DESIGN OF HEAT EXCHANGER BY PINCH INTEGRATION

USING REAL-TIME DATA

Project report submitted in partial fulfilment
of the requirements for the degree of

BACHELOR OF TECHNOLOGY
in
CHEMICAL ENGINEERING
Submitted by

LEON JOHN D ALMEIDA

(Registration No. 180903007)
&
CHETHAN SHENOY
(Registration No. 180903060)
Under the guidance of

DR. SVSR KRISHNA BANDARU

Professor
Department of Chemical Engineering
Manipal Institute of Technology

DEPARTMENT OF CHEMICAL ENGINEERING

MANIPAL INSTITUTE OF TECHNOLOGY
(A constituent unit of MAHE)
Manipal, Karnataka, India - 576104.

JUNE 2022
DESIGN OF HEAT EXCHANGER BY PINCH INTEGRATION
USING REAL-TIME DATA
Project report submitted in partial fulfilment
of the requirements for the degree of

BACHELOR OF TECHNOLOGY
in
CHEMICAL ENGINEERING
Submitted by

LEON JOHN D ALMEIDA

(Registration No. 180903007)
&
CHETHAN SHENOY
(Registration No. 180903060)
Under the guidance of

DR. SVSR KRISHNA BANDARU

Professor
Department of Chemical Engineering
Manipal Institute of Technology

DEPARTMENT OF CHEMICAL ENGINEERING

MANIPAL INSTITUTE OF TECHNOLOGY
(A constituent unit of MAHE)
Manipal, Karnataka, India - 576104.

JUNE 2022
 I. ACKNOWLEDGMENTS

” Success is often the result of taking a misstep in the right direction”

In the present competitive world, the existence of race succeeds those having
the will to explore their ambitions by facing the challenges. Project work is like
a bridge between theoretical and practical experience. It is our determination
that has prompted us to join this particular project.

It is a radiant sentiment to place on record our best regards and deepest gratitude
to Dr. K. Balakrishna Prabhu , Professor and Head of Department for arranging
all facilities. We would also like to express our sincere appreciation to all those
who had extended their valuable advice and support to complete this report.
Special thanks to our guide and professor, Dr. SVSR Krishna Bandaru for his
support, inspiring suggestions, and encouragement that motivated us during the
fabrication process and in writing the report.

We would also like to acknowledge with much appreciation, the crucial role of
the staff in NMCE lab (Numerical Methods and Computational Engineering
laboratory), who have provided us the permission and the necessities to use the
lab equipment and tools to compute the values, and design.

<><><>

i
 II. SYNOPSIS

This thesis aims at the implementation of Heat Integration designs for a Gas-
Phase Heat Exchanger. The heat exchanger is a system used to transfer heat
between two or more fluids. They are used in both cooling and heating
operations. Heat integration is a systematic and general method for designing
integrated production systems ranging from individual processes to total sites,
with special emphasis on the efficient use of “Energy” and reducing
“Environmental” effects [1]. Fundamentally, it reduces or minimizes the energy
consumption of industry, without changing the process, and effective
calculations will cut down the cost of energy consumption. Heat integration is
commonly analyzed using pinch technology, which focuses on producing a heat
exchanger design that pairs hot streams’ excess energy with cold streams that
need to be heated. These designs usually cut utility costs, but require the
installation of more heat exchangers to be placed within the process.

The Aspen Energy tool is used in conjunction with the Aspen HYSYS
simulation software to produce a process simulation [2]. From the tool, we are
able to attain the required pinch temperature for both hot and cold streams by
inputting the data and its physical properties. Hint software can also be used as
an alternative that helps produce the data. These can be cross-referenced by
entering the values in Excel.

The results obtained in this thesis help in the process of designing the Heat
Exchanger and obtain an understanding of its efficiency when adding more Heat
Exchangers to the process. The composite curves obtained are in the form of
T-H diagrams which are used to visualize cold and hot streams and potential
heat transfer between them. It is a graphical technique used for visualizing the
heat cascade, while the grand composite curve displays the net heat-flow
characteristics of a process versus its temperature. This allows to quickly
identify regions where heating and cooling utilities are required. The area for
the heat exchanger is calculated in terms of the heat duty, mean logarithmic
temperature difference, and the heat transfer coefficient. The rate of heat
transfer is directly proportional to the surface area through which the heat is
being conducted.

ii
From finding the area alone, we cannot come to the conclusion. We need to
calculate the effective cost, which can be calculated by finding its effectiveness.
This will allow us to predict how a given heat exchanger will perform in new or
different circumstances by essentially predicting the steam outlet temperatures
without a trial-and-error solution that would otherwise be necessary. The
capital cost can be calculated using the CAP COST function in excel which can
later be compared with the Aspen Energy Analyser. Overall software or tools
used are Pinch Analysis Tool, HINT software, and Aspen Energy Analyser.

iii
 III. CANDIDATE’S DECLARATION

I declare that this project work / thesis submission represents my ideas in my

own words and where others’ research work / ideas / words have been included,
I have adequately cited and referenced the original sources. I also declare that I
have adhered to all principles of academic honesty and integrity. I have not
misrepresented or fabricated or falsified any idea / data / source in my project
work submission. I understand that any violation of the above will be cause for
disciplinary action by the institute and can also evoke penal action from the
sources which have thus not been properly cited or from whom proper
permission has not been taken when needed.

Leon John D Almeida

&
Chethan Shenoy

Date: 04/06/2022

iv
 V. LIST OF TABLES

Table No Table Title Page No

1 Individual Heat Transfer Coefficient 14

2 Flange and Gasket Design 15

3 Thermal Data for Pinch Analysis 19

4 Stream Matching Thermal Data 25

5 Stream Data of the Selected Match for Designing 26

6 Shell Side and Tube Side Designing 27

vi
 VI. LIST OF FIGURES

Figure No Figure Title Page No

1 The Onion Diagram 4

2 Flowchart For Methodology 9

Conditions To Be Applied While Stream Matching For
3 10
The Above Pinch
Conditions To Be Applied While Stream Matching For
4 10
The Below Pinch
5 Composite Curve For Hot And Cold With Its Cascade 20

6 Combined Composite Curve To Indicate The Pinch 21

7 Cascade Method For Problem Table 23

8 Stream Matching 24
Correction Factor For Cross-Flow One Mixed And Other
9 26
Unmixed

vii
 VII. TABLE OF CONTENTS

Page
No
Synopsis ii
List of Figures vi
List of Tables vii

Chapter 1 INTRODUCTION 1
1.1 OBJECTIVES 1
1.2 SECONDARY OBJECTIVES 1

Chapter 2 LITERATURE REVIEW 4

Chapter 3 METHODOLOGY 7
3.1 INTRODUCTION 7
3.2 GRAPHICAL 7
3.3 ANALYTICAL 7
3.4 PROCESS SIMULATION 8
3.5 PROCESS DESIGN OF SHTE 13
3.6 ASSUMPTIONS PLACED 17

Chapter 4 RESULT AND DISCUSSION 19

Chapter 5 CONCLUSION 31

REFERENCES 32
 Chapter 1. INTRODUCTION

In many industrial processes, there is a waste of energy or a heat stream that is

being exhausted. Heat Exchangers can be used to recover this heat and use the
recovered by heating a different stream in the process. In industrial plants and
factories, heat exchangers are required to keep machinery, chemicals, water,
gas, and other substances within a safe operating temperature. The chemicals
pose some challenges to the heat exchangers. The demand for the consumption
of energy in industries has made designers build efficient heat transfer
exchangers. Temperature plays a crucial role in this and mainly controls the
driving factor ΔTmin.

1.1 Objectives:
● Identifying the Pinch temperature using the Problem Table method and
Composite Curve method using industrial data.
● Heat integration of the steams at above and below pinch
temperature.(heat load matchings)
● The process design of one representative Heat Exchanger equipment.

1.2 Secondary Objectives:

● To evaluate the heat loads, LMTD and overall heat transfer coefficient.
● To calculate the Reynolds number at the shell and tube sides.
● To calculate the heat transfer coefficient for inside and outside fluids.
● To measure and determine the shell and tube sides pressure drop.

This project is about studying and designing the heat exchanger using real-time
data, in addition to the plant design, the main focus of this project is to look into
the benefits of heat integration, rather than conventional utilities to heat or cool
various process streams within the process.

Heat integration, or process integration, is a common industrial practice that

began in the late 1970s. The goals of heat integration include efficient
integration of energy and materials as well as reducing emission and waste
generation [3]. Heat integration uses energy that is available within the process
to heat or cool various process streams. One common analysis for heat
integration is known as pinch technology. Pinch analysis commonly tries to
minimize the overall cost of new equipment, and the overall operating costs of
the equipment as well as the utilities.

