1 Design of Equipment

1.1 Shell and Tube Heat Exchanger Design

 Cold Fluid Data:

Ti ⟶ t1=21℃=69.8℉

To ⟶ t2=210℃ =410℉

w (weight flow) = 15141.92996 kg/hr

 Calculation of Heat load

Qh= m Cp ∆T
= 15141.92996*1.4*(210-25) =392366.8596 kg/hr

So, Qc= m Cp ∆Tm

= Qc/ (Cp ∆T)

= 392366.8596/(∆H)

=392366.8596/ (2801.5-2643.7)

=2486.482 Kg/hr

 Hot Fluid data

Temperature in (T1) = 250℃

Temperature out (T2) = 80℉

Weight flow (W)=2486.482 kg/hr

 ∆TLMTD Calculation
∆TLMTD= (∆T1-∆T2 / ln(∆T1/∆T2))

o
∆TLMTD= 47.10 F

R and S values calculations

R= (T2-T1)/(t2-t1) = 0.918
S = (t2-t1)/(T2-t1) = 0.822

Correction Factor calculation

by using LMTD correction factor curves to get Ft from Graph we get, Ft=0.845

also, R and S values satisfy with Correction factor value for 4-8 shell and tube heat
exchanger.

∆tln= ∆TLMTD*Ft
= 47.1*0.845 = 39.79℉

 Ud calculation

2
From references the UD value of Nitrobenzene ranges from 60-90 W/m K

By assuming a value of UD to be 80

Calculation of heat transfer area

A= Q/ UD*∆t
2
= 371893.4406/ (80*39.79) = 116.83 ft

Length of the tube L=16’0’’ (3/4 in. OD,16BWG)-Square pitch from the table,

Flow area per tube a’ 2

t=0.302in

2
Outside area per linear ft a’’=0.1963 ft
Tube inside diameter will be D=0.62 in (which Obtained from tables)
So, the No. of tubes per shell

Nt= Heat transfer area/ (No. of shell side passes* total surface area)

Nt= 116.83/ (2*16*0.1963)

= 18.5988

= 19 tubes

For 4 passes, 3/4in.OD on 1-in. Square pitch (entering the table), the Nearest count from (19
tubes) will be 20 tubes in an 8in.ID shell

 Corrected UD Calculation:

UD, corr = Q/A* ∆ T LMTD

A= No. of passes * No. of tubes * Length of the tube * Outside area

= 2* 20* 16* 0.1963

=125.632 ft2

UD= Q/(A*∆T)

=371893.4406/ (125.632*39.79)

=74.395

 Calculation of Tube side

at = Nt * at/(144n)

2
=20* 0.302/ (144*4) = 0.01049 ft

Mass velocity:
Gt = w/ at

= 5481.754466/0.01049

=522569.5392 lb./ hr ft2

At Tavg= 180℃

Ret = D*Gt / μ
And, inside diameter of tube = D = 0.62in

= 0.62/12 =0.0517
So, Ret = 0.0517*522569.5392 / (0.0375) = 720449.2047

J factor for heat transfer curve (jH)

At L/D = 16/0.0517
, jH = 750
, Cp = 0.47 btu/lb.
2
and, K = 0.0187 btu/ hr. ft . OF
1/3
hi = jH *(K/D) *(Cμ/K)

= 750*(0.187/0.0517) *(0.47*0.0375/0.187)1/3

= 265.975 ≅ 266

And since, hio= hi * ID/OD

2
= 265.97 * 0.62/0.75 =220 btu/hr. ft .OF

At Re = 720449.2047

f= 0.0001, S= 0.7
 2 10
Tube side pressure drop (∆Pt) = f Gt Ln/ (5.22*10 *D *S)

2 10
∆Pt= 0.0001*522569.5392 *16*4/ (5.22*10 *0.0517*0.7)

=0.925 Psi

Gt = 522569.5392

2
And v /2g = 0.03352

2
So, ∆Pr = 4n/ S*(v /2g)

= 4*4*(0.03352)/0.7 =0.7662

So. the total pressure drops (∆PT) = ∆Pt +∆Pr

= 0.925 + 0.7662=1.6912 Psi

 Calculations of Shell side

B= 12in

C = 0.25in

PT = C + Tube OD = 0.25+0.75 =1 in

Flow area as = ID* C*B/(144PT) = (8*0.25*12)/ (144*2) = 0.0833 ft2

Mass velocity:

Gs = W/as

= 33382.2413/ (0.0833) = 400586.8959 lb./ hr.ft2

Since, Tavg= 117.5℃

, μ = 0.4 and Cp = 0.4*2.42 = 0.968 lb./ft. hr

So, Res = De* Gs/μ = 32761.48847

JH =80

K = 0.16 W/ m.K

= 0.16*6.93 btu/hr. ft2. ℉

=1.1088 btu/hr. ft2. ℉

ho = jH* K/ D*(Cμ/K)1/3

= 80*1.1088/0.792*(0.968*0.334/1.1088)1/3

= 742.68 btu/hr. ft2. ℉

f = 0.0018, S= 0.76

So, No. of Crosses N+1 = 12L/ B

= 12*4*16/12 = 64

Shell diameter (Ds)= 8/12 = 0.667 ft

Shell side pressure drop

∆Ps = f Gs2Ds(N+1)/ (5.22*1010*0.079*0.76) = 3.9342 Psi

Uc (Clean overall Coefficient):

Uc = hio* ho/ (hio + ho)

= 95.87 btu/hr.ft2. ℉

Finally, Rd = UC- UD/ (UC*UD)

 = 95.87-74.395/ (95.87*74.395)

=3.01097*10-3 hr.ft2. ℉/ btu

1.2 Fixed Bed Reactor Design

1.2.1 Volume estimating of the reacting mixture

1 kmol: at {STP} equal 22.4

P1V1 ∕ T1= P2V2 ∕ T2
1×22.4 ∕ 273=3×V2 ∕ 593
(22.4) (593) = (3V2) (273)
V2=16.22 m3
At 3 atmosphere 1 kmol of hydrogen (350 CO) = 16.22 m3
1 Kmol of reactant mixture= (0.9×2.015680) + (0.1×123.11) = 14.125 gm
18093.83217 kg ∕ hr. of reactants = 1280.9792 kmol ∕ hr. = 20777.4826 m3 ∕ hr.
= 5.7715 m3 ∕ sec
1.2.2 Volume estimating of products mixture
P1V1 ∕ T1= P2V2 ∕ T2
1×22.4 ∕ 273 = 2×V2 ∕ 600
(2×V2) (273) = (22.4) (600)
V2= 24.615 m3
AT 2 atmosphere and 600 kelvin 1 kmol of products = 24.615 m3
Also the product mixture of 1 kmol = 15.69 gm
18093.83217 kg ∕ hr. = 1158.746857 kmol ∕ hr. = 28522.553 m3 ∕ hr. = 7.922 m3 ∕ sec.
Therefore Basis = 6.8467 m3 ∕ sec.
By using tubes of outside diameter 1.5 {BWG 10 no} and also L = 4 meter
BWG 10 no tube wall thickness = 0.134
The calculation of the inside diameter tube (1.5 – 2 × 0.1341) = 1.232 = 31.2928 mm.
Every tube V= (π/4× (31.3×10-3)2 ×4) = 3.0764×10-3 m3.
By assuming a Residence time = 0.4 second with in reactor
In which Residence time = the volume of the reactor ÷ volumetric flow rate
Therefore volume of the reactor = volumetric flow rate × residence time
Therefore V= 6.8467 × 0.4 = 2.73868 m3.
By letting no of tubes to be N
Therefore 2.73868 = (3.0764×10-3) × N
Then N = 890.22 (Approx.) N = 890 Tubes
Heat transfer area = (do × π × h) × N
= (38.1×10-3 × π × 4 × 890) = 426.113 m2.
Since triangular pitch has the ability to be used in accommodating 890 number of tubes
Then triangular tube pitch
Pt. = 1.25 do (therefore 38.1 × 1.25 = 47.625 mm.)
Db = do (Nt ∕ K1)1 ∕ n1 (Bundle diameter) in which n1 and also k1 should obtained from the table
based on the arrangement tube types.
Therefore: (890 / 0.319)1/2.142 × 38.1 = 1547 mm.
Bundle diameter and shell inside graph
If we are extrapolating the diameter bundle to be equal to 2.358 meter and also, we have
shell- ID Bundle
Which equal to (20+ (20-10)) × (5.41-1.2) ÷ (1.2- 0.2)
= 62.1 mm
Shell ID = 62.1 + bundle diameter
Therefore 1547 + 62.1 = 1609.1 mm
Since the volume of the reactor = (H × (π/4) × D2)
In which H of the reactor = 10 meter
Therefore V= (10 × (1609.1×10-3)2 × (π/4))
Volume of the reactor= 20.33 m3
1.3 Cooler Design

