Aircooler (AIRCOOL): Page 1 of 11 Sheet no.

of
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Reference: Process Heat Transfer, D.Q.Kern

McGraw-Hill, 1950

Program description:
====================
Comments: The program sizes an aircooler for given flowrate, temperature, tube
diameter and geometry and fin geometry.
The program consists of eleven pages, see list below:
Page 1: Specification of tube- and airside conditions.
Page 2: Spec. tubeside geometry, calc.tube side heat transfer.
Page 3: Spec. airside geometry, calc. airside heat transfer.
Page 4: Overall heat transfer calc's and summary.
Page 5: Tubeside pressure drop calculation.
Page 6: Tube layout calculations.
Page 7: Air side pressure drop calculation and fan sizing.
Page 8: Weight estimate and layout summary.
Page 9: Solution of fin heatbalance.
Page 10: Calculation of Bessel functions at inner fin radius.
Page 11: Calculation of Bessel functions at outer fin radius.

Specify tubeside conditions:

============================
Input: Pressure P = 1000 psia
Inlet temp. Tin = 187 deg.F
Outlet temp. Tout= 140 deg.F
Flowrate liquid vl0 = 20000 BPD
gas vg0 = 0 MMscfd
Density liquid SG = 0.85
gas MW = 20 lb/lbmole
Heat conductivity ko = 0.08 Btu/hr/ft/F
Heat capacity Cpo = 0.62 Btu/lb/F
Viscosity myo = 1.00 cP
Results: Vol.flow liquid vl = 4675 ft3/hr
gas vg = 0 ft3/hr
total vtot= 4675 ft3/hr
Mass flow liquid wl = 247962 lb/hr
gas wg = 0 lb/hr
total wtot= 247962 lb/hr
 Density average d = wtot/vtot = 53.04 lb/ft3
Viscosity myo = 2.42*myo = 2.42 lb/ft/hr

Specify air conditions:

=======================
Input: Inlet temp. tin = 22 deg.C
Temperature increase (+/-) delt= 6 deg.C
Air velocity ua = 20 m/s
Heat conductivity ka = 0.0150 Btu/hr/ft/F
Viscosity mya = 0.0180 cP
Air heat capacity Cpa = 0.24 Btu/lb/F
Results: Inlet temp. tin = 71.60 deg.F
Temperature diff. delt= 10.80 deg.F
Air velocity ua = 65.62 ft/s
Air density da = 0.0748 lb/ft3
Viscosity mya = 2.42*mya = 0.0436 lb/ft/hr
Aircooler (AIRCOOL): Page 2 of 11 Sheet no. of
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Tubeside heat transfer calculation:

===================================

Tube and fin materials data:

Mat. Material Temp. Heat cond.

no. deg.F Btu/hr/ft/F

Data: 1 Aluminium 212 119

2 Steel 212 30
3 Brass 212 60

Select tube material:

Input: Tube material no. Matt= 2

Tube properties:

Input: Outer diameter Do = 1.900

Wall thickness Wt = 0.400
Roughness e = 0.05
Number of parallel tubes Nt = 24
Fouling factor Rdi = 0.002
Result: Inner diameter Di = Do-2*Wt = 1.100
Outer radius rb = Do/2/12 = 0.0792
Inner radius ri = Di/2/12 = 0.0458
Flow area per tube fa = pi*ri^2 = 0.0066
Inner area Ai/L = pi*2*ri = 0.2880
Heat conductivity kt = 30

Tubeside heat transfer:

Results: Reynolds no.

Re = Di/12*wtot/Nt/fa/my = 59300
Prandtls no.
Pr = Cpo*myo/ko = 18.76
Nusselts no.
Nu = 0.023*Re^0.8*Pr^0.33 = 402.30
Film coeffcient
hi = Nu*ko/(Di/12) = 351.09
Corr.film coeff.
hi' = hi/Rdi/(hi+1/Rdi) = 206.26
no. of Aircooler (AIRCOOL): Page 3 of 11
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Project:
Case :

Airside heat transfer calculation:

===================================

Select fin material:

Specific
gravity Input: Fin material no. Matf=

2.7
7.9 Fin properties:
8.5
Input: Fin height Hf =
Fin thickness Ft =
Fin spacing/fin height s/Hf=
Fouling factor Rdo =
Results: Fin diameter Df = Do+2*hf =
Fin radius re = Df/2/12 =
Half thickness yb = Ft/2/12 =
Fin spacing s = s/Hf/12 =
in Number of fins per length
in Nf/L = 1/(2+2*yb) =
mm Fin area Af/L=
2*pi*Nf/L*(re^2-rb^2+2*yb*re) =
hr*ft2*F/Btu Bare tube area
in A0/L = 2*pi*rb*(1-Nf/L*2*yb) =
ft Proj. Perimeter
ft Pp/L = 2*(1+2*Nf/L*(re-rb)) =
ft2 Eff. diameter
ft2/ft Deff = 2*(Af/L+A0/L)/(pi*Pp/L)=
Btu/hr/ft/F Heat conductivity kf =

Airside heat transfer:

Results: Reynolds no.

Re = Deff*va*3600*da/mya =
Prandtls no.
Pr = Cpa*mya/ka =
Nusselts no.
 Nu = 0.0916*Re^0.72*Pr^0.33 =
Btu/hr/ft2/F Film coefficient
hf = Nu*ka/Deff =
Btu/hr/ft2/F Corr.film coeff.
hf' = hf/Rdo/(hf+1/Rdo) =

Efficiency of fins:

Results: Xaxis variable fig. 16.13a

X = (re-rb)*sqrt(hf'/kf/yb) =
Ratio of radii re/rb =
Efficiency, calc. or read off fig.16.13a
Omega =
Correct to inner surface hfi'=
(Omega*Af/L+A0/L)*hf'/(Ai/L) =
Sheet no. of Aircooler (AIRCOOL): Page 4 of 11
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Overall heat transfer calculations:

===================================

Tubeside:

1 Results: Inlet temp.

Outlet temp.
Duty
wtot*(Tin-Tout)*Cpo/1000000 =
Film coefficient
1 in
0.05 in
0.25 in Air side:
0.003 hr*ft2*F/Btu
3.9 in Results: Inlet temp.
0.1625 ft Outlet temp.
0.0021 ft Mass flowrate
0.0208 ft wa = Q*1000000/Cpa/delt =
Volumetric flowrate
40.0 fins/ft va = wa/3600/da =
Flowarea at air velocity ua
5.2316 ft2/ft A = va/ua =

0.4145 ft2/ft
Overall heat transfer:
15.3333 ft/ft
Results: Outer film
0.2344 ft Steel pipe
119 Btu/hr/ft/F ht = kt/(ri*ln(rb/ri) =
Inner film
Overall coefficient
UDi = 1/(1/hfi'+1/ht+1/hi') =
Mean temp.diff.
LMTD = (Tin-tout)-(Tout-tin))/
95066 LN((Tin-tout)/(Tout-tin))
Crossflow correction coefficients
0.70 S = (tout-tin)/(Tin-tin) =
R = (Tin-Tout)/(tout-tin) =
311.75 Input: Corr. factor fig.16.17b
Results: True mean temp. diff.
19.95 Btu/hr/ft2/F TMTD = FT*LMTD =

18.82 Btu/hr/ft2/F
Area calculation:

Results: Inner tube area

Ai = Q*1000000/UDi/LMTD =
Length of tubes
0.73 Ltot = Ai/(Ai/L)
2.05 Length of each tube
L = Ltot/Nt
0.80 Number of fins
Nf = Ltot*Nf/L =
301.76 Btu/hr/ft2/F
 Sheet no. of Aircooler (AIRCOOL): Page 5 of 11
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Tubeside pressure drop:

========== =======================

Tubeside pressure drop:

Tin = 187 deg.F Results: Relative roughness

Tout= 140 deg.F er = e/25.4/Di =
Q = Reynolds no.
7.23 MMbtu/hr Friction factor calc.
hi' = 206.26 Btu/hr/ft2/F A = -2*Log(er/3.7+12/Re) =
B = -2*Log(er/3.7+2.51*A/Re) =
C = -2*Log(er/3.7+2.51*B/Re) =
f=
0.25/(A-(B-A)^2/(C-2B+A))^2 =
tin = 71.6 deg.F Gravitational acc.
tout= 82.4 deg.F Pressure drop calc.
dPt =
2787659 lb/hr 32/pi^2*f*L/d/(Di/12)^5*
(wtot/3600/Nt)^2/144/gc =
10355 ft3/s

