‘12.10.1. Heat-transfer fundamentals ‘The fundamentals of condensation heat transfer are covered in Volume 1, Chapter 7. The normal mechanism for heat transfer in commercial condensers is Slmwise condensation. Dropwise condensation will give higher heat-transfer coefficients, but is. ‘onpredictable; and is not yet considered a practical proposition for the design of ‘condensers for general purposes. ; The basic equations for filmwise condensation were derived by Nusselt (1916) and his ‘equations form the basis for practical condenser design. The basic Nusselt equations are detived in Volume 1, Chapter 7. In the Nusselt model somtente aa ‘sumed in the film, and heat transfer is assumed to take entirely conduction ‘through the film. In practical condensers the Nusselt model will strictly only apply at low ligid and vapour rates, and where the flowing condensate films und Ts ‘canbe induced in the liquid film at high liquid rates and by shear at high a el Will generally increase the rate of heat transfer over that prediced aaa "cee effect of vapour shear and film turbulence are discussed in ‘ ho Butterworth (1978) and Taborek (1974) Physical properties Physical properties of te condense fee on at the average condensate ‘and the tube-wall temperature: Scanned with CamScannertows sini veueal wa flow smoothly from row to row, Fig. 12.42a, and coefficient predicted by the Nusselt model is related to th thay, = (ho Ne : — fw __ In practice, the condensate will not flow smoothly from tube to tube, Fig. factor of (V,)~''* applied to the single tube coefficient in equation 12.49, ‘beto0 conservative. Based on results from commercial exchangers, Kern (195 ‘using an index of | /6. Frank (1978) suggests multiplying single tube coefficient of 075. Scanned with CamScannerW, W, Dee pas) Nid, Nixa, 1251 will apply up toa Reynolds number of 30; above this value waves: te film become important. The Reynolds number for the condensate! s presence of waves will increase the heat-transfer coefficient, so the use of equation ‘above a Reynolds number of 30 will give conservative (safe) estimates. The Hs on condensate film on heat transfer is discussed by Kutateladze (1963) " Aboves Reynolds number of around 2000, the condensate film et of turbulence in the condensate film was i n's results are generally used for condenser shown on Fig. 12.43. The Prandtl number for the ‘condensate 1243 can be used to estimate condensate film oie ee 1d downward vert ble vapour shear. Horizontal an diver i. 12.43 will give heat transfer, and the use of Fi Scanned with CamScannerng yy Wen ] whee J=14[P% |x Po ‘suffixes 1 and 2 refer to the inlet and outlet conditions resp Bee evaluated for single-phase flow of the total condensate (th Point 2). That is, the coefficient that would be obtained if the condensate was flowing alone; this can be evaluated using any suitable correlatio ‘convection in tubes; see Section 12.8. Boyko and Kruzhilin used the correlation: hj = 0.021 (k, /d;)Re®® Pr°43 In a condenser the inlet stream will normal totally condensed. For these conditions equation 12.52 becomes: 1+ /pi/p, (hdae= i vp f] lly be saturated vapour and the For the design of condense flow, the coefficient shoul higher value selected, gE Flooding in vertical tubes , ‘When the vapour flows up the tul care must be taken to e Ts with condensation inside the tubes and do Md be evaluated using Fig, 12.43 and equation 12.52 ibe, \ will be the usual arrangement for an Hout’ that the tubes do not flood. Several oe ited ie he Prediction of flooding in vertical tubes, see P ii low-viscosity ‘Scanned with CamScannerby, = 021 mNs/m? Pr,= 121 on outside the tube __ 001s = 25x10? _ 4x 0491 = 021 x10-> Ty = 0-191 kg/sm = 3638 From Fig. 12.43 5 13 | Hi J = 165107 ky, Lovto~ P08 =1 5. 0.688 (oat x10? | h, = 1-65 x 107" x 931(931 —1.65)981 = 6554 W/m?°C sation inside the tube ’ 001s largo ee Re. = 557x107? 