Académique Documents
Professionnel Documents
Culture Documents
Submitted by
Nitish Bir
13112022
Final year undergraduate
Department
Engineering
NIT Jalandhar
of
Chemical
Table of Contents
1. Acknowledgement
2. Organisation Profile
3. Vision Values Promise
4. Jubilant Bhartia Group
5. Sustainability Goals
6. Pyridine Production Plant
7. Products
8. Heat Exchangers
9. Steps for designing of Shell and Tube Heat Exchanger
10. Results of Summer Internship Project
11. Conclusion
12. References
Acknowledgement
The satiation and euphoria that accompany the successful completion of the project would be
incomplete without the mention of the people who made it possible.
I would like to take the opportunity to thank and express my deep sense of gratitude to my
mentors Mr. Anurag Varshney and Mr Kamal Pal. I am greatly indebted to both of them for
providing their valuable guidance at all stages of study, their advice, constructive suggestions,
positive and supportive attitude and continuous encouragement, without which it would have
not been possible to complete the project.
I would like to thank Mr Anuj Vats (HR) who in spite of busy schedule has co-operated with
me continuously and indeed, his valuable contribution and guidance have been certainly
indispensable for my project work.
I owe my wholehearted thanks to entire members of plant include shift in charges, staff and
lab scientists for their cooperation and assistance during the course of internship.
I hope I can build upon the experience and knowledge that I have gained and make a valuable
contribution towards this industry in coming future.
Organisation Profile
Jubilant Life Sciences Limited is an integrated global pharmaceutical and life sciences
company engaged in manufacturing and supply of APIs, Solid Dosage Formulations,
Radiopharmaceuticals, Allergy Therapy Products, Advance Intermediates, Fine Ingredients,
Crop Science Ingredients, Life Science Chemicals and Nutritional Products. It also provides
services in Contract Manufacturing of Sterile Injectables and Drug Discovery Solutions. The
Companys strength lies in its unique offerings of Pharmaceutical and Life Sciences products
and services.
Their success is an outcome of strategic focus on the pharmaceuticals and life sciences
industry, moving up the pharmaceutical value chain for products and services across
geographies, constantly investing in various growth platforms and promoting a culture of
innovation.
They are engaged in continuous improvement of products and processes to enhance the
quality of production and cost competitiveness in order to build value for our customers.
Jubilant Life Sciences serves its customers globally with sales in over 100 countries and
ground presence in India, North America, Europe and China. They are well recognised as a
Partner of Choice by leading life sciences companies worldwide. Jubilant has relationship
with 19 of Top 20 pharmaceutical companies and 6 amongst top 10 agrochemical companies
across the globe.
Over the years, Jubilant Life Sciences has extended its footprint beyond India in the USA,
Canada, Europe, and other countries across the globe. We have also expanded the business by
building capabilities internally, through strategic expansions and acquisitions This resulted in
a network of 7 world class manufacturing facilities in India and 4 in North America and a
team of around 6100 multicultural people across the globe with ~ 1200 in North America and
~900 in R&D.
The multi-location presence helps them in getting closer to customers and serving them better
with the best in class products developed most efficiently, economically with speed to market.
Jubilant Life Sciences' progress in diverse businesses has been made possible through the
contribution of R&D; for quality, non-infringing process for product development and cost
reduction through process innovation. Innovation at Jubilant is backed by strong chemistry,
bio science expertise and the knowledge bank created over the years. We have harnessed our
strengths a strong R&D team, modern R&D facilities, command over cheap technologies
and economies of scale into a synergistic organic entity, continuously creating and nurturing
high quality products and technologies.
In line with Jubilant Life Sciences continued focus on sustainability of business, they aim at
improving stakeholder value through improved eco efficient use of capital and natural
resources. Jubilants approach to sustainable development focuses on the triple bottom line of
Economics, Environment and Social performance. We are committed and working on various
areas for energy conservation and climate change mitigation. Their sustainability efforts have
been reported through a Corporate Sustainability Report since 2003 and this report has been
receiving GRI G3.1 A+ level & GRI Check, since 2007 from Global Reporting Initiative
(GRI). This reflects Jubilant Life Sciences commitment towards sustainable development and
continued efforts directed towards protecting the environment wherever we operate.
Corporate Social Responsibility is an integral part of how Jubilant Life Sciences conducts
business and how the efforts are directed towards community development through focus on
primary education, basic healthcare service, and livelihood generation programs focused on
improving the employability of women and local youth.
