3.

0 Detail Calculation

1. Initial 9. Head and

Concentration, 8. Thickness of
Closure of
Reactor
CAO Reactor

2. Initial Molar 7. Diameter and 15. General

10. Number of
Height of Design
Flow Rate, FAO Tubes
Reactor Considerations

3. Volumetric 6. Weight of 11. Outside

14. Baffle
Surface Area of
Flow Rate, VO Catalyst, Wcatalyst Spacing
Total Tube

5. Volume of
4. Volume of 12. Bundle 13. Shell
Catalyst Bed,
Reactor, VR Diameter Diameter
Vcatalyst bed

There are several steps of calculations must be followed based on basic design and theory
before started to be created or design the packed bed reactor. The several steps of
calculations are shown in above.

3.1 Process Condition

The operating condition of reactor R-101 feed with 200°C temperature and 3039.75 kPa pressure at stream 3 for
inlet condition for reactant and stream 4 for outlet condition that produce product which is methanol and other
by product.

1. Initial Concentration, C AO

Y AO Y AO PO
C AO = =
RT O RT O
By referring to Mass Balance from the Design Project 1

Y AO = Mole Fraction = 0.079

PO = Initial Pressure = 30 atm = 3039.75 kPa

 kPa . dmᵌ
R = Ideal Gas Constant = 8.314
mol . K
T O = 200°C = 473.15 K

Y AO Y AO PO (0.079)(3039.75 kPa)
mol
C AO = = = kPa . dmᵌ = 0.06
RT O RT O (8.314 )(473.15) dmᵌ
mol . K

2. Initial Molar Flow Rate, F AO

By referring to mass balance from the Design Project 1, value taken directly from mass balance.

kmol mol
F AO = 29029.30 = 8063.69
hr s

3. Volumetric Flow Rate, V O

mol
8063.69
F AO s dmᵌ
C AO = = = 134394.83
C AO mol mol
0.06
dmᵌ ❑

4. Volume of Reactor, V R

V R = VO x τ

V O = Volumetric Flow Rate

τ = Residence Time
Residence Time finding by referring to the journal article used from Design Project 1
(Scholarlycommons et al., 2017) and Design Project 1 mass balance.

Mass flow rate( journal) τ ( journal)

=
Mass flow rate(inlet MB ) τ (inlet MB)

29576.35 kg/min 1.03 min

=
5438.95 kg/min τ ( Inlet Mass Balance)
1.03 min
= 0.19 min = 11.4 s
5.44

dmᵌ
V R = 134394.83 x 11.4 s = 1532101.06 dmᵌ = 1532.06 mᵌ
mol

5. Volume of Catalyst Bed, V Catalyst Bed

V Catalyst Bed = V R x ε

ε =Porosity of catalyst
By referring the journal article (Scholarlycommons et al., 2017), the porosity of copper chromium
catalyst that been used was 0.42

V Catalyst Bed = 1532.06 mᵌ x 0.42 = 643.47 mᵌ

6. Weight of Catalyst, W Catalyst

Weight of Catalyst:

W catalyst=V catalyst bed × ρcatalyst

ρcatalyst =Density of catalyst

By referring the journal article (Scholarlycommons et al., 2017), the density of copper
kg
chromium catalyst that been used was 641
mᵌ

kg
W catalyst = 643.47 mᵌ x 641 = 412464.27 kg
mᵌ
Volume of catalyst:

2 2
V catalyst = = = −4
3 V R 3(1530.06 mᵌ ) 4.35 x 10

7. Diameter and Height of Reactor

Diameter of Reactor
2
πD H
V R=
4
D R=
√ √
4V R
3π
=
4(1532.06 mᵌ )
3π
= 25.49 m = 25490 mm

Height of Reactor

Standard ratio diameter to height is 1:3.

H R=3 D

H R = 3 (25.49m) = 76.47 m

8. Thickness of Reactor

Pi Ri
t= +C
2 Se−Pi

Pi=Internal pressure

Pi= 3039.75kPa = 3039.75N/mm² x 0.001N/mm² = 3.04N/mm²

Ri=Internal radius of reactor

D R 25.49 m
Ri = = = 12750 m
2 2

S= Design stress( journal /book )

Material that used for construction of Multi-tubular Packed Bed Reactor for Reactor
R-101 was stainless steel 316 (18cr/8Ni mo 2 ½ percent).

Figure above: Design stress for stainless steel 316 in various temperatures refer Coulson
Richardson Book pg. 812 (Sinnott R. K. Coulson J. M. & Richardson J. F., 2005)
Design stress at 200°C is 120 N/mm²

e=Joint efficiency ( journal/book )

1.0 double welded has been chosen for join efficiency used for Multi-tubular Packed Bed Reactor
designation.

