Panchal Manish Kumar S U19CH071

PEDD

NOTES
by

Panchal Manish Kumar S

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Panchal Manish Kumar S U19CH071

Contents
STEPS FOR SHELL DESIGN .................................................................................................. 4

Internal pressure ..................................................................................................................... 4

(1) Cylindrical shell ........................................................................................................... 4

(2) spherical shell. .............................................................................................................. 5

External pressure .................................................................................................................... 5

DESIGN OF SUPPORT ............................................................................................................ 6

CYLINDRICAL VESSEL UNDER COMBINED LOADING ................................................ 7

STEPS FOR HEAD DESIGN ................................................................................................... 9

If head are subjected to internal pressure ............................................................................... 9

Flat head ............................................................................................................................. 9

Conical Heads .................................................................................................................... 9

Shallow dished head and tori-spherical head ................................................................... 10

Elliptical Head (semi-ellipsoidal) .................................................................................... 10

Hemispherical head .......................................................................................................... 10

STEPS FOR NOZZLE DESIGN ............................................................................................. 11

DESIGN OF REINFORCEMENT .......................................................................................... 11

Area to area method ............................................................................................................. 11

DESIGN OF FLANGE ............................................................................................................ 12

Selection of gaskets.............................................................................................................. 12

Calculation of bolts .............................................................................................................. 12

DESIGN OF HEAT EXCHANGER ....................................................................................... 14

Kern’s method ...................................................................................................................... 14

Step 1 ............................................................................................................................... 14

Step 2 ............................................................................................................................... 14

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Panchal Manish Kumar S U19CH071

Step 3 ............................................................................................................................... 16

Step 4 ............................................................................................................................... 18

Step 5 ............................................................................................................................... 20

Step 6: Estimate tube- and shell-side heat transfer coefficient ........................................ 20

Step 7 Pressure drop......................................................................................................... 23

Step 8 ............................................................................................................................... 23

DESIGN OF DISTILLATION COLUMN .............................................................................. 24

shell design........................................................................................................................... 24

Shell thickness ................................................................................................................. 24

Head design ...................................................................................................................... 24

Shell thickness at different heights .................................................................................. 24

determination of value of X ............................................................................................. 25

skirt design ........................................................................................................................... 25

STORAGE TANK ................................................................................................................... 27

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Panchal Manish Kumar S U19CH071

STEPS FOR SHELL DESIGN

INTERNAL PRESSURE
Shell is subjected to internal pressure

There are two types of shells are generally useful in industry (1) Cylindrical shell (2) spherical
shell.

(1) CYLINDRICAL SHELL

In cylindrical shell the internal pressure gives stresses in two directions
(1) circumferential stress (2) longitudinal stress

Here maximum stress is circumferential stress so that is being used while creating a design for
cylindrical shell

𝑝𝐷
𝑡 |𝑚𝑚 = 1.
2𝑓𝐽
For Diameters like inside and outside

𝑝𝐷 𝑝𝐷𝑖 𝑝𝐷𝑜
𝑡= = = 2.
2𝑓𝐽 2𝑓𝐽 − 𝑝 2𝑓𝐽 + 𝑝
Here,

𝑁 = Internal design pressure

𝑝 | 𝑚𝑚2

𝐷 | 𝑚𝑚 = Mean diameter
𝐽 = Joint efficiency
𝑁 = Design or permissible stress At design pressure
𝑓 | 𝑚𝑚2

𝐷𝑖 | 𝑚𝑚 = Inside diameter
𝐷𝑜 | 𝑚𝑚 = Outside diameter
∗ Here if operating pressure is given instead of design pressure
we will take 𝑝𝑑𝑒𝑠𝑖𝑔𝑛 = 1.1 ∗ 𝑝𝑂𝑝𝑒𝑟𝑎𝑡𝑖𝑜𝑛𝑎𝑙
Because IS 2825 suggest us to take 10% extra pressure of safety purposes

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Panchal Manish Kumar S U19CH071

(2) SPHERICAL SHELL.

For spherical shell both stresses are same so the longitudinal or circumstantial stress is being
used while creating shell design

𝑝𝐷 𝑝𝐷𝑖 𝑝𝐷𝑜
𝑡= = = 3.
4𝑓𝐽 4𝑓𝐽 − 𝑝 4𝑓𝐽 + 𝑝

EXTERNAL PRESSURE
If the shell is subjected operate under external pressure, then following calculation must be
done for design purposes

5
𝑡 2
2.42 𝐸 (𝐷 )
𝑜
𝑝𝑐 = [ 3] 1 4.
(1 − 2
𝜇 )4 𝐿 𝑡 2
(𝐷 ) − 0.45 (𝐷 )
[ 𝑜 𝑜 ]

Here

𝐿 | 𝑚𝑚 = Unsupported length of the vessel

𝐷𝑜 | 𝑚𝑚 = Outside diameter
𝑡 | 𝑚𝑚 = Thickness
𝑁 = Modulus of elasticity
𝐸 | 𝑚𝑚2

𝜇 = Poisson’s ration
𝑛 = Number of lobes formed (if there is)
𝑁 = Critical buckling pressure
pc | 𝑚𝑚2

For the thickness we have calculated form internal pressure calculated

𝑝𝑐 and f𝑐 should be 4 times than required according to safety factor. It requires increase
the thickness until satisfaction.

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Panchal Manish Kumar S U19CH071

DESIGN OF SUPPORT
Thickness of base plate.

Average pressure on the

𝑃 5.
𝑝𝑎𝑣 =
𝑎𝐵

Maximum stress in a rectangular plate subjected to a pressure 𝑝𝑎𝑣 and the fixed at the
edges is given by

𝐵2 𝑎4 6.
𝑓 = 0.5 ∗ 𝑝𝑎𝑣 ∗ ∗ ( )
𝑇12 𝐵 4 + 𝑎4

If load is only distribute on the surface of contact between the base plate and supporting
beam, the actual stress may be taken 40% extra

𝐵2 𝑎4 7.
𝑓 = 0.7 ∗ 𝑝𝑎𝑣 ∗ ∗ ( )
𝑇12 𝐵 4 + 𝑎4

Thickness of gusset plate

𝑃∗𝐶 8.
𝑚𝑜𝑚𝑒𝑛𝑡 𝑓𝑜𝑟 𝑒𝑎𝑐ℎ 𝑝𝑙𝑎𝑡𝑒 =
2
1 9.
𝑠𝑒𝑐𝑡𝑖𝑜𝑛 𝑚𝑜𝑑𝑢𝑙𝑢𝑠 𝑜𝑓 𝑝𝑙𝑎𝑡𝑒 = ∗ 𝑇 ∗ ℎ2
6 2

If the edge is at angle of 𝜃 from horizontal

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Panchal Manish Kumar S U19CH071

Therefore, the maximum compressive stress parallel to the edge of the web plate

3∗𝑃∗𝐶 1 10.
𝑓= ∗
𝑇2 ∗ ℎ2 𝑐𝑜𝑠𝜃

CYLINDRICAL VESSEL UNDER COMBINED

LOADING
In addition of the internal pressure the other loadings are there. So, we have to consider that
for the calculation of shell design.

(1) shell in the circumferential direction due to the internal pressure known as hoop stress

𝑝(𝐷𝑖 + 𝑡)
𝑓𝑡 = 11.
2𝑡
(2) Stress due to longitudinal or axial direction

(a) due to internal pressure

𝑝𝐷𝑖
𝑓1 = 12.
4𝑡
(b) due to the weight of vessel and content

𝑊
𝑓2 = 13.
𝜋𝑡(𝐷𝑖 + 𝑡)
W | N– weight of the vessel and content

(c) due to wind load or piping in the case of vessels or due to weight of vessel in case of
horizontal vessel.

𝑀 𝑀
𝑓3 = ± = 14.
𝑍 𝜋𝐷𝑖 2 𝑡
M – bending moment

Z – modulus of section of the vessel of the cylindrical vessel

𝑓𝑎 = 𝑓1 + 𝑓2 + 𝑓3 15.

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Panchal Manish Kumar S U19CH071

(3) stress due to offset piping

2𝑇
𝑓𝑠 = 16.
𝜋𝐷𝑖(𝐷𝑖 + 𝑡)
T – torque about the vessel axis

1
𝑓𝑅 = [𝑓𝑡2 − 𝑓𝑡 𝑓𝑎 + 𝑓𝑎2 + 3𝑓𝑠2 ]2 17.

