DESIGN

OF SHELL & TUBE HEAT EXCHANGER

FEED PROPERTIES
Heat duty of heat exchanger :

Shell side :

Q= mc*Cp*ΔT

=16365.498*0.96*(466-364) = 1602509.56 KJ/h

=445.14 KW

Tube side :

Q= mh*Cp*ΔT

=22306.328*1.05*(513.6-450)

= 1489616.58 KJ/h

=413.78 KW
Temperature driving force :

LMTD = ΔT1 – ΔT2/ ln ( ΔT2 /ΔT2 )

ΔT1 = 513.6 – 466 = 47.6

ΔT2= 450 – 364 = 86

LMTD = 47.6 – 86/ ln (47.6/86)

= 64.92

For 1 shell and 2 tube passes

ΔTlm = FT * LMTD

P= ( TC2 – TC1 )/ ( Th1 – Th2 )

=( 466 – 364 )/ (513.6 – 364 )

=0.68
R= ( Th1 – Th2 )/ ( TC2 – TC1 )

=( 513.6 – 450 )/ (466 – 364 )

R=0.62

From PR chart,

FT = 0.65

ΔTlm = 0.65 * 64.92

= 42.200 C
Estimated area :

Q = UAΔT lm

A = Q/ UΔTlm

Let as assume over all heat transfer co- efficient = 250 W/ m2 0C

A = 413.79 × 103/ 250 × 42.20

= 39.22 m2

Tube pitch = 1.25 ( OD )

=1.25 * 0.01905

=0.024 m
Heat transfer area of each tube

length – allowance )

=3.14 * 0.01905 * ( 4.88 – 0.05 )

=0.2889 m2

Number of tubes required

=A/ surface area of tube

=39.22/ 0.288

=136
Fluid flow area:

At =3.14/4 × (ID)2 × ( NT/NP )

=3.14/4 ×(0.01574 )2 × (136/2)

=0.01m2
Fluid velocity in tube :

V = mass velocity/ρ × At
=4.55/ 0.95 × 0.11
=0.48 m/s

Wall temperature :
TW = 0.5 ( ( Th1 +( TC1 + TC2/ 2 ) )

=0.5 ( 928.60 )

=464.3 0 C
Film temperature :

Tfilm = Twall + Th1/ 2

= 464.3 + 513.6/ 2
=488.9 0C

Film co- efficient of shell side :

h0 De/ k = 0.36 ( Nre ) 0.55 (Npr)0.33 (ϻ/ ϻw )0.14

NRE = GS De / µ
G S = MS / A S
AS = DS C „ B/PT

Clearance C „= PT – OD

= 0.024 – 0.019 = 0.005 m

Baffle spacing B = DS

B= 0.4489 m
AS = 0.4489 * 0.005 * 0.4889/0.024
= 0.0498 m2

GS = 6.2/0.0498

= 124.50

Kg/m2 Equivalent diameter :

De =4(PT2 – 3.14/4(OD)(*OD)
=4(0.0242 -3.14/4(0.0192)2 )(*0.019)
=0.0196 m

NRE = 124.5 * 0.019/0.2 * 10-3

= 8448.21
NPR = CP ϻ/k
=1.05 * 0.28 * 10-3 * 1000/ 0.132
=2.23

Let as assume (ϻ/ ϻw ) = 1 for low viscous fluids

h0 *0.0196/ 0.132 = 0.36 ( 8448.21 ) 0.55 ( 2.23)0.33
h0 = 451.73 W/ m2 0C
film heat transfer co-efficient of tube side :

hiDi/ k = 0.023( Nre ) 0.88 (Npr)0.33 (ϻ/ ϻw )0.14

NRE = Gt Di / ϻ

Gt = Mt/ At

= 4.55/ 0.01
= 455 kg / m2s

At =3.14/4 × (ID)2 × ( NT/NP )

=3.14/4 ×(0.01574 )2 × (136/2)
=0.01 m2

NRE = 455 * 0.0157/ 0.32 * 0.001

= 22323.44
NPR = 1.05 * 0.32/ 0.112
=3
hi *0.015/ 0.124 = 0.023 ( 22323.44 ) 0.8 ( 3)0.33

hi = 766.03 W/m2 0C

hi0 = hi ( ID/OD )
=766.03 ( 0.0157 / 0.01905 )
hi0 =631.32 W/m2 0C
TUBE WALL RESISTANCE :

RW = D0 / 2KW ln ( D0 / Di )

=0.0195/ 2*55 ln ( 0.01905 / 0.0157)

=3.349 * 10-5 m2 0C / W
Rdi0 = 1.76 * 10-4
Rdo = Rdi ( D0 / Di )

= 1.76 * 10-4 * ( 0.01905/ 0.0157 )

=2.13 * 10 -4 m2 0C / W
Over all heat transfer co-efficient :

U0 = ( 1/h0 + RW + Rdi0 + Rdo + 1/ hio )

= 254.60 W/m2 0C
Required heat transfer area

Ar = Q/ U0 ΔTm

= 413.9/254.60 * 42.20

=38 m2

Heat transfer area available

Aa =(OD ) * L * Nt

=3.14 ( 0.01905 ) * 4.88 * 136

=39.70 m2
Available heat transfer area is greater than the required heat transfer area so Design is safe.

