Design of condenser

Presentation Transcript
1. Introduction A condenser is a type of heat exchanger in which vapors are transferred into
liquid state by removing the latent heat with the help of a coolant such as water. Condensers may
be classified into two main types: 1. Those in which the coolant and condensing vapor are brought
into direct contact. 2. Those in which the coolant and condensate stream are separated by a solid
surface, usually a tube wall
2. Different types of the Condenser 1. Double pipe and multiple pipe 2. Plate Condensers 3. Air-
Cooled Condensers 4. Compact Condensers 5. Shell & tube type
3. DESIGN CALCULATIONS FOR CONDENSER Inlet temperature of the process stream T1 = 45 o C
Outlet temperature of the process stream T2 = 45 o C Inlet temperature of the water t1 = 25 0 C
Outlet temperature of the water t2 = 40 o C Mass flow rate of the process stream m = 8060
Kg/hr Enthalpy of Vapors of Process Stream = 1940 KJ/Kg Removed 1 T2 = 45 o C t1= 25 o C t2 =
40o C T1 = 45 o C Condenser
4. Heat Load: Q = m (1) Q = 4343 KW Mass flow rate of cooling water tC Q m p = = 68.9 Kg/sec Log
Mean Temperature Difference LMTD = (t2-t1)/ log (t2/t1) LMTD = 14.4o C Cp = 4.2 KJ / Kg.K
5. Assumed Calculations Assumed Value of Overall Coefficient UD = 1000 W/m 2 C True Mean
Temperature Difference Dimensionless Temperature Ratios R R = (T1-T2) / (t2-t1) = (45-45) / (40-25)
= 0 S S = (t2-t1) / (T1-t1) = (40-25)/ (45-25) = 0.75
6. From Literature the value of Ft is 1 tm = Ft x LMTD = 1 x 14.4 = 14.4 o C Heat Transfer Area = 301
m 2 Surface Area of single tube = 3.14 x 19 x 4.88 / 1000 = 0.292 m 2 No. of tubes = 301/.292 = 1030
Pitch Pt = 1.25 19.05= 23.8 mm tU Q A D =
7. Tube Bundle Diameter Db = d0 (Nt/K1)1/n1 = 19 (1030/0.158)1/2.263 = 920 mm No. of tubes in
centre row Nr = Db / Pt = 920 / 23.8 = 39 Shell Side Calculations Estimate tube wall temperature Tw
Assume condensing coefficient of 4250 W/m2 C (from literature) Mean Temperature Shell side =(
45+45) / 2 = 45 o C Tube side = (25+40) / 2 = 32.5 o C (45-Tw) x 4250 = (45-25) x 1000 Tw = 40.3 o C
8. Physical Properties Viscosity of the liquid L = 0.8 mNs/m2 Density of liquid L = 993 Kg/m3
Thermal conductivity kL = 0.571 W/m C Average M. Wt. of Vapors = 42.8 Density of vapor = 29 x
273 x 1/(22.4 x 1 x (273+42)) = 1.12 Kg / m3 Condensate loading on a horizontal tube h = m / L x Nt
= 8060 / 3600 x (4.88 x 1030) = 4.45 x 10-3 Kg/m s # of tubes in the vertical row Nr = 2/3 x 39 = 26
mm Heat transfer coefficient in condensation h0 = 0.95 x kL ( L x (L v ) g / (L x h)1/3 x Nr-1/6
= 4396.0 W/m2 C As our assumed value is correct so no need to correct the wall temperature
9. Tube Side Calculations Tube cross sectional area = 3.14 / 4 x (19 x 10-3 )2 x 1030 / 4 = 0.073 m2
Density of water at 30 0 C = 993 kg/m3 Tube velocity = m / (H2O x At ) = 68.9 / (993 x 0.073) =
0.95m/s Film heat transfer coefficient inside a tube hi = 4200(1.35+0.02 x t) Vt0.8 / di . 0 2 =
4809.67 W/m2 0 C From Literature take fouling factor as 6000 W/m2 0 C Thermal Conductivity of
the tube wall material Kw = 50 W/m0 C
10. Overall Coefficient 1/U0 = 1/ho + 1/hod + (d0 ln(d0/di))/2kw +d0/di x 1/hid +d0/di x 1/hi = 0.001
U0 = 1100.29 W/m2 0 C So assumed value is correct
11. Shell Side Pressure Drop For pull through floating head with 45% cut baffles From literature
clearance = 88 mm Shell internal diameter Ds = Db+88 = 1008 mm Cross flow area As = m2 A=
0.205 m2 Mass Velocity Gt = m / As = 8060 / (3600 x 0.205) = 10.92 Kg/s m2 Equivalent diameter de
= 1.27 (Pt2 -0.785d0 2 ) / d0 = 19 mm Viscosity of vapors = 0.009 mNs/m2 Reynolds No. Re = de
Gt / = 19 x 10-3 x 10.92 /0.009 x 10-3 Re = 23053
12. From literature jf = 0.029 By neglecting the viscosity correction factor Where Ds = dia of shell L =
Length of tubes lB = baffle spacing So = 765 N/m2 = 0.765 Kpa = 0.109 Psi
13. Tube side pressure drop Viscosity of water = 0.9 x 10-3 Ns/m2 Re = Vt di / = 0.95 x 993 x
16.56 x 10-3 / 0.6 x 10-3 = 26036 From literature jf = 0.0039 Where Np = No. of tube passes So Pt =
4119.8 N/m2 = 4.119Kpa = 0.59 psi Acceptable
14. hio = hi I.D/O.D hio = 4165.2 W/m2 0 C Clean Overall Coefficient: = 2138.7 W/m2 0 C Design
Overall Coefficient Calculated dirt factor Rd = 0.0005 D D UU UU R C C d = oio oio C hh hh U + =
15. SPECIFICATION SHEET CONDENSER Identification: Item condenser No. Required = 8 Function:
Condense vapors by removing the latent heat of vaporization Operation: Continuous Type: 1-4
Horizontal Condenser Shell side condensation Heat Duty = 4343 KW Tube Side: Fluid handled: Cold
Water Flow rate = 68.9 Kg/sec Pressure = 14.7 psia Temperature = 25 o C to 40 o C Tubes: 0.75 in.
Dia. 1030 tubes each 16 ft long 4 passes 23.8 mm triangular pitch Pressure Drop = 0.59 psi Shell Side:
Fluid handled = Steam Flow rate = 8060 Kg/hr Pressure = 10 KPa Temperature = 45 o C to 45 o C
Shell: 39 in. dia. 1 passes Baffles spacing = 3.5 in. Pressure drop =0.109 psi Utilities: Cold water Ud
assumed = 1000 W/m 2 C Ud calculated =1100.97 W/m 2 C Rd = 0.0005
16. References Chemical Engineering Design Volume 6 by Coulson &v Richardsons Process Heat
Transfer by D.Q. Kern Plant Design & Economics for Chemical Engineers 5th Edition by Max S.
Peters, Klaus D. Timmerhaus, Ronald E. West Perrys Chemical Engineers Handbook by Robert H.
Perry, Don. W. Green