1.

Fermenter Design

1.1 Material Balance

Fermenter V-101

mseed cell = 3.285 g/d mcell,out = 36.21 g/d

Fermenter V-101 ṁbroth,out = 24.042075 kg/d
ṁbroth,in = 27 kg/d ṁenzyme = 2.925 kg/d

Assuming,
Maximum specific growth rate, μ = 0.3 h-1
Specific rate of product formation, qp = 88.838 d-1
Retention time, τ = 8 hr
1 𝑥
Now, τ = 𝜇 ln 𝑥𝑓
𝑜

Where, xf = final amount of cell

xo = initial amount of cell = 3.285 g/d bacteria seed

1 𝑥𝑓
8 = 0.3 ln 3.285

Solving for xf, we get, xf = 36.21 g/d

𝑃𝑟𝑜𝑑𝑢𝑐𝑡 𝑓𝑜𝑟𝑚𝑎𝑡𝑖𝑜𝑛 (𝑘𝑔 𝑛𝑒𝑤 𝑝𝑟𝑜𝑑𝑢𝑐𝑡/𝑡𝑖𝑚𝑒) 𝑞𝑝 𝑥𝑜

Now, =
𝑆𝑢𝑏𝑠𝑡𝑟𝑎𝑡𝑒 𝑢𝑠𝑒𝑑 (𝑘𝑔 𝑠𝑢𝑏𝑠𝑡𝑟𝑎𝑡𝑒/𝑡𝑖𝑚𝑒) 𝑟𝑠

Substrate used, rs = 27 kg/day

36.21− 3.285
Product formation = 88.838 × = 2.925 kg/d
1000
36.21 − 3.285
Amount of outlet broth, ṁbroth,out = 27 – 2.925 - = 24.042075 kg/d
1000
Summary of mass balance for V-101
Components Mass in Mass out
Cell 3.285 g/d 36.21 g/d
Nutrient broth 27 kg/d 24.042075 kg/d
Enzyme 0 2.925 kg/d
Total 27.003285 kg/d 27.003285 kg/d

Doing similar calculation balance for other four fermenters can be done. These balances are
summarized in table below-

Summary of mass balance for V-102

Components Mass in Mass out
Cell 36.21 g/d 1.32522 kg/d
Nutrient broth 474.042075 kg/d 454.753065 kg/d
Enzyme 2.925 kg/d 20.925 kg/d
Total 477.003285 kg/d 477.003285 kg/d

Summary of mass balance for V-103, V-104, V-105

Components Mass in Mass out
Cell 0.44174 kg/d 97.80407 kg/d
Nutrient broth 2851.584355 kg/d 2716.197025 kg/d
Enzyme 6.975 kg/d 45 kg/d
Total 2859.001095 kg/d 2859.001095 kg/d
1.2 Oxygen Uptake Rate (OUR)

Fermenter V-101

This fermentation is undertaken at atmospheric pressure since with increasing pressure enzyme
productivity gets reduced. (from different research)

Density of Nutrient Broth = 991 g/L

Outlet mass flow rate of broth = 24.042075 kg/d

24042.075
Volume flow rate of broth = = 24.26 L/d
991

36.21
Maximum cell concentration, Xmax = 24.26 = 1.49 g/L

Now, from literature

Aeration capacity, kLa = 0.085 s-1

Oxygen solubility of broth = 8 × 10-3 kg m-3

𝑘𝐿 𝑎 × Oxygen solubility of broth

Now, Xmax = 𝑚𝑚𝑜𝑙 1ℎ 1 𝑔𝑚𝑜𝑙 32 𝑔 1 𝑘𝑔
𝑂𝑈𝑅 × × × ×
𝑔.ℎ 3600 𝑠 1000 𝑚𝑚𝑜𝑙 1 𝑔𝑚𝑜𝑙 1000 𝑔

Where, OUR = Specific Oxygen Uptake Rate in (mmol/g.h)

