Design of Pre-Heater

Note: all information including figures and charts were obtained from Colson &
Richardson, Chemical Engineering, volume 6)

1. Setting tube diameter and BWG, Assume tube length, L

Tube Diameter =30 mm
Tube length=3 m

2. Assuming fouling factor based on inside and outside tubes, hdi and hdo
Fouling factor=5000( W / m¿¿ 2℃ )¿

3. Using Stainless steel as material of construction for the tubes Æ thermal

conductivity?
Stainless Steel(18 /8)at 0−134 ℃ : 16 K w (W / m℃ )

1. Juice Pre-Heater Steam Requirements On Exhaust Steam

4. Calculation of heat duty,q .
You have the option to assume three known temperature and find the fourth
one or four temperature values and find one of the shell or tube side flow
rate. Use the heat duty equation q = mc cp c (Tc ou −Tc in ) = mh cp h (Th ,out −Th,in
) where subscripts c and h refer to cold and hot streams. Then obtain the heat
duty, q.

Optimum Juice Feed: 4.97 ton/hr

Feed Temp: 27.32 ℃
Outlet Temp: 95 ℃
Feed Enthalpy: 0.0005 ×27.32+3.8014 × 27.32−0.0109
=103.857 kJ /kg

Outlet Enthalpy: 0.0005 ×95+ 3.8014 ×95−0.00109

361.1696 kJ /kg

Enthalpy Difference, Cp ∆ T: 361.1696−103.857=257.29915 kJ /kg

Therefore; Q=¿
Q=355.216 KW

Assuming 5 % losses of Q : 355.216 ×1.05

Q=372.977 KW
 ∆ H vap Steam at 1.8 ¿¯: 2700.6 kJ /kg
∆ H vap Steam at 1 ¯¿: 2675.5 kJ / kg
Steam at 1.8 bar Required: 372.977/2700.6 ×3600 /1000 ton/ hr
0.497192 ton/hr
Steam at 1 bar Required: 372.977/2675.5 ×3600 /1000 ton/hr
0.501857ton/ hr

° Brix : 16.92
Number of heat exchanger banks 1-3: 2
Number of exchangers in each Bank: 3
Number of pass: 2
Number of tubes per pass: 32
Tube ID: 30mm
30 /1000 2
Cross Sectional Area of tubes per HX: π∙ ( 2 ) ∙ 32

¿ 0.0226 m 2
Total Cross-Sectional Area: 0.0226 m 2 × 2 banks
¿ 0.04524 m 2
Volumetric flowrate at SG = 1.06: 4.97 /1.06/3600
¿ 0.00130241 m3 /s

Length of tubes: 3m
Perimeter of tubes: π ∙ 30 /1000=0.094248 m
(0.00130241 m3 /s)
velocity in tubes (1.5-2) (Hugot):
0.04524 m2
¿ 0.028789601 m/s

Heat Transfer Coefficient Calculations:

Feed Temp: 27.32 ℃
Outlet Temp: 95 ℃
Steam Temp: 133 ℃
( 133−95 )−(133−27.32)
delta Tlm: ( 133−95 )
ln (
(95−27.32) )
¿ 117.25
 delta Tlm corrected: 0.95 ×117.25=111.39

Density: 0.00000006 ×° Brix 3+ 0.00001×° Brix 2+ 0.0039× ° Brix +1

0.00000006 ∙ 16.923 +0.00001 ∙ 16.922 +0.0039 ∙ 16.92+ 1
¿ 1.07 kg /m3

0.85
Viscosity: ¿( 0.37+° Brix × ×(0.6−0.37))× 10−4
20
0.85
¿( 0.37+16.92× ×(0.6−0.37))×10−4
20
¿ 5.35 ×10−5 lbfs /sqft
¿ 5.35 ×10−5 /0.0000209 /1000
¿ 2.56 ×10−3 kg /ms

Heat Transfer Area per pass: ¿ 3 m× 0.094248 m×32

¿ 9.048 m2

Heat Transfer Area per bank (6 pass): ¿ 9.048 ×3 × 2

¿ 54.288 m2

Overall Heat transfer Area: ¿ 54.288 m2 ×2

¿ 108.576 m 2

U=Q/(∆tlm*A): ¿ 372.977/108.576/117.25
¿ 0.0293 kW /m2 ℃

1. Juice Pre-Heater Steam Requirements On V1 Steam

Optimum Juice Feed: 4.97 ton /hr
Feed Temp: 27.32 ℃
Outlet Temp: 95 ℃
Feed Enthalpy: 0.0005 ×27.32+3.8014 × 27.32−0.0109
=103.857 kJ /kg

