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Heat Exchanger Thermal Design

Shell&Tube V8.4

File: C:\Users\..\aspen files\exchanger design.EDR

Page 1
Printed: 9/30/2014 at 11:13:20 AM

Warnings and Messages


Description
1121

Input for Str.1 Liq.viscosity, 53277.35 mPa*s is beyond the expected range, from 0.01 mPa*s to
1000 mPa*s

1121

Input for Str.1 Liq.viscosity, 21752.67 mPa*s is beyond the expected range, from 0.01 mPa*s to
1000 mPa*s

1128

A further 4 similar warnings for Str.1 Liq.viscosity are omitted for clarity.

1121

Input for Str.2 Liq.density, 177.68 kg/m3 is beyond the expected range, from 200 kg/m3 to 3000
kg/m3

1816

P21: Stream 2 at pressure 91.00997 bar has an unusual value of compressibility, 0.3144747,
(calculated from vapor data at the dew point) and/or of molecular weight 16.65921. This may
affect the accuracy of the calculated results.

1816

P21: Stream 2 at pressure 89.18982 bar has an unusual value of compressibility, 0.3166472,
(calculated from vapor data at the dew point) and/or of molecular weight 16.65921. This may
affect the accuracy of the calculated results.

1826

P57: The dew (or bubble) points for Stream 2 at pressure levels 1 and 2 indicate a lower
temperature at the higher pressure. This is unusual, though not impossible. Check the Physical
Properties Temperature-Enthalpy-Quality data for this stream. Note. This message can apply to
an extrapolated (effective) bubble or dew point. If so, and there are no obvious inconsistencies
in the T-h-x data, the message can be ignored.

1860

The consolidated process conditions for Stream 1, prior to the main calculations, give a heat
load of -53473 kW, for a flow of 1537.683 kg/s, with outlet temperature 6 C and quality (vapor
mass fraction) 0.

1860

The consolidated process conditions for Stream 2, prior to the main calculations, give a heat
load of 53473 kW, for a flow of 85.3056 kg/s, with outlet temperature 2 C and quality (vapor
mass fraction) 1.

1446

The Advanced calculation has converged after 35 iterations

1701

Design calculation successfully completed.

1611

The HTFS flow induced vibration analysis has identified possible or serious problems in one or
more areas: Fluid Elastic Instability: 5 warnings, of which 2 serious; Resonance Assessments:
6 warnings, of which 3 serious.

1661

There is an unsupported straight tube span of 2068.52 mm which exceeds the TEMA maximum
unsupported straight tube span of 1524 mm.

1902

The number of baffles 2 in a shellside flow path is small. Some of the assumptions in the
Shell&Tube thermal model and temperature difference calculation are less valid than normal.

1903

The ratio 2.418431 of an end space length to the baffle space is larger than normal. Shellside
heat transfer and pressure drop calculations may be less accurate than normal, especially if
there is a small number of baffles. Note that the fraction of the overall resistance to heat
transfer due to the shellside is 0.1385429.

1913

There is a risk of phase separation in a tubeside header. The effects of phase separation are not
included in the thermal model.

Heat Exchanger Thermal Design

Shell&Tube V8.4

Page 2

File: C:\Users\..\aspen files\exchanger design.EDR

Printed: 9/30/2014 at 11:13:20 AM

Optimization Path
Shell

Tube Length

Units

Total

Price

2294

Dollar(US)
1594535 Near

2413

1663130 Near

3223

2243910 (OK )

3405

2366675 Near

666.75

3324

2325130 (OK )

0.25

660.4

3517

2460935 Near

0.01416

0.71

660.4

3432

2383630 (OK )

1.44 *

0.00484

0.24

660.4

3637

2542435 Near

0.24008

0.93

0.01345

0.67

660.4

3554

2464905 (OK )

1.14

0.36561

1.41 *

0.00471

0.24

654.05

3764

2616825 Near

4783.3

1.15

0.35698

1.38 *

0.00461

0.23

647.7

3875

2699260 Near

5486.4

4681.8

1.17

0.38037

1.47 *

0.00444

0.22

558.8

4111

2866260 Near

1828.8

4876.8

4854.9

0.24191

0.94

0.0042

0.21

419.1

4255

2919890 (OK )

14

1854.2

4876.8

4815.8

1.01

0.24034

0.93

0.00412

0.21

419.1

4393

3018005 (OK )

15

1879.6

4876.8

4787

1.02

0.23456

0.91

0.00406

0.2

419.1

4512

3094860 (OK )

16

1905

4876.8

4754.9

1.03

0.23213

0.9

0.00399

0.2

419.1

4658

3194565 (OK )

