EH2208O

DESIGN PROJECT II (MARCH 2017)

PRODUCTION OF 20,000 METRIC TONNES OF

POLYTETRAFLUOROETHYLENEPER YEAR

CHAPTER 3:
MULTICOMPONENT
DISTILLATION COLUMN (T-102)

STUDENTS NAME:
NURBADAYU BINTI BASIRON
2013493592

SUPERVISOR:
MS CHRISTINA VARGIS

FACULTY OF CHEMICAL ENGINEERING

UNIVERSITI TEKNOLOGI MARA
SHAH ALAM
 CHAPTER 3

EQUIPMENT DESIGN

DESIGNED BY: NURBADAYU BINTI BASIRON

3.6.1 MULTICOMPONENT DISTILLATION COLUMN (T-102)

3.6.1.1 INTRODUCTION

This distillation column is installed to separate between the product which are TFE and HCL,
and the waste which is the water before it goes to the treatment plant. The components are
separate based on their boiling points. The higher the boiling point is less volatile the
component, therefore it being discharge at the bottom outlet as the liquid. Since the water is
less volatile component, it will be removing at the bottom product as the nearly pure product.
The top component is recycling back to the process to avoid any waste of the raw materials.
This column operates at pressure and temperature,43.23 and 450 kPa at top and 550
kPa, 155.5 at bottom part with boiling point of TFE is about -40.9, HCL at -85.05 and
water at 100. A design consists of chemical and mechanical evaluation to calculate for
total stages, height, thickness, support, as well as the insulation. A key in distillation process
is relative volatility, .

431
 585 kg/h

0.9755 TFE
0.0245 HCL

778 kg/h

0.2486 Water
0.7329 TFE
0.0184 HCL

193 kg/h

1.00 Water

Figure 3.1: Flow diagram of T-102

Table 3.1: Inlet and outlet compositions

Components Feed Mole Top Mole Bottom Mole
(kmol/hr) fraction,xf (kmol/hr) fraction,xd (kmol,hr) fraction,xb
TFE 5.71 0.34 5.71 0.94 -
Water 10.74 0.64 - - 10.74 1.00
HCL 0.39 0.02 0.39 0.06 - -
Total 16.84 1.00 6.1 1.00 10.74 1.00

Table 3.2: Properties inlet and outlet stream

Parameter Feed column Top (distillate) column Bottom column
Temperature ( 0K) 323 233 428
Pressure (Kpa) 2000 460 540

432
3.6.1.2 CHEMICAL DESIGN OF T-102

Step 1: Calculation of bubble point, Tbp and dew point Tdp

For multi component mixture, trial and error procedure is required to calculate bubble and
dew point by using the Antoine Equation. By using Antoine Equation to find the vapor
pressure (P) with related at equilibrium, Constant K,

Po
Ki =
P
B
Ln P 0 (mm Hg) = A
T( oK) + C

Table 3.3: Antoine constant

Components A B C
TFE 15.5602 1704.80 -41.30
HCL 16.5040 1714.25 -14.45
Water 18.3036 3816.44 -46.13

Bubble point (Feed column)

: = = 1
Bubble point is calculated by using Microsoft Excel Goal Seek function. The goal is set so
that the summation of yi is equal to one by changing the guess temperature. Different
temperature will yield different Ki value. After calculating, bubble point for feed is 3910K.

Temperature : 391 0K
Components PO (kpa) Ki xi Yi=kixi
TFE 5871.50404 2.93575202 0.34 0.99815569
HCL 20809.0583 10.4045291 0.64 6.65889866
Water 188.710109 0.09435505 0.02 0.0018871

0.99950786

433
Dew point (Top column)
y
: i = i = 1
xi

Dew point is calculated by using Microsoft Excel Goal Seek function. The goal is set so that
the summation of xi is equal to one by changing the guess temperature. Different
temperature will yield different Ki value. After calculating, dew point for top column is 269 0K.

Temperature : 2690K

Components PO (kpa) Ki yi Xi=yi/ki

TFE 424.4487 0.943219 0.94 0.985985

HCL 2318.352 5.151893 0.06 0.013587
Water 0.426361 0.000947 - -

0.999572

Bubble point (bottom column)

: = = 1
Bubble point is calculated by using Microsoft Excel Goal Seek function. The goal is set so
that the summation of yi is equal to one by changing the guess temperature. Different
temperature will yield different Ki value. After calculating, bubble point for bottom column is
4220 K

Temperature : 422 0K
Components PO (kpa) Ki xi Yi=kixi
TFE 8710.34011 15.836982 0.01 0.15836982
HCL 29356.0183 53.3745788 - -
Water 467.298909 0.84963438 0.99 0.84113804
0.99950786

434
Step 2: Determination of the Relative volatility

The relative volatility of two components can be expressed as the ratio of their K value:
i= Ki/Kj
where, Ki= light components
Kj= heavy components

=

In this case, at distillate, the light component is HCL and the heavy one is TFE. Thus,

5.151893
= = 5.462031
0.943219

For bottom part,only volatility of water is taken into calculation because the HCl contain in
bottom part is being considered as trace component. Thus,
= 0.849634

Average relative volatility is calculated by using equation:

=
= 2.154235

Step 3: Minimum number of stages for total reflux

For number of stages, the value of i of the light component is used in Fenskes Equation:

log[( )( )]

=
log(, )
Substituting into equation above,
0.066.10 0.9910.73
log[( )( )]
= 0.946.10 0.0110.73
log( 2.154235)
= 2.4022 theoretical stages = 3 stages.

435
Step 4: Calculation of feed condition, q, at feed stream

The phase of the feed mixture is classified by the feed quality, q value. Equation below is
used to calculate the q value.
, ( )+,
=
,
Where,
q = Feed quality
Cp = Heat capacity at feed, kJ/kmolC
Tbubble = Bubble point temperature at feed, C
T = Temperature at feed, C
Hv = Latent heat of vaporization at feed, kJ/kmol

Table 3.4: Latent heat of vaporization and heat capacity

Component XI,F Latent heat of Heat Capacity
vaporization,hv(kJ/kmol) (kJ/kmol.)
TFE 0.34 20211 57.30
HCL 0.02 16366 75.3747
Water 0.64 40641 75.3027

Cp = (0.32 x 57.30) + (0.02 x 75.3757) + ( 0.64 x 75.3027)

CP = 68.037 kJ/kmol.0K
HV= (0.32 x 20211 ) + (0.02 x 16366) + (0.64 x 40641)
HV = 32805.08 kJ/kmol

68.037 (391.56 323.29) + 32805.08

q=
32805.08
q = 1.1415
Since q is large than 1, feed condition is in sub-cooled liquid.

436
Step 5: Estimation of Minimum reflux ratio

The minimum reflux ration is that reflux ratio which will require an infinite number of trays for
given separation of the key components. For multi component distillation, two pinch point or
zones of constant composition occur: one in the section above the feed plate and another
below the feed tray.
Underwoods method is being used to determine the minimum reflux ratio:

1 =


+ 1 =

Where, = the relative volatility of component i with respect to some reference component,
usually the heavy key
Rm = the minimum reflux ratio
XiF = concentration of component i in the tops at minimum reflux

Table 3.5: Relative volatility is calculate using water as reference

Component xIf Relative
volatility
TFE 0.34 31.11388
HCL 0.02 110.27
Water 0.64 1

1 =

(31.11388 0.34) (110.27 0.02) (1 0.64)

1 1.1415 = + +
31.11388 110.27 1

By using goal seek analysis in Microsoft Excel, the value of is determined to be 2.2116.

Table 3.6: Relative volatility is calculate using TFE as reference

Component xiD Relative
volatility
TFE 0.94 1
HCL 0.06 5.462
Water - 0.001

437

+ 1 =

( 1 0.94) (5.462 0.06)
Rm + 1 = +
(1 2.2116) (5.462 2.2116)
Rm + 1 = -0.675
Rm= 0.325

The optimum reflux ratio is 1.5 of Rm. Thus,

R= 0.325 x 1.5 = 0.4875
Next, Erbar-Maddox correlation is used to determine the number of stages

0.325
= = 0.245
+ 1 0.325 + 1
0.4875
= = 0.328
+ 1 0.4875 + 1

From the chart, Nm/N is 0.47. From step 3, Nm is 3,

N = 3/ 0.35 = 8.57 = 9 stages

438
 Figure 3.2: Erbar-Maddox correlation

Step 6: Determination of column efficiency using Oconells correlation

A quick estimation of the overall column efficiency can be obtained from the correlation by
OConnel (1946).

0= 51 32.5 log()
Where,
= Molar average viscosity, mNs/m 2
avg = Average volatility of light key

439
From ASPEN HYSYS, molar average viscosity of the mixture is 0.9233 kg/ms. Taking
average volatility from previous step, the overall column efficiency is then calculated,

0 = 51 32.5 log(0.9233 2.154235)

0 = 41% efficiency.

Step 7: Determination of the actual number of stages

Actual stages, Nact are stages required for the column after factoring the efficiency of the
stages. The stages can be calculated by using equation below:

=
0
9
=
0.41
= 21.95
= 21.95 22

Step 8: Estimation of feed-plate location

Kirkbride has devised an approximate method to estimate the number of theoretical stages
above and below the feed which can be used to estimate the feed-stage location. This
empirical relation is as follows:
, , 2
= 0.206 log[( ) ( ) ]
, ,

Where,
Ne = Number of stages above the feed, including condenser
Ns = Number of stages below the feed, including reboiler
B = Molar flow of bottom outlet, kmol/h
D = Molar flow of distillate outlet, kmol/h
xf,HK = Mole fraction of the heavy key in the feed
x,f,LK = Mole fraction of the light key in the feed
xd,HK = Mole fraction of the heavy key in the distillate
xb,LK = Mole fraction of the light key in the bottom

440
 0.64 10.73 0.01 2
= 0.206 log[( ) ( ) ]
0.02 5.71 0.93

= 0.359

Also, Ne + Ns = 0.359NS + NS =N, N = 22 Stages.

Solving,
Ns = 16and Ne = 6. This means there are 16 stages below the feed including reboiler

Step 8: Pressure Drop

Pressure at top column: 460 kPa

Pressure at bottom column: 540 kPa
Thus the pressure drop is,
= 540 460 = 80

Step 9: Determination of relative molecular mass

Relative molecular mass (RMM) is the average molecular mass of the composition of
component in distillate and bottom product in the distillation column.