Outlet Enthalpy: 0.0005 ×95+ 3.8014 ×95−0.00109

 361.1696 kJ /kg

Enthalpy Difference, Cp ∆ T: 361.1696−103.857=257.29915 kJ /kg

Therefore; Q=¿
Q=355.216 KW

Assuming 5 % losses of Q : 355.216 ×1.05

Q=372.977 KW
∆ H vap Steam at 0.8 ¿: 2213.6 kJ /kg
¯
Steam at 0.8 bar Required: 372.977/2213.6 ×3600 /1000 ton / hr
0.6063925 ton/hr

° Brix : 16.92
Number of heat exchanger banks 1-3: 2
Number of exchangers in each Bank: 3
Number of pass: 2
Number of tubes per pass: 32
Tube ID: 30mm
30 /1000 2
Cross Sectional Area of tubes per HX: π∙ ( 2 )
∙ 32

¿ 0.0226 m 2
Total Cross-Sectional Area: 0.0226 m 2 × 2 banks
¿ 0.04524 m2
Volumetric flowrate at SG = 1.06: 4.97 /1.06/3600
¿ 0.00130241 m3 /s

Length of tubes: 3m
Perimeter of tubes: π ∙ 30 /1000=0.094248 m
(0.00130241 m 3 /s)
velocity in tubes (1.5-2) (Hugot):
0.04524 m 2
¿ 0.028789601 m/s

Heat Transfer Coefficient Calculations:

Feed Temp: 27.32 ℃
Outlet Temp: 95 ℃
 Steam Temp: 91.78 ℃
( 95−91.78 )−(91.78−27.32)
delta Tlm: ( 95−91.78 )
ln (
( 95−27.32) )
¿ 20.11
delta Tlm corrected: 0.95 ×20.11=19.1045

Density: 0.00000006 ×Cp ∆ T 3+ 0.00001× Cp ∆T 2 +0.0039 ×Cp ∆ T +1

0.00000006 ∙ 257.33+ 0.00001∙ 257.32 +0.0039 ∙257.3+1
¿ 3.69 kg /m3

0.85
Viscosity: ¿( 0.37+Cp ∆ T × ×(0.6−0.37))× 10−4
20
0.85
¿( 0.37+257.3 × ×(0.6−0.37))×10−4
20
¿ 2.89 ×10−4 lbfs /sqft
¿ 2.89 ×10−4 /0.0000209/1000
¿ 1.38 ×10−2 kg /ms

Heat Transfer Area per pass: ¿ 0.04524 m2 × 0.00130241 m3 / s ×16.92

¿ 9.9 ×10−4 m 2

Heat Transfer Area per bank (6 pass): ¿ 9.9 ×10−4 ×2213.6 ×0.6063925
¿ 1.3289 m2

Overall Heat transfer Area: ¿ 1.3289 m2 ×355.216

¿ 472.042 m 2

U=Q/(∆tlm*A): ¿ 372.977/ 472.042/19.1045

¿ 0.041359 kW /m2 ℃
2. Evaporator Steam Requirements @ constant feed
rate

Juice Feed: 4.97 t /hr

Juice Brix: 16.92 %

Syrup Brix: 22 %
Brix Feed: ¿¿
¿ 0.8409 t /hr (Assuming no sugar carry over)

Evaporator outlet: ¿¿¿

¿ 3.8224 t /hr

Working out evaporator recycle mass flow rate:

Juice Feed: 4.97 t /hr
Feed Temperature: 95 ℃
Boiling Temperature water @ 1.8 bar A:
(0.18−0.175)
¿ ×(120.23−116.06)+116.06
(0.2−0.175)
¿ 116.894 ℃

Boiling point elevation @ 21 Bx:

¿−0.00007 ( ° Brix )3 +0.0037 ( ° Brix )2 +0.0695(° Brix)−0.147 4
¿−0.00007 ( 22 )3+ 0.0037 ( 22 )2+ 0.0695(22)−0.147 4
¿ 2.42704 ℃

Boiling Point of Syrup: ¿ 116.894 ℃ +2.42704 ℃

¿ 119.894 ℃

Outlet Temperature: ¿ 116.894 ℃ +2.42704 ℃

¿ 119.32 ℃
Recycle temperature(pre-feed): 120 ℃
Recycle temperature(post-feed): 1 12.25℃

