Chapter 5

Equipment Design

Heat exchanger

DESIGN OF HEAT EXCHANGER

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Equipment Design

Heat exchanger

DESIGN OF HEAT EXCHANGER

Definition
A heat exchanger is a device which is used to transfer heat between two streams, having different temperatures, through a boundary wall. OR A device used to transfer heat from a fluid flowing on one side of a barrier to another fluid flowing on the other side of the barrier.

Types of heat exchangers

Following are the basic types of heat exchanger being used in Chemical industry;

Double pipe exchanger Shell and tube exchanger Plate and frame exchanger Plate- Fin exchanger

Spiral heat exchanger Air cooled heat exchanger Gas to gas heat exchanger

Uses of heat exchangers in chemical industry:

Heat exchangers find wide application in the chemical process industries, such as; Petroleum refining and petrochemical processing. In the food industry, for example, for pasteurization of milk and canning of processed foods In the generation of steam for production of power and electricity In nuclear reaction systems In aircraft and space vehicles In fact, Heat exchangers are the workhorses of the entire field of heating, ventilating, airconditioning, and refrigeration. 63

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Factors to be considered while selecting a heat exchanger

Cost wish to have an exchanger that costs the least. Efficiency wish to have an exchanger that operates most efficiently, with minimum loss of energy in the transfer, and minimum drop in pressure of the fluids. Space wish to have an exchanger that is small. Materials want an exchanger built from materials that are compatible with the process streams and dont cost a lot. Maintenance want an exchanger that can be easily cleaned. Ease of construction. Environmental, health, and safety considerations and regulations.

Selection of shell & tube heat exchanger

I selected Shell and Tube Heat Exchanger due to the following reasons; In process industries, shell and tube exchangers are used in great numbers, far more than any other type of exchanger. It has well-established procedures for design. It can be manufactured from a wide variety of materials. It has provided many years of satisfactory service. Its codes and standards for design and fabrication are easily available. Due to their design, shell and tube heat exchangers offer a large heat transfer area and provide high heat transfer efficiency. It has good mechanical layout. It can be easily cleaned.

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Types of shell & Tube heat exchangers

There are three principal types of Shell and Tube heat exchangers, including; Fixed tube-sheet exchangers U-Tube exchangers Floating Head exchangers

Design of shell & tube heat exchanger

Following are the standard design steps which should be followed while designing a Shell and Tube Heat Exchanger; Define the duty: heat-transfer rate, fluid flow rates, and temperatures. Collect together the fluid physical properties required: density, viscosity and thermal conductivity. Decide on the type of heat exchanger to be used. Select the trial value for heat transfer coefficient - UD. Calculate the mean temperature difference -Tm. Calculate the area required - A. Decide the exchanger layout. Calculate the individual coefficients. Calculate the overall coefficient and compare with the trial value. If the difference is more than 30% then substitute the calculated value and do the calculations again. Calculate the exchanger pressure drop.

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Properties of fluid on the shell & tube side

Following table shows the properties of fluids at both sides of the exchanger;

Shell Side Lean Amine Solution

mh 12.2912 kg/s mc

Tube Side Rich Amine Solution

13.659 kg/s

Th,in

123.3

Tc,in

68.3

Th,out

84.11

Tc,out

105.22

Cp

3.68 9.97*10-4

kJ/kg.K

Cp

3.51 1.45*10-3

kJ/kg.K

Pa.s kg/ m3

Pa.s kg/ m3

1006

1038

0.4259

W/m.K

0.4175

W/m.K

Design calculations Heat load

Qcold = mc*Cp*(Tc, out Tc, in) =1770.059 kJ/s Where, mc = mass flow rate of cold stream Tc, out = Outlet temperature of cold stream Tc, in = Inlet temperature of cold stream 66

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Equipment Design

Heat exchanger

=mh* Cp *(Th, in Th, out) =1770.059 kJ/s Where, mh = Mass flow rate of hot stream Th, in = Inlet temperature of hot stream Th, out = Outlet temperature of hot stream Hence, Qcold = Qhot

Ft FACTOR:
R = (Th, in - Th, out)/ ( Tc, out - Tc, in) =1.06 S = (Tc, out - Tc,in)/ ( Th,in - Tc,in) =0.67 So, for 3-6 exchangers; Ft=0.88 Where, Ft = Temperature correction factor

[8]

Log Mean Temperature Difference:

LMTD =[(Th,in Tc,out)-(Th,out Tc,in)] / [ln(Th,in - Tc,out)/( Th,out - Tc,in)] = 16.92 oC

True Temperature Difference:

To,m =LMTD* Ft =14.89 oC Where, To, m = True temperature difference

Assumed Overall Heat Transfer Co-efficient:

Now assumed the value of Ud as; Ud =500 W/mK [9]. Where, Ud = Assumed value of Overall Heat Transfer Co-efficient

Heat transfer area

A =Q / Ud To, m =237.7 m2 Where, Q = Heat Duty

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There are three 1-6 heat exchangers in series, so this heat exchanger becomes 3-18 heat exchanger. So, calculation for one 1-6 heat exchanger is as follows: Area of one heat exchanger is calculated as follows; Area of 1 heat exchanger; A/3 =79.25 m2

Tube dimensions:
Length of the Tube = L = 3.66 m BWG = 14 Outside Diameter = Do = 0.01905 m Inside Diameter = Di = 0.01483 m Flow Area = Ac = 0.000173 m2 Surface area per unit length = As = 0.046604 m2/m No. of tubes = nt = A/(As*Lt) =465 No. of tube passes = np = 6 Tube pitch = Pt = 0.023813 m (Square Pitch) Tube clearance = Pd = Pt Do = 0.004763 m [10]

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Shell dimensions
K1 =0.0402 n1 =2.617 (For 6 passes and square pitch, From Table 12.4 coulson vol# 6) Tube Bundle Diameter = Db = Do(nt/K1)1/n1 =0.68 m Clearance between Bundle Diameter and Shell inside diameter = C = 0.062 m (Using fig.12.10 coulson vol#6) Shell inside diameter = Ds = C + Db = 0.742 m Baffle Spacing = Lb = 0.25 m Baffle Thickness = Tb = 0.006 m No. of Baffles = Nb =[L/(Tb+ Lb)]-1 =14

Tube side calculations

Tube side mass velocity = Gi = (mc*np)/ (Ac*nt) =1019.33 kg/m2s Tube side Velocity = ut = Gi / =0.982m/s Reynolds number = Re = (Di* Gi)/ = 10442 Prandtl number = Pr = (Cp*)/k = 12.17 As Re > 10,000, so Tube side heat transfer co-efficient = hi = 2443 W/m2K

[11]

Shell side calculations

Shell flow area = Sm = (Ds*Pd*Lb)/Pt = 0.037 m2 Shell side mass velocity = Gs = mh / Sm = 331.29 Kg/ms Shell equivalent diameter = De = 1.27*(Pt2-0.785* Do2)/ Do =0.0188m (eq.12.23 coulson vol. 6) Shell side velocity = us = Gs / =0.329 m/s Reynolds number = Re = (De*Gs)/ = 6263 Prandtl number = Pr = (Cp*)/k = 8.60 Now from fig-12.29, page#672, Coulson vol. 6 Friction factor = Jh = 0.0055 So, Shell side heat transfer co-efficient = hs = Jh (k/De) (Re) (Pr) 1/3 =1594.9 W/m2K

Over all heat transfer coefficient

Assuming; Tube side dirt co-efficient = Rdi =0.0004 m2K/ W Shell side dirt co-efficient = Rdo =0.0004 m2K/ W Now, using equation; [13]

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1 1 1 Di ln( Do / Di ) Di Di = + + + + Ui hi hid 2kw hoDo hodDo

Where, Kw = thermal conductivity of tube wall material hid = tube side dirt co-efficient hod = shell side dirt co-efficient Hence, Ud = 605 W/m2K

Check for Ud:

Percentage Variation = [(Ucalculated-Uassumed)/Uassumed] 100 = 21 % Because this variation is within the range given at page 680, CHEMICAL ENGINEERING-An Introduction to chemical engineering Design, Volume 6, J.M. Coulson, J.F. Richardson, and R.K. Sinnott. Hence, our design is satisfactory.

Pressure drop calculations Tube side calculations

Tube side pressure drop = Pt = Np [8jf (L/Di)+2.5]Gi2/2 Now, Tube side friction factor = jf = 0.005 (From fig-12.24 coulson, vol.6) Hence, Pt = 37.145 kPa

Shell side calculations

Shell side friction factor = jf = 0.045 (From fig-12.24 coulson, vol.6) Hence, Shell side pressure drop = Ps =
4 j f Gs 2 Ds ( Nb +1)

De

=11.6 kPa

Specification sheet

(All calculations are for a single 1-6 exchanger.)

Unit No. of shell passes No. of tube passes No. of Units Heat Transfer area Shell & tube heat exchanger 1 6 3 79.25 m2 70

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Diameter of shell Pitch (Square) No. of tubes Type of tube used No of baffles & type OD of tube ID of tube Length of tube P on shell side P on tube side

0.74 m 0.023813 m 465 14BWG 14 (45%cut baffle) 0.01905 m 0.01483 m 3.66 m 11.6 kPa 37.145 kPa

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