CHAPTER 2.

MECHANICAL DESIGN

2.2.1 Material Selection

There are a few important characteristics that need to be considered before

selecting a material for the construction of distillation column (T-100). The
characteristics are mechanical properties, impact of high and low temperatures on the
mechanical properties, corrosion resistance, ease of fabrication (forming, welding, and
casting), availability in standard sizes-plates, sections, tubes and cost.

The best material as comparing the fabrication guide and mechanical guide
provided in suggested material by Sinnot, 2003 to be adopted as the material of
fabrication for the vessel, closures is Stainless Steel (Type 304 18Cr/8 Ni) due to its top
ranking as a more economized material of construction. They are readily formable and
easily wieldable, though special precautions are necessary during fabrication to
preserve their optimum corrosion resistance. These steels are suitable for high
temperature service and have high resistance against corrosion. The mechanical
properties of stainless steel and sizing details of the column are shown in Table 2.12.
 Table 2.14: Mechanical Properties and Sizing Details

Parameter Details
Operating Pressure, P (kPa) 106.3
Operating Temperature (°C) 70
Column Inner Diameter, Di (m) 2.080
Material of Construction Stainless Steel (Type 304
18Cr/8 Ni)
Typical Design Stress, fs (N/mm2) 145 (for Stainless Steel)
Ultimate Tensile Strength (U.T.S), (N/mm2) 510
Number of trays 16
Weld Join Efficiency, J 0.85
Weir Length, lw (m) 1.560
Total column height (m) 11
Total no of holes 3008
Plate thickness, s (m) 0.003
 Figure 2.17: Typical design stresses for plate (Sinnot,2003)

Each of these characteristics shall be analysed with the material selected above
(Stainless Steel 304) to check on its applicability with the design condition. The strength
of a welded joint is dependent upon the type of joint and quality of welding. Welding joint
off Class 2 is adopted which require less non-destructive testing and maximum plate
thickness. The welding specifications are:

Welding type: Class II

Specific details: Double welded butt joint fully penetrated

Weld joint efficiency, J: 0.85

2.2.2 DESIGN OF THICKNESS OF VESSEL AND HEAD DESIGN

2.2.2.1 Design of Cylindrical Shell

Design Pressure

The design pressure, Pd is the maximum pressure or in other words the worst
case pressure in which the equipment has to with stand. The starting point for
calculating Pd is the pressure calculated for the equipment during the process design,
Pp. T-100 is operated at Poperating = 106.3 kPa. The column must be design to
withstand the maximum differential pressure. The P d Normally is 5 – 10 % above the
normal working pressure (Smith, 2003).

Pd = Poperating x 1.09

=106.3 x 1.09 = 115.61kPa =0.11561 N/mm2

Design Temperature

The design temperature is determined from the process design temperature. The
design temperature of the column is taken at the maximum working temperature of the
material, as the strength of metal decreases with increasing temperature. Factor of 1.05
is to consider the safety limit for column operation (Smith, 2003).

Td = Toperating x 1.05

Td = 70 ˚C x 1.05 = 73.5 ˚C

Cylindrical Shell Thickness

It is necessary to find out the minimum thickness of the column wall to ensure
that the column is sufficiently rigid to withstand its own weight and any accidental load.
However, the minimum practical wall thickness is also a function of column diameter.
Do t
The equation is only valid if: ≤1.5 and D ≤0.25
Di o
 𝑖 𝑖 𝑃𝐷
Minimum shell thickness, t = 2𝑓𝐽− +c
𝑃 𝑖

Where

Di = Internal diameter

fs = Design stress

t = Minimum thickness required

Pi = Design absolute pressure

c = Corrosion allowance is 2mm

0.11035 × 2.080 × 103

𝑡= + 2 = 2.976𝑚𝑚
2 × 0.85 × 145 – 0.11035

Outer diameter is given by,

D0 = Di + 2t = 2.080 + 2(2.976/1000) = 2.086m,

𝐷𝑜 2.086
= = 1.003 < 1.5 ⇒ valid
𝐷𝑖 2.080

𝑡 2.976
= = 0.001 < 0.25 ⇒ valid
𝐷𝑖 2.080 ×1000
2.2.2.2 Design of Head and Closure

