He Design Report Group 2

PLANT DESIGN OF REBOILER IN PRODUCING PROPYLENE GLYCOL
TK-2203 HEAT TRANSFER
HEAT EXCHANGER
FINAL DESIGN REPORT
20/04/2018 DRR Issued for Internal Review 2nd Initial 3rd Initial DL
SUBMITTED
DATE EXPLANATION CHECK APPR. LECTURER
BY
PLANT DESIGN OF REVOILER IN PRODUCING PROPYLENE GLYCOL
Nasywa Kamilah 13016201

Fitridhia Aliyafaiqah Alis 13016211
Dina Rizkia Rachmah 13016213
Reyhan Fitri Ananda 13016215
REPORT 29 Pages
Page 1 from 29
Table of Contents
1 INTRODUCTION 3
1.1 PROCESS DESCRIPTION 3
1.2 PROCESS FLOW DIAGRAM IN HEAT EXCHANGER PROCESS 3
1.3 FACTORY PROFILE 3
2 EXCHANGER DESIGN DATA 4
2.1 PROCESS FLUID 4
2.1.1 BRIEF DESCRIPTION 4
2.1.2 COMPOSITION AND PROPERTY OF PROCESS FLUID 4
2.1.3 PROCESS FLUID FLOW CONDITION 5
2.2 SERVICE FLUID 5
2.2.1 BASIC CONSIDERATION IN SELECTING SERVICE FLUID 5
2.2.2 COMPOSITION AND PROPERTY OF SERVICE FLUID 5
2.2.3 SERVICE FLUID FLOW CONDITION 6
3 DESIGN METHODOLOGY 7
3.1 ASSUMPTIONS 7
3.2 DESIGN ALGORITHM 9
3.3 HEAT EXCHANGER TYPE 10
3.4 BASIC CONSIDERATION TO SELECTED HEAT EXCHANGER TYPE 10
4 DESIGN RESULTS 11
4.1 CALCULATION RESULT 11
4.2 TEMA SHEET HEAT EXCHANGER 12
5 ANALYSIS 14
5.1 DESIGN LOGICAL ANALYSIS 14
5.2 PROCESS OPERATION PARAMETER 15
5.3 TECHNO-ECONOMIC ANALYSIS 15
6 CONCLUSION 15
7 REFERENCES 16
APPENDIX A – PHYSICAL FLOW DATA 17
APPENDIX B – CALCULATION MODEL 19
APPENDIX C – EXCEL CALCULATION 27
APPENDIX D – FLOW DIAGRAM EXPLANTION 28
Page 2 from 29
1 INTRODUCTION
1.1 Process Description
Propylene Glycol (PG) Production is a process where propylene glycol is produced by the
hydration of propylene oxide, commercially. This process produces small amounts of biproducts
such as dipropylene and tripropylene glycols, and small quantities of higher glycols as well. The
hydration reaction between propylene oxide and water takes place at a temperature of 200 ℃ and a
pressure of 12 bar. One way to favor the propylene glycol is to control the amount of water being
used. To produce the steam in the oulet of the reboiler as saturated vapor, minimum area and
pressure drop have to come to consideration.
1.2 Process Flow Diagram in Heat Exchanger Process
Figure 1.1 Shell and Tube Kettle Reboiler
1.3 Factory Profile

The Dow Chemical Company is well known to be a leading producer of propylene glycol
worldwide since 1948. The company is located in Midland, Michigan, USA as the main
headquarter. The propylene glycol product from the Dow Chemical Company includes industrial
PG grades for technical applications, industrial applications, and specialty PG grades for sensitive
applications such as pharmaceuticals and foodstuff. The total net sales of the Dow Chemical
Company was $48,158 million in 2016 based on the company’s 2016 annual report.
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2 EXCHANGER DESIGN DATA

2.1 Process Fluid
2.1.1 Brief Description
The process fluid used consists of 98.1359% propylene glycol, 0.0398% propylene oxide, and
1.8243% water, hence it can be assumed that propylene glycol is the only product. Propylene
glycol is a product from the hydration of propylene oxide. Propylene glycol is used in chemical,
food, and pharmaceutical industries as an antifreeze might lead to contact with food.
2.1.2 Composition and Property of Process Fluid

Table 2.1 Composition of Process Fluid
No. Compound Composition (mole-%)
1. Propylene Glycol 98.1359
2. Propylene Oxide 0.0398
3. Water 1.8243
Table 2.2 Property of Propylene Glycol at 176.5 ℃
No. Properties Values

1. Molecular Weight 73.03308 g/mol
2. Critical Temperature 351.55 ℃
3. Critical Pressure 63.86594 bar
4. Surface Tension 0.0181 N/m
5. Specific Heat 3.396 kJ/(kg.K)
6. Viscosity 0.4474 mPa.s
7. Thermal Conductivity 0.1558 W/(m.K)
𝑘𝑔⁄
908.01 (liquid),
8. Density 𝑚3
𝑘𝑔
3.06 ⁄ 3 (gas)
𝑚
9. Latent Heat 726.9 kJ/kg
Source: ASPEN Exchanger Design and Rating
Page 4 from 29
2.1.3 Process Fluid Flow Condition

The conditions for the reboiler feed in liquid phase are:
Fluid Rate : 433 kmol/hr