1
The methodology for this project has been divided into three types, namely, the
simulation methods, graphical methods, and analytical and empirical methods.
One important aspect of the research is to obtain the real data from the company
which can be used for process design and evaluation. After obtaining the data,
the process simulation will begin by using the Aspen Energy Analyser and
HINT software. In order to use this software effectively, it is important to
document and input all the physical properties and their respective data. Since
Pinch analysis is highly complex, simulation software will be used to generate
plausible scenarios for heat integration. The main method we opt to analyse is
the Kern Method. The other methods are the Bell Delaware method.

The ideal heat exchanger transfers the maximum amount of heat, equal to the
product⁠. The arithmetic means temperature difference, which generates the
minimum amount of entropy, making it the most efficient and least irreversible
heat exchanger.

Shell and Tube Heat Exchangers are the most versatile type of Heat Exchangers
whose applications will vary with alternative energy (Geothermal, tidal) and
types of industries (Process, conventional and nuclear, steam generators…etc.).
Shell and tube heat exchangers provide relatively large ratios of heat transfer
area to volume and are easy to clean.

Two important problems in Heat Exchanger analysis are

● Rating existing heat exchangers
● Sizing heat exchangers for a particular application.

Rating involves the determination of the rate of heat transfer, the change in
temperature of the two fluids, and the pressure drop across the heat exchanger.
Sizing involves the selection of a specific heat exchanger from those currently
available or determining the dimensions for the design of a new heat exchanger,
given the required rate of heat transfer and allowable pressure drop. LMTD can
be readily used when inlet and outlet temperatures of both the hot and cold
fluids are known. When the outlet temperatures are not known, the LMTD can
only be used in an iterative scheme. The commonly used type of heat
exchanger is the shell and tube, heat exchanger. Shell–and–tube heat exchanger
is applied where high temperature and pressure demands are significant and can
be employed for a process requiring large quantities of fluid to be heated or
cooled. Due to their design, these exchangers offer a large heat transfer area
and provide high heat transfer efficiency in comparison with others.

From this thesis, we aim to achieve the mechanical aspects and design of any
one selected Heat Exchanger such as the Gasket and Flange design, shell and
2
tube sheet thickness with the number of tubes per each passing, The operating
and the design conditions with the materials of construction. From this, we can
learn to optimize, process design, and reduce waste in terms of capital cost and
energy. The calculated overall heat transfer coefficients will be used to predict
how the actual setup will respond under different conditions. This theoretical
project is an excellent illustration of many important topics covered since it
deals very closely with the determination of the overall heat transfer coefficient
in a system of heating and cooling between two fluids.

3
 Chapter 2. LITERATURE REVIEW

Pinch Analysis involves mainly the collection of heating and cooling stream
data using heat and mass balances. Calculation of energy targets, constructing
the T-H diagram and the hot and cold composite curves, Finding the pinch
point, examining the opportunities for any process change, designing a heat
exchanger network according to the targets, and calculating the mechanical
aspects of the parts involved in the heat exchange by performing the Kern
Method.

Pinch Technology is a technique used to design a particular system in a

processor in an overall plant by placing the entire Heat Exchanger in series or
parallel to minimize the energy consumption or the requirement. It has its main
benefits in a huge range of plants and processes, mainly in large industries but is
used in smaller industries also. It is considered an important first step in
designing and developing the overall process which contributes to the synthesis
and optimization of already working plants. Pinch technology is mainly used in
major chemical manufacturing plants or refineries, where heating or cooling of
feed streams are required, hence the analysis uses the hot streams to heat the
cold streams and vice versa, thus saving the hot or cold utility loads which helps
in energy and cost savings directly [4].

Figure 1: The onion diagram

The order of the hierarchy represents the order in which the process
optimization should be done. Firstly, the reactor which is also the “core” of the
onion is designed. Once the feed, product, recycle concentrations, and flow

4
rates are obtained, the design of separators in the second layer of the onion
begins. The material and heat balance are established and the third layer i.e. the
heat exchanger network is then designed. The cold and hot streams which were
not utilized in the heat exchanger network are optimized by the utility system
which is the fourth layer. The help of the pinch technology can help in process
designing and assist the process engineer to analyse the working of the plant or
the process they are working on and find the possible opportunities for the
application of the pinch technology [5].

In reference to Mr. Gireesh and Rao [6] the authors mainly studied the pressure
drop inside the shell of ‘Shell and Tube Heat Exchangers’ considering different
baffles, using fluent software. The normal baffle, inclined baffle, and helical
baffle have been considered for their study. The authors have concluded that the
helical baffle had performed well for effective pressure drop in the case of shell
and tube exchangers. Haran et al [7] has considered the thermal analysis in the
case of shell and tube heat exchangers considering both water and oil type
which is mostly used in refrigeration and air conditioning industries. The
authors have developed a program using C for calculating thermal analysis
considering counter flow in the case of water-oil type shell and tube heat
exchangers. There is a possibility to study thermal analysis with the least time
and accuracy using this program was one of the many conclusions derived by
the authors. In reference to, Petinin and Dare [8] the authors have studied the
shell and tube heat exchangers by considering different tube patterns like
triangular, rotated triangular, and the combined shell and tube heat exchangers.
The triangular shell and tube heat exchangers are more desirable, as they have
more heat transfer coefficient for the same pressure drop was conclusion
derived by the authors. Pranita et al [9] have studied the shell and tube
exchangers considering the effect of the baffles seeing thermal performance and
pressure drop other factors such as numerical simulations on different baffles
considering single, double, and helical baffles were noted. The conclusion that
the authors arrived at is that double segmental baffles reduce the vibrational
damage to the system and helical baffles show a decrease in pressure drop.
From the reference of Cahya and Permatasari [10], shell and tube heat
exchangers have been analysed by comparing analytical calculations with
simulation results using heat transfer research. The quality of the heat
exchangers considering heat transfer coefficient, contraflow to the hot fluid and
various flow rates were analysed. The authors have concluded the calculations
by plotting the various graphs of heat transfer coefficient on cold fluid flow
considering the number of tubes and shell diameter. In Reference to Eberhard
et al [11] the authors stated that the commonly used joints are the flange
connections with the metal-to-metal contact. The place where the total bolt load
is taken over by the gasket load is necessary for the metal-to-metal contact in
the project. The additional bolt load that is transmitted to the flange-flange

5
contact has to be compensated for the unloading effects in service due to the
internal pressure and the external loadings. To avoid the loss of the metal-to-
metal contact (MMC) bolt load must be decreased by increasing the internal
pressure and the external loadings. This led to the conservative assessment of
the loads which then limited the rotation of the flange. If the gasket width is
less than 6mm, then it will cause complications, such as internal collapse and
leakage by buckling. The analysis was done on two types of gaskets mainly the
SWG with graphite and the PTFE filler without inner and outer distance ring
and the SWG with graphite filler with external distance ring designed for the
use of ANSI flange. The test performed was the comprehension test to
determine the thickness change, the gasket stress and leakage test to determine
the maximum sealable internal pressure, the corresponding leakage rate and
relaxation of gasket stress. The authors have concluded that the clearance on
the outer diameter is an important parameter and if the difference between the
outer and inner diameter is less, then the stress will increase and will become
impracticable hence the acceptable clearance range is 1mm to 1.5mm with the
gasket width at 6mm. The optimum width with respect to adequate MMC stress
is about 10mm or less. This type of gasket shows excellent tightness or low
leakage rate.

6
 Chapter 3. METHODOLOGY

3.1 Introduction – Methodology is mainly defined as a system of practices,

techniques, procedures, and rules. The methodology used in this project is sub-
divided into three parts namely the Graphical method, the Analytical method,
and the Software method.

3.2 Graphical – Graphical methods mainly represent an optimization algorithm

for solving by plotting temperatures of process, i.e. hot streams versus
temperatures of process cold streams.
● COMPOSITE CURVE – Composite curves are used to simultaneously
visualize the hot streams, cold streams, and the heat transfer potential
between them on the same graph. By plotting this we can determine the
heat cascade and likewise obtain the pinch temperature graphically.
● BALANCED COMPOSITE CURVE – The balanced composite curve
is a modification of the hot and cold composite curves to include heating
and cooling utilities. In this process, the minimum heating and cooling
utility duties identified and the balanced composite curves become zero.
● The main role in the graphical problem is the minimum temperature
difference known as the Tmin, also referred to as a driving force. This
guarantees a technically and economically feasible Heat Exchanger
network. If the pinch isn’t able to obtain from the graph, we can move
down the hot stream by (Tmin/2) or move up the cold stream by (Tmin/2)
[12].