Figure above: Joint efficiency chosen by refer Coulson Richardson Book pg. 813 Chapter 13
(Mechanical Design of Process Equipment) (Sinnott R. K. Coulson J. M. & Richardson J. F., 2005)

e = 1.0 double welded

C=Corrosion allowance (Coulson∧Richardson ’ s)

2 mm have been chosen for minimum corrosive allowance used for Multi-tubular Packed Bed
Reactor designation by refer Coulson Richardson Book pg. 813 (Sinnott R. K. Coulson J. M. &
Richardson J. F., 2005).

3.04 N
( 2
)(12750 mm)
mm
Thickness of Reactor, t= +2 mm = 165.57 mm
(
2 120
mm
N
2 )(1.0 )−3.04 N /mm ²
9. Head & Closure of Reactor

Minimum Thickness of Hemisphere Head: -

Refer Coulson Richardson Book (Sinnott R. K. Coulson J. M. & Richardson J. F., 2005)

Minimum Thickness:

Pi D i
t m=
4 se−0.4 P i
Pi=Internal pressure

Pi= 3039.75kPa = 3039.75N/mm² x 0.001N/mm² = 3.04N/mm²

Di=Internal diameter = = 25490 mm

Design stress, S at 200°C is 120 N/mm²

e = 1.0 double welded

3.04 N
( 2
)(25490 mm)
mm
t m= = 161.85mm
120 N 3.04 N
4( )(1.0)−0.4 ( )
m m2 mm2
Radius of Hemisphere:

DR 25490 mm
R Hemisphere= = = 12745 mm
2 2
Volume of Hemisphere

2 D 2 25490 mm
V Hemisphere= π ( ¿ ᵌ = π ( ¿ ᵌ = 4.34 x 1012
3 2 3 2

10. Number of Tube

VR
Number of tubes= 2
π ×r × H

Tube radius, r 2 = 0.10 m (Brogan, 2011)

1532.06 mᵌ
Number of tubes= 2 = 638 tubes
π ×0.10 ×76.47 m
11. Outside Surface Area of Total Tube

AO =π × DO × Number of tube × H

Outside tube diameter, D O=¿ ¿0.3 m (Brogan, 2011)

AO =π × 0.3 m× 638 ×76.47 m = 45981.47

12. Bundle Diameter

( )
1
Number of tube
DB =DO n1
k1

Outside tube diameter, D O=¿ ¿0.3 m (Brogan, 2011)

Figure above: Constants pitch for K1 and n1 value refer from Gavin Towler & R.K Sinnot 2005 book
(Gavin Towler, R K Sinnott - Chemical Engineering Design Principles Practice and Economics of Plant
and Process Design-ButterworthHeinemann (2007), n.d.)

By referring to the (Gavin Towler, R K Sinnott - Chemical Engineering Design Principles Practice and
Economics of Plant and Process Design-ButterworthHeinemann (2007), n.d.) book, the pitch pattern have been
chosen was square pitch and number of passes = 1 where:

K 1= 0.215

n1 = 2.207

( )
1
638
DB =0.3 2.207
= 11.23mm = 11230mm
0.215
13. Shell Diameter

DS =DB + Clearance
By reference from Coulson Richardson Book (Sinnott R. K. Coulson J. M. & Richardson J. F., 2005). The
clearance value between tubes obtained from the reference book was 6.4 mm.

DS =11230 mm+ 6.4 mm = 11236.4mm

14. Baffle Spacing

DS
Lb=
5
11236.4 mm
Lb= = 2247.28 mm
5
Baffle Cut = (25% x Lb )

Baffle Cut = (25% x 2247.28mm) + 2247.28mm = 2809.1mm

15. General Design Consideration

5.0 Specification Datasheets

MECHANICAL DESIGN SPECIFICATION SHEET R-101

Identification Methanol Production Reactor Vessel

Tag No R-101

No Required 1

Date 12/5/2023

Designed By Sugie Anak Baki

Operation Continuous

OPERATING CONDITION

Temperature 200ᵒC

Pressure 3039.75 kPa

Bed Porosity 0.42

Initaial Molar Flowrate 8063.69 mol/s

SPECIFICATION

Type Packed Bed Reactor Vessel

Material Stainless Stell 316

Type of Catalyst Copper Chromium (Cu-Cr)

Volume of Catalyst 1532.06 mᵌ

Weight of Catalyst 412464.27 kg

Diameter of Reactor 25.49 m

Height of Reactor 76.47 m

TUBE SIDE SHELL SIDE

Diameter = 0.3m Diameter = 11.24m

Length = 76.47 Baffle Spacing = 2.247

No of Tube = 638 Baffle Cut = 2.81m

Pitch Spacing =Squre Pitch