Module: COMPUTATIONAL METHODS FOR CHEMICAL ENGINEERS CHEP 221

Topic:

Design a switch condenser (shell and tube horizontal type). Use Microsoft Visio to draw a PFD
and a P &ID and do a HAZOP of the system. Mass and energy balances/modelling (simulate
using ChemCad software).

Members of group 1:

1. Bindura Dominic M2332W

2. Chakanya Takuda M2335J
3. Chechita Gerald T M235CG
4. Chigiji Gorden R182690B
5. Chingangu Oscar T M22BMZ
6. Gola Happy T M2229M
7. Kahari Dillon R1933388
8. Matutu Brain R1917269R
9. Moyo Gideon C M233JF
10. Mtakiwa Chioneso E M232NJ
11. Murangwa Charity M23611R
12. Muteve Lister R1917359T
13. Mutsambira Blessing K M232DF
 14. Nyamadzi Nokhtula M22AMJ

Assignment Contributions:

Background and introduction: H. T. Gola and D. Kahari

Process description: T. Chakanya, C. E. Mtakiwa and B. K. Mutsambira

Simulation methodology: B. K. Mutsambira

Mass and energy balance tables from ChemCad: D. Bindura and G. T. Chechita

Choice of condenser: N. B. Nyamadzi and O. T. Chingangu

Choice of operating conditions: T. Chakanya and N. B. Nyamadzi

Design methodology: L. Muteve, C. E. Mtakiwa

Design parameters for condenser: G. C. Moyo and D. Kahari

Specification sheet of the switch condenser: G. Chigiji, D. Bindura and G. C. Moyo

Process control, developing P and ID: C. Murangwa, B. Matutu and O. T. Chingangu

HAZOP: H. T. Gola and G. T. Chechita

1.0 Background and introduction of a switch condenser.

The rapid growth of high-voltage direct current (HVDC) transmission systems and flexible AC
transmission systems (FACTS) has driven the development of advanced switch condenser
designs (Hingorani & Gyugyi, 2000). A switch condenser is a critical component in these
systems, enabling precise control over voltage and reactive power flow (Arrillaga, 1998). The
design of switch condensers involves careful consideration of electrical, thermal, and mechanical
factors to ensure optimal performance under various operating conditions.

The electrical design of a switch condenser involves selecting suitable components, such as
power electronic devices (e.g., IGBTs, thyristors), capacitors, and inductors (Chen, 2014). The
choice of power electronic devices depends on factors such as switching frequency, voltage
rating, and current handling capability (Mohan et al., 2012). Capacitors and inductors are
selected based on their capacitance, inductance, and quality factor (Q) to ensure optimal filtering
and resonance characteristics (Kimbark, 1971).

Thermal management is crucial in switch condenser design to prevent overheating and ensure
reliable operation (Chen, 2014). Heat sinks, thermal interfaces, and cooling systems (e.g., air,
liquid, or hybrid) are used to dissipate heat generated by power electronic devices and other
components (Mohan et al., 2012). Thermal modeling and simulation techniques are employed to
optimize thermal design and predict temperature distributions within the switch condenser
(Malhotra et al., 2017).

The mechanical design of a switch condenser involves selecting suitable materials and structures
to ensure mechanical integrity, electrical insulation, and thermal management (Chen, 2014).
Materials commonly used in switch condenser construction include metals (e.g., aluminum,
copper), ceramics, and polymers (Mohan et al., 2012). Mechanical design considerations include
component placement, bus bar design, and enclosure selection to ensure safe and reliable
operation.

Optimization techniques, such as genetic algorithms, particle swarm optimization, and model
predictive control, are employed to optimize switch condenser design and operation (Malhotra et
al., 2017). Switch condensers are used in various applications, including HVDC transmission
systems, FACTS, renewable energy systems, and power quality conditioning (Hingorani &
Gyugyi, 2000).This paper/research aims to explore the key design considerations and
optimization techniques for switch condensers, focusing on electrical, thermal, and mechanical
aspects. A detailed review of existing literature and design methodologies will be presented,
followed by a case study on the design and optimization of a switch condenser for a specific
application.

