Faculty of Engineering

Department of Chemical
Engineering

Bellville Campus

PROCESS DESIGN IV

(PQD470S)

Main Design Project

Chapters 3:Heat exchanger

Kalala muleya

215086597

Lecturer: Mr. Tafirenyika Fraser NYAMAYARO MADZIMBAMUTO

Due date: 29th June 2020

Table of Contents

Synopsis ii

Chapter 1 1

1. Introduction 1

1.1 Problem Statement 1

1.2 Aim and Objective 1

1.2.1 Aim 1

1.2.2 Objectives 1

1.3 Literature Review: 1

1.3.1 Cumene 1

1.3.2 Chemical hazard 2

1.3.3 Chemical Properties 3

1.4 Catalyst 1

1.4.1 Solid phosphoric acid (SPA) 1

1.4.2 Aluminium chloride 1

1.4.3 Zeolite 1

1.4.4 Q-MAXTM process description for cumene production 2

1.5 Preliminary Design 3

1.5.1 Preliminary Process Description 3

1.5.2 Adjustments to Preliminary Design 4

1.5.3 1.3.3. Eliminating Stream composition differences 4

1.5.4 Eliminating differences in phase 5

1.5.5 Integration to form Process flow Diagram 5

1.5.6 Material Balance 5

● Propylene Balance 6

● Propane Balance 6

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 ● Benzene balance 6

● Benzene Column (T-202) Balance 7

● Cumene Column (T-201) Balance 7

● Separator (S-201) Balance 7

● Reactor (R-201) Balance 8

● Overall Mass Balance 8

1.5.7 Production scaling 8

1.6 Gross margin analysis 9

1.7 Health and environmental consideration 11

1.8 Process controllability, instrumentation and what if hazard analysis 14

1.8.1 What-If Analysis of the PFD 15

1.9 Discussion 16

1.10 Conclusion 17

Chapter Two 18

2. Introduction 18

2.1 Literature Review 18

2.1.1 Alkylation Reactor 18

2.1.2 Depropanizer 19

2.1.3 Trans alkylation Reactor 22

2.2 Separation process overview 22

2.3 Energy Balance 23

2.4 Preliminary Energy Balance 24

2.4.1 Property data for Energy Balance 25

2.3.1. Heat Exchanger (E-103) Balance 26

2.3.2. Fired Heater Balance (H-201) 26

2.3.3. Reactor Balance (R-201) 27

2.3.4. Heat Exchanger (E-101) 28

2.3.5. Distillation column Balance (T-201) 29

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 2.3.6. Condenser balance 29

2.3.7. Heat Exchanger (E-102) balance 30

2.3.8. Heat Exchanger (E-104) balance 30

2.4. Economic Analysis 30

2.5 Discussion 32

2.6 Conclusion 34

3. References 1

List of Figures

Figure 1:Q-MAX process.............................................................................................................2

Figure 2:preliminary design of cumene process...........................................................................3

Figure 3:preliminary process flow diagram of the cumene process..............................................5

Figure 4:P&ID for the distillation column....................................................................................14

Figure 5:alkylation equipment description..................................................................................18

Figure 6:depropanizer equipment..............................................................................................19

Figure 7. PFD used for preliminary energy balance...................................................................24

Figure 8:Intergrated Process flow Diagram..................................................................................3

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 Chapter 1

1. Heat transfer coefficient

The coefficient side heat transfer of the tube is a result of the variables, such as the number
of Prandtl, the number of Reynolds, and the diameter of the tube. Such parameters may be
separated into simple parameters which are physical properties (viscosity, thermal
conductivity and real heat), diameter of the tube and velocity of mass.

The change in liquid viscosity has the most significant impact on the heat transfer coefficient,
so this physical change is absolute.

In the case of turbulent thermal energy within the tube, the basic equation is:

( hDk )=0.027( DGμ )0.8 ( cμk ) 0.33

Nu=0.027 ( ℜ ) .0.8 ( Pr ) .33 .∨

The coefficient of heat transfer is influenced by the viscosity when it is a parameter of the
number Reynolds or a parameter of the number Prandtl.

The mass velocity has quite a strong effect on the coefficient of heat transfer.

2. Pressure drops
The rise in mass velocity contributes to increased pressure drop, which is faster than heat
transfer coefficient change. the inside tubes recommended minimum velocity liquid is 1.0 m /
s and the maximum are 2.5-3.0 m / s. Because of the erosion present when speed is very
high. Limiting the pressure drop is however necessary to control the existence of erosive
velocity.

