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Shell and Tube Heat Exchanger Data
Sheet Description
Gas Exhasut
Cooler
Operating Data
Type TEMA AES Removable tube bundle, split clamp-ring floating head
Configuration Horizontal, with condensation in the shell, and cooling medium in
the tubes.
Heat transfer area 2
1.6828 m
Performance of one unit
Shell-side Tube-side
Fluid circulating Reaction Gases water
Total fluid 0.15 kg 0.39 kg
circulating s s
Material of Stainless Steel, type 304 Stainless Steel, type 304
construction
Type TEMA Type E Plain, seamless
No. of passes 1 2
Pressure drop 83.04kPa 0.12kPa
In Out In Out
Vapor Yes Yes Yes Yes
Temperature 440C 140C 30C 60C
Construction of one shell
Design Pressure 111.4575 kPa
Design Temperature 511.315C
Tube
BWG Outside Thickness Length Pitch Pitch type No. of
diameter tubes
14 25.41 mm 2.11 mm 1.8293 m 31.80 Square 12
mm
Shell
Tube sheet Floating Head
Shell cover type Standard Torispherical Head
Inside diameter Shell thickness Shell cover Channel cover Tube sheet
thickness thickness thickness
0.2033m 3.2 mm 3.2 mm 4.0748 mm 3.3296 mm
Baffle
Type Percent cut Spacing No. of baffles
Single segmental 45% 0.1016 m 17
Q=49.50 kW
kg
mass of cooling water , mw =0.3948
s
T 1 =440 C
T 2 =140C
t 1 =30C
t 2 =60 C
( T 1t 2 )(T 2t 1 )
T lm=
T 1t 2
ln ( )
T 2t 1
( 44060 )(14030)
T lm=
44060
ln ( )
14030
T lm=217.7962 K
t 2t 1 6030
S= = =0.0732
T 1t 1 44030
Correction Factor:
Ft =F ( R , S )=0.96
T m=F t T lm
T m=0.96 ( 217.7962 )
T m=210.1301 K
Q
A=
U 0, assumed T m
A=
( 49.50 kW ) ( 1000W
1 kW )
W
( 140
m2 K )
( 210.1301 K )
2
A=1.6828 m
at = ODt Lt
at = ( 0.02541m ) ( 1.8293m )
at =0.1460 m 2
Number of Tubes:
A 1
nt =( ) no . of shell passes )
( at
1.6828 m2
nt =(0.1460 m2 )( )1
1
=11.53
nt 12
N t 12 tubes
K 1=0.156
n1=2.291
1
N
D bundle =ODt t
K1 ( ) n1
1
12
D bundle =( 0.02541 ) ( 0.156 ) 2.291
D bundle =0.1691 m
D b 0.1691 m
N r , c= = =5.32
Pt 0.0318
N r , c 6 tubes
Baffle spacing:
45 % baffle cut
B=0.5 ID s=0.5 ( 0.2033 m )
Number of baffles:
Lt
=nB +1
B
Where:
Lt
=no . of the flow crosses the tubebundle
B
Lt 1.8293
n B= 1= 1
B 0.1016
n B=17 baffles
Check:
B n B= ( 0.1016 m) ( 17 baffles )=1.7276 m<1.8293 m(Tube Length)
Where:
W
hi=inside ceofficient for water [ ]
m2
t=water temperature []
m
ut =water velocity[ ]
s
t 1 +t 2 303.15+333.15
t= =
2 2
t=318.15 K
Water
Density kg
991.2546
m3
Viscosity kg
0.0007
m s
Thermal Conductivity W
0.6304
m K
Specific Heat Capacity kJ
4.1833
kg K
Tube cross-sectional area:
A t ,c = ( IDt )2= ( 0.02118 mm )2
4 4
A t ,c =0.0003523 m2
Nt 12
nt , p= =
no . of tube passes 2
nt , p=6 tubes
A t ,total=n t , p At ,c =6 ( 0.0003523 m 2 )
A t ,total=0.0021139 m2
kg
0.39484
m s
Gt = w =
At ,total 0.0021139 m2
kg
Gt =186.7809 2
m s
kg
186.7809
G 2
m s
ut = t =
w kg
991.2546 3
m
m
ut =0.1884
s
kg
=
Gd
=
(
t
186.7809
e m s)
( 0.02118 m )
2
w kg
0.0007
m s
=6,022.84
Lt 1.8293
=
ID s 0.02118
Lt
=86.37
ID s
Tube-side coefficient:
W
hi=1350.0954
m2
Where:
Qg sensible heat
Z= =
Q T tot heat transfer
T 1 +T 2 713.15+413.15
T= =
2 2
T =563.15 K
kg
W s =0.1452
s
C=0.006352 m
A s =0.004131 m2
kg
