5.

3 HEAT EXCHANGER CHEMICAL DESIGN

5.3.1 PROCESS FLOW CHART
The purpose design of the heat exchanger E-105 is to heat the hydrocarbon liquid from
separator, stream 13, to a desired temperature before further reaction. It is heated by
the superheated steam.

Stream 4

Tho = 280 0C

P=1800 kPa

Stream 1
Stream 3
0
Tci = 20 C
Tco = 100 0C
P = 800 kPa
P=835kPa

Stream 3

Thi = 400 0C

P = 2000 kPa

5.3-1
5.3.1.1 Type of heat exchanger used
Heat exchanger is a device that provides the flow of thermal energy between 2
or more fluids at different temperature. The purpose of this equipment is to increase the
mixture to the desired temperature that is from temperature 20oC to temperature 100oC.
Type of heat exchanger that has been chosen is the shell-and-tube heat exchanger.
The shell and tube heat exchanger is the most common of the various types of
unfired heat transfer equipment used in industry. Although it is not especially compact,
it is robust and its shapes make it well suited to pressure operation. Shell-and-tube heat
exchanger gives a lot of advantage, which include;
a) Good mechanical layout; a good shape for pressure operations.
b) It can provide a large transfer area in a small space.
c) It also can be constructed from a wide range of materials.
d) Easy to clean.
e) It used well-established fabrication technique and design procedure.

Shell-and-tube heat exchangers are built of round tubes mounted in long cylindrical
shell with the tubes axis parallel to that of the shell. One fluid stream flows through the
tube while the other flows on the shell side, across or along the tubes. A number of
shell-and-tube flow arrangements are used in shell-and-tube heat exchanger depending
on heat duty, pressure drop, pressure level, fouling manufacturing technique and cost,
and cleaning problems. Shell-and-tube heat exchanger is design on a custom basis for
any capacity and operating condition and this is contrary to many heat exchanger types.

5.3-2
There are three types of heat exchanger used in industries, which are
a) Shell-and-tube heat exchanger
b) Plate heat exchanger
c) Spiral heat exchanger
Among the three types of exchanger, the one that have been chosen is shell-and-
tubes heat exchanger because it is the most widely used and can be designed for
virtually application. Besides, it also relatively cheaper than other heat exchanger with a
sufficient in its applications.
Selection of Shell-and-Tube-Type of Heat Exchanger
There are various types of heat exchanger used in industries; each one of it can give its
own advantages and disadvantages. Table 5.3.1 shows the advantages and
disadvantages of each type of heat exchanger: (Ramesh K. Shah and Dusan P.Sekulic,
2003)

Table 5.3.1: The Advantages and Disadvantages of Each Types of Heat

Exchanger
Construction Advantages Disadvantages
Non-  Less costly  Shell side can be cleaned only by
removable Give maximum heat transfer chemical means.
Bundle, surface per given size of
Fixed Tube shell and tubes
Sheet Provides multi-tube pass
arrangement

Removable  Shell side can be  Shell side fluids limited to non

Bundle, mechanically cleaned volatile
Packed  Bundle can be easily  Tube side arrangement limited to
Floating replaced or repair one or 2 passes
Tube Sheet  Less costly than pull,  Tubes expand as a group, not
internal floating head individually, so sudden shock’s
types should be avoided
 Maximum surface per  Limits design pressure and
given shell and tube size temperature
Removable  Good for handling  More costly than fixed tube sheet

5.3-3
Bundle, flammable or toxic fluids or U tube heat exchanger design
Internal  High surface per given  Shell cover, clamp ring and floating
Clamp ring, shell and tubes size head cover must be removed prior
Types  Provides multi tubes to removing the bundle. Results in
Floating pass arrangement higher maintenance cost
head cover.
Removable  Less costly than floating  Tube side only can be cleaned by
Bundle U head or packed floating chemical means
tube tube sheet design  Individual tube replacement is not
 Provides multi tube pass practical
arrangement  Cannot made single tube pass
 High surface area  Draining tube side difficult in
 Capable of withstanding vertical position
thermal shock

(Ramesh K. Shah and Dusan P.Sekulic, 2003)

5.3-4
TEMA (Tubular Exchanger Manufacturer Association) give classification of heat
exchanger. Table 5.3.2 give the types of heat exchanger that have been chosen and
reasons why it being selected for this process.

