Horizontal Shell and Tube Condenser

Design (HSTC)

1
 CONDENSER CONFIGURATION
 This section covers the design of shell and tube exchangers used as condensers.
 The construction of a condenser will be similar to other shell and tube exchangers, but with a
wider baffle spacing, typically 𝑙𝑙𝐵𝐵 = 𝐷𝐷𝑠𝑠 .
FOUR TYPES OF CONDENSER CONFIGURATION:
1) Horizontal, with condensation in the shell and 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

2
 CONDENSER CONFIGURATION
FOUR TYPES OF CONDENSER CONFIGURATION CONT…:
• Horizontal shell side and vertical tube side are the most commonly used.
• Horizontal with condensation in the tubes is rarely used as a process condenser.
• The fundamentals of condensation heat transfer can be found in Volume 1.
• The physical properties of the condensate are used to evaluated the average condensate film
temperature: the mean of the condensing temperature and the tube wall temperature.

3
HORIZONTAL SHELL AND TUBE CONDENSER

4
HORIZONTAL SHELL AND TUBE CONDENSER

5
CROSS-SECTIONAL VIEW FOR HSTC

6
CROSS-SECTIONAL VIEW FOR HSTC

7
 CONDENSATION OUTSIDE HORIZONTAL TUBES
1⁄
𝜌𝜌𝐿𝐿 𝜌𝜌𝐿𝐿 −𝜌𝜌𝑉𝑉 𝑔𝑔 3
ℎ𝑐𝑐 𝑙𝑙 = 0.95𝑘𝑘𝐿𝐿 (Eq. 1)
𝜇𝜇𝐿𝐿 Γ

𝑊𝑊
Γ=
𝐿𝐿𝑁𝑁𝑡𝑡
hc = mean condensation film coefficient, for a single tube (W/m2.℃)
kL = condensation thermal conductivity (W/m.0C)
g = gravitational acceleration (9.81 m/s2)
W = condensate flow rate (kg/s)
Nt = total number of tubes in bundle
𝜌𝜌𝐿𝐿 = condensate density (kg/m3)
𝜌𝜌𝑉𝑉 = vapour density (kg/m3)
8
 CONDENSATION OUTSIDE HORIZONTAL TUBES
1⁄
𝜌𝜌𝐿𝐿 𝜌𝜌𝐿𝐿 −𝜌𝜌𝑉𝑉 𝑔𝑔 3
ℎ𝑐𝑐 = 0.95𝑘𝑘𝐿𝐿 (Eq. 1)
𝜇𝜇𝐿𝐿 Γ

𝑊𝑊
Γ=
𝐿𝐿𝑁𝑁𝑡𝑡
𝜇𝜇𝐿𝐿 = condensate viscosity (Pa.s or N.s/m2)
Γ = the tube loading, the condensate flow per unit length of tube (kg/m.s)

9
 CONDENSATION ON HORIZONTAL TUBES
 Equation 1 accounts for vertical stacks of tubes.
 When tubes are stacked vertically, condensate drainage from tubes above causes an increase in
loading and an increase in film thickness on the lower tubes rows.
 The condensate tends to drain from tubes in drops and rivulets that disturb the film on the tubes
below and promote turbulence.
 If there are Nr tubes in vertical row and the condensation is assumed to flow smoothly from row
to row.
 In practice, the condensate will not flow smoothly from tube to tube and the correction factor is
1
−4
required, which is 𝑁𝑁𝑟𝑟 applied to the single tube coefficient.
10
 CONDENSATION OUTSIDE HORIZONTAL TUBES
 Therefore, Kern suggest using an index of 1/6.
 Frank suggest multiplying single tube coefficient by a factor of 0.75.
 Using Kern method
1�
𝜌𝜌𝐿𝐿 𝜌𝜌𝐿𝐿 − 𝜌𝜌𝑉𝑉 𝑔𝑔 3
−1�6
(ℎ𝑐𝑐 )𝑏𝑏 = 0.95𝑘𝑘𝐿𝐿 𝑁𝑁𝑟𝑟
𝜇𝜇𝐿𝐿 Γ
Nr = average of tubes in a vertical row
Nr can be taken as two-thirds of the number in the central tube row

11
CONDENSATION OVER TUBE BANKS

12
 CONDENSATION INSIDE AND OUTSIDE VERTICAL TUBES
 The mean condensation coefficient, 𝑊𝑊⁄
𝑚𝑚2 .℃ , given by the Nusselt model as:
1�
𝜌𝜌𝐿𝐿 𝜌𝜌𝐿𝐿 − 𝜌𝜌𝑉𝑉 𝑔𝑔 3
(ℎ𝑐𝑐 )𝑣𝑣 = 0.926𝑘𝑘𝐿𝐿
𝜇𝜇𝐿𝐿 Γ𝑣𝑣
𝑘𝑘𝑘𝑘⁄
 Γ𝑣𝑣 is for a vertical tube loading, condensate rate per unit tube perimeter, 𝑚𝑚.𝑠𝑠

 for a tube bundle,

𝑊𝑊𝑐𝑐 𝑊𝑊𝑐𝑐
Γ𝑣𝑣 = 𝑜𝑜𝑜𝑜
𝑁𝑁𝑡𝑡 𝜋𝜋𝑑𝑑𝑜𝑜 𝑁𝑁𝑡𝑡 𝜋𝜋𝑑𝑑𝑖𝑖
 Mean condensation coefficient equation will apply to a Reynolds number of 30, above this value
waves on the condensate film become important.

