4.

Perancangan HE Tipe Recuperator

4.1 Tujuan perancangan
 menentukan luas area kontak perpindahan panas A

 menghitung laju perpindahan panas yang dipertukarkan, Q
 memperkirakan hilang tekan pada masing - masing aliran
4.2 Luas area kontak perpindahan panas
 Temperatur operasi berupa temperatur fluida pemanas dan
dipanaskan masuk dan keluar HE, Thi , Tho , Tci , Tco
 Beda temperatur perpindahan panas didifinisi kan dari temperatur operasi
di atas dalam bentun beda temperatur logaritmik atau log - mean temperature
difference yang disimbulkan oleh TLMTD
 Konfigurasi aliran kedua fluida berbentuk aliran searah, berlawanan arah dan silang
 Untuk aliran silang, korekasi TLMTD perlu dikoreksi dengan
faktor ε st dari TLMTD aliran berlawanan arah
 Koeffesien perpindahan panas total U harus dievaluasi secara tepat dan akurat
 Luas area kontak A ditentukan dari hubungan :
Q
A
Uε st TLMTD

1
4.3 Koeffisien perpindahan panas total U
 Permukaan kontak untuk perpindahan panas diwujudkan
umumnya dengan penggunaan tubes
 Luas area kontak ini didasarkan atas salah satu area permukaan
dalam tube A i , atau area permukaan luar tube A o atau area
atas dasar diamater rata - rata tube A m
 Koeffisien perpindahan total U yang digunakan untuk salah satu
dasar area di atas dinyatakan sebagai U i bila A i yang dipakai atau
U o untuk A o atau Um untuk A m

 ,Q
4.4 Laju panas yang dipindahkan, Q  ,Q

h c
 Fluida pemanas mengalir dengan laju alir massa m
 h memberikan panas
ke fluida yang dipanaskan sebesar
Q  m  h  h  , h adalah entalpi fluida pemanas, indek i dan o
h h hi ho h
menyatakaninlet dan outlet
 Fluida yang dipanaskan dan mengalir dengan laju alir massa m
c
akan menerima panas pada laju : Q  m  h  h 
c c co ci
2
 Bila semua panas yang dilepaskan oleh fluida pemanas
diterima oleh fluida yang dipanaskan maka : Q  Q  Q
h c
 Jika masing - masing fluida tidak mengalami perubahan fasa,
laju panas yang dipindahkan dinyatakan oleh persamaan
m h  c ph   Thi  Tho   m c  c pc   Tco  Tci 
 Fluida yang dipanaskan mengalami perubahan fasa dari subcool
ke uap jenuh, maka Q  m  h  h   m  c   T  T   m h
c c co ci c plc bc ci c vc
 Fluida yang didinginkan mengalami perubahan fasa dari
superheated vapour ke saturated liquid
Q  m  h  h   m  c   T  T   m h
h h hi ho h pvh hi bh h vh

3
4
5
4.5 Luas area perpindahan untuk U yang berubah
 Koeffisien perpindahan panas konveksi dapat
bervariasi dengan temperatur yang memberikan
nilai koeffisien perpindahan panas gabungan U
juga fungsi temperatur
 Neracan energi tanpa perubahan fasa :
mc  c pc   Tco  Tci   m h  c ph   Thi  Thc 
 Tco  Tci   Tc  mh  c ph 
 Thi  Thc  Th mc  c pc 
 Perbedaan temperatur fluida pemanas dan fluida yang
dipanaskan T  Th  Tc ,
  UA T  T  atau
 Persamaan perpindahan panas : Q h c
per elemen dA : dQ  UTdA dan dintegrasikan
A
menghasilkan Q   U  Th  Tc dA 6
0
   UAT
 Apabila U konstan maka Q LMTD ,
A
1
TLMTD    Th  Tc  dA
A0
 Hubungan neraca energi dengan koeffesien
 h c phdTh  U  Th  Tc  dA
 c c pc dTc  m
perpindahan panas : m
 Luas area perpindahan dinyatakan oleh :
Thi Tco
m
 h c phdTh m
 c c pc dTc
A  U  Th  Tc    U  Th  Tc 
Tho T ci

7
4.6 Faktor koreksi TLMTD konfigurasi silang
 Ratio kapasitas (R) dari sebuah HE didifinisikan
Thi  Tho Th
R 
Tco  Tci Tc
 Kefektifan sebuah HE (P) dinyatakan oleh :
Tco  Tci Tc
P 
Thi  Tci Tmax
 Faktor koreksi TLMTD ,  st untuk aliran silang
dinyatakan oleh :  st  f  P , R, tipe HE 
yang diberikan pada gambar - gambar berikut

8
t’2=Tci
t”2=Tco
t’1=Thi
t”1=Tho

9
10
11
12
13
14
15
16
17
18
19
20
 Example 2.1
Determine the heat transfer surface area of an apparatus where hot oil (5kg/hr) is cooled from 100 oC to 30 oC using cold oil,
which is heated from 20 oC to 45 oC. The heat capacity of both fluids is C = 0.4 kcal/kg oC. The heat transfer coeffecient area :

Temperature of hot fluid, ThoC 100 80 60 40 30

Heat trasfer coefficient 350 330 300 250 200

U, Jcal/m hr C
2 o
1
Eq.(2.42) is used to determine the heat transfer area. For graphical intergration of this equationt, a plot is made of
U  Th  Tc 
Vs.t1. eq.(2.17)is then used to determine the cold fluid temperatures T c corresponding to the different Th values:
 h  c ph 
m
Tco  Tci   Thi  Tho 
 c  c pc 
m
and
m h  c ph  Tc 45  20
   0.375
 c  c pc 
m Th 100  30
Consequently,
Tc = 45 – 0.357 (100-Th)
Calculationts for the different temperatures are given in the table
Th ,oC Tc,oC Th-Tc U 1
m 2 hr  C / Kcal
Kcal/m hr C
2 o
U  Th  Tc 

100 45.0 55.0 350 0.52 x 10 -4

80 37.9 42.1 330 0.72 x 10 -4
60 30.7 29.3 300 1.14 x 10 -4
40 23.6 16.4 250 2.44 x 10 -4
30 20.0 10.0 200 5.00 x 10 -4

21
Using this data, the graph is constructed (fig.2.2), asssuming these scales: along the x-axis 1 o = 0.4 mm and along the
y-axis 1 x 10-4 m2hr/Kcal = 8 mm; therefore, the unity of integrand value corresponds to 0.4 x 8 x 10 4 = 3.2 x 104 mm2.
using planimeter around the dashed area (fig.2.2) the area is foud to be 312 m 2, consequently,
100 2 o
dTh 312  4 m hr C
 
U  Th  Tc  3.2  104
 97 .5  10
Kcal
30

the average ordinate is 11.1 mm, which correspons to an average heat flux q = U (T h –Tc ) = 7200 Kcal/m2hr. Using eq.
(2.24), the heat transfer area is calculated to be:
A = 500 (.4) (97.5 x 10-4) = 19.5 m2

22
Example 2.2. The heat of the residu in a unit is used to heat the feed for the same unit. The temperature of the residu
changes from t1‘ = 350 oC to t2“ = 150 oC and the temperature of the feed from t2‘ = 20 oC to t2“ = 120 oC .
Determine the LMTD for co-current and counter-flow
1. For co-courent flow, the change of temperatures of fluids is characterized by the following scheme:
350 oC → 150 oC
20 oC→ 120 oC
Hence
tmax= 350 – 20 = 330 oC
tmin = 150 – 120 = 30 oC

the log mean temperature difference

t max  t min 330  30

t m    125�
C
t max �330 �
2.3log 2.3log � �
t min �30 �
2.For counter-current flow
350 oC → 150 oC
120 oC → 20 oC
tmax= 350 – 120 = 230 oC
tmin = 150 – 20 = 130 oC

it follows from eq.(2.35) that at equal heat transfer rates and value of heat transfer coeffecients
A counter current t m,cocurrent 125
   0.7
A co-current t m,counter current 175

That is, in counter current flow the transfer area is decreased by 30%

23
Example 2.3.
Perform the some calculations as for example 2.2 for the case of a simple mixed flow when the hot fluid has two passes in the
tube and the cold fluid one pass in the shell. This case is related to the scheme given in fig.2.8. First, compute the coefficients
t1 350  150
R   2.0
t 2 120  20
t 2 120  20
P   0.303
t max 350  20
For these value εt = 0.87 (fig.2.8). Therefore, from Eq.(2.40) at tm, counter current = 175 oC
tm = 0.87 x 175 = 152 oC
The same calculation may be performed by applying eq. (2.41):
M   t1  2   t 2  2  200 2  100 2
224
t m   153C
230  130  224
2.3 log
230  130  224

24
Example 2.4
Perform the same computationt as in example 2.2 for cross current flow with the hot fluid in the shell pass and the cold one in
the tubes. This case is related to fig.2.13. using the previously determined value of R = 2.0 and P = 0.303, fig 2.13 gives εt
=0.91, and from eq. (2.40),
tm = 0.91 x 175 = 159 oC
From Eq. (2.43)
tt = t2 = 120 – 20 = 100 oC
tsh = t1 = 350 – 150 = 200 oC
tmax = t1’ – t2” = 350 – 20 = 230 oC
Consequently,
1 100
t m    160 o C
1 2.3 log 1.87
2.3 log
100  200 
1 log1  
200  330 

25
 Example 2.5

Product (G = 7500 kg/hr) with a heat capacity C = 0.8 Kcal/Kg oC, is cooled from t1’ = 90 oC to t1”= 30 oC, using water at t2’=15
o
C. Determine the LMTD for the heat exchangers (cooler) for co-and countercurrent flow, the cooling surface required, and the
water flow rate, assuming tmin = 5 oC. The overall heat transfer coefficient U = 1200 Kcal/m 2hr oC.
1.For Co-current flow
90 oC → 30 oC
15 oC → 25 oC
∆tmax = 90 – 15 = 75 oC
∆tmin = 30 – 25 = 5 oC
75  5
t m   25.8o C
75
2.3 log
5

Heat load
Q = G1 c1 (t1’ – t2”) = 7500 x 0.8 x (90 – 30) = 360,000 Kcal/hr
Heat transfer surface
Q 360,000
A   11 .6m 2
U  t m 1200  25.8

Flow rate of cooling

Q water
360,000
W   36,000 kg
t 2 "t 2 ' 25  15 hr

2. For countercurrent flow

90 oC → 30 oC
15 oC → 25 oC
∆tmax = 90 – 15 = 75 oC
∆tmin = 30 – 25 = 5 oC 26
 15  5
t m   9.2O C
15
2.3 log
5
360,000
A  32.6m 2
1200  9.2
360,000
W   5150 kg
85  15 hr

