Pre-Heater

HX-2001
Design Description
Preheater is needed to raise the temperature of the liquid product from the gas absorber to
allow the separation of N-methylpyrrolidone and acetylene in the flash tank. A concentric double
pipe heat exchanger is used.
Data Assumptions:
1 hr operation
614.06 kJ/day heat duty (from energy balance)
The amount of liquid to be heated is 66559.28 kg/day (from material balance)
Design Requirements:
1. Shell Side
a. Inside Diameter
b. Outside Diameter
c. Shell Thickness
d. Head Thickness
2. Tube Side
a. Inside Diameter
b. Outside Diameter
c. Length
d. Tube Pitch
e. Baffle Cut
f. Baffle Spacing
g. Number of Tubes
3. Heat Transfer Area
4. Material of Construction
Design Calculations:
Given:
Steam:
Inlet temperature= 235C
Outlet temperature= 200C
Bulk temperature= (235+200)/2 C= 217.5C
Using ASPEN HYSYS Simulation Software,
At 217.5C,
 Properties
Density 0.44765 kg/m3
Specific heat capacity 1.9499 kJ/kg-K
Thermal conductivity 0.035887 W/m-K
Viscosity 1.7062x10-5 Pa-s
Fouling Factor 4500 W/m2-C

NMP-acetylene mixture:
Inlet temperature= 38C
Outlet temperature= 60C
Bulk temperature= (38+60)/2 C= 49C
Using ASPEN HYSYS Simulation Software,
At 45C,
Properties
Density 1005.29 kg/m3
Specific heat capacity 1.70199 kJ/kg-K
Thermal conductivity 0.12986 W/m-K
Viscosity 0.001285 Pa-s
Fouling Factor 5000 W/m2-C

Calculating LMTD (Logarithmic mean temperature difference)

2 1
=

2
1

(1 2 ) (2 1 )
=
( 2 )
1
(2 1 )
(235 60) (200 38)
=
(235 60)

(200 38)
= 168.42
The proposed design uses one shell pass with two tube passes, therefore:
1 2
=
2 1
200 235
=
38 60
 = 1.59
2 1
=
1 2
60 38
=
235 38
= 0.1117
Temperature correction factor (Ft):
1
2 + 1 ln(1 )
=
2 ( + 1 2 + 1
( 1)ln[ ]
2 ( + 1 + 2 + 1
1 0.1117
1.592 + 1 ln( )
1 (1.59)(0.1117)
=
2 0.1117(1.59 + 1 1.592 + 1
(1.59 1)ln[ ]
2 0.1117(1.59 + 1 + 1.592 + 1
= 0.995
(Ref. Eq. 12.5 Coulson and Richardsons Chemical Engineering Design Vol. 6, 4th Ed.)
True temperature difference:
=
= (0.995)(172.49)
= 171.63
Concentric Double Pipe Heat Exchanger
LASSM= 62.72 m
Length of Hairpin (Lh)= 6m
Inner Pipe Diameter = 1 in sched 40
OD = 1.32 in = 0.03353 m
ID = 1.049 in = 0.02664 m
Outer Pipe Diameter = 2 in sched 40
OD = 2.38 in = 0.06045 m
ID = 2.067 in = 0.0525 m
Inner Pipe Calculation
Equivalent Diameter (De) = Inside Diameter (Di) = 0.02664 m
2
( ) =
4

( ) = (0.02664)2
4
 ( ) = 0.000575 2

() =

0.7704 /
() =

1005.29 3 0.000575 2

() = 1.3328 /

() =


(0.02664 )(1.3328 )(1005.29 3 )

() =
0.001285
() = 27,777.1344

() =


(1.70199 )(1000 )(0.001285 )

() =
0.12986

() = 16.84
= (0.782 1.51)0.2
= [0.782ln(27,777.1344) 1.51]0.2
= 0.6879
2
(8)( 1000)(Pr)(1 + )3
() = 2 ( )0.14
0.5
1 + 23.7(8) ( 3 1)

( )0.14 = 1

0.6879 0.0525018 23
( )(27,777.1344 1000)(16.84)(1 +
() = 8 62.72 )
0.6879 2
1 + 23.7( 8 )0.5 (16.843 1)

() = 976.9906

() =


=


976.9906 0.12986
=
0.02664

= 4761.39
2
Outer Pipe Calculation
Equivalent Diameter (De) = Di Outside Pipe - Do Inner Pipe
= 0.052502 m 0.033528 m
= 0.018974 m
2
( ) = ( 2
4

( ) = [(0.052502)2 (0.033528)2 ]
4
( ) = 0.001282 2

() =

0.09558 /
() =

0.44765 3 0.001282 2

() = 166.5484 /

() =


(0.018974 )(166.5483 )(0.44765 3 )

() =
1.7062105
() = 82,910.1994

() =


(1.9499 )(1000 )(1.7062105 )

() =
0.035887

() = 0.92705
 = (0.782 1.51)0.2
= [0.782ln(57.95) 1.51]0.2
= 0.9031
2
(8)( 1000)(Pr)(1 + )3
() = 2 ( )0.14
0.5
1 + 23.7(8) ( 3 1)

( )0.14 = 1

0.9031 0.018974 23
()(82,910.1994 1000)(0.92705)(1 +
() = 8 46.2 )
0.9031 2
1 + 23.7( 8 )0.5 (0.927053 1)

() = 14,105.72

() =


=


14,105.72 0.12986
=
0.035887

= 51,042.68
2
Overall Coefficient Calculations
The thermal conductivity of Carbon Steel Kst = 45 W/m-K.
Taking the fouling coefficients from Table 12.2 of Coulson and Richardsons Chemical Engineering
Design Vol. 6, 4th Ed.; acetylene-NMP (organic liquid) is 5000 W/m2-K and steam (oil free) is 8000
W/m2-K.

1 1 1 ln( ) 1 1
= + + + ( )+ ( )
2
0.0525
1 1 1 0.0525 ln(0.02664) 0.0525 1 0.0525 1
= + + + ( )+ ( )
51,042.68 6000 2 (45) 0.02664 5000 0.02664 4761.39

= 613.27
2
Hairpin Calculations
 =

=

664060
=
613.27 171.63
= 6.309 2
=

=

6.309 2
=
0.033528
= 59.90
= 62.72


( ) =
2
62.72
( ) =
2(6)
( ) = 5.23 6
Pressure Drop Calculations
= 0.3673()0.2314 ( )
2
=
7.5 1012 ( )0.14

Where,
0.14
( ) =1

:
=

= ( ) 2

Pressure Drop due to Direction Changes
For Turbulent Flow,
2
= 1.61013 (2 1)

= +
Inner Pipe
= 0.3673()0.2314
= 0.3673(27,777.1344)0.2314
= 0.0344
2
=
7.5 1012 ( )0.14

3.28 0.7704 2.2 1 2

(0.0344)(62.72 1 )( )2
0.000575 1 10.7639 2
2
=
3.28
7.5 1012 0.0266446 1 (1.005)(1)

= 8.0562 107

13
2
= 1.610 (2 1)

0.7704 2.2 1 2 2
( 2)
0.000575 2 1 10.7639
= 1.61013 (2(6) 1)
1.005
= 1.3133107
= +
= 8.0562 107 + 1.3133107
= 9.3695 107
Annular Space
= 0.3673()0.2314
= 0.3673(82,910.1994)0.2314
= 0.0267
2
=
7.5 1012 ( )0.14

 3.28 0.09558 2.2 1 2
(0.0267)(62.72 1 )( )2
0.001282 2 1 10.7639 2
=
3.28
7.5 1012 0.018974 1 (0.996)(1)

= 2.7435 109
2
= 1.61013 (2 1)

0.09558 2.2 1 2 2
(
2 1 2)
0.001282 10.7639
= 1.61013 (2(6) 1)
0.996
= 4.10311010
= +
= 2.7435 109 + 4.10311010
= 3.1538 109
Heat Exchanger Effectiveness

= 0.09558 /( 4.186 )


= 0.4001


= 0.7704 /( 1.9499 )


= 1.5022


=

0.4001
= = 0.2663
1.5022

=

613.27
( 1000 )(6.309)
=
0.4001
= 9.6704
 1 [(1)]
=
1 [(1)]
1 [9.6704(10.2633)]
=
1 0.2633 [9.6704(10.2633)]
= 0.9994 99.94%
MECHANICAL DESIGN:
Basis:
As per Engineering Standard for Process Design (Standard Code IPS-PR-880)
1. For fluid inlet (Gas or Liquid): v2 < 1000
2. For gas outlet: v2 < 3600
3. For liquid outlet: v= 1 m/s
Inside Tube

Density (kg/m3) 1005.29

2 (kg/ms2) 1000

1000 kg/m 2
= = 0.9974 m/s
1005.29 kg/3

Feed Flow Rate= 0.5079 kg/s

0.7704 kg/s
= = = 7.6834 104 2
(1005.29 kg/3 )( 0.9974 m)
s
4 4(7.6834 104 2 )
= = = 0.03128 31.28

Dn= 1.2314 in therefore 1 -inch Nominal Pipe Size Schedule 40 steel

Inside Tube

Density (kg/m3) 0.44765

2 (kg/ms2) 1000

1000 kg/m 2
= = 47.2640 m/s
0.44765 kg/3

Feed Flow Rate= 0.5079 kg/s

 0.09558 kg/s
= = = 4.5175 103 2
(0.44765 kg/3 )( 47.2640 m)
s
4 4(4.5175 103 2 )
= = = 0.07584 75.48

Dn= 2.9859 in therefore 3 -inch Nominal Pipe Size Schedule 40 steel