GAZI UNIVERSITY

FACULTY OF ENGINEERING
DEPARTMENT OF
CHEMICAL ENGINEERING
CHE451 CHEMICAL ENGINEERING DESIGN I

ASSIGNMENT 2
HEAT EXCHANGER DESIGN

Prof. Dr. Dilek VARIŞLI

Asst. Doğa ŞAHİN

TEAM – A
161140063 Ömer ÖZYILMAZ
171140029 Aleyna ERKEK
171140033 Mahmut İLBEYİ
171140054 Fatma Sıla MERZİFONLUOĞLU
171140058 Aslı ÖNGELEN
181140090 Sonay YILDIRIM

2021, ANKARA
 ABSTRACT
This report is about the design of a heat exchanger . This report is about the design of a heat
exchanger for cooling Sulphur Dioxide 450℃ to 250℃. The type of heat exchanger is one shell
and two pass tubes. For the coolant fluid is water. We made a detailed study for ℎ o, ℎ i values,
number of tubes and proper U calculation, which are part of the heat exchanger design. We
carefully decided on the main factors such as tube type, tube placement, flow pattern. For this,
we did literature and internet research. Then we chose 316 carbon steel for our material,
considering the thermal conductivity and production possibilities. We decided that the
triangular arrangement. We determined made the necessary calculations and moved to the
economic research step and the pressure drops. For economic calculations, Timmerhause is
used. Obtained values are added to excel file. We created the CHEMCAD drawings in
accordance with our flow chart. In this chart is shown as heat exchanger, feed, and products.
Finally in this design work we design a 11,35669654 and tube heat exchanger which have 342
tubes. The type of this heat exchanger is countercurrent flow. We cooled down to Sulphur
Dioxide with a cooling water which has a flow rate of 6,6166689 kg/s. Water inlet temperature
is 19 ℃ and outlet temperature is 44 ℃. For this design total capital investment calculated as
120107,2941.

i
 TABLE OF CONTENTS

ETHICS STATEMENT ................................................................................................... viii

WORKING PLAN............................................................................................................. ix

1. INTRODUCTION....................................................................................................... 1

2. THEORY.................................................................................................................... 2

2.1. Basic Theory of Heat Transfer in Exchangers......................................................... 2

2.1.1. Conduction .................................................................................................... 2

2.1.2. Convection .................................................................................................... 2

2.1.3. Radiation ....................................................................................................... 3

2.1.4. Overall Heat-Transfer Coefficient................................................................... 3

2.1.5. Fouiling Factor .............................................................................................. 3

2.2. Heat Exchangers ................................................................................................... 4

2.2.1. Shell-and-Tube Heat Exchangers.................................................................... 5

2.2.2. Double Tube Heat Exchangers ....................................................................... 7

2.2.3. Tube in Tube Heat Exchangers ....................................................................... 7

2.2.4. Plate Heat Exchangers.................................................................................... 8

2.2.5. Plate-fin Exchangers ...................................................................................... 8

2.2.6. Spiral Heat Exchangers .................................................................................. 9

2.2.7. Air Coolers and Condensers ........................................................................... 9

2.2.8. Direct Contact.............................................................................................. 10

2.2.9. Fired Heaters ............................................................................................... 11

2.2.10. Tube Layout ............................................................................................. 11

2.2.11. Tubular Exchanger Manufactures Association (TEMA) ............................. 12

2.3. Design Methods of Shell and Tube Heat Exchangers ............................................ 13

2.3.1. Kern Method................................................................................................ 13

ii
 2.3.2. Bell-Delaware Method ................................................................................. 20

2.4. Tail Gasses ......................................................................................................... 21

3. DECISION OF COOLING FLUID AND HEAT EXCHANGER................................ 22

3.1. Cooling Fluid...................................................................................................... 22

3.2. Shell And Tube Exchanger.................................................................................. 23

4. METHOD OF CALCULATIONS ............................................................................. 24

5. DESIGN OF CHEMCAD.......................................................................................... 27

6. DESIGN OF CALCULATIONS................................................................................ 29

7. COST ESTIMATION ............................................................................................... 33

8. RESULTS................................................................................................................. 35

9. DISCUSSION ........................................................................................................... 36

10. CONCLUSION ...................................................................................................... 37

11. HAZOP ANALYSIS .............................................................................................. 38

12. REFERENCES....................................................................................................... 39

11. APPENDICES ............................................................................................................ 40

APPENDICES 1 ............................................................................................................... 40

APPENDICES 2 ............................................................................................................... 45

APPENDICES 3 ............................................................................................................... 50

APPENDICES 4 ............................................................................................................... 50

APPENDICES 5 ............................................................................................................... 51

APPENDICES 6 ............................................................................................................... 51

APPENDICES 7 ............................................................................................................... 52

APPENDICES 8 ............................................................................................................... 52

APPENDICES 9 ............................................................................................................... 53

APPENDICES 10 ............................................................................................................. 53

APPENDICES 11 ............................................................................................................. 54

iii
 LIST OF FIGURES

Figure 1. U Tube Exchanger............................................................................................... 5

Figure 2. Straight-Tube Heat Exchanger (One Pass Tube-Side) ........................................... 6
Figure 3. Straight-Tube Heat Exchanger (Two Pass Tube-Side)........................................... 6
Figure 4. Section of The Heat Exchanger [6] ........................................................................ 7
Figure 5. Plate Fin Exchanger............................................................................................. 8
Figure 6. Spiral Heat Exchangers........................................................................................ 9
Figure 7. Air Cooled Condenser ......................................................................................... 9
Figure 8. Direct Contact ................................................................................................... 10
Figure 9. Fired Heaters..................................................................................................... 11
Figure 10. Tube Layout.................................................................................................... 12
Figure 11. TEMA............................................................................................................. 12
Figure 12. Square and Triangular Pitch-Tube Layouts ....................................................... 16
Figure 13. Heat Exchanger Design of Chemcad ................................................................ 27

iv
 LIST OF TABLES

[3] .............................................
Table 1. An Example For Classification of Heat Exchanger 4
Table 2. The Thermodynamic Properties of R718 (Water) Refrigerant ............................... 22

v
 SYMBOLS
Symbols Description
A Heat transfer area, m 2
B Distance between baffles, m
c Net distance between heat exchanger tubes, m
Cp ethanol Heat capacity of ethanol, J/kg.K
Cp water Heat capacity of water, J/kg.K
D Diameter, m
d LM Logarithmic mean diameter, m
Di Inside diameter of tube, m
Do Outside diameter of tube, m
Ds Shell diameter, m
F Logarithmic mean temperature difference correction factor
G Mass flux, kg/m2 -s
h Convection heat transfer coefficient, W.m-2.K
h di Fouling coefficient of inside, W.m-2.K
h do Fouling coefficient of outside, W.m-2.K
hi Heat transfer coefficient in the tube side, W.m-2.K
ho Heat transfer coefficient in shell side, W.m-2.K
k ethanol Thermal conductivity of ethanol, W/m.K
k water Thermal conductivity of water, W/m.K
kw Thermal conductivity of wall, W/m.K
L Length (m)
Lb Baffle spacing
methanol Mass flow rate of ethanol, kg/s
mwater Mass flow rate of water, kg/s
n Number of heat exchanger tube side passes
N Number of tubes
Nu Nusselt number
p Net distance between the centers of the heat exchanger
Tubes, m
Pr Prandtl number
Q Heat duty, J/s

vi
 Re Reynolds number
Sc Cross-sectional area, m2
Tca Inlet temperature of water, ℃
Tcb Outlet temperature of water, ℃
Th a Ethanol inlet temperature, ℃
Th b Outlet temperature of ethanol, ℃
u Velocity of fluid, m/s
Uo Overall heat transfer coefficient of outside, W/m 2.K
xw Wall thickness of tube, m
Δ Difference
ΔTLm Temperature approach, K
μethanol Viscosity of ethanol, Pa.s
μwater Viscosity of water, Pa.s
ρ ethanol Density of ethanol, kg/m3
ρ water density of water kg/m3
𝜎 Stefan Boltzmann constant, W.m -2.K-4

vii
 ETHICS STATEMENT

We declare that scientific and ethical principles are followed in the report writing process, that
all the sources used are specified in the bibliography in accordance with the principles of
citation, and that all statements except these sections belong to us.