Feed Enthalpy: ¿ 3.8612× 95 ℃ +0.5306

¿ 367.3446

Outlet Enthalpy: ¿ 3.8612× 119.32 ℃ +0.5306

¿ 4 61. 253
Circulating juice enthalpy:
¿ 3.8612× Circulating juice temperature +0.530 6
¿ 3.8612× 122.25+0.5306
¿ 433.9503
Difference (circulating juice): ¿ 461.253−433.9503
¿ 27.3027 ℃

Difference: ¿ 461.253−461.253
¿ 93.9084 ℃

Pre-feed Enthalpy: ¿ 3.8612× 120 ℃+ 0.5306

¿ 463.8746

Enthalpy Difference: 433.9503−367.3446

¿ 66.6057

( 4.97 ×367.34 )−( 4.97× 463.87 )

Recycle Flowrate around evaporator:
( 433.95−463.87)
¿ 16.035 t/hr

⁰Bx after mixing point:

(16.035−4.97)×22 16.923
( 100
+ 4.97 ×
100 )
16.035× 100
¿ 20.426
V1 steam produced @ 0.8 bar: ¿ 4.97−3.8224
¿ 1.1476 t /hr
Feed Temperature: 95 ℃

Enthalpy 95 – 120 ℃: ¿ 461.253−461.253

¿ 93.9084 ℃

Q to heat juice:
¿ 16.027 ×1000/3600 ×27.303+ 93.908× 4.9 7
¿ 588.13 7 KW

Pressure: 0.8 kPaA

H vaporization @ 0.8 bar: 2210 kJ /kg

Energy required for vaporization: ¿ 1.1467 ×1000/3600 ×2210

¿ 703.9428 kJ /kg

Overall energy Required: ¿ 703.9428+588.13 7

¿ 1292.080 kW

∆ H vap Steam @1.8 :̄ 2700.6 kJ /kg

∆ H vap Steam @1 :̄ 2675.5 kJ / kg

Steam @ 1bar required: ¿ 2675.5/1292.080 ×3600/1000

¿ 1.7385 ton/hr

Steam @ 1.8bar required: ¿ 2 700.6/2700.6 × 3600/1000

¿ 1.7224 ton/hr

Heat Transfer Coefficient Calculations:

Juice Feed Temp: 95 ℃
Juice Outlet Temp: 120 ℃
Steam Temp: 133 ℃
 ( 133−120 ) −(133−95)
delta Tlm: ( 133−120 )
(
ln
(120−95) )
¿ 38.23
delta Tlm corrected: 0.95 ×38.23=36.3185

Density:
¿ 0.00000006 × Feed T ℃ 3+ 0.00001× Feed T ℃ 2 +0.0039 × Feed T ℃ +1
¿ 0.00000006 ∙ 953 +0.00001∙ 952 +0.0039 ∙ 95+1
¿ 1.51 kg/m 3

0.85
Viscosity: ¿( 0.37+ Feed T ℃ × ×(0.6−0.37))× 10−4
20
0.85
¿( 0.37+95 × ×(0.6−0.37))× 10−4
20
¿ 1.30 ×10−4 lbfs /sqft
¿ 1.30 ×10−4 /0.0000209/1000
¿ 6.21 ×10−3 kg /ms

Evaporator Stats
ID: 10 mm
ID: 0.01 m
Perimeter: ¿ π ∙ d=π ∙ 0.01
¿ 0.0314 m

Number: 2069
Length: 11.998
Area: ¿ 0.0314 m ×2069 ×11.998
¿ 779.8646 m2

Heat Transfer Area per pass: ¿ 779.8646 m 2

Overall Heat transfer Area: ¿ 779.8646 m 2 ×588.13 7 KW

¿ 458 667.2263 m 2KW
U=Q/(∆tlm*A):
¿ 588.13 7/458 667.2263/36.3185
¿ 3.53 ×10−5 kW /m2 ℃

Total Exhaust Steam Required for The distillery @ 1.8 bar:

¿ 1.7224+ 0.49704=2.21944 ton/hr

Total Exhaust Steam Required for The distillery @ 1.0 bar:

¿ 1.7385+0.5017=2.2402ton /hr

2. Evaporator Steam Requirements @ constant V1

Juice Feed: 4.97 t /hr
Juice Brix: 16.92 %
Syrup Brix: 22 %
Brix Feed: ¿¿
¿ 0.8409 t /hr (Assuming no sugar carry over)

Evaporator outlet: ¿¿¿

¿ 3.8224 t /hr

Working out evaporator recycle mass flow rate:

Juice Feed: 4.97 t /hr
Feed Temperature: 95 ℃
Boiling Temperature water @ 1.8 bar A:
(0.18−0.175)
¿ ×(120.23−116.06)+116.06
(0.2−0.175)
¿ 116.894 ℃

