PRODUCTION OF 100,000 TONNE PER ANNUM OF 2-ETHYLHEXYL ACRYLATE 5-1 MECHANICAL AND CHEMICAL DESIGN

CHAPTER 5

HEAT EXCHANGER

5.1 INTRODUCTION Heat exchangers are found in most chemical system. Sinnot (1999) reported that heat exchanger is a device that is used to transfer thermal energy between two or more fluids at different temperatures and in thermal contact (Sinnot, 1999). Some of more common applications are found in heating, cooling, evaporation or condensation, control process liquid and etc. Direct and indirect transfers are two ways of heat being transferred by heat exchanger. In direct contact type of heat exchanger or recuperators, the fluid does not mix because it was separated by the walls. It contrasts with indirect contact of heat exchanger or simply regenerator where heat exchange is done via energy storage and rejection trough the exchanger surface. In designing heat exchanger, there are several criteria that to be taking into consideration. The details such as the type of fluid and phase will be the major factor in choosing the type of heat exchanger.

5.1.1

Types of heat exchangers

The term of exchanger absolutely applies to all types of equipment in which heat exchange specifically to donate equipment in which heat is exchanged between two process streams. For example if exchanger in which a process fluid is heated or cooled by a plant service stream is referred to as heaters and coolers, if the process stream is vaporize, the exchanger is called vaporizers.

PRODUCTION OF 100,000 TONNE PER ANNUM OF 2-ETHYLHEXYL ACRYLATE 5-2 MECHANICAL AND CHEMICAL DESIGN The types of heat exchanger used in chemical process and allied industry are listed below:

Table 5.1: Heat exchanger type No. Types 1. 2. 3. 4. 5. 6. 7. 8. 9. Double pipe heat exchanger Shell and tube heat exchanger Plate exchanger Plate-fin exchanger Spiral heat exchanger Air cooled Direct contact Agitated vessels Fired heaters Functions The simplest type. Use for heating and cooling. Used for all application. Use for heating and cooling. Use for heating and cooling. Use for heating and cooling. Cooler and condenser. Cooling and quenching. Use for heating and cooling. Use for heating and cooling. (Sinnot, 1999) 5.1.2 Shell and Tube exchangers: Construction details

The shell and tube exchanger is the most common type of heat transfer equipment used in chemical and allied industries. The advantages of this type are: I. II. III. IV. V. VI. The configuration gives a large surface area in a small volume Good mechanical layout: a good shape for pressure operation Uses well-established fabrication techniques Can be constructed from a wide range of materials Easily cleaned Well established design procedures.

In manufacturing industry, the application of heat exchanger is used for the process of system to derive the final product. The selection of heat exchanger is very important in order to achieve 3Ps which are people, profit and planet. The safety of people or workers, safe environment and earn profit with recycle back waste of heat in the process. In order to select an appropriate heat exchanger, one would firstly consider the design limitations for each heat exchanger type. Although cost is often the first criterion evaluated.

PRODUCTION OF 100,000 TONNE PER ANNUM OF 2-ETHYLHEXYL ACRYLATE 5-3 MECHANICAL AND CHEMICAL DESIGN The simplest and cheapest heat exchanger is the fixed tube sheet design. The main advantages are the bundle cannot be removed for cleaning and there is no provision for differential expansion of shell and tubes. The U-tube requires only one tube sheet and is cheaper than the floating-head types. This type is widely used but limited in use to relative cleans fluids as the tube and budles are difficult to clean.

The exchanger with floating head is more versatile than fixed head and U-tube exchangers. They are suitable for high temperature differentials and easier to clean and also can be used for fouling liquids.

PRODUCTION OF 100,000 TONNE PER ANNUM OF 2-ETHYLHEXYL ACRYLATE 5-4 MECHANICAL AND CHEMICAL DESIGN Table 5.2: Selection of heat exchanger Significant feature Application best suited Both tube sheets fixed to shell Condenser; liquid-liquid; gasgas; liquid-gas, cooling and heating, horizontal or vertical, reboiling. Floating head or tube sheet (removable and nonremovable bundles) One tube sheet floats in shell or with shell, tube bundle may or may not be removable from shell, but back cover can be removed to expose tube ends. u-tube, u-bundle Only one tube sheet required. Tubes bent in U-shape. Bundle is removable. High temperature differentials which might require provision for expansion in fixed tube units. Clean service or easily cleaned conditions on both tube side and shell side. Horizontal or vertical Kettle Tube bundle removable as Utype or floating head. Shell enlarged to allow boiling and vapor disengaging. Boiling fluid on shell side, as refrigerant, or process fluid being vaporized. Chilling or cooling of tube side fluid in refrigerant evaporation on shell side. Bends must be carefully made or mechanical damage and danger of rupture can result. Tube side velocities can cause erosion of inside of bends. Fluid should be free of suspended particles. For horizontal installation. Physically large for other applications. High temperature differentials, above about 200F. Extremes; dirty fluids requiring cleaning of inside as well as outside of shell, horizontal or vertical. Internal gaskets offer danger of leaking. Corrosiveness of fluids on shell side floating parts. Usually confined to horizontal units.

