Shell Diameter:

Bundle diameter:
Db = d0 {Nt/K}1/n
Where,
d o = tube diameter,
Nt = no. of tubes=63
For single pass,
K=0.319 and n=2.142
From which,
Db = 19.05{63/0.319}1/2.142
Db = 224.624 or 225mm.
For clearance if we add 35 mm
Then shell diameter: 260 mm

Tube side Co-efficient:

Mean water temperature= {24+34}/2
= 29 0C
Tube cross-section area= [/4]Di2
Where Di is inside diameter of tube =
15.7mm=0.0157m
Area = 0.0410 m2
Mean velocity = velocity of water/area of tube
= 2.99798/0.0410
= 73 Kg/m2.s

Linear velocity of water= mean velocity/density

of water
= 73/995
= 0.0734 m/s
This velocity is too low
Therefore choose 4-passes
Tube cross-section area = {Nt/np} {/4}Di2
Where np= no. of passes
From which tube cross section area= 0.003050
m2
And
water mean velocity= 2.9978/0.003050
= 982.94 kg/m2.s
And
Linear water velocity= 982.94/995
= 0.98788 m/s

hi=

4200[1.35+ 0.02t ]u0.8

d 0.2

Where,
t = mean water temperature= 290C
u= linear water velocity = 0.98788 m/s
d= i.d. of tube = 15.7 mm

from which
hi = 4627.959 W/m2. 0C
with no. of passes changed,
new Shell diameter = Db = d0 {Nt/K}1/n
where,

K= 0.175 and n=2.285

with these values,

new shell diameter =240 mm, for shell
clearance of 20mm
new shell diameter = 260 mm.

Shell side Co-efficient:

v

l

g
l ( l h ] 1/ 3 N 1 /6

hco =0.926 K l

Calculation of mean temperature of condensate

film:
Let tw = tube wall temperature
Assume, hco = 1700 W/m2 0C,
At steady state,
Heat transfer rate through cold film= Over all
heat transfer
hco *Ac *(tc-tw)

Uc * Ac * (tc-tavg)

Ac on both sides cancels and substituting the

values of
hco = 1700 W/m2 0C

and Uc =525 W/m2 0C

and tavg= (28.453+32)/2 , tc= 76.67 0C

we get tw = 62.6355
therefore, mean temperature of condensate film
= (tc+tw)/2
= (76.67+62.6355)/2 = 69.65 0C
All the physical properties are calculated at this
temperature
Kl = liquid thermal conductivity of mixture
For Butanol it is 0.18 W/m.K
And for MEK it is 0.15 W/m.K
Therefore,
Average thermal conductivity=
KmekxWm+KbutanolxWbutanol
From which,
Kl = 0.16 W/m. K
l = density of liquid condensate = 806 Kg/m3
= density of vapor = 2.97 kg/m3
l = avg. viscosity of condensate liquid
Average viscosity of condensate liquid is
calculated as follows:

1 W of mek W of Butanol
=
+
of mek of butanol

Where,
W is weight fraction of MEK= 0.897 and W of
butanol = 0.103
of MEK and Butanol are 0.16 and 1.2 mNs/m2
Substituting the values
= 0.17569x10-3 kg/m.s

= 0.17569 mNs/m 2

h = horizontal tube loading of condensate per

unit length of tube (kg/m.s)

=

Wc
L Nt

Where Wc = condensate flow Kg/s =640/3600

= 0.177 kg/s
L = length of tube= 1.83m and Nt= no. of tubes
= 63
Substituting
h = 0.0015 Kg/m.s

Nr = average no. of tubes in vertical tube row

= (2/3)Nr
= (2/3) (Db/Pt)
Where, Db= diameter of bundle = 240 mm
and Pt = pitch = 23.8125
Substituting the values we get

Nr = 6.719
Substituting the values in the equation
v

l

g
l ( l h ] 1/ 3 N 1 /6

hco =0.926 K l

co

= 2342.5 W/m2. 0C.

for sub-cooling,
standard value from kern,
hosub= 283.77 W/m2 0C

Overall Heat transfer Co-Efficient:

Overall heat transfer co-efficient can be
calculated from following formula:

hi +

d0 1
d i hid

d
d0 ln 0
di d0 1
1
1
+ +
+
hoc hod
2 kw
di
1
U oc =

Generally for organic vapors,

hod = 10000 W/m2 0C

and

for cooling water hid = 4000 W/m2 0C

as SS-304L is selected:
Kw = 16.3 W/m0C
Substituting the values
U oc =

1
19.05
0.01905 ln
1
1
15.748 19.05
1
19.05
1
+
+
+
x
+
x
2342.5 10000
2 x 16.3
15.748 4627.959 15.748 4000

