HORIZONTAL SHELL AND TUBE CONDENSERS

Kari Saari

March 9, 2016

1
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CONDUCTANCE OF TUBE CONDENSERS

Conductance of a horizontal tube condenser can be calculated based on the heat transfer
coecients inside and outside of the tube and on the heat conductivity of the metallic
tube wall. Conductance per unit length of tube is dened as

G
(1)
0
G =
l

where l is length of the tube, and G is conductance of the tube

Conductance per unit length of the tube can be calculated using the following equation

 
1 1

1

1 1 ln ddus
(2)
0
0 = R = + Rdirt + +
G πds hs πdu hu 2πλ

where R is the heat transfer resistance per unit length of the tube, ds is inside diameter
0

of the tube, hs is heat transfer coecient inside of the tube (cooling water side), Rdirt is
heat transfer resistance of the dirt layer caused by cooling water, du is outside diameter
of the tube, hu is heat transfer coecient outside of the tube (condensing wapour) and λ
is the heat conductivity of metallic tube wall.

The extra heat transfer resistance caused by sedimentation from normal cooling water is
approximately Rdirt = 0, 05 mkWK . When the cooling water is rather dirty the extra
2

resistance is approcimately Rdirt = 0, 1...0, 2 mkWK .

2

The total conductance of the condenser is

(3)
0
G = LG

where L = N l is the total length of all tubes, N is total number of tubes and l is length
of one single tube.

The heat ow Φ in the condenser is calculated similarly as in all heat exchangers

Φ = Gθ = ṁh ∆hL = ṁv cp ∆T (4)

where θ is the mean temperature dierence between condensing vapour and cooling
water, ṁh is mass ow of the condensing vapour, ∆hL is latent heat of vapourization,
ṁv is mass ow of cooling water , cp is the specic heat of cooling water and ∆T is the
temperature rise of cooling water. Logarithmic mean tremperature dierence can be
used as the mean temperature dierence.
 3

(Th − Tv1 ) − (Th − Tv2 )

θ = θln = T −T (5)
ln Thh −Tvv1
2

where Th is the condensing temperature of the vapour, Tv1 is the inlet temperature of
the cooling water and Tv2 is outlet temperature of the cooling water. If you want to use
eectiveness of the condenser, it can be expressed as

∆T
ε= = 1 − e−z (6)
θ0
where ∆T is temperature rise of cooling water, θ0 is temperature dierence between con-
densing vapour temperature and inlet cooling water temperature. z = G/Ċmin is dimen-
sionless conduvtance of condenser which can be calculated using the following equation

G
z= = −ln(1 − ε) (7)
Ċmin

COOLING WATER SIDE

The heat transfer coecient inside of the tubes can be calculated based on classical
correlations of Nusselt number

hs ds
Nu = (8)
λ

One of the most used correlations is Dittus-Boelter correlation

N u = 0.023Re0.8 P r0.4 (9)

and the other more precise correlation especially for short tubes is Hausen-correlation,
which takes into account the enhanced heat transfer at the inlet of the tube (the thin
thermal boundary layer). According to Hausen the mean Nusselt number is

 !2/3 
f
(Re − 1000)P r ds
Nu = 8 q 1 +  (10)
1 + 12.7 f8 (P r2/3 − 1) l

where l is length of the tube,ds is inside diameter of the tube, and the coecient f can
be calculated using the following equation

f = (1.82log10 Re − 1.64)−2 (11)

The frictional pressure drop inside of the tubes is

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L1 2
∆p = ξ ρw (12)
ds 2

where w is the mean velocity of the ow, ρ is density of the uid, L is length of the tube
and ds is inside diameter of the tube. The friction coecient of the ow ξ is dependent
on the Reynolds number of the ow and on the roughness of the tube. For smooth tubes
the friction coecient can be calculated using the correlation of Blasius

0.3164
ξ= √
4 Re
(13)

which is valid, when Re < 105

If the tubes are not smooth, but have have a roughness k , the friction coecient can be
approximated as

1 d
√ = 2lg( s ) + 1.14 (14)
ξ k

This is strictly valid only if Re > 10000000. For smaller Reunolds numbers the Moody
diagram can be used to calculate the friction coecient as a function of Reynolds
number

Figure. 1. Moody diagram for friction coecient

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This diagram is based on the correlation of Colebrookin and White

" #
1 2.52 k
√ = −2.0lg √ + (15)
ξ Re ξ 3.71ds

which can be used recursively to solve the friction coecient. The roughness of the
tubes is given in the following table.

