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Basic Refinery Equipment - Heat Exchanger (E003/1)

Basic Refinery Equipment - Heat Exchanger (E003/1) is a document that introduces heat exchangers, including their functions, heat transfer principles, types, and design considerations. It discusses why heat recovery is required in refineries, the key functions of heat exchangers to allow heat exchange between fluids, and the mechanisms of heat transfer through conduction, convection and radiation. It also summarizes different types of heat exchangers like shell and tube, thermosiphon, air cooler and their characteristics, as well as design parameters for heat exchanger selection and engineering requirements.

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191 views27 pages

Basic Refinery Equipment - Heat Exchanger (E003/1)

Basic Refinery Equipment - Heat Exchanger (E003/1) is a document that introduces heat exchangers, including their functions, heat transfer principles, types, and design considerations. It discusses why heat recovery is required in refineries, the key functions of heat exchangers to allow heat exchange between fluids, and the mechanisms of heat transfer through conduction, convection and radiation. It also summarizes different types of heat exchangers like shell and tube, thermosiphon, air cooler and their characteristics, as well as design parameters for heat exchanger selection and engineering requirements.

Uploaded by

ebsmsart
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Basic Refinery Equipment

- Heat Exchanger (E003/1)


by
Punnee Kitjareonvong

Outline
Introduction
Theory of Heat transfer
Basic principles of heat exchangers
Types of heat exchangers
Functions of each heat exchanger
Design Principle parameters and criteria for
heat exchanger design

Introduction
Why require Heat Exchanger?

Why require?
Heat

generate at a high temp ( > 300 deg C)


in a furnace (fuel gas , fuel oil, waste gas , offgas ., etc) by combustion to desired
temperature.
After that, heat recovery is required when
already satisfy the process requirement for
economic optimization .
Down to almost close to air inlet temp (50 degC)
or cooling water temp ( 45 deg C) depend on
process side requirement.
4

Key function

Any devices which allow heat to exchange


from one fluid to another, physically separated.

Heat Transfer Principle


Sensible

heat : Temperature change

Q = m * Cp * (T2-T1)
where Cp = Specific heat (kg/kj-deg K)
m = Flowrate ( kg/s)
Ti = Temperature (deg K)

Latent

heat : Phase change whereas


temperature constant
Q = m * LHV
where m = Flowrate (kg/s)
LHV = Lower Heating Valve (kj/kg)
6

Three

Mechanisms of heat transfer :

Conduction, : laminar film liquid through the tube wall


in heat exchanger
Convection : in space where gas/liquid flow is
turbulent i.e, fluid inside or outside the tube of
exchangers.
Radiation : at high temperature ( > 200-300 degC)
ie., in furnace.

Heat changer
Conduction (tube wall) and
convection ( fluid inside/outside tube )

Design a shell &tube Heat Exchanger


t2 = 230 C
T1 =250 C

T2 = 150 C

Shell : T
Tube : t

t1 = 120 C
Correction factor

Local overall heat transfer coefficient ,


W/m2 K (fouled , cleaned)

Q = F*U*A*LMTD
Total effective area (m2)

T1 =250

GTD
T2 = 150

Greater t2 = 230
Temp
Difference

t1 = 120

LTD
Lesser
Temp
Difference
9

LMTD
Long Mean Temperature Difference
= average driving force
LMTD

= (GTD- LTD)/ ln(GTD/LTD) , deg K

10

Correction Factor (F)


Depend on the heat exchanger internal arrangement and
temperature of the respective flow.
Temperature efficiency
P = (t2-t1)/(T1-t1)

Capacity Ratio
R = (T1-T2)/(t2-t1)

Use P, R, and geometry to indicate the F valve

11

Fouling Resistance/coefficient
Fouling

Resistance= ultimate additional


resistance to heat transfer cause by deposit and
corrosion = f( type of fluid, material,
temperature, flow velocity)

Fouling

coefficient = the reciprocal of fouling


resistance
( an increase fouling = and decrease in fouling
coefficient)
12

Types of heat exchangers


Shell&tube

Heat exchanger feed


preheated/ Trim cooler (by cooling water)
Thermosiphon/Kettle-type Reboiler
Air cooler Condensor

13

Shell&Tube Heat exchanger


Tube

side : 1-pass/2-pass compartment and

Floating head for thermal expansion of shell&tube.


