EH2208O

DESIGN PROJECT II (MARCH 2017)

PRODUCTION OF 20,000 METRIC TONNES OF

POLYTETRAFLUOROETHYLENEPER YEAR

CHAPTER 3: HEAT EXCHANGER,

E-103 (COOLER)

STUDENTS NAME:
FATIN FATIHA BINTI ABDUL RAHIM
2014850038

SUPERVISOR:
MS CHRISTINA VARGIS

FACULTY OF CHEMICAL ENGINEERING

UNIVERSITI TEKNOLOGI MARA
SHAH ALAM
 CHAPTER 3

EQUIPMENT DESIGN

DESIGNED BY: FATIN FATIHA BINTI ABDUL RAHIM

3.1.1 PROCESS DESCRIPTION OF PTFE PLANT

The raw material used for the production of PTFE is chlorodifluoromethane

(CHClF2). The material is stored within a pressurized vessel at 15 bar and 25C to
maintain it in liquid phase as this allows for easier storage and transportation. Upon
exiting the tank, the pressure of CHClF2 is reduced to 12 bar using a valve to
prevent damage to the upcoming equipment due to sudden inflow of high pressure
liquid.

The stream is then heated to 450C as a preparatory step before entering

a tubular reactor (Ebnesajjad, 2013). Within the reactor, gaseous CHClF2
undergoes pyrolysis reaction and is converted to TFE (C2F4) alongside hydrochloric
acid (HCl) as the side product. When operating at 810C and 6.55 bar, a conversion
of 100% can be achieved as stated by (Ebnesajjad, 2016). The product stream
containing TFE and HCl is then condensed to liquid state before entering a
distillation column for purification and separation. Since HCl has a lower boiling
point than TFE, it will exit through the overhead stream meanwhile TFE exits
through the bottom stream. The separation produces product streams containing
99.9% w/w HCl and 99.5% w/w TFE, respectively.

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 Chemical Design

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).

A heat exchanger consists of heat-exchanging elements generally

having a core or matrix containing the heat transfer surface and fluid
distribution element such as headers or tanks, inlet or outlet nozzles or
pipes. Usually, there are no moving parts of any heat exchanger elements
but exceptional for rotary regenerator in which the matrix is driven to rotate
at some design speed (Theodore, 2011).

Heat exchanger can be classified according to the fluid flow types;

parallel flow, cross flow and counter current flow. In parallel fluid flow, both
cold and hot fluid move in same direction through same inlet direction and
exit at same outlet direction. For cross flow, process fluids run in
perpendicular direction from each other. Meanwhile for counter current fluid
flow, the fluids flow in opposite direction with each other. There are many
types of heat exchanger used in industry but the most widely use are;

i. Shell and tube heat exchanger

ii. Spiral heat exchanger
iii. Gasket heat exchanger
iv. Double pipe heat exchanger

Table 3.1 summarises the types, functions, applications, advantages as

well as disadvantages of stated heat exchangers.

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

For this plant in producing Polytetrafluoroethylene, PTFE, heat exchanger

E-103, as in Figure 3.1, acts as a cooler that functions to cool the mixture
of TFE and HCl products which coming out from pyrolysis reactor, R-101.
Before coming into cooler E-103, the process fluid will undergoes a heat
exchanger (E-101) and a cooler (E-102). The operating temperature is from
180 C to 30C. In order to cool down the mixture, cooling water is used as
a cold fluid side meanwhile the mixture at hot fluid side. The cooling water
inlet temperature is selected at 25C around the atmospheric temperature
of surrounding location in Gebeng, Pahang, Malaysia. Material selection of
this exchanger must be carefully selected as it will be crucial since the
mixture dealt consist of organic substances, which is corrosive to certain
material. Therefore, the design of this exchanger must be done as reliable
as possible to avoid any complications occur during the production period.

Figure 3.1 Heat exchanger E-103 containing TFE and HCl

3.1.1.4.1.1.3 Selection of Suitable Heat Exchanger

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

Table 3.2 Specification of selected heat exchanger

Heat Exchanger Specification
Type Shell and tube
Purpose Cooling
Head type Split ring floated head
No. of passes 2 shell pass, 4 tube pass
Tube internal diameter 16 mm
Tube outside diameter 20 mm
Length 3.66 mm

3.1.4.1.1.4 Calculations

3.1.4.1.1.4.1 Mass Flowrate of Cooling Water

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 /

The cooling water inlet taken is taken to be 25 and outlet of 90 in order

to keep the cooling water in liquid form along the exchanger for the heat
transfer to happen continuously.

