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Anand V P Gurumoorthy
Associate Professor
Chemical Engineering Division
School of Mechanical & Building Sciences
VIT University
[EDITED BY AFRAZ ]
Cold and hot fluid flow through the unit without mixing
with each other. The transfer of heat occurs through the
metal wall.
Regenerative:
Direct contact:
Hot and cold fluids are in direct contact and mixing occurs
among them; mass transfer and heat transfer occur
simultaneously.
Bell-Delaware method
Most widely used.
Takes into account:
Leakage through the gaps between tubes and baffles and the baffles and
shell.
Bypassing of flow around the gap between tube bundle and shell.
Db
Nt is the number of tubes
Db is the bundle diameter (mm)
D0 is tube outside diameter (mm)
Nt
d0
K
Q UA Tm
where Q is the rate of heat transfer (duty),
U is the overall heat transfer coefficient,
A is the area for heat transfer
Tm is the mean temperature difference
We are not doing a mechanical design, only a
thermal design.
d0
d 0 ln
di
1
1
1
U 0 h0 hod
2k w
d0 1 d0 1
d i hid d i hi
LMTD
LMTD is given by:
(T1 t 2 ) (T2 t1 )
Tlm
T t
ln 1 2
T2 t1
where T1 is the hot fluid temperature, inlet
T2 is the hot fluid temperature, outlet
t1 is the cold fluid temperature, inlet
t2 is the cold fluid temperature, outlet
Counter-current Flow
Temperature Proflies
T F T
(T1 T2 )
R
(t 2 t1 )
(t 2 t1 )
S
(T1 t1 )
Temperature correction factor, one shell pass, two or more even tube passes
Pressure Drop
As the process fluids move through the heat exchanger there is
associated pressure drop.
For liquids: viscosity < 1mNs/m2 35kN/m2
Viscosity 1 10 mNs/m2 50-70kN/m2
Nu C Re
Nu
hi d e
kf
0.8
Pr
0.33
u d
Re t e
0.14
Pr
Cp
kf
St E Re 0.205 Pr 0.505
St Nu
For laminar flow (Re<2000):
Re Pr
hi
ut C p
d
Nu 1.86(Re Pr)0.33 e
L
0.33
0.14
hi d i
0.33
jh Re Pr
kf
w
0.14
Kerns method
Bells method
( p t d 0 ) Ds b
pt
Ws
G
Gs
us s
As mass flow rate in the shell in kg/s
where Ws is the fluid
pt2 d 02
4
4
de
d 0
pt
1 d 02
4 0.87 pt
2
2
4
de
d 0
2
Re
Gs d e
us de
Nu
hs d e
jh Re Pr1 / 3
kf
w
0.14
Ds L u
given
by following
chart.
8
j
where jf is the friction
factor
s
f
d e B 2 w
2
s
(Figure 8 in notes)
(T1 T2 )
(t 2 t1 )
(t 2 t1 )
S
(T1 t1 )
(Figure 4 in notes)
Q UA Tm
1 / n1
N
Db d 0 t
K1
(Figure 2)
hi
(Figure 9 in notes)
As
( p t d 0 ) Ds b
pt
pt
1 d 02
4 0.87 pt
2
2 4
de
d 0
2
(Table 3 in notes)
d
d 0 ln 0
1
1
1
di d0 1 d0 1
U 0 h0 hod
2k w
d i hid d i hi
(Figure 10 in notes)
L m
u 2
Pt N p 8 j f 2.5 t
d i w
2
(Figure 12 in notes)
Ds
Ps 8 j f
de
2
s
0.14
Bells Method
In Bells method, the heat transfer coefficient and pressure drop are
estimated from correlations for flow over ideal tube banks.
The effects of leakage, by-passing, and flow in the window zone are
allowed for by applying correction factors.
Re
Gs d 0
u s d 0
hoc d 0
1/ 3
jh Re Pr
kf
w
0.14
Fn ( N c' ) 0.18
Ab B ( Ds Db )
For the case of no sealing strips, Fb as a function of Ab/As can be
obtained from the following chart
2N
A
s
Fb exp b 1
As N cv
1/ 3
Atb
0.8d 0
(Nt N w )
2
Cs Ds
Asb
(2 b )
2
where Cs is baffle to shell clearance and b is the angle subtended by baffle chord
AL=Atb+Asb
( Atb 2 Asb )
FL 1 L
A
L
Pi 8 j f N cv
2 w
2
s
0.14
2N
A
s
Fb' exp b 1
As N cv
1/ 3
A
L
'
L
'
L
Coefficient for FL
u z2
2
uz uwus
uw is the velocity in the window zone
uw
Ws
Aw
( N wv N cv ) '
Pe Pi
Fb
N cv
Ncv is the number of tube rows encountered in the cross-flow section
Nwv is number of restrictions for cross-flow in window zone,
approximately equal to the number of tube rows.
Ps 2Pe ( N b 1)Pc N b Pw
Effect of Fouling
Above calculation assumes clean tubes
Condensers
Construction of a condenser is similar to other shell and tube
heat exchangers, but with a wider baffle spacing
l B Ds
Four condenser configurations:
Horizontal, with condensation in the shell
Horizontal, with condensation in the tubes
Vertical, with condensation in the shell
Vertical, with condensation in the tubes
Dropwise condensation
1/ 3
where (hc)1 is the mean condensation film coefficient, for a single tube
kL is the condensate thermal conductivity
L is the condensate density
v is the vapour density
L is the condensate viscosity
g is the gravitational acceleration
is the tube loading, the condensate flow per unit length of tube.
If there are Nr tubes in a vertical row and the condensate is assumed to flow
smoothly from row to row, and if the flow is laminar, the top tube film coefficient
is given by:
(hc ) Nr (hc )1 N
1/ 4
r
Wc
h
LN t
L ( L v ) g
(hc ) v 0.926k L
L v
Colburns Results
Boyko-Kruzhilin Correlation
A correlation for shear-controlled condensation in tubes; simple to use.
The correlation gives mean coefficient between two points at which vapor quality, x, (mass fraction of
vapour) is known.
(hc ) BK
L v
J11/ 2 J 21/ 2
hi
where
J
kL
hi 0.021
d
i
0.8
Pr 0.43
Re
In a condenser, the inlet stream will normally be saturated vapour and vapour will be totally
condensed. For these conditions:
( hc ) BK
1
hi
L
2
For design of condensers with condensation inside the tubes and downward vapor flow, coefficient
should be evaluated using Colburns method and Boyko-Kruzhilin correlation and the higher value
selected.
1/ 2
v
No general satisfactory method exists that will give accurate predictions over a
wide flow range.
For stratified flow, the condensate film coefficient can be estimated as:
L ( L v ) g
(hc ) s 0.76k L
L h
1/ 3
Condensation of steam
For air-free steam a coefficient of 8000 W/m2-0C should be used.
Tlm
( t 2 t1 )
Tsat t1
ln
Tsat t 2