PROJECT HEAT

EXCHANGER DESIGN
LUKMAN MARTINUS GUNAWAN GO
02111540000115
 PROBLEM

Design a shell-and-tube heat exchanger to be used as a crude oil

cooler. 120 kg/s of crude oil enters the shell side of the heat
exchanger at 102°C and leaves at 65°C. The coolant to be used is city
water entering the tube side at 21°C with a flow rate of 65 kg/s.
Shell-side pressure drop is limited to 150 kPa.
 Preliminary estimation of unit size
Size and Pipe Material :
-carbon steel ( k = 60 W/m.k ) 1 inch OD, 8 BWG tubes on a 1 in. square pitch, straight tubes (
25,4 mm OD & 17,2 mm ID ) and tube is squared pitch with PR = 1,25
Number of Tube passes : 1
Number of Shell passes : 1
Length of Tube = 2 m
CTP = 0,93 ( For 1 Tube Passes )
CL = 1 ( For Square Layout )
Baffle spacing ≈ 0,5 from shell diameter
Baffle cut = 25%
Counter flow
 Properties & assumption
Crude Oil ( At 357K ) • Water ( At 311 K ) • Oil ( At 60,78ºC ≈ 333,8 K )
- ρ = 786,4 kg/m3 - ρ = 995 kg/m3 - µw = 0,002 Pa.S
- µb = 0,00189 Pa.S - µb = 0,00072 Pa.S
- k = 0,122 W/m.k - k = 0,605 W/m.k
- Pr = 33,73
- Cp = 4,2 KJ/kg
- Cp = 2,1 KJ/kg
- Pr = 6,29
• We need to estimate heat transfer coefficient for both fluid :
- hw = 4500 W/m2.k
- ho = 1300 W/m2.k
• Assume F = 0,9 ( LMTD correction factor )
• Water Flow inside tube and Oil Flow on Shell
 Calculation FOR ESTIMATION OF UNIT
SIZE
1. T out cold (Water ) 4. Heat Load

From Q hot = Q cold

= 9324 kW
=

Tc2 = 55,15 ºC 5. Overall Heat Transfer Coefficient For clean

2. Log Mean Temperature Difference = 837,05 W/m2.k

= 45,41 ºC 6. Overall Heat Transfer Coefficient For fouling

3. Log Mean Temperature Difference = 684,29 W/m2.k

With Correction Factor

= 40,87 ºC
 7. Area
8. %Over Surface
For Fouling For Clean
= 122,3%
= 333,42 m2 = 272,57m2 (over surface 22,3%)

9. Shell Diameter ( Estimation )

10. Baffle Spacing
𝐵 = 0,4 𝐷𝑠
= 0,976 m
= 0,488 ≈ 0,5

11. Number Of Tubes

= 659
 Design Result
From Table 9.3 For 1-in. OD tubes on 1-1/4-in. Square From Table 9.3 For 1-in. OD tubes on 1-1/4-in.
pitch and From Estimated Ds = 38,47 inch and Nt = triangular pitch and From Estimated Ds = 34,45 inch
659 we can use : and Nt = 756 we can use :
Design : 1 Design : 2
Shell Diameter : 39 Inch = 0,991 m • Shell Diameter : 21¾ Inch = 0,552 m
Number of Tube Passes : 1 ( Max number of tube = 665) • Number of Tube Passes : 1 ( Max number of tube =
766 )
Number of Tube : 659
• Number of Tube : 756
Tube length : 6,2 m • Tube length : 5,4 m
Tube Diameter : OD = 25,4 mm & ID = 17,2 mm • Tube Diameter : OD = 25,4 mm & ID = 17,2 mm
Baffle Spacing : B = 0,5 m & Baffle cut 25% • Baffle Spacing : B = 0,5 m & Baffle cut 25%
Pitch ratio Pτ / do = 1,25 & square pitch • Pitch ratio Pτ / do = 1,25 & triangular pitch
Pτ = 0,02375 m • Pτ = 0,02375 m
 Calculation for RATING OF
PRELIMINARY DESIGN
For Shell :
For Tube : 6. Nusselt Number
1. Equivalent Diameter 5. Friction Factor
1. Area of Tube For Turbulent Flow

6. Nusselt Number For Laminar Flow

2. Surface Area
2. Velocity in tube

7. Inner Heat
Transfer Coefficient
3. Reynold Number
3. Mass Velocity 7. Outer Heat Transfer Coefficient
𝑁𝑢. 𝑘
ℎ𝑜 =
𝐷𝑒
4. Reynold Number 4. Friction Factor
 Calculation for RATING OF
PRELIMINARY DESIGN
1. Overall Heat Transfer Coefficient for Fouling 5. Length 6. Number Of Baffles

2. Overall Heat Transfer Coefficient for Clean 7. Pressure Drop

For Shell For Tube

3. %Over Surface
8. Work Pump

For Shell : For Tube :

4. Total Area For Fouling
 Result From RATING
DESIGN 1 DESIGN 2
Uf 647,42 W/m2.k Uf 636,74 W/m2.k
Af 352,41 m2 Af 358,32 m2
L 6,5 m L 5,4 m
Nb 11 Nb 10
∆P shell 130,65 kPa ∆P shell 119,352 kPa
∆P tube 14,51 kPa ∆P tube 10,796 kPa
W pump shell 24,92 Kw W pump shell 22,77 kW
W pump tube 1,18 kW W pump tube 0,881 kW
 Conlusion
Kesimpulan dari pengujian :
- L terkecil dari design ke 2 yaitu = 5,4 m
- Pressure Drop on Shell terkecil dari design 2 = 119,352 kPa ( Oil )
- Pressure Drop on Tube terkecil dari design 2 = 10,796 kPa ( Water )
Didapatkan L rating yang lebih besar dari L design ( 6,1 m & 5,4 m ) maka panjang heat exchanger
bertambah menjadi sepanjang L rating ( 6,5 m & 5,8 m )
Pressure Drop di oil dibawah batasnya yaitu 150 kPa
Design 1 dan Design 2 sama-sama memenuhi kriteria, design 2 mempunyai keunggulan di pressure drop
tube dan pressure drop shell lebih kecil dan Panjang Heat exchanger lebih pendek, dan design 1
mempunyai keunggulan di banyak pipa yang lebih sedikit.
 DESIGN
Oil in

Pipe detail

oil Out
Water in
Water Out

( satuan dalam mm )