13
 CONDENSATION INSIDE AND OUTSIDE VERTICAL TUBES
 Presence of waves will increase the heat-transfer coefficient, so the use of mean condensation
coefficient above a 𝑅𝑅𝑅𝑅𝑐𝑐 of 30 gives conservative estimate.
 Therefore, the Reynolds number for the condensate film is:
4Γ𝑣𝑣
𝑅𝑅𝑅𝑅𝑐𝑐 =
𝜇𝜇𝐿𝐿
 𝑅𝑅𝑅𝑅𝑐𝑐 above 2000, the condensate film becomes turbulent. Effect of turbulence in the condensate
film was investigated by Colburn (1934) and the results are generally used for condenser design.
 The Prandtl number for the condensate film is:
𝐶𝐶𝑝𝑝 𝜇𝜇𝐿𝐿
𝑃𝑃𝑃𝑃𝑐𝑐 =
𝑘𝑘𝐿𝐿
14
CONDENSATION COEFFICIENT FOR VERTICAL TUBES

15
 CONDENSATION INSIDE HORIZONTAL TUBES
 Heat transfer coefficient in horizontal tube at any point along the tube will depend on the flow
pattern at that point.
 Various pattern for two-phase (vapour and liquid) – more info Volume 1 chapter 5.

16
 CONDENSATION INSIDE HORIZONTAL TUBES
 In condensation, flow will vary from a single-phase vapour at the inlet to a single-phase liquid at
the outlet.
 Correlations for estimating the average condensation coefficient have been published, but there
is no general satisfactory method that will give accurate predictions over a wide flow range.

17
 CONDENSATION INSIDE HORIZONTAL TUBES
 There are two flow models used to estimate the mean condensation coefficient in horizontal
tubes: stratified flow figure 12.45a, and annular flow, figure 12.45b.
 Stratified flow model – limiting condition at low condensate & vapour rates, and
 Annular model – condition at high vapour & low condensate rates.
4 Stratified flow model – condensation film
coefficient is estimated from Nusselt equation.
 Annular model – condensation film coefficient is
estimated from Boyko-Kruzhilin equation.

18
 MEAN TEMPERATURE DIFFERENCE
 Isothermal process – a pure, saturated, vapour will condensed at a fixed temperature at constant
pressure.
 No correction factor required for multiple passes.
 The logarithmic mean temperature difference will be given by:
𝑡𝑡2 − 𝑡𝑡1
Δ𝑇𝑇𝑙𝑙𝑙𝑙 =
𝑇𝑇𝑠𝑠𝑠𝑠𝑠𝑠 − 𝑡𝑡1
𝑙𝑙𝑙𝑙
𝑇𝑇𝑠𝑠𝑠𝑠𝑠𝑠 − 𝑡𝑡2
Tsat = saturation temperature of the vapour,
t1 = inlet coolant temperature,
t2 = outlet coolant temperature.

19
 DE-SUPERHEATING AND SUB-COOLING
 If the vapour entering the condenser is superheated, and the condensate leaving the condenser is
cooled below its boiling point (sub-cooled), the temperature profile will be as shown in Figure
12.46.

20
 CONDENSATION OF MIXTURES
 The design of a condenser for a mixture of vapours is a more difficult task.
 The term “mixture of vapours” covers three related situation of practical interest:
 Total condensation of a multi-component mixture, as distillate from multicomponent
distillation.
 Condensation of only part of multi-component vapour mixture, all components of which are
theoretically condensable. Where the dew point of the lighter components is above coolant
temperature.
 Condensation from a non-condensable gas, where the gas is not soluble to any extent in the
liquid condensed. These exchangers are often called cooler-condensers.
21
 CONDENSATION OF MIXTURES
Therefore, the following features are considered in the developing design methods for mixed
vapours condensers:
The condensation will not be isothermal. As the heavy component condenses out the
composition of the vapour, therefore its dew point change.
Because the condensation is not isothermal there will be a transfer of sensible heat from the
vapour to cool the gas to dew point. There will be a transfer of sensible heat from condensate.
The transfer of sensible heat from the vapour can be particularly significant.

