Design of Heat Exhangers

DO1
Design of Condenser
Design Parameters Conditions
Inlet Temperature of Process Stream, T1 50 °C
Outlet temperature of Process Steam, T2 50 °C
Inlet Temperature of cooling water, t1 22 °C
Outlet Temperature of cooling water, t2 26 °C
Mass flow rate of Process Stream, m 403.5265468 kg/s
Enthalpy at Inlet Condition of Stream, h 2285.955363 kJ/kg
Enthalpy at Outlet Condition of Stream, hf 209.33 kJ/kg
Enthalpy of Vapors Removed, ƛ 2076.625363 kJ/kg

Heat Load
Qr = m ƛ
Qr = 403.5265468 kg/s (2076.625363 kJ/kg)
Qr = 835896.8364 kW
Mass Flow Rate of Cooling Water
Qr
mw=
Cpw(t2-t1)
835896.8364 kW
mw=
4.187(26-24)
mw=49910.24817 kg/s
Log Mean Temperature Difference

(Tc -T1 ) - (Tc -T2 )

LMTD=
(T -T )
𝑙𝑛 c 1
(Tc -T2 )
where: T1 = Inlet temperature of cooling water
T2 = Outlet temperature of cooling water
(50-22)-(50-26)
LMTD=
50-22
ln
50-26
LMTD = 25.94863678°C

Calculations
From Tube Materials and Temperature Limits (Hewitt Table 6.1)
For Nickel-Chromium-Iron:
Tube Outside Diameter = 25mm
Overall Coefficient, U = 1880 W/m2 °C
True Mean Temperature Difference
Dimensionless Temperature Ratios

T1 -T2
R=
t2 -t1
50-50
R=
26- 22
R=0
Temperature Efficiency, P
T2 -t1
P=
T1 -t1
26-22
P=
50-22
P = 0.1428571429

Correction Factor of LMTD

From LMTD Correction Factor, Ft = 1
From Dimensionless Temperature Ratios Figure
MTD = Ft x LMTD
MTD = 1 x (25.94863678°C)
MTD = 25.94863678°C
Heat Transfer Area
Qr
A=
U(∆t)
835896.8364 kW
A=
1.880kW/m2 °C (25.94863678°C )
A = 17134.84915 m2

Surface Area of a single tube

Surface Area of a single tube = 3.14 x D x L
From Process Design of Heat Exchanger, NPTEL, Chemical
Engineering Design:
Assuming 1 shell pass and 2 tube pass shell and tube heat
exchanger,
Pitch Type: Fixed Tube Plate
Tube OD, mm: 25 mm
Tube Pitch: 1¼ in = 31.75 mm
 1m
Tube length: 16 ft x = 4.876562024 m
3.281 ft

Tube-size fluid: Cooling water

Substituting,
Surface Area of a single tube = 3.14 x 0.025m x 4. 876562024 m
Surface Area of a single tube = 0.3830042857 m2

Number of Tubes
Heat Transfer Area
Number of Tubes=
Single Area of Single Tube
835896.8364 m2
Number of Tubes=
0.3830042857 m2 / tube
Number of Tubes=44738.00691 tubes use 44739 tubes

Equipment Specifications
Surface Condenser
Heat Load: 45.6 MW
Condenser Design Pressure:

Type: Shell and Tube HE, Single flash, indirect contact, single shell

CW Flow quantity: 1119 kg/s

No. of CW Passes: 2

No. of tubes: 21787 Tubes

Tube Type: Carbon/High Alloy Steel

Tube Diameter: 19mm

Tube Length: 4.88m

Condenser Design Pressure: 0.005 Mpa

DO2
Design of Condenser
Design Parameters Conditions
Inlet Temperature of Process Stream, T1 50 °C
Outlet temperature of Process Steam, T2 50 °C
Inlet Temperature of cooling water, t1 22 °C
Outlet Temperature of cooling water, t2 26 °C
Mass flow rate of Process Stream, m 193.8252234 kg/s
Enthalpy at Inlet Condition of Stream, h 2775.5 kJ/kg
Enthalpy at Outlet Condition of Stream, hf 209.33 kJ/kg
Enthalpy of Vapors Removed, ƛ 2556.17 kJ/kg

Heat Load
Qr = m ƛ
Qr = 193.8252234 kg/s (2556.17 kj/kg)
Qr = 495450.2213 kW
Mass Flow Rate of Cooling Water
Qr
mw=
Cpw(t2-t1)
495450.2213
mw=
4.187(26-22)
mw = 29582.64995 kg/s
Log Mean Temperature Difference

∆t2 - ∆t1
LMTD=
∆t2
𝑙𝑛
∆t1
(33.151-20.4)-(33.151-30)
LMTD=
33.151-20.4
ln
33.151 - 30
LMTD = 6.867493951°C

Calculations
Value of Overall Coefficient, U = 1000W/m2 °C

True Mean Temperature Difference

Dimensionless Temperature Ratios

T1-T2
R=
t2-t1
33.151-33.151
R=
30 - 20.4
R=0
Temperature Efficiency, P
t2-t1
P=
T1-t1
 30-20.4
P=
33.151-20.4
P = 0.7528821269

