PROJECT REPORT

TITLE: DESIGN OF HEAT

EXCHANGER
Guided by:
Mr. C.V.Ingle
Production Manager
IOCL Refinery, Barauni

Submitted by:
Pratibha Roy
B.Tech 3rd Year, NIT Trichy
Hari Om Choudhary
B.Tech 3rd Year, IIT Roorkee

ACKNOWLEDGEMENT
We would take this opportunity to thank Mr. C.V.Ingle, who
guided and motivated us throughout the project and clarified our
doubts from time to time. We would also like to thank Mr.
P.K.Prabhakar, whose technical expertise was the inspiration for
us and was always very supportive and helpful. Last but not the
least, we would like to thank our family and friends without whose
constant moral support it wouldnt have been possible.

Problem statement:
Design a heat exchanger for preheating the naphtha+hydrogen
feed in the NHDT unit so as to fulfill the following purposes:
Reducing furnace firing
Lessening fuel oil consumption
Efficient usage of the downstream steam in the unit and
improving steam economy

Given data:
Operating Pressure: 52 kg/cm2
Inlet temperature of the cold fluid (Hydrocarbon and Hydrogen
gas mixture):
265 deg cel
Outlet temperature of cold fluid: 275 deg cel
Feed specification:
Hydrogen-7500 kg/hr
Naphtha, cyclohexane, hexane, other c6 isomers 28,000 kg/hr
Total feed flow rate- 35,500 kg/hr
High pressure (HP) steam:
Pressure: 35-36 kg/cm2
Temperature: 340 deg cel
flow rate: 1 ton/hr

Standard data:
Heat capacities:
Naphtha- 2.07 KJ/KgK; Hydrogen- 14.53 KJ/KgK
Superheated steam at 30 bars- 2825 KJ/KgK
Overall heat transfer coefficient for steam-light HC mixture, U=
567.83-1135.66 W/m2degC
Fouling coefficient of naphtha- 5000 W/m2 degC, Steam- 400010000 W/m2 degC
Viscosity of steam-0.18*10^-3 cP

Solution:
The exchanger is designed using Kerns method. Only the thermal
design is considered.
T1=265 deg cel, T2=275 deg cel, t1=340 deg cel
Calculating outlet temperature of steam t2,
Heat lost by steam=heat gained by feed mixture
1000*2825*(340-t2) = 35500*(275265)*(0.8*2.07+0.2*14.53)
Hence t2= 282 deg cel
Now,
R= (T1-T2)/(t2-t1) = 5.8
S= (t2-t1)/(T1-t1) = 0.133
LMTD= 38.68 deg cel
For one shell-two pass heat exchanger

Temperature correction factor,

Ft=[ {(R^2+1)^(1/2) ln (1-S)}/(1-RS)]/ {(R-1) ln(2-S(R+1( R^2+1)^(1/2)}/(2-S(R+1+( R^2+1)^(1/2)}
=0.8
Hence, T=38.68*0.8= 35.5887 deg cel
Taking U value as 600 W/m2C
A= Q/UT = (1000*2825*58)/(600*35.5887)= 680 m2

Fixed tube plate:

1 OD(do)(14BWG) on 1.25 triangular pitch (Pt)
Outer diameter of tube= 1
Tube length(Lt)= 4
Tube ID (di)= 0.834
Number of tubes calculation
Nt= A/3.14*do*Lt
=650
Check for fluid velocity
Re= 4mk(Np/Nt)/3.14*di*u = 11122 > 10000
V= (Re*u)/(density*dia)= 1.68 m/s
Hence its in acceptable range.
Determination of Heat transfer coefficient:
Tube side heat transfer coefficient
Pr = uCp/k= 0.861
(hi*di)/k = jH*Re*Pr^0.33

Where, jH=4*10^(-3)
Substituting values, we get, hi=1179.504 W/m2C
Shell side heat transfer coefficient
For triangular pitch of 1.25
Bundle diameter
Db= do(Nt/K1)^(1/n1)
=1*(650/0.249)^(1/2.207)
{n1 and K1 values are
taken from design charts}
=35.3275= 900 mm
From chart, bundle diameter clearance= 70mm
Shell diameter
Ds =900+70= 970 mm
Baffle spacing=Ds/5=194 mm
Tube pitch= 1.25*1=1.25= 31.75 mm
Cross flow area
As= [(31.75-25.4)*970*194]/31.75
=0.037636 m2
Mass velocity
Gs= 35500/ (3600*0.037636)
= 261.274 kg/s m2
Equivalent diameter
De= 1.10(31.75^2- 0.917*25.4^2)/do
= 18.035 mm
Reynolds number
Re= GsDe/u
= 26178.595
Prandtl number
Pr = uCp/k
(Cp of naphtha-1.2234 kJ/kgK, K0.59)
= 3.732
jH= 1.5*10^(-3)
hs= K*jH*Re*(Pr)^(0.33)/De
= 1983.8
Overall heat transfer coefficient:
1/Uo= 1/hs + 1/hod + do ln (do/di)/2Kw + do/di*hid + do/dihi

= 1/1983.8 + 1/5000 + 25.4 *10^-3 ln (25.4/21.1836)/100 +

25.4/(21.1836*4000) +
25.4/(21.1836*1179.504)
Uo=573 W/m2C
Now, Uo calculated=573, Uo assumed= 600
(600-573)/600=0.045=4.5%
Hence the calculated overall heat transfer coefficient is well
within the design criteria.

References:
1) Chemical Engineering Design, By Coulson and Richardson
2) Heat Exchanger Design Handbook, By T. Kuppan
3) Refinery manuals