Within the CPI, the tubing diameters are usually 3/8, 1/2, 5/8, 3/4, 1, 11⁄4, and 11⁄2 within.
3/4 And 1 in., are more widely used. The tube diameters that are less than 3⁄4 cannot be
used for fouling facilities.

3. Shell side design

The calculations on the shell side are much more complex than those on the tube side. The
explanation for this because on the shell side, there is a flow current, a central flow steam
and four sources of leakage or bypass. Analysis of the shell side stream is calculated by
utilizing specific shell side flow structures, varying tube structure designs and baffling
designs.

(h𝐷) = 0.027 (𝐷𝐺) 0.8 (𝑐𝜇) 0.33 𝑘μ𝑘

 4. Fouling factor
The heat transfer layers of the heat exchanger may be protected by the contaminants in the
liquid systems, or they may be corroded by the contact with the fluids and the material used
for heat exchanger design. Therefore there is an additional heat flow resistance and reduces
the heat transfer performance. A fouling factor (or fouling resistance), Rf, often underlines
the combined effect. For such an improvement in the total heat transfer coefficient the
fouling element together with the other thermal resistance must be considered. The values of
U for both clean and dirty states in the heat exchanger are used to describe the fouling
factor.

1 1
Rf= +
U dirty U clean

5. Tube layout patterns

Tube layout patterns have 4 different types, which are triangular (30oC), rotated triangular
(60oC), square (90oC), and rotated square (45oC).

Figure 18 – Types of tube layout pattern

There would be more tubes in a triangular shape or rotating triangle pattern than a square
pattern or rotated square pattern. A triangular design produces strong friction and hence a
large coefficient of heat transfer. Hence it is easier to use a triangular pitch for heat
transmission and surface area per unit volume. The 45oC or 90oC square pitch is typically
required for dirty shell side services

6. Tube pitch
Tube pitch for two adjacent tubes is the smallest number. When measure the number of
tubes, the lowest tube pitch will be chosen since the minimum tube pitch results in the
smallest shell diameter.

6.1. Increasing tube pitch

Using the smaller tube pitch lead to the smaller shell diameter and reducing cost

The tube pitch is generally set at 1.25 times the tube outside diameter.

For the conversion of pressure drop to heat transfer, the optimum tube-pitch to tube-
diameter ratio: Turbulent flow: 1.25< (tube pitch)/(tube diameter) < 1.35

Laminar flow: (tube pitch)/(tube diameter) ≈ 1.4

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Reducing the pressure drop by increasing the tube pitch is not highly recommended.
Because the tube diameter increase when the tube pitch increase and lead to the cost
increase.

7. Baffling
Baffle

Baffle functions support the tubes, enabling a suitable velocity to be retained for a shell side
fluid and preventing tube collapse, which is induced by fluctuation of the flow.

There are 2 kinds of baffles which are plate and rod. Plate baffles include single-section,
double-section, and triple-section.

Figure 19 – Types of segmental baffe

Baffle spacing

The spacing of the baffles is the centerline-to-centreline gap from adjacent baffles. Maximum
spacing of the baffle is defined as one-fifth within diameter of the shell (1/5 ID shell). The
nearer package would allow the shell side fluid to insufficiently reach the package and the
difficult issue of mechanically outside tube cleaning.

The maximum of the baffle and the diameter inside the shell is of equal value. There will be
the primarily longitudinal flow, which is far less efficient than crossflow, when the spacing of
the baffle is greater. The higher baffle width often creates broad unsupported tube stretches
which can result in the exchanger's tube collapse due to friction caused by flow.

The rising pressure drop rate is even higher when reducing the baffle spacing than the rising
heat-transfer coefficient. Optimum baffle spacing ratio is usually 0.3 to 0.6 (0.3 < Lb > 0.6).
This optimal ratio would result in the maximum conversion of pressure drop to heat transfer.
Decreasing the spacing of the baffles can raise the pressure drop without increasing the
heat transfer coefficient accordingly. As the baffle width reduces, the resistance and the
pressure decline of the central cross-flow direction rises. The leaking and bypass streams
often rise before all the streams have exceeded the equilibrium of the pressure drops due to
the pressure drops of all five streams.

baffle cut 

The height of section is named baffle break, which is split in each baffle. The baffle cut helps
the shell side fluid to pass through the baffle and is shown as a percentage of the shell within
diameter. The baffle cut below 20 percent results in an increase throughout the shell side
heat transfer performance, and if the baffle further than 35 percent cause a decrease in shell
side pressure drop. Typically both of these contribute to bad design.

