T1=923 K

t2= ?

t1=373 K

T2=673 K

T2=673
K

t1=373 K

T1=92
3K

t2=573 K

2116 Kg/hr of the flue gases leaving the reactor

are used to transfer its heat to 5118.7 Kg/hr of the
original secondary butanol.

Hot fluid will be cooled from 673K to 423K while

cold fluid is heated from 373K to 573K

Inlet temperature of the process stream

= t1

Outlet temperature of the process stream= t2

Inlet temperature of utility stream = T1

= 373 K
= 573 K

= 923 K

Outlet temperature of utility stream

= T2

= 673 K

Mass flow rate of process stream

= m

= 1558.5 Kg/hr

Specific heat capacity of the process stream = CP

=2.038 KJ/Kg.K

Specific heat capacity of the utility stream = CP = 1.20KJ/Kg.K

Mass flow rate of the utility stream= m = ?

Heat load Calculations

q mC p T
q 1558.5 * 2.038 * 200

q 635244.6 KJ / hr
Mass flow rate of utility stream
q mC p T

m 635244.6 * 1.2 * 250

m 2116 kg

hr

LMTD
Tm

Tm

(T1 t 2 ) (T2 t1 )
(T t )
ln 1 2
(T2 t1 )

(923 573) (673 373)

(923 573)
ln
(673 373)

Tm 324 K

Assumed value
UD = 100 W/m2.K

Heat transfer area

A

Q
U D t

635244.6
A
100 * 324

A = 19.60 m2

Now, lets take values from table

Tube length = 3.0 m
Tube OD(do) = 17.1 mm
Tube ID(di)

= 12.48 mm

Area of one tube = doL = 0.1394 m2

No. of tubes required = Total H.T. area/single tube area

=140 tubes

Pitch = PT = 1.25 *do

= 0.02138 m
Assuming 4 Tie rods required, n t =140 + 4 = 144
nd2 = 1/3(4nt - 1) = 242
nd =13.6
Shell Diameter, ds = PT(nd + 1) = 0.02138 (13.6 + 1)
=0.312 m

From tube count table for triangular pitch in table

For 170 tubes shell I.D. = 0.387 m for one pass
Maximum number of tubes in the inside Diameter of
the shell is,
nd = ds/PT 1 = 13.59

AssumeBaffle spacing = B = 250 mm.

TUBE SIDE CALCULATIONS

Flow area
at = *(Nt**di2)

at = 0.0202 m2

Mass velocity

m
Gt
at

1558.5
Gt
0.0176 * 3600
Gt 24.59 kg

sec .m 2

Reynolds No.
Re

D Gt

Re = 23734
Viscosity, A = 1.293 * 10-5 kg/m.sec
Value of JH from tube side heat transfer curve
JH = 70
Thermal Conductivity of steel = kA = 0.040 W/m.K

Prandtl Number
Pr = CPAA/kA
(2.038 *103 )(1.293 *10 5 )
Pr
0.04
Pr = 0.66

Heat Transfer coefficient

hi = jH(kA/di)(Pr)1/3
hi 70(

0.04
)(0.66)1/ 3
0.01248

hi = 195 W/m2.K

SHELL SIDE CALCULATIONS

Tube Clearance

C = (PT - do ) = 0.00428 m
Flow area

ID * C ' B
as
PT

0.336 * 0.00428 * 0.25

as
0.02138

as 0.0168m 2

Mass velocity
m
Gs
as

Gs

2116
3600 * 0.0168

G s 35.59 kg

sec m 2

Equivalent Diameter

DE = 8(0.43 PT2 1/8 d2o)/ do

DE = 0.0122m

Flue gas viscosity, fg = 2.75 * 10-5

kg/m.sec

Reynolds No.
De G s
Re

Re 15779
Value of JH from shell side heat transfer curve
JH = 70
Thermal conductivity, k = 0.00458 W/m.K

Prandtl Number
Pr = CPfg*fg/kfg
(1200)(2.75 *10 5 )
Pr
0.0458

Pr = 0.72

Shell side coefficient

k Cp

ho J H
De k

0.14

0.01458 1200 * 2.75 *10

ho 70
0.0124
0.0458

ho = 235 W/m2.K

Coefficient correction

Clean
coefficient

hio = hi * I.D/O.D
hio
=235.34*0.01248/0.017
hio = 171 W/m2.K

overall

UC

hio ho
hio ho

UC

Uc = 102.2 W/m2.K

171* 235
171 235

Design overall coefficienta

UD = [1/UC + x/kw+ Rdi + Rdo]-1

UD =(1/102.2+0.0003+0.00031

UD = 96 W/m2.K

This value is sufficiently close to the assumed the value of 100 W/m2.K to be acceptable.

PRESSURE DROP CALCULATIONS

Tube side

For Reynolds number = 20703

Friction factor for tube side, f = 0.03456
Tube diameter, di = 0.01248
Number of passes, n = 1
Density of sec-butanol, = 1.91 kg/m3
Mass Velocity, Gt = 21.45 kg/m2.sec
Tube length, L = 3.0 m
2

fGt Ln
Pt
di t
Pt 2.02kPa

47.703

0.0238

(Figure)

SHELL SIDE
Reynolds No, Re = 15779
Mass velocity, Gs = 35.59 kg/m2.sec
Friction factor, f = 0.2808
(Figure)
Density if Flue gases = fg = 0.645 kg/m3
No. of crosses, N+1 = 12L/B = 14.4 = 15

fG s d s ( N 1)
Ps
fgDe s

Ps 179kPa

SPECIFICATION SHEET
Unit Exchanger
Type
Function
Operation
Heat duty
Heat transfer area
Overall heat transfer coefficient
Material of construction
Inside tube diameter
Baffle spacing
Pitch
Length

Heat exchanger
Shell and tube
To preheat cold feed
Continuous
6.352 x 105 kJ/hr
19.60 m2
96 W/m2.K
Stainless steel alloy
0.312m
250 mm
0.02138m
3.0 m

No of tubes

144