Heat Exchanger Design

Introduction and General Workflow

May 24, 2023

 Objectives

Provide new Process Engineers with a reference

for Heat Exchanger Design
Review theory and the work process
Discuss datasheet input from a process
engineering perspective

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 Basic Theory

Q=mCp∆T (sensible heat)

 Q=mλ (phase change)
 Q=UA(EMTD) (overall exchanger)

U – heat transfer coefficient is a measure of the resistance to heat transfer

EMTD – Effective Mean Temperature Difference. Sometimes referred to as
Corrected Mean Transfer Difference (CMTD). This is a corrected form of Log Mean
Temperature Difference which compensates for deviations from true cocurrent or
countercurrent flow.

Hot
Q Cold

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 References for Heat Transfer Theory

GPSA Engineering Databook

Perry’s Chemical Engineer’s Handbook
Heat Exchanger Specialist
 Has detailed knowledge of exchanger design

Is responsible for details such as: Baffle Spacing, Vibration, Inlet/Exit
Velocities, Tube Layout

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 Types of Exchangers

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 Shell and Tube

 TEMA Types

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 Shell and Tube
 Shell vs. Tube Side
– Shell Side – Provides higher turbulence and increased heat transfer for lower flows

High Viscosity

Low Flow

Condensing or Mixed Phase
– Tube Side – Better velocity control, economic considerations

Corrosive Fluid

High Temp / High Pressure

High Available Pressure Drop

Cooling Water or Fouling Service

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 Services

 Cooler / Heater
 Feed/Effluent
 Reboiler – Thermosiphon, Kettle, Forced Circulation
 Condenser
 Trim Cooler
 Intercooler / Aftercooler
 Superheater
 Vaporizer
 Steam Generator
 Waste Heat Boiler

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 Typical Workflow

Gather Data

Select Type

Establish Pressure Drop and

Velocity Criteria

Provide Process Input on the

Datasheet

Mech / Process Heat

Check Results Exchanger Design
Specialist

Assemble Calc
Package

Check by
Process Engr

Issue Mech
Vendors
Datasheet Group

Review and Squad Check

Comment Design

9 05/24/23
 Gathering Data: Heat Curves
Heating Curve E-1300 (Cold Side)
Total Vapour Vapour Vapour Vapour Vapour Liquid Liquid Liquid Liquid Liquid Liquid Latent Liquid Critical Liquid Critical Vapor Liquid Vapor Critical Vapor Critical
Number Pressure Temperature Enthalpy Vap Frac Density Viscosity Therm Cond Heat Capacity Enthalpy Density Viscosity Therm Cond Heat Capacity Enthalpy Surf Tens Heat Temp Pressure MW MW Temp Pressure

KG/CM2 C M*KCAL/HR FRAC KG/M3 CP KCAL/HR-M-C KCAL/KG-C M*KCAL/HR KG/M3 CP KCAL/HR-M-C KCAL/KG-C M*KCAL/HR DYNE/CM KCAL/KG C KG/CM2 C KG/CM2
1 9.1399 37.7778 6.6582 0.0860 2.5227 0.0116 0.0651 1.1498 3.0600 667.8789 0.2920 0.1073 0.5278 3.5982 17.7673 83.3363 243.6457 31.3710 7.2879 90.3667 -200.4662 17.6820
2 9.1399 74.8148 13.3157 0.1944 4.6207 0.0134 0.0539 0.7744 6.5956 635.4380 0.2216 0.0973 0.5741 6.7201 14.1657 77.1699 245.9053 31.1785 14.8562 91.2104 -158.4894 19.1529
3 9.1399 111.8518 23.3965 0.5180 8.8684 0.0134 0.0441 0.6108 17.0911 601.9511 0.1645 0.0870 0.6220 6.3054 10.9714 70.5684 251.4184 30.8108 30.9161 93.3589 -71.6239 21.8998
4 9.1399 138.1326 33.9092 1.0000 12.5683 0.0128 0.0400 0.5803 33.9092 45.6239 4.4657 23.9987
5 9.1399 148.8889 35.2694 1.0000 12.1924 0.0131 0.0419 0.5898 35.2694 45.6239 4.4657 23.9987
6 9.1399 185.9259 40.1215 1.0000 11.0698 0.0140 0.0488 0.6222 40.1215 45.6239 4.4657 23.9987
7 9.1399 222.9630 45.2291 1.0000 10.1524 0.0149 0.0561 0.6536 45.2291 45.6239 4.4657 23.9987
8 9.1399 297.0370 56.1741 1.0000 8.7330 0.0166 0.0723 0.7127 56.1741 45.6239 4.4657 23.9987
9 9.1399 334.0741 61.9908 1.0000 8.1698 0.0175 0.0811 0.7403 61.9908 45.6239 4.4657 23.9987
10 9.1399 371.1111 68.0228 1.0000 7.6781 0.0183 0.0903 0.7665 68.0228 45.6239 4.4657 23.9987

