INDEX

Sr. No.

PARTICULARS

Title of the project

Objective of the study

Rational for Study

Detailed methodology to be used for carrying out the study

The expected contribution from the study

List of activities carried out to complete the project

Activity bar chart showing the time schedule to complete the project

Places/labs/equipments and tools required and planning of arrangements

Problems envisaged in carrying out the project, if any

PAGE NO.

FORMAT OF SYNOPSIS
1. Title of the project:
DESIGNING OF A 1-1 PASS SHELL AND TUBE HORIZONTAL CONDENSER
2. Objective of the study:
Waste management facilities, Bhabha Atomic Research Center, Mumbai is to manage various types of Radioactive
waste generated during the different types of processes. In my plant, High Level Waste (HLW) is treated by
concentrating it in an evaporator and then vitrified it to glass matrix by using induction furnaces. This HLW in glass
matrix will be stored safely for further surveillance.
Main objective of the concentration of HLW is the reduction of liquid volume to reduce the heat load of induction
furnaces. Concentration of fresh high level waste is carried out in a thermosyphon evaporator. This consists of
evaporator feed tank, thermosyphon evaporator, fractionator, condenser and condensate collection tank.
Vapours generated from evaporator goes to fractionator. Fractionator is used to separate HNO 3 from water vapour.
Fractionator is basically a distillation column packed with SS pall rings. The vapour leaving the thermosyphon
evaporator is fed to the fractionator, where they are separated to two streams. Top product is 0.01 molar acid vapours
whereas bottom product is concentrated acid of about 5.5 molar nitric acid.
This top product of 0.01 molar HNO 3 - H2O vapour is condensed in a 1-1 pass shell and tube condenser. This
condensate will be collected in a condensate collection tank.
The objective of this project is to study and design a 1-1 pass shell and tube heat exchanger to condense the 0.01
molar HNO3 H2O vapours by using demineralised water.
3. Rational for Study:
To achieve systematic approach to understand the heat exchangers, selection criterion, to select a most suitable heat
exchanger for a specific requirement with its thermal design by using Kerns method.
Thermal design of a compact and economic heat exchanger for the process conditions defined in the objective of the
study shall be carried out a project work.
4. Detailed methodology to be used for carrying out the study:
The main objective of this study is to prepare report on the heat exchanger i.e. study, selection and thermal design of
1-1 pass horizontal condenser. The project report shall cover necessary theoretical background for heat exchangers,
selection criterion, selection and thermal design of heat exchanger for the condensation of the 0.01 molar HNO 3 - H2O
vapours. The Kerns method for heat exchanger design shall be followed to complete the project work.
This study will contain theoretical background for the objective of the study i.e. study of the heat exchangers,
selection criterion, selection of the heat exchanger for a specific requirement, and thermal design of the selected heat
exchanger for the specific requirement as specified in the objective of the study.
5. The expected contribution from the study:
This study will be provide systematic approach to study and thermal design of 1-1 pass shell and tube horizontal
condenser.
This study can be used as a preliminary training manual on heat exchanger design in the industries and education
institutions.
6. List of activities carried out to complete the project:
The following table is the approximate time required for completion of project
Sr. No. Activity

Time duration(Days)

Literature survey

Study of literature

Preliminary design

Final design and optimisation

Preliminary project report preparation

Final report preparation

Report submission and dispatch

7. Activity bar chart showing the time schedule to complete the project:

Report submission and dispatch

Final report preparation
Preliminary project report preparation
Final design and optimisation

Individual activity
Total

Preliminary design
Study of literature
Literature survey
0

10

20

30

40

50

8. Places/labs/equipments and tools required and planning of arrangements:

Library in the Bhabha Atomic Research Centre (BARC). Waste Management Division ,BARC , Other resources used
are,
1. Personal computer
2. Internet
3.Technical Books
Perry's handbook for Chemical engineers
Richardson & Coulson's Chemical Engineering,Volume-6
Process Heat Transfer by D.Q.Kern

9. Problems envisaged in carrying out the project, if any:

During the study and design of the condenser preliminary assumption of overall heat transfer coefficient and fouling
factor for the process streams may be suitably justified with source of assumed data.

