FINNED TUBE HEAT EXCHANGER (COOLER) DESIGN

Group Group Members

Number
05160000274 Seda ARSLAN
05170000216 Zeynep Doğa CEYLAN
12 05170000223 Buse ŞAHİN
05170000257 Elif TEKİN
05170000269 Ecem KENAR
RESULT
Table.1 General Information

Production capacity, 67500

tons/year
Heat load, Q, kW 6850
Flow rate of the process 5.4
stream, kg/s
Inlet and outlet 343 – 83.7
temperatures of process
stream, °C
Logarithmic mean 162.195
temperature difference
Type Inlet Outlet Cp, , µ, k,
T°C T°C kJ/kgK kg/m3 kg/ms W/mK
Utility @25 °C & 1 atm
Therminol 10 40 2,11 758 0.00116 0.1092
D12
Type Thermal conductivity, k,
Tube material W/mK
Stainless steel 16

Table.2 Spesifications and Result

ho, AoR Nw,

hi, Ptu jH f U,
vtube, W/ Pshell, w, Ao, V, Nz,
Cases Rei W/m be, and Reo and W/m
m/s m2 atm 𝐦𝟐 𝐊 m2 m3 and
2
K atm f
K o 2
K
Ntotal
𝐤𝐖
0,01 0,49 59.3 32/
(Afr)=
1710 0.21 7/ 5.44*10 0/ 0,74 17/
2,5 2.04 1040 2000 162 ^-4
726 2.70
0 5 0,04 0,57 7 544
L1=5
2 7
0,01 36.6 26/
0,83/
(Afr)=5 0.08 3/ 1.58*1 0,74 33/
1.16 9700 893 998 618 0^-4
0,85 1180 4.38
L1=5 10 0,04 7 858
9
4
0,01 56.3 34/9
(Afr)=2
3030 2/ 5.05*1 0,57/ 0,74 /306
,5 L2 3.63 2220 1.04 2000 114 0^-4
766 2.85
0 0,03 0,64 7
=10
7
Selected Design No:1
Table.3 Pipe Properties

Pipe do (m) di (m)

Stainless Steel 0.0164 0.0128 0.016

Figure.1 Heat transfer and friction factor for a circular tube–circular fin heat exchanger

Figure.2 Efficiency of annular fins of rectangular profile

Figure.3 Correction factor for a single-pass, cross-flow heat exchanger with one fluid mixed and the other unmixed

Table.4 Properties of Compounds (Finned Type Heat Exchanger)

@486.355 K & 1 atm

𝐤𝐉
Compound 𝐂𝐩𝐠𝐚𝐬 ( )
𝐤𝐠. 𝐊

Ethanol 46.07 1.40*10-5 2.0 3.58*10-5

Ethylene 28.05 1.58*10-5 2.13 4.59*10-5

Water 18.015 1.68*10-5 0.531 3.52*10-5

DEE 74.12 1.22*10-5 0.001 3.54*10-5

Butene 56.11 1.24*10-5 2.73 3.59*10-5

 DISCUSSION & CONCLUSION
Heat exchangers are commonly used in the cooling and heating process in large-scale
manufacturing processes. The form and size of the heat exchanger used can be modified to
accommodate the operation, based on the type of fluid, its phase, temperature, density,
viscosity, pressure, chemical composition, and other thermodynamic properties. In order to
design finned tube heat exchangers for improved heating transfer area there are two components
of the problem which are heat determination of the necessary heat transfer area and the optimal
spacing of tubes to achieve the required surface area. The heat transfer area can improve the
efficiency of the heat exchanger.

The effect of the number of tubes on the outer fluid flow shall be tested for differences in fluid
velocity. If the velocity of the outer fluid varies dramatically, the coefficients of heat transfer
and the required tube area are reassessed. Thus, in a few such iterations, the optimal
configuration of the finned tubes can be calculated in order to achieve the desired heat transfer
area.

If we regard this as part of our design, the utility used in the heat exchanger is therminol D-12
which is a synthetic, liquid phase heat transfer fluid with excellent heat transfer properties over
a wide temperature range. This fluid is ideally suited for applications that require efficient
cooling and heating. With this utility, the process stream would be a temperature range of 343-
83.7℃ to obtain the desired values. Utility was selected with the inlet temperature of 10℃ and
the outlet temperature of 40℃. Another selection is the material for the tube which is made of
stainless steel with diameters of di: 12.8 mm and do: 16.4 mm.

