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Heat Exchanger PDF
Heat Exchanger PDF
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When the hot and cold stream flows and inlet temperatures are constant, the heat transfer
coefficient may be evaluated using the above formula. It may be observed that the heat
pick up by the cold fluid starts reducing with time.
52
Nomenclature
A typical heat exchanger is shown in figure 4.1 with nomenclature.
Cold fluid in
w, ti
Baffles
Shell
Hot fluid in
W, Ti
..Eqn-1
...Eqn-2
If heat exchanger efficiency is 100%, Eqn-1 must be equal to Eqn-2. If the operating heat
duty (enthalpy calculated by Eqn-2) is less than original heat duty, it may be due to heat
losses, fouling in tubes, etc. Hence, for simple performance monitoring of exchanger,
efficiency may be considered as factor of performance irrespective of other parameter.
However, in industrial practice, fouling factor method is more predominantly used.
53
Where Q is the heat duty, A is the heat transfer area of the exchanger and LMTD is
temperature driving force.
The step by step procedure for determination of Overall heat transfer Coefficient are
described below
a) Monitoring and reading of steady state parameters of the heat exchanger under
evaluation are tabulated as below:
Parameters
Hot fluid flow,W
Cold fluid flow,w
Hot fluid Temp, T
Cold fluid Temp,t
Hot fluid Pressure,P
Cold fluid Pressure, p
Units
kg/h
kg/h
O
C
O
C
bar g
bar g
Inlet
Outlet
b) With the monitored test data, the physical properties of the stream can be
tabulated as required for the evaluation of the thermal data
Parameters
Hot fluid density, h
Cold fluid density, c
Hot fluid Viscosity, h
Cold fluid Viscosity, c
Hot fluid Thermal
Conductivity, kh
Cold fluid Thermal
Conductivity, kc
Hot fluid specific heat
Capacity, Cph
Cold fluid specific heat
Capacity, Cpc
Units
kg/m3
kg/m3
mPaS
mPaS
kW/(m. K)
Inlet
Outlet
kW/(m. K)
kJ/(kg. K)
kJ/(kg. K)
Density and viscosity can be determined by analysis of the samples taken from the flow
stream at the recorded temperature in the plant laboratory. Thermal conductivity and
specific heat capacity if not determined from the samples can be collected from
handbooks.
54
c) Calculate the thermal parameters of heat exchanger and compare with the design
data
Parameters
Units
Test Data
Design Data
Heat Duty, Q
kW
bar
*
Hot fluid side pressure drop, Ph
bar
*
Cold fluid side pressure drop, Pc
O
C
Temperature Range hot fluid , T
O
Temperature Range cold fluid , t
C
Capacity ratio, R
----Effectiveness, S
----O
Corrected LMTD, MTD
C
Heat Transfer Coefficient, U
kW/(m2. K)
* - The pressure drop for the design flow can be rated with the relation
Pressure drop is proportional to (Flow)1.75
d) The following formulae are used for calculating the thermal parameters:
1. Heat Duty, Q = qs + ql
qs is the sensible heat and ql is the latent heat
qs = Wx Cph x(Ti- To)/1000/3600
(or)
qs = w x Cpc x (to-ti)/1000/3600
in kW
ql= W x h ,
h Latent heat of Condensation of a hot condensing vapor
(or)
= w x c ,
c - Latent heat of Vaporization
2. Hot Fluid Pressure Drop, Ph = Pi Po
3. Cold fluid pressure drop, Pc = pi- po
4. Temperature range hot fluid, T = Ti- To
55
Co-current flow
Ti
To
Ti
To
to
ti
ti
to
=
( 1 R) x ln
2- S ( R + 1 (R +1)1/2)
2- S ( R + 1 + (R +1)1/2)
9. Corrected LMTD
= F x LMTD
10. Heat Transfer Co-efficient
U = Q / (A x Corrected LMTD)
56
4.4.2 Examples
a. Liquid Liquid Exchanger
A shell and tube exchanger of following configuration is considered being used for oil
cooler with oil at the shell side and cooling water at the tube side.
Tube Side
460 Nos x 25.4mmOD x 2.11mm thk x 7211mm long
Pitch 31.75mm 30o triangular
2 Pass
Shell Side
787 mm ID
Baffle space 787 mm
1 Pass
The monitored parameters are as below:
Parameters
Hot fluid flow, W
Cold fluid flow, w
Hot fluid Temp, T
Cold fluid Temp, t
Hot fluid Pressure, P
Cold fluid Pressure, p
Units
kg/h
kg/h
O
C
O
C
bar g
bar g
Inlet
719800
881150
145
25.5
4.1
6.2
Outlet
719800
881150
102
49
2.8
5.1
Parameters
Hot fluid density, h
Cold fluid density, c
Hot fluid Viscosity, h
Cold fluid Viscosity, c
Units
kg/m3
kg/m3
mPaS
mPaS
Inlet
901
994
0.4
0.7
Outlet
905
994
0.4
0.7
W/(m. K)
.086
.086
W/(m. K)
.575
.575
kJ/(kg. K)
2.487
2.487
kJ/(kg. K)
4.187
4.187
57
=
( 1 R) x ln
2- S ( R + 1 (R2 +1)1/2)
2- S ( R + 1 + (R2 +1)1/2)
F = 0.977.
9. Corrected LMTD
= F x LMTD = 0.977 x 85.9 = 83.9 deg C.
