TABLE OF CONTENTS

1 Air cooled heat exchanger .................................................................................................. 1

1.1 Introduction ................................................................................................................. 1

1.2 Equipment Description ................................................................................................ 2

1.3 Major Components ...................................................................................................... 6

1.4 Equipment for cold climates ...................................................................................... 10

1.5 Advantages and Disadvantages ................................................................................. 11

1.6 General Application ................................................................................................... 13

2 Design of Air Cooled Heat Exchangers .............................................................................. 14

2.1 Design Guidelines ...................................................................................................... 14

2.2 Basic Design Procedure.............................................................................................. 15

2.3 Design Strategy .......................................................................................................... 17

3 Introduction To Simulation ............................................................................................... 28

3.1 Simulation Modeling and Analysis............................................................................. 28

3.2 Purposes of Simulation .............................................................................................. 28

3.3 Advantages to Simulation .......................................................................................... 28

3.4 Disadvantages to Simulation ..................................................................................... 29

3.5 Steps in simulation..................................................................................................... 29

3.6 Computer Software ................................................................................................... 30

3.7 Using ACOL................................................................................................................. 32

0
1 AIR COOLED HEAT EXCHANGER
1.1 Introduction
Air-cooled heat exchangers are second only to shell-and-tube exchangers in frequency of
occurrence in chemical and petroleum processing operations. These units are used to cool
and/or condense process streams with ambient air as the cooling medium rather than
water. Cooling with air is often economically advantageous, e.g., in arid or semi-arid
locations, in areas where the available water requires extensive treatment to reduce fouling,
or when additional investment would otherwise be required to expand a plant’s existing
cooling-water supply. Regulations governing water use and discharge of effluent streams to
the environment also tend to favor air cooling. Although the capital cost of an air-cooled
exchanger is generally higher, the operating cost is usually significantly lower compared with
a water-cooled exchanger. Hence, high energy cost relative to capital cost favors air cooling.
Air cooling also eliminates the fouling and corrosion problems associated with cooling water,
and there is no possibility of leakage and mixing of water with the process fluid. Thus,
maintenance costs are generally lower for air-cooled exchangers.

Air cooled heat exchangers are used to transfer heat from a process fluid to ambient air. The
process fluid is contained within heat conducting tubes. Atmospheric air, which serves as the
coolant, is caused to flow perpendicularly across the tubes in order to remove heat. In a
typical air cooled heat exchanger, the ambient air is either forced or induced by a fan or fans
to flow vertically across a horizontal section of tubes. For condensing applications, the
bundle may be sloped or vertical. Similarly, for relatively small air cooled heat exchanger, the
air flow may be horizontal across vertical tube bundles.

In order to improve the heat transfer characteristic of air cooled exchanger, the tubes are
provided with external fins. These fins can result in a substantial increase in heat transfer
surface. Parameters such as bundle length, width and number of tubes rows vary with the
particular application as well as the particular finned tube design.

Atmospheric air (having temperature varying from 20 to 450C, depending on season) can be
used as cooling medium if the process fluid is to be cooled up to 600C. If it is to be cooled
below 600C, then atmospheric air cannot be used as a cooling medium, as minimum driving
force required for heat transfer in air cooled heat exchanger is 100C.

1
1.2 Equipment Description

1.2.1 Overall configuration

In an air-cooled heat exchanger, the hot process fluid flows through a bank of finned tubes,
and ambient air is blown across the tubes by one or more axial-flow fans. For applications
involving only sensible heat transfer, the tubes are oriented horizontally as shown in Figures

2
For condensers, an A-frame configuration (as shown in Figure) is often used, with the
condensing vapor flowing downward through the tubes, which are oriented at an angle of
60◦ with the horizontal.

In units employing horizontal tubes, the fan may be located either below (forced draft) or
above (induced draft) the tube bank. In either case, the air flows upward across the tubes.
The fan drive assembly in an induced-draft unit may be mounted below the tube bundle or it
may be mounted above the fan. With the former arrangement, the drive assembly is easily
accessible for inspection and maintenance, and it is not exposed to the heated air leaving
the unit. However, the drive shaft passes through the tube bundle, requiring omission of
some tubes, and the relatively long shaft is more susceptible to vibration problems.

3
The forced-draft configuration provides the simplest and most convenient fan arrangement.
With all blower components located below the tube bundle, they are easily accessible for
maintenance and are not exposed to the heated air leaving the unit. However, these
exchangers are susceptible to hot air recirculation due to the low velocity of the air leaving
the unit. Induced-draft operation gives more uniform air flow over the tube bundle and the
exit air velocity is several times higher than in forced-draft operation, thereby reducing the
potential for hot air to be recirculated back to the intake of the unit or other nearby units.
Hot air recirculation tends to reduce the capacity of the heat exchanger, thereby requiring a
higher air flow rate and/or more heat-transfer surface. The induced-draft configuration also
provides some protection from the elements for the tube bundle, which helps to stabilize
the operation of the unit when sudden changes in ambient conditions occur.

For a given mass flow rate of air, induced-draft operation in principle entails greater power
consumption than forced-draft operation due to the higher volumetric flow rate of the
heated air that is handled by the induced-draft fan. In practice, however, this potential
disadvantage tends to be offset by the more uniform flow distribution and lower potential
for hot gas recirculation obtained with induced-draft operation. As a result, induced-draft
units typically do not require significantly more power than forced-draft units and in some
cases may actually require less power.

If the difference between fluid outlet temperature (required) and ambient air temperature is
less than 300C, induced draft unit is preferred because of the less percentage recirculation of
hot exhaust air. But if the same is more than 300C, forced draft unit is preferred as it
consumes less power.

1.2.2 Forced vs. Induced Draft

Advantages and disadvantages of forced and induced draft air-cooled heat exchangers are
shown here to aid in selection.

1.2.2.1 Advantages of Induced Draft

ü Better distribution of air across the bundle.

ü Less possibility of the hot effluent air recirculating around to the intake of the
sections. The hot air is discharged upward at approximately 2.5 times the velocity
of intake, or about 1500 ft/min.

ü Better process control and stability because the plenum covers 60% of the bundle
face area, reducing the effects of sun, rain, and hail.

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 ü Increased capacity in the event of fan failure, since the natural draft stack effect is
much greater with induced draft.

1.2.2.2 Disadvantages of Induced Draft

v Higher horsepower since the fan is located in the hot air.

v Effluent air temperature should be limited to 2OO0F, to prevent potential damage
to fan blades, bearings, V-belts, or other mechanical components in the hot air
stream.
v The fan drive components are less accessible for maintenance, which may have to
be done in the hot air generated by natural convection.
v For inlet process fluids above 350°F, forced draft design should be used; otherwise,
fan failure could subject the fan blades and bearings to excessive temperatures.
v Plenums must be removed to replace bundles

1.2.2.3 Advantages of Forced Draft

ü Slightly lower horsepower since the fan is in cold air. (Horsepower varies directly
as the absolute temperature.)

ü Better accessibility of fans and upper bearings for maintenance.

ü Easily adaptable for warm air recirculation for cold climates.

ü Better accessibility of bundles for replacement.

ü Accommodates higher process inlet temperatures.

1.2.2.4 Disadvantages of Forced Draft

v Less uniform distribution of air over the bundle.

v Greatly increased possibility of hot air recirculation, due to low discharge velocity
from the bundles and absence of stack.
v Low natural draft capability on fan failure due to small stack effect.
v Complete exposure of the finned tubes to sun, rain, and hail, which results in poor
process control and stability

5
1.3 Major Components
The major components of air cooled heat exchangers include the

ü Finned tube

ü Tube bundle

ü Fan and drive assembly

ü Air plenum chamber

ü Overall structural assembly

Each component is briefly described below

1.3.1 Finned Tubes

Common to all air cooled heat exchangers is the tube, through which the process fluid flows.
To compensate for the poor heat transfer properties of air, which flows across the
outside of the tube, and to reduce the overall dimensions of the heat exchanger, external
fins are added to the outside of the tube. A wide variety of finned tube types are available
for use in air cooled exchangers. These vary in geometry, materials, and methods of
construction, which affect both air side thermal performance and air side pressure drop.

The operating environment may influence the choice of materials used and the shape of the
fin. Aluminum is very often satisfactory as a fin material, although copper, steel and stainless
steel fins are also used. The fin shape may be of edge-type, L-foot type or double L-foot
design. The edge type is used for the grooved fin tube, and in cases, where the base tube is
not subject to corrosion.

Various types of high-fin tubing are available, including:

• Integrally finned (K-fin)

• Bimetallic (E-fin)
• Tension-wound fin (L-fin or I-fin)
• Embedded fin (G-fin)
• Brazed find

6
1.3.2 Tube Bundle
A typical tube bundle arrangement is illustrated in Figure

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Tube bundles are rectangular in shape and usually 6–12 ft wide. Since tube bundles are
factory assembled and shipped to the plant site, maximum bundle width is limited by
transportation requirements. The tubes are either welded to or rolled into long rectangular
tube sheets that are welded to box-type headers. Both front and rear headers are equipped
with screwed plugs that are aligned with the tube holes as illustrated in Figure. The plugs can
be removed to provide access to the tubes for cleaning and other maintenance.

1.3.3 Fan and Drive Assemblies

Fans are used, which correspond to the dimensions of the tube bundle and the performance
requirements for the heat exchanger. Normally, the fan diameter is approximately equal to
the bundle width, although smaller diameters may be used. For square or nearly square
bundles, one fan is used. For long rectangular bundles, a number of fans operating in parallel
may be used. Fans are of axial flow design, which move relatively large volumes of air at low
pressure. In order to minimize air recirculation and improve fan efficiency, fan blades are
set within orifice rings which provide close radial clearance between the ring and the blade
tips.