Temperature : 176.5 ℃
Pressure : 95.3 kPa-abs
2.2 Service Fluid

2.2.1 Basic Consideration in Selecting Service Fluid
The service fluid chosen for this heat exchanger design is water as water availability is abundant.
As most service fluids will foul the heat transfer surfaces in heat exchangers, water lessens the
2
fouling with fouling factor ranging from 0.0001-0.0003 𝑚 ℃⁄𝑊 as it has a relatively small
viscosity.
2.2.2 Composition and Property of Service Fluid

Table 2.3 Property of Water at 298.8 ℃
No. Properties Values
1. Molecular weight 18.00999 g/mol
2. Critical Temperature 374.13℃
3. Critical Pressure 221.0599 bar
4. Surface Tension 0.0152 N/m
4.881 kJ/(kg.K) (liquid),
5. Specific Heat
2.695 kJ/(kg.K) (gas)
0.0956 mPa.s (liquid),
6. Viscosity
0.0205 mPa.s (gas)
0.5221 W/(m.K) (liquid),
7. Thermal Conductivity
0.0491 W/(m.K) (gas)
𝑘𝑔⁄
718.53 𝑚3 (liquid),
8. Density 𝑘𝑔
14.38 ⁄𝑚3 (gas)
9. Latent Heat 1406 kJ/kg
Source: ASPEN Exchanger Design and Rating
Page 5 from 29
2.2.3 Service Fluid Flow Condition

The conditions for the service fluid feed in superheated steam are:
Temperature : 298.8 ℃
Pressure : 34.9 bar
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3 DESIGN METHODOLOGY
3.1 Assumptions
Table 3.1 Assumptions Used in the Design
No. Process Assumption
The process fluid used is considered as only

propylene glycol as the percentage is 98.1359
mol-%, causing the other impurities such as
1. Determination of process fluid
propylene oxide and water having really
small mole percentages. Thus, their
percentages can be neglected.
The temperature of the shell-side fluid in any

pass is constant across any section, there is no
Condition for calculating log mean
2. leakage of fluid between shell passes, and a
temperature difference
constant overall heat transfer coefficient in
each pass.
Fluid is assumed to evaporate perfectly on the

reboiler. Evaporation temperature of
3. Outlet condition
propylene glycol is evaluated on the inlet
pressure.
4. Mass balance determination System is assumed to have 5% heat loss.
Determination of latent heat of

Latent heat of propylene glycol is not a
5. propylene glycol on operating
function of temperature and pressure.
pressure
The material price obtained is based on a

6. Material Price Determination vendor, hence it is assumed to be a
literature’s price.
The velocity and temperature at the entrance

of the heat exchanger on each fluid side are
uniform over the flow cross section and the
7. Fluid flow rate determination
fluid flow rate is uniformly distributed
through the exchanger on each fluid in each
pass.
Heat exchanger operates under steady state

8. Operating Condition
conditions.
Determination of wall thermal Wall thermal resistance is distributed

9.
resistance uniformly in the entire heat exchanger.
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10. Fluid flow determination The fluid flow is counter-current.
Determination of heat exchanger Copper-nickel 30% is used to be the heat

11.
material exchanger material.
The standard dimensions of copper-nickel

Determination of standard
12. 30% is assumed to have the standard
dimensions and price
dimensions of steel and the price of steel.
Page 8 from 29
3.2 Design Algorithm
Figure 3.1 Design Algorithm
Page 9 from 29
3.3 Heat Exchanger Type

The heat exchanger type that is used is a shell and tube kettle heat exchanger U-Tube type, with
copper-nickel (cupronickel) 30% as the material for the heat exchanger. Counter-current flow will
be applied for the service fluid is water and the process fluid is propylene glycol
3.4 Basic Consideration to Selected Heat Exchanger Type