Xmax = Maximum cell concentration in g/m3

Putting values,

3
0.085 × 8 ×10−3
1.49 × 10 = 𝑚𝑚𝑜𝑙 1ℎ 1 𝑔𝑚𝑜𝑙 32 𝑔 1 𝑘𝑔
𝑂𝑈𝑅 × × × ×
𝑔.ℎ 3600 𝑠 1000 𝑚𝑚𝑜𝑙 1 𝑔𝑚𝑜𝑙 1000 𝑔

OUR = 51.25mmol O2/g.h

57.56 × 8 × 36.21 × 29
= L/h air
1000 × 0.21 ×1.225 ×8

= 209.22 L/h air

With similar calculation, air flow rate for the aeration of other fermenters are summarized below:

Fermenter Air flow rate, L/d

V-101 209.22
V-102 3957.36
V-103, V-104 and V-105 23636.96

1.3 Fermenter Size Calculation

(ref: Joshi and timmerhaus)

Fermenter V-101

Total outlet solution flow rate = 27.003285 kg/d

Density of the broth, cell and enzyme solution = 999.143 kg/m3

27.003285
Total outlet volumetric flow rate = m3/d
999.143

= 0.027026m3/d

= 27.026 liter/d

Outlet biomass flow rate = 36.21 g/d

36.21
Outlet biomass concentration, Cx = g/liter
27.026

= 1.3398 g/liter

Inlet biomass flow rate = 3.285 g/d

3.285
Inlet biomass concentration, Cxo = g/liter
27.026

= 0.1215 g/liter

Maximum specific growth rate, μ = 0.3 h-1

 𝜇𝐶𝑥
Dilution rate, D =
𝐶𝑥 −𝐶𝑥𝑜

0.3 × 1.3398
=
1.3398 − 0.1215

= 0.3299 h-1

= 2.6393 d-1 (considering 8 hr operating time)

𝑀𝑒𝑑𝑖𝑢𝑚 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒

Now, dilution rate, D =
𝑐𝑢𝑙𝑡𝑢𝑟𝑒 𝑣𝑜𝑙𝑢𝑚𝑒

27.026
Fermenter volume = liter
2.6393

= 10.2398 liter

Assuming 75% of the total fermenter volume will be occupied,

10.2398
VR = liter = 13.65 liter
0.75

= 0.01365 m3

Vessel shape: Typical vessels are vertical cylinders with specialized top head and bottom head.

Vessel head type: ASME 2:1 semi-ellipsoidal head

𝜋 𝐷𝑡3
Volume possessed by top and bottom ellipsoidal vessel heads = 2
24

Now, taking diameter to height ratio to be 0.5:1

𝐷𝑡 1
=
𝐻 2

𝐷𝑡2 𝜋𝐷𝑡3
So, using the volume of a cylinder and two ellipsoidal heads, VR = π 𝐻+2
4 24

𝐷𝑡2 𝜋 𝐷𝑡3
 0.01365 = π 2𝐷𝑡 +
4 12

Solving for Dt

Fermenter diameter, Dt = 0.2056 m

Fermenter height, H = 0.4112 m

𝐷𝑡
Impeller diameter, Di = = 0.06853 m
3

𝐷𝑖
Impeller length, Li = = 0.01713 m
4

𝐷𝑖
Impeller width, Wi = = 0.01371 m
5

Distance between sparger (aerator) and impeller, E = W = 0.01371 m

Sparger type: for small stirred fermenters orifice sparger (ring shaped perforated pipe) is
commonly used for better bubbling performance and less amount of blocking. Sparger holes must
be greater or equal to 6 mm diameter to prevent blocking and to minimize pressure drop.

3𝐷𝑖
Sparger ring diameter, Ds = = 0.0514 m
4

𝐷𝑡
Baffle plate diameter, Db = = 0.01713 m
12

𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑙𝑖𝑞𝑢𝑖𝑑 ℎ𝑒𝑖𝑔ℎ𝑡 × 𝑎𝑣𝑒𝑟𝑎𝑔𝑒 𝑠𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝑔𝑟𝑎𝑣𝑖𝑡𝑦

No. of agitators = 𝑡𝑎𝑛𝑘 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟

0.75 ×0.41121 × 0.999143

= = 1.5
0.2056

So, two agitators must be employed for proper and uniform mixing operation

The distance between agitators should be 1 to 1.5 times the impeller diameter. Taking an average
of 1.25Di, distance between the two agitator = 1.25 × 0.06853 = 0.08567 m

Agitator is commonly located at a height not less than one agitator diameter length from the bottom
of the vessel. So, minimum distance between the bottom of vessel and agitator = Di = 0.06853 m

The blade angle for pitched-blade turbine agitators varies between 30o to 60o. For V-101,
considering small amount of fluid the blade angle is taken as 30o. For rest of the fermenters the
blade angle is chosen as 45o considering higher amount of liquid.

All these parameters for other four fermenters are summarized in the following page.
 Fermenter V-103,
Dimensions Fermenter V-101 Fermenter V-102
V-104 and V-105

Volume VR, L 13.653 171.988 703.341

Fermenter diameter, Dt, in 8.095 18.835 30.120

Fermenter height, H, in 16.189 37.669 60.239

Impeller diameter, Di, in 2.698 6.278 10.040

Impeller blade length, Li, in 0.675 1.570 2.510

Impeller blade width, Wi, in 0.540 1.256 2.008

Distance between sparger and

0.540 1.256 2.008
impeller, E, in

Baffle plate diameter, Db, in 0.675 1.570 2.510

Sparger ring diameter, Ds, in 2.024 4.709 7.53

Number of agitators 2 2 2

Distance between agitators, in 3.37 7.85 12.55

Minimum distance between

2.698 6.278 10.040
agitator and bottom of vessel, in

Blade angle, degree (o) 30 45 45

1.4 Power Calculation

(ref: timmerhaus)

Fermenter V-101

Agitator type: Turbine

Impeller: Pitched blade, for both radial and axial flow, 6 blades, KT = 5.75

No. of baffles: four

Turbine revolution, Nr = 180 rpm = 3 rev/s

Density of the fluid handled, ρ = 999.143 kg/m3

Viscosity of the fluid handled, μ = 0.001 kg/m.s

𝐷𝑖2 𝑁𝑟 𝜌
Reynolds no., Re =
𝜇

0.0685352 × 3 × 999.143
=
0.001

= 14078.9

Power, P = KTNr3Di5ρ

= 5.75 × 33 × 0.0685355 × 999.143

= 0.2345 W

For two turbine agitators, power required = 2 × 0.2345 W = 0.469 W

With 25% overdesign,

Power required, Pcalculated = (0.469 × 1.25) W

= 0.58625 W

Gland loss may be taken as 10% of the agitator power or 0.5 hp whichever is greater (ref: Joshi,
pg 424)

Gland loss = 0.5 hp = 372.85 W

Power input = 373.43625 W

20% Transmission losses = 0.2 × 373.43625 W = 74.687 W

Total power required, PTotal = 448.12 W

Calculated total power for all the fermenter agitators are summarized below:

Fermenter Total agitator power, W (hp) Advisable Motor, hp

V-101 448.12 (0.6) 1
V-102 495.41 (0.664) 1
V-103, V-104 and V-105 949.28 (1.273) 2
1.5 Heat Transfer Calculation

1.5.1 Fermenter V-101

Temperature of nutrient broth entering = 10 oC

Fermentation to be maintained at 37 oC

Mass flow rate, ṁsoln = 27.003285 kg/d = 3.375 kg/h (considering retention time 8 h)

According to Jacob et al. the overall heat transfer co-efficient of a stirred fermenter is,

1 1 𝛥𝑙 1
= + +
𝑈 ℎ𝑤 𝜆𝑤 ℎ𝑖

Heat transfer jacket wall thickness, Δl = 0.125 in = 3.175 × 10-3 m

If stainless steel is used as construction material for heat exchange surface, λw = 14 W/m.K

Steam condensate at 50 oC is used as heating medium to maintain 37 oC incubation temperature.

