Chapter 8 Evaporator Design
8.1 INTRODUCTION
The process inside is evaporation. It is a thermal separation
technique used to concentrate a liquid solution, emulsion or suspension. A feed mixture is
introduced into the evaporator, a part of it is evaporated and separated, the rest being a
concentrated solution. A complete evaporation stage consists of an evaporator, a separator
and a condenser to cool the end product.
8.1.1 Objective
We have to separate TDI from crude TDI mixtute.
8.1.2 Selection of Evaporator
Depending upon different modes of evaporation
and system characteristics there are many types of evaporators. So in order to select an
adequate type of evaporator we have some selection charts here:
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Chapter 8 Evaporator Design
For a low viscosity and low fouling system we can see that film type mode of
evaporation is the first choice. Our system has both of these properties, film type
evaporation is the most suitable mode for our case.
Another selection chart is available here:
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Chapter 8 Evaporator Design
Our system has got low viscosity, low fouling, non foaming attitude and
with no crystal production. In accordance with this chart, for all the above mentioned
characteristics and also for economical considerations the most suitable choice is the long
tube vertical falling film evaporator. Here is another selection chart:
A diagram of long tube vertical falling film evaporator is as shown below:
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Chapter 8 Evaporator Design
Long Tube Vertical Falling Film Evaporator
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Chapter 8 Evaporator Design
8.1.3 Main Features Of Falling Film Evaporator
Best product quality
High energy efficiency
Simple process control and automation
Flexible Operation
Can handle large capacities
Also suitable for temp. sensitive products
Can be used for liquids containing small amount of solids
Most economical
8.1.4 Process Description
The long vertical section is called the calendria, its lower
portion is called calendria base and the assembly on the right side is a separator. The
crude TDI mixture is coming from distillation column at its saturation temperature. It
contains TDI, its dimers and trimers. Feed is introduced at the top of the calendria of
evaporator wihch is a long vertical section and is like a shell and tube heat exchanger
with one shell pass and one tube pass. The crude mixture is fed into the tube side where
as on the shell side there is a hot fluid i.e Toluene. The liquid feed mixture forms a thin
film while passing through a liquid distributer on the inner side of tubes while coming
down and gets vaporised under vacuum coditions. Below this there is the calendria base
through which some of the liquid is withdrawn and the rest is fed to a vapor liquid
separator. Here the heavy liquids settle down and vapors are collected at the top. Vapors
of TDI and a very little fraction of ODCB are sent to a condenser. On shell side the hot
fluid enters at the top and leaves near the bottom of calendria.
Properties Data
Cold Fluid Mixture
m(res) = 705.3 Kg/h
m(TDI) = 4880.6 Kg/h
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Chapter 8 Evaporator Design
cp(res) = 490.9 J/KgC
cp(TDI) = 0.172 KJ/KgC
λ(TDI) = 259.212 KJ/Kg
T1(Res) = 252.2 C
T2(Res) = 270 C
T1(TDI) = 219.44 C
T2(TDI) = 270 C
Cp(mix) = 2.456 KJ/KgC
μ(mix) = 0.558Kg/mh
K(mix) = 0.144 KJ/hmC
Hot Fluid (Toluene)
Cp = 2.71 KJ/KgC
μ = 0.0001.26 Kg/mh
K = 0.342 KJ/mC
T1 = 300 C, T2 = 266.67 C
8.2 DESIGN OF EVAPORATOR
It involves the design of
Calendria
Separator
Condenser
8.2.1 Calendria