The considerations are:
 Counter-current flow is the most efficient method as it would give the greatest concentration
of the product.
 Shell and tube heat exchanger is used because it is less expensive than plate types, less
pressure drop, it can be used with higher operating temperature and pressure, easily cleaned,
can be constructed from a wide range of materials, and its configuration gives a large surface
area in a small volume.
 Kettle reboilers have lower heat-transfer coefficients compared to other types as they return
only vapor to the column, hence no liquid circulation.
 Kettle reboilers are suitable for high rates of vaporization up to 80% of the feed and they
provide large heat transfer surface.
 U-tube type is chosen for its ability to handle large temperature differences between the
service fluid.
 Copper-nickel 30% (cupronickel) is used for its strength, corrosion resistance, and ductility.
Page 10 from 29
4 DESIGN RESULTS
4.1 Calculation Result
Table 4.1 HE Design Result
No. Parameter Value Unit
1. Total heat load 6.676 kW
Maximum total heat load
2. 7.010 kW
(5% heat loss)
Mean temperature
3. 86.137 K
difference
4. Area of heat transfer 7.5 m2
5. Vapor velocity 0.19 m/s
Maximum allowable vapor
6. 1.577 m/s
velocity
7. Reynolds number
8. Critical heat flux 233118.78 W/ m2
9. Maximum heat flux 163183.14 W/ m2
10. Mass flux of the steam 2.73 kg/( m2.s)
11. Pressure drop on tube side 9105.3 Pa
Dimension of Heat Exchanger
1. Inner diameter of tube 0.026 m
Outside diameter of the
2. 0.030 m
tube
3. Length of the tube 5 m
Thermal conductivity of
4. 0.0491 W/(m.K)
tube
5. Inside diameter of shell 1.471 m
6. Outside diameter of shell 2.206 m
7. Length of the shell 5 m
Thermal conductivity of
8. 0.1558 W/(m.K)
the shell
9. Number of tubes 509 pieces
10. Tube pitch 0.0375 m
11. Bundle diameter 0.7354 m
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4.2 TEMA Sheet Heat Exchanger
Page 12 from 29
Figure 4.xx TEMA Sheet of Shell and Tube Kettle Heat Exchanger
Page 13 from 29
5 ANALYSIS
5.1 Design Logical Analysis
The analysis is approached with different factors such as overall heat transfer coefficient (Uo),
fouling factor, service fluid flow rate, pressure loss, and fluid regime.
According to literature, fouling factor of steam is in a range of 1500-5000 W/m2K and for light
hydrocarbon is 5000 W/m2K. The fouling factor of steam chosen in the range is 3000 W/m2K, and
this value is used for the overall heat transfer coefficient calculation.
As stated, the overall heat transfer coefficient allowed is within a range of 900-1200 W/m2.K for
the hot fluid is steam and the cold fluid is light hydrocarbon, which is polypropylene glycol. The
𝑊
result of Uo calculation shows 1154.09 , consequently proving the literature and the
𝑚2 .𝐾
assumption of fouling factor of steam.
Service fluid flow rate at the liquid surface obtained from calculation is 0.383 𝑚/𝑠, which is
lower than the maximum service fluid flow rate at the liquid surface. This fulfills the requirement
of having 𝑢̂𝑣 < 𝑢̂𝑣,𝑚𝑎𝑥 to avoid excesive entrainment. This also proves that the tube length
assumed makes sense.
The pressure drop calculated is 9105.3 𝑃𝑎, which is relatively small. This fits the type of heat
exchanger chosen as the desired pressure drop is minimum.
The fluid regime result shows a laminar flow with a Reynold’s number of 320.21. This
corresponds with the material chosen for the heat exchanger, which is copper-nickel 30%. Copper-
nickel 30% cannot withstand fluid with high velocity and tension. Thus, copper-nickel 30% as the
heat exchanger material can be accepted.
Bundle diameter of the tube obtained is 0.7354 m and diameter inside of the shell is 1.471 m.
Outside diameter chosen from standard dimension is 0.03 m and inner diameter is 0.026 m with a
length of 5 m. Even though smaller diameters (16 to 25 mm) are prefered for most duties as they
will give more compact and therefore cheaper price, larger tubes (> 25 𝑚𝑚) are easier to clean
by mechanical methods. The tube thickness is selected to withstand the internal pressure and give
an adequate corrosion allowance, affecting the inner diameter as well. According to Coulson, the
optimum tube length to shell diameter will usually fall within the range of 5 to 10 m, which 5 m
has been chosen as the length.
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5.2 Process Operation Parameter

Process operation parameters that are crucial to operate the heat exchanger are as followed:
1. Type of fluids used, along with their phase
2. Inlet and outlet temperature of operating fluids
3. Pressure of fluids
5.3 Techno-Economic Analysis

Purchased cost is used as the basis of the factorial method of cost estimation and must be
determined as accurately as possible. Purchased cost of shell-and-tube kettle reboiler is estimated
by using the following equation:
𝐸𝑞𝑢𝑖𝑝𝑚𝑒𝑛𝑡 𝑝𝑢𝑟𝑐ℎ𝑎𝑠𝑒𝑑 𝑐𝑜𝑠𝑡 = (𝑏𝑎𝑟𝑒 𝑐𝑜𝑠𝑡) × 𝑅𝑒𝑏𝑜𝑖𝑙𝑒𝑟 𝑡𝑦𝑝𝑒 𝑓𝑎𝑐𝑡𝑜𝑟 × 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑓𝑎𝑐𝑡𝑜𝑟
Factors considered to determine the purchased cost of shell-and-tube are: bare cost, material
factor, and pressure factor. Bare cost is the cost of material used in designing the reboiler, which
can also be chosen based on the basic material that make up the material used. Reboiler type
factor is determined based on type of reboiler chosen beforehand to carry out the problem.
Pressure factor is used to determine the changes in volume caused by pressure change.
The type factor for kettle type is 1.3 and the pressure factor of the tube is also 1.3. For the total
bare cost, copper-nickel 30% is assumed to have the same price as steel. Therefore, by using
copper-nickel’s density and with the price of $250/ton, the total bare cost is $854,490.
Finally, the equipment purchased cost would be $1,444,088. This could be caused by the use of a
relatively large tube diameter as using smaller tubes would cost less.
6 CONCLUSION
1. From the calculations, operation data obtained are:
 Flow rate of hydrocarbon = 433 kmol/hr with outlet flow saturation temperature 459.26 K.
𝑊
 The total heat transfer coefficient = 1154.09 .
𝑚2 .𝐾
 Heat transfer area needed is 81.38 𝑚2 .

 Pressure drop = 9105.3 Pa.
Page 15 from 29
2. From the calculations, dimension of heat exchanger obtained are:

 Inner diameter of tube = 0.026 m; outer diameter of tube = 0.03 m.
 Inner diameter of shell = 1.471 m; outer diameter of shell = 2.206 m.
 Length of tube & length of shell = 5 m.
𝑊
 Material used = copper-nickel 30% with conductivity of 33.18 .
𝑚.𝐾
 Amount of tubes = 509 pieces.

