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Transfer Equipment
Objectives
By the end of this lecture, students will obtain
knowledge and skills on:
Introduction
Heat transfer is required for control of:
fluid temperature and/or its phase
rate of mass transfer between phases
rate of chemical reaction
temperature to prevent failure of equipment
The transfer of heat takes place in most equipment, but we deal
here with equipment that is designed specifically for the transfer of
heat. Heat transfer equipment can be divided into three basic types:
fluid-fluid, such as pipe in pipe, shell and tube, plate and
frame, etc
air coolers, such as fin fans, and cooling towers
fired heaters
Regardless of the type of exchanger, each makes use of the
fundamental heat transfer mechanisms.
ENCH 607-Dr. Nassar
Conduction
Conduction of heat occurs by the excitation of adjacent
molecules as opposed to overall mixing of the molecules.
Fouriers law of heat conduction applies:
Q kA
dT
dx
(Eq 7-1)
Conduction
Flat Surface:
For heat flow in a cylindrical shape where the heat flow is normal to
the axis, as in heat flow through a cylindrical vessel or pipe wall.
2LkT
(Eq 7-3)
Q
ln( Do / Di )
T: Ti -To (K or oC)
Do: outside diameter (m)
Di: inside diameter (m)
L: length of surface (m)
ENCH 607-Dr. Nassar
Conduction
Cylindrical Shape:
2Lk ( Do Di ) Ti To
ln( Do / Di ) Do Di
2k ( Ao Ai ) Ti To
ln( Ao / Ai ) Do Di
Q 2kAlm
T
D
(Eq 7-4)
(Eq 7-5)
(Eq 7-6)
Ao Ai
Alm = is the log mean area =
ln( Ao / Ai )
ENCH 607-Dr. Nassar
Conduction
Spherical Shape:
2kT
(1 / Di 1 / Do )
(Eq 7-7)
Di Do
Do Di
(Eq 7-8)
Q 2kT
T
Q 2kAgm
D
Agm: is the geometric mean area =
(Eq 7-9)
Ai Ao
The thermal conductivities for refractories and insulations are given in FIG 8-3 of
the GPSA Engineering Data Book. Thermal conductivities of metals can be found in
FIG 8-8 and FIG 9-8 in GPSA Engineering Data Book.
A conduction problem is shown as Example 8-1 in the GPSA Engineering Data
Book.
ENCH 607-Dr. Nassar
10
Convection
Convection is heat transfer that takes place by the physical
movement of molecules, usually a fluid passing next to a solid.
Most of the resistance to heat transfer occurs in a thin film at the
surface of the solid. This film exists even if the bulk fluid flow is very
turbulent.
Newtons law of cooling applies in this situation:
Q hAT
(Eq 7-10)
11
Natural Convection
Natural or free convection occurs where the only force promoting
fluid flow is a result of the temperature difference of the fluid.
For natural convection the heat transfer coefficient is governed by
the Nusselt equation.
Nu C Gr Pr
(Eq 7-11)
hL
k
D 3 2 gT
1000C p
(Eq 7-12)
(Eq 7-13)
(Eq 7-14)
k
ENCH 607-Dr. Nassar
12
Natural Convection
The values of C and m in equation 7-11 depend on geometry and dimensions
of the surface. Values for the coefficients for various conditions can be found
in FIG 8-4 of the GPSA Engineering Data Book.
Of most interest to us, are long horizontal cylinders (L>D) and vertical plates
or cylinders. Table 7-1 provides the coefficients.
Table 7-1: Heat transfer constants for vertical plates and horizontal cylinders
Table 7-1
Vertical Plates
or Cylinders (Y = Gr. Pr)
Y < 104
1.36
0.20
0.55
0.25
Y > 109
0.13
0.33
Horizontal Cylinder
D < 0.1
0.53
0.25
0.47
0.25
0.5 < D
0.11
0.33
13
Natural Convection
14
Forced Convection
Forced convection occurs when the fluid flow adjacent to the solid is
promoted by external forces such as pumping or agitation. This increases
the heat transfer rate.