22
 CONDENSATION OF MIXTURES
Therefore, the following features are considered in the developing design methods for mixed
vapours condensers:
As the composition of the vapour and liquid change throughout the condenser their physical
properties vary, therefore consider the mixture of physical properties.
The heavy component must diffuse through the lighter components to reach the condensing
surface. The rate of condensation will be governed by rate of diffusion as well as the rate of
heat transfer.

23
 ESTIMATION OF HEAT-TRANSFER COEFFICIENTS
Total condensation:

 For the design of a multi-component in which the vapour is total condensed, an estimation of the

mean condensing coefficient can be using the single component with the liquid physical

properties evaluated at the average condensation composition.

Partial condensation:

 The methods for partial condensation and condensation from non-condensable gas can be

divided into two classes:

24
 ESTIMATION OF HEAT-TRANSFER COEFFICIENTS
 Empirical methods: approximate methods, consider the resistance to heat transfer to control

the rate of condensation and the mass transfer resistance is neglected.

 Analytical methods: more exact procedure, based on some model of the heat and mass

transfer process, and which take into account the diffusional resistance to mass transfer. They

are suited for computer solution using numerical methods.

Approximate methods:
 The local coefficient for heat transfer can be expressed in terms of the local condensate film
coefficient and local coefficient for sensible heat transfer from the vapour.

25
 ESTIMATION OF HEAT-TRANSFER COEFFICIENTS
Fog Formation:
 In the condensation of a vapour from a non-condensable gas, if the bulk temperature of the gas
falls below the dew point of the vapour, liquid can condense out directly as mist or fog.

26
 PRESSURE DROP IN CONDENSERS
 The pressure drop on the condensing side is difficult to calculation as two phase exist and vapour
mass velocity is changing throughout the condenser.
 Common practice, use the method for the single phase flow & apply a factor to allow for the
change in vapour velocity.
FOR TOTAL CONDENSATION:
 Frank (1978): a factor of 40% of the value based on the inlet condition.
 Kern (1950): a factor of 50%
FOR PARTIAL CONDENSER:
 Estimation of pressure drop is given by Gloyer (1970), see e.g. 12.7 in Coulson and Richardson,
Volume 6 27
 THERMAL DESIGN OF THE CONDENSER
1) Energy balance:
𝑞𝑞 = 𝑚𝑚∆𝐻𝐻
̇
2) Cooling water properties: determine c/w properties at average c/w temperature; e.g.
1
𝑡𝑡𝑐𝑐⁄𝑤𝑤,𝑖𝑖𝑖𝑖 + 𝑡𝑡𝑐𝑐⁄𝑤𝑤,𝑜𝑜𝑜𝑜𝑜𝑜
2
3) Fluid Properties: Cp, k, 𝜌𝜌, 𝜇𝜇
4) Cooling water flowrate:
𝑞𝑞 = 𝑚𝑚̇ 𝑐𝑐/𝑤𝑤 𝐶𝐶𝑝𝑝𝑝𝑝/𝑤𝑤 Δ𝑇𝑇

28
 THERMAL DESIGN OF THE CONDENSER
5) Mean Temperature Difference
∆𝑇𝑇𝑚𝑚 = 𝐹𝐹. ∆𝑇𝑇𝑙𝑙𝑙𝑙
 F = can be found from graph
5a) Estimate of overall heat transfer coefficient:
 𝑈𝑈0 = get estimate from Table, take mid range value
5b) Tubing specification (refer in Tables):
 Tube diameter, BWG, tube layout, tube pitch
6) Heat transfer area and number of tubes:
𝑞𝑞 𝐴𝐴0
𝐴𝐴0 = 𝑛𝑛𝑡𝑡 =
𝑈𝑈0 ∆𝑇𝑇𝑚𝑚 𝜋𝜋𝐷𝐷𝑜𝑜 𝐿𝐿

29
 THERMAL DESIGN OF THE CONDENSER
7) Number of tube passes, np
𝑚𝑚̇
𝐷𝐷𝑖𝑖
𝑚𝑚̇ 𝜋𝜋𝐷𝐷𝑖𝑖2 𝑛𝑛𝑡𝑡
𝜌𝜌𝜌𝜌𝐷𝐷𝑖𝑖 𝐴𝐴𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡
𝐷𝐷𝑖𝑖 ∗
4 𝑛𝑛𝑝𝑝 4𝑚𝑚𝑛𝑛
̇ 𝑝𝑝
𝑅𝑅𝑅𝑅 = = = =
𝜇𝜇 𝜇𝜇 𝜇𝜇 𝜋𝜋𝜋𝜋𝐷𝐷𝑖𝑖 𝑛𝑛𝑡𝑡

To have fully turbulent flow: Re ≥ 104

Fluid velocity can also be used as a criterion for setting no. of tube-side passes
It is desirable to maintain liquid velocity of 0.9 – 2.5 m/s in the tubes.
Too low velocity can cause excessive fouling
Very high velocity can cause erosion of the tube wall