27
 Example 2.6

The secondary stream of an evaporator of saturation temperature t 1 = 95 oC is used for heating water. Determine the optimum
temperature of heated water if the cost of heat is a = 12.5 x 10 -6 dol/Kcal and the operating cost of heat transfer surface is b = 15
x 10-3 dol/m2hr. The heat transfer coefficient U = 800 Kcal/m 2hroC.
The given conditionts correspond to the first case given above. According to Eq.(2.59),
15103
t 2 " , opt  95   93.5O C
12.5106 800

If the steam is used to heat air, then there is drastic decrease in the heat transfer coefficient (up to U = 25 Kcal/m 2hr0C) and the
optimum final temperature of heated air becomes
1510 3
t 2 " , opt  95  6
 47 O C
12.510  25

28
Example 2.7

The heat exchanger of a conversiont unit (fig.2.26) uses flue gases at t 1’ = 500 oC to heat a product initially at t2’= 75 oC.
Determine the optimum final temperatures of the fluids and the mean temperaturedifference if G 1 = 5,000 Kg/hr, G2 = 4,000 kg/hr,
and C1 = C2 = 0,25 Kcal/KgoC. The cost of heat is a = 5,5 x 10-6 dol/Kcal, and operating cost is b = 6.25 x 10 -3 dol/m2hr. U = 15
Kcal/m2hroC. The conditionts correspond to case 2 considered previously. Calculationts will be made for both co – and
countercurrent flow.
a). For co-current flow:
W1 = G1C1 = 5,000 x 0.25 = 1,250 Kcal/hrOC
W2 = G2C2 = 4,000 x 0.25 = 1,000 Kcal/hrOC
And b 6.2510 3
 76
aU 5.510 6 15

Using Eq.(2.63) to obtain the final temperature of the hot fluid,

1,250
500  75  76
1,000 776
t1" , opt    345O C
1,250 2 . 25
1
1,000

And the final temperature of the cold fluid id determined by

w 1,250
t 2 " , opt  t 2 ' 1  t1 't1" , opt   75   5000  345  269O C
w2 1,000

The LMTD is:

500 OC → 345 OC
75 OC → 269 OC
∆tmax = 500 – 75 = 425 OC
∆tmin = 345 – 269 = 76 OC
t  t min 349
t m  max   203O C
t max 2.30.747
2.3 log
t min

29
b). For countercurrent flow:
from Eq. (2.63) the values of B and b/aU are found:
 1,250 
B  1  2 75  5001    274
 1,000 
b/aU = 76
consequently,
1 1,000  1,250 
t1" , opt   274  75  10  4
6
 75  274  75  76 500  75   
2 1,250  1,000 

2.5
1
  
274  7510 6  5  15.1103  32.310 3  270O C

and
1,250
t 2 " opt  75   500  270   363O C
1,000
LMTD is
500 OC → 270 OC
363 OC → 75 OC
∆tmax = 270 – 75 = 195 OC
∆tmin = 500– 363 = 137OC

195  137
t m   166O C
195
2.3 log
137

30
 Example 2.8

Determine the mean temperature of the fluids from the data given in the example 2.2 for co – and countercurrent flow
Case 1. for co-current flow:
350 OC → 150 OC
20 OC → 120 OC
t1 350  150
R   2; t m  125O C
t2 120  20
From Eq. (2.69)
2 20  125
t1,m   2.3O C
2 1
T2,m = t1,m - ∆tm = 213 – 125 = 88OC
This corresponds to the values calculated from Eq. (2.70).
The mean arithmetic value determined previously were 250 O and 70O. Which do not correspond to the more accurate values
calculated above, and ∆tm from Eq. (2.67).
Case 2. for cuountercurrent flow:
350 OC → 150 OC
20 OC → 120 OC
∆tm = 175 OC
From Eq. (2.69),
2120  175  350
t1,m   240O C
2 1

t2,m = 240 -175 = 65OC  t 

 here max  2 
Which differs a little from the mean arithmetic value  t min 

31
Example 2.9
Determine the heat load of the tube ( L = 3m, d in/dout = 30/33) of a stem-water heater; k = 50 Kcal/mhr OC. The tube is heated
from the outside with steam (h1 = 8,000 Kcal/m2hrOC), and the water is heated inside the tube (h2 = 4,000 Kcal/m 2hrOC). The
mean temperature difference is ∆t = 12 OC
1.Calculation from equationts for cylindrical wall. Calculate the partial thermal resistance from Eq. (2.81):
1
R 1   1210 10 6
8000 0.033
1 0.033
Rw  2.3 log  300 10 6
250 0.030
1
R2   265010 6
40000.03
The total thermal resistance
R t  R 1  R w  R  2  416010 6
 

Heat transfer coefficient

1
U   *  240 Kcal / mhr O C
Rt
Calculate the heat load from Eq. (2.77):
Q = 240 x 12 x 3 = 8650 Kcal/hr
2. Calculation from equations for flat wall:
Calculate the partial thermal resistance from Eq. (2.75):
1
R1   12510 6
800
0.0015
Rw   3010  6
50
1
R2   25010 6
4000

The total thermal resistance

Rt = R1 + Rw + R2 = 405 x 10-6
Heat transfer coefficient
32
U = 1/Rt = 2470 Kcal/m2hrOC
Since h1 and h2 are of the same order, d p may be determined from Eq. (2.84):
0.033  0.030
dp   0.0315m
2
Calculate the heat load from Eq. (2.82):
Q = 2470 x 12 x π x 0.0315 x 3 = 8800 Kcal/hr

33
 Example 2.10
A heater is to be design for heating 35,000 Kg/hr of NaOH solution (concentrationt 30% by weight) from 30 to 90 OC. The
heating agent is saturated steam (p = 1.2 atm). The heater is a vertical multipassed exchanger; tube diameter is d = 30/33 mm,
length = 1.5 m. solution velocity is w = 1.5 m/sec. Surface utilization factor  = 0.8
1.Temperature conditions. At steam pressure p = 1.2 atm the saturation temperature is t s = 104 OC. For the given design
spesificationts, the temperature conditiont are:
t1 = ts = 104 oC; ∆tmax = 104 – 30 = 74 OC
t’2 = 30 OC → t”2 = 90 OC; ∆tmin = 104 – 90 = 10 OC
LMTD is: 74  14
tm   36O C
74
2.3 log
14
Mean temperature of the heat solution:
tm = t1 - ∆tm = 104 – 36 = 68 OC
At this temperature, the properties of the 30% NaOH solution area
viscosity  = 5.2 cp
Spesific weight γ = 1,295 Kg/m3
heat capacity c = 0.88 Kcal/KgOC
Conductivity k = 0.53 Kcal/mhrOC
5.2 2
  10 3  4.02106 m
The kinematic viscosity = /γ 1,285 sec
Prandtl number
 4.02106
pr  3600 c  3600 0.881,285  31.2
k 0.53
2. Thermal load and steam flow rate. The thermal load of the heater (with allowance made for heat losses)
Q = x G2C2 (t”2-t’2) = 1.03 x 35 x 103 x 0.88 (90 – 30) = 1.9 x 10 6 Kcal/hr
Steam flow rate (at I = 540 Kcal/Kg)
Q 1.9 10 6
D   3500 kg
i 540 hr

34
3. Heat transfer coeffecient. The heat transfer coeffecient is determined by a trial-and-error method, since for aphase
change such as steam condensation the value of the heat flux is unknow.
Firs approximation
a). Assume q = 50000 Kcal/m2hr and R1/Rt = 0.3. in this case the mean temperature of condensate film
tcond = t1 – 0.5 R1/R2 t = 104 – 0.5 x 0.3 x 36 = 99 OC

at this temperature the parameter of water area

γ = 958 Kg/m3
v = 0.295 x 10-6 m2/sec
r = 539 Kcal/Kg
the regime of the condensate film flow is determined from the following relation
q 50001.5106
Re cond    137  180
r 36005399580.295

which shows that the flow regime is laminar. For a laminar film flow (Re cond < 180)
1 1
 gr  3
1  1
6
3
h1  19.9k   p2  q 
    
or
A1
h1 
 q 13
where A1 is taken from Fig. (2.31). At t cond = 99 OC fig. (2.31) gives A1 = 270 x 103. consequently
27010 3
h1   6450 Kcal
 500001.5 1
3 m 2 hr O C
1
R1   15510 6
h1
The thermal resistance of the wall ( = 1.5 mm) at k = 50 Kcal/mhrOC is

1.510 3
Rw    30 10 6
k 50
35
For the heat flux from the wall to the liquid,
wd 1.50.03
Re    12500  10000
 4.0210 6
i.e. the flow is turbulent. for the heating of the liquid
Nu = 0.0209 Re0.8 Pr 0.45 = 0.0209 x 125000.8 x 31.20.45 = 187
Hence
k 0.53
hw  Nu  187  3300 Kcal 2 O
d 0.03 m hr C
or
1
R2   30010  6
h2

Fouling thermal resistance

1 1
Rf  R0   R1  Rw  R2   1  0.8 485106  120106
  0.8
Total thermal resistance
Rt = Ro + Rf = (485 + 120) x 10-6 = 605 x 10-6
or
U = 1/Rt = 1650 Kcal/m2hrOC
To check the first approximations of the value of q and R 1/Rt :
q = U x ∆t – 1650 x 36 = 59300 Kcal/m2hr
R1/Rt = 155/605 = 0.25
Since these value do not correspond to the first approximated values, a second approximation must be made. The final value of q
and R1/R2 are used for the seccond approximation.
second approximation.
a). Assume q = 59000 Kcal/m2hr and R1/Rt = 0.25
tcond = 104 – 0.5 x 0.25 x 36 = 100 OC
For the film flow regime:
59000
Re cond  137  162  180 36
50000
Consequently
270103
h1   6100 Kcal 2 O
 590001.5 13 m hr C
And correspondingly
1
R1   160 10 6
h1
The value of Rw, R2, and Rf are not changed in the second approximation. Therefore
Rt = R1 + Rw + Rf + R2 = (160 + 30 + 120 + 300) x 10-6 = 610 x 10-6
and
U = 106/610 = 1640 Kcal/m2hrOC
Checking the assumed values in the second approximation gives:
q = 1640 x 36 = 59000 Kcal/m2hr
R1/Rt = 160/610 = 0.26
The close agreement between the U’s obtained in the two approximations may be explained by the small effect of the heat flux
Q on U1 due to relatively small value of the thermal resistance R1. taking the ratios of the partial resistances,
R1 : Rw : Rf : R2 = 0.26 : 0.05 : 0.20 : 0.49
i.e, the main thermal resistance is the resistance for the flow from the wall to the solution heated (R2 = 0.49 Rt). Heating surface
area Q 1.9 106
A   32m 2
Ut m 164036