Fan efficiencies are typically about 65 % while drive efficiencies are 95 % or better. This
power advantage for forced-draft designs generally proves to result in a more economical
heat exchanger. Since the fan is close to the ground, structural costs may be less with the
drive assembly, located at ground level. However, induced-draft air cooled heat
exchangers offer the advantage of better air distribution across the bundle, due to relatively
low air velocities approaching the tubes. Furthermore, the air exit velocities of induced-draft
heat exchangers are much higher than a forced-draft design. Thus, the possibility of
recirculating hot discharge air is less for the induced-draft. When cooling the process fluid to
a temperature close to the inlet ambient air temperature, this may be of particular
importance.

The fans are situated in bays, which are self-contained sections of an air-cooled heat
exchanger. A bay consists of one or more tube bundles, the fans and drive assemblies that
supply air to the bundles, and the associated framework and support structures. Except in
unusual circumstances, multiple tube bundles are placed side by side in the bay. Bays are
usually designed for one to three fans, with two-fan bays being most common.

Fan bays can be preassembled and shipped to the plant site provided they are small enough
to meet transportation requirements. Otherwise, they must be assembled in the field, which
adds to the cost of the heat exchanger. An air-cooled heat exchanger consists of one or more
fan bays, with multiple bays operating in parallel. Some typical configurations are illustrated
in Figure.

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1.3.4 Air Plenum Chamber
The velocity of the air, flowing through the fan, can be as much as 3 to 4 times the velocity
across the face of the tube bundle. Also, the air, coming from the circular shape of the
fan, must be distributed across the square or rectangular shape of the bundle. The air
plenum chamber is intended to make this velocity and shape transition, such that the
distribution of air is uniform across the bundle. Common practice is to install the fan in a
chamber, such that the distance from the first row of the tube bundle to the fan is about
one-half the fan diameter The plenum chamber design may be a simple box shape, formed
by flat sides and bottom, or curved transition sections may be used to obtain a tapered
smooth transition from the rectangular bundle to the circular fan. Either design may be used
for forced-draft or induced-draft air cooled heat exchangers.

1.3.5 Structural Assembly

The structural assembly of the air cooled heat exchanger is strongly dependent upon the
particular plant site requirements of the user. Taken into account should be mechanical
loads upon the heat exchanger structure, due to its own weight, of course, but other
loadings, such as wind loads, impact loads, nozzles loading and seismic forces must be
considered. The presence of equipment beneath the air cooled heat exchangers may require
particular designs. Safety considerations may call for fencing or fan guards. Environmental
factors could indicate the need for louvers, hail screens, or other protective devices. In
addition, the physical location of the heat exchangers may require ladders, platforms,
railings, safety cages and other miscellaneous items, which the user will require.

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1.4 Equipment for cold climates
Air-cooled heat exchangers are designed to operate over a wide range of environmental
conditions, including ambient temperatures from −600F to 1300F. Special design features are
employed for operation in cold climates in order to prevent freezing of the process fluid. If
the wall temperature of a tube carrying a hydrocarbon stream reaches the pour point of the
hydrocarbon, the liquid will congeal around the wall, thereby reducing the flow area and
increasing the tube-side pressure drop. If water is present in the process stream, ice can
form around the tube wall with similar effect. Likewise, methane hydrates can form on the
tube walls of natural gas coolers.

The standard method for preventing freezing is to intentionally recirculate some of the
warm air leaving the unit in order to raise the temperature of the intake air. This can be
accomplished in a number of ways, depending on whether forced-draft or induced-draft
operation is employed and the severity of the winter climate.

Figure shows a typical configuration for a forced-draft unit with external recirculation, which
provides the most reliable freeze protection.

The unit is completely contained in an enclosure equipped with adjustable louvers to control
both exhaust and intake air rates. The manual louvers are adjusted seasonally while the
automatic louvers are adjusted continuously via pneumatic mechanisms directed by a
temperature controller that maintains the temperature of the air entering the tube bundle
at an appropriate level. A recirculation chamber projects beyond the front and rear headers,

10
providing ducts where cold ambient air mixes with warm recirculated air. The flow rate of
recirculated air is controlled by internal louvers in the ducts that open as the external intake
louvers close. Either variable-pitch or variable-speed fans are used in these units. The pitch
or speed is automatically adjusted by a second temperature controller that maintains the
outlet temperature of the process fluid at the desired temperature.

A row of steam tubes is installed below the tube bundle to warm the air stream during
startups and shutdowns in cold weather. These tubes are typically the same type and size as
those in the tube bundle, but with a pitch equal to twice that of the bundle. The steam tubes
are commonly referred to as a steam coil.

1.5 Advantages and Disadvantages

Air cooled heat exchanger has certain advantages as well as disadvantages over cooling
water cooled exchanger using water.

1.5.1 Advantages
Ø Generally operating cost for Air Cooled Heat Exchanger (ACHE) is less than the same
of water cooled heat exchanger (WCHE). Operating cost of WCHE includes cost of
make-up water for the cooling water, power required for the cooling tower fans and
for the circulating pump, cooling tower maintenance, etc. while operating cost of
ACHE includes cost of power consumed by fan. Day by day cost of water increases
and hence the difference in operating cost between WCHE and ACHE increases.

