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STUDENTS NAME:
FATIN FATIHA BINTI ABDUL RAHIM
2014850038
SUPERVISOR:
MS CHRISTINA VARGIS
EQUIPMENT DESIGN
The purified HCl is then diluted with water and sold as a second source of
revenue. Meanwhile, the purified TFE is fed to a continuous stirred tank reactor
(CSTR) for polymerization reaction and produce PTFE. Additionally, water and
benzoyl peroxide are added to the reaction which acts as the solvent and organic
initiator, respectively (Ebnesajjad, 2013). According to (Mori, Tsuchiya, & Okahata,
2005), the conversion can achieve as high as 80% and produce PTFE ranging
between 10,000 g/mol to 1,000,000 g/mol.
211
The product stream is then fed to a mixing tank whereby a surfactant,
sodium borate is added to reduce the interfacial tension and form a stable colloidal
dispersion of PTFE. (Fernandez & Jebbanema, 2007). The sludge-like stream is
subsequently transported using an extruder to a filter press to remove unwanted
components from PTFE.
The discharged stream containing unreacted TFE, HCl and water is purified
using two distillation columns whereby TFE and HCl are recycled back into the
process meanwhile wastewater is sent to a water treatment facility. The solid PTFE
is then transferred onto a conveyer belt and dried to remove residual moisture and
achieve the desired 99% purity.
212
3.1.2 PROCESS FLOW DIAGRAM BEFORE HEAT INTEGRATION
213
3.1.3 PROCESS FLOW DIAGRAM AFTER HEAT INTEGRATION
214
3.1.4.1 DESIGN OF HEAT EXCHANGER, E-103 (COOLER)
3.1.4.1.1.1 Introduction
A heat exchanger is a heat transfer device mainly be applied for the transfer
of internal thermal energy between two or more fluids available either in
liquid, gas, or two phase stream at different temperatures (Thulukkanam,
2013).
215
Table 3.1 Characteristics of Different Heat Exchanger Types
Type Function Application Advantages Disadvantages
Shell and Heating and - Steam heating - Can withstand a process at - Less efficient in conducting
Tube cooling of all types - Cooler and high temperature and thermal condition than other
of application. heater pressure. types of heat transfer
- Waste heat - The design will give large equipment.
recovery heat transfer surface. - Can lead to equipment failure
- Able to clean easily since it if subject to flow induced
can be dismantled. vibration.
- It can be built from various - Able to form stagnant zones
range of materials. (dead zones) on the shell
side thus leading to corrosion
issues.
Spiral Heating and - Dirty process - Has high thermal efficiency. - Only suitable for low
cooling, vaporizing fluids and - Has self-cleaning passage. temperature and pressure.
and condensing, slurries - Suitable for high viscosity
vapours sub fluid.
cooling or
condensate
Gasket-plate Designed to - Waste heat - Provide high heat transfer - Not suitable for high
separate recovery surface area. temperature difference
two media from situations.
each other at the - Leads to high pressure loss.
216
transfer ports by - Food and - Easy to clean for it is easy to
means of a double beverages disassemble and
gasket guidance industries reassemble.
system - Cost efficient.
Double pipe - Heating - Food industries - Suited to high pressure - Limited to low heat duties in
and cooling - Dairy industries applications. which the surface areas
- Has flexible design whereby should be less than 47 m2.
the units can be added or - Flow pattern must be only in
removed as required counter flow.
- Modular type construction
217
3.1.4.1.1.2 Process Background
Heat exchanger that is going to be used for the stated process is shell and
tube heat exchanger because it is commonly used for the purpose of
heating and cooling. The shell and tube heat exchanger is selected to have
a two shell pass and four tube passes, as shown in the calculation part.
While, counter current flow type is proved to be more effective at
transferring heat between hot and cold fluids and therefore is chosen for
exchanger E-103.
