.

DYNAMIC SIMULATION OF SHELL AND TUBE HEAT EXCHANGER

PROCESS

NIRWAYANTI BINTI TAJUDDIN

UNIVERSITY COLLEGE OF ENGINEERING & TECHNOLOGY MALAYSIA

.

DYNAMIC SIMULATION OF SHELL AND TUBE HEAT EXCHANGER

PROCESS

NIRWAYANTI BINTI TAJUDDIN

A thesis submitted in fulfillment of the

requirements for the award of the degree of
Bachelor of Chemical Engineering

Faculty of Chemical and Natural Resources Engineering Technology

University College of Engineering and Technology Malaysia

NOVEMBER 2005
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To my beloved father and mother; Hj. Tajuddin Dollah and Hjh. Mariawati Hashim,
siblings; Mohd Zainal, Azlina Aminah, Aisyah, Nurul Natasya
and late brother; Mohd Syahfiq.
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..

ACKNOWLEDGEMENT

First of all, I would like to thank to Allah S.W.T., because giving the
opportunity and strength to me to overcome every obstacles to complete this
research.

I would like to express my appreciation to the following persons for their

unlimited and kindness help as well as guidance, which enabled me to complete the
research project in time as a partial fulfillment of the requirement of the degree of
Bachelor in Chemical Engineering.

I would like to thank my supervisor Mr. Mohd Yusri bin Mohd Yunus, who
helped me a lot during the progress of the research project, either in the way of
searching the required information or giving me valuable opinions and
encouragement. Without his continued support and generosity in sparing their
precious time to guide me, this research would not have been the same as presented
here. I would like to express great appreciation my examiner, Puan Wan Hanisah
binti Wan Ibrahim, for giving the professional guidance to me, besides examining
my thesis report.

Not forget also, I wish to convey my appreciation especially to my group

members, and also to Cairolyn Palawat for their helpfulness by sharing their
knowledge and running the experiment together. My sincere appreciation also
extends to all my entire course mates for their high spirit and co-operation during the
progress of the project.

Last but not least, I am grateful to my beloved parents for always giving me
an enthusiasm and morality support all along my study.
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ABSTRACT

With the development in the field of computer technology, simulation is

getting more and more interesting alternative for pilot plants companies.
AspenPlus/AspenDynamics is a simulation tool for multi-engineering purpose
developed by Aspen Technology. In order to be able to make any valid conclusions
the shell and tube heat exchanger (STHE) has to be verified, this study tries to verify
the dynamics over a STHE. The STHE used in this study is a single-pass 1-1
exchanger. The model includes time-dependent inlet conditions for both the cold and
the hot streams. Hence, a number of start-up cases can be simulated and, once the
system reaches a stationary operating point, a disturbance can be introduced in the
inlet temperatures or the flow rates. This project was completed by fulfill the
objectives of doing the simulation and compare the results between simulation and
experiment There exists an error of about -3.56% to 7.68% in the temperature
differences, which these available errors were not out from the range error of ±10%.
This particular feature makes the simulation very useful not only for design purposes
but also for transient analysis and control system design.
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ABSTRAK

Dengan kemajuan bidang teknologi perkomputeran, simulasi menjadi

alternatif yang semakin diminati bagi syarikat-syarikat loji yang besar.
AspenPlus/Aspen Dynamics ialah alat simulasi bagi kebanyakan kegunaan
kejuruteraan yang dikeluarkan oleh Aspen Technology. Untuk memastikan sebarang
kesimpulan dibuat dengan mungkin, “shell and tube heat exchanger” (STHE)
seharusnya ditentukan terlebih dahulu, iaitu dengan mencuba untuk menentukan
pergerakan dinamik dalam STHE. STHE yang digunakan dalam projek ini ialah
single-pass 1-1 exchanger. Pemodelan ini termasuklah keadaan kemasukan yang
bergantung kepada masa bagi kedua-dua aliran air sejuk dan panas. Dengan itu, nilai
untuk kes-kes permulaan dapat disimulasikan dan sekiranya sistem tersebut
mencapai nilai operasi yang tetap, gangguan dapat diselitkan pada suhu dan kadar
alir awal. Projek ini telah memenuhi objektif yang diinginkan dengan membuat
simulasi dan perbandingan di antara keputusan simulasi dan eksperimen. Walaupun
wujudnya perbezaan suhu dalam lingkungan -3.56% to 7.68%, tetapi ia tidak
melebihi nilai yang dianggarkan sebanyak ±10%. Ciri khusus ini akan membuatkan
simulasi tersebut menjadi lebih berguna bukan sahaja untuk tujuan reka bentuk tetapi
juga reka bentuk sistem kawalan.
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TABLE OF CONTENTS

CHAPTER TITLE PAGE

TITLE PAGE i

DECLARATION ii

DEDICATION iii

ACKNOWLEDGEMENT iv

ABSTRACT v

ABSTRAK vi

TABLE OF CONTENTS vii

LIST OF TABLES x

LIST OF FIGURES xi

LIST OF ABBREVIATIONS xiii

LIST OF APPENDICES xvi

1 INTRODUCTION 1
1.1 Introduction 1
1.2 Shell and Tube Heat Exchanger Plant 2
1.3 Benefits of Dynamic Simulation 3
1.4 Problem Statement 4
1.5 Research Objectives 4
1.6 Research Scopes 5
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2 LITERATURE REVIEW 6
2.1 Heat Transfer 6
2.1.1 Overall Heat Transfer Coefficient 7
2.2 Shell and Tube Heat Exchanger 8
2.2.1 Single-pass 1-1 Exchanger Design 8
2.2.2 Flow Arrangements 9
2.2.3 Applications of Heat Exchanger 11
2.3 Dynamic Simulation 13
2.4 Aspen Software 14
2.5 Literature Review of Previous Study 15

3 METHODOLOGY 18
3.1 Introduction 18
3.2 Data Collection 19
3.2.1 Shell and Tube Heat Exchanger 20
3.2.2 Water Tank 21
3.2.3 Heating and Cooling Systems 21
3.2.4 Circulation Pumps 22
3.2.5 Other Specifications 22
3.3 Simulation Process 23
3.3.1 Steady-state Simulation 24
3.3.2 Dynamic Simulation 32
3.4 The Experiment 36
3.5 Results Analysis 39
3.6 Results Comparison and Validation 39
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4 RESULT AND DISCUSSION 40

4.1 Results Analysis 40
4.1.1 Simulations Results 40
4.1.2 Experiment Results 48
4.2 Results Comparison 50
4.2.1 Steady-state Results Comparison 50
4.2.2 Dynamic Results Comparison 51
4.3 Results Validation 55

5 CONCLUSION AND RECOMMENDATIONS 56

5.1 Conclusion 56
5.2 Recommendations 57

REFERENCES 59

APPENDIX A 62

APPENDIX B 65

APPENDIX C 66
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LIST OF TABLES

TABLE NO. TITLE PAGE

2.1 Application of Heat Exchanger Technologies 12

2.2 List of Available Software for Simulation 14

3.1 STHE Properties Data 20

3.2 Water Tank Properties Data 21

3.3 Heating and Cooling Systems Properties Data 22

3.4 Circulation Pump Properties Data 22

3.5 Valve Arrangement for STHE 38

4.1 Streams Results Summary 41

4.2 Simulation Results Table; (a) Hot Water Inlet 44

Temperature; (b) Cold Water Inlet Temperature

4.3 Overall Results for STHE; (a) Hot Water Inlet 46

Stream; (b) hot Water Outlet Stream; (c) Cold Water
Inlet Stream; (d) Cold Water Outlet Stream

4.4 Experiment Results Table 48

4.5 Steady-state Comparison Table 50

4.6 Dynamic Comparison Table 52

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.
.

