PERFORMANCE ANALYSIS ON A SHELL AND TUBE

HEAT EXCHANGER
(A Case Study of Crude Distillation Unit 1 (KRPC), Shell and tube Heat Exchanger)

A
Technical Report

Presented To

The Chemical Engineering Department

By

Abubakar Bello Digijim

(05/05/02/022)

In Partial Fulfillment of the Requirement of the Course

CHE 490
(Industrial Training II)

University Of Maiduguri
Maiduguri

February, 2010.
 DEDICATION

I dedicate the work to the Almighty Allah and to my beloved parents for their
moral, disciplinary & financial support. May Almighty Allah (S.W.T) with his
bountiful mercy reward them abundantly with paradise, Ameen.

2
 ACKNOWLEGENMT

My profound gratitude goes to Almighty Allah for giving me strength & good
health throughout my industrial training, to my family for their support
encouragement, to Head of department Engr.Babagana Gutti for his advice and
orientation, to staff of chemical engineering department and also to all my class mates
for their help & assistance

ABSTRACT

3
 This investigation was carried out on crude/kerosene shell and tube heat
exchanger of the Crude Distillation Unit-I (K.R.P.C) to find the performance of the
heat exchanger by determining its effectiveness.
The calculations were carried out based on theories and method from past related
works. The physical properties of Kerosine and Crude oil and other parameters used
are given in appendix B.
The work was carried out by finding the inlet and outlet temperature of fluid
stream to the heat exchanger for a period of five days (14 to 18 November, 2009).
Charts and related formulae from literature were exploited to evaluate the
performance of the heat exchanger.
This investigation found the working efficiency to be 89.0%, U o = 254.91 W/m2
0
C and Q=1834.13 kW respectively. The heat exchanger is design to operate at 96 to
98% efficiency, comparing with working efficiency, it was concluded that the S&H
heat exchanger is operating below the designed standard.

TABLE OF CONTENT

4
TITLE......................................................................................................................1
DEDICATION........................................................................................................2
ACKNOWLEDGEMENT.....................................................................................3
ABSTRACT............................................................................................................4
TABLE OF CONTENT.........................................................................................5-6
LIST OF TABLES.................................................................................................7
LIST OF FIGURES...............................................................................................8
LIST OF NOTATIONS AND SYMBOLS...........................................................9
CHAPTER ONE...................................................................................................10
1.0 INTRODUCTION....................................................................................10
1.1 AIMS AND OBJECTIVES......................................................................11
CHAPTER TWO..................................................................................................12
2.0 LITERATURE REVIEW.........................................................................12
2.1 HEAT TRANSFER..................................................................................12
2.2 HEAT TRANSFER MECHANISM........................................................12
2.2.1 Convection.........................................................................................12
2.2.2 Conduction........................................................................................13
2.2.3 Radiation...........................................................................................13
2.3 HEAT TRANSFER EQUIPMENTS........................................................13
2.3.1 Types of Heat transfers......................................................................14
2.4 SHELL AND TUBE HEAT EXCHANGERS.........................................14
2.4.1 Details................................................................................................14-15
2.4.2 Exchanger types.................................................................................15-17
2.4.3 Dimensions........................................................................................17-18
2.4.4 Baffles................................................................................................18
2.4.5 Shell and Tube fluid Velocities..........................................................18
2.4.6 Stream Temperature..........................................................................18
2.4.7 Pressure drop....................................................................................19
2.5 FOULING IN HEAT EXCHANGERS......................................................19-21
2.6 SHELL AND TUBE HEAT EXCHANGER ANALYSIS.........................21
2.6.1 Log mean temperature difference.....................................................21-23
2.6.2 Film heat transfer coefficient............................................................23
2.6.3 Overall heat transfer coefficient.......................................................23-24
2.6.4 Heat transfer Area............................................................................24
2.6.5 Shell and Tube heat exchanger performance...................................24-25
2.7 SHELL AND TUBE HEAT EXCHANGER GENERAL DESIGN
CONSIDERATIONS.................................................................................25
2.7.1 Fluid allocation................................................................................25-26
2.8 PROBLEM SOLVING IN SHELL AND TUBE HEAT EXCHANGER......26
CHAPTER THREE............................................................................................27
3.1 MATERIALS AND METHOD..................................................................27
3.2 MATERIALS/EQUIPMENTS...................................................................27-28
3.3 METHOD....................................................................................................28-29
CHAPTER FOUR.............................................................................................30
4.0 RESULTS AND DISCUSSIONS OF RESULT.......................................30-31
4.1 DISCUSSION OF RESULT.....................................................................31-32

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CHAPTER FIVE...............................................................................................33
5.0 CONCLUSION AND RECOMMENDATION............................................33
5.1 CONCLUSION.............................................................................................33
5.2 RECOMMENDATION.................................................................................33
REFERENCE....................................................................................................34
APPENDIX (A)..................................................................................................35
CALCULATIONS..............................................................................................35-39
APPENDIX (B)..................................................................................................40-42

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 LIST OF TABLES

Table 2.3.1: Fouling coefficient, typical values for S&H heat exchangers……...............21
Table 4.1.1: Data obtain from investigation……………………………………….. 30
Table 4.1.2: Calculated values…………………………………………………….31
Table 4.1.3: Temperature of stream to and from the heat exchanger...……………….35
Table 4.1.4: Physical properties of Kerosine and Crude oil … ……………………....40

