HEAT TRANSFER AND HEAT EXCHANGERS

Slide 1

What We Will Cover

Heat transfer theory-review Relation of heat transfer theory to shell and tube heat exchangers Design of a S&T exchanger--procedure outline Design features and parameters of shell and tube exchangers

Slide 2

BASIC HEAT TRANSFER CONCEPTS

Flow of heat behaves like flow of fluids and flow of electrons Driving Force Resistance

Rate K x QK x

(General)

Pressure Drop Resistance

Voltage Resistance

(Fluids)

I = 1.0 x

(Electricity)

Temperature Difference QK x Resistance

Slide 3

(Heat)

COMPARISON WITH FLUIDS

Fluids: Q A
2

= K x (P2 - P1)

(Remember Section 3?)

Heat:

fL D Q = 1 x (T2 - T1) A RT FLUIDS HEAT

Q = Volume / Second P2, P1 = Higher, lower pressures

A = Area available for flow

Q = Btu / Hour T2, T1 = Higher, lower temperatures RT = Total specific resistance

A = Area available for flow of heat

fL 4 * D = Number of fluid flow resistance units

Slide 4

BASIC HEAT TRANSFER EQUATION

Q = 1 x (T2 - T1) = 1 x T A RT RT RT = Total Resistance, Hr x FT2 x F / Btu I = Total Conductivity = U Btu / Hr x Ft2 x F RT Q = 1 x U T A Q = U x A x T Btu / Hr U is Referred to as the Overall Heat Transfer Coefficient
Slide 5

TOTAL RESISTANCE TO HEAT FLOW - HEAT EXCHANGERS

There are two areas through which heat must flow: The inside tube area and the outside tube area. Resistance occurs at both areas. The Industry Standard Reference Area is the Outside Tube Area.

Slide 6

INDIVIDUAL COMPONENTS OF THE TOTAL RESISTANCE

Inside Film Resistance = R io = R i Inside Fouling Resistance = r io = r i
Ao Ai Ao Ai

Tube Wall Resistance = r w = w / k w

Outside Fouling Resistance = ro Outside Film Resistance = Ro

Rio + rio + rw + ro + Ro = RT =
w = Wall Thickness, Feet

I U

Kw = Thermal Conductivity, Btu / Hr x Ft 2 x F Ft r = Resistances, Hr x Ft2 x F/Btu

Slide 7

INDIVIDUAL COMPONENTS OF THE TOTAL RESISTANCE

Slide 8

TYPICAL RESISTANCE VALUES

Very Low

Typical

Very High

Film Resistances (Each) (Inverse = h)

Fouling Resistance (Each) Inverse Wall Resistance Inverse Total Resistance Inverse

0.00050 (2000)
0.001 (1000) 0.000030 (32,000) 0.00303 (330)

0.004 (250)
0.002 (500) 0.00027 (3760) 0.01227 (81)

0.04 (25)
0.01 (100) 0.00049 (2030) 0.10050 (10)

Slide 9

THE CONTROLLING COEFFICIENT

Frequently One of the two film coefficients determines the value of the overall coefficient:

Out side Coefficient, Inside Coefficient,

h hio Ro Rio rw + rio + ro RT U Improvement

= = = = = = = =

75 1000 0.01333 0.00100 0.00070 0.01503 66.5 Base

75 3000 0.01333 0.00033 0.00070 0.01436 69.6 +4.6%

150 1000 0.00667 0.00100 0.00070 0.00837 119.5 +80%

Hence h is the Controlling Coefficient, and efforts to improve exchanger performance should concentrate on this side of the exchanger.

Slide 10

TEMPERATURE DROPS ACROSS THE RESISTANCES

Temperature drop across each of the resistances is directly proportional to each resistance. For example, If T2 = 200 and T1 = 80, then total temperature drop = 120F, and: Temperature Drop

Ro Rio rw rio+ ro RT

= = = = =

0.01333 0.00500 0.00030 0.00200 0.02063

77.6 29.1 1.7 1.6 120F

0.01333 0.02063

x 120

Slide 11

TEMPERATURE DROPS ACROSS THE RESISTANCES

A Useful Concept is Heat Flux =

Q A

Btu Hr x Ft2

Q = U x A x (T2 - T1) = U x A x T Then T = Q UxA =

Q A

* x

Flux x Resistance

Then Q = T = A RT

120 0.02063

= 5817 Btu , and T across Ro = 5817 x 0.01333 = 77.6 F Hr x Ft as shown on that slide.
Slide 12

BACK TO BASICS
Weve looked at basic theory, and discussed Q = U x A x T. In refinery work we usually know either Q or A, and need to calculate the other value. How do we do it? Either question requires calculating U or T.

Well talk about U later, first lets discuss T, the temperature driving force.
Note that capital letter T denotes the hot stream, while lower case t denotes the cold stream: T1 = Hot In t1 = Cold In T2 = Hot Out t 2 = Cold Out

Slide 13

FLOW PATTERNS AND TEMPERATURE DRIVING FORCE

Slide 14

FLOW PATTERNS AND TEMPERATURE DRIVING FORCE

Slide 15

FLOW PATTERNS AND TEMPERATURE DRIVING FORCE

Slide 16

FLOW PATTERNS AND TEMPERATURE DRIVING FORCE

Slide 17

TEMPERATURE DRIVING FORCE

From the preceding slides, it is clear that some sort of average driving force must be used in design calculations. What is this average? The average is called The Effective Mean Temperature Difference, or MTDe. For true countercurrent and true cocurrent flow, the effective driving force equals the log mean average of the two extreme (largest and smallest) deltas.
(T1 - t2) - (T2 - t1) (T1 - t2)

Te = LMTD =

LN

(T2 - t1)

This is precisely true only when the heat release curves are straight lines. Otherwise it is an approximation.

Slide 18

TEMPERATURE DRIVING FORCE

What about mixed flow: Shell and Tube Exchangers? The complex flow in these units was analyzed mathematically many years ago, resulting in rigorous equations for a Correction Factor, Fn. This is multiplied by the LMTD to give the correct MTDe. MTDe = Fn x LMTD Equations are valid only when heat release curves are linear. Similar relations are available for transverse flow (air fin coolers, for example).

Slide 19

CALCULATION OF Fn
Depends on the number of shells in series (Shell Passes)

The more shells one has in series, the closer Fn approaches 1.0
Typically the minimum acceptable value of Fn is 0.8

What exactly do we mean by shells in series or shell passes?

Slide 20

CALCULATION OF Fn - SHELL PASSES

Slide 21

CALCULATION OF Fn - SHELL PASSES

Slide 22

CALCULATION OF Fn
Complex equations simplified to charts See TEMA Section 7, or Exxon DP IX-D Applicable only to linear heat curves

Slide 23

CALCULATION OF Fn

Example

T1 = 300 T2 = 105
P = j = 115 - 85 = 0.14 300 - 85 R = 300 - 105 = 6.5 115 - 85

t1 = 85 t2 = 115

R n (1 Shell) = <0.8 (unreadable on chart) - Unacceptable

Fn (2 Shell) = 0.95 Use two shells
Slide 24

CALCULATION OF Fn

Since this technique is applicable only to the case of straight-line heat release, how do we estimate number of shells and MTDe for other cases?

Slide 25

NON-LINEAR HEAT RELEASE - MTDe SUGGESTION FOR COMPLEX CASES SUCH AS REFORMER FEED/EFFLUENT

Plot T Vs. Enthalpy Step Off to Get Minimum Number of Shells Calculate MTDe for Each Shell (Discuss Later)

Slide 26

NON-LINEAR HEAT RELEASE--MTDe SUGGESTION FOR CONDENSERS

Plot the condensing curve Assume cold side is linear and draw in cold side flow pattern If two shells, assume equal duties

Slide 27

MTDe FOR CONDENSERS (Continued)

Calculate the LMTD for each zone, assuming that the cold temperature in each zone is the average of the inlet/outlet cold temperatures of the shell in which the zone occurs (see graph) Then weight the overall MTDe as follows:

MTDe (Weighted) =

Qtotal Qzone1 + Qzone2 + Qzone3 LMTD1 LMTD2 LMTD3

+ Qzone4 LMTD4

Slide 28

HEAT TRANSFER COEFFICIENTS

Film coefficients are relatively easy to estimate:

They are a function of

Reynolds Number DV

Prandtl Number (Cp) () K

Similarly, pressure drop is a function of Reynolds number and length of flow path.

Slide 29

HEAT TRANSFER COEFFICIENTS (Continued)

The handouts just examined are suitable ONLY for estimates of coefficients.

For detailed coefficients on which to base the purchase of an exchanger, detailed computer calculations are necessary.
Detailed computer calculations examine the effects of many other parameters, particularly shell-side effects such as channeling and baffle leakage.

Slide 30

Show Videotape

Slide 31

EXCHANGER DESIGN PROCEDURE First need to know:

Permissible tube sizes - diameter, gauge, length. (Frequently set by refinery maintenance department)
The appropriate tube material for the service The allowable system pressure drops for each stream.

Slide 32

EXCHANGER DESIGN PROCEDURE (Continued)

(1) Assume an overall heat transfer coefficient (Uo) and calculate
tube surface area (A).

(2)

Using the required tube size and length, calculate the number of tubes.
Using a reasonable tube-side velocity (0.6-4.5 m/s), calculate the tubeside cross sectional area required for each tube pass: Acs = m3/s m/s Determine the EVEN number of tube passes which will most closely approximate the needed flow area. # tubes/pass= Acs / single tube cross sectional area # passes = (# tubes/pass) / # tubes

(3)

(4)

Slide 33

EXCHANGER DESIGN PROCEDURE (Continued)

(5) Calculate the bundle diameter. (6) Using a reasonable value of shell-side velocity, calculate the flow area required between shell-side baffles (gives baffle spacing). (7) Calculate tube-side and shell-side pressure drop. If satisfactory, continue to step 8. If not, modify the exchanger geometry until pressure drop requirements are met. (8) Calculate the overall coefficient U. (9) Compare [U(calculated) x A x MTDe ] with the required value of Q. If it doesnt agree within about 10%, then change exchanger geometry and repeat calculations.

Slide 34

HEAT EXCHANGER DESIGN

There are several major types of heat exchanger used in refineries/chemical plants:
+ + + + Shell-and-Tube Air-Fin Coolers Double-Pipe Plate and Frame

The vast majority are S & T. We will briefly review usage of the minor types and then concentrate on the features of shell-and-tube exchangers.

Slide 35

AIR COOLED EXCHANGERS

Used for cooling high to medium temperature streams where heat recovery is not practical Consists of tube bundle and motor driven fans Can be forced or induced draft Can be countercurrent or cocurrent to air flow Tubes are usually equipped with circumferential fins Design outlet temperature is limited by ambient air temperature

Detailed design of air-fins is left to the individual vendors. Process Designers simply provide duty specification.

Slide 36

DOUBLE PIPE
Consists of one or more pipes within a larger pipe Internal pipes can be bare surface or have longitudinal fins True cocurrent or true countercurrent flow can be achieved Available in standard off-the-shelf sizes Several standard units may be connected in series or in parallel Not usually economical where surface requirements exceed about 500 square feet Especially suited for high-pressure applications

Slide 37

PLATE AND FRAME

Consists of a series of alternating corrugated plates pressed together in a compression frame Process fluids flow on alternate sides of the plates in channels formed by the corrugations

Units achieve true countercurrent flow

Slide 38

PLATE AND FRAME (Continued)

ADVANTAGES
True countercurrent flow Highly compact - take up much less space than an equivalent S &T Much less expensive than S & T Very small holdup of process fluids Small probability for cross contamination of the two fluids

DISADVANTAGES
Limited to moderate temperatures and pressures (up to about 300F / 150C and 300 psig / 21 barg) Some hydrocarbon streams attack the interplate gasketing Require great time in assembly/disassembly Best suited to aqueous streams, e.g. amines, water

Slide 39

SHELL AND TUBE

Most common type in refinery service Consists of tube bundle within external shell

Not truly cocurrent or countercurrent

Slide 40

NOMENCLATURE Components of Shell and Tube Exchangers

1. 2. 3. 4. 5. 6. 7.

SHELL SHELL COVER SHELL FLANGE SHELL COVER END FLANGE SHELL NOZZLE FLOATING HEAD TUBESHEET FLOATING HEAD COVER

8. 9. 10. 11. 12. 13. 14. 15.

FLOATING HEAD COVER FLANGE CHANNEL PARTITION PLATE STATIONARY TUBESHEET CHANNEL CHANNEL COVER CHANNEL NOZZLE TIE RODS AND SPACERS TRANSVERSE BAFFLES OR SUPPORT PLATES

16. 17. 18. 19. 20. 21. 22.

IMPINGEMENT BAFFLE VENT CONNECTION DRAIN CONNECTION TEST CONNECTION SUPPORT SADDLES LIFTING RING SPLIT RING

Slide 41

MAJOR TYPES OF S & T UNITS

Fixed tube sheet (uncommon) Floating tube sheet

+ Pull-through floating head + Split ring floating head

U-Tube

Slide 42

SHELL & TUBE EXCHANGERS

Fixed Tube Sheet
Cleanest. Consider only when shell side fouling factor 0.004 (m2*C/W) and shell side can be chemically cleaned.
Because of thermal stresses, this type is generally unacceptable if the average shell temperature and average tube temperature differ by more than 10C

U-Tube
Least expensive for high tubeside design pressure. Normally used when tubeside fouling 0.004. (except for water)

Split Ring Floating Head

This type is normally specified unless very frequent mechanical cleaning is required

Pull-Through Floating Head

Most expensive type of S & T unit; thermally inefficient because of shell bypassing. Use when both sides must be mechanically cleaned

Slide 43

PRELIMINARY DECISIONS: DESIGN OF SHELL-AND-TUBE UNITS Which fluid to put in the tubes Tube nominal diameter, wall thickness and material Tube length Tube layout Baffle orientation Baffle pitch (spacing)

Maximum bundle diameter (bundle weight)

Slide 44

TUBE SIDE FLUID

Between the two streams, the stream with the higher:
Pressure Corrosion Rate Fouling Rate

Is usually placed on the TUBE SIDE.

When these characteristics apply to both streams, the designer uses his judgement.

