Condenser

engineering-resource.
com
Group Members
M.Rizwan Qureshi
2006-Chem-60
Ch Aamir Rafiq
2006-Chem-72
Ch Awais Ahmad
2006-Chem-74
engineering-resource.com
Topic:
Condensation
(A Rating Problem)
Common Discussion
Condensation is the process by which a vapor
is converted to its liquid state. Because of
the large internal energy difference between
the liquid and vapor states. A significant
amount of heat can be released during the
condensation process. For this reason, the
condensation process is used in many
thermal systems. In general, a vapor will
condense to liquid when it is cooled
sufficiently or comes in contact with
something (e.g., a solid or another fluid) that
is below its equilibrium temperature.
CONDESER:
Heat exchangers used to liquify vapors
by removing their latent heats are
called condenser. The latent heat is
removed by absorbing it in a cooler
liquid called coolant.
Normally cooling water is used for this
purpose.
CLASSIFACTION
Condensers fall into two classes.
In the first, called shell and tube
condensers, the condensing vapors
and coolant are separated by a tubular
heat transfer surface.
In the second, called contact
condenser the coolant and vapor
streams both are physically mixed and
leave the condenser as single stream.

SHELL AND TUBE CONDENSER:

CONTACT CONDENSER:

PROBLEM STATEMENT:
A horizontal 1-2 condenser is required for the
condensation of 60,000 lb/hr of substantially
pure n-propanol (propyl alcohol) coming
form the top of distillation column operating
at 15 psig at which pressure it boils at
244F.Water at 85F will be used as a cooling
medium a dirt factor of 0.003 is required
with allowable pressure drops of 2.0 psi for
the vapor and 10 psi for the water. Because
of the location of condenser assume that 8
tubes are used, tubes are to be OD,
16BWG on 15/16 triangular pitch.
SOLUTION:
DATA:
SHELL SIDE:
Hot Fluid: n-propanol
MFR=60,000lb/hr
Boiling temp=244
0
F
Operating pressure=15psig
TUBE SIDE:
Cold Fluid: Cooling water
Inlet temp=85
0
F
Length of tube=8ft
OD=3/4
Thickness=16BWG
Triangular pitch of 15/16
STEP No:1
Calculation of Heat Duty:
For Hot Fluid:
Q= m(Given in literature)
Q=60,000*285
Q=17,100,000 BTU/hr
For Cold Fluid:
Q=mCpT
m=Q/Cp*T
=17100,00/1*(120-85)
=488,000 lb/hr
STEP No :2
LMTD (Log Mean Temp Difference)
Calculation:

Hot Fluid Cold
Fluid
Difference
244 Higher
Temp
120 124
244 Lower Temp 85 159
LMTD=(Higher temp diff)-(lower temp diff)
/Ln (higher temp diff/lower temp diff)
=159-124/ln(159/124)
=141
0
F

Here we assume counter current flow and
shell side fluid is isothermal.
STEP No :3
Design Overall Coefficent:
Av.temp of water ,Ta=85+120/2
=102.5 F
Now assume
Ud=100
Overall heat transfer area will be then
A=Q/Ud*LMTD
=17,100,000/100*141
=1213 ft.sq

Number of tubes=Total H.T area/ H.T
area per tube
=1213/8*0.1963
=773
Assume 4 tube passes, quantity of
water is very large but condenser will
have a large number of tubes,
making 2 passes assumption is
inadequate.

Now from table with 4 tube
passes,3/4OD,16BWG and 15/16
triangular pitch, the nearest number
of tubes is 776, 31 ID Shell.
A=N*d(l)
=766*8*0.1963=1205 ft.sq
So corrected Ud will be
Ud=Q/A*LMTD
=17,100,0000/1205*141
=101 BTU/ft.sq*F


STEP NO :4
TUBE SIDE CALCULATION:
Flow area per tube
At=0.302inch.sq(from table)
Flow area for all tubes
At=NtAt/144n
=766*0.302/144*4
=0.402 ft.sq
Mass velocity
Gt=w/At
=488,000/0.402
=1,210,00 lb/hr*ft.sq



Velocity
V= Gt/3600
=1,210,000/3600*62.5
=5.42 ft/s
At 102.5 F
=0.72*2.42=1.74 lb/fthr
ID=0.620/12=0.0517 ft (From table)




Re=ID*Gt/
=0.0517*1,210,000/1.74
=36,200
Now
hi = 1300 (from figure)
hio =hi *ID/OD
=1300*0.62/0.75
=1075 BTU/hr F ft.sq

Shell Side Calculations:
SHELL SIDE FILM COEFFICENT:
Assume maximum baffle spacing that
will be 31 and number of baffles
would be 2 and 3 crosses for side-to-
side flow.
Area of shell will be
As=ID*CB/144Pt
=31*0.1875*31/144*0.937
=1.34 ft.sq
Mass velocity
Gt=W/As
=60,000/1.34
=44,700 lb/hr ft.sq
Loading G=W/L*(Nt^2/3)
=60,000/8*(766^2/3)
=89.3 lb/hr linear ft
Assume ho=200
hio=1075(calculated in tube side)
Tw=ta+ho/(hio+ho)*(Tv ta)
=102.5+200/1275(244-102.5)
=125 F
Tf=(Tv+tw)/2
=(244+125)/2
=184.5 F
Kf=0.094 BTU/hr ft.sq (F/ft)
Sf=0.80
f=0.62 cp


Now from the graph we get
ho =172 BTU/ hr ft.sq F
Now we make another iteration and
assume ho =172 rather than 200 as
we did previously but it is not
necessary here bcoz condensate
properties will not change materially.


STEP No :5
Pressure Drop Calulations:

On Tube side:
For Re=36,200
f = 0.0019 ft.sq(from figure)
P=fGt
2
nL/5.22*10
10
*D*s*t

=0.00019*1.210,000^2*8*4/(5.22*10^
10*0.0517*1*1)
=3.3 psi


Return losses
Pr=(4n/s)(v
2
/2g)
=(4*4/1)0.20
=3.2psi
Total tube side pressure drop
P= Pt + Pr
=3.3+3.2
=6.5 psi
SHELL SIDE:

At Tv=244F
v
=0.010*2.42
=0.0242 lb/hr ft
D
e
= 0.55/12=0.0458 ft (from figure)
R
e
=DsGs/
=0.0458*44,7700/0.0242
=84600
f=0.00141 ft.sq /in.sq (from figure)
No. of crosses, N+1=3
Mol.wt of n-Propanol=60g/gmoles
Density,=60/359(704/492)(14.7/297)
=0.238 lb/ft
3
Specific gravity
s= 0.238/62.4=0.00381
D
s
=31/12=2.58 ft


Ps=f*Gs
2
*Ds(N+1)/2*5.22*10
10
*De
*s
=0.0014*44,7700^2*2.58*3/2*2.52
2*10^10*0.0458*0.00381
=1.2 psi
STEP No :6
CLEAN OVERALL COEFFICiENT:
Uc=hio*ho/(hi
o
+ho)
=1075*172/(1075+172)
=148.5 BTU/hr ft.sq F

STEP No :7
DIRT FACTOR:
Rd=Uc-Ud/Uc*Ud
=148.5-101/148.5*101
0.0032 hr ft.sq F /BTU
Conclusion:

Uc=148.5
Ud=101
Rd calcluated=0.0032
Rd required= 0.003
172 Film
Coefficient
1075
1.2 Calculated P

6.5
2.0 Allowable P

10.0

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