Beruflich Dokumente
Kultur Dokumente
Educational
Version 2.0
ISBN 85-901256-1-0
HES
Educational Proposal
Heat exchangers are very common equipment in the chemical industries. Among the
several kinds of heat exchangers used in the industry, the shell and tube heat exchanger is special
due to its versatility, easiness of operation and maintenance and for its high capacity of
processing. However, the calculations required for its design is very hard requiring an enormous
number of equation and correlation.
Several calculation methods exist to design shell and tube heat exchangers. Among them,
Kern, Tinker and Bell-Delaware methods are the most known methods in the open literature.
Teaching heat exchangers is considered very complicated due to the great time required to teach
the methods. The time needed to perform heat exchanger design calculations, by hand, is high
and therefore the students do a small number of exercises. And not always these exercises show
the application of the heat exchanger in the industry.
The software HES (Heat Exchanger Simulator) was developed in order to complement
the teaching of heat exchangers, bringing to the student a knowledge of the applications of these
exchangers and cases where the calculation of these equipment are required in the industry.
HES
Exercises
Shell and Tube Heat Exchangers
v Cosmetic Industry [Exercise 1]
In this exercise the student must search for the best operational condition for a given
chemical process, respecting the pressure drop limits of the equipment. The initial data presented
to the student leads to a pressure drop that is bigger than the recommended for the equipment
(10 psi).
Problem
Heating of Water with Thermal heat transfer fluid
Water (Tubes)
flow rate
inlet temperature
outlet temperature
28.8 ton/h
25 C
40 C
inlet temperature
150 C
unknown flow rate and outlet temperature
Requirements
10 psi
The student should change only the process conditions of the heat transfer fluid. The
configuration of the heat exchanger should not be changed, since the heat exchanger in the
exercise is an existing one.
Expected Results
Water
flow rate
outlet temperature
shell pressure drop
3.1 kg/s
87.3 C
9.8 psi
Obs: Several students will try to change the number of baffles in the exchanger, what would not
be an economical alternative to do with an existing heat exchanger.
HES
flow rate
inlet temperature
outlet temperature
150 ton/h
25 C
80 C
Thermal (Tubes)
inlet temperature
300 C
unknown flow rate and outlet temperature
Requirements
tube length
fouling resistance
maximum pressure drop
12 ft
0.002 h.ft2.F/BTU
10 psi
The exercise can be considered correct if the considerations done for the design of the heat
exchanger is coherent and if the operational parameters such as the pressure drop and the fouling
resistance be near to the recommended ones.
Expected Results
Thermal 159
flow rate
inlet temperature
outlet temperature
161.5 ton/h
300 C
250 C
Heat Exchanger
shell diameter
tube external diameter
tube pitch
number of tubes
tube length
number of passes in the tubes
number of baffles
baffle cut
Other Results
fouling resistance
shell pressure drop
tube pressure drop
19.25 in
0.75 in
1.0 in
256
12 ft
2
23
0.25
0.0081 h.ft2.F/BTU
9.3 psi
3.3 psi
HES
flow rate
inlet temperature
outlet temperature
650 ton/h
100 C
80 C
available fluids
inlet temperature
outlet temperature
Requirements
fouling resistance
maximum pressure drop
Testing the fluids, it will be observed that the fluids Thermal 155 and 120TX could be used.
The fluids Thermal 100N and 166 exceeds the maximum pressure drop and the Water presents a
fouling resistance higher that the maximum required for the process.
Expected Results
Thermal 155 best choice
flow rate
fouling resistance
shell pressure drop
366.4 ton/h
0.0038 h.ft2.F/BTU
8.3 psi
Thermal 120TX
flow rate
fouling resistance
shell pressure drop
426.5 ton/h
0.0049 h.ft2.F/BTU
8.6 psi
Thermal 100N
flow rate
fouling resistance
shell pressure drop
376.8 ton/h
0.0006 h.ft2.F/BTU
13.9 psi
Thermal 166
flow rate
fouling resistance
shell pressure drop
530.8 ton/h
0.0043 h.ft2.F/BTU
14.5 psi
HES
5
Water
flow rate
fouling resistance
shell pressure drop
176.4 ton/h
0.0063 h.ft2.F/BTU
1.5 psi
Thermal 159
flow rate
inlet temperature
outlet temperature
Expected Results
Operational Conditions for Reactor Loading Time of 30 minutes
Thermal 159 (Shell)
flow rate
inlet temperature
outlet temperature
456.6 ton/h
200 C
150 C
Heat Exchanger
19.1 psi
17.1 psi
0.00056 h.ft2.F/BTU
560 ton/h
230 ton/h
26 min
HES
6
Operational Conditions for Maximum Pressure Drop of 10 psi
350 ton/h
145 ton/h
41 min
Obs: loading time and flow rate may change depending on the outlet temperature of Thermal
159 that is set.
flow rate
inlet temperature
outlet temperature
600 ton/h
145 C
150 C
Steam
inlet temperature
Requirement
fouling resistance
maximum pressure drop
450 C
0.02 h.ft2.F/BTU
10 psi
The exercise can be considered correct if the considerations done for the design of the heat
exchanger is coherent and if the operational parameters such as the pressure drop and the fouling
resistance be near to the recommended ones.
The exercise can have multiple answers depending on the chosen tube length, tube diameter
and number of passes in the tubes.
