Thermal Equipment Design Air Cooled Heat Exchanger Eng. Ahmed TeamahOneNote 2° VG Fie@oeesd —~W [8 BRIO RR fir Cooled Heat Exchanger ®O Ln troduction - Tt is a het exchanger thal uses Cooling Fluid. Sim ply, it is qa Finned tubes wheve ai is oukide at the Ans side ash, Nb so it need lage Suftace ala mack by Fins. Tubes Aves - Het Flid inside tubes es L's Frontal Area of Air or Fac ne of ne = fudineal % bur i bas se eT Hlgpll @ eae al Air Cw Gol g pi | lead! ps tye daw Ql Syaat) Glaoll 4 Tebes I 2 “Flow ie we “ 7 air as the cI Flu vate)! y Lode lye Lan by 3 % Lue Js 4 = Gnslant Flow air)! (yt 6S lr Face ata Ii beh 5 Qge= Ase Velw = Ace Vee = nstane Accu V a “Be M so let Vega” ¥, max “. Ag. Vi= A bt Oz Aru < | fis lll fee Vine Rabo eben Arce Sas J. O-t fae. Vince “Hens Vee tir? rid Ay kVi 2 ONLY,OneNote Oo VV Fie5e3@es| ~ is BHO BB @ As hay Wwe increase velo city of air by using bans‘ DInduced aa Tabes)| 95 Spa i) Poad dFt fin, Tibes I ano Spa Flow JI Qe Gree shea, pitch) Clongitedinal B © 7 Oo “O- O ‘pitch as Flow J) ols! & hous O- oO O- 3 “He fo, 2p +R 3p: an fev the above example ‘- Nez 4, N,=3 Neo le . N= Np Ne= Wx H PB PB olaitec = Td, Me te Hiekines of fin” (A) ow —_> \ =>oe 1999 Fieeees| ~: isBxlo ag © A,= 4, (lene 74,42) (tex ng) *BS Fk ashe +2bp)- 4] any whefe Np = hum bo oF Kas LL a gn Sp GAGS ibd = 4b Cd,+ &) ’ f= E{reaz}e[1-2] Vo Volume of fund * AY & Luly > = Volume of Caboid “chbinw gjlore i LW H let B ” Com paces ratio = zis th GC! | sluce p2 Gy (SH! poll &, toll slgel 55 supe pk Hl we « befell 5) See Ans J) 248 r5y) bs IS ae hak balence - Q: in @ BT) = m GAT)... = UA ST Gu. AT, = Fx AT h Gun hf Llow Ne Fe/ Lal tomer G3 =OneNote 2° VV Fie@ooe —~ [8 BRIO RB yaw! \ Re. i nat ot o Rhett RE lected her based on inside bq my 45 =A, by Re. = Yes bead = Fes hie at - aaling te Resi tinte owk side neglected x — BR Js based Ak on onbside aver based on Ae files ‘china! g Wika Dye » ir-Cooled H. . thermal analysis equations 2 Heat transfer coefficients, hi and he: D> resis) h; rc Velocry oF Aud insite tube First trial assume Vistesse~1.0 m/s pad coobeh ne, with negligible tube wall thermal resistance based on Aj ( U,= 7 ff . +ry+ ‘ Giver Oe Ly on AS Fin efficiency is calculated graphically using charts for circular fins. Q Mean Temperature Difference, ATm: AT = F XAT yeep =F a Heat load of a heat exchanger can be estimated from heat balance: q=(ne,) (.,-T,,)= (we, ),(T,,-T,.) a The total outer area, _4 4 Tar. a. Exchanger Dimensions, L, W and H: The dimensions of the air-cooled exchanger of the box type are expressed by: - a The length of the tube, L oy Its [ The width of the exchanger, The depth of the exchanger, Where, ‘Ne: number of tube per row 1; : number of rows Continuity equation for the air: Mie = PWLW ce wr =| ae py, @ then; Continuity equation for the process fluid: o sad fileS! fim, J) Ga HEx N, (2 WH —|—d? VV, N,=N.N,= Cc” rr X-( 2a? Vine and t PP. Shellonce = O OV FY Fi@@ ee 8 ~ |e BIS (a 2) WWM rive R 4 Where; Nip: number of tube passes The heat transfer area: A, = Bx Volume = B(WHL) A, . WHL=— Then; B (c) Where; fis the heat exchanger compactness, m”/m’, and defined as: 6, (, 2¢ 1 wa pam f147%) 4); ]] = % Too Prisyl Sy Q Total number of tubes, Ne: y,=N,n, = PP, 2 Pressure Losses, AP: Pp, df, Y Tube-side Pressure losses, AP: EX Shell a 7 la a Oe tule fl a”, ee oe Sf =(1.580nRe, - 3.28)" Y Airside Pressure losses, 4 Pus The pressure drop for flow across a bank of high-finned tubes is given by the following equation: — IN, Gin Par ‘air =ote 2 O VV Fi@eoeesd ~ 8 BxIO AR v ® For the flow of air across tube banks with equilateral triangular pitch, the friction factor correlation is: AV ted Yq induced . colt 1, Induced draught fan: 4 =1636Re,*"(R,/a, (Ae bore 2. Forced draught fan: thot emery = d, f =1.532Re,°* Where; G,,d, Re, = Gartln u d, d,= Pp (é, /2s,)°* {1M P, /d, - 1? d,= (Ag! Avro), 20,N,+1 The secondary losses causes often from 10 % to 25 % of bundle pressure drop. Notes - Dah given in pAblen 3 Br ore bundle <6 (Qo of heat load tol = Ql x Member of dle band les Fo Connected in patillel which mean afk bunts op etates on Same Condifisas oF Aw rates end temp, 65 taj? Grime dg Il 52 4 No, oF burdles PF sre '. As SF Qoy, nel d JI Jqos)! Bist JI ge thle Md J) z5y> Gl obec spond DOS pol se nat oem or ol S24OneNote ae VI Feo2ee 8 ~~ F§ BRO RB Air Cooled Problem: ‘An Induced draught air-cooled unit used to cool a process fluid of hydrocarbon liquid in a petroleum company. The cooler has 4 tube-bundles with each bundle has the following process and constructional data: LProcess conditions: Tem Units Process fuid Coolant Fluid name = Hydrocarbon liquid ‘Ais Flow rate kgs 384 120 ke’s Inlet temperature °C 150 5 Outlet temperature °C Gequired) Gequired) Specific heat, Cp ke 2a 1.004 ‘Dynamic viscosity, Nein TES 2ES Thermal conductivity, E Wimk 0.121 0.027 Density, 2 Kent 800 1.150 ‘Prandtl number, Pr = 173 07 Fouling &contact resistances, 77 | __F 0.021 (based on Kw A) Flow arealface area °c - 049 ‘IL Mechanical design data: Tem Symbol Waite Value Description ‘Tubes: size & layout Gd, pitch, angle mm 25.4, 21.18, 60.3, 30° ‘Tube material Catbon steel = = No. of tube passes Ne = 2 Bundle Tube length and width L&W m 9.75 & 3.25 ‘Number of bundles N = 4 No of deep rows N = 4 ‘No of tubes /row N. = 34 Fins: Alum, embedded, helical- ‘ype, number/m, thick., height, mm 433, 0.4, 15.875, ‘outer diameter, fin spacing 575,191 Finned surface effectiveness te = 0.86 Finned surface arealinner area AUAL = 28.25 Based on the above data calculate: a- The overall heat transfer coefficient U, based on the cooler outside surface area. b- The total cooling capacity of the air-cooled unit in MW. c- The exit temperatures of the exchanger fluids.8 B)*/5 8 8 ie VV Feeeesd ~ Steps :- Answer i D Wu h; Calcalahin :- a V, Cham mm) of iF nok given asserme V2 \mb D Re, 2 hj 2] hy Calealetion s- Vea C Bom nid of iF not given assume Ym max, 4) i: t Vos, Mim = DR d — U. —s Fst Yeguired as it is vatirg péablem use (E-NTW not (hn) (a) 4] Von bande” Dee Ch Crm Cg ee Sey D Qua? Smin€ TT) 7 9 i= , Aas (Bee Ae = ren Ted, 6M, =~ “A, Given NTU: Ute Coin st = - -c x YY Ez [- expC ec! —— vw eh, E {Ohya Que Oe Qe : me x)= oe Tg Te z%. "saOneNote ao VV Fiee@ee@ 8) ~ 8 Bx <7 anale ~~ Problem Solution Tube-Side Calculations: Heat transfer coefficient, hj From the continuity equation for the hot fluid N= My N= 4454 4x34, t 38.4 =800¢4 0.02118") V,=1.2615 mis * * Re, = Pld: _800*1.2615*0.02118 _ 44575 h, moony |mrnes essen? =1084 Wim?K t Air-Side Calculations: Heat transfer coefficient, ho From the continuity equation for the coolant fluid (air) m7 ARE 120=1.15x9.75x3.25xV,,, Vee =3.3 m/s , OFoes = GG OC OY FY Fi@ 0882) ~~: s Bx) . 