CHAPTER 8 CONDENSER DESIGN
Topics to be covered;
8.1 Introduction
8.2 Design Calculations
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CHAPTER 8 CONDENSER DESIGN
8.1 C O N D E N S E R
A condenser is a two-phase flow heat exchanger in which heat is generated
(Latent heat) by the conversion of vapor into liquid (condensation) and the
heat generated is removed from the system by a coolant.
Types of Condensers:
Steam Turbine Exhaust Condensers/surface condensers
1. Plate Condensers
2. Air-Cooled Condensers
3. Direct Contact Condensers
4. Shell & Tube
Selection of Condenser Configurations:
Four Condenser Configuration are Possible:
Horizontal with condensation in shell side and cooling medium in the
tubes.
Horizontal with condensation in tube side cooling medium in shell side.
Vertical with condensation in the shell.
Vertical with condensation in the tubes.
Horizontal shell side and vertical tube side are the most commonly used
types of condensers. In this process we have used the horizontal with
condensation in shell side & cooling medium in tube.
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CHAPTER 8 CONDENSER DESIGN
8.2 DESIGNING STEPS OF CONDENSER:
Heat Balance.
Assumed Calculations.
Calculations of Heat Transfer Coefficients.
Calculations of Pressure Drops.
Different Parameters Given:
Operational Pressure of condenser = 1 atm
Inlet temperature of the process stream = T1 = 89 oC
Outlet Temperature of the process stream = T2 = 89 oC
Inlet Temperature of the water = t1 = 25 oC
Outlet Temperature of the water = t2 = 35 oC
Mass flow rate of process stream = m1 = 3472.47 Kg/hr
Mass flow rate of the Water = m2 = 208440 Kg/hr
Enthalpy of Vapor mixture = λ1 = 2715 KJ/Kg
Enthalpy of condensate = λ2 = 206 KJ/Kg
True Mean Temperature Difference (LMTD):
T1=890C T2=890C
t2=350C t1=250C
LMTD = (T1 – t1) – (T2 – t2)
ln(T1 – t1)
(T2 – t2)
= 17.6oC
R = T1 – T2 = 3.9
t2 – t1
S = t2 – t1 = 0.16
T1 – t1
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CHAPTER 8 CONDENSER DESIGN
Ft = 0.98 (Ref: fig. 12.19 coulson vol. 6)
True Mean Temperature Diff. = TMTD = Ft x LMTD
= 17 oC
Assumed Overall Coeff. = 950 W/m2.oC
(Ref: Coulson vol. 6 Table 12.1)
HEAT LOAD:
Q = m1 x (λ1 – λ2)
3600
= 2420 KW
COOLING WATER FLOW RATE:
m = Q/ (Cp (water) x ∆T)
= 58 Kg / Sec
TUBE DIMENSIONS:
O.D. = 25 mm
I.D. = 21.8 mm
Length of tube = Lt = 1.83 m
(Ref: Kern table 9 and 10)
Surface area of one tube = Asurface = п x O.D. x Lt
= 0.144 m2
HEAT TRANSFER AREA
Trial area = A = (HL / UD (estimated)) x TMTD
= 69.03 m2
Number of Tubes = Ntubes = A / Asurface
= 481
Use Square pitch = Pt = 1.25 x O.D
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CHAPTER 8 CONDENSER DESIGN
= 31 mm
1 / 2.263
Tube bundle Dia = Db = O.D. x (Ntubes /0.158)
= 865 mm
Number of tubes in centre row = Db/Pt
= 28
Tube-wall Temperature ‘Tw’:
Assumed condensation coefficient = 2000 W/m2.0C
Mean Temperature:
Shell-side = Ts = T1 + T2 = 69.5oC
2
Tube-side = Tt = t1+ t2 = 30 oC
2
Tw = Ts – ((Ts – Tt) x UD (estimated)) / Assumed condensation co-efficient
= 50.7 oC
Mean Temperature condensate = Tc= Ts+Tw
2
= 60oC
PHYSICAL PROPERTIES AT 60ОC
µL = 0.71 mNs / m2
ρL = 994.92 Kg / m3
kL = 0.17 W / m оC
Average Mol. Wt. of Vapors = Mv = 18.38
Vapor Density at mean vapor temperature (Using ideal gas law):
ρv = (Mv / V) x (T/273+Ts) x P/ P0
= 0.7 kg / m3
Condensate loading on the horizontal tube:
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CHAPTER 8 CONDENSER DESIGN
Ѓh = (m1/3600) / Length of tube x Ntubes
= 1.1 x 10-3 kg/sec. m
Average number of tubes in a vertical tube row:
Tv = 2/3 x number of tubes in centre row
= 18
Heat Transfer Coefficient in condensation:
hc = 0.95 x KL(ρL(ρL- ρV) x 9.81)/µL x Ѓh/1000))1/3 x Tv-1/6
= 2303.2 W/m2.oC
Tube cross-sectional area:
Xt = /4 x (I.D./1000)2 x Ntubes / 2
= 0.045 m2
Density of water at 35 oC = 993 kg / m3
Tube velocity:
Vt = FRw x 1/(993 x Xt)
= 1.30 m/s
hi = (4200 x (1.35 + 0.02 x Tt) x Vt0.8)/I.D.0.2
= 5457.67 W / m2 oC
Fouling Factor, as neither of the fluid is heavily fouling, use 5000 W/m 2.oC for
each case.
