GROUP NO 7

SHEET 1
FINAL YEAR DESIGN PROJECT JOB CODE
DESIGN OF
MOHD HAZIQ
ETHYLENE PRODUCTION PLANT BIN MOHD
DESIGNER
GHAZALI
(13581)

DETAILED DESIGN OF

MINOR EQUIPMENT

ETHYLENE STORAGE TANK ( T-600)

PUMP (P-500)
INTEGRATED HEAT EXCHANGER (E-101)
COOLER (E-400)

DESCRIPTION PREPARED BY REVIEWED BY DATE

01 STORAGE TANK HAZIQ

02 PUMP HAZIQ

INTEGRATED HEAT HAZIQ

03
EXCHANGER
04 COOLER HAZIQ

INFORMATION CONTAINED IS OUR PROPERTY AND MUST NOT BE USED OR

CONVEYED TO ANY PERSON WITHOUT AUTHORITY

i
 Table of Contents

LIST OF TABLES ................................................................................................................................. iv

LIST OF FIGURES ................................................................................. Error! Bookmark not defined.

CHAPTER 1: ETHYLENE STORAGE TANK (T-600) ........................................................................ 1

1.0 TYPES OF TANKS ...................................................................................................................... 1

1..1MINIMUM TANK CAPACITY................................................................................................... 2

1.2 DIMENSION OF TANK .............................................................................................................. 2

1.3 MINIMUM SHELL THICKNESS ............................................................................................... 3

1.4 TORISPHERICAL HEAD............................................................................................................ 3

1.5 COST ............................................................................................................................................ 4

CHAPTER 2: PUMP (P-500) ................................................................................................................. 5

2.0 INTRODUCTION......................................................................................................................... 5

2.1 HEAD CALCULATION .............................................................................................................. 5

2.2 POWER......................................................................................................................................... 6

2.3 PUMP EFFICIENCY .................................................................................................................... 6

2.4 SHAFT POWER ........................................................................................................................... 7

2.5 NET POSITIVE SUCTION HEAD .............................................................................................. 7

2.6 BRAKE HORSE POWER, BHP .................................................................................................. 8

2.7 COST ............................................................................................................................................ 8

CHAPTER 3: INTEGRATED HEAT EXCHANGER (e-101) ............................................................ 10

3.0 INTRODUCTION....................................................................................................................... 10

3.1 TYPE OF HEAT EXCHANGER ............................................................................................... 10

3.2 DESIGN OF HEAT EXCHANGER ........................................................................................... 12

ii
CHAPTER 4: COOLER (E-400) .......................................................................................................... 27

4.0 INTRODUCTION....................................................................................................................... 27

4.1 COOLER SIZING ....................................................................................................................... 28

4.2 TUBE SIDES .............................................................................................................................. 31

4.3 SHELL SIDE .............................................................................................................................. 34

4.4 OVERALL HEAT TRANSFER COEFFICIENT ....................................................................... 37

4.5 COST .......................................................................................................................................... 38

CHAPTER 5: REFERENCES .............................................................................................................. 41

iii
Table Number Description Page

Summary properties of Feed Stream to Ethylene Storage Tank

(extract from HYSYS software) 1
1
2 SPECIFICATION DATA SHEET (STORAGE TANK) 4
3 Operating Condition (HYSYS) 5
4 SPECIFICATION DATA SHEET (PUMP) 9
5 Hot Stream Properties 12
6 Cold Stream Properties 12
Standard Dimension For Tubes
7 17
Source: (Geankoplis, 2003), (Sinnort, 2005), (Smith, 2005)

8 Cost estimation of heat exchanger 24

9 SPECIFICATION DATA SHEET (HEAT EXCHANGER) 26
10 Inlet and Outlet Streams Data for Shell and Tube Sides 28
11 Details of Tube Dimensions 31
12 Details of shell dimension 34
13 Data of heat transfer coefficients 37
14 Estimated Cost 37
15 SPECIFICATION DATA SHEET (COOLER) 39

iv
Figure Number Description Page

1 Pump Efficiency At Optimum Speed 6

2 Shell-And-Tube Heat Exchanger 11

3 Temperature Correction Factor (Sinnott, 2005) 15
4 Heat Transfer Factor (Sinnot, 2005) 20
5 Friction Factor (Sinnott, 2005) 23
6 Cooler E-400 27
7 Temperature Correction Factor (Sinnott, 2005) 30
8 Tube-Side Heat Transfer Factor (Sinnott, 2005) 32
9 Tube-Side Friction Factors (Sinnott, 2005) 33

10 Shell-Side Heat Transfer Factors, Segmental Baffles (Sinnott, 35

2005)
11 Shell-Side Friction Factors,Segmental Baffles (Sinnott, 2005) 36

v
MINOR EQUIPMENT DESIGN

CHAPTER 1: ETHYLENE STORAGE TANK (T-600)

