6 HEAT EXCHANGERS 6.1 Types and selection of heat exchangers ». 6.2 General design considerations .. 6.3 Estimating shell and tube surface area and pressure drop 6.4 Air coolers and condensers : 6.5 Condensers .. 6.6 Reboilets .. 6.1 Types and Selection of Heat Exchangers Heat exchange is the science that deals with the rate of heat transfer between hot and cold bodies. There are three methods of heat transfer: © Conduction © Convection © Radiation In a heat exchanger heat is transferred by conduction and convection, with conduction usually being the limiting factor. The equipment used in heat exchanger service is designed specifically for the duty required of it. That is, heat exchange equipment cannot be purchased as a stock item for a service but has to be designed for that service. The types of heat exchange equipment used in the process industry and their selection for use are as follows: (2) The shell and tube exchanger ‘This is the type of exchanger most commonly used in a process plant. It consists of a bundle of tubes encased in a shell. It is inexpensive and is easy to clean and maintain, There are several types of shell and tube exchangers and some of these have removable bundles for easier cleaning. The shell and tube exchanger has a wide variety of normal service. This includes vapour condensation (condensers), process liquid cooling (coolers), exchange of heat between two process streams (heat exchangers), and reboilers (boiling in fractionator service). Most of this chapter will be dedicated to the uses and design specification of the shell and tube exchanger. (2) The double-pipe exchanger A double-pipe exchanger consists of a pipe within a pipe. One of the fluid streams flows through the inner pipe while‘TYPES AND SELECTION OF HEAT EXCHANGERS: 301 the other flows through the annular space between the pipes. The exchanger can be disinantled very easily and is therefore easily cleaned. The double pipe exchanger is used for very small process units or where the fluids are extremely fouling. Either true concurrent or countercurrent flows can, be obtained, but because the cost per square foot is relatively high it can only be justified for special applications. ‘The following table gives the heat transfer area for various pipe lengths and diameters: No. of Shell Tube size Surface area (£2) tubes size (in) Gin) 108 204 208 1 2 1 58 10 163 1 3 15 109 w9 r 1 4 2 BI. 261 38.5 (3) Extended surface or fin tubes This type of exchanger is similar to the double-pipe but the inner pipe is grooved or has longitudinal fins on its outside surface. Its most common use is in the service where oné of the fluids has a high resistance to heat transfer and the other fipid has a low resistance. It can rarely be justified if the equivalent surface arca of a shell and tube exchanger is greater than 200300 ie, ‘ i (4) Finned air coolers These are the more common type of air coolers used in * the process industry. Air cooling for process streams gained prominence: during the early 1950s. In a great many applications and geographic areas they had considerable economic advantage over the conventional water cooling, ‘Indeed, today it is uncommon to se6 process plants’of any reasonable size without ai coolers: Air coolers consist of a fan and one or more heat transfer sections mounted on a frame. In most cases these sections consist of finned tubes through which the hot fluid passes. The.fan located either above or below the tube section induces or forces air around the tubes of the section. The selection of air coolets over shell and tube is one of cost., Usually, air coolers find favour in condensing fractionator, overheads to. ‘temperatures of about 90-100 °F and process liquid product streams to storage temperatures. Ait coolers are widely used in most areas of the world where ambient air temperatures are most times below 90°F. At atmospheric temperatures above’ 100°F ‘huinidifiers are’ incorporated into ‘the cooler design and ‘operation. The cost under these’circumstances is greatly increased and their use is often than not justified, i In very cold-¢limates the air temperature around the tubes is controlied to prevent the’ skin: temperature: of ‘the fluid being cooled falling: below: a freezing criterion or; in the case of petroleum products, its pour point. This control is achieved by’ louvres installed to recitculate the air flow’or by varying the quantity-of-air flow by changing the fan pitch. (5) Box coolers These are the simplest form of heat exchange. However, they are generally less efficient, more costly and require a large area of the plant302 HEAT EXCHANGERS plot. They consist of a single coil or ‘worm’ submerged in'a' bath of cold water, The fluid flows through the coil to be cooled by the water surfounding it, The box cooler found use in the older petroleum refineties for cooling heavy residuum to storage temperatures: Modern practice is to use a tempered water system where the heavy oil is cooled on’the shell side of a shell and tube exchanger against water at a’controlled temperature flowiig in the tube side. The water is recycled through an ait coolet to control its temperature to a level which will not cause the skin temperature of the oil in the shell and tube exchanger to fall below its pour point, (8) Direct contact condensers In this exchanger’ the process vapotit ‘to be condensed comes into direct contact with the cooling medium (usually water). This contact is made in a packed section of a small tower. The most common use for this type of condenser is in vacuum-producing equipment. Here the vapour and motive steam for each ejector stage is condensed'in a packed direct contact condenser. This type has a low-pressure drop which is essential for the vacuum-producing process. 6.2 General Design Considerations : BASIC HEAT TRANSFER: EQUATIONS ‘The following equations define the basic. heat: transfer, relationships. ‘These equations are used to determine the overall surface area required, for the transfer, of heat from a hot source to,a cold source. be Fany © The overall heat transfer equation ‘The ‘usual heat transfer, mechanism are conduction; natural convection, forced convection; condensation, and, vapor- ization. When heat is transferred by these means the overall equation is as follo% Q = VAAtn) where . Q = heat transferred in BTUAL mo U = overall heat transfer coefficient rumen, we A = heat transfer surface aréa (ft?) “ Ain, = corrected log mean temperature difference cy" ©. The overall heat transfer coefficient U: This coefficient, is the summation ofall the resistance to the flow of heat in-the transfer mechanism. These resistances are the resistance to heat transfer contained in the flujds, the resistance caused by fouling, and the resistance to heat transfer of the tube, wall., The resistance to the flow of heat from the liquid outside the tube wall is measured by. the film coefficient of that fluid. The resistance of the flow of heat: from the fluid inside the tube is similarly the film coefficient of the inside. fluid. These film coefficients are products of dimensionless numbers which include: © The Reynolds number . pees ‘ © The'Graetz numberGENRRAL DESIGN CONSIDERATIONS 303 ‘The Grashof number The Nusselt number The Peclet number © The Prandtl number ¢ The Stanton number ‘The format of these numbers and their use are found in all standard textbooks on heat transfer (for example, Kern, Process Heat Transfer, and McAdams, Heat Transmission), These resistances are defined therefore by the following expression: : +070 * Crd x * : where “ Uy = overall hit tandfer coefficient based on outsidé tube surface (BTU/fP PE) : ‘he film coefficient (BTU /n/te PF) a fouling factors (1/BTU/h/fC °F) 1y = heat transfer vate through tube wall (BTU/h/t?/F) A = surface area (f) Subscripts.o and i tefer to outside surface anid inside surface respectively. FLOW ARRANGEMENTS ‘The two more common flow paths are concurrent and countercurrent. ‘In concurrent flow both the’hot fluid and the cold fluid:flow in the same direction. This is the least desirable of the flow: arrangements and is: only used in those chemical processes where there is a danger of the cooling fluid congealing, - subliming, or crystallizing at near-ambient temperatures. Countercurrent flow is the most desirable arrangement, Here the hot fuid enters at one end of the exchanger‘and the cold fluid enters at the opposite end. ‘The streams flow in directions opposite to one another. This arrangeinent allows the two streams, exit temperatures to approach one another. . LOGARITHMIC MEAN TEMPERATURE DIFFERENCE Afi, In either a countercurrent ‘or a concurrent: flow’ arrangement the log mean temperature difference used in the overall heat transfer equation is determined by the following expression: : Sy A= Ab ye In(At/Ate) ‘The A/’s are the temperature differences at each end of the exchanger and At is the larger of the two. In true countercurrent flow the At, calculated can be used directly in the overall heat transfer equation! However, such a situation is not common and true countercurrent flow rarely exists. Therefore a correction factor Abn304 . HEAT EXCHANGERS: needs to be applied to arrive at the correct Afy. These are given in Figure A1.6 in Appendix 1. The equation given above for Ay is resolved to the following: _ Ahm Ab loge(@n/ae) FLUID VELOCITIES AND PRESSURE DROPS Film coefficients ace a function of fluid velocity, density (vapour), and viscosity (liquids). Within limits; increasing the velocity of a fluid reduces its resistance to heat transfer (je. it increases its heat transfer coefficient). Increasing the fluid velocity, however, increases its pressure drop. An economic balance needs:to be sought therefore between the, cost of heat transfer surface, and pumping cost. This’ exercise should be undertaken to find a payout balance of 2 to, 4 years. This exercise has been done many times and the followirig data’ are considered a reasonable balance between velocity and pressure drop for some comnition cases: ‘Tube side Shell side Velocity Preisiire drop” Veldcity ' Presire atop hy. (si) 5) (psi) Non-viscous 68 10 15-25 10 liquids 8 oy wa ne he gens : : Viscous liquids 6 Dos oh Oma 5 A S-20 Clean cooling” 628! 