It is the vertical long tube section of the overall
assembly. Following steps are involved in the designing of Calendria :
1. Heat Balance
2. Calculation of (∆T)LMTD
3. Assumed Calculations
4. Calculations for Film Coefficients
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Chapter 8 Evaporator Design
5. Clean Overall Coefficient and a check for Design Overall Coefficient
1. Heat Balance
Heat supplied by Toluene(Hot Fluid) = Sensible heat gained by residues + Latent heat of
vaporization of TDI + Heat required by TDI to get superheated, i.e
Q = mcpΔT(res) + mλ(TDI) + mcpΔT(TDI)
Total heat transfered = Q = 1501623 KJ/h
Q
Mass flow rate of Toluene = ms = CpT = 16680 Kg/h
2. Calculation of ΔT(LMTD)
Hot Fluid Cold Fluid Difference
300 Higher Temp 220 80
266.67 Lower Temp 220 46.67
Δt2 = 80 C , Δt1 = 47.33 C
t 2 t1
ΔT(LMTD) =
ln t 2 t1
ΔT = 61.84 C
3. Assumed Calculations
Trial
UD = 1206.43 KJ/hm²K
Q
Heat Transfer Area = A = = 21.2 m²
U D T
According to this area shell and tube side dimensions are selected and the respective no
of tubes are calculated. The dimensions are given as:
Shell & Tube Dimensions
Shell Side Tube Side
ID = 0.254 m 16 BWG
De = 0.018 m OD = 0.019 m
B = 0.61 m ID = 0.0157m
C = 0.00635 m n=1
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Chapter 8 Evaporator Design
Pt= 0.0254 m at´ = 0.00019 m2
n=1 at = 0.06m2/m
Lt = 5.5 m
nt = 61
4. Calculations for Film Coefficients
For the calculations of film coefficients we
have parallel calculations on shell side and tube side. All the parameters used in the
formulae have already been mentioned and only results are shown here.
Shell Side, Hot Fluid Tube Side, Cold Fluid
(Toluene) (Feed Mixture)
(1´) Shell Area (1) Tube Area
ID C B nt at
as = at =
Pt n
= 0.0387 m2 = 0.0121 m2
(2´) Mass Velosity (2) Mass Velosity
ms mt
Gs = Gt =
as at
= 430675 Kg/hm² = 466588 Kg/hm²
(3´) Reynold’s no (3) Reynold’s no
Gs De IDGt
NRe = NRe =
= 6340 = 13184(Suitable relation is given
as:)
(4´) jH value (4) Tube Side Film Coefficient
From graph hi =
0.27 k ID IDGt Cp k
0.8 0.33
jH = 42 = 1840.32 KJ/hm²C
(5´) Shell Side Film Coefficient (5) Inside Film Coefficient depending
on OD is:
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Chapter 8 Evaporator Design
ID
ho = jH k De Cp k 0.33 hio = hi
OD
= 1786.14 KJ /hm²C = 1520.14 KJ/hm²C
5. Clean overall coefficient UC
ho hio
Uc =
ho hio
= 1472.25 KJ/hm2C
Allowable dirt resistance = Rd = 0.000147 hm²C/KJ
6. Check for UD
UC
UD =
1 Rd U C
= 1210.5 KJ/hm²C
Which is very close to the assumed value i.e 1206.43 KJ/hm²C.
So the design is satisfied.
SPECIFICATION SHEET FOR EVAPORATOR (V-410)
Identification : Unit Evaporator
Item No. V-410
Type Falling Film Vertical
No. of Items 1
Function : To evaporator TDI from crude TDI mixture.
Operation : Continuous
Heat duty : 1.5x106 KJ/hr
Heat transfer area : 21.2 m2
Overall H.T Coefficient : 1206.43 KJ/hr-m2 oC
Dirt factor : 0.00014hr-m2 oC/KJ
Shell side Tube side
Fluid circulated Toluene Crude TDI Mixture
Flow rates 16680 Kg/hr 5586 Kg/hr
Temperature T1=300C,T2=266.67C T1 = 252C, T2 = 270C
Pressure 153.3 Kpa 48.25 Kpa
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Chapter 8 Evaporator Design
Construction material Stainless steel 204 Stainless steel 204
Design dimensions I.D = 0.254 m OD = 0.019 m, 16 BWG
C = 0.00365 m Pitch = 0.0254 m
B = 0.61 m Triangular arrangement,
Length = 5.5 m
Nt = 61
8.22 Separator
With a long tube vertical falling film evaporator, a vertical vapor
liquid separator is used here. It’s actually a vapor liquid separation drum. Separation
takes place on density difference basis. The liquid settles down and vapors passing
through the demister are collected at the top and sent to a condenser.
