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2, 2012
If all of Stream 1 first exchanges heat with Stream 2, then with Stream 4, the heat transferred initially would be 8250 kW and the intermediate temperature would be found as follows: 8250 Tint = = 200 (Tint 30 ) 71.25C
Checking that this agrees with the required heat transfer of 13750 kW in the second heat exchanger: Q = 200 (140 71.25) = 13750 kW
The temperature-enthalpy diagrams below show the hot and cold stream conditions in the two heat exchangers:
160C
T
120C
Th1 = 150C
160C
Ch =
15 0
W/K
T
120C
Ch
Th2 = 95C
/K 0 kW = 25
/K 0 kW = 20 C
c
Tc1 = 30C 0C 0C
W/K 200 k c=
8250 kW
13750 kW
Tlm
Th Tc T ln h T c
78.75 65 78.75 ln 65
71.655C
U for the two heat exchangers was calculated in the notes as 0.375 and 0.3429 kW m2 K1, respectively, leading to A1 = Q1 U 1Tlm1 Q2 U 2 Tlm 2 = 8250 0.375 71.655 13750 0.3429 15.896 = 307 m 2
A2
2523 m 2
Total area = 2830 m2, c.f. 749 + 1365 = 2114 m2 previously. So operating the heat exchangers in series rather than in parallel would require larger heat exchangers why? (Because the temperature driving forces in the first heat exchanger are larger, but in the second much smaller.) Area targeting by the -NTU method for heat exchanger 1:
0.4583
C*
71.25 30 150 95
0.75
Checking: C* = Cmin Cmax = 150 200 = 0.75 1 1 0.4583 0.75 ln = 1 0.75 1 0.4583
NTU = = A1 =
1 C * 1 ln 1 C* 1
U 1 A1 Cmin 0.7675 150 = 0.375
0.7675
307 m 2
as above!
For HE2:
C*
0 .8
0 .8
NTU = A2 =
4.3244 =
U 2 A2 Cmin
2522 m 2
again, in (close enough) agreement with the LMTD method. Note that the larger area for HE2 arises from the larger heating duty and the much smaller temperature driving forces. Note too that an NTU of 4.3 is large and probably not economic. Looking at the Heggs chart, for a C* of 0.8 and of 0.8730, only a countercurrent (1) or cross-flow design (3) could achieve the required heat transfer.
Of course, we could try to exchange heat between Streams 1 and 4 first, then between Streams 1 and 2. Then, the heat transferred initially would be 13750 kW and the intermediate temperature would be: 13750 = Tint = 200 (Tint 30 ) 98.75C
Checking that this agrees with the required heat transfer of 8250 kW in the second heat exchanger: Q = 200 (140 98.75) = 8250 kW
The temperature-enthalpy diagrams below show the hot and cold stream conditions in the two heat exchangers. From this it becomes evident that this arrangement would not be possible, because the intermediate temperature of 98.75C is now too high to allow Stream 2 to be cooled to 95C.
160C
T
120C
Th1 = 150C
160C
Ch
Th2 = 95C
/K 0 kW = 25
Tc2 = 98.75C
T
120C
Th1 = 150C
/K kW
80C
80C
K kW/ 200 c=
40C
0C
13750 kW
8250 kW
350
300
250
Temperature T ( C)
200
150
100
50
Enthalpy H (kW)
Figure 2.1. Balanced composite curve for a four stream problem with only cold utility. Using the attached template, determine the average heat transfer coefficient and the area targets for each interval using both the LMTD and the e-NTU methods. Then, use the Heggs chart to identify suitable heat exchanger designs for each interval. Note that each enthalpy interval occurs at a change in slope for one of the two curves, at which point the temperature is easily determined (as it is the inlet or outlet temperature of one of the streams). However, the corresponding temperature of the other stream must be found by interpolation. For example, the first kink in the cold composite curve occurs at a temperature of 40C (the cooling water outlet temperature) and an accumulated duty of 750 kW (650 from the cooling water plus the 100 kW to bring stream 3 from 20 to 40C). This 750 kW is recovered from streams 1 and 2, which have a combined heat capacity of 15 kW K1 and come out at 70C; hence the inlet hot stream temperature for enthalpy interval 1 is 70 + 750 15 = 120C . This temperature is shown on the template below. To find the others, insert the stream data as illustrated below for streams 1 and 2, then perform the energy balance across each interval.
Template for calculating hot and cold stream duties in enthalpy intervals, for two hot, two cold and two utility streams.
k
Hot stream temperature (C)
Qi ,k
Qi ,k
Qi ,k
Q j ,k
Q j ,k
Q j ,k
Qi ,k hi
Qi ,k hi
Qi ,k hi
Q j ,k hi
Q j ,k hi
Q j ,k hi
Q hi i =1 i
h
j =1
Qj
j
1
CP = 5, h = 0.8
Total: -
200 600 200 100 250 Total: 1350 400 200 500 Total: 1100 300 300 300 100 Total: 1000
650 -
400 1200 400 200 500 250 125 312.5 750 750 750 250
CP = 5, h = 0.5
2
CP = 10, h = 1.6 CP = 5, h = 0.4
40 20
Total: 800
Total: 650
Enthalpy interval k
Q hi i =1 i
h
j =1
Qj
j
J Q Q hi + h j i =1 i j =1 j I
Qk
(kW)
Tlm (K)
Area (m2)
C*
NTU
Area (m2)
5 5 10 5 15
Any 1,3,4a,7a,9 1,3,4a,7a, 7b?,9 Any except 10b Any except 10b
Figure 5. The Heggs Chart: Asymptotic values of the maximum thermal effectiveness as NTU , for different heat exchanger types.