MECHANICAL DESIGN OF PROCESS EQUIPMENT

CPE 639

GROUP ASSIGNMENT

DESIGN OF PRESSURE VESSEL FOR PRODUCTION OF METHANOL

(SEPARATOR)

GROUP:
EH 222 6C

GROUP MEMBERS:
1) MOHAMAD SYAMIL BIN MAZLAN 2013604042
2) NOR ATIRA BINTI ARSHAD 2013212982
3) NURUL FAEZAH BINTI TUSERAN 2013650418
4) AZLEEN HAZIERA BINTI HISHAMUDDIN 2013609056
5) NUR ALIAH BINTI NOOR MOHD JASMANI 2013282486

SUBMITTED TO: MADAM NUR AZRINI BT RAMLEE

 CONTENT

1. Abstract

2. Introduction

3. Content/literature

3.1 Description of the equipment

3.2 Materials of construction

3.3 Joints and support

3.4 Welded joint efficiency and construction categories

3.5 Wind loading

3.6 Compensation for opening and branches

3.7 Weight of vessel

3.8 Analysis of stresses

3.9 Vessel support

3.10 Design of flanges

4. Drawing of pressure vessel

5. Reference and appendix

 1. ABSTRACT

Methanol is one of materials that provide an alternative to petroleum-based liquid transportation

fuels. Methanol can be made from any renewable biomass hydrocarbon source by partial
oxidation in an oxygen-blown gasifier to produce synthesis gas, which is then converted into
methanol. The purpose of this report is to design any pressure vessel by applying the theory
that learned in the subject course. In this report, separator is chosen as pressure vessel that
has to design either is economical and convenient to the condition. There are pressure changes
between pressures in tank with the atmospheric pressure.

2. INTRODUCTION

Interest sources of liquid transportation fuels that are not petroleum based have
increased due to global economic, environmental and political forces. Renewable biomass has
potential to provide alternative energy source that offers many long-term advantages over
petroleum. Biomass can be converted into synthesis gas by gasification, and the gas can be
converted into methanol using present technology. It is possible that, most liquid consuming
transportation vehicles such as cars, trains, planes may utilize methanol as their energy
sources. Olah et al.1 propose a "methanol economy" as a more reasonable methodology
contrasted with the generally talked about "hydrogen economy" in light of the fact that existing
fluid fuel base (pipelines and tanks) could be utilized with little alteration, and the wellbeing
concerns connected with hydrogen can be maintained a strategic distance from.

According to journal from Luyben (2013), it shows process of converting methanol from
synthesis gas by reacting hydrogen with carbon monoxide and carbon dioxide. For the overall
process, the productions are plays with variety of temperatures and pressures. In this case, our
group chooses separator as pressure vessel that we have to design it. Operating pressure for
this tank is 106.5 bar with operating temperature is 38C. Based on this information, the
characteristics of the tank are determined by taking the condition of location, materials and
weight of the tank.
 3. CONTENT/ LITERATURE

Temperature: 38C

Pressure: 106.5 bar

Diameter: 1 m

Height: 2 m

3.1 Design Temperature

38C = 38 + 273K = 311 K

311 K x 1.1 = 342.1 K = 69.1 C = 156.38F

3.2 Design Pressure

106.5 bar 1 bar = 105.5 bar x 1.1 = 116.05 bar

= 116.05 bar 0.1 N/mm2 = 11.605 N/mm2

1 bar
 3.3 MATERIALS, MAXIMUM ALLOWABLE STRESS,CORROSION
ALLOWANCE,DESIGN LOADS,DESIGN OF THIN-WALLED VESSEL UNDER
INTERNAL PRESSURE

3.3.1 CARBON STEEL

Maximum allowable stress = 12.9 x 6.8948 = 88.94 N/mm2

Shell:

Cylinder
. ()
= = .
(. ) .

Head and Closures:

Flat Ends

(Flanged, c=0.17)

. (. )
= = .
.

(Plates welded, c=0.33)

. (. )
= = .
.

