Design of Shell & Tube HX - App

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Organic SolventsShell Side11WaterTube Side

Design

SHELL SIDEEthylene1TUBE SIDEWater-1

symbolvaluesunitsSI ValuessymbolvaluesunitsSI Values

Thermophysical Properties :Density of FluidS =840kg/m3840.00000Density of FluidT =993kg/m3993.00000ViscosityS =0.33cP0.00033ViscosityT =0.0008kg/ms0.00080Thermal ConductivitykS =0.1156J/s m K0.11560Thermal ConductivitykT =0.623J/s m K0.62300Specific Heat cp,S =2.093KJ/kg K2093.00000Specific Heat cp,T =4.175KJ/kg K4175.00000Fouling FactorRdO =0.00021h m2 C / kcal0.00018Fouling FactorRdi =0.00035h m2 C / kcal0.00030

Temperature T:Temperature InTS,in =135C408.15000Temperature InTT,in =30C303.15000Temperature OutTS,out =40C313.15000Temperature OutTT,out =40C313.15000

0Specify :EthyleneMass Flow Rate50tonne/day5.7870370500E-01

Mass Flow RatemS =0.578703705kg/sMass Flow RatemT =2.7560850583kg/sVolumetric Flow RateqS =0.000688933m3/sVolumetric Flow RateqT =0.0027755137m3/sLMTD Calculation:Heat DutyQ =115066.551183675J/sec115066.551183675Flow Type :Counter-Current

[assume] Overall Heat Transfer coefficientRange:250 - 750 W/m2 KHot Ends Temp. DiffT1 =95KU* =350kcal/h m2 C407.05Cold Ends Temp. DiffT2 =10Kz00Correction FactorR =9.5S =0.0952380952Log Mean Temp. DiffLMTD =37.7561007652KAutofT =fT =0.8LMTD (corrected)LMTD* =30.2048806121K0Heat Transfer Area :AHT =9.358887222m2

Design Specifications :Shell DiameterDS =10in.0.254Length of TubeLT =4.5m4.5Tube Clearance cT =0.0064m0.0064Outside Dia. of TubedO =0.75in.0.01905Baffle Spacing B =0.1m0.1Thickness of Tube =16BWG0.001651Tube PitchPT =1in.0.0254Inside Dia. of Tubedi =0.015748Outer Surface Area [Single Tube] :aST =0.2693130302m2

Pitch Type :Equivalent DiameterNo. of TubesNT =35No. of Tube Passes NP :TriangularDH =0.0180335262mNo. of Tubes per Passn =94

Flow Area [= cT B DS / PT]aS =0.0064m2Flow Area of Tube [inside]aT =0.0017530052m2Phase:Linear Velocity of Tube [inside]uT =1.5832888929m/sLiquid

Mass Velocity [= mS / aS]GS =90.4224539062kg/m2 sMass Velocity [= mT / aT]GT =1572.2058706082kg/m2 s

Heat Transfer Co-efficient Calculations :Reynolds # [= DHGS/S]ReS =4941Turbulent FlowReynolds # [= TuTdi /T]ReT =30949Turbulent FlowPrandtl # [= cp,S S / kS]PrS =5.975Prandtl # [= cp,T T /kT]PrT =5.361

Method:NuS =69.838062217Method:NuT =174.8456384031AutojH =32AutojH =85Shell Side HT Co-efficienthO,S =447.6817192338W / m KTube Side HT Co-efficienthi,T =6916.994712036W / m K

[Design] Overall Heat Transfer coefficientUdo =338.6123558014W / m K

Pressure Drop Calculations :

g =9.8

Friction Factor (use graph)fS =0.052Friction Factor (use graph)fT =0.0037Number of BafflesNb =44Pressure DropPT =537.1088772591kg / m2Pressure DropPS =16.3676428622kg / m2Return LossPr =2032.0457895678kg / m2Shell Side Pressure DropPS =16.3676428622kg / m2Tube Side Pressure DropPT =2569.1546668269kg / m2