Table 5.3.2: Selection of Heat Exchanger

Type Reasons of Selection
Front End Type A  Good for frequent cleaning of
Stationary  Channel and tubes
Head Types removable
cover
Shell Types Type E  The most commonly used in
 One pass industries
shell  More cheaper and simple
Rear Ends Type T  Give a smaller number of tubes
Head Types  Pull through  Reduced maintenance time
floating head because the bundle can be
withdrawn from the shell without
removing shell or floating-head
covers
(Ramesh K. Shah and Dusan P.Sekulic, 2003)

Assumptions for chemical design:

1. The flow is assumed as steady state flow
2. The kinetic and potential energy changes are negligible
3. The assumption of overall heat coefficient is 500 W/m2°C
(Sinnot,1996)

Assumptions for mechanical design

5.3-5
1. Design pressure is assumed to be 10% above the operating pressure.
2. Design temperature is taken at the maximum of operating temperature.
3. The thickness of design is assumed by adding 4 mm for the corrosion
allowance.
4. Assumed that no joint in the head,therefore J = 1
(Sinnot,1996)

5.3-6
5.3.2 PROCEDURES IN DESIGNING THE HEAT EXCHANGER
5.3.2.1 The steps in a typical design procedure are given below:

1. Define the duty: heat-transfer rate, fluid flow-rates, and temperatures.

2. Collect together the fluid physical properties required: density, viscosity, thermal
conductivity.
3. Decide on the type of exchanger to be used.
4. Select a trial value for the overall coefficient, U.
5. Calculate the mean temperature difference, ∆Tm.
6. Calculate the area required from equation 12.1.
7. Decide the exchanger layout.
8. Calculate the individual coefficients.
9. Calculate the overall coefficient and compare with the trial value. If the
calculated value differs significantly from the estimated value, substitute the
calculated for the estimated value and return to step 6.
10. Calculate the exchanger pressure drop; if unsatisfactory return to steps 7 or 4 or
3, in that order of preference.
11. Optimize the design: repeat steps 4 to 10, as necessary, to determine the
cheapest exchanger that will satisfy the duty. Usually this will be the one with
the smallest area.

5.3-7
5.3-8
Figure 5.3.1 Flowchart for design procedure for horizontal floating shell-and-tube-heat
exchangers

5.3-9
5.3.3 THEORETICAL ASPECTS OF HEAT EXCHANGER
5.3.3.1 Determine the heat load

Q = ṁCp∆T (5.3.1)

Q = quantity of heat energy (kW/s)

ṁ = fluid flowrate
Cp = specific heat capacity
∆T = temperature difference

5.3.3.2 Physical properties of streams involved

The physical properties such as density, viscosity, specific heat capacity,

thermal conductivity, temperatures of each streams involved are calculated and
tabulated.

5.3.3.3 Assumption of overall coefficient Uo value

Overall coefficient, Uo, is assumed from Figure 1 in Appendix C.

5.3.3.4 Mean Temperature Difference

The flow arrangement of the fluid is counter current where hot and cold fluids
enter at opposite directions, flow in opposite direction and leave at opposite
ends. The temperature’s distribution between the fluids can been shown in
figure below;

(Th,i - Tc,o ) - (Th,o - Tc,i )

Tlm  (5.3.2)
(T - T )
ln h,i c,o
(Th,o - Tc,i )

5.3-10
 Where
Tlm = Log mean temperature difference
Th,I = Hot fluid inlet temperature
Th,o = Hot fluid outlet temperature
Tc,I = Cold fluid inlet temperature
Tc,o = Cold fluid outlet temperature

In most shell and tube exchangers, the flow will be a mixture of co-current,
counter-current and cross flow. The usual practice in the design of shell and tube
exchangers is to estimate the “true temperature difference” from the logarithmic mean
temperature by applying a correction factor for the departure from true counter-current
flow:

The “true temperature difference” is given by:

Tm  FtTlm
(5.3.3)

Where ΔTm = True temperature difference, the mean temperature difference for
use in the design equation Q = UAΔTm
Ft = The temperature correction factor.

