Process Design of Heat Exchangers 5 | = Shell side heat transfer coefficient, W/(m? - °C) OD of tube, m D of tube, m Thermal conductivity of tube wall material, W/(m - °C) hjq = Fouling coefficient for tube side fluid, W/(m? - °C) hoq = Fouling coefficient for shell side fluid, W/m? - °C) For the various types of fluids, recommended fouling coefficient are given in Table 6.9. Table 6.9 Recommended Fouling Coefficients (Ref. 4, 6 & 7) Fluid Fouling Coefficient Fluid Fouling Coefficient Wim? “C) Whm?-'C) Cooling water 3000-6000 ‘Aqueous Organic Solution 5000 Steam 4000-10 000 Vegetable oils 3000 Steam condensate 1500-5000 Caustic Solutions 5000 Brine 3000-5000 Gasoline 5000 Air 5000-10 000 Kerosene 3000-5000 Organic vapours 10000 Light gas oil 3000-5000 Organic Liquids 5000 Heavy gas oil 2000-3000 Heavy hydrocarbons 2000 Napthas 5000 Aqueous sult solutions 3000-5000 Coal flue gas 1000 Light Hydrocarbon 5000 Heavy Hydrocarbon 3000 6.3.13 Calculating the Heat Transfer Area Required 4, (6.43) UAT, i Also calculate actual heat transfer area A,, A, =N,nd,L. A. {1.1 to 1.2) 4 AP © 10.8101), Pr max Ps max {0.8 to 1} Thus an optimum design of shell and tube heat exchanger can be obtained. Example 6.1 A lube-oil cooler for 2 MW steam turbine is to be designed for following operating conditions. Lube-oil, conforming to ISO VG-46 grade, flows at the rate of 450 L/min ee Ee176 Introduction to Process Engineering and Design Viscosity of lube oil at 55°C = 15 ¢P Cooling water inlet temperature = 35°C ing water outlet temperature = 39°C Solutio Heat duty, g,= m1, C,, Ar Volumetric flow rate of oil = 450 L/min = 450 x 60 x 10° m°fh = 27 m/h fin = 27 X 869 = 23 463 kg/h. 6, = 23 463 kg/h x 2.1413(65 - 45) LMTD ¢, = 1004 826 ki/h 65°C Heat balance Tiny Chy At 279.118 = th, x 4,1868(39 ~ 35) 6.667 kg/s (= 60 m°/h) (6.12) For the first trial calculations, let the number of tube side pass Allocating lube oil on tube side and cooling water on shell side. %-% -4 re 2, fl hh -h =O C Z=45°C, = 35°C, = 39°C 65-45 39-35 5, Ss = 0.1333 39-35 65-35 From Fig. 6.11, F,=0.95 Mean temperature difference, A%, = F, Fy Ag, = 0.95 x 16.745 = 15.908°C Assume overall heat transfer coefficient U, = 400 W/(m*.C). (Ref.: Table 6.7) Provisional heat transfer area for the first trial calculation Ae 6, 279.118 10° ~ U,AT,, 400 15.908 A= 43.8644 m? = Nyed,L d, = 518 in. = 15.875 mm, L = 6 ft = 1.8288 m 43.8644 —__ 43.8644 ___ _ 480.93 = N= Fe (O.015 875 x 1.8288) ~ 8099 = 480Process Design of Heat Exchangers From Table 6.2 for N, = 1.175, ny = 2.285 \w2.aas D,=15 ss{ 80. 480_) } 075mm 0.175. Let clearance between shell ID and D, = 12.5 mm = 520 mm Evaluation of fy: ‘Tube side flow area: (6.20) d, = 13.3858 mm (for 18 BWG tube) a= Zoos 3858)" = 0.016 887 m? ‘Tube side mass velocity (23403 a ) 3600 0.016687 Viscosity of oil: = 15 cP = 15x10" kgm: s) 390.57 kg/(m? - s) d,G, _ 0.0133858 x 390.57 ‘ # 15x10 To increase the Reynold number, let the number of tube side passes N, = 8 K, = 0.0365, n= (_480 D, = 15875| Sr Shell ID =D, + 12 = 562mm Evaluation of hj a,= ae x 2 0.013 3858)" = 8.4436 x 10 m* G,=39057« 8 = 781.14 kg/(m? - 8) G _ 781.14 Beate Pp 869 Re, = 348.54 x 2 = 697 =0.9 m/s C,H 2.1413x15x108 Introduction to Process Engineering and Design Using SiederTate equation (R,, < 2000) Ind, (ee Nu= a = 1.86(Re- Pr- ane} (6.18) 5g \033 =1 86 697 247 00135658) xd 1.8288 = 19.618 >3.5 k 19.618 0.13 - h, = 19.62 x <=——____~ = 190,526 Wim? - °C) (too low) d, — 0.0133858 To improve oil side heat transfer coefficient, allocate lube oil on shell side and water on tube side. Increase the tube length from 6 ft to 10 ft for the same value of heat transfer area provided. It will decrease the shell side flow area and will improve the shell side heat transfer coefficient L= 10x 0.304 yyy = 43.8644 mi N, = 288.56 = 288 Let number of tube side passes N, k, =0.175,m, =2.285 (Ref.: Table 6.2) 048 m itd, = N, x x 0.015 875 x 3.048 p, =15875( 288 yr = 406 mm : 0.175 Shell ID, D; = 406 + 12 Evaluation of hy: 288. (0,013 3858 4 4 18 mm =0.01 m? 16.667 0.01 Density