CPE 601: MATERIALS AND DESIGN OF PROCESS EQUIPMENT

Prepared by:

1) Nur Adelya Binti Azizan (2017985239)

2) Danial Fikri Bin Mohd Amri (2017581835)

3) Muhammad Afif Irfan Bin Mohd Nor Azman (2016250068)

4) Mhd Badhrul Bin Bahar (2016589039)

5) Nurulhuda Binti Ismail (2016249956)

6) Muhammad Shukri Bin Abdul Rahim (2016249998)

Date of Submission:

18 th December 2019

Name of Lecturer:

Dr Norin Zamiah

Faculty of Chemical Engineering,

UiTM Campus Shah Alam.

TABLE OF CONTENT

CONTENT PAGE
INTRODUCTION
1. PROCESS DESCRIPTION
2. PROCESS FLOW DIAGRAM 1-4
3. TABLE STREAM DATA

SELECTION OF EQUIPMENT 5
MATERIALS OF SELECTION 6
DESIGN FOR HEAT EXCHANGER
1. DESIGN CONSIDERATION
(THEORY) 7-17
2. CALCULATION FOR HEAT
EXCHANGER
DESIGN FOR PRESSURE VESSEL OF
SHELL SIDE
1. DESIGN CONSIDERATION
(THEORY) 18-32
2. CALCULATION FOR SHELL
ACT AS PRESSURE VESSEL
DESIGN FOR HEAT EXCHANGER 33-36
SUPPORT
MECHANICAL DRAWING FOR HEAT 37-38
EXCHANGER (AUTOCAD)
REFERENCES 39
APPENDICES 40-43
1.0 PROCESS DESCRIPTION

This process was patented in 1831 by British vinegar merchant Peregrine Phillips. In addition
to being a far more economical process for producing concentrated sulfuric acid than the
previous lead chamber process, the contact process also produces sulfur trioxide and oleum.

The process can be divided into five stages:

1) Combining of sulfur and oxygen (O2) to form sulfur dioxide.

2) Purifying the sulfur dioxide in a purification unit.
3) Adding an excess of oxygen to sulfur dioxide in the presence of the catalyst vanadium
(V) oxide at 450 °C and 1-5 atm.
4) The sulfur trioxide formed is added to sulfuric acid which gives rise to oleum
(disulfuric acid)
5) The oleum is then added to water to form sulfuric acid which is very concentrated.

Purification of the air and sulfur dioxide (SO2) is necessary to avoid catalyst
poisoning (i.e. removing catalytic activities). The gas is then washed with water and dried
with sulfuric acid. Sulphur dioxide can be made by burning sulphur in an excess of air:

S (g) + O2(g) ⇌ SO2(g)

Sulfur dioxide and dioxygen then react as follows:

2 SO2(g) + O2(g) ⇌ 2 SO3(g): ΔH = -197 kJ·mol−1

According to the Le Chatelier's principle, a lower temperature should be used to shift

the chemical equilibrium towards the right, hence increasing the percentage yield.
However too low of a temperature will lower the formation rate to an uneconomical
level. Hence to increase the reaction rate, high temperatures (450 °C), medium
pressures (1-2 atm), and vanadium (V) oxide (V2O5) are used to ensure an adequate
higher conversion. The catalyst only serves to increase the rate of reaction as it does
not change the position of the thermodynamic equilibrium. The mechanism for the
action of the catalyst comprises two steps:
 Oxidation of SO2 into SO3 by V5+:

2SO2 + 4V5+ + 2O2- → 2SO3 + 4V4+

Oxidation of V4+ back into V5+ by dioxygen (catalyst regeneration):

4V4++ O2 → 4V5+ + 2O2-

Unabsorbed SO3 gas escaping from the oleum tower is absorbed by a recirculating stream of
98-99% sulfuric acid. The recycle ratio of the sulfuric acid is, once again, determined by the
desired purity of the sulfuric acid product. Environmental regulations frequently require that
waste gas from the sulfuric acid tower pass through another absorbing tower to eliminate SOx
emissions that cause acid rain. A second conductivity measurement is placed in the final
recirculation line between the last sulfuric acid tower and the circulation tank.

Then, hot sulfur trioxide passes through the heat exchanger and is dissolved in concentrated
H2SO4 in the absorption tower to form oleum:

H2SO4 (l) + SO3 (g) → H2S2O7 (l)

Note that directly dissolving SO3 in water is impractical due to the highly exothermic nature
of the reaction. Acidic vapor or mists are formed instead of a liquid. Oleum is reacted with
water to form concentrated H2SO4.

