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Column and HE Sizing

Depok, 10 Oktober 2017


Irwan
Agenda

Design Distillation Column

Perpindahan Panas

Jenis Heat Exchanger dan Aplikasinya

Penentuan Estimasi Harga untuk HE


Design of Distillation Columns
Determination of the Number of Actual Stages

The vapor leaving each stage was in equilibrium with the liquid leaving the same stage. However, in
practice, the trays are not perfect, i.e. there are deviations from ideal conditions. The assumption of
thermal equilibrium is reasonable, but the assumption of equilibrium with respect to the mass
transfer is seldom justified due to:
insufficient time of contact between the liquid and vapor phases
insufficient degree of mixing of the both phases (the presence of stagnant zones on large-
diameter distillation trays)
the effects of entrainment and weeping.

To determine the actual number of trays required for a given separation, the number of theoretical
stages must be adjusted with a overall column efficiency and a safety coefficient:

N th s
N eff 2 N th
E OV

Neff number of actual stages


Nth number of theoretical stages
s safety coefficient (s = 1,3 2)
EOV overall column efficiency
Design of Distillation Columns
Determination of the Number of Actual Stages
Overall Column Efficiency, Murphree Tray Efficiency

The overall column efficiency EOV depends on the geometry and design of the trays, flow rates and flow paths
of vapor and liquid streams, compositions and properties of both phases. Values of EOV can be predicted by
comparsion with performance data from industrial columns for similar systems, by use of empirical correlations
or semitheoretical tray models or by scale-up from laboratory data. Guideline values are:

Tray Type Tunnel Tray Bubble Cup Tray Sieve Tray Valve Tray
EOV 0,5 0,7 0,6 0,8 0,7 0,8 0,7 0,9

The Murphree tray efficiency Ej that describes the separation achieved on individual tray j is usually based on
the vapor phase:
Separation effect of the actual stage y y j 1 a
Ej *j 1
Separation effect of the theoretical stage y j y j 1 b

y j 1 x j 2 y
Equilibrium
j+1 Curve

z y j x j 1 Operating Line
y *j
j y j b
a y j y j 1 actual composition change
z y j 1 x j y j 1
y *j y j 1 maximal feasible composition
j1 change (predicted by equilibri-
um)
y j 2 x j 1 x j x j 1 x
Design of Distillation Columns
Determination of the Tray Column Height

Once the overall column efficiency EOV is known, it can be used on the McCabe-Thiele graphical method in the
form of a pseudo-equilibrium curve. In stepping off stages, the overall vapor-side efficiency EOV = a/b, can be
used to dictate the percentage of the vertical distance taken from the operating line to the equilibrium curve.
Following the staircase construction between the pseudo-equilibrium curve and the operating lines the number
of actual stages Neff required for the given separation is determined:

1
Pseudo-equilibrium curve for
b a
EOV = a/b = const.
y Equilibrium curve for EOV = 1
a
Operating lines
E OV
b
b e.g., for E OV 0, 75 ; s 1; N th 3:
a
Nth s
N eff 4
E OV
0 x B x x D 1

The height of trayed portion of column H and the column height Htot, required to meet the product
specifications, are

N th s
H N eff z z H tot H Hmin H 3 z
E OV
where z is the tray spacing, typically z = 0,2 0,6 m.
Design of Distillation Columns
Operating Region of Tray Columns

Tray columns can only be operated within certain limits of gas and liquid flow. The operating region of a tray
column can be represented in a diagram with x-coordinate VL and y-coordinate VG . Often these two loads are
referred to the active area Aac. The upper borders for the gas and liquid flow (bold lines) are absolute borders
that can never be crossed without causing mechanical damages. The lower borders (dashed lines) may be
exceeded to a certain extent without encountering any flow problems. However the mass transfer efficiency
may gradually decrease. The shape and size of the operating region depends on the design parameters. The
operation point should be chosen so that a sufficient safety margin to the operation limits remains.


