Shell & Tube Heat Exchanger Designing: Process Equipment Design and Drawing (Che-609)

4 year B.
Tech 6th Semester Examination, 2019
Process Equipment
Design and Drawing
[ChE-609]
Shell & Tube Heat Exchanger
Designing
DESIGNED & COMPILED BY:

MAMPEE MUKHERJEE (T91/CE/166007)
SOMA KUNDU (T91/CE/166008)

SUROJIT MUKHOPADHYAY (T91/CE/166009)
ARNAB MITRA (T91/CE/166010)
SUPRIYA GORAI(T91/CE/166011)
TRISHA GHOSH (T91/CE/166012)
SAYAN JANA (T91/CE/166013)
PROCESS EQUIPMENT DESIGN AND DRAWING||Paper – CHE609||2019
Table of ContentsE&
Shell and Tube Hear Exchanger DesignPage 2

1 Design Problem: .................................................................................................................................. 2

2 Designing of the Internals: ................................................................................................................ 2
2.1 Calculation of LMTD: ............................................................................................................... 2
2.2 Heat Balance: ........................................................................................................................... 3
2.3 Calculation of Total Heat Transfer Area of the Exchanger: ......................................... 3
2.4 Tube Dimensions: ..................................................................................................................... 4
2.5 Selection of Tube Side and Shell Side Fluids: .................................................................... 4
2.6 Tube side calculations: ........................................................................................................... 4
2.7 Shell side calculations:............................................................................................................ 5
2.8 Calculation of Overall Heat Transfer Coefficient, Clean (UC): ................................... 6
2.9 Calculation of Dirt Factor (Rd): ............................................................................................. 6
2.10 Oversize % calculation: .......................................................................................................... 6
2.11 Checking of Overall Heat Transfer Coeffcient: ............................................................... 6
2.12 Calculation of Pressure Drops: ............................................................................................. 7
2.12.1 Shell side pressure drop calculation: .................................................................................. 7
2.12.2 Tube side pressure drop calculation: .................................................................................. 7
3 Mechanical Design .............................................................................................................................. 8
3.1 Available Data from Internal Calculations: ...................................................................... 8
3.2 Shell Thickness: .......................................................................................................................... 8
3.3 Head Cover: .............................................................................................................................. 9
3.4 Channel cover thickness: ...................................................................................................... 9
3.5 Tube sheet thickness: ............................................................................................................ 10
3.6 Nozzle Specifications: ........................................................................................................... 10
3.7 Design of Gaskets: ................................................................................................................. 11
3.8 Designing of Bolts: .................................................................................................................. 12
3.9 Flange Thickness: ................................................................................................................... 13
3.10 Design of Supports: ................................................................................................................ 14
3.11 Mechanical Design Summary: ........................................................................................... 14
4 Referrences: ....................................................................................................................................... 16
PROCESS EQUIPMENT DESIGN & DRAWING || PAPER – CHE 609 || 2018

1 Design Problem:
75,000 kgs/hr of a 30% K3PO4 solution having sp.gr 1.3 at 50⁰C is to be cooled from
60⁰C to 30⁰C using cold water available at 25⁰C.Design a suitable 1-2 shell and tube
heat exchanger.
2 Designing of the Internals:

Here, we have mostly followed the Kern Method for designing of the
internals of the concerned Shell and Tube Heat Exchanger.
2.1 Calculation of LMTD:

Temperature Profile:
Inlet Temperature of Water (T1) 77⁰F
Outlet Temperature of Water (T2) [assumed] 100⁰F
Inlet Temperature of K3PO4 solution(t1) 140⁰F
Outlet Temperature of K3PO4 solution(t2) 86⁰F
Log Mean Temperature Difference
(LMTD)(θm)=20.8⁰F
Capacity Ratio (R) = (T1 – T2)/(t2-t1) = 4.44
Temperature Ratio (S)= (t2 – t1)/( T1- t1) = 0.143
FT , LMTD Correction Factor = 0.975 [ Obtained from D.Q.Kern, pg – 828,
fig- 18 ]
As FT > 0.75, a 1-2 Shell and Tube Heat Exchanger should serve the
purpose.
True temperature difference,∆t= FT × LMTD = 20.28⁰F