LIST OF FIGURES

FIGURE NO. TITLE PAGE

2.1 Single-pass 1-1 Counter-flow Heat Exchanger 9

2.2 Heat Exchanger Flow Arrangement (a) parallel-flow; 10

(b) counter-flow; (c) cross-flow, both fluid unmixed;
(d) cross-flow, fluid 1 mixed, fluid 2 unmixed

2.3 Temperature Perturbation, Simulation and 16

Experiment

2.4 Flow Perturbation, Simulation and Experiment 17

3.1 Flow Chart for Simulated STHE 19

3.2 Relation of Process Input to Process Output 23

3.3 Windows Flowsheet 25

3.4 Windows Flowsheet with STHE Block (HeatX Type) 25

3.5 Data Browser for Setup Specifications 26

3.6 Data Browser for Block STHE (HeatX) 27

3.7 Data Browser for Block STHE (HeatX) (continued) 27

3.8 Data Browser for Components Specifications 28

3.9 Data Browser for Flowsheet Streams 28

3.10 Data Browser for Cold Water Stream Input 29

3.11 Data Browser for Hot Water Stream Input 29

3.12 Process Flow Diagram for STHE 30

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3.13 Results Summary Run Status 31

3.14 Information Messages Exporting Dynamic 33

Simulation

3.15 Process Flow Window for Aspen Dynamics 34

3.16 Run Options 35

3.17 STHE Equipment on Laboratory 36

3.18 Schematic Diagram for Shell and Tube Heat 37

Exchanger (Model: HE 667) in Laboratory

4.1 Simulation Graph of Hot Water Inlet Temperature 45

versus Time

4.2 Simulation Graph of Cold Water Inlet Temperature 45

versus Time

4.3 Experiment Graph of Hot Water Inlet Temperature 49

versus Time

4.4 Experiment Graph of Cold Water Inlet Temperature 49

versus Time

4.5 Comparison Graph of Hot Water Inlet Temperature 53

between Simulation and Experiment

4.6 Comparison Graph of Cold Water Inlet Temperature 54

between Simulation and Experiment
 xiii

LIST OF ABBREVIATIONS

SYMBOL DESCRIPTION

A Total exchanger area, m2

At Tube surface area, m2

AIRCLR Air cooler

CI Cold water inlet stream

CO Cold water outlet stream

Cp Specific heat, kJkg-1ºC-1

CWTANK Cold water tank

di Tube inner diameter, m

ds Shell diameter, m

do Tube outlet diameter, m

FI1 Rotameter for hot water

FI2 Rotameter for cold water

FT1 Hot water flowrate, Lmin-1

FT2 Cold water flowrate, Lmin-1

HI Hot water inlet stream

HO Hot water outlet stream

HV Valve

HWTANK Hot water tank

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h Heat transfer coefficient, Wm-2K-1

hs Tube coefficient for shell side

ht Tube coefficient for tube side

Lt Length of tubes, m

LB Baffle length, m

Bc Baffle cut, dimensionless

m h Mass flowrate, kgs-1

NT Number of tubes

P Power, Kw

P Pressure, bar

P1 Hot water circulation pump

P2 Cold water circulation pump

PUMPC Cold water circulation pump

PUMPH Hot water circulation pump

PT Tube pitch

Q Heat duty, kW

q Heat transfer rate, Js-1

STHE Shell and tube heat exchanger

T Temperature, ºC

∆T Temperature drop

∆Th Hot water temperature difference, ºC

∆Tm Effective mean temperature difference

Tc1 Cold water inlet temperature, ºC

Tc2 Cold water outlet temperature, ºC

Tci Cold water inlet temperature, ºC

Tco Cold water outlet temperature, ºC

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Th1 Hot water inlet temperature, ºC

Th2 Hot water outlet temperature, ºC

Thi Hot water inlet temperature, ºC

Tho Hot water outlet temperature, ºC

TIC Temperature indicator controller

TT1 Hot water inlet temperature, ºC

TT2 Hot water outlet temperature, ºC

TT3 Cold water inlet temperature, ºC

TT4 Cold water outlet temperature, ºC

t Time, s

U Overall heat transfer coefficient, Wm-2ºC-1

V Capacity, L
 xvi

..
.

LIST OF APPENDICES

APPENDIX TITLE PAGE

A Operating Instructions of Shell and Tube Heat 62

Exchanger

B Schematic Diagram for Shell and Tube Heat 65

Exchanger (Model: HE 667) in Laboratory

C Process Flow Diagram for Shell and Tube Heat 66

Exchanger in Simulation
 CHAPTER 1

INTRODUCTION

1.1 Introduction

Dynamic simulations provide powerful, detailed insights into process

dynamics and plant behavior that can be used to improve the design, operability,
safety, and productivity of process facilities while minimizing capital and operating
costs.

The traditional way of making studies is by using real experiments.

Scientists, engineers and companies spend a lot of money and resources each year by
building pilot plants to conduct these real experiments. The most cost efficient way,
up until now, to evaluate and do research has been by building pilot plant. Along
with the development of computer technology, computer modelling and simulation
has become more and more interesting as a new research tool.

Aspen software is a simulation tool for multi-engineering purposes. It is a

complete set of tools to enable users to quickly develop dynamic models for their
processes. However, by substituting real experiments for computer simulation a
certainty, that the computer model correctly describes the real system, has no exist.
If a scientist is to draw valid and reliable conclusions from his research on the
computer model, he has to be certain that the model give correct data, for example he
has to be sure about the validity of his model.
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1.2 Shell and Tube Heat Exchanger Plant

The units or the equipments of shell and tube heat exchanger (STHE) in
today’s plants are much more complex. This situation is happened because of the
improvement to this equipments to increase the production while to make sure the
operation in a safely mode. STHE has more than one type based on it classification
according to the transfer process, construction, flow arrangement, and also heat
transfer mechanisms. Simulation is the best method to train operators to understand
the inner-workings of these complicated processes.

Many refineries are being operated with crude slates that change daily based
on market conditions. This creates constant swings and instabilities in unit
operation. In addition, to maximize profitability, many units such as STHE are run
to capacity limitations. This makes operation much more demanding. The operators
need to be constantly alert with the frequent of operation changes. Training on a
real-time dynamic simulation is the best way to prepare for this situation.

If a plant is currently operating without advanced control, a simulation is a

good method to prove to engineers and operators that a new advanced control
strategy is effective. If the unit such as STHE is operated without advanced control,
there cannot be finding out what the possible causes if there is a problem occurred.
If a plant is operating with advanced control, the operators will have reduced
experience at operating the plant using standard or manual control. A simulation can
be useful to refresh operators in how to operate when the advanced control is
unavailable in the plant.
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1.3 Benefits of Dynamic Simulation

Dynamic plant simulation is a powerful tool that helps managers and

engineers link business operations to process operations. Dynamics simulation
enables manufacturers to use it in many purposes. The benefits of this simulation are
covering many things.

A simulation can be used to ensure that all of the equipment such as STHE
for a new plant is consistently sized. Many past studies have found mis-sized valves
or other mechanical equipment that would have created a capacity limitation. In
addition, the simulation can be used to determine if there will be problems during
startup or shutdown. For example, some complicated heat exchanger trains work
well during normal operation but don’t provide sufficient heat input during startup.

Provided the simulation study is carried out at the right time in the design
phase, the results of the simulation can be used to verify or change equipment design
before it is purchased. In effect, this type of study can prevent the need for costly
debottlenecking after the plant is built.

A simulation can be used to determine if changing some items of equipment

or the operation condition can improve the capacity or operability of an existing
plant. This can include studies of transients during normal operation or emergency
situations. This study is about what if analysis, for example, what will be the output
variable value when the inlet flowrate of the STHE is change during the operation.
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1.4 Problem Statements

Nowadays, the need for operator training keeps increasing. Improperly

operated plants can result in safety hazards and lost production. As a solution,
simulation is the best method to train operators to handle much kind of situations and
maximize safe production. The complexity of process, the changes of the plant
operation more frequently, and sometimes without an advanced control in the plant,
is some of the situations which are always happened in the industries.

At this time, there still have plants which run the process by controlling it
manually. So that, dynamic simulation of STHE process is the method to solve this
situation by turn the operation into automatically controlling by using simulation.
The task here is to relate the input and output variables. The simulation method that
is used in the STHE also can be applied for any other equipment by put the required
data according to the equipment that is used.

1.5 Research Objectives

The main objectives of this project, is to do the dynamic simulation of STHE

by using Aspen software. Both AspenPlus and AspenDynamics will be used in this
project.

Another objective is to define whether the simulated process has the same
characteristics in comparison with the real process. In order to validate the results
experiment will be run in the laboratory by comparing the temperature differences
with the simulation results. This analysis is useful to make sure that the plant can be
run in the real situation.
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1.6 Research Scopes

One effective educational approach to learn how to use dynamic simulators is

to start with the basic simulation is by simulates STHE in steady-state condition.
Then go through the simulation in dynamic, which required an advanced skill. The
study here is by learning the basic operations of moving from a steady-state
simulation to a dynamic simulation.

Besides that, the scope also is running the STHE experiment to study the
temperature variable that change with time. This project will be just including the
counter-flow exchanger. Certainly by doing the project, the study is more to the
results comparison between the simulation using Aspen software with the
experiment.
.

