Lecture 4 - Heat Exchanger Design

Heat exchanger design Heat exchanger design Heat exchanger design Heat exchanger design
Copyright@Dominic Foo H82PLD - Plant Design HE Design - 2

The The The The Onion diagram Onion diagram Onion diagram Onion diagram
Reactor
Separation &
recycle
Heat exchanger
network
Utilities
(Linnhoff et al., 1982;
Smith, 1995, 2005)
We are here
now
Lecture outline Lecture outline Lecture outline Lecture outline
Different types of heat
exchangers
Important equations for heat
exchangers design
Conceptual design for shell-and-tube
heat exchanger
Introduction Introduction Introduction Introduction
This lecture file is a courtesy of Dr John Balwin at
Texas A&M University
The word exchanger refers to all types of
equipment in which heat is exchanged
Other specific terms for heat exchangers:
Process fluid heated/cooled by plant service stream in a
heater/cooler
Process stream is vaporised in a vaporiser
Reboiler is used in a distillation column
Evaporator is used to concentrate a solution
Fired exchanger exchangers heated by combustion
gases, e.g. boiler
Standard flow patterns Standard flow patterns Standard flow patterns Standard flow patterns
Air Air Air Air- -- -cooled heat exchanger cooled heat exchanger cooled heat exchanger cooled heat exchanger
Cross sectional view Cross sectional view Cross sectional view Cross sectional view
2 different types 2 different types 2 different types 2 different types
Air pushed by fans below tubes.
Air pulled by fans
above tubes
Bay arrangements Bay arrangements Bay arrangements Bay arrangements
A AA A- -- -frame type frame type frame type frame type air air air air- -- -cooled exchanger cooled exchanger cooled exchanger cooled exchanger
Engineering view of A Engineering view of A Engineering view of A Engineering view of A- -- -frame air frame air frame air frame air- -- -
cooled exchanger cooled exchanger cooled exchanger cooled exchanger
Other types Other types Other types Other types
Combined air/water cooler Steam flow condenser
Transporting exchangers Transporting exchangers Transporting exchangers Transporting exchangers size size size size
matters! matters! matters! matters!
Plate heat exchanger Plate heat exchanger Plate heat exchanger Plate heat exchanger
Small footprint
Very high convection coefficients
Easy to assemble and disassemble
Self cleaning
Normally for relatively low pressures and relatively normal temp
Can easily be modified to vary the heat transfer area
Spiral plate heat exchanger Spiral plate heat exchanger Spiral plate heat exchanger Spiral plate heat exchanger
Provide true countercurrent flow
Hot fluid enters at the spiral centre & flows outward; while
cold fluid enters at the periphery & flows inward.
Competitive with the shell-and-tube exchanger for heating
& cooling of highly viscous, corrosive, fouling and scaling
fluids at ambient to moderate pressures
Spiral plate heat exchanger Spiral plate heat exchanger Spiral plate heat exchanger Spiral plate heat exchanger
Reflux condenser Down-flow condenser
Spiral tube heat exchanger Spiral tube heat exchanger Spiral tube heat exchanger Spiral tube heat exchanger
For high pressure operation
1 fluid flows through the tube coil, other fluid flows
counter-currently in the spiral gap.
Fired exchanger Fired exchanger Fired exchanger Fired exchanger boiler interior boiler interior boiler interior boiler interior
Brazed aluminum (core) heat Brazed aluminum (core) heat Brazed aluminum (core) heat Brazed aluminum (core) heat
exchanger exchanger exchanger exchanger
Useful for low temperature applications
Primary application: the cold box of olefins plant.
Frequently handle 5 10 (or even more) streams
Scraped surface heat exchanger Scraped surface heat exchanger Scraped surface heat exchanger Scraped surface heat exchanger
Crystallizers
Highly viscous services
Daily application: ice cream
freezer
Plate coil heat exchanger Plate coil heat exchanger Plate coil heat exchanger Plate coil heat exchanger
Internal immersion External clamp-on
Useful for small duty applications,
particularly for auxiliary heating.
Compact diffusion bonded heat Compact diffusion bonded heat Compact diffusion bonded heat Compact diffusion bonded heat
exchanger exchanger exchanger exchanger
Compact size
Robust construction.
Small fluid flow channels that are
easily blocked during fouling
Double Double Double Double- -- -pipe heat exchangers pipe heat exchangers pipe heat exchangers pipe heat exchangers
Simplest form of heat exchanger: 1 inner & 1 outer pipe
1 stream flows through the inner pipe; while 1 stream flows
countercurrently through the annual passage between the
inner & outer pipe.
When more heat transfer area needed, return bends & heads
are used hairpin unit.
Double pipe Multi-tube; double pipe
Hairpin units are available up to 200 ft
2
of heat transfer area
Competitive with shell-and-tube exchangers in the range of
100 - 200 ft
2
.
Not recommended for boiling & vaporisation purposes
1-1 unit
Hairpin unit
Shell Shell Shell Shell- -- -and and and and- -- -tube heat exchanger tube heat exchanger tube heat exchanger tube heat exchanger
Cross Cross Cross Cross- -- -sectional view sectional view sectional view sectional view
The important parts The important parts The important parts The important parts