2.2 Heat Balance:
 The heat duty equation for K3PO4, Q = mhCph∆th……………………….(1.1)

 Mass flow rate of hot fluid (mh) = 75000kg/hr
 Specific heat capacity of hot fluid (Cph) =0.757 Btu/lb⁰F
Putting the respective values in the above equation (1.1)
 Heat duty, Q = 306.58×104 Btu/hr
Again, the heat duty is given by ---
 Q = mh.Cph∆th = mc.Cpc∆tc
Where, mc = Mass flow rate of the cold fluid
Cpc= Specific Heat capacity of the cold fluid
Putting the respective Values, mc= 133.30×103 lb/ hr
2.3 Calculation of Total Heat Transfer Area of the

Exchanger:
Now from equation, Q =UD x A x t ………………….(1.2)

(A), total surface area needs to be calculated.
 Overall Heat Transfer Coefficient with Dirt Factor (UD) = 315
Btu/hr ft2⁰Fwhich includes a dirt factor of 0.003
{Data obtained from pg-840, Table 8, D.Q. Kern for Acetic acid-
Water system; after several trial and errors within the permissible
range, it has been found that this value fits appreciably}
Putting the respective values in appropriate units in
equation(1.2) we find A = 468.33 ft 2
Now,
Total Surface area (A) = No. of tubes × length of tubes × Surface area per lin ft ……….(1.3)

2.4 Tube Dimensions:
 Tubes selected: 16 BWG 1” (inch) OD tubes of Length 16 ft.

 Tube Side Pass : 2
 Shell Side Pass : 1
 Surface area per lin ft = 0.2618 ft / ft2 [ obtained from Table –
10, pg – 843, D.Q.Kern ]
Putting the respective values in equation (1.3)
 No. of tubes = 111
 For 2 Pass tube side using 1.25 inch square pitch , Shell
ID = 17.25 inch ( Table -9 Pg- 841, D.Q.Kern)
 The corresponding no. of tubes for the given Shell ID using 1.25
inch Square pitch is 112
( Table -9 Pg- 841, D.Q.Kern)
No. of Tubes considered: 112
2.5 Selection of Tube Side and Shell Side Fluids:
Sides Fluid Basis

Shell Side Water Cold fluid
Tube Side K3PO4 solution Hot fluid
** Argument established in NPTEL website
(https://nptel.ac.in/courses/103103027/pdf/mod1.pdf)
2.6 Tube side calculations:
a. Cross flow area of the tube side (at) = {(No. of Tubes × Flow area
per tube)/No. Of passes} = 0.231 ft2
b. Mass velocity = Gt = mc/at = 7.15×105 lb/ft2 hr
c. Reynold’s No. (Ret)= DiGt/µ = 17875 [ Di obtained from Table 10 Pg- 843 D.Q. Kern
d. Calculation of tube side heat transfer coefficient:

hi = jH( k/D)(cphµ/k)1/3Φt ………………….(1.4)

 Here Φt = 1 [ argument established in pg 11, D.Q.Kern]
 Thermal conductivity of the hot fluid k = 0.33 Btu/hr ft2⁰F
 Factor of Heat Transfer jH = 81 [ Fig. 24 Pg- 834 D.Q.Kern]
 Cph = 0.757 Btu/lb 0F
 D, {from Table 10, Kern} = 0.0725 ft
 Viscosity of the hot fluid (µ)= 1.164 lb / ft.hr [3]

Putting the respective values in the above equation,
Inner Heat Transfer Coefficient, hi = 693.3 BTU/hr
ft2⁰F
Therefore, hio = hi x (ID/OD) = 603.15 BTU/hr ft2 0F
2.7 Shell side calculations:
a. Equivalent Diameter De = ( PT2 – πd02/4)/πd0
Putting the respective values De = 0.0825 ft
b. Cross sectional Flow area, (as) = (PT – d0/PT)× Ds × Baffle