In a service where one stream is changing phase, that stream is assigned to SHELL SIDE.
In steam-heated vaporizers/reboilers, the condensing steam is placed in THE TUBES. Streams with very HIGH VISCOSITY are placed on the SHELL SIDE (better coefficient).
Slide 45

TYPICAL TUBE DIAMETERS/WALL THICKNESS

1. Oil Service - Ferrous Tubes Severity of Service Non-Fouling or Fouling (<0.003), Mildly Corrosive Non-Fouling or Fouling (<0.003), Corrosive Extremely Fouling ( 0.003), Mildly Corrosive Extremely Fouling ( 0.003), Corrosive 2. General Service Alloy Tubes Water Service-Nonferrous Tubes Non-Fouling or Fouling (<0.003) Extremely Fouling (0.003) 3/4 15/16 or 1.0 16 0.065 OD, In. 3/4 3/4 1 1 Layout and Spacing, In. 15/16 1.00 1.25 1.25 or or or BWG 14 12 12 10 Thickness, In. 0.083 0.109 0.109 0.134

3/4
1

15/16
1.25

or 1.0
or

16
14

0.065
0.083

Slide 46

TUBE LENGTH
Refinery decision (local preference) Most common length is 20 feet (6.1m) Occasionally, 16 (4.9m) length is used For special situations, 8 (2.4m) and 10 (3m) can be considered Longer tube bundles require more plot area for bundle removal. Longer bundles are also more difficult to extract from the shell and to handle.

Slide 47

TUBE LAYOUT

3 Main Layouts-Square 1. Use when ro > 0.004 and shellside must be mechanically cleaned. 2. Reboilers/Vaporizers

Rotated Square Use as square, but only when flow is laminar or for vibration problems

Triangular 30

1. Use when ro 0.004 2. Cheapest, so use when applicable

Slide 48

TYPE OF BAFFLE
Segmental - Most common Double Segmental (modified disk and donut) is used to obtain very low shell-side pressure drop Tube Supports Only - No real baffles. Occasionally used in certain reboiling or condensing services.

Slide 49

BAFFLE ORIENTATION AND CUT

Vertical Chord - Most Common
Condensers, vaporizers and fluids containing suspended solids Flow is side-to-side

Horizontal Chord
Sediment-free fluids being cooled through high temperature range (200 to 300F / 90-150 C) in one shell Flow is over-under

Baffle Cut
This is the percent of the baffle which is cut away to permit flow Typical cut is 25% (40% for double segmental baffles).

Slide 50

BAFFLE PITCH
Minimum allowable spacing (pitch) is 20% of the shell ID or two inches, whichever is greater.

Maximum allowable pitch: + For no change of phase, equals shell ID + For change of phase Tube Size 1 1 Steel 30 37 50 Copper Alloys 26 32 43.5

Slide 51

TEMA
Tubular Exchanger Manufacturers Association
This is the basic industrial standard for shell-and-tube exchangers Covers heavy-duty type (TEMA R) as well as the lighter duty (TEMA C) units Latest edition is the eighth dated 1999

Slide 52

TEMA TYPE
TEMA Type followed by three letters refers to the type of
+ Front end (channel) arrangement + Shell nozzle/baffle arrangement + Rear end (floating head end) arrangement

These three characteristics are each identified by a single letter of the alphabet The result, for example, would be the entry TEMA Type AES in the specification for the heat exchangers. The type MUST be specified.

Slide 53

MOST COMMON TEMA TYPES Front End (Channel) Arrangement

A Removable channel with removable cover plate May be used with fixed or removable tube bundles Tube cleaning easier since no piping disassembly required Flanged channel end is costly and prone to leakage Most commonly used

B Removable channel with integral cover May be used with fixed or removable tube bundles Used for low tube side fouling services or where chemical cleaning is specified. Mechanical cleaning requires piping disassembly Less costly and less prone to leakage than type A C Channel integral with tubesheet and with removable cover Two types: removable bundle and fixed bundle

Slide 54

MOST COMMON TEMA TYPES (Continued)

E F One pass shell Most common type used

Shell Types

Two pass shell with longitudinal baffle Used to improve cross flow correction factor Equivalent to two shells in series Maximum shellside pressure drop of 10 PSI Maximum shellside temperature range of 350 F

G/H Split flow arrangements Use internal baffles to split the shellside flow Used to minimize pressure drop J Divided flow Also used to minimize pressure drop No internal baffle Kettle types Used for vaporizing services (reboilers, steam generators and refrigeration services) Cross flow No baffles Low pressure drop

Slide 55

MOST COMMON TEMA TYPES (Continued)

Rear End Head
S Floating tubesheet sandwiched between split ring and tubesheet cover Tubesheet assembly moves within shell cover to absorb expansion of the tubes Requires removing rear shell cover and floating tubesheet cover for bundle removal, but results in a smaller diameter shell for the same heat transfer surface Usually first choice for removable bundles if mechanical cleaning of shell side will be infrequent T Pull through floating head Floating tubesheet cover bolted directly to floating tubesheet Does not require rear head disassembly for bundle removal Results in larger diameter shell for same heat transfer surface than Type S Preferred where frequent mechanical cleaning of shellside is anticipated U U-tube bundle No floating head. Tube bundle consists of U-tubes Not recommended where mechanical cleaning of tube side is anticipated Good for high pressure, clean services or where chemical cleaning of tubeside is specified

Slide 56

TEMA HEAT EXCHANGER NOMENCLATURE

DP IX-C Figure 2

Notes:

Slide 57

1. 2. 3. 4.

Commonly referred to as channel or channel box. Commonly referred to as bundle types. Recommended for condensers and thermosiphons. Recommended for thermosiphon reboilers only.

MOST COMMON TEMA TYPES (Continued)

Therefore a TEMA AES exchanger has

A = Removable channel and removable channel cover plate

E = One pass shell (one inlet nozzle and one outlet nozzle)
S = Split ring type floating tube sheet construction

Slide 58

HEAT INTEGRATION PRINCIPLES

Object is overall minimum surface/number of shells Try to achieve maximum LMTDs Avoid temperature crosses if possible Incremental surface is cheaper than more shells Do not match streams with large differences in
Heat content Volume

Slide 59

HEAT INTEGRATION PROCEDURES

Identify all heat sources and heat sinks Prepare T-Q curves for sources and sinks Match sources and sinks according to principles Try different arrangements using typical Uos to estimate total surface

Slide 60

Problem 5A Heat Integration

Slide 61

TABLE 1.01 DESIGN CONSTANTS FOR SHELL AND TUBE EXCHANGER CALCULATIONS
SHELL SIDE Maximum Allowable Baffle Pitch Tube O.D. Inches Steel 0.75 30.0 1.00 37.0 1.50 50.0 (For no change of phase, Pb should not exceed the shell ID. Heat Transfer & Pressure Drop Factor B1 and B2 Baffle Position Tube Layout Vertical to tube rows Square On the bias (45) Square Vertical to tube rows Triangular Pressure Drop Fouling Factors, Fs Fluid Fs Liquids 1.15 Gases or condensing vapors 1.00 TUBE SIDE Pressure Drop Fouling Factors Tube O.D. Inches Ft 0.75 Steel 1.50 1.00 Steel 1.40 1.50 Steel 1.20 0.75 Copper Based 1.20 1.00 Copper Based 1.15 Transfer B1 0.50 0.55 0.70

Maximum Pb, Inches Copper, Aluminum Alloys 26.0 32.0 43.5

Pressure Drop B2 0.30 0.40 0.50

Typical Tube Pitch Tube O.D. Inches Pitch In 0.75 Triangular 0.9375 0.75 Square 1.0 1.0 Square 1.25 1.5 Square 1.875

Slide 62

TABLE 1.01 DESIGN CONSTANTS FOR SHELL AND TUBE EXCHANGER CALCULATIONS (Continued)