2.0 Process description:

A hot mixed light hydrocarbon vapour of mass flow rate 45 000 kg/h is to be condensed by
horizontal switch condenser (SC-301) operating at 10bars. The vapour enters the switch
condenser (SC-301) saturated at 333K through stream 1 (P-1) and leaves at 318K through stream
2 (P-2) as condensate thus when condensation will be complete. The average molecular weight
of the vapour is 52 with the assumed enthalpy of 596.5 kJ/kg and the condensate of 247.0 kJ/kg.
The cooling water is available at 303K, entering the switch condenser (SC-301) through stream 3
(P-3) and the temperature rise, is to be limited by 10 0C and this is to be maintained by a
controller. Plant standards require the desired switch condenser to have tubes of 20mm outside
diameter, 16.8mm inside diameter and 4.88m long off admiralty brass. The vapour used is to be
totally condensed and non-sub-cooled is required.

Assumptions:

1. Steady-state operation: The switch condenser is being assumed to operate at a constant load
and temperature.

2. Uniform heat transfer: Heat transfer is assumed uniform across the tube surface.

3. Constant properties: Fluid properties such as density, specific heat capacity, and viscosity are
assumed constant.

4. No heat loss: Heat loss through the switch condenser walls

5. Ideal gas behavior: Gases are assumed to behave ideally, neglecting non-ideal effects like
compressibility and non-ideal gas behaviour.

6. Constant pressure: Pressure drops across the switch condenser are assumed negligible.

7. No fouling: Tube surfaces are assumed clean and free from fouling deposits.
8. Laminar flow: Fluid flow through the tubes is assumed laminar, neglecting turbulence.

9. Constant tube diameter: Tube diameter is assumed constant along the length.

10. Negligible radiation: Radiation heat transfer is assumed negligible compared to convection.

Process Flow Diagram by Microsoft Visio:

Figure 1: switch condenser (SC-301), control valve (CV-301)

3. Simulation Methodology:

The simulation is being done using ChemCad software

 Open ChemCad and click on file then select new

 Go to format and select Engineering units and a table will pop-up
 Select the format of units you want then then click ok
 Go to the unit operations menu and select heat exchanger, right click and a table will pop
up. Select heat exch. #13 model and drag it to a simulation window
 On unit operation select a controller under miscellaneous and drag it to simulation
window. Do the same with the feed and product arrows
  Join inlets and outlets streams for both the hot and cold fluids to produce a single
component
 Go to thermophysical and select, select components. Choose your components on the
table that pops up and then click ok
 Specify the inlet temperature, pressure and flow rate for both inlet streams on the pop up
tables after right clicking them and selected edit stream
 Enter specifications for the unit operations
 Run the simulation

4.0 Mass and energy balance tables from ChemCad

5.0 Choice of condenser:

Recently shell-and-tube exchangers are widely used because they are robust and can work in a
wide range of pressures, flows and temperature (Sinnot et al, 1996) and they are even applied to
heat exchangers, condensers and vaporizers but our main focus is on condensers. A very
important feature of a condenser, as compared with any other type of heat exchanger, is that it
must have a vent for removal of non-condensable gases, as they tend to depress the condensation
temperature, and therefore reducing the temperature difference between the streams, and
lowering the effective condensing-side coefficients. Thus, a condenser will have two outlet pipes
known as 'nozzles'; One for the vent and the other for the condensate outlet.

The construction of a condenser will be similar to other shell and tube exchangers but with a
wider baffle spacing, typically IB = DS, as shown if Figure 2 below.
Figure 2.

The condensers have four configurations which are:

1. Horizontal, with condensation in the shell and the cooling medium in the tubes.

2. Horizontal, with condensation in the tubes

3. Vertical, with condensation in the shell.

4. Vertical, with condensation in the tubes.

Horizontal shell-side and vertical tube side are the most commonly used types of condenser. A
horizontal exchanger with condensation in the tubes is rarely used as a process condenser but is
the usual arrangement far heaters and vaporizers using condensing steam as the heating medium.

Therefore due to the arguments placed above the chosen condenser configuration which is going
to be designed in this paper is the horizontal, with condensation in the shell and the cooling
medium in the tubes because of the following reasons.

 When all else is equal, it is best to have the dirtiest fluid in the tubes than on the shell
side because it is usually easier to make provision for cleaning inside tubes than outside
them.

