Topics covered

Plant Energy Flow Shell & Tube Heat Exchanger

• Heat Exchangers save energy • TEMA Classification
Heat Exchanger Types • Shell, Channel, Tube, Baffles
• Shell & Tube • Type Selection
• Extended Surface. Helixchanger. Hair STHE Design
Pin & Double Pipe
• Tank Heaters. Electrical Heaters Heat Transfer
• Aircoolers • Tube Side, Shell Side
• Plate & Frame • Fluid Allocation
• Printed Circuit • U & Fouling Factors
Feb 2018
• Cold Box - Cryogenic Exchangers • Optimize: Zones Baffle Pitch & Cut

Heat Exchangers Other Types

• Fired Heater Convection Section
Operations
• Temperature Control
Acknowledgment • Waste Heat Recovery • Fouling
Supplier Web pages, Internet Forums • Air Preheating • Safety Alert
“Petroleum Refinery Engineering”, WL Nelson, Chapter 17, Heat Transfer and Exchangers
GPSA Vol I Section 9 Heat Exchangers

Process Energy Flow Heat Exchangers recycle and save energy

• Heat Exchangers recycle and save energy
Cooling
• Fired Heaters and Boilers
Product Energy Inflow Energy Outflow provide energy
#1 Electricity Products

Product
Steam Flue Gas • Heat exchangers recycle and
#2 Fuel Cooling Medium reduce energy demand
Process
Heating • HX payback in months
Process Product Units
Feed
Units #9 • HX heat, cool, vaporize or
Feed at ambient
temperature Process at elevated Product condense fluids
temperature #n
Products at ambient
temperature Recycled Heat,
Energy Inflow Energy Outflow thru Heat
Electricity Products Exchangers
Steam Process Flue Gas
Units Cooling Medium
Fuel

Heat Exchangers 1
 Refinery Crude Distillation Unit Refinery Crude Distillation Unit
CW
110°C (24%) 40°C Product

Crude Column
Top Reflux
30°C Crude Oil
125°C (4%)
CW
80°C Circulating Reflux Product
Crude 180°C (6.5%)
Crude Heater
Column
CW
220°C (12%) Product
Crude Heater
150°C Circulating Reflux
250°C (7.5%)
CW
260°C (7%) Product
350°C
HX Train
325°C (39%) Long Residue to
Downstream Units
300°C HX Train

Heat Exchangers
Refinery & Petrochemical LNG/LPG/Ammonia/C2=
Plants • Cold box Cryogenic Exchanger
• Feed Preheater Ammonia Plants
• Column Condenser & • Synloop Exchanger
Reboiler
• Circulating reflux or Oil & Gas
sidestream exchanger • Feed Heater
• Feed/Effluent Exchanger • Compressor Aftercoolers
• Product Cooler • Waste Heat Recovery
Refrigeration Plants
• Chiller and condenser
Note: Cooling towers, vacuum column jet condensers
and quench are also exchangers - direct type

Heat Exchangers 2
 Heat Exchanger Types Shell & Tube HE - STHE Shell Tubes

Tierods
Two fluids exchange heat Based on Service Widely used Front End Channel
• One inside and other outside tubes • Heater, Cooler • Wide pressure and temperature range Channel Cover
• Sensible heating Baffles
Heat transfer • Different configurations Tubesheet
• No phase change
• By convection from fluid to tube. • Condenser or Reboiler Front End: Fluid enters tube bundle Saddle
By conduction via tube wall. And Support
by convection from tube to fluid • Phase change Rear End - Fluid exits or U-turns in multiple pass
Fluids: Single or multi-phase On Flow Paths Shell - Cylindrical pressure vessel or casing
• Countercurrent • Contains tube bundle, its supports - baffles etc
Our skin: A large surface heat • Co-current
• Tubesheets - support and isolate tubes
exchanger • Cross current • Fixed. Welded to shell on either end. Tube bundles can’t be pulled out
On Construction • Floating. Welded at one end. Other end free to expand. Bundle pulled out for cleaning
t/k = 1/h t = k/h. Knowing h and k, can estimate • U Tube: One end free to expand.
film thickness ~ 2.4 mm gas; 0.0025 steam.
• Shell & Tube Removable tube bundle
Higher the velocity, higher h and thinner film • Aircooler • Thickness to suit design pressure and
Tubesheet

