on 8loo<ing consi<erationsG t;e col9:n <ia:eter is esti:ate<5 T;e 8loo<ing
con<ition 8iDes t;e 966er li:it o8 Ea6or Eelocit=5 T;e Eelocit= Cill nor:all= @e
@etCeen '0 to 10 6er cent o8 t;at C;ic; Co9l< ca9se 8loo<ing5 For <esign, a Eal9e o8
6! to 67 6er cent o8 t;e 8loo<ing Eelocit= s;o9l< @e 9se<5
M,#imum flo2:
MaDi:9: liF9i< :ass 8loCrate, '
2, m,#
K %$54#2' Ag&s
MaDi:9: Ea6o9r :ass 8loCrate, 8
2, m,#
K %353'3$ Ag&s
Minimum flo2:
Mini:9: liF9i< :ass 8loCrate, '
2, min
K %5#'%3 Ag&s
Mini:9: Ea6o9r :ass 8loCrate, 8
2, min
K 05#4B$ Ag&s
%4
Plant Design Project II
Ta@le 4. Tra= Pro8ile In8or:ation 8ro: i*ON
Stage
T P Liquid Flow Liquid flow Vapour Flow Vapor flow
C kPa kgmole/h (kg/h) kgmole/h (kg/h)
1 (code!er) "#$#%&' 1'&%$&''' "&1$#('' 1&)(*$*&1) '$"%%( )*$'+1)
% +%$*&'' 1'&&$'''' "&1$**'' 1&)(&$%'++ 1%##$*''' &*'#1$)'""
) +#$&#&' 1'&#$&''' "&'$&&'' 1&)%&$%'++ 1%##$&''' &*'**$+%''
( 1'%$&''' 1'*'$'''' "(#$&)'' 1&%#'$#+&& 1%#*$(''' &*'1"$*()%
& 1'#$(%&' 1'*%$&''' "('$&#'' 1&1(&$)+') 1%#)$(''' &&""*$+#+%
* 11%$)&'' 1'*&$'''' "%($()'' 1("&($&#+# 1%**$(''' &&&#+$#*)%
# 11#$%#&' 1'*#$&''' #(+$"*'' 1)&1'$+##& 1%&'$)''' &("#)$1**(
" 1%%$%''' 1'#'$'''' (%'$%%'' #&#1$&%(' 11#&$#''' &1&++$1%1*
+ 1%#$1%&' 1'#%$&''' (&($1''' "1"1$+#)" "(*$'+'' )#1))$1+#+
1' 1)%$'&'' 1'#&$'''' (&&$)('' "%'($)1*1 "#+$+#'' )"*%'$1%)(
11 1)*$+#&' 1'##$&''' (&&$(*'' "%'*$(#") ""1$%1'' )"*#($&((&
1% 1(1$+''' 1'"'$'''' (&&$&&'' "%'"$'+++ ""1$))'' )"*#+$"11'
1) 1(*$"%&' 1'"%$&''' (&&$*)'' "%'+$&(1) ""1$(%'' )"*")$#*1'
1( 1&1$#&'' 1'"&$'''' (&&$#%'' "%11$1*)' ""1$&''' )"*"#$%#%'
1& 1&*$*#&' 1'"#$&''' (&&$"''' "%1%$*'(( ""1$&+'' )"*+1$%%1+
1* 1*1$*''' 1'+'$'''' (&&$"+'' "%1($%%*' ""1$*#'' )"*+($#))'
1# 1**$&%&' 1'+%$&''' (&&$+"'' "%1&$"(#* ""1$#*'' )"*+"$*"%+
1" 1#1$(&'' 1'+&$'''' (&*$'*'' "%1#$%"+1 ""1$"&'' )"#'%$*)%"
1+ 1#*$)#&' 1'+#$&''' (%%$'1'' #*')$##*% ""1$+('' )"#'*$&"%#
%' (re,oiler) 1"1$)''' 11''$'''' %#($')'' (+)#$(#%& 1(#$+"'' *(+($&(*%
%'
Plant Design Project II
)otto:s liF9i< <ensit=,
', (ottom
K BB%52%21 Ag&:
#
)otto:s Ea6o9r <ensit=,
8, (ottom
K %%532B$ Ag&:
#
To6 liF9i< <ensit=,
', to9
K '%B5'1BB Ag&:
#
To6 Ea6o9r <ensit=,
8, to9
K %#5342$ Ag&:
#
'
:
;
;
'8
8
'
F

77777777557557 ,EF5F>'-
C;ere '
2
J liF9i< :ass 8loC>rate, Ag&s
8
2
J Ea6o9r :ass 8loC>rate, Ag&s
S9@stit9te all t;e Eal9es into EF5F>'.
F
!/, :aD, @otto:s

2%21 5 BB%
32B$ 5 %%
3'3$ 5 %3
4#2' 5 %$

K 05%0'3
F
!/, :in, @otto:s
<
2%21 5 BB%
32B$ 5 %%
#4B$ 5 0
#'%3 5 %
K 05$23B
F
!/, :aD, to6
K
'1BB 5 '%B
342$ 5 %#
3'3$ 5 %3
4#2' 5 %$
K 05%210
F
!/, :in, to6
K
'1BB 5 '%B
342$ 5 %#
#4B$ 5 0
#'%3 5 %
K 053%%$
T;e ;ig;er Eal9e o8 F
'8, m,#
an< F
'8, min
is taAenG
F
'8, m,#
K 05%210 an< F
'8, min
K 05$23B
T;e o6erating Eal9e o8 F
'8
s;o9l< lie @etCeen F
'8, min
an< F
'8, m,#
5
05%210P F
'8
P05$23B
TaAe t;e F
'8, o9
K 052'B
TaAe tra= s6acing as 0534 :
%B
Plant Design Project II
Accor<ing to ,R. K Sinnott, 1993., Plate s6acing 8ro: 05%3: to %: are nor:all=
9se<5
2.2.3 Surface tension calculation:-
Ta@le '. S9r8ace Tension an< :ole 8raction 8or eac; co:6onent
R
:
KR
%
D
%
OR
2
D
2
O75
R
:
K s9r8ace tension :iDt9re
R
%
K s9r8ace tension co:6onent %
D
%
K :ole 8raction co:6onent %
S9r8ace tension K 31.2769 dyne/cm
Compoet Surface te!io (d-e/cm) .ole fractio
/th-lee 01ide )1$% '$++"%
2ater *'$& '$''%%
%1
Plant Design Project II
Fig9re #. Floo<ing Eelocit= ,R. K. Sinnott, 1993-
Fro: Fig9re F>2. Floo<ing Eelocit=, sieEe 6lates
K
1,o9
K 050B
*orrection 8or s9r8ace tension is calc9late< 9sing EF5F>BG
K
1,o9
0'3% 5 0 0B 5 0
02 5 0
0%$31 5 0
2 5 0

,
_

777777775575 ,EF5F>
B-
T;e :aDi:9: 8loo<ing Eelocit= can @e esti:ate< 8ro: t;e correlation giEen @= F,ir
-1951..
:
: '
o9 f
K u

, % :aD ,
77777777757557 ,EF5F>1-
20
Plant Design Project II
s m u
f
& 432 5 0
32B$ 5 %%
32B$ 5 %% 2%21 5 BB%
0'3% 5 0
:aD ,

FairIs 8loo<ing correlation state< t;at B0 to B3H o8 8loo<ing Eal9e <esign s;o9l< @e
9se< an< 8or t;is <esign B0 6ercent 8loo<ing at :aDi:9: 8loC rate is ass9:e<G
:aD ,
S
f :
u flooding 9er+ent,ge u

77777755 ,EF5F>%0-
s m u
:
& 32%4 5 0 B0 5 0 432 5 0

MaDi:9: Eol9:etric 8loC>rateG

At Tra= 2 ,8ro: i*ON, re8er to Ta@le 4-G
MaDi:9: Ea6o9r ,:olar 8loC- K %2''540 Ag:ole&;
Molec9lar Ceig;t K $#5BBB
Densit=,
E
K %%532B$ Ag&:
#
MaDi:9: Ea6o9r 8loC>rate K
s m & #3% 5 %
#400 32B$ 5 %%
BBB 5 $# 40 5 %2''
#

Net area reF9ire< K

:
u
r,te flo2 :,9our M,#imum S S
7777777557 ,EF5F>%%-
Net area K
2
310% 5 2
32%4 5 0
#3% 5 %
m

: :
2
+
u
8
D

$
777777775577557 ,EF5F>%2-
S9@stit9ting t;e Eal9es into EF5F>%2, t;e <ia:eter is o@taine<5
m D
+
B%40 5 %
310% 5 2 $

D
+
K %5B%40 :
Use sa:e <ia:eter a@oEe an< @eloC 8ee<, re<9cing t;e 6er8orate< area 8or 6lates
a@oEe t;e 8ee<5
2%
Plant Design Project II
b) To Decide on The Liquid Flow Arrangement
At Tra= 2 ,8ro: i*ON, re8er to Ta@le 1-G
MaDi:9: liF9i< ,:olar 8loC- K %2''540 Ag:ole&;
Molec9lar Ceig;t K$#5BBB
Densit=,
!
K BB%52%21 Ag&:
#
MaDi:9: liF9i< 8loC>rate K
s m & 0%'4' 5 0
#400 2%21 5 BB%
BBB 5 $# 40 5 %2''
#