Spacing ………(1.5) Where PT is the Pitch length
d0 is the OD of the tube
 Baffle Spacing (B) a regulatory parameter is set 8 inch.
[after several trial & errors; the minimum value can be taken is
0.2*Ds , i.e, 3.45 inch]
Putting the respective values in equation (1.5) we get
as = 0.190ft2
c. Mass velocity Gs = mc/as = 701.57× 103 lb/ft2 hr

Reynold’s No. (Res) = DeGs/µ = 20308.6

d. Calculation of Shell side heat transfer coefficient:
ho = jH( k/De)(cpcµ/k)1/3Φs ………………….(1.6)

 Factor of Heat Transfer jH = 81[Fig. 24, Pg- 834, D.Q.Kern]
 Thermal Conductivity of cold fluid k = 0.356Btu/hr ft2⁰F
 µ= 1.918 lb / ft.hr [3]
 Here Φs = 1 [argument established in pg 111 D.Q.Kern]
Putting the respective values in equation (1.6) we find,
Outer heat transfer coefficient (h0) = 368.18 Btu/hr ft2 0F
2.8 Calculation of Overall Heat Transfer

Coefficient, Clean (UC):
UC = hihio/(hi + ho) ……………….. (1.7)

Putting the respective values in equation (1.7)
UC = 368.18 Btu/hr ft2 0F
2.9 Calculation of Dirt Factor (Rd):

Rd = (Uc – UD)/Uc.UD
Putting the respective values Rd = 4×10-4
 This is less than the included limit of 0.003 (during assumption), so the
heat exchanger is serviceable and maintenance against fouling is possible.
2.10 Oversize % calculation:
% Oversize = {(Aactual - Areqd)/Areqd} x 100 = 7.8 % , < 10%
Therefore, the design is suitable for intended heat transfer operation, [2]

2.11 Checking of Overall Heat Transfer Coeffcient:

𝑼𝑪−𝑼𝑫
As( 𝑼𝑪 × 100)=14.4%(<30%), therefore there is no need for further trial k errors.
2.12 Calculation of Pressure Drops:
2.12.1 Shell side pressure drop calculation:

 Re= 20308.6
 f = 0.0018 ft2/inch2[ obtained from Fig-29 D.Q.Kern ]
 Specific gravity (s) = 1[ internet sources [3] ]
 No. of crosses, N+1 = 12L/B
Putting the respective values in the above equation N+1 = 11
 N = 23, i.e, No. of baffles required = 10
 Baffle Specification: 25% cut-segmental baffle
 Expression for shell side pressure drop ∆PS = {fGs2
De(N+1)}/{(5.22×1010Des)}
Putting the respective values,
∆PS = 7.09 psi [< allowable limit of 10 psi]
2.12.2 Tube side pressure drop calculation:

 ReT = 17875
 f = 0.000123 ft2/inch2 [obtained from Fig-29 D.Q. Kern ]
 ∆Pt = fGt2Ln/(5.22×1010Ds)
Putting the respective values we get,
 (Tube side pressure drop) ∆Pt=0.76 psi

 (Return Pressure Drop) ∆Pr = 4nV2/2gs
 V2/2g = 0.23 [fig. 27 D.Q.KERN]
 ∆Pr = 0.024 psi
∆PT = ∆Pt + ∆Pr = 0.1 psi [< allowable limit of 10 psi]
ROCESS EQUIPMENT DESIGN & DRAWING || PAPER – CHE 609 || 2018

3 Mechanical Design
3.1 Available Data from Internal Calculations:
1 Shell side pass 1
2 Tube side pass 2
3 No. of tubes 112
4 Tube length 16’ (4.88 m)
5 Tube OD 1” (25.4 mm)
6 Tube BWG 16
7 Tube thickness 0.065” (1.7 mm)
8 Tube ID 0.870” (22.1 mm)
9 Pitch 1.25” (31.8 mm) Square-pitch
10 Shell ID (Ds) 17.25” (438 mm)
11 Type of head Tori spherical
12 Material of construction Carbon Steel
13 Corrosion allowance (c) 1.5 mm
14 Design temperature (60+6) =66⁰C
15 Design pressure (P) 73.8psi + 10% = 81.224psi (0.56N/mm 2)
16 Permissible Stress 100.6 N/mm2
17 Nominal Diameter 457 mm [IS: 2844 - 1964]
3.2 Shell Thickness:

