Bell’s Method

Gives satisfactory predictions for HTC & DP in Shell side of HX

Effects of leakage, bypass, flow in Flow & window Zone, constructional tolerances are
accounted
Limitation: ??? By-pass flow area > 30% of CFA
 𝐵𝑢𝑛𝑑𝑙𝑒𝑐𝑟𝑜𝑠𝑠 sec 𝑡 𝑖𝑜𝑛𝑎𝑙𝑎𝑟𝑒𝑎𝑖𝑛𝑊𝑖𝑛𝑑𝑜𝑤𝑧𝑜𝑛𝑒
𝑅𝑎′ =
𝑇𝑜𝑡𝑎𝑙𝐵𝑢𝑛𝑑𝑙𝑒𝑐𝑟𝑜𝑠𝑠 sec 𝑡 𝑖𝑜𝑛𝑎𝑙𝑎𝑟𝑒𝑎

Nc: No. of tubes in cross flow zone

Shell side heat-transfer coefficient
hoc HTC for CF over an ideal tube bank

Total correction : 0.6 - 0.9

hoc: Ideal cross flow coefficient

 For 10 tube rows
Fn: Tube row correction factor

Flow Regime : laminar & Turbulent

Fn = 1
Fn is function of number of tune rows between baffle tips
Fw: Window correction factor
Effect of flow through Baffle window

This is function of HTA in window zones & the total HTA

Rw : Ratio of number of tubes in window zone to the

number of tubes in bundle

Bundle cross sec tional area in Window zone

Ra' =
Total Bundle cross sec tional area
 For no sealing Strips:

Fb: Bypass correction factor

Fb: Leakage correction factor
Total Shell side Pressure Drop
affects the pressure drop in cross flow zone
affects both cross flow zone and window zones
No leakage in end zones, Only Window Zone
 CONDENSATION

Types of Condensation
Film-wise Condensation
Drop-wise Condensation
Selection ……

Horizontal Shell side

Vertical Tube side

Reasons
 Condensation Outside the Horizontal tube

Condition….???
Vapor shear forces & non condensable gases
HTC increases & HTC decreases
Condensation flow over tube banks Condensation inside the Horizontal tubes

No correction is required

Low condensate & High vapor & low

vapor flow rates condensate flow rates
Boyko & Kruzhilin Correlation for Annular flow:

Based on Vapor Quality at inlet and outlet conditions

If saturated vapor and total condensate

For Stratified flow:

 Condensation inside/Outside the Vertical tubes
Condensation on the Vertical surfaces
Horizontal Position – Natural Convection –
No Reliable correlations are there
Increase the area, Increase the length
PROCESS DESIGN KETTLE TYPE REBOILER

Perfect pool Boling

Heat transfer in nucleate boiling region

Maximum Heat transfer in – Nucleate Boiling regime

Excess Temp: less than or close to Critical temperature drop

For Water : 20-30 oC, For light organics : 20-50 oC

Boiling side pressure drop is negligible – High vacuum distillation

column
PROCESS DESIGN KETTLE TYPE REBOILER
1. Calculation of heat duty
Energy balance around Distillation column
2. Fix the DTm, th = DTm + tb
3. Select the suitable heating medium
4. Mass flow rate of heating medium required
5. Estimate the heat transfer area
6. Fix do (25.4 mm OD), L,
Square pitch, U tube arrangement,
Pitch : 1.5 -2 do , Vapor Blanketting
% Baffle cut : 0, Bs = Ds
7. Shell side boiling coefficient – Monstinski Equation

8. Tube side heat transfer coefficient

9. Calculate Overall heat transfer coefficient
10. Calculate Heat transfer area
11. % excess area : 10-20%
12. Calculate actual heat flux = Heat duty/Aprovided
13. Actual heat flux <= 0.7 Critical heat flux at critical temp drop
14. Critical heat flux : Zuber Equation

