GROUP NO 9

PLANT DESIGN PROJECT SHEET

PRODUCTION OF 1 MMM JOB CODE
LB/YEAR OF STYRENE DESIGNER
MUHAMMAD
HARIEZ

DETAILED DESIGN OF MAJOR

AND MINOR EQUIPMENTS

PACKED BED REACTOR (R-106)

COMPRESSOR (K-102)

MIXER (M-101)

DOC PREPARED REVIEWED

DESCRIPTION DATE
NO BY BY
01 GENERAL DESCRIPTION HARIEZ
02 PROCESS DESIGN HARIEZ
3
03 MECHANICAL DESIGN HARIEZ
04 SPECIFICATION SHEET AND DRAWING HARIEZ
05 COSTING HARIEZ
06 OPERATING MANUAL HARIEZ
07 MINOR EQUIPMENT DESIGN HARIEZ
INFORMATION CONTAINED IS OUR PROPERTY AND MUST NOT BE USED BY OR CONVEYED TO ANY PERSON WITHOUT
AUTHORITY

1
 TABLE OF CONTENTS
CHAPTER 1: R-106 PROCESS DESIGN...........................................................3
CHAPTER 2: R-106 SPECIFICATION SHEET .............................................14
CHAPTER 3: R-106 MECHANICAL DESIGN ...............................................15
CHAPTER 4: R-106 OPERATING PROCEDURE .........................................36
CHAPTER 5: R-106 EQUIPMENT COSTING ...............................................39
CHAPTER 6: K-102 COMPRESSOR DESIGN...............................................40
CHAPTER 7: M-101 MIXER DESIN................................................................43

2
 CHAPTER 1: PROCESS DESIGN

1.1 INTRODUCTION
The reaction stage is the heart of a chemical manufacturing process. In the reactor the raw
materials are brought together under conditions that promote the production of the desired
product and/or by-product as well (Sinnott, 2005). Chemical engineers are responsible to
design reactors in order to maximize net present value for the given reaction. Designers
ensure that the reaction proceeds with the highest efficiency towards the desired output
product, producing the highest yield of product while requiring the least amount of money
to purchase and operate. This section will further discuss on the detail design of oxidative
dehydrogenation reactor to convert 4-vinylcyclohexane into styrene monomer. Following
figure shows the particular reaction with addition of by-product produce such as water and
ethylbenzene in the present of excess oxygen.

Figure 1.1: Oxidative Dehydrogenation Reaction of 4-vinylcyclohexene to Styrene

US patent 4165441 entitle process for production of styrene by DOW chemical suggest the
reaction carried out at atmospheric pressure with operating temperature of 380C and
operating pressure of 101.3 kPa in the present of tin/antimony oxide catalyst. The reaction
takes place in gaseous phase and highly exothermic. The following paragraph explains on
reactor design methodology.

3
1.2 METHODOLOGY OF DESIGN

In general, the design methodology for the major equipment is classified into 2 major
sections; the process design and mechanical design. The overall design is carried out in
series of stages as follow:

1. Selection of major equipment Reactor, R-106

2. Justification of selection of the type of reactor.
3. Determination of the optimum operating conditions.
4. Calculations for the volume of the reactor.
5. Sizing of reactor.
6. Obtain the necessary parameters from reactor sizing calculation.
7. Proceed with equipment mechanical design.
8. Cost evaluation for reactor and the utilities needed.
9. Perform technical drawing of the designed reactor.
10. Perform start up and shut down procedures for the reactor.

1.3 REACTOR SELECTION

There are eight configuration of reactors based on (Smith, 2005). However, since the
reaction in our plant is using catalyst, only two types of catalytic reactors will be taken into
considerations under this topic which are packed-bed catalytic reactors and fluidized-bed
catalytic reactors.

Reactor Packed-bed Catalytic Reactor Fluidized-bed Catalytic

General The packed-bed reactor is a
Features tubular reactor that is packed
with solid catalyst particles. The
catalyst of the reactor may be
placed in one or more fixed beds
(i.e., layers across the reactor) or
may be distributed in a series of
parallel long tubes. Most designs
approximate to plug-flow
behaviour. The simplest form of
packed-bed catalytic reactor uses
an adiabatic arrangement.
Reactor
In fluidized-bed reactors, solid
material in the form of fine
particles is held in suspension by
the upward flow of the reacting
fluid. The fluid stream is passed
up through the particles at a rate
strong enough for them to lift
and not fall back into the
fluidized phase above its free
surface by carryover in the fluid
stream. Overall, the performance
of a fluidized-bed reactor often
lies somewhere between the
mixed-flow and plug flow

4
 models.

Advantages For most reactions, it gives the Savings in operating expenses

highest conversion per weight of
catalyst of any catalytic reactor.
Provides large volumes of
processed reactants.
Gives less chance for back
mixing.
No catalyst or product
separation problems.
Practical and economical
choice at very high pressures.
Disadvantages The catalysts are highly prone
to deactivation.
The catalysts often require
regeneration after a relatively
short period of operation. This
may incur additional cost.
It is difficult to control the
temperature and heat-transfer in
the catalyst bed.
Some part of the catalyst
surface remains unused as a
result of the reaction system and
the rate-controlling step.
Table 1.1: Comparison between packed bed and fluidized bed catalytic reactor
due to heat recovery in the
reaction regeneration steps.
Rapid mixing of reactants-
solids and high heat transfer
rates.
Easy to control both the heat
transfer and the fluid flow
system.
Useful in situations where
catalyst particles need frequent
regeneration.
Attrition of the catalyst can
cause the generation of catalyst
fines, which are then carried
over from the bed and lost from
the system.
For continuous system,
complicated systems like
multiple reactors, extensive
valving and piping are required.
High cost of the reactor and
catalyst regeneration equipment.

From above comparison on the properties of packed bed and fluidized bed reactor, it is
found that packed bed reactor is more convenient to be used as heterogeneous phase exist.
The inlet reactant is in gas phase in contact with the solid catalyst. Following paragraph
describe further justification of using fixed bed reactor for oxidative dehydrogenation
reaction.

