PROJECT REPORT

ON PRODUCTION OF
Vinyl Chloride Monomer
(VCM)

Under the guidance of :-

Dr. V.K. Sachan
Dept. Chemical Engineering
 Project Team

Paridhi Singh Rathore

CSJAM13001390204
Supriya Dubey
CSJMA13001390195
Manish Kumar Sengar
CSJMA13001390196
 Contents

1. Introduction
2. Process flow diagram
3. Material balance
4. Energy balance
5. Equipment design
i. Distillation Column
ii. Heat exchanger
6. Result
7. References
1.1 INTRODUCTION

Vinyl chloride is an organo-chloride with the formula H2C=CHCl that is also

called vinyl chloride monomer (VCM). This colourless compound is an important
industrial chemical chiefly used to produce the polymer POLY-VINYL
CHLORIDE (PVC).VCM is among the top twenty largest petrochemicals
(petroleum-derived chemicals) in world production. The United States currently
remains the largest VCM manufacturing region because of its low-production-cost
position in chlorine and ethylene raw materials. China is also a large manufacturer
and one of the largest consumers of VCM.

Vinyl chloride is colourless gas at normal temperature and pressure. It has a sweet
odour. It is highly toxic, flammable, and carcinogenic. It can be formed in the
environment when soil organisms break down chlorinated solvents. Vinyl chloride
that is released by industries or formed by the breakdown of other chlorinated
chemicals can enter the air and drinking water supplies polluting them.
1.2 PHYSICAL PROPERTIES OF VINYL CHLORIDE

Molecular Weight(g/mol): 62.5

Melting Point(1 atm),K: 119.36

Boiling Point(1 atm),K: 259.25

Heat capacity at constant:

Pressure (J/mol.K):
Vapor at 20ºC: 53.1
Liquid at 20ºC: 84.3
Enthalpy of vaporization (kJ/mol): 20.11

Viscosity(-20ºC) (mPa.s): 0.272

1.3 Problem Introduction

Vinyl chloride monomer (VCM) is one of the leading chemicals used mainly for
manufacturing polyvinyl chloride (PVC). The PVC worldwide production capacity
in 2005 was of about 35 million tons per year. In the 1990s the largest plant in the
USA had a capacity of about 635 kilotonnes, but today there are several plants over
one million tons. At this scale even incremental improvements in technology have
a significant economic impact. Computer simulation, process optimization and
advanced computer- control techniques play a determinant role.
In the past the manufacture of VCM raised concerns regarding hazard, safety and
pollution. Therefore, the VCM technology was among the first to profit from
improvements suggested by process simulation. As a result, the modern VCM
plants are today among the cleanest and safest in the chemical process industries.

1.4 Problem statement

Design a vinyl chloride plant producing 1000 kilotonnes VCM per year.
1.5 Plant Capacity

1000 kilotonnes of product per year

Estimating required production per hour:
For 340 working days, 24 h running plant
Operating hours =8160 h
Molecular Weight of vinyl chloride=62.5g/mol
1000 kilotonnes= 1000 × 1000 × 1000 = 109 kg

Required rate of production :

=109/(8160 × 62.5)
=1960.8 kmol/h
1.6.1 Direct chlorination and Oxychlorination of ethylene produces Ethylene
dichloride(EDC).The EDC is fed to Pyrolysis reactor where its cracking
produces Vinyl Chloride and HCl.

Principal steps in Vinyl Chloride process

1.6.2 PROCESS FLOW SHEET
In the flowsheet on previous page:
 EDC-Ethylene dichloride
 VCM-Vinyl Chloride product
 HX-1,HX-2,HX-3 and HX-4 are heat exchangers 1,2,3,4
 Heavy ends are dichlorobutane and chloroprene
 Light ends are trichloroethane and trichloroethylene
2. Material Balance

2.1 Molecular mass (g/mol)

Ethylene (C2H2) 28
Chlorine (Cl2) 71
Ethylene dichloride(EDC,C2H4Cl2) 99
Vinyl chloride Monomer(VCM,C2H3Cl) 62.5
Hydrochloric acid(HCl) 36.46
Oxygen(O2) 32
Water(H2O) 18
Trichloroethane(C2H3Cl2) 133.4
Ethylene trichloride(C2HCl3) 131.4
Di chlorobutane(Heavies,C4H8Cl2) 127.01
Chloroprene(C4H5Cl) 88.5365
Acetylene(C2H2) 26.04
Cl3-C-CHO(Chloral) 147.38
2.2 Direct chlorination reactor

C2H4 C2H4Cl2
1774 kmol/h 1747.4787 kmol/h

C2H3Cl3

DIRECT CHLORINATION
Cl2 17.6153 kmol/h
REACTOR
1782.78 kmol/h
HCl
17.6513 kmol/h

C2H4
8.87 kmol/h

Main Reaction
C2H4 + Cl2 →C2H4Cl2

Secondary reaction

C2H4 + 2 Cl2 →C2H3Cl3 + HCl

Overall conversion : 99.5%

Selectivity with respect to ethylene : 99%
 100 kmol/hr of feed assumed
Ethylene reacted to form C2H4Cl2 =0.995 × 0.99 × 100
= 98.505 kmol/h

Ethylene reacted to form C2H3Cl = 0.995 × 0.01 × 100

= 0.995 kmol/h

According to reaction
Total ethylene reacted = 98.505+0.995
= 99.5 kmol/h
Ethylene Unreacted = 0.5 kmol/h

