PRODUCTION OF FORMALDEHYDE FROM METHANOL VIA FORMOX

PROCESS

EQUIPMENT DESIGN

PRODUCTION OF FORMALDEHYDE FROM METHANOL VIA FORMOX PROCESS

H-02 DESIGN
GAS COOLER

SPECIFICATION SHEET
Shell and Tube Heat Exchanger
Operation
Functional Description
Type
Configuration

Continuous
Cooler
TEMA AES Removable tube bundle, split clamp-ring floating
head
Horizontal without condensation

Design Code
Shell
Fluid Circulating
Materials of Construction
Type
Pass

Tube

Water
Stainless Steel, type 304
TEMA Type E
1

Hot Gases
Stainless Steel, type 304
Plain, seamless
2

Tube Layout
BWG
Pitch Type
Tube OD-1 in. TEMA std.
Tube ID
Tube Length
Tube Pitch (1.25 x Tube OD)
Number of Tubes (Design)
Tubes per pass
Shell Layout
Shell ID - 12 in.
Baffle Spacing
Number of Baffles
Shell Cover Type

16
Triangular
25.41 mm
22.10 mm
2.4390 m
31.76 mm
52
2
304.878 m
0.1524 m
15
Standard Torispherical Head

GAS
COOLER

PRODUCTION OF FORMALDEHYDE FROM METHANOL VIA FORMOX PROCESS

Stream 9: Hot Gases

Stream 8: Hot Gases

6152.67

kg
6152.67
hr

kg
hr

T 1 =110 C

T 1 =350C
From Overall Energy Balance:
Q=475.30 kW
mass of water required mw =20,418.52

kg
hr

Shell Side: Water

t 1 =30C
t 2 =50C
Tube Side: Hot Gases
T 1 =350C
T 2 =110 C
Log Mean Temperature Difference:
T lm=

( T 1t 2 )(T 2t 1 )
ln (

T lm=

T 1t 2
)
T 2t 1

( 35050 )(11030)
35050
ln (
)
11030

T lm=166.4453 K

GAS
COOLER

PRODUCTION OF FORMALDEHYDE FROM METHANOL VIA FORMOX PROCESS

Dimensionless Temperature Ratio:i

R=

T 1T 2 350110
=
=12.00
t 2t 1
5030

S=

t 2t 1 5030
=
=0.0625
T 1t 1 35030

Correction Factor:

( R 2+1 )
R+1+
2S [ R+1 ( R2 +1 ) ]
2S [ ]
( R1 ) ln
( 1S )
(R2 +1) ln [ ( 1RS ) ]
Ft =

Ft =F ( R , S )=0.9676
Check with correction factor chart for one shell pass two tube passes:

GAS
COOLER

PRODUCTION OF FORMALDEHYDE FROM METHANOL VIA FORMOX PROCESS

True Temperature Difference:

T m=F t T lm
T m=0.9676 ( 166.4453 )
T m=161.0509 K
Assume Overall Heat Transfer Coefficient:

U o , assumed =300

W
m2 K

Heat Transfer Area:

A=

Q
U 0, assumed T m

GAS
COOLER

PRODUCTION OF FORMALDEHYDE FROM METHANOL VIA FORMOX PROCESS

( 475.30 kW )
A=

( 1000W
1 kW )

( 300 mWK )( 161.0509 K )

2

A=9.8374 m

Surface area of a single tube:

at = ODt Lt
at = ( 0.02541m ) ( 2.4390 m)
at =0.1947 m 2
Number of Tubes:

( aA )( no . of shell1 passes )

nt =

nt =

9.8374 m
0.1947 m2

)( )

1
=50.53
1

nt 51
Using TEMA Standard:ii
accdg
N t 52 tubes(TEMA)

Shell inside diameter , IDs =12 0.30488 m

Tube Bundle Diameter:iii
For triangular pitch,

GAS
COOLER

PRODUCTION OF FORMALDEHYDE FROM METHANOL VIA FORMOX PROCESS

K 1=0.249
n1=2.207
N
D bundle =ODt t
K1

( )