TUBE SIDE (Continued) Design Cooling Water Velocity Material Carbon Steel Type of Water Fresh, non-inhibited Fresh, inhibited All types Fresh (inhibited or not) Salt or brackish Fresh (inhibited or not) Salt or brackish All types Most Favorable Velocity, ft/sec 4 6 to 8 6 to 8 6 to 8 3 6 to 8 5 7 to 8 Permissible Range, ft/sec (4) 3 to 6 3 to 10 3 to 4 3 to 10 3 to 5 3 to 10 4 to 8 6 to 12

Red brass Admiralty (inhibited)

Aluminum brass

Cupronickel (70-30)

Cupronickel (90-10)
Monel Type 316 alloy steel

All types
All types All types

7 to 8
8 10

6 to 12
6 to 12 8 to 15

Slide 63

TABLE 1.02 - EXCHANGER TUBE DATA

do= O.D. of = Wall di = I.D. of Internal Cross External Surface Tubing, In. BWG Thickness In. (3) Tubing, In. Sectional Area Sq. In. Per Foot Length Sq. Feet 12 0.109 0.532 0.223 0.1963 14 0.083 (1) 0.584 0.268 0.1963 16 0.065 (2) 0.620 0.302 0.1963 18 0.049 0.652 0.334 0.1963 1 10 0.134 0.732 0.421 0.2618 1 12 0.109 (1) 0.782 0.479 0.2618 1 14 0.083 (2) 0.0834 0.546 0.2618 1 16 0.065 0.870 0.594 0.2618 1 10 0.134 1.232 1.192 0.3927 1 12 0.109 1.282 1.291 0.3927 1 14 0.083 1.334 1.397 0.3927 GAGE EQUIVALENTS MAXIMUM RECOMMENDED NUMBER OF TUBE PASSES Inches BWG Shell ID Inches Max. Passes 0.220 5 <10 4 0.165 8 10-19 6 0.148 9 20-29 8 0.134 10 30-39 10 0.120 11 40-49 12 0.109 12 51-59 (Rare) 14 Notes: 0.095 13 (1) Typical wall thickness for carbon steel tubes. 0.083 14 (2) Typical wall thickness for copper alloy tubes. 0.072 15 (3) Average wall thickness is typically 10% greater than the minimum wall thickness. Tubes may be specified (and purchased) on either an average wall or minimum wall 0.065 16 basis. (Exxon normally specifies minimum wall.) 0.058 17 18 Slide 64 0.049 0.035 20

TABLE 1.03 THERMAL CONDUCTIVITIES OF METALS AT TYPICAL HEAT EXCHANGER TEMPERATURES

Material Admiralty Type 316 Stainless Steel Type 304 Stainless Steel Brass Red Brass Aluminum Brass Cupro-Nickel Cupro-Nickel Monel Inconel Aluminum Carbon Steel Carbon-Moly Steel Copper Lead Nickel Titanium Chrome-Moly Steel

Composition (71 Cu - 28 Zn - 1 Sn) (17 Cr - 12 Ni - 2 Mo) (18 Cr - 8 Ni) (70 Cu - 30 Zn) (85 Cu 15 Zn) (76 Cu - 22 Zn - 2 Al) (90 Cu - 10 Ni) (70 Cu - 30 Ni) (67 Ni - 30 Cu - 1.4 Fe)

(0.5 Mo)

(1 Cr - 0.5 Mo) (2-1/4 Cr - 0.5 Mo) (5 Cr - 0.5 Mo) (12 Cr - 1 Mo)

Thermal Conductivity, k, 64 9 9 57 92 58 41 17 15 11 117 26 25 223 20 36 11 24 22 20 16

Slide 65

TABLE 1.04 TYPICAL FOULING FACTORS - CUSTOMARY

Stream Type Vapor Overheads Virgin Distillate liquids to tankage Virgin Distillate liquids from tankage Cracked distillate liquids from tankage Reduced Crudes Tar, bitumen Cracked Tar Crudes Steam BFW Cooling Water, Fresh Cooling Water, Salt Typical ri or ro 0.001 0.001 0.002 0.002 0.004 0.005 0.010 0.0102-0.004 0.001 0.001 0.0015 - 0.0025 0.0025 -0.0035

Slide 66

TABLE 1.05 SOME TYPICAL OVERALL COEFFICIENTS - CUSTOMARY

Type of Source Light Ends Liquid Coolers (Water) Distillate Coolers (Water) Light Ends Reboilers (Steam) Light Ends Feed/Bottoms Typical Uo 120 70-90 80 100

Crudes/distillates Condensers (Tower overheads)

25-50 90

Slide 67

NOMENCLATURE
A As B1 B2 C Cf D Dt di do Fn Fs Ft G hio ho k kf Total exchanger are, ft2 Area/shell, ft. 2 Bundle factor for shell side heat transfer Bundle factor for shell side pressure drop , dimensionless Specific heat at caloric temperature, Btu/Lb -F. Specific heat of the shell side fluid at average film temperature, Btu/lb-F Shell I.D., inches Diameter of tube bundle (outer tube limit), inches Tube I.D., inches Tube O. D., inches Correction factor for log mean temperature difference (due to partially concurrent flow), dimensionless Shell side pressure drop correction factor, dimensionless Tube side pressure drop correction factor, dimensionless Mass velocity, lbs/sec - ft2 Inside film coefficient corrected to outside area, Btu/hr-ft2-F. Outside film coefficient Btu/hr-ft2 -F Thermal conductivity at caloric temperature, Btu/hr-ft2-F/Ft. Thermal conductivity of the tube metal at average tube temperature, Btu/hr-ft2-F/ft Thermal conductivity of the tube metal at average tube temperature Tube wall thickness, in. Tube length, ft. Mass rate, lbs/hr. Density, lbs/ft3 Number of shell baffles Number of tube passes per shell. Reynolds number, inch-lbs/sec-ft2 - centipoise Number of shells in series. Number of tubes across in the bundle Number of tubes across the center line of the bundle Baffle pitch, inches. Tube pitch, inches. Rate of heat transfer, Btu/hr. Total resistance (clean) to heat transfer (Note 1) Inside film resistance corrected to outside area, (Note 1) Ro Rt rio ro rw S TDS TDT TM T1 T2 t1 t2 tf ts tt tw Uc Uo V VN W Ysh Ysp Yth Ytp z zf zw Ptf Ptr Pt Psf Psr PN Ps te Outside film resistance to heat transfer, (Note 1). Total resistance (duty) to heat transfer (Note 1). Inside fouling factor corrected to outside area, (Note 1). Outside fouling factor (Note 1). Resistance of tube wall metal at average wall temperature(Note 1). Free flow area between shell baffles, in. 2 Design temperature of the shell side, F. Design temperature of the tube side, F. Tube sheet design temperature, F. Inlet temperature of fluid being cooled, F. Outlet temperature of fluid being cooled, F. Inlet temperature of fluid being heated, F. Outlet temperature of fluid being heated, F. Average shell side film temperature, F. Caloric temperature of the shell fluid, F. Caloric temperature of the tube fluid, F. Average tube wall temperature, F. Over-all clean coefficient of heat transfer, Btu/hr-ft2-F. Over-all duty coefficient of heat transfer, Btu/hr-ft2-F. Velocity in the tubes or shell ft/sec. Velocity in the nozzles, ft/sec. Free width between baffles, in. Shell side heat transfer correlation factor. Shell side pressure drop correlation factor. Tube side heat transfer correlation factor. Tube side pressure drop correlation factor. Viscosity at caloric temperature, centipoises. Viscosity of the shell side fluid at average film temperature, centipoises. Viscosity of the tube side fluid at tube wall temperature, centipoises. Tube pressure drop due to friction, psi/tube pass. Tube pressure drop due to turns, psi/tube pass. Total tube side pressure drop, psi. Shell side pressure drop due to friction, psi/shell. Shell side pressure drop due to friction, psi/shell. Nozzle Pressure drop, psi/shell. Total shell side pressure drop, psi. Long mean temperature difference corrected for non-ideal countercurrent flow (Effective temperature difference) F. Weighted effective log mean difference, F.