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 function of two
dimensionless temperature ratios:
T1 - T2
R
t 2 - t1

(5.3.4)

Where T1 = Inlet shell-side fluid temperature

T2 = Outlet shell-side fluid temperature
t1 = Inlet tube-side temperature
t2 = Outlet tube-side temperature

5.3-11
And S,
𝑡 2 −𝑡 1
𝑆= (5.3.5)
𝑇1 −𝑡 1

By using equation for one shell passes and two tube passes, the temperature correction
factor, Ft can be obtained.

 1 S 
R 2  1 ln  
1  RS 
Ft 

2  S R  1  R2  1 
R  1 ln 

 
 2  S R  1  R 2  1 

(5.3.6)
5.3.3.5 The Heat Transfer Area

From general equation for heat transfer across a surface, Q = UA ∆Tm, and the heat
transfer area, Ao is
Q
Ao =
U  Tm
Area of one tube, At = d L
(5.3.7)

5.3.3.6 Tube Dimensions and Layout

Types and material of heat exchanger used for this process is decided. The allocation
of fluid on shell and tube is also essential. The dimensions of the tube used are also
chosen.

5.3.3.7 Number of tubes

Ao
Number of tubes =
At

(5.3.8)

5.3-12
5.3.3.8 Bundle and shell diameter
An estimate of the bundle diameter Db can be obtained from equation below;
1 / n1
N 
Bundle diameter, Db = d o  t 
 K1 
(5.3.9)

Where Nt = Number of tubes

Db = Bundle diameter, mm
do = Tube outside diameter, mm

Ds = Db + Dclearance
Ds = Shell diameter
Dclearance = Shell bundle clearance
5.3.3.9 Tube Side Coefficient
An even number of tube passes is usually the preferred arrangement, as these
positions the inlet and outlet nozzles at the same end of the exchanger, which simplifies
the pipe work.

Tube cross sectional area =   r2

(5.3.10)
r = radius of tube
Total area per passes = no. of tubes x tube cross sectional area
.
m
Volumetric flow rate, Q =

(5.3.11)
ṁ = mass flow rate
Q
Tube side velocity, ut =
A
(5.3.12)

  ut  d i
Reynold’s number =

(5.3.13)

5.3-13
ut = tube velocity
di = tube inside diameter

5.3-14
 Cp  
Prandtl number =
kf
(5.3.14)
Cp = heat capacity
μ = viscosity
kf = thermal conductivity

It is convenient to correlate heat-transfer data In terms of heat transfer” j ” factor.

The use of jh factor enables data for laminar and turbulent flow to be represented on the
same graph. This mean the same equation can be used both for laminar and turbulent
flow. The equation for Nusselt number is;

Nusselt number,Nu = jh Re Pr 0.33

(5.3.15)

0.14
The viscosity correction factor (μ / μw) was neglected when calculating the heat
transfer coefficient. This is reasonable for the reaction gas since it has a relatively low
viscosity.
Thus tube side heat transfer coefficient;
𝑗 𝑕 𝑘 𝑓𝑅𝑒 𝑃𝑟 0.33
hi =
𝑑𝑖
(5.3.16)

5.3.3.10 Shell Side Coefficient

Ds
Take the baffle spacing, IB =
2
(5.3.17)
Ds = Shell diameter
Tube pitch = 1.25do
(5.3.18)

5.3-15
 do = Tube outer diameter

To calculate the area for cross-flow As for the hypothetical tubes at the shell equator
given by:
 pt  do DslB
Cross-flow area, As =
pt

(5.3.19)
Where; pt = Tube pitch
do = Tube outside diameter
Ds = Shell inside diameter, m
IB = Baffle spacing, m

.
m
Volumetric flow rate on shell side, Qs =

Qs
Shell side velocity =
As
The equivalent diameter, de for a triangular pitch arrangement:

de =
1.10
do

Pt  0.917d o
2 2


(
5.3.20)

5.3-16
To obtain the heat transfer factor;
  ut  d i
Reynold’s =

(5.3.21)
Cp  
Prandtl =
kf

(5.3.22)

25% baffle cut is chosen as this an optimum value that will give good heat-transfer
rates without excessive drop. (Sinnot,1996)

The shell-side heat transfer coefficient, hs can be calculated from the equation below:
0.14
hs de  
 jh Re Pr 1 / 3  
kf  w 
(5.3.23)

