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Heat Exchanger:
The purpose of this section is to guide process engineer to fill in a heat
exchanger process data sheet (PDS). While preparing a PDS different
factors are to be considered which are listed one after another in this
section. Many of the listed items are discussed mostly with respect to
shell and tube heat exchanger since it is the most widely used type,
although the same can be extended for other types as well if found as
general in nature. The PDS format can be same for different type of heat
exchangers (e.g., shell & tube, double pipe, plate and frame, spiral etc).
One specimen copy of a PDS format is attached herewith which can be
used as a standard one in absence of any specific format from the
Client. It is the overall project philosophy which decides the scope for
different parties for overall detailed design of a heat exchanger, this
needs to be understood from Principal Engineer and Project Management
before finalization of heat exchanger PDS. Please follow the engineering
units as decided in Project Design Basis. The input in PDS should be
adequate and complete in nature so that the thermal design of the
exchanger can be carried out any of the detailed engineering parties.
The purpose of preparation of a PDS is to furnish all required input to
carry out thermal design of the heat exchanger.
A) Operating parameters:
It is the responsibility of process engineer to finalize the operating
parameters for an exchanger based on Heat and Material Balance (HMB)
of the plant. Please follow operating parameters given in FEED
document/Licensor package etc. Add design margin (if any) as per design
basis/project contract etc. In case of in house simulation please follow
the Heat and Material Balance data for process conditions. . In case of
multiple operating conditions find out the controlling case in terms of
heat duty and other process conditions. Often for multiple operating
conditions thermally and hydraulically controlling conditions are
selected for heat exchanger design. For selection of thermally
controlling case the multiplication factor of U and A needs to be
compared. In selecting these conditions the Principal engineer must be
consulted and detail review must be done by experienced process
engineer.
Following operating parameters are to be provided in PDS.
Flow rate
Complete Flow rates for vapor, liquid, steam, water etc to be
furnished both at inlet and outlet of the exchanger.
Operating Pressure
Operating pressure is more important in case of gas service
rather than liquid. However this should be correctly defined to
make the data consistent with plant operating conditions.
Heat Duty
This should be consistent with both hot and cold fluid flow
rate and properties.
E) Fouling resistance:
The fouling factor needs to be mentioned in process data sheet for
hot and cold fluid. This is to be provided based on fluid type and
physical properties. Some guidelines are available in TEMA which can
be considered in case there is nothing available in FEED or Basic
Engineering package. Before finalization of fouling factors the
Principal Engineer must be consulted.
F) Material of Construction (MOC):
Both shell and tube side MOC needs to be specified in PDS. In case
both shell and tube sides are having different MOC, all main
components of the exchanger MOC need to be specified in PDS.
G) Corrosion allowance:
This is to be specified based on MOC and should be consistent with
the project design basis. For tubes no corrosion allowance is
required, however it is applicable for tube side based on MOC.
H) Design Pressure and Temperature:
It is the responsibility of the process engineer to finalize the design
pressure temperature of the exchanger based on the complete
system design. Normally for most of the projects Design Pressure
Temperature flow diagram are prepared. In absence of that the
Design Basis document needs to be followed to decide the design
Reboilers are similar to shell & Tube exchanger except inlet / outlet
piping and elevation is critical in reboiler as compared to simple shell
& tube exchanger.
Kettle type Reboiler: In kettle type reboiler
shell side and extra space is provided above tube bundle to saperate
out liquid & vapor, outlet fluid contain only vapor. Bottom product
drawn off at other end of reboiler (after overflow ware). Here liquid
level is maintained above tube bundle to achieve pool boiling.
Thermosyphon reboiler: In thermosyphon reboiler cold fluid is
placed either in shell side or in tube side. Outlet fluid contain mix
phase. Thermosyphon reboiler works on pressure difference (Density
difference) and governed by liquid static head. Circulation flow
through reboiler depends on liquid static head. Hence liquid static
head is very important while designing a thermosyphon reboiler.
B) Operating parameter, pressure drop, allocation of fluid, Physical
properties etc. are similar to shell & Tube exchanger.
C) Selection of reboiler type:
Many factors influence reboiler type selection. In the end, all these
factors reduce to economics. Every plant will weigh the trade-off
between these factors differently. No one-size fits all selection
exists. Major factors include:
1) Plot space available
2) Total duty required
3) Fraction of tower liquid traffic vaporized
4) Fouling tendency
5) Temperature approach available
6) Temperature approach required
All these affect the configuration desired. The major configuration
selections include:
Figure 1
Horizontal, shell-side boiling reboilers
Figure2
Vertical reboilers
Figure 3
Flooded bundle reboilers
Figure4
Stab-in and fired heater reboilers
Table1:
Factor
Low bottoms product fraction
compared to boilup
High bottoms product fraction
compared to boilup
Low relative volatility systems
High relative volatility systems
Large exchanger size or high duty
requirements
Small exchangers
Leaks hazardous or difficult to
deal with
Exotic materials
Tight temperature approach
Solids present
Thermally unstable products
Tight plot plan
Ample plot plan
High temperatures
High heat fluxes
Low bottoms product fraction
compared to boilup
High bottoms product fraction
compared to boilup
Low relative volatility systems
High relative volatility systems
Large exchanger size or high duty
Favored types
Disfavored
types
Re circulating Kettle
Once-through
Once-through
Re circulating
Re circulating
Once-through
Re circulating
Horizontal
Vertical
Vertical Stab-in
Stab-in
Stab-in
Spiral-plate / Plate-fin
Kettle / Spiral-plate
Re
circulating
(no
baffle)
Vertical
Horizontal
Fired heaters
Forced
circulation
/Flooded bundles
Shell-and-tube
Plate-fin
Kettle
/Once
through
Horizontal
Natural
circulation
Re circulating Kettle
Once-through
Once-through
Re circulating
Re circulating
Once-through
Horizontal
Re circulating
Vertical
requirements
Small exchangers
Vertical Stab-in
Leaks hazardous or difficult to
Stab-in
deal with
Exotic materials
Stab-in
Tight temperature approach
Spiral-plate / Plate-fin
Solids present
Kettle Spiral-plate
Re
circulating
(no
Thermally unstable products
baffle)
Tight plot plan
Vertical
Ample plot plan
Horizontal
High temperatures
Fired heaters
Shell-and-tube
Plate-fin
Kettle / Once
through
Horizontal
Condensers :
The design of condenser is a wide subject similar to reboilers. There are
considerable variations of services, operating condition, choice of
coolant, condensing range etc. In shell and tube heat exchanger
normally the condensation is preferred in shell side as the flow area is
more and condensate can separate from vapor easily by gravity. Most of
the times the coolant is water and hence it is preferred to place it in
tube side. In case the process fluid is corrosive it can be placed in tube
side, hence tube side condensation is also possible. Use of air as coolant
has become increasingly popular, hence air coolers are used as
condensers in many of the cases. Use of either water or air cooler
depends on the availability of water and investment required for each
system.
B) Usages / Advantages:
1) If calculated area for Shell & tube exchanger is less than 20 m2,
then double pipe exchangers can be considered as an alternative,
however this is not the only basis to be followed for deciding the
double pipe heat exchanger. The overall cost factor, plot plan
service condition needs to be taken into account for deciding the
usage of double pipe exchanger.
2) Double pipe exchanger can be used as feed heater to fine tune
outlet temperature.
3) Advantages: Very simple in construction, can be disassembled for
cleaning, inspection. Double pipe exchanger can be installed on
pipe rack or along distillation column.
Plate Exchangers:
A) General:
With equipment cost rising and limited plot space, compact heat
exchangers are gaining a large portion of heat exchanger market.
Plate and frame exchange is one of the compact type exchanger
which widely used in dairy & food industries. It gives close
temperature approach. Accuratetemperature control is also possible
with PHE. There are two basic types gasketed and welded type plate
exchangers.
Gasket Type Plate & frame Exchangers: In this type, Series of
corrugated alloy material channel plates bonded by gaskets and
guided by longitudinal bars, then compressed by large diameter
tightening bolts between two pressure retaining cover plates. The
frame and channel plates have portholes which allow the process
fluid to enter alternating flow passages. Gasket around the periphery
of the channel plate prevents leakage to atmosphere. Some gaskets
are not suitable for all type of process fluids and higher temperature.
Different gasket materials are used for different temperature range
e.g., rubber gasket can be used up to 200C, graphite gasket can be
used up to 250C etc.
Welded Type Plate & frame Exchangers: To overcume gasket
limitation
welded
plate
exchanges
are
developed
but
one
3) Can be used for higher air outlet temperature (> than 93C)
since fans are not exposed to hot air.
Disadvantages:
1) Total exposure to rain, sun, hail.
2) Increased sensitivity to hot air circulation due to low discharge
velocity.
3) Low natural draft capability on fan failure due to lack of stack
effect.
Forced draft.
Induced Draft Air Cooler: Fans are mounted above tube bundle.
Advantages:
1) Better process control & stability from effects of rain, hail &
sun.
2) Less possibility of hot air circulation due to higher discharge
velocity.
3) Increased natural draft capability on fan failure due to
increased stack effect.
Disadvantages:
1) Poor accessibility to mechanical component as fan is mounted
on top of bundle.
2) Higher fan power consumption since it handles hot air.
3) Exit air temperature limited to 93C because of fan & blade
MOC.
4) The bundle will be wider if the fan shaft is designed to
penetrate the bundle.
1) Economizer: Is a rectangular bundle of tubes that typically is
placed in a hot gas stream. This gas heats the material flowing
inside the tubes. Also typically, tubes are plain, stud-finned, or
serrated finned. Some applications mix bare tubes in the first few
rows with finned tubes further down in the bundle.
Drawing: