SECTION 3: CLARIFICATION AND UTILITIES (1)

Transcription

1 CHPR4402 Chemical Engineering Design Project The University of Western Australia SECTION 3: CLARIFICATION AND UTILITIES (1) Aaliyah Hoosenally

2 TEAM A: ALCOHOLICS ANONYMOUS AALIYAH HOOSENALLY, SECTION 3: CLARIFICATION AND UTILITIES (1) Table of Contents 1. EQUIPMENT SPECIFICATION CALCULATIONS Cold Stabilisation Heat Exchanger HX Skin Separation/Plate and Frame Filter FLTR Membrane Filter FLTR Water Filter FLTR Aging in Barrels BRL Boiler HTR DETAILED DESIGN CALCULATIONS Basic Heat Exchanger Design Tubesheet Detailed Design End Plate Design Vessel Support Design List of Tables Table 1: Racked Red Wine Physical Properties... 2 Table 2: Stabilised Red Wine Physical Properties... 2 Table 3: Standard Tube Lengths and Outer Diameters... 4 Table 4: Tube Length and Shell Diameter Selection Table 5: Tube Length and Shell Diameter Selection Table 6: Racked White Wine Physical Properties Table 7: Stabilised White Wine Physical Properties Table 8: Skin Separation/Plate and Frame Filter FLTR-01 Properties Table 9: Membrane Filter FLTR-02 Properties Table 10: Water Filter FLTR-03 Properties Table 11: Physical Properties of Water for Hot Caustic Solution Table 12: Fixed Tubesheet Effective Pressure Calculation Table 13: Shell Longitudinal Stress Calculation Table 14: Tube Longitudinal Stress Calculation Table 15: Tube-to-Tubesheet Joint Loads Table 16: Flanged Plate Ends - Bolted Covered with Full Faced Gasket Table 17: Bolt Spacing Table 18: Shell Mass Calculation Table 19: Tube Mass Calculation Table 20: Liquid Mass Calculation Table 21: Flange End Plate (Flat Ends) Mass Calculation Table 22: Dead Weight of Vessel Calculation i

3 CHPR4402 Chemical Engineering Design Project The University of Western Australia 1. EQUIPMENT SPECIFICATION CALCULATIONS Aaliyah Hoosenally

4 Team A Equipment Type Heat Exchanger Project Equipment Design Equipment Name Cold Stabilisation Heat Exchanger Design By Aaliyah Hoosenally Equipment Number HX-01 Date 21/08/2008 Page 1 of Cold Stabilisation Heat Exchanger HX-02 As mentioned in the equipment design section, this heat exchanger has been designed specifically to cool the red racked wine from 25 C to 15 C. Table 1: Racked Red Wine Physical Properties Racked Red Wine Inlet Outlet Mean Temperature ( C) Cp (kj/kg. C) k (W/m. C) ρ (kg/m³) μ (mpa.s) mass flow rate (kg/s) Table 2: Stabilised Red Wine Physical Properties Stabilised Red Wine Inlet Outlet Mean Temperature ( C) Cp (kj/kg. C) k (W/m. C) ρ (kg/m³) μ (mpa.s) mass flow rate (kg/s) (Table 5.2, p. 92, Rankine, 2004) Using the specified temperature drop for the Racked Wine stream, the total amount of heat transferred can then be calculated. This can then be used to find the outlet temperature of the Stabilised Wine: Total amount of heat transferred, Q =mcp T (kw) Temperature Out of Stabilised Wine T o =Q/(mCp) + T i ( C) An Overall Heat Transfer Coefficient must now be estimated: Overall Heat Transfer Coefficient, U ass (W/m².C) 100 (Table 12.1, p. 637, Coulson, Richardson & Sinnot, 2005: Organic Solvent to Organic Solvent: W/m².K) 2

5 Team A Equipment Type Heat Exchanger Project Equipment Design Equipment Name Cold Stabilisation Heat Exchanger Design By Aaliyah Hoosenally Equipment Number HX-01 Date 21/08/2008 Page 2 of 10 The log mean temperature must also be calculated using the following equation: dt1 (C) 10 dt2 (C) dt2 - dt1 (C) dt2 / dt1 (C) ( T) lm (C) Racked Wine will flow through the tubes, and the Stabilised Wine will flow through the shell so: Tube In Temperature, t 1 25 Tube Out Temperature, t 2 15 Shell in Temperature, T 1 0 Shell out Temperature, T The correction factor, F 1-2, can now be calculated using two dimensionless temperature ratios, R and S. If F 1-2 is greater than 0.8, a shell and tube heat exchanger with 1 shell and any multiple of 2 tube passes is acceptable. (Eq to 12.8, pp , Coulson, Richardson & Sinnot, 2005) R P 0.4 F As F 1-2 is greater than 0.8, we will begin with 1 shell with 4 tube passes 4 passes because the volumetric flow of the wine is quite small, hence 2 passes would result in a tube side velocity that would be too low. 3

