Engineering Practice

Air Coolers Versus

Shell-and-Tube Water Coolers
As shown here, economical cooling is often achieved with a combination of
and water cooling. Design considerations are also presented here
Manas Kumar Mandal TABLE 1. PERFORMANCE COMPARISON IN AIR COOLER
Fluor Daniel India Pvt. Ltd. Particulars Air in counter-current toAir in co-current to pro­ Air in co-current
process fluid in finned cess fluid in finned tubeto process fluid in
or the last 40 years, air­ tube (Step 1) (Step 2) bare tube(Step 3)

F cooled heat exchangers No. bays/No. of bundles4/4x2

have become an indispens­ No. of tube passes/No. 12/8
able part of many chemical, of rows
petroleum-refining, petrochemical, Heat Duty, MW
MTD, °C
gas processing and power plants, as Hydrocarbon velocity, m/s
12.4
67.6
0.65
5/5x2
12/8

12.4
57.4
0.47
16/8

12.4
64
0.41
8/8 x 1

well as off-shore platforms. In loca­ Surface area requirement, 2.808 (bare). 35.354 3,670 (bare), 46,201 5490
tions such as the Middle East, where m 2
(finned) (finned)
the availability of cooling water is Hydrocarbon NRE, in/out 3.376-301 2,411-222 3,300-200
limited and expensive, air-cooled ex­ Tube skin Temp, °C 50.6 61.5 61.5
changers may be a preferred choice. Exchanger cost, million 0.8 S 1.0 Not estimated
However, even there, due to vari­ (approximate)
ous process constraints, air cooling Installation cost, million 0.63
S 0.8 Not estimated
(approximate)
alone may not always suffice, so 0.24
Operating cost, million S 0.3 Not estimated
water cooling may also be required. (approximate)
Similarly, where cooling water is Total cost, million S 1.67 2.1 Not estimated
plentiful, shell-and-tube coolers may (approximate)
not always be a straightforward so­
lution. Due to the need for elaborate water, the heat-transfer coefficient Fouling. The costs associated with
cooling-water piping circuits, a cool­ will be about one third that of a fouling are usually lower for air cool­
ing tower, large cooling-water circu­ water-cooled exchanger, leading to ing compared to water cooling.
lation pumps and water-conditioninghigher heat-transfer area in air cool­ Shell-and-tube coolers, the cooling-
systems, the complexity and capital ers. In addition, an air cooler requirestower basin and other peripheral
requirements are generally very high,elaborate structures, which further equipment require regular mainte­
leading to a preference for air cool­ increases fixed costs by anywhere nance due to extensive fouling and
ers over shell-and-tube coolers. In from three to ten times that of a shell-scaling, and also biological treatment
this article, with the help of a case and-tube water cooler, depending onis required, without which the perfor­
study, the author discusses situa­ materials of construction. Neverthe­ mance of the operating plant drops
tions where the combination of both less, an air cooler is usually preferred substantially due to deposition or
air cooler and water coolers can be to avoid, completely or partially, the fouling in the shell-and-tube coolers.
used, including considerations for requirement of elaborate cooling- Air coolers may also become fouled
better overall project economics. water piping circuits, cooling tower, on the outside due to the accumula­
cooling-water circulation pumps and tion of dust, insects and other debris
Why use air coolers? water-conditioning systems and so on the finned surface, but less main­
Even though overall economics playon, because such additional equip­ tenance is required to handle this.
a major role, an air-cooled heat ex­ ment incurs much larger fixed costs.Where shell-and-tube overhead con­
changer is used extensively in all In addition to that, the operating costdensers or trim condensers are used
kinds of on-shore plants and off­ of pumping raw water, make-up for cooling or condensing column
shore platforms as a first choice of water and power for cooling-tower overhead vapor, any drop in perfor­
cooling mechanism for one of the fans makes the TIC of water-cooling mance due to fouling can mean loss
following reasons: system much higher than an air-cool­in processing material (hydrocarbon,
Total installed cost (TIC). The TIC ing system, which only requires op­ chemical) and thermal energy. As a
of an air-cooling system is less than erating costs for the fan power and result, the column pressure can be
that of a cooling water system. Due some controls, such as variable fre­ affected and the hydrocarbon mate­
to lower thermal conductivity and quency drive, louver and so on (see rial is lost in slop, or flared, or the pro­
specific heat of air compared to the case study, below). duction of lower-grade material.
42 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM FEBRUARY 2019