Ø Inlet temperature of water to cooling tower (or outlet temperature of cooling water
from heat exchanger circuit) should not be greater than 600C otherwise it creates the
scale formation and also affects the material of construction of cooling tower. While
for air there is no limit for temperature.

Ø Fouling or scale formation does not take place with air cooling.

Ø Since water is not used as the cooling medium, the disadvantages of using water are
eliminated.

Ø Eliminates high cost of water including expense of treating water.

Ø Thermal or chemical pollution of water resources is avoided.

Ø Installation is simplified due to elimination of coolant water piping.

Ø Location of the air cooled heat exchangers is independent of water supply location.

11
 Ø Air cooled heat exchangers will continue to operate (but at reduced capacity) due to
radiation and natural convection air circulation should a power failure occur.

Ø Temperature control of the process fluid may be accomplished easily through the
use of shutters, variable pitch fan blades, variable speed drives, or, in multiple fan
installations, by shutting off fans as required

Ø Excellent for removing high level temperatures, particularly greater than 200°F.

Ø Maintenance generally claimed to be 1/3 or less than water coolers. Clean fins by
compressed air and brushes, sometimes while operating.

Ø Ground space often less than or equal to cooling towers; can also serve dual purpose
by mounting air-cooled units above other equipment or on pipe ways or roofs of
buildings. Vibration is no problem.

1.5.2 Disadvantages
Ø Fixed cost of ACHE is higher than the same of WCHE. Heat transfer coefficient of air is
quite less than heat transfer coefficient provided by cooling water and hence heat
transfer area required by ACHE is more. Also design inlet temperature of cooling
water from cooling tower is always less than design ambient temperature. It gives
lesser Mean Temperature Difference (MTD) for ACHE compared to the same for
WCHE and hence it increases heat transfer area required for ACHE.

Ø Minimum driving force required for heat transfer, ∆tmin is 10-150C for ACHE and 3 to
50C for WCHE. Hence minimum temperature that can be achieved with ACHE is
ambient temperature plus 100C, while with WCHE it is design temperature of cooling
water from cooling tower plus 30C. Hence, if the fluid is to be cooled or condensed
below 550C in a tropical location, ACHE cannot be used.

Ø Outdoor operation in cold winter environments may require special consideration to

prevent freezing of the tube side fluid or formation of ice on the outside surface.

Ø The movement of large volumes of cooling air is accomplished by the rotation of

large diameter fan blades rotating at high speeds. As a result, noise due to air
turbulence and high fan tip speed is generated.

Ø Fire and toxic vapor and liquid hazard, if leaks occur to atmosphere.

Ø Not too suitable for vacuum services due to pressure drop limitations but are used in
application.

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1.6 General Application
Air cooled heat exchangers are commonly used in industrial applications where a reliable
source of water is not available as a cooling medium. Even if water is available, in some
cases, air cooled exchangers are favored for economic or operational reasons – because
dedicated cooling water circuits, pumps, water cooling systems and water conditioning
systems add complexity and capital requirements, as well as operating and maintenance
costs.

Air cooled heat exchangers are used throughout the entire oil and gas industry from
upstream production to refineries and petrochemical plants, under conditions including high
pressure and temperature, as well as corrosive fluids and environments. Common
applications include gas re-injection, gas lift and pipeline applications, cooling and
condensing of hydrocarbon gases, and cooling of machinery oil and heavy hydrocarbons. Air
cooled steam condensers are a special type of heat exchanger employed to condense steam
at the exhaust end of steam turbines for both power generation and mechanical drive
applications.

Air-cooled units have been successfully and economically used in liquid cooling for
compressor engine and jacket water and other recirculating systems, petroleum fractions,
oils, etc., and also in condensing service for steam, high boiling organic vapors, petroleum
still vapors, gasoline, ammonia, etc.

1) When the fluid temperatures are relatively high

2) when water is extremely scarce or expensive

3) Where a maintenance problem results from the use of cooling tower water

4) Where the industrial process or plant design is simplified by its use

5) Where maximum heat loads occur during the winter months. Air cooled exchangers
are extensively used for jacket water cooling of engine driven compressors, for steam
condensing, and for gas and high temperature level cooling or condensing.

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2 DESIGN OF AIR COOLED HEAT
EXCHANGERS
2.1 Design Guidelines

2.1.1 Tubing
Tubing selection should be based on the tube-side fluid temperature and the potential for
corrosion of the external tube surface. Furthermore, it is recommended to choose one of the
tubing configurations given in Table

2.1.2 Air flow distribution

In order to obtain an even distribution of air flow across the tube bundle, the fan area should
be at least 40% of the bundle face area as previously noted. In addition, for two-fan bays,

14
the ratio of tube length to bundle width should be in the range of 3–3.5. It is also desirable
to have a minimum of four tube rows.

2.1.3 Outlet air temperature

For induced-draft operation, the outlet air temperature should be limited to about 2200F in
order to prevent damage to fan blades and bearings. These parts may nevertheless be
exposed to high temperatures in the event of fan failure. Therefore, forced-draft operation
should be considered if the tube-side fluid temperature is greater than 3500F.

