Process Equipment Design: 3 CR

Codes such as: ASTM=American Society of Mechanical Engineers; API=American Petroleum Institute

Brownell, L.E., and Young, E. H., 1959, Process Equipment Design: Vessel Design, Wiley Eastern Limited, New Delhi
1. Vessel/Shell Factors influencing the design of vessels a. Selection of the type of Vessel Type of vessel that is suited for particular service b. The most common types of vessels based on their geometry are: i. Open tanks ii. Flat bottomed, vertical cylinder tanks iii. Vertical cylindrical and horizontal vessels with formed heads iv. Spherical or modified spherical vessels Vessels in each these classifications are widely used as storage vessels and as processing vessels for fluids c. Primary factors that must be considered as follows i. Function and location of vessel ii. The nature of the fluid iii. Operating pressure and temperature iv. Volume of storage or capacity for processing

Coulson, J.M., and Richardson, J.F., 1983, Chemical Engineering Volume 6 (SI Units) Design, Pergamon Press, Oxford p. 622, Chapter 13; Mechanical Design of Process Equipment
The basic data needed by the specialist designer will be:
a. b. c. d. e. f. g. Vessel function Process materials and services Operating and design temperature and pressure Materials of construction Vessel dimensions and orientation Type of vessel heads to be used Openings and connections required

h. Specification of heating and cooling jackets or coils i. Type of agitator j. Specification of internal fittings Classification of pressure vessels are divided into two classes: thin walled vessels with a thickness ratio of less than 1:10; and thick walled above this ratio

General design considerations: pressure vessels

a. Design pressure Pdesign = (1.5-1.1) Poperating ; If hydrostatic pressure in the base of the column should be added to the operating pressure, if significant b. Design temperature The strength of metals decreases with increasing temperature, so the maximum allowable design will depend on the material temperature c. Materials Carbon and alloy steels for pressure vessel construction are covered by the following British Standards: BS 1501, plate etc. d. Design stress (nominal design strength) For design purposes it is necessary to decide a value of the maximum allowable stress that can be accepted in the material construction. For materials not subject to high temperature the design stress is based on the yield stress or the tensile strength of the material at design temperature e. Welded joint efficiency, and construction categories The strength of a welded joint will depend on the type of joints and the quality of the welding. The soundness of welds is checked by visual inspection and non-destructive testing (radiography) f. Corrosion allowance Most design codes and standards specify a minimum allowance of 1.0 mm. For carbon and low-alloy where severe corrosion is not expected, a minimum allowance of 2.0 mm should be used; where more severe conditions are anticipated this should be increased to 4.0 mm. g. Design loads A structure must be designed to resist gross plastic deformation and collapse under all conditions of loading. Major loads 1. Design pressure including any significant static head of liquid; 2. Maximum weight of the vessel and contents, under operating conditions;

3. Maximum weight of the vessel and contents under hydraulic test conditions 4. Wind loads 5. Earthquake loads 6. Load supported by, or reacting on, the vessel Subsidiary loads 1. Local stresses caused by supports, internal structures and connecting pipes; 2. Shock loads caused by water hammer, or by surging of the vessel contents; 3. Bending moments caused by eccentricity of centre of the working pressure relative to the neutral axis of the vessel; 4. Stresses due to temperature differences and differences in the coefficient expansion of materials; 5. Loads caused by fluctuations in temperature and pressure h. Minimum practical wall thickness (Including the corrosion allowance, 2 mm) Vessel diameter (m) Minimum thickness (mm) 1 5 1 to 2 7 2 to 2.5 9 2.5 to 3.0 10 3.0 to 3.5 12

The design of thin-walled vessels under internal pressure

a. Cylinder Shells P (D ) t = i i ; BS 5500 dengan f , Pi , J dan Di are design 2 Jf Pi stress, internal pressure, joint factor and internal diameter, respectively. b. Spherical shells Pi ( Di ) t= ; BS 5500 4 Jf 1.2 Pi c. Heads and closures i. Flat plates and formed heads

ii. Hemispherical heads iii. Ellipsoidal heads iv. Torispherical heads d. Typical shell shapes

Ellipse

Cylinder

Cone Cylinder

Hemispherical Typical vessel shapes

Stresses in Thin Shells Based on Membrane Theory

Rase and Barrow

Rase and Barrow_3

Pada leeward side vessel, beban angin dan dead weight mengakibatkan terjadinya compression internal pressure (longitudinal stress) mengakibatkan terjadinya tension, sehingga berlawanan dengan compression

S = Sw + S0 S p

(R_14)

Allowable stress untuk buckling sama dengan stress karena beban angin dan dead weight

SB = Sw + S0

(R_16)

56

Rase and Barrow_4

Donell memberikan persamaan empiris sebagai berikut:

0,6 t 107 R = E E 1 + 0,004 S y

R t

(R_17)

57

Rase and Barrow_5

Jorgensen, menyerderhanakan rumus (R_4) untuk baja karbon (usual carbon steel) (R_18)

= 2 x1 0

t D

58

Rase and Barrow_6

Windward allowable stress Leeward allowable stress Buckling stress Circumferential stress API_ASME CODE: ASME CODE
t= 2 Pw h 2 PDm W + D ' S Dm S 4 S

t=

2 Pw h 2 PDm W + D ' S Dm S 4S

t=

2 Pw h 2 W + D ' S B Dm S B

t=
t =

PD1 +c 2 SE P

P D1 +c 2 S E 0, 6 P
59

Brownell, L.E., and Young, E. H., 1959, Process Equipment Design: Vessel Design, Wiley Eastern Limited, New Delhi
Flat Bottomed Cylindrical Vessels

Optimum tank proportions

Vessel (bejana) (bejana)

Perbandingan diameter (D terhadap tinggi (H) terletak diantara dua nilai:

Batas bawah untuk: (D/H) optimum untuk:

( cost of shell,bottom, roofs per unit area) f (D, H)

Hal ini terjadi bila tangki volumnya kecil, hanya elastic kecil, stability dan corrosion allowance yang mengendalikan tebal shell

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Vessel (bejana) (bejana) Batas atas untuk:(D/H) optimum untuk:(D/H)

t = f ( D, H )

Bila tebal shell sebagai fungsi d, H (

),

dan unit area costs of the bottom dan roofs tidak tergantung pada D dan H

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Vessel (bejana) (bejana)

Misalkan:
D diameter dalam tangki, ft tangki, H tinggi tangki dalam, ft dalam, V volum tangki dalam, ft3 dalam, Volum tangki tertentu, sehingga H merupakan fungsi D tertentu,

V =
2/21/2013

D2 H
4

atau

H =

4V D 2
85

Vessel (bejana) (bejana)

Bila:
A1=luas shell, ft2, A2=luas bottom (projected area), ft2, C1= annual cost of fabricated shell, $/ft2 C2= annual cost of fabricated bottom, $/ft2 C3= annual cost of fabricated roof, $/ft2 C4= annual cost of installed foundation under the vessel, $/ft2bottom C5= annual cost of land in the tank area chargeable to the tank area, $/ft2 bottom C= total annual cost of the vessel, $/year
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Vessel (bejana) (bejana)

C=

4VC1 D

D2
4

( C2 + C3 + C4 + C5 )

Jika tebal tangki

t f ( D, H )

dC 4VC1 D = 2 + ( C2 + C3 + C4 + C5 ) = 0 dD D 2

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Vessel (bejana) (bejana)

D = 2H

(C 2 + C3 + C 4 + C5 )

C1

, persam aan untuk t f ( D , H )

Tebal tidak merupakan fungsi D dan H Kasus khusus

t f ( D, H )

Tangki kecil (small tank) terbuka, harga tanah dan fondasi diabaikan. terbuka, diabaikan. Biasanya tebal shell sama dengan tebal bottom. Jika C3 = C4 = C5 = 0 dan ,
C1 = C2 didapat

D = 2H

Tangki kecil (small tank) tertutup harga tanah dan fondasi diabaikan, berarti diabaikan, nilai C4 = C5 = 0 dan, C1 = C2 = C3 didapat dan,

D=H
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Vessel (bejana) (bejana)

Jika tebal tangki

t = f ( D, H )
C1 = C6 ( H 1) D

C=

4V C6 ( H 1) D D

D2
4

( C2 + C3 + C4 + C5 )
4V D 2

H diganti dengan

H =

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Vessel (bejana) (bejana)

C = 4VC6

D2 4V 4VC6 + ( C2 + C3 + C4 + C5 ) 2 4 D

32C6V 2 2 D dC = 0+ ( C2 + C3 + C4 + C5 ) = 0 2 4 dD D
Didapat, hubungan diameter dengan tinggi tangki sebagai berikut

D = 4H

( C2 + C3 + C4 + C5 )

C1

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Vessel (bejana) (bejana)

Tangki besar tertutup , atap dan shell harganya dua kali harga bottom, C1 = 2C2 = C3 dan C4 = C5 = 0 didapat
D = 4H 8 = H ( C2 + 2C3 + 0 + 0 ) 3 2C2

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Vessel (bejana) (bejana)

Shell design of small and medium sized vessels (production tanks) pp.43 B&Y.
Vertical flat bottoms disebut production tanks. Tebal sama (single thickness). Ukuran optimum:d (diameter=H(tinggi) (diameter=H(tinggi) Lihat fig:3.7 dan tabel 3.3 (B&Y, pp.43-44) pp.43Tebal:3/16 or , lebar flat 60

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Vessel (bejana) (bejana)

Shell design of large storage tanks (pp.34 B&Y).

Tanks bentuk silinder, great structure strength silinder, dan mudah dibuat Several types of stresses yang mungkin terjadi pada tangki bentuk silinder: silinder: Longitudinal stress internal pressure Circumferential stress internal pressure Residual weld stresses localized heating
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Vessel (bejana) (bejana)

Stresses superimposed loads seperti: wind, snow, and ice, auxiliary equipment, and impact loads Stresses karena thermal differences Others dijumpai didalam paraktek

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Proportioning and head selection for cylindrical vessels with formed heads Chapter 5, p 76With ellipsoidal head with dimension diameter of 2:1.
y y x a D H b

a=2b
Vessel (bejana) (bejana)

Dimensi Vessel
Tebal, inches Tebal, 3/16 sampai 2 L/D 6

2 sampai dengan 6

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Coulson, J.M., and Richardson, J.F., 1983, Chemical Engineering Volume 6 (SI Units) Design, Pergamon Press, Oxford p. 622, Chapter 13; Mechanical Design of Process Equipment
2. Separation Process/Separation Columns Distillation process Absorption Scrubber It will be emphasized on distillation processes due to basic features and many of the design methods also apply to other multistage processes such as stripping, absorption and extraction

The choice between packed and plate columns

Liquid-vapor transfer operation dapat dilakukan pada : Packed or plate columns o Packed column: continuous contact o Plate column: stage wise contact Both system works in different modes Pemilihan menara didasarkan pada empat(4) faktor (Barker &Hakkers): 1. Factors that depend on the system, i.e. the component, 2. Factors that depend on the fluid flow movement, 3. Factors that depend upon the physical characteristics of the column and its internals, 4. Factors that depend upon the of operation I. SYSTEM FACTORS 1. Scale: Diameter<1 m packed columnsmall tray sangat mahal. Diameter kolum yang besar, ada problem dengan distribusi zat cair dan berat menara. First estimate untuk superficial velocity sekitar 1 m/s. 2. Foaming. Froth dihasilkan karena adanya proses bubbling oleh uap melalui liquid packed tower minimizes the effect karena kontak terjadi antara uap dan cairan yang mengalir melalui permukaan packing. 3. Fouling system. Jika fluida mengandung suspensi padatan aatau sludge plate column karena padatan 4. Corrosive systems. Lebih ekonomis memakai packed tower dibandingkan dengan plate tower. Packing bisa dibuat dari keramik Bisa juga memakai bahan anti karat tetapi mungkin ada kesulitan dalam pembuatannya (plate) 5. Heat evolution. Dipilih plate column, karena tidak mungkin memasang koil pada menara packed tower.