Heating Curve E-1300 (Cold Side)

Total Vapour Vapour Vapour Vapour Vapour Liquid Liquid Liquid Liquid Liquid Liquid Latent Liquid Critical Liquid Critical Vapor Liquid Vapor Critical Vapor Critical
Number Pressure Temperature Enthalpy Vap Frac Density Viscosity Therm Cond Heat Capacity Enthalpy Density Viscosity Therm Cond Heat Capacity Enthalpy Surf Tens Heat Temp Pressure MW MW Temp Pressure

KG/CM2 C M*KCAL/HR FRAC KG/M3 CP KCAL/HR-M-C KCAL/KG-C M*KCAL/HR KG/M3 CP KCAL/HR-M-C KCAL/KG-C M*KCAL/HR DYNE/CM KCAL/KG C KG/CM2 C KG/CM2
1 7.3822 37.7780 6.8236 0.0957 2.2421 0.0117 0.0622 1.0747 3.2775 668.4764 0.2941 0.1073 0.5276 3.5461 17.8615 83.4773 245.0176 31.3474 8.0128 90.6973 -196.2613 17.8666
2 7.3822 74.8150 13.9346 0.2314 4.3011 0.0134 0.0504 0.7218 7.5396 636.5602 0.2236 0.0973 0.5736 6.3950 14.2979 77.4448 247.7580 31.1403 17.0938 91.7125 -146.1391 19.5779
3 7.3822 111.8520 25.3983 0.6453 8.2550 0.0130 0.0409 0.5858 20.7743 605.4203 0.1700 0.0872 0.6200 4.6241 11.2486 71.1109 255.2636 30.6334 35.5077 94.7202 -47.2110 22.6316
4 7.3822 129.8090 33.0063 1.0000 10.2906 0.0125 0.0385 0.5698 33.0063 45.6239 4.4657 23.9987
5 7.3822 148.8890 35.3920 1.0000 9.7602 0.0130 0.0418 0.5871 35.3920 45.6239 4.4657 23.9987
6 7.3822 185.9260 40.2252 1.0000 8.8843 0.0139 0.0487 0.6201 40.2252 45.6239 4.4657 23.9987
7 7.3822 222.9630 45.3179 1.0000 8.1626 0.0149 0.0561 0.6519 45.3179 45.6239 4.4657 23.9987
8 7.3822 297.0370 56.2408 1.0000 7.0372 0.0166 0.0722 0.7115 56.2408 45.6239 4.4657 23.9987
9 7.3822 334.0740 62.0490 1.0000 6.5881 0.0174 0.0810 0.7393 62.0490 45.6239 4.4657 23.9987
10 7.3822 371.1110 68.0737 1.0000 6.1950 0.0182 0.0903 0.7656 68.0737 45.6239 4.4657 23.9987

Heating Curve E-1300 (Hot Side)

Total Vapour Vapour Vapour Vapour Vapour Liquid Liquid Liquid Liquid Liquid Liquid Latent Liquid Critical Liquid Critical Vapor Liquid Vapor Critical Vapor Critical
Number Pressure Temperature Enthalpy Vap Frac Density Viscosity Therm Cond Heat Capacity Enthalpy Density Viscosity Therm Cond Heat Capacity Enthalpy Surf Tens Heat Temp Pressure MW MW Temp Pressure