10-15 + = foes water" ” woes mo : Dirty cooling » bee water : ‘Suspiended solids 2 LS mnin'* is in liquids" ” ae wernt ais 1" Gases and vapours = ——!%__Max 3-5 - 3 ‘VGasdensity Condensing vapours. = mos ~ 1 3S _ tNrmally erosion by susperied sfids in iquid occurs st vloctes of above 644, For condensing steam pressure drop is usually not critical but'@ mininiuin steain pressure drop is desitable. Allowable steam velocities in tubes are as follows: Pressure’ "3+! Velocity (ft/s) ' Below atinospheric.cs 25» Atmos. to.100.psig iv... 475, + Above 100.psig sc. ASQ. ee -GENERAL DESIGN CONSIDERATIONS: 305 CHOICE OF TUBE SIDE VERSUS SHELL SIDE ‘There are no hard-and-fast rules governing which fluid flows on which side in a heat exchanger. Much is left to the discretion of individual engineers and their experience. There are some guidelines and these are as follows. : Tube side flow Fouling liquids ‘Tube cleaning is much easier than cleaning the outside of the tubes. Also, fouling can be reduced by higher tube side velocities. Corrosive fluids It is cheaper to replace tubes than shells and shell baffles so, as a general rule, corrosive fluids are put tube side. There are exceptions and a major one are those corrosive fluids that become more corrosive at high velocities. An example of this are naphthenic acids which are present in some. crude oils and their products. High pressure Fluids at high pressure are usually put on the tube side as only the tubes, tube sheet, and channel need to be rated for high pressure in the units design, This reduces the overall cost of the exchanger. Suspended solids Fluids containing. suspended solids should, whenever possible, be made to flow tube side. Shell side flows invariably have ‘dead spaces’ where solids come out of suspension and build up to cause fouling. Cold boxes These sre .exchangers used in cryogenic processes. where condensing of a vapour on one side of the exchanger is accompanied by boiling of a liquid on the other side, The condensing fluid is preferred on the tube side, Better control of the refrigerant flow is accomplished by the level control across the shell side. Shell side flow Available pressure drop Shell side flows generally require ‘a lower pressure drop than tube side, Therefore if # system is pressure drop limiting it should be routed shell side. Condensers Condensing vapours should flow shell side wherevér possible. ‘The larger free area provided by shell side space permits minimum pressure dtop and higher condensate Toadings through better film heat transfer coefficients. Large flow rates In cases where both streams are of a similar nature with imilar properties the stream with the Jergest flow rate should be sent shell side where the differences in flow rates are significant. The shell side provides more flexibility in desiga by baftle arrangements to give the best heat transfer design criteria. Boiling service The boiling liquid, as in the case of reboilers, waste heat secovety units, ete,, should-be on the shell side of the exchanger. This allows space for the proper disengaging of the.vapour phase and provides a means of controlling the system by-level control of the liquid phase.306 HEAT EXCHANGERS ‘TYPES OF SHELL AND TUBE EXCHANGERS Figure 6.1 shows some of the more common arrangements in shell and tube exchangers design. The arrangements here are all one shell pass and one or two tube passes. Equipment with more than two tube passes:(up to five) are also fairly common, particularly in petroleum refining. Shell arrangements are, however, left at one if at all possible, Where multi-pass shell side is requited companies prefer to use complete exchangers i in series or in parallel or both rather than making two or more shell passes using horizontal baffling in one exchanger. 6.3 Estimating Shell and Tube Surface Area and Pressure Drop : ‘There are many excellent computer programs available’ that calculate exchanger surface area and pressure drops from simple input.’ The actual’ calculation when done mianwally is tedious and long, However, to understand alittle of the importance of the input required by these pfogranis it does well to at least view a typical manual calculation, The one given here is for a SKell and tube cooler with ‘no change of phase for either tube side ot shell sie fluids. ‘The calculation follows these steps: © Step1 Establish the following itata by heat balances or from observed plant readings : 3 —The inlet and outlet temperatures oti the shell side and on the tube side. +The flow of tube side fluid atid that for the shell ide, It may be necessary to calculate one or the other from a heat balance over the exchanger. ~Calculate the duty of the exchanger in heat units per unit time (usually in hours). —Establish the stream properties for tube side and shell side’ fluids, The Properties required are SG, viscosity, specific heats, thermal conductivity. © Step2 Calculate the log mean temperdtute difference (ATm) Assume a flow pattern (i.e. cither concurrent or countercurrent). Most flows will be-a form of ‘countercurrent, Then show the temperature flow as follows: Shelli ‘in Shell out ‘Tube out-< Tube in” ‘Temp. diff. AT, AT) : The log mean temperature difference is then calculated using the expression = ATS loge: ania ‘This temperature needs to be corrected for the flow pattern, and this is done using the correction factors-given-in Figure A1.6-in Appendix 1. The use of these are self-explanatory and ate given in the figtre.ESTIMATING SHELL AND TUBE SURFACE AREA AND PRESSURE DROP 307 Step3 Calculate the approximate surface area From Table A1.1 in Appen- dix 1 select a suitable overall heat transfer coefficient U in BTU/h.f.5F. Use the expression to calculate for A: Q=UAAT, where .Q = heat transfered in BTU/h (the exchanger duty) ; U = overall heat transfer coefficient A = exchanger. surface area (ft) : AT, = log mean temperature difference (corrected for flow pattern) (°F) From the surface area calculated select the tube size and pitch, usually fin. on a triangular pitch for clean service and Jin. on a square pitch for dirty or fouling service. A single standard shell will hold about 4100 ft? of surface per pass. Now most companies do not use multi-pass shells and prefer sets of shells in series if this becomes necessary. The ‘norm’ therefore are single-pass shells‘each containing up to 4100 ft? of surface, Step'# Catculate the tube side flow and the number of passes It it cannot be read from plant data calculate tube side flow in f°/h by heat balance. Select the tube gauge and length, The tube data are given in Table A1.7 in Appendix 4 and standard lengths of tubes are 16 and 20ft. Calculate the number of selected tubes per pass from the expression. . , ft x 144 P3600 x A, x Vy where: Np = mumber of tubes per pass , Fy = tube side flow (ft"/h) A; = cross-sectional area of one tube , linear velocity in tube (ft/s) ve See Section 6.2 for recommended fluid velocities. The number of tube passes is arrived at by dividing the total surface area required by the total (external) surface area of the number of tubes per pass calculated above, Step5 Calculate tube side film coefficient corrected to outside diameter (hig) The tube side film coefficient may. be calculated for’ water by: the expression ve * _ 300 x (VW, x tube i/d (in.))98 - he tube od (in.) inside film coefficient based on outside tube diameter (BTU/n.£2.°F) ineat velocity of water tube side (fis)... For fluids other than water flowing tube side use thé expression”! tng = E(cul ig) ™ (D6308, HEA EXCHANGERS Removable, Tubeshest cA Y onnetiyps shell cover Bolts twee Tj A St f Shell : F~ Tub T sheet HY} Tube Removable * * eupport Bolted” shell | Y cy alles. flanges: ebver. + . 1 ohell:pese,{ tube-pags. : : (True countercurrent) : : < [Removable « |fat-type shell cover Pass: “shelipaes, 2 tibe-pass J *" Removable A cicero ey Cem © aye ct »» shell cover Figure 6.1, Some ‘common :-types of shell atid tube cexchangors. (a) Fixed tube sheet; (b) removable tube bundle where, - = inside film cot nt based on outside diameter (BTU/h.f2"F) = theimal edndvetivty ofthe fluid in BTU/h.t? per 1). See Maxwell's Data Book on Hydrocarbons ot Perry's Chemical Engineers’ Handbook = igESTIMATING SHELL AND TUBE SURFACE AREA AND PRESSURE DROP 309 A Pullthrough, floating head TN 1 shell: pass, 2 tube-pass A cover it ring, Hloating head n Sern I, 1 shell-pass, 2 tubs-pass i Usube bundle Jai Ly a N 1 sheltpans, 2 tube-pass ) tside tube diameter (in. ) yecific heat (BTUAbfF) G = mass velocity (Ib/s.ft?) # = absolute viscosity (eP) at average fluid temperature bsolute viscosity (@H) at average tube wall temperature310 HEAT BKCHANGERS 3000 1000 2096 40006000 10.000 20.000 40.000 60.ab0 100.000) 180000} 0 009 50 000} 5000 oom 2000 0 000}. Let 3000 20000 ' {2000 10000] +1000 8000] ‘6000 sd00} er g see 8s 20] 10) 10 | 1B S466 819 26 904950 aot00 , 200 300400600 1000 60 800 +h = Film cootetent (BTUAVI 9) K = Thotmal conductivity (BTU/h 1 ('F por fy | 1. = Heated tub length (t) . D = Inside tube clameer (h). 