MAJOR EQUIPMENT DESIGN

PACKED BED ABSORBER

Equilibrium data for CO2 and Monoethanolamine solution
X Y
mol CO2/mol mol CO2 /mol
MEA sol inerts
0.0038 0.026
0.0047 0.034
0.0057 0.044
0.0067 0.056
0.0076 0.067
0.0086 0.078
0.0095 0.087
0.0105 0.099
0.0115 0.109
0.0124 0.120
0.0133 0.133
0.0145 0.153
0.0160 0.180
0.0170 0.202

Gas flow rate at bottom Gb = 10559.1 kmol/hr

= 41.68 kg/s
Gas flow rate at the top Gt = 8726.9 kmol/hr
= 20.85 kg/s
Yt =0.005
Yb =0.216
Gin = 8683.5 kmol/hr
PROPERTIES
Gas density ρg = 0.487 kg/m3
Liquid density ρl = 934.4 kg/m3
Gas viscosity µg= 0.0175 cP
Liquid viscosity µl = 0.299 cP
Gas diffusivity Dg = 1.65X10-5 m2/s
Liquid diffusivity Dl = 1.96X10-5 m2/s
Gas heat capacity Cpg = 2.094 kJ/kg K
Liquid heat capacity Cpl = 4.145 kJ/kg K
From Graph
(Lin/Gin)min = 11.99
(Lin/Gin) = 1.1×11.99 = 13.189
Lin = 13.189x 8683.5
= 99652.5 kmol/hr
Top Section
Lt = Ls (1+Xt)
= 99652.5 kmol/hr
Bottom Section
Lb = 99652.5(1+Xb)
= 101117.4 kmol/hr
14.5 wt% MEA souliton has molecular wt.= 20.08 kg/kmol
Lt = 198026.6 kg/hr = 555.00 kg/s
Lb = 92452.82 kg/hr = 577.85 kg/s

Calculation of coloumn diameter

Choosing 90 mm pall rings (metal)
Void fraction ε = 0.97
Packing factor Fp = 53
Surface area a = 92 m2/m
 L  ρg 
  = 0.61
G  ρ l
At the bottom

L  ρg 
  = 0.56
G  ρ l
At the top
Hence choosing the larger value of 0.61
From Graph

G 2f Fpψµ l0.2
= 0.038
ρ g ρl g
Where
Gf = gas superficial velocity
Fp = packing factor = 53 m-1
ψ = correction factor for density = 1.029
µl = viscosity of liquid in cp = 0.299
ρg = density of gas = 0.487 kg/m3
ρl = density of liquid = 934.4 kg/m3
g = acceleration due to gravity
On substituting we obtain
Gf =2.085 kg/m2 s
Operating G = 0.85Gf
= 1.772kg/m2s
Ac = Gb/G
Ac = 20.85/1.772
A = 9.948 m2
Di = 3.20 m

Design dia =5m

Pressure drop
∆P = C 2 10 C3U tl ρ gU tg2
∆P = pressure drop expressed in terms of water
C2, C3 are constants for specific type of packing
Utg, Utl = superficial velocities of gas and liquid expressed in ft/s
ρg = gas density in lb/ft3
Utg = Gavg/ρgAc = 4.226 m/s = 14.108 ft/s
Utl = Lavg/ρlAc = 0.0596 m/s =0.197 ft/s

Hence ∆P = 27.43 in of H2O/ft of packing

= 2285.4 mm of H2O /m of packin

Degree of wetting from Nuris & Jackson criterion (Weeping Check)

Lmin
LW =
ρ l aAc
Where
Lmin = minimum flow rate of liquid = 555.00 kg/s
ρl = density of liquid = 934.4 kg/m3
a = surface area of packing per unit volume = 92 m2/m3
wetting rate is greater than 0.85 ft3/ft hr hence no weeping will occur
Evaluation of tower height
Z = H OG N OG
Gm
H OG = H g + m Hl
Lm
For ring type of packings

0.017ψD 1.24 Z 0.33 Sc g0.5

Hg =
(Lf1 f 2 f 3 )0.5
ψ = parameter for a given packing = 75
D = column diameter if diameter is less than 0.6m else 0.6m
Scg = Schmidt no for gas phase =2.1778
L = liquid rate = 55.58 kg/m2s
f1 = (µl/µw) = 0.8243
f2 = (ρl/ρw) =1.0885
f3 = (σw/σl) = 1.0611
substituting we get
Hg = 0.25Z0.33
Liquid phase transfer unit

