DESIGN OF SHELL AND TUBE HEAT EXCHANGER UTILIZING FLUE GASES FROM CALCINERS (Second review)

Internal Guide :Prof. Sunil .A.S

APME , Govt Engg College, Thrissur

External Guide: M.K Prabhakaran

Deputy Chief Engineer (Mechanical), TTPL , Trivandrum

VISHNU.R REG No: ETAKCCT016 M-TECH(ICTM) ROLL NO: 16 GEC THRISSUR

COMPANY PROFILE
Travancore Titanium Products Ltd (TTPL), is the leading manufacturer of anatase grade titanium dioxide in India. The company was incorporated in 1946 at Thiruvananthapuram. The main product is pigment grade titanium dioxide which is extracted from ilmenite. The only industry in Kerala producing TiO2 by sulphate process. Plant capacity : 60 tonnes per day

Production Layout

Concentration
Overhead Tank Vapor + Liquid

Vapor Separator Drum

Liquor From Concentration feed tank 140 gpl Ti02

Precipitation

Lute
Vapor in

Conc. Measuring Tank

190 gpl Ti02

Concentrator
Steam from boiler

Preheater
Vapor in

Condenser
Cooling Water
Vapor Recycled Steam out

GENERAL DESIGN CONSIDERATIONS

The general design considerations are categorized as
Selection of flow path Construction codes Tube bundle vibration Testing / Performance Testing

Selection of Flow Path

Tube side fluid :
More corrosive Dirtier at higher pressures.

Shell Side Fluid :

Fluid of high viscosity Gas.

Construction : Least expensive is alloy

steel with the tube side and carbon steel on the shell side

Cleaning of inside of tubes is readily done than the exterior surfaces. For gauge pressures in excess of 2068 kPa for one of the fluids, the less expensive construction has the high-pressure fluid in the tubes. Heat-exchanger shutdowns are most often caused by fouling, corrosion , and erosion.

Construction Codes
Shell and Tube Heat Exchangers for General Refinery Services, API Standard 660, 4th ed., 1982, is published by the American Petroleum Institute to supplement both the TEMA Standards and the ASME Code.
Standards of Tubular Exchanger Manufacturers Association, 6th ed., 1978 (commonly referred to as the TEMA Standards), serve to supplement and define the ASME Code for all shell-and-tube-type heatexchanger applications. TEMA Class R design is for the generally severe requirements of petroleum and related processing applications. Equipment fabricated in accordance with these standards is designed for safety and durability under the rigorous service and maintenance conditions in such applications.

 TEMA Class C design is for the generally moderate requirements of commercial and general process applications, while TEMA Class B is for chemical process service. Design pressures and temperatures for exchangers usually are specified with a margin of safety beyond the conditions expected in service. Design pressure is generally about 172 kPa (25 lbf/in2) greater than the maximum expected during operation or at pump shutoff. Design temperature is commonly 14C (25F) greater than the maximum temperature in service.

Tube Bundle Vibration

When plate baffled heat exchangers are designed for higher flow rates and pressure drops , tube vibrations are found and cause considerable damage to the equipment in service. The most effective method of dealing with this problem is the avoidance of cross flow by use of tube support baffles which promote only longitudinal flow.

Mechanism of Tube Vibration

Vortex Shedding
The vortex-shedding frequency of the fluid in cross-flow over the tubes may coincide with a natural frequency of the tubes and excite large resonant vibration amplitudes.

Pressure Fluctuations
Turbulent pressure fluctuations which develop in the wake of a cylinder or are carried to the cylinder from upstream may provide a potential mechanism for tube vibration. The tubes respond to the portion of the energy spectrum that is close to their natural frequency.

Fluid Elastic Coupling

Fluid flowing over tubes causes them to vibrate with a whirling motion. The mechanism of fluidelastic coupling occurs when a critical velocity is exceeded and the vibration then becomes self-excited and grows in amplitude. This mechanism frequently occurs in process heat exchangers which suffer vibration damage.

Acoustic Coupling
When the shell-side fluid is a lowdensity gas, acoustic resonance or coupling develops when the standing waves in the shell are in phase with vortex shedding from the tubes. The standing waves are perpendicular to the axis of the tubes and to the direction of crossflow. Damage to the tubes is rare. However, the noise can be extremely painful.

Testing / Performance testing

Hydrostatic testing for emphasizing visual examination of tube ends. Leaking tubes.

Internal-floating-head exchanger

Constructional Details
Fixed Tube Sheet Heat Exchangers
Often used than any other type. This construction requires tube sheet materials welded with the shell. Any number of tube passes. Shell side passes can be one to more. Shells with more than two shell passes are very rare. Clearance between baffles and shell.

 The edge distance between the outer tube limit (OTL) and the baffle diameter must be sufficient to prevent vibration of the tubes from breaking through the baffle holes.

Differential expansion between the shell and the tubes can develop because of differences in length caused by thermal expansion.

Various types of expansion joints are used to eliminate excessive stresses caused by expansion. The need for an expansion joint is a function of both the amount of differential expansion and the cycling conditions to be expected during operation.

Expansion joints

Tube Side Construction

Tube side header The bonnet Channel Special high pressure closures Tube side passes Tubes Manufacturing tolerances Tube joints Rolled tube joints Welded tube joints Double tube sheet joints

Shell side Construction

Shell sizes
Heat-exchanger shells are generally made from standardwall steel pipe in sizes up to 305-mm (12-in) diameter.

Shell Side arrangements

One shell pass Split flow Double Split flow Divided flow

Pitch
It is the shortest distance between two adjacent tubes for a pattern.

Design Approach
The design approach of a shell and tube heat exchanger for this thesis work has been subdivided into two as follows : Service design Mechanical design Service design involves Calculation of heat duty Estimation of U LMTD Estimation of Total heat transfer area Decide Exchanger layout Mechanical design involves the design of individual components of a STHE.

Service Design
Calculation of Mass flow rates of flue gases: From the data collected such as manometer reading , temperatures , cd , area and further using temperature relations and chemical properties of flue gases(eg: Specific heat) in Perrys CEHB , The mass flow rate for exhaust gases was found to be 3.729 kg/s Heat duty of flue gas : 575.64kW

 Mass flow rate of titanium di oxide:

From the calculated heat duty the mass flow rate of the titanium di oxide was found to be 1.64 kg/s.

To check the design feasibility :

The aim is to evaporate the water from the titanium di oxide mixture hence increase the specific gravity from 1.64 to 1.75 Analytically it was estimated that 0.14467 liters of water is to be evaporated from 1 liter of Ti02 to reach the aim. Also the heat required to vaporize the water content was around 351.12kW , which is way lower than the actual heat duty of the flue gas(575.64) . Hence the design was confirmed feasible.

 Log Mean Temperature Difference LMTD= 156.33oC Total number of tubes needed : From the above collected data , and selecting OD 12 BWG tubes and selecting one inch triangular pitch( from TEMA hand book) , the total number of tubes required is 1503. The tube side heat transfer coefficient is 68.592 W/m2 K The shell side heat transfer coefficient is 10.366 W/m2 K

The overall heat transfer coefficient (Uo) = 8.65 Wm2K Heat transfer area requires : 459.7m2 The length of tubes : 6.096m Actual heat transfer area : 548.06m2

Mechanical Design (MS)

Shell side Diameter= 1.067 m Design pressure = 1.05atm Design Temperature = 97oC Shell thickness = 5mm Nozzle thickness = 5mm Nozzle diameter = 125mm
Segmental baffles 25% cut transverse baffles are used Spacing = 400mm Thickness = 6mm Tube side design Thickness of tubes = 3.404mm Tube length : 6.09mm Tube sheet thickness = 11.04mm Channel(CS) = 10.55mm Channel cover= 2mm

Designed Heat Exchanger Specifications

Shell Side Material : Mild Steel Corrosion allowance : 2mm Service fluid : Flue gas No. of passes : 1 Shell diameter : 1067mm Inlet temperature : 300oC Outlet temperature : 160oC Segmental baffles : 25 % cut Shell thickness : 5mm Nozzle diameter : 125mm Nozzle thickness : 5mm Baffle spacing : 400mm Thickness of baffles : 6mm Tube Side Service fluid : Ti02 pulp No. of passes : 1 Outside diameter : 19.05mm Inside diameter : 15.64 Wall thickness : 3.404mm Tube length : 6.096m Pitch (equilateral triangle) : 76mm Number of tubes : 1503 Inlet temperature : 30oC Outlet temperature : 30oC Nozzle thickness : 5mm

Possible flaws associated with analytical calculations

Due to the large effect from other parameters such as design pressure/corrosion allowance, baffle cuts, seal strips, and so on, tube counts , tube passes etc. are to be used as estimates only. Exact tube counts are part of the design package of most reputable exchanger design software and are normally used for the final design. Some of the prominent STHE design softwares are Aspen One (Aspen Engineering Suite) Aspen HYSYS/HTFS/HTFS+ (Aspen Engineering Suite), used mostly in Petrochemical Industries. Chemcad 6/CC-Therm from Chemstations Inc. Comsol multi-physics from Comsol Inc.

ChemCad 6 / CC Therm Interface

Chemcad CC-Therm Design Window

Flow sheet Heat Curve

Proposed Block Diagrams For New Concentration Unit

Draught Fan TiO2 In
Electro Static Precipitator

Fume Stack

Concentrator

Cooling Tower Flue gas out

Flue gas in
Rotary Calciner

TiO2 Out

Combustion Chamber

Secondary blower Primary blower

Atomizing Blower

Proposed Block Diagram of New Concentration Unit

Flue Gas Out

Overhead Tank Shell and Tube Heat Exchanger (Concentrator) Conc. TiO2 Vapor Separator Concentration Measuring tank

Aqueous TiO2

Flue Gas in Condenser

What else to be calculated ?

Final design using Chemcad CC-therm including rating of HE. Cost of proposed concentrator(STHE). Cost of replaced equipment in concentration process. New layout area.

REFERENCES
Perrys Chemical Engineers Handbook , 1999 , The McGraw Hills Companies Inc. Standards of The Tubular Exchanger Manufacturers Association , 1999 , ninth edition. Design and Rating of Shell and Tube Heat Exchangers using Chemcad , John Edwards , MNL 032A Issued 29 August 08, Prepared by J.E. Edwards of P & I Design Ltd, Teesside, UK.

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