6 c Masevelochy Qi 67) . 3pecitic heat of fluld at luid temp. (BTUY tk °F Z = Abeclie viecosy (p) eta. lamp ot had 2y= Absolute viscosity (op) al av. tuba wall temp. Figore 6.2. Heat transfer inside tubes (Reproduced by permission of Keeiger Publishing Company, Malabar, Florida, 1950, Maxwell, Data Book on Hydrocarbons) © Sie 6 Calculate shell side dimensions First determine the shell side average film temperature as follo BET outet ave i Foe shell fluid inlet temperature. ‘ tube outlet temperature... shell outlet temperature ‘ tube inlet temperature 1ESTIMATING SHELL AND TUBE SURFACE AREA AND PRESSURE DROP 311 Average shell side film temperature: Inlet ave. + outlet ave. 2 ‘Use this temperature to determine density and viscosity used in the shell side film coefficient calculations. . The shell diameter * Next calctlate the diameter of the tube bundle and the shell diameter. For this use one of the following equations to calculate the number of tubes across the centreline of the bundle: (1) For a square pitch tube arrangement? Ta= 119 (number of tubes)* (2) For a triangular pitch tube arrangement: Ta = 1.10 (number of tubes) Note these are total number of tubes calculated in step 4 times number of tube passes, The minimum theoretical shell diameter is 74/0.9. The minimum actual shell diameter shall be at least an addition of 3 to the theoretical minimum. i . Set number of baffles and their pitch The type of baffles usually used are shown in Figure 6.3 disk and donut type baffles are used only wheré pressure drop available is very small and there is a pressure drop probleri. Baffles on the bias arc/used in a square pitch tube arrangement and baffles perpendicular to the tubes aré usual for triangular tube arrangements. The minimum baffle pitch should not be less than 16% of the shell diameter. Pitch in this, case is the space between two adjacent baffles. Normally 20% of shell i/d is used for the baffle pitch. The number -of baffles are calculated from 10 x tubé length Free area of flow between baffles ‘The space available for flow on the shell side is calculated as ; : W= D,~ (d,X Ts) where W = space available for flow (in, D; = shell inside diameter (in,) dg = tube outside diameter (in.) Ta = number of tubes across centrelineHEAT EXCHANGERS 312 auFeq yo sodky, “vg amanESTIMATING SHELL AND TUBE SURFACE AREA AND PRESSURE DROP 313, The free area of flow between baffles is now calculated as follows: Ar = WX (Bp ~ 0.187) where , Ay = free flow area between bafiles (in.?) , B, = baffle pitch (in.) © Step7 Calculate the shell side film coefficient f hy The following expession is used to determine the outside film coefficient: ta £ (cutny" dad) where oe outside film coefficient @BTU/h, (2.9m) maximum mass velocity (Ib/s.ft°) “ = outside tube diameter (in.) _K = thermal conductivity specific heat of fluid (BTUAb/F) viscosity at mean film temperature (cP) baffle pitch (in.) D = shell internal diameter (in.) (dyGn/t4) is « function of the Reynolds number read from Figure 6. 4, The Reynolds number is 4 : : re = tom ; ae : MH auneo where Gy, =Ibjs.ft®, This film coefficient is corrected for the type of batfle and tube arrangement by multiplying it,with one of the following factors: For, square, pitch vertical to tube'rows,, toe a 0.80 ‘For square pitch on the, bias Do bop 0.55 For triangular tube pitch = * : : 0.70 © Step 8 Calculate the overall heat transfer coefficient Up The film coefficients caleulated in steps 5 and 7 are now used in the expression overall heat transfer coefficient (BTU/h. 2-8) tube side and shell side fouling factors rape (h.f?°E/BTU). For cléan tubes'this is 0.001 a8 a Sum of both factors. Tay = tbe wall tesistarice to heat tratisfer 1e-R/TU), 9 expressed as tudo 12x KX (dg—2y)314 . HRAT EXCHANGERS 10... 20, 90 40 69,80 100 200,809-400 600 8001000. 2000 4000 6000 10.000 1000 js00 | -]s00 " s00 j400 1300 {200 10 0.01 0.020.030040.06 04° 020804 06081 2 3 45.6 8 10 ao 9.08) 108 ° Figure'6.4,' Heat transfer to ude: quiside: tubes? For tubeand:shell heat exchangers multiply fp by a ‘bundle factor’ as follows: 0.50 for square pitch tubes in line; 0.55 for square pitch tubes at 45". Gy, is evaluated at’ centre row of tubes: (Reproduced by permission of Kreiger Publishing Company, Matabat, Florida, 1950,-Maxwell,Data Book “on Hydrocarbons) Holey fewdl at where « ty = tube wall thickness (is) dy = outside tube diameter (in,) _. K = thermal conductivity (BTU/h.fC°F/f1). See Table 6.1 Compare the calculated value of the overall heat transfer coefficient with the assumed one in step 3, If there, is agreement within +10% then the calculated one will be used for revising, the calculation for surface aga and the other dimensions. Hf,there ig, no agreement repeat the calculation using a new value for the assumed U. © Sep Calculate tube side pressure drop . Using the adjusted dimensional values from the calenlated U,, calculate the tube side presstire drop using one of the following equations: AP, = 0,02F, x Ny x (V2 + (0.158LV"9/d}")ESTIMATING SHELL AND TUBE SURFACE AREA AND PRESSURE DROP 315 ‘Table 6.1. Thermal conductivity of tube metals K (BTU/h.ft."F/ft) Admiralty brass 64 Aluminium brass 58 Aluminium a7 37 Carbon steel 6 Copper, 223 Cupronickel 4L Lead 20 Monel 15 Nickel 36 Red brass. 92 Type 316 alloy ste! 9 Type 304 alloy steel 9 Zine 65. For water only. For fluids other than water use AR = RK Xx Np X (AP i+ AP) where © o che ce APe= BE (ou * VPRO AP =3 X (Pm X V7/9270) F; = Factor based on Reynolds number (see Figure. 6.5) Pn = density ([b/ft*) at mean fluid temperature Hy. = viscosity of fluid at tube wall temperature (cP) (use mean film temperature) ve linear velocity (ft/s) pressure drop fouling factor as follows (dimensionless) ‘Tube ofa Tubé metal ft ‘Steel. 1,50 Steel - 2140, Steel 1.20: admiralty brass, “1.20 Copper ‘Las «The pressure . drop. figures caloulated by. these’ equations are, for one unit. ‘Where there are more than one shell in series multiply the figures by the number of shells, Step 10 Calculate the shell side pressure drop Using the revised dimensions calculated in step 8 the total shell side pressure drop i is calculated using the following equation: «|»... onc vl “ APs HAP + APY316 HEAT EXCHANGERS 1 5 10 50 100 600 1000 '5000 10 000 By. Fip-Nug Ny. x V7/9270) ressure drop due to turns given by We + DGS — ary) mx) By = factor as follows! | oe ey Baffle position’ Tube layout "By Vertical Squate si 6.0.30 « Bias at 45° «- Squates we» 0.40 Vertical Triangular 0.50 Fig = factor based on Reynolds niumber (see Figure 6.6) Nee number of tubes on éentrelirie ‘N,-=number of shell-batfles Py = space between baffles (in.) D = shell i/d (in.) ‘The pressure drop calculated here is for one shell. If there are moze than one shell in series then inultipy these pressixe drops by the number of shells. -. Byample calculation A Tight oll i 10 be cooled by cooling tower water in shell and tube ‘exchanger. Calculate the sutface area required; the overall exchanger dimensions, and theESTIMATING SHELL AND TUBE SURFACE AREA AND PRESSURE DROP 100 500} 109 o.tol O01 005 0,10 080 1.0 . Ree 3h7 60 100 10 Figure 6.6, Presaure drop factor Fp for flows across banks of tubes pressure drops for shell side and tube side, The rate of flow for the light oil is 120000 Ib/h. Other data are as follows: * Temperature (°F) ‘Temperature out (F) Specific heat (BTU/lb.°F) " Specific gravity at 60°F Thermal conductivity (BTU/h.te.°F) Viscosity at 100°F (cP) Inlet pressures (psig). 1 Calculating the exchanger duty and flow of water Shell side ‘Tube side Light Oil Water 215 0 400 90 0.56 10 | 0.850 1.0" 0.082 0.36 2.0 0.68 475. 