PROPLEM DIFINITION

Heat exchanger is a device used to transfer heat from a fluid (liquid or gas) to another fluid where the two fluids are physically separated. The Shell and Tube is the most common type of heat exchanger used in the process, petroleum, and chemical industries, it contains a number of parallel u-tubes inside a shell.

Heat exchanger E-104 is shell and tube (horizontal) heat exchanger with change phase in the tube side by condensate the flow of this stream .In the shell side there are benzene but in the tube there are all water

E-104 is operated in the shell in this condition.

Flow rate 4.95E+04 Kg/h Inlet Temperature ,T1 25 oC Outlet Temperature ,T2 165.1 oC Heat Capaxcity of inlet stream, Cpin 1.5196 KJ/kg°C Heat Capacity of outlet stream, Cpout 2.1685 KJ/kgoC Average Heat Capacity, Cpavg 1.84405 KJ/kgoCMass Density of inlet stream , ρin 872.83 kg/m3

Mass Density of outlet stream , ρout 156.51 kg/m3

Average Mass Density, ρavg 514.67 kg/m3

Average Viscosity of stream, µavg 0.606 mNs/m2

Average Thermal conductivity, Kf 0.131 W/moC

And the tube side is operated in these conditions

Flowrate 4.32E+00 Kg/s

Average Heat Capacity, Cp 2.197 kJ/kgoC

Average Mass Density, ρ 2.16 kg/m3

Average Viscosity of stream, µ 0.028 mNs/m2

Average Thermal conductivity of stream, Kf 0.068 W/moC

inlet Temperature , t1 500 oC

outlet Temperature, t2 151.8 oC

Materials of construction:

I checked in the materials compatibility program I found that with cresol the suitable materials is carbon steel because medium corrosion.

The main functions of heat exchanger E-104 are to controlled the feed temperature of the distillation (T-100) , by increase it from 25to 165.1 for the first and decrease it from 500C to 151.8C respectively

Insulation:

The insulation material for E-104 is mineral wool (10.0) according to this figure. Since the highest temperature is 500C .

Duty = 1.455*10^7KJ/HROverall coefficient:

from table in the book 12.1 (4-4)

CmwU ./500 20

lmtm

lm

TFT

tT

ttS

tt

TTR

tTtT

tTtTT

11

12

12

21

12

21

1221

;

ln

Exchanger Type and Dimension

T1 C 25

T2 C 165.1

t1 C 500

t2 C 151.8

∆Tlm C 214.26

R - 0.4

S - 0.733

Ft= 0.79 From Fig.12.20

∆Tm 169.27 C

Heat Transfer AreaU= 500 W/m2.C

∆Tm 169.27 C

Q= 3549.9 KW

A= 41.94 m2

Assume Outler diameter (do) 50 mm

Assume inside diameter (di) 46 mm

Assume Length of tubes (L) 4.88 m

tringual Pitch =1.25* dia. 57.5 mm

Assume 4 tube passes

Area of one tube m2 0.766# of tubes   55Tubes/Pass   14

Cross sectional area Mm2 1661.9Area/pass Mm2 415.47Velocity m/s 87.9

From table 12.4 K1 0.175  n1 2.285

Bundle and Shell Diameter

10.12.

.,; 11

1

1

1

FigellclearancBundllesheDD

PassesNofnKK

NdD

bs

nt

ob

Db= 576 mmbundle shell clearence

57 mm

Ds= 633mm

Tube side Heat Transfer Coefficients

Re 3.07*10^5

Pr 9.22*!0^-2

where jh is the heat transfer factor , assume that the viscosity of the fluid is the same as at the

wall : (µ/µwall) = 1(hi di / kf) = jh Re Pr0.33 * (µ/µwall)0.14

jh= 3.8E-03

hi 1674W/m2.C

Shell side heat Transfer Coefficient:

de / (1/3)Pr^* Re*jh * kf hs

_Re,

Pr;Re

917.01.1 22

cutbufflefj

k

cdu

dpd

d

A

FlowRateu

p

lDdpA

h

pes

oto

e

ss

t

Bsots

Assume: lb = .05*Ds

As 0.016007

m2

de 35.5 mmus 1.667 m/s

Assume: baffle cut is 25% , then get jh from figure 12.29

Re 5*10^4jh 2.90E-

03

hs 1100.67 W/m2.C

Overall Coefficient:

ii

o

w

i

oo

oo hd

d

k

ddd

hodhU

1

2

ln111

Assume Kw = 45 W/m.C (for carbon stainless steel) (from figure 12.6)

ho 1100.67 W/m^2.C

hi 1674 W/m^2.C

hod 5000 W/m^2.C

1/Uo 0.002017

C.m2/W

Uo 495.78 W/C.m2

For fouling factor (hod) from table 12.25

Tube Side pressure drop

ΔPt = Np [ 8jf (L/di)(µ/µw)^(-m) +2.5 ] ρut²/2Where ΔPt is tube side pressure drop Np is number of tube side passesUt is tube side velocity L length of one tube Neglecting the viscosity correction term, (µ/µw) = 1

Pressure Drop 24948.538

Pa

Thickness:

t = (Pri/(SEJ-0.6P))+CcWhere:t = shell thickness (in)P = Maximum allowable internal pressure (psig)ri = internal radius of shell before allowance corrosion is added (in)EJ = efficiency of jointsS = working stress (psi)Cc = allowance for corrosion (in)

ri =12.45245

458 inP = 587.8 psiS = 13706.66 psiEJ = 0.85  Cc = 0.125 in

t = 0.773 int = 19.6 mm

Cost:Cost = 26500$ from matche program

Definition:

The Vessel V-100 is used as liquid-vapor separator in which the feed to the vessel enters with 190 oC and 3410 KPa

Metals:

The Separator is made from carbon steel because of its ability to tolerate high temperature and its low cost compare to other metals. Also, from the material compatibility program we found that with our component suitable material is carbon material is carbon steel because there is no corrosion. The range of the temperature for the carbon steel is from -20 to 600 F and our Vessel operates at 190 oC which is within the range

Stream Value UnitFeed 4573 Kgmol/hr

Overhead 337.8 Kgmol/hrBottoms 4235 Kgmol/hr

Flow rate:

Insulation:

The insulation material for our Vessel is Glass Fiber 4.0 according to this figure. Since the Vessel highest temperature is 190ºC

Diameter:Parameter Value Unit

L 3.496*10^5 kg/hr

V 26810 kg/hr

ρl 689.91 kg/m3

ρv 22.599 kg/m3

Tin 190 oC

P 34.1 Bar

Thickness:

The thickness is depending on many factors such as material type, operating temperature and the stress on the material. The following

calculations will show the value of the thickness

Parameter Value Unit CommentD 2.71 M CalculatedP 494.7 Psi Pressure at the

V-100S 13700 Psi Maximum

allowable Stress of

Carbon Steel Ej 0.85 Efficiency of

jointCc 0.125 In Allowance of

corrosion

Cost:•Cost of VesselVolum:V=A*tA=((2*r*3.14*H)+(4*3.14*r^2))

A= 189.277m2V= 11.791m3

Weight:W=V*ρ

ρ carbon steel=7900kg/m3w=93154.83kg= 205313.26ib

Cost From Matche 406000$Cost of insulation = (406000) (0.1) =40600$ Cost = 406000+40600=446600 $

Distillation is defined as a process in which a liquid or vapor mixture of two or more substances is separated into its component fractions of desired purity, by the application and removal of heat.

I checked in the materials compatibility program I found that with cresol the suitable materials is Stainless steel 304 because medium corrosion.

The thickness is depending on many factors such as material type (in my case is stainless steel) and the stress on the material.

T = 8.64mm

The insulation material for our Distillation is mineral wool (10.0) according to this figure. Since the highest temperature is 260.1C .

property Unit Top Bottom

Mwtkgmole/

kg 106.03 142.78

Vapor Flow kmol/h 3710.9 3092.1

Liquid Flow kmol/h 618.49 3119.9

surface tension N/m0.00930

120.0080

6

ru liquid kg/m3 671.54 612.07

ru vapor kg/m3 17.65 20.22

mmLiquidN

PPPlate

Dropessure

papressurebottom

papressureTop

E

NN

Nad

stagesofnumberHYSYSFrom

trayOverallassumeEAssume

AVGliquidal

topbottom

o

hysysstagesal

hysysstages

o

176606.0)805.641)(31(8.9

)583960618430(

81.9_Pr

618430

583960

318.0

251

26Re

26

8.0

Re

/Re

/

smKu

smKu

KKCorrection

KKCorrection

V

LBottomF

V

LTobF

BottomV

L

TopV

L

bottomTopiV

Lad

iv

vLBottomf

iv

vLtopf

ibottom

itop

iL

v

iLV

iL

v

iLV

i

iMAXi

iMAXi

ii

ii

i

/5864.022.20

22.2007.612)1083.0(

/673.065.17

65.11754.671)1106.0(

1083.002.0

)00806.0()108.0(

02.0

1106.002.0

)00930.0()129.0(

02.0

1856.007.612

22.20021.1)(

027.054.671

65.171666.0)(

021.100806.0

9.3119

016669.3710

49.618

,;Re

1)(

1)(

2.02.0

1)(1

2.02.0

1)(1

Take Tray spacing = 0.9 mAssume flooding= 85 %Assume Down comer area= 45 %

K1 "Top" = 0.129, K1 "Bottom" = 0.108

smuFloodingu

smuFloodingu

MAXii

MAXii

fBottomf

fTopf

/498.0)586.0)(85.0(%

/572.0)673.0)(85.0(%

)(

)(

smMwtmoleFlow

RateFlowVolumetric

smMwtmoleFlow

RateFlowVolumetric

iv

iiBottomi

iv

iiTopi

/3

119.6)3600)(22.20(

)78.142)(9.3119(__

/3

192.6)3600)(65.17(

)03.106)(9.3710(__

)(

)(

2)(

2)(

27.12119.6

4984.0

%

__

81.10572.0

19.6

%

__

mDowncomeru

RateFlowVolumetricArea

mDowncomeru

RateFlowVolumetricArea

i

i

f

iBottomi

f

iTopi

246.20

246.20

)4(4.01

27.2̀14

2022.18

)4(4.01

81.104

)(

)(

mBottomDMAXTakeD

mArea

D

mArea

D

c

i

Bottomi

i

Topi

28.11Re

/3

104.5)07.612)(3600(

)78.142)(9.3119(

Figuread

smMwtMoleflow

FlowVolumerticliquid

MAX

Single Pass Plate could be used

ml

lFindD

ladA

AFigad

mholeAholeAreaA

holeassume

mAAActiveAreaA

mAANetAreaA

mDowmComerAreaDownComerAA

mDA

w

wc

w

c

d

ah

dca

dcn

cd

cc

053.5)104.5)(99.0(

99.0Re,4.031.11.Re

25092317.0)092317.5)(1.0(%

%5%)(

2092.4)18.8)(2(46.202

227.1218.846.20

218.8

100

)40)(46.20(%

246.20104.525.025.0 22