For this case, convective heat transfer coefficient, hw = 3000 W/m2.K (ref: halman)

For the system,

NRe = 14078.9

Viscosity of the fluid handled, μ = 0.001 kg/m.s

Specific heat capacity, CP = 4000 J/kg.K (ref: sigma-aldrich)

Thermal conductivity of the solution, k = 0.626 W/m.K

Fermenter diameter, Dt = 8.095 in = 0.2056 m

Fermenter radius, rt = 4.0475 in = 0.1028 m

Fermenter height, h = 16.189 in = 0.4112 m

µCp 0.001 × 4000

Pr = = = 6.39
k 0.626
As the Reynolds number suggests a fully developed turbulent flow, then in the case of smooth
tubes and wide temperature range, Sieder and Tate correlation applies for forced convection heat
transfer.

According to Sieder-Tate equation,

hi Dt D2i ηρ 0.8 µCp 1/3 µ

=0.027×( ) ×( ) × (µ )0.14
k µ k w

hi ×0.2056
= 0.027×(14078.9)0.8 × (6.39)1/3× (1)0.14
0.626

W
hi = 318 m2 .𝐾

Now, putting all these values

1 1 3.175 × 10−3 1
= + +
𝑈 3000 14 318

Overall heat transfer co-efficient, U = 270 W/m2.K

Heat transfer surface area, A = 2πrth

= 2 × 3.1416 × 0.1028 × 0.4112 = 0.2656 m2

Overall temperature difference, ΔT = (37-10) 0C = 27 K

Total heat exchange rate, Q = UAΔT

= 270 × 0.2656 × 27 W
= 1936.224 J/s = 1.936 kW
Heating medium circulation calculation
Circulation rate will be calculated considering the heating medium leaving the jacket at 30 oC. So,
Temperature difference, ΔT = (50-30) 0C = 20 K

Q = ṁwCpΔT
Specific heat capacity Cp of water at average temperature 40 oC = 4178.55 J/kg.K
Hence, the mass flow rate of heating medium, ṁw = 0.0232 kg/s = 83.52 kg/h = 1.4 L/min
1.5.2 Fermenter V-102

Mass solution from V-101 at 37 oC, ṁs = 27.003285 kg/d

Temperature of solution, Ts = 37 oC

Mass flow rate of fresh nutrient broth at 10 oC, ṁb = 450 kg/d

Temperature of fresh nutrient broth, Tb = 10 oC

For both stream heat capacity is very close. So taking heat capacity, Cp = 4000 J/kg.K

Now, considering no heat of solution, ṁsCp(Ts - T) = ṁbCp(T - Tb)

 27.003285 × (37 - T) = 450 × (T - 10)

 T = 11.53 oC

Overall heat transfer co-efficient, U = 270 W/m2.K

Radius of the fermenter, rt = (18.835/2) in = 9.4175 in = 0.239 m

Height of the fermenter, h = 37.669 in = 0.957 m

Heat transfer surface area, A = 2πrth

= 2 × 3.1416 × 0.239 × 0.957 = 1.437 m2

Overall temperature difference, ΔT = (37-11.53) 0C = 25.47 K

Total heat exchange rate, Q = UAΔT

= 270 × 1.437 × 25.47 W

= 9882.1053 J/s = 9.8821 kW
Circulation rate will be calculated considering the heating medium leaving the jacket at 30 oC. So,
Temperature difference, ΔT = (50-30) 0C = 20 oC = 20 K

Q = ṁwCpΔT
Specific heat capacity Cp of water at average temperature 40 oC = 4178.55 J/kg.K
Hence, the mass flow rate of heating medium, ṁw = 0.1182 kg/s = 425.52 kg/h = 7.15 L/min
1.5.3 Fermenter V-103, V-104 and V-105

Mass solution from V-101 at 37 oC, ṁs = 477.003285 kg/d

Temperature of solution, Ts = 37 oC

Mass flow rate of fresh nutrient broth at 10 oC, ṁb = 2700 kg/d

Temperature of fresh nutrient broth, Tb = 10 oC

For both stream heat capacity is very close. So taking heat capacity, Cp = 4000 J/kg.K

Now, considering no heat of solution, ṁsCp(Ts - T) = ṁbCp(T - Tb)

