THERMAL DESIGN OF AIR COOLED HEAT EXCHANGER WITH HIGH POUR POINT FLUID

V. DWARAKAKRISHNA V DWARAKAKRISHNA. Consultant, Equipment Engineering (Heat Exchangers) Foster Wheeler, Chennai, India A Technical P T h i l Presentation t ti 13th HTRI CC Meet, Chennai, India 14th February 2011
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The topic

To develop Thermal Design as per HTRI program for Air Cooled Heat Exchanger Unit for fuel oil cooling having high pour point, with an aim to illustrate the use of a simple practical idea avoiding costly appurtenance.

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Design data
Fuel oil conditions
Fluidname Parameter Flowrate Flow rate Temperaturein/out Inletpressure Inlet pressure Allowable pressuredrop Specificheatin/out Viscosityin/out Viscosity in / out Thermalconductivityin/out Densityin/out Liq.surfacetensionin/out Foulingresistance Pourpoint Pour point HighSulphurFuelOil(HSFO) Units 1000Kg/hr 1000 Kg/hr DegC Kg/cm 2A Kg/cm*2 A Kg/cm*2 Kcal/kgC CP Kcal/mhrC Kg/m*3 Dyne /cm C hrm*2/Kcal DegC Deg C Case1 180x1.1 180 x1 1 (allliquid) 131/84 7.033 7 033 3.5 0.47/0.42 18.5/160 18 5 / 160 0.09/0.1 973.4/989 30.7/33.7 0.001 35 Case2 180 x1 1 x1.1 (allliquid) 129/65 6.033 6 033 2.5 0.46/0.42 10.7/87.6 10 7 / 87 6 0.09/0.1 904/923 27.5/32 0.001 28

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Design data
Air side conditions

Forced draft fan arrangement. Design ambient air temperature = 42 C (Summer) Minimum air temperature = 11 C (Winter)

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Design data
Design compliance: Standards & Specifications

Design to comply with requirements of API 661 / ISO 13706 and relevant project specifications

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Design data
Design compliance: Minimum tube wall temperature API 661

As per API 661, when fluids with high pour points are handled, the minimum tube wall temperature attained during the operation shall be maintained at or above the specified minimum tube wall temperature. The specified minimum tube wall temperature shall be 14 C above the pour point of the fluid handled. Refer Table C.2.7 Table C1 of API- 661 category 5.

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Modelling the Air Cooled Heat Exchanger

HTRI Xace, program

Design modelling is done in HTRI Xace, for both the given cases at both summer and winter ambient air conditions.

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Modelling the Air Cooled Heat Exchanger

Salient features of the modelling

Bare tubes are used instead of conventional high fin tubes, as finned surface did not help in improving heat transfer co-efficient of high viscous fluid. i fl id A combination of bare tube & finned tubes also did not provide improvement. Hot air recirculation is not used, as suitable temperature control is obtained with tube side fluid flow reversal (co-current flow) in winter, without enhancing the set point of design ambient air temperature. g p g p Counter-current air flow in summer and co-current air flow in winter is used to control minimum tube wall temperature in winter within API limitations for high pour point liquids. For proper operation in both cases, a bay is isolated from operation in one case.

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Modelling the Air Cooled Heat Exchanger

Salient features of the modelling

A distributed pass-type tube layout (two passes in a row) is used to have even flow with proper velocity (at least 0.3 m/s) in tubes of high viscous fluid. Tube inserts are not used since proprietary devices are not preferred by the user.

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The design proper

Controlling case

The controlling Case is Case 2 with higher heat duty. However Case 1 is found to be pressure drop controlling. Design performed for Case 2 with suitable geometry & configuration and then it is checked with Case 1 for passing. Final design is one that passed both the cases with same geometry and configuration with required air flow control for each case.

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Final design
Performance parameters
Parameter Flowrate Designambientair temperature temperat re Flowpattern Heatduty y No.ofBays(with2bundles) Airfacevelocity Totalairflow Mintubemetaltemp(HTRI ) finalresultsline8) Allowablemin.tubemetal temperature Airstaticpressure Air static pressure Tubepressuredrop m/s 1000Kg/hr DegC DegC mm H2O Kg/Cm*2 2.37 2 37 3.0 0.85 955.6 59.2 49 0.624 0 624 1.16 16.71 16 71 1.495 MM Kcal/hr Units Kg/hr DegC Summer 42
Counter Current

Case1 Winter 11
CoCurrent 4.138

Case2 Summer 42
Counter Current

Winter 11
CoCurrent 5.572

4 0.42 467.2 65.6 2.5 3491 48.03

5 0.69 971.75 46.8 42 1.508 1 508 1.511

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(AsperAPI661=Pourpoint+14C)

Final design
HTRI Minimum tube wall temperature Summer, Counter current

ApartialscreenshotofHTRIoutputofthecase.
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Final design
HTRI Minimum tube wall temperature Winter, Counter current

Belowthe B l th specified minimum temperature. temperature Thedesignisnot acceptable

ApartialscreenshotofHTRIoutputofthecase.
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Final design
HTRI Minimum tube wall temperature Winter, Co-current
Final Results
Released to the following HTRI Member Company: Foster Wheeler Energy Ltd FWEL Xace Ver 6 00 SP2 10/02/2011 16:51 SN: 1500213505 Ver. 6.00 HTRI CC 13 ACHE HIGH POUR POINT. CASE 2 WINTER(CO-CURRENT) Simulation-Horizontal air-cooled heat exchanger forced draft co-current to crossflow 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Process Data Fluid Fl id name Fluid condition Total flow rate (1000-kg/hr) Weight fraction vapor, In/Out (--) Temperature, In/Out (Deg C) Skin temperature Min/Max temperature, (Deg C) Wall temperature, Min/Max (Deg C) Pressure, In/Out (kgf/cm2A) Pressure drop, Total/Allowed (mmH2O) (kgf/cm2) Pressure Drop, A-frame reflux section (kgf/cm2) Velocity - Midpoint (m/s) - In/Out (m/s) Film coefficient, Bare/Extended (kcal/m2-hr-C) Mole fraction inert (--) Heat transfer safety factor (--) Fouling resistance (m2-hr-C/kcal) Airside HSFO Sens. Gas 971.753 1.000 34.88 83.42 83 42 83.42 1.033 0.000 Sens. Liquid 198.000 * 0.000 65.00 85.60 85 60 83.77 4.523 2.500 Tubeside

MKH Units

1.000 11.00 46.73 46 73 46.73 1.033 1.508 1.98 1 98 28.39

0.000 129.00 47.22 47 22 46.80 6.033 1.511 0.31 0 31 0.31 32.39

0.31

28.39 1 0.000000

1 0.001000

ApartialscreenshotofHTRIoutputofthecase.

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Final design
Tube layout: Summer operation
2651.1 mm
2 3 6 7 7 3 6 7 2 3 6 7 2 3 6 7 2 3 6 7 2 3 6 7 2 3 6 7 2 3 6 7 2 3 6 7 2 3 6 7 2 3 6 7 1 3 5 8 9 1 4 5 8 9 1 4 5 8 9 1 4 5 8 9 1 4 5 8 9 1 4 5 8 9 1 4 5 8 9 1 4 5 8 9 1 4 5 8 9 1 4 5 8 9 1 4 5 8 9 1 4 5 8 9 1 4 5 8 9 1 4 5 8 9 1 4 5 8 9 1 4 5 8 9 1 4 5 8 9 1 4 5 8 9 1 4 5 8 9 1 4 5 8 9 1 4 5 8 9 1 4 5 8 2 4 6 7 2 3 6 7 2 3 6 7 2 3 6 7 2 3 6 7 2 3 6 7 2 3 6 7 2 3 6 7 2 3 6 7 2 3 6 7 2 3

10 10 10 10 10 10 10 10 10 10 10 10

10 10 10 10 10 10 10 10 10 10

11 11 11 11 11 11 11 11 11 11 11 11 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 11 11 11 11 11 11 11 11 11 11 14 14 14 14 14 14 14 14 14 14 14 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 14 14 14 14 14 14 14 14 14 14 15 15 15 15 15 15 15 15 15 15 15 15 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 15 15 15 15 15 15 15 15 15 15 18 18 18 18 18 18 18 18 18 18 18 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 18 18 18 18 18 18 18 18 18 18 19 19 19 19 19 19 19 19 19 19 19 19 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 19 19 19 19 19 19 19 19 19 19

Inlettofirstrowattopofbundle I l t t fi t tt f b dl Airfrombottomtotop Countercurrentflowpattern

ApartialscreenshotofHTRIoutputofthecase.

g Number of tubes per pass 22 Tubepass # 1: Tubepass # 2: 21 Tubepass # 3: 22 Tubepass # 4: 22 Tubepass # 5: 22 Tubepass # 6: 21 Tubepass # 7: 22 Tubepass # 8: 22 Tubepass # 9: 21 Tubepass #10: 22 Tubepass #11: 22 Tubepass #12: 22 Tubepass #13: 22 Tubepass #14: 21 Tubepass #15: 22 Tubepass #16: ubepass 6 22 Tubepass #17: 22 Tubepass #18: 21 Tubepass #19: 22 Tubepass #20: 22

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Final design
Tube layout: Winter operation
2651.1 2651 1 mm
19 19 19 19 19 19 19 19 19 19 19 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 19 19 19 19 19 19 19 19 19 19 18 18 18 18 18 18 18 18 18 18 18 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 18 18 18 18 18 18 18 18 18 18 18 15 15 15 15 15 15 15 15 15 15 15 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 15 15 15 15 15 15 15 15 15 15 14 14 14 14 14 14 14 14 14 14 14 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 14 14 14 14 14 14 14 14 14 14 14 11 11 11 11 11 11 11 11 11 11 11 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 11 11 11 11 11 11 11 11 11 11 10 10 10 10 10 10 10 10 10 10 10 10 7 6 3 2 2 6 3 2 7 6 3 2 7 6 3 2 7 6 3 2 7 6 3 2 7 6 3 2 7 6 3 2 7 6 3 2 7 6 3 2 7 6 3 2 7 6 4 1 8 5 4 1 9 8 5 4 1 9 8 5 4 1 9 8 5 4 1 9 8 5 4 1 9 8 5 4 1 9 8 5 4 1 9 8 5 4 1 9 8 5 4 1 9 8 5 4 1 9 8 5 4 1 9 8 5 4 1 9 8 5 4 1 9 8 5 4 1 9 8 5 4 1 9 8 5 4 1 9 8 5 4 1 9 8 5 4 1 9 8 5 4 1 9 8 5 4 1 9 8 5 4 1 9 8 5 3 2 9 7 6 3 2 10 10 10 10 10 10 10 10 10 10 7 6 3 2 7 6 3 2 7 6 3 2 7 6 3 2 7 6 3 2 7 6 3 2 7 6 3 2 7 6 3 2 7 6

Inlettofirstrowatbottomofbundle I l t t fi t t b tt f b dl Airfrombottomtotop Cocurrentflowpattern

ApartialscreenshotofHTRIoutputofthecase.

Right 9.5250 m Number of tubes per pass Tubepass # 1: 22 22 Tubepass # 2: Tubepass # 3: 21 Tubepass # 4: 22 22 Tubepass # 5: 22 Tubepass # 6: 21 Tubepass # 7: 22 Tubepass # 8: 22 Tubepass # 9: p Tubepass #10: 22 21 Tubepass #11: 22 Tubepass #12: 22 Tubepass #13: 22 Tubepass #14: 21 Tubepass #15: Tubepass #16: 22 22 Tubepass #17: 22 Tubepass #18: 21 Tubepass #19: 22 Tubepass #20:

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Final design
Bundle configuration: Pass arrangement
Tubesidein Rows 1 2 3 4 5 A SPLITBUNDLES Drain Vent 6 7 8 9 10 11 14 15 18 19 Drain Tubesideout ViewA 12 13 16 17 20 11 14 15 18 19 Vent 2 3 6 7 10 Passes 1 4 5 8 9 2 3 6 7 10

Bundleissplitintotwo,duetoweightlimitations
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Final design
Other accessories for operation

A steam coil and outlet louvres are suggested so that the bundle can be warmed for start-up and to unfreeze if there is congealing in the tubes. Variable Frequency Drive (VFD) control of air flow for process outlet temperature.

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Final design
Schematic arrangement of the Air Cooled Heat Exchanger
ALL DIMENSIONS IN mm

T1

OUTLET LOUVRES

BUNDLES

STEAM COIL

D T2

(COLUMN CENTRES)

Apartialscreenshotof HTRIoutput.

HTRI Model
On Bundle ne One Bay
(COLUMN CENTRES)

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Final design
Conclusion

The final design is an optimised unit which avoided the need of costly boxed-up hot air recirculation cabins. It is recommended that for every case of high pour point fluid cooling, counter current / co- current design shall be examined first before deciding the need of hot air recirculation. When the pour point is high enough, and not able to obtain a control of minimum tube wall temperature as per API 661, hot air recirculation must be used.

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Thank you. y Any questions?

dwarakakrishna_v@fwuk.fwc.com www.fwc.com

V.DWARAKAKRISHNA Consultant,EquipmentEngineering(HeatExchangers) FosterWheeler,Chennai,India

2011 Foster Wheeler. All rights reserved.