Table 1: Summary properties of Feed Stream to Ethylene Storage Tank (extract from HYSYS software)

Component Mass flow rate Mol. Weight Density Volumetric

(kg/hr) (kg/m3) flow rate
(m3/hr)
Ethylene at 25283.56 28.09 567.7 44.54
99.5%

1.0 Types of Tanks

Many types of storage classifications are available for above ground storage.
There are two basic types of vessels used to store ethylene: pressurized or cylindrical
(bullet tanks) and flat bottom storage tanks. The most common way to store liquid
ethylene is in flat bottom insulated tanks at atmospheric pressure (temperature is -66C).
For smaller capacities, liquid ethylene can be stored in pressurized vessels (cylinders or
spheres). In industrial application, ethylene is usually stored as liquid at very low
temperatures (around -103C), hence cryogenic tanks are commonly employed.

For this proposed ethylene plant design, flat bottom insulated tank is chosen. These tanks
are made of stainless steel or carbon steel for low temperatures. Flat bottom tanks are
designed and equipped for storage of contents at atmospheric conditions. Flat-bottomed,
vertical, cylindrical, storage tanks for refrigerated liquefied gases have been traditionally
been of the single containment design where the liquid is contained in a single shell
surrounded by a conventional low bund wall at a considerable distance. The double wall
design with full containment type is the tank-within-a-tank concept, which creates an
interstitial space that can be monitored. Though double-wall designs are more naturally
more expensive than a single-wall, the area between the inner and outer tanks enables
leak detection without fear that hazardous substance has been released to the
environment. This secondary tank or outer shell is intended to retaining the insulation
and prevent the release of the liquefied products into the surrounding area in case of
leakage from or damage to the inner tank. This philosophy results in increased safety for
the surrounding area.

1
 The inner tanks may be made from carbon-manganese steel, low nickel steel, 9%
nickel steel, aluminium or stainless steel while the outer tanks made from prestressed
concrete, reinforced concrete with an earth embankment or one of the metal specified for
single containment tanks only. These tanks were built according to British Standards, BS
5500.

1.1 Minimum Tank Capacity

Assumption: The storage tank is required to store at least 14 days of inventory

Volume of storage (m3) = Vvapor + VL (assuming 10% volume added for vapour flow) =
1.1VL

= 14965.44 m3 x 1.1 = 16461.984 m3 16462 m3

1.2 Dimension of Tank

Assume ration H/D = 1.3 (ICARUS Corporation, 1998)

H = 1.3D

Volume of tank (m3), VL =

16462m3 =

D = 25.263m

Height of tank, Htank = 1.3(D) = 1.3(25.263 m) = 32.842 m

For safety purpose, take the maximum height of liquid in the tank as 90% of total tank
height. Thus, the total height of tank

Total height of tank, Htotal = = 36.491 m

2
1.3 Minimum Shell Thickness
The minimum thickness of shell can be obtained from the equation as shown below:

Di = Internal diameter

F = Material design stress

T = Minimum thickness required

Pd = Internal pressure

J = Welding efficiency, 1 as it is assumed to be fully radio graphed

c = Corrosion allowance

Therefore,

Pd = 1.1 x 101325 = 111457.5 Pa

Shell thickness, t =

= 8.048 mm 8.05 mm

Allow for 2mm corrosion (corrosive environment in Malaysia), the thickness will be
10.05 mm or 11 mm.

1.4 Torispherical Head

From BS 5500,

3
Allow for 2mm corrosion (the corrosive environment in Malaysia), the thickness will be
6.023 mm or 7 mm.

1.5 Cost
Calculate shell mass;

Total cost;

Table 2: SPECIFICATION DATA SHEET (STORAGE TANK)

Equipment No T-600
Ethylene Storage Tank Data Sheet Description To store ethylene
Sheet No 1/1
Operating Data
Type Of Tank Vertical cylindrical with the torispherical head
Volumetric Flow 44.54 m3/hr Mass Flow Rate 25283.56 kg/hr
Detention Time 14 days Design Flow Rate 27813.92 kg/hr
3
Liquid Volume 14965.44 m
Working Pressure 14.7 psi / 101.3 kPa
Working -105 oC
Temperature
Channel Velocity 0.2 m/s
Equipment Data
Depth Of Tank 36.491 m Solid/Fluid Process fluid
Depth Of Fluid 32.842 m
Diameter 25.263 m
Technical Design Data
Weir Loading 125 m3/m.d Electrical Supply Direct
3 2
Overflow Rate 30 m /m .d Type Of Motor NA
Average 80 m3/m2.d Motor Power NA
Peak Hourly 80 m3/m2.d
Materials Of Contruction
Shaft Metal alloy Seal Or Glands Metal alloy
Support Cast iron
Equipment Cast iron

4
CHAPTER 2: PUMP (P-500)
2.0 Introduction

The function of the pump is to pump Ethylene which was separated and the
second column to the Ethylene storage tank. Usually, pump is divided into dynamic
pumps, such as centrifugal pump and positive displacement pump, such as reciprocating
and diaphragm pumps. Selection of pump itself can be done depending on the flow rate
and head required. A single stage horizontal overhung centrifugal pump is the most
common used pump in chemical process industry.