1) Flow arrangement

With the reaction highly exothermic, single flow will prone to create reactor hot spot due
to the uneven heat release. To overcome this, a multi-tubular reactor is used. It is a
modified multiple packed-bed units, where the multiple beds are catalyst-filled tubes
arranged in parallel with conduction fluid flowing outside the tubes. Reactor temperature
can be maintain with the increase of cooling surface area.

5
2) Lower capital and operating cost

Operating pressure required for the process is at 101.3 kPa. For operating pressure, the
required volume for packed bed catalytic reactor is smaller compared to fluidized bed
reactor. Therefore, lower capital cost is required.

3) Catalyst loss reduced

The catalyst is packed in the tubes when it is at contact with the reactant in fixed bed
catalytic reactor which results in low possibility of catalyst loss. Gasification process that
take place in fluidized bed reactor increase the possibility of catalyst particles carry over
along with fines.

1.4 OPERATING CONDITION

Reactor R-106 operating condition and component involved tabulated as follow:

Operating Temperature 380C

Operating Pressure 101.3 kPa

1..1 Inlet Flow

Component Mass Fraction Flow Rate (kg/h) Flow Rate (kgmole/h)

1,3-butadiene 0.000000 0.00000 0.0000
I-Butene 0.000000 0.00000 0.0000
1-butene 0.000000 0.00000 0.0000
Cis-2-butene 0.000000 0.00000 0.0000
Trans-2-butene 0.000000 0.00000 0.0000
N-butane 0.000000 0.00000 0.0000
Isobutane 0.000000 0.00000 0.0000
Vinylcyclohexene 0.157821 76911 710.96
Oxygen 0.195945 94949 2967.2
Styrene 0.000000 0.00000 0.0000
Nitrogen 0.645286 312000 11162
Hydrogen 0.000000 0.00000 0.00000
Benzene 0.000048 23.176 0.29672
Water 0.000000 0.00000 0.00000
Carbon dioxide 0.000000 0.00000 0.00000
Ethylbenzene 0.000000 0.00000 0.00000
1.3.2 Reactor outlet

6
 Component Mass Fraction Flow Rate (kg/h) Flow Rate (kgmole/h)
1,3-butadiene 0.000000 0.00000 0.00000
I-Butene 0.000000 0.00000 0.00000
1-butene 0.000000 0.00000 0.00000
Cis-2-butene 0.000000 0.00000 0.00000
Trans-2-butene 0.000000 0.00000 0.00000
N-butane 0.000000 0.00000 0.00000
Isobutane 0.000000 0.00000 0.00000
Vinylcyclohexene 0.024999 12114 111.98
Oxygen 0.144088 69821 2181.9
Styrene 0.122555 59386 570.19
Nitrogen 0.645283 312690 11162
Hydrogen 0.000038 18.633 9.2424
Benzene 0.000048 23.176 0.29672
Water 0.046757 22657 1257.7
Carbon dioxide 0.014206 6883.6 156.41
Ethylbenzene 0.002025 981.23 9.2424

1.5 HEAT OF REACTION

Reaction takes

Main reaction

C8H12 + O2 C8H8 [

] + 2H2O HR = -4 x 105 kJ/kgmole (1)

Side reaction

C8H12 C8H10 + H2 HR = -3.5 x 104 kJ/kgmole

(2)

C8H12 + 11 O2 8CO2 + 6H2O HR = -4.7 x 106 kJ/kgmole

(3)

All reaction are highly exothermic reaction since the heat of reactions shows negative sign.

1.6 CATALYST

7
In the production process of styrene from 4-vinylclclohexene (VCH) comprising
contacting feed stream in a gas phase with catalyst comprising tin, antimony and oxygen
under sufficient condition. The catalyst has a half-life of 1000 hours. (US Patent 4165441).

1.7 OPERATING CONDITIONS OPTIMISATION

i. Temperature Optimisation

In order to design the reactor, suitable temperature must be chosen so as to maximize

conversion and selectivity, but up to the extent that it does not lower the catalyst activity.
According to Contreras et al., to design the reactor, it was established that it had to be done
isothermally trying to prevent the sections that may turns lower the catalyst activity. Based
on patent, the temperature of the reactor may be chosen in the range between 300 C to 500
C. Thus, it is desirable to use inlet temperature of 380 C.

ii. Pressure Optimisation

The reaction can be performed under a low degree of pressure, under reduced pressure or
at normal conditions. Thus, based on economic justification operation at atmospheric
pressure is desirable. In this design, the pressure of 1.013 bar (101.3 kPa) is used where it
is at atmospheric condition to make sure no outside air enter the reactor in case of leakage.

1.8 REACTOR VOLUME

For packed bed or homogenous reactors, the gas hourly space velocity (GHSV) is a way of
rapidly sizing reactors. Space velocity is defined as the ratio of the volumetric feed flow
rate to the reaction volume or the ratio of mass feed flow rate to the catalyst mass. The
volumetric feed-gas flow rate is calculated at a standard temperature and pressure. Thus,
the space velocity is defined by:

GHSV = hourly volumetric feed-gas flow rate/reaction volume

LHSV = hourly volumetric liquid-feed flow rate/reaction volume
WHSV = hourly mass feed flow rate/catalyst mass

8
In this design, the reaction takes place in gas phase. According to the patent, GHSV for the
reaction is in the range of 5000 h-1 to 1000 h-1. Thus for the calculation 1000 h-1 is
considered where it means that 1000 reactor volume of 4-vinylcyclohexene at standard
condition is converted in one hour.

i. Volumetric flow rate at standard condition.

  
 =


 =


Where, Qstd = volumetric flow rate at standard condition

s = molar density
R = gas constant = 8.20510-2
T = temperature = 273.25 K
P = pressure = 1 atm
Thus,

s = 0.04462 kg.mol/m3

Qstd = 563.4 m3/h (STP)

ii. Bed volume.


  !" =
 #$%&

Where, SVGHSV = hourly volumetric feed-gas flow rate/reaction

volume

Thus,

Bed volume = 0.5634 m3

Note that in this design, only 1 reactor will be used.

iii. Volumetric flow rate at actual condition.