30
 THERMAL DESIGN OF THE CONDENSER
𝜌𝜌𝜌𝜌𝐷𝐷𝑖𝑖 4𝑚𝑚𝑛𝑛
̇ 𝑝𝑝
𝑅𝑅𝑅𝑅 = =
𝜇𝜇 𝜋𝜋𝜋𝜋𝐷𝐷𝑖𝑖 𝑛𝑛𝑡𝑡
4𝑚𝑚𝑛𝑛
̇ 𝑝𝑝
𝑜𝑜 =
𝜋𝜋𝜌𝜌𝐷𝐷𝑖𝑖2 𝑛𝑛𝑡𝑡

8) Shell size and Tube count

See Table C2
Obtain shell inside diameter
Obtain number of tubes
Revised value of nt = value from Table C2
Revised value of U: recalculate U using revised value of nt

31
 THERMAL DESIGN OF THE CONDENSER
9) Required Overall heat transfer coefficient
𝑞𝑞
𝑈𝑈𝑟𝑟𝑟𝑟𝑟𝑟 = nt = use the value from Table C2
𝜋𝜋𝐷𝐷𝑜𝑜 𝐿𝐿𝑛𝑛𝑡𝑡 ∆𝑇𝑇𝑚𝑚

10) Calculate hi (tube side heat transfer coefficient)

𝑁𝑁𝑁𝑁 = 0.023𝑅𝑅𝑅𝑅 0.8 𝑃𝑃𝑃𝑃 0.33
ℎ𝑖𝑖 𝐷𝐷𝑖𝑖
𝑁𝑁𝑁𝑁 =
𝑘𝑘𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓

11) Calculate ho (shell side heat transfer coefficient)

(i) get a first estimate of tube wall temperature using Tw = ½(tave + Tave )
Tave = average shell side temperature, tave = average tube side temperature and
Tw = tube wall temp

32
 THERMAL DESIGN OF THE CONDENSER
Tave = ½ (Tvap,in + Tcondensate,out)
tave = ½(tc/w,in + tc/w, out)
(ii) calculate average film temperature, Tf = 0.75Tw + 0.25Tv, where Tv = Tave
(iii) determine µL at Tf
(iv) Determine Γ
(v) Determine ho
(vi) Calculate Tw and Tf
𝐷𝐷
ℎ𝑖𝑖 𝑡𝑡𝑎𝑎𝑎𝑎𝑎𝑎 +ℎ𝑜𝑜 𝐷𝐷𝑜𝑜 𝑇𝑇𝑎𝑎𝑎𝑎𝑎𝑎
𝑖𝑖
𝑇𝑇𝑤𝑤 = 𝐷𝐷
ℎ𝑖𝑖 +ℎ𝑜𝑜 𝐷𝐷𝑜𝑜
𝑖𝑖

Tf,new = 0.75Tw + 0.25Tv

33
 THERMAL DESIGN OF THE CONDENSER
(viii) Recalculate ho
Determine µL at Tf
Determine ho
If ho value is close to previous value, no further iterations required.
If ho value is not close to previous value, then go back to step (vi) recalculate, Tw, Tf, µL, ho until ho is closer
to new ho
12) Overall heat transfer coefficient
𝐷𝐷𝑜𝑜
1 𝐷𝐷𝑜𝑜 𝐷𝐷𝑜𝑜 𝑙𝑙𝑙𝑙 1 1 𝐷𝐷𝑜𝑜 1
𝐷𝐷𝑖𝑖
= + + + +
𝑈𝑈 ℎ𝑖𝑖 𝐷𝐷𝑖𝑖 2𝑘𝑘𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 ℎ𝑜𝑜 ℎ𝐷𝐷𝐷𝐷 𝐷𝐷𝑖𝑖 ℎ𝐷𝐷𝐷𝐷
1 1
𝑎𝑎𝑎𝑎𝑎𝑎 ; tube side and shell side dirt coefficient (W/m2.K)
ℎ𝐷𝐷𝐷𝐷 ℎ𝐷𝐷𝐷𝐷
34
 THERMAL DESIGN OF THE CONDENSER
13) Overdesign
𝑈𝑈
𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂 = − 1 ∗ 100 = 10% or approximately
𝑈𝑈𝑟𝑟𝑟𝑟𝑟𝑟

If overdesign > 10%, the condenser is oversized, go to step 5a. Repeat the calculations from 5a and
continue the iteration until U values converge.

If overdesign < 10%, insufficient safety margin, Repeat the calculations from 5a and continue the iteration
until U values converge.

