DESIGN OF HEAT EXCHANGER

CHAPTER No.6
DESIGN OF HEAT EXCHANGER
6.1 HEAT EXCHANGER :

A heat exchanger is a device built for efficient heat transfer from one medium to another,
whether the media are separated by a solid wall so that they never mix, or the media are
in direct contact. They are widely used in space heating, refrigeration, air conditioning,
power plants, chemical plants, petrochemical plants, petroleum refineries, and natural gas
processing. One common example of a heat exchanger is the radiator in a car, in which a
hot engine-cooling fluid, like antifreeze, transfers heat to air flowing through the radiator.

6.2 WORKING PRINCIPLE OF SHELL AND TUBE

HEAT EXCHANGERS:

Heat exchangers are devices that facilitate the exchange of heat between two fluids that
are at different temperatures while keeping them from mixing with each other.
Heat Exchangers differ from mixing chambers in that they do not allow to fluids involved
mixing.
Heat exchangers work because heat naturally flows from higher temperature to lower
temperatures. Therefore if a hot fluid and a cold fluid are separated by a heat conducting
surface heat can be transferred from the hot fluid to the cold fluid.

55
Production of Acrylonitrile
 DESIGN OF HEAT EXCHANGER

Simplified Heat Exchanger

Heat transfer in a heat exchanger usually involves Convection in each fluid and
conduction through the wall separating the two fluids. The layer of deposits represents
additional resistance to heat transfer and cause the rate of heat transfer in a heat
exchanger to decrease.

6.3 TYPES OF HEAT EXCHANGERS

 Shell and Tube heat exchanger
 Plate heat exchanger
 Regenerative heat exchanger
 Adiabatic Wheel heat exchanger
 Fluid heat exchangers
 Dynamic Scraped surface heat exchanger
6.4 SHELL AND TUBE HEAT EXCHANGER

Shell and tube heat exchangers consist of a series of tubes. One set of these tubes
contains the fluid that must be either heated or cooled. The second fluid runs over the
tubes that are being heated or cooled so that it can either provide the heat or absorb the
heat required. A set of tubes is called the tube bundle and can be made up of several types
of tubes: plain, longitudinally finned etc. Shell and Tube heat exchangers are typically
used for high pressure applications (with pressures greater than 30 bar and temperatures
greater than 260°C). This is because the shell and tube heat exchangers are robust due to
their shape.

There are several thermal design features that are to be taken into account when
designing the tubes in the shell and tube heat exchangers. These include:

 Tube diameter: Using a small tube diameter makes the heat exchanger both
economical and compact. However, it is more likely for the heat exchanger to
foul up faster and the small size makes mechanical cleaning of the fouling
difficult. To prevail over the fouling and cleaning problems, larger tube diameters
can be used. Thus to determine the tube diameter, the available space, cost and
the fouling nature of the fluids must be considered.

56
Production of Acrylonitrile
 DESIGN OF HEAT EXCHANGER

 Tube thickness: The thickness of the wall of the tubes is usually determined to
ensure:
 There is enough room for corrosion
 That flow-induced vibration has resistance
 Axial strength
 Ability to easily stock spare parts cost

Sometimes the wall thickness is determined by the maximum pressure differential

across the wall.

 Tube length: Heat exchangers are usually cheaper when they have a smaller shell
diameter and a long tube length. Thus, typically there is an aim to make the heat
exchanger as long as possible. However, there are many limitations for this,
including the space available at the site where it is going to be used and the need to
ensure that there are tubes available in lengths that are twice the required length
(so that the tubes can be withdrawn and replaced). Also, it has to be remembered
that long, thin tubes are difficult to take out and replace.
 Tube pitch: When designing the tubes, it is practical to ensure that the tube pitch
(i.e. the centre-centre distance of adjoining tubes) is not less than 1.25 times the
tubes' outside diameter

6.5 CONSTRUCTION OF 1-2 SHELL AND TUBE HEAT

EXCHANGER
Shell

57
Production of Acrylonitrile
 DESIGN OF HEAT EXCHANGER

The shell is simply the container for the shell-side fluid. The shell normally has a circular
cross section and is commonly made by rolling a metal plate of the appropriate
dimensions into a cylinder and welding the longitudinal joint large diameter, near-
atmospheric pressure shells have been designed with a partial ball-joint in the shell
designed to allow the shell to partially "rotate" to accommodate stresses.

Tubes
The tubes are the basic component of the shell and tube exchanger, providing the heat
transfer surface between one fluid flowing inside the tube and the other fluid flowing
across the outside of the tubes. The tubes may be seamless or welded and most
commonly made of copper or steel alloys. Other alloys of nickel, titanium, or aluminum
may also be required for specific applications.