 477.003285 × (37 - T) = 2700 × (T - 10)

 T = 14.05 oC

Overall heat transfer co-efficient, U = 270 W/m2.K

Radius of the fermenter, rt = (30.12/2) in = 15.06 in = 0.383 m

Height of the fermenter, h = 60.239 in = 1.53 m

Heat transfer surface area, A = 2πrth = 2 × 3.1416 × 0.383 × 1.53 = 3.68 m2

Overall temperature difference, ΔT = (37-14.05) 0C = 22.95 K

Total heat exchange rate, Q = UAΔT

= 270 × 3.68 × 22.95 W = 22803 J/s = 22.803 kW

Circulation rate will be calculated considering the heating medium leaving the jacket at 30 oC. So,
Temperature difference, ΔT = (50-30) 0C = 20 oC = 20 K

Q = ṁwCpΔT
Specific heat capacity Cp of water at average temperature 40 oC = 4178.55 J/kg.K
Hence, the mass flow rate of heating medium, ṁw = 0.273 kg/s = 982.8 kg/h = 16.5 L/min

Total available hot condensate = 0.2396 kg/s

Total hot condensate needed = 0.273 × 3 + 0.1182 + 0.0232 = 0.9604 kg/s

So to meet the need, a boiler with saturated steam capacity 1 kg/s is to be purchased.
1.6 Detailed Mechanical Design

Fermenter V-101

Equipment design codes and standards = ASME Section VII, Division 01

1.6.1 Shaft Design

Material: Stainless steel 304

Power required, P = 0.6 hp

Turbine revolution, Nr = 180 rpm

ℎ𝑝 × 75 × 60
Continuous average rated torque on the agitator shaft, Tc = 2𝜋 × 𝑁𝑟

0.6 × 75 × 60
 Tc = 2𝜋 ×180

 Tc = 2.387 kg-m

Maximum torque, Tm = 1.5Tc = 1.5 × 2.387 = 3.58 kg-m

Permissible shear stress in shaft, fs = 1000 kg/cm2

Modulus of elasticity for SS 304, E = 19.8 × 105 kg/cm2

𝑇𝑚 3.58 × 100
Polar modulus of section of the shaft cross-section, ZP = =
𝑓𝑠 1000

 ZP = 0.358 cm3

𝜋𝑑 3
Now, = ZP = 0.358
16

 d3 = 1.823
 d = 1.22 cm ≈ 1.5 cm
Impeller diameter, Di = 0.068535 m = 6.8535 cm
Impeller radius, ri = 3.427 cm
The torque Tm is resisted by a force Fm acting at a radius of 0.75ri from the axis of the agitator
shaft.
𝑇𝑚 3.58 × 100
Fm = 0.75𝑟 =
𝑖 0.75 × 3.427
  Fm ≈ 140 kg
Maximum bending moment M occurs at a point near the bearing, from which the shaft overhangs
M = Fm × l
l = shaft length between agitator and bearing
l = 0.4112 - 0.0685 - 0.0857 = 0.257 m
M = 140 × 0.257 = 35.98 kg-m

Now, equivalent bending moment, Me = 0.5[M + √𝑀2 + 𝑇𝑚2 ]

 Me = 0.5 × [35.98 + √35.982 + 3.582 ]

 Me = 36.07 kg-m

Now, average elastic limit or yield strength for SS 304 = 257.5 MPa = 2625.78 kg/cm2

The stress due to equivalent bending moment is given by

𝑀𝑒 36.07 × 100 36.07 × 100

f= = 𝜋𝑑3
= 𝜋 × 1.53
𝑍
32 32

 f = 10886.1 kg/cm2

Stress f is higher than the permissible elastic limit 2625.78 kg/cm2. Therefore, using a 2.5 cm
diameter shaft is recommended for which the stress will be 2351.4 kg/cm2.

