Reactor Design For The Conversion of Waste Plastic Into Fuel Oil and Gas

See
discussions, stats, and author profiles for this publication at: https://www.researchgate.net/publication/297978449
Reactor Design for the Conversion of Waste

Plastic into Fuel Oil and Gas
Technical Report April 2015

DOI: 10.13140/RG.2.1.4757.1607
CITATIONS READS
0 655
1 author:
Kasun Thivanka Samarasiri

University of Moratuwa
7 PUBLICATIONS 0 CITATIONS
SEE PROFILE
Some of the authors of this publication are also working on these related projects:
Strategies to overcome inhibition caused by long-chain fatty acids in anaerobic digestion process
View project
All content following this page was uploaded by Kasun Thivanka Samarasiri on 13 March 2016.
The user has requested enhancement of the downloaded file.

UNIVERSITY OF MORATUWA
Faculty of Engineering
GPA Module CH 4202: Comprehensive Design Project

INDIVIDUAL DESIGN REPORT
ASSIGNMENT 8
Detailed equipment design description and parameter calculation

Reactor Design for the Conversion of Waste Plastic into
Fuel Oil and Gas
B.K.T. SAMARASIRI
100472X
Department of Chemical and Process Engineering

University of Moratuwa, Sri Lanka.
PREFACE
Attitude is the best morality in life which can make a man more responsible and productive
than he was before. This is the most important lesson Ive learnt during my undergraduate
period of 4 years at the Department of Chemical and Process Engineering, University of
Moratuwa. The lessons Ive learnt, experiences Ive gained and the people Ive met during
this period of my life were priceless and unforgettable. I think that experience will give me a
huge boost in my higher studies and future carrier. So, I would say that it was the best period
of my life, without any doubt.
The comprehensive design project consists of four group design assignments and four
individual design assignments. Hence the group design assignments were completed; selected
individual design will be focused from this report. In the assignment 5, detailed equipment
design description and parameter calculation of the individual design of the selected
equipment of the plant will be presented. In the assignment 6, mechanical design and drawing
will be discussed. In the assignment 7, control, piping, instrumentation and other aspects will
be presented. In the assignment 8, Final individual submission will be done.
From this individual design report, my main objective is to present descriptive information
about the equipment design and the parameter calculation. It will be divided into several
chapters to discuss about it in detail.
ACKNOWLEDGEMENT
Studying as an undergraduate at Department of Chemical and Process Engineering is the best

period in my life without any doubt. Ive learnt how to manage and plan the rest of my whole
life within this very short period of my life. For that greatest achievement, first of all I should
give my gratitude to my farther; Eng. Sarath Samarasiri and my mother, Mrs. Lakshmi Peiris
whom guided me from my childhood. Secondly, I would like to give my gratitude to Dr. C.
W. W. Kannangara and the general public in Sri Lanka whom gave me this golden
opportunity to study from free education up to this level.
In my comprehensive design project, I should give my gratitude to Dr. Mahinsasa Narayana

whom supervised us throughout the module and Dr. Olga Gunapala whom coordinated our
work throughout the module. I should also give my gratitude to my fellow colleges Dilhara
Sethunga, Shaniru Tharaka, Isuru Sampath and Viranga Shehani whom worked with me
together to present a successful group design work.
In this individual design assignment, I should give my gratitude to Dr. Mahinsasa Narayana,
Lecturer Supuli Jayaweera and Lecturer Poorna Vidanage of Department of Chemical and
Process Engineering, University of Moratuwa whom directed me to complete my detailed
equipment design description and parameter calculation.
Additionally I would like to thank Prof. Paul Williams at University of LEEDs whom carried
out researches on usage of HZSM-5 zeolite catalyst for the conversion of waste plastic into
fuel oil and gas. Eng. Jayasiri Kumarasinghe from Sigma Delta Technologies (pvt.) ltd. and
Eng. Harindra Kodagoda from Ceylon Petroleum Corporation also helped me in selecting the
process and the designing of the reactor. I would also like to thank both of them. Special
thanks to Eng. Jayasiri Kumarasinghe whom advised me throughout the design. I would like
to thank Mr. Lakshman Perera, CEO of C&T Worldwide (Pvt.) Ltd. whom also encouraged
me to carry on my project.
Finally, I should also give my gratitude to my teachers whom taught me at school, my other
university friends whom helped me during my comprehensive design project, university
lecturers whom gave us lectures to be the person that Im today.
ABSTRACT
Chemical reactor design is the major equipment design in each and every chemical plant of
different industries all around the world. Whenever the reactor fails or does not work up to
the expected process requirement, total production process will be failed. Therefore reactor
designing is one of the crucial factors in designing of a chemical process plant. Different
technologies have been developed by the scientists and researchers all around the world in
order to do a proper design of a chemical reactor. The design of a reactor is very complex and
it should be done by considering the whole chemical process in detail.
The scientific method of designing and developing a reactor should be done by step by step.
The first step is to prepare a laboratory scale reactor unit and run several testing to ensure
whether the expected outcomes will be achieved. After a successful laboratory scale testing
then a pilot scale plant trial could be done. Scaling up the reactor should be done at the end.
Due to the time considerations, the appropriate engineering techniques will be followed in
this individual equipment design in order to make sure that itll be up to the expected
standards.
This report includes detailed design of the reactor in a process plant which is to be converted
waste plastic into fuel oil and gas using fluidised-bed catalytic pyrolysis method which has
been used HZSM-5 Zeolite as the catalyst. According to the group design which was
previously done in the comprehensive design project, there were two main reactors at the
initial stage of the waste plastic into fuel oil and gas conversion plant. A detailed equipment
design description of those two reactors will be done according to the process parameters
from this report.
TABLE OF CONTENTS
LIST OF FIGURES ................................................................................................................................ 4
1. INTRODUCTION .............................................................................................................................. 5
1.1. PLANT OVERVIEW .................................................................................................................. 5
1.2. CLASSIFICATION OF REACTORS ......................................................................................... 6
1.2.1. CLASSIFICATION BY THE MODE OF OPERATION .................................................... 6
1.2.2. CLASSIFICATION BY THE PHASES PRESENT ............................................................. 7
1.2.3. CLASSIFICATION BY PROCESS ..................................................................................... 7
1.2.4. CLASSIFICATION BY OPERATING PRESSURE ........................................................... 8
1.2.5. CLASSIFICATION BY OPERATING TEMPERATURE .................................................. 9
1.2.6. CLASSIFICATION BY OPERATING CONDITION ......................................................... 9
1.2.7. CLASSIFICATION BY GEOMETRICAL SHAPE ............................................................ 9
1.2.8. CLASSIFICATION BY ORIENTATION .......................................................................... 10
1.2.9. CLASSIFICATION BY WALL THICKNESS .................................................................. 11
1.2.10. CLASSIFICATION BY HEATING METHOD ............................................................... 11
1.2.11. CLASSIFICATION BY FABRICATING MATERIAL .................................................. 11
1.2.12. CLASSIFICATION BY FABRICATION METHOD ...................................................... 12
1.2.13. CLASSIFICATION BY LOCATION .............................................................................. 13
1.3. REACTOR DESIGN ................................................................................................................. 14
1.3.1. SELECTION OF THE REACTOR PROCESS .................................................................. 14
1.3.2. PROS AND CONS OF FLUDISED BED CATALYTIC PYROLYSIS REACTORS ...... 14
1.3.3. DETERMINATION OF THE NUMBER OF REACTORS ............................................... 15
1.3.4. GENERAL DESIGN OVERVIEW OF THE REACTOR FOR THE CONVERSION OF
WASTE PLASTIC INTO FUEL OIL AND GAS ........................................................................ 15
1.3.5. BASIC PRE DESIGN LAYOUT OF THE REACTOR ..................................................... 16
1.4. CHEMICAL DESIGN ............................................................................................................... 17
1.4.1. MATERIAL BALANCE FOR THE REACTOR ............................................................... 17
1.4.1.1. ASSUMPTIONS .......................................................................................................... 17
1.4.1.2. CALCULATION ......................................................................................................... 18
1.4.1.2.1. FEED FLOW RATES (at 25C, 1atm) ................................................................. 18
1.4.1.2.2. PRODUCT FLOW RATES (at 500C, 1.5atm) ................................................... 19
1.4.1.3. SUMMARY ................................................................................................................. 20
1.4.2. ENERGY BALANCE FOR THE REACTOR ................................................................... 21
1
1.4.2.1. ASSUMPTIONS .......................................................................................................... 21
1.4.2.2. CALCULATION ......................................................................................................... 21
1.4.2.2.1. ENTHALPY OF FORMATION OF FEED (at 500C, 2atm) .............................. 24
1.4.2.2.2. ENTHALPY OF FORMATION OF PRODUCT (at 500C, 2atm) ..................... 25
1.5. CALCULATION OF DIMENSIONS OF THE REACTOR ..................................................... 28
1.5.1. CALCULATION OF VESSEL HEIGHT AND DIAMETER ........................................... 28
1.5.1.1. LITERATURE DATA OF THE CHEMICAL AND PHYSICAL PROPERTIES OF
THE CATALYST ..................................................................................................................... 29
1.5.1.2. KUNII AND LEVENSPIEL FLUIDISED-BED REACTOR MODEL ...................... 30
1.5.1.2.1. CALCULATION OF THE SPHERICITY OF HZSM-5 ZEOLITE CATALYST
.............................................................................................................................................. 32
1.5.1.2.2. CALCULATION OF THE VOID FRACTION AT THE POINT OF MINIMUM
FLUIDIZATION................................................................................................................... 33
1.5.1.2. CALCULATION OF THE DIAMETER AND HEIGHT OF THE VESSEL IN
MINIMUM FLUIDIZATION................................................................................................... 33
1.5.2. CALCULATIONS FOR THE NITROGEN GAS SUPPLY .............................................. 36
1.5.2.1. CALCULATION OF MINIMUM FLUIDIZATION VELOCITY ............................. 36
1.5.2.2. CALCULATION OF THE PRESSURE DROP ACROSS THE FLUIDISED BED
REACTOR ................................................................................................................................ 37
1.5.3. CALCULATIONS FOR THE GAS DISTRIBUTOR PLATE ........................................... 37
2. MECHANICAL DESIGN ................................................................................................................ 39
2.1. MATERIAL SELECTION ........................................................................................................ 39
2.2. CALCULATION OF DESIGN TEMPERATURE ................................................................... 41
2.3. CALCULATION OF DESIGN PRESSURE ............................................................................. 42
2.4. DETERMINATION OF DESIGN STRESS .............................................................................. 43
2.5. CALCULATION OF WALL THICKNESS OF THE SHELL ................................................. 44
2.6. SELECTION OF SUITABLE END CLOSURES ..................................................................... 46
2.6. SELECTION OF SUITABLE REACTOR INTERNALS ......................................................... 48
2.6.1. SELECTION OF A SUITABLE DISTRIBUTOR PLATE ................................................ 48
2.7. DESIGN OF NOZZLES AND OPENINGS .............................................................................. 50
2.8. VESSEL SUPPORTS ................................................................................................................ 53
2.8.1. CALCULATION OF THE TOTAL LOAD OF THE VESSEL ......................................... 53
2.8.1.1. CALCULATION OF THE WEIGHT OF THE SHELL ............................................. 54
2.8.1.2. CALCULATION OF THE WEIGHT OF THE END CLOSURES ............................ 54
2.8.1.3. CALCULATION OF THE WEIGHT OF THE DISTRIBUTOR PLATE .................. 55
2.8.1.4. CALCULATION OF THE TOTAL LOAD ................................................................ 55
2
2.8.1.5. CALCULATION OF THE SKIRT WALL THICKNESS .......................................... 56
2.8.1.6. CALCULATION OF THE BEARING PLATE THICKNESS ................................... 58
2.8.1.7. CALCULATION OF THE BOLT ROOT THICKNESS ............................................ 59
3. CONTROL, PIPING, INSTRUMENTATION AND OTHER ASPECTS ....................................... 61
3.1. PIPE, PUMP AND VALVE SELECTION ................................................................................ 61
3.1.1. PIPE SELECTION .............................................................................................................. 61
3.1.2. PUMP SELECTION ........................................................................................................... 65
3.1.3. VALVE SELECTION ........................................................................................................ 66
3.2. FLANGE SELECTION ............................................................................................................. 67
3.2. PIPING AND INSTRUMENTATION DIAGRAM .................................................................. 68
3.3. START UP AND SHUT DOWN PROCEDURES ................................................................... 69
3.3.1. START UP PROCEDURE ................................................................................................. 69
3.3.1. SHUT DOWN PROCEDURE ............................................................................................ 70
3.4. PROCESS CONTROL ASPECTS ............................................................................................ 70
3.5. SAFETY ASPECTS .................................................................................................................. 71
3.6. ECONOMIC ASPECTS ............................................................................................................ 73
ANNEXES ............................................................................................................................................ 77
REFERENCES ..................................................................................................................................... 78
3
LIST OF FIGURES
Figure 1: Types of Vessel Heads ............................................................................................................ 10

Figure 2 : Operating Temperatures of Metals ...................................................................................... 12
Figure 3 : Waste Plastic into Fuel Oil by Catalytic Pyrolysis Process..................................................... 14
Figure 4 : FCC Reactor Predesign .......................................................................................................... 16
Figure 5 : Energy Balance For Waste Plastic Cracking .......................................................................... 22
Figure 6 : Energy Balance for HZSM5 Zeolite ........................................................................................ 22
Figure 7 : Energy Balance for Nitrogen Gas .......................................................................................... 23
Figure 8 : Length to Diameter Ratio ...................................................................................................... 28
Figure 9 : Vessel Geometry ................................................................................................................... 28
Figure 10 : Structure of FCC Particle ..................................................................................................... 29
Figure 11 : Different Types of Fluidization ............................................................................................ 31
Figure 12 : Pressure drop across the fluidised-bed vs. Air Velocity ...................................................... 31
Figure 13 : Geometry of the process vessel .......................................................................................... 34
Figure 14 : Pressure drop across the bed ............................................................................................. 37
Figure 15 : Types of distributor plates .................................................................................................. 38
Figure 16 : Classification of Metals by their temperature range .......................................................... 40
Figure 17 : Materials for high temperature Applications ..................................................................... 40
Figure 18 : Temperature Drop across the Vessel .................................................................................. 41
Figure 19 : Torispherical Head design Overview................................................................................... 46
Figure 20 : Distributor Plate Design ...................................................................................................... 48
Figure 21 : Different Types of Distributor Plates .................................................................................. 49
Figure 22 : Skirt Supports ...................................................................................................................... 56
Figure 23 : Wind Patterns in Sri Lanka .................................................................................................. 56
Figure 24 : Wind Load ........................................................................................................................... 56
Figure 25 : Tensile and Compressive Characteristics of SS ................................................................... 57
Figure 26 : Selection of Fluid Services ................................................................................................... 63
Figure 27 : P&I Diagram ........................................................................................................................ 68
Figure 28 : NFPA Fire Diamond ............................................................................................................. 72
Figure 29 : Layers of Protection ............................................................................................................ 72
4
1. INTRODUCTION
1.1. PLANT OVERVIEW
Over thousands of years, the human race was evolved by the development of new concepts,
inventions and technologies through the discoveries. From the discovery of the fire to the
space shuttle, the science and technology has developed by the scientists, researchers,
mathematicians and etc. all around the world. The growth of the population of the human
race gradually rises up day by day because of the development of these new technologies.
Today, the world is facing with issues because of the limited availability of the resources to
fulfill the expectations of the each and every human being. In order to overcome this issue,
the scientists and researchers have developed three key technologies. They are,
1. Reducing
2. Reusing
3. Recycling
In the 20th century with the development of petroleum industries, plastics have become one of
the commonly used materials in our day today work. Most of these plastics are non-
biodegradable and as a result of that waste plastic has become one of the most common
garbage problems in the cities all around the world. In order to avoid this, reducing, reusing
and recycling of plastics will be done. Most of the plastics are recyclable but some are non-
recyclable due to some restrictions in their chemical structure and physical parameters.
Plastic is an outcome of the petroleum industry. In the late 90s the conceptual idea of turning
non-recyclable plastic waste into fuel oil and gas was developed. Since then, thousands of
researches were carried out all around the world and now it has been developed into
commercial scale to reduce the environmental pollution and generate extra income from
waste plastics which cannot be recyclable.
In the plant design of converting waste plastic into fuel, the major equipments such as
reactors, heat exchangers, flash distillation columns, scrubbers, cooling towers and etc. must
be individually designed and combined by using advanced technologies. Among them,
chemical reactor designing is one of the advanced equipment designing technology in the
field of chemical and process engineering.
5
1.2. CLASSIFICATION OF REACTORS
The classification of chemical reactors is generally done by considering the characteristics of

the chemical process as mentioned below.
1. Mode of operation (batch, continuous, semi-batch or semi-continuous)
2. Phases present (homogeneous or heterogeneous)
3. Process (stirred tank reactor, tubular reactor, packed bed, uidised-bed)
4. Operating pressure (internal, external, atmospheric)
5. Operating temperature (low, normal, medium, high)
6. Operating condition (open, closed)
7. Geometrical Shape (cylindrical, spherical, rectangular)
8. Orientation (vertical, horizontal, sloped)
9. Wall thickness (thin walled, thick walled)
10. Heating method (fired, unfired)
11. Fabricating material (steel, cast iron, aluminium, etc.)
12. Fabrication method (Field/shop fabricated, welded, cast forged, multi-layered, etc.)
13. Location (Inside plant, field equipment)
The above characteristics should be separately identified in order to make a proper design.
1.2.1. CLASSIFICATION BY THE MODE OF OPERATION
In batch reactors, all the chemical regents are added in the beginning and when the reaction
process proceeds, the composition changes with time. When the reaction is done, the process
is stopped and the product at the required composition will be withdrawn. Batch processes
are very suitable for the small scale production processes.
In continuous reactors, the chemical regents are added continuously and the product also
withdrawn continuously. Hence the continuous reactors operate under the steady state
conditions; they normally give lower production and maintenance cost than the batch
reactors.
The processes which does not tally with the above two major processes were processed by
using semi-batch or semi-continuous reactors.
6
In semi-batch reactors, a certain portion of chemical regents is added or a certain portion of
the product is removed during the process. In semi-continuous reactors, the process will be
interrupted periodically for some purpose. Eg. Regeneration of catalysts. [1]
1.2.2. CLASSIFICATION BY THE PHASES PRESENT
In homogeneous reactors, the reactants, products, catalysts and any other chemical regents
will react under one continuous phase: gaseous or liquid. Homogeneous gas phase reactors
are operated in continuous processes and tubular reactors are used for that. Homogeneous
liquid phase reactors are operated in batch or continuous processes and both tubular and
stirred tank reactors are used for that.
In heterogeneous reactors, two or more phases exist and the possible combinations of those
phases are mentioned below.
Liquid-liquid phase reactions reaction in between immiscible liquid phases
Liquid-solid phase reactions reaction in liquid phases in contact with a solid
reactant or solid catalyst.
Liquid-solid-gas phase reactions Reaction in liquid and gas phases in contact
with a solid catalyst.
Gas-solid phase reactions Reaction in gas phases in contact with a solid
reactant or solid catalyst.
Gas-liquid phase reactions Reaction in gas phase in contact with a liquid
reactant or liquid catalyst. [2]
1.2.3. CLASSIFICATION BY PROCESS
The chemical reactors are also categorized according to their processes. The four basic types
of reactors classified according to their processes are mentioned below.
stirred tank reactor
tubular reactor
packed bed
uidised bed
7
Stirred tank reactors generally consist of a tank tted with a separate mechanical agitator
and a cooling jacket or coils. They can be operated in batch as well as continuous processes.
Tubular reactors generally used for gaseous reactions. They are also suitable for some
liquid-phase reactions. They are also called as plug flow reactors.
There are two basic types of packed bed reactors. One is where the solid is a reactant and
the other is where the solid is a catalyst. Among them, the packed bed reactors in which the
solid is used as a catalyst are recommended and generally used by the designers. Packed bed
reactors are not recommended for the reactions which have high heat-transfer rates.
Fluidised bed reactors are used for the high heat transfer rate reactions where mainly
catalysts are reacted inside the fludised bed reactor and then transferred to another vessel for
regeneration. [3]
1.2.4. CLASSIFICATION BY OPERATING PRESSURE
Reactors can be classified according to their operating pressures. They are internal pressure
vessels, external pressure vessels and atmospheric pressure vessels.[4]
If Pinner > Pouter internal pressure vessel
Low pressure vessel (L): 0.1 P < 1.6 MPa
Medium pressure vessel (M): 1.6 P < 10 MPa
High pressure vessel (H): 10 P < 100 MPa
Ultra-high pressure vessel (U): P 100 MPa
If Pinner = Pouter atmospheric pressure vessel (0.1 MPa)
If Pinner < Pouter external pressure vessel
8
1.2.5. CLASSIFICATION BY OPERATING TEMPERATURE
Reactors can be classified according to their operating temperatures. They are low
temperature, normal temperature, medium temperature and high temperature reactors.
Low Temperature Vessels (L): T < -20C
Normal Temperature Vessels (N): -20C T < 150C
Medium Temperature Vessels (M): 150C T < 450C
High Temperature Vessels (H): T 450C
1.2.6. CLASSIFICATION BY OPERATING CONDITION
Reactors can be classified according to their operating condition. They are open and closed
reactors.
Open reactors: Containing non-volatile and non-hazardous fluids, reactions
under atmospheric temperature and pressure.
Closed reactors: Containing volatile or hazardous fluids. Reactions under or
over atmospheric temperature and pressure conditions.
1.2.7. CLASSIFICATION BY GEOMETRICAL SHAPE
Reactors can be classified according to their geometrical shapes. They are cylindrical,
spherical and rectangular reactors.
Cylindrical reactors: most widely used type of reactors in process plants. Less
expensive than fabricating spherical reactors but not as strong as spherical
ones. Different types of rounded heads are fixed in order to increase the vessel
strength.
Hemispherical head: Hemi sphere is the ideal shape for a head. The
height of the head is half of the diameter.
Ellipsoidal head: This shape is more economical than the hemi
spherical head. The height of the head is just a quarter of the diameter.
Torispherical head: This is the most economical shape in
manufacturing vessel heads even though the strain would not be quite
9
as evenly distributed, but it would be close. The height of the head is
close to a quarter of the diameter.
Spherical reactors: most ideal type of reactors but not used widely because of
their expensiveness. Generally used for the storage of gasses and very high
pressure industrial processes.
Rectangular reactors: not used in most cases because the strain is not evenly
distributed. Using for few industrial applications in storage and mixing.
Figure 1: Types of Vessel Heads
1.2.8. CLASSIFICATION BY ORIENTATION
Reactors can be classified according to their orientation. They are vertical, horizontal, sloped
reactors. Orientation is specially considered in cylindrical reactors.
Vertical reactors: generally used for gaseous reactions.
Horizontal reactors: used for heavy weight liquid, solid reactions.
Sloped reactors: used for special purposes.
10
1.2.9. CLASSIFICATION BY WALL THICKNESS
Reactors can be classified according to their wall thickness. They are thin walled and thick
walled reactors.
Thin walled reactors: if thickness of reactor is less than 1/10th of the radius.
Thick walled reactors: if thickness of reactor is more than 1/10th of the radius.
1.2.10. CLASSIFICATION BY HEATING METHOD
Reactors can be classified according to their heating method. They are fired and unfired
reactors.
Fired reactors: if the reactor partially or totally open to an external heat source.
o Industrial gas burner
o Industrial oil burner
o Industrial biomass burner
o Electrical heating
o Radiant heating
o Jacketed heating
Unfired reactors: if the reactor does not expose to an external heat source.
1.2.11. CLASSIFICATION BY FABRICATING MATERIAL
Reactors can be classified according to their fabricating material. They are steel, cast iron,
aluminium and etc. Depending on the design parameters, the suitable material for the
fabrication should be selected wisely.
Steels
Nonferrous materials such as aluminum and copper
Specialty metals such as titanium and zirconium
Nonmetallic materials, such as, plastic and composites
11
Figure 2 : Operating Temperatures of Metals
1.2.12. CLASSIFICATION BY FABRICATION METHOD
Reactors can be classified according to their fabrication method. They are field/shop
fabricated, welded, cast forged, multi-layered, etc.
12
1.2.13. CLASSIFICATION BY LOCATION
Reactors can be classified according to their location. They are inside the plant equipment
and outside the plant field equipment. For the inside plant equipment, ventilation should be
considered and for the field equipment, the wind effect should be considered.
13
1.3. REACTOR DESIGN
1.3.1. SELECTION OF THE REACTOR PROCESS
The latest, optimized and economically viable process in conversion of waste plastic into fuel
oil and gas in the current scenario was the fluidised bed catalytic pyrolysis process. In this
process a selected catalyst is introduced into the pyrolysis reactor from the bottom and
because of the high velocity of the fluid, the catalyst particles will flow upwards and then
regenerated by a separate regeneration unit. It will reduce the activation energy of the
decomposition process so that the decomposition temperature can be reduced drastically.
Figure 3 : Waste Plastic into Fuel Oil by Catalytic Pyrolysis Process
1.3.2. PROS AND CONS OF FLUDISED BED CATALYTIC PYROLYSIS

REACTORS
There are advantages as well as disadvantages of the selection of fludised bed catalytic
pyrolysis reactors for the conversion of waste plastic into fuel oil and gas. The advantages of
fluidised bed catalytic pyrolysis reactors are,
Operated at lower temperatures and lower pressures because of the catalyst.
Ability to crack longer chain hydrocarbon molecules.
The capital cost and the maintenance cost of the conversion method is low.
Volume of the solid waste is significantly low.
14
The disadvantages of fluidised bed catalytic pyrolysis reactors are,
Catalyst disposal or regeneration should be done as it is coated with carbon.
The conversion process must be done in the absence of oxygen.
The conversion temperature is low thereby production of toxic organic compounds.
1.3.3. DETERMINATION OF THE NUMBER OF REACTORS
There are advantages as well as disadvantages increasing the number of reactors in any
industrial production process. When the number of reactors is increased,
Fabrication of the reactors will be easier at smaller scale when there are several
reactors. When it comes to larger scale, design will be complex and accept the
limitations in designing, transportation, manufacturing, maintenance, safety concerns
and etc.
Residence time of the production process will be decreased. Therefore the rate of the
production will be increased.
Catalyst regeneration and controlling part will be complex when there are several
reactors.
For this conversion of waste plastic into fuel oil and gas plant design, two reactors should be
fabricated according to the plant design. The first reactor is the batch reactor and the second
reactor is the catalytic cracking fluidised bed catalytic pyrolysis reactor which makes a
significant role in cracking process. As a process implementation, both reactors have been
combined together and one complete reactor which does the same work with lesser energy
requirement will be developed here.
1.3.4. GENERAL DESIGN OVERVIEW OF THE REACTOR FOR THE

CONVERSION OF WASTE PLASTIC INTO FUEL OIL AND GAS
A chemical reactor is a specific type of pressure vessel. Considering the application, the
reactors can be classified considering various facts. For the reactor design of conversion of
waste plastic into fuel oil and gas, the below design overview will be considered.
15
Mode of operation Semi-batch
Phases present Heterogeneous
Process Fluidised bed
Operating pressure Internal medium pressure (0.2MPa)
Operating temperature High temperature (500C)
Operating condition Closed
Geometrical Shape Cylindrical
Orientation Vertical
Wall thickness Thick walled
Heating method Fired
Fabricating material -
Fabrication method -
Location Field equipment
1.3.5. BASIC PRE DESIGN LAYOUT OF THE REACTOR
Figure 4 : FCC Reactor Predesign
A basic pre design layout is drawn here in order to get a basic idea about the reactor design
for the conversion of waste plastic into fuel oil and gas. Waste plastic is fed from the bottom
16
of the reactor and heated up to 500C. The gaseous hydrocarbons are allowed to flow through
the HZSM-5 Zeolite fluidised bed and further cracking is done.
1.4. CHEMICAL DESIGN
In chemical design of the catalytic pyrolysis fluidised bed reactor, the material balance and
the energy balance of the input plastic feed and catalyst and the material balance and the
energy balance of the output product will be evaluated by the fludised bed reactor design
technologies.
1.4.1. MATERIAL BALANCE FOR THE REACTOR
The material balance of the catalytic pyrolysis fluidised bed reactor will be evaluated
according to the product compositions, degree of cracking of the input plastic waste, the
optimum cracking temperatures and pressures inside the reactor and the fluidization of the
catalyst. Material balance is done according to the law of conservation of mass.
1.4.1.1. ASSUMPTIONS
There are several assumptions that should be taken in the material balance for the designing
of the catalytic pyrolysis fluidised bed reactor.
No HCl in the input plastic.

Every entered plastic feed gives same fuel output yield and composition.
No leakages from vessels.
The catalysts activity will be the same even after the regeneration.
All the pressure reducing valves are adiabatic.
No gas accumulation inside the reactor
All the used plastic cracked and goes out from the reactor.
Residue is only the spent catalyst and coke
Catalyst is not carried by the out gas stream
Catalyst is not thermally decomposed
System is at steady state
17
1.4.1.2. CALCULATION
1.4.1.2.1. FEED FLOW RATES (at 25C, 1atm)
The general mass balance equation is denoted by,

+
= +
+ { }
The feed compositions of the waste plastics are assumed and mentioned below.
TYPE OF THE MASS FLOW RATE MATERIAL VOLUMETRIC FLOW
MATERIAL (kg/h) DENSITY (kg/m3) RATE (m3/h)
LDPE 30 920 0.032608696

HDPE 40 950 0.042105263
PP 90 910 0.098901099
PS 40 1060 0.037735849
SUB TOTAL 200 0.211350907
HZSM - 5 ZEOLITE 20 1400 (0.01428571429)

NITROGEN GAS - - -
TOTAL 0.22563662129
Hence the process of the reactor is a fluidised bed catalytic cracking technology; the catalyst
will not be continuously added to the reactor. It will be remained inside the reactor and
regenerated after several process circles.
For the initial start up of the factory, Nitrogen is purged at high pressure inside the reactor
and after that the pressure inside the reactor will be controlled by pressure controllers.
Summary of feed flow rates

The input plastic feed rate = 200 kg/h = 0.225636621 l/h
The catalyst inside the reactor = 20 kg/h = 0.01428571429 l/h
The purged Nitrogen gas inside the reactor = x
18
1.4.1.2.2. PRODUCT FLOW RATES (at 500C, 1.5atm)
TYPE OF THE MATERIAL COMPONENT MASS FLOW

RATE (kg/h)
C1-C4 METHANE 1.285246733
ETHANE 2.227761003
PROPANE 10.39555107
BUTANE 4.971739239
ETHANE 0.676873073
PROPENE 1.580900560
BUTENE 1.355982382
AROMATICS BENZENE 10.45122155
ETHYLBENZENE 33.00518318
O-XYLENE 6.049604585
M-XYLENE 3.024802292
P-XYLENE 3.024802292
TOLUENE 12.08743951
N-PROPYLBENZENE 6.049604585
N-BUTYLBENZENE 9.062637218
ALIPHATIC/ ALKANE N-PENTANE 3.598690852
N-HEXANE 3.598690852
N-HEPTANE 3.598690852
N-OCTANE 3.598690852
N-NONANE 3.598690852
N-DECANE 3.598690852
N-UNDECANE 3.598690852
N-DODECANE 3.598690852
ALIPHATIC/ ALKENE 1-PENTENE 3.598690852
1-HEXENE 3.598690852
1-HEPTENE 3.598690852
1-OCTENE 3.598690852
1-NONENE 3.598690852
1-DECENE 3.598690852
1-UNDECENE 3.598690852
1-DODECENE 3.598690852
CYCLOALKANE CYCLOHEPTANE 3.834319419
CYCLOOCTANE 3.834319419
CYCLOHEXANE 3.834319419
CYCLOPENTANE 3.834319419
CYCLOBUTANE 3.834319419
SOLID RESIDUE 18.00000000
TOTAL 200.0000000
19
According to the general mass balance equation, in the absence of nuclear reaction, the
number of atoms flowing in and out must remain the same. Therefore,
+
= +
+ { }
By applying overall material balance,

Mass in = Waste plastic feed (200kg/h) + HZSM-5 Zeolite Catalyst(20kg/h)
Mass generation = Hydrocarbon compounds (182kg/h) + Coke (18kg/h)
Mass out = Product output (182kg/h)
Mass accumulated = Solid residue (38kg/h)
Mass consumed = Waste plastic feed (200kg/h)
Therefore,
Mass out = Hydrocarbon compounds (182kg/h)
Mass accumulated = Solid residue (38kg/h)
1.4.1.3. SUMMARY
COMPONENT MATERIAL MASS FLOW RATE VOLUMETRIC FLOW RATE

(kg/h) (m3/h)
WASTE PLASTIC 200 0.211350907
FEED FEED
CATALYST
(HZSM5 ZEOLITE) 20 0.01428571429
NITROGEN GAS - -
TOTAL 220 0.22563662129
PRODUCT HYDROCARBON
MIXTURE 182 -
RESIDUE COKE RESIDUE 18 0.00794000882
CATALYST RESIDUE 20 0.01428571429
TOTAL 220 0.02222572311
20
1.4.2. ENERGY BALANCE FOR THE REACTOR
The energy balance of the catalytic pyrolysis fluidised bed reactor will be evaluated
according to the catalytic pyrolysis fluidised bed process by considering thermophysical
properties of feed and product at different temperatures and pressures inside the reactor.
Energy balance is done according to the law of conservation of energy.
1.4.2.1. ASSUMPTIONS
There are several assumptions that should be taken in the energy balance for the designing of
the catalytic pyrolysis fluidised bed reactor.
System is at steady state.

Minimum fluidization will occur.
Every entered plastic feed gives same fuel output yield and composition.
No leakages from vessels.
All the used plastic cracked and goes out from the reactor.
Pressure drop is constant throughout the process.
Heat loss of the furnace to the surroundings is negligible.
1.4.2.2. CALCULATION
The general energy balance equation is denoted by,

=

+
+ { }
According to the Hesss law of reaction enthalpy change,

= ( ) () ( ) ()
21
LDPE + HDPE + Hydrocarbon
PP + PS Mixture
(182kg/h) + Coke
(200kg/h) (18kg/h)
at 25C, 2atm at 500C, 1.5atm
C(s) + H2(g)
Figure 5 : Energy Balance For Waste Plastic Cracking
HZSM-5 Zeolite HZSM-5 Zeolite

Catalyst Catalyst
(20kg/h) (20kg/h) )
at 25C, 2atm at 500C,
1.5atm
Na(s) + Al(s) +
Si(s) + O2(g) +
H2(g)
Figure 6 : Energy Balance for HZSM5 Zeolite
22
N2(g) N2(g)
(xkg/h) (xkg/h) )
at 25C, 2atm at 500C, 1.5atm
N2(g)
Figure 7 : Energy Balance for Nitrogen Gas
23
1.4.2.2.1. ENTHALPY OF FORMATION OF FEED (at 500C, 2atm)
The enthalpy of formation of feed is mentioned below.
SPECIFIC HEAT FORMATION ENERGY OF

TYPE OF THE MASS FLOW ENTHALPY OF
CAPACITY Cp(T-298.15) THE MATERIAL AT 500C
MATERIAL RATE (kg/h) FORMATION AT 25C (kJ/kg)
(kJ/kg.K) (kW)
LDPE 30 -1730.401191 1.9 902.5 -21.94084326

HDPE 40 -1734.122484 2 950 -29.82358315
PP 90 -456.3918177 1.8 855 -32.78479544
PS 40 -981.5426621 1.2 570 -17.23936291
TOTAL 200 -101.7885848
HZSM - 5 No Mass Flow

ZEOLITE (20kg) - 1.5 712.5 -3.958333333
NITROGEN GAS - - 1.056 501.6
24
1.4.2.2.2. ENTHALPY OF FORMATION OF PRODUCT (at 500C, 2atm)
The enthalpy of formation of product is mentioned below.

SPECIFIC FORMATION
ENTHALPY OF
TYPE OF THE MASS FLOW HEAT Cp(T- ENERGY OF THE
COMPONENT FORMATION AT
MATERIAL RATE (kg/h) CAPACITY 298.15) MATERIAL AT 500C
25C ( kJ/kg)
(kJ/kg.K) (kW)
C1-C4 METHANE 1.285246733 -4645.31 3.05 1448.75 -2.175658529
ETHANE 2.227761003 -2787.59 2.63 1249.25 -2.498087424
PROPANE 10.39555107 -2373.91 2.55 1211.25 -10.3526983
BUTANE 4.971739239 -2164.24 2.55 1211.25 -4.661682246
ETHENE 0.676873073 1871.81 2.24 1064 0.151884677
PROPENE 1.58090056 480.75 2.27 1078.25 -0.262385579
BUTENE 1.355982382 -8.91 2.29 1087.75 -0.4130699
AROMATICS BENZENE 10.45122155 9.34752 1.72 817 -2.344709723
ETHYLBENZENE 33.00518318 14.02128 1.9 902.5 -8.145667474
O-XYLENE 6.049604585 9.34752 1.92 912 -1.516858495
M-XYLENE 3.024802292 4.67376 1.88 893 -0.746392013
P-XYLENE 3.024802292 4.67376 1.88 893 -0.746392013
TOLUENE 12.08743951 18.6914 1.81 859.75 -2.823956931
N- 6.049604585 65.73 1.97
PROPYLBENZENE 935.75 -1.462021384
N- 9.062637218 -97.9 2.03
BUTYLBENZENE 964.25 -2.673855589
ALIPHATIC/ N-PENTANE 3.598690852 -2034.12 2.53
ALKANE 1201.75 -3.234693269
N-HEXANE 3.598690852 -1937.22 2.5 1187.5 -3.123583689
N-HEPTANE 3.598690852 -1872.72 2.49 1182.75 -3.054358872
25
N-OCTANE 3.598690852 -1827.47 2.48 1178 -3.004377054
N-NONANE 3.598690852 -1783.48 2.47 1173.25 -2.955654779
N-DECANE 3.598690852 -1753.28 2.47 1173.25 -2.925465761
N-UNDECANE 3.598690852 -1706.75 2.27 1078.25 -2.783987229
N-DODECANE 3.598690852 -1730.11 2.69 1277.75 -3.006766185
ALIPHATIC/ 1-PENTENE 3.598690852 -308.27 2.33 1106.75 -1.414505425
ALKENE 1-HEXENE 3.598690852 -495.13 2.35 1116.25 -1.610794018
1-HEPTENE 3.598690852 -640.52 2.36 1121 -1.760879419
1-OCTENE 3.598690852 -730.22 2.37 1125.75 -1.855295072
1-NONENE 3.598690852 -819.87 2.38 1130.5 -1.949660744
1-DECENE 3.598690852 -870.49 2.38 1130.5 -2.000262336
1-UNDECENE 3.598690852 -810 2.39 1135.25 -1.944542606
1-DODECENE 3.598690852 -830 2.39 1135.25 -1.964535332
CYCLOALKANE CYCLOHEPTANE 3.834319419 507.97 2.15 1021.25 -0.546688742
CYCLOOCTANE 3.834319419 -1098.34 2.12 1007 -2.242373902
CYCLOHEXANE 3.834319419 -1465.08 2.25 1068.75 -2.69875377
CYCLOPENTANE 3.834319419 -1500 2.24 1064 -2.730887497
CYCLOBUTANE 3.834319419 -1650 2.25 1068.75 -2.895709978
SOLID RESIDUE 18 0 0.85 403.75 -2.01875
TOTAL 200 -92.3940766
26
According to the Hesss law of reaction enthalpy change,
= ( ) () ( ) ()
Enthalpy of formation of the feed at 500C, 2atm = -101.7885848 kW

Enthalpy of formation of the product at 500C, 2atm = -92.3940766 kW
Therefore,
The heat energy requirement for the cracking process
= (-92.3940766 kW) (-101.7885848 kW)
= 9.3945082 kW
27
1.5. CALCULATION OF DIMENSIONS OF THE REACTOR
1.5.1. CALCULATION OF VESSEL HEIGHT AND DIAMETER
In reactor design for the conversion of waste plastic into fuel oil and gas, the Kunii and
Levenspiel fluidised-bed bed catalytic cracking process and the ASME code for is used for
the calculation of height and diameter. According to the literature data, the optimum vessel
length to diameter ratio categorization according to the pressure is mentioned below. [100]
Figure 8 : Length to Diameter Ratio
The design pressure for the fluidised-bed catalytic cracking reactor is 2 atm (13.75 PSIG)
Therefore, the most suitable L/D Ratio for the reactor = 3
According to the ASME boiler and pressure vessel code, the volume of the reactor can be
evaluated by considering the below diagram.
According to this, the effective length (L) of the reactor

should be taken as, l + (2h/3) in order to calculate the
required volume.
According to the classification of torispherical heads (and
ellipsoidal heads), the height of the vessel head is taken as
of the diameter of the vessel. Therefore, L = l + (D/6)
According to that, the total geometrical volume of the vessel
(V) = (D^2)L/4
= (D^2){l+(D/6)}/4
= 3(D^3)/4 (hence L/D = 3)
Where D = diameter of the vessel, l = height of the shell,
Figure 9 : Vessel Geometry L = effective length of the vessel, V = volume of the vessel
28
Considering the material balance of the reactor, the maximum initial and product volumetric
flow rates are mentioned below.
Total initial feed flow rate = 225.63662129 l/h
Total residue product flow rate = 22.22572311 l/h
Therefore, for the fabrication, the minimum volume can be assumed as 225.63662129 l/h
without considering the fludised-bed height at the initial conditions. Therefore, for that the
Kunii and Levenspiel fluidised-bed bed catalytic cracking process should be considered in
order to calculate the required height of the vessel.
1.5.1.1. LITERATURE DATA OF THE CHEMICAL AND PHYSICAL

PROPERTIES OF THE CATALYST
The catalyst selected for the waste plastic to fuel oil conversion process was HZSM-5 Zeolite
Catalyst by following a research done by University of Leeds, London which is attached in
ANNEX 1. The advantages of selecting HZSM-5 Zeolite catalyst are,
High yield of required product
Low cracking temperature
Low Carbon content
Figure 10 : Structure of FCC Particle
According to the literature data, FCC catalyst is usually a porous microsphere (about 50%
pore volume) which is spray-dried to a powder with a particle size distribution of 10 to 120
29
microns, with a particle density of about 1400 kg/m3. According to literature data, Zeolite
catalysts with high Si/Al ratio will give best results in catalytic cracking processes.
1.5.1.2. KUNII AND LEVENSPIEL FLUIDISED-BED REACTOR

MODEL
For the energy calculation, the Kunii and Levenspiel fluidised-bed reactor model is applied
for the fluidised-bed catalytic pyrolysis of converting waste plastic into fuel oil and gas.
From the Kunii and Levenspiel fluidised-bed reactor model,
= 1 = 1
Where,
=
=
=
=
=
, =
After the drag exerted on the particles equals the net gravitational force exerted on the
particles, that is denoted by,
= 1
Where,
=
=
=
=
=
30
Figure 11 : Different Types of Fluidization
Considering different types of fluidization, the required minimum velocity (flow rate) of the
Nitrogen gas can be evaluated from where the minimum fluidization occurs. At the same
time, the pressure drop across the fluidised-bed will remain constant according to the below
graph.
Figure 12 : Pressure drop across the fluidised-bed vs. Air Velocity
When the minimum fluidization occurs, the weight of the bed should be equal to the pressure
drop across the bed.
=
31
1.5.1.2.1. CALCULATION OF THE SPHERICITY OF HZSM-5
ZEOLITE CATALYST
Vp - Unit Cell Volume 5395.29

dp () 21.76
As 1487.626776
Surface area (m2/g) 425

Density (kg/m3) 1400
Unit cell volume (m3) 5.39529E-27
Unit cell mass (kg) 7.55341E-24
Unit cell mass (g) 7.55341E-21
Unit cell area (m2) 3.2102E-18
Ap 321.019755
- Sphericity 4.634066137
32
1.5.1.2.2. CALCULATION OF THE VOID FRACTION AT THE POINT
OF MINIMUM FLUIDIZATION
- Sphericity 4.634066137
mf - Void Fraction 0.248369754
1.5.1.2. CALCULATION OF THE DIAMETER AND HEIGHT OF THE

VESSEL IN MINIMUM FLUIDIZATION
Considering that the maximum height of the bed in minimum fludization occurs at the initial
condition of flow rate = 211.350907 l/h and considering the sintered plate is located at the
height of D + D/4 = 5D/4,
= 1
Mass flow rate at the initial condition = 220 kg/h

Hence the residence time of the reaction is 30 min, actual = 110kg
A = (D^2)/4
= average density of plastics and catalyst particle mixture
= 990.4545455 kg/m3
= 9.81 ms-2
= 0.248369754
Therefore, height of the fluidised-bed (h) = {4 }/{ (D^2)( ) 1 }

According to the total geometrical volume of the vessel (V) = (D^2)L/4
= (D^2){l+(D/6)}/4
= 3(D^3)/4 (hence L/D = 3)
33
Considering all the above factors, the below graph is drawn.
5
4.5
4
3.5
3
D,V
2.5 Diameter
2
Volume
1.5
Fluidised-bed Height
1
0.5
0
0 0.5 1 1.5 2 2.5 3
x
According to that, when L/D ratio is taken to be as constant (L/D = 3), the volume of the
reactor increases with the length x value.
Length X value is the additional length

required for the vessel where L = x + D
and V = 3(D^3)/4 from that we can
draw the above graph.
The x value is a user considerable data

where we can use for the ease of
fabrication.
According to the above considerations,

the height of the vessel = 3D
Figure 13 : Geometry of the process vessel The minimum requirement for the x is
D/2 and above every D/2 value can be
taken.
Considering the shell, l = L (D/6)
34
5
4.5
4
3.5
3
D,V
2.5 Extra length

2
Volume
1.5
Fluidised-bed Height
1
0.5
0
0.85 0.95 1.05 1.15 1.25
d
According to the above graph, when the diameter increases, the fluidised bed height
decreases but the extra length (x) and the volume of the vessel (v) increases.
This volume is more than enough for the required volume for the fluidization. Therefore, x =
D is taken as for the ease of fabrication.
Diameter of the Vessel (m) 0.903

X value (m) 0.973
Volume of the Vessel (m3) 2.170449357
Effective length of the vessel (m) 2.919
Length of the shell (m) 2.756833333
35
1.5.2. CALCULATIONS FOR THE NITROGEN GAS SUPPLY
1.5.2.1. CALCULATION OF MINIMUM FLUIDIZATION VELOCITY
According to the Kunii and Levenspiel fluidised-bed reactor model, the minimum fluidization
velocity could be calculated from the below equation.
According to the previous calculations,

Hence,
= 1
() = {4 }/{ (D^2)h 1 }
() = {4 }/{ (D^2)h 1 }
- sphericity 4.634066137
d - diameter of the vessel (m) 0.903
- viscosity (Pas) 1000
g - gravitational force (ms-2) 9.81
- density (kg/m3) 990.4545455
mf - void fraction 0.248369754
Umf (ms-1) 2.31E-02
36
1.5.2.2. CALCULATION OF THE PRESSURE DROP ACROSS THE
FLUIDISED BED REACTOR
Considering the pressure drop across the reactor in order to gain a proper fluidization,
=
Hence Ws = 110 kg and Ac = (D^2)/4 = (0.903^2)/4 = 0.640420731
Pressure drop across the fluidised-bed = 1684.986053 Pa
Figure 14 : Pressure drop across the bed
When P2 = 202650 Pa,

P1 = P2 + = 204335 Pa
1.5.3. CALCULATIONS FOR THE GAS DISTRIBUTOR PLATE
According to the literature data, FCC Zeolite catalyst is usually a porous microsphere (about
50% pore volume) which is spray-dried to a powder with a particle size distribution of 10 to
120 microns, with a particle density of about 1400 kg/m3.
Assuming that the particle size of the HZSM-5 Zeolite is 50 m, the appropriate distributor
plate could be selected.
The available types of different distributor plates are shown below.
37
Figure 15 : Types of distributor plates
According to the researches, it was found that the punched plate design is more effective than
the perforated plate design.
38
2. MECHANICAL DESIGN
2.1. MATERIAL SELECTION
Material selection in the mechanical design of the reactor is the most important factor which
considers its safety and economical viability. If the material selected is not suitable enough to
withstand in the process operating temperature, operating pressure and etc., there will be a
huge catastrophe while if the material selected is far beyond the expected material
requirement, the payback period of the plant will be very higher. The below considerations is
very important in the material selection.
Operating conditions (temperature, pressure, corrosion resistance)
Corrosion resistance
Ease of fabrication
High service performance
Good market availability
Design life
The process of the reactor for the conversion of plastic into fuel oil and gas is very much
similar to the crude oil refinery process. Therefore the standards of the selection of material
for the crude oil refinery processes can be applied for the material selection of the conversion
of plastic into fuel oil and gas.
The most common material used in petroleum refineries is the Standard Carbon Steel in
which used for 80% of the components. Low alloy steels are used for the average temperature
applications. Stainless steels are used for high temperature sulfidic and naphthenic acid
conditions which is more expensive and slightly reduced strength.
The below figure shows the general temperature ranges for the common metals. The FCC
reactor design for the conversion of waste plastic into fuel works under low pressure but high
temperature operating conditions.
39
Figure 16 : Classification of Metals by their temperature range
Figure 17 : Materials for high temperature Applications
40
Considering the operating temperature, operating pressure and the corrosion resistance,
stainless steels are the most suitable materials for the fabrication of the FCC reactor. Monel
and Inconel are also considerable due to their higher temperature ranges.
Considering the general types of stainless steel 304, stainless steel 316, Monel and Inconel,
the most appropriate metal for the fabrication of FCC reactor can be determined by
considering the below factors.
FCC reactor is a fired vessel
FCC maximum operating temperature is around 500C and operating pressure is
around 2 atm (204335 Pa)
Possibility of operation under sulfidic and naphthenic acid conditions
Ease of fabrication and good market availability
Considering all the above factors and data, SS 304 is selected for the designing of the FCC
reactor.
2.2. CALCULATION OF DESIGN TEMPERATURE
Generally in reactor designing, the design temperature is evaluated by giving an additional

temperature allowance for the safety and loss prevention. According to the ASME Boiler and
Pressure Vessel code, the design temperature must not be less than the mean temperature
expected to be occur across the thickness of the metal part.
Maximum operating temperature inside the vessel = 500C

Maximum outside temperature of the vessel = 800C
(Assumed temperature of outside wall of the vessel at gas
burners)
Therefore, mean temperature of the vessel = 650C
There are three types of SS 304. They are SS 304, SS 304L

Figure 18 : Temperature Drop across the and SS 304 H. Among them the material properties of SS
Vessel
304 L rapidly falls after 425C according to ASME
41
material properties. Therefore, SS 304 is selected for the fabrication because maximum
recommended service temperature for SS 304 is around 830C.
For safety precautions, an additional 10C is added.

Therefore design temperature for SS 304 is 660C.
2.3. CALCULATION OF DESIGN PRESSURE
Generally in reactor designing, the design pressure of internal pressure vessels is evaluated by
considering the gauge pressure, hydrostatic pressure and extra allowance. According to the
ASME Boiler and Pressure Vessel code, the design pressure must be chosen to face the most
severe condition of the reactor operation.
Gauge pressure = maximum vapour guage pressure inside the reactor

= 204335 Pa 101325 Pa
= 103010 Pa
Hydrostatic pressure = pressure due to the molten plastic and catalyst bed mixture in the
fluidized bed at initial conditions
= hg
= 18941.3483 Pa
When extra allowance is taken as 10%,
Design pressure = (Gauge pressure + Hydrostatic pressure)*1.1

= 134146.48313 Pa
42
2.4. DETERMINATION OF DESIGN STRESS
The maximum allowable stresses of any material will changes with the temperature.
Normally at very high temperatures, the materials show very poor stress characteristics. For
the determination of the design stress, the maximum allowable stress of the material is
considered. ASME Boiler and Pressure Vessel code material data is followed for that.
Min.
Applic.
Yiel Applic. Applic. Applic.
Alloy Min. and Max.
d and Max. and Max. and Max.
Nominal Spec. Type/ Desig./ Tensile Temp.
Stre Temp. Temp. Temp.
Composition No. Grade UNS Strength Limit-
ngth Limit- I Limit- III Limit-
No. (MPa) VIII-1
(MP (C) (C) XII (C)
(C)
a)
SA-
18Cr-8Ni 240 304 S30400 515 205 816 427 816 343
Maximum Allowable Stress Values for SS 304 at different temperatures are listed in the below tables.
65C 100C 125C 150C 200C 250C 300C 325C 350C

(MPa) (MPa) (MPa) (MPa) (MPa) (MPa) (MPa) (MPa) (MPa)
138 137 134 130 126 122 116 114 111
375C 400C 425C 450C 475C 500C 525C 550C 575C 600C
(MPa) (MPa) (MPa) (MPa) (MPa) (MPa) (MPa) (MPa) (MPa) (MPa)
109 107 105 103 101 99.3 98 93.3 79.6 65.4
625C 650C 675C 700C 725C 750C 775C 800C 825C

(MPa) (MPa) (MPa) (MPa) (MPa) (MPa) (MPa) (MPa) (MPa)
51.4 41.7 32.9 26.5 21.3 17.2 13.9 11.1 8.73
43
According to the above facts, the design stress is equal to the maximum allowable stress at
the most severe operating condition. Its evaluated by consideration of the operating
temperature because for high temperature applications, the design stress greatly reduced and
it has to be considered more.
Design temperature = 660C
650C 660C 675C
(MPa) (MPa) (MPa)
41.7 38.18 32.9
Therefore maximum allowable stress of SS 304 at 660C = 38.18 MPa
2.5. CALCULATION OF WALL THICKNESS OF THE SHELL
According to the ASME Boiler and Pressure Vessel code, the thickness of the cylindrical
shells can be determined by the below equation.

=
0.6
Where,
t Theoretical thickness of the shell
P Design pressure
R Inside radius of the cylinder
S Maximum allowable stress
E Joint efficiency (For full radiography longitudinal cylindrical joints E = 1)
P = 134146.48313 Pa
R = 0.4865 m
S = 38.18 MPa
E=1
Therefore theoretical t = 1.71mm

Considering the maximum allowable corrosion rate per year of SS 304 is 0.1 mm per year,
for 15 year plant run,
Design thickness for the vessel = 1.71mm + 1.5 mm = 3.21 mm
44
45
Considering the standard sheet metal gauges, the available gauge for the thickness above
3.21mm is gauge 10 (3.51 mm)
2.6. SELECTION OF SUITABLE END CLOSURES
Considering the classification of reactors by its geometrical shape, torispherical head is used
for the designing of the top and bottom heads of the reactor.
Figure 19 : Torispherical Head design Overview
In torispherical heads, the radius of the sphere R is called as the crown radius and a is
called as the "knuckle radius". In the beginning, the h was taken as D/4 and c was taken as
D/2.
By assuming a = D/8, and taking C = D/2 and h = D/4,
46
C2 + (R h)2 = (R a)2
Therefore,
C2 a2 + h2
R=
2(h a)
When D = 0.973m
R = 1.1554375m
According to the ASME Boiler and Pressure Vessel code, the thickness of the torispherical
heads can be determined by the below equation.
0.885
=
0.1
Where,
P Design pressure
L Crown radius
E Joint efficiency (For full radiography circumferential cylinder joint E = 1.4)
P = 134146.48313 Pa
L = 1.1554375 m
S = 38.18 MPa
E = 1.4
Therefore theoretical t = 2.57mm

Design thickness for the head = 2.57mm + 1.5mm = 4.07mm
Considering the standard sheet metal gauges, the available gauge for the thickness above
4.07mm is gauge 8 (4.37 mm)
47
2.6. SELECTION OF SUITABLE REACTOR INTERNALS
2.6.1. SELECTION OF A SUITABLE DISTRIBUTOR PLATE
In FCC reactor design for the fluidised-bed catalytic cracking of waste plastic into fuel oil
and gas, theres a gas distributor plate which holds the weight of the catalyst bed and molten
plastic inside the FCC reactor. Unlike the shell and the head, it should not be welded because
separation of that plate is important for the cleaning and maintenance purposes. According to
the ASME Boiler and Pressure Vessel code, the thickness of the flat unstayed circular head
(bolted) can be determined by the below equation.
1.9
= +
3
Where,
d Diameter
C Attachment factor
P Design pressure
E Joint efficiency (For full radiography E = 1)
S Maximum allowable stress Figure 20 : Distributor
Plate Design
W Total bolt load given for circular head
h Gasket moment action equal to the radial distance
R Inside radius of the cylinder
From the above equation, the thickness of the distributor plate can be calculated.
C = 0.3 for circular heads and covers bolted to the vessel
The above equation can be further simplified into the below equation according to ASME
Boiler and Pressure Vessel code with the limitation that Z need not be greater than two and
one-half
48

=

Assumption: Z = 1.5,
Hence the maximum temperature inside the reactor is 500C, the design stress for the
distributor plate can be calculated by adding 50C extra temperature.
At 550C, the design stress (of SS 304) = 93.3 MPa
Therefore theoretical thickness t = 24.75mm
Design thickness for the plate = 24.75mm + 1.5mm = 26.25mm
Considering the standard sheet metal, the available thickness very close to 26.25mm
(1.0334646 inch) is 1 inch SS 304 sheets.
For the catalytic cracking spray-

dried to a powder with a particle
size distribution of 10 to 120
microns is used. Assuming that
the particle size of the HZSM-5
Zeolite is over 50 m, the
appropriate distributor plate could
be selected. According to the
researches, it was found that the
punched plate design is more
effective than the perforated plate Figure 21 : Different Types of Distributor Plates
design. In order to avoid the

catalyst particles to go through the mesh, additional SS 316 mesh with 50 m is attached with
the plate.
Hence a minimum fluidization occurs, no need of having a top mesh because there is no
turbulent flow. So, after the reactor, the excess catalyst particles with the gas can be separated
by a filter.
49
2.7. DESIGN OF NOZZLES AND OPENINGS
Reactor design will be weakened when material is removed to create nozzles and openings.
The ASME Boiler and Pressure Vessel code provides a procedure to give proper
reinforcement to such areas.
For smaller vessels, creating manholes is not good. Flanged head as a manhole at the top of
the vessel is perfect for that. Hence all the calculations are done by considering the top head
is a torispherical head, and the diameter is just 0.973m creating a manhole is not good.
The list of feed in, product out and other components which require having nozzles and
openings in the FCC reactor design is mentioned below.
SECTION PURPOSE CATEGORY OUTSIDE DIAMETER (inch)
TOP HEAD Plastic/Catalyst Feed Opening (radial) 12

Inlet
Gas Outlet Nozzle (radial) 2.5
Pressure Relief Valve Nozzle (radial) 2
Safety Valve Nozzle (Radial) 2
Pressure Guage Nozzle (Radial) 2
SHELL Catalyst Removal Opening (tangential) 12

Thermocouple 1 Nozzle (tangential) 2
BOTTOM HEAD Gas Inlet (Nitrogen) Nozzle (tangential) 2.5

Drain Opening (tangential) 2.5
Gas Inlet (Other) Nozzle (tangential) 2.5
Designing of the Nozzles and Openings can be done using the below equations.
According to the ASME Boiler and Pressure Vessel code, the required wall thickness of the
nozzle can be determined by the below equation.

=
0.6
Where,
t Theoretical thickness of the nozzle
P Design pressure
50
R Outside radius of the opening
E Joint efficiency (For full radiography E = 1)
P = 134146.48313 Pa
R = varies
S = 38.18 MPa (For SS 304)
E=1
the corrosion allowance should be added to the theoretical thickness of the nozzle to get the
design thickness.
From the design thickness (T), the outside diameter of the openings can be evaluated.
= 2 2 ( + )
Where,
Outer diameter
R Inside diameter
T Design thickness
K Constant (corrosion allowance)
According to the ASME Boiler and Pressure Vessel code, the area of required reinforcement
can be determined by the below equation.
=
Where,
R Area of required reinforcement
Outer diameter
Design thickness of the shell/head
F Correction factor (normally 1.0)
51
SECTION PURPOSE CATEGORY DESIGN INSIDE SHELL/ HEAD AREA OF
THICKNESS DIAMETER DESIGN THICKNESS REINFORCEMENT
(m) (m) (m) (m^2)
TOP HEAD Plastic/Catalyst Feed Opening (radial) 0.002036593 0.297726814 0.00437 0.001301
Inlet
Gas Outlet Nozzle (radial) 0.00161179 0.05727642 0.00437 0.00025
Pressure Relief Valve Nozzle (radial) 0.001589432 0.044621136 0.00437 0.000195
Safety Valve Nozzle (Radial) 0.001589432 0.044621136 0.00437 0.000195
Pressure Gauge Nozzle (Radial) 0.001589432 0.044621136 0.00437 0.000195
SHELL Catalyst Removal Opening 0.002036593 0.297726814 0.00351 0.001045

(tangential)
Thermocouple 1 Nozzle 0.001589432 0.044621136 0.00351 0.000157
(tangential)
(tangential)
(tangential)
BOTTOM Gas Inlet (Nitrogen) Nozzle 0.00161179 0.05727642 0.00437 0.00025

HEAD (tangential)
Drain Opening (radial) 0.00161179 0.05727642 0.00437 0.00025
Gas Inlet (Other) Nozzle 0.00161179 0.05727642 0.00437 0.00025
(tangential)
52
2.8. VESSEL SUPPORTS
Design parameters for the vessel supports are another important fact which has to be
considered in designing of FCC reactor. For the vessel support designing, the important
factors such as design pressure, weight of the vessel, weight of attached equipment, such as
motors, machinery and etc., internal and external fittings and attachments, wind, snow, and
seismic reactions, geometry of the vessel and many other factors should be considered. There
are different types of supports chosen according to the size and orientation. They are,
Saddle support for horizontal vessels
Leg support for small vertical drums (max L/D ratio = 2:1)
Lug supports for small vertical vessels (max L/D ratio = 2:1 to 5:1)
Skirt support for tall vertical vessels
For the FCC reactor, the chosen design ratio L/D at the very beginning is 3:1. Therefore, lug
support is the most suitable type of vessel support for that. Calculations for the lug supports
are not directly addressed by ASME Boiler and Pressure Vessel code. Therefore skirt support
is chosen for the design.
2.8.1. CALCULATION OF THE TOTAL LOAD OF THE VESSEL
For the calculations of the skirt support, its a must to calculate each and every loads acting
on the vessel.

= +
+ +
+ + ()
+ 30%
For the calculations, the maximum density of the SS 304 is taken as 8060kg/m^3.
53
2.8.1.1. CALCULATION OF THE WEIGHT OF THE SHELL
The weight of the shell can be evaluated by the below equation.

=
Where,
Weight of the shell
D Mean diameter of the shell
t Design thickness of the shell
L Length (height) of the shell
Density of the design material
g Gravitational force
D = {D + (D+t)}/2 = 0.9748m
t = 3.51mm
L = 3D
= 8060kg/m^3
g = 9.81 m/s^2
Therefore, = 2480.7934 N
2.8.1.2. CALCULATION OF THE WEIGHT OF THE END CLOSURES
The weight of the torispherical end closures can be evaluated by the below equation.
=
Where,
t Design thickness of the end clousure
Surface area = 2.05 m^2

t = 4.37 mm
= 8060kg/m^3
54
g = 9.81 m/s^2
2.8.1.3. CALCULATION OF THE WEIGHT OF THE DISTRIBUTOR

PLATE
The weight of the distributor plate can be evaluated by the below equation.
2
=
4
Where,
D Inner diameter of the shell
t Design thickness of the plate
D = 0.973m
t = 25.4mm
= 8060kg/m^3
g = 9.81 m/s^2
If two plates are used, then = 2986.643 N
2.8.1.4. CALCULATION OF THE TOTAL LOAD

= +
+ +
+ + ()
+ 30%
Total load of the vessel = 2480.7934 N + 1416.6721 N + {(110)*9.81 N} + 2986.643 N +
30% extra load = 7963.2086N + 30% extra load = 10352.1712N
55
2.8.1.5. CALCULATION OF THE SKIRT WALL THICKNESS
Considering the strength of the skirts, both tensile and compressive stresses have to be
considered.
Tensile stress - Compressive stress

4 M wind W 4 M wind W
tensile com pressive
t s D0 Di Do t s t s D0 Di Do t s
For the fabrication of the skirt supports, both tensile and compressive strength
must be considered because it varies with the temperature and the maximum
allowable tensile and compressive stresses are different even in the same material.
Figure 22 : Skirt Supports
Hence the selected location for the plant is

at Ambatale which is in zone 3, the
maximum wind velocity can be taken as
38 m/s.
Figure 23 : Wind Patterns in Sri Lanka
According to the above information, the wind power = 1.24 kN/m^2

H = height of the tower + height of the skirt = 3.0812m + 1m = 4.0812m
K = coefficient depending on shape factor = 0.7
D = Outer diameter of the vessel = 0.97651m
= Wind load = k*Pw*HD = 3459.2687N
Figure 2456
: Wind Load
= thickness of the skirt
= total load of the vessel = 10352.1712 N
= inner diameter of the skirt
= outer diameter of the skirt
Assuming that = 1.27 mm and taking = 0.97651m, = 0.97778m
Load on skirt = 3459.2687N

Load on skirt = 10352.1712 N
Maximum tensile stress = 978618.2952 Pa = 0.978 MPa

Maximum compressive stress = 6285833.493Pa = 6.2858 MPa
SS 304 compressive stress at 660C = 38.18MPa. It is above the level of maximum

compressive stress required. Normal carbon steels cannot be used because of the higher
temperature conditions. But can go for alternative cheaper materials or reduce the thickness.
Maximum tensile stress and maximum

compressive stress values are perfect in
comparing with the tensile and compressive
stress characteristics of SS 304 at higher
temperatures. The below diagram from an
austenitic stainless steel producer proves that
the tensile strength of stainless steels are very
much higher than the compressive strength of
stainless steels. Therefore SS 304 will surely
withstand for tensile stress of 0.978 MPa at
660C. (Min. 200 MPa ASME Data but at Figure 25 : Tensile and Compressive Characteristics of SS
undefined temperature)
Therefore SS 304 is good but not the best option for the fabrication of the skirt regarding the
pricing.
57
2.8.1.6. CALCULATION OF THE BEARING PLATE THICKNESS
For the calculation of the outer radius of the baring plate, the below equations are used.
Tensile stress - Compressive stress
4 M wind W 4 M wind W
tensile com pressive
t s D0 Di Do t s t s D0 Di Do t s
Where,
= Wind load = 3459.2687N
= total load of the vessel = 10352.1712 N
= thickness of the bearing plate
= inner diameter of the bearing plate
= outer diameter of the bearing plate
Assuming that = 1.27 mm and taking = 0.97778m, = 0.97905m
Load on one skirt = 3459.2687N

Load on one skirt = 10352.1712 N
Maximum tensile stress = 972637.2195Pa = 0.972 MPa

Maximum compressive stress = 6272968.026Pa = 6.2730 MPa
pricing.
58
2.8.1.7. CALCULATION OF THE BOLT ROOT THICKNESS
For the calculation of the bolt root area, the below equations are used.
4
= /

Where,
A Bolt root area
M Bending moment acting on bolts
D Bolt circle diameter
W Weight of the vessel
N Number of bolts
E Maximum allowable bolt stress
Bending moment = Wind Load x H/2 = 3459.2687N x (4.0812/2)m = 7058.98370922Nm

Weight of the vessel = 10352.1712 N
59
Considering above data and below table, we can calculate the maximum allowable stress.
4
= /

By assuming Bolt diameter = 1 inch, we can get A = 0.551 square inch =
0.00035548316m^2
The diameter of the bolt circle = outer diameter of the bearing + (edge distance x2) + Bolt
diameter
= 0.97905m + (1.5inch x 2) + (1 inch)
= 1.08065m
Number of bolts that can be used = (PI*Diameter of bolt circle/(Bolt diameter*Bolt spacing)
= 56.277 bolts
= 56 maximum bolts can be used
Considering all the facts,
47058.98370922
= 10352.1712 /560.00035548316
1.08065
Maximum allowable stress = 792507.2681 Pa
= 0.7925 MPa
Maximum tensile stress and maximum compressive stress values are perfect in comparing
with the tensile and compressive stress characteristics of SS 304 at higher temperatures.
pricing. Additionally, the number of bolts can be greatly reduced by choosing different
criteria.
60
3. CONTROL, PIPING, INSTRUMENTATION AND OTHER ASPECTS
3.1. PIPE, PUMP AND VALVE SELECTION
3.1.1. PIPE SELECTION
The design of nozzle and opening is done in the Chapter 2.7 by following ASME Boiler and
Pressure Vessel code.
OUTSIDE OUTSIDE
SECTION PURPOSE CATEGORY DIAMETER DIAMETER
(inch) (m)
TOP HEAD Plastic/Catalyst Feed Inlet Opening (radial) 12 0.3048

Gas Outlet Nozzle (radial) 2.5 0.0635
Pressure Relief Valve Nozzle (radial) 2 0.0508
Safety Valve Nozzle (Radial) 2 0.0508
Pressure Gauge Nozzle (Radial) 2 0.0508
Opening
SHELL Catalyst Removal (tangential) 12 0.3048
Nozzle
Thermocouple 1 (tangential) 2 0.0508
Nozzle
Nozzle
BOTTOM Nozzle
HEAD Gas Inlet (Nitrogen) (tangential) 2.5 0.0635
Drain Opening (radial) 2.5 0.0635
Nozzle
Gas Inlet (Other) (tangential) 2.5 0.0635
The design of nozzle and opening is done in the Chapter 2.7 by following ASME Boiler and
Pressure Vessel code. According to the ASME code for Pressure Piping, B 31 the 2 inch
diameter pipes are commonly available at the market and therefore they can be directly used
for the piping.
Feeding should be done by a pneumatic system or different process and its not discussed
here, because of its complication. For catalyst removal, thermocouples, pressure relief valve
61
and pressure gauges, theres no need of a piping system. Therefore the below table is
simplified for better understandings.
OUTSIDE OUTSIDE
SECTION PURPOSE CATEGORY DIAMETER DIAMETER
(inch) (m)
TOP HEAD Gas Outlet Nozzle (radial) 2.5 0.0635

Safety Valve Nozzle (Radial) 2 0.0508
BOTTOM HEAD Gas Inlet (Nitrogen) Nozzle (tangential) 2.5 0.0635

Drain Opening (radial) 2.5 0.0635
Gas Inlet (Other) Nozzle (tangential) 2.5 0.0635
The piping parameters are evaluated by the ASME code for Pressure Piping, B 31. According
to that wall thickness of the pipes are evaluated.
Design pressure = (Gauge pressure)*1.1
= 113311 Pa
Design temperature = (Mean temperature of the pipe) + 10C
800+500
= + 10C
2
= 660C
According to the ASME code for Pressure Piping, the thickness of the pipe can be evaluated
by the below equation.
( + 2)
=
2( + )
Where,
t Theoretical thickness of the pipe
P Design pressure
d Inside radius of the pipe = outside radius of the nozzle
c Sum of the mechanical allowances (thread or groove depth + corrosion allowances)
S Maximum allowable stress at design temperature
E Quality factor (E=1)
W Weld joint strength
Y Pre defined coefficient
62
According to the ASME code for Pressure Piping, B 3, there are 4 types of fluid service
categories. They are Category D, Normal, Category M and High Pressure.
Among them for the pipelines which transfer highly toxic fluids that a leakage of a very small
quantity can produce serious irreversible harm is categorized into the Category M. SS 304
pipes can be taken for a piping material of Category M.
Figure 26 : Selection of Fluid Services
The maximum allowable stress for the piping material can be taken from the ASME Boiler
and Pressure Vessel code.
Maximum allowable stress of SS 304 at 660C = 38.18 MPa
The weld joint factor can be taken from the below table. (W=1)
63
The pre defined coefficient can be taken from the below table. (Y=0.4)
Minimum theoretical thickness of different pipes can be calculated by using the above data.
INSIDE THEORETICAL DESIGN SELECTED

SECTION PURPOSE CATEGORY DIAMETER THICKNESS THICKNESS PIPE
(m) (m) (m) TYPE
TOP Nozzle
HEAD Gas Outlet (radial) 0.0635 1.00E-04 2.10E-03 2.5 in. 5SA
Safety Nozzle
Valve (Radial) 0.0508 8.12E-05 2.08E-03 2 in. 10SA
BOTTOM Gas Inlet Nozzle

HEAD (Nitrogen) (tangential) 0.0635 1.00E-04 2.10E-03 2.5 in. 5SA
Opening
Drain (radial) 0.0635 1.00E-04 2.10E-03 2.5 in. 5SA
Gas Inlet Nozzle
(Other) (tangential) 0.0635 1.00E-04 2.10E-03 2.5 in. 5SA
64
Hence the theoretical minimum required thickness is calculated ~ 0.03 mm, with the
corrosion factor(c) of 2 mm, the design thickness for all the pipelines is around 2 mm 2.1
mm.
Considering the inner diameter of standard welded and seamless stainless steel pipes (ASTM
data) with their thicknesses, when inside diameter is 2.5 inch, the market available pipe
thickness is 2.11mm when the design thickness is 2.1mm. Schedule 5SA pipes can be
selected for them. When inside diameter is 2.0 inch, the market available 2.77mm pipe
thickness is 2.11 when the design thickness is 2.1 mm. Schedule 10SA pipe can be selected
for them.
3.1.2. PUMP SELECTION
In FCC reactor designing for the catalytic cracking of plastic into fuel oil and gas, there is no
specified liquid pump feed. But for the fluidization process, a Nitrogen gas feeder with gas
regulators and a gas compressor to circulate the petroleum gas product.
The specification for the Nitrogen gas feeder depends on the initial requirement of the
pressure drop across the fluidized bed and the Nitrogen gas flow rate. For the Nitrogen gas
feeder,
Minimum fluidization velocity = 0.0231 m/s
Diameter of the vessel = 0.973m
Required gas flow rate = 0.0224763m^3/s
Pressure is regulated into 204335 Pa.
65
3.1.3. VALVE SELECTION
In FCC reactor designing for the catalytic cracking of plastic into fuel oil and gas, the valve
selection is another very important aspect in designing. Special consideration should be given
to the valves in order to avoid the leakage to the outside environment. There are thousands of
different types of valves used in different industrial purposes. Among them, using the
common valves used in the petrochemical industries is suitable for the piping system of FCC
reactor.
Gate valves
Plug valves
Ball valves
ARC valves
Bellow sealed valves
Breather valves
Butterfly valves
Globe valves
ORBIT valves
Pressure seal valves
For the selection of suitable valve, the design parameters such as operating pressure,
operating temperature, flow rate, pipe dimensions and etc. should be considered. The API
standard for the Specification for Pipeline Valves is followed for the selection of valves. The
places where valves needed and their configuration are listed from the below table.
PURPOSE CATEGORY INSIDE TYPE OF

DIAMETER(inch) VALVE
Nozzle Butterfly
Gas Outlet 2.5
(radial) Valve
Pressure Relief Nozzle 2 -
Valve (radial)
Nozzle
Safety Valve 2 Rupture Disc
(Radial)
Gas Inlet Nozzle 2.5 Ball Valve
(Nitrogen) (tangential)
Opening Butterfly
Drain 2.5
(radial) Valve
Gas Inlet Nozzle 2.5 Ball Valve
(Other) (tangential)
66
3.2. FLANGE SELECTION
Flanges are generally selected from industrial standards. For the selection of suitable flange,
the design parameters such as operating pressure, operating temperature, pipe dimensions,
nozzle and opening dimensions, valve dimensions and etc. should be considered. Industrially
flanges are available from different sizes. For the openings and nozzles, valves and etc.
flanges have to be selected.
SECTION PURPOSE OUTSIDE INSIDE REQUIRED NUMBER OF

DIAMETER DIAMETER NUMBER BOLTS,BOLT
OF NOZZLE OF FLANGE OF DIAMETER AND
/OPENING (inch) FLANGES BOLT CIRCLE
(inch) DIAMETER (inch)
TOP Plastic/Catalyst 12 12 12 1 17
1
HEAD Feed Inlet
Gas Outlet 2.5 2.5 4 0.75 5.5
3
Pressure Relief 2 2 4 0.75 4.75
1
Valve
Safety Valve 2 2 4 0.75 4.75
3
Pressure Gauge 2 2 4 0.75 4.75
1
SHELL Catalyst 12 12 12 1 17
1
67
Removal
Thermocouple 1 2 2 4 0.75 4.75
1
1
1
BOTTOM Gas Inlet 2.5 2.5 4 0.75 5.5

5
HEAD (Nitrogen)
Drain 2.5 2.5 4 0.75 5.5
3
Gas Inlet 2.5 2.5 4 0.75 5.5
5
(Other)
3.2. PIPING AND INSTRUMENTATION DIAGRAM
Process control and instrumentation is used in process industries for the process optimization
and the profit maximization. Mainly, its used for the process optimization to control the
process parameters such as operating temperature, operating pressure, volumetric flow rates
and etc.
68
Figure 27 : P&I Diagram

E-1 FCC REACTOR
E-2 CATALYST FILTER
E-3 COMPRESSOR
V-1 FEEDING VALVE FOR NITROGEN GAS
V-2 FEEDING VALVE FOR CIRCULATED PRODUCT GAS
V-3 LIQUID DRAIN
V-4 PRODUCT REMOVAL VALVE
V-5 PRODUCT FEEDING VALVE FOR SECOND STAGE
FC-1 FLOW CONTROLLER FOR CONTROLLING NITROGEN GAS FEED
FC-2 FLOW CONTROLLER FOR CONTROLLING CIRCULATED PRODUCT
GAS
FC-3 FLOW CONTROLLER FOR CONTROLLING
TC-1 TEMPERATURE CONTROLLER FOR MAINTAINING REQUIRED
TEMPERATURE
FI-1 FLOW METER FOR NITROGEN GAS FEED
FI-2 FLOW METER FOR CIRCULATED PRODUCT GAS
TI-1 THERMOCOUPLE 1 TANGENTIAL TO THE VESSEL
3.3. START UP AND SHUT DOWN PROCEDURES
3.3.1. START UP PROCEDURE
The catalytic cracking of plastic into fuel oil and gas is a semi-continuous process.
Considering that, the startup procedure developed for the process is mentioned below.
Adding 10 kg catalyst powder to the FCC reactor through the rotary feeder from the
opening at the top.
Purging Nitrogen gas at 500C into the reactor by V1 Valve and remove the air
which contains unnecessary atmospheric gases such as Oxygen.
After the removal of atmospheric gases, close the V5 Valve and circulate the heated
up Nitrogen gas.
69
When the catalyst fluidised-bed is formed because of the pressure drop across the
fluidised-bed, start up the heating of the reactor from the furnace.
After the inside temperature of the reactor has reached 500C, add feed plastics from
the rotary feeder at the top opening.
Control the process for 30 min. reaction time.
3.3.1. SHUT DOWN PROCEDURE
After 30 minutes of FCC reaction at 500C, fully close the V1, V2, V3 and V4 valves
and vacuum the reactor to remove the existing harmful gas inside the vessel and to
remove the catalyst and carbon residue from the tangential opening in between the
two distributor plates.
After the cleaning is done, close all valves and openings and purge Nitrogen gas up to
the atmospheric pressure.
Add new 10kg of catalyst from the rotary feeder and start up the process again. (send
the carbon coated catalyst for the catalyst regeneration unit)
3.4. PROCESS CONTROL ASPECTS
In FCC reactor designing for the catalytic cracking of waste plastic into fuel oil and gas,
process control is the key main factor which controls everything from the start up to the shut
down processes. Process control is done through the controlling instrumentation of the
process.
Process control is needed for,
Controlling the operating temperature of the reaction
Controlling the pressure drop across the fluidized-bed
Controlling the minimum fluidization velocity
Controlling the circulation of product gas with the Nitrogen gas feed
To optimization of the process for maximum production at proper process conditions
For safety and loss prevention of the reactor and the other equipment
For safety and loss prevention of the workers, property, outside community and the
environment.
70
3.5. SAFETY ASPECTS
In FCC reactor designing for the catalytic cracking of waste plastic into fuel oil and gas, or
any of the chemical process plant, the safety and loss prevention should be considered all the
time in order to avoid catastrophe. Reactor is the most favorable component in the chemical
process plants which tends to fail if its not well designed. Therefore, safety aspects of the
chemical reactor should be considered at No.1 place.
The safety aspects can be considered by many facts. But for the reactor design, the Non
Destructive Examination Methods (NDE) can be carried out in order to make sure whether
the reactor is up to the standard or not.
Non Destructive Examination Methods
Visual Inspection (VI)
Liquid Penetrant Inspection (LPI)
Magnetic Particle Inspection (MPI)
Radiographic testing (RT)
Ultrasonic Test (UT)
Visual Inspection (VI)

It is the evaluation of severe instances of corrosion, erosion, and etc. by eye contact.
Liquid Penetrant Inspection (LPI)
It is the evaluation of breaking discontinuities by the penetration of low surface tension fluid
into clean and dry surface
Magnetic Particle Inspection (MPI)
It is the evaluation of breaking discontinuities in ferromagnetic materials by attraction of
ferrous ion particles to the magnetic flux leakage due to void air in breaking discontinuities.
The magnetic flux will be generated by giving AC or DC current.
Radiographic Testing (RT)
It is the evaluation of breaking discontinuities by decreasing the attenuation of the X-ray and
producing greater exposure on the film from the holes, voids, and discontinuities.
Ultrasonic Testing (UT)
It is the evaluation of breaking discontinuities by ultrasonic waves.
71
Considering the instrumentation,
Safety relief valve with rupture disc
Scrubber to avoid harmful gases to release into the atmosphere (specially should be
connected from reactor through the safety relief valve)
Gas vents and drains for pipelines
Valves to control flow rates of different parts
Considering the hazardous process material generated in conversion of waste plastic into fuel
oil and gas, Hazard and Operability Analysis (HAZOP) should be
carried out for the safety and loss prevention. From that the permissible
and hazardous levels of inhalation of petroleum mixtures and other
factors can be evaluated. The Material Safety Data Sheets (MSDS) of
process chemicals and NFPA 704: Standard System for the
Identification of the Hazards of Materials for Emergency Response by
National Fire Protection Association should be evaluated one by one Figure 28 : NFPA Fire
Diamond
and factory workers should be advised for the safety precautions,
elementary first aid and etc. before involving with plant operations.
Considering safety and loss prevention, the seven

layers of protection that are typically developed and
maintained inside a chemical process industry are
mentioned in the figure on the left. By the
implementation of this seven layers of protection even
for the process vessel, the safety aspects of the reactor
design can be ensured further.
Figure 29 : Layers of Protection
72
3.6. ECONOMIC ASPECTS
In FCC reactor designing for the catalytic cracking of waste plastic into fuel oil and gas, the
economical analysis should be done considering the below facts.
Material cost of the reactor (shell, heads, distributor plates and etc.)
Fabrication cost of the reactor (shell, heads, distributor plates and etc.)
Piping and instrumentation cost for the reactor (pipes, valves, flanges, filter,
compressor, burners, vacuum pump, indicators, controllers and etc.)
Process chemical cost (HZSM-5 Zeolite catalyst, waste plastic, Nitrogen gas)
Transportation cost (For everything above)
Operation cost (heating, electricity and etc.)
Maintaining cost (repairs, cleaning, catalyst regeneration and etc.)
The prices could be deviated by different suppliers and their locations. Prices are calculated
by considering the general material and equipment prices found from the wholesale Chinese
worldwide suppliers in the Alibaba Group of Companies.
NOTE: The market available maximum SS 304 plate size is 8 ft. x 4 ft. So, for the shell
designing its not acceptable because the designing is done considering only one sheet is
taken for the shell designing. Considering plate, 1 inch SS 304 plates are not available in Sri
Lanka. So, the design proportions need to be changed for that. Considering overall cost
estimation, different plates, pipes and etc. costs differently and the calculation is done by
adding design, fabrication, transportation and other costs.
73
DUTY (25%) +
WEIGHT PRICE HANDLING & FABRICATION TOTAL
COMPONENT MATERIAL COST (Rs)
(kg) (Rs/kg) TRANSPORTATION (25%) COST (Rs)
(15%)
SHELL SS304 2480.7934 550 1364436.37 1910210.918 341109.0925 2251320.011

HEAD (x2) SS304 2833.3442 550 1558339.31 2181675.034 389584.8275 2571259.862
PLATE (x2) SS304 2986.643 550 1642653.65 2299715.11 410663.4125 2710378.523
SKIRT SS304 31.4230003 550 17282.65016 24195.71023 4320.662541 28516.37277
TOTAL 7561474.767
DUTY(25%) +
LENGTH DIAMETER THICKNESS WEIGHT PRICE COST HANDLING & FABRICATION TOTAL
PIPE MATERIAL
(m) (in) (mm) (kg) (Rs/kg) (Rs) TRANSPORTATION (50%) COST (Rs)
(15%)
GAS
OUTLET SS304 10 2.5 2.1 337.6586926 550 185712.3 259997.1933 92856.14046 352853.3337
SAFETY
VALVE SS304 10 2 2.08 267.5543164 550 147154.9 206016.8236 73577.43701 279594.2606
0
NITROGEN
INLET SS304 10 2.5 2.1 337.6586926 550 185712.3 259997.1933 92856.14046 352853.3337
DRAIN SS304 10 2.5 2.1 337.6586926 550 185712.3 259997.1933 92856.14046 352853.3337
OTHER
GAS
INLET SS304 10 2.5 2.1 337.6586926 550 185712.3 259997.1933 92856.14046 352853.3337
TOTAL 1691007.596
74
DIAMETER
VALVES TYPE PRICE (Rs.)
(inch)
GAS OUTLET BUTTERFLY 2.5 136890

PRESSURE RELIEF VALVE RELIEF 2 40300
SAFETY VALVE SAFETY 2 40300
GAS INLET (NITROGEN) BALL 2.5 136890
GAS INLET (OTHER) BUTTERFLY 2.5 136890
DRAIN BALL 2.5 136890
TOTAL 628160
INSTRUMENTATION PRICE (Rs.)

THERMOCOUPLE (x3) 165750
PRESSURE GUAGE 9100
FLOW METER (x2) 260000
FILTER 260000
VACUUM PUMP 260000
HEATING BURNERS 780000
CONTROLLERS 260000
TOTAL 1994850
TOTAL CAPITAL COST (Rs.) 12994792.36
75
REDUCTION OPERATING OPERATIONG COST
MATERIAL COST (Rs./kg)
RATE(kg/h) COST (Rs./h) (Rs./month) - 8 hours per day
HZSM-5 ZEOLITE (With 80%

4 884 3536
regeneration) 848640
WASTE PLASTIC 200 85 17000 4080000
TOTAL 20536 4928640
TOTAL OPERATING COST (Rs./month) 4928640
76
ANNEXES
77
REFERENCES
Thousands of websites has been browsed throughout the whole design project to gather
various ideas from different sources. Among them books and international standards gave a
great support for the design of the FCC reactor. The most important sources which helped for
this design to implement up to this level is mentioned below.
List of Books
Fluid Catalytic Cracking: Science and Technology J.S. Magee & M.M. Mitchell
Fundamentals of Industrial Catalytic Processes - C. H. Bartholomew and Robert J.
Farrauto
Fluidization Engineering Daizo Kunii, Octave Levenspiel
Zeolites and Microporous Crystals T. Hattori, T. Yashima
Handbook of Fluidization and Fluid-Particle Systems (Chemical Industries) Wen-
Ching Yang
Handbook of Plastics, Elastomers, and Composites Charles A. Harper
Lange's Handbook of Chemistry James Speight
Fundamentals of Polymer Engineering Arie Ram
Introduction to Chemical Engineering Kinetics and Reactor Design Charles G. Hill
and Thatcher W. Root
Perry's Chemical Engineers' Handbook, Eighth Edition Don Green and Robert Perry
Chemical Reactor Analysis and Design Gilbert F. Froment
Coulson and Richardson's Chemical Engineering, Volume 6 R.K. Sinnott
Pressure Vessel Design Manual, Third Edition - Dennis Moss
Guidebook for the Design of ASME Section VIII Pressure Vessels Maan H Jawad
Practical Guide to Pressure Vessel Manufacturing Sunil Kumar Pullarcot
Pressure vessel design handbook Henry H. Bednar
List of Codes and Standards

NIST (National Institute of Standards and Technology ) Standard reference of
materials (National Institute of Standards and Technology
ASME (American Society of Mechanical Engineers) Code for boiler and pressure
vessel design
78
ASME Code for pressure piping B31
API (American Petroleum Institute) Standard in Specification for Pipeline Valves
ASTM (American Society for Testing and Materials) Standard for iron and steel
products
79
View publication stats

Reactor Design For The Conversion of Waste Plastic Into Fuel Oil and Gas

Загружено:

Сведения о документе

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Reactor Design For The Conversion of Waste Plastic Into Fuel Oil and Gas

Загружено:

Авторское право:

Доступные форматы

See

Reactor Design for the Conversion of Waste

Technical Report April 2015

Kasun Thivanka Samarasiri

The user has requested enhancement of the downloaded file.

GPA Module CH 4202: Comprehensive Design Project

Detailed equipment design description and parameter calculation

Department of Chemical and Process Engineering

Studying as an undergraduate at Department of Chemical and Process Engineering is the best

In my comprehensive design project, I should give my gratitude to Dr. Mahinsasa Narayana

Figure 1: Types of Vessel Heads ............................................................................................................ 10

1.1. PLANT OVERVIEW

The classification of chemical reactors is generally done by considering the characteristics of

1.2.1. CLASSIFICATION BY THE MODE OF OPERATION

1.2.2. CLASSIFICATION BY THE PHASES PRESENT

1.2.3. CLASSIFICATION BY PROCESS

1.2.4. CLASSIFICATION BY OPERATING PRESSURE

1.2.6. CLASSIFICATION BY OPERATING CONDITION

1.2.7. CLASSIFICATION BY GEOMETRICAL SHAPE

Figure 1: Types of Vessel Heads

1.2.8. CLASSIFICATION BY ORIENTATION

1.2.10. CLASSIFICATION BY HEATING METHOD

1.2.11. CLASSIFICATION BY FABRICATING MATERIAL

1.2.12. CLASSIFICATION BY FABRICATION METHOD

1.3.1. SELECTION OF THE REACTOR PROCESS

Figure 3 : Waste Plastic into Fuel Oil by Catalytic Pyrolysis Process

1.3.2. PROS AND CONS OF FLUDISED BED CATALYTIC PYROLYSIS

1.3.3. DETERMINATION OF THE NUMBER OF REACTORS

1.3.4. GENERAL DESIGN OVERVIEW OF THE REACTOR FOR THE

1.3.5. BASIC PRE DESIGN LAYOUT OF THE REACTOR

Figure 4 : FCC Reactor Predesign

1.4. CHEMICAL DESIGN

1.4.1. MATERIAL BALANCE FOR THE REACTOR

No HCl in the input plastic.

1.4.1.2.1. FEED FLOW RATES (at 25C, 1atm)

The general mass balance equation is denoted by,

LDPE 30 920 0.032608696

SUB TOTAL 200 0.211350907

HZSM - 5 ZEOLITE 20 1400 (0.01428571429)

Summary of feed flow rates

TYPE OF THE MATERIAL COMPONENT MASS FLOW

By applying overall material balance,

COMPONENT MATERIAL MASS FLOW RATE VOLUMETRIC FLOW RATE

System is at steady state.

The general energy balance equation is denoted by,

According to the Hesss law of reaction enthalpy change,

Figure 5 : Energy Balance For Waste Plastic Cracking

HZSM-5 Zeolite HZSM-5 Zeolite

Figure 6 : Energy Balance for HZSM5 Zeolite

Figure 7 : Energy Balance for Nitrogen Gas

The enthalpy of formation of feed is mentioned below.

SPECIFIC HEAT FORMATION ENERGY OF

LDPE 30 -1730.401191 1.9 902.5 -21.94084326

TOTAL 200 -101.7885848

HZSM - 5 No Mass Flow

The enthalpy of formation of product is mentioned below.

Enthalpy of formation of the feed at 500C, 2atm = -101.7885848 kW

1.5.1. CALCULATION OF VESSEL HEIGHT AND DIAMETER

Figure 8 : Length to Diameter Ratio

According to this, the effective length (L) of the reactor

1.5.1.1. LITERATURE DATA OF THE CHEMICAL AND PHYSICAL

Figure 10 : Structure of FCC Particle

1.5.1.2. KUNII AND LEVENSPIEL FLUIDISED-BED REACTOR