Design of Reactor R-1

Reactor Type
Continuous Stirred Tank Reactor
Material Used
304 Stainless steel
Operating Temperature
150 C
Operating Pressure
0.03 MPa
Conversion
Supplied HNO3 = 39,436.9747 kg/day = 625.9837 kmol/day
Used HNO3 = 39,381.3758 kg/day = 625.1012 kmol/day
Unreacted HNO3 = 0.8825 kmol/day
625.98370.8825
X a=
625.9837
X a=0.9985

Residence Time
The reaction between Nitric Acid and Ammonia follows a first order reaction [1]
The rate reaction constant is 2.1x10-4/s. This value is consistent with the empirical measures. [2]

1 1
t= ln
k (
1X A )
1 1
t= 4
2.1 x 10 /s
ln (
10.9985 )
sechr
t=30963.29
3600 sec
t=8.60 hrs
Reactor Sizing
Inlet Stream
(ref: Table 2-68, Perrys ChE Handbook, 8 th Ed.)
At 60% aqueous HNO3 solution
Density = 1.1817 kg/L
(ref: Table 2-189, Perrys ChE Handbook, 8 th Ed.)
Density NH3 = 0.4890 kg/L
( 39,436.9747+26,291.3165 ) kg
day
QNitric Acid Solution = =55.62 m3 /day
kg 1000 L
( 1.1817)(
L m3 )
( 10,643.784 ) kg
day
Q Ammonia= =21.77 m3 /day
kg 1000 L
(
0.4890
L )( m3 )
3
Q Total Inlet =77.39 m /day

Outlet Stream
(ref: Table 2-68, Perrys ChE Handbook, 8 th Ed.)
Density HNO3 solution = 0.9295 kg/L
(ref: Table 2-39, Perrys ChE Handbook, 8 th Ed.)
Density NH4NO3 = 1.1385 kg/L
( 55.598902+ 26,291.3165 ) kg
day
QNitric Acid Solution = =28.35 m3 /day
kg 1000 L
( 0.9295)(
L m
3 )
( 50,000.1597+26,291.3165 ) kg
day
Q Ammonium Nitrate Solution= =67.01 m3 /day
kg 1000 L
( 1.1385 )(
L m
3 )
 3
QTotalOutlet =95.36 m /day

Total Volume of Reactor

The value for space-velocity (s) or space-time (t) depends on the conditions selected. If they are of the
stream entering the reactor, the relation between s and t and the other pertinent variables is [3]
Reactor Total Volume
t=
Volumetric Feed Rate
3
Reactor Total Volume=77.39 m /day(8.60 /24) day
3
Reactor Total Volume=27.73 m
Volume of Reactor with 20% Allowance [4]
V Reactor =V Total x 1.2

V Reactor =27.73 m3 x 1.2

V Reactor =33.276 m3

Tank Diameter
V =V Cylinder +V Torispherical Bottom +V Torispherical Head

V =V Cylinder +2 V Torispherical Head

D 2t H cy
V Cylinder =
4
Where:
H t =2 Dt

Dt
H sb=
2
H cy=2 D t Height of Torispherical HeadBottom
2
Dt H cy D3
V= +
4 24
Dt

V Without Allowance =
(
D 2t 2 D t
2 )+ D 3

4 24
 Dt

27.73 m = 3
2
(
Dt 2 Dt
2 )+ D t
3

4 24
D t =2.767 m

Tank Height

V Reactor = Dt 2 H +
4 24 (
Dt 3 )

33.276 m3= (2.767 m)2 H +
4

24
(2.767 m)3
[ ]
H=5.073 m

Height of Torispherical Head and Bottom

Dt
H sb=
2
2.767 m
H sb=
2
H sb=1.3835 m

Impeller Design
6-Blade Disk Impeller Type [6]
Impeller Diameter
Dt
D i=
3
2.767 m
D i=
3
D i=0.9223 m