It was chosen since it is relatively inexpensive, have lower maintenance, relative small
space needed, can handle fluid with dirts, can operate at low suction pressure, and easier
to control over wide range of capacity at constant speed.

Centrifugal pumps are mainly made of an impeller attached to the rotating shaft and the
stationary casing which house the impeller. The impeller usually consist of a number of
curved blades arrange in regular patter around the shaft.

2.1 Head Calculation

The ethylene pump operating condition gained from HYSYS is listed as the following

Table 3: Operating Condition (HYSYS)

Properties Unit Value

Inlet Pressure kPa 101.3
Outlet Pressure kPa 200
Pressure Difference P kPa 98.7
Liquid Density kg/m3 567.7
Mass Flow rate Kg/hr 25283.56
m3/hr 44.5368
Volumetric Flow rate m3/s 0.0124
US Gallon/min 196.09
Viscosity cP 0.16835
Gravity m/s2 9.81
Internal Pipe Diameter m 0.15

5
Assuming the density and viscosity remains constant

2.2 Power

2.3. Pump Efficiency

By referring to the pump efficiency graph below, the efficiency of the pump can be

gained. (note : 1.26 m3/min = 332.86 US gallons/minute)

Figure 1: Pump efficiency at optimum speed

Therefore the pump efficiency, , is 68%

6
2.4 Shaft power

2.5 Net positive suction head

Since the pipeline used is the commercial steel pipeline, thus it is assumed to
have diameter of 0.15m and length of 10 meters. Therefore the cross sectional area, A,
can be calculated as follows;

Since Re> 4000, therefore it is a turbulent flow.

Based table 5.2 of Coulson and Richardsons (2005), the absolute roughness of
commercial steel pipe is 0.046mm.

Relative toughness= /d = 0.046/150= 0.000307

From figure 5.7 in Coulson and Richardsons (2005) shows that the corresponding

Reynolds number and relative toughness give the pipe friction, f, of 0.00205. Thus the

pressure drop across the pipe is:

7
Thus the piping arrangement must be made that the NPSHavail is higher than NPSHrequired

2.6 Brake Horse Power, bhp

2.7 Cost

M&S = 1353.8

Fc = 1

BHP = 6.49

Thus total cost = $47663.82 x 3.18 = RM 151570.95

8
 Table 4: SPECIFICATION DATA SHEET(PUMP)

Equipment
P-500
No
PUMP DATA SHEET
Description Pump

Sheet No. 1/1

GENERAL DATA

Medium Propane Corrosive No

Operation Continuous Hazardous

Yes
Connection Parallel Service

FLUID PROPERTIES SUCTION CONDITION

Viscosity cP 0.16835 Power kW 2.674

Mass Flow
kg/hr 25283.56 Efficiency % 68
Rate
Total
3
Density kg/m 567.7 Suction m 17.7
Head
NPSH, TOTAL DYNAMIC HEAD AND
DISCHARGE CONDITION
POWER

NPSH Fluid
m2 17.69 m/s 0.702
Available Velocity

Brake Horse
Bhp 6.49
Power
Shaft Power W 3932.35

9
CHAPTER 3: INTEGRATED HEAT EXCHANGER (E-101)
3.0 Introduction

The transfer of energy in the form of heat occurs in many chemicals and other
types of processes. The heat transfer occurs because of a temperature-difference driving
force and heat flows from the high to low temperature region. In the process industries,
the transfer of heat between two fluids is generally done in heat exchangers. The most
common type is one in which the hot and cold fluids are separated by a tube wall or a flat
or a curved surface. The transfer of heat from the hot fluid to the wall or tube surface is
accomplished by convection, through the tube wall or plate by conduction, and then by
the convection to the cold fluid (Geankoplis, 2003).

The heat exchangers can be classified into three main categories according to their flow
arrangement. In parallel-flow heat exchangers, the two fluids enter the exchanger at the
same end, and travel in parallel to one another to the other side. In counter-flow heat
exchangers the fluids enter the exchanger from opposite ends. In a cross-flow heat
exchanger, the fluids travel roughly perpendicular to one another through the exchanger.
Out of the three, counter-flow heat exchangers is the most efficient when comparing heat
transfer rate per unit area (Engineers Edge, 2010).