For :aDi:9: liF9i<>8loC rate K 050%'4' :

#
&s
D
+
K %5B%40 :
Using Fig9re F>$. Selection o8 liF9i< 8loC arrange:ent
T;e 6late <ia:eter is insi<e t;e range o8 Fig9re #, it is clear t;at t;e 6late to @e 9se<
is cross 8loC ,single 6ass- 6late5 *ross 8loC 6late t;e liF9i< 8loCs across t;e 6late
an< Ea6or 96 t;ro9g; t;e 6late5
Fig9re $. Selection o8 !iF9i< FloC Arrange:ent ,RK Sinnott, 1993-
22
Plant Design Project II
c) To Determine the Trial Layout (To estimate the downcomer area, active area,
hole area, hole size, weir height)
Fro: a- *ol9:n <ia:eter, D
+
K %5B%40 : an< *ol9:n area, &
+
K 25310%:
2
T;e <oCnco:er area an< 6late s6acing :9st @e s9c; t;at leEel o8 t;e liF9i< an< 8rot;
in t;e <oCnco:er is Cell @eloC t;e to6 o8 t;e o9tlet Ceir on t;e 6late a@oEe5 T;e
@acA>96 o8 liF9i< in t;e <oCnco:er is ca9se< @= t;e 6ress9re <ro6 oEer t;e 6late an<
t;e resistance to 8loC in t;e <oCnco:er itsel85
i5 To esti:ate <oCnco:er area, &
d
Initial esti:ate, taAe &
d
as %2 6er cent &
+
&
d
K 05#%0B :
2
ii5 To esti:ate net area, &
n
&
n
K &
+
J &
d
&
n
K 25310% > 05#%0B
K 252'1# :
2
iii5 To esti:ate actiEe area, &
,
&
,
K &
+
J 2&
d
&
,
K 25310%J 2,05#%0B-
K %514B3 :
2
iE5 To esti:ate ;ole area, &
h
Initial esti:ate, taAe &
h
as 4 6er cent &
,
&
h
K 05%%B% :
2
Using Fig9re $. Relation @etCeen <oCnco:er area an< Ceir lengt;G
H 00 5 %2 %00
+
d
&
&
'30 5 0
+
2
D
l
777777775577557 ,EF5F>%#-

m l
2
#42 5 %
Initial esti:ationG
0eir ;eig;t, h
2
K 30::
Hole <ia:eter, d
h
K %0::
Plate t;icAness K 3::
2#
Plant Design Project II
Fig9re 3. 0eir lengt; correlation ,RK Sinnott, 1993-
d) To Check for Weeping Rate
T;e loCer li:it o8 t;e o6erating range occ9rs C;en liF9i< leaAage t;ro9g; t;e 6late
;oles @eco:es eDcessiEe5 T;is is AnoCn as Cee6 6oint5 T;e Ea6or Eelocit= at t;e
Cee6 6oint is t;e :ini:9: Eal9e 8or sta@le o6eration5
i5 To esti:ate :aDi:9: liF9i< rate
MaDi:9: liF9i< ,:olar 8loC- K %2''540 Ag:ole&;
Molec9lar Ceig;t K $#5BBB
MaDi:9: liF9i< rate, '
2,m,#
K
s m & 3'3 5 %3
#400
BBB 5 $# 40 5 %2''
#

,
_

ii5 To esti:ate :ini:9: liF9i< rate
TaAe :ini:9: liF9i< rate at B0 6er cent t9rn><oCn
Mini:9: liF9i< rate, '
2,min
K 05B0,%353'3- K %25$4 :
#
&s
2$
Plant Design Project II
iii5 To esti:ate :aDi:9: an< :ini:9: Ceir liF9i< crest, h
o2
T;e ;eig;t o8 t;e liF9i< crest oEer t;e Ceir can @e esti:ate< 9sing t;e
Fr,n+is 2eir 8or:9la state< @eloC5 For a seg:ental <oCn co:er t;e eF9ation
can @e Critten as.
# & 2
'30
1
]
1

2 '
2
o2
l
'
h

7777777557 ,EF5F>%$-
C;ere l
2
J Ceir lengt;, :
h
o2
J Ceir crest, :: liF9i<
'
2
J :in liF9i< 8loC rate, :
#
&s
0it; seg:ental <oCnco:ers t;e col9:n Call constricts t;e liF9i< 8loC, an<
t;e Ceir crest Cill @e ;ig;er t;an t;at 6re<icte< @= t;e Francis 8or:9la 8or
8loC oEer an o6en Ceir5
At :aDi:9: liF9i< 8loCG 8ro: 6art a-
!
K 2#405# Ag&:
#
Fro: 6art c-
m l
2
#42 5 %
li/uid mm h
o2
S B4 5 2'
#42 5 % 40 5 %2''
$40 5 %2
'30
# & 2
:in ,

1
]
1

li/uid mm h
o2
S ## 5 #2
#42 5 % 40 5 %2''
3'3 5 %3
'30
# & 2
:aD ,

1
]
1

Fro: 6art c- 0eir ;eig;t, h

2
K 30::G
T;ere8ore at :ini:9: rate h
2
O h
o2
K 30 O2'5B4K ''5B4 ::
iE5 To <eter:ine t;e :ini:9: Ea6or Eelocit= t;ro9g; t;e ;oles,
:in , h u

( ) [ ]
( )
2 & %
2
:in ,
$ 5 23 10 5 0
:
h
h
d K
u

777777755 ,EF5F>%3-
C;ere
:in , h u

> :ini:9: Ea6or Eelocit= t;ro9g; t;e ;oles ,@ase< on ;ole

area-, :&s
d
h
J ;ole <ia:eter, :: K %0::

8
J %%532B$ Ag&:
#
at :aDi:9: Ea6or 8loC, 8ro: 6art a-
K
"
J a constant o@taine< 8ro: Fig9re 3. 0ee6>6oint correlation ,0dul=ee,
1979- K#05'
23
Plant Design Project II
24
Plant Design Project II
Fig9re 4. 0ee6>6oint *orrelation ,0dul=ee, 1979-
( ) [ ]
s m uh & 1B1 5 $
- 32B$ 5 %% ,
%0 $ 5 23 10 5 0 B 5 #0
2 & %
:in ,

Mini:9: Ea6or 8loC rate K 05B0,#530%B- K 25B0%$:

#
&s
Fro: 6art c- &
h
K 05%%B%:
2
Act9al :ini:9: Ea6or Eelocit=, u
n
K 25B0%$&05%%B% K 2#5'204 :&s
e) To Estimate Plate Pressure Drop, h
t
T;e 6ress9re <ro6 oEer t;e 6lates is an i:6ortant <esign consi<eration5 T;ere are tCo
:ain so9rces o8 6ress9re lossG t;at <9e to Ea6or 8loC t;ro9g; t;e ;oles ,an ori8ice
loss-, an< t;at <9e to t;e static ;ea< o8 liF9i< on t;e 6late5
( )
r o2 2 d t
h h h h h + + +
77777757 ,EF5F>%4-
i5 To esti:ate <r= 6late 6ress9re <ro6, h
d
T;e 6ress9re <ro6 t;ro9g; t;e <r= 6late can @e esti:ate< 9sing eD6ressions
<eriEe< t;ro9g; ori8icesG
'
:
o
h
d
C
u
h

2
:aD ,
3%
1
1
1
]
1

7777777557 ,EF5F>%'-
C;ere C
o
J 89nction o8 6late t;icAness, ;ole <ia:eter an< t;e ;ole to
6er8orate< area ratio5
u
h,m,#
J Eelocit= t;ro9g; t;e ;oles, :&s
Fro: 6art a- :aDi:9: Ea6or 8loC>rate K %5#3% :
#
&s
Fro: 6art c- &
n
K 252'1# :
2
s m uh & 312' 5 0
2'1# 5 2
#3% 5 %
:aD ,

Fro: 6art c- &

h
K 05%%B% :
2,
&
,
K %514B3 :
2,
6late t;icAness K 3:: an< ;ole
<ia:eter, d
h
K %0::
,
h
9
h
&
&
&
&

777777775557 ,EF5F>%B-
2'
Plant Design Project II
H 00 5 4 %00
9
h
&
&
3 5 0
%0
3 S

h
d
thi+3ness Pl,te
Using Fig9re 4. Disc;arge coe88icient, sieEe 6lates ,'ie(son et ,l., 197-
C
o
K 0541
2B
Plant Design Project II
Fig9re '. Disc;arge coe88icient, sieEe 6lates ,'ie(son et ,l., 197-
Fro: 6art a- !iF9i< <ensit=,
',m,# flo2
K BB%52%21 Ag&:
#
an< Ea6or <ensit=,

8,m,# flo2
K %%532B$ Ag&:
#
li/uid mm h
d
S $12# 5 0
2%21 5 BB%
32B$ 5 %%
41 5 0
312' 5 0
3%
2

