HEAT EXCHANGER DESIGN
(I) Thermophysical Properties
S.No. Parameters Air Mixture Steam
(at 1950C) (at 3600C)
1. Density (kg/m3) 0.754 0.346
2. Viscosity (Pa-s) 2.592×10-5 2.327×10-5
3. Thermal Conductivity (W/m-K) 0.03726 0.0505
4. Specific Heat (kJ/kg-K) 1.0239 2.02654
(II) Calculate heat duty and flow rate of steam
S.No. Parameters Air Mixture Steam
1. Mass Flow rate (kg/h) 74250 ?
2. Temperature of input stream (°C) 90 400
3. Temperature of output stream (°C) 300 320
4. Temperature Difference (ΔT) (°C) 210 80
(I) Heat Duty
Q = 16450586 kJ/h = 4569607.2 W
(II) Flow rate of steam
We know that:
Q= mh * cph * (Thi-Tho)= mc * cpc * (Tco-Tci)
So, mc = Q / [cpc * (Tco- Tci)]
= (4569.6) / (2.02654*633.15)
= 3.56 Kg/s
(III) Shell and tube side passes
The Air mixture passes through the shell side and the steam passes through the
tube side.
i. Shell side pass =1
ii. Tube side pass = 4
(IV) Log Mean Temperature Difference (LMTD) & LMTD correction factor (FT)
400°C
90oC 320oC
300
The tube side and shell side fluid are flowing in a
counter current manner.
( 400−90 )−( 320−300 )
LMTD = 400−90
ln(320−300 )
0
= 105.8 C
From graph ,
FT = 0.92
(LMTD)TRUE = 0.92 x 105.8 = 97.3oC
(V) Uassumed & Area available
From the table given for overall heat transfer coefficient of different fluids , we
assume a value of U [from table 1,Appendix I]
Uass = 120 W/m2°C
Since Q = U A (LMTD)
So, A = Q/ [U × (LMTD)True]
= ( 4569607.2) / (120 x 97.3)
= 391.36 m2
(VI) Selecting tube diameter, length, thickness, baffle cut
Assume:
Inner diameter of tube (di) = 16 mm
Outer diameter of tube (do) = 19 mm
Tube length (L) = 4.88 m
Tube sheet thickness = 25 mm
Baffle cut = 25%
Length for heat transfer = 4.88 - (2 × 25 × 10-3)
= 4.83 m
(VII) Number of tubes
Area of one tube = π × d o × L
= (3.14 × 19×10-3 × 4.83)
= 0.288 m2
No. of tubes (Nt) = 391.36 / 0.288 = 1358.88
(VIII) Tube Layout
Considering the tubes to be arranged in triangular pitch arrangement.
Pitch (Pt) = 1.25 do
= 1.25 × 19 × 10-3
= 0.02375 m
(IX) Shell Diameter
Bundle diameter (Db) = do × [(Nt / K1) (1/n1)]
K1 and n1 values are taken from [table 2,appendix I]
For 4 tube passes: K1= 0.175
n1= 2.285
Db = 19× [(1358.8 / 0.175) (1/ 2.285)]
= 957.66 mm
From the given graph between bundle diameter & shell-bundle clearance,
Ds – Db = 72 mm
Ds = Db + 72 = 957.66 + 67 = 1029.66 mm = 1.029 m
(X) Tube side Calculation
(a) Mean (steam) Temperature = (400+320)/2 = 360°C
(b) Flow area = πdi2/4 = [3.14×(16×10-3)2]/4
= 2.0 × 10-4 m2
(c) Tubes per pass = 1358.88/4 = 339.72
(d) Total Flow area = 339.72 × 2 × 10-4
= 0.068 m2
(e) Tube side velocity = m/(A × ρ)
= 3.56 / ( 0.068 × 0.346)
= 151.31 m/s
(f) Reynolds Number (Re)
Re = diuρ/µ
= (16 × 10-3 × 151.31 × 0.346)/ (2.327 × 10-5)
= 35997.084
μcp
Prandtl no. =
k
= (2.327 × 10-5 × 2.02654 × 103) / 0.0505
= 0.934
(g) Li/di = (4.83/16 × 10-3)
= 301.8
From given graph, jH = 3.3 × 10-3
( hidi )/kf = jh x Re x Pr0.33 x (µ/µw)0.14
hi = (0.05056/16*10-3)*(3.4 *10-3)*( 35997.084)*(0.934)0.33
= 367.01 W/ m2 oC
where hi= inside coefficient (W/m2 oC)
(h) Tube side pressure drop
For Re = 35997.084, friction factor (jf)= 3.3 × 10-3
ΔP = 8jf (L/di) (ρut2/2)
= 8 × 3.3 × 10-3 × [4.83 /0.016] × {[0.346× (151.31)2]/2}
= 31557.64 Pa = 31.5 kPa= 4.57 psi
(XI) Shell side calculation
(a) Mean Shell Temperature = (90+300)/2 =195°C
(b) Ds = 1029.66 mm = 1.029 m , B = 0.2 x DS
(c) Cross flow area
as =[(pt - do) × Ds × B]/ pt
= [(0.02375 - 0.019) × (1.029)2 × 0.2]/ 0.02375
= 0.0423 m2
(d) Mass velocity
Gs = mmix/as =( 20.7 kg/s)/ (0.0423 m2)
= 489.36 kg/m2s
(e) Equivalent Diameter
de = (1.27/do) (pt2 – 0.785do2)
= [1.27/ 0.019] {0.023752 – [0.785 × (0.019)2]}
= 0.01876 m
(f) Reynolds Number
Re = Gsde /µ = (489.36 × 0.01876)/ (2.59× 10-5)
= 354455.35
(g) Prandtl Number
Pr = µCp/k = (2.59 × 10-5 × 1.0239 × 103)/ (0.03726)
= 0.712
(h) Heat transfer coefficient
For 25% baffle cut, from graph
Heat transfer factor (jh) = 1.3 × 10-1
(hsde/kf) = jh x Re x Pr0.33 (µ/µw)0.14
Without the viscosity correction factor
hs = [(0.03726 / 0.019) × (1.3 × 10-1 ) × (354455.35 ) × (0.712)0.33]
= 80781.61 W/ m2 oC
(XII) Overall coefficient
(1/Uo)= (1/ho) + (1/hod) + [(do ln(do/di))/ (2kw)]+(do/dihid)+(do/dihi)
1/Uo= (1/80781.61) + 0.0002 + 3.26 × 10-5 + 2.96 × 10-3 + 3.235 × 10-3
Uo =155.05 W/ m2 °C
Ucal > Uass
155.05 W/ m2 °C > 120 W/m2 °C
% excess = [(155.05 - 120) × 100 ]/ 120 = 29.2 %