14) Shell and head types

Specify shell type e.g. E-Shell

Specify head type e.g. Floating head, and Specify overall heat exchanger type e.g. AEU exchanger
35
 THERMAL DESIGN OF THE CONDENSER
15) Tube-side pressure drop
𝑓𝑓𝑛𝑛𝑝𝑝 𝐿𝐿𝐺𝐺 2
∆𝑃𝑃𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 = ; ∆𝑃𝑃𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 is pressure drop due friction
7.50∗1012 𝐷𝐷𝑖𝑖 𝑠𝑠𝑠

𝑠 = 1; s = specific gravity; 𝑓𝑓 = 0.4137𝑅𝑅𝑅𝑅 −0.2585 ;

𝑚𝑚̇
𝐺𝐺 = 𝜋𝜋𝐷𝐷𝑖𝑖2 𝑛𝑛𝑡𝑡
4 𝑛𝑛𝑝𝑝

16) Shell side pressure drop

1 𝐷𝐷𝑠𝑠 𝐿𝐿 𝜌𝜌𝑢𝑢𝑠𝑠2
∆𝑃𝑃𝑠𝑠 = 8𝑗𝑗𝑓𝑓
2 𝑑𝑑𝑒𝑒 𝑙𝑙𝑏𝑏 2

jf is friction factor from chart

lb = baffle spacing

36
 THERMAL DESIGN OF THE CONDENSER
Pressure drop on condensing side is difficult to predict as two phases occurs and the
vapour mass velocity is changing throughout the condenser.
Common practice is to calculate pressure drop using the methods for single-phase
flow and apply a factor to allow for change in vapour velocity.
For total condensation Kern suggest a factor of 50%.
Calculate ΔPs using inlet flow:
𝐺𝐺𝑠𝑠 𝑚𝑚̇ 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 𝐼𝐼𝐼𝐼𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 .𝑙𝑙𝑏𝑏 .𝐶𝐶
𝜌𝜌 = 𝜌𝜌𝑣𝑣𝑣𝑣𝑣𝑣 ; 𝑢𝑢𝑠𝑠 = ; 𝐺𝐺𝑠𝑠 = ; 𝑎𝑎𝑠𝑠 =
𝜌𝜌𝑣𝑣𝑣𝑣𝑣𝑣 𝑎𝑎𝑠𝑠 𝑃𝑃𝑇𝑇

IDshell = lb = typical for condenser

C = PT – Do = clearance
PT = tube pitch
37
 THERMAL DESIGN OF THE CONDENSER
Example 12.7

Saturated vapour
m = 45000 kg/h
0
T = 60 C

Hot water out Cooling water in

Condenser 0
0
T = 40 C T = 30 C

Condensate
T = 450C

38
 THERMAL DESIGN OF THE CONDENSER
MM vapour = 52
Enthalpies:
Hvapour = 596.5 kJ/kg
Hcondensate = 247.0 kJ/kg
Total condensation, no sub-cooling
Condensate is at 450C not at 600C – not vapour entering is a
mixture and not a single vapour

39
 THERMAL DESIGN OF THE CONDENSER
Heat Duty
Qc = heat lost by vapour = m vap(Hvap – Hcondensate) = (45000/3600)(596.5 – 247)
Qc = 4368.8 kW or 4368.8 x 103 J/s
c/w flowrate
Qc = mc/wCp,c/w (Tco – Tci)
mc/w = 4368.8/(4.18(40 – 30)) = 104.5 kg/s
ΔT1 = 60 – 40 = 200C Vapour in T = 600C T = 450C
ΔT2 = 45 – 30 = 150C ΔT1 ΔT2
∆𝑇𝑇1 −∆𝑇𝑇2 20−15 T = 400C Cooling water in T = 300C
∆𝑇𝑇𝑙𝑙𝑙𝑙 = ∆𝑇𝑇 = 20 = 17. 40 𝐶𝐶
𝑙𝑙𝑙𝑙 1 𝑙𝑙𝑙𝑙
15
∆𝑇𝑇2
40
 THERMAL DESIGN OF THE CONDENSER
Assume 1 shell and 4 tube passes: NB you need to verify and justify this assumption at
the end
From chart Ft = 0.92
ΔTm = FtΔTlm = 0.92(17.4) = 160C.
ITERATION 1
Assume Uass = 1000 W/m20C: NB you need to verify and justify this assumption at the
end
Q = UAΔTm
𝑄𝑄 4368.8 𝑥𝑥 103
𝐴𝐴𝑟𝑟𝑟𝑟𝑟𝑟 = = = 273 𝑚𝑚2
𝑈𝑈∆𝑇𝑇𝑚𝑚 (1000)(16)