The shell and tube heat exchanger is limited to equipped with two
choices of head types; U-Tube head and internal floating head either pull-
through or split-ring head. For external floating head type, the usage is not
suitable in this process condition since it cannot be used for toxic and
218
flammable material (Sinnott, 2005). The diagram of split ring shell and tube
heat exchanger is shown is Figure 3.2.
Figure 3.2 Split-Ring Pull-Through Floating Shell and Tube Heat Exchanger
3.1.4.1.1.4 Calculations
The purpose of this heat exchanger is to cool down the exit stream of from
main reactor, pyrolysis reactor(R-101) which contains TFE and HCl by
using cooling water as utilities. The general formula for calculating the duty
of heat exchanger is as follows:
219
The energy of this cooler is obtained from the calculation using the above
equation after considering the heat integration between hot and cold energy
stream in the plant. When process fluid changes its temperature from from
180C to 30C the duty value of cooler E-103 is;
, ( ) = 147.03 = 147.03
From the duty obtained, the temperature of cooling water outlet can be
calculated by using the following formula
= ,
147.03 = (4.184 ) (363.15 298.15 )
.
= 0.541 /
(1 2 )(2 1 )
= ( )
ln 1 2
(2 1 )
Where;
220
In order for the process fluid or cooling water to be either in the shell side
or the tube side, few properties must considered. The properties and
explanation is tabulated in Table 3.3
(180 90)(3025)
= (18090)
ln
(3025)
= 29.41 C
221
correlated as a function of two dimensionless temperature ratio; R and
S.
1 2
=
2 1
18030
= 9025
= 2.31
2 1
=
1 1
9025
= 18025
= 0.419
For R = 2.31 and S = 0.419, the temperature correction factor is 0.75 with
shell and tube heat exchanger of two shell passes and four tube passes.
From the same reference states that the value of Ft will be close to 1.0 when
the terminal temperature differences are large, and shows an economic
efficiency when Ft value is above 0.75.
Where;
222
Tm = 0.75 29.41
= 22.06 C
147.03
=
(550 )(22.06 )
.
= 22.217 2
The tube length preferred in shell and tube heat exchanger will be 6 ft. (1.83
m), 8 ft. (2.44 m), 12 ft. (3.66 m), 16 ft. (4.88 m) 20 ft. (6.10 m), and 24 ft.
(7.32 m). The optimum tube length is usually in the range of 5 to 10 ft.
(1.52m to 3.05m) (Sinnott, 2005).
223
3.1.4.1.1.4.3 Number of Tubes
Tube number of shell and tube heat exchanger can be calculated using the
formula as follows:
Nt =
Types of heat exchanger selected: Shell and tube with floating head.
a =
= 0.230 m2
= 1.25
= 1.25 (0.020)
= 0.025
Nt =
22.217
= 0.230
= 96.50
97
Np = 4
224
97
= 4
= 24.25
24
2
Acs = 4
(0.018)2
= 4
= 2.545 104 m2
Ap = Acs Np
= (2.545 104 ) 24
= 0.0061 m2
Where;
MW = Molecular weight
225
Table 3.5 Relative molecular mass for E-103
73.2172
Vapour mixture;
73.2172 273.15 6.0
=
453.15 1
22.4
= 11.821
3
Vt =
4253.73
=
11.821 3
= 0.100 m3/s
Ut =
0.100 3 /s
= 0.0061 2
= 16.393 m/s
226
3.1.4.1.1.4.5 Tube Side heat Transfer Coefficient
Where;
= 196655.00
Prandtl number, Pr
,
Pr =
Where;
Pr = Prandtl number
227
Cpt = fluid heat capacity of tube side, J/kgC
(1019.5)(1.7737 105 )
= (0.040)
= 0.452
3.66
= 0.018
= 203.33
0.14
= 0.33 ( )
= 378.30
(378.30) (0.040)
= 0.018
= 840.67 W/m2 C
228
3.1.4.1.1.4.6 Bundle and Shell Diameter
To calculate the bundle and shell diameter (Db and Ds), the value of K1 and
n1 is selected based on the pitch type and the number of tube passes of
heat exchanger. For this heat exchanger, shell and tube heat exchanger
with two shell passes and four tube passes is selected. For tube
arrangements in heat exchanger, the triangular pattern is selected for it can
give higher heat-transfer rates as compared to square pattern, as shown in
Figure 1.3. The recommended tube pitch, which is the distance between
tube centers is 1.25 times the tube outside diameter, do.