There are two principle cases, one where viscosity effects are minimal, and
the other where viscosity is significant.
Dittus-Boelter Equation
When viscosity effects are minimal
Nu C Re m Pr 0.33
(Eq 7-15)
Seider-Tate Equation
When viscosity effects are important
m
0.33 b
Nu C Re Pr
w
0.14
(Eq 7-16)
15
Forced Convection
The value of C and m in equations 7-15 and 7-16 depends on geometry and
dimensions of the surface. Values for the coefficients for various conditions
can be found in FIG 8-5 of the GPSA Engineering Data Book. The data
covers flat plates, flow across a cylinder, flow inside pipes, and flow on the
outside of tubes.
16
Forced Convection
(Eq 7-17)
with the values of C, m and n for various configurations given in Table 7-2.
17
Forced Convection
Table 7-2
18
Deq Do Di
(Eq 7-18)
Weigand has proposed the following for the turbulent flow heat transfer
coefficient on the outer wall of the inner pipe
0.023k Deq v
h
Deq
0 .8
1000C p
0 .4
Do
Di
0.45
(Eq 7-19)
19
DGmax
hD
C
k
(Eq 7-20)
Where Gmax is the product of density times velocity at the minimum cross
section. Gas properties are evaluated at the arithmetic mean of the gas and the
tube wall temperature.
The coefficients for tube banks 10 or more rows deep are given in Table 7-3
Table 7-3: Coefficients for Grimison Equation
C
0.482
0.556
0.229
0.632
20
1000C p
DGmax
hD
1.1
C
k
k
0.33
(Eq 7-21)
For banks of tubes less than 10 rows deep, equation 7-20 can be used and
the heat transfer coefficient adjusted using the ratio in Table 7-4.
Table 7-4: Ratio of Mean Heat Transfer Coefficients for a Bank of Tubes N rows
Deep to the Coefficient for Tubes in a Single Row
N
10
Triangular
1.0
1.10
1.22
1.31
1.35
1.40
1.42
1.44
1.46
1.47
Square
1.0
1.25
1.36
1.41
1.44
1.47
1.50
1.53
1.55
1.56
21
1000C p
hD
2.0 0.6
k
k
0.33
Dv
0 .5
(Eq 7-22)
Dvs
h 26.82vs C p
(1 )
0.5
1000C p
0.67
(Eq 7-23)
rhombohedral packing
Porosity: 26%
ENCH 607-Dr. Nassar
22
Radiation
Radiation is the process whereby a body emits heat waves that may be absorbed, reflected,
or transmitted through a colder body.
A hot body emits a whole spectrum of wavelengths. Heat is transmitted through the full wave
length, infrared, visible, ultraviolet. An estimate of the radiant heat flux between two surfaces
is:
4
4
Q F T1 T2
A 1 1
1
1 2
(Eq 7-24)
The geometry or shape factor, F, is the fraction of the surface area that is
exposed to and absorbs radiant heat. The value of F must be determined by
an analysis of the geometry and should normally be greater than 0.67.
The emissivities of common materials are given in FIG 8-9 of the GPSA
Engineering Data Book. The emissivities of gases are more complex, as it
depends on the partial pressure of the gas and the path length. Gas
emissivities are given in FIG 8-12.
A radiation problem is shown as Example 8-6 in the GPSA Engineering Data
Book.
ENCH 607-Dr. Nassar
23
24
25
xa
ka A
x
T2 T3 Q b
kb A
T1 T2 Q
T3 T4 Q
xc
kc A
(Eq 7-25)
(Eq 7-26)
(Eq 7-27)
xa xb xc
T1 T4 Q
k a A kb A k c A
(Eq 7-28)
and therefore
T1 T4
xa xb xc
k a A kb A k c A
(Eq 7-29)
This is equivalent to Ohms law for electricity, and the denominator is the overall
resistance to heat transfer. Since Q/A is the same for all layers, the temperature
gradient, T/x, is inversely proportional to the thermal conductivity of the layer.