Tube sheets:
A tube sheet is an important component of a heat exchanger. It is the principal barrier
between the shell-side and tube-side fluids. Proper design of a tube sheet is important for
safety and reliability of the heat exchanger. Tube sheets are mostly circular with uniform
pattern of drilled holes. Tube sheets of surface condensers are rectangular shape. Tube
sheets are connected to the shell and the channels either by welds (integral) or with bolts
(gasketed joints) or with a combination of both. Tube-sheet connection with the shell and
channel for fixed tube-sheet exchanger can be categorized into two types:

1. Both sides integral construction

2. Shell-side integral and tube-side gasketed construction

Tube-sheet connection with the shell and channel for floating heat exchanger and U-tube
heat exchangers can be categorized into three types:

 Both sides integral construction

 One side integral and the other side gasketed construction
 Both sides gasketed construction
Tube to Tube-Sheet Attachment

Tubes are attached to the tube sheet by:

 rolling
 welding
 rolling and welding
 explosive welding
 brazing
Schematic sketch of tube to tube-sheet attachment are given in fig. Expansion of the
tubes into the tube sheet is most widely used and is satisfactory for many services.
However, when stresses are higher, or where pressures are such that significant leakage

58
Production of Acrylonitrile
 DESIGN OF HEAT EXCHANGER

could occur, or where contamination between fluids is not permitted, the tubes are welded
to the tube sheet. Explosion welding can be used instead of conventional welding where
there is incompatibility between tube and tube-sheet materials and for tube plugging
under hazardous conditions.

Nozzles
The nozzles are the inlet and exit ports which allow the entrance and departure of two
fluid streams separately in the shell and tube heat exchanger.

Impingement plate
The inlet nozzle often has an impingement plate (Fig.1.37)
set just below to divert the incoming fluid jet from impacting
directly at high velocity on the top row of tubes.
Tube-Side Channels
Tube-side channels and nozzles simply control the flow
of the tube-side fluid into and out of the tubes of the exchanger. Since the tube-side fluid
is generally the more corrosive, these channels and nozzles will often be made out of
alloy materials (compatible with the tubes and tube sheets, of course). They may be clad
instead of solid alloy.
Channel Covers
The channel covers are round plates that bolt to the channel flanges and can be removed
for tube inspection without disturbing the tube-side piping. In smaller heat exchangers,
bonnets with flanged nozzles or threaded connections for the tube-side piping are often
used instead of channels and channel covers.

Pass Divider
A pass divider is needed in one channel or bonnet for an exchanger having two tube-side
passes, and they are needed in both channels or bonnets for an exchanger having more
than two passes. If the channels or bonnets are cast, the dividers are integrally cast and
then faced to give a smooth bearing surface on the gasket between the divider and the
tube sheet. If the channels are rolled from plate or built up from pipe, the dividers are
welded in place.

Baffles
Baffles serve two functions:

 They support the tubes in the proper position during assembly and operation and
prevent vibration of the tubes caused by flow-induced eddies

 They guide the shell-side flow back and forth across the tube field, increasing the
velocity and the heat transfer coefficient.
Classification of Baffles:
59
Production of Acrylonitrile
 DESIGN OF HEAT EXCHANGER

Baffles are either normal or parallel to the tubes. Accordingly, baffles may be classified as
transverse or longitudinal.

 Transverse Baffles:
The transverse baffles direct the shell-side fluid into the tube bundle at approximately
right angles to the tubes, and increase the turbulence of the shell fluid.

Transverse baffles are of two types:

 Plate baffles
 Rod baffles

Three types of plate baffles are

 Segmental baffles
 Disk and doughnut baffles
 Orifice baffles

1. Segmental Baffles:
The segmental baffle is a circular disk (with baffle holes) having a segment removed.
Predominantly, a large number of shell and tube exchangers employ segmental baffles.
This cutting is denoted as the baffle cut and it is commonly expressed as a percentage of
the shell inside diameter.
The segmental baffle is also referred to as a single segmental baffle. The heat transfer and
pressure drop of cross flow bundles are greatly affected by the baffle cut. The baffle cuts
vary from 20 to 49% with the most common being 20-25%, and the optimum baffle cut is
generally

20%, as it affords the highest heat transfer for a given pressure drop. Baffle cuts smaller
than 20% can result in high pressure drop. As the baffle cut increases beyond 20%, the
flow pattern

60
Production of Acrylonitrile
 DESIGN OF HEAT EXCHANGER

deviates more and more from cross flow and can result in stagnant regions or areas with
lower flow velocities; both of these reduce the thermal effectiveness of the bundle.

