University of Alexandria

Faculty of Engineering

Chemical Engineering Department-MSc division

Advanced Study in Heat Transfer

Shell and Tube Heat

Exchanger Design
A case study, For Cooling Hydrogen Sulfide
Gas using water

Submitted by:

Ahmed Magdy Abdel-Aziz

Mahmoud Mohamed Taha
Asmaa Ali Mohamed Harraz

Submitted to;
Prof. Dr. Hassan Farag

February, 2012
 ABSTRACT

This is a case study for cooling hydrogen sulfide gas by using water as cooling
fluid. The cooling process is carried out by using a shell and tube heat exchanger.
A theoretical background on the different classifications, different types of heat
exchangers and general methods for process design of heat exchangers was
mentioned. A detailed design work for the shell and tube heat exchanger suitable
for the case study is conducted according to the operating conditions. The design
work included the determination of the tube side, shell side, overall heat transfer
coefficient, pumping power and pumping costs of the tube side and shell side
fluids. Finally an optimization process is conducted to get the optimum
dimensions of the shell and tube heat exchanger and the optimum annual
pumping costs for the tube side and shell side fluids.
 NOMENCLATURE

= constant for evaluating outside film coefficient of heat transfer,

ao
dimensionless.

A = area of heat transfer, ft2; subscripts m designates mean area; subscript o

designates outside area; subscript f designates film area.

bo = constant for evaluating shell-side friction factor, dimensionless.

Bi = correction factor to account for friction due to sudden contraction,

sudden expansion, and reversal of flow direction, dimensionless.

Bo = correction factor to account for friction due to reversal of flow direction,

recrossing of tubes, and variation in cross section, dimensionless.

cc = constant, dimensionless; defined in Table 4.

cP = heat capacity, Btu/(lb)(oF); prime refers to process fluid.

CAo = installed cost of heat exchanger per unit of outside-tube heat-transfer

area, $/ft 2.

Ci = cost for supplying 1 ft.lbf to pump the fluid through the inside of the
tubes, $/ft. Ibf.

Co = cost for supplying 1 ft.lbf to pump the fluid through the shell side of the
exchanger, $/ ft.lbf.

CT = total annual variable cost for heat exchanger and its operation, $/year.

Cu = cost of utility fluid, $/lb.

D = diameter or distance, ft.

D` = diameter, in.

Dc = clearance between tubes to give smallest free area across shell axis, ft.

De = equivalent diameter = 4 x hydraulic radius, ft.

E = power loss per unit of outside-tube heat-transfer area. ft-lbf/(h)(ft2);

subscript i designates inside tubes, and subscript o designates outside tubes.

fi = Fanning friction factor for isothermal flow, dimensionless.

f` = special friction factor for shell-side flow, dimensionless.

Fs = safety factor to account for bypassing on shell side of exchanger,

dimensionless.

FT = correction factor on logarithmic-mean At for counterflow to give mean

At, dimensionless.

g = local gravitational acceleration, ft/(s)(s).

gc = conversion factor in Newtons law of motion, 32.17 ft * Ibm/(s)(s)(lbf).

G = mass velocity inside tubes, lb/(h)(ft2).

Gs = shell-side mass velocity across tubes based on the minimum free area
between baffles across the shell axis, lb/(h)(ft 2).

h = film coefficient of heat transfer, Btu/(h)(ft2)(oF); subscript c indicates

convection; subscript d represents dirt or fouling; subscript co indicates
conduction.

Hy = hours of operation per year, h/year.

k = thermal conductivity, Btu/(h)(ft2)(oF/ft).

KF = annual fixed charges including maintenance, expressed as a fraction of

the initial cost for the completely installed unit, dimensionless.
L = heated length of straight tube or length of heat-transfer surface, ft; if
tubes in parallel are involved, L is the length of one tube.

nb = number of baffle spaces = number of baffles plus 1, dimensionless.

np = number of tube passes, dimensionless.

NC = number of clearances between tubes for flow of shell-side fluid across

shell axis, dimensionless.

NPr = Prandtl number = cp/k, dimensionless.

Nr = number of rows of tubes across which shell fluid flows, dimensionless.

NRe = Reynolds number = DG/p, dimensionless.

Nt = total number of tubes in exchanger = number of tubes per pass X np,

dimensionless

Nv = number of rows of tubes in a vertical tier, dimensionless.

P, p = pressure, lbf/ft2.

q = rate of heat transfer, Btu/h.

Q = amount of heat transferred in time, , Btu.

Rdw = combined resistance of tube wall and scaling or dirt factors, [Btu/(h)(ft 2)
(oF)]-1.

SH = cross-sectional flow area of header per pass, ft2.

Si = cross-sectional flow area inside tubes per pass, ft 2.

So = shell-side free-flow area across the shell axis, ft2.

t = temperature, oF; subscript b refers to average bulk temperature;

subscript or refers to original temperature; subscript s refers to surface; in
general, primes refer to the process fluid, subscript 1 refers to the entering
temperature, and subscript 2 refers to the leaving temperature .

t = temperature of second fluid in a heat exchanger, oF; refers, in general, to

process fluid .

T = absolute temperature, oR.

U = overall coefficient of heat transfer, Btu/(h)(ft2)(oF); subscript d indicates

that a dirt or fouling factor is included; subscript o indicates based on outside
area and fouling factor included.

V = velocity, ft/h; subscript i indicates in tubes.