(Bolted, c=0.25)

. (. )
= = .
.
Domed Ends

Hemispherical

=
.

(. )()
= = .
(. ) . (. )

Ellipsoidal

=
.

(. )()
= = .
(. ) . (. )

Torispherical

.
=
.

. (. )()
= = .
. . (. )
Corrosion Allowance
70 mm+ 2mm = 72 mm

Weight Loads
= ( + . )

= +
= 1 m + 0.072 m
= 1.070 m

= . . ( + . (. )).
= .
 3.3.2 LOW ALLOY STEEL

Maximum allowable stress = 17.1 x 6.8948 = 117.9 N/mm2

Shell:

Cylinder
. ()
= = .
(. ) .

Head and Closures:

Flat Ends

(Flanged, c=0.17)

. (. )
= = .
.

(Plates welded, c=0.33)

. (. )
= = .
.

(Bolted, c=0.25)

. (. )
= = .
.
Domed Ends

Hemispherical

=
.

(. )()
= = .
(. ) . (. )

Ellipsoidal

=
.

(. )()
= = .
(. ) . (. )

Torispherical
.
=
.

. (. )()
= = .
. . (. )
Corrosion Allowance
52 mm+ 2mm = 54 mm

Weight Loads
= ( + . )
= +
= 1 m + 0.054 m
= 1.054 m

= . . ( + . (. )).
= .
 3.3.3 KILLED CARBON STEEL

Maximum allowable stress = 17.1 x 6.8948 = 117.9 N/mm2

Shell:

Cylinder
. ()
= = .
(. ) .

Head and Closures:

Flat Ends

(Flanged, c=0.17)

. (. )
= = .
.

(Plates welded, c=0.33)

. (. )
= = .
.

(Bolted, c=0.25)

. (. )
= = .
.
Domed Ends

Hemispherical

=
.

(. )()
= = .
(. ) . (. )

Ellipsoidal

=
.

(. )()
= = .
(. ) . (. )

Torispherical

.
=
.

. (. )()
= = .
. . (. )

Corrosion Allowance
52 mm+ 2mm = 54 mm

Weigh Loads
= ( + . )
= +
= 1 m + 0.054 m
= 1.054 m
= . . ( + . (. )).
= .
Table 1: The different materials of construction

Material of Construction
Carbon steel Low alloy steel Killed carbon steel
(MOC)

Thickness of vessel (mm) 69.794 51.76 51.76

Domed ends Domed ends Domed ends

Type of head and closure
ellipsoidal (66.103mm) ellipsoidal (49.7mm) ellipsoidal (49.7mm)

Weight load (kN) 57.17 41.94 41.94

From the table 1, the most suitable material for the construction of this pressure vessel is
killed carbon steel. This is because the thickness of vessel is the smallest and thus, reduce the
cost for the material part of construction. Although low alloy steel and killed carbon steel have
the same design, the killed carbon steel is better than low alloy steel. For low alloy steel, the
maximum allowable stress decreases as the temperature increases. However, this situation
does not applicable to the killed carbon steel as it can withstand at high temperature while
maintaining its maximum allowable stress. The weight load is also the lightest.
 3.4 WELDED-JOINT EFFICIENCY AND CONSTRUCTION CATEGORIES

In this case, the types of welds for this pressure vessel is type D which are the welds
are connecting with communicating chambers or nozzles to the main shell, to heads or to neck.
It is double welded butt joint with full degree of radiographic examination.

3.5 WIND LOADING

Table 2: The wind loads and bending moment at different site location

Pelabuhan Klang, Pasir Gudang,

Site location Kuantan, Pahang Kuching, Sarawak
Selangor Johor

Wind speed, uw
8.0 9.6 1.6 14.4
(km/h)

Wind pressure, PW
= 0.05 x (8.0)2 = 0.05 x (9.6)2 = 0.05 x (1.6)2 = 0.05 x (14.4)2
(N/m2)
= 3.200 = 4.608 = 0.128 = 10.368
= 0.05uw2

Wind loads,W (N)

= (2 +0.108) x = (2 +0.108) x = (2 +0.108) x = (2 +0.108) x
= DeffPW
3.200 4.608 0.128 10.368
-thickness of killed
= 6.746 = 9.714 = 0.270 = 21.856
carbon steel = 54mm

Bending moment
=6.734/2 x (2m)2 =9.695/2 x (2m)2 =0.269/2 x (2m)2 =21.814/2 x (2m)2
(Nm)
=13.468 =19.390 =0.538 =43.628
=W/2.Hv2

All of the site locations chosen are the places that have the largest production of biofuels and
the best location would be in Kuching, Sarawak. This is because the wind loading and the
bending moment is the lowest compare to the others as the wind speed at that particular place
(ground level) is only 1.6 km/h or 1 mph based on Wikipedia.
3.6 COMPENSATION FOR OPENINGS AND BRANCHES

Forged reinforcing rings are chosen because it is very effective. Since our pressure is very high,
we need some kind of technique that make sure the opening of pressure vessel does not easily
break and later on causing leaking.

3.7 WEIGHT OF VESSEL

Using fibre glass (100kg/m3)

Thickness, t = 75mm

Approximate volume of insulator

= (. )
=0.471 m3

Weight of insulation
=0.471 m3 x 100 kg/m3 x 9.81 m/s2
=462 N / 0.462kN

The weight must double to allow fittings,

Weight of insulation
= 2 x 0.462 kN = 0.924 kN

Total weight
=Weight of vessel + weight of insulation
=41.94kN + 0.924kN
=42.864 kN
3.8 ANALYSIS OF STRESSES

At bottom tangent line

Pressure stresses:

=

. / ( )
= = 53.73 N/mm2


=

. / ()
= = 107.45 N/mm2
()

Dead Weight Stress:

=
( + )
.
= =2.397 x 10-3 N/mm2
(+)

Bending Stress:
= () + ( ) =

= ( )


= ( )

=2.490 x 1010 mm
(. )
= (/ + )
(. )
= . /
Resultant longitudinal stress:
= +
* is compressive and therefore negative
= + +
= . 2.397 x 10-3 + .
=53.728 N/mm2
= +
= . 2.397 x 10-3 - .
=53.728 N/mm2
3.9 VESSEL SUPPORTS

The method used to support a vessel will depend on the size, shape, and weight of the vessel.
For our case, the vessel is horizontal position. Thus, it is mounted on two saddle support. A
vessel supported on two saddle can be consider as a simply supported beam with an essentially
uniform load and the distribution of longitudinal axial bending moment will be as shown below.

For a uniformly loaded beam, the position will be at 21% of the span, in from each end.
This is because the saddle support for a vessel usually be located nearer the ends than this
value, to make use of the stiffening effect of the ends. The contact angle should not be less than
120 and will not normally be greater than 150.
Achor bolts

Approximate pitch circle

Diameter, DB = 0.15 + 1m +0.108
= 1.258m
Circumference of bolt circle = 1258
No of bolts required at minimum

Recommended bolt spacing =

= 6.6
Closest multiple of 4 = 8 bolts
3.10 DESIGN OF FLANGES

The suitable material of construction for flanges is according to the analysis of stresses. The
previous calculation shows stresses involved is 53.73N/mm2. Thus we choose corrugated metal
(stainless s777teel) as this material gives the nearest stress reading.

Flange assembly must be sized so as to have sufficient strength and rigidity to

resist bending moment. Insufficient rigidity, may cause it to rotate slightly and the joint
will leak.
Based on journal, the diameter tube is
.
= .

= 9.32 inch
Reference

1. Luyben, W. L. (2010). Design And Control Of A Methanol Reactor/ Column Process.

6150-6163.

2. 2. Gavin Towler, Ray Sinnott, (2008) Chemical Engineering Design, Principles, Practice
And Economics Of Plant And Process Design, Chapter 13, Mechanical Design Of
Process Equipment ,page 980-1030.
3. Retrieved from www.inspeed.com/