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 Reducing pressure drop by modifying baffle design

Increasing in pressure drop over the heat exchanger in particular by adding the same single
pass shell and single segmental baffles may minimize such an important circumstance if
other parameters relevant to geometric tube and shell configurations are treated.

8. Shell side stream analysis

The five streams flow in parallel paths of different hydraulic resistance. Thus, all streams
start and finish at the inlet and the outlet nozzles, and each stream contributes to the same
pressure drop.

As the path resistance of the flow fraction is strongly dependent, the stream evaluation and
the shell side output would be determined by either of the below design parameters:

• baffle spacing and baffle cut;

• tube layout angle and tube pitch;

• number of runs in the direction of the flow and width of the lane;

• reactivation between the tube and the and the baffle hole;

• clearance between the shell I.D. and the baffle; and

• location of sealing strips and sealing rods.

9. Mean temperature difference

Counter-current flow in different directions through a tube wall is known as the hot and cold
stream. However co-current flow is considered to flow in the very same direction as hot and
cold streams.

Figure 20 – Counter-current flow and Co-current flow

Due mainly to the existing temperature cross, which is also the outlet temperature of the cold
stream is greater than that of the outlet temperature of the hot stream, the counter-current
flow is generally preferred to concurrent flow.

A correlation coefficient, Ft varies based on the shell style and the temperature of the four
terminals. The correction factor can be calculated graphically, given the structure of the shell
and the tube is known. Nevertheless, the average heat transfer coefficient over shell length
is not affected by the LMTD and Ft component principle theory.

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 10. Temperature profile distortion
In general, the cool fluid is the shell side stream, while the hot fluid is the tube side stream.
With this situation, the temperature between both the hot and the cold streams becomes
lower all over the heat exchanger 's range. The mean temperature differential then
decreases, and it is regarded as the deviation (or correction) factor in the temperature
profile.

In several cases the distortion factor of the temperature profile is significant, the baffles are
loaded as near as possible to achieve the highest coefficient of shell side heat transfer,
enabling pressure drop.

11. Relevant Theory

Heat duty:

Q=mc (h out −h ¿ )

: Mass flow rate of cold fluid (kg/h)

: Specific enthalpy of input stream (kJ/kg): Specific enthalpy of output steam (kJ/kg)

When the variations in the stream temperatures are constant with the distance across the
heat exchanger (or with stream enthalpy), otherwise the ∆ T m is just a result of the guiding

forces at the two ends of the heat exchanger, namely , ∆ T 2 𝑎𝑛𝑑 ∆ T 1. Therefore, the specific
log-mean temperature is calculated as:

∆ T 2−∆ T 1
∆ T LM =
∆T2
ln
∆T1

Where: ∆ T 1=T h ,1−T c ,1

∆ T 2=T h ,2−T c ,2

The rate of heat transfer between two streams flowing through a heat exchanger is
administered by:

Q=UA ∆T m

Where

Q: energy flow (W)

U: overall heat-transfer coefficient (Wm-2K-2)

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∆ T m: mean temperature driving force (K)

The surface area of heat exchanger can be estimated by rearranging the equation:

Q
A=
U ∆T m

The number of tubes can be calculated from:

A=π × d o × N t × L

Where

𝑑𝑜: Tube outside diameter

𝑁𝑡: Number of tubes

𝐿: Tube length

Then rearranging the equation:

A
∆ T m=
π do L

F correction factor

The average mean variation in temperature ∆ T m is determined by the multiple changes in

direction of two fluids. A correction factor, F, increases when the resultant range ∆ T mis less
than the specific log-mean temperature is calculated, based on counter-current flow.

T hot ,∈¿−T
R= hot ,out
¿
T cold , out −T cold ,∈¿ ¿

T cold ,∈¿
S=T cold , out − ¿
T hot ,∈ ¿−T hot ,out
¿

Shell diameter,

CL
D S =0.637 ×
√ CTP
× A¿¿

Where:

CTP: tube constant for the incomplete coverage of the shell diameter by the tube

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CL : tube layout constant

Having number of tubes and inside diameter, the area heat transfer can be calculated from
the equation:

π .d 2i
A s=N t ×
4

The velocity of fluid in each tube pass or in shell is calculated by using the equation:

m
v=
ρ× A S

Equivalent diameter can be determined as:

1.10 2
d e= (p t −0.917 d 2o )
do

The Reynolds number can be obtained from:

ut × d e × ρ
Re =
μ

The pressure drops of tube side and shell side:

2
L μ ρu
∆ Pt =N P [8 j f
di ( )( )
μw
+ 2.5] t
2

L D S ρu2t
∆ P s=8 j f
( )( )
LB de
(
2
)¿

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