Team Leader Mahmut İLBEYİ

viii
 WORKING PLAN

Risk
Objective: Heat Exchanger Design
Assessment
Team
MAHMUT İLBEYİ
Leader:

Task # Description Time Responsible

Pandemic
1 Organization 1 day Mahmut İLBEYİ
Conditions
Basic theory of heat ALL GROUP OF Pandemic
2 1 day
transfer MEMBERS Conditions
Searching about heat ALL GROUP OF Pandemic
3 2 day
exchanger types MEMBERS Conditions
Features of heat Pandemic
exchangers and ALL GROUP OF Conditions
4 1 day
selection of heat MEMBERS
exchanger
Selection of Pandemic
ALL GROUP OF
5 equipments and 1 day Conditions
MEMBERS
materials
ALL GROUP OF Pandemic
6 Create a flow diagram 1 day
MEMBERS Conditions
All heat exchanger ALL GROUP OF Pandemic
7 4 day
calculations MEMBERS Conditions
Cost analysis and ALL GROUP OF Pandemic
8 1 day
calculations MEMBERS Conditions

ALL GROUP OF
9 CHEMCAD 1 day Pandemic
MEMBERS
Conditions
Recommendations for ALL GROUP OF Pandemic
10 1 day
design MEMBERS Conditions
Generate report ALL GROUP OF Pandemic
11 3 day
content MEMBERS Conditions
Editing and combining ALL GROUP OF Pandemic
12 3 day
of the report MEMBERS Conditions

ix
 1. INTRODUCTION

A heat exchanger is a device that is used to transfer thermal energy (enthalpy) between two or
more fluids, between a solid surface and a fluid, or between solid particulates and a fluid, at
different temperatures and in thermal contact. In heat exchangers, there are usually no
external heat and work interactions. Typical applications involve heating or cooling of a fluid
stream of concern and evaporation or condensation of single or multicomponent fluid streams.
In a few heat exchangers, the fluids exchanging heat are in direct contact. In most heat
exchangers, heat transfer between fluids takes place through a separating wall or into and out
of a wall in a transient manner. In many heat exchangers, the fluids are separated by a heat
transfer surface, and ideally, they do not mix or leak.
Shell and tube heat exchangers (STHE) are widely used in industries because of their large heat
transfer area over a small floor space. Moreover, the well-known rigorous design procedures
available in the open literature such as Kern’s method used for the mechanical and thermal
design of these units result in efficient and optimum designs.
Shell and Tube Heat Exchanger is one of the most common used heat exchanger type and it is
available for all applications in almost all materials. It also has a safe construction, and the
design of this heat exchanger can be easily adapted according to operating conditions. Common
examples of heat exchangers are shell-and tube exchangers, automobile radiators, condensers,
evaporators, air preheaters, and cooling towers. One way to enhance the overall heat transfer
coefficient in heat exchangers is by mixing additives to the liquids. Thermal conductivity of the
mixed fluid plays an important role in such enhancement since it improves the energy transfer
between the working fluid and the heated surface.

1
 2. THEORY

2.1.Basic Theory of Heat Transfer in Exchangers

Heat can be transferred from a source to a receiver by conduction, convection, or radiation. In

many cases, the exchange occurs by a combination of two or three of these mechanisms. When
the rate of heat transfer remains constant and is unaffected by time,flow of heat is designated
as being in a steady state; an unsteady state exists when the rate of heat transfer at any point
varies with time. Most industrial operations in which heat transfer is involved are assumed to
be operating under steady-state conditions even though such processes may encounter
unsteady-state conditions during startup, cooldown, and surge conditions. On the other hand,
unsteady-state conditions are encountered in batch processes, cooling and heating of materials
such as metals, polymers, or glasses, and certain types ofregeneration, curing, or activation
processes. [1]

2.1.1. Conduction

Fourier’s law is the fundamental differential equation for heat transfer by conduction:

𝑑𝑄 𝑑𝑇
= −𝑘𝐴 (1)
𝑑𝜃 𝑑𝑥

where dQ/dθ (quantity per unit time) is the rate of flow of heat, A is the area at right angles to
the direction in which the heat flows, and −dt/dx is the rate of change of temperature with the
distance in the direction of the flow of heat, the temperature gradient. The factor k is called the
thermal conductivity; it is a characteristic property of the material through which the heat is
flowing and varies with temperature. [2]

2.1.2. Convection

Convection heat transfer is the transfer of energy by the mass movement of groups of molecules.
It is restricted to liquids and gases, as mass molecular movement does not occur at an
appreciable speed in solids. It cannot be mathematically predicted as easily as can transfer by
conduction or radiation and so its study is largely based on experimental results rather than on
theory. The most satisfactory convection heat transfer formulae are relationships between
dimensionless groups of physical quantities. Furthermore, since the laws of molecular transport
2
govern both heat flow and viscosity, convection heat transfer and fluid friction are closely
related to each other.
𝑞 = ℎ𝐴 (𝑇𝑤 − 𝑇∞) (2)

The quantity h is called the convection heat transfer coefficient.

2.1.3. Radiation

Radiation heat transfer is the transfer of heat energy by electromagnetic radiation. Radiation
operates independently of the medium through which it occurs and depends upon the relative
temperatures, geometric arrangements and surface structures of the materials that are emitting
or absorbing heat. The calculation of radiant heat transfer rates, in detail, is beyond the scope
of this book and for most food processing operations a simplified treatment is sufficient to
estimate radiant heat effects. Radiation can be significant with small temperature differences
as, for example, in freeze drying and in cold stores, but it is generally more important where
the temperature differences are greater.
The basic formula for radiant-heat transfer is the Stefan-Boltzmann Law;

𝑞 = 𝐴 𝑥 𝜎 𝑥 𝑇4 (3)

2.1.4. Overall Heat-Transfer Coefficient

The general equation for heat transfer across a surface is:

𝑄 = 𝑈 𝑥 𝐴 𝑥 ∆𝑇 𝑥 𝑀 (4)

The prime objective in the design of an exchanger is to determine the surface area required for
the specified duty (rate of heat transfer) using the temperature differences available.

2.1.5. Fouiling Factor

Most process and service fluids will foul the heat-transfer surfaces in an exchanger to a greater
or lesser extent. The deposited material will normally have a relatively low thermal conductivity
and will reduce the overall coefficient. It is therefore necessary to oversize an exchanger to
allow for the reduction in performance during operation. Fouling factors are usually quoted as
heat-transfer resistances, rather than coefficients.

3
 2.2.Heat Exchangers

At temperatures, which can be of many different types in practice, the way of transition,
in structure, in assembly, in small size according to their passengers, they can be designed.
Heat can be transferred from a source to a receiver by conduction, convection, or radiation. In
many cases, the exchange occurs by a combination of two or three of these mechanisms. When
the rate of heat transfer remains constant and is unaffected by time,flow of heat is designated
as being in a steady state; an unsteady state exists when the rate of heat transfer at any point
varies with time. Most industrial operations in which heat transfer is involved are assumed to
be operating under steady-state conditions even though such processes may encounter
unsteady-state conditions during startup, cooldown, and surge conditions. On the other hand,
unsteady-state conditions are encountered in batch processes, cooling and heating of materials
such as metals, polymers, or glasses, and certain types ofregeneration, curing, or activation
processes. As shown in Table 1.

Table 1. An Example For Classification of Heat Exchanger [3]

Classification According To Construction Examples

Tubular double pipe, shell and tube, spiral tube, pipe coils

Plate-Tube PHE, spiral, plate coil, printed circuit

Extended Surface plate fin, tube fin

Regenerative rotary, fixed-matrix, rotating hoods

There are many types of heat exchangers applied in the process industry. These types include:
➢ Shell and Tube Exchangers
➢ Hairpin/Double Tube Exchangers
➢ Tube and Tube Exchangers
➢ Plate Heat Exchangers
➢ Plate-fin Exchangers
➢ Spiral Heat Exchangers
➢ Air Coolers and Condensers
➢ Direct Contact
➢ Fired Heaters
4
 2.2.1. Shell-and-Tube Heat Exchangers

It is the most common type of heat exchanger in oil refineries and other large chemical
processes, and is suited for higher-pressure applications. As its name implies, this type of heat
exchanger consists of a shell (a large pressure vessel) with a bundle of tubes inside it. One fluid
runs through the tubes, and another fluid flows over the tubes (through the shell) to transfer heat
between the two fluids. The set of tubes is called a tube bundle, and may be composed of several
types of tubes: plain, longitudinally finned, etc. There are also multiple arrangements possible,
including U-tube, fixed tube, or a floating head configuration. [4]

There can be many variations on the shell and tube design. Typically, the ends of each tube are
connected to plenums (sometimes called water boxes) through holes in tube sheets. The tubes
may be straight or bent in the shape of a U, called U-tubes.

Figure 1. U Tube Exchanger

In nuclear power plants called pressurized water reactors, large heat exchangers called steam
generators are two-phase, shell-and-tube heat exchangers which typically have U-tubes. They
are used to boil water recycled from a surface condenser into steam to drive a turbine to produce
power. Most shell-and-tube heat exchangers are either 1, 2, or 4 pass designs on the tube side.
This refers to the number of times the fluid in the tubes passes through the fluid in the shell. In
a single pass heat exchanger, the fluid goes in one end of each tube and out the other.

5
 Figure 2. Straight-Tube Heat Exchanger (One Pass Tube-Side)

Surface condensers in power plants are often 1-pass straight-tube heat exchangers (see surface
condenser for diagram). Two and four pass designs are common because the fluid can enter and
exit on the same side. This makes construction much simpler.