D bundle =( 0.02541 )

1
n1

52
0.249

1
2.207

D bundle =0.2858 m

Number of Tubes in Center Row:iv

N r , c=

D b 0.2858 m
=
=8.9992
Pt 0.03176

N r , c 9 tubes

Baffle spacing:
33 % baffle cutv

B=0.5 ID s=0.5 ( 0.30488 m )

B=0.1524 m
Number of baffles:

Lt
=nB +1
B
Where:

Lt
=no . of the flow crosses the tubebundle
B

GAS
COOLER

PRODUCTION OF FORMALDEHYDE FROM METHANOL VIA FORMOX PROCESS

n B=

Lt
2.4390
1=
1
B
0.1524

n B=15 baffles
Check:
B n B= ( 0.1524 m )( 15 baffles )=2.29 m<2.4390 m(Tube Length)
Therefore, baffle spacing is acceptable.

GAS
COOLER

PRODUCTION OF FORMALDEHYDE FROM METHANOL VIA FORMOX PROCESS

TUBE-SIDE HEAT TRANSFER COEFFICIENT: SINGLE PHASE vi

Tube-side mean temperature:

T=

T 1 +T 2 623.15+383.15
=
2
2

T =503.15 K
Thermodynamic properties of hot gases at tube-side mean temperature vii
Hot Gases
Density

Viscosity

Thermal Conductivity

Specific Heat Capacity

1.9949

kg
m3

0.00002674

kg
m s

0.0391

W
mK

1.1205

kJ
kg K

Tube cross-sectional area:

A t ,c = ( IDt )2= ( 0.0221m )2

4
4
A t ,c =0.0003837 m2
Tube per pass:

GAS
COOLER

PRODUCTION OF FORMALDEHYDE FROM METHANOL VIA FORMOX PROCESS

nt , p=

Nt
52
=
no . of tube passes 2

nt , p=26 tubes
Total flow area:
A t ,total=n t , p At ,c =26 ( 0.0003837 m2 )
A t ,total=0.009977 m2
Tube-side mass velocity:
kg
1.7091
m gas
s
Gt =
=
At ,total 0.009977 m 2
Gt =171.3048

kg
2
m s

Tube-side linear velocity:

kg
2
G
m s
ut = t =
gas
kg
1.9949 3
m
171.3048

ut =85.8701

m
s

Tube-side Reynolds number:

GAS
COOLER

PRODUCTION OF FORMALDEHYDE FROM METHANOL VIA FORMOX PROCESS

kg
171.3048
( 0.0221 m)
(
Gd
m s)
=
=
2

gas

0.00002674

kg
m s

=141,583.37

Tube-side Prandtl number:

c
Pr= gas gas =
k gas

kJ
1000 J
kg

0.00002674
(1.1205 kgK
kJ )(
m s )
(0.0391 mW K )

Pr=0.7667

GAS
COOLER

PRODUCTION OF FORMALDEHYDE FROM METHANOL VIA FORMOX PROCESS

Length to diameter ratio:

Lt
2.4390
=
ID s 0.30488
Lt
=8
ID s
Tube-side coefficient:
E=0.0225exp ( 0.0225 ( ln 0.7667 )2)
E=0.02246

St=0.02244 ( 141,583.370.205 )( 0.76670.505 )

St=0.002258

hi= ( 0.002258 )( 1.9949 ) ( 85.8701 )( 1.1205 ) (1000)

hi=433.5048

W
m2 K

GAS
COOLER

PRODUCTION OF FORMALDEHYDE FROM METHANOL VIA FORMOX PROCESS

SHELL-SIDE HEAT TRANSFER COEFFICIENT: SINGLE PHASE viii

Shell-side mean temperature:
t=

t 1 +t 2 303.15+323.15
=
2
2

t=313.15 K

Thermodynamic properties of water at shell-side mean temperature: ix

Water
Density

991.2546

Viscosity

kg
m3

0.0006568

Thermal Conductivity

Specific Heat Capacity

kg
ms

0.6304

W
m K

4.1833

kJ
kgK

Clearance between tubes:

C=Pt ODt =0.03176 m0.02541 m
C=0.006352 m

Cross flow area:

As=

As=

C ID s B
Pt

( 0.006352 m )( 0.30488 m ) ( 0.1524 m )

0.03176 m
A s =0.009295 m2

GAS
COOLER

PRODUCTION OF FORMALDEHYDE FROM METHANOL VIA FORMOX PROCESS

GAS
COOLER

PRODUCTION OF FORMALDEHYDE FROM METHANOL VIA FORMOX PROCESS

Shell-side mass velocity:

kg
5.6718 )
(
W
s
G=
=
s

As

0.009295 m2

Gs=610.1962

kg
m2 s

Shell-side linear velocity:

kg
G
m2 s
us = s =

kg
991.2546 3
m
610.1962

us =0.6156

m
s

Shell-side equivalent diameter (hydraulic diameter):x

d e=

1.27 2
P t 0.785 OD2t )
(
OD t

de=

1.27
( 0.0317620.785 ( 0.02541 )2 )
0.02541m

d e =0.0180 m

Shell-side Reynolds number:

kg
610.1962
( 0.0180 m )
(
G d
m s)
=
=
2

6.568 104

kg
m s

=16,758.93

GAS
COOLER

PRODUCTION OF FORMALDEHYDE FROM METHANOL VIA FORMOX PROCESS

Shell-side Prandtl number:

kJ 1000 J
4.1833

6.568 x 10
(
c
kgK
kJ )(
P=
=
k
(0.6304 mWK )

kg
m s

Pr=4.3591
Baffle cut: 33 % baffle cutxi
From Fig. 12.29xii

j h=5 x 103

Shell-side coefficient:
1
hs d e

= j h Pr 3
k
w

0.14

( )

Without viscosity correction term:

w
0.6304
(
mK )
h=
( 5 x 10

0.0180 m

h s=4782.9753

) ( 16,758.93 ) ( 4.3591 ) 3

W
m2 K

GAS
COOLER

PRODUCTION OF FORMALDEHYDE FROM METHANOL VIA FORMOX PROCESS

Overall Heat Transfer Coefficient

Estimate:xiii
tube wall material thermal conductivity , k w =16

outside dirt coefficient , hod =5000

inside dirt coefficient , hid =6000

W
m

W
2
m

W
m2

Overall Heat Transfer Coefficient, U

1
1 1
= + +
U o ho hod

1
=
Uo

ODt ln

( )

2 kw

1
4782.9753

ODt
ID t

W
2
m K

U o , calc=297.3815

1
5000

][

OD t 1
OD t 1

IDt h id
IDt hi

W
2
m K

( 0.02541
0.0221 ) 0.02541
1
0.02541
+

0.0221
W
0.0221
W
6000
43
2 (16
m K )
m K

( 0.02541 m) ln
+

W
2
m K

Percent Errorxiv

%Error=0 <

297.3815300
100 <30
300

%Error=0.87

GAS
COOLER

][

PRODUCTION OF FORMALDEHYDE FROM METHANOL VIA FORMOX PROCESS

Therefore, the assumed overall heat transfer coefficient is acceptable.

GAS
COOLER

PRODUCTION OF FORMALDEHYDE FROM METHANOL VIA FORMOX PROCESS

PERCENT OVERSURFACE:

oversurface=15

U C U o , calc
100 <50
UC

Where:
U C =cleanoverall heat transfer coefficient
Calculating for hio
hio =h i

IDt
OD t

hio =433.5048

W
0.0221m

2
m K 0.02541m

hio =377.1491

W
m2 K

Calculating for U C
U C=

ho hio
ho +hio

U C=

4782.9753 377.1491
4782.9753+377.1491

U C =349.5836

W
m2 K

Calculating for percent oversurface

oversurface=

349.5836297.3815
100
349.5836

GAS
COOLER

PRODUCTION OF FORMALDEHYDE FROM METHANOL VIA FORMOX PROCESS

oversurface =15
Therefore, the oversurface is acceptable.