K1 = 0.175
n1 = 2.285
229
Bundle diameter, Db;
1
Db = (1 )1
1
97
= 0.02 (0.175)2.285
= 0.318 m
For a split ring floating head exchanger, the bundle clearance value is
obtained from Figure 12.10, taken from Coulson and Richardson (2005) as
shown in Appendix, A-4; The clearance value will be 55 mm (0.055m). So,
the shell inside diameter will be,
Ds = 0.318 + 0.055
= 0.373 m
1
Db = (1 )1
= 0.318
= 0.373
230
i. Take baffle spacing as 1/5 from the shell diameter, baffle spacing, IB
IB = 5
0.373
= 5
= 0.0746
( )
=
Where;
Pt = Tube pitch, m
IB = Baffle spacing, m
= 0.0056 2
1.10
= ( 2 0.917 2 )
1.10
= (0.0252 0.917 (0.020)2 )
0.020
= 0.0142
0.541
=
0.0056 2
231
= 96.61
2 .
v. Shell-side Velocity, us
196.61
2 .
=
981.13 3
= 0.095
Where;
(981.13)(0.095)(0.0142)
=
6.1125 104
= 2153.91
,
Pr =
Where;
Pr = Prandtl number
232
s = Fluid dynamic viscosity of shell-side, Ns/m2
(4187.5)(6.1125 104 )
= (0.6378)
= 4.013
For segmental baffle, a 25 per cent baffle cut is optimum because it provide
a good heat-transfer rates without too large pressure drop. Based on Figure
12.29 taken from Coulson and Richardson (2005) (shown in Appendix, A-
7),
jh = 1.3 102
1
3
hs =
Where;
= 1989.35 2
.
233
3.1.4.1.1.4.8 Overall Heat Transfer Coefficient, Uo
1 1 1 ln 1 1
= + + + ( + )
2
Where;
Based on Table 12.2 taken from Coulson and Richardson (2005), shown in
Appendix, A-8;
234
Therefore,
1 1 1 ln 1 1
= + + + ( + )
2
(0.02)
1 1 1 (0.02) ln 0.02 1 1
(0.018)
= 1989.35
+ 3000
+ 2 (16)
+ 0.018 (5000 + 840.67 )
1
= 0.00244
= 409.43
Error;
% =
100%
550 409.43
% = 409.43
100%
= 25.56 %
235
3.1.4.1.1.4.9 Pressure Drop
3.1.4.1.1.4.9.1 Tube Side Pressure Drop
Table 3.9 Tube-side specification
Tube Specification
Tube number 97
Number of passes 4
Inside diameter, m 0.018
Outside diameter, m 0.020
Velocity, Ut (m/s) 16.393
Reynolds number 196655
Tube-side friction factor, jr 2.2 103
2
Pt = [8 () () + 2.5] 2
Where;
jr = Friction factor
L = Tube length, m
Neglect the viscosity correction term, () the equation becomes;
2
Pt = [8 ( ) + 2.5]
2
3.66 (11.821)(16.393)2
Pt = 4 [8(2.2 103 ) (0.018) + 2.5] 2
Pt = 0.589 bar
236
3.1.4.1.1.4.9.2 Shell Side Pressure Drop
0.14 2
Ps = [8 () () () ] 2
Where;
L =Tube length, m
IB = Baffle spcing, m
de = Equivalent diameter, m
Neglect the viscosity correction term, ( ) the equation becomes;
2
Ps = [8 ( ) ( )] 2
Ps = 0.0052 bar
From the calculation, the pressure drop of tube and shell side are
acceptable since it lie below 1 bar. Therefore, all calculations are valid and
acceptable when error of overall coefficient is below 30%.
