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MATERIAL SELECTION:

When considering material selection for a sulfur furnace some special process conditions should be considered namely Temperature, Pressure and corrosion. Because of the vessel is associated with SO2 and SO3 gasses with high temperature and pressure. Also behavior of mechanical properties such as Strength, Toughness, Creep resistance and Young's modulus at higher temperature should be considered as furnace is operate at 600 0C. Ease of fabrication, working life and Availability in standard sizes should be considered before selecting material. Also selected material should be economical with required properties. Different types of materials are available for fabrication of process vessel namely steels and its alloys, Aluminum, Copper, Nickel and their alloys, plastic and composites, etc. When considering mechanical properties, Strength, Toughness and Youngs modulus, decrease with increasing temperature. So at 600 0C those properties will decreases. Also furnace is subjected to high stress at higher temperature; it can be easily victim of creep failure. So when considering mechanical properties; Mild Steel, Stainless Steel, Nickel alloys, Monel, Inconel Glass fiber reinforced plastic. But selected material must maintain it mechanical properties at 600 0C. So Stainless Steel, Nickel alloys, Inconel Monel, But on other hand Corrosions resistance is another factor which consider when selecting materials for pressure vessel fabrication. Vessel is associated with SO2 and SO3. So there may be uniform corrosion. Also at welded areas Intergranular and pitting corrosion may happen. Vessel and its parts are subjected to stress. So stress corrosion cracking can occur as SO2 and SO3 there. Also galvanic corrosion can occur, because of the usage of different types of materials. Carbon and low alloy steels will oxidize rapidly and subjected to corrosion at high temperatures, and their use is limited to temperature s below 480 8 C. So, Mild steel not prefer for this application. Also Inconel is not prefer as it is not suitable for sulfur environment Therefore Stainless Steel is good for this vessel. But there are three types of Stainless Steels are there, namely Ferritic, Austenite and Martensitic. The uniform grain structure of Austenite is the structure desired for corrosion resistance and Austenite Stainless Steel has greater strength than at elevated temperatures. Also there are different grades of Austenite Stainless Steel are available according its composition. Therefore Austenite Stainless Steel having 316 AISI number (SA 240 A.S.M.E. Specification No.) is suitable for this furnace fabrication. Because it consists of: Chromium (16-18%): which increase the corrosion resistance. Silicon (1%): High temperature corrosion resistance. Molybdenum (2-3%): Increase corrosion resistance Nickel (10-14%): Improve high temperature stability Carbon (0.08%): Manganese (2%):

CALCULATION OF THE DESIGN PRESSURE (P Design) AND THE DESIGN TEMPERATURE (T Design):
Sulfur furnace should withstand at its operating Pressure and Temperature without any failure. So the designing of furnace should be done to restrict failure at its operating Pressure and Temperature. But it must also withstand at sudden change of Pressure and Temperature. DESIGN PRESSURE:

The sulfur furnace should be designed to withstand in severe situation where it operating pressure can increase suddenly to higher value. According to the operating conditions;

Therefore; So;

DESIGN TEMPERATURE:

On the other hand furnace should be design to sustain at severe situations where it operating Temperature can increase suddenly to higher value. In this case body of the furnace is heated directly. Also there is exothermic reaction take place. So if refractory material isnt used for fabrication;

So;

CALCULATION OF THE DESIGN STRESS (

):

Design stress is another important parameter as it always contains factors of safety. Because of this parameter intended to account for the uncertainties in load, the dimensions, and the material properties. Material selection for this sulfur furnace is Austenite Stainless Steel having 316 AISI number (SA 240 A.S.M.E. Specification No.). So is determined according to A.S.M.E. rules for the pressure vessel constriction. There are some Rules for the determine design stress to Construction of Pressure Vessels. It is advocate to using the lesser of the following: 25 percent of the specified minimum tensile strength at room temperature . 1 25 percent of the tensile strength at design temperature 2.