= 832 W/m2 0C
Hence required area for condensation:
U oc T

Aco =

mc

Qcond

109075.654
832 X 45.725

m2
Required area for sub-cooling:
hi+

d0 1
d i hid

1
hosub

d 0 ln

d0
di

d 1
1
+
+ 0
hod
2 kw
di
1
U osub =

Substituting the values,

hosub= 283.77 and rest values as same
U osub

= 232.70 W/m2 0C
Therefore,

= 2.86

Area required for subcooling=

U osub T

Asub =

mc

16443.88
232.7 X 29.20

= 2.42 m2

Total area = 2.86+2.42

5.28 m2
Here,

A assumed
A calculated

= 6.79/5.28 = 1.2859

i.e. 28.59% extra area is provided which is more

than 10% than required in design.
Therefore we can go with the designed area of
6.79 m .
2

Area calculated for condensation : 4.543 m2

Area calculated for Sub-cooling
m2

: 2.252

Area provided for condensation in excess:

= 2.86+28% of 2.86
= 3.6608 m2
And for sub-cooling,
= 2.42X1.28
=3.0976 m2
Hence compared to total area of 6.79 m2
45.6% of total area should be provided for subcooling.

Assuming that tubes are uniformly distributed in

the cross section of shell,
0.456= { y * D2i}/(/4) D2i
From which y = 0.456 X
y = 0.358
for this value of `y, h/Di = 0.386
hence,
38.6% of shell must be submerged in the pool of
condensate to facilitate sub-cooling.
This can be achieved by providing U-loop seal in
the drain line of condensate.
Therefore,
38.6% of 260 mm = 100 mm height.

Shell side Pressure drop:

Shell side flow area:
As=

( P td o ) B s D s
Pt

X x'

Where,
x = 1-(h/di) =1-0.386=0.618
pt = tube pitch = 23.8125
do = tube O.D.=19.05 mm
Bs = Baffle spacing = 0.260
Ds= Shell I.D. = 0.260

Substituting the values,

As = 0.008355 m2
Shell side velocity = Gs/v
v = 2.79 Kg/m3
Gs =m/As = (658/3600)/0.008355
= 21.8 Kg/m2.s
Therefore,
Shell side velocity = 21.8/2.79
= 7.84 m/s
Equivalent diameter for triangular pitch,
de=

1.1 2
Pt 0.907 d 2o )
(
d0

From which, de = 13.736 mm

G s de

Reynolds number Re =
Substituting value = 0.01
Re= 9790

For 25% baffle cut segment and given Reynolds

no. of 9790
Jf =0.08
P=0.58J f

v u2s
2

( ) ( )( ) ( )
Ds
de

L
Bs

Substituting the values

0.14

 P = 3.987 KPa.

This is the calculated pressure drop on shell side

Tube side Pressure Drop:

Tube side pressure drop can be calculated
for
Pt =N p [ 8 J h

L
d si

( )( )

u 2t
+ 2.5 ]
2

Jh calculation: Re = (d*v*)/
Where, = 995 kg/m3, v = 0.9878 m/s,
d=0.015748m
And = 0.8x10-3
Substituting,
Therefore,

Re = 19337
Jh= 4x10-3

L= 2000 mm, di= 15.748mm, ut = 0.9878 m/s,

Np = 4
Substituting in pressure drop formula,
Pt = 12.680 KPa

FINAL HEAT EXCHANGER DATA:

HEAT EXCHANGER SPECIFICATION SHEET
EQUIPMENT NAME AND TYPE: MEK CONDENSER AND SHELL AND TUBE (FIXED-TUBE SHEET)
SERVICE: CONDENSING AND SUB-COOLING OF MEK AND BUTANOL VAPORS GENERATED FROM REACTOR IN
PRESENCE OF HYDROGEN AS A NON-CONDENSIBLES

FLUID PROPERTIES DATA:

FLUID STATE
TEMPERATURE IN (OC)

SHELLSIDE
VAPOR

TUBESIDE
LIQUID

157.5 0C

24 0C

TEMPERATURE OUT (OC)

320C

340C

DENSITY (KG/M3)

2.97

995

VISCOSITY (Kg/m.s)

0.17569x10-3

SENSIBLE HEAT (J/KG/OK)

LATENT HEAT (KJ/KG)
PROCESS DATA:
HEAT DUTY (KW)
FLOW RATE (KG/HR)
PRESSURE DROP (KPA)

