Heat Exchanger Thermal Design Hetran 11.

1 Page 1
File: HE-101 - Main condenser.BJT Date: 7/22/2016 Time: 7:04:44 AM
Description
Heading
Company: Harman fino Chem
Location:
Service of Unit: Main condenser Our Reference: Rajasekhar
Item No.: HE-101 Your Reference:
Date:01.12.10 Rev No.: 00 Job No.:
Hot Side Cold Side
Fluid name Methanol+ Water water

Remarks

Application Options
Hot side application Narrow range condensation
Condensation curve Specified in input
Condenser type Normal

Cold side application Liquid, no phase change

Vaporization curve Specified in input
Vaporizer type Forced circulation

Location of hot fluid Shell side

Program mode Design

Process Data
Hot Side Cold Side
In Out In Out
Fluid quantity, total kg/h 1784
Vapor quantity kg/h 1784
Liquid quantity kg/h 1784
Temperature C 64.83 64.83 35 40
Dew / Bubble point C 64.83
Operating pressure (absolute) mmHq 760 1471.1

Heat exchanged kcal/h

Allowable pressure drop kgf/cm2

Fouling resistance ft2*h*F/BTU 0.001 0.003

Heat Load Balance Options Program Program

Databanks

Hot Side Use properties from the following:

Cold Side Use properties from the following:

Aspen Plus or Aspen Properties run file

Hot side composition specification Weight flowrate or %

Cold side composition specification Weight flowrate or %
Heat Exchanger Thermal Design Hetran 11.1 Page 2
File: HE-101 - Main condenser.BJT Date: 7/22/2016 Time: 7:04:45 AM
Hot Side - Component
Components Source Vapor in Liquid in Liquid out Component
type
Methanol Databank 100 Program
Water Databank 0 Program

Hot Side - Liquid Properties

Temperature Specific heat Thermal Viscosity Density Surface
cond. tension

C kcal/(kg*C) kcal/(h*m*C) cp kg/m3 dynes/cm

Heat Exchanger Thermal Design Hetran 11.1 Page 3
File: HE-101 - Main condenser.BJT Date: 7/22/2016 Time: 7:04:45 AM
Hot Side - Vapor Properties
Temperature Specific heat Thermal Viscosity Density Molecular Diffusivity
cond. weight
C kcal/(kg*C) kcal/(h*m*C) cp kg/m3 m2/s

Cold Side - Component

Components Source Liquid in Vapor in Vapor out Component
type
Water Databank Program
Heat Exchanger Thermal Design Hetran 11.1 Page 4
File: HE-101 - Main condenser.BJT Date: 7/22/2016 Time: 7:04:45 AM
Cold Side - Liquid Properties
Temperature Specific heat Thermal Viscosity Density Surface
cond. tension
C kcal/(kg*C) kcal/(h*m*C) cp kg/m3 dynes/cm

Exchanger Type
Front head type B - bonnet bolted or integral with tubesheet
Shell type E - one pass shell
Rear head type M - bonnet
Exchanger position Horizontal

Front cover type Program Rear cover type Program

Cover welded to a cylinder Program Cover welded to a cylinder Program
Shell cover type Program

Tubesheet type Program Flange type - hot side Program

Tube to tubesheet joint Program Flange type - cold side Program
Include expansion joint Program

Tubes
Tube type Plain Fin height mm
Tube outside diameter 19.05 mm Fin thickness mm
Tube wall thickness 1.6 mm Fin density #/m
Tube wall specification Average Surface area per unit length m
Tube material Carbon Steel Outside/Inside surface area ratio
Tube pattern Triangular
Tube pitch 32 mm

Twisted tape ratio

Twisted tape width mm
Tapered tube ends for knockback condensers
Heat Exchanger Thermal Design Hetran 11.1 Page 5
File: HE-101 - Main condenser.BJT Date: 7/22/2016 Time: 7:04:45 AM
Bundle

Pass layout Program will optimize Open space between shell ID and outermost tube
Impingement protection type Program PercShellID Distance
Outer tube limit diameter mm at top, S1 mm
at bottom, S2 mm
at sides, S3 mm
Pool boiler options
Provide disengagement space in shell 1
Percent of shell diameter for disengagement