17

1320.8

3657.6

4051.5

0.9 *

0.28417

1.1 *

0.02368

1.18 *

463.55

2051

1676880 Near

18

1346.2

3657.6

3988.4

0.92 *

0.20475

0.79

0.02163

1.08 *

609.6

2160

1751016 Near

19

1371.6

3657.6

3924.2

0.93 *

0.21879

0.85

0.02049

1.02 *

609.6

2232

1815876 Near

20

1397

3657.6

3870.6

0.94 *

0.21069

0.81

0.01892

0.95

603.25

2344

1889316 Near

21

1422.4

5486.4

5116.2

1.07

0.35243

1.36 *

0.00541

0.27

603.25

2531

2045274 Near

22

1422.4

4267.2

3724.6

1.15

0.18018

0.7

0.01925

0.96

603.25

2461

2001774 (OK )

23

1676.4

5486.4

4601.7

1.19

0.27733

1.07 *

0.0041

0.21

679.45

3567

2960922 Near

24

1701.8

5486.4

4565.8

1.2

0.2773

1.07 *

0.00402

0.2

679.45

3681

3057450 Near

25

1727.2

5486.4

4487.1

1.22

0.32598

1.26 *

0.00395

0.2

558.8

3793

3134940 Near

26

1752.6

5486.4

4445.2

1.23

0.31845

1.23 *

0.00387

0.19

558.8

3923

3237798 Near

27

1778

4876.8

4436.3

1.1

0.27422

1.06 *

0.00371

0.19

666.75

4015

3292200 Near

28

1803.4

5486.4

4405.7

1.25

0.2394

0.93

0.00374

0.19

660.4

4161

3457194 (OK )

29

1828.8

4876.8

4557.4

1.07

0.18992

0.73

0.00357

0.18

419.1

4301

3510750 (OK )

30

1193.8

4267.2

4047.6

1.05

0.30768

1.19 *

0.02902

1.45 *

419.1

1659

1582707 Near

31

1219.2

4876.8

3835.5

1.27

0.26878

1.04 *

0.02937

1.47 *

647.7

1727

1687644 Near

32

1244.6

4876.8

3806.2

1.28

0.29848

1.15 *

0.02727

1.36 *

558.8

1808

1750707 Near

33

1270

3657.6

3915.2

0.93 *

0.16387

0.63

0.02065

1.03 *

641.35

1925

1785224 Near

34

1295.4

3657.6

3844.3

0.95 *

0.1711

0.66

0.0197

0.98

635

1985

1857023 Near

35

1320.8

3657.6

3772.4

0.97 *

0.17049

0.66

0.018

0.9

635

2095

1954568 Near

36

1346.2

3657.6

3689.1

0.99 *

0.167

0.65

0.01704

0.85

628.65

2185

2037070 Near

37

1371.6

3657.6

3666.7

1*

0.16407

0.63

0.01584

0.79

628.65

2276

2116331 Near

38

1397

3657.6

3596.9

1.02

0.15758

0.61

0.01479

0.74

622.3

2386

2201255 (OK )

39

1422.4

3657.6

3540.2

1.03

0.17114

0.66

0.0139

0.7

615.95

2486

2291968 (OK )

40

1447.8

3657.6

3492.1

1.05

0.17107

0.66

0.01325

0.66

527.05

2574

2381351 (OK )

41

1473.2

3657.6

3440.9

1.06

0.18713

0.72

0.01253

0.63

520.7

2681

2471476 (OK )

42

1473.2

3048

2963.6

1.03

0.23018

0.89

0.02934

1.47 *

520.7

2628

2421391 Near

22

1422.4

4267.2

3724.6

1.15

0.18018

0.7

0.01925

0.96

603.25

2461

2001774 (OK )

Item

Size

Actual

Reqd.

mm
1397

mm
4267.2

mm
4168.8

1422.4

4267.2

1625.6

4267.2

1651

Pressure Drop
Area
ratio

Baffle

Tube

Shell

Dp Ratio

Tube

Dp Ratio

Pitch

No. Tube No.


