%% input data for BEM shell and tube heat exchanger

T1=100; %C inlet temp of lube oil

T2=50; %C outlet temp of lube oil
Ptotal=49; %kPag operating pressure
ma=500; %Nm3/hr Air flowrate(Butanol free)
LHV=642; %kJ/kg Latent heat of vaporization of butanol
Cl=2.8763; % kJ/kg C Specific heat of butanol condensate
Dl=810; % kg/m3 Density of butanol condensate
kl=0.168; %w/m C thermal conductivity of butanol condensate
Vl=0.95; %cP viscosity of butanol condensate
Cp=1.3043; % kJ/kg C Specific heat of air-butanol vapour mixture
Dp=2.012; % kg/m3 Density of air-butanol vapour mixture
kp=0.03; %w/m C thermal conductivity of air-butanol vapour mixture
Vp=0.0174; %cP viscosity of air-butanol vapour mixture
t1=32; %C inlet temp of water
t2=40; %C outlet temp of water
Cpw=4.1868; %kJ/kg C specific heat of water
Vw=0.72; %cP viscosity of water
Dw=1000; %kg/m3 density of water
kwater=0.63; %w/m C thermal conductivity of water
%%specification of BEM Type heat exchanger
Di=387; %mm Shell inside diameter
do=19.05; %mm tube o.d.
di=15.748; %mm tube i.d.
L=1.5; %m tube length
Pt=25.4; %mm tube Pitch
Nt=134; %no. of tubes
Np=4; %no. of tube side passes
Bs=120; %mm baffle spacing
kw=16; %w/m C thermal conductivity of wall
hid=5000; %w/m2 C tube side dirt coefficient
hod=5000; %w/m2 C shell side dirt coefficient
%% heat load & energy balance
Da=(1*29*273)/((298*1*22.414); %kg/m3 density of air
ma=(500*1.1853/3600); %kg/sec Air flowrate(Butanol free)
Pv=exp(17.216-(3137.02/(373-94.43))); %torr Partial pressure of Butanol vapour at
inlet
Ptotal=(49+101.325)*7.5; %torr
yi=(Pv/Ptotal); % mole fraction of Butanol Vapour in incoming air-butanol mixture
mvi=yi*((ma/29)/(1-yi))*74; %Kg/sec mass flowrate of butanol at inlet
Pv=exp(17.216-(3137.02/(323-94.43))); %torr Partial pressure of Butanol vapour at
outlet
Ptotal=(49-13.8+101.325)*7.5; %torr
yo=(Pv/Ptotal); % mole fraction of Butanol Vapour in outgoing air-butanol mixture
mvo=yo*((ma/29)/(1-yo))*74; %Kg/sec mass flowrate of butanol at outlet
mv=(mvi+mvo)/2; %Kg/sec
mbc=mvi-mvo; %Kg/sec mass flowrate of butanol
Qt=((ma+mv)*Cp*(T1-T2))+(mbc*LHV); %kW heat load
mw=Qt/(Cpw*(t2-t1)); %kg/sec mass flowrate of water
%% mean temp difference
dT1=T1-t2;
dT2=T2-t1;
LMTD=(dT1-dT2)/log((dT1)/(dT2)); %C
ft=0.96; %LMTD correction
MTD=LMTD*ft; %C
Apro=(Nt*pi*L*do/1000); %m2 Area provided
%% evaluation of tube side HTC
at=(Nt/Np)*(pi/4*(di/1000)^2); %m2 tube side flow area
Gt=mw/at; %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;
hi=(0.023*Ret^0.8*Prt^0.33*kwater)/(di/1000); %w/m2 C tube side HTC
%% evaluation of shell side HTC
Th=mbc/(L*Nt); %kg/m sec
Nr=(2*Di)/(3*Pt);
Dv=(143.425*74*273)/((348*101.325*22.414); %kg/m3 density of vapour
hc=0.95*kl*((Dl*(Dl-Dv)*9.81)/(Vl/1000*Th))^(1/3)*(Nr)^(-1/6); %w/m2 C mean
condensate film coefficient
As=((Pt-do)*Di*Bs)/(Pt*1000*1000); %m2 Shell side flow area
Gs=(ma+mv)/As; %kg/m2sec shell side mass velocity
de=(1.1*(Pt^2-(0.907*do^2)))/do; %mm equivalent diameter
Res=(de/1000*Gs)/(Vp/1000);
Prs=(Cp*Vp/1000*1000)/kp;
hg=(0.36*Res^0.55*Prs^(1/3)*1*kp)/(de/1000); %w/m2 C gas film coefficient
Qg=(ma+mv)*Cp*(T1-T2); %kW
ho=((hc^-1)+(Qg/(Qt*hg))^-1; %w/m2 C shell side HTC
%% overall HTC
Uo=((ho^-1)+(hod^-1)+((do*log(do/di))/(2*kw*1000))+(do/(di*hid))+(do/(di*hi)))^-1;
%w/m2 C overall HTC
Areq=(Qt*1000)/(Uo*MTD); %m2 area required
excessarea=((Apro/Areq)-1)*100; % percentage excess area
%% shell side pressure drop
AdPs=13.8; %kPa allowable pressure drop
Jf=0.042;
yavg=(yi+yo)/2;
Ds=(143.425*37.4163*273)/(348*101.325*22.414); %kg/m3 density of air-vapour
mixture
us=Gs/Ds; %m/sec shell side linear velocity
dPs=8*Jf*(Di/de)*(L*1000/Bs)*Ds*us^2*1/(2*1000); %kPa shell side pressure drop
must be less than allowable pressure drop
%% tube side pressure drop
AdPt=68; %kPa allowable pressure drop
Jf=0.0043;
dPt=Np*((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
%% Result
disp('Design Calculation of Shell & Tube Exchanger for Condensate with Non-
Condensable')
fprintf('Mass Flowrate of Air = %8.3f kg/sec\n',ma)
fprintf('Mass Flowrate of Butanol Vapour = %8.3f kg/sec\n',mv)
fprintf('Condensate Flowrate of Butanol = %8.3f kg/sec\n',mbc)
fprintf('Heat Duty = %4.2f kW\n',Qt)
fprintf('Mass Flowrate of Water = %8.3f kg/sec\n',mw)
fprintf('Mean Temperature Difference = %4.2f Degree Celsius\n',MTD)
fprintf('Area Provided = %8.3f m^2\n',Apro)
fprintf('Tube side flow area = %8.3f m^2\n',at)
fprintf('Tube side mass velocity = %4.2f kg/m^2sec \n',Gt)
fprintf('Tube side linear velocity = %4.2f m/sec \n',ut)
fprintf('Tube side Reynolds number = %d\n',round(Ret))
fprintf('Tube side Prandtl number = %4.2f \n',Prt)
fprintf('Tube side Heat Transfer coefficient = %4.2f W/m^2 C \n',hi)
fprintf('Mean Condensate film coefficient = %4.2f W/m^2 C \n',hc)
fprintf('Shell side flow area = %8.3f m^2\n',As)
fprintf('Shell side equivalent diameter = %4.2f mm\n',de)
fprintf('Shell side mass velocity = %4.2f kg/m^2sec \n',Gs)
fprintf('Shell side linear velocity = %4.2f m/sec \n',us)
fprintf('Shell side Reynolds number = %d\n',round(Res))
fprintf('Shell side Prandtl number = %4.2f \n',Prs)
fprintf('Gas film coefficient = %4.2f W/m^2 C \n',hg)
fprintf('Shell side Heat Transfer coefficient = %4.2f W/m^2 C \n',ho)
fprintf('Overall Heat Transfer coefficient = %4.2f W/m^2 C \n',Uo)
fprintf('Area Required = %8.3f m^2\n',Areq)
fprintf('percentage excess area = %d\n',round(excessarea))
disp('Percentage heat transfer area is between 10 to 20 percentage which is
sufficient for the given heat duty')
fprintf('Allowable Shell side pressure drop = %4.2f kPa \n',AdPs)
fprintf('Shell side pressure drop = %4.2f kPa \n',dPs)
disp('Shell side pressure drop is very close to allowable shell side pressure drop
Hence it is satisfactory ')
fprintf('Allowable Tube Shell side pressure drop = %4.2f kPa \n',AdPt)
fprintf('Tube side pressure drop = %4.2f kPa \n',dPt)
disp('Tube side pressure drop is less than allowable tube side pressure drop which
is acceptable')

