FACULTY OF CHEMICAL ENGINEERING

CPE 601
PRODUCTION OF NITRIC ACID
(AMMONIA VAPORIZER)

PREPARED FOR : DR. SUHAIZA HANIM BINTI HANIPAH

DATE OF SUBMISSION: 13 DECEMBER 2019

NO. NAME MATRIC NO. CLASS

1 TENGKU HARUN DIN BIN TENGKU SAMAD 2016718167 EH2206B
2 MUHAMMAD AFIQ BIN JOHARI 2016537543 EH2206B
3 NORANIERAH BINTI NOHO 2016728775 EH2206A
4 NUR ALIA SYAFIEQA BT MOHD YUSLAN 2016238886 EH2206A
TABLE OF CONTENT
NO. TITLE PAGES

1.0 INTRODUCTION 1

2.0 PROCESS SELECTION 2-3

3.0 BLOCK FLOW DIAGRAM ( BFD) 4

4.0 PROCESS FLOWSHEET DIAGRAM (PFD) 5

5.0 MASS BALANCE OF AMMONIA VAPORIZER 6-7

6.0 ENERGY BALANCE OF AMMONIA VAPORIZER 7-8

7.0 CHEMICAL DESIGN OF AMMONIA VAPORIZER 9-13

7.1 TYPE OF HEAT EXCHANGER 9

7.2 SELECTION OF HEAT EXCHANGER 9-11

7.3 TYPE OF SHELL AND TUBE HEAT EXCHANGER 11-12

7.4 SADDLE AND BAFFLE SELECTION 12-15

8.0 MECHANICAL DESIGN OF AMMONIA VAPORIZER 15-19

9.0 CONCLUSION 20

10.0 REFERENCES 21

11.0 APPENDICES 22-24

Introduction

Nitric acid is a colourless liquid that is used in the manufacture of inorganic and
organic nitrates and nitro compounds for fertilizers, dye intermediates, explosives and many
different organic chemicals. Nitric acid is most commonly manufactured by Ostwald process.
The Ostwald process converts ammonia to nitric acid and involves two steps. Nitric
acid(HNO3) also known as aqua fortis( Latin for strong water ) is a highly corrosive mineral
acid. The pure compound is colourless but older samples tend to acquire a yellow cast due to
decomposition into oxides of nitrogen and water. Most commercially available nitric has a
concentration of 68% in water. When the solution contains more than 86% HNO3, it referred
as furning nitric acid.

Nitric acid used as the primary reagent for nitration. The addition of a nitro group
typically to an organic molecule. Nitric acid is commonly used as strong oxidizing agent.
Some resulting nitro compounds are shock and thermally sensitive explosives. A few are
stable enough to be used in munitions and demolition. The chemical nature and composition
of nitric acid were first determined in 1784 by the English chemist and physicist Henry
Cavendish (1731-1810). Cavendish applied an electric spark to moist air and found that a
new compound – nitric acid was formed. Then Cavendish was able to determine the acid’s
chemical and physical composition. The method of preparation most commonly used for
nitric acid today was one invented in 1901 by the Russian born German chemist Friedrich
Willhelm Ostwald (1853-1932). The Ostwald process involves the oxidation of ammonia
over a catalyst of platinum or a platinum-rhodium mixture.

The corrosive effects of nitric acid are exploited for some specialty applications such
as etching in printmaking, pickling stainless steel or cleaning silicon wafers in electronics.
Nitric acid used either in combination with hydrochloric acid or alone to clean glass cover
slips and glass slides for high end microscopy application. Nowadays, nitric acid is used
widely in chemical industries. Nitric acid has become the most important chemical
compounds used in industry.

1
Process Selection

Nitric acid is most commonly manufactured by Ostwald process. The Ostwald process
has many well known uses in both the industrial and health field. Through the Ostwald
process, nitric acid is commonly used in fertilizers and pharmaceuticals and because of it is
chemical reaction with some compounds, it is used in rocket fuel and explosive like
trinitrotoluene (TNT). The Ostwald process converts ammonia to nitric acids and involves
two steps. In 1st step, ammonia is oxidized to form nitric oxide and also nitrogen dioxide.