H2SO4 (l) + H2O (l) → 2 H2SO4 (l)

This can either be made by burning sulphur in an excess of air or by heating sulphide ores
like pyrite in an excess of air. In either case, an excess of air is used so that the sulphur
dioxide produced is already mixed with oxygen for the next stage. Converting the sulphur
cdioxide into sulphur trioxide. This is a reversible reaction, and the formation of the sulphur
trioxide is exothermic. Converting the sulphur trioxide into sulphuric acid uncontrollable that
it creates a fog of sulphuric acid. Instead, the sulphur trioxide is first dissolved in
concentrated sulphuric acid. The product is known as fuming sulphuric acid or oleum. This
can then be reacted safely with water to produce concentrated sulphuric acid - twice as much
as you originally used to make the fuming sulphuric acid.
1.1 PROCESS FLOW DIAGRAM (PFD)

FIGURE 1.1: PROCESS FLOW DIAGRAM FOR PRODUCTION OF SULFURIC ACID

1.2 TABLE STREAM DATA FOR PRODUCTION OF SULFURIC ACID

FIGURE 1.2: TABLE STREAM DATA FOR PRODUCTION OF SULFURIC ACID

2.0 SELECTION OF EQUIPMENT.

The objective of this mini project is to design one of the equipment from the process
flow diagram (PFD) that we picked. Our group choose heater (E-105) to be our equipment
that need to design based on the specific calculation and assumption of the engineering study.
Process fluid (Stream 13) need to be cooled to at least 350C . Furthermore, we are using
cooling water as our utilities. Figure 1.5 show all the parameters that we need to use for
design of heat exchanger.

FIGURE 2.1: HEAT EXCHANGER (E-105)

Stream Type Temperature Target M

Cp (kJ/kg.
number Supply (°C) Temperature (kg/hr)
°C)
(°C)
13 Hot 60 35 1.34 66.43
 3.0 MATERIAL OF CONSTRUCTION

The choice of materials of construction is an extremely important step in the design of

distillation towers, as it affects the safety of the process and also the capital cost. In
consideration of this, there are several characteristics in selection of materials for
construction.

 Mechanical properties (i.e., strength, stiffness, toughness, wear resistance, fatigue

resistance, creep resistance)
 Effect of high and low temperatures on the mechanical properties
 Corrosion resistance
 Any special properties required; such as, thermal conductivity, electrical resistance,
magnetic properties
 Ease of fabrication forming, welding, casting
 The availability in standard sizes plates, sections, tubes
 Cost

For this shell and tube heat exchanger we have decided to use carbon steel as it can resist
corrosion from sulphuric acid and it is placed at the tube side as it is more corrosive and we
want to decrease the temperature to 35oC. Furthermore, carbon steel is cheap compared to
other metals. For the utilities, we chose water and it is placed at the shell-side as it has low
temperature. The choice of materials much from the compatibility chart of the material that
affected greatly by the process fluid properties and maximum operating temperature
condition for the heat exchanger. The compatibility chart for sulfuric acid is the main factors
for us to choose the carbon steel as the main material for construction of our shell and tube
heat exchanger along with the operating temperature condition which is not too high for
carbon steel to loss its mechanical properties.
4.0 DESIGN CONSIDERATION FOR HEAT EXCHANGER.

A heat exchanger is a device designed to efficiently transfer or "exchange" heat from

one matter to another. When a fluid is used to transfer heat, the fluid could be a liquid, such
as water or oil, or could be moving air. The fluids may be separated by a solid wall to prevent
mixing or they may be in direct contact.

There are many different types of heat exchanger available, the three main types are

1. Shell and Tube.

Shell and Tube Heat Exchangers consist of a large number of small tubes
which are located within a cylindrical shell. The tubes are positioned into the
cylinder using a tube bundle or "tube stack" which can either have fixed tube
plates (permanently fixed to the body) or, a floating tube stack which allows
the tube bundle to expand and contract with varying heat conditions as well as
allowing the tube bundle to be easily removed for servicing and maintenance.
Figure 1 shows the Shell and Tube Heat Exchangers.

