COLOSO, Ma. Jinelle V.

ChE511-Equipment Design
5ChE-B November 5, 2017

SHELL AND TUBE HEAT EXCHANGER

INTRODUCTION

One of the most used equipment in every industry and is considered as a necessity
is the Heat Exchanger. It is a device which efficiently transfers heat from one medium to
another, typically between a solid object and a fluid or even between two fluids. The
mediums are separated by a solid wall to prevent direct contact and mixing [1]. Most of
these devices are used to increase the temperature of a compound before it enters
another equipment, for example, a distillation column or a reactor. The most common
heat exchanger application is the car radiator. In this device, a solution of water and
ethylene glycol transfers heat from the engine to the radiator and from the radiator to the
ambient air flowing through it [2].

The heat exchanger consists of a shell, a large vessel and bundle of tubes inside
of the shell. It is designed to allow two fluids of different entering temperatures to flow
through in which one fluid flows on the tube side and the other on the shell side. Heat
transfer is experienced between the fluids either from the shell side to the tube side or
vice versa. Liquids or gases may be used in either the shell side or the tube side [3].

There are several types of heat exchangers found in different industries. The most
common are the shell and tube, plate types, and air cooled heat exchangers [2]. In the
case of KCl recovery from brine wastewater, a shell and tube heat exchanger was used
to bring the brine to a temperature just under boiling in preparation for the deaerator while
also cooling the effluent steam to the liquid state to pump out of the plant as a product
[4].
INPUT CONDITIONS

As mentioned above, a heat exchanger is needed to bring the brine to a

temperature just under boiling in preparation for the deaerator. This is done in the
recovery of KCl from brine wastewater. The goal of this paper is to design a heat
exchanger suitable for the success of the operation. Specifically, 10,000kg/hr of saturated
brine enters the process at approximately -8oC (Exiting temperature: -4OC) and 101.325
KPa, which will become the feed of the heat exchanger. The flowrate of air and type of
flow will be computed using MATHCAD. The pressure and temperature of the inlet air is
at 101.325 KPa and 800C (Exiting temperature of air: 5oC). For most heat exchangers, a
counter current flow is observed.For the type of flow of both fluids are in turbulent flow.
The air flows in the tube side and the saturated brine flows in the shell side of the heat
exchanger. The following assumptions were made for this equipment:

1. There are no heat loss in the external surrounding of the pipe,

2. Neglect the fouling (dirt coefficient) inside the pipes
3. There is no phase change for the two fluids inside the pipe.

FLOW DIAGRAM and MATERIAL BALANCES:

NaCl Brine NaCl Brine

t1 = -4oC T2 = -8oC

Air Air

T2 = 5oC T1 = 80oC
Material Balances:
Heat Transfer Equation: q = UATLM
Heat Balance: (WCpT)air = (WCpT)brine

EQUIPMENT DESIGN THEORETICAL CALCULATIONS

Table 1 shows the properties of brine and air that entered the heat exchanger.
Table 1. Properties of brine and air
Brine (NaCl) Air
Temperature (In-Out), oC -8 to -4 80 to 5
Pressure, KPa 101.325 101.325
Density (kg/m3) 2160 1.1315
Viscosity (Pas) 0.0005408 0.00001904
Thermal Conductivity 0.44 0.0272
Specific Heat 3210.876 1005.6
Flow rate (kg/hr) 10,000 1,703*
*See Appendix A for the calculation.

Table 2 shows the other properties that were computed necessary to complete the
design of the heat exchanger. Calculations of this are seen in Appendix B.
Shell Side Tube Side
Pressure Drop (kPa) 35.837 2.185
Flow Velocity (m/s) 0.112 36.564
Film transfer coefficient
118.158 473.74
(W/m2-K)
Heat Duty (kW) 31.647
Over all heat transfer
17.924
coefficient (W/m2K)
Heat Transfer Area (m2) 48.969
EQUIPMENT SPECIFICATIONS

All calculations for the equipment design is seen in Appendix C. The calculations
were based on Seader and Henley.

Material of Construction

The heat exchanger will be made of carbon steel with tubes, BWG pipes,
constructed from monel, to avoid corrosion due to the brine.

SHELL AND TUBE HEAT EXCHANGER

Function: To bring the brine to a temperature just under boiling in preparation for the
deaerator while also cooling the effluent steam to the liquid state to pump out of the plant
as a product

Design Data:

Design Pressure: 1115000 Pa

Channel cover thickness: 34.906mm

Total length: 2.091m

Minimum number of bolts: 3.539

Shell side:

Corrosion Allowance: 12mm

Maximum diameter: 534.69mm
Thickness: 7.663mm
Tube side:
Material of construction: Monel Tube velocity: 10.228m/s
Maximum Length: 195mm Number of tubes: 420
Outside Diameter: 19.05mm Tube sheet thickness: 43.5831mm
Pitch: Triangular, 23.81mm
*Other calculations such as the nozzle diameter and the design of gaskets are in
Appendix C
RENDERED MODEL

Figure 1Shell and tube heat exchanger

Figure 2 Tubes Arrangement

CONCLUSION AND RECOMMENDATION
A heat exchanger was successfully design to to bring the brine to a temperature
just under boiling in preparation for the deaerator while also cooling the effluent steam to
the liquid state to pump out of the plant as a product. In order to successfully design a
column, knowledge on heat and mass transfer must be mastered.
A double pipe heat exchanger can also be used as a substitute for the process.
REFERENCES

[1] Heat exchanger. (2017, November 02). Retrieved November 05, 2017, from
https://en.wikipedia.org/wiki/Heat_exchanger

[2] How do heat exchangers work? Explain that Stuff, 12 Nov. 2016,
www.explainthatstuff.com/how-heat-exchangers-work.html.

[3] Heatex. (2011). Corrugated Tubular Heat Exchanger. Retrieved from

http://www.heatexchange.nl/media/2637/cthe.pdf
[4] Rempel, Arthur M., et al. MgCl2 and KCl Recovery from Brine
Wastewater. University of Pennsylvania.
McCabe, W. L., Smith, J. C., & Harriot, P. (1993). Unit Operations of Chemical
Engineering: Fifth Edition. New York: McGraw-Hill International Editions.
Perry, R. H. & Green, D. W. (2008). Perrys Chemical Engineers Handbook: 8th
Edition. New York: McGraw-Hill Companies Inc.
TETRA Technologies, Inc. (2010) Materials of Construction. Retrieved from
http://www.tetrachemicalseurope.com/resources/materials_of_construction.aqf
Towler, G. & Sinnot, R. (2008). Chemical Engineering Design Principles, Practice
and Economics of Plant and Process Design. London: Elsevier Inc.
Douglas, James. Conceptual Design of Chemical Processes. McGraw-Hill, Inc.,
1988
APPENDIX A

APPENDIX B
APPENDIX C