Chlorine reacted = 98.505+(2 × 0.995)

= 100.495

C2H4Cl2 formed = 99.5 kmol/h

HCl formed = 0.995 kmol/h

Components Moles Input Mass Input Moles Mass Output

(kmol) (kg) Output (kg)
(kmol)
C2H4 100 2800 .5 14
Cl2 100.495 7135.145 - -
C2H4Cl2 - - 98.505 9751.995
C2H3Cl3 - - .995 132.733
HCl - - .995 36.277
Total 9935.145 9935
 2.3 Oxychlorination reactor

C2H4 1774 kmol/h C2H4 54.87 kmol/h

HCl 3548 kmol/h HCl 264.45 kmol/h
OXYCHLORINATION
O2 887 kmol/h O2 1.6498 kmol/h
Cl2 103.14 kmol/h
REACTOR C2H4Cl2
1667.56 kmol/h
Cl3-C-CHO
51.57 kmol/h

H2O 1719.13

Main Reaction
C2H4+ 2 HCl + ½ O2 → ClCH2CH2Cl + H2O

Side Reaction
C2H4 + 2Cl2 + O2 → Cl3-C-CHO + HCl + H2O

Conversion: 94% ( In terms of CH2CH2)

Selectivity in EDC: 97%
Assume 100 kmol/h of C2H4

Ethylene reacted to form C2H4Cl2 = 94 kmol/h

Ethylene reacted to form Cl3-C-CHO = 2.907 kmol/h

Unreacted ethylene = 100-96.907

= 3.093kmol/h
HCl reacted = 188 kmol/h
HCl formed in side reaction = 2.907 kmol/h
Unreacted HCl = (200+2.907) – 188
= 14.907 kmol/h

Components Moles Input Mass Input Moles Mass Output

(kmol) (kg) Output (kg)
(kmol)
C2H4 100 2800 3.093 86.604
O2 50 1600 .093 2.976
Cl2 5.81 412.794 - -
HCl 200 7292 14.907 541.509
C2H4Cl2 - - 94 9302
H2O - - 96.907 1744.326
Cl3-C-CHO - - 2.907 428.43
12104.794 12104.281
 2.4 Pyrolysis reactor

C2H3Cl=1980.08 kmol/h

HCl=1981.07 kmol/h
C2H4Cl2
PYROLYSIS
3415.039 kmol/h C2H4Cl2=1433.058 kmol/h
REACTOR 3415.039 kmol/h
C4H5Cl=0.634 kmol/h

C2H3Cl3=1.0292 kmol/h

C2HCl3=0.12 kmol/h

C4H8Cl2=0.797 kmol/h

Main reaction
C2H4Cl2 → C2H3Cl + HCl

Conversion of C2H4Cl2 : 0.58

Selectivity:99.704 %
 Side reactions

Fractional Selectivity(%) Reaction

Conversion
0.54 0.096 2 C2H4Cl2 → C4H8Cl2 + Cl2
0.5 0.058 C2H3Cl + Cl2 → C2H3Cl3
0.5 0.064 C2H2 + C2H3Cl → C4H5Cl
0.2 0.058 C2H4Cl2 + Cl2→ C2H3Cl3 + HCl
0.3 0.02 C2H2 + 2 Cl2→ C2HCl3 + HCl

We get 192.505 kmol/h from other two reactors ( Direct chlorination reactor and
oxychlorination reactor)

Overall conversion : 0.58

kmol of EDC reacting = 111.652 kmol/h
kmol of EDC unreacted = 80.852 kmol/h
kmol of VCM formed = 111.652 kmol/h
kmol of HCl formed = 111.682 kmol/h

C2H2 + C2H3Cl → C4H5Cl

When 1562.67 kmol of VCM formed , 1 kmol of C4H5Cl formed

When 1 kmol of VCM is formed , (0.064 × 10−2 kmol) of C4H5Cl formed
When 111.6529 kmol of VCM formed,
(0.064 × 10−2 × 111.6529 × 𝑐𝑜𝑛𝑣𝑒𝑟𝑠𝑖𝑜𝑛) kmol
C4H5Cl formed=0.03575 kmol/h
Similarly evaluating for other reactions:

C2H3Cl + Cl2 → C2H3Cl3 (0.032 kmol/h formed)

C2H4Cl2 + Cl2→ C2H3Cl3 + HCl(0.0129 kmol/h each of VCM and HCl is formed)

C2H2 + 2Cl2→C2HCl3 + HCl(0.00655 kmol/h each of the products formed)

2C2H4Cl2→C4H8Cl2 + Cl2(0.058 kmol/h of each product formed)

Components Moles Input Mass Input Moles Output Mass Output

(kmol) (Kg) (kmol) (Kg)
C2H4Cl2 192.505 19057.795 80.781 7996.338
C2H3Cl - - 111.617 6975.071
HCl - - 111.672 4070.681
C2H2 .035 .930 - -
C4H5Cl - - .035 3.165
C4H8Cl2 - - .058 7.366
C2H3Cl3 - - .044 5.989
C2HCl3 - - .006 .8922
Total 19058.93 19058.5
2.5 CONVERSION IN DISTILLATION COLUMNS

Conversion 0.995 across each distillation column

So ultimately VCM product that we get=111.61715*0.995*0.995 kmol/hour
=110.5kmol per hour

2.6 SCALING FACTOR

Required production=1960.8 kmol/h
Required production
Scaling factor =
Production taking 100 kmol of feed

Scaling factor=1960.8/110.5=17.74
Hereby we multiply all streams by this factor.
 2.7 DISTILLATION COLUMNS
2.7.1 In first distillation column we separate HCl from the product mixture that
comes from Pyrolysis reactor.