15. Find the shell diameter

Shell ID = Liquid level + 0.15 to 0.25 m
Liquid level = Tube bundle diameter + 50 to 100 mm
Heat flux Shell ID/Tube bundle dia ratio
< 25000 W/m2 1.2 – 1.5
25000 - 40000 W/m2 1.4 – 1.8
> 40000 W/m2 1.7 – 2
16. Check liquid entrainment, Vmax = 0.2 {(rLiq - rVap)/rVap}0.5
Actual vapour velocity should be less than Vmax (Vact @liq surface = (mv/rv)/(Liq Surface area)
Monstinski Equation
PROCESS DESIGN VTSRB

1. Calculation of heat duty

Energy balance around Distillation column
2. Fix the DTm, th = DTm + tb
3. Select the suitable heating medium
4. Mass flow rate of heating medium required
5. Assume overall HTC, Uo = 1000 W/m2 oC &
Estimate the heat transfer area
6. Fix do, L, Pitch,
Pitch : 1.5 -2 do , Vapor Blanketting
% Baffle cut : 15 -45%, Bs = Ds
7. Recirculation Ratio (4 -24)
.0
m Lo mLo - Mass flow rate of liquid at outlet of reboiler
Liquid recirculation = 0 mvo - Mass flow rate of vapor at outlet of reboiler
m Vo
PROCESS DESIGN VTSRB

8. Do the pressure balance:

At SS Condn., Available differential head = Pressure loss in the circuit

DPavail = DP in base of DC + DP in Piping & Nozzles

+ DP in reboiler (Tube side DP)

Velocity at DC bottom << Velocity of liquid through pipes

Piping is smooth & higher in sizing

At SS Condn., DPavail = DP in reboiler (Tube side DP)

DPavail = L (rL - rav) g ,
rL Density in cold leg, rav Density in hot leg, L : Length of the tube
Vo  mvo  +  mLo 
ln  rV   r L 
Vo = 
Vi
r avg = mvo − mLo
Vo − Vi Vi = 1
rL

9. Compare both DPavail & DPt , Five Different cases are possible.
 Five Different cases are possible:

1. DPavail = DPt 1. Proceed to next step

2. DPavail > DPt 2. RCR assumed < RCR actual
3. DPavail >> DPt or DPavail /DPt > 50 3. RCR assumed << RCR actual
4. DPavail < DPt 4. RCR assumed > RCR actual
5. DPavail << DPt 5. RCR assumed >> RCR actual
Case 3: DPavail >> DPt

DPavail = L’ (rL - rav) g

DPavail = DP t + DP Flow meter + DP Control Valve
Case 4: DPavail < DPt

DPavail = L (rL - rav) g + r g h

Increase the No. of tubes and decrease the length

What will happen?

Case 5: DPavail << DPt

Actual RCR is very low…or < 4

When viscosity is low, this is possible.

Pump in the inlet line to the reboiler

10. Estimate the Tube side HTC
In addition Kern mentioned that
if hi is more than 1700 W/m2 oC,
take 1700 W/m2 oC
11. Shell side HTC : 6000 W/m2 oC
12. Calculate Overall heat transfer
coefficient
13. Calculate Heat transfer area
14. % excess area : 10-20%
15. Find the shell side Pressure drop
Forced Circulation Reboiler

1-2 HX : When process fluid in Shell side

1-1 HX : When process fluid in Tube side

High tube velocities : 3-9 m/s

Commercial Reboiler:

Heat Flux < 63 000 W/m2 for Organics

Heat Flux < 95 000 W/m2 for Water & Aq. Solutions
CONVECTIVE BOILING

Different from Pool Boiling

Role of State of the fluid

Single Phase flow Region:

Liquid below its boiling point

Sub-cooled Boiling Region:

Near the wall – Boiling Point

Saturated boiling Region:

Bulk boiling of the liquid – Nucleate boiling –
Different flow patterns

Dry wall Region: Mist flow – Both Cvn & Rdn

CHEN’s METHOD

hcb : Forced Convective HTC

h’fc : Convective Boiling HTC
h’nb: Nucleate Boiling HTC
Convective Boiling HTC
Nucleate Boiling HTC
Chen’s Method for Vertical tubes – Suitable Correlations can be used to predict hfc

Vapor Quality changes continuously – Section wise HTC & HTA Estimation

Example : 12.8 CR- Vol 6

EVAPORATOR
 EVAPORATOR
Evaporation : Concentrating the solution (Non volatile solute + Volatile Solvent)

