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    Design: of Shell & Tube Heat Exchanger

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    Balamurugan Sakthivel
    The document describes the design of a shell and tube heat exchanger and centrifugal pump. Key details include a heat duty of 413.9 kW for the heat exchanger requiring an area of 38 m2 with 136 tubes. The pump is designed to handle a flow rate of 6.53 m3/h with a suction pressure of 1.63 kg/cm2, discharge pressure of 20.75 kg/cm2, and requires 0.96 hp of motor power.

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    Design: of Shell & Tube Heat Exchanger

    Uploaded by

    Balamurugan Sakthivel
    102 views27 pages
    The document describes the design of a shell and tube heat exchanger and centrifugal pump. Key details include a heat duty of 413.9 kW for the heat exchanger requiring an area of 38 m2 with 136 tubes. The pump is designed to handle a flow rate of 6.53 m3/h with a suction pressure of 1.63 kg/cm2, discharge pressure of 20.75 kg/cm2, and requires 0.96 hp of motor power.

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    The document describes the design of a shell and tube heat exchanger and centrifugal pump. Key details include a heat duty of 413.9 kW for the heat exchanger requiring an area of 38 m2 with 136 tubes. The pump is designed to handle a flow rate of 6.53 m3/h with a suction pressure of 1.63 kg/cm2, discharge pressure of 20.75 kg/cm2, and requires 0.96 hp of motor power.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    102 views27 pages

    Design: of Shell & Tube Heat Exchanger

    Uploaded by

    Balamurugan Sakthivel
    The document describes the design of a shell and tube heat exchanger and centrifugal pump. Key details include a heat duty of 413.9 kW for the heat exchanger requiring an area of 38 m2 with 136 tubes. The pump is designed to handle a flow rate of 6.53 m3/h with a suction pressure of 1.63 kg/cm2, discharge pressure of 20.75 kg/cm2, and requires 0.96 hp of motor power.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 27

    DESIGN

    OF SHELL & TUBE HEAT EXCHANGER


    FEED PROPERTIES
    Heat duty of heat exchanger :

    Shell side :

    Q= mc*Cp*ΔT

    =16365.498*0.96*(466-364) = 1602509.56 KJ/h


    =445.14 KW

    Tube side :

    Q= mh*Cp*ΔT

    =22306.328*1.05*(513.6-450)

    = 1489616.58 KJ/h

    =413.78 KW
    Temperature driving force :

    LMTD = ΔT1 – ΔT2/ ln ( ΔT2 /ΔT2 )

    ΔT1 = 513.6 – 466 = 47.6

    ΔT2= 450 – 364 = 86

    LMTD = 47.6 – 86/ ln (47.6/86)


    = 64.92

    For 1 shell and 2 tube passes

    ΔTlm = FT * LMTD

    P= ( TC2 – TC1 )/ ( Th1 – Th2 )

    =( 466 – 364 )/ (513.6 – 364 )

    =0.68
    R= ( Th1 – Th2 )/ ( TC2 – TC1 )

    =( 513.6 – 450 )/ (466 – 364 )

    R=0.62

    From PR chart,

    FT = 0.65

    ΔTlm = 0.65 * 64.92

    = 42.200 C
    Estimated area :

    Q = UAΔT lm

    A = Q/ UΔTlm

    Let as assume over all heat transfer co- efficient = 250 W/ m2 0C

    A = 413.79 × 103/ 250 × 42.20

    = 39.22 m2

    Tube pitch = 1.25 ( OD )

    =1.25 * 0.01905

    =0.024 m
    Heat transfer area of each tube

    length – allowance )

    =3.14 * 0.01905 * ( 4.88 – 0.05 )

    =0.2889 m2

    Number of tubes required

    =A/ surface area of tube

    =39.22/ 0.288

    =136
    Fluid flow area:

    At =3.14/4 × (ID)2 × ( NT/NP )

    =3.14/4 ×(0.01574 )2 × (136/2)

    =0.01m2
    Fluid velocity in tube :

    V = mass velocity/ρ × At
    =4.55/ 0.95 × 0.11
    =0.48 m/s

    Wall temperature :
    TW = 0.5 ( ( Th1 +( TC1 + TC2/ 2 ) )

    =0.5 ( 928.60 )

    =464.3 0 C
    Film temperature :

