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    1.0 Sizing and Costing 1.1. Medium Pressure Decomposer: L V L V

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    Shahmi Asnawi
    The document provides design specifications and calculations for sizing a medium pressure decomposer vessel, including: 1) Process specifications like liquid and vapor flow rates, densities, temperature, and pressure. 2) Dimensions and properties calculated for the carbon steel vessel, such as a diameter of 0.983m, height of 18.8711m, and wall thickness of 0.0101m. 3) Steps shown to calculate the vessel cost, including empty vessel cost of $6683.60 and total purchase cost of $9545.75. Similar specifications and calculations are provided for a low pressure decomposer vessel.

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    1.0 Sizing and Costing 1.1. Medium Pressure Decomposer: L V L V

    Uploaded by

    Shahmi Asnawi
    569 views8 pages
    The document provides design specifications and calculations for sizing a medium pressure decomposer vessel, including: 1) Process specifications like liquid and vapor flow rates, densities, temperature, and pressure. 2) Dimensions and properties calculated for the carbon steel vessel, such as a diameter of 0.983m, height of 18.8711m, and wall thickness of 0.0101m. 3) Steps shown to calculate the vessel cost, including empty vessel cost of $6683.60 and total purchase cost of $9545.75. Similar specifications and calculations are provided for a low pressure decomposer vessel.

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    Plant Design

    Original Title

    Decomposer

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    The document provides design specifications and calculations for sizing a medium pressure decomposer vessel, including: 1) Process specifications like liquid and vapor flow rates, densities, temperature, and pressure. 2) Dimensions and properties calculated for the carbon steel vessel, such as a diameter of 0.983m, height of 18.8711m, and wall thickness of 0.0101m. 3) Steps shown to calculate the vessel cost, including empty vessel cost of $6683.60 and total purchase cost of $9545.75. Similar specifications and calculations are provided for a low pressure decomposer vessel.

    Copyright:

    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd
    Download as docx, pdf, or txt
    569 views8 pages

    1.0 Sizing and Costing 1.1. Medium Pressure Decomposer: L V L V

    Uploaded by

    Shahmi Asnawi
    The document provides design specifications and calculations for sizing a medium pressure decomposer vessel, including: 1) Process specifications like liquid and vapor flow rates, densities, temperature, and pressure. 2) Dimensions and properties calculated for the carbon steel vessel, such as a diameter of 0.983m, height of 18.8711m, and wall thickness of 0.0101m. 3) Steps shown to calculate the vessel cost, including empty vessel cost of $6683.60 and total purchase cost of $9545.75. Similar specifications and calculations are provided for a low pressure decomposer vessel.

    Copyright:

    © All Rights Reserved
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    of 8

    1.

    0 SIZING AND COSTING


    1.1. MEDIUM PRESSURE DECOMPOSER
    1.1.1. Introduction
    The purpose of this section is to further stripping of NH3, CO2 and the left Carbamate. it is
    divided into 2 parts: top separator, where the released Flash gases are condensed and recycled
    to the reactor before the solution enters the tube bundle, where the last carbamate is
    decomposed and required heat is supplied by means of steam saturated at 4.5 atm.

    1.1.2. Design Calculation


    Table 4.1: Medium Pressure Decomposer Specification Sheets

    Equipment Specification Sheet


    Identification Medium Pressure
    Decomposer
    Function: To separate the feed stream into gas and liquid products.

    Process Specification/Operating Condition


    Liquid Flow Rate, FL 15421.38 kg/h
    Vapor Flow Rate, FV 21479.87 kg/h
    Density of liquid, ρL 1178.696 kg/m3
    Density of vapor, ρV 21.526 kg/m3
    Surface Tension,σ 65.00 dyne/cm
    Temperature, To 140.00 ˚C
    Pressure, Po 18 atm
    Equipment Properties
    Type Vertical vessel
    Bare-module Factor, FBM 2.45
    Material of Construction Carbon Steel
    Density, ρcarbon steel 7861.0929 kg/m3
    Material Factor, FM 1.00
    Maximum Allowable Stress, S 15000 psi
    Vessel Internal Diameter, DT 0.983 m
    Vessel Height, L 18.8711 m
    Wall thickness to withstand internal
    0.0101 m
    pressure, tP
    Average vessel wall thickness, tV 0.0614 m
    Corrosion Allowance, tc 0.003175 m
    Shell Thickness, ts 0.0646 m
    Weight, W 1031.613 kg
    Cost of Pressure Vessel
    Cost of empty vessel, Cv $ 6683.60
    Added cost, CPL $ 2907.15
    f.o.b Purchase cost, Cp $ 9545.75

    Density of Urea = 1230 kg/m3

    Density of biuret = 1467 kg/m3

    Density of water = 1000 kg/m3

    Density of Liquid (ρl) = (0.7611 x 1230) + (0.00776 x 1467) + (0.231 x 1000)

    = 1178.696 kg/m3

    P × Mwt
    Density of NH3 (gas) =
    RT

    4.5× 17
    =
    0.0082× 353

    = 2.64 kg/m3

    P × Mwt
    Density of CO2 (gas) =
    RT

    4.5 × 44
    =
    0.0082× 353

    = 6.8 kg/m3

    P × Mwt
    Density of Carbamate =
    RT

    4.5 ×78
    =
    0.0082× 353

    = 12.126 kg/m3

    Density of gases (ρv) = 2.64 + 6.8 + 12.126

    = 21.526 kg/m3

    Mass flow rate of gases = 4531.755 kg/hr

    Qv = mass flow rate of gases/ density of gases (ρv)