3.3 Analytical – Analytical methods are used for generic processes combining
the power of the scientific method with the use of the formal process to solve
any type of problem.
● PROBLEM TABLE – Problem Table algorithm mainly uses the
minimum utility in heat integration requirements in a heat exchanger
network. This method was developed by Linnhoff and Flower to
calculate the energy targets algebraically. There is a correlation between
the value of Tmin in the exchanger and the total utility load on the system.
This means that, if we choose Tmin values, we have an energy target for
how much heating and cooling we should be using by designing our own
Heat Exchangers. If the hot utility load is increased by any value of ‘’

7
 then the same value of cold utility has to be increased. Select a global
Tmin for the calculation then convert the actual stream temperature ‘T-act’
into shifted temperatures ‘T-shift’ by subtracting half the minimum
temperature difference from the hot stream temperatures, and by adding
half to the cold stream temperatures [13].

3.4 Process Simulation – Simulations mainly help to design new systems,

monitor current systems, optimize existing operations, as well as prevent or
solve heat transfer problems. The program rigorously simulates integrated
processes and allows us to monitor the performance of individual exchangers or
an entire heat transfer network. We will be able to compare the HEN synthesis
which is the heat integration between hot and cold process streams to reduce
heating and cooling utility consumption in the industrial processes [14].
● HINT – This program/educational software mainly assists in the steps of
designing, graphing out the energy and cost targeting along with utility
design, Heat Exchanger network design and optimization, and retrofitting
analysis based on the use of heat exchanger loops and utility paths. In
between, if any stream is left out, we can add it to save a lot of time,
when compared to the pen and paper method in terms of error and
efficiency. It is readily available for students’ use.
● Energy Analyser – Aspen Energy Analyser is energy management
software for performing optimal heat exchanger network design to
minimize process energy. By using this tool, it is possible to cut down
unnecessary energy use, for a less expensive and greener process design.
It is represented by providing the graphical or algorithmic method. We
can identify the best exchanger network design solutions without
spending an excessive amount of resources. It is not necessary to input
the data directly into Aspen Energy Analyser. We can derive it from
Aspen Hysys also, as this two software are linked with each other.

8
 Figure 2: Flowchart for Methodology

(Figure 2) explains the step to be followed when designing the heat exchanger.
The first step in the process is obtaining the Heat Exchanger data sheet from
which we choose one side of the stream data for Hot and Cold. These streams
are then arranged in the form of stream data (Figure 3); these data are arranged
in the form of Heat Balances with the Enthalpy data. The pinch temperature is
then obtained by constructing the problem table. The stream is then arranged in
a horizontal fashion with the pinch known and then the CP is marked on the
right side to perform the analysis of stream matching. The matches are placed
by following the conditions 𝑁𝑁𝑝𝑝ℎ ≤ 𝑁𝑁𝑝𝑝𝑝𝑝 , 𝐶𝐶𝑝𝑝ℎ ≤ 𝐶𝐶𝑝𝑝𝑝𝑝 for the above pinch and for
below pinch 𝑁𝑁𝑝𝑝ℎ ≥ 𝑁𝑁𝑝𝑝𝑝𝑝 , 𝐶𝐶𝑝𝑝ℎ ≥ 𝐶𝐶𝑝𝑝𝑝𝑝 for the below pinch.

9
Figure 3: Conditions to be applied while stream matching for the above
pinch.

Figure 4: Conditions to be applied while stream matching for the below

pinch.

10
From (Figure 3) the analysis for stream splitting or stream matching is initiated
and the step is to analyse the number of streams in the above pinch of the hot
stream to less than the cold stream. If not satisfied, then we need to split the
cold stream and start the process again and if the condition has been satisfied
then we can proceed to the next step of analysis that the specific heat capacity
of hot to be less than the specific heat capacity of the cold stream. If the
condition is not satisfied then the hot stream will be split into two-stream and
the heat capacity is then divided keeping in mind the requirement of the heat to
be either given or taken. Once the best possible matches are obtained, and then
proceed to (Figure 4) (that is below the pinch). The analysis proceeds as
follows; by taking into factor, the number of hot streams more than the number
of cold streams, if the condition is not satisfied we need to split the hot stream,
and then only we can proceed to the next part of the analysis. The specific heat
capacity of the hot stream to be more than a cold stream, if the condition is not
satisfied then we need to split the cold stream in such a way that it can accept
the heat from the hot stream. The best possible matches obtained are then sent
for design by choosing any one of the respective heat exchangers as mentioned
in the third objective.

The process design for any one of the respective Heat Exchangers is done by
finding the Shell and tube thickness, Gasket, flanges diameter, number of tubes
along with the fluid properties, routing of the fluids, baffle spacing and
dimensions. While designing we must take into the consideration the problems
faced such as:
● Vibration issues.
● Exchanger leakage.
● Increasing exchanger energy consumption.
● Fouling

Design is a universal concept, a par excellence intellectual activity linking the

immaterial world of concepts to the physical world. It is an essential area of
human experience, expertise, and knowledge that deals with our ability to mold
our environment.

It is decomposed into two phases:

● The first is proceduralization, (leading from requirements to a procedure).

11
 ● The second is materialization.

The conceptual design is the foundation on which good design stands, and even
technology can fall if there isn't a backing concept. It is considered a
framework for establishing the underlying idea behind a design and a plan for
how it needs to be expressed. The term “concept” describes the idea and
intention behind the design. The main purpose of conceptual design is to give a
visual shape to an idea.

There are three main sides to the goals of conceptual design:

● To establish a basis of logic.
● To create a design language (visual characteristics).
● To achieve originality.

While on the other hand the rigorous design [15] system flow is defined as a
formal accountable and iterative process composed of steps and based on four
principles:
● Separation of concerns.
● Component-based construction.
● Semantic coherency.
● Correctness-by-construction.

Applying these principles will define the methodology for human intervention
and ingenuity to resolve the design choices. An implementable system model is
progressively derived by source-to-source automated transformations in a single
host component-based language rooted in well-defined semantics. The presents
view for rigorous system design has been amply implemented in the BIP
(Behavior, Interaction, Priority) component framework and substantiated by
numerical, experimental results showing both its relevance and feasibility. To
discover optimized solutions, the design choices should be implied only by
requirements. The designers often preclude possible solutions by eliminating
alternatives based on the idea that the flexibility they afford would be difficult
or impossible to exploit later. There exist two classes of successful rigorous
design techniques, one applied to hard real-time systems ensuring trustworthy
control and the other is hardware engineering.

3.5 Process Design of STHE:

12
Pinch Analysis -
● 𝑄𝑄 = 𝐶𝐶𝐶𝐶 ∗ (𝑇𝑇2 − 𝑇𝑇1 )ℎ𝑜𝑜𝑜𝑜 = 𝐶𝐶𝐶𝐶 ∗ (𝑇𝑇2 − 𝑇𝑇1 )𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 (1)
● 𝐶𝐶𝐶𝐶 = 𝑚𝑚 ∗ 𝑐𝑐𝑐𝑐 (2)

Problem Table Method-

● Divide the temperature range into intervals and shift the cold temperature
scale.
● Make a heat balance in each interval
● Cascade the heat surplus/deficit through the intervals.
● Add Heat so that no deficit is cascaded.

Notations- Q is the Heat exchanged in KW, cp is the heat capacity which is the
ratio of the heat absorbed by the material to the temperature change, T2 (Tho,
Tco) is the temperature outlet for hot and cold streams respectively and T1 (Thi,
Tci) is the temperature inlet for hot and cold stream respectively and the unit is in
celsius (℃).