Shell entrance construction Normal with full layout

Shell exit construction Normal with full layout

Diametric clearances Design symmetrical tube layout

Shell ID to baffle OD mm Maximum % deviation in tubes per pass
Baffle OD to outer tube limit mm Number of tie rods
Baffle tube hole to tube OD mm Number of sealing strip pairs
Pass partition lane width mm Minimum u-bend diameter mm

Baffles
Number of intermediate supports
Baffle type Single segmental
at inlet
Baffle cut (% of diameter) 30
at outlet
Baffle cut orientation Horizontal

Number of supports at u-bend

Rating/Simulation

Shell outside diameter mm Kettle outside diameter mm

Shell inside diameter 650 mm Kettle inside diameter mm
Baffle spacing center-center 250 mm
Baffle spacing at inlet 400 mm Vapor belt outside diameter mm
Baffle spacing at outlet mm Vapor belt inside diameter mm
Baffle number Vapor belt length mm
Tube length 2000 mm
Tube number 308 Shell cylinder thickness mm
Tube passes 4 Front head cylinder thickness mm
Shells in series Front tubesheet thickness mm
Shells in parallel Rear tubesheet thickness mm
Baffle thickness mm

Nozzles
Diameter Quantity Orientation Dome OD
mm mm
Hot Side Inlet
Hot Side Outlet
Hot Side Condensate
Cold Side Inlet
Cold Side Outlet
Heat Exchanger Thermal Design Hetran 11.1 Page 6
File: HE-101 - Main condenser.BJT Date: 7/22/2016 Time: 7:04:45 AM
Nozzles
Hot Side Cold Side
Nozzle flange rating Program Program
Nozzle flange type Program Program

Flow direction for first tube pass Countercurrent

Location of nozzle at u-bend Program

Design Constraints
Increment Minimum Maximum
Shell diameter mm
Tube length 2000 mm
Tube passes Program
Baffle spacing 250 250 mm

Use shell ID or OD as reference Program Allowable number of baffles Program

Use pipe or plate for small shells Program Allow baffles under nozzles Program
Minimum shells in series Use proportional baffle cut Program
Minimum shells in parallel

Hot Side Cold Side

Allowable pressure drop kgf/cm2 kgf/cm2
Minimum fluid velocity 6.2 m/s m/s
Maximum fluid velocity 6.2 m/s m/s

Minimum % excess surface area required

Materials
Cylinder - hot side SS 304
Cylinder - cold side Carbon Steel
Tubesheet SS 304
Double tubesheet (inner)
Baffles SS 304
Tube material Carbon Steel

Thermal conductivity of tube material kcal/(h*m*C)

Tubesheet cladding - hot side

Tubesheet cladding - cold side
Gaskets - hot side
Gaskets - cold side

Specifications
Hot Side Cold Side
Design Code ASME Code Sec VIII Div 1 Design pressure kgf/cm2
Service class Normal Design temperature C
TEMA class B - chemical service Vacuum design pressure kgf/cm2
Material standard ASTM Test pressure kgf/cm2
Dimensional standard ANSI - American Corrosion allowance mm
Heat Exchanger Thermal Design Hetran 11.1 Page 7
File: HE-101 - Main condenser.BJT Date: 7/22/2016 Time: 7:04:45 AM
Thermal Analysis Options
Hot Side Cold Side
Heat transfer coefficient kcal/(h*m2*C)
Heat transfer coefficient multiplier 0.8 0.8
Pressure drop multiplier 1.2 1.2

Percent of u-bend area used for heat transfer

Maximum rating for thermosiphons Program

Mean temperature difference C

Minimum allowable temperature approach C
Minimum allowable MTD correction factor
Maximum allowable heat flux kcal/(h*m2)
Flow direction for first tube pass Countercurrent

Desuperheating heat transfer method Program

Condensation heat transfer model Program
Suppress nucleate boiling coefficient
Minimum temperature difference for nucleate boiling C
Tube side two phase pressure drop correlation Program
Simulation mode area convergence tolerance
Number of calculation intervals
Type of interval calculation Program