= xi
Where,
xi = Component composition
MW = Molecular weight
xf = composition of component at feed
xd = composition of component at distillate
xb = composition of component at bottom

Table 3.7: Relative molecular weight of feed, distillate and bottom

Component MW(kg/kmol) xf RMM Xd RMM Xb RMM
TFE 86.468 0.37 29.399 0.94 80.415 - -
HCL 36.461 0.61 23.335 0.06 2.5527 0.01 0.36461
Water 18.015 0.02 0.3603 - - 0.99 17.835

441
xIRMM 53.093 82.9677 18.19961

RMM at feed = 53.093 kg/kmol

RMM at distillate = 82.9677 kg/kmol
RMM at bottom = 18.19961 kg/kmol

Step 10: Calculation the density of mixture

The density of the mixture can be calculated by using the following equations:

, =

Liquid : ,=

Table 3.8: Density of pure component

Component Density (kg/m3)
TFE 1409.172
HCL 1192.98
Water 1000

Liquid density:
Distillate,D = (0.93 X 1409.172) + (0.07 X 1192.98)
=1394 kg/m3
Bottom,B = (0.01 X 1192.98) + (0.99 X 1000)
= 1002 kg/m3

Vapor density:
82.9677 273 450
Distillate,D =
22.4 230 101.325

= 19.52 kg/m3

18.19961 273 550

Bottom,B =
22.4 428.5 101.325

= 2.81 kg/m3
Table 3.9: Density of component at distillate and bottom

442
Variable Distillate Bottom
Liquid density ( kg/m3) 1394 1002
Vapor density ( kg/m3) 19.52 2.81

Step 11: Determination of vapor and liquid flow rate at distillate and bottom

The value of vapor and liquid flow rate at distillate and bottom is taken from ASPEN HYSYS
and tabulated in Table 3.10.

Table 3.10: Liquid and vapor flow rate at bottom and distillate
Location Liquid flow rate (kmol/h) Vapor flow rate (kmol/h)
Distillate 165.2 749.8
Bottom 257.8 64.34

Step 12: Maximum vapor volumetric flow rate

Maximum volumetric flow rate,Q =

Where,
Vm = vapor molar flowrate (kmol/h)
RM= relative molecular mass
= vapor density

(749.8 82.9677)
QTop = = = 0.8853 /
19.52(3600)
64.34 18.19961
QBottom = = = 0.11573 /
2.81 (3600)

Step 13: Calculation of flooding velocity

The diameter of column can be determined by using equation below:

Q=AUf

Rearranging,A=

Where flooding velocity, Uf is

443

=

To find the value of ki, the liquid-vapor flow factor has to be determined first. The liquid-
vapor flow factor, FLV can be determined by below equation:
0.5
= ( )( )

Where,
LW = Liquid flow rate, kmol/h
VW = Vapor flow rate, kmol/h
pv = Vapor density, kg/m 3
pL = Liquid density, kg/m 3

At the top column,

1.722 19.52 0.5
,= ( )( ) = 0.026
7.818 1394

At the bottom column,

14.31 2.81 0.5
,= ( )( ) = 0.212
3.571 1002

444
 Figure 3.3: Flooding velocity,sieve plate

Assume 0.5 m of tray spacing, from Figure 3.5, value of Ki can be determined.
Ki top = 0.1
Ki bottom = 0.7

Calculating the flooding velocity,

, =

1394 19.52
, = 0.1 = 0.84 /
19.52

, =

445
 1002 2.811
, = 0.07 =1.32 /
2.811

For design, the optimum value is 80-85% of flooding, 91% of downspout area, 95% for
foaming at maximum flow rate ( Sinnott,2005). Thus,

Top = 0.84 x 0.85 x 0.91 x 0.95 = 0.617 m/s

Bottom = 1.32 x 0.85x 0.91 x 0.95 = 0.97 m/s

Step 14: Calculation of Net area required

Net required, An = ( , 2005)

Atop= 0.885/0.617= 1.434 m2

Abottom = 0.1157/0.95 = 0.122 m2

Step 15: Calculation of column diameter

4
=

41.434
= = 1.35

40.122
= = 0.4

Step 16: Calculation of column height

Column height, Hc is the product of number of trays and tray spacing.

=
= 22 0.5 = 11

446
According to Geankoplis, 2003, the rule of thumb in designing the column height is to add
1.2 m at top of column to minimize entrainment and extra spacing for man hole and add
1.8m at the bottom of reboiler. Thus,

= 11 + 1.2 + 1.8 = 14

Step 17: Liquid flow pattern

Maximum volumetric vapor flow rate, Ql,max can be calculated using equation below:

Maximum liquid flow rate,Ql,max =

Where,
Lm = liquid molar flowrate (kmol/h)
RM= relative molecular mass
= liquid density

(165.2 82.9677)
QL,top = = = 0.002733 /
1394(3600)
(257.8 18.19961)
QL,bottom = = = 0.00133 /
1002 (3600)

Liquid flow pattern to be used for this column is single-pass plate.

Step 18: Provisional Plate Design

In designing plate, column area, down comer area, active area, holes area, holes size and
weir weight are needed to be determine first. The column area, Ac is calculated by using the
largest diameter, Dc equal to 1.35 m.
1.352
= = 1.432
4

The down comer area, Ad is assumed to be 12% of the total column area.
= 0.12 x 1.43 =0.17 m2
The net area, An is then calculated,
= = 1.43-0.17 =1.26 m2

447
Follows by calculation of active area,
= 2 = 1.43- 2x0.17 = 1.09 m2
The holes area, Ah, is calculated by taking 7% of total active area, Aa,
h = 0.07 1.09= 0.0763 m2
A chart on the relation between down comer area and weir length from Sinnott, 2005, is
used.
0.17
100% = 100% = 11.88%
1.43