Kern Method-
● 𝑄𝑄 = (𝐶𝐶𝐶𝐶 ∗ 𝛥𝛥𝛥𝛥)ℎ𝑜𝑜𝑜𝑜 = (𝐶𝐶𝐶𝐶 ∗ 𝛥𝛥𝛥𝛥)𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 (𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻 𝐸𝐸𝐸𝐸𝐸𝐸ℎ𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎) (3)
𝑇𝑇ℎ𝑖𝑖 −𝑇𝑇ℎ𝑜𝑜 𝑇𝑇𝑐𝑐𝑐𝑐 −𝑇𝑇𝑐𝑐𝑐𝑐
● 𝑅𝑅 = , 𝑆𝑆 = , 𝐹𝐹𝑡𝑡(𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓 𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔ℎ) (𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶 𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹) (4)
𝑇𝑇𝑐𝑐𝑐𝑐 −𝑇𝑇𝑐𝑐𝑐𝑐 𝑇𝑇ℎ𝑖𝑖 −𝑇𝑇𝑐𝑐𝑐𝑐
𝛥𝛥𝑇𝑇2 −𝛥𝛥𝑇𝑇1
● 𝛥𝛥𝑇𝑇𝑇𝑇𝑇𝑇 = 𝛥𝛥𝑇𝑇 , 𝛥𝛥𝑇𝑇1 = 𝑇𝑇ℎ𝑖𝑖 − 𝑇𝑇𝑐𝑐𝑐𝑐 , 𝛥𝛥𝑇𝑇2 = 𝑇𝑇ℎ𝑜𝑜 − 𝑇𝑇𝑐𝑐𝑐𝑐 (𝐿𝐿𝐿𝐿𝐿𝐿𝐿𝐿) (5)
𝑙𝑙𝑙𝑙(𝛥𝛥𝑇𝑇2 )
1
● 𝑈𝑈𝑈𝑈𝑈𝑈𝑈𝑈𝑈𝑈𝑈𝑈𝑈𝑈𝑈𝑈 =
𝑄𝑄
(𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼 𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜 ℎ𝑒𝑒𝑒𝑒𝑒𝑒 𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 𝑐𝑐𝑜𝑜𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒) (6)
𝐴𝐴∗𝑛𝑛
𝛱𝛱∗𝐷𝐷2
● 𝐴𝐴 = (𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴) (7)
4
𝐴𝐴𝐴𝐴
● 𝑁𝑁 = (𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁 𝑜𝑜𝑜𝑜 𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡) (8)
𝛱𝛱∗𝑑𝑑𝑑𝑑∗𝐿𝐿
● 𝐴𝐴𝐴𝐴𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 = 𝛱𝛱 ∗ 𝑑𝑑𝑑𝑑 ∗ 𝐿𝐿 ∗ 𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁 (𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶 𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎) (9)
● 𝑈𝑈𝑈𝑈𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 =
𝑄𝑄
(𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅 𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻 𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐) (10)
𝐴𝐴𝐴𝐴𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 ∗𝛥𝛥𝛥𝛥𝛥𝛥𝛥𝛥
● 𝐵𝐵 = 0.4 ∗ 𝐷𝐷𝐷𝐷 (𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠) (11)
𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙ℎ
● 𝑁𝑁𝑁𝑁. 𝑜𝑜𝑜𝑜 𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏 = (12)
𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠
1
● 𝑎𝑎𝑠𝑠 = 𝐷𝐷𝐷𝐷 ∗ 𝐶𝐶 ∗ 𝐵𝐵 ∗ (𝐶𝐶𝐶𝐶𝐶𝐶 𝑓𝑓𝑓𝑓𝑓𝑓 𝑠𝑠ℎ𝑒𝑒𝑒𝑒𝑙𝑙) (13)
𝑃𝑃𝑡𝑡
● 𝐶𝐶 = 𝑃𝑃𝑡𝑡 − 𝑑𝑑𝑑𝑑 (𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐) (14)

13
 𝛱𝛱 𝑁𝑁
● 𝑎𝑎𝑡𝑡 = ∗ 𝑑𝑑𝑖𝑖 2 ∗ (𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 𝐶𝐶𝐶𝐶𝐶𝐶, 𝑛𝑛 = 𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛 𝑜𝑜𝑜𝑜 𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝) (15)
4 𝑛𝑛

Table 1: Individual heat transfer coefficient

Shell Side Tube Side

0.44∗𝑃𝑃𝑡𝑡 ^2− ∗𝑑𝑑𝑜𝑜2

𝛱𝛱
di= (known)
𝐷𝐷𝑒𝑒𝑒𝑒 = 4 ∗ 𝛱𝛱𝛱𝛱𝛱𝛱
4
(16)
2

𝑚𝑚𝑠𝑠 𝑚𝑚𝑡𝑡
𝐺𝐺𝐺𝐺 = (17) 𝐺𝐺𝐺𝐺 = (18)
𝑎𝑎𝑠𝑠 𝑎𝑎𝑡𝑡

𝐷𝐷𝐷𝐷𝐷𝐷∗𝐺𝐺𝐺𝐺 𝑑𝑑𝑑𝑑∗𝐺𝐺𝐺𝐺
𝑅𝑅𝑅𝑅(𝑠𝑠) = (19) 𝑅𝑅𝑅𝑅(𝑡𝑡) = (20)
𝜇𝜇 𝜇𝜇

𝐶𝐶𝐶𝐶∗𝜇𝜇 𝐶𝐶𝐶𝐶∗𝜇𝜇
𝑃𝑃𝑃𝑃 = (21) 𝑃𝑃𝑃𝑃 =
𝐾𝐾 𝐾𝐾

𝑁𝑁𝑁𝑁(𝑠𝑠) = 0.36 ∗ (𝑅𝑅𝑅𝑅)0.55 (𝑃𝑃𝑃𝑃)0.33 𝑁𝑁𝑁𝑁(𝑡𝑡) = 0.027 ∗ (𝑅𝑅𝑅𝑅)0.8 ∗ (𝑃𝑃𝑃𝑃)0.33

(22) (23)

ℎ𝑜𝑜∗𝐷𝐷𝐷𝐷𝐷𝐷 ℎ𝑖𝑖∗𝑑𝑑𝑑𝑑
𝑁𝑁𝑁𝑁(𝑠𝑠) = (24) 𝑁𝑁𝑁𝑁(𝑡𝑡) = (25)
𝐾𝐾 𝐾𝐾

𝑁𝑁𝑁𝑁(𝑠𝑠)∗𝐾𝐾 𝑁𝑁𝑁𝑁(𝑡𝑡)∗𝐾𝐾
ℎ𝑜𝑜 = (26) ℎ𝑖𝑖 = (27)
𝐷𝐷𝐷𝐷𝐷𝐷 𝑑𝑑𝑑𝑑

𝑓𝑓∗𝐺𝐺𝑠𝑠2 ∗𝐷𝐷𝐷𝐷 𝐿𝐿 𝑓𝑓∗𝐺𝐺𝑡𝑡2 ∗𝐿𝐿∗𝑛𝑛

𝛥𝛥𝑃𝑃 = ∗ (28) 𝛥𝛥𝑃𝑃 = + 2.26 ∗ 𝑛𝑛 ∗ 𝑣𝑣2 (29)
2∗106 ∗𝐷𝐷𝐷𝐷∗𝑠𝑠 𝐵𝐵 2∗106 ∗𝑑𝑑𝑑𝑑∗𝑠𝑠

14
 Table 2: Flange and Gasket Design

𝐺𝐺𝐺𝐺
=(
𝑦𝑦−𝑚𝑚∗𝑃𝑃
)0.5 (30) Go = Gasket outer diameter
𝐺𝐺𝐺𝐺 𝑦𝑦−𝑃𝑃∗(𝑚𝑚+1)
Gi = Gasket inner diameter

y = Gasket seating stress

m = Gasket factor

P = Shell side design pressure

𝑁𝑁 =
𝐺𝐺𝐺𝐺−𝐺𝐺𝐺𝐺
(31) N= Actual Gasket Width
2

𝑏𝑏𝑏𝑏 =
𝑁𝑁
(32) bo = Basic gasket seating width (after
2
applying load)

𝑏𝑏 = 𝑏𝑏𝑏𝑏, 𝑤𝑤ℎ𝑒𝑒𝑒𝑒 𝑏𝑏𝑏𝑏 ≤ 6.3𝑚𝑚𝑚𝑚 (33) b = Effective gasket seating

width(after applying load)
√𝑏𝑏𝑏𝑏
𝑏𝑏 = , 𝑤𝑤ℎ𝑒𝑒𝑒𝑒 𝑏𝑏𝑏𝑏 ≻ 6.3𝑚𝑚𝑚𝑚 (34)
2

𝑊𝑊𝑚𝑚1 = 𝜋𝜋 ∗ 𝑏𝑏 ∗ 𝐺𝐺 ∗ 𝑦𝑦 (35) Wm1=Bolt load due to initial gasket

load reaction

𝐻𝐻𝐻𝐻 = 𝑊𝑊𝑚𝑚2 − 𝐻𝐻 (36) Hg=gasket load reaction force

𝜋𝜋
𝐻𝐻 = *𝐺𝐺 2 ∗ 𝑃𝑃 (37) H = Hydrostatic end force
4

15
𝐻𝐻𝐻𝐻 = 𝜋𝜋 ∗ 2 ∗ 𝑏𝑏 ∗ 𝐺𝐺 ∗ 𝑚𝑚 ∗ 𝑃𝑃, Hp = total joint contact surface
𝐻𝐻𝐻𝐻 = 𝐻𝐻𝐻𝐻 compression