Type designation Fixed tube sheet

limitations Temperature difference at extremes of about 200F

Source: Rules of Thumbs for chemical engineer, Carl Branan, 2002.

PRODUCTION OF 100,000 TONNE PER ANNUM OF 2-ETHYLHEXYL ACRYLATE 5-5 MECHANICAL AND CHEMICAL DESIGN 5.2 BASIC DESIGN PROCEDURES

5.2.1

Design Criteria for process heat exchanger

The criteria that a process heat exchanger must satisfy are easily enough stated if we confine ourselves to a certain process. The criteria include:

1) The heat exchanger must meet the process requirements. This means that it must effect the desired change in thermal condition of the process stream within the allowable pressure drops. At the same time, it must continue doing this until the next scheduled shut down for maintenance. 2) The heat exchanger must withstand the service conditions of the environment of the plant which includes the mechanical stresses of installation, start-up, shutdown, normal operation, emergencies and maintenance. Besides, the heat exchanger must also resist corrosion by the environment, processes and streams. This is mainly a matter of choosing materials of construction, but mechanical design does have some effect. 3) The heat exchanger must be maintainable, which usually implies choosing a configuration that permits cleaning and replacement. In order to do this, the limitations is the positioning the exchanger and providing clear space around it. Replacement usually involves tubes and other components that may be especially vulnerable to corrosion, erosion, or vibration. 4) The cost of the heat exchanger should be consistent with requirements. Meaning of the cost here implement to the cost of installation. Operation cost and cost of lost production due to exchanger malfunction or unavailable should be considered earlier in the design. 5) The limitations of the heat exchanger. Limitations are on length, diameter, weight and tube specifications due to plant requirements and process flow.

PRODUCTION OF 100,000 TONNE PER ANNUM OF 2-ETHYLHEXYL ACRYLATE 5-6 MECHANICAL AND CHEMICAL DESIGN Figure 5.1 shows the general outlines of the design procedures.

Step 1 Specification define duty

Step 10 Decide baffle spacing and estimate shell-side heat transfer coeffcient

Step 2 Collect physical properties

Step 11 Calculate overall heat transfer coefficient including fouling

Step 3 Assume value of overall coefficient Uo, ass

0 < Uo, cal Uo, ass < 30% Uo, ass

Step 4 Decide no of shell and tube passes calculate Tlm, correction factor and Tm

Step 12 Estimate tube and shell side pressure drops

Step 5 Determine heat transfer area required

Set Uo, ass = Uo, calc Pressure drop within specification ?

Step 6 Decide tube, tube size, material assign fluid to shell or tube side If No

If yes Step 13 Estimation cost of heat exchanger

Step 7 Calculate no of tubes Can design be optimized to reduce cost ?? Step 8 Calculate shell diameter

Step 9 Estimate tube-side heat transfer coefficient

If yes Accpet design

Figure 5.1: Design procedure of heat exchanger (Sinnot, 1999).

PRODUCTION OF 100,000 TONNE PER ANNUM OF 2-ETHYLHEXYL ACRYLATE 5-7 MECHANICAL AND CHEMICAL DESIGN 5.2.2 Fluid allocation factor

Table 5.3: Fluid allocation Factor Corrosion Fouling Fluid allocation The more corrosive fluid should be allocated to the tube side The fluid that has the greatest tendency to foul the heat transfer surfaces should be place in tube Fluid temperature If the temperature is high enough to require the use of special alloy, placing the higher temperature fluid in the tubes Operating pressure The higher pressure stream should be allocated to the tube side Viscosity A higher heat-transfer coefficient will be obtained by allocating the more viscous material to the shell side. (Sinnot, 1999) 5.3 5.3.1 CHEMICAL DESIGN OF HEAT EXCHANGER Step 1: Specification

The product, 2 ethylhexyl acrylate 12430 kg/hr, leaves at top of distillation column at 119.7C and is to be cooled to 30C by exchange with water at 20C.