ENCH 607-Dr. Nassar
26
Where:
T1 T4
Db
Dc
1 Da
Alm1
A2 A1
A
ln 2
A1
Ai Di L
(Eq 7-30)
(Eq 7-31)
ENCH
(Eq 607-Dr.
7-32)Nassar
27
T1 T4
Db
Dc
1 Da
(Eq 7-32)
Agm A1 A2
28
Finned Tubes
Gas side heat transfer coefficients are usually much less than liquid side
coefficients, and fins on the gas side are often used to increase the heat
transfer.
For tubes used in combustion gases, typical fins are 1.25 3.0 mm thick,
12.5 40 mm length, with a linear density of 80 - 240 fins/m.
The total external fin area and the cross flow area per linear meter are then
given by:
2
2
d o
n.t n. d f d o
Ao
1
n.t.(d f d o )
do
ACS
1000
106
(Eq 7-34)
(Eq 7-35)
29
Finned Tubes
The surface area of the fin is not as efficient as the external pipe surface, so there is
an efficiency adjustment that is determined by using FIG 8-6 in the GPSA
Engineering Data Book. The fin efficiency is then applied to the total heat transfer
area.
In order to calculate the fin efficiency, from FIG 8-6, two parameters must be
determined as follows:
0 .5
ho
X 0.0405 H f
k t
f
d f do 2H f
do
do
H
(Eq 7-36)
(Eq 7-37)
Fin tip temperature must be considered if the tube is in the hot convection zone of a
furnace. The fin tip temperature can be determined from FIG 8-7 in the GPSA .
The maximum recommended fin tip temperature for various materials, and the
material thermal conductivities are given in FIG 8-8.
A fin efficiency problem is shown as Example 8-5 in the GPSA Engineering Data Book.
ENCH 607-Dr. Nassar
30
31
32
33
Q U o Ao Tlm
For a tube:
Uo
(Eq 7-38)
1
Ao
A
t A
1
1
o w o
hi Ai h fi Ai k w Alm h fo ho
(Eq 7-39)
34
ri
ro
Ao
h fi Ai
(Eq 7-40)
1
h fo
Typical values for the overall heat transfer coefficients and fouling resistances are
given in FIG 9-9 of the GPSA Engineering Data Book. Values can also be found in
ENCH 607-Dr. Nassar
the literature.
35
36
Heat Exchangers
Heat transfer theory is put into practice by construction
equipment to transfer heat between two streams without
physically mixing the streams themselves.
There are a variety of different heat exchangers to transfer
heat from one process fluid to another. The most common
types are pipe-in-pipe, shell and tube, spiral, and plate and
frame.
Special exchanger types include brazed aluminum, printed
circuit, and coil wound exchangers.
Before looking at the various exchangers, it is worthwhile to
look at Figure 7-3 showing the temperature profiles that can
be expected.
ENCH 607-Dr. Nassar
37
Heat Exchangers
38
Heat Exchangers
The lines shown in the previous figure represent fluids that have a constant heat
capacity. In actual fluids, the heat capacity is a function of temperature so the
cooling curves tend to be slightly curved.
For each side of the exchanger, the heat transferred into or out of the fluid must be
equal.
(Eq 7-41)
Q m1C P1 (Tin Tout )1
(Eq 7-42)
(Eq 7-43)
If there is sensible heat and heat of vapourization on one side, then the Q
calculation will have to include a term to capture each region in the exchanger.
In addition, the exchanger must follow the overall heat transfer equation.
Q U o Ao F Tlm
Tlm
(Eq 7-44)
T2 T1
T
ln 2
T1
(Eq 7-45)
39
Heat Exchangers
40
41
42
1. Design Calculations
In design calculations, the two flow rates, and three temperatures will be known.
