Heat Exchanger HX required to heat water/butanol binary mix
Tube-Side Fluid Water/Butanol
Shell-side Fluid Steam
Parameter Formulas Value Units
Tube-Side
Inlet Mass Flow 500 kg/hr
Inlet Temperature assumed 25 oC
Required Outlet Temperature 99.5 oC
Delta T 74.5 oC
Shell-Side
Inlet Temperature 100 oC
Outlet Temperature assumed 55 oC
Delta T 45 oC
Fluid Properties
Tube Fluid
Heat Capacity of Water 4.19 kJ/kg K
Heat Capacity of Butanol 2.41 kJ/kg K
Composition Water 0.50 mass frac
Composition Butanol 0.50 mass frac
Heat Capacity of Mixture 3.30 kJ/kg K
Thermal Conductivity Water 606.90 mW/mK
Thermal Conductivity Butanol 132.40 mW/mK
Shell Fluid
Steam Heat Capacity 1890.00 J/kg K
Steam Thermal Conductivity 0.02 W/mK
Duty
Q mCpdeltaT 34101.9 W
Required Steam Mass Flowrate Cps*deltaTs/Q 2.5 kg/s
ESTIMATED U
Condensation Organic Vapours 1250 W/m2K
Steam Condensing 4500 W/m2K
Estimated U 1700 W/m2K
True Mean Temperature
Hot Inlet (Steam) T1 100 oC
Hot Outlet (Steam) T2 55 oC
Cold Inlet (W/B) t1 25 oC
Cold Outlet (W/B) t2 99.5 oC
T1-t2 0.5 oC
T2-t1 30 oC
Log mean temp (counter current) 7.21 oC
R value 0.60
S value 0.83
Ft for 1:2 HX from graph none
Ft for 2:4 HX from graph 0.82
True Mean Temp (deltaTm) 5.91 oC
Required Area
A Q/U*deltaTm 3.40 m2
Number of Tubes
Tube OD (do) 0.02 m
Tube length (L) 2.44 m
Number of tubes (Nt) Nt=A/do*L*pi 23.27 tubes
Rounded Nt 24 tubes
Bundle Diameter
K1 0.175
n1 2.285
Pitch (pt) 0.02 m
Bundle Diameter (Db) 0.16 m
Shell Inner Diameter (Ds)
Ds-Db (for Fixed Head) from graph 0.01 m
Ds 0.17 m
Chosen Bundle Spacing Factor 0.35
Number of Baffles 3.00
Bundle Spacing (Ib) 0.4*Ds or Ds/no baffles 0.06 m
Baffle Cut Percent 0.25
ITERATED HEAT TRANSFER U
Tube Side Calculation
Number of tubes (Nt) 24 tubes
Inner Tube Diameter (di) 0.02 m
Tube Length (L) 2.44 m
Mass Flowrate (m) 0.14 kg/s
Density (p) 990.18 kg/m3
Viscosity (µ) 2.44E-04 kg/ms
Heat Capacity (Cp) 3295.75 J/kgK
Thermal Conductivity (kf) 0.37 W/mK
Tube side Linear Velocity (ut) m/(p*pi*di^2/4) 0.67 m/s
Reynolds Number (Re) (p*ut*di)/µ 44606.44168
Ratio (L/di) L/di 149.77 m
jh from graph 0.0034
Prandtl Number (Pr) Cp*µ/kf 2.17
Nusselt Number (Nu) jh*Re*Pr^0.33 195.87
Heat transfer Coeff (hi) Nu*kf/di 4447.18 W/m2K
Fouling Factor Tubeside (hid) from table 19.2 Sinnot 0.0002 m2K/W
Shell Side Calculation
Steam Density (ps) 0.59 kg/m3
Steam Viscosity (µs) 0.000012 kg/ms
Steam Heat Capacity (Cps) 1890 J/kgK
Steam Thermal Conductivity (kfs) 0.018 W/mK
Steam Mass Flowrate (ms) 2.49 kg/s
Tube Outer Diameter (do) 0.019 m
Shell Diameter (Ds) 0.17 m
Bundle Spacing (Ib) 0.06 m
Bundle Pitch (pt) 0.024 m
Equivalent Diameter 1.10/do*(pt^2-0.917do^2 0.014 m
Shell-side Crossflow Area (As) (pt-do)*Ds*Ib/pt 0.0020 m2
Steam Mass Velocity (Gs) ms/As 1232.30 kg/m2s
Steam Linear Velocity (us) Gs/ps 2088.65 m/s
Reynolds Number (Res) ps*us*de/µs 1389059
Prandtl Number (Prs) Cps*µs/kfs 1.23
jh from graph for BC=25% 0.07