Flexibility. An air cooler offers more
flexibility for controlling the process-
fluid outlet temperature. There are
various ways to safe energy by con­
trolling the process-fluid outlet tem­
perature in an air cooler, as follows
(see also the case study below):
• Switching one fan off during winter
months or during the night time
• Using variable-speed drive motors
having 10-100% operable range
• Using auto variable-pitch fans
where blade angles change to
draw more or less air (power)
Such operational flexibility is non­
existent in shell-and-tube coolers, as
rarely any control is provided for the
cooling water side of water coolers.
Location. No specific location is re­
quired for air coolers. However, any
process plant that uses a shell-and-
tube cooler together with a water­
cooling system will be preferred
when the location is near a source of
water, such as river, lake or the sea.
Power. In the event of a power failure,
cooling can continue in an air cooler
by natural convection. When fan mo­
tors fail to run due to mechanical or
electrical problems, an air cooler can
still provide cooling of 10-15% of the
design heat duty by natural convec­
tion. Loss of power or other mechani­
cal issues in a shell-and-tube cooler
can cause the water to be heated up
more than the desired outlet temper­
ature, causing scaling and fouling.
Why shell-and-tube coolers?
Cooling range. Air coolers can be
used mostly as primary coolers for
process fluid that requires cooling
before storage. If a process fluid is to
be cooled or condensed from 100°C
or above, to 45°C or below, an air
cooler can first cool the process fluid
down to 65-70°C, then further cool­
ing is provided by a shell-and-tube
water-trim cooler for final cooling be­
fore it proceeds for rundown or stor­
age. A shell-and-tube cooler or con­
denser may not be a direct choice
due to the probability of high tube-
skin temperature, which can lead to
scaling in the tubes. Where process
cooling is in a lower range (70-45°C)
obviously air coolers cannot be used
at all, and shell-and-tube water cool­
ers are the only choice.
Approach temperature. Shell-and-
tube water coolers can accept a
lower approach temperature. For an
CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM FEBRUARY 2019
i
air cooler, an economical approach
temperature between the outlet of
process fluid and the ambient air
temperature is generally 15-25°C,
whereas for shell-and-tube water
coolers, the approach temperature ■ 11
can be as low as 5°C. I
Winterization. In cold climates, air
coolers require extensive winteriza­ ■ i
tion arrangements to protect against i;
congealing (due to low pour point of
process fluid) or freezing for very low
air-inlet design temperature. Elabo­
rate ducting with louvers, actuators,
steam coil or heating fans under
each fan can increase the capital
cost many times. In shell-and-tube ■i
11^ ;T1
I »
p- f.
water coolers, simply switching the
cooling medium to a tempered water ITS
system can prevent freezing of the *
\ to
process fluid.
Plot areas. Air coolers require a
large plot area due to the larger
heat-transfer area requirement. In
contrast, a shell-and-tube cooler is
very compact and requires much Ml
less space.
Location and performance. The
performance of air coolers is affected \
by the proximity of other structures.
The efficiency of air coolers goes
down drastically when the wind di­
rection changes seasonally, affecting
air inlet temperature to the bundles -
due to the presence of furnace ^- &
stack, columns and other equipment
in the path of the changing air-flow
direction. Because these equip­ Hydrogenation
ment cannot be positioned very far
from other structures due to space Solids blending / drying
constraints in the operating plant,
the air temperature may increase by Pharma, food, cosmetics
few degrees. Also, if sufficient space
is not allocated between air coolers Finechemicals
and columns, furnaces and buildings
in the same unit, hot-air dispersion
gets hampered, leading to hot-air re­
circulating to the fresh intake air. This
lowers the mean temperature differ­
ence (MTD), and the area for cooling Your fast lane to
becomes inadequate. advanced mixing technology:
Maintenance. Air coolers gener­
ally have higher maintenance re­ Phone: +1 201 825 4684
quirements than shell-and-tube Ext.: 205
condensers. An air cooler consists
of many static and rotating com­ usa@ekato.com
ponents that may have mainte­
nance issues, such as: 1) fan-shaft
misalignment, leading to high fan/
motor vibration which stops fan; 2)
www.ekato.com
high fan/motor bearing tempera­
ture, resulting in failure of coupling
For details visit adllnk*.chemcnqonllne.com.'736S1-07
43
 Front tube sheet side Front tube sheet side
Avg. air Avg.
Sk -i
Tube Rear tube sheet $*Je Avg. air Avg Tube Rear tube sheet side than one row per pass, and should
S"1r I Skin
temp. °C
Temp°C
Process fad flow
temp, °C Temp °C
Ft«J enters to tube
preferably have at least two passes
Process fuid entry £ i ■
Flu*} enters to tube
• Flu*} enCs Iron lube
60 bom tube per row, so that the fluid flowing in
Row Hni»tO TST 56 3*94 h.iv.
C
' Row 1Pa* ? ro c
i
74'C 598
two rows due to pass distribution, is
141*6
Row 2 534 721 ss3 128*C Row 2 619 [Pass io. 7*'c
Row 3Pw»* • ••r c St 8 627 pms TT* .... Row 3PsiS.SIX I 18 588 mixed in later passes after exchang­
Row 4r
jpc Wsstr
: 501 594
rr
Row 4PasMff'C. 583 629 # ing heat with air at different tempera­
H Pass 5. J"- Pass 6 99 C
ROWS 92C
491
•» c Row 5
P»>« a
105C
57.4 633
tures in different rows. This phenom­
Row 6. 482 538 Row 6 559 658 Pass 4. t2t'C

