JR Heat Exchanger Design

Components Molar Flow Mole fraction Mol. Weight Mass flow

kmol/hr kg/s
Methyl Chloride 124.58754 0.9999 50.49 6290.4248946
Dimethyl Ether 0.01246 0.0001 48.01 0.5982046

Total 124.6 1 6291.0230992

Stream Specifications

Flow into condenser 6291.0230992 kg/s

Pressure 101.325 Kpa
Temperature inlet T1 136.4 oC
outlet T2 135 oC
mean Tm 135.7 oC

Vapour enthalpy of process stream 3901277.709

Cooling Water Temperature inlet t1

outlet t2
mean Tm

Cooling Water Stream

Specific heat capacity, Jkg C
-1o -1
4202
Thermal conductivity, Wm-1K-1 0.611
Viscosity, Pas 0.0008904
Density, kg/m3 998.1

Q (process stream) = mCpT 68708541.162

Tube Layout

Cooling water flow rate 191.99804027 kg/s

R (_1_2)/(_2_1) 0.056
S (_2_1)/(_1_1) 0.2244165171

Ft 1 Assuming that we use one shell pass and two tub

(_1_2)(_2_1)/
TLM (_1_2)/(_2_1 ) 97.725525364

TLM *Ft 97.725525364

From page 637 U, W/m2oC 600

=/(_
Heat transfer area, A _ ) 343.98031384

Tube Dimensions
Outer diameter 20 mm 0.02
Wall thickness 2 mm 0.002
Inner diameter 16 mm 0.016
Baffel cut 45 %
Length of tube 6.1 m ASSUMED

Surface area of 1 tube 0.3832743037 m2

Cross sectional area 0.0002010619 m2

Number of tubes 897.47815203 98

Number of tubes per pass 49 tubes

Total flow area 0.0098520346 m2

Pitch; A triangular pitch is recommended

Thus; Pitch 25 mm 0.025 m

_=/
Tube side volumetric flow 0.192363531

Tube side velocity _=_/( 19.525259456

)
Bundle and Shell Diameter Coulson pg 649
K1 0.249
n1 2.207
Db 817.78769236 mm 0.8177876924 m

Clearance height for split-ring floating head exchanger

Ds 870.78769236 mm

_=_/

Number of tubes in centre row; _=_/ 32.711507694

Tube Side Heat Transfer Coefficient

= ()/
Reynolds number 350191.58064

Pr =
Prandlt number 6.1235037643
(_)/

Ratio of L/di 381.25

Heat transfer factor, jh pg 665 0.0036

Nusselt number =
2306.4366525
^(1/3)
_= ()/
Tube side coefficient 88077.049669

Shell Side Heat Transfer Coefficient

Baffel Spacing _= 870.78769236

0.8707876924
Cross flow area between tubes 151654.24103
_=((__)/_ )_ 0.151654241
_

Equivalent diameter 14.201

0.014201
_=(1.10/)(
^2(0.9
17
^2 ))

Volumetric flow rate _=/ 7.012022057

Shell side velocity 46.236900526

Re 2786638.7011

Pr 4.0865637823

Heat transfer coefficient, jn pg 672 0.0033

Shell side coefficient 116055.94261

=(/)

^(1/3)
 =(/)

^(1/3)

Overall Heat Transfer Coefficient

do
1/_ = 1 1 d
The overall heat transfer coefficient; o
hidc h1 di 2
Heat transfer fouling factors pg 640
Process Stream hodc 5000 W m-2 oC-1
WaterStream hidc 6000 W m-2 oC-1

Thermal conductivity of tube wall material

k carbon steel 51.8 W m-2 oC-1

Thus; 1/Uo 0.0006589776

Uo 1517.5023324 W m-2 oC-1

Percentage Difference -152.9170554 %

Pressure Drop

Tube side pressure drop; Pt =

L
m

N p 8 j f 2.5
di w
Friction factor, jf 0.026 pg 667

Thus Pt 8115363.0557 Pa
8115.3630557 Kpa

Ds L
0.14

Shell side pressure drop; Pt = 8 j f
de lB w

Friction factor, jf 0.028 pg 673

Linear velocity 0.192363531

Thus; Pt 112852604.71 Pa
112852.60471 Kpa
- Inputs

Mass fraction Density Vol flow Enthalpy of Vapourization

kg/m3 m3/s kJ/kmol
0.9999049114 897.2 7.01117353 31310
9.508860E-005 652.6 0.00091665 35460