3.1 Type of Heat Exchanger

3.1.1 Shell-and-tube Heat Exchanger

Shell and tube heat exchangers are comprised of multiple tubes through which
liquid flows. The tubes are divided into two sets: the first set contains the liquid to be
heated or cooled. The second set contains the liquid responsible for triggering the heat
exchange, and either removes heat from the first set of tubes by absorbing and
transmitting heat away in essence, cooling the liquid or warms the set by transmitting its
own heat to the liquid inside (Thomas Net, 2011).

10
3.1.2 Plate Heat Exchanger

Plate heat exchangers consist of thin plates joined together, with a small amount
of space between each plate, typically maintained by a small rubber gasket. The surface
area is large, and the corners of each rectangular plate feature an opening through which
fluid can flow between plates, extracting heat from the plates as it flows. The fluid
channels themselves alternate hot and cold fluids, meaning that heat exchangers can
effectively cool as well as heat fluid they are often used in refrigeration applications.
Because plate heat exchangers have such a large surface area, they are often more
effective than shell and tube heat exchangers (Thomas Net, 2011).

After considering all the factors, Heat Exchanger E-2015 will be designed in shell-and-
tube type. Some of the advantages of shell-and-tube heat exchanger are (Sinnort, 2005):

1. The configuration gives a large surface area in a small volume.

2. Good mechanical layout: a good shape for pressure operation.

3. Uses well-established fabrication techniques.

4. Can be constructed from a wide range of materials

5. Easily cleaned

6. Well-established design procedures

Figure 2: Shell-and-tube heat exchanger

(FigureSource : http://www.optek.com)

11
3.2 Design of Heat Exchanger

The heat exchanger will be designed according to the design procedure by Chemical
Engineering Design, 4th Edition by R.K Sinnort.

Step 1: Physical properties

Table 5: Hot Stream Properties

Hot Stream
Hot Stream Outlet Average
Parameters Symbol Unit Inlet
(Stream 21) Value
( Stream 19)
O
Temperature T1, T2 C 140 102.3 -
Flowrate mt kg/hr 25773.72 25773.72 -
Phase - - Vapour Vapour -
Heat Capacity Cp,t kJ/kg.C 1.910 1.794 1.852
Thermal
kt W/m.K 0.03408 0.02962 0.03185
Conductivity
Viscocity t Pa.s 1.398E-5 1.274E-5 1.336E-5
Density t kg/m3 0.9917 1.001 0.9964
Major
- - Ethylene Ethylene -
Component

Table 6: Cold Stream Properties

Hot Stream
Hot Stream Outlet Average
Parameters Symbol Unit Inlet (
(Stream 6) Value
Stream 13)
O
Temperature t1, t2 C 70 100 -
Flowrate mt kg/hr 33834.41 33834.41 -
Phase Vapour,
- - Vapour -
Aqueous
Heat Capacity Cp,t kJ/kg.C 1.754 1.827 1.7905
Thermal
kt W/m.K 0.02604 0.02927 0.02766
Conductivity
Viscocity t Pa.s 1.069E-5 1.170E-5 1.1195E-5
Density t kg/m3 0.8841 1.205 1.0446
Major
- - Ethylene Ethylene -
Component

Heat duty, Q (from HYSIS) = 498333W

12
Step 2: Estimate Overall Coefficient

The literature has much tabulation of such typical overall coefficients for commercial
heat transfer services. In Chemical Engineering Volume 6, for shell-and-tube heat
exchanger which the gases flows in the shell side and inside the tubes, the typical overall
heat transfer coefficient, U estimated is in the range of 10-50 W/m2.K. Consider the
average, the estimated U = 50 W/m2.K.

Step 3: Heat Exchanger Dimension

Log-Mean-Temperature-Difference Correction Factors

In Chemical Engineering Design by RK Sinnot, it was shown that when hot and cold
fluids in a heat exchanger are in true counter-current flow, the log mean temperature
difference should be use:

Where;

Tlm = log mean temperature difference (oC)

T1 = inlet hot fluid temperature (oC) = 140

T2 = outlet hot fluid temperature (oC) = 102.3

t1 = inlet cold fluid temperature (oC) = 70

t2 = outlet cold fluid temperature (oC) = 100

13
Assumptions:

1. Equal heat transfer areas in each pass.

2. A constant overall heat-transfer coefficient in each pass.
3. The temperature of the shell-side fluid in any pass is constant across any cross
section.
4. There is no leakage of fluid between shell passes.

= 36.01 oC

The correction factor is a function of the shell and tube fluid temperatures, and the
number of tube and shell passes. It is normally correlated as a function of two
dimensionless temperature ratios:

In order to determine the true temperature difference, the correction factor, Ft needs to be
determined. The correction factor Ft is given in Figure 2 (Sinnott, 2005).