Row 7
ton 10
P*»11. 476 10
Row 7NwJ.urc J Pass 5 535
67 \Sc |P*»3
enon is shown in Figure 1.
-i7rc c 47 73 C o Pass 12
Row 8 506
Row 8frM'.WCcl" V Pass i To avoid such a situation, and if
Air tlow Fluid temperature in rear Air Now Process Rear chanel side the tube-skin temperature cannot
Fluid temperature in front header side header side fluid flow fluid temperature
Front Chanel side fluid temperature
be achieved in conventional flow ar­
FIGURE 1. As seen by these two examples, the tube skin temperature in an air cooler is linked to the
rangement (hot fluid entering from
direction of the airflow
top nozzles), a co-current arrange­
and belt; 3) dust/debris/pollen built tube-side pressure drop, which can ment is tried out where process
up on tubes, leading to increased be justified economically because fluid enters from bottom nozzles
air pressure drop in the bundle and the increase in the operating and and moves up the bundle. Due to
reduction of airflow (some reverse capital cost of the pump is small lower MTD in such an arrangement,
flow also can be seen) leading to compared to surface area and cost the required surface area goes up
loss in cooling capacity; 4) corro­ of air cooler saved. In general, this further. As is usually the case, this
sion of finned tubes due to salty at­ design has a relatively higher surfacekind of design is tube-side resis­
mosphere or mishandling by water area requirement. Adopting a deep tance controlling, and a bare-tube
washing and so on; 5) breakage bundle design also helps improve design instead of finned tube will be
or stuck louver or the failure of the the air-flow distribution in the bun­ less expensive. Even after all these
louver positioner, causing restriction dle. Bundles should have no more alternatives are considered, if the
in air flow and reduction of cooling
TABLE 2. PERFORMANCE COMPARISON WITH TEMPERED WATER
capacity; and 6) mal-operation of SHELL-AND-TUBE COOLER
auto-variable pitch fan blades, as Process fluid is same as as stated inHydrocarbon the cooling by tempered water in a shell-and-
they can get stuck and then air flow case study tube cooler and cooling of same tempered water cooling
cannot be adjusted by variable- in an air cooler
blade pitch angle. Type of exchanger Shell-and-tube Air cooler
Fluid Type Backwash oil/ Tempered water
Tempered water/Air
Case study Temp, C, In/out 204-70/60-80 80/60
As an example, we discuss the chal­ Heat duty, MW 12.4 12.4
lenges in handling a high-viscosity, MTD, °C 45.3
high-fouling and low-pour-point hy­ Hydrocarbon flowrate, kg/h 152.106 Nil
drocarbon in an air cooler. Tempered water flowrate, kq/h 525,668 525.668
No. of bundles/shells required - / 3 in series 4A
A residue-upgrading project in
1.000m2
Shell-and-tube area/ air cooler bare area, 1.500
a petroleum refinery has a back­ Reynolds number 1,330-50
wash oil cooler where hydrocarbon Exchanger cost, million S (approximate) 0.26 0.51
is cooled from 204 to 70°C. The oil Installation cost, million S (approximate) 0.32 0.61
viscosity is in the range of 1.4 to 40 Total installed cost, million S (approximate!
0.58 1.12
cP and the pour point is 38°C. In this
project, the engineer has restricted TABLE 3. PERFORMANCE WITH COMBINED AIR COOLER AND TEMPERED WATER
the Reynolds number to a minimum SHELL-AND-TUBE COOLER
of 2,000. The design ambient-air Process fluid is same as usedHydrocarbon
in Cooling of same
cooling partly by an air cooler
Table 2 followed by tempered water in a shell-and- tempered water in
temperature is 47°C. The location of tube cooler an aircooler
the refinery does not require exten­ Type of exchanger Air cooler Shell-and-tube Aircooler
sive winterization for such a liquid. Fluid Type Backwash oil/Air Backwash oil/ Tempered Tempered water/
The design target for handling water Air
high-viscosity, high-fouling and con­ Temp. °C, In/out 204/110 110-70/60-80 80/60
gealing (low pour point) hydrocarbon Heal duly, MW 9.01 3.4 3.4
is to achieve a tube skin temperature MTD. °C 67.6 16.2 15
of at least 15°C above pour point, Hydrocarbon flowrate, kg/h 152,106 152,106 Nil
maximizing the tube velocity and the Tempered water llowrate, kg/h Nil 143,757 143.757
heat-transfer coefficient such that Bundles/shells required 2/- Nil/2 in series 2/-
z 375
the Reynolds number lies in the tur­ Bare area, m 634 800
Reynolds number 16.985-2,870 351 at midpoint
bulent region.
Exchanger cost, million S 0.23 0.16 0.16
To get a reasonably high velocity (approximate)
in the tube side for such fluid re­ Installation cost, million S 0.29 0.23 0.23
quires increasing the number of tube (approximate)
passes in a deep bundle of 8 to 12 Total installed cost, million S 0.52 0.39 0.39
rows. But this also leads to a higher (approximate)
44 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM FEBRUARY 2019
 design target is a higher tube-skin
temperature and a higher tube-side ul
velocity, the Reynolds number in FIGURE 2. For applications where the fluid is tboth (i.
the transition zone is not achieved, viscous and clean, twisted tape turbulators can be
so other alternatives must be con­ inserted into the tubes to increase heat transfer i s Column
sidered, such as cooling with tem­ fluid starts congealing.
Z7 Pipe rack wit
pered water. The following five design steps
In the actual situation, the viscositywere considered for using an air
of the process fluid increases as the cooler (Steps 1-3), using a tem­
temperature of the process fluid fallspered water shell-and-tube cooler
while progressing in the tube bundle.(Step 4) and a combination of the FIGURE 3. Shown here is a computer model of an
Also, if there is mal-distribution in thetwo (Step 5). The results of the per­ air cooler mounted on the pipe rack
air side of the multi-pass air cool­ formance characteristics are sum­
ers, invariably the process fluid coolsmarized in Tables 1-3. Several key Step 2. By arranging the process
more in some of tubes than in others.observations are pointed out in the fluid flow co-currently to air flow, the
This will further increase the viscos­ following paragraphs: MTD goes down from 67°C (coun­
ity in the cooler tubes and therefore Step 1. The first attempt in thermal ter-current) to 57°C and therefore,
reduce flow through the tubes, whichdesign, using a conventional coun­ the surface area requirement goes
causes further cooling and more flowter-current flow arrangement in an airup. The existing design of four bays
reduction. This process continues cooler, results in a Reynolds numberbecomes inadequate in surface
until ultimately, we may notice that at the outlet of 300 (deep laminar area, so one more bay is added (5
fluid has stopped flowing in many flow) and a tube-skin temperature oftotal). As the number of bays is in­
of the tubes, and is only flowing in 50.6°C. The design also has a high creased, the tube-side velocity goes
a very few tubes with higher veloc­ tube-side pressure drop and a low down further (0.47 m/s) and so does
ity and turbulent flow regime. Pres­ tube-side velocity, in spite of 12 tubethe overall heat-transfer coefficient,
sure drop may be substantially higher passes in an eight-tube row bundle, as tube side resistance is control­
and, unless the pump can deliver theand therefore high surface area re­ ling by 85%. Even if the tube-skin
needed head, flow may stop and quirement (high cost). temperature is improved, there is not
r 1