The objective is to determine the quantity of heat transferred, the unknown
temperature, and the product of UoAo. The solution proceeds as follows:
Q is calculated using one of the flow rates and the inlet and outlet
temperatures for that side of the exchanger,
The fourth temperature is calculated using the other fluid flow rate and the
third temperature (inlet or outlet for that side of the exchanger),
UA is determined from the overall heat transfer equation and an assumption
about the type of exchanger,
Details of U and A are then calculated iteratively along with allowable pressure
drops
The number, size, and pitch layout of tubes are assumed
Ao is calculated based on the tube data
Flow velocities are calculated, and inside and outside heat transfer
coefficients are calculated (hi and ho) from fluid properties, geometry, and
the Dittus-Boelter or Sider-Tate equations.
Uo is calculated from all of the individual heat transfer coefficients,
The calculated values of Ao and Uo are used to see if the overall duty, Q
can be met.
Pressure drop calculations are performed to see if the hydraulic
constraints are met.ENCH 607-Dr. Nassar
43
2. Performance Calculations
For performance calculations the exchanger is existing, so all of the geometry is
known, and Ao is known. The following process data should be available:
Four temperatures and two flow rates (best)
Three temperatures and two flow rates (better)
Four temperatures and one flow rate (good)
The above data is used to calculate Q. In the first case you can calculate Q with
two sets of data, and the results will likely be different. Engineering judgment
should be applied to determine if one calculated value is more reliable than the
other, or if the two Q values should be averaged. For the other two data sets, the
missing piece of data must be calculated and there is no check available for data
quality.
Once Q is determined, Uo can be calculated from the heat transfer equation and
the known exchanger geometry. The calculated value of Uo can be compared to
the design value of Uo. Individual components of the overall Uo; hi, ho, the
conduction term and the total fouling resistance are determined. The inside and
outside fouling resistances cannot be separated. The results indicate if the
exchanger is fouled more than its design fouling and if cleaning is required.
ENCH 607-Dr. Nassar
44
3. Performance Prediction
45
Pipe-in-Pipe Exchangers
This type of exchanger is good for small heat loads where one stream is a
gas or viscous liquid, or for relatively small exchangers operating at high
pressure.
In these exchangers a piece of pipe serves as the shell. The internals
may be a single concentric pipe or a group of pipes. The internal pipes
have a U-tube design. The process diagram is shown in Figure 7-4.
Counter current flow
Shell side
Tube side
46
Pipe-in-Pipe Exchangers
47
Pipe-in-Pipe Exchangers
Double pipe exchangers are intended for small duties, where surface
areas of 10-20 m2 are required.
They are usually assembled in 12, 15, or 20 ft sections, as longer lengths
result in sagging of the inner tube and poor flow distribution.
Standard sizes are:
Outer Pipe (NPS)
2
2
3
4
48
Pipe-in-Pipe Exchangers:
Design Equations
The design equations are used to calculate duty, pipe diameter, wall thickness,
pressure drop, and heat transfer coefficient. Some iteration may be required given
the interaction of the variables.
The exchanger duty is calculated based on the flow, heat capacity, and
temperature change of one of the fluids. The other fluid flow rate or temperature
change is then determined.
A trial pipe diameter is selected based on a velocity of 1-3 m/s. Higher flow rates
will provide better heat transfer.
Wall thick can then be determined based on the operating pressure and the trial
pipe diameter. If the high pressure is in the annulus, a calculation for external
pressure will have to be done.
The heat transfer calculation is performed next. The inside and outside heat
transfer coefficients can be calculated using the Seider-Tate or the Dittus-Boelter
equations. For the inside heat transfer coefficient, the diameter to use is the inner
diameter of the inside tube.