𝐹𝑚 𝑙 3
Deflection of shaft, δ =
3𝐸𝐼

l = shaft length between agitator and bearing, cm = 25.7 cm

I = moment of inertia of the cross-section of shaft
140 × 25.73 × 64
 δ=
3 × 19.8 × 105 × 𝜋 × 2.54
 δ = 0.209 cm

60 × 4.987 60 × 4.987
Critical speed, Nc = =
√𝛿 √0.209

 Nc = 654.5 rpm
Actual shaft speed is 180 rpm which is 27.5% of the critical speed. So, the critical shaft speed is well above
the actual shaft speed which implies that there is negligible chance of severe damage due to vibration in the
shaft.

1.6.2 Blade Design

Blade width, bw = 0.0137 m = 1.37 cm

Thickness of blade, bt = 5 mm = 0.5 cm

𝑇𝑚 3.58 × 100
Stress, f = 𝑏𝑡 × 𝑏2
= 0.5 × 1.372
𝑤
6 6

 f ≈ 2289 kg/cm2

The value of stress is well within the endurance limit for SS 304.

1.6.3 Hub and Key Design

Agitator blades are directly attached to a hub.

Hub diameter of agitator = 2 × shaft diameter

= 2 × 2.5 = 5 cm

Length of hub = 2.5 × 2.5 = 6.25 cm

Length of key, l = 1.5 × shaft diameter

= 1.5 × 2.5 = 3.75 cm

Now for agitator key, material is commonly carbon steel.

Permissible shear stress, fs = 650 kg/cm2

Permissible crushing stress, fc = 1300 kg/cm2

2𝑇𝑚 𝑙𝑡
= lbfs = 𝑓
𝑑 2 𝑐

2 × 3.58 × 100 3.75 × 𝑡

 = 3.75 × b × 650 = × 1300
2.5 2

Solving, b = 1.175 mm, t = 1.175 mm

So, using a 2 mm × 2 mm × 4 cm key is recommended.

1.6.4 Coupling Design

A clamp coupling is suggested which is made of cast iron.

For bolts, permissible stress = 587 kg/cm2

2𝑇𝑚
Force per bolt = 𝑛
𝜋𝜇𝑑×
2

Where, μ = coefficient of friction between shaft and sleeve

n = total number of bolts, 6 upto 50 mm shaft diameter. In this case shaft diameter is 25 mm which
is lower than 50 mm.

2 × 3.58 × 100
 Force per bolt = 6
𝜋 × 0.25 × 2.5 ×
2

 Force per bolt = 121.55 kg

121.55
Area of bolt = = 0.207 cm2
587

0.207 × 4
Diameter of bolt = √ = 0.51 cm = 5.1 mm
𝜋

So, using 10 M size bolts is recommended.

Overall diameter of coupling = 2 × 2.5 = 5 cm

1.6.5 Stuffing Box and Gland Design

Fermentation is done at atmospheric pressure. So internal pressure for fermentation = 101.325 kPa
= 1.03 kg/cm2

For small fermentation volume and mild mixing, internal pressure due to centrifugal force is
generally taken as 1.03 kg/cm2

So total internal pressure = 2.06 kg/cm2

Considering 10% overdesign, internal design pressure, P = 2.06 × 1.1 kg/cm2

  P = 2.266 kg/cm2

Now, internal diameter of stuffing box, b = d + √𝑑 = 2.5 + √2.5 = 4.08 cm

𝑃𝑏
t = (2𝑓 ) × 10 + c

c = corrosion allowance, mm

2.266 × 4.08 × 10
 t= +c
2 × 1000
 t = 0.046 cm + c = 0.46 mm + c
 t = 1.5 mm, considering corrosion allowance as per ASME UG-16
𝜋
Load on gland, F = 4 × 2.266 × (4.082 – 2.52) = 18.5 kg

Size of stud
𝜋
18.5 = 4 × do2 × n × ft

𝜋
 210 = 4 × do2 × 4 × 587

 do2 = 0.01 cm2

 do = 0.1 cm = 1 mm

Minimum stud diameter = 15 mm

Flange thickness = 1.75 × 15 = 26.25 mm ≈ 30 mm

1.6.6 Vessel Design

Internal design pressure, P = 2.266 kg/cm2

𝑃𝐷𝑡
For vessel with plain jacket, vessel shell thickness is given by, ts =
2𝑓𝐽−𝑃

Where, Dt = fermenter vessel inner diameter, mm = 205.6 mm

J = joint efficiency = 0.85

f = Permissible shear stress, kg/cm2 = 1000 kg/cm2

2.266 × 205.6
 ts = = 0.274 mm
2 × 1000 × 0.85−2.266
Using 1.5 mm thickness including corrosion allowance is recommended as per ASME UG-16.