1
]
1

ii5 To esti:ate t;e resi<9al ;ea<, h

r
T;e si:6le eF9ation 6ro6ose< @= )unt et ,l. -1977. can @e 9se<.
'
r
h

#
%0 3 5 %2

777777777555 ,EF5F%1-
0;ere t;e resi<9al <ro6 as 8iDe< Eal9e o8 %253 :: o8 Cater ,%&2 in5-
21
Plant Design Project II
Fro: a- !iF9i< <ensit=,
',m,# flo2
K BB%52%21 Ag&:
#
li/uid mm h
r
S %B3 5 %$
2%21 5 BB%
%0 3 5 %2
#

iii5 To esti:ate t;e total 6late 6ress9re <ro6, h

t
re8er to EF5F>%4
( )
r o2 2 d t
h h h h h + + +
li/uid mm h
d
S $12# 5 0
h
2
O h
o2
K ''5B4 mm>li/uid
li/uid mm h
r
S %B3 5 %$
li/uid mm h
t
S 3#' 5 12 %B3 5 %$ B4 5 '' $12# 5 0 + +
*ol9:n 6ress9re <ro6 K 30000 Pa ,30 APa-
f) To Estimate Downcomer Back-up, h
b
T;e :ain resistance to 8loC Cill @e ca9se< @= t;e constriction at t;e <oCnco:er
o9tlet, an< t;e ;ea< loss in t;e <oCnco:er can @e esti:ate< 9sing t;e eF9ation giEen
@= Ci+,lese et ,l. -19?.5
i5 To esti:ate t;e <oCnco:er 6ress9re loss, h
d+
2
%44
1
]
1

m '
2d
d+
&
'
h

777777777 ,EF5F20-
0;ere '
2
J liF9i< 8loC rate, Ag&s
&
m
J eit;er t;e <oCnco:er area &
d
or t;e clearance area 9n<er t;e
<oCnco:er &
,9
, C;ic;eEer s:aller, :
2
Fro: 6art <- '
2d
K %353'3 :
#
&s
Fro: a- !iF9i< <ensit=,
',m,# flo2
K BB%52%21 Ag&:
#
T;e clearance area 9n<er t;e <oCnco:er is giEen @=.
2 ,9 ,9
l h &
7777777775 ,EF5F>2%-
C;ere h
,9
J ;eig;t o8 t;e @otto: e<ge i8 t;e a6ron a@oEe t;e 6late5
Accor<ing to RK Sinnot -1993. since t;is ;eig;t is nor:all= set at 3 to %0
:: @eloC t;e o9tlet Ceir ;eig;t.
- %0 S S 3 , mm to h h
2 ,9

Since Ceir ;eig;t, h
2
K 30::
TaAe %0::
h
,9
K $0::
#0
Plant Design Project II
Fro: 6art c-
m l
2
#42 5 %
)= s9@stit9ting all t;e Eal9es into EF5F>2%.
2
03$3 5 0 #42 5 %
%000
$0
m &
,9

Fro: 6art c- &
d
K 05##1:
2
&
m
< &
d
K 05#%0B :
2
, s9@stit9te t;e Eal9es into EF5F>20.
mm h
d+
4B 5 3#
#%0B 5 0 2%21 5 BB%
3'3 5 %3
%44
2

1
]
1

ii5 To esti:ate t;e @acA>96 in <oCnco:er, h
(
In ter:s o8 clear liF9i< t;e <oCnco:er @acA96 is giEen @=.
( )
d+ t o2 2 (
h h h h h + + +
7777755575 ,EF5F>22-
C;ere h
(
J <oCnco:er @acA>96, :eas9re< 8ro: 6late s9r8ace, ::
h
d+
J ;ea< loss in t;e <oCnco:er, ::
h
2
O h
o2
K ''5B4mm>li/uid
li/uid mm h
t
S 3#' 5 12
mm h
d+
4B 5 3#
li/uid mm h
(
S 0'' 5 22$ 4B 5 3# 3#' 5 12 B4 5 '' + +
h
(
K 0522$% :
For sa8e <esign t;e clear liF9i< @acA>96, t;e calc9late< h
(
8ro: EF5F>22
s;o9l< not eDcee< ;al8 t;e 6late s6acing, l
t
to aEoi< 8loo<ing5 AlloCing 8or
t;e Ceir ;eig;t.
( )
2 t (
h l h + <
2
%
777775775 ,EF5F>2#-
Fro: 6art c- 0eir ;eig;t, h
2
K 30:: an< 6late s6acing, l
t
K 053:
( ) m h l
2 t
2'3 5 0 3 5 0 +
0522$%: P 052'3:
iii5 To esti:ate t;e <oCnco:er resi<ence ti:e
S988icient resi<ence ti:e :9st @e alloCe< in t;e <oCnco:er 8or t;e
entraine< Ea6or to <isengage 8ro: t;e liF9i< strea:G to 6reEent ;eaEil=
Taerate<U liF9i< @eing carrie< 9n<er t;e <oCnco:er5 A ti:e o8 at least #
secon<s is reco::en<e< @= RK Sinnot -1993..
2d
' (+ d
r
'
h &
t

777757555775 ,EF5F>2$-
#%
Plant Design Project II
C;ere t
r
J resi<ence ti:e, s
h
(+
J clear liF9i< @acA>96, :
Fro: 6art c- &
d
K 05#%0B :
2
Fro: 6art 8- h
(
K h
(+
K 0522$% :
Fro: 6art <- '
2d
K %353'3 :
#
&s
Fro: 6art a- !iF9i< <ensit=,
',m,# flo2
K BB%52%21 Ag&:
#
s t
r
1$0' 5 #
3'3 5 %3
2%21 5 BB% 22$% 5 0 #%0B 5 0

t
r
#s is reco::en<e<
g) To Check for Entrainment,
Entrain:ent can @e esti:ate< 8ro: t;e correlation giEen @= Fair ,%14%-, Fig9re '
C;ic; giEes t;e 8ractional entrain:ent ,Ag&Ag gross liF9i< 8loC- as a 89nction o8
t;e liF9i< Ea6or 8actor, F
'8
Cit; is t;e 6ercentage a66roac; to a 8loo<ing 6ara:eter5

:aD ,
S
h
n
u
u
flooding Per+ent,ge
7777777775 ,EF5F>23-
Fro: 6art a-
s m u
f
& 312' 5 0
:aD ,

Fro: 6art e-
s m uh & 432 5 0 :aD ,

H 1% 101 5 0
432 5 0
312' 5 0
S flooding Per+ent,ge
Using Fig9re *>B. Entrain:ent correlation 8or sieEe 6lates ,F,ir, 1951-
Fro: 6art a- TaAe t;e F
'8, o9
K 052'B
As a ro9g; g9i<ance t;e 966er li:it o8 can @e taAen as 05#, @eloC t;is Eal9e
e88ect on e88icienc= Cill @e s:all5
K 0502P 052'B ,E88icienc= Cill @e s:all-
#2
Plant Design Project II
Fig9re B. Entrain:ent correlation 8or sieEe 6lates ,Fair, %14%-
##
Plant Design Project II
h) Trial Layout
i5 To esti:ate t;e 6er8orate< area
Fro: 6art a- D
+
K %5B%40:
Fro: 6art c-
m l
2
#42 5 %
'300 5 0
+
2
D
l
Fig9re 1. Relation @etCeen angle s9@ten<e< @= c;or<, c;or< ;eig;t an< c;or< lengt;
!et
+
K 14
AlloC 30:: i:6er8orate< stri6 ro9n< 6late e<geG 30:: Ci<e cla::ing
?ones5
Angle s9@ten<e< at 6late e<ge @= i:6er8orate< stri6 K %B0 J 14 K B$
Mean lengt;, i:6er8orate< e<ge stri6s K ,%5B%40>30%0
>#
-B$&%B0
K 253B1:
Area o8 i:6er8orate< e<ge stri6s K 30%0
>#
253B1 K 05%213 :
2
#$
Plant Design Project II
Mean lengt; o8 cla::ing ?one K ,%5B%40 > 30%0
>#-
sin ,14&2-
K %5#%2$ :
Area o8 cla::ing ?one K 2,%5#%2$ 30%0
>#-
K 05%#%2$:
2
Total area 8or 6er8orations,
&
9
K V&
n
J ,*la::ing area- J ,I:6er8orate< Area-W
&
9
K 252'1# J 05%#%2$ J 05%213 K 250%B4 :
2
Fro: 6art c- &
h
K 05%%B%:
2
&
h
&&
9
K 05%%B%&250%B4K 0503B3%
Fro: Fig9re 1, t;e relation @etCeen ;ole area an< 6itc; are 8o9n<5
l
9
&d
h
K #5'
0Pl
9
&d
h
P $50
ii5 To esti:ate n9:@er o8 ;oles
Fro: 6art a- D
+
K %5B%40:
Area o8 one ;ole K %514$%0
>$
:
2
Fro: 6art c- &
h
K 05%%B%:
2
N9:@er o8 ;oles K 40%
%0 14$ 5 %
%%B% 5 0
$

Fig9re %0. Trial !a=o9t
%5#%2$:
30::
%5B%40:

+
30::
#3
Plant Design Project II
Fig9re %%. DoCnco:er @acA96
i) Plate Specification
Plate No5 % T9rn><oCn B0 6er cent :aD rate
Plate I5D5 %5B%40 : Plate :aterial *ar@on steel
Hole si?e %0 :: DoCnco:er :aterial IS. *ar@on Steel
Hole 6itc; 23 ::
Plate s6acing %50:
Plate t;icAness 3 :: ActiEe ;oles 40%
Plate 6ress9re <ro6 253 +6a
l
t
K053:
h
(
K0522$:
h
,9
K050$:
h
2
K0503:
h
o2
K2'5B4 :: liF9i<
#4
Plant Design Project II
3.0 MECHANICAL DESIGN
T;is s9@c;a6ter Cill coEer <etail :ec;anical <esign 8or Et;=lene ODi<e
69ri8ication col9:n in *>'025 Fig9re %2 @eloC s;oCs t;e :et;o<olog= in
<esigning :ec;anical <esigns
Figure 1": Methodology for Me+h,ni+,l Designs
1. %esi&n pressure and material specification
Set D
i
an< !
Material F
s
, (
O6erating P, T P
<esign
2. Shell thic'ness