For the outside heat transfer coefficient, the equivalent diameter for heat transfer
must be used. Similar to the equivalent diameter of pressure drop, the equivalent
diameter is defined as the ratio
Flow area/wetted perimeter
ENCH 607-Dr. Nassar
49
Pipe-in-Pipe Exchangers:
Design Equations
For heat transfer, the wetted perimeter is only the outside of the inner pipe. The
equivalent diameter for heat transfer is then
4 D22 D12
D22 D12
De
4D1
D1
(Eq 7-46)
It is customary to use the outside area of the inner tube for the heat transfer
equation, so the overall heat transfer coefficient is given by
Uo
1
Ao
t A
1
ri w o ro
hi Ai
k w Alm
ho
(Eq 7-47)
Ao
Q
U oTlm
(Eq 7-48)
50
Pipe-in-Pipe Exchangers:
Design Equations
Based on the required area and the inner pipe outer wall
diameter, the length of pipe is determined. In some cases,
two or three units can be connected together to provide the
required surface.
Pressure drop calculation can now be performed on the inner
pipe and the annular space using the methods in Lecture 5.
If the pressure drop is too high, then a larger diameter pipe is
required, and the calculation is repeated.
51
52
Shell and tube exchangers can be made with different end closures
and different shell designs. These are designated in TEMA by a three
letter designation indicating front end, shell type, and rear end. Thus,
each exchanger is given three letter designation
A description of the types and their letter designation can be found in
FIG 9-23 in the GPSA Engineering Data Book. A shell and tube
exchanger selection guide is provided in FIG 9-24 to help select the
type of exchanger configuration.
Front end
stationary head
type
Shell
Rear end
head type
53
Courtesy of
TEMA
ENCH 607-Dr. Nassar
54
55
Tubes
Exchanger tubes must be designed to withstand the differential
pressure across the tube, but should be checked to ensure that
they can handle the internal or external pressure if the start-up can
pressure up one side prior to the other.
Tubes come in various outside diameters, OD, and different wall
thickness. OD is usually specified in inches, and wall thickness in
Birmingham Wire Gauge, BWG. Tubing characteristics are
provided in FIG 9-25 of the GPSA Engineering Data Book.
56
Shells
The surface area required in an exchanger must be placed
inside a shell. The number of tubes that can fit into a circular
cross section depends on the tube OD, and the tube pitch.
57
Typically, 1 in tubes on a
1.25 in pitch or 0.75 in
tubes on a 1 in pitch
58
59
Design Tips
The tube length is often taken as 20 feet (about 6 m) as this is a common
length of tube that can be purchased. Other lengths are of course
available. The following general guidelines are useful:
Shell side
viscous fluid to increase the value of U
fluid with the lower flow rate
condensing or boiling fluid
fluid for which pressure drop is critical
if one fluid is a gas
Tube side
toxic fluid to minimize leakage
corrosive fluid
fouling fluid, higher velocity and easier to clean
high temperature fluids requiring alloy pipe
high pressure fluid to minimize cost
cool water
ENCH 607-Dr. Nassar
60
61
62
63
Types of Baffles
64
65
66
t 2 t1
T1 t1
(Eq 7-49)
T1 T2
t 2 t1
(Eq 7-50)
67
Figure 7-9
LMTD
Factor Chart
ENCH
607-Dr.Correction
Nassar
68
1 P
R 2 1 ln
RP
FT
2 P R 1 R2 1
R 1
2
2 P R 1 R 1
(Eq 7-51)
When all four temperatures are known, as in a design case, the values of
P and R are calculated and then a configuration is selected. If the value
of F is less than 0.8, then increase the number of shell passes.
69
70
Tube side and shell side film coefficients are calculated based on the
Dittus-Boelter or Siedler-Tate equations. Once film coefficients are
estimated, the overall heat transfer coefficient is calculated using Eq 7-47.
Calculation of the inside film coefficient is straight forward.
Calculation of the shell side coefficient is more complicated. The tube
bundle baffles provide cross flow and turbulence resulting in higher film
coefficients than for undisturbed flow along the tube axis. Flow across the
tubes also results in increased turbulence, and the velocity is not constant
across the bundle.