Boiling point elevation @ 21 Bx:

¿−0.00007 ( ° Brix )3 +0.0037 ( ° Brix )2 +0.0695(° Brix)−0.147 4
¿−0.00007 ( 22 )3+ 0.0037 ( 22 )2+ 0.0695(22)−0.147 4
¿ 2.42704 ℃
Boiling Point of Syrup: ¿ 116.894 ℃ +2.42704 ℃
¿ 119. 32℃

Outlet Temperature: ¿ 116.894 ℃ +2.42704 ℃

¿ 119.32 ℃

Evaporator Outlet: ¿¿¿

¿ 3.8223 ton/hr

Recycle temperature(pre-feed): 120 ℃

Recycle temperature(post-feed): 1 12.25℃

Feed Enthalpy: ¿ 3.8612× 95 ℃ +0.5306

¿ 367.3446

Outlet Enthalpy: ¿ 3.8612× 119.32 ℃+ 0.5306

¿ 461.253
Circulating juice enthalpy:
¿ 3.8612× Circulating juice temperature +0.530 6
¿ 3.8612× 122.25+0.5306
¿ 433.9503
Difference (circulating juice): ¿ 461.253−433.9503
¿ 27.3027 ℃

Difference: ¿ 461.253−461.253
¿ 93.9084 ℃

Pre-feed Enthalpy: ¿ 3.8612× 120 ℃+ 0.5306

¿ 463.8746

Enthalpy Difference: 433.9503−367.3446

¿ 66.6057

( 4.97 ×367.34 )−( 4.97× 463.87 )

Recycle Flowrate around evaporator:
( 433.95−463.87)
 ¿ 16.035 t/hr

⁰Bx after mixing point:

(16.035−4.97)×22 16.923
( 100
+ 4.97 ×
100 )
16.035× 100
¿ 20.426

V1 steam produced @ 0.8 bar: ¿ 4.97−3.82

¿ 1.14 67 t /hr

Feed Temperature: 95℃

Enthalpy 95 – 120 ℃: ¿ 461.253−461.253

¿ 93.9084 ℃

Q to heat juice:

¿( 4.97 ×((257.299)/( 95−27.32)) ×(119.32−95) ×1000)/360 0

¿ 127 . 616 KW

Pressure: 0.8 kPaA

H vaporization @ 0.8 bar: 2210 kJ /kg

Energy required for vaporization: ¿ 1.1467 ×1000/3600 ×2210

¿ 703.9428 kJ /kg

Overall energy Required: ¿ 703.9428+127.616

¿ 831.559 kW

∆ H vap Steam @1.8 :̄ 2700.6 kJ /kg

∆ H vap Steam @1 :̄ 2675.5 kJ / kg
Steam @ 1bar required: ¿ 831.559/1292.080 ×3600/1000
¿ 1.119 ton /hr

Steam @ 1.8bar required: ¿ 831.559/2 700.6 ×3600/1000

¿ 1.1085 ton/hr

Heat Transfer Coefficient Calculations:

Juice Feed Temp: 95 ℃
Juice Outlet Temp: 120 ℃
Steam Temp: 133 ℃
( 133−120 ) −(133−95)
delta Tlm: ( 133−120 )
ln (
(120−95) )
¿ 38.23
delta Tlm corrected: 0.95 ×38.23=36.3185

Density:
¿ 0.00000006 × Feed T ℃ 3+ 0.00001× Feed T ℃ 2 +0.0039 × Feed T ℃ +1
¿ 0.00000006 ∙ 953 +0.00001∙ 952 +0.0039 ∙ 95+1
¿ 1.51 kg/m3

0.85
Viscosity: ¿( 0.37+ Feed T ℃ × ×(0.6−0.37))× 10−4
20
0.85
¿( 0.37+95 × ×(0.6−0.37))× 10−4
20
¿ 1.30 ×10−4 lbfs /sqft
¿ 1.30 ×10−4 /0.0000209/1000
¿ 6.21 ×10−3 kg /ms

Evaporator Stats
ID: 10 mm
ID: 0.01 m
Perimeter: ¿ π ∙ d=π ∙ 0.01
 ¿ 0.0314 m

Number: 2069
Length: 11.998
Area: ¿ 0.0314 m ×2069 ×11.998
¿ 779.8646 m2

Heat Transfer Area per pass: ¿ 779.8646 m 2

Overall Heat transfer Area: ¿ 779.8646 m 2 ×588.13 7 KW

¿ 458 667.2263 m 2KW

U=Q/(∆tlm*A):
¿ 588.13 7/458 667.2263/36.3185
¿ 3.53 ×10−5 kW /m2 ℃

Total Exhaust Steam Required for The distillery @ 1.8 bar:

¿ 1.1085 ton/hr

Total Exhaust Steam Required for The distillery @ 1.0 bar:

¿ 1.1189 ton/hr

5. Based on the type of flow, calculate Log Mean Temperature Difference, LMTD.
For counter current LMTD = (Thi −Tco) − (Tho −Tci)

ln
 For co-current LMTD =
(Thi −Tci) − (Tho

−Tco) ln
6. Based of the exchanger configuration obtain the Temperature correction
factor. For 1 shell-2 tube pass exchanger

For other configurations use the following charts

Temperature correction factor: one shell pass; two or more even tube 'passes
Temperature correction factor: two shell passes; four or multiples of four tube
passes

Temperature correction factor: divided-flow shell; two or more even-tube

passes

Temperature correction factor, split flow shell, 2 tube pass

7. Calculate the mean temperature difference using DTm = Ft × LMTD

8. Assume overall heat transfer coefficient as initial guess from the table bellow:
 q
9. Calculate the provisional area A =
U.DTm
10. Based on the assumed tube diameter (ID and OD at a given BWG) and tube
A
length, L, calculate number of tubes: Nt =
π.do.L
11. Calculate tube pitch and the bundle diameter
Where K1 and n1 are obtained from the table bellow based on the type of tube
arrangement (Triangular or square pitch):

12. Provide/Assume the type of floating head of the exchanger and obtain the
bundle diameter clearance, BDC . Use the chart bellow:
13. Calculate the shell diameter. Ds = Db+BDC
14. Calculate the baffle spacing. Bs = 0.4Ds
15. Calculate the are for cross-flow, As = (pt −do )Ds.Bs pt
shell-side flowrate [kg/s]
16. Calculate the shell-side mass velocity, Gs = As
17. Calculate the shell equivalent diameter
18. Calculate the shell-side Reynolds number

19. Calculate Prandtle number. Pr = µ

.Cp
k
20. Obtain the shell-side heat transfer coefficient

Where jh is obtained from the chart bellow

21. Calculate the pressure drop in the shell

Where j f may be obtained from the chart bellow

22. Calculate the number of tubes per pass; Ntpp = Nt passes ofnumber / tube
-side flowrate [kg/s]
23. Calculate tube-side mass velocity, Gm = Ntpp ×π 2 / 4
i
d
Gm
24. Calculate tube-side velocity v = where ρi is the density of fluid inside
tubes. ρi
25. Calculate Prandtle and Reynolds numbers for fluids inside tubes Pr =
µ.Cp ρidiv
, Re = where subscript i refers to fluid inside tubes. k µi
26. Calculate heat transfer coefficient hi by using either the following relations
0.33 0.14
kf 0.33 ⎛ di ⎞ ⎛
⎜ µ ⎞⎟
If Re < 2100 (Laminar flow) then hi =1.86 di (Re.Pr) ⎜⎝ L ⎟⎠⎜⎝µw ⎟⎠
0.7

k f 0.8 Pr 0.33
⎛
⎜1+ di ⎞⎟ If Re > 2100 (Transition and Turbulent) hi =
0.023 Re
di ⎝ L⎠

Or by analogy hi = jh kdfi Re.Pr 0.33 ⎜⎝⎛⎜ µµw ⎠⎞⎟⎟0.14

27. Calculate the overall heat transfer factor
1
Based on “inside tubes flow” Ui = 1 1 di ln(do / di ) d i d i
+ + + +
hi hdi 2kw dohdo doho
1
Or based on “outside tubes flow” Uo = 1 1 do ln(do /di ) do do
+ + + +
ho hdo 2kw diho dihdi
Where hdi and hdo are the heat transfer coefficients for the scales (dirt) inside
and outside tubes, respectively.

28. Compare the calculated overall heat transfer coefficient you obtained from
the previous step with that you assumed in step 8. if it is close to what you
assumed, then you had a valid assumption, then tabulate your results such as
total surface area of tubes, number of tubes, exchanger length and diameter,
heat duty and other design specification. Otherwise, use the calculated value
in step 8 and do loop until the difference between the calculated U between
two consecutive iterations is small.
29. The tube-side pressure drop may be calculated using the relation

∆P =⎛⎜⎜⎝1.5+ Nt ⎡⎢2.5+ 8dj fi L + (µµw )−m ⎤⎥⎦⎞⎠⎟⎟ρi2v2

⎣