Within our assumptions and considerations, the optimal conditions were found to achieve an
effective heat exchanger according to the design guidelines. As shown in the Results section,
operations were carried out in three design cases. In the case chosen, L assumed as 5m & 𝐴𝑓𝑟
assumed as 2.5 m. Our calculations, which began with the determination of mole fractions and
their conversion to the appropriate unit, proceeded with the calculation of the viscosity mixture.
After that, the evaluation of the Reynolds number was performed and the result was found for
the chosen case as 2000 which shows a laminar flow behavior. Within a consideration of it,
jH read as 0.017 from graph then, Pr number was calculated as 0.521. With the help of found
values in the ho formula, it was calculated as 162 W/m2K. Then nf (%) 𝑟𝑒𝑎𝑑 𝑎𝑠 0.49.

Another important calculation was to determine tube side heat transfer coefficient for inside of
tubes (hi) which is evaluated by some assumptions and other calculations. Ntube is assumed as
544 so we can made iterations to calculate the real number of tubes. Amount of utility has been
kg
obtained as 108 and shown in the result tables. Then the vtube calculations has been carried
s

out. The most important thing here is that the velocity value must be about 0.9-2.4 m/s. As can
be seen in these calculations in the Appendix section, vtube was calculated as 2.04 m/s and
approved as acceptable since it was between the limits. After that, using the heat transfer
expression rate for the heat exchanger, the tube number is retrieved and tested with the first
assumed tube number and, if it is equal, the calculations are done. Finally, the pressure drop
was calculated on the basis of the flow through the finned tubes and also on the shell side. They
were found as 0.000544 atm on the shell side and 0.215 atm on the tube side, which are
acceptable values.

In order to achieve an optimal heat exchanger configuration, the parametric analysis was
applied. The effect of frontal area 𝐴𝑓𝑟 and tube length L is analyzed. To understand the effect
of frontal area variation, we raised the frontal area value from 2.5 m2 to 5 m2, so the vtube value
decreased. In comparison, in this case, the Ntotal value increased considerably and the overall
coefficient of heat transfer decreased. Another analysis which examines the effect of tube length
would summarizes that if we change the length of tube from 5 m to 10 m, the vtube value and
the Ntotal value increased but it is seen that overall heat coefficient slightly decreased. As a
result, first case was chosen as the most effective design.
 NOMENCLATURE
Q̇ : Heat Load [kW]
JH: Heat Transfer Factor -
z: Height for Finned Tube Heat Exchanger [m]
Dh: Hydraulic Diameter of Flow Passage [m]
Tc,i: Inlet Temperature of Cold Stream (Utility) [oC, K]
Th,i: Inlet Temperature of Hot Stream (Process Stream) [oC, K]
Tc,o: Outlet Temperature of Cold Stream (Utility) [oC, K]
Th,o: Outlet Temperature of Hot Stream (Process Stream) [oC, K]
Lfin: Length of Fin [m]
∆Tlm: Logarithmic Mean Temperature Difference [oC, K]
ṁ 1−t: Mass Flow Rate for One Tube Pass [kg/s]
Lc: Corrected Fin Length [m]
r2c: Corrected Radius [m]

ρutility: Density of Utility

Df: Diameter of Fin [m]

ηf: Fin efficiency of One Tube -
Ap: Fin Profile Area [m2]
t: Fin Thickness [m]
Aflow: Flow Area of Boiling Mixture [m2]
Aff: Free Flow Area of Finned Passages

fs: Friction Factor for Shell Side -

ft: Friction Factor for Tube Side -
Afr:Frontal Area [m2]
FT: Logarithmic Mean Temperature Difference Correction Factor -
ṁ utility = ṁ t: Mass Flow Rate of Tube Stream (Utility) [kg/s]
SW: Number of Tube Columns [m]
nt−p: Number of Tube Passes -
α: Ratio of Heat Transfer Area to Total Volume [m−1]
Remix: Reynolds Number of Process Fluid -
SV: Number of Tube Rows [m]

Reutility: Reynolds Number of Utility -

kW
ho: Shell Side Heat Transfer Coefficient m2 .K

P: Total Pressure [atm]

kW
hi : Tube Side Heat Transfer Coefficient [ ]
m2 K

Nuutility: Nusselt Number of Utility

η0: Overall Fin efficiency
Uo: Overall Heat Transfer Coefficient

σ: Ratio of the Free Flow Area to Frontal Area

Prmix: Prandtl Number of Process Fluid

Prutility: Prandtl Number of Utility

∆Ps: Shell Side Pressure Drop

Ao: Shell Side Surface Area

Cp−mix: Specific Heat Capacity of Process Fluid

Cp−utility: Specific Heat Capacity of Utility

ϑi: Specific Volume of Inlet Stream

ϑ0: Specific Volume of Outlet Stream [m3]

