Organic Solvents Shell Side

11

Water Tube Side

 SHELL SIDE hydrocarbon 1 TUBE SIDE Water -1
symbol values units SI Values symbol values units SI Values

Thermophysical Properties :
Density of Fluid ρS = 662.5 kg/m3 662.50000 Density of Fluid ρT = 993 kg/m3 993.00000
Viscosity μS = 0.117 cP 0.00012 Viscosity μT = 0.0008 kg/ms 0.00080
Thermal Conductivity kS = 0.08376 J/s m K 0.08376 Thermal Conductivity kT = 0.623 J/s m K 0.62300
Specific Heat cp,S = 0.117 KJ/kg K 117.00000 Specific Heat cp,T = 4.175 KJ/kg K 4175.00000
Fouling Factor RdO = 0.00021 h m2 C / kcal 0.00018 Fouling Factor Rdi = 0.00035 h m2 C / kcal 0.00030

Temperature ΔT:
Temperature In TS,in = 211 C 484.15000 Temperature In TT,in = 25 C 298.15000
Temperature Out TS,out = 107 C 380.15000 Temperature Out TT,out = 50 C 323.15000

0 Specify : hydrocarbon Mass Flow Rate 50 tonne/day 5.7870370500E-01

Mass Flow Rate mS = 0.578703705 kg/s Mass Flow Rate mT = 0.06746507 kg/s
Volumetric Flow Rate qS = 0.000873515 m3/s Volumetric Flow Rate qT = 6.794065E-05 m3/s

Heat Duty Q = 7041.666682 J/sec 7041.66668244 LMTD Calculation:

Flow Type : Counter-Current

[assume] Overall Heat Range: 250 - 750 W/m2 K Hot Ends Temp. Diff ΔT1 = 161 K
Transfer coefficient U* = 350 kcal/h m2 C 407.05 Cold Ends Temp. Diff ΔT2 = 82 K
0 0
Correction Factor R= 4.16 S= 0.134408602150538 Log Mean Temp. Diff LMTD = 117.0916594 K
Auto fT = fT = 1 LMTD (corrected) LMTD* = 117.0916594 K
0
Heat Transfer Area : AHT = 0.1477412 m2

Design Specifications :
Shell Diameter DS = 10 in. 0.254 Length of Tube LT = 4.5 m 4.5
Tube Clearance cT = 0.0064 m 0.0064 Outside Dia. of Tube dO = 0.75 in. 0.01905
Baffle Spacing B= 0.1 m 0.1 Thickness of Tube δ= 16 BWG 0.001651
Tube Pitch PT = 1 in. 0.0254 Inside Dia. of Tube di = 0.015748
Outer Surface Area [Single Tube] : aST = 0.269313 m2

Pitch Type : Equivalent Diameter No. of Tubes NT = 1 No. of Tube Passes NP :

Triangular DH = 0.01803353 m No. of Tubes per Pass n= 1 4

Flow Area [= cT B DS / PT] aS = 0.0064 m2 Flow Area of Tube [inside] aT = 0.000194778 m2 Phase:
Linear Velocity of Tube [inside] uT = 0.348810085 m/s Liquid

Mass Velocity [= mS / aS] GS = 90.42245391 kg/m2 s Mass Velocity [= mT / aT] GT = 346.3684146 kg/m2 s
 Heat Transfer Co-efficient Calculations :
Reynolds # [= DHGS/μS] ReS = 13937 Turbulent Flow Reynolds # [= ρTuTdi /μT] ReT = 6818 Turbulent Flow
Prandtl # [= cp,S μS / kS] PrS = 0.163 Prandtl # [= cp,T μT /kT] PrT = 5.361

Method: NuS = 37.63721893 Method: NuT = 52.12704472

Auto jH = 32 Auto jH = 85
Shell Side HT Co-efficient hO,S = 174.812925 W/mK Tube Side HT Co-efficient hi,T = 2062.17608 W/mK