3.1.4.1.1.4.2 Heat Exchanger Load and Dimension

i. Logarithmic mean temperature difference (LMTD) (Perrys Chemical

Handbook)
Counter current flow;

(1 2 )(2 1 )
= ( )
ln 1 2
(2 1 )

Where;

T1 = Inlet hot fluid temperature, C

T2 = Outlet hot fluid temperature, C

t1 = Inlet cold temperature, C

t2 = Outlet cold temperature, C

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

Table 3.3 Consideration of Fluids on Shell and Tube Side

High pressure A high-pressure fluid is normally put on the tube side to
minimize exchanger cost. Process fluid pressure is
between 655 kPa to 620 kPa.
Corrosion The more corrosive fluid should be allocated to the tube-
side for it will reduce the cost of expensive alloy
components. In this case, E-104 will be handling
hydrocholoric acid, HCL, which is a very corrosive
material.
Fouling A fluid with a tendency to foul generally should be designed
in the tube side This is because cleaning straight tubes are
easier than cleaning the shell
Expensive A corrosive fluid on the tube side so that only the tubes,
materials
tubesheets, heads and channels will need expensive
corrosion-resistant alloys. In contrast, a corrosive fluid on
the shell side requires the entire exchanger to use the
materials.
Fluid temperatures Placing a higher temperature fluid in the tubes will reduce
the overall cost when using a special alloy material.
Tube side pressure High-pressure tubes will be cheaper than a high-pressure
shell.

Based on the explanation in Table 3.3, it is decided that process fluid

product from pyrolysis reactor (R-101) containing TFE and HCL will be fed
along the tube side meanwhile the cooling water will flow into the shell side.

(180 90)(3025)
= (18090)
ln
(3025)

= 29.41 C

ii. The correction factor, Ft

The correction factor, Ft, is a function of the shell and tube fluid
temperatures, and the number of tube and shell passes. It is normally

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

Based on Figure 12.20 taken from a book reference (shown in Appendix,

A-1), Chemical Engineering Design, 4th Edition, Coulson and Richardson
(Sinnott, 2005);

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.

iii. By taking into account the temperature correction factor calculated

above, new LMTD is as follows to allow for the departure from true
counter-current flow;

Where;

Tm = True temperature difference, C

Ft = Temperature correction factor

Tlm = Logarithm mean temperature, C

222
 Tm = 0.75 29.41

= 22.06 C

iv. Overall Coefficient, Uo

Initial heat transfer overall coefficient is guesses based on the type of
fluid used in the process. In this case, the fluids used are TFE and HCl
which is in vapour form and cooling water. So, overall coefficient range
that needs to be used for this production shell and tube heat exchanger
is between 250 and 750 W/m2. C (Sinnot, 2005). Thus as initial value
for the iteration step, it is selected as 550 W/m2. C

v. Heat Transfer Area

147.03

=
(550 )(22.06 )
.

= 22.217 2

vi. Layout and tube size

In industry, the tubes size diameters in the range of 16 mm to 55 mm are

commonly used for heat exchanger. Taking into cost considerations, more
compact size is usually applied in the range of 16 mm to 25 mm tube
diameter.

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).

Table 3.4 Tube dimensions

Dimensions Data
Inner diameter, di 18 mm
Outer diameter, do 20 mm
Length of tube, L 3.66 m

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.

Number of shell and passes: 2 shell and 4 tube passes

According to the tube dimensions decided, the area of one tube is

calculated as follows:

i. Area of one tube, a;

a =

= 3.142 (0.02) (3.66)

= 0.230 m2

ii. Tube pitch, Pt is given as;

= 1.25

= 1.25 (0.020)

= 0.025

iii. Number of tube, Nt

Nt =

22.217
= 0.230

= 96.50

97

iv. Number of tubes per pass, Np

Np = 4

224
 97
= 4

= 24.25

24

3.1.4.1.1.4.4 Tube Side Velocity

i. Tube cross-sectional area, Acs

2
Acs = 4

(0.018)2
= 4

= 2.545 104 m2

ii. Area per pass, Ap

Ap = Acs Np

= (2.545 104 ) 24

= 0.0061 m2

iii. Density of mixture in the tube

In order to determine the density of mixture gases, relative molecular

mass (RMM) must first be known whereby RMM is the average
molecular mass of composition TFE and HCl in the tube side of the
exchanger.

