final reactor design

PILOT PLANT REACTOR

1 MINIMUM CHARGING - 30 lit, sufficient for mixing and temperature indication

2 MAXIMUM WORKING - 500 litersCAPACITY

3 CONICAL BOTOM

4 L/D Large -1.5

5 BAFFLES REACHING ALOMOST NEAR BOTTOM

6 MATERIAL OF CONSTRUCTION SS316

7 BOTTOM DISCHARGE FLUSH VALVE

8 ARRANGEMENT FOR STEAM/NITROGEN/AIR BLANKETING,SPARGING. ROTAMETERS FORAIR/NITROGEN FLOW MEASUREMENT

9 MANHOLE SIZE AND SHAPE. Suitable for addition of powder RM directly in the liquid without falling on stirrer/baffles/ reactor wall.

10 JACKETS Steam/water/oil : split in at least 3 levels with air flush arrangement.

11 COIL Steam/water/oil circulation

12 STIRRER Variable speed drive, mechanical seal, connection of ammeter to note current drawn duringreaction

Basic requirements :-

etc to handle from thin to viscous, pasty , consistency, emulsification etc.

13 TEMPERATURE INDICATOR At 3 levels, digital

14 Pressure indicators Digital

Reactor to operate between 3 torr - 1

Suitable for WR vaccum pump + Steam jet ejector system.

Changeable from PADDLE/ TURBINE/ ANCHOR/ GATE/ PITCHED BLADE

PILOT PLANT REACTOR Prepared by - GAURAV KAKAD.

NMIMS (MPSTME)MBA-TECH(CHEM)-207

30 lit, sufficient for mixing and temperature indication

Suitable for addition of powder RM directly in the liquid without falling on stirrer/baffles/ reactor wall.

Steam/water/oil : split in at least 3 levels with air flush arrangement.

Steam/water/oil circulation

Variable speed drive, mechanical seal, connection of ammeter to note current drawn during

etc to handle from thin to viscous, pasty , consistency, emulsification etc.

At 3 levels, digital

Reactor to operate between 3 torr - 1kg/cm^2

Suitable for WR vaccum pump + Steam jet ejector system.

Changeable from PADDLE/ TURBINE/ ANCHOR/ GATE/ PITCHED BLADE

DESIGNING OF A REACTOR VESSEL IS DIVIDED IN TO FOLLOWING PARTS

1. SHELL2. HEAD (TOP AND BOTTOM)3. JACKETS4.COILS5. AGITATOR6. SHAFT7. BAFFLES8. NOZZLES AND FLANGES

DESIGNING OF A SHELL

1As per the standard condition, volume of the reactor

DESIGNING VOLUME OF THE REACTOR = 500*1.35 = 675 LIT. = .675 m^3

2

3

4

5

6

7

8 As per the internal design pressure

9 As per design external pressure

VOLUME OF THE VESSEL = 500 LIT.

must be 35% more than the actual capacity,

L/D = 1.5

Diameter of the shell = 0.830m or 830mm

Length of the shell =1.245m or 1245 mm

Internal pressure = 0.98 N/mm^2 ( 10 kg/cm^2)design internal pressure = 0.98 + 10% of 0.98total design internal pressure = 1.078 N/mm^2

Design external pressure = 0.945 N/mm^2 aprroximately equal to 1N/mm^2

Permissible stress = 130 N/mm^2

thickness of the shell (t) = 4.038 mm5 mm or more can be used.

thickness of the shell (t') = 3.772 mm (less than design internal pressure, not applicable)

DESIGNING OF A SHELL

DESIGNING VOLUME OF THE REACTOR = 500*1.35 = 675 LIT. = .675 m^3

0.945 N/mm^2 aprroximately equal to 1N/mm^2

3.772 mm (less than design internal pressure, not applicable)

HEAD DESIGN

1

2 As per design internal pressure


therefore thickness of the head in design internal pressure is not applicable)

→ Conical head- at bottom

1



→Elliptical head

1



(since t'<t , thickness of the head by external design pressure is not applicable)

→ Torispherical head - AT TOP

Crown radius = 830mm knuckle radius = 49.8 mmstress intensification factor ( W ) = 1.77

thickness of the head(t) = 8mm to 9mm

thickness of the head(t') = 9.72 mm10 mm or more can be used

(since t'>t,

(α= 45 degree, apex angle)

Diameter of the head = 830mm


thickness of the head(t')= 5.505 mm to 6 mm

(since t'<t, thickness of head by external design pressure is not applicable)


thickness of the head(t) = 6.022 mm to 7 mm

thickness of the head (t') = 5.633 mm to 6 mm

→ Hemispherical head

1



(since t'< t , thickness of the head by external design pressure is not applicable)



thickness of the head(t')= 1.877 mm to 2.5 mm

therefore thickness of the head in design internal pressure is not applicable)

(since t'<t , thickness of the head by external design pressure is not applicable)

(FLANGE LENGTH = 3*10 = 30mm)

(flange length = 7*3.5 = 24.5 )

since t'<t, thickness of head by external design pressure is not applicable)

(flange length = 7*3.5 =24.5 )

(since t'< t , thickness of the head by external design pressure is not applicable)

(flange length = 20mm)

Agitator

ASSUMPTIONS : -

1

DENSITY= 0.99*10^3 KG/M^3

→ TURBINE AGITATOR

1

2

3Power number

4

5

→ PADDLE AGITATOR(BLADES OF THESE AGITATORS NORMALLY EXTEND CLOSE TO TANK WALLS)

1

2

→ PROPELLER AGITATOR

1

It is shaped wid tapering blade to minimise the effect of centrifugal forceand produce a maximum axial flow