NTube: Total Number of Tubes -
di:Tube Inside Diameter [m]
Do:Tube Outside Diameter [m]
∆Pt: Tube Side Pressure Drop [atm]
Ai: Tube Side Surface Area [m2]
vt: Velocity of Tube Side [m/s]

µmix: Viscosity of Process Fluid [kg/m.s]

V: Volume [m3]
x: Wall Thickness [m]
w: Width [m]
 REFERENCES
1. Cüneyt Ezgi, Basic Design Methods of Heat Exchanger, 2017
2. Ludwig's Applied Process Design for Chemical and Petrochemical Plants, Volume 1,
Fourth Edition
3. Perry, R. H., & Green, D. W. (2008). Perry's chemical engineers' handbook. New York:
McGraw-Hill.
 APPENDIX
In selected design,
➢ L assumed 5m & 𝐴𝑓𝑟 assumed 2.5 m

➢
Afr 2.5
Afr = L × z, z= = = 0.5 m:
L 5
kg kg kg kg kg 𝐤𝐠
ṁtotal = 2.585696 + 0.258325 + 2.145446 + 0.019931 + 0.391018 = 𝟓. 𝟒
s s s s s 𝐬

➢ 𝐷ℎ = 0.00668 𝑚 (given)

xtotal = 0.411 + 0.025 + 0.531 + 0.001 + 0.03 = 𝟎. 𝟗𝟗𝟖

𝛍𝐦𝐢𝐱 Calculation:
𝛍𝐦𝐢𝐱 = μethanol × xethanol + μethylene × xethylene + μwater × xwater + μDEE × xDEE + μbutene × xbutene
𝒌𝒈
= 𝟏. 𝟔𝟏 × 𝟏𝟎−𝟓
𝒎. 𝒔
616 + 356.71
𝑇𝑎𝑣𝑔 = = 486.355
2

Aff
➢ = 0.449 (given)
Afr

𝐀 𝐟𝐟 = 0.449 × 2.5 = 𝟏. 𝟏𝟐𝟐𝟓 𝐦𝟐

mtotal 5.4 kg/s 𝐤𝐠
𝐆= = = 𝟒. 𝟖𝟏𝟎𝟔𝟗 𝟐
Aff 1.1225 𝐦 .𝐬
kg
G × Dh 4.81069 m2 . s × 0.00668 m
𝐑𝐞 = = = 𝟐𝟎𝟎𝟎
μmix kg
1.61 × 10−5 m. s

➢ jH read as 0.017 from graph

𝐂𝐩𝐦𝐢𝐱 = Cpethanol × xethanol + Cpethylene × xethylene + Cpwater × xwater + CpDEE × x DEE

𝐤𝐉
+ Cpbutene × xbutene = 𝟏. 𝟐𝟖
𝐤𝐠. 𝐊
ho jH × 𝐺 × Cpmix Cpmix × μmix
jH = × Pr 2/3 & ho = & 𝑃𝑟 =
G × Cpmix Pr 2/3 k mix
𝐤 𝐦𝐢𝐱 = k ethanol × xethanol + k ethylene × xethylene + k water × xwater + k DEE × xDEE + k butene × xbutene
𝐤𝐖
= 𝟑. 𝟗𝟓 × 𝟏𝟎−𝟓
𝐦. 𝐊
kJ kg
1.28 × 1.61 × 10−5 0.017 × 4.81069 × 1.28 𝐤𝐖
kg. K m. s
𝐏𝐫 = = 𝟎. 𝟓𝟐𝟏 𝐡𝐨 = = 𝟎. 𝟏𝟔𝟐 𝟐
kW (0.521)2/3 𝐦 .𝐊
3.95 × 10−5 m. K

