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8.1 INTRODUCTION
The process inside is evaporation. It is a thermal separation
technique used to concentrate a liquid solution, emulsion or suspension. A feed mixture is
introduced into the evaporator, a part of it is evaporated and separated, the rest being a
concentrated solution. A complete evaporation stage consists of an evaporator, a separator
and a condenser to cool the end product.
8.1.1 Objective
We have to separate TDI from crude TDI mixtute.
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Chapter 8 Evaporator Design
For a low viscosity and low fouling system we can see that film type mode of
evaporation is the first choice. Our system has both of these properties, film type
evaporation is the most suitable mode for our case.
Another selection chart is available here:
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Chapter 8 Evaporator Design
Our system has got low viscosity, low fouling, non foaming attitude and
with no crystal production. In accordance with this chart, for all the above mentioned
characteristics and also for economical considerations the most suitable choice is the long
tube vertical falling film evaporator. Here is another selection chart:
A diagram of long tube vertical falling film evaporator is as shown below:
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Chapter 8 Evaporator Design
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Chapter 8 Evaporator Design
Properties Data
Cold Fluid Mixture
m(res) = 705.3 Kg/h
m(TDI) = 4880.6 Kg/h
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Chapter 8 Evaporator Design
8.2.1 Calendria
It is the vertical long tube section of the overall
assembly. Following steps are involved in the designing of Calendria :
1. Heat Balance
2. Calculation of (∆T)LMTD
3. Assumed Calculations
4. Calculations for Film Coefficients
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Chapter 8 Evaporator Design
1. Heat Balance
Heat supplied by Toluene(Hot Fluid) = Sensible heat gained by residues + Latent heat of
vaporization of TDI + Heat required by TDI to get superheated, i.e
Q = mcpΔT(res) + mλ(TDI) + mcpΔT(TDI)
Total heat transfered = Q = 1501623 KJ/h
Q
Mass flow rate of Toluene = ms = CpT = 16680 Kg/h
2. Calculation of ΔT(LMTD)
According to this area shell and tube side dimensions are selected and the respective no
of tubes are calculated. The dimensions are given as:
Shell & Tube Dimensions
Shell Side Tube Side
ID = 0.254 m 16 BWG
De = 0.018 m OD = 0.019 m
B = 0.61 m ID = 0.0157m
C = 0.00635 m n=1
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Chapter 8 Evaporator Design
jH = 42 = 1840.32 KJ/hm²C
(5´) Shell Side Film Coefficient (5) Inside Film Coefficient depending
on OD is:
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Chapter 8 Evaporator Design
ID
ho = jH k De Cp k 0.33 hio = hi
OD
= 1786.14 KJ /hm²C = 1520.14 KJ/hm²C
5. Clean overall coefficient UC
ho hio
Uc =
ho hio
= 1472.25 KJ/hm2C
Allowable dirt resistance = Rd = 0.000147 hm²C/KJ
6. Check for UD
UC
UD =
1 Rd U C
= 1210.5 KJ/hm²C
Which is very close to the assumed value i.e 1206.43 KJ/hm²C.
So the design is satisfied.
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Chapter 8 Evaporator Design
Area = A = VV VV = 0.183m²
Diameter of Separator = D = 2 A 3.14 = 0.48 m
Calculations for the length
Volumetric Flow Rate of Liquid = VL = mL d L = 0.000163m3/s
Liquid Level in the Separator = LL = VL t s A
LL = 0.673 m
Length of Separator = L = LL 1.5 D 0.457
L = 1.86 m
Since, the Ratio, L/D = 3.82 < 5
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Chapter 8 Evaporator Design
Final Design
Length of Separator = 1.86 m
Diameter of Separator = 0.48 m
Thickness of Demister = 0.1524 m
8.2.3 Condenser
A condenser is a two-phase flow heat exchanger in which heat
is generated from the conversion of vapor into liquid i.e condensation and the heat
generated is removed from the system by a coolant.
Selection of Condenser
Horizontal shell side and vertical tube side are the most
commonly used types of condensers. In this process we have used the horizontal with
condensation in shell side & cooling medium in tube. In our case it is a desuperheater
condenser that first removes heat by desuperheating and then by condensation.