41
 THERMAL DESIGN OF THE CONDENSER
Select standard tube layout
Check the Table 9: ¾ in OD on 1-in square pitch, 16 BWG, 16 ft
do = 19.05 mm, di = 0.620 in = 15.748 mm, PT = 25.4 mm, L = 16ft = 4.88 m
Use Areq to calculate number of tubes
𝐴𝐴𝑟𝑟𝑟𝑟𝑟𝑟 273
𝑁𝑁𝑁𝑁 = = = 935
𝜋𝜋𝑑𝑑𝑜𝑜 𝐿𝐿 𝜋𝜋(19.05𝑥𝑥𝑥0−3 )(4.88)
From Table 9, the closest value is 982 and shell ID = 39 in, therefore Nt = 982
Bundle diameter
1 1
𝑁𝑁 𝑛𝑛1 −3 982 2.263
𝐷𝐷𝑏𝑏 = 𝑑𝑑𝑜𝑜 = 19.05𝑥𝑥𝑥0 = 0.904 𝑚𝑚
𝐾𝐾1 0.158
From Table: K1 = 0.158 and n1 = 2.263
42
 THERMAL DESIGN OF THE CONDENSER
𝐷𝐷𝑏𝑏 904
No. of tube in the centre row = Nr = = = 36
𝑃𝑃𝑇𝑇 25.4
Shell-side heat transfer coefficient
Mean temperature
Shell side = ½ (60 + 45) = 52.50C and Tube side = ½ (40 + 30) = 350C
0
Sat vapour = 52.5 C
ho
Tw
hi
c/w out 0 c/w in
35 C

43
 THERMAL DESIGN OF THE CONDENSER
ho(52.5 – Tw) = U(52.5 – 35)
Assume ho = 1667 W/m20C: NB: need to verify assumption later
1667(52.5 – Tw) = 1000(52.5 – 35)
Tw = 420C
Mean temperature of condensate = ½(Tb – Tw) = ½ (52.5 – 42) = 470C
Tb = mean temperature of vapour-condensate on shell side
Tw = tube wall temperature
Physical properties at 470C
µL = 0.16 x 10-3 Pa.s; ρL = 551 kg/m3; kL = 0.13 W/m20C

44
 THERMAL DESIGN OF THE CONDENSER
Vapour density at mean vapour temperature of 52.50C
𝑃𝑃1 𝑉𝑉1 𝑃𝑃2 𝑉𝑉2
=
𝑛𝑛1 𝑇𝑇1 𝑠𝑠𝑠𝑠𝑠𝑠 𝑛𝑛2 𝑇𝑇2
𝑛𝑛2 𝑃𝑃2 𝑇𝑇1 𝑛𝑛1
𝑀𝑀𝑀𝑀 = 𝜌𝜌2 = 𝑀𝑀𝑀𝑀
𝑉𝑉2 𝑃𝑃1 𝑇𝑇2 𝑉𝑉1
10 273 1
𝜌𝜌2 = 52 = 19.5 𝑘𝑘𝑘𝑘/𝑚𝑚3
1 273+52.5 22.4
45000
𝑊𝑊𝑐𝑐 3600 −3 𝑘𝑘𝑘𝑘
Γℎ = = = 2.61𝑥𝑥10 . 𝑚𝑚
𝐿𝐿𝑁𝑁𝑡𝑡 (4.88)(982) 𝑠𝑠
2 2
𝑁𝑁𝑟𝑟 = 𝑁𝑁𝑁𝑁. 𝑜𝑜𝑜𝑜 𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 𝑖𝑖𝑖𝑖 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 𝑟𝑟𝑟𝑟𝑟𝑟 = 36 = 24
3 3

45
 THERMAL DESIGN OF THE CONDENSER
1⁄
𝜌𝜌𝐿𝐿 𝜌𝜌𝐿𝐿 −𝜌𝜌𝑉𝑉 𝑔𝑔 3 −1⁄6
ℎ𝑐𝑐 = 0.95𝑘𝑘𝐿𝐿 𝑁𝑁𝑟𝑟
𝜇𝜇𝐿𝐿 Γ
1⁄ 1
551 551−19.5 9.81 3 −
ℎ𝑐𝑐 = 0.95 0.13 24 6 = 1383 W/m20C
0.16𝑥𝑥10−3 2.61𝑥𝑥10−3
ho assumed is not equal hc, therefore further iteration
Note: you must iterate until your ho,ass = hc or closed enough or < 10%
ℎ𝑐𝑐 −ℎ𝑜𝑜
𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶: 0 < < 10%
ℎ𝑜𝑜
For the purposes of illustration of this worked example assume ho,ass and hc,calc are
close enough

46
 THERMAL DESIGN OF THE CONDENSER
Tube-side heat transfer coefficient, hi
Correlation by Eagle and Ferguson for water
4200(1.35+0.02𝑡𝑡)𝑢𝑢𝑡𝑡2
ℎ𝑖𝑖 =
𝑑𝑑𝑖𝑖0.2
t = water temperature,0C; t = water velocity, m/s; di = tube inside diameter, mm
Tube cross-sectional area per pass = Atube
2
𝜋𝜋𝑑𝑑𝑖𝑖2
𝑁𝑁 𝜋𝜋 15.748𝑥𝑥𝑥𝑥 −3 982
𝐴𝐴𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 = * = ∗ = 0.0478 𝑚𝑚2
4 𝑛𝑛 4 4
Density of water at 350C = 993 kg/m3
𝑚𝑚̇ 𝑐𝑐/𝑤𝑤 104.5
𝑜𝑜𝑡𝑡 = = = 2.20 𝑚𝑚/𝑠𝑠 [Recommended range (1.5 – 2.5 m/s)
𝜌𝜌𝐴𝐴𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 993(0.0478)
water velocity in tubes- C&R]
47
 THERMAL DESIGN OF THE CONDENSER
Water velocity is within desired range so number of tube passes assumes is
adequate.
Water velocity being within range also means that fouling would be reduced as well
as tube vibration.
4200(1.35+0.02𝑡𝑡)𝑢𝑢𝑡𝑡2 4200(1.35+0.02(35)(2.2)2
ℎ𝑖𝑖 = = = 9322 𝑊𝑊/𝑚𝑚20 𝐶𝐶
𝑑𝑑𝑖𝑖0.2 (15.748)2

