Preheaters:

Preheater (E-101):

Figure 1.1: Preheater (E-101)

1. Heat balance:
Cold Stream (C6H12O6+C12H22O11 + H2O)
P= 1.01 bar
t in = 77 ℉
t out = 149.9 ℉
t mean = (77 F + 149.9 F)/2
= 113 ℉
P= 1.01 bar

μ = 0.46 cp
m=1888.85 lb/hr

K = 0.075Btu/(hr.ft. ℉)
Q = w*Cp*Δt
Q= 22949.52 Btu/hr

Hot Stream (Steam)

P= 2.7 bar
T= 266 ℉
Latent heat of vaporization= λ = 977.95 Btu/lb
i
 Q=m× λ
Q
m=
λ
2080903.56
m=
2107.42
m = 2127.82 lb/hr

𝜇 =0.0341 lb /hr ft

Cp =2.16 Btu /lb ℉

K =0.083 Btu-in /hr℉

2.Δt = LMTD

Hot fluid(℉) Temperatures Cold fluid(℉) Difference(℉)

266 High temperature 149.9 116.1

266 Low temperature 77 189

0 Difference 73 73

Δt = (Δt2 - Δt1)/ln(Δt2/ Δt1)

Δt = (189 - 116.1)/ ln(116.1/189)

Δt = 144.74 ℉

3.Tc and tc:

A check of both streams shows that none of the fluids is viscous at the cold end and the
temperature difference and temperature ranges are moderate. The coefficients may accordingly
be evaluated from properties at the average temperatures Tmean and tmean. So we assume (μ/
μw )0.14 =1, because the viscosities are not great enough to introduce an error.

4.Calculation of heat transfer area and tube numbers:

Assumming 1 shell pass and 2 tube pass shell and tube exchanger with following dimensions and
considerations.
 Fixed tube plate
 1” OD tubes (do) (14 BWG) on 11/4 “ square pitch (PT)
 Outer dia of tubes= 1”
 Tube Length=16’
 Tube ID (di)= 0.834”

ii
 𝑇𝟐−𝑻𝟏 𝐭𝟐−𝐭𝟏
R= =0 S=𝐓𝟏−𝐭𝟏=0.42 FT =1 (Fig 14.4,Page 648, Plant design book)
𝒕𝟐−𝒕𝟏

Determining the heat transfer area (‘A’):

The value of overall heat transfer coefficient(Uo,assume) of 45 Btu/ hr ℉
𝑄
A=
𝑈𝑎𝑠𝑠𝑚∗𝐿𝑀𝑇𝐷∗𝐹𝑡
2080903.56
=45∗144.74∗1= 319.48 ft2
Calculating number of tuubes (nt):
𝐀
nt=
𝛑 𝐝𝐨 𝐋𝐭
𝟑𝟏𝟗.𝟏𝟖
nt= 𝟏 = 76.30
𝟑.𝟏𝟒∗ ∗𝟏𝟔
𝟏𝟐

Check the fluid velocity:

𝐧𝐩
𝟒 𝐦𝐭 ( )
𝐧𝐭
Re=
𝛑𝐝𝐢𝛍

𝟒∗𝟐𝟏𝟐𝟕.𝟗∗𝟐/𝟕𝟔
Re= = 30103.49
𝟑.𝟏𝟒∗𝟎.𝟖𝟑𝟒∗𝟎.𝟎𝟑𝟒𝟏
𝑹𝒆 𝝁𝒕
U=
𝒅𝒊ƒ

𝟑𝟎𝟏𝟎𝟑.𝟒𝟗∗𝟎.𝟎𝟑𝟒𝟏
U= 𝟎.𝟖𝟑𝟒∗𝟏.𝟒𝟒 = 10183.73 ft/hr

Hot Fluid: Outer Pipe (Steam) Cold Fluid: Inner Pipe

Tube side heat transfer coefficient(hi): Shell side heat transfer coefficient:
𝒉𝒊𝒅𝒊 µ𝒕 𝑪𝒕 -1/3 * 𝝁 -0.14 Assumptions:
Jh= ∗( ) ( )
𝒌 𝑲𝒕 µ
 25% segmental cut baffels
𝝁
( )=1  Baffle spacing, B=0.5 Ds=15.5’’
µ
𝟏 𝟏 𝛑
Jh=40 for tube side fluid at Re=30103.49 𝟒( ∗𝐩𝐭∗𝟎.𝟖𝟔∗𝐏𝐭− ∗ ∗𝐝𝐨𝟐)
𝟐 𝟐 𝟒
De= 𝟏
∗𝛑𝐝𝐨
𝐡𝐢∗𝟎.𝟖𝟑𝟒 𝟎.𝟎𝟑𝟒𝟏∗𝟐.𝟏𝟔 -1/3 𝟐
40= ( )
𝟎.𝟎𝟖𝟑 𝟎.𝟎𝟖𝟑 (Trinangular Pitch)

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hi =100 btu/hr ft ℉ 𝟏 𝟏 𝟑.𝟏𝟒
𝟒[ ∗𝟏.𝟐𝟓∗𝟎.𝟖𝟔∗𝟏.𝟐𝟓− ∗ ∗(𝟎.𝟎𝟖𝟑)𝟐]
𝟐 𝟐 𝟒
De= 𝟏 =
∗𝟑.𝟏𝟒∗𝟎.𝟎𝟖𝟑
𝟐
2.65ft