Change Codes
Heat Exchanger Thermal Design Hetran 11.1 Page 8
File: HE-101 - Main condenser.BJT Date: 7/22/2016 Time: 7:04:45 AM
Thermal Details - General

Shell Side Tube Side

Gases (in/out) kg/h 1784
Liquids (in/out) kg/h 1784 93535 93535
Temperature (in/out) C 64.83 64.83 35 40
Dew point or bubble point C 64.83

Film coefficient kcal/(h*m2*C) 1741.7 6337

Fouling resistance m2*h*C/kcal 0.0002 0.00061
Velocity m/s 5.42 2.02
Pressure drop (allow./calc.) kgf/cm2 0.052 0.01 0.703 0.371

Total heat exchanged kcal/h 467811 Type BEM hor 1 ser 1 par
Overall coef. - dirty kcal/(h*m2*C) 569.4 Shell size 598 2000 mm
Effective surface area m2 30.5 Tube No-OD 262 19.05 mm
MTD corrected C 27.25 Baffles single seg 29 % hor
MTD correction factor 1 Tube passes 4 quad

Thermal Details - Thermal Resistances

Clean Spec. foul Max. foul

Area reqd. m2 14 30.1 30.5

Excess surface % 118.28 1.05

Overall coefficient kcal/(h*m2*C) 1229.9 569.4 563.5

Overall resistance m2*h*C/kcal 0.00081 0.00176 0.00178

Shell side fouling m2*h*C/kcal 0.0 0.0002 0.00021

Tube side fouling (at tube ID) 0.0 0.00061 0.00063

Distribution of overall resistance

Shell side film % 70.62 32.69 32.35
Shell side fouling % 0.0 11.66 11.77
Tube wall 0.00005 % 6.06 2.8 2.77
Tube side fouling % 0.0 42.05 42.42
Tube side film % 23.33 10.8 10.69
Heat Exchanger Thermal Design Hetran 11.1 Page 9
File: HE-101 - Main condenser.BJT Date: 7/22/2016 Time: 7:04:46 AM
Thermal Details - Coefficients

Shell Side Tube Side

Film coefficients kcal/(h*m2*C)
As calculated by program 2177.2 7921.2
As specified by user in input
User specified multiplier 0.8 0.8
As used in design 1741.7 6337
Desuperheating coefficient
Condensing coefficient 1741.7
Vapor sensible coefficient
Liquid sensible coefficient 6337
Boiling coefficient
Liquid cooling coefficient

Reynolds number 166.68 46471.18

Fin efficiency factor 1
Mean metal temperature C 64.83 52.33

Thermal Details - MTD and Flux

Mean temperature difference C Flux kcal/(h*m2)

Corrected MTD used in design 27.25 Actual flux 15356

LMTD Boiling fluid

MTD correction factor
Long. baffle efficiency factor
Calculated corrected MTD
User specified corrected MTD
Flow direction
1 Nucleate maximum flux
Program maximum flux
27.25 Specified maximum flux
Controlling maximum flux
Heat Exchanger Thermal Design Hetran 11.1 Page 10
File: HE-101 - Main condenser.BJT Date: 7/22/2016 Time: 7:04:46 AM
Thermal Details - Pressure Drop

Shell Side Tube Side

Pressure Drop kgf/cm2

Allowable 0.052 0.703
Calculated, clean 0.01 0.371
Calculated, dirty 0.011 0.382
User specified bundle multiplier 1.2 1.2

Velocity and pressure drop distribution m/s %dp m/s %dp

Inlet nozzle 23.54 47.73 1.43 1.39

Entering bundle 6.5 16.96 2.02 13.34
Crossflow 5.42 26.49
Through baffle windows 5.92 6.84
Through tubes 2.02 70.51
Exiting bundle 0.02 2.02 13.36
Outlet nozzle 0.33 1.98 1.43 1.4

Thermal Details - Shell Side Stream Analysis

Shell Side Stream Analysis Flow fraction Diametric clearances

% mm

Crossflow 70.22
Clearance: Baffle hole - tube od 12.35 0.79
Clearance: Shell id - baffle od 11.79 4.76
Clearance: Shell id - bundle otl 5.64 14.33

Rho*V2 analysis Rho*V2 TEMA limit

kg/(m*s2) kg/(m*s2)

Inlet nozzle 640 2232

Shell entrance 284 5953
Bundle entrance 49 5953
Bundle exit 0 5953
Shell exit 26 5953
 Heat Exchanger Specification Sheet
1 Company: Harman fino Chem
2 Location:
3 Service of Unit: Main condenser Our Reference: Rajasekhar
4 Item No.: HE-101 Your Reference:
5 Date:01.12.10 Rev No.: 00 Job No.:
6 Size 598 -- 2000 mm Type BEM hor Connected in 1 parallel 1 series
7 Surf/unit(eff.) 30.5 m2 Shells/unit 1 Surf/shell (eff.) 30.5 m2
8 PERFORMANCE OF ONE UNIT
9 Fluid allocation Shell Side Tube Side
10 Fluid name Methanol+ Water water
11 Fluid quantity, Total kg/h 1784 93535
12 Vapor (In/Out) kg/h 1784
13 Liquid kg/h 1784 93535 93535
14 Noncondensable kg/h
15
16 Temperature (In/Out) C 64.83 64.83 35 40
17 Dew / Bubble point C 64.83
18 Density kg/m3 1.15 749.83 996 994.43
19 Viscosity cp 0.011 0.363 0.72 0.653
20 Molecular wt, Vap
21 Molecular wt, NC
22 Specific heat kcal/(kg*C) 0.3608 0.7108 1.0004 1.0002
23 Thermal conductivity kcal/(h*m*C) 0.015 0.169 0.528 0.534
24 Latent heat kcal/kg 262.23 262.23
25 Pressure kgf/cm2 1.033 2
26 Velocity m/s 5.42 2.02
27 Pressure drop, allow./calc. kgf/cm2 0.052 0.01 0.703 0.371
28 Fouling resist. (min) m2*h*C/kcal 0.0002 0.00061
29 Heat exchanged 467811 kcal/h MTD corrected 27.25 C
30 Transfer rate, Service 563.5 Dirty 569.4 Clean 1229.9 kcal/(h*m2*C)
31 CONSTRUCTION OF ONE SHELL Sketch
32 Shell Side Tube Side
33 Design/Test pressure kgf/cm2 5.273 -1.034 Code 5.273 Code
34 Design temperature C 98.89 76.67
35 Number passes per shell 1 4
36 Corrosion allowance mm 1.59
37 Connections In 152.4 150 ANSI 152.4 150 ANSI
38 Size/rating Out 50.8 150 ANSI 152.4 150 ANSI
39 mm Intermediate 150 ANSI 150 ANSI
40 Tube No. 262 OD 19.05 Tks-avg 1.6 mm Length 2000 mm Pitch 32 mm
41 Tube type Plain Material CS Tube pattern 30
42 Shell SS304 ID OD 609.6 mm Shell cover
43 Channel or bonnet CS Channel cover
44 Tubesheet-stationary SS304 Tubesheet-floating
45 Floating head cover Impingement protection Circular plate on bundle
46 Baffle-crossing SS304 Type single seg Cut(%d) 29 hor Spacing: c/c 249.94 mm
47 Baffle-long Seal type Inlet 422.78 mm
48 Supports-tube U-bend Type
49 Bypass seal Tube-tubesheet joint groove/expand
50 Expansion joint Type
51 RhoV2-Inlet nozzle 640 Bundle entrance 49 Bundle exit 0 kg/(m*s2)
52 Gaskets - Shell side Tube Side
53 Floating head
54 Code requirements ASME Code Sec VIII Div 1 TEMA class B
55 Weight/Shell 1100.4 Filled with water 1877.1 Bundle 636.6 kg
56 Remarks
57
58
Heat Exchanger Thermal Design Hetran 11.1 Page 12
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Calculation Details - Shell Side - Liquid Properties
Temperature Density Specific Thermal Viscosity Surface Latent
bulk wall heat conductivity bulk wall tension heat
C C kg/m3 kcal/(kg*C) kcal/(h*m*C) cp cp dynes/cm kcal/kg
64.83 53.68 749.83 0.7108 0.169 0.363 0.414 18.5 262.23
64.83 53.68 749.83 0.7108 0.169 0.363 0.414 18.5 262.23
64.83 53.06 749.83 0.7108 0.169 0.363 0.417 18.5 262.23
64.83 52.8 749.83 0.7108 0.169 0.363 0.418 18.5 262.23
64.83 52.64 749.83 0.7108 0.169 0.363 0.419 18.5 262.23
64.83 52.54 749.83 0.7108 0.169 0.363 0.42 18.5 262.23
64.83 52.46 749.83 0.7108 0.169 0.363 0.42 18.5 262.23
64.83 52.41 749.83 0.7108 0.169 0.363 0.42 18.5 262.23
64.83 52.37 749.83 0.7108 0.169 0.363 0.42 18.5 262.23
64.83 52.35 749.83 0.7108 0.169 0.363 0.421 18.5 262.23