We have been recognised with several awards and recognitions, which bear testimony to our
commitment towards operational excellence, innovation, corporate governance and social
responsibility.
Jubilant Life Sciences is committed to leverage innovation and scale of operations at every
step of the pharmaceutical value chain to deliver value to our stakeholders.
Our Values
We will carefully select, train and develop our people to be creative and empower them to
take decisions, so that they respond to all stakeholders with agility, confidence and teamwork.
We stretch ourselves to be cost effective and efficient in all aspects of our operations and
focus on flawless delivery to create and provide the best value to our stakeholders.
By sharing our knowledge and learning from each other and from the markets we serve, we
will continue to surprise our stakeholders with innovative solutions.
With utmost care for the environment and safety, we will always strive to excel in the quality
of our processes, our products and our services.
The group operates in various sectors like Pharmaceuticals and Life Sciences, Food
Services (QSR), Oil and Gas, Agri & Performance Polymers and Consulting Services in
Aerospace and Oilfield industries.
Over the years, Jubilant Life Sciences has extended its footprint beyond India in the USA,
Canada, Europe, and other countries across the globe. The Company has also expanded the
business by building capabilities internally, through strategic expansions and acquisitions,
resulting in a network of 7 world class manufacturing facilities in India and 5 in North
America and a team of around 6100 people across the globe with ~ 1200 in North America
and ~900 in R&D.
For a large number of global companies, Jubilant is a trusted name and a 'partner of choice'
owing to its ability to operate in an ever changing environment that presents both
opportunities and challenges. The group's promise of Caring, Sharing and Growing is
reflected in all its endeavours.
The Group lays emphasis on the environmental, social and economic concerns, in order to
operate within a sustainable environment and build a robust self-sustained nation, the group
has formed an entity, Jubilant Bhartia Foundation.
This Foundation is relentlessly involved in taking initiatives aimed at empowerment of
communities through focus on primary education, providing basic healthcare and skill
development facilities and enabling employability and self-sustenance.
The Company enjoys leadership positions in many product categories, key ones being No. 1
in India and amongst Top 2 manufactures in the world for Food Polymers, No. 1 in India and
globally No. 2 for Vinyl Pyridine Latex used for automobile tyres. Amongst Top 3 brands in
India for Single Super Phosphate fertilizer and a significant agro nutrient player. Jivanjor is
the 2nd largest consumer brand in India in consumer adhesives category and a significant
player in the Indian wood finishes market.
Services
Jubilant Enpro, through its alliances with international companies, provides business,
marketing and technical support related to Oil & Gas services, Power & Infrastructure
services, and Aviation related services (sales/maintenance of aircrafts & helicopters).
Jubilant Enpro is the sole authorized Independent Representative of Bell Helicopter in India
for sales, marketing and customer support. Also represent other international aerospace
companies.
Jubilant Enpro is also the Consultant to Transocean-offshore drilling company and also
Manning and Marketing services for Tidewater Marine International etc
Auto
Jubilant MotorWorks is one of the largest Luxury Auto Retail Company in India, engaged in
sales and servicing of Audi, Porsche and Maserati Cars
Audi Cars :
Jubilant Motorworks holds dealership for Audi Cars and the state of the art showrooms are
located in Bangalore, Mangalore, Chennai and Pune. Audi Cars have been well recognised
globally as a manufacturer of high-quality and innovative luxury cars, it is one of the world's
leading premium brands which is among the most admired car brands across the world.
Porsche Cars :
Jubilant MotorWorks through Jubilant Performance Cars (JPCPL) holds dealership for
Porsche cars in Mumbai to cater to Maharashtra. JPCPL take pride in offering enhanced
motoring experience to all luxury car enthusiasts. With a wide range of Porsche cars to offer,
the showroom is designed to keep the customer satisfaction right at the focus.
Maserati Cars :
Jubilant MotorWorks, through Jubilant AutoWorks holds dealership for Maserati cars in
Bengaluru to cater to south India. Maserati is one of the most fascinating car production
companies with a long history of appeal, tradition and sporting success. The state-of-the-art
showroom located in Bengaluru is in line with Maserati global standards, equipped with
modern facilities
Food
Jubilant Consumer Private Limited (JCPL) has been set up to promote sales of ready-to-use
fresh vegetables and gourmet salads under the brand name Jubilant Fresh. Since its inception
in 2013, Jubilant Fresh has gained trust in the food industry, offering an extensive range of
fresh produce, ready-to-cook vegetable combo packs, canned products and ready-to-eat fresh
meals & snacks. In a short span of three years, it has grown to become one of the leading
suppliers of fresh and high quality food products customised to the needs of customers.
Stringent quality checks, traceability, timely services and SOP-driven delivery practices have
given Jubilant a competitive advantage. With prime focus on food safety and hygiene along
with innovative packaging and a value-driven approach, Jubilant Fresh has become a
preferred business partner for its clients.
Sustainability Goals
Sustainability Policy
Whistle-blower Policy
Quality Policy
department and Ombudsmans office takes care of the employee/labour relationship issues
while the EHS department ensures safe and healthy work environment.
Jubilant Life Sciences aims at the protection of human rights through implementation of
ethical policies and compliance to country regulation on human rights. We have adopted
policies covering key aspects of human rights like Child Labour, Forced & Compulsory
Labour, Non Discrimination and others. Jubilant Life Sciences is a signatory to UN Global
Compact (UNGC), and recognises United Nations Universal Declaration of Human Rights.
We practice to procure material from trustworthy vendors who do not violate human rights
and standards as stipulated. We make sure to add this clause in the contract agreement of our
Company. At Jubilant, the supply chain department also requires the vendors to fill a selfdeclaration form including human rights aspects, based on which the suppliers are audited.
We do not support any sort of discrimination based on gender, cast, creed, colour, religion or
any other factor. Equal remuneration is offered to men or women for the same nature of work.
Jubilant Life Sciences is a signatory to the CII Code of Conduct on Affirmative Action that
reconfirms our commitment to equal employment opportunity for all sections of society.
Freedom of Association and Collective Bargaining is respected. We respect the right of our
employees to form an association in accordance with the local laws applicable. The
employees have a right to join associations of their own choice or to refrain from joining one,
unless otherwise prohibited/ necessitated by law.
Child Labour is strictly against our company policy. The HR Department verifies the age of
every new employee by demanding a proof of age. On the other hand, we direct our efforts
towards betterment of children by supporting the cause for eradication of child labour. We
also encourage our Suppliers to work towards a no child-labour policy and require them to
fill a self-evaluation form which delineates prohibition of Child Labour.
We respect the dignity of labour and discourage all forms of forced & compulsory labour.
The terms of employment at Jubilant, are transparent and voluntary. Jubilant life Sciences is a
diverse organisation, and we have our operations in various locations across India & North
America. We embrace the local culture and heritage at the respective regions. We have a welldefined grievance identification and redressal mechanism in place for human rights violation
cases that affects our stakeholders. Ombudsman office and whistle blower policy sets the
basis of employee grievance redressal system.
Sustainability Reporting
Reporting Greenhouse Gas emissions with worlds largest climate change database
representing 722 Financial Institutions Investor Signatories
Jubilant Life Science is one of the few companies in India disclosing GHG emissions and
taking voluntary reduction initiatives. We have been able to do so by participating in the
Carbon Disclosure Project (CDP), executed by WWF and CII in India. CDP today holds the
largest database of primary corporate climate change information in the world. Jubilant held
the 2nd position in Carbon Disclosure Project (CDP), 2010 with Carbon Disclosures
Leadership Index (CDLI) Score 77. We achieved this position, owing to our integrated
climate change initiatives and potential risks opportunities related to climate change, into
our business.
'Jubilant has been reporting to Carbon Disclosure Project since, 2010'
UN Global Compact
Responsible care
performance. The improvement initiatives are taken together with open and transparent
communication with stakeholders. We submit annual report against Key Performance
Indicators (KPI) to Indian Chemical Council (ICC) including our key sustainability
performance data.
PYRIDINE
PRODUCTION
PLANT
PRODUCTS
1. Pyridine
Pyridine, a basic organic chemical, is a versatile building block and excellent solvent in
agrochemical, pharmaceutical and other industries. It is completely soluble in water, alcohol,
ether and benzene. It acts as a scavenger and can catalyze reactions. Initially Pyridines were
isolated from coal tars from coking operations; Currently, Synthetic processes account for the
majority of world production of pyridines.
The most common synthetic processes for production of pyridines involve vapor-phase fluid
bed reactions of acetaldehyde and ammonia, with or without formaldehyde. Producers can
use the same equipment and catalysts to produce the mix of pyridine/beta-picoline or alphapicoline/gamma-picoline mixtures by selecting raw materials. Changing catalysts and
reaction conditions influences the ratio of products formed.
Applications
Agricultural Chemicals: Paraquat, a non-selective contact herbicide, is a major agriculture
chemical derived from pyridine.
2-choloropyridine: Pyridine goes into manufacturing of 2- choloropyridine, which goes into
manufacturing of Zinc pyrithione, an active antimicrobial ingredient in anti-dandruff
shampoos and used in variety of other industrial applications such as paints, caulks, sealants,
adhesives, grouts and patching compounds.
Piperidine: Piperidine is produced via hydrogenation of Pyridine. Major application of
Piperidine is for production of Dipentamethylene thiuram tetrasulfide(DPTT).
Solvent and other: Pyridine is used as a synthetic intermediate and a solvent in a variety of
pharmaceutical and cosmetic applications. It is completely soluble in water, alcohol, ether
and benzene. It acts as a scavenger and can catalyze reaction.
2. Alpha Picoline
Alpha Picoline, also called 2-Picoline or 2-Methylpyridine, is a clear organic liquid. It is
completely soluble in Water, Alcohol and Ether.
Applications
The largest application of Alpha Picoline is 2- Vinylpyridine monomer (2 VP), which is
used in the manufacturing of VP Latex
Other application of Alpha Picoline is in the manufacturing of agrochemicals: Picloram and
Nitrapyrin
Alpha Picoline is also the raw material for 2-Cyanopyridine
It is also used in the pharmaceuticals industry
3. Beta Picoline
Beta Picoline, also called 3-Picoline or 3-Methylpyridine, is a clear organic liquid. It is
completely soluble in Water, Alcohol and Ether.
Applications
The largest application of Beta Picoline is in the manufacturing of Vitamin B3
(Niacinamide)
Beta Picoline is a significant intermediate for agrochemicals like Chlorpyrifos, Haloxyfop
and Fluazifop Butyl
Also used in pharmaceutical intermediates REACH Status: Registered as Full Phase in and
Transported Isolated Intermediate (TII)
4. Gamma Picoline
Gamma Picoline, also called 4-Picoline or 4-Methylpyridine, is a clear organic liquid. It is
completely soluble in Water, Alcohol and Ether.
Applications
Gamma Picoline finds application in the manufacturing of several catalysts such as DMAP
and the drug INH & other pharmaceuticals
Gamma Picoline is used in the manufacturing of 4- Vinylpyridine (4 VP)
Gamma Picoline is also the raw material for 4-Cyanopyridine REACH Status: Preregistered
5. 2-Cyanopyridine
2-Cyanopyridine is a white to off-white solid at room temperature with almond like odour. It
is derived from Alpha Picoline.
Applications
2-Cyanopyridine finds applications in pharmaceuticals, agrochemicals & fine chemicals
2-Cyanopyridine is converted to Chromium and Zinc Picolinate for use in human and
animal nutrition
6. 3-Cyanopyridine
3-Cyanopyridine is a white crystalline solid and used to manufacture 3 substituted Pyridine
derivatives and Industrial intermediates.
Applications
3-Cyanopyridine is used in the manufacturing of Niacinamide & Niacin (Vitamin B3)
Other major application areas of 3-Cyanopyridine are: Pymetrizone, 2 Chloro Nicotinic
Acid, and 3-Aminomethylpyridine, pharmaceuticals & agrochemicals
7. 4-Cyanopyridine
4-Cyanopyridine is a white to off-white solid at room temperature. It is derived from Gamma
Picoline.
Applications
4-Cyanopyridine finds applications in the manufacturing of the drug INH Isoniazid and
other pharmaceuticals and agrochemicals
8. Piperidine
Piperidine is a colourless fuming liquid, derived by the hydrogenation of Pyridine.