Shell Shell Shell Shell- -- -and and and and- -- -tube heat exchanger tube heat exchanger tube heat exchanger tube heat exchanger
Shell flow pattern Shell flow pattern Shell flow pattern Shell flow pattern
Two-shell-pass
Four-shell-pass
Different configurations Different configurations Different configurations Different configurations
Most simplest type: 1-shell-pass; 1-tube-pass (denoted as 1-1)
Limitation for fixed heat type 1-1 exchanger:
Outside surface cannot be cleaned
When large T between shell & tube sides, differential expansion may
exceed limits for bellows or expansion joins
Velocity of the tube side too low for good heat transfer coefficient
Overcome by other configuration, e.g. floating head
12 fixed head
12 floating head
12 U-tube
24 floating head
Baffle arrangements Baffle arrangements Baffle arrangements Baffle arrangements
Other baffle arrangements Other baffle arrangements Other baffle arrangements Other baffle arrangements
Tube arrangement Tube arrangement Tube arrangement Tube arrangement
Triangular & rotated
square:
Higher heat transfer
Higher pressure drop
Square/rotated
square:
Heavy fouling fluids
Ease for mechanical
cleaning at the outer
layer
Recommended tube
pitch = 1.25 x tube OD
Square pitch
Triangular pitch
Square pitch rotated
Triangular pitch
(with cleaning lane)
P
t
P
t
P
t P
t
Kettle type Kettle type Kettle type Kettle type reboiler reboiler reboiler reboiler
Large shell Large shell Large shell Large shell- -- -and and and and- -- -tube exchangers tube exchangers tube exchangers tube exchangers
On a 42-wheeler?
Tube Tube Tube Tube- -- -sheet for large shell sheet for large shell sheet for large shell sheet for large shell- -- -and and and and- -- -tube tube tube tube
exchangers exchangers exchangers exchangers
33 rows
of tubes!
Tube Tube Tube Tube- -- -sheet of a fouled exchanger sheet of a fouled exchanger sheet of a fouled exchanger sheet of a fouled exchanger
Tube Tube Tube Tube- -- -sheet of a fouled exchanger sheet of a fouled exchanger sheet of a fouled exchanger sheet of a fouled exchanger
A dissembled tube bundle A dissembled tube bundle A dissembled tube bundle A dissembled tube bundle
A U A U A U A U- -- -tube bundle tube bundle tube bundle tube bundle
Tube bundle while cleaning Tube bundle while cleaning Tube bundle while cleaning Tube bundle while cleaning
Horizontal shell Horizontal shell Horizontal shell Horizontal shell- -- -side condenser side condenser side condenser side condenser
Excess vapor or
noncondensables
vent
Gravity-
controlled
flow
Shear-
controlled
flow
Vapor in
Baffle,
vertical cut
Condensate out
Coolant in
Coolant out
Fluid allocation Fluid allocation Fluid allocation Fluid allocation
Material of construction tube side if expensive
material is required for corrosive or high temp
fluid
Fouling tube side if fluid that has tendency to
foul (higher velocity in tube reduces fouling)
Operating pressure tube side for higher pressure
stream(tube needs thinner wall due to smaller
diameter, compared to shell)
Pressure drop tube side for lower P (higher
heat transfer coefficient in tube)
Fluid allocation (continue) Fluid allocation (continue) Fluid allocation (continue) Fluid allocation (continue)
Viscosity shell side for more viscous material,
provided it is turbulent flow (higher heat transfer
coefficient)
Stream flowrate lower flowrate to the shell side
(higher heat transfer coefficient)
Fluid temperature hotter fluid in tubes (reduce
heat loss & safety reasons)
Design of Design of Design of Design of shell shell shell shell- -- -and and and and- -- -tube HE tube HE tube HE tube HE
1-1 HE (1 shell 1 tube
pass)
Lowest surface area
requirement
Normal practise: hot
fluid flows vertically
down
hot liquid becomes
denser as it is cooled
1-2 HE
Normal practise: cold
stream flows
upwards
Less dense when
heated
Liquid may vaporise
Important equations for heat Important equations for heat Important equations for heat Important equations for heat
exchanger design exchanger design exchanger design exchanger design
Heat transfer (Q) across a surface:
Q = UAT
Lm
where,
U = overall heat transfer coefficient;
A = heat transfer area;
T
Lm
= log mean temp difference
Change of an individual stream: Q = mC
p
T
where,
m = mass flowrate;
C
p
= heat capacity;
T= temp difference across heat exchanger
5 resistances to heat transfer 5 resistances to heat transfer 5 resistances to heat transfer 5 resistances to heat transfer
Overall heat transfer coefficient (U):
T i
o
TF i
o
i
o o
SF S
h d
d
h d
d
d
d
k
d
h h U
1 1
ln
2
1 1 1
+ +
|
|
\
|
+ + =
(h
S
)
(h
SF
)
(h
TF
)
(h
T
)
(k)
Film transfer coefficient ( Film transfer coefficient ( Film transfer coefficient ( Film transfer coefficient (h hh h
S SS S
, ,, , h hh h
T TT T
) )) )
Fouling coefficient ( Fouling coefficient ( Fouling coefficient ( Fouling coefficient (h hh h
SF SF SF SF
, ,, , h hh h
TF TF TF TF
) )) )
Tube wall coefficient (k) Tube wall coefficient (k) Tube wall coefficient (k) Tube wall coefficient (k)
T TT T
Lm Lm Lm Lm
calculation calculation calculation calculation
T
H, in
= 260C
T
H, out
= 220C
T
C, in
= 150C
T
C, out
= 200C
T
H
=60
T
C
=70
Q
T
( ) ( )
C ________
ln ln
C
H
C H
in C, out H,
out C, in H,
in C, out H, out C, in H,
Lm
=

=
T
T
T T
T T
T T
T T T T
T
Limitation of Limitation of Limitation of Limitation of T TT T
Lm Lm Lm Lm
Only applicable in the following
situation:
Stream flows are at steady-state
Co-current & counter-current flow
Sensible heat transfer, with constant
specific heat
Overall heat transfer coefficient is
constant
No heat losses
In most situation, flow in heat
exchanger is a mixture of co-
current, counter-current & cross-
flow, e.g. 1-2 exchanger.
Counter-current
Co-current
1 11 1- -- -2 design HE 2 design HE 2 design HE 2 design HE
Many practical advantages:
Allowance for thermal
expansion
Easy mechanical cleaning
Good heat transfer coefficient
on tube side (high velocity)
Flow arrangement: mixture of
co-current & counter-current
larger area than 1-1 design
Correction factor (F
t
) needed:
Q = UAF
t
T
Lm
where 0 < F
t
< 1.
Correction factor (F Correction factor (F Correction factor (F Correction factor (F
t tt t
) )) )
Correlated with 2 dimensionless ratio:
Ration of heat capacity flowrate
Thermal effectiveness of HE
Hence, F
t
depends only on T
in
& T
out
of streams.
Various plots of F
t
are available.
in C, out C,
out H, in H,
H , H
C , C
T T
T T
C m
C m
R
p
p
= =
in C, in H,
in C, out C,

