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By:
Majid Hayati
Kern’s method
3
Objectives
4
Introduction to Kern’s method
Step 7
Calculate unspecified flow rates
Estimate tube- and shell-side
Calculate ΔTLMTD and ΔTM
pressure drop
Step 3 Step 6
Assume value of overall Estimate tube- and shell-side
coefficient Uo,ass heat transfer coefficient
Step 4 Step 5
Calculate tube number
Determine fouling factors
Calculate shell diameter
Fig. 1: Algorithm of design procedure
6
Kern’s Method Design Example
7
Solution: Step 1
HE specifications:
Coolant (brackish water) is corrosive, so assign to tube-side.
Use one shell pass and two tube passes.
At shell side, fluid (methanol) is relatively clean. So, use 1.25 triangular pitch
(pitch: distance between tube centers).
8
Tube Arrangements
10
Step 2
• 100000
Heat load = Q = m Cph (T1 - T2 ) = × 2.84 (95 - 40) = 4340 kW
h 3600
11
Step 2 (Cont’d)
The cold and the hot stream heat loads are equal. So, cooling water flow rate
is calculated as follow:
. Q 4340
Cooling water flow = mc = = _
= 68.9 kg/s
CP c (t 2 _ t1) 4.2 (40 25)
12
Mean Temperature Difference
13
Temperature Correction Factor
t 2 t1
S
T1 t1
14
Step 2
Fig. 4: Temperature correction factor: one shell pass; two or more even tube passes (available in TEMA)
15
Step 2 (Cont’d)
T1 T2 95 40
R 3.67
t 2 t1 40 25
(t 2 t1 ) 40 25
S 0.21
(T1 t1 ) 95 25
The values given in Table 1 and Fig. 5 can be used for the preliminary
sizing of equipment for process evaluation, and as trial values for
starting a detailed thermal design.
18
Step 3 (Cont’d)
Fig. 5: Overall coefficients (join process side duty to service side and read U from centre scale)
19
Step 4
20
Step 4 (Cont’d)
N t 1n1
Db do ( )
K1
where Db = bundle diameter in mm, do = tube outside diameter in
mm., Nt = number of tubes.
As the shell-side fluid is relatively clean use 1.25 triangular pitch.
So, for this example:
918 1
Bundle diameter D b 20 ( ) 2.207 826 mm
0.249
21
Step 4 (Cont’d)
22
Step 4 (Cont’d)
Note 2: Shell size could be read from standard tube count tables
[Kern (1950), Ludwig (2001), Perry et al. (1997), and Saunders (1988)].
23
Step 4 (Cont’d)
40 + 25
Mean water temperature (Tavg ) = = 33 C ⇒ ρ = 995 kg m3
2
π π
Tube cross - sectional area (a) = D2 = × 16 2 = 201 mm2
4 4
Since we have two tubes pass, we divide the total numbers of tubes
by two to find the numbers of tubes per pass, that is:
918
Tubes per pass = = 459
2
Total flow area is equal to numbers of tubes per pass multiply by
tube cross sectional area:
Total flow area = 459 × (201 × 106 ) = 0.092 m2
25
Step 6 (Cont’d)
L 4.83 × 103 _
= = 302 ⇒ From Fig. 8, jh = 3.9 × 10 3
di 16
kf μ 0.59 _
2
hi = jh Re Pr 0.33 ( )0.14 = _ × 3.9 × 10 3
× 14925 × 5.7 0.33
× 1 0.14
= 3812 W m C
di μw 16 × 10 3
31
Step 6 (Cont’d)
Baffle spacing:
Choose baffle spacing = 0.2 Ds=0.2 894 = 178 mm
Tube pitch:
Pt = 1.25 do= 1.25 20 = 25 mm
Cross-flow area:
(p t _ do ) (25 _ 20) _
As = Dslb = × 894 × 178 × 10 6 = 0.032 m2
pt 25
32
Step 6 (Cont’d)
Shell-side mass velocity Gs and the linear velocity ut:
Ws
Gs =
As
G
us = s
ρ
Where Ws = fluid flow-rate on the shell-side, kg/s,
ρ = shell-side fluid density, kg/m3.
33
Step 6 (Cont’d)
Ws 100000 1 kg
Mass velocity, Gs = = × = 868
As 3600 0.032 s m2
1.10 2 _ 1.1
de = (p t 0.917 d2o ) = (25 2 _
0.917 × 202 ) = 14.4 mm
do 20
34
Step 6 (Cont’d)
95 + 40
Mean shell side temperatur e = = 68 C
2
Methanol density (ρ) from Table 1 = 750 kg m3 )
Viscosity of methanol (μ from Table 1 = 0.34 mNs m2 )
Heat capacity from Table 1 = 2.84 kJ kgC
Thermal conductivi ty Table 1 = 0.19 W mC
ρu sde G sde 868 × 14.4 × 10 - 3
Re = = = _ = 36762
μ μ 0.34 × 10 3
_
Cpμ 2.84 × 10 × 0.34 × 10 3
3
Pr = = = 5.1
kf 0.19
35
Step 6 (Cont’d)
For the calculated Reynolds number, the read value of jh from Fig. 9
for 25 per cent baffle cut and the tube arrangement, we can now
calculate the shell-side heat transfer coefficient hs from:
h sde μ 0.14 0.19
Nu = = jh Re Pr 1 3 ( ) (without viscosity correction term) → hs = - 3 × 3.3 × 10 - 3 × 36762 × 5.1 1 3
kf μw 1.44 × 10
= 2740
Pressure drop
Tube side: From Fig. 10, for Re = 14925
jf = 4.3 10-3
Neglecting the viscosity correction term:
L μ -m ρu2t
ΔPt = Np [8jf ( )( ) + 2.5]
di μw
3
- 3 4.83 × 10 995 × 0.75 2
= 2 (8 × 4.3 × 10 ( ) + 2.5)
16 2
2
= 7211N m = 7.2 kPa (1.1 psi)
low, could consider increasing the number of tube passes.
Shell side
G 868
Linear velocity = s = = 1.16 m/s
ρ 750
From Fig. 11, for Re = 36762
jf = 4 10-2
could be reduced by increasing the baffle pitch. Doubling the pitch halves
the shell side velocity, which reduces the pressure drop by a factor of
approximately (1/2)2
272
ΔPs = = 68 kPa (10psi), acceptable
4
This will reduce the shell-side heat-transfer coefficient by a factor of
(1/2)0.8(ho∝ Re0.8 ∝ us0.8)
ho = 2740 (1/2)0.8 = 1573 W/m2°C
This gives an overall coefficient of 615 W/m2°C – still above assumed value of
600 W/m2°C
41
Step 8 (Cont’d)
Uo = 738 W m2 C
42
References
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