Chilled water inlet, 20C 2-ethylhexyl acrylate at inlet, 119.7 C S24 E-107 S25 2-ethylhexyl acrylate at outlet, 30C

water outlet, 35C

The heat load was 2.989 x 106 kJ/hr or 830.278 kW

PRODUCTION OF 100,000 TONNE PER ANNUM OF 2-ETHYLHEXYL ACRYLATE 5-8 MECHANICAL AND CHEMICAL DESIGN

Cooling water balance ( )( )

Table 5.4: Fouling factor Fluid Coefficient (W/m2.C) Factor (resistance) (m2C/W) Cooling water (towers) Organic liquids 3000 - 60000 5000 0.0003 0.00017 0.0002 (Sinnot, 1999) 5.3.2 Step 2: Physical properties Table 5.5: Properties at tube side (Chilled water) Properties Temperature spec heat thermal conductivity density viscosity Flow rate Inlet 20 4.044 0.611 1007 0.8904 49320 Mean 27.5 4.0415 0.6213 1001.45 0.7719 49320 Outlet Unit 35 C 4.039 kJ/kgC 0.6315 W/mC 995.9 kg/m3 0.6514 cP 49320 kg/hr

Table 5.6: Properties at shell side (2-ethylhexylacrylate) Inlet Temperature spec heat thermal conductivity density viscosity Flow rate 119.7 2.966 9.903 x 10-2 792.7 0.394 12430 Mean 74.85 2.8335 0.1069 833.55 0.8565 12430 Outlet Unit

30 C 2.701 kJ/kg C 0.1147 W/m C 871.4 kg/m3 1.319 cP 12430 kg/hr

PRODUCTION OF 100,000 TONNE PER ANNUM OF 2-ETHYLHEXYL ACRYLATE 5-9 MECHANICAL AND CHEMICAL DESIGN

5.3.3

Step 3: Overall coefficient

According to typical overall coefficient as shown in Table 5.7, the overall coefficient will be in the range 250 to 750 W/m2C. So, first trial starts with 500 W/m2C.

Table 5.7: Typical overall coefficient Shell and Tube heat exchangers Hot fluid Coolers Organic Light oils Heavy oils Gases Organic Water Water Water Water Brine 250 - 750 350 - 900 60 - 300 20 - 300 150 - 500 (Sinnot, 1999) Cold fluid U (W/m2C)

5.3.4

Step 4: Exchanger Type and Dimensions

An even number of tube passes is usually the preferred arrangement, at these positions the inlet and outlets nozzles at the same end of heat exchanger which simplifies the pipe work.

PRODUCTION OF 100,000 TONNE PER ANNUM OF 2-ETHYLHEXYL ACRYLATE 5-10 MECHANICAL AND CHEMICAL DESIGN

T1 Temperature Shell t2 T2

t1

Tubes
Figure 5.2: Heat exchanger

Heat transfer

Start with one shell pass and two tube passes. ( ) ( ( ( ) ) )

Where

Assumptions: I. II. III. No change in specific heat The overall heat transfer coefficient is constant No heat losses

PRODUCTION OF 100,000 TONNE PER ANNUM OF 2-ETHYLHEXYL ACRYLATE 5-11 MECHANICAL AND CHEMICAL DESIGN True temperature difference by applying correction factor to allow for the departure from counter current flow:

Where Ft is temperature correction factor Two dimensionless temperature ratios: ( ( ) )

( (

) )

R = equal to the shell-side fluid flow rate times the fluid mean specific heat devided by the tube side fluid flow rate times the tube-side fluid specific heat. S = measure of the temperature efficiency of the exchanger Based on figure 12.19 0.98 An economic exchanger design cannot normally achieved if the correction factor falls below about 0.75

5.3.5

Step 5: Heat transfer area

5.3.6

Step 6: Layout and Tube size

PRODUCTION OF 100,000 TONNE PER ANNUM OF 2-ETHYLHEXYL ACRYLATE 5-12 MECHANICAL AND CHEMICAL DESIGN A shell-and-tube type heat exchanger is recommended because it is a versatile exchanger often used in similar applications. The main factors prompting this decision are the large surface area provided in a small volume, a good shape for higher pressure operations, and the ease of cleaning. The final factor is that design and fabrication methods are well established. This enables the design specification to be as close to the optimum as is practical. A floating head-type shell-and-tube heat exchanger is recommended for this application because of the need to provide capacity for thermal expansion of the tube bundle. The floating head also enables easy withdrawal of the tube bundle for cleaning purposes. This factor may be very advantageous, not because the streams are subjected to fouling, but because of the possibility high boiling residues carryover from the reactor will be deposited on the walls of the tubes. Finally, a split-ring heat exchanger is selected. This split-flange design reduces the large clearances for efficiency and ease of cleaning.

