Process heat transfer Double pipe heat exchanger

Group members: Sannan salabat butt (2007-CHEM-19) Harris mehmood khan (2007-CHEM-99)

Discussion
Double

pipe heat exchanger Internal parts Diagrams Flow arrangements Calculations for L.M.T.D Advantages Limitations Comparison with conventional shall and tube heat exchanger Design types Cost estimation Numerical problems

HEAT EXCHANGER: Heat exchanger is a device in which two fluid streams , one hot & another cold are brought into thermal contact in order to effect transfer of heat from the hot fluid stream to the cold. DOUBLE PIPE HEAT EXCHANGER: A typical double pipe heat exchanger basically consists of a tube or pipe fixed concentrically inside a larger pipe or tube. OR Heat exchanger which are used when the flow rates of the fluids and the heat duty are small (less than 500 kW)

Construction of double pipe

Hair pin: union of two legs hairpin construction is preferred because it requires less space Packing & gland: The packing and gland provides sealing to the annulus and support the inner pipe. Return bend: The opposite ends are joined by a U-bend through welded joints. Support lugs: Support lugs may be fitted at these ends to hold the inner pipe position. Flange: The outer pipes are joined by flanges at the return ends in order that the assembly may be opened or dismantled for cleaning and maintenance. Union joint: For joining the inner tube with U-bend.

Contd.
Nozzles: small sections of pipes welded to the shell or to the channel which acts as the inlet or outlet of the fluids are called nozzles. Gaskets: Gaskets are placed between the two flanges to make the joint leak-free. Different types of gaskets
Used up to 110 oC for mineral oils, dilute mineral acids, and aliphatic hydrocarbons. Used up to 160 oC for mineral acids, or bases, aqeuous solutions or steam Used up to 100 oC for hydrocarbons and chlorinated hydrocarbons

Nitrile rubber. EPDM. (ethylene-propylene-diene monomer) Viton. ( copolymer of vinylidine flouride and hexafluoro-propylene)

Double Pipe Heat Exchangers

fluid flow passages & configuration

Basically there are two flow arrangements of double pipe heat exchanger: Co-current Counter current
Co-current counter current

configuration Series & parallel arrangement

Counter current max. heat transfer within minimum area due to more L.M.T.D Co-current Used for viscous fluids & gives lesser value of L.M.T.D Co & counter current gives same value of L.M.T.D if one of the fluid stream is isothermal (e.g steam) Series-parallel arrangement This configuration is used when value of pressure exceeds its limits (500psig shell side and 500 psig tube side) .pressure drop problem can be solved by: Reversing the location of streams By-passing one of the fluid streams Dividing of stream at higher pressure drop( series-parallel arrag.)

Log Mean Temperature evaluation T T1 TLn = 2 T2 ln T 1

1 CO CURRENT FLOW 2 1
T3
T1 T2

COUNTER CURRENT FLOW

2
T4 T6 T6 T2 T8 T9 T10

T1

Wall

T7

A
T10 T1 T4 T5 T2 T3 T6 T3 T8 T7 T9 Parallel Flow T1 T4

A
T10 T5 T2 T6

T1 = T T
in h

in c

= T3 T7

T7

T8

T9

T2 = Thout Tcout = T6 T10

T1 = T Tcout = T3 T7
in h
Counter - Current Flow

T2 = Thout Tcin = T6 T10

ADVANTAGES.

Compactness Very high heat transfer coefficients on both sides of the exchanger Close approach temperatures in counter-current flow Ease of maintenance. Heat transfer area can be added or subtracted with out complete dismantling the equipment. High pressure ranges (30 MPa shell side , 140 MPa tube side) High temperatures range (600 C)

CONTD..