Triangular pitch provides more turbulence than square pitch, and film
coefficients are about 25% for triangular pitch.
Clearly, the same equation cannot be used to calculate the tube side and
the shell side film coefficients. The form of the equation however has been
retained, with special definitions used for the mass velocity and the
equivalent diameter.
ENCH 607-Dr. Nassar
71
For values of the Reynolds number from 2000 to 1,000,000, the following equation
applies
D G
ho Des
0.36 es s
k
0.55
1000C p
0.33
0.14
(Eq 7-52)
72
Calculation of the mass velocity is based on the maximum flow area of the
hypothetical tube row at the centre of the shell.
The length of the flow area is taken as the baffle spacing. There is usually no
row of tubes at the centre, but rather two equal maximum rows on either side,
having fewer tubes than computed for the centre. This difference is negligible.
The flowing area is then given by
as
Ds C ' B
PT
(Eq 7-53)
Gs
W
as
(Eq 7-54)
73
C ' PT d o
(Eq 7-55)
And the equivalent diameters for use in the Reynolds number are
4 PT2 d o2
Des
1000d o
(Eq 7-56)
(Eq 7-57)
74
Pressure Drop
2 f f G2L
g c D
ENCH 607-Dr. Nassar
(Eq 7-58)
75
Pressure Drop
f f 16 / Re
(Eq 7-59)
Re 2100
f f 0.054 / Re 0.2
(Eq 7-60)
PN Kvn2 / 2
(Eq 7-61)
Pe KN t vt2 / 2
(Eq 7-62)
76
Pressure Drop
(Eq 7-63)
For high pressure drop systems, tube velocity might limit due to erosion
concerns. Liquid velocity greater than 5 m/s may cause erosion.
ENCH 607-Dr. Nassar
77
78
79
80
81
Spiral Exchangers
A spiral exchanger is a true countercurrent exchanger that separates the two
fluids by a single plate.
Cold fluid enters the outside shell and
exits the center of the exchanger. Hot fluid
enters the centre of the exchanger and
circulates to the outside as shown in
Figure 7-11.
The surface area is increased by
increasing the width of the exchanger.
A gasketed plate covers and seals the
channels and can be removed for
cleaning.
The units are compact, have low pressure
drop, and a tight approach temperature.
They are ideal for handling sludge.
Capacities up to about 2000 kW are
available.
ENCH 607-Dr. Nassar
83
84
ti t o
UA
Tlm m C P
(Eq 7-64)
85
k d eG
h 0.2536
d e
Laminar flow12
d eG
h 0.742C PW
0.65
0.62
1000C P
1000C P
0 .4
0.67
(Eq 7-65)
0.14
(Eq 7-66)
1 1 t
1
r1 r2
U h1 k w h2
ENCH 607-Dr. Nassar
(Eq 7-67)
t = plate thickness (m)
kw = thermal conductivity of plate (W/m K)
86
87
88
Compablock Exchangers
The Compablock exchanger, as
shown in Figure 7-13, is a
variation of the plate and frame
units.
In a Compablock, the plates are
completely welded together and
there are no gaskets between the
plates.
There are four gaskets on the
cover plates.
The unit can be used for liquid- Figure 7-13 Compablock Exchanger
liquid exchange, and as a
reboiler or a condenser.
The units are compact and
robust.
89
ENCH 607-Dr. Nassar
Compablock Exchangers
90
Compablock Exchangers
91
92
93
94
95
96
97
Aerial Coolers
98
Mechanical Arrangements
Aerial coolers typically come as forced draft units or induced draft units. Forced
draft units have the tube section on the discharge side of the fan, while induced
draft units have the tubes on the suction side of the fan.
A diagram showing typical layouts is shown in FIG 10-2 of the GPSA Engineering
Data Book. More than one tube bundle can be included in a unit, and more than
one fan bay can be included in a unit as shown in FIG 10-3.