9
   
 =


 =


Where, Q = volumetric flow rate at actual condition

s = molar density
R = gas constant = 8.20510-2
T = temperature = 573.15 K
P = pressure = 1.52 atm
Thus,

s = 0.03232 kg.mol/m3

Q = 746300 m3/h (STP)

Note that in this design, only 1 reactor will be used.

iv. Bed area.


'( =


Where, Ab = Bed area

Q = volumetric flow rate at actual condition
Vs = Superficial velocity = 2.5 m/s
Thus,

Ab = 225.36 m2

v. Bed Diameter.

4'(
) = *
,

Thus,

D = 4.068 m

10
 Normal sizing is round off to the nearest feet. 4.068 m = 13.26 ft. is round off to
13.50 ft. thus actual bed diameter is 4.115 m.

vi. Bed Length.

  .!"
-( =
'(

Thus,

Lb = 6.3246 m

vii. Actual bed total volume.

,)/
= -(
(
4

Thus,

Vb = 84.12 m3

1.9 TUBE SELECTION

Tube material selection must be made in accordance to the suitability to the process.
Carbon steel IS: 3609 -1966 1% Cr Mo is selected due to good corrosion resistance and
mechanical properties. With the catalyst inside the tubes, the reactor volume must be equal
to the inside volume of the tubes. By specifying the tube diameter and length of a single
tube, the volume per tube can calculated. Preliminarily, tubes of 2 1/2 in. carbon steel IS:
3609 -1966 1% Cr Mo, with 14.68 m length are selected. This is a large size for heat
exchanger tubing but a large size is desirable for good catalyst distribution and minimal
wall effects. The properties of the pipe are stated as below (Values obtained from
Timmerhaus (2003) Table D-13):

11
 Table 2.1: Tube Specification

Nominal pipe size 2 1/2 in (0.0635 m)

Outside diameter 2.88 in (0.0732 m)
Inside diameter 2.469 in (0.0627 m)
Wall thickness 0.411 in (0.0104 m)
Cross sectional area 4.785 in2 (0.00309 m2)

i. Effective tube length.

-(,233 = 4 

Where, Lb,eff = Effective bed length

= Space time = 3.6 s
Vs = Superficial velocity = 2.5 m/s
Thus,

Lb,eff = 9m

ii. Volume of one tube.

!"  
!5 = 677 7 89
   -(,233

Thus,
Volume of one tube = 0.02781 m2

iii. Number of tube.

: =
(
.!"  
!5

Where, Nt = Number of tube

Vb = bed volume = 84.12 m3

Thus,
Nt = 3009 tubes

12
1.10 PRESSURE DROP ON TUBE SIDE

There are 2 major sources of pressure loss on the tube side which are the friction loss in the
tubes and the losses due to the sudden contraction, expansion and flow reversals
experienced by the fluid while flowing through the tube arrangement. For fluid flow
through fixed-bed, the most popular method of calculating pressure drop in a packed
porous bed is the Erguns equation. According to Fogler (2001),

 2?; - A
= (1 )/
; ;
B(1 ) 150(1 )J
?; = [ + 1.75B]
DE ; )F G )F
"77 . 89
B=
 !5 7  

Where, G = superficial mass velocity

= porosity = 0.99
gc = constant = 1.0
Dp = Diameter of particle in bed = 6 mm
= fluid viscosity = 2.709 10-2 pa.s
o = mass density = 1.207 kg/m3
Po = pressure inlet = 150 kPa
Thus,
G = 8.55 kg/s.m2
o = 182.139 Pa/m
P = pressure drop = Po-P = 3.315 kPa

13
 CHAPTER 2: SPECIFICATION SHEET

Equipment Tag No R-106

REACTOR DATA SHEET Description Oxidative
Dehydrogenation
Reactor
Sheet No 1/1
OPERATING DATA
No. Required 1 ORIENTATION Vertical
TYPE Multitubular Catalytic Packed JACKETED Yes
Bed Reactor
R-106
CONTENT Gaseous Phase 4-vinylcyclohexene
DIAMETER (INSIDE) 4.115 m
DIAMETER (OUTSIDE) 4.127 m
LENGTH 10 m
MAX WORKING PRESSURE 1.575 Bar
DESIGN PRESSURE 1.590 Bar
PRESSURE DROP 3.315 kPa
MAX WORKING TEMPERATURE 305oC
DESIGN TEMPERATURE 315oC
VELOCITY
HEAXT EXCHANGED
MECHANICAL DESIGN ON SHELL
MATERIAL Carbon Steel
JOINT FACTOR 1
CORROSION ALLOWANCE 2 mm
THICKNESS 5.85 mm
NO OF BOLTS
NO. OF BOLTS 176 DIAMETER 18 mm MATERIAL Cr-Mo Steel
NOZZLE THICKNESS 3.85 mm MATERIAL Same As Shell
FLANGE THICKNESS 9.35 mm MATERIAL Same As Shell
GASKET WIDTH 10 mm MATERIAL ASBESTOS
MECHANICAL DESIGN OF TUBES
Material Carbon Steel
No. of Tubes 3009
OD 0.0732 m
ID 0.0627 m
THICKNESS 0.0104 m
TUBE PITCH 0.142875 (triangular)
CATALYST
TYPE Tin, Antimony and Oxygen
WEIGHT 121256.4 kg
BULK DENSITY 1440 kg/m3

14
 CHAPTER 3: MECHANICAL DESIGN

3.1 DESIGN METHODOLOGY

15
3.2 REACTOR SHELL DESIGN

3.2.1 Reactor Design Pressure

Based on the patent 4165441, process for the production of styrene, suggested the
oxidative dehydrogenation of 4-vinylcyclohexe to styrene can be performed under a low
degree of pressure, under reduced pressure or at normal conditions. In this design, reactor
operating pressure is set at 1.013 kPa. In calculating the design pressure, maximum
working pressure (MWP) has to be considered. The maximum working pressure is the
maximum gauge pressure expected in the equipment under any condition. It should not be
exceeded under any conditions to avoid damage to the equipment. MWP for the column is
taken as 5% above the operating pressure, to take care of valve hysteresis, noise and
overpressure.

