Thermal Design Of Condensers
SingleComponent Condensers
Mean Temperature Difference In condensing a single component at its saturation temperature, the entire resistance to heat transfer on the condensing side is generally assumed to be in the layer of condensate. A mean condensing coefficient is calculated from the appropriate correlation and combined with the other resistances in Eq. (112). The overall coefficient is then used with the LMTD (no FT correction is necessary for isothermal condensation) to give the required area, even though the condensing coefficient and hence U are not constant throughout the condenser.
If the vapor is superheated at the inlet, the vapor may first be desuperheated by sensible heat transfer from the vapor. This occurs if the surface temperature is above the saturation temperature, and a singlephase heattransfer correlation is used. If the surface is below the saturation temperature, condensation will occur directly from the superheated vapor, and the effective coefficient is determined from the appropriate condensation correlation, using the saturation temperature in the LMTD. To determine whether or not condensation will occur directly from the superheated vapor, calculate the surface temperature by assuming singlephase heat transfer.
Tsurface Tvapor 7 (Tvapor Tcoolant) (1126)
h where h is the sensible heattransfer coefficient for the vapor, U is calculated by using h, and both are on the same area basis. If Tsurface > Tsaturation, no condensation occurs at that point and the heat flux is actually higher than if Tsulfloe < Tsaturation and condensation did occur. It is generally conservative to design a purecomponent desuperheatercondenser as if the entire heat load were transferred by condensation, using the saturation temperature in the LMTD.
The design of an integral condensate subcooling section is more difficult, especially if close temperature approach is required. The condensate layer on the surface is on the average subcooled by onethird to onehalf of the temperature drop across the film, and this is often sufficient if the condensate is not reheated by raining through the vapor. If the condensingsubcooling process is carried out inside tubes or in the shell of a vertical condenser, the singlephase subcooling section can be treated separately, giving an area that is added onto that needed for condensation. If the subcooling is achieved on the shell side of a horizontal condenser by flooding some of the bottom tubes with a weir or level controller, the rate and heatbalance equations must be solved for each section to obtain the area required.
Pressure drop on the condensing side reduces the final condensing temperature and the MTD and should always be checked. In designs requiring close approach between inlet coolant and exit condensate (subcooled or not), underestimation of pressure drop on the condensing side can lead to an exchanger that cannot meet specified terminal temperatures. Since pressuredrop calculations in twophase flows such as condensation are relatively inaccurate, designers must consider carefully the consequences of a largerthancalculated pressure drop.
Horizontal InShell Condensers The mean condensing coefficient for the outside of a bank of horizontal tubes is calculated from Eq. (593) for a single tube, corrected for the number of tubes in a vertical row. For undisturbed laminar flow over all the tubes, Eq. (597) is, for realistic condenser sizes, overly conservative because of rippling, splashing, and turbulent flow (Process Heat Transfer, McGrawHill, New York, 1950). Kern proposed an exponent of —j on the basis of experience, while Freon11 data of Short and Brown (General Discussion on Heat Transfer, Institute of Mechanical Engineers, London, 1951) indicate independence of the number of tube rows. It seems reasonable to use no correction for inviscid liquids and Kern's correction for viscous condensates. For a cylindrical tube bundle, where N varies, it is customary to take N equal to twothirds of the maximum or centerline value.
Baffles in a horizontal inshell condenser are oriented with the cuts vertical to facilitate drainage and eliminate the possibility of flooding in the upward crossflow sections. Pressure drop on the vapor side can be estimated by the data and method of Diehl and Unruh [Pet. Refiner, 36(10), 147 (1957); 37(10), 124 (1958)].
High vapor velocities across the tubes enhance the condensing coefficient. There is no correlation in the open literature to permit designers to take advantage of this. Since the vapor flow rate varies along the length, an incremental calculation procedure would be required in any case. In general, the pressure drops required to gain significant benefit are above those allowed in most process applications.
Vertical InShell Condensers Condensers are often designed so that condensation occurs on the outside of vertical tubes. Equation (588) is valid as long as the condensate film is laminar. When it becomes turbulent, Fig. 510 or Colburn's equation [Trans. Am. Inst. Chem. Eng., 30,187 (19331934) may be used.
Some judgment is required in the use of these correlations because of construction features of the condenser. The tubes must be supported by baffles, usually with maximum cut (45 percent of the shell diameter) and maximum spacing to minimize pressure drop. The flow of the condensate is interruptedby the baffles, which may draw off or redistribute the liquid and which will also cause some splashing of freefalling drops onto the tubes.
For subcooling, a liquid inventory may be maintained in the bottom end of the shell by means of a weir or a liquidlevelcontroller. The subcooling heattransfer coefficient is given by the correlations for natural convection on a vertical surface [Eqs. (533a), (533b)], with the pool assumed to be well mixed (isothermal) at the subcooled condensate exit temperature. Pressure drop may be estimated by the shellside procedure.
Horizontal InTube Condensers Condensation of a vapor inside horizontal tubes occurs in kettle and horizontal thermosiphon reboilers and in aircooled condensers. Intube condensation also offers certain advantages for condensation of multicomponent mixtures, discussed in the subsection "Multicomponent Condensers." The various intube correlations are closely connected to the twophase flow pattern in the tube [Chem. Eng. Prog. Symp. Ser., 66(102), 150 (1970)]. At low flow rates, when gravity dominates the flow pattern, Eq. (5101) may be used. At high flow rates, the flow and heat transfer are governed by vapor shear on the condensate film, and Eq. (5100a) is valid. A simple and generally conservative procedure is to calculate the coefficient for a given case by both correlations and use the larger one.