The shell thickness (ts) can be calculated as:
𝑃𝐷𝑠
ts=(𝑓𝑗−0.6𝑃)+1.5………………………..(2.1)
=4.99mm =5mm
where, j = joint efficiency = 0.7 (ranges from 0.7 to 0.9)
Therefore, from equation (2.1) ts is found to be 5 mm
In accordance to IS: 4503, the value taken is: 8 mm

3.3 Head Cover:

Torispherical head is selected, as it is most widely used in chemical industries
for operating pressure upto 200 psi. The minimum thickness of the shell
cover(th,min) should be atleast equal to the thickness of the shell (ts) [IS: 4503].
The required thickness of torispherical head (th):
𝑃𝑅𝑖𝑊
th = +1.5
2𝑓𝑗−0.2𝑃
j=1 taken for head design
Ri = Crown radius = 438 mm (Ri = Ds is
considered)
ri = knucle radius = (0.06 x 438) = 26.28
mm
Inside depth of head (hi):
hi = 58.61 mm
Effective length of the exchanger = Leff = (Lt + 2 x hi) = 5 m
, therefore, W = 1.77
From equation (2.2) we get the required thickness (th) as 3.86 mm
Thickness of the Head taken is 8 mm (In accordance to IS: 4503)

3.4 Channel cover thickness:
Channel cover material: Carbon Steel
The effective channel cover thickness (tcc in mm) is calculated from the
formula (IS: 4503 section 15.6.1)

Dc = diameter of the cover (in mm), usually same as the Shell

OD = 454 mm C1 = 0.3, for bolting with ring type gaskets
P = design pressure in kgf/cm2 ; f = allowable stress in kgf/mm2
Therefore, tcc = 5.79 (including a corrosion allowance of 1.5 mm)
So, the Cover thickness taken as 8 mm (IS:4503)
3.5 Tube sheet thickness:

The tube sheet thickness is calculated based on the bending and considering the
design pressure only by the following equation [TEMA standard]. It is assumed the
shear does not control the design. Carbon steel is used for tube sheet material.
……….. (2.4)
F = 1 for fixed tube sheet ;GP=438mm
k = 0.5 for square-pitch From equation (2.4)
we get, tts = 15.4 mm
Therefore, the thickness of tube sheets is taken as 19 mm [satisfies IS:4503 for 1” OD tube]
3.6 Nozzle Specifications:

Material: Carbon Steel
Nozzle Thickness:
………. (2.5) ; tn = 1.804 mm
Nozzle thickness taken as per IS:4503 is 6 mm

Nozzle ID: It is taken as 3 inches (77 mm) as per the following table [IS:4503]

The pressure at the entry point of both tube side and shell side fluids are
same.Therefore, the same nozzle specification can be used for both the sides.
3.7 Design of Gaskets:

Material: Flat iron jacketed gasket, asbestos filled
………………….(2.6)
The Gasket Factor, m = 3.75, Y = minimum design seating stress = 5.35
kgf/mm2 [taken as per the following Table by BROWNELL & YOUNG]
Therefore, DOG / DIG = 1.099
Again, DIG = DS + 0.25 = 438.25 mm

Therefore, DOG ≈ 481.64 mm
Gasket Width (N) = (DOG - DIG)/2 = 5.87 mm ≈ 35 mm
Mean gasket diameter, G = (DOG + DIG)/2 ≈ 439.943 mm
Basic gasket seating width ( b0 ) = N/2 = 17.5 mm

DESIGN & DRAWING || PAPER – HE 609 || 2018
Effective gasket seating width, b = 0.5 x ( b0 )0.5 = 2.09 mm
3.8 Designing of Bolts:

Bolt Material: Carbon Steel
The minimum initial bolt load (Wm1) at atmospheric pressure and temperature is given
by: ………………. (2.7)
Therefore, Wm1 = 16156.82kgf=
153114 N
The bolt load under tight
pressure (Wm2),
………………… (2.8)
Therefore, Wm2 = 105731.15 N

As, Wm1 > Wm2, Wm1 is the controlling load.
The minimum bolt cross-sectional area (Am) is given by,