60. ‘Heat removed from oil = Ib/h x spht x temp. diff. = 120000, x.0,56 x. (215 — 100) = 7728000 BTU/h 2 Water flow rate = <5 (Temp.diff.) where Q = exchanger duty = 7.728 mm BTU/h 25760016,318 HPAT EXCHANGERS 2 Calculate the log mean temperature difference AT, Assume countercurrent flow. Then temperature flow will be Toh hen outlet temperature of oil shell side 1; =inlet temperature of water tube side fo = outlet temperature of water tube side 215 100 9 60 Diff, 2540 . AT. = 75°R Using Figure A1.6 for correcting the calculated log mean temperature to flow pattern (23:) ye BZ 90-60 Nh US—6. HOI a te ST _ ts — 100 Ah 9-60 =3.83 foie met Correction factor for one shell pass and tw6.or more tube passes is 0.885. This value is above 0.8 and is acceptable. we ‘Then corrected LMTD is 75°F x 0.885 = ATy, = 66,4 °F * 3 Cateulate approximate total heating surface area: «1 Selected overall heat transfer coefficient from Table Al.1 in Appendix 1 = 80 BIU/hPF. * wine Using the expression /Q# UAT, A= TPO 80X64 eta = 45510 s is fairly clean service so fin. o/d tubes on a triangular pitch will be used, Maxiraum recommended surface area per shell-is 4100 for triangular pitch, Therefore one shell will easily accommodate this calculated surface area.ESTIMATING SHELL AND TUBE SURFACE AREA AND PRESSURE DROP 319 4 Tube side flow and the number of tube passes Cooling water flows tube side. Set the linear velocity at about 2.5 ft/s. Ib/h of water = 257.600 Max. temp. °F = 90 lb/ft? at 90°F = 62.12 £8 = 4147 Tubes are to be copper and 14 BWG, Use standard length of 16 ft. Internal cross-sectional area of one tube = 0:302 in? ue 4147 x 144 3600 X 0.302% 2.5 = 220 tubes/pass. External area per foot of tube = 0.193 (se Table ALT in Appencix 1) ‘Then number of tubes per pass = Set tube length as a'standard 16 Then total ft per pass = 16 x 0,193 x 20= ou or © Number of passes = we = 2:1 (emake it two paises) Based on a two-tube pass arrangement: ie por pass = 2) = 715 acne 7215 , Nuniier of tubes per pass = —227:2__ i Nes oF aos Per PS 76 X0.1968: 4147 x 144 | Velocity in'tibes = = 2.370 | 3600 x 0.302 x 232 5 Calculate tube side film coefficient hia For water flowing tube side use : 300 x (Vix tube if ys tube be off in.) hig = where hn ~ inside film coefficient based on outside tibe diaméter (BTU/h.£0“) Y= linear velocity of water tube side in fy = 2.37 Ys Hig = x x 2. 37 x 0.584)" = 518.8. BTU ie -E320 HEAT EXCHANGERS 6 Calculate shell side flow arid dimensions . Shell mean film temperature ‘is as ‘follows: Ty + Tp. 2 Inlet ave, = Outlet ave. = y+ 2 where T, = shell fluid inlet temperature, = 215 °F The 90°F Ty= Viscosity of light oil at 116.3 °F = rh Density of light oil at mean fluid temp. of 158°F = 0. To.caleulate. the number of tubés across contreline of tube bundle and shell i/d use: " Ta AO" (2 x232)05 = 23.7 tubes Theoretical diatneter of tube bundle = 32 = %6.3in. For shell diameter use 26.3 + 3.0 = 29.3 (make it 30 in, i/d) ‘To eqleulate area of flow'for fluid shellside:, ... 1 coe W = D,— (dy X Ta) 2,23 in, : Baffles to be vertical to grade with a pitch of 20% of shell i/d, “Number of battles = — 10h 27, bcs "02x 36), : Free area of flow between each set of baffles: , eed W x (baille pitch — 0.187) = 12,23 x (6.0 — 0.187) = 71.1 in?PSTIMATING SHELL AND TUBE SURFACE AREA AND PRESSURE DROP 21 7 Calculate shell side film coefficient ho fy = (CuK daa) A/D) where ‘A, = outside film coefficient (BTU/h.f0.°F) Gq, = maxinmam mass velocity (1b/s.£°) do = outside tube diameter (in,):= 0.75 x = thermal conductivity. = 0.0784 BTU/h.t?.°#/ft) = specific heat of fluid (BTUAD/R) = 0.85 oe = viscosity at mean film temperature (cP) = 1,3 Py, = baffle pitch (in.) ° D; = shell internal diameter (in.) $(4oGr/t#) is a function of the Reynolds, number read from Figure 6,4, The Reynolds number is, ©3600 X 711 X16 ftom Figute 6.4 6(d3Gy/j4) = 780 he = 208 5 ery 780% 07 08 * Conrection factor for baffles. See step 7. hy = O.1O4S, x 2.415 700 X 0.7 X 0.98 = 121.9 BTU/h.f2.°F <8. Caleulate over heat transfer coefficient. Us ° ‘ Kn for: admiralty brass = 6400). in Pa ty X do” 12K X (dy ~ 2ty) where = thermal resistance of wall to heat transfer (h. ft. “10, 0 ='wall thickness (in. ), . 0,083 * 0.75 12 x 64 x (0.75 — 0.166) * = 0.00014 ht.°F/BTU +324 HEAT EXCHANGERS Tube bundle Air plenum: chembor Supporting structure, Fen sing Airplenum chamber Figure 6.8. Air coolers—induced draught normally connected by a °V’ belt or by'a shaft and gearbox: Blectric motor drives are by far the most common prime drivers for air coolers. ‘The units may be installed on a structure at grade or, as'is often the case, on a structure above an elevated pipe rack. Most air coolers in condensing service are elevatéd above pipe racks to allow free flow of condensate into a receiving drum. ‘THERMAL RATING ‘Thermal rating of an aie cooler is similar in some réspécts to that of a shell and tube described in Section 6.3, The basic energy equation Q=UATA is used to determine the surface area required: The calculation for U is different susossunaasene i i i i 4AIR COOLERS AND CONDENSERS in that it requires the calculation for the air side film coellicient, This film coefficient is usuaily based on an extended surface area which is formed by adding fins to the bare surface of the tubes. Thermal rating, surface area, fan dimensions and horsepower aze calculated by the following steps: ® Step1 Calculate the heat duty and the tube side material characteristics. © Step2 Caleulate the log mean temperature for the exchanger. Using the following equation determine the temperature rise for.the air flowing over the tubes; At, = (Ue + 1)/10)).(ATin/2) — t4)) where: Atm = air temperature rise (CF) U, = overall heat transfer coefficient assumed {from ‘Table 6. 2) AT, = mean tube side {emperature (°F) ty = inlet air temperature (°F) Caeutate te fog mean temperate difference (LMTD) a instep 2 of Section 63. be galt . Some comnon overall transfer coefficients for air cooling : din, by 9 din, by 10, . in’ ht by fin ‘Bin ht by fin/in. Service... ve We th U, th Process water! 5 9S 65 mo 52 Hydrogen liquids Vise at ave. temp. €2) 190 47 to 5 as 25 35 26 6.05 25 12 10.0 B06 ‘Hydrogen gases at pressures (psig) 50 35 16 ‘ 100: 40 19 300 356 500 6 30 1000 90 42 Hydrocarbon condensers Coolitig range O°F 85 S93) 10000 47 ° 10°F BO SE 9s ad 60°F. “ 6s 45 BK 35 100+°F o 4b Tan Refrigerants 2 " aad ‘Amimoni ‘ 000-76" 130 GL “Freon 65 45 35 {U, teansforeoeticont fr finned sutice ‘Ups teansfereootiient fo bate tubes.326 HEAT EXCHANGERS © Step 3 Determine an approximate surface area using the,expression’ AB = —2 UE- AT, where & AE = extended surface area’ (ft?) Q = exchanger. duty (BTU/n) : VE = overall heat trarisfer coefficient (based on extetided surface from Table 6.2) AT, = log mean temperature difference corrected for number of passes CE) © Step 4 Calculate the number of tubes from the expression AB x A L total number of tubes extended surface area (ft?) : Ag = extended area per foot of fin tube read from Table 6.3 ““L = Length of tube (30 ft is standard). , © Step'5 Fix the number of ‘passes (usually three or four) and caléulate the mass flow of tube side'fluid using the expression Ge Ibfli of tube side fluid x Np x 144 “ON, x Ay x 3600 \ass velocity (Ib/s/ft?) N, = number of tube passes side cross-sectional area of tube (in.”). Table 6.3..Fin tube to bare tube relationships. (Based on Lin. off tubes) ‘Fin ht by finfin. din, by 9 din. by 10 ‘Area/ftfintube 38 5.58 : Ratio of areas fin/oare tube 145: a4 Tube pitch fin.) = 2A AAs AA ha Bundle area ttt ‘ Three tows 684 60.6 891, 80.4. Four rows, . 912 808 118.8. 107.2 Eive rows, 114.0 101.0 148.5 134.0 Six rows 136.8 1212 1782 1608 * Bundte area is the external area of the bundle face are in f/f,AIR COOLERS AND CONDENSERS 327 © Step Calculate the Reynolds number for tube side using the expression rea eS where Re = Reynolds number (dimen) d, = tube if (in). - + = tube side fluid viscosity at average temperature. (cP) © Step7 Calculate the inside film coefficient from the expression tig = E (CH RY Mule) 66/2) where: = inside film coefficient (BTU/h.£.°F) K = thermal conductivity of the fluid (BTU/h.fCE per ft). See Maxwell, Data Book on Hydrocarbons, or Retry, Chemical ___Bigineer's Handbook © iiside tabie diameter (in: "+ = specific heat (BTU/lb/'F) o: mass velocity (Ib/s..?) = absolute viscosity (cP) at average fluid temperature tem = absolute viscosity (€P) at average tube wall temperature o(DG/p) = from Figure 6.2 sep Caleta the moss velosy of si and he fm cootint on the ei side, thus: Weight of air = ——2__ 1 Coin X AT ie where Q = exchanger duty (BTU/h) ric = specific heat of air (use 0.24) jemperature rise of the air (°F), Face area of tubes Ar is calculated as follows. Set the ofd of the tubes (usually Tin), length, fin size (tsitally Sf8in. at 10 to the inch or $in, gt 9 to the inch), pitch (ee ‘Table 6.3), and inumber of tube rows (oer with,3 or am ‘Thon face area is : : "Total extended sueface area AE External area per ft of bundle (from Table 6.3) Mass velocity of sir i calculated front the expression Gg, wloper hhourof ait flow : Face area-Ap ‘The film coefticiont for the air side is read from Figure 6.9... Ate28 HEAT EXCHANGERS Fim coottetoee, °F +1), extended surtace 1000 7000, 30004000 ‘Ax taco mass veloctiy, / (onto face area) Figure 6.9. Air film coefficients ® Step9 Calculate the overall heat transfer coefficient as follows, Area ratio of bare tube outside to finned: outside is read from: Table 6.3. Then factor to convert all heat flow resistance to outside tube diameter basis is tbe o/d Fw Ac etabe oft LEAR + ry tl U, hike where Hap aes ne inside fouling factor ‘ = tube metal resistance (viofuially ighored) If ihe caléulatéd 'U. is within 10% of the assumed there ‘will be tio need to ‘ recalculate with a new assiimed Value, for U, ‘The. dimensions aiid data are ‘Adjusted, howevér, using the calculated value for U. . © Step 10 Calculate the required fan area and the fan diameter as follows: 0.4 X face area-Ay Assimed number of fans Begin with assuming two fans and continue with multiples ‘of 2 until a reasonable fan diameter (about 10-12 ft) is obtained, On very large units fans” can be maximized at 16 ft. Fan diameter = (fan area * 4/7) + Fan areaAIR COOLERS AND CONDENSERS 329 © Step 17 Calculate air side pressure drop and actual air flow in ft?