MNO = ;F2PQRST 1.05

MNO = 1.013 V 1.05 = W. XYZY[ \]^

Design pressure is taken as more than the maximum working pressure. Design pressure is
the differential pressure between the outside atmospheric pressure and PMWP, to give the
column maximum allowance for operation. Factor of 1.05 is added to the differential
pressure which resemble 5% safety factor.

2RTS = (MNO Q_ ) 1.05

2RTS = (1.06365 V 1.013 V ) 1.05 = X. X[Z` \]^

3.2.2 Reactor Design Temperature

Prior to find the value of allowable stress for the material of construction which is
temperature dependent, it is vital to determination the appropriate design temperature.
Design temperature is determined from the process design temperature.

Generally, the following heuristics are applied in order to determine the design
temperature:
1. For unheated part consider the highest temperature of the stored material.

16
 2. For part that is heated by means of steam, hot water, and oil consider the highest
temperature of the heating media, or 10C higher than the maximum temperature
that any part of body is likely to attain during course of operation.
3. For vessel where direct internal or external heating is employed by means of fire,
flue gas or electricity or for severe exothermic reactions that takes place:
a. Consider the highest temperature of the inside material plus minimum of
20C if vessel is shielded.
b. Consider the highest temperature of the inside material plus minimum of
50C if vessel is not shielded.
c. For highly exothermic reactions, same condition as above applies.

For the oxidative dehydrogenation reactor, first heuristic is applied. Factor of 1.05 is to
consider the safety limit for column operation.

2RTS = ;F2PQRST 1.05

2RTS = 3806 1.05 = Zbbc

3.2.3 Reactor Material Selection

Pressure vessels are usually constructed from plain carbon steels, low and high alloy steels,
other alloys, clad plate, and reinforced plastics (Sinnott, 2005). Several issues need to be
considered for material selection such as corrosion, compatibility of the material toward
process environment and the cost. In this design Carbon-Steel is selected for oxidative
dehydrogenation reactor because the reaction taking place at both moderate temperature
and pressure as well as it involve non-corrosive gases component.

3.2.3 Reactor Cylindrical Shell Thickness

A minimum wall thickness required to ensure that the column is sufficiently rigid to
withstand the design pressure for the reaction is given in the equation below.

Minimum shell thickness,  = / 3gh O +8

O e
d f
d

17
Where Di = Internal Diameter
f = Design stress = 85 N/mm2
PD = Design absolute pressure = 0.159 N/mm2
J = Welding efficiency = 1.0
c = Corrosion allowance

For carbon and alloy steel, where severe corrosion is not expected, a minimum corrosion
allowance of 2 mm should be taken into account (Sinnott, 2005). From reactor process
sizing, the internal reactor diameter, Di = 4.115 m.

Thus, t= 5.85 mm

However, the minimum practical wall thickness is also a function of column diameter. The
1.5 and e 0.25
ei 
ef
condition above is only valid if:
f

Do = Di + 2t = 4.115 m + 2 (0.00585 m) = 4.127 m

= k.AAn m = 1.00 < 1.5 => Valid

ei k.A/l m
ef

= = 0.001 < 1.5 => Valid

 p.ppnqnm
ef k.AAn m

3.3 REACTOR HEAD AND CLOSURE

The ends of a cylindrical process vessel are to be closed by heads of various shapes.
According to (Sinnott, 2005), the principal types used are:

1. Flat plates and formed flat heads.

2. Hemispherical heads.
3. Ellipsoidal heads.
4. Torispherical heads.

The selection for a particular type of head depends on the factors such as process
temperature and pressure, nature of the materials to be handled and products produced,

18
position of the vessel, nature of the support and above all the economy. Standard
torispherical heads (dished ends) are the most commonly used end closure for vessels up to
operating pressures of 15 bar and it has less stress concentration as compared to flat plate.
The minimum thickness required can be calculated using equation below.

r 6%
 =
2 s +  (6% 0.2)

1 r
6% = (3 + * )
4 t

Where, P = Pressure = 0.15 N/mm2

f = Design stress = 85 N/mm2
J = Joint factor = 1.0
RC = Crown radius = Do = 4.127 m
RK = Knuckle radius = 0.06 RC = 0.2476

Thus, CS = 1.77
Substituting all the values above into thickness equation gives,

t = 6.436 mm

3.4 REACTOR HEIGHT

Height of the closure is also assumed, ho = 0.5 m

Thus, the total height of the reactor = height of closures + tube length
= 2 (0.5 m) + 9 m
= 10.0 m

3.5 DESIGN OF BOLTED FLANGE JOINTS

Flanged joints are used for connecting pipes and instruments to vessels, for manhole
covers, and for removable vessel heads when ease of access is required. Flanges may also
be used on the vessel body, when it is necessary to divide the vessel into sections for
transport or maintenance (Sinnott, 2005).

19
Several different types of flange are used for various applications. The principal types used
in the process industries are:
1. Welding-neck flanges.
2. Slip-on flanges, hub and plate types.
3. Lap-joint flanges.
4. Screwed flanges.
5. Blank, or blind, flanges.

Figure 3.1: Welding-neck flanges

In this design, welding-neck flanges are suitable to be used because it can withstand
extreme service condition such as temperature, shear and vibration loads. It have a long
tapered hub between the flange ring and the welded joint. This gradual transition of the
section reduces the discontinuity stresses between the flange and branch, and increases the
strength of the flange assembly.