Applications
The major application of Piperidine is for the production of Dipiperidinyl Dithium
Tetrasulfide, which is used as a rubber vulcanisation accelerator
Piperidine is also used as a solvent and base in agrochemical and pharmaceutical industries
for Mepiquat Chloride, Dipyridamoil and Minidoxil
DESIGNING OF AMMONIA
PREHEATER
Heat Exchangers
Heat exchangers are devices used to transfer heat energy from one fluid to another. Typical
heat exchangers experienced by us in our daily lives include condensers and evaporators used
in air conditioning units and refrigerators. Boilers and condensers in thermal power plants are
examples of large industrial heat exchangers. There are heat exchangers in our automobiles in
the form of radiators and oil coolers. Heat exchangers are also abundant in chemical and
process industries. There is a wide variety of heat exchangers for diverse kinds of uses, hence
the construction also would differ widely. However, in spite of the variety, most heat
exchangers can be classified into some common types based on some fundamental design
concepts. We will consider only the more common types here for discussing some analysis
and design methodologies.
Figure 1
Amongst of all type of exchangers, shell and tube exchangers are most commonly used heat
exchange equipment. The common types of shell and tube exchangers are:
Fixed tube-sheet exchanger (non-removable tube bundle): The simplest and cheapest
type of shell and tube exchanger is with fixed tube sheet design. In this type of exchangers
the tube sheet is welded to the shell and no relative movement between the shell and tube
bundle is possible (Figure 2).
Removable tube bundle: Tube bundle may be removed for ease of cleaning and
replacement. Removable tube bundle exchangers further can be categorized in floating head
and U-tube exchanger.
Fig
ure 2. Fixed-tube heat exchanger ([1]).
Fi
gure 3. Floating-head heat exchanger (non-pull through type) [1].
Fi
gure 4. Removable U-tube heat exchanger [1].
Typical parts and connections shown in Figures 2, 3 and 4 (IS: 4503-1967) are
summarized below.
1. Shell
2. Shell cover
3.Shell flange(channel end)
4. Shell flange(cover end)
5. Shell nozzle or branch
6. Floating tube sheet
7. Floating head cover
8. Floating head flange
9. Floating head gland
10. Floating head backing ring
11. Stationary tube sheet
12. Channel or stationary head
13. Channel cover
14. Channel nozzle or branch
15. Tube(straight)
16. Tubes
17. Tie rods or spacers
18. Transverse baffles or support plates
19. Longitudinal baffles
20. Impingement baffles
21. Floating head support
22. Pass partition
23. Vent connection
24. Drain connection
25. Instrument connection
26. Expansion bellows
27. Support saddles
28. Lifting lungs
29. Weir
30. Liquid level connection
and tube passes, type of heat exchanger (fixed tube sheet, removable tube bundle etc), tube
pitch, number of baffles, its type and size, shell and tube side pressure drop etc.
1. Shell
Shell is the container for the shell fluid and the tube bundle is placed inside the shell. Shell
diameter should be selected in such a way to give a close fit of the tube bundle. The clearance
between the tube bundle and inner shell wall depends on the type of exchanger ([2]; page
647). Shells are usually fabricated from standard steel pipe with satisfactory corrosion
allowance. The shell thickness of 3/8 inch for the shell ID of 12-24 inch can be satisfactorily
used up to 300 psi of operating pressure.
2. Tube
Tube OD of and 1 are very common to design a compact heat exchanger. The most
efficient condition for heat transfer is to have the maximum number of tubes in the shell to
increase turbulence. The tube thickness should be enough to withstand the internal pressure
along with the adequate corrosion allowance. The tube thickness is expressed in terms of
BWG (Birmingham Wire Gauge) and true outside diameter (OD). The tube length of 6, 8, 12,
16, 20 and 24 ft are preferably used. Longer tube reduces shell diameter at the expense of
higher shell pressure drop. Finned tubes are also used when fluid with low heat transfer
coefficient flows in the shell side. Stainless steel, admiralty brass, copper, bronze and alloys
of copper-nickel are the commonly used tube materials.
4. Tube passes
The number of passes is chosen to get the required tube side fluid velocity to obtain greater
heat transfer co-efficient and also to reduce scale formation. The tube passes vary from 1 to
16. The tube passes of 1, 2 and 4 are common in application. The partition built into
exchanger head known as partition plate (also called pass partition) is used to direct the tube
side flow. Various shell and tube passes are shown in Figure 10.
5. Tube sheet
The tubes are fixed with tube sheet (Figure 11) that forms the barrier between the tube and
shell fluids. The tubes can be fixed with the tube sheet using ferrule and a soft metal packing
ring. The tubes are attached to tube sheet with two or more grooves in the tube sheet wall by
tube rolling. The tube metal is forced to move into the grooves forming an excellent tight
seal. This is the most common type of fixing arrangement in large industrial exchangers. The
tube sheet thickness should be greater than the tube outside diameter to make a good seal.
The recommended standards (IS:4503 or TEMA) should be followed to select the minimum
tube sheet thickness.
6. Baffles
Baffles are used to increase the fluid velocity by diverting the flow across the tube bundle to
obtain higher transfer co-efficient. The distance between adjacent baffles is called bafflespacing. The baffle spacing of 0.2 to 1 times of the inside shell diameter is commonly used.
Baffles are held in positioned by means of baffle spacers. Closer baffle spacing gives greater
transfer co-efficient by inducing higher turbulence. The pressure drop is more with closer
baffle spacing. The various types of baffles are shown in Figure 12.
In case of cut-segmental baffle, a segment (called baffle cut) is removed to form the baffle
expressed as a percentage of the baffle diameter. Baffle cuts from 15 to 45% are normally
used. A baffle cut of 20 to 25% provide a good heat-transfer with the reasonable pressure
drop. The % cut for segmental baffle refers to the cut away height from its diameter. Figure
13. shows segmental baffles.
7. Fouling
Material deposits on the surfaces of the heat exchanger tubes may add more thermal
resistances to heat transfer. Such deposits, which are detrimental to the heat exchange
process, are known as fouling. Fouling can be caused by a variety of reasons and may
significantly affect heat exchanger performance. It is shown in Figure 14.
Fouling can be caused by the following sources:
1) Scaling is the most common form of fouling and is associated with inverse solubility salts.
Examples of such salts are CaCO3, CaSO4, Ca3(PO4)2, CaSiO3, Ca(OH)2, Mg(OH)2,
MgSiO3, Na2SO4, LiSO4, and Li2CO3.
2) Corrosion fouling is caused by chemical reaction of some fluid constituents with the heat
exchanger tube material.
3) Chemical reaction fouling involves chemical reactions in the process stream which results
in deposition of material on the heat exchanger tubes. This commonly occurs in food
processing industries.
4) Freezing fouling is occurs when a portion of the hot stream is cooled to near the freezing
point for one of its components. This commonly occurs in refineries where paraffin
frequently solidifies from petroleum products at various stages in the refining process.,
obstructing both flow and heat transfer.
5) Biological fouling is common where untreated water from natural resources such as rivers
and lakes is used as a coolant. Biological microorganisms such as algae or other microbes can
grow inside the heat exchanger and hinder heat transfer.
6) Particulate fouling results from the presence of micro scale sized particles in solution.
When such particles accumulate on a heat exchanger surface they sometimes fuse and harden.
Like scale these deposits are difficult to remove.
design
Simple to apply
Accurate enough for preliminary design calculations
Accurate enough for designs when uncertainty in other design parameter is such that
the use of more elaborate method is not justified
Disadvantage
The prediction of pressure drop is less satisfactory, as pressure drop is more affected
Thermo-physical Properties
1. Heat capacity
2. Density
3. Viscosity
4. Thermal conductivity
Step 2. Perform energy balance and find out the heat duty (Q) of the exchanger.
Q = mh*cph* T=mc*cpc* t
mh= mass flow rate of hot fluid
mc= mass flow rate of cold fluid
cph= heat capacity of hot fluid
cpc= heat capacity of cold fluid
T= temperature difference in hot fluid
t= temperature difference in cold fluid
T1
t2
T2
t1
Step 4. Decide tentative number of shell and tube passes (n p). Determine the LMTD and the
correction factor FT. FT normally should be greater than 0.75 for the steady operation of the
exchangers. Otherwise it is required to increase the number of passes to obtain higher F T
values.
nt = A/( *do*L)
Calculate tube side fluid velocity:
Re= [4m*(np/nt)]/(di)
Where, m, and are mass flow rate, density and viscosity of tube side fluid. However, this
is subject to allowable pressure drop in the tube side of the heat exchanger.
Step 7. Decide type of shell and tube exchanger (fixed tube sheet, U-tube etc.). Select the
tube pitch (PT), determine inside shell diameter (Ds) that can accommodate the calculated
number of tubes (nT) Use the standard tube counts table for this purpose.
Table 3. Tube pitch values for different number of passes
Step 9. Assign fluid to shell side or tube side (a general guideline for placing the fluids is
summarized in Table 5). Select the type of baffle (segmental, doughnut etc.), its size (i.e.
percentage cut, 25% baffles are widely used), spacing (B) and number. The baffle spacing is
usually chosen to be within 0.2 Ds to Ds.
Table 5. Guidelines for placing fluids in shell and tube side
Step 10. Determine the tube side film heat transfer coefficient (hi) using the suitable form of
Sieder-Tate equation in laminar and turbulent flow regimes.
For Laminar flow
Nu= 0.027*Re0.8*Pr1/3
Select the outside tube (shell side) dirt factor (Rdo) and inside tube (tube side) dirt factor (Rdi).
Table 5. Values of dirt factor for various fluids
Calculate overall heat transfer coefficient (Uo,cal) based on the outside tube area (you may
neglect the tube-wall resistance) including dirt factors:
Uo,cal1=[(1/ho)+Rdo+(A0/Ai(do-di/2kw)) +(Ao/Ai(1/hi))+((Ao/Ai)*Rdi)]-1
Step 11. If 0<( Uo,cal Uo,ass )/ Uo,ass< 30%, go the next Step 12. Otherwise go to Step 5,
calculate heat transfer area (A) required using Uo,cal , and repeat the calculations starting from
Step 5. If the calculated shell side heat transfer coefficient (h o) is too low, assume closer
baffle spacing (B) close to 0.2 Ds and recalculate shell side heat transfer coefficient. However,
this is subject to allowable pressure drop across the heat exchanger.
Step 12. Calculate % overdesign. Overdesign represents extra surface area provided beyond
that required to compensate for fouling. Typical value of 10% or less is acceptable.
% Overdesign =(A-Areq )/Areq
A = design area of heat transfer in the exchanger; Areq = required heat transfer area.
Step 13. Calculate the tube-side pressure drop (PT): (i) pressure drop in the straight section
of the tube (frictional loss) (Pt) and (ii) return loss (Prt) due to change of direction of fluid
in a multi-pass exchanger. Total tube side pressure drop: PT = Pt + Prt .
Step 14. Calculate shell side pressure drop (PS ): (i) pressure drop for flow across the tube
bundle (frictional loss) (Ps) and (ii) return loss (Prs) due to change of direction of fluid.
Total shell side pressure drop: PS = Ps+ Prs . If the tube-side pressure drop exceeds the
allowable pressure drop for the process system, decrease the number of tube passes or
increase number of tubes per pass. Go back to step 6 and repeat the calculations steps. If the
shell-side pressure drop exceeds the allowable If the shell-side pressure drop exceeds the
allowable pressure drop, go back to step 7 and repeat the calculations steps
References
1. EAGLE, A. and FERGUSON, R. M. (1930) Proc. Roy. Soc. A. 127, 540. On the
coefficient of heat transfer fromthe internal surfaces of tube walls.
2. KERN, D. Q. (1950) Process Heat Transfer (McGraw-Hill).
3. LUDWIG, E. E. (2001) Applied Process Design for Chemical and Petroleum Plants, Vol. 3,
3rd edn (Gulf).
4. PERRY, R. H., GREEN, D.W. and MALONEY, J. O. (1997) Perrys Chemical Engineers
Handbook, 7th edn (McGrawHill).
5. Richardson and Coulson, Chemical Engineering Volume 6
6. SAUNDERS, E. A. D. (1988) Heat Exchangers
Conclusion
During the summer internship at Jubilant Life Sciences, the key objective of getting a firsthand experience of chemical plant was successfully accomplished. The purpose of
understanding the production process of pyridine and beta-picoline, and that of recognizing
the major section of raw material storage, reaction section, distillation section, utilities
section etc. was fulfilled and I assimilated the knowledge of plant layout and working.
I understood the working, fundamental principles, problems encountered of the various
equipment used in the industry which enhanced my practical knowledge in the field of
chemical engineering and will surely help me in my future endeavours. The process of waste
incineration, which is of great importance, was also included in this part of the project.
The second part was designing of a heat exchanger (ammonia preheater), which is used in
ammonia recovery process. Firstly all the concepts are thoroughly revised before designing of
heat exchanger. The heat exchanger used was of shell and tube type, and main objective was
to calculate area to process the liquid with given flow rates with pressure drop in given limits.
Kerns method was employed to design the shell and tube heat exchanger and numerous
iterations were performed to obtain the correct and desired result. It was successfully
designed and we get more area than the actual one and hence there is need to reduce the flow
rates so as to get minimum pressure drop.
Calculations of Ammonia
Preheater