T T
T T
S
=
Correction factor for 1 Correction factor for 1 Correction factor for 1 Correction factor for 1- -- -2 22 2
Graphical approach Graphical approach Graphical approach Graphical approach
For design, it is desire to have F
t
> 0.85
F
t
< 0.75 is not acceptable, as below this value, curves turn
sharply downward small errors in R & S result in F
t
much lower than anticipated.
When F
t
is unsatisfactory, a multiple-shell-pass HE is used.
More shell passes higher F
t
value.
Solution:
T
Lm
= _________
R = _________ ; S = _________
Determine F
t
:
Exchanger 1-2: temp crossover
Exchanger 2-4: < 0.5
Exchanger 3-6: < 0.7 (risky)
Exchanger 4-8: 0.85 (satisfactory)
F
t
T
Lm
= _________
Example 1 Example 1 Example 1 Example 1
A hot stream is being cooled from 200F to 140F by
a cold stream that enters the exchanger at 100F &
exists at 190F. Determine the true mean
temperature driving force for multiple tube-pass
shell-and-tube exchanger.
200F
140F
100F
190F
T
hot
=10
T
cold
=40
Q
T
Graphical approach Graphical approach Graphical approach Graphical approach
For design, it is desire to have F
t
> 0.85
F
t
< 0.75 is not acceptable
When F
t
is unsatisfactory, a multiple-shell-pass
heat exchanger is used iterative procedure to
find no of shell (e.g. try 1-2 2-4 3-6, etc.)
An insight on F An insight on F An insight on F An insight on F
t tt t
plot plot plot plot
0.75
Temperature
approach
Q
T
Temperature
cross
Q
T
Large
temperature
cross
Q
T
(Smith, 2005)
Length
T
An insight on F An insight on F An insight on F An insight on F
t tt t
plot plot plot plot
To be confident in design,
steep part of the F
t
chart
should be avoided,
irrespective of F
t
> 0.75.
For any value of R, there is
a maximum asymtropic
value value for S, i.e. S
max
,
where F
t
tends to .
Practical design will be limited to some fraction of S
max
, i.e.
S = X
P
S
max
; where 0 < X
P
< 1
For conceptual design, a value of X
P
= 0.9 is reasonable.
This approach restricted to 1-2 heat exchanger.
0.75
X
P
= 0.9
(Smith, 2005)
Algebraic approach Algebraic approach Algebraic approach Algebraic approach
( )
( )
( )
( )(
(
+ + +
+ +
+
=
1 1 2
1 1 2
ln 1
1
1
ln 1
: 1 For
2
2
2
R R S
R R S
R
RS
S
R
F
R
t
Lm
T UAF Q
t
=
( )
( )
(
+