6 Team A Equipment Type Heat Exchanger Project Equipment Design Equipment Name Cold Stabilisation Heat Exchanger Design By Aaliyah Hoosenally Equipment Number HX-01 Date 21/08/2008 Page 3 of 10 The estimated heat transfer area can now be calculated: Heat Transfer Area, A=Q/(U( T) lm F 1-2 ) (m²) The table below displays the standard sizes of tube lengths and outer diameters (OD): Table 3: Standard Tube Lengths and Outer Diameters Length (ft) Length (m) Tube OD, d o (in) Tube OD, d o (m) If we use a standard tube OD of m (1/2 in.) and a tube length of m (6 feet), we can find the surface area of one tube, the total number of tubes required, the number of tubes required per pass, tube cross-sectional area, total area per pass, and the tube side velocity. The bundle diameter and shell clearance needed for each bundle can then also be calculated to find the optimal shell inner diameter. A tube OD of 0.5 was chosen due to the small volumetric flowrate of the wine. Mechanical cleaning of the tubes is not necessary; hence the small tube diameter will not be a problem. Tube OD d o (m) Tube Length L (m) Number of Tube Passes 4 Tube Cross-Section Area A tc =π(d o /2) 2 (m²) Volumetric Flow Rate Q=ρ*mass flow (m³/s) Tube Surface Area A t =πd o L (m²) N t = A/A t 786 Tubes per pass N p = N t /4 196 Area per pass A p = N p A tc (m²) Tube Side Velocity, u t = Q/A p (m/s) K Table 12.4, p. 649, Coulson, Richardson & Sinnot,

7 Team A Equipment Type Heat Exchanger Project Equipment Design Equipment Name Cold Stabilisation Heat Exchanger Design By Aaliyah Hoosenally Equipment Number HX-01 Date 21/08/2008 Page 4 of 10 n Bundle Diameter D b = d o (N t /K 1 ) 1/n1 (m) Shell Clearance (m) Shell ID D s = D b + Shell Clearance (m) Equation 12.3b, p. 648, Coulson, Richardson & Sinnot, 2005 Figure 12.10, p. 646, Coulson, Richardson & Sinnot, 2005 Optimum L/D ratio will fall between 5-10, p. 645, Coulson, Richardson & Sinnot, 2005 The same calculation can be performed for all the different tube lengths to find which length will give the optimum Shell ID: Table 4: Tube Length and Shell Diameter Selection 1 L t (m) A t (m²) N t N p A p (m²) u t (m/s) D b (m) L c (m) D s (m) L/D The above table shows that the tube length of 3.66 m that seems to give the optimum shell ID. The tube side and shell side heat transfer coefficients can now be calculated, in order to check whether the initial estimate of the overall heat transfer coefficient is correct. Tube Side HTC Tube ID d i (m) Re = ρutd i /μ Pr = Cpμ/k L/d i 389 j h Using Figure 12.23, p. 665, Coulson, Richardson & Sinnot, 2005 Nu = j h RePr 1/ h t =Nuk/d i (W/m².C) To calculate the shell side heat transfer coefficients, the following formulas can be used to find the cross-sectional area of the shell, A s, and the equivalent diameter, D e, for a square pitch arrangement: 5

8 Team A Equipment Type Heat Exchanger Project Equipment Design Equipment Name Cold Stabilisation Heat Exchanger Design By Aaliyah Hoosenally Equipment Number HX-01 Date 21/08/2008 Page 5 of 10 (Equations and 12.22, p. 672, Coulson, Richardson & Sinnot, 2005) Shell Side HTC Tube Pitch p t = 1.25d o Baffle Spacing, l B =0.2D s (m) p. 652, Coulson, Richardson & Sinnot, 2005 Cross Sectional Area, A s (m²) Equivalent Diameter, D e (m) Volumetric Flow Rate (m³/s) Shell Side Velocity, u s (m/s) Re = ρu s D e /μ Pr = Cpμ/k Baffle Cut % 25 j h Nu = j h RePr 1/ h s =Nuk/D e (W/m².C) The overall heat transfer coefficient can now be calculated using the following equation: (Equation 12.2, p. 635, Coulson, Richardson & Sinnot, 2005, 2003) 6

9 Team A Equipment Type Heat Exchanger Project Equipment Design Equipment Name Cold Stabilisation Heat Exchanger Design By Aaliyah Hoosenally Equipment Number HX-01 Date 21/08/2008 Page 6 of 10 Overall Coefficient Tube k w (W/mC ) 16 Stainless Steel 316 Tube h od (W/m².C) 3000 h id (W/m².C) /U o (m².c/w) U o (W/m².C) Fouling Factors taken from 'Organic Liquids' Table 12.2, p. 640, Coulson, Richardson & Sinnot, 2005 The error in the overall heat transfer coefficient that was used initially can now be found: Error in U o = U o -U ass /U o 58% This is an unacceptable error; hence we will have to make some adjustments: Since the tube and shell side velocities are so small, we will have to increase the number of tube passes from 4 to 8 passes. This will increase the heat transfer coefficient; hence will use a new assumed overall heat transfer coefficient of 300 W/m².C. New Overall Heat Transfer Coefficient, U ass (W/m².K) New Heat Transfer Area, A (m²) Number of Tube Passes 8 K Table 12.4, p. 649, Coulson, Richardson & n Sinnot, 2005 Table 5: Tube Length and Shell Diameter Selection 2 L t (m) A t (m²) N t N p A p (m²) u t (m/s) D b (m) L c (m) D s (m) L/D

10 Team A Equipment Type Heat Exchanger Project Equipment Design Equipment Name Cold Stabilisation Heat Exchanger Design By Aaliyah Hoosenally Equipment Number HX-01 Date 21/08/2008 Page 7 of 10 Tube Side HTC Tube ID d i (m) Re = ρutd i /μ Pr = Cpμ/k L/d i 259 j h Nu = j h RePr 1/ h t =Nuk/d i (W/m².C) Shell Side HTC Tube Pitch p t = 1.25d o Baffle Spacing, l B =0.2D s (m) Cross Sectional Area, A s (m²) Equivalent Diameter, D e (m) Volumetric Flow Rate (m³/s) Shell Side Velocity, u s (m/s) Re = ρu s D e /μ Pr = Cpμ/k Baffle Cut % 25 j h Nu = j h RePr 1/ h s =Nuk/D e (W/m².C) Overall Coefficient Tube k w (W/m.C ) 16 h od (W/m².C) 3000 h id (W/m².C) /U o (m².c/w) U o (W/m².C) Error in U o = U o -U ass /U o -16% 8

11 Team A Equipment Type Heat Exchanger Project Equipment Design Equipment Name Cold Stabilisation Heat Exchanger Design By Aaliyah Hoosenally Equipment Number HX-01 Date 21/08/2008 Page 8 of 10 This error is acceptable so we can now check the tube and shell side pressure drops: The equation for the tube side pressure drop is: (Equation 12.20, p. 667, Coulson, Richardson & Sinnot, 2005). For the shell side pressure drop: (Equation 12.26, p. 675, Coulson, Richardson & Sinnot, 2005). j f (tube) P t (kpa) j f (shell) P s (kpa) Figure 12.24, p.668, Coulson, Richardson & Sinnot, 2005 Figure 12.30, p. 674, Coulson, Richardson & Sinnot, 2005 Both these pressure drops are low but acceptable if the nozzles are assumed to have a further pressure drop of 10kPa. The tube OD could be decreased further, or the number of passes increased further, to increase fluid velocity, but this would make it extremely difficult to clean the tubes thoroughly or to fit the tube passes into a fixed tube exchanger. Ease of cleaning is important in this winery, due to the frequent changes between grape types. The nozzle and flange size can now be selected for the heat exchanger by estimating the optimal diameter of a nozzle for each inlet and outlet using the following equation: 9

12 Team A Equipment Type Heat Exchanger Project Equipment Design Equipment Name Cold Stabilisation Heat Exchanger Design By Aaliyah Hoosenally Equipment Number HX-01 Date 21/08/2008 Page 9 of 10 Flanges & Nozzles Tube Inlet Tube Outlet Shell Inlet Shell Outlet Mass Flowrate, G (kg/s) Density, ρ (kg/m³) Optimal Diameter, D opt (mm) Nominal Diameter, DN (mm) Nozzle Outer Diameter (mm) Inner Diameter (mm) Flange Size Flange OD (mm) (Nozzle Schedule 10) White Wine: Using the overall heat transfer coefficient and heat transfer area of the heat exchanger that has been design to cool the racked red wine from 25 C to 15 C, it is possible to find out what the output temperature of the shell and tube fluid will be when the heat exchanger is used with white wine: Physical Properties: Table 6: Racked White Wine Physical Properties Racked White Wine Inlet Outlet Mean Temperature ( C) Cp (kj/kg. C) k (W/m. C) ρ (kg/m³) μ (mpa.s) mass flow rate (kg/s) Table 7: Stabilised White Wine Physical Properties Stabilised White Wine Inlet Outlet Mean Temperature ( C) Cp (kj/kg. C) k (W/m. C) ρ (kg/m³) μ (mpa.s) mass flow rate (kg/s) (Table 5.2, p. 92, Rankine, 2004) 10

13 Team A Equipment Type Heat Exchanger Project Equipment Design Equipment Name Cold Stabilisation Heat Exchanger Design By Aaliyah Hoosenally Equipment Number HX-01 Date 21/08/2008 Page 10 of 10 It can be seen from the above tables that the racked white wine exits the heat exchanger at 8.9 C while the stabilised white wine is heated up to 6.1 C. This was calculated using the solver function on excel, solving for the racked white wine outlet temperature which gave the previously calculated final heat exchange area, using the final calculated overall heat transfer coefficient. 11

14 Team A Equipment Type Filter Project Equipment Design Equipment Name Plate and Frame Filter Design By Aaliyah Hoosenally Equipment Number FLTR-01 Date 21/08/2008 Page 1 of Skin Separation/Plate and Frame Filter FLTR-01 The Plate and Frame filter is used in two separate processes in the winery. It is first used as a Skin Separation Filter for white wine, to remove any remaining (large) solids from the free run and press fraction before fermentation. It is then reused later on in the process to re-filter the wine before it is membrane filtered. At this stage (clarification), any remaining particles larger than 0.3μm are removed. The following information was taken from This filter has been designed based on the KAPPA-5 40x40 Plate and Frame Filter. Table 8: Skin Separation/Plate and Frame Filter FLTR-01 Properties Process Skin Separation Clarification Recommended Flow Rate (litres/hour.m²) Differential Pressure (kpa) Minimum Gauge Exit Pressure Required (kpa) Minimum Required Gauge Inlet Pressure (kpa) Filter Sheet size 40x40 40x40 Filter Sheet Area (m 2 ) Maximum Number of Plates Maximum Total Filter Area (m²) Maximum Actual Flow Rate (litres/hour) Approx. Total Volume to be Filtered (litres) Total Time to be Filtered (hours) Example of Calculations for Skin Separation Filter: Minimum Required Gauge Inlet Pressure (kpa) = Differential Pressure + Minimum Gauge Exit Pressure Required = = Maximum Total Filter Area (m 2 ) = Filter Sheet Area (m 2 ) x Maximum Number of Plates = 0.16 x 40 = 6.4 Maximum Flow Rate (litres/hour) = Recommended Flow Rate (litres/hour.m²) x Maximum Total Filter Area (m 2 ) = 1500 x 6.4 = 9600 Total Time to be Filtered (hours) = Approx. Total Volume to be Filtered (litres) / Maximum Flow Rate (litres/hour) = / 9600 =

15 Team A Equipment Type Filter Project Equipment Design Equipment Name Plate and Frame Filter Design By Aaliyah Hoosenally Equipment Number FLTR-01 Date 21/08/2008 Page 2 of 2 Clarification: Minimum Required Gauge Inlet Pressure (kpa) = Maximum Total Filter Area (m 2 ) = 6.4 Maximum Flow Rate (litres/hour) = 3200 Total Time to be Filtered (hours) =

16 Team A Equipment Type Filter Project Equipment Design Equipment Name Membrane Filter Design By Aaliyah Hoosenally Equipment Number FLTR-02 Date 21/08/2008 Page 1 of Membrane Filter FLTR-02 Membrane filters are used as the last step of clarification to ensure microbial stability. The filter size of the Absolute PES Cartridge Filter that has been chosen to membrane filter the wine before bottling is PES 0.45, as it has a small enough pore size to remove (nearly) all yeast and bacteria from wine it has % efficiency. The following information was taken from Table 9: Membrane Filter FLTR-02 Properties Membrane Filter type Absolute PES Cartridge Filter Pore Size (microns) 0.45 Flow for 10" cartridge (0.7m²) (GPM/psid) 4.1 Flow for 10" cartridge (0.7m²) (litres per minute / kpad) Wine/Beer Maximum Operating Differential Pressure (psid) 30 Wine Maximum Operating Differential Pressure (kpad) ph 1 to 13 Maximum Working temperature ( F) 150 Maximum Flow Rate (GPM) at 30 psid 123 Maximum Flow Rate (litres/minute) at 207 kpad Actual Approximate Flow Rate out of Ageing (litres/minute) 450 Volume to be Filtered per type of wine (litres) Total Time for Membrane Filtration (hours) Maximum Flow for 10" cartridge (0.7m²) (litres per minute / kpad) = Maximum Flow for 10" cartridge (0.7m²) (GPM/psid) x (psid/gpm x litres/minute) = 2.25 Wine Maximum Operating Differential Pressure (kpad) = Wine/Beer Maximum Operating Differential Pressure (psid) x (kpa/psi) = Maximum Flow Rate (GPM) = Maximum Flow for 10" cartridge (0.7m²) (GPM/psid) x Wine/Beer Maximum Operating Differential Pressure (psid) = 123 Maximum Flow Rate (litres/minute) = Maximum Flow for 10" cartridge (0.7m²) (litres per minute / kpad) x Wine Maximum Operating Differential Pressure (kpad) = Total Time for Membrane Filtration (hours) = Volume to be Filtered per type of wine (litres) / Actual Approximate Flow Rate out of Ageing (litres/minute) /60 (minutes/hour) =

17 Team A Equipment Type Filter Project Equipment Design Equipment Name Water Filter Design By Aaliyah Hoosenally Equipment Number FLTR-03 Checked By Andrew Plavina PFD Location CHPR4401-A-0106 Date 21/08/2008 Page 1 of Water Filter FLTR-03 The Absolute PES Cartridge Filter with a PES 0.22 pore size will be utilised to produce sterile water, which will be used for the final cleaning rinse over equipment. The following information was taken from Table 10: Water Filter FLTR-03 Properties Membrane Filter type Absolute PES Cartridge Filter Pore Size (microns) 0.22 Flow for 10" cartridge (0.7m²) (GPM/psid) 3.2 Flow for 10" cartridge (0.7m²) (litres per minute / kpad) Wine/Beer Maximum Operating Differential Pressure (psid) 30 Wine Maximum Operating Differential Pressure (kpad) ph 2 to 13 Maximum Working temperature ( F) 150 Maximum Flow Rate (GPM) at 30 psid 96 Maximum Flow Rate (litres/minute) at 207 kpad Actual Approximate Flow Rate (litres/minute) Volume to be Filtered (litres) Total Time for Membrane Filtration (hours) 0.92 Maximum Flow for 10" cartridge (0.7m²) (litres per minute / kpad) = Maximum Flow for 10" cartridge (0.7m²) (GPM/psid) x (psid/GPM x litres/minute) = 1.76 Wine Maximum Operating Differential Pressure (kpad) = Wine/Beer Maximum Operating Differential Pressure (psid) x (kpa/psi) = Maximum Flow Rate (GPM) = Maximum Flow for 10" cartridge (0.7m²) (GPM/psid) x Wine/Beer Maximum Operating Differential Pressure (psid) = 96 Maximum Flow Rate (litres/minute) = Maximum Flow for 10" cartridge (0.7m²) (litres per minute / kpad) x Wine Maximum Operating Differential Pressure (kpad) = Total Time for Membrane Filtration (hours) = Volume to be Filtered (litres) / Actual Approximate Flow Rate (litres/minute) /60 (minutes/hour) =

18 Team A Equipment Type Barrel Project Equipment Design Equipment Name Ageing in Barrels Design By Aaliyah Hoosenally Equipment Number BRL-01 Date 21/08/2008 Page 1 of Aging in Barrels BRL-01 An example calculation will be shown in detail for Chardonnay: Total grapes arriving (tonnes) = 80 Wine to Ageing (tones/5 tonnes grapes input into Crusher Destemmer) = Note. See Stream and Mass Balance Table in Volume 2 Supplement, PFD Location: CHPR4401-A % Wine to Ageing = Wine to Ageing (tones/5 tonnes grapes input into Crusher Destemmer) / 5 (tonnes) x 100 = 43 Total Wine at Ageing (tonnes) = % Wine to Ageing x Total grapes arriving (tonnes) / 100 = Temperature of Wine at Ageing = 20 C Density of Wine at Ageing (kg/m³) = 975 (Table 5.2, p. 92, Rankine) Total Wine at Ageing (litres) = Total Wine at Ageing (tonnes) x 1000 (kg/tonne) x 1000 (litres/m³) / Density of Wine at Ageing (kg/m³) = Bordeaux Barrel Volume (litres) = 225 Number of Barrels Required = Total Wine at Ageing (litres) / Bordeaux Barrel Volume (litres) = ~ 156 barrels required Sauvignon Blanc: Total Grapes (tonnes) 80 Wine to Ageing (tonnes/5 tonnes grapes) % Wine into Ageing 43% Total Wine (tonnes) Density (kg/m 3 ) 975 Total Wine (litres) Barrel Volume (litres) 225 Number of Barrels Required 156 This gives a total of 312 barrels of white wine. 16

19 Team A Equipment Type Barrel Project Equipment Design Equipment Name Ageing in Barrels Design By Aaliyah Hoosenally Equipment Number BRL-01 Date 21/08/2008 Page 2 of 2 Shiraz: Total Grapes (tonnes) 65 Red Wine to Ageing (tonnes/5 tonnes grapes) % Red Wine to Ageing 51% Total Red Wine (tonnes) Density (kg/m 3 ) 975 Total Wine (litres) Barrel Volume (litres) 225 Number of Barrels Required 151 Cabernet Sauvignon: Total Grapes (tonnes) 120 Red Wine to Ageing (tonnes/5 tonnes grapes) % Red Wine to Ageing 51% Total Red Wine (tonnes) Density (kg/m 3 ) 975 Total Wine (litres) Barrel Volume (litres) 225 Number of Barrels Required 279 This gives a total of 430 barrels of red wine. The total number of barrels required = = 742 barrels. 17

20 Team A Equipment Type Heater Project Equipment Design Equipment Name Boiler Design By Aaliyah Hoosenally Equipment Number HTR-01 Checked By Andrew Plavina PFD Location CHPR4401-A-0106 Date 21/08/2008 Page 1 of Boiler HTR-01 The boiler will be used to heat water in order to produce a 5% hot caustic solution that is 80 C for cleaning. To find a suitable boiler, we must first find the power required to do this: Water Flow Rate (L/minute) = 100 Water Flow Rate (m³/s) = Water Flow Rate (L/minute) / 1000 (L/m³) / 60 (seconds/minute) = Table 11: Physical Properties of Water for Hot Caustic Solution Boiler In Out Mean Temperature ( C) ρ (kg/m3) Cp (kj/kg.k) Mass Flow Rate In (kg/s) = Water Flow Rate (m³/s) x ρ in (kg/m3) = Required Duty (kw) = Mass Flow Rate In (kg/s) x Cp mean (kj/kg.k) x (T out ( C) T in ( C)) = Available sizes include: 30, , 160 and 500 kw (TCG Boiler Hire Brochure, Hence the closest size will be 500 kw. 18

21 CHPR4402 Chemical Engineering Design Project The University of Western Australia 2. DETAILED DESIGN CALCULATIONS: HX-01 Aaliyah Hoosenally

22 Project Detailed Design Equipment Type Heat Exchanger Design By Aaliyah Hoosenally Equipment Name Cold Stabilisation Heat Exchanger Date 03/09/2008 Equipment Number HX-01 Location CHPR4401-A-0102 CHPR4401-A-0103 Page 1 of Basic Heat Exchanger Design See Section 1.1 for basic heat exchanger design Tubesheet Detailed Design Using RCB-7.132, p. 39, TEMA, 1999, we can calculate the effective tubesheet thickness needed in order to resist bending stresses: The mean ligament efficiency, η, is calculated using the following equation: Stress in Tension, S (psi) Table 3.3.1(B), AS 1210, 1997 Shell ID, D s (inches) Mean Ligament Efficiency, η Effective Design Pressure, P (psi) See later for calculation Correction Factor, F 0.8 Figure RCB-7.132, p. 40, TEMA, 1999 Effective Tubesheet Thickness, T (inches) Minimum Tubesheet Thickness (inches) RCB-7.13, C-7.131, p. 38, TEMA, 1999 Actual Tubesheet Thickness (inches) 1 Actual Tubesheet Thickness (m) Tubesheet Type Supported As fixed tube exchanger We must also check if shear stresses are controlling, in which case a different formula must be used to calculate effective tubesheet thickness. Shear will not control when: (RCB-7.133, p. 43, TEMA, 1999). P/S (1 - d o /pitch) Shear Controlling? NO 20

23 Project Detailed Design Equipment Type Heat Exchanger Design By Aaliyah Hoosenally Equipment Name Cold Stabilisation Heat Exchanger Date 03/09/2008 Equipment Number HX-01 Location CHPR4401-A-0102 CHPR4401-A-0103 Page 2 of 7 To calculate the fixed tubesheet effective design pressure, P, the equivalent differential expansion pressure, effective shell side design pressure, and effective tube side design pressure must first be calculated. Refer to RCB to RCB-7.65, pp , TEMA, 1999, for equations: Table 12: Fixed Tubesheet Effective Pressure Calculation J (assuming no expansion joint needed) 1 See later for checking this. Elastic Modulus of Shell Material, E s (psi) 2.87E+07 Table 3.3.7, p.84, Elastic Modulus of Tube Material, E t (psi) 2.85E+07 AS 1210, 1997 Elastic Modulus of Tubesheet, E (psi) 2.86E+07 Shell Wall Thickness, t s (inches) Tube Wall Thickness, t t (inches) Differential Thermal Growth, L (inches) 0 Tube Length b/w outer faces, L t (inches) Tube Length b/w inner faces, L (inches) Tubesheet Thickness Used, T (inches) 1 Shell OD, D o (inches) 14.0 Tube OD, d o (inches) 0.5 Number of tubes in shell, N 200 Correction Factor, F 0.8 Shell ID, D s (inches) Tube and shell both constructed of Stainless Steel 316 Figure RCB-7.132, p. 40, TEMA, 1999, K RCB-7.161, p. 48, TEMA, 1999 F q RCB-7.161, p. 48, TEMA, 1999, 1999 Differential Expansion Pressure, P d (psi) 0 RCB-7.161, p. 48, TEMA, 1999, 1999 Equivalent Bolting Pressure- tube side, P Bt (psi) 0 RCB-7.162, p. 49, TEMA, 1999, 1999 Equivalent Bolting Pressure- shell side, P BS (psi) 0 RCB-7.162, p. 49, TEMA, 1999 Shell Side Design Pressure, P s (psi) RCB-7.163, p. 50, TEMA, 1999 f s RCB-7.163, p. 50, TEMA, 1999 P s ' (psi) RCB-7.163, p. 50, TEMA, 1999 Effective Shell Side Design Pressure (psi) RCB-7.163, p. 50, TEMA, 1999 Tube Side Design Pressure, P t (psi) RCB-7.164, p. 51, TEMA, 1999 f t RCB-7.164, p. 51, TEMA, 1999 P t ' (psi) RCB-7.164, p. 51, TEMA, 1999 Effective Tube Side Design Pressure (psi) RCB-7.164, p. 51, TEMA, 1999 Fixed Tubesheet Effective Pressure, P (psi) RCB-7.165, p. 52, TEMA,

24 Project Detailed Design Equipment Type Heat Exchanger Design By Aaliyah Hoosenally Equipment Name Cold Stabilisation Heat Exchanger Date 03/09/2008 Equipment Number HX-01 Location CHPR4401-A-0102 CHPR4401-A-0103 Page 3 of 7 As a fixed tubesheet exchanger is being used, we must check whether shell expansion joints will be required to cope with any longitudinal stresses that might occur during the heat exchange. Refer to RCB-7.22 and RCB-7.23, pp , TEMA, 1999, for equations: Table 13: Shell Longitudinal Stress Calculation C s 0.5 Shell OD, D o (inches) Shell Wall Thickness, t s (inches) P 1 = P t - P t ' (psi) P s ' (psi) P s * = P 1 + P s ' (psi) Maximum Longitudinal Shell Stress, S s (psi) Allowable Stress in Tension, S (psi) RCB-7.22, p. 53, TEMA, 1999 Table 14: Tube Longitudinal Stress Calculation F q Shell ID, D s (inches) Number of Tubes, N 200 Tube Wall Thickness, t t (inches) Tube OD, d o (inches) 0.5 C t 0.5 P P P t * = P Maximum Longitudinal Tube Stress, S t (psi) Allowable Stress in Tension, S (psi) RCB-7.23, p. 54, TEMA, 1999 Hence, as both the shell and tube longitudinal stresses are well under the stress in tension of Stainless Steel 316 at the mean temperature, a shell expansion joint is not required. The tube-to-tubesheet joint load must also be calculated in order to check whether the maximum load that may occur is allowable. See RCB-7.25, p. 56, TEMA, 1999 for equations: 22

25 Project Detailed Design Equipment Type Heat Exchanger Design By Aaliyah Hoosenally Equipment Name Cold Stabilisation Heat Exchanger Date 03/09/2008 Equipment Number HX-01 Location CHPR4401-A-0102 CHPR4401-A-0103 Page 4 of 7 Table 15: Tube-to-Tubesheet Joint Loads F q P t * = P Shell OD, D o (inches) Number of Tubes, N 200 Maximum Effective Joint Load, W j (lbf) Maximum Allowable Joint Load (lbf) RCB-7.25, p. 56, TEMA, 1999 Hence the tube-to-tubesheet joint load is within an acceptable limit End Plate Design The ends of the shell will be bolted flat end covers (blind flanges) with a full faced gasket. The minimum thickness required is given by: (Equation 13.42, p. 818, Coulson, Richardson & Sinnot, 2005). Table 16: Flanged Plate Ends - Bolted Covered with Full Faced Gasket Design Constant, C p 0.4 Bolt Circle Diameter, D e (m) Design Pressure (N/mm 2 ) Design Tensile Stress (N/mm 2 ) 129 Required Plate Thickness (m) Actual Plate Thickness (m) p. 818, Coulson, Richardson & Sinnot, 2005 ND=350, Figure v, Table D, AS 2129, 2000 The bolt spacing of the flange must now be checked. The maximum bolt spacing for a flange with a full faced gasket is: ( , p. 190, AS 1210, 1997). 23

26 Project Detailed Design Equipment Type Heat Exchanger Design By Aaliyah Hoosenally Equipment Name Cold Stabilisation Heat Exchanger Date 03/09/2008 Equipment Number HX-01 Location CHPR4401-A-0102 CHPR4401-A-0103 Page 5 of 7 Table 17: Bolt Spacing Minimum Bolt Diameter (m) Nominal Diameter 350 Actual Bolt Diameter, d B (m) Flange Thickness, t f (m) Gasket Type Flat Metal - Stainless Steel Gasket Factor 6.5 Elastic Modulus of Flange Material (Steel), E (MPa) 1.96E+05 Maximum Bolt Spacing, max P b (m) RCB-11.1, C-11.1, p.77, TEMA, 1999 Figure v, Table D, AS 2129, 2000 Table (A), p. 205, AS 1210, 1999 Bolt Circle Diameter (m) Figure v, Table D, Actual Number of Bolts 12 AS 2129, Vessel Support Design The main sources of load to consider are 1. Pressure 2. Dead weight of vessel and contents 3. Wind 4. Earthquake 5. External Loads The longitudinal stresses on the shell have already been shown to not be an issue in comparison to the tensile strength of the stainless steel. Wind loads would not be an issue either as the vessel is small and horizontal, and will most likely be places indoors. The chances of an earthquake occurring in Western Australia are extremely low; hence seismic loads do not have to be considered either. External loads will be to a minimum. Hence, the only significant load that must be considered is the dad weight of the vessel and contents: The shell and tubes will be constructed out of stainless steel pipe, hence their volume (steel volume) can be calculated by: Where D 1 is the outer diameter of the shell or tube, and D 2 is the inner diameter. 24

27 Project Detailed Design Equipment Type Heat Exchanger Design By Aaliyah Hoosenally Equipment Name Cold Stabilisation Heat Exchanger Date 03/09/2008 Equipment Number HX-01 Location CHPR4401-A-0102 CHPR4401-A-0103 Page 6 of 7 Table 18: Shell Mass Calculation Stainless Steel 316 Density (kg/m³) 8000 Actual Shell OD, D o (m) Actual Shell ID, D s (m) Actual Shell Thickness (m) Shell Length, L s (m) Shell Volume (m³) Shell Mass (kg) Table 19: Tube Mass Calculation Stainless Steel 316 Density (kg/m³) 8000 Tube OD (m) Tube Thickness (m) Tube ID (m) Tube Length (m) Tube Volume (m³) Tube Mass (kg) Number of Tubes 200 Total Tube Mass (kg) Table 20: Liquid Mass Calculation Average Density (kg/m³) 977 Max Liquid Volume (m³) Max Liquid Mass (kg) The maximum liquid volume was calculated assuming the entire shell is filled with liquid. Table 21: Flange End Plate (Flat Ends) Mass Calculation Stainless Steel 316 Density (kg/m³) 8000 Blind Flange Diameter (m) Blind Flange Thickness (m) Blind Flange Volume (m³) Blind Flange Mass (kg) Number of Ends 2 Total End Mass (kg)

28 Project Detailed Design Equipment Type Heat Exchanger Design By Aaliyah Hoosenally Equipment Name Cold Stabilisation Heat Exchanger Date 03/09/2008 Equipment Number HX-01 Location CHPR4401-A-0102 CHPR4401-A-0103 Page 7 of 7 Table 22: Dead Weight of Vessel Calculation Shell Mass (kg) Max Liquid Mass (kg) Total End Mass (kg) Total Tube Mass (kg) Total Vessel Mass (kg) Sum of shell, liquid, tube and ends. Correction factor 1.08 Corrected Vessel Mass (kg) Taking into account any external fittings. Dead Weight of Vessel (kn) =9.81*Vessel Mass Figure (a), p. 847, Coulson, Richardson & Sinnot, 2005 can now be used to design saddle supports for the vessel (See Volume 2, Section 3, Chapter 3). 26