Table 1 . Roughness of dierent tube materials

Material k [mm]
steel 0.03
mildly rusty steal 0.25
aluminium 0.025
copper 0.025
rubber 0.025
glass 0.0025
galvanized metals 0.15
smooth plastic 0.0025

CONDENSATION OF VAPOUR
In condensers the eective temperature of condensing vapour is aected by non-condensable
gases and by pressure drop of the vapour ow. If the vapour velocity in the condenser
is too small, the non-condensable gases are gathered on the heat transfer surfaces. The
partial pressure of water vapour is decreased in the near region of heat transfer tubes
when also the saturation temperature is decreased. In this way the available tempera-
ture dierence between vapour and cooling water is decreased, which can be seen as a
diminished eective heat transfer coecient of condensing vapour. On the other hand , if
the vapour velocity is too large, the pressure drop of the vapour decreases the saturation
temperature of the condensing vapour and the available temperature dierence between
vapour and cooling water is again decreased. There exists experimentally specied opti-
mum point (optimum velocity) for dierent kind of shell and tube condensers where the
vapour velocity is high enough to prevent the accumulation of non-condensable gases and
small enough not to increase the pressure drop. This optimum is dependent on the tem-
perature level where the condensation is happening. In the following graph the optimum
00 2 P
point is locating on top of the curves, which are plotted using the product ṁh as a
parameter. [Tekniikan käsikirja 4, page 487].
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Figure. 2. Optimal operation point of shell and tube condensers,

 00 2 P
heat transfer coecient
as a function of condensation temperature and product ṁh

2 P
The parameter ṁh which is used for dimensioning of the condenser is calculated
 00

based on the specic vapourPow of the condenser ṁh and on the pressure drop
00

coecient of the condenser . The specic vapour ow of the condenser is dened as

ṁ
(16)
00
ṁh =
S

where ṁ is the mass ow of the condensing vapour and S is the heat transfer surface
area where the condensation is happening (outside area of the tubes).

If the vapour velocity is too high, the operation point is moving to the left from the
top, and the eective heat transfer is decreased. If the velocity is too small , the non-
condensable gases are gathering on the tube surfaces and the operation point is moving
to the right from the top, thus decreasing again the eective heat transfer coecient.

Lets consider next how the pressure drop coecient is calculated. The total outside
P

heat transfer area of condenser tubes is Stot and the tubes are positioned triangularly in
such a way that the number of the tube rows in the direction of the ow is n . At the
inlet (the rst row of the tube bundle) the cross sectional ow area for the vapour ow
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is A(1). The heat transfer surface area (outside surface area of the tubes) where the
vapour is condensing after the cross section A(1) is marked as S(1). Analogically at the
tube row x the cross sectional ow area for the vapour ow is A(x) , and the heat
transfer surface area following this cross section is S(x).

Figure. 3. Cross sectional area A and condensing surface area S of the condenser

The mass ow of vapour which is owing through the cross section A(x) and is
condensing on the surface area S(x) is ṁh (x) when the specic mass ow of the
condenser after the row x is

ṁh (x)
(17)
00
ṁh (x) =
S(x)

The vapour velocity at the tube row x is then

00
ṁh (x) ṁ (x)S(x)
u(x) = = h (18)
ρA(x) ρA(x)
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The frictional pressure drop of one tube row x is

1
∆p(x) = ρξ[u(x)]2 (19)
2

where ξ(x) is friction coecient of tube row x. If it is assumed that density of the
vapour ρ is constant, the frictional pressure drop of all n tube rows is


00 !2 
1 x=n ṁh (x)S(x)
(20)
X
∆p = ξ(x) 
2ρ 1 A(x)

When it is also assumed that the friction coecient ξ(x) is the same for all rows
ξ(x) = ξ = constant and that the specic mass ow is constant all over the condenser,
the pressure drop of the condenser can be written as

n
!2
ξ  00 2 X S(x) ξ  00 2 X
∆p = mh = mh (21)
2ρ 1 A(x) 2ρ

where

n
!2
S(x)
(22)
X X
=
1 A(x)

which is pressure drop coecient of the condenser.

In normal condensers the geometrical positioning of the tubes is triangular in such a

way that the ratio s/d = 1.3.

s
 9

Fig. 4. Tube arrangement

Normally in shell and tube condensers the vapour velocity is tried to keep approximately
constant, when the accumulation of non-condensable gases is not a problem , if the
velocity is high enough. The pressure drop coecient for this kind of condenser can be
calculated based on the rst row values A(1) and S(1) because in this case

S(x) S(1)
= = constant
A(x) A(1)

and the pressure drop coecient Σ is

!2
S(1)
(23)
X
=n
A(1)

At dierent pressure levels the shell and tube condensers have very dierent specic
mass ows. This is mainly due to the fact that the specic volume of vater wapour is
very stronly dependent on the pressure level. At low pressures the volume ows are
increasing dramatically which is restricting the specic mass ow of the condenser. The
00 2 P
following table gives approximate dimensioning values for the product mh as a


function of water vapour saturation pressure. In the table is also given the friction
coecient for one tube row, which is needed in pressure drop calculations.