Pressure drop during condensation inside horizontal tubes can be computed by using the correlations for twophase flow given in Sec. 6 and neglecting the pressure recovery due to deceleration of the flow.
Vertical InTube Condensation Verticaltube condensers are generally designed so that vapor and liquid flow cocurrently downward; if pressure drop is not a limiting consideration, this configuration can result in higher heattransfer coefficients than shellside condensation and has particular advantages for multicomponent condensation. If gravity controls, the mean heattransfer coefficient for condensation is given by Figs. 59 and 510. If vapor shear controls, Eq. (599a) is applicable. It is generally conservative to calculate the coefficients by both methods and choose the higher value. The pressure drop can be calculated by using the LockhartMartinelli method [Chem. Eng. Prog., 45,39 (1945)] for friction loss, neglecting momentum and hydrostatic effects.
Vertical intube condensers are often designed for reflux or knockback application in reactors or distillation columns. In this case, vapor flow is upward, countercurrent to the liquid flow on the tube w all; the vapor shear acts to thicken and retard the drainage of the condensate film, reducing the coefficient. Neither the fluid dynamics nor the heat transfer is well understood in this case, but Soliman, Schuster, and Berenson [J. Heat Transfer, 90, 267276
(1968)] discuss the problem and suggest a computational method. The DiehlKoppany correlation [Chem. Eng. Prog. Symp. Ser. 92, 65
(1969)] may be used to estimate the maximum allowable vapor velocity at the tube inlet. If the vapor velocity is great enough, the liquid film will be carried upward; this design has been employed in a few cases in which only part of the stream is to be condensed. This veloc ity cannot be accurately computed, and a very conservative (high) outlet velocity must be used if unstable flow and flooding are to be avoided; 3 times the vapor velocity given by the DiehlKoppany correlation for incipient flooding has been suggested as the design value for completely stable operation.
Multicomponent Condensers
Thermodynamic and MassTransfer Considerations Multicomponent vapor mixture includes several different cases: all the components may be liquids at the lowest temperature reached in the condensing side, or there may be components which dissolve substantially in the condensate even though their boiling points are below the exit temperature, or one or more components may be both noncondensable and nearly insoluble.
Multicomponent condensation always involves sensibleheat changes in the vapor and liquid along with the latentheat load. Compositions of both phases in general change through the condenser, and concentration gradients exist in both phases. Temperature and concentration profiles and transport rates at a point in the condenser usually cannot be calculated, but the binary cases have been treated: condensation of one component in the presence of a completely insoluble gas [Colburn and Hougen, Ind. Eng. Chem., 26, 11781182 (1934); and Colburn and Edison, Ind. Eng. Chem., 33, 457458 (1941)] and condensation of a binary vapor [Colburn and Drew, Trans. Am. Inst. Chem. Eng., 33, 196215 (1937)]. It is necessary to know or calculate diffusion coefficients for the system, and a reasonable approximate method to avoid this difficulty and the reiterative calculations is desirable. To integrate the point conditions over the total condensation requires the temperature, composition enthalpy, and flowrate profiles as functions of the heat removed. These are calculated from component thermodynamic data if the vapor and liquid are assumed to be in equilibrium at the local vapor temperature. This assumption is not exactly true, since the condensate and the liquidvapor interface (where equilibrium does exist) are intermediate in temperature between the coolant and the vapor.
In calculating the condensing curve, it is generally assumed that the vapor and liquid flow collinearly and in intimate contact so that composition equilibrium is maintained between the total streams at all points. If, however, the condensate drops out of the vapor (as can happen in horizontal shellside condensation) and flows to the exit without further interaction, the remaining vapor becomes excessively enriched in light components with a decrease in condensing temperature and in the temperature difference between vapor and coolant. The result may be not only a small reduction in the amount of heat transferred in the condenser but also an inability to condense totally the light ends even at reduced throughput or with the addition of more surface. To prevent the liquid from segregating, intube condensation is preferred in critical cases.
Thermal Design If the controlling resistance for heat and mass transfer in the vapor is sensibleheat removal from the cooling vapor, the following design equation is obtained:
U' is the overall heattransfer coefficient between the vaporliquid interface and the coolant, including condensate film, dirt and wall resistances, and coolant. The condensate film coefficient is calculated from the appropriate equation or correlation for pure vapor condensation for the geometry and flow regime involved, using mean liquid properties. ZH is the ratio of the sensible heat removed from the vaporgas stream to the total heat transferred; this quantity is obtained from thermodynamic calculations and may vary substantially from one end of the condenser to the other, especially when removing vapor from a noncondensable gas. The sensibleheattransfer coefficient for the vaporgas stream h„ is calculated by using the appropriate correlation or design method for the geometry involved, neglecting the presence of the liquid. As the vapor condenses, this coefficient decreases and must be calculated at several points in the process. Tv and Tc are temperatures of the vapor and of the coolant respectively. This procedure is similar in principle to that of Ward [Petro/Chem. Eng., 32(11), 4248 (1960)]. It may be nonconservative for condensing steam and other highlatentheat substances, in which case it may be necessary to increase the calculated area by 25 to 50 percent.
Pressure drop on the condensing side may be estimated by judicious application of the methods suggested for purecomponent condensation, taking into account the generally nonlinear decrease of vaporgas flow rate with heat removal.
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