Baffle Spacing:
The practical range of single-segmental baffle spacing is to 1 shell diameter, though
optimum could be 40-50% [2]. TEMA provides maximum baffle spacing for various tube
outer diameters, tube materials, and the corresponding maxi- mum allowable temperature
limit. The baffles are generally spaced between the nozzles. The inlet and outlet baffle
spacings are in general larger than the “central” baffle spacing to accommodate the
nozzles, since the nozzle dimensions frequently require that the nozzle should be located
far enough from the tube sheets.

2. The disk and doughnut baffle:

The disk and doughnut baffle is made up of alternate “disks” and “doughnut” baffles as
shown in Fig. Disk and doughnut baffle heat exchangers are primarily used in nuclear
heat exchangers.

This baffle design provides a lower pressure drop compared to a single segmental baffle
for the same unsupported tube span, and eliminates the tube bundle to shell bypass
61
Production of Acrylonitrile
 DESIGN OF HEAT EXCHANGER

stream.

3. Orifice baffle:
In an orifice baffle, the tube-to-baffle hole
clearance is large so that it acts as an orifice
for the shell-side flow. These baffles do not
provide support to tubes, and, due to fouling,
the annular orifices plug easily and cannot be
cleaned. This baffle design is rarely used.

Longitudinal baffles:
Longitudinal baffles divide the shell into two or more sections, providing multipass on
the shell side. The longitudinal baffles are used to control the direction of the shell side
flow. But this type should not be used unless the baffle is welded to the shell and tube
sheet. Nevertheless, several sealing devices have been tried to seal the baffle and the
shell, but none has been very effective.
They are:
 Sealing strips or multiflex arrangement
 Packing arrangement
 Slide-in or tongue-and-groove arrangement

Flanged joints:
Flanges are often employed to connect two sections by bolting them together so that the
sections can be assembled and disassembled easily. In heat exchangers, the flange joints
are used to connect together the following components:
 Channel and channel cover
 Heads or channels with the shell/tube sheets
 Inlet and outlet nozzles with the pipes carrying the fluids
The flanged joints play an important role from the standpoint of integrity and reliability
of heat exchangers. Improper design of flanges causes leakage of heat exchanger fluids.
Therefore, preventing the liquid or gas leaks is one of the most important considerations
while designing flanged joints.

Flanged Joint Types:

From a conceptual standpoint, flanged joints may be subdivided into two major
categories:
1. Bolted joints
2. Pressure-actuated or self-energizing joints

Tube pitch:

62
Production of Acrylonitrile
 DESIGN OF HEAT EXCHANGER

The shortest center-to-center distance between the adjacent tubes is termed as tube pitch.
Although The square pitch has the advantage of easier external cleaning, the triangular
pitch is sometimes preferred because it permits the use of more tubes in a given shell
diameter.

6.6 THE THERMAL STRESS PROBLEM:

Since, by its very purpose, the shell of the heat exchanger will be at a significantly
different temperature than tubes, the shell will expand or contract relative to the tubes,
resulting in stresses existing in both components and being transmitted through the tube
sheets. The consequences of the thermal stress will vary with circumstances, but shells
have been buckled or tubes pulled out of the tube sheet or simply pulled apart. The fixed
tube sheet exchanger shown in Fig. is especially vulnerable to this kind of damage
because there is no provision made for accommodating differential expansion.

6.7 SOLUTIONS TO THE THERMAL EXPANSION

1. Expansion Joint on the Shell:
The most obvious solution to the thermal expansion
problem is to put an expansion roll or joint in the shell
as shown in Fig. This becomes less attractive for
large diameter shells and/or increasing shell-side
pressure. However, very large diameter, near
atmospheric pressure shells have been designed
with a partial ball-joint in the shell designed to allow
the shell to partially "rotate" to accommodate
stresses.

2. Internal Bellows
In recent years, an internal bellows design Fig.
has become popular for such applications as
waste heat vertical thermosiphon reboilers,
63
Production of Acrylonitrile
 DESIGN OF HEAT EXCHANGER

where only one pass is permitted on the tube side.

These bellows have been designed to operate
successfully with high pressure boiling water on the tube side and high temperature
reactor effluent gas on the shell.

3. Pull-through bundle Floating head

The simplest floating head design is the pull-through bundle" type, shown in Fig. One of
the tube sheets is made small enough that it and its gasketed bonnet may be pulled
completely through the shell for shell-side inspection and cleaning. The tube side may be
cleaned and individual tubes may be replaced without removing the bundle from the
shell. Unfortunately, many tubes must be omitted from the edge of the full bundle to
allow for the bonnet flange and bolt circle.

