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5/7/12

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

44


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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

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