/min. hth Average air temperature From Figure 6.10 Dy = felative density factor for air at elevations of site From Figure 6.11 AP,.= pressure drop of ait in inches of HO AP, x No. of. rows AP, corrected = «09 ar tad 4 400} 300 250 Temperawre,*F 150) 5 hoses : Roference state: dy alrat 70°F end sea love, 14.7 psia 100) $0 +50} 100 03° 04 05 08 OF" of 09 10 44 12 13 14 Donat ratio, O, cinensiontess Figure 6.10, Relative density of air330, HEAT EXCHANGERS fou 5 i 0.10] 0.09} 0.08} 0.07] § 0.08] B os 0.04] 0.03| ELL 1000 7000 39007 4900 Air face mass veloc, Q,°/ Wei theo face aaah! Figure 6.11. Pressure drop air side in inches of water Density of air at corrected AP, 29° ay i GIB x 14.7 x T.M(Ty (Cori AP, + 14.7) | | where T, and T, are absolute temperatures. scfm of air is therefore Ibft of air,’ Density x.60 i AP of air at the fan is obtained by the‘expréssion . : : 2 : AP { acim ) . © N4oo0 (rd?) : in inches of water gauge... © Step 11 Calculate the-fan horsépower.as follows: + Hydraulic ip = 221m % density of ait x ff, head i ft 33000 1 Differential Read = TOW! AP at fan in inches HyO x 5.193 Density ohp = Hei hp : ‘Where 1’ is the fan efficiency (usually 70%).ATR COOLERS AND CONDENSERS 331 Example cateulation ‘The example given in Section 6.3 will be used here but in this case the light oil will be cooled by an air cooler, An cxample of a. two-phase exchanger will be discussed and given later in Section 6.6. Ambient air temperature = 80°F Elevation of site = at sca level ‘Tube length = 30ft Fin artangentent'= jin. at 23in. A pitch Tube o/d standard 4-in..CS tubes 14 BWG Average temperature of the light oil: as. 254100 100 =158°F Calculating temperature of the air out tz Assume overall heat tidns coefficient U, = 3.6 (Table 6.2) ‘Then air temperature rise = 4) (222 - where 4 = air inlet temperature (°F). ‘Air temperature rise = 0.46 + 77.5 = 35.7 (say 36°F) and air outlet tempera- ture is 80 + 36 = 116°F = fy. AT, = 215-—> 100, eo ete dak 116 —_80 yi 9 = 49°F ‘Assume four tube passes. Then correction factor from Figure A1.6 ‘Appendix 1 is as follows: ’ 20. 027 215 #80 ae = 45.674 ft 6332, EAT BXCHANGERS Use standard 1-in. tubes 30 ft long and fin. fins (10 per inch). and four rows on ai in. A pitch, Then from Table 6.3: : Extetnal area per ft of bundle = 107.2 Face area = 15544 _ og g2 107.2 mo Calculating the number of tubes: y= Approx. arca ‘Ay X30 A; = extended area of tube from Table'6.3 Ny = 273 (call it'270 tubes) Calculating the mass velocity of the tube side fluid: 144 x 120000 x 4.0 2 to Ga TA. = 130.2 Ibfoift?.., ‘ 210 x 0.5463 x 3600 is Calculating the: Re number: Calculating the inside film coefficient 24: h ee where ine = inside film coefficient in a BTU/hs £0.°F = thermal conductivity of the fluid in BTU/h.f2 (F per fi) (see Maxwell or Petry) ="0.082 2 = inside tube djameter (in. = specific heat, (BTU/Ib/F) = 0.56 = absolute viscosity (cP) at average fluid-temporature = 0.8 Le = absolute viscosity (cP) at average tube wall temperature = 0.86 (DG/p) = From Figure 6.2 = 1060 Average wall temperature: 21+AIR COOLERS AND CONDENSERS 333 = 183.7 BTU/i.f?."F : Calculating the mass velocity of air and air side film coefficient fo: . A 7728000 Weight of air = 77260 : ish 0.24 (116 — 80) = 894444 Ibn Gy= bln = B84a8 Face area. 426 ‘ = 2099 Ib/h.f From Figure 6.9 hg = 7.4BTU/hf2°F a Calculating the overall heat.transfer coefficient Up: Area ratio of Lin. fin tube (Ax) = 21.4 for fin. fin Ay _ 21.4 x 1.0 ‘Then conversion factor to outside area is — = Ae 0,834 = 25.66 x05, 66) o865+ ho (ry =tube- defoulingfactor=0: 0005) “26.1394 0.043 + 0.135 = 0.287. “ tee ‘ 9 Ug 13.48 BTU/h. °F, Assumed was 3.6 BTU/h.ft°F:. Therefore calculated is acceptable being less than 10% difference. ‘Adjusting the data and dimensioris to the dalculated Uc: Suiface stéa ‘A, = 49229 f? Facé area = 459 1? No, of tubes = 294 foe ane Gy = 1896 bf. om . . Calculating the fan area and diameter: ran area = 24% face atea . . No. of fans = 04 X459 (yo tans.assumed) 918334 HIBAT EXCHANGERS Fan diameter = Y(OL8 x 4/n) = 10,8it (Say 11 ft, which is acceptable) Calculating air side pressure drop and acfin of air: Average air temperature neross tubes = 82+ 116 + 116 a 5 98F From Figure 6.10, D, = 0.94 for sea level From Figure 6.11, presairé drop factor = 0.067 in, WG . 0.067 x 4 Pi thi sh tubes = ———-—— esse drop though tub hoe = 0.285 in. WG Density of air at atmos. + 0.285 in. WG and 98°F or 558°R + 29 = ((378 x 14:7 x 558) + (520°x 15.09) = 0.073 Ib/fe | . - 1200000. ef of air = 200000. cen pteir 0.073 x 60 ‘There are two fans, Then load per fan = 136986 ft/min. ‘= 273972 ft/min 4 22. Total AP at fan = AP, + (pete ee) x D, = 0.285 + 0.407 = 0.692in, WG Calculating hydraulic and brake horsepower: ‘Hydraulic hp = acm X density X diff. head (FE) i Diff. head = lb/ft? + density 20+ - 0.695 in, WG = 0.695 x 5,193 Ib/ft? corse ‘Hydraulic hp = 136986. X 0,692 x 5.193. : 33000. Assume an efficiency of 70% . Then’the brake hpwill be 136986 x 0.692 x 5.193 33000 x 0.7 Calculating exchanger width: | = 21.3 perfar Face area Tube lerigth = 459/30 = 15.3 (say 15 ft 6in.) Width =:CONDENSERS 335, Summary Exchanger has 294 tubes 1 in. o/d with gin. fins, There will be four passes and the tubes are on 2in. A pitch. These will be. standard length of 50ft with a total width of 154 ft. The exchanger will be equipped with two fans each requiring 21.3. bhp supplied by two motors each 30 hp. 6.5. Condensers ~ In chemical process plants vapouts are condensed in the shel] side of a shell and tube exchanger, the tube side, of an air, cooler, or, by direct ;contact with the coolant in a packed tower. By far. the most common of these operations are the _ first two methods, In, the case of the shell.arid tube condenser the condensation ‘may be.produced by. cooling the vapour. by heat exchange with a.cold -process stream or by water. Air cooling, has overtaken the shell and tube condenser in the case of water as coolant in popularity as described in Section 6.4. ¢ Tn, the design. or, performance analysis of condensers the. procedure for determining thermal rating and surface area is more complex. than that for a ‘single-phase cooling and heating described in Section 6,3 and 6.4. In condensers there are three mechanisms to be considered for the rating procedure: 9 The resistance. to heat transfer of the condensing film + ‘© The resistance to heat transfer of the vapour cooling echo © The resistance to heat transfer of the condensate film cooling... Each of these mechanisms is treated separately and along preselected sections of the exchanger. The procedure for determining the last two of the mechanisms follows that described in Section 6.3 for single-phase heat transfer. The following expression is used to calculate the film coefficient for the condensing vapour: : 03 hg = — BBX ke x () (Ma[ Lao * a where he = condensing film coefficient M, = mass condensed ({b/h) Le = tube length for condensation A, Aone x (7, 40.5) 4 ( ) .08 Ni for triangular pitch = thermal conductivity of condensate at film temperature 8G = specific gravity of condensate Ju viscosity of condensate at film temperature (cP) ‘Again there: are mahy excellent. computer pfograms that calculate condenser thermal ratings, and these, of course, save the tedium of manual calculation, ‘However, no matter which method of calculation is selected there is required one336 HEAT EXCHANGERS major additional piece of data over that necessary for single-phase heat exchange. ‘That is the enthalpy curve for the vapour. Enthalpy curves are given as the heat content per pound or per liour'contained in the mixed phage condensing fluid plotted against temperature. An exainple of Such a curve is given in Figure 6.12, Thése entlialpy curves are develépéd from the vapourfliquid or flash calculations described in Section 1.4: Briefly, the calculation for the curve commences with determining the dew point of the vapour and the bubble point of the condensate. ‘Three or more temperatures are selected between the dew and bubble points and the VL calculation of the fluid at these temperatures carried out, Enthalpy for the vapour phase and the liquid phase are addéd for each Composition of thé phases at the selected témperatures. ‘These together with the enthalpy at dew point and bubble point are then plotted, As inthe case of the shell aid tibe exchanger (Sectién 6:3) and the air cooter (Section 6.4), a maniual ealenlation for condensers is described hve. “Aga this is doné to provide some understanding of the data Tequited to size such a unit and its significance. in’ the calculation procedure. Computer-aided design’ should, however, be used for these calculations wheiiever possible.” EAE The following steps describe a method for caleulating'the film deficient of a vapour conderisiig on the shell side of a shell and tube exchatiger. "The complete ating calculation will hot be given Hiere as much of the restiainlng’ calculation is simply iepietitive. : coe ws ves * Step? Calculate thé ‘dew point of the vapour stream at its’ source pressure. Estimate the pressute drop across the system. Usually 35 péi will account for Piping and the exchanger pressuté drop. Calculate the bubble point of the loss (psc) $05 "40607! “108 109" 10 ss Te ee fa . oa ae 80,4, 786 Enya Brin Figure 6.12, Enthalpy curve