(
=
=
2 2 2
2 2 2
ln
1
2
: 1 For
S
S
S
S
F
R
t
in C, in H,
in C, out C,
in C, out C,
out H, in H,
; where
T T
T T
S
T T
T T
R
=
t
in
Q
T
T
in
t
out
T
out
Algebraic approach Algebraic approach Algebraic approach Algebraic approach
Situation often encountered where design is infeasible in a single 1-2
shell multiple shell is considered.
By using two 1-2 shells in series, temp cross is reduced.
(Smith, 2005)
Basic principles Basic principles Basic principles Basic principles
In principle, profile achieved by a 2-4 shell is achievable by two 1-2 shell.
For N
shells
in series, some heuristics to remember :
F
t
of each shell = F
t
across all N
shells
shell passes
Rof each shell = Racross all N
shells
shell passes
Values of S of each shell pass (S
1-2
) are equal, but not equal to S across all
N
shells
shell (S
N-2N
).
Equation to determine N
shell
:
Notes:
N
shell
is round up to the next largest number to obtain no of shell
S in this equation is applicable to both S
1-2
and S
N-2N
X
p
is chosen to satisfy the min allowable F
t
, e.g. for F
t, min
= 0.75; X
P
= 0.9.
P
P
X R R
RX R R
W
2 1 1
2 1 1
where
2
2
+ + +
+ + +
=
W
S
RS
N R
ln
1
1
ln
: 1 For
shells
|
\
|
=

2
2
1
1
: 1 For
shells
P
P
X
X
S
S
N R
|
|
\
|
+ |
\
|
= =
Calculation procedure Calculation procedure Calculation procedure Calculation procedure
From R & S
N-2N
, determine N
shell
.
Next, S
1-2
is calculated for each shell:
Finally, substitute to obtain F
t
:
Area can be calculated:
R Z
Z
S
R
N
N
shell
shell
1
1
2 1
1
: 1 For
N N
N N
S
RS
Z
2
2
1
1
where
=
Lm
T UF
Q
A
t
=
(Smith, 2005)
( )
( )
( )
( )(
(
+ + +
+ +
+
=
1 1 2
1 1 2
ln 1
1
1
ln 1
: 1 For
2
2
2
R R S
R R S
R
RS
S
R
F
R
t
( )
( )
(
+

(
=
=
2 2 2
2 2 2
ln
1
2
: 1 For
S
S
S
S
F
R
t
shells shells 2 2
2
2 1
: 1 For
N N S S
S
S
R
N N N N
N N
+
=
=


Example 2 Example 2 Example 2 Example 2
A hot stream is to be cooled from 300 to 100C by
exchange with a cold stream being heated from 60 to
200C in a single unit. 1-2 shell-and-tube heat
exchangers are to be used subject to X
P
= 0.9. The duty
for the exchanger is 3.5 MW & the overall heat transfer
coefficient (U) is estimated to be 100 W.m
-2
.K
-1
.
Calculate:
i. Number of shells required
ii. S
1-2
for each shell
iii. F
t
for the shells in series
iv. Heat transfer area
300C
100C
60C
Q
T
200C
Solution for Example 2 Solution for Example 2 Solution for Example 2 Solution for Example 2
i. Number of shells required:
ii. S
1-2
for each shell:
iii. F
t
for the shells in series:
iv. Heat transfer area:
5833 . 0
60 300
60 200
; 4286 . 1
60 200
100 300
2
=
= =
=
N N
S R
( )( )
) passes shell (3 2.33
6749 . 0
372 . 2
601 . 1
;
ln
5833 . 0 1
5833 . 0 4286 . 1 1
ln
=
= =
(
= W
W
N
s
3805 . 0
4286 . 1 4 . 0
1 4 . 0
4 . 0
4167 . 0
1667 . 0
3
1
3
1
2 1
=
= = =
S Z
86 . 0 3805 . 0 ; 4286 . 1
2 1
= = =
t
F S R
2
6
m 9 61
65.48 x 0.86 x 100
10 x 5 . 3
= =
=
T UF
Q
A
t
in C, out C,
out H, in H,
T T
T T
R
=
in C, in H,
in C, out C,

