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ABSTRACT
A shell and tube type heat exchanger has been designed to obtain a set of optimum
dimensions and geometry for the equipment. The design problem is to cool kerosene that
leaves from the base of a kerosene side-stripping column at 200 to 90C by exchange with
light crude oil coming from storage at 40C. Thermal and mechanical design calculations
were carried out to meet the heat duty requirement and a given set of design constraints. The
design parameters were iterated and modified multiple times to achieve the final design that
provides maximum overall heat transfer within allowable pressure drops and also withstands
the loads, pressure and temperature in the design. Lastly, the calculated results were
summarized in the proposed design with a 2D and 3D representation of the optimized shell
and tube heat exchanger.
1
I. INTRODUCTION
Due to their resistant manufacturing features and design flexibility, shell and tube heat
exchangers are the most used heat transfer equipment in industrial processes. They are
also easy adaptable to operational conditions. Thats why a basic understanding of their
design, construction and performance is important to a chemical engineer. However,
some difficulties are found, especially in the shell-side design, because of the complex
characteristics of heat transfer and pressure drop.
A. Definition
A shell and tube heat exchanger is a class of heat exchanger designs. It is the most
common type of heat exchanger in oil refineries and other large chemical processes,
and is suited for higher-pressure applications. As its name implies, this type of heat
exchanger consists of a shell with a bundle of tubes inside it.
B. Theory
Two fluids, of different starting temperatures, flow through the heat exchanger.
One flows through the tubes and the other flows outside the tubes but inside the shell.
Heat is transferred from one fluid to the other through the tube walls, either from tube
side to shell side or vice versa. 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, so there are many tubes. In this way, waste heat can be put to use
which is a great way to conserve energy. Heat exchangers run on the principles of
convective and conductive heat transfer. Conduction occurs as the heat from the hot
fluid passes through the inner pipe wall. To maximize the heat transfer, the inner-pipe
wall should be thin and very conductive. However, the biggest contribution to heat
transfer is made through convection.
C. Advantages
The advantages of a shell and tube heat exchanger are:
1. The configuration gives a large surface area in a small volume.
2. Good mechanical layout: a good shape for pressure operation.
3. Uses well-established fabrication techniques.
4. Can be constructed from a wide range of materials.
2
5. Easily cleaned.
6. Well-established design procedures.
D. Classification
The common types of shell and tube exchangers are:
a. Floating-head exchanger
It consists of a stationery tube sheet which is clamped with the shell
flange. At the opposite end of the bundle, the tubes may expand into a
freely riding floating-head or floating tube sheet. A floating head cover is
bolted to the tube sheet and the entire bundle can be removed for cleaning
and inspection of the interior.
b. U-tube exchanger
This type of exchangers consists of tubes which are bent in the form of
a U and rolled back into the tube sheet. This means that it will omit
some tubes at the center of the tube bundle depending on the tube
arrangement. The tubes can expand freely towards the U bend end. The
U-tubes permit unlimited thermal expansion, the tube bundle can be
removed for cleaning and small bundle to shell clearances can be achieved.
3
III. PROBLEM STATEMENT
20,000 kg/h of kerosene (42 API) leaves the base of a kerosene side-stripping
column at 200C and is to be cooled at 90C by exchange with 70,000 kg/h light crude oil
(34API) coming from a storage at 40C. The kerosene enters the exchanger at a pressure
of 5 bar and the crude oil at 6.5 bar. A pressure drop of 0.8 bar is permissible on both
streams. Design a suitable heat exchanger for this duty.