for a debutapizer overhead condensesCONDENSERS: 387 condensate at the tetminal pressure. Selected three or more temperatures between dew point and ‘bubble point and calculate the vapour/liquid quanti- ties at these conditions of temperature and pressure. @ Step2 Calculate the enthalpy of the vapour and liquid at these temperatures. Plot the total enthalpies against temperature to construct the enthalpy curve. Establish the properties of the vapour phase and liquid phase for each temperature interval. The properties mostly required are SG, viscosity, mole wt, thermal conductivity and specific heats, @ Step” In the case of a water cooler calculate the duty of the exchanger and the quantity of water in Ib/h. Contmence the heat transfer calculation by assuming an overall heat transfer coefficient (use the data given in Table A1.1 in Appendix 1). Calculate the corrected LMTD and the surface area. © Step4 Using the surface area calculated in step 3 define the exchanger geometry in ters of numiber of tube passes, number of tubes on the contreline, shell diameter, baffle arrangement and the shelt free flow area. Calculate also the water flow in feet per second. © Step5 Divide the exchanger into three or four zones by selecting the zone temperatures on the enthalpy curve, Calculate the average weight of vapour and the average weight of condensate in cach zone, Using: these averages, calculate the average heat transferred for: Cooling of the vapour Q, « Cooling of the condensate Q) Condensing of the vapour which will be: | ‘Total heat in the zone (from the enthalpy curve) less the sum of Q, and Qi. © Step6 Calculate the film coefficient for the tube side fluid (see Section 6.3). e.:Step 7. Starting with .zone..J..and knowing the outlet, temperature of the coolant fluid, the total heat duty of the zone, and the shell side, temperatures calculate the coolant inlet temperature. Using this calculate the LMTD for the zone, Assuming a zone overall heat transfer coefficient U calculate a surface area for the zone. Using this sind the total exchanger area estimated in step 4 establish L, in feet. . © Step8 Calculate 'the condensing film coefficient from ,the equation given eatlict. This will be an uncorrected value for. fg. This will be. corrected to account for turbulence by the-expression het) = he X (Gul? where G, = average vapour mass velocity (Ib/h.£) © Step9 Calculate the value of G, using the free flow area allocated to the ‘vapour yy. The following expressions are iused for this: wel-H, . 1. . fin + SRE MES WEPOUE 5 (in) (ofa 8° n ‘Ave. mass liquid Ave. mass vapour "25 x free flow area X yy "|338 HBAT BXCHANGERS: * Step 10 Caleulate the film coefficient hy for the vapour cooling mechanism, This will be the procedure used for a single-phase cooling given in Section 6.3. This is corrected to account for resistance of the condensate film by the expression Hyeort he V-25hy +» © Stepil Calculate the film coefficient for the’ condensate. cooling mechanism. Again this is the procedure described in Section 6.3 for single-phase cooling on the shell side. This is corrected for drip cooling that occurs over a tube bank: : Drip cooling Aa: = 1.5. he . 2% de X ty : " * and fy = one emcees has hy, be © Step 12° Calculate® the tia zone fil costint: hy using the following ‘expression: Ove (Qef hie) + (Qr/ hy). + Giny Where Q:,'Qrs Oj'are the eiithélpies' for’ condensing, ‘apouricooling, and condensate cooling respectively: * Step 13 Calealate the overall heat transfer eoeticent neglect ng’ the shell side cotlticlent from step 12. Thus: hy = 0 Ls tre cbie't Ra I Where: 76; rip’ rip are fouling faetors for shell fluid, wall; vind tube side fluid “respectively, and Rais the tube side film coefficient calculated in step 6. © Step 14 Calculate the overall heat transfer coefficient Ujogs for" the zone using the expression to X Uy Shot Ue = Check the ealeulated U against the assumed ‘Tor the zone,. Repeat the calculation if necessary to make a match. * Step 15 Calculate the zone area using the acceptable, calculated U. Repeat steps 7 to 14 forthe other zones. ‘The total surface area, et. isthe sum of that for each zone. Note that the following example ‘calculation i is carried out, for zone 1 only. The remaining calculation is simple repetition. eta ic a ew atCONDENSERS 339 Example calculation ‘A debutanizer tower operates at 123 psia and 138°F at the tower top. The total overhead (reflux and product) is condensed in a shell and tube water cooled condenser to its bubble point at 120 psia and 100°F. Calculate the surface area required. by the condenser. The. total mass flow is 27027 b/n with a mole wt of 52.3 and 4,58 Ib/gal. The composition of the stream is as follows: Moles/h : 24.96 Cy 169.65 iC, 62.79 nCy 250.38 iC; 8.97- 1 Calculating dew point and bubble point Bubble point calculation—reflux drum conditions ‘st trial at 120 pilg Me oo fact, K YsKy KY ='Ke GQ 0.048 37 0.178 42° 0.302 G 032813 0426 1.43. 0.469 * iC 0122 © (020.078. 0.65"* * 0.079 nC 0485 06 0.223048 0.238 iC 0017 = 0.200.003 0.220.004 Total 1.000 0.906 0.987 Second trial: use K for C3: 0.906 | Gorsesponding presse = 125 psia (110 psig) ‘Actual pressure = 243 = 1.45 0,987 corresponding to 120 psia or 105 psig); : 4 Debutanizer reflux drum will operate at 100°F and:105 psig for the ‘otal condensation of ovérhead product and reflux: Predicting the tower top pressure: Reflux drum pressure = 105 psig Overhead line pressure drop = 1 psi Condenser pressure drop = = _3 psi Total tower top pressure = 109 psig340 ‘Tower top temperature, Mole 2nd trial at 138°F fact ca enaann ¥, K ox=¥4K Q 9.048, z . 48 0.010 Gq 0328-250. 0431 2.00 0.164 iCy 0.122 138 0.088 1.00, 0.122 Cy 0.485 10. 0485 0.746 0.650 iC 0017 = 052. 0.033 0.360.047 Total 1.000 0.746 0.993, Second trial: use NC,K value: HEAT BKCHANGERS Now K = 1,0 x 0.746 . 746 woe Corresponding to 138°F ‘This trial is close enough. Tower top conditions Pressure 109, psig 123.7 psia ‘Temperature 138 °F 2° Calculating flash curve points At 123 psia and 130° ‘Assume V/L = 0.3 a Scie ‘Mol Lb Lb gph Comp. Moh K ViLK LE Vapour Vapour Liquid Liquid CQ 296 55° "16S 1.43 23.53 706 43 4 Cy 169.65 1.8. S44 26.5 | 143,15, 1299 1167 276 iCy 6279-095 2.85 A631 464B 2996946202 n@et, 250.38 0.672 62.01% 83M. | 1672. 9698 4826-993 iy 8.97 0.33... -9.99 PAS 4d BBL DSB Total 516,75 1.93 384.02 1972073071548 Cateulated ¥/L = 2.92 MW vapour = 51.2 MW liguid = 33.4 SG liquid = 0.567CONDENSERS. 341 At 122 psia and 120 °F Assume V/L = 05. . F Mol Lb Lb gph Comp. Moh K V/L.K Le EK Vapour Vapour Liquid Liquid & 24.96 5.1 2.55 ros’ 47.93" 538 Cy 169.65 1.69 0.845 91.95 7170 3419. 4046-957 iC, 62.79 0.86 0.43 43.91 18.88 10963547544 nC, 250.38 0.60 0.30 192.6 5178. 3353 UITL 2299 ics 897 0.27 0.35 7.90 Lol 7 $69,109 Total’ 516,75 Zz 343,39 173.36 8483 18544) 3980 Coletned V/L 0.508 . MW vapour = 48 MW liquid 54 5G liquid = 0.55, At 120 psia and 10°F Assume V/L = 0,1 7 PF P Mol Lb Lb ‘gph Comp. Mol/a K Vitek Ly TK Vapour Vapour Liquid Liquid GQ 24.95 48 0.48 "16.86 8.10 43 506 Gq 169.65 15 0.15" 14752-2213 974A iCy 62.79 0.73 0.073, 58.52 427. 48 3394 nC, 250.38 0.54 0.054 237.55 12.83 74613778 iCs 897 024 0.024 8.76 0.21 15 631 Total $16.75 469.21 4754 2226 24801 Coleulated V/L = 0.101 . . . oe MW vapour» 46.8, MW liq ' . SG gal : ‘ 3° Calculating enthalpies at the flash intervals At130°F : . Vapour = 19720 Ib/h x 300 BTUAI Liquid = 7307 Ib/n x: 172 BTU Total =7173000BTU/h At 120°F ‘Vapour = 8483 Ib/h x 320 BTU/D = 2715000 BTU/h Liquid = 18544 lbh x 165 BTU/Ib'=3 060000 BTU/h ‘Total = 5775000 BTU/h342 HEAT EXCHANGERS: At 10°F ‘Vapour = 2226 lb/h x 315 BTU/Ib = 702000 BTU/h Liquid = 24801 Ib/h x 160 BTU/b ='3968 000 BTU/h Total = 467000 BTU At dew point ‘Vapour = 27,027 tb/h x 304 BrUfo= 8216000 BTU/h At bubble point Liquid = 27027 lbh x 150 BTUfb = 4054 000BTU/i ‘These points are plotted in Figure 6.12 to give an enthalpy curve for the condenser. The total duty of the condenser is 8216000 — 4054000 = 4162000BTU/h 4 Calculating the flow of water coolant Water inlet is 60 °P and outlet is fixed at 90°F. ‘Then a 2 i bes vb/h of water = vf of water "Oa 4162000 30 " = 138733 Ib/h | 5 Calculating approximate surface area of condenser From Table Alt in Appendix 1 let U be 90 and the exchanger LMTD corrected is as follows:CONDENSERS 343. Q= VAAT, An @... = 4162000 UAT, 9039 = 1186 sqft 6 Establishing the condenser configuration Tubes will be Admiralty brass }in. 14 BWG ‘on triangular pitch with standard 16-ft length: 3.82-x total surface area (k= 015) x dy _ 3.82.X 1186 © 15.5 0.75 = 390 Numiber of tubes NT = Assume four tube passes. Then tubes per pass = 98 Crose-sectional area of tube side = 28% 0-286 ‘Water linear velocity V = ye Bai x 3600 x 0.182 138733 5 a ts : Si 40687 ‘Number of tubes across centreline = NT¢ = 1.10 x (NT) =28 Outer tube limit = (NTe — 1)Pr + dy ‘Where PT is tube pitch = Lin. + = (21.8 x 1) + 0,75 = 22.53in, Shell i/d = 22.55/0.9 = 25in, min. Add 3 in, shell i/d = 28 in. Fix baffle pitch at 20% of shell i/d = 5.6 (say 6in.) ‘Free width for vapour W = D — (dy X NTc) : = 2B ~ (0.75 x 21.8) ‘ . ee TLS in, * Total free atea of flow, between two adjacent baffles "0 ' = W(P, — 0.187) = 67-7in, Number of baffles Np = 10L/P3 oy c = 160/6=27 .344 HEAT EXCHANGERS: 7 Calculating the tube side film voefficient hig ho = ma where Aig = tube side film coefficient (BTU/h. £2. d, and dj = outside and inside diameters = 0.75 in. and 0.584.in, linear velocity of water in tubes = 2.85 ft/s 601 BTU/h.f2°F ! : ' Ai 8 Dividing the condenser into temperature zones establishing zone conditions ide the enthalpy curve into four zones as follows: Zone 1 = Dew point (138 °F) to 130°F. Zone 2 = 130°F to 120°F Zone 3 = 120°F to 110°F Zone 4 = 110°F to 100°F Calculate the enti attributed to: © Cooling the vapour © Condensing the vapour © Cooling thie condensate for each zone. Avetage mest Mow of liguid and vapour in each zone will be used for this. Zone 1: Average vapour Yapiatin vip out = 23374 Ibfh Vapour cooling = 23374 x G x (138 - 130) 23374 X°0.43 x 8 80405 BTU/h = Qn Condensate cooling =: a x 0.78 X 8 oO a 23.000 BTU = Qu 80405 + 23000 Total to cooling mechanisi From enthalpy curve: total heat in Zone athaley due to condensing = 1043000 — 103.405 : , = 940000 BTU/h = Qu The remaining zone enthalpies are similarly calculated to give the following table:CONDENSERS 345 a Zone Qs mmBTUh Qe, Oona 1 0.08 0.023 0.94 = 1.043 2 0.061. 