Submitted by
ASHOK S. JADHAV
ST-633024-5

Approved by
SUDHIR H. ABHYANKAR
(Project guide)

Designing of 1-1 pass shell and tube horizontal condenser

This condenser is used to condense the 0.01molar 0.01 molar HNO3 H2O hot vapours coming from fractionator by
using De-mineralised water.
This condenser is a 1-1 pass horizontal shell and tube heat exchanger in which cooling water is in tube side and 0.01
molar HNO3 H2O hot vapours are in shell side.
Assumptions and considerations
1. For simplification steam at atmospheric pressure is considered as the hot fluid in place of 0.01 molar HNO 3 H2O
vapours. Physical and thermal properties of 0.01 molar HNO3 vapour is found to be approximately matching with
that of water vapour.
2. SS304L has a better compatibility with acidic radioactive environment. Hence this is considered as MOC for this
condenser.
3. No consideration is given for sensible heat part. That is only latent heat of condensation of heating media is
available.
Data available for hot fluid
1. Inlet temperature of the hot fluid(T1) = 3730K
2. Outlet temperature of the hot fluid(T2) = 3730K
3. Mass flow rate of the hot fluid = 550kg/hr = 0.1528 kg/sec
4. Latent heat of the hot fluid at 1000C = 2256.9 KJ/kg
5. Density of the hot fluid = 0.59kg/m3
6. Viscosity of the hot fluid = 0.000012 kg/m.sec
Data available for cold fluid
Mean temperature of the water = (30+40)/2 = 350C
1. Inlet temperature of the cold fluid(t1) = 3730K
2. Outlet temperature of the cold fluid(t2) = 3730K
3. Specific heat of water at 350C = 4.1725 KJ/kg
4. Thermal conductivity of water at 350C = 0.58 W/m.0K
5. Density of water at 350C = 995 kg/m3
6. Viscosity of water at 350C = 0.000719 kg/m.sec
Heat balance for Heat Exchanger
Mass flow rate of the hot fluid (M) = 0.1528 kg/sec
Latent heat of the hot fluid () = 2257KJ/kg
Heat given out by hot fluid during condensation = M.
= 0.15282257 x 103
= 344869.6 W
Heat given out by hot fluid during condensation = Heat taken by cooling water
M. = m.Cp.T
344869.6 = m x 4.1778103 x10
m= 8.255kg/sec
Mass flow rate of the cooling water through tube = 8.255 kg/sec
Calculation of LMTD

Temp

Distance
T1 = 1000C, T2 = 1000C , t1 = 300C, t2 = 400C
T1 = (100 30) = 700C
T2 = (100 40) = 600C
LMTD = ( T1 - T2 ) / ln ( T1 / T2 )

= (70 60) /ln 1.1667

= 64.870C
As the shell side fluid almost condensing steam and tube side fluid is DM water,an overall heat transfer coefficient
(UD) of 2500 W/m2.0K is assumed
Q= U.A. T
A= 344869.6 / (250064.87)
Surface heat transfer area AS = 2.1265 m2
Calculation of number of tubes required
Considering following dimensions during selection of tubes
Length of tube = 1.0 m
Outside diameter of tube = 19.05mm(3/4'')
Inside diameter of tube = 14.83 mm
Thicknes of tube = 2.1 mm (14BWG)
Length of the exchanger is decided by considering space availability inside the radioactive cell.
Surface area available per tube = n x D x L
= 3.1420.019051
= 0.0598 m2
Total surface area of the tube = N x n x D x L
= 2.213m2
Corrected UD
= 34486936 / (2.21364.87)
= 2402 W/m2.oK
Calculation of velocity through tubes
Volumetric flow rate = 8.25 / 995 = 8.2910-3 m3 /sec
Cross sectional area per tube = n x d2 /4 = 1.72610-4 m2
Total cross sectional area of tube = 1.72610-4 m237 = 6.387810-3 m2
Flow velocity through the tube = Volumetric flow rate / Total cross sectional area of tube
= 8.2910-3 / 6.387810-3
= 1.2978 m/sec
Calculation of Tube side heat transfer coefficient (hi)
Mean water temperature = (40+30)/2 = 35oC
N Re = (D.u.)/ = (0.014831.2978995) / 0.000798
=23997.67
as N Re = is greater than 2100, flow inside the tube is turbulent
N Pr = Cp. / k = (4.17751000 x 0.000798) /0.58
= 5.748
Dittus bolter equation for the calculation of heat exchanger coefficient
(hi x Di) / k = 0.023 x (N Re)0.8 x (N Pr)0.4
(hi x Di) / k = 0.023 x (23997.67)0.8 x (5.748)0.4
Tube side heat transfer coefficient (hi) = (147.798 x 0.58) / 0.01483
= 5780.38 W / m2.oK
Calculation of Shell side heat transfer coefficient (ho)
Choosing a baffle spacing of 0.5 tinmes of the shell diameter
Baffle spacing = Ds x 0.5 = 203.1 x 0.5 = 101.6 mm
Tube pitch = 1.25 x tube outside diameter
= 1.25 x 19.05 = 23.81 mm
Cross flow area = [(Pt-Do) x Ds x B] / Pt
= [(23.81-19.05) x 203.1 x 101.6] / 23.81
= 4.127 x 10-3 m2
Mass velocity through shell (Gs) = mass flow rate / cross flow area
= 0.1528 / 4.127 x 10-3
= 37.02 kg/m2.sec
Equivalent diameter (De) = 4 x [0.5 Pt x 0.87 Pt 0.5n(do)2 / 4] /n.do
(for triangular pitch) = 1.27/19.05 x [(23.80)2 0.785(19.05)2]
= 18.80 mm
Average heat transfer coefficient of shell side fluid condensing on horizontal tube bundle can be calculated from the
equation
ho = 0.725 x [k3. 2.g. / n.Do. . T]1/4
Calculation of wall temperature (Tw)
Assuming a heat transfer coefficient of 10000 W/m2.oK on shell side
Shell side mean temperature = 100oC
Tube side mean temperature = (40+30) / 2 = 35oC