 Pitch Coefficient = 1.25.
 Bundle Diameter = 0.7354 m.
3. The price of the designed reboiler with the material of copper-nickel 30% is $1,444,088.
7 REFERENCES
Towler, Gavin and Ray Sinnott. 2008. Chemical Engineering Design: Principles, Practice, and
Economics of Plant and Process Design. London: Butterworth- Heinemann.
Sinnott,R.K. 2005. Coulson & Richardson’s Chemical Engineering Design 4𝑡ℎ ed, vol. 6. Oxford:
Elsevier’s Science & Technology Rights Department.
Shah, R. and Seculic, D. 2003. Fundamentals of Heat Exchanger Design. New Jersey: John Wiley &
Sons, Inc.
Heaslip, Bob. 2008. Heat Exchangers.
ICIS. 6 November 2007. Propylene Glycol (PG) Production and Manufacturing Process.
https://www.icis.com/resources/news/2007/11/06/9076444/propylene-glycol-pg-production-and-
manufacturing-process/; Accessed on 6 April 2018.
Dow. 2018. Propylene Glycols for Industrial Applications. https://www.dow.com/en-

us/products/PropyleneGlycol#sort=%40gtitle%20ascending; Accessed on 6 April 2018.
Dow. 2017. The Dow Chemical Company 2016 Annual Report.

http://www.annualreports.com/HostedData/AnnualReports/PDF/NYSE_DOW_2016.pdf;
Accessed on 6 April 2018.
Copper Development Association Inc. 2017. Copper-Nickel Alloys.

https://www.copper.org/applications/marine/cuni/; Accessed on 18 April 2018.
MatWeb Material Property Data. 2018. Copper Nickel 30% UNS C71500.
http://www.matweb.com/search/datasheet.aspx?matguid=1de470e1f95c442990e87658c7b6eb36&
ckck=1; Accessed on 19 April 2018.
Alibaba.com. 2018. Price per Meter Square Steel. https://www.alibaba.com/showroom/price-per-

square-meter-of-steel.html ; Accessed on 20 April 2018.
Page 16 from 29
Appendix A – Physical Flow Data
1. Propylene Glycol Physical Properties

The temperature of propylene glycol is:
 Inlet temperature : 459.26 K
 Outlet temperature : 449.5 K
Physical
Inlet Outlet Mean Dimension
Properties
Density 908.1 3.06 455.58 Kg/m3
Viscosity 0.4474 0.0284 0.2379 mPa.s
Specific heat 3.395 1.988 2.6915 kJ/(kg.K)
Latent heat 726.9 kJ/kg
Thermal
0.1558 0.0237 0.08975 W/(m.K)
conductivity
Molecular weight 75.03 75.03 75.03 g/mol
Saturation
459.26 K
temperature
Critical pressure 63.86594 bar
2. Physical Properties of Steam

The temperature of the steam is:
 Inlet temperature : 571.15 K
 Outlet temperature : 517.241 K
Physical
Inlet Outlet Mean Dimension
Properties
Density 14.38 10.14 12.26 Kg/m3
Viscosity 0.0205 0.018 0.01925 mPa.s
Specific heat 2.695 2.512 2.6035 kJ/(kg.K)
Latent heat 1406 kJ/kg
Page 17 from 29
Thermal
0.1558 0.0237 0.5221 W/(m.K)
conductivity
Molecular weight 75.03 75.03 18 g/mol
Saturation
517.241 K
temperature
Page 18 from 29
Appendix B – Calculation Model
1. Calculation to determine the data properties of Propylene Glycol with Pressure of 0.953 bar
It is known that the Antoine coefficient for Propylene Glycol are as follow:
A = 6.07936
B = 2692.187
C = -17.94
By using the Antoine equation:
𝑏
𝑇𝑠𝑎𝑡 = −𝑐
𝑎 − log(𝑃)
2692.187
𝑇𝑠𝑎𝑡 = − (−17.94)
6.07936 − log(0.953)
𝑇𝑠𝑎𝑡 = 186°𝐶 = 459.26 𝐾
2. Calculation to determine the data properties of Steam with Pressure of 34.9 bar
It is known that the Antoine coefficient for steam (water) are as follow, by assuming that the
temperature range for steam is between 99°C and 374°C:
A = 3.55959
B = 643.748
C = -198.043
By using the Antoine equation:
𝑏
𝑇𝑠𝑎𝑡 = −𝑐
𝑎 − log(𝑃)
643.748
𝑇𝑠𝑎𝑡 = + 198.043
3.55959 − log(34.9)
𝑇𝑠𝑎𝑡 = 517.241 𝐾
3. Calculation to determine Heat Load

𝑄 = 𝑚̇𝑃𝐺 × 𝑐𝑝𝑃𝐺 × ∆𝑇𝑃𝐺 + 𝑚̇𝑃𝐺 × ∆𝐻𝑣𝑎𝑝,𝑃𝐺
𝑄 = 𝑚̇𝑃𝐺 × 𝑐𝑝𝑃𝐺 × (𝑇𝑃𝐺,𝑜𝑢𝑡 − 𝑇𝑃𝐺,𝑖𝑛 ) + 𝑚̇𝑃𝐺 × ∆𝐻𝑣𝑎𝑝,𝑃𝐺
𝑘𝑔 𝑘𝐽 𝑘𝑔 𝑘𝐽
𝑄 = 8.784 × 3.396 × (459.26 − 449.5)𝐾 + 8.784 × 726.9
𝑠 𝑘𝑔. 𝐾 𝑠 𝑘𝑔
𝑄 = 6676.24 𝑘𝑊
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By assuming that there is 5% heat loss,

