Sulfuric Acid - Design of Equipments
Sulfuric Acid - Design of Equipments
Sulfuric Acid - Design of Equipments
ABSORBER
BASIS:
1 HOUR OF OPERATION
N2 3298.32 0.8301
SO3 403.732 0.1016
SO2 13.777 0.00346
O2 257.395 0.06478
TOTAL 3973.23 1.0
Sulfur Trioxide is absorbed in 98% sulphuric acid and the gases after absorption are
returned back to the converter. The exit concentration of the acid is assumed to be 103%
(3% free oleum)
Assuming negligible absorption of the other gases and at the average temperature of the
gas inside the tower at 95 ÛC,
Now,
For 0.12157 W = 10452.8 Kgs
then, For W = 85982 Kgs acid / Hr
= 23.88 Kgs/s
G = 37.08 Kgs/s
!
'HQVLW\ G) = 1.0711 Kg/m3
DIAMETER CALCULATION:
First we calculate,
!
>/*@ [ ^ G !L) }0.5
= 0.0155
In the Literature given by RICHARDSON & COULSON, Pg 544
From the Plot of K4 9V >/*@ [ ^ !G !L) }0.5
K4 at flooding line = 6.1
Lets choose the following packing, as given in RICHARDSON & COULSON, Pg 533
K4 = 1.9
Then,
% Loading = {1.9 / 6.1}0.5 x 100%
= 56 %
And,
G* = 3.95 Kg/m2-s
L = 23.88 Kgs/s
!
'HQVLW\ L) = 1850 Kg/m3
GV = 37.08 Kgs/s
!
'HQVLW\ G) = 1.0711 Kgs/m3
VP = 3.57 / 0.75
= 4.76 m/s
Given that,
Surface Area of Packing = 69 m2/m3
Liquid Density = 1850 Kg/m3
Then,
Wetting Rate = 2.54 / [1850 x 69]
= 1.9898 x 10-5 m3/m-s
The Above wetting rate is greater than the required minimum limit and this is adequate
for wetting the packing.
The Methodology adopted for the calculation of Height of the Packing is referred from
the literature by NORMAN W.S (ABSORPTION, DISTILLATION AND COOLING
TOWERS), Pg 214.
The Average Properties of the gas at the temperature are given as follows,
!
'HQVLW\ RI WKH JDV PL[WXUH G) = 1.0711 Kg/m3
9LVFRVLW\ RI WKH JDV PL[WXUH mix) = 2.772 x 10-5
Diffusivity of the gas (D) = 8.2 x 10-6 m2/s
kG x (RT/ VP) x (P/pBM [ ^mix >!G x D]}0.5 = [ ^>!G x d x VP@mix)}-0.25
Now,
With (P/pBM) =1(approx), we have,
For the conditions specified above the partial pressure of SO3 in equilibrium with the acid
is extremely small and it may be assumed that the absorption is controlled by gas film.
MATERIAL :
Carbon Steel
Permissible tensile stress ( f )= 950kg/cm2
THICKNESS OF SHELL:
Let X be the distance in “m” from the top of the shell, then
BASIS:
1 HOUR OF OPERATION
GIVEN:
WATER:
INLET TEMPERATURE = 25 ÛC
OUTLET TEMPERATURE = 40 ÛC
SULFURIC ACID:
The Sulfuric acid coming out from the absorption towers are cooled from a high
temperature to a lower temperature in a Shell and Tube Type Heat Exchanger. Water
which enters the Heat Exchanger at room temperature is heated to 40 ÛC and comes out of
the system.
1. HEAT LOAD:
Q = mh x CPh [ >û7@h
= 13.49 x 1.4435 x 103 x (112 - 30)
= 1.596 x 106 J/s
2. LMTD:
ACID WATER û7
TEMPERATURES 112.0 40 72 ÛC
TEMPERATURES 30.0 25 5 ÛC
4. DETERMINATION OF AREA:
5. CHOICE OF TUBES:
Do = 1.0 inch
= 25.4 mm
Di = 0.87 inch
= 22.1 mm
ï
P = 31.75 mm
(hi di / k) = 184.45
hi = 5199 W/m2 K
Nb = 35
ï ï
Sm = [ Ls (P - Do) Ds ] / P
= [(0.03175 – 0.0254) x 0.1689 x 0.635 / 0.03175
= 0.02145 m2
vs = mh / (Sm [ !h)
= {48572/3600} / (0.02145 x 1850)
= 0.340 m/s
The above value of velocity is also in the range of 0.3 to 1m/s, so this is also
acceptable.
