CME450 PROJECT

College of Engineering
Department of Chemical Engineering

Process Design CME450

Dr. Chandra Mouli

Project One – Design of shell and tube heat exchanger

GROUP 2

Student Name ID Number SECTION

Salma Saeed AlNowahi 1045971 51
Zaina Rashed AlDhaheri 1046702 52
Laila Owda 1052119 52
Saniha Aysha Ajith 1051470 52
Sumaitha Rahman 1050771 51

Date of Submission: Sunday, 5th November 2017

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The problem statement assigned to our group for the project was problem 2 where we were
asked to design a shell and tube heat exchanger that allows 120,000 lb/hr of aniline is cooled
from 275℉ to 200℉ by heating 100,000 lb/hr of benzene from 100℉ to 200℉.
For solving it, we chose the STHE method where we went through the 14 step flow chart
given below in order to obtain the design that would suit our conditions.

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SOLUTION
Given Data
 Aniline
Flow rate: 120,000 lb/hr
275℉  200℉
135℃  93.3℃
408.15 K  366.483 K
Mean temperature = 237.5℉ = 387.316 K = 114.2℃
Molecular weight = 93.13 g/mol
 Benzene
Flow rate: 100,000 lb/hr
100℉  200℉
37.78℃  93.3℃
310.928 K  366.483 K
Mean temperature = 150℉ = 338.706 K = 65.6℃
Molecular weight = 78.11 g/mol

Pressure specifications: Should not exceed 10 psi on both shell and tube side

STEP ONE Specifications

- Fouling factors for both benzene and aniline = 𝟎. 𝟎𝟎𝟏𝟖 (𝑾⁄𝒎𝟐 ℃)−𝟏 [1]
- Duty of aniline  𝑞 = 𝑚𝐶𝑃 ∆T
𝑙𝑏 0.453592 𝑘𝑔 2.39 𝑘𝐽 41.7 𝐾
= 120,000 ℎ𝑟 × × ×
1 𝑙𝑏 𝐾𝑔𝐾 3600𝑠
= 𝟏𝟓𝟎𝟔. 𝟖𝟖 𝒌𝑾

STEP TWO Physical Properties [2]

Benzene Inlet Outlet Mean
Temperature 310.928 366.483 338.706 K
Specific Heat 1.1037 1.3156 1.212 kJ/kgK
Thermal Conductivity 0.143 0.126 0.135 W/mK
Density 860.036 800.277 830.888 Kg/m3
Viscosity 5.122×10-4 2.802×10-4 3.73×10-4 Ns/m2 (Pa∙s)

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Aniline Inlet Outlet Mean

Temperature 408.15 366.483 387.316 K
Specific Heat 2.47 2.31 2.39 kJ/kgK
Thermal Conductivity 0.152 0.163 0.157 W/mK
Density 958.54 922.5 941.72 Kg/m3
Viscosity 3.85×10-4 8.2×10-4 5.75×10-4 Ns/m2 (Pa∙s)

STEP THREE Overall heat transfer coefficient

For this type of heat exchanger, U should be between 114 𝑊⁄𝑚2 ℃ and 340.7 𝑊⁄𝑚2 ℃

Assume that U = 300 𝑾⁄ 𝟐

𝒎 ℃

STEP FOUR Exchanger type and dimensions

To determine which organic liquid goes in the shell and tube side, the following comparison
was made:
Property Aniline Benzene Result
Benzene →Shell
Viscosity Lower Higher
Aniline → Tubes
Benzene →Shell
Flow Rate Higher Lower
Aniline → Tubes
Benzene → Shell
Corrosion factor More corrosive Less corrosive
Aniline → Tubes
Benzene → Shell
Temperature Higher Lower
Aniline → Tubes

Therefore as the results indicate, aniline will flow in the tube side while benzene will flow in
the shell side.