Ease of inspection on both sides Ease of cleaning Low cost No Local over heating and possibility of stagnant zones is also reduced Fouling tendency is less low pressure loss Used for small applications

LIMITATIONS

It is not as cost effective as most shell and tube exchangers It requires special gaskets Limited volumetric capacity Fouling

Contd..
Fouling :formation of a scale or a deposit on a heat transfer surface is called fouling Types of fouling: Precipitation fouling ( due to dissolved salts of Ca & Mg ) Particulate fouling( due to suspended particles ) Corrosion fouling Chemical reaction fouling (due to deposits formed by chemical reactions) Bio fouling ( due to the attachment of bio chemical species ) Solidification fouling ( due to sub cooling of fluids )

Comparison with shell & tube heat exchanger

shell & tube heat exchangers are: designed to withstand the greatest temperature and pressure condition Ideal for large scale applications Commonly used in petrochemical industry where dangerous substances are present (protective shell) Consists of very bulky or heavy construction, baffles are used to increase mixing Subject to water hammer and corrosion High pressure loses

Design types
In case of any design equipment , the design of a heat exchanger may be divided into two parts.
Design types

Process design (Thermal design)

Mechanical design

Estimation of heat transfer area. Material of construction Determination of tube diameter. Thickness of tubes Number & length of tubes. Flanges, gaskets, support design Tube layout ( series or parallel ) Shell & tube side pressure drops.(hydraulic design)

Mechanical design
Double pipe Heat exchangers can be made with various materials: Carbon steel Alloy steels Copper alloys Exotic materials (tantalum)

Cost of heat exchanger

Some of the major factors which influence the cost of heat exchanger are : Heat transfer area Tube diameter and thickness Tube length Pressure of fluids Materials of construction Special design features ( finned surface,U-bends,removeable bundles e.t.c )

DESIGN STEPS WITH SOLVED EXAMPLE 1)Thermal design. 2) Hydraulic design.

ASSUMPTIONS

The heat exchanger operates under steady state conditions. No phase change occurs: both fluids are single phase and are unmixed. Heat losses are negligible The temperature in the fluid streams is uniform over the flow cross section. There is no thermal energy source or sink in the heat exchanger. The fluids have constant specific heats. The fouling resistance is negligible.

In thermal design we tabulate physical properties of: hot stream(Benzene) cold stream(Water)

Benzene(hot stream)
entering temp.= 75C Leaving temp.=50C average temp=62.5C Sp.heat=1.88 kJ/kg C Viscosity=0.37cP density = 860 kg./m3 thermal conductivity = 0.154 W/m K. Flow rate = 1000 Kg/hr

Water(cold stream)
entering temp.= 30C Leaving temp.=40C average temp=35C Sp.heat=4.187 kJ/kg C Viscosity=0.8cP density = 1000 kg./m3 thermal conductivity = 0.623 W/m K. Flow rate = ?

outer pipe spec.

i.d. = 41 mm o.d. = 48 mm. LMTD = ? Uo = ?

Inner tube spec.

i.d=21mm O.d=25.4mm Wall thickness=2.2mm thermal conductivity of wall=74.5 W/m K.

Selection of tube & pipe fluid & flow passage type

Flow rates Cannot be considered because water side flow rate is not given Flow areas Higher mass flow rate stream is passed through greater flow area which cannot be considered because we don't know which stream is of higher flow rate Tube side fluid As we know that water causes a lot of fouling and corrosion hence we will take water in the tube side in this way it would cause lesser damage to the heat exchanger. Pipe side/annulus side Benzene will be taken on annulus side Flow arrangement Counter current flow is selected because it reduces the required surface area

General design equation & steps

Q =Uo A (T)

Step 1: Calculate (T) LMTD Step 2: Calculate heat duty Q Step 3: Calculate overall heat transfer co-efficient on the basis of outer diameter of tube Putting all the three values will give us the required heat transmission area of double pipe. Such a problem in which we have to calculate size of heat exchanger is called sizing problem

Calculation of LMTD (step 1)

benzene 75 C water 40 C t1=75-40=35C 50 C 30 C t2=50-30=20C

L.M.T.D= (t1- t2) / Ln (t1/ t2) LMTD =(35 20)/Ln(35/20) = 26.8C

SOLUTION (a) 1000 kg of benzene is cooled from 75C to 50C per hour. Therefore, Heat duty (Q) = m Cp (T2-T1) = (1000 kg,/h)(1.88 kJ/kg C)(75 50)C = 47,000 kJ/h Heat given by the hot stream = Heat taken by the cold stream