V = velocity, ft/s.

w = weight rate of flow, lb/h; no subscript indicates per tube; subscript u

indicates total flow rate of utility fluid; subscript i indicates total flow rate of
inside-tube fluid; subscript o indicates total flow rate of outside-tube fluid.

w = total weight rate of flow of process fluid, lb/h.

xL = ratio of pitch parallel to flow to tube diameter, dimensionless.

xT = ratio of pitch transverse to flow to tube diameter, dimensionless.

GREEK SYMBOLS
= thermal diffusivity = k/pc, ft2/h.
= coefficient of volumetric expansion, l/R.
= t designates temperature-difference driving force, F; subscript f
designates across film; subscript m designates mean t; subscript oa or no
subscript designates overall t; t1 = t2 t1; t, = t1 t2; P and p designate
pressure drop; p = - P.
= emissivity, dimensionless.
= time, h.
c = latent heat of condensation, Btu/lb
= Lagrangian multiplier, dimensionless; defined by Eq. (43)
= absolute viscosity, lb/(h)(ft)
 = 3.1416
= density, lb/ft3
= Stefan-Boltzmann dimensional constant for radiant heat transfer;
defined
= correction factor for nonisothermal flow, dimensionless.
i, o = dimensional factors for evaluation of Ei and Eo.

SUBSCRIPTS
f = across film or at average film temperature.
i = inside pipe or tube, based on average bulk temperature.
L = liquid at average liquid temperature.
m = mean.
o = outside pipe or tube, based on average bulk temperature.
oa = overall.
opt = optimum conditions.
u = utility fluid.
v = vapor at average vapor temperature.
w = tube or pipe wall, based on temperature at wall surface.
 LIST OF FIGUR

Figure 2-1, Classification of Heat Exchangers.............................................11

Figure 2-2, Double pipe heat exchanger. (a) Single pass with counterflow; and (b)
multipass with counterflow............................................................................12

Figure 2-3, Glass Coil Heat Exchanger.........................................................14

Figure 2-4, Plate Heat Exchanger.................................................................15

Figure 2-5, Alpha-Laval spiral plate heat exchanger..................................16

Figure 2-6- Shell and tube heat exchanger.............................................17

Figure 2-7-the fixed tube-sheet heat exchanger...........................................18

YFigure A- 1, Log Mean Temperature Difference..30

 LIST OF TABLES

Table A- 1, Calculations for overall heat transfer Coefficient.....................33

Table A- 2, calculating optimum heat transfer coefficients.........................38

Table A- 3, Calculating optimum parameters..............................................39

Table A- 4, Calculating optimum pressure drop, and power cost...............39

 1. INTRODUCTION

A heat exchanger is a heat-transfer device that is used for transfer of internal

thermal energy between two or more fluids available at different temperatures.
In most heat exchangers, the fluids are separated by a heat-transfer surface, and
ideally they do not mix. Heat exchangers are used in the process, power,
petroleum, transportation, air conditioning, refrigeration, cryogenic, heat
recovery, alternate fuels, and other industries. Common examples of heat
exchangers familiar to us in day-to-day use are automobile radiators, condensers,
evaporators, air pre-heaters, and oil coolers. Heat exchangers could be classified
in many different ways.
 2. THEORETICAL BACKGROUND

In general, industrial heat exchangers have been classified according to (1)

1. Construction,
2. Transfer processes,
3. Degrees of surface compactness,
4. Flow arrangements,
5. Pass arrangements,
6. Phase of the process fluids, and
7. Heat-transfer mechanisms.

According to constructional details. heat exchangers are classified as :

1. Tubular heat exchangers-double pipe, shell and tube, coiled tube

2. Plate heat exchangers-gasketed, spiral, plate coil, lamella
3. Extended surface heat exchangers-tube-fin, plate-fin
4. Regenerators-fixed matrix, rotary
Figure 2-1, Classification of Heat Exchangers
Tubular Heat Exchanger

Double Pipe Exchangers. A double pipe heat exchanger has two concentric
pipes, usually in the form of a U-bend design as shown in Figure 2-2. The flow
arrangement is pure countercurrent.

Figure 2-2, Double pipe heat exchanger. (a) Single pass with counterflow; and (b) multipass with
counterflow.

A number of double pipe heat exchangers can be connected in series or parallel

as necessary. Their usual application is for small duties requiring, typically, less
than 300 ft2 and they are suitable for high pressures and temperatures, and
thermally long duties. This has the advantages of flexibility since units can be
added or removed as required, and the design is easy to service and requires low
inventory of spares because of its standardization. Either longitudinal fins or
circumferential fins within the annulus on the inner pipe wall are required to
enhance the heat transfer from the inner pipe fluid to the annulus fluid. Design
pressures and temperatures are broadly similar to shell and tube heat
exchangers. The design is straightforward. And carried out using the method of
Kern [6], or proprietary programs.

Shell and Tube Heat Exchanger. In process industries, shell and tube
exchangers are used ingreat numbers, far more than any other type of exchanger.
More than 90% of heat exchangersused in industry are of the shell and tube type.
The shell and tube heat exchangers are the work horses of industrial process
heat transfer. They are the first choice because of wellestablished procedures for
design and manufacture from a wide variety of materials, many years of
satisfactory service, and availability of codes and standards for design and
fabrication.

They are produced in the widest variety of sizes and styles. There is virtually no
limit on the operating temperature and pressure.

Coiled Tube Heat Exchanger.