V
s « *
■jr X *
*
«r .♦ t T r-.
* *~
POWTECH ■ 4
f

z^9 ■
World-leading Trade Fair for Proe«s»ng. m
Analysis, and Handling of Powder and Bulk Solids n.
*V *
4 :
~/*.7
•-A
V-
t /
i.

PROCESSES EXPERIENCE THE DYNAMIC

ENERGY, SHARE KNOWLEDGE,
TO KNOW. OPTIMISE PROCESSES
First comes the experience, then the success: discover
•*m
»Hi ') ■ SOLUTION^ the entire spectrum and dynamic energy of mechanical
process engineering. POWTECH is the trade fair event
for bulk solids - and the place where process
»r
k
TO V*oi
optimisation begins.
New strategies are needed for "green chemistry". In the
Expert Forum Chemistry, you'll learn about sustainable
* concepts for procurement, production and sales, loT,
mixed reality and new processes in solids production.

9-11.4.2018 •- *
•1•
Directly from the experts - for everyone who wants
to make their processes more efficient.
NUREMBERG, GERMANY
'*
Honorary sponsors Together with

VDI A|ftV
PARTEC *• NURNBER <^MESSE

For details visit adlinks.chemengonline.com/73851-14

 0#
inside the tubes. The swirling fluid
promotes greater contact with the
tube wall (increasing shear stress
Header for at the walls many times more) en­
tach bay (Typ.)
age hancing tube-side convective heat
transfer efficiency. The increase in
values of Nusselt number, Reynolds
.. 1.
number, Prandtl number, pressure
drop and friction factor will depend
£ FIGURE 5. When a perfectly symmetrical distribu­
upon the configuration of twisted
tape (twisted ratio, pitch ratio, tape
FIGURE 4. Normally, the inlet piping of an airtion is not possible (as in Figure 4), an equivalent
cooler requires a symmetrical distribution width, wire diameter and so on).
distribution of headers can be designed

much improvement in the Reynolds perature (110°C) from the air cooler Structural considerations
number, and because it is outside is high enough to have a Reynolds Support options. For an air-cooled
the user’s requirement, this method number above 2,000. The rest of theexchanger, there are two support
is also not adequate. heat duty can be cooled in a closed-options: 1) to place it on pipe rack or
Step 3. From the above, since loop tempered water system, as 2) to place it on a separate structure
tube-side film coefficients are very shown in Table 3. supported from the ground. Even
low and become controlling, there By opting for a combined system, though air-cooled exchangers re­
is generally no advantage in using the surface area is optimized sub­ quire more space than water-cooled
fins on the air side to increase the stantially and the total installed cost exchangers, the majority of space
overall heat-transfer rate. Bare tube is lower. An air cooler can handle a problems can be resolved if they
bundles with a large number of rowshigher inlet temperature, and a high are placed on a pipe rack (Figure
and split passes are more practical, Reynolds number can be maintained3) . Normally the tube bundle length
as shown above. The bare surface by limiting the outlet temperature of is fixed, based on the width of the
area calculated by the software is the air cooler. Then hydrocarbon pipe rack. If the pipe rack width is 9
not very high, and the power re­ is passed through the shell side m, the tube length could be 9.5 to
quirement is also similar to the first of a downstream tempered water 9.7 m. The supporting legs of the air­
two designs. The real advantage of shell-and-tube cooler where higher cooler bundle are fixed on the main
using bare tube bundles is that the viscosity can be tackled better by civil or structural beams, which sim­
number of bundles is reduced from considering rotated-square (45 deg) plifies the pipe rack design. At the
10 to 8, while maintaining a skin tube arrangement. As the bulk tem­ same time, it is desirable to adjust
temperature of 61,5°C. perature in the shell is above 65°C, the pipe rack or the structure lon­
Step 4. Most of the challenges seen despite the low Reynolds number, gitudinal column spacing, based on
in the designs of Steps 1-3 can be heat transfer coefficient and shell the width of the air-cooler bundle, so
avoided if we bring tempered water side velocity are acceptable. that the bundle legs sit straight on
as a coolant, since normal cooling Therefore, we see that a combina­top of the columns. Sometimes, it
water is not suitable for cooling a tion of both shell-and-tube and air may not be possible to adjust spac­
process fluid with high viscosity, low cooler play a definite role in the over­ing, since each tube bundle might
pour point and a limited tube-skin all cost economics, and together theyhave different widths, depending on
temperature. When the total heat achieve more benefits when com­ service condition. Therefore, adjust­
duty is cooled in a shell-and-tube, bined than when used separately. ing the pipe rack columns for differ­