➢ Df = 0.0285 m (given)
 0.0285 m
𝐫𝟐 = = 𝟎. 𝟎𝟏𝟒𝟐𝟓 𝐦 𝐋𝐟𝐢𝐧 = r2 − r1 = 𝟎. 𝟎𝟎𝟔𝟎𝟓 𝐦
2

t 0.254 × 10−3
𝐋𝐜 = Lfin + = 0.00605 + = 𝟎. 𝟎𝟎𝟔𝟐 𝐦
2 2
𝐀𝐩 = Lc × t = 0.0062 × 0.254 × 10−3 = 𝟏. 𝟓𝟕 × 𝟏𝟎−𝟔 𝐦𝟐
1 1
3 ho 2 2 0.162 2
(Lc )2 ×( ) = (0.0062)3 ×( −7
) = 1.24
k stainless steel × Ap 0.016 × 1.57 × 10
t 0.254 × 10−3
𝐫𝟐𝐜 = r2 + = 0.01425 + = 𝟎. 𝟎𝟏𝟒𝟑𝟖 𝐦
2 2
𝐫𝟐𝐜 0.01438
= = 𝟏. 𝟕𝟓𝟑
𝐫𝟏 0.0082

➢ nf (%) 𝑟𝑒𝑎𝑑 𝑎𝑠 0.49 A

ηo = 1 − A f × (1 − ηf ) = 0.577
o

Af
➢ Ao
= 0.83 (given)

Ai di Af 0.0128m
= (1 − ) = (1 − 0.83) = 𝟎. 𝟏𝟑𝟐𝟔𝟖𝟑
Ao do Ao 0.0164m

➢ do = 0.0164 m & di = 0.0128 m(given)

d 0.0164
di × ln ( o ) 0.0128 × ln (0.0.128) 𝐦𝟐 𝐊
di
Ao R w = = = 𝟎. 𝟕𝟒𝟕𝟏𝟓
A 2 × 0.016 × (0.132683) 𝐤𝐖
2 × k stainless steel × ( i )
Ao
Calculation of 𝒉𝒊 :
Cputility × μutility 2.11 × 0.00116
𝐏𝐫 = = = 𝟐𝟐. 𝟒𝟏𝟑𝟗
k utility 0.0001092

➢ Ntube assummed as 544

Heat Calculation:
356.71 356.71
Q = ṁethylene × ∫ Cpvap_ethylene dT + ṁethanol × ∫ Cpvap_ethanol dT + ṁDEE
616 616
356.71
×∫ Cpvap_DEE dT
616
+ ṁ butene
356.71
×∫ Cpvap_butene dT
616
373 356.71
+ ṁ water × ∫ Cpvap_water dT + ṁ water × ∫ Cpliq_water dT + ∆Hvap_water × ṁ water
616 373
𝐤𝐣
= −𝟔𝟖𝟓𝟎
𝐬
−Q
ṁ utility =
Cputility × (Tc,o − Tc,i )
 ➢ Tc,i = 10℃ & Tc,o = 40℃

kj
6850 𝐤𝐠 mutility 108
s
𝐦̇ 𝐮𝐭𝐢𝐥𝐢𝐭𝐲 = 2.11×(40−10) = 𝟏𝟎𝟖 𝐬
𝐦𝟏−𝐭 = Ntube
= 544 = 𝟎. 𝟏𝟗𝟗

4 × m1−t 4 × 0.199 𝐦
𝐯𝐭 = 2 = 758 × π × (0.0128)2 = 𝟐. 𝟎𝟒 𝐬 (𝒄𝒐𝒏𝒔𝒊𝒔𝒕𝒆𝒏𝒕)
ρutility × π × di
kg m
ρutility × vt × di 758 m3 × 2.33 s × 0.0128 m
𝐑𝐞𝐮𝐭𝐢𝐥𝐢𝐭𝐲 = = = 𝟏𝟕𝟏𝟎𝟎 (𝐓𝐮𝐫𝐛𝐮𝐥𝐞𝐧𝐭)
μutility kg
0.00116 m. s
1
( )
𝐍𝐮𝐮𝐭𝐢𝐥𝐢𝐭𝐲 = 0.024 × Re0.8 3
utility × Prutility = 0.024 × (17100)
0.8
× (22.4139)1/3 = 𝟏𝟔𝟒

Nuutility × k utility 183 × 0.0001092 𝐤𝐖

𝐡𝐢 = = = 𝟏. 𝟒𝟎 𝟐
di 0.0128 𝐦 𝐊
1 1 1 1 1
= + Ao R w + = + (0.74715314) +
A
U h × ( i) ηo × ho 1.56 × (0.132683) 0.577 × (0.162)
i Ao
kW W
➢ U found as 0.0593 = 59.3
m2 𝐾 m2 𝐾