KG/CM2 C M*KCAL/HR FRAC KG/M3 CP KCAL/HR-M-C KCAL/KG-C M*KCAL/HR KG/M3 CP KCAL/HR-M-C KCAL/KG-C M*KCAL/HR DYNE/CM KCAL/KG C KG/CM2 C KG/CM2
1 4.9215 371.1110 76.3872 1.0000 1.7801 0.0214 0.1164 0.7864 76.3872 19.7790 -116.8484 22.9016
2 4.9215 334.0740 70.1769 1.0000 1.8890 0.0206 0.1061 0.7649 70.1769 19.7790 -116.8484 22.9016
3 4.9215 297.0370 64.1433 1.0000 2.0123 0.0197 0.0961 0.7422 64.1433 19.7790 -116.8484 22.9016
4 4.9215 260.0000 58.2959 1.0000 2.1528 0.0188 0.0866 0.7184 58.2959 19.7790 -116.8484 22.9016
5 4.9215 185.9260 47.2015 1.0000 2.5033 0.0169 0.0687 0.6666 47.2015 19.7790 -116.8484 22.9016
6 4.9215 148.8890 41.9765 1.0000 2.7256 0.0159 0.0604 0.6386 41.9765 19.7790 -116.8484 22.9016
7 4.9215 111.8520 36.9813 1.0000 2.9921 0.0148 0.0526 0.6091 36.9813 19.7790 -116.8484 22.9016
8 4.9215 94.5001 34.7234 1.0000 3.1360 0.0143 0.0491 0.5949 34.7234 19.7790 -116.8484 22.9016
9 4.9215 74.8150 28.1793 0.7940 2.7570 0.0138 0.0495 0.6443 26.7868 802.8364 0.2781 0.1038 0.4428 1.3926 21.4313 91.1582 300.0888 44.6147 16.4791 86.6598 -137.4204 21.8302
10 4.9215 37.7780 15.1400 0.3887 1.6794 0.0120 0.0577 0.9454 13.0133 824.3409 0.3442 0.1128 0.4093 2.1267 24.8790 94.1503 288.9616 45.5182 8.9971 83.1484 -185.8943 19.0535

Heating Curve E-1300 (Hot Side)

Total Vapour Vapour Vapour Vapour Vapour Liquid Liquid Liquid Liquid Liquid Liquid Latent Liquid Critical Liquid Critical Vapor Liquid Vapor Critical Vapor Critical
Number Pressure Temperature Enthalpy Vap Frac Density Viscosity Therm Cond Heat Capacity Enthalpy Density Viscosity Therm Cond Heat Capacity Enthalpy Surf Tens Heat Temp Pressure MW MW Temp Pressure

KG/CM2 C M*KCAL/HR FRAC KG/M3 CP KCAL/HR-M-C KCAL/KG-C M*KCAL/HR KG/M3 CP KCAL/HR-M-C KCAL/KG-C M*KCAL/HR DYNE/CM KCAL/KG C KG/CM2 C KG/CM2
1 3.1638 371.1110 76.4020 1.0000 1.1448 0.0214 0.1163 0.7861 76.4020 19.7790 -116.8484 22.9016
2 3.1638 334.0740 70.1948 1.0000 1.2148 0.0206 0.1060 0.7645 70.1948 19.7790 -116.8484 22.9016
3 3.1638 297.0370 64.1648 1.0000 1.2939 0.0197 0.0961 0.7418 64.1648 19.7790 -116.8484 22.9016
4 3.1638 260.0000 58.3217 1.0000 1.3841 0.0188 0.0865 0.7178 58.3217 19.7790 -116.8484 22.9016
5 3.1638 185.9260 47.2381 1.0000 1.6087 0.0169 0.0686 0.6658 47.2381 19.7790 -116.8484 22.9016
6 3.1638 148.8890 42.0202 1.0000 1.7510 0.0158 0.0603 0.6376 42.0202 19.7790 -116.8484 22.9016
7 3.1638 111.8520 37.0336 1.0000 1.9212 0.0148 0.0525 0.6079 37.0336 19.7790 -116.8484 22.9016
8 3.1638 82.8723 33.3009 1.0000 2.0796 0.0139 0.0467 0.5837 33.3009 19.7790 -116.8484 22.9016
9 3.1638 74.8150 31.7197 0.9710 2.0792 0.0137 0.0456 0.5843 31.5256 815.1411 0.3030 0.1033 0.4417 0.1941 22.4510 91.1711 315.7227 42.9046 19.3251 92.6820 -119.5415 22.7770
10 3.1638 37.7780 16.9000 0.4745 1.2862 0.0123 0.0528 0.8277 15.0956 830.1856 0.3504 0.1127 0.4068 1.8044 25.2264 95.4585 292.5446 45.5438 10.7116 83.8972 -174.7438 19.6995

