ENGINEERING CALCULATION

THERMAL CALCULATION OF HEAT EXCHANGER TYPE: SHELL & TUBES HELL

EVELOPED USING EXCEL BY REY FIEDACAN,MECHANICAL ENGINEER, 11.07.2010 -fi

Designed by Date
r @ h . m

Rey Fiedacan 11.07.2010 HX - 01 -09 1

Doc. N . . No. Revi i

Pr ject Title Part

: :

HEAT EXCHANGER FOR CHILLED WATER Horizontal Shell

Sketch :

H HEAT EXCHANGER THERMAL CALCULAT EXCH ER T AL ULATION BY REY FIEDAC R EDACAN, MEP - ME

I.HEAT & MASS BALANCE 1.0 Temperature of outlet fluid - Cold fluid ( Predicted from energy and mass balance) msCps(Ts1-Ts2) = 295.3 K mtCpct 2.0 Log mean temperature difference across the heat exchanger (LMTD) Ts2 =

LMTD =

tmax - tmin tmax ln tmin P = 0.19431 R = 3.00208 F = 0.9400

7.1

where: LMTD = LMTD =

6.21 for parallel flow 7.08 for counterflow

3.0 LMTD Calculation ( Corrected ) where : Tm = F(LMTD) = 6.655 K for Counter flow 4.0 HEAT DUTY OF HEAT EXCHANGER

heat transfer between shell & tubes

based on the temperature difference between hot fluids inlet and outlet condition.
1,462.55 KW

Q =(mscps)(Ts1 -Ts2) =

5.0 NUMBER OF TUBES - based on the mass flowrate of cold fluid inside the tubes and recommended velocity on the specified number of passes. Nt = 4mtNp/ tvt di = II. TUBE SIDE CALCULATION: 1.0 TUBE SIDE HEAT TRANSFER ht = Nutkt di where: Nut Kt di = Nusselt number of fluid inside the tubes = Thermal conductivity of fluid inside the tubes = Inside diameter of tubes
2

1,121 tubes 374 per pass

2.0 NUSSELT NUMBER ( CORRELATION FROM Petukhov - Kirililov for Turbulent flows ) which predicts results in the range of 104< Ret < 5 x106 and 0.5 < Prt < 200 Nut = 2.1 2.2 2.3 Prandtl number Reynold number at tube side Friction factor at given Re (f/2)RetPrt 1.07+12.7(f/2)1/2(Prt2/3 -1) Prt Ret Ft = = 6.80236
tv tdi/t

32,488.20 the flow is turbulent

-2

= (1.58lnRet - 3.28)

0.005797

Nut =

(f/2)RetPrt 1.07+12.7(f/2)1/2(Prt2/3 -1) Nutkt di

225.72
2 8,526.66 W/m -K

ht =

( This correlated heat transfer coefficient at tube side condition of flow )

III.SHELL SIDE CALCULATION 1.0 SHELL SIDE HEAT TRANSFER BY KERN CORRELATION which predicts results in the range of 2x103< Res = GsDe/< 1 x106 ht =
0.55 1/3 0.36ks Res Prs De

where: Nus Ks de Res Prs

= = = = =

Nusselt number of fluid outsidethe tubes Thermal conductivity of fluid outside the tubes Equivalent diameter of shell Reynold number flow outside the tubes Prandtl number of flow outside the tunes
11,649.06 the flow is turbulent

2.1 2.2

Reynolds Number Equivalent Diameter

Res De

= (ms/As)(De/s) =

= f(Square,Triangular layout)
do Flow PT

De of square pitch in tube layout De

2 4(PT -

do /4) De

= 0.024 m s

De of triangular pitch in tube layout De

1/2 2 = 4(PT (3) /4- do /8) do/2 0 2 2 = 0.018 m s

Flow do

Use: 2.3 Bundle Crossflow As

Square Pitch

De =

0.024234

= f(Clearance, Baffle spacing) = DsCB PT 0

2 = 0.125 m s

2.4

Total flow area of tubes

As

= f(Clearance, Baffle spacing) di N t = 0.225 m 4 0 s = f(Clearance, Baffle spacing) =

2 2 t 1/2 = 0.637(CL/CTP)( do PR N ) 0 s = f(Clearance, Baffle spacing) 2

2.5

Estimated Shell Diameter

Ds

0.996

2.6 2.7

Tube Pitch Ratio Tube Layout Constant

PR

= PT/do = f(Clearance, Baffle spacing) for 90 and 45 for 30o and 60o one tube pass two tube pass three tube pass Use:
0.55 1/3 0.36ks Res Prs De o o

= 1

1.337

CL = =

CL = CL = CTP = CTP = CTP = 1.0 CTP = 0.930

2 2,800.32 W/m -K

0.87 0.93 0.9 0.85

ht =

( This correlated heat transfer coefficient at shell side condition of flow )

IV. OVERALL HEAT TRANSFER COEFFICIENT 1.0 Outer surface area - Clean heat transfer coefficient -1 do do 1 do ln( di ) 1 Uc = kt ho + di hi + 2 = 1,869.27 W/m2-K

1.1

Surface area of heat exchanger for clean condition ( No fouling Effect ) Ac = = 97.11
2

Q Uc Tm Uc = Use: 2.0 Outer surface area - Fouled heat transfer coefficient

2263.2

do -1 do 1 do ln( di ) 1 Uf = + Rft = kt ho + di hi + 2

1,406.54

W/m -K

2.1

Surface area of heat exchanger for clean condition ( with fouling Effect ) Af = Q Uf Tm Af Ac = 156.25 m2

2.2

Check for % surface design Os = Use: = 61% Os = 30 %

2.3

Surface design area of heat exchanger at certain 30 % more allowance for fouling effect 2 A' = 126.24 m Effective length of tube for area in heat transfer A' L = N t do Use: L =

2.4

1.89 m

4.00 m

2.5

New Shell Diameter

Ds'

= f(Clearance, Baffle spacing) = 0.637(CL/CTP)1/2(A'PR2do/L)1/2 0.68 m corrected shell diameter at the given length = however, the actual diameter shall be the nearest available size either seamless pipe or fabricated as rolled plate ' Use: Ds = 0.80 m

V. PRESSURE DROP - This is used to determined the pumping power required to handle the fluid in tubes and shell. 1.0 TUBE SIDE PRESSURE DROP 1.1 1.2 Tube side friction factor Tube side friction factor ft Pt = (1.5ln(Ret) - 3.28) ftLNp di 4Np
-2

= c2 2

0.005797

= 58.6762 Kpa = 8.5 psi

, head required to pump the fluid into the tubes

2.0 SHELL PRESSURE DROP The shell-side fluid experiences a pressure drop as it passes through the exchanger, over the tubes, and around the baffles. 2 fsG s(Nb+1)D's Ps = 2 sD e s 2.1 Shell side friction factor fs = exp(0.576 -0.19ln(Res)) = 0.300

2.2

Bundle crossflow area

As

DsCB PT

= 0.125 m , based on corrected shell clearance of tubes and baffle spacing. Ts1+Ts2 2 the tube length
1 2

2.3

Wall temperature

Tw

Tt1+Tt2 2

= 297.8 K , average temperature between cold and hot fluid across therefore: the absolute viscosity and wall temperature of = 0.0009001 kg/m - s 2.4 Correction Factor
s

24.8 oC

s w L B Ms As

0.14

0.989

2.5

Number of Baffles

Nb =

-1

2.6

Number of Baffles

Gs =

= 398.593 kg/m2-s

therefore:

Ps

= = =

fsG s(Nb+1)D's 2 sD e s 6.4 0.9 Kpa psi , head required to pump the fluid into the shell

TUBE SIDE : 1 2 3 4 5 6 7 8

HOT SI E 20 150 998.2 0.6044

o

Inlet temperature Mass flowrate Density Ther al Conductivity Dyna ic viscocity Specific Heat Prandtl number Velocity of fluid inside the tubes

C kg/s kg/m3 kg/

W/m - K 0.0009832 N.s/m2 4181.6 J/kg - K 6.8023645 2 m/s 0.000176 m2 - K/W 32 25 28.5 50 996.4 0.6144
o o o

9 Total fouling factor SHELL SIDE: COLD SIDE 1 2 3 4 5 6 7 Inlet temperature Outlet temperature Average temperature Mass flowrate Density Thermal Conductivity Dynamic viscocity

C C C
3

kg/s kg/m

9 Specific Heat 5.6396127 10 Prandtl number CONSTRUCTIONAL DATA OF THE PROPOSED SHELL AND TUBE HX 0.800 1 Shell diameter m 1121.07 2 Number of tubes 3 4 5 6 7 8 9 10 11 12 13 14 15 Length of tubes(Allowancefor tubesheet not included) Tube outside diameter Tube inside diameter Baffle spacing ( baffle cut at 25%) Tube pitch Number of passes Thermal Conductivity of tubes Tube side heat transfer coefficient Shell side heat transfer coefficient Clean overall heat transfer coefficient Fouled overall heat transfer coefficient Tube side pressure drop Shell side pressure drop 4.000 0.019 0.016 0.500 0.025 3.000 42.300 8526.66 2800.32 1869.27 1406.54 58.68 6.40 m m m m

W/m - K 0.0008292 N.s/m2 4178.7 J/kg - K

W/m - K W/m2 - K W/m2 - K W/m2 - K W/m2 - K Kpa Kpa

Summary of THE HEAT EXCHANGER S ary f THERMAL DESIGN OF HE T E HANGE L ESI

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