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ABSORBER
PROCESS DESIGN OF ABSORBER:
BASIS:
1 HOUR OF OPERATION
COMPOSITION OF THE INCOMING GAS:
COMPONENT
AMOUNT IN KMOLES
N2
SO3
SO2
O2
TOTAL
3298.32
403.732
13.777
257.395
3973.23
MOLE FRACTION
0.8301
0.1016
0.00346
0.06478
1.0
=110 C
Sulfur Trioxide is absorbed in 98% sulphuric acid and the gases after absorption are
returned back to the converter. The exit concentration of the acid is assumed to be 103%
(3% free oleum)
Assuming negligible absorption of the other gases and at the average temperature of the
= 158.014
SO3to be absorbed
= 403.732 - 158.014
= 245.718 Kmoles
= 19657.5 Kgs
= 110.98 Kmoles
= 110.98 Kmoles
= 10876.04 Kgs
Free SO3with it
Total SO 3absorbed by water
= 326.3
= 110.98 x 80 + 326.3
= 9204.7 Kgs
= 19657.5 9204.7
= 10452.8 Kgs
= 0.03 x 1.0889 W
= 0.03267 W
= (1.0889 + 0.03267) W
= 1.12157 W
= 1.12157 W W
= 0.12157 W
Total Weight
Kgs of SO3absorbed by W Kgs
Now,
For 0.12157 W
then, For W
= 10452.8 Kgs
= 85982 Kgs acid / Hr
= 23.88 Kgs/s
DIAMETER CALCULATION:
Adopting the methodology as given inRICHARDSON AND COULSON,VOLUME 6 ,
First we calculate,
0.5
> / * @ [ ^! G ! L) }
= 0.0155
In the Literature given by RICHARDSON & COULSON, Pg 544
0.5
Lets choose the following packing, as given in RICHARDSON & COULSON, Pg 533
Material
= 3 Ceramic, Raschig Rings
Nominal Size
= 76 mm
3
Bulk Density
= 561 Kg/m
2
3
Surface Area
= 69 m /m
-1
Packing Factor
= 65 m
Voidage
= 75%
Then,
*
-0.1 0.5
G
= [ {K4 [ ! G ! L ! G )} / {13.1 x Fp [ ! L L) }]
-3
0.1 0. 5
= [ {6.1 x 1.0711 ( 1850 - 1.0711 )} / {13.1 x 65 x (6 x 10 / 1850) }]
2
= 7.08 Kg/m -s
Designing for a Pressure Drop of 42 mm water per m of packing, we have
K4
= 1.9
% Loading
= {1.9 / 6.1}
= 56 %
Then,
And,
G
0.5
x 100%
= 3.95 Kg/m -s
= 23.88 Kgs/s
3
= 1850 Kg/m
= 37.08 Kgs/s
3
= 1.0711 Kgs/m
= 3.57 m/s
= 3.57 / 0.75
= 4.76 m/s
= 23.88 / 9.38
2
= 2.54 Kgs/m -s
Given that,
Surface Area of Packing
Liquid Density
= 69 m /m
3
= 1850 Kg/m
Then,
Wetting Rate
The Above wetting rate is greater than the required minimum limit and this is adequate
for wetting the packing.
The Methodology adopted for the calculation of Height of the Packing is referred from
the literature by NORMAN W.S (ABSORPTION, DISTILLATION AND COOLING
TOWERS), Pg 214.
The Average Properties of the gas at the temperature are given as follows,
= 1.0711 Kg/m
'HQVLW\RIWKHJDVPL[WXUH
! G)
-5
= 2.772 x 10
9LVFRVLW\RIWKHJDVPL[WXUH
mix)
-6
= 8.2 x 10 m /s
mix> ! G) x (D)]
-5
-6
= 2.772 x 10 / [1.0711 x 8.2 x 10 ]
= 3.15
>!G x d x V P@ mix)
-5
= [1.0711 x 4.76 x 0.0253] / (2.772 x10 )
= 4654
Cited in the Reference
NORMAN W.S (ABSORPTION, DISTILLATION AND
COOLING TOWERS), Pg 212, the co-relation is,
kGx(RT/ V ) Px (P/p
BM[^
mix>
! G x D]}
0.5
= [^>
! G x d x V P@
mix)}
-0.25
Now,
With (P/pBM) =1(approx), we have,
kG
-0.25
= [ 0.04 x (4654)
x (3.15)
2
= 0.316 lb mole / hr-ft -atm
-0. 5
Area of Packing
= 69 x 9.38
= 647.22
Height of Packing Required = 5140 / 647.22
= 7.94 m
Therefore the height of the packing required is 8m
= 3.45 m
= 8m
= 2m
3
= 7700 Kg/m
2
= 130 Kg/m
MATERIAL :
Carbon Steel
2
Permissible tensile stress ( f)= 950kg/cm
THICKNESS OF SHELL:
Thickness of shell, ts
Where,
Inner Diameter of vessel, Di
Working Pressure
Design Pressure, p
Permissible Stress
Joint Efficiency(J)
Corrosion allowance
= [p D / (2f J p)] + c
= 3.45 m
5
2
= 1.013 x10 N/m
5
= 1.05 x 1.013 x10 N/m
2
= 0.10635 N/mm
2
= 95 N/mm
= 0.85
= 3mm
Hence,
ts=2.25 mm
We take thickness as 8mm
So outer diameter of shell Do = 3.45 m + 2 x 0.008m = 3.466 m
STRESS ANALYSIS AND SHELL THICKNESS AT DIFFERENT HEIGHTS:
Let X be the distance in m from the top of the shell, then
1.