CHAPTER 2

LITERATURE REVIEW

2.1 Heat Transfer

In industrial processes heat energy is transferred by a variety of methods,

including conduction in electric-resistance heaters; conduction-convection in
exchangers, boilers, and condensers; radiation in furnaces and radiant heat dryers;
and by special methods such as dielectric heating (McCabe, et al., 2001).

Heat transfer is a dynamic process in which heat is transferred spontaneously

from one body to another cooler body. The rate of heat transfer depends upon the
differences in temperature between the bodies, the greater the difference in
temperature, the greater the rate of heat transfer. Heat can be transferred in three
ways; by conduction, by radiation and by convection.

In conduction, the molecular energy is directly exchanged, from the hotter to

the cooler regions, the molecules with greater energy communicating some of this
energy to neighboring molecules with less energy. Radiation is the transfer of heat
energy by electromagnetic waves, which transfer heat from one body to another, in
the same way as electromagnetic light waves transfer light energy. Convection is the
transfer of heat by the movement of groups of molecules in a fluid. The groups of
molecules may be moved by either density changes or by forced motion of the fluid.
 7

In general, heat is transferred in solids by conduction, in fluids by conduction

and convection. Heat transfer by radiation occurs through open space, can often be
neglected, and is most significant when temperature differences are substantial. In
practice, the three types of heat transfer may occur together. For calculations it is
often best to consider the mechanisms separately, and then to combine them where
necessary.

2.1.1 Overall Heat Transfer Coefficient

Generally, the overall heat transfer coefficient is treated as constant in the

heat exchanger analysis. The overall heat transfer rate, q, equation is

q = m h C p ∆Th (2.1)

q = UA∆Tm (2.2)

Here m h is the mass flowrate, Cp is specific heat, ∆Th is hot water temperature
differences, U is the overall heat transfer coefficient, A is the heat transfer surface
area, and ∆Tm is the effective mean temperature difference.

(Thi − Tco ) − (Tho − Tci )

∆T m = (2.3)
⎡ (T − Tco ) ⎤
ln ⎢ hi ⎥
⎣ (Tho − Tci ) ⎦

When consider a single-pass counter-flow exchanger in which U varies

linearly with the temperature of either fluid stream, U. In this case, the mean value
of U∆T, where ∆T is the temperature difference between the hot and cold fluids, is as
given by Colburn (1933). The equation in this project is for the counter-flow based
on the scope of this project
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2.2 Shell and Tube Heat Exchanger

In process industries, shell and tube heat exchanger (STHE) are used in great
numbers, far more than any other type of exchanger. More than 90% of heat
exchangers used in industry are of the shell and tube type (Chisholm, D., 1980). The
STHE are the “work horses” of industrial process heat transfer (Minton, P.E., 1990).
They are the first choice because of well-established procedures for design and
manufacture from a wide variety materials, many years of satisfactory service, and
availability of codes and standards for design and fabrication. They are produced in
the widest variety of sizes and styles. There is virtually no limit on the operating
temperature and pressure. STHE very adaptable and flexible and can operate over
the full range of pressures and temperatures encountered in chemical processes
(Kuppan, T., 2000).

Other types of heat exchangers are used when economical. Although the
application of other types of heat exchangers is increasing, the STHE will continue
its popularity for a long time, largely because of its versatility. STHE are used in the
process industries, in conventional and nuclear power stations as condensers, steam
generators in pressurized water reactor power plants, and feed water heaters. They
are also proposed for many alternative energy applications including ocean, thermal
and geothermal.

2.2.1 Single-pass 1-1 Exchanger Design

In this project, the type of STHE used is single-pass 1-1 exchanger which is
the simplest type of STHE. It has one shell-side pass and one tube-side pass, where
one shell serves for many tubes. This kind of STHE is the most common due to its
cheapness, simplicity, and ease of manufacture.

In an exchanger the shell-side and tube-side heat transfer coefficients are of

similar importance, and both must be large if a satisfactory overall coefficient is to be
attained. The velocity and turbulence of the shell-side liquid are as important as
 9

those of the tube-side fluid. To promote cross-flow and raise the average velocity of
the shell-side fluid, baffles are installed in the shell. In the construction shown in
Figure 2.1, baffles consist of circular disks of sheet metal with one side cut away
(McCabe, W. L., et al, 2001). Common practice is to cut away a segment having a
height equal to one-fourth the inside diameter of the shell. Such baffles are called 25
percents baffles. The baffles are supported by one or more guide rods.

Tubes are arranged in a triangular or square layout, known as triangular pitch

or square pitch. Triangular pitch is used unless the shell-side tends to foul badly,
because more heat transfer area can be packed into a shell of given diameter than
with square pitch.

Figure 2.1 Single-pass 1-1 Counter-flow Heat Exchanger; A, baffles; B, tubes; C,

guide rods; D, D’, tube sheets; E, spacer tubes

2.2.2 Flow Arrangements

Heat exchangers may be classified according to the fluid-flow path through

the heat exchanger. The three basic flow configurations are parallel-flow, counter-
flow, and cross-flow.

In parallel-flow heat exchangers, the two fluid streams enter together at one
end, flow through in the same direction, and leave together at the other end as shown
in Figure 2.2a (Kakaç, S., et al, 2002). In counter-flow heat exchangers, two fluid
streams flow in opposite directions as shown in Figure 2.2b. In a single cross-flow
 10

heat exchangers, one fluid flows through the heat transfer surface at right angles to
the flow path of the other fluid. Cross-flow arrangements with both fluids unmixed
or one fluid mixed and the other unmixed are illustrated in Figures 2.2c and 2.2d.

Figure 2.2 Heat Exchanger Flow Arrangement; (a) parallel-flow; (b) counter-
flow; (c) cross-flow, both fluid unmixed; (d) cross-flow, fluid 1 mixed, fluid 2
unmixed

Multipass-flow arrangements are commonly used in heat exchanger designs,

especially in shell and tube heat exchangers with baffles. The main difference
between the flow arrangements lies in the temperature distribution along the length
of the heat exchanger and the relative amounts of heat transfer under given
temperature specifications for specified heat exchanger surfaces. A parallel-flow
heat exchanger requires maximum area, a counter-flow heat exchanger requires
minimum area, and a cross-flow heat exchanger requires an area in between.
 11

This project was study on the counter-flow or counter-current. In the

counter-flow or counter-current exchanger, the two fluids flow parallel to each other
but in the opposite directions within the core. It is the most efficient flow
arrangement, producing the highest temperature change in each fluid compared to
any other two-fluid flow arrangements for a given overall thermal conductance, fluid
flowrates, and fluid inlet temperatures. Besides, the maximum temperature
difference across the exchanger wall thickness either at the hot or cold fluid end is
the lowest, and produce minimum thermal stresses in the wall for an equivalent
performance compared to any other flow arrangements (Ramesh, K. S., et al, 2003).

2.2.3 Applications of Heat Exchanger

Kakaç, S. and Liu, H., (2002) have discussed that the most common heat
exchangers are two-fluid heat exchangers. Three-fluid heat exchangers are widely
used in cryogenics. They are also used in chemical and process industries such as air
separation systems, purification and liquefaction of hydrogen, ammonia gas
synthesis, etc.

Heat exchangers are used in a wide variety of applications as in the process,

power, air conditioning, refrigeration, cryogenics, heat recovery, and manufacturing
industries (Collier, J. G., et al, 1988). In the power industry, various kinds of fossil
boilers, nuclear steam generators, steam condensers, regenerators, and cooling towers
are used. In the process industry, two-phase flow heat exchangers are used for
vaporizing, condensing, freezing in crystallization, and as fluidized beds with
catalytic reactions. The air conditioning and refrigeration industries need condensers
and evaporators.

Energy also can be saved by direct contact condensation. By direct contact

condensation of a vapor in a liquid of the same substance under high pressure,
thermal energy can be stored in a storage tank. When the energy is needed again, the
liquid is depressurized and flashing occurs, which results in the production of vapor.
The vapor can then be used for heating or as a working fluid for an engine.
 12

There have been considerable developments in heat exchanger applications

(Mayinger, F., et al, 1988). One of the main stages in the early development of
boilers was the introduction of the water-tube boilers. The demand for more
powerful engines created s need for boilers that operated at higher pressures, and, as
a result, individual boilers were built larger and larger. The boiler units used in
modern power plants for steam pressures above 80 bar consist of furnace water-wall
tubes, super heaters (Kitto, J. B., et al, 1991). The development of modern boilers
and more efficient condensers for the power industry has represented a major
milestone in engineering. In the process industry, engineers are concerned with
designing equipment to vaporize a liquid. In the chemical industry, the function of
an evaporator is to vaporize a liquid or to concentrate a solution by vaporizing part of
the solvent. The wide variety of applications of heat exchanger equipment is shown
in Table 2.1 which discussed by Kakaç, S., et al (2002).

