'-

l, RigorousHeat Exchanger
I,...
& TASK An existing heat exchangerruns with a shellsideoutlet temperatureof
161°F.You want to increasethe throughputof the exchangerandneedto
- calculatethe shellsideoutlet temperatureunderthe new conditions.Set
up the simulationof the exchanger.This exerciseis in two parts:
"-

Part A Determine the fouling of the heat exchangerunder presentoperating

conditions.
~

Part B Using the fouling resultsfrom Part A, rate the existing fouled exchanger
'- for the increasedthroughput.

, The fIowsheet,streamandprocessdataareprovidedbelow.
~
,.
.
Figure 51:
Schematicof a
'-- Rigorous Heat BT1
Exchanger

;
I.,.. EA1

-- BT2

'-'

'- Table27: Feed StreamData

Component FD1Mole % BT1Mole %
\.,. NC4 15 4
IC5 14 15
NC5 16 16
- NC6 22 25
NC7 13 15
NCB 20 25
"'" Temperature 70°F 220°F

Pressure 195psia 135 psia

"-
CurrentFlowrate 550000Ib/hr 500000Ib/hr
IncreasedFlowrate 606000Ib/hr 660000Ib/hr

:
I-
GettingStartedWorkbook 55

~,~~1j
Heat ExchangerData

Customer Job No
Referalce No
Adcress Pr~osal No
PlantLocattJn Date IRev .
Servte ofUnit ItemNo
Size ~240 IT~ AES HaiZa1lal HorI Vert Cornded in 1 pa-aiEI 1 serEs
Surt'Unlt 2295 SqFt Shells/Unlt 1 Surf/Shell 2295 1t2
PERFORMANCEOF ONE UNIT .
Flukj AlkJcattJn Shell Side T~ Side
Flukj Name BT1 FO1
Flukj Quantity,Total Ib/IT 500,000 550,000
Va~r (1r'/QJt)
UlJJid S{X),OOO S{X),OOO 5ffJ,OOO 5ffJ,OOO
Steam
Water
NonconcEnsabEs
Temperaure (Ir'/QJt) Of' 220 155 70 134
Specr!c GraYly O~ O.~ 065 065
Viscosty, LilJJid cP 0.15 022 032 02
Molecu~r weight, V~r
Molecu~r Wei!ilt, Noncondensables
Specric Heat Btu lib Of' 0.64 0 [9 054 057
Thermal CorliJctlvty Btu Mlrlt2 Of' 0.C5f 0.a5B 0.07 0.003
La1entHeat Btu/IJ @ Of'
InletPressure psig 1~ 1.
Velocty ft/s 12 65
PressureOr~ AlbWI Calc psi 10 / 5 10 / 7
FoulngResistance
(min.) 0001 0.001
HeatEXCta1~d 222 MM Btu".. 00 MTD(Corrected) Of'
TransferRae ServiCe 110 Clean 135 Btu/hr1t2Of'
CONSTRUCTK>NC»"ONESHEll Sketch(8JndIPlNozzIe
OrEntation)
ShellSkE TubeSide
Des~rVTestPresSlre ps~ 175/ 25:)/ ID11
Des~n Tem~rawre Of' S{X) S{X) - ;!r
No Passes~r Shell 1 2 FIJI r"L-

Corrosion
AlbWance In 118' 1/8"exrep ~s ~ I EA1 )
-3XJ# ..
CornctkJns
Size&
Rating
Out
In

Intermediate
r- 3XJ#
r I"

I"-~
-~ FD2

~
~ 5T2
1

TubeNo ~ 00 0.75 i'1 thk,MIn/Avg USWG Len~ ~ It Pitch 1.25~ 30\.~) 00 45

Tuber;pe Barf! Material CS
Shell 1.0 38 OD. in ShellCOler C.S ( IntegI Fecmov.)
Channelor 9:lmet I C.S. Channel
COler CS
Tubesheet-~atOlary I CS Tubesheet-FbalrIJ CS
FloatingHe~ ~r I CS Impin~mertProtection Yes
-
B~s Cross CS T~ Sirge Cut (Diam/~ea) ~ Spachgc/c U Inlet 24 In
Ba~s-LInJ N~ SealT~ N~~
SUWorts - Tube U-Bend T~
Bvoass
Seal~ra~mert NIR Tube-
Tubeshe~
Joi'1t Ro/le1
ExpansionJolrt NIR T~
p.'"2 InEtNozzle BundleEnnnce BuroleExit
-
Gas~ts ShellSkje TubeSide
Gas~ FbatirIJHead
CodeRequremerts ASMEsectbnVIIION1 TEMA
Class R
weigtt/Shell Filled~ Water Burole Ib
Rema-ks

