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Introduction

The document discusses the design calculations for a shell and tube condenser. Key details include: - The condenser removes latent heat from vaporizing process streams at 8060 kg/hr and 45°C to liquefy them. - Cooling water at 25°C enters and exits at 40°C, with a mass flow rate of 68.9 kg/sec calculated to meet the 4343 kW heat load. - Design calculations determine the condenser will require 1030 tubes that are 0.75 inches in diameter and 16 feet long. - The calculated overall heat transfer coefficient is 1100.97 W/m2°C, close to the assumed value of 1000 W/m2°C.

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Mitul Prajapati
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70 views

Introduction

The document discusses the design calculations for a shell and tube condenser. Key details include: - The condenser removes latent heat from vaporizing process streams at 8060 kg/hr and 45°C to liquefy them. - Cooling water at 25°C enters and exits at 40°C, with a mass flow rate of 68.9 kg/sec calculated to meet the 4343 kW heat load. - Design calculations determine the condenser will require 1030 tubes that are 0.75 inches in diameter and 16 feet long. - The calculated overall heat transfer coefficient is 1100.97 W/m2°C, close to the assumed value of 1000 W/m2°C.

Uploaded by

Mitul Prajapati
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 17

• Introduction

• A condenser is a type of heat exchanger in which


vapors are transferred into liquid state by removing
the latent heat with the help of a coolant such as
water.

• Condensers may be classified into two main types:


1. Those in which the coolant and condensing vapor
are brought into direct contact.
2. Those in which the coolant and condensate stream
are separated by a solid surface, usually a tube
wall
Different types of the Condenser

1. Double pipe and multiple pipe


2. Plate Condensers
3. Air-Cooled Condensers
4. Compact Condensers
5. Shell & tube type
DESIGN CALCULATIONS FOR CONDENSER

T2 = 45 oC T1 = 45 oC

Condenser

t1= 25 oC t2 = 40oC

• Inlet temperature of the process stream ‘T1’ = 45 oC


• Outlet temperature of the process stream ‘T2’ = 45 oC
• Inlet temperature of the water ‘t1’ = 25 0C
• Outlet temperature of the water ‘t2’ = 40 oC
• Mass flow rate of the process stream ‘m’ = 8060 Kg/hr
• Enthalpy of Vapors of Process Stream = 1940 KJ/Kg
Removed ‘λ1’
Heat Load:
Q = m (λ1)
Q = 4343 KW

Mass flow rate of cooling water


Q
m= Cp = 4.2 KJ / Kg.K
C p Δt
= 68.9 Kg/sec

Log Mean Temperature Difference

LMTD = (∆t2-∆t1)/ log (∆t2/∆t1)


LMTD = 14.4oC
Assumed Calculations

Assumed Value of Overall Coefficient ‘UD’ = 1000 W/m 2C

True Mean Temperature Difference

Dimensionless Temperature Ratios


R
R = (T1-T2) / (t2-t1)
= (45-45) / (40-25)
= 0
S
S = (t2-t1) / (T1-t1)
= (40-25)/ (45-25)
= 0.75
From Literature the value of Ft is 1

∆tm = Ft x LMTD
= 1 x 14.4
= 14.4 oC
Heat Transfer Area
Q
A=
U D Δt

= 301 m 2
Surface Area of single tube = 3.14 x 19 x 4.88 / 1000
= 0.292 m 2
No. of tubes = 301/.292
= 1030
Pitch ‘Pt’ = 1.25 × 19.05= 23.8 mm
Tube Bundle Diameter
Db = d0 (Nt/K1)1/n1
= 19 (1030/0.158)1/2.263
= 920 mm

No. of tubes in centre row


Nr = Db / Pt
= 920 / 23.8
= 39
Shell Side Calculations

Estimate tube wall temperature Tw


Assume condensing coefficient of 4250 W/m2C (from literature)
Mean Temperature
Shell side =( 45+45) / 2 = 45 oC
Tube side = (25+40) / 2 = 32.5 oC
(45-Tw) x 4250 = (45-25) x 1000
Tw = 40.3 oC
Physical Properties
Viscosity of the liquid ‘µL’ = 0.8 mNs/m2
Density of liquid ‘ρL’ = 993 Kg/m3
Thermal conductivity ‘kL’ = 0.571 W/m C
Average M. Wt. of Vapors = 42.8
Density of vapor = 29 x 273 x 1/(22.4 x 1 x (273+42))
= 1.12 Kg / m3

Condensate loading on a horizontal tube ’Ѓh’ = m / L x Nt


= 8060 / 3600 x (4.88 x 1030)
= 4.45 x 10-3 Kg/m s
# of tubes in the vertical row ’Nr’ = 2/3 x 39 = 26 mm
Heat transfer coefficient in condensation
‘h0’ = 0.95 x kL ( ρL x (ρL – ρv ) g / (µL x Ѓh)1/3 x Nr-1/6
= 4396.0 W/m2оC
• As our assumed value is correct so no need to correct the
wall temperature
Tube Side Calculations

Tube cross sectional area = 3.14 / 4 x (19 x 10-3)2 x 1030 / 4


= 0.073 m2
Density of water at 30 0C = 993 kg/m3
Tube velocity = m / (ρH2O x At )
= 68.9 / (993 x 0.073)
= 0.95m/s
Film heat transfer coefficient inside a tube
‘hi’ = 4200(1.35+0.02 x t) Vt0.8 / di. 0 2
= 4809.67 W/m2 0C
From Literature take fouling factor as 6000 W/m2 0C
Thermal Conductivity of the tube wall material
‘Kw’ = 50 W/m0C
Overall Coefficient

1/U0 = 1/ho + 1/hod + (d0 ln(d0/di))/2kw +d0/di x 1/hid +d0/di x 1/hi


= 0.001
U0 = 1100.29 W/m2 0C

So assumed value is correct


Shell Side Pressure Drop
For pull through floating head with 45% cut baffles
From literature clearance = 88 mm
Shell internal diameter ‘Ds’ = Db+88
= 1008 mm
Cross flow area ‘As’ = m2

A= 0.205 m2
Mass Velocity
Gt = m / As
= 8060 / (3600 x 0.205)
= 10.92 Kg/s m2
Equivalent diameter ‘de’ = 1.27 (Pt2 -0.785d02) / d0 = 19 mm
Viscosity of vapors ‘µ’ = 0.009 mNs/m2
Reynold’s No.
Re = de Gt / µ
= 19 x 10-3 x 10.92 /0.009 x 10-3
Re = 23053
From literature
jf = 0.029
By neglecting the viscosity correction factor

Where
Ds = dia of shell
L = Length of tubes
lB = baffle spacing
So
= 765 N/m2
= 0.765 Kpa
= 0.109 Psi
Tube side pressure drop

Viscosity of water ‘µ’ = 0.9 x 10-3 Ns/m2


Re = Vt ρ di /µ
= 0.95 x 993 x 16.56 x 10-3 / 0.6 x 10-3
= 26036
From literature
jf = 0.0039

Where
Np = No. of tube passes
So
∆Pt = 4119.8 N/m2
= 4.119Kpa
= 0.59 psi
Acceptable
hio = hi ×I.D/O.D
hio = 4165.2 W/m2 0C

Clean Overall Coefficient:


h io h o
UC =
h io +h o

= 2138.7 W/m2 0C

Design Overall Coefficient Calculated


UC − UD
Rd =
UCU D

dirt factor Rd = 0.0005


SPECIFICATION SHEET CONDENSER
Identification: Item condenser
No. Required = 8
Function: Condense vapors by removing the latent heat of vaporization

Operation: Continuous
Type: 1-4 Horizontal Condenser
Shell side condensation
Heat Duty = 4343 KW
Tube Side: Tubes: 0.75 in. Dia.
Fluid handled: Cold Water 1030 tubes each 16 ft long
Flow rate = 68.9 Kg/sec 4 passes
Pressure = 14.7 psia 23.8 mm triangular pitch
Temperature = 25 oC to 40 oC Pressure Drop = 0.59 psi

Shell Side: Shell: 39 in. dia. 1 passes


Fluid handled = Steam Baffles spacing = 3.5 in.
Flow rate = 8060 Kg/hr Pressure drop =0.109 psi
Pressure = 10 KPa
Temperature = 45 oC to 45 oC

Utilities: Cold water


Ud assumed = 1000 W/m 2C Ud calculated =1100.97 W/m 2C
Rd = 0.0005
References

• Chemical Engineering Design


Volume 6 by Coulson &v Richardson’s
• Process Heat Transfer
by D.Q. Kern
• Plant Design & Economics for Chemical Engineers
5th Edition by Max S. Peters, Klaus D. Timmerhaus,
Ronald E. West
• Perry’s Chemical Engineers’ Handbook
by Robert H. Perry, Don. W. Green

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