This document summarizes the design of a heat exchanger used to cool a process stream consisting primarily of methyl chloride. It details the stream specifications and properties, proposed tube layout with 98 tubes, and calculations of heat transfer coefficients, pressure drops, and overall heat transfer for both the tube and shell sides. The overall heat transfer coefficient is calculated to be 1517.5 W/m2C with a pressure drop of around 8 MPa for the tube side and 113 kPa for the shell side.
This document summarizes the design of a heat exchanger used to cool a process stream consisting primarily of methyl chloride. It details the stream specifications and properties, proposed tube layout with 98 tubes, and calculations of heat transfer coefficients, pressure drops, and overall heat transfer for both the tube and shell sides. The overall heat transfer coefficient is calculated to be 1517.5 W/m2C with a pressure drop of around 8 MPa for the tube side and 113 kPa for the shell side.
This document summarizes the design of a heat exchanger used to cool a process stream consisting primarily of methyl chloride. It details the stream specifications and properties, proposed tube layout with 98 tubes, and calculations of heat transfer coefficients, pressure drops, and overall heat transfer for both the tube and shell sides. The overall heat transfer coefficient is calculated to be 1517.5 W/m2C with a pressure drop of around 8 MPa for the tube side and 113 kPa for the shell side.
This document summarizes the design of a heat exchanger used to cool a process stream consisting primarily of methyl chloride. It details the stream specifications and properties, proposed tube layout with 98 tubes, and calculations of heat transfer coefficients, pressure drops, and overall heat transfer for both the tube and shell sides. The overall heat transfer coefficient is calculated to be 1517.5 W/m2C with a pressure drop of around 8 MPa for the tube side and 113 kPa for the shell side.
Pressure 101.325 Kpa Temperature inlet T1 136.4 oC outlet T2 135 oC mean Tm 135.7 oC
Vapour enthalpy of process stream 3901277.709
Cooling Water Temperature inlet t1
outlet t2 mean Tm
Cooling Water Stream
Specific heat capacity, Jkg C -1o -1 4202 Thermal conductivity, Wm-1K-1 0.611 Viscosity, Pas 0.0008904 Density, kg/m3 998.1
Q (process stream) = mCpT 68708541.162
Tube Layout
Cooling water flow rate 191.99804027 kg/s
R (_1_2)/(_2_1) 0.056 S (_2_1)/(_1_1) 0.2244165171
Ft 1 Assuming that we use one shell pass and two tub
(_1_2)(_2_1)/ TLM (_1_2)/(_2_1 ) 97.725525364
TLM *Ft 97.725525364
From page 637 U, W/m2oC 600
=/(_ Heat transfer area, A _ ) 343.98031384
Tube Dimensions Outer diameter 20 mm 0.02 Wall thickness 2 mm 0.002 Inner diameter 16 mm 0.016 Baffel cut 45 % Length of tube 6.1 m ASSUMED
Surface area of 1 tube 0.3832743037 m2
Cross sectional area 0.0002010619 m2
Number of tubes 897.47815203 98
Number of tubes per pass 49 tubes
Total flow area 0.0098520346 m2
Pitch; A triangular pitch is recommended
Thus; Pitch 25 mm 0.025 m
_=/ Tube side volumetric flow 0.192363531
Tube side velocity _=_/( 19.525259456
) Bundle and Shell Diameter Coulson pg 649 K1 0.249 n1 2.207 Db 817.78769236 mm 0.8177876924 m
Clearance height for split-ring floating head exchanger
Ds 870.78769236 mm
_=_/
Number of tubes in centre row; _=_/ 32.711507694
Tube Side Heat Transfer Coefficient
= ()/ Reynolds number 350191.58064
Pr = Prandlt number 6.1235037643 (_)/
Ratio of L/di 381.25
Heat transfer factor, jh pg 665 0.0036
Nusselt number = 2306.4366525 ^(1/3) _= ()/ Tube side coefficient 88077.049669
Shell Side Heat Transfer Coefficient
Baffel Spacing _= 870.78769236
0.8707876924 Cross flow area between tubes 151654.24103 _=((__)/_ )_ 0.151654241 _
Equivalent diameter 14.201
0.014201 _=(1.10/)( ^2(0.9 17 ^2 ))
Volumetric flow rate _=/ 7.012022057
Shell side velocity 46.236900526
Re 2786638.7011
Pr 4.0865637823
Heat transfer coefficient, jn pg 672 0.0033
Shell side coefficient 116055.94261
=(/)
^(1/3) =(/)
^(1/3)
Overall Heat Transfer Coefficient
do 1/_ = 1 1 d The overall heat transfer coefficient; o hidc h1 di 2 Heat transfer fouling factors pg 640 Process Stream hodc 5000 W m-2 oC-1 WaterStream hidc 6000 W m-2 oC-1
Thermal conductivity of tube wall material
k carbon steel 51.8 W m-2 oC-1
Thus; 1/Uo 0.0006589776
Uo 1517.5023324 W m-2 oC-1
Percentage Difference -152.9170554 %
Pressure Drop
Tube side pressure drop; Pt =
L m
N p 8 j f 2.5 di w Friction factor, jf 0.026 pg 667
Thus Pt 8115363.0557 Pa 8115.3630557 Kpa
Ds L 0.14
Shell side pressure drop; Pt = 8 j f de lB w
Friction factor, jf 0.028 pg 673
Linear velocity 0.192363531
Thus; Pt 112852604.71 Pa 112852.60471 Kpa - Inputs
Mass fraction Density Vol flow Enthalpy of Vapourization
Process Stream 2167 0.1121 0.0002114 at 135 897.17674133 Liquid 3.16 Vapour
72609818.871 kJ/hr 20169.394131 kJ/s se one shell pass and two tube passes
o C
o C
m2
m m m
tubes
m3/s
m/s
53 mm tubes
Condensation outside the tube
v =/_( _ ) 3060.84156 kg/s m
Rec =(4) _ 57915639.8 /_ hc 6282.99208
W m-2 oC-1
mm m mm2 m2
mm m
m3/s
m/s
W m-2 oC-1 d d o ln o 1
1 d o di 1 1 idc h1 di 2 kw hodc hs
m u t2 2.5
w 2
L
0.14 u s2
lB w 2 Design Temperature and Pressure
Operating Temperature Design Temperature
Shell side 50 OC Shell side 90 OC Tube side 136.4 OC Tube side 176.4 OC
Operating Pressure design Pressure
Shell side 112852.6 Kpa Shell side 135423.1 Kpa Tube side 8115.363 Kpa Tube side 9738.436 Kpa
Tube Specifications
Outer diameter 20 mm 0.02 m
Wall thickness 2 mm 0.002 m Inner diameter 16 mm 0.016 m Baffel cut 45 % Tube length 6.1 m Shell internal diameter 600 Surface area of 1 tube 0.383274 m2 Tube cross sectional area 0.000201 m2
Shell Thickness
Corrosion allowance 3 mm Weld joint efficiency 1
Design Stress Maximum tensile stress 258.75 N/mm2 Maximum yield stress 202.5 N/mm2 P di tmin = C Shell thickness 2 F J P 304.4126 mm 4.8 mm FROM STANDARDS
Outer diameter 1208.825 mm 1.208825 m
Baffel spacing 604.4126 mm 0.604413 m
Number of baffels 9.092443 approximately 20
Baffel length 332.4269 mm 0.332427 m
Nozzle Dimensions
The optimum diameter is given by;
Process Stream Mass flow rate of fluid 6291.023 kg/s Density of process stream 897.1767 kg/m3
Thus; dopt 2441.322 mm
95.38269 inches d optimum 293 G 0.53 0.37
Cooling Water Stream
Mass flow rate of fluid 191.998 kg/s Density of cooling stream 998.1 kg/m3
Thus; dopt 369.25 mm
14.53741 inches
Heat Exchanger Tube Plate Design
Plate thickness due to bending
Pitch 25 mm Di 16 mm Ligament eff 0.36
Cph 0.05 Db 817.7877 mm fp 135 N/mm2 P -125685 N/mm2
tp1 #VALUE! mm
Plate thickness due to shear thinning
tough 67.5 N/mm2
tp2 -486423
The bigger thickness would be used
Thus; thickness -486423 mm
However, standards say that the minimum thickness is
tp 25 mm
Combined Loading
Shell Weight
Cv 1.15 Ws 1577.648 Dm 0.904413 m Hv 6.1 t 0.304413
Tube Weight
do 0.02 Wt 5206.513 di 0.016 L 6.1 density 7850 N 98 g 9.81
Fluid Weight
Wft = Ms (distance travelled by fluid / velocity) g
Ms 6291.023 Wtf 38561.45
d travelled 12.2 Us 19.52526
Wfs
Ms 191.998 Wts 496.9777
d travelled 12.2 Us 46.2369
Wf 39058.42
Insulation Weight
do 0.024 Wi 1.503968 di 0.016 L 6.1 density 100 (fibre glass)