GAS
COOLER

PRODUCTION OF FORMALDEHYDE FROM METHANOL VIA FORMOX PROCESS

PERCENT OVERDESIGN

overdesign=0 <

[(

A A reqd
100 <10
A reqd

Design area ( N t =51 )

A= OD t Lt N t
A= ( 0.02541 m )( 2.4390 ) ( 51 )
A=9.9284 m2
Required heat transfer area ( N t =52 )
A reqd = ODt Lt N t
A reqd = ( 0.02541 m) ( 2.4390 ) (52 )
A reqd =10.1231 m 2

Calculating for percent overdesign

overdesign=

( 9.928410.1231
) 100
9.9284

overdesign=1.92

Therefore, the overdesign is acceptable.

GAS
COOLER

PRODUCTION OF FORMALDEHYDE FROM METHANOL VIA FORMOX PROCESS

TUBE-SIDE PRESSURE DROP

u 2t
2

[ ( ) ]( )

L
Pt =N p 8 j f
+2.5
ID t

Hot Gases
Density

1.9949

Viscosity

kg
3
m

0.00002674

Linear velocity

85.8701

jf

m
s

141,583.37

Reynolds number

Estimate

kg
m s

from Figure 12.30xv

j f =0.0025

Pt =2 8 ( 0.0025 )

2.4390
+2.5
0.0221

(] (

1.9949

kg
m
85.8701
3
s
m
2

)(

Pt =69,238.26 Pa
Pt =69.24 kPa

GAS
COOLER

PRODUCTION OF FORMALDEHYDE FROM METHANOL VIA FORMOX PROCESS

SHELL-SIDE PRESSURE DROP

{ ( )( )( )( ) }

ID s
Ps = 8 j f
de

Lt
B

u2s
2

0.14

Shell-side fluid
Equivalent diameter

0.0180 m

Baffle spacing, B

0.1524 m

Density

991.2546

Viscosity

6.568 x 10

Linear velocity

0.6156

jf

kg
m s

m
s

16,758.93

Reynolds number

Estimate

kg
3
m

xvi

33 % baffle cutxvii

j f =0.046

Ps = 8 ( 0.046 )

0.30488 m 2.4390 m
0.0180 m 0.1524 m

)(

991.2546

kg
m
0.6156
3
s
m
2

)(

)}
( 1)

Ps =18,688.91 Pa
Ps =18.69 kPa

GAS
COOLER

PRODUCTION OF FORMALDEHYDE FROM METHANOL VIA FORMOX PROCESS

EFFECTIVENESS OF HEAT EXCHANGER

For one shell pass and two tube passes:

[
]
1exp [ ( NTU ) ( 1+ C ) ]
0.5

0.5

=2 1+C r + ( 1+C 2r )

1+exp ( NTU ) ( 1+C 2r )

2 0.5
r

For vapor mixture:

Ch =mh Cp h= 1.7091

Ch =1.9150

kg
kJ
1.1205
s
kgK

)(

kW
=Cmin
K

For water:

C c =mc Cp c = 5.6718

C c =23.7271

kg
kJ
4.1833
s
kgK

)(

kW
=C max
K

Capacity ratio:
Capacity Ratio, C r=

Cr =

C min
C max

1.9150
23.7271

Cr =0.0807

GAS
COOLER

PRODUCTION OF FORMALDEHYDE FROM METHANOL VIA FORMOX PROCESS

Inside depth of the head:xviii

[(

ID s
ID s
d i=R c R c
R c+
+2 Rk
2
2

)(

0.5

Where:
Rc =ID s=304.878 mm
Rk =0.06 R c =18.2927 mm

[(

304.878
304.878
d i=304.878 304.878
304.878+
+2 ( 18.2927 )
2
2

)(

0.5

d i=40.7766 mm

Effective exchanger length:xix

Leff =Lt + 2 di =2.4390 m+2 ( 0.04078 m )
Leff =2.5206 m
Area effective:
A e = ODt Leff N t = ( 0.02541m ) (2.5206 m) ( 52 )
A e =10.4616 m