𝑄𝑙𝑜𝑎𝑑 = 105% × 𝑄
𝑄𝑙𝑜𝑎𝑑 = 105% × 6676.24 𝑘𝑊
𝑄𝑙𝑜𝑎𝑑 = 7010.05 𝑘𝑊
4. Calculation to determine the flow rate of the steam

By using heat balance equation,
𝑄𝑠𝑡𝑒𝑎𝑚 = 𝑄𝑃𝐺
𝑚̇𝑠𝑡𝑒𝑎𝑚 × 𝑐𝑝𝑠𝑡𝑒𝑎𝑚 × ∆𝑇𝑠𝑡𝑒𝑎𝑚 = 𝑚̇𝑃𝐺 × 𝑐𝑝𝑃𝐺 × ∆𝑇𝑃𝐺 + 𝑚̇𝑃𝐺 × ∆𝐻𝑣𝑎𝑝,𝑃𝐺
𝑚̇𝑠𝑡𝑒𝑎𝑚 × 𝑐𝑝𝑠𝑡𝑒𝑎𝑚 × (𝑇𝑠𝑡𝑒𝑎𝑚,𝑜𝑢𝑡 − 𝑇𝑠𝑡𝑒𝑎𝑚,𝑖𝑛 ) = 𝑚̇𝑃𝐺 × 𝑐𝑝𝑃𝐺 × ∆𝑇𝑃𝐺 + 𝑚̇𝑃𝐺 × ∆𝐻𝑣𝑎𝑝,𝑃𝐺
𝑚̇𝑃𝐺 × 𝑐𝑝𝑃𝐺 × (𝑇𝑃𝐺,𝑜𝑢𝑡 − 𝑇𝑃𝐺,𝑖𝑛 ) + 𝑚̇𝑃𝐺 × ∆𝐻𝑣𝑎𝑝,𝑃𝐺
𝑚̇𝑠𝑡𝑒𝑎𝑚 =
𝑐𝑝𝑠𝑡𝑒𝑎𝑚 × (𝑇𝑠𝑡𝑒𝑎𝑚,𝑜𝑢𝑡 − 𝑇𝑠𝑡𝑒𝑎𝑚,𝑖𝑛 )
𝑘𝑔 𝑘𝐽 𝑘𝑔 𝑘𝐽
8.784 × 3.396 𝑘𝑔.𝐾 × (459.26 − 449.5)𝐾 + 8.784 × 726.9 𝑘𝑔
𝑠 𝑠
𝑚̇𝑠𝑡𝑒𝑎𝑚 = 𝑘𝐽
2.695 𝑘𝑔.𝐾 × (571.15 − 517.241)𝐾
𝑘𝑔
𝑚̇𝑠𝑡𝑒𝑎𝑚 = 45.94
𝑠
5. Calculation to determine Log Mean Temperature Difference (∆𝑇𝑙𝑚 )

∆𝑇1 = 𝑇𝑠𝑢𝑝𝑒𝑟ℎ𝑒𝑎𝑡𝑒𝑑 𝑠𝑡𝑒𝑎𝑚 − 𝑇𝑠𝑎𝑡,𝑣𝑎𝑝𝑜𝑟
∆𝑇2 = 𝑇𝑃𝐺(𝑙) − 𝑇𝑃𝐺(𝑔)
By using the equation:
∆𝑇1 − ∆𝑇2
∆𝑇𝑙𝑚 = ∆𝑇
𝑙𝑛 ∆𝑇1
2
(571.95 − 517.241) − (459.26 − 449.75)

∆𝑇𝑙𝑚 = (571.95−517.241)
𝑙𝑛 (459.26−449.75)
∆𝑇𝑙𝑚 = 86.137 𝐾 = 86.137 °𝐶
6. Prediction of Total Heat Transfer Coefficient (𝑈𝑜 )

Based on Table 12.1 from Coulson & Richardson’s “Chemical Engineering Design” 4th Edition,
Uo, predicted is 1000 W/(m2.°C). The predicted value is chosen because the hot fluid is steam,
and cold fluid is light organics with the range between 900-1200 W/(m2.°C).
Page 20 from 29
Source: Coulson, 2005.
7. Calculation to determine the heat transfer area

𝑄𝑙𝑜𝑎𝑑 = 𝑈𝑜,𝑝𝑟𝑒𝑑𝑖𝑐𝑡𝑒𝑑 × 𝐴𝑜 × ∆𝑇𝑙𝑚
𝑄𝑙𝑜𝑎𝑑
𝐴𝑜 =
𝑈𝑜,𝑝𝑟𝑒𝑑𝑖𝑐𝑡𝑒𝑑 × ∆𝑇𝑙𝑚
7010.05 𝑘𝑊
𝐴𝑜 = W
1000 𝑚2 .°C × 86.137 °𝐶
𝐴𝑜 = 81.38 𝑚2
Page 21 from 29
8. Calculation to determine the number of pipes used in heat exchanger
Source: Gavin, 2008.

