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Design of Superheater:
Specification
The project assigned is to design a superheater heat exchanger of tube and shell type
to heat ammonia of flow rate 2335.88 kg/h from 35 °C to 177°C using saturated steam
entering at 40 bars.
To complete the specification, the duty (heat transfer rate) needed to be added to gas mixture
must be calculated using the formula:
Q=ṁC p ∆ T
= 0.6489 kg/s x 2.38 kJ/kg K x (177K-35K)
= 219.30 kJ/s
For steam:
Q lost =Q gain=mℷ
219.30 kg /s
m steam= = 0.128 kg/s
1712.9 Kj /kg
Physical Properties
Ammonia Component
Component Cp μ Thermal ρ
Conductivity
(kJ/kg.K) (Pa.s) (kg/m3)
(W/m.K)
NH 3 2.38 1.32 x 10−4 0.0364 7.04
Component Cp (kJ/kg.K) μ Kv ρv ℷ
(kJ/kg)
(Pa.s) (W/m.K) (kg/m3)
Standard 1.958 1.84 x 10−5 0.0388 20.12 1712.9
Steam
Table 2: Physical Properties of standard steam at 40 bars and T ave =¿ 250.33℃
Overall Coefficient
The heat exchanger will consist of one shell pass and two tube passes. For an exchanger of
this type, the overall coefficient will be in the range 30 to 300 W/m 2K, see Table A in
Appendix A. Cold fluid is ammonia while hot fluid is condensing steam. Hence, the
following value of overall heat transfer coefficient U can be estimated: U= 50 W/m2 ℃ .
As this positions the inlet and outlet nozzles at the same end of the exchanger, an even
number of tube passes is commonly the preferred arrangement, which simplifies the
pipework. The heat exchanger will consist of one shell pass and two tube passes. Hence, start
with it.
∆ T out −∆ T ¿
∆ T lm= ∆ T out
ln
∆T¿
( 250.3−177 )−(250.3−35)
= ln
(250.3−177) ℃
(250.3−35)
= 131.79℃
Let T 1= 263.92℃
T 2 = 233.84℃
t 1 = 35℃
t 2 = 177℃
T 1−T 2 (263.92−233.84)
R= = = 0.2
t 2−t 1 (177−35)
t 2−t 1 (177−35)
S= T −t = (263.92−35) = 0.62
1 1
From the value R and S, the value of F t can be determined from Figure 12.19 in textbook for
F tas function of (R, S).
F t= 0.97
According to A in Appendix A, cold fluid is ammonia while hot fluid is condensing steam.
The value of overall heat transfer coefficient U can be estimated.
U= 50 W/m 2 ℃
Q = UA∆ T m
Q (219.30 kJ / s)(1000)
A= = = 34.31m 2
U ∆ T m (50 W /m 2 ℃ )(127.84 ℃ )
Choose 25 mm for outside diameter and 21 mm for inside diameter of mild steel tubes to
resist corrosion problems as condensing steam is placed in the shell side. Take tube length,
L= 5m (a popular size).
Number of Tubes
= π x 0.025m x 5 m
= 0.3927 m2
A 34.31 m2
Number of tubes, N t = = = 87 tubes
π x d L 0.3927 m 2
π
Tube cross-sectional area= (0.021m¿2= 0.0003464 m 2
4
1
Volumetric Flow = 0.6489 kg/s x = 0.0922 m3/s
7.04
0.0922m3 / s
Tube-side velocity, ut = = 6.05 m/s
0.0152 m2
Db = d o ¿
= 25¿
= 331.39 mm
=0.3314 m
For a split-ring floating head exchanger the typical shell clearance from Figure A is 63 mm,
so the shell inside diameter,
L 5000 mm
= = 238
di 21 mm
j h =¿ 4.0 x 1 0−2
0.0364
hi = 551.97x ( ) = 956.75 W/m 2℃
0.021
Kern’s Method will be used to find area for cross flow of the shell side, A s .
Pt −d o
A s=( ) D s LB
Pt
Where,
31.25 mm−25 mm
A s=¿ ( )(384.39 mm)(76.878 mm) = 5,910.23 mm 2
31.25 mm
= 0.0059102 m 2
mshell 0.128 kg /s
Gs = ( )= 2
2 = 21.657 kg/m s
As 0.0059102m
21.657 kg/m 2 s
Shell-side velocity, ut = = 1.076 m/s
20.12 kg /m3
1.10 2
d e= (Pt −0.917 d2o ¿
do
1.10
= [(31.25¿2- 0.917(25¿2 ] = 17.75 mm = 0.01775 m
25
Use segmental baffles with a 25% cut. This should give a reasonable heat transfer coefficient
without too large a pressure drop.
Overall Coefficient
do
d o ln
1 1 1 1 do di
1 d
= + +
U o ho h od 2 K w
+ + ( o)
hi di h id d i ( )
U o = overall coefficient based on outside area of the tubes
hid = inside dirt "fouling" coefficient = 3000 (W/m2.oC) (From Table B in Appendix E)
25
1 (0.025) ln
= 1 1 21 1 25 1 25
Uo +
178.22W /m ℃ 3000W /m2 ℃
2
+
2 x 54
+ ( ) + ( )
956.75 21 3000 21
U o = 131.133 W /m2 ℃
The value of U o = 131.133 W /m 2 ℃ is well below the initial estimated value of 300 W /m 2 ℃ .
The number of tubes does not change, but first check the pressure drops.However, the present
design satisfactory is good.
Pressure Drop
L ρ v2
[ () ]
∆ Pt = N p 8 j f
di
+2.5 [
2
]
Where,
jf = fraction factor ' depending on Re ' Found from Figure 12.24 in the text book assuming
baffle cut of 0.25 = 5.5 x 10-3
∆ Pt = 2 ¿