REPORT 2

HEAT EXCHANGER DESIGN ALGORITHM

By :

Ulayya Ardhyanesha Adiprana (13020101)

Lintang Mutiara Adya P. (13020113)
Muhammad Muis Firdaus (13020123)

CHEMICAL ENGINEERING
FACULTY OF INDUSTRIAL TECHNOLOGY
INSTITUT TEKNOLOGI BANDUNG
2022
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TABLE OF CONTENTS

TABLE OF CONTENTS 2
HEAT EXCHANGER DESIGN FLOWCHART 3
HEAT EXCHANGER DESIGN DESCRIPTION 4
Problem Identification 4
Selection of a Basic Heat Exchanger Type 4
Selection of a Tentative Set of Exchanger Design Parameters 5
Rating of the Design: Thermal Performance and Pressure Drops 6
Evaluation of the Design 7
Mechanical Design and Costing 7
REFERENCES 9

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HEAT EXCHANGER DESIGN FLOWCHART

Picture 1.1 Heat Exchanger Design Flowchart

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HEAT EXCHANGER DESIGN DESCRIPTION

In designing a heat exchanger there are several algorithms that need to be

considered. The following is a description of the heat exchanger design algorithm:
1. Problem Identification
The first step in designing a heat exchanger algorithm is to identify
the problem. Identifying the problem is the first step in developing a heat
exchanger algorithm. The proposed heat exchanger design in case (40)
must be able to define the heat transfer events that occur in a column.
Separation of the dimethyl ether product from contaminants is also
accomplished using the heat exchanger. DME, acetaldehyde, acetone, and
methanol are the components needed in this scenario, and the
compositions are as follows:

2. Selection of a Basic Heat Exchanger Type

Heat exchangers are increasingly being used in a variety of
industries to decrease and increase temperatures in an attempt to reach
technical criteria for a variety of products. The type of heat exchanger to
employ is determined by the type of flow that is used. For the case 40 the
right type of heat exchanger is shell and tube because it is fed by cooling
water and requires condensation.

Picture 2.1. Shell and Tube

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3. Selection of a Tentative Set of Exchanger Design Parameters

It is mandatory to firstly estimate the value of heat transfer
coefficient. This value can be obtained using a formula that consists of 5
transfer phenomena

or using the table of past approximations from other experiments.

In terms of Case 40, the cooling fluid is water and the overhead column is
filled with organic compounds which means that we can use the overall
heat transfer coefficient value of 240-650 W/m².K.
Other than that, we also need to make an estimation of the fouling
resistance value, where commonly is marked as 1 for counterflow heat
exchanger with single tube pass and 0.9 for the one with even number of
tube passes. For Case 40, we can use the first assumption.
Next, using the heat load balance formula

we can obtain the temperature values and later calculate the Log Mean
Temperature Difference. This is useful to estimate the required area
for the heat exchanger because the area’s equation consists of some of the
main features that are fundamentally needed to be known from the first
place, namely the number of tubes with diameter do and shell diameter Ds
to support the number of tubes with the available tube length. The formula
for area itself is

Meanwhile the further calculation for shell diameter Ds can be done using

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where CL is the tube layout constant that is measured based on the angle,
CTP is the tube count calculation constant where it would be assumed as
0.93 for a one tube pass heat exchanger, and PR is the tube pitch ratio
(PT/do). Lastly, the number of tubes, Nt, itself can be confirmed using the
equation

4. Rating of the Design: Thermal Performance and Pressure Drops

Thermal design difficulties are classified into two broad categories,
namely rating and sizing. When a heat exchanger is rated, the geometry
and dimensions of the heat exchanger are stated in detail. The entering
flow rates and temperatures of the fluids are known. The task is to
determine each stream's thermal efficacy (heat transmitted) and pressure
drop. In a sizing problem, the designer specifies the heat exchanger
requirement and must compute the heat exchanger size. Pressure drop
limitations are typically specified for each fluid stream. Due to the fact that
the entering flow rates, temperatures, and pressures are provided, as is the
heat duty (or leaving temperatures), the thermal efficacy and NTU
(number of transfer units) may be calculated immediately.

Pressure drop on the shell's side

Baffles are frequently used on the shell side of shell and tube
exchangers. They cause the fluid on the shell side to flow across the tubes.
This results in 'cross flow' situations, which enhances overall heat
transmission. However, the shell side fluid must overcome additional
impediments in the form of the tube bundle. This results in turbulence and
pressure loss on the exchanger's shell side. At times, turbulence is
preferable. For instance, a more viscous fluid is frequently used on the
shell side. Turbulence generated as a result of this results in an increased
heat transfer coefficient on the side of the viscous fluid.

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Pressure drop on the tube's exterior

In comparison to the shell side, the tube side flow is much more
streamlined, resulting in a modest pressure drop. The total tubeside flow is
partitioned into a series of smaller tubes. Thus, the pressure drop on the
tube side can be further reduced or increased / decreased by adjusting the
tube size or the number of tubes. Due to the smaller pressure drop on the
tube side, this configuration is preferred for services with a minimal
permitted pressure drop across the exchanger.

5. Evaluation of the Design

The performance of the heat exchanger is monitored solely for the
rate of heat transfer. The simplest indicator of a heat exchanger's
performance is the temperature change of the fluid being exchanged. As
we recall from our high school thermodynamics classes, the rate of heat
transfer is equal to the product of the rate of heat capacity and the
temperature change. Thus, temperature change can be read as the ratio of
heat transfer rate to heat capacity rate, i.e. when temperature change
increases, more heat is transferred from one fluid to another in comparison
to the heat capacity rate. Thus, a change in temperature might be construed
as a measure of the heat exchanger's performance.

6. Mechanical Design and Costing

After establishing the heat exchanger's specification, we can
optimize it to achieve the target cost. The cost analysis of constructing a
heat exchanger can be divided into three categories, namely:
a. The material utilized to construct the heat exchanger.
b. The material used to construct the heat exchanger's shell and tube
components.

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c. The amount of energy required by the pump to circulate the fluid,

as well as other parameters such as operating and maintenance
costs.
If the cost has not yet matched the production’s budget and/or the
specific heat exchanger requirement, the design may be altered until it
satisfies all the criteria. This can be done by modifying the features,
recalculating the formulas, or even creating 3D models in softwares.
Lastly, if the design is finished, we can proceed into building the heat
exchanger mechanically.

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REFERENCES

Geankoplis, C.J., Allen Hersel, Daniel H. Lepek. 2018. Transport Processes and
Separation Principles (5th Edition). New York: Pearson

Shah, Ramesh K. & Dušan P. Sekulić. (2003). Fundamentals of Heat Exchanger

Design. United States of America: Wiley.

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