021 x 10-* Scanned with CamScanner0-688 27 = # @233) hx 0001 xg TOMI oe i2s4) Re LASTS) ra wint-c Take higher value, = 7723 W/m? °C Example 12.4 It is proposed to use an existing distillation column, which is fitted with; (reflux condenser) which has 200 vertical, SO mm i.d., tubes, for separating beng mixture of chlorobenzenes. The top product will be 2500 kg/h benzene and will operate with a reflux ratio of 3. Check if the tubes are likely to flood. pressure will be 1 bar. Solution ‘The vapour will flow up and the liquid down the tubes. The maximum flow: will occur at the base of the tube. Vapour flow = (3 + 1)2500 = 10,000 kg/h Liguid flow = 3 x 2500 = 7500 kg/h " : Tota area tubes = * (50 10-9) Densities at benzene boiling point x 200 = 0:39 m? = 840 kg/m, p, = 2.7 kg/m? Vapour velocity (vapour flowing alone in tube) aj ‘Scanned with CamScannervpere condensation occurs in a horizontal tube the heat Vicfone the tube will depend on the flow pattern at that tatonsist in two-phase flow are shown in Fig. 12.44; and are i In condensation, the flow will vary from a single-phase liquid at the outlet; with all the possible patterns of flow these points. Bell et al. (1970) give a method for following the change in flow patierm aS “pondensation occurs on Baker flow-regime map. Correlations for estimating the average ‘ondensation coefficient have been published by several workers, but there is no generally ‘stisfactory method that will give accurate predictions over & wide flow range. A ‘comparison of the published methods is given by Bell et al. (1970). * \ i Fic, 12.44, Flow pattern «s, vapour condensing in a horizontal whe nls the limiting condition at the condition at high vapour the condensate film coefficient can n if @ suitable correction for the reduction in the coell on of condensate in the bottom of the tube. The correction 08, so the coefficient for stratified flow can be pulps on)" iy, = 0764 ee Scanned with CamScannerSh) ale : 7 cial Bi iransferred from vapour = 50% (5565-2470) = 43688 kW 43688 water flow = w-%18 1045 kg/s med overall coefficient (Table 12.1) = 900 W/m?°C Mean temperature difference: the condensation range is small and the change in “saturation temperature will be linear, so the corrected logarithmic mean tem Scanned with CamScanner1263 aaE = 954 mm (1238) o,=20(35) 954 P= Se = 38 ‘Number of tubes in centre row N, Shell-side coefficient Estimate tube wall temperature, T,; assume condensing coefficient of 150 Mean temperature Shell-side = aes = 525°C Tube-side = Se = 35°C (525 ~ 7,)1500 = (52.5 ~35)900 T, = 20°C | h f Mean temperature condensate = 25rd =47rC Physical properties at 47°C 4. = 0-16 mN s/m? PL= 551 kg/m? k= 0-13 Wimc i ob a Scanned with CamScanner200(1-35 + 0:02 x 35) 1918/1 = 8218 W/m? °C ig factors: as neither fluid is heavily fouling, use 6000 W Foulini k, = S0W/m°C Significantly lower than the assumed value ‘of 900 W/m?“ value of 750 W/m? Repeat calculation using new (7 3 4368 x 10° _ 364 m? rea = —— 750 x 16 364 =F 1194 bes = 9305 Number of tul Scanned with CamScanner‘Close enough to estimate, firm up design. Shell-side pressure drop ‘Use pull-through floating head, no need for close clearance. | ‘Select baffle spacing = shell diameter, 45 per cent cut. From Fig. 12.10, clearance = 95 mm. Shell id. = 1035+95 = 1130 mm | Use Kern's method to make an approximate estimate. 221) Cross-flow area A, = eo = 0255 m? Mass flow-rate, based on inlet conditions 1130 x 1130 107% oe 1 = 4902k i +3600 “Dass” 402 kaa (12.22) Equivalent diameter, d, = m (25? —0-785 x 20°) = 198mm Vapour viscosity = 0-008 mN/m? 4902 « 198 x 10°9 Rew 0008 x 1923 — = 121,325 ‘Scanned with CamScannerViscosity of water = 0-6 mN s/m? 59 x 993 x 168 x 107 From Fig. 12.24, j = 35x 10-*, Neglect viscosity correction. = _3 (488 « ]993 x 1:59 ap,=4[ 435x100 (wesw +25 | = 53,388 N/m? = 53kPa_ (7-7 psi, (12.20) acceptable. 12.11. Reboilers and vaporisers in thi: i be used for The design methods given 1p this section can be r Reboilers are used with distillation columns to vaporisea fraction Whereas in a vaporiser essentially all the feed is va Three principal types of reboiler are US" : 1. Forced circulation, Fig. 12.50: in vin 1 ay and the vapour formed is S¢1 in 3 vaporiser a disengagement vessel ; 2 Thermosyphon, natural circulations sy ee rs Sin the tubes, or horizontal exchange. porisal i exchan: Scanned with CamScanner