Coiled Tube Heat Exchanger Used for Liquefaction Systems. One of the three
classical heat exchangers used today for large-scale liquefaction systems is the
coiled tube heat exchanger (CTHE). Construction of these heat exchangers
involves winding a large number of small-bore ductile tubes in helix fashion
around a central core tube, with each exchanger containing many layers of tubes
along both the principal and radial axes. Tubes in individual layers or groups of
layers may be brought together into one or more tube plates through which
different fluids may be passed in counter flow to the single shell side fluid.

The high-pressure stream flows through the small-diameter tubes, while the low-
pressure return stream flows across the outside of the small-diameter tubes in
the annular space between the inner central core tube and the outer shell.
Pressure drops in the coiled tubes are equalized for each high-pressure stream by
using tubes of equal length and varying the spacing of these in the different
layers. Because of small-bore tubes on both sides, CTHEs do not permit
mechanical cleaning and therefore are used to handle clean, solid-free fluids or
fluids whose fouling deposits can be cleaned by chemicals. Materials are usually
aluminum alloys for cryogenics, and stainless steels for high-temperature
applications.

Figure 2-3, Glass Coil Heat Exchanger.

Plate Heat Exchangers

Plate heat exchangers are less widely used than tubular heat exchangers but
offer certain important advantages. Plate heat exchangers can be classified in
three principal groups:

1. Plate and frame or gasketed plate heat exchangers used as an alternative

to tube and shell exchangers for low- and medium-pressure liquid-liquid
heat-transfer applications.
2. Spiral heat exchanger used as an alternative to shell and tube exchangers
where low maintenance is required, particularly with fluids tending to
sludge or containing slurries or solids in suspension.
3. Plate coil or panel heat exchangers made from embossed plates to form a
conduit or coil for liquids coupled with fins.

Plate Heat Exchangers. A plate heat exchanger (PHE) essentially consists of a

number of corrugated metal plates in mutual contact, each plate having four
apertures serving as inlet and outlet ports, and seals designed to direct the fluids
in alternate flow passages. The plates are clamped together in a frame that
includes connections for the fluids. Since each plate is generally provided with
peripheral gaskets to provide sealing arrangements, the plate heat exchangers
are called gasketed plate heat exchangers.

Figure 2-4, Plate Heat Exchanger

Spiral Plate Heat Exchanger. Spiral plate heat exchangers (SPHEs) have been
used since the1930s, when they were originally developed in Sweden for heat
recovery in pulp mills. Spiral plate heat exchangers are classified as a type of
welded plate heat exchanger. An SPHE is fabricated by rolling a pair of relatively
long strips of plate around a split mandrel to form a pair of spiral passages.
Channel spacing is maintained uniformly along the length of the spiral passages
by means of spacer studs welded to the plate strips prior to rolling. An SPHE is
shown in Figure 2-5. For most applications, both flow channels are closed by
alternate channels welded at both sides of the spiral plate. In some services, one
of the channels is left open, whereas the other closed at both sides of the plate.
These two types of construction prevent the fluids from mixing.
Figure 2-5, Alpha-Laval spiral plate heat exchanger
SHELL AND TUBE HEAT EXCHANGER

A shell-and-tube heat exchanger is essentially a bundle of tubes enclosed in a

shell and so arranged that one fluid flows through the tubes and another fluid
flows across the outside of the tubes, heat being transferred from one fluid to the
other through the tube wall. A number of other mechanical components are
required to guide the fluids into, through, and out of the exchanger, to prevent
the fluids from mixing, and to ensure the mechanical integrity of the heat
exchanger

Figure 2-6- Shell and tube heat exchanger

The major components of a shell and tube exchanger are tubes, baffles, shell,
front head, rear head, tube sheet(s), and nozzles. Expansion joint is an important
component in the case of fixed tube-sheet exchanger for certain design conditions.
The selection criteria for a proper combination of these components are
dependent upon the operating pressures, temperatures, and thermal stresses,
corrosion characteristics of fluids, fouling, cleanability, and cost. Other
components include nozzles and supports.

Shell-and-tube heat exchangers have been constructed with heat transfer areas
from less than 0.1 m2 (1 ft2) to over 100,000 m2 (1,000,000 ft2), for pressures from
deep vacuum to over 1000 bar (15,000 psi), for temperatures from near 0 to over
1400 K (2000oF), and for all fluid services including singlephase heating and
cooling and multiphase vaporization and condensation. The key to such flexibility
is the wide range of materials of construction, forming and joining methods, and
design features that can be built into these exchangers.

The most popular type of shell and tube heat exchanger is the fixed tube-sheet
heat exchanger. It uses straight tubes secured at both ends into tube sheets,
which are firmly welded to the shell. Hence, gasketed joints are minimized in
this type, and thereby least maintenance is required. Fixed tube-sheet heat
exchangers are used where

1. It is desired to minimize the number of joints.

2. Temperature conditions do not represent a problem for thermal stress.

3. The shell-side fluid is clean and tube bundle removal is not required.

Figure 2-7-the fixed tube-sheet heat exchanger

(1) Stationary head-channel; (2) stationary headbonnet; (3) stationary head flange-
channel or bonnet; (4)channel cover; (5) stationary head nozzle; (6) stationary
tubesheet; (7) tubes; (8) shell; (9) shell cover; (10) shell flange-stationary head end;
(11) shell flange-rear head end; (12) shell nozzle; (13) shell cover flange; (14)
expansion joint; (15) floating tubesheet; (16) floating head cover; ( 17) floating
head cover flange; (18) floating head backing device; ( 19) split shear ring; (20)
slip-on backing flange; (21) floating head cover-external; (22) floating tubesheet
skirt; (23) paclung box; (24) packing; (25) packing gland; (26) lantern ring; (27)
tierods and spacers; (28) transverse baffles or support plates; (29) impingement
plate; (30) longitudinal baffle; (3 1) pass partition; (32) vent connection; (33) drain

TO DETERMINE WHICH FLUID SHOULD BE ROUTED THROUGH THE SHELL SIDE

AND WHICH FLUID ON THE TUBE SIDE, CONSIDER THE FOLLOWING FACTORS.