3. (ead and Closure
)otto:
To6
)lanA <ia:eter
4. %esi&n of )as'et and *olts
GasAet s6ecs :aterial, :, =, Ci<t;
)olt loa<s
No o8 @olts
. %esi&n of Rin& +lan&e
Flange t;icAness
Flange <ia:eter
!. ,essel sub-ect to combined loadin&
Total Ceig;t K s;ell O 6late O ins9lation
". .ind loadin&
Stress anal=sis at @otto:
Princi6al stresses
*;ecA elasticit=
#. %esi&n of S'irt Support
*;ecA criteria 8or <esign ,tensile an< co:6ressiEe-

SAirt t;icAness
/. $o00le si0in&
Fee< no??le
To6 no??le ,Ea6or o9t an< re8l9D in-
)otto: no??le ,liF9i< o9t an< @oil 96 in-
NO
NO
NO
#'
Plant Design Project II
3.1 The Design of Thin-Walled Vessels under Internal Pressure
3.1.1 Materials of Construction
Selection o8 :aterial to @e 9se< in t;e constr9ction o8 t;e <istillation col9:n is @ase< on
t;e i:6ortant c;aracteristics as @eloC.
i5 Mec;anical Pro6erties
Strengt; J tensile strengt; is a :eas9re o8 t;e @asic strengt; o8 a
:aterial5 It is t;e :aDi:9: stress t;at t;e :aterial Cill Cit;stan<5
Sti88ness J elastic :o<9l9s 89nction o8 t;e :aterial an<
t;e s;a6e o8 cross section o8 t;e :e:@er ,secon< :o:ent o8 area-5 It is
t;e a@ilit= to resist @en<ing an< @9cAling5
To9g;ness J 8ract9re resistance an< cracA 6ro6agation
Har<ness J Cear resistance
Fatig9e resistance J s9@ject to c=cling loa<ing
*ree6 resistance J gra<9al eDtension o8 a :aterial 9n<er
a stea<= tensile stress
ii5 E88ect o8 ;ig; an< loC te:6erat9re on t;e :ec;anical 6ro6erties
Decrease Cit; increasing te:6erat9re
*orrosion resistance
Ease o8 8a@rication
AEaila@ilit= o8 stan<ar< si?es
*ost
In or<er to select t;e correct :aterial o8 constr9ction, t;e 6rocess enEiron:ent to C;ic;
t;e :aterial Cill @e eD6ose< to :9st @e clearl= <e8ine<5 T;e :aterial o8 constr9ction
c;osen is *ar@on Steel5 T;e reason 8or t;is selection is t;at t;e Et;=lene ODi<e is
reactiEe in nat9re5 *ar@on Steels are 9se< 8or corrosion resistance <9e to cost
consi<eration5

#B
Plant Design Project II
3.1.2 Design Pressure
O6erating 6ress9re. %03253 APa
O6erating te:6erat9re. B'5'# *
Material o8 *onstr9ction. Ni>Resist corrosion>resistant cast iron
,ASTM A$#4&$#4 M-
*orrosion AlloCance. 2:: is a<<e<
T;e corrosion alloCance is generall= a<<itional :etal t;icAness a<<e< to alloC
8or :aterial lost @= corrosion, erosion an< scaling5 In t;is 6rocess, t;e 8l9i< is not
corrosiEe t;ere8ore a :ini:al t;icAness is a<<e< on5
Design 6ress9reG is taAen as %0 6er cent a@oEe t;e nor:al o6erating 6ress9re,
Design 6ress9re, P
i
K ,%053# @ar > %- %5%
K %05$B @ar
Press9re tolerance is to aEoi< s69rio9s o6eration <9ring :inor 6rocess 96sets5
3.1.3 Thickness of vessel
T;is is t;e 8or: o8 eF9ation giEen in t;e )ritis; Stan<ar<, )S 3300
i
i i
P @f
D P
t

2
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C;ere D
i
J internal <ia:eter
t J :ini:9: t;icAness reF9ire<
f J <esign stress K %04 N&::
2
,Ta@le 2-
P
i
J internal 6ress9re
@ J joint 8actor K %50 since Cel<s Cill @e 89ll= ra<iogra6;e<
,Ta@le %#5#. MaDi:9: alloCa@le joint e88icienc=-
S9@stit9te t;e Eal9es into EF5F>24
For a c=lin<rical s;ell t;e :ini:9: t;icAness reF9ire< to resist internal 6ress9reG
a) Cylindrical section
#1
Plant Design Project II
0all t;icAness, mm t B1B 5 0
%0$B 5 0 %04 % 2
%0 B%40 5 % %0$B 5 0
#

A<< corrosion alloCance 05B1B O 2K 25B1B ::

Sa= #50 :: 6late5
b) Doomed head
Tr= a stan<ar< <is;e< ;ea< ,toris9here-.
*roCn ra<i9s, R
+
K D
i
K %5B%40 :
+n9cAle ra<i9s K 4 6er cent R
+
K05%010 :
A ;ea< o8 t;is si?e Co9l< @e 8or:e< @= 6ressing. no joints, so (K%
Fig9re %#. Toris6;erical
''0$ 5 %
%010 5 0
B%40 5 %
#
$
%
#
$
%

,
_

,
_

+
3
+
s
R
R
C
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2 5 0 ''0$ 5 % B%40 5 % % %04 2
''0$ 5 % %0 B%40 5 % %0$B 5 0
#

Tr= a stan<ar< elli9soid,l ;ea<, ratio :ajor. :inor aDes K 2. %

Fig9re %$. Elli6soi<al
$0
Plant Design Project II
i
i i
P @f
D P
t
2 5 0 2

7775557777775 ,EF5F>
21-
mm t B1'B 5 0
- %0$B 5 0 , 2 5 0 % %04 2
%0 B%4 5 % %0$B 5 0
#

So an elli9soid,l he,d Co9l< 6ro@a@l= @e t;e :ost econo:ical5 TaAe as

sa:e t;icAness as Call #50 :: reF9ire< 8or 6ress9re loa<ing5
A :9c; t;icAer Call Cill @e nee<e< at t;e col9:n @ase to Cit;stan< t;e
Cin< an< <ea< Ceig;t loa<s5
3.2 Combined loading on Vessel
Heig;t @etCeen tangent lines K $:
SAirt s966ort ;eig;t K 05': ,ass9:e-
2 sieEe 6lates, eF9all= s6ace<
Ins9lation :ineral Cool K '3:: t;icA
/essel to @e 89ll= ra<iogra6;e< ,joint 8actor %-
As a 8irst trial <iEi<e t;e col9:n into 8iEe sections ,co9rses-, Cit; t;e t;icAness
increasing @= 2:: 6er section5 Tr= 2, $::5
3.2.1 Dead weight of vessel
( )
#
%0 B 5 0

+ t D ) g D C ;
m : m m : :
77755577777755 ,EF5F>
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:
J total Ceig;t o8 t;e s;ell, eDcl9<ing internal 8ittings, s9c; as
6lates
C
:
J A 8actor acco9nt 8or t;e Ceig;t o8 no??les, :an Ca=s, internal
s966orts, etc5
)
:
J Heig;t, or lengt;, @etCeen tangent lines ,t;e lengt; o8 t;e c=lin<rical
section-, :
g J GraEitational acceleration, 15B% :&s
2
t J 0all t;icAness, ::
$%
Plant Design Project II

m
J Densit= o8 Eessel :aterial, Ag&:
#
D
m
J :ean <ia:eter o8 Eessel K ,D
i
O t %0
>#
-, :
For a steel Eessel,
( )t D ) D C ;
m : m : :
B 5 0 2$0 +
77755575777775 ,EF5F>
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T;e a@oEe eF9ation onl= a66lies strictl= to Eessels Cit; 9ni8or:
t;icAnessG it can @e 9se< to get a ro9g; esti:ate o8 t;e Ceig;t o8 t;is
Eessel @= 9sing t;e aEerage t;icAness, 4::5
TaAe C
:
K %5%3, Eessel Cit; 6lates
D
m
K %5B%40 O 4 %0
>#
K %5B22 :
)
:
K 20 :
t K 4 ::
;
:
K 2$0 %5%3 %5B22Q,20 O ,05B %5B22--Q4
K 4$5'$# AN
a) Weight of plates
Plate area K &$ %5B%40
2
K 25310% :
2
0eig;t o8 a 6late K %52 25310% K #5%0B AN
20 6lates K 20 #5%0B K 425%4 AN
b) Weight of insulation
Mineral Cool <ensit= K %#0 Ag&:
#
A66roDi:ate Eol9:e o8 ins9lation K %5B%4 20
K %%$5%0# :
#
0eig;t K %%$5%0# %#0 15B% K %$3,3%354 N ,%$353%4 AN-
Do9@le t;is to alloC 8or 8ittings, etc, K 21%50#2 AN
Total Ceig;t.
S;ell 4'5'$# AN
Plates 425%40 AN
$2
Plant Design Project II
Ins9lation 21%50#2 AN
$2051#3 AN
3.3 Wind Loading
TaAe t;e <=na:ic Cin< 6ress9re as %2B0 N&:
2
Mean <ia:eter, incl9<ing ins9lation K %5B22 O %5B22,4 O '3- %0
>#
K %51414 :
!oa<ing ,6er linear :etre- F
2
K %2B0 %51414 K 232%50BB N&:
)en<ing :o:ent at @otto: tangent line.
2
2
2#
M
#
77777555 ,EF5F>#2-
*m M
#
'0$ 5 20%4B $
2
0BB 5 232%
2

