EH2208O

DESIGN PROJECT II (MARCH 2017)

PRODUCTION OF 20,000 METRIC TONNES OF

POLYTETRAFLUOROETHYLENEPER YEAR

CHAPTER 3: HEAT EXCHANGER,

E-104 (CONDENSER)

STUDENTS NAME:
MUHAMMAD FAHMI BIN NIZAM
2013251462

SUPERVISOR:
MS CHRISTINA VARGIS

FACULTY OF CHEMICAL ENGINEERING

UNIVERSITI TEKNOLOGI MARA
SHAH ALAM
 CHAPTER 3

EQUIPMENT DESIGN

DESIGNED BY: MUHAMMAD FAHMI BIN NIZAM

3.2.1 Heat Exchanger (Condenser) E-104

3.2.1.1 Introduction

The process of heat exchanger between two fluids that are at different temperature
and separated by a solid wall occurs in many engineering applications. The
equipment used to implement this exchange is termed a heat exchanger, and a
specific applications may be found in space heating and air-conditioning, power
production, waste heat recovery and chemical processing.

A heat exchanger is a device used to passively transfer heat from one

material to another. These materials may be liquid or gaseous, depending on the
situation in which the heat exchanger is being used. There are many models and
types of heat exchangers, but they essentially work based on the laws of
thermodynamics. One of those laws states that when an object is heated, the heat
energy contained within that object will diffuse outward to the surrounding
environment, until the heat energy in the object and in the environment have reach
equilibrium. (Source: Fundamentals of Heat and Mass Transfer, 6th Edition)

262
Figure 3.1: Design procedure for condenser calculation

263
3.2.1.2 Duty

The purpose of this heat exchanger is to cool down the exit stream from cooler, E-
103 which contains TFE and HCl. The general formula for calculating the duty of
heat exchanger is as follows:

=
= 4107.56 0.5840 (30 + 50)
= 53

However, in dealing with changes in phase situation, the formula above

needs to be modified taking into account the phase change. So, the suitable
formula for this situation is as follows:

= ()
Where:
Q = Duty, kW
m = mass flowrate, kg/s
= latent heat, kJ/kg

= 4107.56 (0.6 168.21) + (0.4 442)

= 1140086/
= 317

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. So, the duty value of cooler E-102 is:

, = (317 + 53) = 370

264
3.2.1.3 Physical properties of fluid of E-102

Physical properties of tube side

Table 3.1: Physical properties of tube side

Properties Inlet Outlet Mean
Temperature (C) 30 -50 -10
Pressure (kPa) 620 600 610

Physical properties of shell side (refrigerant)

Table 3.2: Physical properties of shell side (refrigerant)

Properties Inlet Outlet Mean
Temperature -80 -60 -70
(C) (kPa)
Pressure 101 81 91

3.2.1.4 Heat Exchanger Calculations

3.2.1.4.1 Logarithmic mean temperature difference (LMTD)

Counter flow:

(1 2 ) (2 1 )
=
( 2 )
1
(2 1 )
Where:
T1 = inlet hot fluid temperature
T2 = outlet hot fluid temperature
t1 = inlet cold fluid temperature
t2 = outlet cold fluid temperature

(1 2 ) (2 1 )
=
( 2 )
1
(2 1 )
(30 + 60) (50 + 80)
=
(30 + 60)

(50 + 80)
= 55

265
3.2.1.4.2 Correction factor:

(1 2 )
=
(2 1 )
(30 + 50)
=
(60 + 80)
=4
(2 1 )
=
(1 1 )
(60 + 80)
=
(30 + 80)
= 0.2

3.2.1.4.3 New LMTD

=
= 0.8(55)
= 44

3.2.1.4.4 Heat Transfer Area

=

=

370 103
=
550 44
= 15.4 2

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), 24 ft (7.32 m). For a given
surface area, the use of longer tubes will reduce the shell diameter; which will
generally result in a lower cost exchanger, particularly for high shell pressures. The
optimum tube length to shell diameter will usually fall within the range of 5 to 10.