Based on table above, the values chosen are:
Outside diameter (Do) = 0.03 m
Inner diameter (Di) = 0.026 m
Length = 5 m
Then, calculate the number of pipes used based on the values chosen.
𝐴𝑜
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑝𝑖𝑝𝑒𝑠 (𝑁𝑇 ) =
𝐴𝑜𝑢𝑡𝑒𝑟,𝑐𝑎𝑙𝑐𝑢𝑙𝑎𝑡𝑒𝑑
112.032
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑝𝑖𝑝𝑒𝑠 (𝑁𝑇 ) =
3.14 × 0.03 × 5
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑝𝑖𝑝𝑒𝑠 (𝑁𝑇 ) = 237.860 𝑝𝑖𝑝𝑒𝑠
Calculate the pipe nominal used by assuming that passes used as 2.

𝑁𝑇
𝑁𝑇,𝑛𝑜𝑚𝑖𝑛𝑎𝑙 =
𝑝𝑎𝑠𝑠𝑒𝑠
237.860 𝑝𝑖𝑝𝑒𝑠
𝑁𝑇,𝑛𝑜𝑚𝑖𝑛𝑎𝑙 =
2
𝑁𝑇,𝑛𝑜𝑚𝑖𝑛𝑎𝑙 = 118.390 𝑝𝑖𝑝𝑒𝑠 = 118 𝑝𝑖𝑝𝑒𝑠
9. Calculation of Pitch
𝑃𝑖𝑡𝑐ℎ = 𝑘𝑝𝑖𝑡𝑐ℎ × 𝐷𝑜
𝑃𝑖𝑡𝑐ℎ = 1.25 × 0.03 𝑚
𝑃𝑖𝑡𝑐ℎ = 0.0375 𝑚
Page 22 from 29
10. Calculation to determine Heat Flux

𝑄
𝑞=
𝐴
7010.05 𝑘𝑊
𝑞=
81.38 𝑚2
𝑘𝑊
𝑞 = 86.14 2
𝑚
11. Calculation to determine the heat transfer coefficient by using Mostinski Equation
0.69 0.7
𝑃𝑖𝑛 0.17 𝑃𝑖𝑛 1.2 𝑃𝑖𝑛 10
ℎ = 0.104 . 𝑃𝑐 .𝑞 [1.8 . ( ) +4 ( ) + 10 ( )
𝑃𝑐 𝑃𝑐 𝑃𝑐
0.69 3 0.7
0.953 0.17 0.953 1.2
ℎ = 0.104 × 63.86594 × (86.14 × 10 ) [1.8 × ( ) +4 ( )
63.86594 63.86594
0.953 10
+ 10 ( ) ]
63.86594
𝑊
ℎ = 4727.67
(𝑚2 . 𝐾)
12. Calculation to determine Uo,calculated

By using data:
Category Value Dimension
Fouling Coefficient 3000 W/(m2.K)
Propylene Glycol Fouling W/(m2.K)

5000
Coefficient
Steam Condensing Coefficient 5000 W/(m2.K)
Thermal Conductivity of Wall W/(m.K)

33.18
(Copper-nickel 30%)
Inner Diameter 0.026 M
Outer Diameter 0.030 M
Page 23 from 29
𝑑
1 1 1 𝑑0 𝑙𝑛 𝑑0 𝑑 1 𝑑0 1
𝑖 0
= + + + 𝑥 + 𝑥
𝑈0 ℎ𝑜 ℎ𝑜𝑑 2𝑘𝑤 𝑑𝑖 ℎ𝑖𝑑 𝑑𝑖 ℎ𝑖
0.03
1 1 1 0.03 × 𝑙𝑛 0.026 0.026 1 0.03 1
= + + + 𝑥 + 𝑥
𝑈0 4727.67 5000 2 × 33.18 0.03 3000 0.026 5000
𝑊
𝑈𝑜 = 1154.09
𝑚2 . 𝐾
13. Evaluation of critical heat flux by using Zuber Equation
Category Value Note
Kb 0.44 For square pitch arrangement
2xNt = For U-tubes

Nt,calculated
2𝑥237.860
Vapour Density 14.38 kg/m3
Liquid Density 908.01 kg/m3
𝑡𝑢𝑏𝑒 𝑝𝑖𝑡𝑐ℎ ∆𝐻𝑣𝑎𝑝 𝑃𝐺

𝑞𝑐𝑏 = 𝐾𝑏 ( )( ) [𝜎𝑔(𝜌𝐿 − 𝜌𝑉 )𝜌𝑉 2 ]0.25
𝐷𝑜 𝑡𝑢𝑏𝑒 √𝑁𝑡
0.0375 726.9 × 103

𝑞𝑐𝑏 = 0.44 ( )( ) [0.0181 × 9.81 × (726.9 − 14.38)14.382 ]0.25
0.03 √2 × 237.860
𝑞𝑐𝑏 = 233118.78 𝑊/𝑚2
14. Comparison of Maximum Heat Flux and Critical Heat Flux

𝑞𝑚𝑎𝑥 = 0.7𝑞𝑐𝑏
𝑞𝑚𝑎𝑥 = 0.7(233118.78)
𝑞𝑚𝑎𝑥 = 163183.14 𝑊/𝑚2
Since, 𝑞𝑚𝑎𝑥 < 𝑞𝑐𝑏 the design does not violate assumptions made previously.
Page 24 from 29
15. Calculation of Bundle Diameter of the Tube