Figure 3. Straight-Tube Heat Exchanger (Two Pass Tube-Side)

6
 ➢ One of the big advantages of using a shell and tube heat exchanger is that they are often
easy to service, particularly with models where a floating tube bundle is
available.(where the tube plates are not welded to the outer shell). [5]
➢ The cylindrical design of the housing is extremely resistant to pressure and allows all
ranges of pressure applications.

Figure 4. Section of The Heat Exchanger [6]

2.2.2. Double Tube Heat Exchangers

Double tube heat exchangers use what is known as a tube within a tube structure. There are two
pipes where one is built inside the other. Just like the example above, one fluid flows through
the inner pipe while the second fluid flows around the first fluid in the outer pipe. This type of
heat exchanger is known for being the most basic and affordable of all. Its size makes it ideal
for tight spaces, allowing for some extra flexibility in the layout of the manufacturing process.
[7]

2.2.3. Tube in Tube Heat Exchangers

Similar to the other types of heat exchangers, a tube in tube heat exchanger is comprised of two
tubes, one for each fluid. However, the tubes are coiled together to form an outside and inside
pattern. The application for a tube in tube design can get fairly creative. Since the tubes are
coiled together, most designs for this type are compact. Applications for a tube in tube heat
exchanger center around high temperature and high pressure. Since it runs at a higher output, a
tube in tube heat exchanger tends to have greater efficiency.

7
 2.2.4. Plate Heat Exchangers

While all of the types of heat exchangers discussed so far have a similar design, the plate heat
exchanger is the exception. Metal plates are used to transfer heat between two fluids. The plate
is a metal shell, with spaces inside each plate that act as hallways for fluids to travel through.
With a plate heat exchanger, there is a greater surface area in contact with the fluids, so it has
better rates of heat transfer compared to all other types. Although plate heat exchangers can be
more expensive, the efficiency gained by the design is a big plus. This type of heat exchanger
is best used in places like power plants because of its durability and low repair rates.

2.2.5. Plate-fin Exchangers

A plate-fin heat exchanger is a type of heat exchanger design that uses plates and finned
chambers to transfer heat between fluids. It is often categorized as a compact heat exchanger to
emphasise its relatively high heat transfer surface area to volume ratio. The plate-fin heat
exchanger is widely used in many industries, including the aerospace industry for its compact
size and lightweight properties, as well as in cryogenics where its ability to facilitate heat
transfer with small temperature differences is utilized. [8]

Figure 5. Plate Fin Exchanger

8
 2.2.6. Spiral Heat Exchangers

A spiral heat exchanger is a useful alternative to shell and tube designs for many applications
prone to fouling and plugging problems. For more than 60 years, it has been used in difficult
services ranging from PVC slurry coolers to asphalt heaters. Its f low-channel geometry and
single-channel design induce highly turbulent flow, so the compact exchanger can operate
reliably with low fouling rates even in heavy fouling, fibrous or slurry duties. It can be opened
quickly and easily for inspection,cleaning and maintenance.

Figure 6. Spiral Heat Exchangers

2.2.7. Air Coolers and Condensers

Air cooled condensers are engineered to project products with several architecture and
customized design. The air cooled condenser belongs to the dry cooling systems. In direct dry
cooling, steam from the steam turbine passes through air-cooled fin tubes. The condensate is
not in contact with the cooling air.

Figure 7. Air Cooled Condenser

9
 2.2.8. Direct Contact
The exchange of heat between two fluid streams can, in general, be accomplished using either
direct contact or surface-type heat exchangers. There are, however, several limitations to the
use of direct contactors. First, if two fluid streams are placed in direct contact, they will mix,
unless the streams are immiscible. Thus, stream contamination will occur depending on the
degree of miscibility. The two streams must also be at the same pressure in a direct contactor,
which could lead to additional costs. The advantages in utilizing a direct contactor include the
lack of surfaces to corrode or foul, or otherwise degrade the heat transfer performance. Other
advantages include the potentially superior heat transfer for a given volume of heat exchanger
due to the larger heat transfer surface area achievable and the ability to transfer heat at much
lower temperature differences between the two streams. Still another advantage is the much
lower pressure drop associated with direct contactors as compared to their tubular counterparts.
[9]

Figure 8. Direct Contact

10
 2.2.9. Fired Heaters
Fired heaters, also commonly called furnaces, are a primary source of thermal energy for
process heating operations in petroleum refining and chemical plants. They have been studied
extensively, both experimentally and theoretically, and previous work draws attention to the
need of conserve energy, improve energy efficiency and reduce carbon emissions. Notably,
most fired heaters models from literature are lumped parameter models with steady-state
assumptions, mainly due to the complex thermodynamic mechanisms making the problem
computationally expensive to solve. [10]

Figure 9. Fired Heaters

2.2.10. Tube Layout

Tube layout which is considered the best for this design is triangle. The reasons for choosing
this tube layout is that this layout will accommodate more tubes than a square tube layout and
also because it produces higher turbulence and higher heat transfer coefficient. Also, because
heat exchanger used in this design is fixed tube sheet heat exchanger, triangle tube pattern is
appropriate; square pattern is used for floating head heat exchangers. According to outside
diameter which is ¾ in, pitch (shortest distance between two adjacent tubes) is selected as 1
in. Triangle layout can be seen in Figure 10.
11
 Figure 10. Tube Layout

2.2.11. Tubular Exchanger Manufactures Association (TEMA)

TEMA (Tubular Exchangers Manufacturers Association) is important set of standards for

constructing shell and tube manufactures and it is accepted worldwide. These standards are
used for defining style of heat exchanger and can be seen in Figure 11.

Figure 11. TEMA

12
 2.3. Design Methods of Shell and Tube Heat Exchangers
2.3.1. Kern Method
The first attempts to provide methods for calculating shell-side pressure drop and heat transfer
coefficient were those in which correlations were developed based on experimental data for
typical heat exchangers. One of these methods is the well-known Kern method, which was an
attempt to correlate data for standard exchangers by a simple equation analogous to equations
for flow in tubes. However, this method is restricted to a fixed baffle cut (2 5%) and cannot
adequately account for baffle-to-shell and tube-to-baffle leakages. However, although the Kern
equation is not particularly accurate, it does allow a very simple and rapid calculation of shell-
side coefficients and pressure drop to be carried out and has been successfully used since its
inception. [11]
2.3.1.1.Thermal Analysis for Tube-Side

Number of Tubes
The flow rate inside the tube (𝑚̇ 𝑡) is a function of the density of the fluid (ρ t), the velocity of
the fluid (u t), cross-sectional flow area of the tube (A c), and the number of tubes (N t).

𝑚̇ 𝑡 = 𝜌𝑡 𝑥 𝑢𝑡 𝑥 𝐴𝑐 𝑥 𝑁𝑡 (5)

By using Eq. (5) and replacing 𝐴𝑐 by 𝜋𝑑𝑖2 / 4 number of tubes can be calculated as;
4𝑚̇ 𝑡
𝑁𝑡 = (6)
𝜌𝑡 𝑥 𝑢𝑡 𝑥 𝜋 𝑥 𝑑𝑖2
where d i is the tube inside diameter.

Tube-Side Reynolds Number

The criterion of distinguishing between laminar and turbulent flow is the observed mixing
action. Experiments have shown that laminar flow exists when the Reynolds number (Re) is
less than 2000. [12]
𝜌𝑡 𝑥 𝑢𝑡 𝑥 𝑑𝑖
𝑅𝑒𝑡 = (7)
𝜇𝑡

where µ t is the viscosity of the tube-side fluid, u t is fluid velocity inside the tubes, and t ρ t is the
density of fluid in the tubes.

13
Tube-Side Nusselt Number
Nusselt number is a function of Reynolds number (Re) and Prandtl number (Pr). However, there
are equations developed according to the type of flow. For turbulent flow, the following
equation developed by Petukhov-Kirillov can be used. [13]

𝑓
( ) 𝑥 𝑅𝑒𝑡 𝑥 𝑃𝑟𝑡
2
𝑁𝑢𝑡 = 2 (8)
𝑓 1
1,07 + 12,7 𝑥 ( )2 𝑥 (𝑃𝑟𝑡3 − 1)
2

where f is the friction factor which can be calculated from

𝑓 = (1,58 𝑙𝑛 𝑅𝑒𝑡 − 3,28) −2 (9)

Eq. (8) predicts the results in the range 10 4 < Ret < 5 × 10 6 and 0,5 < Prt < 200 with 5 to 6 %
error, and in the range 0.5 < Pr t < 2000 with 10 % error.
For laminar flow, the Sieder and Tate correlation can be used. [13]

𝑅𝑒𝑡 𝑥 𝑃𝑟𝑡 𝑥 𝑑𝑖 1
𝑁𝑢𝑡 = 1,86 𝑥 ( )3 (10)
𝐿

Where Ret is the Reynolds number for the tube-side, Prt is the Prandtl number for the tube-side
fluid, d i is the tube inside diameter, and is the tube length. Eq. (10) is applicable for 0,48 < Prt
< 16700 and Eq. (10) > 2.