3.4 Analysis of Stresses
At @otto: tangent line.
i. Pressure stresses:
t
PD
i
'
$
777555777777775 ,EF5F>##-
2
#
& ''#4 5 $
%0 $
%0 B22 5 % %0$B 5 0
mm *
'

t
PD
i
h
2
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2
#
& 3$'# 5 1
%0 2
%0 B22 5 % %0$B 5 0
mm *
h

ii. Dead weight stress:
( )t t D
;
i
:
2
+

777555777777755575 ,EF5F>#3-
( )
2
#
& %2022 5 %
%0 %0 %B22
%0 '$# 5 4$
mm *
2

+

,co:6ressiEe-
$#
Plant Design Project II
iii. Bending stress:
D
o
K %B22 O ,2 %0- K %B$2 ::
A
:
K
( )
$ $
4$
i
D Do

7775557777775575 ,EF5F>#4-
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:
K
( )
$ %0 $ $
%0 $%$42 5 2 %B22 %B$2
4$
mm

2
%0
#
& B$$$$ 5 0 %0
2
%B22
%0 $%$42 5 2
%0 1 5 22%#B
mm *
(
t

,
_

t
T;e res9ltant longit9<inal stress is.

B
K
'
O
2
t
(
7775557777775775 ,EF5F>#'-

2
is co:6ressiEe an< t;ere8ore negatiEe

B
,96Cin<- K $5''#4 J %5%2022 O 05B$$$$ K O$5$1'B2 N&::
2

B
,<oCnCin<- K $5''#4 J %5%2022 J 05B$$$$ K 25B0B1$ N&::
2
As t;ere is no torsional s;ear stress, t;e 6rinci6al stress Cill @e
B
an<
h
T;e greatest <i88erence @etCeen t;e 6rinci6al stresses Cill @e on t;e <oCn>Cin< si<e
,$5$1'B2 J 25B0B1$- K %54BBBB N&::
2
Cell @eloC t;e :aDi:9: alloCa@le <esign stress5
iv. Check elastic stability (buckling)
*ritical @9cAling stress.
2 $
& %0 2 mm *
D
t
o
+

,
_

77755575575775 ,EF5F>#B-
$5B%2#
$5$1'B2
U6>Cin<
$5B%2#
25B0B1$
DoCn>Cin<
$$
Plant Design Project II
2 $
& 3'B 5 %0B
%B$2
%0
%0 2 mm *
+

,
_

v. Principal stresses
T;e 6rinci6al stresses Cill @e giEen @=.
( )
1
]
1

+ + +
2 2
%
$
2
%

B h B h
7775555555575 ,EF5F>#1-

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1
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2
( )
1
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1

+ + +
2 2
2
$
2
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B h B h
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K
B
or
B
K ,96Cin< or <oCnCin<-
,
1
>
"
-
96Cin<
K ,$5B%2# J $5$1'B2- K 05#%$$B N&::
2
,
1
>
"
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K ,$5B%2#>25B0B1$- K 2500##4 N&::
2
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2
iv. Check for Elastic Stability
stress %ending 2eight De,d
+om9
S S
:aD ,
+
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stress %ending 2eight De,d
+om9
S S
:aD ,

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%5%2022 O 05B$$$$ K %514$44 N&::

2

:aD , +om9

>%5%2022 J ,05B$$$$- K >%5%14$44 N&::2

+
N
+om9,m,#
Design is satis8actor=
$3
Plant Design Project II
3.5 Vessel Skirts and Supports
T;e :et;o< 9se< to s966ort a Eessel Cill <e6en< on t;e si?e, s;a6e an< Ceig;t o8 t;e
Eessel5 Generall= sAirt s966orts are 9se< 8or tall Eertical col9:n as t;e= <o not
i:6ose concentrate< loa<s on t;e Eessel s;ell5 A sAirt s966ort is t;ere8ore c;osen
s966ort in co:6arison Cit; sa<<le s966orts or racAet s966orts5 A sAirt s966ort
consists o8 a c=lin<rical or conical s;ell Cel<e< to t;e @ase o8 t;e Eessel5 A 8lange at
t;e @otto: o8 t;e sAirt trans:its t;e loa< to t;e 8o9n<ations5 O6enings :9st @e
6roEi<e< 8or t;e connecting 6i6es5
Tr= a straig;t c=lin<rical sAirt ,
s
K 10- o8 6lain car@on steel5
i. To determine skirt thickness
A66roDi:ate Ceig;t K
* '% 5 3%%3$ B% 5 1 %000 2 B22 5 %
$
2

,
_

0eig;t o8 Eessel 8ro: #, K 4$5'$# AN

Total Ceig;t K 3%5%33 O 4$5'$# K %%35B1B AN
0in< loa<ing, 8ro: $ K 250%4B AN&:
)en<ing :o:ent at @ase o8 sAirt K 3*m 1323 5 2#%
2
%3
0%4B 5 2
2

)en<ing stress in t;e sAirt.
( )
s s s s
s
(s
D t t D
M
+

$
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s
J :aDi:9: @en<ing :o:ent, eEal9ate< at t;e @ase o8 t;e sAirt ,<9e to
Cin<, seis:ic an< eccentric loa<s
D
s
J insi<e <ia:eter o8 t;e sAirt at t;e @ase
t
s
JsAirt t;icAness
As a 8irst trial, taAe t;e sAirt t;icAness as sa:e as t;at o8 t;e @otto: section o8 t;e
Eessel %0 ::5
( )
2
# #
& B$'B 5 B
%0 %B22 %0 %B22
%0 %0 1323 5 2#% $
mm *
(s

+

$4
Plant Design Project II
( )
s s s
2s
t t D
;
+

77755577777775555 ,EF5F>$3-
( )
2
#
& %2022 5 %
%0 %0 %B22
%0 '$# 5 4$
- , mm * o9er,ting
2s

+

( )
2
& #0'44 5 %
%0 %0 %B22
'324%
- , mm * test
2s

+

MaDi:9:

,co:6ressiEe- K %%524%0 O %5#0'44 K %2534B' N&::

2
MaDi:9:

,tensile- K %%524%0 J %5%2022 K %05%$0B N&::

2
TaAe t;e joint 8actor @ as 05B35
*riteria 8or <esign.

,tensile- N f
s
@ sin
%05%$0B N 05B3 %04 sin 10
%05B#$# N 1352#$

,co:6ressiEe- N 05%23 E
sin

,
_

s
s
D
t
%2534B' N 05%23 200000
10 sin
%B22
%0

,
_

%2534B' N %#'52%2
)ot; criteria are satis8ie<, a<< 2 :: 8or corrosion, an< giEe a <esign t;icAness o8
%2::
ii. To determine base ring and anchor bolts
A66roDi:ate 6itc; circle <ia:eter, sa= %53 :
*irc9:8erence o8 @olt circle K %300
)olt s6acing K mm 32 5 21$
%4
%0 3 5 %
#

1
]
1

;
D
M
f ;
&
(
s
( (
(
$ %
7775557777775 ,EF5F>
$4-
$'
Plant Design Project II
2 #
#
B1B3 5 2'4 %0 '$# 5 4$
3 5 %
%0 1323 5 2#% $
%23 %4
%
mm &
(

1
]
1

Use M#0 @olts ,)S $%10.%14'-G root area K 34%::

2
)olt root <ia:eter K mm ''43 5 %B
$ B1B3 5 2'4

Total co:6ressiEe loa< on t;e @ase ring 6er 9nit lengt;

1
1
]
1

+
s
s
s
(
D
;
D
M
F

2
$
777555777777575 ,EF5F>$'-
m * F
(
& %0 2'$ 5 %00
B22 5 %
%0 '$# 5 4$
B22 5 %
%0 1323 5 2#% $
#
#
2
#

1
]
1

TaAing t;e @earing 6ress9re as 3 N&::
2
,Range #53 to ' N&::
2
-
#
%0
%

+
(
(
f
F
'
77755577577775 ,EF5F>$B-
mm '
(
03$B 5 20
%0
%
3
%0 2'$ 5 %00
#
#

Act9al Ci<t; reF9ire<, !

