Process Design of Condenser

The following is the detailed design of the total condenser for the Distillation

column. The condenser is operated at the same pressure as that of the column. The vapor

from the column is condensed and sent as reflux and product. Any changes in

compensation are neglected. The optimization of the condenser is done in several

iterative steps. The final trial is presented here. The design methods used here are from

Chemical Engineering by Coulson and Richardson, vol.6

Shell side

Feed = 41.34 kmol/hr

Average molecular weight Mf = 32.00

T = 301.8 K = 28.8 °C

Mass flow rate = 1322.90 kg/hr

Latent heat of vaporisation, ∆HV = 1197.0 kJ/Kg (From literature)

Heat Load, Q = mλ = 1583506.70 KJ/hr (or) 439.86kW

Tube Side

Cooling water at 35 °C

1. Heat Balance

Heat load = Q = 1583506.70 = m (4.184)(50-35)

m = 25231.15 kg/hr, where m is the cooling water flow rate.

2. LMTD

LMTD = ((28.8 – 35)-(28.8-50))/ln((28.8-35.0)/(28.8-50)) = 51.29 °C

3. Heat transfer area.

Choose the overall heat transfer coefficient (U) as 500 W/(m2K)

Q = UA(LMTD)

A = 439.86/(500X51.29)

A = 17.19 m2

4. Tubes

Choose 1” OD, 16 BWG tubes of 6ft length laid in a 1.25” Square pitch

Tube OD = 25.4 mm

Tube ID = 22.098 mm

Flow Cross sectional area = 3.8353x10-4 m2

Surface area/tube = 2*3.14*0.0254/2*6*0.030 = 0.1459 m2

Number of tubes (Nt) = 17.19/0.1459 = 118 tubes

Bundle diameter Db = OD (Nt/k) 1/n

K = 0.156; n = 2.291

Bundle diameter Db = 458.5 mm

For a TEMA 1-2 exchanger with tube pitch = 1.25 (OD),

Number of tubes in the central row (Nr) = 2/3(Db/pt) = 2/3(458.5/ (1.25X25.4)) = 9.627

Say, Number of tubes in the central row (Nr) = 10.0

5. Shell side film transfer coefficient

The film temperature Tf is evaluated by an iterative procedure by first assuming a

film coefficient and recalculating the film coefficient using the film temperature.
The shell side film transfer coefficient is calculated by using a modified Nusselt’s

equation:

Mass flow rate per unit length (Γh) = m / (L.Nt)

= 25231.15 / (3600 x 1.83 x 118)

= 3.2456 X10-2 kg/ (m.s)

Film transfer coefficient (hC)

hC = 0.95kL[ρL(ρL-ρV)g / (µΓh)]1/3Nr-1/6

= 0.95X 0.1935 [787.0 (787.0 -0.2428) 9.81/(4.4 x10-3 x 3.2456 X10-2 )]1/310-1/6

= 437.16 W/ (m2K)

6. Tube Side Heat Transfer Coefficient

Tube velocity (ut) =7.00 /(1000x3.8353 x10-4 x118/2)

= 0.309 m/s

Tube side coefficient, hi

hi = 4200(1.35+ 0.02 Tav) ut0.8 / di0.2

= 4200 (1.35 + 0.02 x 42.5) * (0.309)0.8 /(22.098) 0.2

= 1944.32 W/(m2 K)

7. Overall Heat Transfer Coefficient

Assuming dirt coefficient as 6000 W/(m2K) for both sides and k(wall) = 50 W/mK
1/U = 1/4371.16 + 1/6000 + 25.4 x 10 – 3 ln (25.4 / 22.098) / 100 + 25.4 / (22.098 x 6000)
+ 25.4 / (22.098 x 1944.32)
U = 824.02 W/(m2K)
8. Pressure drop in tube side
Reynold’s number
Re = 22.098 x10-3 x 0.309 x 1000 / (5.44 x10-4)
= 12552
Friction factor, jH = 3.8 x10-3
Pressure drop, ∆Pt
∆Pt = NP [8 jH (L/D)+2.5] ρ ut2/2
= 2 [8 x 3.8 x10-3 x1.83 / (22.098 x10-3)+2.5] (787 x 0.309 2/2)
= 1.657 kPa
Pressure drop is acceptable.
9. Shell side pressure drop
Select baffle spacing (lb) = shell diameter, baffles 45% cut
For TEMA Pull-Through Floating Head Heat Exchanger,
Clearance = 93 maintenance
Shell diameter = Ds = 608.15 mm
Cross Flow area:
As = (pt-Do) Ds lb / pt
= (1-1/1.25)(0.6081)(0.6081)
= 0.074 m2
Equivalent diameter:
d = 1.27/Do (pt2- 0.6081Do2)
= 1.27/25.4 x [(1.25 x 25.4)2- 0.608(25.4)2]
= 30.79 mm
Mass flux:
GS = m /As = 1322.90/ (3600 x 0.074) = 4.97 kg / (m2s)
Reynold’s number:
Re = dGS/ (Asµ)
= 30.79 x 4.97 / (0.074 x 8.0 x 10-4)
= 2584903.7
From the correlation, friction factor
jf = 2.5 x 10-3
Vapor velocity:
us = GS/ρV
= 4.97 / 0.2428
= 20.46 m/s
Pressure drop:
∆PS = 8jf(DS/d)(L/lb)ρuS2/2
= 8 x 2.5 x 10-3 (608.1 / 25.0806) (1.83 / 0.6081) 0.2428 x 20.462/2
= 1.80 kPa
Summary of Condenser design
Shell outer diameter = 608 mm
Bundle diameter = 458.5 maintenance
Number of tubes = 118
Tube OD = 1”
Pitch = 1.25”
Tube length = 6ft
Shell side pressure drop = 1.80 kPa
Tube side pressure drop = 1.657 kPa
Condenser type: TEMA Pull-Through Floating Head 1-2 Heat Exchanger
Mechanical Design of Condenser
Design Temperature = T = 100 °C
Design pressure = 0.1 N/mm2 (external)
Number of tubes = 118
Bundle diameter = 458.5 mm
Shell diameter = 608 mm
Baffles: Spacing= 608 mm, 45% cut