Where;

xi = Component composition in mass fraction

MW = Molecular weight

225
 Table 3.5 Relative molecular mass for E-103

Component MW (kg/kmol) RMM

TFE 100.02 0.5783 57.8416
HCl 36.46 0.4217 15.3756

73.2172

The density of the mixture can be calculated by using the following

equations;

Vapour mixture;

73.2172 273.15 6.0
=
453.15 1
22.4

= 11.821
3

iv. Volumetric flow rate, Vt

Vt =

4253.73
=
11.821 3

= 0.100 m3/s

v. Tube side velocity, ut

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

Table 3.6 Physical properties of tube side

Properties Value
Specific Heat (J/kg. ) 1019.5
Thermal Conductivity (W/m. ) 0.040
3
Density (kg/m ) 11.821
Viscosity (Ns/m2) 1.7737 105
*Value of specific heat, viscosity and thermal conductivity of vapour mixture (TFE
and HCl) are taken and calculated from Chemical Properties Handbook, Carl L.
Yaws (1999)

i. Reynolds number, Ret

Where;

Ret = Reynold number of fluid in tube-side

t = fluid density of tube side, kg/m3

Ut = fluid velocity of tube side, m/s

= fluid dynamic viscocity of tube side, Ns/m2

di = inside diameter of tube side, m

11.821 16.393 0.018

=
1.7737 105

= 196655.00

Prandtl number, Pr

,
Pr =

Where;

Pr = Prandtl number

227
 Cpt = fluid heat capacity of tube side, J/kgC

t = Fluid dynamic viscosity of tube-side, Ns/m2

kt = fluid thermal conductivity of tube side, Wm C

(1019.5)(1.7737 105 )
= (0.040)

= 0.452

3.66

= 0.018

= 203.33

Based on Figure 12.23 taken from Coulson and Richardson (2005);

For Re = 196655 and L/di = 203.33;

Heat transfer coefficient factor, jh = 2.5 10-3 (Graph is shown in Appendix,

A-3)

Nusselt number, Nut

0.14
= 0.33 ( )

Neglecting viscosity term;

= (2.5 103 )(196655)((0.452 )0.33 )

= 378.30

Tube side heat transfer coefficient, ht;

(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.

Figure 1.3 Triangular tube pattern

Table 3.7 Constants for tube arrangements

Triangular Pitch, pt = 1.25do

No. Passes 1 2 4 6 8
K1 0.319 0.249 0.175 0.0743 0.0365
n1 2.142 2.207 2.285 2.499 2.675
Square Pitch, pt = 1.25do
K1 0.215 0.156 0.158 0.0402 0.0331
n1 2.207 2.291 2.263 2.617 2.643

For triangular pitch with number of passes = 4

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

3.1.4.1.1.4.7 Shell Side Heat Transfer Coefficient

Table 1.8 Physical properties of shell side

Properties Value
Specific Heat (J/kg. ) 4187.5
Thermal Conductivity (W/m. ) 0.6378
Density (kg/m3) 981.13
Viscosity (Ns/m2) 6.1125 104
*Value of specific heat, viscosity and thermal conductivity of cooling water is taken
and calculated from Chemical Properties Handbook, Carl L. Yaws (1999)

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

ii. Cross flow area, As

( )
=

Where;

As = Cross flow area, m2

Pt = Tube pitch, m

Ds = Shell inside diameter, m

IB = Baffle spacing, m

(0.0250.020) 0.373 0.0746

= 0.025

= 0.0056 2

iii. Equilateral triangular pitch arrangement, de;

1.10
= ( 2 0.917 2 )

1.10
= (0.0252 0.917 (0.020)2 )
0.020

= 0.0142

iv. Shell mass side velocity, Gs;