0.15
ϕC  Z 
Hl = Scl0.5  
3.28  3.05 
ϕ = correlation parameter for a given packing = 0.11
C = correlation parameter for high gas flow rates = 0.5
Scg = Schmidt no for liquid phase = 163.6
Z = tower height
On substitution
Hl = 0.181Z0.15
m = slope of the equilibrium curve =11.25
Lm = 100449.7 kmol/hr
Gm = 9643.0 kmol/hr
Overall number of transfer units in the gas phase

1  1 + Yb 
Yb
dY
N OG = ∫Y Y − Y * 2 ln 1 + Yt
− 

t

Y Y* 1/(Y-Y*)
0.005 0 200
0.015 0.005 100
0.025 0.010 66.67
0.035 0.015 50
0.045 0.020 40
0.055 0.025 33.33
0.065 0.032 30.30
0.075 0.039 27.78
0.085 0.047 26.32
0.095 0.057 26.32
0.105 0.065 25
0.115 0.075 25
0.125 0.083 23.81
0.135 0.095 25
0.145 0.100 22.22
0.155 0.107 20.83
0.165 0.116 20.41
0.175 0.128 21.17
0.185 0.138 21.17
0.195 0.151 22.73
0.205 0.164 24.49
0.210 0.171 25.64
0.215 0.180 28.57
0.215
dY
∫
0.005
Y −Y*
= 7.284 + 0.259 = 7.543

Computing by using Simpsons 1/3 rule for numerical integration

Hence
Z = N OG H OG = 1.862Z 0.33 + 1.452Z 0.15
computing the value of Z by trial and error we have

Z = 5.0 m

The total pressure drop is ∆P = 11.427 m of H2O

 MINOR EQUIPMENT
Shell and tube heat exhanger
The gases coming out of the NH3 converter is at a very high temperature of
778K These gases are used to heat the inlet gases to the converter. The gases then
are cooled to a temperature of 313 K before it enters the condenser where
Ammonia is condensed. Because the heat load is very high five HE are used in
parallel.
Amount of heat to be removed Q = 4989.1 kW
Mass flow rate of gas mh = 23.8 kg/s
Inlet temperature T1 = 405 K
Outlet temperature T2 = 313 K

It is assumed that cooling water inlet temperature is 293 K and exit temperature
is 308 K.
Amount of cooling water mc = Q/Cp ∆T = 79.4 kg/s
Inlet temperature t1 = 293 K
Outlet temperature t2 = 308 K

LMTD =
(T1 − T2 ) − (t 2 − t1 )
 T − T2 
ln  1 
 t1 − t 2 
= 50.38 K

T1 − T2
R= = 6.46
t 2 − t1
t 2 − t1
S= = 0.12
T1 − t1

For these values the LMTD correction factor FT = 1

(LMTD)c = 50.38 K
Properties
Gas stream at 359 K Water at 300.5 K
ρ (kg/m3) 20.03 996.4
µ (Pa s) 4.876 x 10-5 9 x 10-4
k (W/m K) 0.125 0.359
Cp (kJ/kg K) 1.991 4.187

Routing of Fluids
The gases are taken on shell side. Cooling water is taken on the tube side.

AREA OF HEAT TRANSFER

Assuming Ud = 350 W/m2K
Area of heat transfer is given by

Q
A= = 242.83m 2
U d (LMTD )C
For the exchanger 1 inch 16 BWG tubes are chosen
do = 25.4 mm
di = 22.1 mm
area of tube per unit length = 0.2168 ft2/ft
Assumption is made that the tubes are of length 16 ft
Hence the area per tube a = 4.1888 ft2 = 0.3333 m2
No of tubes

A
Nt = = 730
a
From the tube count table we have for 1 inch o.d tubes on 1.25 inch square pitch
Nt =738 Np = 4 Ds = 1067 mm
Hence corrected area for heat transfer A =Nt x a = 245.97 m2
Thus corrected coefficient of heat transfer Uac = 341 W/m2 K
Velocity
Tube side
Tube cross sectional area for flow of fluid in one tube pass

π 2 Nt
aT = di = 0.0708m 2
4 Np
where
di is the tube inside diameter =22.1 mm
Nt is the number of tubes =738
Np is the number of tube passes =4

Tube side velocity

mC
vT = = 1.125 m
aT ρ T s
where
mc is the mass flow rate of cold water
ρt is the density of tube side fluid
The velocity of a liquid should lie between 1 and 2 m/s which is satisfied.

