Department of Chemical Engineering

University of the Philippines Diliman

Shell-and-Tube Heat Exchanger Design
ChE 133
AY 2014-2015
PDRamoso
! The Design Process (excerpts from ChE 141)
! Shell-and-Tube Heat Exchanger Design
! General methodology
! Rules of thumb
! Sample: ChE 142 Final Presentation
2
Why are chemical engineers consistently one
of the highest paid engineering professions?
A vaguely
dened
problem
statement
important
underlying,
relevant
physical
science
plan of action
and set of
detailed
specications
Predicted
nancial
outcome
PERCEIVE UNDERSTAND
CREATE RETURNS
*Slide from ChE 141 lectures of R. de Leon
General Chemical Process
4
Raw Material
Storage
Feed
Preparation
Reaction
Product
Separation
Product
Purication
Product
Storage
*Slide from ChE 141 lectures of R. de Leon
Preliminary Process Synthesis
Continuous
or
Batch?
Raw Material
and Product
Specication?
Assembling
Process
Congurations
*Slide from ChE 141 lectures of R. de Leon
Continuous or Batch?
! Low production rates
(pharmaceuticals,
electronics)
! Intermittent product
demand (quantity and
timing)
! For reliability
! Process involves
hazardous or toxic
chemicals
! Low-quantity multi-
product operations
! Can operate closer to
optimal
! More efficient
! For operations that
involve long start-up
times (e.g., coal power
plants)
! Continuous large
demand
! CONTINUOUS
! BATCH
*Slide from ChE 141 lectures of R. de Leon
Raw Material and Product Specification
Other properties that
may be required:
! Intrinsic viscosity
! Average molecular
weight
! Color
! Odor
Specify values for the
following:
1. Mass (flow rate)
2. Composition (mole or
mass fraction of each
chemical specie)
3. Phase (solid, liquid or
gas)
4. Form (e.g. particle
size distribution,
particle shape)
5. Temperature
6. Pressure
*Slide from ChE 141 lectures of R. de Leon
Objective of each process operation
Raw Material
Product
Progressive reduction of
property di"erences between
raw material and product
*Slide from ChE 141 lectures of R. de Leon
Process Operations
BASIC PROCESS
OPERATIONS
! Chemical reaction
! Separation of chemicals
! Phase separation
! Change of Temperature
! Change of Pressure
! Change of Phase
! Mixing and splitting of
streams or batches
PURPOSE
To eliminate differences in..
! Molecular structure
! Composition
! Phase
! Temperature
! Pressure
! Phase
! To distribute chemicals or
streams
*Slide from ChE 141 lectures of R. de Leon
Example: Process Synthesis of Vinyl
Chloride Manufacture
! Preliminary Synthesis (an example from Seider)
*Slide from ChE 141 lectures of R. de Leon
Problem Statement
! An opportunity has arisen to satisfy a new demand
for vinyl chloride monomer, on the order of 800
million pounds per year, in a petrochemical
complex on the Gulf Coast, given that an existing
plant owned by the company produces 1 billion
pounds per year of this commodity chemical.
Because vinyl chloride is an extremely toxic
substance, it is recommended that all new facilities
be designed carefully to satisfy governmental
health and safety regulations.
*Slide from ChE 141 lectures of R. de Leon
Step 1: Eliminate differences in molecular type
! Reaction pathway selection and reaction system synthesis
12
Direct
chlorination
Pyrolysis
C
2
H
4
+ Cl
2
"C
2
H
4
Cl
2
C
2
H
4
Cl
2
"C
2
H
3
Cl

+ HCl

C
2
H
4
Cl
2
HCl
C
2
H
3
Cl
C
2
H
4
Cl
2
Cl
2

113,400 lb/h

C
2
H
4

44,900 lb/h

HCl
58,300 lb/h
C
2
H
3
Cl
100,000 lb/h
*Slide from ChE 141 lectures of R. de Leon
Step 2: Distribute the chemicals
! Match sources and sinks
! Select process conditions
13
Direct
chlorination
Pyrolysis
C
2
H
4
+ Cl
2
"C
2
H
4
Cl
2
C
2
H
4
Cl
2
"C
2
H
3
Cl

+ HCl

C
2
H
4
Cl
2

158,300 lb/h

HCl
C
2
H
3
Cl
C
2
H
4
Cl
2
Cl
2

113,400 lb/h

C
2
H
4

44,900 lb/h

HCl
58,300 lb/h
C
2
H
3
Cl
100,000 lb/h
C
2
H
4
Cl
2
105,500 lb/h
Heat absorbed
52 x 10
6
Btu/h

Heat liberated
150 x 10
6
Btu/h

1
2
3
*Slide from ChE 141 lectures of R. de Leon
Step 3: Eliminate differences in
composition
! Separation and purication steps
! ChE 123/132 and 133
14
Direct
Chlorination
90
o
C, 1.5 atm
Pyrolysis
500oC
26 atm
C
2
H
4
Cl
2
158,300 lb/h
Cl
2