Expected Results
Steam (Shell)
flow rate
inlet temperature
outlet temperature
1.95 ton/h
450 C
300 C
Heat Exchanger
shell diameter
tube external diameter
tube pitch
31 in
0.75 in
0.9375 in
HES
7
number of tubes
tube length
number of passes in the tubes
number of baffles
baffle cut
766
8 ft
4
6
0.25
Other Results
fouling resistance
shell side pressure drop
tube side pressure drop
0.054 h.ft2.F/BTU
8.6 psi
5.1 psi
Obs: It should be observed that only the steam sensible heat should be used, not been allowed
the use of the steam latent heat (phase change). Therefore it is desirable that the outlet
temperature of the steam be higher than 290C.
HES
flow rate
inlet temperature
outlet temperature
3.0 ton/h
70 C
30 C
Water (Shell)
inlet temperature
outlet temperature
flow rate not set
23 C
27 C
Requirements
maximum velocity
fouling resistance
hairpin length
2.5 m/s
0.005 ft2.h.F/BTU
4 ft
The exercise can have multiple answers depending on the considerations that have been
made. A good result is shown below.
Expected Result
Heat Exchanger
shell diameter
tube diameter
number of hairpins
3.5 in
1.9 in
6 countercurrent flow
8 cocurrent flow
HES
flow rate
inlet temperature
outlet temperature
100 ton/h
45 C
47 C
Water (Tube)
inlet temperature
outlet temperature
flow rate not set
97 C
60 C
Requirements
Expected Result
Water
flow rate
1.8 ton/h
Exchanger
shell diameter
tube diameter
number of hairpins
shell velocity (Thermal 166)
tube velocity (Water)
exchange area
overall heat transfer coef. (clean)
4.5 in
1.0 in
3
3.8 m/s
1.8 m/s
158 ft2
92.7 BTU/ft2.h.F
HES
10
flow rate
inlet temperature
outlet temperature
67 ton/h
25 C
120 C
inlet temperature
outlet temperature
flow rate not set
Requirements
fouling resistance
maximum pressure drop
360 C
335 C
0.01 ft2.h.F/BTU
10 psi
Expected Result
Thermal 100N
flow rate
112.4 ton/h
Exchanger
flow
shell diameter
tube diameter
hairpin length
number of hairpins
shell velocity
tube velocity
exchange area
shell pressure drop
tube pressure drop
parallel / countercurrent
6.5 in
3.5 in
8 ft
3
0.9 m/s
3.2 m/s
552 ft2
0.9 psi
1.8 psi
hairpin length
number of hairpins
shell velocity
tube velocity
exchange area
shell pressure drop
tube pressure drop
16 ft
2
0.9 m/s
4.9 m/s
1473 ft2
0.5 psi
1.8 psi
HES
11
Pinch Technology
v Benzene Process [Exercise 1]
In this exercise the energy integration of a benzene production process should be analyzed.
The student should study the effect of the minimum approach temperature on the required hot
and cold utilities and on the heat exchanged between the streams.
Initial System
Streams
Diphenyl
Benz + Tol
H2
Toluene
Inlet
Temp
[C]
250
200
90
130
Outlet
Temp
[C]
120
100
150
190
Flow
Rate
[kg/h]
526
1740
205
2609
Cp
[J/g.K]
1.9
2.3
14.6
2.3
Expected Results
Energy Integration Delta T = 10C
pinch temperature
required hot utility
required cold utility
heat exchanged between streams
135 C
70000 kJ/h
60000 kJ/h
940000 kJ/h
pinch temperature
required hot utility
required cold utility
heat exchanged between streams
137.5 C
95000 kJ/h
85000 kJ/h
890000 kJ/h
pinch temperature
required hot utility
required cold utility
heat exchanged between streams
140.0 C
120000 kJ/h
110000 kJ/h
840000 kJ/h
The results show that the pinch temperature, as well as the quantity of hot and cold
utilities required increase with the increase of the minimum approach temperature.
HES
12
Air
NO
NO2
NH3
Effluent
Inlet
Temp
[C]
20
350
150
20
50
Outlet
Temp
[C]
250
150
45
120
100
Flow
Rate
[ton/h]
16
17
14
4
1
Cp
[J/g.K]
1.05
1.13
1.25
2.30
1.13
Energy Integration
pinch temperature
required hot utility
required cold utility
heat exchanged between streams
25 C
336.3 kJ/h
279.1 kJ/h
9840.3 kJ/h
Air
NO
NO2
NH3
Effluent
Air 2
HNO3
NO recycled
Inlet
Temp
[C]
20
350
150
20
50
20
50
50
Outlet
Temp
[C]
250
150
45
120
100
130
30
100
Flow
Rate
[ton/h]
16
17
14
4
1
10
20
1
Cp
[J/g.K]
1.05
1.13
1.25
2.30
1.13
1.05
2.30
1.13
Energy Integration
pinch temperature
required hot utility
required cold utility
heat exchanged between streams
45 C
845.9 kJ/h
745.1 kJ/h
11244.3 kJ/h
The new streams when not integrated to the energy conservation system, needed 1168
kJ/h of cold utility and 1211.5 kJ/h of hot utility. Therefore the system as a hole needed 1504.3
HES
13
kJ/h of cold utility and 1547.8 kJ/h of hot utility. The student should note that the calculation of
these quantities is needed in order not to incur in error.
With the three new streams, the energy integration of the plant requires 845.9 kJ/h of hot
utility and 745.1 kJ/h of cold utility, what means a reduction of 45% in hot utility requirement and
of 50% of cold utility requirement.
HES
14
Information
Required System
PC-486 or higher (Pentium is recommended)
8 Mb Ram (16 Mb recommended)
Windows 95 or higher
CD-Rom (for installation)
Support
Contact
EFFTech Engineering Software
e-mail: efftech@yahoo.com
http://efftech.tripod.com