Equipment Design Report No.

10

DESIGN OF HEAT TRANSFER EQUIPMENT

Al Paulo Ladica Zabala

BS Chemical Engineering – 5

14 September 2018
Introduction

Equipment Design Problems & Solutions

Seatwork Design Problem
Given:

 300,000 lb/hr crude oil @ 70 ° F heated to 136 ° F using Bottoms product

 257,000 lb/hr bottoms product @ 295 ° F to be cooled to 225 ° F
Average properties

Bottoms product Crude oil

−1
C p , BTU l b ° F 0.525 0.475
μ , cP 5.2 2.9
ρ , lb f t
−3
54.1 51.5
k , BTU f t −1 h−1 ° F−1 0.069 0.0789

Required: Recommend shell and tube heat exchanger

SI units

 136,077.72 kg/hr crude oil @ 21.11 ° C heated to 57.78 ° C using Bottoms product
 116,573.25 kg/hr bottoms product @ 146.11° C to be cooled to 107.22° C

Bottoms product Crude oil

−1
C p , kJ k g ° C
−1
2.2 1.99
μ , cP 5.2 2.9
ρ , kg m
−3
866.60 824.95
−1 −1
k ,W m K 0.119 0.136
Solution:
Step 1: Specification
Duty based on the crude oil
kg
136,077.72
Duty=
3600
sec
hr
(1.99 kgkJ∙° C )( 57.78−21.11° C ) =2,758.344 kW ≈ 2758 kW
hr
Duty based on the bottoms product
kg
116573.25
Duty=
3600
sec
hr
2.2 (
kJ
kg ∙° C )
( 146.11−107.22 ° C )=2,770.487 kW ≈ 2770 kW
hr
There is a difference of 12.14 kW which is negligible compared to the duties calculated. The
Duty of the crude oil will be used for further calculations because it has the minimum
required heat to be transferred.
The crude oil will be on the tube side because of the maintenance factor.
Step 2: Physical properties
Physical properties is given above.
Step 3: overall coefficient
For a shell and tube of this type base on figure 12.1, hot heat transfer oil and heavy
organics, the range of U is from 300 to 550 W/m2°C. Using 300 W/m2°C as initial
assumption.
Step 4: Exchanger type and dimensions
Even number of passes is the usual preferred arrangement.
A 1 shell and 2 tube passes is used
∆ T 2−∆ T 1 ( 146.11−57.78 )− (107.22−21.11 )
T lm= = =87.21° C
ln
( )
∆ T2
∆ T1
ln(146.11−57.78
107.22−21.11 )
T 1−T 2 146.11−107.22
R= = =1.06
t 2−t 1 57.78−21.11
t 2−t 1 57.78−21.11
S= = =0.29336
T 1−t 1 146.11−21.11

From figure 12.19(Sinnot) 1 shell and 2 tube pass F T =0.97

∆ T m=F T ∆ T lm=( 0.97 )( 87.21 ° C )=84.59 ° C

Step 5: Heat transfer area

Ao =
q
=
2758.334 kW ( 1000
1 kW )
W
2
=108.68 m ≈109 m 2
U o ,ass ∆ T lm W
3 00 2 ( 84.59 °C )
m ∙ °C
Step 6: layout and tube size
For tube length, the usual lengths are 6’,8’,12’,16’,20’,24’, 16 ft is the commonly used, which
is equivalent to 4.88m ≈ 5m. ¾ inch OD(19.05 mm) & 14.83 mm ID. A triangular placement
is used with 23.81 mm pitch.
Step 7: number of tubes
Neglecting thickness of the tube sheet

At of 1 tube=πDL=π ( 19.05 x 10−3 m) ( 5 m )=0.2992 m2

A o 108.68m 2
number of tubes= = =363 tubes≈ 360 tubes
A t 0.2992m 2
2 tube passes will be used
360
tubes= =180 tubes per pass
2
Check if reasonable
π π 2
tube CSA= ( ID ) = ( 14.83 x 10 m ) =0.0001727 m
2 −3 2
4 4

Area per pass=tubes x CSA=( 180 ) ( 0.0001727 m ) =0.031086 m

2 2

kg
136077.72

( )
3
ṁ hr 1 m
VFR= = =0.04582
ρ sec kg s
3600 824.95
hr m3

m3
0.04582
VFR s m
Tube side velocity= = 2
=1.47
CSA 0.031086 m s
It is satisfactory between 1 to 2 m/s for the tube side velocity
Step 8: Bundle & shell diameter

From table 12.4, for 2 tube passes, K 1=0.249∧n1=2.207

( ) ( )
1 1
tube 360
D b =O D tube n1
=( 19.05 mm ) 2.207
=51 7 mm ≡0.5 2 m
K1 0.249

Shell inside diameter

Base on figure 12.10, the clearance for this HE is 56 mm
D s =517 mm+56 mm=57 3 mm
Step 9: Tube side heat transfer coefficient

ℜ=
Dvρ
=
(
( 14.83 x 10−3 m ) 1.47 m 824.95 kg3
s )( m ) =6 162
μ −3
2.9 x 10 Pa ∙ s
C p μ ( 1.99 x 103 ) ( 2.9 x 10−3 )
Pr= = =42.43
kf 0.136
L 5000 mm
= =337.15
ID 14.83 mm
−3
From figure 12.23, with Re and Pr, j h =3.6 x 10

Nu= j h ReP r 0.33=( 3.6 x 10−3 ) ( 6201 )( 42.43 )

0.33
=76. 41

hi =Nu ( IDk )=( 76.89 ) ( 14.830.136x 10 )=70 0.8 m W∙ ° C

−3 2

Step 10: Shell-side heat transfer coefficient

Kerns method
Equation 12.21 for area cross flow

( Pt−d o ) Ds lB
A s=
Pt
Using 5 Baffles
570.9 mm
lB = =114 mm ≡115 mm
5
( 23.81−19.05 mm ) (570 .9 mm ) ( 115 mm ) 2
A s= =13127.73 mm
23.81 mm
Shell side mass velocity, Gs and linear velocity us

Gs =
Ws
=
116573.3 ( ) =2466.64 kg
kg 1 hr
hr 3600 s

13127.73 m m (
1000 mm )
As 1m2 m ∙s
2 2

kg
2466.64
G m2 ∙ s m
u s= s = =2.85
ρs kg s
866.60 3
m
Calculate for the shell-side equivalent diameter, for equilateral triangular pitch arrangement:
1.10 2 1.10
de=
do
( p t −0.917 d 2o )= 19.05 mm ( ( 23.81 mm )2−0.917 ( 19.05 mm )2 ) =13.519 mm≡ 0.013519 m

Calculate shell-side Reynolds number

kg
2466.64 ( 0.013519 m)
G s de 2
m ∙s
ℜ= = =6413
μs 5.2 x 10−3 Pa∙ s
The calculated Nre is used in figure 12.29 along with the 25% baffle cut to get the heat
transfer factor, jh which is approximately 0.0073.
J
C μ
2.2 x 10
3
( 5.2 x 10−3 Pa∙ s )
kg ∙ °C
Pr= p , s s = =96.134
ks W
0.119
m∙K
In calculating the Nusselt number, Nu, the viscosity at the wall and the fluid is the same due
to the

( )
1 0.14
μ
Nu= j h ReP r 3
μw
Concluding Remarks

References
 Coulson, J. M., Richardson, J. F., & Sinnott, R. K. (2005). Coulson & Richardsons
chemical engineering(4th ed., Vol. 6). Oxford: Elsevier Butterworth-Heinemann.