56 RigorousHeatExchanger
I
:

~~~.;
ii,

l
z~

.,
 I-..

ct SOLUTION
--
Part A Determine the fouling of the heat exchanger under current operating
I ~
I
conditions. In this part of the exercise, you require a shellside outlet tem-
! :" peratureof 161°F.

- Build the flow sheetandenterthe UOM, components,andthermody-

namic data,asusual.Enter streamdata.

L Step1 EnterUnitData
In this example,the shellsideoutlet temperatureis givenand we want to
determinethe fouling resistance.SelectShell Outlf1;Temperaturefrom
'-- the list andenterthe valuein the Temperaturefield.

L >- Click eachbutton and enter the appropriatedata.Fields outlined in

greenmeansthat, if you do not enter a value,PRO/II calculatesone.
>- In the Film Coefficientsdialog box, setthe tubing fouling resistance
--- to O.
You want PROm to calculatean overall fouling resistanceto meet the
specification.You could supplyvaluesfor both the tubesideand a shell-
- side fouling resistancesandhavePROm adjustthemto meetthe perfor-
'I mance specification.However, for simplicity, it is easierto set the
-L tubesidefouling resistanceto zero and allow PRom to report the calcu-
lated overall resistance as the required shellside resistance.

>- Click Dm~l8\j to checkthe Extendedbox to requestan addi-

'- tional data sheet with information about streamproperties, heat
exchangerconfigurationandhydrodynamics.
~ >- Run the simulation and view the results. Make a note of the required
shellsidefouling resistance.

.
i,.;

'- ,,1;5it:.1;i)1.!.} :';)"-!;

"-, .
.. '".

\.-

L' GettingStartedWorkbook . 57

'-'
.L, Figure 52:
HeatExchan er SHELL AND TUBE EXCHANGERDATA SHEET FOR EXCHANGER'El '
g 1 1
Results I EXCHANGER NAME UNIT ID El I
-Part A I SIZE 36 - 240 TYPE AES HORIZONTAL CONNECTED1 PARALLEL 1 SERIES I
I AREA/UNIT 2295. FT2 ( 1891.FT2 REQUIRED) AREAl SHELL 2295. FT2 I
1 1
I PERFORMANCE OF ONE UNIT SHELL-SIDE TUBE-SIDE I
I ~ 1
I FEED STREAM ID BTl FDl I
I FEED STREAM NAME I
I TOTAL FLUID LB/HR 500000. 550000. I
I VAPOR (IN/OUT) LB/HR III
I LIQUID LB/HR 500000./500000. 550000./550000. I
I STEAM LB/HR 1 1 I
I WATER LB/HR III
I NON CONDENSIBLE LB/HR I
I TEMPERATURE (IN/OUT) DEG F 220.0/162.0 70.0/128.8 I
-- I PRESSURE (IN/OUT) PSIG 120.00 1 118.07 180.00 1 174.67 I
1 1
I SP. GR., LIQ (60F/60F H2O) 0.669/0.669 0.659/0.659 I
I VAP (60F/60F AIR) III
I DENSITY, LIQUID LB/FT3 36.387/38.544 40.904/39.021 I
I VAPOR LB/FT3 1 1 I
I VISCOSITY, LIQUID CP 0.158 1 0.217 0.305 1 0.231 I
.! I VAPOR CP 1 1 I
~ I THRML COND,LIQ BTU/HR-FT-F 0.0594/0.0658 0.0756/0.0692 I
," , .." I VAP BTU/HR-FT-F 1 1 I
I SPEC.HEAT,LIQUIDBTU/LB-F 0.6367/0.5909 0.5301 1 0.5718 I
:1 I VAPOR BTU/LB-F 1 1 I
I LATENT HEAT BTU/LB I
I VELOCITY FT/SEC 1.21 6.85 I
I DP/SHELL PSI 1.94 5.35 I
",,',., I FOULING RESIST HR-FT2-F/BTU 0.00200 ( 0.00393 REQD) 0.00000 I
1 1
I TRANSFERRATE BTU/HR-FT2-F SERVICE 110.58 (91.15 REQD)CLEAN 141.98 I
I HEAT EXCHANGED MM BTU/HR 17.789 MTD(CORRECTED) 85.0 FT 0.928 I
1 1
I CONSTRUCTION OF ONE SHELL SHELL-SIDE TUBE-SIDE I
1 1
- II DESIGN
NUMBER PRESSURE
OF PASSES PSIG 285.
1 285.
2 II