tempered water cooler, the capital ent widths may not be feasible from
cost is very attractive, as shown in Handling lube oil in air coolers a structural design and detailing
Table 2. However, because an air In off-shore platforms where space point of view.
cooler is required for cooling tem­ is at a premium, air coolers are Walkways. There will be walkways
pered water, the costs balance out. used for cooling lubricant oil. Lube between sets of air coolers across
If a tempered water system is used oil is both viscous and clean, and the length and near the headers for
elsewhere in the plant that can be therefore it is possible to use turbu­ facilitating operators to inspect the
tweaked and ramped up to accom­ lence promoters (Figure 2) or tube bundle or operate the valves. The
modate this cooler, the scheme can inserts (turbulators) in this type of width of these walkways is gener­
definitely be made attractive. How­ air cooler. Such inserts can increaseally 1.5-2.0 m. Air coolers must
ever, in spite of more turbulence duethe tube-side heat-transfer coeffi­ have access platforms mounted all
to baffling in the shell side, the Reyn­cient by 100-250% over bare tube around on the structure to provide
olds number is poor, because the exchangers, with an increase in maintenance. Air coolers have mo­
bulk temperature of the process fluidpressure drop, but without much tors hanging at the bottom of the
is 61 °C in the coldest shell. increase in velocity. Twisted tape air-cooler plenum. Hence, it is re­
Step 5. We can split the total cool­ turbulators are formed into a heli­ quired to have access platforms un­
ing load into two stages and use an cal fashion and they increase heat- derneath the cooler for maintenance
air cooler in a series with a temperedtransfer efficiency by breaking up of the motors. A regular staircase
water trim cooler. The outlet tem- the laminar flow pattern of fluids should be provided for accessing
46 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM FEBRUARY 2019
the air cooler platforms or motor where a total of ten bays are divided have to be considered. The length
maintenance platforms. Monkey lad- into five bays both sides and vapor is of all branch pipes for all tube
ders are also provided in addition to distributed equally to both sides. The bundles from its header has to be
a staircase from the structure. piping of the air cooler needs to be more or less similar to keep the
Piping considerations. For a mini- supported, so either the structural pressure drop the same; this will
mum of two fans per bay, the height columns or the pipe-rack structural ensure equal distribution of fluids
of the underside of the fan inlet bell columns need to be extended up- to all bundles.
(for forced-draft units) or of the un- wards to properly support the pip- 2. Normally, the inlet-side header
derside of the bundle (for induced- ing. Such data have to be given at a box is considered as fixed for the
draft units) should be at least 2 m or very early stage in the project, since piping connection and the other
one fan diameter (whichever is the this needs to be considered during header is floating. But the bundle
greater) above the ground level, el- the design of the pipe rack, can move in transverse direction
evated floor or pipe bridge. The air The air coolers for an overhead of tubes by a few millimeters (say,
coolers on the pipe rack should be system are normally used when a 6 mm minimum) or if it is fixed at
located in such a way that the bun- large quantity of vapor is required for one edge, then it can move by a
dies are accessible with a crane — condensation or a huge quantity of higher margin (say, 12.7 mm mini­
at least from one side. gas or liquid needs to be cooled. The mum) in the other direction, as per
Normally, the inlet piping of an major points that need to be taken American Petroleum Institute (API,
air cooler requires a symmetrical care of when routing the inlet and 7th edition) recommendations.
distribution for condensers. There- outlet pipes are as follows: Usually, this value can be any­
fore, the number of bays/bundles 1. If the supply line has a very low where between 5 and 60 mm. This
is based on 2n = 2, 4, 8, 16, 32 ... operating pressure, which is usu­ header displacement is necessary
(Figure 4), When such an exact sym­ ally the case for connecting a to compensate for piping inlet/out­
metry is not possible due to some distillation column, care needs to let header expansion. The value
constraint, such as pressure drop be taken to keep the number of decided upon should be con­
or structural limitation, efforts should bends or elbows leading to the air firmed with the vendor of the air
be made to maximize an equivalent cooler at a minimum. But func- cooler, since the vendor may use
symmetry, as shown in Figure 5, tionality and stress requirements a different displacement provision.