Calculating for NTU:

NTU =

U o ,calc A e
C min

W
297.3815
( 10.4616 m )
(
m K)
NTU =
2

( 1.9150 kWK 1000W

kW )

GAS
COOLER

PRODUCTION OF FORMALDEHYDE FROM METHANOL VIA FORMOX PROCESS

NTU =1.6246

Effectiveness:

2 0.5

=2 1+0.0807 ( 1+0.0807 )

2
1+ exp [ ( 1.6246 ) ( 1+0.0807 )

0.5

2
1exp [(1.6246 ) ( 1+ 0.0807 )

]
]

0.5

=77.73
MECHANICAL DESIGN

Material of construction
Allowable stress (Design stress)

Shell
Tube
Stainless Steel, type 304
Stainless Steel, type 304
130 MPa

Design pressure:
Take as 10 percent above operating pressure xx
'

P =1.1 x 300 kPa

'

P =330 kPa
Design temperature:
Take as 10 percent above operating temperature xxi
T ' =1.1 x 423.15 K ( 110 )
T ' =421.465 K ( 148.315 )

SHELL DESIGN
Shell thickness:
For a cylindrical shell, the minimum thickness required to resist internal pressure can be
determined from the equation below based on the maximum allowable stress and corrected for
welded joint efficiency:

GAS
COOLER

PRODUCTION OF FORMALDEHYDE FROM METHANOL VIA FORMOX PROCESS

P' IDs
e=
2 Jf P'
Where:
f =design stress

e=minimum thickness required

J = joint factor , range 0.71.0

GAS
COOLER

PRODUCTION OF FORMALDEHYDE FROM METHANOL VIA FORMOX PROCESS

Calculating for shell thickness:

e=

( 0.33 MPa ) ( 304.878 )

2 ( 0.7 )( 130 MPa ) ( 0.33 MPa )

e=0.5538 mm

Add corrosion allowance taken as 2.0 mm:

e=0.5538 mm+2.00 mm=2.5538 mm
e 3.2 mm

This value is in accordance to IS: 4503 corresponding to the shell diameter.

Shell outside diameter:

OD s=ID s+ e
OD s=304.878 mm+3.2 mm
OD s=308.0780 mm

COVER AND CHANNEL DESIGN

For the shell head design, a torispherical head is selected. According to IS: 4503, the minimum
thickness of the shell cover should be at least equal to the thickness of the shell.

Shell cover thickness:

The required thickness of a torispherical head can be determined from the equation below.
'

e sc =

P Rc C s
'
2 fJ+ P ( C s0.2 )

Where:
C s=stress concentration factor

GAS
COOLER

PRODUCTION OF FORMALDEHYDE FROM METHANOL VIA FORMOX PROCESS

Rc =crown radius
For torispherical head, stress concentration factor is given by:
C s=

( )

R
1
3+ c
4
Rk

Where:
Rk =knuckle radius
Let:
Rc =ID s=304.878 mm
Rk =0.06 R c =18.2927 mm
For formed domed heads (no joints in the head), joint factor J =1.0

Calculating for stress concentration factor:

C s=

1
304.878
3+
4
18.2927

C s=1.7706

Calculating for shell cover thickness:

e sc =

( 0.33 MPa ) ( 304.878 ) (1.7706 )

2 ( 130 MPa ) (1 ) + ( 0.33 MPa ) ( 1.77060.2 )

e sh =0.6838 mm

Add corrosion allowance taken as 2.0 mm:

e sh =0.6838 mm+2.00 mm=2.6838 mm

GAS
COOLER

PRODUCTION OF FORMALDEHYDE FROM METHANOL VIA FORMOX PROCESS

e sc 3.2mm

Use same thickness as for wall in accordance to TEMA standard.