The condition favouring the formation of the products at suitable reaction rates for the
reaction are high pressure, excess air, a catalyst and a high temperature as is consistent with
practicable reaction rates, catalyst efficiency and operating pressure. Most of the plants
operate with moderate pressures (10-13 atm), oxygen (air), an alloy of platinum and rhodium
as catalyst and temperatures at 1200 K.

In primary oxidation, the oxidation of ammonia is carried out in a catalyst chamber in

which one part ammonia and eight parts of oxygen by volume are introduced. The
temperature of chamber is about 600ᵒC. the chamber contains a platinum gauze which serves
as catalyst. This oxidation of ammonia is reversible and exothermic process. According to
Le-chatelier’s principle, a decrease in temperature favours reaction in forward direction.95%
of ammonia is converted into nitric acid (NO) in primary oxidation.

4NH3 + 5O2 ↔ 4NO + 6H2O ∆H -24.8 Kcal/mol

Secondary oxidation is the formation of nitrogen dioxide. The nitric oxide obtained
from the oxidation of ammonia is very hot. To reduce its temperature, it is passed through a
heat exchanger where the temperature of nitric oxide is reduces to 150ᵒC. After cooling, the
nitric oxide is transferred to another oxidizing tower where at about 50ᵒC it is then being
oxidized to nitrogen dioxide (NO2).

2NO + O2 ↔2 NO2

The tertiary step is formation of HNO3 from absorption of NO2. Nitrogen oxide from
secondary chamber is introduced into a special absorption tower so that more and more NO2
get absorbed. HNO3after recycle becomes about 68% concentrated.

2
 The last step is to ensure to increase the concentration of HNO3. Vapours of HNO3 are
passed over concentrated H2SO4 to increase the concentration of HNO3. H2SO4 acts as
dehydrating agent to absorbs water from HNO3and concentrated HNO3 is obtain.

The advantages and disadvantages of nitric acid

Nitric acid market is driven chiefly by the demands of the fertilizer industry. In the
US, the agricultural industry consumes 80% of the country fertilizer demand. Within the
agricultural demand site, corn production is the largest nitrogeneous fertilizer consumer,
followed by wheat, soybeans and cotton. The us farm economy and income within the sector
is the main force behind fertilizer demand. Unpredictable weather conditions are probably the
most important determinant in fertilizer needs. (Heller, Depro, Norris, & Lentz, 2012)(No,
1964)

Nitric acid also become the demand in industrial explosives as it is used in mining and
mineral industries. The demand for coal and basic metals drives the increase in nitric acid
production.

Adipic acid and TDI are the other main chemical products in which nitric acid is used,
both of which have a wide variety of applications and tend to follow gross domestic product
(GDP) trends in terms of demand. TDI is used in the production of flexible urethane foams,
which are used across several industries. Nylon 6,6 fibers has been used mainly in industrial
carpeting.

3
Block Flow Diagram (BFD)

Figure 1: Block Flow Diagram for Production of Nitric Acid

4
Process Flow diagram (PFD)

Figure 2: Process Flowsheet Diagram for Production of Nitric Acid

5
Material Balances

Chemical engineers are interested in many of the physical parameters associated with each
phase in chemical processes, such as the flow rate of material entering and leaving a piece of
equipment and several other parameters, including material temperature and material
pressure. Material balance is a fundamental in the development of any chemical or physical
process system used in any chemical industry. Calculation of the material quantity of any
stream that enters or leaves a unit is the material balance. This helps maximize energy,
equipment, process control and safety utilization. The best way to deal with a problem of
material balance will depend on the information provided, the information required from the
balance and the constraints arising from the nature of the problem.

Conservation of Mass

In a chemical reaction, the law of conservation of mass states that matter cannot be created or
destroyed. Material balances depend on the conservation law of materials which can be
written as follows:

Input + Generation = Output + Accumulation + Consumption

There is no accumulation for a steady state activity, so the conservation law becomes:

Input + Generation = Output + Consumption

For steady state operation and without chemical reaction there is no disappearance or
generation thus the conservation law becomes:

Input = Output

Ammonia Vaporizer

Ammonia vaporizer is a shell and tube type heat exchanger. Since the storage of fluid mass at
the heat exchanger is ignored, therefore the mass flow value of inlet and outlet is equal.