Data used for designing
Mass flow rate of liquid = mL = 705.3 Kg/h
Mass flow rate of vapor = mv = 4880.6 Kg/h
Residence time = ts = 300 sec
Constant = kv = 0.11 m/s
Liquid density = dL = 4Kg/m³
Vapor density = dv = 1202 Kg/m³
Calculations for Diameter
Volumetric Flow Rate of Vapor = Vv´= mv d v = 0.34 m³/s
Vapor Velocity = Vv = k v d L dV dV 1 2 = 1.84 m/s
Area = A = VV VV = 0.183m²
Diameter of Separator = D = 2 A 3.14 = 0.48 m
Calculations for the length
Volumetric Flow Rate of Liquid = VL = mL d L = 0.000163m3/s
Liquid Level in the Separator = LL = VL t s A
LL = 0.673 m
Length of Separator = L = LL 1.5 D 0.457
L = 1.86 m
Since, the Ratio, L/D = 3.82 < 5
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Chapter 8 Evaporator Design
Thus the design is satisfactory for a Vertical Vapor Liquid Separator.
Final Design
Length of Separator = 1.86 m
Diameter of Separator = 0.48 m
Thickness of Demister = 0.1524 m
Specification Sheet for Separator
Identification : Unit Separator
Item No. V-411
Type Horizontal Vapor Liquid
No. of Items 1
Function : To separate TDI vapors from residues.
Operation : Continuous
Design dimensions :
Length = 1.86 m, Diameter = 0.48 m
Demister thickness = 0.1524 m
8.2.3 Condenser
A condenser is a two-phase flow heat exchanger in which heat
is generated from the conversion of vapor into liquid i.e condensation and the heat
generated is removed from the system by a coolant.
Selection of Condenser
Horizontal shell side and vertical tube side are the most
commonly used types of condensers. In this process we have used the horizontal with
condensation in shell side & cooling medium in tube. In our case it is a desuperheater
condenser that first removes heat by desuperheating and then by condensation.
Design of a Desuperheater Condenser
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Chapter 8 Evaporator Design
Steps involved in the designing of a desuperheater condenser
are given as:
1. Heat Balance
2. Calculation of Weighted LMTD(∆T)
3. Assumed Calculations
4. Calculations of Film Coefficients
5. Clean Overall Coefficient and check for Design Overall Coefficient
6. Pressure Drop Calculations
Properties Data
mass flow rate of TDI = m(TDI) = 4880.6 Kg/h
T1(TDI) = 270 C
T2(TDI) = 250 C
Specific Heat of TDI = Cp(TDI) = 0.837 KJ/KgC
Latent Heat of Vaporization of TDI = λ(TDI) =259.2 KJ/Kg
Specific Heat of Water = Cp(water) = 4.187 KJ/KgC
T1(Water) = 21.11 C
T2(Water) = 37.78 C
1. Heat Balance
Heat gained by cold water = Heat given off by TDI in the desuperheating
+ Heat given off by TDI in condensing
i.e
Q = Qd + Qc
Qd = mCpΔT(TDI)
Qc = mλ(TDI)
So
Qd = 72755.31 KJ/h
Qc = 1264967.7 KJ/h
Thus
Q = 1337721.56 KJ/h
Mass flow rate of water
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Chapter 8 Evaporator Design
Q
m(Water) = CpT = 16168.25 Kg/h
2. Calculations for Weighted LMTD(∆T)
Since there is desuperheating following by a phase change
in the condenser therefore a weighted value of LMTD is calculated as:
Q
ΔT =
Qd Td Qc Tc
Where, ΔTd = LMTD for Desuperheating
ΔTc = LMTD for Condensing
Calculation for ΔTd(LMTD)
Hot Fluid Cold Fluid Difference
270 Higher Temp 37.78 232.22
250 Lower Temp 36.8 213.2
Δt2 = 232.22 C , Δt1 = 213.2 C
t 2 t1
ΔTd(LMTD) =
ln t 2 t1
ΔTd = 223.67 C
Calculation for ΔTc(LMTD)
Hot Fluid Cold Fluid Difference
250 Higher Temp 36.8 213.2
250 Lower Temp 21.11 228.9
Δt2 = 228.9 C , Δt1 = 213.2 C
t 2 t1
ΔTc(LMTD) =
ln t 2 t1
ΔTc = 223.11 C
Thus the Weighted LMTD from the formula is = 223.14 C
3. Assumed Calculations
Trial
UD = 2740 KJ/hm²C
Q = 1337721.56 KJ/h
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Chapter 8 Evaporator Design
ΔT = 223.14 C
Heat Transfer Area
Q
A= = 2.2 m²
U D T
Shell and Tube Dimensions
According to this H.T area shell and tube dimensions are adjusted
by selecting a suitable length and some dimensions for tube.
Shell Dimensions Tube Dimensions
ID = 0.2 m 16 BWG, 0.0254 m Δpitch
De = 0.018 m OD = 0.019 m
B = 0.1524 m ID = 0.0157 m
C = 0.00635 m at = 0.06 m²/m
Pt = 0.0254 m a´t = 0.0003 m²
n=1 n=2
Lt = 1.23 m
nt = 30
4. Calculations for Film Coefficients
For finding film coefficients parallel steps of calculations on shell side
and tube side are given as under:
Hot Fluid, Shell Side Cold Fluid, Tube Side
(TDI) (Water)
(1´) Shell Area (2) Tube Area
ID C B nt at
as = at =
Pt n
as = 0.00774 m² at = 0.003 m²
Calculations For Desuperheating
(2´) Mass Velosity (2) Mass Velosity
Gs = ms/as Gt = mt/at
Gs = 285869 Kg/hm² Gt =6567508 Kg/hm²
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Chapter 8 Evaporator Design
Velocity
Gt
V=
3600
V = 1.83 m/s
(3´) Reynold’s no (3) Reynold’s no
at Tavg= 264.11 C at Tavg = 29.44 C
μ = 0.0504 Kg/hm μ=3.13 Kg/hm
Gs De IDGt
NRe = NRe =
NRe = 104774 NRe = 32981
(4´) jH
From graph
jH = 200
(5´) ho (5) hi
ho = jH k De Cp k 0.33 at Tavg = 261.11 C
k = 0.126 KJ/hmC hi = 26522.4 KJ/hm²C
ID
Cp = 0.837 KJ/KgK hio = hi
OD
ho = 261.56W/m²K hio = 21974.4 KJ/hm²C
(6) Clean Overall Heat Transfer Coefficient Ucd for Desuperheating
ho hio
Ucd =
ho hio
Ucd = 903 KJ/hm²C
(7) Clean Surface required for Desuperheating
Qd
Acd =
U cd Td
Acd = 1.18 m²
Calculation for Condensation
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Chapter 8 Evaporator Design
(2´) Loading
ms
G˝ = 23
Lc nt
Let the condensation
occures over 84% of
tube length Lc.
Lc = 1.22*0.84
Lc = 1.02 m
G˝ = 313.32 Kg/h lin.m
(3´) Shell Side Coefficient
Let ho =4089.6 KJ/hm²C
hio = 21974.4 KJ/hm²C
(4´) Wall Temp.
ho
tw = ta+
ho hio Ta t a
tw = 64.4 C
(5´) Film Temp.
