Jump Start: Rigorous Shell & Tube Exchanger Sizing in Aspen Plus V8

2013 Aspen Technology, Inc.
AspenTech
, aspenONE
, the Aspen leaf logo, the aspenONE logo, and OPTIMIZE are trademarks of Aspen Technology, Inc. All rights reserved. 11-3814-0713
Jump Start: Rigorous Shell & Tube Exchanger
Sizing in Aspen Plus
V8
A Brief Tutorial (and sample case for interactive sizing in Aspen Plus V8.0)
Lauren Sittler, Product Management, Aspen Technology, Inc.
Tom Ralston, Director of Equipment Design and Rating, Aspen Technology, Inc.
2013 Aspen Technology, Inc. AspenTech
, aspenONE
Jump Start: Rigorous Shell & Tube Exchanger Sizing in Aspen Plus
V8
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tutorial Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Overview of the Example Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Interactive Sizing in Aspen Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Getting Started. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Using the EDR Sizing Console. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Introduction
Aspen Plus V8 features a unique integrated workflow for transforming Shell and Tube Exchangers and Air Cooled
Exchangers from simple models to rigorous models in the simulation environment. This new functionality utilizes the same
rigorous Aspen Exchanger Design & Rating (EDR) methods as the stand-alone product. This integration enables process
engineers to create designs that are more energy efficient prior to consulting Energy Optimization Experts and Costing
departments and also serve as an excellent basis for subsequent detailed thermal and mechanical designs. Process
designs created using rigorous heat exchanger designs are more precise and automatically adapt to changes in process
design or process operation changes.
This is not meant to be used as a stand-alone reference document. We recommend that a range of other resources be
called upon to give the new user a comprehensive view of how to complete rigorous exchanger sizing in Aspen Plus.
These may include:
AspenTech support website (support.aspentech.com)
AspenTech courseware available in on-line and in-person versions
AspenTech business consultants
Additional Jump Start Guides
This Jump Start Guide is mainly focused on the preliminary design of heat exchangers where the objective is to rapidly
assess the size and cost of exchangers required for a given process duty, including requirements for multiple shells in
series and in parallel. It assumes that the user has Aspen Plus V8.0 or higher installed on her or his computer and has a
basic understanding of modeling in Aspen Plus.
Tutorial Overview
This Jump Start guide will provide step-by-step instructions for completing interactive sizing in Aspen Plus using an
example Aspen Plus case file to demonstrate the integrated workflow. The EDR Solution Case for the final EDR design has
also been included. The files associated with Aspen Shell & Tube Knowledge Base are available for download on the
Customer Support & Training website.
Overview of the Example Case
Open the case Shell&TubeforInteractiveSizing.bkp and Click on the Main Flowsheet tab. This case models a petroleum
separation process in which the feed is flashed, heated in the tube side of a shell and tube exchanger, and sent to a
distillation column. The lighter components are distilled off as gas and the heavier components enter the shell side of the
exchanger, providing the heat source for the cold oil. The warm Natural Gas Liquid (NGL) is then cooled in a cooler and
pumped as Liquid Natural Gas (NLG). This tutorial will focus on sizing the SHELLTUB exchanger. Currently, this shell and
tube exchanger is specified using the shortcut method. The tutorial guides you through opening the EDR interactive sizing
console, using default parameters to generate a preliminary design, and then makes adjustments to the design to make it
better suited for the process application.
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Figure 1. Petroleum Separation Flowsheet
Interactive Sizing in Aspen Plus
Getting Started
1. Open the file Shell&TubeforInteractiveSizing.bkp. Run Aspen Plus from the Home Ribbon > Run group or by pressing F5.
2. Run the simulation and ensure there arent errors by looking at the Control Panel. If a simulation does contain any errors
these must be fixed before EDR rigorous sizing can be used.
3. Locate the SHELLTUB exchanger, immediately downstream of the first separator. Double-click on the exchanger icon on
the flowsheet to open the setup form. On the Specifications tab of the set up form, youll see the Calculation box. Notice
that the calculation mode is currently set to Shortcut.
Figure 2. Size Shell&Tube in Aspen Plus
4. Click on the Size Shell&Tube button to begin interactive sizing. The EDR Sizing Console will open inside of Aspen Plus.
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Using the EDR Sizing Console
5. On the EDR Sizing Console, you will see that the default parameters (which appear in red) have already been set for the
geometry. Click the Size Exchanger button to run the optimization and find the first preliminary design. The run status
tab will become active while calculations are running.
Figure 3. Size the Exchanger with Default Parameters
6. When the calculation is complete, the results will be displayed on the Geometry Tab shown in Figure 3. Here, you will
see the setting plan and stream temperature profiles, as well as the exchanger dimensions and cost information. The
first design is the default BEM TEMA type with 1 shell, 110 tubes, 1 tube pass, and a 30-Triangular tube pitch. It has a
total cost of $19,397.
7. Next, changes will be made to the exchanger to make it better suited for our process. Since we have petroleum oil
entering the tube side, it is recommended that a removable cover with a floating head and a 90 degree tube pattern be
used to make defouling the exchanger easy. For greater accuracy, a realistic fouling factor will be specified. Set the
specifications as shown in Figure 4.
Figure 4. Geometry Tab Results
Geometry Tab
TEMA Type AES
Tube Pattern 90-Square
Process Tab
Fouling Resistance (Hotside and Coldside) 0.001 hF/BTU
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Figure 5. EDR Sizing Console Results
9. Click the Size Exchanger button again to run the second design.
10. After the optimization is complete, we can compare the new design with our preliminary sizing. In the middle columns
as shown in Figure 5, you can see the new design side-by-side with the previous run. In this case, adding a removable
cover and a floating head has made our design more expensive. Our shell diameter has increased, as well as the
number of tubes and tube passes. Compare your design with the EDR solution file provided, SHELLTUB Solution.edr.
11. At this stage, you could continue redesigning the exchanger until it satisfies the desired cost and performance, but for
now we will keep this as the final design, save it, and update the model in our simulation.
12. To save this rigorous exchanger design in the Aspen Plus flowsheet, click Accept Design from the EDR Console, as
shown in Figure 6. The other options available on the console are to cancel the design, open another EDR file or
template (to start a new design), or save the current results as an EDR standalone file without exiting the interactive
console in Aspen Plus.
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Figure 6. EDR Sizing Console Options
13. Run the Aspen Plus case again to update the Shell&Tube results within simulation. When calculations have completed,
click on the EDR Shell&Tube Results form from the navigation pane. This will provide a summary (shown in Figure 7) of
overall design results, thermal results, pressure drop, setting plan, tubesheet layout, and profile plots.
Figure 7. EDR Shell&Tube Results in Aspen Plus
About AspenTech
AspenTech is a leading supplier of software that optimizes process manufacturingfor energy, chemicals,
engineering and construction, and other industries that manufacture and produce products from a
chemical process. With integrated aspenONE
solutions, process manufacturers can implement best

