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Lecture Objectives
After this lecture, you should: Be familiar with the major types of available heat-exchange equipment, with particular emphasis on shell-and-tube heat exchangers. Know how to estimate overall heat transfer coefficients for a shell-and-tube heat exchanger. Know how to compute pressure drops on both sides of a shell-and-tube heat exchanger. Be able to perform mechanical design of the most appropriate shell-and-tube heat exchanger to meet desired duty and pressure drops.
7-2 PLANT DESIGN - Daniel R. Lewin Heat Exchanger Design
LECTURE SEVEN
Segmental baffles
Segmental baffles
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7-5
7-6
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7-7
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1-1 Fixed Head 1-2 U-tube 1-2 Fixed Head 2-4 Floating Head 3-6 Fixed Head
7-9
C
http://www.tema.org
Heat Exchanger Design
7 - 10
LECTURE SEVEN
Design issues: (a) Use Heuristic 56 for initial design; (b) Design the tube-banks similarly to a shell-and-tube heat exchanger.
7 - 11 PLANT DESIGN - Daniel R. Lewin Heat Exchanger Design
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Operation principles: Process stream flows through a coil heated by combustion of fuel in the furnace chamber.
7 - 13 PLANT DESIGN - Daniel R. Lewin Heat Exchanger Design
Convection section
Radiation section
Gas burners
Dividing wall
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Temperature-Driving Forces
The rate of heat transfer in an shell-and-tube exchanger is computed as: Q = mc (HC ,out - HC ,in ) = mh (HH ,out - HH ,in ) Assuming (1) steady-state; (2) counter- or cocurrent flow; (3) constant overall heat transfer coefficient; (4) no phase changes on either side; and (5) negligible heat losses: Q = U A TLM where: TLM =
(T
h ,in
-Tc ,out ) - ( h ,out -Tc ,in ) T T -T ln h ,in c ,out T h ,out -Tc ,in
Heat Exchanger Design
7 - 17
Temperature-Driving Forces
For multiple-pass shell-and-tube exchangers, the flow directions of the two fluids are combinations of countercurrent and co-current flow, reducing the effective value of TLM . For a 1-2 exchanger, with assumptions 1, 3, 4 and 5: It is desirable to have a value of FT Q = U A TLM F T for 1-2
where: F = T
Nagle (1933)
FT
ln [(1 S ) (1 RS )] R + 1
2
2 S R + 1 FT = 1 for phase ( R 1 ) ln 2 2 S R + 1 + R + 1 change in duty fluid When FT < 0.75, Th ,in -Th ,out Tc ,out -Tc ,in increase the R = , and S = shell passes. Tc ,out -Tc ,in Th ,in -Tc ,in
PLANT DESIGN - Daniel R. Lewin Heat Exchanger Design
( (
) )
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LECTURE SEVEN
Temperature-Driving Forces
FT for 1-2 shell-and-tube exchanger.
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Example 13.5
A hot stream is cooled from 200 to 140 oF by a cold stream entering at 100 oF and exiting at 190 oF. Determine the true TLM and select the appropriate shell-and-tube configuration. Solution: 40 - 10 = 21.6 oF For counter-current flow: TLM = 40 ln 10 For multiple-pass exchangers: T -T 200 - 140 FT for 1-2 R = h ,in h ,out = = 0.667 Tc ,out -Tc ,in 190 - 100 T -T 190 - 100 FT for 4-8 S = c ,out c ,in = = 0.9 Th ,in -Tc ,in 200 - 100
7 - 20 PLANT DESIGN - Daniel R. Lewin Heat Exchanger Design
10
LECTURE SEVEN
FT = 0.85
Thus, 4 shells need to be installed, in a 4-8 configuration. In this case, FT = 0.85, and: TLM F = 21.6 0.85 = 18.4o F T
7 - 21 PLANT DESIGN - Daniel R. Lewin
S = 0.9
Heat Exchanger Design
7 - 22
11
LECTURE SEVEN
Class Exercise 1
A hot stream is cooled from 1,150 to 560 oF by a cold stream entering at 400 oF and exiting at 1,000 oF. Determine the true TLM and select the appropriate shell-and-tube configuration. Solution: For counter-current flow: TLM = For multiple-pass exchangers: T -T R = h ,in h ,out = Tc ,out -Tc ,in T -T S = c ,out c ,in = Th ,in -Tc ,in
7 - 23 PLANT DESIGN - Daniel R. Lewin
Configuration
FT
JH
h D Cp = I I k k
1 3
0.14
vs.
WT ,A = 4 A T T
DI GT 2 DI
JH
h D Cp = O O k k
1 3
0.14
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12
LECTURE SEVEN
PT
PT
PT
P tube pitch (in) T C ' tube clearance (in)
de =
pitch: de =
2 4P 2 DO T
DO
WS d C 'B , AS = S AS 144P T
pitch: de =
2 12P 2 DO T
DO
WS total shell side mass flow (lb/hr), AS shell crossflow area (ft2 ) dS shell diameter (in),B baffle spacing (in)
7 - 25 PLANT DESIGN - Daniel R. Lewin Heat Exchanger Design
RF ,O
1 + hO
tW A O + kW AM
1 A O +R + hI AI F ,I
A O AI
Internal fouling
Wall resistance
AO = DO L
Udirty =
AI = DI L
DO D I
AM =
RF ,O
1 + hO
1 DO + h D + RF ,I I I
Uclean =
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13
LECTURE SEVEN
fGT2LNT
0.14
[psi]
f = friction factor [ft2/in2], GT = tube mass velocity [lb/ft2 hr], L = tube length [ft], NT = total number of tube passes, S = specific gravity, DI = tube I.D. [ft].