Tw t w
tf =
2
tf = 158.33 C
Kf = 0.432 KJ/hmC
μf = 0.152*1010 Pas
sf = 1.203
From Graph
ho = 4090 KJ/hm²C
(6) Clean Overall Heat Transfer Coefficient for Condensation
ho hio
Ucc =
ho hio
Ucc = 3447.94 KJ/hm²C
(7) Clean Surface required for Condensation
115
Chapter 8 Evaporator Design
Qc
Acc =
U cc Tc
Acc = 1.645 m²
Check for Condensing Length Lc
Formula
Acc
100
Acc Acd
= 82 %
Thus the assumption for Lc is true.
5. Clean Overall Coefficient UC and a Check
for Design Overall Coefficient UD
Clean Overall Coefficient
U cd Acd U cc Acc
Uc =
Acc Acd
Uc = 2986 KJ/hm²C
Allowable dirt resistance, Rd is 0.0001 hm²C/KJ
Design Overall Coefficient
Uc
UD =
1 U c Rd
UD = 2731 KJ/hm²C
This is very close to the assumed value. Thus the Design is Satisfactory.
6. Pressure Drop Calculations
Shell Side Tube Side
For Desuperheating Section
(1´) For NRe =104774 (1) For NRe=32981
f = 0.00475 m²/m f = 0.000731 m²/m
(2´) No of crosses (2) Tube Side pressure drop
2
fGt Ln
N + 1 = Ld/B ΔPt =
5.22 1010 IDs
116
Chapter 8 Evaporator Design
Ld = 0.2 m ΔPt = 23.14 KPa
N+1=1
(3´) Shell Side pressure drop (3) Return pressure loss
4n s
for desuperheating ΔPr =
V 2
2g
fGs De N 1
2
ΔPd = v²/2g´=0.0023
5.22 1010 IDs
ΔPd = 3.45 KPa ΔPr=0.25 KPa
For Condensation Section
(2´) N+1
N+1 =Lc/B
N+1 = 7
(3´) Shell Side Pressure Drop
for condensation
fGs ID N 1
2
ΔPc =
2 5.22 1010 Des
ΔPc = 9.13 KPa
(4´) Total Shell Side Pressure Drop (4) Total Tube Side Pressure Drop
ΔPs = ΔPc+ ΔPd ΔPT = ΔPt+ΔPr
ΔPs = 9.5 KPa ΔPT = 24.64 KPa
Allowable ΔPs is 13.8 KPa Allowable ΔPT is 68.93 KPa
Thus the results are satisfactory.
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Chapter 8 Evaporator Design
SPECIFICATION SHEET FOR CONDENSER
Identification Unit Condenser
Item No. V-412
Type Horizontal Shell and Tube
No. of Items 1
Function To condense TDI vapors from superheated state to saturated liquid.
Operation Continuous
Heat duty 1.34x106 KJ/hr
Heat transfer area 2.2 m2
Overall H.T Coefficient 2740 KJ/hm2 oC
Dirt factor 0.00014 hm2 oC/KJ
Shell side Tube side
Fluid circulated TDI Water
Flow rates 4880.3 Kg/h 16168.25 Kg/h
Temperature T1=252.2 oC,T2 =270 oC T1 = 21.11oC, T2 = 37.78 oC
Pressure 101.325 Kpa 101.325 Kpa
Pressure drop 9.5 Kpa 24.64 Kpa
Material of Stainless steel Stainless steel
construction
Design dimensions I.D = 0.2 m OD = 0.019 m, 16 BWG
C = 0.00635 m Pitch = 0.0254 m
B = 0.1524 m Triangular arrangement,
Length = 1.23 m
Nt = 30
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Chapter 8 Evaporator Design
8.3 SUBCOOLERS
A subcoolers is a two-phase flow heat exchanger in which
heat is generated from the conversion of saturated liquid into a liquid at some lower
temperature i.e subcooling and the heat generated is removed from the system by a
coolant. Their types and the related theory have already been described in the section of
condenser.
Objective
Our objective is to cool saturated TDI and the Residues to almost room
temperature.
8.3.1 TDI Subcooler
This is a shell and tube heat exchanger used here in order to
subcool TDI from saturated liquid state to some lower required temperature.