𝑀̇out = 2335.88 kg/h

Tout = 35℃
P = 1240 kPa

𝑀̇in = 2335.88 kg/h

Tin = -15℃
P = 1240 kPa

6
 Input = Output

𝑀̇in = 𝑀̇ out

Energy Balances

The energy balance provides the account of all the process's energy requirement that is based
on the energy conservation principle. The principle is that energy can be either created or
destroyed, but it can be transformed from one form to another. It can also transfer energy
from one body to another. Energy is either transmitted as energy or as work. There is no heat
in a system, but heat or work transfer to a system changes its internal energy. The energy
received by the process from its surroundings is historically known as positive and energy
released as negative. Energy conservation, however, differs from the mass in that in a
chemical process, energy can be generated (or consumed).

Conservation of Energy

As for the balance of materials, a general formula for the energy balance can be written as;

Energy out – Energy in + Generation – Consumption = Accumulation

This is a statement of the first law of thermodynamics. An energy balance can be written for
any process step. Chemical reactions may produce (exothermic) energy or absorb
(endothermic) energy. The accumulation of both mass and energy will be zero for steady
state processes. The formula we used to determine the Q (heat duty) or W (work) energy for
any unit:

Q-W= ∆HR + (-∆Hin) + (∆Hout) + (∆KE) + (∆PE)

Where;

∆KE = the change in the kinetic energy

∆PE = the change in the potential energy

Based on specific and latent heat data, enthalpy can be calculated. If the terms of kinetic and
potential energy are neglected;

H2 – H1 = Q – W

7
Usually, this simplified equation is sufficient to estimate the heating and cooling
requirements of the various chemical process unit operations. The work term will be zero or
negligibly small for many processes and the above equation reduces to a simple equation of
heat balances;

H2 – H1 = Q

Vaporizer Energy Balance

The ammonia vaporizer receives liquid ammonia from the adjacent plant at -15℃ and 1240
kPa and vaporizes it at 35℃ using warm water. The warm water loop circulates water from
the ammonia vaporizer to the secondary cooler. The water enters the ammonia vaporizer at
90℃ and exits at about 50 ℃.

E-101

For S4: NH3 at -15℃

For S5: NH3 at 35 ℃

Tref = -15℃

𝑄̇ = ∑ 𝑛𝑜𝑢𝑡 − 𝐻𝑜𝑢𝑡 − ∑ 𝑛𝑖𝑛 − 𝐻𝑖𝑛

𝑄̇ = ∑ 𝑛𝑜𝑢𝑡 − 𝐻𝑜𝑢𝑡 − 0

𝑇𝑏𝑜𝑖 𝑇𝑜𝑢𝑡
𝐻𝑜𝑢𝑡 = 𝑛[∫𝑇𝑟𝑒𝑓 𝐶𝑝 𝑑𝑇 + l +∫𝑇𝑏𝑜𝑖 𝐶𝑝 𝑑𝑇 ]

𝑇 𝑏 𝑐 𝑑
∫𝑇 𝐶𝑝 𝑑𝑇 = a (T2- T1) + 2 (𝑇22 -𝑇12 ) + 3 (𝑇23 -𝑇13 ) + 4 (𝑇24 -𝑇14 )
2
1

1133.642
∑ 𝐻𝑜𝑢𝑡 = 1000 × 137.405 [1.78 + ( × 17) + 0.07232]
1000

∑ 𝐻𝑜𝑢𝑡 = 𝑄̇ = 2.9025 x 106 KJ/ h

−15
∑ 𝐻𝑖𝑛 = ∫−15 𝐶𝑝 𝑑𝑇 = 0

8
Chemical Design of Ammonia Vaporizer
Type of Heat Exchanger
- Shell and Tube (2 passes per shell on the tube side)
- Internal baffles
Selection of Heat Exchanger

There are often baffles directing flow through the shell side so the fluid does not take a short
cut through the shell side leaving ineffective low flow volumes.