Δt1
• Plate & Frame temperature. ASME, Sec VIII, Divn 1
Δt1 • Printed Circuit Bonnet Tubes
Δt1 Δt2
Δt2 Δt2 Baffles
Countercurrent CoCurrent Crosscurrent

Bonnet
Shell & Tube HE - STHE Enhanced Surface Tubes
Channel
Channel Or Bonnet • Rough surface and fins Low Fins
• Route tubeside fluids with pass partitions • Increase turbulence, heat transfer and area - UA
Tubes • Good with low heat transfer coefft. Retrofit for more area
• Heat Transfer Surface. Passage for tube side fluids • Low finned tubes
Tubesheet • Extruded external surface. Fin OD ≈Tube plain end OD
• Holed sheet. Supports tubes on either ends • Grooved inside. 2-3 x Area. Can replace existing tubes
• Tubes are expanded into tubesheets. Seal welded
• Finned tubes ~ as in air coolers Low Fins
Baffles - single, double and triple segment • High Heat Flux Tubes ~ in boiling service
• Intermediate tubesheets
• Coatings or porous / sintered surface promote hi flux
• Route shell side fluids across tube bundle
nucleate boiling. 10 x Surface
• ID coated. OD bare or fluted
• OD coated. ID bare or finned High Heat Flux
Turbulators
• Tube inserts Twisted tapes

• Wound wires inserts or twisted tapes

Heat Exchangers 3
 Helixchanger Twisted Tubes Hairpin - Double Pipe/ Multi-tube
• Helical baffling creates helical flow • Packs more 40-50% surface area Double Pipe - Pipe in Pipe 2”-6”
pattern in shell side • Good turbulence. Reduced ΔP • Single bare or finned tube inside a bigger
• Increases shellside heat transfer and • Reduced vibration and fouling tube. Spiral or longitudinal fins
reduces shellside fouling
• Reduced weight and foot print
• Good for high ΔP and vibration Multi-tube 3”-16”
services • Multiple inner tubes, bare or finned. Spiral
• Longer run lengths between cleaning or longitudinal fins
• Reduced Capex in petrochemical
Good for
• Hi energy-efficiency feed/ effluent
• Shell side Viscous or low transfer coefft
• Good substitute for “E” and “J” shells
or low fins or tube inserts • Finning helps
• Countercurrent  smaller surface area Type Double Pipe Multi-tube
• U tubes. Expansion joint not required Shell Dia, in 2”-6” 3”-16”
• Shorter delivery. Standard sections Tube dia, in ¾”-4” ¾”-1”
• Modular. Good for temperature cross No of fins 0-72 0-24
• Ease of cleaning, inspection, replacement
Fin height, mm 0-¾” 0-½“
• Gas-Gas. Gas-Liquid. Fuel Gas. Compressor
Cooler Surface m²/m 0.15-0.6 1.1-23
Bare surface area of a 1” tube 0.08m²/m

Tank Heaters Aircooler

• To maintain temperature or heat • Where water is scarce
• Wall mounted coils or panels
• Prime cooler to 65°C + trim cooling by water
• Inline/ Suction
• Intermittent while pumping out. Bigger area • Wide pressure and temperature range
• Floor or Stub-in • Tube bundles, usually above pipe rack ID Fans
• Continuous heating + Provide heat loss. Tank is
insulated. Smaller area. • FD or ID fans or Natural draft Plenum
Tube Bundle
• Floor coil gets water logged • Fan motors: Typical 5 - 30 kW
• Heating • Air plenum between fan and bundle Plenum = Distribution chamber
• Steam or Hot Water or Heating Medium
• Temperature control: Fan speed or on/off Tube Bundle
Plenum
control or louvres FD Fans
Electric Heaters • Cross flow
• For start-up or high temperature heating FD Vs ID: FD: Runs cooler. Lower kW. Can handle high
• Typically Fuel Gas Superheater • Winterization steam coils process temperature. Easy access

• Thyristor controlled Poor air distribution. Hot air recirculation. Low natural
draft on power loss. Poor temperature control as
tubes are exposed to natural elements, sun and rain

