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Lecture 4 - Heat Exchanger Design
Lecture 4 - Heat Exchanger Design
Lecture 4 - Heat Exchanger Design
\
|
+ + =
(h
S
)
(h
SF
)
(h
TF
)
(h
T
)
(k)
Copyright@Dominic Foo H82PLD - Plant Design HE Design - 51
Film transfer coefficient ( Film transfer coefficient ( Film transfer coefficient ( Film transfer coefficient (h hh h
S SS S
, ,, , h hh h
T TT T
) )) )
Copyright@Dominic Foo H82PLD - Plant Design HE Design - 52
Fouling coefficient ( Fouling coefficient ( Fouling coefficient ( Fouling coefficient (h hh h
SF SF SF SF
, ,, , h hh h
TF TF TF TF
) )) )
Copyright@Dominic Foo H82PLD - Plant Design HE Design - 53
Tube wall coefficient (k) Tube wall coefficient (k) Tube wall coefficient (k) Tube wall coefficient (k)
Copyright@Dominic Foo H82PLD - Plant Design HE Design - 54
T TT T
Lm Lm Lm Lm
calculation calculation calculation calculation
T
H, in
= 260C
T
H, out
= 220C
T
C, in
= 150C
T
C, out
= 200C
T
H
=60
T
C
=70
Q
T
( ) ( )
C ________
ln ln
C
H
C H
in C, out H,
out C, in H,
in C, out H, out C, in H,
Lm
=
=
T
T
T T
T T
T T
T T T T
T
Copyright@Dominic Foo H82PLD - Plant Design HE Design - 55
Limitation of Limitation of Limitation of Limitation of T TT T
Lm Lm Lm Lm
Only applicable in the following
situation:
Stream flows are at steady-state
Co-current & counter-current flow
Sensible heat transfer, with constant
specific heat
Overall heat transfer coefficient is
constant
No heat losses
In most situation, flow in heat
exchanger is a mixture of co-
current, counter-current & cross-
flow, e.g. 1-2 exchanger.
Counter-current
Co-current
Copyright@Dominic Foo H82PLD - Plant Design HE Design - 56
1 11 1- -- -2 design HE 2 design HE 2 design HE 2 design HE
Many practical advantages:
Allowance for thermal
expansion
Easy mechanical cleaning
Good heat transfer coefficient
on tube side (high velocity)
Flow arrangement: mixture of
co-current & counter-current
larger area than 1-1 design
Correction factor (F
t
) needed:
Q = UAF
t
T
Lm
where 0 < F
t
< 1.
Copyright@Dominic Foo H82PLD - Plant Design HE Design - 57
Correction factor (F Correction factor (F Correction factor (F Correction factor (F
t tt t
) )) )
Correlated with 2 dimensionless ratio:
Ration of heat capacity flowrate
Thermal effectiveness of HE
Hence, F
t
depends only on T
in
& T
out
of streams.
Various plots of F
t
are available.
in C, out C,
out H, in H,
H , H
C , C
T T
T T
C m
C m
R
p
p
= =
in C, in H,
in C, out C,
T T
T T
S
=
Copyright@Dominic Foo H82PLD - Plant Design HE Design - 58
Correction factor for 1 Correction factor for 1 Correction factor for 1 Correction factor for 1- -- -2 22 2
Copyright@Dominic Foo H82PLD - Plant Design HE Design - 59
Correction factor for 2 Correction factor for 2 Correction factor for 2 Correction factor for 2- -- -4 44 4
Copyright@Dominic Foo H82PLD - Plant Design HE Design - 60
Correction factor for 3 Correction factor for 3 Correction factor for 3 Correction factor for 3- -- -6 66 6
Copyright@Dominic Foo H82PLD - Plant Design HE Design - 61
Correction factor for 4 Correction factor for 4 Correction factor for 4 Correction factor for 4- -- -8 88 8
Copyright@Dominic Foo H82PLD - Plant Design HE Design - 62
Graphical approach Graphical approach Graphical approach Graphical approach
For design, it is desire to have F
t
> 0.85
F
t
< 0.75 is not acceptable, as below this value, curves turn
sharply downward small errors in R & S result in F
t
much lower than anticipated.
When F
t
is unsatisfactory, a multiple-shell-pass HE is used.
More shell passes higher F
t
value.
Copyright@Dominic Foo H82PLD - Plant Design HE Design - 63
Solution:
T
Lm
= _________
R = _________ ; S = _________
Determine F
t
:
Exchanger 1-2: temp crossover
Exchanger 2-4: < 0.5
Exchanger 3-6: < 0.7 (risky)
Exchanger 4-8: 0.85 (satisfactory)
F
t
T
Lm
= _________
Example 1 Example 1 Example 1 Example 1
A hot stream is being cooled from 200F to 140F by
a cold stream that enters the exchanger at 100F &
exists at 190F. Determine the true mean
temperature driving force for multiple tube-pass
shell-and-tube exchanger.
200F
140F
100F
190F
T
hot
=10
T
cold
=40
Q
T
Copyright@Dominic Foo H82PLD - Plant Design HE Design - 64
Graphical approach Graphical approach Graphical approach Graphical approach
For design, it is desire to have F
t
> 0.85
F
t
< 0.75 is not acceptable
When F
t
is unsatisfactory, a multiple-shell-pass
heat exchanger is used iterative procedure to
find no of shell (e.g. try 1-2 2-4 3-6, etc.)
Copyright@Dominic Foo H82PLD - Plant Design HE Design - 65
An insight on F An insight on F An insight on F An insight on F
t tt t
plot plot plot plot
0.75
Temperature
approach
Q
T
Temperature
cross
Q
T
Large
temperature
cross
Q
T
(Smith, 2005)
Length
T
Copyright@Dominic Foo H82PLD - Plant Design HE Design - 66
An insight on F An insight on F An insight on F An insight on F
t tt t
plot plot plot plot
To be confident in design,
steep part of the F
t
chart
should be avoided,
irrespective of F
t
> 0.75.
For any value of R, there is
a maximum asymtropic
value value for S, i.e. S
max
,
where F
t
tends to .
Practical design will be limited to some fraction of S
max
, i.e.
S = X
P
S
max
; where 0 < X
P
< 1
For conceptual design, a value of X
P
= 0.9 is reasonable.
This approach restricted to 1-2 heat exchanger.
0.75
X
P
= 0.9
(Smith, 2005)
Copyright@Dominic Foo H82PLD - Plant Design HE Design - 67
Algebraic approach Algebraic approach Algebraic approach Algebraic approach
( )
( )
( )
( )(
(
+ + +
+ +
+
=
1 1 2
1 1 2
ln 1
1
1
ln 1
: 1 For
2
2
2
R R S
R R S
R
RS
S
R
F
R
t
Lm
T UAF Q
t
=
( )
( )
(
+
(
=
=
2 2 2
2 2 2
ln
1
2
: 1 For
S
S
S
S
F
R
t
in C, in H,
in C, out C,
in C, out C,
out H, in H,
; where
T T
T T
S
T T
T T
R
=
t
in
Q
T
T
in
t
out
T
out
Copyright@Dominic Foo H82PLD - Plant Design HE Design - 68
Algebraic approach Algebraic approach Algebraic approach Algebraic approach
Situation often encountered where design is infeasible in a single 1-2
shell multiple shell is considered.
By using two 1-2 shells in series, temp cross is reduced.
(Smith, 2005)
Copyright@Dominic Foo H82PLD - Plant Design HE Design - 69
Basic principles Basic principles Basic principles Basic principles
In principle, profile achieved by a 2-4 shell is achievable by two 1-2 shell.
For N
shells
in series, some heuristics to remember :
F
t
of each shell = F
t
across all N
shells
shell passes
Rof each shell = Racross all N
shells
shell passes
Values of S of each shell pass (S
1-2
) are equal, but not equal to S across all
N
shells
shell (S
N-2N
).
Equation to determine N
shell
:
Notes:
N
shell
is round up to the next largest number to obtain no of shell
S in this equation is applicable to both S
1-2
and S
N-2N
X
p
is chosen to satisfy the min allowable F
t
, e.g. for F
t, min
= 0.75; X
P
= 0.9.
P
P
X R R
RX R R
W
2 1 1
2 1 1
where
2
2
+ + +
+ + +
=
W
S
RS
N R
ln
1
1
ln
: 1 For
shells
|
\
|
=
2
2
1
1
: 1 For
shells
P
P
X
X
S
S
N R
|
|
\
|
+ |
\
|
= =
Copyright@Dominic Foo H82PLD - Plant Design HE Design - 70
Calculation procedure Calculation procedure Calculation procedure Calculation procedure
From R & S
N-2N
, determine N
shell
.
Next, S
1-2
is calculated for each shell:
Finally, substitute to obtain F
t
:
Area can be calculated:
R Z
Z
S
R
N
N
shell
shell
1
1
2 1
1
: 1 For
N N
N N
S
RS
Z
2
2
1
1
where
=
Lm
T UF
Q
A
t
=
(Smith, 2005)
( )
( )
( )
( )(
(
+ + +
+ +
+
=
1 1 2
1 1 2
ln 1
1
1
ln 1
: 1 For
2
2
2
R R S
R R S
R
RS
S
R
F
R
t
( )
( )
(
+
(
=
=
2 2 2
2 2 2
ln
1
2
: 1 For
S
S
S
S
F
R
t
shells shells 2 2
2
2 1
: 1 For
N N S S
S
S
R
N N N N
N N
+
=
=
= =
=
N N
S R
( )( )
) passes shell (3 2.33
6749 . 0
372 . 2
601 . 1
;
ln
5833 . 0 1
5833 . 0 4286 . 1 1
ln
=
= =
(
= W
W
N
s
3805 . 0
4286 . 1 4 . 0
1 4 . 0
4 . 0
4167 . 0
1667 . 0
3
1
3
1
2 1
=
= = =
S Z
86 . 0 3805 . 0 ; 4286 . 1
2 1
= = =
t
F S R
2
6
m 9 61
65.48 x 0.86 x 100
10 x 5 . 3
= =
=
T UF
Q
A
t
in C, out C,
out H, in H,
T T
T T
R
=
in C, in H,
in C, out C,
T T
T T
S
=
Copyright@Dominic Foo H82PLD - Plant Design HE Design - 73
Overall design Overall design Overall design Overall design
procedure procedure procedure procedure
We have only learnt
until Step 5 (the rest
of the steps will
remain as your
coursework!)
(Sinnott, 2005)
Copyright@Dominic Foo H82PLD - Plant Design HE Design - 74
Bell Bell Bell Bell s method s method s method s method
Heat transfer coefficient and pressure drop are
estimated from correlations for flow:
Over idea tube-banks
Effects of leakage
Bypassing
Flow in window zone
More satisfactory prediction than Kerns method
Copyright@Dominic Foo H82PLD - Plant Design HE Design - 75
Basic concepts Basic concepts Basic concepts Basic concepts
Sometimes called the stream
analysis method
Based on the notion that the stream
flow through a shell side of an
exchanger consist of multiple flows.
The streams are as follows:
A. Leaking through the clearance between tubes and baffles
B. Main cross-flow streamflowing through one window across the cross-flow
section and out through the opposite window
C. Bundle bypass stream, flowing around the tube bundle between the
outermost tubes in the bundle and the inside of the shell
D. No stream with this ID
E. Shell to baffle leakage stream flowing through the clearance between the
baffles and the inside diameter of the shell
F. Flowing through any channels within the tube bundle caused by the
provision of pass dividers in the exchanger (only in multiple tube-pass
configurations)
Copyright@Dominic Foo H82PLD - Plant Design HE Design - 76
Shell Shell Shell Shell- -- -side heat transfer side heat transfer side heat transfer side heat transfer
coefficient coefficient coefficient coefficient
0.9. to 0.6 from vary will correction total The
factor. correction Leakage F
factor, correction stream Bypass F
factor, correction effect Window F
rows, tube vertical number for factor Correction F
bank, tube ideal an over t coefficien transfer Heat h where
by calculated is t coefficien transfer heat side - shell The
b
w
n
oc
=
=
=
=
=
=
l
L b w n oc s
F F F F h h
Copyright@Dominic Foo H82PLD - Plant Design HE Design - 77
P and cross P and cross P and cross P and cross- -- -flow zone flow zone flow zone flow zone
Determined by separate calculations for the cross-
flow and the window zones individually and then
summed for the total amount.
Cross-flow zones:
factor correction leakage
factor correction pass - by
bank tube ideal
equivalent an for calculated drop pressure the
leakage and passing - by for corrected tips, baffle
e between th zone flow - cross a in drop pressure the where
=
=
=
=
=
L
b
i
c
L b i c
F
F
P
P
F F P P
Copyright@Dominic Foo H82PLD - Plant Design HE Design - 78
References for detailed design References for detailed design References for detailed design References for detailed design
Kerns method - proposed by D. K. Kern during
the 1930s found in Seider et al. (2003) & Smith
(2005)
Stream Analysis approach originated by Ken
Bell at the University of Delaware during the
1950s and 1960s a good summary of the method
is found in R. K. Sinnott (2005) Chemical
Engineering Design (Vol 6), Butterworth
Heinemann.
Copyright@Dominic Foo H82PLD - Plant Design HE Design - 79
Problem for revision Problem for revision Problem for revision Problem for revision
A crude oil stream is to be heated from by recovering heat from
a kerosene product in a single heat exchanger unit. 1-2 shell-
and-tube heat exchangers are to be used subject to X
P
= 0.9.
The flowrates, temperature and physical properties (at the
mean temperature) of the process stream are given in the
following table.
Kerosene Crude oil
Flowrate (m
3
.s
-1
) 0.0370 0.0535
Initial temperature, T
in
(C) 200 40
Final temperature, T
out
(C) 50 150
Heat capacity (J.kg
-1
K
-1
) 2470 2050
Density (kg.m
-3
) 730 830
Copyright@Dominic Foo H82PLD - Plant Design HE Design - 80
Problem for revision (continue) Problem for revision (continue) Problem for revision (continue) Problem for revision (continue)
Determine the following:
Determine the number of shells (N
shell
) required for heat
recovery
Value of temperature correction factor (F
t
) for the shells in
series. Explain briefly why two different variables of S are
needed for the calculation.
In the early stage of heat exchanger design, an estimated
value of overall heat transfer coefficient (U) of 300W.m
-2
.K
-1
is used. Estimate the heat transfer area needed using this
estimated coefficient.
The shell-side heat transfer coefficient (h
o
) is earlier
estimated as 2400 W.m
-2
.K
-1
. This leads to a higher value of
U of 350 W.m
-2
.K
-1
. However, it is later determined that the
h
o
has a lower value of 1600 W.m
-2
.K
-1
. Calculate the value
of U and determine the discrepancy in the heat transfer area
calculation due to the different values of U.
[Final exam Spring 2006]