Result
Design Calculation of Shell & Tube Exchanger for Condensate with Non-Condensable
Mass Flowrate of Air = 0.165 kg/sec
Mass Flowrate of Butanol Vapour = 0.116 kg/sec
Condensate Flowrate of Butanol = 0.204 kg/sec
Heat Duty = 149.57 kW
Mass Flowrate of Water = 4.465 kg/sec
Mean Temperature Difference = 33.49 Degree Celsius
Area Provided = 12.029 m^2
Tube side flow area = 0.007 m^2
Tube side mass velocity = 684.35 kg/m^2sec
Tube side linear velocity = 0.68 m/sec
Tube side Reynolds number = 14968
Tube side Prandtl number = 4.78
Tube side Heat Transfer coefficient = 3375.51 W/m^2 C
Mean Condensate film coefficient = 2037.45 W/m^2 C
Shell side flow area = 0.012 m^2
Shell side equivalent diameter = 18.25 mm
Shell side mass velocity = 24.18 kg/m^2sec
Shell side linear velocity = 13.05 m/sec
Shell side Reynolds number = 25361
Shell side Prandtl number = 0.76
Gas film coefficient = 142.60 W/m^2 C
Shell side Heat Transfer coefficient = 741.12 W/m^2 C
Overall Heat Transfer coefficient = 441.90 W/m^2 C
Area Required = 10.107 m^2
percentage excess area = 19
Percentage heat transfer area is between 10 to 20 percentage which is sufficient
for the given heat duty
Allowable Shell side pressure drop = 13.80 kPa
Shell side pressure drop = 14.05 kPa
Shell side pressure drop is very close to allowable shell side pressure drop Hence
it is satisfactory
Allowable Tube Shell side pressure drop = 68.00 kPa
Tube side pressure drop = 5.41 kPa
Tube side pressure drop is less than allowable tube side pressure drop which is
acceptable