‫ملحق مشروع التخرج ((فاطمة الشمري))‬

‫*‪*4‬‬

‫الفصل الرابع‬

‫~(تصميم المعدات)~‬

‫تصميم املبادل احلراري‬

 ‫املقدمة ‪- :‬‬

‫تسمح المحادالت المرالاة ااتادال المادة اح احدع الم اآخا‪،‬اعدالةاالو المسمحد ا‬

‫ادتتصد ااة المسولع ‪ .‬ا‬
‫ا‬ ‫لمحادالت المرالاة اهياحعالل اتسمممح اانق المرالاةاح اسمممدع اسمممدخ الم‬
‫ا‬ ‫سممدع ااداال‪.‬ا يالمعالةالاح المتااةقد المهنالسممة ‪،‬اح المحسممترس م اةةدالةاالا‬
‫ا‬ ‫رالاةاسمدع اولرالاأثندءاتااةالاآتخا‪.‬اةتمالسمتخاللمالمحادالت اعل انادقاولسم‬
‫ا‬ ‫ياتااةقمد المامدةم اولمعحلةمد المحتنوعم احثم احرامد المامدةم ‪ .‬احراكمد‬
‫ا‬ ‫لمسممةدال ‪،‬اوأنظح اتال ع الألحدك ‪،‬اوأنظح المتااةالاوتكةةفالمهولء‪،‬اولمعحلةد‬
‫لماتاوكةحدعة ‪،‬اوتااةالالإلمكتاونةد ‪،‬اوهنالس الماةع ‪.‬ا ا‬
‫تعتحالالمحادالت المرالاة ااشممك اعدماعل اأنداةأاأسمماولنة اولمحسممدر امك ا‬
‫عدا‬
‫ورالةار ماتنتق اح اخالمهدالمرالاة‪.‬اأكثااأنولعالمحادالت المرالاة اشممةو ً‬
‫هوانوعالمغالفاولألناوأ‪،‬ارةثاةسمممتخالمارةح اح الألنداةأالمتياةتال ناح ا‬
‫خالمهداأرالالمسمممولع ‪.‬اةتماوهم م اهابالألنداةأا يا الفاح اتو ةاالمسمممولع ا‬
‫لألخاىامتتمال ناعااالمفال مد ااة الألنمداةمأ‪.‬اةحك االرا م الألنمداةمأا يا‬
‫ت دوةفا يامو الألناوأ‪،‬اأواحلروح اعل امو الألناوأ‪،‬اأواكلةهحدامهمممحد ا‬
‫عمالمالمتسممممماأ‪.‬اتعتااالمحامدالت المرالاةم الملورةم اأكثاا مدعلةم األنهمداتو اا‬
‫حسمممممدر اأعل امنقم المرالاة‪.‬اتو االمحامدالت المرالاة المحمالح م المحصمممممغاةا‬
‫حعمدحم انقم ارالاةاحاتف املغمدةم ااسممممامأاةااهمدالمصمممممغةااوحعمالت اتمال نا‬
‫لمسولع المعدمة ‪ ..‬ا‬
‫ا‬
‫ا‬
‫ا‬
‫ا‬
‫ا‬

‫‪2.4‬ا‪-‬المحعاةد المحالوا املتصحةما‪ -:‬ا‬

‫ا‬
 FluidCondition Shell Side Tube Side

Component Solvent Glaucous Water

Flow rate (Kg/hr) 3174 ‫؟‬

Temperature in ( C ) 30 110
Temperature out (C ) 50 60
pressure 8 5

‫ااااااااااااااااااااا‬

‫ ا‬-‫ ا‬:‫لمخولصالمفةةةدعة امحدءالمتسخة ا‬

110+60
‫ ا‬Tav = =85 C = 358 K
2

‫ ا‬inside tube
Heat Capacity :

Cp = A + BT + CT2 + DT3 Ludwig's Applied

Process Design page 767 Cp = 92.053 + (–3.9953 * 10-2 ) * 358 + (–2.1103 *
10-4 ) *(358)2 + (5.3469 * 10-7 ) * (358)3 Cp = 75.23 J / mol K
‫ → ا‬Cp = 4.2 KJ/ kg C
‫ا‬
Density :

ρ = A B – ( 1-T/Tc)n ( Ludwig's Applied Process Design page 759)

ρ = 0.34710 * (0.27400) – (1 – (358 / 647.13))0.2857
ρ = 0.971 Kg/L
‫ → ا‬ρ = 971 kg / m3
Viscosity thermal conductivity :

‫ ا‬Μ(water) = 0.56 m Ns/m2 K (water) =0.685 W/m C

‫احدء)ا‬+‫لمخولصالمفةةةدعة امحرلو الم لوكوةا( لوكوةا‬

30+50
‫ ا‬Tav = = 40 C = 313 K
2

From V.6
 Heat Capacity

‫ ا‬CpWater = 4.2 KJ/ kg C

Cp For : (C =11.7 ,H=18 ,O=25.1) KJ/ kg C
SO Cp ( C6H12O6 ) =(6*11.7+12*18+6*25.1)
=176.8 J/mol C
= 2.275 KJ/ kg C
CpT = (0.7*2.275)+(0.3*4.2)=2.8525 KJ/ kg C
Density (ρ) :
‫ا‬ρ Glaucous =1540 Kg/m3

Water = ρ = A B– ( 1-T/Tc)n ( Ludwig's Applied Process Design page 759)

ρ = 0.34710 * (0.27400) – (1 – (313 / 647.13))0.2857

ρ = 1.014 Kg/L
‫ → ا‬ρ = 1014 kg / m3

Total = (0.7*1540)+(0.3*1014)=1382.2 kg / m3

Viscosity (μ) : thermal conductivity :

μ (Glaucous Solvent) = 0.486 m Ns/m2 K (Glaucous Solvent)

=0.54 W/m C

4-Design

4.1 - Q load and Q utility :

 m (Glaucous solvent) = 3174 kg/hr
‫ ا‬Q(Glaucous solvent) = Q(water)
Q = m* CPΔT
Q(Glaucous solvent) = 3174*2.8525*(50-30) = 181077 J/hr
=50.299 KW/s
Q(water) = m CP ΔT
‫ ا‬m (water) = 50.299 / 4.2 * (110 – 60 )
m (water) = 0.23952 kg/s

4.2 - ΔTlm Calculation :

(𝟏𝟏𝟎−𝟓𝟎 )−( 𝟔𝟎−𝟑𝟎)

ΔTlm = =43.28 C
𝒍𝒏(( 𝟏𝟏𝟎−𝟓𝟎 )/( 𝟔𝟎−𝟑𝟎 ))

4.3 – R – S – F Calculation :

𝑡1−𝑡2 30−50
R= = = 0.4
𝑇2−𝑇1 60−110

𝑇2−𝑇1 60−110
S= = = 0.625
𝑡1−𝑇1 30−110
F = 0.9
ΔTm = F * ΔTlm
= 0.9 * 43.28
 = 38.952 C

4.4 - Figure 1.2 Heat Exchanger one shell pass ; two tube
passes

4.5 - Number of tubes Calculation :

Q = 50.299 kW = 50299 W , do = 25 mm , di = 23 mm
L = 3.66 m
Assume U = 100 𝒘/𝒎𝟐 𝑪 ( at Vol.6 Table 12.1)
ΔTm = 38.952 C
Q = U A ΔTm
50299 = 100 * A * 38.952
A = 13 m2
At = π dₒ L
= 3.14 * 0.025 * 3.66
= 0.28 m2

N: number of tube = A / At = 13/0.28 = 46 tubes

4.6- Overall heat transfer Coefficient Calculation
4.6.1 - hi (tube side Coefficient) calculation :
 Cross sectional area of one tube = 𝝅/𝟒 * di2
Where :
di : inside tube diameter ( 23 mm = 0.023 m )
Cross sectional area of one tube = (3.14 / 4 ) (0.023)2
= 0.000415265 m2
Tubes per passes = N/2 = 46/2 = 23 tube
Total flow area per pass= 23 * 0.000415265 = 0.00956 m2
𝑚 (𝑤𝑎𝑡𝑒𝑟) 0.23952
𝑉𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖c Fiowrate = = =0.00030667 m3/s
𝜌 971
𝑉𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝐹𝑖𝑜𝑤𝑟𝑎𝑡𝑒 0.00030667
𝑢= = 0.037 m/s
Total flow area per pass 0.00956

ρ = 971 kg/m3 , μ = 0.56 mNs/m2 , Cp = 4.2 kJ/kg.oC ,

Kf = 0.685 W/mC
Re = ρ u di / μ
Re = (971 * 0.037 * 16 * 10-3)/ (0.685 * 10-3)
Re = 1479 laminar flow
Pr = Cp μ / Kf
Pr = 4.2 * 1000 * 0.56 * 10-3 / 0.685
Pr = 3.43
Jh = 1.98 * 10-3

𝐡𝐢 (𝟏𝟔 * 10-3 )/ 0.685 = 1.98 x10-3 (1479)(3.43)0.33 (0.56 * 10-3/0.56 * 10-3)0.14

𝐡𝐢 = 132 W/m2 . oC

4.6.2- ho ( shell side Coefficient) calculation :

Bundle Diameter Db = do ( Nt / K1)1/n1 use triangular pitch

Db = 0.025 (46 / 0.249 ) 1 / 2.207 = 266 mm =0.266 m
Bundle Diameter clearance (Dc) = 55 mm
Shell Diameter ( Ds ) = Db + Dc
Ds = Db + Dc = 266 + 55 = 361 mm ≈ (0.361 m)

Take baffle spacing 1/5 shell diameter

IB = Ds/5 = 0.361/5 = 0.07223 m
Tube pitch Pt = 1.25 * do =1.25 * 0.025 =0.03125 m

(0.03125−0.025)∗0.361∗0.07223
As = = 0.00522 m2
0.03125

Gs = m / As
m = 3174 Kg/hr = 0.88 Kg/s
𝑉𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖c Fiowrate = 0.88/ 1382.2= 0.00064 m3/s
 𝑉𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝐹𝑖𝑜𝑤𝑟𝑎𝑡𝑒 0.00064
𝑢= = 0.12227 m/s
As 0.00522

de = ( 1.1 / 0.025 ) ( ( 0.03125)2 – 0.917 (0.025)2 ) = 0.01805m

ρ = 1382.2 kg/m3 , μ = 0.00049 Ns/m2 , Cp = 2.8525 kJ/kg.oC ,
Kf = 0.54 W/m oC
Re = ρ * u *de / μ
= (1382.2 *0.12227 *0.01805)/ 0.000486
=6277 turbulent flow
Pr = Cp μ / Kf
= (2852.5 *0.00049)/ 0.54
= 2.567
( μ / μw ) = 1 for turbulent flow
Choose 25 percent baffle From Figure 12.29 at vol.6 page
(673)
Jh = 0.0032

ho = (0.54 /0.01805) * (0.0032) * (6277) * ( 2.567)0.33

= 820.2 W/m2 oC

4.6.3 - Uo ( overall Coefficient) calculation :

Hid = 4000
Hod = 5000
 0.025
0.025∗𝑖𝑛( )
0.023
1/Uo = (1/820.2)+(1/5000) + + (0.025/0.023)*(1/4000)
2∗45

+ (0.025/0.023)*(1/132)
= 0.00985
Uo = 100.52 𝒘/𝒎𝟐 𝑪 This is acceptable compared to the assumed value
101.564−100
Error = *100 % = 1.5%
101.564

4.7- Pressure drop

4.7.1- ΔPt (Pressure drop in tube side) calculation :

ΔPt = Np (8 Jf (L / di ) (μ/μ w)-0.14 + 2.5 ) * (ρ * u2 / 2 )

Where :

Np: number of passes tubes ( 2 )

ρ :density of Water in tube side ( 971 kg/m3 )

u: velocity inside tubes (0.037 m/s)

di: inside diameter ( 0.023 m)

L : length of tube ( 3.66 m )

Jf : friction factor ( 8 * 10-3 )

μ : Viscosity of liquid iside the tube (water)

μw : Viscosity of water

→ (μ/μ w)-0.14 = 1
ΔPt = 2 ( 8 * 7 * 10-3 ( 3.66/ 0.023 ) + 2.5 ) ( 971∗ 0.037𝟐 /2 )

= 15.2331 N/m2 = 0.0152331 KN/m2 = 2*10-3 psi

4.7.2-ΔPt (Pressure drop in shell side) calculation :

ΔPt = 8* Jf ( L / IB )( Ds / de )( ρ*us 2 /2 ) ( μ / μw)-0.14

Where :

ρ :density of Glaucous solvent in shell side ( 1382.2 kg/m3)

u : velocity inside the shell ( 0.12227 m/s)

Ds = shell diameter ( 0.361 m )

de: Equivalent diameter(0.01805 m)

L:length of tube (4.88m)

IB: Baffle spacing( 0.2559 )

Jf: friction factor ( 5 * 10-2 ) from figure 12.30 for Re = 6277

ΔPt =8*(5 * 10-2)( 3.88/0.2559)( 0.652/ 0.014)(1382.2*0.122272)/ 2

ΔPt =4189.65 N/m2 = 4.18965 kN/m2 = 0.608 psi

4.8- Mechanical Design

(Vol.6 page 812 table (13-2))

e: shell thickness (mm)

Pi: maximum working pressure (8 bar )

 Ds: Shell diameter (0.361 m)

S: Maximum allowable working stress for carbon ( 123

N/mm2 )

E: welded efficiency ( 1 )

C : corrosion allowance (2mm) for carbon steel

the maximum working pressure is 8 bar

Pi= 8 bar *1.1 = 8.8 bar =0.88 N/mm2

Maximum allowable working stress (at maximum

temperature=110 ºC)

a. Shell thickness (cylindrical):

e = ( 0.88 * 0.361 * 1000) / (2*123*1 – 1.2*0.88) +2 = 3.297 mm

b. Head thickness (Ellipsoidal):

e = ( 0.88 * 0.361 * 1000) / (2*123*1 – 0.2*0.88) +2 =3.292 mm

C- Diameter of Input and output shell :

m = 3174 Kg/hr , ρ = 1382.2 Kg/m2 , u = 0.12227 m/s

𝑚 () 0.88
𝑉𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖c Fiowrate = = =0.00064 m3/s
𝜌 1382.2

A = 𝑉𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖c Fiowrate / u =0.00064/0.12227= 5.2*10-3 m2

A= (3.14 /4 )*d2 → d= 0.0814 m = 81.4 mm

D- Diameter of Input and output tube :

m = 0.23952 Kg/s , ρ = 971 Kg/m2 , u = 0.12227 m/s

𝑚 (𝑤𝑎𝑡𝑒𝑟) 0.23952
𝑉𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖c Fiowrate = = =0.00030667 m3/s
𝜌 971

A = 𝑉𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖c Fiowrate / u =0.00030667/0.037 = 8.3 *10-3 m2

A= (3.14 /4 )*d2 → d= 0.103 m = 103 mm