Batch Process Modelling & Optimisation Intro to CAPD
PSE
DESIGN/SIZING OF HEAT
EXCHANGERS
Copyright@FKKKSA, UTM Computer-Aided Process Simulation Project Intro to PD - 1
PSE
Design of Heat Exchangers
What to design ??
Consider the following block diagram.
Q = mh ⋅ c p ( h ) ⋅ (Thi − Tho ) = mc ⋅ c p ( c ) ⋅ (Tco − Tci ) = U ⋅ A ⋅ ΔTLM
ΔT1 − ΔT2
ΔTLM =
⎛ ΔT ⎞
ln⎜⎜ 1 ⎟⎟
⎝ ΔT2 ⎠
Copyright @ CEPP, UTM SuperPro Designer
Batch Process Modelling & Optimisation Intro to CAPD
PSE
Minimum Temp. Approach, ΔTmin
The smallest difference between the
temperatures at two ends.
Sometimes occurs at an intermediate
location, if phase changes (vaporization,
condensation).
Can cause temperature crossover within
the exchanger, thus violate the 2nd law
of thermodynamics.
Selection of appropriate ΔTmin is
important so as to avoid temperature
crossover especially when the phase
changes.
PSE
Copyright @ CEPP, UTM SuperPro Designer
Batch Process Modelling & Optimisation Intro to CAPD
PSE
Pressure drop due to friction
PSE
Copyright @ CEPP, UTM SuperPro Designer
Batch Process Modelling & Optimisation Intro to CAPD
PSE
Heuristic 54
For shell
shell-and-tube
and tube heat exchangers,
exchangers tubes
are typically ¾-in. O.D., 16 ft long, and on 1-
in. triangular spacing. A 1-ft I.D. shell can
accommodate 300 ft2 tubes outside area, 2-
ft: 1330 ft2, 3-ft: 3200 ft2.
PSE
Copyright @ CEPP, UTM SuperPro Designer
Batch Process Modelling & Optimisation Intro to CAPD
PSE
Shell-and tube: commonly used heat exchanger, area 50
to 12000 ft2.
PSE
Heuristic 55
The tube side is for corrosive, fouling,
scaling, hazardous, high T & P, and
expensive fluids. The shell side is for more
viscous, cleaner, lower flow rate,
evaporating and condensing fluids
fluids.
Copyright @ CEPP, UTM SuperPro Designer
Batch Process Modelling & Optimisation Intro to CAPD
FT: Correction factor for ΔTLM in
PSE
Shell-and-Tube Heat Exchangers
Flow directions are combinations of countercurrent and cocurrent in
multiple shell-and-tube passes.
The resulting ΔTLM suppose to be lower than it should be
be.
Introducing the correction factor, FT for shell-and-tube exchangers:
R 2 + 1 ln[(1 − S ) / (1 − RS )]
FT =
⎡[ (
(R − 1) ln ⎢ 2 − S R + 1 − R 2 + 1 ⎥
2
)]⎤
[ (
⎢⎣ 2 − S R + 1 + R + 1 ⎥⎦ )]
Th ,i − Th ,o Tc ,o − Tc ,i
R=
Tc ,o − Tc ,i
S=
Th ,i − Tc ,i
Q = U ⋅ A ⋅ FT ⋅ ΔTLM
PSE Fig 18.14: FT for 1-2 Shell-and-Tube
Copyright @ CEPP, UTM SuperPro Designer
Batch Process Modelling & Optimisation Intro to CAPD
PSE FT, The Correction Factor
FT > 0.85: desirable
FT < 0.75: unsatisfactory, unacceptable
FT can be enhanced by using multiple-shell-pass heat
exchangers.
FT=1, if only countercurrent flow.
FT=1, if vaporization or condensation presence in one of
the streams (no change in temperature)
PSE Overall Heat Transfer Coefficient, U
Estimated from experience, or sum of the individual thermal
resistances (if you could).
Typical values of U are given in Table 1818.5.
5
Referred as Udirty, include fouling factor Rf,o + Rf,i.
1
Ui =
⎛ D ⎞ ⎛ 1 Di ⎞ ⎛ t w Di ⎞ ⎛ 1 ⎞
R f ,o ⎜⎜ i ⎟⎟ + ⎜⎜ ⎟⎟ + ⎜⎜ ⎟⎟ + ⎜⎜ ⎟⎟ + R f ,i
⎝ o ⎠ ⎝ o o ⎠ ⎝ w m ⎠ ⎝ hi ⎠
D h D k D
1 1 1
= =
UA U o Ao U i Ai
Copyright @ CEPP, UTM SuperPro Designer
Batch Process Modelling & Optimisation Intro to CAPD
PSE
NOTE: If area is greater than 8000 ft2,
consider
id using
i ttwo hheatt exchangers
h off
the same area in parallel. Ex., if the
calculated area is 15000 ft2, two
exchangers of 7500 ft2 are used in
parallel.
PSE
Copyright @ CEPP, UTM SuperPro Designer
Batch Process Modelling & Optimisation Intro to CAPD
PSE
DESIGN/SIZING OF PUMP,
COMPRESSOR, EXPANDER
Courtesy of Mr. M Fadil A. Wahab
Gas Eng. Dept., FChE UTM
Copyright@FKKKSA, UTM Computer-Aided Process Simulation Project Intro to PD - 17
PSE PUMP
Pumping action: Cause increase the elevation, velocity and
pressure of a liquid.
Main purpose to provide energy to move liquids from one
place to another.
Common application is to increase the pressure of liquid.
Copyright @ CEPP, UTM SuperPro Designer
Batch Process Modelling & Optimisation Intro to CAPD
PSE Pump Characteristics
¾ Capacity (Q) in gal/min (gpm) [conversion, 1ft3= 7.48 gal]
¾ Pump head (H) in ft or m
⎛V 2
P ⎞ ⎛V P ⎞ 2
H =⎜ +z +
d
⎟ −⎜
d
+z + s
⎟
s
⎝ 2g ρ g ⎠ ⎝ 2g
d
d
ρ g⎠ s
for negligible ΔV and Δz and constant ρ ,
ΔP
H=
ρg
Subscripts d and s refer to discharge and suction,
respectively
PSE
Heuristic 37
9 For heads up to 3200 ft (multiple stages) and flow rates in
the range 10 to 5000 gpm
gpm, use centrifugal pump
pump.
9 For high heads up to 20000 ft and flow rate up to 500 gpm,
use reciprocating pump.
9 Less common are axial pumps for heads up to 40 ft for flow
rates in the range of 20 to 100000 gpm and rotary pumps for
heads up to 3000 ft for flow rate in the range 1 to 1500 gpm.
9 For liquid water,
9 Head of 3000 ft correspond to ΔP of 1300 psi,
9 Head of 20000 ft correspond to ΔP of 8680 psi.
Copyright @ CEPP, UTM SuperPro Designer
Batch Process Modelling & Optimisation Intro to CAPD
PSE
Heuristic 38
For liquid flow, we need to include the following when
determining the required pumping head.
A pipeline pressure drop of 2 psi/100ft of pipe
A control valve pressure drop of at least 10 psi
A pressure drop of 4 psi per 10-ft rise in elevation
Self-learn example at page 170.
PSE
Heuristic 38
Estimate the theoretical horsepower (THp) for pumping
liquid using,
THp = (gpm)( pressure increase, psi ) /1714
Self-learn example at page 170.
Copyright @ CEPP, UTM SuperPro Designer
Batch Process Modelling & Optimisation Intro to CAPD
PSE COMPRESSOR
To increase the velocity and/or pressure of gases.
Similar to fan and blower but at higher discharge pressure or
compression ratio.
Presence of liquid can damage the compressor blades.
Method: Centrifugal, positive displacement and momentum
transfer.
transfer
If exit T exceeds 375 oF, a multistage compressor with
intercoolers must be employed.
See Heuristic 36 for tips on multistage-compressor.
PSE
Heuristic 34
¾ Use fan to increase the gas P from atmospheric P to as high
as 40 inches of water (10.1 kPa gauge or 1.47 psig).
¾ Use a blower or compressor to raise the gas P to as high as
206 kPa gauge (30 psig).
¾ Use a compressor or a staged compressor system to attain
P greater than 206 kPa gauge (30 psig).
Copyright @ CEPP, UTM SuperPro Designer
Batch Process Modelling & Optimisation Intro to CAPD
PSE
Heuristic 35
¾ THp (adiabatic) for compressing a gas from,
⎛ T ⎞ ⎡⎛ P ⎞ ⎤
a
Thp = SCFM −1
⎝ 8130a ⎠ ⎢⎣⎜⎝ P ⎟⎠ ⎥
1 2
⎦ 1
¾ SCFM= std cubic ft per min at 60oF and 1 atm
¾ T1 inlet gas T in oR
¾ P1 and P2 are inlet and outlet P (absolute)
¾ a=(k-1)/k where k=Cp/Cv is specific heat ratio
⎛P⎞
a
¾ T2 is estimated as,
T =T ⎜ ⎟ 2
⎝ P⎠
2 1
PSE EXPANDER
Known as turbo
turbo-expander
expander or expansion turbine.
Used in place of valve to recover power as pressure is
decreased.
Also the gas T is reduced, check for possible condensation.
Often chilling of gas is more important than the power
recovery.
Widely used at cryogenic conditions.
If there is condensation, the design should avoid impeller
erosion.
For high P liquid, the power recovery through turbine is not
economical.
Copyright @ CEPP, UTM SuperPro Designer
Batch Process Modelling & Optimisation Intro to CAPD
PSE SUMMARY- WHAT TO DESIGN
Focus on Major Equipment.
Distillation column: Reflux ratio, No. of trays, Height,
Diameter.
Reactor: Volume, Diameter, Height.
Absorption, stripping: Height, Diameter.
Heat Exchanger: Total area, Shell diameter, No. of tubes,
Length, Type of shell-and tube exchanger.
Pump Compressor,
Pump, Compressor Expander: Head (for pump),
pump) Thp.
Thp
In report: show equations (in text) and only one sample
calculation for each equipment (in appendix). Summarize all
results in Table.
PSE 10 Minutes Presentation- What is Expected
To be conducted at my office, details will be posted in e-learning.
All members must present.
Convince your superior/manager to take the project proposal
proposal.
Alternatives, E.P
Novelty and sustainability of the project
Process Flowsheet and simulation (Run)
M&E balances: Manual and simulation (% error)
Heat integration- PTA, Grid matching, T-profile
Equipment sizing & costing (Summarize in Table)
Optimization
Copyright @ CEPP, UTM SuperPro Designer
Batch Process Modelling & Optimisation Intro to CAPD
PSE
Copyright @ CEPP, UTM SuperPro Designer