FOR SATISFACTORY DESIGN FOLLOWING MUST BE SATISFIED

𝑓𝑅 ≤ 𝑓𝑡
𝑓𝑎 ≤ 𝑓𝑡
𝑓𝑎 ≤ 𝑓𝑐

Where

1 𝐸 𝑡
𝑓𝑐 (𝑝𝑒𝑟𝑚𝑖𝑠𝑠𝑖𝑏𝑙𝑒) = ( )∗( ) ∗ ( ) 18.
12 1/2 𝐷𝑜
(3 ∗ (1 − 𝜇 2 ))
2

Where,

𝐸 = Modulus of elasticity
𝜇 = Poisson’s ratio
𝐷0 = The outside diameter of the vessel

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Panchal Manish Kumar S U19CH071

STEPS FOR HEAD DESIGN

𝑆𝑓 = Length of straight flange
𝑡ℎ = Thickness of head
∗ 𝑆𝑓 = 3*𝑡ℎ (if 3*𝑡ℎ > 20)
𝑆𝑓 =20mm (if 3*𝑡ℎ < 20)

IF HEAD ARE SUBJECTED TO INTERNAL PRESSURE

There are 5 types of head are being used according to the stress value.

FLAT HEAD
Flat heads are often used as manhole covers in low pressure vessel and small-bore openings.

3 𝑅 2 3 𝐷 2
𝑓= ∗𝑝∗( ) = ∗𝑝∗( ) 19.
4 𝑡 16 𝑡

𝑝
𝑡ℎ = 𝐶 ∗ 𝐷 ∗ √ 20.
𝑓

Where

𝐶 = Edge fixing content

𝐷 = Diameter of the plate which is actually under operating pressure (0.4 to 0.7)
𝑝 = Working pressure
𝑓 = Design stress at operating temperature
𝐷
𝑅 = 2

CONICAL HEADS
𝑝∗𝐷
𝑡= 21.
2 ∗ cos(𝛼)
Where

The half apex angle of the cone (no extra attachment required)
𝛼 |degree If it exceeds 30°, a provision has to be added made taking knuckle.
(𝑅1 = 0.1 ∗ 𝐷𝑖)

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Panchal Manish Kumar S U19CH071

N
𝑝| Design pressure
mm2

SHALLOW DISHED HEAD AND TORI-SPHERICAL HEAD

𝑝 ∗ 𝑅𝑐 ∗ 𝑊
𝑡ℎ = 22.
2∗𝑓∗𝐽
1
1 𝑅𝑐 2
𝑊 = ∗ (3 + ( ) ) 23.
4 𝑅1

Where

𝑅𝑐 | 𝑚𝑚 = crown radius (generally equal to the Di)

𝑊 = stress intensification factor
𝑅1 | 𝑚𝑚 = Knuckle radius (Generally 6% of the Di)
∗ = Preferable for the pressure between 2 to 15 atm

ELLIPTICAL HEAD (SEMI-ELLIPSOIDAL)

𝑝𝐷𝑉
𝑡ℎ = 24.
2𝑓𝐽
Where

𝑉 = stress intensification factor = 1 ∗ (2 + 𝑘 2 )

6

𝐾 = 𝐾 = 𝑚𝑎𝑗𝑜𝑟 𝑎𝑥𝑖𝑠 Common value of K is 2 and shouldn’t be more than 2.6

𝑚𝑖𝑛𝑜𝑟 𝑎𝑥𝑖𝑠

∗ = Preferable for the pressure between 10 to 30 atm

HEMISPHERICAL HEAD
𝑝𝐷 𝑝𝐷𝑖 𝑝𝐷𝑜
𝑡ℎ = = = 25.
4𝑓𝐽 4𝑓𝐽 − 𝑝 4𝑓𝐽 + 𝑝

∗ = preferable for the pressure more than 30 atm

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Panchal Manish Kumar S U19CH071

STEPS FOR NOZZLE DESIGN

Nozzle are the openings provided in vessel to satisfy certain requirement such as inlet or outlet
connection, man-hole, hand-hole, vents and drains.

Nozzle formed from sheet or directly formed by extrusion process and thickness of nozzle can
be calculate as similar to shell.

𝑝𝐷 𝑝𝐷𝑖 𝑝𝐷𝑜
𝑡= = = 26.
2𝑓𝐽 2𝑓𝐽 − 𝑝 2𝑓𝐽 + 𝑝

DESIGN OF REINFORCEMENT
There are three methods to design reinforcement

1. Area to area method

2. Controlled maximum stress method
3. Experimental yield method

AREA TO AREA METHOD

Maximum horizontal distance AB = 4∗𝑟 =2∗𝑑

Maximum vertical distance AD = 6 ∗ 𝑡 𝑜𝑟 3.5 ∗ 𝑡𝑠 + 2.5 ∗ 𝑡𝑠
Area for which reinforcement required A = 𝑡𝑠 ∗ 𝑑
Compensation is only provided by nozzle 𝐻1 = 2.5 ∗ 𝑡𝑠
Compensation is only provided by nozzle and 𝐻1 = 2.5 ∗ 𝑡𝑛
reinforcement
Area provided by head/shell‘s extra thickness 𝐴𝑠 = 𝑑 ∗ (𝑡𝑠 − 𝑡 ′ 𝑠 − 𝐶. 𝐴)

