CHAPTER 8

HEAT EXCHANGERS

General
Steam exhausted to atmosphere
-Acts as a condenser
Condenser reduces make-up water
Make-up cannot be reduced to zero because there are always some losses from
traps boiler blowdown,leaks at the packing glands, and contaminated returns
from steam heating systems or oil consuming equipment.
Condenser lowers exhaust pressure thus increasing efficiency
Feedwater heater raises the temperature of the condensed steam before
inducting it into boiler
Feedwater heater prevents contraction of metals in boiler

CONDENSERS

Barometric and low-level jet Condensers

Methods of condensing
1. Mixing or direct contact
2. Surface

Surface Condenser
-eliminates contamination of feed water

Condenser Calculations

= 

   
 = =  


 
  
 

 = 
 8 9
  !"#
 $%# #&#!')!** !"#
 &#!&!**"#
  + "# *
1 $ %!
0.75 *#!!

*cleanliness factor
0.85 &#! & !#'
0.95 '1# !'!
Example 1
Design a surface condenser for a turbine that exhausts 50000 lb/hr of steam at 2in Hg abs with
circulating water entering at 802. Use an 8 degree terminal difference,7fps velocity,3/4in 18 BWG
tubes, and a cleanliness factor of 0.85.

Tsat @2 in hg =101.1 0F

93.1 80
34 = = 13.50752
101.1 80
&!
8
From Fig8-9 = 713
Or for in = 2708&
= 2707
= 714.3528

Temperature correction factor = 1.05

Eq 8-3
 = 
 = 1
 = 0.85
 = 1 $ %!
;$
 = 714.35281.0510.851 = 637.5599
" < 2

Solving for the surface area of condenser

= = >3

From page 356

%$
= = 950 !! # $ %!
&%
%$
= = 1000 !! #&#!
&%
#

= 950 50000
>= = = 5515.6613" <
3 637.5599 13.54

*find for the number of tubes

Compute for the volume/mass of water neeeded to extract theq.

Using
= @AC
Applicable for water with low temperature and near atmospheric pressure
;$
D = 1
&% 2

E = 93.1 80

F 50000 950 &%

= = = 3,625,954.198 1#
DE 193.1 80

J
Using H. I KL density of water (assumption)

Compute for the volume flow rate

 3,625,954.198 " N
+= = = 58108.2404
M 62.4

K L
It is stated that velocity of water is O PQ and Iin 18BWG Di=0.652in from page 353
For this size of tube and velocity the maximum volume flowrate for 1 tube is:

R 0.652 < 3600* " N

+ = >+& = S T 7 S T = 58.4283  $%
4 12 1

KL
To accommodate a total volume flowrate of 58108.2404 UV increase the number of tube:
58108.2404
= 994.53$%* 995$%*
58.428
*find for the tube length
The needed surface is 5526.1272K
> = RXY Z[

0.75
5515.6613 = R S T Z995
12

Z = 28.2322"
Now refer to table 8-2 page 354 for a surface area of 3000-6000K the approximate
recommended L is 14-20. So the L computed is out of range. Make the tube 2pass, dividing the
length in to two, thus \. L  = I. H K

*Find for the friction loss

^
A condenser of this size would have < ! thick tube sheets so the actual tube length could be
^ ^
14.1161" + `< 2 ^<a = 14.1994

From Fig 8-11, the friction loss in the condenser would be

214.19940.4 + 21.41 = 14.1795"

Problem 8-4
A surface condenser is to operate under the following conditions: 150,000kw turbine exhaust
steam rate 8lb per kwhr, 1.017687075in Hg abs, single-pass, in no. 18 BWG Admiralty tubes,
502 inlet water temp 8fps velocity, 2ft friction drop in the inlet tunnel, 1ft for the outlet tunnel,
3ft drop in the inlet pipe, 1.5ft in the outlet pipe, top of the outlet pipe 18ft above river level,
85% cleanliness, 15terminal difference, 80% circulating pump efficiency.
Find: a)outlet temp of circulating water
b)surface
c)gpm of circulating water
d)number of tubes in condenser
e)effective tube length
^
f)total weight of tubes in condenser ,allowing 1 ! tube sheet thickness
c
g)friction drop through condenser
h)total dynamic head for circulating pump
i) horsepower of circulating pump motor
solution
14.7
1!d = 0.5*#
29.92
Tsat @0.5 psi=79.562