4. Split-ring floating head

This objection is met in the "split-ring floating head" type (Fig.) by bolting the floating
head bonnet to a split backing ring rather than to the tube sheet. At some cost in added
mechanical complexity, most of the tubes lost from the bundle in the pull-through design
have been restored, and the other features retained.

6.8 SHELL & TUBE HEAT EXCHANGER DESIGN

There can be many variations on the shell and tube design. Typically, the ends of each
tube are connected to plenums (sometimes called water boxes) through holes in tube
sheets. The tubes may be straight or bent in the shape of a U, called U-tubes.

In nuclear power plants called pressurized water reactors, large heat exchangers called
steam generators are two-phase, shell-and-tube heat exchangers which typically have U-
tubes. They are used to boil water recycled from a surface condenser into steam to drive
the turbine to produce power. Most shell-and-tube heat exchangers are either 1, 2, or 4
pass designs on the tube side. This refers to the number of times the fluid in the tubes
64
Production of Acrylonitrile
 DESIGN OF HEAT EXCHANGER

passes through the fluid in the shell. In a single pass heat exchanger, the fluid goes in one
end of each tube and out the other.

Surface condensers in power plants are often 1-pass straight-tube heat exchangers (see
Surface condenser for diagram). Two and four pass designs are common because the fluid
can enter and exit on the same side. This makes construction much simpler.

There are often baffles directing flow through the shell side so the fluid does not take a
short cut through the shell side leaving ineffective low flow volumes.

Counter current heat exchangers are most efficient because they allow the highest log
mean temperature difference between the hot and cold streams. Many companies
however do not use single pass heat exchangers because they can break easily in addition
to being more expensive to build. Often multiple heat exchangers can be used to simulate
the counter current flow of a single large exchanger.

6.9 THERMO HYDRAULIC DESIGN PROCEDURE SHELL

AND TUBE HEAT EXCHANGER
Thermo hydraulic design steps for shell and tube heat exchanger are,

 Calculation of heat duty

 Calculation of log mean temperature difference

 Finding out correction factor for LMTD

 Correction of LMTD

 Assuming overall dirt coefficient(Ud)

 Area calculation

 Calculation of number of tubes

 Corrected area

 Corrected overall dirt coefficient

 Shell side calculation

 Selection of shell inside diameter

65
Production of Acrylonitrile
 DESIGN OF HEAT EXCHANGER

 Baffle spacing
 Pitch calculation
 Tube clearance
 Shell area
 Mass velocity
 Equivalent diameter
 Reynold’s number across shell side
 Factor for heat transfer calculation
 Prandtl’s number
 Individual heat transfer coefficient

 Tube side calculation

 Flow area per tube

 Number of tubes calculation
 Tube area calculation
 Mass velocity calculation
 Reynold’s number across tube side
 Velocity calculation
 Prandtl’s number
 Calculation of factor for heat transfer coefficient
 Calculation of individual heat transfer coefficient

 Calculation of overall clean coefficient

 Dirt factor

 Pressure drop calculations

 Pressure drop across shell side

 Pressure drop across tube side

For Design
It is desired to cool the process stream from 420oC to 220oC by the use of cooling water
as cooling media.

66
Production of Acrylonitrile
 DESIGN OF HEAT EXCHANGER

STEP 1:-
To complete the specification, the duty (heat transfer rate) needed to be
calculated. The mean temp of process stream is 593K and the mean temp of water is
385K.
Now: - For process stream duty or heat transfer rate
q = m Cp  T
q = 114528 x 707 x (693 – 493)
q = 2.98x107 KJ/hr
For water mass flow rate:-
q = m Cp  T
2.98x107 = m x 522 x (473 – 298)
m= 36500 Kg/hr

STEP 2:-
Physical Properties Of Process stream

INLET MEAN OUTLET UNITS

Temperature 693 593 493 K
Specific heat (Cp) 521 KJ/Kg K
Thermal conductivity (k) 0.044 W/mK
Density () 800 Kg/m3
Viscosity () 6.31x10-4 kgm-1s-1

For Water:-

67
Production of Acrylonitrile
 DESIGN OF HEAT EXCHANGER

INLET MEAN OUTLET UNITS

Temperature 298 385 473 K
Specific heat (Cp) 490 KJ/Kg K
Thermal conductivity (k) 0.6912 W/mK
Density () 445 Kg/m3
Viscosity () 1.028x10-3 kgm-1s-1
Step 3:-
For system of water & light organics, the value of Uo lies in the range of 375-
750W/m2 K, so assume.
Uo=650 W/m2 K
Step 4:-
Usually an even number of tube passes the preferred arrangement.

