%% input data for isothermal condensation shell and heat
exchanger T1=85.2; %C inlet temp of N-PROPANOL
T2=85.2; %C outlet temp of N-
PROPANOL t1=32; %C inlet temp of
water
t2=45; %C outlet temp of water
ml=40000; %kg/hr massflowrate of N-
PROPANOL Dl=800; %kg/m3 density of N-
PROPANOL Yp=158; %kcal/kg latent heat
of N-PROPANOL
kl=0.14; % Kcal/hr*m^2*˚C thermal conductivity of N-
PROPANOL Vl=0.62; %cP viscosity of N-PROPANOL
kwater=0.628; % Kcal/hr*m^2*˚C thermal conductivity of
water Cpw=1; %kJ/kg C specific heat of water
Vw=0.72; %cP viscosity of water
Dw=1000; %kg/m3 density of water
%%specification of fixed tube sheet heat
exchanger do=19.05; %mm tube o.d.
di=15.75; %mm tube
i.d. Pt=23.81; %mm
tube pitch L=2.43; %m
tube length
Np=4; %no. of tube side
passes ft=1; %LMTD
correction Bs=13.74; %mm
baffle spacing
AUo=688; % Kcal/hr*m^2*˚C assumed overall heat transfer coefficient
%% heat load & energy
balance Q=ml*Yp; %kcal/hr
heat load
mw=Q/(Cpw*(t2-t1)); %kg/hr mass flowrate of water
%% mean temp
difference dT1=T1-t2;
dT2=T2-t1;
LMTD=(dT1-dT2)/log((dT1)/(dT2));
%C MTD=LMTD*ft; %C
Apro=(Q)/(AUo*MTD); %m2 Area
provided Nt=Apro/(pi*L*do/1000);
%no. of tubes
Db=do.*((Nt/0.175)^(1/2.285)); % tube bundle diameter in mm
Di=(Db+0.015);% shell side inside diameter in mm
%% evaluation of tube side HTC
at=(Nt/Np)*(pi/4*(di/1000)^2); %m2 tube side flow
area Gt=mw/(at*3600); %kg/m2sec tube side mass
velocity ut=Gt/Dw; %m/sec tube side linear
velocity Ret=(di/1000*Gt)/(Vw/1000);
Prt=(Cpw*Vw/1000*1000)/kwater;
t=(t1+t2)/2; %avg temp
hi=(0.86*4200*(1.35+(0.02*t)).*(ut^0.8))/(di^0.2); %tube side h.t.c.in
Kcal/hr*m^2*˚C
%% tube side pressure drop
AdPt=80; %kPa allowable pressure
drop Jf=0.00355;
dPt=((8*Jf*(L*1000/di)*1)+2.5)*Dw*ut^2/(1000*2); %kPa shell side pressure
drop must be less than allowable pressure drop
%% evaluation of shell side HTC
Tt=ml/(L*Nt*3600); %for tube Loading
Ps=0.3; %pressure of N-propanol in Kgf/cm^2*˚C
Ps1=(Ps*98.066)+101.325;
Dv=(Ps1*60)/(8.314*(T1+273.15)); %for Density of vapour in kg/m^3
%for shell side heat transfer coefficient
Nr=(2*Db)/(3*Pt);
hc=(0.95*kl)*(((Dl*9.81*(Dl-Dv))/(Vl*0.001*Tt))^(0.33))*(Nr^(-1/6)); %for
shell side h.t.c. with phase change in Kcal/hr*m^2*C
%% overall HTC
hid=2500; % Kcal/hr*m^2*˚C tube side dirt
coefficient hod=2500; % Kcal/hr*m^2*˚C shell side
dirt coefficient kw=39; % Kcal/hr*m*˚C thermal
conductivity of wall
Uo=((hc^-1)+(hod^-1)+((do*log(do/di))/(2*kw*1000))+(do/(di*hid))+(do/
(di*hi)))^-1; %
Kcal/hr*m^2*˚C overall HTC
Areq=(Q)/(Uo*MTD); %m2 area
required
excessarea=((Apro/Areq)-1)*100; % Percentage excess
area NL=3.5; %m tube length
NTt=ml/(NL*Nt*3600); %for tube Loading
Nhc=(0.95*kl)*(((Dl*9.81*(Dl-Dv))/(Vl*0.001*NTt))^(1/3))*(Nr^(-1/6)); %for
shell side h.t.c. with phase change in Kcal/hr*m^2*C
NUo=((Nhc^-1)+(hod^-1)+((do*log(do/di))/(2*kw*1000))+(do/(di*hid))+(do/
(di*hi)))^-1;
%w/m2 C overall HTC
NAreq=(Q)/(NUo*MTD); %m2 area
required
NApro=(Nt*pi*NL*do/1000); %m2 Area provided
Nexcessarea=((NApro/NAreq)-1)*100; % Percentage
excess area de=(1.1*(Pt^2-(0.907*do^2)))/do; %mm
equivalent diameter
As=((Pt-do)*Di*Di)/(Pt*1000*1000); %m2 Shell side
flow area Gs=ml/(As*3600); %kg/m2sec shell side mass
velocity us=Gs/Dv; %m/sec shell side linear velocity
Res=(de/1000*Gs)/(0.01/1000);
%% shell side pressure drop
AdPs=20; %kPa allowable pressure
drop Jf=0.0345;
% 25%cut baffle spacing
Bs=0.01374;
dPs=0.5*8*Jf*0.001*(NL/Bs)*((Dv*us^2)/2); %kPa shell side pressure drop is
more than allowable pressure drop
NJf=0.024;
NdPs=0.5*8*NJf*0.001*(NL/Bs)*((Dv*us^2)/2); %kPa shell side pressure drop
is more than allowable pressure drop
%% Result
disp('Design Calculation of Shell & Tube Exchanger with No Phase
Change') fprintf('Heat Duty Q = %4.2f kW\n',Q)
fprintf('Mass Flowrate of Water mw = %8.3f kg/sec\n',mw)
fprintf('Mean Temperature Difference = %4.2f Degree Celsius\
n',MTD) fprintf('Area Provided Apro = %8.3f m^2\n',Apro)
fprintf('number of tubes Nt = %d\
n',round(Nt)) fprintf('Tube side flow area at
= %8.3f m^2\n',at)
fprintf('Tube side mass velocity Gt = %4.2f kg/m2sec \
n',Gt) fprintf('Tube side linear velocity ut = %4.2f
m/sec \n',ut) fprintf('Tube side Reynolds number Ret =
%d\n',round(Ret)) fprintf('Tube side Prandtl number Prt
= %4.2f \n',Prt)
fprintf('Tube side Heat Transfer coefficient hi = %4.2f Kcal/hr*m^2*C \
n',hi) fprintf('Tube Shell side pressure drop AdPt = %4.2f kPa \
n',AdPt) fprintf('Tube side pressure drop dPt = %4.2f kPa \n',dPt)
disp('Tube side pressure drop is less than allowable tube side pressure drop
which is acceptable')
fprintf('tube loading = %4.4f kg/ms\n',Tt)
fprintf('density of vapor = %4.4f kg/ms\n',Dv)
fprintf('pressure = %4.2f kpa\n',Ps1)
fprintf('Shell side Heat Transfer coefficient hc = %4.2f Kcal/hr*m^2*C \
n',hc) fprintf('Overall Heat Transfer coefficient Uo = %4.2f
Kcal/hr*m^2*C \n',Uo) fprintf('Area Required Areq = %8.3f m^2\n',Areq)
fprintf('Percentage excess area = %d % \
n',round(excessarea)) disp('percentage heat transfer area is
negative')
disp('to decrease it we have to increase tube lenght to 3.5 m')
fprintf('Shell side Heat Transfer coefficient Nhc = %4.2f Kcal/hr*m^2*C \
n',Nhc) fprintf('Overall Heat Transfer coefficient NUo = %4.2f
Kcal/hr*m^2*C \n',NUo) fprintf('Area Required NAreq = %8.3f m^2\n',NAreq)
fprintf('Area Required NApro = %8.3f m^2\n',NApro)
fprintf('percentage excess area = %d % \
n',round(Nexcessarea)) fprintf('Shell side flow area As =
%8.3f m^2\n',As) fprintf('Shell side mass velocity Gs =
%4.2f kg/m2sec \n',Gs) fprintf('Shell side linear velocity
us = %4.2f m/sec \n',us) fprintf('Shell side Reynolds
number Res = %d\n',round(Res)) fprintf('Shell side
pressure drop dPs= %4.2f kPa \n',dPs)
disp('shell side pressure drop is more than allowable pressure so increase
baffle cut 25% to 45%')
fprintf('Shell side pressure drop NdPs= %4.2f kPa \n',NdPs)
disp('Shell side pressure drop is less than allowable shell side pressure
drop which is acceptable')
SOLUTION:
Design Calculation of Shell & Tube Exchanger with No Phase Change
Heat Duty Q = 6320000.00 kW
Mass Flowrate of Water mw = 486153.846 kg/sec
Mean Temperature Difference = 46.40 Degree Celsius
Area Provided Apro = 197.989 m^2
number of tubes Nt = 1361
Tube side flow area at = 0.066 m^2
Tube side mass velocity Gt = 2036.53 kg/m2sec
Tube side linear velocity ut = 2.04 m/sec
Tube side Reynolds number Ret = 44549
Tube side Prandtl number Prt = 1.15
Tube side Heat Transfer coefficient hi = 7793.64 Kcal/hr*m^2*C
Tube Shell side pressure drop AdPt = 80.00 kPa
Tube side pressure drop dPt = 14.27 kPa
Tube side pressure drop is less than allowable tube side pressure drop which is acceptable
tube loading = 0.0034 kg/ms
density of vapor = 2.6330 kg/ms
pressure = 130.74 kpa
Shell side Heat Transfer coefficient hc = 1007.48 Kcal/hr*m^2*C
Overall Heat Transfer coefficient Uo = 481.22 Kcal/hr*m^2*C
Area Required Areq = 283.063 m^2
Percentage excess area = -30 percentage heat transfer area is negative
we have to increase tube lenght to 3.5 m
Shell side Heat Transfer coefficient Nhc = 1252.13 Kcal/hr*m^2*C
Overall Heat Transfer coefficient NUo = 530.76 Kcal/hr*m^2*C
Area Required NAreq = 256.645 m^2
Area Required NApro = 285.169 m^2
percentage excess area = 11
Shell side flow area As = 0.185 m^2
Shell side mass velocity Gs = 60.18 kg/m2sec
Shell side linear velocity us = 22.86 m/sec
Shell side Reynolds number Res = 82623
Shell side pressure drop dPs= 24.18 kPa
shell side pressure drop is more than allowable pressure so increase baffle cut 25% to 45%
Shell side pressure drop NdPs= 16.82 kPa
Shell side pressure drop is less than allowable shell side pressure drop which is acceptable
