HEAT EXCHANGER ( E-102 )

MECHANICAL DESIGN

3.3.4.2 Mechanical Design for Heat Exchanger

There are some parameters that are required in order to design the mechanical design for heat
exchanger such as the corrosion allowance, shell thickness , operating design for both
temperature and pressure, head and closure, nozzle, weight loads of heat exchanger and also
flange.

a) Material Selection
In industry, there are few materials that have always been used in the industry in order to
design the heat exchanger such as stainless steel304, carbon steel and stainless steel 316.
Each of this material have their owns pros and cons. Table below shows the difference
between this three materials.

Table Comparison Between The Materials

Characteristics Stainless Steel 304 Stainless Steel 316 Carbon Steel
Corrosion  This material  This material  An excellent
Resistance have a good are much corrosion
range the better resistance for
corrosive compared to halogen-free
media and also the stainless inorganic and
range of steel 304 organic
atmospheric  This material compounds
have also an
excellent
corrosion
resistant
Tensile Strength 515 Mpa 516 Mpa 1680 Mpa
(MPa)
Effect  If the  This material are  This material
Temperature temperature much better in can operate at
 increase, the term of effect low pressure and
tensile strength temperature. temperature
will be  If the
decreasing and temperature
the hardness will increase, the
be increasing hardness will be
increase as well
and he tensile
strength will be
decreasing.
Cost The cost for this The cost for this The cost will be in
material is $1000 material is $4000 the range of $300 to
per tonne per tonne $400 per tonne

b) Design Pressure
We have ensure that the heat exchanger to be operates at the maximum pressure where the
design of heat exchanger is assumed to be 10% above the working condition since it is
considered for safety factor in the industry.

Shell side,
𝑃𝑠 = 𝑃𝑜 𝑥 1.1
Where,
Po = Operating Pressure, N/mm2
Ps = Design Pressure at shell side, N/mm2
Pt = Design Pressure at tube side, N/mm2

Operating Pressure, Po = 3.50 bar – 1 = 2.50 bar

Operating Pressure, Po = 0.25 N/mm2
𝑃𝑠 = 𝑃𝑜 𝑥 1.1
𝑁
𝑃𝑠 = 0.25 𝑥 1.1
𝑚𝑚2
𝑁
𝑃𝑠 = 0.275
𝑚𝑚2
 Tube side,
𝑃𝑡 = 𝑃𝑜 𝑥 1.1
𝑁
𝑃𝑡 = 0.250 𝑥 1.1
𝑚𝑚2
𝑁
𝑃𝑡 = 0.275
𝑚𝑚2

c) Design Temperature
The design temperature are based on the strength of the construction material and the
maximum operating temperature of the material should be taking as the consideration in
mechanical design of heat exchanger.

Shell Side,
𝑇𝑠 = 𝑇𝑜 𝑥 1.1
Where,
To = Maximum operating Temperature, °C
Ts = Design Temperature for shell side, °C
Tt = Design Temperature for tube side, °C

The highest operating temperature, To for shell side is 495 °C

By taking a safety factor of 10% ,
𝑇𝑠 = 𝑇𝑜 𝑥 1.1
𝑇𝑠 = 495 𝑥 1.1
𝑇𝑠 = 544.5 °C

Tube side,

The highest operating temperature, To for tube side is 50 °C

By taking a safety factor of 10% ,
𝑇𝑡 = 𝑇𝑜 𝑥 1.1
𝑇𝑡 = 50 𝑥 1.1
𝑇𝑡 = 55 °C
d) Welded Joint Efficiency and Corrosion Allowance

Welded joints are designed in order to meet the strength and also safety requirements where
there are so many factors that need to be considered in designing a welded joint such as the
type and also the quality of the welding since it can affects the strength of the welded joint.
The welde joint factor, J is taken as 1.0 where the joint are as strong as the virgin plate.

Meanwhile, the corrosion allowance are the additional thickness of metal added in order to
allow for material lost by corrosion, scaling and alaso erosion. For both carbon and also low
alloy steel where there are no severe corrosion expected. Therefore, the minimum allowance
for the corrosion is 2.0 mm.

e) Design Stress (Nominal Design Strength)

Design stress can be degined as the allowable maximum stress for any structural that are
subjected in order to exceeding loads or other uncertainties occurs in order to prevent any
failure. Figure below shows the typical design stress for different type of material.

Figure Typical Design Stresses For Different Metal

 Based on the above figure, the design stress for stainless steel 316 at temperature
493.33°C and 50°C is 95N/mm2 and 175N/mm2 respectively.

f) Minimum Practical Wall Thickness

Shell Thickness,

The minimum thickness is important in order to ensure that any vessel is sufficiently rigid in
order to withstand its own weight and also any incidental loads. The following equation are
specified by ASME BPV Code (Sec. VIII D.1 Part UG-27) are used in order to calculates the
minimum thickness.