Table 5.8: Design specification Material Length of tube, Lt (m) Outer diameter, Dto, (m) Inner diameter, Dti, (m) Material thermal conductivity,(W/m.K) Pitch, Pt =1.25Dto (m) Stainless Steel 4.2672 0.01905 0.01575 16 0.02381 (Christie, 1993) 5.3.7 Step 7: Number of Tubes

)(

PRODUCTION OF 100,000 TONNE PER ANNUM OF 2-ETHYLHEXYL ACRYLATE 5-13 MECHANICAL AND CHEMICAL DESIGN

) Equation 5.11

5.3.8

Step 8: Bundle and Shell Diameter

( Where

Db = bundle diameter Dto = tube outside diameter

Table 5.9: Constant for use in equation 5.14

PRODUCTION OF 100,000 TONNE PER ANNUM OF 2-ETHYLHEXYL ACRYLATE 5-14 MECHANICAL AND CHEMICAL DESIGN

Triangular pitch, pt = 1.25 Dto number of passes K1 n1 1 0.319 2.142 2 0.249 2.207 4 0.175 2.285 6 0.0743 2.499 8 0.0365 2.675 (Sinnot, 1999)

Tube pinch = 1.25Dto Shell bundle clearance, Figure 12.12 is 58 mm The shell inside diameter, Ds = Db + 58 Ds = 386 + 58 Ds = 444 mm = 0.44m

5.3.9

Step 9: Tube side heat transfer coefficient

)(

PRODUCTION OF 100,000 TONNE PER ANNUM OF 2-ETHYLHEXYL ACRYLATE 5-15 MECHANICAL AND CHEMICAL DESIGN

5.3.10 Step 10: Shell side heat transfer coefficient 0.249 2.207

Shell bundle clearance, Figure 12.12 is 58 mm, (Sinnott and Towler 2009).

The shell inside diameter, Ds = Db + 58 Ds = 386 + 58 Ds = 444 mm = 0.444m As a first trial, take baffle spacing = Ds/2, this spacing should give good heat transfer without too high a pressure drop. Baffle spacing Lb= 222 Number of baffle = Nb +1 = L/Lb Nb = 18 baffles Cross flow As for the hypothetical row of tubes at the shell equator: ( ( ) )

Where Pt = tube pitch lb = baffle spacing

PRODUCTION OF 100,000 TONNE PER ANNUM OF 2-ETHYLHEXYL ACRYLATE 5-16 MECHANICAL AND CHEMICAL DESIGN Calculate the shell side equivalent diameter (hydraulic diameter) ( ( ) )

( (

)( )

Use baffle with a 25% cut which should give a reasonable heat transfer coefficient without too large pressure drop. From figure 12.29, By neglecting viscosity correction, ( )

5.3.11 Step 11: Overall Coefficient

( )

Where Uo = Overall Coefficient, W/m2C hs = Shell side coefficient, W/m2C

PRODUCTION OF 100,000 TONNE PER ANNUM OF 2-ETHYLHEXYL ACRYLATE 5-17 MECHANICAL AND CHEMICAL DESIGN hi = tube side coefficient, W/m2C hod = shell fouling factor, W/m2C hid = tube fouling factor, W/m2C kw= thermal conductivity of the tube wall material, W/m2C ( ( ) )

Percent error:

The value falls within the range, thus it is acceptable 5.3.12 Step 12: Pressure Drop 5.3.12.1Tube-side pressure drop

* Where

)(

Np= number of tube-side passes Ut = tube-side velocity, m/s L = length of tube. Jf = tube side friction factor, figure 12.24 = 2.7 x 10-3 Neglect viscosity correction ( )

5.3.12.2Shell-side pressure drop

PRODUCTION OF 100,000 TONNE PER ANNUM OF 2-ETHYLHEXYL ACRYLATE 5-18 MECHANICAL AND CHEMICAL DESIGN

)(

)(

Jf = shell side friction factor, figure 12.30 = 6 x 10-2 Neglect viscosity correction ( )

)(

)]

5.4

MECHANICAL DESIGN FOR HEAT EXCHANGER

In the mechanical design for heat exchanger subject to internal pressure, several steps need to be taken into consideration, the steps involve are:

1.

Design pressure and design temperatures

2. Material of construction 3. Design stress

4. Wall thicknesses 5. Head and closure thickness

6. Channel cover thickness 7. Dead weight load 8. Vessel support 9. Nozzle diameter 10. Baffle heat exchanger

5.4.1

Design pressure and temperature

PRODUCTION OF 100,000 TONNE PER ANNUM OF 2-ETHYLHEXYL ACRYLATE 5-19 MECHANICAL AND CHEMICAL DESIGN For vessel under internal pressure, the design pressure is taken as the pressure at which 5 to 10% above the normal operating pressure in order to prevent from spurious operation of relief valve during minor upsets. The strengths of materials decrease with increasing temperature, thus the maximum allowable stress will depend on the material of construction. Under the ASME BPV Code, the maximum working temperature at which the maximum allowable stress is evaluated should be taken as the maximum working temperature. Take a safety factor as 10%. For tube side, Operating temperature Design temperature For shell side Operating temperature Design temperature : 119.5 C : 119.5 x 1.1 = 131.45 C : 30 C : 30 x 1.1 = 33 C

Table 5.10: Design pressure and temperature for heat exchanger Operating Shell side Temperature , C 119.5 Tube side 35 Shell side 131.45 Design Tube side 38.5

Take design pressure of 3 bars for both shell and tube heat exchanger because of for safety reason and leakage inspection purpose (BASF). 5.4.2 Material of construction

Selection of suitable material must take into account the suitability of the material for fabrication as well as compatibility of the material with the process environment. A few factors that should be considered while choosing the material of construction are: Corrosion Resistance Operating conditions Economic feasibility

PRODUCTION OF 100,000 TONNE PER ANNUM OF 2-ETHYLHEXYL ACRYLATE 5-20 MECHANICAL AND CHEMICAL DESIGN Suitability for fabrication Process safety

Table 5.11: Material of construction Material Carbon Steel Advantage Low cost, easy to fabricate, abundant, most common material. Resists most alkaline environments well. Relatively low cost, still easy to fabricate. Resist a wider variety of environments than carbon steel. Available is many different types. Moderate cost, still easy to fabricate. Resistance is better over a wider range of concentrations and temperatures compared to stainless steel. Very good resistance to chlorides (widely used in seawater applications). Strength allows it to be fabricated at smaller thicknesses. Superior resistance to chlorides, even at higher temperatures. Is often used on sea water application where Titanium's resistance may not be acceptable. Disadvantage Very poor resistance to acids and stronger alkaline streams. More brittle than other materials, especially at low temperatures. No resistance to chlorides and resistance decreases significantly at higher temperatures. Little resistance to chlorides and resistance at higher temperatures could be improved.

Stainless Steel

254 SMO (Avesta)

Titanium

Pd stabilized Titanium

While the material is moderately expensive, fabrication is difficult. Much of cost will be in welding labor. Very expensive material and fabrication is again difficult and expensive.

PRODUCTION OF 100,000 TONNE PER ANNUM OF 2-ETHYLHEXYL ACRYLATE 5-21 MECHANICAL AND CHEMICAL DESIGN Nickel Very good resistance to high temperature caustic streams. Very wide range to choose from. Some have been specifically developed for acid services where other materials have failed. One of the few materials capable of withstanding weak HCl streams. Moderate to high expense. Difficult to weld. Fairly expensive alloys. Their use must be justified. Most are easy to weld. Brittle, very expensive, and very difficult to fabricate. Some stream components have been known to diffusion through some types of graphites. Extremely expensive, must be absolutely necessary.

Hastelloy Alloy

Graphite

Tantalum

Superior resistance to very harsh services where no other material is acceptable.

(Source: http://www.cheresources.com/exprules.shtml)

Vessel and pipes should be made of stainless steel or aluminium. Although 2-ethylhexyl acrylate does not corrode carbon steel, there is a risk of contamination if corrosion does occur (http://www2.basf.us).

Table 5.12: Types and characteristics of stainless steel Type 304(18/8) Characteristics Generally used. Contains minimum Cr and Ni that give Stable austenitic structure. Carbon content is low enough for heat treatment not to be normally needed with thin sections to prevent weld decay. low carbon version of type 304(<0.03 percent C) Used for thicker welded sections where carbide precipitation usually occur in 304. A stabilized version of 304 With titanium to prevent carbide precipitation during welding. Has slightly higher strength than 304L and more suitable for high temperature use. Molybdenum is added to improve corrosion resistance in reducing conditions such as in dilute

304L

321

316

PRODUCTION OF 100,000 TONNE PER ANNUM OF 2-ETHYLHEXYL ACRYLATE 5-22 MECHANICAL AND CHEMICAL DESIGN sulfuric acid.

From criteria selection above, it can be concluded that Stainless Steel 316 is the best material to be used in designing heat exchanger. Weld decay is the intergranular corrosion in chemical plant. This is caused by the precipitation of chromium carbides at the grain boundaries in a zone adjacent to the weld. Weld decay can be avoided by using low carbon grades (<0.3 percent C), or grades stabilized by the addition of titanium or molybdenum. Type 321 (or in BS1501 called 801-Ti) is a stabilized version of 304, stabilized with titanium to prevent carbides precipitation during welding.

