Académique Documents
Professionnel Documents
Culture Documents
Slide 1
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
Flow of heat behaves like flow of fluids and flow of electrons Driving Force Resistance
Rate K x QK x
(General)
(Fluids)
I = 1.0 x
(Electricity)
(Heat)
= K x (P2 - P1)
Heat:
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
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
Rio + rio + rw + ro + Ro = RT =
w = Wall Thickness, Feet
I U
Slide 7
Slide 8
Very Low
Typical
Very High
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
= = = = = = = =
Hence h is the Controlling Coefficient, and efforts to improve exchanger performance should concentrate on this side of the exchanger.
Slide 10
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 0.02063
x 120
Slide 11
Q A
Btu Hr x Ft2
* 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
Slide 14
Slide 15
Slide 16
Slide 17
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
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
Slide 20
Slide 21
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
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
Slide 27
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) =
+ Qzone4 LMTD4
Slide 28
Similarly, pressure drop is a function of Reynolds number and length of flow path.
Slide 29
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
Slide 32
(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
Slide 34
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
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
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
Slide 38
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
Most common type in refinery service Consists of tube bundle within external shell
Slide 40
1. 2. 3. 4. 5. 6. 7.
SHELL SHELL COVER SHELL FLANGE SHELL COVER END FLANGE SHELL NOZZLE FLOATING HEAD TUBESHEET FLOATING HEAD COVER
FLOATING HEAD COVER FLANGE CHANNEL PARTITION PLATE STATIONARY TUBESHEET CHANNEL CHANNEL COVER CHANNEL NOZZLE TIE RODS AND SPACERS TRANSVERSE BAFFLES OR SUPPORT PLATES
IMPINGEMENT BAFFLE VENT CONNECTION DRAIN CONNECTION TEST CONNECTION SUPPORT SADDLES LIFTING RING SPLIT RING
Slide 41
U-Tube
Slide 42
U-Tube
Least expensive for high tubeside design pressure. Normally used when tubeside fouling 0.004. (except for water)
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)
Slide 44
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
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
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
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
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
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
Slide 56
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.
E = One pass shell (one inlet nozzle and one outlet nozzle)
S = Split ring type floating tube sheet construction
Slide 58
Slide 59
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
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
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
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
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)
Slide 65
Slide 66
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.
Slide 68
tew -
Slide 69
Slide 70
Slide 71
Slide 72
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
Slide 78
Section
I X-B
Page
Date
HEAT EXCHANGE EQUIPMENT DESIGN CONSIDERATIONS FOR ALL TYPES OF HEAT EXCHANGERS
PROPIETARY INFORMATION -For Authorized Company Use Only
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
Slide 79
Section
I X-B
Page
Date
HEAT EXCHANGE EQUIPMENT DESIGN CONSIDERATIONS FOR ALL TYPES OF HEAT EXCHANGERS
PROPIETARY INFORMATION -For Authorized Company Use Only
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
13 17 23 27 38 43 55 60 50 31
Slide 80
Section
I X-B
Page
Date
HEAT EXCHANGE EQUIPMENT DESIGN CONSIDERATIONS FOR ALL TYPES OF HEAT EXCHANGERS
PROPIETARY INFORMATION -For Authorized Company Use Only
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
Slide 81
Section
I X-B
Page
Date
HEAT EXCHANGE EQUIPMENT DESIGN CONSIDERATIONS FOR ALL TYPES OF HEAT EXCHANGERS
PROPIETARY INFORMATION -For Authorized Company Use Only
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
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
Slide 82
Section
I X-B
Page
Date
HEAT EXCHANGE EQUIPMENT DESIGN CONSIDERATIONS FOR ALL TYPES OF HEAT EXCHANGERS
PROPIETARY INFORMATION -For Authorized Company Use Only
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
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
Isobutane Tower Feed Rerun Tower Feed Debutanizer Tower Feed Hydrogenation Reactor Feed Powerformer Stabilizer Feed
82 80 100 110 75 89 47
Slide 83
Section
I X-B
Page
Date
HEAT EXCHANGE EQUIPMENT DESIGN CONSIDERATIONS FOR ALL TYPES OF HEAT EXCHANGERS
PROPIETARY INFORMATION -For Authorized Company Use Only
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
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
Slide 85
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
Slide 88
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
WELDED PLATE
PLATE-FIN
Slide 91
Slide 92
Slide 93
Slide 94
Slide 95
Slide 96
Slide 97
Slide 98
Slide 99
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
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
- 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
Slide 104
(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
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
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
h io
Y th d
o
cz k
z z
w
0.14
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
(3)
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
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
(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
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
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
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
=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
Slide 116