C2H3Cl=9.9 kmol/h

HCl=1971.2 kmol/h

C2H4Cl2 =1433.058 kmol/h

HCl=1981.1196 kmol/h

C2H3Cl=1980 kmol/h

C4H5Cl=0.634 kmol/h

C2HCl3=0.12045 kmol/h

C2H3Cl3=0.7965 kmol/h

C4H8Cl2=1.02892 kmol/h
C2H4Cl2 =1433.058 kmol/h

HCl=9.9196 kmol/h

C2H3Cl=1970.1 kmol/h

C4H5Cl=0.634 kmol/h

C2HCl3=0.12045 kmol/h

C2H3Cl3=0.7965 kmol/h

C4H8Cl2=1.02892 kmol/h
 2.7.2 In second distillation column we get the product VCM at the top

C2H3Cl=1960.8 kmol/h

C2HCl3=0.0006 kmol/h

C2H4Cl2 =1433.058 kmol/h

C2H3Cl=1970.1 kmol/h

C4H5Cl=0.634 kmol/h

C2HCl3=0.12045 kmol/h

C2H3Cl3=0.7965 kmol/h

C4H8Cl2=1.02892 kmol/h
C2H4Cl2 =1433.058 kmol/h

C2H3Cl=9.3 kmol/h

C4H5Cl=0.634 kmol/h

C2HCl3=0.1198 kmol/h

C2H3Cl3=0.7965 kmol/h

C4H8Cl2=1.02892 kmol/h
3. Energy Balance

3.1 Direct Chlorination

The reaction takes place at 150°C and 5 bar.

It is an exothermic reaction.

C2H4 + Cl2 →C2H4Cl2 ∆H0298 = -218kJ/mol

C2H4 + 2 Cl2 →C2H3Cl3 + HCl ∆H0298 = -214.895 kJ/mol

Sum of the standard of heats of formation of all products – Sum of standard heat of
formation of all reactants = Heat of reaction at standard conditions

Standard heats of formation:

∆H0f C2H4 = 52.40 KJ/mol

∆H0f Cl2 = -74.81 KJ/mol
∆H fC2H3Cl3 = -145 KJ/mol
0

∆H0fHCl = -92.31 KJ/mol

Standard heat of reaction is evaluated for side reaction by using above heats
of formation values at standard conditions to be -214.89 kJ/mol

Components Mass flow rates( kmol/s)

C2H4 0.48
Cl2 (main reaction) 0.49
C2H4Cl2 0.48
C2H4 0.00486
Cl2(side reaction) 0.00972
C2HCl3 0.00486
HCl 0.00486
For reactant

=𝛴𝑛𝑖𝐶𝑝𝑖𝑑𝑇
= (0.48 + 0.00486)(125)(49.24) + (0.00972 + 0.49)(125)(29.739)
= 2984 + 1857.7 kW
= 4841.7 kW

For product

=(0.48 ∗ 137.617 ∗ 125) + {(0.00486) ∗ (86.201) + (0.00486) ∗ (34.876)} ∗

(125)
= 8257.02 + 73.55 kW
= 8330.57 kW

Finally we add up the sensible heats of the reactants and products for bringing
them down to standard temperature
=4.8417+8.33
=13.147 MW
To this we add 𝛴𝑛𝑖 𝛥𝐻°𝑓
= 13.417 + (0.48 ∗ −218) + (0.00486 ∗ −214.89)
= −92.5 𝑀𝑊
This is the heat given by the reactor that needs to be removed.
3.2 Oxychlorination

CH2CH2 + 2 HCl + ½ O2 → ClCH2CH2Cl + H2O ∆H0 298 = -295 KJ/mol

C2H4 + 2Cl2 + O2 → Cl3-C-CHO + HCl + H2O

∆𝐻𝑓 O2= -426.93

∆𝐻𝑓 Cl3CCHO = -226.16
∆𝐻𝑓 H2O =-241.83

Evaluating heat of reaction of side reaction

= {(−226.16 + (−92.31) + (−241.83)} − {54.40 + (426.93) + (2 ∗ −74.81)}
= −38.15 𝑘𝐽/𝑚𝑜𝑙

Evaluating sensible heats for bringing feed to standard conditions

Reactant
= (0.46 + .0142)(112.5)(51.755) + (0.23 + 0.0142)(112.5)(29.9463)
+ (0.92)(29.1681)(112.5)
= 2760.99 + 822.69 + 3018.89 𝑘𝑊
= 6602.578 𝑘𝑊
Product
= (0.46)(112.5)(89.769) + (0.46 + 0.0142)(112.5)(34.126)
+ (0.0142)(112.5)(29.168) + (0.0142)(112.5)(106.706)
= 4645.566 + 1820.55 + 46.596 + 170.46
= 13.286 𝑀𝑊
Heat given out = (0.46 ∗ −295) + (−38.15 ∗ 0.0412) + 13.286
= −123.984 𝑀𝑊
3.3 Pyrolysis