FIGURE 4.1: SHELL AND TUBE HEAT EXCHANGER

2. Plate Type
Plate Heat Exchangers operate in very much the same way as a shell and tube
heat exchanger, using a series of stacked plates rather than tubes. Plate heat
exchangers are usually brazed or gasketed depending on the application and
fluids being used. Their compact stainless steel construction makes them an
ideal choice for use with refrigerants or in food and beverage processing.
Figure 4.2 to shows the Plate Heat Exchangers

FIGURE 4.2: THE PLATE OF HEAT EXCHANGER

3. Air Cooled

Air Cooled Heat Exchangers are commonly used in vehicles or other

mobile applications where no permanent cool water source is available. Air
cooled Heat exchanger is designs and supplies combination cooling packs (or
combi-coolers) which combine an engine jacket water cooler, oil cooler and
charge air cooler into a single unit reducing space requirements and improving
efficiency. Cool air is provided either by a fan or by air flow caused by the
movement of the vehicle. Figure 3 shows the Air Cooled Heat Exchangers

FIGURE 4.3: AIR COOLED HEAT EXCHANGER

4.1 CALCUTION MECHANICS OF HEAT EXCHANGER

Shell and Tube Heat Exchanger

Shell T1 = 60 0C Tube t1 = 25 0C

T2 = 35 0C t2 = 40 0C

m sulphuric acid = 100 000 kg/hr

Cp sulphuric acid = 1.34 kJ/kg.K

Cp H2O = 4.2 kJ/kg. 0C

Convert 100 000 kg/hr x 1hr/3600s = 27.78 kg/s

Q = 27.78 (1.34) (60.35)

= 930.63

(𝑇1−𝑡2)−(𝑇2−𝑡1)
ΔTlm = 𝑇1−𝑡2
ln⁡( )
𝑇2−𝑡1

(60⁡−⁡40)−(35⁡−⁡25)
= 60⁡−⁡40
ln⁡( )
35⁡−⁡25

10
= 20
ln
⁡10

= 14.43 0C
Cooling Water

Q = mCpΔT

930.63
= (4.2)(40−25)

= 14.778 kg/s

Assume 1 shell pass 2 tube passes

From appendix:

Ft = 0.85

𝑇1−𝑇2 𝑡2−𝑡1
R = S =
𝑡2−𝑡1 𝑇1−𝑡1

60−35 40−25
= =
40−25 60−25

= 1.6667 = 0.4286

From Appendix:

U = 250 W/m2.K

Q = UATlmFL

930 630 = 250A(14.43)(0.85)

A = 303.4952 m2

Assume Outer Diameter = 20 mm

Inner Diameter = 16 mm

Length = 4.88 m
Area of tube = 2ПrL

= 2П(10 x 10-3) (4.88)

= 0.3067 m2

303.4952
Number of tube = 0.3067

= 989.5507 ~ 999 tubes

Tube Coefficient , hi

999⁡𝑡𝑢𝑏𝑒𝑠 ПDi²
A = x
2⁡𝑝𝑎𝑠𝑠𝑒𝑠 4

999 П(16)²
= x
2 4

= 100 430.4339 mm2

= 0.10043 m2

m = ρAUt
𝑚
Ut = 𝜌𝐴

14.772⁡𝑘𝑔/𝑠
= (1000𝑘𝑔/𝑚³)⁡(0.10043⁡𝑚2 )

= 0.1471 m/s

40+25
Mean water temperature, t = 2

= 32.5 ⁰ C

4200⁡(1.35+0.02𝑡)𝑈𝑡⁡^⁡0.8⁡
hi = 𝑑𝑖⁡^⁡0.2

4200⁡[(1.35+0.02(32.5)]𝑈𝑡⁡^⁡0.8⁡
= 16⁡^⁡0.2

= 1041.1142 W/m2.⁰ C
Bundle Diameter

𝑁𝑡
Db = dₒ ( 𝑘𝑖 )1/ni

From appendix:

For 2 tube passes

ki = 0.249

ni = 2.207

999
Db = 20 ( 0.249 )1/2.207

= 858.4772 mm ~ 859 mm

From appendix:

Clearance = 68 mm

Ds = Db + clearance

= 859 + 68

= 927 mm

Bundle diameter

𝑁𝑡1/𝑛𝑖
𝐷𝑏 = 𝑑𝑜⁡
𝑘𝑖

From appendix:

For 2 tube passes

ki = 0.249

ni = 2.207

9991/2.207
𝐷𝑏 = 20⁡ = 858.4772𝑚𝑚⁡ ≈ 859𝑚𝑚
0.249
From appendix:

Clearance = 68mm

Ds = Db + clearance

= 859 + 68

= 927 mm

Shell side coefficient, hs

Assume; lb = 0.4Ds

= 0.4(927)

= 370.8

Pt = 1.25 Do

= 1.25(20)

