UNIVERSITY OF TECHNOLOGY, JAMAICA

HEAT TRANSFER PROJECT

Lecturer: Lt. Col G. Junior Virgo
Due Date: November 28, 2015
Module Name: Unit Operations 4 (Heat Transfer)
Module Code: CHE3004
Programme: Chemical Engineering (UBECHENFXU1A)
Submitted by: Adrian Fagan
ID #: 1301500

OVERVIEW OF CLARIFICATION PROCESS

The first stage of clarification is to separate the solids (bauxite residue) from the pregnant
liquor (sodium aluminate remains in solution) via sedimentation. Chemical additives
(flocculants) are added to assist the sedimentation process. The bauxite residue sinks to the
bottom of the settling tanks, then is transferred to the washing tanks, where it undergoes a series
of washing stages to recover the caustic soda (which is reused in the digestion process).
Further separation of the pregnant liquor from the bauxite residue is performed utilising a
series of security filters. The purpose of the security filters is to ensure that the final product is
not contaminated with impurities present in the residue.Depending on the requirements of the
residue storage facility, further thickening, filtration and/or neutralisation stages are employed
prior to it being pumped to the bauxite residue disposal area. The green liquor enters the process
at 215 0F then then a heat exchanger is use to decrease the temperature to approximately 185 0F.
This pro will aim to design a heat exchanger for this process.

Design Calculations

Assumptions
1. Overall heat transfer coefficient is constant.
2. No change in specific heats.
3. No heat losses to the surrounding.
4. There is no leakage of fluid between shell passes.

5.

The temperature of the shell-side fluid in any pass is constant across any cross-

section.

6.

Specific determination between mixtures is linearly related.

Shell and tube heat exchanger

The green liquor was placed on the tube side because it is more corrosive and water was used on
the tube side

Tube side -

green liquor

Shell side

water

Flow rate

1301500 L/h = 1301.5 m/h

Inlet temperature-

215F = 374.82K

Outlet temperature

185 F = 358.15K

Cp for NaAlO2 = 73.6 J/mol,k

Rmm for NaAlO2 = 81.97 g/mol
Therefore Cp = 897.9 J/Kg.K
Density of sodium aluminate = 1500kg/m3
Cp for H2O =4181.1 J/Kg.K
Density of water at 55C = 986kg/m3

BASIC OF CALCULATION
Inlet temperature for cooling liquid = 55C
Mass flow rate of cooling liquid water) = 582,000.00kg/h

2NaAlO2 + 4H20 is produce as green liquor

Mole ratio = 1:2
RMM NaAlO2 = 81.970* 2 = 163.94g
RMM H20 = 18*4 = 72g
Mass of sodium aluminate solution = 163.94 + 72
= 235.94g
Mass fraction of 2NaAlO2

163.94 = 0.695
235.94
Mass fraction of 4H20

72 = 0.305
235.94

avg = (x * )
= (0.695 * 1500 kg/m) + (0. 305* 986 kg/m)
=1,343.23 kg/m
green liquor = 1301.5000 m/h x avg
=1301.5 m/h x 1,343.23kg/m
=1,748,213.8kg/h

Cp of green liquor solution = (0.695 * 897.9 J/kg. K) + (0.305 * 4181 J/kgK)

= 1899.2 J/kg.K
Energy Balance for Cold side:
Qin, cold = (m Cp)cold (Tco Tci )
Energy Balance for hot side:
Qin, hot = (m Cp)hot (Tho Thi )

Heat Load
Q = mh x Cph x Th
= 1,748,213.8kg/h x 1899.2 J/Kg.K x (374.82 358.15)
= 5.535 *1010 J/h
=1.5374*107 J/s
15,374 KJ/s

Cooling fluid outlet temperature:

(m Cp)hot = (Tco Tci )

(m Cp)cold

(Tho Thi )

(1,748,213.8kg/h x 1899.2 J/Kg.k) = Tco 328.15K________

-(582,000 kg/h x 4181 J/KgK)

Tco = 1.36 (16.67)
Tco = 350.77 K

(358.15 374.82K )