2.
= p Di / 4 ( ts c )
2
= 184 Kg/cm
= Di + 2 t s
= 3.466 m
3
= Asbestos
= 100 mm
3
= 575 Kg/m
Let,
Dins
Dm
= Diameter of insulation,
= Mean diameter of vessel
And,
For large diameter column,
Dins = Dm
fdins
= 1850 Kg/m
2
= [ ( /4 ) Di X l ]/ Dm ( t s c )
6
2
= 3.19 x10 N/m
2
= 31.9 Kg/cm
e)
fw
Permissible Stress
And,
= 95 N/mm
ftmax
=0
=0
Total weight
Diameter of Skirt
Considering the height of Skirt is 8m
2
Wind Pressure is 1285 N/m
Stress due to Dead Weight
Thickness of the skirt support is tsk
Stress due to dead load
fd= Total Weight / Dst sk
= 9.302 x 10 5 N/m2
2
2
= (/4) ( D o Di) x H x s x 9.81 +
2
( /4) Di x H x l x 0.6 +
2
( /4) Di x H x p + 35000N + 1600 x H
= 1.422 x10 7 N
= 3.45 m
plw = k p1h D
1 o
puw = k p2h D
2 o
Where K is coefficient depending on the shape factor.
k=0.7 for cylindrical surface
p1is wind pressure for the lower part of the vessel.
p2is wind pressure for the upper part of the vessel
p1= 700 N /m2
p2= 2000 N /m2
h1=20m
h2=14 m
plw = k p1h D
1 o
= 47686.8
puw = k p2h D
2 o
= 149872.8
Bending moment due to wind at the base of the vessel is determined by
Mw =plw (h1/2) + p uw ( h1+ h /2)
2
=4.09 x 10 6 Nm
fwb = 4 x Mw / Dot sk
=10.71 x10 7 /t sk
Stress due to Seismic Load
Load F= CW
W is total Weight of vessel
C is Seismic Coefficient
C=0.08
2
fsb = ( 2/3)[ CWH/ Rok tsk]
Where,
Rok is radius of skirt
= 4.159 x 10 6 /t sk N/m2
Maximum Stress at bottom of Skirt
ftmax = ( fwb or fsb ) fdb
2
= (3.229 x 10 6 / t sk ) N / m
2
HEAT EXCHANGER
PROCESS DESIGN OF HEAT EXCHANGER:
BASIS:
1 HOUR OF OPERATION
GIVEN:
THE FLUIDS ARE:
WATER:
INLET TEMPERATURE
= 25 C
OUTLET TEMPERATURE = 40 C
SULFURIC ACID:
INLET TEMPERATURE
= 112 C
OUTLET TEMPERATURE = 30 C
The Sulfuric acid coming out from the absorption towers are cooled from a high
temperature to a lower temperature in a Shell and Tube Type Heat Exchanger. Water
which enters the Heat Exchanger at room temperature is heated to 40 C and comes out of
the system.
BULK TEMPERATURE OF THE ACID
= (30 + 112)/2
= 71.0 C
NUMERICAL VALUE
32.5 C
3
994.86 Kg/m
4.184 KJ/Kg-K
0.623 W/m-K
0.8 Centipoise
NUMERICAL VALUE
71 C
3
1850 Kg/m
1.4435 KJ/Kg-K
0.655 W/m-K
6.83 Centipoise
1.
HEAT LOAD:
HEAT INPUT = HEAT OUTPUT
mh
= 48572 Kg/Hr
= 13.49 Kg/s
Q = mhx C Ph [ > 7@
h
3
= 13.49 x 1.4435 x 10 x (112 - 30)
6
= 1.596 x 10 J/s
Q = 1596.7 x 10 3J/s
Overall Heat Balance gives,
mwx 4187 x 15 = 1596.7 x 10
mw = 25.42 Kg/s
2.
LMTD:
ACID
112.0
30.0
TEMPERATURES
TEMPERATURES
72 C
5 C
WATER
40
25
3.
ROUTING:
Shell Side
Tube Side
4.
= Sulfuric Acid
= Cooling Water
DETERMINATION OF AREA:
2
CHOICE OF TUBES:
From the tubing characteristics as given in PERRY,
We choose the following dimensions of the tube,
1 inch Outer Diameter tubes with 1.25 inch Triangular Pitch,16BWG
Do
Di
P
= 1.0 inch
= 25.4 mm
= 0.87 inch
= 22.1 mm
= 31.75 mm
7.
