Given Data
Benzene Cold Fulid (cf)
Toluene Hot fluid (hf)
Nomenclature Symbol
mass flow rate of (cf) ṁ
inlet temperature of (cf) t1
outlet temperature of (cf) t2
Temperature Range of (cf) TRc=(t2-t1)
inlet temperature of (hf) T1
outlet temperature of (hf) T2
Temperature Range of (hf) TRh=(T1-T2)
Dirt Factor of inside scale based on inner surface Rsi
Dirt Factor of outside scale based on outer surface Rso
Allowable Pressure drop ∆P
Length of 1 leg of hairpin ∆L
Length of per hairpin LHP=2*∆L
NPS for outer pipe NPSi
NPS for Inner pipe NPSo
Average or mean Temperature of (cf) tAM=(t1+t2)/2
Average or mean Temperature of (hf) TAM=(T1+T2)/2
Molecular weight of (cf) Mcf
Molecular weight of (hf) Mhf
No.of Hairpins=?
For Counter Current Flow
Hot terminal end temperature difference ∆θ1=(T1-t2)
Cold terminal end temperature difference ∆θ2=(T2-t1)
μ at θmax 0.59054101574495
μ at θmax 0.437184137362414
Properties Calculations (At θAM)
Specific Heat Capacity For (cf) in J/gmol.K
Cp 140.048831494126
Thermal Conductivity For (cf) in (W/m.K)
k 0.14162884928377
Density For (cf) in (g/mL)
ρ 0.860116787143808
Dynamic Viscosity For (cf) in (cP)
μ 0.504419001565511
From given NPS of inner and outerpipe note Inner and Outer Diameters of both pipies
Reference PHT by Kern 1st Edn. Pg844
NPS
Flow Channel
(inch)
Inner Pipe 1.25
Outer Pipe 2
Equivalent Diameter of Annulus fot H.T Calculations De=(Di^2-do^2)/do
0.076149046184739
Name of Parameter For inner pipe
di
Equivalent Diameter for H.T Calculations
0.115
Ap
Flow Area (Af)
0.0103868907122875
GP=ṁcf/Ap
Mass velocity OR Mass Flux (G)
945422.48224323
Up=Gp/ρcf
Linear Velocity (U)
17607.1506420773
Re=(ρcfdiUp)/μcf
Rynold's Number (Re)
89067.0281838679
Pr= (μcfCpcf)/kcf
Prandtl Number (Pr)
6.38512755344106
xLHP/di
Dimensionless Ratio or (L/D) ratio (x)
313.04347826087
ɸ=μcf/μw
Viscosity Number (ɸ)
1
Now as Seder Tate Equation for turbulent flow is
Nu=0.023(Re^0.8)(Pr)^1/3*(ɸ)^n*(1+x^-2/3) Euqation8
Last term in above equation i.e. (1+x^-2/3) is correction factor for end effects during turbulent flow
Correction factor for end effects (Ψ) For Inner Pipe (Ψp)
1.02169020015827
And by defination
Nu=(hDfc)/k Euqation9
But for Isothermal Conditions (means wall temp.=mean temp of fluid)
Seder Tate Equation for turbulent flow becomes
Nu'=0.023(Re^0.8)(Pr)^1/3*1*(1+x^-2/3) Euqation10
Using Equation 10
For Inner Pipe
Nu'
397.384105593105
Similarly for Isothermal Conditions (means wall temp.=mean temp of fluid) Equation9 becomes
Nu'=h'Dfc/k
Rearranging gives
h'=Nu'k/Dfc Equation11
For Inner Pipe
h'
h'
h'i
282.890442818858
For Isothermal condition H.T coefficient based on outer surface (of inner pipe)
U'=h'/2
For Inner Pipe
U'
U'i
141.445221409429
Now As
Wall temperature (θw)=(h'iotc+h'oTc)/(h'io+h'o) Euqation12
where
And Caloric temperature θc= θmin. + Fc*(θmax. - θmin.)
For (cf) Caloric temp. is tc= t1+ Fc*(t2-t1)
For (hf) Caloric temp. is Tc= T2 +Fc*(T1-T2)
where Fc is know as caloric fraction
Fc=((r/r-1)+(1/Kc))/(1+((ln(1+Kc))/(lnr))) - (1/Kc)
where r= ∆θ2/∆θ1 0.5
and Kc= ((U'hf)/(U'cf))-1 OR ((U'o)/(U'io))-1
Kc 0.167059223972632
Now for Fc (Equation 15)
Numerator 4.98590114463732
Denomirator 0.777122225618283
1/Kc 5.98590114463732
Putting values Numerator, Denomirator and 1/Kc in Equation 15
Fc 0.429950802809566
Fc<0.5
Therefore θc<ΘAM
Now from Equation 13
tc 97.1980321123827
Similarly from Equation 14
Tc 125.797048168574
Now solve Equation 12 for wall temperature (θw)
θw 112.599893360888
317.927718533826
Now calculate dynamic viscosity (μ) at wall temperature (θw) using Empirical Correlation
For Inner Pipe OR (for (cf))
μw μwp OR μwcf in (cp)
0.460233577576245
Now we are able to calculate Viscosity Number (ɸ) and then Correct film coefficient,Correct H.T coefficient.