T T
T T
S
=
Overall design Overall design Overall design Overall design
procedure procedure procedure procedure
We have only learnt
until Step 5 (the rest
of the steps will
remain as your
coursework!)
(Sinnott, 2005)
Bell Bell Bell Bell s method s method s method s method
Heat transfer coefficient and pressure drop are
estimated from correlations for flow:
Over idea tube-banks
Effects of leakage
Bypassing
Flow in window zone
More satisfactory prediction than Kerns method
Basic concepts Basic concepts Basic concepts Basic concepts
Sometimes called the stream
analysis method
Based on the notion that the stream
flow through a shell side of an
exchanger consist of multiple flows.
The streams are as follows:
A. Leaking through the clearance between tubes and baffles
B. Main cross-flow streamflowing through one window across the cross-flow
section and out through the opposite window
C. Bundle bypass stream, flowing around the tube bundle between the
outermost tubes in the bundle and the inside of the shell
D. No stream with this ID
E. Shell to baffle leakage stream flowing through the clearance between the
baffles and the inside diameter of the shell
F. Flowing through any channels within the tube bundle caused by the
provision of pass dividers in the exchanger (only in multiple tube-pass
configurations)
Shell Shell Shell Shell- -- -side heat transfer side heat transfer side heat transfer side heat transfer
coefficient coefficient coefficient coefficient
0.9. to 0.6 from vary will correction total The
factor. correction Leakage F
factor, correction stream Bypass F
factor, correction effect Window F
rows, tube vertical number for factor Correction F
bank, tube ideal an over t coefficien transfer Heat h where

by calculated is t coefficien transfer heat side - shell The
b
w
n
oc
=
=
=
=
=
=
l
L b w n oc s
F F F F h h
P and cross P and cross P and cross P and cross- -- -flow zone flow zone flow zone flow zone
Determined by separate calculations for the cross-
flow and the window zones individually and then
summed for the total amount.
Cross-flow zones:
factor correction leakage
factor correction pass - by
bank tube ideal
equivalent an for calculated drop pressure the
leakage and passing - by for corrected tips, baffle
e between th zone flow - cross a in drop pressure the where
=
=
=
=
=
L
b
i
c
L b i c
F
F
P
P
F F P P
References for detailed design References for detailed design References for detailed design References for detailed design
Kerns method - proposed by D. K. Kern during
the 1930s found in Seider et al. (2003) & Smith
(2005)
Stream Analysis approach originated by Ken
Bell at the University of Delaware during the
1950s and 1960s a good summary of the method
is found in R. K. Sinnott (2005) Chemical
Engineering Design (Vol 6), Butterworth
Heinemann.
Problem for revision Problem for revision Problem for revision Problem for revision
A crude oil stream is to be heated from by recovering heat from
a kerosene product in a single heat exchanger unit. 1-2 shell-
and-tube heat exchangers are to be used subject to X
P
= 0.9.
The flowrates, temperature and physical properties (at the
mean temperature) of the process stream are given in the
following table.
Kerosene Crude oil
Flowrate (m
3
.s
-1
) 0.0370 0.0535
Initial temperature, T
in
(C) 200 40
Final temperature, T
out
(C) 50 150
Heat capacity (J.kg
-1
K
-1
) 2470 2050
Density (kg.m
-3
) 730 830
Problem for revision (continue) Problem for revision (continue) Problem for revision (continue) Problem for revision (continue)
Determine the following:
Determine the number of shells (N
shell
) required for heat
recovery
Value of temperature correction factor (F
t
) for the shells in
series. Explain briefly why two different variables of S are
needed for the calculation.
In the early stage of heat exchanger design, an estimated
value of overall heat transfer coefficient (U) of 300W.m
-2
.K
-1
is used. Estimate the heat transfer area needed using this
estimated coefficient.
The shell-side heat transfer coefficient (h
o
) is earlier
estimated as 2400 W.m
-2
.K
-1
. This leads to a higher value of
U of 350 W.m
-2
.K
-1
. However, it is later determined that the
h
o
has a lower value of 1600 W.m
-2
.K
-1
. Calculate the value
of U and determine the discrepancy in the heat transfer area
calculation due to the different values of U.
[Final exam Spring 2006]

Lecture 4 - Heat Exchanger Design

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