[Design] Overall Heat Transfer coefficient Udo = 145.95093 W/mK

Pressure Drop Calculations :

g= 9.8

Friction Factor (use graph) fS = 0.052 Friction Factor (use graph) fT = 0.0037
Number of Baffles Nb = 44 Pressure Drop ΔPT = 26.06874157 kg / m2
Pressure Drop ΔPS = 20.75293586 kg / m 2
Return Loss ΔPr = 98.6259561 kg / m2

Shell Side Pressure Drop ΔPS = 20.7529359 kg / m2 Tube Side Pressure Drop ΔPT = 124.694698 kg / m2

(
Background

A shell and tube heat exchanger, also known as the “workhorse” of industrial process heat transfer, i
It is the most common type of heat exchanger in oil refineries and other large chemical proc
applications. Other types of heat exchangers are used when economical. Though the applicatio
increasing, the shell and tube heat exchanger will continue its popularity for a long time, largely beca

Construction
As its name implies, this type of heat exchanger consists of a shell (a large pressure vessel) with a b
through the tubes, and another fluid flows over the tubes (through the shell) to transfer heat betw
called a tube bundle, and may be composed by several types of tubes: plain, longitudinally finned,
Shell and tube heat exchanger units can be designed for almost any combination of pressure and tem

Requirements of Heat Exchangers

Heat exchangers have to fulfil1 the following requirements:

1. High thermal effectiveness
2. Pressure drop as low as possible
3. Reliability and life expectancy
4. High-quality product and safe operation
5. Material compatibility with the process fluids
6. Convenient size, easy for installation, reliable in use
7. Easy for maintenance and servicing
8. Light in weight but strong in construction to withstand the operational pressures
9. Simplicity of manufacture
10. Low cost
11. Possibility of effecting repair to maintenance problems

Design Equations of Shell & Tube Heat Exchangers

 Reference: http://www.engineeringpage.com/technology/thermal/transfer.html
Page 840 | D. Q. Kern' Process Heat Transfer

Typical Overall Coefficients

Shell & Tube Exchangers
Range
Organic Solvents Water 250 750
Hot fluid Cold fluid U (W/m2°C)
Water Water 800 1500
Organic Solvents Organic Solvents 100 300
Light Oils Light oils 100 400
Heavy Oils Heavy oils 50 300
Reduced Crude Flashed crude 35 150
Regenerated DEA Foul DEA 450 650
Gases (P = atm) Gases (P = atm) 5 35
Gases (P = 200 bar) Gases (P = 200 bar) 100 300

Coolers
Organic Solvents Water 250 750
Light Oils Water 350 700
Heavy Oils Water 60 300
Reduced Crude Water 75 200
Gases (P = atm) Water 5 35
Gases (P = 200 bar) Water 150 400
Gases Water 20 300
Organic Solvents Brine 150 500
Water Brine 600 1200
Gases Brine 15 250

Heaters
Steam Water 1500 4000
Steam Organic Solvents 500 1000
Steam Light Oils 300 900
Steam Heavy Oils 60 450
Steam Gases 30 300
Dowtherm Heavy Oils 50 300
Dowtherm Gases 20 200
Flue Gases Steam 30 100
Flue Gases Hydrocarbon Vapours 30 100

Condensors
Aqueous Vapours Water 1000 1500
Organic Vapours Water 700 1000
Refinery Hydrocarbons Water 400 550
Organics (some non-condensables) Water 500 700
Vacuum Condensors Water 200 500

Vaporisers
Steam Aqueous Solution 1000 1500
Steam Light organics 900 1200
Steam Heavy Organics 600 900
Dowtherm Refinery Hydrocarbons 250 550
er.html

Index
11

FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
TRUE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
 Special Thanks: Muhammad Arsalan Khan [2010 - CH - 120
Reference: Page 37 | Ernest E. Ludwig' Applied Process Design for Chemical & Petroche

Tube Count [Fixed Tubes]

Shell & Tube Exchangers
NP Pitch Type dO (m) PT (m) Tube Count

4 Triangular 0.01905 0.0254 0 44 72 96 134 180 232 294 360

inches 8 10 12 13.25 15.25 17.25 19.25 21.25 23.25

Inner Diameter of
SHELL
metres 0.2032 0.254 0.3048 0.33655 0.38735 0.43815 0.48895 0.53975 0.59055