113,400 lb/h

C
2
H
4

44,900 lb/h

112
o
C

Heat absorbed
52 x 10
6
Btu/h

Heat liberated
150 x 10
6
Btu/h

100,000 lb/h C
2
H
3
Cl

105,500 lb/h C
2
H
4
Cl
2
HCl
58,300 lb/h
C
2
H
3
Cl
100,000 lb/h
C
2
H
4
Cl
2
105,500 lb/h
-26.2
o
C

33
o
C

Liquid
b.p.
6
o
C

93
o
C

146
o
C

1
*Slide from ChE 141 lectures of R. de Leon
Step 4: Eliminate differences in T, P, phase
! ChE 133 and ChE 134, ChE 12x
! With the states of each stream fixed, operations are inserted
to eliminate T, P and phase differences between feed
sources and product sinks.
! Study each of the feeds and output streams from reaction
and separation operations.
15
*Slide from ChE 141 lectures of R. de Leon
Adjustments that need to be done
! Liquid dichloroethane from the mixer is at 112
o
C and 1.5
atm.
! Its T and P will need to be adusted to the pyrolysis
conditions
! It will have to be in the vapor state.
! Hot vapor effluent from the pyrolysis operation needs to
be adjusted to conditions of the feed to the first tower:
! T and P need to be lowered to dew point at 26 atm
! Vapor mixture needs to be condensed by lowering P, cooling
and removing latent heat of condensation.
STEP 4: Eliminate Differences in T, P and phase
*Slide from ChE 141 lectures of R. de Leon
17
T
Phase
change
6
o
C
12 atm

170
o
C
26 atm

112
o
C
26 atm

P
Phase
change
T T
112
o
C
1.5 atm

242
o
C
26 atm

500
o
C
26 atm

112
o
C
26 atm

Direct
Chlorination
90
o
C, 1.5 atm
Pyrolysis
500
o
C
26 atm
C
2
H
4
Cl
2
158,300 lb/h
Cl
2

113,400 lb/h

C
2
H
4

44,900 lb/h

Heat absorbed
52 x 10
6
Btu/h

Heat liberated
150 x 10
6
Btu/h

100,000 lb/h C
2
H
3
Cl

105,500 lb/h C
2
H
4
Cl
2
HCl
58,300 lb/h
C
2
H
3
Cl
100,000 lb/h
C
2
H
4
Cl
2
105,500 lb/h
-26.2
o
C

33
o
C

93
o
C

146
o
C

242
o
C
26 atm

*Slide from ChE 141 lectures of R. de Leon
Step 5: Task Integration
18
Evaporator
Pump
Spray Quench Tank
Condenser
Condenser
Cooler
*Slide from ChE 141 lectures of R. de Leon
Example
! Philippine Mango Wine and Puree Production Plant in the
Philippines
! A. Chua, A.J. Repollo, K.N. Tejada, M.L. Baynosa, J.T.
Adolacion
! Best Plant Design Presentation, ChE Undergraduate Research
and Plant Design Colloquium 2012
! link to le
19
Design Project
! Submit 2-3 topics for your design project
! Find from process ow diagrams/owsheets, journals,
patents, industry websites
! Dont use textbook examples/illustrations!
! Dont use old Plant Design reports
! Industrial/plant scale
! Per topic, answer the following:
! What is the uid to be heated/cooled? (a.k.a. process uid)
! What is the heating/cooling uid? (no phase change)
! Flowrates, terminal temperatures
! Submit hardcopy on Friday
! Attach references
Department of Chemical Engineering
University of the Philippines-Diliman
Shell-and-Tube Heat Exchanger
Design
21
STHE Design Process
22
Preliminary Steps
23
# Process uid, heating/cooling uid, and which goes where
# Temperatures and owrates
# Density, viscosity, specic heat, thermal conductivity at
the system T (and P)
# Rules of thumb
# Log-Mean Temperature Di"erence
# Area required (initial value)
Preliminary Steps
24
Preliminary Steps
25
Preliminary Steps
26
Design methodology
27
Heat exchanger layout
! Diameter: use recommended range of velocities
28
Pressure drop
29
30
Example
! link to le
31
Homework
! Read Towler: Chapter 12
! Until Example 12.3
! Follow and repeat the calculations shown
32
By now, you should have learned:
Summary
# How heat exchanger design is related to the overall process
and plant design methodology
# How the shell-and-tube heat exchanger (STHE) is designed
based on given process requirements
# What are the preliminary calculations that need to be done
# What are the typical range of velocities and pressure drop that
are allowable in STHE designs
# How the design methodology becomes iterative
Questions?
34