Calculation Details - Shell Side - Vapor Properties

Temp. Density Specific Thermal Viscosity
bulk wall heat conductivity bulk wall
C C kg/m3 kcal/(kg*C) kcal/(h*m*C) cp cp
64.83 53.68 1.15 0.3608 0.015 0.011 0.011
64.83 53.68 1.15 0.3608 0.015 0.011 0.011
64.83 53.06 1.15 0.3608 0.015 0.011 0.011
64.83 52.8 1.15 0.3608 0.015 0.011 0.011
64.83 52.64 1.15 0.3608 0.015 0.011 0.011
64.83 52.54 1.15 0.3608 0.015 0.011 0.011
64.83 52.46 1.15 0.3608 0.015 0.011 0.011
64.83 52.41 1.15 0.3608 0.015 0.011 0.011
64.83 52.37 1.15 0.3608 0.015 0.011 0.011
64.83 52.35 1.15 0.3608 0.015 0.011 0.011

Calculation Details - Shell Side - Heat Load

Temp. Flowrate Mass Total
Vapor Liquid transfer load
C kg/h kg/h kcal/h kcal/h
64.83 1784
64.83 1784
64.83 1586 198 51979 51979
64.83 1388 396 103958 103958
64.83 1189 595 155937 155937
64.83 991 793 207916 207916
64.83 793 991 259895 259895
64.83 595 1189 311874 311874
64.83 396 1388 363853 363853
64.83 198 1586 415832 415832
64.83 1784 467811 467811
64.83 1784 467811 467811
Heat Exchanger Thermal Design Hetran 11.1 Page 13
File: HE-101 - Main condenser.BJT Date: 7/22/2016 Time: 7:04:46 AM
Calculation Details - Shell Side - Performance
Vapor Vapor weight Heat load Overall Area reqd. Temperature Pressure
temperature coefficient difference drop
C % kcal/(h*m2*C) % C %
Inlet 64.83 100 64.69
desup dry 64.83 100
desup wet 64.83 100
64.83 88.89 11.11 605.7 11.34 25.11 2.54
64.83 77.78 11.11 582.4 11.54 25.66 2.36
64.83 66.67 11.11 573 11.48 26.22 8.71
64.83 55.56 11.11 566.9 11.36 26.77 6.9
64.83 44.44 11.11 562.9 11.21 27.33 5.24
64.83 33.33 11.11 560 11.04 27.88 3.76
64.83 22.22 11.11 558 10.86 28.44 2.13
64.83 11.11 11.11 556.6 10.68 29 1.29
64.83 11.11 556 10.49 29.55 0.37
liquid cooling 64.83

