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PLANT DESIGN FORSULFURIC ACID
MANUFACTURECHU492 PROJECTHarshadul Faseem.P
Minas. VPMuhammed Dhanish
Guide: Dr.Lity Alen Varghese
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CONTENTS
Objectives
The Process
Design of absorber 1
Design of acid cooler
22
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OBJECTIVES
Design a plant for manufacturing sulfuricacid with a capacity of 1000 tones/day of98% sulfuric acid
Optimization of processes
Maximize the heat recovery
3
3
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Process Flow Chart
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DESIGN OF ABSORBER 1
Used to absorb SO3 obtained fromthird stage of the reactor
Absorption with chemical reaction 98% sulfuric acid itself is the
absorbent
Water present in the 98 % sulfuricacid is converted to H2SO4
Since the reaction is the absorption is
purely gaseous phase controlled
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On the basis of literature study onecan choose a packed tower
Packing properties
intalox, flexi saddle Nominal size ;75mm
Bulk density ;576 kg/m3
Surface area ;92 m2/m3
Packing factor ;72
Voidage ; 79
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5/7/12 Metal Intalox saddles
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General design data
gas liquid
Inlet flow rate(Kmol/hr)
3973.147 2450.718
Outlet flow rate(Kmol/hr)
3727.43 2450.718
Inlet temperature(o C ) 120 30
Outlet temperature(o C
)
104 104
Density(kg/m3 )
1.035 1776.15
Viscosity(Pa.S)
2.772x10-5 6x10-3
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Process Design
Assumptions
Isothermal condition
Design pressure drop is 45mm H2O/m Purely gaseous phase controlled
absorption
Absorption occur at 1 atm % flooding: 54
Cross sectional area of packing: 9.68
m2
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Height of packing calculation
The average mass transfer coefficient iscalculated as 1.334 kmole/m2 hr atm
Packing height : 6.8 m
The total height of the absorption
column is 9.7m
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Mechanical design
Process specifications
Inner diameter of :3.51 m
Height :8.8 m Operating conditions
Inside pressure: 1 atm
Maximum temperature : 130oC
Material
Carbon steel
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c ness o e s e
Thickness of shell, ts = [p Di / (2f J
p)] Where
Inner Diameter of vessel, Di = 3.51m
Design Pressure, p =0.10635 N/mm2
Permissible Stress = 95N/mm2
Joint Efficiency, J = 0.85
ts= 2.29 mm
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Maximum height of tower
A uniform thickness of 8mm isassumed to the shell
Permissible stress of material = 95N/mm2
Maximum height can be found by
equating maximum permissiblestress of the material to the sum ofall stress loads acting at the bottom
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Stress analysis
Axial stress due to pressure Stress due to dead load
Compressive stress due to weight of
shell Compressive stress due to weight of
insulation
Compressive stress due to liquid in thecolumn
Stress due to wind
Compressive stress due to attachment
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Column Internals
Packing suppot
Gas-injection packing support
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Liquid distributor
Weir type liquid distributor
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Mist eliminator
Mist eliminator
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Vessel support
Skirt support is chosen
Design considerations
Bending stress by wind ( ) Weight stress in test loading ( )
Weight stress in operation ( )
Material to be used : structural steel(IS 800)
Skirt support with 2m ht and 8mm
thickness is found to be satisfactory
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The proposed design
Diameter of the shell :3.51m
Thickness of the shell :8mm
Height of shell :9.7 m Intalox saddles packing
Height of the packing 6.8m Skirt support with 2m ht and
8mm thickness
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ACID COOLER
GASKETED PLATE HEAT EXCHANGER The plate-and-frame or gasketed plate
heat exchanger (PHE) consists of a
number of thin rectangular metal platessealed around the edges by gaskets andheld together in a frame
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The frame usually has a fixed end
cover (headpiece) fitted withconnecting ports and a movable endcover (pressure plate,follower, ortailpiece)
Advantages
Easy to clean
Heat transfer area can be readilychange
Fouling is less
Higher heat transfer coefficient
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Limitations
Capable of handling up to 3Mpapressure only
They also limit the maximum operatingtemperature to 2600C
Gasket life is sometimes limited
They are not suited for high-vacuumapplications
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e es gn
Design conditions
Assumptions Flow is counter current
Overall heat transfer coefficient predicted as 5000W/m2K
Fluid Flow rateKg/s
Inlettemperature
Celsius
Outlettemperature
Celsius
Sulfuric acid 126.35 101.2 30Water 126.21 25 50
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Design data
Heat duty 131830 kW
Heat transfer area 141.23 m2
Overall heat transfercoefficient
5895 W/m2K
Pressure drop 15.68 bar
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Proposed design
Number of plates =117
Plate material = titanium
Plate spacing = 7mm Length of the plate = 1.2m
Width of the plate = 1m
Thickness of the plate = .5 mm
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FUTHER STEPS
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REFERENCES
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THANK YOU