= 25mm

(𝑃𝑡 − 𝑑0) )𝐷𝑠⁡ 𝑙𝑏

𝐴𝑠 = ⁡
𝑃𝑡

(25 − 20)(927)(370.8)
𝐴𝑠 = ⁡ = 68,746.32𝑚𝑚2
25

⁡⁡⁡⁡⁡⁡⁡⁡⁡⁡⁡⁡⁡⁡⁡⁡⁡⁡⁡⁡⁡⁡⁡⁡⁡⁡⁡⁡⁡⁡⁡⁡⁡⁡⁡⁡⁡⁡⁡⁡⁡⁡⁡⁡⁡⁡⁡⁡⁡⁡⁡= 0.06875𝑚2

𝑊𝑠
𝐺𝑠 =
𝐴𝑠

27.78
𝐺𝑠 = = 404.094
0.06875
Equilateral triangle

1.1
𝑑𝑒 = ⁡ ⁡(⁡𝑃𝑡2 − 0.917𝑑𝑜2 )
𝑑𝑜

1.1
𝑑𝑒 = ⁡ ⁡[252 − 0.917(202 )]
20

= 14.201𝑚𝑚

= 0.0142⁡𝑚

Ρsulphuric acid = 1840 kg/m3

Viscosity, μ = 0.025 Ns/m2

Cp = 1.34 kJ/kgoC

kf = 0.5 W/moC

𝐺𝑠(𝑑𝑒)
𝑅𝑒 =
𝜇

404.094(0.0142)
𝑅𝑒 = = 229.526
0.025

𝐶𝑝(𝜇)
Pr = ⁡
𝑘𝑓

(1.34⁡𝑥⁡103 )(0.025)
Pr = ⁡ = 67⁡
0.5
Choose 25% baffle cut from figure 12.29

jh = 3.3 x 10-1

ℎ𝑠 𝑑𝑒 𝑗ℎ⁡𝑥⁡𝑅𝑒⁡𝑥⁡𝑃𝑟 1/3
=
𝑘𝑓 𝑑𝑒

𝑗ℎ⁡𝑘𝑓 𝑥⁡𝑅𝑒⁡𝑥⁡𝑃𝑟 1/3

ℎ𝑠 =
𝑑𝑒

0.5(⁡3.3⁡𝑥⁡10−1 )𝑥⁡(229.526)⁡𝑥⁡671/3 𝑊
ℎ𝑠 = = 10832.2603 3
0.0142 𝑚 . ˚𝐶

Overall coefficient

Kw ( carbon steel) = 45 W/k.m

hod (sulphuric) = 200

hid = (water cooling) = 6000

𝑑
1 1 1 𝑑𝑜 𝑙𝑛 𝑜 𝑑𝑜 1 𝑑𝑜 1
𝑑𝑖
= + +⁡ +( 𝑥 )+( 𝑥 )
𝑈𝑜 ℎ𝑜 ℎ𝑜𝑑 2𝑘𝑊 𝑑𝑖 ℎ𝑖𝑑 𝑑𝑖 ℎ𝑖

20
1 1 1 (20⁡𝑥⁡10−3 )𝑙𝑛 16 20 1 20 1
= + +⁡ +( 𝑥 )+( 𝑥 )
𝑈𝑜 10832.2603 200 2𝑘𝑊 16 6000 16 1041.1142

= 6.5062 x 10-3

Uo = 153.699 W/m2.oC
Pressure drop (Tube side)

𝜌𝑢 𝑑𝑖 1000(0.147132)(16⁡𝑥⁡10−3 )
From appendix: for, 𝑅𝑒 = =⁡ = 2942.64
𝜇 0.8⁡𝑥10−3

jf = 6.5 x 10-3

𝑏 1−𝑚 𝜌(0.892 )
∆𝑃𝑓 = 8⁡𝑗𝑓 [ (𝜇/𝜇𝑤 ) + 2.5]
𝑑𝑖 2

488⁡𝑥103 𝜌(0.892 )
∆𝑃𝑓 = 8⁡(6.5⁡𝑥⁡10−3 ) [ + 2.5]
16 2

= 14,542.956⁡𝑁/𝑚2

Shell side

Re = 229/526

Jf = 1.1 x 10-1

𝐺𝑠 404.094
𝑈𝑠 = = = 0.21962
𝜌 1840

𝐷𝑠 𝐿 𝜌𝑈𝑠2 𝜇
∆𝑃𝑠 = 8𝐽𝑓 ( )( ) )( )
𝑑𝑒 𝑙𝑏 2 𝜇0

927 4.83⁡𝑥103 (1840)(0.21962 )

∆𝑃𝑠 = 8(1.1⁡𝑥⁡10−1 ) ( )( )[ ]
14.2 370.8 2

𝑁
= 33,205.7872 = 33.206⁡𝑘𝑃𝑎
𝑚2
5.0 DESIGN OF PRESSURE VESSEL ( Shell side of heat exchanger)

According to ASME code, when the operating pressure of the equpiment reach the
pressure of 15 psig , the equpiment act as a pressure vessel in which for our equipment, the
operating pressure is 1 atm to 5 atm. Hence the consideration of the thickness of our shell and
tube heat exchanger need to be design based on the pressure vessel calculation and
assumption. There are some general design consideration that need to take into account for
the design :

1. Design pressure.
- A vessel must be design to withstand the maximum pressure to which it likely to
happen during operation.
- Normally, design pressure take 5 to 10 percent above operating pressure to avoid
spurious operation during minor process upsets.

2. Design temperature
- The maximum allowable stress design depend on the material temperature,
strentgh of materials decreases with increasing temperature.
- The heat exchanger highest temperature was on the inlet stream of the process
fluid which is 60 0C. The appendix from table below shows the selection of
maximum allowable stress design for our equpiment which is 135 N/mm2.
 FIGURE 5.1: TYPICAL DESIGN STRESS FOR MATERIALS

3. Materials of Construction.
- Selection of suitable material also take into account for example, the suitability of
the materials for the fabrication (welding) as well as the compatibility of the
materials with the process environment.

4. Design stress.
- Design stress important in deciding the maximum allowable stress that can be
accepted by the materials.
- There are two factors that need to take into account which is :
a) When the vessel is not subjected to high temperature, the design stress is based
on the yield stress, or tensile strength of materials at design temperature.
b) When the materials subjected to condition at which creeps is likely to be
happen. The design stress is based on the creep characteristics of the materials.
- The heat exchanger is likely to be fall in cases a) where the operating temperature
is not too high, the highest temperature for the equipment is as the inlet stream of
the process fluid which is 600C.
-
5. Welded joint efficiency. (E)
- Strength of the joint depends on the type of joint and quality of the welding where
soundness of welds is check by radiography technique.
- The value of the joint factor for the design depend on the type of joint and amount
of radiograph required by the design code. The table 4.2 shows the typical value
for the joint factor used in the design.

FIGURE 4.2: MAXIMUM ALLOWABLE JOINT EFFICIENCY

- We take and assume the joint factor of 1 fully radiograph, implies that the joint is
equally strong as the virgin plate (Carbon Steel).

6. Corrosion Allowance.
- Corrosion allowance is the additional thickness of the materials added to allow
for the material lost by erosion or corrosion.
- Allowance corrosion usually picked by the experinced of the same material from
the previous design.
- Where for carbon steel. The minimum allowance of 2 mm should be used.

7. Minimum wall thickness.

- Minimum wall thickness is the value required for any vessel can sufficiently
withstand its own weight, and any incidental loads.
8. Choice of closure.
- The cost of the closure is the main factor in choosing the type of closure, there are
4 types of closure which is flat plate, hemispherical heads, ellipsoidal heads and
torispherical heads. The most economical closure can be identified by comparing
the thickness of the closure to the thickness of the vessel.
- As for our cases, we choose the flat end type because the shell diameter is small
and the operating pressue is considered small. Falat end typer is the cheapest type
of closure among other type of closure, however it is limited to the small diamter
and small operating pressure. The equation for the design of flat end is ;

𝐶𝑃𝑖
Tflat = De√ 𝑆𝐸

Where ; C = design constant, take as 0.17 as the corner radius is not more than 3t.

De = Nomimal plate diamter, equals to the diameterof the vessel (Di)

S = Allowable maximum design stress

E = joint factor efficiency

Pi = Design Pressure.
 9. Combined Loading consideration.
- Pressure vessel must be design to withstand the worst combination of loading
without failure.
- We choose the combination of weight load and the wind load as the combined
loading.

a) Weight load:

 Vessel shell weight (dead Weight).

Wv = 240 Cv Dm ( Hv + 0.8(Dm) ) tvessel

Where; Cv = a factor to account for the weight of nozzles, man
Dm = mean diameter of vessel, (Di + tvessel x 10-3)
Hv = Height of vessel, We assume lenght of Heat exchanger at tube side as Hv.
Tvessel = thickness of vessel.

b) Wind loading.

 In Malaysia, at 10 m height the wind velocity take as 32.5 m/s to 33.5

m/s.

Pw = 0.05 Uw2

Where; Pw = wind pressure (N/m2)

Uw2 = Velocity of wind (km/hr)

Fw = Pw Deff

Where; Deff = Di + 2 (tvessel + tinsulation )

𝐹𝑤
Fw = wind loading Bending moment, Wb = Hv2
2
 10. Stress analysis.
- Due to combined loading, the primary stresses arising from this loads are
considered.
- There are three types of primary stresses which is;

a) Longitudinal and circumferential stresses due to external and internal

pressure.
Circumferential stress,

𝑃𝑖⁡𝐷𝑖
σh = 2𝑡

Longitudinal stress,

𝑃𝑖⁡𝐷𝑖
σL = 4𝑡

b) The direct stress, due to the weight of the vessel, its content and
attachment.