7
 LIST OF FIGURES
Figure 2.4.1 Baffle spacer and Tie rods……………………………………15
Figure 2.4.2 Internal floating head with clamp ring heat exchanger……….17
Figure 2.5.1 Temperature correction factor ……………………………….41
Figure 2.5.2 Tube-side heat-transfer factor ……………………………….42
Figure 2.6.3 Shell-side heat-transfer factor with segmental baffles ……….42

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 LIST OF NOTATION AND SYMBOLS

Q = heat transfer per unit time, W

U o = overall heat transfer coefficient, W/m2 0C
Ao = heat transfer area, m2
ΔT lm = log mean temperature difference, 0C

ΔT m =corrected log mean temperature difference, 0C

Ft = correction coefficient
Ff = fouling coefficient, m2 0C/W
G = mass flow rate of fluid, kg/s
Cp = specific heat capacity, kJ/kg 0C
Re = Reynolds number
Nu = Nusselt number
ρ = density of fluid, kg/m3

de = hydraulic mean diameter, m

Vp = volumetric flowrate, m3/s
up = channel velocity, m/s
μ = viscosity of fluid,
kf = thermal conductivity of fluid, W/m2 0C
ks = thermal conductivity solid, W/m2 0C
hp = film heat transfer coefficient, W/m2 0C
T ti= inlet temperature of Crude oil, 0C
T ¿= outlet temperature of Crude oil, 0C
T si= inlet temperature of kerosine, 0C
T so= outlet temperature of kerosine, 0C
η = effectiveness
LMTD = log mean temperature, 0C
S&H = Shell and Tube heat exchanger

9
 CHAPTER ONE

1.0 Introduction
In the process industries, the transfer of heat between two fluids is generally
done in heat exchangers. Heat exchanger is a device built for efficient heat transfer
from one fluid to another, whether the fluids are separated by a solid wall or tube so
that they never mix, or fluid are directly contacted. The transfer of heat is
accomplished from the hot fluid to the wall or tube surface by convection, through the
tube wall or plate by conduction, and then by conduction to the cold fluid.
Heat exchangers are of different types (see chapter two), but the more
common ones found in most process industries are the shell and tube, and plate heat
exchanger. Shell and Tube heat exchangers are the common type of exchangers found
in Crude distillation Unit 1 (CDU1) of Kaduna refining and petrochemical company
(KRPC). There are different types of shell and tube exchangers in the unit, such as the
Fixed head plate heat exchanger, the Floating head exchanger, U-Tube heat exchanger
e.t.c. Most of these exchangers especially the split- ring floating head exchangers are
for pre-heating the crude oil before going into the main distillation column.
The investigation in this report is focused on the crude/S.R Kerosine shell and
tube heat exchanger crude distillation unit 1 of KRPC (a split-ring floating head heat
exchanger). Problems associated to the S&H heat exchanger which are mostly due to
fouling are discussed. Fouling in the S&H heat exchanger may result to the following
problems;
- Increase in pressure drop in the unit
- Reduction of heat transfer rate
- Reduction in working efficiency
- Over-heating of the unit
- Reduction in pressure drop.
This research work provides a method of solving the above stated problems to achieve
the maximum working efficiency.

10
1.1 Aim and Objectives
The aim of this research work is to provide a theoretical method of assessing the
overall performance of the S&H heat exchanger to see if there is any drop in
performances, which may be caused as a result of fouling and how to solve the
problems if any.
This can be achieved by calculating the rate of heat transfer Q and
efficiency/effectiveness η , based on the present working condition of the S&H heat
exchanger. Hence comparing the values obtained to the design values of the heat
exchanger. Reduction in working efficiency means, de-scaling of the tubes surfaces
must be done.

11
 CHAPTER TWO

2.0 Literature Review

2.1 Heat transfer

The transfer of energy in the form of heat occurs in many chemical and other
types of processes. Heat transfer occurs because of a temperature difference driving
force and heat flows from the high to the low temperature region.
Heat transfer can be of steady or unsteady state. Steady state heat transfer is
one in which the temperature at any given point and the heat flux are always constant
with time while unsteady state heat transfer is one in which the temperature at any
given point in the system changes with time. The general equation that represents heat
transfer is given below;

(Rate of heat in) + (Rate of generation of heat) = (Rate of heat out) + (Rate of heat
accumulation) ……… 2.1-1

2.2 Mechanisms of heat transfer

Heat transfer may occur by any one or more of the three basic mechanism of
heat transfer i.e. conduction, convection and radiation.

2.2.1 Conduction
In conduction, heat can be conducted through solids, liquids and gases. The
heat is conducted by the transfer of energy of motion between adjacent molecules. In
gases the “hotter” molecules which have greater energy and motion impact energy to
the adjacent molecules at lower energy levels. This type of heat transfer is present to
some extent in all solids, gases or liquids in which the temperature gradient exists. In
conduction, energy can also be transfer by “free electrons” which is quite important in
metallic solid. Example of heat transfer mainly by conduction is heat transfer through
walls of exchangers or refrigerator. The transfer of heat by conduction also follows
the basic equation below and is written as Fourier’s law for heat conduction in fluids
or solids.