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Chapter 8 Evaporator Design
Properties Data
mass flow rate of TDI = m(TDI) = 4880.6 Kg/h
T1(TDI) = 270 C
T2(TDI) = 250 C
Specific Heat of TDI = Cp(TDI) = 0.837 KJ/KgC
Latent Heat of Vaporization of TDI = λ(TDI) =259.2 KJ/Kg
Specific Heat of Water = Cp(water) = 4.187 KJ/KgC
T1(Water) = 21.11 C
T2(Water) = 37.78 C
1. Heat Balance
Heat gained by cold water = Heat given off by TDI in the desuperheating
+ Heat given off by TDI in condensing
i.e
Q = Qd + Qc
Qd = mCpΔT(TDI)
Qc = mλ(TDI)
So
Qd = 72755.31 KJ/h
Qc = 1264967.7 KJ/h
Thus
Q = 1337721.56 KJ/h
Mass flow rate of water
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Chapter 8 Evaporator Design
Q
m(Water) = CpT = 16168.25 Kg/h
3. Assumed Calculations
Trial
UD = 2740 KJ/hm²C
Q = 1337721.56 KJ/h
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Chapter 8 Evaporator Design
ΔT = 223.14 C
Heat Transfer Area
Q
A= = 2.2 m²
U D T
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Chapter 8 Evaporator Design
Velocity
Gt
V=
3600
V = 1.83 m/s
(3´) Reynold’s no (3) Reynold’s no
at Tavg= 264.11 C at Tavg = 29.44 C
μ = 0.0504 Kg/hm μ=3.13 Kg/hm
Gs De IDGt
NRe = NRe =
NRe = 104774 NRe = 32981
(4´) jH
From graph
jH = 200
(5´) ho (5) hi
ho = jH k De Cp k 0.33 at Tavg = 261.11 C
k = 0.126 KJ/hmC hi = 26522.4 KJ/hm²C
ID
Cp = 0.837 KJ/KgK hio = hi
OD
ho = 261.56W/m²K hio = 21974.4 KJ/hm²C
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Chapter 8 Evaporator Design
(2´) Loading
ms
G˝ = 23
Lc nt
Let the condensation
occures over 84% of
tube length Lc.
Lc = 1.22*0.84
Lc = 1.02 m
G˝ = 313.32 Kg/h lin.m
(3´) Shell Side Coefficient
Let ho =4089.6 KJ/hm²C
hio = 21974.4 KJ/hm²C
(4´) Wall Temp.
ho
tw = ta+
ho hio Ta t a
tw = 64.4 C
(5´) Film Temp.
Tw t w
tf =
2
tf = 158.33 C
Kf = 0.432 KJ/hmC
μf = 0.152*1010 Pas
sf = 1.203
From Graph
ho = 4090 KJ/hm²C
(6) Clean Overall Heat Transfer Coefficient for Condensation
ho hio
Ucc =
ho hio
Ucc = 3447.94 KJ/hm²C
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Chapter 8 Evaporator Design
Qc
Acc =
U cc Tc
Acc = 1.645 m²
Check for Condensing Length Lc
Formula
Acc
100
Acc Acd
= 82 %
Thus the assumption for Lc is true.
5. Clean Overall Coefficient UC and a Check
for Design Overall Coefficient UD
Clean Overall Coefficient
U cd Acd U cc Acc
Uc =
Acc Acd
Uc = 2986 KJ/hm²C
Allowable dirt resistance, Rd is 0.0001 hm²C/KJ
Design Overall Coefficient
Uc
UD =
1 U c Rd
UD = 2731 KJ/hm²C
This is very close to the assumed value. Thus the Design is Satisfactory.
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Chapter 8 Evaporator Design
fGs ID N 1
2
ΔPc =
2 5.22 1010 Des
ΔPc = 9.13 KPa
(4´) Total Shell Side Pressure Drop (4) Total Tube Side Pressure Drop
ΔPs = ΔPc+ ΔPd ΔPT = ΔPt+ΔPr
ΔPs = 9.5 KPa ΔPT = 24.64 KPa
Allowable ΔPs is 13.8 KPa Allowable ΔPT is 68.93 KPa
Thus the results are satisfactory.