Counter current heat exchangers are most efficient because they allow the highest log mean
temperature difference between the hot and cold streams. Many companies however do not
use them because they can break easily in addition to being more expensive to build. Often
multiple heat exchangers can be used to simulate the counter current flow of a single large
exchanger.

Heat Exchangers Calculations:

The main basic Heat Exchanger equation is:

Q = U x A x ΔTm =

The log mean temperature difference ΔTm is:

ΔTm= (T1 – t2) – (T2–t1) = °C

ln (T1 – t2)
(T2 – t1)

9
Where:

T1 = Inlet tube side fluid temperature;

t2 = Outlet shell side fluid temperature;
T2 = Outlet tube side fluid temperature;
t1 = Inlet shell side fluid temperature.

Note: When used as a design equation to calculate the required heat transfer surface area,
the equation can be rearranged to become:

A = Q/ (U x ΔTm)

Where:
A = Heat transfer area (m²) (ft²);
Q = Heat transfer rate (kJ/h) (Btu\h);
U = Overall heat transfer coefficient (kJ/h.m².°C) (Btu/h°F);
ΔTm = Log mean temperature difference (°C) (°F). And:

Ct = Liquid specific heat, tube side (kJ/kg°K) (Btu/lb°F);

Cs = Liquid specific heat, shell side (kJ/kg°K) (Btu/lb°F).

10
 Typical Overall Heat Transfer Coefficients in Heat Exchangers
Type Application and Conditions U U
W/(m².K) Btu/(hr.ft².°F
)
Tubular, Gases at atmospheric pressure inside and outside 5 - 35 1-6
heat- ing or tubes
cooling Gases at high pressure inside and outside tubes 150 - 500 25 - 90
Liquid outside (inside) and gas at atmospheric
15 - 70 3 - 15
pressure inside (outside) tubes
Gas at high pressure inside and liquid outside tubes 200 - 400 35 - 70
Liquids inside and outside tubes 150 - 1200 25 - 200
Steam outside and liquid inside tubes 300 - 1200 50 - 200
Tubular, con- Steam outside and cooling water inside tubes 1500 - 4000 250 - 700
densation Organic vapors or ammonia outside and cooling
300 - 1200 50 - 200
water inside tubes
Steam outside and high-viscous liquid inside tubes,
Tubular, 300 - 900 50 - 150
natural
evapo- circulation
ration
Steam outside and low-viscous liquid inside tubes,
600 - 1700 100 - 300
natural
circulation
150 – 500
Steam outside and liquid inside tubes, forced 900 - 3000
circulation
Air-cooled heat Cooling of water 600 - 750 100 - 130
exchangers Cooling of liquid light hydrocarbons 400 - 550 70 - 95
Cooling of tar 30 - 60 5 - 10
Cooling of air or flue gas 60 - 180 10 - 30
Cooling of hydrocarbon gas 200 - 450 35 - 80
Condensation of low pressure steam 700 - 850 125 - 150
Condensation of organic vapors 350 - 500 65 - 90
Plate heat ex-
Liquid to liquid 1000 - 4000 150 - 700
changer
Spiral heat ex- Liquid to liquid 700 - 2500 125 - 500
changer
Condensing vapor to liquid 900 - 3500 150 - 700

Type of Shell and Tube

To be able to transfer heat well, the material should have

- Good thermal conductivity. Because heat is transferred from a hot to a cold side
through the tubes, there is a temperature difference through the width of the tubes.
Because of the tendency of the tube material to thermally expand differently at
various temperatures, thermal stresses occur during operation. This is in addition to
any stress from high pressures from the fluids themselves.

11
 - Compatible with both the shell and tube side fluids for long periods under the
operating conditions (temperatures, pressures, pH, etc.) to minimize deterioration
such as corrosion.
- Strong, thermally-conductive, corrosion-resistant, high quality tube materials and
typically metals. Poor choice of tube material could result in a leak through a tube
between the shell and tube sides causing fluid cross-contamination and possibly loss
of pressure.