Design of TDI Subcooler
Steps involved in the designing of a desuperheater condenser are given as:
1. Heat Balance
2. Calculation of Weighted LMTD(∆T)
3. Assumed Calculations
4. Calculations of Film Coefficients
5. Clean Overall Coefficient and check for Design Overall Coefficient
6. Pressure Drop Calculations
Properties Data
mass flow rate of TDI = m(TDI) = 4880.6 Kg/h
T1(TDI) = 250 C
T2(TDI) = 30 C
T1(Water) = 21.11 C
T2(Water) = 37.78 C
Specific Heat of TDI = Cp = 2 KJ/KgC
Specific Heat of Water = Cp(water) = 4.2 KJ/KgC
Viscosity of TDI = µ = 0.87 Kg/ms
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Chapter 8 Evaporator Design
Viscosity of Water = µ = 2 Kg/ms
Thermal conductivity of TDI = K = 0.36 KJ/hmC
Thermal conductivity of Water = K = 2.32 KJ/hmC
Mass flow rate of TDI = m = 4880.3 Kg/h
1. Heat Balance
Heat gained by cold water = Heat given off by TDI
mCp∆T (Water) = mCp∆T (TDI)
Heat Duty = 2049600 KJ/h
Putting all the variables in this relation we get the mass flow rate of water which is 12200
Kg/h.
2. Calculation of ΔT(LMTD)
Hot Fluid Cold Fluid Difference
250 Higher Temp 220 80
30 Lower Temp 220 46.67
Δt2 = 80 C , Δt1 = 47.33 C
t 2 t1
ΔT(LMTD) =
ln t 2 t1
ΔT = 53.5 C
3. Assumed Calculations
Trial
UD = 1580 KJ/hm²K
Q
Heat Transfer Area = A = = 24.25 m²
U D T
According to this area shell and tube side dimensions are selected and the respective no
of tubes are calculated. The dimensions are given as:
Shell & Tube Dimensions
Shell Side Tube Side
ID = 0.254 m 16 BWG
De = 0.018 m OD = 0.019 m
B=1m ID = 0.0157m
120
Chapter 8 Evaporator Design
C = 0.00635 m n=2
Pt= 0.0254 m at´ = 0.00019 m2
n=1 at = 0.06 m2/m
Lt = 7.75 m
nt = A/ at * Lt
nt = 52
4. Calculations for Film Coefficients
For the calculations of film coefficients
we have parallel calculations on shell side and tube side. All the parameters used in the
formulae have already been mentioned and only results are shown here.
Shell Side, Hot Fluid Tube Side, Cold Fluid
(Toluene) (Feed Mixture)
(1´) Shell Area (1) Tube Area
ID C B nt at
as = at =
Pt n
= 0.0635 m2 = 0.01 m2
(2´) Mass Velosity (2) Mass Velosity
Gs = ms/as Gt = mt/at
= 76850 Kg/hm² = 1169835 Kg/hm²
Gt
Velosity = V =
3600
= 1.08 m/s
(3´) Reynold’s no (3) Reynold’s no
Gs De Gt ID
NRe = NRe =
= 22437 = 9183
(4´) jH value (4) Tube Side Film Coefficient
From graph From graph
jH = 90 hi = 8177 KJ/hm2C
(5´) Shell Side Film Coefficient (5) Inside Film Coefficient depending on
OD
121
Chapter 8 Evaporator Design
ID
ho = jH k De Cp k 0.33 hio = hi
OD
= 2959.56 KJ /hm²C = 6756.58 KJ/hm²C
5. Clean overall coefficient UC
ho hio
Uc =
ho hio
= 2058.07 KJ/hm2C
Allowable dirt resistance = Rd = 0.000147 hm²C/KJ
6. Check for UD
Uc
UD =
1 U c Rd
= 1580.05 KJ/hm²C
Which is very close to the assumed value i.e 1580 KJ/hm²C. So the design is satisfied.