Then we know
(100 Tw) x 10000 = (100 35) x 2402
Tw = 84.38 oC
Mean temperature of the condensate = (100 + 84.38) / 2 = 92 oC
Physical properties of condensate at 92 oC
K = 0.8 W/m.oK
= 962 kg/m3
= 0.000297 kg/ m.sec
= 2263 KJ/kg
Do = 0.01905 m
ho = 0.725 x [k3. 2.g. / n.Do. . T]1/4
= 0.725 x [(0.6)3 x (962)2 x 9.81 x 2263 x 1000 / 0.000297 x 0.01905 x 15.62]1/4
Shell side heat transfer coefficient (ho) = 10825.86 W/m2.oK
Assumed and calculated h are approximately same so no need of Tw correction is required
Calculation of overall heat transfer coefficient
1
= 1 + 1 x Do + Xw x Do
Uc
ho
hi
Di
K
Dw
1
Uc

1
+
1
x 0.01905 + 0.0021 x 0.01905
10852.86
5780.38
0.01483
54
0.01685
= 2792.457 W/m2.oK
Clean overall heat transfer coefficient (Uc) = 2792.457 W/m2.oK
Calculation of design heat transfer coefficient (UD)
Considering a shell side fouling factor (RDS) 0.0005 m2.oC / W for steam condensate and tube side fouling factor (R Dt)
0.0003 m2.oC / W for cooling water
RD = RDS + RDT
= 0.0003 + 0.0005
= 0.0008 m2.oC / W
1/ UD = (1 / UC) + RD
= (1 / 2792.457) + 0.0008
= 3490 W/m2.oK
Design heat transfer coefficient (UD) = 3490 W/m2.oK
Calculation of design heat transfer area
Q= U.A. T
A = 344869.6 /(349064.87)
= 1.523 m2
Total surface area of the tube = N x n x D x L
1.523 = 373.142 x 0.01905 x L
Length of the tube required = 0.688 m 0.7 m
Calculation of tube pressure drop
Pt = 8 Jf [(L/Di) x ( / w ) + 2.5] x (.Ut2 / 2)
Where
Pt = Pressure drop inside the tube
L = Length of the tube
Di = Inside diameter of the tube
Ut = Velocity of fluid through tube
= Density of tube side fluid
Jf = Friction factor
Reynold's number = 23997.67
Corresponding Jf from graph = 3.2510-3
Pt = 83.25 x 10-3 [(1000/14.83) + 2.5] x (995 x (1.2978)2 / 2]
= 3563.88 N/m2
= 3.56 Kpa
Tube side pressure drop = 3.56 Kpa
Calculation of shell side pressure drop
Ps = 8 Jf[(Ds/De) x (L / B )] x (.Ut2 / 2)
Ps = Pressure drop inside the shell
L = Length of the tube
Ds = Inside diameter of the shell
De = Equivalent diameter
Ut = Velocity of fluid through shell
= Density of tube side fluid
Jf = Friction factor

