Mechanical Design of Shell and Tube Heat Exchangers and Its Challenges and Its Latest Trends

9. DESIGN PROBLEM

150000 lb per hour of kerosene will be heated from 75 to 120F by cooling a gasoline
stream from 160 to 120F. Inlet pressure will be 50 psia for each stream and the
maximum pressure drop of 7 psi for gasoline and 10 psi for kerosene are permissible.
Published fouling factors for oil refinery streams should be used for this application.
Design a shell and tube heat exchanger for this service.

PART 1: THERMAL DESIGN:

Given data:

Hot fluid inlet temperature (T1)= 160F

Hot fluid outlet temperature (T2) = 120F
Cold fluid inlet temperature (t1) = 75F
Cold fluid outlet temperature (t2) = 120F
Fouling factor of hot fluid (Rdg) = 0.0005 (for gasoline)
Fouling factor of cold fluid (Rdk) = 0.001 (for kerosene)

Pinlet (for hot fluid) = 50 psia

Pinlet (for cold fluid) = 50 psia
pmax (for hot fluid) = 7 psi
pmax (for cold fluid) = 10 psia
Mass flow rate of cold fluid (mk) = 150000 lb.h-1
(Subscripts k for kerosene and g for gasoline) k m.

I. Calculation of caloric temperature

For the calculation of caloric temperature

API of hot fluid=76;

Therefore Kc = 1; Fc = 0.455

Sinhgad Institute of Technology, Lonavala, M. E. (Mechanical) (Design Engineering)

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Mechanical Design of Shell and Tube Heat Exchangers and Its Challenges and Its Latest Trends

(The caloric temperature factor, Fc with API as a function Kc is available in reference)

Caloric temperature of the hot fluid,

=120+0.455(160-120)
=138.2F

Caloric temperature of the cold fluid,

=75+0.455(120-75) =95.475F

II. Fluid properties at caloric temperature

Viscosity:
76API gasoline, g=0.2cp (0.484 lb.ft-1.h-1)
46API kerosene, k =1.6 cp (3.872 lb.ft-1.h-1)

Density:
g=685 kg.m-3 (42.7 lb.ft-3)
k=800 kg.m-3 (49.8 lb.ft-3)

Thermal conductivity:
kg=0.075 Btu h-1ft-1 F-1
kk=0.083 Btu h-1ft-1 F-1

Specific heat capacity:

Cg = 0.57 Btu lb-1ft-1
Ck = 0.48 Btu lb-1ft-1

Specific gravity:
Sg = 0.685
Sk = 0.80

Sinhgad Institute of Technology, Lonavala, M. E. (Mechanical) (Design Engineering)

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Mechanical Design of Shell and Tube Heat Exchangers and Its Challenges and Its Latest Trends

III. Energy balance

Assume no heat loss to the surrounding.

IV. Calculation of heat transfer area and tube numbers

Assumptions:
Fixed tube plate type
1 OD tubes (14 BWG) on 1 square pitch (PT)
Tube length (Lt) = 24 (the tube length is increased from 16)
1 shell pass-6 tube pass (tube passes is increased to 6 from 2)
Tube ID=0.834
Flow area per tube=0.546 inch2

No. of tubes:

n t = 368 is taken corresponding to the closest standard shell ID of 31 for fixed tube
sheet, 1-shell and 6-tube pass exchanger with 1 tube OD on 1 square pitch.

Sinhgad Institute of Technology, Lonavala, M. E. (Mechanical) (Design Engineering)

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Mechanical Design of Shell and Tube Heat Exchangers and Its Challenges and Its Latest Trends

Fluid velocity:

= 12945.15 ft/h (3.59 ft/s) = 1.04 m/s

(So the design velocity is within the acceptable range).

V. Determination of heat transfer co-efficient Tube side heat transfer co-efficient

(hi):

Shell side heat transfer co-efficient (ho):

Assumptions:
25% cut segmental baffles
Baffles spacing, B= 0.5DS=15.5 (half of the shell ID is selected)

Sinhgad Institute of Technology, Lonavala, M. E. (Mechanical) (Design Engineering)

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Mechanical Design of Shell and Tube Heat Exchangers and Its Challenges and Its Latest Trends

C= Tube clearance =PT - do =1 -1=0.25

jH=110 for the shell side fluid at Re=35668 with 25% cut segmental baffles

Sinhgad Institute of Technology, Lonavala, M. E. (Mechanical) (Design Engineering)

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Mechanical Design of Shell and Tube Heat Exchangers and Its Challenges and Its Latest Trends

Overall heat transfer co-efficient (U o,cal ):

Fouling factor, Rdk=0.001 h ft2 F Btu-1 for kerosene and Rdg= 0.0005 h ft2 F Btu-1
for gasoline is taken for this service.