14
 Figure 3: Temperature Correction Factor (Sinnott, 2005)

From figure, the Ft value with respect to the S and R value, Ft = 0.832. Because the Ft is
more than 0.75, an economic heat exchanger design can be achieved. From correction
factor, we can calculate the actual temperature difference, Tm.

15
Step 4: Determine the heat transfer area required

The prime objective in the design of the heat exchanger is to determine the surface area
required for the specified duty (rate of heat transfer) using the temperature differences
available (Sinnort, 2005). A general equation for heat transfer across a surface is:

Where;

Q = Heat transferred per unit time (W) = 498333W

U = The overall heat transfer coefficient (W/m2.K) = 50 W/m2.K

Tm = Actual temperature difference (C) =29.96oC = 303.11K

A = Heat transfer area (m2)

Heat transfer area required is 32.88 m2

16
Step 5: Decide tubes and shells dimension, type and layout

Tubing that is generally used in TEMA sizes is made from low carbon steel, copper,
copper-nickel, stainless steel, hastalloy, inconel, titanium and a few others. It is common
to use tubing from 5/8 inch to 2 inch in the designs. The preferred lengths of tubes for
heat exchangers are 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). All the data gathered from Appendix A.5.-2, Transport Processes
and Unit Operation by Christie J. Geankoplis and Coulson & Richardson's Chemical
Engineering volume 6 by Sinnott R.K are tabulated in the Table 7 below.

Table 7: Standard dimension for tubes

Source: (Geankoplis, 2003), (Sinnort, 2005), (Smith, 2005)
Material of construction Stainless Steel (low grade)
BWG number 16
Length of tubes (Lt), m 3.66
Inside diameter (di), mm 22.1
Outside diameter (do), mm 25.4
Wall thickness, mm 1.65
Material thermal of conductivity, W/m.K 16

As for the material of construction, stainless steel tubes are preferred more than carbon
steel tubes due to the acidic and corrosive nature of the heat transfer fluids.

Step 6: Calculate number of tubes and bundle

A rotated square configuration is chosen for the design. Tube pitch (pt) is the center-to-
center distance between adjacent tubes and is usually 1.25 times the outside diameter (pt
= 1.25do).

Tube pitch, pt = 1.25 x do = 1.25 x 25.4mm = 31.75mm

Area of one tube, At = Ltdo = 3.66m x x 0.0254m = 0.2921m2

Number of tubes, 112.56 113 tubes

Number of tubes per pass,

Tube cross sectional area,

17
Total flow area per pass,

Tube side velocity, ut;

Bundle:

Where;

Db = bundle diameter, mm

Nt = number of tubes per pass = 57 tubes

K1 = constant = 0.156

N1 = constant = 2.291

18
Step 7: Calculate shell diameter

Where;

Ds = shell diameter, mm

Pc = Pitch configuration factor for square pitch = 1

pt = tube pitch, mm = 31.75 mm

do = tube outside diameter, mm = 25.4 mm

L = length of tubes, mm = 3660 mm

A = heat transfer area on the tube outside surface, mm2

Calculate A;

Step 8: Estimate tube-side heat transfer coefficients

Tube-side heat transfer coefficient

19
The value of jh (jh = 0.003) can be found from Figure 4 (Sinnott, 2005) below.
Assumption made in this part is assuming viscosity of the fluid is identical at the wall
and of the bulk fluid.

Figure 4: Heat Transfer Factor (Sinnot, 2005)

20
Step 9: Estimate baffle spacing and shell-side heat transfer coefficient

Shell-side Heat Transfer Coefficient

Baffle

Baffles are used in the shell to direct the fluid stream across the tubes, to increase the
fluid velocity and so improve the rate of transfer. A close baffle spacing will give will
give higher heat transfer coefficients but at the expense of higher pressure drop. The
optimum spacing will usually be between 0.3 to 0.5 times the shell diameters. The value
chosen is 0.5. The clearance needed will depend on the shell diameter; typical values,
and tolerances, are given in the table below (Coulson & Richardson's Chemical
Engineering, page 651).

21
The value of jh (jh = 0.0023) can be found from (selecting 25% for baffle cut) Coulson &
Richardson's Chemical Engineering., 6 (Design), Sinnott R.K. Assumption made in this
part is assuming viscosity of the fluid is identical at the wall and of the bulk fluid.