Fouling Factor (Dirt factor)

Use 6000 W/m20C for each side. Refer to dirt factor Table in C&R
Overall heat transfer coefficient
1 1 1 1 1
= + + + :thin walled tubes, so tube wall resistance is neglected
𝑈𝑈 ℎ𝑜𝑜 ℎ𝑑𝑑𝑑𝑑 ℎ𝑖𝑖 ℎ𝑑𝑑𝑑𝑑

48
 THERMAL DESIGN OF THE CONDENSER
1 1 1 1 1
= + + +
𝑈𝑈 1383 6000 9322 6000
Ucalc = 859 W20C
Uass = 1000 W20C
Ucalc is significantly lower than Uass so further iteration is required.
Check Area first
𝑄𝑄 4368𝑥𝑥103
𝐴𝐴𝑟𝑟𝑟𝑟𝑟𝑟 = = = 318 𝑚𝑚2
𝑈𝑈𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 ∆𝑇𝑇𝑚𝑚 859(16)
𝐴𝐴𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 = 𝜋𝜋𝑑𝑑𝑜𝑜 𝐿𝐿𝐿𝐿 = 𝜋𝜋 19.05𝑥𝑥10−3 4.88 982 = 287 𝑚𝑚2
Aavailable < Arequired This design is unacceptable
Therefore: condenser or heat exchanger is too small; New iteration is required
49
 THERMAL DESIGN OF THE CONDENSER
ITERATION 2
Assume U = 860 W20C
𝑄𝑄 4368𝑥𝑥103
𝐴𝐴𝑟𝑟𝑟𝑟𝑟𝑟 = = = 317 𝑚𝑚2 :Area required based on U assumed
𝑈𝑈𝑎𝑎𝑎𝑎𝑎𝑎 ∆𝑇𝑇𝑚𝑚 860(16)
Select standard tube layout
Check the Table 9: ¾ in OD on 1-in square pitch, 16 BWG, 20 ft
do = 19.05 mm, di = 0.620 in = 15.748 mm, PT = 25.4 mm, L = 20ft = 6.1 m
Use Areq to calculate number of tubes
𝐴𝐴𝑟𝑟𝑟𝑟𝑟𝑟 317
𝑁𝑁𝑁𝑁 = = = 868
𝜋𝜋𝑑𝑑𝑜𝑜 𝐿𝐿 𝜋𝜋(19.05𝑥𝑥𝑥0−3 )(6.1)
From Table 9, the closest value is 886 and shell ID = 37 in, therefore Nt = 886
50
 THERMAL DESIGN OF THE CONDENSER
Shell side heat transfer coefficient
ho(52.5 – Tw) = U(52.5 – 35)
Assume ho = 1400 W/m20C: NB: need to verify assumption later
1400(52.5 – Tw) = 860(52.5 – 35)
Tw = 420C
So physical properties remain the same
45000
𝑊𝑊𝑐𝑐 3600 −3 𝑘𝑘𝑘𝑘
Γℎ = = = 2.31𝑥𝑥10 . 𝑚𝑚
𝐿𝐿𝑁𝑁𝑡𝑡 (6.1)(886) 𝑠𝑠
Bundle diameter
1 1
𝑁𝑁 𝑛𝑛1 −3 886 2.263
𝐷𝐷𝑏𝑏 = 𝑑𝑑𝑜𝑜 = 19.05𝑥𝑥𝑥0 = 0.864 𝑚𝑚
𝐾𝐾1 0.158
From Table: K1 = 0.158 and n1 = 2.263
51
 THERMAL DESIGN OF THE CONDENSER
𝐷𝐷𝑏𝑏 864
𝑁𝑁𝑁𝑁. 𝑜𝑜𝑜𝑜 𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 𝑖𝑖𝑖𝑖 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 𝑟𝑟𝑟𝑟𝑟𝑟 = = = 34
𝑃𝑃𝑇𝑇 25.4
2 2
𝑁𝑁𝑟𝑟 = 𝑁𝑁𝑁𝑁. 𝑜𝑜𝑜𝑜 𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 𝑖𝑖𝑖𝑖 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 𝑟𝑟𝑟𝑟𝑟𝑟 = 34 = 23
3 3
1⁄
𝜌𝜌𝐿𝐿 𝜌𝜌𝐿𝐿 −𝜌𝜌𝑉𝑉 𝑔𝑔 3 −1⁄6
ℎ𝑐𝑐 = 0.95𝑘𝑘𝐿𝐿 𝑁𝑁𝑟𝑟
𝜇𝜇𝐿𝐿 Γ
1⁄ 1
551 551−19.5 9.81 3 −
ℎ𝑐𝑐 = 0.95 0.13 23 6 = 1451 W/m20C
0.16𝑥𝑥10−3 2.31𝑥𝑥10−3
ho assumed is close to hc, therefore no further iteration is required
Note: you must make sure that ho,ass = hc or closed enough or < 10%
ℎ𝑐𝑐 −ℎ𝑜𝑜 1451−1400
𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶: 0 < < 10%: x100 = 3.6%
ℎ𝑜𝑜 1400
52
 THERMAL DESIGN OF THE CONDENSER
Tube side heat transfer coefficient
2
𝜋𝜋𝑑𝑑𝑖𝑖2
𝑁𝑁 𝜋𝜋 15.748𝑥𝑥𝑥𝑥 −3 886
𝐴𝐴𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 = * = ∗ = 0.0431 𝑚𝑚2
4 𝑛𝑛 4 4
Density of water at 350C = 993 kg/m3
𝑚𝑚̇ 𝑐𝑐/𝑤𝑤 104.5
𝑜𝑜𝑡𝑡 = = = 2.44 𝑚𝑚/𝑠𝑠 [Recommended range (1.5 – 2.5 m/s)
𝜌𝜌𝐴𝐴𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 993(0.0431)
water velocity in tubes- C&R]
ut is within the recommended range, number of passes is adequate, fouling is
minimised etc.
4200(1.35+0.02𝑡𝑡)𝑢𝑢𝑡𝑡2 4200(1.35+0.02(35)(2.44)0.8
ℎ𝑖𝑖 = = = 10127 𝑊𝑊/𝑚𝑚20 𝐶𝐶
𝑑𝑑𝑖𝑖0.2 (15.748)0.2