C2H4Cl2 → C2H3Cl + HCl ∆H0298 = 71 kJ/mol

2 C2H4Cl2 → C4H8Cl2 + Cl2 ∆H0298 = 26.54 kJ/mol

C2H3Cl + Cl2 → C2H3Cl3 ∆H0298 = -108.29 kJ/mol

C2H2 + C2H3Cl → C4H5Cl ∆H0298 = -165.36 kJ/mol

C2H4Cl2 + Cl2→ C2H3Cl3 + HCl ∆H0298 = -30.5 kJ/mol

C2H2 + 2 Cl2→ C2HCl3 + HCl ∆H0298 = -187.39 kJ/mol

∆𝐻𝑓C2H4Cl2 = -132
∆𝐻𝑓 C4H8Cl2 = -162.65
∆𝐻𝑓C2H2 = 226.70
∆𝐻𝑓C2H3Cl = 38.10
∆𝐻𝑓 C2HCl3 = -18
∆𝐻𝑓C4H5Cl = 99.44
Reactant
= (0.545)(108.452)(475) + (0.00033)(77.361)(475)
+ (0.000016)(475)(17.57) + (0.000206)(475)(55.541)
= 28097 𝑘𝑊
Products
= (0.54)(77.361)(475) + (0.545)(475)(29.374)
+ (0.000219)(475)(120.251) + (0.00028)(475)(36.235)
+ (0.00028)(475)(178.654) + (0.000174)(475)(131.94)
+ (0.0000319)(101.286)(475)
= 19843.2 + 7604.3 + 12.51 + 4.819 + 23.76 + 10.9 + 1.54 𝐾𝑊
= 27500 𝑘𝑊
Heat Input to the system=𝛴(𝑛𝑖 𝛥𝐻𝑓 + 𝑛𝑖𝐶𝑝𝑑𝑇𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑠 + 𝑛𝑖𝐶𝑝𝑑𝑇𝑟𝑒𝑎𝑐𝑡𝑎𝑛𝑡𝑠)
=93.89 MW
 4. DISTILLATION COLUMN DESIGN
HCl=1971.2 kmol/h

C2H3Cl=9.9 kmol/h

C2H4Cl2 =1433.058 kmol/h

HCl=1981.1196 kmol/h

C2H3Cl=1980 kmol/h

C4H5Cl=0.634 kmol/h

C2HCl3=0.12045 kmol/h

C2H3Cl3=0.7965 kmol/h

C4H8Cl2=1.02892 kmol/h
C2H4Cl2 =1433.058 kmol/h

HCl=9.9196 kmol/h

C2H3Cl=1970.1 kmol/h

C4H5Cl=0.634 kmol/h

C2HCl3=0.12045 kmol/h

C2H3Cl3=0.7965 kmol/h

C4H8Cl2=1.02892 kmol/h
4.1 Estimation of dew point and bubble point

Components Ki (Bottom) αi(Bottom) Ki (Top) αi(Top)

C2H4Cl2 0.096 0.0604 4.80*10-5 2.66*10-3

VCM 1.589 1 0.018 1

HCl 14.994 9.436 1.373 76.2778

C4H8Cl2 7.654*10-3 4.817*10-3 1.109*10-7 6.16*10-6

C4H5Cl 0.188 0.1183 1.403*10-4 0.00779

C2HCl3 0.099 0.0623 20223*10-5 0.001235

C2H3Cl3 0.033 0.02076 3.74*10-6 0.000207

Using chemcad the bubble point and dew point is evaluated and ki values are
obtained at that temperature

Dew point temperature=251.14 K

Bubble point temperature=354.6 K

4.2 Using Fenske equation we evaluate minimum number of stages

Minimum number of stages:
Nm = (log [xLK/xHK]d[xHK/xLK]b)/log αLK
Nm=log{(0.995/0.005)*(0.577/0.0029)}/log42.8569=3

4.3 Evaluating q value

heat to vaporize one mole of feed

q=
molar latent heat

=27.127/22.901=1.12
Components Flowrate Latent Heat Cp Mole Fraction
kmol/s
HCl 0.55 0 29.1499 0.367
C2H3Cl3 0.00003346 32589.8 130.655 2.27*10-5

C2H3Cl 0.55 17475.1 57.8017 0.367

C2H3Cl3 0.00022125 37445.1 156.548 1.47*10-4

C2H4Cl2 0.398 33324.8 134.375 0.265

C4H5Cl 0.000176 27809.2 146.022 1.17*10-4

C4H8Cl2 0.0002858 43484.4 190.45 1.91*10-4

4.4 Using Underwood equation,

Evaluating θ using excel
θ = 1.735

Σ(αi)(xid)/( αi – θ) = Rm + 1

4.5 Using Erbar-Maddox correlation

Rm + 1=1.03
Rm/ (Rm + 1) = 0.03
R=0.11 N=12
R=0.11, N=11, excluding reboiler.
4.6 Feed tray location

Using Kirkbride equation

log [Nr/Ns] = 0.206 x log [(B/D)(XfHK/XfLK)(XbLK/XdHK)2]

= 0.206 x log [(3415.657/1981.1)(0.995/0.577)(0.0.367/0.367)