3^
3<

A) C = 79.56 15 = 64.56
h h  <n.op^o
B) efCg = i mij = iq.rs = 21.46312
kl kl
mj jr

For in No. 18 BWG tube 8fps water velocity

=  +
= 2708 = 763.6753

with 502 inlet water, from Fig 8-9

 = 0.84
 = 1
 = 0.85
 = 1

 = 763. 841. 851 = 545.2641811

;$
F = 9508150000 = 1140000000

F = >34

1140000000
>= = 97410.18175" <
545 21.4631

C) Gpm of circulating water

 F 1.14 10n &%
= = = 78296703.3
DE 164.56 50

&% 1" N 7.481#& 1

78296703.3 = 156447.0185
62.4&% 1" N 60!

D) Number of tubes
From table 8.1 for in 18 BWG tube Di=0.652in
R 652 < " <
> = S. T = 2.3185 10N
4 12 $%

Total volume of water needed

1 1 " N
= 78296703.3 S TS T = 348.5430168
62.4 3600 *

Volume flow rate per tube

R 0.652 < " N
= S T 8 = 0.01854  $%
4 12 *

Number of tubes
348.54
= = 18790.73718 18791$%*
0.01854

E) The total outside surface needed is: 97410.18791" < as computed for a in tube the
u.vo ^
outside are per ft is:= R ` a 1 = R
^< ^p

For all tubes

1
= R18791 = 3689.604
16

Length of tubes
97410
= = 26.40125495"
3689

Consulting table 8-2 for a surface are over 20000 " < the approximate table length is
22-30ft

The actual tube length with 1 tube thickness

1.25
= 26.40125 + 2 S T = 26.60958829"
12

From table 8-1 for in 18BWG the weight of tube per linear ft is: 0.417 lb/ft

Weight of total tubes

= 26.6. 41718791 = 208508.6626 &%

F) Actual tube length as computed above: 26.6095ft

 G) Friction drop through condenser from Fig 8-11 for in 18 BWG tube and 8fps
"d< 0
$% " ! &** = 0.52  #**
"
wxyi u
Pressure loss in water box= 1.74 z{||
Friction Drop through condenser
= 0.5226.6095 + 1.74=15.57694 ft H20

H) Total dynamic head for circulating pump

= 15.57 + 2 + 1 + 3 + 1.5 = 23.07694 ft H20

Assuming 10% of friction loss in the pipe top outlet = 0.10(18ft)=1.8

= 24.87694 " d< }

8<
X~!# #' = 24.87 + = 25.8707" < }
2 32.2

I Horsepower
1 25.87
1# d = F = 78296703.3 S T = 1023.026 < } d
60 33000
1023
 d = = 1278.7833
0.8

Problem 8-6 Design a surface condenser for the following conditions: 25000kw turbine, exhaust steam
rate 8lb per kwhr, two pass, 7/8 in no. 18 BWG tubes, 7fps water velocity, 8-degree terminal difference,
2-ft friction drop in inlet tunnel,1 ft in outlet tunnel, 3ft in inlet pipe,1.5 ft in outlet pipe, outlet pipe 24ft
above river level, 86% circulating-pump efficiency.
Find: A) outlet temperature of circulating water
B) gallons per minute of circulating water
C) surface area
D) number of tubes in condenser
E) total weight of tubes, assuming tube sheet thickness of 1in.
F) friction drop through condenser
G) total dynamic head on circulating pump
H) horsepower of circulating-pump motor.