5.4.3

Design stress

For design purpose it is necessary to decide the value for maximum allowable stress (nominal design strength) that can be accepted in the material of construction. 5.4.3.1 Tube side Material of construction Design temperature, C Internal pressure, Pi Allowable stress, S : Stainless steel 316 : 38.5 : 3 bar = 0.3 N/mm2 : 137.6891 N/mm2

5.4.3.2 Shell side Material of construction Design temperature, C Internal pressure, Pi Allowable stress, S 5.4.4 Wall thickness : Stainless steel 316 : 131.45 : 3 bar = 0.3 N/mm2 : 112.3163N/mm2

5.4.4.1 Minimum thickness of tube wall

Where

PRODUCTION OF 100,000 TONNE PER ANNUM OF 2-ETHYLHEXYL ACRYLATE 5-23 MECHANICAL AND CHEMICAL DESIGN Inner pressure, Pi = 0.3 N/mm2 Allowable stress, S = 137.6891 N/mm2 Inner diameter, Di = 15.75 mm Joint efficiency, E = 0.85 0.02 mm Corrosion allowance = 3mm Minimum thickness, t = 3.02 mm, 4.22 mm has chosen as tube thickness (Standard size).

5.4.4.2 Minimum thickness of shell wall

Where Inner pressure, Pi = 0.3 N/mm2 Allowable stress, S = 112.3163 N/mm2 Nominal shell diameter, Ds = 444 mm Joint efficiency, E = 0.85 0.7 mm Corrosion allowance = 4mm Minimum thickness, t = 4.7 mm, minimum thickness of 5 mm is chosen (Sinnot, 1999).

5.4.5

Head and closure thickness Table 5.13: Choice of closure

Flat plates and formed head

Cover for manways Channel cover for heat exchanger Cheapest type Limited to low pressure and small- diameter vessel Most commonly used For vessel up to operating pressure of 15 bar Most economical closure for pressure above 15 bar The strongest shape For high pressure

Torispherical head

Ellipsoidal head

Hemispherical head

PRODUCTION OF 100,000 TONNE PER ANNUM OF 2-ETHYLHEXYL ACRYLATE 5-24 MECHANICAL AND CHEMICAL DESIGN Price higher than Torispherical head

From Table 5.13 types of closures, by conducting the process condition and diameter of vessel, the most suitable head of closure are Torispherical head. 5.4.5.1 Torispherical head

uat

Rc = crown radius = 444 mm Inner pressure, Pi = 0.3 N/mm2 Allowable stress, S = 112.3163 N/mm2 Joint efficiency, E = 0.85

5.4.6

Channel cover thickness

Flat plates are used as the closure of heat exchangers. The minimum thickness of the channel cover required is calculated as follows: t
e

uat

Bolted cover with a full face gasket, take Cp = 0.4 and D equal to the bolt circle diameter. De = Ds t ( )

t= 9.1787mm + 4 mm = 13.1787mm 5.4.7 Dead weight load

5.4.7.1 Weight of vessel

PRODUCTION OF 100,000 TONNE PER ANNUM OF 2-ETHYLHEXYL ACRYLATE 5-25 MECHANICAL AND CHEMICAL DESIGN The calculations weight of a cylindrical vessel with domed ends, and uniform wall thickness, can be estimated from the following equation:

m )t

uat

Wv = total weight of shell Cv = 1.08 for vessel with few internal fittings Hv = length of cylindrical section = 4.2672m g = 9.81m/s2 t = wall thickness, mm = 5 mm Dm = mean diameter = (Ds + t x 10-3), m = (444 + 5) x 10-3 = 0.449 m
m

= density of vessel material, kg/m3 , stainless steel = 8300 kg/m3 ( )( )( )( ( )) )

5.4.7.2 Weight of tubes ( ) uat

Nt = number of tubes = 190 Do = outer diameter = 0.01950 m Di = inner diameter = 0.01575 m

= density of material = 8300 kg/m3 ( )( )( )( )

5.4.7.3 Weight of insulation Mineral wool density = 130 kg/m3 Thickness of insulation = 75 mm

PRODUCTION OF 100,000 TONNE PER ANNUM OF 2-ETHYLHEXYL ACRYLATE 5-26 MECHANICAL AND CHEMICAL DESIGN Density of insulation = 130 x 2 = 260 kg/m3

Approximate volume of insulation t V = 0.45 m3 W = Vg W = (130) (9.81) (0.45) W = 573.8850 N e u at uat

Total weight = vessel weight + tube weight + insulation weight Total Weight = + + 573.8850 = 29015.44 N = 27.26 kN

5.4.8

Vessel support

The support vessel will depend on the size, shape and weight of the vessel; the design temperature and pressure; the vessel location and arrangement and the external and internal fittings and attachments. Horizontal vessel normally mounted on two saddle support.

Saddles must be designed to withstand the load impose by the weight of the vessel and contents. The dimension of typical standard saddle designed are given in table

Table 5.14: Standard steel saddles (adapted from Bhattacharyya, 1976)

PRODUCTION OF 100,000 TONNE PER ANNUM OF 2-ETHYLHEXYL ACRYLATE 5-27 MECHANICAL AND CHEMICAL DESIGN

(Sinnot, 1999)

Table 5.15: Saddle support for heat exchanger Vessel Weight diameter kN m 0.45 m 27.26 Dimension , m V 0.37 Y 0.11 C 0.42 E 0.18 J 0.15 G 0.07 t2 t1 mm bolt bolt diameter holes 4.6 3.9 15.43 19.29 (Sinnot, 1999)

Figure 5.3: The diagram for saddle support and its dimensions (Sinnot, 1999).