(38)

𝐺𝐺 =
𝐺𝐺𝐺𝐺
+
𝐺𝐺𝐺𝐺
𝑖𝑖𝑖𝑖 𝑏𝑏𝑏𝑏 ≤ 6.3(39) G = diameter at the location of gasket
2 2
load reaction
𝐺𝐺 = 𝐺𝐺𝐺𝐺 + 2 ∗ 𝑛𝑛 − 2 ∗ 𝑏𝑏 (40)

𝑖𝑖𝑖𝑖 𝑏𝑏𝑏𝑏 > 6.3

𝐴𝐴𝑚𝑚1 =
𝑊𝑊𝑚𝑚1
(41) fa = permissible stress at atmospheric
𝑓𝑓𝑓𝑓
condition
𝑊𝑊𝑚𝑚2
𝐴𝐴𝑚𝑚2 = (42) fb = permissible stress at operating
𝑓𝑓𝑓𝑓
conditions
𝑊𝑊𝑚𝑚1 > 𝑊𝑊𝑚𝑚2 𝑜𝑜𝑜𝑜 𝑊𝑊𝑚𝑚2 > 𝑊𝑊𝑚𝑚1
𝐴𝐴𝑚𝑚1 = Area of the bolt considering
𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤 𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 𝑡𝑡ℎ𝑒𝑒 𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏 𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙 stress at atmospheric condition
𝐼𝐼𝐼𝐼 𝐴𝐴𝑚𝑚1 > 𝐴𝐴𝑚𝑚2 𝑡𝑡ℎ𝑒𝑒𝑒𝑒 𝐴𝐴𝑚𝑚1 𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤 𝑏𝑏𝑏𝑏 𝐴𝐴𝑚𝑚2 = Area of the bolt considering
𝑢𝑢𝑢𝑢𝑢𝑢𝑢𝑢 𝑡𝑡𝑡𝑡 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 𝑛𝑛𝑛𝑛𝑛𝑛𝑏𝑏𝑏𝑏𝑏𝑏 𝑜𝑜𝑜𝑜 𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏 stress at operating condition

𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒 𝑖𝑖𝑖𝑖 𝐴𝐴𝑚𝑚2 > 𝐴𝐴𝑚𝑚1 , 𝐴𝐴𝑚𝑚2 𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤 𝑏𝑏𝑏𝑏

𝑢𝑢𝑢𝑢𝑢𝑢𝑢𝑢 𝑡𝑡𝑡𝑡 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛 𝑜𝑜𝑜𝑜 𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏

𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁 𝑜𝑜𝑜𝑜 𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏 =

𝐴𝐴𝑚𝑚1 𝑜𝑜𝑜𝑜 𝐴𝐴𝑚𝑚2 Number of bolts should be in multiple
𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵 𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎
of 4
(43)
(if number of bolts is 10.05 it should
be chosen as 12)

𝐴𝐴𝐴𝐴 = 𝑁𝑁𝑁𝑁 𝑜𝑜𝑜𝑜 𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏 ∗ 𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏 𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 Ab = Actual area(this Ab is used for
all further calculation
𝐴𝐴𝐴𝐴 > 𝐴𝐴𝐴𝐴1 𝑜𝑜𝑜𝑜 𝐴𝐴𝐴𝐴2

16
 𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 = 3.5 𝑡𝑡𝑡𝑡 5 ∗ 𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏 𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵 𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑
= 1.5 ∗ 𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵 𝑡𝑡ℎ𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖
𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 (44)

𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁 =
(𝐴𝐴𝐴𝐴∗𝑓𝑓𝑓𝑓)
(45) Nmin = required minimum gasket width
2∗𝜋𝜋∗𝑦𝑦∗𝐺𝐺

𝐼𝐼𝐼𝐼 𝑁𝑁 > 𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁 𝑡𝑡ℎ𝑒𝑒𝑒𝑒 𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 𝑖𝑖𝑖𝑖 𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜

𝐵𝐵 = 𝐺𝐺𝐺𝐺 + 2 ∗ (𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏 𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑) + B = Bolt circle diameter

12𝑚𝑚𝑚𝑚 (46)

𝑡𝑡𝑡𝑡 = 𝐺𝐺 ∗
𝑃𝑃0.5
(47) tf = Flange thickness
(𝐾𝐾∗𝑓𝑓)0.5

1
𝑤𝑤ℎ𝑒𝑒𝑒𝑒𝑒𝑒 𝐾𝐾 =
0.3+(1.5∗𝑊𝑊𝑊𝑊∗ℎ𝑔𝑔)/(𝐻𝐻∗𝐺𝐺)
(48)

𝐴𝐴 = 𝐵𝐵 + 2 ∗ (𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠) (49) A = outside diameter of the flange

3.6 Assumptions Placed:

● ∆Tmin=10°C
● Type of Heat Exchanger is 1-2 shell and tube exchanger.
● Counter-flow is assumed.
● Q is assumed as 10% more than the calculated to compensate possible
heat loss and increase the duty.
● Standards opted are: TEMA (Tubular Exchanger Manufacturers
Association), BS: British Standards and for bolts it is M12 to M36 with
SB: Structural Bolting.
● For Shell ID- TEMA L or M is assumed for designing.
● Wall Thickness- BWG (Birmingham Wire Gauge)

17
● The flow through the tubes is assumed as mixed flow hence for Ft
(correction factor), the graph used is one mixed flow while the other is
unmixed flow, Since Ft>0.75 hence desirable.
● Low pressure steam is taken in the shell side while Boiler feed water is
passed through the tube side qt<qs (flow rate).
● U (Overall Heat Transfer Coefficient) is assumed from 750 (W/m^2*K)
to 25000 (W/m^2*K) to which U predicted is calculated till it converges
at a point.
● The type of pitch/formation of the tubes assumed is triangular pitch since
it provides a more compact arrangement, usually resulting in smaller shell
and stronger header sheet for a specified shell-side flow area. It is
preferred when the operating pressure difference between the two fluids
is large.
● Assumed the baffle spacing to be 0.4 Ds, closer spacing causes a higher
heat transfer rate and pressure drop. On the other hand, higher baffle
spacing reduces both the heat transfer rate and pressure.
● Material for flange and gasket designing:
○ Gasket (Corrugated metal asbestos inserted soft aluminium
Y=20(N/mm^2), m=2.5. Suitable when used to a maximum
temperature of about 260℃.
○ Flanges (Narrow faced flanges) since less number of bolts, all the
face contact area lies inside the circle enclosed by the bolt holes,
the gasket is applied inside the bolt circle.
● Grade for the shell and tube heat exchanger chosen is IS: 2416-1963.
● Gi which is the gasket inner diameter is iterated to outer diameter of the
shell + 9000mm.
● The specification of the bolt material chosen is SB-408 which has the
composition of 33NI-42Fe-21Cr with temperature limit of 816℃ for
division 1, 427℃ for class 2 and 343℃ for class 3. It has the allowable
stress of 116 MPa at 250℃ temperature with the yield of 205 MPa. The
bolt material has a minimum tensile strength of 515 MPa.

18
 Chapter 4. RESULTS & DISCUSSION

The first step in analysis is the identification of the “Pinch” and to initiate it, we
must set up the “Heat and Enthalpy Balances” also referred as the thermal data
by tabulating the stream in the form of hot and cold temperature with their
respective enthalpies.

Table 3: Thermal Data for Pinch Analysis

Cp CP
Stream Ti (℃) Tf (℃) m(kg/s) ΔH(KW)
KJ/kg*K (KW/K)

H1 99 46 63.45 2.614 165.8583 8790.489

H2 206.1 50 14.10 1.020 14.382 2245.030

H3 100 44 14.81 2.175 32.212 1803.872

H4 175 144.38 0.65 3.231 2.100 64.302

C1 110 220 29.73 4.1989 124.833 -13731.6

C2 50 130 8.06 2.2247 17.931 -1434.48

The thermal data for Pinch Analysis is shown in Table 1 here “Hot Stream” are
the streams that need cooling (i.e. heat sources) while “Cold Streams” are the
streams that need heating (i.e. heat sinks). The supply temperature of the stream
is denoted as “Ti” and the target temperature “Tf”. The heat capacity flow rate
(CP) as denoted in Equation-1 i.e. Cp is the specific heat capacity of the stream
(KJ/kg*°c) and M is the mass flow rate (kg/sec). The CP of a stream is
measured as enthalpy change per unit temperature (KW/°C). A minimum
temperature difference of 10°C is assumed during the analysis. The hot utility
is, steam available at 200°C and the cold utility is, cooling water available
between 44°C to 50°C as shown in figure 5.