𝑇𝑎 − 𝑇𝑏 100 − 200
𝑹= = = 𝟏. 𝟑𝟑
𝑡𝑏 − 𝑡𝑎 200 − 275
𝑡𝑏 − 𝑡𝑎 200 − 275
𝑺= = = 𝟎. 𝟒𝟐𝟖𝟔
𝑇𝑏 − 𝑇𝑎 100 − 275
100℉  200℉
∆𝑻 = 𝟏𝟎𝟎℉ ∆𝑻 = 𝟕𝟓℉
200℉  275℉

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∆𝑇2 − ∆𝑇1 100 − 75

∆𝑻𝒍𝒏 = = = 𝟖𝟔. 𝟗𝟎𝟏℉
∆𝑇2 100
𝑙𝑛 ∆𝑇 𝑙𝑛
1 75
From 2-4 shell exchanger graph [Figure 1 in Appendix],
Correlation factor, F = 0.9615
∆𝑻𝒎 = ∆𝑇𝑙𝑛𝐹 = (0.9615)(86.901) = 𝟖𝟑. 𝟓𝟓℉

STEP FIVE Heat transfer area

𝑞
𝐴=
𝑈𝐷 ∆𝑇𝑚
1506.88 × 103 𝑊
𝑨= = 𝟏𝟎𝟖. 𝟐𝟏𝒎𝟐
𝑊
300 2 × 46.42℃
𝑚 ℃

STEP SIX Layout and tube size

- Using a split ring floating head for efficiency and ease of cleaning
- Using 40 schedule carbon steel pipe.
- Tube dimensions: [3]
Outer diameter, O.D = 16 mm
Inner diameter, I.D = 11.43 mm
Triangle pitch = 1.25 Do = 20 mm
Length = 5m (popular size)

STEP SEVEN Number of tubes

𝐀𝐫𝐞𝐚 𝐨𝐟 𝐨𝐧𝐞 𝐭𝐮𝐛𝐞(neglecting tube thickness) = π × 16 × 10−3 × 5 = 𝟎. 𝟐𝟓𝟏 𝐦𝟐
108.21 𝑚2
𝐍𝐮𝐦𝐛𝐞𝐫 𝐨𝐟 𝐭𝐮𝐛𝐞𝐬 = = 𝟒𝟑𝟎 𝐭𝐮𝐛𝐞𝐬
0.251𝑚2
430
𝐅𝐨𝐫 𝟒 𝐩𝐚𝐬𝐬𝐞𝐬 = = 𝟒𝟎 𝐭𝐮𝐛𝐞𝐬
4
π
𝐓𝐮𝐛𝐞 𝐜𝐫𝐨𝐬𝐬 𝐬𝐞𝐜𝐭𝐢𝐨𝐧𝐚𝐥 𝐚𝐫𝐞𝐚 = (11.43 × 10−3 )2 = 𝟏. 𝟎𝟐𝟔 × 𝟏𝟎−𝟒 𝐦𝟐
4
𝐀𝐫𝐞𝐚 𝐩𝐞𝐫 𝐩𝐚𝐬𝐬 = 110 × 1.026 × 10−4 = 𝟎. 𝟎𝟏𝟏𝟐𝟕 𝐦𝟐
120,000 × 0.453592 𝐦𝟑
𝐕𝐨𝐥𝐮𝐦𝐞𝐭𝐫𝐢𝐜 𝐟𝐥𝐨𝐰 = = 𝟎. 𝟎𝟏𝟔𝟏
3600 × 941.72 𝐬
0.161 𝐦
𝐓𝐮𝐛𝐞 𝐬𝐢𝐝𝐞 𝐯𝐞𝐥𝐨𝐜𝐢𝐭𝐲 = = 𝟏. 𝟒𝟑
0.01127 𝐬

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STEP EIGHT Bundle and shell diameter

From Table 1 in Appendix, for four passes, k1 = 0.175 and n1 = 2.285
430 1
𝐃𝐛 = 16[ ]2.285 = 487.4mm = 𝟎. 𝟒𝟖𝟕𝐦
0.175
Shell inside diameter from Figure 2 in Appendix
𝐃𝐬 = 487.4 + 58 = 𝟓𝟒𝟓. 𝟒 𝐦𝐦

