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Heat Transfer Design

1. An exchanger is needed to cool 60,000 lb/hr of acetone from 250°F to 100°F by transferring heat to 168,000 lb/hr of acetic acid increasing its temperature from 90°F to 150°F. 2. A shell and tube heat exchanger with 3 passes is designed using 3/4" tubes in a 1" square pitch arrangement. 3. The design achieves a heat transfer of 5.13 million BTU/hr within pressure drop limits for both fluids.

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John Unk
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329 views

Heat Transfer Design

1. An exchanger is needed to cool 60,000 lb/hr of acetone from 250°F to 100°F by transferring heat to 168,000 lb/hr of acetic acid increasing its temperature from 90°F to 150°F. 2. A shell and tube heat exchanger with 3 passes is designed using 3/4" tubes in a 1" square pitch arrangement. 3. The design achieves a heat transfer of 5.13 million BTU/hr within pressure drop limits for both fluids.

Uploaded by

John Unk
Copyright
© Attribution Non-Commercial (BY-NC)
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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HEAT TRANSFER DESIGN

Acetone at 60,000 lb/hr and 250oF is to be cooled before being sent to storage at 100oF. Transfer of energy will be made to 168,000 lb/hr of Acetic Acid (100%) entering at 90oF and leaving the exchanger at 150oF. Specify an exchanger to affect this transfer.

HEAT TRANSFER DESIGN


TEMP. oF IN OUT AVERAGE* T Acetone 250 100 175 150 Rich Oil 90 150 120 60 *KERN USES CALORIC TEMPERATURE INSTEAD OF AVERAGE TEMPERATURE TO ESTIMATE PHYSICAL PROPERTIES STATE: BOTH ARE LIQUIDS AT THESE CONDITIONS (P > 1 ATM) 1. MASS BALANCE [MASSIN = MASSOUT]; W = ACETONE, w = ACETIC ACID 2. ENERGY BALANCE [Q = 0] HACETONE = HACETIC ACID (CP)ACETONE = 0.57 BTU/LB-OF @ 175OF (CP)ACETIC ACID = 0.51 BTU/LB-OF @ 120OF

HACETONE = 60,000 x 0.57 x (250-100) = 5,130,000 BTU/HR HACETIC ACID = 168,000 x 0.51 x (150-90) = 5,130,000 BTU/HR

HEAT TRANSFER DESIGN


ACETIC ACID 168,000 LB/HR 90OF

ACETONE 60,000 LB/HR 250OF

100OF

150OF

HEAT TRANSFER DESIGN


3. LOG-MEAN TEMPERATURE DIFFERENCE:

TEMP. oF IN Acetone 250 Rich Oil 90


KERN HOT FLUID 250 100

OUT 100 150

AVERAGE 175 120

T 150 60

HIGH LOW

COLD FLUID 150 90

t 100 10

TLM = [tHIGH-tLOW]/LOGe(tHIGH/tLOW) = (100-10)/LOGe(100/10) = 39.1OF

HEAT TRANSFER DESIGN


5. Vol. Flow Rate: VACETONE = 60,000/49.3 = 1,217 FT3/HR (INNER) VACETIC ACID = 168,000/66.8 = 2,515 FT3/HR (OUTER)
6. FOR A REASONABLE VELOCITY (10 FT/SEC): AREAACETONE = 1217/36000 = 0.034 FT2 AREAACETIC ACID = 2515/36000 = 0.07 FT2

HEAT TRANSFER DESIGN


4a. Specific Gravity: Acetone @ 175oF = 0.79 x 62.4 = 49.3 LB/FT3 Acetic Acid @ 120oF = 1.07 x 62.4 = 66.8 LB/FT3 4b. Viscosity: Acetone: 0.2 centipoise (0.49 lb/ft-hr) Acetic Acid: 0.85 centipoise (2.06 lb/ft-hr)

4c. Heat Capacity: Acetone: 0.63 BTU/lb-oF Acetic Acid: 0.51 BTU/lb-oF
4d. Thermal Conductivity: Acetone: 0.095 BTU/hr-ft2-oF/ft Acetic Acid: 0.098 BTU/hr-ft2-oF/ft

HEAT TRANSFER DESIGN


7. CONSIDER A DOUBLE PIPE HEAT EXCHANGER: FA = d2/4 = 0.035; d = 0.21 FT (INNER) SA = dL; SA/L = 0.66 FT SA = H/UTLM = 5,130,000/(50 x 39.1) = 2,624 FT2 L = 2,624/0.66 = 3,976 FT
IF PIPE IS PURCHASED IN 20 FOOT SECTIONS:

N = 3,976/20 = 199 SECTIONS (200 ROUND-OFF) THIS IS IMPRACTICAL; CONSIDER SHELL & TUBE EXCHANGERS

HEAT TRANSFER DESIGN


8. SHELL & TUBE EXCHANGERS TEMP. oF Acetone Rich Oil KERN HOT FLUID 250 100 IN 250 90 OUT 100 150 AVERAGE 175 120 T 150 60

COLD FLUID HIGH LOW

150 90

t 100 10

R = tHOT/tCOLD = 150/60 = 2.5 S = tCOLD/[(THOT)HIGH-(TCOLD)LOW] = 60/(250-90) = 0.375 FT = N/A (1-2 EXCHANGER) FT = 0.67 (2-4 EXCHANGER) FT = 0.88 (3-6 EXCHANGER) FIG. 18 KERN, FT = f(R,S) FIG. 19 KERN, FT = f(R,S) FIG.20 KERN, FT = f(R,S)

FT IS AN EFFICIENCY INDEX. THIS VALUE SHOULD BE 0.8+ IN ORDER TO JUSTIFY A COMPLEX SHELL & TUBE HEAT EXCHANGER DESIGN BECAUSE OF THE COST OF MANUFACTURING.

HEAT TRANSFER DESIGN


9. 3-6 SHELL & TUBE EXCHANGER THE GEOMETRY FOR THIS CONFIGURATION YIELDS IMPORTANT PARAMETERS NEEDED IN THE DESIGN CALCULATIONS. ID = SHELL INSIDE DIAMETER (LARGE ENOUGH TO ENCAPSULATE ALL OF THE TUBES) C = CLEARANCE (DISTANCE BETWEEN TUBES) B = BAFFLE SPACING (RANGE: B=ID TO B=0.125ID) PT = PITCH IS THE DISTANCE BETWEEN TUBE CENTERS (SQUARE OR TRIANGULAR CONFIGURATION), P. 139 KERN at = FA OF ONE TUBE HAVING DIAMETER dt

HEAT TRANSFER DESIGN


C PT

PT SQUARE PITCH

C TRIANGULAR PITCH

HEAT TRANSFER DESIGN


10. SPECIFYING TUBE & SHELL DIMENSIONS AVAILABILITY AND EXPERIENCE -See Table 10, page 843 (Appendix) -1/2 to 1-1/2 inch diameter (BWG) Then Table 9, page 841-2, specifies the shell ID based on pitch type and size and number of tube passes. THE PLAN IS TO USE 3 EXCHANGERS IN SERIES TO MEET THE HEAT LOAD REQUIREMENT.

HEAT TRANSFER DESIGN


11. ESTIMATING INDIVIDUAL HEAT TRANSFER COEFFICIENTS

TUBE SIDE: [ACETIC ACID, COLD FLUID] -SELECT INCH, 14 BWG TUBES, 16 FEET LONG. -ALSO SELECT 1 INCH SQUARE PITCH, 2 TUBE PASSES
Dt = 0.584 inches at = 0.268 IN2 at = Ntat/144n Nt = 270 at = 270 x 0.268/(144 x 2) = 0.251 FT2 (TABLE 10) (TABLE 9)

MASS VELOCITY: Gt = w/at = 168,000/0.251 = 670,000 LB/HR-FT2 (Re)t = DGt/ = (0.584/12)(670,000)/2.06 = 15,800 jH = 55 (FIGURE 24)