,... I MATERIAL CARB STL CARB STL I

I INLET NOZZLE ID IN 8.0 8.0 I
I OUTLET NOZZLE ID IN 8.0 8.0 I
*N81atJ';
,.
1
I TUBE: NUMBER 600 OD 0.750 IN BWG 14 LENGTH 20.0 FT
1
I
Md .~~i~ I TYPE BARE PITCH 1.3 IN PATTERN 60 DEGREES I
I SHELL: ID 36.00 IN SEALING STRIPS 0 PAIRS I
I BAFFLE: CUT 0.300 SPACING (IN/CENT/OUT): IN 24.0/24.0/24.0,SINGLE I
I RHO-V2: INLET NOZZLE 4350.9 LB/FT-SEC2 I
I TOTAL WEIGHT/SHELL,LB 10393.6 FULL OF WATER 30135.8 BUNDLE 11825.0 I
1 1

Part B Using the fouling results you havejust calculated,ratethe existing ;.,;'ll
",."

fouled exchangerfor the increasedthroughput.

.. Changethe flowratesof both feed streams.

.. Click :-r:t1jrjjJ
rnfr[~rmi1_~,;".J",and enter the new value for the shellside j]£~i
fouling resistancecalculatedin PartA. -
.. In the RigorousHeat Exchangermain dialog box, changethe Calcu-
lation Typeto Rating (Predictive).
.. Run the simulationandview the results.Note the tubesideand shell- ~
sideexit temperatures.
-
58 RigorousHeatExchanger
-

-
I-

f'c'V".';-:,~,;',~;;;::~r'fi~

'- Figure53:
HeatExchanger SHELLANDTUBEEXCHANGER
DATASHEETFOREXCHANGER'
E1 .
I I
Results I EXCHANGER NAME UNIT ID E1 I
- PanB I SIZE 36 - 240 TYPE AES HORIZONTAL CONNECTED1 PARALLEL 1 SERIES I
. I AREA/UNIT 2295. FT2 AREA/SHELL 2295. FT2 I
-- I I
I PERFORMANCE OF ONE UNIT ,., SHELL-SIDE TUBE-SIDE I
I ~-~'~ I
I FEED STREAM ID BT1 FD1 I
I FEED STREAM NAME I
~ I TOTAL FLUID LB/HR 650000. 600000. I
I VAPOR (IN/OUT) LB/HR / / I
I LIQUID LB/HR 650000. / 650000. 600000. / 600000. I
I STEAM LB/HR / / I
I WATER LB/HR / / I
I I NON CONDENSIBLE LB/HR I
I TEMPERATURE(IN/OUT) DEGF 220.0 / 169.6 70.0 / 131.1 I
I PRESSURE (IN/OUT) PSIG 120.00 / 116.73 180.00 / 173.75 I
I ~ ~ I
I SP. GR., LIQ (60F/60F H2O) 0.669 / 0.669 0.659 / 0.659 I
~ I VAP (60F/60F AIR) / / I
I DENSITY, LIQUID LB/FT3 36.387 / 38.276 40.904/38.943 I
I VAPOR LB/FT3 / / I
-" i VISCOSITY, LIQUID CP 0.158 / 0.215 0.305 / 0.229 I
\ I VAPOR CP / / I
~ I THRML COND,LIQ BTU/HR-FT-F 0.0594 / 0.0650 0.0756/0.0690 I
I VAP BTU/HR-FT-F / / I
I SPEC.HEAT,LIQUID BTU/LB-F 0.6367 / 0.5966 0.5301/0.5735 I
I VAPOR BTU/LB-F / / I
I LATENT HEAT BTU/LB I
- --- I VELOCITY FT/SEC 1.58 7.48 I
I DP/SHELL PSI 3.27 6.25 I
I FOULING RESIST HR-FT2-F/BTU 0.00393 0.00000 I
1 1
! TRANSFERRATE BTU/HR-FT2-F SERVICE 99.48 CLEAN 163.33 I
- I HEAT EXCHANGED MM BTU/HR 20.194 MTD(CORRECTED) 88.4 FT 0.939 I
I 1
I CONSTRUCTION
OF ONE SHELL SHELL-SIDE TUBE-SIDE I
1 , , 1
I DESIGN PRESSURE PSIG 285. 285. I
'- I NUMBER OF PASSES 1 2 I
I MATERIAL CARB STL CARB STL I
I INLET NOZZLEID IN 8.0 8.0 I
I OUTLET NOZZLE
ID IN 8.0 8.0 I
I ~ ~ 1
'- ' I TUBE: NUMBER 600 OD 0.750 IN BWG 14 LENGTH 20.0 FT I
I TYPE BARE PITCH 1.3 IN PATTERN 60 DEGREES
I
I SHELL: ID 36.00 IN SEALINGSTRIPS 0 PAIRS I
, I BAFFLE: CUT 0.300 SPACING(IN/CENT/OUT): IN 24.0/24.0/24.0,SINGLE I
I RHO-V2: INLET NOZZLE 7353.0 LB/FT-SEC2 I
~ I
1
TOTALWEIGHT/SHELL,LB
10393.6 FULLOFWATER
30135.8 BUNDLE
11825.0 I
1
.y'

- ". .

I-

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~

"-'

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GettingStartedWorkbook 59