Project Name Johnson Matthey's low pressure methanol synthesis

Project Number Sheet 1 of

REV DATE BY APVD REV DATE BY

METPRO SDN. BHD 1 11/9/2017 Li Jie

Company Name: METPRO Sdn. Bhd

Plant Location: Units: Metric
Case Description
Equipment label: R-401 Equipment name : Radial steam raising methanol reactor
Plant section Section 4
Process service
Design code: ASME Exchanger type: BEM Orientation: Vertical
Shells per unit 1
DATA PER UNIT
SHELL SIDE TUBE SIDE
Conditions
IN OUT IN OUT
Stream No. 403 404 U-407 U-408
Phase Gas Liquid Vapour
Total mass flow rate kg/h 376350.24 113704.00
Total vapor flow kg/h 44330.61 44330.61 0.00 113704.00
Total liquid flow kg/h 0.00 0.00 113704.00 0.00
Density kg/m3 16.64 20.04 898.58 14.08
Dynamic viscosity N.s/m2 2.36E-05 2.30E-05 3.13E-04 1.74E-05
Specific heat capacity kJ/kg.K 3.06 2.85 4.80 2.27
Thermal conductivity W/m.K 1.50E-01 1.20E-01 1.18E+00 5.10E-02
Operating temperature ºC 239.69 243.26 90.11 243.26
Max temperature ºC 305.55 305.55 253.27 253.27
Min temperature ºC 239.69 239.69 80.11 80.11
Pressure bara 70.00 69.25 30.00 30.00
Pressure drop allowed bar 0.75 3
Pressure drop calculated bar 0.67 1.00E-05
Flow velocity m/s 15.00 30.00 1.00 30.00
DESIGN CONDITION
SHELL SIDE TUBE SIDE
Conditions
IN OUT IN OUT
Film transfer coefficient W/m2.K 1912.43 404.91
Fouling coefficient W/m2.K 5000 5000
Overall heat transfer coefficient W/m2.K 268.67
Heat duty kW 82412.93
FT factor 1.00
Effective mean temperature difference ºC 78.46
Design Temperature ºC Max : 305.55 ; Min :80.11 Max : 253.27 ; Min : 80.11
Design Pressure bara 77.00 33.00
CONSTRUCTION & MATERIALS
SHELL TUBE PERFORATED PIPE
Material Stainless clad carbon steel (304) Material Duplex 2205 stainless steel Material Carbon steel
Inner Diameter (m) 5.24 Inner Diameter (mm) 0.05 Inner Diameter (m) 3.00
Outer Diameter (m) 5.57 Outer Diameter (mm) 0.05 Outer Diameter (m) 3.13
Thickness (mm) 327.19 Thickness (mm) 4.80 Thickness (mm) 130.22
Length (m) 9.00 Length (m) 9.00 Length (m) 512.00
Bundle Clearance (mm) 33.70 Total Number of Tubes 3714.00 Total Number of Holes 22.00
Baffle Spacing (m) 1 Type of Tube Plain Type of Tube Perforated
Number of Baffle 7.00 Pitch Length (mm) 62.50 Holes diameter (mm) 450.00
Baffle Percentage Cut (%) 25.00 Tube Arrangement/Pattern Triangular Total Weight (kN) 856.94
Type of Baffle Disc and dougnut Tube Pitch Orientation 30 deg
Number of Passes 1.00 Number of Passes per Shell 1.00
Weight (kN) 17187.99 Total Weight (kN) 904.81
STRESS ANALYSIS Catalyst
Maximum Allowable Stress (MPa) 94.38 Catalyst Type Copper/Zinc Oxide/Alumina
Dead weight stress (MPa) 3.22 Catalyst shape Cylindrical
Upwind (MPa) 27.51 Catalyst nominal diameter (mm) 4.20
Downwind (MPa) 27.76 Catalyst height (mm) 4.20
Hoop stress (MPa) 61.71 Catalyst bed depth (m) 5.12
Bending stress (wind loading) (MPa) 0.125 Catalyst bed volume (m3) 42.23
Hydrostatic pressure (MPa) 11.55 Catalyst bed bulk density (kg/m3) 1190.00
Greatest difference between principle stress (MPa) 66.83 Catalyst bed void fraction 0.29
Critical buckling stress (MPa) 1174.34 Catalyst Weight (kN) 352.15
Hydrotesting (MPa) 92.56 Insulation
Lifting Lug Insulation Type Mineral Wool
Material Carbon Steel Grade A285 Thickness (mm) 32.00
Length (m) 0.70 Weight (kN) 191.27
Width (m) 0.56 Cladding Type Aluminium Grade 110
Hole Diameter (m) 0.14 Thickness (mm) 5.00
Equipment Sketch Cladding Weight (kN) 161.17
Heads and Closure (Bonnet)
Type Ellipsoidal
Material Stainless Clad Carbon Steel (304)
Length (m) 1.76
Thickness (mm) 266.00
Corrosion Allowance (mm) 2.00
Vessel Support
Type Straight Skirt
Welding Type Bottom Head Welding
Material Stainless Steel Grade 304
Thickness (mm) 333.00
Height (m) 5.00
Tensile stress (Mpa 3.10
Compressive Stress (MPa) 3.13

Flange
Construction material: Carbon steel
Nozzle Description DN Flange Class Flange Rating (bar)
Reactor Inlet 750 600 83.9
Reactor Outlet 500 600 83.9
Boiling water Inlet 150 300 43.8
MP Steam outlet 200 300 39.8
Pressure Relief Device (tube) 65 400 41.9
Pressure Relief Device (shell) 80 400 41.9

Notes
Control and instruments were considered such as PRVs , detailed information will be discussed in P&ID of this equipment.