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BackgroundAshell and tube heat exchanger, also known as the workhorse of industrial process heat transfer,is a class ofheat exchanger designs.It is the most common type of heat exchanger in oil refineries and other large chemical processes, and is suited for higher-pressure applications. Other types of heat exchangers are used when economical. Though the application of other types of heat exchangers is increasing, the shell and tube heat exchanger will continue its popularity for a long time, largely because of its versatility

ConstructionAs its name implies, this type of heat exchanger consists of a shell (a largepressure vessel) with a bundle of tubes inside it. One fluid runs through the tubes, and another fluid flows over the tubes (through the shell) to transfer heat between the two fluids. The set of tubes is called a tube bundle, and may be composed by several types of tubes: plain, longitudinally finned, etc.Shell and tube heat exchanger units can be designed for almost any combination of pressure and temperature.

Requirements of Heat Exchangers

Heat exchangers have to fulfil1 the following requirements:1. High thermal effectiveness2. Pressure drop as low as possible3. Reliability and life expectancy4. High-quality product and safe operation5. Material compatibility with the process fluids6. Convenient size, easy for installation, reliable in use7. Easy for maintenance and servicing8. Light in weight but strong in construction to withstand the operational pressures9. Simplicity of manufacture10. Low cost11. Possibility of effecting repair to maintenance problems

Design Equations of Shell & Tube Heat Exchangers

Typical U values

Reference: http://www.engineeringpage.com/technology/thermal/transfer.htmlPage 840 | D. Q. Kern' Process Heat Transfer

Typical Overall Coefficients

Shell & Tube Exchangers

RangeIndex

Organic SolventsWater25075011

Hot fluidCold fluidU (W/m2C)

WaterWater8001500FALSEOrganic SolventsOrganic Solvents100300FALSELight OilsLight oils100400FALSEHeavy OilsHeavy oils50300FALSEReduced CrudeFlashed crude35150FALSERegenerated DEAFoul DEA450650FALSEGases (P = atm)Gases (P = atm)535FALSEGases (P = 200 bar)Gases (P = 200 bar)100300FALSEFALSECoolersFALSEOrganic SolventsWater250750TRUELight OilsWater350700FALSEHeavy OilsWater60300FALSEReduced CrudeWater75200FALSEGases (P = atm)Water535FALSEGases (P = 200 bar)Water150400FALSEGasesWater20300FALSEOrganic SolventsBrine150500FALSEWaterBrine6001200FALSEGasesBrine15250FALSEFALSEHeatersFALSESteamWater15004000FALSESteamOrganic Solvents5001000FALSESteamLight Oils300900FALSESteamHeavy Oils60450FALSESteamGases30300FALSEDowthermHeavy Oils50300FALSEDowthermGases20200FALSEFlue GasesSteam30100FALSEFlue GasesHydrocarbon Vapours30100FALSEFALSECondensorsFALSEAqueous VapoursWater10001500FALSEOrganic VapoursWater7001000FALSERefinery HydrocarbonsWater400550FALSEOrganics (some non-condensables)Water500700FALSEVacuum CondensorsWater200500FALSEFALSEVaporisersFALSESteamAqueous Solution10001500FALSESteamLight organics9001200FALSESteamHeavy Organics600900FALSEDowthermRefinery Hydrocarbons250550FALSE

Tube Count

Special Thanks: Muhammad Arsalan Khan [2010 - CH - 120]Reference: Page 37 | Ernest E. Ludwig' Applied Process Design for Chemical & Petrochemical Plants, 3rd Ed, Vol.3 (1999)

Tube Count [Fixed Tubes]

Shell & Tube ExchangersCalculated # of Tubes35

NPPitch TypedO (m)PT (m)Tube CountIndex

4Triangular0.019050.02540447296134180232294360424508596692802912102412

Inner Diameter of SHELLinches8101213.2515.2517.2519.2521.2523.252527293133353710

metres0.20320.2540.30480.336550.387350.438150.488950.539750.590550.6350.68580.73660.78740.83820.8890.93980.254