practices for optimizing their engineering, manufacturing, and supply chain operations. As a result,
AspenTech customers are better able to increase capacity, improve margins, reduce costs, and become
more energy efficient. To see how the worlds leading process manufacturers rely on AspenTech to
achieve their operational excellence goals, visit www.aspentech.com.
, aspenONE
, the Aspen leaf logo, the aspenONE logo, and OPTIMIZE are trademarks of Aspen
Technology, Inc. All rights reserved. 11-3814-0713
Worldwide Headquarters
Aspen Technology, Inc.
200 Wheeler Road
Burlington, MA 01803
United States
phone: +17812216400
fax: +17812216410
info@aspentech.com
Regional Headquarters
Houston, TX | USA
phone: +12815841000
So Paulo | Brazil
phone: +551134436261
Reading | United Kingdom
phone: +44(0)1189226400
Singapore | Republic of Singapore
phone: +6563953900
Manama | Bahrain
phone: +97317503000
For a complete list of offices, please visit
www.aspentech.com/locations
Additional Resources
Check out other training materials specifically for this product:
Public Website
http://www.aspentech.com/products/aspen-edr.aspx
Online Training
www.aspentech.com/products/aspen-online-training
Video Tutorials
Autosizing Shell & Tube Exchangers in Aspen HYSYS V8.0
https://www.brainshark.com/aspentech1/autosize-shell-tube-HYSYS
New Interactive Sizing in Aspen Plus
https://www.brainshark.com/aspentech1/edr-integration-aspen-plus
Jump Start Tutorials Series
Jump Start: Aspen Shell & Tube Exchanger V8.0
Getting Started in Aspen Shell & Tube Exchanger V8.0

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