7. Pressure Drop Calculations
Shell Side Tube Side
(1´) For NRe =22437 (1) For NRe= 9183
f = 0.0018 m²/m f = 0.0003 m²/m
(2´) No of crosses (2) Tube Side pressure drop
2
fGt Ln
N + 1 = L/B ΔPt =
5.22 1010 IDs
N+1=8 ΔPt = 2.3 KPa
(3´) Shell Side pressure drop (3) Return pressure loss
4n s
ΔPr =
V 2
2g
fGs De N 1
2
ΔPS = V2/2g´=0.008
5.22 1010 IDs
ΔPS = 0.0054 KPa ΔPr = .45 KPa
Total Pressure = PT = ΔPt + ΔPr
= 2.75 KPa
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Chapter 8 Evaporator Design
Allowable ΔPS is 13.8KPa Allowable ΔPT is 68.93KPa
Thus the results are satisfactory.
Specification Sheet For TDI Subcooler
Identification Unit Subcooler
Item No. V-413
Type Horizontal Shell and Tube 1
Function To subcool TDI saturated liquid state to a lower temp liquid.
Operation Continuous
Heat duty 2x106 KJ/hr
Heat transfer area 24.25 m2
Overall H.T coefficient 1580 KJ/hm2 oC
Dirt factor 0.000147 hm2 oC/KJ
Shell side Tube side
Fluid circulated TDI Water
Flow rates 4880.3 Kg/h 12200 Kg/h
Temperature T1=250 oC,T2 =30 oC T1 = 21.11oC, T2 = 37.78 oC
Pressure 101.325 Kpa 101.325 Kpa
Pressure drop 0.0054 Kpa 2.75 Kpa
Material of Stainless steel Stainless steel
construction
Design dimensions I.D = 0.254 m OD = 0.019 m, 16 BWG
C = 0.00635 m Pitch = 0.0254 m
B=1m Triangular arrangement,
Length = 7.75 m
Nt = 52
8.3.2 Residue Subcooler
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Chapter 8 Evaporator Design
This is a shell and tube heat exchanger used here
to subcool residues. These residues are a mixture of a number of heavy organic
compounds, mostly dimmers and trymers of TDI and some quantity of TDI.
Design of Residue Subcoole
Steps involved in the designing of a residue subcooler are given as:
1. Heat Balance
2. Calculation of Weighted LMTD(∆T)
3. Assumed Calculations
4. Calculations of Film Coefficients
5. Clean Overall Coefficient and check for Design Overall Coefficient
6. Pressure Drop Calculations
Properties Data
T1(Res) = 270 C
T2(Res) = 30 C
T1(Water) = 21.11 C
T2(Water) = 37.78 C
Specific Heat of Res = Cp = 1.5 KJ/KgC
Specific Heat of Water = Cp(water) = 4.2 KJ/KgC
Viscosity of Res = µ = 7.2 Kg/ms
Viscosity of Water = µ = 2 Kg/ms
Thermal conductivity of TDI = K = 0.15 KJ/hmC
Thermal conductivity of Water = K = 2.32 KJ/hmC
Mass flow rate of Res = m = 705.3 Kg/h
1. Heat Balance
Heat gained by cold water = Heat given off by Residues
mCp∆T (Water) = mCp∆T (Res)
Heat Duty = Q = 2.4*105 KJ/h
Putting all the variables in this relation we get the mass flow rate of water which is
