6/12/2021 Shell and Tube Multipass Heat Exchanger Design | Tubular juice heater

S.no Particulars Sign and formulas Values UOM

Data to be required for calculation
1 Crushing rate TCH 210 TCH
2 Juice % cane P 102 %
3 Velocity of Juice Vj 1.8 m/sec
4 Density of juice ρ 1.06 gm / ml3
5 Tube OD OD 45 mm
6 Tube Thickness Tk 1.2 mm
7 Tube ID ID 42.6 mm
8 Tube length L 4000 mm
9 Specific heat of juice Cp 0.9 Kcal/Kg/oC
10 Legment Lg 12 mm
11 Vapour inlet temperature Tv 85 oC

12 Juice inlet temperature ti 60 oC

13 Juice outlet temperature to 75 oC

14 Tube plate thickness Tb 25 mm

15 Velocity of vapour Vv 40 m/sec
16 Heater Heating Surface S 250 m2
17 Velocity of condensate Vc 1 m/sec
18 Proportional factor β = 0.7 to 0.8 0.7  
 
19 Latent heat of vapour 548.24 kcal/Kg

20 Specific volume of vapour μ 2.83 M3/kg

         
Calculation part  
         
1 Number of tubes per pass      
  Volume of the juice M = (TCH x P) / ( ρ x 3600) 0.0561 M3/sec
  Area of the one tube A = 0.785 x ID2 0.0014 M2
    M / ( A x Vj) 21.89 tubes/pass
    i.e 22.00  
2 Number of the tubes      
  Mean Dia Dm = OD – Tk 43.8  
  Effective tube length L m = L – 2 x Tb – 2 x 5 3940  
  Number of the tubes  N t = S / ( π  x Dm x Lm ) 461.36  
    i.e 462.00 no.s
3 Number of Passes n = Nt / tubes per pass 21.00  
3 Number of passes should be always taken even number ( n ) 22  
         
         
  As Per Even number of passes Heater parameters to be calculated
4 No. of compartments Top side = n/2 +1 12  
    Bottom side = n/2 11  
5 Actual number of tubes Nt = n x tubes per pass 484 no.s
         
6 Actual heating surface S = π x Dm x Lm x Nt 262 m2
         
7 Actual velocity Vj = M /  Area of one pass 1.79 m/sec
8 pressure drop across the juice heater 0.0025 x n x Vj2 x ( L/ ID +3) 17.10 MWC
         
9 Tube plate dia      
Pt = OD + Legment + Tube
  Pitch Tolerance(0.5mm) + Hole 57.6  
Tolerance(0.1mm)
  Tube plate Area At = 0.866 x Pt 2 x Nt /  β 1.99 m2
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6/12/2021 Shell and Tube Multipass Heat Exchanger Design | Tubular juice heater

    Take 10% extra 2.19 m2

  Tube plate dia Dt = SQRT ( At / 0.785)
1668 mm
10 Dia of juice inlet pipe      
    Area Aj = M / Vj
0.031 m2
    Dj = SQRT ( Aj / 0.785)
0.199 mtrs
    i.e 200 NB
11 Vapour inlet Dia Qj x Cp x ΔT = W x λ   mtrs
    Qj = TCH x P x 1000 214200 Kg/hr
    ΔT  = to -ti 15 oC

    W = weight of the vapour 5274.515 kg/hr

    Qv = W x μ /3600 4.146 M3/ sec
    Av = Qv / Vv 0.104 m2
    Take 10% extra 0.114 m2
    Dv = SQRT ( Av / 0.785) 0.381 mtrs
    i.e 400 NB
12 Condensate pipe Dia      
Qc = weight of the condensate =
    0.00147 M3/sec
W
    Ac = Qc/ Vc 0.00147 M2
    Take 50% extra for free removal 0.00220 M2
    Dc = SQRT ( Ac /0.785) 0.053 mtrs
    i.e 75 mm
13 NCG pipe line dia      
2
For every 10m  Heating surface
  Cross section area of pipe required 1 cm2 area to be 26.23 cm2
required ( An )
    SQRT (( An/4) / 0.785) 2.89 cm
4 no.s NCG points and each
  NCG pipe line dia 32 mm
having
14 Calendria shell thickness (P*  Di / (2*F*J – P) ) + C    
  Maximum allowable pressure P (Hydraulic test pressure) 3 kg/cm2
  ID of the Juice heater Di 1668 mm
  Allowable stress F 1400 kg/cm2
  Welding Joint efficiency J 0.75  
  Corrosion allowance C = 1.5 for calendria shell 1.5 mm
  Calendria shell thickness   3.89 mm
  Say   4 mm
  But as per standard specification 12mm for longitude of equipment
         
15 Tube plate thickness f x G x SQRT((0.25 x P)/F) + C    
  Corrosion allowance C = 3.0mm for tube plate 3 mm
  Allowable stress F 1400 kg/cm2
  Maximum allowable pressure P 3 kg/cm2
  Modulus factor for MS sheet Es 2100000 kg/cm2
  Modulus factor for SS sheet Et 1900000 kg/cm2
  ID of the shell G 1668 mm
  Thickness of the shell ts 12 mm
  Thickness of tube tt 1.22 mm
  OD of the tube do 45 mm
  Do = OD of the calendria sheet Do = ID + 2 x shell thickness 1692 mm
  Number of tubes Nt 484 no.s
K =( Es x ts x (Do -ts)) /(Nt x Et
  K 0.862174  
x tt x(do -tt))
  f = safety factor f = SQRT ( K / (2 + 3K)) 0.433567  
  Tube plate thickness   19.74 mm
  But as per standard specification 25mm for tube plate
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6/12/2021 Shell and Tube Multipass Heat Exchanger Design | Tubular juice heater

         
16 Thickness of the cover plate tc = Gc x SQRT ( K x P /f ) + C.A    
  ID of the shell Gc 1668 mm
  For flat joint K = 0.3 0.3  
  Design Pressure P 3 kg/cm2
  Allowable stress f 1400 kg/cm2
  Corrosion allowance C = 1.5mm for cover plate 1.5 mm
  Thickness of the cover plate   43.79 mm
  But as per the Indian practice to given 32mm cover plate with adequate stiffening is sufficient

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