And then using Kern's model i.e. Equation 2 we can find Area (Ao) from which Length of H.E can be determined0 and then fin
For Inner Pipe OR for (cf)
Viscosity Number (ɸ) ɸp
1.09600651960677
For Inner Pipe OR for (cf)
Viscosity Number Correction factor for turbulent flow is (ɸ^(n))=(ɸ)^(0.14)
1.01291695150651
For Inner Pipe
h=h'*(ɸ^(n))=(ɸ)^(0.14)
hi
286.544524950403
Now using ho and hio we can find I/Uco using Equation 5 i.e. 1/Uco=1/ho + 1/hio
1/Uco 0.00788828660863442
Now using Equation 7 i.e. Rsio= Rsi * Ao/Ai = Rsio * do/di Calculate Rsio
Rsio 0.00120289855072464
Now calculate overall dirt factor based on outer surface of inner pipe
RDo=Rsio + Rso 0.00220289855072464
Now calculate Wall resistance based on outer surface of inner pipe (Rwo)
Rwo=(do/2kw)*(ln(do/di))
At θw=112.6°F Or 317.93K thermal conductivity of wall (kw) is 34.574
Therefore
Rwo 0.000369567945217627
Now using Euqation4 calculat Overall H.T Coeficient
1/UDO=1/Uco + RDo + Rwo 0.0104607531045767
UDO 95.5954117263785
Now Apply Kern's Model i.e. Qdot=UDoAo(LMTD)
All other parameters are know except Ao
Therefore Ao= Qdot/(UDO*LMTD) 60.9815267384024
Ao<500ft^2
As
Ao=∏doL
Therefore
L=Ao/∏do 140.320646984676
L=NHPLHP
NHP=L/LHP 3.89779574957432
Now Let NHP 4
Therefore Lfc
Equivalent Diameter of Annulus fot Pressure Drop Calculations De'=Di-do
0.0339166666666667
Important parameters and their formulas for P.Drop Calculations Re'=ρhf*De'Uhf/μhf
Kinetic head (hk)= (U^2)/2g
Dynamic Pressure Pd=(1/2)ρ(U)^2
Total Pressure Drop=∆P=∆Psf + ∆Pff Equation 16
where
Pressure Drop due to skin friction ∆Psf=ρghsf
∆Pff=ρghff
and
Head loss due to skin friction (hsf)=Kf*hk
Head loss due to form friction (hff)=KL*hk
Total Head Loss ∆h= hsf+hff
Friction Parameter (Kf)=(fd*Lfc)/Dfc
where
Darcy friction factor (fd) for turbulent flow=0.01
value of (g) in ft/s^2 32.174
Pressure Drop Calculations
For Inner Pipe
Kinetic Head (hk)
hkp
0.371738981945781
For Inner Pipe
Dynamic Pressure Pd
Pdp in (pdl/ft^2)
642.214354369722
Note:Pd should be less than 2000 pdl/ft^2
For Inner Pipe
Darcy friction factor (fd)
fdp
0.0228060833997905
For Inner Pipe
Friction Parameter (Kf) Kfp
28.5571826919115
For Inner Pipe
Head loss due to skin friction (hsf)=Kf*hk
hsfp (ft)
10.6158180211309
For Inner Pipe
Pressure Drop due to skin friction ∆Psf=ρghsf
Psf in (pdl/ft^2)
18339.8326451042
Loss Coefficient (KL)
K'L Loss Coefficient per hairpin
KL=NHP*K'L Total Loss Coefficient
K'L
For Inner pipe
0
K'L
For Annulus
1
For Inner Pipe
Head loss due to form friction (hff)=KL*hk
hffp (ft)
0
For Inner Pipe
Pressure Drop due to form friction ∆Pff=ρghff
Pff in (pdl/ft^2)
0
For Inner Pipe
Total Head Loss ∆h= hsf+hff
∆hp (ft)
10.6158180211309
For Inner Pipe
Total Pressure Drop=∆P=∆Psf + ∆Pff
∆P (Psia)
3.95846821964307
For NHP=3 ∆P < 10psia (allowable limit)
For NHP=4 ∆P < 20psia (allowable limit)
Therefore use NHP=4 having LHP=2*18=36ft because in that case pressure drop is in allowable limit i.e. ∆P < 20psia
Calculations For Over design and Over surface
Ado=Qdot/Udo∆ΘLM 60.9815267384024
ACo=Qdot/UCo∆ΘLM 48.1396103362049
Ao=∏doLHPNHP 62.58052566768
Fraction
Over design= ∆d= (Ao/Ado)-1 0.0262210379897003
Over surface= ∆c= (Ao/Aco)-1 0.299979896609475
Amount/Value Units
9820 lbm/hr
80 OF 299.816666666667
120 OF 322.038888888889
40 OF
160 OF 344.261111111111
100 OF 310.927777777778
60 OF
0.001 hr.oF.ft2/Btu