6. Pressure drop. Lebih rendah pada packed column dibandingkan dengan plate column. 7. Liquid hold-up. Lebih kecil pada packed column dibanding-kan dengan plate column. Pada plate colum selalu ada cairan sedangkan pada packed column ada lapisan tipis cairan pada permukaan packing. II. PHYSICAL CONSIDEARTIONS 1. Maintenance. Manholes pada plate tower mudah dilengkapi, sedangkan pad packed tower harus mengeluarkan packing. 2. Berat. Penggunaan keramik atau metal pada menara menyebabkan menara menjadi lebih berat dibandingkan jika dipakai plate tower, sehingga perlu memperhatikan fondasi dan penyangga packing. Hal ini dapat diatasi dengan penggunaan packing dari plastik, karena lebih ringan. 3. Side streams. Pengambilan side streams dan pemasukan side streams lebih mudah pada plate tower, meskipun tray spacing pada tempat tersebut harus dimodifikasi. Pada packed tower hal ini tidak mungkin, karena akan mengganggu proses pemisahan. 4. Size and cost. Jika diameter lebih rendah dari 1 m, packed tower yang dipilih, karena pembuatan plate lebih mahal untuk tujuan yang sama. Diatas diameter 1 meter, tidak dapat dilakukan generalisasi. Terhadap tinggi, packed column biasanya lebih lebih pendek dibandingkan dengan plate colum untuk tujuan yang sama, meskipun plate column dapat memberikan diameter yang lebih kecil untuk kecepatan gas yang sama.

III. MODE OF OPERATION 1. Batch distillation. Liquid recovery sangat tinggi untuk komponen yang lebih ringan (dua komponen) 2. Intermittent distillation. Plate tower, karena memberikan positive seal for liquid. 3. Continous distillation. Tidak ada salah satu faktor yang dominan, semua faktor harus dipertimbangkan. 4. Turndown. Perbandingan antara loading maksimum dengan loading minimum pada kondisi flooding dan the lowest efficiency can be accepted. Untuk umpan dengan turndown ration > 2,5:1, dipilih a plate column 5. Semua faktor tersebut diatas harus dipertimbangkan dan untuk pemilihan akhir harus ada kompromi diantaranya. . IV. TIPE, UKURAN PACKING, DIAMETER MENARA DAN LIQUID DISTRIBUTOR 1. RASCHIG RINGS: ukuran packing <1/30 diameter menara. Distributor: 20ft(6m) atau (2,5-3) diameter menara mana yang lebih kecil

2. BERL OR INTALOX SADDLES:ukuran packing <1/15 diameter menara. Distributor: 20ft(6m) atau (5-8) diameter menara mana yang lebih kecil 3. PALL RINGS:ukuran packing <1/10 - 1/15 diameter menara. Distributor: 20ft(6m) atau (5-10) diameter menara mana yang lebih kecil.

Basic equations for separation column

Lewis-Sorel method (equimolar overflow) Rectifying

Stripping

URUT - URUTAN PERANCANGAN KOLOM DISTILASI

PENEKANAN PADA PROSES DISTILASI PROSES LAINNYA SEPERTI:STRIPPING, ABSORPTION DAN EXTRACTION MEMPUNYAI DESIGN METHOD DAN BASIC CONSTRUCTION FEATURES YANG SERUPA /MIRIP DISTILASI MERUPAKAN POROSES PEMISAHAN YANG BANYAK DIPAKAI PENGETAHUAN TENTANG KESETIMBANGAN SANGAT DIPERLUKAN UNTUK MERANCANG KOLUM DISTILASI ATAU PROSES - PROSES KESETIMBANGAN LAIN

PERANCGAN KOLOM DISTLASI, ABSORPSI, STRIPPING TERUTAMA TERDIRI DARI TIGA LANGKAH (PROCESS PLANT DESIGN OLEH J.R. BACKHURST DAN J.H. HARKER, 1983 ): 1. PEMILIHAN INTERNAL DEVICE : PLATE ATAU PACKING 2. JUMLAH TRAYS ATAU TINGGI PACKING 3. KALKULASI DIAMETER KOLUM CEHCK LIST OF DESIGN ITEMS FOR BUBBLE-CAP, PERPORATED, AND VALVE TRAY (DISTILLATION OLEH MATTHEW VAN WINKLE, 1967)

COLUMN 01. OPERATING TEMPERATURE AND PRESSURE 02. REFLUX RATIO 03. NUMBER OF TRAYS 04. FEED AND DRAW OFF TRAYS AND LOCATION 05. COLUMN DIAMETER 06. TRAY SPACING TRAY 07. LIQUID-FLOW ARRANGEMENT OR TRAY TYPE 08. ACTIVE AREA 09. DWONCOMER TYPE, AREA, AND CLEARANCE 10. TRAY OUTLET WEIR TYPE, HEIGHT AND LENGTH 11. TRAY INLET WEIR TYPE, HEIGHT AND LENGTH (IF ANY) 12. TRAY OUTLET SPLASH BAFFLE, ANTI JUMP BAFFLES 13. TRAY AND WEIR LEVEL TOLERANCES 14. MATERIAL OF CONSTRUCTION BUBBLE CAP 15. BUBBLE-CAP DIAMETER, NUMBER 16. CAP LAYOUT, PITCH, AND SPACING 17. SKIRT SEAL 18. STATIC SEAL 19. RISER DIMENSIONS 20. TRAY BAFFFLES 21. TRAY DRAIN HOLES 22. LEAKAGE PERFORATED 15. FREE HOLE AREA 16. HOLE SIZE, PITCH PATTERN 17. TRAY THICKNESS 18. HOLE BLANKING