Table 2. Approximate dimensioning values for vapour side

 00
2 P
p0 t0 ξ mh
kg 2
-
 
kN ◦
m2
C 2
m s
0 0 1.2 0.1
2 20 0.98 1
7 40 0.83 10
20 60 0.70 102
70 90 0.59 103
250 130 0.50 104
800 170 0.43 105
2800 230 0.37 106
8000 300 0.32 107

2 P
More precisely the dimensioning value for the product mh can be read from Fig. 2,
 00

which gives it as a function of saturation temperature. The values for the product
 00 2 P
mh can be manipulated a little further. Based on the eq. 16. you can write for the
row x
 10

S(x) u(x)
= 00 (24)
A(x) vh (x)mh (x)

where vh (x) is the specic volume of the vapour at row x . Pressure drop coecient
P

can then be written as

n
" #2
u(x)
(25)
X X
= 00
i=1 vh (x)mh (x)

If it is assumed that the specic vapour ow and specic volume of the vapour are
constant all over the condenser this can be written as

n
(26)
00
(vh mh )2 [u(x)]2
X X
=
i=1

If the cross sectional ow area of the condenser is decreasing in such a way that the
velocity within the condenser with n rows is constant, u(x) = u(1) = u(n) = u and

n
[u(x)]2 = nu2 (27)
X

i=1

The constant velocity within the condenser is then

s
00
(vh mh )2
P
u= (28)
n

Examining the top values of the curves in Fig. 2 and making some calculations it is
possible to notice that the following condition is approximately true for the top points of
the curves ( valid only when T < 200o C )

m2
" #
(29)
00
(vh mh )2 = 752
X
s2

Now you can substitute this equation into Eq. 26 and solve the velocity as a function of
total row number n

s
752 75 m
 
u = u(1) = u(n) = =√ (30)
n n s
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which is the dimensioning target velocity for the shell and tube condenser with constant
vapour velocity. It is independent of the pressure or temperature level. Using this
velocity the condenser is working approximately on top of the curves in Fig. 2, which
means that the pressure drop is reasonable , and on the other hand the velocity is high
enough to sweep away the accumulating non condensable gases.

The following gure gives the tube arrangement for a 4-row shell and tube condenser.
The vapour is owing inwards and condenses on each tube row. In the middle of the
condenser is the suction channel, which is used to pump away the non condensable gases
which are owing through the condenser together with a small amount of passage vapour
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CONDENSER WITH 4 ROWS

Cross sectional area contracting
when flowing inwards

i=n
N =6 ∑ i
i=1

s/du = 1,3

A1 = 1,8Lndu

S1 =(N-3n)Lπdu

Figure 5. Condenser tube locations, number of tubes and areast

Based on the equations presented in the g. 5 the total outside surface area of the
condenser tubes is

Stot = Ltot πdu = N Lπdu (31)

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where L is length of one tube = Ltot /N and N is number of tubes

Energy balance (Eq. 4) gives the total mass ow of vapour ṁtot = φ/4hL , when the
specic vapour ow is

ṁtot φ/4hL
(32)
00
ṁh = =
Stot N Lπdu
The condensing surface after the cross section area A1 is S1 , when the mass ow at the
cross section A1 is

S1 (N − 3n)Lπdu N − 3n
ṁ1 = ṁtot = ṁtot = ṁtot (33)
Stot N Lπdu N
When the specic volume of vapour is vh , this mass ow corresponds to the volume ow

N − 3n
V̇1 = ṁ1 vh = ṁtot vh (34)
N
Based on this volume ow the velocity at the cross section A1 is then
N −3n
V̇1 ṁtot vh
u1 = = N (35)
A1 1, 8Lndu

When the vapour velocity within the condenser is approximately constant, u1 = u = un ,

and the dimensioning can be done based on the velocity u1 . The condenser must be
dimensioned in such a way that this vapour velocity u1 at the cross section A1 is the same
(or a little larger) than the target velocity u (Eq. 30).

DIMENSIONING OF HORIZONTAL TUBE BANK (STEP BY

STEP)

The dimensioning can begin by choosing the cooling water velocity to be about 2m/s in
order to get large heat transfer coecient of cooling water. Then choose the row number
n (when also the number of tubes N is dened, see Fig. 5). Now you can calculate
the mass ow and temperature rise of cooling water and the total needed conductance
and vapour mass ow using equations 4-7. The heat transfer coecient of cooling water
can be calculated using equations 8-10 and the heat transfer coecient for vapour side is
given in Fig. 2 by using the top values of curves. The conductance per unit length of the
tube is then calculated using equations 1-3 after which the lentgth of one tube L can be
calculated, because N (number of tubes) is already xed. Finally the vapour velocity u1
at cross section A1 can be calculated using the equation 35 and the known mass ow of
vapour. This velocity should be the same as the targer velocity u in equation 30. If this
is not the case, choose a new row number n until the velocity u1 is the same or a little
larger than target velocity.
You can calculate the frictional pressure drop of cooling water using Moody diagram.
The pressure drop of vapour side can be calculated using the equation 20 after you rst
calculate the pressure drop coecient using the equation 23 or 25.
P