PRODUCTION OF 100,000 TONNE PER ANNUM OF 2-ETHYLHEXYL ACRYLATE 5-28 MECHANICAL AND CHEMICAL DESIGN 5.4.9 Nozzle diameter

Designing tube side and shell side nozzles heat exchanger is based on TEMA heat exchanger standard. : Dopt = 293G0.52 : Dopt = 260G0.52
-0.37 -0.37

For carbon steel For stainless steel

Equation 5.33 Equation 5.34

Figure 5.4: Typical standard flange design, (BS 4504) (All dimensions mm) (Sinnot, 1999) 5.4.9.1 Tube side nozzle

PRODUCTION OF 100,000 TONNE PER ANNUM OF 2-ETHYLHEXYL ACRYLATE 5-29 MECHANICAL AND CHEMICAL DESIGN

Pipe size at inlet: Material of construction Flow rate Density Optimum duct diameter : : : :
:

Stainless steel 13.7 kg/s 1007 kg/m3 260G0.52 78.5 mm

The nearest value for optimum duct diameter is nominal pipe 80mm:

Pipe size at outlet: Material of construction Flow rate Density Optimum duct diameter : : : :
:

Stainless steel 13.7 kg/s 995.9 kg/m3 260G0.52

78.84 mm

The nearest value for optimum duct diameter is nominal pipe 80mm

5.4.9.2 Shell side nozzle Pipe size at inlet: Material of construction Flow rate Density Optimum duct diameter : : : :
:

Stainless steel 3.453 kg/s 792.7 kg/m3 260G0.52

41.895 mm

The nearest value for optimum duct diameter is nominal pipe 50 mm

Pipe size at outlet: Material of construction Flow rate Density Optimum duct diameter : : : :
:

Stainless steel 3.453 kg/s 871.4 kg/m3 260G0.52

40.45 mm

The nearest value for optimum duct diameter is nominal pipe 50 mm

PRODUCTION OF 100,000 TONNE PER ANNUM OF 2-ETHYLHEXYL ACRYLATE 5-30 MECHANICAL AND CHEMICAL DESIGN 5.4.10 Baffle heat exchanger

From chemical design calculation: Tube outside diameter Pitch, Pt Number of tubes Bundle diameter, Db Shell inside diameter, Ds Baffle spacing, Ib , Dto : : : : : : 0.01905m

0.02375m 190 0.386m 0.444m 0.222m

HC = baffle cut height = Ds x Bc, where Bc is the baffle cut as a fraction, Bc = 0.25 Hb, = height from the baffle chord to the top of the tube bundle, Bb= "bundle cut" = Hb/Db, b = angle subtended by the baffle chord, rads, Db = bundle diameter. Height from the baffle chord to the top of the tube bundle ( ( m ) uat )

Bundle cut uat m

From Figure 5.5, Ra (ratio of the bundle cross-sectional area in the window zone to the total bundle cross-sectional area) = 0.15 and b (angle subtended by the baffle chord) 1.9 rad = 108.86.

PRODUCTION OF 100,000 TONNE PER ANNUM OF 2-ETHYLHEXYL ACRYLATE 5-31 MECHANICAL AND CHEMICAL DESIGN

Figure 5.5: Baffle geometry factor (Sinnot, 1999) Number of tubes in window zone Nw = Nt x Ra Nw = 190 x 0.15 = 28.5 = 29 tubes For equilateral triangular pitch, pt= 0.87pt Pt = 0.87(0.02375) = 0.02066m Number of tube rows in window zone, Nwv
wv pt

Equation 5.37

uat

Nwv = 3.97 = 4 rows Number of tubes in cross flow zone, Nc = Nt 2Nw Nc = 132 tubes Ratio number of tubes in window zone to total number, Rw Equation 5.39

PRODUCTION OF 100,000 TONNE PER ANNUM OF 2-ETHYLHEXYL ACRYLATE 5-32 MECHANICAL AND CHEMICAL DESIGN
w w t

uat

Rw = 0.3 Window zone area: Aw

a)

uat

Aw = 0.015m2 Number of tube rows in cross flow zone area: Ncv ( ( Hb )

Ncv = 10.74 = 11 rows Baffle cut height, Hc Hc = Ds x Bc Equation 5.43

Hc = 0.444 x 0.25 = 0.111 m Assume tube to baffle clearance, Ct = 0.8 mm and baffle to shell clearance, Cs = 1.6mm Tube to baffle clearance area, Atb ( ) ( Atb = 0.00385 m2 Baffle to shell clearance area, Abs )

PRODUCTION OF 100,000 TONNE PER ANNUM OF 2-ETHYLHEXYL ACRYLATE 5-33 MECHANICAL AND CHEMICAL DESIGN

) ( ) ( )

Abs = 0.00156m2 Baffle cut area, Ab = Ib (Ds Db) Ab = 0.222(0.444 0.386) = 0.0129 m2

Figure 5.6: Baffle and tube geometry (Sinnot,1999).