Equivalent Diameter, de = 1.1 {31.752 – 0.917 x 25.42 }/ 25.4
= 18.04 mm
NPr = 42.9
ho = 3763 W/m2 K
Taking,
[ 1 / hod ] = 1 / 3000 (m2-K)/W
[ 1 / hid ] = 1 / 5000 (m2-K)/W
Uo = 923 W/(m2-K)
Note: As this value of Uo is greater than the corrected value of Uoc, so the design
with the above specifications is accepted.
f = 0.079 x (NRe)-0.25
= 0.00604
û3t ! x Vt2 / 2]
[ > f
= 1397 N/m2
û3T = Np û3L û3t)
= 20252 N/m2
= 20.25 KPa
Note: As the value of the pressure drop is less than 70KPa, the design is
acceptable from the tube side pressure drop consideration.
NRe = 1668
b = 2 x 10-3
fK = 0.25
!h !f) = 1850 Kg/m3
mh(W) = 13.49 Kg/s
Nc = [ Ds ( 1 – 2 {Lc/Ds} ) / Pp ]
= 635 x (1-2 x 0.25) / 22
= 14.43
= 14.5
Ncw = 0.8 lc / Pp
= [0.8 x 0.25 x 635] / 22
=6
b = 5 x 10-4
Sw = Swg - Swt
From the graph from PERRY Fig. 10-18, Pg. 10-29
Fc = 0.65
Swt = (250 / 8) x ( 1 – 0.6 [ [ 2
= 0.0222 m2
Sw = Swg - Swt
= 0.0645 – 0.0222
= 0.0423 m2
Therefore the total Pressure Drop on the shell side is calculated by the following
relation
As this value of Pressure Drop on the shell side is less than the 70 KPa, the design
is acceptable from the Pressure Drop Point of View.
The entire mechanical design is referred from the literature in PROCESS EQUIPMENT
DESIGN by M.V JOSHI.
1. SHELL THICKNESS
From the Table 9.2, its found that minimum shell thickness when severe
conditions are not expected is 8mm, which includes the Corrosion Allowance.
2. NOZZLES
Minimum nozzle thickness is 6mm and 8mm is choosen which includes the
corrosion allowance.
Also only the inlet and outlet nozzles need compensation. The compensation
required is minimum and is given by pads of 10mm thickness.
3. HEAD
Head thickness ( th ) = [ P x Rc x W ] / { 2 f J }
Where,
W = (1/4) x [ 3 + (Rc / Rnk)0.5 ]
= 1.54
Head thickness ( th ) = [ P x Rc x W ] / { 2 f J }
Head thickness = 6.66 mm
4. TRANSVERSE BAFFLES
Number of Baffles = 35
Baffle cut = 25%
Baffle thickness = 6mm (standard)
6. FLANGE DESIGN
Shell OD = 0.635 m
Shell Thickness = 0.008 m (g)
Shell ID = 0.627 m
Under atmospheric conditions, the bolt load due to gasket reaction is given by
Wm1 = π b G y
= π x 2 x 665 x 52.39
= 1061 KN
Am = Ao =W/S
7. FLANGE THICKNESS
Where,
B = Outside diameter of Gasket + 2xDiameter of Bolt +12mm
= 680 + 2 x 24 + 12
= 740 mm
Then, hG = (B – G )/2
= 37.5 mm
tf = [G√(p/Kf) ] + C
= 35.8 + C
= 38 mm
Hence the thickness of flange = 38 mm
TUBE SIDE
Where,
Working pressure = 12 N/mm2
Design pressure, P = 14 N/mm2
Permissible Stress, f = 100.6 N/mm2
Joint Efficiency, J =1
Thickness of tube = 1.65 mm
Use tube with thickness of 2mm
1. 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
4. GASKET SIZE
Under atmospheric conditions, the bolt load due to gasket reaction is given by
Wm1 = π b G Ya
= 991.8 KN
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 x 2 b x G x m x P + ( π / 4 )G2 P
= 6069 KN
Am = area of bolt
Am1 = Wm1 / fa
= 7075 mm2
Am2 = Wm2 / fb
= 43165 mm2
To determine the size of bolts , the larger of above two areas should be considered
5. THICKNESS OF NOZZLE
Considering inlet and outlet diameter to be 100mm, then thickness of the nozzle is
given by,
6. FLANGE THICKNESS:
Weight of Head, Wh = Vh x ρs
= 173 Kgs
Q = (W/2)
= 12.91 KN-m
Now, we calculate,
Distance of saddle center line from shell end ,
A = 0.4 x Ri
= 0.4 x (635/2)
= 127 mm
1. LONGITUDINAL BENDING MOMENTS
Radius, R = 0.317 m
Depth of head, H = 0.250 m
For θ =120Û
k1 = 0.107
k2 = 0.192
Thickness of shell, t = 8 mm
f1 = M1/( k1πR2 t)
= 297 x 103 N/m2
f2 = M1/( k2π R2 t)
= 165.2 x 103 N/m2
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 )
=6.63 x 106 N/m2
Axial Stress in Shell due to internal pressure
fp = (P x Di )/ (4 t)
= 2.262 x 106 N/m2
All combined stresses ( fp + f1 ) , ( fp + f2 ) , and ( fp + f3 ) are well within
allowable limits. Hence, the given parameters can be considered for design.