Impeller Disc Diameter

Dd 3
=
Di 4
 3
Dd = D i
4
3
D d = 0.9223m
4
Dd =0.6917 m

Impeller Blade Width

Di
W i=
5
0.9223 m
W i=
5
W i=0.1845m

Impeller Blade Length

Di
I=
4
0.9223m
I=
4
I =0.2306 m
Impeller Clearance
Dt
IC =
3
2.767 m
IC =
3
I C =0.9223 m

Impeller Distance from tank Bottom

Z I =D i

Z I =0.9223 m

Impeller Tip Speed

Tip Speed= Di N
 Impeller Speed=150 rpm [7]
N=150 rpm
150 min
Tip Speed= ( 0.9223 m) x x
min 60 sec
m
Tip Speed=7.24
s

Baffle Width
W 1
=
Dt 10

Dt
W=
10
2.767 m
W=
10
W =0.2767 m
Baffle Offset from Top
W
Offset top =
6
0.2767 m
Offset top =
6
Offset top =0.04612 m

Baffle Offset from Bottom

Di
Offset bottom=
2
0.9223 m
Offset bottom=
2
Offset bottom=0.4612 m

Impeller Power Number

 Q
N A= 3
N Dt
3
m 8.60
21.77 x day
day 24
N A=
rev
(
2.5
s )
(2.767 m )3

N A =0.1473

Crown Radius
The crown is the head of the torispherical dome. Its radius or the crown radius is equal to the radius of the
cylindrical tank.
Dt
rc=
2
2.767 m
rc=
2
r c =1.3835 m

Knuckle Radius
r k =0.06 Dt=0.06(2.767 m)
r k =0.1660 m

Height of Head

2
( Dt )
H h=r c r c2
4

2
H h=1.3835 m ( 1.3835 m )
(2.767 m)2
4
H h=1.3835 m

The computed height of the bottom is equal to the height of the head using this equation.
Shell Thickness [7]
 Pi D i
t s= +C
2 f Pi

Operating pressure is 4.5 atm

Safety factor is 10% of the operating pressure
Pi=0.03 MPa x 1.1=0.033 MPa

N
Pi=0.033
mm2
N
f =110
mm2
C=2.25 mm
N

t s=
( 0.033
mm 2 )
( 0.9223 x 103 mm)
+2.25 mm
N N
(
2 110
mm2 )
0.033
mm2
t s=2.3884 mm

Head Thickness
For Torispherical Head
Pi r c C s
ht = +C
2 fJ + Pi (C s0.2)

Where
J =0.9
N
f =110 2
mm
C=2.25 mm

C s=
1
4 ( )
r
3+ c
rk

C s=
1
4 (
3+ )
1.3835 m
0.1660 m
=1.4717
 N

Ht=
( 0.033
mm 2 )
(1.3835 x 10 3 mm)(1.4717)
+2.25 mm
N N
2 ( 0.9 ) 110
(mm 2 )(
+ 0.033
mm2 )
(1.47170.2)

H t =2.5893 mm

Sparger Design [8]

At a residence time of 8.60 hrs a day:
dayhr
L
kg 60 mins
1 m3
day 0.4890 kg
Q Ammonia=10,643.784
8.60 hr 1000 L
3 3
m 3.28 ft
Q Ammonia=0.04218
min
( m )
ft 3
Q Ammonia=1.4885
min

Pressure at Bottom
gh
PBottom= +head space pressure
gc

kg m m1 N . s2 (
PBottom=1138.5 3 9.81 2 5.073 + 0.03 x 106 Pa )
m s kg . m
PBottom=86658.7390 Pa=12.5723 psi

Determination of Actual Cubic Feet per Minute

 The design calculation for the actual cubic feet per minute or the actual gas volumetric
flowrate of the sparger is based on the liquid pressure and the temperature at the sparger
and not on the gas pressure.