Sizing of Nozzle
6QF 1/3
Using empricial equation, diameter of nozzle, 𝑑𝑁 = ( )
π

Now, volumetric flow rates,

3.375
QF = = 9.384 × 10-7 m3/s =3.31 × 10-5 ft3/s
3600 × 999.143

Hence, dN = 0.0398 ft. = 0.0121 m = 1.21 cm

Length of support bracket to mount drive system = 0.8H = 328.96 mm = 32.896 cm

1.6.7 Vessel Head Design

For ASME 2:1 semi-ellipsoidal type head,

Knuckle radius, Rk = 0.15Dt = 30.84 mm

Crown radius, Rc = 0.8Dt = 164.48 mm

Depth of dishing or dish head, DH = 0.25Dt = 51.4 mm = 5.14 cm

𝑅
W = 0.25 (3 + √𝑅𝑐 )
𝑘

 W = 1.33

𝑃𝑅𝑐 𝑊 2.266 × 164.48 × 1.33

Head thickness, th = = = 0.292 mm
2𝑓𝐽 2 × 1000 × 0.85

Using 1.5 mm thickness including corrosion allowance is recommended as per ASME UG-16.

1.6.8 Weight of Vessel

Density of stainless steel 304 = 8000 kg/m3

Outer diameter of vessel, Do = Dt + 2ts = 208.6 mm

𝜋 𝜋
Volume of solid cylindrical section, V1 = × Do2 × H - × Dt2 × H = 401.3 cm3
4 4
 𝜋𝐷𝑜3 𝜋𝐷𝑡3
Volume of top and bottom semi-ellipsoidal heads, V2 = 2 × ( − ) = 101.06 cm3
24 24

Total volume, V = V1 + V2 = 401.3 + 101.06 = 502.36 cm3 = 0.000502 m3

Weight of vessel, Wv = 0.000334 × 8000 = 4.02 kg

1.6.9 Surface Area for Insulation

Surface area of cylindrical section, S1 = π × Do × H = 0.269 m2 = 2694.74 cm2

𝜋𝐷𝑜2 1 2×0.866+2
Surface area for top and bottom semi-ellipsoidal heads, S2 = 2 × (2 + ln ( ))
8 4×0.866 2−√3

S2 = 0.094 m2 = 943.38 cm2

Total surface area for insulation, S = S1 + S2 = 3638.12 cm2 = 0.3638 m2

1.6.10 Weight of Insulation

Material of insulation = Polyurethane foam (best fit for fermentation process)

Density of insulation, ρins = 30 kg/m3

Thermal conductivity, k = 0.026 W/m-K

Heat transfer coefficient of air, havg = 10 W/m2-K

𝑘
Critical radius, rc = ℎ = 0.0026 m = 2.6 mm
𝑎𝑣𝑔

Assuming, thickness of insulation, tins = 20 mm

Diameter of insulation, Dins = Do + 2tins = 248.6 mm

π π
Volume of insulation for cylindrical section, V1 = 4 ×Dins 2 ×H - 4 ×Do2 ×H = 0.0059 m3

Volume of insulation for top and bottom semi-ellipsoidal section,

3
𝜋𝐷𝑖𝑛𝑠 𝜋𝐷𝑜3
V2 = 2 × ( − ) = 0.00165 m3
24 24

Total Volume, V= V1+V2 = 0.0059 + 0.00165 = 0.00755 m3

Weight of Insulation, Wins = 0.00755 × 30 = 0.2265 kg = 226.5 g

1.6.11 Dead Weight of Vessel

Weight without internals= Wv + Wins = 4.02 + 0.2265 = 4.2465 kg

Dead weight, W = dead weight of vessel + weight of internals (10% of dead weight of vessel)
= 4.2465 + 10% of 4.2465 = 4.67 kg

1.6.12 Jacket Design

Assuming 85% of the vessel length to be covered with jacket where the liquid level is 75% of the
vessel length.