Neglecting the viscosity correction term in equation above, hs is:

0.14
kf   
hs  jh Re Pr   1/ 3

de  w 

(5.3.24)
5.3.3.11 Overall Coefficient

The relationship between overall coefficient and individual coefficients is given by:

1 1 1 d ln(d o /d i ) 1  do  1 do
= + + o +   + ( )
U o ho hod 2kw hid  di i  hi di

(5.3.2
5)

5.3-17
Where; Uo = The overall coefficient based on the outside tube area, W/m2 0C
ho = Outside fluid film coefficient, W/m2 0C
hi = Inside fluid film coefficient, W/m2 0C
hod = Outside dirt coefficient (fouling factor), W/m2 0C
hid = Inside dirt coefficient, W/m2 0C
kw = Thermal conductivity of the tube wall material, W/m 0C
di = Tube inside diameter, m
do = Tube outside diameter, m

5.3.3.12 Tube side pressure drop

The tube-side pressure drop can be calculated from:

 L   ut2
Pt  N p 8 j f ( )  2.5
 di  2

(5.3.26)

Where ∆ Pt = Tube side pressure drop, N/m2 (Pa)

Np = Number of tube-side passes
ut = Tube side velocity, m/s
L = Length of one tube

5.3.3.13 Shell-side Pressure Drop

The shell side pressure drop can be calculated from equation 2.23.
D  L  U s 2
ΔPs = 8 j f  s  
 de  l B  2
(5.3.27)

Where ∆ Ps = Shell side pressure drop, N/m2 (Pa)

Ds = Shell inside diameter, m
Us = Shell side velocity, m/s
lB = Baffle spacing

5.3-18
L = Length of one tube

5.3-19
Table 5.3.3: Optimum Pressure Drop (Maximum Allowable Pressure Drop) Based on
Economic Considerations (Sinnot,1996)
Fluid Optimum, ∆pt or ∆ps, kPa
Liquids of μL < 1 cP 35
Liquids of μL < 1 cP 50-70
Gas or vapour at 1 to 2 atm 13.8
Gas or vapour at high vacuum (up to 60 torr absolute 0.4 to 0.8 (3-6 torr)
pressure)
Gas or vapour at high pressure >10 atm 0.1 times operating pressure

5.3-20
5.3.4 Calculation of heat exchanger design
5.3.4.1 Calculation of the heat load
From Equation 5.3.1, the total heat load is
Q = ṁ x Cp x ∆T
Propanal
Latent heat = 506.3681 kJ/kg (Perry’s,8th Edition)
Boiling point = 47.5 °C
∆Ĥ𝐶3 𝐻6 𝑂 =
𝑇2 47.5
8.162𝑥10−1 𝑇 2 2.7350𝑥10−3 𝑇 3 3.766𝑥10−6 𝑇 4
𝐶𝑝 𝑑𝑇 = 59.054𝑇 + − + 𝑑𝑇
𝑇1 20 2 3 4

= 0.3055 kJ/kg
Superheating
∆Ĥ𝐶3 𝐻6 𝑂 =

𝑇2 47.5
4.8385𝑥10−3 𝑇 2 3.3514𝑥10−4 𝑇 3 3.051𝑥10−7 𝑇 4
𝐶𝑝 𝑑𝑇 = 5.8911𝑥10−1 + − +
𝑇1 20 2 3 4
8.3305𝑥10−11 𝑇 5
+ 𝑑𝑇
5

= 0.0445 kJ/kg
Mass flowrate for propanal,ṁ = 5.35 kg/s (source:HYSYS)
Q vaporization = 5.35 kg/s x 506.3681 kJ/kg
= 2709.07 kJ/s
Q superheating = 5.35 kg/s x (0.3055+ 0.0445) kJ/kg
= 1.872 kJ/s
Q vaporization + Q superheating = 2709.07 kJ/s + 1.872 kJ/s
= 2710.94 kJ/s
= 2710940 J/s

Carbon monoxide
Latent heat = 215.709 kJ/kg (Perry’s,8th Edition)
Boiling point = -191.5 °C

