CHEMICAL ENGINEERING DESIGN 2B – CEDB201

EXAMINER: DR F. O. AFOLABI START DATE: 16 AUGUST 2024

INTERNAL MODERATOR: MRS CP DUBE DUE DATE: 6 SEPTEMBER 2024
DEVELOPED GAS: 3 AND 5 MARKS: 100
GROUP DESIGN PROJECT 1: THERMAL DESIGN OF A HORIZONTAL SHELL AND TUBE CONDENSER (HSTC)

The assignments for the module are designed specifically to show the development of the required Graduate
Attributes (GAs). The two GAs being developed are GA3: Engineering Design and GA5: Engineering methods, skills,
tools, including Information technology will not be assessed, however a certain level of competency is expected.
The development of these GAs must be achieved to obtain a Duly Performance (DP) for this module (as per the
learner guide). This assignment is assessing the development of the Gas. The assignment must be conducted by a
group of maximum of three members with all meetings minuted and attached.

BACKGROUND:
Distillation column is both a mass and heat transfer unit. Distillation column consists of three units: the column,
the condenser with reflux drum and the reboiler. Distillation column is used for the separation of liquid mixtures
(multi-component) based on their relative volatilities of the components. Those components that have low
relative volatilities are easier to separate and generally leave at the top of the column as vapours and enters the
condenser. The condenser is used cool and condensed vapours to liquid, and a reflux drum and reflux pump is
used to hold the condensed vapours from the top of the column so that liquid can be recycled back to the
column and a portion of the liquid is collected as distillate product. The components with greater relative
volatilities leave at the bottom of the column and a portion of the product enters the reboiler. Figure 1 shows a
typical distillation column.

CHEMICAL ENGINEERING DESIGN 2B: AUGUST 2024. PAGE - 1 -

PROBLEM STATEMENT:
A condenser is required to sub-cool condensate from a n-butanol condenser leaving the top of a distillation
column to 40 0C. The n-butanol is essentially pure and is a saturated vapour at a pressure of 2.1 bar. Design a
horizontal shell and tube condenser (HSTC) capable of handling a vapour rate provided (see table 1) as it applies
to your group. Cooling water is available at 30 ℃ and the temperature rise is to be limited to 30 ℃. The pressure

drop on the vapour stream is to be less than 50 𝑘𝑁⁄𝑚2 , and on the water stream less than 70 𝑘𝑁⁄𝑚2. Take

the saturation temperature of n-butanol at 2.1 bar as 120 ℃. All the other physical properties required can be
found in the literature or estimated with clear justification.

Determine if the design of a horizontal shell and tube condenser as per the design information given is feasible
for the mentioned purpose. All assumptions made in the design must be clearly stated and justified, and all
calculations must be in SI units. The methodology applied in designing the condenser must be presented in a
clear and logical sequence.

SCOPE OF THE REQUIRED DESIGN:

1. Detail thermal design of the horizontal shell and tube condenser.
2. Set-up EXCEL spreadsheet for the iterative sizing calculation for condenser using formulas.
3. Present a Specification Sheet of the final design for condenser.

DATA INFORMATION FOR THE CONDENSER.

1. The n-butanol vapour leaving the top of the column enters the condenser at its saturation temperature and
vapour pressure of 2.1 bar of 120 ℃.
2. The condenser is a total condenser. The condensate leaves at its saturation temperature, it is sub-cooled to
a condensate liquid.

NB: ASSIGNMENT MUST BE NEATLY TYPED AND PRESENTED CLEARLY AND LOGICALY. THE REPORT MUST BE
UPLOADED ON MOODLE “CEDB201 CONDENSER DESIGN ASSIGNMENT_2024” BEFORE 16H00 ON 6
SEPTEMBER 2024 BY ONE GROUP MEMBER.

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Requirements:
1. A typed report with a standard cover page and as per the rubric (assessment sheet). State and justify all
assumptions made.
2. The report uploaded on Moodle will have “Similarity report” generated and resubmission on Moodle
before the due date to reduce the similarity percentage is permitted.
3. Turnitin penalties sliding scale will apply as stipulated in the learner guide.
4. Resubmission will only be granted to those that have 45–49 % in their assignment.
5. No late assignments will be accepted even via email.
6. A subminimum of Developing (level 2) for all indicators of interest is required in the report to achieve each
of the GAs. Failure to achieve this will require a resubmission of the assignment and penalty will apply.
7. A subminimum of 50 % for a report is required to pass this module.