Corrected HT Area
[[[ 2
= 119.69 m
Corrected U oc
= 637.07 W/m -K
>[ Gi x Nt ] / [ 4 x N P]
= 0.024 m
Gst
= 25.42 / 0.024
2
= 1059.16 Kg/m -s
Mass velocity
P > ! [ Dt ]
= 1059.16 / 994.865
= 1.06 m/s
= [Gst x d i @
-3
-3
= [1059.16 x 22.1 x 10 ] / 0.8 x 10
= 29260
Prandtl Number, N Pr
= 5.37
(hi d i/ k)
where,
jH
Then,
= jH x (NRe) x (NPr)
(hi d i/ k)
= 184.45
2
= 5199 W/m K
hi
8.
(1/3)
= 0.0036
L =6m
Ls = 0.266 x Ds
= 168.9 mm
= 6 / Ls
Nb+1
Nb
= 35
Sm
= [ Ls(P - D )o D ]s / P
= [(0.03175 0.0254) x 0.1689 x 0.635 / 0.03175
2
= 0.02145 m
vs
= mh/ (S m [ ! h)
= {48572/3600} / (0.02145 x 1850)
= 0.340 m/s
The above value of velocity is also in the range of 0.3 to 1m/s, so this is also
acceptable.
Equivalent Diameter, de
NRe
= [de *@
-3
-3
= [ 629 x 18.04 x 10 ] / 6.83 x 10
= 1661
NPr
= 42.9
w)
0.14
ho
[ 1 / U o] =
(1/3)
= jH (NRe) (NPr)
= 103.65
= 3763 W/m K
Taking,
[ 1 / hod ]
[ 1 / hid ]
= 1 / 3000 (m -K)/W
2
= 1 / 5000 (m -K)/W
-3
[ 1 / U o]
= 1.083 x 10 (m -K)/W
Uo
Note: As this value of Uois greater than the corrected value of U , ocso the design
with the above specifications is accepted.
9.
= 0.079 x (NRe)
= 0.00604
3L
= [(4fLVt [ ! f ] / {2 x Di }
2
= 3666 N/m
3t
[> ! f x V t / 2]
2
= 1397 N/m
3T
= Np 3L 3t)
2
= 20252 N/m
= 20.25 KPa
Note: As the value of the pressure drop is less than 70KPa, the design is
acceptable from the tube side pressure drop consideration.
For Shell Side,
Pressure Drop in the Cross Flow section is calculated by,
3c
= [{b x f K x W x N c `
! f x S m @[^
b}
0.14
KN/m
NRe
= 1668
-3
b
= 2 x 10
fK
= 0.25
3
! h ! f) = 1850 Kg/m
mh(W) = 13.49 Kg/s
Nc
= [ Ds( 1 2 {L /D
c }
s ) / P ]p
= 635 x (1-2 x 0.25) / 22
= 14.43
= 14.5
3c
-3
KN/m
3e
3c ( 1 + {N cw / Nc} )
Ncw
= 0.8 lc/ P p
= [0.8 x 0.25 x 635] / 22
=6
3e
= 1.55 [1 + ( 6 / 14.5 )]
= 2.191 KPa
KN/m
3w
= [ b x W x ( 2 + 0.6 N
b
Sw
= 5 x 10
= Swg - Swt
-4
cw
) / { Sm x S w [ ! f }]
KN/m
= 100 inch
2
= 0.0645 m
= ( Nt / 8 ) x ( 1 F c [ [ '
2
o
= 0.65
= (250 / 8) x ( 1 0.6[
2
= 0.0222 m
Sw
= Swg - Swt
= 0.0645 0.0222
2
= 0.0423 m
3w
-4
Therefore the total Pressure Drop on the shell side is calculated by the following
relation
3s (TOTAL)
[ 3e + (Nb [ 3c + Nb [ 3w
= 2 x 2.191 + 35 x 1.55 + 36 x 0.303
= 69 KPa
As this value of Pressure Drop on the shell side is less than the 70 KPa, the design
is acceptable from the Pressure Drop Point of View.
Thus, the design is acceptable from process design consideration.
SUMMARY OF PROCESS DESIGN FOR HEAT EXCHANGER
Mass flow rate of acid
Mass flow rate of water
Shell outer diameter
Number of tubes
Tube OD
Pitch (Triangular)
Tube length
Shell side pressure drop
Tube side pressure drop
Heat Exchanger type
= 13.49 Kg/s
= 25.42 Kg/s
= 635 mm
= 250
= 1 inch
= 1.25 inch
=6m
= 69 KPa
= 20 KPa
= TEMA P or S type 1-4 Heat Exchanger
= 1 atm
= 110 C
= 1.1 atm
= 250
= 635 mm
The entire mechanical design is referred from the literature in PROCESS EQUIPMENT
DESIGN by M.V JOSHI.
1.
SHELL THICKNESS
Material: IS 2825-1969 Grade I plain Carbon steel.
Shell thickness , (t S)
From the Table 9.2, its found that minimum shell thickness when severe
conditions are not expected is 8mm, which includes the Corrosion Allowance.
2.
NOZZLES
Take inlet and outlet nozzles as 100mm diameter.
Vent nozzle
Drain nozzle
Relief Valve
Nozzle thickness
= 25mm diameter
= 25mm diameter
= 50 mm diameter.
