Calculation of a 2-4 Oil Cooler

A 33.5API oil has viscosity of 1.0

centipoise at 180F and 2.0 centipoise at
100F.49,600lb/hr of oil leaving a distilling
column at 358F and is to be used in an
absorption process at 100F.Cooling will
be achieved by water from 90F to
120F.Pressure drop allowances of 10psi
may be used on both streams along with a
combined dirt factor of 0.004.
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Available for this service from a
discontinued operation is 35in.ID 2-
4exchanger having 454 1in.OD ,11BWG
tubes 120 long laid out on 1-in.squre
pitch. The bundle is arranged for six
tube passes and vertical cut baffles are
spaced 7in. apart. The longitudinal
baffle is welded to the shell.
Is it necessary to use a 2-4 exchanger?
Will the available exchanger fulfill the
requirements?

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2-6 Shell and tube heat exchanger:-
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Temperature profile:
T1(358)

t2(120)

T2(100)

t1(90)
L
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Solution:-
Exchanger
shell side Tube side
ID=35in. Number=454
Baffle spacing=7in. Length=120
Passes=2 OD,BWG=1in.,11
Pitch=1in.squre
Passes=6
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Hot fluid Cold fluid
difference
T1=358F t2=120F t1=238F
T2=100F t1=90F t2=10F
Temperature range:-
(T1-T2) (t2-t1)
258F 30F
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LMTD:-
LMTD= t1-t2
ln(t1/t2)
LMTD = 238-10
ln(238/10)
LMTD =72F
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Correction factor:-
R= (T1-T2)/(t2 - t1)
R=238/30
R=8.6
S=(t2-t1)/(T1-t1)
S=30/(358-90)
S=0.112

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True temperature difference:-
t=FTLMTD
From table: FT=0.93
LMTD=72F
t=0.9372
t=66.96F
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Heat balance:-
Oil
Q=W cp(T1-T2)
Q=49,6000.545(358-100)
Q=6,980,000Btu/hr
Water
Q=mcp(t2-t1)
Q=23,2666.671.0(120-90)
Q=6,980,000.1Btu/hr
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Caloric temperatures:-
t2/t1=10/238=0.042
For
API=33.5 and temperature
range(258F) Kc=0.47(from table)
For Kc=0.47 and t2/t1=0.042
Fc=0.267
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Caloric temperature of hot fluid:
Tc=T2+Fc(T1-T2)
Tc=100+0.267(258)
Tc=165F
Caloric temperature of cold fluid:
tc=t1+Fc(t2-t1)
tc=90+0.267(30)
tc=98F
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Hot fluid: shell side
Flow area
as=1/2(IDCB)/144PT
as=1/2(350.257)/1441.25
as=0.17ft
2
Mass velocity
Gs=W/as
Gs=49,600/0.17
Gs=292000lb/(hr)(ft
2
)

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Viscosity:
At Tc=165F (from table)
=1.12cp
=1.122.42
=2.71lb/(ft)(hr)
Equivalent diameter:
De=0.99 in. (from table)
De=0.99/12
De=0.0825ft
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Reynolds number:
Res=DeGs/
Res=0.0825292000/2.71
Res=8900
jH=52.5 (from table)
Prandtl number:-
Pr=(c/k)
For
API=33.5 and =2.71 (from table)
k(Pr)=0.20Btu/(hr)(ft
2
)(F)

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Film coefficient:
ho=jH (k/De) (Pr)s
ho/s= 52.5 0.2/0.0825
ho/s=127
Cold fluid: tube side
Flow area:
at=0.455 in. square
at=(Ntat)/(144n)
at=(4540.455)/(1446)
at=0.239ft
2
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Mass velocity:
Gt=m/at
Gt=232666.67/0.239
Gt=973500lb/(hr)(ft
2
)
Fluid velocity:
V=Gt/(3600)
V=973500/(360062.37)
V=4.33fps
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Diameter:
D=0.76 in./12 (from table)
D=0.0633ft
Viscosity:
At tc=98F
=0.73 cp (from table)
=0.732.42
=1.77 lb/(hr)(ft)

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Reynolds number:
Ret=D Gt/
Ret=(0.0633 973500)/1.77
Ret=348156
Film coefficient:
For
V=4.33fps (from table)
hi=10100.96
hi=970 Btu/(hr)(ft2)(F)

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hio=hi(ID/OD)
hio=970(0.76/1.0)
hio=737 Btu/(hr)(ft
2
)(F)
Tube-wall temperature:
tw=tc+ ho (Tc-tc)
(ho+hio)
tw=98+ 127 (165-98)
(127+737)
tw=108F

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At tw:
w=1.952.42
w=4.72 lb/(hr)(ft)
s=(/w)
s=(2.71/4.72)
s=0.92
ho=1270.92
ho=117 Btu/(hr)(ft
2
)(F)
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Clean overall coefficient Uc:
Uc= (hioho)/ (hio+ho)

Uc=(737117)/(737+117)

Uc=101 Btu/(hr)(ft
2
)(F)
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Design overall coefficient UD:
UD=Q/(A t)
A(total)=45412ft(0.2618ft
2
/lin ft)
A=1425ft
2
UD=6980000/(142566.96)
UD=73.15 Btu/(hr)(ft
2
)(F)
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Dirt factor Rd:
Rd=(Uc-UD)/UcUD
Rd=(101-73.15)/(10173.15)
Rd=0.00377 (hr)(ft
2
)(F)/Btu

Rd (required) 0.004
Rd(calculated) 0.00377
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Pressure drop: (on shell side)
For Res=8900 (from table)
f=0.00215ft
2
/in.
2
No of crosses, N+1=12L/B
N+1=(12 12)/7
N+1=20.1 ( Say,21)
Ds=35 in./12
Ds=2.92ft
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S( specific gravity)=0.82 (from fig.)
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Ps = fGs
2
Ds(N+1)
5.2210
10
Dess
Ps =0.00215292000
2
2.9242
5.2210
10
0.08250.820.92
Ps =7.0psi (allowable=10psi)
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Pressure drop: (on tube side)
Ret =34815.6 (from fig.)
f=0.000195ft
2
/in.
2
Pt=(fGt
2
Ln)/(5.2210
10
Dst)
Pt= 4 psi
Gt=973500,v
2
/2g=0.13 (from fig.)
Pr=(4nv
2
)/(2gs)
Pr=3.2 psi
PT=Pt+Pr=7.2psi(allowable=10psi)
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2-4 Shell and tube heat exchanger:-
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Only replace value of n=6 to n=4
At=0.3585
Gt=649000
V=2.89fps
Ret=23210
hi=760 Btu/(hr)(ft
2
)(F)
hio=577 Btu/(hr)(ft
2
)(F)
tw=110F
ho=117 Btu/(hr)(ft
2
)(F)
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Uc=94 Btu/(hr)(ft
2
)(F)
Rd=0.003 (hr)(ft
2
)(F)/Btu
F=0.00025
Pt=1.53 psi ,v
2
/2g =0.065
Pr=1.04 psi
PT=Pt+Pr=2.57psi
(allowable=10psi)s
So,2-6 STHE is more suitable as
compare to 2-4 STHE.


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