Am = Wm1 / fa (where fa = allowable bolt stress at ambient temp. = 100.6 N/mm2)
Or, Am = 1574.99 mm2

Bolt Specifications Selected --- as per IS: 4866-1968 , Table 1
Nominal Diameter: 457 mm [IS:4503 ]
Number Nominal Root Bolt circle Min. Vessel
of Bolts thread Diameter diameter (Cb). Thickness criteria
diameter (dbr), mm Mm (mm)
20 M16 18 510 6 (matched)
Corresponding actual bolt circle area, Ab = 0.25π x (dbr)2 x no. of bolts = 5089.38
mm2
As Ab > Am, the selected bolts are suitable.
The minimum gasket width, Nmin = (Ab fb / 2πYG) = 34.65 mm < 35 mm ( selected N)
3.9 Flange Thickness:

a. For gasket seating condition:
W = [(Ab+Am)/2] x fa = 335217.81 N
Flange moment, Mf0 = W(Cb - G)/2 = 8389663.75 N.mm
b. For operating condition:
HD = πB2P/4 = 90654.55 N
hD = (Cb-B)/2 = 28 mm
MD = HD x hD = 2538327.4 N.mm
HG = [Wm2 – (0.25πG2P)] =
4021.70 N
hG = (Cb-G)/2 = 50.055 mm
MG = HG x hG = 201306.194 N.mm
HT = H – HD = 2389.75 N
hT = (hD + hG)/2 =
39.0275 mm
MT = 93265.97 N.mm


Summation of moments under operating condition,

Mf = ( MD +MG + MT ) = 2832899.56 N.mm
As Mf0 > Mf, Mf0 is the controlling moment.
 Flange thickness (Carbon steel):

tf = (Mf0 x y / fa x B)0.5 (as K = A/B = 550/444 = 1.24, y ≈ 18, IS:4866-1968)
=57.5 mm
𝑨
K= =1.21
𝑩
3.10 Design of Supports:

Minimum of 2 Saddle supports (widely used in horizontal heat
exchanger units) are to be used [IS:4503].
3.11 Mechanical Design Summary:
CATEGORY SUBCATEGORY DIMENSIONS
Length of the Effective 5m

exchanger
Shell Material Carbon Steel

Thickness 6 mm
OD 450 mm
Head Cover Type Torispherical

Material Carbon Steel
Thickness 6 mm
Depth 58.7 mm
Tube Sheet Material Carbon Steel

Thickness 10 mm
Channel Cover Material Carbon Steel

Thickness 6 mm

Nozzles Thickness 6 mm
ID 77 mm
Gaskets Material Flat iron jacketed gasket,

asbestos filled
OD 450 mm
Width 35 mm
Mean Diameter 445 mm
Basic seating width 17.5 mm
Bolts Material Carbon Steel

Quantity 20 pcs.
Nominal thread M16
Diameter
Root diameter 18 mm
Bolt Circle diameter 510 mm
Flanges Material Carbon Steel

Thickness 66 mm
Support Type Saddle

Quantity 4 pcs. (min)
Width 330 mm
Height 173 mm

4 Referrences:
1. D. Q. Kern, Process Heat Transfer, McGraw-Hill Book Company, Int. ed. 1965.
2. NPTEL website (https://nptel.ac.in/courses/103103027/pdf/mod1.pdf),
accessed on 15th September, 2018
3. Engineering Toolbox, (2004). (https://www.engineeringtoolbox.com),
accessed on 15th September, 2018
4. Indian Standard (IS: 4503-1967): Specification for Shell and
Tube Type Heat Exchangers, BIS 2007, New Delhi.
5. Indian Standard {IS 4864 to 4870 (1968)}: Shell Flanges for Vessels and
Equipment [MED 17: Chemical Engineering Plants and Related Equipment]
(http://questin.org/sites/default/files/standards/is.4864-4870.1968_0.pdf)
6. R. K. Sinnott, Coulson & Richardson‟s Chemical Engineering: Chemical
Engineering Design (volume 6), Butterworth-Heinemann, 3rd ed. 1999.
7. Brownell L.E. and E.H. Young, Process Equipment Design, John
Wiley and Sons, Inc. 1959. New York.
8. Standards of the Tubular Exchanger Manufacturers Association
(TEMA), Inc. 18 ed., 1999, New York.