For 1 shell and 2 tube passes

LMTD

LMTD = [(T1-t2) – (T2-t1)]/ln[(T1-t2)/(T2-t1)]

LMTD = [(693-473) – (493-298)]/ln[(693-473)/(493-298)]
=207.2 K
R , S & Ft

R=(T1-T2)/(t2-t1)
=(693-493)/(473-298)
=1.1428
S=(t2-t1)/(T1-t1)
=(473-298)/(693-493)
=0.44

From Fig 12.19 (coulson 6) Temp correction factor

Ft= 0.91

Corrected LMTD
68
Production of Acrylonitrile
 DESIGN OF HEAT EXCHANGER

Corrected LMTD= Tm=Ft * LMTDcalc

= 0.91 * 207.2
=188.52K

Step 5:-
Heat Transfer Area:
Q = Uo Ao  Tm
Ao = Q / Uo  Tm
Ao = 2.98x107 / 650 x 188.52
Ao = 68m2

6.10 SELECTION OF HEAT EXCHANGER

 A < 2m2 (21.5 ft2) select a coiled heat exchanger

 2 m2 < A < 50 m2 (538 ft2) select a double-pipe heat exchanger

69
Production of Acrylonitrile
 DESIGN OF HEAT EXCHANGER

 A > 50 m2 select a shell-and-tube heat exchanger. ( ref. Chemical process

engineering design & Economics By Harry Silla)
 As area >50m2, shell and tube heat exchanger with 1-2 shell . Tube pass to get
low pressure drop is selected.

Floating head type Heat Exchanger

 The floating head type exchanger is more robust exchanger capable of handling
both high temperature & high pressure.
 It’s one end of tube bundle is not attached to shell & thus can move within shell to
take care of stresses from thermal expansion.
 Since its fabrication is complex so it is approx 25% more expensive than fixed
tube type for same surface area.

So floating head type heat exchanger is selected, keeping in view its above
advantages.

The fluid is not corrosive, so plain carbon steel can be used for the shell and tubes.

70
Production of Acrylonitrile
 DESIGN OF HEAT EXCHANGER

71
Production of Acrylonitrile
 DESIGN OF HEAT EXCHANGER

Fluid Allocation
 Allocate the fluid on the tube side if the fluid is:
1. More corrosive

2. Less viscous

3. More fouling

4. At a higher pressure

5. Hotter

6. At a higher flow rate

7. If the fluid requires a low pressure drop.

 Process Fluid is placed on the tube side because:

1. The tube side is relatively easy to clean

2. Tubes are easier to replace or plugged if damaged

3. High heat-transfer coefficients can be obtained at a low pressure drop

4. A high-pressure fluid is more economically contained in tubes because of their

smaller diameter compared to the shell.

Tubes Layout:
ODt = 3/4 in from TEMA std (AES) type
Corresponding to BWG= 14
Tube IDt = 14.83x10-3m
Tube OD= 19.05x10-3m
Tube thickness= 0.002m
Length of tube=5m
Pitch

72
Production of Acrylonitrile
 DESIGN OF HEAT EXCHANGER

For design triangular pitch 1.25 in. is selected because it permits the use of more tubes &
hence results in more surface area in a given shell diameter.
(1.25xdo) triangular pitch=1.25x19.05x10-3m =23.81x10-3

Tube Side Heat Transfer Coefficient

Step 6:-
At = (area of one tube) =  do L

= 3.14 x 19.05x10-3 x 5

= 0.299m2

No. of tubes = provisional area /area of 1 tube

# of tubes = 68/ 0.299 = 227
Tubes to nearest count = 224
Tubes/pass = 224/2= 112

Step 7:-
Tube cross sectional area =  / 4 (di2)
= /4 x (14.83x10-3)2
=1.72x10x-4m2
Tubes per pass =224/2 =112
73
Production of Acrylonitrile
 DESIGN OF HEAT EXCHANGER

Total flow area = 1.72x10-4 *112

= 0.193 m2
Mass velocity:
Gt = m/at
=114528/0.193
= 1650 kg/sec. m2

Linear velocity
Ut = Gt /ρ
=1650/800
Ut = 2.06 m/sec (< 4 m/sec acceptable)

Step 8:-
Tube Bundle and Shell Dia:

From table 12.4 for 2 tube passes and triangular pitch (Coulson 6)

K1 = 0.249

n1 = 2.207

Db = do (Nt / K1)1/n1

= 19.05x10-3 (224 / 0.249) 1/2.207

Tube bundle dia Db = 0.415

For a spilt ring floating head exchanger the typical shell clearance from (fig 12.10

coulson 6)