Heat Exchangers 4
 Aircooler Parts Aircooler
1 Tube bundle 2 Plenum 3 Fan ring 4 Fan blade 5 Supporting structure for V-belt drive & • Tubes: 3 to 8 rows. Max 12.
motor 6 Steel construction 7 Walkway and ladder
L = 6 to 12m. Bundle W ≈ 4m
• Bay: 2 or more bundles
covered by a set of fans
• Low air side coefft. Finned • Embedded to 400° C
surface • Fins wound mechanically into groove
under tension. Displaced metal
• Solid or serrated fins pressed on each side of the fin. Locks
it in place
• Serrated hi coefft + hi ΔP
• Extruded Fins to 260° C
• Aluminum fins. High ‘k’. Ease of • Fins extruded out of an outer
fabrication aluminum tube mechanically bonded
• Service temperature decides, to inner tube
embedded or extruded or footed • Footed Fins to 150~260° C
type fins • L shaped fins tension wound over
tube

Plate & Frame Plate & Frame

• Pressed (corrugated) metal plates. Plus Minus
Movable End
• Pressed turbulent flow channels. Cover
1. Easy to clean. Disassemble 1. Gasket requires good care
Fixed End
High heat transfer. Low fouling. Cover
2. Easy to rearrange - add/ remove plate 2. Lower temperature limits. 70-200°C
Plate Pack
• CS to SS to Titanium plates 3. Low fluid residence time and hold up 3. Lower pressure limits. 10 - 20 barg
• Inlets and outlets stamped into 4. No stagnant, hot or cold spot that can 4. Gasket materials are not compatible
damage temperature sensitive fluids with all fluids. Not good for vacuum
corners of each plate service
5. Low fouling. High turbulence. High hi
• Plates gasketed and bolted 6. Small plot area c.f shell and tube HX
• Gaskets to suit service temperature 7. Maintenance area within frame size.
No separate bundle pulling area
• Piping connections at fixed end
• Area/ plate = 0.05 to 4 m². 600 plates/unit
• Can add more plates or area
• Indirect cooling - Water/ Water coolers
• Low pressure oil coolers

Others: Spiral Plate Exchanger, Scraped Surface, Welded Plate

Heat Exchangers 5
 Pressed Plate

Welded Plate Exchanger Printed Circuit - PCHE

• Thin stamped metal plates. • Compact and corrosion resistant
Welded. No gaskets • Made of SS, Titanium, Nickel and Nickel Alloys
Plate
• Plate & tube in cross flow • Narrow fluid passages. Photo-chemically
Plate
etched on thin plates
• Wave shaped plate and elliptical Tube • Plates stacked and diffusion bonded into solid
tube passage block Low diameter. High coefft
• Depth of plate pressing to suit ΔP • High pressures. Cryogenic to high temperature
or particles • Fluids: Liquid, gas or two-phase.
• P =FV to 60 bar T= -200 to 900°C Countercurrent, cocurrent or cross flow
• More than 2 fluids can exchange heat 2 mm x 1 mm
• Plates 0.5 to 1.0 mm thick • Free of vibration or tube rupture issues
• W = 350 L = 200 to 12,000 mm
• Narrow passages. Limits to clean service 4 MW Gas-Gas Cooler - S&T Vs PCHE
• Service • Inlet/ Outlet strainers required. 300μ
• Gas-Gas. Gas-Liquid. Liquid-Liquid • Compressor after-coolers, gas/gas, cryogenic 105 t
• Evaporators and condensers • Light ends. Feed-effluent in HDS and platforming
Rapid coolant control valve response can create thermal cycling, fatigue
Comparison with Shell & Tube crack and inter-stream leak. HC to cooling water. Ensure stable control. 15 t

MCHE - Main Cryogenic

Transfer Line Exchanger Heat Exchanger
• Quick quenching of ethylene Cold Box or MCHE
• Spiral or helically wound coils
cracker effluents (850~ to
• Multiple streams
400° C) to avoid secondary • High design pressure and cryogenic
reaction. Maximize C2= yield temperature
• Millisecond quenching • LPG, LNG, NH3, Air Separation, C2=
production
• Steam side: High pressure TLE

• HC side: High temperature

• Bundle or double pipe design 2-3 tube bundles 5mØ x 55m l – 500 t
Double Pipe
Bundle

Heat Exchangers 6
 MCHE - Main Cryogenic
Heat Exchanger Fired Heaters Convection Section
Feed

