EG-339 Process Equipment Design

Coursework 2024

Question-1-Part- (a):

The mass flow rate of n-heptane: (ṁ) heptane = 2800 kg/hr = 0.77 kg/s, an inlet temperature of n-
heptane: Tin = 0 ⁰C, the Outlet pressure of n-heptane: P out =2 bar gauge, Heat source: Steam at
8 bar gauge, Vaporiser type: Kettle style (typically used for vaporizing liquids).

Using the thermodynamic properties of n-heptane:

Specific heat of liquid n-heptane (Cp)heptane = 2.25 kJ/kg·K for n-heptane, latent heat of
vaporization (ΔHvap) = around 317 kJ/kg for n-heptane, assuming the boiling point of n-
heptane at 2 bar gauge is approximately 98 ⁰C = Tboiling.

Sensible heat = Qsensible = (ṁ)heptane × (Cp)heptane × (Tboiling - Tin) = 0.77 × 2.25 × (98 – 0) ≈
169.78 kW

Latent heat = Qlatent = (ṁ)heptane × ΔHvap = 0.77 × 317 ≈ 244.09 kW

Total Heat Duty = QTotal = Qsensible + Qlatent = 169.78 + 244.09 ≈ 413.87 kW

Consider a 5% for heat losses:

Maximum heat duty = Qmax = 1.05 × 413.87 = 434.56 kW

The enthalpy of steam at 8 bar gauge (9 bar absolute) using the thermodynamic properties of
n-heptane: hsteam ≈ 2778 kJ/kg, hcondensed ≈ 720 kJ/kg

ΔHsteam = hsteam + hcondensed = 2778 – 720 = 2058 kJ/kg

QTotal
The mass flow rate of steam = (ṁ)steam = = ¿ ) = 0.201 kg/s
ΔH steam

Question-1-Part- (b):

Let's assume a typical tube size of 25 mm (1 inch) outer diameter and 5 m length (one U-
tube), often used in heat exchangers used for medium to large-scale applications [1][2].
Outer diameter = OD = 25 mm = d

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Clearance = Ct = 2 mm (given)
Inner diameter = OD – (2 × Ct) = 25 – (2 × 2) = 21 mm
Tube pitch = P = 1.25 × OD (square pitch arrangements)
Tube pitch = P = 1.25 × 25 = 31.25 mm
Let us assume a typical steam-heated shell and tube-type heat exchanger where n-heptane is a
cold fluid that comes in the category of heavy organic fluid, therefore the overall heat transfer
coefficient (U) will be approximately 1000 W/m2.K [3].
Using the thermodynamic properties of steam and n-heptane:
Steam temperature (8 bar gauge) ≈ 170°C, n-heptane feed temperature = 0°C, the outlet, the
temperature of the n-heptane at 2 bar gauge ≈ 98°C, and QTotal = 413.87 kW

( 170−98 )−( 170−0 )

−98
Log mean temperature difference = ΔTLMTD = ( 170−98 ) = = 115.29 °C
ln −0.85
( 170−0 )
QTotal = U ×A ×ΔTLMTD = 1000 × A × 115.29

413870
A= = 3.58 m2
( 1000× 115.29 )

Hence, the heat transfer area = A = 3.58 m2

Now, the area of each tube = At = π ×0.025 × 5 ≈ 0.4 m2
Then, the number of tubes = Nt = A/At = 3.58/0.4 = 8.95 ≈ 9 (safe side)
Hence, the number of tubes = Nt = 9
For a square pitch arrangement, bundle diameter can be estimated as Db = P √ ( N t ) / 0.215
Db = (31.25) √ ( 9 ) / 0.215 = 202.18 mm ≈ 0.2022 m (safe side)
Hence, bundle diameter = Db = 0.2022 m
Shell diameter = Ds = 2 × Db = 2 × 0.2022 = 0.4044 m
Hence, Shell diameter = Ds = 0.4044 m

Bundle-shell clearance: The bundle-shell clearance refers to the distance between the outer
edge of the tube bundle to the inner wall of the shell in a shell-and-tube heat exchanger [4].
Hence, bundle-shell clearance = 0.4044 – 0.2022 = 0.2022 m or 202.2 mm
The freeboard is the space above the liquid level and should be about 15-20% of the shell
diameter:
Hence, freeboard = 0.2 ×0.4044 = 0.0808 m or 80.8 mm
The liquid level is typically set at around 75% of the shell diameter:
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Hence, liquid level = Ll = 0.75 ×0.4044 = 0.3033 m or 303.3 mm

Freeboard
= 80.8 mm

Liquid level
= 303 mm
Tube bundle
OD = 202 mm

To calculate the vapor velocity at the surface, we have to calculate the cross-sectional area at
the top of the liquid level:

Qmax 434.56
Heat flux based on estimated area = = = 121.38 kW/m2
A 3.58

Avapor = Shell area – Bundle area = (π ×(0.4044)2/4) – (π ×(0.2022)2/4) = 0.128 – 0.032

Avapor = 0.096 m2
The mass flow rate of steam = (ṁ)steam = 0.201 kg/s (calculated in Part-A)
The density of steam at 8 bar gauge and 172 ⁰C = 4.16 kg/m3

0.201
Hence, the vapor velocity at the surface = Vv = = 0.503 m/s
4.162 ×0.096

For condensing or evaporating fluids, lower velocities are usually preferred to ensure
efficient phase change and prevent damage to the tube walls. Lower vapor velocities reduce
the risk of erosion and vibration in the tubes, which can extend the lifespan of the exchanger.
Additionally, a lower vapor velocity can help maintain stable heat transfer without causing
excessive pressure drop or impingement on the tubes. Therefore, a vapor velocity of 0.503
m/s should be acceptable and should provide safe, stable operation without significant
erosion or vibration issues [5] [6].
Question-1-Part- (C):

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P1 = Shell side pressure = 2.5 MPa

P2 = Tube side pressure = 1.5 MPa

Corrosion allowance = 2 mm

Tubesheet design temperature = 200 ⁰C

Allowance stress for mild steel at 200 ⁰C = f = 150 MPa

Allowable shear stress = τ = 90 MPa

The elastic modulus for mild steel = E = 200 GPa

The elastic modulus for tube = Et = 190 GPa

Design stress factor = Ω = 1

Acting pressure on tube = p = 2.5 – 1.5 = 1 MPa

Tube sheet material = Mild steel

Allowance stress for mild steel at 200 ⁰C for tube side = ft = 105 MPa

Allowable shear stress for tube side = τt = 63 MPa

Tube diameter = d = 25 mm = OD

Tube clearance for insertion in hole = Ct = 2 mm

Tube hole diameter = dh = 27 mm or (d + Ct)

Tube pitch = P = 31.25 mm

Ligament efficiency for shear = λ = (P - dh)/P = (31.25 - 27)/31.25 = 0.136

h = tube bundle to shell clearance = 202.2 mm

Do = diameter of outer tube limit circle for square layout = P

mm
√ Nt
(π /4) √
= 31.25
9
(π /4)
= 105.7

Design assumption (given) = D1 = D2 = DO + 2h = 105.7 + (2 ×202.2) = 510.1 mm

P 31.25
P* =
√ 1−
π Do
2
√
16 D o P =
1−
16 × 105.7 ×31.25 = 43.40 mm
π ×105.7
2

Length of expansion = l = tube sheet thickness = e

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 Et f t l
dh* = max{[d – 2et ( ) ( )( )]; [d – 2et]}
E f e

Et f t l 190 105 1
[d – 2et ( ) ( )( )] = [25 – 2×2 ( )( )( )] = 22.34 mm
E f e 200 150 1

[d – 2et] = 25 – (2×2 ) = 21 mm

Hence, dh* = 22.34 mm (maximum of two calculated above)

¿ ¿
P −d h 45.28−22.34
Ligament efficiency of tube sheet and tube walls in bending = μ = = =
P¿ 45.28
0.506

p 1
V=[ ]0.5 = [ ]0.5 = 0.114
Ω× μ × f 1× 0.506 ×150

d 2 25 2
X1 = 1 – N ( ) =1–9( ) = 1 – 0.503 = 0.497
Do 105.7

d−2 e t 2 25−( 2 ×2 ) 2
X2 = 1 – N ( ) =1–9( ) = 0.645
Do 105.7

δ = X2 - X1 = 0.645 – 0.497 = 0.148

Fs = 0.5 (X2 + X1) = 0.5(0.645 + 0.497) = 0.571

Here, p1 > p2

R = D1/Do = 510.1/303 ≈ 1.06

Using Table 3.9.1

Basic design factor (Co) = 0.576

Corrective design factor (ΔC) = 0

Design factor (C) = Basic design factor (C o) + Corrective design factor (ΔC) = 0.576 + 0 =
0.576

eB = C × Do × V = 0.576 ×105.7 × 0.114 = 6.94

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 0.155 × Do× p 0.155 ×105.7 ×1
Shear = es = = = 1.33
λ×τ 0.136 ×90

Minimum acceptable thickness = e = max {eb, es} = eb = 6.94

Tube sheet thickness = e + corrosion allowance = 6.94 + 2 = 8.94 mm

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 EG-339 Coursework 2024
Group Member Names:
Student Numbers:

Part (a) Duty = 413.87 kW Steam Demand = 0.201 kg/s

Part (b) d = 25 mm Nt = 9 Db = 202.2 mm
P = 31.25 mm Npasses = NA U = 1000 W/m2°C
Clearance = 2 mm Di = 21 mm A = 3.58 m2
Freeboard = 80.8 mm Liquid Level = 303.3 mm Vapour velocity at
surface = 0.503 m/s

Part (c): U-tube tubesheet design working form adapted (for teaching purposes only) from PD5500:2018
Load Case: Clause
reference
Consistent Units: dimensions = ; p/f/τ/ E =

Shellside Tubeside U-tube sheet thickness 3.9.3

Design pressure 2.5 MPa 1.5 MPa Pressure acting on tube

Corrosion allowances 2 mm 2 mm 𝑝 = | 𝑝2 − 𝑝1 | 1 MPa 3.9.3.1

[ ]
1/2
Tubesheet design 200 ⁰C 200 ⁰C P 0.114
V = Ω× μ × f

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 temperatures
Tubesheet material Mild steel Mild steel

Allowable bending f =150 ft = 105 𝑅 = 𝐷1 ⁄𝐷0 if 𝑝1 > 𝑝2 1.06 Note 2

= 𝐷2 ⁄𝐷0 if 𝑝2 > 𝑝1
stress at MPa MPa
design
= max of above if 𝑝1 = 𝑝2
shear τ = 90 τt = 63
temperature
MPa MPa

Co 576 Table:3.9-1
Design stress factor (3.9.1)

Young’s Tubesheet E = 200 GPa ΔC 0 Table:3.9-1

modulus
Tubes Et = 190 GPa C = C + ΔC 0.576

Ligament Efficiency (ref 3.9.2.1) Bending 𝑒𝐵 = 𝐶𝐷𝑜 𝑉 6.94 3.9.3.1

3.9.3.1
0.155 × Do × p 1.33
For shear: Shear = es =
𝜆 = (𝑃 − 𝑑ℎ ) ⁄𝑃 = 0.136
λτ

Min. acceptable thickness = 6.94

𝑒 = max {𝑒𝐵 ; 𝑒𝑆}
For bending:

Tubesheet thickness = 8.94

e + allowances

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 P
𝑃∗ =
√ [
1−4 min ( S ) ;
( 4 Do P
πD 2
o
)] = 43.40 mm

¿ Et f t
d h = max [𝑑 − 2𝑒t ( )( )]=22.34mm
E f

𝜇=
¿ ¿
P −d h
= 0.506
P¿

Pressure factors (ref 3.9.1)

𝑥1 = 1 − N ( D ) = 0.497
d
o

𝑥2 = 1 – N (
d−2 e t 2
) = 0.645
D0

𝛿 = 𝑥2 − 𝑥1 = 0.148

𝐹S = 0.5(𝑥1 + 𝑥2) = 0.571

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(i) Tube inside diameter = 21 mm
(ii) Tube outer diameter = 25 mm
(iii) Number of tubes (Nt) = 9
(iv) Tube pitch (P) = 31.25 mm
(v) Bundle diameter (Db) = 202.18 mm
(vi) Shell diameter (Di) = 404.4 mm
(vii) Bundle-Shell Clearance = 202.2 mm
(viii) Freeboard = 80.8 mm
(ix) Liquid Level = 303.3 mm
(x) Vapour velocity at surface = 0.503 m/s
(xi) Overall Heat Transfer Coefficient (U) = 1000 W/m2.C⁰
(xii) Heat Transfer Area (A) = 3.58 m2

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References:
[1] Mukherjee R. Effectively design hell-and-tube heat exchangers. Chem Eng Prog
1998;94:21–37.
[2] Towler G, Sinnott R. Principles, Practice and Economics of Plant and Process Design.
2013.
[3] Design HE. Typical overall heat transfer coefficients. Fundam Ind Heat Exch
2024:455–6. https://doi.org/10.1016/b978-0-443-13902-4.09980-7.
[4] Mr. Sunil R Taware, Mr. Dipak S Patil, Dr. R. R. Arakerimath. Design, Fabrication
and Testing of Shell and Tube Heat Exchanger for Heat Recovery from Hydraulic Oil.
Int J Eng Res 2017;V6. https://doi.org/10.17577/ijertv6is070289.
[5] Green DW, Perry RH. Perry’s Chemical Engineers’ Handbook, Eighth Edition. 8th ed.
/. New York: McGraw-Hill Education; 2008.
[6] Towler, Gavin, and Sinnot R. Chemical Engineering Design. 2022.
https://doi.org/10.1016/c2019-0-02025-0.

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