VL height
Entrainment Froth

D
Operating region

Downcomer
capacity

Aac
Minimum crest Weeping
over weir

Note: See https://www.youtube.com/watch?v=D0H9FWsk_Ck, https://www.youtube.com/watch?v=Ch68_F-G9z8,


https://www.youtube.com/watch?v=I6G8yGBpX5I for videos showing different operation modes of tray columns.
Design of Distillation Columns
Operating Region of Tray Columns

As described below the gas and liquid loads has to be kept between a maximum and a minimum value.
Therefore, four limitations can be defined:

Minimum Gas Load: at low gas velocities either the gas no longer flows uniformly though all the
tray openings (bypassing part of the tray) or the liquid leaks though the tray
(weeping)
both modes of operation should be avoided due to tray efficiency losses
because of insufficient degree of mixing of the both phases
the main factor that affects weeping is the hole diameter (the minimum gas
load increases with increasing hole diameter)

Maximum Gas Load: at high gas velocities the gas blows the liquid off the tray in form of fine
droplets (entrainment, jet flood)
the liquid flows no longer countercurrently to the gas, and proper column
operation ends
the maximum feasible gas load depends on system properties (density of gas
and liquid, surface tension) as well as on tray design
entrainment flooding of trays is decisive at very large tray spacings z, for
smaller tray spacings z the froth height on the tray sets a lower limitation
Design of Distillation Columns
Operating Region of Tray Columns

Minimum Liquid at extremely low liquid loads, liquid flows unevenly across the VL
Load: tray (maldistribution), which decreases the mass transfer
efficiency hl
minimum height of the weir overflow hwo 5 mm
this corresponds to a minimum liquid weir load of: hwo
z
VL / lw 2 m/(m h)

Maximum Liquid the liquid flow downward through the downcomers is enforced VG
Load: by gravity forces which results in a limitation of the maximum
liquid load
the following four empirical rules are often used to determine
the maximum liquid flow rate
lw
the weir load should be VL / lw 60 m/(m h)
the liquid velocity in the downcomer should not exceed a
value of 0,1 m/s
the volume of the downcomer should permit a liquid
residence time of more than 5 s
the height of the clear liquid in the downcomer should not
exceed half of the tray spacing (hl z/2)

Ideally, the column is operated in the range of 60 to 90 % of the flooding vapor velocity.
Design of Distillation Columns
Comparsion of Common Tray Types

3
1 2

* within optimum operating range


Design of Distillation Columns
Summary of the Geometry and Layout of Common Tray Types at Different Operating Pressures

3
1 2

* DS column diameter in m, hw outlet weir height in m


Design of Distillation Columns
Determination of the Tray Column Diameter

The tower diameter and, consequently, the cross-sectional area of the column must be sufficiently large to
handle the gas and liquid rates within the operating region. The diameter of a distillation column is generally
controlled by the vapor velocity.
For designing a column the vapor velocity of the inside cross-sectional area of the empty tower is used. The
vapor flows vertically upward usually at velocity from 0,5 to 2,5 m/s, and from 3 to 6 m/s in bubble-cup or
tunnel tray columns. In contrast, the downflow velocity range of the liquid is from 110-3 to 1510-3 m/s.
The required free cross-sectional area of the column is determined using the maximum vapor volumetric flow
rate during the operation and the allowable vapor velocity referred to the total column cross-sectional area:

V m G max N MG
AQ Di 2 G max G max
4 w G zul G w G zul G w G zul

AQ free (total) cross-sectional area of the column [m]


Di column internal diameter [m]
maximum vapor volumetric flow rate [m/s]
V
wG zul G max allowable vapor velocity referred to the area AQ [m/s] (0,56 m/s)
maximum vapor mass flow rate [kg/s]
m
G maxmaximum vapor molar flow rate [kmol/s]
N
G G maxavarage density of the vapor phase [kg/m]
MG average molecular weigth of the vapor phase [kg/kmol]
Design of Distillation Columns
Determination of the Tray Column Diameter

Column internal diameter Di can be expressed as:

2 2 N G max M G
Di AQ
G w G zul

Assuming ideal gas behavior for the vapor phase, the average vapor density can be substituted:

mG N MG p MG
G G max p operating pressure [Pa]
VG VG R T
T operating temperature [K]
R universal gas constant
(R = 8314,5 J/(kmolK)

Thus, the column internal diameter at a given operating pressure and operating temperature is:

2 N G max R T N G max T
Di 102, 89
p w G zul p w G zul

where Di [m], N G max [kmol/s], T [K], p [Pa], wG zul [m/s]