37
Example 2.11.
Design a cooler for cooling 35,000 Kg/H or 30% NaOH from 90 to 30 OC. The cooling agent is water at t = 20 OC. The cooler is
countercurrent and sectional; seven tubes (d = 30/33 mm) are installed in sections with D = 150/156 mm. the coefficient
surface utilization  = 0.85
1. temperature conditions of cooling. In order to further utilize the cooling water and decrease its flow rate, the final
water temperature is assumed t”2 = 70 OC. Then the following data is obtained:
t’1 = 90 OC → t”2 = 30 OC; ∆tmax = 90 – 70 = 20OC
t”2 = 70 OC ← t’2 = 20 OC; ∆tmin = 30 – 20 = 10OC
The mean tempearture difference (taking into account that ∆t max/ ∆tmin = 2) is
20  10
t m   15O C
2

The temperature of90the working fluids are:

 30
t1m   60O C
2
20  70
t2m   45O C
2
The physical properties of the working fluids at these temperature are:
Working Tm,OC V x 106 K, C, Y, Pr
fluid m /sec
2
Kcal/mhr C
O
Kcal/KgOC Kg/m3
30% NaOH
solutiont 90 4.2 0.53 0.88 1300 32.7
Water 45 0.6 0.55 1.00 990 3.9

2. thermal load and water flow rate. Thermal load (allowing for heat losses):
Q = 1/x G1c1 (t’1 – t”1) = 0.97 x 35 x 103 x 0.88 (90 – 30) = 1.87 x 106 Kcal/hr
Water flow rate Q 1.8106
W   36000 Kg
t"2 t '2 70  20 hr

3. heat transfer coeffecient

38
a). Heat transfer coefficient from solution being cooled to the wall.
Cross-sectional area of flow:
d in 2  0.032
f1  n  7  0.005m 2
4 4
Solution velocity:
G 35000
W1  1   1.5 m
 1 f1 360013000.005 sec

Reynolds number:
W d 1.50.03
Re1  1 1   10700  10000
1 4.2 10 6
Nu1 = 0.0263 Re10.8Pr10.35 = 0.0263 x 107000.8 x 32.70.35 = 155
Hence
k1 0.53
h1  Nu1  155  2700 Kcal 2 O
d1 0.03 m hr C

And
R1 = 1/2700 = 370 x 10-6

b). Thermal resistance

 0of.0015
the wall at k = 50 Kcal/mhr OC
Rw    3010  6
k 50

c). Heat transfer coefficient

2
from2 the wall to the cooling water. Cross sectional area of flow:
Din Dout 
f2 
4
n
4
 
 0.152  7 0.0332  0.0116m 2
4
Water velocity:
G 36000
W2  2   0.9 m
 2 f 2 36009900.0116 sec

Equivalent diameter of the cross section:

4f 40.0116
d2  2   0.064m
 7 0.033 39
Reynold number:
wd 0.9 0.064
Re 2  2 2   96000  10000
2 0.6 106
Nu2 = 0.0209 Re20.8Pr20.45 = 0.0209 x 960000.8 x 3.90.45 = 375
Hence
k 0.55
h2  Nu 2 2  375  3200 Kcal 2 O
d 0 .064 m hr C
And 2

1
R2   310 10 6
3200
d). Thermal resistance of fouling at  = 0.85
1 1  0.85
Rf  Ro   370  30  310 106  12510 6
 0.85
e). Total thermal resistance,
Rt = Ro + Rf = 835 x 10-6
Or
U = 106/835 = 1200 Kcal/m2hrOC
Taking the ratios of the partial resistances,
R1 : Rw : Rf : R2 = 0.44 : 0.04 : 0.15 : 0.37
R1 and R2 have almost equal relative values, while the influence of the wall is insignificant

4. Cooling
Q surface
1.810area
6
A   100m 2
Ut m 120015

40
Example 2.12
Determine the optimum operating regime of a heater consisting of five heat exchangers connected in series. The heater is to be
used for heating a sugar solution. The following data are given:
pressure of the heating steam p = 0.6 atm
flow rate of the solution G1 = 45000 kg/hr
initial temperature of the solution t’2 = 50 OC
final temperature of the solution t”2 = 80 OC
The heater are vertical and tubular, with one tube pass.
tube diameter d = 30/33 mm

tube length = 1950 mm
tube diameter n = 120
surface utilization factor  = 0.8
Physical properties of 20% sugar solution at mean temperature 65 – 70 OC:
c = 0.9 Kcal/Kg OC
v = 0.7 x 10-6 m2/sec

= 1070 Kg/m3
k = 0.54 Kcal/mhrOC
pr = 4.5
First set of calculation:
1.Determination of heat transfer coefficient
a). For film condensation of steam and laminar flow of condensate
A1 Kcal
h1 
 q 13 m 2 hr O C

For mean condensate film temperature tc = 80 OC, the coefficient, A, may be obtained from the equition
A1 = 1000 (141 + 1.85 x 80 – 0.0053 x 80 2) = 250 x 103
The heat flux is given by
q = Q/A Kcal/m2hr
The thermal load of the heaters may be determined as follows: 41
Q = xG2c2 (t”2 – t’2) = 1.03 x 45000 x 0.9 x (80 – 50) = 1.25 x 10 6 Kcal/hr
The surface area of the set of heaters is
A = mπdLn = 5 x π x 0.03 x 1.95 x 120 = 110 m2
The heat flux
1.2510 6
q  11400 Kcal 2
110 m hr

Heat transfer coefficient 3

250 10
h1   9200 Kcal 2 O
11400 1.95 3 m hr C
1

And 1
R1   110 10 6
9200

b). The thermal resistance of the wall

 0.0015
Rw    30 10  6
k 50
c). The cross-sectional area of flow
d 2 0.032
f n  120  0.085m 2
4 4
The solutiont velocity
G 45000
W   0.14 m
3600f 360010700.085 sec
Reynold number
wd 0.14 0.03
Re    6000
 0.7 10 6

For intermediate values of reynold numbers (2300 < Re < 10000)

Nu = 0.008Re0.9Pr0.43 =0.008 x 60000.9 x 4.50.43 = 40
Hence
k 0.54
h 2  Nu  40   720 Kcal 2 O
d 0.03 m hr C 42
And
R2 = 1/720 = 1390 x 10-6
d). The total thermal resistance
Ro = R1 + Rw + R2 = 1530 x 10-6
1 0.2
Rf  R0  1530106  380106
 0.8

Rt = Ro + Rf = 1910 x 10-6
Thus, the heat transfer coefficient
U = 106/1910 = 520 Kcal/m2hrOC

Q 1.25106
tR   of the required
2. Determination  22O C temperature difference.
UA 520110

3. Determination of available temperature difference. For steam (at saturated temperature, t s = 85OC). The temperature
conditionts are:
t1 = ts = 85 OC; ∆tmax = 85 – 50 = 35 OC
t’2 = 50Ot C → t”2 = 80 O35
C;∆t
5 min = 85 O– 80 = 5 C
O
max  t min
Therefore, the
t av  
availabletemperature
t
 15.5 C
difference
35
2.3 log max 2.3 log
t min 5

t 15.5
a  av   0.7  1
4. Capacitytreserve
req 22and analysis of results. The capacity reserve

Shows that the apparatus has insufficient capacity.

Second set of calculationts
43
Since the capacity of the apparatus in the first set of calculations was inadequate, the operating parameters will be changed and
a new set of calculations made. The number of passed in each heater will be increased from one to three. In this case the
 Nu = 0.0209 Re0.8 Pr0.45 = 0.0209 x 180000.8 x 4.50.45 = 100
Hence
0.54
h2  100  1800 Kcal m 2 hr OC
0.03
1
And R2   55010 6
800
Further
1 1
R   R1  R2  R2   110  30  550 106  860106
 0.8
And
U = 106/860 = 1150 Kcal/m2hrOC
The required temperature difference
1.25106
t req   10O C
1150 110
Finally, the capacity reserve at ∆tav = 15.5 OC
a = 15.5/10 = 1.55
Shows a more than sufficient exchanger capacity. Thus, increasing the number of passed in the exchanger significantly increases
the capacity of the apparatus.

44
Example 2.13:
7500 kg of product with heat capacity c = 0.9 Kcal/Kg OC is cooled in a batch reactor from temperature t’1 = 120 OC to t”1 = 60 OC.
The cycle time is  = 1.5 hr. determine the transfer area A and flow rate of cooling water W if the initial temperature of the cooling
water is t’2 = 20 OC and its mean heating tw,m = 50 OC. The heat transfer coefficient is U = 800 Kcal/m 2hrOC.
1.Characteristics of the cooler from eq. (2.111)
t t ' t ' 50 120  20
Y  w,m  2.3 log 1 2   2.3 log  0.765
t '1 t"1 t"1 t '2 120  60 60  20

2. Thermal load at  = 0.95

Q = Gc(t’1 – t’2)  = 7500 x 0.9 (120 – 60) 0.95 = 38500 Kcal
3. Flow rate of cooling water
Q 38500
W   5130 kg
t  50 1.5 hr
w, m

The outlet temperature of cooling water at the beginning of the cycle

t’2 in = t’2 + t’w = t’2 + (t’1 – t’2) y = 20 + (120 – 20) x 0.765 = 96.5 OC
At the end of the cycle
t”2fin = t’2 + t”w = 20 +(60 -20) x 0.765 = 50.5 OC
4. Mean temperaturet wdiffrence from Eq.(2.110)
t m  ,m
x

Where, from Eq. (2.108)

1 1
X  2.3 log  2.3 log  1.45
1 Y 1  0.765

The same result may be obtained from the Fig (2.34) if the cooler characteristic is known. Thus,
50
t m   34.5O C
1.45