IV. SPECIFICATION
A. Given Data
4
C. Physical Properties
kJ
Specific Heat 2.72 2.47 2.26
kgC
W
Thermal Conductivity 0.130 0.132 0.135
mC
kg
Density 690 730 770
m3
mN - s
Viscosity 0.22 0.43 0.8
m2
kJ
Specific Heat 2.09 2.05 2.01
kgC
W
Thermal Conductivity 0.133 0.134 0.135
mC
kg
Density 800 820 840
m3
mN - s
Viscosity 2.4 3.2 4.3
m2
5
V. THERMAL DESIGN
The thermal design of shell and tube heat exchanger involves a large number of
geometric and operating variables as a part of the search for heat exchanger geometry that
meets the heat duty requirement and a given set of design constrains. The design
parameters are iterated multiple times to achieve a final design that provides maximum
overall heat transfer within allowable pressure drops. The thermal design of a shell and
tube heat exchanger typically includes:
1. Consideration of process fluids in both shell and tube side;
2. Selection of required temperature specifications;
3. Limiting the shell and tube side pressure drop;
4. Setting shell and tube side velocity limits; and
5. Finding heat transfer area including fouling factor.
STEP 1:
Assume tube diameter,
BWG and tube length
STEP 2:
Assume fouling factor
STEP 3:
Assume material of
construction for the tubes
STEP 4:
Calculate the unknown
temperature and heat duty
STEP 5:
Calculate the log mean
temperature difference
6
STEP 6:
Obtain the temperature
correction factor
STEP 7:
Calculate the true
temperature difference
STEP 8:
Assume overall heat transfer
coefficient
STEP 9:
Calculate the provisional
area
STEP 10:
Calculate the no. of tubes
STEP 11:
Calculate the tube pitch and
bundle diameter
STEP 12:
Obtain the bundle diameter
clearance
STEP 13:
Calculate the shell diameter
STEP 14:
Calculate the baffle sapacing
7
STEP 15:
Calculate the area for cross-
flow
STEP 16:
Calculate the shell-side mass
velocity
STEP 17:
Calculate the sell equivalent
diameter
STEP 18:
Calculate the shell-side
Reynolds number
STEP 19:
Calculate the shell-side
Prandtle number
STEP 20:
Obtain the shell-side heat
transfer coefficient
STEP 21:
Calculate the pressure drop
in the shell
STEP 22:
Calculate the number of
tubes per pass
8
STEP 23:
Calculate the tube-side mass
velocity
STEP 24:
Calculate the tube-side
velocity
STEP 25:
Calculate the tube-side
Reynolds and Prandle no.
STEP 26:
Calculate the tube-side heat
transfer coefficient
STEP 27:
Calculate the overall heat
transfer coefficient
STEP 28:
U o ,calc U o ,ass
If 0< <30%,
U o ,ass
then you have a valid
assumption. Otherwise, go
back to step 8 and set
UO,assumed=UO,calculated
STEP 29:
the overall heat transfer
coefficient Calculate
STEP 1:
Assume,
TUBE DIAMETER
3
D0 = in = 19.05mm
4
Di = 0.584in = 14.83mm
TUBE LENGTH
L = 5m = 16.40 ft
BWG NUMBER
BWG =14
TUBE PATTERN
Triangular Pitch
STEP 2:
Based on inside and outside tubes,
FOULING FACTOR
1 m 2 C
Crude stream : = 0.00035
h id W
