Heat Exchanger design

Physical properties

Mass flow rate of gas in= mass flow rate of gas out= 33,424.8Kg/day = 0.386 Kg/sec

Temperature of gas in= T1 = 400C =673 K

Temperature of gas Out= T2= 25C= 298K

Temperature of Cooling water in t1= 25C = 298K

Temperature of cooling water Out t2= 40C =313 K

Heat Duty Q=mcΔT

=282.82KJ/s
Cp of water= 4.2KJ/kgk

Mass of water in= Mass of water out M=4.55* 10^-3 kg/sec

Q=mcΔT
282.82 KJ/s= m * 4.2* (313-298)

M = 4.51 kg/s

Overall heat transfer coefficient

For this type of heat exchanger overall coefficient will be in the range of 20-250 W/m2k. so we start
at the trial value of heat transfer coefficient of 200 w/m2k

Exchanger Type and dimensions

An even number of tube passes is usually the preferred arrangement.

Start with one shell pass and two tube passes.

LMTD=
[ ( T 1−t 1 ) – ( T 2−t 2 ) ]
T 1−t 2
ln [ T 2−t 1 ]
T m= 111.84 K

400−25 40−25
R=
40−25
= 25 S=
400−25
=0.04

From fig Ft= 0.98 which is acceptable

ΔT lm= 0.98*111.84 =109.6

Overall heat transfer coefficient

For the heat exchanger of this type the overall heat transfer coefficient will be in the range of 20-300
W/m2K. So we start at the trial value of heat transfer coefficient of 200 W/m2K

Heat transfer area

At,

Q=UA ΔT lm

282.82∗103
A¿ = 8.6m 2
200∗109.6

Layout and tube size

We are using the split- ring floating head exchanger for efficiency and ease of cleaning ,

Cupper nickel is opted as a material of construction for the shell and tubes.

The tubes are of length 4.5m, with outer diameter of 20mm and inner diameter of 16mm with
triangular pitch 1.25

Number of tubes
On neglecting thickness of tube sheets

Area of one tube= A=πdL = 4.5* 14¿ 10 = 0.282 m Number of tubes= 8.6/0.282= 30 tubes
−3 2

So, for 2 passes, tubes per pass =15

−3 2
Tube cross-sectional area= A=π r 2 =
[ π ( 16∗10 ) ] =201∗10 −6
4

So area per pass= 15 *201∗10−6= 3.01∗10−3

Mass velocity of water= 4.5/3.01∗10−3= 1503.3kg/sm2

Density of water= 995kg/m3

Water linear velocity= 1503.3/995= 1.5m/s

[ 4200 ( 1.35+ 0.02T n ) U 0.84

t ]
hi=
16 0.2

hi=6706.4 W /m2 K

Shell side Coefficient

 Ds
Baffle space= = 45.2mm
5

Tube pitch= 1.25*20= 25mm

[ ( P t – d o ) D S Lb ] −3 2
Cross- sectional flow area As= = 2.04∗10 m
Pt

flowrate
∗1
Mass velocity (gas) = 3600
=186.2
m
As s

1.10
Equivalent diameter=
d o ( P −0.917 d 2o ) = 14.4mm
2
t

400+25
Mean shell side temperature= = 212.5 °C
2

G S∗d e
Re = = 115.5
μ

C p∗μ
Pr = = 1.25
kf

Choose 25% baffle cut, from fig 12.29

j h = 5.2¿ 10−2

h s=( k f Re P 0.33 2
r ) /d e = 450.6 W /m k

Overall Coefficient

Fouling coefficient
2
Tube side fouling coefficient= hid =3000W /m k

2
Shell side fouling coefficient = h od=500 W / m k

do
1 1 1
= + +
[ ( )]
do l n
di
+
do
di
∗1
+
do
di
∗1

U o ho h od 2 kw hid hi

U o =¿ 207.3¿

Well above assume value

Pressure drop
From fig, for

G S∗d e
Re = = 29850
μ

j f =3.9∗10 −3

2
1 ¿∗ρ U t
Pt =N p 8 j f
( ( ))
di
+ 2.5
2
= 26.6 k pa

Shell side pressure drop

U s=Gs / ρ =0.339 m/s

G S∗d e
Re = = 111720
μ

From fig, at Re

j f =3∗10 −2

DS L U 2s
Δ Pt =8 j h ρ = 25.90 N / m 2
D e Lb 2

Heat Exchanger design sheet

Heat Exchanger Equipment No.

No. of units= One Sheet No.
Function: Lower temperature of process fluid
Overall Heat Exchanger Log Mean Temperature difference 109.6

Heat Exchanger size 8.6 m 2 Material of construction Cupper Nickel

Heat Load 282.82KJ/ Overall Heat Transfer Coefficient 200 W/m2K

Tubes side Shell side

Flow rate of Water 4.5 Kg/s Flow rate of Gas 0.38kg/s

Temperature of water in 25 Temperature of Gas In

400 C

Temperature of water Out 40 Flow rate of Gas out

0.38 kg/s
Thermal conductivity of water 55 W/m2K Thermal conductivity of Gas 0.028 W/m2 K

Number of passes 2 Number of shell pass 1

Outside diameter of tubes 20mm Shell diameter 14.4mm

Inside diameter of Tubes 16mm Bundle diameter 226mm

Length of tubes 4.5m Baffle spacing 45.2mm

Tube arrangement Triangular Baffle Cut 25%

Tube side fouling factor 3000 W /m 2 k Shell side fouling factor 500 W/m2K

Tube side heat transfer 6706.4 W /m 2 k Shell side heat transfer coefficient 450.6 W/m2K
coefficient
Tube side pressure drop 26.6 Pa Shell side pressure Drop 25.90 N/m2