Corrosion: Fewer corrosion resistant alloys or clad

components are needed if the corrosive fluid is placed on the
tube side.
 Fouling: This can be minimized by placing the fouling fluid in
the tubes to allow better velocity control; increased velocities
tend to reduce fouling.
Cleanability: The shell side is difficult to clean; chemical
cleaning is usually not effective on the shell side because of
bypassing, and requires the cleaner fluid. Straight tubes can be
physically cleaned without removing the tube bundle; chemical
cleaning can usually be done better on the tube side.
Temperature: For high-temperature services requiring
expensive alloy materials, fewer alloy components are needed
when the hot fluid is placed on the tube side.
Pressure: Placing a high-pressure fluid in the tubes will
require fewer costly high-pressure components and the shell
thickness will be less.
Pressure drop: If the pressure drop of one fluid is critical and
must be accurately predicted, then that fluid should generally
be placed on the tube side.
Viscosity: Higher heat-transfer rates are generally obtained
by placing a viscous fluid on the shell side. The critical
Reynolds number for turbulent flow in the shell is about 200;
hence, when the flow in the tubes is laminar, it may be
turbulent if the same fluid is placed on the shell side. However,
if the flow is still laminar when in the shell, it is better to place
the viscous fluid only on the tube side since it is somewhat
easier to predict both heat transfer and flow distribution.
Toxic and lethal fluids: Generally, the toxic fluid should be
placed on the tubeside, using a double tube sheet to minimize
the possibility of leakage. Construction code requirements for
lethal service must be followed.
Flow rate: Placing the fluid with the lower flow rate on the
shell side usually results in a more economical design and a
design safe from flow-induced vibration, Turbulence exists on
the shell side at much lower velocities than on the tube side.

GENERAL METHODS FOR PROCESS DESIGN OF HEAT

EXCHANGERS (2)

The procedures used for developing the design of heat exchangers vary with the
type of problem and the preference of the worker. Some engineers prefer to
develop the design for a heat exchanger by a method known as rating an
exchanger. In this method, the engineer assumes the existence of an exchanger
and makes calculations to determine if the exchanger would handle the process
requirements under reasonable conditions. If not, a different exchanger is
assumed, and the calculations are repeated until a suitable design is developed.
For example, with a given set of process requirements, the engineer could assume
the existence of an exchanger with a designated tube size, tube spacing, baffle
type, baffle spacing, and number of tubes and passes. The engineer might then
proceed through the process-design calculations by computing an overall heat-
transfer coefficient and evaluating all flow rates, areas, lengths, and pressure
drops. Repeated trials may be necessary to obtain an accurate overall coefficient.
If the results of the final design indicate that the assumed exchanger has
reasonable dimensions, reasonable cost, and acceptable pressure drops, the unit
is considered as adequate and the design is complete.

An alternative approach, of course, is to base the design on optimum economic

conditions, using the methods described in the preceding sections. No matter
which approach is used, the general method of attack for a given set of process
conditions consists of the following steps:

1. Determine the rates of flow and rate of heat transfer necessary to meet the
given conditions.
2. Decide on the type of heat exchanger to be used, and indicate the basic
equipment specifications.
3. Evaluate the overall heat-transfer coefficient and also the film coefficients,
if necessary. In many cases, fluid velocities must be determined in order to
obtain accurate heat-transfer coefficients.
4. Evaluate the mean temperature-difference driving force.
5. Determine the necessary area of heat transfer and the exchanger
dimensions.
6. Analyze the results to see if all dimensions, costs, pressure drops, and
other design details are satisfactory.
7. If the results of (6) show that the exchanger is not satisfactory, the
specifications given in (2) are inadequate. Choose new specifications and
repeat steps 3 through 7 until a satisfactory design is obtained.
 3. PROBLEM STATEMENT
H2S gas flowing at a rate of 4000 CFM (cubic feet per minute) at 20 bars is to be
cooled from 1200oF to 600oF using water that enters at 80 F and comes out at
150 F.

It is required to perform optimization to come out with a Shell and Tube Heat
Exchanger design that can carry out the duty and the following information
should be included in the design

Process information Mechanical information

1. Fluids to be used 1. Size of tubes

a. Include fluid properties if a. Diameter
they are not readily b. Length
available to the fabricator c. Wall thickness
2. Flow rates or amounts of 2. Tube layout and pitch
d. Horizontal tubes
fluids
e. Vertical tubes
3. Entrance and exit
3. Maximum and minimum
temperatures
temperatures and pressures
4. Amount of vaporization or
4. Necessary corrosion
condensation
allowances
5. Operating pressures and
5. Special codes involved
allowable pressure drops 6. Recommended materials of
6. Fouling factors
construction
7. Rate of heat transfer
 4. PROCESS INFORMATION BEFORE

OPTIMIZATION

1. FLUIDS TO BE USED

Process fluid: Hydrogen Sulfide gas (H2S), It is the tube side fluid

Fluid properties:

Influent temperature (t1) 1200 F

Effluent temperature (t2) 600 F

Bulk Temperature(tb)

Pressure(P) 20 bar 20 atm

Specific heat (Cpi) 0.3Btu/(lbm.oF)