Table 2.1 Application of Heat Exchanger Technologies

Application Examples
Transportation Car cooling, radiator, and oil cooling.
Converter, amplifier, personal computer, and
Electronics
transformer.
Household Electric heater, hot water tank, and air conditioner.
National defense Aircraft cooling, and engine cooling.
Industry Cooling tower, distiller, and water-heat recovery.
Geothermal energy, boiler, electricity, freezing A/C,
Energy
super-conduction, heat engine, and cogeneration.
Farm and Fishery Freezer, and vacuum fridge.
Environment Engineering Heat recovery, and water-water cooling.
 13

2.3 Dynamic Simulation

Dynamic Simulation is any process can be modeled mathematically, that is,

represented at least approximately by a set of algebraic and differential equations
whose variables represent particular characteristics of the process. Simulation is the
numerical solution of these model equations. Steady-state simulation produces the
time-independent values of the variables while dynamic simulation gives the
transient solutions of the equations. A process dynamic simulator can thus be
regarded as a program system capable of simulating the dynamic behavior of the
plant.

The process industries are faced with an increasingly competitive

environment, ever-changing market conditions, and government regulations. Yet,
they still must increase productivity and profitability. These business objectives are
achieved by reducing the time required to get new products to market, increasing the
quantity and quality of product produced, operating the plant more safely and
efficiently and or designing plants for an optimum performance along their lifecycle.

In the chemical process industries, operational efficiencies, production

economies, product quality and ultimately, and bottom line performance can be
adversely affected by a multitude of factors. Many of these factors are extremely
complex and subject to varying degrees of unpredictability. To avoid production
delays, downtime or off-spec product, process manufacturers require cost-effective
tools that help identify and ‘correct’ anticipated problems before they occur.

The purpose with the dynamic simulations is to make a comparison with the
real experiments. This comparison can only be made if the simulation and real
experiments experience the same condition. Dynamic plant simulation is a powerful
tool that helps managers and engineers link business operations to process operations
and faced the challenging as state above. Dynamic simulation enables manufacturers
to ensure safety and environmental compliance. It is also can improve operability,
start-up and shut-downs while can achieve consistent product quality.
 14

Process engineers routinely address difficult manufacturing and production

issues. Unfortunately, experience alone is not always sufficient to answer the
questions that continually arise and ‘trial and error’ efforts to provide meaningful
insight are usually cost-prohibitive if not occasionally risky.

For most companies, the benefits of using simulation go beyond simply

providing a look into the future. These benefits are mentioned by many authors
(Banks et al., 1996; Law and Kelton, 1991; Pegden et al., 1995; Schriber, 1991).

2.4 Aspen Software

Many different digital simulation software packages are available on the

market. Modern tools are numerically powerful, highly interactive and allow
complicated types of graphically and numerical output. Many packages also allow
optimization and parameter estimation. Table 2.2 below show some of the available
software that can be use for simulation process. This software were discussed by
Banks, J. (1998)

Table 2.2 List of Available Software for Simulation

Software Company
AspenPlus/AspenDynamics Aspen Technology
HYSIS Hyprotech Inc.
Dymola Dynasim
GPSS/H Wolvrine Software Corporation
SLX Wolvrine Software Corporation
SIMSCRIPT II.5 CACI Products Company
AweSim Symix (formerly Pritsker Corporation)
SIMPLE++ AESOP Corporation
Extend Imagine That Inc.
 15

There are several commercial software packages that have dynamic

capability. The two mostly used are “HYSIS” from Hyprotech Inc. and
“AspenPlus/AspenDynamics” from Aspen Technology. But just AspenPlus/
AspenDynamics simulator will be used in this project. For the dynamic simulation
using Aspen software, dynamics products enable comprehensive dynamic plant
modeling to evaluate designs for profitability, operability, safety, and to improve
existing plant operations over their lifecycle. By linking dynamic modeling, fast
start-ups, optimum feed switch strategies, detailed unit and plant-wide performance
improvements, and optimal safety of the plant, can all be accomplished. Although
these simulators are far from perfect, they do provide a reasonably effective tool for
studying process dynamics (Luyben W.L., 2002).

2.5 Literature Review of Previous Study

Based on Luyben, W. L. (2004) research, the most commonly used

simulation software is that developed by Aspen Technology, which is AspenPlus for
steady-state simulation and AspenDynamics for dynamic simulation. In this steady-
state simulators contain a variety of algorithms. For example, the have three
available methods as Weigstein, Broyden, and Newton that can be use by the user.
Convergence tolerances and the maximum number of iterations can also be adjusted.

The converge of recycle loops is the most difficult part of steady-state

simulation. Normally, some conditions of a recycle stream (flow, temperature,
pressure and composition) and work down through the flowsheet need to assume
until the calculated values of the recycle stream are available. If the assumptions that
are made and calculated values are not sufficient close, new guesses somehow must
be made. The process repeated until convergence between the assumed and
calculated values has been attained. Noted that, is not a problem that the issue of
requiring good initial guesses of plant conditions in order to converge. This is
because all the equipments have been converged individually before exporting into
AspenDynamics.
 16

There are several items that must be considered of to convert a steady-state

simulation into a dynamic simulation by which sizing all the equipment developing a
control structure. Keep in mind that not all of the units that are available in steady-
state AspenPlus will be supported in AspenDynamics. For STHE, the volumes can
be calculated from the heat transfer area. For most STHE, shell volume is
approximately equal to the tube volume.

Another researcher from University of Lund Sweden, Kauhanen, P., stated

that computer modeling and simulation is the interesting new research tool. This tool
can solve a problems that are faces in the plant nowadays. Dymola is the software
that was used in the research. But this software also has the same function with the
Aspen Dynamics to do a modeling and simulation.

In the research, perturbation was given during the process, to analyze the
effect to the temperature and flow characteristics. The same disturbance also was
done during the experiment to make a comparison. The study on perturbation was
done to verify whether the heat exchanger model is the good description of the real
heat exchanger.

Figure 2.3 Temperature Perturbation, Simulation and Experiment

 17

Figure 2.4 Flow Perturbation, Simulation and Experiment

From the research, the temperature and flow differences comparison between
the simulation and experiment was not more or less than ±10%. By pasting the
sampled data into tables that controls the temperatures and the flows in the model,
almost the same disturbance can be performed. Figures 2.3 and 2.4 above are a
comparison between the simulated perturbation and the experimental perturbation
that was done by Kauhanen, P. All simulated perturbations have the same pattern
that is shown in these figures.

Besides that, a different study on simulation process was done by using B-

JAC. This simulator type can also perform the appropriate calculations. It was used
to determine both outlet streams, heat exchanger area and the duty. Later, it will use
to determine the characteristics of the heat exchangers in the laboratory.
.

CHAPTER 3

METHODOLOGY

3.1 Introduction

Every simulation study begins with a statement of the problem. The task is
already recognizing, which is to run a dynamic simulation of shell and tube heat
exchanger (STHE) process. The first step of simulation process is gathering or
collecting data for each of the equipment and operation condition that will be use in
the simulation. These data is very important, because it will be filled in the dialog
box during the simulation process. This simulation process will be run at Aspen
software. Later, laboratory experiment of STHE will be done. The value that will
use in the simulation process must be same when running the laboratory experiment.
So that, the results from the simulation will be analyze because lastly, it were needed
to compare with the results from the experiment. After that, the validation is to
determine whether the results from the simulation can be used in the real process.
Figure 3.1 is the summary of the methodology of the project. Finally, all the process
and the achievement results will be record in a report.
 19

Data Collection

Simulation Process

The Experiment

Data Analysis

Result Comparison and Validation

Figure 3.1 Flow Chart for Simulated STHE

3.2 Data Collection

Firstly, the data will be collected from a manufacturing company which has
built the model of STHE and has the information that will be needed for the input
parameters to the model. It is helpful when validating a model to have real data to
compare the performance measures of the model with the experimental. These raw
data will provide a basis for establishing the model's input parameters and will help
identify those input parameters requiring more precise data collection. Even when
using raw data, a triangular distribution will be based on a minimum, maximum, and
most likely value, rather than simply use an average value. The data that needed here
is one that related to the equipment that we used in the simulation process. The exact
value that we used is the less assumption can be made for the simulation. This
information data is the variables that use in the STHE such as temperatures,
pressures, heat duty, and flow rates.
 20