Nr/Ns = 1.25

Nr + Ns = 11

Overall Column Efficiency = 0.6

Total no. of trays = 13/0.6 = 18

N = 18

Ns + (1.25 x Ns) = 18

Nr=10
Ns=8
Allowable plate pressure drop=100mm

F=5396.758, D=1981.1, B=3415.657, R=0.11, N=18

For Rectifying section,

L = R x D =0 .11*1981.1kmol/h
= 217.921 kmol/h
V = L + D = 217.921 + 1981.1 kmol/h
= 2199.021 kmol/h
V = V + (1 – q) x F
= 2199.021 + (1-1.12)*5396.75kmol/h
= 1551.41
For Stripping section,
L’ = V’ + B L’ = L + (q x F)
V’ = 6262.289 – 3415.657 L’ = 217.921 + (1.12*5396.75)
V’ = 2846.632 kmol/h L’ = 6262.289kmol/h
Top
ρV = 4.52 kg/m3
μ = 9.511 x 10-6 Ns/m2

σ = 1.19 x 10-2 N/m

ρL = 732.951 kg/m3

fLV= (LW/VW) x (ρV/ρL)0.5

= 0.5 x (19.33/1101.5086)0.5
= 0.013
Bottom
ρV = 19.1153 kg/m3
μ = 2.703 x 10-4 Ns/m2

σ = .0157N/m

ρL= 1043.8701 kg/m3

fLV= (LW/VW) x ( ρV/ ρL)0.5= (6262.289/2846.632) x (19.1153/1043.8701)0.5

= 0.2977
Assume plate spacing = 0.5 m

K1(Top) = 0.08
K1(Bottom) = 0.065
4.7 Flooding velocity

uf = K1 x [(ρL- ρV)/ ρV]0.5

uf(Top) = 0.598 m/s
uf(Bottom) = 0.476 m/s

4.8 Actual velocity

85% of Flooding velocity,
u (Top) = .5083m/s
u (Bottom) = 0.4046 m/s
Volumetric Flow Rate (Top) = 1.053 m3/s
Volumetric Flow Rate (Bottom) = 3.807 m3/s

4.9 Area (Top) = 2.072 m2

Area (Bottom) = 9.409 m2
Assume downcomer area to be 12% of Column area
Column Top area = 2.072/.88 = 2.35 m2
Column Bottom Area = 9.409/0.88 = 10.692 m2
Column Top Diameter (dc) = 1.73 m
Column Bottom diameter (dc) = 3.69 m
So, standard column based on D = 3.69 m

4.10 Column Area (Ac) = 10.692 m2

Downcomer Area (Ad) = 12% Ac = 1.283 m2
Net Area (An) = Ac-Ad = 9.409 m2
Active Area (Ac – 2Ad) = 8.126 m2
Hole Area (10%Active area) = 0.8126 m2

4.11 Weir length (Lw) = 100 x Ad/Ac = 12

Lw/Dc =0.76
Lw= 2.804 m

Assumptions
Weir Length (lw) = 2.804 m
Weir height (hw) = 50 mm
Hole diameter (Dh) = 5 mm
Plate thickness = 5 mm
Check Weeping
Maximum liquid flowrate = 6262.289kmol/h = 135.41 kg/s
Minimum liquid rate at 70% turn down = 0.7 x 135.41 =94.787kg/s
Maximum weir liquid crest (how max) = 750 [Lw/ (ρL x lW)]2/3 = 96.64 mm
Minimum weir liquid crest (how min) = 76.19mm
At minimum rate = h + how = 50 + 76.19 = 126.19 mm
K2= 31.3
Minimum design vapor velocity,
uh = [ K2 – 0.90 (25.4 - dh)]/ (ρV)0.5

uh = [31.3 – 0.90(25.4– 5)]/(19.1153)0.5

uh min = 2.96 m/s

We need to decrease the hole area in order to increase the actual vapor velocity and
ensure a significant difference between the actual vapor velocity and the minimum
vapor velocity.
Actual vapor velocity at minimum condition = (volumetric flow rate at bottom*0.7
6)/hole area =3.297 m/s

So, the operating flow rate will be well above the weeping point.
Plate Pressure Drop
hd = 51 [uh/Co]2 (ρV/ ρL) Dry plate pressure drop
maximum vapor velocity through holes
uh=3.807/0.8126
=4.68 m/s

For plate thickness/hole diameter=1, &Ah/Ap = Ah/Aa =0.08

Co = 0.84
hd = 51 *31.041*0.0183 = 28.97 mm liquid
Residual head hr= 12.5 x 103 / ρL
= 17.396 mm liquid
Total drop
ht=hd+hw+ how+ hr

ht= 126.19 + 28.97 + 11.97 = 167.18 mm liquid

Total pressure drop = 157.51 x 718.527 x 9.81 x 22/ 1000 = 0.244 bar
Pressure at bottom = 1.99 bar ---------> Assumed
Pressure at bottom = 1.97 bar ---------> Actual
So, 157.51 mm per plate pressure drop is acceptable.

Downcomer Liquid Backup

Downcomer backup is given by

hb= (hw + how) + ht + hdc
hb = downcomer backup measured from plate surface (mm)
hdc = 166 [(Lwd)/(ρL x Am)]2
Am = Aap/ Ad whichever is smaller.
hap = hw – (5 to 10) = 50-10 = 40 mm
Aap = hap x lw = 40 x 10-3 x 2.8044 = 0.112 m2
Ad = 0.181 m2
Aap< Ad
Therefore, Am = 0.0422 m2

hdc=166[(8.45)/(718.527 x 0.0422)]2
= 12.89 OR 13 mm
Backup in downcomer
hb = (50+30) + (157.5) + (13) = 517 mm < 0.5 (Plate spacing + weir height)
.517 < 1.65
Therefore, tray spacing = 0.5 m is acceptable.

