GAZI UNIVERSITY

DEPARTMENT OF CHEMICAL ENGINEERING

CHE451 CHEMICAL ENGINEERING DESIGN I

Assoc. Prof. Dr. Hüseyin ARBAĞ

Asst. Hale AKANSU
2020-2021 Fall Semester

ASSIGNMENT II

HEAT EXCHANGER DESIGN

TEAM B

131145085 - Elif Döndü ŞENGÜN

151140061 - Ayşe Ebrar MÜYESSEROĞLU
151140080 - Ogün TAŞTAN
161140007 - İrem Nur AYDOĞAN
171140080 - Zeynep Cansu ULUTAŞ
171140750 - Hazal DENİZ

DUE DATE: 02.12.2020

DECEMBER 2020

ANKARA
ABSTRACT

This report is about the design of a heat exchanger for cooling ethanol 77℃ to 40℃ with a flow
rate of 16 kg/sec. We made a detailed study for ℎ𝑖, ℎ𝑜 values, number of tubes and proper U
calculation, which are part of the heat exchanger design. We carefully decided on the main
factors such as tube type, tube placement, flow pattern.
Our first step was to choose the area where the heat exchanger will be installed and to
investigate with which source it will be cooled. For this, we did literature and internet research.
Then we chose 304 stainless steel for our material, considering the thermal conductivity and
production possibilities. We deduced that the triangular arrangement is more advantageous
since our material is a small amount of contaminants. We determined the pressure drops and
made the necessary calculations and moved to the economic research step.
In this step, we interviewed local companies one on one and made a cost information research.
We determined the appropriate value by comparing the prices we obtained and our tube
calculations in the excel file. Safety factor was our priority in all steps of our operations and the
stages we made our choices.
We created the CHEMCAD drawings in accordance with our flow chart. Care was taken to
proceed in accordance with the working plan at each stage of the design, and each step was
noted and included in this report.
Finaly in this design work we design a 7.32 m shell and tube heat exchanger which have a 384
tubes. The type of this heat exchanger is countercurrent flow and one shell pass-one tube pass.
We cooled down to ethanol with a cooling water which has a flow rate of 28 kg/sec. Water inlet
temperature is 25℃ and outlet temperature is 40 ℃. For this design total capital investment
calculated as 557 000 TL and total annual cost calculated as 212 000 TL/year.

i
 TABLE OF CONTENTS
ABSTRACT ........................................................................................................................... i

LIST OF FIGURES .............................................................................................................. iv

LIST OF TABLES .................................................................................................................v

SYMBOLS ........................................................................................................................... vi

WORKING PLAN ............................................................................................................. viii

1. INTRODUCTION ..........................................................................................................1

2. THEORETICAL INFORMATION .................................................................................2

2.1. Basic Theory of Heat Transfer in Exchangers ..............................................................2

2.1.1. Conduction............................................................................................................2

2.1.2. Convection ............................................................................................................2

2.1.3. Radiation...............................................................................................................3

2.1.4. Overall Heat-Transfer Coefficient .........................................................................3

2.1.5. Fouling Factors .....................................................................................................6

2.2. Selection for Heat Exchanger Type ..............................................................................6

2.2.2. Heat Exchangers Standarts and Codes ...................................................................9

2.2.3. Heat Exchanger Tubes...........................................................................................9

2.2.4. Tube Arrangements ...............................................................................................9

2.2.5. Shells .................................................................................................................. 10

2.2.6. Baffles ................................................................................................................ 11

3. DESIGN CHOICES ......................................................................................................... 14

3.1. Heat Exchanger Type ................................................................................................. 14

3.2. Material of construction.......................................................................................... 14

3.3. Flow Type .............................................................................................................. 14

3.4. Flow Allocation......................................................................................................15

3.5. Tube Pattern ...........................................................................................................15

3.6. Baffle ..................................................................................................................... 16

ii
4. METHOD OF CALCUALTIONS ................................................................................ 17

4.2. Method of Calculation for Heat Exchanger ............................................................. 17

4.3. Method of Calculation for Cost Analysis ................................................................ 19

5. SAMPLE CALCULATIONS........................................................................................ 20

5.2. Sample Heat Exchanger Calculation ....................................................................... 20

5.3. Sample Cost Calculation......................................................................................... 23

6. RESULTS .................................................................................................................... 25

7. DISCUSSION............................................................................................................... 30

8. CONCLUSIONS ..........................................................................................................31

9. RECOMMENDATIONS .............................................................................................. 32

REFERENCES ..................................................................................................................... 33

APPENDICES...................................................................................................................... 34

APPENDICE 1 – Fluid Allocation Information ................................................................ 34

APPENDICE 2 – Material Safety Data Sheet For Ethanol ................................................ 35

iii
 LIST OF FIGURES

Figure-1 Overall Heat Transfer Coefficients [2] ......................................................................5

Figure-2 Concentric tube heat exchangers. (a) Parallel flow. (b) Counterflow [5] ..................7

Figure-3 Cross-flow heat exchangers. (a) Finned with both fluids unmixed. (b) Unfinned with

one fluid mixed and the other unmixed. [5].............................................................................7

Figure-4 Shell and tube heat exchanger with one shell pass an done tube pass [5] ...................8

Figure-5 Shell and tube heat exchanger with one shell pass an two tube pass [5] ....................8

Figure-6 Tube patterns [3] .................................................................................................... 10

Figure-7 Shell-bundle clearance [3] ...................................................................................... 11

Figure-8 Types of baffle used in shell and tube heat exchangers. (a) Segmental (b) Segmental

and strip (c) Disc and doughnut (d) Orifice [3]......................................................................11

Figure-9 Temperature profile for parallel flow (a) and countercurrent flow (b) type [2] ........ 14

Figure-10 Flow Diagram for Our Process .............................................................................16

Figure-11 flow diagram from CHEMCAD simulation .......................................................... 26

Figure-12 The effect of water outlet temperature on TAC and Utilities ................................. 29

Figure-13 The effect of items on Total Annual Cost ............................................................. 29

Figure-14 Fluid Allocation information from Timmerhause 5th edition page:660 [2] .............34

iv
 LIST OF TABLES

Table-1 Typical overall heat transfer coefficients [2] ..............................................................4

Table-2 Fouling Factors Typical Values [3] ............................................................................6

Table-3 Standard dimensions for steel tubes [3] ......................................................................9

Table-4 Minimum shell thickness [3].................................................................................... 10

Table-5 Some items effect on flow allocation ....................................................................... 15

Table-6 Results for type (1-1) heat exchanger ....................................................................... 25

Table-7 Detailed calculation for different water outlet temperatures ..................................... 26

Table-8 CHEMCAD simulation results ................................................................................ 27

Table-9 Calculated results for heat exchanger by CHEMCAD .............................................. 28

Table-10 Results of cost analysis for (1-1) type heat exchanger ............................................ 28

v
 SYMBOLS
A heat transfer area, m2
B distance between baffles, m
c net distance between heat exchanger tubes, m
Cpethanol heat capacity of ethanol, J /kg.K
Cpwater heat capacity of water, J /kg.K
d diameter,m
𝑑𝐿𝑀 logarithmic mean diameter,m
Di inside diameter of tube, m
Do outside diameter of tube, m
Ds shell diameter, m
F logarithmic mean temperature difference correction factor
G mass flux, kg/𝑚2 -s
hdi fouling coefficient of inside, W/m2.K
hdo fouling coefficient of outside , W/m2.K
hi heat transfer coefficient in the tube side , W/m2.K
ho heat transfer coefficient in shell side , W/m2.K
kethanol thermal conductivity of ethanol, W/m.K
kwater thermal conductivity of water, W/m.K
kw thermal conductivity of wall, W/m.K
L length
Lb baffle spacing
methanol mass flow rate of ethanol, kg/s
mwater mass flow rate of water , kg/s
n number of heat exchanger tube side passes
N number of tube
Nu Nusselt number
p net distance between the centers of the heat exchanger tubes ,m
Pr Prandtl number
Q heat duty, J/s
Re Reynolds number
𝑆𝑐 cross-sectional area, 𝑚2
𝑇𝑐𝑎 inlet temperature of water, ℃
𝑇𝑐𝑏 outlet temperature of water, ℃
vi
𝑇ℎ𝑎 ethanol inlet temperature, ℃

𝑇ℎ𝑏 outlet temperature of ethanol, ℃

u velocity of fluid, m/s

Uo overall heat transfer coefficient of outside, W/m2.K
xw wall thickness of tube, m
Δ difference

TLM temperature approach, K

ethanol viscosity of ethanol, Pa.s
water viscosity of water, Pa.s
ethanol density of ethanol, kg /m3
water density of water kg /m3

vii
 WORKING PLAN
Objective: Heat Exchanger Design

Team Leader: İrem Nur AYDOĞAN

Task # Description Time Responsible

1 Searching about All Team Members
properties of ethanol 12.11.2020/15.11.2020
Basic theory of heat Ayşe Ebrar
2 transfer 12.11.2020/15.11.2020 Müyesseroğlu
Features of heat Ayşe Ebrar
3 exchangers and 15.11.2020/29.11.2020 Müyesseroğlu
selection of heat
exchanger
Selection of İrem Nur Aydoğan
4 equipments and 16.11.2020/17.11.2020
materials
Create a flow 17.11.2020/18.11.2020 Ayşe Ebrar
diagram Müyesseroğlu
5