Tube-Side Heat Transfer Coefficient

The heat transfer coefficient for the tube-side is expressed as follows:
𝑘𝑡
ℎ 𝑡 = 𝑁𝑢𝑡 𝑥 (11)
𝑑𝑖

Where 𝑁𝑢𝑡 is the Nusselt number for the tube-side fluid which is found by using Eqs. (8) and
(10), k is the thermal conductivity of the tube-side fluid, and d i is the tube inside diameter.

14
 2.3.1.2. Thermal Analysis for Shell-Side

Shell Diameter
The number of tubes is calculated by taking the shell circle and dividing it by the projected
area of the tube layout. That is [14]
𝜋 𝑥 𝐷𝑠2
𝑁𝑡 = (𝐶𝑇𝑃) 𝑥 (12)
4 𝑥 𝐴1
Where A1 is the projected area of the tube layout expressed as area corresponding to one tube
(Eq. 13), Ds is the shell inside diameter, CTP and is the tube count calculation constant that
accounts for the incomplete coverage of the shell diameter by the tubes, du e to necessary
clearances between the shell and the outer tube circle and tube omissions due to tube pass lanes
for multitude pass design.[14] The CTP values for different tube passes are given below: [14]

one-tube pass → CTP = 0.93

two-tube pass → CTP = 0.90
three-tube pass → CTP = 0.85

A1 is expressed as;
𝐴1 = (𝐶𝐿) 𝑃𝑇2 (13)
Where PT is the tube pitch and CL is the tube layout constant.
for 90º and 45º → CL = 1.0
for 30º and 60º → CL = 0.87

Combining Eq. (12) with Eq. (13), one gets;

𝜋 𝑥 (𝐶𝑇𝑃) 𝑥 𝐷𝑠2
𝑁𝑡 = (14)
4 𝑥 (𝐶𝐿) 𝑥 (𝑃𝑅) 2 𝑥 (𝑑𝑜 ) 2

where PR is the tube pitch ratio given by

𝑃𝑇
𝑃𝑅 = (15)
𝑑𝑜

In Eq. (15), d o is the tube outside diameter. The shell inside diameter from Eq. (14) can be
written as; [14]

15
 1/2
𝐶𝐿 𝐴𝑜 𝑥 (𝑃𝑅) 2 𝑥 𝑑𝑜
𝐷𝑠 = 0,637 𝑥 √ 𝑥 [ ] (16)
𝐶𝑇𝑃 𝐿

Where Ao is the outside heat transfer surface area based on the outside diameter of the tube and
can be calculated by the following formula
𝐴𝑜 = 𝜋 𝑥 𝑑𝑜 𝑥 𝑁𝑡 𝑥 𝐿 (17)

Shell Equivalent Diameter

The equivalent diameter is calculated along (instead of across) the long axes of the shell and
therefore is taken as four times the net flow area as layout on the tube sheet (for any pitch
layout) divided by the wetted perimeter. [11]
4 𝑥 𝑓𝑟𝑒𝑒 − 𝑓𝑙𝑜𝑤 𝑎𝑟𝑒𝑎
𝐷𝑒 = (18)
𝑤𝑒𝑡𝑡𝑒𝑑 𝑝𝑒𝑟𝑖𝑚𝑒𝑡𝑒𝑟

Figure 12. Square and Triangular Pitch-Tube Layouts

As shown in Figure 10 [14], for the square pitch, the perimeter is the circumference of a circle
and the area is a square of pitch size (𝑃𝑇2) minus the area of a circle. Therefore, for a square
pitch (as if flow is parallel to the axis of the heat exchanger): [11]
𝜋 𝑥 𝑑𝑜2
4 𝑥 (𝑃𝑇2 − )
4
𝐷𝑒 = (19)
𝜋 𝑥 𝑑𝑜

and for the triangular pitch: [11]

16
 𝑃𝑇2 √3 𝜋 𝑥 𝑑𝑜2
4𝑥 ( − )
4 8
𝐷𝑒 = (20)
𝜋 𝑥 𝑑𝑜
2
where d o is the tube outside diameter.

The number of tubes at the centerline of the shell is calculated by;

𝐷𝑠
𝑁𝑡 = (21)
𝑃𝑇
where Nt is the number of tubes and Pt is the tube pitch and the flow area associated with each
tube between baffles is (C x B) ; hence
𝐷𝑠
𝐴𝑠 = 𝑥 𝐶 𝑥𝐵 (22)
𝑃𝑇

where As is the bundle cross flow area, D s is the inner diameter of the shell, C is the clearance
between adjacent tubes, and B is the baffle spacing. As shown in Figure 10, the tube clearance
(C) is expressed as
𝐶 = 𝑃𝑇 − 2𝑟𝑜 = 𝑃𝑇 − 𝑑𝑜 (23)
Then the shell-side mass flow rate is found with;
𝑚̇ 𝑠
𝐺𝑠 = (24)
𝐴𝑠
where 𝑚̇ 𝑠 is the flow rate of the shell-side fluid.

Shell-Side Reynolds Number

Reynolds number for the shell-side is based on the tube diameter and the velocity on the cross-
flow area at the diameter of the shell:
𝑚̇ 𝑠 𝐷𝑒
𝑅𝑒𝑠 = ( ) 𝑥 (25)
𝐴𝑠 𝜇𝑠

where De is the equivalent diameter on the shell-side, 𝑚̇ 𝑠 is the flow rate of the shell-side fluid,
µs is the viscosity of the shell-side fluid, and As is the cross flow area at the shell diameter.

17
Shell-Side Heat Transfer Coefficient
The heat transfer coefficient for the shell-side in the Kern Method can be estimated from[11]
0,36 𝑥 𝑘 𝑠 1/3
ℎ𝑜 = 𝑥 𝑅𝑒𝑠0,55 𝑥 𝑃𝑟𝑠 (26)
𝐷𝑒
𝐺𝑠 𝐷𝑒
𝑓𝑜𝑟 2 𝑥 103 < 𝑅𝑒𝑠 = < 1 𝑥 106
𝜇

where k s is the thermal conductivity of the shell-side fluid, Re s is the Reynolds number for the
shell-side, Prs is the Prandtl number for the shell-side fluid, and De is the equivalent diameter
on the shell-side

Overall Heat Transfer Coefficient for the Heat Exchanger

The overall heat transfer coefficient for clean surface (U c) is given by

𝑟
1 1 1 𝑑𝑜 𝑟𝑜 𝑥 𝑙𝑛 ( 𝑜 )
𝑟𝑖
= + ( 𝑥 )+ (27)
𝑈𝑐 ℎ𝑜 ℎ 𝑖 𝑑𝑖 𝑘
where h o is the shell-side heat transfer coefficient, h i is the tube-side heat transfer coefficient,
ro is the tube outer radius, r i is the tube inner radius, and k is the thermal conductivity of the
tube material.
The heat transfer coefficient for fouled surface (U f) can be calculated from the following
expression:
1 1
= + 𝑅𝑓𝑡 (28)
𝑈𝑓 𝑈𝑐

Outlet Temperature Calculation and Length of the Heat Exchanger

The amount of heat exchange between two fluids as they flow through a one shell-pass, two
tube-passes shell-and-tube heat exchanger due to temperature the outlet temperature for the
fluid flowing through the tube is;
(𝑚̇ 𝑐𝑝 )ℎ 𝑥 (𝑇ℎ1 − 𝑇ℎ2 )
𝑇𝑐2 = + 𝑇𝑐1 (29)
(𝑚̇ 𝑐𝑝 )𝑐
Since the total heat transfer rate is also known, the surface area o f the heat exchanger for the
fouled condition is;
𝑄
𝐴𝑓 = (30)
𝑈𝑓 𝑥 (𝐹 ) 𝑥 (𝐿𝑀𝑇𝐷)

18
and for the clean condition
𝑄
𝐴𝑐 = (31)
𝑈𝑐 𝑥 (𝐹 ) 𝑥 (𝐿𝑀𝑇𝐷)
where the LMTD is always for the counter flow,
( 𝑇ℎ1 − 𝑇𝑐2 ) − ( 𝑇ℎ2 − 𝑇𝑐1 )
𝐿𝑀𝑇𝐷 = (32)
𝑙𝑛[(𝑇ℎ1 − 𝑇𝑐2 )/(𝑇ℎ2 − 𝑇𝑐1 )]

The over surface design (OS) can be calculated from;

𝐴𝑓 𝑈𝑐
𝑂𝑆 = = (33)
𝐴𝑐 𝑈𝑓
The corresponding total resistance will be from Eq. (28)
1 1
𝑅𝑓𝑡 = − (34)
𝑈𝑓 𝑈𝑐
The length of the heat exchanger is calculated by;
𝐴𝑓
𝐿=
𝑁𝑡 𝑥 𝜋 𝑥 𝑑𝑜
where Nt is the total number of the tubes, d o is the tube outer diameter, and L is the length of
the heat exchanger.

