viii LIST OF CONTENTS

TITLE 2.1 INTRODUCTION

PAGE 1

2.2

CHEMICAL DESIGN 2.2.1 2.2.2 2.2.3 2.2.4 Process Stream Condition Selection of Equipment Allowable Pressure Drop E-100 Design Calculations 2.2.4.1 2.2.4.2 2.2.4.3 2.2.4.4 2.2.4.5 2.2.4.6 2.2.4.7 2.2.4.8 2.2.4.9 Specification Heat Load in Shell and Tube Side Overall Coefficient Type and Dimensions Heat Transfer Area Layout and Tube Size Number of Tubes Bundle and Shell Diameter Tube-Side Heat Transfer Coefficient 2 2 24 4 5 5 6 6 6 6 7 7 8 9 -10 10 11 11 12 12

2.2.4.10 Shell-Side Heat Transfer Coefficient 2.2.4.11 Overall Coefficient 2.2.4.12 Tube Side Pressure Drop 2.2.4.13 Shell Side Pressure Drop 2.2.4.14 Conclusion of Chemical Design 2.2.4.15 Summary of Chemical Design of Heat Exchanger

ix 2.4 MECHANICAL DESIGN 2.3.1 2.3.2 2.3.3 2.3.4 2.3.5 2.3.6 Design Pressure and Temperature Material of Construction Maximum Allowable Stress (Nominal Design Strength) Welded-Joint Efficiency Corrosion Allowance Design Criteria 2.3.6.1 Minimum Practical Wall Thickness 2.3.6.2 Cylinder Shell Thickness 2.3.7 Heads and Closure 2.3.8 Design of Nozzle 2.3.8.1 Tube Side Nozzle (steam) 2.3.8.2 Shell Side Nozzle (stream 5) 2.3.9 Design of Flange Joint 13 14 14 15 15 15 16 16 16 17 18 18 18 19 19 20 21 21 21 22 22 23 23 24 24 25 26

2.3.10 Baffles 2.3.11 Insulator Thickness 2.3.12 Weight Load 2.3.12.1 Vessel Shell Weight 2.3.12.2 Tube Weight 2.3.12.3 Weight of Liquid to Fill the Vessel 2.3.12.4 Weight of Insulator 2.3.12.5 Total Weight Loads 2.3.13 Vessel Support Design 2.3.13.1 Design of Saddle 2.3.14 Design Specification for Heat Exchanger

2.4

TECHNICAL DRAWING

27 28 28 29

2.5

CONCLUSION 2.5.1 2.5.2 Summary of Chemical Design of Heat Exchanger Design Specification for Heat Exchanger

REFERENCES

30

APPEDICES

31 - 36

x LIST OF TABLES

TABLE 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9

TITLE Properties of inlet and outlet process stream of E-100. Classification of stream for shell and tube side of E-100. Selection on type of heat exchanger. Selection on tube characteristics Allowable pressure drop for shell and tube side. Physical properties of stream 5 and steam. Temperature for each stream. Summary of chemical design of E-100. Design pressure and temperature for shell and tube, taking safety factor as 10%.

PAGE 2 3 3 4 4 5 5 11 14

3.10

Types of materials selected for construction for shell and tube.

14

3.11

Design stress for shell and tube, taking safety factor as 10%.

15

3.12 3.13 3.14 3.15 3.16 3.17

Specification for tube side (based on chemical design). Specification for shell side (based on chemical design). Total weight loads of E-100. Summary for mechanical design of E-100. Summary of chemical design of E-100. Summary for mechanical design of E-100.

17 17 24 26 27 28

xi LIST OF FIGURES

FIGURE 3.1 3.2

TITLE Model input and output of heater, E-100 AES, Channel and removable cover, one pass shell, floating head with backing device.

PAGE 2 3

3.3 3.4 3.5

Welding-neck flanges Single segmental baffles design Standard steel saddles

19 20 25

xii LIST OF NOMENCLATURES

A Ao A Acs At b Cp Cv Db de Ds Dh Dms Dmt do di es eH F Ft g Gt Gs hv hi ho hod hid hs IB Iw J Jh

Heat transfer area Clearance area between bundle and shell Tube external surface area Tube cross-sectional area Total flows area Effective sealing width of gasket heat capacity at constant pressure Factor weight of nozzle Bundle diameter Equivalent diameter Shell diameter diameter of tube holes in baffles Mean diameter of vessel Mean diameter of tube tube outside diameter tube inside diameter cylindrical shell thickness head thickness design stress Log mean temperature difference correction factor Gravitational acceleration Steam mass flow rate Shell side mass flow rate per unit area length between tangent lines heat transfer coefficient in condensation Film heat transfer coefficient inside a tube Heat transfer coefficient outside a tube Fouling coefficient on outside of tube Fouling coefficient on inside of tube Shell-side heat transfer coefficient Baffle spacing (pitch) insulation of mineral wool welded joint efficiency Heat transfer factor

xiii k1 k kf kw L LMTD Nb Np Nt n1 P pt Pt Ps Q T T T1 T2 Tlm Tm t t1 t2 U Uo u us ut

constant value for tube arrangement Thermal conductivity Thermal conductivity of fluids Thermal conductivity of tube wall material Length of the tube Log mean temperature different number of baffle segmental number of tubes per pass Number of tubes constant value for tube arrangement Total pressure Tube pitch Tube-side pressure drop Shell-side pressure drop Heat transfer in unit time Shell side temperature Temperature of surface Shell-side inlet temperature Shell-side outlet temperature Logarithmic mean temperature difference Mean temperature different Tube side temperature Tube-side inlet temperature Tube side exit temperature Overall heat transfer coefficient Overall heat transfer coefficient based on tube side area fluid velocity Shell-side fluid velocity Tube side fluid velocity Latent heat Viscosity Density Viscosity at wall temperature Surface Tension Prandtl number Reynold number

Pr Re