In addition, the repeated changes in direction caused by the numerous passes in the tubes adds additional pressure loss, called the return loss: 4NT vT2 [psi] Pr = 2g The total pressure drop is: P = P + Pr [psi] t
PLANT DESIGN - Daniel R. Lewin
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fGs2DS (NB + 1 )
0.14
[psi]
f friction factor [ft2 /in2 ] GS mass velocity in shell [lb/ft2 hr] DS I.D. of shell [ft] NB number of baffles
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LECTURE SEVEN
Fluid velocity
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Shell diameter Tube diameter Tube length Tube packing configuration (pitch) and spacing Number of tube and shell passes
Heat Exchanger Design
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Class Exercise 2
Design a shell-and-tube heat exchanger to preheat a stream of 30 T/hr containing ethylbenzene and styrene from 10 to 97 oC. Additional data: Density 856 kgm-3, Viscosity 0.4765 cP, Specific heat 0.428 kcalkg-1oC-1, Thermal conductivity 0.133 kcalhr-1m-1oC-1 Heat supply medium Saturated steam at 10 barg.
Notes: (a) For this application, the process fluid is fed to the tubes. (b) Maximum P in the process side is 0.8 bar. (c) Fouling - process: 0.0002, steam: 0.0001 hr m2/kcal
7 - 32 PLANT DESIGN - Daniel R. Lewin Heat Exchanger Design
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LECTURE SEVEN
Units
kg/hr
oC oC
Cold side Hot Side Notes Tube side Shell side EB/Styrene Sat. steam Q = mtubeCptubeT 30,000 2,113 =30,0000.428(97-10) = 1,117,080 kcal/hr 10 115 msteam = Q/ 97 115 = 528.7 kcal/kg 856 0.4765
oC
kg/m3 cP Kcal/kg
0.9712 0.1262
Kcal/hr cm hr m2/kcal
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Units
oC oC oC oC
Value
18 105 49.33 49.33
LM T D =
Notes
LMTD c-LMTD
C. Heat Duty
Q UEstimated AEstimated Kcal/hr
T2 T1 10 5 18 = = 4 9 .3 3 ln ( T 2 T 1 ) ln (1 0 5 1 8 )
kcal/(hr oC m2) 490-980 Item 5: For light organics, U = 100-200 BTU/(hr oF ft2). m2 23-46 A = Q/( UEstimatedc-LMTD)
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Units
Value
4 1 Assumed Assumed
Notes
m m m/sec m2 m3/hr
Taking 1 (I.D.) 12 BWG tubing as basis. Thus DI = 0.782 Allowed range: 1.2-3 m/sec 1.4 m/sec = 4.59 ft/sec AT = (DI2)/4
qT in each tube
92 6
Units
m2 m m2
Value
44 -1 0.4382 51
Notes
A = NSNTotalLDO = 44 m2 -pitch selected (why?) 17 shell holds 106 tubes. A = NS 106LDO = 51 m2
Note that the available heat transfer area, 51 m2, is larger than the value estimated previously, 23-46 m2, so can be reduced! We shall now compute the heat transfer coefficient and the pressure drops in the tube and shell, and compare with our targets.
7 - 36 PLANT DESIGN - Daniel R. Lewin Heat Exchanger Design
18
LECTURE SEVEN
m2 Kg/(hr
3,653,462 GT = mtube/AT
1 1,538 7,342
7 - 37
UDirty
756
UService UEstimated
444 490-980
UService = Q/(AAvailablec-LMTD)
Uclean =
1 1 DO + hO hI DI
Udirty =
RF ,O
1 + hO
1 DO DO + + RF ,I hI DI DI
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LECTURE SEVEN
f
Pt, friction Pr, return P
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B NB + 1 de C AS GS Res f
PS
Note that the shell P is usually much lower than the tube value.
7 - 40 PLANT DESIGN - Daniel R. Lewin Heat Exchanger Design
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LECTURE SEVEN
The heat transfer surface is larger than necessary. In contrast, the pressure drop is much lower than its permitted value. Possible next steps include: Increase/decrease the shell diameter Increase/decrease the number of tubes Increase/decrease the number of passes Increase/decrease tube diameter
7 - 41 PLANT DESIGN - Daniel R. Lewin Heat Exchanger Design
Summary
After reviewing the materials in this lecture, you should: Be familiar with the major types of available heat-exchange equipment, with particular emphasis on shell-and-tube heat exchangers. Know how to estimate overall heat transfer coefficients, including the effect of fouling. Be able to perform mechanical design of the most appropriate shell-and-tube heat exchanger to meet desired duty and pressure drops.
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21
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7 - 43
130
42,300
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22
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0.000185
42,300
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7 - 46
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0.0015
22,195
7 - 47
24