CHEMICAL ENGINEERING

CHEMICAL PROCESS CATEGORY L T P CREDIT

CHT401
EQUIPMENT DESIGN I PCC 2 1 0 3

Preamble: The objective of this course is to give a foundation for the undergraduates in the
design of equipment used in process industries for the unit operations heat transfer, evaporation
and evaporative cooling. This course includes sizing of equipment and selection of the internal
parts. It also covers the use of standards and codes for the design of equipment.

Prerequisite: Knowledge in heat and mass transfer, process calculations, fluid and particle
mechanics, thermodynamics and material science

Course Outcomes: After the completion of the course the student will be able to

CO 1 Develop the thermal design of double pipe exchangers for a given heat exchange
operation between single-component fluids
CO 2 Develop the thermal design of shell and tube exchangers for a given heat exchange
operation between single-component fluids
CO 3 Design tubular condensers for condensation of single-component fluids
CO 4 Develop the process design of evaporators for a given feed solution and terminal
conditions
CO 5 Design mechanical draft cooling tower for a given tower fill

Mapping of course outcomes with program outcomes

PO PO PO PO PO PO PO PO PO PO PO PO
1 2 3 4 5 6 7 8 9 10 11 12
CO 1 3 2 3 3
CO 2 3 2 3 3
CO 3 3 2 3 3
CO 4 3 2 3 3
CO 5 3 2 3 3

Assessment Pattern

Continuous Assessment
Bloom’s Category Tests End Semester Examination
1 2
Remember
Understand
Apply 50 50 100
Analyse
Evaluate
Create
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Mark distribution

Total ESE
CIE ESE
Marks Duration

150 50 100 3 hours

Continuous Internal Evaluation Pattern:

Attendance : 10 marks
Continuous Assessment Test (2 numbers) : 25 marks
Assignment/Quiz/Course project : 15 marks

End Semester Examination Pattern: There will be two parts; Part A and Part B.

• Question paper contains 2 numerical design questions from each module on different topics
of which the student shall have to answer any one from each module. Each question carries
50 marks. There can be subdivisions for the main question/topic only.
• The questions should be clear in respect of type of equipment and its alignment if any,
operating conditions, and materials handled. Data required for design such as equilibrium
data and physical properties in case it cannot be obtained from handbook, material of
construction etc shall be provided with the question.
• Question paper should contain instruction as given below:
Apart from scientific calculators (including programmable) the following books and data
books are permitted for the exam:
1. Steam tables
2. Perry’s Handbook
3. Dühring's charts, Nomographs, charts and tables used in design taken from TEMA
standard/other editions of Handbook. The copies should be attested by the course faculty
concerned or as directed by university.

Course Level Assessment Questions

Course Outcome 1 (CO1): Do thermal design of double pipe exchangers, tubular exchangers and
condensers for a given heat exchange operation between single component fluids

1. Design a double pipe heat exchanger to cool 3600 kg/hr ethanol from 80°C to 40°C using
cooling water enters the heat exchanger at 20°C and leaves at 26°C. A fouling factor of
should be provided for each stream, and allowable pressure drop on each

stream is 10 psi. The heat exchanger consists of 20 ft hairpins of 2 x 1.25 in. Schedule
number 40S steel pipes.
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Course Outcome 2 (CO2) Develop the thermal design of shell and tube exchangers for a given
heat exchange operation between single-component fluids

1. A counterflow shell and tube heat exchanger is to be used to cool water from 27 0C to 6 0C
using brine entering at -20C and leaving at 30C. The overall heat transfer coefficient is
estimated to be 500 W/m2 0C. Estimate the size of the exchanger for a design heat load of 10
kW.
2. 24,000 kg/hr of ethylene glycol is to be cooled from 90 0C to 40 0C by water available at 20
0
C. The maximum temperature to which water can be heated is 35 0C. A 1-2 shell and tube
heat exchanger is to be designed for this purpose using 19mm OD 10 BWG steel tubes.
Design the exchanger if the length of the tube is limited to 4 m. Fouling resistance and wall
resistance can be neglected.

Properties of fluids at mean temperatures are:

Property Ethylene glycol Water

Density, kg/m3 1078 995

Viscosity, Ns/m2 3.22 x10-3 0.853 x 10-3

Specific heat, J/kg K 2650 4180

Thermal conductivity, W/mK 0.261 0.614

Course Outcome 3 (CO3): Design tubular condensers for condensation of single-component fluids

3. 5000 kg/hr of propanol is to be condensed in a shell and tube condenser at 1atm pressure.
Cooling water is circulated in tubes with inlet temperature 200C and outlet temperature
30oC. Design a vertical condenser

Course Outcome 4 (CO4): Develop the process design of evaporators for a given feed solution
and terminal conditions

4. Design a single effect short tube vertical evaporator to concentrate 5000 kg/hr of 2% NaOH
solution by weight, available at 25oC to a concentration of 20% NaOH by weight. Saturated
steam is available at 1.5 kgf/cm2 (abs). The pressure in the evaporator is 70 cm of Hg.
Boiling point elevation of the solution is 60C. Enthalpy of feed and thick liquor is 18kcal/kg
and 80kcal/kg respectively. The cross sectional area of the down comer should be
approximately 50% of the total tube flow area. Draw to a suitable scale.

5. A double effect short tube vertical evaporator is used for concentrating 20000 kg/h of 5%
sugar solution to 40% using saturated steam available at 3.8 atm absolute. The feed is at
300C and a vacuum of 600 mm Hg is maintained in the evaporator. For the 1st and 2nd
effects, the corrected heat transfer coefficients are 2000 and 1200 W/m2 0C respectively and
boiling point elevations are 7 and 5oC respectively. Estimate the size of the evaporator and
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prepare a data sheet indicating the fluids handled, operating conditions, heat duty, steam
flow rate, economy, heat transfer area, calandria details and vapor drum details.

Course Outcome 5 (CO5): Design mechanical draft cooling tower for a given tower fill

6. Water at 40oC is to be cooled to 25oC by means of air in an induced draft cooling tower.
Water flows at a rate of 2.5 m3 /s. Air is at DBT 30oC with a relative humidity of 70%.

Fill mass transfer coefficient, Kx.a: 2 s-1

Properties of air and water are:
Density of air: 1.21 kg/m3
Specific heat of air: 1005 J/kgK
Specific heat of water vapour: 1884 J/kgK
Latent heat of vaporization: 2334.7 kJ/kg

Estimate the size of tower required for this cooling operation, fan hp for 90% performance and
calculate the makeup water required if blow down is once in three cycles.
Draw a neat sketch of the tower sectional elevation to a suitable scale
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Model Question Paper

QP CODE: PAGES: 2

Reg No:________________________
Name :_________________________

APJ ABDUL KALAM TECHNOLOGICAL UNIVERSITY

SEVENTH SEMESTER B. TECH DEGREE EXAMINATION, MONTH & YEAR
Course Code: CHT 401

Max Duration: 3 Hours Marks:100

CHEMICAL PROCESS EQUIPMENT DESIGN I

(2019 Scheme)
Instructions:
Apart from scientific calculators (including programmable) the following books and databooks are
permitted for the exam:
1. Steam tables
2. Perry’s Handbook
3. Attested copies of Dühring's charts, Nomographs, charts and data tables used in design
taken from TEMA standard/ Other editions of Handbook

(Answer one full question from each module; each full question carries 50 marks)
Module -I

1. Design a double pipe heat exchanger to cool 2700 kg/hr ethanol from 80°C to 40°C using
cooling water enters the heat exchanger at 20°C and leaves at 26°C. A fouling factor of
should be provided for each stream, and allowable pressure drop on each

stream is 10 psi. The heat exchanger consists of 20 ft hairpins of 2 by 1.25 in. Schedule number 40
steel pipes. (50marks)

OR

2. 5000 kg/hr of saturated iso-propyl alcohol is to be condensed in a shell and tube condenser
at 1atm pressure. Cooling water is available for circulation in tubes with inlet temperature 20oC and
maximum outlet temperature 30oC. Design a horizontal condenser. (50marks)

Module -II

3. A double effect long tube falling film evaporator is used for concentrating 15000 kg/h of
10% sucrose solution to 50% using low pressure steam available at 1.8 atm absolute. The feed is at
30oC and a vacuum of 630 mm Hg is maintained in the evaporator. The corrected heat transfer
coefficients are 2000 and 1200 W/m2 oC respectively for 1st and 2nd effect and boiling point
elevation are 7 and 5oC. Design a long tube falling film evaporator. (50 marks)

OR
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4. A paper mill producing 200 tons of pulp per day by the magnesium sulphite process
concentrates a 10% waste liquor to 50% in a triple effect forward feed evaporator unit. The solution
entering in the first effect at 56oC is evaporated by 40 psig saturated steam. The last effect vapour
space is at 26 inch Hg. Boiling point rise in the effects are 10, 8, 5 oC respectively. Mean specific
heat of solution at all concentrations may be taken as 3.65 kJ/kgoC. The overall heat transfer
coefficients in the first, second and third evaporators are 1200, 1080, 975 W/m2K respectively.
Estimate the heat transfer area and design a rising film evaporator. (50 marks)

***********
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Syllabus

Module 1

Thermal design of double pipe heat exchanger: Constructional features - Calculation of heat transfer
area – estimation of heat transfer coefficient – calculation of the size of double pipe – pressure drop
estimation in double pipe flow.

Thermal design of shell and tube heat exchanger: Constructional features – baffles and pass
partition – TEMA nomenclature – routing of fluids - Calculation of heat transfer area – estimation
of tube bundle size - estimation of overall heat transfer coefficient using Bell’s method – pressure
drop in shell side and tube side.

Thermal design of shell and tube condensers for single component isothermal condensation of
saturated vapours in shell. Estimation of heat transfer area – Estimation of bundle size and shell
diameter - estimation of in-shell condensation coefficients using Dukler charts – estimation of
overall heat transfer coefficient

Module 2

Thermal design of evaporators: Constructional features and design of short tube calandria
evaporator, long tube evaporator, and forced circulation evaporator – estimation of heat transfer area
in multiple effect evaporators with negligible boiling point rise (double/triple effect forward feed
only) – effect of boiling point elevation in evaporator calculation

Process design of mechanical draft Cooling Towers: Estimation of air quantity, tower characteristics
- number of diffusion units using graphical method, water concentration, tower cross section area,
fan hp, make-up water requirement

Reference Books, codes and standards

1. Perry. R.H & Green.D.W., Chemical Engineers Handbook, Mc- Graw Hill.
2. Kern D.Q., Process Heat Transfer, Tata McGraw Hill.
3. Badger & Bancharo, Introduction to Chemical Engineering, McGraw Hill
4. Coulson J.M.& Richardson J.F., Chemical Engineering, Vol.6, 3rd Edn, Butterworth
Heinemann, (Indian print)
5. M.V Joshi & Mahajan V.V., Process Equipment Design, 3rd Edn, Mac-Milan & Co. India.
6. Datta B.K., Heat Transfer: Principles and Applications, Prentice Hall India.
7. McCabe W.L., Smith J.C. & Harriott P., Unit Operations in Chemical Engineering, McGraw
Hill.
8. E. Ludwig, Applied Process Design for Chemical & Petrochemical Plants, Vol I, II, III, Gulf
Publication, London
9. Standards of Tubular Exchanger Manufacturers Association
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Course Contents and Lecture Schedule

No Topic No. of
Lectures

1 MODULE-I 18

1.1 Thermal design of double pipe heat exchanger: Constructional features - 3

Calculation of heat transfer area – estimation of heat transfer coefficient

1.2 Thermal design of double pipe heat exchanger: calculation of the size of 2
double pipe

1.3 Thermal design of double pipe heat exchanger: pressure drop estimation in 1
double pipe flow.

1.4 Thermal design of shell and tube heat exchanger: Constructional features 1
– baffles and pass partition – TEMA nomenclature

1.5 Thermal design of shell and tube heat exchanger: routing of fluids - 2
Calculation of heat transfer area – estimation of tube bundle size

1.6 Thermal design of shell and tube heat exchanger: estimation of overall 2
heat transfer coefficient using Bell’s method

1.7 Thermal design of shell and tube heat exchanger: pressure drop in shell 2
side and tube side

1.8 Thermal design of shell and tube condensers for single component 2
isothermal condensation of saturated vapours in shell. Estimation of heat
transfer area

1.9 Thermal design of shell and tube condensers for single component 3
isothermal condensation of saturated vapours in shell. Estimation of
bundle size and shell diameter - estimation of in-shell condensation
coefficients using Dukler charts – estimation of overall heat transfer
coefficient

2 MODULE-II 17

2.1 Thermal design of evaporators: Constructional features and design of 6

short tube calandria evaporator and long tube evaporator –effect of boiling
point elevation in evaporator calculation

2.2 Thermal design of evaporators: estimation of heat transfer area in multiple 6

effect evaporators with negligible boiling point rise (double and triple
effect forward feed) – effect of boiling point elevation in multiple effect
evaporator calculation - trial and error method to estimate heat transfer
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area in each effect

2.3 Process design of mechanical draft Cooling Towers: Estimation of air 3

quantity, tower characteristics - number of diffusion units using graphical
method

2.4 Process design of mechanical draft Cooling Towers: Estimation of water 2

concentration, tower cross section area, fan hp, make-up water
requirement