Kw = 50 W/m2.oC
(Ref. Perry’s Handbook)
OVERALL COEFFICIENT
1/U = (1 / hc)+ (1/5000) + O.D. x Ln (O.D./I.D.)/(2 x 1000 x Kw) + (O.D./I.D.) x
(1/5000) + (O.D./I.D.) x hi
= 0.0011 m2.0C / W
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CHAPTER 8 CONDENSER DESIGN
U = 934.86 W/m2.oC
SHELL-SIDE PRESSURE DROP
Use pull-through floating head, no need for close clearance.
Select baffle spacing = Shell diameter, 45 % cut.
Clearance = 94 mm ( Ref: fig. 12.10 Coulson vol. 6)
Shell I.D. = Tube bundle dia + Clearance
= 959 mm
Cross-flow area = As = (Pt – O.D.) x Shell I.D. x Shell I.D./(1000000 x Pt)
= 0.184 m2
Mass flow-rate, based on inlet conditions:
Gs = (m1 / 3600) x (1 / As)
= 5.24 kg / Sec.m2
Equivalent Diameter:
de = 1.27 x (Pt2 – 0.785 x O.D.2) / O.D.
= 24.7 mm
Vapor viscosity = 0.00008 N.Sec / m2
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CHAPTER 8 CONDENSER DESIGN
Reynold's Number:
NRe = (Gs x de) / (vapor viscosity x 1000)
= 16178 ~ 16000
Friction Factor = jf = 0.038
(Ref: Fig. 12.30 coulson vol. 6)
Shell-Side Fluid Velocity:
Us = Gs / ρv
= 8.02 m/s
Shell-side Pressure Drop:
∆Ps = 0.5 x (8 x jf x (Shell I.D. x de) x (Lt x 1000 / Shell I.D.) x (ρv x Us2 /2))
= 236.78 N / m2 = 0.237 KPa
= 0.03 Psi
TUBE-SIDE PRESSURE DROP
Viscosity of Water = ηw = 0.6 mN.Sec / m2
Reynold’s number = NRe = Vt x 993 x I.D. / 1000 x ηw
= 46938 ~ 47000
Friction Factor = Jf = 0.0038
(Ref: Figure 12.24 coulson vol. 6)
Tube-side Pressure Drop:
∆Ps = 4 x (8 x Jf x (Lt x 1000/I.D.) + 2.5) x 993 x Vt2 /2)
= 16981 N / m2
= 16.98 KPa
= 2.46 Ps i
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CHAPTER 8 CONDENSER DESIGN
SPECIFICATION SHEET
CONDENSER
Identification: Item condenser
No. Required = 1
Function: Condense vapors by removing the latent heat of vaporization
Operation: Continuous
Type: 1-2 Horizontal Condenser
Shell side condensation
Heat Duty = 2420 Kw
Tube Side: Shell Side:
Fluid handled cold water Fluid handled = ISPAC+ISPE
Flow rate = 57.9 Kg/Sec Flow rate = 3472.47 Kg/hr
Pressure = 14.7 psia Pressure = 14.7 psia
Temperature = 25 oC to 35 oC Temperature 89 oC to 89 oC
Tubes: 1 in. dia . Shell: 38 in. dia. 2 passes
481 tubes each 7 ft long Baffles spacing = 38 in.
2 passes Pressure drop =2.46 psi
1.25 in. square pitch
pressure drop = 0.03 psi
Utilities: Cold water
Ud assumed = 950 W/m 2C
Ud calculated =934.86 W/m 2C
Uc calculated = 2303.2 W/m 2C
Ut calculated = 5457.67 W/m 2C
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