Nusselt Number (Nus) jh*Res*Prs^0.33 104181.6001
Heat transfer Coeff (ho) Nus*kfs/de 141717.9738 W/K
Fouling Factor Shellside (hod) from table 19.2 Sinnot 0.0001 m2K/W
Thermal Conductivity of Tube (kw) 401 W/mK
1/ho 0.000007
1/hod 0
1/hi 0.000225
1/hid 0
do/di 1.170076
ln(do/di) 0.157068
Reiterated U long eqn 1644.987745 W/m2K
PRESSURE DROP CALCULATION
Tube Side Pressure Drop
Number of tube side passes (Np) 4 passes
Tube side velocity (ut) 0.67 m/s
Tube Length (L) 2.44 m
Tube Inner Diameter (di) 0.02 m
Mixture Density (p) 990.18 kg/m3
Friction Factor (jf) from graph 0.00325
L/di 149.8
p*ut^2/2 224.7 kg/ms2
Tube Side Pressure Drop 5.75 kPa
Shell Side Pressure Drop
Shell Diameter (Ds) 0.17 m
Shell Equivalent Diameter (de) 0.014 m
Tube Length (L) 2.44 m
Baffle Spacing (Ib) 0.06 m
Shell Side Linear Velocity (us) 2088.65 m/s
Steam Density (ps) 0.59 kg/m3
jfs 0.07
p*us^2/2 1286927.194 kg/ms2
Ds/de 12.88103801
L/Ib 41.98473639
Shell Side Pressure Drop 389748.361 Kpa
heat water/butanol binary mixture to its bubble point inputs
Notes
Tube-Side
Inlet Mass Flow 500 kg/hr
Inlet Temperature assumed 25 oC
Required Outlet Temperature 99.5 oC
Delta T 74.5 oC
http://www.solvents.basf.com/portal/load/fid245440/ISOBUTANOL
Tube Fluid
Heat Capacity of Wa
Heat Capacity of But
Composition Water
Composition Butanol
Heat Capacity of Mix
Thermal Conductivit
Thermal Conductivit
Viscosity (µ)
Heat Capacity (Cp)
for process(butanol/water) service(steam)
from the graph
determined from Aspen heat exchanger auto output for bubblepoint with UNIQUAC (reference)
here we select the largest correction factor (>0.8) to obtain the best heat transfer
therefore we choose 2:4 HX WHY NOT SPLIT FLOW
this is 3/4 inch and 8ft based on supplier values http://www.engineeringpage.com/technology/thermal/tubesize
and recommendation for HX http://web2.clarkson.edu/projects/subramanian/ch302/notes/designshelltube.pdf
these empirical values obtained from table 19.4 Sinnot for Triangular arrangement
from figure 19.10 Sinnot
based on May Lims recommendation
based on May Lims recommendation
>2000 therefore turbulent flow
assume µ/µw=1
therefore turbulent
for turbulent flow with above assumption
higher range chosen to account for worst case scenario (oil free steam assumed)
low carbon steel chosen as Copper : http://www.shell-tube.com/Materials-and-Construction.html
http://www.slideshare.net/savasadiya55/heat-exchangers-52902228
within the limit
Shell-Side
Inlet Mass Flow -
Inlet Temperature 100 oC
Outlet Temperature assumed 55 oC
Delta T 45 oC
Shell Fluid
4.186 kJ/kg K Steam Heat Cap 1890 J/kg K
2.4055 kJ/kg K Steam Thermal 0.0184 W/mK
0.961538461538462 mass frac Steam Density ( 0.59 kg/m3
0.0384615384615385 mass frac Steam Viscosity 0.000012 kg/ms
4.11751923076923 kJ/kg K
606.9 mW/mK
132.4 mW/mK
0.0002435 kg/ms
4117.51923076923 J/kgK
NIQUAC (reference)
e.com/technology/thermal/tubesize.html