2.1.4 Air velocity

The air velocity based on bundle face area and air at standard conditions is usually between
400 and 800 ft/min, with a value of 500–700 ft/min being typical for units with four to six
tube rows. A value in this range will usually provide a reasonable balance between air-side
heat transfer and pressure drop.

2.2 Basic Design Procedure

The general equation for heat transfer across a surface is:

Q = UA∆Tm

Where

Q = heat transferred per unit time

U = the overall heat transfer coefficient
A = heat-transfer area
∆Tm = the mean temperature difference, the temperature driving force

The prime objective in the design of an exchanger is to determine the surface area required
for the specified duty (rate of heat transfer) using the temperature differences available.

The overall coefficient is the reciprocal of the overall resistance to heat transfer, which is the
sum of several individual resistances. For heat exchange across a typical heat exchanger tube
the relationship between the overall coefficient and the individual coefficients, which are the
reciprocals of the individual resistances, is given by:

15
Where

Uo = the overall coefficient based on the outside area of the tube

ho = outside fluid film coefficient
hi = inside fluid film coefficient
hod = outside dirt coefficient (fouling factor)
hid = inside dirt coefficient
kw = thermal conductivity of the tube wall material
di = tube inside diameter
do = tube outside diameter

The steps in a typical design procedure are given below:

1. Define the duty: heat-transfer rate, fluid flow-rates, temperatures.

2. Collect together the fluid physical properties required: density, viscosity, thermal
conductivity.
3. Decide on the type of exchanger to be used.
4. Select a trial value for the overall coefficient, U.
5. Calculate the mean temperature difference, ∆Tm.
6. Calculate the area required.
7. Decide the exchanger layout.
8. Calculate the individual coefficients.
9. Calculate the overall coefficient and compare with the trial value. If the calculated
value differs significantly from the estimated value, substitute the calculated for the
estimated value and return to step 6.
10. Calculate the exchanger pressure drop; if unsatisfactory return to steps 7 or 4 or 3, in
that order of preference.
11. Optimise the design: repeat steps 4 to 10, as necessary, to determine the cheapest
exchanger that will satisfy the duty. Usually this will be the one with the smallest
area.

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2.3 Design Strategy
The basic design procedure for air-cooled heat exchangers is similar to that for shell-and-
tube exchangers. An initial configuration for the unit is obtained using an approximate
overall heat-transfer coefficient together with the design guidelines given above. An
important preliminary step in the design process is the selection of the outlet air
temperature. This parameter has a major effect on exchanger economics. Increasing the
outlet air temperature reduces the amount of air required, which reduces the fan power
and, hence, the operating cost. However, it also reduces the air-side heat-transfer coefficient
and the mean temperature difference in the exchanger, which increases the size of the unit
and, hence, the capital investment. The same situation exists with water-cooled heat
exchangers, but the feasible range of outlet temperatures tends to be significantly greater
for air-cooled exchangers. Thus, optimization with respect to outlet air temperature (or
equivalently, air flow rate) is an important aspect of air-cooled heat-exchanger design.

Problem Statement
A liquid hydrocarbon stream with a flow rate of 250,000 lb/h is to be cooled from250◦F to
150◦F in an air-cooled heat exchanger. The unit will be mounted at grade and there are no
space limitations at the site. The design ambient air temperature is 95◦F and the site
elevation is 250 ft above mean sea level. An outlet air temperature of 150◦F is specified for
the purpose of this example. Average properties of the hydrocarbon and air are given in the
table below. A fouling factor of 0.001 h·ft2·◦F/Btu is required for the hydrocarbon, which is
not corrosive, and a maximum pressure drop of 20 psi is specified for this stream. Inlet
pressure will be 50 psia. The maximum allowable air-side pressure drop is 0.5 in.H2O. Design
an air-cooled heat exchanger for this service:

17
Solution
a) Make initial specifications
i. Tubing type
G-fin tubing with carbon steel tubes and aluminum fins is specified based on its
excellent durability. It is assumed that the environment at the plant site is not
highly corrosive; otherwise, bimetallic tubing would be a better choice.
ii. Tube size and layout
One inch OD, 13 BWG tubes with 10 fins per inch and a fin height of 0.625 in. are
specified with reference to Table. The tube layout is triangular (30◦) with a tube
pitch of 2.5 in.
iii. Draft type
Since the process fluid temperature is below 350◦F, an induced-draft unit will be
used. For simplicity, diffusers are not specified and it is assumed that
winterization of the unit is unnecessary.
iv. Headers
The pressure is low and based on the specified tube-side fouling factor, frequent
cleaning is not anticipated. Therefore, plug-type headers will be used.

b) Energy balances

For the specified outlet air temperature of 150◦F, the required mass flow rate of air is

c) LMTD

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d) LMTD correction factor
This factor depends on the number of tube rows and tube passes, which have not yet
been established. Therefore, in order to estimate the required heat-transfer surface
area, F =0.9 is assumed.

e) Estimate UD
Based on Table below, a value of 4.5Btu/h·ft2·◦F is assumed, which is in the expected
range for light hydrocarbon liquid coolers.

