Heat Exchanger Design

In partial fulfillment of the requirements in

ChE 192 Chemical Process Equipment Design

Submitted by
Jed S. Albarico
ChE 192 U

Submitted to
Sir Gino Apollo Guerrero

March 19, 2015

Design Problem:
Design a shell and tube heat exchanger to be used in cooling kerosene using light crude
oil. Assume the working pressure for kerosene to be 5 bars and light crude oil to be 6.5 bars.
Also, assume fouling allowance for kerosene to be 2 x 10-4 (W/m2C)-1 and for crude oil to be 3
x 10-4 (W/m2C)-1.
Other information is as follows:
Mass flow rate of kerosene = 15 000 kg/hr
Kerosene inlet temperature = 200C
Kerosene outlet temperature = 90C
Mass flow rate crude oil = 70 000 kg/hr
Light crude oil inlet temperature = 45C

Given:
Light crude oil
Tout = ?

Heat Exchanger
Kerosene

Flowrate = 70 000 kg/hr

Tin = 45C
Tout = 90C

Flowrate = 15 000 kg/hr

Tin = 200C

Required:
Design Specifications of the Heat Exchanger

Solution:
1. Duty of the heat exchanger
* Choose light crude oil in the tube since it is a dirty fluid, kerosene in the shell.
Tube side data: Light crude oil
Flowrate = 70 000 kg/hr
Tin = 45 C
Tout = ?

Shell side data: Kerosene

Flowrate = 15 000 kg/hr
Tin = 200 C
Tout = 90 C

2. Fluid physical properties

* Assume properties vary with temperature linearly.
Table 1. Physical properties of kerosene.
Property
Temperature
(C)
Specific heat
(kJ/kgC)
Thermal conductivity
(W/mC)
Density
(kg/m3)
Viscosity
(mNs/m2)

Values

Linear Eqn vs T

200

145

90

2.72

2.47

2.26

4.181818x10-3T + 1.876797

0.130

0.132

0.135

-4.545454x10-5T + 0.138924

690

730

770

-0.727272T + 835.454545

0.22

0.43

0.80

-5.272727x10-3T + 1.247879

Source: Towler, 2013.

Table 2. Physical properties of light crude oil (34 API).
Property
Temperature
(C)
Specific heat
(kJ/kgC)
Thermal conductivity
(W/mC)
Density
(kg/m3)
Viscosity
(mNs/m2)

Values

Linear Eqn vs T

78

59

40

2.09

2.05

2.01

2.105263x10-3T + 1.925789

0.133

0.134

0.135

-5.263158x10-5T + 0.137105

800

820

840

-2.052632T + 882.105263

2.4

3.2

4.3

-0.05T + 6.25

Source: Towler, 2013.

3. Type of heat exchanger

* Use 2-6 shell and tube heat exchanger.
4. Trial value for overall coefficient, U
* Based on Figure 1, choose 200 W/m2C.

Figure 1. Typical overall coefficients. Obtained from: Towler, 2013.

5. Mean temperature difference, Tlm

Qshell =Qtube
mCpdT

crude
mCpdT

kerosene=

kg
15000
hr

90

kg
( 4.18 x 10 T +1.88 ) dT = 70000
hr
200

) (2.11 x 10

45

X =73.546013 C

T lm =

T 2 T 1
ln

T2
T1

( )

T 2=( 20073.55 ) C=120.45 C

T 1=( 9045 ) C=45 C

T +1.93 ) dT

 T lm=

(120.4545) C
120.45 C
ln (
)
45 C

T lm=78.835390 C
* It must be noted that the greatest temperature difference (120.45C) is at least 30F
(-1.11C) and the minimum temperature difference (45C) is at least 10F (-12.22C),
conforming to the standards in temperature difference.
Table 3. Physical properties of kerosene at inlet, mean and outlet temperature.
Property
Temperature
(C)
Specific heat
(kJ/kgC)
Thermal conductivity
(W/mC)
Density
(kg/m3)
Viscosity
(mNs/m2)

Values
90

145

200

2.253

2.483

2.713

0.135

0.132

0.130

770

730

690

0.773

0.483

0.193

Table 4. Physical properties of light crude oil (34 API)

at inlet, mean and outlet temperature.
Property
Temperature
(C)
Specific heat
(kJ/kgC)
Thermal conductivity
(W/mC)
Density
(kg/m3)
Viscosity
(mNs/m2)

Values
45

59.273

73.546

2.021

2.051

2.081

0.135

0.134

0.133

834.737

819.713

804.688

4.000

3.286

2.573

Temperature correction factor:

* R:

R=

T 1T 2
200 90
=
=3.853429
t 2t 1 73.546 45

t 2t 1 73.546 45
S=
=
=0.184168
* S:
T 1t 1
200 45

Figure 2. Temperature correction factor.