STEP NINE Tube side heat transfer coefficient

ρvD 941.72×1.43×0.011433
𝐑𝐞 = = = 26,776 ≈ 𝟐. 𝟔𝟖 × 𝟏𝟎𝟒 (𝐓𝐔𝐑𝐁𝐔𝐄𝐋𝐍𝐓)
μ 5.75×10−4

𝜇𝑐𝑝 (5.75×10−4 )(2.39×103 )

𝐏𝐫 = = = 𝟖. 𝟕𝟓
𝐾 0.157

𝐋 5000
= = 𝟒𝟑𝟕. 𝟑
𝐃𝐢 11.433
From Figure 3 in Appendix, 𝐣𝐡 = 𝟐. 𝟒𝟗𝟔 × 𝟏𝟎−𝟑
𝐍𝐮 = jh × Re × P𝑟 0.33 = (2.496 × 10−3 )(26.776)(8.75)0.33 = 𝟏𝟑𝟔. 𝟕𝟑
NuK 136.73 × 0.157
𝒉𝒊 = = = 𝟏𝟖𝟕𝟖. 𝟏 𝐖⁄ 𝟐
D1 11.433 × 10−3 𝐦 ℃

STEP TEN Shell side heat transfer coefficient

Ds 545.4
𝐁𝐚𝐟𝐟𝐥𝐞 𝐬𝐩𝐚𝐜𝐢𝐧𝐠 = = = 109.08 = 𝟏𝟏𝟎 𝐦𝐦
5 5
20 − 16
𝐀𝐬 = ( ) = 545.4 × 110 = 11998.8 mm2 = 𝟎. 𝟎𝟏𝟏𝟗𝟗𝟖𝟖 𝐦𝟐
20
4(0.86P2 −0.25𝜋𝐷𝑜 2 )
From equation 14.34, de = [3]
𝜋𝐷𝑜

4(0.86(20)2 −0.25𝜋(16)2 )
𝐝𝐞 = = 𝟏𝟏. 𝟑𝟕 𝐦𝐦
𝜋(16)

lb 1 kg 1 m3 𝐦𝟑
𝐕𝐨𝐥𝐮𝐦𝐞𝐭𝐫𝐢𝐜 𝐟𝐥𝐨𝐰 𝐫𝐚𝐭𝐞 = 100,000 × × 0.453592 × = 𝟎. 𝟎𝟏𝟓𝟐
hr 3600 lb 830.88 kg 𝐬
0.0152 m
𝐒𝐡𝐞𝐥𝐥 𝐬𝐢𝐝𝐞 𝐯𝐞𝐥𝐨𝐜𝐢𝐭𝐲 = = 1.26 ≅ 𝟏 𝐦⁄𝐬
0.0119988 s
830.88 × 1 × 11.37 × 10−3
𝐑𝐞 = = 25328 ≅ 𝟐. 𝟓 × 𝟏𝟎𝟒 ≈ 𝐓𝐔𝐑𝐁𝐔𝐋𝐄𝐍𝐓
3.73 × 10−4
μCp 3.73 × 10−4 (1.212 × 103 )
𝐏𝐫 = = = 𝟑. 𝟑𝟓
K 0.135

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Recommended baffle cut is 20-25%. [3] Assume 25% in this case for reasonable heat
transfer coefficient without huge pressure drop.

STEP ELEVEN Overall heat transfer coefficient, U

16
𝟏 1 16 16 × 10−3 ln [11.43] 1
=[ + 0.00018] + + + 0.00018
𝐔𝐨 1878.1 11.43 2 × 54 1760.96

= 557.997 W⁄mK = 𝟓𝟓𝟖 𝐖⁄𝐦𝐊

557.997−300
% 𝐞𝐫𝐫𝐨𝐫 = [ ] × 100% = 𝟖𝟔% > 30%
300

Since the error percentage is too high, go back to STEP 5.