Step 10: Calculate overall heat transfer coefficient, Uo

22
Step 11: Estimate tube-side and shell-side pressure drop

Tube-side pressure drop

Friction factor jf (jf = 0.0019) can be obtained from Figure 4 Coulson & Richardson's
Chemical Engineering., 6 (Design), Sinnott R.K. & the value of m is 0.14. The value of
m depends on Reynolds number.

m = 0.25 for laminar flow, Re < 2100 and;

m = 0.14 for turbulent flow, Re > 2100

Figure 5: Friction factor (Sinnott, 2005)

23
Shell-side pressure drop

Friction factor jf (jf =0.002) can be obtained from Figure 12.30 (selecting 25% for baffle
cut) Coulson & Richardson's Chemical Engineering., 6 (Design), Sinnott R.K. & the
value of m is 0.14. The value of m depends on Reynolds number.

Step 12: Estimate cost of heat exchanger

All the calculations below are based on Chemical Process Design and Integration (2005),
Robin Smith, page 17-21.

Table 8: Cost estimation of heat exchanger

Heat transfer area, m2 32.88

Operating pressure, kPa 16141.045
Operating temperature, oC 220.00
Material of construction Stainless Steel (low grade)
Capital cost factor for material of construction, 2.9
fm
Capital cost factor for design pressure, fp 1.0
Capital cost factor for design temperature, ft 1.6
Total capital cost of installation 3.4

24
The actual cost of equipment can be estimated using the equation as shown below:

Where;

CE = equipment cost for carbon steel

CB = known base cost for equipment with capacity Q, $ = 3.28 x 104

Q = Design capacity (heat transfer area), m2 = 32.88

QB = Base size, m2 = 200

M = constant depending on equipment type = 0.68

25
 Table 9: SPECIFICATION DATA SHEET

Equipment No. HE-101

Shell and tube heat

HEAT EXCHANGER DATA SHEET Description
exchanger
Sheet No 1/1
OPERATING DATA

Shells Per Unit 1 Type Shell and tube

Surface Per Unit 2 Orientation Horizontal

PERFORMANCE OF ONE UNIT

Shell Side Tube Side

Fluid Circulating Product Product

Total Fluid Entering (kg/hr) 33834.41 25773.72

In Out In Out

Temperature (OC) 70 100 140 102.3

Vapor Fraction 0.914 1 1 1
Heat Capacity (kJ/kmoloC) 1.754 1.827 1.910 1.794

Viscosity (kg.m.s) 1.069E-5 1.170E-5 1.398E-5 1.274E-5

Thermal Conductivity
0.02604 0.02927 0.02962 0.03185
(W/moC)

Density (kg/m3) 0.8841 1.205 0.9917 1.001

MECHANICAL CONSTRUCTION

Shell Side Tube Side

Stainless
Material SS Length of Tube (mm)
Steel
Internal Diameter (mm) Outer Diameter (mm) 25.4
Baffle Spacing (m) 0.115 Inside Diameter (mm) 22.1

Thermal Conductivity
Pressure Drop (Pa) 458148 16
(W/m.K)
Heat Transfer
9199.63 Number of Tube 113
Coefficient (W/m2.K)

Shell Diameter, m 0.19126 Number of Tube Per Pass 57

Buffle Diameter, m 0.18966 Tube Cross Sectional Area, 383.5963
mm2

26
CHAPTER 4: COOLER (E-400)

From Stream 21 To Distillation Column

Figure 6: Cooler E-400

4.0 Introduction

Cooler E-400 as shown in Figure 6 is a shell and tube heat exchanger where most of
chemical industries commonly use it as a heat transfer equipment. The advantage of
using a cooler is that its configuration provides large heat transfer area in a small volume
and gives a good mechanical layout in the form of pressure operation. The construction
materials can vary, while the fabrication techniques are usually well-established.

The function of E-400 is to cool down the temperature of stream 8 which exits from Heat
Exchanger (E-101) from 102.3 C to -100 C, before entering the Distillation Column.
The Cooler E-400 will be designed with the advantages of:

i. The shell side provided with a number of baffles to promote high velocities and
largely more efficient cross flow on the outsides of the tubes
ii. Single phases, condensation or boiling can be accommodated in either tubes or
shell, in vertical or horizontal positions
iii. Pressure range and pressure drop are virtually unlimited, and can be adjusted
independently for the two fluids
iv. Thermal stresses can be accommodated inexpensively
v. A great variety of materials of construction can be used and may be different for
the shell and tubes
vi. Extended surfaces for improved heat transfer can be used on either side
vii. A great range of thermal capacities is obtainable
27
 viii. The equipment is readily dismantles for cleaning and repair

4.1 Cooler Sizing

Table below shows the properties of both fluids entering the shell and tube of heat
exchanger.