Obtained from: Towler, 2013.

* Correction factor: Based from Figure 2, Y 0.94

6. Heat transfer area
Q=UAY T lm
90

15000 kg /hr (4.18 x 10 T + 1.88) dT

3

A=

Q
=
UY T lm

200

(200 W /m)(0.94)(78.84 )

1 hr
1000 J
( 3600
)(
s
1 kJ )

A=76.79579 m2
7. Heat exchanger layout
* Use split ring floating head for efficiency and ease of cleaning.
* Plain carbon steel can be used for the shell and tube since neither fluid is corrosive.
* Crude oil is dirtier than kerosene, so put the crude through the tubes and the kerosene in
the shell.
* For tubes: choose 25 mm (0.025 m) outer diameter, 21 mm (0.021 m) inside diameter,
length = 12 ft (3.6575 m), triangular pitch = 1.25Do, baffle cut = 25%.
Number of tubes:
Area of 1 tube:

A 1 tube = d o L= ( 0.025 m ) (3.6575 m )=0.287267 m

A
76.80 m2

tubes=
=
=267.332248 268tubes
# of tubes:
A 1 tube 0.287 m2

# tubes/pass: tubes/ pass=268/6 45

Tube-side velocity:
2

Cross section area of 1 tube:

Area/pass:

A tube =

di ( 0.021 m )
=
=3.4636 x 104 m2
4
4

Atube
tubes
=
A tube =433.46 x 104 m2=0.014894 m2
pass
pass

70000 kg /hr
1 hr
3
Volumetric flow: v = G = 819.713 kg/m
=0.023721m3 /s

3600 s

Linear velocity:

vt =

3
v
0.024 m / s
=
=1.592711 m/ s
Atube 0.0150 m 2
pass

* The tube-side velocity is satisfactory since velocity is between 1 and 2 m/s.

Bundle and shell diameter:

Figure 3. Constants for bundle diameter. Obtained from: Towler, 2013.

Bundle diameter:

N
D b=d o t
K1

1/ n1

( )

D b=( 0.025 m )

; from Figure 3, at 6 pass, K1=0.0743, n1=2.499

256
0.0743

1
2.499

=0.650739 m

Figure 4. Shell-bundle clearance. Obtained from: Towler, 2013.

Shell Diameter:

DS =( DS DB ) + DB

D
; from Figure 4, ( SD B ) = 0.063 m

DS =( 0.063+0.6507 ) m=0.713739 m

L/Ds:

L 3.6576 m
=
=5.124564
D S 0.071m

* Since L/DS is between 5 and 10, DS is the optimum shell diameter.

Shell thickness:

Figure 5. Shell thickness.

Obtained from: Towler, 2013.

* Shell to be used is rolled from plate with a minimum thickness of 7.9 mm.
8. Individual heat exchanger coefficients
Tube-side heat transfer coefficient:
Reynolds Number:
Prandtl Number:
L/Di:

d i v t (819.713 kg /m 3)(0.021 m)(1.59 m/ s)

N =
=
=8342.65215

3.286 x 103 Ns /m2

N Pr =

2
Cp ( 2.051kJ /kgC)(3.286 mNs /m )
=
=50.2958209
k
0.134 W /mC

L/ Di=3.6576 m/0.021 m=174.1714

Figure 6. Reynolds Number vs tube heat transfer factor.

Obtained from: Towler, 2013.

Heat transfer factor: Based on Figure 6,

j H =3.0 x 103

h = N N 0.33 j
Heat transfer coefficient: t d i Pr H w

0.14

( )

ht =

0.134 W /mC
( 8342.65 )( 50.30 )0.33 ( 3.0 x 103 ) ( 1 )=555.99689 W /m 2 C
0.021 m

* Since ht is much greater than the assumed Uo (190W/m2C), the heat transfer coefficient
is satisfactory.
Shell-side heat transfer coefficient

Area of crossflow:

As=

( p td o ) D s l B
pt

( 0.0312 m0.025 m ) ( 0.071m )

=

0.0312 m

Area of crossflow per pass:

Linear velocity:

us =

Equivalent diameter:

As
As
0.020 m2
=
=
=0.010188 m 2
pass shell pass
2

Ws
15000 kg /hr
=
=0.560218 m/s
A s (730 kg/m3 )(0.010 m2 )
de=

1.10 2
2
t 0.917 d o )
(
do

d e=

Reynolds Number:

( 0.0715 m )=0.020377

1.10
( ( 0.031 m)2 0.917 ( 0.025 m)2 ) =0.018270 m
0.025 m

d e v s (730 kg /m3 )(0.018 m)(0.56 m/ s)

N =
=
=15458.8703

0.483 x 103 Ns /m2

2

Prandtl Number:

N Pr =

Cp ( 2.483 kJ / kgC )(0.483 mNs/ m )

=
=9.070131
k
0.132 W / mC

Figure 7. Reynolds number vs shell heat transfer factor.