53
 THERMAL DESIGN OF THE CONDENSER
Overall heat transfer coefficient
1 1 1 1 1
= + + + :thin walled tubes, so tube wall resistance is neglected
𝑈𝑈 ℎ𝑜𝑜 ℎ𝑑𝑑𝑑𝑑 ℎ𝑖𝑖 ℎ𝑑𝑑𝑑𝑑
1 1 1 1 1
= + + +
𝑈𝑈 1451 6000 10127 6000
Ucalc = 892 W20C and Uass = 860 W20C
𝑈𝑈𝑐𝑐𝑎𝑎𝑎𝑎𝑎𝑎 −𝑈𝑈𝑎𝑎𝑎𝑎𝑎𝑎 892−860
𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶: 0 < < 10%: x100 = 3.7%
𝑈𝑈𝑎𝑎𝑎𝑎𝑎𝑎 860
𝑄𝑄 4368𝑥𝑥103
𝐴𝐴𝑟𝑟𝑟𝑟𝑟𝑟 = = = 306 𝑚𝑚2
𝑈𝑈𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 ∆𝑇𝑇𝑚𝑚 892(16)
𝐴𝐴𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 = 𝜋𝜋𝑑𝑑𝑜𝑜 𝐿𝐿𝐿𝐿 = 𝜋𝜋 19.05𝑥𝑥10−3 6.1 886 = 323 𝑚𝑚2
𝐴𝐴𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 −𝐴𝐴𝑟𝑟𝑟𝑟𝑟𝑟 323−306
Aavailable > Arequired % Safe factor: 0 < < 10%: x100 = 5.6%
𝐴𝐴𝑟𝑟𝑟𝑟𝑟𝑟 306
54
 THERMAL DESIGN OF THE CONDENSER
Acceptable tube layout
Shell ID = 37 in = 940 mm or Db + 95 = 864 + 95 = 959 mm
Shell side pressure drop
Refer to example in the text book
% baffle cut = 45%
Note for condenser: lb = Ds (ID shell = 940 mm for this example)
Tube side pressure drop
Refer to example in the text book
ACCEPTABLE DESIGN: CONDENSOR

55
 Evaluate the photocatalytic activity of a locally produced TiO2
pigment on the degradation of bacteria in river water for
potable water purposes and hence optimize the process. The
specific objectives are as follows:

Evaluate the photocatalytic activity of the mTiO2 on

degradation of organics in river water to produce clean water.
Optimize process parameters of temperature, starting pH of
the solution and mTiO2 loading on the degradation of bacteria
in river water.
Investigate the percentage removal of mTiO2 and bacteria in
treated water using a Polyester Woven Microfiltration
Membrane (PEWMM).
56