Aspen Exchanger Design and Rating - Learn The Basics

Rigorous Design and Rating of Aspen EDR Heat Exchangers
Aspen Exchanger Design & Rating
© 2019 Aspen Technology, Inc. AspenTech®, aspenONE®, the Aspen leaf logo,
the aspenONE logo and OPTIMIZE are trademarks of Aspen Technology, Inc. All rights reserved.
Contents
Design an Oil Cooler Exercise ............................................................................................. 2
Steps...................................................................................................................................... 2
1 Perform Exchanger Design ........................................................................................ 2
2 Review Results and Re-Design ............................................................................... 11
3 Transfer Geometry to Rating/Checking................................................................... 15
Additional Resources .......................................................................................................... 18
© 2019 Aspen Technology, Inc. AspenTech®, aspenONE®, the Aspen leaf logo, the aspenONE logo, and OPTIMIZE
1
are trademarks of Aspen Technology, Inc. All rights reserved.
Design an Oil Cooler Exercise

The objective of this workshop is to design a single-phase heat exchanger using
Aspen Shell & Tube Exchanger for an unknown fluid where only the minimum
required properties are known and evaluate the impact on the geometry and cost of
the unit by switching the allocation of the fluids
The Design/Sizing calculation will determine the shell length and diameter, the
nozzle sizes, the number of tubes and passes, the number of baffles and baffle cut,
along with other exchanger geometry considerations. Other details such as tube
layout, shell and header, baffle and tube type will use program defaults.
The Aspen Shell & Tube Exchanger design logic will optimize the heat transfer
against the allowable pressure drop on both the shell and tube sides. The program
has built in heuristic rules, which will stop it searching once it realizes that further
calculations are not required.
This exercise includes the following tasks:

• Perform Exchanger Design
• Review Results and Re-Design switching the allocation of the fluids
• Transfer Geometry to Rating/Checking
Steps
1 Perform Exchanger Design
In this workshop, you will perform your heat exchanger design calculation from
scratch – rather than opening a pre-built starter file. Recall that the minimum
required inputs for a Design/Sizing calculation include stream process conditions,
physical property data, and any geometry settings/defaults.
1.1 Create a new case
Start a new Aspen Shell & Tube Exchanger case by selecting File | New, and then
checking the Shell & Tube box. Click Create to start your new case.
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Aspen Shell & Tube Exchanger will open to the Console menu. If you wish, you
could use the Console to provide your process condition inputs and exchanger
geometry preferences. However, the instructions and screenshots in this workshop
will follow along with the dedicated input forms in the Input section of the EDR user
interface.
1.2 Change the Unit Set
From the Home tab of the ribbon, set your preferred unit set. All input data in this
exercise will provided in both English/Imperial and Metric units.
Hint: You can set a particular unit set as your program default, so that it will be
active each time you open the Aspen Exchanger Design & Rating product suite.
Just navigate to the Customize ribbon tab and select the Units Database button.
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1.3 Select the Hot Fluid Location
Select the Input | Problem Definition | Application Options form from the EDR
Navigation Pane.
Change the Location of hot fluid to Tube side and the geometry dimensional
standard to US. Keep all other settings at their defaults.
1.4 Enter the Process Conditions
The next series of inputs required are the hot and cold side process conditions. In
Aspen Shell & Tube Exchanger, you can navigate to/from required inputs such as
these process conditions in either of two ways.
• Manually navigate on the form from the EDR Navigator, or
• Use the Next button.
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The Next button is located on the Home tab of the EDR ribbon. It is a very helpful
feature as it will always take you to the next required input as you define your
Aspen Shell & Tube Exchanger calculation input. Once you have completed all
required input, pressing the Next button would prompt the program to calculate.
Click the Next button; this should change the active menu to the Problem
Definition | Process Data form.
• Specify the name of the Hot Stream/Tube Side fluid as Fuel Oil, and the
name of the Cold Stream/Shell Side as Water.
• Using the table below, enter the process data for this heat exchanger:
Hot Stream/Tube Side (Fuel Oil) Cold Stream/Shell Side (Water)
284000 kg/h 59100 kg/h