3.5.1 Gasket Design

Gaskets are used to make a leak-tight joint between two surfaces. It is made from soft
semi-plastic material which will deform and flow under load to fill the surface
irregularities between the flange faces, at the same time retains sufficient elasticity to take
up the changes in the flange alignment that occur under load. Selection of gasket material
depends on the process condition such as pressure, temperature and corrosive action of
chemicals that may contact the gasket, the gasket location and type of gasket construction
as well on the type of flange and flange face. The data for gasket calculation is listed
below:

20
 Table 3.1: Gasket material (Based on a similar table in BS 5500: 1991)

Minimum Minimum
Gasket Gasket
design Sketches Gasket
Material Factor
seating stress Width

Asbestos with a
suitable binder 2.75 25.5 N/mm2 10 mm
(1.6 mm thick)

u  e "
= *
R  e (" + 1@

Where, PD = Design pressure = 0.15 N/mm2

y = Minimum design seating stress
m = Gasket factor
di = Gasket inner diameter
do = Gasket outer diameter

Thus;
u
 1.069
R

i. Inside diameter of gasket

Assume gasket inside diameter 5 mm larger the reactor outside diameter. Thus:

R  )u  2 <5 mm@
Where, DO = Reactor outside diameter = 4.127 m
Thus;
di = 4137 mm

ii. Outside diameter of gasket

21
 u
 1.069
R

Thus;
do = 4422.5 mm

iii. Gasket width, N

u  R
: =
2

Thus;
N = 142.75 mm
The minimum width of the gasket is 10 mm. The calculated value can be used as
gasket width.

iv. Effective gasket sealing width, b

5 = 2.5 x5u
0.5 (u R )
5u =
2

Thus;
b = 21.12 mm

v. Diameter at gasket load reaction, G

u +  R
B =
2

Thus;
G = 4279.75 mm

3.5.2 Bolt Sizing

The bolts hold the flange faces together, resisting the forces acting on a flanged joint.
Table below shows the suitable bolt material used for the design and its characteristic.

Bolt material 5% Cr-Mo Steel

Allowable Stress of Bolting Material (Sg) 1.38E+08 N/m2

22
 i. Bolt loads, W

For bolt loads estimation, there are 2 conditions namely:

a. Bolt loads under operating condition, Wm1

yMA  z  zT
,B / R
z 
4
zT  ,B<25)"R

Where, WM1 = Min bolt load at operating condition

H = total pressure force
Hg = gasket reaction (pressure force)
= pi = 3.142
G = Diameter at gasket load reaction = 4279.75 mm
Pi = internal pressure = 0.15 N/mm2
b = Effective gasket sealing width = 21.12 mm
m = Gasket factor = 2.75

Thus;
WM1 = H + Hg = 2158113.34 N + 85200.03 N = 2243313.37 N = 2.24 MN

b. Bolt loads under bolting-up condition, Wm2

yM/ = ,B5

Where, WM1 = Min bolt load at bolting-up condition

y = Minimum design seating stress = 25.5 N/mm2
= pi = 3.142
G = Diameter at gasket load reaction = 4279.75 mm
b = Effective gasket sealing width = 21.12 mm
Thus;
WM2 = 6390002.28 N = 6.39 MN

Since Wm2 is greater than Wm1, it controls the load. Further calculation will base on
Wm2.

23
 ii. Minimum bolting area, Abf

y_
'(3 
(

Where, Abf = Minimum bolt area

Wm = Bolt loads = WM2 = 6.39 MN
fb = maximum allowable bolt stress = Sg = 1.38E+08
N/m2
Thus;
Abf = 0.0463 m2

iii. Checking the gasket material,

Make sure the gasket material is strong enough for bolting. If the left hand term
(LHS) of equation below is less than the right hand term (RHS), the material
selected is strong enough for bolting.

< 2
'(3 T
,B:QE{Q|

Where, Abf = Minimum bolt area = 0.0463 m2

Sg = maximum allowable bolt stress = 1.38E+08
N/m2
= pi = 3.142
G = Diameter at gasket load reaction = 4279.75 mm
N = Gasket width = 142.75 mm
y = Minimum design seating stress = 25.5 N/mm2
Thus;
Left hand side (LHS), 3.329 < 51, Right hand side (RHS)
Gasket material used, Asbestos with a suitable binder (1.6 mm thick) is justified.

3.5.3 Flange Design

i. Moment about flange , W

a. Hydrostatic end force on area inside flange, W1

24
 , / e
yA 
4

Where, B = Shell outside diameter = Do = 4127

mm
PD = Design absolute pressure = 0.159 N/mm2
= pi = 3.142
Thus;

W1 = 2127 kN

b. Unbalanced forces due to pressure acting on downward direction, W2

<B /  / @ ,e
y/ 
4

Where, G = Diameter at gasket load reaction = 4279.75 mm

Thus;

W2 = 160 kN

c. Gasket load, W3
yG  ,B<25)e

Where, b = Effective gasket sealing width = 21.12 mm

Thus;

W3 = 90 kN

ii. Moment arm of flange, a1, a2 and a3

6
A =
2
A + G
/ =
2
6B
G =
2

Where, G = Diameter at gasket load reaction = 4279.75 mm

25
 B = Shell outside diameter = Do = 4127
mm
C = Bolt circle diameter = 4300 mm

Thus;

a1 = 86.50 mm
a2 = 53.38 mm
a3 = 20.25 mm

iii. Moment of force

;  yA A  y/ /  yG G
T  yT G

T
'(3  (
2
yT 

Where, Mo = Bolt moment of force (operating condition)

Mg = Bolt moment of force (bolting up condition)
Abf = Minimum bolt area = 0.0463 m2
Ab = actual bolt area = 0.0463 m2
Sg = maximum allowable bolt stress = 1.38E+08
N/m2
Thus;
Mo = 194.3 kNm
Mg = 129.4 kNm

Since Mo > Mg. Thus Mo is used for further calculation.

iv. Flange thickness, tf

6} 
3 = *


Where, M = Mo = 194.3 kNm

Cf = bolt pitch correction factor = 1.00
Y = correction coefficient = 18.55

26
 St = Allowable stress of flange material = 10 000
MN/m2
B = Shell outside diameter = Do = 4127
mm

Thus;
Cf = 9.35 mm

3.6 NOZZLES & PIPE SIZING

i. Optimum nozzle diameter , Dopt

Pipe diameter for both inlet and outlet of oxidative dehydrogenation reactor can be
determine using correlation below (Richardson's, 1994).
)uFR_{_  226 B p.n hp.Gn