A) C = \ \ = O2
B) Heat released by steam
;$
F = 825000950 = 1.9 10

Energy released by steam
F = DE
Assume water temp(inlet)=502

1.9 10 &%
= = 8636363.636 "  $&#! 1#
72 50
 Converting to GPM using the mean water temp and steam table to get the specific
volume
1
= 50 + 72 = 612
2
"  *# #%&*#$ #' 612

" N
+ = 0.0160345
&%
Therefore the volume flow rate of water is:
7.481
+ = 8636363.6360.016035 S T = 17266.65807
60

C) Surface area
F = >34
 = 

= cv = 2637 = 695.8325948
assumed
 = 6950.8410.851 = 469.8245

72 75
34 = = 16.64452
80 50
&! 80 72

1.9 10
>= = 22976.25157 " <
49616.64

D) No. of tubes in the condenser

From table 8-1, 7/8 in no. 18 BWG tube, the flow rate of this tube with a velocity
of 1fps is 1.48gpm
17266.11966 $%*
. " $%* = = 1667
1.48 7 #**

For 2 pass: total no. of tubes

= 16672 = 3334 $%*
K
From table 8-1 for 7/8 in OD outside surface per linear ft = 0.2297
K
Therefore:
229766
""+ &! " $% = = 60.004"
16670.2297
For 2 passes
= 30.002"

Providing for tube sheet thickness

1
#$#& &! = 30.002 + 2 S T = 30.16"
12
From page 354:
 Since there is a cost penalty for excess length the assumed values for steam
exhaust pressure and inlet water temperature should be reconsidered.

Taking inlet water temperature to be 602 instead of 502

From Fig 8-9, it will be 0.93
Thus
= 26370.931. 851 = 550.0556662
Still using 1inHg abs steam exhaust pressure:
< = *# 3 = 80 8 = 722
Then

72 60
34 = = 13.0962
80 60
&! 80 72

1.9 10
>= = 26375.39704
55013.096

F 1.9 10 &%
1# "&1 # = = = 15833333.33
DE 72 60

1
#! 1#  = 72 + 60 = 662
2

+" = 0.016043

8 = 31671.33301

31671
!. " $%* = = 3058
1.48 7

" 1 #*** = 6116 $%*

26375
""+ $% &! = = 37.5491"
30580.2297
" 1 #*** = 18.7745
2
#$#& &! = 18.77 + = 18.94"
12

Comparing with values in table 8-2 this length is too short to give a proportioned condenser
take 1.5 in Hg abs. Steam exhaust pressure tsat=912
< = 91 8 = 832

83 60
34 = = 16.67982
91 60
&! 91 83

1.9 10 1.9 10
>= = 20342.89569 " < 1# "&1 # = = 8260869.565
55016.97 83 60
 1
#! 1#  = 60 + 83 = 71.52 722
2

+" = 0.016050

7.481
8 = 82608690.016054 S T = 16535.50367
60

16535 $%*
!. " $%* = = 1597
1.48 7 #**

" 1 #*** = 3194 $%*

20342.89
""+ $% &! = = 55.45
15970.2297

" 1 #** = 27.72789273

>$#& $% &! = 27.8945"

#& 1 " $%* = 0.49027.893194 = 43656.65913 &%*

From fig 8-11

" ! &** ! !'!* = 227.890.33 + 21.41 = 21.23037 " " 1#

7<
#& '+&' '~!# #' = 21.23037 + 2 + 1 + 1.5 + 2.4 +
64.4
= 31.89 " " 1#

1653531.89
d = = 133.166d
3960

133
 d = = 154.8442d
0.6

FEEDWATER HEATERS

8-8 Surface Type of Feedwater Heater

Difference (condenser and heater)

1. Heater temperature
2. Pressure
3. Strength of parts

8-9 heat Balance calculation for surface heaters

 * +  = ' + 2

2 1
=
* '