DUE DATE: 6 SEPTEMBER 2024 AT 16H00

The following are excuses that will not be entertained:

▪ Any request for an extension of due dates will result in a maximum final mark of 50 % for the entire class
▪ Any sudden ‘illnesses’ near or on the due dates
▪ Any group disputes and break up. Students are requested to deal with these issues on their own
▪ Any sudden viruses on flash drives and laptops and thefts of laptops (an affidavit with a case number
from the South African Police will only be accepted should the laptop be stolen. The student will still be
required to submit their work on the due date).
▪ Any sudden ‘electricity outages’ and load shedding near or on the due dates

CHEMICAL ENGINEERING DESIGN 2B: AUGUST 2024. PAGE - 3 -

 Water in Water out

Condenser

Reflux
drum

Distillate product
Feed Distillation
column Pump

Steam in
Kettle
reboiler Steam out

Bottom products
Figure 1: Distillation column with condenser and kettle reboiler.

Table 1: Flow rate for n-butanol

cooling
Parameter n-butanol Table 2: Flowrate selection e.g.
water
Use the last 2 digits of the student number of all 3
members; or use the last 3 digits of the student Student Flowrate
number of all 2 members. No. Order (kg/h)
Flowrate
- 21859024
ascending

(kg/h)
If the first number is zero of 2 digits, make it 8. E.g.
246771
06 ≈ 86 0r 056≈856. 21916967
22010471

CHEMICAL ENGINEERING DESIGN 2B: AUGUST 2024. PAGE - 4 -

 DEPARTMENT OF CHEMICAL ENGINEERING -BNCME1 Report Mark : ________
CHEMICAL ENGINEERING DESIGN 2B – CEDB201 Late Penalty : ________

ASSESSMENT SHEET - 2024 Copying Penalty: ________

THERMAL DESIGN OF HORIZONTAL SHELL AND TUBE CONDENSER (HSTC)

STUDENT/S INFO.

GA 3 MARK NOT EVALUATED BUT MUST SHOW COMPETENCY DEVELOPMENT IN YOUR WORK
GA 5 MARK NOT EVALUATED BUT MUST SHOW COMPETENCY DEVELOPMENT IN YOUR WORK
FINAL REPORT MARK
EXAMINERS COMMENTS:

MODERATOR’S COMMENTS:

ASSESSMENT CRITERIA ALLOCATED SUB- EXAMINER’S RE-SUBMIT MODERATOR’S

MARK (%) MINIMUM MARK (%) MARK (%) MARK (%)
Title Page/ Cover Page: The following have been included: 1.5
• Title of project
• Full name of authors and student numbers

CHEMICAL ENGINEERING DESIGN 2B: AUGUST 2024. PAGE - 5 -

Preface: 1
The following details have been included:
• where the work was carried out (e.g. S31evel 01, Steve Bike
Campus, DUT)
• Under whose supervision it was done, and over what period
it was conducted.
Declaration: 1
• A signed declaration by the students that the report
represents their own work;
• Place and date of submission.
Acknowledgements: Contributions to the project by others have 1.5
been acknowledged:
• the work of one's supervisor/mentor.
• the support of any organization or institution which have
provided assistance or funding.
• The active help of anyone directly involved with the project
(colleagues, assistants).
Abstract: 10 5
• The problem has been defined.
• Brief details of the approach/procedure/methods have been
described.
• The important/final design results that were found have been
stated.
• Appropriate conclusions and recommendations have been
stated.
Table of Contents: 5
• Includes: main headings, sub headings, page numbers,
• List of tables,
• List of figures
• Table of Abbreviations / Nomenclature and.
• Definitions of Terms / Glossary
Introduction: 5
• Background information has been given.
• The problem has been defined.
• Reasons why the problem was worthy of being studied has
been explained.
• Detailed objectives are described.
• Technical report layout
Part A: Mechanical Thermal Design of HSTC: Extensive and 55 25
relevant presentation of the design of shell and tube condenser.