Flow rate Flow rate
(626102 lb/h) (130291 lb/h)
213 °C 50 °C
Temperature In Temperature In
(415.4 °F) (122 °F)
Temperature 168 °C Temperature 165.3 °C
Out (334.4 °F) Out (329.5 °F)
12 bar 50 bar
Pressure In Pressure In
(174.05 psia) (725.19 psia)
Allowable 1.5 bar Allowable 1 bar
pressure drop (21.76 psi) pressure drop (14.5 psi)
Fouling 0.0005 m2*K/W Fouling 0.000088 m2*K/W
resistance (0.0028 ft2*hr*°F/BTU) resistance (0.0005 ft2*hr*°F/BTU)
After specifying these parameters, your Process Data form should be completed.
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1.5 Define the Physical Property Data
The next requirement for a Design/Sizing calculation is physical property data for
both sides of the exchanger.
Physical properties can either be manually specified by the user, imported from a
process simulation program (i.e. Aspen Plus or HYSYS), or generated internally in
Aspen EDR via a component database. In this workshop you will make use of the
internal databases to retrieve properties for the cold side fluid, and manually define
physical properties for the hot side fluid.
Click the Next button; this should take you to the Property Data | Hot Stream
Properties form.
Go back up one menu in the EDR Navigation Pane to verify which physical
property option will be employed. This selection is made on the Property Data |
Hot Stream (1) Compositions form.
In the Navigation Pane, select the Property Data | Hot Stream Compositions
menu item. Keep the Physical property package selected as User specified
properties.
Go to Property Data | Hot Stream Properties form and note the Pressure Levels
in the top-right corner of the window.
Click and highlight the 10.5 bar (152.3 psia) pressure level and remove it by
clicking the Delete Set button. We will only provide pressure information for the 12
bar (174.05 psia) pressure level.
6
Using the table below, provide physical property data for the hot side stream at the
two temperatures given (i.e. inlet and outlet temperatures):
Property 1 2
Temperature 213 °C (415.4 °F) 168 °C (334.4 °F)
Liquid density 879.4 kg/m3 909.8 kg/m3
(54.9 lb/ft3) (56.8 lb/ft3)
Liquid specific heat 2.34 kJ/kg*K 2.18 kJ/kg*K
(0.559 BTU/lb*°F) (0.521 BTU/lb*°F)
Liquid viscosity 1.94 mPa*s (1.94 cP) 3.37 mPa*s (3.37 cP)
Liquid thermal conductivity 0.1 W/m*K 0.107 W/m*K
(0.058 BTU/ft*hr*°F) (0.062 BTU/ft*hr*°F)
Check your inputs against the screenshot below:
Click the Next button, which should take your to the Property Data | Cold Stream
Properties form. For the cold side, rather than manually defining property data,
you’ll access physical properties from an internal database.
7
Select the Property Data | Cold Stream Compositions form and from the
Physical property package menu item select the Aspen Properties option. At the
bottom of the window, click the Search Databank button.
A component search window will appear; type in “water” in the search field, click
the Add selected compounds button, and then select Use Selected Compounds
to accept the component. Water should now be shown in the component list for the
cold side.
8
Go to the Property Methods tab and select IAPWS-95 in Aspen property method
Move on to the Property Data | Cold Stream Properties menu. You can view the
accessed properties for water by clicking the Get Properties button.
1.6 Review the Geometry Inputs and Limits
Move on by manually selecting the Exchanger | Geometry | Geometry Summary

form from the Navigation Pane.
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Note that inputs are not required for exchanger geometry in a Design calculation.
You may adjust some of the geometry defaults, but it is not required. In this case,
leave all current inputs at their defaults.
Go to Program Options | Design Options | Geometry Limits and specify design

constrains for tube length and shell diameter.
Note: Geometry limits are taken as a design constrains, the selected design will be
using, in most of the cases that dimensions.
1.7 Run and Save the mode
The model is ready to solve. Click the Run button to perform the design.
Save your case as Hot-TubeSide.edr.
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2 Review Results and Re-Design
Using the available results forms in Aspen Shell & Tube Exchanger, you are asked
to record some results from your initial design. To do so, we will make use of the
Recap of Designs tool, which allows for customization of your results, along with
comparison of one design to another.
2.1 Customize the Recap of Design report
Click the Result Summary | Recap of Designs menu item. Once there, click the
Customize button at the bottom of the results table.
Note: The Recap of Designs menu can be fully customized to include any
exchanger parameters or properties you wish. You may add additional variables on
to the default list, remove variables, or even clear out the entire list and build a new
one from scratch!
Select Shell ID on the list and click the double-arrow button pointing towards the
left to clear out all un-selected variables.
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Shell ID should remain as the only selected variable. Keep this variable and add
on Tube length – actual from the list of Available variables. Simply select it and
click the single-arrow button pointing towards the right.
Continue in the same way adding the following variables:
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Selected variables…
Area reqd., dirty Area actual effective
Pressure drop, SS Pressure drop, TS
Shells in parallel Shells in series
Film coef overall, SS Film coef overall, TS
Hot side fluid location Total price
You can save this list to use it later by changing the name and click on Save List
The results would look like in the following screenshot:
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2.2 Change the Hot Fluid Location and review the results
Compare the resulting heat exchanger design assuming the hot fluid is on the shell
side. Switch the Location of hot fluid on the Problem Definition | Application
Options form and re-run the design.
Save your file as ELG131-Hot-ShellSide.edr
Check the warnings and messages after this run.
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Record your results from the Recap of Designs and compare them to the case
where the hot fluid is on the tube side.
Results Hot fluid on tube side Hot fluid on shell side