266
 Table 3.3: Specification heat exchanger
Dimensions Data
Inner diameter, di 16mm
Outer diameter, do 20mm
Length of tube, L 5m

3.2.1.4.5 Tube Number

Tube number of shell and tube heat exchanger can be calculated using the formula
as follows:

Types of heat exchanger selected is shell and tube with floating head.
According to the tube dimensions decided, the area of one tube is calculated as
follows:

=
= 0.02 5
= 0.3142 2

Tube pitch, Pt is given as:

= 1.25
= 1.25 (0.02)
= 0.025

Therefore, the number of tubes is:

=

15.4
=
0.3142
= 50

267
For two passes tube:

50
=
2 2

= 25
2

3.2.1.4.6 Tube velocity

Tube cross sectional area:

2
=
4
(16 103 )2
=
4
= 0.0002 2

Area per pass:

= 12 0.0002
= 0.0024 2

Density mixture:

=
Where;
xi = Component composition in mass fraction
MW = Molecular weight

Table 3.4: Relative molecular mass for E-104

Component MW (kg/kmol) RMM
TFE 100.02 0.5783 57.8416
HCl 36.46 0.4217 15.3756

73.2172

268
3.2.1.4.7 Density

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

3.2.1.4.8 Volumetric Flowrate

=

4107.56 1
=
3600 11.821
3
= 0.0965

Tube side velocity:

=

0.0965
=
0.0024
= 40.2 /

3.2.1.4.9 Bundle and Shell Diameter

1
1
= ( )
1
1
50 2.285
= 0.02 ( )
0.175
= 0.1272

269
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 below. The clearance value will be 55 mm (0.055m). So, the shell inside
diameter will be:

= 0.1272 + 0.055
= 0.1822

3.2.1.4.10 Tube Side Heat Transfer Coefficient

Reynolds number, Ret

=

Where;
Ret = Reynold number of fluid in tube-side
t = fluid density of tube side, kg/m 3
Ut = fluid velocity of tube side, m/s
= fluid dynamic viscocity of tube side, Ns/m 2
di = inside diameter of tube side, m

=

11.821 40.2 0.016
=
1.7737 105
= 428667
Prandtl number, Pr:

,
Pr =

Where;
Pr = Prandtl number
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

270

=

1019.5 1.7737 105
=
0.04
= 0.45

5
=
0.016

= 312.5

The value of heat transfer factor, h is: 4.00x10-3. So, the tube heat transfer
coefficient can be found by equation follows:

1 0.14
= = 3 ( )

By neglecting viscosity term:

= (4 103 )( 428667)(0.451/3 )
= 1317

Tube side heat transfer coefficient, ht:

=

0.04
= 1317
0.016

= 3292.5 2
.

3.2.1.4.11 Shell Side Heat Transfer Coefficient

For first baffle spacing:

0.1822
= =
5 5
= 0.0364

271
For flow area:

( )
=

(0.025 0.020)(0.1822)(0.0364)
=
0.025
= 0.0001 2

Equilateral triangular pitch arrangement, de:

1.10
= ( 2 0.917 2 )

1.10
= (0.0252 0.917(0.02)2 )
0.02
= 0.0142

Shell mass side flowrate, Gs:

=

0.5
=
0.0001

= 5000 2
.

Shell side velocity, us:

=

5000
=
986.96

= 5.066

Reynolds and Prandlt number:

=

= 27758.37

272

=

= 3.95

Use segmental baffles with a 25% cut. This should give a reasonable heat transfer
coefficient without too large a pressure drop. The value of j h is equal to 3.1x10-3.
Neglecting the viscosity correction:

1 0.14
= = 3 ( )


= 0.33

= 3.1x103 27758.37 3.950.33

= 135.4
2 .

3.2.1.4.12 Overall 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/m 2. C.
= Inside fluid film coefficient, W/m 2. C.
= Inside dirt coefficient, W/m2. C.
= Outside dirt coefficient, W/m 2. C.
= Thermal conductivity of tube wall material, W/m 2. 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

273
The overall coefficient is calculated as follows:

1 1 1 ( ) 1 1

= + + + ( + )
2
0.02
1 1 1 0.02 ( ) 0.02 1 1
= + + 0.016 + ( + )
7484.50 3000 2(17) 0.016 5000 1213.89

= 532.47
2 .

