SHELL AND TUBE HEATEXCHANGER DESIGN

SHELL & TUBE CONDENSER DESIGN METHOD

SERVICE - CONDENSER DESIGN BY OMESH

CONDENSER NO. - REFERANCES D.Q.KERN / R .C.6

STEP - 1
TO CALCULATE HEAT LOAD
1) SHELL SIDE FLUID HOT FLUID ORG MIX
2) TUBE SIDE FLUID COLD FLUID WATER

INPUT DATA : OUTPUT DATA :

1) Cp OF SHELL SIDE FLUID( Kcal/Kg OC) 0.8 1) HEAT LOAD Q ( KCAL/HR) 120000 139.2 KW
2) Cp OF TUBE SIDE FLUID( Kcal/Kg OC) 1 2) AVERAGE TEMP (ºF) 98.6 54.23 0 C
3) FLOWRATE OF SHELL SIDE FLUID (Kg/Hr) 250 (COLD FLUID)
4) FLOWRATE OF TUBE SIDE FLUID (Kg/Hr) 12000
5) TEMP. OF HOT FLUID INLET ( OC ) 100 212 ºF
6) TEMP. OF HOT FLUID OUTLET ( OC ) 100 212 ºF
7) TEMP. OF COLD FLUID INLET ( OC ) 32 89.6 ºF
8) TEMP. OF COLD FLUID OUTLET ( OC ) 42 107.6 ºF
9)SP.GR. OF SHELL SIDE FLUID 0.6
10) LATENT HEAT OF VAPORISATION (Kcal/KG ° C) 480

STEP - 2
TO CALCULATE LMTD FOR COUNTER CURRENT FLOW : OUTPUT DATA
HOT FLUID IN 100 HOT FLUID OUT 100 1)LMTD= 62.867502 0 C
COLD FLUID OUT 42 COLD FLUID IN 32
DIFFERENCE 58 0 C 68 0 C

STEP - 3
OVERALL HEAT TRANFER COEFFICIENT CONSIDERATION. 488 Kcal/M2.hr.°C 568 W/M2 0 K
CONSIDERED= 100 BTU/HrM2OK

STEP - 4
HEAT TRANSFER AREA CALCULATION
INPUT DATA OUTPUT DATA
1) HEAT LOAD = ( Kcal/Hr ) 120000 1)H.T. AREA = ( M2 ) 3.91142692
2) LMTD 62.867501951
3) OVERALL HEAT TRANSFER COEFFICIENT = 488
( Kcal/HrM2 OC )
(W/M2 0 K) 568

STEP - 5
CALCULATION OF NO. OF TUBES
INPUT DATA OUTPUT DATA
1) HEAT TRANSFER AREA = ( M2 ) 3.9114269171 1) NO. OF TUBES = 21.843554
2) LENGTH OF TUBE = ( M ) 3
3) O.D. OF TUBE = ( MM ) 19 SELECTED NO. OF TUBES= 24
4) I.D. OF TUBE = ( MM ) 15
5) PITCH OF TUBE ( MM ) 23.75 Refer Table-9, D Q Kern
6) O.D. OF TUBE = ( INCH ) 0.75
7) PITCH OF TUBE (INCH ) 0.94
8) I.D.OF TUBE FROM TABLE 10 KERN 0.59
9) TYPE OF PITCH TRIAGULAR
STEP - 6
CALCULATION CORRECTED H.T.COEFFICIENT
1) LENGTH OF TUBE = ( M ) 3.00 OUTPUT DATA
2) O.D. OF TUBE = ( MM ) 19.00 CORRECTED H.T.C. Kcal/M2.hr.°.C 443.94
3) SELECTED NO. OF TUBES= 24.00 CORRECTED H.T.C. Btu/Ft2.Hr.°K 91
4) TOTAL H.T.AREA 4.30 CORRECTED H.T.C. W/M2°.C 78
5) LMTD 62.87

STEP - 7
CALCULATION OF VELOCITY IN TUBES
INPUT DATA OUTPUT DATA
1) TUBE SIDE FLOW = ( Kg/Hr ) 12000 1) VELOCITY = (M/Sec) 1PASS 0.78584844
2) CROSS SECTION AREA OF TUBE = ( M2 ) 0.0001767375 2) VELOCITY = (M/Sec) 2PASS 1.57169688
3) NO. OF TUBES 24 3) VELOCITY = (M/Sec) 4PASS 3.14339377
4) THICKNESS OF TUBES = ( MM ) 2 4) VELOCITY = (M/Sec) 6PASS 4.71509065
5) I.D. OF TUBE 15 5) VELOCITY = (M/Sec) 12PASS 9.4301813
6) SP. GRAVITY OF TUBE SIDE FLUID 1
7) VOLMETRIC FLOWRATE (M3/Sec) 0.0033333333