B = Baffle spacing
Reynold's number = 57998
Corresponding Jf = from graph for shell side with 45% cut segmental baffles = 5.7510-2
Ps = 85.7510-2 [(203.2/18.80)] x (1000 / 101.6)] x (962 x (0.038)2 / 2)
= 34.8 N/m2
Shell side pressure drop = 34.8 N/m2
Final results
Function

1 1 pass Shell and Tube Horizontal Condenser

Heat duty

344869.6 W
1.523 m2

Heat Transfer Area

3490 J/m2.oK

Design overall heat transfer coefficient

Fluid
Flow rate

Shell

Tube

0.01 molar HNO3 H2O

vapour

De-mineralised water

550 kg/hr

8.753 kg/sec

Temperature In

100 C

30 oC

Temperature Out

100 oC

40 oC

Material Of Construction

SS304L

SS304L

One

One

Passes

Tube Details
Numbers
Size
Thickness
Length
Pitch
Shell Diameter
Shell Length

37 tubes
19.05 mm OD
2.11 mm
0.7 m
23.81 mm (triangular)
203.1 mm
0.9 m

Conclusion
1. This heat exchanger is designed to perform effectively in a corrosive environment of 0.01 molar HNO3 H2O
vapours.
2. As condensing steam is a non-fouling fluid which is used in shell side, this condenser is used triangular pitch
arrangement of tubes to get better heat transfer coefficient.
3. De-mineralised water is used as the cooling water inside the tubes.
4. As the pressure drop is low in shell side, this condenser can be used for more range velocity of shell side fluid.
5. Length and diameter of the heat exchanger is limited to approximately 0.7 m and 0.203 m respectively. This is due
to the space availability of sophisticated radioactive cell.
6. SS304L has better compatibility with acidic radioactive environment. Hence this is considered as MOC for this
condenser.
7. Fixed heat type shell and tube heat exchanger is used to avoid moving parts and to reduce the maintenance in
radioactive plant.
Scope of future study
My study on the designing of 1 1 pass horizontal condenser will help the plant to utilize this data to install a new
heat exchanger in the upcoming modification of the plant. This horizontal condenser is designed based up on the data
of upcoming modifications. So this can be installed on the top of the fractionating column to condense the hot
vapours coming out of fractionating column. This will give me an opportunity to understand its working and will help
me to give some suggestions if required to improve the performance.
MOC used in designed horizontal condenser is SS304L which has a better compatibility with acidic radioactive
environment. This can be evaluated in the future performance of the condenser and if any modifications of MOC are
required that can be done in future based on its performance.
INTRODUCTION
1.1 Process Heat transfer