𝑊𝑧
σw = 𝛱⁡(⁡𝐷𝑖+𝑡)𝑡

where; Wz = Total weight of the vessel

σw = Direct stress.

c) Bending stress,

𝑀 𝐷𝑖
σb = ± 𝐼𝑣 ( 2 + 𝑡⁡)

Where; Iv = second moment area of the vessel,

𝛱
Iv = 64 ( D04 - Di4 )
 D0 = Di + 2 tvessel

M = total bendng moment.

- Other than the primary stresses, principal stress also arised when designing the
pressusure vessel.

1
σ1 = 2 ( σh + σz + √(⁡σh − ⁡σz⁡) + 4𝛤2 )

1
σ2= ( σh + σz - √(⁡σh − ⁡σz⁡) + 4𝛤2 )
2

Where; σz =total longitudinal stress, σz = σL + σw ± σb

σw = should be counted as positive if tension and negative if compressive.

𝛤 = Usually not significant

- Allowable stress Intensity.

σz – σh
Where; σz – σh must be lower than maximum allowable stress design., if not the failure will
occur and the thickness of vessel wall need to be recalculated.
- Compresive stress and Elastic stability.

𝑡⁡𝑣𝑒𝑠𝑠𝑒𝑙
σc = 2 x 104 ( )
𝐷0

Where; σw + σb should not exceed the critical buckling stress, σc..

5.2: DESIGN CALCULATION FOR HEAT EXCHANGER ACT AS PRESSULE
VESSEL.

Parameters :

A) Height of column, Hv assumed to be equal with the lenght of tube in Heat Exchanger
Hv = L = 4.88 m

B) Internal diamter, Di assume to be equal with the Ds of heat exchanger.

Di = Ds = 927 mm

C) Operating pressure (absolute), 1 atam to 5 atm. Take maximum pressure of 5 atam (5

bar).

D) Material of consctruction, Carbon steel with maximum allowable stress, S = 135

N/mm2.

E) Welded joint efficiency, E = 1 (fully radiograph).

F) Cv factors for nozzles, manways and internal support. Cv = 1.08

G) Corrrosion allowance, 2 mm.

1. Design pressure, Pi : take 10 percent above operating pressure.

Pi = ( 5 bar – 1 bar ) x 1.1

= 4.4 bar
= 0.44 N/mm2

2. Thickness of shell, tshell .

𝑃𝑖⁡𝐷𝑖
tshell = 2⁡𝑆⁡𝐸−1.2⁡𝑃𝑖

𝑁
(0.44 )𝑥⁡(927⁡𝑚𝑚)
𝑚𝑚2
= 𝑁 𝑁
2⁡(⁡135 )⁡(⁡1)−1.2⁡(𝑜.44 )
𝑚𝑚2 𝑚𝑚2

= 1.51 mm ≈ 2 mm

3. Choice of closure,

i) Flat end type ( because of low pressure and low internal diamter )

𝐶⁡𝑃𝑖
tflat end = De√ 𝑆⁡𝐸

𝑁
(⁡0.17)⁡(⁡0.44 )
𝑚𝑚2
= (927 mm)√ 𝑁
(1)⁡(135 )
𝑚𝑚2

= 21.82 mm ≈ 24 mm

However, the the cost of flat end type is larger because of the thicknes is 24
mms which is too bigger compare to thickness of vessel which is 2 mm.
 ii) Ellipsoidal domed head type,

𝑃𝑖⁡𝐷𝑖
tellipsoidal = 2⁡𝑆⁡𝐸−0.2⁡𝑃𝑖

𝑃𝑖⁡𝐷𝑖
= 𝑁
2⁡(135𝑁/𝑚𝑚2)⁡(1)−0.2⁡⁡(0.44 )
𝑚𝑚2

= 1.52 mm ≈ 2 mm.

Elliposidal type of closure is more economical rather than flat end type.

4. Load analysis.

Dead weight, Wv = 240 Dm C v ( Hv + 0.8Dm ) tshell

Dm = Di + tshell

= 0.927 + 0.002

= 0.929 m

Hv = 4.88 m

Cv = 1.08

Wv = 240 (0.929) (4.88) (1.08) (4.88 + 0.8(0.929)) 2

= 2708.1 N
5. Wind loading,

Wind speed from previous discussion based on Malaysia annual data.