Where, G = Inlet flow rate (simulation data) = 39.75 kg/s

Outlet flow rate (simulation data) = 39.75 kg/s
= Inlet fluid density (simulation data) = 1.207 kg/m3
Outlet fluid density (simulation data) = 1.113 kg/m3

Thus;
D inlet nozzle = 1134.1 mm
D outlet nozzle = 1372.5 mm

ii. Nozzle thickness , e

e )R
=
2 e

Where, e = Nozzle thickness

Di = Internal Diameter = 4.115 m
f = Design stress (Carbon steel) = 85 N/mm2
PD = Design absolute pressure = 0.159 N/mm2

Thus;
e inlet nozzle = 3.85 mm

27
 e outlet nozzle = 3.85 mm

Adding corrosion allowance of 2 mm, thickness inlet/outlet nozzle = 5.85 mm

3.7 REACTOR WEIGHT

3.7.1 Weight of Shell

For cylindrical vessel with domed ends, and uniform wall thickness, the approximate
weight can be estimated using following equation:

y~  6~ ,_ )_ <z  0.8)_ ) 10hG

Where, Wv = total weight of shell, excluding internal fittings

Cv = factor to account for the weight
= 1.15 for distillation columns, or similar vessels, with
several manways and with plate support rings, or
equivalent fittings.
Hv = Height = 10 m
g = gravitational acceleration = 9.81
m/s2
= pi = 3.142
Dm = mean diameter of vessel, (Di + t), m = 4.1211
m
t = wall thickness = 5.85
mm

Thus;
Wv = 67 727 N

3.7.2 Weight of Fluid in Reactor

28
Total weight of fluid in reactor comprises of the weight of fluid, catalyst and the heating
medium molten salts. On the tube side, the volume of fluid and catalyst are calculated
whilst at the shell side the weight of molten salts is taken into consideration.
i. Weight of fluid , Wf
y3  3 D
 4

Where, Wf = weight of fluid

f = fluid density = 1.207 kg/m3
V = fluid volume
g = gravitational acceleration = 9.81 m/s2
= space time = 3.6 s
Q = volumetric flow rate (simulation data) = 1.185x105
m3/h
Thus;
V = 118.5 m3
Wf = 1403.12 N

ii. Weight of Catalyst , Wc

yE  E D

Where, Wc = weight of catalyst

f = catalyst density = 1440 kg/m3
V = Catalyst volume = 84.12 m2
g = gravitational acceleration = 9.81 m/s2

Thus;
Wc = 1188312.8 N

3.7.3 Weight of Fluid in Reactor

yR  R D
 ,); z~

29
 Where, Wi = weight of insulating material
i = insulation density (mineral wool) = 130 kg/m3
V = insulation volume
= pi = 3.142
Do = reactor outside diameter = 4.127 m
t = insulation thickness = 0.1 m
Hv = Reactor height = 10 m

Thus;
V = 12.965 m2
Wi = 16534.26 N

3.7.4 Total Reactor Weight

y  y3  yE  yR  y&

Where, Wf = weight of fluid = 1403.12 N

Wc = weight of catalyst = 1188312.8 N
Wi = weight of insulating material = 16534.26 N
Wv = total weight of shell, = 67 727 N
Thus;
W = 1273.98 kN

3.8 WIND LOADING

The load imposed on any structure by the action of the wind will depend on the shape of
the structure and the wind velocity. For a smooth cylindrical column or stack the following
semi-empirical equation can be used to estimate the wind pressure:

i. Wind pressure , Pw
  0.05(! )/

Where, Pw = dynamic wind pressure

uw = wind speed = 160 km/h

Thus;

30
 Pw = 1280 N/m2

ii. Loading per unit length , Fw

The loading per unit length of the column can be obtained from the wind
pressure by multiplying by the effective column diameter: the outside diameter
plus an allowance for the thermal insulation and attachments, such as pipes and
ladders. An allowance of 0.4 m should be added for a caged ladder.
   )233

Where, Fw = loading per unit length

Pw = dynamic wind pressure = 1280 N/m2
Deff = Effective column diameter
= Do + 2tinsulation + 0.4 = 4.727 m
Thus;
Fw = 6050.6 N/m

iii. Bending moment , M

-/
2
  

Where, Fw = loading per unit length = 6050.6 N/m

L = reactor height = 10 m
Thus;
M = 302530 Nm

3.9 ANALYSIS OF STRESSES AT BOTTOM SECTION

3.9.1 Pressure stress

The longitudinal and circumferential stresses due to pressure given by:

)R
=
4
)R
$ =
2

Where, L = longitudinal stress

31
 H = circumferential stress
P = Operating pressure = 0.15 N/mm2
Di = Inner diameter = 4115 mm
t = wall thickness = 5.85 mm
Thus;
L = 26.378 N/mm2
H = 52.756 N/mm2

3.9.2 Dead weight stress

y&
N 
,<)R  @

Where, W = Dead weight stress

Wv = weight of vessel (reactor) = 67 727 N
Di = Inner diameter = 4115 mm
t = wall thickness = 5.85 mm
Thus;
W = 0.894 N/mm2

3.9.3 Bending stress

()u k )R k )
,
64
& 

 )R
( = ( + )
& 2

Where, IV = Second moment of area of the shell

M = Longitudinal bending stress at the mid-span =
== 302530 Nm
Di = Inner diameter = 4115 mm
DO = Outer diameter = 4127 mm
t = wall thickness = 5.85 mm
Thus;
IV = 1.6491011 mm4
b = 3.785 N/mm2

3.9.4 Resultant longitudinal stress

32
   N (
W is compressive, thus the value will be a negative.

Where, L = longitudinal stress = 26.378

N/mm2
b = Bending stress = 3.785
N/mm2
W = Dead weight stress = -0.894 N/mm2
Thus;
Z (Upwind) = 29.269 N/mm2
Z (Downwind) = 21.699 N/mm2

As assume that there is no torsional shear stress, the principal stresses will be Z and h.
The radial stress is negligible,

R
2

Where, Pi = Internal pressure = 0.15 N/mm2

Thus;

= 0.075 N/mm2

3.9.5 Elastic stability (buckling)

If the resultant axial stress, z due to the combined loading is negative, the reactor may fail
due to elastic instability (buckling). The condition for this not to take place is the
maximum compression stress, c must be more than the critical buckling stress, c max.

r,_Q =  + ((h~2)
r = 2 10k (/); )

Where, b = Bending stress = -3.785 N/mm2

W = Dead weight stress = -0.894 N/mm2
DO = Outer diameter = 4127 mm
t = wall thickness = 5.85 mm

33
 Thus;

c, max = -4.679 N/mm2

c = 28.35 N/mm2

The maximum compression stress is 4.679 N/mm2 which is lower than 28.35 N/mm2. It is
well below the critical buckling stress. Thus, design is satisfactory.