VALVE 15. SIZE HOLES AND VALVE TYPE 16. NUMBER OF VALVES AND SPACING 17. TRAY THICKNESS URUT - URUTAN PERANCANGAN KOLOM DISTILASI 1. TENTUKAN SPESIFIKASI HASIL(KOM POSISI DISTILAT / BOTTOM) 2. PILIH KONDISI OPERASI ( BATCH & KONTINUE ), TEKANAN OPERASI 3. CONTACTING DEVICES ( PLATE / PACKING 4. STAGE IDEAL& REFLUKS 5. UKURAN KOLOM ( DIAMETER & JUMLAH REAL STAGE DESIGN THE COLUMN INTERNAL : PLATES, DISTRIBUTORS, PACKING SUPPORT 6. MECHANICAL DESIGN: VESSEL & INTERNAL FITTING

LANGKAH UTAMA:
1. 2. 3. 4. PERHITUNGAN JUMLAH STAGE REFLUX YANG DIPERLUKAN JIKA CAMPURAN BINER , RELATIF MUDAH JIKA MULTIKOMPONEN , KOMPLEKS & SULIT TEKANAN (P) pada puncak kolum PENDINGIN : AIR ( PEMILIHAN PERTAMA) SUHU AIR : 30 -36 DEG.C DELTA SUHU APPROACH : UMUM 20 DEG.C; AIR = 3 - 7 DEG.C SUHU DEW POINT SEKITAR 50-56 DEG.C TRIAL P; JIKA P TERLALU TINGGI PIKIRKAN PEMAKAIAN REFRIGERATION. BAHAN SENSITIF THD SUHU, P < 1 ATM P SEPANJANG KOLOM DIANGGAP SAMA ( AWAL PERHITUNGAN ), LALU DIKOREKSI SETELAH JUMLAH STAGE DIKETAHUI OPERASI VACUUM PRESSURE DROP PENTING MULTICOMPONENT SYSTEM SHORT CUT .......PRELIMANARY DESIGN SHORT CUT ...... DIBAGI DUA -PENYEDERHANAAN PLATE TO PLATE CAL. - MISALNYA : METODE HENGSTEBECK -METODE EMPIRIS - MISALNYA : KORELASI GILLILAND DAN ERBAR-MADDOX KEY COMPONENT LIGHT DAN HEAVY KEY COMPONENTS LIGHT KEY COMPONENT ( LK ) .....TOP HEAVY KEY COMPONENT (HK ) .... BOTTOM

SPESIFIKASI PRODUK JUMLAH LK DAN HK MENUJU TOP ATAU BOTTOM DIBATASI OLEH SPESIFIKASI PRODUK ADJACENT KEY COMPONENT..... BERURUTAN PADA LISTING BERDASARKAN ALPHA SPLIT KEY COMPONENT.... JIKA ADA KOMPONENT LAIN DIANTARANYA NON KEY COMPONENT YANG ADA PADA TOP DAN BOTTOM DISEBUT DISTRIBUTED COMPONENT. JIKA TIDAK ADA PADA SALAH SATU PRODUK DISEBUT NONDISTRIBUTED COMPONENT.

REFLUX R OPTIMUM = ( 1,2-1,5 ) R MINIMUM ( COLUSON DAN RICHARDSON, 1983) R OPTIMUM = ( 1,25-1,3) R MINIMUM( PERRY DAN CHILTON, 1973) PENGARUH REFLUX TERHADAP N = JUMLAH STAGE DAPAT DICARI DENGAN CARA SHORT CUT METHOD

3. HEAT EXCHANGER, DESIGN OF HEAT EXCHANGER Shell and Tube Exchanger Double pipe Exchanger 4. REACTOR Batch Flow reactor a. CSTR b. PFR c. FBR d. Semi batch reactor