0.001 hr.oF.ft2/Btu
20 psia
18 ft
36 ft Important Note1: Trmax<100 °F
1.25 in
2 in
100 OF 310.927777777778
130 OF 327.594444444444
78.114 g/gmol
92.141 g/gmol
Units
40 K or °F
20 K or °F Important Note2: ∆θ<50°F
0.340127266365616
Important Note3: μmax<1cP
0.504419001565511
For (hf) in J/gmol.K For (cf) in J/g.K For (hf) in J/g.K
162.29345597378 1.79287748027404 1.76135982867323
For (hf) in (W/m.K) For (cf) in (Btu/hr.ft. °F) For (hf) in (Btu/hr.ft. °F)
0.126669875251293 0.0818663868692314 0.0732195810701118
For (hf) in (g/mL) For (cf) in lbm/ft^3 For (hf) in lbm/ft^3
0.836725483604008 53.6953707878136 52.235098490431
For (hf) in (cP) For (cf) in (lbm/ft.hr) For (hf) in (lbm/ft.hr)
0.406317024865205 1.22069398378854 0.983287200173796
Since neither Schedule No. nor Pipe material is mentioned in Problem, therefore assume
Outer Diameter (OD) Inner Diameter (ID)
(inch) (ft) (inch)
1.66 0.138333333333333 1.38
2.38 0.198333333333333 2.067
Value of pi 3.141592654
For Annulus Units
De=(Di^2-do^2)/do ft
0.076149046184739
Aa ft^2
0.00827334607523161 Note:Ap>Aa
GP=ṁhf/Aa lbm/ft^2.hr
805455.520538324
Ua=Ga/ρhf ft/hr Up(ft/s)
15419.8143358699 4.8908751783548
Re=(ρhfDeUa)/μhf
62377.1667345867 Re>10000
Pr= (μhfCphf)/khf
5.64961713976691
xLHP/De
472.757070556909
ɸ=μhf/μw Note:As wall temperature is unkwon yet,therefore v
1 Hence take ɸ=1 i.e. isothermal condition and after f
For Annulus (Ψa) Note:if x>60 then Ψ can be neglected.
1.01647813202202
Note: ɸ is taken as 1
For Annulus
285.443000219295
h' is film coefficient under isothermal conditions
For Annulus For Inner Pipe based on outer surface Units
h'o h'io=hi*(di/do) Btu/hr.ft^2. °F
274.461965613447 235.173982584352
For Annulus For Inner Pipe based on outer surface Units
U'o U'io=Ui*(di/do) OR h'io/2 Btu/hr.ft^2. °F
137.230982806723 117.586991292176
tc is caloric temp. of (cf)
Tc is caloric temp. of (hf)
h'io is film coefficient of inner fluid based on outer surface (of inner pipe) under isothermal conditions
h'o is film coefficient of outer fluid based on outer surface (of inner pipe) under isothermal conditions
Euqation13
Euqation14
Equation15
tc<tAM Units (°F)
Tc<TAM Units (°F)
Units (°F)
Units (K)
For Annulus OR (for (hf)) For Inner Pipe OR (for (cf)) For Annulus OR (for (hf))
μwa OR μwhf in (cp) μwp OR μwcf in (lbm/ft.hr) μwa OR μwhf in (lbm/ft.hr)
0.445141118648179 1.11376525773451 1.07724150712859
Note:Here correct means under non isothermal or r
For Annulus OR for (hf)
ɸa
0.912782503892527
For Annulus OR for (hf)
0.987305196791776
For Annulus For Inner Pipe based on outer surface Units
ho hio=hi*(di/do) Btu/hr.ft^2. °F
270.977724971842 238.211713512986
hr.oF.ft2/Btu
hr.oF.ft2/Btu
hr.oF.ft2/Btu
(Btu/hr.ft. °F) Reference:TEAM Standard, TableD12 (pg222 on pdf)
Note:Value is calculated by interpolation b/w 100&150 °F
hr.oF.ft2/Btu
hr.oF.ft2/Btu
Btu/hr.ft^2. °F
ft^2
OK
ft
144 ft
Units
ft
27782.6929915251
n friction (hsf)=Kf*hk
m friction (hff)=KL*hk
Kf)=(fd*Lfc)/Dfc Note: It tells about skin friction
(fd) for turbulent flow=0.014+1.056Re^(-0.42)
For Annulus Units
hka ft
0.285113797402236
For Annulus For Inner Pipe For Annulus
Pda in (pdl/ft^2) Pdp in (psia) Pda in (psia)
479.165686053333 0.13861550217852 0.103423088797483
For Annulus
fda
0.0283641091129711
For Annulus
Kfa
120.42550503001
For Annulus
hsfa (ft)
34.3349730431882
For Annulus For Inner Pipe For Annulus