Error:

% = 100%

550 532.47
% = 100%
532.47
% = 3.29%

3.2.1.4.13 Calculation of Pressure Drop

Tube Side Pressure Drop:

2
= [8 ( ) + 2.5]
2
5 12.46(7.05)2
= 4 [8(4.8 103 ) ( ) + 2.5]
0.016 2

= 17939.50 2 = 0.18

Shell Side Pressure Drop:

2
= 8 ( ) ( ) ( )( )
2

Neglecting the viscosity term ( ) :

0.8704 5 (986.96)(0.48)2
= 8(4.9 102 ) ( )( )( )
0.0142 0.4352 2

= 62375.14 = 0.62
2

274
3.2.1.5 Summary of Chemical Design for E-104

Item: Heat Exchanger (Condenser)

Item No: E-104
Function: Cooling product from cooler E-103 from 30C to -50C.
Operation: Continuous
Type: Split-ring floating head shell and tube heat exchanger (one shell passes; two tube
passes)
Heat Duty, Q: 370 kW
Heat Transfer Area: 15.4 m2
Tube Side Tube Details
Fluid type: Inorganic mixture in vapour Inside Diameter, di: 16 mm
phase Outside Diameter, do: 20 mm
Flowrate: 1.14 kg/s Length, L: 5 m
Pressure: 620 kPa Bundle Diameter, DB: 0.1272 m
Temperature: 30C to -50C No of Tubes, Nt: 49
Heat Transfer Coefficient: 3292.5 W/m.C No of Tubes per pass, Nt/4: 12
Pressure Drop: 0.18 bar

Shell Side Shell Details

Fluid Handle: Refrigerant (Ethane) Diameter, Ds: 0.1822m
Flowrate: 0.5 kg/s Baffle spacing: 0.0364 m
Pressure: 101 kPa
Temperature: 25C to 90C
Heat Transfer Coefficient: 135.4 W/m.C
Pressure Drop: 0.62 bar

275
3.2.2 MECHANICAL DESIGN

3.2.2.1 General Consideration

There are elements that needs to be considered before doing the design procedure
due to obtain accurate mechanical design. The table below is summarized the
critical consideration that needs to be emphasized during design process.

Table 3.5: General consideration of heat exchanger

Consideration Explanation
Design pressure The design pressure is normally taken
as the pressure at which the relief
device is set for vessels under internal
pressure.
Design temperature The design temperature at which the
design stress is evaluated should be
taken as the maximum working
temperature of the material.
Construction material Selection of a suitable material must
consider the suitability of the material
for fabrication and the compatibility of
the material with the process
environment.
Welded joint efficiency Joint efficiency is a numerical value,
which represents a percentage that
represented as the ratio of the
strength of a riveted, welded, or
brazed joint to the strength of the
base material.
Corrosion allowance The corrosion allowance is the
additional thickness of metal added to
allow for material lost by corrosion
and erosion, or scaling.
Design stress Design stress factor allows for any
uncertainty in the design methods, the

276
 loading, the quality of the materials,
and the workmanship.
Design loads The major loads including design
pressure, maximum vessel weight
and its content, wind loads,
earthquakes and also loads supported
or reacting on vessel.

3.2.2.2 Design Pressure

The design pressure of any pressure vessel should consider 10% of pressure
higher than operating pressure for safety factor. It is important to prevent any risks
during operation being conducted. Therefore, the design pressure for the tube and
shell side for heat exchanger E-102 are as follows:

Tube side:

= 1.1
= 6.2 1.1
= 6.82
= 0.682 /2

Shell side:

= 1.1
= 1.01 1.1
= 1.11
= 0.111 /2

3.2.2.3 Design Temperature

The 10% safety consideration should be added to operating temperature to

prevent any problem during plant operation. The operating temperatures are taken
as the maximum temperature occur in tube and shell side. So, the design
temperature is as follows:

277
Tube side:

= 1.1
= 30 1.1
= 33

Shell side:

= 1.1
= 60 1.1
= 66

3.2.2.4 Material Selection

In designing mechanical part for equipment, the construction material is one of

important factor that need to be consider. Material selection must be suitable for
substances that are used in the production to avoid any undesired incident and
unwanted accident. The selection of suitable material is very important in order to
maintain the equipment for a longer period of time. In selecting the most suitable
construction material, few considerations must be taken into account for the better
decision. The consideration is as follows:
Operating condition
Corrosion resistance
Process safety
Economic feasibility
Suitability for fabrication

Welded joint efficiency

The strength of welded joint will be based on the type of joint and the quality of the
welding. The value of welded joint factor, J is taken as 1.