% excess area = Aa - Ar / Ar * 100

=( 39.70 – 38 )/38 * 100 = 4.47 %

Pressure drop in shell side :

Δps = { ( f * GS 2 * DS ) ( Nb + 1) } / ( 2 * 106 * De * S* ψS )

f  fanning friction factor

GS mass velocity of shell side fluid

DS  diameter of shell

Nb no of baffles

S specific gravity of shell side gas

F = 1.87( NRE ) -0.2

=1.8 ( 8448.21 )-0.2
0.31

S = 0.53

Nb = lenth of tube/ baffle spacing

= 4.88/0.4889 = 10
Δps = { ( 0.31 * 124.5 2 * 0.4889 ) ( 10 + 1) } / ( 2 * 106 * 0.0196* 0.53* 1 )
= 1.24 < 20 kpa

Design is safe.
Pressure drop in tube side :

Δpt = { ( f * Gt2 * L * NP )/2*106 *Di* S* ψS ) + ( 2.5* NP *V2 *S )

F fanning friction factor

Gt  mass velocity of tube side fluid
Di  inner diameter of tube
Np  no of passes
S  specific gravity
V  velocity
F = 0.72( NRE ) -0.33

=0.72 ( 22323.44 )-0.33

=0.03

Δpt = { ( 0.03* 4552 * 4.88* 2 )/2*106 *0.0157* 1* 1) + ( 2.5* 2 *0.482 *1 )

= 3.08< 20 kpa

Design is safe .
DESIGN SUMMARY

Heat duty of the heat

exchanger 413.9 kW

Area required for heat transfer 38 m2

Area available for heat transfer 39.5 m2
No of tubes 136
No of passes in tube side 2
No of passes in shell side 1
Film heat transfer co-efficient
in tube side 766.03W/ m2 o C
Film heat transfer co-efficient in
shell side
451.73W/ m2 o C
Overall heat transfer co –
efficient 254.60W/ m2 o C
Pressure drop in the tube side 3.08kpa
Pressure drop in the shell side
1.24kpa
Design of centrifugal pump :

Data :
Suction side :

Flow rate = 6.53 m3/h

Diameter of the pipe= 0.06 m

Geometric pipe length = 10 m

Discharge side :

Flow rate = 6.53 m3/h

Diameter of the pipe= 002 m

Geometric pipe length = 30 m

Density = 1000 kg/ m3

Viscosity = 0.75 cp
Determination of suction pressure :

Flow rate = area * velocity

Q =D2/4 * V

6.53/3600 = 3.14 * 0.062/4* V

V= 0.64 m/s

Total equivalent length =geometric length +length of the fittings

Geometric length =10m

Length of h the fittings = 500*0.06=30m
Total equivalent length =40 m

Line pressure drop = 4fLv2/2g D

NRE = DVρ/µ
=0.06 * 0.64 * 1000/0.75 * 0.001
=51200
F = 0.0035 + 0.264 (NRE )-0.42
= 6.27 * 10-3

Δpf = ( 4 * 0.006 * 40 * 0.64 * 0.64 ) / 2 * 9.81 * 0.06

= 0.33 m
=0.33 * 10-4 *1000
= 0.03 kg/cm2

Static head =(10-4)*10-4 *1000

=0.6kg/cm2

Suction pressure:

System pressure =10 kg/cm2

Static head =0.6kg/cm2
Line pressure drop =0.03kg/cm2
Suction pressure =1.63kg/cm2
Determination of discharge pressure :

Flow rate = area * velocity

Q =D2/4 * V

6.53/3600 = 3.14 * 0.022/4* V

V = 5.77 m/s

Total equivalent length = geometric length + length of the fittings

Geometric length =30m

Length of the fittings = 600*0.116=70m
Total equivalent length =100m
Line pressure drop = 4fLv2/2g D

NRE = DV ρ/µ

=0.02* 5.77 * 1000/0.75 * 0.001

=153866.66

F = 0.0035 + 0.264 (153866.66)-0.42

= 5.24 * 10-3

Δ pf = ( 4 * 0.0052 * 100 * 5.77 * 5.77 ) / 2 * 9.81 * 0.02 = 176 m

=176 * 10-4 *1000

= 17.6 kg/cm2

Static head = 10 * 10-4 * 1000

= 1.0 kg/cm2
 discharge pressure :

System pressure = 2.11 kg/cm2

Static head = 1 kg/cm2

Line pressure drop = 17.64 kg/c

discharge pressure = 20.78 kg/cm2

differential pressure :

differential pressure = discharge pressure – suction pressure

=20.75 – 1.63
=19.12 kg/cm2
=191.2 MWC

NET POSITIVE SUCTION HEAD :

NPSH = SUCTION PRESSURE – VAPOUR PRESSURE
=1.63 – 1.05
=0.58 kg/ cm2
=5.8 MWC
SAFETY MARGIN :

Safety margin = (NPSH) – 0.6/ specific gravity

=5.8 – 0.6/0.6 = 8.7 MWC

Horse power required :

HP = flow rate * ( density * differential pressure in MWC ) / 75

= 6.53/3600 * (1000 * 19.12)

= 0.46 hp
Break horse power required :

BHP= HP/PUMP EFFICIENCY

=0.46/0.6
=0.77hp
Motor horse power required :

MHP = BHP/ MOTOR EFFICIENCY

Motor power efficiency is 80%

= 0.77/0.8

=0.96 hp

Efficiency = HP/BHP * 100

=0.46/ 0.77

=60 %
DESIGN SUMMARY:
Suction pressure = 1.63 kg/cm2

Discharge pressure = 20,75 kg/cm2

Differential pressure = 19.12 kg/cm2

Net positive suction head = 0.58 kg/cm2

Pump efficiency = 60 %

Horse power required = 0.46 hp

Break horse power required = 0.77 hp

Motor horse power required = 0.96 hp

T H A N K