Portfolio DCIII

Column specification

The design of this column is followed the standard and codes of design of the American Society
Mechanical Engineering (ASME) codes. The diameter of the plate is calculated by using the steps
used in the plate hydraulic design. The General ASME Code guidelines used in the design for each of
the section are as follows.

 Column diameter : standard head size (NPS)

 Column thickness : ASME BPV Code
 Piping size around Column : ASME B36.10 sizing
 Domed head size : ASME BPV code

Analysis of the Design Stress.

This section will focus on the mechanical design of the distillation column. The detailed
mechanical design of processing equipment will not be usually carried out by chemical engineers. It
is usually mechanical engineers who are responsible for this. However, in this section of the report
certain aspects of the mechanical design will be investigated including; shell thickness, skirt design
and weight of plates. In order to carry out the mechanical design certain assumptions and
specifications have to be stated. They are as follows:

Height : 13 m
Diameter : 1295 mm
Operating Pressure : 1 bar (101.325 kPa)
Operating Temperature : 406 K
Material of construction : Stainless steel 304
Corrosion Allowable : 4 mm
Maximum allowable stress : 93.9 N/mm2
Skirt Support, height :3m
Insulation, mineral wool : 75 mm thickness
Sieve plate, equally spaced : 16 trays

Column analysis subjected to the internal pressure:

 Thickness specification is calculated as follows:
Assume the design pressure as 10% higher than the operating gauge pressure,

= 1.01 kpa x 1.1 = 1.111 Bar / 0.111 N/mm2.

With reference to Sinnot & Towler (2009), the allocated allowable stress obtained by
interpolation is 93.1 N/mm2.

A) Cylindrical Section
ASME BPV code section (Viii D.1 part UG-27) is used to calculate the minimum wall
thickness that is required by the cylindrical section. The joint efficiency is set to
E =1.0, taking formed head by pressing with no joint in the head or welds.

For circumferential stress,

ρi D i (0.111)(1.295)
t= = =0.766 mm
2 SE−1.2 ρi 2 ( 93.9 )( 1 ) −1.3(0.111)

For longitudinal stress,

ρi D i (0.111)(1.295)
t= = =0.379 mm
4 SE−0.8 ρi 4 ( 93.9 ) ( 1 )−0.8(0.111)

Thus, t=0.766 mm will be note as the minimum wall thickness of the section and the
addition of 4 mm will be from the corrosion allowable. Thus, the total t is,
t=0.379+ 4+ 0.766=(5.145) mm

The ASME BPV code (sec Viii D.1) shows the minimum wall thickness of 1.5 mm not
including the corrosion is to be applied in this column. According to Sinnot & Towler (2009),
vessel that have the diameter of 1 to 2 m , the minimum thickness allowed should not be less
than of 5.0 mm including the corrosion allowance with respective with the vessel dimension
and material used for the construction. Hence, a wall thickness of 0.766 mm is chose to
accommodate the minimum value required.

Vessel Diameter Minimum Thickness

1 5
1 to 2 7
2 to 2.5 9
B) Domed Head Section

i) Trying for a standard dished head (torisphere)

In Accordance with ASME BPV code (Sec.Viii D.1 Part UG-32), the minimum thickness for
the torisphere head can be calculate by using the following formula:

0.885 P i Rc 0.885(0.111)(1295)
t= = =1.366 mm
SE+ 0.1 Pi (93.1)(1)+ 0.1(0.111)
Where,
Rc = Column Diameter
Crown radius: Knuckle Radius ratio is 0.06: 1.00

ii) Trying for Standard Ellipsoidal head

In Accordance with ASME BPV code (Sec.Viii D.1 Part UG-32), the standard Ellipsoidal
head can be calculated by using:

Pi Rc ( 0.111) ( 1295 )
t= = =0.7655 mm
2 SE+0.2 Pi 2 ( 93.1 ) ( 1 )+ 0.2 ( 0.111 )
Where,
Ratio of major: minor axes = 2:1
∴ Ellipsoidal head is chose as the domed head since it is more economical compared to
dished head.