1Triangular0.019050.02381253369105135193247307391481553663763881101911431269FALSE1Triangular0.019050.025433579111715721727734342349357766776588910071127FALSE1Square0.019050.0254335385101139183235287355419495587665765865965FALSE1Triangular0.02540.0317515335773103133163205247307361427481551633699FALSE1Square0.02540.031751733456583111139179215255303359413477545595FALSE2Triangular0.019050.023812532589412416622830037045252862673484696410881242FALSE2Triangular0.019050.02542856901101542082643263984685566467468589721088FALSE2Square0.019050.025426487894126172222280346408486560644746840946FALSE2Triangular0.02540.031751632526292126162204244292346410462530608688FALSE2Square0.02540.031751226405676106136172218248298348402460522584FALSE4Triangular0.019050.0238125488410815419626633241248457668078890410241172FALSE4Triangular0.019050.02544472961341802322943604245085966928029121024TRUE4Square0.019050.0254487288126142192242308366440510590688778880FALSE4Triangular0.02540.0317524446078104138176212258308368422486560638FALSE4Square0.02540.031752440487484110142188214260310360414476534FALSE6Triangular0.019050.0238125801161742302943724405326327328449641106FALSE6Triangular0.019050.025466104156202258322388464548640744856964FALSE6Square0.019050.02545478116158212266324394460536634224818FALSE6Triangular0.02540.03175345682112150182226274338382442514586FALSE6Square0.02540.03175446688116154184226268318368430484FALSE8Triangular0.019050.0238125941401982583323984845766827909021040FALSE8Triangular0.019050.025482124170224286344422496588694798902FALSE8Square0.019050.025494132174228286352414490576662760FALSE8Triangular0.02540.031756690120154190240298342400466542FALSE8Square0.02540.031757494128150192230280334388438FALSE

Dropdownstonne/day1.15740741E-02GaugeRangeHot.FluidsProcess.FluidProcess.FRFluid.SideFlowTypePitchTypeFT.EntryPhaseTube.Pitch.ValuesHi.CalcMass.FR(7/0)Aqueous VapoursEthyleneMass Flow RateShell SideParallelTriangularAutoGas15/16Autokg/s1.00000000E+00(6/0)DowthermWaterVolumetric Flow RateTube SideCounter-CurrentSquareManualLiquid1Manualkg/min1.66666667E-02(5/0)Flue Gases1 1/4kg/h2.77777778E-04(4/0)Gaseskg/day1.15740741E-05(3/0)Gases (P = 200 bar)Temp.LengthGaugeDensityViscositytonne/h2.77777778E-01(2/0)Gases (P = atm)KmBWGkg/m3kg/mstonne/day1.15740741E-020Heavy OilsCcmSWGg/LPtonne/yr3.17097921E-051Light OilsFmmAWGg/cm3cPg/s1.00000000E-032Organic Solventsftlb/ft3g/min1.66666667E-053Organic Vapoursin.lb/in.3g/h2.77777778E-074Organics (some non-condensables)g/day1.15740741E-085Reduced Crudelb/s4.53592370E-016Refinery HydrocarbonsThermal.CondHeat.CapacityHT.C.Fouling.Factorlb/min7.55987283E-037Regenerated DEAW/m KJ/kg KW/m2 Km2 K / Wlb/h1.25997881E-048SteamJ/s m KKJ/kg Kcal/s m2 Cs m2 C / calMlb/h1.25997881E-019Water BTU/hr ft Fcal/g Ckcal/h m2 Ch m2 C / kcallb/day5.24991169E-0610BTU/lb FBTU/hr ft2 Fhr ft2 F / BTUM lb/day5.24991169E-0311Cold.FluidsMM lb/day5.24991169E+0012Aqueous Solutiontn(short)/s9.07184740E+0213Brinetn(short)/min1.51197457E+0114Flashed Crudetn(short)/h2.51995761E-0115Foul DEAtn(short)/day1.04998234E-0216Gasestn(long)/s1.01604691E+0317Gases (P = 200 bar)tn(long)/min1.69341152E+0118Gases (P = atm)tn(long)/h2.82235253E-0119Heavy Oilstn(long)/day1.17598022E-0220Heavy OrganicsVol.FR21Hydrocarbon Vapoursm3/sec1.00000000E+0022Light Oilsm3/min1.66700000E-0223Light Organicsm3/h2.77800000E-0424Organic Solventsm3/day1.15700000E-0525Refinery HydrocarbonsL/sec1.00000000E-0326SteamL/min1.66700000E-0527WaterL/h2.77800000E-0728L/day1.15700000E-0829barrel/s1.58987295E-0130barrel/min2.64960000E-0331barrel/h4.41600000E-0532barrel/day1.84000000E-0633gallon/s [US]3.78541200E-0334gallon/min [US]6.30900000E-0535gallon/h [US]1.05200000E-0636gallon/day [US]4.38333333E-0837MGPD4.38100000E-0538MMGPD4.38100000E-0239gallon/s [UK]4.54609000E-0340gallon/min [UK]7.57681667E-0541gallon/h [UK]1.26280278E-0642gallon/day [UK]5.26167824E-084344454647484950