0.541
=
0.0056 2

231

= 96.61
2 .

v. Shell-side Velocity, us

196.61
2 .
=
981.13 3

= 0.095

vi. Reynolds number, Res

Where;

Res = Reynold number of fluid in shell-side

s = fluid density of shell side, kg/m3

Us = fluid velocity of shell side, m/s

= fluid dynamic viscocity of t shell side, Ns/m2

de = inside diameter of shell side, m

(981.13)(0.095)(0.0142)
=
6.1125 104

= 2153.91

vii. Prandtl number, Pr

,
Pr =

Where;

Pr = Prandtl number

Cps = fluid heat capacity of shell side, J/kgC

232
 s = Fluid dynamic viscosity of shell-side, Ns/m2

Ks = fluid thermal conductivity of shell side, Wm C

(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;

hs = heat transfer coefficient of shell-side, W/m2 C

de = inner diameter of tube-side, m

kf = thermal conductivity of shell tube, W/mC

jh = heat transfer factor of shell-side

Re = Reynolds number of shell side

Pr = Prandtl number of shell-side

(0.6378) (2.5 102 ) (2153.91) (4.013)0.33

hs = (0.0142 )

= 1989.35 2
.

233
3.1.4.1.1.4.8 Overall Heat Transfer Coefficient, Uo

The true overall coefficient is required to be confirmed whether it is

acceptable or not. So, the overall coefficient is calculated as follows:

1 1 1 ln 1 1

= + + + ( + )
2

Where;

= Overall coefficient based on outside tube area, W/m2. C.

= Outside fluid film coefficient, W/m2. C.
= Inside fluid film coefficient, W/m2. C.
= Inside dirt coefficient, W/m2. C.
= Outside dirt coefficient, W/m2. C.
= Thermal conductivity of tube wall material, W/m2. C.
= Tube inside diameter, m.
= Tube outside diameter, m.

From calculation, hi = ht = 840.67 W/m2 C

ho = hs = 1989.35 W/m2 C

Based on Table 12.2 taken from Coulson and Richardson (2005), shown in
Appendix, A-8;

hod (water) = 3000 W/m2 C

hid (organic vapour) = 5000 W/m2 C

Material of construction of tube-side is stainless steel, thus kw is 16 W/m C

as based on Table 12.6 taken from Coulson and Richardson (2005) shown
in Appendix, A-5.

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

Tube pressure drop, Pt,

2
Pt = [8 () () + 2.5] 2

Where;

Np = Number of tube passes

jr = Friction factor

L = Tube length, m

di = Inside diameter of tube, m

Ut = Fluid viscosity of tube-side, m/s

= Fluid density in tube-side, kg/m3

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

Table 3.10 Shell-side specification

Shell Specification
Inside diameter, Ds (m) 0.373
de (m) 0.0142
Length (m) 3.66
Baffle spacing, IB (m) 0.0746
Density, (kg/m3) 981.13
Velocity, Us (m/s) 0.095
Renolds number, Res 2153.91
Tube-side friction factor, jf 7.2 103

Shell side pressure drop,

0.14 2
Ps = [8 () () () ] 2

Where;

L =Tube length, m

IB = Baffle spcing, m

de = Equivalent diameter, m

Us = Fluid velocity in shell-side, m/s

Neglect the viscosity correction term, ( ) the equation becomes;

2
Ps = [8 ( ) ( )] 2

0.372 3.66 (981.13)(0.095)2

Ps = [8(7.2 103 ) (0.0142) (0.0618)] 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)

Item: Heat Exchanger (Cooler)

Item No: E-103
Function: Cooling product from reactor R-101 from 180C to 30C.
Operation: Continuous
Type: Split-ring floating head shell and tube heat exchanger (two shell passes; four tube
passes)
Heat Duty, Q: 147.03 kW
Heat Transfer Area: 22.217 m2

Tube Side Tube Details

Fluid type: Vapour phase mixture
Flowrate: 1.182 kg/s
Pressure: 600 kPa
Temperature: 180C to 30C
Heat Transfer Coefficient: 840.67 W/m.C
Pressure Drop: 0.589 bar
Inside Diameter, di: 18 mm
Outside Diameter, do: 20 mm
Length, L: 3.66 m
Bundle Diameter, DB: 0.318 m
No of Tubes, Nt: 97
No of Tubes per pass, Nt/4: 24