45
Example 2.14
3600 kg of product with heat capacity c = 0.8 Kcal/Kg OC is cooled in a reactor from t’1 = 100 OC to t”1 = 40 OC. The water velocity
in the tube is w = 0.88 m/sec, and its spesific weight is  =995 Kg/m 3. The mean value of heat transfer coefficient is U = 800
Kcal/m2hrOC. Determine the time of the cycle and the mean temperature of the exit water from the reactor. The reactror has a
cylindrical coil cooler consisting of a tube of d = 45 mm with a transfer area A = 12.5 m 2.
1. Characteristicsx of the batch cooler from Eq. (2.106)
e 1
Y
ex
Where X = UA/W
Flow rate of cooling water

d 2 0.0452
W w 3600  0.889953600  5000 Kg
4 4 hr
Which is the same as the water equivalent of the cooling fluid
W = 5000 Kcal/hrOC
Therefore
800 12.5
X  2.0
5000
And
e2 1
Y  2  0.855
e
2. Thermal load at  = 0.95
Q = Gc (t’1 – t”1)  = 36000 x 0.8 x (100 – 40) 0.95 = 164000 Kcal
3. heating of the cooling water:
a). At the start of the cycle
t”w = (t’1 – t’2) y = (100 – 10) x 0.855 = 77 OC
b). At the end of the cycle
t”w = (t”1 – t’2) y = (40 – 10) x 0.855 = 25.5 OC
c). The average water temperature during the cycle [ Eq.(2.109)]
77  25.5
t w, m   46.5O C
77
2.3 log
25.5
46
4. The mean water temperature at the outlet
t2,m = t’2 + tw,m = 10 + 46.5 = 56.5 OC
5. The time of the cycle
Q 164000
   0.7hr
Wt w,m 5000 46.5

47
Example 2.15
Determine the pressure drop through a condenser given the following data:
flow rate of cooling water G = 150 t/hr
velocity of cooling water in tubes w1 = 1.6 m/sec
water temperature tm = 24.2 OC
spesific weight of water y = 1.025 t/m3
number of passes in tubes z = 2
length of tubes between plates ℓ = 1.35 m
tube inside diamter di = 0.01 m
Solution:
1. inside diameters of inlet and outlet nozzles is assumed d i = 0.15 m
2. velocity of cooling water in nozzles
G 150
W2    2.3 m
2825d1 
2
2825  10.15 2
10.25 sec

3. total tube length

L = ℓ + 25 = 1.35 + 2 x 0.02 = 0.39 m
4. hydraulic resistance of2 the condenser
 L W1 W  W
2 2
h  z  0.031   1.4 1   2 
 di 2 g 2g  2g
 1.39 1.6 2 1.6 2  2.32
2 0.031  0.965  1.4    1.41m.water
 0.014 2 9.81 2 9.81  2 9.81

48
Example 2.16:
Determine the pressure drop through a water heater given the following data:
water velocity in tubes w1 = 1.7 m/sec
spesific weight of water y = 0.974 t/m3
number of passes in tubes z = 6
thickness of tube plate S = 0.05 m
mean tub length ℓ = 1.8 m
inside tube diameter di = 0.013m
reynolds number Re = 56800

Solution:
1.Total tube length
L = ℓ + 25 = 1.8 + 2 x 0.05 = 1.9 m
2. Frictional pressure drop factor
0.3164 0.3164
 4 4  0.205
Re 56800

3. Frictional pressure drop

2
in the straght tubes 2
zL w1  6 1.9 1.7 974
P1     0.2050   2600 Kg 2
di 2g 0.013 29.81 m

4. Local losses in chambers at transition from one tube bundle to another

2
zw  6 1.7 2 974
P2   1 1  0.5
2 2 g 2  29.81
  1.5 from tab 2.4

6. Local losses in the inlet and outlet chambers

2
w1  1.7 2 974
P4   3 2  1.5 2   430 Kg 2
2g 29.81 m
 3  1.5 from table 2.4

49
7. Hydraulic resistance of water heater
h = (∆P1 +∆P2 + +∆P3 ) x 10-3 = (2600 + 717 + 430)10-3 = 3962 m water

50
Example 2.18.
Determine the pressure drop of a water-water heat exchange (Fig. 2.47)
Given : Number of section z = 8
Primary water moves inside twelve brass tubes with velocity W1=1.5 m/sec
Tube length l = 400 mm
Water temperature t1 = 1050C
Secondary water moves with velocity w2 = 0.8 m/sec in intertubular space of a steel shell
Shell diameter D = 100 mm
Water temperature t2 = 800C
Solution :
I. Hydraulic pressure drop for a primary water flow
1. Reynolds number at v = 0.28 x 10-6
1.5 x 0.014
Re1   75000
0.28 x 10- 6

Neglecting wall raoughness of inside walls of brass tubes, the resistance coeffisient is
0.3164 0.3164
λ 0.25
  0.019
Re 75000 0.25

2. Local pressure drop factors

inlet and oulet …..  =2 x 1.5 = 3.0
reducers ………...  = 7 x 2 = 14.0
total …………….  =17.0
3. Pressure drop at  = 955 kg/m3
2
 8x4  1.5
P1   0.019  17.0  x955  700 kg/m 2
 0.014  2g

II. Pressure drop for secondary water flow

1. Equivalent diameter of the cross section
 D2 d 2 
4 n 
 4 4  D 2  nd 2
d eq  
  D  nd  D nd
0.12  12 x 0.0162
  0.024 m
0.1 12 x 0.016

51
Assuming absolute roughness of inside wall of the steel shell  = 0.3 mm we obtain
0.1 0.1
 0.25
 0.25
 0.04
r  12 
   
   0.3 

2. Local pressure drop factors for secondary water flow

inlet and outlet ………….  = 2 x 1.5 = 3.0
reducers …………………  = 7 x 2.5 = 17.5
overflowing of baffles …..  = 8 x 2 x 0.5 = 8.0
Total  = 23.5
3. Pressure drop for secondary water flow
2
 8.4  0.8
P2   0.004  28.5  970  2600 kg/m 2
 0.024  2g
or P2 = 0.26 atm.

52
Example 2.19.
Calculate the pressure drop through an oil cooler.
Given : Capacity of the cooler G = 16/hr
Length of the baffle rim (chord) S = 0.366 m
Tube pitch t = 13.5 mm
Outside tube diameter d0 = 10 mm
Distance between the shell and end tubes y0 = 13.5 mm
Number of tube rows crossed by flow m = 18
Number of space between baffles n = 12
Distance between baffles h = 0.094 m
Mean oil velocity between baffles w1 = 0.307 m/sec
Mean oil velocity over baffles w2 = 0.307 m/sec
Kinematic viscosity of oil  = 57 x 10-6 m2/sec
Specific weight of oil  = 879 kg/m3
Cross section are for oil passing over baffles f2 = 0.0164 m2
Solution :
1. Free section for oil passing at a baffle
s - 2y 0  d 0 0.366 - 2 x 0.0153 - 0.01
bs-  d 0  0.366 - x 0.01  0.116 m
t 0.0135

2. Cross section area for oil passing at a baffle rim

f1 = b x h = 0.116 x 0.094 = 0.0109 m2
3. Oil velocity at the baffle rim
G 16
w   0.462 m/sec
3600f1 3600 x 0.0109 x 0.879

4. Function of Reynolds-0.2number 0.2

 w(t - d 0   0.462(0.0135  0.01) 
f  0.75  0.75   0.384
    57 x 10- 6

5. Oil pressure drop inpases between baffles

4fmw 2 n 4x0.384x18x0.4622 x879x12
P1    3200 kg/m 2
2g 2 x 9.81
53
6. Oil pressure drop at flow baffles
2
P2  0.0815w2  (n - 1)  0.0815 x 0.3072 x0.879(12 - 1)  74 kg/m2

7. Oil pressure drop at inlet and outlet of the inter-tubular space

2
w1  0.3072 x879
P3  ( 1   2 )  (1.5  1.0)  10.6 kg/m 2
2g 2 x 9.81
8. Oil pressure drop through a shell space of oil cooler
P  (P1  P2  P3 )10-4  (3200  74  10.6)10-4  0.33 kg/m 2

To evaluate an optimum pressure drop for a given of equipmen, an economic balance between the cost of the exchaer surface
area and the cost of pump or compressors must be done. High mass velocities through the exchanger require a smaller heat
transfer surface area but require a higher pressure drop. Therefore higher than optimum investment and operating costs for the
compressor or the pump result; however exchanger drop available it should be uses to minimaze the cost of the exchanger.
In general, the necessily for a detailed economic balance between pressure drop and exchanger surface can be fdetermined
from looking at the effect of the individual film coefficient on the overall heat transfer coefficient. Little can be gained by spcifying
increased pressure drop for one fluid in an exchanger when the other fluid has a significantly lower film coefficient. For such
cases, a detailed economic balance is unnecessary.

54
Example 2.20.
Design a single-pass shell-and-tube exchange for heating air (in shell space) with nitrose gases. The initial and final air
temperature are t'2 = 20 0C and t”2 = 3500C and the initial temperature of the nitrose gases is t'1=800 0C . the gas flow rate is
22000 kg/hr and pressure 6.5 atm. The air flow rate is 19000m kg/hr and pressure 7.0 atm. The physical properties of gas
similar to air.
1. Heat flow
Q = 19000 x 0.25 (350 – 29) = 1570000 Kcal/hr
Where 0.25 Kcal/kg0C is the mean heat capacity of air.
2. The final temperature of Nitrose Gases. Neglecting heat losses and assuming the mean heat capacity c = 0.27 Kcal/kg0C, we
obtain
1570000 = 22000 x 0.27 (800 – t”1), hence t”1 = 5350C
3. Mean temperature difference (at countercurrent flow)
8000  5350
350 0
 200 415  515
450 0
515 0 t m   4020
2
Mean air temperature t2m = 20  350
 1850
Mean temperature of gases t1,m2= 185 + 482 = 6670
4. Determination of tube heat transfer coeffisient h1. if the gas velocity is assumed to be w0= 8m/sec, then the weight velocity W
= w00p = 8 x 1.29 x 6.5 = 67 kg/m2sec. The total cross section area of the tubes s t  22000.  0.091 m 2
3600 x 67
The tube diameter is assumed to be d = 32/27 mm. The cross sectional area of one tube  = 0.785 x 0.0272 = 0.000572 m2. The
0.091
 159
number of tubes n = 0.000572

Assume a hexagon layout with n=169, then the internal cross section area of all tubes is
St = 169 x 0.000572 = 0.0965 m2
Weight velocity
W = 22000/3600 x 0.0965 = 63.3 kg/m2 sec
For gases, the tube heat transfer coefficien
H1 = 3.1 x W0.8 di-0.2=3.1 x 63.30.8 x 0.027-0.2  180 Kcal/m2hr0C
5. For air, shell heat transfer coefficient, h 2. at  = 1.0 and t = 44 mm the shell diameter is
n
D  1.05 x t  1.05 x 44 169  600 mm
 55
 s0
Where   (s0 =  x ; s = tube sheet area). Longitudinal shell free cross section area is
s

 
Ssh  D 2  nd 0  0.785 0.62  169 x 0.0322   0.146 m 2
4
2

in order to increase the shell heat transfer coefficient h 2, baffles are located as in Fig. 2.51, II. Assume S t2 = 0.45 Ssh = 0.4 x 0.146
= 0.0585 m2, then weight flow rate Wt2 = 19000/0.0585 = 90.3 kg/m2sec. Assume tw2 = 4300C, then the film temperature
t   t m2 430  185
t film  w2   3070 C
2 2
h2 = 3.24w0.56 x d0-0.44 = 3.24 x 90.30.56 x 0.032-0.44=176 kcal/m2hr0C d0
distance between baffles at gas flow perpendicular to diagonal0.(from t ))
0585 formula Ssh = Dℓb(1-
b   0.36m
 32 
0.61  
 44 

6. The overall heat transfer coefficient. At w = 0.0025 m and K = 20 Kcal/m2hr0C

1 1
U   87 Kcal/m 2 hr 0C
1  1 1 0.0025 1
   
h1 K h 2 180 20 176

tw
Checking the 2 temperature
U by formula
t w 2  t  t  t  q/h 2
h2
87
t w 2  185  x 482  4330 C
176

which is close to the assumed value

7. Heating surface Q 1570000
   38 m 2
U x t 87 x 482

38 if we calculate the heating area  by mean tube diameter is

Working length of a tube
  2.5 m 56
3.14 x 0.0295 x 169
8. Hydraulic resistance of the tubular space
  t   
zW 2 1  1m  a  b  1 x 63.32 1  667  0.1  0.00167 x 2.5
 273  d0   273 
P  
 0p 1.29 x 6.5
 410 mm H 2 0  0.04 atm
0.038 0.038
where a = 0.1 mm, b = 4 d  4 27  0.00167
0

9. Hydraulic resistance of the shell space :

 t   185 
zW1  2m  a  bm  7 x 90.31   0.15  0.005 x 15
 273   273 
Ps   
 0p 1.29 x 7
 236 mm H 2 0  0.24 atm
 3
where a = 0   0.15
2g 2 g

m = 15 (the number of tube along the hexagon diagonal)

 n
b  0.15
2 g Re x2g
From Table 2.11, n = 0.56.
TABEL 2.11
t/d0 1.2 1.3 1.4 1.6 2 2.5
“n" for stanggered tube bundle 0.88 0.64 0.53 0.42 0.34 0.30
“n” for not-stangered tube bundle 0.90 0.60 0.45 0.32 0.20 0.15
3600 x 90.3 x 0.032
Re   114000
0.091
0.56
b  0.05
2 x 9.18 x 114000 0.15

57
Example 2.21.
Design a horizontal multipass shell-and-tube heat ex-change for heating 40000 kg/hr cyclohexane from t'2 = 30 to t”2 = 140 0C
with saturated steam. The pressure of cyclohexane p = 25 atm.
The assumed steam temperature is t1 = t”2 + 20 = 140 + 20 = 1600C. at this temperature the pressure of the saturated steam is P s
= 6.3 atm. The tube diameter is assumed to be d 0/d1 = 25/21 mm, and pitch t = 32 mm.
The saturated steam form neither scale nor fouling, but the cyclohexane may form tars which foul the tubes. Therefore steam is
introduced in the shell space and cyclohexane in the tubular space, which is convenient for cleaning the LMDT is
(t  t' ) - (t1  t"2 ) (160  30) - (160  140)
t  1 2   58.80 C
(t1  t'2 ) (160  30)
2.3 log 2.3 log
(t1  t"2 ) (160  140)

The mean temperature of the cyclohexane t2 = t1 – t = 160 – 58.8 = 101.20C Reynolds number.
where w2 = velocity of cyclohexane; w2 = 1 m/sec (assumed).
din = inside tube diameter; d1 = 0.021m.
v2 = kinematic viscosity of cyclohexane at t2 = 101.2°C.
For Re > 10000

0.25
 Pr2 
Nu2 = 0.021 Re Pr 2
0.8
2
0.43  
Pr
 w
0.25
 7.43 
  
 6.33 
= 0.021 x 428500.8 x 7.430.43 259.3
where 3600 2C2 2 number
3600 xat0.49 10 -6 x 0.603 x 700
t2 =x101.2°C
Pr2Pr
 2 = Prandtl   7.43
K2 0.1

K2 = conductivity of cyclohexane, Kcal/m hr°C

C2 = heat capacity of cyclohexane, Kcal/kg°C
For determination of the Prandtl number Pr w, it is necessary to assume the mean wall temperature t w. It is between t2 and t1,
nearer to t1 3600ν
since Cγ 3600transfer
the heat x 10the
x 0.3786from 6
x 0.64
steamx 654
side is more intensive. Assume t w = 147°C, then
Prw    6.33
K 0.09 58
The heat transfer coefficient from the tube wall to the cyclohexane,
Nu 2 K 2 259.3 x 0.1
h2    1235 Kcal/m2 hr 0 C
d in 0.021
The heat transfer coefficient h1 from the saturated steam to the horizontal tubes. The temperature of condensate film

Tk = t1 – 0.5 U 0 t = 160 – 0.5 x 0,098 x 58.8 = 1570C

h1

The value Uo/hi should be assumed and when U0 and h1 are determined it should be checked. In this case U o/h = 0.098. The
temperature difference At' = t1 – t1,w = Uo/hi t = 0,098 x 58.8 = 5.86  6 C.
0

Galileo number gd 0 3 9.81 x 0.0253

Ga  2   4124 x 106
ν 
0,1938 x 10  6

2

where d0 = outside tube diameter; d0 = 0.025 m

v = condensate kinematic viscosity at t k = 175°C
The dimensionless
r number
497,4
  80
Ct' 1.0363 x 6

where C = condensate heat capacity at t k, Kcal/kq°C

r = heat of vaporization at t1, Kcal/kg
For heat transfer coefficient to one 0.25
row of horizontal tubes
 r 
Nu1  0.72 Ga pr x  
 Ct 
0.72(4124 x 106 x 1.1165 x 80)0.25 = 559

where Pr = Prandtl
Nu1number
K1 559for condensate at tk. Heat
x 0.5872 transfer coefficient for the too row of tubes,
h1    13120 Kcal/m2 hr 0 C
d0 0.025

To determine the mean value of the heat transfer coefficient for the tube bundle we need to know the number of horizontal tube
rows. The number of 4G
tubes in one pass is 4 x 40000
n1  2
2
 2
 45.8  46 59
3600 x πx 0 w 2 γ 2 3600 x 3.14 x 0.021 x 1 x 700
In selectinq the number of passes we should avoid a very small diameter for long tubes. We assume the number of passes, z, to
be equal four. The total number of tubes in the shell n = n1 x z = 46 x 4 = 184. The number of tubes on the external side of
hexagon n = 3a(a - 1) + 1; 184 = 3a (a - 1) + 1, hence a  8. The number of tubes in the hexagon diagonal is
B = 2a – 1 = 2 x 8 – 1 = 15
The correction factor, n, for 15 rows of tube (see Table 2.12) is 11.175/15 = 0.746 (the data of the Table for 15 rows at a
staggered layout is summed then divided by 15).
TABLE 2.11
Values of n vs row number of a bundle
Bundle 1 2 3 4 5 6 7 8 9 10
Non- 1 0.85 0.775 0.725 0.680 0.645 0.620 0.600 0.580 0.560
staggered
Staggered 1 1.0 0.900 0.840 0.795 0.760 0.730 0.705 0.680 0.660

Bundle 1 2 3 4 5 6 7 8 9 10
Non- 1 0.85 0.775 0.725 0.680 0.645 0.620 0.600 0.580 0.560
staggered
Staggered 1 1.0 0.900 0.840 0.795 0.760 0.730 0.705 0.680 0.660
The mean heat transfer coefficient for the tube bundle is h1,m = 0.746 x h, = 0.746 x 13120 = 9800 Kcal/m hr°C. The overall
heat transfer coefficient from steam to cyclohexane (without scale and fouling),
1 1
U0    957.5 Kcal/m 2 hr 0 C
1 δ 1 1 0.002 1
   
h1,m k h 2 9800 15 1235

where  = tube wall thickness,  = (d0 – di) 2

= (0.025 - 0.021) 2 + 0.002m
k = conductivity, Kcal/mhr°C
We check the ratio Uo/h1 = 957.5/9800 = 0.0977
Before it was assumed Uo/h1 = 0.098
He check tw = t2 + Uo/h1 t = 101.2 + 957.5/7235 x 58.8 = 146.8
60
Before it was assumed tw = 147.0
Assume the coefficient of utilization of the heat transfer surface  = 0.9. The design heat transfer coefficient = U = U0  = 957.5 x
0.9 = 861.7 Kcal/ m2hr°C
Thermal load Q2 = G2Cp(t"2 - t'2) = 40000 x 0.579 (140 - 30) = 2549000 Kcal/hr.
The mean approximate heat capacity of cyclohexane in the range from t'2 to t"2
is Cp + (Cp1 + Cp2)/2 = (0.515 + 0.643)/2 = 0.579 Kcal/kg°C
Heat transfer area
Q 2549000
'  2   50.3 m 2
Ut 861.7 x 58.8
tube length
' 50.3
L   4.13 m
nd i 184 x 3.14 x 0.021
Assume L = 4 m.
Actual heat transfer area A = ndiL = 184 x 3.14 x 0.021 x 4 ~2 48.6 ; 50 m .
Assume four-pass shell-and-tube exchanger with integral floating head. The steam flow rate
Qx 2549000
G1  2   5610 kg/hr
i1  i 2 658.7  158.21

where i l = steam enthalpy at t1=1600C, Kcal/kg

Lk = condensate enthalpy at tk = 157°C, Kcal/kg
x = coefficient considering heat losses
Rational design. Diameter of the tube bundle,
D0 = (b - 1) t + d0 = (15 - 1) 32 + 25 = 473 mm
Nozzle diameter for steam
4G1 4 x 5610
d1 '    0.17 m
3600π61 ' w1 ' 3600 x 3.14 x 3.258 x 21
Assume 180/168 mm tube.
Nozzle diameter for condensate
4G1 4 x 5610
d1"    0.0465 m
3600 x πxk w k 3600 x 3.14 x 910.3 x 1 61
Assume 50/45 mm tube.
Nozzle for non-condensable substances is assumed to be 25/21 mm tube.
Nozzle diameter for supplying of cyclohexane (t 21 = 30°C)
4G 2 4 x 40000
d2 '    0.102 m
3600π62 ' w 2 ' 3600 x 3.14 x 769 x 1.8
Assume 114/102 mm tube.
Nozzle diameter for cyclohexane discharge (t2" = 140°C)
4G 2 4 x 40000
d1 "    0.109 m
3600π62 " w 2 " 3600 x 3.14 x 662 x 1.8
Assume 121/109 mm tube.
Pressure drop in tube space.27 The limiting Reynolds number below which the tubes are considered hydraulically smooth
(the thickness of laminar boundary layer formed is larger than the height of the roughness projections)
23d1 23 x 0.021
Re cr    2415
 0.2 x 10-3
where  = mean height of roughness projection;  = 0.2 x 10-3 m. Since Re2 > Recr, i.e 42850 > 2415 the tubes are
considered to be rough. The value of the Reynolds number above which the square law of resistance should be applied is
560d i 560 x 0.021
Re' c2 Δ = 0.2 x 10 3 = 58800. The friction factor  of the tube whose length is equal to its diameter is determined
from the following approximate formula (Recr < Re2 < Re'c2).
0.25 0.25
 Δ 100   0.2 x 10  3 100 
λ  0.11.46    0.11.46    0.03565
 d i Re 2   0.021 42850 