Downcomer Residence time

tr = Ad x hbc x ρL/ Lwd
tr = 1.283x 517 x 10-3 x 1043.87/ 135.41
= 5.1 s
t r> 3 s
This value of downcomer residence time is satisfactory.
Entrainment check
un = actual velocity based on net area = 0.85/1.33 = 0.63
Flooding velocity = 0.77 m/s
% flooding = (0.405/0.476) x 100 = 85 %
FLV = 0.2977

ψ = 0.0065< 0.1
Ψ<0.1 indicates that the effect of entrainment is very insignificant and can be
ignored.
Number of holes:
Area of one hole = (π / 4) x (5 x 10-3)2 = 1.963 x 10-5
Number of holes = hole area/area of one hole=0.8126/(1.963 x 10 -5) =41395 holes.
 HEAT EXCHANGER DESIGN PROCESS

Statement
We are designing a Shell and Tube heat exchanger to cool a mixture stream containing ethylene
di chloride, vinlylchloride, hydrogen chloride chloroprene, ethylene trychloride ,
tricholoroethane, dichlorobutane from 500°C to 450°C..The fluid is cooled by cool water.

19044 kg/hr of hot stream enters at 500°C and is to be cooled to 450 by exchange with water
coming at 25°C and leaving the exchanger at 90°.A pressure drop of 10 psi is permissible on
shell as well as on tube side. Allowance is made for fouling by including a fouling factor of
3.3×10-4 (m2 °C/W) on hot stream and 3.3×10-4 (m2 °C/W) on the treated boiler feed water
stream.

The heat exchanger is designed through Kern’s method followed by calculating shell side
pressure drop through Bell’s method which estimates the pressure drop and heat transfer
coefficient for the shell side from correlations for flow over ideal tube banks, and the effects of
leakage, by passing and flow in the window zone which are allowed for applying correction
factors.
Mean temperature for inlet stream = ( 500+400)/2

= 450 °C

Mean temperature for water = (25+90)/2

= 57.5 °C

Heat Duty

Q ₌ mFCpFΔTF

= [5.29*1.10*(500-400)]

= 581.9 kw

Also heat Duty, 𝑄 = 𝑚𝑤𝐶𝑝𝑤𝛥𝑇𝑤 Hence, mass flow rate of water,

𝑚𝑊 = 𝑄/(𝐶𝑝𝑤𝛥𝑇)

=[(581.9*1000)/4186*(90-25)]

=2.412 kg/s

= 8683.2 kg/h
Physical Properties
Inlet Stream

Temperature = 450°C

Specific Heat = 1.10 kJ/kg K

Thermal Conductivity = 0.0404 W/m°C

Density = 1.054 kg/m3

Viscosity = 0.0000247 Pa.s

Water

Temperature = 57.5°C

Specific Heat = 4186 J/kg °C

Thermal Conductivity = 0.637 W/m °C

Density = 991 kg/m3

Viscosity = 0.00089 Pa.s

Overall heat transfer coefficient:

Overall heat transfer coefficient is assumed to be 30 W/m2 °C

Uo=30W/m2k (assumed)
 Figure: Temperature Profile

Where Thi = 500°C , T ho = 400°C , Tci =25°C , T co=90°C

LMTD= [(𝑇ℎ𝑖 − 𝑇𝑐𝑜) − (𝑇ℎ𝑜 − 𝑇𝑐𝑖)]/𝑙𝑛[(𝑇ℎ𝑖 − 𝑇𝑐𝑜)/(𝑇ℎ𝑜 − 𝑇𝑐𝑖)]

= (500-90)-(400-25)/ln(500-90)/(400-25)

= 392.2°C

For LMTD Correction Factor,

We choose 1-shell-1-tube pass heat exchanger,

FT= 1

(LMTD) Calculated = 392.2 °C

Heat Transfer Area

𝑄 = 𝑈𝐴𝑜(𝐿𝑀𝑇𝐷)

Area, 𝐴𝑜 = 𝑄/𝑈(𝐿𝑀𝑇𝐷)

= (581.9 ∗ 1000)/(30 ∗ 392.2)

= 49.5 𝑚2

Layout and Tube Size:

We are using a split-ring floating head heat exchanger for efficiency and ease of cleaning. Fluid
has EDC which is mildly corrosive may result in scaling, hence we will flow it through the tube
side. The operating pressure is not too high, so carbon steel is used for sheet and tubes. Using
tube diameter as 38mm, tube thickness as 2mm, tube sheet thickness as 25mm, tube length is
2.44m on a triangular pitch of 1.25 times tube outer diameter.

Number of Tubes:

Actual length of tubes = Length - 2*Tube Sheet Thickness

= 2.44 - 2×0.025

= 2.39 m

Curved surface area of 1 tube= 3.14 ∗ 𝑑𝑜 ∗ 𝐿

= 𝜋 ∗ 38 ∗ 10 − 3 ∗ 2.39

= 0.28 m2

Number of tubes = Ao/πdol

= 49.5/0.28

= 177 tubes

Tube cross-sectional area = ( π(di)2)/4

= 3.14 *(34*10-3)2

=9.074×10-4 m2

So, Flow area per pass = Tubes per pass * Cross sectional area

= 178*9.07* 10-4

= 0.16 m2

Volumetric Flow = 𝑚𝐹/ 𝜌𝐹

= 5.29/1.31

= 4.03 m3/s

Tube Side Velocity, ut = (Volumetric flow rate)/(Flow area per pass)

= 4.03/0.16

= 26 m/s

The velocity is satisfactory, i.e., within the range of 10to 30 m/s

Bundle and Shell Diameter

For 1 tube passes

K1 = 0.319

n1 = 2.142
Db = do*(Nt/K1)(l/n)

=38×10-3*(178/0.319)1/2.142

= 727 mm

For a split-ring floating head exchanger, the typical shell clearance

(Ds - Db) = 64mm

Ds = 727+ 64 mm

= 791mm

Tube Side Heat Transfer Coefficient calculation:

Re =di *ut*ρ/µ

= (34*10-3*26*1.31)/2.47*10-5

= 377222.10

Pr = µFcpf/Kf

= (2.47*10-5*1.10*1000)/0.0404

= 0.67

(L/di) = 2.39/34*10-3

= 70.29

jH = 3.2*10-3

Nu = jH (Re) (Pr).33 (µ/µw)0.14

Neglecting Viscosity Correction Factor,

hidi/Kf = 3.2*10-3*37722*(0.67)0.33

hi = 1256 W/m2 °C

Shell Side Heat Transfer Coefficient: (Using Kern’s Method)

Baffle Spacing, lB = 0.5*DS

= 0.5*791

= 395.5 mm

Pitch, pt = 1.25do

= 1.25*38*10-3

= 47.5 mm

Cross Flow Area, AS = [(pt-do) Ds lB]/pt

= [(47.5-38)*791*395.5]/47.5×10^-6

= 0.0625m2

Equivalent Diameter, de = (1.1/do)(pt2 - 0.917do2)

= (1.1/38)(47.52 - 0.917*(38)2)

= 26.9 mm

Volumetric Flow Rate on Shell Side = mw/ρw

= 2.142/991

= 0.002166 m3/s

Shell Side Velocity, us = (Volumetric flow rate)/As

= 0.002166/0.0269
= 0.03458 m/s

Reynolds number, Re = ρwusde/µw

= (991*0.0.03458*0.0269)/8.9*10-4

= 1035.86

Prandtl number, Pr = µWCpw/Kw

= (8.9*10-4*4186)/0.637

= 5.85

We use segmental baffles with at 25% cut. This should give a reasonable heat transfer
Coefficient without too large a pressure drop.

jH = 1.5*10-2

Nus = jH (Re) (Pr).33 (µ/µw)0.14

Neglecting Viscosity Correction Factor,

hsde/Ks = 1.5*10-2 (1035.86)(5.85)0.33

hs =658.71W/m2 °C

Overall heat transfer coefficient

1/Uo = 1/hs + Rds + [doln(do/di)]/2Kw + do/di (1/hi + Rdi)

For Carbon Steel, Kw = 54 W/m℃

1/UO = { (1/1256) +(1/3000)} +{38*10-3 ln(38/34)/(2*54)}+

{38/34(1/3000)+(1/658.7)}

U0 = 33.314 W/m2

Q = UoAo(LMTD)calculated
Ao = Q/Uo(LMTD)calculated

Ao = 44.50 m2

The calculated value of the overall heat transfer coefficients greater than the initial estimate of
30 W/m2 oC and the calculated area is 0.10% less than the estimated area. Hence, the number of
tubes can be reduced but first we will check the pressure drop.

Pressure Drop

Tube Side

Number of passes = 1, Number of tubes = 178 tubes di = 34 mm do = 38mm

ut = 26m/s

Re = 377222.

L= 2.39 m

jF = 2.5×10-3

∆Pt = Np[8jF(l/di)+2.5]ρut1/2
= 2[(1×2.5×10-3*2.39/0.034)+2.5]1.31*(26)2/2
= 15.76N/m2

= 0.002283 psi

The tube side pressure drop is within the specified limits.

Shell Side

Ds =791mm, de = 26.9 mm l = 2.39 m lB = 395 mm

ρw = 991 kg/m3 us = 0.03458m/s

jF = 6*10-1

∆Ps = (8jF(Ds/de)(l/lB)ρus2 )/2

=8*6*10-1 (0.791/0.0269)(2.89/0.3955)90.034582/2)
= 0.509 N/m2

The pressure drop for shell side is within the specified limits.
Summary: The proposed Design

Split ring, floating head, 1 shell pass, 1 tube passes

178 carbon steel tubes, 2.44m length

Outer diameter = 38 mm, Inner diameter = 34 mm

Triangular pitch, pitch = 47.5 mm

Shell inner diameter = 791 mm

Baffle Spacing = 395 mm, 25% Baffle cut

Tube side Coefficient (clean), hi = 1256 W/m2°C

Shell side Coefficient (clean) hs = 658.7W/m2°C

Overall Coefficient, calculated (dirty) = 33.3 W/m2°C

Overall Coefficient, required (dirty) = 30 W/m2°C

Heat transfer area (calculated) = 44.5m2

Dirt/ fouling factors:

Tube side (EDC) = 3.3*10-4 m2 °C/W Shell side (water)

Pressure Drops:

Tube side, calculated = 0.00283 psi

Tube side specified pressure drop = 10 psi

Shell side, calculated = 7.1*10-5 psi

Shell side specified pressure drop = 10 psi

Shell Side Heat Transfer Coefficient and Pressure Drop:

(Using Bell’s Method)