    Tfilm = Twall + Th1/ 2


    = 464.3 + 513.6/ 2
    =488.9 0C

    Film co- efficient of shell side :

    h0 De/ k = 0.36 ( Nre ) 0.55 (Npr)0.33 (ϻ/ ϻw )0.14

    NRE = GS De / µ
    G S = MS / A S
    AS = DS C „ B/PT

    Clearance C „= PT – OD

    = 0.024 – 0.019 = 0.005 m


    Baffle spacing B = DS

    B= 0.4489 m
    AS = 0.4489 * 0.005 * 0.4889/0.024
    = 0.0498 m2

    GS = 6.2/0.0498

    = 124.50

    Kg/m2 Equivalent diameter :


    De =4(PT2 – 3.14/4(OD)(*OD)
    =4(0.0242 -3.14/4(0.0192)2 )(*0.019)
    =0.0196 m

    NRE = 124.5 * 0.019/0.2 * 10-3


    = 8448.21
    NPR = CP ϻ/k
    =1.05 * 0.28 * 10-3 * 1000/ 0.132
    =2.23

    Let as assume (ϻ/ ϻw ) = 1 for low viscous fluids


    h0 *0.0196/ 0.132 = 0.36 ( 8448.21 ) 0.55 ( 2.23)0.33
    h0 = 451.73 W/ m2 0C
    film heat transfer co-efficient of tube side :

    hiDi/ k = 0.023( Nre ) 0.88 (Npr)0.33 (ϻ/ ϻw )0.14

    NRE = Gt Di / ϻ

    Gt = Mt/ At

    = 4.55/ 0.01
    = 455 kg / m2s

    At =3.14/4 × (ID)2 × ( NT/NP )


    =3.14/4 ×(0.01574 )2 × (136/2)
    =0.01 m2

    NRE = 455 * 0.0157/ 0.32 * 0.001


    = 22323.44
    NPR = 1.05 * 0.32/ 0.112
    =3
    hi *0.015/ 0.124 = 0.023 ( 22323.44 ) 0.8 ( 3)0.33

    hi = 766.03 W/m2 0C

    hi0 = hi ( ID/OD )
    =766.03 ( 0.0157 / 0.01905 )
    hi0 =631.32 W/m2 0C
    TUBE WALL RESISTANCE :

    RW = D0 / 2KW ln ( D0 / Di )

    =0.0195/ 2*55 ln ( 0.01905 / 0.0157)

    =3.349 * 10-5 m2 0C / W
    Rdi0 = 1.76 * 10-4
    Rdo = Rdi ( D0 / Di )

    = 1.76 * 10-4 * ( 0.01905/ 0.0157 )

    =2.13 * 10 -4 m2 0C / W
    Over all heat transfer co-efficient :

    U0 = ( 1/h0 + RW + Rdi0 + Rdo + 1/ hio )

    = 254.60 W/m2 0C
    Required heat transfer area

    Ar = Q/ U0 ΔTm

    = 413.9/254.60 * 42.20

    =38 m2

    Heat transfer area available

    Aa =(OD ) * L * Nt

    =3.14 ( 0.01905 ) * 4.88 * 136

    =39.70 m2
    Available heat transfer area is greater than the required heat transfer area so Design is safe.

    % excess area = Aa - Ar / Ar * 100

    =( 39.70 – 38 )/38 * 100 = 4.47 %


    Pressure drop in shell side :

    Δps = { ( f * GS 2 * DS ) ( Nb + 1) } / ( 2 * 106 * De * S* ψS )

    f  fanning friction factor

    GS mass velocity of shell side fluid


    DS  diameter of shell

    Nb no of baffles

    S specific gravity of shell side gas

    F = 1.87( NRE ) -0.2


    =1.8 ( 8448.21 )-0.2
    0.31

    S = 0.53

    Nb = lenth of tube/ baffle spacing

    = 4.88/0.4889 = 10
    Δps = { ( 0.31 * 124.5 2 * 0.4889 ) ( 10 + 1) } / ( 2 * 106 * 0.0196* 0.53* 1 )
    = 1.24 < 20 kpa

    Design is safe.
    Pressure drop in tube side :

    Δpt = { ( f * Gt2 * L * NP )/2*106 *Di* S* ψS ) + ( 2.5* NP *V2 *S )

    F fanning friction factor


    Gt  mass velocity of tube side fluid
    Di  inner diameter of tube
    Np  no of passes
    S  specific gravity
    V  velocity
    F = 0.72( NRE ) -0.33

    =0.72 ( 22323.44 )-0.33

    =0.03

    Δpt = { ( 0.03* 4552 * 4.88* 2 )/2*106 *0.0157* 1* 1) + ( 2.5* 2 *0.482 *1 )