Shell clearance = 56x10-3m

So,

Ds = Shell inside dia = 0.415+56x10-3=0.471m

74
Production of Acrylonitrile
 DESIGN OF HEAT EXCHANGER

Step

9:-

75
Production of Acrylonitrile
 DESIGN OF HEAT EXCHANGER

Re = Gt x di / 

Re = 1650x 14.83x10-3 / 6.31x10-4

Re = 38768

Prandtle Number:-

Pr = (Cp x  / k) 1/3

= (521 x 6.31x10-4 / 0.044)1/3

Pr = 3.4

Now:- L/di = 5 / 14.83x10-3

= 337

Using L/di, the corresponding JH value from

Fig 12.23 (Coulson – vol 6) is

jH = 3.5x10-3

hi = JH Re Pr(k / do)

= 3.5 x 10-3 x 38768 x 3.4x(0.044 / 19.05x10-3)

hi = 2590W/m2 K

76
Production of Acrylonitrile
 DESIGN OF HEAT EXCHANGER

77
Production of Acrylonitrile
 DESIGN OF HEAT EXCHANGER

Shell Side Heat Transfer Coefficient:

(Ds) = inside dia of shell = 0.471m

Range of baffle spacing is Ds/5 to Ds/Ds

Assume take a baffle spacing = 94.2x10-3m

This baffle spacing gives good heat transfer without too much high-pressure

drop.

As = cross flow area = (Pt – do / Pt) x Ds x Baffle spacing

= (23.81x10-3 – 19.05x10-3 / 23.81x10-3) x 0.471 x 94.2x10-3

As = 0.0103m2

Shell Side Equivalent Dia :

de = 1.1 / do (pt2 – 0.917do2)

= 1.1 / 19.05x10-3 ((23.81x10-3)2 – 0.917x (19.05x10-3)2)

de = 0.01352m

Mass velocity on shell side = m / As

= 36500/ 0.0103

= 984 kg /sec.m2

Us = shell-side velocity = mass velocity/density

= 984/ 445

Us = 2.2 m/sec

78
Production of Acrylonitrile
 DESIGN OF HEAT EXCHANGER

Reynolds No:

Re = Gsx de shell / 

= 984 x 0.01352 / 1.028x10-3

= 15100

Prandtl No:-

Pr = (Cp  / k)1/3

= (490x1.028x10-3/0.6912)1/3

=2.83

Use 25% Cut Segmental Baffles

From fig 12.29 coulson 6

JH = 4.0 x 10-3

ho = jH x Re x Prx(k/de)

= 4.0 x 10-3 x 15100 x 2.83x (0.6912 / 0.01352)

ho = 3160.7W/m2 K

79
Production of Acrylonitrile
 DESIGN OF HEAT EXCHANGER

80
Production of Acrylonitrile
 DESIGN OF HEAT EXCHANGER

Overall Coefficient:-

1/Uo = (1/hi + 1/hio) do/di + doln do/di / 2kw + 1/ho + 1/hod

Uo = the overall coefficient based on the outside area of the tube, W/m 2 K

ho = outside fluid film coefficient, W/m2 K.

hi = inside fluid film coefficient, W/m2 K

hod = outside dirt coefficient (fouling factor) , W/m2 K

hid = inside dirt coefficient, W/m2 K

kw = thermal conductivity of the tube wall material, , W/m K

di = tube inside diameter, m,

do = tube outside diameter, m

1/Uo = (1/2590+ 0.0002) 19.05x10-3 / 14.83x10-3 +19.05x10-3ln

19.05x10-3/14.83x10-3 / 2 x 45 + 1/3160.7 + 0.00035

1/Uo = 7.5x10-4+5.3x10-5+3.1x10-4+0.00035

Uo = 683.5W/m2 K

Step 10:
Pressure Drop:
Tube Side Pressure Drop:-
For Re= 38768

The Jf = 3.2 x 10-3 (from Fig 12.24 coulson 6)

No. of passes = (Np) = 2

81
Production of Acrylonitrile
 DESIGN OF HEAT EXCHANGER

Pressure drop for the tube side is given by

 Pt = Np [8jf (L/di) (/w)0.14 + 2.5] ut2 / 2

neglecting (/w)0.14

= 2[ 8 x 3.2 x 10-3 (5/ 14.83x10-3) + 2.5] 800.4x (2.06)2 /2

 Pt = 35 Kpa =5 psi

Allowable pressure drop = ΔPT = 10 psi

Hence, the tube-side pressure drop is satisfactory for service.