of water at 34°C, p = 993.328 kg/m? (Table 3.28 of Ref. 2) G _ 1666.7 p 993.328 ‘Tube side mass velocity, G, 1666.7 kg/(m? - s) = 1.678 m/s 4G, Re= Viscosity of water at 37°C, 41 = 0.73 cP = 0.73 x 107 kg/m - s) 7 = 30 561.8 > 4000Process Design of Heat Exchangers _ 4.1868 x 0.73 x10 10° rs = 4.867 0.628 Using Dittus-Bolter equation hyd; 3f ny" Nu = —— = 0.023 Re®* Pr “(4 r My h, = 0.023 x 2628 __ (39 561.8)°8 x 4.3679 0.013 3858 = 7046.6 Wim": °C) Evaluation of oil side heat transfer coefficient (,): Shell side flow area R-d,) x DsX Bs Pid, = 1.25, Ds =418 mm, By = 5 = 125d, =<, Os* C1 25d,) X 0.418 x 0.0836 = 6.989 x 103 m? m \s Shell side mass velocity, G, 1 23.463x 1 = 3000 _ 939 537 kg/m? 6.989 x10 G9 u, = 2 = 232537 © 1.973 avs p 869 Shell side equivalent diameter for triangular pitch (P? - 0,907?) d= }1_ [19,8437 — 0.907 x (15.875) 15.875 = 11.4465 m 4.G, Shell side Reynolds number Re = 0.011 4465 x 932.537 (6.19) (6.29) (6.30) (632)Introduction to Process Engineering and Design _ Cpt _ 2.1413 (15x10) x10" Pr k 0.13 =247 Re = 711.62 = J, =2 x 10” (From Fig. 6.14 for 25% baffle cut) ae =J,Re prn( £) (6.36) Hy 2x1oex 3 _ x 741,62x 247)! x 1 0.011 4465 = 1014.18 Wim? - °C) Overall heat transfer coefficient (i) d, In| 1 1,4 4) 4 1 41 etity + + (642) u fy Moa 2k, qGha ah From Table 6.9 hig = 3000 Win? - °C), Ig = 5000 Wim? - °C) 0.015875 15875 ) alii yi, 13.3858) | 15.875 1 U, ~ 1014.18” 3000 2x50 13.3858 5000 ‘Thermal conductivity of tube material k,, = 50 Wm - °C) Tube material: steel or cupronickel ) U, = 570.8 Wim? °C) 9, UAT Heat transfer area required, A, (6.43) 279.118 x10° 570.8% 15.908 Aono % Excess heat transfer area = (= - = 30.739 m* 42.7 % (sufficiently high)Process Design of Heat Exchangers Shell side Pressure Drop: . 27, you wf 2 [2 Pots | (6.40) d, \ Be} 2 \tw } D, = 0418 m,d, = 0.011 4465 m, L = 3.048 m 0.0836 m, u, = 1.073 mvs, p, = 869 kg/m? hell side friction factor For R,, = 711.62, J,= 7.7 x 10? (From Fig. 6.15) 4p, Fi 869 x 1.073" srr i0°[ et \(ea)« ex 0.011 4465 )\.0.0836. 2 = 410 281.7 Pa = 410.282 kPa (too high) To decrease the shell side pressure drop, baffles spacing can be increased from 83.6 mm. to 160 mm. Revised value of B, = 160 mm = 0.16 m Shell side flow area, A, = 6.989 x 103 x ak = 0.013 376 m? 6.989 x10? : Shell side mass velocity, G, = 932.537 x = 487.25 kg/m? -s) 0.013 376 #8725 _ 9.56 mis 369 0.014465 x 487.25 = = 371.82 15x10” (6.36) for Re = 371.82 = J, = 2.7 x 10” (from Fig. 6.14) hd, Nu= a = 2.7 x 10 x 371.82 x(247)"® = 62.989 f h, = 62.989 x —°-13__ 745.37 wim? - °C) 0.011 4465Introduction to Process Engineering and Design % 279.118x10° 462.15 15.908 = 37.96 m? U, AT, ( ) { Excess heat transfer area = { oan ~1} = 100= 15.55% (adequate Revised Shell side Pressure Drop: For D,=0418m, B,=0.16m, d,=0.011 4465 m, L=3.048 m, u,=0.56 m/s, P, = 869 kg/m* 2 “01 DVL) Pai ( H) =9/— | + = 6.40) wou ha aCe) a For Re = 371.82, J=9.26 10? (From Fig. 6.15) 0.418 (228) 8690.56" x1 0.011465 }\ 0.16 2 Ap, = 70 220.7 Pa = 70.22 kPa (acceptable) ‘Tube side Pressure Drop: Rain a (ea 5)(2) vs}sth 27) AG 9, =8%928%10°{ L= 3.048 p= 993.328 kg/m®, wt, Re, = 30 561.8 J,= 3.6 x 10 (From Fig. 6.13) ) Ap, = 4|8x3.6x107 x} 3048 | 1495 |x 0.013 3858, Ap, = 50 668 Pa = 50.668 kPa ‘Comments: ing cost. 6.4 CRITERIA OF SELECTION BETWEEN HORIZONTAL In this case viscosity of Iube oil is very high, hence it gives very poor Reynolds number. Fluid, which provides poor Reynolds number must be allocated shell side to get the higher heat transfer coefficient, Here also, by changing the alloca- tion of lube oil from tube side to shell side, lube oil side coefficient increased consid- erably. In any (without phase change) shell and tube heat exchanger for the fixed value of heat transfer area, increase in tube length (correspondingly decrease in number of eases the overall heat transfer coefficient but at the expense of pressure drop or in other words increase in tube length for the fixed value of heat transfer area decreases the fixed cost of heat exchanger but increases its operat=