Figure 3.4: Relation between downcomer area and weir length

From Figure 3.6,

= 0.76

= 0.76x 1.43 =1.0868 m

Table 3.11: Summary of provisional plate design

Column diameter, Dc 1.35 m
Column area,Ac 1.43 m2

448
Downcomer area, Ad 0.17 m2
Net area, An 1.26 m2
Active area,Aa 1.09 m2
Hole area,Ah 0.0763 m2
Weir length,lw 1.0868 m

Step 19: Check for weeping

From the book of Chemical Engineering Design Volume 6, the suggested dimension for weir
and plate are;
Weir height, hw = 45 mm
Hole diameter = 5 mm
Plate thickness = 3 mm

LW =
3600
257.818.19961
= 1.303 kg/s
3600
Minimum liquid rate at 70 % turn-down ratio = 0.7 x 1.303 = 0.9121 kg/s

Step 20: Weir liquid crest

Francis weir formula is used to estimate the height of the liquid crest over the weir. For a
segmental down comer, the formula can be written as,

2/3
= 750( )

Where,
how = Weir crest, mm liquid
Lw = Liquid flowrate, kg/s
lw = Weir length, m

449
 1.303 2
= 750 ( ) 3 = 8.453
10021.0868

At minimum rate, clear liquid depth:

h + h = 8.453 + 45 =53.45
From Figure 3.7, the weep point correlation, K2 is found, K2 = 30.1

Figure 3.5: Weep point correlation

Step 21: Weep Point

The vapor velocity at weep point is the minimum value for a stable operation. Minimum
vapor velocity through the holes based on the holes area, Uh is calculated by:

450
 [2 0.90(25.4 )]
=
0.5
Where,
Uh = Minimum vapor velocity through the hole
dh = Hole diameter, mm
K2 = Constant depending on the depth of clear liquid on the plate

30.1 0.90(25.4 5)]

= = 7.00 /
2.810.5

The minimum vapor velocity through the hole will be compared against the operating vapor
velocity. Vapor velocity is the ratio of minimum vapor volumetric rate over the holes area.

,
, , =

The vapor volumetric rate was calculated in step 15, Q = 0.1157 m3/s

, = 0.1157 = 1.516 /
0.0763

The vapor velocity is above the minimum vapor velocity which will cause weeping. Thus, no
weeping will occur.

Step 22: Plate pressure drop

To calculate pressure drop, orifice coefficient has to be known first. Orifice coefficient, Co
can be determine through the relationship between percent perforated area with orifice in
Figure 3.8

0.003
= = 0.6
0.005
0.0763
= ( ) 100 = 100 = 7
1.09

From the figure 3.8, Co = 0.71

, 0.884
, , = = = 11.58/
0.0763

451
 Figure 3.6: Orrifice coefficient and per cent perforated area correlation

According to Sinnott, 2005, pressure drop through the holes can be predicted from a
modification of equation for flow through an orifice.

= 51 ( ) 2 ( )
0
Where,
Uh = Vapor velocity throughout holes, m/s
pv = Vapor density
pl = Liquid density

452
Co = Orifice coefficient
The orifice coefficient is a function of the plate thickness, hole diameter and the hole of
perforated area ratio.
11.58 19.52
2(
= 51 ( ) ) = 190
0.71 1394

Calculate residual head

Residual head can be calculated using Hunt et al (1955) equation:

12.5103 12.5103
= = = 8.97
1394

Total pressure drop

, = +( + ) +
= 190 + (53.45) + 8.97 = 252.42

Step 23: Down comer liquid back up

, = 10 = 45 10 = 35
, = = 0.035 1.0868 = 0.038 2

Since Aap is less than Ad, Aap is used to calculated head loss in down comer, hdc

= 166 ( )

1.303
= 166 ( ) = 5.68
10020.038

, = ( + ) + +
= (53.45) + 69.45 + 5.68 = 128.58 = 0.12858
According to Thomas and Shah, 1964, for safe design,the liquid backup in downcomer, h b,
should not exceed half the plate spacing plus weir length to avoiding flooding.
1
< ( + )
2
1
0.128 < (0.5 + 0.045)
2

453
 0.128 < 0.2725

In this case , plate spacing is acceptable. Furthermore, according to Kister, 1992, he

recommends that the height in down comer should not greater than 80% of the tray spacing.

100% < 80%
0.5
0.128
100% = 25.6%
0.5
Thus, the plate spacing is acceptable for both recommendations.

, = > 3

0.170.1251002
= = 19.59
1.0868
is greater than 3s as recommended by Sinnott, 2005.

Step 24: Entrainment check

Entrainment can be estimated from the correlation given by Fair (1961). Figure 3.9 gives the
fractional entrainment (kg/kg gross liquid flow) as a function of liquid-vapor factor, FLV with
the percentage approach to flooding as a parameter. The percentage flooding is calculated
as,

= 100%

0.1157
= = = 0.0918 /
1.26
0.0918
= 100% = 79.3%
0.1157

From Figure 3.9 by using the value of FLV = 0.212 and flooding percentage = 79.3%, the
value of is 0.012. The value is below than 0.1, thus the column diameter proposed earlier
is acceptable (Sinnott, 2005).