Shell ID
Tube length - actual
Area reqd., dirty
Area actual effective
Pressure drop, SS
Pressure drop, TS
Shells in parallel
Shells in series
Film coef overall, SS
Film coef overall, TS
Hot side fluid location
Total price
QUESTION: Which option gives a lower cost exchanger? Less heat transfer area
required?
3 Transfer Geometry to Rating/Checking
While the lower cost/smaller area heat exchanger might seem like a better design,
recall how you received some vibration warnings associated with that design. The
exchanger with hot fluid on the tube side had no vibration concerns. Nonetheless,
we’d like to explore the geometry of the exchanger design with the hot fluid in the
shell (V10) to see if any adjustments can remove this vibration issue. We’ll do so in
the Rating/Checking mode of Aspen Shell & Tube Exchanger.
Note: This task of the workshop will not include a thorough overview of exchanger
vibration and its modes.
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3.1 Change the Calculation Mode
In the Home ribbon tab, click on the Rating/Checking button. Select the Use
Current button from the resulting pop-up.
3.2 Run the model
Run the case in Rating mode and check the Warnings & Messages form.
You will get the Operation Warning 1611: Flow induced vibration analysis has
identified problems
3.3 Change the unit geometry
Now that the case is in Rating mode, you may make any adjustments to the
exchanger geometry that you wish. View the Exchanger Geometry | Geometry
Summary form.
To try and alleviate the vibration warnings indicated with the hot fluid on the shell
side, you will adjust a pair of parameters on the heat exchanger baffles. Try
changing the baffle center-center spacing and the number of baffles.
Enter a baffle spacing (center-center) of 381 mm (15 in) and the total number of
baffles at 10.
These changes might require a re-design of the heat exchanger tubesheet. To

facilitate this, delete the number of tubes value that also appears on the
Exchanger Geometry | Geometry Summary form.
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Run the Rating/Checking case.
QUESTION: Is the vibration warning still present? Are any other warnings present?
QUESTION: What is the new required surface area for the heat exchanger?
How could you improve the exchanger design so that the exchanger is once again
sufficiently sized to handle the heat duty requirements? Discuss any possibilities
with your instructor and fellow students. Feel free to try making changes to your
heat exchanger rating case.
View some of the other result reporting forms. Save your case as Hot-ShellSide-
Rating.edr when finished.
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Additional Resources
For more information, visit the pages below:
Public Website
www.aspentech.com
Resource Center
www.aspentech.com/en/resource-center
Customer Support Portal
esupport.aspentech.com
Training
training.aspentech.com
AspenTech eLearning
www.aspentech.com/eLearning
About AspenTech
AspenTech is a leading softw are supplier for optimizing asset performance. Our products thrive in complex,
industrial environments w here it is critical to optimize the asset design, operation and maintenance lifecycle.
AspenTech uniquely combines decades of process modeling expertise w ith big data machine learning. Our
purpose-built softw are platform automates know ledge w ork and builds sustainable competitive advantage by
delivering high returns over the entire asset lifecycle. As a result, companies in capital-intensive industries can
maximize uptime and push the limits of performance, running their assets faster, safer, longer and gr eener.
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Rigorous Design and Rating of Aspen EDR Heat Exchangers

Aspen Exchanger Design & Rating

Design an Oil Cooler Exercise

This exercise includes the following tasks:

1 Perform Exchanger Design

1.1 Create a new case

1.2 Change the Unit Set

1.3 Select the Hot Fluid Location

1.4 Enter the Process Conditions

Hot Stream/Tube Side (Fuel Oil) Cold Stream/Shell Side (Water)

284000 kg/h 59100 kg/h

1.5 Define the Physical Property Data

Check your inputs against the screenshot below:

1.6 Review the Geometry Inputs and Limits

Move on by manually selecting the Exchanger | Geometry | Geometry Summary

Go to Program Options | Design Options | Geometry Limits and specify design

1.7 Run and Save the mode

Save your case as Hot-TubeSide.edr.

2 Review Results and Re-Design

2.1 Customize the Recap of Design report

Continue in the same way adding the following variables:

The results would look like in the following screenshot:

Save your file as ELG131-Hot-ShellSide.edr

Check the warnings and messages after this run.

Results Hot fluid on tube side Hot fluid on shell side

3 Transfer Geometry to Rating/Checking

3.1 Change the Calculation Mode

3.2 Run the model

3.3 Change the unit geometry

These changes might require a re-design of the heat exchanger tubesheet. To

Run the Rating/Checking case.

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