Other types of AGITATOR which can be used are:-1 HELICAL SCREW AGITATOR

LIQUID INSIDE THE REACTOR IS FUEL OIL VISCOSITY= 8081*10^-3 POISE

DIAMETER OF THE AGITATOR=277 mm

BLADE LENGTH = 1/4 th of agitator diameter blade length = 69.25 mm to 70 mm

REYNOLD'S NOS is 7.833

Np=9 (from power curve)

CENTRAL DISC = 1/8* 277=34.625mm

MOTOR REQUIRED TO MOVE THE AGITATOR= 6-7 hP

THE BLADE ANGLE OF A CURVED BLADE TURBINE AGITATOR IS 45⁰

PADDLE DIAMETER= 0.8 Times the tank diameter PADDLE DIAMETER= 0.8*830=664mm

width of the blade =1/4*664=166mm

DIAMETER OF PROPELLER AGITATOR= .2*830=166mm

2 CONE TYPE AGITATOR

3 RADIAL PROPELLER AGITATOR

4 HIGH SPEED DISC AGITATOR

5 DOUBLE MOTION AGITATOR

(DIAMETER OF AGITATOR/3)

(BLADES OF THESE AGITATORS NORMALLY EXTEND CLOSE TO TANK WALLS)

It is shaped wid tapering blade to minimise the effect of centrifugal force

1/4 th of agitator diameter

MOTOR REQUIRED TO MOVE THE AGITATOR= 6-7 hP

THE BLADE ANGLE OF A CURVED BLADE TURBINE AGITATOR IS 45⁰

0.8 Times the tank diameter

DIAMETER OF PROPELLER AGITATOR= .2*830=166mm

SHAFT

For Shaft design assume power rquired as 6 hP

1on the agitator shaft

2

3cross section

4

Continuous average rated torque(Tc) = 859.43Nm

Maximum TORQUE (Tm ) = 2148.59Nm

Polar modulus of section of the shaft (Zp)=16.527 Cm^3

Diameter of the shaft (d) = 4.38 cmwe can use a shaft of diameter upto 5cm to 6cm

Continuous average rated torque(Tc) = 859.43Nm

Maximum TORQUE (Tm ) = 2148.59Nm

Polar modulus of section of the shaft (Zp)=16.527 Cm^3

Diameter of the shaft (d) = 4.38 cmwe can use a shaft of diameter upto 5cm to 6cm

HUB AND KEY DESIGN

1

2

3

4stress

5

6

Hub diameter of agitator= 2*shaft dia=2*5=10cm

length of the key = 1.5*5=7.5cm

permissible stress for key= 130N/mm^2

shear stress & crushing = 130N/mm^2

b = 0.73mm to 1mm

t = 2mm

HUB AND KEY DESIGN

Hub diameter of agitator= 2*shaft dia=2*5=10cm

length of the key = 1.5*5=7.5cm

permissible stress for key= 130N/mm^2

shear stress & crushing = 130N/mm^2

b = 0.73mm to 1mm

t = 2mm

JACKETS and COILS

1

2

3 thickness of the jacket=

4 length of the jacket =

BAFFLES

1

2

Thickness of the coil = 3 mm

diameter of the coil = 540 mm

Baffle width = 83mm (1/10th of tank diameter)

Max Baffle height = 1128mm

JACKETS and COILS

83mm (1/10th of tank diameter)

(baffle height can b kept little more than the max. levelof the liquid inside the tank)

NOZZLES

1

2

31st- on top head of reactor, 2nd- on jacket, 3rd- on bottom head.)

4

5

6

7

8

9

10 without falling on stirrer/baffles/reactor walls)

11

Number of nozzles required = 15

coils requires " 2 nozzles " ( INLET AND OUTLET, AT THE TOP OF THE HEAD)

For temp. indicator " 3 nozzles" are required (digital)

Jacket requires " 2 nozzles " 1 for inlet and other for outlet

" 1 nozzle at the bottom of the head " for drain purpose

" 1 nozzle at the bottom for removal of product "

" 1 nozzle at the top head for pressure indicator purpose(digital) "

" 1 nozzle at the top of the head for rotameter "

" 1 nozzle in the middle of the top head, for shaft "

" 1 nozzle at the top of the head , as a hand hole" (for addition of powder RM directly in the liquid

" 2 nozzles for reflux condensors "

DIMENSIONS

(20mm away from the center nozle , diameter= 30-50mm)

1st- on top head of reactor, 2nd- on jacket, 3rd- on bottom head.) 2nd and third, diameter- 20-25 mm

(20-40mm diameter)

(20-35 mm diameter)

(140-150mm diameter)

(3-4mm away from the boundry of the head, 20-25mm diameter,in first quadrant, at 10-20⁰ from the center.)

without falling on stirrer/baffles/reactor walls) in 3rd quadrant)

2 nozzles " ( INLET AND OUTLET, AT THE TOP OF THE HEAD)

1st- on top head of reactor, 3-4mm away from the boundry of the head diameter- 20-25mm in 3rd quadrant.at 5-10⁰ from the center)

1 nozzle at the top head for pressure indicator purpose(digital) "


AT the center 0⁰, 6cm.(diameter)

for addition of powder RM directly in the liquid FROM THE CENTER AT 45-50⁰, 140-150mm (diameter)

(20mm away from the center nozle , diameter= 30-50mm)


1st- on top head of reactor, 3-4mm away from the boundry of the head diameter- 20-25mm in 3rd quadrant.at 5-10⁰ from the center)


⁰, 140-150mm (diameter)

final reactor design

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