8-10 Surface Calculations

 PAPVVP = *# 0.8 ZEX

EXAMPLE 8-4
A 12650kw turbine generator may have either three or four stages of feedwater heating. If the unit will
operate at the load for 4000hr/yr. calculate the return on the investment for the fourth heater for the
following data; 5/8 in no.16 BWG no 16 BWG 80/20 Cu-Ni tubes, water temperature of 275 2 entering
heater and 3502 leaving, improvement in heat rate is 175 Btu per kwhr, heater costs $14.00 per sqft
surface plus $6000 for installation and piping 5F TD, 120000 lb per hr of water, fuel cost 31cents per 10^p ,
pump efficiency is 69% (wire to water), additional piping pressure loss is 4psi, cold water velocity in the
tubes to be 8fps, plant heat rate of 125000 Btu per kwhr with four heaters.

vo
34 = = 27.052

r
;$
w # 350  = 321.6
&%
;$
w # 275  = 243.9
&%
;$
F = = 120000321.6 243.9 = 9324000

&  = 355 0.827.05 = 333.362
Above 2502 use curve for 250
Fig 8-23
 = 910 0.88 = 800.8

9324000
>= = 430.4383232" <
800.8 27.05

No. of Tubes:
 120000 " N
+& = = = 0.5341880342
M 62.4 3600 *
R
+&  $% = X  8&
<
4
From Table 8-1 # 16 BWG Di=0.495 in
R 0.495 < " N
+&  $% = S T 8 = 0.01069  $%
4 12 *

0.53
!. " $%* = = 49.96 50 $%*  #**
0.01
Effective length
Surface area of 50 tubes per 1ft
= RXY Z! " $%*

From Table 8-1 # 16 BWG Do=0.625 in

0.625 " <

= RS T 150 = 8.18123
12 $%

430.43
Z= = 26.3064 "
8.18 2#**

26.3064
Z= = 13.1532 ""$ #**
2
Friction loss from fig 8-24
12Z + 5.5'[
 =
'^.<o
F1=0.135

Average water temp

= 355 27.05 = 327.35
2 = 0.75

. 135. 7513.2 + 5.50.4954

 = = 15.4225*
0. 495^.<o

 = 15.42 + 4 = 19.4225
 120000
= 266
500 0.903

0.74626619.4
 !$ = = 3.25)1
0.691714

3.2512500 17540000.31
#!!$#& cost " #''!#& 1 = = $49.80
10p

1751265040000.31
#!!$#& *#+!* = = 2750
10p

! $ ! = 2750 49.80 = 2700

* " # = 43114 + 6000 = 12030

2700
} = = 22.4%
12030

Problem 8-25 A surface heater operates at 380psi and receives 670,000 lb/hr of feedwater at 3602.
Calculate the surface and friction drop for no 14 BWG 70/30 Cu-Ni tubes that are 5/8 in diameter. Use
cold water velocity of 4fps and a 22 TD.

*# @ 380 = 439.7

< = 439.7 2 = 437.7

F = >3

F =  < ^ 
< = " @ 437.7 = 416.4224

^ = " @ 360 = 332.35

%$
F = 670000416.4224 332.35 = 56328508

3< 3^
3 =
3
&! 3<
^

3< = 439.7 360 = 79.7

3^ = 2
79.7 2
3 = = 21.084781312
79.7
&! 2

#+ # "&  = *# 0.83 = 439.7 0.821 = 422.8321752

From figure 8-23

Average film temp exceed 2502, so use the so use the curved for 2502 and with cold water
velocity= 9fps

%$
= 940
" < 2

Correction factor for no. 14 BWG 70/30 Cu Ni tubes is 0.77

thus:

= 940 0.77 = 723.8

F 56328508
>= = = 3690.970452 " <
3 723.821.08

*for friction drop

#+ # 1#  #$  = *# 3 = 439.7 21.084 = 417.6152187

From fig 8-24 at average water temperature=417.6, F2; for cold water velocity=9fps, F1= 0.166

< ^ Z + 5.5'[
=
'^.<c
D=0.458
The specific volume of water at average water temp (417.6)
From steam table
Vf=0.01889904
1
1# "&1 # = 6700000.01887.481 S T = 1578.784854 
60
From table 8-1 for 5/8in OD no. 14 BWG tube