237
3.1.4.1.5 Summary Table for Chemical Design of Heat Exchanger, E-103
(Cooler)
238
REFERENCES
Lawate, S., & Deshmukh, B. B. (2015). Analysis of Heads of Pressure Vessel, 759765.
http://doi.org/10.15680/IJIRSET.2015.0402098
Theodore, L. (2011). Heat Transfer Applications for the Practicing Engineer. John Wiley
& Sons.
Thulukkanam, K. (2013). Heat Exchanger Design Handbook. (C. Press, Ed.) (Second
Edi).
239
APPENDIX
A-1 Temperature correction factor: two shell pass; four or more even tube passes
240
A-2 Tube-side heat-transfer factor
241
A-5 Conductivity of metals
242
A-7 Shell-side friction factors, segmental baffles
243
3.1.4.1.2 Mechanical Design
Economic feasibility
Operating condition
Corrosion resistance
Suitability for fabrication (welding)
Process safety
In this PTFE production plant, the material that flow into the heat
exchanger E-103 are TFE and HCl. Since HCl is corrosive, the most
suitable material decided for E-103 construction is stainless steel for the
tube side and carbon steel for shell side since the materials are considered
as a good corrosion resistance at a high elevated temperatures.
244
3.1.4.1.2.3 Design Pressure
The temperature increases with the increase of pressure, thus the 10%
safety precaution also must be considered to operating temperature to
avoid any risks during plant operation. The operating temperatures are
taken for the maximum temperature occur in tube and shell side. So, the
design temperature are as follows;
Operating temperature = 90 C
Design temperature = (90 C) (1.1)
= 99 C
245
3.1.4.1.2.5 Minimum Thickness of Shell and Tube Construction
Material
Minimum allowable thickness for the heat exchanger E-103 must be known
and the properties can be extracted from Figure 13.2 from Coulson and
Richardson (2005). Thus, the maximum allowable stress can be decided for
the temperature as follows;
Table 3.11 Material Thickness Determination
Shell Tube
Temperature (C) 99 198
Pressure (N/mm2) 0.11146 0.66
Material of Construction Carbon steel Stainless steel 316
Design stress at 125.5 120.6
temperature (N/mm2)
Welded joint efficiency, J 1 1
Shell diameter, Ds (mm)/ 373 18
Tube internal diameter
(mm)
Where;
F = 1.0 for floating tube sheet
G = Diameter over which pressure is acting
f = Design stress
= 0.42 m
246
= 0.076 + 2
= 2.075
2.1
= 0.00132 + 2
= 2.00132
2
flat plates
hemispherical heads
ellipsoidal heads
torispherical heads
247
Table 3.12 Type of heads and its applications (Tooley and Dingle, 2007) (Lawate and Deshmukh, 2015).
Type of Heads Applications
Flat pates and formed flat May be plain and flanged, and bolted or welded.
Considered as the cheapest type of head but limited to low pressure and small
diameter vessel.
1
= (3 + )
4
248
Ellipsoidal For pressures over 10 bar, ellipsoidal heads are often used, most commonly
is 15 bar.
In cross-section, the head resembles an ellipse, its radius varying
continuously.
Ellipsoidal heads are deeper than torispherical heads. The shape of the
ellipsoidal head is defined by the ratio of the major and minor axis, whereby a
standard arrangement on vessels is the 2:1 elliptical head.
The equation for determining the thickness of ellipsoidal head is:
=
2 0.2
Hemispherical The strongest form of closure that can be used with cylindrical pressure
vessel.
The applications on pressure containment and safety precaution is often
restricted which makes is costly.
Used for high-pressure applications and for tall vertical towers because it is
practically free from discontinuities.
249
The minimum thickness for E-103 should be considered by choosing
the three types of heads between ellipsoidal and torispherical since both
type of heads are the most practical.