Heat duty calculations(step 2)

Water is heated from 30C to 40C Therefore, Water flow rate = Q / Cp x (t2-t1) = 47000/(4187)(10) =1122 kg/h

overall heat transfer coefficient(step 3)

Calculate convective heat transfer coefficient for tube side (hi). Calculate convective heat transfer coefficient for shell side (ho). Outside surface area of tube (Ao) Inside surface area of tube (Ai ) Mean surface area (Am) 1/Uo=1/ho +(Ao/Am)x(ro-ri/kw)+Ao/Ai(1/hi)

Calculating hi( tube side water )

Velocity = volumetric flow rate / flow area =0.9 m/sec Reynolds number, Re = dvp/u = (21 x 10-3)(0.9)(1000)/8 x 10-4 =23,625 Prandtl number, Pr = Cpu/k =(4.187)(1000)(8 x 10-4)/0.623 = 5.37 Use of Dittus-Boelter equation to calculate hi, Nu = hidi/k = 0.023(Re)0.8(Pr)0.3 = (0.023)(23,625)0.8 (5.37)0.3 =120 Thus,hi=120x(k/di)=35660W/m2C

Calculating ho( annulus side

for annulus calculation we calculate hydraulic diameter benzene )inner cross-section of the pipe - outer cross-section of the Flow area annulus =
tube

= Pi/4(iD2) - Pi/4(OD1)=8.13x10-4 m2

wetted perimeter= Pi(iD2+OD1)=0.2086m hydraulic diameter of annulus dh=4 x ( flow area/wetted perimeter) =0.0156m

Contd
Benzene mass flow rate = 1000 kg/h Benzene volumetric flow rate = (1000)/(860) = 1.163 m 3/hr Velocity = volumetric flow rate / flow area = 0.397 m/s Reynolds number, Re = dvp/u = 14395 Prandtl number,Pr = Cpu/k = 4.51 Calculation of ho from the Dittus-Boelter equation
Nu = hodi/k = 0.023(Re)0.8(Pr)0.3 =(0.023)(14395)0.8(4.51)0.4 = 89.12

ho = (89.12 x k/dh) = 879.8W/m2C

Contd
outside area of tube = A0 = OD L = (0.0254)(L) inside area of tube = Ai = ID L = (0.021)(L) Am = (OD-ID) / Ln (OD/ID) = (0.0254 - 0.021)(L)/ Ln (0.0254/0.021) = 0.023 (L) A0/Am = 1.098 A0/Ai = 1.21 1/Uo=1/ho +(Ao/Am)x(ro-ri/kw)+Ao/Ai(1/hi) Uo = 662.3W/m2K

Length of double pipe

Now calculate the required area from Q = UoAoTm Q = 1122 kg/h Uo = 662.3W/m2K Tm= 26.8 C Ao = Q / UoTm= 0.74m2 Tube length necessary, L = Ao / OD1 L = 0.74 / (0.0254) = 9.3 m where,

Hydraulic design

In hydraulic design involves calculations of pressure drop on: The pipe side (annulus side) The tube side

Contd

P = f G2 L / 2 g p Di
Where, F = friction factor G = mass velocity of the fluid L = length of the tube G =9.8m/s2 p = density of tube fluid Di = inside diameter of tube = dimensionless viscosity ratio P =pressure drop

P( tube side ) = 1.476 x 10-4 kgf/m2 P( pipe /annulus side ) = 2.50 x 10-4 kgf/m2

Calculation on software

Auto-cad design (2D & 3D)

DESIGN PROBLEM : Double Pipe Heat Exchanger

Double pipe lube oil crude oil exchanger:6900lb/hr of

26 API lube oil must be cooled from 450 to 350F by 72500lb/hr of 34 API mid continent crude oil. The crude oil will be heated from 300 to 310F. stream, and the allowable pressure drop on each stream will be 10psi.

A fouling factor of 0.003 should be provided for each

CONTINUED

A number of 20-ft hairpins of 3 by 2inch IPS are

available. How many must be used, and how shall they be arranged? The viscosity of crude oil may be obtained from graph. For the lube oil, viscosities are 1.4cp at 500F, 3.0 at 400F and 7.7 at 300F. These are enough to introduce an error if (u/uw)0.14=1 is assumed.