Shell Side Shell Details

Fluid Handle: Cooling water Diameter, Ds: 0.373 m
Flowrate: 0.541 kg/s Baffle spacing: 0.0746 m
Pressure: 101.325 kPa
Temperature: 25C to 90C
Heat Transfer Coefficient: 1989.35 W/m.C
Pressure Drop: 0.0053 bar

238
REFERENCES

Lawate, S., & Deshmukh, B. B. (2015). Analysis of Heads of Pressure Vessel, 759765.
http://doi.org/10.15680/IJIRSET.2015.0402098

Sinnott, R. K. (2005). Chemical Engineering Design. Coulson & Richardsons.

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).

Tooley, M., & Dingle, L. (2007). Higher National Engineering. Routledge.

Yaws, C. L. (1999). Chemical Properties Handbook. McGraw Hill Companies.

239
APPENDIX

A-1 Temperature correction factor: two shell pass; four or more even tube passes

240
A-2 Tube-side heat-transfer factor

A-4 Shell-bundle clearance

241
 A-5 Conductivity of metals

A-6 Tube-side friction factors

242
A-7 Shell-side friction factors, segmental baffles

A-8 Fouling factors (coefficient), typical values

243
 3.1.4.1.2 Mechanical Design

3.1.4.1.2.1 General consideration

In order to design the mechanical part of a vessel or equipment, few criteria

must be considered relating to pressure inside the equipment. In this
chemical plant for heat exchanger (E-103), the mechanical design
consideration must be done for split-ring floating head shell and tube heat
exchanger as designed in the previous subchapter.

In most cases, mechanical design of any pressure vessel has to take

into account the safety precaution, usually about 5% to 10% from operating
pressure to prevent any undesired incident from happening. Since the heat
exchanger, E-103 has operating pressure at 6.0 bars and temperature inlet
at 180 C, therefore a proper mechanical design should be consider.

3.1.4.1.2.2 Material Consideration

The material of construction is one of the important parts in designing the

mechanical section for an equipment. Material selected must be suitable for
substances that are used in the production for fabrication as well as to avoid
any undesired occurrence or harmful incident. Also, the selection of suitable
material is very important in order to maintain the equipment for a longer
lifetime and to make it compatible to the process environment.

In selecting the most suitable construction material, few considerations

must be taken into account for a better decision. The consideration is as
follows:

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

As explained in Section 1.4.1.2.1, the design pressure of any pressure

vessel should consider a 10% of pressure higher than the operating
pressure for safety precaution. Thus, the design pressure for the tube and
shell side for E-103 are as follows;

For tube side:

Operating pressure = 6.0 bar

Design pressure = 6.0 (1.1)
= 6.6 bar
= 0.66 N/mm2.

For shell side:

Operating pressure = 1.01325 bar

Design pressure = 1.01325 (1.1)
= 1.1146 bar
= 0.11146 N/mm2.

3.1.4.1.2.4 Design Temperature

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;

For tube side:

Operating temperature = 180 C

Design temperature = (180 C) (1.1)
= 198 C

For shell side:

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)

Minimum thickness for tube material according to British Standard PD 5500;

=
3

Where;
F = 1.0 for floating tube sheet
G = Diameter over which pressure is acting
f = Design stress

The equation k (for triangular type);

0.907
=1
2
( )

0.907
=1
25 2
(20)

= 0.42 m

Therefore, the tube thickness is;

(1.0)(2.0) 0.66
= 3
(0.42)(120.6)

246
 = 0.076 + 2
= 2.075
2.1

Minimum thickness for shell material according to British Standard PD

5500;

=
2
(0.11146)(309)
= 2 (1.0)(125.5)(0.11146)

= 0.00132 + 2
= 2.00132
2

3.1.4.1.2.6 Head and Closure

There are four main types of head closures which include;

flat plates
hemispherical heads
ellipsoidal heads
torispherical heads

Hemispherical, ellipsoidal and torispherical are classified as domed

head. In choosing a suitable type of head for pressure vessel,
considerations of pressure range and thickness have to be thorough
enough to avoid any undesired circumstances. Types and applications of
each is represented in Table 3.12

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.