STEP FIVE (2nd trial) Heat transfer area

Taking 𝐔 = 𝟓𝟓𝟖 𝐖⁄𝐦𝐊

1506.88 × 103 W
𝐀𝐨 = = 𝟓𝟖. 𝟏𝟕𝟓𝐦𝟐
W
558 mK × 46.42K

STEP SIX (2nd trial)

𝐎. 𝐃 = 𝟏𝟔 𝐦𝐦
𝐈. 𝐃 = 𝟏𝟏. 𝟒𝟑 𝐦𝐦
∆ 𝐩𝐢𝐭𝐜𝐡 = 𝟐𝟎 𝐦𝐦
𝐥𝐞𝐧𝐠𝐭𝐡 = 𝟓 𝐦

STEP SEVEN (2nd)

𝐀𝐫𝐞𝐚 𝐨𝐟 𝐨𝐧𝐞 𝐭𝐮𝐛𝐞 = 𝟎. 𝟐𝟓𝟏𝐦𝟐
58.175
𝐍𝐮𝐦𝐛𝐞𝐫 𝐨𝐟 𝐭𝐮𝐛𝐞𝐬 = = 231 tubes ~ 𝟐𝟑𝟎 𝐭𝐮𝐛𝐞𝐬
0.251
230
𝐅𝐨𝐫 𝐟𝐨𝐮𝐫 𝐩𝐚𝐬𝐬𝐞𝐬 = = 57.9 ~ 𝟔𝟎 𝐭𝐮𝐛𝐞𝐬
4
𝐓𝐮𝐛𝐞 𝐜𝐫𝐨𝐬𝐬 𝐬𝐞𝐜𝐭𝐢𝐨𝐧𝐚𝐥 𝐚𝐫𝐞𝐚 = 𝟏. 𝟎𝟐𝟔 × 𝟏𝟎−𝟒 𝐦𝟐
𝐀𝐫𝐞𝐚 𝐩𝐞𝐫 𝐩𝐚𝐬𝐬 = 60 × 1.026 × 10−4 = 𝟔. 𝟏𝟓𝟔 × 𝟏𝟎−𝟑 𝐦𝟐
𝐦𝟑
𝐕𝐨𝐥𝐮𝐦𝐞𝐭𝐫𝐢𝐜 𝐟𝐥𝐨𝐰 𝐫𝐚𝐭𝐞 = 𝟎. 𝟎𝟏𝟔𝟏
𝐬

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0.0161 𝐦
𝐓𝐮𝐛𝐞 𝐬𝐢𝐝𝐞 𝐯𝐞𝐥𝐨𝐜𝐢𝐭𝐲 = −3
= 𝟐. 𝟔𝟏
6.156 × 10 𝐬

STEP EIGHT (2nd)

For four passes from Table 1in Appendix, k1 = 0.175 and n1 = 2.285
1
230 2.285
𝐃𝐛 = 16 [ ] = 370.66mm = 𝟎. 𝟑𝟕𝟏𝐦
0.175
Shell inside diameter [Figure 12.10]
𝐃𝐬 = 370.66 + 54 = 𝟒𝟐𝟒. 𝟔𝟔 𝐦𝐦

STEP NINE (2nd trial) Tube side heat transfer coefficient

ρvD 941.72 × 2.61 × 0.011433
𝐑𝐞 = = = 48871.38 ~ 𝟒. 𝟖𝟗 × 𝟏𝟎𝟒
μ 5.75 × 10−4
μCP
𝐏𝐫 = = 𝟖. 𝟕𝟓
k
𝐋
= 𝟒𝟑𝟕. 𝟑
𝐃𝟏
From Figure 3 in Appendix, using the interpolation, the value 𝐣𝐡 = 𝟑. 𝟒𝟑 × 𝟏𝟎−𝟑
𝐍𝐮 = jh × Re × Pr 0.33 = 3.43 × 10−3 × 48871.38 × 8.750.33 = 𝟑𝟒𝟑. 𝟏𝟗𝟖
Nuk 343.198 × 0.157
𝐡𝐢 = = = 𝟒𝟕𝟏𝟐. 𝟖𝟔 𝐖⁄𝐦℃
D1 11.433 × 10−3