19
Figure 5: Composite Curve for Hot and Cold Curve with its Cascade.

20
Figure 6: Combined Composite Curve to Indicate the Pinch

21
Pinch analysis provides a target for the minimum energy consumption and these
targets are obtained by using the tool called the “Composite Curves”.
Constructing the composite curves mainly consist of temperature-enthalpy
(T-H) profiles of heat availability. The construction of the combined Hot and
Cold composite is possible and also a necessary. From the graph we can obtain
the pinch of 10°C that is, we must spot the place where the smallest ΔT and if
we cannot obtain it then we can add some amount of heat to the cold composite
curve to shift it closer to the hot composite curve and if it is too close to the hot
stream then we can remove the heat from the hot composite curve till we can
spot the smallest △Tmin. This process is trial and error from which we can
obtain the hot and cold pinch. The composite graph is constructed by
calculating the cascade for Hot and Cold curve which is then combined to
obtain the pinch which is depicted in figure 6.

These data’s are then combined and the pinch is obtained as hot pinch at 100℃
and a Cold pinch at 89℃ which are then cross-referenced with the problem
table method. Composite method is not settled as the final selection for
obtaining the pinch temperature. By constructing it, we lose information on the
vertical arrangement of heat transfer between streams which has proved to be an
inconvenience. Hence we must settle it by the problem table method.

Problem Table known as the cascade method, also referred as the method based
on table is helpful in solving the heat-exchanger networks manually. The first
step will be to enter the data in the enthalpy and heat balances form as shown in
(table 3). The difference between the problem table and the composite method
is the use of the shifted temperature and not the actual temperature like the
composite method.

22
 Figure 7: Cascade Method for Problem Table

𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐:
● 𝛥𝛥𝛥𝛥 = 225 − 201.1 = 23.9℃
● Σ𝐶𝐶𝐶𝐶ℎ − Σ𝐶𝐶𝐶𝐶𝑐𝑐 = −124.833 𝐾𝐾𝐾𝐾/𝑘𝑘𝑘𝑘 ∗ 𝐾𝐾
● △ 𝐻𝐻 =△ 𝑇𝑇 ∗ ( Σ𝐶𝐶𝐶𝐶ℎ − Σ𝐶𝐶𝐶𝐶𝑐𝑐 ) = 23.9 ∗ (−124.833) = −2983.51𝐾𝐾𝐾𝐾
From the problem table, we proceed to the next part of the analysis that is the
stream matching. For obtaining the best possible matches between the heat
exchanger, we must follow the steps as indicated in (Figure 3 and Figure 4).
The stream matches obtained are indicated in (Figure 8).

23
 Figure 8: Stream Matching

By using the conditions as depicted in (Figures 3 and 4) in the above pinch

(cooling) and below pinch (heating). Total number of heat exchanger matches
obtained is 8 including the utilities. The matches are then placed in the form of
a stream matches thermal data as indicated in (table 4).

24
 Table 4: Stream Matching Thermal Data

Above
Pinch
Stream Th1 Th2 ΔHh Stream Tc1 Tc2 ΔHc Utility
(℃) (℃) (KW) (℃) (℃) (KW) (KW)
H2 201.1 100 1454 C1 110 121.6 1454 -12277.6
H4 175 144.38 64.302 C1 110 110.52 64.302 -13667.3
Below
Pinch

H3 100 46 1739.5 C3 50 147.01 1739.5 1022.21

Utility
H1 8790.5KW

H2 2245.03 KW

From Table 4, we find a possibility of the stream matching between H2 to C1

from temperature 121.6°C to 220°C, an utility of -12277.6 KW of heat is
produced which can be cooled down. Another possibility is H4 to C1 from
temperature range 110.52°C to 220°C, and utility of -1366738 KW is used as
cooling to the hot stream. For the extra streams C1 and C2, their utilities will be
used as cooling to both H1 and H2, hence totalling 4 Heat Exchangers for the
above pinch.

Below Pinch we take the possibility of the heat exchanged from H3 to C2 of

temperature range from 90°C to 147.01°C, an utility of “+1022.21 KW” is
added to the cold stream in the form of a cooler and from H1 (+8790.474 KW)
and H2 (+791.01 KW) stream having excess heat is removed by using its
respective stream-cooler. To remove heat from H1, H3 and H2 we must use
coolers, hence the number of Heat Exchangers Above Pinch is 4 and Below
Pinch 4 thus sum up to 8 Heat Exchangers.

From the possibilities, we choose one of the respective Heat Exchanger and
design it using Kern’s method.

25
 Table 5: Stream Data of the selected match for Designing

Stream Type T1 T2 CP
Hot Low-Pressure steam 175 144.38 2.1
Cold Boiler Feed Water 110.52 110 123

● 𝑄𝑄 = 𝐶𝐶𝐶𝐶 ∗ 𝛥𝛥𝑇𝑇ℎ = 𝐶𝐶𝐶𝐶 ∗ 𝛥𝛥𝑇𝑇𝑐𝑐 = 2.1 ∗ (175 − 144.38) = 123 ∗ (110 −

110.52)
● 𝛥𝛥𝑇𝑇1 = 175 − 110.52 = 64.48
● 𝛥𝛥𝑇𝑇2 = 144.38 − 110 = 34.38
𝛥𝛥𝑇𝑇 −𝛥𝛥𝑇𝑇 64.48−34.38
● 𝛥𝛥𝑇𝑇𝑙𝑙𝑙𝑙 = 1 𝛥𝛥𝛥𝛥1 2 = 64.48 = 47.86
𝑙𝑙𝑙𝑙(𝛥𝛥𝛥𝛥2) 𝑙𝑙𝑙𝑙(34.38)

𝑇𝑇ℎ𝑜𝑜 −𝑇𝑇ℎ𝑖𝑖
● 𝑅𝑅 = = 58.885
𝑇𝑇𝑐𝑐𝑐𝑐 −𝑇𝑇𝑐𝑐𝑐𝑐

𝑇𝑇𝑐𝑐𝑐𝑐 −𝑇𝑇𝑐𝑐𝑐𝑐
● 𝑆𝑆 = = 8 ∗ 10−3
𝑇𝑇ℎ𝑖𝑖 −𝑇𝑇𝑐𝑐𝑐𝑐

1−𝑆𝑆
�√𝑅𝑅 2 +1�∗ln( )
● 𝐹𝐹𝐹𝐹 = 1−𝑅𝑅𝑅𝑅
2−𝑆𝑆�𝑅𝑅+1−�𝑅𝑅2 +1�
= 0.9988
(𝑅𝑅−1)∗ln( )
2−𝑆𝑆�𝑅𝑅+1+�𝑅𝑅2 +1�

Figure 9: Correction Factor for Cross Flow one mixed and other
unmixed

26
 Table 6: Shell Side and Tube Side Designing

Details Shell Side (1 pass) Tube Side (2 pass)

Assumed Overall Heat 𝑈𝑈𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 = 20000 𝑤𝑤/𝑚𝑚2 ∗ 𝐾𝐾
Transfer Coefficient
Diameter 𝐷𝐷𝐷𝐷 = 1.73894 𝑚𝑚 𝑑𝑑𝑑𝑑 = 0.0157 𝑚𝑚

Area 𝐴𝐴𝐴𝐴 =
64.302 ∗ 103
= 0.074𝑚𝑚2 𝐴𝐴𝐴𝐴 =
3.14 ∗ 0.2032
= 0.0323𝑚𝑚2
20000 ∗ 47.86 4

Fluid Property 𝑁𝑁𝑁𝑁𝑁𝑁 = 367.2811, 𝑁𝑁𝑁𝑁𝑁𝑁 = 2.1 𝑁𝑁𝑁𝑁𝑁𝑁 = 11546.85, 𝑁𝑁𝑁𝑁𝑁𝑁 = 0.9615
𝑁𝑁𝑁𝑁𝑁𝑁 = 302403.6 𝑁𝑁𝑁𝑁𝑁𝑁 = 8038525

Individual Heat ℎ𝑜𝑜 =

367.2811 ∗ 0.032
ℎ𝑖𝑖 =
11546.85 ∗ 0.51
transfer Coefficient 1.73894 0.0157
= 19958.74 = 373945.3 𝑊𝑊/𝑚𝑚2 𝐾𝐾
𝑊𝑊/𝑚𝑚2 𝐾𝐾

Predicted Overall Heat 𝑈𝑈𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝 =

1
1/ℎ𝑜𝑜+1/ℎ𝑖𝑖∗𝑑𝑑𝑑𝑑/𝑑𝑑𝑑𝑑
= 18691.73 𝑊𝑊/𝑚𝑚2 ∗ 𝐾𝐾
Transfer Coefficient
Pressure Drop 𝛥𝛥𝛥𝛥𝛥𝛥ℎ𝑒𝑒𝑒𝑒𝑒𝑒 = 1.1399 𝛥𝛥𝛥𝛥𝛥𝛥𝛥𝛥𝛥𝛥𝛥𝛥 = 20051.42293

Details Baffles

Tube Pitch 0.03 m

Bundle Diameter=do*(Nt/K1)^1/n 0.0514058 mm

Type Traverse

Number of Baffles 12

Spacing 0.0812 m

Since the 𝑈𝑈𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 and 𝑈𝑈𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝 converge at the point, the design is ok.