    = 3.08< 20 kpa

    Design is safe .
    DESIGN SUMMARY

    Heat duty of the heat


    exchanger 413.9 kW

    Area required for heat transfer 38 m2


    Area available for heat transfer 39.5 m2
    No of tubes 136
    No of passes in tube side 2
    No of passes in shell side 1
    Film heat transfer co-efficient
    in tube side 766.03W/ m2 o C
    Film heat transfer co-efficient in
    shell side
    451.73W/ m2 o C
    Overall heat transfer co –
    efficient 254.60W/ m2 o C
    Pressure drop in the tube side 3.08kpa
    Pressure drop in the shell side
    1.24kpa
    Design of centrifugal pump :

    Data :
    Suction side :

    Flow rate = 6.53 m3/h

    Diameter of the pipe= 0.06 m

    Geometric pipe length = 10 m


    Discharge side :

    Flow rate = 6.53 m3/h

    Diameter of the pipe= 002 m

    Geometric pipe length = 30 m

    Density = 1000 kg/ m3

    Viscosity = 0.75 cp
    Determination of suction pressure :

    Flow rate = area * velocity

    Q =D2/4 * V

    6.53/3600 = 3.14 * 0.062/4* V

    V= 0.64 m/s

    Total equivalent length =geometric length +length of the fittings

    Geometric length =10m


    Length of h the fittings = 500*0.06=30m
    Total equivalent length =40 m

    Line pressure drop = 4fLv2/2g D

    NRE = DVρ/µ
    =0.06 * 0.64 * 1000/0.75 * 0.001
    =51200
    F = 0.0035 + 0.264 (NRE )-0.42
    = 6.27 * 10-3

    Δpf = ( 4 * 0.006 * 40 * 0.64 * 0.64 ) / 2 * 9.81 * 0.06


    = 0.33 m
    =0.33 * 10-4 *1000
    = 0.03 kg/cm2

    Static head =(10-4)*10-4 *1000


    =0.6kg/cm2

    Suction pressure:

    System pressure =10 kg/cm2


    Static head =0.6kg/cm2
    Line pressure drop =0.03kg/cm2
    Suction pressure =1.63kg/cm2
    Determination of discharge pressure :

    Flow rate = area * velocity

    Q =D2/4 * V

    6.53/3600 = 3.14 * 0.022/4* V


    V = 5.77 m/s

    Total equivalent length = geometric length + length of the fittings

    Geometric length =30m


    Length of the fittings = 600*0.116=70m
    Total equivalent length =100m
    Line pressure drop = 4fLv2/2g D

    NRE = DV ρ/µ

    =0.02* 5.77 * 1000/0.75 * 0.001

    =153866.66

    F = 0.0035 + 0.264 (153866.66)-0.42

    = 5.24 * 10-3

    Δ pf = ( 4 * 0.0052 * 100 * 5.77 * 5.77 ) / 2 * 9.81 * 0.02 = 176 m

    =176 * 10-4 *1000

    = 17.6 kg/cm2

    Static head = 10 * 10-4 * 1000

    = 1.0 kg/cm2
    discharge pressure :

    System pressure = 2.11 kg/cm2

    Static head = 1 kg/cm2

    Line pressure drop = 17.64 kg/c

    discharge pressure = 20.78 kg/cm2

    differential pressure :

    differential pressure = discharge pressure – suction pressure


    =20.75 – 1.63
    =19.12 kg/cm2
    =191.2 MWC

    NET POSITIVE SUCTION HEAD :


    NPSH = SUCTION PRESSURE – VAPOUR PRESSURE
    =1.63 – 1.05
    =0.58 kg/ cm2
    =5.8 MWC
    SAFETY MARGIN :

    Safety margin = (NPSH) – 0.6/ specific gravity

    =5.8 – 0.6/0.6 = 8.7 MWC

    Horse power required :

    HP = flow rate * ( density * differential pressure in MWC ) / 75

    = 6.53/3600 * (1000 * 19.12)


    = 0.46 hp
    Break horse power required :

    BHP= HP/PUMP EFFICIENCY

    =0.46/0.6
    =0.77hp
    Motor horse power required :

    MHP = BHP/ MOTOR EFFICIENCY

    Motor power efficiency is 80%

    = 0.77/0.8

    =0.96 hp

    Efficiency = HP/BHP * 100

    =0.46/ 0.77

    =60 %
    DESIGN SUMMARY:
    Suction pressure = 1.63 kg/cm2

    Discharge pressure = 20,75 kg/cm2

    Differential pressure = 19.12 kg/cm2

    Net positive suction head = 0.58 kg/cm2

    Pump efficiency = 60 %

    Horse power required = 0.46 hp

    Break horse power required = 0.77 hp

    Motor horse power required = 0.96 hp


    T H A N K

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