Top and Bottom Closure

Standard torispherical heads (dished ends) are the most commonly used end
closure for vessels up to operating pressures of 15 bars, above 15 bars an ellipsoidal
head will usually prove to be the most economical closure to use. A hemispherical head
is the strongest shape,capable of resisting about twice the pressure of a torispherical
head of the same thickness. The cost of forming a hemispherical head will, however, be
higher than that for a shallow torispherical head. Hemispherical heads are used for high
pressure (Sinnot,2003).

A torisperherical head which is the standard head is chosen as the top and
bottom closure head. First the maximum thickness of closure needs to be determined. A
stress concentration factor, Cs is introduced to allow for increased stress due to the
discontinuity at the junction of crown and knuckle radius. The thickness calculation is
shown in Appendix 3(c).

𝑃𝑅 𝐶
Minimum closure thickness, t = 2𝑓𝐽+ 𝑃𝑖 (𝐶𝑐 𝑠− 0.2)
𝑖 𝑠

Where:

1 𝑅
Cs = stress concentration factor for torispherical heads = 4 (3 + √𝑅 𝑐 )
𝑘

Rc = crown radius,

Rk = knuckle radius.

The ratio of the knuckle to crown radii should not be less than 0.06, to
avoid buckling and the crown radius should not be greater than the diameter of the
cylindrical section.
Rc=Di=2.080m

Rk = 0.06 x 2.080 = 0.125m

1 2.080
Cs = (3 + √0.125) = 1.771
4

Hence, the minimum closure thickness for torispherical head

0.11035 × 2080 × 1.771

𝑒= + 2 = 3.478𝑚𝑚
2 × 0.85 × 145 + 0.11035(1.771 − 0.2)

Comparing the thickness with the cylindrical thickness, it is economical to use the
torispherical head.

2.2.2.3 Vessel Subject to Combined Loading

Dead Weight Loading of Vessel

a) Weight of Shell

For cylindrical vessel with domed ends, and uniform wall thickness, the weight of
shell is given by

Wv  240Cv Dm(H v  0.8Dm )t m

Where:

Cv = Factor to account for the weight of nozzles, manholes, internal supports, etc.

1.15 for distillation columns

Hv = height of cylindrical section = 11m

tm = average wall thickness = 7 mm (assumed)

Dm = mean diameter of vessel = 3.813m

Hence, weight of shell,

 Wv = 240 ∗ 1.15 ∗ 5.813 (11 + 0.8 ∗ 2.080) ∗ 10.5 = 271.264kN

b) Weight of Plate

Weight of trays also adds up to the dead weight of vessel for a distillation column.

W p  W f  Ap  N

Where

Wp = Weight of plates

Wf = Weight of

Ap = Plate area

N = Number of plates

𝜋 𝜋
Plate area, Ap = 4 𝐷𝑖 3 = (2.0803 ) = 7.068𝑚2
4

Assuming the contacting plates has been taken 1.2 kN/m2 for liquid loading

Weight of plate, W = 1.2 X 7.068 = 8.482 kN

Total weight of plates, Wp = 16 x 8.482 = 135.712kN

c) Weight of Insulation

Table 2.15: Insulating Material Properties

Information Properties
Insulation Material Mineral Wool
Thickness of insulation material 0.1m
Density 130kg/m3

Volume of insulation, VI = 𝜋𝐷𝑜 𝑡𝐼 𝐻𝑣

Where:

Do = Average outside diameter of column, m

= 2.080 + (2(7 x10-3)) m = 2.094 m

VI = 𝜋 × 2.094 × 0.1 × 11 = 7.236 m3

Double the volume to allow for attachment fittings, sealing and moisture absorption:

VI = 7.236  2 = 14.472 m3

Weight of insulation, Wi = 14.472 x 130 x 9.81 = 18.456 kN

d) Total dead weight

The total dead weight = weight of plates + weight of insulation + weight of shell

= 135.712 + 18.456 + 271.264

= 425.432kN
Wind Loading

Wind loading will only be important on tall columns installed in the open. For a smooth
cylindrical column or stack the following semi-empirical equation can be used to
estimate the wind pressure,

Pw = 0.07uw2

Where,

Pw = Wind pressure, N/m2

uw = Maximum wind velocity, 160 km/hr

k = 0.07 for allowance of ladders and pipe work.

Pw = 0.07uw2 = 0.07 x 160 2 = 1792 N/m2

Deff = Di + 2(tav + ti) = 2.080 + 2(7+ 75) x 10-3= 2.162 m

Wind loading, Fw = Pw x Deff = 1792 x 2.162 = 3874.304 N/m

Bending moment at bottom tangent line,

𝐹𝑤 3874.304
𝑀𝑥 = × 𝐻𝑣 2 = × 112 = 234395 𝑁𝑚
2 2
2.2.2.4 Analysis of Stresses On Vessel

The longitudinal and circumferential stresses due to pressure (internal or external),

given by

At bottom tangent line

a) Pressure stresses
Circumferential stress

𝑃𝐷𝑖
𝜎ℎ =
2𝑡

Where

P = Design pressure

Di = Internal diameter of vessel

t= Thickness of wall

0.11561 ∗ 2.080 ∗ 1000

𝜎ℎ = = 17.176 𝑁/𝑚𝑚2
2∗7

Longitudinal stress,

𝑃𝐷𝑖
𝜎𝑙 =
4𝑡

0.11561 ∗ 2.080 ∗ 1000

𝜎𝑙 = = 8.588 𝑁/𝑚𝑚2
4∗7
b) Dead weight stress

𝑊𝑣
𝜎𝑤 =
𝜋(𝐷𝑖 + 𝑡)𝑡

Where

Wv = Total weight which is supported by the vessel wall at the plane considered

425.432 ∗ 1000 9.270𝑁

𝜎𝑤 = = ( 𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒)
𝜋(2.080 ∗ 1000 + 7)7 𝑚𝑚2

c) Blending stress
𝑀 𝐷𝑖
𝜎𝑏 = ± ( + 𝑡)
𝐼𝑣 2
Where
Iv = Second moment of area of the vessel about the plane of bending
M = Total bending moment at the plane being considered

𝜋 𝜋
𝐼𝑣 = (𝐷𝑜 4 − 𝐷𝑖 4 ) = (20864 − 20804 ) = 1.065 × 1010 𝑚𝑚4
64 64

Therefore,

234395 ∗ 1000 2.080 ∗ 1000

𝜎𝑏 = ± ( + 7) = ±23.043 𝑁/𝑚𝑚2
1.065 × 1010 2
 The resultant longitudinal stress is given by

𝜎𝑧 = 𝜎𝑙 + 𝜎𝑤 ± 𝜎𝑏

Where

𝜎𝑤 = Is compressive and therefore negative.

𝜎𝑧 (upwind) = 8.588 − 9.270 + 23.043 = + 22.361 𝑁/𝑚𝑚2

𝜎𝑧 (downwind) =8.588 − 9.270 – 23.043 = −23.725 𝑁/𝑚𝑚2

23.361 23.725

17.176 17.176

Up-wind Down-wind

d) Critical buckling stress

For steels at ambient temperature, E = 200000 N/mm2, and equation

13.72 with a factor of safety of 12 gives,

𝑡 7
𝜎𝑐 = 2 × 104 ( ) = 2 × 104 ( ) = 67.114 𝑁/𝑚𝑚2
𝐷𝑜 2.086 ∗ 1000