Data:

Reaction A R
density

Flow rate
Pressure

F
P

Specific heat
viscosity
Prandtl number
Operation per year

Cp

Pr

1000 kg/m3
0.000769231 kg/s
1 atm
4180
0.001
5
7800
85
8000
8
200
0.85

fp
s
s
s
j

density of steel
electricity cost
steel cost
Joint efficiency

J/kg. K
Pa.S
Hr
atm
kg/m3
Rs/KW hr
/kg

0.836 W/m.K

Design Calculation
Consider Reaction is in PFR Fibrous bed reactor
Volume of reacter

L/D

D
5.839089
2.710265
1.584973
1.257994
0.99847
0.872244
0.792486
0.735679

1
10
50
100
200
300
400
500

156.3800905 m3
L
5.839088938
27.10265001
79.24862939
125.7993577
199.6940327
261.6732088
316.9945176
367.8395533

Ah
107.0582
230.6498
394.4057
496.92
626.08
716.6827
788.8114
849.7213

As (m2) Vavg m/s

26.76454
2.87407E-05
5.766246 0.000133402
1.972028 0.000390071
1.2423 0.000619199
0.7826 0.000982917
0.597236 0.001287986
0.493007 0.001560283
0.424861 0.001810548

Re
167.8193
361.5557
618.2516
778.9482
981.4132
1123.438
1236.503
1331.983

Nu
2.356468
4.354398
6.688367
8.046274
9.679868
10.78517
11.64512
12.3591

h W/m2K
0.337383
1.343144
3.527806
5.347153
8.104769
10.33702
12.28453
14.04445

f
0.016512
0.014162
0.012721
0.012147
0.011598
0.011289
0.011074
0.010911

1000 0.583909 583.9088938 1070.582 0.267645

1200 0.549479 659.375168 1137.663 0.237013
1500 0.510091 765.1371042 1225.51 0.204252

0.002874066 1678.193 14.8683 21.2874 0.010418

0.00324552 1783.346 15.60905 23.74824 0.010292
0.003766093 1921.051 16.56606 27.15047 0.01014

helical reactor designing

dia of 1
loop

L/D
100
200
300
400
500
1000

5
5
5
5
5
5

length of 1
loop
15.7
15.7
15.7
15.7
15.7
15.7

no of
no of
loops
loops
8.012698
12.71937
16.66708
20.19073
23.42927
37.19165

pitch
9
13
17
21
24
38

1.2
0.9
0.8
0.7
0.7
0.5

total
height of
reactor
10.8
11.7
13.6
14.7
16.8
19

original
annual production total
share
annual production
batch running time
approx batches per year
working hrs annually
hourly production

hourly flow
HRT
Vol. of reactor (theorotically)
Voidage
actual vol of reactor
Volume of reactor
L/D (from lab data)
Dia of reactor
Length of reactor

P Pa
2.7278E-08
5.04057E-06
0.000193558
0.000931422
0.004482095
0.011236246
0.02156829
0.035766662

1.45E+11
0.0001
14500000
65
5
7800
1858.974359
1000
1.858974359
48
89.23076923
0.85
104.9773756
105
57.97101449
1.306062479
78.36374874

kg/year
kg/hr
days

kg/hr
kg/m3
M3/hr
hr
m3
m3
m3
60

with corrections
data collected from Amul Industries
monthly production total
yearly production
batch running time
approx batches per year
working hrs annually
hourly production

hourly flow
HRT
Vol. of reactor (theorotically)
Voidage
actual vol of reactor
Volume of reactor
L/D (from lab data)
Dia of reactor
Length of reactor

Power P
Power KW
power kw.hr Cost of power
2.09831E-11
2.09831E-14 1.63668E-10
3.87736E-09
3.87736E-12 3.02434E-08
1.48891E-07
1.48891E-10 1.16135E-06
7.16478E-07
7.16478E-10 5.58853E-06
3.44777E-06
3.44777E-09 2.68926E-05
8.64327E-06
8.64327E-09 6.74175E-05
1.6591E-05
1.6591E-08 0.00012941
2.75128E-05
2.75128E-08
0.0002146

1.30935E-09
2.41947E-07
9.2908E-06
4.47082E-05
0.000215141
0.00053934
0.001035278
0.0017168

1800
21600000
65
5
7800
2769.230769
1000
2.769230769
48
132.9230769
0.85
156.3800905
156.3800905
57.97101449
1.49151631
89.49097859

thickness (mm)
40.41
18.76
10.97
8.71
6.91
6.04
5.48
5.09

0.17211276 0.000132394
0.260189975 0.000200146
0.431472633 0.000331902

1.32394E-07 0.001032677
2.00146E-07 0.00156114
3.31902E-07 0.002588836

0.008261412
0.012489119
0.020710686

4.04
3.80
3.53

5.839088938
T/month
kg/yr
days

kg/hr
kg/m3
M3/hr
hr
m3
m3
m3
60

Volume of steel
4.326105156
4.326105156
4.326105156
4.326105156
4.326105156
4.326105156
4.326105156
4.326105156

mass of steel cost of reacter Rs.

34608.84124
6921768.249
34608.84124
6921768.249
34608.84124
6921768.249
34608.84124
6921768.249
34608.84124
6921768.249
34608.84124
6921768.249
34608.84124
6921768.249
34608.84124
6921768.249

4.326105156 34608.84124
4.326105156 34608.84124
4.326105156 34608.84124

6921768.249
6921768.249
6921768.249