kw L L M M NB NP NReNS NT NTC Pb Pt Q RC Rio -

Slide 68

tew -

FIGURE 1.01 - LMTD CORRECTION FACTORS

Slide 69

FIGURE 1.02 - LMTD CORRECTION FACTORS

Slide 70

FIGURE 1.03 - LMTD CORRECTION FACTORS

Slide 71

FIGURE 2.01 FRICTIONAL PRESSURE DROP FOR FLUIDS FLOWING IN TUBES

Slide 72

FIGURE 2.02 HEAT TRANSFER COEFFICIENT FOR FLUIDS IN TUBES

Slide 73

FIGURE 5.01 FRICITONAL PRESSURE DROP FLUIDS FLOWING ACROSS TUBE BANKS

Slide 74

FIGURE 5.02 HEAT TRANSFER COEFFICIENT FLUIDS FLOWING ACROSS TUBE BANKS

Slide 75

FIGURE 5.01 VALUES OF THE THERMAL FUNCTION k(PRANDTL NO.)1/3 FOR LIQUID HYDROCARBONS

Slide 76

FIGURE 5.02 VALUES OF THE THERMAL FUNCTION K(PRANDTL NO.)1/3 FOR HYDROCARBON VAPORS

Slide 77

ADDENDUM 5.02 FOR FLOW INSIDE TUBES APPROXIMATE EFFECT OF VARIABLES IN THE TRANSFER OF MOMENTUM AND HEAT To Find P2 Multiply P1 By:

Property Changed NRe > 10,000 (Note 1) Linear Velocity Tube Diameter (at constant linear velocity) Viscosity Density (at constant linear velocity) NRe > 2,100 (Note 1) Linear Velocity Tube Diameter (at constant linear velocity) Tube Diameter (at constant weight rate) Density (at constant linear velocity Tube Length Laminar Flow* Turbulent Flow

To Find h2 Multiply h1 By:

(V2/V1)1.8 (D1/D2)1.2 (2/1)0.2 (2/1)0.8

(V2/V1)0.8 (D1/D2)0.2 (2/1)0.5 (2/1)0.8

V2/V1 (D1/D2)2 (D1/D2)4 No dependence L2/L1

(V2/V1)0.33 (D1/D2)0.33 D1/D2 (2/1)0.33 (L1/L2)0.33

Note 1: This is dimensionless Reynolds Number.

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Date

HEAT EXCHANGE EQUIPMENT DESIGN CONSIDERATIONS FOR ALL TYPES OF HEAT EXCHANGERS
PROPIETARY INFORMATION -For Authorized Company Use Only

EXXON DESIGN PRACTICES

TABLE 1 TYPICAL OVERALL HEAT TRANSFER COEFFICIENTS - Uo

U0(1) BTU U0(1) W

Fluid Being Cooled

Fluid Being Heated

Hr ft2 F
Shell and Tube Units with Smooth Tubes Exchangers Atmospheric P/S Top Pumparound Atmospheric P/S No. 3 S/S Atmospheric P/S Bottom Pumparound Atmospheric P/S Bottoms Reduced Crude Lean Oil Hydrocracker Effluent Hydrogenation Reactor Effluent Hydrofiner Effluent Debutanizer Effluent Powerformer Effluent Acetylene Converter Feed Regenerated DEA Catalyst-Oil Slurry Cracking Coil Vapors Rerun Still Overhead Splitter Overhead

m2 C

Crude Crude Crude Crude Flashed Crude Fat Oil Hydrocracker Feed Hydrogenation Reactor Feed Hydrofiner Feed Debutanizer Feed Powerformer Feed Acetylene Converter Effluent Foul DEA Gas Oil Feed Gas Oil Rerun Still Feed Debutanizer Feed

60 - 70 48 - 58 55 - 85 26 45 25 60 75 51 55 50 68 70 50 80 22 30 110 40 30 50 55

340 - 400 270 - 330 310 480 150 - 260 140 340 430 290 310 280 390 400 280 450 120 170 630 230 170 280 310

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HEAT EXCHANGE EQUIPMENT DESIGN CONSIDERATIONS FOR ALL TYPES OF HEAT EXCHANGERS
PROPIETARY INFORMATION -For Authorized Company Use Only

EXXON DESIGN PRACTICES

TABLE 1 - (Continued)
Fluid Being Cooled Fluid Being Heated U0(1) BTU Hr ft2 F U0(1) W m2 C 850 - 1190 570 650 390 430 480 - 510 240 110 - 140 450 400 230 630 160 180

Coolers Water Brine Debutanizer Bottoms Debutanizer Overhead Products Debutanizer Bottom Products Vacuum P/S Bottoms Absorber Oil Lean Oil Heavy Gas Oil Regenerated DEA Reduced Crude
Gas Coolers Air, 27 psig (186 kPa gage) 105 psig (724 kPa gage) 320 psig (2206 kPa gage) Primary Fractionator Gas Hydrocarbon Vapors (30 M.W.) Hydrocarbon Vapors (25 M.W.) Propylene Ethylene

Water Sour Water Water Water Water Water Water Water Water Water Water

150 210 (2) 100 115 68 75 85 90 43 20 25 80 70 40 110 29 32

Water Water Water Water Water Water Water Water

13 17 23 27 38 43 55 60 50 31

70 100 130 150 220 240 310 340 280 180

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HEAT EXCHANGE EQUIPMENT DESIGN CONSIDERATIONS FOR ALL TYPES OF HEAT EXCHANGERS
PROPIETARY INFORMATION -For Authorized Company Use Only

EXXON DESIGN PRACTICES

TABLE 1 - (Continued)
U0(1) BTU Hr ft2 F Condensers Atmospheric P/S Overhead Atmospheric P/S Overhead Atmospheric P/S Distillate Vacuum P/S Overhead Debutanizer Overhead Deethanizer Overhead Depentanizer Overhead LPG Tower Overhead Hydrofiner Effluent Stabilizer Overhead Splitter Overhead Rerun Still Overhead DEA Regenerator Overhead Primary Fractionator Overhead Primary Fractionator Overhead & Products Powerformer Effluent Hydrocracker Effluent Propylene Steam (3) Water Crude Water Water Water Water Water Water Water Water Water Water Water Water Water Water Water Water Water 80 90 35 45 70 80 115 130 90 100 110 90 113 99 91 105 75 85 85 113 70 400 100 40 (50% cond) 60 (25% cond) 55 60 85 120 400 600 U0(1) W m2 C 450 510 200 260 400 - 450 650 740 510 570 620 510 640 560 510 600 430 480 480 640 570 230 340 310 340 480 680 2270-3410

Fluid Being Cooled

Fluid Being Heated

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HEAT EXCHANGE EQUIPMENT DESIGN CONSIDERATIONS FOR ALL TYPES OF HEAT EXCHANGERS
PROPIETARY INFORMATION -For Authorized Company Use Only

EXXON DESIGN PRACTICES

TABLE 1 - (Continued)
Fluid Being Cooled Fluid Being Heated U0(1) BTU Hr ft2 F Chillers Ethylene (4) Demethanizer Overhead (4) Deethanizer Overhead (4) Depropanizer Overhead (4) Ethylene Demethanizer feed Demethanizer Feed Reboilers Steam Lean Oil Steam Atmospheric P/S Top Pumparound Steam Steam Atmospheric P/S Top Pumparound Atmospheric P/S Bottoms Steam Steam Steam Steam U0(1) W m2 C