Advantages and disadvantages of each layout are described in the GPSA. For
process fluids above 175 oC, forced draft units should be used to keep the fan
components from becoming too hot.
Fan sizes range from 0.9 8.5 m, but units of 4.3-4.9 m diameter are the most
common.
Drivers are usually electric and a speed reducer is required to match motor speed
to fan speed. A fan tip speed of 3650 m/min or less is common. V-belt drives are
used up to about 22 kW and gear drives are used for higher power. Maximum
motor size is limited to 37 kW.
The tube bundle is fabricated with multiple rows (3-8) of finned tubes and may
have one pass or two passes. Tube diameters are 16-38 mm, fin heights are 12.7
mm to 25.4 mm, and fin densities range from 276 433 fins/metre.
Tubes in gas processing services are usually carbon steel, but stainless steel may
also be used in some services.
For low pressure service, header boxes are built with a cover plate. For higher
pressure service the end plate must be thicker, and then the header will have plugs
for access to the tubes. FIG 10-5 illustrates the two types of header boxes.
ENCH 607-Dr. Nassar
99
Process Control
The outlet temperature of the process stream is controlled, but if the process fluid becomes
viscous or freezes when cooled, the air temperature may also have to be controlled. When the
ambient temperature is low, recirculation of warm air is often required to keep the bottom row of
tubes from becoming too cold.
The two control schemes must work together. Refer to FIG 10-7 in the GPSA Engineering Data
Book to see the arrangement of air control louvers on a typical cooler.
Temperature control of the process stream is usually accomplished by changing the amount of air
that flows past the coil. The top louver can be adjusted to change the back pressure on the fan and
change the air flow rate. In addition, fan drivers often have two speed motors or completely
variable speed motors. In addition, in multi-fan units, one of more of the fans can be shut off. Some
older units had variable pitch fans, but these were generally high maintenance units and have
mostly been replaced by variable speed drives.
The cooler is designed to provide sufficient cooling when the ambient temperature is high. In
Alberta, a typical design air temperature is 28 - 30 oC. In the Middle East, the air design temperature
can be as high as 50 oC. The process temperature that can usually be achieved is 12 - 15 oC higher
than the air temperature. As the ambient temperature falls below design, less air is required to
provide the process duty, and the fans will slow down or stop to reduce the air flow. As the ambient
temperature gets colder, the operators will close the manual louvers, to limit the intake of cold air.
At some point, the top louvers will start to close to reduce the air flow even more. If this does not
keep the inlet air warm enough, the recirculation louvers will open to allow warm air to mix with the
incoming air. Since the cooler is designed for an inlet air temperature of 28 30 oC, there is no
problem with making the process temperature if the blended air temperature is 10 15 oC. If the
inlet air temperature is allowed to get too cold, the bottom row of tubes can freeze.
ENCH 607-Dr. Nassar
100
Thermal Design
Thermal design of an aerial cooler is done in much the same manner as for any
other exchanger. The basic design equations are:
Q mC P T1 T2
(Eq 7-68)
Q ma C Pa t 2 t1
(Eq 7-69)
Q U A F LMTD
(Eq 7-70)
The temperature correction factor, F in the heat transfer equation can be found
from FIG 10-8 or 10-9 in the GPSA Engineering Data Book. The factor is based
on values of P and R as follows:
t 2 t1
T1 t1
(Eq 7-71)
T1 T2
t 2 t1
(Eq 7-72)
101
Thermal Design
102
103
104
105
For preliminary calculations for liquids, the overall heat transfer coefficients in
Table 7-5, based on bare tube area may be used:
7-5
106
For preliminary calculations for condensing fluids, the overall heat transfer
coefficients in Table 7-6, based on bare tube area may be used.