Analysis of column Subjected to external Pressure:

The critical pressures that will cause buckling are calculated as follow:
a) Cylindrical Shell

Given that,
Poisson’s Ratio, v = 0.3
Young’s modulus, EY = 200,000 N/mm2
External Diameter, D o =D i+ 2t =1295+2 ( 9.53 ) =1314 mm
Critical Pressure,
 t 9.53 ❑
Pc =2.2 EY ( )
Do
=2.2 ( 200,000 ) (
1314.06 )
=143 N /mm 2

b) Vessel Head

For the Ellipsoidal head, the radius can be taken as the maximum radius of the curvature,
since the radius of the curvature of an ellipse is not constant, the use of the maximum will
oversized the thickness required which is given as:

a2
R s=
b

Where,
2a = D o= Major axis
2b = 2h = Minor axis
h = Height of the head from the tangent line.

(657)2
R s= =333.3
1295

Critical Pressure,
t 2 9.53 2
Pc =1.21 EY ( )
Rs
=1.21 ( 200,000 ) (
333.3 )
=197.85 N /mm2

Analysis of column Subjected to Combined Loading.

Pressure vessel must be designed to withstand the worse combination of loading without failure. A
trial thickness is assumed and the resultant stresses from the load were determined to ensure that the
maximum allowable stress intensity is not exceeded at any point. The main sources of load to consider
are as follows:

 Pressure
 Dead weight of vessel and content
 Wind

a) Weight Loads
The major sources of dead weight load includes the vessel shell, the vessel fitting and internal
fitting and the insulation.

Taking the vessel thickness as uniform at the average thickness of t = 9.53 mm

w v =C w π ρm D m g ( H v + 0.8 D m ) t ×10−3

( 1.15 ) π ( 8000 )( 1.3 ) ( 9.81 ) ( 13+ 0.8 ( 1.3 ) ) × 9.53 ×10−3=42.29 kN

Where,

w v =¿ Total weight of the shell, excluding internal fitting, such as plates, N

C w =¿ 1.15 for distillation column, or similar vessels, with several manways and with plate
support rings or equivalent fitting.

H v =¿ Height or length, length of the cylindrical section, m

g=¿ Gravitational acceleration, 9.81 m/s2

t=¿ Wall thickness, mm

ρm =¿Density of vessel material, kg/m3

Dm =¿ mean diameter of vessel = ( D i +t × 10−3 ¿ ,m

Weight of plate

π π
Plate area = Ap = = ( 1.295 )2=1.31713 m 2
4D 4
2

Weight of plate including fluid on it, w p ≈ 1.2 A p

= 1.2 (1.31713)

= 1.58 kN

For 16 plates, wp = 16 x 1.58 kN

 = 25.28 kN

Weight of insulation:

Mineral wool density, ρi=130 kg/m 3

Approximate insulator volume, Vi = πD H v t i=π (1.295 )( 13 ) ( 0.075 )=3.356 m 3

Weight of insulator, wi = ρi v i g=130 ( 3.356 ) ( 9.81 )=4279 N

Doubling this weight to allow fitting, wi = 2 x 4.28 kN = 8.56 kN

Total dead weight, Wd =w v +w p+ wi=42.29+25.28+8.56=76.13 kN

B) Wind loads (tall vessel)

A column is designed to withstand the highest wind speed that is likely to be encountered at the site
during the life of the plant. The plant location is at Selangor which is rarely to experience wind speed
more than 12 m/s (30 km/h). even so, Malaysia are experience the highest wind speed during the
monsoons and can reach up to 30 knots which is (55.56 km/h) as reported by Malaysia meteorology
department.

Wind speed, uw = 55.56 km/h

Wind pressure, Pw = 0.05 uw 2=0.05 ( 55.56 )2
154.35 N/m2
Mean diameter including insulation, D m , i = 1.295 + 2(9.53 + 75x10-3)
1.46406 m
Loading (per linear meter), F w = Pw D m ,i =154.35 ( 1.46406 )
225.978 N/m
Bending moment at the bottom, m = F w H 2v 225.978 (13)2
=
2 2
13671.669 Nm

C) Analysis of stress

At the bottom, t = 9.53 mm

Pressure stresses:

P Di 0.111(1.295× 103)
σl= =
4t 4 ×9.53
 = 3.7708 N/mm2

P Di 0.111(1.295× 103)
σ h= =
2t 2× 9.53

= 7.513 N/m2

Dead weight stress:

wv 13671.669
σ w= =
π ( D i +t ) t π ( 1295+ 9.53 ) 9.53

= 2.801 N/mm2

External Diameter:

D o =D i+ 2t=1295+ ( 2+ 9.53 )=1314 mm

Bending stresses:

π π
I v= ( D o4 −D i4 ) = ( 13144 −12954 )
64 64

= 8.282 x 109 mm4.

m Di 13671.669 1295
σ b=±
Iv 2(+2 = )
8.282 x 10 9 2
+9.53 ( )
= ± 1.651x10-6 (657.03)

= ± 1.085 N/mm2

The resultant longitudinal stress is:

σ z=σ L +σ w ± σ b

σ zis the compressive and therefore negative:

σ z (Upwind) = 3.7708 – 1.082 + 1.085 = 3.7738 N/mm2

σ z (Downwind) = 3.7708 – 0.801 – 1.085 = - 0.1142 N/mm2

As there is no torsional sheer stress, the principal stresses will be σ zand σ h. Thus the radial stress is

negligible, ( Pi /2 ¿=0.5 N /mm2

 3.778 -0.11

7.53 7.53

Up- wind Down-wind

The greatest difference between the principal stresses will be on the downwind side:

(7.53 – (- 0.11)) = 7.64 N/mm2 well below the maximum allowable design stress.

D) Hydraulic testing Case.

Under the hydraulic test condition, the vessel is filled with water and thus the dead weight load will be
greater during the test.

Take the density of water as ρwater =1000 kg /m3

The maximum weight of water in the vessel excluding the volume of vessel internal is:

π
w w= ρg(3 D 2i −2 D 3i )
12

π
w w= (1000)(9.81)¿
12

New total dead weight, wd

w d =w v + w p + wi +w w

w d =42.29+25.28+ 4.28+153.286

w d =225.76 kN

New dead weight stress, σ w

 d 225.136 kN
σ w= = =5.75 N /mm 2
π ( D i +t ) t π ( 1295+ 9.53 ) 9.53

The new resultant Longitudinal stress, σ w

σ w ( upwind )=3.7738−5.76+1.085=−0.9012 N /mm2

σ w ( downwind )=3.7738−5.76−1.085=−3.0712 N /mm2

-0.9012 -3.072

7.4 7.4

upwind downwind

The different between the principal stresses during the hydraulic test is on the downwind side:

= 7.4 – (-3.072)

= 10.472 N/mm2

e) Elastic Stability check (Buckling)

Critical bucking stress

σ c =2× 104 ( Dt )=2× 10 ( 1314

o
9.53
4
)=145.05 mmN 2
Maximum Compressive Stress when the vessel is not under pressure

= 2.801 + 1.085

= 3.886 (well below the critical buckling stress)

Hence, the design is satisfactory

Vessel Skirt support design

Straight cylindrical skirt design

Height = 3m
Material of construction = Carbon steel
Maximum allowable stress = 89 N/mm2
Young’s modulus = 200,000 N/mm2

The maximum dead weight load on the skirt support is occurs when the column is under hydraulic
test.

Total dead weight load:

Wd = 76.13 + 153.286 = 229.416 kN

Bending moment at the base of skirt:

F w H 2s 225.978 (3 )2
ms = = =20135
2 2

Taking the skirt thickness as the same as the base section of the column

4 ms
σ bs =
π ( D s+ t s)t s D s
 4 (20135)
σ bs = =1.875 N /m2
π (1295+15) 15(1295)

Dead weight stress in the skirt,σ ws

wd
σ ws (Hydraulic Test )=
π (D s +t s )t s

229.416 kN
σ ws= =3.716 N /m2
π (1295+15)15

wd
σ ws (Operating Test )=
π ( D s +t s)t s

76.13 kN
σ ws= =1.233 N /m2
π (1295+15)15

Maximum σ s (compressive)

= 1.875 + 3.716
= 5.591 N /m 2
Maximum σ s (Tensile)
= 1.875 + 1.233
= 0.642 N / m 2

Take the joint efficiency as E: 0.85, the criteria for the design is

σ s (Compressive) < 0.125 EY (ts / Ds) sin θ

5.4001 < 0.125 (200,000) (15/295) sin 90

5.4001 < 289.57

σ s (Tensile) < Ss E sin θ

0.4372 < 89 (0.85 sin 90)