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Chapter 8 Evaporator Design
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Chapter 8 Evaporator Design
8.3 SUBCOOLERS
A subcoolers is a two-phase flow heat exchanger in which
heat is generated from the conversion of saturated liquid into a liquid at some lower
temperature i.e subcooling and the heat generated is removed from the system by a
coolant. Their types and the related theory have already been described in the section of
condenser.
Objective
Our objective is to cool saturated TDI and the Residues to almost room
temperature.
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Chapter 8 Evaporator Design
1. Heat Balance
Heat gained by cold water = Heat given off by TDI
mCp∆T (Water) = mCp∆T (TDI)
Heat Duty = 2049600 KJ/h
Putting all the variables in this relation we get the mass flow rate of water which is 12200
Kg/h.
2. Calculation of ΔT(LMTD)
Hot Fluid Cold Fluid Difference
250 Higher Temp 220 80
30 Lower Temp 220 46.67
Δt2 = 80 C , Δt1 = 47.33 C
t 2 t1
ΔT(LMTD) =
ln t 2 t1
ΔT = 53.5 C
3. Assumed Calculations
Trial
UD = 1580 KJ/hm²K
Q
Heat Transfer Area = A = = 24.25 m²
U D T
According to this area shell and tube side dimensions are selected and the respective no
of tubes are calculated. The dimensions are given as:
Shell & Tube Dimensions
Shell Side Tube Side
ID = 0.254 m 16 BWG
De = 0.018 m OD = 0.019 m
B=1m ID = 0.0157m
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Chapter 8 Evaporator Design
C = 0.00635 m n=2
Pt= 0.0254 m at´ = 0.00019 m2
n=1 at = 0.06 m2/m
Lt = 7.75 m
nt = A/ at * Lt
nt = 52
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Chapter 8 Evaporator Design
ID
ho = jH k De Cp k 0.33 hio = hi
OD
= 2959.56 KJ /hm²C = 6756.58 KJ/hm²C
6. Check for UD
Uc
UD =
1 U c Rd
= 1580.05 KJ/hm²C
Which is very close to the assumed value i.e 1580 KJ/hm²C. So the design is satisfied.
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Chapter 8 Evaporator Design
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Chapter 8 Evaporator Design
1. Heat Balance
Heat gained by cold water = Heat given off by Residues
mCp∆T (Water) = mCp∆T (Res)
Heat Duty = Q = 2.4*105 KJ/h
Putting all the variables in this relation we get the mass flow rate of water which is
1450 Kg/h.
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Chapter 8 Evaporator Design
2. Calculation of ΔT(LMTD)
Hot Fluid Cold Fluid Difference
270 Higher Temp 220 80
30 Lower Temp 220 46.67
Δt2 = 80 C , Δt1 = 47.33 C
t 2 t1
ΔT(LMTD) =
ln t 2 t1
ΔT = 58.35 C
3.Assumed Calculations
Trial
UD = 349.9 KJ/hm²K
Q
Heat Transfer Area = A = = 11.93 m²
U D T
According to this area shell and tube side dimensions are selected and the respective no
of tubes are calculated. The dimensions are given as:
Shell & Tube Dimensions
Shell Side Tube Side
ID = 0.254 m 16 BWG
De = 0.0185 m OD = 0.019 m
B=1m ID = 0.0157m
C = 0.00635 m n=2
Pt = 0.0254 m at´ = 0.0002 m2
n=1 at = 0.06 m2/m
Lt = 6.6 m
nt = A/ at * Lt
nt = 30
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Chapter 8 Evaporator Design
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Chapter 8 Evaporator Design
6. Check for UD
Uc
UD =
1 U c Rd
= 349.91 KJ/hm²C
Which is very close to the assumed value i.e 349.9 KJ/hm²C. So the design is satisfied.
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Chapter 8 Evaporator Design
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