Saddle in Baffles Selection

Baffles may be classified as transverse and longitudinal types. The purpose of longitudinal
baffles is to control the overall flow direction of the shell fluid such that a desired overall flow
arrangement of the two fluid streams is achieved. Transverse baffles may be classified as plate
baffles and grid (rod, strip,and other axial-flow) baffles. Plate baffles are used to support the
tubes during assembly and operation and to direct the fluid in the tube bundle approximately
at right angles to the tubes to achieve higher heat transfer coefficients. Plate baffles increase
the turbulence of the shell fluid and minimize tube-to-tube temperature differences and
thermal stresses due to the crossflow.

Shown in Figure 7A are single and multisegmental baffles and disk and doughnut baffles.
Single- and double-segmental baffles are used most frequently due to their ability to assist
maximum heat transfer (due to a high shell-side heat transfer coefficient) for a given pressure
drops in a minimum amount of space. Triple and no-tubes in window segmental baffles are
used for low pressure drop applications. The choice of baffle type, spacing and cut is
determined largely by flowrate, desired heat transfer rate, allowable pressure drop, tube
support and flow induced vibrations. Disk and doughnut baffles support plates are used
primarily in nuclear heat exchangers (Figure 7A). These baffles for nuclear exchangers have
small perforations between tube holes to allow a combination of crossflow and longitudinal
flow for lower shell-side pressure drop. The combined flow result in a slightly higher heat
transfer coefficient than that for pure longitudinal flow and minimizes tube-to-tube
temperature differences.

Rod (orbar) baffles,the most common type of grid baffle used to support the tubes and
increase the turbulence of the shell fluid are shown in Figure 7B.The flow in a rod baffle heat
exchanger is parallel to the tubes and flow induced vibrations are virtually eliminated by the
baffle support of the tubes. One alternative to a rod baffle heat exchanger is the use of twisted

12
tubes (after flattening the circular tubes they are twisted) shown in Figure 7C.Twisted tubes
pro-vide rigidity and eliminate flow induced tube vibrations can be cleaned easily on the shell
side with hydrojets, and can be cleaned easily inside the tubes but cannot be retubed. Low
finned tubes are also available in a twisted tube configuration. A helical baffle shell-and-tube
exchanger with baffles as shown in Figure 7D also has the following advantages: a lower
shell-side pressure drop while maintaining the high heat transfer coefficient of a segmental
exchanger, reduced leakage streams, and elimination of dead spots and recirculation zones
(thus reducing fouling). Every shell and tube exchanger has transverse baffles which have
support plates because the sole purpose of these transverse baffles is to support the tubes.

Figure 7A: Plate baffle types, modified from Mueller (1973).

13
Figure 7B: Four rod baffles held by skid bars (no tubes shown); (b) tube in a rod baffle
exchanger supported by four rods ;(c)square layout of tubes with rods;(d) triangular
layout of tubes with rods (Shah,1981).

Figure 7C: Twisted tube bundle for a shell-and-tube exchanger. (Courtesy of Brown
Fintube Company, Houston, TX.)

14
 Figure 7D: Helical baffle shell-and-tube exchanger: (a) single helix; (b) double helix.
(Courtesy of ABB Lumus Heat Transfer, Bloomfield, NJ.)

Mechanical Design of Ammonia Vaporizer

From references, assume flowrate of ammonia = 2335.88 kg/h. Flowrate of water = 0.0722 kg/s. T in =
-15 °C Tout = 35 °C

Specification
2335.88
Duty = x 2.17 kJ/kg°C x (35 – (-15)
3600

= 70.40 kW or 70400 W

Physical properties

Ammonia Water
Inlet Mean Outlet Inlet Mean Outlet
Temperature, -15 25 35 90 70 50
°C
Specific 2.17 2.16 2.16 4.21 4.19 4.18
Heat,
kJ/kg.°C
Thermal 0.02407 0.02493 0.02587 0.6729 0.6597 0.6406
Conductivity,
W/m.°C
Density, 0.72 0.6943 0.6705 965.3 977.74 988.05
kg/m3
Viscosity, 9.76X10-6 10.12X10-6 10.49X10-6 0.00032 0.0004 0.00055
Ns/m2

Overall coefficient

Q = UA∆Tm

U = 8.334 W/m2. °C

15
Exchanger type and dimensions

An even number of tube passes is usually the preferred arrangement, as this positions the inlet
and outlet nozzles at the same end of the exchanger, which simplifies the pipework.Start with
one shell pass and 2 tube passes.