    = 4531.755/21.526

    = 75.854 m3/hr

    = 0.0210 m3/sec

    Mass flow rate of liquid = 89409.39 kg/hr

    QL = 89409.39 /1178.696

    = 210.524 m3/hr

    = 0.0584 m3/sec

    1
    ρl−ρv
    Ut = 0.07 × (
    ρv ) 2

    1
    1178.696−21.526
    = 0.07 × ( 21.526 ) 2

    = 0.513 m/sec

    Without demister,

    Uv = 0.15 ut, Uv = 0.0769 m/sec

    4 ×Qv
    Dv = = 0.983 m
    π ×Uv

    Qv
    A= = 0.0210/0.0769
    Uv

    = 0.7596 m2

    Setting time = 10 min = 600 sec

    Volume held in the vessel = 600 x 0.0584

    = 35.087 m3

    V 35.087
    Liquid height (HL) = =
    A 0.7596

    =16.643 m

    Feed height (Hf) = 0.5 x Dv = 0.491 m

    Vapor or gas height (Hv) = Dv = 0.983 m


    Total height = 0.983 + 0.491+16.643

    = 18.8711 m

    Figure x.x Low Pressure Decomposer Design Sumamry

    Vessel Costing Purchase Cost, Cp

    Step 1 : Calculate the design pressure, Pd.


    Since Po is between 10 psig to 1000 psig,

    Pd = exp[0.6068 + 0.91615 (ln Po) + 0.00015655 (ln Po)2]

    = exp[0.6068 + 0.91615 (ln 264.527) + 0.00015655 (ln 264.527)2]

    = 305.1868 psig

    Step 2 : Calculate the design temperature, Td

    Td = To + 50 oF

    = (140 + 273.15) + 50

    = 463.15 oF
    Step 3 : Since Td is within range of -20 oF to 650 oF, carbon steel SA-285, grade C
    is selected.
    Therefore, maximum allowable stress, S = 15000 psi

    Step 4 : By assuming weld efficiency, E = 1,


    Calculate cylindrical shell wall thickness, tp,

    PD D T
    tp =
    2 SE−1.2 P D

    305.1868 ×0.983
    =
    (2 ×15000 ×1)−(1.2× 305.1868)

    = 0.0101 m

    Step 5 : Calculate necessary thickness to withstand wind load or earthquake at the


    bottom of the column, t W.

    0.22 ( 0.983+ 18 ) L2
    tw =
    SD20

    0.22(0.983+18)18.8711 2
    =
    15000 ×0.9832

    = 0.1026 m

    Step 6 : Calculate the average vessel wall thickness, tv.

    2t p +t w
    tv =
    2

    2(0.0101)+ 0.1026
    =
    2

    = 0.0614 m

    Step 7 : Calculate final vessel thickness, ts

    ts = tv + tc

    = 0.0614 + 0.003175
    = 0.0646 m

    Step 8 : Calculate the weight, W

    Where ρcarbon steel = 7861.0929 kg/m3

    W = π (DT + Ts) (L + 0.8DT) Ts ρcarbon steel

    = π (0.983 + 0.002157) (18.8711 + 0.8 (0.983)) (0.002157) (7861.0929)

    = 1031.613 kg

    Step 9 : Calculate cost of empty vessel, Cv

    Cv = exp[5.336 + 0.4599(ln W) + 0.00582(ln W)2]

    = exp[5.336 + 0.4599(ln 1031.613) + 0.00582(ln 1031.613)2]

    = $ 6683.60

    Step 10 : Calculate the added cost, CPL

    CPL = 2275Di 0.2094

    = 2275(3.225) 0.2094

    = $ 2907.15

    Step 11 : Calculate the f.o.b purchase cost, CP


    where Material Factor, FM for carbon steel is 1.0.

    CP = FMCV + CPL

    = (1 x 6683.60) + 2907.15

    = $ 9545.75

    Notes: The above steps are then repeated to calculate the f.o.b purchase cost for Low Pressure
    Decomposer
    1.2. LOW PRESSURE DECOMPOSER
    1.2.1. Introduction
    The purpose of this section is to further stripping of NH3, CO2 and the left Carbamate. it is
    divided into 2 parts: top separator, where the released Flash gases are condensed and recycled
    to the reactor before the solution enters the tube bundle, where the last carbamate is
    decomposed and required heat is supplied by means of steam saturated at 4.5 atm.

    1.2.2. Design Calculation


    Table 4.1: Medium Pressure Decomposer Specification Sheets

    Equipment Specification Sheet


    Identification Low Pressure Decomposer
    Function: To separate the feed stream into gas and liquid products.

    Process Specification/Operating Condition


    Liquid Flow Rate, FL 93941.14 kg/h
    Vapor Flow Rate, FV 4531.755 kg/h
    Density of liquid, ρL 1178.696 kg/m3
    Density of vapor, ρV 21.526 kg/m3
    Surface Tension,σ 65.00 dyne/cm
    Temperature, To 80.00 ˚C
    Pressure, Po 4.5 atm
    Equipment Properties
    Type Vertical vessel
    Bare-module Factor, FBM 2.45
    Material of Construction Carbon Steel
    Density, ρcarbon steel 7861.0929 kg/m3
    Material Factor, FM 1.00
    Maximum Allowable Stress, S 15000 psi
    Vessel Internal Diameter, DT 0.983 m
    Vessel Height, L 18.8711 m
    Wall thickness to withstand internal
    0.0101 m
    pressure, tP
    Average vessel wall thickness, tV 0.0614 m
    Corrosion Allowance, tc 0.003175 m
    Shell Thickness, ts 0.0646 m
    Weight, W 1031.613 kg
    Cost of Pressure Vessel
    Cost of empty vessel, Cv $ 6683.60
    Added cost, CPL $ 2907.15
    f.o.b Purchase cost, Cp $ 9545.75

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