ECH 4605 - HW 2-Fall 2020

ECH 4605 HW 2 Fall 2020
A 1-1 countercurrent heat exchanger is designed to heat a single component

process stream from 150 oC to 180 oC using a floating head shell and tube heat
exchanger. The hot utility is superheated steam with 50 K superheat. The steam is
at 10barg with saturation temperature of 184 o C. The latent heat of vaporization of
available steam is 2000 kJ/kg while C p of steam is 2.1 J/(g·K) and water is 4.3
KJ/(kg·K). The heat transfer coefficients are 1000 kJ/ (hr·sq.meter·K) for L-L
systems, 2000 kJ/ (hr·sq.meter·K) for superheated steam-liquid systems, and 8000
kJ/ (hr·sq.meter·K) condensing steam-liquid systems. The process stream has a
flow rate of 1000 k-moles/hr and heat capacity of 100 kJ/ (k-mole K). You can
assume plant operates 8400 hrs a year.
A. What is the lowest possible outlet temperature possible for the heating steam
stream and the corresponding annual utility consumption?
B. What is the highest possible outlet temperature possible for the heating
steam stream and the corresponding annual utility consumption?
C. What are the corresponding heat exchanger areas for parts A and B.
D. Create a plot with at least 10 intermediate outlet conditions of the steam

stream versus total heat exchanger area and annual utility consumption.
Solution:
At first, the heat duty of process stream will be calculated using following formula:
Q = m*Cp*(T2-T1)
kmol KJ
Q = 1000 hr * 100 Kmol K * (180 – 150) K
KJ
Q = 3000,000 hr
Now, temperature of supersaturated steam used at 10 barg is determined as
follows:
Saturated steam @ 10 barg temperature = 184 C
Super saturation level = 50 K = 50 C
Super saturated steam temperature = 184 + 50
= 234 C
Part A:
Since the utility stream used here is super saturated steam, both outlet temperature
and mass flow rate of it is unknown. As per the pinch analysis, minimum
temperature difference of 10 C has to be maintained between two working fluids.
The outlet temperature of process stream is 180 C and to avoid pinch point the
minimum temperature of utility stream should be 160 C.
180 C 150 C
234 C 160 C
Hence, process stream is being heated up from 150 to 180 degree.
On the other hand, temperature of utility stream will drop from 234 to 184 C
(where phase change will occur) and then from 184 C to 160 C.
Q(process stream) = Q(superheated steam) + Q (saturated steam) + Q(condensed steam)

KJ
3000,000 hr = (m * Cp * (T2 – T1)) + (m* lemda) + (m * Cp * (T2 – T1))
KJ
3000,000 hr = m { (2.1 * (234 -184)) + 2000 + (4.3 * (184 – 160)) }
Where,
Mass flow rate of utility stream = 1358.57 Kg/hr
Moreover,
Annual utility consumption = Annual operating hours * Mass flow rate
= 8400 * 1358.57
= 11412009 Kg
Part B:
Since the utility stream used here is super saturated steam, both outlet temperature
and mass flow rate of it is unknown. The maximum possible outlet utility
temperature for this process is 233 C, giving higher flow rate consumption as
shown below:
Q(process stream) = Q(superheated steam)

KJ
3000,000 hr = m * Cp * (T2 – T1)
KJ KJ
3000,000 hr = m * 2.1 Kg. K * (234 -233)
Whereas,
Mass flow rate of utility stream = 1428571 Kg/hr
Moreover,
Annual utility consumption = Annual operating hours * Mass flow rate
= 8400 * 1428571
= 1.2 * 1010 Kg
Part C:
Heat exchanger area can be calculated using following formula:

Q
A = U∗LMTD
Where,
A = Heat transfer area (m2)
Q = Heat transfer rate (KJ/hr)
U = Heat transfer coefficient (KJ/(hr.m2.K)
LMTD = Log mean temperature difference (K)
Where LMTD can be calculated as:
T1 = Inlet tube side fluid temperature
t2 = Outlet shell side fluid temperature
T2 = Outlet tube side fluid temperature
t1 = Inlet shell side fluid temperature
For part A:
Total length is divided in 3 parts as shown in figure:
For zone-1:
Utility side Q is calculated as:
Q = m*Cp*delta T
Q = 1358.57 * 4.3 * (184 – 160)