Propylene Ethylene Propylene Propylene Ethylene Ethylene Propylene

98 107 113 115 99 105 96 113 100 122

560 610 640 650 560 600 550 640 570 690

Demethanizer Bottoms Demethanizer Bottoms Deethanizer Bottoms Deethanizer Bottoms Depropanizer Bottoms Debutanizer Bottoms Debutanizer Bottoms Debutanizer Bottoms Depentanizer Bottoms Debenzenizer Bottoms Detoluenizer Bottoms Splitter Bottoms

75 60 73 86 66 89 74 100 65 56 81 102 77 80

430 340 410 490 370 510 420 570 370 320 460 580 440 450

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HEAT EXCHANGE EQUIPMENT DESIGN CONSIDERATIONS FOR ALL TYPES OF HEAT EXCHANGERS
PROPIETARY INFORMATION -For Authorized Company Use Only

EXXON DESIGN PRACTICES

TABLE 1 - (Continued)
U0(1) BTU Hr ft2 F U0(1) W m2 C 400 470 650 420 270 400 430 440 820 1360 370

Fluid Being Cooled

Fluid Being Heated

Reboilers (Continued) Dowtherm Steam Steam Steam Dowtherm Steam Powerformer Effluent Steam Steam Dowtherm
Preheaters Steam Steam Steam Steam Powerformer Stabilizer Bottoms

Splitter Bottoms Stripper Bottoms Stabilizer Bottoms Rerun Tower Bottoms Rerun Tower Bottoms LPG Bottoms Powerformer Stabilizer Bottoms K3PO4 Stripper Bottoms DEA Regenerator Bottoms Phenol

70 82 115 74 47 70 75 77 145 240 65

Isobutane Tower Feed Rerun Tower Feed Debutanizer Tower Feed Hydrogenation Reactor Feed Powerformer Stabilizer Feed

82 80 100 110 75 89 47

520 450 570 620 430 510 270

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HEAT EXCHANGE EQUIPMENT DESIGN CONSIDERATIONS FOR ALL TYPES OF HEAT EXCHANGERS
PROPIETARY INFORMATION -For Authorized Company Use Only

EXXON DESIGN PRACTICES

TABLE 1 - (Continued)
Fluid Being Cooled Fluid Being Heated U0(1) BTU Hr ft2 F U0(1) W m2 C 200 380 490 170 310 50 90 260 340

Steam Generators Vacuum P/S Bottoms Vacuum P/S Bottom Pumparound Primary Fractionator Slurry Flue Gas Reformer Effluent

Feed Water Feed Water Feed Water Feed Water Feed Water

35 67 86 30 55 8 15 45 60

Longitudinal Fin Units (Coefficients based on total outside surface) Heavy Naphtha Water (6 ft/sec(1.8m/s) in annulus) Water (3 ft/sec(0.9 m/s) in annulus) Light Naphtha Water (6 ft/sec(1.8 m/s) in annulus) Water (3 ft/sec(0.9 m/s) in annulus) Clean K3PO4 Water Clean K3PO4 Foul K3PO4 Notes: 1. 2. 3. 4.

25 20 30 25 40 42

140 110 170 140 230 240

Coefficients given represent a range of typical coefficients. Where only one coefficient given, typical coefficients can be higher or lower than the tabulated value. Coefficient highly dependent on fouling factors. Steam surface condenser. Refer to Heat Exchange Institute Standards for Steam Surface Condensers. Condensing Service.

Slide 84

Attachment IX - Safety Factor Selection

Slide 85

Correction Factor for Non-Condensables Calculation Procedure

Slide 86
See HEXTRAN Users Guide, located in HEXTRAN program folder

Attachment IXB - Pressure-Drop-Multiplier Selection See also DP IX-D p. 40-41 Tubeside Pressure-Drop Multiplier (DPSCALAR)

Slide 87

Attachment IXB - Pressure-Drop-Multiplier Selection (cont.) See also DP IX-D p. 40-41

Shellside Pressure-Drop Multiplier (DPSCALAR)

Fluid Liquids Gases or condensing vapors
(1) (2) This value may be increased for extremely dirty service Use a larger number if vapors are known to be fouling.

DPSCALAR 1.15 (1) 1.0 (2)

Slide 88

ENHANCED HEAT TRANSFER TECHNOLOGIES (EHT)

WHAT ARE THEY? Technologies used to improve heat transfer performance and reliability of shelland-tube (S&T) heat exchangers, or as alternates to S&TS.

ADVANTAGES OF EHTS Low initial cost Low maintenance Compact size - Save plot space, have small weight and hold-up volume can debottleneck existing exchangers
SEVEN TYPES OF EHTS Plate type heat exchangers (PHE) Spiral heat exchangers (SHE) Rod baffle exchangers (RBE) Integral fin tubes (IFT) Nucleate boiling tubes (NBT) Turbulence promoters (TP) On-line mechanical cleaning devices (OMC)
Slide 89

Heat transfer enhancement is obtained by increasing heat transfer coefficient, surface are per unit volume or temperature driving force

Q = U x A x MTD PHE - Increase U by turbulence and MTD by countercurrency SHE - Increase U by turbulence and MTD by countercurrency RBE - Increase U by allowing higher flow rate IFT - Increase A of tube surface; Increase U for condensing and vaporizing NBT - Increase U by enhancing vaporizing heat transfer TP - Increase U by enhancing HI OMC - Increase U by reducing fouling; some types also increase HI

Slide 90

PLATE TYPE HEAT EXCHANGERS (PHE)

WHAT DOES IT DO? It is an alternative to shell-and-tube exchangers. Provides a compact heat exchanger because of high surface area per unit volume Provides true counter current flow and high heat transfer coefficients Typical Applications - Final product cooling (close approach Tempered water cooling Low temperature feed/effluent exchanger Sea water cooling (high metallurgy) WHAT DOES IT LOOK LIKE? Multiple streams possible

PLATE & FRAME

WELDED PLATE

PLATE-FIN

Slide 91

SPIRAL HEAT EXCHANGERS (SHE)

WHAT DOES IT DO? It is an alternative to shell-and-tube exchangers. Provides a compact heat exchanger because of high surface area per unit volume It can handle fluids with high viscosity or high solid particle content Typical applications Final product cooling (close approach) Overhead condensers (tower top) Tar cooling (high viscosity) Slurry exchangers (solids) WHAT DOES IT LOOK LIKE? Two plates rolled together. Spacing maintained by studs.

Slide 92

ROD BAFFLEHEAT EXCHANGERS (RBE)

WHAT DOES IT DO? It eliminates tube vibration in shell-and-tube heat exchangers It allows debottlenecking of pressure drop limited exchangers Typical applications - To correct known vibration problems Compressor inter/after coolers (high velocity gas) Reboilers (high velocity vapor or two-phase) WHAT DOES IT LOOK LIKE? Rod baffles replace conventional baffles on a S&T tube bundle

Slide 93

INTEGRAL FIN TUBES (IFT)

WHAT DOES IT DO? Provides higher heat transfer area compared to plain tubes Enhances shell side heat transfer coefficient in two-phase applications Typical applications - Overhead condensers Compressor inter and after coolers Good for single or change of phase WHAT DOES IT LOOK LIKE? Commonly referred to as low-fin tubes Note that ID is smaller than plain tube of same OD and thickness New fin geometries developed and double (inside and outside) enhanced tubes are available.