Shell Diameter
Shell diameter can be recalculated from Eq. (16) as;
1/2
𝐶𝐿 𝐴𝑓 𝑥 (𝑃𝑅) 2 𝑥 𝑑𝑜
𝐷𝑠 = 0,637 √ 𝑥 [ ] (35)
𝐶𝑇𝑃 𝐿

2.3.1.3.Hydraulic Analysis for Tube-Side

The pressure drop encountered by the fluid making Np passes through the heat exchanger is a
multiple of the kinetic energy of the flow. Therefore, the tube side pressure drop is calculated
by:
𝐿𝑁𝑝 𝑝𝑡 𝑥 𝑢2𝑡
∆𝑝𝑡 = (4𝑓𝑡 𝑥 + 4𝑁𝑝 ) 𝑥 (36)
𝑑𝑖 2

where L is the tube length, N p is the number of passes, ρ t is the density of the fluid flowing
inside the tubes, and ft is the friction factor calculated from Eq. (9). The second term in Eq. (36)
𝑝𝑡 𝑥 𝑢2𝑡
which is 4𝑁𝑝 𝑥 is the additional pressure drop introduced by the change of direction in
2
19
the passes. The tube fluid experiences sudden expansions and contractions during a return that
is accounted for allowing four velocity heads per pass.

2.3.1.4.Hydraulic Analysis for Shell-Side

The shell-side fluid experiences a pressure drop as it passes through the exchanger, over the
tubes, and around the baffles. If the shell fluid nozzles (inlet and outlet ports) are on the same
side of the heat exchanger, then the shell-side fluid makes an even number of the tube bundle
crossings, but if they are on opposite sides, then it makes an odd number of the bundle
crossings. The number of bundle crossings therefore influences the pressure drop. Based on
experiment, the pressure drop experienced by the shell-side fluid is calculated by;

𝑓𝑠 𝑥 𝐺𝑠2 𝑥 (𝑁𝑏 + 1) 𝑥 𝐷𝑠
∆𝑝𝑠 = (37)
2 𝑥 𝜌𝑠 𝑥 𝐷𝑒 𝑥 𝜑𝑠

Where ∅𝑠 = (𝜇 𝑏 /𝜇𝑤 )0,14 , Nb is the number of baffles, (N b + 1) is the number of times the
shell fluid passes the tube bundle, D e is the shell equivalent diameter determined from Eqs.
(18) and (19), ρ s is the density of the shell-side fluid, and Ds is the shell inner diameter. The
friction factor, fs, for the shell is calculated from:
𝑓𝑠 = exp(0,576 − 0,19𝑙𝑛𝑅𝑒𝑠 ) (38)
where
𝐺𝑠 𝑥 𝐷𝑒
400 < 𝑅𝑒𝑠 = ≤ 1 𝑥 106
𝜇

Note that µ b is the viscosity of the shell-side fluid at bulk temperature, and µ w is the viscosity
of the tube-side fluid at wall temperature. The wall temperature can be calculated as follows:
1 𝑇𝑐1 + 𝑇𝑐2 𝑇ℎ1 + 𝑇ℎ2
𝑇𝑤 = 𝑥 ( + ) (39)
2 2 2

2.3.2. Bell-Delaware Method

In Bell Delaware method, the fluid flow in the shell is divided into several individual streams.
Each of these streams introduces a correction factor which is used to correct heat transfer
coefficient and pressure drop across the shell. This article gives step-by-step guidance on doing
heat exchanger rating analysis based on Bell-Delware method. [15]

20
 2.4.Tail Gasses

Gas produced in a refinery and not required for further processing. The tail gas is introduced
into the inlet zone of the thermal oxidizer via a tail gas inlet. Tail gas is introduced from one or
more carbon black reactors to the thermal oxidizer via the tail gas inlet. The tail gas
compositions that can be treated by the methods and apparatus described herein to reduce NOx
levels therein are not particularly limited. The tail gas unit (TGU) process has been developed
to remove sulphur compounds from Claus tail gas in order to comply with stringent emission
regulations. [16]

21
 3. DECISION OF COOLING FLUID AND HEAT EXCHANGER

3.1. Cooling Fluid

For this design process cooling fluid is chosen as Natural Cooling Fluid: R-718 (Water)
water. Water is successfully used in steam-jet cooling machines and air conditioning systems.
As a coolant, water is the most abundant and easily available substance compared to other
coolants. The transition to zero-degree solid phase limits its usage area. It is cheap and non-
toxic. It has a high latent temperature. Its volumetric amount per ton is large. Besides, brines
and antifreezes, which are coolants with lithiumum bromite and many absorbent materials,
require the presence of water.
The thermodynamic properties of R718 (Water) refrigerant are given in the Table 2.

Table 2. The Thermodynamic Properties of R718 (Water) Refrigerant

Cooling Fluid Freezing Point Normal Boiling Critical Critical

(°C) Point at 1 Atm Temperature Pressure (kPa)
(°C) (°C)

R718 0 100 132,4 1.133

If there is no cold flow in the process, cooling should be accomplished using either air or water.
If the hot stream temperature is not too high, it is appropriate to utilize water as in most
processes. The temperature of the water that can be used as cooling water in the process is
usually determined. Water is at the forefront of what is required in processes as utilities.
Because it needs to be used in large quantities, it is generally not considered for single use, and
cooling towers are used in facilities to ensure its repetitive use in the process.

22
 3.2. Shell And Tube Exchanger

Advantages of shell-and-tube heat exchangers:

➢ Internal reliability. Shell-and-tube heat exchangers are more resistant to scale

formation, which implies that cleaning should be done less frequently than with other
heat exchangers.
➢ Possibility of power regulation. If necessary, increase or decrease the power, adjust the
number of sections, the length and diameter of the pipes.
➢ Long service life. Shell-and-tube heat exchangers have a long service life.

23
 4. METHOD OF CALCULATIONS

Formulas given below are used in calculations of properties.

𝐶𝑝 = 𝐴 + (𝐵 × 𝑇) + (𝐶 × T 2 ) + (𝐷 × 𝑇 3 ) + (𝐸 × 𝑇 4 ) (40)
𝜇 = 𝑒 (𝐴+(𝐵×𝑇)+×(𝐶×𝑙𝑛(𝑇))+(𝐷×𝑇 𝐸)) (41)
𝑘 = 𝐴 + (𝐵 × 𝑇) + (𝐶 × 𝑇 2 ) + (𝐷 × 𝑇 3 ) + (𝐸 × 𝑇 4) (42)
Cp × μ
𝑃𝑟 = (43)
𝑘

In this section, calculations for logarithmic mean temperature, P and R are done. Also, heat loss
and heat gain are calculated, and the overall heat transfer coefficient calculation is accepted and
used.

m x Cp x ∆𝑇 = Q (44)
Qhot = -Qcold (45)
∆T1 = Th,i – Tc,o (46)
∆T2 = Th,o – Tc,i (47)
∆T1−∆T2
∆𝑇𝐿𝑀 = (48)
𝐼𝑛 (∆T1/∆T2 )

The heat exchanger consists of two parts. These are tubes and shells. In order to decide which
type of heat exchanger to use, the tube part is calculated. Firstly, the single tube area is
calculated.

𝑄 = 𝑈 × 𝐴𝑂 × ∆𝑇𝐿𝑀 × F (49)
𝑄
𝐴0 = (50)
𝑈𝑂 𝑥 ∆𝑇𝐿𝑀 𝑥 𝐹

𝐴0 = 𝜋 𝑥 𝐿 𝑥 𝑑0 𝑥 𝑁 (51)
𝜋 𝑥 𝐷İ2
Area of 1 tube (At) = (52)
4
𝑁
Tube per pass = (53)
4

Total Tube Area = (Area of 1 tube) x (Tube per pass) (54)

𝑚̇
𝐺𝑡𝑢𝑏𝑒 = (55)
𝑇𝑜𝑡𝑎𝑙 𝑇𝑢𝑏𝑒 𝐴𝑟𝑒𝑎
𝐺𝑡𝑢𝑏𝑒
𝑉𝑡𝑢𝑏𝑒 = (56)
𝜌

Reynolds number is calculated using this velocity.

24
 𝐷𝑖 𝑥 𝑣 𝑥 𝜌
𝑅𝑒 𝑇𝑢𝑏𝑒 = (57)
𝜇

𝜇 0,14 ℎ𝑖 𝑥 𝐷𝑖
𝑁𝑢 = 0,027 × (𝑅𝑒) 0,8 x (𝑃𝑟) 0,33 𝑥 ( ) = (58)
𝜇𝑤 𝑘

𝐴i = 𝜋 𝑥 𝐿 𝑥 𝑑𝑖 𝑥 𝑁 (59)
𝑄
Heat flux tube = = ( 𝑇𝑤 − 𝑇𝑖 ) x ℎ 𝑖 (60)
𝐴İ

Heat flux is calculated for tube and shell side and calculation is shown below.

