A Project Report

On

HDPE Plant Overview & Design of Heat Exchanger

By

Deepak Pandey
B. Tech 3rd Year
Applied Petroleum Engineering (Specialization in Gas)
University of Petroleum & Energy Studies
Dehradun (248001)

Under Guidance
Of

Mr. Sandeep Maji

Production Manager (HDPE)
IOCL (Panipat)

Project Report Approval Sheet

It is to certify that the project entitled, HDPE Plant Overview & Design of Heat
Exchanger was completed by Mr. Deepak Pandey under my guidance during
the period w.e.f. 1st July 2014 to 31st July 2014. The same is hereby approved.

Mr. Sandeep Maji

Production Manager (HDPE),
Indian Oil Corporation Ltd. (IOCL)
Panipat, Haryana

Acknowledgement

I would like to thank the Management of IOCL, Panipat Refinery &

Petrochemicals for giving me the opportunity to do my summer internship under
the guidance of Mr. Sandeep Maji, Production Manager (HDPE). I am thankful to
him for his guidance, constant supervision, for providing necessary information
regarding the project and also for his support in completion of the project. I would
also like to give my gratitude to my family and my colleagues for their constant
encouragement and support.

Table of Contents

Project Report Approval Sheet .................................................................................................... 2

Acknowledgement ....................................................................................................................... 3
List of Figures ............................................................................................................................. 6

Chapter 1: Overview of Panipat Refinery & Petrochemicals ..................................................... 7

1.1.

PANIPAT REFINERY ................................................................................................. 7

1.2.

PANIPAT PETROCHEMICALS................................................................................. 9

Chapter 2: HDPE Unit Description ........................................................................................... 12

2.1.

Introduction .................................................................................................................... 12

2.2.

Layout of HDPE Plant ................................................................................................ 12

2.3.

Block & Process Flow Diagram ................................................................................. 13

2.4.

Brief Process Description ........................................................................................... 14

2.5.

Other Process Facilities .............................................................................................. 23

2.6.

Description of Chemicals Used .................................................................................. 24

2.6.

Utility Characteristics ................................................................................................. 25

2.7.

General Material Balance ........................................................................................... 25

Chapter 3: Design of Heat Exchanger ....................................................................................... 26

3.1.

Basic Design Theory .................................................................................................. 26

3.2.

Design Specifications of Different Components of Shell & Tube Heat Exchanger .. 27

3.3.

Important Formulae used in Heat Exchanger Design ................................................. 28

3.4.

Kerns Method ............................................................................................................ 32

Chapter 4: Design Calculations for Heat Exchangers ............................................................... 33

4.1.

Operational & Design Data ........................................................................................ 33

4

4.2.

Assumptions ............................................................................................................... 35

4.3.

Calculations ................................................................................................................ 35

4.4.

Calculated Data Sheet ................................................................................................. 41

4.5.

Excel Sheet Calculation .............................................................................................. 42

Conclusion................................................................................................................................. 43

List of Figures

Figure 1: HDPE Plant Layout ...................................................................................................... 12

Figure 2: Block Diagram.............................................................................................................. 13
Figure 3: Schematic Diagram ...................................................................................................... 13
Figure 4: Fluidized Bed Dryer ..................................................................................................... 16
Figure 5: Powder Treatment Vessel ............................................................................................. 17
Figure 6: Distillation & C4 Recovery Column ............................................................................. 19
Figure 7: Wax Evaporator ............................................................................................................ 20
Figure 8: Pellet Drying & Conveying .......................................................................................... 21
Figure 9: Extruder ........................................................................................................................ 22
Figure 10: Design Data Sheet ...................................................................................................... 34
Figure 11: Final Calculated Sheet ............................................................................................... 41

Chapter 1: Overview of Panipat Refinery & Petrochemicals

Indian oil Panipat complex in a sprawling area of 4225 acres of land is located in villages Baholi
and BAL Jatan. The largest integrated Refinery and Petrochemicals hub in India and third in
south East Asia, the Complex comprises of the 15 MMTPA Panipat Refinery, PX/PTA
Aromatics Complex, Panipat Naphtha Cracker, Northern Region Pipelines, Panipat Marketing
Complex and a Unit of Business Development division for marketing Petrochemicals.
1.1. PANIPAT REFINERY
Panipat Refinery, the 7th Refinery of finding Oil Corporation Limited, is situated amidst Lush
green fields of the historic district of Panipat in the State of Haryana. The Refinery is located
about 23 km from Panipat city and around 100 km from Delhi. The Refinery was commissioned
on 12th July, 1998. Panipat Refinery meets the demand of Petroleum products not only of
Haryana but also of the entire North-Western Region including Punjab, J&K, Himachal Pradesh,
Chandigarh, Uttaranchal and Parts of Rajasthan, U.P. and Delhi.
The initial installed Capacity of the refinery was 6.0 MMTPA. The major secondary Processing
units of the Refinery include Catalytic Reforming Unit, Once-Through Hydrocracker Unit, Resin
Fluidized Catalytic Cracking Unit, Visbreaker Unit, Bitumen Blowing Unit, and Sulphur Black
and associated Auxiliary Facilities.
Panipat Refinery was built using world-class technology from IFP, France; Haldor-Topsoe,
Denmark; UNOCAL/UOP, USA and Stone& Webster, USA. It has the capacity to process a
wide range of both indigenous and imported grades of crude oil. The refinery receives crude
from Vadinar through 1370 km long Salaya-Mathura Pipeline (extended to Panipat).
In order to improve diesel Quality, a Diesel Hydro Desulphurization Unit (DHDS) was
subsequently commissioned in 1999. A Propylene Separation Unit was also installed in 1999 for
recovery of Propylene from cracked LPG. In line with an Indian Oils commitment to
environment protection a standby Sulfur Recovery Unit and a high efficiency Gas Turbine for
power and steam generation were also commissioned in 2001.
Panipat Refinery Expansion to 12 MMTPA
With a view to meet the growing deficit of petroleum products, especially in the Northern
Region of the country, Capacity of Panipat Refinery was expanded from 6MMTPA to 12
MMTPA in August 2006. Major secondary units with the expanded facilities include Full
Conversion Hydro cracking unit, Hydrogen Generation, Unit, Sulphur Black and the associated
auxiliary facilities. For the supply of crude oil for the expansion units, the Kandla-Bhatinda
product pipeline was converted to crude oil service and the crude oil service and the crude oil are
received at the Mudra Port on Gujarat Coast and supplied to the refinery through this pipeline.