DECIDE NO. OF PASSES BASED ON VELOCITY IN TUBE & Nre

VELOCITY OF FLUID IN TUBE SHOULD BE BETWEEN 1-1.5 M/S

STEP - 8
CALCULATION OF H.T. COEFF ON TUBES
1) I.D.OF TUBE(MM) 15 OUTPUT DATA
2) DENCITY OF FLUID(KG/M3) 1000 RENOLDS NUMBER= 24000
3) VELOCITY OF FLUID IN TUBE(M/S) 1.6 NOTE: IF NRE. IS GREATER THAN 4000
4) VISCOCITY(CENTPOISE) 1 THEN FLOW IS TURBULENT WHICH IS DESIRED
5) SP. HEAT Cp (KJ/Kg 0 C) 4.18
6) THERMAL CONDUCTIVITY (BTU/hr ft 0 F) 0.393
(W/M 0 K) 0.67989 PRANDLE NUMBER= 6.14805336
7)TUBE LENGTH AND TUBE ID RATIO (L/di) 200
8) TUBE SIDE HEAT TRANSFER FACTOR (Jh) 0.0035 Refer Fig-12.23, R.C. 6

NUSSULT NUMBER= 152.954657

H.T. C ON TUBE (hi) (W/M2 K) 6932.82277

(Btu/ft2 h 0F) 1220.17681

STEP - 9
CALCULATION OF SHELL DIAMETER
1) O.D.OF TUBE MM 19 OUTPUT DATA
2) PITCH OF TUBE 23.75 SHELL DIAMETER MM 152.81
3) NO. OF PASSES 2 INCH 6.02
4) TOTAL NO. OF TUBES 24.00
5) CORRECTION FACTOR 0.866 FOR TRIANGULAR PITCH C.F. 0.866
FOR SQUARE PITCH C.F. 1
FACTORE Ki FOR PASSES 0.319 NOTE: FOR DIFFERENT PASS AND PITCH
FACTORE ni FOR PASSES 2.142 VALUES OF Ki & ni CHANGES .Reffer R C. 6, Pg no 649
6) BUNDLE DIA (MM) 142.8127341
7) CLEARENCE betn SHELL AND TUBE BUNDLE(MM) 10.00
STEP -10
CALCULATION OF H.T. COEFF ON SHELL
1) No. OF BAFFLE 8 HORIZONTAL BAFFLE
2) BAFFLE SPACING (MM) 375 SELECTED BAFFLE SPACING(MM) 375
3)SHELL SIDE C/S AREA (MM2) 11460.955058
4) EQUIVALENT DIA De (MM) 18.761075
5) VOLM FLOWRATE (M3/Sec) 0.0724662887
6) DENCITY OF FLUID(KG/M3) 0.9583 RENOLDS NUMBER= 939.483263
7) VELOCITY OF FLUID IN SHELL (M/S) 6.322883941 NOTE: IF NRE. IS GREATER THAN 4000
8) VISCOCITY(CENTPOISE) 0.121 THEN FLOW IS TURBULENT WHICH IS DESIRED
9) SP. HEAT Cp (KJ/Kg 0 C) 3.83
10) THERMAL CONDUCTIVITY (BTU/hr ft 0 F) 0.014
(W/M 0 K) 0.02422 PRANDLE NUMBER= 19.1341866
11) SHELL SIDE HEAT TRANSFER FACTOR (Jh) 0.012 Refer R.C 6 Pg 673
ASSUMING 25% BAFFLE CUT
NUSSULT NUMBER= 29.8584731

H.T. C ON SHELL (ho) (W/M2 K) 38.5464169

(Btu/ft2 h 0F) 1220.17681

STEP -10
CALCULATION OF CLEAN O.V .COEFFICIENT
OUTPUT DATA
1) O.D OF TUBE (MM) 19 OVERALL CLEAN COEFFICIENT 38.2038702
2) I.D OF TUBE (MM) 15 Uc (W/M2 K)
3) hi 6932.8227662
4) ho 38.546416946 Uc> Ureq CONTINUE IF NOT CHANGE ASSUME U.
5)THERMAL CONDUCTIVITY OF WALL kw (W/M K) 45

STEP -11
CALCULATION OF DESIGN O.V .COEFFICIENT

1) FOULING FACTORE ON TUBE SIDE( Rdi) M2 C/W 0.0002 Refer RC. 6 Pg. 640
2) FOULING FACTORE ON SHELL SIDE( Rdo) M2 C/W 0.0003
3)TOTAL FOULING ALLOWANCE (Rd) (M2 C/W) 0.0005533333 OUTPUT DATA
OVERALL DESIGN COEFFICIENT 37.4129794
Ud (W/M2 K)

STEP-12
PRESSURE DROP ON SHELL SIDE
1) REYANOLD NO. 939.48326339
2) FRICTION FACTORE Jf 0.055 Refer Fig 12.30 R.C6
3) PRESSURE DROP ON SHELL (mmHg) 2.5308941358
(PSI) 0.0488462568
STEP-13
PRESSURE DROP ON TUBE SIDE
1) REYANOLD NO. 24000
2) FRICTION FACTORE Jf 0.0035 Refer Fig 12.24 R.C6
3) PRESSURE DROP ON TUBE (mmHg) 0.05275648
(PSI) 0.0010182001