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Panchal Manish Kumar S U19CH071

Area provided by nozzle outside the shell/head 𝐴𝑜 = 2 ∗ 𝐻1 ∗ (𝑡𝑛 − 𝑡 ′ 𝑛 − 𝐶. 𝐴)

Area provided by nozzle inside the shell/head 𝐴𝑖 = 2 ∗ 𝐻1 ∗ (𝑡𝑛 − 𝐶. 𝐴)
Additional compensation 𝐴𝑎𝑐 = 𝐴 − 𝐴𝑠 − 𝐴𝑜 − 𝐴𝑖

DESIGN OF FLANGE
SELECTION OF GASKETS
minimum gasket design seating stress According to gasket
𝑌𝑎 | N/mm2
specification
gasket factor 𝑚 According to gasket specification
gasket width N | mm According to gasket specification
gasket inside diameter 𝐺𝑖 |mm 𝐷𝑖 𝑜𝑟 slightly higher
gasket outside diameter 𝐺𝑜 | mm = 𝐺𝑖 + 2 ∗ 𝑁
basic gasket seating width = ( 𝐺𝑜 − 𝐺𝑖 )
𝑏0 |mm
4
effective gasket seating width = 2.5 ∗ √𝑏0 𝑖𝑓 𝑏0 > 6.3
b |mm
𝑏0 𝑖𝑓 𝑏0 < 6.3
diameter of gasket load reaction = (𝐺𝑜 + 𝐺𝑖 )
𝐺 |mm
2

CALCULATION OF BOLTS
permissible tensile stress in bolt under =
𝑓𝑎 |N/mm2
atmospheric condition
permissible tensile stress in bolt under =
𝑓𝑏 |N/mm2
operating condition
minimum bolt load at atmospheric = 𝜋 ∗ 𝑏 ∗ 𝐺 ∗ 𝑌𝑎
𝑊𝑚1 |N
condition
minimum bolt load at Operating = 𝜋 ∗ 2𝑏 ∗ 𝐺 ∗ 𝑚 ∗ 𝑝 + 𝜋 ∗ 𝐺 2 ∗ 𝑝
𝑊𝑚2 |N 4
condition
cross section of bolt at atmospheric = 𝑊𝑚1
𝐴𝑚1 |mm2 𝑓𝑎
condition

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Panchal Manish Kumar S U19CH071

cross section of bolt at operating = 𝑊𝑚2

𝐴𝑚2 |mm2 𝑓𝑏
condition
bolt area provided minimum limit = 2 ∗ 𝜋 ∗ 𝑌𝑎 ∗ 𝐺 ∗ 𝑁
𝐴𝑏 | mm2
𝑓𝑎
Actual bolt area provided should be = 𝐴𝑏 𝑎𝑛𝑑 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑣𝑎𝑙𝑢𝑒
and
between 𝑓𝑟𝑜𝑚 𝐴𝑚1 𝑎𝑛𝑑 𝐴𝑚2

flange permissible stress ff |N/mm2

corrosion allowance CA |mm
number of bold suggested 𝐺(𝑐𝑚)
2.5
number of bold 𝑁𝑏𝑜𝑙𝑡 (User can choose according to requirement)
Nominal diameter of bolt 𝑋 (From bolt specification)
Area offered by one bolt 𝑦|mm2 0.51 ∗ 𝑋 2.09
Total bolt area from above value 𝑦 ∗ 𝑁𝑏𝑜𝑙𝑡
mm2
It must be between 𝑾𝒎 𝒂𝒏𝒅 𝑨𝒃
bolt circle diameter B | mm 𝐺𝑜 + 2𝑋 + 12
bolt pitch 𝜋∗𝐵
𝑁𝑏𝑜𝑙𝑡
bolt pitch / bolt diameter 𝜋∗𝐵
it must be between 3.5 to 5 𝑁𝑏𝑜𝑙𝑡 ∗ 𝑋

flange outside diameter A |mm 𝐵+2∗𝑋

𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑣𝑎𝑙𝑢𝑒
𝑊𝑚 |N
𝑓𝑟𝑜𝑚 𝐴𝑚1 𝑎𝑛𝑑 𝐴𝑚2
𝜋 ∗ 𝐺2 ∗ 𝑝
H
4
𝐵−𝐺
ℎ𝐺
2
1
k 1.5 ∗ 𝑊𝑚 ∗ ℎ𝐺
[0.3 + ]
𝐻∗𝐺
flange face thickness 𝑝
𝑓𝑠 |mm 𝐺∗√ + 𝐶. 𝐴
𝑘𝑓

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Panchal Manish Kumar S U19CH071

DESIGN OF HEAT EXCHANGER

KERN’S METHOD

STEP 1
STEP 2
Heat load 𝑄 = 𝑚 ∗ 𝐶𝑝 ∗ ∆𝑇 27.