1 m 2 C
Kerosene stream : = 0.0002
h od W
STEP 3:
CARBON STEEL
W
k w = 55
mC
10
STEP 4:
q = m c cp c (Tc o - Tc i ) or
q = m h cp h (Th o - Th i )
KEROSENE:
q = m h cp h (Th o - Th i )
kg 1h kJ
q = (20,000 )(2.47 )[(200 - 90)C]
h 3600s kgC
kJ
q = 1509.44
s
q = 1509.44 kW
CRUDE OIL:
As a first trial take the mean temperature of the crude oil as equal to the inlet
temperature, 40C; specific heat capacity at this temperature =2.01 kJ/kgC
q = m c cp c (Tc o - Tc i )
kJ kg 1h kJ
1509.44 = (70,000 )(2.01 )[(Tc o - 40C]
s h 3600s kgC
Tc o = 78.62C
11
STEP 5:
(Th i - Tc o ) - (Th o - Tc i )
Tlm =
(Th i - Tc o )
ln
(Th o - Tc i )
(200 - 78)C - (90 - 40)C
Tlm =
(200 - 78)C
ln
(90 - 40)C
Tlm = 80.7C
STEP 6:
Th i - Th o 200 - 90
R= = = 2.9
Tc o - Tc i 78 - 40
Tc o - Tc i 78 - 40
S= = = 0.24
Th i - Tc i 200 - 40
Th i - Th o 200 - 90
R= = = 2.9
Tc o - Tc i 78 - 40
Tc o - Tc i 78 - 40
S= = = 0.24
Th i - Tc i 200 - 40
(1 - S)
(R 2 + 1)ln[ ]
(1 - RS)
Ft =
2 - S(R + 1 - (R 2 + 1)
(R - 1)ln[ ]
2 - S(R + 1 + (R 2 + 1)
(1 - 0.24)
(2.9 2 + 1)ln[ ]
(1 - (0.24)(2.9 )
Ft =
2 - (0.24)[2.9 + 1 - (2.9 2 + 1) ]
(2.9 - 1)ln[
2 - (0.24)[2.9 + 1 + 2.9 2 + 1)]
Ft = 0.88 : ACCEPTABLE
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STEP 7:
Calculate,
MEAN TEMPERATURE DIFFERENCE
Tm = Ft Tlm
Tm = (0.88)(80. 7C)
Tm = 71C
STEP 8:
Assume,
OVERALL HEAT TRANSFER COEFFICIENT
W
U o = 300
m 2 C
STEP 9:
Calculate,
PROVISIONAL AREA
q
A=
U o Tm
1000W
(1509.44kW )
A= 1kW
W
(300 )(71C)
m 2 C
A = 70.86 m 2
STEP 10:
NUMBER OF TUBES
A
Nt =
D o L
70.86m 2
Nt =
1m
(19.05mm )(5m)
1000mm
N t = 237 : make it 240 to make it even
N t = 240 tubes
13
CHECKING THE NUMBER OF TUBES:
To check the number of tubes, see if the evaluated tube-side velocity looks
reasonable. Tube-side velocity for process fluids should be within 1-2 m/s.
TUBE CROSS - SECTIONALA REA = (D ) 2
4 I
1m
TUBE CROSS - SECTIONALA REA = (14.83mm )2
4 1000mm
TUBE CROSS - SECTIONALA REA = 0.0001727 m 2
AREA PER PASS = TUBE PER PASS TUBE CROSS - SECTIONAL AREA
= 120 0.0001727m 2
= 0.02073 m 2
m
VOLUMETRIC FLOW =
mean
kg 1h
(70,000 )
= h 3600s
kg
820 3
m
3
m
= 0.0237
s
VOLUMETRIC FLOW
TUBE SIDE VELOCITY =
AREA PER PASS
0.0237 m3 /s
=
0.02073m 2
m
= 1.14 : VELOCITY IS SATISFACTO RY BUT
s
MAY BE A LITTLE LOW
14
0.0237m 3 /s
T UBE SIDE VELOCITY =
0.01036m 2
= 2.29m/s : NOT SATISFACTO RY SINCE TUBE
SIDE VELOCITY MUST BE WITHIN 1 - 2 m/s
Assume 4 PASS,
STEP 11:
N t n11
Db = D o ( ) : BUNDLEDIA METER
K1
For 4 tube passes, triangula r pitch
K 1 = 0.175
n1 = 2.285
N t n11
Db = D o ( )
K1
1
360 2.285
Db = (19.05mm)( )
0.175
Db = 537mm = 0.54m
15
STEP 12:
STEP 13:
SHELL DIAMETER
Ds = Db + BDC
Ds = 537mm + 59mm
Ds = 596mm
STEP 14:
BAFFLE SPACING
Bs = 0.5Ds
Bs = 0.5(596mm)
Bs = 100mm
STEP 15:
(Pt - D o )
As = DsBs
Pt
(23.81 - 19.05)mm
As = (596mm)(10 0mm)
23.81mm
As = 11.915mm 2
As = 0.011915m 2
16
STEP 16:
SHELL-SIDE VELOCITY