454
Figure 3.7: Fractional entrainment and liquid-vapor flow factor correlation

455
Step 25: Perforated area

Figure 3.8: relaxation between angle subtended by chord, chord height and chord length

1.0868
= = 0.81
1.35

456
From the Figure 3.10,

= 0.21

= 1080

Mean length of unperforated edge strips, La

Assume 0.05 m width of unperforated strips around plate edge, ws

= ( )
180

108
= (1.35 0.05 )
180

= 2.38

Area of unperforated edge strip, As

=
= 2.38 0.05 = 0.1192

Approximation of mean length of calming zone

, = +
= 1.0868 + 0.05 = 1.136

, = 2
= 2 1.136 0.05 = 0.1136 2

Total area available for perforation, Ap

= ( + )
= 1.09 (0.119 + 0.1136 = 0.8574 2
The ratio of Ah / Ap is,
0.0763
= = 0.088
0.8574

457
From Figure 3.11, the value of lP /dh is 3.1 It is satisfactory as it is within 2.5 to 4 ( Sinnott,
2005)

Figure 3.9: Ah / Ap and lp /dh correlation

2 0.0052
, 1 = = = 1.963 105 2
4 4
0.0763
= = = 3886.9 3887
1 1.963 105

458
3.6.2 SUMMARY OF CHEMICAL DESIGN FOR T-102

Table 3.12: Chemical design sheet for distillation column (T-102)

Specification Value Unit
Design Data
Total feed inlet 778 Kg/h
Distillate 585 Kg/h
Bottom 193 Kg/h
Key components
Heavy component Water
Light component TFE,HCL
Bubble point (feed) 391.56 K
Dew point ( top) 269 K
Bubble point ( bottom) 422 K
Number of tray 22 Stages
Feed point location 6nd Stages
Column efficiency 41 %
Minimum reflux ratio 0.325
Column height 14 m
Column diameter 1.35 m
Column area 1.43 m2
Liquid flow pattern Single pass
Plate Design
Downcomer area 0.17 m2
Net area 1.26 m2
Active area 1.09 m2
Hole area 0.0763 m2
Area of one hole 1.963x10-5 m2
Number of hole per plate 3887 holes
Plate spacing 0.5 m
Plate thickness 3 mm
Weir length
Weir height 45 mm

459
 Hole diameter 5 mm
Weir length 1.0868 m
Weir liquid crest
Minimum vapor velocity 1.516 m/s
Weep point 7 m/s
Plate pressure drop
Dry pressure drop 190 mm
Residual head 8.97 mm
Downcomer design
Downcomer pressure loss 35 mm
Head loss in downcomer 5.68 mm
Backup in downcomer 0.128 m
Residence time 19.59 s
Perforated area 0.8574 m2
Mean length, unperforated 2.38 m
edge strips
Area of unperforated edge 0.119 m2
strips
Mean length, calming zone 1.136 m

460
3.6.3 MECHANICAL DESIGN OF DISTILLATION COLUMN (T-102)

Step 1: Design temperature

The strength of metals decreases with increasing of temperature. Thus, it is vital to identify
the design temperature before design stress be evaluated. The operating temperature for T-
102 is shown in table below

Table 3.13: Operating temperature of T-102

Column Temperature ( )
Distillate -43
Bottom 155

Therefore, 155C is decided to be the design temperature as it is the highest. 10%

allowance in the wall temperature
Design temperature, = 155 x 1.1 = 171

Step 2: Design pressure

Design for pressure is taken at 50% above the operating pressure. It includes 10% pressure
at which the relief device is set and 40% excess to avoid crack of the column during
pressure make up above 25% of normal working pressure.

Table 3.14: Operating temperature of T-102

Column Pressure ( kpa)
Distillate 450
Bottom 550

Therefore, 550 kPa is taken as the operating pressure as it is the highest. Designing at 10%
above the operating pressure,
Design pressure, PD = 550 kPa x 1.1 = 605 kPa = 0.605 N/mm 2

461
Step 3: Material of construction

Selection of suitable materials must take into account in order to make the compatibility with
the
process environment of the design T-102 and also the suitability of materials for
fabrication.T-102 has 3 components, TFE, Water and HCL and the nature of these
components have to be taken into account when selecting the material of construction. For
chemical plant, the materials are chosen based on the ability of the material to resist
corrosion and also based on the economical factor. It is preferable to choose the material
that has lowest cost over the working life of plant, allowing for maintenance and
replacement. By reviewing and considering the factors, the most suitable and economical
material of construction for these components is
HASTELLOY B-2 alloy is a nickel-base wrought alloy with excellent resistance to
hydrochloric acid at all concentrations and temperatures. It also withstands hydrogen
chloride, sulfuric, acetic and phosphoric acids. The alloy has excellent resistance to pitting,
to stress corrosion cracking and to knife line and heat-affected zone attack. It resists the
formation of grain-boundary carbide precipitates in the weld heat affected zone, thus making
it suitable for most chemical process applications in the as welded condition.

Step 4: Design stress, S

It is necessary to determine the maximum allowable stress that can be accepted or

withstand by the material without failure under operating condition. To calculate the
maximum allowable stress, the material design stress factor is being used. By referring to
Figure 1.1,

Material of construction : HASTELLOY,B-2 alloy

Design temperature : 170.5
Tensile strength : 849.4 N/mm 2
Design stress,S : 350.25 N/mm 2

462
 Figure 3.10: HASTELLOY B-2 alloy (Source:
http://specialmetals.ir/images/technical_info/nickel%20base/hastelloy%20B2.pdf)

Step 5: Welded Joint Efficiency

Joint efficiency selected is 1.0 because it can allow the use of all material. If the joint factor
is lower, the vessel will be thicker and heavier. The use of lower joint factors in design,
though saving costs on radiography, will result in a thicker, heavier, vessel, and the designer
must balance any cost savings on inspection and fabrication against the increased cost of
materials. Wield joint factor, J = 1.0

Table 3.15: Maximum allowable joint efficiency.

