EditedDesignofaShellandTubeHeatExchanger PDF

Design of a Shell and Tube Heat Exchanger
By
Subasgar Kumareswaran
Department of Chemical and Process Engineering, University of Moratuwa
A design report was submitted on 10th of January 2014 to the University of Moratuwa in partial fulfillment of the
requirements for an Honours Degree of Bachelor of Science of Engineering in Chemical and Process Engineering.
CH 4202 Comprehensive Design Project
Individual Report
DESIGN OF A SHELL AND TUBE HEAT EXCHANGER
Name: K. SUBASGAR
Index No: 090502X
Date of submission: 10th January 2014
Department of Chemical and Process Engineering
University of Moratuwa
Shell and Tube Heat Exchanger Design
NOMENCLATURE
Q Heat transferred in unit time

𝑚̇ Mass flow rate
𝐶𝑝 Heat capacity at constant pressure
∆𝑇 Temperature difference
LMTD Log mean temperature difference
R Dimensionless temperature ratio
P Dimensionless temperature ratio
𝐹𝑡 Log mean temperature difference correction factor
∆𝑇𝑙𝑚 Log mean temperature difference
∆𝑇𝑚 Corrected mean temperature
U Overall heat transfer coefficient
A Heat transfer area
L Length of tube
𝑁𝑡 Number of tube
𝑑𝑜 Outside diameter of tube
𝑑𝑖 Inside diameter of tube
𝐷𝑏 Bundle diameter
𝐷𝑠 Shell diameter
ℎ𝑖 Film heat-transfer coefficient inside a tube
𝑘𝑓 Thermal conductivity
𝑗ℎ Heat transfer factor
Re Reynolds number
Pr Prandtl number
𝜇 Viscosity at bulk fluid temperature
𝜇𝑤 Viscosity at wall temperature
𝑃𝑡 Tube pitch
𝐴𝑠 Cross-flow area between tubes
𝐺𝑠 Shell-side mass flow-rate per unit area
𝑑𝑒 Equivalent diameter
ℎ𝑠 Shell-side heat-transfer coefficient
∆𝑃𝑡 Tube-side pressure drop
∆𝑃𝑠 Shell-side pressure drop
𝑢𝑡 Tube-side fluid velocity
𝑢𝑠 Shell-side fluid velocity
Department of Chemical & Process Engineering, University of Moratuwa Page i

TABLE OF CONTENTS
NOMENCLATURE .......................................................................................................... i
TABLE OF CONTENTS .................................................................................................ii
LIST OF FIGURES ........................................................................................................vii
LIST OF TABLES ...................................................................................................... viiii
CHAPTER 1 UNIT SELECTION .................................................................................... 1
1.1 Introduction ....................................................................................................... 1
1.2 Comprehensive Design Project-Group .............................................................. 1
1.3 Comprehensive Design Project – Individual ..................................................... 2
1.4 Heat Exchangers ................................................................................................ 2
1.4.1 Types of Heat Exchangers.......................................................................... 2
1.4.2 Tubular Heat Exchangers ........................................................................... 4
1.4.3 Plate Heat Exchangers ................................................................................ 5
1.4.4 Extended Surface Heat Exchangers ........................................................... 7
1.4.5 Regenerative Heat Exchanger .................................................................... 8
1.5 Selection of a Shell and Tube Heat Exchanger ................................................. 9
1.6 Shell and Tube Heat Exchangers ....................................................................... 9
CHAPTER 2 CHEMICAL DESIGN ............................................................................. 11
2.1 Absorption Pre-cooler - Heat exchanger ......................................................... 11
2.2 Mass Balance ................................................................................................... 11
2.3 Energy Balance ................................................................................................ 12
2.4 Specification and Physical Properties of Mixture and Water .......................... 13
Applying Q = m × Cp × (∆T); ................................................................................. 13
2.5 Fluid Allocation – Shell or Tube ..................................................................... 14
2.6 Log Mean Temperature Difference (LMTD) Calculation ............................... 15
2.7 Correction Factor (Ft) and Corrected Mean Temperature ∆Tm Calculation ... 15
2.8 Heat Transfer Area Calculation ....................................................................... 17
2.9 Number of Tubes and Tube Size ..................................................................... 17
2.10 Bundle and Shell Diameter .............................................................................. 18
Department of Chemical & Process Engineering, University of Moratuwa Page ii

2.11 Design methods ............................................................................................... 18

2.12 Kern method .................................................................................................... 19
2.12.1 Tube-side Heat Transfer Coefficient ........................................................ 19
2.12.2 Shell-side Heat Transfer Coefficient ........................................................ 20
2.12.3 Viscosity Correction Factor ..................................................................... 21
2.12.4 Overall Coefficient ................................................................................... 22
2.12.5 Pressure drop – Tube side ........................................................................ 23
2.12.6 Pressure drop - Shell side ......................................................................... 24
2.13 Bell method...................................................................................................... 25
2.13.1 Calculating the Shell Side Heat Transfer Coefficient .............................. 26
2.14 Summary – The Proposed Design ................................................................... 31
CHAPTER 3 MECHANICAL DESIGN........................................................................ 33
3.1 Introduction ..................................................................................................... 33
3.2 Material Selection ............................................................................................ 33
3.2.1 Selection of tube material ......................................................................... 33
3.2.2 Tube Sheets .............................................................................................. 34
3.2.3 Shell Assembly ......................................................................................... 34
3.2.4 Heat exchanger heads ............................................................................... 34
3.3 Selection of Shell, Front End Header, and Rear End Header Types ............... 35
3.3.1 TEMA Designations ................................................................................. 36
3.3.2 Selection of Floating Head Exchanger ..................................................... 38
3.3.3 Selection of E-Type Shell ........................................................................ 38
3.3.4 Selection of A-Type front header ............................................................. 38
3.3.5 Selection of S-Type Rear Header ............................................................. 38
3.4 Mechanical Design Parameter Calculation ...................................................... 38
3.4.1 Calculation of Shell Thickness ................................................................. 38
3.4.2 Calculation of the thickness and height of the Floating head cover ......... 41
3.4.3 Calculation of the thickness of the flat closure (Channel cover) ............. 45
3.4.4 Stationary head channel thickness ............................................................ 46
3.4.5 Pass Partition ............................................................................................ 47
3.4.6 Shell cover calculation ............................................................................. 47
3.4.7 Calculation of the nozzles ........................................................................ 52
3.4.8 Thickness calculation of stationary tube sheets and floating tube sheets 55
Department of Chemical & Process Engineering, University of Moratuwa Page iii

3.4.9 Design of the tie rod ................................................................................. 56

3.4.10 Gasket ....................................................................................................... 56
3.4.11 Calculation of the number of bolts ........................................................... 57
3.4.12 Saddle supports design ............................................................................. 59
3.5 Description of fabrication ................................................................................ 65
3.6 Summary of Design ......................................................................................... 68
CHAPTER 4 MECHANICAL DRAWING ................................................................... 71
CHAPTER 5 PIPING AND INSTRUMENTATION .................................................... 72
5.1 Introduction ..................................................................................................... 72
5.2 Selection of the pipes in the absorption pre-cooler system (Heat exchanger) . 72
5.3 Selection of the pumps and blowers in the absorption pre-cooler system....... 73
5.4 Selection of the valves in the absorption pre-cooler system ........................... 75
5.5 Measuring instruments .................................................................................... 75
5.6 Pipe Supports and Fittings ............................................................................... 76
5.7 P&I Diagram for absorption pre-cooler Section.............................................. 76
CHAPTER 6 SAFETY AND CONTROL ..................................................................... 78
6.1 Safety in the absorption pre-cooler (shell and tube heat exchanger) ............... 78
6.2 HAZOP study .................................................................................................. 78
6.3 General safety procedure ................................................................................. 81
6.4 Process control of the absorption pre-cooler ................................................... 81
CHAPTER 7 START UP – SHUT DOWN AND ECONOMIC ASPECTS ................. 84
7.1 Start up and shut down .................................................................................... 84
7.2 Start up operation............................................................................................. 84
7.3 Shut down operation ........................................................................................ 84
7.4 Economic Aspects ........................................................................................... 85
7.4.1 Material cost ............................................................................................. 85
7.4.2 Material cost of components .................................................................... 85
7.4.3 Total cost .................................................................................................. 86
CHAPTER 8 CONCLUSION AND RECOMMENDATIONS TO THE INDUSTRY 87
REFERENCE .................................................................................................................. ix
ANNEX ........................................................................................................................... xi
Department of Chemical & Process Engineering, University of Moratuwa Page iv

LIST OF FIGURES
Figure 1.1: Classification of heat exchangers .................................................................. 3
Figure 1.2: Double-pipe heat exchanger .......................................................................... 4
Figure 1.3: Shell and tube heat exchangers ...................................................................... 5
Figure 1.4: Gasketed plate- and-frame heat exchanger .................................................... 6
Figure 1.5: Spiral plate heat exchanger with both fluids in spiral counter flow .............. 6
Figure 1.6: Lamella heat exchanger ................................................................................. 7
Figure 1.7: Basic components of a plate-fin heat exchanger ........................................... 8
Figure 1.8: Shell and tube heat exchanger ..................................................................... 10
Figure 2.1: Inlet and outlet streams from the absorption pre-cooler - Heat exchanger .. 11
Figure 2.2: Mass Balance ............................................................................................... 12
Figure 2.3: Energy Balance ............................................................................................ 12
Figure 2.4: LMTD Correction for One shell pass and any even number of tube passes 16
Figure 2.5: Shell-bundle clearance ................................................................................. 18
Figure 2.6: Tube-side heat-transfer factor ...................................................................... 20
Figure 2.7: Shell-side heat-transfer factors, segmental baffles ...................................... 21
Figure 2.8: Tube-side friction factors ............................................................................. 23
Figure 2.9: Shell-side friction factors, segmental baffles ............................................... 24
Figure 2.10: Baffle and tube geometry........................................................................... 25
Figure 2.11: Tube row correction factor Fn ................................................................... 26
Figure 2.12: Baffle geometrical factors .......................................................................... 27
Figure 2.13: Window correction factor .......................................................................... 27
Figure 2.14: Coefficient for FL, heat transfer ................................................................ 29
Figure 3.1: Type BEM, CFU and AES exchangers ...................................................... 35
Figure 3.2: TEMA nomenclature .................................................................................. 37
Figure 3.3: Torispherical head ....................................................................................... 42
Figure 3.4: Thickness-C values relationship .................................................................. 45
Figure 3.5: Representation of a flat closure ................................................................... 46
Figure 3.6: Thickness-C values relationship .................................................................. 51
Figure 3.7: Cooling water nozzles.................................................................................. 52
Figure 3.8: Nut and Bolt ................................................................................................. 57
Figure 3.9: Plan view of the stationary channel flange .................................................. 57
Figure 3.10: Plan view of the stationary channel flange ................................................ 58
Figure 3.11: Standard steel saddles (adapted from Bhattacharyya, 1976) ..................... 62
Figure 5.1: ANSI Flange Dimensions ............................................................................ 73
Figure 5.2: Centrifugal pump selection guide ................................................................ 74
Figure 5.3: P&I Diagram ................................................................................................ 77
Figure 6.1: different control strategies for a heat exchanger .......................................... 82
Figure 6.2: different control strategies for a heat exchanger .......................................... 82
Figure 6.3: Suggested process control scheme ............................................................... 83
Department of Chemical & Process Engineering, University of Moratuwa Page v

LIST OF TABLES
Table 2.1: Energy Balance ............................................................................................. 13
Table 2.2: Flow rate of Gas mixture............................................................................... 14
Table 2.3: Properties of Gas mixture and Water ............................................................ 14
Table 2.4: Overall heat transfer coefficient .................................................................... 17
Table 2.5: Fouling factors (coefficients), typical values ................................................ 22
Table 2.6: Calculated parameters in kern method .......................................................... 25
Table 3.1: Shell and tube geometric terminology .......................................................... 36
Table 3.2: Shell and tube geometric terminology .......................................................... 36
Table 3.3: Design stress calculation table ...................................................................... 39
Table 3.4: Minimum practical wall thickness ................................................................ 40
Table 3.5: Design stress of stainless steel ...................................................................... 41
Table 3.6: Table for calculating the dimensions of torispherical head .......................... 44
Table 3.7: Stress concentration factors........................................................................... 44
Table 3.8: Minimum practical wall thickness without Corrosion resistance ................. 47
Table 3.9: Minimum practical wall thickness ................................................................ 48
Table 3.10: Table for calculating the dimensions of torispherical head ........................ 50
Table 3.11: Stress concentration factors ........................................................................ 50
Table 3.12: Tie rod data ................................................................................................. 56
Table 3.13: Table of Factor K ........................................................................................ 63
Table 5.1: ANSI Flange Dimensions calculated ............................................................ 73
Table 6.1: HAZOP Study Applied to the Absorption pre-cooler ................................... 79
Department of Chemical & Process Engineering, University of Moratuwa Page vi

CHAPTER 1 UNIT SELECTION
1.1 Introduction
This report is prepared as part of a project which is Design of a Plant to Manufacture

Sulfuric Acid from Sulfur (Comprehensive Design Group Project). Here, the designing
of a heat exchanger for the sulfuric acid manufacturing plant is discussed in detail in
terms of introduction, heat exchanger unit selection, chemical design, parameter
calculation, and equipment sizing.
1.2 Comprehensive Design Group Project
A sulfuric acid manufacturing plant design project was carried out and a report
submitted to the University of Moratuwa in partial fulfillment of the requirements for
an Honours Degree of Bachelor of Science of Engineering in Chemical and Process
Engineering.
The plant designed was primarily based on the Sulfur based effluents that are currently
disposed from the Ceylon Petroleum Corporation refinery at 25 MTPD were to be
completely regenerated in the form of Sulfuric acid by installing a manufacturing plant.
The production was scaled up to correspond to 35 MTPD of Sulfur inputs, to account
for future growth in demand for oil refining in Sri Lanka.
There are two main processes for manufacture of Sulfuric acid that are adopted at
plants across the globe as mentioned below.
1. Lead chamber process

2. Contact processes
The contact process is categorized into three different processes that are based on the
general operating principle of the contact process.
 Single contact process

 Double contact process
 Wet Contact Process (WCP)
Department of Chemical & Process Engineering, University of Moratuwa Page 1

SULFUR FROM CPC
SULFURIC ACID MANUFACTURING PLANT FROM SULFUR - PFD
MAIN STREAMS
HOT WATER
COOLING WATER
STEAM LINES
SULFUR TANK WATER TANK
COOLING TOWER
(MS 01)
(US 04)
SCRUBBER
(MS 01) To effluent
(US 03) plant
(US 01)
WASTE HEAT BOILER
(MS 26)
(MS 14) P-96
FUEL TANK (US 02)

SILFUR MELTER Send to flash
drum
(MS 03)
(MS 14) (MS 16) (MS 24)
AIR IN
(MS 03) (MS 22)
SO2 DRYER (MS 18)
P-69
ESP
(MS 17)
(MS 10)
(MS 12) MAIN / FINAL
ABSORBER
(MS 20)
SPAY
MAIN BLOWER
(MS 13) (MS 25)
(US 09)
(MS 19) (MS 21) P-22
(MS 08)
INTERMEDIATE
SULFUR FURNECE
(US 10) ABSORBER
(MS 09) (MS 23)
ESP V-1 (US 13)

P-8
CAT. CONVERTER
(MS 04)
(MS 07) (MS 21)
Send to flash (MS 21)
drum
(US 14) (MS 23)
(MS 16)
AIR DRYER
To
effluent
plant (MS 17)
(MS 25)
(MS 05) (MS 05)
(MS 06)
(MS 06)
(MS 29)
OLEUM TANK
WATER FILTER
OLEUM FOR DRYING (MS 27)
(MS 30)
WATER TANK
(MS 28)
DILUTION TANK
OLEUM HEADER
98.5%
SULFURIC
ACID
STORAGE TANK
Based on the literature review, it was revealed and concluded by the group that the
double contact double absorption process (DCDA) is an optimum choice for a process
to manufacture Sulfuric acid in terms of its economic feasibility, product purity and
environmental impact. The group in its analysis for a suitable site has selected the
general area of Sapugaskanda as a suitable location for installation of the plant, taking
into account its close proximity to the CPC as well as the Colombo harbor as well as
established infrastructure and availability of water and other utilities.
1.3 Comprehensive Design Individual Project
The individual design project is carried out to study and design a heat exchanger to cool
down the mixture which is coming from converter to intermediate absorption tower.
The objective of the project is to gain experience in designing engineering unites for
large scale processing plants.
1.4 Heat Exchangers
A heat exchanger is a piece of equipment built for efficient heat transfer from one
medium to another. The media may be separated by a solid wall to prevent mixing or
they may be in direct contact. They are widely used in space heating, refrigeration, air
conditioning, power plants, chemical plants, petrochemical plants, petroleum refineries,
natural gas processing, and sewage treatment.
1.4.1 Types of Heat Exchangers
Large numbers of heat exchanger configurations are available for various heat transfer
operations. Those heat exchangers can be classified based upon the basic operation,
construction, heat transfer, and flow arrangements.
 Classification according to transfer process

 Classification according to surface compactness
 Classification according to construction
 Classification according to flow arrangements
 Classification according to heat transfer mechanisms

Figure 1.1: Classification of heat exchangers

1.4.2 Tubular Heat Exchangers

These exchangers are generally built of circular tubes, although elliptical, rectangular,
or round/flat twisted tubes have also been used in some applications. Tubular heat
exchangers are primarily used for liquid-to-liquid and liquid-to-phase change heat
transfer applications. They are used for gas-to-liquid and gas-to-gas heat transfer
applications primarily when the operating temperature and/or pressure is very high or
fouling is a severe problem on at least one fluid side and no other types of exchangers
would work. These heat exchangers can be further classified into several types as
follows.
 Double pipe heat exchangers
A typical double pipe heat exchanger consists of one pipe placed concentrically inside
another of large diameter with appropriate fittings to direct the flow from one section to
the next. The major use of double pipe exchangers is for sensible heating or cooling of
process fluids where the small heat transfer areas are required. The major disadvantage
is that double pipe heat exchangers are bulky and expensive per unit transfer surface.
Figure 1.2: Double-pipe heat exchanger
 Shell and tube heat exchangers
This is generally built of a bundle of round tubes mounted in a cylindrical shell with the
tube axis parallel to that of the shell. One fluid flows inside the tubes, the other flows
across and along the tubes. It is the most common type of heat exchanger in oil
refineries and other large chemical processes, and is suited for higher-pressure
applications. The fluids can be either liquids or gases on either the shell or the tube
side. In order to transfer heat efficiently, a large heat transfer area should be used,
leading to the use of many tubes.