excess area 0.02

Outlet 64.83 1.98

Calculation Details - Shell Side - Coefficients

Temp. Vapor Condensing Pure Condensing Coefficient Dry gas Film
bulk wt. % regime shear gravity resulting coef.
C kcal/(h*m2*C) kcal/(h*m2*C) kcal/(h*m2*C) kcal/(h*m2*C) kcal/(h*m2*C)
64.83 95.22 Shear-gravity 2900.9 2579.9 2666.1 78.5 2132.9
64.83 84.11 Gravity 2691.1 2337.4 2337.4 73.2 1869.9
64.83 73 Gravity 2491.4 2219.8 2219.8 67.5 1775.8
64.83 61.89 Gravity 2279.7 2149.2 2149.2 61.4 1719.4
64.83 50.78 Gravity 2046.5 2103 2103 54.8 1682.4
64.83 39.67 Gravity 1781.7 2071.4 2071.4 47.5 1657.2
64.83 28.56 Gravity 1467.6 2049.4 2049.4 39.4 1639.5
64.83 17.44 Gravity 1060.2 2034.1 2034.1 29.7 1627.3
64.83 6.33 Gravity 775.6 2028.4 2028.4 17.2 1622.7
Heat Exchanger Thermal Design Hetran 11.1 Page 14
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Calculation Details - Tube Side - Liquid Properties
Temperature Density Specific Thermal Viscosity
bulk wall heat conductivity bulk wall
C C kg/m3 kcal/(kg*C) kcal/(h*m*C) cp cp
35.23 50.9 995.93 1.0004 0.528 0.716 0.544
35.68 51.11 995.8 1.0004 0.529 0.71 0.542
36.14 51.31 995.66 1.0004 0.529 0.704 0.54
36.59 51.52 995.52 1.0004 0.53 0.697 0.538
37.05 51.73 995.39 1.0003 0.53 0.691 0.537
37.5 51.94 995.25 1.0003 0.531 0.685 0.535
37.95 52.15 995.11 1.0003 0.531 0.679 0.533
38.41 52.36 994.96 1.0003 0.532 0.673 0.531
38.86 52.57 994.81 1.0002 0.532 0.667 0.53
39.32 52.78 994.66 1.0002 0.533 0.662 0.528
39.77 52.99 994.51 1.0002 0.533 0.656 0.526

Calculation Details - Tube Side - Heat Load

Temp. Flowrate Sensible heat Total
Liquid Liquid load
C kg/h kcal/h kcal/h
35 93535
35.45 93535 42534 42534
35.91 93535 85066 85066
36.36 93535 127598 127598
36.82 93535 170128 170128
37.27 93535 212658 212658
37.73 93535 255186 255186
38.18 93535 297713 297713
38.64 93535 340240 340240
39.09 93535 382765 382765
39.55 93535 425289 425289
40 93535 467812 467812
Heat Exchanger Thermal Design Hetran 11.1 Page 15
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Calculation Details - Tube Side - Performance
Temp. Heat load Overall Area reqd. Temperature Pressure
coefficient difference drop
C % kcal/(h*m2*C) % C %
Inlet 35 14.74
35.45 9.09 568.3 9.11 27.25 6.39
35.91 9.09 568.5 9.11 27.25 6.38
36.36 9.09 568.7 9.1 27.25 6.37
36.82 9.09 568.9 9.1 27.25 6.36
37.27 9.09 569.2 9.09 27.25 6.35
37.73 9.09 569.4 9.09 27.25 6.34
38.18 9.09 569.6 9.09 27.25 6.33
38.64 9.09 569.8 9.08 27.25 6.32
39.09 9.09 570 9.08 27.25 6.31
39.55 9.09 570.2 9.08 27.25 6.3
40 9.09 570.4 9.07 27.25 6.29
excess area 0.73
Outlet 40 14.76

Calculation Details - Tube Side - Coefficients

Temp. Flow Velocity Coefficients
bulk Pr Re regime free forced Actual
C m/s kcal/(h*m2*C) kcal/(h*m2*C) kcal/(h*m2*C)
35.23 4.89 44438.19 Turbulent 2.02 7785.1 6228.1
35.68 4.84 44840.9 Turbulent 2.02 7812.6 6250.1
36.14 4.79 45246.04 Turbulent 2.02 7840.1 6272.1
36.59 4.75 45652.67 Turbulent 2.02 7867.7 6294.1
37.05 4.7 46060.79 Turbulent 2.02 7895.2 6316.1
37.5 4.65 46471.18 Turbulent 2.02 7922.7 6338.2
37.95 4.61 46879.07 Turbulent 2.02 7950 6360
38.41 4.57 47284.47 Turbulent 2.02 7977 6381.6
38.86 4.52 47692.08 Turbulent 2.02 8004.1 6403.3
39.32 4.48 48100.11 Turbulent 2.02 8031.1 6424.9
39.77 4.44 48508.6 Turbulent 2.02 8058.1 6446.4