0.101 1.236 3 0,024 0.169 0.912 4 0,005... 0,202 0.409 Total 0.170, 0,495, 3,497 9 Zone 1 calculations to deterypine zone surface area Catculating temperature of water into the zone: Temp. of water out = 90°F; Then temp. of water in = 1043000 2 gy _ 138733 x= 85°F " ‘ Calculating LMTD across the zone: AT, = 138 130 90, 82.5 eS =y BF ws Caleulating percentage of tube allocated to zone 1 (approx.): Assume. Usone 1, = 120 BTU/n.f.°F 1.043.000 120 x-48 = 181 ft? % of tube = 781 = 15.3% 180 ‘Then approx. area = Ly = 15.3% (L = 0.5) = 2.37 ft For calculating condensing film coefficient jig use the following expression: 8.33 x 10° x Rx u(y” oye (Me/Le nndensing film coefficient be ass condensed in Ib/h ibe length for condensation = 2:37 ft 08 N,°4% for triangular pitch = 27:61" ky = Thermal conductivity of condensate at film temperature = 110 °F346, HEAT EXCHANGERS: SG = Specific gravity of condensate = 0.53 14 = viscosity of condensate at film temperature (cP) = 0.13. ha = am x 0.0785 x 1.2928 = 177.3 BTU/h."F.LC (uncorrected) Calculating Gy; average vapour mass velocity in bp. fe: Fraction of frée flow area for vapour is ya = 1 Yn where Ay 4 Aves mus ap. x (2) fa an mu ‘Ave. mass liquid \ Pu ou 0555 A244 33% x (2044) x() Yi 3653 L013). (10, = 36.89 a Then yy = 0.027 Ya = 1 - 0.027 = 0.973 Gy = Ave mass vapour 7 “25 X free flow area X 0.973 = x 09978 25 x 61.7 “ = 14.19 Ib/a.t? Correcting ha: Pe Sy ona ' 1 Wa core = Hs % (G45) = 177.26 x 2.075 = 368 Calculating film coefficient for vapour cooling Ay: fig, (uncorrected) = 4 Ceus/kS X Olde Guifun) X 9.7 where k = thermal cond. = 0.011 BTU/h.{t. “Ft, : . “= specific heat = 0.4 BTU mo : ‘ue =iviscosity at film temp: = 0.014 cP do,= tube ofd = 0.75 in. | Reno, = “Ou ~ 769 0.014 do Guilte) = seco rom Figure 6.4 1, 4x 0.014/0, oi) x $309 x 0,7 feat 0. ve = 62.2.%.0,7 = 43.54 BTU. °P.,347 conpnsens Calculating hy corrected: fay, corrected = 1 + —1__. lia 125% hy, = 0.0028 ++ 0.0183 17.6 ‘Calculating film coefficient for condensate cooling hy: Mi 25 x free flow area X yy 3653 25 x 67.7 * 0.027 19.9 \bfite noes ' Liquid mass velocity Gy = Re no, = 461" 0:13" » $(do.Gy/y49) = 4000 from Figure 6.2 hy = emf t x 4000 x 0.7 (0.79 x 0.13/0. ores) x 4000 x 0.7 asset sy a = 457 (uncoirected) X-0.7 pow = 320BTU/nAPF - Correcting his for drip cooling: Figg = 1.5 % . = 552 vies Con hég X Fay 5 etary + Cone hy = 25S, . hogs acct 4 2.x 552, x 320 . 952 + 320 5 = 405 BTU/n.tt °F . * Calculating zone shell side film coefficient oz 0 OT) ® Onltad+ (Olin) , oe 1043000, 1 Bier nmin ORT, = 243 BTU/at2.2F348 HBAT EXCHANGERS Calculating shell side overall heat transfer coefficient for zone 1: Beads Lamimete Un hy = 4 40.0013. + 0.001 + nes 243 601 * 0083 23 Brute £0.°F which is close to assumed of 0 BTU/h.ft2.7 1.043 000 13X48, : ot = mnt This concludes the calculation’ to determine the surface atea for the first zone. The assumed area at the beginning of the calculation was 181 f? which is within 10% of that calculated. Then the calculated atea of 1774? is acceptable. The surface areas for the remaining zones.ate calculated in the same way. ‘The results of these caiculations are summarized as follows: Zone 1 surface area = : bee FR eas Zone1 177.0 "Zone 2, 303.0 Zone3 315.5 ;, Zone 4, 3315. “Total "1127.0 which is 5.2% more than the assumed: area at ‘the beginning of the calculation, This should not warrant a revision but.the largest calculated area should now be used for any further work. 6.6 Reboilers Reboilers are used in fractionation to provide a heat source to the system, and to generate a stripping vapour stream to the tower. Théy are operated by either the natural circulation of a fluid or forced tircilation of the fluid to be reboiled. This section deals only with natural circulation reboilers, There are three common types of reboilers: © The kettle © The once-through thermosyphon © The recirculating thermosyphon THE KETTLE REBOILER The following is sketch of a typical Kettle reboiler showing its plot layout relative to the fitotionation tower.” ‘Mote details of a kettle reboiler are given in Figure 6.13.REBOILERS 349 This type of reboiler is extremely versatile. It can handle @ very wide range of vaporization loads (og. when used as LPG vaporizer for fuel- gas purposes it vaporizes 100% of the foed). ‘The equipment consists of a large shell into which is fitted a tube bundle through which the heating mediuin flows. The liquid to be reboiled enters the bottom of the shell at the end adjacent to the tube inlet/outlet chamber. The liquid is boiled and partially vaporized by flowing across the tube bundle. The diameter of the shell is sized such that there is sufficient space above the tube bundle and the top of thé shell to allow some disengaging of the liquid and vapour. A bafile weir is installed atithe end of the tube bundle furthest from the inlet. This baffle weir establishes a liquid level over the tube bundle in the shell. The boiling liquid flows.over this-weir to the shell outlet nozzle, while the vapour generated is allowed to exit from the top of the shell through one ar two nozzles. The space downstream of the wel is sized for liquid hold-up to satisfy the surge requirements for the product. ‘Thus it ig not necéssary to provide space in the bottom of the tower for product surge. If the heating medium is non-fouling it is permissible to use U-tubes for the tube bundle. Otherwise the tube bundle must be of the floating-head type. The Kettle type reboiler should always be the first to be considered if there aie no‘ elevation constraints to pumping the bottoms product away. ONCE-THROUGH THERMOSYPHON REBOILER This typé of reboiler and its location felatiye to the tower is given in the following sketch. This type of reboiler should be considered when a relatively high amount of surge is required for the bottom product and when itis necessary to provide head for the pfoduét pump (NPSH requirement). ‘This reboiler takes the liquid from the bottom tray of the fractionator as feed. This stream enters the shell side of a vertical single tubepass shell and tube exchanger by gravity head to the bottom of the shell. The heating medium flows350 HEAT EXCHANGERS: C0, 11 U-tube 6 vapour-disenzaging space, lates, 11 U- ernal displacer), 1 inlet nozzle, support pla ‘of level-instrument housing (ext 1% 18 ); 3 Entrainment baffles, 4 70REROILERS 351 JAs required for ‘circulation tube side to partially vaporize the liquid feed. A syphoning effect is cauged by the difference in density between the reboiler feed andthe vapourfliquid effilent. This allows the reboiler effluent to exit from the top of the shell side and re-enter the tower where the vapour disengages from the-liquid phase: The liquid is the bottom product of the fractionator and is discharged’ fromthe bottom ‘of the tower. Both the kettle and the once-through thermosyphon ‘types constitute a theoretical tray as regards fractionation. Unlike the, kettle, rebbiler, the once- through thermosyphon is limited to a vaporization of not hore than 60% ‘of the feed. The low hold-up of the feed from a tiay results in severe surging through the reboilér at high vaporization rates," Cokes ee . THE RECIRCULATING ‘THERMOSYPHON REBOILER ‘When a vaporization rate higher than’ 60% of reboile: feed is requived’and a Kettle reboiler is unsuitable a recirculating thermosyphon type reboiler should be considered. A sketch showing this type of reboiler is given below.352 HEAT RXCHANGERS This reboiler is similar to the once-through thermosyphon in that it operates by flowing a liquid feed through the shell side of the vertical reboiler by the syphon mechanism. In the case of the recirculating reboiler, however, the feed to the reboiler is a stream of the bottom product from the fractionator. This is vaporized as described earlier and the liquid/vapout effluent returned to the tower. The vaporization by this reboiler can exceed 60% without danger of surging. However, vaporization in this type of reboiler should not exceed 80% . Its action is directed solely to inputting heat only to the tower and because it recycles the same composition sticam to the tower bottom it cannot be considered as a theoretical fractionating tray (although