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9. DESIGN PROBLEM
150000 lb per hour of kerosene will be heated from 75 to 120F by cooling a gasoline
stream from 160 to 120F. Inlet pressure will be 50 psia for each stream and the
maximum pressure drop of 7 psi for gasoline and 10 psi for kerosene are permissible.
Published fouling factors for oil refinery streams should be used for this application.
Design a shell and tube heat exchanger for this service.
Given data:
=120+0.455(160-120)
=138.2F
=75+0.455(120-75) =95.475F
Viscosity:
76API gasoline, g=0.2cp (0.484 lb.ft-1.h-1)
46API kerosene, k =1.6 cp (3.872 lb.ft-1.h-1)
Density:
g=685 kg.m-3 (42.7 lb.ft-3)
k=800 kg.m-3 (49.8 lb.ft-3)
Thermal conductivity:
kg=0.075 Btu h-1ft-1 F-1
kk=0.083 Btu h-1ft-1 F-1
Specific gravity:
Sg = 0.685
Sk = 0.80
Assumptions:
Fixed tube plate type
1 OD tubes (14 BWG) on 1 square pitch (PT)
Tube length (Lt) = 24 (the tube length is increased from 16)
1 shell pass-6 tube pass (tube passes is increased to 6 from 2)
Tube ID=0.834
Flow area per tube=0.546 inch2
No. of tubes:
n t = 368 is taken corresponding to the closest standard shell ID of 31 for fixed tube
sheet, 1-shell and 6-tube pass exchanger with 1 tube OD on 1 square pitch.
Fluid velocity:
Assumptions:
25% cut segmental baffles
Baffles spacing, B= 0.5DS=15.5 (half of the shell ID is selected)
jH=110 for the shell side fluid at Re=35668 with 25% cut segmental baffles
Fouling factor, Rdk=0.001 h ft2 F Btu-1 for kerosene and Rdg= 0.0005 h ft2 F Btu-1
for gasoline is taken for this service.
Therefore, the calculated overall heat transfer co-efficient is well within the design
criteria.
Therefore the tube side pressure drop is within the maximum allowable pressure
drop of 10 psi.
Therefore the shell side pressure drop is within the maximum allowable pressure
drop of 7 psi.
The minimum information required for the mechanical design of some important
components of shell and tube exchanger is summarized below:
a. Shell side and tube side passes: 1 shell pass and 6 tube passes.
b. Number, type, size, and layout of tubes: Number of tubes 318; tube length 20
(6.096 m as per IS: 4503-1967 and IS:2844-1964 standards); tube OD 1 (25.4 mm);
tube ID: 0.834 (21.2 mm); square pitch (=141"); fixed tube sheet.
The tube sheet thickness is calculated based on the bending and considering the design
pressure only. It is assumed that shear does not control the design. Carbon steel is used
for tube sheet material.
The pressures at the entry point of both shell side and tube fluid are same.
Therefore, the same nozzle specification can be used for tube side fluid also.
Gasket factor =3.75, minimum design seating stress Y= 5.35 kgf/mm2 (for flat iron
jacketed, asbestos fill)
Flange thickness
(Reference: Kuppan T. Heat Exchanger Design Handbook, Marcel Dekker, Inc. 2000,
New York.)