3.10 REACTOR SUPPORT (SKIRT)

Reactor will be placed vertically. Cylindrical skirt support is used. The skirt thickness must
be sufficient to withstand the dead weight loads and bending moments imposed on it by the
vessel; it will not be under the vessel pressure. From (Sinnott, 2005),

3.10.1 Bending stress in the skirt

4
( 
,<)   @  )

<z~  z @/
2
  

Where, Ms = Maximum bending moment

W = Reactor total weight = 1273.98 kN
Ds = Inside diameter of skirt at the base = 4127 mm
ts = skirt thickness (assume) = 6 mm
Hv = vessel height = 10000 mm
Hs = skirt height (assume) = 1500 mm
Thus;

Ms = 6.0506 10-3 N/mm2

bs = 4.977 N/mm2

3.10.2 Dead weight stress in the skirt

y
 =
,() +  ) 
Thus;

ws = 16.35 N/mm2

34
3.10.3 Resultant skirt stresses

 <
79 @  ( 
 <8" 779. @  (  

Thus;

s (tensile) = -11.37 N/mm2

s (compressive) = 21.328 N/mm2

3.10.4 Skirt thickness design check

 <
79 @ s sin

 <8" 779. @  0.125 sin
)

Where, f = Maximum allowable design stress

= material carbon steel = 85 N/mm2
J = weld joint factor =1
= base angle = 90
E = young modulus = 200 000
N/mm2
Thus;

s (tensile) < 85 N/mm2 (justified)

2
s (compressive) < 36.346 N/mm (justified)

35
 CHAPTER 4: OPERATING PROCEDURE

Unit SOP Manual SOP: R-106

OPERATION OF Page
REACTOR (R-106) Rev. No.: 0
Prepared By: MHMY Approved By:
Revised By: Revision Date:

4.1 Scope and Objectives

This procedure provides operating instruction for the R-106 s ystem, inclusive
of operation instructions for system start-up and shutdown.

4.2 Applicable Documents

Material Safety Data Sheet (MSDS)

4.3 Material & Equipment

Special equipment or materials are required to perform these procedures.

4.4 Safety & Health

No safety or health issues which require special attention are associated

with operation of the MA Reactor.

4.5 Standard Operating Condition (SOC)

Loop ID Normal Set Point (R-106)

Temperature 380C
Pressure 101.3 kPa

36
4.6 Procedures
4.6.1 Reactor Pre-Start up Procedures
No. Procedures Checklist
Ensure that ample inventory is available at each unit operation.
1
Note that reactor will be last unit operation to start up.
Verify Vessel Readiness for start-up, i.e., all maintenance and
I&E works completed, the reactor is clean and rinse with process
2
water if necessary, man way closed, all blinds are removed and
proper gasket are installed.
3 Line up molten salt into the shell-side of R-106.
4 Line up all transmitters and stroke all control valves.
5 Close, plug and cap all bleeders.
Place the reactor temperature indicator (TI) and pressure
6
indicator (PI) in service.
Purge reactor with high pressure N2 until the vent of O2 is
7
lower than 6%.
Pressure up the reactor with high-pressure nitrogen to 400kPa
8
and perform leak check on all flanges.
10 Pressure up the reactor to 800kPa and check flanges for leaks.

4.6.2 Initiation of Reactor

No. Procedures Checklist
1 Set reactor operating condition at 1.013 kPa and 380 C.
2 Stop circulation. Allow reactor effluent to pass through.
3 Adjust the feed with air at a ratio of 5%
4 Increase feed to 100%.
The system is stabilized, after air, steam are
5 heated up to the standard operating condition (refer to SOC).

37
 4.6.3 Hot Hold and Shut Down of Reactor
No. Procedures Steps Checklist

1 Notify Wastewater Unit, Utilities Unit and Shipping Unit.

2 Reduce the rate of air entering reactor to 70% of feed

rate.

3 Shut down by gradually reducing the hot stream flow rate.

4 Reduce reactor feed further to 50% of feed rate, then to 30%.

5 Isolate feed to the reactor.

6 To HOT HOLD the reactor, block all isolation valves, control

valves. Manual block valves for molten salt ang air feed. Verify at
field that all isolation and control valves are closed. This is to put
reactor on HOT HOLD.

7 To SHUT DOWN the reactor, block all isolation valves, control

valves. Manual block valves for air feed at inlet reactor.
Verify at field that all shutoff and control valves are closed.

8 Open both man ways of the reactor and inspect the cleanliness
inside the reactor. Access the need of washing.

9 Access the condition of catalyst inside reactor. Check if there is

any occurrence of coking or crash powder of catalyst.

10 Prepare the reactor for washing with process water if required.

11 If reactor is clean, then proceed with blinding and prepare vessel

for maintenance.

12 If reactor is not clean, then close the man ways and perform
washing with process water.

38
 CHAPTER 5: COSTING

The costing for reactor is based on the cost correlation method of reactors (Douglas,
1988).