Shell side cross flow area:

𝐂𝐁𝐃𝐬
as=
𝐏𝐭

C=Pt-do
𝟎.𝟐𝟓 𝟏𝟓.𝟓 𝟑𝟏
∗ ∗
𝟏𝟐 𝟏𝟐 𝟏𝟐
as= =0.675ft2
𝟏.𝟐𝟓/𝟏𝟐

Mass Velocity

Gs=ms/as
= 2798.30 lb/hr ft2

Re=DeGs/𝝁
Re= 0.082*2798.30/1.46
15716
Jh=70 for shell side fluid at Re=15716
𝒉𝒊𝒅𝒊 µ𝒕 𝑪𝒕 -1/3 * 𝝁 -0.14
Jh= ∗( ) ( )
𝒌 𝑲𝒕 µ
𝝁
( )=1
µ

𝐡𝐨∗𝟎.𝟎𝟖𝟐 𝟎.𝟒𝟔∗𝟎.𝟐𝟕𝟓 -1/3

70= ( )
𝟎.𝟎𝟕𝟓 𝟎.𝟎𝟕𝟓

ho=76.21 btu/hr ft ℉

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Overall heat transfer coefficient(Uo,cal):
Rds=0.0002 h ft2 ℉ /Btu
Rdt=0.0002 h ft2 ℉ /Btu
Let brass material with thermal conductivity, Kw=70
1 Ao do−di 𝐴𝑜 1 Ao
Uo,cal=[
ℎ𝑜
+ Rds +
At
( 2kw
) + 𝐴𝑡 ∗ (hi) + At ∗ Rdt ]-1
1 3.14 0.0833−0.0695 3.14 1 3.14
Uo,cal=[
76
+ 0.0002 +
2.1840
( 2∗70
) + 2.1840 ∗ (100) + 2.1840 ∗ 0.002 ]-1
Ao=𝜋do2=3.14(1)2=3.14
At=πdi2=3.14(0.834)2=2.1840

Uo,cal=50.46 Btu/hr ft2 ℉

Uo,cal−Uo,assm
∗ 100=
Uo,ass

50.46−45
*100=16.9%≤ 30%
45

Therefore, the calculated overall heat transfer coefficient is well with in the design criteria.

Pressure drop calculations

Tube side pressure drop Shell side pressure drop

Friction factor=0.00022*144=0.03168 for Tube clearance, C=0.25”
Re=31103.49
Spacing, B=15.5”

v
at=(nt)*(flow area per tube)/(no of passes) as=0.675 ft2
76∗0.546 Mass velocity, Gs=2798.30 lb/hr ft2
at=
2∗144
Re=15716
at=0.144 ft2
No of baffels, nb =tube length/ baffle spacing
Gt=mt /at
nb=16/1.29
Gt=14776 lb/ hr ft2
=12.40
Frictional pressure drop:
Friction factor=0.0020*144=0.288 for
ƒ∗Gt2∗Lt∗np
∆Pt= Re=15716
7.5∗1012 ∗𝑑𝑖∗𝑆

0.03168∗(14776)^2∗2
∆Pt=
7.5∗1012 ∗0.0695∗0.8 Frictional pressure drop:
∆Pt=1.5 psi ƒ∗Gt2∗Lt∗(nb+1)
∆Ps=
7.5∗1012 ∗𝑑𝑒∗𝑆
Return loss:
0.288∗(2798.30)^2∗(13+1)
∆Ps=
7.5∗1012 ∗0.082∗0.685
∆Pr=1.33*10-13(2 np-1.5) Gt2/S
=3.21 psi
∆Pr=1.33*10-13(2*2-1.5) (14776)2/(0.8)
∆Pr=0 (in case of single shell pass flow)
∆Pr=0.91psi
∆PT=3.25 psi
∆PT=∆Pt +∆Pr

∆PT=1.5+0.91

=2.41Psi

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Over surface:

Over surface=Uc-Ucal /Uc

Clean overall coefficient, Uc=ho*hio / ho+hio
hio=hi * di/do
hio=100*0.834
hio=83.4
Uc=60.89

over surface=60.89-50/60.89
=18%

Specification Sheet
Identification
Item: Preheater (E-101)
Type: 1 shell and 2 tube pass heat echanger
Annulus Inner Pipe
Fluid: Hot Fluid: Cold
Utility: Steam Process Fluid: (C6H12O6+C12H22O11 + H2O)
Flow rate: 2127.79 lb/hr Flow rate: 1888.85 lb/hr
Temperature:2660F to 2660F Temperature:770F to 150.80F
Nominal pipe size: 1.25in. IPS Degmental cut baffles: 25%
ID: 0.834 in. B: 0.5
OD: 1 in Ds:15.5 in
∆Pa=2.41 psi De=0.082 ft
Area: 319.48 ft2 Rd=0.0002 hr.ft2.F/Btu
Number of tubes:76 ∆Pa=3.25 psi
Rd= 0.0002 hr.ft2.F/Btu

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