@
K2!
<
K2,20503$B- K$05%014 ::
!
r
K !
@
Ot
s
O30K$05%014O%2O30K%025%014::
SAirt @ase angle,
s
K tan>%
( )

3 5 B2
2% 5 2 #
2
%
#
Sin B253 K 0511 ,Nor:all= B0 to 10 <egree-
Re8erring to Fig9re %#5#0. Anc;or @olt c;air <esign
Act9al @earing 6ress9re on concrete 8o9n<ation.
2
#
#
& %2# 5 %
%0 33B$ 5 %%2
%0 #14 5 %24
X mm * f
+

7775557775555575 ,EF5F>$1-
mm t
(
'1 5 B
33B$ 5 %%2
%2# 5 % #
3BB$ 5 30

7775557777555775 ,EF5F>30-
Ro9n< o88 to 1::
*;air <i:ensions 8ro: Fig9re %#5#0 8or @olt si?e M#05
$B
Plant Design Project II
3.6 Design of flanges
Flanges are generall= 9se< 8or connecting 6i6es an< instr9:ents to Eessels 8or
eDa:6le in t;is <esign, t;e 6i6es entering an< eDiting as Cell as t;e :an;oles5
So:eti:es 8langes are 9se< on t;e Eessel @o<= to ease o6ening it 96 8or
:aintenance5 T;e 6ro6er <e8inition 8or a :an;ole accor<ing to t;e )S $'0 Co9l<
@e ;oles or o6enings on a str9ct9re t;at 6er:it t;e 6erson entr= an< eDit5 For
clearer :eaning access Co9l< @e <e8ine< as t;e insertion into a Eessel o8 :ore
t;an a 6ersonIs ;ea< an< ar:5
3.7 Flange for manholes
i. To determine the gasket width
Flange :aterial IS.200$>%142 *lass 2
)olting :aterial 3H *r>Mo Steel
GasAet As@estos
S;ell o9tsi<e <ia:eter, % 053:
S;ell t;icAness %0::
AlloCa@le stress o8 8lange :aterial %00 N&::
2
AlloCa@le stress o8 @olting :aterial %#B N&::
2
Ass9:e g
1
K g
!
&05'0'
Ass9:e C
F
K % an< y K %B533
*;oose %54:: t;icAness
: K 25'3
= K 23530
Mini:9: gasAet Ci<t; K %0 ::
2 & %
0
- % ,

,
_

m P y
Pm y
d
d
i
7775557775775 ,EF5F>3%-
002% 5 %
- % '3 5 2 , %0$B 5 0 30 5 23
'3 5 2 %0$B 5 0 30 5 23
2 & %
0

,
_

i
d
d
!et d
i
o8 gasAet K %0 :: larger t;an Eessel o9ter <ia:eter, d
o
d
i
K % O %0::
K 0530 O 050%
K 053% :
d
o
K 053% %5002% K 053%%0' :
$1
Plant Design Project II
GasAet Ci<t;, * K
m
$
%0 #3 5 3
2
3% 5 0 3%%0' 5 0

*;oose an eEen Ci<t;, * K %0::

d
o
K 053%%0' O 0502 K 053#%0' :
)asic gasAet seating Ci<t; (
o
K
mm
*
%0
2
20
2

ii. To determine the diameter at location of gasket;
!ocal reaction, C K d
i
O *
K 053% O 0502 K 053# :
iii. To estimate the bolt loads
!ocal <9e to <esign 6ress9re, ) K P
C

$
2

77777777775 ,EF5F>
32-
) K * B02 5 2#%20 %0$B 5 0
$
- %0 3# 5 0 ,
2 #


!ocal <9e to ;96 joint tig;t 9n<er, )
9
K
mP ( C - 2 ,
77775555 ,EF5F>
3#-
( K %0 3 5 2 K '51
)
9
K * BB 5 '3B% %0$B 5 0 '3 5 2 - 1 5 ' 2 , %0 3# 5 0
#

Total o6erating loa< K ) O )
9

;
o
K 2#%205B02 O '3B%5BB K #0'0254B2 N
!oa< to seat gasAet 9n<er @olting 96 con<itionsG
;
g
K C ( y777555777777777777775775 ,EF5F>3$-
* ;
g
%$ 5 ##3$2# 3 5 23 1 5 ' %0 3# 5 0
#

Since ;
g
N ;
o
, ;
g
is controlling loa< K ##3$2#5%$ N
30
Plant Design Project II
iv. To determine the minimum bolting area
o
g
o m
S
;
& &
77755577757775 ,EF5F>33-
2
40 5 2$#0
%#B
%$ 5 ##3$2#
mm & &
o m

!et 9s consi<er )olt si?e, M%4, M%B, M20 an< M22
Ta@le B. )olt si?e
Bolt size
Root diameter
(mm)
Root area, 1
r
(mm
2
)
1
m
21
r
Actual
number,
M%4 %53 %#5%1 %#454$ %'5'1 20
M%B 2 %$5$B %4$54' %$5'4 %4
M20 2 %45$B 2%#5#% %%5#1 %2
M22 2 %B5$B 24B522 1504 %2
3%
Plant Design Project II
Ta@le 1. )olt si?e
( ) m g
$ $
%
%0 $#04 5 % %0 B03 5 2 3% 5 0


- , 2
%
R g % C + +
777555777777777777775755575 ,EF5F>34-
R m R C 2 30 5 0 - %0 $#04 5 % , 2 3 5 0
$
+ + +

R C 2 %0 30# 5 0
#
+
Fro: ta@le, t;e :ini:9: )*D o@taine< c;oosing M%B D 2 @olts, %4 n9:@ers
)olt circle <ia:eter K 0533$:
N9:@er o8 @olts K %4
Si?e K M%B D 2
R K 0502' :
v. To determine the flange outside diameter
& K C O @olt <ia:eter O 0502:77777777757555775 ,EF5F>3'-
K 0533$ O 050%B O 0502
K 05312 :
& K 054 :
vi. To check gasket width
y
* C
S &
g (
2 <

7775557775775555 ,EF5F>3B-
( ) 30 5 23 2
%0 %0 3# 5 0
%#B - 4' 5 %4$ %4 ,
#
<

0 5 3% B$ 5 2% <
*on<ition satis8ie<
Bolt size
Actual
number,
R (mm) *
s

s
%
C - , 2
%
R g % C + +
M%4 %53 20 23 '3 $''5$4 330
M%B 2
%4 2' '3 #B%51' 33$
M20 2 %2 #0 '3 2B45$B 340
M22 2
%2 ## '3 2B45$B 344
32
Plant Design Project II
vii. To determine flange thickness, t
*
P %
; $# 5 203''
$
%0$B 5 0 %0 30 5 0
$
# 2
%




7777555775 ,EF5F>31-
% 2
; ) ;
K 2#%205B02 J 203''5$#0
K 23$#5#'2 N
;
o
K #0'0254B2 N
) ; ;
o

#
K #0'0254B2 J 2#%205B02
K '3B%5BB N
m
g
R , 02'0'2 5 0
2
%0 $#04 5 %
02' 5 0
2
$
%
%

+ +

77755575575 ,EF5F>40-
m
, g R
, 0#1%$ 5 0
2
0%2 5 0 %0 $#04 5 % 02' 5 0
2
$
# %
2

+ +

+ +

75 ,EF5F>4%-
m
C C
, 0%2 5 0
2
3# 5 0 33$ 5 0
2
#

7777777555775 ,EF5F>42-
Mo:ent 9n<er o6erating con<itionsG
# # 2 2 % %
, ; , ; , ; M
o
+ +
777555777775 ,EF5F>
4#-
- 0%2 5 0 , BB 5 '3B% - 0#1%$ 5 0 , #'2 5 23$# - 02'0'2 5 0 , $# 5 203'' + +
o
M
K '$'5402
N:
For @olting 96 con<itionsG
g
( m
S
& &
;
+

2
777555777775 ,EF5F>4$-
2
40 5 2$#0 mm &
m

2
'2 5 24#$ mm &
(

* ; 0B 5 #$130' %#B
2
'2 5 24#$ 40 5 2$#0

+

#
, ; M
g

77755577555775775 ,EF5F>43-
3#
Plant Design Project II
*m M
g
0B 5 $%1$ 0%2 5 0 0B 5 #$130'
M
g
D M
o
Mo:ent 9n<er o6erating con<ition, M
o
is controlling
M K M
o
K #125#$B N:
$
F
%S
y MC
t
2
7775557775777575 ,EF5F>
44-
mm t 34 5 %$3
%00 %0 3 5 0
33 5 %B % %0 #$B 5 #12
#
#
2

t K %2504:: ,050%204:-
)olt 6itc; correcting 8actor, C
F
2 & %
2

,
_

t d
%
C
s
F
77755577755775 ,EF5F>4'-
m %
s
%0B'B 5 0
%4
33$ 5 0

30$3 5 %
0%204 5 0 %0 %B 2
%0B'B 5 0
2 & %
#

,
_

F
C
224' 5 %
F
C
M9lti6l= calc9late< t @=
F
C
t K 050%$'1: ,%$5'1::-
Select 8lange t;icAness %350 ::
3.8 Design of nozzles (similar to design of flanges)
3.8.1 Nozzles for piping
i. To determine the gasket width
Flange :aterial *ar@on Steel ,IS. 200$>%142 *lass 2-
)olting :aterial Hot rolle< car@on steel
GasAet As@estos
Internal <ia:eter o8 6i6e 05%3:
3$
Plant Design Project II
Design 6ress9re %B0APa
*orrosion alloCance 05003:
AlloCa@le stress o8 8lange :aterial B53%0
%
N&::
2
AlloCa@le stress o8 @olting :aterial %5#B%0
2
N&:
2
Ass9:e g
1
K g
!
&05'0'
Ass9:e C
F
K % an< y K %B533
*;oose %54:: t;icAness
: K 25'3
= K 23530
Mini:9: gasAet Ci<t; K %0 ::
+
P @f
D P
t
i
i i
+

