Equipment Fundamentals: Heat Exchangers. Chapter 3
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1 Equipment Fundamentals: Heat Exchangers Chapter 3
2 Tpics Equipment heat exchangers Cmbines infrmatin abut fluid flw & heat transfer acrss internal bundaries Cnsideratins When d I need t knw the specifics f the heat exchange cnfiguratin? Hw is the heat transfer cefficient related t the utlet temperatures? What is an apprach temperature? Fundamentals f heat transfer & exchange Heat transfer acrss bundaries Cnductin Cnvectin Radiatin Cupled with internal energy changes Sensible heat effects Phase change 2
3 Tpics Fundamentals f heat transfer & exchange Heat transfer acrss bundaries Cnductin Cnvectin Radiatin Cupled with internal energy changes Sensible heat effects Phase change Area-averaged temperature difference Equipment heat exchangers Cmbines infrmatin abut fluid flw & heat transfer acrss internal bundaries Cnsideratins When d I need t knw the specifics f the heat exchange cnfiguratin? Hw is the heat transfer cefficient related t the utlet temperatures? What is an apprach temperature? 3
4 Fundamentals
5 Heat Transfer Mdes f heat transfer Cnductin Flw f heat thrugh material with n bulk mvement f the material itself Usually thught f thrugh slid, but can als be thrugh a stagnant fluid Fr a flat sld: Q Tht T k A x cld Thrugh a circular pipe: Q 2 L ln D D Thrugh a sphere: i kt ht T 2 Q ktht Tcld 1 1 D D i cld 5
6 Heat Transfer Mdes f heat transfer Cnvectin Flw f heat assciated with fluid mvement natural & frced cnvectin Radiatin Q ht ht T A cld Heat transferred via electrmagnetic radiatin Q A T T 4 4 ht cld 2 2 T ht Tcld Tht Tcld Tht Tcld 6
7 Heat Exchangers Sme Basics Fcus is n the system t have heat flw frm the ht fluid(s) t the cld fluid(s) usually withut direct cntact Use bulk flw parameters t relate the heat cnductin acrss the flw barrier t the change in energy f the ht & cld fluids Accunt fr the series f resistances t heat transfer between the ht & cld fluids Heat exchangers Heat t & frm flwing fluids thrugh impermeable barrier(s) Driving frce fr heat thrugh barriers is the temperature difference between the tw fluids n ppsite sides f the barrier Relate the heat effects in the flwing fluids t the change in enthalpy Often this can be related t the difference in the inlet & utlet temperatures fr the fluids ˆ ˆ Q m Hˆ Hˆ Q m C T T fr cnstant Cˆ Q m Hˆ Hˆ Q m C T T fr cnstant Cˆ H H Hin, Hut, H H ph, Hin, Hut, ph, C C Cut, Cin, C C pc, Cut, Cin, pc, 7
8 Heat Exchangers Sme Basics Relate the heat acrss the barrier t the temperature difference acrss the barrier d Q / L dx TH,in TC,ut U Th Tc Q UA Th Tc AREA AVERAGED It can be shwn that fr many typical cnfiguratins the AREA AVERAGED temperature difference is the LMTD (Lg Mean Temperature Difference) TH(x) TC(x) x TH,ut TC,in where Q UA T T LM LM TH,0 TC,0 TH,1 TC,1 TH ln T T,0 C,0 T H,1 C,1 8
9 Heat Exchangers Sme Basics LMTD is a prescribed calculatin calculating the LMTD frm the prcedure is always crrect. LMTD T 1 ln T T T 1 2 T T T T and limlmtd LMTD is apprpriate fr use as the area averaged temperature difference when temperature vs. heat released/absrbed is a straight line 1-1 c-current & cunter-current flw and Bth ht & cld sides have a cnstant heat r Only pure cmpnent phase change n ne side r the ther (n subcling and/r superheating) 9
10 Heat Transfer Sme Basics Heat exchangers C-Current vs. Cunter-Current vs. Crss-Current flws Cunter-current flw allws the utlet temperatures t apprach mre clsely t the inlet temperature f the ther fluid Crss-current flw is cmplicated & requires knwledge f the actual flw patterns C-Current Cunter-Current Crss-Current Heat exchangers Industrial Heat Exchangers Industrial heat exchangers have a cmbinatin f heat transfer thrugh multiple barriers and a cmbinatin f cunter-current & c-current flw LMTD must be crrected t give the actual area-averaged temperature difference (i.e., driving frce) this is the surce fr ne type f F factr 10