1.984

0.001

4.1868

432.78
SHELLSIDE
125.519

TUBESIDE
-

658

10792.72

3.987

12.680

TUBE VELOCITY (M/S)

CONSTRUCTION DATA:
HEAT TRANSFER AREA (M2)

6.79

NUMBER OF TUBES/SHELL

63

TUBE OUTSIDE DIAMETER (MM)

19.05

TUBE BWG NUMBER

16

TUBE LENGTH (METER)

1.83

TUBE PITCH AND ORIENTATION

TRIANGULAR

INSIDE SHELL DIAMETER (MM)

260

SHELL MATERIAL

CARBON STEELl

TUBE MATERIAL

STAINLESS STEELl

BAFFLE SPACING (MM)

260 mm

MECHANICAL DESIGN:
Shell thickness:
Shell material is chosen as Carbon steel. And
operating pressure is 1.064X105 N/m2
Therefore design pressure is 10% more than
operating pressure and that comes to 1.11X10 5
N/m2
Pd D

Tsh = 2 fj+ P
Here, Pd= 0.11, D = 260, f = 95 N/m2 ( for
carbon steel) and
J= 0.85 (joint efficiency)
Substituting the values,
Tsh = 0.170 mm
Taking minimum thickness as 6 mm and
corrosion allowance of 2 mm total thickness
comes as 8 mm
Taking standard thickness,
Shell thickness: 10 mm.
Head : (Torrispherical head)
P R c
T h=
W
2 fJ

Where, =

R
1
W = 3+ c
4
Ric

Rc= crown radius = 260 mm

Ric = 6% of crown radius=15.6 mm
With these values W = 1.77
And substituting the values of W and P* of 0.11
N/m2
F=95 and J = 1
We get thickness of head = Th = 0.25 mm
So, same thickness of shell i.e. 10 mm of head is
selected.
Thickness of baffles is selected as a 6 mm
standard.

BAFFLES SPACING:
Segmental baffles are used.
Baffle spacing = = 260/5 =52 mm
Thickness of baffles = 6 mm
Tie rods and spaces
Diameter of tie rod = 10 mm
Number of tie rods = 6
Design of Flanges:
Shell thickness = go = 10 mm

Flange material IS: 2004 1962 class 2

Gasket material asbestos composition
Bolting steel = 5% Cr Mo steel
Allowable stress of flange material 100 MN / m2
Allowable stress of bolting material, Sg 138 MN/m 2
Outside diameter = B = 260 + (2 x 10)
= 280 mm
Gasket width
do / di = [(y- pm)/ (y- p{m+1})] 0.5
m gasket factor 2.75
y min design seating stress 25.5 MN / m2
lets assume Gasket thickness = 1.6 mm
Thus,
do / di = 1.002
Let di of the gasket equal 290 mm [10 mm greater than shell
dia]
do = 0.290 x 1.002.= 0.290.58m=290.58mm

Mean gasket width = (0.290.58 0.290) /2

= 0.29 x 10-4
Taking gasket width of 12 mm,
do = 0.291 m
Basic gasket seating width, bo = 5mm
Diameter of location of gasket load reaction is,
G = di + N
= 0.290 + 0.012
= 0.302m
Estimation of bolt loads
Load due to design pressure:
H = G2 P / 4 = (3.14 x 0.302 x 0.11) / 4
= 0.0260 MN
Load to keep joint tight under operation:
Hp = G(2b)mp
=3.14 x0.302 x 2 x 5 x 10-3 x 2.75 x 0.11
=0.00286 MN

Total load = 0.0260+0.00286

=0.0288 MN
Load to seat gasket under bolting up condition
Wg

Gby

= 3.14x 0.302 x 0.005 x 25.5

=

0.1209 MN

Controlling load

Minimum bolting area

=

0.1209/138

8.76 x 10-4 m2

0.1589 MN
=

Am

Wg/Sg

Lets take M 18 x 2
Root area of bolt = 1.54 x 10-4 m2
Therefore no. bolts required
= 8.76 x 10-4/1.54 x 10-4 =5.689
8 no. of bolts are selected.
R
g1
go

=
=

0.027m
go/0.707

10mm

1.415 g0 for weld leg

Bolt circle diameter,

C

I.D +2(g1+R)

0.260 + 2 (1.415 x 0.010 + 0.027)

0.3423m

Calculation of outside diameter of flange:

A = C + Bolt diameter + 0.02 (minimum)
= 0.3423+0.018+.02
= 0.3641m
Check gasket width:
= (Ag * Sb)/GN
= 8x1.51x10-4 x 138/3.14 x 0.302 x 0.012
= 14.6496
Which is less than 2y (2 x25.5)
Therefore condition is satisfied.
Flange moment computation:
a) For operating condition:
Wo