STEP TEN (2nd trial) Shell side heat transfer coefficient

Ds 424.66
𝐁𝐚𝐟𝐟𝐥𝐞 𝐬𝐩𝐚𝐜𝐢𝐧𝐠 = = = 84.932 mm = 𝟖𝟓 𝐦
5 5
20 − 16
𝐀𝐒 = [ ] × 424.66 × 85 = 7219.22 mm2 = 𝟕. 𝟐𝟏𝟗 × 𝟏𝟎−𝟑 𝐦𝟐
20
𝐃𝐞 = 𝟏𝟏. 𝟑𝟕 𝐦𝐦
𝐦𝟑
𝐕𝐨𝐥𝐮𝐦𝐞𝐭𝐫𝐢𝐜 𝐟𝐥𝐨𝐰 𝐫𝐚𝐭𝐞 = 𝟎. 𝟎𝟏𝟓𝟐
𝐬
0.0152 𝐦
𝐒𝐡𝐞𝐥𝐥 𝐬𝐢𝐝𝐞 𝐯𝐞𝐥𝐨𝐜𝐢𝐭𝐲 = −3
= 𝟐. 𝟏𝟎𝟓
7.219 × 10 𝐬
830.88 × 2.105 × 11.37 × 10−3
𝐑𝐞 = −4
= 53314.09 ~ 𝟓. 𝟑𝟑 × 𝟏𝟎𝟒 [𝐓𝐔𝐑𝐁𝐔𝐋𝐄𝐍𝐓]
3.73 × 10
𝐏𝐫 = 𝟑. 𝟑𝟓

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𝐁𝐚𝐟𝐟𝐥𝐞 𝐜𝐮𝐭 = 𝟐𝟓%

From Figure 5 in Appendix 3, 𝐣𝐡 = 𝟕. 𝟗𝟓 × 𝟏𝟎−𝟑
0.135
𝐡𝐬 = [ × 103 ] × 7.95 × 10−3 × 53314.09 × 3.350.33 = 𝟕𝟒𝟔𝟎. 𝟑𝟖 𝐖⁄ 𝟐
11.43 𝐦 ℃

STEP ELEVEN (2nd trial) Overall heat transfer coefficient

16
𝟏 1 16 16 × 10−3 ln [11.43] 1
=[ + 0.00018] + + + 0.00018
𝐔𝐨 4712.85 11.43 2 × 54 7460.38

U = 𝟔𝟑𝟖. 𝟒𝟔 𝐖⁄𝐦𝐊
638.46 − 557.907
% 𝐞𝐫𝐫𝐨𝐫 = | | × 100% = 𝟏𝟒. 𝟒𝟐% < 𝟑𝟎% 𝐬𝐨 𝐢𝐭 ′ 𝐬 𝐚𝐜𝐜𝐞𝐩𝐭𝐚𝐛𝐥𝐞
557.907

STEP TWELVE (2nd trial) Pressure Drop

Tube side:
230 tubes, tube I.D = 11.43 mm, 4 passes, ut = 2.61 m/s
𝐑𝐞 = 𝟒. 𝟖𝟗 × 𝟏𝟎𝟒
From Figure 4 in Appendix, 𝐣𝐟 = 𝟓. 𝟗 × 𝟏𝟎−𝟑
5000 2.612 5.75 −0.14
∆𝐏𝐓 𝐟𝐨𝐫 𝐨𝐧𝐞 𝐩𝐚𝐬𝐬 = 8 × 5.9 × 10−3 × [ ] × 941.72 × [ ]×[ ]
11.43 2 3.73
N
= 62333.903 m2 ~ 𝟗. 𝟎𝟒𝟏 𝐏𝐬𝐢

∆𝐏𝐓 𝐟𝐨𝐫 𝐟𝐨𝐮𝐫 𝐩𝐚𝐬𝐬𝐞𝐬 = 9.041 × 4 = 𝟑𝟔. 𝟏𝟔𝟒 𝐩𝐬𝐢

424.66 5000 830.88 × (2.105)2 3.73 −0.14
∆𝐏𝐬 𝐟𝐨𝐫 𝐨𝐧𝐞 𝐩𝐚𝐬𝐬 = 8 × 5.9 × 10−3 [ ][ ][ ][ ]
11.37 85 2 5.75
N
= 202815.3 m2 ~ 𝟐𝟗. 𝟒𝟏𝟔 𝐏𝐬𝐢

∆𝐏𝐬 𝐟𝐨𝐫 𝐭𝐰𝐨 𝐩𝐚𝐬𝐬𝐞𝐬 = 𝟓𝟖. 𝟖𝟑𝟐 𝐩𝐬𝐢

Since the values are higher than the allowable pressure drops (10 psi), we go back to
STEP SIX.