Heat transfer has been described as the study of the rates at which heat is exchanged between heat sources
and receivers usually treated independently. Process heat transfer deals with the rates of heat exchange as they occur
in the heat transfer equipment of the engineering and chemical processes.
Mechanism of heat transfer
There are three distinct ways in which heat may pass from a source to a receiver, although most engineering
applications are combinations of two or three. These are Conduction, Convection and Radiation.
Conduction : Conduction is the transfer of heat through fixed materials such as a metallic wall. Although heat
conduction is usually with heat transfer through solids, it is also applicable with limitations to gases and liquids.
If 't' is the temperature at any point in the wall and 'x' is the thickness of the wallin the direction of the heat flow,the
quantity of heat flow dQ is given by
dQ = kA(-dt/dx) Watt
Where, dt/dx is the temperature gradient.(Negative sign indicates t is higher at x = 0 and lesser at x = X)
k = Proportionality constant, thermal conductivity(peculiar to conductive heat transfer)
A = Area
Convection
Convection is the transfer of heat between relatively hot and cold portions of a fluid by mixing. The transfer of heat
through adjacent layers from hot to cold portion due to density difference owing to thermal expansion is a natural or
free convection. If any other agitation occurs such as that produced by a stirrer, it is forced convection. This type of
heat transfer may be described in an equation ,which imitates the form of the conduction equaton and is given by
dQ = h.A.dt
where h = heat transfer coefficient
In the integrated form,dQ = h.A.dt; Newtons law of cooling
Radiation
Radiation involves the transfer of radiant energy from a source to a receiver. When radiation issues from a source to
receiver, part of the energy is absorbed by the receiver and part reflected by it. Based on second law of
thermodynamics,Boltzmann established that the rate at which a source gives of heat is;
dQ = ..dA.T4 Fourth power law
where T = absolute temperature
= dimensional constant
= emissivity (peculiar to radiation)
The transfer of heat to and from process fluids is an essential part of most of the chemical processes. Therefore, Heat
Exchangers are used extensively and regularly in process and allied industries and are very important during design
and operation. A heat exchanger is the device that is used to transfer thermal energy (enthalpy) between two or more
fluids, between a solid surface and a fluid or between solid particulates and a fluid at different temperatures. A heat
exchanger consists of heat transfer elements such as a core or matrix containing the heat transfer surface and fluid
distribution elements such as headers, manifolds, tanks ,inlet and outlet nozzles or pipes or seals.
Not only are heat exchangers often used in the process, power, petroleum, transportation, air-conditioning ,
refrigeration, cryogenic, heat recovery, alternative fuel and manufacturing industries. They also serve as key
components of many industrial products available in the market place.
HEAT EXCHANGERS
Heat transfer equipment is defined by the function it fulfils in a process. Exchangers recover heat between two
process streams. Steam and cooling water are utilities and are not considered in the same sense as recoverable process
streams. Heaters are primarily used to heat process fluids, and steam is usually employed for this purpose. Coolers are
employed to cool the process fluids, water being the main cooling medium. Condensers are coolers whose primary
purpose is the removal of latent heat instead of sensible heat. The purpose of reboilers is to supply the heat
requirements of a distillation process as latent heat. Evaporators are employed for the concentration of a solution by
the evaporation of water. If any other fluid is vaporised besides water the unit is a vaporiser.
Counter flow and parallel flow
For a system of two concentric pipes when the annulus fluid and pipe fluid travels in opposite directions along a pipe,
they are in counterflow. When the two fluids travels in the same directions, they are in parallel flow.
Overall coefficient of Heat Transfer
Consider two concentric pipes in which two streams each having a particular film coefficient and whose temperature
vary from inlet to outlet. The inner pipe being very thin, the resistances encountered are the pipe fluid- film
resistance, the pipe wall resistance Lm/Km and the annulus fluid-film resistance. Since Q = T/ R
where R = 1 + Lm + 1
Overall resistances
hi
Km
ho
1 =
1
+ 2.3Do log Do + 1
U
hi(Ai/A)
2Km
Di
ho
where U = Overall coefficient of heat transfer
A = Outside area of inner pipe
Ai = Inside area of inner pipe
1 =
1
+ 2.3Do log Do + 1
U
hi(Ai/A)
2Km
Di
ho