2
77777775775 ,EF5F>4B-
0all t;icAness.
m t 022'4 5 0 003 5 0
%B0 5 0 B3 5 0 % 2
%3 5 0 %B0 5 0
+

) K 05022'4 O 05%3: K 05%'2'4 :

2 & %
0
- % ,

,
_

m P y
Pm y
d
d
i
7775557775555775 ,EF5F>3%-
00#2% 5 %
0

i
d
d
!et d
i
o8 gasAet K%0 :: larger t;an Eessel o9ter <ia:eter
d
i
K 0502'3B$ :
d
!
K 0502'4'# :
GasAet Ci<t;, * K
m 0 3 $2'2 5 $
2
02'3B$ 5 0 02'4'# 5 0

*;oose an eEen Ci<t;, * K 2::

)asic gasAet seating Ci<t; (
o
K
mm
*
%
2
2
2

ii. To determine the diameter at location of gasket;
!ocal reaction, C K d
i
O *
K 0502B3B$:
33
Plant Design Project II
iii. To estimate the bolt loads
!ocal <9e to <esign 6ress9re, ) K P
C

$
2

77777777775 ,EF5F>
32-
) K #34B532$
!ocal <9e to ;96 joint tig;t 9n<er, )
9
K
mP ( C - 2 ,
77775555 ,EF5F>
3#-
( K 253 ::
)
9
K $025#4B N
Total o6erating loa< K ) O )
9

;
o
K #34B532$ O $025#4B K #1'05B12 N
!oa< to seat gasAet 9n<er @olting 96 con<itionsG
;
g
K C ( y777555777777777777775775 ,EF5F>3$-
* ;
g
'23 5 314B
Since ;
g
N ;
o
, ;
g
is controlling loa< K 0g is t;e controlling loa<
iv. To determine the minimum bolting area
o
g
o m
S
;
& &
77755577757775 ,EF5F>33-
2
40 5 2$#0
%#B
%$ 5 ##3$2#
mm & &
o m

34
Plant Design Project II
!et 9s consi<er )olt si?e, M%4, M%B, M20 an< M22
Ta@le %0. )olt si?e
Bolt size
Root diameter
(mm)
Root area, 1
r
(mm
2
)
1
m
21
r
Actual
number,
M%2 %53 153$ '5%$1e>3 B502$B %2
M%$ %53 %%5%%1 15'%%e>3 351'0$ B
M%4 %53 %#5%1 %#454$
$5%1B0
B
M%B 2 %$5$B %4$54'
#5$B##
$
M20 2 %45$B 2%#5#%
254B12
$
M22 2 %B5$B 24B522
25%#B4
$
3'
Plant Design Project II
Ta@le %%. )olt si?e
4 $2'3 5 2#
%
0 g
- , 2
%
R g % C + +
777555777777777777775755575 ,EF5F>34-
- - 4 $2'3 5 2# ,, 2 %3 5 0 R 0 C + +
Fro: ta@le, t;e :ini:9: )*D o@taine< c;oosing M%$ D %53 @olts, B n9:@ers
)olt circle <ia:eter K 05%1#4:
N9:@er o8 @olts K
Si?e K M%$ D %53
R K 05022 :
v. To determine the flange outside diameter
& K C O @olt <ia:eter O 05022 :7777777757555775 ,EF5F>3'-
K 05%1#4O 050%B O 05022
K 052##4 :
& K 052##4 :
vi. To check gasket width
y
* C
S &
g (
2 <

7775557775775555 ,EF5F>3B-
$# 5 32 41 5 $3 <
*on<ition satis8ie<
Bolt size
Actual
number,
R (mm) *
s

s
%
C - , 2
%
R g % C + +
M%2 %53
%2 20 '3
2B45$$%B %10
M%$ %53
B 22 '3
%10514%2 %1$
M%4 %53
B 23 '3
%10514%2 200
M%B 2
$ 2' '3
135$B031 20$
M20 2
$ #0 '3
135$B031 2%0
M22 2
$ ## '3
135$B031 2%4
3B
Plant Design Project II
vii. To determine flange thickness, t
* ; 4B3 5 %0$
%
7777777555775 ,EF5F>
31-
% 2
; ) ;
K 2B2'5B4$*
;
o
K #2435$3'
) ; ;
o

#
K ##2510B *
m
g
R , 02#3 5 0
2
%
%
+ 7775557775575 ,EF5F>40-
m
, g R
, 03#$' 5 0
2
# %
2

+ +
777575 ,EF5F>4%-
0B#2$ 5 0
2
#

C C
,
777755555775 ,EF5F>42-
Mo:ent 9n<er o6erating con<itionsG
# # 2 2 % %
, ; , ; , ; M
o
+ +
777555777775 ,EF5F>
4#-
*m M
o
#'' 5 %B%
For @olting 96 con<itionsG
g
( m
S
& &
;
+

2
777555777775 ,EF5F>4$-
* ; %' 5 %4B2#4
#
, ; M
g

77755577555775775 ,EF5F>43-
*m M
g
1B 5 %$00#
M
g
D M
o
Mo:ent 9n<er o6erating con<ition, M
o
is controlling
M K M
o
K %B%5#'' N:
31
Plant Design Project II
$
F
%S
y MC
t
2
7775557775777575 ,EF5F>44-
m t 31 5 %%1%
2

t K 050#$3:
)olt 6itc; correcting 8actor, C
F
2 & %
2

,
_

t d
%
C
s
F
77755577755775 ,EF5F>4'-
0$#3# 5 0
s
%
B#$33 5 0
F
C
1%#3 5 0
F
C
M9lti6l= calc9late< t @=
F
C
t K 050#%32 : ,#%532::-
Select 8lange t;icAness #2 ::
40
Plant Design Project II
4.0 SPECIFICATION SHEETS AND DETAILED DRAWING
4.1 Specification Sheet
Column tray data sheet (C-702)
Tag. No. C-702
Sheet No 1 of 1
Function
To separate Ethylene Oxie
fro! "ater
Operating data

TOWER INI!E !I"#ETER 1#1$ !! TOWER O$TI!E !I"#ETER 1#1% !!
TR"% &"CIN' 1.0 ! ENRIC(IN' TR"% 7 T&'(S
TOT") TR"% IN ECTION 20 T&'(S RECTI*%IN' TR"% 1) T&'(S
Operating +onditions
*EE! TO& ,OTTO#
TE#&ER"T$RE (
O
C) #$.* #2.# 1#1.)
&RE$RE (-&") 10#0 10*0 1100
#O)"R *)OW(-#O).(R) $7#.%# *#2.%0 %$.0#
#" *)OW (-'.(R) 2#+*0.00 2**#2.)2 2#$7.$#
#W (-'.-#O)) +1.%01 +).### 1#.112
!ENIT% (-'.#
/
) 20.$#) 11.*2#+ ##1.212%
0ICOIT% (C&) 1.77%E-0* 1.+#+2E-0+ 1.+$+2E-0+
Te+hni+al . #e+hani+al data
TOWER #"N(O)E !I"#ETER 7*$.)0 !! *)"N'E !I"#ETER %$2.7+ !!
*EE! NO11)E T(IC-NE +.)2 !! ,O)T CIRC)E !I"#ETER 1%).$ !!
0"&OR NO11)E T(IC-NE 2.0) !! ($, !IT"NCE -
RE*)$2 NO11)E T(IC-NE +.10 !! *)"N'E T(IC-NE +*.2) !!
)I3$I! NO11)E T(IC-NE +.27 !! (E)) T(IC-NE 10.00 !!
,OI) $& NO11)E T(IC-NE 2.00 !! #"2 T(IC-NE O* ($, -
CO)$#N INI!E !I"#ETER 1#1$.00 !! '"-ET INI!E !I"#ETER 7#+.)$ !!
CO)$#N O$TI!E !I"#ETER 1#1%.00 !! '"-ET O$TI!E !I"#ETER 7#$.#$ !!
CORROION "))OW"NCE ).00 !!
0EE) #"TERI") C'&,ON STEE-
IE0E TR"% (O)E
!I"#ETER 10 !!
TR"% #"TERI") C'&,ON STEE- WEIR )EN'T( 1)$2 !!
-IRT #"TERI") C'&,ON STEE- WEIR (EI'(T *0.00 !!
TOWER "TT"C(#ENT - (O)E &ITC( -
TR"% *RO# TO& TO ,OTTO# 20 T&'(S !OWNCO#ER "RE" 0.)10# !
2