Table 10: Inlet and Outlet Streams Data for Shell and Tube Sides

Shell Tube
(Refrigerant, Propane) (To Distillation Column)
Design Type Split ring floating head
Heat Exchanger Orientation Horizontal
Flow Rate, q (kg/hr) 2737.08 25773.72
Inlet Temperature, Ti (C) t1 = -110 T1 = 102.3
Outlet Temperature, To (C) t2 = -10 T2 = -100
Specific Heat, Cp (kJ/kmol C) 0.0736 50.78
Heat Transfer, Q (kW) 2388
Density, (kg/m3) 654.3 1.001
Viscosity, (Pa.s) 0.0005254 0.00001274
Viscosity, (cP) 0.5254 0.01274
Thermal Conductivity, k 0.1721 0.02962
(W/m.K)
Molecular Weight, MW 44.10 28.30

The type of heat exchanger selected is shell and tube exchanger, with an internal floating
head of split-ring type. This type of exchanger is more versatile compared to the other
type of exchanger due to the easiness to be cleaned inside and outside as the tube bundles
can be removed. It is also permits the thermal expansion and suitable for the high
temperature differentials. The configuration chosen is horizontal.

Basically, the flow rate of propane in Table 1 is not stated in Hysys. Therefore, manual
calculation is needed in order to determine the flow rate of cooling water inside the shell
side of the heat exchanger. The equation used for the calculation is:

28
In order to determine the heat transfer area, A, several numbers of calculation steps need
to be done.

Log mean temperature is calculated using formula:

In order to determine the true temperature difference, the correction factor, Ft,
needs to be determined first by referring to Figure 2 (Sinnott, 2005). From Figure
2, the Ft value with respect to the S value obtained above is 0.5.

29
 Figure 7: Temperature Correction Factor (Sinnott, 2005)

The true temperature difference, can be calculated as

By referring to Sinnott (2005), U = 300 W/m2 C for gases as hot fluid and
propane as cold fluid.
The area required for the heat transfer, A is therefore,

30
4.2 Tube Sides

The table below summarized the details of material that is selected from Geankoplis
(2003) to be used for the construction of tube sides of this cooler.

Table 11: Details of Tube Dimensions

Material Stainless Steel

Outside Diameter, do (m) 0.01588
Inside Diameter, di (m) 0.01033
Wall Thickness (m) 0.00277
Length of Tube (m) 3.66
Thermal Conductivity (W/m C) 16.3

Area of tube is calculated using the following equation:

With this, the number of tubes, Nt will be

Tube side velocity, vt = volumetric flow rate (from hysis) / (Nt x At)

= 1217 m3/hr / (1184 x 0.1826)

= 5.629 m/hr x 1hr / 3600s

= 0.001564 m/s

The tube side heat transfer coefficient is then determined as follow:

i. Finding the Reynolds Number, . Since Re < 2100, thus

it is a laminar flow
ii. Finding the length to diameter ratio = L / di = 354.3

iii. Finding the Prandlt number, = 0.477

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 Figure 8: Tube-side heat transfer factor (Sinnott, 2005)

Based on Figure 8 (Sinnott, 2005), Tube side heat coefficient, jh = 0.2

The tube side heat transfer coefficient,

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 Figure 9: Tube-side friction factors (Sinnott, 2005)

In order to calculate the tube side pressure drop, the tube side friction factor, jf need to be
determined first by referring to Figure 9 (Sinnott, 2005). From there, the jf is
approximately 0.5. Then, the pressure drop is calculated with the viscosity correction
term neglected.

Np = number of tube side passes = 2 passes

From table 12.4 of Sinnott (2005),

Triangular pitch, K1 = 0.249, n = 2.207

Bundle diameter, Db

33
4.3 Shell Side

The table below summarized the details of material that is selected for the construction of
shell sides of this cooler.

Table 12: Details of shell dimensions

Arrangement Triangular Pitch

Shell Diameter, Ds 0.508 m
Baffle Spacing, IB 0.254 m
Tube pitch, pt 0.01985 m
Tube Outside Diameter, do 0.01588 m

Cross flow area, As, shell-side mass velocity, Gs and linear velocity, us can be determined
by:

I. Cross flow area, As

II. Shell side mass velocity, Gs, where Ws = 0.7603 kg/s

III. Linear velocity, us

34
The shell side heat transfer coefficient is then determined through steps as follow:

I. Equivalent diameter, de is represented by

II. Reynolds Number, Re

III. Prandtl number, Pr

35
 Figure 10: Shell-side heat transfer factors, segmental baffles (Sinnott, 2005)

Selecting 25% for baffle cut, the value of jh as taken from Figure 9 (Sinnott, 2005) is jh =
0.3

Shell-side heat transfer coefficient, hs

36
 Figure 11: Shell-side friction factors,segmental baffles (Sinnott, 2005)

In order to determine the shell-side pressure drop, the shell-side friction factor, jr is first
determined by referring to Figure 10 (Sinnott, 2005) where jr = 0.1. The pressure drop is
calculated by using the following equation.