( Ref : Coulson Richardson, Chemical Engineering Design,4 th edition)
Type of joint Degree of radiography
100 percent spot none
Double-welded butt or equivalent 1.0 0.85 0.7
Single-weld butt joint with bonding strip 0.9 0.80 0.65

463
Step 6: Corrosion Allowance

The corrosion allowance is the additional thickness of metal added to allow for material lost
by corrosion and erosion, or scaling. For light corrosion is expected, a corrosion allowance
of 3.0 mm should be used.

Step 7: Determination of vessel thickness

Minimum thickness of vessel is required to resist the internal pressure. A much thicker wall
will be needed at the column base to withstand the wind and dead weigh load. Hence, the
minimum thickness of column is calculated based on the equation below.

Minimum vessel thickness, t = +
21.2

Where,
Pi = Design pressure, N/mm 2
Di = Column diameter, mm
S = Design stress, N/mm 2
E = Joint factor (1 for double-welded joint)
c = Corrosion allowance (3 mm )

(0.605)(1350)
Minimum vessel thickness, t = + 3 = 4.17
2(350.25)(1)1.2(0.605)

Step 8: Determination of head and closures

1. Hemispherical head design

= +
4 0.4

(0.605)(1350)
= + 3 = 3.58
4(350.25)(1) 0.4(0.605)
2. Torispherical head design
0.885
= +
0.1

464
Where,
RC= Crown radius = D i

0.885(0.605)(1350)
= + 3 = 5.06
(350.25)(1) 0.1(0.605)

3. Ellipsoidal head design

= +
2 0.2
(0.605)(1350)
= + 3 = 4.17
2(350.25)(1) 0.2(0.605)

Table 3.16: Minimum thickness for hemispherical, torispherical and ellipsoidal head
Type of head Hemispherical Torispherical Ellipsoidal
Minimum thickness,t 3.58 5.06 4.17
(mm)

From table 3.17, the minimum thickness for hemispherical, torispherical, and ellipsoidal
head is 3.58 mm, 5.06 mm and 4.17 mm respectively. In this case, ellipsoidal head is
chosen as the thickness is the closest to the vessels wall thickness. Ellipsoidal head also
usually proves to be the most economical closure to use whereas the cost of forming
hemispherical head will be higher than that for a shallow ellipsoidal head even though
hemispherical head is best known for the strongest shape.

Step 9: Determination of weight loads

a) Dead weight of vessel, W v

The major sources of the dead weight loads are,
1. The vessel shell
2. The vessel fittings; manhole, nozzles
3. Internal fitting; plates
4. External fitting
5. Auxiliary equipment which is not self-supported
6. Insulation
7. The weight of liquid to fill the vessel

465
Dead weight of vessel can be calculated by using Equation below:

= 240m( + 0.8)

Where,
Wv = Total weight of the shell, excluding internal fittings
Cw = Factor to account for the weight of nozzles, manways, internal supports (1.5 for
distillation
column)
Dm = Mean diameter of vessel (Dm = Di + t x 10-3), m
Hv = Height, m
t = Wall thickness, mm

Recall minimum wall thickness is 4.17 mm, divide the column into five sections, with
thickness increasing by 2 mm per section. Try 4.17 mm, 6.17 mm, 8.17 mm, 10.17 mm and
12.17 mm. Thus, rough estimation of the weight of this vessel by using the average
thickness is 8.17 mm.

Dm = 1.35 + (8.17 x 10-3) = 1.36 m

Hv = 14 m
Wv = 240(1.5)(1.36)[14+(0.8 x 1.36)] 8.17
Wv = 60.35 kN

b) Weight of plate, W p

Weight of steel contacting plate including typical liquid loading may be estimated by factor of
1.2 kN/m2 area given by Nelson (1963).
2
=
4

= 1.352 = 1.432
4
= 1.2 = 1.2 1.43 = 1.716
, = 1.716 . = 1.71622 = 37.752

466
c) Weight of insulation, W i

The distillation column should be well insulated to prevent loss of heat and to protect against
burns. On columns located outdoors, because of size and safety, the insulation bracket will
shield the column from increased heat loss due to wind currents. According to Kvaalen et
al.,(1990), two to three inches of fiberglass insulation is good. Fiberglass insulation can
withstand temperature range from -30C to 540C. The temperature fit in the design
temperature, 170.5C. In this design, the fiberglass insulation is assumed to be 2 inch which
is approximately 50mm.

Fiberglass density, = 100 kg/m3

Thickness of insulation, ti = 50 mm
, =
Vi = 1.36 14 50 103 = 3 3
, =
W i = 3 x 100 x 9.81 = 2943 N
This weight is double to allow for fitting, thus,
W i = 2943 x 2 =5886 N = 5.886 kN

Total weight:
Wt = W v + W p + W i = 60.35 +37.752 + 5.886
Wt = 103.988 kN.

Step 10: Wind load

Wind loading is significant due to the columns height and its open space installation. Its
value depends on the dynamic wind pressure and column area. A column must be designed
to withstand the highest wind speed that is likely to be considered at the site during the life
of the plant. A wind speed of 160 km/h can be used for the preliminary design studies,
equivalent to a wind pressure of 1280 N/m (Sinnott, 2005).