The local pressure

Am drop
Amcoefficient
L of a tone
" t 'pass tube bundle is determined as follows
2 2 2
= 0.5 (1- Ak )+(1- Ak ) + d
2
273  t '
eq 2

0.0159 0.0159 4 140  30

0.03565 2  8.261
= 0.5 (1- 0.0452 )+(1-0.0452 ) +
2
0.021 273  30
where Am = free section of a tube bundle for one pass; Am = n 1 π/4 di2
3.14
 46 0.0212  0.0159m 2
4
62
  D2k 3.14 x 0.482
Ak = free section in the head for one pass; Ak =   0.0452 m 2
4 2 4x4
z = number of passes
L = tube length, m
di = inside tube diameter, m
Pressure drop at passing of cyclohexane in tubes
2
γ2w 2 700 x 12
ΔP1  zζ  4 x 8.261  1178 kgf/m 2
2g 2 x 9.81
Pressure drop in bends of the floating head and cover is determined similarly to Ap in U-turn

w2 0.3512
ΔP2  (z - 1) ζ γ 2  (4 - 1) x 13.873 700  183 kgf/m2
2g 2 x 9.81
where Y2 - specific weight of cyclohexane at 101.2°C, kg/m
w = liquid velocity in U-turn
4z g 2 4 x 4 x 40000
w   0.351 m/sec
3600 2D k
2
3600 x 700 x 3.14 x 0.482

1 = pressure drop coefficient

1 = K KRe C m + t = 1.5 x 1.23 x 1 x 7.5 + 0.0334  13.873
K = coefficient considering roughness, K = 1.5 at Re > 40000 and
Δ   0.2 
 0.001    0.009 
di  d i 21 
KRe = coefficient considering the rate of turbulence
0  15 
At Re  2 x 105 and  0.3;  0   0.0632 ; K Re  1.23
b0  b 0 237.58 

ℓ0 = width of a tube sheet strip not filled with tubes, near the contact with a baffle
b0 = width of the flow at the exit from the tubes (for one pass)

0
= friction factor, m = (l - b )= 0.03565 (1 - 0.0632) = 0.0334
0
63
0
 b0
e = local pressure drop coefficient,  = 7.5 for bk/b0 = 0.5 and =0.0632
bk = flow width at a turn by 90° to the tube sheet
z-1 = number of turns
Pressure drop at abrupt expansion at the inlet from the nozzle into the head:
2
w'
2
 A  w'2  0.00817 2  1.82
P3   p 2  '2  1 - 1   '2  1 -  x 769  85.2 kg/m 2
2g  A k  2g  0.0452  2 x 9.81

A1 = cross sectional area of the head (for first pass)

Ak = cross sectional area of a nozzle
The cyclohexane pressure drop at exit from the exchanger into the nozzle (sudden contraction):
w"2
2
 A  w" 2 2
 0.00933  1.8 x 662
P4   p  "2  0.51 - 1  2  "2  0.51 -  x  43.3 kg/m 2
2g  A k  2g  0.0452  2 x 9.81
The total pressure drop
P = P] + P2 + P3 + P4 = 1178.0 + 183 + 85.2 + 43.3 = 1489.5 kg/m2
Structural design of exchanger's elements 28-32
The thickness of the floating head cover
pDk D 25 x 48 48
δ1  x k C x  0.3  0.878 cm
4 σ φ  p 2h 4 x 1251 x 1 - 25 2 x 10

where Dk = Head inside diameter; Dk = D +0.7 cm = 48 cm

h = Height of the head; h = 0.2 Dk = 0.2 x 43 = 9.6 cm;
assumed h = 10 cm
[] = allowable stress for steel at t = 160°C [o] = 1251 kg/cm
1 = 0.9 cm (assumed)
Design of studs fixing the floating head. Assume tongue-and-groove flange. Asbestos gasket inside diameter di = Dk + 21 = 480
+2x9= 498 mm. Assume 500 mm. Outside gasket diameter d 0 = 500 + 20 = 520 mm. Gasket thickness is 3 mm, Diameter of stud
circle, Db = 550 mm.2 Force acting on the studs,
D 25 x 3.14 x 512
Pb  P1  P2  P 1  D1bq 2   3.14 x 51 x 1 x 750  75300 kg
4 4

64
here D1 = diameter of a central gasket circle
where q2 = specific pressure on the gasket.
Stud thread inside diameter
4P1 4 x 75300
d1    1.91 cm
z   k 20 x 3.14 x 1316 x 1
Assumed d1 = 2.0 cm.
[] = allowable stress for steel at 160°C; [] = 1316 kg/cm2
K = factor considering stud torsion at stud fixing for diameters more than 22 m
Stud pitch
D1 3.14 x 510
t   80 mm
z 20
The ratio t/d = 80/24 = 3.34 is permissible.
Diameter of tube sheet Dm = Db + dw = 550 + 45 = 595  596 mm.
Washer diameter for a stud is dw =45 mm.
Flange thickness for the floating head cover
  m
2
D
p  k  C  C'  4bc 
2 2 Dk
S  1.62 x 3   
EF ' D 2
n m  m
EF Dk
2
 48  0.9 x 2250
25  0.8  1.05  4 x 1 x 0.8 
2 2 48
 1.62 x 3   x 0.9
1.91 x 106 59.6 2
x 0.8925 x 2.3 x log 2250
2.05 x 106 48

= 2.526 cm = 2.6 cm

D b  d b  D1 55  2.4  51
c   0.8 cm
where 2 2
D  D k   11 51  48  0.9
c'  1   1.05 cm 65
2 2
Ef’ and Ef = flange material elasticity modules at operating conditions and at t = 20°C.
The yield point for steel is m = 2250 kgf/cm2 Strength factor for the flange:
D m α - D k 59.6 x 0.979 - 48
ψ   0.8925
Dm - Dk 59.6 - 48
2
2 d0 2.52
Db - z 55  20
2

 4  4  0.979
2 d0 2. 52
Db  z 552  20
4 4
here z = number of studs
The sheet thickness of the floating tube sheet

0.1P 0.1P
Sm  D1  C  51x D1  0.3  5.3 cm
  1000 x 0.258

whe're [] = allowable stress for steel at 160°C; [] = a  = 1250 x 0.8 =
 =1000 kgf/cm2
 = tube sheet safety factor,

bt - (b - 1) d 15 x 32 - (15 - 1) 25
   0.258
bt  d 15 x 32  25

Checking of tube sheet thickness for tightness of expanded joints

Sm' = +5 mm = + 5 = 8.13 mm < 53 mm
The minimum wall cross section between tubes should be more than minimum shown in the Table 2.13
Table 2.13
Outside tube diameter, mm 20 30 40 50 60 70 80 90
Minimum section of a wall, 100 144 188 232 276 320 364 408
mm2

The actual cross section of a wall is determined as follows

F = (t – d0)1 66
The tightness of the rolled joint is provided by the following sheet thicknesses

d0
for steel tube sheets 1   5 mm
8
d0
for copper tube sheet  1   10 mm
8
According to the Table 2.13 f’ = 122 mm2
The actual wall cross sectional area f = 53 (32 - 25) = 371 mm2
Checking the tube sheet for bending
P 25
 2
 2
 6.6 kgf/cm 2
 d  s   25  53 
3.61 - 0.7 0  m  3.61 - 0.7  
      37.8  37.8 
which is insignificant
t  t cos 600  t sin 600 321  0.5  0.876
   37.8 cm
2 2
Exchanger shell thickness
p m D1 6 x 60
 C  0.36  0.576 cm  6 mm
2.3   p 2.3 x 1002 x 0.7 - 6
where [] = allowable stress for steel shell without reinforced openings,
[] = a  = 1180 x 0.85 = 1002 kgf/cm2
 = 0.7 = safety factor at one side hand welding
D1 = shell inside diameter
C = C1 + C3 - allowance, considering the negative clearance;
C1 = 0.6 mm and corrosion C3 = 3 mm.
Exchanger cover thickness
Pm Di D 60 x 6 60
1  x i C x  0.36  0.521 cm
4[ ] - p 2h 4 x 1120 x 0.918 - 6 2 x 12