 Also, it is best to have the highest pressure stream inside the tubes because, then, only
the tubes and the headers need be built to handle the high pressure, while the shell
(which is very often a very costly item) need only handle a lower pressure.

 When special materials are required to handle corrosive fluids, such fluids are better on
the tubes ide in order to avoid having the shell made out of special materials. Additional
 guidance on the various types is given in Table 1, which is adapted from Bell and
Mueller. When there is no obvious advantage in one type of exchanger over another, it
may be advantageous to design the alternative types and see which is the cheapest.

Table 1

6.0 Choice of operating conditions (Inlet and operating temperature):

Operating temperatures in the shell

Stream 1:

Inlet temperature = 333K

Stream 2:

Outlet temperature = 318K

Operating temperatures in the tube

Stream 3:
Inlet temperature = 303K

Stream 4 and 5:

Outlet temperature = 313K

7. Design Methodology:

When designing a shell and tube switch condenser, certain parameters have to be defined to
ensure effective heat transfer, material compatibility and operational reliability. The optimum
conditions can be determined by software tools like excel solver.

7.1 Operating conditions

The heat to be transferred known as heat duty has to be calculated. The SI units are usually watts
or BTU/hr. The hot fluid and cold fluid properties have to be defined. This includes the mass
flow rates, pressure and temperature of the vapor inlet and condensate. The fluid characteristics
have to be determined like corrosiveness of the fluids under different conditions.

7.2 Shell and tube geometry

The material used to make the condenser is chosen. Steel and copper are the most common
materials used. The material must be corrosion resistant. It must have a high thermal
conductivity. The tube diameter and length have to be calculated. The shell type can be either
single-pass or multi pass. Heat exchangers in which all the tubes make one U-turn in the shell,
for example, are called one-shell-pass and two tube-passes heat exchangers. A multi pass ensures
that more heat is transferred in as little space as possible. Likewise, a heat exchanger that
involves two passes in the shell and four passes in the tubes is called a two-shell-passes and four-
tube-passes heat exchange. An additional descriptive term identifies the relative directions of the
two streams, the terms used being parallel flow or co-current flow if the fluids flow in the same
direction, countercurrent flow or simply counter flow if the fluids flow in opposite directions, and
crossflow if the two fluids flow at right angles to one another.

A temperature difference of 50°C or more between the tubes and the shell will probably pose
differential thermal expansion problems and needs to be considered.
7.3 Heat transfer calculations

The coefficient is determined by accounting for conduction and convection resistances between
fluids separated by composite plane and cylindrical walls, respectively. Heat transfer in
condensers is a combination of conduction and convection.

Q = UAΔTm (equation 7.1)

 Q is the heat duty

 U overall coefficient
 A heat transfer area
 ΔTm is the log mean temperature difference


ΔT 1−ΔT 2
But ΔTm = ΔT 1 (equation 7.2)
ln
ΔT 2

 ΔT1 is the temperature difference at one end

 ΔT2 is the temperature difference at the other end

1 1 1 t
= + + (equation 7.3)
U hi ho k

where

 ho shell side heat transfer

 hi tube side heat transfer
 t is the wall thickness
 k is the tube thermal conductivity

7.4 Determination of Pressure drop

Pressure drop in condensers have to be optimum. A small pressure drop is necessary to move
fluids through the heat exchanger. A large pressure drop reduces the flow rate hence a more
power pump will be required to push the flow which will in turn reduce efficiency and cause
equipment failure. It leads to an increase in operational costs

L ρv2
ΔPtube = f. (equation 7.4)
D 2

 f is friction factor
 L tube length
 D tube diameter
 ρ fluid density
 v fluid velocity

7.5 Baffle design

Baffles are usually installed to increase the convection coefficient of the shell-side fluid by
inducing turbulence and a cross-flow velocity component relative to the tubes. In addition, the
baffles physically support the tubes, reducing flow-induced tube vibration. Segmental baffles are
common. The baffle spacing is between 0.2 to 0.5 times the shell diameter. The baffle cut is
typically 20-25% of the shell diameter.