All heat exchanger Zeynep Cansu

calculations 18.11.2020/19.11.2020 Ulutaş
& Ogün Taştan
6
Cost analysis and
7 calculations 20.11.2020/24.11.2020 Hazal Deniz
8 Ogün Taştan &
CHEMCAD 25.11.2020/28.11.2020 Zeynep Cansu
Ulutaş

Recommendations
for design & MSDS 25.11.2020/29.11.2020 Elif Döndü Şengün
for ethanol
9
10 Generate report 25.11.2020/26.11.2020 All Team Members
content
11 Editing and 26.11.2020/30.11/2020 Zeynep Cansu
combining of the Ulutaş
report

viii
 1. INTRODUCTION
A heat exchanger is a device that is used to transfer thermal energy (enthalpy) between two or
more fluids, between a solid surface and a fluid, or between solid particulates and a fluid, at
different temperatures and in thermal contact. In heat exchangers, there are usually no external
heat and work interactions. Typical applications involve heating or cooling of a fluid stream of
concern and evaporation or condensation of single- or multicomponent fluid streams. In other
applications, the objective may be to recover or reject heat, or sterilize, pasteurize, fractionate,
distill, concentrate, crystallize, or control a process fluid. In a few heat exchangers, the fluids
exchanging heat are in direct contact. In most heat exchangers, heat transfer between fluids
takes place through a separating wall or into and out of a wall in a transient manner. In many
heat exchangers, the fluids are separated by a heat transfer surface, and ideally they do not mix
or leak. Such exchangers are referred to as direct transfer type, or simply recuperators. In
contrast, exchangers in which there is intermittent heat exchange between the hot and cold
fluids—via thermal energy storage and release through the exchanger surface or matrix— are
referred to as indirect transfer type, or simply regenerators. Such exchangers usually have fluid
leakage from one fluid stream to the other, due to pressure differences and matrix rotation/valve
switching. Common examples of heat exchangers are shell-andtube exchangers, automobile
radiators, condensers, evaporators, air preheaters, and cooling towers. If no phase change occurs
in any of the fluids in the exchanger, it is sometimes referred to as a sensible heat exchanger.
There could be internal thermal energy sources in the exchangers, such as in electric heaters
and nuclear fuel elements. Combustion and chemical reaction may take place within the
exchanger, such as in boilers, fired heaters, and fluidized-bed exchangers. Mechanical devices
may be used in some exchangers such as in scraped surface exchangers, agitated vessels, and
stirred tank reactors. Heat transfer in the separating wall of a recuperator generally takes place
by conduction. However, in a heat pipe heat exchanger, the heat pipe not only acts as a
separating wall, but also facilitates the transfer of heat by condensation, evaporation, and
conduction of the working fluid inside the heat pipe. In general, if the fluids are immiscible, the
separating wall may be eliminated, and the interface between the fluids replaces a heat transfer
surface, as in a direct-contact heat exchanger. [1]

1
 2. THEORETICAL INFORMATION
2.1. Basic Theory of Heat Transfer in Exchangers
Heat can be transferred from a source to a receiver by conduction, convection, or radiation. In
many cases, the exchange occurs by a combination of two or three of these mechanisms. When
the rate of heat transfer remains constant and is unaffected by time,flow of heat is designated
as being in a steady state; an unsteady state exists when the rate of heat transfer at any point
varies with time. Most industrial operations in which heat transfer is involved are assumed to
be operating under steady-state conditions even though such processes may encounter
unsteady-state conditions during startup, cooldown, and surge conditions. On the other hand,
unsteady-state conditions are encountered in batch processes, cooling and heating of materials
such as metals, polymers, or glasses, and certain types ofregeneration, curing, or activation
processes.[2]
2.1.1. Conduction
Fourier’s law is the fundamental differential equation for heat transfer by conduction:

𝑑𝑄 𝑑𝑡
= −𝑘𝐴 𝑑𝑥 (equation-i)
𝑑𝜃

where dQ/dθ (quantity per unit time) is the rate of flow of heat, A is the area at right angles to
the direction in which the heat flows, and −dt/dx is the rate of change of temperature with the
distance in the direction of the flow of heat, i.e., the temperature gradient. The factor k is called
the thermal conductivity; it is a characteristic property of the material through which the heat
is flowing and varies with temperature. [4]

2.1.2. Convection
Convection heat transfer is the transfer of energy by the mass movement of groups of molecules.
It is restricted to liquids and gases, as mass molecular movement does not occur at an
appreciable speed in solids. It cannot be mathematically predicted as easily as can transfer by
conduction or radiation and so its study is largely based on experimental results rather than on
theory. The most satisfactory convection heat transfer formulae are relationships between
dimensionless groups of physical quantities. Furthermore, since the laws of molecular transport
govern both heat flow and viscosity, convection heat transfer and fluid friction are closely
related to each other.

2
𝑞 = ℎ𝐴(𝑇𝑤 − 𝑇∞ ) (equation-ii)

The quantity h is called the convection heat transfer coefficient. [5]

2.1.3. Radiation
Radiation heat transfer is the transfer of heat energy by electromagnetic radiation. Radiation
operates independently of the medium through which it occurs and depends upon the relative
temperatures, geometric arrangements and surface structures of the materials that are emitting
or absorbing heat.

The calculation of radiant heat transfer rates, in detail, is beyond the scope of this book and for
most food processing operations a simplified treatment is sufficient to estimate radiant heat
effects. Radiation can be significant with small temperature differences as, for example, in
freeze drying and in cold stores, but it is generally more important where the temperature
differences are greater.

The basic formula for radiant-heat transfer is the Stefan-Boltzmann Law:

𝑞 = 𝐴𝜎𝑇 4 (equation-iii)

where T is the absolute temperature şn degrees Kelvin (K) in the SI system, and σ is the
Stefan Boltzmann constant = 5.73 x 10−8 J 𝑚−2 𝑠 −1 𝐾 −4 .

2.1.4. Overall Heat-Transfer Coefficient

The general equation for heat transfer across a surface is:

𝑄 = 𝑈𝐴∆ 𝑇𝑀 (equation-iv)

Where;
Q = heat transferred per unit time, W,
U = the overall heat transfer coefficient, W/m2 °C,
A = heat-transfer area, m2,
ΔTm = the mean temperature difference, the temperature driving force, °C.

The prime objective in the design of an exchanger is to determine the surface area required for
the specified duty (rate of heat transfer) using the temperature differences available. Typical
values of the overall heat-transfer coefficient values for various types of heat exchanger are
given in Table-1 and also can find from Figure-1.

3
Table-1 Typical overall heat transfer coefficients [2]

4
Table-1 Continued…

Figure-1 Overall Heat Transfer Coefficients [2]

5
2.1.5. Fouling Factors
Most process and service fluids will foul the heat-transfer surfaces in an exchanger to a greater
or lesser extent. The deposited material will normally have a relatively low thermal conductivity
and will reduce the overall coefficient. It is therefore necessary to oversize an exchanger to
allow for the reduction in performance during operation. Fouling factors are usually quoted as
heat-transfer resistances, rather than coefficients. They are difficult to predict and are usually
based on past experience. Fouling factors can be determined from Table-2 for different fluids.

Table-2 Fouling Factors Typical Values [3]

The selection of the design fouling coefficient will often be an economic decision. The optimum
design will be obtained by balancing the extra capital cost of a larger exchanger against the
savings in operating cost obtained from the longer operating time between cleaning that the
larger area will give. Duplicate exchangers should be considered for severely fouling
systems.[3]

2.2. Selection for Heat Exchanger Type

The selection process normally includes a number of factors, all of which are related to the
heat-transfer application. These factors include, but are not limited to, the following items:
1. Thermal and hydraulic requirements
2. Material compatibility
3. Operational maintenance
4. Environmental, health, and safety considerations and regulations
5. Availability
6. Cost [2]

6
Different heat transfer applications require different types of hardware and different
configurations of heat transfer equipment. One fluid in a double-pipe heat exchanger flows
through the smaller pipe while the other fluid flows through the annular space between the two
pipes. Two types of flow arrangement are possible in a double-pipe heat exchanger: in parallel
flow (in figure-2 (a)), both the hot and cold fluids enter the heat exchanger at the same end and
move in the same direction. In counter flow (in figure-2 (b)), on the other hand, the hot and cold
fluids enter the heat exchanger at opposite ends and flow in opposite directions. Another type
for heat exchanger is cross flow heat exchanger, whic is shown in Figure-3.

Figure-2 Concentric tube heat exchangers. (a) Parallel flow. (b) Counterflow [5]

Figure-3 Cross-flow heat exchangers. (a) Finned with both fluids unmixed. (b)
Unfinned with one fluid mixed and the other unmixed. [5]

7
2.2.1. Shell and Tube Heat Exchangers

The shell and tube exchanger is by far the most commonly used type of heat-transfer
equipment used in the chemical and allied industries. (1-1) type heat exchanger shown In
figure-4 and (1-2) type heat exchanger shown in figure-5. The advantages of this type are:
[Link] configuration gives a large surface area in a small volume.
2. Good mechanical layout: a good shape for pressure operation.
3. Uses well-established fabrication techniques.
4. Can be constructed from a wide range of materials.
5. Easily cleaned.
6. Well-established design procedures.

Figure-4 Shell and tube heat exchanger with one shell pass an done tube pass [5]

Figure-5 Shell and tube heat exchanger with one shell pass an two tube pass [5]

8
2.2.2. Heat Exchangers Standarts and Codes
The mechanical design features, fabrication, materials of construction, and testing of shell and
tube exchangers is covered by British Standard, BS 3274. The standards of the American
Tubular Heat Exchanger Manufacturers Association, the TEMA standards, are also universally
used. The TEMA standards cover three classes of exchanger: class R covers exchangers for the
generally severe duties of the petroleum and related industries; class C covers exchangers for
moderate duties in commercial and general process applications; and class B covers exchangers
for use in the chemical process industries.[3]

2.2.3. Heat Exchanger Tubes

5 5
Tube diameters in the range 8 in. (16 mm) to 2 in. (50 mm) are used. The smaller diameters 8

to 1 in. (16 to 25 mm) are preferred for most duties, as they will give more compact, and
therefore cheaper, exchangers. Larger tubes are easier to clean by mechanical methods and
would be selected for heavily fouling fluids. The tube thickness (gauge) is selected to
withstand the internal pressure and give an adequate corrosion allowance. Standard diameters
and wall thicknesses for steel tubes are given in Table-3. [3]

Table-3 Standard dimensions for steel tubes [3]

The preferred lengths of tubes for heat exchangers are: 6 ft. (1.83 m), 8 ft (2.44 m), 12 ft (3.66
m), 16 ft (4.88 m) 20 ft (6.10 m), 24 ft (7.32 m). For a given surface area, the use of longer
tubes will reduce the shell diameter; which will generally result in a lower cost exchanger,
particularly for high shell pressures. The optimum tube length to shell diameter will usually fall
within the range of 5 to 10. [3]

2.2.4. Tube Arrangements

The tubes in an exchanger are usually arranged in an equilateral triangular, square, or rotated
square pattern. (Figure-6)
The triangular and rotated square patterns give higher heat-transfer rates, but at the expense
of a higher pressure drop than the square pattern. A square, or rotated square arrangement, is

9
used for heavily fouling fluids, where it is necessary to mechanically clean the outside of the
tubes. The recommended tube pitch (distance between tube centres) is 1.25 times the tube
outside diameter; and this will normally be used unless process requirements dictate
otherwise. Where a square pattern is used for ease of cleaning, the recommended minimum
clearance between the tubes is 0.25 in. (6.4 mm). [3]

Figure-6 Tube patterns [3]

2.2.5. Shells
The British standard BS 3274 covers exchangers from 6 in. (150 mm) to 42 in. (1067 mm)
diameter; and the TEMA standards, exchangers up to 60 in. (1520 mm). Up to about 24 in.
(610 mm) shells are normally constructed from standard, close tolerance, pipe; above 24 in.
(610 mm) they are rolled from plate. Minimum Shell thickness for carbon steel and alloy
steel is shown in Table-4. [3]

Table-4 Minimum shell thickness [3]

The shell diameter must be selected to give as close a fit to the tube bundle as is practical;
to reduce bypassing round the outside of the bundle. The clearance required between the
outermost tubes in the bundle and the shell inside diameter will depend on the type of
exchanger and the manufacturing tolerances; typical values are given in Figure-7. [3]

10
 Figure-7 Shell-bundle clearance [3]

2.2.6. Baffles
Baffles are used in the shell to direct the fluid stream across the tubes, to increase the fluid
velocity and so improve the rate of transfer. The most commonly used type of baffle is the
singlesegmental baffle shown in Figure-8(a), other types are shown in Figures-8(b),(c),(d).
The term “baffle cut” is used to specify the dimensions of a segmental baffle. The baffle cut is
the height of the segment removed to form the baffle, expressed as a percentage of the baffle
disc diameter. Baffle cuts from 15 to 45 per cent are used. Generally, a baffle cut of 20 to 25
per cent will be the optimum, giving good heat-transfer rates, without excessive drop. There
will be some leakage of fluid round the baffle as a clearance must be allowed for assembly. [3]

Figure-8 Types of baffle used in shell and tube heat exchangers. (a) Segmental (b) Segmental
and strip (c) Disc and doughnut (d) Orifice [3]

11
2.3. Heat Exchanger Design

Design is an activity aimed at providing complete descriptions of an engineering system,

part of a system, or just of a single system component. These descriptions represent an
unambiguous specification of the system/component structure, size, and performance, as
well as other characteristics important for subsequent manufacturing and utilization.
This can be accomplished using a well-defined design methodology.
Lifecycle design assumes considerations organized in the following stages.
• Problem formulation (including interaction with a consumer)
• Concept development (selection of workable designs, preliminary design)
• Detailed exchanger design (design calculations and other pertinent considerations)
• Manufacturing
• Utilization considerations (operation, phase-out, disposal) [1].

The proper use of basic heat-transfer knowledge in the design of practical heat-transfer
equipment is an art. Designers must be constantly aware of the differences between the
idealized conditions for and under which the basic knowledge was obtained and the real
conditions of the mechanical expression of their design and its environment. The result must
satisfy process and operational requirements (such as availability, flexibility, and
maintainability) and do so economically. An important part of any design process is to consider
and offset the consequences of error in the basic knowledge, in its subsequent incorporation
into a design method, in the translation of design into equipment, or in the operation of the
equipment and the process. Heat-exchanger design is not a highly accurate art under the best of
conditions.

The design of a process heat exchanger usually proceeds through the following steps [4]:

1. Process conditions (stream compositions, flow rates, temperatures, pressures) must be

specified.

2. Required physical properties over the temperature and pressure ranges of interest must be
obtained.

3. The type of heat exchanger to be employed is chosen.

4. A preliminary estimate of the size of the exchanger is made, using a heat-transfer coefficient
appropriate to the fluids, the process, and the equipment.

12
5. A first design is chosen, complete in all details necessary to carry out the design calculations.

6. The design chosen in step 5 is evaluated, or rated, as to its ability to meet the process
specifications with respect to both heat transfer and pressure drop.

7. On the basis of the result of step 6, a new configuration is chosen if necessary and step 6 is
repeated. If the first design was inadequate to meet the required heat load, it is usually necessary
to increase the size of the exchanger while still remaining within specified or feasible limits of
pressure drop, tube length, shell diameter, etc. This will sometimes mean going to multiple-
exchanger configurations. If the first design more than meets heat-load requirements or does
not use all the allowable pressure drop, a less expensive exchanger can usually be designed to
fulfill process requirements.

8. The final design should meet process requirements (within reasonable expectations of error)
at lowest cost. The lowest cost should include operation and maintenance costs and credit for
ability to meet long-term process changes, as well as installed (capital) cost. Exchangers should
not be selected entirely on a lowest-first-cost basis, which frequently results in future penalties.
[4]

13
3. DESIGN CHOICES
3.1. Heat Exchanger Type
Shell and tube heat exchanger advantages are:

• The configuration gives a large surface area in a small volume.

• Good mechanical layout: a good shape for pressure operation.
• Uses well-established fabrication techniques.
• Can be constructed from a wide range of materials.
• Easily cleaned.
• Well-established design procedures.

✓ Shell and tube heat exchanger type selected with respect to these advantages. Also to
reduce the design to simple passes type are selected as (1-1)

[Link] of construction
Selected material of construction should be suitable for design and should be more affordible.
Carbon stell is more affordible than stainles steel but the companies we contacted did not
produce the carbon steel heat exchanger tubes. Because of that we are caught between the 304
and 316 stainless steel. When we compare these two, 304 stainless steel is more affordible
than 316 stainless steel and the thermal conductivity for 304 stainless steel is higher than 316
stainless steel.

✓ Thus, material of construction is selected as 304 stainless stell.

[Link] Type
In this design, there is no phase changes in fluids.

(a) (b)

Figure-9 Temperature profile for parallel flow (a) and countercurrent flow (b) type [2]

14
Temperature profile for parallel and countercurrent flow is shown in figure-9. According to
figure-9 for countercurrent flow, temperature distribution is more effective than parallel flow.

✓ Thus, flow type selected as countercurrent flow.

[Link] Allocation

Table-5 Some items effect on flow allocation

Shell Side Tube Side

More corrosive fluid should be ethanol water
allocated to tube side
The fluid that has the greatest tendency ethanol water
should be allocated to tube side
Hotter fluid should be allocated to tube water ethanol
side
The higher pressure stream should be ethanol water
allocated to tube side
Fluid with the lowest pressure drop water ethanol
allocated to tube side
More viscous fluid should be allocated water ethanol
to shel side
Fluid with the lowest flow rate should ethanol water
be allocated to tube side

✓ According the Table-5 water more suitable for allocated the tube side and ethanol
allocated the shell side. (Table-5 create with respect to Appendice-1)
[Link] Pattern

✓ Tube pattern selected as triangular. According to give higher heat-transfer rates for
triangular tube pattern because more tubes can be inserted.

15
 [Link]
We determine to use %25 cut industrial baffles for create (or increase) a turbulant flow in the
shell side and we aimed to make the fluid temperature mixed better.

Drawn by Ayşe Ebrar Müyesseroğlu

Figure-10 Flow Diagram for Our Process

Flow diagram for our process is shown in Figure-10. Process is located in Ankara. Ethanol
comes from a distillation column at 77 ℃ and cooled down and send to the storage tank at 40
℃. Cooling process is provided by the cooling tower.

16
4. METHOD OF CALCUALTIONS
[Link] of Calculation for Heat Exchanger

1) Heat exchanger typed selected as (1-1) and flow type selected as countercurrent flow.

2) Hot ethanol passing determined as through the shell side and soft cooling water

passing determined as tube side.

3) Stream temperatures determined as;

▪ Tha: 77 ℃
▪ Thb: 40 ℃
▪ Tca: 25 ℃
▪ Tcb: 40 ℃

4) 𝑚ℎ × 𝐶𝑝ℎ 𝑥 × ∆𝑇ℎ = 𝑚𝑐 × 𝐶𝑝𝑐 × ∆𝑇𝑐 (equation-4.1)

𝑚𝑐 determined from (egn-4.1)

∆𝑇2 −∆𝑇1
5) ∆𝑇𝐿𝑀 = ∆𝑇2 (equation-4.2)
ln( )
∆𝑇1

∆𝑇1 = 𝑇ℎ𝑎 −𝑇𝑐𝑏 (equation-4.3)

∆𝑇2 = 𝑇ℎ𝑏 − 𝑇𝑐𝑎 (equation-4.4)

6) Pipe properties selected as;

Do = 19.05 mm
Di = 16.56 mm

Xw = 1.24 mm
𝑑𝑜 −𝑑𝑖
7) 𝑑𝐿𝑀 = 𝑑 (equation-4.5)
ln( 0 )
𝑑𝑖

8) İnternal cross sectional area for one tube:

𝜋
𝑆𝑐 = × (𝑑𝑖 )2 (equation-4.6)
4

𝑚𝑐
9) 𝑚𝑐,𝑡𝑢𝑏𝑒 = (equation-4.7)
𝑁

10) Tube side Reynolds number:

17
 𝑑𝑖 𝐺𝑖
𝑅𝑒, 𝑡 = (equation-4.8)
𝜇𝑐

1 𝜇 0.14
11) 𝑁𝑢 = (0.027) × (𝑅𝑒)0.8 × (𝑃𝑟)3 × (𝜇 ) (equation-4.9)
𝑤

𝑁𝑢×𝑘
12) ℎ𝑖 = 𝑑𝑖
(equation-4.10)

13) 𝑐 = 𝑝 − 𝑑𝑜 (equation-4.11)

14) 𝐵 = (0.75) × 𝑑𝑠 (equation-4.12)

15) Cross flow area for shell:

𝑑𝑠 ×𝐵×𝑐
𝑆𝑐 = (equation-4.13)
𝑝

16) Mass flux for shell side

𝑚ℎ
𝐺𝑐 = 𝑆𝑐
(equation-4.14)

3.44𝑝2 −𝜋𝐷𝑜2
17) 𝐷𝑒 = 𝜋𝐷𝑜
(equation-4.15)

1
𝐷𝑒 ×𝐺𝑐 0.55 𝐶𝑝ℎ ×𝜇ℎ 3 𝜇 0.14
18) 𝑁𝑢 = 0.36 × ( 𝜇ℎ
) ×( 𝑘ℎ
) ×( )
𝜇
(equation-4.16)
𝑤

𝑁𝑢×𝑘
19) ℎ𝑜 = 𝐷𝑒
(equation-4.17)

1
20) 𝑈𝑜 = 𝑑𝑜 𝑑 𝑥 𝑑 1 1 (equation-4.18)
+ 𝑜 + 𝑤∙ 𝑜 + +
𝑑𝑖 ℎ𝑑𝑖 𝑑𝑖 ℎ𝑖 𝑘𝑤 𝑑𝑙𝑚 ℎ𝑜 ℎ𝑑𝑜

21) 𝐴 = 𝑁𝜋𝑑𝑜 𝐿 (equation-4.19)

22) 𝑄𝑅 = 𝑚ℎ 𝐶𝑝ℎ ∆𝑇ℎ (equation-4.20)

23) 𝑄𝐷 = 𝑈𝑜 𝐴𝑜 𝐹∆𝑇𝐿𝑀 (equation-4.21)

𝑄
24) 𝑄𝐷 ≅ 1.05 − 1.15 (equation-4.22)
𝑅

𝑓 𝐺2 𝐿 𝑛
25) ∆𝑃𝑡𝑢𝑏𝑒 = 2×103𝑖 𝑑 + 2.066 × 10−3 𝑛 𝑣 2 𝜌 (equation-4.23)
𝑖𝜌∅

𝑓 𝐺 2 𝑑𝑠 𝐿
26) ∆𝑃𝑠ℎ𝑒𝑙𝑙 = 2×103𝑐𝐷 (equation-4.24)
𝑒𝜌∅𝐵

18
 [Link] of Calculation for Cost Analysis

1) 𝑃𝑢𝑟𝑐ℎ𝑎𝑠𝑒𝑑 𝐸𝑞𝑢𝑖𝑝𝑚𝑒𝑛𝑡 𝐶𝑜𝑠𝑡 = 𝑁 × 𝐿 × 𝑐𝑜𝑠𝑡 𝑓𝑜𝑟 1 𝑡𝑢𝑏𝑒 × 2

2) 𝐼𝑛𝑠𝑡𝑎𝑙𝑙𝑎𝑡𝑖𝑜𝑛 = 0.25 × 𝑝𝑢𝑟𝑐ℎ𝑎𝑠𝑒𝑑 𝑒𝑞𝑢𝑖𝑝𝑚𝑒𝑛𝑡 𝑐𝑜𝑠𝑡

3) 𝐼𝑛𝑠𝑡𝑟𝑢𝑚𝑒𝑛𝑡𝑎𝑡𝑖𝑜𝑛 𝑎𝑛𝑑 𝐶𝑜𝑛𝑡𝑟𝑜𝑙𝑠 = 0.08 × 𝑝𝑢𝑟𝑐ℎ𝑎𝑠𝑒𝑑 𝑒𝑞𝑢𝑖𝑝𝑚𝑒𝑛𝑡 𝑐𝑜𝑠𝑡

4) 𝑃𝑖𝑝𝑖𝑛𝑔 = 0.1 × 𝑝𝑢𝑟𝑐ℎ𝑎𝑠𝑒𝑑 𝑒𝑞𝑢𝑖𝑝𝑚𝑒𝑛𝑡 𝑐𝑜𝑠𝑡

5) 𝐷𝑖𝑟𝑒𝑐𝑡 𝐶𝑜𝑠𝑡 = 𝑃𝑢𝑟𝑐ℎ𝑎𝑠𝑒𝑑 𝐸𝑞𝑢𝑖𝑝𝑚𝑒𝑛𝑡 𝐶𝑜𝑠𝑡 + 𝐼𝑛𝑠𝑡𝑎𝑙𝑙𝑎𝑡𝑖𝑜𝑛 +

𝐼𝑛𝑠𝑡𝑟𝑢𝑚𝑒𝑛𝑡𝑎𝑡𝑖𝑜𝑛 𝑎𝑛𝑑 𝐶𝑜𝑛𝑡𝑟𝑜𝑙𝑠 + 𝑃𝑖𝑝𝑖𝑛𝑔

6) 𝐸𝑛𝑔𝑖𝑛𝑒𝑒𝑟𝑖𝑛𝑔 𝑎𝑛𝑑 𝑆𝑢𝑝𝑒𝑟𝑣𝑖𝑠𝑖𝑜𝑛 = 0.1 × 𝑑𝑖𝑟𝑒𝑐𝑡 𝑐𝑜𝑠𝑡

7) 𝐶𝑜𝑛𝑠𝑡𝑟𝑢𝑐𝑡𝑖𝑜𝑛 𝐸𝑥𝑝𝑒𝑛𝑠𝑒 𝑎𝑛𝑑 𝐶𝑜𝑛𝑠𝑡𝑟𝑎𝑐𝑡𝑜𝑟 ′ 𝑠 𝐹𝑒𝑒 = 0.1 × 𝑓𝑖𝑥𝑒𝑑 𝑐𝑎𝑝𝑖𝑡𝑎𝑙 𝑖𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡

8) 𝐶𝑜𝑛𝑡𝑖𝑛𝑔𝑒𝑛𝑐𝑦 = 0.05 × 𝑓𝑖𝑥𝑒𝑑 𝑐𝑎𝑝𝑖𝑡𝑎𝑙 𝑖𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡

9) 𝐼𝑛𝑑𝑖𝑟𝑒𝑐𝑡 𝐶𝑜𝑠𝑡 = 𝐸𝑛𝑔𝑖𝑛𝑒𝑒𝑟𝑖𝑛𝑔 𝑎𝑛𝑑 𝑆𝑢𝑝𝑒𝑟𝑣𝑖𝑠𝑖𝑜𝑛 +

𝐶𝑜𝑛𝑠𝑡𝑟𝑢𝑐𝑡𝑖𝑜𝑛 𝐸𝑥𝑝𝑒𝑛𝑠𝑒 𝑎𝑛𝑑 𝐶𝑜𝑛𝑠𝑡𝑟𝑎𝑐𝑡𝑜𝑟 ′ 𝑠 𝐹𝑒𝑒 + 𝐶𝑜𝑛𝑡𝑖𝑛𝑔𝑒𝑛𝑐𝑦

10) 𝑇𝑜𝑡𝑎𝑙 𝐶𝑎𝑝𝑖𝑡𝑎𝑙 𝐼𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡 = 𝐹𝑖𝑥𝑒𝑑 𝐶𝑎𝑝𝑖𝑡𝑎𝑙 𝐼𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡 = 𝐷𝑖𝑟𝑒𝑐𝑡 𝐶𝑜𝑠𝑡 + 𝐼𝑛𝑑𝑖𝑟𝑒𝑐𝑡 𝐶𝑜𝑠𝑡

11) 𝐹𝐶𝐼 = 𝐷𝑖𝑟𝑒𝑐𝑡 𝐶𝑜𝑠𝑡 + (0.1 × 𝐷𝑖𝑟𝑒𝑐𝑡 𝐶𝑜𝑠𝑡) + (0.1 × 𝐹𝐶𝐼) + (0.05 × 𝐹𝐶𝐼)

12) 0.85 × 𝐹𝐶𝐼 = 𝐷𝑖𝑟𝑒𝑐𝑡 𝐶𝑜𝑠𝑡 + (0.1 × 𝐷𝑖𝑟𝑒𝑐𝑡 𝐶𝑜𝑠𝑡)

1.1×𝐷𝑖𝑟𝑒𝑐𝑡 𝐶𝑜𝑠𝑡
13) 𝐹𝐶𝐼 = 0.85

14) 𝑈𝑡𝑖𝑙𝑖𝑡𝑖𝑒𝑠 = 𝑃𝑟𝑖𝑐𝑒 𝑜𝑓 𝑐𝑜𝑜𝑙𝑖𝑛𝑔 𝑤𝑎𝑡𝑒𝑟 + 𝑃𝑢𝑚𝑝 𝐸𝑙𝑒𝑐𝑡𝑟𝑖𝑐𝑖𝑡𝑦

15) 𝑀𝑎𝑖𝑛𝑡𝑒𝑛𝑎𝑛𝑐𝑒 𝑎𝑛𝑑 𝑅𝑒𝑝𝑎𝑖𝑟𝑠 = 0.03 × 𝑇𝑜𝑡𝑎𝑙 𝐶𝑎𝑝𝑖𝑡𝑎𝑙 𝐼𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡

𝑇𝑜𝑡𝑎𝑙 𝑐𝑎𝑝𝑖𝑡𝑎𝑙 𝑖𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡

16) 𝐷𝑒𝑝𝑟𝑖𝑐𝑖𝑎𝑡𝑖𝑜𝑛 = 15

17) 𝐿𝑜𝑐𝑎𝑙 𝑇𝑎𝑥𝑒𝑠 = 0.025 × 𝑇𝑜𝑡𝑎𝑙 𝐶𝑎𝑝𝑖𝑡𝑎𝑙 𝐼𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡

18) 𝐼𝑛𝑠𝑢𝑟𝑎𝑛𝑐𝑒 = 0.005 × 𝑇𝑜𝑡𝑎𝑙 𝐶𝑎𝑝𝑖𝑡𝑎𝑙 𝐼𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡

19) 𝑇𝑜𝑡𝑎𝑙 𝑃𝑟𝑜𝑑𝑢𝑐𝑡 𝐶𝑜𝑠𝑡 = 𝑇𝑜𝑡𝑎𝑙 𝐴𝑛𝑛𝑢𝑎𝑙 𝐶𝑜𝑠𝑡 = 𝑂𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 𝐿𝑎𝑏𝑜𝑢𝑟 + 𝑈𝑡𝑖𝑙𝑖𝑡𝑖𝑒𝑠 +
𝑀𝑎𝑖𝑛𝑡𝑒𝑛𝑎𝑛𝑐𝑒 𝑎𝑛𝑑 𝑅𝑒𝑝𝑎𝑖𝑟𝑠 + 𝐷𝑒𝑝𝑟𝑖𝑐𝑖𝑎𝑡𝑖𝑜𝑛 + 𝐿𝑜𝑐𝑎𝑙 𝑇𝑎𝑥𝑒𝑠 + 𝐼𝑛𝑠𝑢𝑟𝑎𝑛𝑐𝑒

19
5. SAMPLE CALCULATIONS
[Link] Heat Exchanger Calculation
1.) Heat Exchanger Type is (1-1)

2.) Shell side passes → Ethanol (Hot fluid)

Tube side passes → Water (Cold fluid)

3.) 𝑀ℎ : 16 𝑘𝑔/𝑠
𝑇ℎ𝑎 : 77 ℃
𝑇ℎ𝑏 : 40 ℃
𝑇𝑐𝑎 : 25 ℃
𝑇𝑐𝑏 : 40 ℃
Properties determined.

4.) 𝑀ℎ × 𝐶𝑝ℎ × 𝛥𝑇ℎ = 𝑀𝑐 × 𝐶𝑝𝑐 × 𝛥𝑇𝑐

𝑀ℎ × 𝐶𝑝ℎ × (𝑇ℎ𝑎 − 𝑇ℎ𝑏 ) (16) × (2980) × (77 − 40)

𝑀𝑐 = = = 28 𝑘𝑔/𝑠
𝐶𝑝𝑐 × (𝑇𝑐𝑏 − 𝑇𝑐𝑎 ) (4175) × (40 − 25)

5.) 𝛥𝑇1 : 𝑇ℎ𝑎 − 𝑇𝑐𝑏 = 77 − 40 = 37

𝛥𝑇2 : 𝑇ℎ𝑏 − 𝑇𝑐𝑎 = 40 − 25 = 15

𝛥𝑇2 − 𝛥𝑇1 (15 − 37)

𝛥𝑇𝐿𝑀 = = = 24.4 ℃
𝛥𝑇2 15
ln (𝛥𝑇 ) ln 37
1

6.) 𝐷𝑜 = 19.05 𝑚𝑚

𝐷𝑖 = 16.56 𝑚𝑚

𝑥𝑤 = 1.24 𝑚𝑚

𝑑𝑜 − 𝑑𝑖 19.05 − 16.56
𝑑𝐿𝑀 = = = 17.8 𝑚𝑚
𝑑𝑜 19.05
ln ( 𝑑 ) ln (16.56)
𝑖

7.) Internal cross section area for 1tube:

𝜋 𝜋
𝑆𝑐 = × (𝑑𝑖 )2 = × (0.01656)2 = 2.2 × 10−4 𝑚
4 4
𝑚𝑐 28
8.) 𝑚𝑐 𝑡𝑢𝑏𝑒 = = = 0.0734 𝑘𝑔/𝑠
𝑁 384

20
9.)Mass flux for tube side

𝑚𝑐 𝑡𝑢𝑏𝑒 0.0734
𝐺𝑖 = = = 334.64 𝑘𝑔/𝑚2
𝑆𝑐 2.2 × 10−4

10.) Tube side Reynolds:

𝑑𝑖 × 𝐺𝑖 (0.01656) × (334.64)
𝑅𝑒𝑡 = = = 7197 → 𝑇𝑢𝑟𝑏𝑢𝑙𝑎𝑛𝑡 𝑓𝑙𝑜𝑤
𝜇𝑐 0.00077

𝜇 0.14
11.)𝑁𝑢 = 0.027 × (𝑅𝑒)0.8 × (𝑃𝑟)1/3 × (𝜇 )
𝑤

1/3
(4175) × (0.00077
𝑁𝑢 = 0.027 × (7197 )0.8 ×( ) × (1)0.14 = 57
0.621

𝑁𝑢×𝑘 (57)×(0.621) 𝑊
12.)ℎ𝑖 = 𝑑𝑖
= 001656
= 2138 𝑚2 𝐾

13.) 𝑐 = 𝑝 − 𝑑𝑜

𝑐 = 25.4 − 19.05 = 6.35 𝑚

𝐵 = (0.75) × (0.54) = 0.41 𝑚

14.) Cross flow area

𝑑𝑠 × 𝐵 × 𝑐 (0.54) × (0.41) × (0.00635)

𝑆𝑐 = = = 0.0554 𝑚2
𝜌 0.254

15.) Mass flux for Shell side

𝑚ℎ 16
𝐺𝑐 = = = 289 𝑘𝑔/𝑚2 𝑠
𝑆𝑐 0.0554

(3.44)×𝑝2 −𝜋×(𝐷𝑜)2 (3.44)×(25.4)2 −𝜋×(19.05) 2

16.) 𝐷𝑒 = =
𝜋×(𝐷𝑜) 𝜋×(19.05)

𝐷𝑒 = 0.018 𝑚

𝐷𝑒 ×𝐺𝑐 0.55 𝐶𝑝ℎ ×𝜇ℎ 1/3 𝜇 0.14

17.) 𝑁𝑢 = 0.36 × ( ) ×( ) × (𝜇 )
𝜇ℎ 𝑘ℎ 𝑤

0.55
(0.018)0 × (289) (2980) × (0.000612) 1/3
𝑁𝑢 = 0.36 × ( ) ×( ) × (1)0.14 = 115
0.000612 0.171

𝑁𝑢×𝑘 (115)×(0.171)
18.) ℎ𝑜 = = = 1093 𝑊/𝑚2 𝐾
𝐷𝑒 0.018

21
19.) ℎ𝑜 < ℎ𝑖 → 𝑈𝑜 𝑤𝑖𝑙𝑙 𝑢𝑠𝑒𝑑.

1
𝑈𝑜 =
𝑑𝑜 𝑑𝑜 𝑥𝑤 𝑑𝑜 1 1
{ }
𝑑𝑖 × ℎ𝑑𝑖 + 𝑑𝑖 × ℎ𝑖 + 𝑘𝑤 × 𝑑𝐿𝑀 + ℎ𝑜 + ℎ𝑑𝑜

1
𝑈𝑜 =
(19.05) (19.05) (0.00124) 19.05 1 1
{ + + × 17.8 + 1093 + }
(16.56 × (3774) (16.56) × (2138) 14 2857

𝑈𝑜 = 454 𝑊/𝑚2 𝐾

20.) 𝐴 = 𝑁 × 𝜋 × 𝑑𝑜 × 𝐿 = (384) × (𝜋) × (0.01905) × (7.32) = 168.2 𝑚2

21.) 𝑄𝑅 = 𝑚ℎ × 𝐶𝑝ℎ × 𝛥𝑇ℎ = (16) × (2980) × (77 − 40) = 1764160 𝑊

22.) 𝑄𝐷 = 𝑈𝑜 × 𝐴𝑜 × 𝐹 × 𝛥₸𝐿𝑀 = (454) × (168.2) × (1) × (24.4) = 1863252 𝑊

𝑄 (1863252)
23.) 𝑄𝐷 = (1764160) = 1.0056
𝑅

𝑓 𝐺2 𝐿 𝑛
24.) ∆𝑃𝑡 = 2×103𝑖 𝑑 + 2.066 × 10−3 𝑛 𝑣 2 𝜌
𝑖𝜌 ∅

0.0384 × (334.61)2 × 7.32 × 1

∆𝑃𝑡𝑢𝑏𝑒 = + 2.066 × 10−3 × 1 × (0.3)2 × 995 ≅ 1.14 𝑘𝑃𝑎
2 × 103 × 0.01656 × 995
≅ 0.0114 𝑏𝑎𝑟

𝑓 = 0.72 × (𝑅𝑒)−0.33 = 0.72 × (7197)−0.33 = 0.0384

𝑓 𝐺 2 𝑑𝑠 𝐿 0.306×(289) 2 ×0.591×7.32
25.) ∆𝑃𝑠ℎ𝑒𝑙𝑙 = 2×103𝑐𝐷 = = 9.065 𝑘𝑃𝑎 ≅ 0.09 𝑏𝑎𝑟
𝑒 𝜌∅𝐵 2×103 ×0.018×755×0.41

𝐷𝑒 𝐺𝑐 0.018 × 289
𝑅𝑒𝑐 = = = 8500
𝜇 0.000612
𝑓 = 1.87 × (𝑅𝑒𝑐 )−0.2 = 1.87 × (8500)−0.2 = 0.306

22
 [Link] Cost Calculation
Tc,b=40 oC
N: 316
L: 7.32 m
Do: 19.05 mm
Xw: 1.24 mm

8.5 𝑇𝐿 𝑇𝐿
• 𝐶𝑜𝑠𝑡 𝑓𝑜𝑟 1 𝑡𝑢𝑏𝑒 = 6.3 $ × $
= 53.5 𝑚

• 𝑃𝑢𝑟𝑐ℎ𝑎𝑠𝑒𝑑 𝐸𝑞𝑢𝑖𝑝𝑚𝑒𝑛𝑡 𝐶𝑜𝑠𝑡 = 𝑁 × 𝐿 × 𝑐𝑜𝑠𝑡 𝑓𝑜𝑟 1 𝑡𝑢𝑏𝑒 × 2 = 384 × 7.32 × 53.5 × 2 ≅

301000 𝑇𝐿

• 𝐼𝑛𝑠𝑡𝑎𝑙𝑙𝑎𝑡𝑖𝑜𝑛 = 0.25 × 𝑝𝑢𝑟𝑐ℎ𝑎𝑠𝑒𝑑 𝑒𝑞𝑢𝑖𝑝𝑚𝑒𝑛𝑡 𝑐𝑜𝑠𝑡 = 0.25 × 301000 = 75250 𝑇𝐿

• 𝐼𝑛𝑠𝑡𝑟𝑢𝑚𝑒𝑛𝑡𝑎𝑡𝑖𝑜𝑛 𝑎𝑛𝑑 𝐶𝑜𝑛𝑡𝑟𝑜𝑙𝑠 = 0.08 × 𝑝𝑢𝑟𝑐ℎ𝑎𝑠𝑒𝑑 𝑒𝑞𝑢𝑖𝑝𝑚𝑒𝑛𝑡 𝑐𝑜𝑠𝑡 =

0.08 × 301000 = 24080 𝑇𝐿

• 𝑃𝑖𝑝𝑖𝑛𝑔 = 0.1 × 𝑝𝑢𝑟𝑐ℎ𝑎𝑠𝑒𝑑 𝑒𝑞𝑢𝑖𝑝𝑚𝑒𝑛𝑡 𝑐𝑜𝑠𝑡 = 0.1 × 301000 = 30100 𝑇𝐿/𝑦𝑒𝑎𝑟

• 𝐷𝑖𝑟𝑒𝑐𝑡 𝐶𝑜𝑠𝑡 = 𝑃𝑢𝑟𝑐ℎ𝑎𝑠𝑒𝑑 𝐸𝑞𝑢𝑖𝑝𝑚𝑒𝑛𝑡 𝐶𝑜𝑠𝑡 + 𝐼𝑛𝑠𝑡𝑎𝑙𝑙𝑎𝑡𝑖𝑜𝑛 +

𝐼𝑛𝑠𝑡𝑟𝑢𝑚𝑒𝑛𝑡𝑎𝑡𝑖𝑜𝑛 𝑎𝑛𝑑 𝐶𝑜𝑛𝑡𝑟𝑜𝑙𝑠 + 𝑃𝑖𝑝𝑖𝑛𝑔 = 301000 + 75250 + 24080 + 30100 =
430430 𝑇𝐿

• 𝐸𝑛𝑔𝑖𝑛𝑒𝑒𝑟𝑖𝑛𝑔 𝑎𝑛𝑑 𝑆𝑢𝑝𝑒𝑟𝑣𝑖𝑠𝑖𝑜𝑛 = 0.1 × 𝑑𝑖𝑟𝑒𝑐𝑡 𝑐𝑜𝑠𝑡 = 0.1 × 430430 ≅ 43000 𝑇𝐿

• 𝐶𝑜𝑛𝑠𝑡𝑟𝑢𝑐𝑡𝑖𝑜𝑛 𝐸𝑥𝑝𝑒𝑛𝑠𝑒 𝑎𝑛𝑑 𝐶𝑜𝑛𝑠𝑡𝑟𝑎𝑐𝑡𝑜𝑟 ′ 𝑠 𝐹𝑒𝑒 = 0.1 × 𝑓𝑖𝑥𝑒𝑑 𝑐𝑎𝑝𝑖𝑡𝑎𝑙 𝑖𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡 =

0.1 × 557000 = 55700 𝑇𝐿

• 𝐶𝑜𝑛𝑡𝑖𝑛𝑔𝑒𝑛𝑐𝑦 = 0.05 × 𝑓𝑖𝑥𝑒𝑑 𝑐𝑎𝑝𝑖𝑡𝑎𝑙 𝑖𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡 = 0.05 × 557000 = 27850 𝑇𝐿

• 𝐼𝑛𝑑𝑖𝑟𝑒𝑐𝑡 𝐶𝑜𝑠𝑡 = 𝐸𝑛𝑔𝑖𝑛𝑒𝑒𝑟𝑖𝑛𝑔 𝑎𝑛𝑑 𝑆𝑢𝑝𝑒𝑟𝑣𝑖𝑠𝑖𝑜𝑛 +

𝐶𝑜𝑛𝑠𝑡𝑟𝑢𝑐𝑡𝑖𝑜𝑛 𝐸𝑥𝑝𝑒𝑛𝑠𝑒 𝑎𝑛𝑑 𝐶𝑜𝑛𝑠𝑡𝑟𝑎𝑐𝑡𝑜𝑟 ′ 𝑠 𝐹𝑒𝑒 + 𝐶𝑜𝑛𝑡𝑖𝑛𝑔𝑒𝑛𝑐𝑦 = 126550 𝑇𝐿

• 𝑇𝑜𝑡𝑎𝑙 𝐶𝑎𝑝𝑖𝑡𝑎𝑙 𝐼𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡 = 𝐹𝑖𝑥𝑒𝑑 𝐶𝑎𝑝𝑖𝑡𝑎𝑙 𝐼𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡 = 𝐷𝑖𝑟𝑒𝑐𝑡 𝐶𝑜𝑠𝑡 + 𝐼𝑛𝑑𝑖𝑟𝑒𝑐𝑡 𝐶𝑜𝑠𝑡

• 𝐹𝐶𝐼 = 𝐷𝑖𝑟𝑒𝑐𝑡 𝐶𝑜𝑠𝑡 + (0.1 × 𝐷𝑖𝑟𝑒𝑐𝑡 𝐶𝑜𝑠𝑡) + (0.1 × 𝐹𝐶𝐼) + (0.05 × 𝐹𝐶𝐼)

• 0.85 × 𝐹𝐶𝐼 = 𝐷𝑖𝑟𝑒𝑐𝑡 𝐶𝑜𝑠𝑡 + (0.1 × 𝐷𝑖𝑟𝑒𝑐𝑡 𝐶𝑜𝑠𝑡)

1.1×𝐷𝑖𝑟𝑒𝑐𝑡 𝐶𝑜𝑠𝑡 1.1×430430

• 𝐹𝐶𝐼 = 0.85
= 0.85
≅ 557000 𝑇𝐿

23
• 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝐿𝑎𝑏𝑜𝑢𝑟 𝑎𝑡 3 𝑠ℎ𝑖𝑓𝑡𝑠 = 0.5 × 3 = 1.5

• 𝑂𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 𝐿𝑎𝑏𝑜𝑢𝑟 = 4500 × 1.5 × 12 = 81000 𝑇𝐿/𝑦𝑒𝑎𝑟

• 𝑃𝑟𝑖𝑐𝑒 𝑜𝑓 𝑐𝑜𝑜𝑙𝑖𝑛𝑔 𝑤𝑎𝑡𝑒𝑟 = 𝑚̇ × 10−3 × 86400 × 330 × 0.075 = 28.1 × 10−3 × 86400 ×
330 × 0.075 ≅ 60000 𝑇𝐿/𝑦𝑒𝑎𝑟

• 𝑃𝑢𝑚𝑝 𝐸𝑙𝑒𝑐𝑡𝑟𝑖𝑐𝑖𝑡𝑦 = 𝑃𝑢𝑚𝑝 𝑃𝑜𝑤𝑒𝑟 × 0.45 × 24 × 330 = 0.05 × 0.45 × 24 × 330 ≅

180 𝑇𝐿/𝑦𝑒𝑎𝑟

• 𝑈𝑡𝑖𝑙𝑖𝑡𝑖𝑒𝑠 = 𝑃𝑟𝑖𝑐𝑒 𝑜𝑓 𝑐𝑜𝑜𝑙𝑖𝑛𝑔 𝑤𝑎𝑡𝑒𝑟 + 𝑃𝑢𝑚𝑝 𝐸𝑙𝑒𝑐𝑡𝑟𝑖𝑐𝑖𝑡𝑦 = 60000 + 180 =

60180 𝑇𝐿/𝑦𝑒𝑎𝑟

• 𝑀𝑎𝑖𝑛𝑡𝑒𝑛𝑎𝑛𝑐𝑒 𝑎𝑛𝑑 𝑅𝑒𝑝𝑎𝑖𝑟𝑠 = 0.03 × 𝑇𝑜𝑡𝑎𝑙 𝐶𝑎𝑝𝑖𝑡𝑎𝑙 𝐼𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡 = 0.03 × 557000 ≅

16700 𝑇𝐿/𝑦𝑒𝑎𝑟

𝑇𝑜𝑡𝑎𝑙 𝑐𝑎𝑝𝑖𝑡𝑎𝑙 𝑖𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡 557000

• 𝐷𝑒𝑝𝑟𝑖𝑐𝑖𝑎𝑡𝑖𝑜𝑛 = 15
= 15
≅ 37000 𝑇𝐿/𝑦𝑒𝑎𝑟

• 𝐿𝑜𝑐𝑎𝑙 𝑇𝑎𝑥𝑒𝑠 = 0.025 × 𝑇𝑜𝑡𝑎𝑙 𝐶𝑎𝑝𝑖𝑡𝑎𝑙 𝐼𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡 = 0.025 × 557000 ≅ 14000 𝑇𝐿/𝑦𝑒𝑎𝑟

• 𝐼𝑛𝑠𝑢𝑟𝑎𝑛𝑐𝑒 = 0.005 × 𝑇𝑜𝑡𝑎𝑙 𝐶𝑎𝑝𝑖𝑡𝑎𝑙 𝐼𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡 = 0.005 × 557000 ≅ 2800 𝑇𝐿/𝑦𝑒𝑎𝑟

• 𝑇𝑜𝑡𝑎𝑙 𝑃𝑟𝑜𝑑𝑢𝑐𝑡 𝐶𝑜𝑠𝑡 = 𝑇𝑜𝑡𝑎𝑙 𝐴𝑛𝑛𝑢𝑎𝑙 𝐶𝑜𝑠𝑡 = 𝑂𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 𝐿𝑎𝑏𝑜𝑢𝑟 + 𝑈𝑡𝑖𝑙𝑖𝑡𝑖𝑒𝑠 +

𝑀𝑎𝑖𝑛𝑡𝑒𝑛𝑎𝑛𝑐𝑒 𝑎𝑛𝑑 𝑅𝑒𝑝𝑎𝑖𝑟𝑠 + 𝐷𝑒𝑝𝑟𝑖𝑐𝑖𝑎𝑡𝑖𝑜𝑛 + 𝐿𝑜𝑐𝑎𝑙 𝑇𝑎𝑥𝑒𝑠 + 𝐼𝑛𝑠𝑢𝑟𝑎𝑛𝑐𝑒 = 81000 +
60180 + 16700 + 37000 + 14000 + 2800 ≅ 212000 𝑇𝐿/𝑦𝑒𝑎𝑟

24
6. RESULTS
Table-6 Results for type (1-1) heat exchanger

Tube Side Shell Side

Inlet Outlet Inlet Outlet
Fluid Cooling water Ethanol
Flow rate, kg/h 28 16
Fluid Phase Liquid Liquid
Temperature, ℃ 25 40 77 40
MBT, ℃ 32.5 58.5
Pressure, bar 1.1 1.09 1.1 1.01
Density, kg/m3 995 756
Viscosity, cP 0.770 0.612
Specific Heat, J/kg-K 4175 2980
Latent Heat, J/kg 2256x103 8460x103
Heat Exchanger Shell and Tube
Heat duty, kW (QR) 1764.16
LMTD,℃ 24.4
F 1
Number of passes 1 1
Tube Number 384
Velocity, m/s 0.3 0.4
Heat transfer coefficient, W/m2K 2138 1093
Material of construction 304 stainles steel
k, W/m2K 14
Overall heat transfer coefficient,
Uo, W/m2K 454
Ui, W/m2K 522
Heat transfer area
Ao, m2 168
Ai, m2 146
Calculated heat duty, W (QD) 1863252
Safety factor, QD/QR 1.056

25
Table-7 Detailed calculation for different water outlet temperatures

T,cb (assumption) 30℃ 35℃ 40℃ 45℃ 50℃

Qrequired,W 1758240
mwater , kg/s 84 42 28 21 16
ΔTLM 28 26 24 22 20
Number of shel passes 1 1 1 1 1
N, number of tubes 470 316 384 559 745
Shel inside diameter,m 0.635 0.54 0.591 0.686 0.737
L, tube length, m 4.88 7.32 7.32 7.32 7.32
Number of Tube passes 1 1 1 1 1
hi , W/m2K 4395 3468 2138 1262 834
ho W/m2K 916 1094 1093 841 777
Uo, W/m2K 498 526 454 363 301
Ao, m2 138 138 168 245 325
F 1 1 1 1 1
Qdesign, W 1914739 1910324 1863252 1994169 2011483
QD/QR 1.089 1.087 1.056 1.134 1.144

Figure-11 flow diagram from CHEMCAD simulation

26
Table-8 CHEMCAD simulation results

27
 Table-9 Calculated results for heat exchanger by CHEMCAD

Table-10 Results of cost analysis for (1-1) type heat exchanger

Estimation of Principal TL Estimation of Total Product TL/year
Investment Cost Cost
[Link] Cost 430430 [Link] Production Cost 157880
1.1 Purchased [Link] 301000 1.1 Operating Labour 81000
1.2 Installation 75250 1.2 Utilities 60180
1.3 Instrumentation and 24080 1.3 Maintenance and Repairs 16700
Controls
1.4 Piping 30100 2. Fixed Charges 53800
2. Indirect Cost 126550 2.1 Depriciation 37000
2.1 Engineering and 43000 2.2 Local Taxes 14000
Supervision
2.2 Construction Expense and 55700 2.3 Insurance 2800
Contractor’s Fee
2.3 Contingency 27850 Total Annual Cost 212000
Total Capital Investment 557000

28
Figure-12 The effect of water outlet temperature on TAC and Utilities

Figure-13 The effect of items on Total Annual Cost

29
7. DISCUSSION
First of all, the heat exchanger type has chosen according to section 3. The heat exchanger type

suitable for the design is the shell and tube type. Then, the number of tube passes for the shell

and tube heat exchanger is decided as 1-1 type. When we compared ethanol and cooling water,

it has decided to pass it through tube side because the more polluted substance is water. Triangle

has chosen as the tube shape among triangle and square types. Because the fact that more

triangular tubes can be placed in the same area has been more effective for heat transfer. After

that, the number of tubes and lengths at each temperature have tested one by one for the

temperature output range we determined and the numbers appropriate to our design values have

selected. After all the values have taken as standard and made suitable for calculation, it has

determined at what temperature is economically more affordable. As a result, it has decided

that the 1-1 pass shell and tube type design, in which the cooling water on the tube side has 25

degrees inlet and 40 degrees outlet, is the optimum design.

In detailed calculation results shown in table-6. Chemcad flow diagram shown in figure-11 and

in table-8 the results for chemcad simulation shown relevantly. Overall heat transfer coefficient

is calculated as 454 W/m2K. Heat duty calculated as 1863252 W. Detailed Chemcad calculation

shown in table-9. Overall heat transfer coefficient calculated as 346 W/m2K and heat duty

calculated 1540550 W by chemcad simulation. Heat transfer area has a similar result in both

calcualtion. (≈168 m2) Chemcad simulation may be have used the sensitive properties of

ethanol and water, may be used different fouling factor values and may be used different

thermal conductivity value for material. When we consider about the overall heat transfer

coeffcient formula (eguation-4.18), all items that we say just now probably effected on the

difference in calculated and chemcad values.

30
8. CONCLUSIONS

The effect of parameters on calculations is important. When we are considering about table-7,
we can see when the water outlet temperature are incereases; water flow rate are decreases,
number of tubes required are increases, overall heat transfer coefficient and heat transfer area
is incerases too. By the way, tube lengt increases is more effective than tube number increases
on the ratio of QD/QR. Also when the number of tubes are increases, purchased equipment
cost are increase too much according to tube length increases.

When we considering about the cost analysis, the most effecting parameter is material of
construction besides the number of tubes and tube length in purchsed equipment cost.
Installation, instrumentation and controls and piping cost were calculated according to
purchased equipment cost. The direct cost was found with total of these. Fixed Capital
Investment that is Total Capital Investment had to be known for the indirect cost. We found
this by solving the equation. We can say that the most effecting parameter is construction
expense and constractor’s fee in indirect cost. We have seen that utilities are the most effecting
parameter to total product cost that is total annual cost. (Figure-13). Price of cooling water is
the biggest effective item on utilities according to electricity consumed by pumps. As a result
of all these calculations, minimum total annual cost was found when the water outlet
temperature is 40 degrees. (Figure-12). The results of calculations are shown in Table-10.

31
9. RECOMMENDATIONS

▪ In this work, cooling water used as coolant. However, an another liquid that can absorb

higher heat than the cooling water can be used to cool the ethanol.

▪ If coolant is water, than demineralization unit should be used for decrease the fouling

of water on heat exchanger.

▪ An unexpected temperature and pressure increases may be happen. Design of the heat

exchanger should be withstand in such condition.

▪ A relatively high temperature surface should be covered by insulation.

▪ The heat exchanger should be designed for a safe maintenance environment.

▪ At high temperatures ethanol will be evaporates quickly. To prevent this situation,

internal floating roof tank type can be used, storage tank walls should be insulated and

painted light color.

32
 REFERENCES

[1] Shah, R,K. Fundamentals of Heat Exchanger Design. 2003. (November 2020)

[2] Timmerhaus, Peter, West. Plant Design and Economics for Chemical Engineers. New York:

McGraw Hill, 2002. (November 2020).

[3] Sinnott, Towler. Chemical Engineering Design Principles Practice and Economics of Plant

and Process Design. Massachusetts: Elsevier, 2008. (November 2020).

[4] Perry. Perry's Chemical Engineers' Handbook. New York: McGraw Hill, 1997.

[5] Holman. Heat Transfer. New York: McGraw Hill, 2010.

33
 APPENDICES
APPENDICE 1 – Fluid Allocation Information

Figure-14 Fluid Allocation information from Timmerhause 5th edition page:660 [2]

34
APPENDICE 2 – Material Safety Data Sheet For Ethanol

Hazard Signs

SECTION 1. First Aid measures

1.1 Description of first aid measures

After inhalation: fresh air.

In case of skin contact: Take off immediately all contaminated clothing. With water

wash.

After eye contact: rinse out with plenty of water. Call an eye specialist. Contact lenses

remove.

After swallowing immediately make victim drink 2 glasses of water. Consult the doctor.

1.2 Most important symptoms and effects, both acute and delayed

Irritant effects, respiratory paralysis, dizziness, narcosis, intoxication,

feeling energetic (euphoria), nausea, vomiting

SECTION 2. Firefighting measures

2.1 Fire extinguishers

Suitable fire extinguishers

Carbon dioxide (CO2), Foam, Dry powder, Water

Unsuitable extinguishing media

There is no restriction on extinguishing agents for this substance / mixture.

2.2 Special hazards arising from the substance or mixture

Flammable.

There may be flashback. Be careful.

It forms explosive mixtures with atmospheric air.

Vapors heavier than air may condense on the floor.

35
In the event of fire, dangerous flammable gases or vapors may develop.

2.3 Advice for firefighters

Special protective equipment for firefighters

In case of fire, use full mask with oxygen cylinder.

Additional information

Remove container from danger area and cool with water. Of fire fighting water

Prevent it from entering earth or groundwater.

SECTION 3. Accidental release measures

3.1 Personal precautions, protective equipment and emergency procedures

3.1.1 For Non-Emergency Personnel

Warn non-emergency personnel. Do not breathe vapor, aerosol. Matter

prevent contact. Make sure you have good ventilation. From the heat and

Keep away from anything that could cause ignition. Evacuate danger zone, emergency

follow the case procedures, consult a specialist.

Recommendations for emergency responders:

3.2 Environmental precautions

Make sure that it does not interfere with the sewer. Risk of explosion.

3.3 Methods and materials for containment and cleaning up

Close the drainage channels. Collect spills, wrap and pump away.

Observe possible material restrictions. Take with liquid absorbent material. Submit for

destruction. Clean the affected area.

SECTION 4. Handling and storage

4.1 Precautions for safe handling

4.1.1 Safe handling recommendations

36
Pay attention to the precautions on the label.

Fire and explosion protection recommendations

Away from naked flames, hot surfaces and anything that may cause ignition.

Take precautionary measures against static discharge.

4.1.2 Hygiene measures

Change contaminated clothing. Wash hands after working with substance.

4.2 Conditions for safe storage, including any incompatibilities

Storage conditions

Keep container tightly closed in a dry and well-ventilated place. From the heat and

Keep away from anything that could cause ignition.

Recommended storage temperature, see product label.

SECTION 5. Exposure controls / personal protection

5.1 Control parameters

Components with workplace control parameters

Components

Basis Value Threshold Limits Notes

Ethanol (64-17-5)

TR MAK Acceptable

maximum

concentration (MAK) 1,000 mbp

1.900 mg / m3

Suggested monitoring procedures

The requirements of DIN EN 482 and DIN EN 689 norms for measurement methods related

to the workplace atmosphere must meet.

5.2 Exposure controls

37
5.2.1 Appropriate Engineering Controls

Technical measures and proper work operations, use of personal protective equipmentshould

be given priority in the face.

5.2.2 Individual Protective Measures

Protective clothing, depending on the concentration and amount of the dangerous substance

used,

It should be selected specifically for the workplace. To avoid chemicals, preservative

Resistances contained in clothing must be determined by each supplier.

Eye / face protection

Goggles

Hand protection full contact:

Glove material: butyl rubber

Glove thickness: 0.7 mm

Penetration time: 480 minutes

SECTION 6. Physical and chemical properties

6.1 Information on basic physical and chemical properties

Physical state liquid

Color colorless

Smell like alcohol

Odor threshold 0,1-5058,5mbp

Ph 7,0

Melting point -114,5

38
Solubility in water at 20 completely miscible

Partition coefficient log pow: -0,31

Fluidity 1,2 mPa.s at 20

Boiling point at 78,3 1.013hPa

Lower explosion limit 3,1%

Upper explosion limit 27,7%

Vapor pressure at 20 59hPa

Relative vapor density 1,6

SECTION 7. Stability and reactivity

7.1 Reactivity

Vapors can form an explosive mixture in air.

7.2 Chemical stability

The product is chemically stable under standard ambient conditions (room temperature).

7.3 Possibility of hazardous reactions

There is a risk of explosion / exothermic reaction with:

hydrogen peroxide, perchlorates, perchloric acid, Nitric acid, mercury (II) nitrate,

permanganic

acid, Nitriles, peroxy compounds, Strong oxidizing agents, nitrosyl compounds,

Peroxides, sodium, Potassium, halogen oxides, calcium hypochlorite, nitrogen dioxide,

metallic oxides, uranium hexafluoride, iodides, Chlorine, Alkali metals, Alkaline earth

metals, alkali oxides, Ethylene oxide silver with nitric acid silver compounds with ammonia

potassium permanganate with conc. sulfuric acid

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Risk of explosion or formation of flammable gases or vapors with: halogen-halogen

compounds, chromium (VI) oxide, chromyl chloride, Fluorine, hydrides, Phosphorus oxides

of platinum Nitric acid with potassium permanganate

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