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f) Calculate heat-transfer area

g) Number of tube rows, tube length, and number of tubes

The bundle face area required for a given (standard) face velocity is

Assuming a (standard) face velocity of 600 ft/min from the design guidelines gives

Thus, the ratio of heat-transfer surface area to bundle face area is

From Table

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 The closest ratio is 107.2 for four tube rows. Using this value, the required face area is:

Based on the design guidelines, a tube length, L, of three times the bundle width, W, is
assumed, giving

Thus

The number of tubes is found using the value of ATot/L =5.58 from Table

Taking the closest integer divisible by four gives 224 tubes with 56 tubes per row. The
corresponding bundle width is the tube pitch times the number of tubes per row.
Allowing 2 in. for side clearances gives:

The actual bundle face area and (standard) face velocity are

h) Number of tube passes

The tube-side fluid velocity is:

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 Two, three, or four passes will give a velocity in the range of 3–8 ft/s. Since the tube-
side pressure drop allowance is fairly generous, four passes are chosen for the first trial
in order to maximize the heat-transfer coefficient and minimize fouling. Checking the
Reynolds number

The flow is fully turbulent and, hence, the configuration is satisfactory. This completes
the preliminary design calculations.

i) LMTD correction factor

The correct value of the LMTD correction factor can now be determined using
Figure12.A5 of “Process Heat Transfer; Principles and Applications” by “Robert W.
Serth”, Page Number 674.

j) Calculate required overall coefficient

22
k) Calculate hi

For turbulent flow (ReǦ104), the Seider–Tate equation is used in the form

l) Calculate ho
The maximum air velocity in the tube bundle is calculated using Equation

The face velocity is first converted from standard conditions to conditions at the
average air temperature. The fin thickness is taken as 0.013 in.

Equation below is used to calculate the air-side heat-transfer coefficient with ATot/Ao
=21.4

23
m) Wall temperatures and viscosity correction factors
No viscosity correction is required for the air-side heat transfer coefficient, so only Tp is
needed for the tube-side correction. In the present case, no viscosity data were given
for the tube-side fluid. Therefore, φi is assumed to be 1.0 and the wall temperature is
not calculated.

n) Calculate the clean overall coefficient

The clean overall coefficient is given by Equation below with the fouling factors
omitted. The contact resistance is neglected and ATot/Ai =26.3 is obtained from Table.

Since UC >Ureq, continue.

o) Fouling allowance
The tube-side fouling factor was specified in the problem statement as
0.001Btu/hft2◦F. except in unusual circumstances, air-side fouling is minimal and,
therefore, RDo is taken as zero. Thus, the total fouling allowance is:

24
p) Calculate the design overall coefficient

Since UD >Ureq =4.10 Btu/hft2.◦F, the heat exchanger is thermally workable.

q) Tube-side pressure drop

Following equations are used to calculate the tube side pressure drop

For laminar flow, the friction factor is given by:

For turbulent flow in commercial heat-exchanger tubes, the following equation can be
used for Re≥3000:

25
 Assuming 5-in. schedule 40 nozzles are used, the flow area per nozzle from Table B.1 of
“Process Heat Transfer; Principles and Applications” by “Robert W. Serth”, Page
Number 718. is 0.1390 ft2. Hence,

r) Air-side pressure drop

Thus

26
Design Summary
Number of fan bays: 1
Number of tube bundles per bay: 1
Number of fans per bay: 2
Bundle width and length: 11.8 ft×37 ft (including headers)
Number of tube rows: 4
Number of tube passes: 4
Number of tubes: 224
Tubing type: G-fin
Tube size: 1 in. OD, 13 BWG, 36 ft long
Tube layout: Equilateral triangular with 2.5-in. pitch
Fins: 10 fpi, 0.625 in. high, 0.013 in. thick
Heat-transfer surface area: 45,000 ft2
Draft type: Induced draft
Fan diameter: 10.5 ft
Motor size: 20 hp
Tube-side nozzles: 5-in. schedule 40
Headers: Plug-type box headers
Materials: Carbon steel tubes, aluminum fins, carbon steel headers, tube sheets, pass
partitions and nozzles

27
3 INTRODUCTION TO SIMULATION
3.1 Simulation Modeling and Analysis
Simulation modeling and analysis is becoming increasingly popular as a technique for
improving or investigating process performance. It is a cost-effective method for evaluating
the performance of resource allocation and alternative operating policies. In addition, it may
also be used to evaluate the performance of capital equipment before investment. These
benefits have resulted in simulation modeling and analysis projects in virtually every service
and manufacturing sector.

Simulation modeling and analysis is the process of creating and experimenting with a
computerized mathematical model of a physical system.

3.2 Purposes of Simulation

The simulation modeling and analysis of different types of systems are conducted for the
purposes of

• Gaining insight into the operation of a system

• Developing operating or resource policies to improve system performance

• Testing new concepts and/or systems before implementation

• Gaining information without disturbing the actual system

3.3 Advantages to Simulation

• Experimentation in compressed time

• Reduced analytic requirements

• Easily demonstrated models

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3.4 Disadvantages to Simulation
Although simulation has many advantages, there are also some disadvantages of which the
simulation practitioner should be aware. These disadvantages are not really directly
associated with the modeling and analysis of a system but rather with the expectations
associated with simulation projects. These disadvantages include the following:

• Simulation cannot give accurate results when the input data are inaccurate.

