Equipment Design - 4" year Chapter Six Assist. Prof. Ihsan Habib Dakhit Example 1: Design an exchanger to sub-cool condensate from a methanol condenser from 95°C to 40°C. Flow-rate of methanol 100,000 kg/h. Sea water will be used as the coolant, with a temperature rise from 25° to 40°C. Solution This example illustrates Kern’s method. Coolant is corrosive, so assign to tube-side. Heat capacity methanol = 2.84 ki/kg°C 100,000 i = 2.84(95 — 40) = 4340 kW Heat load = “PS x 2.84495 ~ 40) Heat capacity water = 4.2 kI/kg°C Coolirig water flow = ——— = 68.9 kg/s (95 - 40) - Tig = = 95 — 40 R Wo 3.67 -2! = 28 0.21 95-25 From Figure 6 F, = 0.85 N AT, = 0.85% 31 = 26°C From Figure 3 U = 600 W/m?°C Provisional area 4 IO 7 mt 26 x 600 Beer shed else | ST sella felsee pd ed I hae FaasEquipment Design - 4" year Chapter Six Assist. Prof. Ihsan Habib Dakhit ., 4.88 m long tubes (3in x 16 ft), cupro-nickel. 16 mm Choose 20 mm o. Allowing for tube-sheet thickness, take L=483m Area of one tube = 4.83 x 20 x 10-2 = 0.303 m* 278 Number of tubes = 7355 = 18 As the shell-side fluid is relatively clean use 1.25 triangular pitch. 91g \ "2207 le dic =20|—— = 82¢ (Table Bundle diameter Ds (as) mm (Table 3) Since the coolant liquid is water (fouling liquid), use a split-ring internal floating head type. From Figure 17, bundle diametrical clearance = 68 mm, shell diameter, D, = 826 + 68 = 894 mm. a 38 Tube-side coefficient 0+ 25 - Mean water temperature = 4 = 33°¢ x > Tube cross-sectional area = 4a* 16? = 201 mm? 18 Tubes per pass = a = 459 Total flow area = 459 x 201 x 10-® = 0.092 m? 68. 2 Water mass velocity = os 749 kg/s m? Density water = 995 kg/m? Water linear velocity = 2 = 0.75 m/s N 4200(1.35 + 0.02 x 330.7598 y= Tene 3852 W/m?*C iy Aah eh fhe pn entb A—l da Blo cae Ghed rueldl SLM awEquipment Design - 4" year Chapter Six Assist. Prof. Ihsan Habib Dakhit The coefficient can also be calculated using equation below: aus fids _ i, Repro (+) ky Dy Viscosity of water = 0.8 mNs/m? Thermal conductivity = 0.59 W/m?C Uf pud; — 995 x 0.75 x 16 x 10-3 2 = 14,92: = 0.8 x 10-3 =e Gb 42x 1 x DBx 10> Pr= Eo 039 =57 Neglect (£ Bw 3 | dj 16 . Ww From Figure 21, jx =3.9 x 1073 0.59 5 «= Texctos * 39% 1073 x 14,925 x 5.7953 = 3812 Wim?*C x 1053 Checks reasonably well with value calculated from equation 7; use lower figure. Shell-side coefficient . 894 Choose baffle spacing = =" = = = 178 mm. Tube pitch = 1.25 x 20 = 25 mm Cross-flow area Ay = Sa o94 x 178 x 10-§ = 0.032 m? ae | = 868 kg/s m? Mass velocity, Gs = — 3600” 0.032 Ll Equivalent diameter d. = we 0.917 x 20°) = 14.4 mm Sel cee heed tues se o's salah foe pal fam 21 ale 3, fwEquipment Design - 4" year Chapter Six Assist. Prof. Ihsan Habib Dakhit Mean shell side temperature = 25-+49 _ ggo¢ Methanol density = 750 kg/m? Viscosity = 0.34 mNs/m? Heat capacity = 2.84 ki/kg°C Thermal conductivity = 0.19 W/m?C Gd, 868 x 14.4x 10-3 \ = = a TER _ Cyft _ 2.84 x 10° x 0.34 x 10-3 0.19 Choose 25 per cent baffle cut, from Figure 24 jn =33x 107 Without the viscosity correction term 0.19 ~ 144 x 10-3 Estimate wall temperature, Equation 6 can be written for the shell-side as: ho (tw- t) = U(T-t) “ : Mean temperature in the shell = (95+40)/2 = 67.5 °C Mean temperature in the tube = (25+40)/2 = 32.5 °C Mean temperature difference = 68 — 33 = 35°C across all resistances Re = 5.1 h, x 3.3 x 1073 x 36,762 x 5.1! = 2740 W/m? U 600 - across methanol film = (tw-t) = i: x AT= 740 x35=8°C Mean wall temperature = 68 — 8 = 60°C Py = 0.37 mN/m? ya (4) = 0.99 Bw which shows that the correction for a low-viscosity fluid is not significant. Beer shed else SN sal Lalegl felsee pd ead hake aeEquipment Design - 4" year Chapter Six Assist. Prof. Ihsan Habib Dakhit Overall coefficient Thermal conductivity of cupro-nickel alloys = 50 W/m°C. brackish water (sea water), take as highest value, 3000 Wm-?>C-! 20 x 10-in (22 16 2x50 well above assumed value of 600 W/m?°C. Pressure drop Tube-side From Figure 22 , for Re = 14,925 a= Neglecting the viscosity correction term AP, =2 (s x 4.3 x 10-3 (a = 7211 Nim? = 7.2 kPa Shell side 868 inear velocity = = = 1.16 mis Linear velocity = —* = 555 = 1.16 m/s From Figure 25 , at Re = 36,762 ip =4x 107 etree ghael chat stadt NTS sel jlabel folder pe few WS, lh ole Fw‘Equipment Design - 4" year Chapter Six Assist. Prof. Ihsan Habib Dakhit Neglect viscosity correction 2 (894) (4.83 x 10°) 750 x 1.167 AP, =8x4x 10 (=) Sas = 272,019 Nim? = 272 kPa (39 psi) too high, could be reduced by increasing the baffle pitch. Doubling the pitch halves the shell-side velocity, which reduces the pressure drop by a factor of approximately (1/2) 272 AP, = = = 68 kPa (10 This will reduce the shell-side heat-transfer coefficient by a factor of (1/2)°8(h, x RES ox u?8) acceptable ho 740 x (4) = 1573 Wim?C This gives an overall coefficient of 615 W/m?C - still above assumed value of 600 W/m?*C. Sel cee heed tues se ig elle folaee nad edt A6—, fh dae