Shell Side Pressure Drop:-

The formula for pressure drop on shell side is

 Ps = 8 x Jf (Ds / de) (L/IB) (us2 / 2) (  / w)0.14

for Re = 15100

Fanning friction factor (from Fig 12.30 coulson 6)

jf = 4.5 x10-2

Where L = length of tube

IB = Baffle spacing [Neglecting (/w) 0.14 ]

 Ps = 8 x 4.5 x 10-2 x (0.471/ 0.01352) (5 / 94.2x10-3) x 445 x (2.2)2/2

 Ps = 67.9KPa =9.6psi

Allowable pressure drop = ΔPT = 10 psi

Hence, the tube-side pressure drop is satisfactory for service.

82
Production of Acrylonitrile
 DESIGN OF HEAT EXCHANGER

6.11 MECHANICAL DESIGN

Material of construction=Plain C steel

Whose density=7877.61kg/m3
Shell Side
No. of passes=1
Working pressure=29.4psi=0.203N/mm2
Design Pressure=1.1*P”=0.2233N/mm2
Temperature of inlet stream=25 oC
Temperature of outlet stream=200 oC
Permissible strength for C steel=95N/mm2

SHELL THICKNESS:

ts = (PD)/ (2ƒj - P)
Where,
ts = Shell thickness = ?
P = Design Pressure = 0.2233 N/mm2
Ds = Inner diameter of shell = 0.471 m
Permissible strength for carbon steel = ƒ = 95 N/mm2
J= Joint factor = 85%
ts = 0.652 mm=6.52x10-4m
Allowable corrosion allowance = 2 mm
So, minimum shell thickness is = 2.652 mm=2.652x10-3m (including corrosion
allowance)

NOZZLE DIAMETER:
Material used = carbon steel
Feed nozzle for Shell Fluid
Mass flow rate of shell side fluid = 36500 kg/hr
Density of fluid = 445 kg/m3

83
Production of Acrylonitrile
 DESIGN OF HEAT EXCHANGER

Velocity of fluid =3132 m/hr

A=m/ρv
A = 0.0261 m2
Diameter of the nozzle = [0.0261 x 4 / Π] 0.5
= 0.182 m
Dn =182 mm
Feed nozzle outlet also has the same diameter.

NOZZLE THICKNESS:
tn = {(PDn) / (2ƒj –P)} + C
Corrosion allowance = C =2 mm
= [0.2233x 182/ {(2 x 95 x 0.85) –0 .2233}] + 2
= 2.25 mm
=2.25x10-3m
tn=2.25x10-3m
HEAD THICKNESS:
Take a floating head, the thickness can be calculated as:
th=PRcW / 2ƒJ
Where th = thickness of head
P = 0.2233 N/mm2
W=1/4 {(3+ (Rc/Rk) 0.5)}
Rc = Crown radius = outer radius of shell = 2.652+235.5 = 238.152 mm
Rk = Knuckle radius = 0.06 Rc = 14.89 mm
So,
W=1.77
th = (0.2233 x 238.152 x1.77)/(2x 95x0.85)
= 0.583 mm
Taking 2mm corrosion allowance we have,
th =0.583 + 2
= 2.583 mm
th=2.583x10-3m
84
Production of Acrylonitrile
 DESIGN OF HEAT EXCHANGER

RODS &SPACERS
The rods and spacers shall be provided to retain all cross baffles and tube support plates
accurately in position. From Ludwig (2nd edition, vol, 3, page # 26) table # 10.6
For shell diameter 152– 1000 mm
Diameter of tie rod is 12.5 mm and number of rods = 8
Spacers diameter = 12.5 mm

Baffle Detail:
Baffle cut: 25% cut (the length of the baffle from the shell to the flat edge of the baffle
is 75% of the diameter of the shell)
Baffle diameter:
From Coulson & Richardson (vol 6, 3rd edition ,page # 651)
For shell diameter of 152 to 635 mm,
Baffle diameter is given by the relation,
Db = Ds – 3.2 mm
= 471-3.2
Db = 467.8 mm

Baffle spacing :

B = 94.2x10-3 m = 94.2mm
Let thickness of the baffles = 0.5 in = 12.7 mm
From Ernest Ludwig, TEMA standard 1978, page #11,
Height of baffle = 0.75 * Ds
= 0.75 * 471 =353.25 mm =353.25x10-3m

No of baffles:
Nb=(Ls/Lb + tb) - 1
Nb=(5/94.2x10-3 + 12.7x10-3) – 1
Nb=45

Tube Side
Material used = Plain C steel
No. of tube passes =2
Number of tubes =224
85
Production of Acrylonitrile
 DESIGN OF HEAT EXCHANGER

Allowable stress = 0.0001 N/mm2 (from literature)