, , = + 2(1 + )
Where,
t1 = Wall thickness, m

467
ti = Insulation thickness, m
Dc = Internal diameter, m
= 1.35 + 2(0.00817 + 0.05) = 1.47 m
The loading unit per length of the column, Fw = Pw x Deff
Fw = 1280 x 1.47 = 1881.6 N/m
The bending moment,M at the bottom base:
2 142
= ( ) = 1881.6 ( ) = 184397
2 2

Step 11: Analysis of stresses

The resultant stresses from all loads should be determined to ensure that the maximum
allowable stress intensity is not exceeding at any point (Sinnott, 2005).

Pressure stress:

, =
4
Where,
P = Operating pressure, N/mm 2
D = Column diameter
T = Column thickness, m
0.55 1350
= = 22.72 /2
4 8.17

, =
2

0.55 1350
= = 45.44 /2
2 8.17
Dead weight stress:

=
( + )
Where,
Wt = Total weight of the column, N
Dc = Column diameter, mm
t = Column thickness, mm

468
 103.988 103
= = 2.98 /2
(1350 + 8.17)8.17
Bending stress:
0 = + 2
0 = 1350 + 2( 8.17) = 1366.3

= ( 4 4 )
64 0

= (1366.34 13504 ) = 8.018109 4
64
0
= ( + )
2
184397 103 1366.3
= ( + 8.17) = 15.89 /2
8.018 109 2

Principle stress:
The resulted longitudinal stress is,
= +
Since is compressive stress, therefore it becomes negative sign, therefore,
, = 22.72 2.25 + 15.89 = 36.36 /2
, = 22.72 2.25 15.89 = 4.58 /2
The greatest difference between the principle stresses will be on the downwind side,

= ,
= 45.44 4.58 = 40.86 /2
The value obtained, 40.86 N/mm 2 is well below the maximum allowable design stress which
is
350.25 N/mm2.

Step 12: Check elastic stability

A column design must be checked to ensure that the maximum value of the resultant axial
stress does not exceed the critical value at which buckling will occur.

, = 2 104 ( )
0

469
 8.17
= 2 104 ( ) = 121 /2
1350
The maximum compressive stress will occur when the vessel is not under pressure,
+ = 2.25 + 15.14 = 18.14 /2
The design is satisfactory as the value is below the critical buckling stress.

Step 13: Design for vessel support

The method used to support a vessel depends on size, shape and weight of the vessel, the
design temperature and pressure, the vessel location and arrangement, and the internal and
external fittings and attachments. The supports must be designed to carry the weight of the
vessel and contents, and any superimposed loads, such as wind loads. There are three
types of support which are;
1. Skirt supports; used for tall and vertical columns
2. Brackets, or lugs; used for all types of vessel
3. Saddle support; used for horizontal vessel.

Step 14: Skirt support design

Skirt support is recommended for vertical vessels as it does not impose concentrated loads
on the vessel shell. In other word, it is particularly suitable for use will tall columns subject to
wind loading. Thus, skirt support design will be used to support the bottom of reactor column
and it is illustrated in Figure 3.12.

470
 Figure 3.11: Skirt support design

Type of support : Straight cylindrical skirt

Material of construction : Carbon steel
Design stress, S : 89 N/mm 2
Young modulus : 20000 N/mm 2
Angle, s : 90

Approximate weight, = ( 2 )
4

= ( 1.352 14) 1002 9.81 = 196.98
4
From previous calculation, weight of vessel = 103.98 kN
New net total weight,W total,
Wtotal = 103.98 + 196.98 = 300 kN

Bending moment at base skirt, Ms

By taking skirt support equal to 3, the equation become,
( + )2
=
2
(14 + 3)2
= 1881.6 = 271.89
2

471
The resultant stresses in the skirt will be,
() =
() = +
Where,
bs = Bending stress at the skirt
ws = Dead weight stress at the skirt
Bending stress at the skirt is given by,
4
=
( + )
Where,
Ds = Inside diameter of the skirt, at the base
ts = skirt thickness
4 (271.89)(1000)(1000)
= = 23.95 /2
(1350 + 8.17)(8.17)(1350)

Dead weight stress, ,

For testing, the weight is equal to 300 kN

, =
( + )
300 1000
, = = 8.60 /2
(1350 + 8.17)(8.17)

For testing, the weight is equal to 103.98 kN

103.98 1000
, = = 2.98 /2
(1350 + 8.17)(8.17)

Thus, the resulting stress in the skirt is,

() = ,
() = 23.95 2.98 = 20.97 N/mm 2

() = + ,
() = 23.95 + 8.6 = 32.55 N/mm2.

The criteria for designing are,

(, ) <

472

(, ) < 0.125

Where,
= Young modulus
Ss = Design stress of skirt

For s (maximum, tensile), by taking joint factor, E equal to 0.85,

20.97 < 89 0.85 sin (90)
20.97 < 75.65

For (, ),
8.17
32.55 < 0.125 x 200000 x x sin (90)
1350

32.55 < 151.3

Since both of the criteria are satisfied, the design is acceptable.