5.3-21
 Superheating
∆ĤCO gas
100
0.411𝑥10−5 𝑇 2
0.3548𝑋10−8 𝑇 3 2.22𝑋10−12 𝑇 4
= 28.95𝑋10−3 𝑇 + − + 𝑑𝑇
2 3 4
−191.5

= 4.003 X 10-5
Q superheating = ṁ CO x ∆ĤCO
= 0.0129 x 4.003 X 10-5
= 5.164 X 10-7 kJ/s
Q vaporization + Q superheating = (215.709 kJ/kg X 0.0129 kg/s) + 5.164 X 10-7 kJ/s
= 2.783 kJ/s
= 2783 J/s
Hydrogen
Latent heat = 452 kJ/kg (Perry’s,8th Edition)
Boiling point = -252.76°C

Superheating

100
0.0065𝑥10−5 𝑇 2
0.3548𝑋10−8 𝑇 3
∆ĤH2(gas ) = 28.84𝑋10−3 𝑇 + −
2 3
−252.76 1

0.8698𝑋10−12 𝑇 4
+ 𝑑𝑇
4

= 0.000343 kJ/kg
Q vaporization + Q superheating = (452 kJ/kg x 0.0063 kg/s) + (0.000343 kJ/kg x 0.0063 kg/s)
= 2.848 kJ/s
= 2848 J/s

5.3-22
Total heat load, Q
= 2710.94 kJ/s + 2.783 kJ/s + 2.848 kJ/s = 2716.572 kJ/s
= 2716572 J/s

5.3.4.2 Physical Properties

The tables below show the physical properties of streams involved collected from hysys
simulation. Table 5.3.4is the physical properties for stream 1 and 3. Stream 1 is to be
heated by superheated steam before entering the reactor.

Table 5.3.4: Physical properties of Stream 1 and 3

Properties of mixture Stream 1 Mean Stream 3
Temperature (0C) 20 60 100
Specific heat (kJ/kg0C) 2.2004 1.9465 1.6926
Thermal conductivity ( W/m0C) 0.1531 0.087 2.08x10-02
Viscosity ( N sm-2) 0.00037251 0.000190793 9.08x10-06
Density (kg/m3) 784.07 397.9935 11.917

Table 5.3.5shows the physical properties for stream 2 and 4. This stream, superheated
steam, will heat stream 1 to the desired temperature.

Table 5.3.5: Physical properties of Stream 2 and 4

Properties of mixture Stream 2 Mean Stream 4

Temperature (0C) 400 340 280

Specific heat (kJ/kg0C) 2.1868 2.2756 2.3643

Thermal conductivity ( W/m0C) 0.0567 0.0501 0.0435

Viscosity ( N sm-2) 0.00002456 0.00002192 0.0000193

Density (kg/m3) 6.6152 7.0297 7.4442

5.3-23
5.3.4.3 Assumption of overall coefficient Uo value
The value of overall coefficient for preliminary sizing of shell and tube must be
assumed to start the calculation. From Figure 1 in Appendix A, under the heater, the hot
fluid is superheated steam and the cold fluid is hydrocarbon liquid. The overall heat
transfer coefficient is between 500 – 1000 W/m2 0C. Therefore, for the calculation, the
overall heat transfer area is assumed as 500 W/m2 0C. (Sinnot,1996)

Uo, ass = 500 W/m2.oC

5.3.4.4 Mean temperature difference

Thus, from equation 5.3.2 (page 5.3.9), the log mean temperature difference is:

Tlm = (400 - 100) - (280 - 20)

(400 - 100)
ln
(280 - 20)

= 279.5 0C
Therefore from equation 5.3.4 (page 5.3.10),

400 - 280
R =
100 - 20

= 1.5
and equation 5.3.5 (page 5.3.11),
100  20
S =
400  280

= 0.21

𝐹𝑡 = 0.98

5.3-24
The true temperature difference can be calculated by using equation 5.3.3 of page
5.3.10.