Cold Box or MCHE Heats process fluids. Cools flue gas Steam
to stack
• Brazed aluminium plate-fin • Efficiency improved from 60 to 90+%
• High area/ volume • Radiant section fluid pre-heat
• BFW, Steam Generation, Superheating,
• Multiple streams Air
• High design pressure and cryogenic temperature Top or side mounted
• LPG, LNG, NH3, Air Separation, C2= production Bottom 2 rows bare. “Shock tubes”.
Get firebox radiation
Flue gas heat transfer coefft low.
Extended surface tubes Studs
• Finned - Gas and light oil firing
• Studded - Oil firing. More fouling
• High heat flux at low cost
Fins - Serrated or solid

Gas Turbine WHRU Common WHRU for 2 Turbines

Fired Heater Air Pre-heaters
Gas turbines run generators Tubes, plates or heat pipes
and compressors Sturdy cast iron extended
• Exhaust at 500°C. 16-18% O2 surfaces - fins inside/ outside
• 0.5 to 15 MW
• Efficiency 30-40%
Glass or polymer tubes to
• Generate steam to run Steam cool flue gas below acid dew
Turbine. Efficiency upped point, to withstand acid
corrosion
Tubular
• Exhaust to heat hot oil or hot Polymer Tubes Cast Air pre-heater with
water or generate steam Side in/out inside and outside fins
Top tube removal Heat Pipes. Sealed pipes with heat
• Finned tubes. Similar to heater Bypass
Glass Tubes transfer fluid. Vaporizes on flue
convection section gas side and condenses on air side

WHRU

Heat Exchangers 7
 Regenerative Air Pre-heaters
Large surface
• Gas and air transfer coeffts low
Regenerative
• Light metal elements packed in Rotary Basket
rotating baskets
• Alternatively heated by flue gas
and cooled by air
• Or air inlet/ outlet ducts rotate
• 5-15% air leak
• Reduced efficiency and cold end
corrosion. Marginally bigger FD/ID
Fans. Local fire hazard
• Small size. Low weight and cost.
Good with clean fuels
Inlet and outlet air duct rotate. Flue gas
pass in areas not covered by air duct

STHE Parts TEMA Standard

• AES and AKT - Tubes free to expand Tubular Exchanger Manufacturers Association
Tubesheet
standard provides
Tubesheet (Fixed) Floating
(Floating) • Nomenclature, dimensional tolerances, manufacturer’s and
AES Head
purchaser’s responsibilities, general installation and operating
Tie Rods
Channel Tubes Shell guidelines, and specific design and fabrication practices
Pass Cover • Seismic design, large diameter exchangers, tube vibration,tube-to-
Partition Baffles
Shell tubesheet stress, nozzle loading and design limiting features

Shell
AKT • Class R, C and B
Tubesheet Floating • R: Severe operating and maintenance characteristics

Tubesheet (Fixed) Tie Rods (Floating) Head • C: Less severe
Channel Weir
Pass Tubes
Baffles
• B: Moderate. Between R and C
Partition

Heat Exchangers 8
 Baffled
Non-baffled
For temperature cross, go for F or multiple shells
TEMA Classification Shell
Classified by 3 letters, say AES • Shell. 3m dia x 12m. Floating: 1.5m dia x 6-9 m. E
• “E” - Most common - Single shell pass T1
• Front end/ shell/ rear end type • “F” - For temperature cross t1> T2 t1 F
• Fixed or Floating Head. Straight or U tubes • 2 Shell pass. With 2 Tube passes, Countercurrent flow. T2
t2
For temperature cross G
• See TEMA for more
• “G” Split flow. Horizontal thermosiphon reboiler
• 1 central support plate. No baffles. Low ΔP. Tube length 3m max
H
• “H” Double split flow. Horiz. thermosiphon reboiler
• 2 central support plates. No baffles. Two-’G’s. Tube length 6m max
AKT
• “J” Divided flow. Velocity + flow path halved. ΔP = 1/8th J
AES
• 1 inlet. 2 outlets {OR} 2 inlets and 1 outlet
• “K” Kettle reboiler - vaporizer, chiller or steam generator K
• Low pressure drop. Vapor disengagement space
AEU
• “X” Cross flow. Ideal for vaporizer, condenser or cooler
• Very low pressure drop. Vacuum Service. Gas cooler
X
CFU From: Effectively Design Shell-and-Tube Heat Exchangers, Rajiv Mukherjee, Chemical Engineering Progress, February 1998