= [ P x D i] / { 2 f J - P }
= 0.68 mm
Minimum nozzle thickness is 6mm and 8mm is choosen which includes the
corrosion allowance.
Also only the inlet and outlet nozzles need compensation. The compensation
required is minimum and is given by pads of 10mm thickness.
3.
HEAD
Torispherical heads are taken for both ends.
Rc(Crown radius)
= 635 mm
= 63.5 mm
= [ P x R cx W ] / { 2 f J }
W
= (1/4) x [ 3 + (R c/ R )nk
= 1.54
0.5
= [ P x R cx W ] / { 2 f J }
= 6.66 mm
TRANSVERSE BAFFLES
Number of Baffles
= 35
Baffle cut = 25%
Baffle thickness = 6mm (standard)
5.
6.
FLANGE DESIGN
Flange is ring type with plain face.
Flange material: IS 2004-1962 Class 2 Carbon Steel
Bolting steel: 5% Chromium, Molybdenum Steel
Gasket Material: Asbestos
Shell OD
Shell Thickness
Shell ID
= 0.635 m
= 0.008 m (g)
= 0.627 m
2
= 52.386 N/mm
= 3.75
Inner Diameter
= 650 mm
Mean Gasket Diameter, G
= 665 mm
Minimum gasket width,
Choose N
= 30 mm.
Basic gasket seating width, bo= 30/2
= 15 mm
Effective Gasket Seating Width, b
= 2.5 x [b o]
= 9.7 mm
0.5
=W/S
= G / [box 2.5]
= 665 / [15 x 2.5]
= 18 bolts
1/2
= [(Am1 / Number of bolts ) x ( 4 / ) ]
= 24 mm
FLANGE THICKNESS
Thickness of flange , tf
= [G(p/Kf) ] + C
Where,
C is the Corrosion allowance
hG is radial distance from gasket load reaction to bolt circle
2
Hydrostatic end force, H
= ( /4) G p
= 38.69 KN
K
=1/[ 0.3 + {( 1.5 W m hG) / (H x G)}]
hG
= (B G )/2
Where,
B
Then,
hG
K
= [G(p/Kf) ] + C
= 35.8 + C
= 38 mm
Hence the thickness of flange = 38 mm
tf
TUBE SIDE
Material:Stainless steel ( IS- grade 10)
Thickness of tube = t f= {P x D }o / ( 2 f J + P)
Where,
Working pressure
= 12 N/mm
2
Design pressure, P
= 14 N/mm
2
Permissible Stress, f = 100.6 N/mm
Joint Efficiency, J
=1
Thickness of tube
= 1.65 mm
Use tube with thickness of 2mm
No Corrosion allowance, since the tubes are of stainless steel.
1.
TUBE SHEET
The tube sheet is held between shell flange and the channel. The joint on the shell
flange side is of male and female facing and on the channel side of ring facing,
since the pressure on the channel
Thickness of Tube Sheet , tts
= FG[(0.25 P)/f]
Where,
F
Thickness of tube sheet
2.
= 1.25
= 155 mm
= 95 N/mm
GASKET SIZE
Width of ring gasket, N
= 30 mm
= 5.5
2
= 126.6 N / mm
=N/8
= 30 / 8
= 3.75 mm
= bo
= 665 mm
Under atmospheric conditions, the bolt load due to gasket reaction is given by
Wm1
= b G Ya
= 991.8 KN
After the internal pressure is applied, the gasket which is compressed earlier, is
released to some extent and the bolt load is given by
Wm2
2
= x 2 b x G x m x P + ( / 4 )G P
= 6069 KN
= 140.6 N/mm
= area of bolt
= Wm1 / fa
2
= 7075 mm
= Wm2 / fb
2
= 43165 mm
To determine the size of bolts , the larger of above two areas should be considered
Diameter of bolts,Db
5.
1/2
= [( A m2 / Number of bolts ) x ( 4 / )]
= 46 mm
THICKNESS OF NOZZLE
Considering inlet and outlet diameter to be 100mm, then thickness of the nozzle is
given by,
Thickness of nozzle, tn
Permissible stress, f
Joint Efficiency, J
Then,
Thickness of nozzles
6.