Q = U × Ao × ∆Tlm × FT (FT read as 0.98 from figure)

∆T1 − ∆T2
∆Tlm =
∆T
ln (∆T1 )
2

∆T1 = Th,i − Tc,o = 343 − 40 & ∆T2 = Th,o − Tc,i = 87.3 − 10 & ∆𝐓𝐥𝐦 = 𝟏𝟔𝟐. 𝟏𝟗𝟓 𝐊
Q 6850 kW
𝐀𝐨 = = = 𝟕𝟐𝟔 𝐦𝟐
U × ∆Tlm × FT kW
0.0613 2 × 162.195 K × 0.98
m K
Ao 𝐦𝟐
𝛂= = 𝟐𝟔𝟗 𝟑
V 𝐦
Ao 703 2.61m3
𝐕= α
= 269 = 𝟐. 𝟕𝟎 𝒎𝟑 V= L ×z×w 𝐰= 5×0.5
= 𝟏. 𝟎𝟖 𝐦

➢ Sw = 0.0343 m
➢ Sv = 0.0313 m
➢ Df = 0.0285 m, read from figure

w − Df 1.08 m − 0.0285 m
Nw = +1= + 1 = 31.7 ≈ 32 tubes
Sw 0.0343 m
z − Df 0.5 m − 0.0285 m
Nz = +1= + 1 = 16.06 ≈ 17 tubes
Sv 0.0313 m
𝐍𝐭−𝐜𝐚𝐥𝐜𝐮𝐥𝐚𝐭𝐞𝐝 = Nw × Nz = 32 × 17 = 𝟓𝟒𝟒 𝐭𝐮𝐛𝐞𝐬
Tube-Side Pressure Difference Calculations:
−0.33
𝐟𝐭 = 0.72 × (Reutility ) = 0.72 × (17100)−0.33 = 𝟎. 𝟎𝟐𝟖𝟗
mutility 108 𝐤𝐠
𝐆𝐭 = = 2 = 𝟏𝟓𝟓𝟎 𝟐
π × d2i 544 ×
π × 0.0128 𝐦 .𝐬
Nt × 4 4
ft × Gt2 × (L × nt−p ) vt2
∆Pt = + 2.5 × ρutility × × nt−p = 𝟎. 𝟐𝟏𝟓 𝐚𝐭𝐦 (nt−p = 1)
2 × di × ρutility 2

➢ ∆𝐏𝐭 must be < 0.5 atm, since ∆𝐏𝐭 = 𝟎. 𝟐𝟏𝟓 𝐚𝐭𝐦, its acceptable

Shell-Side Pressure Difference Calculations:

G2 × ϑi ϑo Ao ϑm
∆Ps = × [(1 + σ2 ) × ( − 1) + f × × ] (𝐟 read as 0.042 from figure)
2 ϑi Aff ϑi
1 1
ϑi = & ϑo =
ρinlet ρoutlet
kg 10−3 kmol
1 atm × 222.365 × 𝐤𝐠
𝛒𝐢𝐧𝐥𝐞𝐭 = mol mol × 103 = 𝟒. 𝟒𝟎 𝟑
L. atm 𝐦
0.0821 × 616 K
mol. K

kg 10−3 kmol
1 atm × 222.365 × 𝐤𝐠
𝛒𝐨𝐮𝐭𝐥𝐞𝐭 = mol mol × 103 = 𝟕. 𝟓𝟗 𝟑
L. atm 𝐦
0.0821 × 356.7 K
mol. K
1 𝐦𝟑 1 𝐦𝟑 𝐦𝟑
𝛝𝐢 = = 𝟎. 𝟐𝟐𝟕 & 𝛝𝐨 = = 𝟎. 𝟏𝟑𝟐 & 𝛝𝐦 = 𝟎. 𝟏𝟖𝟎
4.40 𝐤𝐠 7.59 𝐤𝐠 𝐤𝐠

➢ 𝛔 read as 0.449 from figure

(4.81069)2 × 0.227 0.132 726 0.180

∆𝐏𝐬 = [ × [(1 + 0.4492 ) × ( − 1) + 0.042 × × ] Pa
2 0.227 1.1225 0.227
−6
9.869 × 10 atm
× = 𝟓. 𝟒𝟒 × 𝟏𝟎−𝟒 𝐚𝐭𝐦 < 𝟎. 𝟓 (𝐚𝐜𝐜𝐞𝐩𝐭𝐚𝐛𝐥𝐞)
Pa