1 Triangular 0.01905 0.0238125 33 69 105 135 193 247 307 391 481
1 Triangular 0.01905 0.0254 33 57 91 117 157 217 277 343 423
1 Square 0.01905 0.0254 33 53 85 101 139 183 235 287 355
1 Triangular 0.0254 0.03175 15 33 57 73 103 133 163 205 247
1 Square 0.0254 0.03175 17 33 45 65 83 111 139 179 215
2 Triangular 0.01905 0.0238125 32 58 94 124 166 228 300 370 452
2 Triangular 0.01905 0.0254 28 56 90 110 154 208 264 326 398
2 Square 0.01905 0.0254 26 48 78 94 126 172 222 280 346
2 Triangular 0.0254 0.03175 16 32 52 62 92 126 162 204 244
2 Square 0.0254 0.03175 12 26 40 56 76 106 136 172 218
4 Triangular 0.01905 0.0238125 48 84 108 154 196 266 332 412
4 Triangular 0.01905 0.0254 44 72 96 134 180 232 294 360
4 Square 0.01905 0.0254 48 72 88 126 142 192 242 308
4 Triangular 0.0254 0.03175 24 44 60 78 104 138 176 212
4 Square 0.0254 0.03175 24 40 48 74 84 110 142 188
6 Triangular 0.01905 0.0238125 80 116 174 230 294 372
6 Triangular 0.01905 0.0254 66 104 156 202 258 322
6 Square 0.01905 0.0254 54 78 116 158 212 266
6 Triangular 0.0254 0.03175 34 56 82 112 150 182
6 Square 0.0254 0.03175 44 66 88 116 154
8 Triangular 0.01905 0.0238125 94 140 198 258 332
8 Triangular 0.01905 0.0254 82 124 170 224 286
8 Square 0.01905 0.0254 94 132 174 228
8 Triangular 0.0254 0.03175 66 90 120 154
8 Square 0.0254 0.03175 74 94 128
Khan [2010 - CH - 120]
Chemical & Petrochemical Plants, 3rd Ed, Vol.3 (1999)