Therefore, the calculated overall heat transfer co-efficient is well within the design
criteria.

VI. Pressure drop calculation VI.1. Tube side pressure drop:

Sinhgad Institute of Technology, Lonavala, M. E. (Mechanical) (Design Engineering)

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Mechanical Design of Shell and Tube Heat Exchangers and Its Challenges and Its Latest Trends

Therefore the tube side pressure drop is within the maximum allowable pressure
drop of 10 psi.

Sinhgad Institute of Technology, Lonavala, M. E. (Mechanical) (Design Engineering)

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Mechanical Design of Shell and Tube Heat Exchangers and Its Challenges and Its Latest Trends

Therefore the shell side pressure drop is within the maximum allowable pressure
drop of 7 psi.

The required heat transfer area (where, t n =335):

Sinhgad Institute of Technology, Lonavala, M. E. (Mechanical) (Design Engineering)

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Mechanical Design of Shell and Tube Heat Exchangers and Its Challenges and Its Latest Trends

Part 2: Mechanical design

The minimum information required for the mechanical design of some important
components of shell and tube exchanger is summarized below:

a. Shell side and tube side passes: 1 shell pass and 6 tube passes.

b. Number, type, size, and layout of tubes: Number of tubes 318; tube length 20
(6.096 m as per IS: 4503-1967 and IS:2844-1964 standards); tube OD 1 (25.4 mm);
tube ID: 0.834 (21.2 mm); square pitch (=141"); fixed tube sheet.

c. Shell diameter and head: Shell ID 31 (787.4 mm); torispherical head is

selected;carbon steel for both shell and head.

d. Corrosion allowance: Corrosion allowance of 3 mm for carbon steel is taken as per

IS:4503 for the service in the petroleum industries.

e. Design temperature and pressure: design temperature 1.1160=176F (80C) (10%

greater than the highest process fluid temperature is taken); design pressure 0.38
N/mm2 (55 psia) (10% higher than the inlet pressure of both the streams).

f. Permissible stress, =100.6 N/mm2 for carbon steel.

Sinhgad Institute of Technology, Lonavala, M. E. (Mechanical) (Design Engineering)

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Mechanical Design of Shell and Tube Heat Exchangers and Its Challenges and Its Latest Trends

i. Shell thickness calculation

ii. Torispherical head

Sinhgad Institute of Technology, Lonavala, M. E. (Mechanical) (Design Engineering)

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Mechanical Design of Shell and Tube Heat Exchangers and Its Challenges and Its Latest Trends

iii. Channel cover thickness

iv. Tube sheet thickness

The tube sheet thickness is calculated based on the bending and considering the design
pressure only. It is assumed that shear does not control the design. Carbon steel is used
for tube sheet material.

=1 for fixed tube sheet; =0.5 (square pitch)

=22.8 mm (satisfies the IS:4503 specification for 1 outside diameter tube)

vi. Nozzle thickness ()

Use carbon steel for the nozzle (same material)

Considering diameter of nozzle ( ) to be 203.2 mm (8 inch)

=0.8

Use 6 mm thickness including the corrosion allowance.

The pressures at the entry point of both shell side and tube fluid are same.
Therefore, the same nozzle specification can be used for tube side fluid also.

Sinhgad Institute of Technology, Lonavala, M. E. (Mechanical) (Design Engineering)

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Mechanical Design of Shell and Tube Heat Exchangers and Its Challenges and Its Latest Trends

vii. Design of gaskets

Gasket factor =3.75, minimum design seating stress Y= 5.35 kgf/mm2 (for flat iron
jacketed, asbestos fill)

Flange thickness

Sinhgad Institute of Technology, Lonavala, M. E. (Mechanical) (Design Engineering)

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Mechanical Design of Shell and Tube Heat Exchangers and Its Challenges and Its Latest Trends

Summary of Mechanical Calculations:

1. Shell Thickness: 8 mm
2. Torispherical Head Thickness: 8 mm
3. Channel Cover Thickness: 22.8 mm
4. Nozzle Thickness: 6 mm
5. Gasket Width : 17 mm
6. Flange Thickness: 56.4 mm
7. Number of tubes and dia: 368 and 25.4 mm.

(Reference: Kuppan T. Heat Exchanger Design Handbook, Marcel Dekker, Inc. 2000,
New York.)

Sinhgad Institute of Technology, Lonavala, M. E. (Mechanical) (Design Engineering)

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