HEAT EXCHANGER DESIGN

Process Design
Flow rate of Methanol, (Kg/h) 150000.00
Temperature of Methanol, T1 (
0
C) 90.00
Temperature of Methanol, T2 (
0
C) 45.00
Temperature of Water, t1 (
0
C ) 20.00
Temperature of Water, t2 (
0
C ) 40.00
Heat Exchanger Type : Split ring floating head type
Choose Baffle Cut, % 25.00
Shell Passes 1.00
Tube Passes 2.00
Heat Exchanger Design:
Actual Value
||||||||------DATA-------||||||||
Flow rate of Methanol, (Kg/h) 150000
Heat capacity of methanol, (KJ/Kg 0C) 2.84
Heat capacity of Water(Coolant/Hot fluid),
(KJ/Kg 0C)
4.2
Temperature of Methanol, T1 (0C) 90
Temperature of Methanol, T2 (0C) 45
Temperature of Water, t1 ( 0C ) 20
Temperature of Water, t2 (0C ) 40
Heat Load (KW or KJ/s) 5325
Cooling Water Flow,m (Kg/s) 63
Logarithmic mean temp. difference, T
lm,
0
C 36.1 25
R 2.25
S 0.29
Ft 0.87
Corrected Mena Temperature Difference, T
m
31 2
######################################
Assume Overall Heat Transfer Coefficient, U
W/m2 0C 700 TRUE 25
Provisional Area of exchanger, A, m
2
244
Tube length,L (m) 4.83
Outside Diameter, Do (mm) 20
Inside Diameter, Di (mm) 16
MOC of tube Steel
Area of One tube, A (m
2
) 0.303
No. of tubes, N
T
806
Triangular Pitch / Square Pitch, P
t
(mm) 25
No. of tube Passes 2
K1 0.249
n1 2.207
Bundle Diameter, D
b
(mm) 779
Tubes in Centre row 31.15628523
From Graph, bundle
diameter clearance Vs Bundle diameter for
differnet type of exchanger, take value of bundle
diameter Clearance
Bundle Diameter Clearance (mm) 65
Shell Diameter, Ds (mm) 844
===================================
Tube Side Coefficient, hi, (W/m
2 0
C)
Mean Water/coolant temperature, (
0
C) 30
Tube cross-sectional area, (mm
2
) 201.06
Heat Exchanger Type : Split ring floating head type
Tubes per pass 403
Viscosity of water, (mNs/m2) 0.8
Thermal Conductivity,(W/m0C) 0.38
Reynold No. 15647
Total flow area, A
t
(m
2
) 0.081
Water mass velocity, (Kg/m
2
s) 782
Density of water, (kg/m3) 993
Water linear velocity, (m/s) 0.79
Tube Side Coefficient, hi, (W/m
2 0
C) 4007
Shell Side Coefficient, h
s
(W/m
2 0
C)
Baffle Spacing, (mm) 169
Cross flow area, As (m
2
) 0.028
Mass velocity, Gs (Kg/s m
2
) 975
Equivalent diameter, d
e
(mm) 14.2 0.917
Mean Shell side temperature, (
0
C) 68
Methanol density, (kg/m3) 750
Methanol viscosity, (mNs/m2) or cP 0.34
Thermal Conductivity, (W/m 0C) 0.19
Reynold No. 40728
Prandtl No. 5.082105263
Choose Baffle Cut, % 25
From Graph Jh 0.0032
Shell Side Coefficient, h
s
(W/m
2

0
C) 2998
Mean temp. diff. across all resistance, (
0
C) 38
Temp. diff across methanol film, (
0
C) 9
Mean wall temperature, (
0
C) 59
Overall Coefficient
Thermal Conductivity of steel (W/m 0C) 50
Fouling Coefficinet(Dirt Factor), (W/m2 0C) 5000
Overall Coefficient, U
0
(W/m
2 0
C) 877
Area required, (m
2
) 193.4887179
A
0
, (m
2
) 244.6031474 232.186461
% Excess Area 26.10554386
Tube side Pressure Drop