Gs
us =
kg
466.27
us = s - m2
kg
730 3
m
m
u s = 0.638
s
STEP 17:
1.10 2
de = (Pt - 0.917Do 2 )
Do
1.10
de = [(23.81mm) 2 - 0.917(19.05mm) 2 ]
19.05mm
d e = 13.52mm
17
STEP 18:
u s d e
Re =
m kg
(0.638 )(13.52 10 -3 m)(730 3 )
s m
Re =
kg
0.43 10 3
s-m
Re = 14644
STEP 19:
c p
Pr =
k
3 N-s 3 J
(0.43 10 2 )(2.47 10 )
m kgC
Pr =
W
(0.132 )
m - C
Pr = 8.05
STEP 20:
k 1
h o = hs = [(j h RePr 3 )( ) 0.14 ] neglect the viscositycorrelation
de w
1
k
ho = (j RePr 3 )
de h
W
0.132 1
mC -3
ho = ( )[(4.8 10 )(14644)(8 .05) 3 ]
13.52 10 3 m
W
h o = 1366 2
m C
18
STEP 21:
Ds L u s 2 0.14
Ps = 8jf ( )( )( )( ) neglect the viscositycorrelation
d e Bs 2 w
kg m 2
596mm 5000mm (730 3 )(0.638 )
m s
Ps = 8(4.6 10 )(
-2
)( )[ ]
13.52mm 100mm 2
N
Ps = 120,510 2
m
Ps = 1.2bar
STEP 22:
Nt
Nt pp =
number of passes
360
Nt pp =
4
Nt pp = 90 tubes per pass
STEP 23:
19
STEP 24:
TUBE-SIDE VELOCITY
Gm
t =
kg
1250.78
s - m2
t =
kg
820 3
m
m
t = 1.52
s
STEP 25:
dv
Re =
kg -3 m
(820 3 )(14.83 10 m)(1.52 )
m s
Re =
N -s
3.2 10 -3
m
Re = 5792
c p
Pr =
k
N-s J
(3.2 10 -3 2 )(2.05 10
3
)
m kgC
Pr =
W
(0.134 )
mC
Pr = 48.96
20
STEP 26:
STEP 27:
1
Uo =
do
d o ln( )
1 1 di do do
+ + + +
h o h do 2 kw d i h i d i h di
1
Uo = -3
(19.05 10 )
(19.05 10 -3 )ln
1 (14.83 10 -3 ) 19.05 10 -3 19.05 10 -3
+ 0.0002 + + + (0.00035)
1366 2 55 (14.83 10 -3 )(1366) (14.83 10 -3 )
W
U o = 301.74
m 2 C
W
U o = 302 2
m C
STEP 28:
8jf L -m i 2
P = (1.5 + N p [2.5 + + ( ) ])
di w 2
8(5.5 10 -3 )(5000) 820(1.52) 2
P = {1.5 + 4[2.5 + ]}( )
14.83 10 -3 2
N
P = 67,103.40
m2
P = 0.67 bar
21
V. MECHANICAL DESIGN
Mechanical design of heat exchangers includes design of various pressure and non-
pressure parts. The structural rigidity and satisfactory service of heat exchangers depends on
the appropriate mechanical design. Mechanical design is generally performed according to
the design standards and codes. Some mechanical design standards used in heat exchanger
design are: TEMA (United States), IS:4503 (India);BS: 3274 (United Kingdom) and BS:
20414 (United Kingdom). In this mechanical design, the design standard used is IS:4503.
i. Design Temperature
10C greater than the maximum allowable temperature
T = 1.1 200C
T = 220C(428F)
ii. Design Pressure
10% greater than the maximum allowable working pressure
P = 1.1 6.5 bar
P = 7.15 bar(0.715 N )
mm 2
B. MATERIALS OF CONSTRUCTION
The material of construction chosen is carbon steel which is cost effective and compatible
with the process fluids and others parts of the heat exchanger.
i. Carbon steel
Allowable fluid temperatu re = 540C (1004F)
Permissibl e stress = 100.6 N
mm 2
Corrosion Allowance = 3 mm
22
C. DESIGN COMPONENT CALCULATION
The major mechanical design components of shell and tube heat exchangers are: shell and
tube-sheet thickness, shell cover, flanges, nozzles, gaskets, stress calcultions and design
of supports.
