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Heat Transfer Equipment 1. Heat Exchangers: Chemical Engineering Design
Heat Transfer Equipment 1. Heat Exchangers: Chemical Engineering Design
1. Heat Exchangers
• Tubular Exchangers
• Convection
Q = U A DT
• Usually the governing mechanism in most process applications
Q U A Th Tc
ro
ln ro / ri
ri
1 1 1
ro U ro h o k ri h i
• Q = U A ΔTm
DTlm
ΔTh ΔTc
ΔT
ln h
ΔTc
A useful shortcut to know:
DTh/DTc 1.0 1.5 2.0 3.0 4.0
DTlm / DTc 1.0 1.2 1.4 1.8 2.2
DTgeom mean = √(DTc x DTh)
DTgeom mean /DTc 1.0 1.22 1.41 1.73 2.0
Q = U A F ΔTlm
• F is sometimes called Ft
hot out
hot in
cold out cold in
• Tubular Exchangers
Into this -
Baffle assembly
Inserting
Welding the shell tubes
Final
product
Tubesheet
Source: Bos-Hatten Inc.: www.Bos-Hatten.com
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
Tube Bundles
U-tubes
Tubesheet
Baffles
Source: UOP
A B • B Type
• Must break piping connections to open
exchanger
• Single tube side joint
C N • C Type
• Channel to tubesheet joint eliminated
• Bundle integral with front head
• N Type
D • Fixed tubesheet with removable cover
plate
• D Type
• Special closures for high pressure
applications
F • F Type
• Counter current flow obtained. Baffle leakage problems.
G
• G Type
• Lower pressure drop
• H Type
H • Horizontal thermosyphon reboilers
• J Type
J • Older reboiler designs
• K Type
K • Phase separation integral to exchanger
• X Type
X • Lowest pressure drop, low F factor
• M Type
L M • Same as B type front head
• N Type
P • Same as N type front head
N
• P & W Types
• Rarely used
S T
• S Type
• Floating head with backing ring
U W
• T Type
• Floating head pulls through shell
• U Type
• Removable bundle without floating head
t1 R = (T1 - T2)
T2 (t2 – t1)
• Most simulators
show an error if
there is a low F
factor
• For example, in
UniSim Design
the exchanger
shows up
yellow
(c) E102
30 60 90 45
• Sometimes use larger pitch for easier cleaning (but bigger shell,
lower shellside h.t.c.)
FEATURE USE PATTERN:
lower DP on shellside square (effective only at low Re number)
shellside fouling square - easier cleaning
horizontal shellside square - prevent vapor blanketing
boiling
decrease shell size fit 15% more tubes if triangular pitch used
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
Baffle Types & Shell Flow Patterns
max unsupported
tube span
FULL
TUBEFIELD
max unsupported
tube span
FULL
TUBEFIELD
max unsupported
tube span
• Tubular Exchangers
Vapors
Air, 10 psig 10 10
Hydrogen, 50 psig 100 100
Hydrogen, 500 psig 400 400
Hydrocarbon vapor, 50 psig 60 60
Noncondensible gas, 2 psig 5 5
Note: Coefficients are based on 3/4 inch diameter tubes. For Tube side flows, correct by
multiplying by 0.75/Actual OD. Estimated accuracy is 25%. For 50% hydrogen in
vapor, reduce h to 2/3 of pure H2 value.
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
Approximate Fouling Factors
Fluid f (Btu/(hr.ft2.F))
• Tubular Exchangers
U
tubes
Plates
Gasket
Source: Alfa-Laval, www.AlfaLaval.com
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
Gasket Layout of Alternating Plates
• Disadvantages
• Lots of gaskets
• Lower design pressure, temperature
• External leakage if gaskets fail
• Applications
• Food processing, brewing, biochemicals, etc.
Source: Alfa-Laval,
Alfa-Laval www.AlfaLaval.com
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
Welded Plate Heat Exchangers
Feed Outlet
Effluent Inlet
Vent
• Advantages
– Higher thermal efficiency
Hot End Bellows
– Single unit can replace multiple shell &
Source: Alfa-Laval Packinox
Manhole
Feed Header
Effluent Header tube units
Bundle Support
– Closer approach to hot inlet temperature
Pressure Vessel
– Low pressure drop
Welded
Plate Bundle – Little chance of vibration problems
– Excellent distribution of two phase flows
• Disadvantages
– Single alloy material for plates
Bracket
(or Skirt)
– Difficult to clean
– Few manufacturers at large scale (Alfa
Effluent Header Laval Packinox)
Venturi
Spray Bar
Liquid Feed • Used in large scale clean services that
Cold End Bellows
Recycled Gas Inlet need close temperature approach
Effluent Outlet
© 2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
Questions ?