 Contains: Pressure, Temp, Enthalpy, Vapor and Liquid Physical

Properties

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 Design

Input to HTRI for Design

FILE ,'C:\HTRI\CST\EOR 85.DAT'
 PROB ,EOR 85
 CONT , 0, 0, 2, ,56.57391
 HPRO ,215.11, 1,0.3981714, 371.11, 37.78
 , 4.22, 0.00, 0.000000, 0, 0, 0,
 HFLU ,'EOR 85' , 1
 HOTQ , 1, 4.218, 371.11, 334.07, 297.04, 260.00, 185.93
 , 148.89, 111.85, 91.28, 74.81, 37.78
Microsoft Excel
 ,352.2912,323.57374,295.68062,268.6566,217.4129 Worksheet
 ,193.2987,170.26113,157.94788,134.0741,70.75448
 , 1, 1, 1, 1, 1
 , 1, 1, 1,0.841804,0.398171
 HPVA , 1,1.567277,1.6631768,1.7716516,1.895369,2.203632
 ,2.399172,2.6333404, 2.784657,2.545402,1.514376
 ,0.021392,0.0205377,0.0196576,0.018749,0.016833
 ,0.015819,0.0147609,0.0141527,0.013732,0.012135
 ,0.116457, 0.10605,0.0960336,0.086421,0.068461
 ,0.060139,0.0522748, 0.048108,0.047978,0.056607
 ,0.786133,0.7644567,0.7416062,0.717513,0.665145
 , 0.63681,0.6070022,0.5898072,0.622006,0.914139
 ,75.77995,69.602654,63.602676,57.78965,46.76682
 ,41.57971,36.624191,33.975536,27.76734,13.11165
 HPLI , 1, 0, 0, 0, 0, 0
 , 0, 0, 0,797.5209,815.8128
 , 0, 0, 0, 0, 0
 , 0, 0, 0,0.282435,0.345377
 , 0, 0, 0, 0, 0
 , 0, 0, 0, 0.10342,0.112397
 , 0, 0, 0, 0, 0
 , 0, 0, 0,0.447937,0.415109
 , 0, 0, 0, 0, 0
 , 0, 0, 0,1.072802,2.108068
 , 0, 0, 0, 0, 0
 , 0, 0, 0,21.36369,24.57724
 , 0, 0, 0, 0, 0
 , 0, 0, 0,43.53983,44.65401
 , 0, 0, 0, 0, 0
 , 0, 0, 0,302.1961,288.5542
 , 0, 0, 0, 0, 0
 , 0, 0, 0, 90.429,93.32978

11 05/24/23
 Datasheet and Calculation Package

 Provide Process Data for the Heat Transfer Specialist and Other
Engineering Disciplines
 Calculation Package is Assembled and Checked Prior to Release of
Data

Microsoft Office
Excel Worksheet

 Calculation package includes:

– Cover Sheet
– PFD / P&ID
– Heat and Material Balance
– Calculations / Software Output
– Datasheet

12 05/24/23
 Follow Up

Heat exchanger design is a collaboration. After issuing

the datasheet, follow up.
Check subsequent revisions/squad check copies for:
 Compliance with Client requirements

Deviation from Process data
 Plot space requirements

Pressure drop and velocity requirements

13 05/24/23
 Questions

14 05/24/23