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Shows good understanding and integration of literature into the
complete document.
a) Design of horizontal shell and tube condenser: 30 15
• Table of properties for hot and cold fluids (reference).
• Present complete material and energy balance for the
condenser. Clearly indicate and justify all assumptions
made.
• Outline calculation on the final iteration in the logical
manner, include all equations used as well as heat transfer
coefficient correlations. Do not just list the equations, state
what equations is for, and references all values taken from
Tables and Figures.
• Number the equations. For example;
The tube side heat transfer coefficient was calculated using
the Dittus-Boelter equation for heat transfer in a turbulent
environment. This equation is given below
Nu = CRe0.8Pr0.33 ( eq. 3.5)
where Nu = Nusselt Number = hidi/kfi
C = constant = 0.023 for liquids (Sinnot, 2007)
Re = Reynolds Number
Pr = Prandtl Number = µCp/kfi
Nu = CRe0.8Pr0.33
Nu = 0.023(37000)0.8(4.8)0.33
Nu = 174
• No sample calculation in the Appendix
• Specify the type of the condenser.
• Provide reasons for fluid allocations.
• Tubes configuration.
• Detail of material of construction used for the design, give
reasons.
• Shell and tube sizes (diameter and wall thickness, length).
Provide reasons.
• A neat annotated dimensioned diagram showing the cross-
sectional area of the condenser.
• The total length of horizontal shell and tube condenser,
number tube, and other components.
• Tube and shell heat transfer coefficients.
• Overall heat transfer coefficient.
• Area required and area available.

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• Show all iterations on spreadsheet and highlight iterated
value
• Safety factor
• Tube and shell pressure drop
• Discuss all the important results and include the specification
table
• Scaled and dimensioned plan in isometric projection showing
all of the piping and piping components.
• Correct P&ID codes and standards are applied.
• Drawings have title block and legend.
• Draw a control system of the exit stream of hot water out to
ensure the temperature is attained
b) Determine the capital cost of the constructed shell and tube
heat exchanger and the expected payback period for the 15 7.5

project.
▪ Discuss the capital cost and operation cost.
▪ The shell, tubes, fittings, and other instruments are correctly
priced.
▪ Total capital cost of designing HSTC.
▪ Costing is formulated in Excel.
▪ Correct method is used to determine the payback period.
▪ Relevant equations and correlations used has been fully
stated and discussed together with the nomenclature
(definition of symbols with their units).
▪ Discuss the final analysis for costing
c) Occupational Health and Process Safety Aspects: 10 5

▪ All potential occupational health and process hazards

identified on the HSTC design.
▪ Mitigation of all hazards are proposed on the HSTC design.
▪ Determine the safety impact the installation of the HSTC.
Conclusion and Recommendations: 5 5
• All important information learned from this work has been
listed.
• The recommendations developed from the design in terms of
requirements, resources and constraints have been listed.
• Implications of the construction and commission the shell and
tube heat exchanger.
References: 5
• only one reference system used: DUT Harvard Referencing
System.

CHEMICAL ENGINEERING DESIGN 2B: AUGUST 2024. PAGE - 8 -

• Anonymous reference will not be acceptable.
• punctuation and elements standardised exactly (e.g. order of
elements, punctuation, capitalization and publishing details).
Appendices: The appendix includes: 5
• Excel spreadsheets used of the formula Editing.
• Format and layout of spreadsheet is appropriate and easy to
use.
• Spreadsheet is functional.
• Printed spreadsheet must be included.
• All Figures and Tables used must be presented.
• Isometric, process flow and piping and instrumentation
drawings.
• Rubric must be also included
• Minutes of the group meetings to show participation of the
members must be attached.
Organisation and Presentation: Clear, logical, easy to follow, 5
starts & ends well, no unclear or weak points. Smooth transitions
between sections. The report says what it sets out to say. It
addresses the design scope.
• Presented computer-generated work neatly and
professionally.
• Punctuated, spelt and constructed sentences appropriately.
• The needs of the readership have been addressed.
• Computer graphics have been appropriately generated.
• Diagrams have been accurately, neatly and legibly annotated.
• Calculations in computer-generated spreadsheets have been
presented.
• Graphic material has been appropriately integrated.
• Professional and technical vocabulary has been appropriately
used.
• Content has been critically and logically selected and
arranged.
• Page space has been effectively and efficiently used.

TOTAL 100 100

Signatures

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CHEMICAL ENGINEERING DESIGN 2B: AUGUST 2024. PAGE - 10 -
 DEPARTMENT OF CHEMICAL ENGINEERING
CHEMICAL PROCESS DESIGN 2B – CEDB201
DESIGN ASSIGNMENT COVER PAGE_2024
Surname, Initials Student Number Signature

STUDENT/S
INFORMATION

ASSIGNMENT TITLE

DUE DATE

SUBMISSION DATE

EXAMINER/LECTURER

A statement along the lines of

Submitted in partial fulfilment of the requirements of the Chemical Process Design

2B in the Department of Chemical Engineering, Faculty of Engineering and the Built
Environment at the Durban University of Technology

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