.ate of en/uiry .ate of orer
Orer No. .&0 No.
1anufacturer

Notes
213 4nternal 5apor an li/ui loaings at the li!iting sections are re/uire to ensure proper tray esign.
.ensities are re/uire at actual insie to"er conitions of te!perature an pressure6 5iscosity is not re/uire unless greater than 0.7 cp
223 Cross out i!ensions units "hich o not apply. Tray supplier to a5ice.
7repare NE' NE'
Chec8e
'ppro5e
.ate Eng6 7rocess &e5 ,y 'ppr. .ate
Ser5ice Ethylene Oxie purification Co!pany 0&O97 )+ CONS9-T'NT
E/uip!ent No. C-702
4%
Plant Design Project II
7ro:ect No.
4.2 Technical Engineering Drawing
42
Plant Design Project II
5.0 COSTING
Costing of Ethylene Oxide Purifier Column (C-702)
Data reF9ire<.>
Dia:eter, DcK%5B%40 :
Heig;t, Hc K20500 :
O6erating Press9re K %03# APa
T=6e o8 Eessel K SieEe tra=
Material o8 constr9ction K *ar@on steel
N9:@er o8 tra=, Nact9al K 20
4#
Plant Design Project II
Ste9 1: Pur+h,se +ost of 8erti+,l Columns
Fig9re %3. P9rc;asing cost o8 Eertical col9:ns
Fro: t;e gra6; a@oEe, t;e 69rc;asing cost o8 col9:n alone Cit;o9t tra= an< internals
Cit; re8erence o8 ;eig;t o8 col9:n <esigne< at 20 :eters, t;e cost <e<9ce< is
a66roDi:atel= YB3,000500 US <ollars5
Ste9 ": Pur+h,se +ost of $r,ys in $r,y Columns
4$
Plant Design Project II
Fig9re %4. P9rc;ase< cost o8 tra=s in tra= col9:ns
T;e gra6; a@oEe <etails t;e 69rc;asing cost o8 tra=s o8 Eario9s t=6es o8 tra= col9:ns
:a<e o8 Cit; :9lti8ario9s t=6es o8 :aterial5 T;e col9:n <esigne< is :a<e o9t o8 car@on
steel an< Cit; sieEe t=6e tra=s5 )ase< on <esigne< <ia:eter o8 %5B%40 :, t;e 69rc;ase<
cost 8or tra=s t;at incl9<es tra= <ecA, risers, <oCnco:ers an< str9ct9ral steel 6arts is YB30
US <ollars 6er tra=5 T;9s, since col9:n consists o8 20 tra=s Cit; a F9antit= 8actor o8 %500
,@ase< on ta@le in gra6; a@oEe-, t;e total cost o8 tra=s 8or Et;=lene ODi<e 69ri8ier col9:n
*>'02 is Y%',000500 US <ollars5
Ste93: Cost of industri,l Ansul,tion
43
Plant Design Project II
Fig9re %'. Installe< cost o8 Eario9s in<9strial ins9lations 8or col9:ns, toCers an< tanAs5
T;e ins9lation selecte< 8or t;e <istillation col9:n is :ineral Cool o8 05% : in t;icAness5
Mineral Cool is alternatiEel= AnoCn as 8i@erglass an< 8ro: gra6; a@oEe, t;e cost to
ins9late col9:n Cit; an al9:in9: jacAet is a66roDi:atel= Y%30 US <ollars 6er sF9are
:eter5 T;e <istillation col9:n <esign is o8 ;eig;t 20 :eter an< <ia:eter %5B%40 :eter5
T;9s area o8 C;ole <istillation col9:n is.
Area o8 col9:n. 20 : " ,#5%$2Q%5B%40 :- K%%$5%%' :
2
T;9s, total cost o8 ins9lation. %%$5%%'Q Y%30 US <ollars K Y%',%%'533 US <ollars
$ot,l Pur+h,se 0/ui9ment +ost -PC0.
T;e total cost o8 69ri8ier col9:n *>'02 is. P9rc;ase cost o8 /ertical *ol9:ns O P9rc;ase
cost o8 Tra=s in Tra= *ol9:ns O *ost o8 in<9strial Ins9lation5
. YB3,000500 US <ollars O Y%',000500 US <ollars O Y%',%%'533 US <ollars K
44
Plant Design Project II
$119,117.55 USD
6.0 OPERATING PROCEDURE
6.1 Pre Start-Up Procedure
No. Procedures Steps Checklist
4'
Plant Design Project II
% /eri8= t;at t;e toCer is rea<= 8or start 965 Ens9re t;at all
:aintenance CorAs ;aEe @een co:6lete<, all @lin<s are re:oEe<
an< 6ro6er gasAets are installe<5
2 *;ecA an< :aAe s9re t;at all 69:6s ;aEe 6ro6er l9@rication
# *o::ission cooling Cater
$ *on<9ct 9rge ,to re:oEe gases 8ro: *>'02- in case t;e col9:n
Cere o6ene< 8or :aintenance5 P9rge 8or #0 :in9tes or 9ntil t;e
leEel o8 oD=gen gas is @eloC 3H5
3 *lose t;e reF9ire< @lee<s an< install 6l9gs or ca6s a8ter 69rging5
4 *;ecA t;e 8olloCing trans:itters are at ?ero.
Stea: to re@oiler an< Ea6or to con<enser
6.2 Start-Up Procedure
No. Procedures Steps Checklist
%
*lose t;e isolation EalEe to isolate col9:n *>'025
2 Fill 96 *>'02 to a@o9t 30 H leEel @= o6ening t;e EalEe5
# *;ecA t;e leEel in t;e sig;t glass to Eeri8= t;e leEel trans:itter in
4B
Plant Design Project II
*>'02
$ 0ar: 96 t;e col9:n @= t;rottling t;e stea: 8loC to t;e re@oiler5
3 *ontrol t;e @otto: leEel at 30 H5
4
Increase t;e stea: to 9ntil t;e @otto: te:6erat9re reac;es t;e
<esire< Eal9e ,or 9ntil t;e stea: 8loC rate reac;es t;e <esire<
Eal9e-5
'
Start t;e re8l9D 8loC to *>'02 an< :aintain t;e re8l9D 8loC o8
stea: on re@oiler5
B
A<j9st t;e re8l9D to @ring t;e te:6erat9re to t;e <esire<
te:6erat9re
1
Note. 0;en re8l9D is co::issione< to t;e col9:n *>'02, t;e
C;ole col9:n te:6erat9re 6ro8ile Cill start to <ro65 I::e<iatel=
increase t;e stea: to re@oiler to co:6ensate Ea6or loa< lost <9e
to t;e cooling e88ect 8ro: t;e re8l9D5 Tr= to increase t;e stea: to
re@oiler to :aintain a goo< col9:n te:6erat9re 6ro8ile ,9se t;e
toCer te:6erat9re as g9i<e-5 Use t;e stea: 8loC incre:ent
8olloCe< @= re8l9D incre:ent 9ntil t;e col9:n is at its <esire<
o6eration5
%0
A<j9st t;e stea: 8loC 9ntil @otto: te:6erat9re reac;es <esire<
te:6erat9re
%%
Sa:6le t;e toCer @otto:s as t;e toCer sta@ili?es5 A<j9st t;e
re8l9D 8loC as necessar= to Aee6 t;e to6 6ro<9ct at <esire<
s6eci8ication5
%#
Monitor t;e to6 anal=?ers an< co:6are t;e: Cit; t;e la@
anal=sis5 MaAe slig;t a<j9st:ents on t;e stea: 8loC or re8l9D as
necessar= to control t;e toCer at its <esire< con<itions5
41
Plant Design Project II
6.3 Shutdown Procedure
No. Procedures Steps Checklist
%
T9rn o88 t;e <istillation col9:n stea: EalEe5
2 SloCl= close t;e :ain stea: inlet EalEe to *>'025
# Drain t;e liF9i< 8ro: t;e sieEe tra=s insi<e t;e *>'025
$
Drain t;e 8ee< tanA5 T;e 8ee< EalEe to *>'02 s;o9l< @e close< an<
t;e <rain EalEe s;o9l< @e o6ene< an< t9rn on t;e 69:65
3
Drain t;e sol9tion in t;e re@oiler to t;e 8ee< tanA an< note its
concentration5 T;e <rain EalEe s;o9l< @e close< an< t;e 8ee<
EalEe s;o9l< @e o6ene<5
4
Drain t;e still 6ot an< t;e 8ee< tanA5 )ot; t;e 8ee< EalEe an< t;e
<rain EalEe s;o9l< @e o6ene< an< t;e 69:6 s;o9l< @e on5
' T9rn o88 all Cater an< 6oCer so9rces5 Un6l9g t;e 69:65
7.0 REFERENCES
%5 Sea<er an< Henle= ,%11B-, Se6aration Process Princi6les, 0ile= an< Sons, NeC
orA5
25 R5+ Sinnott ,%11#-, *o9lson an< Ric;ar<sonIs *;e:ical Engineering, /ol9:e 4,
ElseEier )9tterCort;>Heine:an5
#5 (a:es M Do9glass ,%11B-, *once6t9al Design o8 *;e:ical Processes, McGraC
Hill International E<itions5
$5 *;ristie (5 GeanAo6lis ,%11#-, Trans6ort Processes an< Unit O6eration, #
r<
E<ition, Prentice Hall5
35 Ro@in S:it; ,2000-, *;e:ical Process Design, McGraC Hill International
E<itions5
'0
Plant Design Project II
45 Stic;:air an< Fair ,%11B-, Distillation Princi6les an< Practice, 0ile= /*H
'5 G D Ulric;, *;e:ical Engineering Plant Econo:ics an< *ost *alc9lation
B5 )5* );attac;ar==a ,%1B3-, Intro<9ction to *;e:ical EF9i6:ent Design
Mec;anical As6ect, *)S P9@lis;ers an< Distri@9tors5
15 Rior<an an< Pa9le= ,%111-, Tec;nical Re6ort 0riting To<a=, '
t;
E<ition, T;o
s
M
on !earning5
8.0 APPENDIX
Ethylene Oxide Purifier Column C-702
'%