Flow rate =0.514 gpm/tube @1fps

1578.78
! " $%* = = 342 $%*  #**
0.5149

From table 8-1, for 5/8in OD no.14 BWG tube

Surface per linear ft=1636 ft2/ft

Assuming one pass

3690.97
""+ $% &! = = 65.96767276
3420.1636
< ^ Z + 5.5'[ 0.1660.7565.96 + 5.50.458
= = = 22.4544 *
'^.<c 0.458^.<c

EVAPORATORS
-one method of purifying make-up water for the system

Two types of evaporators:

1. Film type
2. Submerged type

EVAPORATOR ARRANGEMENT AND ENERGY CALCULATIONS

A) Evaporators in Parallel

B) Evaporators in Series
 Advantages of series
1. Less steam per pound of vapor
2. Less vapor must be condensed in the condenser

Heat head

Example 6
Calculate the steam requirement for a double-effect evaporator system Fig 8-33(b), when steam enters
the system saturated at 50psia. Vapor leaves the second effect at 16psia. Raw water at 30000 lb/hr enters
the system at 602. Divide the total heat head for the system equally between the two effects.

@50 psia
Tsat=2812
Hs=1174.1hg
Hdi=250.1hf

@16 psia
T2=216.3
H2=1152 hg @ 16psia

Total heat head=64.7

For each effect

64.7
= 32.35
2
 Thus ^ = 281 32.35 = 248.62

Vapor leaving 1st effect is saturated

@248.62
Psat=29.1psi
Hi=1163.5hg
Hd2=217hf

Assume 1lb of steam entering the first effect`

** '^  = 1^ 

** '^  11174.1 250.1

1= = = 0.8138 &%
^ 1163.5 28.1

We now have 0.8138 lb of vapor entering the coils of the second effect; it will evaporate w2
pounds of raw water

1< <  = 1^ ^ < 

1^ 1 '<  0.81381163.5 217

1< = = = 0.6853 &%
<  1152 28.1

Therefore each pound of steam will evaporate

 &% " 1#
0.8138 + 0.6853 = 1.4991
&% *#
Total steam required

30000 &%
= = 20010
1.4991
0.8183
" * "" +# = 30 S T = 16300
1.4991
*!' "" +# = 30000 16300 = 13700

Review Problems:

8-2
8-4
8-12
8-14
8-17
8-20
8-25
8-31
8-35
8-40
8-42
8-48
8-62

Board exam problems

1. Hot water enters a counterflow heat exchanger at 990C. It is used to heat a cold stream of water from
40C to 320C. The flow rate of the cold stream is 1.3 kg/s, and the flowrate of the hot stream is 2.6 kg/s. the
overall heat transfer coefficient is 830 W/m2-0C. Compute the heat exchange area in m2.

2. (a)A heat exchanger has an overall coefficient of heat transfer of 0.5 kW/m2-0C. Heat loss is 11 kW and
the mean temperature difference is 150C. What is the heat transfer in ft2.

3. An oil heater heats 100 kg per minute of oil from 350C to 1000C in a counter flow heat exchanger. The
average specific heat of the oil is 2.5 kJ/kg-0C. Exhaust gases used for heating enter the heater with an
average specific heat of 1 kJ/kg-0C, a mass flow rate of 250 kg/min and an initial temperature of 2000C.
The overall heat transfer coefficient is 75 W/m2-0C. Determine heating surface in square meters.

4. A surface condenser serving a 50, 000 kW steam turbo-generator unit receives exhaust steam at the
rate of 196,000 kg/hr. Vacuum in condenser is 702 mm Hg. Sea water for cooling enters at 29.5 0C and
leaves at 37.50C. For steam turbine condenser, manufacturers consider 950 Btu/lb of steam turbine
condensed as heat given to the cooling water. Calculate logarithmic mean temperature difference in 0F.
(saturation temperature at 733 kPa = 40.86 0C.)