The integrated study state modification of Fourier's general equation may then be written as Q = UA t where t =
temperature difference between the two streams for the entire surface A.
For simplification, the thin metal pipe wall resistance is negligible, hence
1 =
1
+ 1
U
hi(Ai/A)
ho
Fluids flowing in Annuli : The Equivalent Diameter
When the fluid flows in a conduit having other than a circular cross section, such as an annulus, it is convenient to
express heat transfer coefficients and friction factors by the same types of equations and curves used for pipes and
tubes.
The equivalent diameter is four times the hydraulic radius and the hydraulic radius is in turn the radius of the
pipe equivalent to the annulus cross section
De = 4rh = 4 x flow area
= 4 (D22 -D12) = D2-D1
wetted perimeter
4 (D2 -D1)
Fouling factors
The overall coefficient for the heat transfer required to fulfil the process conditions may be determined from the
Fourier's equation when the surface A is known and Q and t are calculated from the process conditions. Then U =
Q / A t. If the surface is not known U can be independently obtained from the Fourier's equation from the two film
coefficients
1 = Rio + Ro = 1 + 1
U
hio
ho
or U = hio.ho
hio + ho
When U is obtained from values h io and ho and Q and t are calculated from the process conditions, the surface A
required for the process can be computed. The calculation of A is known as design.
When heat transfer apparatus has been in service from sometime, however dirt and scale deposite on the inside and
outside of the pipe, adding two more resistances than were included in the calculation of U. The additional resistances
reduces the original value of U and the required amount of heat is no longer transferred by the , original surface A, T2
rises above and t2 falls below the desired outlet temperatures although h i and ho remain substantially constant. To
overcome this resistance Rd called the dirt, scale or fouling factor or resistance is introduced.
Rd = Rdi + Rdo
where Rdi = dirt factor for inner pipe fluid
Rdo = dirt factor for outer pipe fluid
1 = 1 + Rdi + Rdo
UD
UC
where UD = design or dirty overall coefficient
UC = clean overall coefficient
1 = 1 + Rd
UD
UC
If t is calculated from observed temperatures instead of process temperatures then Fourier's equation Q = U D. A. t
may be used to determine Rd for a given fouling period.
Rd = 1
1
UD
UC
Rd = UC - UD
UC.UD
When Rd (deposited) > Rd (allowed), as after a period of service, the apparatus no longer delivers a quantity of heat
equal to the process requirements and must be cleaned.
Shell and Tube type Heat Exchanger
The fulfilment of many industrial services requires the use of a large number of double pipe hairpins. These consumes
considerable ground area and also entail a large number of points at which leakage may occur. Where large heat
transfer surfaces are required, they can best be obtained by means of shell and tube equipment.
The simplest type of heat exchanger is the fixed or stationary tube sheet exchanger. The essential parts are a shell (i)
equipped with two nozzles and having tube sheets (ii) at both ends which also serve as flanges for the attachment of
the two channels (iii) and their respective channel covers (iv) the tubes are expanded into both tube sheets and are
equipped with transverse baffles (v) on the shell side.
Tubes and Tubes sheets
Tubes are drawn to definite wall thickness in terms of BWG and true outside diameter (OD) and they are available in
all common metals. Tubes are arranged on triangular or square pitch. Unless the shell side tends to foul badly,
triangular pitch is used because more heat transfer area can be packed into a shell of given diameter than in square
pitch. Tubes in triangular pitch cannot be cleaned by running a brush between the rows because no space exists for
cleaning lanes. Square pitch allows cleaning of the outside of the tubes. Also square pitch gives a lower shell side
pressure drop than triangular pitch.
Shell and Baffles
It is apparent that higher heat transfer coefficients result when a liquid is maintained in a state of turbulence. To

induce turbulence outside the tubes it is customary to employ baffles which cause the liquid to flow through the shell
at right angles to the axes of the tubes. This causes considerable turbulence even when a small quantity of liquid
flows through the shell.
The distance between the baffles (centre to centre) is the baffle pitch, or baffle spacing. It should not be less than the
inside diameter of the shell.
Tubes are usually attached to the tube sheets by grooving the holes circumferentially and rolling the tube ends into the
holes by means of a rotating tapered mandrel, which stresses the meal of the tube beond the elastic limit so the metal
flows into the grooves. In high pressure exchangers, the tubes are welded or brazed to the tube sheet after rolling.
Shell side film coefficientsThe heat transfer coefficient outside tube bundles are referred to as shell side coefficients.
The higher transfer coefficients results from the increased turbulence. When the pressure drop and cleanability are of
little consequence,triangular pitch is superior for the attainment of higher shell side film coefficients due to higher
urbulence. In addition to the effects of the baffle spacing, the shell side coefficient is also affected by the type of pitch
, tube size, clearance and fluid flow characteristics. For values of R e from 2000 to 10,00,000 however the data are
closely represented by the equation,
ho.De = 0.36 (De.Gs /)0.55 (Cp. / k)1/3 ( / w)0.14
k
wherre ho = film coefficient
De = equivant diameter
Gs = shell side mass velocity
Shell side mass velocity
Gs = W/As lb/(hr) (ft2)
where As = shell side or bundle cross flow area given by
as = ID x C'.B ft2
PT x 144
where ID =inner diameter of tube
C' = clearance between tubes
PT = tube pitch
B = baffle spacing
Shell side equivalent diameter
For square pitch De = 4 x flow area
ft
wetted perimeter
or
de = 4 x (PT2 .do2 /4) in
.do
For triangular pitch
de = 4 x (1/2.PT x 0.86 PT 1/2..do2 /4) in
1/2..do