Removable Cover
Removable Channel
Split Ring Floating Head
Channel Pull thru Floating Head
U Tubes
Channel Floating head with
backing device (split ring)
Tubeside fluids with pass partitions Floating Tubesheet - “S”, “T”, “P”, “W”
“A” “L” “S”
• Integral or removable. Removable - “A”, “C”, “L”, “N”
• Support tubes in floating end
Fixed Tubesheets. Simple. Economical • Thermal expansion/ contraction
• Front: “A”, “B”, “N” Rear: “L”, “M”, “N” “B” “M”
• Cleaning tubes inside/ outside easy
• Tubesheets welded to shell. Avoids shellside leakage
• “S” - Larger shell cover + Split backing ring
• Tube outside surface: Chemical cleaning
• Bonnet ends, “B” and “M”- requires piping removal for “N” “N” • Floating tubesheet sandwiched between split ring and head cover
clean out • Shell cover + Floating cover removed to pull out tube bundle
U tubes. “M” Rear End • A has 2 seals / leak paths Vs 1 in B.
• “T” - Pull thru. Easy to maintain
• Only 1 tubesheet. Bundle free to expand and contract Access to tubes without disturbing • Smaller floating cover. High ‘shell-to-bundle’ gap
piping. Same in L Vs M “T”
• Bundle can be pulled out and externally cleaned • C and D good for HP. Difficult to
• Only shell cover removed to pull out tube bundle. Lower
• Tube inside U part difficult to clean. Clean fluids only repair or replace tubes as bundle is downtime. Good in dirty service. Bigger and expensive shell
integral part of header. So also N
U Tube: BEU. Removable CEU
• A for dirty fluid. B for clean • “P” and “W” - For LP and non-hazardous service
Fd Tubesheet: BEM, AEL Pull through
Removable: Split Ring CES, Pull • C for hazardous fluids in tubes. N
floating head
thru CET for hazardous fluids on shell

Heat Exchangers 9
 30°Δ 45°Rotated□ 60°RotatedΔ 90°□
Diamond

Tube Baffles
 Staggered Spacing  Inline  • Metal plates. Direct shell side flow. Support tubes
• Tubes
• ¾ - 1”(20-25mm) OD. 1¼“ for dirty stocks. Smaller tubes get plugged • Create turbulence. Increase heat transfer
• Length 6-9 m. By owner to minimize inventory. 18m max. Straight or U • Baffles cut or window
• Pattern: Angle made by shellside flow to tube layout viz. 30°Δ. 45° Diamond • Provides parallel or cross flow area Max 50%. Centre tubes will not be supported
or Rotated□. 60°RotatedΔ. 90°□. Staggered or Inline spacing • Baffle cut. 15% to 45%. Usual 20-35%. Max 50%
• Δ: Hi coefft. Hi ΔP. More tubes in a shell. Difficult to mechanically clean • Horizontal Cut: Sweeps deposits from shell
• □: Easy to clean □: Not used in Fixed tubesheet. Mechanical cleaning not feasible • Vertical Cut: 2 pass “F” shell
• Fixed tubesheet: Δ Chemical. Floating: □ Mechanical. U: Δ or □ by service • Baffle spacing
• Pitch, center to center tube spacing = min(1.25OD, OD+6 mm) • Min(20% shell ID, 50mm). Max = Shell ID Main Main
Eddy
• Usual 0.3-0.6 shell ID Eddy
• Even number of tube passes, to have inlet/outlet on the same side. Tube
pulling plot on other side. Passes: Usual 1,2,4,6,8 • Larger - less ΔP. Low heat transfer coefft Main

• More passes, less flow area. High velocity, hi and ΔP. ΔP  V² and L • Multi-segmented baffles. Lower ΔP
Small Cut Large Cut Ideal cut
• ΔP2/ ΔP1 = (V2/V1)²*(L2/L1) = (Pass2/Pass1)2.8 f = Re-0.2 • Shell side flow gets divided
• Larger baffle spacing Tube vibration: Segmental baffle with
• ΔPcalc << ΔPallowed no tubes in window
Fixed
Removable/ Floating Wire (or rod) baffles available NTIW = No Tubes in window