1
𝑁 𝑛
Bundle Diameter (𝐷𝑏) = 𝑑0 𝑥 ( 𝑡𝑢𝑏𝑒 ) (61)
𝑘

Clearance (C) = Pitch - 𝐷0 (62)

Shell Diameter ( 𝐷𝑠 ) = 𝐷𝑏 + 𝐶 (63)
𝐷𝑠
Baffle Spacing = (64)
5
𝑝𝑖𝑡𝑐ℎ− 𝐷0
Cross Flow Area of Shell (𝐴𝑠 ) = 𝑥 𝐷𝑠 x Baffle Spacing (65)
𝑃𝑖𝑡𝑐ℎ

Shell side area is calculated.

𝑚̇
𝐺𝑠 = (66)
𝐴𝑠
𝐺𝑠
𝑣𝑆 = (67)
𝜌𝑠

Mass velocity and shell side velocity are calculated, and the Reynolds number is found using
this data.

𝐷0 𝑥 𝑣 𝑥 𝜌
𝑅𝑒𝑠ℎ𝑒𝑙𝑙 = (68)
𝜇

𝜋 𝑥 𝐷02
Free flow area ( 𝑆𝑏 ) = 𝑓𝑏 𝑥 (69)
4

𝑁𝑏 = 𝑓𝑏 𝑥 𝑁𝑡𝑜𝑡𝑎𝑙 (70)
𝐷𝑒 𝑥 𝐺 𝑠 0,55 ( 𝜇) 0,14 ℎ0 𝑥 𝐷0
𝑁𝑢 = 0.35 × ( ) 𝑥 (𝑃𝑟) 0,33 𝑥 ( ) = (71)
𝜇 𝜇𝑤 𝑘

𝐷𝑒 =
1.10 𝑥 [𝑃𝑡2 − (0.917𝑥 𝑑02 )] (72)
𝑑0

𝑄
Heat Flux Shell = = (𝑇𝑐,𝑜 - 𝑇0 ) x ℎ 0 (73)
𝐴0

25
In this part, firstly the fouling factor of fluids was found. Then, Overall heat transfer coefficient
is calculated. Overall heat transfer coefficient and assumed values of overall heat transfer
coefficient were compared with try end error method.

ℎ𝑜 < ℎ𝑖 so we calculated 𝑈0
𝑑
1 1 1 0 𝐼𝑛(𝑑0/𝑑 ) 𝑑0 1 1
𝑖
= + + + ( + ) (74)
𝑈0 ℎ0 ℎ𝑜𝑑 2∗𝑘𝑊 𝑑𝑖 ℎ𝑖𝑑 ℎ𝑖

𝑄𝑑𝑒𝑠𝑖𝑟𝑒𝑑 = 𝑈0 𝑥𝐴0 𝑥∆𝑇𝐿𝑀 (75)

𝑄𝑑𝑒𝑠𝑖𝑟𝑒𝑑
= 1.05 – 1.15 (76)
𝑄𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑

( 𝐿) 𝜇 −𝑚 𝜌∗𝑣2
∆𝑃𝑡𝑢𝑏𝑒 = 𝑁𝑃 x [8 x 𝐽𝑓 𝑥 (( )
)x( ) + 2.5 ] x (77)
𝑑𝑖 𝜇𝑤 2

𝐷 𝐿 𝜇 −0,14 𝜌∗𝑣2
∆𝑃𝑠ℎ𝑒𝑙𝑙 = 8 𝑥 𝐽𝑓 𝑥 ( 𝑠 ) 𝑥 ( ) 𝑥 ( ) 𝑥 (78)
𝐷𝑒 𝐼𝐵 𝜇𝑤 2

26
 5. DESIGN OF CHEMCAD

Figure 13. Heat Exchanger Design of Chemcad

Simulation: Untitled

STREAM PROPERTIES
Stream No. 1 2 3 4
Name
- - Overall - -
Molar flow kmol/s 0.0702 0.0702 0.3675 0.3675
Mass flow kg/s 4.5000 4.5000 6.6200 6.6 200
Temp C 450.0000 250.0000 44.1367 19.0000
Pres bar 1.0000 1.0000 1.0000 1.0000
Vapor mole fraction 1.000 1.000 0.0000 0.0000
Enth MJ/s -19.466 -20.162 -104.57 -105.27
Tc C 157.6000 157.6000 374.2000 374.2000
Pc bar 78.8410 78.8410 221.1823 221.1823
Std. sp gr. wtr = 1 1.434 1.434 1.000 1.000
Std. sp gr. air = 1 2.212 2.212 0.622 0.622
Degree API -32.8250 -32.8250 10.0000 10.0000
Average mol wt 64.0650 64.0650 18.0150 18.0150
Actual dens kg/m3 1.0661 1.4762 990.3293 998.0424
Actual vol m3/h 15195.6201 10973.8291 24.0647 23.8787
Std liq m3/h 11.2971 11.2971 23.8320 23.8320
Std vap 0 C m3/h 5667.6978 5667.6978 29650.9590 29650.9590
- - Vapor only - -
Molar flow kmol/s 0.0702 0.0702
Mass flow kg/s 4.5000 4.5000
Average mol wt 64.0650 64.0650
Actual dens kg/m3 1.0661 1.4762
Actual vol m3/h 15195.6201 10973.8291
Std liq m3/h 11.2971 11.2971
Std vap 0 C m3/h 5667.6978 5667.6978
Cp kJ/kg-K 0.8020 0.7383
Z factor 0.9996 0.9979
Visc N-s/m2 2.952e-005 2.226e-005
Th cond W/m-K 0.0297 0.0201
- - Liquid only - -
Molar flow kmol/s 0.3675 0.3675
Mass flow kg/s 6.6200 6.6200
Average mol wt 18.0150 18.0150
Actual dens kg/m3 990.3293 998.0424

27
Actual vol m3/h 24.0647 23.8787
Std liq m3/h 23.8320 23.8320
Std vap 0 C m3/h 29650.9590 29650.9590
Cp kJ/kg-K 4.1787 4.1857
Z factor 0.0009 0.0010
Visc N-s/m2 0.0006272 0.001058
Th cond W/m-K 0.6306 0.5975
Surf. tens. N/m 0.0688 0.0731

Flow rates in kg/s

Sulfur Dioxide 4.5000 4.5000 0.0000 0.0000
Water 0.0000 0.0000 6.6200 6.620 0

CHEMCAD 7.1.2 24.11.2021

0:26 AM

Simulation: Untitled

FLOW SUMMARIES:

Stream No. 1 4 2 3
Stream Name
Temp C 450.0000 19.0000 250.0000 44.0000
Pres bar 1.0000 1.0000 1.0000 1.0000
Enth MJ/s -19.466 -105.27 -20.162 -104.58
Vapor mole frac. 1.0000 0.00000 1.0000 0.00000
Total kmol/s 0.0702 0.3675 0.0702 0.3675
Total kg/s 4.5000 6.6200 4.5000 6.6200
Total std L m3/h 11.2971 23.8320 11.2971 23.8320
Total std V m3/h 5667.70 29650.96 5667.70 29650.96
Flow rates in kmol/s
Sulfur Dioxide 0.0702 0.0000 0.0702 0.0000
Water 0.0000 0.3675 0.0000 0.3675

CHEMCAD 7.1.2 24.11.2021

0:21 AM

28
 6. DESIGN OF CALCULATIONS

𝑄 = 𝑚̇ 𝑥 𝐶𝑝 𝑥 ∆𝑇
𝑘𝑔 𝐽
𝑄 = 4.5 𝑥 768,26876 𝑥 (450 − 250) = 691.4419 𝑘𝑊
𝑠 𝑘𝑔𝑥𝐾

𝑄ℎ𝑜𝑡 = −𝑄𝐶𝑜𝑙𝑑
− 691.4419𝑘𝑊 = 𝑚̇ 𝑥 𝐶𝑝 𝑥 ∆𝑇
J
− 691.4419𝑘𝑊 = 𝑚̇𝑐𝑜𝑜𝑙𝑖𝑛𝑔 𝑤𝑎𝑡𝑒𝑟 𝑥 4026,4 x (44°C − 19°C)
kgK

𝑚̇𝑐𝑜𝑜𝑙𝑖𝑛𝑔 𝑤𝑎𝑡𝑒𝑟 = 6,617 kg/s

Overall heat transfer coefficient assume for shell and tube exchanger

𝑊
𝑈 = 10 − 250
𝑚2 𝑥𝐾

𝑊
Assumed = 198
𝑚2 𝑥𝐾

𝑇ℎ,𝑖 = 450 °𝐶

𝑇ℎ,𝑜 = 250 °𝐶

𝑇𝑐,𝑖 = 19 °𝐶

Assumed as

𝑇𝑐,𝑜 = 44 °𝐶

∆𝑇1 −∆𝑇2
∆𝑇𝑙𝑚 = ∆𝑇1
ln ( )
∆𝑇2

( 450−44) −(250− 19)