10. Heat Transfer Co-efficient
Overall HTC, U = Q/ A T = 24477.4/ (264.55 x 83.9) = 1.104 kW/m2. K
58
Units
Test Data
24477.4
1.3
1.301
1.1
1.11
43
23.5
25
0.547
0.20
83.8
1.104
0.556
0.375
82.2
1.178
kW
Bar
Bar
--------O
C
kW/(m2. K)
Design Data
25623
1.34
0.95
45
Inferences:
Actual measured
T
L Distance across the heat
exchanger;
T- Terminal temperatures
Design profile
L
Heat Duty: Actual duties will be practically nil as these duty differences could be because
of the specific heat capacity deviation with the temperature. Also, there could be some
heat loss due to radiation from the hot shell side.
Pressure drop: Also, the pressure drop in the shell side of the hot fluid is reported normal
(only slightly less than the design figure). This is attributed with the increased average
bulk temperature of the hot side due to decreased performance of the exchanger.
Temperature range: As seen from the data the deviation in the temperature ranges could
be due to the increased fouling in the tubes, since a higher pressure drop is noticed.
Heat Transfer coefficient: The estimated value has decreased to increased fouling that has
resulted in minimized active area of heat transfer.
Physical properties: If available from the data or Lab analysis can be used for verification
with the design data sheet as a cross check towards design considerations.
Troubleshooting: Fouled exchanger needs cleaning.
59
b. Surface Condenser
A shell and tube exchanger of following configuration is considered being used for
Condensing turbine exhaust steam with cooling water at the tube side.
Tube Side
20648 Nos x 25.4mmOD x 1.22mm thk x 18300mm long
Pitch 31.75mm 60o triangular
1 Pass
Units
kg/h
kg/h
O
C
O
C
Bar g
Bar g
Units
kg/m3
kg/m3
MpaS
MpaS
W/(m. K)
W/(m. K)
kJ/(kg. K)
kJ/(kg. K)
60
Inlet
939888
55584000
No data
18
52.3 mbar
4
Outlet
939888
55584000
34.9
27
48.3
3.6
Inlet
Outlet
61
Units
kW
Bar
Test Data
576990
4 mbar
4 mbar*
0.4
0.41
Design Data
588430
9 (27-18)
9 (28-19)
--------O
C
kW/(m2. K)
11.8
1.75
8.9
2.37
Bar
O
3.7 mbar
Inferences:
Actual measured
Design profile
L
Duty: Actual duties will be practically nil as these duty differences could be because of
the specific heat capacity deviation with the temperature. Also, there could be some heat
loss due to radiation from the hot shell side.
Pressure drop: The condensing side operating pressure raised due to the backpressure
caused by the non-condensable. This has resulted in increased pressure drop across the
steam side
Temperature range: With reference to cooling waterside there is no difference in the
range however, the terminal temperature differences has increased indicating lack of
proper heat transfer.
Heat Transfer coefficient: Heat transfer coefficient has decreased due to increased
amount of non-condensable with the steam.
Trouble shooting:
Operations may be checked for tightness of the circuit and ensure proper venting of the
system. The vacuum source might be verified for proper functioning.
62
c. Vaporizer
A shell and tube exchanger of following configuration is considered being used for
vaporizing chlorine with steam at the shell side.
Tube Side
200 Nos x 25.4mmOD x 1.22mm thk x 6000mm long
Pitch 31.75mm 30o triangular
2 Pass
Area = 95.7 sq.m
63
Units
kg/h
kg/h
O
C
O
C
Bar g
Bar g
Units
kg/m3
kg/m3
MpaS
MpaS
W/(m. K)
Inlet
5015
43500
108
30
0.4
9
Outlet
5015
43500
108
34
0.3
8.8
Inlet
Outlet
28.2
27.3
3.73
1.84
W/(m. K)
kJ/(kg. K)
kJ/(kg. K)
64
65
Design Data
3130
Neg
0.44
Inferences:
Actual measured
Units
kg/h
kg/h
O
C
O
C
Bar g
Bar g
66
Inlet
3000
92300
150
30
Outlet
3000
92300
150
95
200 mbar
180 mbar
Parameters
Hot fluid density, h
Cold fluid density, c
Hot fluid Viscosity, h
Cold fluid Viscosity, c
Hot fluid Thermal
Conductivity, kh
Cold fluid Thermal
Conductivity, kc
Hot fluid specific heat
Capacity, Cph
Cold fluid specific heat
Capacity, Cpc
Units
kg/m3
kg/m3
MpaS
MpaS
W/(m. K)
Inlet
Outlet
3.73
1.84
W/(m. K)
kJ/(kg. K)
kJ/(kg. K)
67
Units
Test Data
Design Data
Duty, Q
kW
1748
1800
Bar
Neg
Neg
Bar
20
21*
15
65
63*
65
79
79
kW/(m2. K)
0.026
0.03
C
C
Capacity ratio, R
-----
Effectiveness, S
-----
68
Inferences:
Actual measured
69
Parameters
Fluid flow
Temperature
Units
Instruments used
kg/h
Pressure
Bar g
Density
kg/m3
Viscosity
mPa.S
J/(kg.K)
Thermal conductivity
W/(m.K)
Composition+
70
Co current flow
exchanger
Counter flow
exchanger
Cross flow
Density
Effectiveness
Fouling
Fouling Factor
Heat Duty
Heat exchanger
Heat Flux
Definition
Unit
71
72
QUESTIONS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
73