12
 qx dT
=−k .....................................................................................2.1−2
A dx

2.2.2 Convection
The transfer of heat by convection implies the transfer of heat by bulk
transport and mixing of macroscopic elements of warmer portions with cooler
portions of a gas or liquid. It also involves the energy exchange between a solid
surface and a fluid. A distinction must be made between forced convection heat
transfer, where a fluid is forced to flow part a solid surface by pump, fan, or other
mechanical means. And natural convection where warmer or cooler fluid next to the
solid surface causes a circulation because of density difference results from
temperature difference in the fluid. Example of heat transfer by convection is loss of
heat from a car radiator. Equation (2.2-3) represents heat transfer by convection.

q=hA ( T w −T f ) ........................................................................................2.1−3

2.2.3 Radiation
Radiation differ from heat transfer by conduction and convection in that, there
is no physical medium needed for its propagation. Radiation is the transfer of energy
through space by means of electromagnetic wave in much the same way as
electromagnetic light waves. The same law which governs the transfer of light
governs radiant heat transfer. Solids and liquids tend to absorb the radiation being
transfer through them, so radiation is important primarily in transfer through space or
gases.

2.3 Heat transfer equipment

The transfer of heat to and from process fluid is an essential part of most
chemical processes, these is normally carried out in heat exchangers. The word
“exchanger” really applied to all types of equipment in which heat is exchanged but is
often used specifically to denote equipment in which heat is exchanged between two
streams. Exchangers in which a process fluid is heated or cooled by a service stream

13
are referred to as heaters and coolers. If the process stream is vaporize; a re-boiler if
associated with distillation column; and an evaporator if used to concentrate a
solution. Exchangers can be classified as fired and unfired. The term fired is use for
exchangers heated by combustion gases such as boiler; other exchangers are referred
to as “unfired exchanger”.

2.3.1 Types of heat exchangers

The principal types of heat exchanger used in the chemical processes and
applied industries are listed below but only plate heat exchanger will be discussed in
this report.
 Double pipe exchanger
 Shell and tube exchanger
 Plate and frame exchanger
 Plate and fin exchanger
 Spiral heat exchanger
 Air cooled: coolers and condensers
 Direct contact: cooling and quenching
 Agitated vessels
 Fired heaters

2.4 Shell and Tube heat exchanger

2.4.1 DETAILS
The shell and tube exchanger is by far the most commonly used type of heat-
transfer equipment used in the chemical and allied industries. The advantages of this
type are:
1. The 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.

14
6. Well-established design procedures.
Essentially, a shell and tube exchanger consists of a bundle of tubes enclosed in a
cylindrical shell. The ends of the tubes are fitted into tube sheets, which separate the
shell-side and tube-side fluids. Baffles are provided in the shell to direct the fluid flow
and support the tubes. The assembly of baffles and tubes is held together by support
rods and spacers.
Figure2.4.1

Baffle spacers and tie rods

2.4.2 Exchanger types

The Floating head with clamp ring type of shell and tube exchanger is shown in
fig.2.3.2. The standard nomenclature used for shell and tube exchangers is given
below; the numbers refer to the features shown in Figures.2.3.2
Nomenclature
Part number
1. Shell
2. Shell cover
3. Floating-head cover
4. Floating-tube plate
5. Clamp ring

15
6. Fixed-tube sheet (tube plate)
7. Channel (end-box or header)
8. Channel cover
9. Branch (nozzle)
10. Tie rod and spacer
11. Cross baffle or tube-support plate
12. Impingement baffle
13. Longitudinal baffle
14. Support bracket
15. Floating-head support
16. Weir
17. Split ring
18. Tube
19. Tube bundle
20. Pass partition
21. Floating-head gland (packed gland)
22. Floating-head gland ring
23. Vent connection
24. Drain connection
25. Test connection
26. Expansion bellows
27. Lifting ring

The simplest and cheapest type of shell and tube exchanger is the fixed tube
sheet design. The main disadvantages of this type are that the tube bundle cannot be
removed for cleaning and there is no provision for differential expansion of the shell
and tubes. As the shell and tubes will be at different temperatures, and may be of
different materials, the differential expansion can be considerable and the use of this
type is limited to temperature differences up to about 80°C. Some provision for
expansion can be made by including an expansion loop in the shell, but their use is
limited to low shell pressure; up to about 8 bar. In the other types, only one end of the
tubes is fixed and the bundle can expand freely.

16
 The U-tube (U-bundle) type requires only one tube sheet and is cheaper than the
floating-head types; but is limited in use to relatively clean fluids as the tubes and
bundle are difficult to clean. It is also more difficult to replace a tube in this type.

Fig. 2.4.2 Internal floating head with clamp ring.

2.4.3 Dimensions
2.4.3a Tubes
Tube diameters in the range | in. (16 mm) to 2 in. (50 mm) are used. The smaller
diameters 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. Steel tubes for heat exchangers are covered by BS
3606 (metric sizes), the standards applicable to other materials are given in BS 3274.
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).

2.4.3b Shells

17
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.

2.4.4 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 single segmental baffle.

2.4.5 Shell and tube fluid velocities

High velocities will give high heat-transfer coefficients but also a high-pressure
drop. The velocity must be high enough to prevent any suspended solids settling, but
not so high as to cause erosion. High velocities will reduce fouling. Plastic inserts are
sometimes used to reduce erosion at the tube inlet. Typical design velocities are given
below:
Liquids
Tube-side, process fluids: 1 to 2 m/s, maximum 4 m/s if required to reduce
fouling; water: 1.5 to 2.5 m/s. Shell-side: 0.3 to 1 m/s.
Vapours
For vapours, the velocity used will depend on the operating pressure and fluid
density; the lower values in the ranges given below will apply to high molecular
weight materials.
Vacuum 50 to 70 m/s
Atmospheric pressure 10 to 30 m/s
High pressure 5 to 10 m/s

2.4.6. Stream temperatures

The closer the temperature approach used (the difference between the outlet
temperature of one stream and the inlet temperature of the other stream) the larger

18
will be the heat-transfer area required for a given duty. The optimum value will
depend on the application, and can only be determined by making an economic
analysis of alternative designs. As a general guide the greater temperature difference
should be at least 20°C, and the least temperature difference 5 to 7°C for coolers
using cooling water, and 3 to 5°C using refrigerated brines.