=
2 0.2
(0.11146)(373)
= 2(125.5)(1.0)0.2(0.11146)
= 0.166 + 2
= 2.166
2.2
1
= (3 + )
4
= = 309
= 0.06 = (0.06)(309) = 18.54
1
= (3 + )
4
1
= 4 (3 + (373/18.54)
= 1.874
Thus,
(0.11146)(373)(1.874)
=
2(1.0)(125.5) (0.11146)(1.874 0.2)
= 0.311 + 2
= 2.311
2.3
250
Based on the calculation above, the most suitable head to be used for
exchanger E-103 is ellipsoidal head since it is more economical than
torispherical.
1. Vessel shell.
6. Insulation.
= ( + 0.8 )
Where;
t = wall thickness, mm
251
Table 3.13 Information to calculate dead weight of E-103
Dimensions Value
Length of Shell, m 3.66
Shell wall thickness, mm 2.00
Shell inside diameter, mm 373
Shell mean diameter, mm Dm = Ds + t = 375
Gravitational acceleration, m/s2 9.81
Density of stainless steel, kg/m3 7990
Density of carbon steel, kg/m3 7850
Factor to account nozzle weight, Cv 1.08
Number of tubes, NT 97
Tube outside diameter, m 0.02
Tube inside diameter, m 0.018
= 0.375 m
= 776.01
= 0.776
= 6644.04 N
= 6.644
252
Weight of insulation, WI;
Insulation thickness = 50 mm
Volume of insulation =
= ()(0.375)(3.66) ( 50 10-3)
= 0.216 m3
Insulation weight = V
= (0.216)(130)(9.81)
= 381.41
= 0.381
Fluid weight,
2
Wf,s = ( )
4
(0.373)2
= ( 4
) 3.66 981.13 9.81
= 3849.32
= 3.849
(2 2 )
Wf,t = [ 4
]
(0.022 0.0182 )
= (97) [
4
] 3.66 11.821 9.81
= 2.457
= 0.0024
253
Total weight = Wv + Wt + WI + Wf,s + Wf,t
= 11.65
1
2
= [ ]
Where:
1
0.11146 2
= (0.4)(373) [ ]
125.5
= 4.446 + 2
= 6.446
3.1.4.1.2.9 Baffles
Baffles are made for shell and tube heat exchanger to increase fluid
velocity, direct fluid streams across the tubes and to enhance heat transfer
rate between fluids in the shell and tube. As fluid velocity increases, the rate
of heat transfer is also improved.
254
Baffles diameter;
B =S 4.8
B = 373 4.8
368.2
IB =
2
373
= 2
= 186.5
NB =
3660
=
373
= 9.123
Where;
= Shell diameter
= 373 0.25
= 93.25
255
3.1.4.1.2.11 Design of Nozzles
An appropriate pipe sizes will be used for the inlet and outlet nozzles. This
criteria is important to avoid flow restrictions at the inlet and outlet nozzles
so as to prevent excessive pressure drop and flow induced vibration of the
tubes.
i. Tube-side nozzle
= 113.91
114
= 14.677
15
3.1.4.1.2.12 Flanges
256
Used for connecting pipe sections where ease of assembly and
dismantling is required for maintenance.
257
Screwed Used to connect screwed fittings
to flanges and sometimes for
alloy pipe which is difficult to weld
satisfactorily.
258
Figure 3.4 Typical saddle design
259
3.1.4.1.2.14 Summary Table for Mechanical Design of Cooler E-103
Other Specifications
Baffles Type Segmental
Nozzle Type Welding-Neck Flange
Spacing 186.5 mm Shell Side Nozzle 15 mm
Diameter
Cut 25% Tube Side Nozzle 114 mm
Diameter
Support Type Saddle Total Weight 11.65 kN
260
References
Lawate, S., & Deshmukh, B. B. (2015). Analysis of Heads of Pressure Vessel, 759765.
Sinnott, R. K. (2005). Chemical Engineering Design. Coulson & Richardsons.
Tooley, M., & Dingle, L. (2007). Higher National Engineering. Routledge.
261