some amount of fractionation does occur in this system). Note in the description of both thermosyphon type reboilers the heating fluid is shown as flowing tube side. There may be cases where this stream will be routed shell side and the reboiler. fluid directed tube side. Some guidance to this selection is provided by the following preference for tube side fluid: Gl). Corrosive,or fouling fluids ys (2). Tite less viscous of the two fluids (3) The fluid'under the highest pressure (4) Condensing stéam oo REBOILER SIZING La os As in the case of most heat exchangels, the sizing calcillation i quite tigorouis'and complex. Normally, process engincers rarely need to compute this in detail. There will’be a need, however, to estimate the size of these items for cost purposes or for plot layout studies, This sizing is greatly simplified by applying heat flux quantities to the predetermined reboiler duty, Heat flux is the value of heat transferred per unit time pér fof surface. The following list gives'a range of‘heat fluxes that have been used jn design and observed in operating units, Design» Observed’ Fist es (BTU/hAPy i Kettle type 12000 1000-20000 Onee-through 15000 1750+. Recirculating 15000 - up to 20000 Forced circulation 20000 ‘The duty of the reboiler is obtained by the overall heat balance aver the tower. This is accomplished by equating the total heat out of a fractionating tower to the heat supplied, making the reboiler duty the unknown in the heat-supplied statement, Now the heat out of the fractionator is the total heat in the products leaving plus the ednderiser duty. ‘The heat supplied to the tower is the heat brought in with the feed, and the heat supplied by the reboiler. Example calculation The feed to a fractionator is. 87960 Ib/h of mixed hydrocarbons. It enters the tower as a vapour and liquid stream and has a total enthalpy of 15.134 mmBTU/h.REBOILERS 353 “The overhead products are a distillate and a vapour stream at 95°F. ‘Che yapour is, 1590 lb/h with an enthalpy of 320BTU/lb.. The distillate is 8028 Ib/h with an enthalpy of 170BTU/h, The bottom product from the tower is 78342Ib/n and Ieaves as a liquid at its boiling point at 440°F, Its enthalpy is 370 BTU/Ib. The overhead condenser duty is 4.278 mmBTU/b. Calculate the reboiler duty. Calculation Calculate the reboiler duty from the overall tower ‘heat balance as in the following: Bnthalpy V/L “APL = “ES sb/h_sBTU/b— MMBTU/h In : Feed VL - 300 879600 15.134 Reboiler duty x Total in : 87960 15.134 + x OUT . Bottom prod. Ley os 4G 78342370 28.986 ‘O/nead dist. L - 95 8028 170 1.364 ‘Ofnead vapour v - 9 = 1590320 0.508 Condenser duty 4.278 Total out 87960 35.136 "Heat in = heat out Then ‘ 15.134 + x = 35.136 : Reboiler duty x = 20,002 mm BTU/h pes Using a heat flux of 15000 BTU/H.ft” the surface area for the reboiler becomes ‘ {2.002000 1393.58 15000 ESTIMATING THE LIQUID AND VAPOUR FLOW FROM THE REBOILBR uit : - bs It is necessaty"to know the vapottrarid liquid 'flow leaving ‘the “teboiler’ and entering the tower for the following reasor © To establish that thore is:sufficient; vapour: rising. in the tower to strip the bottom product effectively © To establish the vapour loading to the bottom tray for calculating the tray loadings 'e”'To be abie’to ‘calculate the driving for for flow through’ the exchanger in the tase of thermhosyphon reboilers, sty 8 ees354 HEAT EXCHANGERS The calculation of this flow is again based on a heat balance. In this cise it is thie heat balance actoss the reboiler itself. With the duty of the reboiler now established by the overall tower heat balance, as described above the balance over the reboiler can progeed as follows: ~_ 90°F 440 °F ‘Steam Condensate Vet i” 49027 us 5 LE Bottom prod * Enthalpy V/L fAPL, °R... Ibfh, = BTU/lb — mmBTU/t In Liquid from tray] - 430 783424 V 369 | 28,908 woe ‘ +3697 Reboiler duty bea ‘ byl 20.002 Total in 784+ 48.910 + 369V OUT sot DNs EN gr eet Bottom prod. L - 44078342, 370 28,986 Vapourtotrayl = Vo. =, 440° 458 458 Total out voy T8424 28,986 + 458V ‘The temperature of the Bottom tray (430 °F) is’ estimated from‘a straight-line temperature profile of the tower. As a rule of thumb, for a 30-40 tray:tower the bottom tray will,be.about 10°F lower than the botfom temperature: ‘Again heat in'= heat out , * Then'48.910 + 369V = 28.986 + 458V . , Y= 223865,10/h. bo Now, the mole weight of the vapour,.is determined. from the bubble point calculation of the bottom product used to determine the.tower bottom tempera-‘REBOILERS: 355 ture (see Section 1.3). In the case of the calculation example given above the ‘bubble point calculation for the bottom product was as follows: Pressure at bottom of tower = 220 + (30 x 0.25) = 227 psia Ast trial (00°F 2nd trial = 435°F ————_ —— Weight tbf Vol XK Y=XK K Y=XK MW factor gal factor 0.053" 58 3.14.86 (0.64 0103 72 © 74 5.200 1.42 API nC, 0.017 27 0.046 iC; 0.047 1.9 © 0.089 53.1 nC; 0.055 “L7 0.094 0105 2 16 525 1.45 Ce 0.345 (0.95 0.331 81-364 6.83. 5.33 C 0322 0.44 (0.142 0,190 “102 «19.46.84 2.84 Ce 0.214 0.17 0,036 0.054 128 6.9 6.94 0.99 Total 1.000 0.738 0,954 84.7 80.8 6.38 12.67 “Actual temperature = 440°F Se ‘The mole weight of the vapour is that calculated for the ¥ column in the above table, which is 84.7. : : vot CALCULATING THE PRESSURE HEAD DRIVING FORCE THROUGH A THERMOSYPHON REBOILER ‘The main advantage of the:mosyphon reboilers is that there are no working parts, such as pumps, that can go wrong and caise failure. However, a major cause of failure in a thermosyphon reboilet is losé of driving force-to' move the fluid over or through the tube bundle: Much of this kind of problem occurs during commission- ing when the reboilér ‘has been’ incortectly positioned relative to the tower nozzles, or during start-up where debris left after maintenance blocks one or other of the nozzles. Th both these cases the problem is really the loss of pressure hoad that drives the fluid to-be reboiled through the exchaiiger. The calculation to _ determine the theoretical driving force is-baged on the density of the. incoming liquid, the head of thet liquid to the inlet nozzle, the density of the out flowing liquidjvapour fluid, and its head. An example of a pressure driving force calculation based on a once'througlt’ thermosyphon (as shown in the diagram below) is as follows. ‘The flow data is basedon the heat balance given earlier in this chapter. : cons The density of the liquid to the reboiler js 38.2 [b/{t? at 430 °F and the ‘total flow is 302207 ib/h: : © Hot t?/ye = 7911 Hot gpm = 966356 HEAT PXCHANGERS: (TSE oti aon The transfer line from the tower to the bottom nozzle of the reboiler is.a 8-in. schedule 40 seamless steel pipe. ‘The head between the bottom of the tower draw-off pot and the reboiler nozzle is 13 ft, The equivalent horizontal line length including fittings is 15 ft. From the fiction loss tables in the appendix, itead loss due to friction = 66.4 £t/100 ft of line (viscosity is taken as 1,1 St), ‘Total line length to the reboiler:is 13 + 15 ft Head loss due t6 {ricicn Head of liquid in draw-off pot = 24in. Head of guid to the rebiter inlet nozele = 13 + 2 follows: c " £0 liquid + £¢ vapour wy of liquid (this is bottom product) = 39.4 at 40°F . Mole wt of vapour (scé bubble point’ . i: calculation above) = 847 . f/h of liquid Beet = 1963.5 :REBOILERS 357 25865 nln = 2643 moles/h = 2643 x 378 x 14.7 x (460 + 440°F) 227 x 520 = 111974.6 fe/n 302207 1963.5 + 111974.6 = 2.65 lb/ft? f/m of vapour = Density of fluid from reboiler = In this case the fluid to be reboiled flows shell-side of the exchanger. The manufacturer’s certified shell side pressure drop based on all vapour flow is 1.5 psi. The mixed phase pressure drop is calculated using Figure 6.14 thus: ae 865. _ 111933 tb/h siokr «7830 190275 ibfh my = average mass of vapour ‘my = average mass of liquid = py = average density of vapour 1.01b/e 2 p= average density of liquid = Bae? = 39.35 bjt? 1 Referring to Figure 6.14, Ry = ———-—_ (nay/mm) + (r/o) 1 (111 933/190275) + (1.0/39.32) = 163) From Figure 6.1400 evs bates 0.42 @X APs 0.42. 1.5 psi va : 63 pai To calculate the total head of liquid from exchange! ‘Tube length isstandard 16 ft. Assume bottom 20% of length is all Nauia phase a a density of 38.8 Ib/tt? ‘Then head is 10% 02 * 38:8 — 9 g69, psi : ae ’ Remaining head is mixed phase ae density of 2.65 ib/tt? 16 x 0.8 xX'2.65 " Then head is 24 psi358 HEAT EXCHANGERS ~ Joot ot 02 03 04 050607 910. 2 3 4 5 6 78910 08 Ry Figure 6.14. Two-phase pressure drop factor for flow across staggered tubes Neglecting the small pressure drop due fg, friction in the 4ft long return line to tower the total hend to outlet nozzle = Fri¢tion loss through exchanger = 0,630 psi Lower section head = 0.862 psi wath | i Upper section head'="0.240 psi ist! s+ i Total 732 psi : a Then driving force = pressiiré head available - pressure head required. .49 psi ~ 1.732 psi .758 psi, which i satisfactory for good flow. Note that the height of tower above grade is usually fixed by pump suctionREROTLERS 359 requirements in the first place. It may be adjusted upwards if necessary to accommodate a head to a reboiler. However, this necessity is quite rare. ‘The transfer line to the reboiler should have its horizontal section at least 3.0 ft above atade to allow for maintenance, ete.