Shell inlet temperature, T1 ( ) = 25 Shell-side fluid (service flu

Shell outlet temperature, T2 ( ) = 35 Tube-side fluid (process flu

Tube inlet temperature, t1 ( ) = 471
Tube outlet temperature, t2 ( ) = 217

Energy Balance Table

Heat in Heat out
Species kmol/hr kJ/kmol kW kJ/kmol kW
SO2 2.66 -276010.15 -203.9408 -288518.79 -213.1833
SO3 29.4 -326122.83 -2663.336 -343291.88 -2803.55
H2S 0.38 -3148.91 -0.332385 -13131.96 -1.386151
O2 8.61 13955.92 33.37791 5772.4 13.80566
N2 346.06 13302.23 1278.714 5620.98 540.3323
CO2 13.64 -373540.52 -1415.304 -385596.63 -1460.983
Total -2970.821 -3924.965

1. Energy/heat transferred (kW) =HIn- Hout

= 954.1432
Q=mCp(T)
Q (kW) = 954.1432
Cp (kJ/kg.) = 4.2
T ( ) = 10

2. Required cooling water flow rate, m (kg/s) 22.71769

Total flow of gas mixture, (kg/s) = 3.64

3. Log mean temperature difference

LMTD = (Th1-Tc2) - (Th2-Tc1)

Th1-Tc2
ln ( )
Th2-tc1
LMTD = 297.507689

4. Corrected mean temperature (Tm)

(Tm) = Ft x (Tlm)

R = (T1 - T2) / (t2 - t1)

R = 0.03937008 = 0.04

S = (t2 - t1) / (T1 - t1)

S = 0.56950673 = 0.57
 Ft = 0.9950334 = 0.995

Tm () = 296.02015 = 296.02

5. Overall heat transfer coefficient of gases - water range is 20-300 W/m2

Therefore Uf assume to be 20 W/m2

Uf,W/m2 = 20

Q=Uf x A x (Tm)
A, m2 = 161.161863

6. Number of tubes

20mm outside diamter, 16mm inside diameter, 2m long tubes and copper tubes is selected
di,mm = 16
L ,m = 2.5
do, m = 0.02
do,mm = 20
Area of one tube, m = DL
2

0.15707963

Number of tubes, Nt = 1025.988

= 1026

7. Bundle diameter and shell diameter

Bundle diameter for 1.25 triangular pitch

Nt
D b= do( )1/nl
Kl
From Table 12.4, Kl =0.249, nl=2.207
Db, mm = 868.913482
=869
From Figure 12.10,
Considering split-ring floated head type,

Bundle diametrical clearance,mm = 69

Ds, mm = Db+ Bundle diametrical clearance

938

8. Tube side heat transfer coefficient

Tube cross sectional area = d2/4

= 201.0619
= 201

Considering passes = 2
Tube per pass = 513

Total flow area, m2 = 0.103113

Gas mixture mass velocity, kg/m2.s = 35.3010775

Density of gas mixture,kg/m3 = 0.6355

Gas mixture linear velocity, m/s = 55.54851

Given,
Dynamic viscosity of gas mixture, m.Ns/m2 = 0.0294
Thermal conductivity of gas mixture, W/m. = 0.0426
Specific heat capacity of gas mixture, kJ/kJ. = 1.03

Re = pudi/
19211.4707

Pr =Cp/kf
= 0.71084507

L/di = 156.25

From Figure 12.23,

jh = 0.0039

hidi/kf = jhRePr0.33(/w)0.14

Neglecting /w
hi , W/m2. = 178.238112

9. Shell side heat transfer coefficient

Select baffle spacing as 1/5 shell diameter,l b (mm) = Ds/5

187.6

Tube pitch, Pt (mm) = 1.25 x do

25

Cross flow area, As (m2) = (pt - do)Dslb/pt

= 0.035194

Mass velocity, Gs (kg/m2.s) = 645.5035

Equivalent diameter, de (mm) = 1.1/do x (pt2 - 0.917 x do2)

14.201

Mean shell side temperature, 30

Water density, kg/m3 = 995.7

Viscosity of water, mNs/m2 = 0.798

Heat capacity of water, kJ/kg. = 4.2

Thermal conductivity of water, W/m. = 0.6144

Re = Gsde/
= 11487.2117

Pr = Cp/kf
= 5.45507813

From Figure 12.29,

Consider 25% baffle cut
jh = 0.0055

hs = kf/de x jh x Re x Pr0.33 x (/w)0.14

Neglect viscosity correction term

hs,W/m2. = 4811.82606
10. Viscosity correction factor

Mean tube side temperature = 344

Mean temperature difference across all resistance = 314

Across water film, = U x (T) / ho

= 1.305118

Mean wall temperature, = 342.6949

Water viscosity at the wall, w (m.Ns/m2) = 0.086

(/w)0.14 = 1.366

Therefore, hs (W/m2.) = 6572.953

11. Overall coefficient

Thermal conductivity of copper, W/m. = 395

Air and industrial gases fouling coefficient range from 5000 - 10000 W/m 2.
Take highest value, = 10000

Cooling water coefficient range from 3000 - 6000 W/m 2

Take highest value, = 6000

1/Uo = 0.00746254
Uo, W/m .
2
= 134.002543

Therefore, the design has adequate area for the initial estimation of 20W/m 2.