ACFM =SCFM ( 14.714.7+ P )( 460+T

520 )

ft 3
(
ACFM = 1.4885
min )( 14.7+12.5723
14.7
)( 460+302
520 )

ft 3
ACFM =1.1757
min

Agitator Tip Speed in Feet per Second

m 3.28 ft ft
FPS=7.24
s
x(1m )
=23.747
sec

Mott Corporation gives a gas exit velocity chart as a function of agitator tip speed in feet
per second. Since the FPS is more than 10 therefore the FPM would be 50 feet per minute
in gas exit velocity chart. [9]
The gas exit velocity or the FPM denoted as feet per minute is the velocity of the gas
entering the neutralizer.
Area of Sparger
The area can be calculated by dividing the volumetric flowrate to velocity. In the same way,
the area of sparger can be determined by dividing ACFM to gas entering the neutralizer or
FPM.

ft 3
1.1757
ACFM min 2
A Sparger = = =0.0235 ft
FPM ft
50
min

Diameter of Sparger
2
A Sparger = D
4
 2
0.0235 ft 2= D
4
m
D Sparger =0.1730 ft x
3.28 ft
DSparger =0.05274 m

Using Motts selection, L=24 inches/ 0.6096 meter, Hole Diameter= 0.25 inches/ 6.35 mm. The length
between the spargers inlet to hole or G can be any length. The determination of G is based on the
positioning of the sparger. It should be on the center of the reactor. G=2.2 m.

Jacket Design
D t =DoDi

Where:
D o=Outside Diameter of Inner Vessel

D i=Inside Diameter of Jacket

D i=2 ( t s )

D o=D t +2 ( t s )=2.767 m+2 ( 0.0023884 m )

D o=2.7718 m

Distance of Vessel outside Diameter to Jacket [10]

Dt
=20
Dj

Where Dj = Distance of Vessel Outside Diameter to Jacket

2.767 m
Dj= =0.13835 m
20
D 1=Do +2 ( D j )

D 1=2.7718+2 ( 0.13835 )
 D 1=3.0485 m

D e =3.0485 m2.7718 m

D e =0.2767 m

Flow Area

( D21D2o )
Af =
4

( 3.04852 2.77182 ) m2
Af =
4
2
A f =1.2649 m

Nozzle Sizing
The nozzle sizing for the inlet and outlet stream of the reactor is based on the guidelines
of NPTEL Chemical Engineering Design Module.
D n=10 inch=254 mm

D n=254 mm

Nozzle Thickness
f = 110 N/mm2
C = 2.5 mm

p Dn
t n= +C
2 fp
N

t =
( 0.03
mm )
( 254 mm)
2
+ 2.5mm
n
N N
( mm )(0.03 mm )
(2 ) 110 2 2

t n=2.5346 mm

References:
[1] Massad, R.-S., & Benjamin, L. (n.d.). Review and Integration of Biosphere- Atmosphere Modelling of
Reactive Trace. National Bookstore Powershop

Retrieved from Google Books.

[2] Taylor, E., & McMillan, A. (n.d.). Air Quality Management: Canadian Perspective on a Global Issue.
Springer Science and Business Media

Retrieved from Google Books.

[3] Levenspiel, O., (1999). Chemical Reaction Engineering New York: John Wiley and Sons, Inc.
[4] Walas, S. M. (1990). Chemical Process Equipment Selection and Design. USA: Butterworth-
Heinemann.
[5] [6] McCabe. (2001). Unit Operations of Chemical Engineering Volume 6. Singapore: McGraw-Hill Book
Corporation..
[7] [10] Sinnott, R. (1998). Coulson & Richardsons Chemical Engineering. Oxford: Elsevier Butterworth-
Heinemann Publication.
[8] [9] Mott Corporation. (n.d.). Sparging/ Gas-Liquid Contacting Design Guide and Part Selection.
Springlane, Farmington: Mottcorp.