Flange and Gasket Design:

● 𝑌𝑌 = 20 (𝑁𝑁/𝑚𝑚𝑚𝑚2 ), 𝑚𝑚 = 2.5 .

27
 ● 𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷 𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃 = 5 − 10% = 0.06428(𝑠𝑠ℎ𝑒𝑒𝑒𝑒𝑒𝑒), 1.27(𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡) 𝑘𝑘𝑘𝑘𝑘𝑘/
𝑚𝑚𝑚𝑚2 .
● 𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷 𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 = 250℃ (𝑠𝑠ℎ𝑒𝑒𝑒𝑒𝑒𝑒) 𝑎𝑎𝑎𝑎𝑎𝑎 (𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡).
● 𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀 𝑜𝑜𝑜𝑜 𝑐𝑐𝑐𝑐𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛 = 𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶 𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆
● 𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆 𝑜𝑜𝑜𝑜 𝑠𝑠ℎ𝑒𝑒𝑒𝑒𝑒𝑒 = 𝐼𝐼𝐼𝐼: 2416 𝑎𝑎𝑎𝑎𝑎𝑎 𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆 𝑜𝑜𝑜𝑜 𝑡𝑡ℎ𝑒𝑒 𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 =
𝐼𝐼𝐼𝐼: 2416.
● 𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁 𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷 𝑜𝑜𝑜𝑜 𝑡𝑡ℎ𝑒𝑒 𝑠𝑠ℎ𝑒𝑒𝑒𝑒𝑒𝑒 = 0.25 𝑚𝑚𝑚𝑚
● 𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀 𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 𝑠𝑠ℎ𝑒𝑒𝑒𝑒𝑒𝑒 𝑡𝑡ℎ𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖 = 0.03628 𝑚𝑚𝑚𝑚
● 𝑇𝑇𝑇𝑇𝑇𝑇 𝑅𝑅𝑅𝑅𝑅𝑅 = 4
● 𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁 𝑜𝑜𝑜𝑜 𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 = 2
● 𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁 𝑜𝑜𝑜𝑜 𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 𝑝𝑝𝑝𝑝𝑝𝑝 𝑒𝑒𝑒𝑒𝑒𝑒ℎ 𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝 = 1
● 𝑑𝑑𝑑𝑑 = 0.02 𝑚𝑚
● 𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃 𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆: 𝑆𝑆ℎ𝑒𝑒𝑒𝑒𝑒𝑒 = 7.4, 𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 = 7.4 (𝑘𝑘𝑘𝑘𝑘𝑘/𝑚𝑚𝑚𝑚2 )
● 𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁: 𝐼𝐼𝐼𝐼 − 2 𝑖𝑖𝑖𝑖, 50.8 𝑚𝑚𝑚𝑚
𝑝𝑝∗𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛 𝐼𝐼𝐼𝐼
● 𝑝𝑝 = 0.064, 𝑡𝑡𝑡𝑡 = = 0.22 + 3 (𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎) = 4
2∗𝑓𝑓∗1−𝑝𝑝
● 𝐺𝐺𝐺𝐺 = 9225.96 𝑚𝑚𝑚𝑚, 𝐺𝐺𝐺𝐺 = 9211 𝑚𝑚𝑚𝑚
● 𝑁𝑁 = 7.4798
● 𝑏𝑏𝑏𝑏 = 3.73 (< 6𝑚𝑚𝑚𝑚)=b
● 𝐺𝐺 = 9218.4798 𝑚𝑚𝑚𝑚
● 𝐻𝐻 = 463.3713 𝑘𝑘𝑘𝑘𝑘𝑘
● 𝐻𝐻𝐻𝐻 = 𝐻𝐻𝐻𝐻 = 34567.50157 𝑘𝑘𝑘𝑘𝑘𝑘
● 𝑊𝑊𝑚𝑚1 = 2165116.167 𝑁𝑁
● 𝑊𝑊𝑚𝑚2 = 4323270.209 𝑁𝑁
● 𝑓𝑓𝑓𝑓 = 168𝑀𝑀𝑀𝑀𝑀𝑀 = 𝑓𝑓𝑓𝑓 = 𝑓𝑓
● 𝐴𝐴𝑚𝑚1 = 0.01289 𝑚𝑚2
● 𝐴𝐴𝑚𝑚2 = 0.02573 𝑚𝑚2
● 𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵 𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴 = 0.000394 𝑚𝑚2
● 𝑇𝑇ℎ𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖 𝑜𝑜𝑜𝑜 𝑡𝑡ℎ𝑒𝑒 𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏 = 38 𝑚𝑚𝑚𝑚
● 𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵 𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 = 1.5 ∗ 𝑡𝑡ℎ𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖 𝑜𝑜𝑜𝑜 𝑡𝑡ℎ𝑒𝑒 𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏 = 0.057 𝑚𝑚
● 𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁 𝑜𝑜𝑜𝑜 𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏 = 𝐴𝐴𝐴𝐴/(3.14 ∗ 𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵 𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝑟𝑟 2 /4) = 10.089
● 𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴 𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛 𝑜𝑜𝑜𝑜 𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏 = 12 (𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚 𝑜𝑜𝑜𝑜 4).
● 𝐽𝐽𝐽𝐽𝐽𝐽𝐽𝐽𝐽𝐽 𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒 = 0.85
● 𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻 𝑡𝑡ℎ𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖 = 𝑡𝑡𝑡𝑡 = 𝑡𝑡𝑡𝑡 + 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤 = 8 𝑚𝑚𝑚𝑚
● 𝐵𝐵 = 𝐺𝐺𝐺𝐺 + 2 ∗ 𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵 𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷 + 12 (𝑚𝑚𝑚𝑚) = 9351.959678 𝑚𝑚𝑚𝑚
𝐵𝐵−𝐺𝐺
● 𝐻𝐻𝐻𝐻 = = 66.7399 𝑚𝑚𝑚𝑚
2
● 𝐴𝐴𝐴𝐴 = 𝑛𝑛𝑛𝑛 𝑜𝑜𝑜𝑜 𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏 ∗ 𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏 𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 = 0.004728 𝑚𝑚𝑚𝑚2
𝐴𝐴𝐴𝐴∗𝑓𝑓𝑓𝑓
● 𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁 = = 0.6860216 𝑚𝑚𝑚𝑚
2∗3.14∗𝑦𝑦∗𝐺𝐺

Since N>Nmin (7.4>0.68) hence design is ok.

28
𝑭𝑭𝑭𝑭𝑭𝑭𝑭𝑭𝑭𝑭𝑭𝑭 𝑻𝑻𝑻𝑻𝑻𝑻𝑻𝑻𝑻𝑻𝑻𝑻𝑻𝑻𝑻𝑻𝑻𝑻:

● 𝐻𝐻 = 4288474, 𝐺𝐺 = 9218.48, 𝑊𝑊𝑊𝑊 = 4323270, ℎ𝐺𝐺 = 66.7399.