Examples: Sugar from aq. Solns., NaCl, NaOH, Milk, Glycerol, Orange Juice, Water
from Sea water

Chemical Evaporators
Power plant Evaporators

Processing factors:
Concentration (Density, Viscosity & Boiling Point)
Solubility, Temperature sensitivity, Pressure & Temperature, Foaming, Scale,

Types of Evaporation – Single & Multistage

Main Components of the Evaporator:

1. Tube Bundle surrounding the shell (Calendria) Dia : 1 m – 6 m,

2. Evaporator body (Vapor release Chamber) OD : 25 mm – 75 mm
3. Two heads L : 750 mm – 2000 mm
Central Down Take :
40-100% of C/S Area of Tubes
• Standard Vertical Short Tube Evaporator (Calendria)
Area occupied by each tube:

Area occupied by ‘n’ tubes:

Types of Evaporator:

1. Open Pan/Kettle Es
2. Hztl tube Natural Circulation Es
3. Vertical Natural Circulation Es
4. LTVEs
5. Falling film Es
6. Forced Circulation Es
7. Agitated film Es
8. Open pan solar Es
Boiling Point Elevation
Boiling Point Elevation
MULTIPLE EFFECT EVAPORATOR
 CALCULATION OF MULTIPLE EFFECT EVAPORATOR
The Known values:

(i) Feed Conditions & Flow in I Effect

(ii) Steam Pressure in I effect

(iii) Final effect Pressure in vapor space

(iv) Final Concentration in the liquid leaving the last effect

(v) Physical Properties such as enthalpies,/ Cp of L & V

(vi) Overall HTC in each effect

1. From known concentration & ‘Pressure’ in last effect - Estimate the ‘BP’
in last effect, BPE can be from Duhring line plot
2. Estimate the Vapor evaporated from OMB
First Trial, V1 = V2 = … =Vn
From MB in each effect, Calculate L1 = L2 = … =Ln
From Solute Balance, find out Solids concentration in each effect
3. Using the equation, ,

estimate
If Cold feed, extra heating load, proportionately large
4. Using Material and Energy Balance in each effect, Calculate Vapor & Liquid flow
rate in each effect.
Compare this values with Initial assumption on V1 , V2 , … Vn
If difference is more, Repeat the procedure using calculated values of
V1 , V2 , … Vn

5. Once arrived the satisfied values, Calculate the value of ‘q’ transferred in each effect
Calculate the Area using rate equation for each effect, A1 , A2 , …
An

Calculate the average value

If Areas are not nearly equal, Second trial should be tried

6. Obtain new values of
A solution having 10% dissolved solids is to be concentrated to 30%
solids by weight in a triple effect evaporator at the rate of 10 TPH.
The feed is at 100oC. Low pressure steam is available at 1.5 kg/cm2
gauge. A forward feed configuration is used with a vacuum of 660
mm Hg maintained in the final effect using a single stage steam jet
ejector. The BPE in the final effect is 10oC and in the absence of
more data, the BPE can be approximately taken to be proportional
to the solid concentration in wt.% If the overall heat transfer
coefficients in the effects are 2500, 2000 and 1000 kcal/h mr2 oC
respectively, calculate the evaporator area in each effect.
A Triple effect forward feed evaporator is being used to evaporate a sugar
solution containing 10 wt % solids to a concentrated solution of 50%. The
boiling point rise of the solutions can be estimated from
BPR (oC) solution = 1.78x + 6.22x2,
where x is wt fraction of sugar in solution.
Saturated steam at 205.5 kPa is being used. The pressure in the vapor
space of the third effect is 13.4 kPa. The feed rate is 22680 kg/h at 26.7oC.
The heat capacity of the liquid solutions is Cp = 4.19 – 2.35x kJ/kg K.
The heat of solution is considered to be negligible. The coefficients of heat
transfer have been estimated as U1 = 3123 W/m2 K, U2 = 1987 W/m2 K and
U3 = 1136 W/m2 K. Calculate the area and other dimensions of the
Evaporator.