Slide 94

NUCLEATE BOILING TUBES (NBT)

WHAT DOES IT DO? Increases shell side heat transfer coefficient for boiling services Typical Applications - horizontal reboilers - shell side boiling vertical reboilers - tubeside boiling excellent in refrigeration systems (C3 reboilers) WHAT DOES IT LOOK LIKE? Coating on inside or outside tube surface (UOP high flux) special fin geometry (Wieland)

Slide 95

TURBULENCE PROMOTERS (TP)

WHAT DOES IT DO? Increases tubeside heat transfer coefficient by the following mechanisms: Thermal mixing through bulk or near-wall flow disturbance Disruption of thermal boundary layer by changing bare tube surface Impart swirl to mix flow, change flow direction or both Typical Applications - Tar oil heating (high viscosity) Lube oil cooling (high viscosity) Tubeside condensers (increase HI and AI) WHAT DOES IT LOOK LIKE?

BULK FLOW MIXERS (LAMINAR OR TRANSITION)

NEAR-WALL MIXERS (TURBULENT)

Slide 96

ON-LINE MECHANICAL CLEANING (OMC)

WHAT DOES IT DO? Keep shell-and-tube heat exchangers clean, on the run Typical Applications Crude preheat with crude on tube side Hydrofiner feed on tube side Cooling water on tubeside WHAT DOES IT LOOK LIKE? Devices are permanently installed in the bundle
SPIRELF TURBOTAL BRUSH & BASKET

Slide 97

LOGIC DIAGRAM TO SELECT EHT

Slide 98

ADVERTISEMENT UNFIRED HEAT TRANSFER AT EMR&E

O Consulting Expertise + Traditional heat exchanger design practice + Advanced concepts with new technologies + Assist with redesign of problem heat exchangers + General heat transfer questions/problems O Computer Programs + Mainframe programs for heat exchanger design/rating/simulation + Insulation programs O Source of Available Outside Technology + HTRI/HTFS state-of-the-art heat transfer technology + R & D efforts to identify applications/developments of new technology O Technical Training + Courses at EMR&E or affiliate location + Subjects include:
Advanced heat transfer ExxonMobil computer programs

Slide 99

HEAT EXCHANGER REFERENCES

Design Practices, Section IX (Heat Exchangers) and XIV (Fluid Flow) Global Practices (GPs), Section 6 Heat Exchanger Specialists: L.A. (Lou) Curcio, (281) 834-7892, AMERICAS(LACURCI) R.C. Tomotaki, (281) 834-4419, AMERICAS (LESEREB)

Slide 100

ADDENDUM 5.01 SECTION 5 - PROCESS DESIGN COURSE - HEAT EXCHANGER DESIGN

A shortcut procedure for approximate evaluation of shell and tube exchangers with no change of phase IMPORTANT NOTE AND WARNING:

This procedure must not be used for the definitive design of heat exchangers. It is a shortcut technique which makes many simplifying assumptions, especially with regards to shell-side calculations The Reynolds Number used in this addendum is dimensional.

INDEX
DESCRIPTIVE MATERIAL
1. 2. 3. 4. 5. 6. 7. 8. 9. LMTD & Caloric Temperature/Properties Shell Side, Tube Side Flowrates Fouling Tube Side Calculations Shell Side Calculations Duty & Clean Coefficients Design Temperature of Tube Sheet Calculation Form Nomenclature Summary General Design Constants Exchanger Tube Data Thermal Conductivities of Metals Typical Fouling Factors Typical Overall Coefficients Fn Factors Tube Side Correlations Shell Side Correlations Thermal Function K (Pr)1/3

TABLE
1.01 1.02 1.03 1.04 1.05

FIGURES
1.01-1.03 2.01-2.02 3.01-3.02 4.01-4.02

Slide 101

SHORTCUT PROCEDURE
SCOPE The following subsection presents an approximate procedure for evaluating shell and tube exchangers in which there is no change of phase, (I.e., vapor/vapor, vapor/liquid or liquid/liquid exchangers). The actual calculations can be made on the calculation form. Each Step of the procedure is explained in the following paragraphs. DETAILED PROCEDURE 1. Terminal Conditions and Effective Log Mean Temperature Difference a. Determine the following temperatures Inlet temperature of fluid being cooled, T 1 Outlet temperature of fluid being cooled, T 2 Inlet temperature of fluid being heated, t 1 Outlet temperature of fluid being heated, t 2 b. Determine the log mean temperature difference, tm (T 1 - t 2) - (T 2 - t 1)

tm = ln

(T1 - t 2) (T2 - t 1)

c. From Figure 1.01 - 1.03, determine the minimum number of shells required for a temperature correction factor (Fn) of at least 0.8000. d. Determine the effective log mean temperature differences, t e t e = Fn t m
Slide 102

SHORTCUT PROCEDURE (Continued)

2. Caloric Temperatures a. Decide which fluid to pass through the tubes and which through the shell b. Calculate the caloric temperatures. For the fluid being heated, t t or t s = 0.4(t 2 - t 1 ) + t 1

For the fluid being cooled, t s or t t = 0.4(T 1

3. Caloric Properties of Fluids a. Tube Side of Exchanger

- T 2) + T 2

1. At the caloric temperature t t, determine the following tube side fluid properties: For water: density, m For hydrocarbon liquids or vapors: density, m; viscosity, z For other fluids: density, m; viscosity, z; specific heat, c; and thermal conductivity, k b. Shell Side of Exchanger 1. At the caloric temperature, determine the density, m of the shell side fluid.

Slide 103

SHORTCUT PROCEDURE (Continued)

4. Shell Side and Tube Side Flow Rates The values of the respective flow rates in lb/hr will normally be determined during the heat and material balance calculations 5. Fouling Factors a. Decide the tube side fouling factor r i (See Table 1.04) b. Decide the shell side fouling factor ro (See Table 1.04) 6. Iteration, Tube Side (1) The heat duty for the exchanger will normally be determined during the heat and material balance calculations. (2) Assume U, the over-all coefficient (See Table 1.05) (3) Calculate total area A = Q / U te (4) Calculate the area per shell. As = A / Ns If necessary, the number of shells should be increased to meet the maximum shell size limitations (typically 48). This will require recalculating Fn te, A, A s (5) Decide the tube metal and determine tube thermal conductivity, kw (See Table 1.03).

Slide 104

SHORTCUT PROCEDURE (Continued)

(6) Choose the tube length, diameter, wall thickness, pitch, and layout (See Tables 1.01 and 1.02). (7) Determine the number of tubes as follows: NT = 3.82 As (L - 0.5) do (8) Estimate Np, the even number of tube passes per bundle which will give a reasonable tubeside velocity (3-20 fps). (9) Calculate the linear velocity in the tubes and in the nozzles:

(d N = Nozzle ID)
V=

Np M
19.6 ; mN T d i
2

M
VN = 19.6 m dN
2

(10) Tube side pressure drop and heat transfer coefficient (for water). a. Tube side heat transfer coefficient, hio for water from approximately 80F to 180F. 1 R io = h io = 368 do (Vd i) 0.7 tt 100
0.26

Slide 105

SHORTCUT PROCEDURE (Continued)

b. Total tube side pressure drop, P t, for water at approximately 100F. P t = 0.020 F t N s N p V 2 + 0.158L V 1.73 d i1.27 For PN, See Step 15 (nozzle pressure drop). (11) For fluids other than water: a. Calculate the tube side mass velocity, G G = mV b. Calculate tube side Reynolds Number, Nre (dimensional) + PN

N Re = d i G
z Note: At this point, check for a transition problem by calculating N Re using fluid properties at inlet (or outlet) conditions. An Exchanger design is not valid if the type of flow conditions changes from viscous to turbulent (or vice- versa) within the unit. (12) From Figure 2.01 determine the tube side pressure drop correlation factor, Y tp.

