JOSHI s Process Equipment Design

JOSHI s Process Equipment Design

JOSHI s Process Equipment Design Fifth Edition Fifth Edition V V Mahajani S B Umarji (An Imprint of Laxmi Publications Pvt. Ltd.) BANGALORE CHENNAI COCHIN GUWAHATI HYDERABAD JALANDHAR KOLKATA LUCKNOW MUMBAI RANCHI NEW DELHI BOSTON, USA

PROCESS EQUIPMENT DESIGN Copyright by the Author All rights reserved including those of translation into other languages. In accordance with the Copyright (Amendment) Act, 2012, no part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise. Any such act or scanning, uploading, and or electronic sharing of any part of this book without the permission of the publisher constitutes unlawful piracy and theft of the copyright holder s intellectual property. If you would like to use material from the book (other than for review purposes), prior written permission must be obtained from the publishers. Printed and bound in India Fifth Edition First Reprint 2014 TPE-3515-450-PROCESS EQUIP DESIGN-MAH ISBN 978-93-5138-019-1 Price: ` 450.00 Limits of Liability/Disclaimer of Warranty: The publisher and the author make no representation or warranties with respect to the accuracy or completeness of the contents of this work and specifically disclaim all warranties. The advice, strategies, and activities contained herein may not be suitable for every situation. In performing activities adult supervision must be sought. Likewise, common sense and care are essential to the conduct of any and all activities, whether described in this book or otherwise. Neither the publisher nor the author shall be liable or assumes any responsibility for any injuries or damages arising herefrom. The fact that an organization or Website if referred to in this work as a citation and/or a potential source of further information does not mean that the author or the publisher endorses the information the organization or Website may provide or recommendations it may make. Further, readers must be aware that the Internet Websites listed in this work may have changed or disappeared between when this work was written and when it is read. All trademarks, logos or any other mark such as Vibgyor, USP, Amanda, Golden Bells, Firewall Media, Mercury, Trinity, Laxmi appearing in this work are trademarks and intellectual property owned by or licensed to Laxmi Publications, its subsidiaries or affiliates. Notwithstanding this disclaimer, all other names and marks mentioned in this work are the trade names, trademarks or service marks of their respective owners. Published in India by & Bangalore 080-26 75 69 30 & Chennai 044-24 34 47 26, 24 35 95 07 & Cochin 0484-237 70 04, 405 13 03 & Guwahati 0361-254 36 69, 251 38 81 & Hyderabad 040-27 55 53 83, 27 55 53 93 & Jalandhar 0181-222 12 72 & Kolkata 033-22 27 43 84 & Lucknow 0522-220 99 16 & Mumbai 022-24 91 54 15, 24 92 78 69 (An Imprint of Laxmi Publications Pvt. Ltd.) 113, GOLDEN HOUSE, DARYAGANJ, NEW DELHI - 110002, INDIA Telephone : 91-11-4353 2500, 4353 2501 Fax : 91-11-2325 2572, 4353 2528 & C Ranchi 0651-220 44 64 www.laxmipublications.com info@laxmipublications.com Printed at: Branches

Dedicated to Late Shri M V JOSHI xq#czzãk xq#foz".kq% xq#nszoks egsüoj%a xq#% lk{kkrijczã rles Jhxq#os ue%aa

Preface to the Fifth Edition This edition of the book, like the previous edition, is dedicated to late Professor MV Joshi, who was the architect and the author of this book. This edition brings you few updates and additions, like chapter 12 gives you a new write up on hydrocyclone, in Auxiliary Process Vessels; Chapter 14 gives a write up on Jet Mixer and Eductor, in Mixers; and Appendix J, gives a calculation of volume of a horizontal tank, with formulae, and so on. We are very much thankful to Dr VV Chavan, Managing Director, Mamko Design and Engineering Private Ltd Mumbai 400 063 for pictures of Jet Mixers and hydrocyclone. His suggestions on brief write up of these items are thankfully acknowledged. Suggestions by Professor (Dr) S P Deshmukh of ICT (UDCT) Mumbai 400 019 were very much valuable. We acknowledge with thanks the support of our friends and student community and now look forward to their comments and suggestions for the next edition. V V Mahajani S B Umarji

Preface to the Fourth Edition This revised edition is dedicated to late Professor M V Joshi who was the main architect and the author of this book. The emphasis in this fourth revised edition is on mechanical design, as in the earlier editions, and not on process design. In this edition, an attempt has been made to eliminate all types of errors missed out in earlier editions. The chapters have been revised wherever necessary. The reference list at the end of each chapter has been updated with some very old references being deleted. The chapter on Agitators (Chapter 14) has been renamed as Mixers taking into account static mixers also. All numerical problems have been reworked on to make them more comprehensive without altering the main definition. Illustrations have been presented to appreciate equipment, particularly the mechanically agitated reactor. We take this opportunity to thank all those who gave feedback to bring forth this revision. Our thanks are due to Dr P D Vaidya and research scholars, Mr T L Gunale for going through illustrations and the revision, and Mr M S Talekar for updating literature search. Their constructive suggestions from the students point of view have been invaluable. We thank Mr S M Mokashi, former Managing Director of Xytel India Ltd and Director (then) Davy Powergas India Ltd, for making the opening Chapter 1 more appealing. Our sincere thanks are due to Dr V V Chavan, Director, Mamko Design and Engineering Pvt Ltd, Mumbai for their inputs on static mixers. We thank with equal sincerity Mr Kekatpure of Evergreen Technologies Pvt Ltd Mumbai for permitting to use photographs of structured packings and mist eliminators. We also thank Professor (Dr) J B Joshi, Director, Institute of Chemical Technology, Matunga, Mumbai, where this revision was designed and executed.