1
𝑁𝑇 𝑛1
𝐷𝑏 = 𝐷𝑜 𝑥 ( )
𝐾1
237.860 1
𝐷𝑏 = 0.03 𝑥( )291
0.156
= 0.7354 𝑚
16. Calculation of Ratio Between Bundle Diameter and Shell Diameter

𝐷𝑖,𝑠ℎ𝑒𝑙𝑙 = 2𝐷𝑏
𝐷𝑖,𝑠ℎ𝑒𝑙𝑙 = 1.471 𝑚
17. Surface area of the fluid
𝐴 = 𝑙𝑒𝑛𝑔𝑡ℎ × 𝑤𝑖𝑑𝑡ℎ
Assume: length = 5 m
width = 1.5 m
𝐴 = 5 × 1.5 = 7.5 𝑚2
18. Calculate the flow rate and maximum flow rate of vapor on surface
𝑚̇𝑝𝑟𝑜𝑝𝑦𝑙𝑒𝑛𝑒 𝑔𝑙𝑦𝑐𝑜𝑙
𝑢̂𝑣 =
𝜌𝑝𝑟𝑜𝑝𝑦𝑙𝑒𝑛𝑒 𝑔𝑙𝑦𝑐𝑜𝑙,𝑜𝑢𝑡 × 𝐴𝑠𝑓
8.784 𝑘𝑔/𝑠
𝑢̂𝑣 = = 0.383 𝑚/𝑠
𝑘𝑔
7.5 𝑚2 × 3.06 ⁄𝑚3
𝜌𝑙 − 𝜌𝑣 0.5
𝑢̂𝑣,𝑚𝑎𝑥 = 0.2 × ( )
𝜌𝑣
𝑘𝑔⁄ 𝑘𝑔⁄
908.01 𝑚3 − 14.38 𝑚3 )0.5
𝑢̂𝑣,𝑚𝑎𝑥 = 0.2 × (
𝑘𝑔
14.38 ⁄𝑚3
𝑢̂𝑣,𝑚𝑎𝑥 = 1.577 𝑚/𝑠
Page 25 from 29
19. Calculate the mass flux of the steam
𝐺 = 𝜌𝑠𝑡𝑒𝑎𝑚,𝑖𝑛 × 𝑣
𝑘𝑔⁄ 𝑚 𝑘𝑔⁄
𝐺 = 14.38 𝑚 3 × 0.383 = 5.51 𝑚2 . 𝑠
𝑠
20. Calculation of Reynold’s Number
𝐺 × 𝐷𝑖𝑛,𝑝𝑖𝑝𝑒
𝑁𝑅𝑒 =
𝜇𝑝𝑟𝑜𝑝𝑦𝑙𝑒𝑛𝑒 𝑔𝑙𝑦𝑐𝑜𝑙
𝑘𝑔⁄
5.51 𝑚2 . 𝑠 × 0.026 𝑚 = 320.21 (𝑙𝑎𝑚𝑖𝑛𝑎𝑟)
𝑁𝑅𝑒 =
0.4474 𝑚𝑃𝑎. 𝑠
21. Calculation of Pressure Drop on Tube Side
𝐿𝑡𝑢𝑏𝑒 𝐺2
∆𝑃𝑡 = 𝑁𝑝𝑎𝑠𝑠𝑒𝑠 × [8𝑓 × ( ) + 2.5] ×
𝐷𝑖,𝑡𝑢𝑏𝑒 𝜌𝑠𝑡𝑒𝑎𝑚
5 5.51 2
∆𝑃𝑡 = 2 × [8 × 1.4 × ( ) + 2.5] × = 9105.3 𝑃𝑎
0.026 14.38
Page 26 from 29
Appendix C – Excel Calculation
Page 27 from 29
Appendix D – Flow Diagram Explantion
In a plant producing propylene glycol, there is a production unit consist of distillation column and a
reboiler that is used to separate impurities from the product steam. Thus, the algorithm methodology is
designed to engineer the reboiler.
It is known that the reactor outlet flow contains propylene glycol is unwanted impurities. The bottom
product of the column which temperature, absolute pressure, and flow rate of 176.5°C, 95.4 kPa-abs, and
433 kmol/hour flow, respectively, is boiled with superheated steam. Superheated steam itself has a
property of 298.8°C and 34.9 bar-abs. The composition of bottom product which consist of propylene
glycol, propylene oxide, and water is 98.1359%-mole, 0,0398%-mole, and 1.8243%-mole, respectively.
Steam that comes out of the reboiler is in the form of saturated vapor.
The first step that is conducted is determining the properties of the fluid, which includes: density,
viscosity, thermal conductivity, heat capacity, boiling point of the fluid, latent heat, critical pressure, and
molecular weight. Through the properties determined beforehand, type of heat exchanger/reboiler that
will be used can be determined. For this case, the reboiler tube that is used is shell-and-tube with U-tube -
kettle reboiler type. The tubes are arranged with square alignment and counter current flow.
After determining the reboiler type, the flow rate of steam is calculated based on the heat balance
equation that is supported by heat capacity data and latent heat. Then, log mean temperature difference is
calculated in order to determine the temperature driving force for heat transfer system. Temperatures used
to determine the log mean temperature difference includes temperature of steam both entering and leaving
the reboiler, and temperature of propylene glycol entering and leaving the reboiler.
To determine the dimension of reboiler, inner diameter and outer diameter of the pipe and shell, length of
the pipe and shell, pitch of the pipe, and material used to design the pipe and its conductivity. Predicted
area is then calculated by considering predicted overall coefficient, log mean temperature difference, and
heat. Inner and outer diameter can be chosen from Table 12.3 from Coulson & Richardson’s Chemical
Engineering Design volume 6. Material chosen to design the pipe is copper-nickel 70/30 since its
corrosion resistance is high, and by adding copper to nickel, the strength is increased while letting the
material to remain ductile.
In determining design feasibility, overall coefficient is calculated using Mostinski Equation. The
assumptions include condensing coefficient, fouling coefficient, and propylene glycol fouling coefficient.
It is then followed by calculation of total heat load that could be withheld by reboiler according to
Page 28 from 29
predicted overall coefficient. To determine heat load, it is assumed that during the reaction, there is 5%
heat loss. Design feasibility also considers the diameter of the tube used, number of tubes used, and area
of tubes.
Critical heat flux is then calculated using Zuber’s equation by considering the tube pitch, outer diameter
of tube, enthalpy of propylene glycol, number of tubes used in reboiler, gravity, density of propylene
glycol, and density of steam. The calculated critical heat flux is compared with maximum heat flux
calculated beforehand. If critical heat flux is bigger than those of maximum heat flux, the assumptions are
correct since critical heat flux is used as the maximum heat flux that reboiler can bear. On the other hand,
if the maximum heat flux calculated beforehand is bigger than those of critical heat flux, the assumptions
need to be checked again.
Bundle diameter, inner diameter of the shell that is assumed to be twice of bundle diameter value, length
of fluids from the bottom, and width of fluids from the bottom needs to be evaluated so that the vapor
velocity and maximum allowable vapor velocity can be determined. The value of each is then compared.
If the vapor velocity is much higher than those of maximum allowable vapor velocity, vapor velocity
needs to be re-evaluated by changing assumptions related with each factor affecting the calculation.
Before calculating Reynolds number in order to determine flow regime, and its friction factor
assumptions, calculation of steam mass flux should be done first. After that, pressure drop on tube side
can be calculated by considering factors affecting the number, including number of passes, length of tube,
inner diameter of tube, mass flux and steam density.
Page 29 from 29