Uw = 33.5 m/s2 x ( 3600 s/hr ) x ( 1km/1000m )

= 120.6 km/hr

Dynamic wind, Pw = 0.05 ( Uw2 )

= (0.05) (120.6)2

= 727.218 N/m2

Deff = Di + 2( tshell + tinsulation)

= 0.927mm + 2( 0.002mm)

= 0.931mm

Loading per linear metre, Fw = Pw Deff

= (727.218N/m2) (0.931m)

= 676.837 N/m
 𝐹𝑤
Bendind moment, Wb = Hv2
2

676.837⁡𝑁/𝑚
= (4.88m)2
2

= 8059.23 Nm

6. Stress analysis.

𝑊𝑣
i) Dead weight stress, σw = 𝜋⁡(𝐷𝑖+𝑡)𝑡

2708.1⁡𝑁
= 𝜋⁡(927𝑚𝑚+2𝑚𝑚)2𝑚𝑚

= 0.46 N/mm2

ii) Pressure stress,

𝑃𝑖⁡𝐷𝑖
Longitudinal stress, σL= 4⁡𝑡

44𝑁
(𝑜. )⁡(927𝑚𝑚)
𝑚𝑚2
= 4⁡(2𝑚𝑚)

= 50.985 N/mm2

𝑃𝑖⁡𝐷𝑖
Circumferential stress, σh = 2⁡𝑡

44𝑁
(𝑜. )⁡(927𝑚𝑚)
𝑚𝑚2
= 2⁡(2𝑚𝑚)

= 101.91 N/mm2
 𝑊𝑏 𝐷𝑖
iii) Bending stress, σb = ± ( 2 + 𝑡⁡)
𝐼𝑣

𝛱
Iv = 64 ( D04 - Di4 )

D0 = Di + 2 tvessel

D0 = 927mm + 2(2mm)

D0 = 931mm

𝛱
Iv = 64 ( D04 - Di4 )

𝛱
= 64 ( 9314 - 9274 )

= 6.3 x 108 mm4

8059.23⁡𝑥⁡10^3⁡⁡𝑁𝑚𝑚 927𝑚𝑚
σb = ± 6.3⁡𝑥⁡108 𝑚𝑚4
( 2
+ 2⁡)

= ± 5.95 N/mm2
iv) Resultant longitudinal force, σz

σz = σL+ σw ± σb

(Upwind) σz = σL+ σw ± σb

= 50.985 N/mm2 – 0.46 N/mm2 + 5.95 N/mm2

= 56.475 N/mm2

(Upwind) σz = σL+ σw ± σb

= 50.985 N/mm2 – 0.46 N/mm2 - 5.95 N/mm2

= 44.575 N/mm2

56.475 N/mm2 44.575 N/mm2

101.97 N/mm2

101.97 N/mm2
v) Allowable stress intensity,

σz – σh < S (maximum allowable stress design)

σz – σh = 101.97 N/mm2 – 44.575 N/mm2

= 57.395 N/mm2

Which is smaller than S, 135 N/mm2. Then the failure not occur.

vi) Critical buckling stress,

𝑡⁡𝑣𝑒𝑠𝑠𝑒𝑙
σc = 2 x 104 ( )
𝐷0

2𝑚𝑚
= 2 x 104 (931𝑚𝑚)

= 42.96 N/mm2

σw + σb < σc

σw + σb = 0.46 N/mm2 + 5.95 N/mm2

= 6.41 N/mm2.

The critical buckling stress, σc is bigger than when maximum compressive

stress on the Heat Exchanger is occur (σw + σb).

Hence, the thickness of 2 mm satisfy the requirement and the failure of the
equipment will not occure. Adding thickness shell with 2 mm corrosion
allowance give the total thickness as 4mm.
6.0 DESIGN OF HEAT EXCHANGER SUPPORT.

The heat exchanger is designed as horizontally to increase the contact area and the
contact time between the two fluids during the heat exchange. To support this kind of vessels,
saddle support is chosen. The vessel is supported by two saddle that considered as the simple
supported beam.