158 ft2 Tubeside C-factor:

Results: Flowarea
Number of pipes
Volumetric flowrate
hfi'= 301.76 Btu/hr/ft2/F Average density
Velocity
1197.61 Btu/hr/ft2/F vel = vtot/3600/Nt/fa =
hi' = 206.26 Btu/hr/ft2/F C-factor calculation
C = vel*sqrt(d) =
111.15 Btu/hr/ft2/F

= 85.22 deg.F

0.09
4.35
FT = 0.99

84.37

763 ft2

= 2649 ft

= 110 ft

105955
 Sheet no. of Aircooler (AIRCOOL): Page 6 of 11
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Tube layout:
============

Define geometry: Triangular pitch assumed

0.0018 Comments: The airgap between fins together with fi

specified air velocity defines the length o
Re = 59300 to give the airflow area.
These parameters also determine the le
6.327 as the number of parallel tubes in the bu
6.248 fied. The total surface requirement then
6.252 of tube layers.

0.00640 Input: Airgap between fins

gc = 32.17 lb*ft/lbf/sec2 Number of tubes in layer 1
Results: Fin radius
Bare tube radius
Fin thickness
11.9 psi Number of parallel tubes
Number of fins per length
Centerline distances:
Two tubes adjacent layers
SL = 2*re+gap/12 =
fa = 0.0066 ft2 Two tubes same layer
Nt = 24 ST = 2*re+gap/12 =
vtot= 4675 ft3/hr Two layers
d = 53.04 lb/ft3 Hb = sqrt(0.75)*(2*re+gap) =

8.20 ft/sec
Calculate length of exchanger:
59.7
Results: Projected area of tubes
2*rb+Nf/L*2*(re-rb)*Ft/12 =
Spanned area of fins
As/L = 2*re =
Gap area
Ag/L = gap/12 =
Air flow area
 Afl/L = Ag/L+As/L-Ap/L =
Air area req'd to give ua
Total tube length req'd to give ua
Ll = A/(Afl/L) =
Length of exchanger
Le = Ll/N1 =
Width of exchanger
We = N1*(2re+gap/12) =
Number of tube layers
Ntl = Ltot/Ll =
Selected number of layers
Actual tube length
Lact = (N1+(N1-1))/2*Nts*Le =
Excess tube length
Lex = Lact-Ltot =
Lex% = Lex/Lact*100 =
 Sheet no. of Aircooler (AIRCOOL): Page 7 of 11
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Airside pressure drop:
======================

Calculation of Reynolds number:

gular pitch assumed Results: Net free volume

Le*Nts*(We*hb-pi/2*(2*N1-1)*
een fins together with fin geometry and the (rb^2+(re^2-rb^2)*Ft/12*Nt/
ity defines the length of tubes required Fin area
Af = Lact*Af/L =
s also determine the length of the exchanger Bare tube area
parallel tubes in the bundle has been speci- A0 = Lact*A0/L =
ace requirement then determines the number Effective diameter
D' = 4*Vnf/(Af+A0) =
Air flow
gap = 1 in Ga = wa/A =
n layer 1 N1 = 24 Viscosity
re = 0.1625 ft Reynolds no.
rb = 0.0792 ft Re' = D'*Ga/mya =
Ft = 0.05 in Friction factor from fig.16.18
l tubes Nt = 24 f = 0.0085*Re'^-0.1388 =
r length Nf/L= 40 fins/ft Viscosity corr. factor
Air specific gravity
nt layers sga = da/62.4 =
2 = 0.4083 ft Airside pressure drop eq.16.10
dPa =
2 = 0.4083 ft f*Ga^2*Hb*Nts/5.22E10/D'/sg
/phi*(D'/ST)^0.4*(SL/ST)^0.6
(2*re+gap) = 0.3536 ft
Fan size:

Ref. Perry 5'th ed. p. 6.21

Ap/L= Input: Efficiency

rb)*Ft/12 = 0.1861 ft2/ft Results: Volumetric flow
Q = va*60 =
= 0.3250 ft2/ft Pressure difference
p2-p1 = dPa =
= 0.0833 ft2/ft Air power
HPa = 144*Q*(p2-p1)/33000
L-Ap/L = 0.2222 ft2/ft kWa = 0.7457*HPa =
ive ua A = 157.81 ft2 Shaft power
req'd to give ua HPs = HPa/e*100 =
= 710.12 ft kWs = kWa/e*100 =

= 29.59 ft

ap/12) = 9.80 ft

= 3.73 layers
of layers Nts = 4 layers

1))/2*Nts*Le = 2781 ft

= 132 ft
*100 = 4.8 %
 Sheet no. of Aircooler (AIRCOOL): Page 8 of 11
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Weight estimate:
==== ================

Tubes: Length of tubes

Metal area
Vnf = Acst = pi*(rb^2-ri^2) =
i/2*(2*N1-1)* Metal volume
^2)*Ft/12*Nt/L))= 326.07 ft3 Vt = Lact*Acst =
Tube density
= ### ft2 Tube weight
Mt = sgt*Vt*62.4 =
= ### ft2
Fins: Number of fins
0) = ### ft Nf = Lact*Nf/L =
Area of fin
= 17665 lb/hr/ft2 Acsf = pi*(re^2-rb^2) =
mya = 0.04356 lb/ft/hr Fin thickness
Fin volume
= 33682 Vf = Acsf*Ft/12*Nf =
m fig.16.18 Fin density
0.1388 = 0.0020 ft2/in2 Fin weight
phi = 1 Mf = sgf*62.4*Vf =

= 0.0012 Total weightTubes

rop eq.16.106 Fins
Manifolds 1000lb/MMBtu/hr
5.22E10/D'/sga/ Fans 20lb/kWs
*(SL/ST)^0.6 = 0.090 psi Struct. 25%(Mt+Mf+Mm+Mfn)
Total weight

Exchanger layout summary:

p. 6.21
Results: Length
e = 60 % Width
Height 3ft+1ft/MMBtu
= 621281 ft3/min Tubes in parallel
Tubes/layer
= 0.090 psi Layers
Oversurface
2-p1)/33000 = 244 HP Dry Weight
Pa = 182 kW Tubeside press.drop
Airside press.drop
0 = 406 HP Fan power
0 = 303 kW
 Sheet no. of Aircooler (AIRCOOL): Page 9 of 11
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ref.: Handbook of Mathematical Functions

U.S. Dept. of Commerce, 10th Printing,
Lact= 2781 ft
Solution of fin heat balance and determinat
ri^2) = 0.0131 ft2 ==========================

= 36.41 ft3 Summary of previous results:

sgt = 7.9
Results: Airside film coeff.
= 17947 lb Fin heatcond.
Outer pipe diameter
Inner pipe diameter
= 111253 Fin height
Fin thickness
b^2) = 0.0633 ft2 Pipe outer radius
Ft = 0.05 in r0 = Do/2 =
Fin radius
Nf = 29.3 ft3 b = r1 = Do/2+Hf =
sgf = 2.7 Constant
K = 2*hf'/kf/(Ft/12) =
= 4941 lb

Mt = 17947 lb Differential equation solution:

Mf = 4941 lb
MMBtu/hr Mm = 7226 lb Form of solution:
Mfn = 6055 lb
f+Mm+Mfn) Ms = 12659 lb y = alpha*I0(t) + beta*k0(t)
Mtot= 48829 lb
dy/dx = alpha*I0'(t) + beta*K0'(t)
= alpha*I1(t) - beta*K1(t)

Loa = 32 ft Boundary conditions:

Woa = 12 ft
H = 11 ft 1) x=x0 , y0=1
Nt = 24
N1 = 24 2) x=x1 , dy/dx=0
Nts = 4
Lex%= 4.8 % Constants:
Wdry= 49000 lb
dPt = 11.9 psi alpha = y0*K1(x1)/(I0(x0)*K1(x1)+
dPa = 0.090 psi
kWs = 303 kW = 0.3276

beta = alpha*I1(x1)/K1(x1)

= 0.9417

Calculation of efficiency:

(dy/dx),(x=x0) = alpha*I1(x0) - be

omega = -2*r0/(r1^2-r0^2)/y0/sq

= 0.8033
9 of 11 Sheet no. of Aircooler (AIRCOOL): Page 10 of 11
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tical Functions ref.: Handbook of Mathematical Function

, 10th Printing, 1972. U.S. Dept. of Commerce, 10th Printin

and determination of fin efficiency:

====================================Calculation of Bessel functions I0,I1,K0,K
=========================

hf' = 18.82 Btu/ft2/hr/deg.f Results: Constant

kf = 119 Btu/ft/hr/deg.f Independent variable
Do = 1.9 in x0 = r0/12*sqrt(K)
Di = 1.1 in
Hf = 1 in
Ft = 0.05 in SUM = Bessel function I0,I1,K0,K1 =

= 0.95 in j 1/j
j!
f = 1.95 in 0 1
1 1 1.0000
2) = 75.9202 2 2 0.5000
3 6 0.3333
4 24 0.2500
5 120 0.2000
6 720 0.1667
7 5040 0.1429
8 40320 0.1250
beta*k0(t) 9 362880 0.1111
10 3628800 0.1000
t) + beta*K0'(t) 11 ### 0.0909
beta*K1(t) 12 ### 0.0833
13 ### 0.0769
14 ### 0.0714
15 ### 0.0667
16 ### 0.0625
17 ### 0.0588
18 ### 0.0556
19 ### 0.0526
20 ### 0.0500
21 ### 0.0476
/(I0(x0)*K1(x1)+K0(x0)*I1(x1)) 22 ### 0.0455
23 ### 0.0435
24 ### 0.0417
25 ### 0.0400
1)/K1(x1) 26 ### 0.0385
27 ### 0.0370
28 ### 0.0357
29 ### 0.0345
iency: 30 ### 0.0333
31 ###
alpha*I1(x0) - beta*K1(x0) ny
(t/2)^ny
-0.8903

^2-r0^2)/y0/sqrt(K)*(dy/dx)
Page 10 of 11 Sheet no. of Aircooler (AIRCOOL): Page 11 of 11
================= Date ============================
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hematical Functions ref.: Handbook of Mathematical Functions

merce, 10th Printing, 1972. U.S. Dept. of Commerce, 10th Printing, 19

functions I0,I1,K0,K1 at inner fin radius: Calculation of Bessel functions I0,I1,K0,K1 at o

============================================================

K = 75.9202 Results: Constant

pendent variable Independent variable
= r0/12*sqrt(K) = 0.6898 x1 = r1/12*sqrt(K)

n I0,I1,K0,K1 = 1.1225 0.3658 0.6713 1.07270,K1 =

(x^2/4)^j j
sum(1/j) I0(x,i) I1(x,i) K0(x,i) K1(x,i)
0.0000 1.0000 1.0000 0.3449 0.5470 1.4491 0
1.0000 0.1190 0.1190 0.0205 0.1190 -0.3449 1
1.5000 0.0142 0.0035 0.0004 0.0053 -0.0308 2
1.8333 0.0017 0.0000 0.0000 0.0001 -0.0007 3
2.0833 0.0002 0.0000 0.0000 0.0000 0.0000 4
2.2833 0.0000 0.0000 0.0000 0.0000 0.0000 5
2.4500 0.0000 0.0000 0.0000 0.0000 0.0000 6
2.5929 0.0000 0.0000 0.0000 0.0000 0.0000 7
2.7179 0.0000 0.0000 0.0000 0.0000 0.0000 8
2.8290 0.0000 0.0000 0.0000 0.0000 0.0000 9
2.9290 0.0000 0.0000 0.0000 0.0000 0.0000 10
3.0199 0.0000 0.0000 0.0000 0.0000 0.0000 11
3.1032 0.0000 0.0000 0.0000 0.0000 0.0000 12
3.1801 0.0000 0.0000 0.0000 0.0000 0.0000 13
3.2516 0.0000 0.0000 0.0000 0.0000 0.0000 14
3.3182 0.0000 0.0000 0.0000 0.0000 0.0000 15
3.3807 0.0000 0.0000 0.0000 0.0000 0.0000 16
3.4396 0.0000 0.0000 0.0000 0.0000 0.0000 17
3.4951 0.0000 0.0000 0.0000 0.0000 0.0000 18
3.5477 0.0000 0.0000 0.0000 0.0000 0.0000 19
3.5977 0.0000 0.0000 0.0000 0.0000 0.0000 20
3.6454 0.0000 0.0000 0.0000 0.0000 0.0000 21
3.6908 0.0000 0.0000 0.0000 0.0000 0.0000 22
3.7343 0.0000 0.0000 0.0000 0.0000 0.0000 23
3.7760 0.0000 0.0000 0.0000 0.0000 0.0000 24
3.8160 0.0000 0.0000 0.0000 0.0000 0.0000 25
3.8544 0.0000 0.0000 0.0000 0.0000 0.0000 26
3.8915 0.0000 0.0000 0.0000 0.0000 0.0000 27
3.9272 0.0000 0.0000 0.0000 0.0000 0.0000 28
3.9617 0.0000 0.0000 0.0000 0.0000 0.0000 29
3.9950 0.0000 0.0000 0.0000 0.0000 0.0000 30
31
0 1 0 1 ny
1 ### 1 ### (t/2)^ny
ge 11 of 11 Sheet no. of
==================Date
By
C'k'd
App'd