= (P x D )n / [2 x f J P]
2
= 95 N/ mm
= 0.85
=10 mm
FLANGE THICKNESS:
Flange material: IS 2004-1962 Class 2 Carbon Steel
Thickness of the Flange , tf = [G(P/Kf) ] + C
Where,
C is the Corrosion allowance
2
Allowable stress for flange material, f = 100 N/mm
hG is radial distance from gasket load reaction to bolt circle
2
Hydrostatic end force, H
= ( /4) G P
= 4863 KN
K
=1/[ 0.3 + {( 1.5 W m hG) / (H x G)}]
hG
= (B G )/2
Where,
B
= Outside diameter of Gasket + 2xDiameter of Bolt +12mm
= 680 + 2 x 46 + 12
= 784 mm
Then,
hG
K
Then,
tf
= (B G )/2
= 60 mm
= 1/[ 0.3 + {( 1.5 W m2 hG) / (H x G)}]
= 2.1326
= [G(P/Kf) ] + C
= 170 + C
= 175 mm
= 6000 mm
= 635 mm
= 643 mm
= 8 mm
= 25.4 mm
= 250
Density of Steel,s
'HQVLW\RI/LTXLGLQWXEHV
!l
= 7850 Kg /m
3
= 1000 Kg /m
= ( / 4) ( D o2 Di2 ) x L
3
= 0.0482 m
= V x s
= 379 Kgs
Volume of Tubes, V t
2
2
= ( / 4 ) ( d o di ) x L x N t
= 0.185 m3
= V tx s
= 1453 Kgs
Volume of Head, V h
= 0.087 D i
3
= 0.022 m
Weight of Head, Wh
= Vhx s
= 173 Kgs
Weight of Liquid, Wl
2
= ( / 4) (d i) x L x N x l
= 577 Kgs
Total Weight, W
= Ws+ W t+ W +
h W
= 2582 Kgs
Depth of head,
H
Q
1.
= 25.82 KN
= 250 mm
= (W/2)
= 12.91 KN-m
Now, we calculate,
Distance of saddle center line from shell end ,
A
= 0.4 x Ri
= 0.4 x (635/2)
= 127 mm
LONGITUDINAL BENDING MOMENTS
Radius,
Depth of head,
R
H
= 0.317 m
= 0.250 m
k1
k2
Thickness of shell, t
f1
For
f2
3.
=120
= 0.107
= 0.192
= 8 mm
2
= M1/( k 1R t)
3
2
= 297 x 10 N/m
2
= M1/( k 2 R t)
3
= 165.2 x 10 N/m
2
= M2/( R t )
6
=6.63 x 10 N/m
= (P x D i)/ (4 t)
6
2
= 2.262 x 10 N/m
All combined stresses ( f p + f 1 ) , ( f +p f 2 ) , and ( f p + f 3 ) are well within
allowable limits. Hence, the given parameters can be considered for design.
Thus a shell and tube Heat Exchanger with the above specifications is designed.
COOLER
PROCESS DESIGN OF COOLER:
BASIS:
1 HOUR OF OPERATION
GIVEN:
THE FLUIDS ARE:
WATER:
INLET TEMPERATURE
= 25 C
OUTLET TEMPERATURE = 40 C
PROCESS GAS:
INLET TEMPERATURE
= 202.41 C
= (202.41 + 110)/2
= 156.20 C
NUMERICAL VALUE
32.5 C
3
994.86 Kg/m
4.187 KJ/Kg-K
0.623 W/m-K
0.8 Centipoise
For the gas mixture, the only known property is its specific heat and other properties of
the gas mixture are predicted using the Transport Phenomena considerations. The
properties which have to be predicted are namely viscosity and thermal conductivity.
= 1.041 KJ/Kg-K
Pg
we have the
N2
O2
SO2
SO3
Bulk temperature
Pressure
1.
2.
3.
4.
c
CRITICAL
TEMPERATURE(K)
126.2
154.4
430.7
490.8
CRITICAL
PRESSURE(ATM)
33.5
49.7
77.8
83.6
= 154.29 + 273
= 427.29 K
= 2.13 atm
COMPONENT
N2
O2
SO2
SO3
T R (K)
3.380
2.760
0.990
0.870
PR(ATM)
0.06358
0.04285
0.02730
0.02550
COMPONENT
N2
O2
SO2
SO3
COMPONENT
(poise)
1.6
1.2
0.45
0.38
MOLE
FRACTION
c (poise)
-6
1.89 x 10
-6
254.2 x 10
-6
408.5 x10
-6
468.8 x 10
SRLVH
-4
3.024 x 10
-4
3.0504 x 10
-4
1.8380 x10
-4
1.7810 x 10
MOLECULAR
WEIGHT
SRLVH
1.
2.
3.
4.
N2
O2
SO2
SO3
0.8301
0.0647
0.0034
0.1016
-4
28
32
64
80
3.024 x 10
-4
3.0504 x 10
-4
1.8380 x10
-4
1.7810 x 10
(Mi / M j)
1
2
3
4
1.000
0.875
0.437
0.350
1.000
0.990
1.640
1.690
1.000
1.062
1.954
2.202
1
2
3
4
1.142
1.000
0.500
0.400
1.008
1.000
1.659
1.710
0.938
1.000
1.850
2.089
1
2
3
4
2.285
2.000
1.000
0.800
0.607
0.602
1.000
1.032
0.521
0.557
1.000
1.134
1
2
3
4
2.857
2.500
1.250
1.000
0.588
0.583
0.968
1.000
0.455
0.488
0.878
1.000
ij
[ j ij)
1.129
1.0625
0.5871
0.5142
= (1/[>0
/ Mj )
-0.5
@[>
0.5
x (Mj / M i)
0.25
>[ i i
[ j ij) ]
-4
= [{0.8301 x 3.024 x 10 -4}/1.129] + [{0.06479 x 3.0504 x 10 }/1.0625]
-4
-4
+ [{0.003467 x 1.838 x 10 }/0.5871] + [{.1016 x 1.781 x 10 }/0.5142]
= 2.772 x 10 -4 g-cm-1-s -1
-5
= 2.772 x 10 Kg/ms
Pr
0.0635
0.4285
0.0273
0.0255
Tr
3.380
2.760
0.990
0.870
Kc
-4
1.024 x 10
-5
9.459 x 10
-5
3.893 x 10
-5
4.025 x 10
Kr
1
0.78
0.33
0.28
K
-4
1.024 x 10
-5
7.370 x 10
-5
1.284 x 10
-5
1.127 x 10
= [ CP 50@[
1.