Obtained from: Towler, 2013.

Heat transfer factor: Based on Figure 7,

Heat transfer coefficient:
h s=

h s=

j H =1.8 x 103

N N 0.33
Pr j H
de
w

0.14

( )

0.132W /mC
( 15458.87 ) ( 9.07 )0.33 ( 1.8 x 103 ) ( 1 )=403.51363W /m2 C
0.018 m

9. Overall coefficient
1 1 1
= + +
U o ho hod

d o ln

do
di

( )

2 kw

do 1 1
+
d i h id hi

1
1
2
=
=0.0024782 m /W
ho 556.00 W /m2

1
=0.0002 m2 /W
hod

d o ln

do
di

( )

2 kw

0.025 mln
=

m
( 0.025
0.021m )
=3.96 x 10

2(55W /m)

1
2
=0.0003 m /W
hid

1
1
=
=0.001799 m2 /W
2
hi 403.513W /m

m2 /W

1
5 0.025 m
=0.002537+0.0002+3.96 x 10 +
( 0.0003+0.001778 )
Uo
0.021 m
U o=191.71206W /m2 C
* The overall heat transfer coefficient is satisfactory since the assumed heat transfer
coefficient (200 W/m2C) is near (4.32% difference).
10. Heat exchanger pressure drops
Tube-side pressure drop
* Assumption of Franks (1978) correction due to pressure losses

[ (

P= N p 8 j f

L
di

( )( )

+2.5

)]

u t
2

Figure 8. Tube-side friction factor.

Obtained from: Towler, 2013.

* Friction factor: Based from Figure 8,

j f =0.0032

1.52 m/ s 2

(819.713 kg/m3)

[(

P= 4 80.0032

m
( 1 ) +2.5 )
( 3.6576
]
0.021 m )

P=26 821.1839 Pa

* Pressure drop is satisfactory since P is below working pressure of crude oil (6.5 bars =
65 000 Pa). Correction factor for tube pressure drop followed Franks method.
Shell-side pressure drop
P=8 j f

Ds
de

L us

lB
2 w

0.14

( )( ) ( )

Figure 9. Shell-side friction factor.

Obtained from: Towler, 2013

* Friction factor: Based from Figure 9,

0.73 m
P=80.032
0.018 m

)(

j f =0.031
3

kg /m ( 0.54 m/s )
3.6576 m
730
(1)
0.15 m
2

P=26596.467 Pa
* Pressure drop is satisfactory since P is below working pressure of kerosene
50 000 Pa).
Baffle Thickness
T=

T=

GF
2

P
S

( 0.025m ) ( 1.25 ) 26821.18

2
2067857.12
T =0.0017795 m

11. Optimization

(5 bars =

* Adjusting the assumed heat transfer coefficient, U, results to changes in the actual Uo.
Still, the conditions presented are the optimized parameters for the construction of a shell
and tube heat exchanger.
12. Summary

Split ring, floating head, 2 shell pass, 6 tube passes.

268 carbon steel tubes, 3.6576 m long, 25 mm o.d., 21 mm i.d., Triangular pitch, pitch
31.25 mm.

Heat transfer area 76.79579 m2 (based on outside diameter).

Shell i.d. 725.78 mm, rolled from plate with thickness 79 mm, baffle spacing 145.16 mm,
25% cut.

Tube-side coefficient 556 W/m2C, clean.

Shell-side coefficient 403.5 W/m2C, clean.

Overall coefficient estimated 200 W/m2C, dirty.

Overall coefficient required 191.71 W/m2C, dirty.

o
o

Dirt/Fouling factors:
Tube-side (crude oil) 0.0003 (W/m2C)-1
Shell-side (kerosene) 0.0002 (W/m2C)-1
Pressure drops
o Tube side, estimated 2.68 bar; specified 6.5 bar overall.
o Shell side, estimated 2.66 bar; specified 5 bar overall.

13. Design

Figure 10. Cross-section of heat exchanger.

Figure 11. Cross-section of heat exchanger showing pipe arrangement.

Figure 12. Longitudinal section of heat exchanger.

14. References

Towler, G., & R. Sinnot. (2013). Chemical Engineering Design: Principles, Practice and
Economics of Plant and Process Design. 2nd Ed. Elsevier: UK.