Shell Side : baffle to force the cross flow pattern

14

Air cooler
Finned tubes, through which the process fluid
flows with air being forced passing the tube
bundle by fans
There are 2 major types ;

Forced draft
Induced draft

15

Thermosiphon/Kettle type :Reboiler


a) Kettle type
Tubes are kept/submerged in the
boiling liquid by mean of an
overflow weir
The heating medium flow through
2-tube passes
To use in cases where large
volumes of vapor generated.
Horizontal heat exchanger

16

b) Thermosyphon Vertical single pass Heat exchanger


liquid will vaporize pass upward
through tube and the remaining
liquid will leave at the top and
leave out from the bottom of
column.
Heating media is on shell side.
circulation in tube is driven by
difference of density between the
bottom column liquid and
gas/liquid mixture in tube (gas lift)
principle)

17

Design Strategy :Heat integration


Simultaneous

shutdown of unit involved


acceptable. (inter-unit heat exchange)
Or units with a different shutdown timing in
case different in heat sink/source are small
and/or shut down duration is short.
Achieve the best targets (duties, target
temperature etc.,)
Green field project
18

Design Strategy :Heat


integration(cont)
Sensitivity

cases should be considered to absorb


the disturbances in actual operation
5 deg C lower (hot stream) or higher (hot stream)
supply temperature
10%duty to be process adjustment ,related to cutpoint ie., reflux duty
10%duty lower upstream of desalter (not too low)

OHTC

(U) from the existing testrun is very


useful for revamped case.
19

Process Engineer
New

/Revamped Heat Exchanger

1. Known parameter from process datasheet.


a) The required duty (MW)
b) Hot & cold fluid temperature inlet/outlet (deg C)
c) Flowrate (TPD)

2. Heating curve at each pressure and varied


temperature. do either the HTRI (Heat Transfer
Research Inc. Xistprogram) or the HTFS (Heat
Transfer and Fluid Flow Service TASC
Program.
3. Unknow parameter U fouled/ U cleaned and the
required area (m2)
20

Process Engineer (cont.)


4. The case which result the largest theoretical area should be

selected as the design heat exchanger(base case) when min


fuel consumption is the main objective.
5. The case with the largest hot utility requirement should be
taken as base case when min investment is the objective
and no constraint of utility availability.
6. In case furnace duty in base case is lower than other
modes, to consider reduce the heat exchanger area in base
case should be reviewed utilize stable furnace capacity
7. To check the pressure drop , velocity ,likelihood of
mechanical and/or acoustic vibration and nozzle momentum
(rV2)
21

Process Engineer (cont.)


7. To cater the increased dP on shell&tube side from
fouling , rule of thumb can be applied
Fouling resistance
(m2K/w)

Multiplication factor

0.00009 to 0.00033

1.1

0.00034 to 0.00085

1.2

0.00086 and higher

1.3

Typical dP,shell =0.5 bar/tube side = 0.5-1.0 bar


8. Tube side erosion :

rV2 < 7000 kg/m s2 for gas/vapor


rV2 using the max. water velocity

Heat Exchanger Datasheet

22

Process Engineer (cont.)


9.

Cost concern: To reduce dP (pressure drop) parallel


heat exchanger train lower shut-off head and
design pressure system.

23

Engineering Requirement
For Shell and Tube heat exchanger
1. The heated fluid : flow upward/ the cooled fluid : flow
downward.
2. More fouling and corrosive fluid is on tube side for
easy to maintenance (No need to pull tube bundle for
cleaning) including the cooling water service
3.
Better heat transfer, lower pressure drop, smaller size
viscous fluid should be on shell side against the
fouling aspect.
4. For economic, the higher design pressure is on tube
side. (on mechanical construction)
24

Engineering Requirement (cont.)


5.
6.
7.

8.

For economic, more expansive construction material


due to fluid properties, it should be on the tube side.
Heat exchanger should be horizontal except
thermosiphon reboiler.
For longer cycle , the velocity on shell and tube side
shall be > 0.5 and 1 m/s respectively during design
phase.
Isolation valves and by-pass line should be provided
for maintenance with the unit still in operation.

25

Engineering Requirement (cont.)


Flange connection in hydrogen service (>200 C) which
are not readily accessible can have smothering steam
ring. for fire extinguish from hydrogen leakage. Or
steam lance (with good access)
10. Max. surface area of a heat exchanger shell is approx.
600 m2 for floating head and 600-700 m2 for U-tube
11. Min F-factor for shell and tube is 0.8 more shell in
series should be considered.
12. Piping and heat exchanger in high viscosity service
shall not provided with capacity relief valves due to
blockage design system for shut-off head pump
9.

26

Engineering Requirement (cont.)


For air cooler
13. The process fluid usually flow downward.
14. Forced draft : process oultet air inlet > 15 deg C /
ease of fan, motor maintenance
15. Induced draft : Process outlet air inlet < 15 deg C
16. If process temperature is required, variable speed
(VRS)drives to adjust automatic pitch fan.
17. When water is injected , good distribution shall be
critical and be noted in the datasheet for symmetrical
lay out of parallel tube bundle.

27

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