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Shell and Tube Exchangers Application in Industries 1720441667
Shell and Tube Exchangers Application in Industries 1720441667
Raj Saini
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Email : rajsaini.expert@gmail.com
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rks@rksts.in
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1 Introduction
The purpose of this case demostration is to learn/explore for new users and to understand the
design calculations of heat exchangers [1, 2, 3, 4]. In this report, we will see the step by step
solution of a problem (i.e. demonstration purpose only).
1.1 Problem
Design a heat exchanger to sub-col condensate from a methanol condenser from 95 0 C to 40
0
C. Flow rate of methanol 100, 000 kg/h (cp = 2.84 kJ/kg 0 C). Brackish water (cp = 4.2
kJ/kg 0 C) will be used as the coolant with temperature rise from 25 0 C to 40 0 C .
[Note: please refer to the useful graph section if you need any data. ]
We choose 1-2 shell-tube heat exchanger (fig.)
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1.2 Solution
Given data: The temperatures of hot fluid-1 (methanol) and cold fluid-2 (brakish water) are
given Thi = 95 0 C ,Th0 = 40 0 C , Tci = 25 0 C and Tco = 40 0 C Flow rate of methanol=
100, 000 kg/h and (cp = 2.84 kJ/kg 0 C) and temp. 95 0 C to 40 0 C
Brackish water (cp = 4.2 kJ/kg 0 C) and tem 25 0 C to 40 0 C
• With the help of q, we can find out mass flow rate of water,ṁwater = 68.9 kg/s
1
Tco − Tci
S= = 0.21
Thi − Tci
• With the help of Temperature correction factor graph fig.12.19 (ppt), we can find out Ft
Ft ≈ 0.85
• The heat equation for the heat exchanger (Calculation based on outer tube diameter, d0 =
20 mm)
q = Uo Ao 4Tm
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• Mean difference temperature by 4Tm = Ft 4Tln = 26 0 C R
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• Ref-ppt (methanol): U0 = 600 W/m2 .K
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S
q
= 278, m2
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A0 =
U0 4Tm
AT
This area is for the find out number of tubes in use the exchanger. If, we will assume only
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one tube for this area, then will get a large diameter of tube which is not possible physically .
Then we have to assume multi tubes used in heat exchanger design.
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• We can assume the tube has inner dia ID=16 mm , outer dia OD=20 mm and length
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L = 6 m [material (cupro-nickel)]
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Ds = Db + bundle − clearance
• Ref-Useful graph section, Find out bundle − clearance = 68, mm , shell diameter
Ds = 894, mm
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1.3 Shell - tube heat exchanger
1.3.1 Coefficient of tube side (brackish water flowing)
• Mean temperature of water in side the tube =30 0 C and inner dia of tube , di =16 mm
• In shell , there is two passes of tubes Np = 2 , Tube per pass 918/2 = 459
• Total flow area in one pass, At = T ube − per − pass × area − of − one − tube = 0.092
m2
ṁwater
• Mass flux of rate or ( water mass velocity),nwater = At
= 749 kg/m2 − s
nwater
• Water linear velocity , uwater = ρwater
= 0.75 m/s
• Density of water at 30 0 C , ρwater =995 kg/m3 , µwater = 0.8 m Pa-s and kf = 0.59
W/m −0 C
hi di µ
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= jh Re P r0.33 ( )0.14
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kf µf
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where, hi - heat transfer coefficient W/m20 C , µ- viscosity , P a − s , kf − conductivity,
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– L
di
ratio , Ref-ppt, jh = 3.9 × 10−3
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nwater d
– Re = = 14925
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µ
cp µ
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– Pr = kf
= 5.7
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– Pressure drop , 4P
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L µ ρu2
4Ptube = Np [8jf ( )( )−m + 2.5] water
di µf 2
where, Np -number of tubes passes, L−length of tube, m
– from fig.12.24, jf = 4.3 × 10−3
– Substitutting all values , we can get 4Ptube = 7211 Pa or 7.2 kPa
pt = 1.25 × d0
pt = 25, mm
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– Baffle spacing Baffle
Ds
wbaf f le−space =
number − of − shell − partitions
– we assumed number of shell partition=5
– Baffle spacing , wbaf f le−space = 178 mm
– Cross flow area of shell
(pt − ODtube )
As = Ds wbaf f le−space = 0.032, m2
pt
mass−f low−rate−in−shell
– flux rate or( methanol mass velocity),nmethanol = Cross−section−f low−area−shell
=
ṁmathanol
As
= 868 kg/m2 − s
– Equivalent diameter
1.1 2
de = (pt − 0.917d2o ) = 14.4, mm
d0
– Mean temperature of water in side the tube =68 0 C
nmethanol
– Methanol linear velocity, shell side , umethanol = = 1.16 m/s
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ρmethanol
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– Density of water at 68 0 C , ρmethanol =750 kg/m3 , µmethanol = 0.34 m Pa-s and
kf = 0.19 W/m −0 C
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nmethanol de
– Re = = 36762
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µ
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cp µ
– Pr = = 5.1
AT
kf
hs de µ
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= jh Re P r0.33 ( )0.14
kf µf
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L µ ρu2
4Pshell = [8jf ( )( )−m ] methanol
di µf 2
– from fig.12.30, jf = 4.3 × 10−3
– Substituting all values , we can get 4Pshell = 272000 Pa or 272 kPa
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1.3.3 Overall heat transfer coefficient (U)
• Thermal conductivity of tube material, ktube−material = 50 W/m0 C
1 1 1 ln( dd0i ) d0 1 d0 1 d0
= + + ( )+ ( )+ ( )
U hs hf −methaol ktube−material 2 hi di hf −brackish−water di
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1.4.2 Shell bundle clearance
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1.4.4 Temperature correction factor (Ft ) for one-shell and two or more-
even tubes passes
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1.4.5 Temperature correction factor (Ft ) for split-flow-shell and two-tubes
passes
1.4.6 Temperature correction factor (Ft ) for divided-shell and two or more
even-tubes passes
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1.4.8 Tube side heat transfer factor (jh )
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References
1. M. Darwish, F. Moukalled, A unified formulation of the segregated class of algorithms for
fluid flow at all speeds. Numerical Heat Transfer: Part B: Fundamentals, 2000.
2. P. J. P. Robert W. Fox, Alan T. McDonald, Introduction to Fluid Mechanics (8th ed), 8th ed.,
2011.
3. J. B. B. Rao and V. R. Raju, “Numerical and heat transfer analysis of shell and tube
heat exchanger with circular and elliptical tubes,” International Journal of Mechanical and
Materials Engineering, vol. 11, no. 1, p. 6, 2016.
4. N. Afsar and M. I. Inam, “Cfd analysis of shell and tube heat exchanger with different baffle
orientation and baffle cut,” AIP Conference Proceedings, vol. 1980, no. 1, p. 050006, 2018.
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