∆𝑇1 = 450−44 = 310.32 oC
ln ( )
250−19

t2−t1 Th,o− Th,i 250−450

𝑃= =
T1−t1 Tc,i− Th,i
= 19−450
= 0.464

29
 T1−T2 Tc.i − Tc.o 19−44
𝑅= = =
250−450
= 0.125
t2 −t1 Th,o−Th,i

F = 0.9909 for 1-2 Type Heat Exchanger

𝑄 = 𝑈𝑎𝑠𝑠𝑢𝑚𝑒 𝑥 𝐴 𝑥 ∆𝑇𝐿𝑀 𝑥 𝐹

691.4419𝑘𝑊 = 198 𝑥 𝐴 𝑥 ∆𝑇𝐿𝑀 𝑥 𝐹

A= 11,35669654 m 2

• 1-2 Type Heat Exchanger

3⁄4 16 BWG
OD = 19,05 mm = 0.01905 m
ID = 15,75 mm = 0.01575m
t (thickness) = 1.65 mm = 0.00165 m
L=16 ft = 4,88 m

Tube side 𝒉𝒊 coefficient

𝐴=𝜋 𝑥 𝑑𝑜 𝑥 𝐿 𝑥 𝑁
11,36 m 2=𝜋× 0.01905 ×4,88×
𝑁= 38,88546947
Tube number taken from literature (Kern, 1983)

𝑁= 342
𝐷2 𝜋 𝑥 0.015752
𝑇𝑢𝑏𝑒 𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛 𝑎𝑟𝑒𝑎= 𝜋 𝑥 = = 0.000195 𝑚 2
4 4
𝑁 342
𝑇𝑢𝑏𝑒 𝑝𝑒𝑟 𝑝𝑎𝑠𝑠 = = = 171
4 4

𝑇𝑜𝑡𝑎𝑙 𝑡𝑢𝑏𝑒 𝑎𝑟𝑒𝑎 = (𝑎𝑟𝑒𝑎 𝑜𝑓 1 𝑡𝑢𝑏𝑒)×(𝑡𝑢𝑏𝑒 𝑝𝑒𝑟 𝑝𝑎𝑠𝑠)

𝑇𝑜𝑡𝑎𝑙 𝑡𝑢𝑏𝑒 𝑎𝑟𝑒𝑎= 0.000195 𝑚2 𝑥 171 = 0.0333 𝑚 2

30
 𝑚̇ 4.5 𝑘𝑔
𝐺𝑡𝑢𝑏𝑒 = = = 105.222
𝑡𝑜𝑡𝑎𝑙 𝑡𝑢𝑏𝑒 𝑎𝑟𝑒𝑎 0.0333 𝑚2 𝑠
𝑚𝑎𝑠𝑠 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 105.2218478 𝑚
𝑉𝑡𝑢𝑏𝑒 = = = 81.97
𝜌𝑆𝑂2 1.283688 𝑠

𝜌𝑥 𝑉 𝑥 𝐷 1.283688 𝑥 81.97 x 0.01575

𝑅𝑒𝑡𝑢𝑏𝑒 = = = 62589 ,0442
𝜇 2.65 𝑥 10−5
𝐶𝑝 𝑥 𝜇
𝑃𝑟𝑡𝑢𝑏𝑒 = = 0,756559064
𝑘

𝑗ℎ = 0.000315
𝑘 0.026888
ℎ 𝑖 = ( ) 𝑥 𝑗ℎ 𝑥 𝑅𝑒 𝑥 𝑃𝑟 0.33 = ( ) 𝑥 0.00315 𝑥62589,0442 𝑥(0,756559064 ) 0.33
𝑑𝑖 0.01575
𝑊
ℎ 𝑖 = 306,976374
𝑚2 𝐾

Shell side 𝒉𝒔 coefficient

𝑁
Bundle Diameter = 𝐷𝑜 ( ) !/𝑛
𝐾

K = 0.249
n= 2.207
342 1/2.207
Bundle Diameter = 0.01905𝑥 ( ) = 503.102 mm
0.249

Clearance = 50 mm
Shell Diameter = Bundle Diameter + Clearance
Shell Diameter = 562.102 mm = 0.562102 m
Shell Diameter 503.102 m
Baffle spacing = = = 112.4204096 mm = 0.11242 m
5 5

𝑡𝑢𝑏𝑒 𝑝𝑖𝑡𝑐ℎ− 𝐷𝑜
𝐶𝑟𝑜𝑠𝑠 − 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑠h𝑒𝑙𝑙(𝐴𝑠)= 𝑥 𝐷𝑆ℎ𝑒𝑙𝑙 𝑥 𝐵𝑎𝑓𝑓𝑙𝑒 𝑠𝑝𝑎𝑐𝑖𝑛𝑔
𝑡𝑢𝑏𝑒 𝑝𝑖𝑡𝑐ℎ

1.25𝑥 0.01905− 0.01905 0.025−0.01905

𝐴𝑠 = = 𝑥 0.562102 𝑥 0.11242 = 0.012638348 𝑚 2
1.25𝑥 0.01905 0.025
𝑚̇ 6.616669 𝑘𝑔
𝐺𝑠ℎ𝑒𝑙𝑙 = = = 0.52605887
𝑡𝑜𝑡𝑎𝑙 𝑡𝑢𝑏𝑒 𝑎𝑟𝑒𝑎 0.012638348 𝑚2 𝑠
1.1
Equivalent diameter (De) = (𝑡𝑢𝑏𝑒 𝑝𝑖𝑡𝑐ℎ 2 − 0.917 (𝑑𝑜 ) 2
𝑑𝑜
1.1
De = (0.0252 − 0.917 (0.01905 ) 2 = 0.01352645 mm
0.01905
𝐷𝑒 𝑥 𝐺𝑠ℎ𝑒𝑙𝑙 0.0135265 𝑥 0,52605887 x 995.21
𝑅𝑒𝑠ℎ𝑒𝑙𝑙 = = = 12946,2999
𝜇 0.000547
𝐶𝑝 𝑥 𝜇
𝑃𝑟𝑠ℎ𝑒𝑙𝑙 = = 3.580098506
𝑘

31
 𝑘 0.6159
ℎ 𝑠 = ( ) 𝑥 𝑗ℎ 𝑥 𝑅𝑒 𝑥𝑃𝑟 0.33 = ( ) 𝑥0.0050523𝑥12946.3 𝑥(3.58) 0.33
𝑑𝑒 0.01352645
𝑊
ℎ 𝑠 =4361.4273
𝑚2 𝐾

Overall U coefficient
𝑑
1 1 1 𝑑𝑜 ln ( 𝑜 ) 𝑑𝑜 1 𝑑𝑜 1
𝑑𝑖
= + + + 𝑥 + 𝑥
𝑈𝑜 ℎ𝑠 ℎ𝑜𝑑 2 𝑥 15 𝑑𝑖 ℎ𝑖 𝑑𝑖 ℎ𝑖𝑑

𝑊
𝑈𝑜 = 209.44
𝑚2 °𝐶
𝑈𝑜,𝑐𝑎𝑙−𝑈𝑜,𝑎𝑠𝑠𝑚
If 0 < < 30% assumption is correct
𝑈𝑜,𝑎𝑠𝑠𝑚
209.44−198
𝑥100 = 5.8%
198

Tube Side Pressure Drop

Re = 62589,0442

𝑗𝑓 = 0,003
𝐿 𝜌𝑈2
∆𝑃𝑡 = 𝑁𝑝 𝑥 [8 𝑥 𝑗𝑓 𝑥 + 2.5] 𝑥
𝑑𝑖 2

4.88 1.283688 (81.97) 2

∆𝑃𝑡 = 2 𝑥 [8 𝑥 0,003 𝑥 + 2.5] 𝑥
0.01575 2

N
∆𝑃 = 85698 ,31356 = 85.698 𝑘𝑃𝑎
𝑚2

Shell Side Pressure Drop

Re= 12946.2999
𝐷 𝐿 𝜌𝑈2
∆𝑃𝑠 = 8 𝑥 𝑗𝑓 𝑥 ( 𝑠 ) 𝑥 ( ) 𝑥
𝑑𝑒 𝑙𝐵 2

562.102 4.88 995.21𝑥 (0.526) 2

∆𝑃𝑠 = 8 𝑥 0,005075 x ( )x( )𝑥
0.0135 0.11242 2

N
∆𝑃𝑠 = 10085 .21995 = 10.085 𝑘𝑃𝑎
𝑚2

32
 7. COST ESTIMATION

• Fixed Capital Investment Calculation

Purchased Equipment Cost (PEC) = 32760 $/year

• Direct Cost
Purchased Equipment Installation = PEC × 0,47 = 15397,2 $/year
Instrument and Controls = PEC × 0,36 = 11793,6 $/year
Piping = PEC × 0,68 = 22276,8 $/year
Electrical Systems (Installed) = PEC×0,11= 3603,6 $/year
Contingency = PEC×0,44 = 14414,4 $/year
Total Direct Cost = 1,62 × PEC = 67485,6 $/year