Shell Flow Streams - Due to leaks Shell Tube HX Type Selection

5 Streams A, B, C, E and F Design "U" Tube Fixed Tubesheet Floating Head
Outside Packed
Float Head Split
Backing Ring
Float Head Pull-
Through Bundle
• B, main cross-flow stream Differential Tubes free to Shell expansion Floating head Floating head Floating head
• Maximize this. Efficient Expansion? expand joint
Bundle Yes No Yes Yes Yes
• 4 leakage or bypass Removable?
• A, thru tube-to-baffle hole leak Bundle Yes Not practical Yes Yes Yes
Replaceable?
• C, bundle bypass
Single tube External tubes Yes Yes Yes Yes
• E, baffle-to-shell leak. Poor heat transfer Replaceable? only
• F, pass partition bypass Tube inside Chemically Mechanically & Mechanically & Mechanically & Mechanically &
• High ΔP across baffle  more leak/ bypass Cleanable? Chemically Chemically Chemically Chemically
Tube Outside in Δ Chemically Chemically Chemically Chemically Chemically
• Minimize ΔP across baffle. Reduce leaks pitch Cleanable?
• Optimize baffle spacing/ cut. Larger  low V and ΔP Tube Outside in □ Mechanically & Chemically Mechanically & Mechanically & Mechanically &
pitch Cleanable? Chemically Chemically Chemically Chemically
• Equal velocity in window and cross-flow
No of tube Even number No limitation No limitation No limitation No limitation
• Tube layout and pitch Passes
• Clearance of bypass/ leak paths Internal Gasket No No No Yes Yes

From: GPSA, Section 9, Heat Exchangers

Heat Exchangers 10
 Selection Criteria
• Proven type for the service Maintenance
• Duty and ΔP • Channel ends allow access
• Issues without disturbing piping,
• Cyclic pressure and temperature unlike Bonnet ends
• Corrosion / Erosion • Pull thru is better than Split
• Vibration / Noise Ring
• Easy to clean, repair, replace • Chemical cleaning has limits.
parts So also mechanical cleaning.
Select right head and pitch
• Longitudinal baffle, as in F
prone to leak

Check Duty Multiple Zones

Heat Duty - heat balance Countercurrent
If heat exchange not linear with temperature
• Q = mCp∆t , both hot / cold side - no phase change Δt2
Δt1 • Due to phase change, as in condensing or boiling or physical
• Q = mΔh, both hot / cold side - phase change property (viscosity) changes
• Divide into zones and sum up areas
Heat Duty - heat transfer CoCurrent • Two phase fluids:
• Q = U.A.LMTD LMTD correction for multi-pass • Vapor phase may remain in contact and equilibrium with liquid
Δt1 Δt2
• A is usually based on tube OD or outer surface phase or vapor phase may be continuously removed
• LMTD based on Δt1 and Δt2. For countercurrent, LMTD is lower
• LMTD = (Δt1 - Δt2)/ ln(Δt1 / Δt2), whenΔt1 > Δt2

3.Subcooling
Zone 1:

Temperature, t 
• Multi-pass crosscurrent requires correction to LMTD Desuperheating
Propane
Charts available. Ensure CF > 0.8 with right configuration Mixed Crosscurrent 2: Condensing

Cooling Water
Heat Duty, Q 

Heat Exchangers 11
 Fluid Allocation Tubeside Heat Transfer & ΔP
• Dirty fluids to tubes. Easy to Caution: Seawater cooler: ‘k’ influence on hi
clean • Usual: HP gas on tube. Seawater Based on Reynolds number • Water k = 0.65 W/m.°K
hi = 7,000 W/m².°K
• Dirty fluids to shell, if tubes on shell. Titanium tubes. CS
can’t be cleaned as in U tube tubesheets with titanium
• Laminar, turbulent • HC liquid k = 0.1
hi = 300 - 1,500
• Dirty fluids with coke and debris cladding • hi = 0.023 k/d*Re0.8Pr0.33 Dittus-Boelter • HC Gas k = 0.03
to shell hi = 60 - 600
• Galvanic corrosion of CS tube
• HP, corrosive or scaling stocks sheet behind Titanium cladding • hi wall viscosity correction (μ/μw)0.14 Sieder-Tate
to tubes results in H2 release  brittle
• Corrosive on shell side will make Titanium hydride  weak tube • hi ~ μ-0.47 k0.67 Cp0.33 G0.8 d0.2. ΔP α μ0.2 G1.8 ρ-1 d-1.2
both tubes and shell expensive sheet  Leak  Shell failure. HP
gas release • Balancing heat transfer against pressure drop
• Large volume vapors or viscous
stock or low ΔP to shell. Baffles • Seawater on tube side or solid • Pressure drop calculation
improve heat transfer titanium tubesheet
• Low flow to shell. Avoids multi- • Titanium cladding on tube sheet. • