PART A: Assignment Content ChemGemilang Sdn. Bhd. is one of the leading chemical producers in the world. One of its main products is polyurethane (PU). Polyurethane is currently one of the most used polymers worldwide for various applications such as rigid and flexible foams, coatings, elastomers, adhesives and sealants. Polyurethane can be produced via two routes, namely isocyanate route and non-isocyanate route. Synthesis of polyurethane from isocyanate route is usually through polycondensation between a diisocyanate and a diol. However, the use of isocyanate is notably toxic and it is synthesized from an even more toxic substance, phosgene which causes environmental hazards. Therefore, sustainable route for the synthesis of green polyurethane with industrial application is introduced, and known as the non-isocyanate route. This route is an environmentally friendly method in which PU is synthesized from 100% sustainable biomass. In its chemical processing plant located in Shah Alam, Selangor, 100,000 MTPA of PU is produced by ChemGemilang Sdn. Bhd. via the green, non-isocyanate route by utilizing palm oil as raw material. One of the main reactions in this process is the carbonation of epoxidized palm oil to produce carbonated paim oil, as shown in Equation 1. This reaction happens in a vertical packed bed reactor, R-102. Tetrabutylammoniumbromide (TBAB) is used as the solid catalyst. The highest obtainable conversion in R-102 is 99%. R1COCR2+CO2R1COC=OOCR2Epoxidizedpalmoil+carbondioxidecarbonatedpalmoil Equation 1 Table 1 summarizes the chemical design of R-102: 1) This assignment is a group assignment, with three to four (3-4) members per group. It carries 20% of total assessment marks for code CPE601. Since this is a group work, each member should equally contribute to produce the report. Unequal participation or "sleeping partner", if reported by your group member, will be penalized. 2) Based on the assignment content given in Part A, make a comprehensive excel calculation on the mechanical design for vertical packed bed reactor (R102). The design shall thoroughly include (but not limited to) the following items: a) Design pressure b) Design temperature c) Material of construction d) Shell thickness e) Heads selection and thickness f) Total dead weight loads of vessel g) Wind loading h) Bending moment i) Analysis of stresses j) Seismic loading (if necessary) k) Critical buckling stress (if necessary) i) Stiffening ring requirement (if required) m) Vessel support design n) Flange and nozzle design 3) The application of any standard design code (i.e. ASME, 85, API, etc.) must be thoroughly explained and emphasized throughout the design. 4) All design and dimensions must be ensured to be feasible and logic. You are required to summarized you R-102 mechanical design in a summary table. 5) Each group is also required to do a simple equipment drawing of your designed R-102. The drawing should clearly show the front, side and top views of the pressure vessel. One of the views must be a cross-sectional view. All dimensions should be clearly labelled. You may use any software as long as the drawing is delivered. Using AutoCAD will be an added advantage. 6) Any other related discussion and design (open to students' creativity and depth of knowledge) will be given additional marks. 7) All assumptions, statements and selections made must be thoroughly justified and if necessary, supported with credible source of references. Report with only calculation steps without any sound justification given will obtain only minimal marks. 8) All final values must be stated in S.I units, unless unavoidable. 9) Excel report must also include Executive Summary, List of References and Appendices
