X Y
0 0
0.601 0.064
CO
2
Absorber
The Carbon dioxide gas produced resulting due to the reforming reactions, which
is used as a raw material for Urea. It is separated from the gas mixture by the absorption
in the solvent MDEA (Methyl Di ethanolamine).
The gas mixture contains 16.95 mole % of Carbon dioxide which is
separated by absorption in MDEA. The overhead contains 5.91% of carbon dioxide.
Material Balance
Material balance of CO
2
La*Xa + V*y = L*X + Va*Ya
X = { (0.130871*50265.29)- (0.000233*80.42) }/6588.79
= 0.9984
y
1
= 0.1308
y
2
= 0.000233
x
1
= 0.9984
x
2
= 0 (if we consider the pure solvent)
Y
1
= 0.1308/(1-0.1308)
= 0.15
Y
2
= 0.000233/(1-0.000233)
= 0.00023305
X
1
= 0.9984/(1+0.9984)
= 0.499
X
2
= 0
L/V = (0.15-0.000233)/(0.499-0)
=0.3
Now,
The height of the column, Z= (H
OG
)*(N
OG
)
Fig. 9.1 Equilibrium Curve of CO
2
-MDEA system
From that,
Y
1
* = 0.14X1 & Y2* = 0.14X2
N
OG
= (Y1-Y2)/{(Y1-Y1*)-(Y2-Y2*)}/ln((Y1-Y1*)/(Y2-Y2*))
= (0.15-0.000233)/{(0.0802)-(0.000233)}/ln((0.0802)/(0.000233))
= 3.7 4
HTU,
H
OG
= G /{K
ya
* (1-Y)*
LM
}
(1-Y)*
LM
= {(Y1-Y1*)-(Y2-Y2*)}/ln((Y1-Y1*)/(Y2-Y2*))
= (13473.2)/(3000*0.4667)
= 5.34 6
So,
Z= (H
OG
)*(N
OG
)
= (4)*(6)
= 24 unit (m)
Mechanical Design:
If we consider L/D = 8
So, D = 3 m
L = 24 m
Design Pressure = 10.5 kg = 1.029N/mm
2
Temperature = 70 C Packing Height = 2.4 m
Packing type: Pall Rings
Thickness of insulation = 80 mm (PUF)
MOC: Carbon Steel (SA-516 grC)
Fall = 150.48 N/mm
2
E = 2 x 10
5
MN/m
2
Corrosion Allowance = 2mm
Joint efficiency Factor = 0.85
Top disengaging space = 1 m
Weight of attachments (pipes, ladders & platform) = 750 N/m
Wind velocity V
w
= 1.24 m/s
o
i o i
Weight of fluid and Packing = 900 N/m
2
Sp. Gravity of MOC = 7.85 gm. /cm
3
Column Shell Thickness:
ts = PD / 2fJ P
ts = 1.029*3000 / 2*105.48*0.85 1.029
ts = 17.3 mm ~ 18 mm
td = 18 + 2 = 20 mm
Axial Stress due to pressure:
f
ap
= PD/4(t - c)
= 1.029 * 3000 / 4(18)
= 42 N/mm
2
Now, D
o
= D
i
+ 2t
Do = 3040 mm
shell
= 7850 kg/m
3
shell =
7850*9.087/10
6
= 0.077N/mm
2
1) Stresses due to load:
Due to weight of shell:
F
dx
= weight of shell / cross section of shell
= /4(D
2
D
2
) * * H
/4(D
2
= H
D
2
)
= 0.077H N/mm
2
Due to weight of insulation:
D
ins
H
ins
t
ins
F
dins
=
D
m
t
s
C
D
m
= (D
o
+ D
i
)/2 = 3020 mm
D
ins
= D
o
+ 2*t
ins
= 3040 + 2(80)
= 3200 mm
F
dins
= 3200 * 80 * 5640 * 10
-6
*H / 3020*10
= 0.0478H N/mm
2
Due to weight of liquid & tray:
Weight in terms of height = (H/ packing spacing)* (/4*D
i
2
)*(Wt of liq. + tray)
liq
= 1040 kg/m
3
Weight of each tray = 0.8 kN/m
2
= 0.8 * 10
3
/ 9.81 = 81.55 kg/m
3
Weight = (H/4.13)* (/4*3
2
)* 81.55
= 139.5 H kg
Fl
iq
= ( 139.5 H) / ( D
m
t
s
C)
= 139.5 H*9.807/ *3020*18
= 0.008014 H N/mm
2
Due to attachments:
F
datt
= Wt. of attachments * H / ( D
m
t
s
C
= 750*H / (3.14*3020*18)
= 0.00439 H N/mm
2
Now,
Total Stress = (0.077 + 0.0478 + 0.008014 + 0.00439)H
F
dh
= 0.1372 H N/mm
2
Stresses due to wind load:
F
wind
= 1.4 Pw H
2
/ *Do(t-c) P
w
=
0.05(3.6*1.24
2
)
= 0.2767 N/m
2
F
wind
= 1.4*0.2767*H
2
/ *3040*18
= 0.06915 H
2
N/mm
2
Now,
AH
2
- BH + C = D
A = 0.06915
B = 0.1372
C = 40
D = 105.48
On solving the equation,
0.06915H
2
0.1372H + 40 = 105.48
H = 27.2 M
The maximum height that can be withstood 20mm of thickness of this vessel is 27.2m
so we can go further with the thickness of 20mm with 24m of height calculated earlier
in the process design of absorption column.
Skirt Support :
Data :
Dia. of vessel = 3000 mm
Height of the vessel = 24 m
Wt. of vessel + attachments = 351153.27 N
Dia. of skirt = 3000 mm
Height of skirt = 4 m
Wind press. = 1285 N/mm
2
288
Calculation:
Stress due to dead wt.
Fd = W / (dsk tsk)
= 351153.27 / (*3000*tsk)
= 37.27 / tsk N/ mm2
Stress due to wind load
Fwb = Mw/Z = 4Mw / *dok2*tsk
Where
Mw = Plw(h1/2) + Puw(h1 +(h2/2)) Fwb
= 41.2/tsk N/mm2
Sesmic load Fsb = (2/3)*CWH/(*Rok*tsk)
= 0.0181 N/mm2
Min. tensile stress
Ftmax = (41.2 37.27)/tsk
Ftmax = 3.93/tsk N/mm2
Permissible tensile stress = 1400 N/mm2
tsk = 130/1400
= 0.929 mm
Min. compressive stress
Fcmax = (41.2 + 37.27)/tsk
= 78.47 /tsk N/mm2
Fcpermissible < (1/3) yield point
< 200/3 = 66.6 N/mm2
tsk = 78.47/66.6
= 11.78 mm
Use thickness of 12 mm
Skirt bearing plate
Assume bolt circle diagram = skirt dia. + 32.5 cm
= 332.5 cm
Compressive stress between bearing plate and concrete foundation.
fc = (W/A) + (MW/z)
= (351153.27/A) + (0.7*1285*39.82/2*z)
= 1.22 N/mm2
Mmax = fc*bl2/2
= 1.22*162.52/2
f = 6Mmax/btb2w
tb = 24.81 mm > 20mm
So, a bolting chair can be used.
Anchor bolts:
Min. wt. of the vessel = 350403.27 N
Fo = (Wmin/A) (Mw/z)
= -0.91 N/mm2
Since it is negative, the vessel skirt must be anchored to concrete foundation by an anchor
bolt.
24 bolts should be used (Since 3000mm dia. is max. for 24 bolts)
Ab = 1/Nb*fb[(4Ms/Db)-W]
= 1/(24*1.22)[(4*1254/332.5) 351153.27]
= 182.52 mm
2
Bolt Diameter = D
b
= (4 A
b
/)
= (4*182.52/3.14)
= 15.24 mm
Nozzle Design
For Nozzle Gas Inlet Gas Outlet
Nozzle 1 2
diameter (m) 0.45 0.3
pressure (N/m^2) 1961331 1961331
all. Stress f (N/m^2) 98000000 98000000
thickenss of nozzle
(m)
0.00570012
0.00380008
design thickness (m) 0.00770012 0.00580008
thickness (mm) 7.7 5.8
shell dia (m) 3 0.3
thickness of shell
(m)
0.02
0.02
head thickness 0.03 0.03
As (m^2) 0.0417556 0.0042256
A' (m^2) 0.0018614 0.0012464
Ho (m) 0.050870424 0.033988233
Hi (m) 0.040985363 0.023392306
Ao (m^2) -1.218E-08 -5.42526E-09
Ai (m^2) 0.000303292 8.42123E-05
Ar (m^2) -0.04019748 -0.003063407
Tr (mm) -92 -12
Ring pad req. no No
Flange Design
f
fa
= permissible tensile stress in flange under atmospheric conditions
f
fo
= permissible tensile stress in flange under operating conditions.
f
ba
= permissible tensile stress in bolt under atmospheric conditions
f
b0
= permissible tensile stress in bolt under operating conditions.
N
min
= minimum gasket width
Nozzle-
Design pressure
nozzle Diameter
=
=
1.029 (N/mm
2
)
450 (mm)
j Welded shape factor = 0.8
thickness of nozzle(mm) = 5 mm
ya (min gasket seating stress) = 124.11 N/mm
2
m(min. gasket factor) = 5.5
shell diameter (mm) = 3000 Mm
gasket inside dia Gi (mm) = 450 Mm
f
fa
=
129
N/mm
2
f
fo
= 113.76 N/mm
2
f
ba
= 103.42 N/mm
2
f
bo
= 86.87 N/mm
2
N
min
= minimum gasket width
N
min = (Go-GI)/2
N
min
(mm) = 15.5
N
=
Nmin + 0.005 cm
N(mm) = 15.505
Go/Gi
=
(Y-pm/Y-(m+1)*p)
0.5
Go = ((Y-pm/Y-(m+1)*p)^0.5)*Gi
Gi = 300 mm
gasket outside dia Go
1
(mm) = 451.9674419 mm
gasket outside dia Go
2
(mm)
=
2*Nmin+Gi
gasket outside dia Go
2
(mm) = 481 mm
Go(mm) = 481 mm
b
0
= basic gasket seating width
Bo = N/2
bo(mm) = 7.7525
bo>6.3mm then b=(bo/2)^0.5
b(mm) = 1.392165579 mm
G
=
(Gi+Go)/2
G(mm) = 465.5 mm
Hp= force required to keep gasket from leaking
Hp = (2b)Gmp
Hp(N) = 23032.88213 N
H=
total hydrostatic force
H
H(N)
=
=
/4*G
2
*p
175034.7998 N
BOLT LOAD CALCULATIONS
b
Exists under the operating condition Wm1
W
m1
= H+Hp
W
m1
(N) = 198067.6819 N
Because of tightening up of the bolts Wm2
W
m2
= 3.14*G*b*Y
W
m2
(N) = 252549.7836 N
calculation of Minimum Bolting Area Required (A
m
)
A
m1
= W
m1
/f
bo
A
m1
(mm
2
) = 2280.046989 mm
2
A
m2
= W
m2
/f
ba
A
m2
(mm
2
) = 2441.98205 mm
2
A
m
= maximum of Am1&Am2
A
m
(mm
2
) = 2441.98205 mm
2
Bolt calculation (A
b
, d
b
)
Actual cross sectional area of bolt should not exceed
A
b
= 2*3.14*Y*G*N/f
ba
A
b
(mm
2
) = 225.8 mm
2
number of bolts.
N = A
m
/A
b
N = 10.81480093
n
1
= 12
Bolt Diameter(d
b
)
A
m
= 3.14/4*d
2
D
b
= (A
m
*4/3.14)
0.5
d
b
(mm) = 16.10073797 mm
g
1
= 1.5g
o
g
1
(mm) = 7.5 mm
R = (G-Do)/2+10+d
b
/2
R(mm) = 20.5 mm
Bolt circle diameter (C)
C
1
=
ID+2(g
1
+R)
C
1
(mm) = 506 mm
Bolt Spacing (B
s
)
B
s
=
3.14*C
1
/n
1
B
s
(mm) = 132.4033333 mm
thickness from baffle spacing
t
f1
t
f1
(mm)
=
=
(B
s
-2*d
b
)*(m+0.5)/6
100.2018574
mm
E = edge clearance, mm
E(mm) = 20.4 mm
Outside Diameter of Flange(DFo)
D
Fo
=
D
fo
(mm)
=
=
C + 2E
546.8
mm
H*G (mm^2)
=
81478699.3
mm
2
hG = Radial distance fro
H
g
h
G
(mm)
m gasket lo
=
=
ad reaction to bolt circle
C-G/2
20.25
mm
W
m
= total bolt load
W
m
=
max(w
m1
,w
m2
)
W
m
(N) = 252549.7836 N
K
K
=
=
1/(0.3+(1.5*W
m
*h
g
/H
G
))
2.537106732
Flange thickness
T
f
t
f
(mm)
=
=
G*(P/K*f)^0.5+C
27.79477816
mm