Psf in (pdl/ft^2) Psf in (psia) Psf in (psia)
57703.7697360238 3.95846821964307 12.4547777002005
KL
0 Smooth pipe,long 180° bent
KL K'L=0 if U<3ft/s
4 K'L=1 if U>3ft/s
For Annulus
hffa (ft)
1.14045518960894
For Annulus For Inner Pipe For Annulus
Pff in (pdl/ft^2) Pff in (psia) Pff in (psia)
1916.66274421333 0 0.413692355189932
For Annulus
∆ha (ft)
35.4754282327972
For Annulus
∆P (Psia)
12.8684700553904
∆P >10psia (allowable limit)
∆P < 20psia (allowable limit)
mit i.e. ∆P < 20psia
ft^2
ft^2 Uco 121.096828901343
ft^2
Percentage Allowable limits
2.62210379897003 Slightly below the allowable limit (OK) 5≤∆d≤20%
29.9979896609475 OK 20≤∆c≤40%
K
K
K
K
Trmax<100 °F
K
K
For (cf) in Btu/lbm.°F
0.428221429319298
Problem, therefore assume Commercial material
Inner Diameter (ID)
(ft)
0.115
0.17225
Ua(ft/s)
4.28328175996386
Turbulent flow
erature is unkwon yet,therefore viscosity number can't be calculated right now
. isothermal condition and after finding wall temperature use correction factor ɸ^0.14 for turbulent flow for making results realistic
means under non isothermal or real conditions
Important Conversions Use
Length/Diameter
Specific Heat Capacity (Cp)
Dynamic Viscosity ( μ)
Density (ρ)
Thermal Conductivity (k)
Pressure (P)
Correlations for propertuies e.g. Cp,ρ,k and μ
Fliud (or Liquid) Name
Benzene
Toluene
Benzene
Toluene
Benzene
Toluene
Benzene
Toluene
For (hf) in Btu/lbm.°F
0.420693567563111
Commercial material i.e. Carbon steel and Schedule No=40
ore viscosity number can't be calculated right now
fter finding wall temperature use correction factor ɸ^0.14 for turbulent flow for making results realistic
or real conditions
rtant Conversions Used in the solution
1ft
1Btu/lbm OF
1cp
1g/mL
1Btu/hr.ft. OF
1psia
Property Name
Specific Heat Capacity (Cp)
Specific Heat Capacity (Cp)
Density (ρ)
Density (ρ)
Dynamic Viscosity ( μ)
Dynamic Viscosity ( μ)
Thermal Conductivity (k)
Thermal Conductivity (k)
Assumptions
Steady state, steady flow
Constant but unequal Specific Heat capacities
No heat losses
No phase change or chemical reaction
No aging effects
Counter current flow
As our systems follows these above mentioned assumptions therefore we shall use Kern's model
Important Notes
1
2
3
4
Now from Equation 2
Inorder to calculate using this equation we need Qdot,UDO and LMTD, out of which Qdot and LMTD have been calc
As
where
1st term in Equation 4 is
and
where 2nd term in Equation 4 is
where 3rd term in Equation 4 is
where kw is thermal condutivity of wall at wall temperature
12in
4.1868J/g.K
2.42 lbm/ft.hr
62.428 lbm/ft3
1.73W/mK
4633.063pdl/ ft2
Empirical Equation
Cp= A+BT+CT^2+DT^3
Cp= A+BT+CT^2+DT^3
ρ=AB-(1-T/C)^D
ρ=AB-(1-T/C)^D
log μ=A+(B/T)+CT+DT2
log μ=A+(B/T)+CT+DT2
logk=A+B(1-T/C)2/7
logk=A+B(1-T/C)-2/7
Consequences
Rate of Heat Transfer in constant
Constant but unequal Heat capacity Flow rates
Adiabatic system
Only sensible Heat Transfer
Newly designed or regenerated heat exchanger
ssumptions therefore we shall use Kern's model
Our calculations for Heat Exchange will be based on outer surface of inner pipe
For the calculations of No.of hairpins we have to calculate Length of exchanger as
For the calculations of Length of exchanger as we have to find Area (Ao)
And for the calculation of outer area we shall use Kern's model
Basic Design Equation or Kern's model
where
LMTD=(∆θ1-∆θ2)/ln(∆θ1/∆θ2)
As we know