67
Assume 1 =0.6 cm.
where [] = allowable stress for steel, [] = [] = 1180 x 0.95 =
= 1121 kg /cm2
h = cover height; h = 0.2 Di = 0.2 x 60 = 12 cm
 = wall safety factor,
dk = diameter of the nozzle for condensate discharge, cm
Thickness of the top tube sheet
0.1P 0.1 x 25
Sm  D'1  C  64  0.3  6.59  6.5 cm
  1000 x 0.258
Assume gasket size to be 650 x 630 x 3 mm. The mean gasket diameter is D'1 = (650 + 630)/2 = 640 mm.
Design of bolts which fix the head to the top tube sheet. Assume 650 x 630 x 30 asbestos gasket for tongue-and-groove Flange;
bolt circle diameter Db = 690 mm flange outside diameter Df = 740, number of bolts z = 20.
Force acting on bolts:
D1
2
25 x 3.14 x 642
Pb  P1  P2  P  D1bq 2   3.14 x 64 x 1 x 150  109750 kg
4 4
where D1 = gasket mean diameter, cm
b = design gasket width
q2 = specific pressure acting on the gasket which provides tightness of the joint.
Internal thread diameter of bolts
4Pb 4 x 109750
d'    2.35 cm
π z σ  k 3.14 x 20 x 1260 x 1
Assume d = 27 mm.
For steel the allowable stress is [] = 1260 kgf/cm2
Checking the ratio which is permissible.
The thickness of the shell
2
D  δ σm
p  i  C  C'  4bc 
2 2 60 x 0.7
S  1.62 x 3   x
E'F D 2
ψn F σm
EF D1
68
 = 4.23 ; 4.5 cm
where c = (Db – db – D1)/2 = (69 - 2.7 - 64)/2 = 1.15 cm
c’ = (D1 - Db – 1)/2 = (64 - 60 - 0.7)/2 = 1.65 cm

d0 2.82
Db  z 692  20
α 4  4  0.984
2
d0 2.82
Db  z 69  20
2

4 4

D F  Db 74 x0.984  60
   0.915
D F  Db 74  60

69
Example 2.21.
Design a heat exchanger for cooling 30052 kg/hr of hydrocarbon from 103°C to 57°C. Cooling will be effected by water (w =
50063 kg/hr).from 30 to 49°C.
The bulk properties of fluids are:
Water Hydrocarbon
Density, p 1000 kg/m3 827 kg/m3
Viscosity, b 0.00065 Pa.sec 0.00117 Pa.sec
Specific heat, cp 4.19 KJ/kg°C 2.45 KJ/kg°C
Thermal conductivity, K - W/m°C 0.132 W/m°C
SOLUTION
1. Terminal conditions and effective mean temperature difference, MTD
Inlet temperature of fluid being cooled, T1 = 103°C
Outlet temperature of fluid being cooled, T2 = 57°C
Inlet temperature of fluid being heated, t1 = 30°C
Outlet temperature of fluid being heated, t2 = 49°C
Log mean temperature difference, LMTD
(T  t ) - (T2  t1 )
LMTD  1 2  39.0
(T1  t 2 )
n
(T2  t1 )

Fouling factor, for one shell exchanger from Fig. 2.6, when
R = 2.42 and P = 0.26, is T = 0.9
MTDe = t(LMTD) = (0.90}(39.0) = 35.1
2.Bulk temperatures
Tubeside (Heated) TTIn = 30, TTout = 49
TTin  TTout
Fluid (Cooled) TTb = = 39.5
2

Shellside (Heated) TSin = 103, TSout = 57

Fluid (Cooled) TSb = = 80 70
3.Bulk properties of fluids
3.Bulk properties of fluids
Tubes Shell ,
 = 1000 kg/m3 827 kg/m3
b = 0.00065 Pa.s0.00117 Pa.s
Cp = 4.19 KJ/kg°C 2.45 KJ/kg°C
K = W/m°C 0.132 W/m°C
4.Flow rates and name
Tube Shell
Fluid = Water Hydrocarbon
W = 16.13 kg/sec 10.57 kg/sec
5.Fouling factors
tubeside fouling factor ri = 0.00035 (Table 2.14)
shellside fouling factor r0 = 0.00018 (Table 2.14)
6.Mechanical design features
Tube Shell
Design temperature = 77°C 132°C
Design pressure = 517kPa 1900kPa
Nozzle DTNI = 150 mm DSNI = 100 mm
DTNO = 150 mm DSNO = 100 mm
(DTNI and DTNO are tubeside inlet and outlet nozzle diameters; DSNI and DSNO are shellside inlet and outlet nozzle diameters)
7. Iteration, tubeside
a.The heat duty for the exchanger is determined during the heat
and material balance calculations. Heat duty, Q = 1234000W
b.Assume UO, the over-all coefficient, UO = 474, W/m2°C
c.Total surface area, A = (10-3)Q/UO(MTD) = 74.2, m2
d.Surface area per shell, AS = A/NS = 74.2 m2
where NS equals number of shells in series
e.Choose the tube metal = Al Brass; thermal conductivity of the
wall at average tube temperature, kw = 100, U/m°C 71
Tube outside and inside diameters: DO = 25.4 mm, DI = 21.2 mm,
Tube wall thickness, I = 0.00211 m, tube length, L = 6.10 m
f.Tube pitch (PT) and layout = 31.75 and 45°
g.Tubeside fouling factor referred to tube outside surface area
DO
rio = ri = 0.000042, m2°C/W
DI

h. Tube wall resistance, rw

rw = /kw = 0.000021, m2 °C/W
i. Number of tubes, NTT
L = NTT = 318 AS/(L - 0.152)DO = 157
j. Assume NTP, the number of tube passes per shell and N, the number of tubes per pass
NTP = 6
N = NTT/NTP = 26
k. Linear velocity in the tubes, vt
(1.273 x 106 ) W
vt   1.76 m/sec
ρ N(DI)

where W equals the mass rate, kg/sec

1. Tubeside heat transfer coefficient

1.273 x 103 W
Re tubeside Reynolds
(1) The
 
 number

103 ρVt (DI)
 57400
based on tube side mass rate, W, at bulk temperature
μ b (DI)N μb

(2) Heat 1.27 x 104   V x DI hio

h io transfer coefficient,
0.26
0.7  1.8TTe  32 
 , for water from approxi
6349 W/mmately
20
C 27°C to 82°C
t
D0  μ b 

(3) For fluids other3 than water

(10 )C pμ b
Pr  number
(a) Prandtl at bulk temperature
K 72
 (b). If Re 2 10000, the tubeside heat transfer coefficient,
22K 0.8 0.4
h io  Re Pr
DO
where
P = (b/w )0.167 for heating and cooling liquids

ψp 
 TTb  273
for heating gases
 Tw  273
p = 1 for cooling gases
p evaluated after Tw calculated
(c) If Re < 10000, the Grashof number
(1) T= |Tw-TTb|
1 1

ρx ρ y
(2). β 
(tx - ty) (1/ρ av )
x and y refer to two temperatures sufficiently far apart to eliminate round off errors, and "av" refers to average
between x and y.
(3) The Grashof number

DI-3ρ 2β' T
Gr  (9.82 x 10 ) -9
2
μb
(d) If Re  2000
(1). From Fig. 2.56 determine the natural convection Re factor y*
(2). From Fig. 2.57 determine short tube correction
factor . If LI/DI > 60,  = 0
(3). Calculate tube length geometry factor, 
 = DI/LI + 
For U tubes LI = 2000L
(4) The low viscosity correction factor  from
Fig. 2.58. If Pr > 20  = 1
(5) Calculate tubeside heat transfer coefficient, hio
73
 (103 )K  
0.14
0.17  μ b 
h io   2.5  4.5  Re  γ * λ  0.37
Pr  
 μ  ψ
DO   w  

(e).If 2000 < Re < 10000
(1). Calculate the turbulent heat transfer coefficient,
(hio)ture at Re = 1000 as described above
(2).Calculate laminar heat transfer coefficient (hio )eam ,
at Re - 2000 as described above
(3). Calculate transitional flow heat transfer proration
factor, 
 = 1.25 - Re/8000
(4). Calculate the tubeside heat transfer coefficient, hio
hio =  ( hio )eam + (1 – )(hio)turb
(f) The average tube wall temperature, Tw
T w = TTb + Uo (Rio + rio) (TSb - TTb ) 50.6°C
where R10 = inside film resistance to heat transfer corrected to outside area, m2 °C/W
rio = inside fouling factor referred to outside surface area, m2°C/W

(g) At the average tube wall temperature, calculate (b/w )0.14 for laminar flow or p for turbulent flow and make
necessary corrections to heat transfer coefficient.
(h) Tubeside pressure drop
(1) Nozzle pressure drop
(a) The average nozzle velocity, Vn
(1.273 x 106 ) W
Vn   1.37 m/sec
(DTNI)(DTN0)ρ

where DTNI and DTNO are inlet and outlet nozzle sizes.
(b) The nozzleρV
pressure
2 drop, Pn
Pn  n
 1.69 k Pa
1112

74
(2). Tube entrance, expansion and turn-around pressure drop
(a). From Table 2.15, evaluate pressure drop coefficient, Ke = 9.6
(b). Calculate entrance, expansion and turn-around pressure drop,  Pe
2
K ρV
Pe  e t  14.9 k Pa
2000
(3) Frictional pressure drop in the tubes
(a). From Fig. 2.59 evaluate the isothermal friction
(b). From Fig. 2.60 evaluate viscosity gradientcorrection factor,  = 0.97
(c). From Fig. 2.61 evaluate the natural convectioncorrection factor,  = 1.00. If Re  8000,
p= 1
(d). The non-isothermal friction factor,f = f isp = 0.00532

75
Example 2.22.
It is desired to cool 6000 kg/hr of benzene from 60°C to 30°C using water with temperature 20°C. The heat capacity of benzene
is C = 0.42 Kcal/kg°C and specific gravity  = 880 kg/m3 . The less viscous fluid, the water, is passed through the tube
side. Solution:
1.The rate of heat transfer
Q = Gc(T1 - T2) = 6000 x 0.42 (60 - 30) = 756OO Kcal/hr
2. Water mass rate. Assume water outlet temperature t2 to be 30°
Q 75600
M   7560 kg/hr
T2  t 2 30 - 20

3.LMTD (at countercurrent flow)

60°  30°
30  10
30°  20° tm = = 18.2 OC
30
30° 10° 2.3 log
10
Mean temperatures of water and benzene
20  30
tm   250 C Tm  25  18.2  43.20 C
2
4. Determination of tube diameters.
Assume water velocity in the tube v. = 1.0 m/sec then the required cross section area of the inner tube
Mw 7560
Ai    0.0021 m 2
3600 x γ x vt 3600 x 1000 x 1
and the inside diameter of the inner tube
di = 0.051 m
Assume the inner tube of diameter d0/di = 57/51 mm
Assume the benzene velocitv in the annu'lus va =1,0 m/sec, then the
required annular flow area
Me 6000
AA    0.0019 m 2
3600 x γ xv a 3600 x 800 x 1

and the inside diameter of the outer tube, Di may be calculated from the following relation:
76
AA = 0.735 Di2 - 0.705 d02
Or 0.0019 = 0.785 Di2 - 0.735 x 0.0572
Hence Di = 0.076 m.
Assume the outer tube of diameter 89/82 mm, then A. = 0.00275 m2
and the benzene velocity
6000
Va   0.69 m/sec
3600 x 880 x 0.00237
5. Tube side heat transfer coefficient h. for water:
hi = 1700 Vt0.8 x di -0.2 = 1700 x 10.8 x 0.051-0.2 = 3083 Kcal/m2hr°C
Annular heat transfer coefficient ha for benzene:
Equivalent diameter:
4A A 4 x 0.0275
de    0.061 m
πd 0 3.14 x 0.057

ha = 495 x Va0.8 x de –0.2 = 495 x 0.690.8 x 0.061-0.2 = 644 Kcal/m2hr°C

6. Overall heat transfer coefficient U:

δ 1

Assume fouling from tube side K 3000
1
U0   437 Kcal/m 2 hr 0C
1 0.003 1 1
  
3083 40 3000 644

7. Exchanger area
Q 75600
A   9.5 m 2
U 0 x t m 437 x 18.2

77
8.Required tube length (considering the surface by the outside diameter of the inner tube)
A 9.5
   53 m
3.14 x d 0 3.14 x 0.057
Assume 10 tubes, each 5.3 m length.