Thus a shell and tube Heat Exchanger with the above specifications is designed.
COOLER
BASIS:
1 HOUR OF OPERATION
GIVEN:
WATER:
INLET TEMPERATURE = 25 ÛC
OUTLET TEMPERATURE = 40 ÛC
PROCESS GAS:
The Process gas which consists of mixtures of Sulphur Dioxide, Sulfur Trioxide,
Nitrogen (inert) and Oxygen are cooled from a high temperature to a lower temperature
in a Shell and Tube Type Heat Exchanger. Water which enters the Heat Exchanger at
room temperature is heated to 40 ÛC and comes out of the system.
For the gas mixture, the only known property is its specific heat and other properties of
the gas mixture are predicted using the Transport Phenomena considerations. The
properties which have to be predicted are namely viscosity and thermal conductivity.
For the Gas Mixture,
i j (Mi / Mj ) / j )
i -ij [j -ij)
1 1 1.000 1.000 1.000
2 0.875 0.990 1.062 1.129
3 0.437 1.640 1.954
4 0.350 1.690 2.202
In the above tabular column, the value of -ij is calculated by the equation,
COMPONENT Pr Tr Kc Kr K
1. N2 0.0635 3.380 1.024 x 10-4 1 1.024 x 10-4
2. O2 0.4285 2.760 9.459 x 10-5 0.78 7.370 x 10-5
3. SO2 0.0273 0.990 3.893 x 10-5 0.33 1.284 x 10-5
4. SO3 0.0255 0.870 4.025 x 10-5 0.28 1.127 x 10-5
Kc = [ CP 50 @ [
1. HEAT LOAD:
With,
mg = 131518.5 Kg/Hr
= 36.5 Kg/s
Q = mg x CPg [ >û7@gas
= 131518 x 1.041 x 103 x (202.41 – 110)
= 12.65 x 109 J/Hr
= 3.514 x 106 J/s
As the values of Mass Flow Rate (mg ) and Heat Load (Q) are on higher side, we
split the entire flow rate into 4 equal parts so that we have 4 equal area heat
exchangers operating in parallel and which are handling equal heat load.
So, we have
mg = 9.13 Kg/s
Q = 878.5 x 103 J/s
Overall Heat Balance gives,
mw x 4187 x 15 = 878.5 x 103
mw = 13.98 Kg/s
2. LMTD:
GAS MIXTURE WATER û7
TEMPERATURES 202.41 40 162.4 ÛC
TEMPERATURES 110.0 25 85 ÛC
3. ROUTING:
4. DETERMINATION OF AREA:
5. CHOICE OF TUBES:
Do = 0.75 inch
= 0.01905m
Di = 0.62 inch
= 0.01575m
ï
P = 0.0254m
Nb +1 = L / Ls
Ls = 1
ï ï
Sm = [ Ls (P - Do) Ds ] / P
= [(0.0254 – 0.01905) x 0.540] / 0.0254
= 0.135 m2
G = Ws / Sm
= 9.13 / 0.135
= 67.64 Kg/m2-s
!s = PM / RT
= (2.13 x 33.6) / (0.082 x 429)
= 2.044 Kg/m3
NRe
'*
= [ 0.01905 x 67.64 ] / 2.772 x 10-5
= 46484
NPr = 0.8368
ho = 316.7 W/m2 K
Taking,
[ 1 / hod ] = 1 / 3000 (m2-K)/W
[ 1 / hid ] = 1 / 5000 (m2-K)/W
Uo = 250.47 W/(m2-K)
Note: As this value of Uo is greater than the corrected value of Uoc, so the design
with the above specifications is accepted.
f = 0.079 x (NRe)-0.25
= 6.193 x 10-3
û3t ! x Vt2 / 2]
[ > f
= 2266.06 N/m2
û3T = Np û3L û3t)
= 30702.8 N/m2
= 30.7 KPa
Note: As the value of the pressure drop is less than 70KPa, the design is
acceptable from the tube side pressure drop consideration.
NRe = 46484
b = 2 x 10-3
fK = 0.12
!v !f) = 2.044 Kg/m3
mg(W) = 9.13 Kg/s
Nc = [ Ds ( 1 – 2 {Lc/Ds} ) / Pp ]
= 540 x (1-2 x 0.25) / 22
= 12.27
Ncw = 0.8 lc / Pp
= [0.8 x 0.25 x 540] / 22
=5
b = 5 x 10-4
Sw = Swg - Swt
From the graph from PERRY Fig. 10-18, Pg. 10-29
Swg = 75 inch2
= 0.04838 m2
Swt = ( Nt / 8 ) x ( 1 – Fc [ [ 'o2
Fc = 0.65
Swt = (320 / 8) x ( 1 – [ [ 2
= 0.01596 m2
Sw = Swg - Swt
= 0.04838 – 0.01596
= 0.03242 m2
Therefore the total Pressure Drop on the shell side is calculated by the following
relation
As this value of Pressure Drop on the shell side is less than the 70 KPa, the design
is acceptable from the Pressure Drop Point of View.