12. Pressure drop tube side

From the Figure12.24,

jf = 0.004

Neglect [/]()
Pt, N/m2 = 14706.9166
Pt, kPa = 14.7

13. Pressure drop shell side

Linear velocity, m/s = Gs/p

= 0.648291

From the Figure 12.30,

jf = 0.049

Neglect viscosity correction

Ps, N/m2 = 52852.4603

Ps, kPa = 52.8

Design paramater Calculated value

Number of tubes 1026
Shell internal diameter 938 mm
Tube bundle diameter 869 mm
Tube outer diameter 20 mm
Tube pitch 25 mm
Baffle spacing 187.6 mm
hell-side fluid (service fluid) : Water
ube-side fluid (process fluid) : Mixture gases
tubes is selected
d212
b73
b74
b71
f206
b74
b71
d209
d139
Design paramater Calculated value
Number of tubes 1026
Shell internal diameter 938 mm
Tube bundle diameter 869 mm
Tube outer diameter 20 mm
Tube pitch 25 mm
Baffle spacing 187.6 mm

14. Calculating the tube-row correction factor, Fn

Vertical tube pitch (Pt'), mm = 0.87 x Pt =

Baffle cut height (Hc), mm = 0.25 x Ds =
Height between baffle tips, mm = Ds - 2 xHc =
Number of constrictions (tube rows) crossed (Ncv) =

From Figure 12.32,

Tube raw correction factor, Fn = 1.03

15. Calculating the window correction factor, Fw

Bundle cut fraction, Bc Hc/Ds = 0.25

Height of the baffle chord, Hb

=/2 x (0.5)

Hb, mm = 200

Bundle cut, Bb = Hb/Db = 0.23015

From Figure 12.41, R'a = 0.18

Tubes in one window area, Nw

= Nt x R'a
= 184.68
 = 185

Tubes in cross flow area, Nc

= Nt - 2 x Nw
= 656

Rw = 2 x Nw/Nt
= 0.360624

From Figure 12.33,

Window correction factor, Fw
= 1.02

16. Calculating the bypass correction factor, Fb

Ab, m2 = (Ds-Db)Sb
0.012944

Ab/As = 0.367804

Fb = exp[-1.35 x Ab/As]
= 0.608636

Value too low, sealing strips needed

Consider one strip for each three vertical rows

Ns/Nc = 1/3
Ns/Ncv = 0.333333

= 1.35 for Re 100

Fb = 0.939158

17. Calculating the leakage correction, FL

Using the clearance specified in the standards,

Tube to baffle clearance, Ct = 1/32 inch = 0.8

Baffle to shell clearance, Cs = 3/16 inch = 4.8

Area between the tube and baffle, Atb

Atb = Ct x x do x (Nt-Nw)/2
= 21136.64 mm2
= 0.021137 m2

From Figure 12.41 for 25 percent cut,

b = 2.1 rads

Area between the shell and baffle, Asb

Asb = Cs x Ds x ( 2 - b )/2
Asb = 9417.187 mm2
= 0.009417 m2

Total leakage area, AL = Asb + Atb

= 0.030554 m2

AL/As = 0.86816

From Figure 12.35,

Leak factor coefficient, L = 0.48

FL = 1-L x [(Atb + 2 x Asb)/AL]

= 0.372056

18. Shell side coefficient

hs = ho x Fn x Fw x Fb x FL
= 2412.932 W/m2

19. Calculating overall heat transfer coefficient

1/Uo = 0.007725
Uo = 129.4525 W/m2

20. Calculating the new shell side pressure drop

Calculating the pressure drop in ideal tube bank, P i

Pi =

= 1768.635 Pa
= 1.768635 kPa

Calculating the pressure drop in the cross flow zone, P c

Pc = Pi x F'L x F'b

Re > 100, = 4

F'b = 0.318454

Pc = 209.5525 Pa

Calculating the pressure drop in window zone, P w

Aw = (/4 x Ds2 x R'a) - ( Nw x do2/4)

= 0.066266 m2

Thermal fluid velocity through window zone, U w

Uw = Gs/(p x Aw)
= 0.344309 m/s

Geometric mean velocity, Uz

Uz = (Uw x Us)0.5
= 0.472453 m/s
Number of tubes in the window zone (N wv) = Hb/P't
= 9.195402
= 9

Pw = [F'L x (2 + 0.6Nwv)](1/2(pf x Uz2))

= 305.9544 Pa

Calculating the pressure drop in end zone, P e

Pe = Pi( Nwv + Ncv) x Fb / Ncv

= 2354.303 Pa

New shell side pressure drop, Ps

Ps = 2 x Pe + Pc(Nb-1) + NbPw

Baffle spacing = 187.6 mm

Length of tube = 2500 mm

Nb = 13.32623
= 13

Ps = 11200.64 Pa
= 11.2 kPa
 21.75
234.5
469
21.56322
mm
mm