∆Tout = T1 – t2 = (90 – 35) = 55

∆Tin = T2 = t1 = (50 – (-15) = 65

55−65
∆TLM = 55 = 59.86°C
𝑙𝑛
65

90−50
R = 35−(−15) = 0.8

35−(−15)
S = 90−(−15) = 0.48

From figure 12.19, Ft = 0.95

∆TM = 0.95 x 44.25 = 56.87 °C

Heat transfer area

Given Ammonia vaporizer heat exchanger area = 83m2

Layout and tube size

Using a split-ring floating head exchanger for efficiency and ease of cleaning. Neither
fluid is corrosive, and the operating pressure is not high, so a plain carbon steel can be used
for the shell and tubes.
The ammonia is dirtier than the water, so put the ammonia through the tubes and the
water in the shell.
Use 19.05 mm (3/4 inch) outside diameter, 14.83 mm inside diameter, 5 m Long tubes
(a popular size) on a triangular 23.81 mm pitch (pitch/dia. D 1.25).

Number of tubes

Area of one tube (neglecting thickness of tube sheets)

= 𝛑 x 19.05 x 10-3 x 5 = 0.2992 m2

Number of tubes = 83/0.2992 = 277.4 , say 280

16
So, for 2 passes, tubes per pass = 140
Check the tube-side velocity at this stage to see if it looks reasonable.

Tube cross-sectional area =𝛑/4(14.83 x 10-3)2 = 0.0001727 m2

So area per pass = 140 x 0.0001727 = 0.024178 m2

2335.88 1
Volumetric flow = x 0.6943 = 0.9345 m3/s
3600
0.9345
Tube side velocity, ut = 0.024178 = 38.65 m/s

Bundle and shell diameter

From Table 12.4, for 2 tube passes, K1 = 0.249, n1 = 2.207
280
So, Db = 19.05( 0.249 )1/2.207
= 459.51 mm or 0.4595 m

For a split-ring floating head exchanger the typical shell clearance from Figure 12.10 is 57
mm, so the shell inside diameter,

Ds = 459.51 + 57 = 516.51 mm

Tube-side heat transfer coefficient

0.6943 𝑥 38.65 𝑥 0.01483
Re = = 39323.97
0.00001012

2160 𝑥 0.000001012
Pr = = 0.0877
0.02493

𝐿 5000
𝐷𝑖
= 14.83 = 337

From figure 12.23, jh = 3.5 x 10-3

Nu = 3.5 x 10-3 (39323.97)(0.0877)0.33 = 61.65

0.02493
hi = 42.27 x ( 0.01483 ) = 103.63 W/m2.°C

This is clearly too low if Uo is to be 8.334 W/m2.°C. The tube-side velocity did look low, so
increase the number of tube passes to 4. This will halve the cross-sectional area in each pass
and double the velocity.

17
New ut = 2 x 38.65 = 77.3 m/s

Re = 2 x 39323.97 = 78647.94

jh = 3 x 10-3
0.02493
hi = ( 0.01483) x 3 x 10-3 (78647.94)(0.0877)0.33

= 177.66 W/ m2.°C

Shell-side heat transfer coefficient

Kern’s method will be used.

With 4 tube passes the shell diameter will be larger than that calculated for 2 passes.
For 4 passes, K1 = 0.175 and n1 = 2.285
280
Db = 19.05 ( 0.175)1/2.285 = 480.99 mm or 481 mm (0.481 m)

The bundle to shell clearance is still around 57 mm, giving:

Ds = 537 mm

As a first trial take the baffle spacing = Ds/5, say 107 mm. This spacing should give good
heat transfer without too high a pressure drop.

