3.6.

Materials:
Until now, there have been 13 types of materials popularly used in fabricating chemical
vessels, namely:

 Carbon steel
 Stainless steel
 Nickel and alloys
 Aluminum and alloys
 Copper and alloys
 Lead and alloys
 Titanium
 Zirconium
 Tantalum
 Glass
 Plastic materials
 Composite materials
 Linings

When choosing the materials for chemical vessels, there are seven criteria needed to be
concerned, namely, corrosion, design temperature, design pressure, abrasive
environment, ease of fabrication, availability of standard equipment and cost.

For the limitation of this project, only the ferrous material is shown in detail:

Ferrous > 50% Fe

A) Carbon steel
 Low < 0.3% C
 Medium 0.35-0.55% C
 High 0.6-1.5% C
 B) Low Alloy (Chrome and Cr-Mo)
 <5% addition of alloy, i.e., Mn, Ni, Cr, etc.
C) High Alloy
 >10% addition of alloy composition
 Stainless steel
 Ferritic
 Martensitic
 Austenitic (stabilized, low carbon, high carbon)
 Duplex
D) Cast Iron >1.5% C
 Ductile
 Malleable
 White
 Gray

Common names for non-ferrous alloys include Inconel, Incoloy, Monel, Carpenter 20,
Cupronickel, Hastelloy, etc.

Clad material is a combination of base material and some alloy cladding or welding
overlay.

SUS304 is the most versatile and widely used in fabricating pressure vessel. Sometimes,
it is still referred to its old name 18/8 derived from the composition of type 304 being
18% Chromium and 8% Nickel. SUS 304 is an austenitic grade that can be severely deep
drawn, highly ductile, tough, excellently resistant to corrosion in environment,
inexpensive, easy to be fabricated and cleaning, ... those are the reasons why SUS304 is
chosen for our heat exchanger design.

3.7. Corrosion allowance:

The corrosion allowance is the additional thickness of metal added to account for
material lost by corrosion and erosion, or scaling. Usually, this value should be an
agreement between manufacturer and customer. In reality, corrosion is a sophisticated
circumstance that is due to many factors: chemical condition, mechanical condition,
manufacturing, and installation or rounding calculating number. Therefore, these things
are not calculated when the manufacturer enters designing step. However, it could be
based on experience with the material of construction under the similar circumstances to
those for the proposed design.

 According to PD5500 code, for carbon and low-alloy steels, where severe
corrosion is not expected, a minimum allowance of 2.0 mm should be used; where
more severe conditions are anticipated this should be increased to 4.0 mm. Most
design codes and standards specify a minimum allowance of 1.0 mm.
 On the other hand, if the manufacturers follow the ASME code (Section VIII
Division 1):
 The user or his designated agent shall specify corrosion allowances other than
those required by the rules. Where corrosion allowances are not provided, this
fact shall be indicated on the Data Report.
 Vessels or parts of vessels subject to thinning by corrosion, erosion, or
mechanical abrasion shall have provision made for the desired life of the
vessel by a suitable increase in the thickness of the material over that
determined by the design formulas, or by using some other suitable method of
protection.

From the standpoint of corrosion, pressure vessels may be classified under one of the
following groups:

 Vessels in which corrosion rates may be established from information

available to the designer. Such information may, standard commercial
products, be obtained from published sources, or, where special processes are
 involved, from reliable records compiled from results of previous observations
by the user or others under similar conditions of operation.
 Vessels in which corrosion rates, while known to be relatively high, are either
variable or indeterminate in magnitude.
 Vessels in which corrosion rates, while indeterminate, are known to be
relatively low.
 Vessels in which corrosion effects are known to be negligible or entirely
absent.

E-2: When the rate of corrosion is closely predictable, metal thickness that required for
the initial operating conditions should be provided.

E-3: When corrosion effects are indeterminate prior to design of the vessel, or when
corrosion is incidental, localized, and/or variable in rate and extent, according to the
designer’s judgment to establish a reasonable shell thickness.

E-4: When corrosion effects can be shown to be negligible or entirely absent, no excess
thickness need be provided.

E-5: When a vessel goes into corrosive service without previous experience, it is
recommended that inspections be frequently made.

E-6: For parts which are essential to vessel strength such as stiffener rings, the
attachment of the part to the shell must provide adequate corrosion allowance to assure
the required strength.

 Material added for these purposes need not be of the same thickness for all
parts of the vessel if different rates of attack are expected for the various parts.
 No additional thickness need be provided when previous experience in like
service has shown that corrosion does not occur or is of only a superficial
nature.
  Telltale Holes. Telltale holes may be used to provide some positive indication
when the thickness has been reduced to a dangerous degree. Telltale holes
shall not be used in vessels that are to contain lethal substances, except as
permitted for vent holes in layered construction. When telltale holes are
provided, they shall have a diameter of 1/16 in. to 3/16 in. and have a depth
not less than 80% of the thickness required for a seamless shell of like
dimensions.
 Openings for Drain. Vessels subject to corrosion shall be supplied with a
suitable drain opening at the lowest point practicable in the vessel; or a pipe
may be used extending inward from any other location to within 1/4 in. of the
lowest point.
 In another way, Ho Le Vien code illustrate the other way to estimate this kind of
value.

Corrosion allowance: C = Ca + Cb + Cc + Co (mm)

Where,

Ca is the additional thickness due to chemical corrosion (mm)

Cb is the additional thickness due to mechanical corrosion (mm)

Cc is the additional thickness due to manufacturing and installation (mm)

Co is the additional thickness due to rounding the number (mm)

 CHAPTER 4: BASIC INFORMATION OF SHELL-TUBE HEAT EXCHANGER
AND STEPS SUMMARY
4.1. Basic information of shell – tube heat exchanger:

The information of the calculated shell-tube heat exchanger is given as follows:

In this shell-tube heat exchanger, the condensation of FO-R oil occurs inside the tubes,
while water used to condense the fuel oil (FO) flows outside.

Inside the tubes of this vessel:

 The inlet temperature: T ¿=280 ℃ .

 The outlet temperature: T out =220 ℃ .
 The operating pressure: poperate ,vac =0,6 atm .
 The outside diameter of one tube: d out =31mm .
 The length of each tube: l=3150 mm .

Outside the tubes of this vessel:

 The inlet temperature: T '¿=30 ℃ .

'
 The outlet temperature: T out =70 ℃ .
 The operating pressure: poperate , gauge =1 atm.
 The inside diameter of shell: D¿ =890 mm .
 The length of shell: L=3950 mm .
4.2. Steps summary:

Fundamental information of shell –tube heat exchanger

The design of tubes

The design of shell

The design of open and end

The design of tube sheets

The design of flanges

The design of saddles

The mechanical design of

shell – tube heat exchanger