Corrosion allowance
Corrosion allowance means that an extra measurement added to the thickness of
the wall. This helps guess the expected metal loss throughout the lifespan of
equipment in the plant. A minimum corrosion allowance used is 2mm.

278
Design stress
A value for the maximum allowable stress is based on the material of construction
that used for design of a plant. The table below show the maximum allowable
stress for selected material of construction at the design temperature:

Table 3.6: Design stress of material

Material Design stress,f (N/mm2)
Shell: Stainless Steel 304 165
Tube: Stainless Steel 304 165

3.2.2.5 Minimum thickness of tube wall

Shell Tube
Temperature() 66 33
Pressure(N/mm 2) 0.111 0.682
Material Stainless Steel 304 Stainless Steel 304
Design stress, N/mm 2 165 165
Welded joint efficiency, J 1 1
Diameter,mm 741.7 16

Minimum thickness for shell material according to British Standard PD 5500:

=
2
(0.111)(741.7)
=
2(1)(165) 0.111
= 0.25 + 2
= 2.25 2.3

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

=
3

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

279
 0.907
=1
2
( )

0.907
= 1
25 2
( )
20
= 0.42

=
3

(1)(20) 6.82
=
3 (0.42)(165)

= 2.09 + 2
= 4.09

3.2.2.6 Head and Closure

There are four main types of head closures which include flat plates and formed
flat heads, hemispherical heads, ellipsoidal heads and torispherical heads.
Hemispherical, ellipsoidal and torispherical are classified as domed head. The
considerations of pressure range and thickness have to be accurate in order to
choose the suitable type of head that can be used for the pressure vessel.

Flat end:

(0.17)(0.111)
= 741.7
(165)(1)

= 7.93

Torispherical Head:

= = 741.7
= 0.06 = 44.5

280
 1
= (3 + / )
4
1
= (3 + 741.7/44.5)
4
= 1.77

=
2 + ( 0.2)
(0.111)(741.7)(1.77)
=
2(165)(1) + 0.111(1.77 0.2)
= 0.44 + 2
= 2.44

Ellipsoidal Head

=
2 0.2
(0.111)(741.7)
=
2(165)(1) (0.2)(0.111)
= 0.25 + 2
= 2.25

Therefore, the torispherical head is selected for type of head because the thickness
is nearer to the shell material thickness.

3.2.2.7 Design Load

Shell load
Vessel weight, W v:
= ( + 0.8 )

Mean diameter:

= 103
= (741.7 + 2.3) 103
= 0.744

281
 = ( + 0.8 )
= (1.06)(8030)(0.744)(9.81)[5 + 0.8(0.744)](2.3 103 )
= 2511.64 = 2.5

Weight of tube in shell:

= (2 2 )
= 49 (0.022 0.0162 )(5)(8000)(9.81)
= 8698.36 = 8.7

Weight of insulation:
Insulation material: mineral wool
Insulation thickness: t=50 mm
Density of mineral wool: 130 kg/m 3

Volume of insulation:

=
= (0.744)(5) 50 103
= 0.5843 3

Insulation weight:

=
= (0.5843)(130)(9.81)
= 745.16 = 0.7452

Fluids weight:
Weight of fluid in shell:

2
, = ( )
4
0.18222
, = ( ) 5 986.96 9.81
4
, = 1262.2

282
Weight of fluid in tube:

(2 2 )
, =
4
(0.022 0.0162 )
, = 49 (5)(12.46)(9.81)
4
, = 3.39

Total weight:

= + + + , + ,
= 2511.64 + 8698.36 + 745.16 + 1262.2 + 3.39
= 13220.75 = 13.22

3.2.2.8 Minimum Thickness of Channel Cover:

1/2
= ( )

0.111 1/2
= (0.4)(741.7) ( )
165
= 7.69 + 2
= 9.69

3.2.2.9 Baffles

Baffles diameter:

= 4.8
= 741.7 4.8
= 736.9 737

Baffles spacing, lB:

=
2
741.7
=
2
= 370.85

283
Number of Baffles, NB:

=

5000
=
741.7
= 6.74 7

Shell and Bundle Geometry

=
= 741.7 0.25
= 185.43

3.2.2.10 Design of Nozzles

Tube Side Nozzle

Inlet diameter: Flowrate, G = 1.14 kg/s
Density, = 11.82 /3

= 260 0.53 0.37

= (260)1.140.53 11.820.37
= 111.75 112

Shell Side Nozzle

Inlet diameter: Flowrate, G = 0.4 kg/s
Density, = 1.36 /3

= 260 0.53 0.37

= (260)0.40.53 1.360.37
= 142.78 143

284
3.2.2.11 Flanges

The size of flanged joint is differing between equipment, depending on the

application and type of flange. There is several type of flange that commonly used
in industry including welding neck flanges, slip-on flanges, and hub and plate types,
lap-joint flanges, screwed flanges and blank or blind flanges. The type of flanges
and their application is summarized in the table below:

Table 3.7: Types of flange

Type of flange Application
Welding-neck Suitable for extreme service
conditions; where the flange is likely to
be subjected to temperature, shear
and vibration loads.
Lap-joint They are economical when used with
expensive alloy pipe, such as stainless
steel, as the flange can be made from
inexpensive carbon steel.
Blind Are flat plates, used to blank off flange
connections, and as covers for
manholes and inspection ports.
Slip-on Cheaper than welding-neck flanges
and are easier to align, but have poor
resistance to shock and vibration
loads. Slip-on flanges are generally
used for pipe work.
Screwed Used to connect screwed fittings to
flanges. They are also sometimes
used for alloy pipe which is difficult to
weld satisfactorily.

Therefore, based on the temperature used for heat exchanger, E-102, the
most suitable flange to be used for this exchanger is welding-neck flanges. This is
because it is suitable to be used for extreme process conditions.

285
3.2.2.12 Vessel Support

The support structure of a vessel will be depends on parameters such as size,

shape, and vessel weight, design temperature and pressure, vessel location and
fittings. Generally, skirt support is usually suitable for tall and vertical oriented
vessel whereas saddle support is suitable for horizontal oriented. Support design
must be able to withstand the weight of vessel. Proper selection must be made to
avoid vessel collapse during operation. The most suitable support for E-104 is
selected as saddle support as E-104 is mounted in horizontal orientation.

Figure 3.2: Typical saddle design

Table 3.6: Typical dimension of saddle design

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

1.2 180 0.7 0.2 1.0 0.4 0.3 0.1 12 10 24 30

8 0 9 5 6 4

286
3.2.3 Summary of Mechanical Design for E-104

Item: Heat Exchanger (Condenser)

Item No.: E-104
Function: Cooling product from cooler E-103 from 30C to -50C.
Operation: Continuous
Type: Split-ring floating head shell and tube heat exchanger (one shell passes; two tube
passes)
Overall Specification
Tube Pass 2 Number of Tubes 50
Shell Pass 1 Condition Horizontal
Shell Side Details
Length 5000 mm Material Stainless Steel
Diameter 182.2 mm Wall Thickness 2.0 mm
Design 0.111 N/mm2 Design -66C
Pressure Temperature
Head Type Torispherical Head Thickness 9.69 mm
Closure Type Bolted Flat End Closure Thickness 7.69 mm
Insulator Mineral Wool Insulator 50 mm
Thickness
Tube Side Construction
Length 5000 mm Material Stainless Steel
Tube Thickness 2.1 mm Design Pressure 0.682 N/mm2
Inside Diameter 16 mm Design 33C
Temperature
Outside Diameter 20 mm
Other Specifications
Baffles Type Segmental
Nozzle Type Welding-Neck Flange
Spacing 370.85 mm Shell Side Nozzle 143 mm
Diameter
Cut 25% Tube Side Nozzle 112 mm
Diameter
Support Type Saddle Total Weight 13.22 kN

287
REFERENCES

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

Richardsons.
2. Thulukkanam, K. (2013). Heat Exchanger Design Handbook. (C. Press,
Ed.) (Second Edi).
3. Yaws, C. L. (1999). Chemical Properties Handbook. McGraw Hill
Companies.
4. Theodore, L. (2011). Heat Transfer Applications for the Practicing
Engineer. John Wiley & Sons.

288