n/ch302/notes/designshelltube.pdf
Tube OD (do) 0.01905 m
Tube length (L) 2.4384 m
Number of tubes (Nt) 29.0676 tubes
Rounded Nt 30 tubes
K1 0.175
n1 2.285
Pitch (pt) 0.023813 m
Bundle Diameter (Db) 0.180972 m
Ds-Db (for Fixed Head) 0.0101 m
Ds 0.191072 m
Chosen Bundle Spacing Factor 0.35
Number of Baffles 3
Bundle Spacing (Ib) 0.063691 m
Baffle Cut Percent 0.25
thermal cond of water
http://www2.bren.ucsb.edu/~dturney/WebResources_13/WaterSteamIceProperties/PropOfWaterFrom0to100C
Tube Side Calculation Shell Side Calculation
Number of tubes (Nt) 30 tubes Steam Density (ps) 0.59
Inner Tube Diameter (di) 0.016281 m Steam Viscosity (µs) 0.000012
Tube Length (L) 2.4384 m Steam Heat Capacity (Cps 1890
Mass Flowrate (m) 0.138889 kg/s Steam Thermal Conductivit 0.0184
Density (p) 990.18 kg/m3 Steam Mass Flowrate (ms 1.99625
Viscosity (µ) 0.000244 kg/ms Tube Outer Diameter (do) 0.01905
Heat Capacity (Cp) 4117.519 J/kgK Shell Diameter (Ds) 0.191072
Thermal Conductivity (kf) 0.58865 W/mK Bundle Spacing (Ib) 0.063691
Tube side Linear Velocity (ut) 0.673754 m/s Bundle Pitch (pt) 0.023813
Reynolds Number (Re) 44606.44 Equivalent Diameter 0.013526
Ratio (L/di) 149.7697 m Shell-side Crossflow Area 0.002434
jh 0.0034 Steam Mass Velocity (Gs) 820.1836
Prandtl Number (Pr) 1.703246 Steam Linear Velocity (us)1390.142
Nusselt Number (Nu) 180.7998 Reynolds Number (Res) 924514
Heat transfer Coeff (hi) 6536.934 W/m2K Prandtl Number (Prs) 1.232609
Fouling Factor Tubeside (hid) 0.0002 m2K/W jh 0.07
Nusselt Number (Nus) 69340
Heat transfer Coeff (ho) 94323.09
Fouling Factor Shellside ( 0.0001
nd-Construction.html
45000
Tube Side Pressure Drop Shell Side Pressure Drop
Number of tube side passes (Np) 4 passes Shell Diameter (Ds) 0.191072
Tube side velocity (ut) 0.673754 m/s Shell Equivalent Diameter0.013526
Tube Length (L) 2.4384 m Tube Length (L) 2.4384
Tube Inner Diameter (di) 0.016281 m Baffle Spacing (Ib) 0.063691
Mixture Density (p) 990.18 kg/m3 Shell Side Linear Velocity 731
Friction Factor (jf) 0.00325 Steam Density (ps) 0.59
L/di 149.7697 jfs 0.07
p*ut^2/2 224.7433 kg/ms2 p*us^2/2 13500
Tube Side Pressure Drop 5.748045 kPa Ds/de 14.12582
L/Ib 38.285
Shell Side Pressure Drop 146
OVERALL DESIGN
Shell and Tube HX
Counter Current flow
2:4 shell to tube pass arrange
Triangular arrangement
Tube size 3/4inch and 10ft
Fixed Tubesheet heat exchang
BFM TEMA design
es/PropOfWaterFrom0to100Celcius.pdf
kg/m3
kg/ms
J/kgK
W/mK
kg/s
m
m
m
m
m
m2
kg/m2s
m/s
W/K
m2K/W
m
m
m
m
m/s
kg/m3
kg/ms2
Kpa
OVERALL DESIGN Justification
Shell and Tube HX Most common and versatile form of HX
Counter Current flow http://www.engineersedge.com/heat_transfer/parallel_counter_flow_designs.htm
2:4 shell to tube pass arrange see correction factors
Triangular arrangement see notes
Tube size 3/4inch and 10ft based on recommended values
Fixed Tubesheet heat exchangesee notes
BFM TEMA design see notes
nter_flow_designs.htm