B2
W 1=
P
4

W1 + W2 + W3

0.280

2
3.14
W 1=

= 0.00676
W2

H-W1

Where H =(/4)G2= 0.785 x 0.3022 =0.07161

W2=

0.07163 0.00676

=
W3

0.0648 MN

=
=

Wo-H

Hp (gasket load)

0.00286 MN

Total flange moment,

Mo = W1a1 + W2a2 + W3a3

a1 = (C-B) / 2

= (0.3423-0.280)/2 = 0.03115

a3 = (C-B) / 2 = (0.3423-0.302)/ 2 = 0.02015

a3 = (a1+a2) /2 = 0.02565
M0 = 2.838 x 10 -4 MJ
b) For bolting up condition (no internal pressure):
Mg = W. a3
W = (Am +Ab)/(2). Sg

Am = area of bolt
= 8 x 1.56 x 10 -4
= 1.248 x 10 -3 m 2
Am = Minimum bolt area. =1.38 x 10 -3 m 2
Sg = 138N/mm 2
Therefore, W = 0.1813 MN
a3 = 0.02015
Mg= 0.1813 x 0.02015
Mg = 3.65 x 10-3 MJ
MG is greater than M0. Therefore Mg is controlling.
Flange thickness :
t2 =

M CY Y
B ST

K = A/B
Where, A = flange outside diameter = 0.3641 m
B = flange inside diameter = 0.280
K = (0.3641/0.280)
= 1.300

From figure given in 7.6

At K value of 1.300, Y = 10
Assume, Cf =1

and M = 3.65 x 10-3 MJ

St = Allowable stress =100MN / m 2

t2 =( 3.65 x 10-3 x 10) / (0.280 x 100)
= 0.0361m
t = 0.074m
Nozzle for condenser:
Total 5 no. of nozzles must be provided for condenser. Two nozzles on
tube side each cooling water supply in and out. 4 No. nozzles are provided
On shell side
Heat exchanger Piping:
Shell side fluid:
Vapor inlet pipe sizing:

Vapor flow rate: 658 Kg/hr.=0.1827 kg/s

g = 2.75 Kg/m3
volumetric flow rate: 658/2.75 = 243.7 m3hr = 0.06769 m3/s.
Optimum pipe size can be calculated from equation:
For stainless steel,

d opt =293 G

0.53

0.37

Where,
Dopt= optimum pipe size
G = Flow rate, Kg/s=0.1827 kg/s
= density of vapor =2.75 kg/m3
Substituting the values,
Dopt= 81.85 mm
Standard of 80 NB (SCH.10) can be used.
Uncondensed vapor:
Flow rate =112.34 kg/hr = 0.0312 kg/s
And for same density of 2.75 kg/m3,
From the above formula,
The pipe size of 25 NB (SCH.10) can be fixed.
Condensate drain line:
Flow rate: 545.66 kg/hr=0.15157 Kg/s
Density of condensate : 807 kg/m3
Substituting the values in the same equation,
The pipe size of 15 NB (SCH.10) is fixed.
Cooling water lines:
Flow rate: 2.99 kg/s
Density: 985 kg/m3
Substituting the values in same equation:

50 NB (SCH.10) line size is fixed The same size of return line can
be used.

As the final process-design stage is Complete, it becomes possible

to make accurate cost estimation because detailed equipment
specification and definite plant facility information are available.
Direct price quotation based on detailed specification can then be
obtained from various manufacturers. However design project
should proceed to the final stages before costs are considered
and cost estimate should be made through out all the early
stages of the design when complete specifications are not
available. Evaluation of costs in the preliminary design is said predesign cost estimation. Such estimation should be capable of
providing a basis for company management to decide if further
capital should be invested in the project. Evaluation of costs in
the preliminary design phase is some time called guesses

estimations. A plant design obviously must present a process that

is capable of operating under condition which will yield a profit.
As the final process-design stage is Complete, it becomes possible
to make accurate cost estimation because detailed equipment
specification and definite plant facility information are available.
Direct price quotation based on detailed specification can then be
obtained from various manufacturers. However design project
should proceed to the final stages before costs are considered
and cost estimate should be made through out all the early
stages of the design when complete specifications are not
available. Evaluation of costs in the preliminary design is said predesign cost estimation. Such estimation should be capable of
providing a basis for company management to decide if further
capital should be invested in the project. Evaluation of costs in
the preliminary design phase is some time called guesses
estimations. A plant design obviously must present a process that
is capable of operating under condition which will yield a profit.