Capacity and yield improvement revamp was also carried out in existing CCRU and FCC units
in 2008 for improving profitability.
Meeting Socio-Statutory Regulation: Euro III and Euro IV
To meet socially-statutory regulations and environmental standards the Refinery was required to
produce Euro III/IV quality MS. Therefore the MSQ project consisting of PENEX
(Isomerization) 400 TMTPA, Naphtha Hydrotreater Unit 410 TMTPA, Reformate Splitter -470
TMTPA and FCC Casolice Desulphurization- 370 TMTPA was approved at a cost of 1131
crores INR, completed and commissioned in November, 2009. Panipat Refinery is Indian oils
first refinery to produce Euro III/IV MS.
From 12 MMTPA to 15 MMTPA
The refining capacity of Panipat Refinery was enhanced from 12 MMTPA to 15 MMTPA in
November, 2010. The expansion will enable processing of 3 MMTPA High Sulphur Crude. The
expansion will also enable producing Euro-III / IV Quality HSD.
The capacity revamp included Crude and Vacuum Distillation Units (CDU/VDU-I) from 6.0to
7.5 MMPTA, Once through Hydro cracking Unit (OHCU) from 1.7 to 1.9 MMPTA ,Delayed
coking Unit (DCU) from 2.4 to 3.0 MMTPA, Amine Regeneration Unit (ARU) from 296 M3 /
hr. to 400 M3/ hr.
Other jobs included installation of second stage reactors in the diesel Hydro-treating Unit
(DHDT); installation of New sour Water Strippers (SWS and additional train of sulphur recovery
Unit ( SRU) with Tail Gas Treating Unit (TGTU). Augmentation storage-two LPG mounded
bullets, 2 Naphtha, MS Tanks, one DHDT feed tank, utilities new Cooling Towers, Sub-stations
and offsite piping was also carried out.
Products dispatch
The Petroleum products from the Refinery are transported through various modes Rail, Road as
well as Environment-friendly pipelines. The LPG produced from the Refinery is pumped through
a dedicated pipeline to Indian Oils Kohand Bottling Plant where bottling and bulk dispatch are
done. The LPG is further transported to Jalandhar through a cross country pipeline,
commissioned in April2009.

1.2. PANIPAT PETROCHEMICALS

To achieve its erstwhile vision of becoming a leading petrochemical player in the country, Indian
Oil Corporation Limited embarked upon setting up world class Petrochemical units comprising
of PX/PTA complex and Naphtha cracker complex.
The project has been designed to synergize with existing Panipat Refinery to generate value
added products Indian Oil has emerged as leading Petrochemicals Player in the country with
commissioning of the countrys largest Purified Terephthalic Acid (PTA) plant. The PTA Unit at
Panipat Refinery with state of the art technology from M/s In vista (earlier DuPont) was
commissioned in mid-2006.
The combined PX-PTA project was set up to produce 360 TMT of Para-xylene and 553 TMT of
PTA per annum utilizing Naphtha from Mathura and Panipat Refineries. Para-xylene is an
intermediate product used in the manufacture of PTA. PTA in turn, serves as an input for the
production of Polyester Staple Fiber PSF, Polyester filament yarn PFY and other resins.
Panipat Naphtha Cracker
The world class Panipat Naphtha Cracker complex comprising of the largest Naphtha Cracker in
India along with downstream polymer units built at a cost of 14439 Crores INR, was
commissioned in March2010. Indian Oil people with dedication and determination, completed
construction and commissioning of the project in a record time of 46 months.
With a number of niche products to its credit today, the project is a cornerstone for Indian Oils
entry into petrochemicals and a new business line for growth. For the State of Haryana, the
project will spur the creation of a world class petrochemicals hub, which will engender
significant industrial activity in the coming years. The Naphtha feedstock for the Naphtha
Cracker is sourced internally from Indian Oils Gujarat, Panipat and Mathura refineries.
Units of Naphtha cracker complex
There are five main process units in the Naphtha cracker complex:
Naphtha cracker & Associated units

Capacities in 1000 Tons per Annum

Ethylene Production Unit

LLDPE / HDPE Swing Unit
Polypropylene Unit
HDPE Unit
MEG Unit
Associated units consist of C4 hydrogenation
unit, Pyrolysis Gasoline Hydrogenation Unit
and
Benzene
Extraction
Unit
Two
Polypropylene Chains of 300,000 TPA each.
Naphtha Cracker Unit (NCU)

800
350
600
300
300
300,000 (TPA Each)

The Naphtha cracker is the largest process unit with a capacity to produce 800000 TPA Ethylene,
650000 TPA Propylene for downstream polymer units. With state-of- the art technology
licensed by CBI Lummis USA and constructed by Tokyo Japan and L&T, the unit also produces
Benzene and other blending streams for the Refinery. A Plant for extraction of Butadiene is
under construction for supply of butadiene as feed to the upcoming emulsified styrene Butadiene
Rubber ESBR joint venture.
Downstream Units
Ethylene is the feedstock for downstream polymer with Swing Unit and HDPE unit for
producing various grades of ploy ethylene polymers. It is also the feedstock for MEG unit which
mainly produces MEG along with DEG and TEG by products.
Quality Assurance and Business Development
To assure quality, propel development and evaluation of new application and new grades of
polymers, Panipat Naphtha Cracker has a Quality Control Laboratory with world class state of
the art instruments and a Product Application and Development center PADC, testing Petroleum
and polymer testing.
Manned by personnel with experience of leading petrochemical companies , the PADC has a
total of four laboratories. Out of them, two polymer processing laboratories have machines
which predict the performance of polymer grades in market by converting them into finished
products like films, molded articles, pipes, storage tanks, blow molded jerry cans, specialty
compounds, etc.
The other two are polymer testing and characterization laboratories with sophisticated equipment
for testing of physical, chemical, weathering, thermal, optical, environmental properties of
polymer raw material as well as finished products.
Products from Naphtha Cracker Complex
The polymers products from the naphtha cracker comprise of LLDPE, HDPE, polypropylene, the
petrochemical/chemical feed stocks are MEG, DEG and BENZENE. Niche grades from the
polypropylene unit include high speed BOPP (biaxial oriented polypropylene) which is used for
food packaging, lamination, etc. high clarity random copolymer used for making food containers,
thin walled products and super impact copolymer grades used for batteries, automobile parts,
luggage, heavy duty transport containers etc. Applications of LLDPE include multilayer film for
packaging, milk packing, water storage tanks and road barriers etc. HDPE is used for making
bins and crates, pipes and pipe coating, woven sack bags, mosquito nets, containers, shopping
bags, containers /bottles for packaging of oil, cosmetics etc.
Mono ethylene glycol the main products with diethyl glycol and tri ethyl glycol as by products
are hygroscopic and have the largest application in the manufacture of the polyesters (PSF, PFY,
10

POY, PET files and bottle grade resin). It has various ranges of applications like explosives,
cosmetics, printing ink, anti-freeze and coolant in automobiles etc. MEG is also used as
stabilizers against gel formation.
Benzene is used for production of detergents, pesticides, solvents, paints & varnishes, adhesives,
in rubber processing etc.
Dispatch of Products
The polymer warehouse at Panipat Asias biggest warehouse is 740 M in length and 80M wide to
accommodate around 55000 MTs of polymer grades packed in 25 kg PP woven sack bags. It has
15 online bagging and pelletizing machines, each with a capacity to bag 1200 bags of 25 kg each
per hour. In addition, it has 50 loading bays and two independent battery charging rooms to
support continuous fork-lift operations.
The PTA warehouse 428m in length and 100m wide has a storage capacity of 50,000 tons and
handles about 18,000 tons per day. There are 50 fork lifts, 2 silos of 3000 tons each and 3
bagging machines capable of bagging 60 tons per hour with 12 loading points. There is a
container siding near the warehouse for rail movement.
Adequately trained manpower in bagging operations, warehouse management and intricacies of
supply chain management coupled with excellent display and tracking system ensures right
grades reach the right customers. Indian Oils contract with Container Corporation of India Ltd.
(CONCOR) for movement of PTA and polymer is also leveraged to reach the product to
container.

11

Chapter 2: HDPE Unit Description

2.1. Introduction
The HDPE (High Density Poly Ethylene) Unit in the Panipat Naphtha Cracker Complex is
designed to produce different grades of high density poly ethylene polymer from polymer grade
ethylene sourced from Naphtha Cracker Unit (NCU) within the complex. The HDPE Unit
employs the Hostalen Slurry Process technology licensed by M / s Basell Polyolefin Gmbh of
Germany. The polymerization is carried out in liquid suspension (slurry) phase and hexane is
used as a diluent (solvent) in the polymerization process.

2.2.

Annual production capacity: 300,000 tons / year of High Density Polyethylene resin
based on a product mix of Bimodal HDPE resins, Broad MWD HDPE resins and Narrow
MWD HDPE resins.
Polymerization Single Line having two reactors and one post reactor in series.
Design operating hours per year: 8,000 (including transition time)
Turndown: The plant will operate at 50 % turndown except the pelletization section,
which would have around 65% turndown.
Catalyst Used: THE, THB, THT and Z501. THE, THB and THT catalysts are nonstoichiometric solid state compounds with varying proportion of Magnesium and
Titanium Chloride. These catalysts are prepared in plant. Z501 is supplied readymade by
BASELL (Ferrara Italy or Frankfurt Germany) and can be used after diluting in
hexane.
Layout of HDPE Plant

Figure 1: HDPE Plant Layout

12

2.3.

Block & Process Flow Diagram

Figure 2: Block Diagram

Figure 3: Schematic Diagram

13

2.4.

Brief Process Description

2.2.1. Catalyst Preparation, Handling and Dosing

The catalyst used in the polymerization is called THE, THB and THT and their
production is performed batch wise from commercially available components (titanium
tetrachloride and magnesium ethoxide) in the catalyst preparation unit (R-1101) as per
prescribed recipe. The 4th catalyst used in polymerization unit is Avant Z501 is supplied
by BASELL as solid powder in drums. The prepared catalyst is transferred to catalyst
suspension vessels V-1102 A/B/C/D. From here the catalyst is supplied to V-1104 A/B,
where some more hexane can be added if required, and continuously sent to reactors via
dosing pumps P-1101 A/B.
2.2.2. Activator Dosing
The polymerization activator is pumped from tank V-4103 (10% TEAL solution in
Hexane) or V-4106 (20% IPRA solution in Hexane) respectively in the activator dosing
vessels V-1103 A/B by their respective pumps P-4103 A/B. From here it is pumped to the
reactor R-1201 & 1202 by the activator dosing pumps. All the vessels and the reactor in
the catalyst preparation area are nitrogen blanketed and the pressure is controlled by split
range loops between nitrogen feed and off gas line. The temperature of the reactor is
controlled by jacket water loop.
2.2.3. Polymerization
The continuous polymerization reaction takes place in an inert solvent Hexane in agitated
reactors R-1201 & 1202. Butene-1 is used as the co-monomer to manipulate the
polyethylene density as per the required grade. Hydrogen is used as the chain terminator
to set the desired the molar mass. Continuous polymerization takes place in 2 reactors
connected in series (K2 BM mode) or parallel (K1 mode) at the temperature of 76 to 85C
and the pressure between 2.6 to 9 kg/sq.cm gauge. A part of slurry discharge is recirculated by the pumps P-1201 A/B and the remaining is flashed back to the vessel V1201 for degassing to control the reaction condition for the next reactor. The suspension
from this vessel is pumped to the second reactor by the pump P-1204. From reactor 2 the
suspension is fed to the reactor R-1204 to convert rest of the ethylene into HDPE. The
products are then pumped into the decanter vessel (acting as the buffer) after being
cooled in suspension cooler E-1301 & 1302. All the reactors as well as the decanter feed
vessel are equipped with top driven multi-stage agitators.
In order to remove the reaction heat, all the reactors are equipped with the cooling
jackets. At the temperature over 89C the monomer and the catalyst supply are stopped
through the interlocks. The water is used for the slurry cooler and the reactor jackets are
fed from the closed system; the secondary cooling water or the jacket water system. The
composition of the gas contained in the gas phase of the two reactors is used as a basis for
polymerization process control, by controlling the hydrogen, butane-1 and the catalyst
feed flow rates (according to the recipe) and the reaction pressure. The gas leaving the
14

flash vessel V-1201 together with the gas leaving R-1204 is sent to the pressure controller
to the condenser E-1303. The gas leaving the condenser is sent to the scrubbing tower C3201, while condensed liquid is discharged to decanter feed vessel V-1301.

Figure 2.4: Reactor Loop 1 (left) and Reactor Loop 2(Right)

2.2.4. Decanter Feed Vessel
The decanter feed vessel V-1301 is an agitated vessel which is normally filled wit7h
suspension up to 20 to 30%. It serves as the buffer vessel to compensate short term
interruption of the product flow in the downstream units of te hexane separation and the
powder drying. By the means of decanter feed pump P-1302 A/B the suspension is
transferred to decanter centrifuges S-2101 A/B/C.
2.2.5. Centrifuge
The decanter centrifuges S-2101 A/B/C, operated in parallel separates a major portion of
Hexane from the soli polyethylene by the means of centrifugal forces. The separated
Hexane (mother liquor) reaches to the mother liquor collecting vessel V-2101 by gravity
and is recycled to the reactors as per the recipe. A stream of mother liquor collecting
vessel is sent to the hexane purification section. The hexane moist HDPE powder is
discharged from centrifuges by gravity to the screw conveyors SF-2101 A/B/C.
2.2.6. Drying
The dryer consists of two stages of which the first is fully back mixed and the second is
working according to the plug flow principle. In the dryer the residual hexane contained
in the HDPE powder is evaporated using the hot nitrogen to the residual content < 1%
(by wt.). The screw conveyors SF-2101 A/B/C feeds the hexane moist HDPE powder to
the first dryer chamber, where the product is fluidized with hot nitrogen to evaporate the
major part of the residual hexane. In the second chamber the rest of the hexane is
separated and the powdered temperature is maintained at around 102C. The dryer is
equipped with internal heating coil or plates fed with the stream at 0.7 kg/sq.cm gauge
and 115C supplying the heat for the drying. Steam rate is controlled based on drying

15

nitrogen temperature in the dryer. The dried HDPE powder is pneumatically conveyed to
the powder purification unit. The drying nitrogen forms a close circuit.

Figure 4: Fluidized Bed Dryer

2.2.7. Nitrogen Scrubbing Tower
The nitrogen containing hexane from the dryer DR-2201 is subjected to scrubbing in
counter current flow with the cold hexane in the nitrogen scrubbing tower C-2201.
Hexane is removed from nitrogen by condensation is sent to the mother liquor collecting
vessel V-2101 by scrubber circulation pump P-2201 A/B.
2.2.8. Powder Conveying
The transport nitrogen is used for conveying HDPE powder also forms a closed circuit.
Transport nitrogen is compressed in transport nitrogen blowers K-2203 A/B, cooled in E2204 by jacket water and supplied to rotary feederME-2205 by which the HDPE powder
from the dryer is pneumatically conveyed to powder purification unit. Nitrogen filter G2302 separates the HDPE powder from the transport nitrogen. Nitrogen is then passed
through a filter G-2202 and cooled in nitrogen cooler E-2203 before being feed in suction
of K-2203 A/B. Apart of nitrogen coming from G-2302 via split range loop is fed to offgas system via compressor Pk-3502.
2.2.9. Powder Treatment Vessel (PTV)
In order to improve the quality (mainly necessary for food application) of the HDPE, the
powder is subject to a post treatment to further reduce the hexane level to less than 0.01%
(by wt.) and to destroy catalyst and co-catalyst residues. The hot HDPE powder is fed
into the filter G-2302 where transport nitrogen is separated from powder and fed back to
16

transport nitrogen circuit. The HDPE powder is fed to powder treatment vessel-2301 via
rotary feeder MR-2301 which also serves as a gas lock. The powder flows through the
silo in a plug flow, counter current to the flow of hot nitrogen used to remove the residual
hexane. Slightly super-heated stream is added to the nitrogen to destroy the catalyst
residues in HDPE powder. The powder has the residence time in rage of hours in the
vessel. The inlet temperature of nitrogen should be greater than 100C in order to avoid
the condensation of steam.

Figure 5: Powder Treatment Vessel

2.2.10. Powder Discharge and Transport
The purified HDPE powder is discharged by a double rotary feeder ME-2302 and ME2303 to the pneumatic conveying system that transfers the purified polymer to the
powder silos V-2401 A/B or directly to extrusion. The capacity of both pneumatic
conveying lines is 42 tons / hour. For conveying purpose, recycled nitrogen is
compressed by compressor K-2402 A/B/C (compressor unit PK-2401). Compressed
nitrogen is then cooled in cooling water exchangers E-2402A for the first line and E2402B for the second line.
2.2.11. Treatment of Waste Gas from Powder Purification
The waste gas from powder treatment vessel V-2301, consisting of steam nitrogen
mixture enriched with hexane and HDPE dust is transferred to the membrane separation
unit PK-2301 via filters G-2301 & 2304. The HDPE dust is separated in G-2301 is
recovered into silo. The gas leaving the filter G-2301 contains traces of HCl and thus
diluted aqueous NaOH (20% by wt.) is sprayed in the gaseous stream for neutralization.
17

2.2.12. Powder Silos

Powder silos V-2401 A/B are operated as the buffer silos in normal operation during start
up and shut down of the polymerization for taking up of spec product obtained when
changing over to a different product grade and during the shutdown of the pelletizing
lines. From the powder silos the HDPE powder is conveyed to the conveyed to the
extrusion section via rotary feeders ME-2401 A/B.
2.2.13. Hexane Distillation
The hexane distillation / purification unit comprises an evaporation step, a distillation
step and an adsorptive purification step. In the evaporation stage (E-3102 and V-3101),
wax and other impurities are removed from the hexane mother liquor. For the wax
separation, the hexane mother liquor is preheated in the preheater E-3101 and transferred
to the separator V-3101. Wax is further enriched in evaporator E-3102 which is steam
heated and is continuously discharged to the wax recovery unit for the further treatment.
Hexane vapors from V-3101 are used for heating up the mother liquor in pre heater E3101, for heating reboiler E-3104 of the hexane distillation column C-3101 and in the
fluidized bed drying circuit for preheating of the nitrogen in E-2201. The various
condensate streams are collected in feed vessel V-3102 and feed to hexane distillation
column C-3101. The hexane distillation column C-3101 separates light ends such as
butene, ethylene and ethane from hexane. The hexane is purified in the distillation
column is pumped by P-3102 A/B to the adsorptive tower C-3102 A/B/C . The noncondensable are sent to the butene column through the butane adsorptive towers C-31-3
A/B.
2.2.14. Hexane Purification / Adsorption
Hexane from the distillation column is cooled by hexane cooler E-3105 and purified in
three adsorption towers C-3102 A/B/C which are packed with specific silica gel to
remove dissolved impurities formed during polymerization as well as H2O and O2 . The
towers are operated alternatively and then subjected to regeneration as and when the
purification efficiency of the tower decreases.
2.2.15. Butene Recovery
Feed gas in the scrubbing tower C-3202 is treated in counter current flow with the
distilled hexane feed from the top of the tower. Distilled hexane from the tank T-4101 is
cooled in chilled hexane cooler E-3202. The feed gas to the column is cooled down to 12C in the vent gas co9oler E-3203 before entering the column and the temperature is
controlled by adjusting the flow of chilled hexane to the cooler. Scrubbing tower C-3201
is operated at the pressure of 0.005 kg/sq.cm gauge. The butene enriched hexane is
collected in the column bottom and pumped by P-3201 A/B bck to the polymerization
reactors and to the mother liquor tank T-4102. The off gas stream leaving the scrubber
18

consisting predominantly of ethylene and ethane and traces of hexane is sent to cracker
gas compressor unit PK-3501.

Figure 6: Distillation & C4 Recovery Column

2.2.16. Wax Recovery
One of the byproducts obtained during the polymerization is an obtained during the
polymerization is an amorphous polyethylene amorphous polyethylene wax which is
dissolved in dispersing agent hexane. Hexane containing wax solution is obtained at the
bottom product in the evaporator E-3102. This bottom product is pumped by wax
treatment feed pump P-3301 through the jacketed pipe-3301 to the wax flash vessel V3301. In the jacketed pipe Hexane is evaporated and the vapors are separated in vessel V3301. Steam is fed to the flash vessel by the means of injector J-3301 in order to improve
the hexane removal from the wax. The wax discharge pump P-3302 discharges wax from
the flash vessel to movable bins, where it cools / freezes at the ambient conditions.
Hexane vapors from the flash vessel V-3301are condensed in condenser E-3302, sub
cooled in E3403and transferred via separation drumV-3401 and the pump P-3401 A/B to
the mother liquor tank T-4102. The gas phase is not condensed in the sub cooler E-3302
is discharged to off gas compressor PK-3502 and then to blow drum V-3502.

19

Figure 7: Wax Evaporator

2.2.17. Off Gas System Waste Gas Compressor
There are 2 waste gas streams from the plant which are subjected to different treatment
processes. The energy rich waste gas with elevated hydrocarbon concentration are sent to
off gas header at OSBL by the means of the off gas compressor Pk-3501 and energy low
by the means of the off gas compressor Pk-3501 and energy low waste gas with low
hydrocarbon concentration are sent to flare by the compressor PK-3502.
2.2.18. Tank Farm Mother Liquor & Hexane tanks
The tanks T-4101 & 4102 are intermediate receivers and the feed vessels for the distilled
hexane and mother liquor respectively used in the polymerization process. The hexane
supplied from BL is sent to mother Liquor tank T-4102. Both the tanks are blanketed
with nitrogen ; a constant blanketing pressure is maintained by the means of pressure
controller. Vapors obtained in both the tanks are fed to the condenser E-3401. Liquid
from the condenser sent to separation drum V-3401 while non-condensable are sent to off
gas compressor PK-3502.
2.2.19. Butene Tank
Butene storage tank V-4107 receives the butene from the battery limits nd this butene is
pumped to the reactor by P-4107 A/B. Butene storage vessel V-4107 is nitrogen
blanketed and pressure and the pressure is controlled in the split range thus regulating the
makeup of nitrogen or the amount of gas sent to V-3502.

20

2.2.20. Activators and TiCl4 Handling and Storage Area

The TEAL / IPRA storage area consists of:
Unloading for TEAL & for IPRA
TEAL storage vessel V-4103 & IPRA storage vessel V-4106 with agitators.
TEAL pumps P-4103 A/B & IPRA pumps P-4106 A/B.
Aluminum Alkyls are supplied in containers that are connected to the TEAL & IPRA storage
vessels on the product and gas side by mobile loading arms. By the means of TEAL & IPRA
loading pumps the activator solution is pumped to the calibration vessel V-1103A (TEAL) /
V-1103B (IPRA). The containers are emptied into the storage vessel by the compressed
nitrogen and after transfer; the line is flushed with the distilled hexane through the same flow
totalizer. Then the AL Alkyls are diluted with the distilled hexane to pre fixed ratio. TiCl4
is also supplied in containers that are connected to TiCl4 storage vessel V-4105 via mobile
loading arms. By the means of TiCl4 supply pump P-4105 Ticl4 is pumped to catalyst
preparation reactor R-1101.
2.2.21. Pelletization
In the pelletization unit the essential quality characteristics and properties of HDPE are
set by homogenization and by mixing with additives. From the pelletizing powder bin V5101, HDPE powder flows by gravity to the main powder dosing scale W-5101 via rotary
feeder ME-5101.Depending upon the powder quantity measured by the scale W-5101; all
additives are as well as off spec pellets from V-5102 are rationed to the powder mixed to
obtain a homogeneous solid mixture in the screw mixture M-5101. Additives are
discharged from the bags emptying station PK-5201 (LZ-5201~5205) into single dosing
facility of main powder and stabilizer dosing package PK-5202 (W-5201~5205). From
the screw mixerM-5101 HDPE powder, additives and recovered pellets are discharged to
the powder vibration screen S-5101 to remove the oversize mixture and subsequently to
the extruder EX-5101.

Figure 8: Pellet Drying & Conveying

21

2.2.22. Extruder
The homogeneous mixture from the screw mixture is fed into hopper of the extruder
which is blanketed with nitrogen. The blanketing nitrogen goes to the atmosphere. The
mixture is then molten and thoroughly homogenized in extruder EX-5101. The energy
required by the extruder is mainly introduced by friction provided by the main drive
motor driven screw. The part upstream and downstream of gear pump, which is an
integral part of EX-5101in the extrusion package unit PK-5102 and the gear pump itself
is steam heated. The melt is pressed through the heated die plate by the gear pump. The
HDPE strands are cut to desired length by the rotating blades located in underwater
pelletizer.

Figure 9: Extruder
2.2.23. Pellet Cooling , Drying, Homogenization & Conveying
The pellets are then transported to the pellet dryer S-5101. On the way to the pellet dryer
pellets cool down in the transport water. In the dryer with the integrated agglomerate
separator, the HDPE pellets acre separated from the transport water by centrifugal force
and dried by air suck fans K-5102. The high temperature of pellet supports this drying
process. After leaving dryer S-5103, HDPE pellets pass through the pellet sieve S-5104
and the pellet conveying station ME-5104 by the means of conveying air from the
compressor station. Pellets can also be diverted to the intermediate pellet bin V-5102 for
reprocessing in the extruder EX-5101. In order to compensate for variations in quality of
characteristic values of the product in upstream pelletizing unit, pellets are homogenized
before they are pneumatically fed to the pellet silos in the logistics center. This is done by
homogenizer V-5301 A~G.

22

2.2.24. Silo Washing

If required for product quality reason, silos V-5301 A~G washing can be done by means
of the silo washing system. Drying of the silo at the end of washing is done using hot air
compressed by K-5403 and heated by low pressure steam in E-5403.
2.2.25. Product Bagging
By the means of pneumatic haulage (PK-5401) HDPE pellets are conveyed to the
bagging silos V-8102 A/B with the capacity of 400 m3 each. From the bagging silos, the
HDPE products are finally bagged with the help of 4 bagging units PK-8110 A/B/C/D,
each having a capacity of 1200 bags / hour. The bagged product is further pelletized in
the pelletizing units PK-8111 A/B/C/D.

2.5.

Other Process Facilities

2.5.1. Refrigeration Unit

Chilled hexane and tempered hexane are supplied by a compression / expansion type
refrigeration unit PK-6101 operated with propylene where hexane is cooled down to
approx. 17C (chilled hexane) and 5C (tempered hexane). Chilled hexane is sent to cooler
E-3202 to cool the hexane used as absorbent by C-3201 to E-3203 to cool down butane -0
rich off gases feeding the scrubber tower C-3201 and to off gas compressor E-3401 to
cool down off gas going to PK-3502. Tempered hexane is sent to E-1302 to cool down
the slurry feeding to the decanter feed vessel and to E-2207 to cool down the reflux to
nitrogen scrubber C-2201.
2.5.2. Jacket Water Unit
The jacket water system which forms a close loop is provided with a jacket water
expansion vessel V-6103 return network to take care of change in volume of water due to
temperature variations. Level in the expansion vessel is maintained by making up with
demineralized water. Jacket water is cooled in the plate exchanger E-6103 A-E by
cooling water and is pumped to various locations by P-6103 A/B/C. temperature of jacket
water supply to users is controlled by regulating the flow of jacket water that by pass the
plate heat exchangers.
2.5.3. Steam & Condensate System
Four different types of steam are used in the plant:
1. High pressure steam at 42 kg/sq.cm gauge.
2. Medium pressure steam at 8 kg/sq.cm gauge for wax treatment, hexane distillation
and rector and slurry cooler cooking.
3. Low pressure steam at 4 kg/sq.cm gauge for trace heating and adsorption tower
regeneration.
4. Very low pressure steam at 0.7 kg/sq.cm gauge to dry polymer into the dryer.
23

The different steams used in the plant are produced by mixing condensates and steam in
requisite amounts to attain the require degree of saturation.
2.5.4. Ethylene Purification Unit
Ethylene coming from Battery Limits contains traces of water and CO2 and needs to be
purified. These traces are removed in C-7101 A/B by adsorption with molecular sieves.
The purified ethylene is then sent to the filter G-7101 A/B to the polymerization reactors.
These two columns are alternatively in operations and regeneration.
2.5.5. Waste Water Collection
The waste water collection system consists of the collection pits LZ-3401 A/B/C/D/E for
pumping to pretreatment V-3403 inside (HDPE section) and final disposal to battery
limits (B.L) of liquid effluents coming from HDPE section plant. The philosophy of this
system is to collect:
1. Process waste water mainly contaminated with hexane and oil spills, polymer powder
and process waste water coming from column regeneration.
2. Rain water, washing water and firefighting water coming from the potentially
polluted paved areas (HDPE polymerization hexane pumps and wax treatment areas).

The waste water collection system of HDPE section has been made up of the following
basins:
LZ-3401 A Diverting Box
LZ-3401 B Process Waste Water / 1st 15 minutes of Rain water / 1st 5 minutes of
Firefighting water collection basin
LZ-3401 C Clean Rain Water collection basin
LZ-3401 D Hexane Basin (basin design to contain 110 % of the largest vessel)
LZ-3401 E Waste Water Basin

2.6.Description of Chemicals Used

Chemical
State
Use
Titanium Tetrachloride (TiCl4)
Liquid
Catalyst as raw material
Magnesium Ethoxide (Mg(OC2H5)
Solid
Catalyst as raw material
Tri Ethyl Aluminum (TEAL)
Liquid
Catalyst as raw material
Iso Prenyl Aluminum (IPRA)
Liquid
Catalyst as raw material
Hexane
Liquid
Catalyst as raw material
Ca Stearate
Solid Powder
Additive in Extruder
Zn Stearate
Solid Powder
Additive in Extruder
Irgafos 168
Solid Powder
Additive in Extruder
Irganos 100
Solid Powder
Additive in Extruder
Viton FFGB
Solid Powder
Additive in Extruder
Table 2.1: List of Catalysts & Additives Used in HDPE Plant
24

2.6.

Utility Characteristics
Pressure (kg/sq.cm gauge)
Temperature
Name of Utility
MinimumNormal Maximum Minimum Normal Maximum
40
42
44
380
390
400
H.P. Steam
M.P. Steam
15.1
16.3
17.7
270
285
310
3.6
4
4.5
195
200
225
L.P. Steam
0.7
115
L.L.P. Steam
4.5
5
5.5
28
33
Cooling Water
2.2
2.8
3
< 45
45
45
Cooling Water
4
7.5
8
30
40
50
DM Water
3
5
6
Ambient
Service Water
8
8
12
Ambient Ambient
Fire Water
6
36
Jacket Water
5.5
46
Jacket Water
6.5
7
Instrumen Air
6
7
8
40
50
Plant Air
4
6
7
40
Nitrogen

Table 2.2: General Utilities in HDPE Plant

2.7.

General Material Balance

Ethylene
Butene - 1
Hydrogen
Catalyst
Co-Catalyst
Calcium Stearate
Irganox

38040
122
25.6
4.4
6.8
67.8
6.8

PE Pellets
(ex Extruder)
Wax
Tail Gas -1
Tail Gas -2

37676

Loss / Unaccounted

6.4

Total

38273.4

Total

38273.4

Figure 2.3: Material Balance

25

151
383
57

Chapter 3: Design of Heat Exchanger

3.1.

Basic Design Theory

The steps in a typical design procedure are given below:

1. Determine the duty, heat-transfer rate, and fluid flow rates, temperature.
2. Collect together the fluid physical properties required density, viscosity, thermal
conductivity.
3. Decide on the type of exchanger to use.
4. Select a trial value for the overall coefficient, U.
5. Calculate the mean temperature difference Tm.
6. Calculate the area required from equation 1.
7. Decide the exchanger layout
8. Calculate the individual coefficients.
9. Calculate the overall coefficient and compare with the trial value.
10. If the calculated value differs significantly from the estimated value, substitute the
calculated for the estimated value and return to step 6.
11. Calculate the exchanger pressure drop; if unsatisfactory return to step 7 or 4 or 3,in that
order of preference.
12. Optimize the design repeat steps 4 to 10,as necessary, to determine the cheapest
exchanger that will satisfy the duty. Usually this will be the one with the smallest area.
The general equation for heat transfer across a surface is:
Q = U A Tm
Where

Q = Heat transferred per unit time, W.

U = Overall heat transfer coefficient, watt / m2 0C.
A = Heat transfer area, m2.
Tm = the log mean temperature difference, 0C.

The prime objective in the design of an exchanger is to determine the surface area required
for the specified duty (rate of heat transfer) using the temperature difference available. The
overall coefficient is the reciprocal of the overall resistance to heat transfer, which is the
sum of several individual resistances. For heat exchanger across a typical heat exchanger
tube the relationship between the overall coefficient and the individual coefficients, which
are the reciprocal of the individual resistances, is given by:

26

Uo = the overall coefficient based on the outside area of the tube, W/m 2 oC.
ho = outside fluid film coefficient, W/m 2 oC.
hi = inside fluid film coefficient, W/m 2 oC.
hod = outside dirt coefficient (fouling factor), W/m 2 oC.
hid = inside dirt coefficient, W/m2 oC.
kw = thermal conductivity of the tube wall material, W/m oC.
di = tube inside diameter, m.
do = tube outside diameter, m.
The magnitude of the individual coefficient will depend on the nature of the heat-transfer process
(conduction, convection, condensation, boiling or radiation), on the physical properties of the
fluids, on the fluid flow-rates, and on the physical arrangement of the heat transfer surface. As
the physical layout of the exchanger cannot be determined until the area is know the design of an
exchanger is of necessity a trial and error procedure.
3.2. Design Specifications of Different Components of Shell & Tube Heat Exchanger
3.2.1. Tubes
Tube diameters in the range 58 in. (16 mm) to 2 in. (50 mm) are used. The smaller
diameters 58 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). For a given surface area, the use
of longer tubes will reduce the shell diameter; which will generally result in a lower cost
exchanger, particularly for high shell pressures. The optimum tube length to shell
diameter will usually fall within the range of 5 to 10.
If U-tubes are used, the tubes on the outside of the bundle will be longer than those on the
inside. The average length needs to be estimated for use in the thermal design. U-tubes
will be bent from standard tube lengths and cut to size. The tube size is often determined
by the plant maintenance department standards, as clearly it is an advantage to reduce the
number of sizes that have to be held in stores for tube replacement. in. (19 mm) is a good
trial diameter with which to start design calculations.

27

3.2.2. Tube Arrangements

The tubes in an exchanger are usually arranged in an equilateral triangular, square, or rotated
square pattern. The triangular and rotated square patterns give higher heat-transfer rates, but

at the expense of a higher pressure drop than the square pattern. A square, or rotated
square arrangement, is used for heavily fouling fluids, where it is necessary to
mechanically clean the outside of the tubes. The recommended tube pitch (distance
between tube centers) is 1.25 times the tube outside diameter; and this will normally be
used unless process requirements dictate otherwise. Where a square pattern is used for
ease of cleaning, the recommended minimum clearance between the tubes is 0.25 in. (6.4
mm).
3.2.3. Shells
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. The shell diameter must be selected to
give as close a fit to the tube bundle as is practical; to reduce bypassing round the outside
of the bundle.
3.2.4. 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.
3.2.5. Support Plates & Tie Rod
Where segmental baffles are used some will be fabricated with closer tolerances, 164 in.
to act as support plates. For condensers and vaporizers, where baffles are not needed for
heat-transfer purposes, a few will be installed to support the tubes. The minimum spacing
to be used for support plates are given in the standards. The spacing ranges from around 1
m for 16 mm tubes to 2 m for 25 mm tubes. The baffles and support plate are held
together with tie rods and spacers. The number of rods required will depend on the shell
diameter, and will range from 4, 16 mm diameter rods, for exchangers under 380 mm
diameter; to 8, 12.5 mm rods, for exchangers of 1 m diameter.

3.3.

Important Formulae used in Heat Exchanger Design

3.3.1. Mean temperature difference (temperature driving force)

The well-known logarithmic mean temperature difference (see Volume 1, Chapter 9)1
is only applicable to sensible heat transfer in true co-current or counter-current flow
(linear temperature enthalpy curves). For counter-current flow, Figure 12.18a, the
logarithmic mean temperature is given by:
28

 Tlm

Tlm =log mean temperature difference,

T1 = hot fluid temperature, inlet,
T2 = hot fluid temperature, outlet,
t1 = cold fluid temperature, inlet,
t2 = cold fluid temperature, outlet.
The equation is the same for co-current flow, but the terminal temperature differences will
be (T1 - t1) and (T2 - t2).
The usual practice in the design of shell and tube exchangers is to estimate the true
temperature difference from the logarithmic mean temperature by applying a correction
factor to allow for the departure from true counter-current flow:
Tm = Ft Tlm
Where,
Tm = true temperature difference, the mean temperature difference for use in the design
equation
Ft = 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:
R=

and S=

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. S is a measure of the
temperature efficiency of the exchanger. For a 2shell pass exchanger, the correction factor is
given by
Ft =

3.3.2. Fluid allocation in shell and tube side

1. Corrosion: The more corrosive fluid should be allocated to the tube-side. This will
reduce the cost of expensive alloy or clad components.
29

2. 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.
3. Fluid temperature: if the temp. are high enough to require the use of special alloys
placing the higher temp fluid in the tubes will reduce the overall cost.
4. Operating pressure: The higher pressure stream should be allotted to the tube-side.
High pressure tubes will be cheaper than a high-pressure shell.
5. Pressure drop: for the same pressure drop, higher heat transfer coefficient will be
obtained on the tube-side than the shell-side, and fluid with the lowest allowable pressure
drop should be allocated to the tube-side.
6. 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.
7. Stream flow-rate: allocating the fluids with the lowest flow-rate to the shell-side will
normally give the economical design.
3.3.3. Shell and Tube Side 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 setting, but not so high as to
cause erosion. High velocities will reduce fouling.
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
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 few milli bars
in vacuum service to several bars in pressure system
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 cost, taking into consideration both
capital and pumping costs.
The value suggested below can be used as general guide, and will normally give designs that
are near the optimum.
Liquids
Viscosity
< 1mNs/m2
35 KN/m2
1 to 10 1mNs/m2
50-70 KN/m2
When a high pressure drop is utilized, care must be taken to ensure that the resulting high
fluid velocity does not cause erosion or flow induced tube vibration.
30

3.3.4. Tube Side Heat Transfer Coefficient and Pressure Drop (Single Phase)
There are two major sources of pressure loss on the tube-side of a shell and tube exchanger:
the friction loss in the tubes and the losses due to the sudden contraction and expansion and
flow reversals that the fluid experiences in flow through the tube arrangement. The tube
friction loss can be calculated using the familiar equations for pressure-drop loss in pipes.
The basic equation for isothermal flow in pipes (constant temperature) is:
P= 8jf ( ) ui2
Where jf is the dimensionless friction factor and L is the effective pipe length.
m = 0.25 for laminar flow, Re < 2100,
m = 0.14 for turbulent flow, Re > 2100.
Another source of pressure drop will be the flow expansion and contraction at the exchanger
inlet and outlet nozzles. This can be estimated by adding one velocity head for the inlet and
0.5 for the outlet, based on the nozzle velocities.
3.3.5. Shell Side Heat Transfer Co-efficient and Pressure Drop (Single Phase)
The flow pattern in the shell of a segmentally baffled heat exchanger is complex, and this
makes the prediction of the shell-side heat-transfer coefficient and pressure drop very much
more difficult than for the tube-side. Though the baffles are installed to direct the flow
across the tubes, the actual flow of the main stream of fluid will be a mixture of cross flow
between the baffles, coupled with axial (parallel) flow in the baffle windows.
The complex flow pattern on the shell-side, and the great number of variables involved,
make it difficult to predict the shell-side coefficient and pressure drop with complete
assurance. In methods used for the design of exchangers prior to about 1960 no attempt was
made to account for the leakage and bypass streams. Correlations were based on the total
stream flow, and empirical methods were used to account for the performance of real
exchangers compared with that for cross flow over ideal tube banks. Typical of these bulkflow methods are those of Kern (1950) and Donohue (1955).
The Engineering Sciences Data Unit has also published a method for estimating shell side
the pressure drop and heat transfer coefficient, EDSU Design Guide 83038 (1984). The
method is based on a simplification of Tinkers work. It can be used for hand calculations,
but as iterative procedures are involved it is best programmed for use with personal
computers.

31

3.4.

Kerns Method
This method was based on experimental work on commercial exchangers with standard
tolerances and will give a reasonably satisfactory prediction of the heat-transfer
coefficient for standard designs. The prediction of pressure drop is less satisfactory, as
pressure drop is more affected by leakage and bypassing than heat transfer. 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.

32

Chapter 4: Design Calculations for Heat Exchangers

4.1.

1.
2.
3.
4.
5.

Operational & Design Data

Client Reference 41- PK-2301

Heat Exchanger Name 41-E-2302
Design Specification MOS:AISI304
Exchanger Type Shell & Tube Heat Exchanger
2 Shell Pass Type Heat Exchanger
Operational Data

6. Shell Pressure 7, 15 kg/sq.cm gauge

7. Tube Pressure 6, 51 kg/sq.cm gauge
8. Shell Temperature 50 C
9. Tube Temperature 39 C
10. Shell Side Medium DM Water
11. Tube Side Medium Jacket Water
12. Shell Fluid Density 979.8 kg/cc
13. Tube Fluid Density 1000 kg/cc
Design Data
14. Shell Pressure -1 kg/sq.cm gauge
15. Tube Pressure 10 kg/sq.cm gauge
16. Shell Temperature 0, 7 C
17. Tube Pressure 150 C
18. Material of Construction Stainless Steel
19. Orientation of Tubes Square
20. Countercurrent flow
Additional Data for the Calculations
21. T1 (hot fluid inlet temperature) = 65
22. T2 (hot fluid outlet temperature) = 50
23. t1 (cold fluid inlet temperature) = 36
24. t2 (cold fluid outlet temperature) = 40
25. Shell Side Flow Rate = 10000 kg/h
26. Tube Side Flow Rate = 20126.5 kg/h
27. Cp of Shell Side Fluid = 4.198 J /kg C (at 65 C)
28. Cp of Tube Side Fluid = 4.184 J/kg C (at (36 C)
29. Outer Diameter of Tube = 0.019 m (acc. to design spec)

33

Figure 10: Design Data Sheet

34

30. Inner Diameter of Pipe = 0.016 m (acc. to design spec)

31. Length of Pipe = 8 m
32. Shell Side Density = 979.8 kg/m3
33. Tube Side Density = 1000 kg/m3
34. k1 = 0.249 (for 2 pass shell)
35. n1 = 2.207 (for 2 pass shell)
36. Shell Side Viscosity = 0.0004355 kg/m.sec (at 65 C)
37. Tube Side Viscosity = 0.000891 kg/m.sec (at 36 C)
38. K = 0.125
39. Pitch = 1.25 (do) = 23.75 mm
40. Kw = 16.2
41. K shell = 0.42

4.2.Assumptions
According to Richardson & Coulson, there are 2 values of overall heat transfer
coefficient, U for Jacket Water at Tube Side depending on the nature of fluid on the
shell side.
1. For light organic solvent, value of U is in the range of 200 300 W/m2C.
2. For aqueous solutions or DM Water, the value of U is in the range of 200 500
W/m2C.
Therefore in this heat exchanger designing we are going to assume the value of U and
then through iterations we can check whether the calculated U is close to assumed U
or not. The assumed value of U for this design is
U (overall heat transfer coefficient) = 500 W/m2C

4.3.

Calculations

4.3.1. Log Mean Temperature Difference (LMTD), R, S, Ft and Corrected

Temperature Difference
Tm =

= 18.97145 oC

R=
S=

= 3.75
= 0.137931

Ft = 0.68 (from figure 12.19 in Richardson & Coulson)

35

Now calculation for corrected temperature difference Tm

Tm = Ft x Tlm
= 0.68 x 18.97145
= 12.90059 oC
4.3.2. Calculation for heat transfer along the shell
Q shell = m Cp T
=
= 174.9167 W/m2 oC
4.3.3. Calculation for Heat transfer area, Number of Tubes and Total Area
Heat transfer area of the exchanger can be given by
Ao =

= 27.11763 m2

Now, Number of tubes

N tubes =
=
= 56.81702
Tubes cross sectional area = (do) 2 =
Total area of tubes = (N tubes x Tube cross sectional area)
= 56.81702 x 0.000201
= 0.011418 m2
4.3.4. Calculation for Volumetric Flow Rate and Tube Side Velocity
Volumetric flow =

36

=
= 0.005591 m3/s
Now,
Tube side velocity =
=
= 0.489641 m/s
4.3.5. Bundle and shell diameter
Pitch (P) = 1.25 x 19 = 23.75
From table 12.4 in Richardson & Coulson two shell pass exchanger has:
k1 = 0.249 and n1 = 2.207
Therefore bundle diameter is given by
Db = do x
=19
= 0.042659
Now, calculation for shell diameter
Ds = Db + 17
Ds = 0.042659 + 17
= 17.04266 cm
4.3.6. Calculation for Reynoldss Number, Prandtl Number and Nusset Number
Reynoldss no. =

=
37

= 8792.654
Now, calculation for Prandtl Number
Pr =
x 1000

=
= 29.82355

Now, calculation for Length by inner diameter ratio, we have

L/Di = (8/0.016) = 500
From the Richardson & Coulson graph, the value of correcting factor jh is 0.004.
Now, calculation for Nusset Number
Nusset Number (Nu) = jh x Re x (Pr) 0.33
= 0.004 x 8792.645 x (29.82355)0.33
= 107.8412
Now, calculation for heat transfer coefficient
hi =
=

= 842.5091 W/m2 C
4.3.7. Calculation for Baffle Spacing, Volumetric Flow Rate and Shell Side Velocity
Baffle spacing (lb.) = Ds / 5
= 17.042659 / 5
= 3.408532
Now, calculation of sectional flow area of shell

38

As = [(P di) x Ds x lb.] / P

= [(23.75-19) x 17.042659 x 3.408532] / 23.75
= 11.61809 mm2
= 0.001162 m2

Now, calculation for effective shell diameter

de =

x (P2 0.917 x di2)

= 13.49095 mm

Now, calculation for volumetric flow rate

Volumetric flow = (flow rate of shell side) / (3600 x shell)
= (10000) / (3600 x 979.8)
= 0.002835 m3/s

Now, calculation for shell side viscosity

Shell side velocity = (volumetric flow rate) / As
= (0.002835 / 0.001162) = 2.4402 m/s

4.3.8. Calculation for Reynoldss Number, Prandtl Number and Nusset Number
Reynoldss no. =

=
= 74065.71
39

Now, calculation for Prandtl Number

Pr =

x 1000

=
= 4.352926

From the Richardson & Coulson graph, the value of correcting factor jh is 0.0037.
Now, calculation for Nusset Number
Nusset Number (Nu) = jh x Re x (Pr) 0.33
= 0.0037 x 74065.71 x (4.352926)0.33
= 445.2631
Now, calculation for heat transfer coefficient
Hs =
=

= 13861.92 W/m2 C
4.3.9. Overall heat transfer coefficient
Now finally overall heat transfer coefficient is to be calculated.

= 0.00202

Uo = 495.0748 W/m2 oC
Comparing this result with the assumed result and calculating the percent
deviation we have:
% Error =

40

= 0.985038

This shows that assumed value of overall heat transfer coefficient U = 500 W/m2C is
closed to the calculated value i.e. U = 495.0748 W/m2C.Moreover, the value of overall
heat transfer coefficient U for jacket water is in between 200 to 500 W/m2C.
4.3.10. Pressure Drop Across Tube and Shell Side
The basic equation for isothermal flow in pipes (constant temperature) is:
P= 8jf

ui2

By putting the respective values in the above formula we have

P across tube side = 2217.671 N/m2
P across shell side = 256.0161 N/m2
4.4.Calculated Data Sheet

Figure 11: Final Calculated Sheet

41

4.5.Excel Sheet Calculation

R
S
F
Tm
Q
A
NUM OF TUBES
Area of one tube
Total area
volumetric flow
tube side velocity

3.75
0.137931
0.68
12.90059
174.9167
27.11763
56.81702
0.000201
0.011418
0.005591
0.489641

Db(bundle dia)
Ds(shell dia)
Reyonlds num(Re)
Pr
L/Di
jh
Nusselt num(Nu)
hi

0.042659
17.04266
8792.654
29.82355
500
0.004
107.8412
842.5091

SHELL
baffle spacing(Lb)
As(in mm2)
As(in m2)
de
volumetric flow rate
shell side velocity
Reyonlds num(Re)
Pr
jh
Nusselt num(Nu)
hs

3.408532
11.61809
0.001162
13.49095
0.002835
2.4402
74065.71
4.352926
0.0037
445.2631
13861.92

overall coefficient
(1/Uo)
Uo

0.00202
495.0748

42

Conclusion
HDPE Plant is one of the units in Panipat Naphtha Cracker Plant. It manufactures different
grades of polyethylene like film grade, pipe grade etc. which poses bimodal properties at the rate
of 300,000 ton per year (900 tons per day). The production specification of plant is 37.5 tons of
HDPE per hour but it is working with the efficiency of 110 % that is it produces 41 tons per hour
manufacturing 900 tons of HDPE a day. The different sections of HDPE Unit are Catalyst
Section, Polymerization Section (also called Reactor Section), Dryer Section, Refrigeration
Section, Hexane Recovery Unit and Extruder. The other facilities inside this plant were Satellite
Sub Stations, Pallet Homogenization & Conveying Section, and Hexane Storage Tanks which
includes Distilled hexane and mother liquor tanks, Intermediate Powder Silos, Effluent Basin,
Jacket Water Additive Dosing, Reactor Cooling Water System and Aluminum Metering System.
The polymerization is done in single phase that is ethylene and butene is reacted in the gaseous
phase and hydrogen is used as the terminator of the reaction. In the first reactor it is controlled
manually and in the second reactor it is controlled automatically by DCS (distributary controller
system) from MCR (main control room). The post reactor is used to provide additional time to
complete the reaction and then the slurry is subjected to decanter feed vessel for the separation of
the lighter & heavier components on the basis of gravity difference. Then the slurry is sent to
decanter centrifuge where by the virtue of centrifugal forces raw HDPE powder and mother
liquor got separated. Mother liquor is sent to ML (mother liquor) storage tank and raw HDPE
powder is sent to the dryer to remove lighter components of the solvent (hexane) from it. Two
fluidized bed dryers are used for the treatment of HDPE powder. The first one works on the
principle of back mixed flow reactor and other one on plug flow type. Here steam and hot
nitrogen flows in the countercurrent fashion in order to evaporate the solvent particles from the
powder. Afterwards through pneumatic dryer these HDPE powders are transported to the PTV
(powder treatment vessel) where the residues of the catalysts are further destroyed by the steam.
Once the powder is completely purified they are sent to extruder for the pelletization process.
Here additives like acid scavengers (calcium stearate and zinc stearate) and anti-oxidants
(IRGAFOX 168 and IRGANOX 100) are added to the HDPE powder. The main purpose for acid
scavengers is to neutralize the effect of bases present in it and anti-oxidants prevent the oxidation
of powder. After dosing the suitable amount of additives in it, the powder is again melted by the
means of screw gear and then sent to the die where the shape and size has been given to the
HDPE pellets. Then the pellets are cooled by the processed water and transported along with it.
Then these pellets are collected in the storage bags with 25kg holding capacity. Besides the
production of HDPE pellets, the plant also recycles and regenerates the hexane and butene by
removing wax from mother liquor. The mother liquor is sent to an evaporator where the vapor of
hexane and butene are removed from wax. The bottom product is wax whereas hexane butene is
the top product. The mixture of hexane & butene is sent to distillation column followed by

43

adsorption column to extract butene which can be used further in the polymerization. The
distilled hexane is stored in hexane tank.
Apart from the plant overview, the design of heat exchanger was given as additional
project from the mentor. The shell & tube exchanger had 2 shell passes and uses jacket water in
tube side and DM water in shell side. Stainless steel was used as the material of construction and
the orientation of tubes is in square patter. The specification of the heat exchanger was given
from the data sheet of the company named BORSELL MEMBRANE TECHNOLOGY as per
the MOC: AISI 304 guidelines. A series of 4 iterations has been done to find the correct and less
deviated value of the overall heat transfer coefficient and it should match with the actual heat
exchanger in the plant.

44