2.4.7 Pressure drop

In many applications the pressure drop available to drive the fluids through the
exchanger will be set by the process conditions, and the available pressure drop will
vary from a few millibars in vacuum service to several bars in pressure systems.
When the designer is free to select the pressure drop an economic analysis can
be made to determine the exchanger design which gives the lowest operating costs,
taking into consideration both capital and pumping costs. However, a full economic
analysis will only be justified for very large, expensive, exchangers. The values
suggested below can be used as a general guide, and will normally give designs that
are near the optimum.

Liquids
Viscosity <1 mN s/m 2 35 kN /m2
1 to 10 mN s/m2 50-70 kN /m2

Gas and vapors

High vacuum 0.4 - 0.8 kN /m2
Medium vacuum 0.1 x absolute pressure
1 to 2 bar 0.5 x system gauge pressure
Above 10 bar 0.1 x system gauge pressure

When a high-pressure drop is utilised, care must be taken to ensure that the
resulting high fluid velocity does not cause erosion or flow-induced tube vibration.

19
2.5 Fouling in heat exchanger
Fouling is a layer developed on heat transfer surface in heat exchanger which
causes resistances to heat transfer. The type of fouling encountered depends on the
process fluid used. The frequency and type of cleaning required by the heat exchanger
is dependent on the type of fouling encountered for the specific application.
Fouling can be minimized by increasing the velocity through the heat
exchanger at regular time intervals. This reduces fouling by creating larger turbulence
that will remove loose scale deposits from the heat transfer surfaces. Fouling in heat
exchangers may include the following;

2.5.1a Scaling
Scaling is a common form of fouling in heat exchangers. It is cause by high
concentrations of calcium, calcium carbonate, sulphate and silicates in cooling water.
Scaling is removed either by chemically cleaning in place or dismantling and using a
soft brush and running water. Chemical cleaning can be done using the following;
Nitric acid, sulfuric acid, citric acid, phosphoric acid, complexing agents EDTA and
NTA and sodium polyphosphates.

2.5.1b Biological fouling

This results from bacteria and other organisms such as protozoa found in the
cooling water.
The fouling is removed either by chemically cleaning in place or dismantling and
using a soft brush and running water. Chemical cleaning can be done using the
following with a maximum concentration of 4% in water and a maximum temperature
of 140 degree F.; sodium hydroxide and sodium carbonate.

2.5.1c Sedimentary fouling

This consists of metal oxide, corrosion products, silt, alumina and diatomic
organisms. Remove sediment in the same way as scaling detailed above.

2.5.1d Residual fouling

20
 This is hydrocarbon based deposits from oils, asphalt and fats. These are
removed by dismantling and cleaning the plates with a soft brush and a paraffinic or
naphtha based solvent (i.e. kerosene) followed by rinsing with water. This cleaning
compound can cause damage to elastomer gaskets so exposure to them should be
limited to one half hour or less.

2.5.1e Gross fouling

Gross fouling or plugging of the heat exchanger can be caused by fibres,
assorted solids and seaweed. There is nothing attached to the plate and a strainer
before the heat exchanger can usually prevent this type of fouling. Back flushing of
the unit may be effective before dismantling of the unit and cleaning the plates with a
soft brush is necessary.
Table 2.5-1 presents some recommended ranges for fouling factors in S&H heat
exchangers.

Table 2.5-1: Fouling factor (coefficient), typical values for Shell and Tube heat
exchangers.
FLUID COEFFICIENTS (W/M2 0C) FACTORS (M2 0C/W)
Sea water 1000 – 3000 0.001- 0.0003
Town water (soft) 1500 0.00007
Lubrication oil 6000 0.00017
Light 5000 0.00021
hydrocarbon
Process fluids 5000-20000 0.0002-0.00005

2.6 Shell and Tube heat exchanger analysis

This section consists of all the parameters and procedures use to evaluate the
performance of S&H Heat Exchanger. Heat exchanger regardless of the type, are
selected to transfer specific quantity of heat under a specific set of conditions. The
simplest form of equation that represents heat transfer across a surface is

21
 Q=UA ΔT m ..................................................................(2.6−1)

Q = GS C P ( T Si −T So ) = GT C P ( T ¿−T Ti )………….. (2.6- 2&3)

2.6.1 Log mean temperature difference

The log mean temperature difference is calculated using the difference
between the entering and leaving temperature of the two fluids according to the
following relationship.

ΔT 1 −ΔT 2
LMTD= .. . .. .. . .. .. .. ... .. ...... .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . ..(2 .6−4 )
ΔT 1
ln
ΔT 2

The corrected mean temperature can be estimated from the relationship below;

ΔT m=F t ×ΔT LD .................................................................(2.6−5)

Where ΔT m= true temperature difference, the mean temperature difference for use
in the design equation,
F t= the temperature correction factor.
The correction factor is a function of the shell and tube fluid temperatures, and the
number of tube and shell passes. It is normally correlated as a function of two
dimensionless temperature ratios

T si −T so
R= ( T ¿ −T ti )
…………………………………… (2.6-6)

And
T ¿−T ti
S= ( T si−T ti )
……………………………………… (2.6-7)

R is equal to the shell-side fluid flow-rate times the fluid mean specific heat; divided
by the tube-side fluid flow-rate times the tube-side fluid specific heat.

22
S is a measure of the temperature efficiency of the exchanger.

2.6.2 Heat transfer coefficient

2.6.2a Tube-side heat transfer coefficient
Turbulent flow
Heat-transfer data for turbulent flow inside conduits of uniform cross-section are
usually correlated by an equation of the form:
Where Nu = Nusselt number = (hi d e /k f ),………………………………..(2.6-8)
Re = Reynolds number = (ρut d e /µ) = (Gt d e /µ)…………………...,(2.6-9)
Pr = Prandtl number = (Cpµ/k f ) …………………………………..(2.6-10)
And: hi = inside coefficient, W/m²°C,
d e = equivalent (or hydraulic mean ) diameter, m = d i for tubes,
Gt
ut = fluid velocity, m/s,= ( )
ρ
……………………………………(2.6-11)

k f = fluid thermal conductivity, W/m°C,

G t = mass velocity, mass flow per unit area, kg/m²s = ( wA ), ……(2.6-12)

s

µw = fluid viscosity at the wall Ns/m2

C p = fluid specific heat, heat capacity, J/kg°C.

2.6.2b Shell-side heat transfer coefficient

The shell-side heat transfer and friction factors are correlated in a similar manner to
those for tube-side flow by using a hypothetical shell velocity and shell diameter. As
the cross-sectional area for flow will vary across the shell diameter, the linear and
mass velocities are based on the maximum area for cross-flow: that at the shell
equator. The shell equivalent diameter is calculated using the flow area between the
tubes taken in the axial direction (parallel to the tubes) and the wetted perimeter of the
tubes.
and
1.10 2
Shell-side equivalent diameter (m) = d e = ( p −0.917 do2 )............... (2.6-13)
do

23
 ( P−d o )
Shell-side cross-sectional Area m 2= A S= D s Lb …………………(2.6-14)
P

Shell-side j h and j f factors for use in this method are given in Figures 2.6-1and
2.6-2, for various baffle cuts and tube arrangements. These figures are based on data
given by Kern (1950) and by Ludwig (1965).

2.6.3 Overall heat transfer coefficient

The overall heat transfer coefficient U (W/m2 0C) of S&H heat exchanger can
be `estimated from the relationship;
1
U O= OR U o = Q A o T m …………………………. (2.6-15&16)
h
Where:
do
h= 1
+
1
+
d o ln
( )
di
+
do
×
1 d o 1 ... (2.6-17)
+ ×
hs hsd 2k w d i hi di d i hi

2.6.4 Heat transfer area

Effective heat transfer area in a S&H heat exchanger A0 is calculated by

multiplying the total number of tubes in the exchanger, by the effective area per
tube.
Area( A0 ) = Total number of tubes ¿ area of one tube (neglecting thickness of
tube sheet)…………………………...…………………..
………………………….(2.6-18)

Area of one tube = πdl ……………………………………………………(2.6-19)

2.6.5 S&H heat exchanger performance

One of the most useful method of evaluating the performance of an existing
heat exchanger or to assess a proposed design is to determine its effectiveness

24
 η , which is defined as the ratio of the actual rate of heat transfer Q to the

maximum rate Qmax that is thermodynamically possible or the ratio of the rate of
heat transfer Q estimated to the rate of heat transfer required.

Q
η= ...................................................................................(2.6−20)
Qmax

Q Estimated
η= Q Required ……..........……………………………………. .(2.6 –21)

Note:
Q REQis the heat transfer rate which would be achieved if it were possible to bring the
outlet temperature of the stream with the lower heat capacity to the inlet temperature
of the other stream.

2.7 Shell and tube heat exchangers general design considerations

2.7.1 Fluid allocation: shell or tubes
Where no phase change occurs, the following factors will determine the allocation of
the fluid streams to the shell or tubes.
Corrosion: The more corrosive fluid should be allocated to the tube-side. This will
reduce the cost of expensive alloy or clad components.
Fouling: The fluid that has the greatest tendency to foul the heat-transfer surfaces
should be placed in the tubes. This will give better control over the design fluid
velocity, and the higher allowable velocity in the tubes will reduce fouling. Also, the
tubes will be easier to clean.
Fluid temperatures: If the temperatures are high enough to require the use of special
Alloys placing the higher temperature fluid in the tubes will reduce the overall cost.
At moderate temperatures, placing the hotter fluid in the tubes will reduce the shell

25
surface temperatures, and hence the need for lagging to reduce heat loss, or for safety
reasons.
Operating pressures: The higher pressure stream should be allocated to the tube-side.
High-pressure tubes will be cheaper than a high-pressure shell.
Pressure drop: For the same pressure drop, higher heat-transfer coefficients will be
Obtain on the tube-side than the shell-side, and fluid with the lowest allowable
pressure drop should be allocated to the tube-side.
Viscosity: Generally, a higher heat-transfer coefficient will be obtained by allocating
the more viscous material to the shell-side, providing the flow is turbulent. The
critical Reynolds number for turbulent flow in the shell is in the region of 200. If
turbulent flow cannot be achieved in the shell it is better to place the fluid in the tubes,
as the tube-side heat transfer coefficient can be predicted with more certainty.
Stream flow-rate: Allocating the fluids with the lowest flow-rate to the shell-side will
normally give the most economical design.

2.8 Problem solving in Shell and Tube heat exchanger

The following is a guide to trouble shooting the shell and tube heat exchanger
Condition: Fluid leak between the tubes and the shell side .
Cause: A loose or damaged tube sheet.
Solution: note which tube is leaking and open the heat exchanger and examine the
tube to see if it has become dislodged from its tube groove or suffered damage.
Reposition or simply block the tube by using a rod with outer diameter same as the
internal diameter of the tube.
Condition: The pressure drop across the heat exchanger is higher then predicted.
Cause: The tubes may have become blocked with debris/scaling or the plates may be
installed wrong.
Solution: Accurately measure the pressure drop across the heat exchanger. Examine
the outer edge of the tube bundle and be certain the outer edges of the tubes form a
checked pattern indicating that the tubes are well installed.
Attempt to flush or back flush the heat exchanger at a high velocity to dislodge
any trapped debris. If this is not successful or available the unit must be dismantled
and cleaned.

26
Condition: The heat transfer capacity of the heat exchanger is declining.
Cause: The shell or tubes are becoming fouled during operation.
Solution: Dismantle and clean the heat exchanger or use chemical cleaning.

CHAPTER THREE

3.0 Materials and Method

Materials and methods adopted during carrying out this investigation on the
performance of a S&H heat exchanger are discussed in this section. This includes;
materials used with their technical specifications and quantity, method followed
and all assumption made if any.

3.1 Materials/equipment
The materials/equipment used when conducting this investigation includes the
following;
- Shell and Tube heat exchanger
- Stop valve
- Pressure gauges
- Thermometer
- Flow meter.

Shell and Tube heat exchanger (10E02) OF CDU1 KRPC

This is the main device on which this investigation is carried on. It is used to
cool out-liquid (kerosene) from stripper at temperature of 213 0C, to a
temperature of about 78 0C. Its technical specifications are stated below.

Manufacturer’s address: PASILAC THERM, /S DK-60PO

KOLDING DENMARK

27
Date built: 1979
Type: split ring floating head S&H heat exchanger
Serial No.: 46811
Drawing No: 1221513-2
Sept code: Temar
Area: 113.15m 2
Pressure drop: Tube side 0.8 bar
Shell side 0.8 bar
Normal heat transfer capacity: 2500kW
Shell weight empty: 2610kg
Tube weight empty: 1080kg
Test pressure: x bar
Maximum difference pressure: x bar
Maximum working temperature: 300°C
Number of tubes/style: 360
Tubes spacing: 1.5mm
Tube material/tube thickness: Cast iron/4.22mm
Frame material: carbon steel

Stop valve
This is used to control the flow of fluid in the process. The valves used are
mainly plug valve.
Pressure gauge
These measure the pressure of the fluid flowing in the conduit.
Thermometer
The thermometer is used in the process to measure the temperature of the
process fluid. There are calibrated in 0C
Flow meter
There are used in the process to measure the flow rate of the fluid. They are
mostly attached to pipe containing flowing liquid. There are calibrated in m3/h.

28
3.2 Method
This investigation was carried out over a period of five days. It involves
thorough observation of the unit in question (S&H heat exchanger) and readings are
taken accordingly.
The S&H heat exchanger has two inlet and two outlet streams, it operates
counter currently. The first inlet stream contains the exit liquid from the stripper, the
liquid consist of hot kerosine at 213 to 78 0C and pressure of 0.4 bar while the second
inlet stream contains the crude oil from the heat exchanger 10E01 at a temperature of
40 to 80.6 0C and flow rate of 60000kg /h (constant). The crude oil comes out of the
heat exchanger at a temperature ranging between77 to 83 0C. The fluid outlet from the
heat exchanger is mainly crude oil and kerosene at different temperatures ( 0C). The
kerosene is sent back to the fractionation column for further heating up and the Crude
oil is passed to the next heat exchanger 10E03 for further heating.
The data obtained during the five days investigation are summarized in table
4.1-1 in chapter four and there are further analyzed. The data includes;
 Inlet and outlet temperature of the streams to and from the S&H heat
exchanger. This is obtained using a thermometer.
 The pressure of Crude oil to the heat exchanger. This is measured using a
pressure gauge
 The flow rate of kerosine to the heat exchanger. This is measured using a flow
meter.

29
 CHAPTER FOUR

4.0 Result and Discussion

The results obtained during the investigation and their interpretations are
discussed in this chapter. The results include inlet and outlet temperature of the fluids
in the heat exchanger as well as their flow rate. Table 4.1-1 shows the data obtain
during the five days investigation period. Table 4.1-2 shows the summary of the
calculated values obtained from the investigation.

Table 4.1-1 Data obtained from investigation

DAYS CRUDE OIL KEROSINE
TEMPERATURE 0C TEMPERATURE 0C
Inlet Outlet Inlet Outlet
16/11/09 40.00 80.60 213.0 78.00
17/11/09 40.00 80.60 213.0 78.00
18/11/09 39.00 78.69 209.0 76.00
19/11/09 41.00 81.50 215.0 79.00
20/11/09 40.00 80.61 215.0 79.00
Average 40.00 80.60 213.0 78.00

The flow rates of the inlet streams to the heat exchanger are not included
because there are always maintain constant. The Crude oil flow rate is 60,000kg/h
while the pressure of kerosine is always 0.4 bars.

30
Table 4.1.2 Calculated Values
PARAMETER GENERAL KEROSINE CRUDE OIL
VALUES
Velocity,m/s , 0.46 1.16
h p ,W /m2 ° C 1521.81 492.75
F f , m2 ° C /W , 0.00021 0.00035

U o , W /m 2 ° C 254.19
1834.13
Q, KW
ɳ,% 89.0
63.59 and 75.7
∆T m and ∆T lm

4.1 Discussion of result

The result obtain during the period of five days were used to evaluate the
performance of the gas heat exchanger. All calculation involved are shown in
appendix A, here only the discussion of the calculated value will be analyzed.
The operating efficiency of the S&H heat exchanger was found to be 89.0%
against the design efficiency of 96 to 98%. The value of the operating efficiency has
drop below the design efficiency by 7 to 9%. Therefore the S&H heat exchanger in
not 100% meeting its requirement. Since there is no leakage observed during the
investigation period, the decline in performance is caused by fouling formed in the
tube surface in the heat exchanger. The outlet temperature 78°C of the Kerosine is
found to be lower than the heat gained by the crude oil with outlet temperature of
80.6°C which is one of the causes of the drop in efficiency of the heat exchanger. This
is definitely a problem associated with Lagging of the exchanger and can be resolved

31
by re-lagging with a new and appropriate material. Also, the fouling coefficient for
Kerosine and Crude oil was found to be 0.00021 and 0.00035 m2 0C/W which are both
below the design limitation of S&H heat exchanger and this is the main cause of the
drop in performance. Since process crude oil is involved, the fouling likely to be
associated is scaling (see chapter two). This problem can be solved in two ways;
either by chemical cleaning in place or by dismantling the S&H heat exchanger and
by hydro-testing it with high pressure remove scales in the tubes surfaces. Details of
these methods are discussed in chapter two (2.4-4 and 2.5). Scaling can also be reduce
by increasing the flow rate of the streams to the heat exchanger at regular time
intervals, these create high turbulence within the tubes and hence removes loose scale
deposit.
The heat transfer capacity was found to be 1,834.13 kW against the design
capacity of 2,060.25 kW. The difference is 226.12 kW and is also cause by scaling
formed in the tubes surfaces and the poor lagging of heat exchanger. This problem
can be solved using the same methods stated above.
Finally, it is observed that the overall performance of the gas heat exchanger
solely depend on whether the transfer surfaces are fouled or not well lagged or not.
Hence to maintain high working efficiency, the S&H heat exchanger transfer areas
and surfaces must be checked, hydro tested and cleaned on regular basis.

32
 CHAPTER FIVE

5.0 Conclusion and Recommendation

5.1 Conclusion
Based on the investigation carried out, it can be concluded that;
I. The operating efficiency was 89.0 %
II. The film heat transfer coefficient of Kerosine is 1521.81 W/m 2 0C and that of
Crude oil is 492.75 W/m2 0C. Hence the overall heat transfer coefficient is 254.91
W/m2 0C.
III. The heat duty was 1834.13 kW.
IV. The S&H heat exchanger is working below its design standard and need to be
serviced regularly for it to achieve its purpose in CDU-1, Fuel section of KRPC.

5.2 Recommendation
During the period of investigation, it was observed that the main problem
resulting to low efficiency of the exchanger is due to fouling effect and poor lagging.
Fouling leads to high pressure drop and low rate of heat transfer. While poor lagging
results to heat loss, low heat transfer and higher cost of energy.
I suggest, the heat exchanger should be well lagged with the appropriate
materials and serviced regularly to reduce/remove fouling on the transfer areas and
surfaces. Doing this will maintain high operating efficiency and reduce cost of energy

33
 REFERENCE

1. J.M Coulson and J.F Richardson, with J.R Backhust and J.H Harker. Chemical
Engineering, Fluid flow, Heat transfer, and Mass transfer. Volume 1, six
edition
2. R.K Sinnott, Chemical Engineering, Chemical Engineering Design, Volume 6,
third edition.
3. Christie J. Geankoplis, Transport Processes and Unit Operations, third
edition.
4. PASILAC THERM, Heat transfer, Shell and Tube heat exchanger
installation and maintenances manual.
5. CHIYODA, Kaduna Petroleum and Petrochemical Company, Crude oil
Distillation Unit 1installation manual.

34
 APPENDIX A

Calculation
TUBE SIDE:

(a )HEAT DUTY ( Rate of heat transfer required )

From overall energy balance equation;
Q ¿ =QOUT

Q = G S C P ( T Si −T So ) = G T C P ( T ¿−T Ti )

Therefore applying equation (2.6-3) from chapter Two we have:

Q REQ = GT C P ( T ¿−T Ti )

60,000
Q REQ = × 2.05 ( 80.6−40 )
3600

Q REQ = 2060.25KW

Where G T is the mass flow rate in ( kgs ) and C p is the average specific heat

capacity of the inlet and outlet streams of the heat exchanger’s tube side in ( kgKJC )
0

(b) LOG MEAN TEMPERATURE DIFFERENCE (LMTD)

Table 4.1-3 Temperature of the streams to and from the heat exchanger

STREAMS INLET TEMPERATURE OUTLET

0
C TEMPERATURE 0C
KEROSINE 213 78

35
 CRUDE OIL 40 80.6

Using equation (2.6-4) from chapter Two;

ΔT 1 −ΔT 2 (213−80 . 6 )−(78−40 )

LMTD=
ΔT 1 213−80. 6
ln ln
ΔT 2 = 78−40
LMTD=75 . 70 C

(c) Corrected Log Mean Temperature Difference ( ΔT m)

ΔT m=F t ×ΔT LD

Where
Ft is the correction coefficient and is obtainable from figure 2.6-1 in
appendixes B, using the values of R and S calculated below.

T si −T so 213−78
R= ( )(
T ¿ −T ti
= )
80.6−40
= 3.33 (applying eqtn. 2.6-6)

T ¿−T ti 80.6−40
S= ( ) (
T si −T ti
=
213−40 )= 0.28 (applying eqtn. 2.6-7)

Therefore: ∆T m = 0.84× 75.7 =63.59°C

(d)HEAT TRANSFER AREA AO

Applying equation (2.6-19) from chapter Two;
Area of one tube (neglecting thickness of tube sheets) = π d OL
= π× 0.02 × 5 = 0.3143m 2
Therefore:
AO = 0.3143 × 360 = 113.15m 2

36
(e)TUBES SIDE VELOCITY (Ut)
π
Tube cross-sectional Area = ( 15.78 ×10−3 )2 = 0.000196m2
4

Area per pass At = 90× 0.000196 = 0.01761m2

60,000 1
Volumetric flowrate V t = × = 0.0204m3 /s
3600 818.64

Vt 0.0204 m
Tubes side velocity U t = = = 1.16
At 0.01761 s

(f)TUBES SIDE HEAT TRANSFER COEFFICIENT hi

ρu t d i 818.64 ×1.16 ×15.78 ×10−3
Re = = = 4757.16 (applying eqtn.
μ 3.15 ×10−3
2.6-9)

2.05× 103 × 3.15 ×10−3

Pr = C ρ μ/ κ = = 48.19 (applying eqtn.
0.134
2.6-10)

From fig. (2.6-2) in appendix B; J h = 3.4×10−3

Applying eqtn. (2.6-8) in chapter Two;

Nu = j h RePr = 3.4×10−3 × 4757.16 × ( 48.19 )0.33 = 58.1

Therefore:
k 0.134 W
hi = Nu ( )
d0
= 58.1× ( 15.78× 10−3 ) = 492.75
m2 C
(applying eqtn. 2.6-

17)

SHELL SIDE:

37
(a)BUNDLE AND SHELL DIAMETER
From literature, for 4 tube pass S&H heat exchanger K 1=0.175 and n1= 2.285.
Therefore applying equation (2.6-13) from chapter 2 then;
1
360
Db = 20( 0.175 ) 2.285
= 565.24mm = 0.5652m

Shell clearance is 56mm so therefore, shell diameter Ds will be;

Ds = 565.24 + 56 = 621.24mm

Baffle spacing = Ds/5 = 621.24/5 = 125mm

(b)SHELL TRANSFER AREA (As)

Applying equition(2.6-14) from chapter 2.

As = ( 23.81−20
23.81 )
×621.24 ×125 = 12,426.12mm 2

(c ) SHELL EQUIVALENT DIAMETER d e

Applying equition (2.6-13) chapter two then;
1.10
d e= ( 23.812−0.917× 202 ) = 11.0m
20

(d)SHELL-SIDE VELOCITY U s
Applying equation (2.6-22) from chapter 2 then;
15000 1
Volumetric flowrate (V s)= × = 0.0057 m 3 /s
3600 730

Vs 0.0057 m
Shell side Velocity (U s) = = = 0.46 (from eqtn.2.6-11 )
As 0.01243 s

(e)SHELL SIDE HEAT TRANSFER COEFFICIENT ( h s )

ρu s d e 730× 0.46 ×11 ×10−3
Re = = = 8590.23 = 8.59 ×10 3
μ 0.43× 10−3

38
 Cp μ 2.49× 103 × 0.43 ×10−3
Pr = = = 8.11
κ 0.132

From figure (2.6-3) in appendix B; j h =7.4×10−3

Therefore;

h s= ( 0.132
11
×10 ) ×7.4 × 10
3 −3
×8590.23 × 8.110.33

W
hs = 1521.81
m2 C

(f)OVERALL HEAT COEFFICIENT (U O )

Applying equation (2.6-17) from chapter 2;
20
1
Uo
=
1
(
492.75
+0.00035
20
15.78
+
20× 10−3 ln
) 15.78 +
1 (
1521.81
)
+ 0.00021
2 ×55

W
U o = 254.91
m2 C
(g)ESTIMATED HEAT TRANSFER RATE (Q EST )

Applying equation (2.6-16) from chapter 2;

Q EST =U o Ao T m
Q EST = 254.91 ×113.15 × 63.5
= 1834.13KW

(h)EFFICIENCY/ PERFORMANCE (ɳ ¿

Applying equation (2.6-21) from chapter 2.

Rate of heat transfer estimated ( QEST )

ɳ= Rate of heat transfer required (Q REQ )

39
 1834.13
ɳ= 2060.25 = 0.89

ɳ = 0.89× 100 = 89%

Hence, the effectiveness of the heat exchanger is 89.0%.

APPENDIX B

Table 4.1-4 Physical properties of Kerosine and Crude oil

KEROSINE UNIT INLET MEAN OUTLET

Temperature °C 213 145.5 78
Specific heat capacity KJ /kg ° C 2.27 2.49 2.09
Thermal conductivity W /m °C 0.130 0.132 0.133
Density kg /m3 680.6 730 800
Viscosity mNsm−2 0.17 0.43 2.40

CRUDE OIL UNIT INLET MEAN OUTLET

Temperature °C 40.0 60.3 80.6
Specific heat capacity KJ /kg ° C 2.01 2.05 2.12
Thermal conductivity W /m °C 0.135 0.134 0.133

40
Density kg /m3 840 818.6 805
Viscosity mNsm−2 4.30 3.15 2.11

Figure 2.5-1 Temperature Correction factor: One shell Pass Two or more even
tube passes

41
42
 Figure 2.5-2 Tube-side heat transfer factor

Figure 2.6.4 Shell-side heat transfer factor with segmental baffle

43