Viscosity (i) 0.031cP= 0.075lbm/ (h.ft)

Density (i) 0.685lbm/ft3

Thermal conductivity (ki) 0.0188Btu/(h.ft.oF)

Prandlt number (NPr) 1.19

Critical Temperature (Tc) 672.954R

Reduced Temperature (Tr) 1.337

Critical Pressure (Pc) 8.963MPa (88.48 atm)

Reduced Pressure (Pr) 0.226

Utility Fluid: Cooling water flowing in the shell side fluid

Fluid properties:

Influent temperature (T1) 80 F

Effluent temperature (T2) 150F

Bulk Temperature(Tb) 115oF

Pressure(P) 1 atm

Film temperature (tf)

Bulk Specific heat (Cp) 1 Btu/(lbm.oF)

Film Specific heat (Cpf) 0.55 Btu/(lbm. F)

Viscosity (f) 0.022 cP=0.053 lbm/ (h.ft)

Density (f) 0.536lbm/ft3

Thermal conductivity (kf) 0.0232Btu/(h.ft.oF)

Prandlt number (NPrf) 1.256

2. FLOW RATES OR AMOUNT OF FLUIDS

Hydrogen Sulfide (H2S) is entering on the tube side at a rate

w i=135066lb m /h
Cooling water Consumption
 w u=347312lbm /h
3. ENTRANCE TEMPERATURE

Hydrogen Sulfide is entering at 1200oF and exit at 600oF

Cooling Water is entering as saturated vapor at 80oF and exit at 150F.

LMTD

T m=754.2

4. OPERATING PRESSURE AND ALLOWABLE PRESSURE DROPS

ACROSS THE TUBE SIDE

Sulfur dioxide is entering the tubes at 20 bar (294 psia).

Allowable pressure drop across the tube side is 0.08 psi.
Pumping power of tube side fluid = 1.4 hp
Pumping cost of tube side fluid =LE 3320.9 /year

ACROSS THE SHELL SIDE

Saturated Steam is entering the shell side at 14.7 psia.

Allowable pressure drop across the shell side is 1.1 psi
Pumping power of shell side fluid = 0.45 hp
Pumping cost of shell side fluid =LE 1077.1/year

5. FOULING FACTOR

hd=300 Btu/h.ft2.h

6. RATE OF HEAT TRANSFER

Duty, 6 ,
q=2410 Btu/h
Overall heat transfer coefficient, Uoa=43 Btu/h.ft2.oF
MECHANICAL INFORMATION
1. SIZE OF TUBES

1 INCH OD 16BWG

Outer diameter of the tube; 1 inch

12 BWG
Inner diameter; 0.782 inch
Tube length; 8 ft
Wall thickness; 0.109 inch

2. TUBE LAYOUT AND PITCH

The tubes are laid out on triangular (staggered) pattern.

Tube pitch is 1.25 inch
Clearance is 0.25 inch
Total number of tubes is 366 tubes
The heat exchanger is one-shell pass one-tube pass
Tube bundle diameter is 31 inch

3. SHELL SIZE

Shell diameter is 31 inch

4. BAFFLE SIZE AND LAYOUT

Number of baffle spaces is 6

Baffle spacing is 22.2 in
Number of baffles is 5
Baffle cut is 75%
Baffle spacing~0.6 Shell inside diameter

5. RECOMMENDED MATERIALS OF CONSTRUCTION

Tubes can be made of carbon steel alloy at Installed cost 20/ft 2

 5. PROCESS INFORMATION AFTER

OPTIMIZATION

7. FLUIDS TO BE USED

Process fluid: Hydrogen Sulfide gas (H2S), It is the tube side fluid

Fluid properties:

Influent temperature (t1) 1200 F

Effluent temperature (t2) 600 F

Bulk Temperature(tb)

Pressure(P) 20 bar 20 atm

Specific heat (Cpi) 0.3Btu/(lbm.oF)

Viscosity (i) 0.031cP= 0.075lbm/ (h.ft)

Density (i) 0.685lbm/ft3

Thermal conductivity (ki) 0.0188Btu/(h.ft.oF)

Prandlt number (NPr) 1.19

Critical Temperature (Tc) 672.954R

Reduced Temperature (Tr) 1.337

Critical Pressure (Pc) 8.963MPa (88.48 atm)

Reduced Pressure (Pr) 0.226

Utility Fluid: Cooling water flowing in the shell side fluid

Fluid properties:

Influent temperature (T1) 80 F

Effluent temperature (T2) 150F

Bulk Temperature(Tb) 115oF

Pressure(P) 1 atm

Film temperature (tf)

Bulk Specific heat (Cp) 1 Btu/(lbm.oF)

Film Specific heat (Cpf) 0.55 Btu/(lbm. F)

Viscosity (f) 0.022 cP=0.053 lbm/ (h.ft)

Density (f) 0.536lbm/ft3

Thermal conductivity (kf) 0.0232Btu/(h.ft.oF)

Prandtl number (NPrf) 1.256

8. FLOW RATES OR AMOUNT OF FLUIDS

Hydrogen Sulfide (H2S) is entering on the tube side at a rate

w i=135066lb m /h
Cooling water Consumption
 w u=347312lbm /h
9. ENTRANCE TEMPERATURE

Hydrogen Sulfide is entering at 1200oF and exit at 600oF

Cooling Water is entering as saturated vapor at 80oF and exit at 150F.