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PLANT DESIGN OF REBOILER IN PRODUCING PROPYLENE GLYCOL

TK-2203 HEAT TRANSFER

PLANT DESIGN OF REVOILER IN PRODUCING PROPYLENE GLYCOL

Nasywa Kamilah 13016201

1.2 Process Flow Diagram in Heat Exchanger Process

Figure 1.1 Shell and Tube Kettle Reboiler

1.3 Factory Profile

2 EXCHANGER DESIGN DATA

2.1.2 Composition and Property of Process Fluid

No. Compound Composition (mole-%)

1. Propylene Glycol 98.1359

2. Propylene Oxide 0.0398

Table 2.2 Property of Propylene Glycol at 176.5 ℃

No. Properties Values

2.1.3 Process Fluid Flow Condition

Fluid Rate : 433 kmol/hr

Pressure : 95.3 kPa-abs

2.2 Service Fluid

2.2.2 Composition and Property of Service Fluid

2.2.3 Service Fluid Flow Condition

Pressure : 34.9 bar

The process fluid used is considered as only

The temperature of the shell-side fluid in any

Fluid is assumed to evaporate perfectly on the

4. Mass balance determination System is assumed to have 5% heat loss.

Determination of latent heat of

The material price obtained is based on a

The velocity and temperature at the entrance

Heat exchanger operates under steady state

Determination of wall thermal Wall thermal resistance is distributed

10. Fluid flow determination The fluid flow is counter-current.

Determination of heat exchanger Copper-nickel 30% is used to be the heat

The standard dimensions of copper-nickel

3.2 Design Algorithm

Figure 3.1 Design Algorithm

3.3 Heat Exchanger Type

3.4 Basic Consideration to Selected Heat Exchanger Type

4.2 TEMA Sheet Heat Exchanger

assumption of fouling factor of steam.

5.2 Process Operation Parameter

1. Type of fluids used, along with their phase

2. Inlet and outlet temperature of operating fluids

5.3 Techno-Economic Analysis

 Heat transfer area needed is 81.38 𝑚2 .

2. From the calculations, dimension of heat exchanger obtained are:

 Amount of tubes = 509 pieces.

Heaslip, Bob. 2008. Heat Exchangers.

Dow. 2018. Propylene Glycols for Industrial Applications. https://www.dow.com/en-

Dow. 2017. The Dow Chemical Company 2016 Annual Report.

Copper Development Association Inc. 2017. Copper-Nickel Alloys.

Alibaba.com. 2018. Price per Meter Square Steel. https://www.alibaba.com/showroom/price-per-

Appendix A – Physical Flow Data

1. Propylene Glycol Physical Properties

Density 908.1 3.06 455.58 Kg/m3

Viscosity 0.4474 0.0284 0.2379 mPa.s

Specific heat 3.395 1.988 2.6915 kJ/(kg.K)

Latent heat 726.9 kJ/kg

Molecular weight 75.03 75.03 75.03 g/mol

Critical pressure 63.86594 bar

2. Physical Properties of Steam

Density 14.38 10.14 12.26 Kg/m3

Viscosity 0.0205 0.018 0.01925 mPa.s

Specific heat 2.695 2.512 2.6035 kJ/(kg.K)

Latent heat 1406 kJ/kg