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Panchal Manish Kumar S U19CH071

1 shell 2 pass 2 shell 4 pass

(𝑇1 − 𝑡2 ) − (𝑇2 − 𝑡1 ) 28.

∆𝑇𝐿𝑀𝑇𝐷 =
𝑇 −𝑡
ln (𝑇1 − 𝑡2 )
2 1

The usual practice in the design of shell and tube exchangers is to estimate the “true temperature
difference” from the logarithmic mean temperature by applying a correction factor to allow for
the departure from true counter-current flow.

∆𝑇𝑚 = 𝐹𝑡 ∗ ∆𝑇𝐿𝑀𝑇𝐷 29.

The correction factor (Ft ) is a function of the shell and tube fluid temperatures, and the number
of tube and shell passes. It is normally correlated as a function of two dimensionless
temperature ratios.

𝑇1 − 𝑇2 30.
𝑅=
𝑡2 − 𝑡1
𝑡2 − 𝑡1 31.
𝑆=
𝑇1 − 𝑡1

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Panchal Manish Kumar S U19CH071

Temperature correction factor : 1 shell pass , 2 or more even tube pass

Temperature correction factor : 2 shell pass , 4 or more multiple of 4 tube pass

STEP 3
Assume value of overall coefficient Uo,ass

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Panchal Manish Kumar S U19CH071

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Panchal Manish Kumar S U19CH071

STEP 4
Provisional area

𝑄 32.
𝐴𝑡𝑜𝑡𝑎𝑙 =
𝑈𝑜,𝑎𝑠𝑠𝑢𝑚𝑒𝑑 ∗ ∆𝑇

Tube specification (As per chosen tubes)

outside diameter od | mm
inside diameter id | mm
Length L|m
Surface area of one tube 𝐴𝑡𝑢𝑏𝑒 𝜋 ∗ 𝑜𝑑 ∗ 𝐿

Numbers of tubes

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Panchal Manish Kumar S U19CH071

𝐴𝑡𝑜𝑡𝑎𝑙 33.
𝑁𝑢𝑚𝑏𝑒𝑟𝑠 𝑜𝑓 𝑡𝑢𝑏𝑒𝑠 = 𝑁𝑡 =
𝐴𝑡𝑢𝑏𝑒

1 34.
𝑁𝑡 𝐾1
𝐷𝑏 = 𝑑𝑜 ∗ ( )
𝐾1
The value of K1 and n1 are available in this table.

After calculating Bundle diameter, we have to find clearance to calculate Shell diameter

𝐷𝑠 = 𝐷𝑏 + 𝑐𝑙𝑒𝑎𝑟𝑎𝑛𝑐𝑒 35.

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Panchal Manish Kumar S U19CH071

STEP 5
STEP 6: ESTIMATE TUBE- AND SHELL-SIDE HEAT
TRANSFER COEFFICIENT
TUBE-SIDE HEAT TRANSFER COEFFICIENT:
𝑇𝑎𝑣𝑒 𝑜𝑓 𝑡𝑢𝑏𝑒 𝑠𝑖𝑑𝑒 𝑓𝑙𝑢𝑖𝑑 = 𝑡1 + 𝑡2
2
𝑡𝑢𝑏𝑒 𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛 𝑎𝑟𝑒𝑎 𝑎 = 𝜋
∗ 𝑑𝑖 2
4
Since we are using more than one pass for tubes

𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑡𝑢𝑏𝑒𝑠 𝑝𝑒𝑟 𝑝𝑎𝑠𝑠 = 𝑁𝑡

𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑝𝑎𝑠𝑠𝑒𝑠
𝑡𝑜𝑡𝑎𝑙 𝑓𝑙𝑜𝑤 𝑎𝑟𝑒𝑎 = 𝑎 ∗ 𝑛𝑢𝑚 𝑜𝑓 𝑡𝑢𝑏𝑒𝑠 𝑝𝑒𝑟 𝑝𝑎𝑠𝑠
𝑡𝑜𝑡𝑎𝑙 𝑚𝑎𝑠𝑠 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒𝑡𝑢𝑏𝑒 𝑠𝑖𝑑𝑒 𝑓𝑙𝑢𝑖𝑑
𝑡𝑜𝑡𝑎𝑙 𝑓𝑙𝑜𝑤 𝑎𝑟𝑒𝑎
𝑙𝑖𝑛𝑒𝑎𝑟 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 (𝑢𝑡 ) 𝑡𝑜𝑡𝑎𝑙 𝑚𝑎𝑠𝑠 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦
𝜌𝑡𝑢𝑏𝑒 𝑠𝑖𝑑𝑒 𝑓𝑙𝑢𝑖𝑑
ℎ𝑖 Eagle and Ferguson (1930): applicable when water is being used.

4200 ∗ (1.35 + 0.02 ∗ 𝑡) ∗ 𝑢𝑡 0.8 36.

ℎ𝑖 =
𝑑𝑖0.2
Where

ℎ𝑖 = inside coefficient, for water, W/m2 °C

𝑡 = Tube side fluid temperature, °C
𝑢𝑡 = Tube side fluid linear velocity
𝑑𝑖 = Tube inside diameter

ℎ𝑖 ∗ 𝑑𝑖 𝜇 0.14 37.
= 𝑗ℎ ∗ 𝑅𝑒 ∗ 𝑃𝑟 0.33 ∗ ( )
𝑘𝑓 𝜇𝑤
Where

ℎ𝑖 = inside coefficient, for water, W/m2 °C

𝑑𝑖 = tube inside diameter, mm
𝑘𝑓 = fluid thermal conductivity, W/m2 °C

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Panchal Manish Kumar S U19CH071

𝑗ℎ = heat transfer factor, dimensionless can be found using figure below by

𝑳
the value of Ratio
𝒅𝒊

𝑅𝑒 = Reynolds number, dimensionless 𝜌 ∗ 𝑢𝑡 ∗ 𝑑𝑖

𝜇
𝑃𝑟 = Prandtl number, dimensionless 𝐶𝑝 ∗ 𝜇
𝑘𝑓
𝜇 = viscosity of fluid, N s/m2
𝜇𝑤 = viscosity of fluid at wall temperature, N
s/m2

SHELL-SIDE HEAT TRANSFER COEFFICIENT:

Baffle spacing: The baffle spacings used range from 0.2 to 1.0 shell diameters. A close baffle
spacing will give higher heat transfer coefficients but at the expense of higher pressure drop.

Area for cross-flow: calculate the area for cross-flow As for the hypothetical row at the shell
equator, given by:

(𝑝𝑡 − 𝑑𝑜 ) ∗ 𝐷𝑠 ∗ 𝑙𝑏 38.
𝐴𝑠 =
𝑝𝑡
Where

𝑝𝑡 = tube pitch (distance between the centers of two tubes)

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Panchal Manish Kumar S U19CH071

𝑑𝑜 = tube outside diameter, m

𝐷𝑠 = shell inside diameter, m
𝑙𝑏 = baffle spacing, m.
(𝑝𝑡 − 𝑑𝑜 ) = the ratio of the clearance between tubes and the total distance between tube
𝑝𝑡 centers.

𝑊𝑠 = 𝑠ℎ𝑒𝑙𝑙 𝑠𝑖𝑑𝑒 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒

𝑠ℎ𝑒𝑙𝑙 𝑠𝑖𝑑𝑒 𝑚𝑎𝑠𝑠 𝑣𝑒𝑙𝑜𝑠𝑖𝑡𝑦 𝐺𝑠 = 𝑊𝑠
𝐴𝑠
𝑠ℎ𝑒𝑙𝑙 𝑠𝑖𝑑𝑒 𝑙𝑖𝑛𝑒𝑎𝑟 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑢𝑠 = 𝐺𝑠
𝜌
𝑠ℎ𝑒𝑙𝑙 𝑒𝑞𝑢𝑖𝑣𝑎𝑙𝑒𝑛𝑡 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑑𝑒,𝑠𝑞𝑢𝑎𝑟𝑒 𝑝𝑖𝑡𝑐ℎ = 1.27
∗ (𝑝𝑡2 − 0.785𝑑𝑜2 )
𝑑𝑜
𝑠ℎ𝑒𝑙𝑙 𝑒𝑞𝑢𝑖𝑣𝑎𝑙𝑒𝑛𝑡 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑑𝑒,𝑡𝑟𝑖𝑎𝑛𝑔𝑢𝑙𝑎𝑟 = 1.10
∗ (𝑝𝑡2 − 0.917𝑑𝑜2 )
𝑑𝑜
calculate the shell-side heat transfer coefficient hs:

ℎ𝑠 ∗ 𝑑𝑒 𝜇 0.14 39.
= 𝑗ℎ ∗ 𝑅𝑒 ∗ 𝑃𝑟 0.33 ∗ ( )
𝑘𝑓 𝜇𝑤
Where

𝑗ℎ = heat transfer factor, dimensionless can be found using figure below by

baffle cuttings given.