3.2.1 Shell and Tube Heat Exchanger

Table 3.1 STHE Properties Data

Specification Value Unit

Exchanger Total exchanger area, A 2.50 m2
layout
Heat transfer coefficient, h 160.50 Wm-2K-1
Tube side Pressure, P -/+3 bar
(Hot water) Temperature, T -50/150 ºC
Capacity, V 9 L
Temperature drop, ∆T -143 ºC
Number of tubes, NT 37
Length of tubes, Lt 1.42 m
Tube inner diameter, di 0.0110 m
Tube outlet diameter, do 0.0140 m
Tube pitch, PT 0.0210 m
Tube surface area, At 0.0491 m2
Cross section area 0.000154 m2
Total cross section area 0.00570 m2
Mass velocity 15.68 kgm-2s-1
Linear velocity 0.0161 ms-1
Heat transfer factor 0.00700
Tube coefficient, hi 226.37
Shell side Pressure, P -/+ 2 bar
(Cold water) Temperature, T -50/150 ºC
Capacity, V 18 L
Temperature drop, ∆T -143 ºC
Shell diameter, ds 0.150 m
Cross flow area 0.0203 m2
Mass velocity 17.14 kgm-2s-1
Linear velocity 0.0173 ms-1
Heat transfer factor 0.0190
Tube coefficient, hs 498.21
Other Baffle length, LB 0.284 m
Baffle cut, BC 25 %
 21

The information data of STHE that shows in Table 3.1 for that installed in the
laboratory can get from the manual report which is supplied from the manufacturer
that builds this equipment.

3.2.2 Water Tank

Cylindrical water tank type is used to storage for both hot and cold water in
the different tank. Hot water tank is more special because at the bottom inside of this
tank was installed with heater to get the desired temperature before entering the
STHE.

Table 3.2 Water Tank Properties Data

Hot water tank Cold water tank Unit

Capacity 100 100 L
Material Stainless steel Stainless steel

3.2.3 Heating and Cooling Systems

Heater is used to heat up the hot water that out from the STHE. This is
because, the temperature for the hot water outlet from STHE is colder while it must
hotter from it before entering the STHE at the inlet temperature as it decided at
initial. Meanwhile, Air cooler will be used as the cooling system. This air cooler is
used to cool down the cold water that out from the STHE. This is because the
temperature for the cold water inlet to the STHE will be hotter after out from it. So
that, it needs to decrease the temperature by using air cooler before entering the
STHE again.
 22

Table 3.3 Heating and Cooling Systems Properties Data

Heater Air cooler Unit

Heat duty 34.5 23.0 kW
Pressure 1 1 bar

3.2.4 Circulation Pumps

Circulation pump is used based on gravitational position. The installation of

STHE in the laboratory is not really in the lower position, which is higher for several
centimeters than it. The pump is used to push up the water up to go in the STHE.

Table 3.4 Circulation Pump Properties Data

Pump (hot stream) Pump (cold stream) Unit

Heat duty 30 – 80 30 – 80 Lmin-1
Height 13.5 – 20.5 12.8 – 20.1 m
Power 0.37 0.37 kW

3.2.5 Other Specifications

For other specification, there have three things that need to recognize or
decide first that are components, flowsheets, and streams.

The component that is used in this simulation is water (H2O) depends on the
component that used in the real experiment. If the simulation used other component,
make sure while doing the experiment, the same component also must be used.

The flowsheet here is the connection of the streams that used in the
equipment must be right, which the inlet and outlet streams must be in the right
place. For example, where should the streams for both hot and cold water must
connect to after go out from the STHE.
 23

Lastly are the streams. Actually, the value for temperature, pressure, total
flow and composition are decided by us but the value that is used must be in the
range of the equipment can operate.

3.3 Simulation Process

The aim of dynamic simulation is to be able to relate the dynamic output

response of a system to the form of the input disturbances, in such a way that an
improved knowledge and understanding of the dynamic characteristics of the system
obtained. Figure 3.2 show the relation of a process input disturbance to a process
input disturbance to a process output response based on discussed by Ingham, J., et
al, (2000).

Input Output
disturbance Simulation model disturbance
or process

Figure 3.2 Relation of Process Input to Process Output

We interact with a block through its ‘dialog box’. The dialog box is a
window shown by clicking twice on the graphic or ‘Icon’ of the block. The dialog
box can contain variables, buttons, checkboxes, control buttons, data tables, as well
as text. These variables, buttons, and others can be changed by us by typing in new
values or by pointing and clicking with the mouse. A third layer, which normally
would be invisible to us, is the source code. Variables in the dialog box as well as
variables received from other blocks are all available to the source code. A
simulation can also write variables to a report file and or a debugging file. So that,
the input can be modify, insert new model blocks and view results dynamically all
without having to enter or even see a line of code.

Actually, there is another stage before doing a dynamic simulation. The stage
here is steady-state simulation.
 24

3.3.1 Steady-state Simulation

First thing that need to do in simulation is by open the Aspen software new
file. To open AspenPlus User Interface from the Start, click Start, point to All
Programs, point to Aspen Tech, point to Aspen Engineering Suite, point to
AspenPlus 12.1, and then click AspenPlus User Interface.

1. AspenPlus Startup
i. Choose Template
ii. Click Ok
2. Click New
i. In the Simulation tab, click Gas Processing with Metric Units
ii. Choose Flowsheet for Run type
iii. Click Ok
3. Click Connect to Engine
i. Choose Local PC for Server type
ii. Click Ok

After open the Aspen software new file the interface will be appear as shown
in Figure 3.3. During the simulation process, the important thing that needs to do in
this stage is to fill all the information data that are state in the Aspen software.
Below are the steps to do this steady-state simulation:

1. First equipment, the model of STHE one-pass shell and one-pass tube (1-1,
exchanger) needs to choose from the list of equipment and installed in the
process flowsheet interface. This STHE is get from the Heat Exchanger tab
below the interface. The STHE that is used is type of HeatX.
 25

Figure 3.3 Windows Flowsheet

Figure 3.4 Windows Flowsheet with STHE Block (HeatX Type)

 26

2. After that double click the graphic of STHE, the dialog box will be appearing
as shown in the Figure 3.4. The user can interact with these input data
through its dialog box. Below are the input data that need to filled in to the
dialog box:

Setup (Figure 3.5)

Global:
Title: Dynamic Simulation of Shell & Tube Heat Exchanger Process
Units of measurement: Input data: METGAS
Output results: METGAS
Global settings: Run type: Flowsheet
Input mode: Steady-state
Valid phases: Liquid only

Figure 3.5 Data Browser for Setup Specifications

Blocks (STHE) (Figures 3.6 and 3.7)

Specifications:
Calculation: Shortcut
Type: Simulation
Flow arrangement: Flow direction: Counter-current
Exchanger specification: Exchanger area = 2.5 m2
 27

Figure 3.6 Data Browser for Block STHE (HeatX)

The STHE that was installed in the laboratory experiment has no nozzle.
So that, just the specification calculation for shortcut can be choose to fill the
data. While, the calculation for detailed cannot be done because even the box
can be filled with the length, diameter and number of tube, and so on with the
shell, but there is no nozzle data that must be filled in for nozzle required data.

Figure 3.7 Data Browser for Block STHE (HeatX) (continued)

 28

Components (Figure 3.8)

Selection:
Define components: Component ID: Water

Figure 3.8 Data Browser for Components Specifications

Flowsheet (Figure 3.9)

Specification: Input Streams: ID: HI, Port: H(IN)
CI, C(IN)
Output Streams: ID: HO, Port: H(OUT)
CO, C(OUT)

Figure 3.9 Data Browser for Flowsheet Streams

 29

Streams (Cold water in) (Figure 3.10)

Specifications: State variables: Temperature = 35 ºC
Pressure = 1 bar
Total flow: Volume = 5 Lmin-1
Composition: Mole-Fraction = 1

Figure 3.10 Data Browser for Cold Water Stream Input

Streams (Hot water in) (Figure 3.11)

Specifications: State variables: Temperature = 50 ºC
Pressure = 1 bar
Total flow: Volume = 20 Lmin-1
Composition: Mole-Fraction = 1

Figure 3.11 Data Browser for Hot Water Stream Input

 30

Figure 3.12 Process Flow Diagram for STHE

 31

3. The simulation can be run after fill up the entire requirement input data. The
result from control panel must be end with “Simulation calculations
completed”. While from the Results summary, the status must stated with
“Calculations were completed normally”. All the results can be seen at
Streams from Results summary.