[101.9)A.p z p.q/ (2.18 + r )]

&
280

79
87, $ 

&
!87 87, $ = [101.9)A.p z p.q/(r )]
280

Where, M&S = Ratio indices = 1615

D = reactor diameter, ft. = 13.54 ft
H = height, ft. = 32.80 ft
Fm = material factor (carbon steel) = 1.15
Fp = pressure factor = 1.50
Fc = correction factor = Fm Fp
(1.725)

Thus,

Installation cost = $ 645 850.15

Purchase cost = $ 165 390.56
Total cost = Installation cost + Purchase cost
= $ 811240.71
= RM 2 628 419.9

USD 1 = RM 3.24

For the design, the total cost is RM 2 628 419.9

39
 CHAPTER 6: K-102 COMPRESSOR DESIGN

AIR COMPRESSOR
6.1 Introduction
Compressor is used to transfer and compress gases from one process unit to another to
carry out chemical reactions, separation and to liquefy gases. In this styrene
production plant, K-102 is located in between a packed bed reactor, R-106 and a heat
exchanger, E-105. The original purpose is to compress product gas coming out of
reactor to an increased pressure before flowing in it into a heat exchanger. The type of
this compressor will be a multistage centrifugal compressor.

6.2 Basic Operation

A positive displacement compressor will usually be used to compress essentially the
same volume of gas in a chamber regardless of the discharge pressure.

6.3 Calculation of Design

The pressure differences between inlet and outlet stream, delta P
 <500 101.3) V = 398.7 V = 3.987 5

Number of stages of the compressor, q

500 V
ln / ln
= A
= 101.3 V = 1.2203 2 7D
ln 3.7 ln 3.7

Polytropic temperature exponent, m

1
=

Vs
6F 6F,RS|2 41.12
VD"
= = = = 1.253
6~ 6F,RS|2  41.12 Vs Vs
8.3144
VD" VD"
Polytropic Efficiency, Ep
= 78.303 %

40
Polytropic temperature exponent, m
1 1.253 1
= = 0.258
(1.253)(0.78303)


Theoretical Outlet Temperature, Tout

/ _ 500 p./nq
= A = 380 = 573.68
A 101.3

Polytropic exponent, n
1 1
= = = 1.3478
1 " 1 0.258

Amount of polytropic work, -W

ShA

/ S
= A 1

1 A
A.GklqhA
1.3478 500 A.Gklq
= (1)(8.314)(653) 1
1.3478 1 101.3

= 10 725.70 Vs V" hA
where
A = 380 = 653
A = 101.3 V
/ = 500 V
6" 779599 8, = 1.000

Actual work required,

98 yV 10725.70 Vs V" hA
= = = 13 697.687 Vs V" hA
0.78303

Shaft Power
= 98 yV   ()

41
 484600 VD 1 V"
 10725.70 Vs V" hA
31.35 VD
= 165 795 030.9 Vs  hA
Vs 1  1 "9

= 165 795 030.9 = 46 054.175 Vs 7 hA = 46 054.175 Vy

 60 "9
60 7

42
 CHAPTER 7: M-101 MIXERDESIGN
7.1 Introduction
Mixer M-101 is a two phase mixer which mixes two inlet streams which are vinyl
cyclohexene, VCH stream and air stream containing oxygen. This mixer will mix
these streams and will have one product stream. This mixing is required prior VCH-
Styrene conversion reaction. The illustration of Mixer, M-101 can be described as
follows:-

Figure 7.1 - Physical Parameter of M-101

The following table shows the conditions of stream entering and leaving the mixer M-
101
Table 7.1- Properties of Streams Entering and Leaving M-101

Stream
In Out
Conditions A 26 27
Phase Vapour Vapour Vapour
Temperature [C] 339.7 339.7 339.6
Pressure [kPa] 101.3 101.3 101.3
Molar Flow [kgmole/h] 1.413 x 104 711.3 1.484 x 104
Mass Flow [kg/h] 4.076 x 105 7.693 x 104 4.846 x 105
Molar Enthalphy
9477 1.308 x 105 1.529 x 104
[kJ/kgmole]
Molar Enthropy
173.3 -30.62 165.1
[kJ/kgmole-C]
8 7
Heat Flow [kJ/h] 1.339 x 10 9.306 x 10 2.270 x 108

43
7.2 Process Design
The minimum size of charge for the mixer is equal to the volume of the outlet strean
abd the time of mixing is assumed to be 5 seconds.
Table Error! No text of specified style in document.-1: Operating Data for M-101

Minimum size of charge = 96 012 m3 h-1

= 26.67 m3 s-1
Time of Mixing = 5s

!"
 79  8D "99
D 9"
 26.67 "G 7 hA 5 7 = 133.355 "G

The mixing is in continuous flow process for 330 days in a year for the production of
styrene. The length and diameter of the vessel which represents the volume of the
1036.55 m3 can be calculated by using trial and error method. The diameter and length
of the mixer is assumed to be following the equation below:-

By assuming the vessel is in cylindrical shape, the volume,

= , / -
Where V = volume, r = radius and L = height or length. Assuming the length of the
vessel, L is at least 5 times of the radius, L = 5r

= , / - = , / (5) = 5, G
= 133.355 "G
 G = 8.49 "G
 = 2.04 "

- = 5 = 5 2.04 " = 10.21 "

Therefore the diameter and length of the vessel are at 4.16 m and 10.21 m
respectively. The mechanical data of the vessel are tabulated in the following table.

44
 Mechanical Data Value
Pressure Operating 101.3 kPa
Design 106.365 kPa
Temperature Operating 339.7 oC
Design 349.7 oC

The operating temperature and pressure are taken from the mixing temperature and
pressure. The design temperature is 10oC higher than operating temperature. The
design pressure is 1.05 of operating pressure.

7.3 Specification Sheet

Equipment No. : M-101
MIXER DATA SHEET PROCESS
Static Mixer
Operating Data
Inlet Inlet Outlet
Stream No. A 26 27
Description Vapour Vapour Vapour
Temperature (oC) 339.7 339.7 339.6
Pressure (kPa) 101.3 101.3 101.3
Flowrate (kg/h) 4.076 x 105 7.693 x 104 4.846 x 105
Dsicharge Size - - 133.355
(m3)
Mixing Time = 5 s -
Mechanical Data
3
Volume (m ) 133.35
Length (m) 10.210
Diameter (m) 4.16
Design Pressure 106.365
(kPa)
Design 349.7
Temperature (oC)

45