x Preface to the Fourth Edition We also wish to express our sincere gratitude to the entire team of Macmillan Publisher India Ltd, in particular Mr Suresh Gopal, Senior Editorial Consultant and Ms Garima Rao, the Development Editor, for their enormous help and cooperation. Finally, we would like to acknowledge the support of the student community to further improve this book. Mumbai V V Mahajani S B Umarji

Preface to the Third Edition During the last ten years, several engineering institutions have started offering courses in chemical engineering. During this period, a large number of chemical industries have been set up, leading to the application of a variety of chemical equipment. This has caused an increased demand for this book both by students and design engineers. To meet this growing demand, the second edition of the book was reprinted three times. However, keeping in view the developments in this field, it was necessary to incorporate some significant and essential features of process equipment in the original text. Hence, the second edition of the book has been thoroughly revised and updated by certain additions and alterations wherever necessary. In the present edition, certain additions relating to items of equipment such as filters, dryers, evaporators, etc., have been made. A chapter on auxiliary process equipment has been incorporated. These items of equipment are functionally essential as a complement to the main items of equipment, data sheets have also been included. A chapter on process flow sheets has been included, since it is desirable for an equipment designer to understand not only the function of the equipment but also its location, necessary piping and instrumentation in overall process. Lately, computer aided design has become a specialized topic of study, and many good books are available in this area. Hence, in the present edition the chapter on computer aided design has been deleted. SI units have been used in all numerical problems and tables. While preparing this edition, information has been obtained from various sources such as textbooks, handbooks, journals, etc. Indebtedness to these sources is freely acknowledged. Special mention must be made of the help received from Mr S M Mokashi and Mr V R Thakur of Davy Powergas India Pvt Ltd for which the authors are grateful to them. Thanks are due to Mr Anand Kulkarni for preparing some of the sketches, and to Prof P K Jadhav for checking the numerical problems. M V Joshi V V Mahajani

Preface to the Second Edition The response to the first edition of the book was most encouraging, both from the students and design engineers from the field of chemical engineering. To fulfil the demand, the book was reprinted in 1979. The purpose of this edition is to update the previous text and to revise certain topics, based upon the comments received from experts in the field. Certain changes will be found in most chapters. In particular, greater emphasis has been laid on topics pertaining to corrosion and its prevention and pressure vessel codes. Pressure vessels form the most important component of chemical equipment. Codes on pressure vessels have been evolved by different countries. The design engineer has, therefore, a wide choice. The information given in this volume will help him to understand the basic difference in the design approach adopted by four important codes. With these additions it is expected that this edition will provide a sound basis for the study of the fundamentals of the subject and will be of some value to practicing engineers. In the preparation of this edition, information has been obtained from various sources such as textbooks, handbooks, journals, etc. Indebtedness to these sources is freely acknowledged. Special mention must be made of the help received from Shri J P Roy, for which the author is grateful to him. Thanks are due to Shri V R Laud, who prepared the sketches and Shri S R Tuvekar who typed the manuscript. M V Joshi V V Mahajani

Preface to the First Edition There are at present only a few books available on the subject of process equipment design. The scope of these books is essentially limited to design of pressure vessel components and some machine elements. However, if the subject is to be made sufficiently comprehensive, much more emphasis is needed on design and construction features of different items of equipment. The present book is an attempt to fill this gap. It is expected to satisfy the long-felt need for a more comprehensive book, which sets out to embrace a wider field, viz., application of fundamental principles of machine design to specific items of equipment and elaborate details of construction illustrated through sketches and drawings. The book is intended both for the undergraduate students of chemical engineering and for practicing engineers in the chemical industry. It is the outcome of experience gained by the author in classrooms and industry. Chemical industries involve problems in process design, unit operations, equipment design and overall plant design. In a design of a chemical plant these problems cannot be segregated. However, in spite of their interdependence, these problems may be advantageously segregated for study and development because of different principles involved in each. Process problems are primarily physicochemical in nature. Unit operation problems are for the most part physical, while equipment design problems are to a large extent mechanical. The fundamentals and theory of chemical engineering process design and unit operations are well covered in a number of books and handbooks. Overall sizing of equipment and its components is no doubt determined by the above considerations. Equipment design is, therefore, essentially limited to mechanical aspects of design and construction features of process equipment. The first few chapters are devoted to a review of materials of construction, corrosion and protective coatings, stresses arising out of different loading conditions and factors which influence design. An outline of the design features of some machine elements, which form a part of chemical equipment, is presented in Chapter 5. Chemical equipment may be classified on the basis of certain