Q = 140204 KJ/hr
Now, calculate temperature at point A of process stream”
Q = m*Cp*delta T
140204 = (1000*100* (T-150) )
T at point A = 151.40 C
In this zone, utility stream temperature is dropped from 184 to 160 C and
temperature of process stream is increasing from 150 to 151.4 C.
LMTD from above mentioned formula is calculated as:
LMTD = 19.12 C
Now using the formula of heat exchange area:

140204
A = 1000∗19.12
A = 7.33 m2
For zone-2:
Q = m*Lemda
Q = 1358.57 * 2000
Q = 2717140 KJ/hr
Now, calculate temperature at point B of process stream”
Q = m*Cp*delta T
2717140 = (1000*100* (T-151.40) )
T at point B = 178.57 C
In this zone, utility stream temperature is dropped from 184 to 184 C (phase
change) and temperature of process stream is increasing from 151.4 to 178.57 C.
LMTD = 15.15 C

2717140
A = 8 000∗1 5 .15
A = 22.41 m2
For zone-3:
Q = m*Cp*delta T
Q = 1358.57 * 2.1 * (234 – 184)
Q = 142649 KJ/hr
Here the final temperature of process stream is 180 C.
In this zone, utility stream temperature is dropped from 234 to 184 C and
temperature of process stream is increasing from 178.57 to 180 C.
LMTD = 29.14 C

14 2649
A = 2000∗21.14
A = 3.373 m2
Hence,
Total required area will be calculated by summing all above 3 zone areas:
Total area = 3.373 +22.41 +7.33
= 33.113 m2
For part B:
LMTD is calculated using above mentioned formula as:
LMTD = 67.46 K
3000 , 000( KJ /hr )
A = 2000 KJ
( 2
hr .m . K )
∗67.46 K
A = 22.23 m2
Part C:
Using the strategy mentioned above, following values are calculated:

Kg K m2
Outlet steam stream Annual utility Heat exchanger
LMTD
temperature consumption area
185 2.45E+08 43.82 34.23
190 2.73E+08 46.65 32.15
195 3.08E+08 49.36 30.39
200 3.53E+08 51.97 28.86
205 4.14E+08 54.50 27.52
210 5.00E+08 56.95 26.34
215 6.32E+08 59.33 25.28
220 8.57E+08 61.65 24.33
225 1.33E+09 63.93 23.46
230 3.00E+09 66.15 22.68

ECH 4605 - HW 2-Fall 2020

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ECH 4605 HW 2 Fall 2020

A 1-1 countercurrent heat exchanger is designed to heat a single component

D. Create a plot with at least 10 intermediate outlet conditions of the steam

Saturated steam @ 10 barg temperature = 184 C

Super saturation level = 50 K = 50 C

Super saturated steam temperature = 184 + 50

Hence, process stream is being heated up from 150 to 180 degree.

Q(process stream) = Q(superheated steam) + Q (saturated steam) + Q(condensed steam)

Mass flow rate of utility stream = 1358.57 Kg/hr

Q(process stream) = Q(superheated steam)

Mass flow rate of utility stream = 1428571 Kg/hr

Annual utility consumption = Annual operating hours * Mass flow rate

Heat exchanger area can be calculated using following formula:

Q = Heat transfer rate (KJ/hr)

U = Heat transfer coefficient (KJ/(hr.m2.K)

LMTD = Log mean temperature difference (K)

Where LMTD can be calculated as:

T1 = Inlet tube side fluid temperature

t2 = Outlet shell side fluid temperature

T2 = Outlet tube side fluid temperature

t1 = Inlet shell side fluid temperature

Total length is divided in 3 parts as shown in figure:

Utility side Q is calculated as:

Q = 1358.57 * 4.3 * (184 – 160)

Now, calculate temperature at point A of process stream”

140204 = (1000*100* (T-150) )

LMTD from above mentioned formula is calculated as:

Now using the formula of heat exchange area:

Utility side Q is calculated as:

Now, calculate temperature at point B of process stream”

2717140 = (1000*100* (T-151.40) )

Now using the formula of heat exchange area:

Utility side Q is calculated as:

Q = 1358.57 * 2.1 * (234 – 184)

Here the final temperature of process stream is 180 C.

LMTD from above mentioned formula is calculated as:

Now using the formula of heat exchange area:

LMTD is calculated using above mentioned formula as:

Using the strategy mentioned above, following values are calculated:

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140204 = (1000100 (T-150) )

2717140 = (1000100 (T-151.40) )