4.4 Overall Heat Transfer Coefficient

Table 13: Data of heat transfer coefficients

Outside fluid film coefficient, hs, W/m2.K 10174.60

Inside fluid film coefficient, hi, W/m2.K 58.55
Outside dirt coefficient (fouling factor), hod, W/m2.K 6000
Inside dirt coefficient (fouling factor), hid, W/m2.K 3000
Thermal conductivity of the tube wall material, kw, W/m2.K 16
Tube inside diameter, di, m 0.01033
Tube outside diameter, do, m 0.01588

37
Overall heat transfer coefficient can be calculated by using the formula:

Therefore, Uo = 30.5904 W/m2 C

All the calculations below are based on Chemical Process Design and Integration (2005),
Robin Smith, page 17-21.

Table 14: Estimated Cost

Heat transfer area, m2 216.07

Operating pressure, kPa 16141.045
Operating temperature, oC 220.00
Material of construction Stainless Steel (low grade)
Capital cost factor for material of construction, 2.9
fm
Capital cost factor for design pressure, fp 1.0
Capital cost factor for design temperature, ft 1.6
Total capital cost of installation 3.4

4.5 Cost

The actual cost of equipment can be estimated using the equation as shown below:

Where;

CE = equipment cost for carbon steel

CB = known base cost for equipment with capacity Q, $ = 3.28 x 104

Q = Design capacity (heat transfer area), m2 = 216.07

QB = Base size, m2 = 200

M = constant depending on equipment type = 0.68

38
39
 Table 13: SPECIFICATION DATA SHEET (COOLER)

Equipment No E-204
Cooler E-204 Data Sheet Description Cooler
Sheet No 1 of 1
OPERATING DATA
No. REQUIRED 1 TYPE Shell and Tube
OPERATION Continuous ORIENTATION Horizontal
DUTY 2388 kW AREA 103.69 m2
PERFORMANCE OF ONE UNIT
SHELL TUBE
FLUID CIRCULATING Propane Stream 13
In Out In Out
TEMPERATURE (C) -110 -10 102.3 -100
VAPOR FRACTION - - 1.00 1.00
LIQUID FRACTION 1.00 1.00 - -
HEAT CAPACITY (kJ/kmol.K) 0.0736 50.78
DENSITY (kg/m3) 654.3 1.001
VISCOSITY (Pa.s) 0.0005254 0.00001274
THERMAL CONDUCTIVITY (W/m.K) 0.1721 0.02962
MECHANICAL DESIGN
SHELL TUBE
MATERIAL Stainless Steel MATERIAL Stainless Steel
INNER DIAMETER 0.508 m INNER DIAMETER 0.01033 m
BAFFLE SPACING 0.254 m OUTER DIAMETER 0.01588 m
SPACING % CUT 25% LENGTH 3.66 m
PRESSURE DROP 0.2467 kPa NO. OF TUBES 568
2
HEAT TRANSFER 10174.60 W/m .K NO. OF PASSES 2
COEFFICIENT
INSIDE FOULING 3000 W/m2.K TUBE PITCH 0.0254 m
(TRIANGULAR)
OUTSIDE FOULING 6000 W/m2.K BUNDLE DIAMETER 0.5278 m
PRESSURE DROP 6.022x10-9 kPa
HEAT TRANSFER 58.55 W/m2.K
COEFFICIENT

40
 REFERENCES

REFEERENCES
Christie J. Geankoplis (1993), Transport Processes and Unit Operation, 3rd Ed.,
Prentice Hall Inc, New Jersey.

Ebrahimi, H., Behroozsarand, A., & Zamaniyan, A. (2010). Arrangement of primary and
secondary reformers for synthesis gas production. [doi: 10.1016/j.cherd.2010.02.021].
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James M. Douglas (1988), Conceptual Design of Chemical Processes, International

Edition, Mc Graw Hill Inc, New York

J. R. Rostrup-Nielsen and K. Aasberg-Petersen, Steam Reforming, ATR, Partial

Oxidation; Catalysts and Reaction Engineering, Ch. 14 of Handbook of Fuel Cells:
Fundamentals,
Technology, and Applications, Vol 3., W. Vielstich, A. Lamm, H. A. Gasteiger, eds.,
Wiley, 2003

Ko, K.-D., J. Lee, et al. (1995). "Kinetics of steam reforming over a Ni/alumina catalyst."
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Megan Strait, G. A., Nisha Gidwani. (2000). SYNTHESIS GAS REFORMERS Retrieved
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R.K. Sinnott (2000), Coulson & Richardsons Chemical Engineering, Volume 6, 3rd
Ed., Butterworth Heinemann, Great Britain.

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