Figure 1.3: Shell and tube heat exchangers
 Spiral tube type heat exchanges
This consists of spirally wound coils placed in a shell or designed as co-axial

condensers and co-axial evaporators that are used in refrigeration systems. Spiral type
heat exchangers are suitable for thermal expansion and clean fluids, since cleaning is
almost impossible.
1.4.3 Plate Heat Exchangers

Plate-type heat exchangers are usually built of thin plates. Generally, these exchangers
cannot accommodate very high pressures, temperatures, or pressure and temperature
differences. They are used for transferring heat for any combination of gas, liquid and
two phase streams. Plate heat exchangers can easily be taken apart into their individual
components for cleaning, inspection, and maintenance.
 Gasketed plate heat exchanger
A gasketed plate heat exchanger consists of a series of thin plates with corrugations or a
wavy surface that separates the fluids. The plate heat exchangers are usually limited to
a fluid stream with a pressure below 25 bar and a temperature below about 250 0C.
These exchangers provide a relatively compact and light weight heat transfer surface.
Gasketed plate heat exchangers are typically used for heat exchange between two liquid

streams. They are easily cleaned and sterilized because they can be completely
disassembled, so they have a wide application in food processing industry.
Figure 1.4: Gasketed plate- and-frame heat exchanger
 Spiral plate heat exchanger
Spiral plate heat exchangers are formed by rolling two long, parallel plates into a spiral
using a mandrel and welding the edges of adjacent plates to form channels. These heat
exchangers are quite compact but are relatively expensive due to their specialized
fabrication.
Figure 1.5: Spiral plate heat exchanger with both fluids in spiral counter flow

 Lamella heat exchangers
Figure 1.6: Lamella heat exchanger

A lamella heat exchanger consists of an outer tubular shell surrounding an inside
bundle of heat transfer elements. These exchangers consist of a set of parallel, welded,
thin plate channels or lamellae (flat tubes or rectangular channels) placed longitudinally
in a shell. The shell side flow is typically a single pass around the plates and flows
longitudinally in the spaces between the channels. There are no shell side baffles and
therefore lamella heat exchangers can be arranged for true countercurrent flow.
Because of high turbulence, uniformly distributed flow, and smooth surfaces, the
lamellae do not foul easily.
1.4.4 Extended Surface Heat Exchangers

Extended surface heat exchangers are devices with fins or appendages on the primary
heat transfer surface (tubular or plate) with the object of increasing heat transfer area.
Fins are widely used in gas to gas and gas to liquid heat exchangers whenever the heat
transfer coefficient on one or both sides is low and there is a need for a compact heat
exchanger. The two most common types of extended surface heat exchangers are plate-
fin heat exchangers and tubular-fin heat exchangers.
 Plate-fin heat exchanger
The plate-fin heat exchangers are primarily used for gas to gas applications. The fluid
streams are separated by flat plates, between which are sandwiched corrugated fins.
The plates or flat tubes separate the two fluid streams, and the fins form the individual
flow passages. By the use of fins, discontinuous in the flow direction, the boundary

layers can be completely disrupted; if the surface is wavy in the flow direction, the
boundary layers are either thinned or interrupted, which results in higher heat transfer
coefficients and a higher pressure drop.
Figure 1.7: Basic components of a plate-fin heat exchanger
 Tube -fin heat exchanger
These exchangers may be classified as conventional and specialized tube-fin

exchangers. In a conventional tube-fin exchanger, heat transfer between the two fluids
takes place by conduction through the tube wall. However, in a heat pipe exchanger (a
specialized type of tube-fin exchanger), tubes with both ends closed act as a separating
wall, and heat transfer between the two fluids takes place through this ‘‘separating
wall’’ (heat pipe) by conduction, and evaporation and condensation of the heat pipe
fluid. Tube-fin exchangers can withstand ultrahigh pressures on the tube side. The
highest temperature is again limited by the type of bonding, materials employed, and
material thickness. Tube-fin exchangers usually are less compact than plate-fin units.
1.4.5 Regenerative Heat Exchanger

In regenerative type heat exchangers, the same flow passage (matrix) is alternatively
occupied by one of the two fluids. The hot fluid stores the thermal energy in the matrix;
during the cold fluid flow through the same flow passage at a later time, stored energy
will be extracted from the matrix. Therefore, thermal energy is not transferred through
the wall as in a direct transfer type heat exchanger. Regenerators can be classified as

follows: rotary regenerators and fixed matrix regenerators. Rotary regenerators can be
further sub-classified as: disc type and drum type.
1.5 Selection of a Shell and Tube Heat Exchanger

The gas mixture (SO2, SO3, O2 and H2S) is flammable and toxic. But shell and tube
heat exchanger is excellent for handling flammable and/or toxic fluids. In this Gas-
Liquid system, the shell and tube heat exchanger is most suitable than other heat
exchangers because;
 It’s less expensive too. Provides maximum heat transfer surface per given shell and
tube size. Provides multi-tube-pass arrangements. The Design of Shell and Tube
Heat Exchangers is very compact.
 Floating end allows for differential thermal expansion between the shell and the
tubes. Shell side can be steam or mechanically cleaned. Bundle can be easily
repaired or replaced.
 It’s capable to handling with High Pressure. Can be used in systems with higher
operating temperatures and pressures. Pressure drop across a tube cooler is less.
 The configuration gives a large surface area in a small volume
 Uses well established fabrication techniques
 Can be constructed from a wide range of materials
1.6 Shell and Tube Heat Exchangers

The shell and tube heat exchanger is the most widely used heat exchanger in industry
today. The Figure 1.8 shows that it consists of a number of tubes contained within the
heat exchanger shell. One fluid passes through the tubes while the other flows through
the shell. This prevents the fluids from mixing with each other. Most of the heat
transfer occurs through the walls of the tubes. A large number of tubes are used to
provide a greater surface area so the heat transfer is faster.
One fluid is flowing through the inside (tube-side) of the pipes and the other fluid is
flowing over the outside (shell-side) of the pipes. It is important in the case of flowing
liquids that the inside of the pipes is full of fluid and has no air gaps. Air has a low
thermal conductivity and will reduce the rate of heat transfer. This will reduce the
efficiency of the heat exchanger and can lead to hot spots which may damage the tubes
if they are not cooled properly. For the same reason, the space outside the tubes should

have no air gaps as well. Since air/gas pockets will rise, they can be removed by vents
located at the top of the heat exchanger.
Figure 1.8: Shell and tube heat exchanger

When designing shell and tube heat exchanger, the following general guidelines should
be considered.
 The fluid at the higher pressure should pass through the tubes (tube-side). This
saves the expense of a high pressure shell.
 The fluid most likely to cause fouling within the exchanger should be tube-side.
The inside of the tubes is easier to clean than the outside.
 The more corrosive fluid should be tube-side.
 The tubes should be made from corrosion-resistant material. This is much less
expensive than having the shell made from this material and, if corrosion
occurs, only the tubes need replacing.
 If the heat exchanger is operating as a liquid-gas system then the gas (with its
larger specific volume) should be shell-side.
 The hotter fluid usually goes through the tubes and the cooler fluid usually goes
through the shell surrounding the tubes.

CHAPTER 2 CHEMICAL DESIGN
2.1 Absorption Pre-cooler - Heat exchanger
The acid stream of absorption pre-cooler is from Converter to Intermediate Absorption

Tower (IAT). The Double Contact Double Absorption process of Sulfuric acid
manufacturing involves sending a portion of the partially converted gas stream to an
IAT where produced Sulfur Trioxide is absorbed to a 98% Sulfuric acid stream. In
order to bring this stream to a temperature that is recommended for absorption
conditions of the two streams the temperature of the upstream flow should be reduced.
The inlet temperature to the column has been taken as the temperature that the stream is
supposed to have after exiting the 3rd bed (from the top) of the converter which is
471oC. The IAT, according to literature operates in the expected conditions when the
gas stream has a temperature in the range of 271oC (Davenport, 2006). In Converter
and IAT, maintaining pressure is around the 1 – 2 atm.
Therefore, it is assumed that in between the converter and the cooler, and the cooler
and the IAT, the lines are sufficiently insulated so that temperature drops due to
transmission losses are negligible.
US-09
ABSORPTION
MS-19 PRECOOLER MS-19
(Heat exchanger)
US-10
Figure 2.1: Inlet and outlet streams from the absorption pre-cooler - Heat exchanger
2.2 Mass Balance
Assumption made during mass balance
 Steady state condition

 No leakage
 No accumulation

Water Out
Materials In kmol/hr Materials In kmol/hr

Sulfur Dioxide 2.66 Sulfur Dioxide 2.66
Sulfur Trioxide 29.40 Sulfur Trioxide 29.40
Hydrogen 0.38 Heat Exchanger Hydrogen 0.38
Sulfide Sulfide
Oxygen 8.61 Oxygen 8.61
Nitrogen 346.06 Nitrogen 346.06
Carbon Dioxide 13.64 Carbon Dioxide 13.64
Water In
Figure 2.2: Mass Balance
2.3 Energy Balance
Water out at 35 ℃
Input stream at 471 ℃ Heat Exchanger Output stream at 217 ℃
Water in at 25 ℃
Figure 2.3: Energy Balance
Assumptions made during energy balance
 The heat exchanger operates under steady state, steady flow conditions
 Heat transfer to the surrounding is negligible
 The temperature of each fluid is uniform over every cross section
 The specific heat at constant pressure is constant for each fluid
 Longitudinal heat conduction in the fluid and the wall are negligible

 The overall heat transfer coefficient between the fluids is constant throughout
the heat exchanger
Table 2.1: Energy Balance

CONVERTER TO INT. ABS. TOWER COOLER
Heat In Heat Out
Stream (oC) 471 Stream ( C) o
217
Species kmol/hr kJ/kmol kW Sp. Enthalpy kW
(kJ/kmol)
Sulfur Dioxide 2.66 -276,010.15 -203.90 -288,518.79 -213.14
Sulfur Trioxide 29.40 -326,122.83 -2,663.30 -343,291.88 -2,803.51
Hydrogen 0.38 -3,148.91 -0.33 -13,131.96 -1.38
Sulfide
Oxygen 8.61 13,955.92 33.36 5,772.40 13.80
Nitrogen 346.06 13,302.23 1,278.70 5,620.98 540.32
Carbon Dioxide 13.64 -373,540.52 -1,415.23 -385,596.63 -1,460.91
TOTAL -2,970.70 -3,924.82
Total Heat Removal (kW) 954.12
The cooling water requirement was calculated assuming that cooling water is supplied
at 25oC and that the water flow rate should be such that cooling water undergoes a
temperature rise of only 10oC. This is because a normal cooling tower operation uses
ambient air or slightly above ambient air, where cooling water returned cannot possess
too high a temperature.
Energy deficit revealed from energy balance = −2970.70 − (−3924.82) 𝑘𝑊
= 954.12 𝑘𝑊
2.4 Specification and Physical Properties of Mixture and Water
Applying 𝑸 = 𝒎̇ × 𝑪𝒑 × (∆𝑻);
954.12
Required cooling water flow rate = = 22.72 𝑘𝑔/𝑠
4.2 × 10
13.1067×1000
From table 2.2, Flow rate of Gas mixture = = 3.64 kg/s
3600

Table 2.2: Flow rate of Gas mixture
Species Flow Rate (MT/hr) w/w (%)

Sulfur Dioxide 0.1704 1.30
Sulfur Trioxide 2.3537 17.96
Hydrogen Sulfide 0.0129 0.10
Oxygen 0.2754 2.10
Nitrogen 9.6940 73.96
Carbon Dioxide 0.6003 4.58
TOTAL 13.1067 100.00
Table 2.3: Properties of Gas mixture and Water
Gas mixture Water

Inlet temperature (℃) 471 25
Outlet temperature (℃) 217 35
Flow rates (kg/s) 3.64 22.72
Specific heat–mean (kJ/kg ℃) 1.03 4.2
Density – mean (kg/m3) 0.6355 995.67
Viscosity – mean (mNs/m2) 0.0294 0.798
Thermal conductivity – mean (W/m℃) 0.0426 0.6144
2.5 Fluid Allocation – Shell or Tube
 Fluid temperatures – If the temperatures are high enough to require the use of
special alloys placing the higher temperature fluid in the tubes will reduce the
overall cost. At moderate temperatures, placing the hotter fluid in the tubes will
reduce the shell surface temperatures, and hence the need for lagging to reduce
heat loss, or for safety reasons. Therefore, Water should be allocated to shell
side, and gas mixture should be allocated to tube side.
 Operating pressures – The higher pressure stream should be allocated to the
tube-side. High-pressure tubes will be cheaper than a high-pressure shell.
 Therefore, in our case, Water is allocated to tube side and Gas mixture is
allocated to shell side.

2.6 Log Mean Temperature Difference (LMTD) Calculation

For the counter current flow, the logarithmic mean temperature is given by:
(TH1 − TC2 ) − (TH2 − TC1 ) (471 − 35) − (217 − 25)

𝐿MTD = =
(TH1 − TC2 ) (471 − 35)
ln ln
(TH2 − TC1 ) (217 − 25)
LMTD = 297.5 ℃
2.7 Correction Factor (Ft) and Corrected Mean Temperature (∆𝐓𝐦 )

Calculation
Multi pass and Cross flow heat exchangers, the correction factor is used where the log
mean temperature difference is expressed as
∆Tm = Ft × ∆Tlm
∆Tm – the actual log mean temperature difference
Ft – correction factor
The following assumptions are made in the derivation of the temperature correction
factor Ft,
 Equal heat transfer areas in each pass.