Jacket length = 350 mm

Typical jacket internal diameter is 1.1 times the vessel internal diameter.

Jacket internal diameter, di = 205.6 mm × 1.1 = 226.16 mm

Taking jacket internal design pressure as 65% of the vessel internal design pressure.

Taking jacket internal design pressure, p = 1.5 kg/cm2

𝑝𝑑𝑖 1.5 × 226.16

Thickness of the jacket, tj = =
2𝑓𝐽−𝑝 2 × 1000 × 0.85 −1.5

 tj = 0.2 mm

Using 1.5 mm thickness including corrosion allowance is recommended as per ASME UG-16.

1.6.13 Skirt Support Design

Vertical vessels are usually supported by cylindrical shells or skirts.

Material of construction for skirt = Structural Steel (IS-800)

Permissible stress: Tension = 1400 kg/cm2

Compression = 1233 kg/cm2

Bending = 1575 kg/cm2

Permissible bearing pressure for concrete = 35 kg/cm2

Assuming,

Skirt Length = 15 cm

Diameter of the skirt, Dok = 205.6 mm

Skirt Thickness = tsk

The stresses acting on the support are:

W 4.67 0.0723
Stress due to dead weight, fd = = = kg/cm2
πDoktsk π × 20.56 × tsk tsk

Stresses due to wind load are neglected due to very low height (41.12 cm) of vessel.

Stresses due to seismic load:

2CWH
fsb = 3πR2oktsk

Where C is the seismic coefficient. C = 0.08 [ASM Woobaidullah et. al]

2×0.08×4.67×41.12 0.0308
Therefore, fsb = = kg/cm2
3×3.14×10.282 ×𝑡𝑠𝑘 𝑡𝑠𝑘

0.0723 0.0308 0.0415

Maximum tensile stress, ft, max = fd – fsb = - = kg/cm2
tsk 𝑡𝑠𝑘 tsk

Permissible tensile stress = 1400 kg/cm2

0.0415
 tsk = = 2.96 × 10-5 cm = 2.96 × 10-4 mm
1400

0.0723 0.0308 0.1031

Maximum compressive stress, fc, max = fsb + fd = + = kg/cm2
tsk 𝑡𝑠𝑘 tsk

1
Permissible compressive stress, fc ≤ of yield point
3

2000
 fc ≤ = 666 kg/cm2
3
0.1031
 tsk = = 1.55 × 10-4 cm = 1.55 × 10-4 mm
666

Using a code minimum thickness of 1.5 mm is thus recommended.

The maximum compressive stress between the bearing plate and the concrete foundation is given
by:

W Mw
fc = + where A is the area of contact between the bearing plate and foundation, Mw is the
A Z

bending moment due to wind and Z is the section modulus of the area.

Again, assuming
Base plate thickness = 20 mm

Base plate ID, Dbi = 205.6 mm

Base plate OD, Dbo = 295.6 mm

Bolt circle diameter = 250.6 mm

Type of Thread = Tema Metric

Nominal Bolt Diameter, Dbolt= 12.7 mm (0.5 inch)

Number of bolts, n = 6
π
A= 4 (Dbo2 -Dbi2 ) = 354.277 cm2

Bending moment due to wind, Mw is negligible due to very low vessel height.

W 4.67
So, fc ≅ = = 0.0132 kg/cm2
A 354.277

A 354.277
Now, load on one anchor bolt, Pbolt = fc × n = 0.0132 × = 0.779 kg
6

Pbolt
Stress in the bolt, fbolt = where Ab is the area of cross-section of the bolt
Ab

π
Ab = 4 ×Dbolt 2 = 1.27 cm2

Therefore, fbolt = 0.613 kg/cm2