∆Tm = 0.98 x 279.5

= 273.9 0C

5.3.4.5 The heat transfer area

The heat transfer area can be calculated from equation 5.3.7 (page 5.3.11),
Q
Ao =
U  Tm
2716572
=
500  273.9
= 19.83 m2
5.3.4.6 Tube dimensions and layout
The shell and tube type floating head exchanger has been used for more
efficiency and easy for cleaning purpose. For dimensions of the tube, the standard
diameter of 25.40 mm (1 inch) outside diameter and 19.30 mm inside diameter is used
after several iterations done. After several iteratins, the length of the tube chosen is 5 m
on a triangular 23.81 mm pitch (pitch/dia = 1.25do). Carbon steel is used for the shell
and tube. (Perry’s,8th Edition)

5.3.4.7 Number of tubes

Area of one tube, At = d L

= 𝜋 × 25.40 × 10−3 × 5
= 0.3991 m2

Thus, form equation 5.3.8 (page 5.3.11)

Ao
Number of tubes =
At
24.0761
=
0.2922
= 49.7 tubes

5.3-25
Take even number of tubes, therefore 52 tubes.

Tube pitch = 1.25do

= 1.25 x 25.40
= 31.75 mm

5.3.4.8 Bundle and shell diameter

From equation 5.3.9 (page 5.3.12), for 4 passes,n1 = 2.285 & K1 = 0.175 from Figure 5
(Appendix C),

1 / 2.285
 52 
Bundle diameter = 25.40  
 0.175 
= 306.9688 mm
For a pill through floating heat exchanger, the typical shell clearance from figure 4
(Appendix C) is 55 mm. So the shell inside diameter

Ds = Db + Dclearance
= 306.9688 + 55
= 361.9688 mm

5.3.4.9 Tube side coefficient

From equation 5.3.10 (page 5.3.12),
Tube cross sectional area = 𝜋 × 𝑟2
= 𝜋 × 19.30 × 10−3 2

= 0.000293 m2

For 4 passes, tube per pass = 52/4

= 13
Total area per pass = 13x 0.000293
= 0.003805 m2
19330 3600
Volumetric flow rate,Q =
397.9935
𝑘𝑔
= 0.01349
𝑠𝑚 2

5.3-26
 0.01349
Tube side velocity =
0.003805
= 3.55 𝑚/𝑠
The velocity is satisfactory because it is between 1 to 2 m/s, maximum 4 m/s if required
to reduce fouling. (Sinnot,1996)
From equation 5.3.13 (page 4-11), Reynold’s number can be calculated using the tube
side velocity calculated earlier. This Reynold’s number is used to calculate tube side
coefficient, hi.
397.99 ×3.55 ×25.40 ×10 −3
Reynold’s number =
0.00019
= 142758.30

Prandtl number can be calculated using equation 5.3.14.

1.9465 ×10 −3 ×0.00019

Prandtl number =
0.0087
= 4.2687

L 5000
=
di 19.30
= 259.0674

From Figure 9 of Appendix C, tube side heat transfer factor,

jh = 0.0032
Thus, tube-side heat transfer coefficient from equation 5.3.16 (page 5.3.13);
0.0032 𝑋 0.087 𝑋 142758 .30 𝑋 4.2687 0.33
hi =
0.01930

= 3324.39 W/m2°C

5.3-27
5.3.4.10 Shell side coefficient
Baffles are used in the shell to direct the fluid stream across the tubes to increase the
fluid velocity and improve the rate of transfer. (Sinnot,1996)
Ds
Baffle spacing, IB =
5
361.9688
=
5
= 72.3938 mm
To decrease pressure drop in the shell to obtain optimum pressure drop, increase baffle
spacing to 361.9688 mm
Thus, from equation 5.3.19 (page 5.3.14),
 pt  do DslB
Cross-flow area, As =
pt

Cross-flow area, As =
31.75  25.40  361.9688  361.9688
31.75
2
= 26204.28 mm
= 0.02620 m2
Shell side volumetric
flowrate, Qs = (7000 3600)/7.0297
𝑚3
= 0.2766
𝑠
0.2766
Shell side velocity =
0.02620
= 10.56 m/s

From equation 5.3.20, the equivalent diameters, de for a triangular pitch arrangement:

1.10 2
𝑑𝑒 = 𝑃𝑡 – 0.917𝑑2𝑜
𝑑0

1.10
= 31.752 – 0.917(25.40)2
25.40

5.3-28
 = 18.04mm
The shell-side Reynold’s number,

74.20  18.043  103

Re =
0.00002192
= 61052.77

2.2756  103  0.00002192

Prandtl number =
0.05008
= 0.9959
25% baffle cut is chosen as to obtain optimum value that will give good heat-transfer
rates without excessive drop. (Sinnot,1996)

jh = 0.0012 (from figure 11 of Appendix C)