Design of Distillation Columns
Determination of the Tray Column Diameter

The allowable vapor velocity referred to the total column cross-sectional area wG zul depends mainly on the tray
type and its geometry, on the liquid load, and on the physical properties of the both phases.
The usual design limit is entrainment flooding, which is caused by excessive carry-up of suspended liquid
droplets by rising vapor to the tray above. At low vapor velocity, a droplet settles out; at high vapor velocity,
it is entrained. At flooding velocity wG max, the droplet is suspended such that the vector sum of the buoyant
force FA, drag force FW, and gravitational force FG acting on the droplet will be zero.
From the balance of forces at a liquid doplet and a safety margin (fraction of flooding) results the allowable
vapor velocity wG zul referred to the total column cross-sectional area:

Aac L G
w G zul f w G max 0, 7 kV
AQ G

wL
f fraction of flooding, e.g. f=0,7
FA
kV capacity parameter of
FW Souders/Brown [m/s]
Two-phase Aac active area of a tray [m]
z Layer
AQ total column cross-sectional area
[m]
FG z tray spacing
L liquid density [kg/m] liquid surface tension
w G max
G vapor density [kg/m]
Design of Distillation Columns
Pressure Drop in Tray Columns

Generally, the column pressure drop should be as low as possible because


obtaining the number of theoretical trays using the McCabe-Thiele graphical method assumes that
the pressure is constant over the whole column
low pressure drop leads to a reduced energy requirement and to a heat supplied by the reboiler at
the bottom at a lower boiling temperature level.

Pressure loss of the vapor significantly depends on both gas and liquid load. The total column pressure drop is
the sum of the hydrostatic pressure loss caused by the clear liquid holdup on the trays, the pressure drop due
to the friction for vapor flow through the openings in the trays, and a loss due to the formation of bubbles by
the gas:
pcol pst pdyn p

pcol total column pressure drop [Pa]


pst hydrostatic pressure drop of clear liquid [Pa]
pdyn pressure drop due to vapor flow resistance [Pa]
p pressure drop due to surface tension [Pa]

The first term in the equation above accounts for the liquid head on a tray, the second term refers to the dry
pressure loss of the tray, the third term is small compared with pcol and is usually negligible.
Due to the numerous variables such as tray geometry, physical properties of vapor and liquid, gas and liquid
loads, operating pressure, etc. a general equation to calculate the columns pressure drop has not yet been
developed. In most cases, the pressure drop must be found depending on the tray type experimentally.
Design of Distillation Columns
Pressure Drop in Tray Columns

The hydrostatic pressure drop of liquid pst depends on the mass of the clear liquid inside the column, as given
by:
mL g
pst
AQ

mL total mass of the liquid in the column [kg]


g gravitational constant g = 9,81 m/s
AQ total cross-sectional area of the column [m]

For tray columns the hydrostatic pressure drop is given by the sum of the pressure drops across the trays:

pst N eff S g hS N eff (1 ) L g hS

Neff number of actual trays []


S average density of the two-phase layer [kg/m]
L density of clear liquid [kg/m]
relative gas/vapor fraction in the two-phase layer []
hS average heigth of the two-phase layer [m]
Design of Distillation Columns
Pressure Drop in Tray Columns

The pressure drop due to the friction for vapor flow up the column pdyn can be expressed approxima-tely by:

G w G2
pdyn
2

orifice coefficient of column internals []


G vapor density [kg/m]
wG vapor velocity referred to the column cross-sectional area [m/s]

The orifice coefficient depends on the type and geometry of the column internals, and on the surface tension
of the liquid. In tray columns, the orifice coefficient can be taken from:

N eff B

B orifice coefficient of a dry tray []

If the column is operated at 85 % of the flooding vapor velocity, the pressure drop per tray is, depen-ding on
tray type, approximately from 2 to 8,5 mbar.
Design of Distillation Columns
Rate-Based Method for Packed Columns

With the availibilty of economical and efficient packings, packed towers are finding increasing use in new
distillation processes and for retrofitting existing trayed towers. They are particularly useful in applications
when the separation is relatively easy and the required column diameter is not very large, where pressure drop
must be low, as in low-pressure distillation, and where liquid holdup must be small, such as when separating
heat-sensitive materials whose exposure to high temperatures must be minimized.
Packed columns are continuous, differential-contacting devices that do not have the physically distin-guishable,
discrete stages found in trayed towers. Thus, packed columns are better analyzed by mass-transfer models
than by equilibrium-stage concepts. However, in practice, packed-tower performance is often presented on
the basis of equilibrium stages using a packed height equivalent to a theoretical plate, called the
HETP and defined by the equation

Packed height H
HETP
Number of equivalent equilibrium stages Nth

Values of the HETP depend mainly on packing type and size, liquid viscosity, surface tension, and operating
conditions. In the absence of detailed information on the HETP, following rough approxima-tions are sufficient:
HETP 0,6 m for random packings, HETP 0,3 m for structured packings.
The required height of the packing within the column H and the total height of the column Htot are:

with Hmin (0,5...1 m) + (1...2 m)


H N th HETP H tot H Hmin
Design of Distillation Columns
HETP Estimation for Random and Structured Packings

For rough estimates of the HETP the following relations can be used (all values are in ft,
1 ft = 0,3048 m)
1. Random packings of second and third generation with low-viscosity liquids

HETP 1, 5 d P dP nominal packing diameter [in] (1 in = 25,4 mm)

2. Structured packings at low-to-modarate pressures with low-viscosity liquids

100
HETP 0, 333 a packing surface area per packed volume [ft/ft]
a

3. Distillation with viscous liquid


HETP 5 6 ft

4. Vacuum service
HETP 1, 5 d P 0, 5

5. Structured packings at high pressures

100
HETP 0, 333
a

6. Small-diameter columns with internal diameter Di < 2 ft


HETP Di , but HETP 1 ft
Design of Distillation Columns
Characteristics of Random Packings

Type Packing Material Nominal Packing


Diameter Factor
dP [in] FP [ft/ft]
Raschig rings Ceramic 1,0 157
2,0 58
3,0 33
Raschig rings Metal 1,0 165
2,0 71
3,0 40
Intalox saddles Ceramic 1,0 92
2,0 30
3,0 15
Intalox saddles Plastic 1,0 36
2,0 25
Pall rings Metal 1,0 56
1,5 29
2,0 27
3,5 16
Pall rings Plastic 1,0 53
2,0 25
3,5 15

Sources: W. D. Seider et al.: Product and Process Design Principles. 3. Aufl., John Wiley, Hoboken 2010;
Design of Distillation Columns
Characteristics of Random and Structured Packings

Packing Material Size Packing Mass-transfer Void Fraction


[mm] Factor Surface Area per Unit [-]
FP [ft/ft] Volume
a [m/m]
Random Packings
Hiflow rings Ceramic 50 29 89,7 0,809
Metal 50 16 92,3 0,977
Plastic 50 20 117,1 0,924
Nor-Pac rings Plastic 50 14 86,8 0,947
Plastic 35 21 141,8 0,944
Plastic 15 311,4 0,918
Tellerettes Plastic 25 40 190,0 0,930
Top-Pak rings Aluminium 50 105,5 0,956

VSP rings Metal 50 104,6 0,980


Metal 25 199,6 0,975
Structured Packings
Euroform Plastic PN-110 110,0 0,936
Gempak Metal A2 T-304 202,0 0,977
Koch-Sulzer Metal CY 70
Koch-Sulzer Metal BX 21
Mellapak Plastic 250 Y 22 250,0 0,970
Montz Metal B1-100 100,0 0,987
Montz Metal B1-200 200,0 0,979
Montz Metal B1-300 33 300,0 0,930
Montz Plastic C1-200 200,0 0,954
Montz Plastic C2-200 200,0 0,900

Source: E. J. Henley et al.: Separation Process Principles. 3. Aufl., John Wiley, Hoboken 2011
Design of Distillation Columns
Determination of the Packed Column Diameter

The column diameter is determined so as to safely avoid flooding and to ensure that pressure drop is below 1,2
kPa/m of packed height. At the flooding point, the pressure drop increases infinitely with increasing vapor
velocity. The internal column diameter Di is based again on a fraction f of flooding velocity wG max by:

2 N G max M G 2 N G max M G
Di
G w G zul G f w G max f fraction of flooding 0,65 < f < 0,9 (f 0,7)

The generalized correlation of Leva gives reasonable estimates of the flooding gas velocity wG max [ft/s]:

FP G
Y w G2 max F F and
g L H2 O

m
L G
Y exp 3, 7121 1, 0371 ln FLG 0,1501 ln FLG 0, 007544 ln FLG with
2 3
FLG
m
G L

packing factor [ft/ft] (usually a packing surface area per packed


a
FP 3 determined experimentally) volume [m/m]

g gravitational constant void fraction [m/m, %, -]
(g = 32,174 ft/s)
G avarage density of the vapor phase [kg/m]
L H2O average density of water [kg/m] ( L H2O = 999,5 kg/m at 20 C, 1 bar)

The above regression model for the dimensionless flooding velocity factor Y = f (FLG) is valid for 0,01 Y 10.
Design of Distillation Columns
Determination of the Packed Column Diameter

The functions F and F are corrections for liquid properties given by:

2
L H2 O L H2 O L H2 O
F 0, 8787 2, 6776 0, 6313 , valid for 0, 65 1, 4
L L
L
L H2O average density of water [kg/m] ( L H2O = 999,5 kg/m at 20 C, 1 bar)

L average density of liquid [kg/m]

F 0, 96 L 0,19 , valid for 0,3 cP L 20 cP


L average dynamic viscosity of liquid [cP]

For a certain value of the flow parameter FLG can firstly be calculated the dimensionless factor Y, and the
superficial gas velocity at flooding wG max = f (Y) is then estimated for a given packing type and size (FP = f (a,
)) and the correction functions F and F.

Finally, using the allowable vapor velocity wG zul, the internal diameter of the distillation column Di can be
determined. The tower inside diameter should be at least 10 times the nominal packing diameter and
preferably closer to 30 times,

Di 10...30 d P dP nominal packing diameter [mm] .

Under these conditions, the negative effect of maldistribution on mass-transfer efficiency is minimised.
Therefore, the column diameter may need to be adjusted accordingly.
Design of Distillation Columns
Pressure drop in Packed Columns

An estimation of pressure drop in Pa/m can be made by using the generalized pressure drop correlation for
packed beds according to Sherwood et al. and Leva:

m
L G
FLG
m
G L

G
Y FP w G2 0,1
L
L G

liquid flow rate [kg/s]


Y m
L
gas flow rate [kg/s]
m
G
L liquid density [kg/m]
G gas density [kg/m]
FP packing factor [ft/ft]
wG gas velocity [m/s], wG = f wG max
J. Bentez: Principles and Modern Applications of Mass
Transfer Operations. 2. Aufl., John Wiley, Hoboken 2009 L liquid viscosity [Pas]

FLG
The flooding curve in the above figure corresponds to a pressure drop of 1200 Pa/m of packed height and can
be accurately described by the polynomial regression:

exp 3, 5021 1, 028 ln FLG 0,11093 ln FLG


2

YFlooding

Design of Distillation Columns
Charts for the Design of Random-Packed Columns:
HETP Estimation INTALOX Metal Tower Packing (IMTP)

FS w G zul G
G
C S w G zul
L G

Source: Koch-Glitsch, LP, Wichita


Design of Distillation Columns
Charts for the Design of Random-Packed Columns:
Estimation of Pressure Drop INTALOX Metal Tower Packing (IMTP)

Source: Koch-Glitsch, LP, Wichita


Design of Distillation Columns
Summary of Distillation Column Design

Distillation/Absorption/Stripping

Tray Columns
Random-/Structured-Packed Columns
(sieve, valve, bubble-cup trays)
stagewise contact between the phases continuous contact between the phases

Concept of equilibrium stages: determination of the number of theoretical stages Nth


McCabe-Thiele graphical equilibrium-stage method
Kremser equation (analytically, assuming straight equilibrium and operation lines absorption/ stripping)

Estimation of the actual number of contacting trays Neff Estimation of HETP depending on packing type and
applying an overall column efficiency EOV: size, liquid viscosity, and surface tension:
N th 0, 3 0, 9 m for random packings
N eff 0,1 EOV 0,9 HETP
E OV 0, 2 0, 7 m for structured packings
Height of the actual equipment:
H tot N eff z Hmin z 0, 45 0, 6 m; Hmin 3 z H tot N th HETP Hmin Hmin 1, 5 3 m

Internal Column Diameter:

2 G max M G
Di with w G zul f w G max ; 0, 65 f 0, 9
G w G zul
Vapor-side pressure drop:
pcol f (tray type) pcol f (packing type)

GPDC charts, correlations


Design of Distillation Columns
Summary of Distillation Column Design

(1) Sketch the column, set the given feed and product specifications
(2) Determine the operating temperature and pressure by the available utilitiy temperatures, the boiling temperature
of the mixture, the desired purity of the separation, and any contraints on the stability of the mixture
(3) Make a material balance over the column to determine the unknown top and bottom compostions and/or flow rates
(4) Plot the vapor-liquid equilibrium curve from data available at the column operating pressure and the diagonal line
on the equilibrium diagram, mark given compositions of feed, distillate and bottom product on the diagram
(5) Draw the q-line
(6) Determine the minimum reflux ratio rmin from intersection of rectifying section operating line and the equilibrium
curve or by calculation
(7) Determine the optimum reflux ratio, e.g. r = 1,2 rmin
(8) Draw operating lines for rectifying and stripping section
(9) Determine the number of theoretical stages Nth using the equilibrium diagram or by analytical methods
(10) Select the type of contacting device: trays or packings
(11) Determine the actual number of trays Neff or HETP and specify the column height Htot
(12) Determine the allowable vapor velocity wG zul
(13) Design the column: inner diameter, column internals (trays, packing, liquid and vapor distribution systems, packing
supports, etc.)
(14) Estimate the total column pressure drop pcol
(15) Evaluate pressure drop according to pcol palow, if necessary select another column internals and return to step
(11)
(16) Determine the energy requirements Q B , Q C , calculate the size of the heat exchangers (basic design of condenser
and reboiler) and the utiliy flows
(17) Estimate the annual total costs Ctot (r) = Cop (r) + Ccap (r)
(18) To minimize the annual total costs modify the reflux ratio, return to step (8) and cycle through steps (8) to (17)
until Ctot (r) min
(19) Carry out the mechanical design of the column considering the operating temperature and pressure and the
corrosion properties of the mixture
Design of Distillation Columns
Distillation of Multicomponent Mixtures without Azeotropes Sequences of Simple Columns

Multicomponent mixtures are often separated in more than two products. In this case, there is a choice of order in which the
products are separated. Consider the design of distillation systems comprising only simple columns, which have a single feed
and two products.
If there is a mixture of three components A, B, C (in order of increasing boiling point) to be separated into three relatively
pure products, then the decision is between two distillation sequences:

a) direct sequence (the lightest component b) indirect sequence (takes the heaviest com-
is taken overhead in each column) ponent as bottom product in each column)

In general, to separate an n-component mixture into nearly pure products n1 simple columns are sufficient, and the
number of different distillation sequences is .
N seq 2 (n 1) !/ n !(n 1)!
The following table shows some sequences of splits that can be used to separate multicomponent nonazeotropic mixtures.
These can all be accomplished in simple columns, which have a single feed and two products. The components are A, B, C,
D, E in order of increasing boiling point. Each of the splits listed corresponds to one simple column. Actually, more columns
can be used, and this is sometimes more economical.
How is the Heat Transfer?

Heat can transfer between the


surface of a solid conductor and the
surrounding medium whenever
temperature gradient exists.

Conduction
Convection
Natural convection
Forced Convection
Natural and Forced Convection

Natural convection occurs whenever heat


flows between a solid and fluid, or between
fluid layers.
As a result of heat exchange
Change in density of effective fluid layers
taken place, which causes upward flow of
heated fluid.
If this motion is associated with heat
transfer mechanism only, then it is called
Natural Convection
Forced Convection

If this motion is associated by


mechanical means such as pumps,
gravity or fans, the movement of the fluid
is enforced.
And in this case, we then speak of Forced
convection.
Heat Transfer Basic Design and Formulas
First Law of Thermodynamic: Energy is conserved.
0 0 0 0
dE
dt


in
m . h in
out
m . h out q w s e generated

Qh A.m
h.Cph.Th
m . h m . h
Qc A.m
c .Cpc .Tc in out

Control Volume COLD

HOT
Thermal Boundary Layer
Cross Section Area
THERMAL
BOUNDARY LAYER

Energy moves from hot fluid to


a surface by convection,
through the wall by conduction,
and then by convection from Region III: Solid
the surface to the cold fluid. Cold Liquid
Convection

Th Ti,wall

To,wall

Tc

Region I : Hot Liquid- Q hot Q cold


Solid Convection

Region II : Conduction
Across Tube Wall
Heat Transfer Basic Design and Formulas
Heat Transfer Basic Design and Formulas
Heat Transfer Basic Design and Formulas
Heat Transfer Basic Design and Formulas
Heat Transfer Basic Design and Formulas
Heat Exchanger Definitions

Exchanger
Performs a double function; simultaneous heating of a cold
fluid and cooling of a hot fluid.
Heater
Increases the sensible heat of a liquid or a gas at the cost of the
latent heat of condensing steam.
Reboiler
Provides heat necessary to reboiler liquid at the bottom of a
fractionating tower. The heating medium may be either
condensing steam or a hot process fluid.
Heat Exchanger Definitions

Thermosiphon Reboiler
Makes use of the natural convection to circulate a boiling
medium back to a fractionating tower. Necessary liquid
head is provided by the buoyant force.
Evaporator
Evaporator is a heater which evaporates water to
concentrate a solution.
Vaporizer
Vaporizer liquid feed either completely or partially by
means of heating medium such as steam.
Heat Exchanger Definitions

Steam Generator
Makes condensate or boiler feed water into steam by
direct firing of waste oil, tars or off-gas.
Cooler
Cools liquids or gases by means of water.
Chiller
Cools process stream to the temperature lower than
prevailing water by refrigerant such as ammonia and
freon.
Heat Exchanger Definitions

Condenser (Total Condenser and Cooler Condenser)


Total condenser condenses all vapors (pure or
mixed) entering, and cooler-condenser condenses
all condensable vapor and cools non-condensable
gases.
Partial Condenser
Condenses only part of total entering vapors.
Heat Exchanger Applications

Heat Exchangers
prevent car engine
overheating and
increase efficiency
Heat exchangers are
used in Industry for
heat transfer

Heat
exchangers are
used in AC and
furnaces
Double Pipe of Heat Exchanger

The closed-type exchanger is the most popular one.


One example of this type is the Double pipe exchanger.

In this type, the hot and cold fluid streams do not come into
direct contact with each other. They are separated by a tube wall
or flat plate.
Other Type of Heat Exchanger
Air Cooled Heat Exchanger
Shell and Tube Heat Exchanger
Component of Shell and Tube Heat Exchanger
TEMA Type
Detail Design of Shell and Tube Heat Exchanger
Detail Design of Shell and Tube Heat Exchanger
Type Selection Guide

Front End Stationary Head Type


a. TEMA type A is used when tube-side fouling resistance exceeds
0.00035 m2K/W (0.0004 m2hoC/Kcal)
b. TEMA type B is used when tube-side fouling resistance is 0.00035 m2K/W
(0.0004 m2hoC/Kcal) and below, and when leakage of the tube-side fluid
should be prevented
c. TEMA type C or N is used to prevent leakage of the tube-side fluid
d. TEMA type D is used when tube-side design pressure is higher than
9800 KPa (100 kg/cm2G)

Shell Type
a. One pass shell (TEMA type E) is the most common type of shell
b. Two pass shell (TEMA type F) produces a shell-side pressure drop 8 times
as large as E shell, but can decrease the number of shells in series when a
temperature pinch exists between the hot and cold fluids.
Type Selection Guide

c. Divided flow shell (TEMA type J) produces a shell-side pressure drop 1/8
smaller than E shell.
d. Split flow shell (TEMA type G) or double split flow shell (TEMA type H) is
used to make the shell-side pressure drop low (under 20.0 KPa (0.2
kg/cm2)) like a reboiler or condenser.
e. Kettle type reboiler (TEMA type K) is used to pool boil shell-side liquid
f. Cross flow shell (TEMA type X) is used when shell-side pressure drop
shall be minimized
Type Selection Guide
Rear End Head Type

Shall be selected according the following flow chart


Type Selection Guide

(a.) Shell-side fouling resistance is under 0.00035 m2K/W (0.0004 m2hoC/Kcal)


or shell-side fouling material can be easily removed by chemical cleaning
(b.) Tube-side fouling resistance is under 0.00035 m2K/W (0.0004 m2hoC/Kcal)
or tube-side fouling material can be easily removed by chemical cleaning
(c.) Leakage should be prevented
(d.) Tube-side design pressure is higher than 3290 Kpa (40 kg/cm2G)
and shell I.D. is 350 mm or greater.

Reboiler Type Selection


a. Pool boiling types, such as kettle and internal reboilers
b. Recirculating types, such as thermosyphon and pump-through reboilers
Type Selection Guide
Type Selection Guide
Fluid Allocation
Fluids to be passed through the shell
- Fluids of which pressure drop should be low
- Highly viscous fluids
- Fluids which exhibit a low heat transfer rate
- Fluids which undergo the phase change

Fluids to be passed through the tube


- Dirty fluids
- Fluids at higher pressure
- Corrosive fluids
- Fluids which contain solids
- Cooling Water
Fluid Allocation

In vertical thermosyphon reboiler, process stream may be passed


through the tube. On the other hand heating medium, such as steam
and hot oil, may be passed through the shell

In fin tube equipment, high-pressure, dirty, or corrosive fluid is passed


through the fin tube because it is relatively cheap, can be easily
cleaned, and has a higher strength than the outside tube.
Vertical or Horizontal Installation

Horizontal Installation
is most frequently used from the viewpoints of economy and easy
maintenance

Vertical Installation
- In case of big size reboiler, compact plot area is required due
to the space limitation.
- In case where the tube material of reboiler is high grade,
vertical installation should be considered for cost saving due
to the compact piping arrangement.
Selection Guide
Case Example

Kita akan mendinginkan feed gas dari suhu 60degC menjadi 40degC
dengan menggunakan air laut.
Feed gas pressure adalah 15 kg/cm2G dan fouling factornya 0.00025
m2K/W.
Air laut fouling factornya 0.00052 m2K/W. Air Laut suhunya adalah
32degC dan meninggalkan HE pada suhu 46degC.

Dari informasi diatas type Shell and Tube Heat Exchanger apa yang
akan diaplikasikan?
Price Estimation of Shell and Tube Heat Exchanger
Cost Estimation of a Heat
Exchanger
Outline
Introduction and Problem Definition
Designs of Heat Exchangers
Base Cost Estimation
Complete Cost Estimation
Conclusions & Recommendation
Problem Definition

Heat cold water from 15 oC to 85 oC


using the minimum resources
Area Limited to 50 square meters
Minimize the cost of operation and
maintenance of the machine
Shell And Tube Heat Exchanger

Efficiency: 48%
Power: 7.317x10 5 Watts
Length of Pass: 4.7 meters, Life Cycle 5 yr.
Counter Flow Heat Exchanger

Efficiency: 48%
Power: 7.317 x 105 Watts
Length 129.55 meters, 8 revolutions, Life Cycle: 5yr.
Cross Flow Heat Exchanger

Efficiency: 61%
Power:2.92 x 105 Watts
Area: 28.4 square meters, Tubes: 7898, Life Cycle 25 yr.
Summary of Designs
Power Life Efficiency
(Watts) Cycle
Shell & 7.137 E5 5 yrs 48 %
Tube
Counter 7.137 E5 5 yrs 48 %
Flow
Cross 2.92 E5 25 yrs 61 %
Flow
Base Cost Estimating Technique

Base Cost = Cost of Materials to Construct Heat Exchanger


+ Cost Of Installation of Heat Exchanger

Conversion of Base Cost to Annual Worth using MARR = 10%


AWHeat Exchanger = (Base Cost) x (A/P,10%,Life Cycle)
Base Cost Estimation Of Heat
Exchanger Designs
Using Annual Worth and assuming repeatability
AWShell and Tube = - $ 14400
AWCounter flow = - $ 63400
AWCross flow = - $2200

Best Alternative for Heat Exchanger is


Cross Flow Heat Exchanger
Complete Cost Estimating Technique

Complete Cost = Base Cost + Operation and Maintenance

Conversion of Complete Cost to Annual Worth using MARR = 10%


AWHeat Exchanger = (Base Cost) x (A/P,10%,Life Cycle) +
(O & M) x (A/P,10%,Life Cycle)
Complete Cost Estimation

Base Cost of Cross Flow Heat Exchanger - $ 2200


Operation and Maintenance Cost + Cost of Gas - $ 2300

Total Cost Over Life Cycle - $ 4500


Conclusions & Recommendation
Cross Flow Heat Exchanger is the most effective
for the purpose
Cross Flow Heat Exchanger is the most Cost
Effective
Aside:
The Shell & Tube and Counter flow reused waste to heat water.

Recommendation : Cross Flow Heat Exchanger


Question and Answer

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FOR YOUR ATTENTION

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