78
Example 2.23.
Recalculate example 2.20 by use of an inner tube to which are attached longitudinally 6 fins, 12 mm high, 2 mm thick, and
with a pitch
3.14 x 57
t  30 mm
6
Annular flow area
AA = 0.00275 - 6 x 0.012 x 0.002 = 0.0026 m2
Benzene velocity
6000
Wa   0.73 m/sec
3600 x 880 x 0.026
Perimeter of heating surface
= 3.14 x 0.057 + 6 x 2 x 0.012 = 0.323 m
Equivalent diameter
4 x 0.0026
de   0.032 m
0.323

Annular heat transfer coefficient neglecting fins

h0 = AW0.8de0.2 = 495 x 0.730.8 x 0.032-0.2 = 770 Kcal/m2hr°C
2h 0 2 x 770
  139;
We have; m = δk 0.002 x 40 mh = 139 x 0.012 = 1.67

β = 0.558 (from Table 2.18). From Eq. (2.143)

The overall duty coefficient of heat transfer
1
Uo   595 Kcal 2 O
1 0.003 1 1 m hr C
  
300 40 3000 1060

i.e., 36% higher than that without fins

79
Example 2.24.
What will be the size of the pipe coil in concentric layout if the heat transfer area is A = 40 m .The Coil is made of a pipe 38/33
mm diameter. The tubeside water flow rate is V = 15 m /hr. Water velocity is assumed to be w = 0.8 m/sec. Then
the flow rate passed through one coil
3600 x 0.785 x 0.0332 x 0.8 = 2.45 m3/hr
Number of coils 15
n 6
2.45

The mean pipe length in each coil

40
L  60m
6 x3.14 x0.0355

Assuming e = 1 and t = 1.5 x 38 = 58 mm, we find the number of coils

L 1x60
n   18
t 3.14 x0.057
Mean diameter of the coil D
L 60
   1.06m
t 3.14 x18
Assuming the clearance between coils b = 80 mm, we determine the coils' diameters
D1 = D - (m - l)b = 1060 - 5 x 80 = 660 mm
D2 = 660 + 2 x 80 = 820 mm
D3 = 820 + 2 x 80 = 980 mm
D4. = 980 + 2 x 80 = 1140 mm
D5 = 1140 + 2 x 80 = 1300 mm
D6 = 1300 + 2 x 80 = 1460 mm
The height of coils H = nt = 18 x 57 = 1026 mm

80
Example 2.25.
Design a trombone cooler for 92% H2SO4, The initial temperature of the acid is t', = 70°C, final t", = 40°C. Cooling water is
available at t'2 = 25°C. Acid flow rate is 40t/hr, its specific weight y: 1800 kg/m3 and heat capacity c = 0.4 Kcal/kg°C.
1. Heat flow.
Q = 40000 x 0.4(70 - 40) = 480000 Kcal/hr
2.Mean temperature difference (assuming t", = 40°C)
70 O → 40 O 30  15
t m   22.5O C
40 ← 25
O O
2
Mean water temperature
25  40
tm2   32.5O C
2
Mean acid temperature
70  40
t m1   55O C
2
3.Acid velocity and pipe diamete. Assuming acid velocity 0.6 m/sec the pipe cross-sectional area is
4000
A1   0.0106m 2
3600 x1800 x 0.6
Assume cast iron pipe diameter 50/65 mm; the area of one pipe 0.785 x 0.052 = 0.00196 m2, the number of parallel sections
0.01030
m  5.25
0.00196
Assume m = 6, then
A = 6 x 0.00196 = 0.0112 m
and velocity
40000
W  0.55 m
3600x1800x0.0112 sec

4. Heat transfer coefficients.

hi = Aw0.8d-0.2 = 410 x 0.550.8 x 0.05-0.2 = 465 Kcal/m2hrOC

81
The irrigation density r is unknown; assuming it to be 800 kg/m hr we find ho = Br 0.4 =- 207 x 8000.4 = 3140 Kcal/m2hrOC
Evaluating the resistance of fouling as from outside the pipes k/ = 2000, and from inside k/ = 1000
5. Overall heat transfer coefficient
1
U  240 Kcal 2 O
1 1 0.0075 1 1 m hr C
   
465 1000 40 2000 3140
6. Heat-transfer surface area
480000
A  90 2 m
240 x 22.5
Pipe length in each section (by calculating the surface with use of internal diameter)
A 90
L   95m
md i 6 x3.14 x 0.05
Assuming e = 3, t = 250, and the number of vertical rows in the section p = 1, we determine the number of pipes
4L 4 x95
1 1 1 1
 pt 3 x1x0.25  11 .7
n 
2 2

L 95
Assume n = 12 The length of each pipe   n  12  7.9m
Assume ℓ = 8 m
7. Water flow rate. From I-X diagram we determine: x" = 0.024 kg/kg (for saturated air at 32.5°C), x = 0.009 kg/kg (at air
temperature 20°C and Ψ = 0.8). Assume Ao = 2A = 2 x 90 = 180 m 2, β= 50 kg/m2hr. The weight of vaporized water Wo =
50 x 180 x (0.024 - 0.009) = 135 kg/hr. The vapor enthalpy at 20° i = 606 Kcal/kg. From the equation:
Q = (W – Wo)(t2 – t1) + Wo (i – ti)
we get
480000 = (W - 135)(40 - 25) + 135 (606 - 25) hence the water flow rate W = 26800 kg/hr
The total length of the top pipes is ℓo = 6 x 8 = 48 m; the density of irrigation is r = 26800/2 x 48 = 280 kg/m hr. Since r is
less than that assumed before, we recalculate h o = 1650 and U = 225; as we see U changes insignificantly.
82
8. Hydraulic resistance of the cooler.
0.0024 x8
H = z(ht + hin + hout + hk) = zw2(a + b ℓ/di) = 12 x 0.55 (0.15 + ) = 1.9 m H 2SO4
0.05
Where a = 0.15; ℓ = 0.8 mm;
0.0064
b 4  0.0024
50

83
Example 2.26
Design the spiral-plate heat exchanger for heating 20t/hr 10% NaOH with initial temperature t’ 2 =50 OC. Heating agent is steam
condensate, t’1 = 95 OC, its flow rate 18t/hr. Spesific weight of the NaOH solution is γ=1100 Kg/m3, heat capacity C = 0.83
Kcal/KgOC.
1. Heat flow. Since R  gc  200000.83  0.923  1 We assume ∆t min = 10 O
GC 180001
t’2 = t’1 - ∆tmin = 95 – 10 = 85OC
heat flow rate
Q = 20000 x 0.83 (85 – 50) = 582000 Kcal/hr
Final temperatureQ of condensate
582000
t"1  t '1   95   62.7 O C
GC 180001

2. Mean temperature difference

950  62.70
850  500 10  12.7
t m   11.3O C
100 12.70 2
Mean temperature of the solution
50  85
t m   67.5O C
2
Mean temperature of condensate
tml = 67.5 + 11.3 = 78.8 OC
3. Flow velocities and cross sectional areas
If we assume the condensate velocity w1 = 1.5 m/sec then the necessary cross section is As = 18 / 3600 x 1.5 = 0.00333 m 2.
assuming the Achannel width b = 6 mm the width of a spiral
0.00333
B s   0.555m
b 0.006

Assume B = 0.6 m, Be = 600 – 20 = 580 18

w1 mm  1.4 m
3600  0 . 0035 sec
As = 0.58 x 0.006 = 0.0035 m and
2

Assuming the same

20000 width of a channel for the solution
w2   1.4 m 84
1100 3600 0.0035 sec
 4. Heat transfer coefficient
Equivalent diameter
4 S 4 Bb
d eq    2b0.006  0.012m
2B 2B

Heat transfer coefficient:

for condensate
h1 = Aw0.8d-0.2 = 2330 x 1.40.8 x 0.012-0.2 = 7600 Kcal/m2hrOC
for solution
h2 = Aw0.8d-0.2 = 1730 x 1.40.8 x 0.012-0.2 = 5450 Kcal/m2hrOC
the overall heat transfer coefficient (at w = 5 mm (steel))
Assuming fouling from the side of the solution k/ = 3000, and the from the condensate side k/ = 7000
1
U  1100 Kcal 2 O
1 1 0.005 1 1 m hr C
   
7600 7000 40 3000 5450

5. Heat transfer surface

582000
Ao  47m 2
1100 11 .3

Effective length
A 47
Le  O   40.5m
2 Be 2 0.58
Pitch (at a sheet thickness  = 5 mm) is t = 6 + 5 = 11 mm. the initial diameter is assumed d = 300 mm
The ratio
r1 1 1  d  1  300 
X      1    1  13.136
t 2 2 t  2  11 

The number of coil:

 2 Le 2 40500
N  2n   x2  x   13.136 2  13.136  37.03
t 3.1416 11
85
 External diameter of a coil
D = d + 2Nt +  = 300 + 2 x 37.03 x 11 + 5 = 1120 mm
Length of a coil ( a = 100 mm, b = 300 mm)
L1 = Le + ¼ πD + a = 40500 + ¼ x 3.1416 x 1120 + 100 = 41480 mm
L2 = Le + ¾ πD - b = 40500 + ¾ x 3.1416 x 1120 – 300 = 42839 mm
Angle of rotation (at No = 36)
 = (N – No) 180 = (37.03 – 36) 180 = 186 OC
6. Hydraulic resistance. The resistance for each chanel is
H = zw2 ( a+ b ℓ/d ) = 1.42(18.5 x 0.04 + 0.0027 x 40.5/0.012) = 19.3 m
where ℓ = Le = 40.5 ; d=deq = 0.012 m; k = 0.3 mm (assumed)
bo = 0.005 (from the table 2.20)
b 0.005
b o  4  0.0027
4 d 12
eq

Number of
N coils
37.03
n   18.5
2 2

TABLE 2.20
Value for k and bo for tube
Tube k, mm Bo
Copper and brass 0.1 0.0038
Lead 0.5 0.0057
Cast iron and ceramic 1.0 0.0067
Steal with non-corrosive
Gases and vapors 0.1 0.0038
Steel with non-corrosive liquids 0.3 0.005
Steel with low corrosive liquids 0.5 0.0057
Steel with highly corrosive liquids 0.8 0.0064
86