Pass

1.02

bar
0.23985

0.93

bar
0.02931

1.47 *

mm
590.55

4053.6

1.05

0.23743

0.92

0.02717

1.36 *

584.2

3603.6

1.18

0.24012

0.93

0.01712

0.86

558.8

5486.4

5002.4

1.1

0.38304

1.48 *

0.00508

0.25

666.75

1651

4267.2

3568.4

1.2

0.20415

0.79

0.01629

0.81

1676.4

5486.4

4909

1.12

0.3731

1.44 *

0.00497

1676.4

3657.6

3621.5

1.01

0.23992

0.93

1701.8

5486.4

4861

1.13

0.37187

1701.8

3657.6

3602.3

1.02

10

1727.2

5486.4

4821.9

11

1752.6

5486.4

12

1803.4

13

Design
Status

Heat Exchanger Thermal Design

Shell&Tube V8.4

File: C:\Users\..\aspen files\exchanger design.EDR

Printed: 9/30/2014 at 11:13:21 AM

Recap of Designs
Shell size

mm

A
1422.4

Tube length - actual

mm

4267.2

Tube length - required

mm

3724.6

Pressure drop, SS
Pressure drop, TS

bar 0.18018
bar 0.01925

Baffle spacing

mm

603.25
2

Number of baffles
Tube passes

Tube number

2461

Number of units in series

Number of units in parallel

Total price
Program mode
Calculation method
Area Ratio (dirty)

Dollar(US) 2001774
Design
(Sizing)
Advanced
method
1.15

Film coef overall, SS

W/(m K)

2598

Film coef overall, TS

W/(m K)

568.1

Heat load
Recap case fully recoverable

Page 3

kW 53472.8
Yes

Heat Exchanger Specification Sheet


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38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58

Size
1422.4 -- 4267.2
Surf/unit(eff.)
3111.6
Fluid allocation
Fluid name
Fluid quantity, Total
Vapor (In/Out)
Liquid
Noncondensable

mm
m

Type AES
Connected in
Hor
6 parallel
1 series
Shells/unit 6
Surf/shell (eff.)
518.6
m
PERFORMANCE OF ONE UNIT
Shell Side
Tube Side
kg/h
kg/s
kg/s
kg/s

Temperature (In/Out)
Dew / Bubble point
Density
Vapor/Liquid
Viscosity
Molecular wt, Vap
Molecular wt, NC
Specific heat
Thermal conductivity
Latent heat
Pressure (abs)
Velocity
Pressure drop, allow./calc.

C
C
kg/m
mPa s

5535659
0
0
1537.683
1537.683
0
0
16
1051.87
3.2336

307100
0
85.3056
0

6
1056.51
4.8908

85.3056
0
0

-136.8
2
-77.86
-78.86
396.87 86.03
0.0736 0.0135
16.66

3.501
3.454
3.436
3.149
kJ/(kg K)
0.4492
0.4474
0.1406 0.0303
W/(m K)
20.9
kJ/kg
20.9
2.816
2.63582
91.01
90.99075
bar
1.13
1.37
m/s
0.25855
0.18018
0.02
0.01925
bar
Fouling resistance (min)
0.00042 Ao based
0.00018
0.00035
m K/W
Heat exchanged
MTD corrected
53472.8
54.7
kW
C
Transfer rate, Service
Dirty
Clean 459
314.2
359.9
W/(m K)
CONSTRUCTION OF ONE SHELL
Sketch
Shell Side
Tube Side
Design/vac/test pressure:g
100.6635
bar 3.44738
Design temperature
54.44
37.78
C
Number passes per shell
1
4
Corrosion allowance
3.18
3.18
mm
Connections
In
508
1
254
mm 1
1
508
Size/rating
Out
1
304.8
Nominal
Intermediate
Tube No.
OD 19.05
Tks-Avg 1.6
Length 4267.2
2461
mm
mm Pitch 23.81
mm
Tube type Plain
Tube pattern
30
#/m Material Carbon Steel
Shell Carbon Steel
ID 1422.4
OD 1447.8
Carbon Steel
mm Shell cover
Channel or bonnet
Channel cover
Carbon Steel
Carbon Steel
Tubesheet-stationary Carbon Steel
Tubesheet-floating
Carbon Steel
Floating head cover Carbon Steel
Impingement protection None
Baffle-cross
Type Single segmental
Cut(%d) 29.92
Carbon Steel
H Spacing: c/c 603.25
mm
mm
Baffle-long
Seal type
Inlet
1458.92
0
Supports-tube
U-bend
Type
T2

T1

Bypass seal
Expansion joint
RhoV2-Inlet nozzle
Gaskets - Shell side
Floating head
Code requirements
Weight/Shell
Remarks

Tube-tubesheet joint
Type None
Bundle entrance 434
1771
Tube Side
Flat Metal Jacket Fibe
Flat Metal Jacket Fibe
ASME Code Sec VIII Div 1
Filled with water 54307
45706.4

S1

S2

Exp. 2 grv
Bundle exit 474
Flat Metal Jacket Fibe
TEMA class
Bundle

kg/(m s)

R - refinery service
12388.5

kg

Heat Exchanger Thermal Design

Shell&Tube V8.4

File: C:\Users\..\aspen files\exchanger design.EDR


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37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57