Shell thickness,

𝑃𝑠𝐷𝑖
𝑡𝑠 =
2𝑆𝐸 − 1.2𝑃𝑖

Where,

Ps = Design pressure at the shell side, N/mm2

Pt = Design pressure at the tube side, N/mm2

S = Maximum allowable stress, N/mm°C

E = Joint efficiency

Di = Shell Diameter

Shell thickness,

0.275 𝐷𝑖
𝑡𝑠 =
2𝑆𝐸 − 1.2𝑃𝑖

𝑡𝑠 =

Adding the corrosion allowance ,

𝑡𝑠 = ⋯ + 2 𝑚𝑚

𝑡𝑠 =
Tube thickness,

𝑃𝑡𝐷𝑖
𝑡𝑡 =
2𝑆𝐸 − 1.2𝑃𝑡

0.275𝐷𝑖
𝑡𝑡 =
2(175)1 − 1.2(0.275)

𝑡𝑡 =

Adding the corrosion allowance ,

𝑡𝑡 = ⋯ + 2 𝑚𝑚

𝑡𝑡 =

g) Head Thickness
There are several types of head that are commonly be found in the industry such as
ellipsoidal head, torispherical head and also hemisperical head. The closest value of the
minimum thickness to the minimum of the shell will be chosen .

Hemispherical Head,

𝑃𝑠𝐷𝑖
𝑡ℎ =
4𝑆𝐸 − 0.4𝑃𝑠

0.275 𝑥 𝐷𝑖
𝑡ℎ =
(4 𝑥 95 𝑥 1) − (0.4 𝑥 0.275)

𝑡ℎ =

Adding the corrosion allowance ,

𝑡ℎ = ⋯ + 2 𝑚𝑚

𝑡ℎ =
Ellipsoidal Head,

𝑃𝑠𝐷𝑖
𝑡𝑒 =
2𝑆𝐸 − 0.2𝑃𝑠

0.275 𝑥 𝐷𝑖
𝑡𝑒 =
(2 𝑥 95 𝑥 1) − (0.2 𝑥 0.275)

𝑡𝑒 =

Adding the corrosion allowance ,

𝑡𝑒 = ⋯ + 2 𝑚𝑚

𝑡𝑒 =

Torispherical Head,

0.885𝑃𝑠𝐷𝑖
𝑡𝑡𝑜 =
𝑆𝐸 − 0.1𝑃𝑠

0.885 𝑥 0.275 𝑥 𝐷𝑖
𝑡𝑡𝑜 =
( 95 𝑥 1) − (0.1 𝑥 0.275)

𝑡𝑡𝑜 =

Adding the corrosion allowance ,

𝑡𝑡𝑜 = ⋯ + 2 𝑚𝑚

𝑡𝑡𝑜 =
 Figure Types of Heads

h) Thickness of Channel Cover

𝐶𝑝𝑃𝑠
𝑡𝑓 = 𝐷𝑖 √
𝑆𝐸

Where,

Cp = Design constant that depend on the edge constraint

Di = Shell diameter, mm

Ps = Design pressure at the shell side, N/mm2

S = Maximum allowable stress, N/mm°C

E = Joint efficiency

𝐶𝑝𝑃𝑠
𝑡𝑓 = 𝐷𝑖 √
𝑆𝐸

𝐶𝑝 𝑥 0.275
𝑡𝑓 = 𝐷𝑖 √
95 𝑥 1
 𝑡𝑓 =

Adding the corrosion allowance ,

𝑡𝑓 = ⋯ + 2 𝑚𝑚

𝑡𝑓 =

i) Loads on Vessel
In order to withstand any kind of failure or problms that might be occur during the operattion
the design of vessel is really important. Design of loads did includes characteristics such as
the vessel shell and tube weights, weights fluid to fill the tubes weights, fluid to fill the
vessel weights and also insulator weights.