1
● 𝐾𝐾 = = 3.21597.
0.3+(1.5∗𝑊𝑊𝑊𝑊∗ℎ𝐺𝐺)/(𝐻𝐻∗𝐺𝐺)
𝐺𝐺∗𝑃𝑃0.5
● 𝑡𝑡𝑡𝑡 = = 121.013 𝑚𝑚𝑚𝑚.
𝐾𝐾∗𝑓𝑓0.5

Discussion:

We can opt for a plate type of Heat Exchanger settled with the shell and tube
Heat Exchanger because it is less costly as compared to plate type coolers. It
can be utilized as a part of frameworks with higher working temperatures and
weights. Pressure drop over a tube cooler is less, tube leaks are effortlessly
found and stopped, since pressure test is simple. Tubular coolers in refrigeration
framework can go as recipient also, but it’s effectiveness is less when compared
to the plate type cooler. Cleaning and maintenance is troublesome since a tube
cooler require enough leeway toward one sode to expel the tube nest. The
capacity of tube cooler can’t be expanded, requires more space in contrast with
plate cooler. Obtaining the real time data was a hassle because of the security
reasons. Obtaining it has delayed the designing process. Trial and error process
was then performed to obtain the best possible matches for both above and
below pinch, hence the data obtained from the company only one part of the
data is selected from the specification sheet for Pinch Analysis. The Design
“U” overall heat transfer coefficient range was not sufficient, that is from 750 to
15000 W/m^2K, as the convergence did not take place hence we crossed the
limit and achieved the U, assumed as 20000 W/m^2K on which the designing of
the shell and tube Heat Exchanger has been done. The baffle also played a big
role in designing the STHE, The main effect of the baffle is the inclination,
impeller design, rotational speed and the stirring effect which is based on the
interaction between the impeller and baffles. They serve as support and
reduction of vibrations; guide the shell-side flow back and forth across the tube
field, increasing the velocity and the heat transfer coefficient. For flange and
Gasket design [17] the gasket factor which is to-date has no standard test
procedure for their derivation, are used to calculate the amount of bolting
required for the assembly, design condition and also to confirm mechanical
compliance. The type of gasket used is corrugated metal gasket since it has
relatively low-cost gasket fabricated from a concentrically corrugated thin piece
of metal. The one selected is a combination of Nickel, Iron and chromium
which is identified as SB-408. Nickel belongs to the transition metals. It is
hard, ductile, and considered corrosion-resistant because of its slow rate of
oxidation at room temperature. It also boasts a high melting point and is
magnetic at room temperature. It has excellent corrosion resistance, strength,
toughness, metallurgical stability, fabric ability and weldability. These

29
properties make these alloys to be used in industries. Applying the chromium
plating can increase the hardness, durability, corrosion resistance of a surface,
also creating a shiny and smooth surface that is easier to clean.

Prandtl number is a dimensionless quantity that puts the viscosity of a fluid in

correlation with the thermal conductivity. It assesses the relation between the
momentum transport and thermal transport capacity of a fluid. Prandtl number
is assumed to be around 0.7 for gases and around 6.9 for water. The Prandtl
number obtained via calculation is 0.9615 which is gas in the shell region.,
Since it is less than 1 at standard conditions, it means the thermal boundary
layer is thicker than the velocity boundary layer and the Heat diffuses very
quickly in liquid metals. While in the Tube region the prandtl number obtained
is 2.1 which ranges in between (1.7 to 13.7) for water, here the heat diffuse
slowly in relation to the momentum. The Reynolds number in both Shell and
tube is considered as turbulent, due to high flow. Nusselt number which is the
key parameter in determining the mode of heat transfer in the case of Shell side
with the Nusselt number at 367 within the range of 100-1000 corresponds to
more active convection with turbulent flow. In the case of tube being at 11546
which is very high pimples that it is a very efficient convection. Larger the
nusselt number more efficient is it’s convection mode of heat transfer.

30
 Chapter 5. CONCLUSION

While choosing the type of tube, we have to consider three factors that are it’s
suitable for water quality, how the tube operates, its design and how it is
maintained. The Boiler Feed water used here will contain impurities which will
affect the conductivity of the heat, and can cause variation in the calculation.
Other factors to be taken into consideration are the PH, temperature and
capability of creating its sediment. The Shell and tube Heat Exchanger can be
used as a preheater of the feed that enters before it is sent to process. The fluid
velocity in this case for tube is high compared to the shell side. With the
increase in speed, there will be increase in the thermal transfer coefficient and
can associate with the pressure drop. Speed should be high to the prevent
particles from depositing but should not be extremely high that can cause tube
corrosion. Extreme high speed causes tube fouling. This is a design for one of
the selected Heat Exchanger matches. If the match is not suitable for designing
then we can select a different match with different stream and properties for
designing the Heat Exchanger or we can increase the ho (outside heat transfer
coefficient) by decreasing the baffle spacing, decreasing the shell ID (Ds),
changing the routing of the fluids in which the corrosive fluids with high
flowrates are place in tubes while the non-corrosive less flowrates fluid are
place in the shell side. If ho is suitable then we can alter the hi value that is we
can increase it by increasing the mass flowrate by decreasing the temperature of
the cold outlet, Increasing the number of tube passes and by increasing the
length of the tube.

31
 Chapter 6. REFERENCES

1. Gunderson T: A process integration primer — implementing agreement

on process integration. Trondheim, Norway: International Energy
Agency, SINTEF Energy Research; 2000.
2. AspenTech: Optimizing Process Manufacturing. Aspen Technology, Inc.,
2017. Web.https://www.aspentech.com/en/industries/engineering-
procurement-and-construction.
3. K. Matsudo, “Applications of pinch technology to total sites: A Heavy
Chemical Industrial complex and a steel plant”, 2013.
4. L. March, “Introduction to pinch technology”, 1998.
5. Somerscales, E.F.C., Fouling of Heat Transfer Equipment. Hemisphere,
New York, 1981.
6. D. Gireesh, J.B Rao, “Design and analysis of Heat Exchangers with
different baffles, Int.J.rag.Eng.Technol”, Manag., Res.4, 1-12 (2017).
7. V. Harit Haran, G. Ravindra Reddy, B. Sreehari, Thermal Analysis of
Shell and Tube Heat Exchanger using C and Hysys, Int.J.Computer
trends Technol, 4, 1-6 (2013).
8. M.O. Petinin, A. A. Dare, Performance of Shell and Tube Type Heat
Exhcnager with varying tube layouts, Br.J.Shell Tube HE varying tube
Layouts 12, 1-8 (2016).
9. P.Bichkar, O.Dandgaval, P.Dalvi, R.Godase, T.Dey, Process and
Manufacturer 20, 195-200 (2018).
10. A.H.Cahya, R. Permatasari, Design of a Shell and Tube Heat Exchanger
for waste water using Heat transfer Researcher inc,
Int;J;Adv.Sci.Technol.29, 611-622 (2020).
11. E. Roos, H. Kockelerman. R.Hahn, “Gasket Characteristics for design og
Bolted flange connections of metal-to-metal contact type, Volume 79,
Issue 1, pages 45-52, January (2002).
12. Assaad Zoughauid, Pinch Methodology To Pinch Integration of Flexible
System, 2017.
13. Ian C Kemp, Pinch Analysis and Process integration, 2007, 2nd edition,
pg.21.
14. Eskild Aas, Optimization of Heat Exchanger using Aspen Energy
Analyzer and SeqHENS, Masters Thesis, pg.6, 2019.
15. J. Sifakis, “rigorous system Design, Volume 6, No. 4, Page 293-362,
(2012).
16. D. Eryener, “Thermoeconomic Optimization of Baffle Spacing for Shell
and Tube HEat Exchangers, Energy Conservation Management, 47,
1478-1489, (2006).

32
17. D. Halkyard, Developments in Gasket Sealing Technology for Girth
Flanges on Shell and Tube Heat Exchanger, October (2017).
18. Data for physical and chemical properties collection,
https://www.engineeringtoolbox.com/

33
 PROJECT DETAILS

Student Details
Student 1 Name Leon John D Almeida
Register Number 180903007 Section / Roll B/3
No
Email Address leondalmeida@hotmail.com Phone No (M) +91-8296388928
Student 2 Name Chethan Shenoy
Register Number 180903060 Section / Roll B/10
No
Email Address chethanshenoy6@gmail.com Phone No (M) +91-9035086577

Project Details

Project Title DESIGN OF HEAT EXCHANGER BY PINCH INTEGRATION

USING REAL-TIME DATA
Date of
Project Duration 4 / 5 months 29-01-2022
reporting
Date of Mid-
Date of Synopsis
09-02-2022 term 19-05-2022
Submission
Presentation
Date of Final Report Date of Final
04-06-2022 10-06-2022
Submission Presentation

Organization Details
Organization
Manipal Institute of Technology
Name
Full postal address
Eshwar Nagar, Manipal, Karnataka 576104, India.
with pin code
Website address https://manipal.edu/mit.html
Location of work Department of Chemical Engineering
Project Guide Details
Project Guide
Dr. SVSR Krishna Bandaru
Name
Designation Professor
Full contact address
with pin code
Email address Krishna.bandaru@manipal.edu Phone No (M) +918202924312

34
 Internal Guide Details
Faculty Name Dr. SVSR Krishna Bandaru
Full contact address Department of Chemical Engineering,
with pin code Manipal Institute of Technology, Manipal, Karnataka, India – 576
104
Email address Krishna.bandaru@manipal.edu

35