Law of Heat exchange
Qdot
Using Equation 2 (ṁhf) can be calculated as
ṁhf
Fulid Allocation
Note:Now as information regarding fluid allocation is not given in problem so we have to decide which fluid should be pla
From properties value calculations it can be seen that viscosity of both fluids is low, both have similar nature (i.e. equally corro
Qdot=UDoAo(LMTD)
we need Qdot,UDO and LMTD, out of which Qdot and LMTD have been calculated hence only UDO is to be calculated
1/UDO=1/Uco + RDo + Rwo
Uco
1/Uco=1/ho + 1/hio
ho
hio
hio= hi * Ai/Ao = hi * di/do
RDo
RDo=Rsio + Rso
Rso
Rsio
Rsio= RSi * Ao/Ai = RSi * do/di
Rwo
Rwo=(do/2kw)*(ln(do/di))
Specified Units A B
T in (K) and Cp in (J/gmol.K) -31.662 1.3043
T in (K) and Cp in (J/gmol.K) 83.703 0.51666
T in (K) and ρ in (g/mL) 0.3009 0.2677
T in (K) and ρ in (g/mL) 0.29999 0.27108
T in (K) and μ in (cp) -7.4005 1181.5
T in (K) and μ in (cp) -5.1649 810.68
T in (K) and k in (W/mK) -1.6846 1.052
T in (K) and k in (W/mK) -1.6735 0.9773
Note: From Cp values it can be seen that Specific Heat capacities are constant but unequal
Note: It can be seen from problem data that both fluids involve only temperature variations
Note: It can be seen from problem data that dirt factor for both sides is 0.001 which is negligible
From Important Notes 1,2&3 it can be concluded that Overall Heat Transfer Coefficient (U) is constant and hence caloric t
outer surface of inner pipe
ulate Length of exchanger as L=NHPLHP Euqation1
e to find Area (Ao)
Qdot=UDoAo(LMTD) Euqation2
UDO overall H.T coefficient based on outer surface of inner pipe under dirty co
Ao H.T area based on outer surface of inner pipe
LMTD Mean temperature difference or overall driving force
28.8539008177793 K or °F
Q̇ absorbed = Q̇ evolved
ṁcfCpcf∆t = ṁhfCphf∆T Euqation3
ṁcfCpcf∆t 168205.37743662
6663.81226961938 lbm/hr
n is not given in problem so we have to decide which fluid should be place inside and which fluid should be placed outside the inner pipe.T
viscosity of both fluids is low, both have similar nature (i.e. equally corrosive or fouling) but mass flow rate of cold fluid i.e. Benzene is hig
ve been calculated hence only UDO is to be calculated
Euqation4
overall H.T coefficient based on outer surface of inner pipe under clean conditions
Euqation5
film coefficinet of outside fluid based on outer surface of inner pipe
film coefficinet of inside fluid based on outer surface of inner pipe
Euqation6
overall dirt factor based on outer surface of inner pipe
dirt factor of outside scale based on outer surface of inner pipe
dirt factor of inside scale based on outer surface of inner pipe
Euqation7
Wall resistance based on outer surface of inner pipe
C D
-0.0036078 0.0000038243
-0.001491 0.0000019725
562.16 0.2818
591.79 0.29889
0.014888 -0.000013713
0.010454 -0.000010488
562.16 0.2857
591.79 0.2857
is constant and hence caloric temperature (θc) can be replaced with Arithematic mean temperatures (θAM).
ace of inner pipe under dirty conditions
e placed outside the inner pipe.This decision can be made on the basis of property values,flow rates and nature of the fluids.
of cold fluid i.e. Benzene is higher than that of hot fluid i.e. Toluene. Therefore Cold fluid should be placed inside the inner pipe and Hot f
ature of the fluids.
ced inside the inner pipe and Hot fluid should be placed on annuler side as(di>De) or (Ap>Aa).