7-6
107
t2 t1 0.00088.CF .U T2 T1 t1
(Eq 7-73)
CF 0.89 0.0025T1 T2
(Eq 7-74)
The above equations will allow the calculation of the value of maCpa
required for the air flow. The Cpa value for the air must consider the relative
humidity of the air.
C pa
RH
RH
33.5
Pvpw 29.1 P
Pvpw
100
100
(Eq 7-75)
108
h
P 101.325 exp
29
.
28
t
1
(Eq 7-76)
RH
RH
18
Pvpw 29 P
Pvpw
100
100
MWa
P
(Eq 7-77)
With the MW of the air and the ambient air conditions, the density of the inlet air
can be determined.
PMWa
Rt1
(Eq 7-78)
109
With the molar flow rate of air and the ambient conditions, the volumetric
flow of air is found.
qa
ma Rt1
P
(Eq 7-79)
With the volumetric air flow rate determined, the fan power requirements
can be estimated using
kW
Pa qa
(Eq 7-80)
110
111
Performance Testing
Performance testing of an aerial cooler is complicated by the
fact that the air flow rate must be determined. This is done by
measuring the air velocity in a number of locations just under
the fan.
The ambient air temperature is available, so the air outlet can
be determined from the value of Q. Q is determined from the
process side conditions.
One can now calculate the overall heat transfer coefficient, the
individual heat transfer coefficients for both the air side and
process side, and then determine the overall fouling factor. If
the overall fouling factor is larger than the design value, the
cooler is fouled and may benefit from cleaning.
Both the inside of the tubes and the fins may need to be
cleaned.
112
ENCH 607-Dr. Nassar
References
Read Section 9 of the GPSA Engineering Data Book Heat Exchangers
Read Section 10 of the GPSA Engineering Data Book Air-Cooled Exchangers
1. Bennett, C.O., and J.E. Myers, Momentum, Heat, and Mass Transfer, McGraw Hill, 1974.
2. Seider, E.N. and G.E. Tate, Ind. & Eng. Chem., 28, (1936), p. 1429.
3. Colburn, A.P., Trans. AIChE, 29, (1933), p. 174.
4. Marriott, J., Where and How to Use Plate Heat Exchangers, Chem. Eng., April 5, 1971, p. 127.
5. API Standard 661, Air Cooled heat Exchanges for General Refinery Service.
6. Steinmeyer, D., Understanding P and T in Turbulent Flow Heat Exchangers, Chem. Eng. Prog.,
(June 1996), p. 49.
7. Poddar, T.K. and G.T. Polley, Optimize Shell and Tube Heat Exchanger Design, CEP (Sept. 2000),
p.41.
8. Standard of the Tubular Exchanger Mft. Assoc., 6th Edition, New York, 1978.
9. Chen, C.C., Chem. Eng., (Mar. 1984), p. 155
10. Bell, K.J., Oil and Gas J., (Dec. 4,1978), p.59.
11. Buonopane, R.A. et al., Chem. Eng. Prog., Vol. 59, No. 7, (1963), p. 185.
12. Jackson, B.W., and R.A. Troup, Chem. Eng. Prog., Vol. 60, No. 7, (1964), p. 62.
13. Burn, J., A.M. Johnston, N.M. Johnston, Experience With Printed Circuit Heat Exchangers,
European GPA Continental Meeting, Budapest, (1999).
14. Rorschach, R.L., Oil and Gas J., (June 13, 1966), p.90.
15. Brown, R., Chem. Eng.,(Mar. 27,1978), p. 108.
16. Glass, J., Chem. Eng.,(Mar. 27,1978), p. 120.
17. Baker, W.J., Hydr. Proc. (May 1980), p.173.
18. Ganapathy, V., Oil and Gas J., (Dec. 3,1979), p.74.
19. Rubin, F.C., Hydr. Proc. (Dec. 1980), p.147.
20. Chopey, N. P., Hicks, T. G., Handbook of Chemical Engineering Calculations, McGraw-Hill, 1984, pp.786.
ENCH 607-Dr. Nassar
113