7.6 NTU method

If only the inlet temperatures are known, it is preferable to use the effectiveness-NTU method.
The effectiveness, ε, as the ratio of the actual heat transfer rate for a heat exchanger to the
maximum possible heat transfer rate

Q = εqmax (equation 7.5)

qmax = Cmin(Th,i – Tc,i) (equation 7.6)

but Q = Ch(Th,i – Th,o) (equation 7.7)

where
  Q actual heat transfer
 qmax is the maximum possible heat transfer
 Cc heat capacity
 Th,i and Th,o are the inlet and outlet temperature of the hot liquid
 Tc,i is the inlet temperature of the cold fluid

Cmin
For any heat exchanger ε = f (NTU, ) (equation 7.8)
Cmax

The number of transfer units (NTU) is a dimensionless parameter that is widely used for heat
exchanger analysis and is defined as

UA
NTU = (equation 7.9)
Cmin

8.0 Design parameters for condenser (Thermal Design and Mechanical Design of the
condenser)

9.0 Specification sheet of the switch condenser

10.0 Process control, developing a P and ID.

Figure 1 below shows a switch condenser (SC-301) were the flow of cooling water is adjusted
using controller valve, flow and temperature sensors based on the flow-rate and temperature of
the inlet stream of hot hydrocarbon vapour. Based on a set of calculations using the heat transfer
coefficient of the heat exchanger, the outlet stream temperature of the condensate can be
predicted. The advantage of this system is that action is taken before changes occur in the outlet
stream temperature. The disadvantage is that if the actual heat exchange capacity differs from the
expected value due to fouling or mechanical problems, the outlet temperature will not be correct.

P and ID from Ms Visio

Figure 1: controller, switch condenser (SC-301), control valve (CV-301), flow indicator
controller (FIC), temperature transmitter (TT), sflow transmitter (FT)

11.0 HAZOP

Parameter Guide word Deviations Causes consequences Action

Flow rate No No Failure of Process fluid Install

of the inlet stream separation is
condensatio flow rate
inlet valve not
n of feed
contacted
stream sensors
total

Flow rate More Less Failure of Output of Install flow

of the inlet feed rate sensors at
condensation process
inlet valve to the inlet and
of feed due
close outlet streams
to limited
stream space time of the
condensate
condenser

too low

Flow rate Less Less feed Pipe leakage Condensate Installatio

of the will contain n of flow
inlet flow in the higher
Meter
levels of
stream condenser
impurities

Compositio Contaminatio Process fluid Contaminatio Outlet Proper

n n contaminatio n in cooling
temperatur maintenance
n
water e too low and

operators

alert

Flow rate No No Failure of Process fluid Install

of the inlet stream separation is
condensatio flow rate
inlet valve not
n of feed
contacted
stream sensors
total

Flow rate More Less Failure of Output of Install flow

of the inlet feed rate sensors at
condensation process
inlet valve to the inlet and
of feed due
close condensate outlet streams
stream to limited
of the
space time
too low condenser

Flow rate Less Less feed Pipe leakage Condensate Installatio

of the will contain
 inlet flow in the higher n of flow
levels of
stream condenser meter
impurities

Compositio Contaminatio Process fluid Contaminatio Outlet Proper

n n contaminatio n in cooling
temperatur maintenance
n
water e too low and

operators

alert

References:

o Cengel, Y. A., & Boles, M. A. (2014). Thermodynamics: An engineering approach (8th

ed.). McGraw-Hill Education.
o Edwards, E. John (2008). Design and rating shell and tube heat exchangers. P & I Design
Ltd, Teesside, UK.
o Indian Standard (IS: 4503-1967) (2007): Specification for Shell and Tube Heat
Exchangers, BIS, New Delhi.
o James R. Couper, W. Roy Penney, James R. Fair, Stanley M. Walas, (2005) Chemical
Process Equipment: selection and design (2nd ed.). Elsevier Inc.
o Kern, D. Q. (1950) Process Heat Transfer .McGraw Hill.
o Malhotra, A., Singh, S. P., & Singh, S. (2017). Thermal analysis and optimization of a
switch condenser using genetic algorithm. IEEE Transactions on Industrial Electronics,
64(10), 8322-8331.
o Perry, R. H. and Green, D. (1984) Perry’s Chemical Engineers Handbook, (6th ed.).
McGraw Hill.
o Sinnott, R. K., (2005). Chemical Engineering Design (4th ed.). Coulson and Richardson’s
Chemical Engineering Series.