4. After the first results are available with no error, so that the second equipment
or block can be installed one by one in the Process Flowsheet Window to
make a complete flowsheet as shown in Figure 3.12. Then, the status must
also state as normal with no error such as in Figure 3.13. The overall results
summary streams can be seen as in Chapter 4.

Figure 3.13 Results Summary Run Status

 32

3.3.2 Dynamic Simulation

The steady-state simulation does not need information that has no effect on
steady-state results such as sizes of control valves and others. However, the dynamic
simulation does need this information because the dynamic response of a process
unit depends on the size of the equipment. The time constant of the system is
dictated by its size, volume or mass, relative to the flowrate, heat-transfer rate, etc.
Therefore all equipment must be sized before dynamic simulations can be performed.

The other important aspect of the flowsheet that must be specified in order to
conduct a dynamic simulation of a process is the plumbing. This includes installing
pumps, compressors and control valves. This task was already done during the
steady-state simulation.

There are two types of dynamic simulations that are “Flow Driven Dyn
Simulation” and “Pressure Driven Dyn Simulation”. In this project it will only
consider Flow Driven Dyn Simulation.

Another important aspect of dynamic simulators is their use of approximate

physical property relationships instead of the thorough methods used for steady-state
simulations. The usage of more simple relationships can decreases the computing
problem and speeds up the simulations. The ratio of “process time” to “computer
time” is important, particularly for plantwide simulations that can have very large
time constants such as hours or days. However, the use of approximate properties
introduces some error in the dynamic simulations.

There are several steps that must be done in order to do a dynamic simulation.
So those, the first thing that need to do by exporting the steady-state into dynamic
simulation. Below are the steps to save into Flow Driven Dyn Simulation file:

1. Click Export from File tab.

2. Type the file name for example “filename.dynf” and save it as “Flow Driven
Dyn Simulation”.
 33

After that, information messages exporting dynamic simulation as shown in Figure

3.14 will be appeared to inform about the situation that need to remind and taken
care before run it as dynamic simulation.

Figure 3.14 Information Messages Exporting Dynamic Simulation

 34

Figure 3.15 Process Flow Window for AspenDynamics

 35

After that, to run this dynamic simulation, the run options must be filled on in
order to control the simulation time. Figure 3.16 below show the example of the
value that need to fill in Run Options window.

Figure 3.16 Run Options

Then, the dynamic simulation now can be run. The result in the graph form
can be view from the Simulation Explorer. To view the results:

1. In the All Items pane of the Simulation Explorer, click Flowsheet.

2. In the Contents pane, double click Streams, double click CI then HI.
3. In the Contents pane, double click the TPFPlot, then the graph will be
appeared. When right click the graph then click Show History, results table
will be appeared. These results will be discussed in Chapter 4.
 36

3.4 The Experiments

The experimental equipment is a STHE (model: HE 667). The experiment is

located in a laboratory of the Chemical and Natural Resources Engineering
Department at University College of Engineering & Technology Malaysia
(KUKTEM) and has been used in the education of KUKTEM chemical engineering
students since 2003. The equipment was manufactured by Solution Engineering Sdn.
Bhd. (Kuala Lumpur, Malaysia). Figure 3.17 below show the equipment of STHE
that was installed on the laboratory.

Figure 3.17 STHE Equipment on Laboratory

 37

Figure 3.18 Schematic Diagram for Shell and Tube Heat Exchanger (Model: HE 667) in Laboratory
 38

The experimental setup that is show in Figure 3.18; STHE is located to the
middle of the figure. For the cold water flow, FT2, mains cold water, controlled by a
flow controller operating a valve, is used. Temperature indicators measure the cold
water inlet and outlet temperatures, TT3 and TT4. For the hot water flow, FT1, a
pump, controlled by a flow controller, pumps water through a heated tank where a
heater, controlled by a temperature controller, heats the water. Temperature
indicators measure the hot water inlet and outlet temperatures, TT1 and TT2. TI1 is
also used as the input to the temperature controller. The heat exchanger was
originally built to study the principles of heat transfer; its application was then
broadened to study transient dynamic and control. In this initial collaboration, the
focus has been on the controller for the hot water inlet temperature.

During the experimental, of course the same value that was use in the
simulation is also use in the input variables of the experiment. The values of
variables that to use to run the experiment must be same with the data that are fill in
the simulation. After the experiment is done, the results also need to be recorded.

In order to run the experiment, it is important that the user read and fully
understand all the instructions and precautions stated in the manufacturer’s manuals
supplied with the unit prior to operating. In this project, it only counter-current flow
that will be study on. Based on Figure 3.18, the arrangement valve is shown in Table
3.5 below.

Table 3.5 Valve Arrangement for STHE

Open Close Leave alone

HV1, HV3, HV4, HV2, HV7, HV11, HV5, HV15
Counter-current HV6, HV8, HV9, HV13
HV10, HV12

For valve HV5 and HV15 are leaving alone because these valves will be open
later and then adjusted to obtain the desired flowrates for both hot water and cold
water streams.
 39

So as to get the results, the data must be recorded for variables, both hot and
cold water flowrates and also both inlet and outlet for hot and cold water
temperatures. The data will be stop taken after the results for inlet temperature for
both hot and water streams. These data will be discussed in Chapter 4.

3.5 Results Analysis

Since analytical chemistry is the science of making quantitative

measurements, understanding the difference between accuracy and precision is vital.
Presentation of data will be show in the form of tables and graphs. Data analysis
here is to analyze the results that got from both simulation and experiment. This is
by to ensure that all the data are available for both of it.

3.6 Results Comparison and Validation

Comparison between the results from the simulation and the experiment is the
main method to know if the simulation is successful or not. The results for both of it
can be compared because the equation such as material and energy balance is
specific and similar that applied for both simulation and experimental. This
comparison also will be discussed in Chapter 4.

Validation is the determination that the conceptual model is an accurate

representation of the real system. The existing system, which is the STHE in the
laboratory, is the base system. An ideal way to validate the model is to compare its
output to that of the base system.
.

CHAPTER 4

RESULT AND DISCUSSION

The comparison between the results from the simulation and the
experimentation should be the same. But if there is a difference between the results,
the error for getting the same values is expected to be around ±10% (Kauhanen, P.).
This is because, the equations that are used in the simulation process such as material
and energy balances are specific and similar with the shell and tube heat exchanger
(STHE) that will be run in the laboratory experiment. The error mostly happened
because of the experimentation and assumption during the simulation process.

1.1 Results Analysis

1.1.1 Simulation Results

Initially, the temperature for hot water inlet is fixed with 50ºC while 35ºC for
cold water inlet. After the simulation was run, the results show that the temperature
for hot water inlet is 50.2ºC and 35.1ºC for cold water inlet just after two iterations.
This iteration is done until there is no errors occur and the process was balance. The
steady-state simulation results are shown as in Table 4.1.
 41

Table 4.1 Streams Results Summary

 42

Table 4.1 Streams Results Summary (continued)

 43

Refer to Table 4.1, the temperature is about 50.2ºC for hot water inlet (HI)
stream to STHE and the temperature is down to 40.1ºC when leave STHE at stream
HO. The temperature was maintained through the valve 5 (HV5) and hot water tank.
While the water passes through the heater, the temperature was increase to 50.0ºC at
stream H3. This is because the water is needed to be heated up before entering
STHE again. The temperature is increase about 0.2ºC to 50.2ºC after passes through
the hot water pump. This is happened because of the effect from the pressure
difference which, more pressure is needed to rise up the water to entering STHE.

While for the temperature for cold water inlet (CI) stream to STHE is about
35.1ºC and the temperature is up to 40.8ºC after passes through the STHE at stream
CO. The temperature was decrease to 35.0ºC at stream C2. This is because the
water is needed to be cool down by air cooler before entering STHE again. Then the
temperature was maintained for stream C3, C4, and C5. The temperature is increase
about 0.1ºC to 35.1ºC after passes through the hot water pump. This phenomenon is
also happened because of to rise up the water.

