Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
Example 1
Freon 12 at a flow rate of 10560 kg/hr, needs to be heated from 240 K
to 300 K. Ethylene glycol is available at 350 K. A typical shell and tube
heat exchanger will be used. The plant manager recommends that the
minimum temperature approach should be at least 10 K. He also
recommends using 20 BWG carbon-steel tubing with a pressure drop
not exceeding 10 psig (0.67 atm) for either the shell or tube side.
Ethylene
Glycol
Freon-12
Ti = 350 K
To = 300 K
Pi =E 2 atm
101
Pi = 7.0 atm
Ethylen Glycol
T = 310 K
For this example, select below property:
Components: Freon-12 (CCl2F2 ) and Ethylene Glycol is (C2H6O2)
Method for the calculations: NRTL-RK
Prepared by CPLEO
Heater Basic heat exchanger, it performs simple energy balance calculations; requires
only one process stream
HeatX Fundamental heat exchanger algorithms, used in rigorous design, will calculate
energy balances, pressure drops, exchanger area, velocities, etc.; requires two process
streamsa hot and a cold. This block will be used for our design calculations.
MheatX Just like the previous block but will accept more process streams
Hetran Heat exchanger algorithm that uses the B-JAC Hetran heat exchanger
program. This will be not used since the B-JAC program is unavailable
Select Heater in this case, any diagrams are just for schematic
purpose.
Prepared by CPLEO
Prepared by CPLEO
Prepared by CPLEO
Prepared by CPLEO
Example 2
Replace the Heater block with HeatX
Each icon represents a different TEMA shell type. Examples of these
shell types can be seen in Perrys 7th edition, pg. 1134.
Add the glycol stream will need to be added.
The Freon-12 stream will be the cold stream and the glycol stream
will be the hot side of the heat exchanger.
Prepared by CPLEO
Prepared by CPLEO
Prepared by CPLEO
Prepared by CPLEO
11
12
13
Prepared by CPLEO
14
Check the inlet and outlet temperatures for both streams for
temperature crossover.
Check the vapor fractions as well.
The glycol stream fell below the design temperature of 310K. (in
circle) The flow rate of this stream needs to be increased to keep
the outlet temperature difference at 10 K. (A design-spec may be
applied to find the correct flow rate) The flow rate for the glycol
stream turns out to be 102.87 kmol/hr.
Prepared by CPLEO
15
After the determination of flow rates and the heat duty, start the
detailed calculations.
In Setup, change the calculation type from shortcut to the
detailed method.
Identify fluids for shell and tube.
Aspen will now calculate a LMTD correction for the exchanger. The
default setting is the correction based on the geometry and that
will be fine.
Prepared by CPLEO
16
Prepared by CPLEO
17
Prepared by CPLEO
18
Prepared by CPLEO
19
Prepared by CPLEO
20
After the heat transfer coefficient calculations are specified, set out
the geometry of the heat exchanger.
Since Aspen does not do every calculation, hand computations will
be needed. Supply the number of tube passes, the shell diameter,
the number of tubes, the length of the tubes, the inside and outside
diameters of the tubes, the pitch, the material of the tubes, the
number of baffles and baffle spacing.
Some of the previous material is arbitrary and doesnt really need
to be calculated. However, the heat transfer area needs to be
estimated, at least for the first simulation run, in order to find the
number of tubes.
Area can be found by using the simple equation of
A = Q/ U DTLM.
The heat duty (Q) was found by Aspen and the log mean
temperature can be easily calculated. (Refer to reference five) To
find the area, you need to find a value for the overall heat transfer
coefficient. Refer to the literature for U-value estimates for the
situation in the example
Prepared by CPLEO
21
22
This calculation only gives the size of the tube bundle and not the
shell diameter.
The shell diameter is now found from adding the tube bundle
diameter and the clearance between the tube bundle and the shell.
The clearance space depends on the exchanger type, but typically
ranges from 10 mm to 90 mm. Refer to reference three or five for
clearance values.
Prepared by CPLEO
23
Prepared by CPLEO
24
In tube-input tab,
Select tube type - either bare or finned type tubes; generally, bare
tubes are used
Total number - specify the total number of tubes
Length specify the total tube length, includes all passes
Pattern - specify the tube layout, either triangular or square pitch,
generally, triangular pitch is used
Pitch - enter in the distance between tube centers within the tube
bundle; generally, the pitch is 1.25 times the outside diameter of one
tube
Material - choose the material of the tubes; Aspen has many
materials to choose from or one can be provided by the user
Conductivity - enter in the thermal conductivity of the material
chosen. Note* if this space is left empty, Aspen will use a default
conductivity for the material from its databanks
Tube size - specify the inner and outer diameter of one tube.
Notice that nominal pipe sizes can be used; the user only need to
supply the size and schedule number. (Note*: Aspen has a small
data-bank of nominal pipe sizes so literature values may have to be
used, the best recommendation is to use literature values for pipe sizes)
Prepared by CPLEO
25
Prepared by CPLEO
26
Prepared by CPLEO
27
Baffle cut
- specify the fraction of cross-sectional area for shell fluid flow; for
example, shown above is a value of 0.25 which means that one baffle
covers 75% of the shell cross-sectional area while 25% is left for fluid
flow. The baffle cut must be between 0 and 0.5.