STEP SIX (3rd trial) Layout and tube size

For the modified design, allow 1.2 psi , a typical figure (about 15% of total) which leaves 8
psi across the tubes.

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230
𝐓𝐮𝐛𝐞𝐬 𝐧𝐞𝐞𝐝𝐞𝐝 = = 530.41 ~ 𝟓𝟑𝟎 𝐭𝐮𝐛𝐞𝐬
6.8 0.5
[36.164]

𝐎. 𝐃 = 𝟏𝟔 𝐦𝐦
𝐈. 𝐃 = 𝟏𝟏. 𝟒𝟑 𝐦𝐦
𝐓𝐫𝐢𝐚𝐧𝐠𝐮𝐥𝐚𝐫 𝐩𝐢𝐭𝐜𝐡 = 𝟐𝟎 𝐦𝐦
𝐥𝐞𝐧𝐠𝐭𝐡 = 𝟓 𝐦𝐦

STEP SEVEN (3rd trial) Number of tubes

𝐀𝐫𝐞𝐚 𝐨𝐟 𝐨𝐧𝐞 𝐭𝐮𝐛𝐞 = 𝟎. 𝟐𝟓𝟏𝐦𝟐

𝐍𝐮𝐦𝐛𝐞𝐫 𝐨𝐟 𝐭𝐮𝐛𝐞𝐬 = 𝟓𝟑𝟎 𝐭𝐮𝐛𝐞𝐬
530
𝐅𝐨𝐫 𝐟𝐨𝐮𝐫 𝐩𝐚𝐬𝐬𝐞𝐬 = = 132 ~ 𝟏𝟑𝟎 𝐭𝐮𝐛𝐞𝐬
4
𝐓𝐮𝐛𝐞 𝐜𝐫𝐨𝐬𝐬 𝐬𝐞𝐜𝐭𝐢𝐨𝐧𝐚𝐥 𝐚𝐫𝐞𝐚 = 𝟏. 𝟎𝟐𝟔 × 𝟏𝟎−𝟒 𝐦𝟐
𝐀𝐫𝐞𝐚 𝐩𝐞𝐫 𝐩𝐚𝐬𝐬 = 𝟎. 𝟎𝟏𝟑𝟑𝟑𝟖 𝐦𝟐
𝐕𝐨𝐥𝐮𝐦𝐞𝐭𝐫𝐢𝐜 𝐟𝐥𝐨𝐰 = 𝟎. 𝟎𝟏𝟔𝟏 𝐦𝟑 ⁄𝐬
𝐓𝐮𝐛𝐞 𝐬𝐢𝐝𝐞 𝐯𝐞𝐥𝐨𝐜𝐢𝐭𝐲, 𝐮𝐓 = 𝟏. 𝟐𝟎𝟕 𝐦⁄𝐬

STEP EIGHT (3rd trial) Bundle and shell diameter

From Figure 1 in Appendix, 𝐤 𝟏 = 𝟎. 𝟏𝟕𝟓 and 𝐧𝟏 = 𝟐. 𝟐𝟖𝟓
1
530 2.285
𝐃𝐛 = 16 [ ] = 534.118 mm = 𝟎. 𝟓𝟑𝟒 𝐦
0.175
Shell side diameter from Figure 2 in Appendix:
𝐃𝐬 = 534.118 + 59 = 𝟓𝟗𝟑. 𝟏𝟏𝟖 𝐦𝐦

STEP NINE (3rd trial) Tube side heat transfer coefficient

ρvD 941.72 × 1.207 × 0.011433
𝐑𝐞 = = = 22600.676 ~ 𝟐. 𝟐𝟔 × 𝟏𝟎𝟒 𝐓𝐔𝐑𝐁𝐔𝐋𝐄𝐍𝐓
μ 5.75 × 10−4
μCp
𝐏𝐫 = = 𝟖. 𝟕𝟓
k
𝐋
= 𝟒𝟑𝟕. 𝟑
𝐃𝟏
From Figure 3 in Appendix, 𝐣𝐡 = 𝟏. 𝟗𝟕𝟐 × 𝟏𝟎−𝟑