HEAT TRANSFER DESIGN


(Pr)t = [c/k]1/3 = [0.51 x 2.06/0.098]1/3 = 2.21
hi = jH (k/D)(Pr)t X 1 = 55 X (0.098/0.0487) x 2.21 = 249 BTU/hr-ft2-oF hio = hi(ID/OD)=249(0.584/0.75)=194 BTU/hr-ft2-oF

HEAT TRANSFER DESIGN


SHELL SIDE: [ACETONE, HOT FLUID] FROM TABLE 9, IN. TUBES ON 1 INCH SQ. PITCH W/2 PASSES: IDSHELL = 21.25 INCHES, C = 0.25 inches, PT = 1 inch USE SEGMENTED BAFFLES 5 INCHES APART (NOTE: B = ID = 5.3 inches) as = ID X CB/144PT = 21.25 (0.25)(5)/[144(1)] = 0.185 FT2 MASS VELOCITY: Gs = W/at = 60,000/0.185 = 324,000 LB/HR-FT2 EQUIVALENT DIAMETER: DE = 0.95/12 = 0.079 FT (Re)S = DEGS/ = (0.079)(324,000)/0.49 = 52,200 jH = 137 (FIGURE 28)

(FIGURE 28)

HEAT TRANSFER DESIGN


(Pr)s = [c/k]1/3 = [0.63 x 0.49/0.095]1/3 = 1.47
ho = jH (k/DE)(Pr)s X 1 = 137 X (0.095/0.079) x 1.47 = 242 BTU/hr-ft2-oF 13. CLEAN OVERALL COEFFICIENT:

UC = hIOhO/hIO + hO = 242 X 194/(242 + 194) = 107.5 BTU/HR-FT2-OF

HEAT TRANSFER DESIGN


14. DESIGN OVERALL HEAT TRANSFER COEFFICIENT 14a. SURFACE AREA PER TUBE: FROM TABLE 10, SAt = 0.1963 FT2/LIN FT

TOTAL SURFACE AREA OF EXCHANGERS (3): SA = 3(270 x 16 x 0.1963) = 2,540 FT2


UD = Q/(SA x TLM x FT) = 5,130,000/(2540x39.1x0.88) = 58.8 BTU/HR-FT2-OF

HEAT TRANSFER DESIGN


15. FOULING COEFFICIENT: RD = (UC UD)/(UCUD) = (107.5-58.8)/(107.5 x 58.8) = 0.0077 HR-FT2-OF/BTU

TYPICAL RD VALUES ARE DETERMINED FROM OPERATING EXPERIENCE. IN THIS CASE A VALUE OF 0.004 IS EXPECTED.
SINCE (RD)CALC > (RD)EXPECTED HEAT EXCHANGER PASSES THERMALLY

HEAT TRANSFER DESIGN


16. PRESSURE DROP (MECHANICAL) 16a. REYNOLDS NUMBERS: SHELL: 52,200 TUBE: 158,000 16b. FRICTION FACTORS: SHELL: 0.00155 FT2/IN2

TUBE: 0.00024

16c. CROSSES (SHELL): N + 1 = 12L/B = 16 x 12/5 = 39

HEAT TRANSFER DESIGN


17. PRESSURE DROP CALCULATION

SHELL:
Ps = fGs2Ds(N+1)/[5.22 x 1010DE(SG)s] = [0.00155 x (324,000)2 x 1.78 x 117]/ [5.22 x 1010 x 0.079 x 0.79 x 1] = 10.4 PSI PALLOWABLE = 10 PSI (marginal) TUBE: Pt = fGt2Ln/[5.22 x 1010D(SG)t] = [0.00024 x (670,000)2 x 16 x 2 x 3]/ [5.22 x 1010 x 0.0487 x 1.07 x 1] = 3.8 PSI

HEAT TRANSFER DESIGN


17. PRESSURE DROP CALCULATION PRESSURE DROP IN THE ROUNDS: Pr = 3(4n/SG)(V2/2g) V2/2g = 0.063 USING Gt = 670,000 AND FIGURE 27 Pr = (3 x 4 x 2/1.07) 0.063 = 1.4 PSI PTOTAL = 3.8 + 1.4 = 5.2 PSI PALLOWABLE = 10 PSI (passes)

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