Outside diameter = 19.05x10-3 m
Inside diameter = 14.83x10-3m
Wall thickness of tubes = 2.1mm
Length of tubes = Lt = 5m
For Triangular pitch, Pt = 1.25 do = 23.81 mm
Working Pressure = 29.4 psi = 0.203 N/mm2
Design Pressure =1.1 * 0.203 = 0.2233N/ mm2
Inlet temp = 420oC
Outlet temp = 220oC
Tube Sheet Thickness:-
Tts = G ( 0.25P/ƒ)0.5
= 0.40 (0.25x 0.2233/ 95)0.5
Tts = 0.00969 m
Channel Design:
Channel Length
Lc= 1.3 x (cross sectional area of tube/pass)/Ds
= 1.3 x (1.72x10-4) / 0.471
Lc= 2.37x10-4m

b. Channel thickness:
tc = Gc  (kP/ƒ)0.5
= 0.40 x (0.3x.2233/95)0.5

= 0.01 m

Nozzle Design For Tube Side:

Material used Is Plain C steel

Mass flow rate = 114528 Kg/hr

Density = 800.4 kg / m3

Velocity of tube side fluid = v = 7416 m/hr

m = ρAv

A = m/ρv

=114528/(800.4x 7416) = 0.0193 m2

86
Production of Acrylonitrile
 DESIGN OF HEAT EXCHANGER

Diameter of the nozzle = d = (0.0193 x 4/ Π) 0.5

= 0.156 m = 156 mm

Nozzle Thickness:-

tn =(Pd D n )/(2ƒJ – P)

= (0.2233156) / (2 95 0.85 – 0.2233) =0.216 mm Now,

Nozzle thickness (with corrosion allowance) =2.216mm

Support Design:

For this shell and tube heat exchanger, we use a saddle type of support.

Material used: Plain carbon steel

Diameter of shell = Ds = 471 mm

Working Pressure = 29.4 psi=0.203N/mm2

Shell thickness = 2.652mm

Head Thickness = 2.583 mm

Corrosion Allowance = 2 mm

Permissible stress = 95 N/mm2

Rc= Crown radius = outer radius of shell = 238.152 mm

Rk = Knuckle radius = 0.06 Rc = 14.89 mm

R = Ds/2 = 235.5 mm

Distance of saddle canter from shell end = A = 0.5 R = 117.75 mm

Total depth of head (H) = (DsRc/ 2)0.5

= 30.8 mm

Shell Weight:

87
Production of Acrylonitrile
 DESIGN OF HEAT EXCHANGER

Ws = Π (Ro2 – Ri2) Lρ of shell material

ρ of shell material = 7877.61 Kg/m3

=3.14x (238.15 2 -235.52) x5x7877.61

Ws = 155.23 kg

Tube Weight:

Wt = Π (Ro2 – Ri2)L nt  ρ

Density of tube material = 7877.61 kg/m3

=3.14x[(9.525x10-3)2 – (7.415x10-3)2] x 5 x 224x 7877.61

Wt = 990.23 kg

Fluid Load In The Shell:

W1 = (shell volume - tube volume)  ρ shell fluid

= [(Π/4)Ds2 – (Π/4) do 2 nt ]  445 kg/m3

W1 = 142 kg

Fluid Load In The Tube :

W2 = (Π/4)n di2 Lρ tube fluid

W2 =154.67 kg

Now, Total Weight = Wt = Ws + Wt + W1 + W2

=155.23 + 990.23 + 142+ 154.67

Wt=1442.15kg

Weight Of Tie Rod, End Covers, Baffles:

WA = 500 kg (From Literature )
Total weight = 500 + 1442.15
= 1942.15 Kg

88
Production of Acrylonitrile
 DESIGN OF HEAT EXCHANGER

6.12 SPECIFICATION SHEET

Identification:
Item Heat Exchanger

Item No. E1

No. Required 2

Tube side Shell side

Light organics Cooling tower water
Flow rate=114528Kg/hr Flow rate=36500kg/hr
Temperature=420oC to 220oC Temperature=25oC to 200oC
Passes= 2 Passes= 1
OD=19.05x10-3m,BWG=14,224 tubes Shell inside dia=0.471m, No of baffles=45
23.81x10-3 Triangular pitch,L=5m
Material used= Plain C steel Material used= Plain C steel
Pressure drop= 5 psi Pressure drop=9.6psi
Tube sheet thickness=0.00969 m Shell thickness=6.52x10-4m
Nozzle dia=0.156 m Nozzle dia=0.182 m
Nozzle thickness=0.0022m Nozzle thickness=2.25x10-3m
Tube weight= 990.23 kg Shell weight=155.23 kg
Total weight=1942.15kg

89
Production of Acrylonitrile