ubes]
rs Calculated # of Tubes 1
be Count Index

424 508 596 692 802 912 1024 12

25 27 29 31 33 35 37 10
0.635 0.6858 0.7366 0.7874 0.8382 0.889 0.9398 0.254
553 663 763 881 1019 1143 1269 FALSE
493 577 667 765 889 1007 1127 FALSE
419 495 587 665 765 865 965 FALSE
307 361 427 481 551 633 699 FALSE
255 303 359 413 477 545 595 FALSE
528 626 734 846 964 1088 1242 FALSE
468 556 646 746 858 972 1088 FALSE
408 486 560 644 746 840 946 FALSE
292 346 410 462 530 608 688 FALSE
248 298 348 402 460 522 584 FALSE
484 576 680 788 904 1024 1172 FALSE
424 508 596 692 802 912 1024 TRUE
366 440 510 590 688 778 880 FALSE
258 308 368 422 486 560 638 FALSE
214 260 310 360 414 476 534 FALSE
440 532 632 732 844 964 1106 FALSE
388 464 548 640 744 856 964 FALSE
324 394 460 536 634 224 818 FALSE
226 274 338 382 442 514 586 FALSE
184 226 268 318 368 430 484 FALSE
398 484 576 682 790 902 1040 FALSE
344 422 496 588 694 798 902 FALSE
286 352 414 490 576 662 760 FALSE
190 240 298 342 400 466 542 FALSE
150 192 230 280 334 388 438 FALSE
 tonne/day 1.15740741E-02 GaugeRange Hot.Fluids
Mass.FR (7/0) Aqueous Vapours
kg/s 1.00000000E+00 (6/0) Dowtherm
kg/min 1.66666667E-02 (5/0) Flue Gases
kg/h 2.77777778E-04 (4/0) Gases
kg/day 1.15740741E-05 (3/0) Gases (P = 200 bar)
tonne/h 2.77777778E-01 (2/0) Gases (P = atm)
tonne/day 1.15740741E-02 0 Heavy Oils
tonne/yr 3.17097921E-05 1 Light Oils
g/s 1.00000000E-03 2 Organic Solvents
g/min 1.66666667E-05 3 Organic Vapours
g/h 2.77777778E-07 4 Organics (some non-condensables)
g/day 1.15740741E-08 5 Reduced Crude
lb/s 4.53592370E-01 6 Refinery Hydrocarbons
lb/min 7.55987283E-03 7 Regenerated DEA
lb/h 1.25997881E-04 8 Steam
Mlb/h 1.25997881E-01 9 Water
lb/day 5.24991169E-06 10
M lb/day 5.24991169E-03 11 Cold.Fluids
MM lb/day 5.24991169E+00 12 Aqueous Solution
tn(short)/s 9.07184740E+02 13 Brine
tn(short)/min 1.51197457E+01 14 Flashed Crude
tn(short)/h 2.51995761E-01 15 Foul DEA
tn(short)/day 1.04998234E-02 16 Gases
tn(long)/s 1.01604691E+03 17 Gases (P = 200 bar)
tn(long)/min 1.69341152E+01 18 Gases (P = atm)
tn(long)/h 2.82235253E-01 19 Heavy Oils
tn(long)/day 1.17598022E-02 20 Heavy Organics
Vol.FR 21 Hydrocarbon Vapours
m3/sec 1.00000000E+00 22 Light Oils
m3/min 1.66700000E-02 23 Light Organics
m3/h 2.77800000E-04 24 Organic Solvents
m3/day 1.15700000E-05 25 Refinery Hydrocarbons
L/sec 1.00000000E-03 26 Steam
L/min 1.66700000E-05 27 Water
L/h 2.77800000E-07 28
L/day 1.15700000E-08 29
barrel/s 1.58987295E-01 30
barrel/min 2.64960000E-03 31
barrel/h 4.41600000E-05 32
barrel/day 1.84000000E-06 33
gallon/s [US] 3.78541200E-03 34
gallon/min [US] 6.30900000E-05 35
gallon/h [US] 1.05200000E-06 36
gallon/day [US] 4.38333333E-08 37
MGPD 4.38100000E-05 38
MMGPD 4.38100000E-02 39
 gallon/s [UK] 4.54609000E-03 40
gallon/min [UK] 7.57681667E-05 41
gallon/h [UK] 1.26280278E-06 42
gallon/day [UK] 5.26167824E-08 43
44
45
46
47
48
49
50
Process.Fluid Process.FR Fluid.Side FlowType PitchType
hydrocarbon Mass Flow Rate Shell Side Parallel Triangular
Water Volumetric Flow Rate Tube Side Counter-Current Square