• Indirect Cost
Engineering and Supervision = PEC × 0,33 = 10810,8 $/year
Legal Expenses = PEC×0,04 = 1310,4 $/year
Total Indirect Cost = 0,81 × PEC = 26535,6 $/year
Fixed Capital Investment ≅ 8070 $/year

• Total Capital Investment

(FCI) = Total Direct Cost (TDC) + Total Indirect Cost (TIC)
FCI = 102091,2 $/year
TCI = FCI/0,85
Total Capital Investment = 120107,2941 $/year

• Fixed Cost Calculation

Depreciation = 0,1 × FCI = 10209,12 $/year
Local Taxes = 0,03 × FCI = 3062,736 $/year
Insurance = 0,008 × FCI = 816,7296 $/year
Total Fixed Cost (TFC)= 0,138 × FCI = 14088,5856 $/year

33
• Operating Cost Calculation
Operating Cost = Electricity Cost
Electricity Cost = FCI × 0,05 = 5104,56 $/𝑦𝑒𝑎𝑟

• Maintenance And Repairs Calculation

Maintenance and Repairs = 0,08 × FCI = 8167,296 $/year

• Total Cost Calculation

TC = TFC + OC + Maintenance and Repairs
TC = 14088,5856 + 5104,56 + 8167,296
Total Cost = 261801,9213 $/year

34
 8. RESULTS

The outlet temperature of the water is assumed as 44 ℃. 𝑄𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 is calculated and found as
691,4419 k𝑊. Heat transfer coefficient assumed as 198 𝑊/𝑚 2𝐾. Heat transfer area calculated
with ¾ 16 BWG dates. Number of tubes calculated as 38. This number of tubes completed as
342 depends on 1 tube and 2 passes. Tube cross-sectional area calculated as 0,000194828 𝑚2.
Then total flow area is 0,033315559 m2. Baffle cut is selected as %25 of shell diameter removed
and baffle spacing is calculated as 0.11242 m. Mass velocity was calculated and then the tube
velocity was calculated. Tube velocity found as 81,96839718 m/s. Tube side Reynold number
calculated with found tube velocity then found as turbulent flow. In the shell velocity is
0,526058867 m/s and founded as turbulent flow. Tube side Reynold number calculated as
62589,0442. Then the diameter of the shell was calculated as 562,1020479 mm to find the shell
side velocity. Cross flow area calculated as 0,012638348 𝑚2. Nusselt number calculated then
h i found as 306,9763736 𝑊/𝑚 2𝐾 and ho found as 4361,427334 𝑊/𝑚 2𝐾. Since h o bigger than
h i so Uo calculated then U o found as 209,4363332 𝑊/𝑚 2𝐾. It can be seen as assumption is
correct. 𝑄𝑑𝑒𝑠𝑖𝑟𝑒𝑑/𝑄𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 found as 0,94737. Tube side pressure drop calculated as 85,698 kPa
and Shell side calculated as 10,085 kPa.

35
 9. DISCUSSION

The design of mentioned heat transfer unit includes a large amount of literature research and a
basic design procedure. The first step was the preliminary calculation method, based on the
physical properties of the cold and hot fluids. In this heat exchanger design, it w as aimed to
design the most economical and efficient exchanger. First, heat exchanger types investigated.
Shell and tube heat exchanger was chosen because of its advantages and suitable according to
our design. Some of these advantages: Easy to clean, it can be design very high pressure, it has
extremely flexible and easy maintenance and repair.
After deciding the type of heat exchanger, it was decided to pass SO 2 tube side and the water
in shell side according to corrosivity and viscosity of the materials. As a result of the
calculations, the type of heat exchanger was decided to be 1 shell and 2 passes. The
countercurrent was selected because high efficiency cooling was achieved. For the material
carbon steel is chosen. This decision’s effective factors are the passing fluid and gas’s physical
and chemical properties. Such as their corrosivity, viscosity, passing temperature and passing
pressure. Triangular layout was preferred because the heat transfer coefficient was larger, and
more tubes could be used. According to calculations, outside fluid film coefficient (h o) was
bigger than inside fluid coefficient (h i). So overall heat transfer coefficient was calculated.
According to our assumptions, the overall heat transfer coefficient’s rate is calculated and
founded as 94,73 %. The expected interval was under the 30% and so we had a new assumption
for this. According to new assumption values, the overall heat transfer coefficient’s rate is
founded 5,263 %.

36
 10. CONCLUSION

This report contains an overview of designing a heat exchanger used in sulphur dioxide. Heat
transfer units are of paramount importance in regulating stream temperatures within chemical
industries. One of the most important steps in our design was the choice of type of heat exchanger.
When we considering about the cost analysis, the most effecting parameter is material of
construction and also the number of tubes and tube length in our cost. In order to achieve a good
heat transfer, it is better to use a tubular heat exchanger.

According to our assumptions, the overall heat transfer coefficient’s rate is calculated and
founded as 94,73 %. The expected interval was under the 30% and so we had a new assumption
for this. According to new assumption values, the overall heat transfer coefficient’s rate is
founded 5,263 %. Thus the design can be improved. The assumption worked well.

The direct cost was found with total of these. As a result of all these calculations, minimum
total annual cost was found. Shell and tube heat exchanger is designed according to all
calculations.

37
11. HAZOP ANALYSIS

GUIDE EQUIPMENT DEVIATION CAUSES CONSEQUENCES ACTION

WORD

Process fluid The system

temperature is not may be
LESS Heat Less cooling Pipe lowered stopped and
Exchanger water. leakage. accordingly. SO2 flow rate
may change.

More cooling Failure of Out of process fluid Install

water flow inlet temperature too temperature
Heat cooling low. indicator
MORE Exchanger water valve before and
to close. after process
fluid line
install.
Water’s The system’s
NO Heat No cooling. temperature Temperature equipmens
Exchanger is in increases. must control
unexpected and stop
level

38
 12. REFERENCES

[1] Timmerhaus, Peter, West. Plant Design and Economics for Chemical Engineers. New York:
McGraw Hill, 2002. (November 2021).
[2] Perry. Perry's Chemical Engineers' Handbook. New York: McGraw Hill, 1997.
[3] http://web.karabuk.edu.tr/erhankayabasi/Heat%20Exchangers%201st%20Lecture.pdf
(Data Accessed: 09.11.2021)
[4] "Shell & Tube Heat Exchangers | UK Heat Exchanger Manufacturers". Sterling Thermal
Technology. Retrieved 2021-08-26.
[5] Heat Exchanger Shell Bellow Piping Technology and Products, (retrieved March 2012)
[6] https://www.comsol.com/blogs/how-model-shell-and-tube-heat-exchanger/ (Data
Accessed : 09.11.2021)
[7] https://www.zwirnerequipment.com/blog/heat-exchanger-types-and-applications/ (Data
Accessed : 09.11.2021)
[8] Taborek,J.,Hewitt,G.F.and Afgan,N. (1983). Heat Exchangers:Theory and
Pratice,Hemisphere Publishing Corporation. ISBN 0-07-062806-8
[9] Jacobs, H. R. (1995b) Direct Contact Heat Transfer, Heat Exchanger Design Handbook.
[10] https://www.sciencedirect.com/topics/engineering/fired-heaters (Data Accessed :
09.11.2021)
[11] Advances in Thermal Design of Heat Exchangers, Eric M Smith, John Wiley & Sons, Ltd.,
2005.
[12] Compact Heat Exchangers, Pergamon, J.E. Hesselgreaves, 2001.
[13] Handbook for Heat Exchangers and Tube Banks Design, D. Annaratone , Springer Verlag,
2010.
[14] Heat Exchangers, CRC Press, A Kakac, H Liu, 2002.
[15] Fundamentals of Heat Exchanger Design, John Wiley & Sons., R K Shah and D P
Sekulic,2003.
[16] Process Heat Transfer, CRC Press, G F Hewuttm G L Shires and T R Bott,1994.
[17] Literature from Web.

39
 11. APPENDICES

APPENDICES 1

SULFURDIOXE MSDS

Continued….
40
Continued….
41
Continued….

42
Continued….
43
44
APPENDICES 2

WATER MSDS

Continued….

45
Continued….

46
Continued….

47
Continued….

48
49
APPENDICES 3

APPENDICES 4

50
APPENDICES 5

APPENDICES 6

51
APPENDICES 7

APPENDICES 8

52
APPENDICES 9

APPENDICES 10

53
APPENDICES 11

54