 A constant overall heat-transfer coefficient in each pass.
 The temperature of the shell-side fluid in any pass is constant across any cross
section.
 There is no leakage of fluid between shell passes.
 Coolant is corrosive, so assign to tube-side.
T1 − T2 Range of shell fluid

R= =
t 2 − t1 Range of tube fluid
10
R= = 0.04
254
t 2 − t1 Range of tube fluid

P= =
T1 − t1 Maximum temperature difference
254
P= = 0.57
446

These values intercept on one shell pass and any even number of tube passes
exchangers;
Figure 2.4: LMTD Correction for One shell pass and any even number of tube passes
The correction factor is approximately Ft = 1 from Figure 2.4.
Or correction factor can be calculated by using Kern (1950) equation;
(1 − P)
√(R2 + 1) ln [ ]
(1 − RP)
Ft =
2 − P [R + 1 − √(R2 + 1)]
(R − 1)ln [ ]
2 − P [R + 1 + √(R2 + 1)]
Ft = 0.995
∆Tm = Ft × ∆Tlm ∆Tm = 0.995 × 297.5 ℃
∆Tm = 296 ℃

2.8 Heat Transfer Area Calculation

Table 2.4: Overall heat transfer coefficient
From Table 2.4, overall heat transfer coefficient of Gases – Water is range of 20 - 300
W/m2 ℃. Therefore Uf = 20 W/m2 ℃ is selected. Then;
Q = Uf A ∆𝑇𝑚
954.12 × 103 𝑊 = 20 W/m2 ℃ × A × 296 ℃

A = 161.169 m2
2.9 Number of Tubes and Tube Size

Choose 20 mm outside diameter, 16 mm inside diameter, 2.5 m long tubes and Copper
tubes which will be explained in Chapter 3.
L = 2.5 m
Area of one tube = 2.5×20×10-3 × 𝜋 = 0.15708 m2
161.17
Number of tubes Nt = = 1026
0.15708

So, for two passes, tubes per pass are 513. As the shell-side fluid is relatively clean use
1.25 triangular pitch.
2.10 Bundle and Shell Diameter

Bundle diameter for 1.25 triangular pitch,
1
𝑁𝑡 2.207
𝐷𝑏 = 𝑑𝑜 ( )
0.249
1
1026 2.207
𝐷𝑏 = 20 × ( ) = 869 𝑚𝑚
0.249
Figure 2.5: Shell-bundle clearance

Use a split – ring floating head type. From Figure 2.5, bundle diametrical clearance is
69 mm. Shell diameter, 𝐷𝑠 = 869 + 69 = 938 mm
2.11 Design methods

There are two major design techniques proposed by two scientists are available for
designing of shell and tube heat exchangers namely Kern method and Bell method. The
Kern method is used to calculate the initial part of the heat exchanger calculations

while the Bell method is taken for the optimization part of the data obtained from the
Kern method. Therefore, calculations should be done in both methods in order to obtain
the most economical values.
2.12 Kern method

Kern method was developed to calculate the shell side heat transfer coefficient, tube
side heat transfer coefficient, overall heat transfer coefficient, shell side pressure drop
and tube side pressure drop after 1960s by Kern and Donohue assuming ideal
conditions (No bypass and leakage streams).
2.12.1 Tube-side Heat Transfer Coefficient

π
Tube cross sectional area = 4 × 162 = 201 mm2
Tube per pass = 513
Total flow area = 513×201×10-6 = 0.1031 m2

3.64 kg/s kg
Gas mixture mass velocity = 0.1031 m2 = 35.3 m−2
s
Density of gas mixture = 0.6355 kg/m3

35.3
Water linear velocity = = 55.55 m/s
0.6355
hi di 0.33
μ 0.14
= jh Re Pr ( )
kf μw
Dynamic viscosity of gas mixture = 0.0294 mNs/m2
Thermal conductivity of gas mixture = 0.0426 W/m ℃
ρ u di
Re =
μ
0.6355 × 55.55 × 16 × 10−3

Re = = 19212
0.0294 × 10−3
Cp μ 1.03 × 103 × 0.0294 × 10−3
Pr = = = 0.711
kf 0.0426
μ L 2.5×103
Neglect( ); = = 156.25
μw di 16

Figure 2.6: Tube-side heat-transfer factor
From Figure 2.6, jh = 3.9 × 10−3

0.0426
hi = 16×10−3 × 3.9 × 10−3 × 19212 × 0.7110.33 = 178 W/m2 ℃
2.12.2 Shell-side Heat Transfer Coefficient

Ds 938
Choose baffle spacing as 1/5 shell diameter, lB = = = 187.6 mm
5 5
Tube pitch Pt = 1.25×20 = 25 mm

(pt −do )Ds lB
Cross flow area As =
pt
(25 − 20)
As = × 938 × 187.6 × 10−6 = 0.0352 m2
25
22.72 kg/s
Mass velocity, Gs = = 645.57 kgs −1 m−2
0.0352 m2
1.1
Equivalent diameter de = × (Pt2 − 0.917 × d2o )
do
1.10
de = (252 − 0.917 × 202 ) = 14.2 mm
20
35+25
Mean shell side temperature = = 30 ℃
2
Water density = 995.7 kg/m3
Viscosity of water = 0.798 mNs/m2
Heat capacity of water = 4.2 kJ/kg ℃

Thermal conductivity of water = 0.6144 W/m ℃
𝐺𝑠 𝑑𝑒 645.57 × 14.2 × 10−3

𝑅𝑒 = = = 11488
𝜇 0.798 × 10−3
𝐶𝑝 𝜇 4.2 × 103 × 0.798 × 10−3

𝑃𝑟 = = = 5.455
𝑘𝑓 0.6144
Figure 2.7: Shell-side heat-transfer factors, segmental baffles

Choose 25% baffle cut, this should be given a reasonable heat transfer coefficient
without too large a pressure drop, From Figure 2.7;
jh = 5.5 × 10−3
k μ 0.14
Without viscosity correction term, hs = d f × jh Re Pr1/3 (μ )
e w
0.6144
hs = 14.2×10−3 × 5.5 × 10−3 × 11488 × 5.4551/3 = 4812.5 W/m2 ℃
2.12.3 Viscosity Correction Factor

Estimate wall temperature
Mean temperature difference = 344 – 30 =314 ℃

across all resistances

U 20
Across water film = h × ∆T = 4812.5 × 314 = 1.3 ℃
o
Mean wall temperature = 344 – 1.3 = 345.3 ℃
Water viscosity at the wall (Physical, 2013), μw = 0.086 mNs/m2
μ 0.14
( ) = 1.366
μw
Therefore, hs = 4812.5×1.366 = 6574 W/m2 ℃
2.12.4 Overall Coefficient

Thermal conductivity of Copper = 395 W/m ℃
Take the fouling coefficients from Table 2.5. Air and industrial gases are range of 5000
– 10000 W/m2 ℃. Take as highest value, 10000 W/m2 ℃.
Cooling water (towers) are range of 3000 – 6000 W/m2 ℃. Take as highest value, 6000
W/m2 ℃.
Table 2.5: Fouling factors (coefficients), typical values
20
1 1 1 20 × 10−3 × ln (16) 20 1 20 1
= + + + × + ×
Uo 6574 6000 2 × 395 16 10000 16 178
Uo = 134 W/m2 ℃

Well above the initial estimate of 20 W/m2 ℃, so design has adequate area for the duty
required.
Heat transfer area based on outside diameter
Ao = 1026 × 0.157 = 161.16 m2
Q 954.12 × 103
U0 required = = = 20 W/m2 ℃
Ao ∆Tm 161.16 × 296
2.12.5 Pressure drop – Tube side
Figure 2.8: Tube-side friction factors

From Figure 2.8, for Re = 19212
jf = 4 × 10−3
Neglecting the viscosity correction term
L μ −m ρ u2t
∆Pt = Np [8 × jf × ( ) × ( ) + 2.5] ×
di μw 2
μ −m
Neglect (μ )
w
2.5 × 103 0.6355 × 55.552

∆Pt = 2 × (8 × 4 × 10−3 × ( ) + 2.5) ×
16 2
N
∆Pt = 14707.7 = 14.7 kPa
m2

2.12.6 Pressure drop - Shell side

Gs 645.57
Linear velocity = = = 0.648 m/s
ρ 995.7
Figure 2.9: Shell-side friction factors, segmental baffles
From Figure 2.9, at Re = 11488, 𝑗𝑓 = 4.9 × 10−2
Neglect viscosity correction
Ds L ρ u2s μ −0.14
∆Ps = 8 × jf × ( ) × ( ) × ×( )
de lB 2 μw
−2
938 2.5 × 103 995.7 × 0.6482 0.798 −0.14
∆Ps = 8 × 4.9 × 10 ×( )×( )× ×( )
14.2 187.6 2 0.086
N
∆Ps = 52809 = 52.8 kPa
m2
This is also a satisfactory pressure drop across the shell for this application. According
to the kern method, the design is quite adequate. But this method fails to account for
shell side inefficiencies such as leakage and bypass losses. So, another design method
should be done to account for these losses. And the provisional design data is as
follows.

Table 2.6: Calculated parameters in kern method
Design parameter Calculated value

Number of tubes 1026
Shell internal diameter 938 mm
Tube bundle diameter 869 mm
Tube outer diameter 20 mm
Tube pitch 25 mm
Baffle spacing 187.6 mm
2.13 Bell method

In the Bell method, the overall heat transfer coefficient and shell side pressure is
calculated by considering the leakages and bypasses. To account them, here, several
correlation factors are added and final design details are more reliable than kern
method, while giving us a more economical design.
The modified heat transfer coefficient (hs) of bell method is given by,
hs =ho.Fn.Fw.Fb.FL
Where,
 Fn = Tube raw correction factor

 Fw= Window correction factor
 Fb = Bypass correction factor
 FL = Leakage correction factor
Figure 2.10: Baffle and tube geometry

2.13.1 Calculating the Shell Side Heat Transfer Coefficient

Ideal tube bank coefficient = heat transfer coefficient of shell side = (ho)
(calculated in kern’s method)
ho = 6574 W/m2 ℃ (This was calculated previously)
2.13.1.1 Calculating the Tube-row Correction Factor (Fn)

 Vertical tube pitch (Pt′ ) = 0.87×Pt =0.87×25 mm = 21.75 mm
 Baffle cut height (Hc) = 0.25×Ds = 0.25×938 mm = 234.5 mm
 Height between baffle tips = Ds – 2×Hc = 938 – 2×234.5 = 469 mm
469
 Number of constrictions (tube rows) crossed (Ncv) = 21.75 = 21.56
Figure 2.11: Tube row correction factor Fn

From Figure 2.11; Tube raw correction factor (Fn) = 1.03
2.13.1.2 Calculating the window correction factor (Fw)

H 234.5
Bundle cut fraction (Bc) = D𝑐 = = 0.25
𝑠 938
Height of the baffle chord (Hb)

Db 869
Hb = − Ds × (0.5 − Bc ) = − 938 × (0.5 − 0.25) = 200 mm
2 2
Hb 200
Bundle cut (Bb) = = = 0.23
Db 869
From Figure 2.12; 𝑅𝑎′ = 0.18
Tubes in one window area (Nw) = Nt×R′a = 1026×0.18 = 185
Tubes in cross flow area (Nc) = Nt − 2 × Nw = 1026 – 2×185 = 656
2×Nw 2×185
Therefore, R w = = = 0.36
Nt 1026

Figure 2.12: Baffle geometrical factors
Figure 2.13: Window correction factor

From Figure 2.13; Window correction factor (Fw) = 1.02
2.13.1.3 Calculating the bypass correction factor (Fb)

Ab = (Ds – Db)×Sb = (0.938 – 0.869) × 0.1876 = 0.0129444 m2
Ab 0.012944
= = 0.368
As 0.0352

𝐴
Fb = exp[ -1.35× 𝐴𝑏 ] = exp[ -1.35×0.368] = 0.61
𝑠
Very low, sealing strips needed; try one strip for each three vertical rows.
1
Ns 1 Ab Ns 3
= ; Fb = exp[−∝× ( ) × (1 − (2 × ) ) ; ∝= 1.35 for Re ≥ 100
Ncv 3 As Ncv
1
1 3
Fb = exp[−1.35 × 0.368 × (1 − (2 × ) )] = 0.939
3
Bypass correction factor (Fb) = 0.939; this value is more acceptable.
2.13.1.4 Calculating the leakage correction factor (FL)

Using the clearance specified in the standards,
Tube to baffle clearance (Ct) = 1/32 inch = 0.8 mm
Baffle to shell clearance (Cs) = 3/16 inch = 4.8 mm
Area between the tube and baffle (Atb)
𝐶𝑡 × 𝜋 × 𝑑𝑜
𝐴𝑡𝑏 = × (𝑁𝑡 − 𝑁𝑤 )
2
0.8 × 𝜋 × 20
𝐴𝑡𝑏 = × (1026 − 185) = 21137 𝑚𝑚2 = 0.02114𝑚2
2
From Figure 2.12; for 25 per cent cut; 𝜃𝑏 = 2.1 𝑟𝑎𝑑𝑠.
Area between the shell and baffle (Asb)
𝐶𝑠 × 𝐷𝑠
𝐴𝑠𝑏 = (2𝜋 − 𝜃𝑏 )
2
4.8 × 938
𝐴𝑠𝑏 = (2𝜋 − 2.1) = 9417 𝑚𝑚2 = 0.009417 𝑚2
2
Total leakage area (AL) = Asb + Atb = 0.00942 + 0.02114 = 0.030557 𝑚2
𝐴𝐿 0.030557
= = 0.868
𝐴𝑠 0.0352

Figure 2.14: Coefficient for FL, heat transfer

Leak factor coefficient (βL) = 0.48
(Atb + 2 × Asb ) (0.02114 + 2 × 0.009417)

FL = 1 − β L = 1 − 0.48 = 0.372
AL 0.030557
Leakage correction factor (FL) = 0.372
2.13.1.5 Shell side coefficient

Therefore, according to the bell method, heat transfer coefficient of the shell side is
given by,
hs = ho×Fn×Fw×Fb×FL = 6574×1.03×1.02×0.939×0.372 =2412.5 W/m2℃
Shell side heat transfer coefficient (by using Bell method) = 2412.5 W/m2℃
This value is much lower than that calculated by kern’s method. So, new value should
be added to calculate the overall heat transfer coefficient.
2.13.1.6 Calculating Overall Heat Transfer Coefficient

New overall heat transfer coefficient (Uo) can be calculated as follows,
d
1 1 1 do × ln ( o ) d 1 do 1
di o
= + + + × + ×
Uo ho hod 2 × kw di hid di hi
20
1 1 1 20 × 10−3 × ln (16) 20 1 20 1
= + + + × + ×
Uo 2412.5 6000 2 × 395 16 10000 16 178

𝑈𝑜 = 129.3 W/m2℃
This is marginally higher than that of the assumed value and finally the design can be
regarded as satisfactory.
2.13.1.7 Calculating the new shell - side pressure drop

 Calculating the pressure drop in ideal tube bank (ΔPi)
1
∆Pi = (8 × jf × Ncv ) × ( (ρf u2f ))
2
1
∆Pi = (8 × 0.049 × 21.56) × ( (995.7 × 0.6482 )) = 1767 Pa
2
Shell − side pressure drop ∆Pi = 1.767 kPa
 Calculating the pressure drop in the cross flow zone (ΔPc)
∆Pc = ∆Pi × FL × Fb
∆Pc = 1767 × 0.372 × 0.803
∆Pc = 528 Pa
 Calculating the pressure drop in window zone (ΔPw)
πD2s πd2o
Aw = ( × R′a ) − (Nw × )
4 4
π × 0.9382 π × 0.0022
Aw = ( × 0.18) − (21.56 × )
4 4
Aw = 0.12432 m2
Thermal fluid velocity through window zone (Uw)
fluid flow rate 22.72

Uw = = = 0.1835 m/s
density × area of window zone 995.7 × 0.12432
Geometric mean velocity (Uz)
Uz = √Uw × Us = √0.1835 × 0.6484 = 0.345 m/s
Hb 200
Number of tubes in the window zone (Nwv) = = =9
P′t 21.75
1
∆Pw = [FL × (2 + 0.6Nwv )] ( (ρf × u2f ))
2

1
∆Pw = [0.372 × (2 + 0.6 × 9)] ( (995.7 × 0.6482 ))
2
∆Pw = 575.5 Pa
Window zone pressure drop = 575.5 Pa
 Calculating the pressure drop in end zone (ΔPe)
Nwv + Ncv
∆Pe = [∆Pi ] ( ) Fb
2
9 + 22
∆Pe = 1767 ( ) 0.939 = 25718 Pa
2
End zone pressure drop (ΔPe) = 25718 Pa
 New shell - side pressure drop (∆𝑷𝒔 )
∆Ps = 2 × ∆Pe + ∆Pc (Nb − 1) + Nb ∆Pw
∆Ps = 2 × 25718 + 528(12 − 1) + 12 × 575.5
∆Ps = 64150 Pa = 64.15 kPa
This is a satisfactory pressure drop through the shell.
2.14 Summary – The Proposed Design