In this steady-state results, the time that is taken to achieve is not showed.
The results from the steady-state simulation are very important to analyze. This is to
make sure that the available results are seemed to be as existent while run the
experiment later. It means that, the values of the parameters that calculated by the
simulator are not presented as much and much larger or smaller than the common
sense understanding. For example, by viewing Table 4.1, while stream H2 is passing
through the heater, the temperature is increase to achieve certain value that depends
with the required data input to the heater.
 44

Table 4.2 Simulation Results Table for Inlet Temperature; (a) Hot Water; (b)
Cold Water

(a) (b)

While in the dynamic table, the time for the temperature reached the steady-
state value are showed. Table 4.2 show the results data from the dynamic simulation.
According to Table 4.2a, hot water inlet temperature achieved the steady-state value
50.186839ºC at 50 seconds. While the cold water inlet temperature, Table 4.2b
achieved the steady-state value 35.104163ºC at 30 seconds.

The value of the simulation results is more accurate with the six decimal
points. The independent variable, time, is run in the seconds’ unit. This is because
the results from the experiment also will be recorded in that unit.

These data were presented in the form of graph as shown in Figures 4.1 and
4.2. The horizontal line is the steady-state values that are not change with time.
 45

Figure 4.1 Simulation Graph of Hot Water Inlet Temperature versus Time

Figure 4.2 Simulation Graph of Cold Water Inlet Temperature versus Time
 46

Table 4.3 below show the overall results of both inlet and outlet for STHE
equipment.

Table 4.3 Overall Results for STHE; (a) Hot Water Inlet Stream; (b) hot Water
Outlet Stream; (c) Cold Water Inlet Stream; (d) Cold Water Outlet Stream

(a)

(b)
 47

(c)

(d)
 48

1.1.2 Experiment Results

The experiment results were recorded as stated for the experiment stage in the
methodology at Chapter 3. The results were taken from initial until the temperature
for both hot and water inlet temperature does not change over the time. Table 4.3
below show the results of this experiment.

Table 4.4 Experiment Results Table

Temperature (ºC)
Time (seconds)
HI CI
0 50.1 32.6
10 50.0 32.8
20 49.9 32.9
30 49.9 33.0
40 49.8 33.0
50 49.5 33.0
60 49.4 33.1
70 49.2 33.1
80 49.2 33.1
90 49.3 33.2
100 49.1 33.3
110 49.0 33.3
120 49.0 33.3
130 49.0 33.3
140 49.0 33.3
150 49.0 33.3

The table shows that the steady-state value for hot water inlet temperature is
49.0ºC at 110 seconds. While the cold water inlet temperature achieved the steady-
state value 33.3ºC at 100 seconds 10 seconds earlier than the hot water inlet
temperature. Figures 4.3 and 4.4 are the results plotted from the table above.
 49

Hot Water Inlet Temperature versus Time

50.2

50.0

49.8
Temperature (deg C)

49.6

49.4

49.2

49.0

48.8
0 20 40 60 80 100 120 140
Time (seconds)

Figure 4.3 Experiment Graph of Hot Water Inlet Temperature versus Time

Cold Water Inlet Temperature versus Time

33.4

33.3

33.2

33.1
Temperature (deg C)

33.0

32.9

32.8

32.7

32.6

32.5

32.4
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
Time (seconds)

Figure 4.4 Experiment Graph of Cold Water Inlet Temperature versus Time
 50

1.2 Results Comparison

Equation 4.1 that showed below is how to calculate the percentage error
occurred between simulation and experiment

Simulation − Experiment
% error = × 100% (4.1)
Experiment

4.2.1 Steady-state Results Comparison

The available temperature results were compared between simulation and

experiment. For the simulation, the results were showed in four decimal points.
While the results for experiment was digitally showed in one decimal point
difference in control panel. Steady-state condition here means the constant results
data when the value was not change with time. These results were recorded when
the values were unchanged.

Table 4.5 Steady-state Comparison Table

Simulation Experiment Error (%)

TT1 (ºC) 50.1868 49.0 2.42
TT2 (ºC) 40.0801 40.7 - 1.52
TT3 (ºC) 35.0142 33.3 5.15
TT4 (ºC) 40.7951 42.3 - 3.56

Example error calculation for hot water inlet temperature, TT1

50.1868 − 49.0
Error, Thi = = 2.42%
49.0

By refer to the simulation results, the balances were achieved after two
iterations. That is mean, the calculation by the simulator will be running up until the
material and energy were balanced. By doing the comparison, the hot water inlet
temperature difference between the simulation and experiment are from 49.0ºC to
 51

50.1868ºC. The difference is presented in the form of percentage error, which is

about 2.42%. The calculation above is showed how to calculate the error of hot
water inlet temperature. The same equation also used in calculates the error for the
rest results. Table 4.5 shows that the error is about -3.56% to 5.15%. It is showed
that the errors are on the range of ±10%. So, the study on the results comparison was
successful by achieving the target range.

Suppose to there was no difference between the simulation and experiment

results. But because of the assumption that was made during the simulation and
while record the results during the experiment make both results are not same to each
other. Other than that, the temperature results that are shown digitally on the control
panel at the laboratory are just with one decimal point. While there were no change
on the results from the simulation with the same point. That is mean; the
temperature changes in the simulation results were too small to compare with the
experiment.

4.2.2 Dynamic Results Comparison

The results from the dynamic simulation also need to compare with the
experiment to examine the time for dynamic and the temperature differences. In the
dynamic simulation, the difference between each result is about three decimal points.
While the results for experiment was digitally showed in one decimal point
difference in control panel.

By doing the comparison, the simulation temperatures for both hot and cold
water inlet were reach the steady-state 60 to 70 seconds earlier than the experiment
temperatures. The errors that are calculated were between 0.17% until 7.68% as
shown in Table 4.6. The calculation was also use the same equation as in the steady-
state comparison. This stated that the error for getting the same values was in the
range target of ±10%. The study on temperature comparison was also successfully
done by achieving the range of expected results.
 52

Table 4.6 Dynamic Comparison Table

Temperature (ºC)
Time Error (%)
Simulation Experiment
(seconds)
HI CI HI CI HI CI
0 50.186964 35.104038 50.1 32.6 0.17 7.68
10 50.186939 35.104080 50.0 32.8 0.37 7.02
20 50.186914 35.104121 49.9 32.9 0.57 6.70
30 50.186889 35.104163 49.9 33.0 0.57 6.38
40 50.186864 35.104163 49.8 33.0 0.78 6.38
50 50.186839 35.104163 49.5 33.0 1.39 6.38
60 50.186839 35.104163 49.4 33.1 1.59 6.05
70 50.186839 35.104163 49.2 33.1 2.01 6.05
80 50.186839 35.104163 49.2 33.1 2.01 6.05
90 50.186839 35.104163 49.3 33.2 1.80 5.74
100 50.186839 35.104163 49.1 33.3 2.21 5.42
110 50.186839 35.104163 49.0 33.3 2.42 5.42
120 50.186839 35.104163 49.0 33.3 2.42 5.42
130 50.186839 35.104163 49.0 33.3 2.42 5.42
140 50.186839 35.104163 49.0 33.3 2.42 5.42
150 50.186839 35.104163 49.0 33.3 2.42 5.42

Example error calculation for hot water inlet temperature at 0 second, HI

50.186964 − 50.1
Error, THI @ 0 s = = 0.17%
50.1

Refer to the table above; the temperatures for experiment take longer time
than simulation because the flowrate also still change over the time. It showed that
the flowrate change will affect the temperature results. These results that showed in
Table 4.6 were presented in graph plotted in Figures 4.5 and 4.6
 53

Hot Water Inlet Temperature versus Time

Simulation
50.18698 50.2
Experiment

50.18696
50.0

Experiment Temperature (deg C)

50.18694
Simulation Temperature (deg C)

49.8

50.18692
49.6

50.18690

49.4
50.18688

49.2
50.18686

49.0
50.18684

50.18682 48.8
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
Time (seconds)

Figure 4.5 Comparison Graph of Hot Water Inlet Temperature between Simulation and Experiment
 54

Cold Water Inlet Temperature versus Time

Simulation
35.10418 33.4
Experiment

33.3
35.10416

33.2

Experiment Temperature (deg C)

35.10414
Simulation Temperature (deg C)

33.1

35.10412
33.0

35.10410 32.9

32.8
35.10408

32.7
35.10406
32.6

35.10404
32.5

35.10402 32.4
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
Time (seconds)

Figure 4.6 Comparison Graph of Cold Water Inlet Temperature between Simulation and Experiment
 55

4.3 Results Validation

Finally, the last stage on this study is to validate the results. By refer to the
difference calculation by compared the results between simulation and experiment
showed that the percentage errors are not out from the target value. The data from
the simulation process can be used to another application for example in the process
control. The study on process control later no needs to run the experiment to get the
results. Therefore, the plant now can be controlling automatically. This is the more
efficient way to handle the plant rather than controlling it manually.
 CHAPTER 5

CONCLUSION AND RECOMMENDATIONS

5.1 Conclusion

Dynamic simulation has become increasingly important as processes become

more complex and are designed and operated closer to constraints. The use of
intermediate buffer tanks has been greatly reduced because of environmental and
safety concerns. Increasing energy costs keep pushing design engineers toward more
heat integration. This trend makes dynamic control more difficult and dynamic
simulation more important. It is vital that all the unit operations of a complex
flowsheet be able to appear together in the face of the inevitable disturbances. These
include production rate changes, feed composition variability, transitions to different
product specifications and rapid ambient temperature changes during storms.