Step 15: Base ring and anchor bolts

The loads carried by the skirt are transmitted to the foundation slab by the skirt base ring
(bearing plate). A variety of base ring designs are used with skirt supports. The preliminary
design of base ring is based on Scheimans short cut method. Scheiman gives the following
guide rules which can be used for the selection of the anchor bolts:

Table 3.17: Design base ring

Approximate pitch circle Dappro(b) = Di + 2(t +tinsulation)
Dappro(b) = 1350 + 2(8.17 + 50)
= 1466.34 mm
Circumference of bolt circle = 1466.34
= 4606 mm
Recommended spacing between bolts 600mm
Minimum number of bolts required, Nb 4606/600 = 7.67
Closest = 8
Bending moment at skirt base, Ms 271890
Total weight of vessel 103980 N

473
Bolts design stress, Sb 125 N/mm2

The bolt area is given by Sinnott,2005,

1 4
= ( )

Where,
Ab = Area of one bolt at the root of the thread, mm 2
Nb = Number of bolts
Sb = Maximum allowable bolt stress, N/mm 2; typically 125 N/mm 2
Ms = Bending moment at the base
W = Weight of the vessel
Db = Bolt circle diameter
1 4 271890
= ( 103980) = 639 2
8 125 1.4634
From Table 3.18, it can be estimated that the conventional bolt size is M36 bolts.

Table 3.18: Anchor bolt chair design

474
 Figure 3.12: Anchor bolt illustration

Table 3.19: Bolt dimension for T-102

Item A B C D E F G
Dimension(mm) 57 102 76 16 32 42 42

Bolt diameter, Db

4 6394
= = = 28.5

475
 Figure 3.13: Base ring illustration

The base ring must be sufficiently wide to distribute the load to the foundation. According to
Sinnott,2005, total compressive load on the base ring per unit length can be estimated by,
4
= 2 +
2
Where,
Fb = the compressive load on the base ring, N/m
Ds = skirt diameter,m
4271890 103980
= + = 228.46 /
1.352 21.350

Minimum width of base ring, Lb

1
=
103
Where,
Lb = base ring width,mm

476
Fc = maximum allowable bearing pressure on the concrete foundation pad, which will
depend on the mix, used and will typically range from 305 to 7N/mm 2 (200 to 1000 psi).
Taking the average, 156 will be used.
228.46 1
= 3 = 0.00146
156 10

Actual width required,

Lb = Lr + ts + 50
Lb = 102 + 8.17 + 50 =160.17 mm

Actual bearing pressure on concrete foundation,

228.46
, = = = 1.43 /2
160.17

Actual minimum base thickness,

3,
=

Where,
Lr = The distance from the edge of the skirt to the outer edge of the ring,mm
To = Base ring thickness,mm
fc = Actual bearing pressure on base, N/mm 2
fr = Allowable design stress in the ring material, typically 140 N/mm 2

31.43
= 102 = 17.86
140

Step 16: Design of piping

There are three nozzles in the distillation column, which are feed inlet, distillate outlet and
bottom outlet. By assuming that the flow of the pipe is turbulent flow, the optimum duct
diameter is,
0.37
= 293 0.53
Where,
G = Mass flowrate, kg/s

477
 = Density of components, kg/m 3

The nozzle thickness, tp, can be calculate from equation:

=
20 +
Where,
Ps = Operating pressure, N/mm 2
= Design stress, N/mm 2

Table 3.20: Flowrate and density at 3 locations

Feed Distillate Bottom
Mass flowrate 0.216 0.1625 0.0536
3
Density (kg/m ) 1143 1394 1002

Feed stream

G = 0.216 kg/s
= 1143 kg/m3
= 350.25 N/mm2
Ps = 2 N/mm2

, = 293(0.216)0.53 11430.37 = 9.6

29.6
= = 0.00274
20(350.25) + 2
, = + = 0.00274 + 3 = 3.00274

Distillate stream

G = 0.1625 kg/s
= 1394 kg/m3
= 350.25 N/mm2
Ps = 0.46 N/mm2

478
 , = 293(0.1625)0.53 13940.37 = 7.68

0.467.68
= = 0.00044
20(350.25) + 0.46
, = + = 0.00044 + 3 = 3.00044

Bottom stream

G = 0.0536 kg/s
= 1002 kg/m3
= 350.25 N/mm2
Ps = 0.54 N/mm2

, = 293(0.0536)0.53 10020.37 = 4.82

0.544.82
= = 0.00037
20(350.25) + 0.54
, = + = 0.00037 + 3 = 3.00037

From the calculation, the optimum diameter is around 9-10 mm. From Table 3.21, the most
suitable flange to be used is the nominal size 10.

479
 Figure 3.14: Standard flange design

Table 3.21: Typical standard flange size and dimension

480
3.6.4 SUMMARY OF MECHANICAL DESIGN FOR T-102

Table 3.22: Mechanical design sheet for distillation column (T-102)

SPECIFICATION VALUE UNIT
Design Operation
Type of construction material HASTELLOY, B-2 alloy
Type of insulation fiberglass
Design pressure 0.605 N/mm2
Design temperature 171
Design stress 350.25 N/mm2
Design of head and closure
Type Ellipsoidal
Joint factor 1
Minimum thickness 4.17 mm
Corrosion allowance 3 mm
Column weight
Column weight of vessel 60.35 kN
Weight of plate 37.752 kN
Weight of insulation 5.886 kN
Total weight 103.988 kN
Bending moment 184397 Nm
Design of support
type skirt
Skirt thickness 8.6 mm
Skirt height 3 m
Design of base ring and anchor bolts
Pitch circle diameter 1466.34 mm
Area of bolts 639 mm2
Bolts size M36
Minimum base ring thickness 17.86 mm

481
REFERENCES

1. Perry, R., Green, D., & Maloney, J. (1984). Perry's Chemical engineers' handbook. New
York:McGraw-Hill.
2. Sinnot, R. (2005). Chemical engineering design. Oxford: Elsevier Butterworth-
Heinemann.
3. Turton, R. (1998). Analysis, synthesis, and design of chemical processes. Upper Saddle
River,N.J.: Prentice Hall PTR.

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