62.5 percent of the specified minimum yield strength at room temperature ..3 62.5 percent of the yield strength at design temperature 4 80% Stress to produce 1 percent creep strain in 100,000 hours at room temperature.. 5 80% Stress to produce 1 percent creep strain in 100,000 hours at design temperature 6

But there are A.S.M.E. tables available find design stress directly according to the material and design temperature. Using following A.S.M.E table can be found.

Design Temperature is So at

. It is

. 4,100 psi.

design stress is 7,400 psi and at

So by interpolating, design stress at

CALCULATION OF THE WALL THICKNESS OF THE SHELL

ECONOMICAL AND SAFE TO


For this sulfur furnace, cylindrical shape shell is used. So;

&

To weld the main shell, weld category A is used as longitudinal welded in main shell belongs to category A. As Double equal V grove welded but joints are used to weld main shell, weld joint efficiency () can be taken according to degree of radiography used.

So if spot radiography is used, weld joint efficiency can be taken as 0.85. Also severe corrosion conditions can be expected here. As stainless steel is used corrosion allowance can be assumed as 3mm.

So wall thickness is selected as 7mm because of it is the minimum practical wall thickness for 1.5m vessel diameter and plates which having 7mm is also available in the market.

Therefore economical and safest wall thickness is 7mm.

SELECTION OF THE SUITABLE ENDS AND CALCULATION OF THEIR WALL THICKNESS.


Selecting of heads for sulfur can be done considering the purpose of usage and design pressure. So Austenite Stainless Steel having 316 AISI number (SA 240 A.S.M.E. Specification No.) material is can be used for head design also. There are several kinds of heads such as there are flat plates, formed heads, hemispherical heads and ellipsoidal heads and Torispherical heads. As design pressure is not a high value and the objective is to burn sulfur, Torispherical head can be used as a head. It is also economical than hemispherical end. Heads are designed according to design of Standard Flanged and Shallow Dished Non-Code Type.

Design of Head Thickness:

Here also Double equal V grove welded but joints are used to weld Heads. But weld joint efficiency () is taken as 1 because of full radiography used. C is called as shape factor depends on effective external head height he.

( [( [( ) ) (

) ( )] )]

So minimum

Following data table can be used to obtain C.

0.002 0.15 0.16934 0.2 4.55 3.6797 2.3

0.005 2.66 2.2887 1.7

0.01 2.15 1.87924 1.45

0.02 1.95 1.7257 1.37

0.04 1.75 1.5837 1.32

Similarly this can be done for So

So shape factor is lies between these two values.

So 7mm thick Austenite Stainless Steel having 316 AISI number (SA 240 A.S.M.E. Specification No.) is selected for design of both head.

FABRICATION PROCEDURE:
Fabrication of burner is another important process. Before fabrication begins, design considerations and specifications should be considered. So design considerations and specifications are: thickness is 7mm Torispherical heads: Austenite Stainless Steel having 316 AISI number (SA 240 A.S.M.E. Specification No.)

For fabrication of burner following steps can be taken. Layout of materials Cutting to correct dimensions Forming into desired shape Fastening Testing Heat-treating Finishing

Initially layouts of the different components are established according to requirements. After that Flat pieces of the metal or other constructional material involved are marked to indicate where cutting and forming are required. Allowances must be made for losses caused by cutting, shrinkage due to welding, or deformation caused by the various forming operations. Then those marked metal pieces are cut according to layout of and correct size. Several methods such as using laser, oxyacetylene flame, shearing, Sawing etc. can be used to cut the metal according to size and looking at economical way After cutting, metal components form them into the desired shape. Methods can be used to shape the metal pieces are rolling, bending, etc. In some cases, heating may be necessary in order to carry out the forming operation. After forming finished different parts are assembled and fitted for fastening. After fitting is complete and all edges are correctly aligned, the main seams can be tack-welded in preparation for the final fastening. Then fastening is done by doing welding. There are different kinds of welding such as Electric Arc, Plasma Arc, Laser etc. can be used to fit the vessel. For this vessel Double equal welded lap joint is used. Then all welding joint are tested using various methods. Then heat treatments are required to remove forming and welding stresses, restore corrosion-resistance properties to heat-affected materials, and prevent stress-corrosion conditions. Finally finishing is done by doing painting, polishing etc.

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