11 Heat Exchanger Example 1 Heat 291,800 lb/hr cld C2+ NGL feed frm 80 F t 105 F using 191,600 lb/hr ht C F Assume nly sensible heat effects Determine C2+ NGL feed heat capacity Btu/lb F C3+ Bttms heat capacity Btu/lb F C3+ Bttms utlet temperature Exchanger duty (UA) fr the exchanger C2+ NGL Feed 291,800 lb/hr 80 F??? F 145 F C3+ Bttms 191,600 lb/hr 240 F 11
12 Heat Exchanger Example 1 Exchanger duty & C3+ Bttms utlet temperature determined frm energy balance arund exchanger T Determinatin f UA requires cnfiguratin infrmatin 1-1 cunter-current flw Q m ˆ ccp, c Tc, ut Tc, in ,353,000 Btu/hr Q Thin F mc ˆ hut,, h p, h T 85.1 F LMTD ln c-current flw T 55.4 F LMTD ln Q Btu UA 157, 000 T 85.1 hr F LMTD Q Btu UA 241, 000 T 55.4 hr F LMTD 12
13 Heat Exchanger Example 1 Determinatin f UA requires cnfiguratin infrmatin 1-2 (1 shell & 2 tube passes) cmbines bth cunter & c-current flw The fluid in the shell pass transfers heat separately t the tw tube banks Ref: GPSA Data Bk, 13 th ed. 13
14 Heat Exchanger Example exchanger calculatins require a cnfiguratin crrectin t relate temperatures t the UA Des nt include crssflw effects acrss the tubes F P R 1ln 1 RP 2 2PR 1 R 1 R 1ln 2 2 PR 1 R 1 Ref: Kern, Prcess Heat Transfer, McGraw-Hill, 1965 Ref: GPSA Data Bk, 13 th ed. 14
15 Heat Exchanger Example exchanger T 85.1 F LMTD ln P R F 0.86 (frm chart) 2 Q UA F T 2 LMTD Btu 182, hr F Ref: GPSA Data Bk, 13 th ed. 15
16 Heat Exchanger Example 1 16
17 Heat Exchanger Example 1 Representatin f temperature prfiles with cmbined flw becmes mre cmplicated. 17
18 Heat Exchanger Example 2 Heat 291,800 lb/hr cld C2+ NGL feed starting frm 80 F using 191,600 lb/hr ht C F. Drive the exchanger t a 10 F apprach temperature Fr 1-1 Cunter-Current flw, what are the utlet temperatures? The C2+ NGL Feed is either heated t 230 F (apprach n the ht inlet side) r the C3+ Bttms is cled t 90 F (apprach n the cld inlet side) Assume nly sensible heat effects Determine C2+ NGL feed heat capacity Btu/lb F C3+ Bttms heat capacity Btu/lb F The utlet temperature that is nt cntrlled by the apprach Exchanger duty (UA) fr the exchanger C2+ NGL Feed 291,800 lb/hr 80 F??? F??? F C3+ Bttms 191,600 lb/hr 240 F 18
19 Heat Exchanger Example 2 Exchanger duty & ther utlet temperature determined frm energy balance arund exchanger If the ht side inlet has the apprach temperature Tcut, Thin, F Qm ˆ ccp, ctc, ut Tc, in ,814,000 Btu/hr Q Thut, Thin, F mc ˆ h This has a temperature crssver this is nt the cntrlling side! If the cld side inlet has the apprach temperature: Thut, Tcin, F Qm ˆ hcp, hth, in Th, ut ,797,000 Btu/hr Q Tcut, Tcin, F mc ˆ c p, h p, c 19
20 Heat Exchanger Example 2 Determinatin f UA fr 1-1 Cunter-Current flw using the cld & ht utlet temperatures f F & 90 F, respectively T 23.0 F LMTD ln Q Btu UA 1, 035, 000 T 23.0 hr F LMTD C2+ NGL Feed 291,800 lb/hr 80 F 90 F F C3+ Bttms 191,600 lb/hr 240 F 20
21 Heat Exchanger Example 3 Heat 291,800 lb/hr cld C2+ NGL feed frm 80 F using 191,600 lb/hr ht C F. 1-1 Cunter-Current heat exchanger frm Example #1 designed with 25% excess heat transfer area (UA=196,000 Btu/hr F) Assume nly sensible heat effects Determine C2+ NGL feed heat capacity Btu/lb F C3+ Bttms heat capacity Btu/lb F Bth utlet temperatures Exchanger duty Need t cuple all three equatins relating heat exchanger duty find the three unknwns C2+ NGL Feed 291,800 lb/hr 80 F??? F??? F C3+ Bttms 191,600 lb/hr 240 F 21