Shell Side Heat Transfer Coefficient

Hs = hoc Fn Fw Fb Fl

Ideal Bank Coefficient, hoc

hoc = 1256 W/m2°C

Tube row correction factor, Fn

Tube vertical pitch, pt’= 0.87pt

= 0.87*0.0475

= 0.041325 mm

Baffle cut height, Hc = 25% of Ds

= 0.25*791

= 197 mm

Height between Baffle tips = Ds - 2*Hc

= 791- 2*197

=395 mm

Ncv = (height between baffle tips)/pt’

= 395/41.325

= 10

Fn = 1.00
Window Correction Factor, Fw

Hb = Db/2 - Ds(0.5 - Bc)

= 727/2 - 729(0.5 - 0.25)

= 165.75mm

Bundle Cut, Bb = Hb/Db

= 165.75/727

= 22.7%

Ra= 0.17

Rw = 2Ra

= 0.34

Tubes in one window area,

Nw = Nt*Ra

= 178*0.17

= 30.26 ≈ 30

Tubes in cross flow area, Nc = Nt - 2Nw

= 178 - 2*30

= 118

Fw = 1.3

Bypass Correction Factor, Fb

Ab = (Ds - Db)lB
= (791 – 727)*395

= 0.025312 m2

As = (pt - do)*Ds*lB/pt

= (1.25do - do)*727*395/1.25do

= 0.0782 m2

Ab/As = 0.0782/0.025312

= 0.323

α = 1.35

Ns/Ncv = 1/5

Fb = exp [-α Ab/As (1 - (2Ns/Ncv)1/3)]

= exp [-1.35*0.0782/0.0253 (1 - (2/5)1/3)]

= 0.33

Fb = 0.33

Leakage Correction Factor, FL

Using clearances as specified in the standards;

Ct (tube-to-baffle), 1/32 in = 0.8 mm

Cs (baffle-to-shell), 3/16 in = 4.88 mm

Total number of tubes, Nt = 178

Number of tubes in one window area, Nw =30 do = 34mm

Ds = 791 mm
Atb = Ct do(Nt – Nw)/2

= 0.8*10-3* 34*10-3*(178 - 30)/2

= 0.0020128m2

22.7% bundle cut, we get

θb = 1.85 radians

Asb = CsDs (2π- θb)/2

= 4.88*10-3*0.791*(2*3.14-1.85)/2

= 0.0085 m2

Total leakage area, AL = (Atb + Asb)

= 0.01056 m2

AL/As = 0.01056/0.0625

= 0.16

βL= 0.18

FL = 1 - βL[(Atb + 2Asb)/AL]

= 1 – 0.18[(0.0020218+ 2*0.0085)/0.01056]

= 0.67

Shell Side Heat Transfer Coefficient:

Hs = hoc Fn Fw Fb Fl

= 1256*1.0*1.3*0.33*0.67

= 361 W/m2°C
hs = 361 W/m2°C

Shell side coefficient, hsis appreciably lower than that predicted by Kern’s method.

Shell Side Pressure Drop

Cross-flow zone pressure drop

At Reynold number = 377222.5 for 1.25 triangular pitch

jf = 4*10-2

us = 0.03458 m/s

∆Pi = (8jf Ncv*ρus2/2)(µ /µw)0.14

Neglecting viscosity correction factor

∆Pi = 8*4*10-2*10*991*(0.03458)2/2

= 4.0645 N/m2

α = 4.00

Fb = exp[-αAb/As(1-(2Ns/Ncv)1/3)]

=exp[-4*(0.323)(1-(2/5)1/3]

= 0.711

For Al/As = 0.16 βL’ = 0.35

Fl = 1-βL [ (Atb + 2Asb)/Al]

=1 - 0.35[ (0.002028 + 2*0.0085)/0.01056]

= 0.369
∆Pc = ∆Pi FbFL

= 4.06*0.711*0.369

= 1.066 N/m2

Window zone pressure drop

For baffle cut 25%, from fig 12.41

Ra = 0.19

Aw = (πDS2/4*Ra)-(Nw* πd2/4)

= (3.14*7912*.19/4)-(30*3.14*382*/4)

= 0.05930 m2

uw= 2.142/(0.0593*991)

=0.0364 m/sec

Uz = (uw us).5

= 0.0354 m/s

Nwv = Hb/pt

=4.01

≈4

∆Pw = (Fl (2 + 0.6Nwv)ρ(uz)2)/2

= 0.369 (2 + 0.6*4)991*(0.0364)2/2

= 1.027 N/m2

End zone pressure drop

∆Pe = ∆Pi[(Nwv + Ncv)/Ncv] Fb

=4.06 [(4 + 10)/10]*0.711

= 4.041 N/m2

Shell Side Total Pressure Drop

Number of Baffles, Nb = (l/lB)-1

= 2.44/0.395 - 1

= 5.17≈ 5

∆Ps = 2∆Pe + ∆Pc (Nb - 1) + Nb∆Pw

= 2*4.041 + 1.066*(5- 1) + 5*1.027

=17.481N/m2

= 0.00253 psi

This value is for the exchanger in the clean condition.

Ds (Shell diameter)/lB (Baffle spacing) = 791/395

=2

Factor = 1.61

∆Ps = Factor* ∆Ps, clean

= 1.61*17.48

=28.14N/m2

=0.00408 psi

This pressure drop is appreciaby lower than the product and that predicted by the Kern’s method.