GIVEN DATA:

Lube Oil:
Mass flow rate=wL=6900lb/hr 26 API Entering temp.=450F Leaving temp.=350F Viscosity =3.0cp at 400F

Crude Oil:
Mass flow rate=wc=72500lb/hr 34 API Entering temp.=300F Leaving temp.=310F Viscosity = use graph

(1)HEAT DUTY CALCULATION :

For lube oil: Q=Wcp(T1-T2)

=6900x0.62(450-350) cp(graph) =427000Btu/hr

. For crude oil:

Q=wcp(t2-t1)
=72500x0.585(310-300) =427000Btu/hr cp(graph)

(2)a LMTD Calculation:

LMTD = ( t)a- ( t)b/ln ( t)a/ ( t)b

( t) = 87.5 F

It will be impossible to put the 72,500lb/hr into single pipe or annulus, since the flow area of each is too small. Assume it will be employed in two parallel streams.

(2)bTemperature difference ( t):

Hot fluid 450 F 350 F _ Temp. Higher temp. Lower temp. _ Cold fluid 310 F 300 F _ Diff. 140 F ( t)a 50 F ( t)b 90 F ( t)a - ( t)b

Concept of caloric temperature:

In our problem we are given with petroleum fractions so we wont use arithematic temperatures for evaluating physical properties. As in case of petroleum fractions, there viscosities show sharp variations with temperature and also overall heat transfer coefficient doesnt remain constant. That is why we will use average caloric temperature for evaluating physical properties like viscosity, specific heat etc

(3)Caloric temperatures:

( t)c/ ( t)h =50/140

= 0.357

Kc factor =0.43 caloric temp. fraction (Fc) =0.395 (graph)

Tc=350x0.395(450-350)=389.5 F tc =300x0.395(310-300)=304 F

Basic objective:

In order to calculate clean overall heat transfer coefficient Uc , we require two things. ho ( from annulus) lube oil hio (from inner pipe) crude oil Since Uc=hio xho/hio +ho

Concept of outer and inner diameter:

We will always take inner diameter of inner pipe while calculating the flow area in tube. In case of annulus inner diameter of outer pipe and outer diameter of inner pipe (equivalent diameter) is considered.. table

Flow area calculations:

Hot fluid (annulus) D2 =3.068/12 =0.256ft D1 =2.38/12 =0.199ft aa = 3.14(D22-D12)/4 =0.0206ft2 Equivalent dia. De=(D22D12)/D1 = 0.13ft

Cold fluid (inner pipe) D =2.067/12=0.172ft ap =3.14D2/4 =0.0233ft2 Since two parallel streams have been assumed so half will flow in each pipe.

Mass velocity calculations:

Ga=W/aa =6900/0.0206 =335000lb/hrft2 At Tc=389.5F =3.0cp =3x2.42=7.25lb/hrft Rea=DeGa/=0.13x33500 0/7.25=6000 If only two hairpins in series are required,L/D will be 2x40/0.13=614 Use L/D=600 jH=20.5

Ga=w/ap =72500/ (2x0.0233)=1560000lb/hrf t2 At tc=304F, =0.83cp Rep=DGp/ =0.172x1560000/2.01=13 3500 jH=320

Calculation of hio and ho :

Tc=389.50F , C=0.615Btu/lbF (graph) K=0.067Btu/hrft2(F/ft) (graph) Pr=(c/k)0.33=(0.615x7.2 5/0.067)0.33=4.05

tc =304F c=0.585Btu/lbF (graph) K=0.073Btu/hrft2(F/ft) (graph) Pr=(c/k)0.33=(0.585x2.0 1/0.073)0.33=2.52

Continued

ho= jHxk/De(c/k)0.33xa
ho/a =20.5x0.067x4.05/0.13 =42.7btu/hrft2F
tw=tc+ (ho/a)/(hio/p)+ (ho/a)x(Tc-tc)

hi= jHxk/D(c/k)0.33x p hi/p =

320x0.073x2.52/0.172= 34btu/hrft2F (hio/p)=(hio/p)x(ID/ OD) =342x2.067/2.38=297

Continued.

tw=304+42.7/ (297+42.7)x(389.5-304) =314F w=6.6x2.42=16lb/fthr a=(/w)0.14=0.9 ho= ho/a xe =38.4

As tw is calculated w=0.77x2.42=1.86 p=(/w)0.14=1.0 ho= hw/p xw =297x1.0=297

Clean overall & design overall co-efficient.