Shell Weight ,

𝑊𝑣 = 𝐶𝑤 𝜋𝜌𝑚 𝐷𝑚 𝑔 (𝐿 + 0.8𝐷𝑚)𝑡

Where,

Dm = Shell diameter and shell thickness, m

Cw = Vessel internal fitting (1.08)

L = Length of tube, m (6.1 m)

ρm = Density of vessel material, kg/m3 (8000 kg/m3)

t = The thickness of shell, m

g = Acceleration of gravity (9.81 m/s2)

𝑊𝑣 = 1.08 𝑥 𝜋 𝑥 8000 𝑥 𝐷𝑚 𝑥 9.81 (6.1 + 0.8𝐷𝑚)𝑡

𝑊𝑣 =
Tubes Weight,

𝑊𝑡 = 𝑁𝑡 𝜋 (𝑑𝑜2 − 𝑑𝑖 2 )𝜌𝑚 𝑔

Where,

do = Outer Diameter, m (0.03550 m)

di = Inner Diameter, m (0.026m)

ρm = Density of vessel material, kg/m3 (8000 kg/m3)

Nt = Number of Tube

g = Acceleration of gravity (9.81 m/s2)

𝑊𝑡 = 𝑁𝑡 𝑥 𝜋 𝑥 (0.035502 − 0.0262 ) 𝑥 8000 𝑥 9.81

𝑊𝑡 =

Weight of Fluid to fill shell side,

𝑊𝑠 = 𝜋 𝑟 2 𝐿𝑡 𝜌𝑚 𝑔

Where,

Dm = Shell diameter and shell thickness, m

Lt = Length of Tube, m (6.1 m)

ρm = Density of water, kg/m3 (1000 kg/m3)

g = Acceleration of gravity (9.81 m/s2)

r = Shell radius, m

𝑊𝑠 = 𝜋 𝑥 𝑟 2 𝑥 6.1 𝑥 1000 𝑥 9.81

𝑊𝑠 =
Weight of Fluid to Fill ube side,

𝑊𝑡 = 𝑁𝑡 𝑉𝑡 𝜌𝑚 𝑔

Where,

ρm = Density of water, kg/m3 (1000 kg/m3)

g = Acceleration of gravity (9.81 m/s2)

Nt = Number of Tube

Vt = Velocity of Tube, m/s

𝑊𝑡 = 𝑁𝑡 𝑥 𝑉𝑡 𝑥 1000 𝑥 9.81

𝑊𝑡 =

Weight of Insulator,

Mineral Wool havae been chosen as the insulator material sinc eot can withstand an extreme
heat compared to any other types of insulator materials. Mineral wool also a non-combustible
insulator since it contents of inorganic components such as stone or slag and molten glass.
Mineral wool can be moulded to any shape where it is resistant to alkaline and high corrosion
resistant. From Coulson & Richardson’s Chemical Engineering, 1990, the characteristics of
mineral wools is as the following below:

Mineral Wool

 Insulation Thickness, ei= 0.05 m since the standard thickness for mineral wools are in
between 0.025m to 0.102m
 Density of the mineral wool, ρm = 130 kg/m3

Volume of Insulation

𝑉 = 𝜋 𝐷 𝐿𝑒𝑖

Where,
D = Diameter of shell side, m
L = Length of tube, m (6.1m)
ei = Insulation Thickness, m (0.05m)
 𝑉 = 𝜋 𝑥 𝐷 𝑥 6.1 𝑥 0.05

𝑉=

Weight of Insulator,

𝑊𝑖 = 𝑉𝜌𝑖 𝑔

Where,

ρi = Densiy of insulation , kg/m3 (130 kg/m3)

g = Acceleration of gravity (9.81 m/s2)

V = Volume of Insulation , m3

𝑊𝑖 = 𝑉 𝑥 130 𝑥 9.81

𝑊𝑖 =

Therefore, the total weight of heat exchanger are as the following below:

j) Baffles
Baffle are usually used as teh support for the tubes and also functioned to increase the
velocity of the fluid. There are two kinds of baffles which are plate and rod. The commonly
used type of baffles is plate baffles where it is possible in a few form such as single-
segmental, double-segmental and also triple segmental. The baffle cut are known as he
height of the segment where it is permit the shell side fluid in order to for it to flow across
the baffle. Baffle cut is in percentage of the shell inside diameter where the most preferable
percentage is in the range of 20% to 35%.

Baffles,
Baffle cuts = 30%
𝐿𝑡
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝐵𝑎𝑓𝑓𝑙𝑒𝑠 = ( )−1
𝐵𝑠
Where,

Lt = Length of tube, m (6.1m)

Bs = Baffle spacing

Where Baffle spacing can be calculated by using the following equation,

𝐷𝑖
𝐵𝑎𝑓𝑓𝑙𝑒𝑠 𝑠𝑝𝑎𝑐𝑖𝑛𝑔 = ( )
0.6

Di = Shell Diameter, m

𝐷𝑖
𝐵𝑎𝑓𝑓𝑙𝑒𝑠 𝑠𝑝𝑎𝑐𝑖𝑛𝑔 = ( )
0.6

Therefore, the number of baffles can be calculated as teh following below,

𝐿𝑡
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝐵𝑎𝑓𝑓𝑙𝑒𝑠 = ( )−1
𝐵𝑠
6.10
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝐵𝑎𝑓𝑓𝑙𝑒𝑠 = ( )−1
𝐵𝑠

𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝐵𝑎𝑓𝑓𝑙𝑒𝑠 =

k) Nozzle
Nozzle also known as branches which is a mechanical device that are designed in order to
control the rate of flow, speed, direction , shape, mass and also to control the pressure of
the stream that are emerges from the nozzle. Nozzle also important in order to channel both
oulet and inlet streams.