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𝐍𝐮 = jh × Re × Pr 0.33
= 1.972 × 10−3 × 22600.676 × 8.750.33
= 𝟗𝟏. 𝟏𝟕𝟖
NuK (91.178)(0.157)
𝐡𝐢 = = = 𝟏𝟐𝟓𝟐. 𝟎𝟕𝟑 𝐖⁄ 𝟐
Di 11.433 × 10−3 𝐦 ℃

STEP TEN (3rd trial) Shell side heat transfer coefficient

Ds 593.118
𝐁𝐚𝐟𝐟𝐥𝐞 𝐬𝐩𝐚𝐜𝐢𝐧𝐠 = = = 118.62 mm = 𝟏𝟐𝟎 𝐦𝐦
5 5
20 − 16
𝐀𝐬 = [ ] × 593.118 × 130 = 15421.068 mm2 = 𝟎. 𝟎𝟏𝟓𝟒𝟐𝐦𝟐
20
𝐕𝐨𝐥𝐮𝐦𝐞𝐭𝐫𝐢𝐜 𝐟𝐥𝐨𝐰 𝐫𝐚𝐭𝐞 = 𝟎. 𝟎𝟏𝟓𝟐 𝐦𝟑 ⁄𝐬
0.0152
𝐒𝐡𝐞𝐥𝐥 𝐬𝐢𝐝𝐞 𝐯𝐞𝐥𝐨𝐜𝐢𝐭𝐲 = = 𝟎. 𝟗𝟖𝟔 𝐦⁄𝐬
0.01542

830.88 × 0.986 × 11.37 × 10−3

𝐑𝐞 = = 25327.36 ~ 𝟐. 𝟓𝟑 × 𝟏𝟎𝟒 𝐓𝐔𝐑𝐁𝐔𝐋𝐄𝐍𝐓
3.73 × 10−4
𝐏𝐫 = 𝟑. 𝟑𝟓
𝐁𝐚𝐟𝐟𝐥𝐞 𝐜𝐮𝐭 = 𝟐𝟓%
From Figure 5 in Appendix, 𝐣𝐡 = 𝟑. 𝟗𝟓 × 𝟏𝟎−𝟑
0.135
𝐡𝐬 = [ × 103 ] × 3.95 × 10−3 × 25327.36 × 3.350.33 = 𝟏𝟕𝟔𝟎. 𝟗𝟏𝟖 𝐖⁄ 𝟐
11.43 𝐦 ℃

STEP ELEVEN (3rd trial) Overall heat transfer coefficient

16
𝟏 1 16 16 × 10−3 ln [11.43] 1
=[ + 0.00018] + + + 0.00018
𝐔𝐨 1252.073 11.43 2 × 54 1760.918

U = 𝟒𝟑𝟓. 𝟔𝟏𝟏 𝐖⁄𝐦𝐊

435.46 − 557.907
% 𝐞𝐫𝐫𝐨𝐫 = | | × 100% = 21.9% ~ 𝟐𝟐% < 𝟑𝟎% 𝐀𝐂𝐂𝐄𝐏𝐓𝐀𝐁𝐋𝐄
557.907

STEP TWELVE (3rd trial) Pressure drop

Tube side:
530 tubes, I.D = 11.43 mm, 4 passes.

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𝐦
𝐮𝐓 = 𝟏. 𝟐𝟎𝟕
𝐬
𝐑𝐞 = 𝟐. 𝟐𝟔 × 𝟏𝟎𝟒
From Figure 12.24, 𝐣𝐟 = 𝟑. 𝟖 × 𝟏𝟎−𝟑
5000 1.2072 5.75 −0.14
∆𝐏𝐓 = 8 × 3.8 × 10−3 × [ ] × 941.72 × [ ]×[ ]
11.43 2 3.73
= 8585.97 N⁄m2 = 𝟏. 𝟐𝟒𝟓 𝐩𝐬𝐢
𝐅𝐨𝐫 𝐟𝐨𝐮𝐫 𝐩𝐚𝐬𝐬𝐞𝐬, 1.245 × 4 = 𝟒. 𝟗𝟖 𝐩𝐬𝐢 < 𝟏𝟎 𝐩𝐬𝐢 𝐀𝐂𝐂𝐄𝐏𝐓𝐀𝐁𝐋𝐄

−3
593.118 5000 830.88 × (0.986)2 3.73 −0.14
∆𝐏𝐬 = 8 × 3.8 × 10 ×[ ][ ][ ]×[ ]
11.37 120 2 5.75
= 13468.12 N⁄m2 = 𝟏. 𝟗𝟓𝟑 𝐩𝐬𝐢
𝐅𝐨𝐫 𝐭𝐰𝐨 𝐬𝐡𝐞𝐥𝐥𝐬, 1.953 × 2 = 𝟑. 𝟗𝟎𝟔 𝐩𝐬𝐢 < 𝟏𝟎 𝐩𝐬𝐢 𝐀𝐂𝐂𝐄𝐏𝐓𝐀𝐁𝐋𝐄

Summary: The Proposed Design

 Split ring, floating head shell and tube heat exchanger with two shells and four passes
 530 tubes, 5 meters long, 16 mm o.d, 11.43 mm i.d, triangular arrangement with pitch
20 mm
 Heat transfer area = 58.175 m2 (based on outside diameter)
 Shell i.d = 593.118 mm, baffle spacing 120 mm, 25% cut
 Tube side coefficient = 1252.073 W/m2oC, clean
 Shell side coefficient = 1760.92 W/m2oC, clean
 Overall coefficient estimated = 300 W/m2.K
 Overall coefficient required = 435.61 W/ m2.K
 Dirt/Fouling factors
Tube side (aniline) = 0.00018 (W/m2oC)-1
Shell side (benzene) = 0.00018 (W/m2oC)-1
 Pressure drops
Tube side: estimated 1.245 psi; specified 10 psi overall
Shell side: estimated 3.906 psi; specified 10 psi overall

Iterations Tube heat Shell heat Tube Shell Overall Pressure Pressure
transfer transfer side side Heat drop tube drop
coefficient coefficient velocity velocity Coefficient, side shell side
(W/m2.K) (W/m2.K) (m/s) (m/s) U (Psi) (Psi)
(W/m2.K)
I 1878.1 1760.96 1.43 1.26 558 - -
II 4712.86 7460.04 2.61 2.12 638.5 36.16 58.83
III 1252.1 1760.9 1.21 0.99 435.61 4.98 3.91

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Nomenclature

Tube side velocity ut m/s

Bundle diameter Db m
Shell diameter Ds m
Reynold’s number Re
Prandtl Number Pr
Nusselts’s Number Nu
Tube side heat coefficient hi W/m2K
Shell side velocity us m/s
Overall heat transfer
Uo W/m2K
coefficient
Shell side heat coefficient Ho W/m2K
Correction factor jh
Friction factor jf
Tube side pressure drop ∆Pt Psi
Shell side pressure drop ∆Ps Psi

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ASPEN- HYSYS Simulation

The following screenshots show the shell and tube heat exchanger designed and simulated
using the Aspen-HYSYS software.

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Appendix

Figure 1 - Temperature correction factor for 2 shell, 4 passes

Table 1 - Constants for 2-4 heat exchanger

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Figure 2 - Shell bundle clearance

Figure 3 - Tube heat transfer coefficient

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Figure 4 - Tube side friction factor

Figure 5 - Shell side heat transfer coefficients

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References
[1 ] R. Serth and T. Lestina, Process heat transfer, 2nd ed. Amsterdam: Elsevier/Academic
Press, 2014.
[2] D. Green, Perry's chemical engineers' handbook, 8th ed. New York [etc.]: McGraw-Hill,
2008.
[3] M. Peters, K. Timmerhaus and R. West, Plant Design and Economics for Chemical
Engineers, 5th ed. McGraw Hill, 2017.

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