Shell & Tube Heat Exchanger Designing: Process Equipment Design and Drawing (Che-609)

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4 year B.

Tech 6th Semester Examination, 2019

DESIGNED & COMPILED BY:

SOMA KUNDU (T91/CE/166008)

Shell and Tube Hear Exchanger DesignPage 2

1 Design Problem: .................................................................................................................................. 2

PROCESS EQUIPMENT DESIGN & DRAWING || PAPER – CHE 609 || 2018

Shell and Tube Hear Exchanger DesignPage 3

2 Designing of the Internals:

2.1 Calculation of LMTD:

Log Mean Temperature Difference

Capacity Ratio (R) = (T1 – T2)/(t2-t1) = 4.44

Temperature Ratio (S)= (t2 – t1)/( T1- t1) = 0.143

FT , LMTD Correction Factor = 0.975 [ Obtained from D.Q.Kern, pg – 828,

True temperature difference,∆t= FT × LMTD = 20.28⁰F

Shell and Tube Hear Exchanger DesignPage 4

PROCESS EQUIPMENT DESIGN & DRAWING || PAPER – CHE 609 || 20

2.2 Heat Balance:

 The heat duty equation for K3PO4, Q = mhCph∆th……………………….(1.1)

Cpc= Specific Heat capacity of the cold fluid

Putting the respective Values, mc= 133.30×103 lb/ hr

2.3 Calculation of Total Heat Transfer Area of the

Now from equation, Q =UD x A x t ………………….(1.2)

Shell and Tube Hear Exchanger DesignPage 5

PROCESS EQUIPMENT DESIGN & DRAWING || PAPER – CHE 609 || 2018

2.4 Tube Dimensions:

 Tubes selected: 16 BWG 1” (inch) OD tubes of Length 16 ft.

No. of Tubes considered: 112

2.5 Selection of Tube Side and Shell Side Fluids:

Sides Fluid Basis

2.6 Tube side calculations:

Shell and Tube Hear Exchanger DesignPage 6

PROCESS EQUIPMENT DESIGN & DRAWING || PAPER – CHE 609 || 2018

hi = jH( k/D)(cphµ/k)1/3Φt ………………….(1.4)

 Viscosity of the hot fluid (µ)= 1.164 lb / ft.hr [3]

Inner Heat Transfer Coefficient, hi = 693.3 BTU/hr

Therefore, hio = hi x (ID/OD) = 603.15 BTU/hr ft2 0F

2.7 Shell side calculations:

a. Equivalent Diameter De = ( PT2 – πd02/4)/πd0

Putting the respective values De = 0.0825 ft

b. Cross sectional Flow area, (as) = (PT – d0/PT)× Ds × Baffle

c. Mass velocity Gs = mc/as = 701.57× 103 lb/ft2 hr

Shell and Tube Hear Exchanger DesignPage 7

d. Calculation of Shell side heat transfer coefficient:

ho = jH( k/De)(cpcµ/k)1/3Φs ………………….(1.6)

2.8 Calculation of Overall Heat Transfer

UC = hihio/(hi + ho) ……………….. (1.7)

UC = 368.18 Btu/hr ft2 0F

2.9 Calculation of Dirt Factor (Rd):

2.10 Oversize % calculation:

% Oversize = {(Aactual - Areqd)/Areqd} x 100 = 7.8 % , < 10%

Shell and Tube Hear Exchanger DesignPage 8

2.11 Checking of Overall Heat Transfer Coeffcient:

2.12 Calculation of Pressure Drops:

2.12.1 Shell side pressure drop calculation:

2.12.2 Tube side pressure drop calculation:

Putting the respective values we get,

 (Tube side pressure drop) ∆Pt=0.76 psi

ROCESS EQUIPMENT DESIGN & DRAWING || PAPER – CHE 609 || 2018

Shell and Tube Hear Exchanger DesignPage 9

3.2 Shell Thickness:

Therefore, from equation (2.1) ts is found to be 5 mm

In accordance to IS: 4503, the value taken is: 8 mm