0.4372 < 75.65

Thus, both Criteria are fulfilled and satisfied

EQUIPMENT COST ANALYSIS

The estimation of equipment cost is made by using the correlation that is found in the Chemical
engineering Design book by sinnott & Towler (2009). These data is act as a preliminary estimator for
the equipment’s cost and the correlation is as follows:

C e =a+bS n

Where,

C e =¿Purchased equipment cost on a US Gulf Coast basis, Jan.2007 (CE index (CEPCI) = 509.7,
NF refinery inflation index = 2059.1)
a , b = Cost constants
S = Size parameter
N = Exponent for specific equipment

Equipment Specification
Height: 13 m
Diameter: 1.295 m
Thickness : 5.145 mm
Distillation Column Material: 304 stainless steel (Density: 8000
kg/m3)
Shell mass, π D c Lc t w ρ=¿ : 1841.9 kg
Tray type: Sieve type
Trays Number of tray: 16
Diameter:1.275m
Heat exchanger type: Shell and Tube
Heat Exchanger Inlet Heater Heat Exchanger Area = 12.0 m2
Condenser Heat Exchanger Area = 25.5 m2
Reboiler Heat Exchanger Area = 27.5m2
Type of pump: Single-stage Centrifrugal
Inlet pump flow rate: 2.3 L/s
Pump Reflux pump flow rate: 2.0 L/s
Reboiler pump flow rate: 0.35 L/s
Table 5-1: Purchased equipment costs for Distillation column unit

No Equipment Description Unit for size Size parameter, s Avg.S Constant n Cost/unit , $ Price, $
lower upper a b
1 Distillation Vertical, ss304 Shell mass, kg 160 250,000 1841.9 15,00 68 0.85 1 302,068
0
2 Trays Sieve tray Diameter. m 0.5 5 1.275 110 380 1.8 16 11,175
3 Inlet Heater Shell and tube Area, m2 1 500 12 1350 180 0.95 1 3257
4 Condenser Shell and tube Area, m2 1 500 25.5 1350 180 0.95 1 5253
5 Reboiler Shell and tube Area, m2 1 500 27.5 1350 180 0.95 1 5544
6 Inlet pump Centrifugal Flow, L/s 0.2 126 2.3 6900 206 0.9 1 7335
7 Reflux pump Centrifugal Flow, L/s 0.2 126 2.0 6900 206 0.9 1 7284
8 Reboiler pump Centrifugal Flow, L/s 0.2 126 0.3 6900 206 0.9 1 6969

Total estimated PCE 34888

By referring to Sinnott & Towler ,(2009), the cost estimation in 2019 is made based on CEPCI
From appendix 1,
Index in 2003: 440
Index in 2007: 550
By extrapolating from the period 2003 to 2008, the M&S index for 2019 will be about 875.28
Thus,
Estimated cost in 2019 = $34888 x 875.28/550
= $ 55521
 Location Factor

From Appendix, the 2003 location factor for Malaysia (SE Asia) was 1.12. The exchange rate
in 2003 averaged RM1 = USD 3.758 and in 2019 it averaged about RM 1 = 4.09

The location factor for Malaysia is thus,

4.09
1.12 × =1.219
3.758

The cost of building distillation column unit III in Malaysia in year of 2019 is:

55,522× 1.219=RM 67,680

Fixed Capital

Table 5-2: fixed capital cost for fluid type of plant

No Items Process type (fluid)
1 fer Equipment erection 0.3
2 fp Piping 0.8
3 fi Instrumentation and control 0.3
4 fel Electrical 0.2
5 fc Civil 0.3
6 fs Structures and building 0.2
7 fl Lagging and paint 0.1
8 fm material cost factor relative to plain carbon 3.3
steel
9 Offsites (OS) 0.3
10 Design and Enginerring (D&E) 0.3
11 Contigency (X) 0.1
ISBL cost, C ∑Ce × [(1 + fp)fm + (fer+fel+fi+fc+fs+ fl)] 496, 771
OSBL cost,Co 30% of ISBL, C cost 149,031
Total fixed C(1+OS) (1 + D&E +X) RM 904,123
capital cost, Cfc