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Panchal Manish Kumar S U19CH071

𝑅𝑒 = Reynolds number, dimensionless 𝜌 ∗ 𝑢 ∗ 𝑑𝑒 𝐺𝑠 ∗ 𝑑𝑒

=
𝜇 𝜇
𝑃𝑟 = Prandtl number, dimensionless 𝐶𝑝 ∗ 𝜇
𝑘𝑓

STEP 7 PRESSURE DROP

Tube side

𝐿 𝜇 −𝑚 𝜌𝑢𝑡2 40.
∆𝑃𝑡 = 𝑁𝑝 ∗ [8 ∗ 𝑗𝑓 ( ) ∗ ( ) + 2.5] ∗
𝑑𝑖 𝜇𝑤 2
Shell side

𝐷𝑠 𝐿 𝜇 −0.14 𝜌𝑢𝑡2 41.

∆𝑃𝑡 = 8 ∗ 𝑗𝑓 ∗ ( )∗( )∗( ) ∗( )
𝑑𝑒 𝑙𝑏 𝜇𝑤 2

STEP 8
𝑑 42.
1 1 1 𝑑𝑜 ln ( 𝑜 ) 𝑑 1 𝑑𝑜 1
𝑑𝑖 𝑜
= + + + ∗ + ∗
𝑈𝑜 ℎ𝑜 ℎ𝑜𝑑 2𝑘𝑤 𝑑𝑖 ℎ𝑖𝑑 𝑑𝑖 ℎ𝑖

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Panchal Manish Kumar S U19CH071

DESIGN OF DISTILLATION COLUMN

SHELL DESIGN
SHELL THICKNESS
𝑃 ∗ 𝐷𝑖 43.
𝑡𝑠 = + 𝐶. 𝐴
2∗𝑓∗𝐽−𝑃

HEAD DESIGN
Mostly hemispherical heads are being used.

𝑃 ∗ 𝐷𝑖 44.
𝑡ℎ =
4∗𝑓∗𝐽

SHELL THICKNESS AT DIFFERENT HEIGHTS

The thickness of the shell calculated as above is satisfactory up to a certain distance from the
top of the shell. In order to determine the distance x, different types of stresses acting on the
shell are taken into consideration.

AXIAL STRESS DUE TO PRESSURE:

𝑃 ∗ 𝐷𝑖 45.
𝑓𝑎𝑝 =
4 ∗ (𝑡𝑠 − 𝐶. 𝐴)

STRESSES DUE TO DEAD LOADS:

Compressive stress due to weight of shell up to a distance x.

𝜋
𝑤𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑠ℎ𝑒𝑙𝑙 ∗ (𝐷𝑜2 − 𝐷𝑖2 ) ∗ 𝜌𝑠ℎ𝑒𝑙𝑙 ∗ 𝑔 ∗ 𝑋 46.
𝑓𝑎𝑠 = = 4
𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝑡ℎ𝑒 𝑠ℎ𝑒𝑙𝑙 𝜋 2 2
4 ∗ (𝐷𝑜 − 𝐷𝑖 )

Compressive stress due to weight of insulation at height x.

𝑤𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑖𝑛𝑠𝑢𝑙𝑎𝑡𝑖𝑜𝑛 𝑝𝑒𝑟 𝑢𝑛𝑖𝑡 ℎ𝑒𝑖𝑔ℎ𝑡 ∗ 𝑋 𝜋 ∗ 𝐷𝑖𝑛𝑠 𝑡𝑖𝑛𝑠 ∗ 𝜌𝑖𝑛𝑠 ∗ 𝑔 ∗ 𝑋 47.

𝑓𝑖𝑛𝑠 = =
𝜋 ∗ 𝐷𝑚 ∗ (𝑡𝑠 − 𝐶. 𝐴) 𝜋 ∗ 𝐷𝑚 ∗ (𝑡𝑠 − 𝐶. 𝐴)

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Panchal Manish Kumar S U19CH071

Compressive stress due to weight of the liquid in the column up to a height x.