This calculation was done with the use of a LMTD calculator results may be seen in appendix
fig 1
TLMTD = (Thot in - Tcold,out) (Thot,out - Tcold.in)
Ln (Thot in - Tcold,out)/
((Thot,out - Tcold.in)

= (Thot in - Tcold,out) (Thot,out - Tcold.in)

Ln (Thot in - Tcold,out)/
(Thot,out - Tcold.in)

= (374.82K 350.77K) (358K- 328.15K)

ln (0.831)
TLMTD = 26.9155 oC
Using 1 shell pass and two tube pass
(t t )
(T T )
P 2 1 R 1 2
(T1 t1 )
(t 2 t1 )

R = 1.3569
P = 0.3572
F = 0.9049 (correction factor Obtain from graph)
Tm =24.3555
Using fig 2 form Appendix the value of U was assumed to be 600W/mK

Q = U*A*Tm
A= Q/(U*Tm)
=1.5374*107 J/s / (600W/ms * 24.3555)
=1,052 m
Basic of design characteristics
Choose 20 mm O.D, 16mm I.D, 4.8 m long tubes with L= 4.8m
Area of 1 tube = D L
= 3.14 * 0.02 * 4.8
= 0.302m2
# of tubes

= 1,052 m/ 0.303 m2
= 3, 484

Since the shell-side fluid is relatively clean I will use 1.25 triangular pitch.

Bundle Diameter
N
Db d 0 t
K1

1 / n1

Using fig 3 from appendix to abtain values for k and n.

Bundle diameter = 20(3, 483/0.249)1/2.207
=1,511mm
Using a split-ring floating head type

Linear extrapolation was done on the split ring floating head heat exchanger graph to obtain the
bundle diametric clearance = 92mm

Shell diameter = Ds=1,511mm +92mm

=1,603mm

Tube-Side Heat Transfer Coefficient

Film temp
Mean green liquor temperature = (374.82 +358.15)/2
= 366.48k = 93.33OC
Tube cross-sectional area

= (*162)/4 = 201 E-06m2

Tubes per pass

=3,484/2 = 1,742

Total flow area

= 201*10^-6 * 1742
= 0.35m2

Green liquor mass velocity

= 1,748,213.8kg/h /(3600 *0.35)

= 1387.47kg/s m2

density of green liquor

green liquor linear velocity

= 1,343.23 kg/m

= (865.40kg/s m2 /1,343.23 kg/m)

= 1.03m/s

Values at Film temperature

Viscosity of NaAlO3 = 2.4 mNs/m2
Thermal conductivity = 1.8 W/ moC
Re = Pvd/ = (1,343.23 * 1.03* *16*10-3 )/2.4*10-3
= 9,224
Pr = Cp /Kf = (1899.2 * 2.4*10-3)/1.8
= 2.53
L/d = 4.8*10-3/10 = 300

Nu = jh RePr0.33(/ w)0.14

From figure 5 in appendices (find jh)

For Re = 9224 & L/D = 300
jh = 3.9*10-3
Nu = (3.9*10-3)*(9224)*(2.53)0.33 = 48.87
htube= (Nu. Kf) D.I
= (48.87 * 1.8) 0.016
= 5,497.8 W/m2. oC

Shell-Side Heat Transfer Coefficient

Choose Baffle spacing (b) = Ds/5 = 1603/5

=320.6mm
Tube Pitch = 1.25*20 = 25mm

As

( pt d 0 ) Ds b
pt

Cross flow Area As

= (25- 20)/25 *( 1603 )* 320.6 *10-6

= 0.103m2
Mass velocity Gs = 582,000/(3,600* 0.103)
= 1,569.6 kg/sm2

p
1 d2
4 t 0.87 pt 0
2
2 4
de
d 0
2

Equivalent diameter =

de= 4(25/2 * 0.87*25 1/2 202/4)/*20/2

De = 14.4E-3m
Mean Shell side Temperature = (350.77 + 328.35)/2
= 339.46K
Film temp

= 66.31oC

Water density = 979kg/m3

Viscosity = 0.894 mNs/m2
Heat Capacity = 4181 J/kgoC

Re

= Gs de/

=1569.6 * 0.0144/0.894*10-3 = 5.79*106

Thermal conductivity (Kf) of water = 0.6 W/mk
Re = 25,282
Pr = Cp/Kf = 4181 * 0.894* 10-3/0.6
= 6.23
Choose 25 percent baffle cut from Fig 6
Jh = 3.8*10-3

Nu = jh Re Pr0.33
=3.80-3(25.282*103) (6.230.33)
=175.7
hshell

= (Nu.K) De
= (175.7 * 0.6) 0.0144
= 7,320.90 W/m2oK

OVERALL COEFFICIENT
Thermal conductivity of copper = 385 (W/m K)

Taking the fouling coefficients from table 12.2:Fig 7

Green liqour 2500Wm-2oC (boiling organics)
Water Coefficient = 2000Wm-2/oC (Cooling Water)

1
1
1

U 0 h0 hod

d0

di d0 1 d0 1
2k w
d i hid d i hi

d 0 ln

1/Uo = 1/7,320 + 1/2500 + (20*10^-3ln(20/16)/2*385) + (20/16 . 1/2000) + 20/16 + 1/5497.9

Uo = 716.9 Wm2ok

Since Uo calculated is well within the 30% deviation from U assumed hence no iteration is
needed.

Pressure drop

TUBE-SIDE
From Fig 8 when the Tube side Re = 9,224

L
Pt N p 8 j f

di
tf = 5.0*10-3

u 2
t
2.5
2

Neglecting the viscosity correction term

Pt = 2 [ 8*5.0*10-3 * 4.8*103/16) + 2.5 ]1343.23*1.032 /2
Pt = 18,881N/m2
= 18.9KPA

SHELL SIDE
Linear Velocity = Gs/density
=1569.6kg/sm2/986kg m-3
= 1.59m/s
From fig 9

At Re 25,282
Jf = 4.5*10-2

D
Ps 8 j f s
de

L u s2

B 2 w

0.14

Neglect viscosity Correction

Pt = 8jf (Ds/di)(L/LB)(PUs2/2)(U/w)-0.14
DPs = 8 * 4.5* 10-2* (1603/14.4)*4.8*103/320.6 *(986*1.592/ 2)
Ps = 747,811N/m2
= 748KPa

TABULATED RESULTS

UNIT DATA

SHELL SIDE

TUBE SIDE

water

Green liquor

161.67

485.6

55

101.6

77.6

85

800

800

986

1343.23

4181

1899

2257

1933

0.6

1.8

8.94*10-4

2.4*10-3

Fluid I.D
Fluid Flow Rate

kg/s

Temperature In

Temperature Out

Operating Pressure

KPa
-3

Density

Kgm

Specific Heat

kJkg-1oC

Latent Heat

kJkg-1

Therm. Cond.
Viscosity

W/m K
2

Ns/m

Molecular Weight

18.02

235.94

748

18.9

2000

2500

g/mol

No. of Passes
Pressure Drop

KPa
2o

Fouling Factor (coeff.) W/m C

Heat Transferred

(KW) 15.374 *106

LMTD: 26.91oC

deltaTm= 24.35 oC

Overall U assumed: 600 W/m2oK

Overall U calculated: 716.9 W/m2oK

CONSTRUCTION
1000

800

55

105

Max. Oper. Pressure (KPa)

Max. Oper. Temperature (C)
Type of Unit: Triangular pitch(1.25)
Tubes Material: Copper
Shell Material: steel

Tube Pitch (Pt) :0.025

O.D:0.02 m

I.D:0.016 m

Diameter(Approx.):1.7m

Length:4.8m

APPENDIX

Fig 1

Fig 2
Appendix B showing the overall coefficients of the heat exchanger based on the hot
and cold fluid used.

Fig 3 showing typical tube arrangements

Fig 4

Fig 5

Construction Details - Shell-Bundle Clearance

Fig 6

FIG 7

Fig 8

FIG 9