Size
1422.4 x 4267.2
Surf/Unit (gross/eff/finned)
Surf/Shell (gross/eff/finned)

mm
3770.9 /
628.5 /

Type
AES
3111.6 /
518.6 /

Design (Sizing)
Process Data
Total flow
Vapor
Liquid
Noncondensable
Cond./Evap.
Temperature
Dew / Bubble point
Quality
Pressure (abs)
DeltaP allow/cal
Velocity

kg/h
kg/s
kg/s
kg/s
C
C

Shell Side
In
Out
5535659
0
0
1537.683 1537.683
0
0
16
6

0
bar 2.816
bar 0.25855
m/s
1.13

Liquid Properties
Density
kg/m 1051.87
Viscosity
mPa s 3.2336
Specific heat
kJ/(kg K) 3.501
Therm. cond.
W/(m K) 0.4492
Surface tension
N/m
Molecular weight
25.15
Vapor Properties
Density
kg/m
Viscosity
mPa s
Specific heat
kJ/(kg K)
Therm. cond.
W/(m K)
Molecular weight
Two-Phase Properties
Latent heat
kJ/kg
Heat Transfer Parameters
Reynolds No. vapor
Reynolds No. liquid
6980.68
Prandtl No. vapor
Prandtl No. liquid
25.2
Heat Load
Vapor only
2-Phase vapor
Latent heat
2-Phase liquid
Liquid only
Tubes
Type
ID/OD
mm
Length act/eff
mm
Tube passes
Tube No.
Tube pattern
Tube pitch
mm
Insert
Vibration problem

0
2.63582
0.18018
1.12

Printed: 9/30/2014 at 11:13:22 AM

Hor

25.15

16.66
86.03
0.0135
3.149
0.0303
16.66
20.9

20.9

139208.1

Plain
15.85 / 19.05
4267.2 / 3521.1
4
2461
30
23.81
None
Yes / No

6 parallel
6

PERFORMANCE OF ONE UNIT


Tube Side
Heat Transfer Parameters
Total heat load
kW
In
Out
307100
Eff. MTD/ 1 pass MTD
C
0
85.3056
Actual/Reqd area ratio - fouled/clean
85.3056
0
0
W/(m K)
Coef./Resist.
85.3056
Overall fouled
359.9
-136.8
2
Overall clean
459
-77.86
-78.86
Tube side film
568.1
0
1
Tube side fouling
2362.1
91.01
90.99075
Tube wall
29642.1
0.02
0.01925
Outside fouling
5678
0.3
1.37
Outside film
2598

396.87
0.0736
3.436
0.1406

37.76
kW
0
0
0
0
-53472.8

Connected in
Shells/unit

m
m

1056.51
4.8908
3.454
0.4474

4615.36

Page 5

25602.82
1.4
1.8
kW
33098.6
45.4
359.2
46.1
19923.4

Shell Side Pressure Drop


Inlet nozzle
Inlet space Xflow
Baffle Xflow
Baffle window
Outlet space Xflow
Outlet nozzle
Intermediate nozzle
Tube Side Pressure Drop
Inlet nozzle
Entering tubes
Inside tubes
Exiting tubes
Outlet nozzle
Intermediate nozzle
Velocity / Rho*V2
Shell nozzle inlet
Shell bundle Xflow
Shell baffle window
Shell nozzle outlet
Shell nozzle interm
Tube nozzle inlet
Tubes
Tube nozzle outlet
Tube nozzle interm

Baffles
Type
Single segmental
Number
2
Cut(%d)
29.92
Cut orientation
H
Spacing: c/c
mm 603.25
Spacing at inlet
mm 1458.92
Spacing at outlet
mm 1458.92

1 series

53472.8
54.7 / 59.1
1.15 / 1.46
m K/W
0.00278
0.00218
0.00176
0.00042
0.00003
0.00018
0.00038

63.35
15.24
1.21
6.34
13.85

bar
0.01467
0.03657
0.06965
0.00552
0.03994
0.01385

%
8.14
20.29
38.64
3.06
22.16
7.69

bar
0.0012
0.00116
0.01214
0.0021
0.00136

%
6.66
6.47
67.59
11.68
7.59

m/s
1.3

kg/(m s)
1771

1.13
1.01

1.12
1.01
1.29

1763

m/s
0.77

kg/(m s)
237

0.3

1.37
2.52

547

Nozzles: (No./OD)
Shell Side
Inlet
mm
1 / 508
Outlet
1 / 508
Other
/
Impingement protection

RhoV2 violation

Tube Side
1 / 273.05
1 / 323.85
/
None

No