Shell Side
Shell side cross sectional area for fluid flow

aS =
(P0 − d o )l s Ds = 0.1423m 2
Po
Where
Po = pitch = 31.75 mm
do = outside diameter = 25.4 mm
Ds = shell inside diameter = 1067 mm
ls = baffle spacing assumed to be 0.5 Ds = 534mm
Shell side velocity is given by

ms
vs = = 10.325 m
as ρ s s
Where
ms = shell side mass flow rate
ρs = shell side fluid density
The velocity of flow for gases must lie between 10 and 40 m/s which is satisfied

Film Transfer Coefficient

Tube side
Reynolds number

ρvd i
Re = = 27524.8
µ
Where
µ is the viscosity of fluid
ρ is the density of fluid
dI is the inside diameter of tube
Prandtl number

µC p
Pr = = 10.75
k
Where
Cp is the specific heat capacity
k is the thermal conductivity
Nusselts equation is given as

Nu = 0.023 Re 0.8 Pr 0.4

ht d i
= 167
k
ht = 2646.1W 2
m s
Where
ht is the tube side heat transfer coefficient
Shell side
Reynolds number

ρv s d o
Re = = 53759
µ
Prandtl number
µC p
Pr = = 0.94
k
By Deitus Bolter equation Nusselts number

Nu = 0.023 Re 0.8 Pr 0.3

hs d o
= 137.6
k
hs = 681.64 W 2
m s
Where
hs is the shell side heat transfer coefficient
Overall heat transfer coefficient

1 1 1 d 1 1  ln (d o d i )
= + + i  +  + d i
U ht htd d o  hs hsd  k

Where
hd represents the dirt coefficient. It is assumed to be 2839 W/m2 K for both shell
and tube side
On substitution we obtain
U = 366.4 W/m2 s
The design value is larger than the assumed value. Hence design is safe.
Pressure Drop
Tube side
Re = 27524.8

f = 0.079 Re −0.25 = 0.00613

 4 fLvt2 
∆PL =   ρg = 3384.38 N m 2

 2 gd i 
where
f is the friction factor
l is length of pipe
vt is the tube side velocity
g is the acceleration due to gravity
di is the tube inside diameter

 ρv 2 
∆Pc = 2.5 t  = 1576.25 N m 2
 2 
∆Pt = N p (∆PL + ∆Pc ) = 19.842kPa

Where
Np is the no of tube passes =4
The pressure drop for liquids must lie between 14 and 70 kPa. Hence the design
is safe from view of pressure drop on the tube side.

Shell Side
Pressure drop in the cross flow section
0.14
f W 2N  µw 
∆Pbk = b k 2 c  
ρS m  µl 
fk is the ideal tube bank friction factor =0.104
W is the mass flow rate = 23.8 kg/s
 D s [1 − 2(l c Ds )]
Nc = = 16.8
Pp
Nc is no of tube rows crossed in one cross flow section
lc is the baffle cut =0.25 Ds
Pp is pitch parallel to flow = 31.75 mm
Ds is the shell inside diameter =1067 mm
ρ is the fluid density = 20.3 kg/m3
Sm is cross flow near centerline for one cross flow section = 0.1423 m2
∆Pbk = 0.4555 kPa
Pressure drop for an ideal window section

W 2 (2 + 0.6 N cw )
∆Pwk = b
SmSw ρ
b =2 x 10-3
Sw is for flow through window =0.1598 m2
∆Pwk = 0.3657 kPa