The entire mechanical design is referred from the literature in PROCESS EQUIPMENT
DESIGN by M.V JOSHI.
1. SHELL THICKNESS
From the Table 9.2, its found that minimum shell thickness when severe
conditions are not expected is 8mm, which includes the Corrosion Allowance.
2. NOZZLES
Minimum nozzle thickness is 6mm and 8mm is choosen which includes the
corrosion allowance.
Also only the inlet and outlet nozzles need compensation. The compensation
required is minimum and is given by pads of 10mm thickness.
3. HEAD
Head thickness ( th ) = [ P x Rc x W ] / { 2 f J }
Where,
W = (1/4) x [ 3 + (Rc / Rnk)0.5 ]
= 1.54
4. TRANSVERSE BAFFLES
Number of Baffles =1
Baffle cut = 25%
Baffle thickness = 6mm (standard)
6. FLANGE DESIGN
Shell OD = 0.540 m
Shell Thickness = 0.008 m (g)
Shell ID = 0.532 m
dO/di = [(y-Pm)/(y-P(m+1))]0.5
Let, di = B+10
= 0.550 m
Choose N = 40 mm.
do = 0.630 m
Under atmospheric conditions, the bolt load due to gasket reaction is given by
Wm1 = π b G y
= π x 2 x 590 x 25.5
= 94.53 KN
H = πG2P/4
= 29.64 KN
where P is the design pressure
Am = Ao =W/S
= 94.53 x 103/ S
7. FLANGE THICKNESS
Where,
C is the Corrosion allowance
hG is radial distance from gasket load reaction to bolt circle
Hydrostatic end force, H = (π /4) G2 p
= 29.63 KN
K =1/[ 0.3 + {( 1.5 Wm hG) / (H x G)}]
hG = (B – G )/2
Where,
B = Outside diameter of Gasket + 2xDiameter of Bolt +12mm
= 630 + 2 x 9 + 12
= 660mm
Then, hG = (B – G )/2
=0.035 m
K = 1/[ 0.3 + {( 1.5 Wm1 hG) / (H x G)}]
= 1.713
tf = [G√(p/Kf) ] + C
= 14.8 + C
= 20 mm
Hence the thickness of flange = 20 mm
TUBE SIDE
Where,
Working pressure = 12 N/mm2
Design pressure, P = 14 N/mm2
Permissible Stress, f = 100.6 N/mm2
Joint Efficiency, J = 1.0
Thickness of tube = 1.24mm
Use tube with thickness of 2mm
1. 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
Where,
F = 1.25
Thickness of tube sheet = 140 mm
Under atmospheric conditions, the bolt load due to gasket reaction is given by
Wm1 = π b G Ya
= 1948 KN
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 x 2 b x G x m x P + ( π / 4 )G2 P
= 6197 KN
Am = area of bolt
Am1 = Wm1 / fa
= 13855 mm2
Am2 = Wm2 / fb
= 44075 mm2
To determine the size of bolts , the larger of above two areas should be considered
5. THICKNESS OF NOZZLE
Considering inlet and outlet diameter to be 100mm, then thickness of the nozzle is
given by,
6. FLANGE THICKNESS:
Weight of Head, Wh = Vh x ρs
= 102 Kgs
Q = (W/2) x (L+4H/3)
= 10.32 KN-m
Now, we calculate,
Distance of saddle center line from shell end ,
A = 0.45 x Ri
= 0.45 x (0.540/2)
= 121.5 mm
1. LONGITUDINAL BENDING MOMENTS
Radius, R = 0.270 m
Depth of head, H = 0.220 m
For θ =120Û
k1 = 0.107
k2 = 0.192
Thickness of shell, t = 8 mm
f1 = M1/( k1πR2 t)
= 876 x 103 N/m2
f2 = M1/( k2π R2 t)
= 488 x 103 N/m2
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 )
=1.80 x 106 N/m2
Axial Stress in Shell due to internal pressure
fp = (P x Di )/ (4 t)
= 1.829 x 106 N/m2
All combined stresses ( fp + f1 ) , ( fp + f2 ) , and ( fp + f3 ) are well within
allowable limits. Hence, the given parameters can be considered for design.
Note: This Cooler is fabricated 4 in number and are operated in parallel to take care of
the Cooling duty required in the Process.