 For the Hot Fluid:

Inlet Temperature T1 = 371.69 °K
= 209.12℉
Outlet Temperature T2 = 303.15°K
=86℉
Weight flow rate (W) = 15882.64 kg/hr
 For Cold Fluid Data:
Inlet Temperature t1 = 25 ℃
= 77℉
Outlet Temperature t2 = 131℉
Weight flow rate (W) = 7166.7 kg/hr
 Calculation of ∆TLMTD:
∆T1= 209.12 - 86 =123.12℉
∆T2 = 86 - 71 =15℉
∆TLMTD = ∆T1 - ∆T2 / ln(∆T1/∆T2)
= 17.79℉
For the calculation of R and S values:
R = (T1-T2) / (t2-t1)
= 2.28
S = (t2-t1)/(T2-t1)
= 0.4
 For the Correction Factor:
Ft is found using LMTD correction factor curves
From Graph we get, Ft = 0.94
The values of R and S satisfy with Correction factor value for 2-4 shell and tube heat
exchanger.
 ∆tln = ∆TLMTD*Ft
= 17.79*0.94 = 16.72℉
Assume a value of UD
Let the value of UD be 70 btu/hr.ft2

 To Calculate heat transfer area:

A= Q/ UD*∆t
= 1315199.141/ (1.055*70*16.72)
= 1118.127 ft2
Length of the tube L=16’0’’ (3/4 in. OD,16BWG) - Square pitch
From the table,
Flow area per tube a’t = 0.302in2
Outside area per linear ft a’’=0.1963 ft2
Tube inside diameter D = 0.62 in (Obtained from tables)
To calculate the No. of tubes per shell:
Nt= Heat transfer area/ (No. of shell side passes* total
surface area)
Nt= 1118.127/ (2*16*0.1963)
= 178.00025
≅ 179 tube
For 3/4in.OD on 1-in. Square pitch (from the table), Nearest count (from 179 tubes):
158 tubes in a 17.25 in.ID shell.
 Calculation of corrected UD:

UD, corr = Q/A* Δ TLMTD

A= No. of passes * No. of tubes * Length of the tube * Outside area
= 2* 158* 16* 0.1963
=992.4928 ft2
UD = Q/(A*ΔT)
=1315199.141/ (1.055*992.4928 *16.72)
=75.123
 For the Tube Side Calculations:
at = Nt * at /(144n)
=158* 0.302/ (144*4)
 = 0.083 ft2
Mass velocity:
Gt = w/ at
= 15882.64 / (0.454*0.083)
= 421491.4283 lb/ hr.ft2
At Tavg= 64.25℃
, μ for aniline-water mixture = 3.46 lb/ft.hr
Ret = D*Gt / μ
Tube inside diameter = Din = 0.62in
0.62
= = 0.0517 ft
12
Ret = 0.0517*421491.4283 / (3.46)
= 6298.0077
(j) factor for heat transfer curve jH
At L/D = 16/0.0517 =25.8
So, jH = 4.2 (from graph)
Also, Cp = 0.65 Btu/lb
, K = 0.17 Btu/ hr.ft2. ᴼF
And since, hi = jH *(K/D) *(Cμ/K)1/3
= 4.2*(0.17/0.0517) *(0.65*3.46/0.17)1/3
= 32.66
And, hio= hi * ID/OD
= 32.66 * 0.62/0.75
=27 Btu/hr. ft2. ℉
At Re = 6298.0077
f= 0.00036 and S= 0.7
and since, Tube side pressure drop (ΔPt) = f*Gt2 Ln/ (5.22*1010*D *S)
ΔPt= 0.00036*421491.42832*16*4/ (5.22*1010*0.0517*0.7)
=2.17 Psi
For Gt = 421491.4283,
And, v2/2g = 0.012
So, return pressure drop (ΔPr) = 4n/ S*(v2/2g)
= 4*4*(0.012)/0.7 =0.274 psi
Finally the total pressure drops (ΔPT) = ΔPt +ΔPr =2.44 Psi
 Shell Side Calculation:
B= 12in
C = 0.25in
PT = C + Tube OD = 0.25 + 0.75 =1 in

So, Flow area (as) = ID* C*B/(144PT) = (17.25*0.25*12)/ (2*144*1)

= 0.1797 ft2
Mass velocity:
Gs= W/as = 7166.7/ (0.454*0.1797) = 87844.65 lb/ hr.ft2
Tavg= 40℃
μ = 0.7 Cp = 1.6933 lb/ft. hr
Res = De* Gs/μ
Since, De =0.95/12 = 0.0792 ft
So, Re = (0.0792*87844.65)/1.6933 =4108.72
jH =37
K = 0.609 W/ m.K
= 0.352 btu/hr. ft2. ℉
ho = jH* K/ D*(Cμ/K)1/3
= 37*0.352/0.0792*(1*1.6933/0.609)1/3
= 231.23 btu/hr. ft2. ℉
f = 0.0026, S= 0.72
And to get the No. of Crosses N+1 = 12L/ B
= 12*16*2/12
= 32
Shell diameter (Ds)= 17.25/12
= 1.4375 ft
Shell side pressure drop:
ΔPs = f*Gs2*Ds*(N+1)/ (5.22*1010*0.079*0.72)
= 0.311 Psi
Clean overall Coefficient Uc:
Uc = hi0* h0/(hi0+h0)
= 80.4 btu/hr.ft2. ℉
Dirt Factor Rd:
 Rd = UC- UD/(UC*UD)
=8.74*10-4 hr.ft2. ℉/ btu

1.4 First Distillation Design

 Since water has a boiling point of 100℃ and the boiling point of Aniline is 185℃, so
water is the more volatile component. It is important for us to mention that since our
design will be based on the MVC.
 To get the theoretical number of stages for the distillation column, mole fractions of
all streams must be determined at first.

1.4.1 Overall mass balance on the Column

Feed = Distillate + Bottom

 For the Feed:

Mass 32202.482
Water mole number = = =1787.517 mole
Molar Mass 18.0152
Mass 1159.665
Aniline mole number = =¿ =12.453 mole
Molar Mass 93.126
So, Total number of feed mole = 1787.517 + 12.453 = 1799.97 mole
 1787.517
And, Mole fraction of water (Xf) = =0.993
1799.97

 For the Distillate:

Mass 4370.532
Water mole number = = =242.6 mole
Molar Mass 18.0152
Mass 163.715
Aniline mole number = =¿ =1.75799mole
Molar Mass 93.126
So, Total number of Distillate = 242.6 + 1.75799 = 244.35799
242.6
And, Mole fraction of water (XD) = =0.992
244.35799
 For the Bottom:
Mass 27831.95
Water mole number = = =1544.91mole
Molar Mass 18.0152
Mass 995.95
Aniline mole number = =¿ =10.6946 mole
Molar Mass 93.126
So, Total number of Bottom = 1544.91 + 10.6946 = 1555.6046
1544.91
And, Mole fraction of water (XB) = =0.9931
1555.6046