Introduction

A condenser is a type of heat exchanger in which

vapors are transferred into liquid state by removing
the latent heat with the help of a coolant such as
water.

Condensers may be classified into two main types:

1. Those in which the coolant and condensing vapor
are brought into direct contact.
2. Those in which the coolant and condensate stream
are separated by a solid surface, usually a tube
wall

Different types of the Condenser

1.
2.
3.
4.
5.

Double pipe and multiple pipe

Plate Condensers
Air-Cooled Condensers
Compact Condensers
Shell & tube type

DESIGN CALCULATIONS FOR CONDENSER

T1 = 45 oC

T2 = 45 oC

Condenser

t1= 25 oC

t2 = 40oC

Inlet temperature of the process stream T1 = 45 oC

Outlet temperature of the process stream T2 = 45 oC
Inlet temperature of the water t1
= 25 0C
Outlet temperature of the water t2
= 40 oC
Mass flow rate of the process stream m
= 8060 Kg/hr
Enthalpy of Vapors of Process Stream
= 1940 KJ/Kg
Removed 1

Heat Load:
Q = m (1)
Q = 4343 KW

Mass flow rate of cooling water

Q
m
C p t

Cp = 4.2 KJ / Kg.K

= 68.9 Kg/sec

Log Mean Temperature Difference

LMTD = (t2-t1)/ log (t2/t1)
LMTD = 14.4oC

Assumed Calculations
Assumed Value of Overall Coefficient UD = 1000 W/m 2C

True Mean Temperature Difference

Dimensionless Temperature Ratios
R
R = (T1-T2) / (t2-t1)
= (45-45) / (40-25)
= 0
S
S = (t2-t1) / (T1-t1)
= (40-25)/ (45-25)
= 0.75

From Literature the value of Ft is 1

tm

= Ft x LMTD
= 1 x 14.4
= 14.4 oC

Heat Transfer Area

A

Q
U D t

= 301 m 2
Surface Area of single tube = 3.14 x 19 x 4.88 / 1000
= 0.292 m 2
No. of tubes = 301/.292
= 1030
Pitch Pt
= 1.25 19.05= 23.8 mm

Tube Bundle Diameter

Db = d0 (Nt/K1)1/n1
= 19 (1030/0.158)1/2.263
= 920 mm

No. of tubes in centre row

Nr = Db / Pt
= 920 / 23.8
= 39

Shell Side Calculations

Estimate tube wall temperature Tw
Assume condensing coefficient of 4250 W/m2C (from literature)
Mean Temperature
Shell side =( 45+45) / 2 = 45 oC
Tube side = (25+40) / 2 = 32.5 oC
(45-Tw) x 4250
= (45-25) x 1000
Tw = 40.3 oC

Physical Properties
Viscosity of the liquid L
= 0.8 mNs/m2
Density of liquid L
= 993 Kg/m3
Thermal conductivity kL
= 0.571 W/m C
Average M. Wt. of Vapors = 42.8
Density of vapor = 29 x 273 x 1/(22.4 x 1 x (273+42))
= 1.12 Kg / m3
Condensate loading on a horizontal tube h = m / L x Nt
= 8060 / 3600 x (4.88 x 1030)
= 4.45 x 10-3 Kg/m s
# of tubes in the vertical row Nr = 2/3 x 39 = 26 mm
Heat transfer coefficient in condensation
h0 = 0.95 x kL ( L x (L v ) g / (L x h)1/3 x Nr-1/6
= 4396.0 W/m2C
As our assumed value is correct so no need to correct the
wall temperature

Tube Side Calculations

Tube cross sectional area
Density of water at 30 0C
Tube velocity

= 3.14 / 4 x (19 x 10-3)2 x 1030 / 4

= 0.073 m2
= 993 kg/m3
= m / (H2O x At )

= 68.9 / (993 x 0.073)

= 0.95m/s
Film heat transfer coefficient inside a tube
hi
= 4200(1.35+0.02 x t) Vt0.8 / di. 0 2
= 4809.67 W/m2 0C
From Literature take fouling factor as 6000 W/m2 0C
Thermal Conductivity of the tube wall material
Kw = 50 W/m0C

Overall Coefficient
1/U0 = 1/ho + 1/hod + (d0 ln(d0/di))/2kw +d0/di x 1/hid +d0/di x 1/hi
= 0.001
U0 = 1100.29 W/m2 0C
So assumed value is correct

Shell Side Pressure Drop

For pull through floating head with 45% cut baffles
From literature clearance
= 88 mm
Shell internal diameter Ds
= Db+88
= 1008 mm
Cross flow area As
= m2

A= 0.205 m2
Mass Velocity

Gt
= m / As
= 8060 / (3600 x 0.205)
= 10.92 Kg/s m2
Equivalent diameter de = 1.27 (Pt2 -0.785d02) / d0 = 19 mm
Viscosity of vapors
= 0.009 mNs/m2

Reynolds No.

Re = de Gt /
= 19 x 10-3 x 10.92 /0.009 x 10-3
Re = 23053

From literature

jf = 0.029
By neglecting the viscosity correction factor

Where

So

Ds = dia of shell
L = Length of tubes
lB = baffle spacing
= 765 N/m2
= 0.765 Kpa
= 0.109 Psi

Tube side pressure drop

Viscosity of water = 0.9 x 10-3 Ns/m2
Re
= Vt di /
= 0.95 x 993 x 16.56 x 10-3 / 0.6 x 10-3
= 26036
From literature
jf
= 0.0039

Where

Np = No. of tube passes

So
Pt
Acceptable

= 4119.8 N/m2
= 4.119Kpa
= 0.59 psi

hio = hi I.D/O.D
hio = 4165.2 W/m2 0C

Clean Overall Coefficient:

UC

h io h o
h io h o

= 2138.7 W/m2 0C

Design Overall Coefficient Calculated

Rd

UC UD
UCUD

dirt factor Rd = 0.0005

SPECIFICATION SHEET CONDENSER

Identification: Item condenser
No. Required = 8
Function: Condense vapors by removing the latent heat of vaporization
Operation: Continuous
Type: 1-4 Horizontal Condenser
Shell side condensation
Heat Duty = 4343 KW
Tube Side:
Fluid handled: Cold Water
Flow rate = 68.9 Kg/sec
Pressure = 14.7 psia
Temperature = 25 oC to 40 oC

Tubes: 0.75 in. Dia.

1030 tubes each 16 ft long
4 passes
23.8 mm triangular pitch
Pressure Drop = 0.59 psi

Shell Side:
Fluid handled = Steam
Flow rate = 8060 Kg/hr
Pressure = 10 KPa
Temperature = 45 oC to 45 oC

Shell: 39 in. dia. 1 passes

Baffles spacing = 3.5 in.
Pressure drop =0.109 psi

Utilities: Cold water

Ud assumed = 1000 W/m 2C
Rd = 0.0005

Ud calculated =1100.97 W/m 2C

References

Chemical Engineering Design

Volume 6 by Coulson &v Richardsons
Process Heat Transfer
by D.Q. Kern
Plant Design & Economics for Chemical Engineers
5th Edition by Max S. Peters, Klaus D. Timmerhaus,
Ronald E. West
Perrys Chemical Engineers Handbook
by Robert H. Perry, Don. W. Green