Slide 106

SHORTCUT PROCEDURE (Continued)

(13) Calculate the tube side velocity head and the nozzle velocity head. mV 2N in the nozzles ; mV 2 in the tubes 9270 9270 (14) Calculate Ptf, the frictional pressure drop per tube pass. Ptf = Ytp L d
i

mV2 9720

Zw z

0.14 or 0.25

The exponent 0.14 is for turbulent flow (N Re < 30); 0.25 is for streamline flow (N

Re<

30).

(15) Calculate the pressure drop per tube pass due to turns, Ptr, and the nozzle pressure drop, PN. P t = 3 mV2 ; PN = 2 9270 mV2 9270 (two nozzles)

Slide 107

SHORTCUT PROCEDURE (Continued)

(16) Calculate the total tube side pressure drop, Pt P t = F t N s N p (P tf + P tr) + PN For : Ft , see Table 1.01. If the pressure drop is reasonably close to the value desired, proceed to the next step. If it seems too high or low, change number of tube passes and repeat step 9 through 16 until the pressure drop is satisfactory. (17) From Figure 2.02, determine the heat transfer correlation factor, Y a. Calculate the thermal function: k cz k For hydrocarbons, refer to Figures 4.01 and 4.02. b. Calculate the tubeside heat transfer coefficient, h 1 R io Initially assume Z ZW
Slide 108
io. 0.33 0.33 th.

h io

Y th d
o

cz k

z z
w

0.14

0.14

= 1, until tube wall temperature is calculated.

SHORTCUT PROCEDURE (Continued)

c. Estimate the average tube wall temperature, tw t w = t t + U o (R io+ r io) (t s- t t) d. At the average tube wall temperature, determine z w and calculate: Z zw
0.14

(18) Recalculate h io using this viscosity correction. (19) Calculate the tube wall resistance, r w rw = 12 kw (See Tables 1.02-1.03) 7. Iteration, Shell Side (1) Estimate t f, the average shell side film temperature. tf = ( t s + t t ) + (U o) (R io + r io + r w + r o) (T s- t t) 2 2

Slide 109

SHORTCUT PROCEDURE (Continued)

(2) At the average shell side film temperature, determine the following shell fluid properties: a. For hydrocarbon liquids or vapors: Viscosity, z f. b. For other fluids: Viscosity, z f; specific heat, c f; and thermal conductivity, k f. Determine the number of tubes across the centerline of the tube bundle, NTC. For square tube layout:

(3)

N TC = 1.19 (N T) For triangular layout:

(4)

0.5

N TC = 1.10 (N T) 0.5 Determine the outer tube limit, D t. D t = (N TC - 1)(P t) + d o Determine shell I.D. as follows: D = D t / 0.9; except for the following limitations: 1. Minimum D = D t + 1 2. Maximum D = D t + 3 Determine the free width for fluid flow normal to and around the tubes. One shell pass, W = D - (d o N TC) ; Two shell pass, W = D - (d o NTC ) 2

(5)

(6)

Slide 110

SHORTCUT PROCEDURE (Continued)

(7) Estimate the baffle pitch Pb which will give a reasonable shell-side velocity (3-15 fps). See Table 1.01 for maximum Pb. (8) Calculate the number of shell side baffles, N B (always a whole number). N B = 10L/Pb (9) Determine the free area, S, for fluid flow across the tube bundle between each pair of baffles. For Calculating the Film Coefficient, h For Calculating the Pressure drop, P

Segmental Baffles: S = W (Pb - 0.375) S = W (Pb - 0.375) Modified Disc & Donut Baffles: S = W (Pb - 0.375) S = 0.85 W (Pb - 0.375) In each case, 0.375 in. represents the approximate baffle thickness. (10) Calculate the shell side mass velocity, G. Disc and donut baffles, G = M/50 x S; Segmental baffles, G = M/25 x S

Slide 111

SHORTCUT PROCEDURE (Continued)

(11) Calculate the shell side linear velocity, V and the shell side nozzle velocity, VN V = G/m Vn = M 19.6 md2N (d N = Nozzle ID)

(12) Calculate the shell side Reynolds number, N Re N Re = d o G/Z f (13) Calculate the ratio of the tube diameter to the tube spacing: do Pt-do From Figure 5.01 determine the shell side pressure drop correlation factor, YSP. Total Shell Side Pressure Drop

(14) Calculate the shell side velocity head and the nozzle velocity head. mV 2 N in the nozzles ; mV 2 in the shell.
9270 9270

Slide 112

SHORTCUT PROCEDURE (Continued)

(15) Calculate Psf, the frictional pressure drop per shell. Table 1.01 gives values for B2. mV 2 9270 (Note!: For Disc & Donut baffles, divide NTC by 2.0) (16) Calculate the pressure drop per shell due to turns, Psr, and the nozzle pressure drop, PN. = B 2Ysp N TC N
B

Psf

(N B + 1) 3.5 - 2Pb mV 2 ; PN = D 9270 (17) Calculate the total shell side pressure drop, Ps. Ps For Fs, see Table 1.01. = Fs N s (Psr + Psf) + PN

Psr =

mV 2 N 9270

If the pressure drop is reasonably close to the desired value, proceed to the next step. If it seems too high or low, change the baffle pitch Pb and repeat steps 7 through 17 until the pressure drop is satisfactory.

Slide 113

SHORTCUT PROCEDURE (Continued)

Shell Side Heat Transfer Coefficient, ho (18) From Figure 5.02 determine the heat transfer correlation factor, Ysh. A. Calculate the thermal function: k
f

cfzf kf

1/3

(For hydrocarbon liquids or vapors, refer to Figures 4.01 and 4.02) b. Calculate the correction factor for the deviation from ideal baffle pitch. 4Pb D
0.1

1 = h o = B 1 Ysh k Ro do See Table 1.01 for B1

c fz kf

1/3

4Pb D

0.1

8. Duty Coefficient Calculate Uo, the over-all duty heat transfer coefficient.

1 = R
Uo

=R

io

+r

io

+R

+r

+r

If Uo calculated does not agree with Uo assumed, repeat the calculations with a new Uo assumed until agreement is reached (10%).
Slide 114

SHORTCUT PROCEDURE (Continued)

9. Clean Coefficient Calculate Uc, the over-all clean coefficient. 1 =R
c

=R

io

+r

+R

+ 0.001

Uc 10. Design Temperatures Determine the following mechanical design features: 1. The design temperature and pressure of the shell and tube sides. 2. The nozzle size and flange rating for the inlets and outlets on both the shell and tube sides. 3. The design temperature of the tube sheet, TM. a. For coolers (water on tube side), specify the higher result of the following equations: TM = TDT + or R io (TDS - TDT) RC (R io + rio) (TDS - TDT)

b.

Rt For other exchangers: (1) When the fluid being cooled is on the tube side TM = TDT - 0.1(TDT - TDS) (2) When the fluid cooled is on the shell side TM = TDT + 0.3 (TDS - TDT)

TM = TDT +

Slide 115

Problem 5 B-E Heat Exchanger Design

Slide 116