PROTECT PUMPS
DRY RUNNING • CAVITATION • BEARING FAILURE • OVERLOAD 1

MONITOR PUMP POWER COMPACT EASY MOUNTING

• Best Sensitivity Only 3.25" x 6.25" x 2”
• Digital Oisplay • Starter Door • Panel
• Raceway • Wall
TWO ADJUSTABLE SET POINTS USTEO
INOCOMTEO
• Relay Outputs UNIQUE RANGE FINDER SENSOR EC-

f.
• Adjustable Delay Timers • Works on Wide-range of Motors
• Simplifies Installation
4-20 MILLIAMP ANALOG OUTPUT
is (*!
WHY MONITOR POWER INSTEAD OF JUST AMPS^
PUMP POWER
VALVE CLOSING
POWER

- PUMPING *
No Sensitivity VALVE OPENING
Power is Linear-Equal Sensitivity <
For Lew Loads
at Both Low and Hgh Loads
NO LOAD FULL LOAD NO LOAD FULL LOAD

ALL PRODUCTS
MADE IN USA

LOAD CONTROLS
INCORPORATED CALL NOW FOR YOUR FREE 30-DAY TRIAL 888-600-3247
WWW.LOADCONTROLS.COM
For details visit adlinks.chemengonline.com/73851-13

CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM FEBRUARY 2019 47

 TABLE 4. OVERHEAD CONDENSER PERFORMANCE WITH RESPECT TO AIR AMBIENT substantial, as shown in Table 4.
TEMPERATURE Such flexibility is not possible
Air cooler used alone (at lower ambient temperature! using only shell-and-tube coolers,
Air ambient temp, °C 50*C 42°C 34°C where operators only very rarely will
Process fluid temp, °C 65 53.7 42.6 adjust the cooling water flowrate by
Heat duty, MW 55.8 58.7 61 operating exchanger valves (manu­
Shaft power requirement. kW 390 370 350 ally or automatically). Therefore, we
Air cooler and trim cooler combination (per design) with air flow optimized for lower ambient
seetemperature
that shell-and-tube and air cool­
Heat duty, MW 558 55.8 55.8
ers both have definite roles in the
Air flowrate, kq/h 5,902,853 4,421,612(75%) 3,467,826 (59%)
overall cost economics.
Shaft power requirement. kW 390 180 104
Saving in shaft power per year 1,680 2,288
Weatherizing for colder climates.
(8,000 h), MW________ In some parts of the world, where
ambient conditions are such that in
The movement of tube bundles and sometimes power is required winter, air temperature dips below
in the transverse direction could for heating coils in cold climates. freezing, temperature control of the
occur only when the piping con­ Normally, the design of the cooler process streams at the air-cooler
nected to equipment nozzles gen­ will be such to accommodate the outlet is required to prevent freezing
erates enough force to overcome highest expected ambient tempera­ of low pour-point hydrocarbons. This
the friction at the bundle supports. ture (for example, 50°C), but be­ leads to a more complicated design
That is why it is a common prac­ cause of seasonal changes, such a for the air cooler.
tice to provide stainless steel, strategy would be wasteful during When a minimum tube-wall tem­
polytetrafluoroethylene (PTFE) or the periods when the ambient tem­ perature has to be maintained in the
other type of plate at the support perature is lower (for example, 40°C)air cooler, a recirculation system is
point to ease the movement. But — which can be as much as 50% employed whereby automatic lou­
this must be done in consultation for the year. Operating power costs vers at the top and sides of the air
with the vendor. can therefore be much lower than cooler housing (containing the entire
3. The loads created on the bundle the installed power costs by using assembly of tube bundles, ducting,
nozzle — due to thermal expan­ two-speed motors, auto-variable steam coils, plenums and fan mo­
sion, the weights of the pipe, in­ pitch fans and variable frequency tors) control the extent of recircula­
sulation and fluid, and the inside drive (VFD) fan-motor control to re­ tion. The recirculation is possible in
pressure of piping — should be duce the air flow. In temperate cli­ forced-draft air coolers, since hot ex­
less than the limits given by API. mates, as much as 50% or more haust air can be recirculated through
Sometimes the vendor allows a of the design power may be saved a duct-and-louver system.
higher allowable load (normally over the course of a year with auto A steam coil is generally a sepa­
two times the code value). variable-pitch fans. rate tube bundle of one or two rows
Locating shell-and-tube coolers. Nowadays, VFD technology has having a length and width similar to
The standalone water condenser become popular and more com­ the main air cooler, that is placed
and shell-and-tube trim water mon rather than auto variable-pitch below the main air cooler bundle. If
cooler can be placed above the fans, which are problematic for a an electric fan heater is to be pro­
condenser drum on a structural number of reasons. The air require­ vided in place of a steam-heated
platform supported from grade. ment can be adjusted from 10 to bundle, the same is placed below
Even though a shell-and-tube water 100% through VFD control. Table each air cooler fan. Low-pressure
cooler will require less space than 4 presents the potential savings (LP) steam being inside finned tubes,
an air cooler, some area allocation that can be expected by adjusting the steam-heated bundle and lou­
is needed on the ground (or on the power requirements to different ver will involve additional pressure
the platform for off-shore applica­ ambient-air temperatures, for both drop in the fan design. Closing the
tions). The pressure of the cooling a standalone air cooler, and for a louver on top of a bundle allows the
water reaching to the tube side of combination of air cooler and trim heating coil to warm the bundle dur­
condensers and trim coolers (when cooler. When the ambient tempera­ ing start up in freezing weather, so
on a platform) is very important for ture drops to below 34°C — which that the material in the bundle will
proper functioning of the condenser can occur during 5 to 6 months not freeze or solidify. A steam coil is
and the trim cooler. If the pressure over the year, the trim cooler may also used to temper very cold air to