1450 Kg/h.
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Chapter 8 Evaporator Design
2. Calculation of ΔT(LMTD)
Hot Fluid Cold Fluid Difference
270 Higher Temp 220 80
30 Lower Temp 220 46.67
Δt2 = 80 C , Δt1 = 47.33 C
t 2 t1
ΔT(LMTD) =
ln t 2 t1
ΔT = 58.35 C
3.Assumed Calculations
Trial
UD = 349.9 KJ/hm²K
Q
Heat Transfer Area = A = = 11.93 m²
U D T
According to this area shell and tube side dimensions are selected and the respective no
of tubes are calculated. The dimensions are given as:
Shell & Tube Dimensions
Shell Side Tube Side
ID = 0.254 m 16 BWG
De = 0.0185 m OD = 0.019 m
B=1m ID = 0.0157m
C = 0.00635 m n=2
Pt = 0.0254 m at´ = 0.0002 m2
n=1 at = 0.06 m2/m
Lt = 6.6 m
nt = A/ at * Lt
nt = 30
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Chapter 8 Evaporator Design
4. Calculations for Film Coefficients
For the calculations of film coefficients we
have parallel calculations on shell side and tube side. All the parameters used in the
formulae have already been mentioned and only results are shown here.
Shell Side, Hot Fluid Tube Side, Cold Fluid
(Toluene) (Feed Mixture)
(1´) Shell Area (1) Tube Area
ID C B nt at
as = at =
Pt n
= 0.05 m2 = 0.006 m2
(2´) Mass Velosity (2) Mass Velosity
Gs = ms/as Gt = mt/at
= 14120 Kg/hm² = 240655 Kg/hm²
Gt
Velosity = V =
3600
= 0.223 m/s
(3´) Reynold’s no (3) Reynold’s no
Gs De Gt ID
NRe = NRe =
= 392 = 1889
(4´) jH value (4) Tube Side Film Coefficient
From graph From graph
jH = 12 hi = 5110.5 KJ/hm2C
(5´) Shell Side Film Coefficient (5) Inside Film Coefficient depending
on OD
ID
ho = jH k De Cp k 0.33 hio = hi
OD
= 404 KJ /hm²C = 4222.86 KJ/hm²C
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Chapter 8 Evaporator Design
5. Clean overall coefficient UC
ho hio
Uc =
ho hio
= 368.88 KJ/hm2C
Allowable dirt resistance = Rd = 0.000147 hm²C/KJ
6. Check for UD
Uc
UD =
1 U c Rd
= 349.91 KJ/hm²C
Which is very close to the assumed value i.e 349.9 KJ/hm²C. So the design is satisfied.
7. Pressure Drop Calculations
Shell Side Tube Side
(1´) For NRe = 392 (1) For NRe= 9183
f = 0.004 m²/m f = 0.0004 m²/m
(2´) No of crosses (2) Tube Side pressure drop
2
fGt Ln
N + 1 = L/B ΔPt =
5.22 1010 IDs
N+1=7 ΔPt = 0.12 KPa
(3´) Shell Side pressure drop (3) Return pressure loss
4n s
ΔPr =
V 2
2g
fGs De N 1
2
ΔPS = V2/2g´=0.001
5.22 1010 IDs
ΔPS = 1.97 KPa ΔPr = 0.06 KPa
Total Pressure = PT = ΔPt + ΔPr
= 0.18 KPa
Allowable ΔPS is 13.8KPa Allowable ΔPT is 68.93KPa
Thus the results are satisfactory.
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Chapter 8 Evaporator Design
SPECIFICATION SHEET FOR TDI SUBCOOLER
Identification Unit Subcooler
Item No. V-414
Type Horizontal Shell and Tube
No. of Items 1
Function To subcool residues.
Operation Continuous
Heat duty 2.4x105 KJ/hr
Heat transfer area 11.93 m2
Overall H.T coefficient 349.9 KJ/hm2 oC
Dirt factor 0.000147 hm2 oC/KJ
Shell side Tube side
Fluid circulated Residues Water
Flow rates 4880.3 Kg/h 12200 Kg/h
Temperature T1=270 oC,T2 =30 oC T1 = 21.11oC, T2 = 37.78 oC
Pressure 101.325 Kpa 101.325 Kpa
Pressure drop 1.97 Kpa 0.18 Kpa
Material of Stainless steel Stainless steel
construction
Design dimensions I.D = 0.254 m OD = 0.019 m, 16 BWG
C = 0.00635 m Pitch = 0.0254 m
B=1m Triangular arrangement,
Length = 6.6 m
Nt = 30
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