The equation for determining the thickness of flat head is:

Torispherical Torispherical heads are made of a dish, with a constant radius.

Often used to close cylindrical pressure vessels.
Formed from part of a torus and part of a sphere.
The shape is close to that of an ellipsoidal head but is easier and cheaper to
fabricate because the availability of regular circular curves on the edges.
By joining the dish directly to the cylindrical section of the vessel would results
in excessive local stresses.
Torispherical heads with pressure ratings above 10 bar are uneconomic.
The equation for determining the thickness of torispherical head is:

=
2 + ( 0.2)

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.

1. Ellipsoidal Head Calculation

=
2 0.2

(0.11146)(373)
= 2(125.5)(1.0)0.2(0.11146)

= 0.166 + 2
= 2.166
2.2

2. Torispherical Head Calculation

=
2 ( 0.2)

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.

3.1.4.1.2.7 Design Load

Dead weight of a pressure vessel must be known in order to design a

proper support for the equipment during operation. Major elements of
dead weight are as follows:

1. Vessel shell.

2. Vessel fittings (manways, nozzles).

3. Internal fittings (fluids, heating and cooling coil).

4. External fittings (ladder, platforms and piping).

5. Auxiliary equipment which not self-supported such as condenser

and agitators.

6. Insulation.

7. Weight of liquid to fill the vessel.

Preliminary calculation of dead weight of pressure vessel can be calculated

using equation as follows:

= ( + 0.8 )

Where;

Wv = total weight of the shell, excluding internal fittings such as plate, N.

Cv = factor to account for the weight of nozzles, manways, internal supports

and others which can be taken as 1.08 for vessel with few internal fittings
and 1.5 for distillation column or similar vessel.

Hv = height, between tangent lines (cylindrical section),m.

g = gravitational acceleration, 9.81 m/s2

t = wall thickness, mm

m = density of vessel material, kg/m3

Dm = mean diameter of vessel (Di + t), m

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

Mean diameter of E-103;

= (373 + 2.00) 10-3

= 0.375 m

Substituting all values in the dead weight equation;

Dead weight, Wv =(1.08)(7850)()(0.375)(9.81)[3.66 + (0.8)(0.375)](2.010-3)

= 776.01

= 0.776

Weight of tube in shell, Wt = (2 2 )

= (97)( ) (0.022 0.0182 )(3.66)(7990)(9.81)

= 6644.04 N

= 6.644

252
Weight of insulation, WI;

Insulation material = Material wool

Insulation thickness = 50 mm

Density of mineral wool = 130 kg/m3

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,

Weight of fluid in shell;

2
Wf,s = ( )
4

(0.373)2
= ( 4
) 3.66 981.13 9.81

= 3849.32

= 3.849

Weight of fluid in tube;

(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

= 0.776 + 6.644 + 0.381 + 3.849 + 0.0024

= 11.65

3.1.4.1.2.8 Minimum Thickness of Channel Cover

1
2
= [ ]

Where:

CP = design constant depends on the edge constraint = 0.4.

De = nominal plate diameter (mm), De=Di=309 mm.

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.

The term baffle cut is used to represent the dimension of segmental

baffles. By definition, baffle cut is the height of the segment removed to form
the baffle, expressed in term of percentage from the baffle disc diameter.
Baffles cut of 15% to 45% is usually used but within range of 20% to 25%
will provide an optimum heat transfer rate between fluids. The baffle type
used for cooler, E-103 will be segmental with baffle cut of 25%.

254
Baffles diameter;

B =S 4.8

B = 373 4.8

368.2

Baffles spacing, IB;

IB =
2

373
= 2

= 186.5

Number of baffles, NB;

NB =

3660
=
373

= 9.123

3.1.4.1.2.10 Shell and Bundle Geometry

Where;