 Split ring, floating head, 1 shell pass, and 2 tube passes.
 Shell side is allocated for cooling tower water
 Tube side is allocated for gas mixture
 20 mm outside diameter, 16 mm inside diameter, 2.5 m long tubes and Copper
tubes.
 Triangular pitch, pitch 25 mm
 Number of tubes 1026
 Heat transfer area 161.16 m2 (based on outside diameter)
 Bundle diameter 869 mm
 Shell inside diameter 938 mm
 Tube side coefficient 178 W/𝑚2 ℃, clean
 Shell side coefficient 2412.5 W/𝑚2 ℃, clean
 Overall coefficient estimated 129.3 W/m2 ℃, dirty
 Overall coefficient required 20 W/𝑚2 ℃, dirty
 Dirt/Fouling factors:

o Shell side (Cooling tower water) 0.00017 (W/𝑚2 ℃)-1

o Tube side (Air and industrial gases) 0.0001(W/𝑚2 ℃)-1
 Pressure drops:
o Tube side, estimated 14.7 kPa
o Shell side, estimated 64.15 kPa
 Baffle spacing 187.6 mm, 25% cut
 Number of baffles are 12, Baffle height is 234.5 mm

CHAPTER 3 MECHANICAL DESIGN
3.1 Introduction
The mechanical design of a shell and tube heat exchanger provides information on
items such as shell thickness, flange thickness, etc. These are calculated using a
pressure vessel design code such as the Boiler and Pressure Vessel code from ASME
(American Society of Mechanical Engineers) and the British Master Pressure Vessel
Standard, BS 5500. ASME is the most commonly used code for heat exchangers and is
in 11 sections. Section VIII (Confined Pressure Vessels) of the code is the most
applicable to heat exchangers but Sections II—Materials and Section V—Non
Destructive Testing are also relevant. Both ASME and BS5500 are widely used and
accepted throughout the world but some countries insist that their own national codes
are used.
3.2 Material Selection

Material selection is one of the main criteria of any kind of chemical design. Many
factors have to be considered when selecting suitable materials for shell and tube heat
exchanger. Maximum operating temperature and maximum allowable pressure are
major factors that should be considered when selecting material for heat exchanger.
The selected materials should be suitable for the process conditions. The most
economical material that satisfies both process and mechanical requirements should be
selected. This will be the material that gives the lowest cost over the working life of the
plant, allowing for maintenance and replacement. Other factors, such as product
contamination and process safety, are also very important considerations.
3.2.1 Selection of tube material

Tube material should have good thermal conductivity. Because heat is transferred from
a hot to a cold side through the tubes, there is a temperature difference through the
width of the tubes. The tube material also should be compatible with both the shell and
tube side fluids for long periods under the operating conditions (temperatures,
pressures, pH, etc.) to minimize deterioration such as corrosion. All of these
requirements call for careful selection of strong, thermally-conductive, corrosion-
resistant, high quality tube materials, typically metals, including copper alloy, stainless
steel, carbon steel, non-ferrous copper alloy, Inconel, nickel, Hastelloy and titanium.

Therefore, Copper material is most suitable for heat exchangers tubes. Copper has
many desirable properties for thermally efficient and durable heat exchangers. Copper's
high thermal conductivity allows heat to pass through it quickly. Other desirable
properties of copper in heat exchangers include its corrosion resistance, biofouling
resistance, maximum allowable stress and internal pressure, creep rupture strength,
fatigue strength, hardness, thermal expansion, specific heat, antimicrobial properties,
tensile strength, yield strength, high melting point, alloyability, ease of fabrication, and
ease of joining. The combination of these properties enables copper to be specified for
heat exchangers tubes.
3.2.2 Tube Sheets

Tube sheets usually constructed from a round, flattened sheet of metal. Holes for the
tube ends are teen drilled for the tube ends in a pattern relative to each other. The tube
sheet comes in contact with both fluids in the exchanger, therefore it must be
constructed of corrosion resistant materials or allowances appropriate for the fluids and
velocities. Therefore, Stainless steel (316) which is corrosion resistant materials and
has good thermal properties, is a suitable material for Tube sheets.
3.2.3 Shell Assembly

The shell is constructed either from pipe or rolled plate metal. For economic reasons,
steel is the most commonly used material, and when applications involving extreme
temperatures and corrosion resistance, others metals or alloys are specified.
Carbon steel is heated for prolonged period of above 455℃ may be subjected to carbon
segregation, which is then transformed into Graphite. When this occurs, the structural
strength of the steel is reduced. But in this exchanger, we use carbon steel for shell
construction, shell side fluid maximum temperature is 35℃. This value is well below
the carbon segregation temperature (455℃) of carbon steel. Hence, the carbon
segregation has no effect on the above design. Finally, carbon steel (SA516) is the most
suitable material for the fabrication of the shell of this heat exchanger. Baffles also
should be constructed with carbon steel (SA516).
3.2.4 Heat exchanger heads

In this case, tube side fluid has maximum temperature of 471℃ and that is a corrosive
fluid. Therefore, Stainless steel is suitable for heat exchanger heads. But floating head
shell cover should be carbon steel (SA516) (Materials, 2013).

3.3 Selection of Shell, Front End Header, and Rear End Header Types
The main components of a shell and tube exchanger are shown in Figure 3.1 a, b and c
and described in Table 3.1.
Figure 3.1: Type BEM, CFU and AES exchangers. © 1988 by Tubular Exchanger
Manufacturers Association

Table 3.1: Shell and tube geometric terminology
1 Stationary (Front) Head—Channel 20 Slip-on Backing Flange

2 Stationary (Front) Head—Bonnet 21 Floating Tubesheet Skirt
3 Stationary (Front) Head Flange 22 Floating Tubesheet Skirt
4 Channel Cover 23 Packing Box Flange
5 Stationary Head Nozzle 24 Packing
6 Stationary Tubesheet 25 Packing Follower Ring
7 Tubes 26 Lantern Ring
8 Shell 27 Tie Rods and Spacers
9 Shell Cover 28 Transverse Baffles or Support Plates
10 Shell Flange—Stationary Head End 29 Impingement Baffle or Plate
11 Shell Flange—Rear Head End 30 Longitudinal Baffle
12 Shell Nozzle 31 Pass Partition
13 Shell Cover Flange 32 Vent Connection
14 Expansion Joint 33 Drain Connection
15 Floating Tubesheet 34 Instrument Connection
16 Floating Head Cover 35 Support Saddle
17 Floating Head Flange 36 Lifting Lug
18 Floating Head Backing Device 37 Support Bracket
19 Split Shear Ring
3.3.1 TEMA Designations
The popularity of shell and tube exchangers has resulted in a standard nomenclature
being developed for their designation and use by the Tubular Exchanger Manufactures
Association (TEMA). This nomenclature is defined in terms letters and diagrams. The
first letter describes the front header type, the second letter the shell type and the third
letter the rear header type. Many combinations of front header, shell and rear header
can be made. The most common combinations for an E-Type Shell are given in Table
1.4 but other combinations are also used.
Table 3.2: Shell and tube geometric terminology
Fixed tubesheet exchangers U-tube exchangers Floating head exchangers

AEL AEU AES
AEM CEU BES
AEN DEU
BEL
BEM
BEN

Essentially there are three main combinations
 Fixed tubesheet exchangers

 U-tube exchangers
 Floating header exchangers
Figure 3.2: TEMA nomenclature. © 1988 by Tubulare Exchanger Manufacturers

Association

3.3.2 Selection of Floating Head Exchanger (P, S, T and W Type Rear Headers)
In this type of exchanger, the tubesheet at the Rear Header end is not welded to the
shell but allowed to move or float. The tubesheet at the Front Header (tube side fluid
inlet end) is of a larger diameter than the shell and is sealed in a similar manner to that
used in the fixed tubesheet design. The tubesheet at the rear header end of the shell is of
slightly smaller diameter than the shell, allowing the bundle to be pulled through the
shell. The use of a floating head means that thermal expansion can be allowed for and
the tube bundle can be removed for cleaning. There are several rear header types that
can be used but the S-Type Rear Head is the most popular. A floating head exchanger
is suitable for the rigorous duties associated with high temperatures and pressures.
3.3.3 Selection of E-Type Shell

E-type shells are the most common. If a single tube pass is used and provided there are
more than three baffles, then near counter-current flow is achieved. If two or more tube
passes are used, then it is not possible to obtain pure countercurrent flow and the log
mean temperature difference must be corrected to allow for combined co-current and
countercurrent flow using an F-factor. Therefore, E– type shell is most suitable for in
this case.
3.3.4 Selection of A-Type front header

This type of header is easy to repair and replace. It also gives access to the tubes for
cleaning or repair without having to disturb the pipe work. It does however have two
seals (one between the tube sheet and header and the other between the header and the
end plate).
3.3.5 Selection of S-Type Rear Header

This is a floating rear header with backing device. It is the most expensive of the
floating head types but does allow the bundle to be removed and unlimited thermal
expansion is possible. It also has smaller shell to bundle clearances than the other
floating head types.
3.4 Mechanical Design Parameter Calculation
3.4.1 Calculation of Shell Thickness

Design specification of heat exchanger shell thickness calculation;
 Gauge pressure = 0.9 atm

 Operating temperature = 35 ℃
 Inner diameter of shell = 0.938 m
3.4.1.1 Calculation of the Design Pressure
𝑃𝐼𝑛𝑡𝑒𝑟𝑛𝑎𝑙
𝑃𝐸𝑥𝑡𝑒𝑟𝑛𝑎𝑙
𝑃𝐼𝑛𝑡𝑒𝑟𝑛𝑎𝑙 > 𝑃𝐸𝑥𝑡𝑒𝑟𝑛𝑎𝑙
Therefore; 𝑃𝐷𝑒𝑠𝑖𝑛𝑔 = 𝑃𝑀𝑎𝑥. 𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 𝑏𝑦 𝑔𝑎𝑢𝑔𝑒 + (10)% 𝑒𝑥𝑡𝑟𝑎

10
So; 𝑃𝐷𝑒𝑠𝑖𝑛𝑔 = 0.9 𝑎𝑡𝑚 + × 0.9 𝑎𝑡𝑚
100
𝑃𝐷𝑒𝑠𝑖𝑛𝑔 = 0.99 𝑎𝑡𝑚 = 100312 𝑃𝑎
3.4.1.2 Calculation of the Design Temperature

0 0
𝑇𝐷𝑒𝑠𝑖𝑔𝑛 = 𝑇𝐻𝑖𝑔ℎ𝑒𝑠𝑡 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑜𝑓 𝑡ℎ𝑒 𝑏𝑜𝑑𝑦 + (10)% 𝑒𝑥𝑡𝑟𝑎
0
Therefor; 𝑇𝐷𝑒𝑠𝑖𝑔𝑛 = 35 ℃ + 3.5 ℃
0
𝑇𝐷𝑒𝑠𝑖𝑔𝑛 = 38.5 ℃
3.4.1.3 Design stress Calculation

Table 3.3: Design stress calculation table

Material is Carbon steel (SA516 Grade 70) and design temperature is 38.5 ℃,
Therefore from table, 𝜎𝐷𝑒𝑠𝑖𝑔𝑛 = 17500 psi = 120.66 N/mm2
3.4.1.4 Wall thickness calculation

Before calculation of the wall thickness, the type of the class of the vessel to be
designed is to be clearly defined. Typical heat exchangers are using second class vessel
or U-69 class with the weld joints of single groove having the efficiency of 80%. In this
class, spot radiography analysis should be done for longitudinal and circumferential
joints.
t actual = t theorotical + C
PDesign × Dinner
t Actual = + C
2 × φ × σDesign
Here, 𝑡𝑎𝑐𝑡𝑢𝑎𝑙 = Actual thickness of the shell
𝑃𝐷𝑒𝑠𝑖𝑔𝑛 = Design pressure of the vessel
𝐷𝑀𝑒𝑎𝑛 = Mean diameter of the vessel
𝜑 = Weld joint efficiency
𝜎𝐷𝑒𝑠𝑖𝑔𝑛 = Design stress
C = Corrosion resistance (Here we take Carbon steel there for C = 2 mm)
100312 × 0.938
𝑡𝐴𝑐𝑡𝑢𝑎𝑙 = 6
+ 2 × 10−3 = 2.5 × 10−3 𝑚
2 × 0.8 × 120.66 × 10
Table 3.4: Minimum practical wall thickness
Vessel Diameter (m) Minimum thickness
1 5
1 to 2 7
2 to 2.5 9
2.5 to 3.0 10
3.0 to 3.5 12
Therefore, 𝑡𝑎𝑐𝑡𝑢𝑎𝑙 < Minimum thickness
So wall thickness is selected as 5mm because of it is the minimum practical wall

thickness for 1m vessel diameter and plates which having 5mm is also available in the
market.

Therefore, economical and safest wall thickness is 5mm.
3.4.2 Calculation of the thickness and height of the Floating head cover
3.4.2.1 Calculation of the Design Pressure
𝑃𝐼𝑛𝑡𝑒𝑟𝑛𝑎𝑙
𝑃𝐸𝑥𝑡𝑒𝑟𝑛𝑎𝑙
𝑃𝐼𝑛𝑡𝑒𝑟𝑛𝑎𝑙 > 𝑃𝐸𝑥𝑡𝑒𝑟𝑛𝑎𝑙
Therefore; 𝑃𝐷𝑒𝑠𝑖𝑛𝑔 = 𝑃𝑀𝑎𝑥. 𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 𝑏𝑦 𝑔𝑎𝑢𝑔𝑒 + (10)% 𝑒𝑥𝑡𝑟𝑎

10
So; 𝑃𝐷𝑒𝑠𝑖𝑛𝑔 = 0.3 𝑎𝑡𝑚 + × 0.3 𝑎𝑡𝑚
100
𝑃𝐷𝑒𝑠𝑖𝑛𝑔 = 0.33 𝑎𝑡𝑚 = 33437 𝑃𝑎
3.4.2.2 Calculation of the Design Temperature

0 0
0
Therefor; 𝑇𝐷𝑒𝑠𝑖𝑔𝑛 = 471 ℃ + 47.1 ℃
0
𝑇𝐷𝑒𝑠𝑖𝑔𝑛 = 518.1 ℃
3.4.2.3 Design stress calculation

Table 3.5: Design stress of stainless steel
Material is Stainless steel (316) and design temperature is 518.1 ℃, Therefore from
table, 𝜎𝐷𝑒𝑠𝑖𝑔𝑛 = 102 N/mm2

3.4.2.4 Head height calculation

Floating Head Cover is required to the one end. Torispherical head is most suitable for
Floating Head Cover. Torispherical head consists with three sections namely the dished
section, knuckle section and cylindrical section (flanged section).
Figure 3.3: Torispherical head
So R Crown = Douter
and rknuckle = 6% Douter
Douter = Dinner + 2t actual
Assume: Inner diameter is 938 mm which is shell inner diameter
𝑡𝑎𝑐𝑡𝑢𝑎𝑙 = 3 𝑚𝑚 (It is explained in calculation of stationary head channel thickness)
Douter = 0.938 + 6 × 10−3 = 0.944 m
So R crown = 0.944m
6
rKnuckle = × 0.944 = 0.05664 m
100
OB = OF = R crown = 0.944 m
Do
CD = = 0.472 m
2
AB = AC = rknuckle = r = 0.05664 m
Do
AD = − r = 0.472 m − 0.05664 m = 0.41536 m
2
OA = R crown − r = 0.944 m − 0.05664 m = 0.88736 m
Do⁄
sin∅ =
AD
= 2 − r = 0.41536
OA R crown − r 0.88736

0.41536
∅ = sin−1 ( ) = 0.4871226 rad
0.88736
hknuckle = rcos∅ = 0.05664 × cos(0.4871226 rad) = 0.05005 m
hdish = OF − OE = R crown − R crown cos∅ = 0.944 − 0.944 × cos(0.48715 rad)

= 0.109803 m
3.4.2.5 Design of head thickness

PDesign × Do × C
t=
2 × σDesign × φ
 Double equal V grove welded but joints are used to weld Heads
 Weld joint efficiency (φ) can be taken as 0.85 as spot radiography used.
 C is called as shape factor depends on effective external head height he.
D2outer 0.9442
he = = = 0.236 m
4R crown 4 × 0.944
Douter × r 0.5 0.944 × 0.05664 0.5

he = ( ) = ( ) = 0.1635 m
2 2
0.5
Do Do
he = R − [(R − ) × (R + − 2r)]
2 2
0.5
0.944 0.944
he = 0.944 − [(0.944 − ) × (0.944 + − 2 × 0.05664)]
2 2
he = 0.1598547 m
So minimum he = 0.1598547 m
he 0.1598547
Then = = 0.1693376
Do 0.944
PDesign × Do × C
Also from equation (A) t =
2 × σDesign × φ
t PDesign 33437
So, = ×C= ×C
Do 2 × σDesign × φ 2 × 0.85 × 102000000
= 1.9283 × 10−4 × C
Following data table can be used to obtain C.

Table 3.6: Table for calculating the dimensions of torispherical head
t/ Douter
he / Douter
0.001 0.002 0.005 0.01 0.02 0.04
0.15 5.18 4.55 2.66 2.15 1.95 1.75
0.20 2.5 2.3 1.70 1.45 1.37 1.32
0.25 1.46 1.38 1.14 1.00 1.00 1.00
0.30 0.97 0.92 0.77 0.77 0.77 0.77
0.40 0.59 0.59 0.59 0.59 0.59 0.59
0.50 0.55 0.55 0.55 0.55 0.55 0.55
he 0.1598547
From = = 0.1693376
Do 0.944
Stress concentration factors for various t/ Douter values corresponding to the above he /
Douter value (0.1693376) can be interpolated.
Table 3.7: Stress concentration factors
t/ Douter
he / Douter
0.0005 0.001 0.002 0.005 0.01
0.15 5.5 5.18 4.55 2.66 2.15
0.1693376 4.3784192 4.1435046 3.679808 2.28871808 1.8792736
0.20 2.6 2.5 2.3 1.70 1.45
t
At = 0.01, t 5 = 0.01 × Do = 0.01 × 0.944 = 9.44 mm
Do
But at this occation C = 1.8792736
t
So by using above equation, = 1.9283 × 10−4 × C
Do
Therefore t ′5 = Do × 1.9283 × 10−4 × 1.8792736 = 0.342087 mm
Similarly, this can be done
t 4 = 4.72 mm and t ′4 = 0.416618831 mm
t 3 = 1.888 mm and t ′3 = 0.6698410435 mm
t 2 = 0.944 mm and t ′2 = 0.7542484405 mm
t1 = 0.472 mm and t1′ = 0.7970103022 mm

10
8
Thickness (mm)
6
4 t
t'
2
0
0 1 2 3 4 5
C values
Figure 3.4: Thickness-C values relationship

4.3784192 − C 0.7970103022 − 0.472
So C can be found using =
C − 4.1435046 0.944 − 0.7542484405
C = 4.23
PDesign × Do × C 33437 × 0.944 × 4.23

Then t = = = 0.77mm
2 × σDesign × φ 2 × 0.85 × 102000000
2 mm thick plates can be purchased from the market. So 2mm thick Austenite Stainless
Steel (316) can use to design floating head cover.
Actual outer diameter = outer diameter + 6% extra + flange height
Actual outer diameter = 0.944 m + 6% ×0.944 m + 2/3 × dish height
Actual outer diameter = 0.944 m + 6% ×0.944 m + 2/3 × 0.109803 = 1.073842 m
3.4.3 Calculation of the thickness of the flat closure (Channel cover)

Flat closer (channel cover) is used for the cooling water supplying end of the heat
exchanger. Flat closer is mounted to the cylindrical shell (Stationary-Front Head
Channel) using flanges in order to withstand for high pressure inside the shell.
 Design pressure is 𝑃𝑑𝑒𝑠𝑖𝑔𝑛 = 33437 Pa

 Design stress 𝜎𝑠ℎ𝑒𝑙𝑙 = 102 N/mm2
 Design Temperature 𝑇𝑑𝑒𝑠𝑖𝑔𝑛 = 518.1℃
 Material is stainless 316
𝑃𝑑𝑒𝑠𝑖𝑔𝑛
𝑡 = 𝐶 × 𝐷𝑒𝑓𝑓𝑒𝑐𝑡𝑖𝑣𝑒 √
𝜎𝑠ℎ𝑒𝑙𝑙

Where, t = Thickness of the flat closer
C = Coefficient depend on the type of the connection (for flanges it is 0.25

according to the ASME section VIII Division 1)
Deffective = Effective diameter
Pdesign = Design pressure
σshell = Design stress of the cylindrical shell
Figure 3.5: Representation of a flat closure

Deffective = Douter + 6% extra + Height of the flanged section
Height of the flanged section = 2/3 ×ℎ𝑑𝑖𝑠ℎ = 73.202 mm
Douter = Dinner + 2×t = 938 + 2 × 3 = 944 mm
ℎ𝑑𝑖𝑠ℎ It was calculated in floating head cover calculation
Deffective = 0.944 + 6%×0.944 m + 2/3 × 0.109803 m = 1.0738 m
33437
𝑡 = 0.25 × 1.0738√
102 × 106
𝑡 = 4.86 𝑚𝑚
This is not available in the market, so the thickness of flat closer is 5 mm, material is
Stainless steel (SS316).
3.4.4 Stationary head channel thickness

Design pressure 𝑃𝐷𝑒𝑠𝑖𝑔𝑛 = 33437 𝑃𝑎
Design Stress 𝜎𝐷𝑒𝑠𝑖𝑔𝑛 = 102𝑀𝑃𝑎
Design temperature 𝑇𝐷𝑒𝑠𝑖𝑔𝑛 = 518.1℃

Material is stainless steel (SS316)
𝑃𝐷𝑒𝑠𝑖𝑔𝑛 × 𝐷𝑖𝑛𝑛𝑒𝑟
𝑡𝐴𝑐𝑡𝑢𝑎𝑙 = + 𝐶
2 × 𝜑 × 𝜎𝐷𝑒𝑠𝑖𝑔𝑛
33437 × 0.938
𝑡𝐴𝑐𝑡𝑢𝑎𝑙 = 6
+ 0 = 1.8 × 10−4
2 × 0.85 × 102 × 10
Table 3.8: Minimum practical wall thickness without Corrosion resistance

(Without Corrosion resistance)
1 3
1 to 2 5
2 to 2.5 7
2.5 to 3.0 8
3.0 to 3.5 10

market. Therefore, economical and safest wall thickness is 3mm.
3.4.5 Pass Partition

𝑃𝐷𝑒𝑠𝑖𝑛𝑔 = 𝑃𝑀𝑎𝑥. 𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 𝑏𝑦 𝑔𝑎𝑢𝑔𝑒 + (10)% 𝑒𝑥𝑡𝑟𝑎
10
So; 𝑃𝐷𝑒𝑠𝑖𝑛𝑔 = 14.7 𝑘𝑃𝑎 + × 14.7 𝑘𝑃𝑎 = 16.17 𝑘𝑃𝑎 = 16170 𝑃𝑎
100
0 0
0
Therefor; 𝑇𝐷𝑒𝑠𝑖𝑔𝑛 = 471 ℃ + 47.1 ℃ = 518.1 ℃
𝜎𝑑𝑒𝑠𝑖𝑔𝑛 = 102𝑀𝑃𝑎
Equivalent diameter of pass partition = 883 mm
𝑃𝑑𝑒𝑠𝑖𝑔𝑛 16170
𝑡 = 𝐶 × 𝐷𝑒𝑞𝑢𝑖 √ = 0.25 × 0.883√ = 2.7 𝑚𝑚
𝜎𝑠ℎ𝑒𝑙𝑙 102 × 106
Therefore, economical and safest wall thickness is 3mm.
3.4.6 Shell cover calculation

Pdesign = 0.99 atm = 100312 Pa

Tdesign = 38.5 ℃
σdesign = 120.66 MPa
 Cylindrical part thickness

PDesign × Dinner
t actual = t theorotical + C = + C
2 × φ × σDesign
C = Corrosion resistance (Here we take Carbon steel there for C = 2 mm)
100312 × 1.080
t Actual = + 2 × 10−3 = 2.561 × 10−3 m
2 × 0.8 × 120.66 × 106
Table 3.9: Minimum practical wall thickness
1 5
1 to 2 7
2 to 2.5 9
2.5 to 3.0 10
3.0 to 3.5 12

market. Therefore, economical and safest wall thickness is 7mm.
3.4.6.1 Torispherical head calculation

Torispherical head is most suitable for shell cover. Torispherical head consists with
three sections namely the dished section, knuckle section and cylindrical section
(flanged section). From Figure 3.3;
So R Crown = Douter
and rknuckle = 6% Douter
Douter = Dinner + 2t actual
Assume: Inner diameter is 1080 mm which is floating head cover flange outer diameter
t actual = 7 mm (It is explained in calculation of stationary head channel thickness)
Douter = 1.080 + 14 × 10−3 = 1.094 m

So R crown = 1.094 m
6
rKnuckle = × 1.094 = 0.06564 m
100
OB = OF = R crown = 1.094 m
Do
CD = = 0.547 m
2
AB = AC = rknuckle = r = 0.06564 m
Do
AD = − r = 0.547 m − 0.06564 m = 0.48136 m
2
OA = R crown − r = 1.094 m − 0.06564 m = 1.02836 m
Do⁄
sin∅ =
AD
= 2 − r = 0.48136
OA R crown − r 1.02836
0.48136
∅ = sin−1 ( ) = 0.4871226 rad
1.02836
hknuckle = rcos∅ = 0.06564 × cos(0.4871226 rad) = 0.058005 m
hdish = OF − OE = R crown − R crown cos∅
hdish = 1.094 − 1.094 × cos(0.4871226 rad) = 0.12725 m
2
hflange = h
3 total
where; htotal = hknuckle + hdish + hflange
So hflange = 2(hknuckle + hdish ) = 2( 0.058005 + 0.12725) = 0.3705 m
3.4.6.2 Design of head thickness

PDesign × Do × C
t=
2 × σDesign × φ
 Double equal V grove welded but joints are used to weld Heads
 Weld joint efficiency (φ) can be taken as 0.85 as spot radiography used.
 C is called as shape factor depends on effective external head height he.
D2outer 1.0942
he = = = 0.2735 m
4R crown 4 × 1.094
Douter × r 0.5 1.094 × 0.06564 0.5

he = ( ) = ( ) = 0.189486 m
2 2

0.5
Do Do
he = R − [(R − ) × (R + − 2r)]
2 2
0.5
1.094 1.094
he = 1.094 − [(1.094 − ) × (1.094 + − 2 × 0.06564)]
2 2
he = 0.185255 m
So minimum he = 0.185255 m
he 0.185255
Then = = 0.1693376
Do 1.094
PDesign × Do × C
Also from equation (A) t =
2 × σDesign × φ
t PDesign 100312
So, = ×C= ×C
Do 2 × σDesign × φ 2 × 0.85 × 120660000
= 4.890358 × 10−4 × C
Following data table can be used to obtain C.
Table 3.10: Table for calculating the dimensions of torispherical head
t/ Douter
he / Douter
0.001 0.002 0.005 0.01 0.02 0.04
0.15 5.18 4.55 2.66 2.15 1.95 1.75
0.20 2.5 2.3 1.70 1.45 1.37 1.32
0.25 1.46 1.38 1.14 1.00 1.00 1.00
he 0.185255
𝐹rom = = 0.1693376
Do 1.094
Stress concentration factors for various t/ Douter values corresponding to the above he /
Douter value (0.1693376) can be interpolated.
Table 3.11: Stress concentration factors
t/ Douter
he / Douter
0.0005 0.001 0.002 0.005 0.01
0.15 5.5 5.18 4.55 2.66 2.15
0.1693376 4.3784192 4.1435046 3.679808 2.28871808 1.8792736
0.20 2.6 2.5 2.3 1.70 1.45
t
At = 0.01, t 5 = 0.01 × Do = 0.01 × 1.094 = 10.94 mm
Do

But at this occation C = 1.8792736

t
So by using above equation, = 4.890358 × 10−4 × C
Do
Therefore t ′5 = Do × 4.890358 × 10−4 × 1.8792736 = 1.0054 mm
Similarly, this can be done
t 4 = 5.47 mm and t ′4 = 1.2245 mm
t 3 = 2.188 mm and t ′3 = 1.9687 mm
t 2 = 1.094 mm and t ′2 = 2.2168 mm
t1 = 0.547 mm and t1′ = 2.3425 mm
12
10
Thickness (mm)
8
6
t
4
t'
2
0
0 1 2 3 4 5
C value
Figure 3.6: Thickness-C values relationship

4.1435046 − C 2.2168 − 1.094
So C can be found using =
C − 3.679808 2.188 − 1.9687
C = 3.7556
PDesign × Do × C 100312 × 1.094 × 3.7556

Then t = = = 2.009 mm
2 × σDesign × φ 2 × 0.85 × 120.66 × 106
3 mm thick plates can be purchased from the market. So 3mm thick Austenite Stainless
Steel (316) can use to design floating head cover.

3.4.7 Calculation of the nozzles

There are four nozzles, two for cooling water inlet and outlet flows and other two for
thermic fluid circulation required for this heat exchanger. Cooling water nozzles are
fabricated in the cylindrical shell surface and thermic fluid nozzles are in flat closer
side all nozzles are external nozzles fluids flows will be restricted by these nozzle
internal parts.
3.4.7.1 Cooling water nozzles (Shell nozzles)

The internal diameter of both nozzles into and out of the superheater is based upon
recommended optimum velocities in pipes (according to the Parrys Chemical
Engineering Hand book)
Thermic fluid flow data:
Mass flow rate (according to the chemical design) = 22.72 kg/s
Thermic fluid average density = 995.7 kg/m3
Volumetric flow rate = 22.72/995.7 = 0.02282 m3/s
Average velocity through the shell = 0.648 m/s
Area required = 0.02282 /0.648 = 0.035216 m2
Nozzle inlet diameter = [(4× 0.035216)/π]0.5= 0.21175 m= 211.75 mm = 8.3366 inch

𝟏
This is not available in the market, so take the internal diameter as 𝟖 𝟐 inch (216 mm)
 Calculation of the shell side nozzle thickness
Figure 3.7: Cooling water nozzles

Here, Assume: L = 2.021 m
Checking the condition for the interaction of nozzles,
𝐿 ≥ 0.86√𝐷𝑜 (𝑡𝑠ℎ𝑒𝑙𝑙 − 𝐶) + 𝑑

𝐿 ≥ 0.86√0.948(5 × 10−3 − 2 × 10−3 ) + 0.216 = 0.262 m
Both nozzles can be placed with L (2.021 m) distance.
Theoretical nozzle thickness (tnth)
𝑃𝑑𝑒𝑠𝑖𝑔𝑛 × 𝑑𝑖𝑛𝑛𝑒𝑟
𝑡𝑛𝑡ℎ =
2 × 𝜎𝑑𝑒𝑠𝑖𝑔𝑛
100312 × 0.216
𝑡𝑛𝑡ℎ = = 0.0898 𝑚𝑚
2 × 120.66 × 106
𝑡𝑛𝑎𝑐𝑡𝑢𝑎𝑙 = 0.0898 + 2 = 2.0898 𝑚𝑚
For market available size is 4 mm. Therefore 𝑡𝑛𝑎𝑐𝑡𝑢𝑎𝑙 = 4𝑚𝑚
𝐻 = √(𝑑𝑜𝑝𝑒𝑛 + 2 × 𝐶)(𝑡𝑎𝑐𝑛𝑜𝑧𝑧𝑙𝑒 − 𝐶)
𝐻 = √(0.216 + 2 × 0.002)(0.004 − 0.002) = 0.020976 𝑚 = 21 𝑚𝑚
1
𝐴𝑏𝑒𝑡𝑤𝑒𝑒𝑛 𝑜𝑝𝑒𝑛𝑖𝑛𝑔 = 𝐴𝑠ℎ𝑒𝑙𝑙 + 2 × ( × 𝐴𝑛𝑜𝑧𝑧𝑙𝑒𝑠 )
2
Here, ‘A’ denoted by the ‘Area’
𝑑0 0.216
𝐴𝑠ℎ𝑒𝑙𝑙 = (𝐿 − 2 × ) (𝑡𝑎𝑐 − 𝐶) = (2.180 − 2 × ) (0.004 − 0.002)
2 2
𝐴𝑠ℎ𝑒𝑙𝑙 = 3.928 × 10−3 𝑚2
𝐴𝑛𝑜𝑧𝑧𝑙𝑒 = 𝐻 × (𝑡𝑛𝑎𝑐 − 𝐶) = 0.020976 × (0.004 − 0.002) = 4.1952 × 10−5 𝑚2
1
𝐴𝑏𝑒𝑡𝑤𝑒𝑒𝑛 𝑜𝑝𝑒𝑛𝑖𝑛𝑔 = 3.928 × 10−3 + 2 × ( × 4.1952 × 10−5 ) = 3.97 × 10−3 𝑚2
2
Checking for the reinforcements;
𝑃 × 𝐷𝑖𝑛𝑛𝑒𝑟 × 𝐿
𝜎𝑠ℎ𝑒𝑙𝑙 = ( )
2 × 𝐴𝑏𝑒𝑡𝑤𝑒𝑒𝑛 𝑜𝑝𝑒𝑛𝑖𝑛𝑔
100312 × 0.938 × 2.180

𝜎𝑠ℎ𝑒𝑙𝑙 = ( ) = 25834004 𝑃𝑎 = 25.8 𝑀𝑃𝑎
2 × 3.97 × 10−3
𝐴𝑠, 𝜎𝑠ℎ𝑒𝑙𝑙 (25.8𝑀𝑃𝑎) < 𝜎𝑑𝑒𝑠𝑖𝑔𝑛 (120.66𝑀𝑃𝑎)
Additional reinforcement is not required.

3.4.7.2 Stationary head nozzles

These nozzles are placed in the same horizontal position of the shell. Therefore, they
are treated as horizontal position nozzles and equations are quite different from above
shell nozzle equations.
Thermic fluid flow data:
Mass flow rate (according to the chemical design) = 3.64 kg/s
Steam average density = 0.6355 kg/m3
Volumetric flow rate = 3.64/0.6355 = 5.72777 m3/s
Average velocity through tubes = 55.55 m/s
Area required = 5.72777/55.55 = 0.10311 m2
Nozzle inlet diameter = [(4× 0.10311)/π]0.5 =0.36233 m =362.33 mm = 14.265 inch

1
This is not available in the market, so take the internal diameter as 142 inch (368.3 mm)
Therefore, nozzle internal diameter = 368.3 mm
Here, Assume: L = 0.938 m (Inner diameter of stationary head channel)
Checking the condition for the interaction of nozzles,
L ≥ 0.86√Do (t shell − C) + d
L ≥ 0.86√0.948(5 × 10−3 − 2 × 10−3 ) + 0.216 = 0.262 m
Both nozzles can be placed with L (0.938 m) distance.
Theoretical nozzle thickness (tnth)
Pdesign × dinner
tnth =
2 × σdesign
33437 × 0.3683
tnth = = 0.06037 mm
2 × 102 × 106
tnactual = 0.06037 + 0 = 0.06037 mm
For market available size is 2 mm. Therefore tnactual = 2mm
H = √(dopen + 2 × C)(tacnozzle − C)
H = √(0.3683 + 2 × 0)(0.002 − 0) = 0.02714 m = 27.14 mm

1
Abetween opening = Ashell + 2 × ( × Anozzles )
2
Here, ‘A’ denoted by the ‘Area’
d0 0.3683
Ashell = (L − 2 × ) (t ac − C) = (0.938 − 2 × ) (0.002 − 0)
2 2
Ashell = 1.1394 × 10−3 m2
Anozzle = H × (tnac − C) = 0.02714 × (0.002 − 0) = 5.428 × 10−5 m2
1
Abetween opening = 1.1394 × 10−3 + 2 × ( × 5.428 × 10−5 ) = 1.19368 × 10−3 m2
2
Checking for the reinforcements;
P × Dinner × L
σshell = ( )
2 × Abetween opening
33437 × 0.938 × 0.938

σshell = ( ) = 12322960.86 Pa = 12.32 MPa
2 × 1.19368 × 10−3
As, σshell (12.32MPa) < σdesign (102MPa)
Additional reinforcement is not required.
3.4.8 Thickness calculation of stationary tube sheets and floating tube sheets
Design pressure of the stationary tube sheet = P design
P external = 1.9 bar
P internal absolute = 1.3 bar
According to the ASME section VIII Division 1,
P design = P external - P internal absolute = 1.9 bar – 1.3 bar = 0.6 bar = 60795 Pa
Material is stainless steel (SS316)
Design stress σdesign = 102 N/mm2
Pdesign
t = C × Deffective √
σshell
Where, t = Thickness of the stationary tube sheet
C = Coefficient depend on the type of the connection (0.25 according to the

ASME section viii Division 1)

Deffective = Effective diameter
Pdesign = Design pressure
σshell = Design stress of the cylindrical shell
Deffective = Douter + 6% extra + Height of the flanged section
Deffective = 0.944 + 6%×0.944 m + 2/3 × 0.109803 m = 1.0738 m
60795
t = 0.25 × 1.0738√ = 6.55 mm
102 × 106
This is not available in the market, so the thickness of stationary tube sheet is 7 mm
3.4.9 Design of the tie rod

Typically tie rods are designed to tighten the tube sheet. The number and diameter of
tie rods depend on the cylindrical shell diameter according to the ‘Standards of tubular
exchanger manufacturing association’. And also they can be calculated from below
table.
Table 3.12: Tie rod data
Normal shell Tie Rod Minimum number of

diameter (mm) diameter (mm) Tie Roads
150 - 400 10 4
400 - 700 10 6
700 - 900 13 6
900 - 1200 13 8
1200 13 10
Diameter of tie rod = 13 mm
Number of tie rods = 8
3.4.10 Gasket
Heat exchanger gasket is usually a metal jacketed gasket with soft filler for higher
temperatures. Kammprofile gaskets are solid metal gasket which may have a soft outer
sealing material in order to conform to flange imperfections. These gaskets are used in
areas where extreme temperatures and excessive movement due to thermal expansion
exist.

3.4.11 Calculation of the number of bolts
Figure 3.8: Nut and Bolt
3.4.11.1 Stationary channel and shell flange

Bolts are used to fix the cylindrical shell and ends through flanges. ½ inch (12.7 mm)
bolt size was selected with the fabrication material of carbon steel.
Figure 3.9: Plan view of the stationary channel flange

Maximum pressure inside the vessel = 100312 Pa
Force exerted on the bolt circle = (100312 N/ m2) × (π/4 ×1.0092 m2) = 8.02094×104 N
Maximum stress per bolt circle = (8.02094×104 N) / (π/4 ×0.01272 m2) = 633.2 Mpa
Number of bolts required = 633.2 Mpa / 120.66 Mpa = 5.25

Number of bolts should be an even number, so then,
Number of bolts required = 6
3.4.11.2 Floating head cover flange

The ½ inch (12.7 mm) bolt size was selected with the fabrication material of stainless
steel.
Outer diameter of floating head cover = 0.944 m
Maximum pressure inside the vessel = 0.99 – 0.33 = 0.66 atm =66874.5 Pa
Force exerted on the bolt circle = (66874.5 N/ m2) × (π/4 ×1.0092 m2) = 5.34728×104 N
3.4.11.3 Shell cover flange

bolt size was selected with the fabrication material of carbon steel.
Actual outer diameter = 1.2445 m
Figure 3.10: Plan view of the stationary channel flange


Force exerted on the bolt circle = (100312 N/ m2) × (π/4 ×1.16952 m2)
= 1.077564×105 N
3.4.11.4 Channel cover-stationary channel flange

bolt size was selected with the fabrication material of stainless steel.
Flange outer diameter 1074 mm
Bolt circle diameter 1009 mm
Stationary channel outer diameter 944
Force exerted on the bolt circle = (33437 N/ m2) × (π/4 ×1.0092 m2) = 2.6736×104 N
Number of bolts required = 211.06 Mpa / 102 Mpa = 2.07
3.4.12 Saddle supports design

Saddle support is necessary for the horizontal vessels while lug support is used for
vertical vessels. The steam superheater is originally designed as the horizontal pressure
vessel so as to achieve the proper heat transfer. Therefore, an acceptable saddle design
should be provided in this report. The saddles must be designed to withstand the load
imposed by the weight of the vessel and contents.
Saddle can be designed by using various materials. Such as,

 Steel plates
 Bricks
 Concretes
Steel plates are most suitable for heat exchangers design.
3.4.12.1 Calculation the total mass and center of gravity when it is filled with
fluids
Since this heat exchanger is not symmetrical, the midpoint of the shell cannot be taken
as the center of gravity. Therefore, the center of the gravity should be initially
calculated and the saddle distance is determined thereafter.
Calculation of the mass of the external parts
Mass of the torispherical head of floating head cover (m1 )

π × 1.0742
= × 0.002 × 7990 = 14.477kg
4
π × 1.2452
Mass of the torispherical head of shell cover (m2 ) = × 0.003 × 7800
4
= 28.487kg
π
Mass of the cylindrical shell (m3 ) = × (0.9482 − 0.9382 ) × 2.427 × 7800
4
= 280.412 kg
π
Mass of the cylindrical channel (m4 ) = × (0.9442 − 0.9382 ) × 0.903 × 7990
4
= 63.987 kg
π
Mass of the shell nozzles (m5 ) = 2 × × (0.2242 − 0.2162 ) × 0.021 × 7800
4
= 0.906 kg
π
Mass of channel nozzles (m6 ) = 2 × × (0.37232 − 0.36832 ) × 0.021 × 7990
4
= 0.781 kg
π
Mass of flat closer(m7 ) = × 1.0742 × 0.005 × 7990 = 36.192 kg
4
π
Mass of channel head flanges(m8 ) = 2 × × (1.0742 − 0.9442 ) × 0.073 × 7990
4
= 240.356 kg

π
Mass of channel side shell flange(m9 ) = × (1.0742 − 0.9482 ) × 0.073 × 7800
4
= 113.935 kg
Floating head cover flanges(m10 )

π
= × 0.073 × 7990 × [(1.0742 − 0.9422 ) + (1.0742 − 0.9382 )]
4
= 247.256 kg
π
Mass of shell cover flange(m11 ) = × (1.22452 − 1.0942 ) × 0.085 × 7800
4
= 157.551 kg
Mass of shell cover side shell flange(m12 )

π
= × (1.22452 − 0.9482 ) × 0.073 × 7800 = 268.635 kg
4
Mass of the bolts can be neglected, since they are very small.
Calculation of the mass of the internals
Since the internal (tube bundle) is symmetrical, its center of gravity lies in the center of
the cylindrical section.
𝜋
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑡ℎ𝑒 𝑡𝑢𝑏𝑒𝑠(𝑚13 ) = × (0.0202 − 0.0162 ) × 2.5 × 8940 × 1024
4
= 2588.391
𝜋
𝑓𝑙𝑜𝑎𝑡𝑖𝑛𝑔 ℎ𝑒𝑎𝑑 𝑠𝑖𝑑𝑒 𝑡𝑢𝑏𝑒𝑠ℎ𝑒𝑒𝑡(𝑚14 ) = × 0.9702 × 0.007 × 7990 = 41.331𝑘𝑔
4
𝜋
𝑐ℎ𝑎𝑛𝑛𝑒𝑙 ℎ𝑒𝑎𝑑 𝑠𝑖𝑑𝑒 𝑡𝑢𝑏𝑒𝑠ℎ𝑒𝑒𝑡(𝑚15 ) = × 1.0742 × 0.007 × 7990 = 50.669𝑘𝑔
4
𝜋
𝑇𝑖𝑒 𝑟𝑜𝑑 (𝑚16 ) = × 0.0132 × 2.51 × 7800 × 8 = 20.789𝑘𝑔
4
𝜋
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟(𝑚17 ) = × 2.5[0.9382 − (0.0202 − 0.0162 ) × 1024] × 995.7
4
= 1431.857𝑘𝑔
Mass of the baffle plates, hot steam and weld joints can be neglected, since they are
very small. Total mass of the heat exchanger (Mg) = 5586 kg
Calculation of the center of the gravity of the heat exchanger
Using the moment theorem,
Moment from total mass = Σ moments of individual masses

Taking the moment around the point of center of the cylindrical shell),
Mg
Assumption: Centre of the gravity of the torispherical head is equal to the center of the
gravity of the hollow hemi sphere (i.e. radius/2).
5586 × 𝑋 = 204592
𝑋 = 37 𝑚𝑚
Therefore, saddles should be placed in same distance apart from the center of gravity in
order to avoid the bending moments.
3.4.12.2 Saddle calculation
Figure 3.11: Standard steel saddles (adapted from Bhattacharyya, 1976)

Here; L = 2427 mm H = 556 mm R = 948 mm b = 150 mm
Following data was assumed, A = 300 mm θ = 1200
W 5586 kg × 9.81 N/kg −1

Q= = = 27399.33 N
2 2
Calculation of max stresses at the saddle due to longitudinal bending
1 − A R2 − H 2
+ 2AL
QA (1 − L 4H )
1+ L
S1 = ±
KR2 t s
Table 3.13: Table of Factor K

K = 0.335, S1 = ±3.485 MPa
P×D 100312 × 0.938

Stress due to pressure = ( )=( ) = 9.409MPa
2×t 2 × 0.005
S1 + stress due to pressure = 3.485 + 9.409 = 12.894 MPa
Design stress = 120.66 MPa
S1 + stress due to pressure < Design stress
Stress due to pressure − S1 = 9.409 − 3.485 = 5.924 MPa
But compressive yield strength of bricks = 40 MPa
1
Stress due to pressure − S1 < compressive yield strength of bricks
2
Therefore, the saddle does withstand for the maximum stress at the saddle due to
longitudinal bending.
Calculation of tension at bottom, compression at top due to longitudinal bending

at mid span
R2 − H 2
QA 1 + 2 × 4A
( L2 − )
4 4H L
1+
3L
S1 = ±
πR2 t s
𝑆1 = ±61855.02 𝑃𝑎
𝑆1 + 𝑠𝑡𝑟𝑒𝑠𝑠 𝑑𝑢𝑒 𝑡𝑜 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = 0.061855 + 9.409 = 9.47𝑀𝑃𝑎
𝑆1 + 𝑠𝑡𝑟𝑒𝑠𝑠 𝑑𝑢𝑒 𝑡𝑜 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 < 𝐷𝑒𝑠𝑖𝑔𝑛 𝑠𝑡𝑟𝑒𝑠𝑠
𝑆𝑡𝑟𝑒𝑠𝑠 𝑑𝑢𝑒 𝑡𝑜 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 − 𝑆1 = 9.409 − 0.061855 = 9.347 𝑀𝑃𝑎
1
𝑆𝑡𝑟𝑒𝑠𝑠 𝑑𝑢𝑒 𝑡𝑜 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 − 𝑆1 < 𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒 𝑦𝑖𝑒𝑙𝑑 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑏𝑟𝑖𝑐𝑘𝑠
2
Therefore, the vessel does not subject to sag at the mid span.
Calculation of the tangential shear
𝑅
𝐴𝑠 𝐴 > ,
2
𝐾2 × 𝑄 𝐿 − 2𝐴
𝑆2 = ( )
𝑅 × 𝑡𝑠 𝐿 + 4𝐻
3

𝐹𝑟𝑜𝑚 𝑡𝑎𝑏𝑙𝑒; 𝐾2 = 1.171, 𝑆2 = 3.90325𝑀𝑃𝑎
0.8 × 𝐷𝑒𝑠𝑖𝑔𝑛 𝑠𝑡𝑟𝑒𝑠𝑠 = 0.8 × 120.66 𝑀𝑃𝑎 = 96.528𝑀𝑃𝑎
𝑆2 < 0.8 × 𝐷𝑒𝑠𝑖𝑔𝑛 𝑠𝑡𝑟𝑒𝑠𝑠
The vessel withstands for the tangential shear.
Calculation of the circumferential stress
At the horn of the saddle, As L < 8 × R,
Q 12 × K 6 × Q × R
S4 = − −
4 × t s (b + 1.56√R × t s ) L × t 2s
From table; K 6 = 0.053, S4 = −277.6MPa

K7 ×Q
At the bottom, S5 = − = −16.18MPa ; K 7 = 0.76
ts (b+1.56√R×ts )
S5 < 0.5 × compression yield stress of the saddle
The saddle can be withstood for circumferential stresses at horn and bottom. Finally,
the brick wall saddle is applicable for the support for this heat exchanger.
3.5 Description of fabrication

Fabrication is the main function of the designing process in any type of pressure vessel.
Because the fabrication is the one and only process which makes the virtual design
(mechanical drawing) into real equipment (final outcome of the design). Carbon steel is
the main fabrication material for the heat exchanger. So this steel can be found in
market with various forms and shapes such as Plates, Sheets, Pipes, Strip, Bars and
Forgings.
In this application, steel plates and pipes, sheets are widely used and a little usage of
steel strips and bars can be seen.
Fabrication of cylindrical shell
Shell fabrication process involves several steps. Each step needs advanced technology.
 Step1: Cutting the steel plate, Stainless steel plates can be cut by gas flame
technique
 Step2: Bevel edges, in this step cur edges are converted into bevel edges.

 Step3: Crimpling, Edges make curved
 Step4: Heating
 Step5. Rolling
 Step6: Clamping the shell
 Step7: Welding. For longitudinal welds double groove welding is suitable. For
this design for shell welding Double V-groove but joint is selected
 Step8: Heat treating

 Step9: Testing
 Cylindrical shell
Heating is performed to make it easy for rolling process. Rolling is the main operation
in cylindrical shell fabrication process and it is done through special equipment called
rolling mill. After the rolling process, both ends meet at the proper radius and this
meeting line should be welded accurately. This shell uses double groove welds and spot
radiography analysis should be done to check the welding progress as this is U – 69
class vessels.
Fabrication of torispherical head
Torispherical heads are spun. It is a type of cold deformation process.

Fabrication of flat closure
Flat closure can be fabricated easily with 4 mm thickness stainless steel plates. The
only operation is the cutting.
Fabrication of nozzles
Nozzles are fabricated in carbon steel pipes and stainless steel pipes with the diameter
of 216 mm and 368.3 mm. Typically these carbon steel and stainless steel pipes in the
market is having the pipe lengths of 6 ft, 12 ft, 18 ft and 24 ft.
Fabrication of tubes
No any prior operation is needed for the fabrication of tubes since the length is 2.5 m.
In the market tubes with 16 mm inner diameter (20 mm outer diameter) and 9 feet long
copper tubes can be easily found and it can be placed to this design as it is.
Fabrication of stationary tube sheet
Initially, Stationary tube sheets are designed as same as flat closure. But it should have
holes to bare the tube bundle. Therefore, the cut stainless steel sheet is carved to have
holes with the diameter of 20 mms.
Fabrication of baffles
Baffles design is quite similar to the stationary tube sheet design. First the unit similar
to the stationary tube sheet should be made with the diameter of 938 mm and it is
necessary to cut it in 25% line in each opposite circumferential points.
Fabrication of tie rods
Tie rods are made by carbon steel bars with 13 mm. Proper steel bar should be selected
and it should be cut in to suitable lengths.
Fabrication of saddle supports
This part was explained under the sub topic of saddle support design.
Assembling of the units

Above fabricated units are then assembled in a correct way. This shell and tube heat

exchanger design uses two assembling techniques called as welding and flanging with
bolts.
Flanging
Flanging is done to assemble of torispherical head to the cylindrical shell, cylindrical

part to the cylindrical and stationary tube sheets to the cylindrical shell.
Welding
Widely used assembling mechanism for this design is welding. Each smaller
connection uses the welding joints to connect each other. Mounting baffle plates to the
cylindrical shell, welding tubes to tube bundle can be taken as examples for weld joint
assembling. Most of the welding is double groove welds since they have higher
strength than other types.
Instead of these two assembling mechanisms, tie rod is mounted to the baffles using
bolt fittings.
3.6 Summary of Design

Part Parameter Specification
Shell Length 2427 mm
Thickness 5 mm
Material Carbon steel (SA516 Grade 70)
Type of connection Flanged
Inner diameter 938 mm
Floating head cover Material Stainless steel (316)
hknuckle 50 mm
hdish 110 mm
Thickness 2 mm
R dish 944 mm
rknuckle 56.64
Channel cover Material Stainless steel (316)
Deffective 1074 mm
Thickness 5 mm

Stationary head Material Stainless steel (316)

channel Thickness 3 mm
Length 700 mm
Pass partition Thickness 3 mm
Shell cover Cylindrical part thickness 7 mm
calculation Inner diameter 1080 mm
hknuckle 58 mm
hdish 127.25 mm
hflange 370.5 mm
R dish 1094 mm
rknuckle 65.64 mm
Thickness 3 mm
Shell nozzles Material Carbon steel (SA516 Grade 70)
L (distance between two 1826 mm
nozzles)
Thickness 4 mm
H (height) 21 mm
Channel nozzle Material Stainless steel (316)
Inner diameter 368.3 mm
Thickness 2 mm
H (height) 27 mm
Tubesheet Thickness 7 mm
Material Stainless steel (316)
Tie rod Diameter of tie rod 13 mm
Number of tie rods 8
Channel-shell flange Actual outer diameter 1074 mm
Bolt diameter 12.7 mm
Material (bolt & flange) Carbon steel (SA516 Grade 70)


Number of bolt 6
Floating head cover Actual outer diameter 1074 mm
flange Bolt diameter 12.7 mm
Material (flange) Stainless steel (316)
Material (bolt) Carbon steel (SA516 Grade 70)
Number of bolt 6
Shell cover-shell Actual outer diameter 1244.5 mm
flange Bolt diameter 12.7 mm
Material (bolt & flange) Carbon steel (SA516 Grade 70)
Bolt circle diameter 1169.5 mm
Number of bolt 8
Channel cover – Actual outer diameter 1074 mm
channel flange
Bolt diameter 12.7 mm
Material (bolt & flange) Stainless steel (316)
Number of bolt 4
Saddle Number of saddle 2
Saddle angle 120°

1 2 3 4 5 6 7 8 9 10 11 12
NOTES:
1. All dimensions in millimeters
2. Flange bolt holes to straddle natural centre lines
A A
1245
1094
1094
705 2427
R1094
B B
948
1024.17
423
285.50 R65.64
C 150 833.12 C
FRONT ELEVATION END

Bill of Materials
Item QTY Description Material
16 1 1 Shell carbon steel (SA516)
D
19 D
2 1 Channel-shell side flange carbon steel (SA516)
15 3 1 Shell-channel side flange Stainless steel (316)
2 4 8 Channel-shell bolts carbon steel

5 3 Gasket corrugated metal
423 1 6 1 Floating head-shell side flange carbon steel (SA516)
368.30
7 2 Shell nozzles carbon steel (SA516)
73 216 7
73 8 2 Shell nozzle flange carbon steel (SA516)
336 9 6 Floating head-shell bolts carbon steel
E 18 8 9 E
10 1 Floating head cover flange carbon steel (SA516)
11 11 1 Floating head cover carbon steel (SA516)

12 1 Saddle floating head side carbon steel (SA516)
13 1 Saddle channel side carbon steel (SA516)
1155 17 14 1 Channel head Stainless steel (316)
14
85 15 2 Channel nozzle flange Stainless steel (316)
4 16 2 Channel nozzle Stainless steel (316)
3
17 1 Flat closure-channel side flange Stainless steel (316)
F
13 18 4 Flat closure bolts carbon steel
F
19 1 Flat closure Stainless steel (316)

448 378 5
73 73
Design Data
Design code ASME VIII
12
Code Seismic code N/A
6 Wind code N/A
10
Shell Tube
G
PLAN ISOMETRIC Inlet temperature 25 Celsius 471 Celsius G
Design
Outlet temperature 35 Celsius 217 Celsius
Condition
Pressure drop 55.6 KPa 1.6 KPa
Fluid Water Gas mixture
Service
Flow rate 22.72 kg/s 3.64 kg/s
2997.6 kg (without 2588.4 kg (Tubes)
Weight tubes)
DESIGN BY: Date: TITLE:
H
K.Subasgar
Shell & Tube Heat
090502X Exchanger
Design 01
MATERIAL:
A2
DWG NO.
Copper, Stailess Stees
& Carbon Steel
1 2 3 4 5 6 7 8 WEIGHT: SCALE:1:20 SHEET 1 OF 1
1 2 3 4 5 6 7 8 9 10 11 12
2500
970 1074
A
365 371 A
12.70
B B
1074 1074
A
13
7
25
C 5 36 C
371 371 365 16
7 73 20
FRONT ELEVATION END 25
7 DETAIL A
D
SCALE 1 : 5 D
E E
BILL OF MATERIALS
F F
ITEM QTY DESCRIPTION MATERIAL
1 1 1 Channel side tube sheet Stainless steel (316)
2 1026 Tubes copper
9 3 1 Floating head side tube sheet Stainless steel (316)
4 4 Baffles upper
6 carbon steel (SA516)
5 6 Floating head flange bolts carbon steel

G G
2 6 1 Floating head-tube side flange Stainless steel (316)
7 6 Channel side tubesheet bolts carbon steel
8 6 Baffles lower carbon steel (SA516)
9 8 Tie rod carbon steel (SA516)
6 3
DESIGN BY: Date: TITLE:
H NOTES:
1. All dimensions in millimeters K.Subasgar
Shell & Tube Heat
090502X Exchanger
ISOMETRIC
MATERIAL:
A2
DWG NO.
Copper, Stailess Stees
& Carbon Steel Design 01-Internals
1 2 3 4 5 6 7 8 WEIGHT: SCALE:1:10 SHEET 1 OF 2
CHAPTER 5 PIPING AND INSTRUMENTATION
5.1 Introduction
Piping and instrumentation are very important part in equipment designing, it will
provide the detailed information and data regarding the flow lines in to and out of the
selected design unit with all controllers, sensors, valves and pumps.
"Piping and Instrumentation Diagram" Its objective is to indicate all process and
service lines, instruments and controls, equipment and data necessary for the design
groups. The process flow diagram is the primary source of information for developing
the P&ID. The P&ID should define piping, equipment and instrumentation well enough
to cost estimation and for subsequent design, construction, operation and modification
of the process. Material balance data, flow rates, temperatures, pressures and piping
fitting details are not shown and purely mechanical piping details such as joints and
unions are inappropriate to P&ID's.
5.2 Selection of the pipes in the absorption pre-cooler system (Heat exchanger)
1 1
There are four pipes with the size of 8 2 inches and 142 inches required for the inlets
and outlets of the cooling water and hot gas stream of the pre-cooler. Each diameter
was calculated under the section of mechanical design. These pipes should be flanged
to the heat exchanger nozzle through bolts. The flange size, number of bolts required
and size of the bolts can be calculated in standard tables which are supplied by the
ANSI. Length of the pipe cannot be designed because we do not know the distance
between the designed units. Therefore, this section of the report contains only diameter
of the pipes and details of the flange connection. If someone has designed the next unit
and the physical situation of the units are known in order to calculate the distance and
number of lines, the lengths of the pipes can be easily determined.
According to the Figure 5.1,
Assume: Use the 150 lb. standard table, and select slip on.
1
Shell side nozzles pipe internal diameter as 8 2 inch (216 mm)
1
Stationary head side nozzles pope internal diameter as 142 inch (368.3 mm)

Figure 5.1: ANSI Flange Dimensions

Table 5.1: ANSI Flange Dimensions calculated
N.P.S D X G t B2 T2 A R Q
7.8 336.1 240.2 263.9 28.1 216 44 213.7 12.7 44
14.4 544.4 410.2 422.9 35.4 368.3 58.3 364.6 12.7 58.3
5.3 Selection of the pumps and blowers in the absorption pre-cooler system
In our case, there are no need pumps or blower because there are small pressure drop
differences which can be handled by using control valves. Any way if needed, we can
use pumps and blowers. All the pumps can be classified into two major types:
1. Dynamic pumps, such as centrifugal pumps.

2. Positive displacement pumps, such as reciprocating and diaphragm pumps.
The single-stage, horizontal, overhung, centrifugal pump is by far the most commonly
used type in the process industry. Other types are used where a high head or other
special process considerations are specified. Since there are no such requirements, a
centrifugal pump is selected.
A centrifugal pump converts the input power to kinetic energy in the liquid by
accelerating the liquid by a revolving device - an impeller. Fluid enters the pump
through the eye of the impeller which rotates at high speed. The fluid is accelerated
radially outward from the pump chasing. A vacuum is created at the impellers eye that
continuously draws more fluid into the pump.
Selection of a pump for a specific task mainly depends on the flow rate and head
required together with other process considerations, such as corrosion or the presence
of solids in the fluid. The chart shown in figure 1.2 can be used to determine the type of
pump required for a particular head and flow rate.
Figure 5.2: Centrifugal pump selection guide

Two pumps are used in the absorption pre-cooler system and both are placed in cooling
water lines. One is feeding cooling water to the heat exchanger while second is drafting
cooling water from the heat exchanger. We cannot do the designing section of pumps
as the head losses in pipes, number of bends of the pipes, bend angles and their friction
factors are not available and not known. That’s why; pump selection has done instead
of pump designing.

Note: If need to change flow rate of hot stream line, we can use air blowers.
5.4 Selection of the valves in the absorption pre-cooler system

The valves used for chemical process plant can be divided into two broad classes
depending on their primary function:
 Shut-off valves (block valves), whose purpose is to close off the flow.
 Control valves, both manual and automatic, used to regulate flow.
The main types of valve used in the chemical and process applications are mentioned
below.
 Gate valve
 Globe valve
 Ball valve
 Butterfly valve
Different types of valves require for different types of applications in this heat
exchanger. Before the pumps, globe valves should be installed as they withstand for
high pressure and complete shut – off property rather than other type of valves. The
same globe valve should be placed in steam input line so as to be controlled manually
by the operator.
In shut down period of the heat exchanger it is needed to create a bypass line for hot
thermic fluid. Therefore, a single by pass valve should be place prior to the heat
exchanger inlet.
Two vent valves are required for thermic fluid outlet section and steam outlet section in
the startup period (this is explained under the chapter of startup and shut down).
There is a single control loop to control the steam outlet temperature. This controller
action requires a controller valve on the thermic fluid inlet section.
5.5 Measuring instruments

Temperature sensors, pressure sensors and flow meters should be placed in each line in
and out of the absorption pre-cooler to observe the process parameters. Operator can
have some understanding on the current operating condition of the absorption pre-
cooler by observing process parameters using above sensors.

5.6 Pipe Supports and Fittings

Over long runs, between buildings and equipment, pipes are usually carried out on pipe
racks. These carry the main process and service pipes (cooling water), and are laid out
to allow easy access to the equipment. Pipe runs are normally made up from lengths of
pipe, incorporating standard fittings for joints, bends and tees. Joints are welded.
Flanged joints are used where this is a more convenient method of assembly such as for
the final connection to the process equipment, valves, sensors and the pump.
5.7 P&I Diagram for absorption pre-cooler Section

Figure show the P&I Diagram of absorption pre-cooler (Shell and tube heat exchanger)
and blow table show the items and abbreviations in absorption pre-cooler section.
Items Abbreviations
VLV-16, 15 Globe valves
VLV-06 Control valve
VLV-02, 09, 10 Gate valves for drain
VLV-01, 03, 12 Gate valves for vent
VLV-13, 11, 04, 05 Glove valves/ Gate valves for shut down
VLV-07, 08 Bypass valves for pump bypass
VLV-14 Vent valve
TT Temperature transmitter
TC Temperature controller

Cooling water outlet
Hot gas outlet
VLV-15
VLV-16
Hot gas inlet

Cooling water inlet
Figure 5.3: P&I Diagram

CHAPTER 6 SAFETY AND CONTROL
6.1 Safety in the absorption pre-cooler (shell and tube heat exchanger)
Safety is the predominant aspect in any kind of a plant or any kind of equipment in
modern days. Because, the plant management should ensure that their workers are free
of injuries and good health conditions both physically and mentally. This absorption
pre-cooler is not very critical or large equipment like boiler or distillation column, so
the safety also spread limited areas only. Safety procedure can be divided into three
sections as
 Worker safety
 Equipment safety
 Chemical safety
Worker safety will account for the safety in humans (permanent workers, contractors
and visitors) while equipment safety and chemical safety ensures the better condition
on machine and chemical handling. Especially in chemical handling, there is only
chemical used in absorption pre-cooler which is thermic fluid. So some safety
precautions regarding the thermic fluid are indicated in the latter part of this chapter.
There are two methods followed to achieve the optimum safety targets in the absorption
pre-cooler called HAZOP study and general safety procedures. HAZOP table is
performed below to identify all possible hazards, consequences and precautions to be
taken to overcome them. Meanwhile, general safety procedures include some safety
regulations in the plant and special behaviors near the absorption pre-cooler.
6.2 HAZOP study

The HAZOP review should be performed after designing any process equipment,
because it seeks various risks, bottlenecks of the equipment and the actions that should
be done to minimize the consequences which are formed due to newly designed vessel.
Table 6.1 shows the complete HAZOP study for this absorption pre-cooler and it
carries several tasks that should be done prior to operating this. These are,
 Installation of alarm system

 Continuous inspection
 Keeping stand by pumps ensure the human and equipment safety

Table 6.1: HAZOP Study Applied to the Absorption pre-cooler
HAZOP Study Applied to the Absorption pre-cooler

Hazards and Operability Review
Project name: Design of Absorption pre-cooler (Shell & tube heat exchanger)
Process: Converter to Intermediate absorption tower
Section: Absorption pre-cooler (Shell & tube heat exchanger)
Study Process Deviations Possible causes Possible consequences Action required
node parameters
Thermic Flow No 1. Closed the control valve 1. Steam will tend to condense 1. Select valve to fail open
fluid line 2. Blocked thermic fluid line and corrosion of vessel might 2.Continuous Check and monitor
3. Failure in thermic fluid be happen. thermic fluid service
service 3. Install thermic fluid flow meter
4. Controller failure and and low flow alarm
closed valves 4. Install low temperature alarm of
steam output side to alert operator
High 1. Opened the control valve 1.Over heating the steam will 1. Install high temperature alarm of
2. Opened the valves due to lead to sudden expansion of steam output side to alert operator
controller failures volume and tend to explode 2. Place controller on critical
instrumentation list
Low 1. Partially blocked thermic 1. Process line efficiency may 1.Continuous Check and monitor
fluid line reduce due to lack of heating thermic fluid service
2. failure in the thermic fluid 2. Install thermic fluid flow meter
boiler or thermic fluid line and low flow alarm
3. Control valve fails to 3. Place valve on critical
respond instrumentation list
part of, 1. Same causes as flow 1. Same consequences as flow 1. Same action required as flow

becomes low becomes low becomes low

Reverse 1. Failure of the thermic fluid 1. Process line efficiency may 1.Continuous Check and monitor
pump reduce thermic fluid pump
2. Backflow due to high 2. Install non return valve
backpressure
Other than, 1. Not considered possible
Sooner 1.High temperature of steam 1. Overheating the steam 1. None
than, feeding line
Later than 1. Operator error 2. Process line efficiency may 1. None
reduce
Temperature Low 1.Thermic fluid line insulation 1.Corrosion occurs inside the 1. Check the thermic fluid line
damage tubes continuously
High 1. Error in the thermic fluid 1. Overheating the steam 2. Install high temperature alarm
boiler
Pressure Low 1. Malfunction of thermic 1. No proper heat transfer 1. Always keep a stand by pump
fluid feeding pump occurs and corrode the tubes 2. Introduce secondary power
2. Power failure supply
High 1. High pump speed due to 1. Overheating the steam 1. None
failure in motor

6.3 General safety procedure

Some common safety aspects are also included here for achieving maximum amount of
safety in workers as well as visitors.
 Absorption pre-cooler is a high temperature heated body. So people can meet

injuries when they move nearby it. Therefore, it is a must to provide a safety
fence around it so as to avoid people coming closer to the absorption pre-cooler.
 Any maintains of the absorption pre-cooler must be done if and only if it is
properly cooled to the room temperature and it is isolated from the process.
 Proper safety lockout procedure should be followed when dismantling the
absorption pre-cooler. (Lockout system of the plant was described in details in
the group design project under the chapter of safety.)
 Hot thermic fluid and steam can be leaked out and has an ability to cause
injuries (burning) to the operator. So then he should wear an overall safety kit as
a safety precaution.
 Thermic fluid is an inorganic compound and it is categorized under the toxic
chemicals. Therefore, proper storage conditions should be provided for storing
of thermic fluid such as, Floor of storage house must be an impervious
(concrete) to avoid thermic fluid contamination with ground water.
6.4 Process control of the absorption pre-cooler

There are many controlling methods are available for controlling heat exchanger. Two
main controlling techniques are described below;
Figure 2.1 shows a heat exchanger where the flow of cooling water is adjusted based on
the temperature of the outlet hot gas and flow rate of the outlet hot gas. The advantage
to this setup is that it is quite straightforward and the cause of the change in the
temperature of the outlet stream does not have to be identified. The disadvantage is that
a temperature change has already occurred before action is taken, and if the lag-time for
the additional cooling water to cool the hot gas is long, the outlet stream temperature
may be inconsistent.
Figure 6.2 shows a heat exchanger were the flow of cooling water is adjusted based on
the flow-rate and temperature of the inlet stream and the temperature of the coolant
stream. Based on a set of calculations using the heat transfer coefficient of the heat
exchanger, the outlet stream temperature can be predicted. The advantage of this

system is that action is taken before changes occur in the outlet stream temperature.
The disadvantage is that if the actual heat exchange capacity differs from the expected
value due to fouling or mechanical problems, the outlet temperature will not be correct.
Figure 6.1: different control strategies for a heat exchanger
Figure 6.2: different control strategies for a heat exchanger

The process control scheme suggested to the absorption pre-cooler is shown in Figure
6.3. Here the cooling water is adjusted based on the flow-rate and temperature of the
outlet stream and the temperature of the hot gas stream because we cannot adjust hot
gas thermic fluid.
Here we use cascaded control system, therefore it will be more accuracy then other
control methods.

Figure 6.3: Suggested process control scheme

CHAPTER 7 START UP – SHUT DOWN AND ECONOMIC ASPECTS
7.1 Start up and shut down

Absorption pre-cooler start up and shut down procedure should be designed to avoiding
any damages to the equipment and minimizing the risks associated with it.
7.2 Startup operation

Shell and tube exchanger fluids must be introduced in such a manner as to minimize
differential expansion between the shell and tubes. The exchanger may be placed into
service by first establishing the colder medium, followed by gradual introduction of the
hotter medium. Startup procedure is given below in stepwise (Important: valves and
pumps are represented in their short forms which explained in the P & I diagram),
I. VLV-13, VLV-05 and VLV-04 should be opened and gradually introduce

cooling water to the Absorption pre-cooler.
II. After completely filled with steam, VLV-13 should be closed.
III. VLV-04 should be closed and open the VLV-05 (and if needed, PMP-01) to
enter the cooling water into the shell side.
IV. After VLV-11, VLV-13 should be opened
V. Slowly increase the hot fluid flow rate and cold fluid flow rate by adjusting the
VLV-11 and VLV-05 to achieve steady state conditions
7.3 Shut down operation

Exchangers may be shut down by first gradually stopping the flow of the hotter
medium, and then the flow of the colder medium through the unit should be stopped.
The unit must be shut down in a manner to minimize differential expansion between
shell and tubes. To reduce water retention after drainage, the tube side of the exchanger
should be blown out with air. Otherwise corrosion inside the tube sheets may be
present. Following steps shows the shutdown procedure of this Absorption pre-cooler.
(Important: valves and pumps are represented in their short forms which explained in
the P & I diagram)
I. VLV-16 should be opened to bypass the hot fluid

II. VLV-12 and VLV-10 should be opened to remove the hot thermic fluid.

III. VLV-05 should be gradually reduced to minimize the steam flow rate and VLV-
15 should be opened to bypass.
IV. Finally tube side and shell side should be blown with air to eliminate the
condensed water droplets.
7.4 Economic Aspects

For most systems, the shell & tube heat exchanger can constitute a large portion of the
mechanical equipment cost. For this reason, it is useful to have a method of evaluating
the capital cost of this component when considering the system design. Final heat
exchanger cost is a function of materials, tube size and tube configuration.
End of the day, any design should be economically feasible; otherwise it is pointless of
doing so-called design calculations. Therefore, the cost calculation is a must after
designing a project. Here the cost calculations based on the May, 2012 steel market
price in India.
7.4.1 Material cost

 Carbon steel US $750 / Ton
 Copper US $8 / Kilogram
 Stainless steel US $3500 / Ton
7.4.2 Material cost of components

Material cost of the torispherical head of floating head cover = 14.477 ×3.5 = 50.67 $
Material cost of the torispherical head of shell cover = 28.487×0.75 = 21.37 $
Material cost of the cylindrical shell = 280.412×0.75 = 210.31 $
Material cost of the cylindrical channel = 63.987×3.5 = 223.95
Material cost of the shell nozzles = 0.906×0.75 = 0.68 $
Material cost of channel nozzles = 0.781×3.5 = 2.73 $
Material cost of flat closer = 36.192×3.5 =126.67 $
Material cost of channel head flanges = 240.356×3.5 = 841.25 $
Material cost of channel side shell flange = 113.935×0.75 = 85.45 $
Material cost of Floating head cover flanges = 247.256×3.5 = 865.40 $
Material cost of shell cover flange = 157.551×0.75 = 118.16 $

Material cost of shell cover side shell flange = 268.635×0.75 = 201.48 $
Material cost of the tubes = 2588.391×8 = 20707.13 $
Material cost of floating head side tubesheet = 41.331×3.5 = 144.66 $
Material cost of channel head side tubesheet = 50.669×3.5 = 177.34 $
Material cost of Tie rod = 20.789×0.75 = 15.59 $
Total Material cost of heat exchanger = 23792 $
7.4.3 Total cost

According to current prices, assume that,
1 $ = 130 LKR
Total cost of raw materials in LKR = 3092960 LKR
Let’s assume,
Fabrication cost = 2×Total raw material cost
Fabrication cost = 2×3092960 = 6185920 LKR
Total cost = Total raw material cost + Fabrication cost
Total cost = 3092960+ 6185920
Total cost = 9278880 LKR
When it compares with the plant total capital cost, this value is very low and it can be
recoverable by the annual profit.

CHAPTER 8 CONCLUSION AND RECOMMENDATIONS TO THE INDUSTRY
Each student in the Department of Chemical and Process Engineering, university of

Moratuwa was given to do a task compulsory design project work as a team by using
their knowledge which they have learnt over four years of undergraduate course period.
The design task involves two equal sections namely group design project and
individual design project. Design of a Sulfuric acid manufacturing plant was given us
as the group design work.
A Shell and tube heat exchanger (absorption pre-cooler) which is a single unit in
Sulfuric acid manufacturing plant to cool down hot gas stream which is from converter
to Intermediate absorption tower, is being designed as the individual design work.
The theories and equations published for the heat transfer and designing of process
equipment was very helpful to this design. This design calculation was mainly based on
the MS excel software. And I have used solidworks software to design shell and tube
heat exchanger and its drawing.
In Sri Lanka, various plants use various types of shell and tube heat transfer equipments
to fulfill their process targets. But none of them are fabricated by Sri Lanka, all are
imported ones. Therefore, it exploitates huge monitory value in this country and also
designing ability of Sri Lankans will be tarnished. This design shows how a shell and
tube heat exchanger is fabricated with a very low cost to operate safely and
economically.
Other than that, the saddle supports are constructed with traditional clay bricks and
cement instead of high cost steels. It also reduces the total cost and makes easier to set
up it in any plant.
The chemical design calculations were done in trial and error procedures to meet the
requirements of lower heat transfer area. It is the best option for primary stage design
process. So any one is going to implement a new shell and tube heat exchanger, he can
use this calculation sheet to obtain the optimum parameters.

The cost calculations are mainly based on the steel, and copper prices in India,
therefore, some slightly variations in the cost might be present. The raw material cost
can be further reduced by fabricating the carbon steel sheets in here itself.

REFERENCE
Alexander J. Smits, Jean-Paul Dussauge (2006) Turbulent shear layers in supersonic

flow, Birkhäuser, ISBN 0-387-26140-0 p. 46
AZoM (2002) Stainless Steel Grade Selection Guidelines. Retrieved November 23,
2013, from <http://www.azom.com/article.aspx?ArticleID=1146>
Brogan, R.J. (2011) Shell and Tube Heat Exchangers. Retrieved November 23, 2013,
from http://www.thermopedia.com/content/1121/
Engineersedge (2013) Thermal conductivity gases. Retrieved November 23, 2013, from
http://www.engineersedge.com/heat_transfer/thermal-conductivity-gases.htm
Engineering ToolBox, (2004) Water - Dynamic and Kinematic Viscosity. Retrieved

November 23, 2013, from http://www.engineeringtoolbox.com/water-dynamic-
kinematic-viscosity-d_596.html
Ernest E.L. (2001) Applied process design for chemical and petrochemical plants,
Volume 3, Third edition
Sadik Kakaç and Hongtan Liu (2002). Heat Exchangers: Selection, Rating and
Thermal Design (2nd ed.). CRC Press. ISBN 0-8493-0902-6.
Shah, R. K., and Sekulic, D. P. (2003). Fundamentals of Heat Exchanger Design. John
Wiley & Sons, Inc., Hoboken, New Jersey. Chapter-1.
Sinnott, R. K. (2005) Coulson & Richardson's Chemical Engineering, Volume 6:

Chemical Engineering Design (4th ed.). Butterworth-Heinemann. p. 73. ISBN 0-7506-
6538-6.
Southwest Thermal Technology (2013) Materials & Construction. Retrieved

November 23, 2013, from <http://www.shell-tube.com/Materials-and-
Construction.html>
ThermExcel (2003) Physical characteristics of boiling water. Retrieved November 29,

2013, from http://www.thermexcel.com/english/tables/eaubou1.htm
Department of Chemical & Process Engineering, University of Moratuwa Page ix

ANNEX
Figure 1: Isometric view of heat exchanger
Figure 2: Sectional isometric view of heat exchanger
Department of Chemical & Process Engineering, University of Moratuwa Page x

1 2 3 4 5 6
A A
R1094
2427 85
372.30
224
58
B B
1074
1074 944 948 1094
1074
C 73 1155 C
R65.64
554 285.50
150
FRONT ELEVATION
all dimensions are in millimeter

D
DESIGNED BY: DATE:
090502X K. Subasgar
MATERIAL:
Heat Exchanger
TITLE:
A4
1 2 WEIGHT: SCALE:1:15 SHEET 3 OF 3

1 2 3 4 5 6
A 376 A
B B
869
C C
2500
376
FRONT ELEVATION
D
DESIGNED BY: DATE:
090502X K. Subasgar
MATERIAL:
Internals
TITLE:
A4

1 2 3 4 5 6
150
150
A
7 A
178 178
529.51 R474 178
135.56
7 135.56
10.50
7 25
B
FRONT ELEVATION END B
929.22
C C
PLAN ISOMETRIC all dimensions are in millimeter

D
DESIGNED BY: DATE:
090502X K. Subasgar
MATERIAL:
Saddle
TITLE:
A4
1 2 WEIGHT: SCALE::12 SHEET 1 OF 1

1 2 3 4 5 6
A A
B B
A 13
DETAIL A
20 SCALE 1 : 3
C C
970
D
DESIGNED BY: DATE:
090502X K. Subasgar
MATERIAL:
Tubesheet
TITLE:
A4

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Design of a Shell and Tube Heat Exchanger

DESIGN OF A SHELL AND TUBE HEAT EXCHANGER

Index No: 090502X

Date of submission: 10th January 2014

Department of Chemical and Process Engineering

Q Heat transferred in unit time

Department of Chemical & Process Engineering, University of Moratuwa Page i

Department of Chemical & Process Engineering, University of Moratuwa Page ii

2.11 Design methods ............................................................................................... 18

Department of Chemical & Process Engineering, University of Moratuwa Page iii

3.4.9 Design of the tie rod ................................................................................. 56

Department of Chemical & Process Engineering, University of Moratuwa Page iv

Department of Chemical & Process Engineering, University of Moratuwa Page v

Department of Chemical & Process Engineering, University of Moratuwa Page vi

CHAPTER 1 UNIT SELECTION

This report is prepared as part of a project which is Design of a Plant to Manufacture

1.2 Comprehensive Design Group Project

1. Lead chamber process

 Single contact process

Department of Chemical & Process Engineering, University of Moratuwa Page 1

FUEL TANK (US 02)

(MS 13) (MS 25)

(MS 09) (MS 23)

ESP V-1 (US 13)

(US 14) (MS 23)

1.3 Comprehensive Design Individual Project

1.4 Heat Exchangers

1.4.1 Types of Heat Exchangers

 Classification according to transfer process

Department of Chemical & Process Engineering, University of Moratuwa Page 2

Figure 1.1: Classification of heat exchangers

Department of Chemical & Process Engineering, University of Moratuwa Page 3

1.4.2 Tubular Heat Exchangers

 Double pipe heat exchangers

Figure 1.2: Double-pipe heat exchanger

 Shell and tube heat exchangers

Department of Chemical & Process Engineering, University of Moratuwa Page 4

Figure 1.3: Shell and tube heat exchangers

 Spiral tube type heat exchanges

This consists of spirally wound coils placed in a shell or designed as co-axial

1.4.3 Plate Heat Exchangers

 Gasketed plate heat exchanger

Department of Chemical & Process Engineering, University of Moratuwa Page 5

Figure 1.4: Gasketed plate- and-frame heat exchanger

 Spiral plate heat exchanger

Department of Chemical & Process Engineering, University of Moratuwa Page 6

 Lamella heat exchangers

Figure 1.6: Lamella heat exchanger

1.4.4 Extended Surface Heat Exchangers

 Plate-fin heat exchanger

Department of Chemical & Process Engineering, University of Moratuwa Page 7

Figure 1.7: Basic components of a plate-fin heat exchanger

 Tube -fin heat exchanger

These exchangers may be classified as conventional and specialized tube-fin

1.4.5 Regenerative Heat Exchanger

Department of Chemical & Process Engineering, University of Moratuwa Page 8

1.5 Selection of a Shell and Tube Heat Exchanger

1.6 Shell and Tube Heat Exchangers

Department of Chemical & Process Engineering, University of Moratuwa Page 9

Figure 1.8: Shell and tube heat exchanger

Department of Chemical & Process Engineering, University of Moratuwa Page 10

CHAPTER 2 CHEMICAL DESIGN

2.1 Absorption Pre-cooler - Heat exchanger