Gs=35.1471
m2 s
m
us =67.9880
s
1.27
de= ( 0.031820.785 ( 0.02541 )2 )
0.02541m
d e =0.0251 m
=
G d
=
(
s
35.1471
e m s)
( 0.0251 m )
2
kg
0.000177444
m s
=4,969.09
Tube loading:
Condensate flow per unit length of tube
kg
h=
Wc
=
( 0.0097 )
s
Lt N t ( 1.8293 m )( 12 )
kg
h=0.000442
m s
[
L ( L v ) g
]( )
1
' 3 1
h =0.95 k L
c
6
L h Nr
2 2
N r = N r , c = ( 6 )=4
3 3
1 1
'
h =0.95 0.0999
c (
m K ) kg kg ()
4
6
(
0.00242
ms )(
0.000442
m s )
W
h'c =1825.3371
m2 K
[( ) ( ) ]
0.2
c 2
3
d e Gs
k
J kg
h'g=
(
0.023 879.70
kgK)(
35.1471 2
m s )
[( )]
2 0.2
)( (
kg
( 879.70
J
kgK )(
0.000177444
kg
m s ) 3
(
( 0.0251 m ) 35.1471
m2 s )
W kg
0.01396
m K 0.000177444
m s )
W
h g=25.9201 2
m K
Shell-side coefficient:
W
ho =206.3761 2
m K
Estimate:
W
tube wall material thermal conductivity , k w =16
m
W
outside dirt coefficient , hod =5000
m2
W
inside dirt coefficient , hid=6000 2
m
ODt
ODt ln
( )ID t
1 1 1
= + +
U o ho hod 2 kw
+
[ OD t 1
IDt h id
+
][
OD t 1
IDt hi ]
( 0.02541
( 0.02541 m ) ln
0.02118 ) 0.02541
[ ][
1 1 1 1 0.02541
= + + + +
Uo W W W 0.02118 W 0.02118
206.3761 5000 2 ( 16 ) 6000
m2 K m2 K 2
mK m K
W
U o , calc=159.2763 2
m K
%Error=
[ 159.2763140
140
100
]
%Error=13.77
PERCENT OVERSURFACE
oversurface=
[ U C U o , calc
UC
100
]
Where:
U C =cleanoverall heat transfer coefficient
IDt
hio =h i
OD t
W 0.02118m
hio =1350.0954
m K 0.02541m
2
hio =1125.50
Calculating for U C
ho hio
U C=
ho +hio
W
U C =174.3978 2
m K
174.3978159.2763
oversurface= 100
174.3978
oversurface=8.67
overdesign=
[( A A reqd
A reqd ) 100
]
Design area ( N t =12 )
A= OD t Lt N t
A= ( 0.02541 m )( 1.8293 ) ( 12 )
A=1.7521 m 2
A reqd = ODt Lt N t
A reqd =1.6061 m2
overdesign= ( 1.75211.6061
1.6061 ) 100
overdesign=9.09
u 2t
[ ( ) ]( )
Pt =N p 8 j f
L
ID t
+2.5
2
Water
Density kg
991.2546
m3
Viscosity kg
0.0007
m s
Linear velocity m
0.1884
s
Reynolds number 6,022.84
(] ( )
kg m
)(
991.2546 3 0.1884
s )
[
Pt =2 8 ( 0.0014 ) ( 1.8293
0.02118 )
+2.5
m
2
Pt =122.03 Pa
Pt =0.12 kPa
{ ( )( )( )( ) }
ID s Lt u2s 0.14
Ps = 8 j f
de B 2 w
Shell-side
Equivalent diameter 0.0251 m
Baffle spacing, B 0.1016 m
Density kg
0.51696 3
m
Viscosity kg
0.000177444
m s
Linear velocity m
67.9880
s
Reynolds number 4,969.09
45 % baffle cut
j f =0.06
{ )}
2
(
kg m
0.2033 m 1.8293 m ( 0.51696
m3)( 67.9880
s )
Ps = 8 ( 0.06 ) ( )(
0.0251 m 0.1016 m ) 2
(1)
Ps =83,635.68 Pa
Ps =83.64 kPa
{ }
1
For water:
kg kJ
(
C c =mc Cp c = 0.394844
s )
4.1833
kg K
kW
C c =1.6518 =Cmax
K
Capacity ratio:
C min
Capacity Ratio, C r=
C max
1.0829
Cr =
4.8527
Cr =0.0799
[(
d i=R c R c
ID s
2 )(
R c+
ID s
2 )
+2 Rk ]
Where:
Rc =ID s=203.2520 mm
Rk =0.06 R c =12.1951mm
0.5
[(
d i=203.2520 203.2520
203.2520
2
203.2520+
203.2520
2 )( )
+2 ( 12.1951 )
]
d i=27.1613 mm
Leff =1.8836 m
Area effective:
A e = ODt Leff N t = ( 0.02541m ) (1.8836 m ) ( 12 )
A e =1.8041 m2
NTU =
( 159.2763
m K)
2
( 1.8041m )2
NTU =2.173
Effectiveness:
=85. 00
Shell Tube
Material of construction Stainless Steel, type Stainless Steel, type
304 304
Allowable stress (Design 110 MPa
stress)
Design pressure:
Take as 10 percent above operating pressure
Design temperature:
Take as 10 percent above operating temperature
SHELL DESIGN
Shell thickness:
For a cylindrical shell, the minimum thickness required to resist internal
pressure can be determined from the equation below based on the maximum
allowable stress and corrected for welded joint efficiency:
P' IDs
e=
2 Jf P'
Where:
f =design stress
e=0.1472 mm
e 3.2 mm
OD s=203.2520 mm+3.2 mm
OD s=206.4520 mm
Where:
C s=stress concentration factor
Rc =crown radius
C s=
1
4( )
3+
Rc
Rk
Where:
Rk =knuckle radius
Let:
Rc =ID s=203.2520 mm
Rk =0.06 R c =12.1951mm
For formed domed heads (no joints in the head), joint factor J =1.0
C s=
1
4(
3+
203.2520
12.1951 )
C s=1.7706
e sh =0.1822 mm
e sc 3.2mm
d C 1 P
'
t cc =
10 f
Where:
t=thickness of the channel cover [mm ]
kgf
P' =design pressure [ 2
]
cm
t cc =1.0748 mm
t cc =4.0748 mm
t ts =
F Gp P
3 kf
For the stationary tube sheet in floating type:
F=1
G p=ID s
0.907
k =1 2
Pt
( ) ODt
0.907
k =1 2
0.0318
( 0.02541 )
k =0.4195
t ts =
3
( 1 ) ( 203.2520mm ) ( .1114575 MPa )
( 0.4195 ) ( 110 MPa )
t ts =3.3296 mm
According to IS: 4503, the protection against impingement may not be required
for the services involving non-corrosive, non-abrasive, single phase fluid.
u2< 125
Where:
g
=fluid density [ 3
]
cm
m3 2
(
u2= 991.2546
kg 1000 g
m3
kg
3
100 cm 3 )(
0.4152
m
s )
0.171<125
NOZZLE DESIGN
Use same nozzle material as for shell. The nozzle thickness is calculated from
the stress formula used in the calculation of shell thickness.
D n=2
Nozzle thickness:
25.4 mm
t n=
(
( .1114575 MPa ) 2
1 )
2 ( 0.7 )( 110 MPa ) ( .1114575 MPa )
t n=0.0368 mm
t n 3.2mm
The pressure at the entry point of both shell-side and tube-side fluids is the
same. Therefore, the same nozzle specification can be used for both.
GASKET DESIGN
DOG
D IG
=
Y P' m
Y P' ( m+1 )
Where:
D OG=outside gasket diameter [mm]
m=gasket factor
D IG =203.502 mm
D IG 8.5 216 mm
m=6.50
DOG
D IG
=
18.28( 0.0114 ) ( 6.5 )
18.28( 0.0114 ) ( 6.5+1 )
=1.0003
Therefore,
D OG 10.13 257 mm
Gasket width:
D OGD IG
N=
2
N 35 mm
257+216
G=
2
G=237 mm
35
bo =
2
bo =17.5
b=0.5 17.5
b=2.09 mm
BOLT DESIGN
N
(
W m 1= ( 2.09 mm ) ( 237 mm ) 179.2656
mm2 )
W m1=278,959.70 N
Where:
H= G2 P' (Total hydrostatic end force)
4
N N
4 (
W m2= ( 237 mm )2 .1114575
mm 2 ) (
+2 ( 2.09 mm ) ( 237 mm ) ( 6.5 ) .1114575
mm2 )
W m 2=7171.7 N
The minimum bolt cross sectional area based on the controlling load:
W m1
Am=
f
278,959.70 N
Am=
N
110
mm2
A m =2536 mm2
Bolting data:
Nominal thread diameter M16
Bolt circle diameter Cb 375
Root diameter d br 18
No. of bolts 12
2
A b =3054 mm
References
Chopey, N., & Hicks, T. (2012). Handbook of Chemical Engineering
Calculations. McGraw-Hill book Company.
Incropera, F. (1981). Funamentals of Heat and Mass Transfer. Wiley.
Kern, D. (1965). Process Heat Transfer. Singapore: McGraw-Hill Book
Company.
NPTEL. (n.d.). Chemical Engineering Design. Retrieved from NPTEL:
nptel.ac.in
Perry, R. (2007). Chemical Engineer's Handbook. McGraw-Hill.
Schlunder, E. (1983). Heat Exchanger Design Handbook. Taylor &
Francis.
Sinnot, R. (1993). Coulson & Richardson's Chemical Engineering
Design. Amsterdam: Elsevier.