Ideally the dynamics of the process should be considered at the very early
stages of the development of the process. Certainly at the pilot plant stage, trade offs
between design and control should be explored, and basic regulatory control
structures should be developed and tested. The engineering time expended at the
early stages can reap enormous economic benefits later in the project in terms of
rapid, trouble-free start-up, reduced product quality variability, less frequent
emergency shutdowns, reduced environmental contamination and safer operation.
Fortunately have the ability to perform plantwide dynamic simulations have also
increased.
 57

As a conclusion, this project was achieve the objectives to do a dynamic

simulation of shell and tube heat exchanger (STHE) process and to define whether
the simulation has the same characteristic with the real process by comparing the
results. From the calculation, this project was done successfully by achieve the
target, which having the error not more or less than ±10%. The calculated errors
were between -3.56% and 7.68% for both steady-state and dynamic conditions. In
order to run a dynamic simulation, the file was converted from AspenPlus to
AspenDynamics.

By doing this project, there are many benefits that can get by study of the
dynamic simulation of STHE process or any other plant. The simulation technique is
the basis step before build up a process plant. Actually, the more study on the
simulation skill, the more understanding, information, and knowledge that can get to
improve the plant.

5.2 Recommendations

This project was run in the counter-flow. For further research, it is

recommended that the study will be continuing for the parallel-flow which is also
referred to as co-current or co-current parallel stream. In a parallel-flow exchanger,
the fluid streams enter together at one end, flow parallel to each other in the same
direction and leave together at the other end.

It is also recommended that the further study will be continuing with varying
the flowrate. This study will give more understanding during taking the dynamic
results. This is because; the results will show the time of the temperature to achieve
steady-state condition in different flowrates. In addition, the effects of either cold or
hot water flowrate can be study on the heat transfer coefficients if the hot or water
flowrate is constant.

Besides that, the research also can be continuing by studying on the pressure
drop analysis. The pressure drop can be analyzed either in tube-side or shell-side.
 58

The recommendations that stated are just three studies on parallel-flow, vary
the flowrate, and pressure drop analysis. There are lots of other analysis can be study
on this dynamic simulation of STHE process.
 59

REFERENCES

Banks, J. (1998). Handbook of Simulation: Principles, Methodology, Advances,

Applications, and Practice. New York: John-Interscience.
Çengel, Y. A., and Boles, M. A. (2004). Thermodynamics: An Engineering
Approach. 4th edition. New York: McGraw-Hill.
Chisholm, D. (1980). Developments in Heat Exchanger Technology. Volume I.
London: Applied Science Publishers.
Collier, J. G., Mayinger, F., Kakaç, S., Bergles, A. E., and Fernandes, E. O. (1988).
Two-Phase Flow Heat Exchangers: Thermal-Hydraulic Fundamentals and
Design. Netherlands: Kluwer Publishers.
Colton, C. K., Knight, M., Khan, R. A., Ibrahim, S., And West, R. A Web-Accessible
Heat Exchanger Experiment. U.K.: University Of Cambridge.
Ingham, J., Dunn, I. J., Heinzle, E., and Přenosil, J. E. (2000). Chemical Engineering
Dynamics: An Introduction to Modelling and Computer Simulation. 2nd
edition. Weinheim: John Wiley & Sons.
Kakaç, S., and Liu, H. (2002). Heat Exchangers: Selection, Rating, and Thermal
Design. Florida: CRC Press.
Kauhanen, P. Verifying the Dynamic Model of a Heat Exchanger Configuration.
University of Lund, Sweden.
Kitto, J. B., Jr. and Albrecht, M. J., and Kakaç, S. (1991). Boilers, Evaporators and
Condensers. New York: John Wiley & Sons.
Kuppan, T. (2000). Heat Exchanger Design Handbook. New York: Marcel Dekker.
Luyben, W. L. (2004). Use of Dynamic Simulation to Converge Complex Process
Flowsheets. U.S.: Lehigh University.
Luyben, W. L. (2002). Plantwide Dynamic Simulators in Chemical Processing and
Control. New York: Marcel Dekker.
 60

McCabe, W. L., Smith, J. C., and Harriott, P. (2001). Unit Operations of Chemical
Engineering. 6th edition. New York: McGraw-Hill.
Najim, K. (1989). Process Modeling and Control in Chemical Engineering. New
York: Marcel Dekker.
Penha, R. L., Hines, J. W., and Upadhyaya, B. R. Monitoring and Diagnosis of a
Heat Exchanger Using Hybrid System Modeling.
Robertson, N., and Perera, T. Automated Data Collection for Simulation. Volume 9,
Issues 6-8: 349-362.
Selmer, A., Goodson, M., Kraft, M., Sen, S., McNeill, V. F., Johnston, B. S., and
Colton, C. K. (2004). Process Dynamics and Control Experiment Performed
Across the Atlantic. U.K.: University of Cambridge.
Shah, R. K., and Sekulić, D. P. (2003). Fundamentals of Heat Exchanger Design.
New Jersey: John Wiley & Sons.
Tubular Exchangers Manufacturers Association (TEMA) (1988). Standards of the
Tubular Exchanger Manufacturers Association. 7th edition. New York:
TEMA.
Young, J. of Aspen Technology. Innovative Training Program to Increase Process
Plant Skill Levels While Reducing Costs. Cambridge: Aspen Technology, Inc.

.
 61

APPENDICES
 62

APPENDIX A
Operating Instructions of Shell and Tube Heat Exchanger

A.1 Description and Assembly

(a) Shell and Tube Heat Exchanger (STHE)

Dimensions : di = 0.011 m; do = 0.014 m
L = 1.42 m
Ds = 0.15 m
NT = 37 tubes (single passes)
PT = 0.0021 m (triangular)
BC = 25%
LB = 0.284 m
Duty : Tube side: hot water
Shell side: cold water
Material : Tube: Borosilicate glass
Shell: Borosilicate glass

(b) Cold Water Circuit

Tank : 100 L, stainless steel
Level control : Float type control valve
Circulation pump : Centrifugal type, 20 LPM, dry-run protected by
level switch
Heating system : 34.5 kW immersion type heaters regulated by
temperature controller and level switch

(c) Instrumentations
Measurements of inlet and outlet temperatures for hot and cold water streams.

(d) Control Panel

To amount all the necessary digital indicators, temperature controller, selector
switches, on/off switches, etc.
To house electrical components and wirings.
 63

A.2 General Operating Procedures

(a) Valve Arrangements

Open Close Leave alone

HV1, HV3, HV2, HV7, HV5, HV15
Counter- HV4, HV6, HV11, HV13
current HV8, HV9,
HV10, HV12
HV1, HV3, HV2, HV7, HV5, HV15
HV4, HV6, HV10, HV12
Co-current
HV8, HV9,
HV11, HV13

(b) Flow Measurements

Digital and local flowrate indicators are provided. Use the flowrate selector
switch on the control panel to select the following measurements:
FT1: hot water flowrate
FT2: cold water flowrate
The flowrates are digitally displayed in LPM

(c) Temperature Measurements

Use the temperature selector switch on the control panel to select the
following temperatures on counter-current flow:
TT1: Hot water inlet temperature
TT2: Hot water outlet temperature
TT3: Cold water inlet temperature
TT4: Cold water outlet temperature
The temperatures are digitally displayed in ºC

(d) Operating Limits

Temperature : maximum 70ºC
 64

A.3 Overall Dimensions

Height : 2.00 m
Width : 2.00 m
Depth : 1.22 m

A.4 General Requirements

Electrical : 415 V AC / 50 Hz (3 phase) @ 50 Amps

Cooling water : Laboratory tap water, 20 LPM @ 2 m head
Drainage point
 65

APPENDIX B
Schematic Diagram for Shell and Tube Heat Exchanger (Model: HE 667) in Laboratory
 66

APPENDIX C
Process Flow Diagram for Shell and Tube Heat Exchanger in Simulation