Temp. Length Gauge Density Viscosity

K m BWG kg/m3 kg/ms
C cm SWG g/L P
F mm AWG g/cm3 cP
ft lb/ft3
in. lb/in.3

Thermal.Cond Heat.Capacity HT.C. Fouling.Factor

W/m K J/kg K W/m2 K m2 K / W
J/s m K KJ/kg K cal/s m2 C s m2 C / cal
BTU/hr ft F cal/g C kcal/h m2 C h m2 C / kcal
BTU/lb F BTU/hr ft2 F hr ft2 F / BTU
FT.Entry Phase Tube.Pitch.Values Hi.Calc
Auto Gas 15/16 Auto
Manual Liquid 1 Manual
1 1/4
 B.W.G
inches m
(7/0) -
(6/0) -
(5/0) 0.5 0.0127
(4/0) 0.454 0.0115316
(3/0) 0.425 0.010795
(2/0) 0.38 0.009652
0 0.34 0.008636
1 0.3 0.00762
2 0.284 0.0072136
3 0.259 0.0065786
4 0.238 0.0060452
5 0.22 0.005588
6 0.203 0.0051562
7 0.18 0.004572
8 0.165 0.004191
9 0.148 0.0037592
10 0.134 0.0034036
11 0.12 0.003048
12 0.109 0.0027686
13 0.095 0.002413
14 0.083 0.0021082
15 0.072 0.0018288
16 0.065 0.001651
17 0.058 0.0014732
18 0.049 0.0012446
19 0.042 0.0010668
20 0.035 0.000889
21 0.032 0.0008128
22 0.028 0.0007112
23 0.025 0.000635
24 0.022 0.0005588
25 0.02 0.000508
26 0.018 0.0004572
27 0.016 0.0004064
28 0.014 0.0003556
29 0.013 0.0003302
30 0.012 0.0003048
31 0.01 0.000254
32 0.009 0.0002286
33 0.008 0.0002032
34 0.007 0.0001778
35 0.005 0.000127
36 0.004 0.0001016
37 -
38 -
39 -
40 -
41 -
42 -
43 -
44 -
45 -
46 -
47 -
48 -
49 -
50 -
No_Passes
1
2
4
6
8
10
 S.W.G
inches m
(7/0) 0.5 0.0127
(6/0) 0.464 0.0117856
(5/0) 0.432 0.0109728
(4/0) 0.4 0.01016
(3/0) 0.372 0.0094488
(2/0) 0.348 0.0088392
0 0.324 0.0082296
1 0.3 0.00762
2 0.276 0.0070104
3 0.252 0.0064008
4 0.232 0.0058928
5 0.212 0.0053848
6 0.192 0.0048768
7 0.176 0.0044704
8 0.16 0.004064
9 0.144 0.0036576
10 0.128 0.0032512
11 0.116 0.0029464
12 0.104 0.0026416
13 0.092 0.0023368
14 0.08 0.002032
15 0.072 0.0018288
16 0.064 0.0016256
17 0.056 0.0014224
18 0.048 0.0012192
19 0.04 0.001016
20 0.036 0.0009144
21 0.032 0.0008128
22 0.028 0.0007112
23 0.024 0.0006096
24 0.022 0.0005588
25 0.02 0.000508
26 0.018 0.0004572
27 0.0164 0.00041656
28 0.0148 0.00037592
29 0.0136 0.00034544
30 0.0124 0.00031496
31 0.0116 0.00029464
32 0.0108 0.00027432
33 0.01 0.000254
34 0.0092 0.00023368
35 0.0084 0.00021336
36 0.0076 0.00019304
37 0.0068 0.00017272
38 0.006 0.0001524
39 0.0052 0.00013208
40 0.0048 0.00012192
41 0.0044 0.00011176
42 0.004 0.0001016
43 0.0036 0.00009144
44 0.0032 0.00008128
45 0.0028 0.00007112
46 0.0024 0.00006096
47 0.002 0.0000508
48 0.0016 0.00004064
49 0.0012 0.00003048
50 0.001 0.0000254
 A.W.G
inches m
(7/0) -
(6/0) -
(5/0) -
(4/0) 0.46 0.011684
(3/0) 0.4096 0.01040384
(2/0) 0.3648 0.00926592
0 0.3249 0.00825246
1 0.2893 0.00734822
2 0.2576 0.00654304
3 0.2294 0.00582676
4 0.2043 0.00518922
5 0.1819 0.00462026
6 0.162 0.0041148
7 0.1443 0.00366522
8 0.1285 0.0032639
9 0.1144 0.00290576
10 0.1019 0.00258826
11 0.0907 0.00230378
12 0.0808 0.00205232
13 0.072 0.0018288
14 0.0641 0.00162814
15 0.0571 0.00145034
16 0.0508 0.00129032
17 0.0453 0.00115062
18 0.0403 0.00102362
19 0.0359 0.00091186
20 0.032 0.0008128
21 0.0285 0.0007239
22 0.0253 0.00064262
23 0.0226 0.00057404
24 0.0201 0.00051054
25 0.0179 0.00045466
26 0.0159 0.00040386
27 0.0142 0.00036068
28 0.0126 0.00032004
29 0.0113 0.00028702
30 0.01 0.000254
31 0.00893 0.000226822
32 0.00795 0.00020193
33 0.00708 0.000179832
34 0.0063 0.00016002
35 0.00561 0.000142494
36 0.005 0.000127
37 0.00445 0.00011303
38 0.00397 0.000100838
39 0.00353 0.000089662
40 0.00314 0.000079756
41 -
42 -
43 -
44 -
45 -
46 -
47 -
48 -
49 -
50 -