Bundle diameter, Db Shell inside diameter, Ds Hc = 0.111 m b = 108.86

: :

0.386m 0.444m

5.4.11 Summary of mechanical design Table 5.16: Mechanical design sheet for heat exchanger Heat Exchanger Specification Sheet Designed by : Abdul Jalil OPERATING DATA
Size (m) Shells per unit Surface per Unit 1 1 Type Shell and tube No of Units 1 HORIZONTAL CONNECTED IN (parallel/series) Parallel Surface per shell 1 No of passes 2 PERFORMANCE OF ONE UNIT SHELL SIDE TUBE SIDE

Equipment No Description Sheet No Heat Exchanger 1/1

PRODUCTION OF 100,000 TONNE PER ANNUM OF 2-ETHYLHEXYL ACRYLATE 5-34 MECHANICAL AND CHEMICAL DESIGN
Fluid circulating Total fluid entering Vapor (kg/h) Liquid (kg/h) 3 Density (kg/m ) Viscosity liquid (cP) Specific Heat (kJ/kg K) Thermal conductivity (W/mK) Temperature (C) Pressure (kPa) Velocity (m/s) No of passes Fouling resistance (W/m2C) Pressure drop, kPa Heat exchange (kJ/hr) Material Insulation 2 Design Pressure (N/mm ) Design Temperature (C) O.D (mm) I.D (mm) Minimum thickness (mm) Length (m) Pitch (mm) Vessel cover Channel cover thickness, mm Dead weight of vessel (N) Weight of tube (N) Weight of insulation (N) Weight of heat exchanger(kN) No of baffles Baffle cut Stream 25 stream 26 IN OUT n/a n/a 12430 12430 833.55 0.8565 2.447 0.1253 119.7 30 121 0.72 1 784.48 5.4 Chilled water IN n/a 49320 1001.45 0.7719 4.0415 0.6213 20 489 0.21 2 3335.296 8.4
6

OUT n/a 49320

35

2.989 x 10 Stainless steel 316 Mineral wool 75mm 0.3 131.45 449 444 5 4.2672 23.81 Torispherical head, 5.2393 mm 13.1787 2869.3284 23817 573.8850 27.26 18 25% 0.3 38.5 19.05 14.83 4.22

REFERENCES

Branan, C. 2002. Rules of Thumb for Chemical Engineer. USA: Elsevier.

Christie, J. G. 1993. Transport Process and Unit Operations. New York: Prentice Hall. Don, W. G. and Perry, R. H. 1997. Perrys Chemical Engineers Handbook . US: McGrawHill Incropera & Dewitt. 2007. Fundamental of Heat and Mass Transfer. US: McGrawHill Publication.

PRODUCTION OF 100,000 TONNE PER ANNUM OF 2-ETHYLHEXYL ACRYLATE 5-35 MECHANICAL AND CHEMICAL DESIGN Sinnot, R. K. 1999. Chemical Engineering Design. Great Britain: Butterworth Heinemann. Thakore, S. B. and Bhatt, B. I. 2007. Introduction to Process Engineering and Design. India: McGrawHill Publication.

APPENDIX E

Table E1: Typical overall coefficient

PRODUCTION OF 100,000 TONNE PER ANNUM OF 2-ETHYLHEXYL ACRYLATE 5-36 MECHANICAL AND CHEMICAL DESIGN

Table E2: Fouling factors (coefficients), typical values

PRODUCTION OF 100,000 TONNE PER ANNUM OF 2-ETHYLHEXYL ACRYLATE 5-37 MECHANICAL AND CHEMICAL DESIGN

Figure E1: Temperature correction factor: one shell pass; two or more even tube passes

PRODUCTION OF 100,000 TONNE PER ANNUM OF 2-ETHYLHEXYL ACRYLATE 5-38 MECHANICAL AND CHEMICAL DESIGN

Table E3: Conductivity of metals

Figure E2: Tube-side heat-transfer factor

PRODUCTION OF 100,000 TONNE PER ANNUM OF 2-ETHYLHEXYL ACRYLATE 5-39 MECHANICAL AND CHEMICAL DESIGN

Figure E3: Shell-side heat-transfer factors, segmental baffles