Heat Exchangers

Chapter 18
ChEN 4253
Terry A. Ring
Flo !atterns
"
!arallel Flo
"
Co#nter C#rrent Flo
"
$hell an% T#&e ith &a''les
"
Cross Flo
Te(perat#re !ro'iles
)T * Approach Te(perat#re
Heat
Exchanger
Te(perat#re
!ro'iles
Flo $tr#ct#re
+*, A F )T
l(-co#nter
( )
( )
( )
( )
in cold in hot
in cold out cold
in cold out cold
out hot in hot
T T
T T
S
T T
T T
R
R R S
R R S
R
RS
S
R
F

1
1
]
1

+ + +
+ +

1
]
1

1 1 2
1 1 2
ln 1
1
1
ln 1
2
2
2
./erall Heat Trans'er Coe''icient
"
$eries o' Resistances
"
0asis
1
2nsi%e
1
.#tsi%e
( ) ( ) [ ] ( )
1
3 3
1 4 ln5 2 1 4 1 5

1
]
1

+ + + +
o f o i o o w i i o
i
o
i f o
R h D D D k h D D
A
A
R U
2nsi%e
T#&es
R
'
*'o#ling 'actors3 insi%e an% o#tsi%e
$ee ta&le 18.5 'or range o' , /al#es 'or %i''erent cases.
Heat Trans'er insi%e a t#&e
T#r&#lent 666 3 16 Re
766 3 18 !r 7 . 6
e s(ooth t#& 3 86 9
!r Re 627 . 6
14 . 6
3 9 1 8 . 6
>
< <
>

,
_

f
p
w
b
f
k
C
D L
k
hD
Nu

Also other correlations /ali% o/er i%er ranges

Heat Trans'er o#tsi%e o' T#&e
666 3 166 Re 46
366 !r 87 . 6
2 . 5 25 . 6
!r 4 Re 68 . 6 Re 4 . 6 5
25 . 6
4 . 6 3 9 2 5 . 6
< <
< <
< <

,
_

+
f
p
w
b
w
b
f
k
C
k
hD
Nu

Also other correlations /ali% o/er i%er ranges

Ther(al Con%#cti/ity
:hat Te(perat#re Approach
"
He#ristic 28.
1
Near-opti(al (ini(#( te(perat#re approaches
in heat exchangers %epen% on the te(perat#re
le/el as 'ollos;
1
16<F or less 'or te(perat#res &elo a(&ient3
1
26<F 'or te(perat#res at or a&o/e a(&ient #p to 366<F3
1
56<F 'or high te(perat#res3
1
256 to 356<F in a '#rnace 'or 'l#e gas te(perat#re a&o/e
inlet process 'l#i% te(perat#re.
:here are the Heat Exchangers=
:hat is happening in each
.ctane Reaction
2C
2
H
4
> C
4
H
16
C
8
H
18
!* 26 psia3 T*?3C3
@*?8A Con/ersion
T
0!
C
2
H
4
B163.7 <C
C
4
H
16
>6.5 <C
C
8
H
18
>125.52 <C
:here are the Heat Exchangers=
Heat Trans'er :ith !hase Change
"
TricCy !ro&le(s
1
Exa(ples
"
Re&oiler on Distillation ,nit
"
Con%enser on Distillation ,nit
"
Flash ,nits
"
0oilers
A :or% A&o#t $tea(
"
$i(#lator Ass#(ptions
1
2nlet 1 $at#rate% Eapor
1
!ress#re
1
166A Eapor
1
.#tlet 1 $at#rate% FiG#i%
"
FiG#i% .nly Fea/es /ia stea( trap
1 !ress#re * !
in
- )! 51.5 psi3 He#ristic-314
1
166A FiG#i%
:here are the TricCy
Heat Exchangers=
Con%ensation Heat Trans'er
"
Drop :ise Con%ensation
1
$pecial Case
"
Eery High Heat Trans'er
"
5 to 16 x Fil( Con%ensation
"
Fil( Con%ensation
1
Fa(inar
4 9 1
3
4 5 4
4 5
1
1
]
1