drop in the cooling water circuit is not even be required at all, since the bundles in continuous operation
not properly calculated while de­ the total heat duty can be handled while the fan is operating and the
signing the inlet/outlet piping, the by air cooler alone. So in addition to exhaust louver is open. When two
actual cooling water flowrate will be the power savings, there will be ad­ fans are operated per bay, an auto­
lower than that of the design cal­ ditional savings for not using coolingvariable-pitch fan or fan with VFD is
culation, and the performance may water, which can cost around $0.4 kept at rear end of the bundle, so
suffer as a result. million/yr. If a refinery decides to that the process fluid outlet temper­
Flexibility. The operating costs for keep both air coolers and trim cool­ ature can be controlled.
the air cooler include the electrical ers on line, power saving through Controlling recirculation. A part
power required to operate the fans reduction of air flow via VFD is very of the air leaving from the top of the
4a CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM FEBRUARY 2019
 system is recirculated and mixes regulate the opening and closing 6. "Heat Exchanger and Cootng Tower Manual," Chevron
Corp., 1989.
with fresh air entering from the sidesof the outlet louver. The duct sizing
6. Thomas, J.W., Air Wins Even with Water Plentiful," 'Heat
so that the combined temperature is calculation and differential pres­ Exchanger Design Handbook.'Gulf Publish**) Co.. 1968.
precisely the design ambient tem­ sure drop across the dampers is 7. Basic Considerations for Equipment and Piping Layout
perature. The lower the ambient carefully done to avoid failure of of Ax-cooled Exchanger Piping, from www.whatisprping
temperature, the greater will be the the system. The vendor’s scope of com/piprig-layoul-air-cooled-heat-exchanger.
extent of recirculation. work will include the design of the 8. Exchanger Optimizer software (Trial version). Heal Trans­
For startup, when ambient tem­ louvers. In general, air-cooler tube- fer Research Institute (HTRI), Navasota, Tex., vwvw.htri.
net/exchanger-optimizer.
perature is lower than design am­ skin temperature is kept 15-20°C
bient temperature, ambient air can above the tube-side fluid pour-
be passed through a live-steam point temperature through this Author
coil, located below the bundle, elaborate system. Manas K Manual is a principal
such that air approaching the bun­ Although the cost of such an air design engineer for Fluor Daniel
India Pvt. Ltd. (6th Floor, Infinity
dle is heated up to the design tem­ cooler is quite high, it is still pre­ Tower B. Cyber City, DLF City
perature. The recirculation of exit ferred in colder climates to prevent Phase II, Gurgaon 122 002. Hary­
air is gradually increased, which icing or frosting. ■ ana, India; Phone: +91-124-
reduces the steam requirement. Edited by Gerald Ondrey 4570700; Fax; +91-124-
4263269; Email: manas.
Eventually, the steam supply can mandal@tluor.com). He has more
be stopped altogether. References than 34 years of experience in the
The air cooler is fitted with a duct 1. Giammaruti. R.. Performance Improvement held of process heat transfer, cost optimization studies,
to Existing
Air-Cooled, Heal Exchangers, Gas Machinery process
Researchdesign and operations, process revamp, project
leading from the top outlet to the control and energy management. Prior to Fluor, he
Council. Dallas Tex.. 2006.
bottom inlet. Louvers are placed in worked at Engineers India Ltd. Delhi and Hindustan Pe­
the bypass duct, at the air inlet and 2.Exchanger
Perkins B.C., Which Cooling Medium-Watertroleum
Design Handbook," Gulf Publishing
or Air. "Heat
Mumbai Refinery. Mandal has presented many
Co.. in
1968.
papers various seminars on heat transfer, energy
at the air outlet. The temperature of 3. Basics of Air Cooled Heat Exchangers Amarcool
management
Manu- and process improvement. Mandal holds
air just below the tube bundles will Wiring Inc Tulsa, Okla. a B.Tech. degree in chemical engineering from the In­
regulate the opening and closing of 4. Williams Jr., GL.and Damron, R.D., Which dian
CoolsInstitute of Technology, Delhi and Masters degree
inlet and bypass louvers, whereas Cheaper: Water or Air," "Heat Exchanger Design in financial
Hand­management from Jamnalal Bajaj Institute
ot Management Studies. Mumbai. India.
the process outlet temperature will book," Gull Publishing Co., 1968.

— ttt

,'»ip
ti1
m
X
I r- Us
[d

:: j

9t ■ f

ji

AFPM 2019 Annual Meeting

Leading Industry Sustainability & Innovation
March 17 -19, 2019 The 2019 meeting will be focused on innovative solutions, education, and
Marriott Rivercenter community. Learn the latest on the issues you care most about and build
San Antonio, TX strategic relationships with over 1,300 industry leaders.

Register today: Featuring luncheon speaker Condoleeza Rice, 66th Secretary of State of
afpm.org/conferences the United States and keynote speaker Gary Heminger, CEO, Marathon.
For details visit adlinks.chemengonline.com/73851-03