Tube side Friction factor, jf 0.004
Tube side Pressure Drop, (N/m
2
) 7495.406533
Shell side Pressure Drop
Linear velocity, (m/s) 1.30
Shell side Friction factor, jf 0.04
Shell side pressure drop, (N/m
2
) 344947.7501
Pressure drop reduction,shell side,(N/m
2
) 86236.93752 86.2369375
heat transfer coefficient,shell side, w/m
2 0
C 1721.855673
Heat capacity of methanol, (KJ/Kg
0
C) 2.84
Methanol density, (kg/m
3
) 750
Methanol viscosity, (mNs/m
2
) or cP 0.34
Thermal Conductivity, (W/m
0
C) 0.19
Heat capacity of Water(Coolant/Hot fluid), (KJ/Kg
0
C) 4.2
Viscosity of water, (mNs/m
2
) 0.8
Thermal Conductivity,(W/m
0
C) 0.38
Density of water, (kg/m
3
) 993
Assume Overall Heat Transfer Coefficient, U W/m
2

0
C 700 TRUE 25
Tube length,L (m) 4.83
Outside Diameter, Do (mm) 20
Inside Diameter, Di (mm) 16
MOC of tube Steel
K1 0.249 0.917
n1 2.207
Thermal Conductivity of steel (W/m
0
C) 50
Fouling Coefficinet(Dirt Factor), (W/m
2 0
C) 5000
F
t
0.87
From Graph J
h
0.0032
Bundle Diameter Clearance (mm) 65
Tube side Friction factor, j
f
0.004
Shell side Friction factor, jf 0.04
Assume viscosity correction factor is equal to one.
temp. F to C, K and R 36.66666667 309.6666667 557.4 98
heat capacity cal/mol K to KJ/kg C 2.84 18
pressure N/m2 to kpa and bar 68.409 684.09 68409
pressure mm Hg to psf, psi,N/m2 1428.752515 9.921892466 68409.04 513.11
Density of liq, g/cc to kg/m3 790 0.79
liquid density, (kg/m3) 992.8961361 30 303 5.459
0.30542
647.13
0.081
Thermal Conductivity, (W/m C) 0.38213422
1.950133
Typical Overall Heat Transfer Coefficients- For Refining Operation
Btu/h ft
2 0
F to W/m
2 0
C 199 256 35 45
Debutanizer Condenser 75 90
Debutanizer Reboiler (STM) 85 100
Deisobutanizer Feed Preheater (STM) 75 100
Deisobutanizer Condenser 80 90
Deisobutanizer Reboiler (STM) 90 100
Depropanizer Feed Preheater (STM) 90 100
Depropanizer Condenser 90 100
Depropanizer Reboiler (STM) 75 95
Depropanizer Feed/Btms Exchanger 60 80
Olefin Feed Chiller 70 80
Refrigeration Condenser 90 100
Rerun Tower Preheater (STM) 60 80
Rerun Tower Condenser 65 80
Rerun Tower Reboiler (STM) 80 100
Rerun Tower Bottoms Cooler 50 70
Range, (Btu/h.ft.F)
Range, (Btu/h.ft.F)
Alkylation
Amine Treating
Rich/Lean Amine Exchanger 75 90
Regenerator Condenser 70 90
Regenerator Reboiler (STM) 100 120
Lean Amine Cooler 80 90
Naphtha Cooler 55 65
Feed / DFO 35 45
DFO Cooler 45 55
DFO Cooler (300-400 F) 80 100
Gas Oil / DFO 40 50
Gas Oil / Quench 35 50
Gas Oil / Tar 30 40
Quench or STB / Feed 35 45
Quench / BFW 60 80
Quench or STB Cooler 30 50
Quench and/or STB Cooler (300-400
F) 50 70
Quench Steam Gen. 70 90
Reduced Crude / Quench 35 45
Reduced Crude / Tar Sep. Btms. 30 40
SYN Tower Condenser 30 40
Crude / Heavy Gas Oil 40 50
Crude / Kerosene 35 45
Crude / Light Gas Oil 40 50
Crude / Naphtha 40 50
Range, (Btu/h.ft.F)
Crude Distillation