>[ i Ki
[ j ij) ]
-4
-5
= [{0.8301 x 1.024 x 10 }/1.129] + [{0.06479 x 7.370 x 10 /1.0625]
-5
-5
+ [{0.003467 x 1.285 x 10 }/0.5871] + [{.1016 x 1.127 x 10 }/0.5142]
-5
= 8.21 x 10 Cal / s-cm-K
-4
= 344.8 x 10 J/s-m-K
HEAT LOAD:
With,
mg = 131518.5 Kg/Hr
= 36.5 Kg/s
Q = mgx C Pg [ > 7@
gas
3
= 131518 x 1.041 x 10 x (202.41 110)
9
= 12.65 x 10 J/Hr
6
= 3.514 x 10 J/s
As the values of Mass Flow Rate (m )g and Heat Load (Q) are on higher side, we
split the entire flow rate into 4 equal parts so that we have 4 equal area heat
exchangers operating in parallel and which are handling equal heat load.
So, we have
mg = 9.13 Kg/s
3
Q = 878.5 x 10 J/s
Overall Heat Balance gives,
3
mwx 4187 x 15 = 878.5 x 10
mw = 13.98 Kg/s
2.
LMTD:
TEMPERATURES
GAS MIXTURE
202.41
WATER
40
162.4 C
TEMPERATURES
110.0
25
85 C
ROUTING:
Shell Side
Tube Side
4.
= Process Gas
= Cooling Water
DETERMINATION OF AREA:
2
CHOICE OF TUBES:
From the tubing characteristics as given in PERRY,
We choose the following dimensions of the tube,
0.75 inch Outer Diameter tubes with 1 inch Triangular Pitch
Do
Di
P
= 0.75 inch
= 0.01905m
= 0.62 inch
= 0.01575m
= 0.0254m
7.
External Area
Corrected HT Area
= 0.0598 m /m length
= 0.0598 x (2 0.05) x 320
2
= 37.31 m
Corrected U oc
P > ! [ Dt ]
= 13.98 / [ 994.86 x 0.01039 ]
= 1.3524 m/s
Prandtl Number, N Pr
= 5.37
0.8
(hi d i/ k)
hi
8.
>[ Gi x Nt ] / [ 4 x N P]
2
= 0.01039 m
(1/3)
L
Nb
= 2m
=1
Nb+1 = L / L
Ls = 1
Sm
= [ Ls(P - D )o D ]s / P
= [(0.0254 0.01905) x 0.540] / 0.0254
2
= 0.135 m
G=W/S s m
= 9.13 / 0.135
2
= 67.64 Kg/m -s
!s
= PM / RT
= (2.13 x 33.6) / (0.082 x 429)
3
= 2.044 Kg/m
-3
NRe
'*
-5
= [ 0.01905 x 67.64 ] / 2.772 x 10
= 46484
NPr
= 0.8368
= j (N Re) (NPr)
= 175.1
2
ho
[ 1 / U o] =
(1/3)
= 316.7 W/m K
[ 1 / ho] + [ D /o D ]i [ 1 / h ] i+ [D x oln {D /Do } /i (2K )] w
+ [ 1 / hod ] + [ Do/ D i] [ 1 / h ]id
Taking,
[ 1 / hod ]
[ 1 / hid ]
= 1 / 3000 (m -K)/W
2
= 1 / 5000 (m -K)/W
-3
[ 1 / U o]
= 3.99 x 10 (m -K)/W
Uo
Note: As this value of Uois greater than the corrected value of U , ocso the design
with the above specifications is accepted.
9.
= 0.079 x (NRe)
-3
= 6.193 x 10
3L
= [(4fLVt [ ! f ] / {2 x Di }
2
= 2851.08 N/m
3t
[> ! f x V t / 2]
2
= 2266.06 N/m
3T
= Np 3L 3t)
2
= 30702.8 N/m
= 30.7 KPa
Note: As the value of the pressure drop is less than 70KPa, the design is
acceptable from the tube side pressure drop consideration.
For Shell Side,
Pressure Drop in the Cross Flow section is calculated by,
3c
= [{b x f K x W x N c `
! f x S m @[^
b}
0.14
KN/m
NRe
= 46484
-3
b
= 2 x 10
fK
= 0.12
3
)
v
f
! ! = 2.044 Kg/m
mg(W) = 9.13 Kg/s
Nc
= [ Ds( 1 2 {L /D
c }
s ) / P ]p
= 540 x (1-2 x 0.25) / 22
= 12.27
3c
-3
KN/m
3e
3c ( 1 + {N cw / Nc} )
Ncw
= 0.8 lc/ P p
= [0.8 x 0.25 x 540] / 22
=5
3e
= 6.6 [1 + ( 5 / 12.27 )]
= 9.28 KPa
KN/m
3w
= [ b x W x ( 2 + 0.6 N
b
Sw
= 5 x 10
= Swg - Swt
-4
cw
) / { Sm x S w [ ! f }]
KN/m
= 75 inch
2
= 0.04838 m
= ( Nt / 8 ) x ( 1 F c [ [ '
2
o
= 0.65
= (320 / 8) x ( 1 [
2
= 0.01596 m
Sw
= Swg - Swt
= 0.04838 0.01596
2
= 0.03242 m
3w
-4
Therefore the total Pressure Drop on the shell side is calculated by the following
relation
3s (TOTAL)
[ 3e + (Nb [ 3c + Nb [ 3w
= 2 x 9.28 + 1 x 23.29
= 41.856 KPa
As this value of Pressure Drop on the shell side is less than the 70 KPa, the design
is acceptable from the Pressure Drop Point of View.
Thus, the design is acceptable from process design consideration.
SUMMARY OF PROCESS DESIGN FOR SINGLE COOLER
Mass flow rate of process gas = 9.13 Kg/s
Mass flow rate of water
= 13.98 Kg/s
Shell outer diameter
= 540 mm
Number of tubes
= 320
Tube OD
= 0.75 inch = 0.01905 m
Pitch (Triangular)
= 1 inch = 0.0254 m
Tube length
=2m
Shell side pressure drop
= 41.86 KPa
Tube side pressure drop
= 30.7 KPa
Cooler type
= TEMA L or M type 1-6 Heat Exchanger
= 0.101 N/mm
2
= 1.03 Kg/cm
= 150 C
2
= 0.1084 N/mm
2
= 1.105 Kg/cm
= 320
= 540 mm
The entire mechanical design is referred from the literature in PROCESS EQUIPMENT
DESIGN by M.V JOSHI.
1.
SHELL THICKNESS
Material: IS 2825-1969 Grade I plain Carbon steel.
Shell thickness , (t S)
From the Table 9.2, its found that minimum shell thickness when severe
conditions are not expected is 8mm, which includes the Corrosion Allowance.
2.
NOZZLES
Take inlet and outlet nozzles as 100mm diameter.
Vent nozzle
Drain nozzle
Relief Valve
Nozzle thickness
= 25mm diameter
= 25mm diameter
= 50 mm diameter.
= [ P x D i] / { 2 f J - P }
= 3.72mm
Minimum nozzle thickness is 6mm and 8mm is choosen which includes the
corrosion allowance.
Also only the inlet and outlet nozzles need compensation. The compensation
required is minimum and is given by pads of 10mm thickness.
3.
HEAD
Torispherical heads are taken for both ends.
Rc(Crown radius)
Rnk (knuckle radius)
= 540 mm
= 54 mm
= [ P x R cx W ] / { 2 f J }
W
= (1/4) x [ 3 + (R c/ R )nk
= 1.54
0.5
Head thickness
= 4.836 mm
Therefore we take Head Thickness as that of the Shell Thickness = 8mm
4.
TRANSVERSE BAFFLES
Number of Baffles
=1
Baffle cut = 25%
Baffle thickness = 6mm (standard)
5.
6.
FLANGE DESIGN
Flange is ring type with plain face.
2
Design pressure
= 0.1084 N/mm (external)
Flange material: IS 2004-1962 Class 2 Carbon Steel
Bolting steel: 5% Chromium, Molybdenum Steel
Gasket Material: Asbestos
Shell OD
Shell Thickness
Shell ID
= 0.540 m
= 0.008 m (g)
= 0.532 m
2
6 (i).
dO/d i
= [(y-Pm)/(y-P(m+1))]
= 25.5 N/mm
= 2.75
= 1.002 m
Let, d i= B+10
= 0.550 m
Minimum gasket width, N
= 0.550(1.002-1)/2
= 0.00055 m
= 0.55 mm
Choose N = 40 mm.
do = 0.630 m
= 40/2
= 20 mm
= 2.5 x [b o]
= 11.18
0.5
= G P/4
= 29.64 KN
2
Hp
= G(2b)mp
= x (590) x (4) x (2.75) x (0.1084)
= 2.210 KN
= H+HT
= 31.85 KN
=W/S
3
= 94.53 x 10 / S
= G / [box 2.5]
= 590 / [20 x 2.5]
= 12 bolts
1/2
= [(Am / Number of bolts ) x ( 4 / ) ]
= 9 mm
Diameter of bolts
7.
FLANGE THICKNESS
Thickness of flange , tf
= [G(p/Kf) ] + C
Where,
C is the Corrosion allowance
hG is radial distance from gasket load reaction to bolt circle
2
Hydrostatic end force, H
= ( /4) G p
= 29.63 KN
K
=1/[ 0.3 + {( 1.5 W m hG) / (H x G)}]
hG
= (B G )/2
Where,
B
Then,
hG
= [G(p/Kf) ] + C
= 14.8 + C
= 20 mm
Hence the thickness of flange = 20 mm
tf
TUBE SIDE
Material:Stainless steel ( IS- grade 10)
Thickness of tube = t f= {P x D }o / ( 2 f J + P)
Where,
Working pressure
= 12 N/mm
2
Design pressure, P
= 14 N/mm
2
Permissible Stress, f = 100.6 N/mm
Joint Efficiency, J
= 1.0
Thickness of tube
= 1.24mm
Use tube with thickness of 2mm
No Corrosion allowance, since the tubes are of stainless steel.