BWGB.W.GNo_Passesinchesm1(7/0)-2(6/0)-4(5/0)0.50.01276(4/0)0.4540.01153168(3/0)0.4250.01079510(2/0)0.380.00965200.340.00863610.30.0076220.2840.007213630.2590.006578640.2380.006045250.220.00558860.2030.005156270.180.00457280.1650.00419190.1480.0037592100.1340.0034036110.120.003048120.1090.0027686130.0950.002413140.0830.0021082150.0720.0018288160.0650.001651170.0580.0014732180.0490.0012446190.0420.0010668200.0350.000889210.0320.0008128220.0280.0007112230.0250.000635240.0220.0005588250.020.000508260.0180.0004572270.0160.0004064280.0140.0003556290.0130.0003302300.0120.0003048310.010.000254320.0090.0002286330.0080.0002032340.0070.0001778350.0050.000127360.0040.000101637-38-39-40-41-42-43-44-45-46-47-48-49-50-

SWGS.W.Ginchesm(7/0)0.50.0127(6/0)0.4640.0117856(5/0)0.4320.0109728(4/0)0.40.01016(3/0)0.3720.0094488(2/0)0.3480.008839200.3240.008229610.30.0076220.2760.007010430.2520.006400840.2320.005892850.2120.005384860.1920.004876870.1760.004470480.160.00406490.1440.0036576100.1280.0032512110.1160.0029464120.1040.0026416130.0920.0023368140.080.002032150.0720.0018288160.0640.0016256170.0560.0014224180.0480.0012192190.040.001016200.0360.0009144210.0320.0008128220.0280.0007112230.0240.0006096240.0220.0005588250.020.000508260.0180.0004572270.01640.00041656280.01480.00037592290.01360.00034544300.01240.00031496310.01160.00029464320.01080.00027432330.010.000254340.00920.00023368350.00840.00021336360.00760.00019304370.00680.00017272380.0060.0001524390.00520.00013208400.00480.00012192410.00440.00011176420.0040.0001016430.00360.00009144440.00320.00008128450.00280.00007112460.00240.00006096470.0020.0000508480.00160.00004064490.00120.00003048500.0010.0000254

AWGA.W.Ginchesm(7/0)-(6/0)-(5/0)-(4/0)0.460.011684(3/0)0.40960.01040384(2/0)0.36480.0092659200.32490.0082524610.28930.0073482220.25760.0065430430.22940.0058267640.20430.0051892250.18190.0046202660.1620.004114870.14430.0036652280.12850.003263990.11440.00290576100.10190.00258826110.09070.00230378120.08080.00205232130.0720.0018288140.06410.00162814150.05710.00145034160.05080.00129032170.04530.00115062180.04030.00102362190.03590.00091186200.0320.0008128210.02850.0007239220.02530.00064262230.02260.00057404240.02010.00051054250.01790.00045466260.01590.00040386270.01420.00036068280.01260.00032004290.01130.00028702300.010.000254310.008930.000226822320.007950.00020193330.007080.000179832340.00630.00016002350.005610.000142494360.0050.000127370.004450.00011303380.003970.000100838390.003530.000089662400.003140.00007975641-42-43-44-45-46-47-48-49-50-