 N 
∆P = [(N b − 1)∆Pbk + N b ∆Pwk ]+ 2∆Pbk 1 + cw 
 Nc 
L
Nb = −1 = 8
ls
∆P = 7.845 kPa
The pressure drop for gases should be between 2 and 20 kPa. Hence the design is
safe on shell side also
 MECHANICAL DESIGN OF ABSORBER
Material for shell is Carbon Steel
THICKNESS OF SHELL
Thickness of shell = ts
pD
ts = +c
2 fJ + p
Where,
Di = Inner Diameter of vessel = 3.2m
Working Pressure = 1 atm = 1.054kgf/cm2
p = Design Pressure = 1.1 x 1.054 = 1.137 kgf/cm2
f =Permissible Stress = 950 kgf/cm2
J= Joint Efficiency = 0.85
c= Corrosion allowance =2mm
ts = 6mm
thickness of shell is 6mm

HEAD DESIGN: FLANGED & SHALLOW

Material stainless steel
Permissible stress = f= 130 N/mm2
Design pressure = p = 1.064 x 10 5 N/m2
Stress identification factor W is given by
W = (¼) [3 + ( Rc/R1)1/2]
Crown Radius = Rc= 3.2m
Knuckle radius = R1 = 0.192m
Stress identification factor W is 1.77
pRcW
Thickness of head = th =
2 fJ

th= 6mm
Axial Stress Due to Pressure
Axial stress due to pressure =fap
pDi
f ap =
4(t s − c )

= 355.4 kgf/cm2
Stress due to Dead Load
a) Compressive Stress due to weight of shell up to a distance X
Do = Di + 2 ts =3.212m
Density of Shell material = ρs = 7700 kg /m3
π 2
(Do − Di2 )ρ s X
f ds = 4
π 2
(Do − Di2 )
4
=.77X kgf/cm2
b) Compressive stress due to weight of insulation at height X
Insulator used is asbestos
Thickness of insulation = tins =100mm
Diameter of insulation = Dins
Density of insulation =2300 kg / m3
Mean diameter of vessel = Dm
For large diameter column
Dins = Dm
πDins t ins ρ ins X
f ins =
πDm (t s − c) )

= 1.925 kgf/cm2
c) Compressive stress due to liquid in column up to height X
Density of liquid =ρl = 934.4 kg/m3
π 2
Di ρ l ε
f liq = 4
πDm (t s − c )

= 23.29 kgf/cm2
d) Compressive stress due to attachment
i. Packing weight
ii. Head weight
iii. Ladder
Density of packing (pall ring) = 270 kg /m3
π 2
Di ρ p X
Packing Weight = 4
πDm (t s − c )

Head weight (approximately) = 2000kg

Weight of Ladder = 140 kg/m
Total compressive stress due to attachments is given by
fattach = ( Packing Weight + Head weight + Ladder ) / [ π Di ( ts – c ) ]
= (3.1972 + 0.2225 X) kg/cm2

Stress due to Wind

Stress due to wind is given by
1.4 Pw X 2
f ws =
πDm (t s − c )

Where,
Pressure due to wind = Pw = 125 kgf/m2
=0.2778 X2 kgf/cm2

To determine the value of X

fmax = 950 kgf/cm2
Upwind side
Jftmax = fwx + fap +fdx
807.5 = 365.4+3.1792+39.6345 X +0.2778 X2
Solving for X we have
X = 10.331m

Downwind side
Jftmax = -fwx - fap -fdx
807.5 = -365.4-3.1792-39.645 X +0.2778 X2
Solving for X for compressive stresses
X=167 m
Hence the column will support a height of 5m as the calculated height is much
higher than 5 m in both cases

DESIGN OF GASKET AND BOLT

Width of gasket =N = 10 mm
Gasket material is asbestos
Gasket factor = m =2
Minimum design seating stress = Ya= 11.2 N / mm2
Basic gasket seating width bo = N/2
bo = 10 mm / 2 = 5mm
Effective gasket seating width
b = 2.5 ( bo )1/2
Inner diameter = Di = 4.85 m
Outer diameter = Do = 4.85m + 2 x 8 x 10 –3
Flange inner diameter =Dfi = 4.866 m
Flange outer diameter = Dfo = 4.926 m
Mean diameter = G = (Dfi + Dfo) / 2
= 4.896 m
Under atmospheric conditions, the bolt load due to gasket reaction is given by
Wm1 = π b G Ya
=962.98 x10 3 N
Design pressure = p
 = 1.064 x 10 5 N/m2
After the internal pressure is applied, the gasket which is compressed
earlier, is released to some extent and the bolt load is given by
Wm2 =π(2b) G x m x p + (π/4)G2 p
=2.039 x 10 6 N
Bolt used is hot rolled carbon steel
fa is permissible tensile stress in bolts under atmospheric condition
fb is permissible tensile stress in bolts under operating condition
fa=58.7 x 10 6 N/m2
fb = 54.5 x 10 6 N /m2
Am is the area of bolt
Am1= Wm1 / fa
Am2 = Wm2 / fb
Am1= 0.016 m2
Am2= 0.037 m2
Number of bolts = mean diameter /bo x 2.5
=392 bolts
To determine the size of bolts, the larger of above two areas should be
considered
Diameter of bolts =[(Am2 /Number of bolts) x (4/π)]1/2
=1.096 cm

FLANGE THICKNESS
Thickness of flange = tf
tf= [G√(p/K f) ] + c
Where,
K=1/[ 0.3 + ( 1.5 Wm hG)/H x G]
Hydrostatic end force = H = (π /4) G2 p
 =2.003 x10 6 N
hG is radial distance from gasket load reaction to bolt circle,
hG = ( B – G )/ 2
= 0.0155
B = outside diameter of gasket + 2 x diameter of bolt + 12mm
= 4.927 m
Wm = 2.039 x 10 6 N
K= 3.28
Hence the thickness of flange = 90.47 mm

NOZZLE THICKNESS
Material Carbon steel
Considering diameter of nozzle = Dn =150 mm
Thickness of nozzle =tn
Material is Stainless steel ( 0.5 cr 18 Ni 11 Mo 3)
Permissible stress =130 x 10 6 N/m2
J=0.85
pD
tn =
2 fJ − p
tn = 1.24mm
No corrosion allowance , since the material is stainless steel.
We can use thickness of 3mm
SUPPORT FOR ABSORBER
Material used is structural steel ( IS 800)
Skirt support is used.
Inner Diameter of the vessel = Di =3.2m
Outer Diameter of the vessel = Do =3.212m
Height of the vessel = H = 5.0m
Density of carbon steel= ρs = 7700 kg /m3
Density of liquid = ρl = 934.4 kg /m3
Total weight = Weight of vessel+ Weight of Attachments (liquid+ packing + head
+ ladder)
=59430 kg
total stress due to dead loads
∑ w 59.00
f ds = = kgf/cm2
πDm t t

Stress Due to wind load

The force due to wind load acting on vessel is
plw = k p1 h1 Do
.
k=0.7 for cylindrical surface
p1 is wind pressure for the part of the vessel upto a height of 20 m.

p1 = 128.5 kgf/m2
h1=8m
1.4 p1 H 2 0.054
f wb = = kgf/cm2
πDm t t
Stress due to Seismic Load
Load F= CW
W is total Weight of vessel
C is Seismic Coefficient =0.08
8CWH 0.2246
f sb = = kgf/cm2
3πDo t t

Maximum Stress at bottom of Skirt

ftmax = ( fwb or fsb ) – fdb
58.775
= kgf/cm2
t
Permissible tensile Stress for structural steel = 950 kgf/cm2
Equating the two we have
t ≥ 0.74mm
therefore the thickness of skirt is taken as 6mm

Maximum Compressive Stress

fcmax = ( fwb or fsb ) + fdb
59.2446
= kgf/cm2
t
permissible tensile stress for structural steel is 950 kgf/cm2
Equating the two we have
t ≥ 0.8mm

Skirt Bearing Plate

∑w Ms
fc = +
A Z
™Z VXP RI DOO WKH GHDG ORDGV
A = (π/4) ( Dsko2 – Dski 2) is the area of contact between skirt plate and the
concrete.
Ms = moment due to wind load
Z = section modulus
fc =5.689 kgf/cm2
Permissible stress f in bending is 950 kgf/cm2
6 M max 3 f cl 2
f = =
bt B2 t B2

tB= 63mm

Anchor Bolt,
Wmin=45000 kg (assumed)
fc = (Wmin/ A ) – (Mw /Z)
= 1.115 kgf/cm2
Fc is positive ,hence anchor bolts are not required if the safety factor is above 1.5
Wmin R
j=
Ms