Catalytic Cracking
Range, (Btu/h.ft.F)
Crude / Reduced Crude 25 35
Crude / Vac. Tar 25 30
Heavy Gas Oil Cooler 50 50
Heavy Gas Oil Steam Gen. 100 120
Kerosene Cooler 55 65
Light Gas Oil Cooler 45 55
Lube Dist. / Crude 40 50
Naphtha Cooler 60 70
Reduced Crude / Gas Oil 35 45
Reduced Crude / Naphtha 40 50
Reduced Crude Cooler 20 30
Tower Overhead / Crude 30 40
Tower Condenser 45 55
Vac. Tar / Steam Gen. 45 55
Vac. Tar Cooler (box) 10 20
Charge / Reactor Effluent 60 70
Charge / Gas Oil Product 55 65
Charge / HTS Off Gas 50 60
HTS Off Gas / Water Condenser 75 85
Stripper Feed / Gas Oil Product 55 65
Stripper Bottoms Cooler 65 75
Stripper Condenser 55 65
Total Gas / Gas Oil Product 55 65
Absorber Intercooler 60 70
Compressor Contactor Cooler 75 90
Deethanizer Condenser 80 100
Deethanizer Reboiler 80 100
Debutanizer Feed / Btms 60 70
Range, (Btu/h.ft.F)
Light Ends Processing
Hydrodesulfurization
Range, (Btu/h.ft.F)
Debutanizer Feed Preheater (STM) 80 100
Debutanizer Condenser 75 90
Debutanizer Condenser Aftercooler 40 50
Debutanizer Reboiler (STM) 80 100
Depropanizer Feed / Btms 70 90
Depropanizer Condenser 90 100
Depropanizer Reboiler (Hot Oil) 55 65
Depropanizer Reboiler (STM) 80 100
Fractionating Abs. Reboiler 75 90
Gasoline Cooler 70 80
Lean Oil / Rich Oil Exchanger 45 55
Lean Oil Cooler 60 70
Propane and/or Butane Cooler 75 85
Stabilizer Btms. / Feed 65 75
Stabilizer Condenser 70 90
Stabilizer Reboiler 75 100
Extraction
Solvent Vapor / Extract Mix (75%
Solvent) 225
Treating Tower Intercooler 60 100
Solvent / Charge Oil 20 40
Solvent Water Cooler 90
Raffinate Oil / Raffinate Oil Mix 20 60
Raffinate Oil / Water Cooler 25 60
Solvent / Raffinate Oil Mix 30
Raffinate Oil Mix / Steam 35
Raffinate Oil Mix / Steam Evaporator
(80% Solvent) 90
Raffinate Oil Mix / Steam Evaporator
(45% Solvent) 70
Raffinate Oil Mix / Steam Evaporator
(13% Solvent) 40
Atmospheric Solvent Vapors / Extract
Mix 60
Extract / Water Cooler (Submerged
Coil) 10 15
Dry Solvent Vapor (Vacuum) / Water
Condenser (+Subcooling) 60
CBM / Water Condenser (Subcooling
to 150F) 120
Vacuum Pump Aftercooler 10
Steam / Steam Superheater 15
Lube & Wax Processing
Range, (Btu/h.ft.F)
Extract Mix / Steam Evaporator (80%
Solvent) 90
Extract Mix / Steam Evaporator (45%
Solvent) 70
Extract Mix / Steam Evaporator (13%
Solv ent) 40
Extract Mix / Solvent Vapor (80%
Solvent) 90 115
Extract Mix / Solvent Vapor (45%
Solvent) 55
Extract Mix / Solvent Vapor (13%
Solvent) 35
Wet Solvent Vapor (Vacuum) / Water
Condenser (+Subcooling) 105
Extract Mix (10% Solvent) / Extract
Mix (80% Solvent) 15
Cold Pressed Oil Mix / Solvent 30
Cold Slack Wax Mix / Steam 45
Flue Gas / Ammonia Chiller 6 10
Flue Gas / Water Cooler 10 20
Hot Solvent / Wax Oil 65
Pressed Oil / Pressed Oil Mix 30 40
Pressed Oil / Water Cooler (to 150F) 25
Slack Wax / Slack Wax Mix 30
Solvent / Ammonia Chiller 60