Tubesheet to 1st baffle spacing
- enter in the length between the tube sheet and the 1st baffle
Baffle to Baffle spacing
- specify the baffle spacing (See aside below)
Last Baffle to tubesheet spacing
- enter in the length between the last baffle and the tubesheet (Aside
Baffle spacing in generalthe previous three spaces setup the baffle
spacing, two of the three spaces need to be filled for the simulation
to run. If the baffle spacing is not known at the start of the simulation,
the best way is to choose spacing between the tubesheet and the
first/last baffle. Then Aspen will automatically calculate the inner baffle
spacing)
Prepared by CPLEO
28
Shell-Baffle clearance
- specify the diametric distance between the shell and the outside of the
baffle; this information is not necessary for simulation and can be left
blank
Tube-Baffle clearance
- specify the diametric distance between the tube and the tube hole in
the baffle; this information is not necessary for simulation and can be
left blank
Prepared by CPLEO
29
Prepared by CPLEO
30
Prepared by CPLEO
31
Prepared by CPLEO
32
Prepared by CPLEO
33
Prepared by CPLEO
34
Prepared by CPLEO
35
Here is the Exchanger Details page for one final design option.
The actual area is 13% over the required area so the geometry of
the exchanger is finished. (It is always smart to over design by 1020%, especially on Aspen) The heat transfer coefficient seems fine;
however, this value should be checked with hand calculations.
Prepared by CPLEO
36
Prepared by CPLEO
37
Prepared by CPLEO
38
Prepared by CPLEO
39
Prepared by CPLEO
40
Prepared by CPLEO
41
Prepared by CPLEO
42
43
Prepared by CPLEO
44
Prepared by CPLEO
45
Here are the results from the shortcut calculations. Make sure and
check the outlet conditions of both streams. The steam has
completely condensed and the Ethylene glycol has risen to 365 K,
the design outlet temperature.
Also notice the saturation temperature of the steam.
Prepared by CPLEO
46
Prepared by CPLEO
47
Select U-methods page and specify that the overall heat transfer
coefficient will be calculated using Film coefficients. (Note*: this is just
one way to calculate heat transfer coefficients for condensation, a Fortran
subroutine can be implemented to calculate the coefficients)
In Film Coefficients page, enter in the heat transfer coefficients manually.
Also remember that this page can only be reached if the overall heat
transfer coefficient is calculated from Film coefficients. Here for the hot
stream, enter in the values obtained from hand calculations. The steam
will have two phases so both the vapor and the condensing spaces
need to be filled.
Remember the
correct unit.
Prepared by CPLEO
48
Prepared by CPLEO
49
Prepared by CPLEO
50
Prepared by CPLEO
51
Prepared by CPLEO
52
Shown at left is the nozzles input page. Input the nozzles diameters.
(See reference one or two for recommendations)
Also remember that the steam is changing from a gas to a liquid
within the tubes, so the tube side inlet diameter will be greater
than the outlet nozzle diameter.
Prepared by CPLEO
53
Prepared by CPLEO
54
Prepared by CPLEO
55
Prepared by CPLEO
56
Utilities
Prepared by CPLEO
58
Prepared by CPLEO
59
Prepared by CPLEO
60
Prepared by CPLEO
61
Energy Analysis
Open and run the demo file if you have V8.2 and any examples if
you do not. Ensure it is converged
Display Activated Analysis
Prepared by CPLEO
62
Choose Low Temperature Process for this demo file and click
OK
Prepared by CPLEO
63
The number on the top of the bar is the sum of actual heating and
cooling cost which calculated based on the actual energy
consumption in the flowsheet and the cost entered for the utilities.
The numbers on the right side of the bar is the target cost
calculated by the energy analysis engine. The difference of energy
cost is 18%.
Select toggle button to show heating and cooling costs separately.
Prepared by CPLEO
64
Prepared by CPLEO
65
Prepared by CPLEO
66
Prepared by CPLEO
67
Prepared by CPLEO
68
The minimum T approach is set as 2.4 and the maximum new area
allowed for each exchanger is 10000m2. These constraints can be
posed for each exchanger.
Prepared by CPLEO
69
Enter 500 in the maximum extra area for E-100 and update.
Select Scenario and Modify Exchangers node.
Click Add Exchanger.
The solution indicates that a new exchanger E-100 could be added
to possible 5 location. In this case (8.1%), very close to 10%
reduction target.
70
Pressure Changers
Prepared by CPLEO
71
Pressure Changers
Prepared by CPLEO
72
73
Prepared by CPLEO
75
In the model area of the PUMP setup specification sheet, select pump.
In the Pump outlet specification area, select Use performance curve
to determine discharge conditions option.
In the Efficiencies, input the Pump Efficiency and/or Driver Efficiency
(or use the defaults). Do not enter a value in the pump efficiency filed
as now you can add efficiency as tabular data or polynomials.
Navigate to the PUMP Performance Curves Curve Setup sheet.
Choose the appropriate curve format: Tabular data, Polynomials, or
User Subroutine.
Choose the Performance (i.e. Head) and Flow variable (vol. flow) and
the number of curves: a single curve at operating or reference speed,
or multiple curves at various speeds.
On the Curve Data Sheet, enter the tabular Data.
Kindly see Pump Curve Example file with an example shows two
pumps, each with a single performance curve at operating speed.
Prepared by CPLEO
76
Prepared by CPLEO
77