Process Design of Heat Exchanger

Process Design of Heat Exchanger

The heat exchanger HE2001 is used to cool the air that is getting heated at the outlet of the

Compressor 1001. The air is to be cooled from temperature 3000 C to 1500 C. It is done

using Dowtherm A (cooling fluid).

Type of heat exchanger used:

Shell and Tube Heat Exchanger

Allocation of fluid:

1. Tube Side Fluid: Hot Air (since air will not corrode the tubes, and we need a good tube

side velocity, so hot air is good at tube side.)

2. Shell side Fluid: Dowtherm A (since the heat duty is too large, it is better to use an

organic fluid which can sustain a higher temperature difference.)

Hot Air Specifications:

Flow rate (m) = 23.75 kg/sec

Density (ρ) = 0.900 kg/m3

Specific heat (Cp) = 1045 J/kg K

Viscosity (µ) = 1.78 x 10-5 Pa.s

Thermal conductivity (k) = 0.454 W/m K

Inlet temperature (THin) = 300 oC

Outlet temperature (THout) = 150 oC

DOWTHERM-A Specifications:

Flow rate (m) = 31.93 kg/sec

Density (ρ) = 1056 kg/m3

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100 TPD of CO2 enriched air
 Process Design of Heat Exchanger

Specific heat (Cp) = 2231 J/kg K

Viscosity (µ) = 2.7 x 10-4 Pa.s

Thermal conductivity (k) = 0.1011 W/m K

Inlet temperature (TCin) = 50 oC

Outlet temperature (TCout) = 100 oC

Using procedure given by Kern, 1965.

Design Algorithm:
1. Internal and External Diameters of tubes are assumed.( Standard Dimensions)
2. The length of the tube is also assumed
3. Overall U is assumed and the required Heat Transfer Area is calculated
4. Number of tubes are found out depending on the total area required

5. Number of tubes is kept constant in each case.

6. Tube velocity is determined.
7. Triangular pitch is assumed.
8. Shell Diameter is determined.
9. Tube Reynolds number is calculated.
10. Inside heat transfer coefficient is calculated
11. Shell side Reynolds number is calculated.
12. Outside heat transfer coefficient is calculated.
13. Overall heat transfer coefficient is calculated
14. Tube and Shell side pressure drops are calculated.
15. The overall heat transfer coefficient calculated is compared with assumed value of
overall heat transfer coefficient
16. An optimum U is found by trial and error keeping in mind the flow conditions and
the pressure drops
The entire algorithm is converted in to Excel Worksheet and worked out

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100 TPD of CO2 enriched air
 Process Design of Heat Exchanger

Heat Balance:

The heat duty Q  m  Cp  dT

= 23.75 × 1000 × 150

= 35.625 x 105 W

Temperature Difference:

Temperature (oC) Hot Fluid Cold Fluid Difference

Higher T 300 100 200

Lower T 100 15 85

Difference 200 85 115

The log mean temperature difference (LMTD) as calculated as

ΔT2  ΔT1
(ΔT ) LM 
ln(ΔT2 ΔT1 )

200−85
= ln⁡(200/85)

= 135

Q  U D  A  (ΔT ) LM

Assuming the design overall coefficient UD = 200 W/m2 K

3562500 = 200 × 𝐴 × 135

 A = 175.9 m2

Calculation of Shell Diameter:

The tubes having the following specifications are used.

35
100 TPD of CO2 enriched air
 Process Design of Heat Exchanger

1 in. OD, 16 BWG, 1.25 in. square pitch (PT)

Thickness t = 0.065 in.

Length of tube L = 4 m

 Tube inner diameter (ID) = 1 - 2t

= 1 - 2 x 0.065

= 0.87 in = 0.0221 m

 Area of one tube =   ID  L

= 0.2083 m2

 No. of tubes = 175.9 / 0.277 =

 Area occupied by one tube = PT2

= 1.5625 in2 = 0.001 m2

 Area occupied by 406 tubes = 635  0.001 = 0.635 m2

The area occupied by all the tubes is the area of the shell.

  Ds 2
 0.635 =
4

 Ds = 0.899 m = 35.44 in.

Let Ds = 40 in.

Calculation of Inside Heat Transfer Coefficient:

Considering 1 tube pass.

The heat transfer coefficients associated with the cooling of hot air are very

high So we can assume the inside heat transfer coefficient hoi = 2000 W/m2 K.

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100 TPD of CO2 enriched air
 Process Design of Heat Exchanger

Calculation of Outside Heat Transfer Coefficient:

Considering a single shell pass.

Baffle spacing (Bs) = DS / 2

 Bs = 40 / 2 = 20 in.

Number of gaps at the center = Bs / PT

= 20/ 1.25 = 16 gaps

Area for flow per gap = Bs  (PT - OD)

= 20 x (1.25 - 1) = 5 in2

 Total area for flow (A) = 16 x 5

= 80 in2 = 0.0516 m2

Q 31.93
Velocity of flow (V) = =
A 1056×0.0516

 V = 0.6 m/s

Equivalent Diameter (Deq.) = (4 x flow area) / wetted perimeter

  OD 2
4  ( PT 2  )
= 4
  OD

 Deq. = 0.0251 m

Deq.  V  ρ
Reynolds Number (NRe) =
μ

0.0251×0.6×1056
=
2.7×10−4
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100 TPD of CO2 enriched air
 Process Design of Heat Exchanger

 NRe = 58901.33

Cp  μ
Prandlt Number (Pr) =
k

2231×2.7×10−4
=
0.1011

 Pr = 5.95

Nusselt Number (Nu) = 0.023  N Re 0.8  Pr 0.33

= 0.023 × 229143.260.8 × 0.4540.33

 Nu = 271.28

ho  Deq.
Nusselt Number (Nu) =
k

ℎ0 ×0.0251
 271.28 =
0.1011

 ho = 249 W/m2 K

Clean Overall Coefficient:

1 1 1
The clean overall coefficient = +
𝑈𝑐 ℎ𝑖 ℎ𝑜

1 1 1
= +
𝑈𝑐 2000 249

 U C = 221 W/m2 K

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100 TPD of CO2 enriched air