FIGURE 6.1: FRONT VIEW OF VESSEL WITH SADDLE

FIGURE 6.2: DIMENSION OF SADDLE

 Table 6.1: Dimension for standard saddle support

Figure 3: Formula to calculate moment at the saddle, M1 and moment at the centre of
the vessel

Length of the vessel (L) = 4.88 m

Saddle Bearing Angle (ϴ) =120o
Mean vessel diameter (Dm) = 0.929 m≈1 m→ Vessel Mean Radius (Rm) = 0.929/2=0.4645 m
Thus, from Table 1, the data as stated obtained:
Maximum weight (Q) = 90 kN
Assume 𝐴 = 0.2𝐿
=0.2(4.88)
=0.976 m
Inside depth of head (H) = radius of the head
= C/2
= 0.91/2
= 0.455 m

0.976⁡𝑚 (0.4645⁡𝑚)2 − (0.455⁡𝑚)2

1 − 4.88⁡𝑚 + 2 × 0.976⁡𝑚 × 4.88⁡𝑚
𝑀1 = −90⁡𝑘𝑁 × 0.976⁡𝑚 × (1 − )
4 0.455⁡𝑚
1 + 3 4.88⁡𝑚

= -25.2668 kN.m
(0.46452 − 0.4552 )
90⁡𝑘𝑁 × 4.88⁡𝑚 1 + 2( ) 0.976⁡𝑚
4.882
𝑀2 = ×( −4× )
4 4 0.455⁡𝑚 4.88⁡𝑚
1 + 3 4.88⁡𝑚

=9.8930 kN.m

Formula to calculate longitudinal stress at top of shell

0,44⁡𝑁/𝑚𝑚2 × 0.4642 × 102 𝑚𝑚 9.8930⁡𝑁. 𝑚𝑚
𝜎1 = −
2 × 8𝑚𝑚 𝜋 × (0.4642 × 102 𝑚𝑚)2 × 8𝑚𝑚
=1.27 N.mm2

Formula to calculate longitudinal stress at bottom of shell

0,44⁡𝑁/𝑚𝑚2 × 0.4642 × 102 𝑚𝑚 9.8930⁡𝑁. 𝑚𝑚
𝜎2 = +
2 × 8𝑚𝑚 𝜋 × (0.4642 × 102 𝑚𝑚)2 × 8𝑚𝑚
=1.28 N/mm2
Formula to calculate longitudinal stress at top of shell at support
0,44⁡𝑁/𝑚𝑚2 × 0.4642 × 102 𝑚𝑚 (−25.2668⁡⁡𝑁. 𝑚𝑚)
𝜎3 = −
2 × 8𝑚𝑚 𝜋 × (0.4642 × 102 𝑚𝑚)2 × 8𝑚𝑚
= 1.28 N/mm2

Formula to calculate longitudinal stress at bottom of shell at support

0,44⁡𝑁/𝑚𝑚2 × 0.4642 × 102 𝑚𝑚 (−25.2668⁡⁡𝑁. 𝑚𝑚)
𝜎4 = +
2 × 8𝑚𝑚 𝜋 × (0.4642 × 102 𝑚𝑚)2 × 8𝑚𝑚
=1.27 N/mm2

Formula to calculate the shear force in the saddle

90𝑘𝑁 × (4.88𝑚 − 2 × 0.976⁡𝑚)
𝑇=
4
4.88⁡𝑚 + 3 (0.455𝑚)

=48.0292 kN
7.0 MECHANICAL DRAWING DESIGN FOR SHELL AND TUBE HE.

FIGURE 7.1: SIDE VIEW OF HEAT EXCHANGER

4.88 M

FIGURE 7.1: TOP VIEW OF HEAT EXCHANGER

 FIGURE 7.3: FRONT VIEW OF HEAT EXCHANGER

FIGURE 7.4: CROSS-SECTIONAL VIEW OF HEAT EXCHANGER

8.0 REFERENCES

1 Production and uses of Sulfuric acid(12//2019). Retrieved from:

https://www.essentialchemicalindustry.org/chemicals/sulfuric-acid.html

2 Chemical and physical properties of Sulfuric Acid(12/2019). Retrieved from:

https://pubchem.ncbi.nlm.nih.gov/compound/Sulfuric-acid

3 Compatibility chart for Sulfuric acid(12/2019). Retrieved from:

http://www.saltech.co.il/_uploads/dbsattachedfiles/chemical.pdf

4 Typical Overall Heat Transfer Coefficient(12/2019). Retrieved from:

https://www.cheresources.com/invision/topic/27702-typical-overall-heat-transfer-
coefficient/

5 Design of Saddle Support for Horizontal Vessel(12/19). Retrieved from:

https://zenodo.org/record/1097060#.XffeCNUzbIU

6 Annual Wind Speed in Malaysia(12/2019): Retrieved from:

http://www.ukm.my/jsm/pdf_files/SM-PDF-44-10-2015/18%20S.Z.%20Satari.pdf
9.1 APPENDICES

Figure 9.1: Temperature correction factor: one shell pass: two or more even tube passes
Figure 9.2: Overall coefficients(trial value)
Figure 9.3: Constant use for equation

Figure 9.4: Shell-bundle clearance

Figure 9.5: Tube-side coefficient factors