Uc=(hioxho)/(hio ho)=297x38.4/
(297+38.4)=34.0btu/hrft2F

38.4 Uc Ud

h (outside) 297 34 28.2 -----

1/Ud=1/Uc+Rd Rd
=0.003x2=0.006hrft2F/Btu Ud=28.2

Surface area.

A=Q/(Udxt)=173ft2
External surface per unit ft=0.622ft Required length=173/0.622=278lin ft This is equivalent to more than six 20-feet hairpins or 240 lin ft. since two parallel streams are employed, use eight hairpins or 320 lin ft. The hairpin should have the annuli connected in series and the tubes in two parallel banks of four exchangers. the corrected Ud will be =24.5.the corrected dirt factor will Rd =1/Ud1/Uc=0.0114

Pressure drop calculations :

De = D2 D1 = 0.058 ft Rea=( De x Ga ) /u =2680 f = 0.0035+0.264/26800.42 s =0.775 , p=62.5x0.775 = 48.4

For Rep =133500 f = 0.0035 + 0.0264/1335000.042 = 0.005375 s = 0.076 ,p = 62.5x0.76 =47.5

Continued

Fa = 4f Ga2La / 2Gp2De
=16.07 ft

V=Ga / 3600 x p
= 1.9 fps Fl =8(v2 /2G)

=0.45 ft Pa= (16.7 + 0.45) x 48.4 /144 =5.8 Psi Allowable pressure drop =10Psi

Fp = 4f Ga2La / 2Gp2De =25.7 ft Pp = 25.7 x47.5/144 = 8.5 Psi Allowable pressure drop =10Psi

Graphical interpretation:

Pressure drop description:

Designed double pipe heat exchanger:

Configurated heat exchanger:

Double pipe heat exchange software calculations:

Software calculations :

Continued

Continued.

Industrial setup flow sheet of double pipe heat exchanger:

Process description:

Inner outer diameter description:

Double pipe description:

OD of pipe

ID of pipe
OD of tube

ID of tube

Graphical interpretation:

Pressure drop description:

Industrial setup flow sheet of double pipe heat exchanger:

Process description:

Books references

Donald .Q. Kern (1950) ,heat transfer & applications ( 2nd Design problem ) Binay K.Datta,heat transfer principles and applications ( 1st Design problem ) Max S. Peters, Klaus D.Timmerhaus,Ronald E.West ,plant design and economics for chemical engineers (fifth edition) Yunus A.Cengel,Heat & Mass transfer,a practical approach (third edition) Y.V.C Rao , heat transfer principles Incropera,F.P.,Dewitt D.P., Fundamentals of Heat and Mass Transfer, 5th ed.,John Wiley & Sons Inc., NY,2000 Kaka S. Heat exchangers selection, rating & thermal design CRC Press, Fla, 1998

Internet references

http://chentserver.uwaterloo.ca/courses/Che025Lab/perry/Chap 11.pdf http://en.wikipedia.org/wiki/Heat_exchanger#Flow_arrangement http://www.advantageengineering.com/fyi/110/advantageFYI110 .php http://www.buildingdesign.co.uk/mech/guntner/dry-aircoolers.htm http://www.engineeringpage.com/heat_exchangers/tema.html http://www.martechsystems.com/downloads/tech_managingre boilerops.pdf http://www.me.wustl.edu/ME/labs/thermal/me372b5.htm http://www.pacificconsultant.net/compact_heat_exchanger.htm http://www.rwholland.com/hairpin.htm http://www.taftan.com/thermodynamics/EXCHANGE.HTM http://www.thomasnet.com/about/exchangers-heat-shell-tube26641001.html

Any question.