CHPR4402 Chemical Engineering Design Project
The University of Western Australia
SECTION 3: CLARIFICATION AND UTILITIES (1)
Aaliyah Hoosenally
10428141
Alcoholics
Anonymous
TEAM A: ALCOHOLICS ANONYMOUS
AALIYAH HOOSENALLY, 10428141
i
SECTION 3: CLARIFICATION AND UTILITIES (1)
Table of Contents
1. EQUIPMENT SPECIFICATION CALCULATIONS ..............................................................................................1
1.1. Cold Stabilisation Heat Exchanger HX-02 .................................................................................................. 2
1.2. Skin Separation/Plate and Frame Filter FLTR-01 .................................................................................. 12
1.3. Membrane Filter FLTR-02 ............................................................................................................................ 14
1.4. Water Filter FLTR-03 ...................................................................................................................................... 15
1.5. Aging in Barrels BRL-01 ................................................................................................................................. 16
1.6. Boiler HTR-01 ................................................................................................................................................... 18
2. DETAILED DESIGN CALCULATIONS ............................................................................................................. 19
2.1. Basic Heat Exchanger Design ...................................................................................................................... 20
2.2. Tubesheet Detailed Design .......................................................................................................................... 20
2.3. End Plate Design ............................................................................................................................................. 23
2.4. Vessel Support Design ................................................................................................................................... 24
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 1 ............................................................................ 5
Table 5: Tube Length and Shell Diameter Selection 2 ............................................................................ 7
Table 6: Racked White Wine Physical Properties ................................................................................. 10
Table 7: Stabilised White Wine Physical Properties ............................................................................. 10
Table 8: Skin Separation/Plate and Frame Filter FLTR-01 Properties ................................................... 12
Table 9: Membrane Filter FLTR-02 Properties ...................................................................................... 14
Table 10: Water Filter FLTR-03 Properties ............................................................................................ 15
Table 11: Physical Properties of Water for Hot Caustic Solution ......................................................... 18
Table 12: Fixed Tubesheet Effective Pressure Calculation ................................................................... 21
Table 13: Shell Longitudinal Stress Calculation ..................................................................................... 22
Table 14: Tube Longitudinal Stress Calculation .................................................................................... 22
Table 15: Tube-to-Tubesheet Joint Loads ............................................................................................. 23
Table 16: Flanged Plate Ends - Bolted Covered with Full Faced Gasket ............................................... 23
Table 17: Bolt Spacing ........................................................................................................................... 24
Table 18: Shell Mass Calculation ........................................................................................................... 25
Table 19: Tube Mass Calculation .......................................................................................................... 25
Table 20: Liquid Mass Calculation ......................................................................................................... 25
Table 21: Flange End Plate (Flat Ends) Mass Calculation ...................................................................... 25
Table 22: Dead Weight of Vessel Calculation ....................................................................................... 26
1
CHPR4402 Chemical Engineering Design Project
The University of Western Australia
1. EQUIPMENT SPECIFICATION
CALCULATIONS
Aaliyah Hoosenally
10428141
Alcoholics
Anonymous
Team A Equipment Type Heat Exchanger
Project Equipment Design Equipment Name Cold Stabilisation Heat
Exchanger
Design By Aaliyah Hoosenally Equipment Number HX-01
Calculation Sheet Checked By Andrew Plavina PFD Location CHPR4401-A-0102/3
Date 21/08/2008 Page 1 of 10
2
Alcoholics
Anonymous
1.1. 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) 25 15 20
Cp (kJ/kg.°C) 4.375 4.325 4.35
k (W/m.°C) 0.515 0.505 0.51
ρ (kg/m³) 973.5 976.5 975
μ (mPa.s) 1.8 2.3 2.05
mass flow rate (kg/s) 1.2188
Table 2: Stabilised Red Wine Physical Properties
Stabilised Red Wine Inlet Outlet Mean
Temperature (°C) 0 10.1235 5.062
Cp (kJ/kg.°C) 4.25 4.3 4.275
k (W/m.°C) 0.49 0.5 0.495
ρ (kg/m³) 982 978 980
μ (mPa.s) 3.8 2.6 3.2
mass flow rate (kg/s) 1.2250
(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) 53.0156
Temperature Out of Stabilised Wine To=Q/(mCp) + Ti(°C) 10.1235
An Overall Heat Transfer Coefficient must now be estimated:
Overall Heat Transfer Coefficient, Uass (W/m².C) 100
(Table 12.1, p. 637, Coulson, Richardson & Sinnot, 2005: Organic Solvent to Organic Solvent: 100 -
300 W/m².K)
Team A Equipment Type Heat Exchanger
Project Equipment Design Equipment Name Cold Stabilisation Heat
Exchanger
Design By Aaliyah Hoosenally Equipment Number HX-01
Calculation Sheet Checked By Andrew Plavina PFD Location CHPR4401-A-0102/3
Date 21/08/2008 Page 2 of 10
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Anonymous
The log mean temperature must also be calculated using the following equation:
dT1 (C) 10
dT2 (C) 10.124
dT2 - dT1 (C) 0.124
dT2 / dT1 (C) 1.012
(∆T)lm (C) 10.062
Racked Wine will flow through the tubes, and the Stabilised Wine will flow through the shell so:
Tube In Temperature, t1 25
Tube Out Temperature, t2 15
Shell in Temperature, T1 0
Shell out Temperature, T2 10.1235
The correction factor, F1-2, can now be calculated using two dimensionless temperature ratios, R and
S. If F1-2 is greater than 0.8, a shell and tube heat exchanger with 1 shell and any multiple of 2 tube
passes is acceptable.
(Eq. 12.6 to 12.8, pp. 655-656, Coulson, Richardson & Sinnot, 2005)
R 1.0124
P 0.4
F1-2 0.9192
As F1-2 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.
Team A Equipment Type Heat Exchanger
Project Equipment Design Equipment Name Cold Stabilisation Heat
Exchanger
Design By Aaliyah Hoosenally Equipment Number HX-01
Calculation Sheet Checked By Andrew Plavina PFD Location CHPR4401-A-0102/3
Date 21/08/2008 Page 3 of 10
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Anonymous
The estimated heat transfer area can now be calculated:
Heat Transfer Area, A=Q/(U(∆T)lmF1-2) (m²) 57.3241
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, do (in) Tube OD, do (m)
6 1.8288 0.250 0.00635
8 2.4384 0.375 0.009525
10 3.048 0.500 0.0127
12 3.6576 0.625 0.015875
16 4.8768 0.750 0.01905
20 6.096 1.000 0.0254
1.250 0.03175
If we use a standard tube OD of 0.0127m (1/2’’ in.) and a tube length of 1.8288m (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 do (m) 0.0127
Tube Length L (m) 1.8288
Number of Tube Passes 4
Tube Cross-Section Area Atc=π(do/2)2 (m²) 0.0001
Volumetric Flow Rate Q=ρ*mass flow (m³/s) 0.0013
Tube Surface Area At=πdoL (m²) 0.0730
Nt = A/At 786
Tubes per pass Np = Nt/4 196
Area per pass Ap = NpAtc (m²) 0.0249
Tube Side Velocity, ut = Q/Ap (m/s) 0.0502
K1 0.175
Table 12.4, p. 649, Coulson,
Richardson & Sinnot, 2005
Team A Equipment Type Heat Exchanger
Project Equipment Design Equipment Name Cold Stabilisation Heat
Exchanger
Design By Aaliyah Hoosenally Equipment Number HX-01
Calculation Sheet Checked By Andrew Plavina PFD Location CHPR4401-A-0102/3
Date 21/08/2008 Page 4 of 10
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Anonymous
n1 0.5037
Bundle Diameter Db = do(Nt/K1)1/n1 (m) 0.0130
Equation 12.3b, p. 648, Coulson,
Richardson & Sinnot, 2005
Shell Clearance (m) 0.5167
Figure 12.10, p. 646, Coulson,
Richardson & Sinnot, 2005
Shell ID Ds = Db + Shell Clearance (m) 3.5395
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
Lt (m) At (m²) Nt Np Ap (m²) ut (m/s) Db (m) Lc (m) Ds (m) L/D
1.8288 0.0730 786 196 0.0249 0.0502 0.5037 0.0130 0.5167 3.5395
2.4384 0.0973 589 147 0.0187 0.0670 0.4441 0.0124 0.4565 5.3414
3.048 0.1216 471 118 0.0149 0.0837 0.4028 0.0120 0.4148 7.3484
3.6576 0.1459 393 98 0.0124 0.1005 0.3719 0.0117 0.3836 9.5352
4.8768 0.1946 295 74 0.0093 0.1340 0.3279 0.0113 0.3392 14.3792
6.096 0.2432 236 59 0.0075 0.1675 0.2974 0.0110 0.3083 19.7700
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 di (m) 0.0094
Re = ρutdi/μ 449.1297
Pr = Cpμ/k 17.4853
L/di 389
jh 0.0043
Using Figure 12.23, p. 665, Coulson,
Richardson & Sinnot, 2005
Nu = jhRePr1/3 5.0126
ht =Nuk/di (W/m².C) 272.0190
To calculate the shell side heat transfer coefficients, the following formulas can be used to find the
cross-sectional area of the shell, As, and the equivalent diameter, De, for a square pitch arrangement:
Team A Equipment Type Heat Exchanger
Project Equipment Design Equipment Name Cold Stabilisation Heat
Exchanger
Design By Aaliyah Hoosenally Equipment Number HX-01
Calculation Sheet Checked By Andrew Plavina PFD Location CHPR4401-A-0102/3
Date 21/08/2008 Page 5 of 10
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Anonymous
(Equations 12.21 and 12.22, p. 672, Coulson, Richardson & Sinnot, 2005)
Shell Side HTC
Tube Pitch pt = 1.25do 0.0159
Baffle Spacing, lB =0.2Ds (m) 0.0767
p. 652, Coulson, Richardson &
Sinnot, 2005
Cross Sectional Area, As (m²) 0.0059
Equivalent Diameter, De (m) 0.0090
Volumetric Flow Rate (m³/s) 0.0013
Shell Side Velocity, us (m/s) 0.2124
Re = ρusDe/μ 586.5296
Pr = Cpμ/k 27.6364
Baffle Cut % 25
jh 0.0220
Nu = jhRePr1/3 39.0127
hs =Nuk/De (W/m².C) 2141.5035
The overall heat transfer coefficient can now be calculated using the following equation:
(Equation 12.2, p. 635, Coulson, Richardson & Sinnot, 2005, 2003)
Team A Equipment Type Heat Exchanger
Project Equipment Design Equipment Name Cold Stabilisation Heat
Exchanger
Design By Aaliyah Hoosenally Equipment Number HX-01
Calculation Sheet Checked By Andrew Plavina PFD Location CHPR4401-A-0102/3
Date 21/08/2008 Page 6 of 10
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Anonymous
Overall Coefficient
Tube kw (W/mC ) 16 Stainless Steel 316 Tube
hod (W/m².C) 3000 Fouling Factors taken from
'Organic Liquids'
Table 12.2, p. 640, Coulson,
Richardson & Sinnot, 2005 hid (W/m².C) 3000
1/Uo (m².C/W) 0.0063
Uo (W/m².C) 157.7759
The error in the overall heat transfer coefficient that was used initially can now be found:
Error in Uo = Uo-Uass/Uo 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, Uass (W/m².K) 300.0000
New Heat Transfer Area, A (m²) 19.1080
Number of Tube Passes 8
K1 0.0365 Table 12.4, p. 649,
Coulson, Richardson &
Sinnot, 2005 n1 2.675
Table 5: Tube Length and Shell Diameter Selection 2
Lt (m) At (m²) Nt Np Ap (m²) ut (m/s) Db (m) Lc (m) Ds (m) L/D
1.83 0.0730 262 33 0.0041 0.3016 0.3508 0.0115 0.3624 5.0503
2.4384 0.0973 196 25 0.0031 0.4019 0.3173 0.0112 0.3285 7.4236
3.048 0.1216 157 20 0.0025 0.5024 0.2899 0.0109 0.3008 10.1320
3.6576 0.1459 131 16 0.0021 0.6029 0.2708 0.0107 0.2815 12.9917
4.8768 0.1946 98 12 0.0016 0.8039 0.2432 0.0104 0.2536 19.2270
6.096 0.2432 79 10 0.0012 1.0048 0.2237 0.0102 0.2340 26.0530
Team A Equipment Type Heat Exchanger
Project Equipment Design Equipment Name Cold Stabilisation Heat
Exchanger
Design By Aaliyah Hoosenally Equipment Number HX-01
Calculation Sheet Checked By Andrew Plavina PFD Location CHPR4401-A-0102/3
Date 21/08/2008 Page 7 of 10
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Anonymous
Tube Side HTC
Tube ID di (m) 0.0094
Re = ρutdi/μ 1796.5189
Pr = Cpμ/k 17.4853
L/di 259
jh 0.002
Nu = jhRePr1/3 9.3258
ht =Nuk/di (W/m².C) 506.0819
Shell Side HTC
Tube Pitch pt = 1.25do 0.0159
Baffle Spacing, lB =0.2Ds (m) 0.0657
Cross Sectional Area, As (m²) 0.0043
Equivalent Diameter, De (m) 0.0090
Volumetric Flow Rate (m³/s) 0.0013
Shell Side Velocity, us (m/s) 0.2896
Re = ρusDe/μ 799.8974
Pr = Cpμ/k 27.6364
Baffle Cut % 25
jh 0.0185
Nu = jhRePr1/3 44.7404
hs =Nuk/De (W/m².C) 2455.9085
Overall Coefficient
Tube kw (W/m.C ) 16
hod (W/m².C) 3000
hid (W/m².C) 3000
1/Uo (m².C/W) 0.0040
Uo (W/m².C) 251.2128
Error in Uo = Uo-Uass/Uo -16%
Team A Equipment Type Heat Exchanger
Project Equipment Design Equipment Name Cold Stabilisation Heat
Exchanger
Design By Aaliyah Hoosenally Equipment Number HX-01
Calculation Sheet Checked By Andrew Plavina PFD Location CHPR4401-A-0102/3
Date 21/08/2008 Page 8 of 10
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Anonymous
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).
jf (tube) 0.0078
Figure 12.24, p.668, Coulson,
Richardson & Sinnot, 2005
∆Pt (kPa) 22.3833
jf (shell) 0.075
Figure 12.30, p. 674, Coulson,
Richardson & Sinnot, 2005
∆Ps (kPa) 38.1766
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:
Team A Equipment Type Heat Exchanger
Project Equipment Design Equipment Name Cold Stabilisation Heat
Exchanger
Design By Aaliyah Hoosenally Equipment Number HX-01
Calculation Sheet Checked By Andrew Plavina PFD Location CHPR4401-A-0102/3
Date 21/08/2008 Page 9 of 10
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Anonymous
Flanges & Nozzles Tube Inlet Tube Outlet Shell Inlet Shell Outlet
Mass Flowrate, G (kg/s) 1.2188 1.2188 1.2250 1.2250
Density, ρ (kg/m³) 973.5 976.5 982 978
Optimal Diameter, Dopt (mm) 31.6639 31.6347 31.6623 31.7011
Nominal Diameter, DN (mm) 32 32 32 32
Nozzle Outer Diameter (mm) 42.2 42.2 42.2 42.2
Inner Diameter (mm) 36.66 36.66 36.66 36.66
Flange Size 32 32 32 32
Flange OD (mm) 120 120 120 120
(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) 15 8.9 11.9
Cp (kJ/kg.°C) 4.325 4.275 4.3
k (W/m.°C) 0.505 0.495 0.5
ρ (kg/m³) 976.5 980 978.25
μ (mPa.s) 2.3 3.2 2.75
mass flow rate (kg/s) 1.2188
Table 7: Stabilised White Wine Physical Properties
Stabilised White Wine Inlet Outlet Mean
Temperature (°C) 0 6.1044 3.102
Cp (kJ/kg.°C) 4.25 4.3 4.275
k (W/m.°C) 0.49 0.5 0.495
ρ (kg/m³) 982 978 980
μ (mPa.s) 3.8 2.6 3.2
mass flow rate (kg/s) 1.2250
(Table 5.2, p. 92, Rankine, 2004)
Team A Equipment Type Heat Exchanger
Project Equipment Design Equipment Name Cold Stabilisation Heat
Exchanger
Design By Aaliyah Hoosenally Equipment Number HX-01
Calculation Sheet Checked By Andrew Plavina PFD Location CHPR4401-A-0102/3
Date 21/08/2008 Page 10 of 10
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Anonymous
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.
Team A Equipment Type Filter
Project Equipment Design Equipment Name Plate and Frame Filter
Design By Aaliyah Hoosenally Equipment Number FLTR-01
Calculation Sheet Checked By Andrew Plavina PFD Location CHPR4401-A-0102/3
Date 21/08/2008 Page 1 of 2
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Anonymous
1.2. 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 http://www.stpats.com/index.htm. 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) 1500 500
Differential Pressure (kPa) 202.65 151.9875
Minimum Gauge Exit Pressure Required (kPa) 30.3975 30.3975
Minimum Required Gauge Inlet Pressure (kPa) 233.0475 182.385
Filter Sheet size 40x40 40x40
Filter Sheet Area (m2) 0.16 0.16
Maximum Number of Plates 40 40
Maximum Total Filter Area (m²) 6.4 6.4
Maximum Actual Flow Rate (litres/hour) 9600 3200
Approx. Total Volume to be Filtered (litres) 20000 16000
Total Time to be Filtered (hours) 2.08 5.00
Example of Calculations for Skin Separation Filter: Minimum Required Gauge Inlet Pressure (kPa) = Differential Pressure + Minimum Gauge Exit Pressure Required = 202.65 + 222.915 =233.0475
Maximum Total Filter Area (m2) = Filter Sheet Area (m2) 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 (m2) = 1500 x 6.4 = 9600
Total Time to be Filtered (hours) = Approx. Total Volume to be Filtered (litres) / Maximum Flow Rate (litres/hour) = 20000 / 9600 = 2.08
Team A Equipment Type Filter
Project Equipment Design Equipment Name Plate and Frame Filter
Design By Aaliyah Hoosenally Equipment Number FLTR-01
Calculation Sheet Checked By Andrew Plavina PFD Location CHPR4401-A-0102/3
Date 21/08/2008 Page 2 of 2
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Clarification: Minimum Required Gauge Inlet Pressure (kPa) =182.385
Maximum Total Filter Area (m2) = 6.4
Maximum Flow Rate (litres/hour) = 3200
Total Time to be Filtered (hours) = 5.00
Team A Equipment Type Filter
Project Equipment Design Equipment Name Membrane Filter
Design By Aaliyah Hoosenally Equipment Number FLTR-02
Calculation Sheet Checked By Andrew Plavina PFD Location CHPR4401-A-0102/3
Date 21/08/2008 Page 1 of 1
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Anonymous
1.3. 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 99.999% efficiency. The following information was taken from http://www.stpats.com/index.htm. 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) 2.2510
Wine/Beer Maximum Operating Differential Pressure (psid) 30
Wine Maximum Operating Differential Pressure (kPad) 206.8427
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 465.61
Actual Approximate Flow Rate out of Ageing (litres/minute) 450
Volume to be Filtered per type of wine (litres) 35000
Total Time for Membrane Filtration (hours) 77.78
Maximum Flow for 10" cartridge (0.7m²) (litres per minute / kPad) = Maximum Flow for 10" cartridge (0.7m²) (GPM/psid) x 0.549027562 (psid/GPM x litres/minute) = 2.25 Wine Maximum Operating Differential Pressure (kPad) = Wine/Beer Maximum Operating Differential Pressure (psid) x 6.894757 (kpa/psi) = 206.84 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) = 465.61 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) = 77.78
Team A Equipment Type Filter
Project Equipment Design Equipment Name Water Filter
Design By Aaliyah Hoosenally Equipment Number FLTR-03
Calculation Sheet Checked By Andrew Plavina PFD Location CHPR4401-A-0106
Date 21/08/2008 Page 1 of 1
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1.4. 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 http://www.stpats.com/index.htm
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) 1.7569
Wine/Beer Maximum Operating Differential Pressure (psid) 30
Wine Maximum Operating Differential Pressure (kPad) 206.8427
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 363.40
Actual Approximate Flow Rate (litres/minute)
Volume to be Filtered (litres) 20000
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 0.549027562(psid/GPM x litres/minute) = 1.76 Wine Maximum Operating Differential Pressure (kPad) = Wine/Beer Maximum Operating Differential Pressure (psid) x 6.894757 (kPa/psi) = 206.84 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) = 363.4 Total Time for Membrane Filtration (hours) = Volume to be Filtered (litres) / Actual Approximate Flow Rate (litres/minute) /60 (minutes/hour) = 0.92
Team A Equipment Type Barrel
Project Equipment Design Equipment Name Ageing in Barrels
Design By Aaliyah Hoosenally Equipment Number BRL-01
Calculation Sheet Checked By Andrew Plavina PFD Location CHPR4401-A-0102/3
Date 21/08/2008 Page 1 of 2
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1.5. 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) = 2.1324
Note. See Stream and Mass Balance Table in Volume 2 Supplement, PFD Location: CHPR4401-A-
0102.
% 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 = 34.12
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) = 34993.23
Bordeaux Barrel Volume (litres) = 225
Number of Barrels Required = Total Wine at Ageing (litres) / Bordeaux Barrel Volume (litres) =
155.53 ~ 156 barrels required
Sauvignon Blanc:
Total Grapes (tonnes) 80
Wine to Ageing (tonnes/5 tonnes grapes) 2.1324
% Wine into Ageing 43%
Total Wine (tonnes) 34.1184
Density (kg/m3) 975
Total Wine (litres) 34993.23
Barrel Volume (litres) 225
Number of Barrels Required 156
This gives a total of 312 barrels of white wine.
Team A Equipment Type Barrel
Project Equipment Design Equipment Name Ageing in Barrels
Design By Aaliyah Hoosenally Equipment Number BRL-01
Calculation Sheet Checked By Andrew Plavina PFD Location CHPR4401-A-0102/3
Date 21/08/2008 Page 2 of 2
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Shiraz:
Total Grapes (tonnes) 65
Red Wine to Ageing (tonnes/5 tonnes grapes) 2.5532
% Red Wine to Ageing 51%
Total Red Wine (tonnes) 33.1916
Density (kg/m3) 975
Total Wine (litres) 34042.67
Barrel Volume (litres) 225
Number of Barrels Required 151
Cabernet Sauvignon:
Total Grapes (tonnes) 120
Red Wine to Ageing (tonnes/5 tonnes grapes) 2.5532
% Red Wine to Ageing 51%
Total Red Wine (tonnes) 61.2768
Density (kg/m3) 975
Total Wine (litres) 62848
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 = 430 + 312 = 742 barrels.
Team A Equipment Type Heater
Project Equipment Design Equipment Name Boiler
Design By Aaliyah Hoosenally Equipment Number HTR-01
Calculation Sheet Checked By Andrew Plavina PFD Location CHPR4401-A-0106
Date 21/08/2008 Page 1 of 1
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1.6. 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) = 0.00167
Table 11: Physical Properties of Water for Hot Caustic Solution
Boiler In Out Mean
Temperature (°C) 20 80 50
ρ (kg/m3) 998.3 972 985.15
Cp (kJ/kg.K) 4.183 4.198 4.1905
Mass Flow Rate In (kg/s) = Water Flow Rate (m³/s) x ρin (kg/m3) = 1.664
Required Duty (kW) = Mass Flow Rate In (kg/s) x Cpmean (kJ/kg.K) x (Tout (°C) – Tin (°C)) = 418.34
Available sizes include: 30, 60 120, 160 and 500 kW (TCG Boiler Hire Brochure,
http://www.tcgboilerhire.com.au/Downloads/TCG_Boiler_Hire_Brochure.pdf)
Hence the closest size will be 500 kW.
19
CHPR4402 Chemical Engineering Design Project
The University of Western Australia
2. DETAILED DESIGN CALCULATIONS: HX-01
Aaliyah Hoosenally
10428141
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Anonymous
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
Calculation Sheet Location CHPR4401-A-0102
CHPR4401-A-0103 Page 1 of 7
20
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2.1. Basic Heat Exchanger Design
See Section 1.1 for basic heat exchanger design.
2.2. 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) 18709.87 Table 3.3.1(B), AS 1210, 1997
Shell ID, Ds (inches) 13.6236
Mean Ligament Efficiency, η 0.4195
Effective Design Pressure, P (psi) 20.3169 See later for calculation
Correction Factor, F 0.8 Figure RCB-7.132, p. 40, TEMA, 1999
Effective Tubesheet Thickness, T (inches) 0.1848
Minimum Tubesheet Thickness (inches) 0.3750 RCB-7.13, C-7.131, p. 38, TEMA, 1999
Actual Tubesheet Thickness (inches) 1
Actual Tubesheet Thickness (m) 0.0254
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 0.001086
1.6 (1 - do/pitch)2 0.064
Shear Controlling? NO
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
Calculation Sheet Location CHPR4401-A-0102
CHPR4401-A-0103 Page 2 of 7
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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-7.161 to RCB-7.65, pp. 48-51, 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, Es (psi) 2.87E+07 Table 3.3.7, p.84,
AS 1210, 1997 Elastic Modulus of Tube Material, Et (psi) 2.85E+07
Elastic Modulus of Tubesheet, E (psi) 2.86E+07
Shell Wall Thickness, ts (inches) 0.1882
Tube Wall Thickness, tt (inches) 0.0650
Differential Thermal Growth, ∆L (inches) 0
Tube and shell both constructed of
Stainless Steel 316
Tube Length b/w outer faces, Lt (inches) 2.4384
Tube Length b/w inner faces, L (inches) 2.3876
Tubesheet Thickness Used, T (inches) 1
Shell OD, Do (inches) 14.0
Tube OD, do (inches) 0.5
Number of tubes in shell, N 200
Correction Factor, F 0.8
Figure RCB-7.132, p. 40, TEMA,
1999,
Shell ID, Ds (inches) 13.6236
K 0.4624 RCB-7.161, p. 48, TEMA, 1999
Fq 4.0454 RCB-7.161, p. 48, TEMA, 1999, 1999
Differential Expansion Pressure, Pd (psi) 0 RCB-7.161, p. 48, TEMA, 1999, 1999
Equivalent Bolting Pressure- tube side, PBt (psi) 0 RCB-7.162, p. 49, TEMA, 1999, 1999
Equivalent Bolting Pressure- shell side, PBS (psi) 0 RCB-7.162, p. 49, TEMA, 1999
Shell Side Design Pressure, Ps (psi) 39.8854 RCB-7.163, p. 50, TEMA, 1999
fs 0.7306 RCB-7.163, p. 50, TEMA, 1999
Ps' (psi) 14.0690 RCB-7.163, p. 50, TEMA, 1999
Effective Shell Side Design Pressure (psi) 14.0690 RCB-7.163, p. 50, TEMA, 1999
Tube Side Design Pressure, Pt (psi) 39.8854 RCB-7.164, p. 51, TEMA, 1999
ft 0.9993 RCB-7.164, p. 51, TEMA, 1999
Pt' (psi) 20.3169 RCB-7.164, p. 51, TEMA, 1999
Effective Tube Side Design Pressure (psi) 20.3169 RCB-7.164, p. 51, TEMA, 1999
Fixed Tubesheet Effective Pressure, P (psi) 20.3169 RCB-7.165, p. 52, TEMA, 1999
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
Calculation Sheet Location CHPR4401-A-0102
CHPR4401-A-0103 Page 3 of 7
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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. 53-54, TEMA, 1999, for equations:
Table 13: Shell Longitudinal Stress Calculation
Cs 0.5
RCB-7.22, p. 53,
TEMA, 1999
Shell OD, Do (inches) 14.0000
Shell Wall Thickness, ts (inches) 0.1882
P1 = Pt - Pt' (psi) 19.5685
Ps' (psi) 14.0690
Ps* = P1 + Ps' (psi) 33.6374
Maximum Longitudinal Shell Stress, Ss (psi) 308.5953
Allowable Stress in Tension, S (psi) 18709.87
Table 14: Tube Longitudinal Stress Calculation
Fq 4.0454
RCB-7.23, p. 54,
TEMA, 1999
Shell ID, Ds (inches) 13.6236
Number of Tubes, N 200
Tube Wall Thickness, tt (inches) 0.0650
Tube OD, do (inches) 0.5
Ct 0.5
P2 10.4646
P3 6.8655
Pt* = P2 10.4646
Maximum Longitudinal Tube Stress, St (psi) 173.6772
Allowable Stress in Tension, S (psi) 18709.87
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:
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
Calculation Sheet Location CHPR4401-A-0102
CHPR4401-A-0103 Page 4 of 7
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Table 15: Tube-to-Tubesheet Joint Loads
Fq 4.0454
RCB-7.25, p. 56, TEMA,
1999
Pt* = P2 10.4646
Shell OD, Do (inches) 13.6236
Number of Tubes, N 200
Maximum Effective Joint Load, Wj (lbf) 30.8548
Maximum Allowable Joint Load (lbf) 3673673
Hence the tube-to-tubesheet joint load is within an acceptable limit.
2.3. 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, Cp 0.4
p. 818, Coulson,
Richardson & Sinnot, 2005
Bolt Circle Diameter, De (m) 0.470
ND=350, Figure v, Table D,
AS 2129, 2000
Design Pressure (N/mm2) 0.275
Design Tensile Stress (N/mm2) 129
Required Plate Thickness (m) 0.0087
Actual Plate Thickness (m) 0.022
The bolt spacing of the flange must now be checked. The maximum bolt spacing for a flange
with a full faced gasket is:
(3.21.4.1, p. 190, AS 1210, 1997).
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
Calculation Sheet Location CHPR4401-A-0102
CHPR4401-A-0103 Page 5 of 7
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Table 17: Bolt Spacing
Minimum Bolt Diameter (m) 0.0127
RCB-11.1, C-11.1,
p.77, TEMA, 1999
Nominal Diameter 350 Figure v, Table D,
AS 2129, 2000 Actual Bolt Diameter, dB (m) 0.0222
Flange Thickness, tf (m) 0.022
Gasket Type
Flat Metal -
Stainless Steel
Gasket Factor 6.5
Table 3.21.6.4(A),
p. 205, AS 1210,
1999
Elastic Modulus of Flange Material (Steel), E (MPa) 1.96E+05
Maximum Bolt Spacing, max Pb (m) 0.0632
Bolt Circle Diameter (m) 0.470 Figure v, Table D,
AS 2129, 2000 Actual Number of Bolts 12
2.4. 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 D1 is the outer diameter of the shell or tube, and D2 is the inner diameter.
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
Calculation Sheet Location CHPR4401-A-0102
CHPR4401-A-0103 Page 6 of 7
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Table 18: Shell Mass Calculation
Stainless Steel 316 Density (kg/m³) 8000
Actual Shell OD , Do (m) 0.3556
Actual Shell ID, Ds (m) 0.3460
Actual Shell Thickness (m) 0.0048
Shell Length, Ls (m) 3.556
Shell Volume (m³) 0.0187
Shell Mass (kg) 149.8697
Table 19: Tube Mass Calculation
Stainless Steel 316 Density (kg/m³) 8000
Tube OD (m) 0.0127
Tube Thickness (m) 0.0017
Tube ID (m) 0.0094
Tube Length (m) 2.4384
Tube Volume (m³) 0.00014
Tube Mass (kg) 1.1179
Number of Tubes 200
Total Tube Mass (kg) 223.5861
Table 20: Liquid Mass Calculation
Average Density (kg/m³) 977
Max Liquid Volume (m³) 0.3344
Max Liquid Mass (kg) 326.7374
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) 0.525
Blind Flange Thickness (m) 0.022
Blind Flange Volume (m³) 0.0048
Blind Flange Mass (kg) 38.0997
Number of Ends 2
Total End Mass (kg) 76.1993
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
Calculation Sheet Location CHPR4401-A-0102
CHPR4401-A-0103 Page 7 of 7
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Table 22: Dead Weight of Vessel Calculation
Shell Mass (kg) 149.8697
Max Liquid Mass (kg) 326.7374
Total End Mass (kg) 76.1993
Total Tube Mass (kg) 223.5861
Total Vessel Mass (kg) 776.3925 Sum of shell, liquid, tube and ends.
Correction factor 1.08
Taking into account any external
fittings.
Corrected Vessel Mass (kg) 838.5039
Dead Weight of Vessel (kN) 8.225724 =9.81*Vessel Mass
Figure 13.26 (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).
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