• Simulation cannot provide easy answers to complex problems.

• Simulation cannot solve problems by itself.

3.5 Steps in simulation

•Problem formulation

• Project planning

• System definition

• Input data collection

• Model translation

• Verification, validation

•Experimental design

•Analysis

• Presenting conclusions and results

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3.6 Computer Software

3.6.1 Introduction to HTFS/Aspen

The HTFS software was originally developed by the Heat Transfer and Fluid Flow Service
Division of the Atomic Energy Research Establishment, UK. The organization was later
privatized and eventually became a part of Hyprotech, Ltd., developer of the HYSYS chemical
process simulator. Hyprotech was subsequently assimilated by Aspen Technology, Inc.
(www.aspentech.com), which now markets the software as part of the Aspen Engineering
Suite. The software interfaces with HYSYS and the Aspen Plus process simulator so that the
extensive thermodynamics and physical properties (including petroleum properties)
packages available in the simulators can be utilized.

AspenTech is a leading provider of award-winning process optimization software and

services. AspenTech’s integrated aspenONE™ solutions enable manufacturers to reduce
costs, increase capacity, and optimize operational performance end-to-end throughout the
engineering, plant operations, and supply chain management processes.

Heat transfer equipment accounts for up to 30% of process capital costs and 90% of
operating costs. Designing or rating heat exchangers effectively is a complicated task.
Multiple engineering groups with different requirements are typically involved in each
aspect of the design process, using standalone tools with a minimum of integration. Manual
transfer of information results in costly errors, delays, and inconsistencies. An integrated
solution that meets the needs of all functional groups is required to provide a truly
optimized design that drives capital and operational efficiency.

The HTFS/Aspen program called ACOL is used for design and rating of air-cooled heat
exchangers. ACOL can operate in checking, simulation, and design modes. However, there
are nine simulation options available. The Standard Simulation option is the one most often
used. In this mode the outlet temperatures and pressures of the two streams are computed
from the given inlet temperatures, pressures, flow rates, and exchanger configuration. The
other simulation options allow different sets of specified and computed parameters. Other
parameters that can be calculated by the program are:

• Air mass flow rate

• Tube-side mass flow rate

• Tube-side inlet temperature

• Tube-side fouling factor

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There is also an option for natural convection that can be used to simulate an air-cooled
exchanger with the fans turned off.

ACOL generates a cost estimate and approximate setting plan for the heat exchanger. The
setting plan is useful for determining the overall dimensions of the unit and visualizing the
layout.

3.6.2 Calculation Modes

ACOL can perform a wide range of crossflow heat exchanger calculations. There are three
basic calculation modes

ACOL Calculation Modes

The program offers a range of exchanger widths and tube lengths,

Design
which satisfy the required thermal duty for a given X-side pressure
(only for air-cooled drop and tube and fin geometry. The designer can select a design
subject to constraints of maximum tubeside pressure drop and
exchangers)
maximum and minimum tubeside velocities.

Calculates a heat transfer area ratio (actual/required) to indicate

whether a given exchanger will meet a required duty, calculated
Checking from the tubeside flow rate and inlet and outlet conditions. An area
ratio equal to or greater than unity indicates that the exchanger will
meet the required duty

ACOL offers nine simulation options:

• SIMU - Standard Simulation. Calculates the tubeside outlet

temperature from the tubeside inlet temperature and flowrate, and
Simulation the X-side inlet temperature and flowrate. Similar to the Tubeside
Outlet Temperature option described below, but uses a combined
(for all types of
forward and backward iteration technique. This is the default option
cross-flow heat
and has shown to run quicker and to be more accurate than the
exchanger)
Tubeside Outlet Temperature option.

• SIM0 - Tubeside Outlet Temperature. Calculated from the tubeside

inlet temperature and flow rate, and the X-side inlet temperature
and flow rate. Similar to the Standard Simulation, described above,

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 but uses a purely forward iteration technique.

• SIM1 - Tubeside Inlet Temperature. Calculated from the tubeside

outlet temperature and flowrate, and the X-side inlet temperature
and flowrate.

• SIM2 - Natural Convection. Calculates the X-side flowrate during

natural convection. Can be used when all fans in an air-cooled heat
exchanger are switched off.

• SIM3 - Tubeside Flowrate. Calculated from the tubeside stream

inlet and outlet temperatures and the X-side inlet temperature and
flowrate.

• SIM4 - X-side Flowrate. Calculated from the specified tubeside

conditions and the X-side inlet temperature.

• SIM5 - Tubeside Fouling Resistance. Calculates a hypothetical

tubeside fouling resistance to give a process duty that matches the
duty calculated from the input tubeside conditions. This gives an
indication of the surplus heat transfer surface area available.

