DESIGN OF A SHELL-AND-TUBE TYPE HEAT EXCHANGER FOR COOLING THE OUTPUT GAS AT PT. X
DOI:
https://doi.org/10.35261/barometer.v11i2.13198Abstract
Cooling the outlet gas from a distillation unit is important for maintaining downstream process stability, reducing thermal load, and preventing efficiency losses caused by high gas temperatures. This study aims to design a shell-and-tube heat exchanger for cooling the outlet gas at PT. X from 95 °C to 50 °C using cooling water at 30–40 °C. The main contribution of this work is the development of an industry-based preliminary design supported by integrated thermal, hydraulic, and fouling evaluations. The Kern method was selected because it is suitable for the preliminary design of shell-and-tube heat exchangers with segmental baffles under limited design data; it is simpler and more practical than the Bell–Delaware method, although it does not explicitly account for shell-side leakage and bypass effects. The design reliability was assessed through energy-balance consistency, comparison between clean and design overall heat-transfer coefficients, fouling-factor evaluation, and pressure-drop verification against recommended design limits. The calculated heat duty was 362814,594 BTU/h with a required heat-transfer area of 276,461 ft². The selected configuration consisted of one shell pass and two tube passes, a triangular tube layout, 66 tubes, 16-ft tube length, BWG 8, and a 13.25-inch shell inside diameter. The calculated fouling factor was 0,00524, lower than the reference value of 0.00230. The shell-side and tube-side pressure drops were 1,5622 psi and 0,0036 psi, respectively, both below the 10-psi design limit. Therefore, the proposed exchanger is acceptable as a preliminary design, but further verification using Bell–Delaware, design software, or operational validation is recommended.
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