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 |


The process of converting the vapour phase into the
liquid phase by removing the heat.

Types of condensers
Contact condensers
Surface condensers
 m
 


Total condenser Partial condensers

Vertical Horizontal

In Shell In Tube In Tube In Shell

condensers Condenser condenser condensers
 _ |_

?

Heat exchanger is the equipment used to exchange
heat between two fluids with different temperature
through a fixed wall without mixing the two.

èm
They are widely used in refineries and chemical
plants
To cool or heat a fluid (gas or liquid)
To condense vaporized material
To evaporate a liquid
To recover waste heat boiler
 - |_|| 

_ |_

The material wall between the fluid must have a
higher thermal conductivity and corrosion
resistance.
The heat transfer area to fluid volume ratio must
be as large as possible.
The flow rate of fluid must be as fast as possible.
The turbulence rate of fluid must be as high as
possible.
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 _
|_

Heat exchangers are classified on the following bases

Contacting techniques
Construction
Flow arrangement
Surface compactness
4
 |

Scraped wall heat exchanger is not desired
Gasketed & Welded plate heat exchanger is not
desired
Spiral plate & tube heat exchanger is not desired
Double pipe heat exchanger is not desired
Shell & tube heat exchanger is desired
 |
|
Cost
Efficiency
Space
Materials
Maintenance
4  _ 
_ |_

This classification is based on the type of tube
bundle fitting in the shell
Fixed tube type
U-Tube type
Floating head type
 44|
 _
|_

Heaters And Coolers
Vaporizer
Reboiler
Evaporator
Fired exchanger
Chiller
  
 _
  |

The criteria for fluid allocation
The most corrosive to be tubeside
The higher pressure fluid to be tubeside
Severe fouling fluids shall be allocated the side which
is accessible
Shellside boiling or condensation is usually preferred

4 _

_|_

 
4
Define the duty: heat-transfer rate, fluid flow rates, and
temperatures.
Collect together the fluid physical properties required:
density, viscosity and thermal conductivity.
Calculate the weighted temperature difference ¶LMTD·
Select the trail value for heat transfer coefficient ¶ Ud·
Calculate the area required ¶A·.
Decide the exchanger layout.
Calculate the individual coefficients during condunsation
and desuper heating.
Calculate the overall coefficient and compare with the
trial value.
Calculate the pressure drop on shell and tube side
o
4_

4__
_ 

_|_

Benzene Water mix (hot Fluid) Water (cold
m = 53668 Kg/ hr fluid)
T = 126 oC T = 25 oC
P = 101.3 KPa P = 101.3 KPa

Benzene Water mix

Water (Cold Fluid)
(hot Fluid)
T = 35 oC
T = 80 oC
 _  
_  ?
â = âdes + âcond = mCp(T2 ² T1) + m nj
=14.65x1.37x(126-82) + 14.65x430
=7311 KJ/s

r = â/ Cpx(t2-t1)


= 7311/4.18x10
= 174.9 Kg/S
¨Twater due to condensation
¨Twater = âcond / MwaterCpwater
= 8.76 oC
 
 
 
 

_
   

_
   

      

o
 _ 
  o 
_ 
  ! 



  ! 
  

 

Desuperheat (¨T)d Condensation (¨T)cond

(¨T)des = LMTD = 67.37 oC (¨T)cond = LMTD = 52 oC
âd/ (¨T)des = 901.26/67.37 âd/ (¨T)cond = 6410.3/52
= 13.37 = 123.3

Weighted ¨tw =
Ë ÿ=
= 53.36 oC
_ 
 
Assume Overall Heat Transfer coeffecient

è    
A =â/Ud Ʀt
= 195 m2
  


"|  #
16 BWG
OD = D0 = 19mm
ID = Di = 0.620in, 15.75mm
Pitch = 1.25Do = 23.75 mm

Length of tube Lt = 6.1 m

Area of one tube at = Ǒ X D0 X L
= 0.364 m
No. of tubes Nt = A/ at
=534
Tube side passes n = 2
 ||
  
| |

 
  (cold fluid)

 =
=



= à = 0.18m

=
= à = 970Kg/m s

=
=
à
K = 0.97 m/s

=
„ à = 17563

D = ID = 15.75 mm
Ǎ = 8.75 * 10-4 Kg/ms (Process Heat transfer by kern Fig: 14)
ǒ = 995 Kg/m3
Õ
   _
| |

hi = 800 Btu/hr ft2 oF
= 4542 W/m2 oC (Process Heat transfer by kern Fig: 14)

  à


Ë Y

 à

 o   Ë o

hio = 3572 W/m2 oC

 _ 

 "_ 
#
Shell ID = 27 in = 0.6858 m
Baffle spacing = 0.3048 m
Shell passes =1
Tube pitch = 1.25Do
= 23.75 mm
o  o
Equivalent dia De = Ä = 

š   o 


o  o
= o
Ä       o
o 

= 0.0135 m
Clerarance C = Pt ² Do
= 23.75 ² 19
= 4.75 mm
 |
$
Shell side crossflow area

 à
  Ë  =

= 0.0418 m2
Mass Velocity  à




= 356.6 Kg/m2 s
Reynold no.  
„ à

= 4.8 x 105
 U 4
Jh = 410 (Process Heat transfer by kern Fig: 14)

r
˜ à
Y

= 1.128
Cp = 0.48 Btu/lb oF = 4.17 Kj/kg oC ( kern Fig 3 )
Ǎ = 0.01cP = 0.01x10-3 Kg/ms ( kern Fig 15)
ĸ = 0.0103 Btu/hrft2oC = 0.058 J/s m2 oC (kern Table 5)
   4_
Y
  à 
Ä ˜
oË

  o
à
o
Äo o oË 

 


= 567 W/m2 oC
Clean Overall coeffecient Udes, Desuperheat
 

 à
 ß 
  
à
  ß 
= 490 W/m2 oC
 |



Assume condensation occurs over 80% of the tube length
L = 6.1x0.8 = 4.88 m
  
 à Ë  à

=
 
 Ë

= 162 Kg/(hr) (lin m)

Assume
hcond = 210 Btu/hr ft2 oC = 1192 W/m2 oC
 |
$
Assume
hcond = 210 Btu/hrft2oC = 1192 W/m2 oC
hio = 661.333 Btu/hrft2 oC = 3572 W/m2 oC
Avg shell side temp during condensation Ta=81 oC
Avg Tube side temp ta = 30 oC


= à =
 Ä
 =

  
tw = 42.3 oC
   |



  =Ñ
=
à

tf = 61.6 oC
At tf 61.6 oC
sf = 0.88 ( kern Fig 6 )
Ǎf = 0.41cP = 0.41x10-3Kg/m s ( kern Fig 14)
ĸf = 0.092 Btu/hrft2oC = 0.52 J/s m2 oC (kern Table 5)
hcond = 210 Btu/hrft2oC (So assumed value is correct)
Clean Over all coeffecient Ucond, condensation:


 à
  
è  
 |
| 
Clean surface area required
 
  à
 
ÿ   
= 27.2 m2
 
 à

 ÿ   

= 136.5 m2

Checking assumed condensing lenhth L


o à 
(So assumed value is correct)
   
 ·_ %
| |

Weighted clean overall coffecient
 Ä


 à


o  

 
à
   o 
= 835.5 W/m2 oC

 š

Dirt Factor Rd  à



   š 
à
 
= 2.3x10-4
è    (So assumed value is correct)
   4
 4
Ret = 17563 ƒ= 0.00023 ft2/in2 ( kern Fig 14)

o 
(


ÿ à  &'
;;
  (( &'  ) m

o   o

( ( (

ÿ à  &'
;;
  (( &' 'o & o

ƒ   

   4
 4
„


  
ÿ ˜à
 ï`
N= 2
V = 3.2 ft/s
ƒ



¨PT = ¨Pt + ¨Pr

= 1.74 + 0.56
= 

 _  4
 4
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Re = 481410 ƒ = 0.001 ft2/in2 ( kern Fig 14)
Ldes = 6.1 x 0.2 = 1.22 m = 4 ft
No fo crosses (N+1) = 12Ldes/B = 4
Specific Gravity s = 0.0141




 
 o
ÿ    à
  
o o


m
U

ƒ 


 _  4
 4
 

Lcond = 6.1 x 0.8 = 4.88 m = 16 ft
No fo crosses (N+1) = 12Lcon/B = 16
Specific Gravity s = 0.0149

o
(
   ß o
ÿ   à o
(Kern Eqn 12.47)
    o
m

¨Pcond = 0.98 psi

¨Ps = ¨Pdes + ¨Pcond =  


 4||
_
SPECIFICATION SHEET FOR 1-2 PASS SHELL SHELL AND TUBE
HEAT EXCHANGER
è _ !

Item No. E-201
Type Fixed Head.
No. of Item 1
Function To condense stream from sulphonator
Operation Continuous
Heat duty 7311 KJ/s
Heat transfer area 195 m2
Overall HT coefficient 700 W/m2
Dirt factor 0.000232
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