matical Functions
erce, 10th Printing, 1972.

ctions I0,I1,K0,K1 at outer fin radius:

==================================================

Constant K = 75.9202
Independent variable
x1 = r1/12*sqrt(K) = 1.4159

1.5676 0.9008 0.2386

1/j (x^2/4)^j
j! sum(1/j) I0(x,i) I1(x,i) K0(x,i)
1 0.0000 1.0000 1.0000 0.7079 -0.3634
1 1.0000 1.0000 0.5012 0.5012 0.1774 0.5012
2 0.5000 1.5000 0.2512 0.0628 0.0148 0.0942
6 0.3333 1.8333 0.1259 0.0035 0.0006 0.0064
24 0.2500 2.0833 0.0631 0.0001 0.0000 0.0002
120 0.2000 2.2833 0.0316 0.0000 0.0000 0.0000
720 0.1667 2.4500 0.0158 0.0000 0.0000 0.0000
5040 0.1429 2.5929 0.0079 0.0000 0.0000 0.0000
40320 0.1250 2.7179 0.0040 0.0000 0.0000 0.0000
362880 0.1111 2.8290 0.0020 0.0000 0.0000 0.0000
3628800 0.1000 2.9290 0.0010 0.0000 0.0000 0.0000
### 0.0909 3.0199 0.0005 0.0000 0.0000 0.0000
### 0.0833 3.1032 0.0003 0.0000 0.0000 0.0000
### 0.0769 3.1801 0.0001 0.0000 0.0000 0.0000
### 0.0714 3.2516 0.0001 0.0000 0.0000 0.0000
### 0.0667 3.3182 0.0000 0.0000 0.0000 0.0000
### 0.0625 3.3807 0.0000 0.0000 0.0000 0.0000
### 0.0588 3.4396 0.0000 0.0000 0.0000 0.0000
### 0.0556 3.4951 0.0000 0.0000 0.0000 0.0000
### 0.0526 3.5477 0.0000 0.0000 0.0000 0.0000
### 0.0500 3.5977 0.0000 0.0000 0.0000 0.0000
### 0.0476 3.6454 0.0000 0.0000 0.0000 0.0000
 ### 0.0455 3.6908 0.0000 0.0000 0.0000 0.0000
### 0.0435 3.7343 0.0000 0.0000 0.0000 0.0000
### 0.0417 3.7760 0.0000 0.0000 0.0000 0.0000
### 0.0400 3.8160 0.0000 0.0000 0.0000 0.0000
### 0.0385 3.8544 0.0000 0.0000 0.0000 0.0000
### 0.0370 3.8915 0.0000 0.0000 0.0000 0.0000
### 0.0357 3.9272 0.0000 0.0000 0.0000 0.0000
### 0.0345 3.9617 0.0000 0.0000 0.0000 0.0000
### 0.0333 3.9950 0.0000 0.0000 0.0000 0.0000
###
0 1 0
(t/2)^ny 1 ### 1
0.3134

K1(x,i)
1.3160
-0.7079
-0.2661
-0.0272
-0.0013
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000

1
###