5.

3 Design of Waste Heat Boiler: (13)

Data:

Flow rate of gas = mg = F7 = 679.8 kmol/hr

Flow rate of cooling water = mw =

F8 = 137.2648 kmol/hr

Temperature of gas at inlet T1 = 678 K

Temperature of gas at outlet T2 = 450K
Temprature at Cooling Water Inlet=333K
Temprature at cooling water outlet=503 K
o
Specific heat of gas = Cpg = 1775 J/Kg - C

1. Heat Load:
Q = mg × Cpg× ∆Tg

Putting all above values we have,

= 1772.29 KW

2. Log mean Temperature Difference:

− )

= 144.3128K

3. Correction Factor for Temperature: ( − )

R=1.4

S=.492

Ft=0.8
Corrected temperature difference:

∆Tm= ∆Tlm FT

∆Tm = 115.2 k

1. Area:

Let us assume:

U = Overall heat transfer Co efficient

2
= 500 W/m – K (6)

A = Q/(U∆Tm)
2
= 30.7m
2. Tube Dimensions:

Let,
D0 = outer diameter = 25 mm
Di =inner dia = 18 mm
Length of tube = 7m (Range 1.83 – 7.32m)
Thickness of tube = 0.2m

Corrected length:

Corrected length= selected length- thickness of tube sheets = 6.8 m

1. Surface Area of one tube:

At = πd0 l
2
= 0.379 m
2. Number of Tubes:

No. of Tubes = Nt= A/At

= 87 tubes

1. Pitch of Tube:

For triangular pitch:

Pt = pitch = 1.25d0
= 31.25 mm

2. Bundle Diameter:
Db= d0( Nt/K1)1/n )

K1 = 0.249

n1 = 2.207

1/2.207
Db = 19 (58/0.249)
= 224.57mm

= 0.2245 m

1. Shell Bundle Clearance:

Let pull through floating head type exchanger is selected because temperature
difference is sufficient

Clearance = dia of shell – dia of tube

bundle Clearance= 88mm

DS = Db + Clearance
 = 224.57 +88

DS = 312.57 mm

= 0.31257 m

1. Tube Side
Cross sectional area of tube:
2
Cross sectional area of tube = At = (π/4) ×di

= 254.34 m2
Tube per pass:
Tube per pass = Nt/2

= 43.5

Total flow area:

Af= Total flow area = tubes per pass × Ai

2
= 11063.2 m
Water linear velocity:

3
δ (Density of water) = 947 kg/m ut
water linear Velocity = wt /ρ × Af
= 0.42 m/s

Inside coefficient of water:

hi = 4200(1.35 + 0.02t) ut0.8 / di0.2

2 0
= 5976.2 W/m - C
Shell side :
1/3
hs = jh×(k/de)×Re×(Pr ) …….. (i)
3
ρ = (Density of shell fluid side at T) = 1.1304 kg/m
CP = Specific heat of shell side fluid at T = 1775/Kg-C k

Thermal conductivity of shell side fluid at T = 0.19

2
μ = viscosity of shell side fluid at T = 0.00054 Ns / m
Equivalent diameter: )

2 2
de= (1.1/19 ) (23.75- 0.917× 19 )
= 13.49095 mm
= 0.01349 m
Baffle Spacing:
Lb= baffle spacing = 0.2 × Ds
= 0.06255 m
Cross flow area:
As= cross flow area = (pt –d0) × Ds× Lb/ Pt
2
= 0.0400m

Linear Velocity of shell side Fluid:

us = wg / (ρ × As)

= 75.85 m/s

Reynolds Number:

Re = ρ de us/ μ

Re=7432
Prandtl Number:

Pr = Cp × k /μ
= 5.044737

2. Overall Heat Transfer Coefficient:

2 0
kw= thermal conductivity of tube material = 45 W/m - C
2 0
h0d = fouling Co efficient of shell side fluid = 3000 W/m - C hid = fouling Co
2 0
efficient of tube side fluid = 3000 W/m - C
20
hi = inside fluid film Coefficient = 2759.94 W.m - C

1/ U0 = 0.0134

2 0
U0 = 745.48 W/m - C
3. Tube Side pressure Drop:
Np= no. of tube passes

3
ρ = Density = 968 kg/m
ut= tube side velocity = 0.42 m/s

2
μ= viscosity of fluid at tube side at t = 0.000785 Ns/m
2
μw = viscosity of fluid at wall temperature Ns/m significant only for viscous fluid,
otherwise leaves it

m= 0.25 for laminar flow Re˂2100, 0.14 for turbulent flow Re>2100
( ) = 1 (significant only for viscous fluids, otherwise equal to 1)

Re =7432.75

jf = Pressure factor = 0.0049 ........ from figure 12.24 (Coulson volume 6)

By putting all values in equation 12.20 for pressure drop it comes out to

∆P = NP(8jf ( )( )-m +2.5)

2
∆P = 413.55 N/m
= 4.13kPa(Sufficient)

3. Shell Side Pressure Drop:

∆P = NP(8jf ( )( )( )-0.14
for less viscous fluids, correction factor is 1.
Shell side Reynolds no = 2142.16

Jh= 0.06 at calculated Reynolds no. of shell side

putting all values in equation ∆P = 4.2 Pa