22 Heat Exchanger Example 3 Even thugh it lks like yu ll have t slve the three equatins in an iterative manner, it can be shwn that the heat transfer duty is: T T 1 Hin, Cin, 1 1 Q where exp UA fr m C m C 1 mc C p, C mc H p, H mc mc C p, C H p, H C p, C H p, H S: 1 1 exp Q T Q Thin F mc ˆ h p, h Q Tcin F mc ˆ hut,, T cut,, c p, c 14, 924, 000 Btu/hr C2+ NGL Feed 291,800 lb/hr 80 F F F C3+ Bttms 191,600 lb/hr 240 F 22
23 Heat Exchange with Phase Change Can get significant heat exchange with little t n change in temperature ΔT = 0 ΔT = 340 Ref: GPSA Data Bk, 13 th ed. 23
24 Heat Exchanger Example 4 Cndense 10,000 lb/hr saturated vapr prpane at 120 F using 95 F air. Figure a 10 F apprach temperature, s heat the air up t 110 F. Needed physical prperties Determine Air heat capacity 0.24 Btu/lb F Prpane heat f 120 F 1,236 Btu/lb Exchanger duty Flw rate f air needed Exchanger UA 24
25 Heat Exchanger Example 4 Duty determined frm the prpane energy balance. N sensible heat effect. Q m h vap ,360,000 Btu/hr Air flwrate frm its energy balance: m c Q 12,360,000 3,430,000 lb/hr Cˆ T T pc, cut, cin, Calculate UA knwing the terminal temperatures T 16.4 F LMTD ln Q Btu UA 755, 000 T 16.4 hr F LMTD 25
26 Heat Exchanger Example 4 Calculating the UA is essentially the same as when there is n phase change since the temperature prfiles with heat release are still straight lines. The ht stream s prfile just happens t be a cnstant temperature. 26
27 Heat Exchanger Example 5 Cndense 10,000 lb/hr prpane vapr that is superheated t 160 F (but still with 120 F vapr pressure) using 95 F air heated up t 110 F. Needed physical prperties Determine Air heat capacity 0.24 Btu/lb F Prpane vapr heat capacity 0.52 Btu/lb F Prpane heat f 120 F 1236 Btu/lb Exchanger duty Flw rate f air needed Exchanger UA 27
28 Heat Exchanger Example 5 Duty determined frm the prpane balance. Cmbine sensible heat & latent heat effects Air flwrate frm its energy balance: Q m ˆ h vap Cp, c Th, in Th, BP ,680,000 Btu/hr m c Q 125,680,000 34,900,000 lb/hr Cˆ T T pc, cut, cin, Just using terminal temperatures gives an incrrect result! Q Btu T 36.1 F UA 3, 480, 000 LMTD T 36.1 hr F ln LMTD
29 Heat Exchanger Example 5 Calculating the UA is mre cmplicated than just using the terminal temperatures since there is a drastic break in the temperature prfile fr the cndensing prpane 29
30 Heat Exchanger Example 5 Determine the intermediate air temperature between the sensible & latent heat znes Calculate the UA values fr the tw znes Q T m 123,600,000 Btu/hr cnd h vap Q cnd 123,600,000 Tcin F mc ˆ 34,900, cmid,, p, c T 16.5 F LMTD ln c T 25.0 F LMTD ln Q Btu UA 3, 420, 000 T 36.1 hr F LMTD Q Btu UA 83, 000 T 25.0 hr F LMTD The ttal UA is the sum f these tw cntributins. 30
31 Heat Exchanger Example 6 Can we cndense 10,000 lb/hr prpane vapr that is superheated t 160 F (but still with 120 F vapr pressure) using 95 F air heated up t 140 F? This still gives an apparent 20 F apprach temperature? The answer is NO! It is nt apparent frm the terminal temperatures but there is an internal pinch pint t the temperature prfiles & there wuld be a temperature crssver. The air s utlet temperature is cnstrained by this internal pinch pint. 31
32 Heat Exchanger Example 6 Mre air flw is needed t accmplish this cling. Using a 10 F internal apprach temperature shws that the air s utlet temperature is cnstrained t F. The required air mass flw wuld be calculated accrdingly. 32
33 Heat Transfer Sme Basics Thermal resistances are added when in series Can be cmbined int an verall heat transfer cefficient Acrss a flat plate (i.e., cnstant crss sectinal area) 1 1 L 1 U h k h i Fr radial heat transfer (e.g., thrugh the wall f a tube) must als take int accunt the change is area with respect t radius Overall heat transfer cefficient must als be related t a reference area / diameter 1 1 L 1 UA ha i i kaave ha 1 1 A L A D D D 1 ln U hi Ai k Aave h hi Di k Di h 33
34 Heat Transfer Crrelatins fr Film Cefficients Flw in tubes with n phase change hd D v C NNu NRe NPr p k k When there is a significant difference between wall & bulk fluid b hd D v Cp b NNu NRe NPr w k k w Stirred liquids, heat transfer frm cil frm tank jacket b hd ND C i i p b NNu 0.9 NRe, i NPr 0.9 w k k w b hd ND C i i p b NNu 0.36 NRe, i NPr 0.36 w k k w
35 Typical Overall Heat Transfer Cefficients Heat transfer cefficients are drastically different fr cnditins f biling and/r cndensatin versus when there is sensible heat change. Bubbles break up the films alng the wall Als dependent upn the temperature difference acrss the wall Fundamentals f Natural Gas Prcessing, 2 nd ed., Kidnay, Parrish, & McCartney, 2011 Ref: GPSA Data Bk, 13 th ed. 35
36 Typical Overall Heat Transfer Cefficients Fundamentals f Natural Gas Prcessing, 2 nd ed., Kidnay, Parrish, & McCartney, 2011 Ref: GPSA Data Bk, 13 th ed. 36
37 Typical Fuling Factrs Add these resistances t the reciprcal f the clean verall heat transfer cefficient Ref: GPSA Data Bk, 13 th ed. 37
38 Equipment
39 Gas Prcessing Applicatins Cmmn heat exchangers Shell and Tube Kettle rebiler Aerial clers Plate Frame Plate-Fin (Brazed Aluminum) Hairpin Tank Heaters 39
40 Shell & Tube Heat Exchangers Wrkhrses f the gas prcessing industry Shell side Baffles used in the shell side t minimize channeling Tube side Maniflds allw fr even distributin f fluids int the tubes & cllectin/mixing f fluids ut f the tubes Multiple tube passes make it easier t pull the tube bundle fr maintenance/cleaning and have better allwance fr thermal expansin effects Fig. 3.6, Fundamentals f Natural Gas Prcessing, 2 nd ed., Kidnay, Parrish, & McCartney,
41 Shell and Tube Heat Exchangers (Types) Ref: GPSA Data Bk, 13 th ed. 41
42 Shell and Tube Heat Exchangers (Selectin) Ref: GPSA Data Bk, 13 th ed. 42
43 Kettle Rebiler Shell & tube heat exchanger with the tubes submerged in biling liquid n the shell side Main resistance t heat transfer is n the tube side since biling is ccurring n the shell side Fig. 3.7, Fundamentals f Natural Gas Prcessing, 2 nd ed., Kidnay, Parrish, & McCartney,
44 Plate Frame Heat Exchangers Psitives Lw cst Cmpact high area per weight & vlume Can get very clse apprach temperatures (5 F r lwer) Can be disassembled t clean Negative cnsideratins Limited maximum allwable wrking pressure Susceptible t plugging Fig. 3.9, Fundamentals f Natural Gas Prcessing, 2 nd ed., Kidnay, Parrish, & McCartney,
45 Tank Heaters Integrated int existing equipment (i.e., tanks r vessels) Ref: GPSA Data Bk, 13 th ed. 45
46 Air-Cled Exchangers Fundamentals Air cled exchangers cl fluids with ambient air Seasnal variatin can greatly impact perfrmance Utilize finned tube in increase heat transfer surface area
47 Aerial Clers Fans either push air thrugh (frced draft) r pull air thrugh (induced draft) tube bundle Can cntrl the air flw rate either with a variable speed mtr r with luviers Fig. 3.8, Fundamentals f Natural Gas Prcessing, 2 nd ed., Kidnay, Parrish, & McCartney,
48 Aerial Cler Design Cnsideratins Typically a small number f diameter tubes (e.g., 1in OD) with fins n the air side (e.g., 1/2 r 5/8 in) Design cnsideratins Prcess side pressure drp fr flw inside f tubes Air side Required air flw May need high air flw t prevent temperature crssver, but High air flw gives higher pressure drp & fan pwer Mechanical cnsideratins Ttal number f tubes Tube layut: number f passes, number f rws, pitch Bay size: typically 45 ft X 15 ft max Ref: GPSA Data Bk, 14 th ed. 48
49 Air-Cled Exchangers Types Frced Draft vs. Advantages: Slightly lwer hrsepwer Better maintenance accessibility Easily adaptable fr warm air recirculatin Mst cmmn in gas industry Induced Draft Advantages Better distributin f air Less pssibility f air recirculatin Less effect f sun, rain, r hail Increased capacity in the event f fan failure 49