= 7.45
The safety factor is above 1.5. Hence anchor bolts are not required.
 MECHANICAL DESIGN OF SHELL AND TUBE HEAT
EXCHANGER

Carbon Steel (Corrosion allowance 3 mm)

SHELL SIDE
Number of pass =1
Fluids in shell are Hydrogen, Nitrogen Ammonia and inerts like Argon and
Methane
Design pressure =50.9 kgf?cm2
Shell diameter = 1067mm
Considering steel dished head (torispherical)
Ri= 1067 mm
ri =0.06 of Ri
Inside depth of head can be calculated as
1
 D  D   2
hi = Ri −  Ri − i  Ri + i  + 2ri 
 2  2  
= 136 mm
Effective Length = L = 4.88 m + 2 x (0.136)
= 5.154 m

NOZZLE THICKNESS
Material used is carbon steel
Considering diameter of nozzle to be 150mm
Permissible stress = f = 950 kgf/cm2
Corrosion allowance = 3mm
pDi
th = +c
2 fJ − p

=5mm
HEAD THICKNESS
pRiW
Thickness of head = t h = +c
2 fJ

1 
W =  3 + Ri  =1.77
4 ri 

Hence th = 60 mm thickness
TRANSVERSE BAFFLE
Spacing between baffles as = 534 mm

FLANGE JOINT ( BETWEEN SHELL AND TUBE SHEET )

This will be made to satisfy the requirements of the flange joint between tube
sheet and channel. Gasket width (N) = 22 mm

Flange Thickness
Inner diameter of flange =Dfi = 1143 mm
Outer diameter of flange = 1167mm
Gasket Size G=1155 mm
Material is Steel Jacketed asbestos
Width of gasket =N = 24 mm
Gasket factor = m = 3.75
Minimum design seating stress = ya= 5.34 kgf/cm2
Basic gasket seating width bo = N/2
bo = 24 mm / 2 = 12 mm
Effective gasket seating width
b = 2.5 ( bo )0.5 = 9 mm
under atmospheric conditions, the bolt load due to gasket reaction is given by
Wm1 = πbGYa = 100500 kg
Design pressure = p = 50.9 kgf/cm2
After the internal pressure is applied, the gasket which is compressed
earlier, is released to some extent and the bolt load is given by
π 2
Wm 2 = 2πbGmp + G p = 667719 kg
4
Thickness of flange = tf

p
tf = G +c
kf

Where,
1
k=
1.5wm hg
0.3 +
HG
π 2
Hydrostatic end force = H = G p
4
hG is radial distance from gasket load reaction to bolt circle,
hG = (B – G )/2
=37.5 mm
B = bolt circle diameter
wm is the greater of the two loads in this case Wm2
Hence the thickness of flange = 138.8 mm

TUBE SIDE
Stainless steel ( IS- grade 10)
Tube thickness
pD
tt =
2 fJ + p
Where,
Working pressure = 1atm = 1.054 kgf/cm2
Design pressure = p =1.1 times 1.054 = 1.136 kgf/cm2
Permissible Stress =f = 950 kgf/cm2
 J=1 for seamless tubes
Thickness of tube =0.2 mm
The thickness of tubes is taken as 2 mm with no corrosion allowance as the
material is made of stainless steel.
Tube Sheet
The tube sheet is held between shell flange and the channel. The joint on the shell
flange side is of male and female facing and on the channel side of ring facing,
since the pressure on the channel
Thickness of Tube Sheet

kp
t ts = FG
f
Where F = 1
K=0.25
Thickness of tube sheet = 18 mm
Channel and Channel Cover
Carbon Steel
Thickness of channel
Permissible stress = f = 95 kgf/cm2
K=0.3
Thickness of channel

kp
th = G
f
Substituting the values the thickness of the channel and channel cover is
obtained as 19mm
Flange Joint
Gasket material is steel jacketed asbestos
Gasket width (N) = 22 mm
Gasket factor = m = 5.5
Minimum design seating stress = Ya= 12.66 kgf/cm2
Basic gasket seating width bo = N / 8
bo = 2.75 mm
Effective gasket seating width
b = bo
Mean diameter = G = 1000mm
Design pressure = p = 1.136 kgf/cm2

Wm1 = πGby a
Under atmospheric conditions, the bolt load due to gasket reaction is given by
= 10002 kgf
After the internal pressure is applied, the gasket which is compressed