• SIM6 - X-side face velocity. Calculates the X-side mass flowrate

from a given X-side face velocity (at actual conditions) and the
bundle geometry and then carries out a Standard Simulation.

• SIM7 - Bundle pressure drop. Calculates the X-side mass flowrate

from a given bundle pressure drop (at actual conditions), inlet X-side
stream density and the bundle geometry.

3.7 Using ACOL

Use ACOL to rate the air-cooled heat exchanger designed in Example and compare
the results with the hand calculations

Solution
ACOL is run in checking mode for this problem and dry air is selected as the X-side
option on the Startup form for consistency with the hand calculations.

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 Data obtained from Example are entered on the appropriate input forms as indicated
below. Items not listed are either left at their default settings or left blank to be computed
by the program.

(a) Bundle geometry

(i) Nozzles/Headers

The number (1) and inside diameter (5.047 in.) of the inlet and outlet nozzles are
entered and plug is selected from the list of header types.

(ii) Bundle Setup

Number of Passes: 4 Number of Rows: 4

Number of Tubes: 224 Rows per Pass: 1

(iii) Tube Details

Tube ID: 0.81 in. Total Length: 432 in.

Tube OD: 1 in. Transverse Pitch: 2.5 in.

Longitudinal Pitch: 2.165 in.

Note: Either longitudinal pitch or tube layout angle can be given here.

(iv) Materials

Tube: Carbon Steel First Fin: Aluminum

Header: Carbon Steel

(b) Extended Surfaces

First type of fin or stud: G-fin (default)

Fin or stud crown frequency: 10/in.

Mean fin or stud thickness: 0.013 in.

Fin or stud tip diameter: 2.25 in.

(c) ACHE Geometry

(i) Unit Configuration

Number of Bays per Unit: 1 Number of Bundles per Bay: 1

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 Number of Fans per Bay: 2 Fan Configuration: Induced Draught

(ii) Fan Details

Fan Support Loss Coefficient: 0.2

Fan Drive Eefficiency: 95%

Approximate Fan Static Efficiency: 60%

Exchanger Fan Diameter: 126 in.

Fan Inlet Type: Conical

(d) Process Data

(i) Process Streams

(ii) Tube-side Fouling

Fouling Resistance: 0.001 h · ft2·◦F/Btu

(iii) Air Stream Conditions

Inlet Dry Bulb Design Temperature: 95◦F Altitude: 250 ft

(e) Options
(i) Main Output Options

Units of Output: British/US

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(f) Physical properties
The bulk properties of the hydrocarbon stream are entered by selecting <Direct
Input> for the Stream Data Source. A single level (50 psia) is entered and values for the
density (49.94 lb/ft3), liquid specific heat (0.55 Btu/lb ·◦F), liquid viscosity (0.5 cp), and liquid
thermal conductivity (0.082 Btu/h · ft ·◦F) are entered on the spreadsheet at a temperature
of 200◦F. No entries are required for the air stream. Hence, this completes the data entry for
this problem.

Running ACOL with the above input data generates the results summary shown
below.

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The manner in which the heat-transfer coefficients are presented in this file requires some
explanation. All coefficients are referenced to the external bare (unfinned) tube surface.
Thus, the value of 400Btu/h.ft2.◦F listed for the tube-side coefficient is actually hiDi/Do. The
value of hi is therefore:

The value of 400Btu/h.ft2.◦F listed for the dirty overall coefficient represents UD(ATot/Ao),
where UD is the overall coefficient based on the total external surface area. Hence, this value
must be divided by the area ratio to obtain UD. The area ratio calculated by ACOL is given as
21.5 in the second line of the results summary. Therefore:

The listed value of 162Btu/h.ft2.◦F for the air-side film coefficient is referenced to the bare
tube surface, i.e.,

The weighted efficiency of the finned surface computed by ACOL is given in the full output
file as 0.818. Therefore:

3.8 Results
Data from the results summary and the full output file were used to prepare the results
comparison shown in the following table.
Item Hand ACOL
Rei 69594 69622
Reo 8115 8442
hi (Btu/h.ft2.oF) 420 494
2 o
ho (Btu/h.ft . F) 9.12 9.29
2 o
UD (Btu/h.ft . F) 4.45 4.56
∆Pi (psi) 15.3 15.6
∆Po (in. H2O) 0.36 0.42

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REFERENCES
R.W. Serth: Air cooled heat exchanger, Process Heat Transfer Principles and Applications,
First edition, 2007, pp.630-668

Nicholas P. Cheremisinoff: Handbook of chemical processing equipment, 2000, pp. 12-19

Thakore/bhatt: Introduction to Process Engineering and Design, February 2008, pp. 159-160,
249-250

Ernest E. Ludwig: Applied process design for chemical and petrochemical plants, Volume 3,
3/e, pp. 252-253

Carl Branan: Rules of thumb for chemical engineers: a manual of quick, accurate solutions
3/e, section # 1, pp. 42 - 43

The Hague: Third World Petroleum Congress, 3/e, 1951, Proceedings Section VIII, PP. 201

Christopher A. Chung: HANDBOOK of simulation and modeling, 2004.

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