= Baffles cut height

= Percentage cut in fraction

= 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

Flowrate, G = 1.182 kg/s

Density, = 11.821 kg/m3

Optimum inlet diameter, do = 260 0.53 0.37

= 260 (1.182)0.53 (11.821) 0.37

= 113.91

114

ii. Shell-side nozzle

Flowrate, G = 0.541 kg/s

Density, = 981.13 kg/m3

Optimum inlet diameter, do = 260 0.53 0.37

= 260 (0.541)0.53 (981.13) 0.37

= 14.677

15

3.1.4.1.2.12 Flanges

A flanges is the edge, rim or collar on a pipe shaft or a wheel. It is used to

hold, support or strengthen an object or assist in attaching one object to
another. Uses of flange are versatile whereby;

It is used for connecting pipes and instruments to vessels, for

manhole covers, and for removable vessel heads when ease of
access is required.
Used on the vessel body when there is necessary to divide the
vessel into sections for transport or maintenance.
Used to connect pipes to other equipment; e.g. pumps and valves.

256
 Used for connecting pipe sections where ease of assembly and
dismantling is required for maintenance.

Flanges make up of different types and the use of it will depend on

the application and size. There is several type of flange that commonly
used in industry including welding neck flanges, slip-on flanges, hub and
plate types, lap-joint flanges, screwed flanges and blank or blind
flanges. Criteria of each of flange is explained in Table 3.14.

Table 3.14 Criteria of flange and its applications

Type of flange Application
Welding-neck Suitable for extreme service
conditions; where the flange is
normally be subjected to
temperature, shear and vibration
loads.
Normally be specified for the
connections and nozzles on
process vessels and process
equipment.
Slip-on This type of flange have poor
resistance to shock and vibration
loads as compared to welding-
neck. It is cheaper than welding-
neck flanges and are easier to
align, generally used for pipe
work.
Lap-joint Commonly used for piped work.
Economically used with
expensive alloy pipe, as the
flange can be made from
inexpensive carbon steel.
Normally welded to the pipe, but
with some schedules of pipe the
lap can be formed on the pipe
itself, and this will give a cheap
method of pipe assembly.

257
 Screwed Used to connect screwed fittings
to flanges and sometimes for
alloy pipe which is difficult to weld
satisfactorily.

Blind Used to blank off flange

connections and as covers for
manholes and inspection ports.

As based on the temperature and pressure used for heat exchanger,

E-103, the most suitable flange to be used for this exchanger is
welding-neck flanges. This is because it is suitable to be used for
severe process conditions.

3.1.4.1.2.13 Vessel Support

The support structure of a vessel must be designed to withstand the load of

the vessel and its content. The support structure of a vessel will be depends
on parameters of size, shape, and vessel weight, design temperature and
pressure, vessel location and fittings. There are two type of vessel support;
skirt support and saddle support. The skirt support is usually suitable for tall
and vertical oriented vessel whereas saddle support is suitable for
horizontal oriented. Proper selection must be made to avoid vessel collapse
during operation. The most suitable support for E-103 is selected as saddle
support as E-103 is mounted in horizontal orientation.

258
 Figure 3.4 Typical saddle design

Table 1.6 Typical dimension of saddle design

Vessel Max Dimension (m) mm
Diamet weight V Y C E J G t2 t1 Bolt D Bolt
er, m , kN holes

1.2 180 0.78 0.2 1.0 0.4 0.3 0.1 12 10 24 30

0 9 5 6 4

259
3.1.4.1.2.14 Summary Table for Mechanical Design of Cooler E-103

Item: Heat Exchanger (Cooler)

Item No.: E-103
Function: To cool down process fluid from stream 7 from 180C to 30C by using cooling water
before entering condenser, E-104.
Operation: Continuous
Type: Shell and Tube; Floating Head-Split Ring
Overall Specification
Tube Pass 4 Number of Tubes 97
Shell Pass 2 Condition Horizontal

Shell Side Details

Length 3660 mm Material Carbon Steel
Diameter 373 mm Wall Thickness 2.0 mm
Operating 0.11146 N/mm2 Operating 99C
Pressure Temperature
Head Type Ellipsoidal Head Thickness 6.446 mm
Closure Type Bolted Flat End Closure Thickness 4.446 mm
Insulator Mineral Wool Insulator Thickness 50 mm

Tube Side Construction

Length 3660 mm Material Stainless Steel
Tube Thickness 2.1 mm Operating Pressure 0.66 N/mm2
Inside Diameter 18 mm Operating 198C
Temperature
Outside Diameter 20 mm

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