1.
TUBE SHEET
The tube sheet is held between shell flange and the channel. The joint on the shell
flange side is of male and female facing and on the channel side of ring facing,
since the pressure on the channel
= FG[(0.25 P)/f]
= 1.25
= 140 mm
= 95 N/mm
4.
GASKET SIZE
Width of ring gasket, N
Inner diameter, D i
Outer diameter, D o
= 22 mm
= 0.550 m
= 0.630 m
= 5.5
2
= 126.6 N / mm
=N/2
= 22 / 2
= 11 mm
= 2.5 x (bo)
= 8.3 mm
= ( Di + D o) / 2
= 0.590 m
Mean diameter, G
0.5
Under atmospheric conditions, the bolt load due to gasket reaction is given by
Wm1
= b G Ya
= 1948 KN
After the internal pressure is applied, the gasket which is compressed earlier, is
released to some extent and the bolt load is given by
Wm2
2
= x 2 b x G x m x P + ( / 4 )G P
= 6197 KN
= 140.6 N/mm
= area of bolt
= Wm1 / fa
2
= 13855 mm
= Wm2 / fb
2
= 44075 mm
= 22 bolts
To determine the size of bolts , the larger of above two areas should be considered
Diameter of bolts,Db
5.
1/2
= [( A m2 / Number of bolts ) x ( 4 / )]
= 51 mm
THICKNESS OF NOZZLE
Considering inlet and outlet diameter to be 100mm, then thickness of the nozzle is
given by,
Thickness of nozzle, tn
Permissible stress, f
Joint Efficiency, J
Then,
Thickness of nozzles
6.
= (P x D )n / [2 x f J P]
2
= 95 N/ mm
= 0.85
=10 mm
FLANGE THICKNESS:
Flange material: IS 2004-1962 Class 2 Carbon Steel
Thickness of the Flange , tf = [G(P/Kf) ] + C
Where,
C is the Corrosion allowance
2
Allowable stress for flange material, f = 100 N/mm
hG is radial distance from gasket load reaction to bolt circle
2
Hydrostatic end force, H
= ( /4) G P
= 3827 KN
K
=1/[ 0.3 + {( 1.5 W m hG) / (H x G)}]
hG
= (B G )/2
Where,
B
= Outside diameter of Gasket + 2xDiameter of Bolt +12mm
= 630 + 2 x 51 + 12
= 744 mm
Then,
hG
= (B G )/2
= 77 mm
K
= 1/[ 0.3 + {( 1.5 W m2 hG) / (H x G)}]
= 1.620
Then,
tf
= [G(P/Kf) ] + C
= 158 + C
= 160 mm
Hence the thickness of flange = 160 mm
= 2000 mm
= 556 mm
= 540 mm
= 8 mm
= 19.05 mm
= 15.75 mm
= 320
Density of Steel,s
Density of Liquid in tubes ,! l
= 7850 Kg /m
3
= 1000 Kg /m
2
2
= ( / 4) ( D o Di ) x L
3
= 0.0275 m
= V x s
= 216 Kgs
2
2
= ( / 4 ) ( d o di ) x L x N t
3
= 0.0577 m
Volume of Tubes, V t
Total Weight of Tubes, W t
= V tx s
= 453 Kgs
Volume of Head, V h
= 0.087 D i
3
= 0.013 m
Weight of Head, Wh
= Vhx s
= 102 Kgs
2
= ( / 4) (d i) x L x N x l
= 124.6 Kgs
Weight of Liquid, Wl
Total Weight, W
Depth of head,
H
Q
= Ws+ W t+ W +
h W
= 900 Kgs
= 9.0 KN
= 220 mm
= (W/2) x (L+4H/3)
= 10.32 KN-m
Now, we calculate,
Distance of saddle center line from shell end ,
A
= 0.45 x R i
= 0.45 x (0.540/2)
1.
= 121.5 mm
LONGITUDINAL BENDING MOMENTS
Radius,
Depth of head,
R
H
= 0.270 m
= 0.220 m
k1
k2
Thickness of shell, t
f1
For
f2
3.
=120
= 0.107
= 0.192
= 8 mm
2
= M1/( k 1R t)
3
2
= 876 x 10 N/m
2
= M1/( k 2 R t)
3
2
= 488 x 10 N/m
f3
fp
= (P x D i)/ (4 t)
6
2
= 1.829 x 10 N/m
All combined stresses ( f p + f 1 ) , ( f +p f 2 ) , and ( f p + f 3 ) are well within
allowable limits. Hence, the given parameters can be considered for design.
Note: This Cooler is fabricated 4 in number and are operated in parallel to take care of
the Cooling duty required in the Process.