Solvent / Cold Slack Wax Mix 10
Solvent / Water Cooler (5# delta P) 90
Solvent / Water Cooler (1# delta P) 70
Solvent Vapor / Pressed Oil Mix 45 100
Solvent Vapor / Slack Wax Mix 65
Solvent Vapor / Pressed Oil 80
Solvent Vapor / Pressed Oil 90
Solvent Vapor / Slack Wax Mix (3:1
Solvent Ratio) 80
Solvent Vapor / Slack Wax Mix (4:1
Solvent Ratio) 90
Solvent Vapor / Water Condenser (No
Subcooling) 100
Steam / Steam Superheater 15
Steam / Pressed Oil (2:1 Solvent
Ratio) 15 70
Steam / Pressed Oil (3:1 Solvent
Ratio) 35 100
Steam / Pressed Oil (4:1 Solvent
Ratio) 125
Steam / Slack Wax Mix (1:2 Solvent
Ratio) 15 70
Steam / Slack Wax Mix (2:1 Solvent
Ratio) 60
Steam / Slack Wax Mix (3:1 Solvent
Ratio) 70
Dewaxing
Steam / Slack Wax Mix (4:1 Solvent
Ratio) 125
Warm Wash Heater 100
Wax Oil Mix / Ammonia DP Chiller
(with Scrapers) 30
Wax Oil Mix / Ammonia DP Chiller
(without Scrapers) 20
Wax Oil Mix / Pressed Oil Mix DP
Exchanger 15 20
Wax Oil Mix / Water Cooler 30
Wet Solvent Vapor Condenser (with
Subcooling) 75
Pretreater Reactor Effluent / Charge
(Cold End) 65 75
Pretreater Reactor Effluent / Charge
(Hot End) 70 80
Pretreater Reactor Effluent Condenser 80 90
Naphtha Splitter Feed / Botomms 65 80
Naphtha Splitter Condenser 65 75
Reactor Effluent Condenser 80 100
Reactor Effluent / Feed (Cold End) 70 85
Reactor Effluent / Feed (Hot End) 80 90
Splitter or Stripper Feed / Pretreater
Effluent 75 85
Stabilizer Reboiler (Hot Oil) 75 95
Coker Combination TWR Condenser 40 50
Gas Oil / Gas Oil 30 40
Naphtha Hydrotreating & Reforming
Range, (Btu/h.ft.F)
Thermal Cracking
Range, (Btu/h.ft.F)
G.O. Cracker O'hd Condenser 45 65
Gas Oil Reflux Steam Gen. 80 90
Gasoline / Naphtha Charge 60 80
Thermal Tar Cooler (box) 10 20
Thermal Tar Steam Gen. 40 50
Top Reflux / BFW 60 80
Top Reflux / Naphtha 60 80
Top Reflux / Naphtha Charge 50 60
Top Reflux Cooler 55 65
Typical Overall Heat Transfer Coefficients
SHELL AND TUBE
EXCHANGERS
Hot fluid Cold fluid U(W/m
2 0
C)
HEAT EXCHANGEERS
Water Water 850-1500
Organic solvent Organic solvent 100-300
Light oil Light oil 100-400
Heavy oil Heavy oil 50-300
Gases Gases
COOLERS
Organic solvent Water 250-750
Organic solvent Brine 150-500
Light oil Water 350-900
Heavy oil Water 60-300
Water Brine 600-1200
Gases Brine 15-250
HEATERS
Steam Water 1500-4000
Steam Organic Solvent 500-1500
Steam Light oil 300-900
Steam Heavy oil 60-450
Steam Gases 30-300
Dowtherm Heavy oil 50-300
Dowtherm Gases 20-200
Flue gases Steam 30-100
Flue Hydrocarbon vapours 30-100
CONDENSERS
Aqueous vapours water 1000-1500
Organic vapours water 700-1000
Organic(non-condensable) water 500-700
vacuum condensers water 200-500
VAPORISERS
Steam Aqueous solution 1000-1500
Steam Light organics 900-1200
Steam Heavy organics 600-900
Tube side heat transfer factor
Bundle diameter clearance
For shell side HTC
For shell side Pressure drop