23.81− 19.05
As (= ) x 537 x 107 = 11486.97 mm2 = 0.0115 m2
23.81

1.10
de = 19.05 (23.812 – 0.917 x 19.052) = 13.52 mm

1
Volumetric flow-rate on shell-side = 0.072 x 977.74 = 7.36 x 10-5 m3/s

0.0000736
Shell-side velocity = = 6.4 x 10-3
0.0115

977.74 𝑥 0.0064 𝑥 0.01352

Re = = 211.5
0.0004

4190 𝑥 0.0004
Pr = = 2.54
0.6597

Use segmental baffles with a 25% cut. This should give a reasonable heat transfer coefficient
without too large a pressure drop.

18
From Figure 12.29, jh = 3.7 x 10-3
Neglecting the viscosity correction:

0.6597
hs = ( 13.52 x 103) x 3.7 x 10-3 x 211.5 x 2.540.33 = 51.94 W/m2.°C

Overall coefficient

Thermal conductivity of mild steel = 46 W/m.°C

Outside dirt fouling coefficient = 3000 W/m.°C
Insite dirt fouling coefficient = 3000 W/m.°C
19.05
1 1 19.05 19.05 𝑙𝑛 1
14.83
= ( 177.66 + 0.0003 ) 14.83 + + 51.94 + 0.0003
𝑈 2 𝑥 46

Uo = 12.66 W/m2.°C
The value of 12.66 W/m2.°C is well above the estimated value of 8.334 W/m2.°C
Hence, the present design satisfactory.
Pressure drop
280 tubes, 4 passes, tube inside diameter = 14.83 mm, ut = 77.3 m/s,
Re = 78647.94`. From Figure 12.24, jf = 2.95 x 10-3

5000 0.6943 𝑥 77.3

∆P = 4 ( 8 x 2.95 x 10-3 x 14.83+ 2.5 ) 2

= 1122.42 N/m2 (acceptable)

Table 1: Tabulation data for calculated design
Parameter Value
Operating pressure (kPa) 1240
Operating temperature(°C) 35
Number of tubes 280 tubes
Material of construction Mild steel
∆TM (°C) 56.87
∆TLM (°C) 59.86
Heat duty (KW) 70.40
Heat transfer area (m2 ) 83
Baffle spacing (mm) 107
Baffle cut (%) 25
Overall heat transfer coefficient (W/m2. °C) 12.66
Pressure drop (N/m2) 1122.42

19
Conclusion

Nitric acid market is driven chiefly by the demands of the fertilizer industry. To generate the
required capacity of 100000 tons of nitric acid per year, the amount of ammonia needed
2335.88 kg / hr and the amount of air required 43537.52 kg / hr.

In most chemical processes, heat transfer to and from process fluids is an essential part. The
most widely used type of heat transfer system is the ubiquitous heat exchanger for shells and
tubes. The term "exchanger" actually refers to all types of equipment where heat is
exchanged, but is often explicitly used to refer to equipment where heat is exchanged
between two system streams (Sinnott, R. K., Richardson, J. F., & Coulson, J. M. ,2005). The
exchanger is called a vaporizer when the process flow is vaporized.

From the design procedures followed and results obtained, the calculated value for the overall
heat transfer coefficient is 12.66 W/m2. °C and the assumed value is 8.334 W/m2.°C. Since
the value of 12.66 W/m2.°C is well above the estimated value of 8.334 W/m2.°C hence, the
present design satisfactory and the assumption is valid. In Table 1 all the calculated value are
tabulated for this design of heat exchanger.

In many applications, the pressure drop available to move the fluids through the exchanger
will be determined by the process conditions and the pressure drop available will range from
a few millibars for vacuum service to several bars in pressure systems. From this design, the
pressure drop obtained is 1122.42 N/m2 in which acceptable. When using a high pressure
drop, care must be taken to ensure that the resulting high fluid speed does not result in
erosion or pipe movement caused by flow.

20
References

Ammonia - Thermophysical Properties. (n.d.). Retrieved from

https://www.engineeringtoolbox.com/ammonia-d_1413.html.

Felder, R. M., Rousseau, R. W., & Bullard, L. G. (2017). Felders elementary principles of q
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