Correction Factor of LMTD

From LMTD Correction Factor, Ft = 1

From Dimensionless Temperature Ratios Figure
MTD = Ft x LMTD
MTD = 1 x (6.867493951°C)
MTD = 6.867493951°C
Heat Transfer Area
Qr
A=
U(∆t)
52073.2786 kW
A=
1kW/m2 °C (6.867493951°C )
A = 7582.57495 m2

Surface Area of a single tube = 3.14 x D x L

From Table Tube Material and Temperature Limits Table, Hewit Table 6.1
Process Design of Heat Exchanger, NPTEL, Chemical Engineering Design
Pitch Type: Square
Tube OD, in: ¾ inch = 19 mm
Tube Pitch: 1 in = 25.4 mm
For Carbon/High Alloy Steel (400)
OD = 19 mm
Length of Tube = 4.88 m
Surface Area of a single tube = 3.14 x 0.019m x 4.88m
= 0.2911409 m2

Number of Tubes
Heat Transfer Area
Number of Tubes=
Single Area of Single Tube
7582.57495 m2
Number of Tubes=
0.2911409 m2 / tube
Number of Tubes=26044.34811 tubes use 26045 tubes
 Equipment Specifications
Surface Condenser
Heat Load: 52 MW
Condenser Design Pressure:

Type: Shell and Tube HE, Single flash, indirect contact, single shell

CW Flow quantity: 1295 kg/s

No. of CW Passes: 2

No. of tubes: 26045 Tubes

Tube Type: Carbon/High Alloy Steel

Tube Diameter: 19mm

Tube Length: 4.88m

Condenser Design Pressure: 0.005 Mpa

DO3
Design of Condenser
Design Parameters Conditions
Inlet Temperature of Process Stream, T1 33.151 °C
Outlet temperature of Process Steam, T2 33.151 °C
Inlet Temperature of cooling water, t1 20.4 °C
Outlet Temperature of cooling water, t2 30 °C
Mass flow rate of Process Stream, m 21.7253 kg/s
Enthalpy at Inlet Condition of Stream, h 2278.578312kj/kg
Enthalpy at Outlet Condition of Stream, hf 138.9548422 kj/kg
Enthalpy of Vapors Removed, ƛ 2139.623512 kj/kg

Heat Load
Qr = m ƛ
Qr = 21.7253 kg/s (2139.623512 kj/kg)
Qr = 46483.9671 kW
Mass Flow Rate of Cooling Water
Qr
mw=
Cpw(t2-t1)
 46483.9671
mw=
4.187(30-20.4)
mw=1156.455674 kg/s
Log Mean Temperature Difference

∆t2 - ∆t1
LMTD=
∆t2
𝑙𝑛
∆t1
(33.151-20.4)-(33.151-30)
LMTD=
33.151-20.4
ln
33.151 - 30
LMTD = 6.867493951°C

Calculations
Value of Overall Coefficient, U = 1000W/m2 °C

True Mean Temperature Difference

Dimensionless Temperature Ratios

T1-T2
R=
t2-t1
33.151-33.151
R=
30 - 20.4
R=0
Temperature Efficiency, P
t2-t1
P=
T1-t1
30-20.4
P=
33.151-20.4
P = 0.7528821269

Correction Factor of LMTD

From LMTD Correction Factor, Ft = 1

From Dimensionless Temperature Ratios Figure
MTD = Ft x LMTD
MTD = 1 x (6.867493951°C)
MTD = 6.867493951°C
Heat Transfer Area
 Qr
A=
U(∆t)
46483.9671 kW
A=
1kW/m2 °C (6.867493951°C )
A = 6768.694291 m2

Surface Area of a single tube = 3.14 x D x L

From Table Tube Material and Temperature Limits Table, Hewit Table 6.1
Process Design of Heat Exchanger, NPTEL, Chemical Engineering Design
Pitch Type: Square
Tube OD, in: ¾ inch = 19 mm
Tube Pitch: 1 in = 25.4 mm
For Carbon/High Alloy Steel (400)
OD = 19 mm
Length of Tube = 4.88 m
Surface Area of a single tube = 3.14 x 0.019m x 4.88m
= 0.2911409 m2

Number of Tubes
Heat Transfer Area
Number of Tubes=
Single Area of Single Tube
6768.694291 m2
Number of Tubes=
0.2911409 m2 / tube
Number of Tubes=23248.86092 tubes use 23249 tubes
Equipment Specifications
Surface Condenser
Heat Load: 46.5 MW
Condenser Design Pressure:

Type: Shell and Tube HE, Single flash, indirect contact, single shell

CW Flow quantity: 1157 kg/s

No. of CW Passes: 2

No. of tubes: 23249 Tubes

Tube Type: Carbon/High Alloy Steel

Tube Diameter: 19mm

Tube Length: 4.88m

Condenser Design Pressure: 0.005 Mpa