33 “2%, = =6.72 mi = 5 049 . Re — Blexts_1.15*6.72*0.0254 _ 9015 = Ma 2*107 For induced draft fan with Ne< 6_& N, uN, <€& eis Vax noid Kay 033 post Ss 02/57 yo1134 i, Sar Sey 0.134) Pro* Ress Ly Ly 5 é os iy f t, h,=493 Wie'K ij PY, ss (z}+ 4 Given NAPA) nigh, (a) U, 2p 4 W’K 22.2 2 |ro0n+{ 5) 1054 0.86x 49.3 if By using e-NTU method: C, =m!Cp, =120x1040=1248 kWK C, =m}Cp, =38.4x2100=80.64 kWK then, Cmin = Ca = 80,64. kW/K Quasx = Cerin, (Thi - Tei) = 80.64 (150 - 25) = 10080 kW Ag = 28.25 Ai= 28.25 (x diL Ny = 28.25 (a * 0.02118 * 9.75 * 4 * 54) Ag= 3958.7 m? _U,A, _14%3958.7 _oer 6 OO OV Y ¥i@ @@@8, ~ ' |S Bix/5 RA e=1-exp(—Z-exp(-Cx NTU) =—1 =-—___ = 0 646 Cuz 1248 2= 0427-2 = Qo bundle Q.. 10080 (b) Then the cooling capacity for each bundle Q= 4304 kW a of bealles 24 xN And, the total cooling capacity, Qyora3 = 17.22 MW g=(mc, )( Len -t,,)= (mc, \.(G.-Te) bundle 4304 =(120x1.04),(r,, -25)=(38.4x2.1),(150—-7,,) Taa=96.63°C, and tep=595°C —> HE Rating Ulu als c? Design sa>\4 dsbOneNote n° VV Feeees ~~ [8 BRIO AR “Pesign pe len :- Alexandria University Thermal Equipment, ME413 Mechanical Engineering Department Date: January 23, 2014 Time: 3 hour erttta tite t tet eter iiiittettaity Solve The Folloiving Problems (105 points) An Induced draft air-cooled heat exchanger is used to cool water liquid-has to be designed for a closed-cycle process. The cooler has the following process and constructional data: L- Process conditions: Ttem Units Tube-side Bundle-side Fluid name ~ Water liquid [Ar | Flow rate ~ m/s __0.005 50 ms Inlet temperature °C 120 (at 5 bar) 30 Outlet temperature °C 60 a | Correction factor F = 1.0 Specific heat, Cp iihkgK 4.188 101 Density, p im 1000 12 Fluid velocity mis Vel mis Ve=3 mis Overall heat transfer Coeff, Ug | W/m7K 30 ‘L_Mechanical design data Number of bundles Fins: Alum, embedded, helical- : type, number/m, thick. height, | ng te rdo, S| mm 433, 0.4, 15.875, 57.15, 1.91 [outer d diameter, fin spacing (Fined) surface effectiveness Finned surface area/inner area AJVolume (Gmpe Based on the above data calculate: a- The dimensions of the air cooler, Ay b- The total number of tubes and the number of deep rows. (25 points) Rewad @ A, WELL. DN, 0.86 28.25 th =OneNote Steps : - © DA. a) Q= mn @ AT) rh GY) 27 , un Know temp ~ Dd OT, OM cre 27 OQ? UA. Shim " As=# — «Ay = (As ' aN, < tdi, Fam ray pV, we ae 7 New Nye bat ad tube ‘noe do fy a ad afl A;=14 6M Ll 4] W Bonn air mass Flow vate LM ef Veace SW L Bo oWit 3 He a po of 7 ae eines Pir p- 4s ( ne “ a= DT = 46.8" me “AN in = 16-93 POS ; 6c . FaF3%c ae V J Fie@oee® ~~ [8 Bx9 Re Solution :- ® Q- ma ATL 2 mG ST, 6,005 x lvoox 4, 1F Bx (leo -6)= $6 x hexlo)x(Tz3) 2. Q+ 12564 Kw, Te, = 50.73% : @: U, A, aT - ~. 1256 4xle 23x Ax 46.53 — 4 A= 892.4 me " A; = BR4 2 3ho5 me 2. 2S mh MR J 0.005 p = RX Ix = x ow2ll8 x i “ Ane So tube > ad Ape Wd LM L=15. 83m bf -. Sox x 3x wx 15. 83 ~~ We |,053m ae 892.4 Le i Be Be 2 Foye Beet Vol. (.oS3xHx 15, 33 7 arf Ve We ‘He 0.0f 65 m 3 #OneNote 1° VV Feoeoe0oes —~ § |S Bx RR HN xp bit He jiven 10 Gestion not ke