x T T
k H g
k
x h
Nu
w v l
l vap v l l
l
x
x

Fa(inar to T#r&#lent Con%ensate
Flo
0oiling Heat Trans'er Coe''icient
Eario#s correlations %epen%ing #pon &oiling (echanis(
Highest Heat
Trans'er Coe'.
0#t har% to
control H@
operating here
He#ristic 28
"
0oil a p#re liG#i% or close-&oiling liG#i%
(ixt#re in a separate heat exchanger3 #sing
a (axi(#( o/erall te(perat#re %ri/ing
'orce o' 45 F to ens#re n#cleate &oiling an%
a/oi% #n%esira&le 5lo h4 'il( &oiling.
E''ecti/e
Flo
Con%itions
ith
0oiling in
Ther(o
siphon
Hettle 5Re40oiler Design
Aspen - Ione Analysis
!roJax 1 Heat Release 2ncre(ents
"
He#ristic 2?.
1
:hen cooling an% con%ensing a strea( in a heat exchanger3 a Kone
analysis3 %escri&e% in $ection 18.13 sho#l% &e (a%e to (aCe s#re
that the te(perat#re %i''erence &eteen the hot strea( an% the
col% strea( is eG#al to or greater than the (ini(#( approach
te(perat#re at all locations in the heat exchanger. The Kone
analysis is per'or(e% &y %i/i%ing the heat exchanger into a
n#(&er o' seg(ents an% applying an energy &alance to each
seg(ent to %eter(ine correspon%ing strea( inlet an% o#tlet
te(perat#res 'or the seg(ent3 taCing into acco#nt any phase
change. A process si(#lation progra( con/eniently acco(plishes
the Kone analysis.
!ress#re Drop
L Flo Rate
"
Fa(inar /s. T#r&#lent
1
He#ristic 31.
"
Esti(ate heat-exchanger press#re %rops as 'ollos;
1
1.5 psi 'or &oiling an% con%ensing3
1
3 psi 'or a gas3
1
5 psi 'or a lo-/iscosity liG#i%3
1
7-? psi 'or a high-/iscosity liG#i%3
1
26 psi 'or a process 'l#i% passing thro#gh a '#rnace.
Controlling )! in $i(#lator
"
$hell si%e
1
NoKKle %ia(eter
"
2nlet an% .#tlet
1
N#(&er o' 0a''les
1
T#&es
"
N#(&er3 %ia(eter3 pitch3 No. passes
"
T#&e si%e
1
NoKKle %ia(eter
"
2nlet an% .#tlet
1
T#&es
"
N#(&er3 %ia(eter3 pitch3 No. passes
Note interactionsM
$hell Hea%s3 $hell Type
"
$ee !roJax Help9in%ex N$hell3 typesO
H@ Cost
"
$iKe Factor H@ Area
" C
0ase58-26664
*expP11.6545-6.?228Qln5A4>6.6?881Qln5A4
2
R
"
!#rchase !rice
1 C
!-'o&
*F
P
5!4QF
Material
5A4QF
L
5F4QC
0ase
Q5C!293?44
1 C
0J
*F
0J
QC
!-'o&
1 C
0J
*3.17QC
!-'o&
"
Cost %epen%s on H@ Area
"
!#(ping Cost
1
:orC * +Q)!
Controlling A in $i(#lator
" A * N
t#&es
S D
t#&es
F
t#&es
"
$hell
1 $hell Dia(eter an% pitch %eter(ines N
t#&es
"
T#&es
1 D
t#&es
1 F
t#&es
1
T#&e pitch-The trans/erse pitch is the shortest %istance 'ro(
the center lines o' to a%Tacent t#&es.
1
T#&e pitch ratio 1.25 to 1.5 typically
Controlling , in a $i(#lator
"
For a gi/en heat %#ty an% geo(etry - , %eter(ines the H@
area
"
$teps
1
2%enti'y the controlling heat trans'er resistance
1 h
o
-Janip#late the shell si%e Reynol%s n#(&er
" $hell %ia(eter
"
T#&e pitch
"
N#(&er o' &a''les
1 h
i
-Janip#late the t#&e si%e Reynol%s n#(&er
" T#&e %ia(eter
" N#(&er o' t#&es 5shell %ia(eter an% t#&e pitch4
" N#(&er o' passes
1
2' o%% things happen checC to see that yo# ha/e the sa(e controlling heat
trans'er resistance
Note interactionsM
.ther 2ss#es

Materials of Construction

Strength at temperature, life time, heat

conduction, fouling

Design layout

Tube pitch, baffles, tube and shell diameters

Heat Exchanger
!ro&le(s
"
Te(perat#res Cross Each
.ther
1
Non-'#nctioning Exchanger
1
To sol/e increase approach )T
"
Con%ensation9E/aporation
1
Heat trans'er ith (#ltiple
heat trans'er coe''icients in a
single apparat#s
"
Eario#s regi(es o' &oiling
"
Eario#s regi(es o' con%ensation