1 7.01209018

22647683.157 kg/hr

409.55 K
408.15 K
408.85 K

kJ/hr

25 oC 298.15 K
50 C o
323.15 K
37.5 oC 310.65 K

Process Stream
2167
0.1121
0.0002114 at 135
897.17674133 Liquid
3.16 Vapour

72609818.871 kJ/hr
20169.394131 kJ/s
se one shell pass and two tube passes

o
C

o
C

m2

m
m
m

tubes

m3/s

m/s

53 mm
tubes

Condensation outside the tube

v =/_( _ ) 3060.84156 kg/s m

Rec =(4)
_ 57915639.8
/_
hc 6282.99208

W m-2 oC-1

mm
m
mm2
m2

mm
m

m3/s

m/s

W m-2 oC-1
 d
d o ln o
1

1 d
o di 1 1
idc h1 di 2 kw hodc hs

m
u t2
2.5

w 2

L

0.14
u s2


lB w 2
Design Temperature and Pressure

Operating Temperature Design Temperature

Shell side 50 OC Shell side 90 OC
Tube side 136.4 OC Tube side 176.4 OC

Operating Pressure design Pressure

Shell side 112852.6 Kpa Shell side 135423.1 Kpa
Tube side 8115.363 Kpa Tube side 9738.436 Kpa

Tube Specifications

Outer diameter 20 mm 0.02 m

Wall thickness 2 mm 0.002 m
Inner diameter 16 mm 0.016 m
Baffel cut 45 %
Tube length 6.1 m
Shell internal diameter 600
Surface area of 1 tube 0.383274 m2
Tube cross sectional area 0.000201 m2

Shell Thickness

Corrosion allowance 3 mm
Weld joint efficiency 1

Design Stress
Maximum tensile stress 258.75 N/mm2
Maximum yield stress 202.5 N/mm2
P di
tmin = C
Shell thickness
2 F J P 304.4126 mm
4.8 mm FROM STANDARDS

Outer diameter 1208.825 mm 1.208825 m

Baffel spacing 604.4126 mm 0.604413 m

Number of baffels 9.092443 approximately 20

Baffel length 332.4269 mm 0.332427 m

Nozzle Dimensions

The optimum diameter is given by;

Process Stream
Mass flow rate of fluid 6291.023 kg/s
Density of process stream 897.1767 kg/m3

Thus; dopt 2441.322 mm

95.38269 inches d optimum 293 G 0.53 0.37

Cooling Water Stream

Mass flow rate of fluid 191.998 kg/s
Density of cooling stream 998.1 kg/m3

Thus; dopt 369.25 mm

14.53741 inches

Heat Exchanger Tube Plate Design

Plate thickness due to bending

Pitch 25 mm
Di 16 mm
Ligament eff 0.36

Cph 0.05
Db 817.7877 mm
fp 135 N/mm2
P -125685 N/mm2

tp1 #VALUE! mm

Plate thickness due to shear thinning

tough 67.5 N/mm2

tp2 -486423

The bigger thickness would be used

Thus; thickness -486423 mm

However, standards say that the minimum thickness is

tp 25 mm

Combined Loading

Shell Weight

Cv 1.15 Ws 1577.648
Dm 0.904413 m
Hv 6.1
t 0.304413

Tube Weight

do 0.02 Wt 5206.513
di 0.016
L 6.1
density 7850
N 98
g 9.81

Fluid Weight

Wft = Ms (distance travelled by fluid / velocity) g

Ms 6291.023 Wtf 38561.45

d travelled 12.2
Us 19.52526

Wfs

Ms 191.998 Wts 496.9777

d travelled 12.2
Us 46.2369

Wf 39058.42

Insulation Weight

do 0.024 Wi 1.503968
di 0.016
L 6.1
density 100 (fibre glass)

Total Weight 45844.09 N

Primary Stresses
ROM STANDARDS