𝑥 − 𝑡𝑜𝑝 𝑐ℎ𝑎𝑚𝑏𝑒𝑟 ℎ𝑒𝑖𝑔ℎ𝑡 48.

𝑓𝑡 = ( + 1) ∗ 𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝐿𝑖𝑞𝑢𝑖𝑑
𝑡𝑟𝑎𝑦 𝑠𝑝𝑎𝑐𝑖𝑛𝑔

Stress due to weight of attachments.

𝜋 49.
𝑤𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑠ℎ𝑒𝑙𝑙 = ∗ (𝐷𝑜2 − 𝐷𝑖2 ) ∗ 𝜌 ∗ 𝑔 ∗ ℎ
4
ℎ = 𝑛𝑢𝑚 𝑜𝑓 𝑡𝑟𝑎𝑦 ∗ (𝑡𝑟𝑎𝑦 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 + 𝑡𝑟𝑎𝑦 𝑠𝑝𝑎𝑐𝑖𝑛𝑔𝑠) + 𝑡𝑜𝑝 50.
+ 𝑏𝑜𝑡𝑡𝑜𝑚 𝑐ℎ𝑎𝑚𝑏𝑒𝑟 ℎ𝑒𝑖𝑔ℎ𝑡
𝑤𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑎𝑡𝑡𝑎𝑐ℎ𝑚𝑒𝑛𝑡 𝑎𝑛𝑑 ℎ𝑒𝑎𝑑 = 0.1 ∗ 𝑤𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑠ℎ𝑒𝑙𝑙 51.
𝑤𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑣𝑒𝑠𝑠𝑒𝑙 52.
𝑓𝑎𝑡 =
𝜋 ∗ 𝐷𝑖 ∗ (𝑡𝑠 − 𝐶. 𝐴)

Total compressive dead weight stress upto height x.

𝑓(𝑐𝑜𝑚) = 𝑓𝑎𝑠 + 𝑓𝑖𝑛𝑠 + 𝑓𝑡 + 𝑓𝑎𝑡 53.

STRESS DUE TO WIND LOAD(FW):

1.4 ∗ 𝑃𝑤 ∗ 𝑥 2 54.
𝑓𝑤 =
𝜋 ∗ 𝐷𝑜 ∗ (𝑡𝑠 − 𝐶. 𝐴)

DETERMINATION OF VALUE OF X
𝑓𝑤 − 𝑓(𝑐𝑜𝑚) + 𝑓𝑎𝑝 − 𝑓(𝑎𝑙𝑙) = 0 55.

SKIRT DESIGN
Stress due to dead weight

∑𝑊 56.
𝜋 ∗ 𝐷𝑜 ∗ 𝑡𝑠𝑘

Stress due to wind load

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Panchal Manish Kumar S U19CH071

𝐻 57.
(𝑘 ∗ 𝑝𝑤 ∗ 𝐻 ∗ 𝐷𝑜 ) ∗ 2
𝜋 ∗ (2)2 ∗ 𝑡𝑠𝑘
Choose the thickness of skirt 𝑡𝑠𝑘 so that below condition satisfy.

𝑓𝑐 (𝑝𝑒𝑟𝑚𝑖𝑠𝑠𝑖𝑏𝑙𝑒) > (𝑠𝑡𝑟𝑒𝑠𝑠 𝑑𝑢𝑒 𝑡𝑜 𝑑𝑒𝑎𝑑 𝑤𝑒𝑖𝑔ℎ𝑡 − 𝑠𝑡𝑟𝑒𝑠𝑠 𝑑𝑢𝑒 𝑡𝑜 𝑤𝑖𝑛𝑑 𝑙𝑜𝑎𝑑)

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Panchal Manish Kumar S U19CH071

STORAGE TANK
𝑃 ∗ 𝐷𝑖 58.
𝑡𝑠 = + 𝐶. 𝐴
2∗𝑓∗𝐽

𝑁 59.
𝑝 = 𝜌 ∗ 𝑔 ∗ (𝐻 − 0.3) ∗ 10−6
𝑚𝑚2

Number of plates required for width (portion of height) of storage tank.

𝐶𝑖𝑟𝑐𝑢𝑚𝑓𝑒𝑟𝑒𝑛𝑐𝑒 𝜋∗𝐷 60.

= =
𝐿𝑒𝑛𝑔𝑡ℎ 𝐿𝑒𝑛𝑔𝑡ℎ
Example

27