πG 2 p
Wm 2 = 2bπGmp +
4
earlier, is released to some extent and the bolt load is given by
= 109374 kgf
Bolt used is hot rolled carbon steel
fa is permissible tensile stress in bolts under atmospheric condition
fb is permissible tensile stress in bolts under operating condition
For Cr Ni Steel,
fa= 1406 kgf/cm2
fb = 66 kgf/cm2

Wm1
Am1 =
fb
=7.114 cm2
Wm 2
Am 2 =
fa
= 16.572 cm2
Am is larger area of Am1 and Am2 =16.572 cm2
Number of bolts = mean diameter / bo x 2 = 40 bolts
To determine the size of bolts , the larger of above two areas should be
considered

Am
db =
4π
= 36 mm
Using M 48 bolts
Pitch diameter = 44.68 mm
Minor diameter = 41.795 mm
π
Ab = (4.4681 + 4.1795)2
8
Actual bolt area is given by
= 19.66 cm2
Minimum pitch diameter = G +N+2db = 1118mm
Hence Bolt diameter is chosen as B= 1150 mm

p
tf = G +c
kf
1
k=
1.5Wm hG
0.3 +
HG
Flange Thickness
=2.91
Hence tf = 25 mm
THICKNESS OF NOZZLE
Considering inlet and outlet diameter to be 200mm

pD
tn =
2 fJ + p
Thickness of nozzle
= 1 mm
Thickness of nozzles is taken as 6mm
SUPPORT FOR SHELL AND TUBE HEAT EXCHANGER
Length of the heat exchanger = 4.88m
InnerdiameterofShell=1067 mm
Outer diameter of Shell = 1137 mm
Inner diameter of tube = 22.1 mm
Outer diameter of tube = 25.4 mm
Number of tubes =738
Density of Steel =ρs =7850 kg /m3
Density of Liquid =ρl = 995.3 kg/m3
Volume of Shell body = V = (π / 4) ( Do2 – Di2 ) x L
= 0.591m3
Weight of Shell body = Ws = V x ρs
= 4479 kg
Volume of Tubes = Vt = ( π / 4 ) ( do2 – di2 ) x L x N
= 0.44 m3
Total Weight of Tubes = Wt = Vt x ρs
= 3360 kg
Volume of Head = Vh = 0.087 Di3
= 0.106m3
Weight of Head = Wh = Vh x ρs
= 801 kg
Weight of Liquid = Wl = ( π / 4) (di2) x L x N x ρl
= 10845 kg
Total Weight = W = Ws+ Wt + Wh + Wl
= 19485 kgf
Q =W/2 =9742.5 kgf
Distance of saddle center line from shell end =A= 0.6 x Ri
=320 mm
Longitudinal Bending Moments
Radius = R =1.067m
Height of head =H = 0.136 m
The bending moment at the supports is
M1 = QA [ 1 – {(A/L)+ (R2 - H2) / 2 AL}/{1 + 4H/3L}]
= 1842.6 kgf m
The bending moment at the center of the span is given by
M2 = ( Q L / 4)[{1+ 2 ( R2 - H2 ) / L2 }/{1+ 4H / 3L} - ( 4A / L) ]
= 2131kgf m

Stress in Shell at the Saddle

For A > 0.5 Ri , the shell is not sufficiently stiffened by the end
For θ =120,
k1= 0.107
k2 = 0.192
Thickness of shell t = 35 mm
f1 = M1/( k1πR2 t)
= 13.97 kgf/cm2
f2 = M1/( k2π R2 t)
=7.79 kgf/cm2

Stress in the shell at Mid- Span

The stress at the mid span is f3, which is either tensile or compressive
depending on the position of the fiber. The resultant tensile stresses ( including
the axial stress due to internal pressure ) should not exceed the permissible
stress, and the resultant compressive stress should not exceed the permissible
compressive stress .
f3 = M2 /(πR2 t )
= 18.62 kgf/cm2
Axial Stress in Shell due to internal pressure
fp = (p Di )/ (4 t)
= 34.99 kgf/cm2
The combined stresses ( fp + f1 ) , ( fp + f2 ) , and ( fp + f3 ) are will within the
permissible values