50 Air-Cled Exchanger Thermal Design ( Temperature CMTD Figs 10-8 & 9) F ~ 1.0 fr 3+ Over/Under Passes
51 Summary
52 Summary Cmmn types f heat exchangers used in the gas prcessing industry Shell & tube Kettle rebiler Air cled exchangers Plate Frame Plate-Fin (Brazed Aluminum) Hairpin Tank Heaters Heat exchange basics Cupling f fluid energy balances with heat transfer acrss barrier Cmmn heat exchanger cnfiguratins Typical heat transfer cefficients Example prcess calculatins invlving heat exchangers 52
53 Supplemental Slides
54 LMTD as Area-Averaged Temperature Difference If the temperature curves are linearly related t the duty then the temperature difference will als be linearly related t duty T T T T T T q dt dq 0 Q Q Can put int differential frm f heat transfer equatin & integrate Q dq U T da d T U T da T T 1 0 dt T T T T T 1 0 d U T T U 1 0 Q T T 1 0 Q da A 0 da T T T T ln T T ln U A QUA UAT T Q T LM 54
55 Shell & Tube Heat Exchangers 55
56 Heat Exchanger Example 7 Heat 291,800 lb/hr cld C2+ NGL feed frm 80 F t 160 F using 191,600 lb/hr ht C F Assume nly sensible heat effects Determine C2+ NGL feed heat capacity Btu/lb F C3+ Bttms heat capacity Btu/lb F C3+ Bttms utlet temperature Exchanger duty (UA) fr the exchanger C2+ NGL Feed 291,800 lb/hr 80 F??? F 145 F C3+ Bttms 191,600 lb/hr 240 F 56
57 Heat Exchanger Example 7 Exchanger duty & C3+ Bttms utlet temperature determined frm energy balance arund exchanger T Determinatin f UA requires cnfiguratin infrmatin 1-1 cunter-current flw Q m ˆ ccp, c Tc, ut Tc, in ,434,000 Btu/hr Q Thin F mc ˆ hut,, h p, h T 67.5 F LMTD ln Q Btu UA 243, 000 T 67.5 hr F LMTD 1-1 c-current flw cannt be dne crssver! 57
58 Heat Exchanger Example exchanger T 67.5 F LMTD ln P R F 0.51 (frm chart) 2 Q UA F T 2 LMTD Btu 477, hr F Ref: GPSA Data Bk, 13 th ed. 58
59 Heat Exchanger Example 7 Crrectin factr belw 0.8. Try 2-4 exchanger T 67.5 F LMTD ln P R F (frm chart) 2 Q UA F T 2 LMTD Btu 263, hr F Ref: GPSA Data Bk, 13 th ed. 59
60 Cling Twer Principles Evaprative cling (Psychrmetry) Dry Bulb versus Wet Bulb Temperature Cntact dry air with water Saturatin f air (vaprizatin f sme water) takes energy Air is cled belw ambient t Wet Bulb temperature Takes advantage f air belw 100% humidity Wet Bulb MUST be lwer than Dry Bulb temperature 60
61 Cling Twer Principles Evaprative cling (Psychrmetry) Wet bulb and dry bulb data fr varius lcatins arund the wrld Fig
62 Example: Hw cld can yu get? Air temperature: 95 F RH = 65% Temperature with cling twer? Temperature with air cler? Wet bulb=84 F
63 Cling Twers Mechanical Induced Draft
64 Cling Twers Mechanical Frced Draft Twertechinc.cm 64
65 Cling Twers Wet Surface Air Cler 65
66 Heat Exchanger Example 1 Heat 291,800 lb/hr cld C2+ NGL feed frm 80 F t 105 F using 191,600 lb/hr ht C F Assume nly sensible heat effects Determine C2+ NGL feed heat capacity Btu/lb F C3+ Bttms heat capacity Btu/lb F C3+ Bttms utlet temperature Exchanger duty (UA) fr the exchanger Des the flw cnfiguratin in a 1-2 exchanger make a difference? C2+ NGL Feed 291,800 lb/hr 80 F??? F 145 F C3+ Bttms 191,600 lb/hr 240 F 66
67 Heat Exchanger Example 1 Determinatin f UA requires cnfiguratin infrmatin 1-2 (1 shell & 2 tube passes) cmbines bth cunter & c-current flw Fur pssible flw cnfiguratins Ht Stream n Shell Side Cld Stream n Shell Side 67
68 Heat Exchanger Example 1 Fur pssible flw cnfiguratins all have the same exit temperatures but different internal prfiles 68
69 Heat Exchanger Example 7 I thught yu said temperature crssvers weren t pssible???? 69
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