GAS
COOLER

PRODUCTION OF FORMALDEHYDE FROM METHANOL VIA FORMOX PROCESS

Channel cover thickness:

The channel cover material is the same as the shell material. The outside diameter of the channel
shall be the same as that of the shell.
The effective channel cover thickness can be determined from the equation below.
'
d C 1 P
t cc =
10 f

Where:

t=thickness of the channel cover [mm ]

d=diameter of the cover [ mm ] usually same as the outside shell diameter
C1 =factor equal 0.3 for ring type gasket
P' =design pressure [

f =design stress[

kgf
]
2
cm

kgf
]
2
mm

Calculating for channel cover thickness:

t cc =

308.0780 mm 0.3 ( 3.365064 )

10
13.2563

t cc =2.3350 mm

Add corrosion allowance taken as 3.0 mm:

t cc =2.3350+3.00 mm
t cc =5.3350 mm

GAS
COOLER

PRODUCTION OF FORMALDEHYDE FROM METHANOL VIA FORMOX PROCESS

Tube sheet thickness:

The tube sheet thickness is calculated based on the bending and considering the design pressure
only. The material is the same as the shell material.
The minimum tube sheet thickness to resist bending can be determined from the equation below.
t ts =

F Gp P
3
kf

For the stationary tube sheet in floating type:

F=1

G p=ID s
Mean ligament efficiency:
k =1

k =1

0.907
Pt 2
ODt

( )
(

0.907
0.03176
0.02541

k =0.4195

Calculating for tube sheet thickness:

t ts =

( 1 ) ( 304.878mm )
( 0.33 MPa )
3
( 0.4195 ) ( 130 MPa )

t ts =7.9052 mm

GAS
COOLER

i Eq. 12.6 & Eq. 12.7. Page 655. Sinnot, R. K. Coulsons and Richardsons Chemical Engineering Design Vol. 6.
ii Table 9. Page 841. Kern D. Q. Process Heat Transfer. (1965).
iii Table 12.4. Page 649. Sinnot, R. K. Coulsons and Richardsons Chemical Engineering Design Vol. 6.
iv Page 649. Sinnot, R. K. Coulsons and Richardsons Chemical Engineering Design Vol. 6.
v Shell and Tube Heat Exchangers. http://www.thermopedia.com/content/1121/
vi Page 662. Sinnot, R. K. Coulsons and Richardsons Chemical Engineering Design Vol. 6.
vii Table 2-305. Thermodynamic Properties of Water. Perry, R.H. and Green, D.W. (2008). Perrys Chemical
Engineers Handbook, 8th Edition. New York: McGraw-Hill

viii Page 669. Sinnot, R. K. Coulsons and Richardsons Chemical Engineering Design Vol. 6.
ix http://www.engineeringtoolbox.com/air-properties-d_156.html
x Eq. 12.22. Page 672. R.K Sinnott. Coulsons and Richardsons Chemical Engineering Design Vol. 6.
xi Shell and Tube Heat Exchangers. http://www.thermopedia.com/content/1121/
xii Fig. 12.29. Page 673. R.K Sinnott. Coulsons and Richardsons Chemical Engineering Design Vol. 6.
xiii Table 12.6, page 662 and Table 12.2, page 640. Sinnot, R. K. Coulsons and Richardsons Chemical
Engineering Design Vol. 6.

xiv Page 684. R.K Sinnott. Coulsons and Richardsons Chemical Engineering Design Vol. 6.
xv Figure 12.24. Page 668. R.K Sinnott. Coulsons and Richardsons Chemical Engineering Design Vol. 6.
xvi Figure 12.30. Page 674. R.K Sinnott. Coulsons and Richardsons Chemical Engineering Design Vol. 6.
xvii Shell and Tube Heat Exchangers. http://www.thermopedia.com/content/1121/
xviii Page 17. Process Design of Heat Exchanger. NPTEL Chemical Engineering Chemical Engineering
Design II

xix Page 17. Process Design of Heat Exchanger. NPTEL Chemical Engineering Chemical Engineering
Design II

xx Page 810. R.K Sinnott. Coulsons and Richardsons Chemical Engineering Design Vol. 6.
xxi Page 810. R.K Sinnott. Coulsons and Richardsons Chemical Engineering Design Vol. 6.