Shell Side,

Pipe size for Inlet,

4𝑥𝐴
𝐼𝑛𝑠𝑖𝑑𝑒 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = √
𝜋

𝐺𝑠
𝐴𝑟𝑒𝑎 = ( )
𝜌 𝑥 𝑉𝑠
Where,

Gs = Flowrate at shell side, kg/s

ρ = Density of fluid at the shell side, kg/m3

Vs = Velocity, m/s

𝐺𝑠
𝐴𝑟𝑒𝑎 = ( )
𝜌 𝑥 𝑉𝑠

𝐴𝑟𝑒𝑎 =

4𝑥𝐴
𝐼𝑛𝑠𝑖𝑑𝑒 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = √
𝜋

𝐼𝑛𝑠𝑖𝑑𝑒 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 =

Pipe Size for the Outlet,

𝐺𝑠
𝐴𝑟𝑒𝑎 = ( )
𝜌 𝑥 𝑉𝑠

𝐴𝑟𝑒𝑎 =

4𝑥𝐴
𝐼𝑛𝑠𝑖𝑑𝑒 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = √
𝜋

𝐼𝑛𝑠𝑖𝑑𝑒 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 =

Tube Side,

Pipe Size for the Inlet,

𝐺𝑡
𝐴𝑟𝑒𝑎 = ( )
𝜌 𝑥 𝑉𝑡

Gt = Flowrate at tube side, kg/s

ρ = Density of fluid at the tube side, kg/m3

Vt = Velocity, m/s
 𝐺𝑡
𝐴𝑟𝑒𝑎 = ( )
𝜌 𝑥 𝑉𝑡

𝐴𝑟𝑒𝑎 =

4𝑥𝐴
𝐼𝑛𝑠𝑖𝑑𝑒 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = √
𝜋

𝐼𝑛𝑠𝑖𝑑𝑒 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 =

Pipe Size for the Outlet,

𝐺𝑡
𝐴𝑟𝑒𝑎 = ( )
𝜌 𝑥 𝑉𝑡

𝐴𝑟𝑒𝑎 =

4𝑥𝐴
𝐼𝑛𝑠𝑖𝑑𝑒 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = √
𝜋

𝐼𝑛𝑠𝑖𝑑𝑒 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 =

Based on the value that we have been calculated above, we can determine size of the pipe by
using table of standard pipe. Table shown below are the Standard Value of Pipe Size.

Table Standard Value of Pipe Size For Stainless Steel 316

l) Selection of Flanges for Nozzle
Flanges are usually used fro nozzles, pipes and other type of attachments to the pressure
vessel. There are many types of flanges such as slip on flanges, welding-neck flanges, lap-
joint flanges, hub and plates flanges, balck and blind flanges and also screwed flanges. For
this heat exchanger, slip on flanges are chosen since it can be easily welded internally and
externally. Compared to teh other types of flanges, slip on flanges are way more cheaper.

Figure Different Types of Flanges

m) Vessel Support
Vessel support are used in order to carry he weight of the vessel where it is also designed
to withstand the wind loading . For this heat exchanger we will be using saddle type support
since the vessel is in the horizontal where saddle support can be constructs by using bricks
or concrete or it also can be fabricated from steel plate. The contact angle for saddle support
are usually in the range of 120o to 150o. Saddle support will give a good uniform load
towards the heat exchanger. Table below shows the standard value for saddle support.
 Figure Standard Saddle Support for vessel up to 1.2m

Figure Standard Saddle Support for vessel more than 1.2m

Summary of Mechanical Design
General summary
Characteristics Value
Design Pressure 𝑁
0.275
𝑚𝑚2
Design Temperature (Shell side)
Design Temperature (Tube side) 55 °C
Material Construction Stainless Steel 316
Design Stress (Shell Side)
Design Stress (Tube Side)
Type of head
Thickness of Shell
Thickness of Tube
Diameter of shell
Thickness of head
Weight of Shell
Weight of tube
Weight of insulation
Weight of content at shell side
Weight of content at tube side
Total weight of heat exchanger
Pipe Size inlet at shell
Pipe Size outlet at shell
Pipe Size inlet at tube
Pipe Size outlet at tube
Numbe rof Baffles
Baffles cut height