LMTD

T m=754.2

10. OPERATING PRESSURE AND ALLOWABLE PRESSURE DROPS

ACROSS THE TUBE SIDE

Sulfur dioxide is entering the tubes at 20 bar (294 psia).

Allowable pressure drop across the tube side is 0.308psi.
Pumping power of tube side fluid = 5.4 hp
Pumping cost of tube side fluid =LE 12848/year

ACROSS THE SHELL SIDE

Saturated Steam is entering the shell side at 14.7 psia.

Allowable pressure drop across the shell side is 57.837psi
Pumping power of tube side fluid =23.58 hp
Pumping cost of tube side fluid =LE 56265/year

11. FOULING FACTOR

hd=300 Btu/h.ft2.h

12. RATE OF HEAT TRANSFER

Duty, 6 ,
q=2410 Btu/h
Overall heat transfer coefficient, Uoa=20.193 Btu/h.ft2.oF
MECHANICAL INFORMATION
6. SIZE OF TUBES

1 INCH OD 16BWG

Outer diameter of the tube; 1 inch

12 BWG
Inner diameter; 0.782 inch
Tube length; 16 ft
Wall thickness; 0.109 inch

7. TUBE LAYOUT AND PITCH

The tubes are laid out on triangular (staggered) pattern.

Tube pitch is 1.25 inch
Clearance is 0.25 inch
Total number of tubes is 481 tubes
The heat exchanger is one-shell pass one-tube pass
Tube bundle diameter is 37 inch

8. SHELL SIZE

Shell diameter is 37 inch

9. BAFFLE SIZE AND LAYOUT

Number of baffle spaces is 27

Baffle spacing is 7.38 in
Number of baffles is 26
Baffle cut is 75%
Baffle spacing~0.2 Shell inside diameter

10. RECOMMENDED MATERIALS OF CONSTRUCTION

Tubes can be made of carbon steel alloy at Installed cost 20/ft 2

 SOURCES AND REFERENCES

1. Kuppan, T. Heat Exchanger Design Handbook. New York : Marcel Dekker,

Inc., 2000.

2. Peter, Max. S. Plant Design and Economics for Chemical Engineers. Tokyo :
McGraw Hill, Inc., 1981.
 APPENDIX

A. DESIGN CALCULATIONS
A.1. FLUIDS DATA AND PROPERTIES

Process fluid: Hydrogen Sulfide gas (H2S), It is the tube side fluid

Fluid properties:

Influent temperature (t1) 1200 F

Effluent temperature (t2) 600 F

Bulk Temperature(tb)

Pressure(P) 20 bar 20 atm

Specific heat (Cp) 0.3Btu/(lbm.oF)

Viscosity () 0.031cP= 0.075lbm/ (h.ft)

Density () 0.685lbm/ft31

Thermal conductivity (k) 0.0188Btu/(h.ft.oF)

Prandlt number (NPr) 1.192

Utility Fluid: Cooling water flowing in the shell side fluid

1
Fluid properties:

Influent temperature (T1) 80 F

Effluent temperature (T2) 150F

Bulk Temperature(Tb) 115oF

Pressure(P) 1 atm

Film temperature (tf)

Bulk Specific heat (Cp) 1 Btu/(lbm.oF)

Film Specific heat (Cpf) 0.55 Btu/(lbm. F)

Viscosity (f) 0.022 cP=0.053 lbm/ (h.ft)

psia


20
P Mwt
= =
RT

Cp
N Pr =
k
 Density (f) 0.536lbm/ft3

Thermal conductivity (kf) 0.0232Btu/(h.ft.oF)

Prandlt number (NPrf) 1.256

A.2. PRE-ELEMENTARY DESIGN

FOR H2S

Mwt=34 lbm/lb-mol

P=20 bar 20 atm

T1=1200+460=1660oR

=4000 ft3/min =24 104 ft3/h

V
R=10.73 ft3.psia/lb-mol oR

Assuming Ideal gas law is applied, wp

P V = RT
Mwt

3
ft
20 240000 2=34 lb m/lbmol
P V Mwt h
wi= = 3
=134688 l bm /h
RT 10.73 ft .atm /lbmol R 1660 R

Assume no heat losses

qu=qp=Uavg AavgTm

TO CALCULATE DUTY Q

l bm Btu 7
q=135066 0.3 (1200600 ) =2.410 Btu/h
h lb m.
FOR WATER

q=wuCpwT=wiCpt

6 Btu
24 10
q h
w u= = =346341lb m /h
Cp w T Btu
1 ( 15080 ) F
lbm F

TO CALCULATE TM 1200 F

600 F
Tm=FT*T lm
T1=1050F

Assume one pass tube flow T2=520 F

150 F
Then FT=1 Figure A- 1, Log Mean
Temperature Difference
T1=1050oF

T2=520oF

T1/ T2 =1050/520=2.019

T 1 T 2
T m = =754.2
T 1
ln
T 2

From table 6 page 601 For steam-Gases

Ud ranges from 5 to 50 Btu/h oF ft2

Assume Ud=35 Btu/h oF ft2 and, hd=300 Btu/h oF ft2

6
q 2410 Btu/h 2
A o= = =918 f t
U d T m 35Btu/h ft 2 754.2

Assume L=8 ft, tubes are 1 12 BWG

 o Do=1
o Di=0.782
o Thickness=0.065

2
A o =N t Di L=909 f t

2
918f t
N t = =439 tubes
1
ft 8 ft
12

Assuming H2S gas is the tube side fluid and cooling water is the shell side fluid

First trial

TO CALCULATE hI

Calculate Reynolds Number (NRe) to assure turbulent flow for better heat
transfer (assuming one tube pass)

4w p
N =
N
D i( t )
np

4 134688 lb m /h
N = =79,994>10,000
0.782 439
0.075 lbm /(h.ft ) ft ( )
12 1

This assures turbulent flow in tube side.

Only one tube pass will be enough to give enormous turbulence!

 From equation 26 page 593, Max Peter, Plant Design and Economics for
Chemical Engineer, NRe >10,000

0.8 1 0.14
hi D i cp
k
=0.023 ( ) ( )( )
DG
k
3
w

NRe=DG/ ,NPr=cP/k , assume (/w)0.14 1

0.8 1 0.14
cp

hi =
0.023 ( ) ( )( )
DG
k
3
w
k=
0.8
0.023 ( 79994 ) (1.19 )
1
3
0.0188
Btu
=59
Btu
Di 0.782 h . ft . h . ft
2
.
ft
12

TO CALCULATE hO

Assume staggered tube alignment, i.e ao=0.33

Take Fs=1.6
Let Baffle spacing=0.6 Shell ID , 25% Baffles Cut
From table 7 page 608, Max Peter, Plant Design and Economics for
Chemical Engineer, Do=1, Nt=439, triangular pitch, then shell ID =31,
pitch=1.25, Dc =clearance= pitch-Do= 0.25
Baffle spacing= 0.6*31= 18.6

clearance 37 0.25 22.2

A s =( Shell ID ) ( pitch )
( Baffle spacing )=
12 1.25 12( )( )( )
=0.801f t
2

w u 346341lbm /h 2
G s= = =432476lb m /hf t
A s 0.801f t 2

From equation 29 page 595, Max Peter, Plant Design and Economics for
Chemical Engineer,
 0.6 1
ho D o ao D o G s cp
=
kf F s ( )( )
f k
3

0.6
lb

( )
1 Btu
0.6 1 ft 432476 m2 1 0.0232
ao DoGs c p 3 k f 0.33 12
ho =
Fs

( )( )
f
=
k f Do 1.6

hf t
0.053 lbm ( h. ft )
3
( 1.256 )
1
h. ft .
ft
=195
B
h . ft
12

Assuming thin walled tube i.e ln r o/r neglected

i

2kL

1 1 1 1 1 1 1
= + + = + +
U o hi h d h o 59 300 195

Btu
U o=39 2
h.f t . F
Relative error=|(35-39)/39|*100=11%

Similarly, trials are performed until relative error is maintained below 5%

Table A- 1, Calculations for overall heat transfer Coefficient.

Trials

Iteratio 1 2 3
n
U 35 39.3697 41.8803
6 5
Ao 918.414 816.476 767.531
8 6
Nt 439 390 367
G 92089.2 103586. 110192.
4 6 3
NRe 79993.9 89981.2 95719.3
9 5 1
hi 58.9930 64.8151 68.1011
4 4 6
shell 31 31 31
ID
As 0.80083 0.80083 0.80083
3 3 3
Gs 432476 432476 432476
Nres 676928. 676928. 676928.
4 4 4
ho 195.475 195.475 195.475
8 8 8
U 39.3697 41.8803 43.2281
6 5 2
error 0.11099 0.05994 0.03117
3 7 8
 A.3. PRESSURE DROP AND POWER CONSUMPTION
CALCULATIONS

TO CALCULATE PRESSURE DROP ACROSS THE TUBE SIDE

From equation (30) page 597

Assume Bi=1, i=1; for simplicity

2
Bi 2f i Gi Ln p
Pi=
gc i D i i

wi 134688 lbm
Gi= = =109989
A i 0.782 2 2
ft h
4 12 ( ) ( 367 )

( )
lb

N =
Di G i
=
0.782
12( )(
ft 109989 2m
ft h )
=95542
i l bm
0.075
ft .h

From Moody Fanning friction factor chart, for smooth tube, fi =0.0011

( 1 ) 2 ( 0.0011 )( 95542 )2 ( 8 ) (1 ) lb
Pi= =11 2f =0.08 psi
( 32.174 36002 ) ( 0.68 ) 0.782 ( 1 ) f t
( ) 12

H2S compressing power:

f t
3
l b f 1 min 1 hp
power=V Pi=4000 11 2 =1.4 hp
min f t 60 s 550 l b f . ft
s

TO CALCULATE PRESSURE DROP ACROSS THE TUBE SIDE

 From equation (31) page 600

B o 2 f ' N r G2s
Po=
g c o

Baffle cut =75%

Nr=Cut*shell D/pitch=0.75*31/1.25=18.619
Bo=Number of baffles+1=L/Baffle spacing+1=8*12/22.2+1=6
 From equation (33) page 602, for triangular pitch

x pitch 1.25
T= = =1.25
Do 1

0.11 0.11
bo =0.23+ 1.08
=0.23+ 1.08
=0.72
x
(T )
1 ( 1.251 )

From equation (32) page 601

0.15
1
'
f =bo
Do Gs
f
0.15

( ) =0.72
12
(
432476
0.053 ) =0.096

620.096194324762 lbf
Po= =159 =1.1 psi
32.17426002 61.79 f t2
Cooling water pumping power;

wu 346341 f t 3 lb f 1 min 1 hp
power=V Po= Po = 159 2 =0.45 hp
o 61.79 min f t 60 s 550 l bf . ft
s
B. OPTIMIZATION

Equation (35) page 626

CT=AoKFCAo+wuHyCu+AoEiHyCi+AoEoHyCo

BASIC ASSUMPTIONS

Do=1
Di=0.782
np=1
pitch= 1.25
Thickness= 0.109
Tubes are laid out on staggered pattern i.e ao=0.33.
tm=754.2
Bi=1
Bo/nb=1
Dc=0.25
Nr Nc/Nt=1
Working hours Hy=8000 h/year
CAo=L.E.20/ft2
Ci=Co=L.E.0.4/kWh
KF=0.2
From equation 33 page 602

x pitch 1.25
T= = =1.25
Do 1

0.11 0.11
bo =0.23+ 1.08
=0.23+ 1.08
=0.72
( x T 1 ) ( 1.251 )

From equation 40 (a) page 630

 [ ]
0.63
w

i=Bi
12200 D
1.5 1.83
i i ( )

2 2.33 1.17
g c D o i k i c p i

0.63
w
Let
()

=
1

[ ]
1.5
0.782
=
( ) 12200
( 0.075 )
12
1.83

=0.00466
i
1
32.174 3600 ( ) 0.68 0.0188
2 2 2.33 1.17
0.3
12

From equation 40(b) page 630

[ ]
0.75 4.75 1.42
Bo N r N c 2 bo D c Do F s f
o= o

nb N t a4.75 2 3.17 1.58

o g c o k f c p o fo

[ ]
0.75
0.25 1
o=
2 0.72
12
( )( )
12
4.75
1.6 0.053
1.42

=1.0 1 0
8
4.75 2 2 3.17 1.58
0.33 32.174 3600 61.79 0.0232 0.55

From equation (46b)

0.83
3.5
(
h 2.5 i H i C i +
i opt
3.5 i H y Ci Di R dw hi , opt
Do
+2.9
i Ci D i
D0 ( ) 0.17
( o Co ) H y h0.22 )
i , opt = K F C A 0

Rearranging
 1
KFCA

(( )
3.5
hi = 0

0.83

)
opt
3.5 i H y C i Di Rdw hi ,opt i C i Di
2.5 i H i C i+
Do
+2.9
D0 ( ) 0.17 0.22
( o C o ) H y hi ,opt

Equation (45c)

0.17
0.74 i Ci Di
ho =
opt
(
o Co D0 ) 0.78
hi ,opt

1
D0
Uo =op t
( 1
+ +R dw
Di hi , opt ho opt
)
Where Rdw=Rw+Rd=1/hd =1/300, assuming thin walled tube i.e Rw=0
Ci=Co=LE 1.50647x10-7/ft.lbf
KF =0.2

o =0.00466 ,
i=1.010(8)
 Using fixed point method, a solution for hi,opt can be found using initial
Guess hi,opt= 68.101Btu/h.ft2.oF

Table A- 2, calculating optimum heat transfer coefficients

Iteration 0 1 2
hi,opt 68.101 32.170 33.293
ho,opt 224.655 125.160 128.555
Uo,opt 37.648 19.580 20.193
ER(hi,opt)% 1.117 0.034
ER(ho,opt) % 0.795 0.026
ER(Uo,opt) 0.923 0.030

Equation (E1) from table 9,

0.2 0.8 1 0.14 1.25

(
hD
Gopt = i i i
ki
0.023 k i C pi i ( )( ) ) 3 wi
i

Equation (L1) from table 9,

0.4 0.6 1 1.67

Gs , opt =
(
ho D o f o Fs k o
k f o ao ( ))
C po o
3

From equation (49)

wi
S i,opt =
Gopt

From equation (50)

4 n p S i, opt
N t, opt =
D2i
 Q
A opt =
U opt T

From equation (51)

A 0,opt
Lopt =
D0 N t, opt

From equation (52)

Wo
S 0,opt =
G s,opt

From equation (54)

0.5
N 3.7
N c ,opt =0.94+ t,opt
0.907( )
From equation (55)

N c ,opt Dc Lopt
nb, opt =
S o,opt
Table A- 3, Calculating optimum parameters

Iteratio 0 1 2
n
Gopt 205091.000 80318.000 83838.000
Si,opt 0.657 1.677 1.607
Nt,opt 197 503 481
Aopt 853.827 1641.739 1591.853
Lopt,ft 16.564 12.473 12.624
 Gs,opt 2944647.000 1108587.000 1159263.000
So,opt 0.118 0.312 0.299
Nc,opt 15.532 24.393 23.891
nb,opt 45.000 27.000 27.000
Nre 178154 69769 72827
fi 0.0041 0.0049 0.0049
pi,psi 2.058 0.286 0.308
shell ID 21.250 37.000 37.000
po,psi 352.100 52.891 57.837

FOR CALCULATING PUMPING POWER AND POWER COST:

Pumping power=-P*V (ft.lbf /min) ,( =-P*V/(60*550) hp)

Pumping cost ($/year) = C(LE/ft.lbf )*pumping power (ft.lbf /h)*Hy

Table A- 4, Calculating optimum pressure drop, and power cost

power Annual Annual

power(in),
Iteration pi,psi po,psi (out), cost cost (out),
hp
hp (in), L.E LE
1 2.058 352.100 35.9 143.54 85719 342531
2 0.286 52.891 5.0 21.56 11893 51454
3 0.308 57.837 5.4 23.58 12848 56265

CALCULATING SHELL ID AFTER OPTIMIZATION

From table 7 page 608, Max Peter, Plant Design and Economics for
Chemical Engineer, Do=1, Nt=481, triangular pitch, then shell ID =37,
pitch=1.25, Dc =clearance= pitch-Do= 0.25
NOTES