23
Effective Exchanger Length (Leff)
L eff = L t + 2 h i ; where :
L eff = effective exchanger length
h i = initial depth of the head
L t = exchanger total length
L eff = 5m + 2 0.08032 m
L eff = 5.161 m
pR i W
th = +c ; where :
(2 fJ - 0.2p)
c = corrosion allowance
1 Ri
W= (3 + )
4 ri
p = design pressure
f = permissibl e stress
J = jointeffic iency
1 600mm
W= (3 + )
4 36mm
W = 1.77 mm
N
(0.715 2 )(600mm)(1 .77mm)
th = mm
N N
[2(100.6 2 )(0.8) - 0.2(0.715 )
mm mm 2
t h = 4.72mm + c
t h = 7.72mm : including corrosion allowance
: use8mm
24
iii. Channel Cover Thickness
Channel cover material: carbon steel
Dc c1 p
t cc = ; where :
10 f
D c = same as the outside shell diameter
c1 = 0.3 for bolted with narrow faced or ring type gaskets
kgf
p = design pressure in
cm 2
kgf
f = allowable stress value in
cm 2
kgf
(0.3)(7.15 )
(606 mm) cm 2
t cc =
10 kgf
10.26 2
cm
t cc = 8.65 mm + c
t cc = 11.65 mm : including corrosion allowance
: use 12mm
FG p p
t ts = ; where : p design pressure
3 kf
G p = diameter over which pressure is acting
F = 1(for floating type tube sheet)
f = allowable stress
k = mean ligament efficiency
For triang ular pitch
0.907
k = 1-
P
( t )2
Do
0.907
k = 1-
23.81 mm 2
( )
19.05mm
k = 0.4
Therefore :
25
v. Impingement plate
26
vii. Design of Gaskets
Gasket Width, N
(D OG - D IG )
N=
2
(702 mm - 600.25 mm)
N=
2
N = 51 mm : Use 60 mm
27
Basic Gasket Starting Width, Bo
N
bo =
2
60 mm
bo =
2
b o = 30 mm
b = 0.5 b o
b = 0.5 30 mm
b = 2.74 mm
viii. Bolts
The bolt load due to gasket reaction under atmospheric conditions is given by:
Wm1 = bGY
N
Wm1 = (2.74 mm)(651 mm)(52.483 5 )
mm 2
Wm1 = 294106N
Wm1
Am =
fa
294106N
Am =
N
100.6
mm 2
A m = 2924mm 2
M16 nominal thread diameter with bolt circle diameter () of 860 mm, 32 bolts
and 18 mm root diameter () are selected from IS:4866-1968.
28
Corresponding actual bolt circle diameter
A b = d br 2 no. of bolts
4
A b = (18mm) 2 (32)
4
A b = 8143mm 2
Since A b > A m , therefore the selected bolts are suitable
W(C b - G)
M f =
2
(556670N)(860mm - 651mm)
M f =
2
M f = 58172015N - mm : flange moment
29
Gasket load under operating conditions
HG = W - H : where :
G 2 p
H=
4
2
(651mm) 2 (0.751 N mm )
H=
4
H = 249972 N
W = Wm2
H G = 281536 N - 249972 N
H G = 31564 N
Moment due to HG
MG = HGhG : where :
(C b - G)
hG =
2
(860mm - 651mm)
hG =
2
h G = 104.5 mm
M G = (31564 N)(104.5 mm)
M G = 3298438 N - mm
30
VI. THE PROPOSED DESIGN
31