Therefore, shell coefficient can be calculated from equation 5.3.24,

0.14
kf  
hs  jh Re Pr  
1/ 3

de  w 

 0.0501 
 103   1.2  10  61052.77  0.9959
3

1/ 3
hs =
 18.04 
= 203.18 W/m2 oC

5.3-29
5.3.4.11 Overall heat transfer coefficient,Uo
The overall heat transfer coefficient is used to for the preliminary sizing of equipment for
process evaluation and as trial values for starting a detailed thermal design.
(Sinnot,1996)
Thermal conductivity of carbon steel = 39W/m0C from Figure 7 of Appendix C. Take the
fouling factor from figure 2 of Appendix C; hydrocarbon 0.0002 m 2 0C/W. Thus, from
equation 5.3.25 of page 5.3.15,

1 1 1 d ln(d o /d i ) 1  do  1 do
= + + o +  + ( )
Uo ho hod 2kw hid  di i  hi di

1 1 25.40  103 25.40 1 25.40 25.40

  0.0001  ln( ) ( )  0.0002( )
Uo 203.18 2(39) 19.30 3324.39 19.30 19.30
Thus, the calculated value of Uo is;

Uo = 173.30 W/m2 0C
Uo calculated is less than U assumed. Therefore, this design is accepted.

5.3.4.12 Tube-side Pressure Drop

From equation 5.3.26 and jf = 0.0028 from figure 10 (Appendix C),

 L   ut2
Pt  N p 8 j f ( )  2.5
 di  2

  397.9935  3.55
2
5000
ΔPt = 48  0.0028( )  2.5
 19.30  2
= 34258.25 N/m2
= 34.26 kN/m2

5.3-30
The pressure drop across the tube is around 35 kPa and is acceptable after several
iterations done by deciding tube size. The pressure drop should be kept 35 kPa as this
is the optimum pressure drop for tube side.

5.3.4.13 Shell-side Pressure Drop

Shell side pressure drop can be calculated from equation 5.3.27,
for Re = 305395.70, jf = 0.2 from Figure 12 (Appendix C),

D  L  U s 2
ΔPs = 8 j f  s  
 de  l B  2

 361.9688  5000  7.0297  10.56

2
= 8  0..2  
 18.04  361.9688  2
= 1.74x105 N/m2
= 174 kN/m2
The pressure drop calculated across the shell is acceptable which is within
specification,0.1 from operating pressure, that is 174 kPa.

5.3.5 Summary of chemical design

As a conclusion, the heat exchanger chosen for this 1-propanol production is
shell and tube exchanger. Shell-and-tube exchangers are the first choice to apply as it
have good mechanical layout, large surface area in a small volume, easy to clean, well-
established design procedures and can be constructed from a wide range of materials.
Furthermore, the horizontal floating head-type shell and tube heat exchanger is
preferred to be used as cooler besides it is widely used in the chemical industries. A
horizontal arrangement is chosen because it provides a significantly higher heat
transfer coefficient. In addition, it is easier for cleaning purpose.(Ramesh K. Shah,2003)

5.3-31
Table 5.3.6 Summary of chemical design for tubes side
Fluid Liquid hydrocarbon
Flowrate Temperature
Inlet 19330 kg/h 20 0C
Outlet 19330 kg/h 100 0C
Outer diameter 25.40 mm
Inner diameter 19.30 mm
Thickness of tubes 5.00 mm
Length of the tubes 5000 mm
Number of tubes 52 tubes
Area of one tube 0.00029 m2
Tube arrangement Triangular
Tube pitch, Pt 31.75 mm
Tube side coefficient, ht 3012.73 W/m2 °C
Pressure drop, P 34.77 kPa

Table 5.3.7 Summary of chemical design for shell side

Fluid Superheated steam
Flowrate Temperature
Inlet 7000 kg/h 400 0C
Outlet 7000 kg/h 280 0C
Bundle diameter 306.97 mm
Shell clearance 88 mm
Shell diameter 394.97 mm
Shell side coefficient, hs 170.65 W/m2 oC
Pressure drop, P 123 kPa

5.3-32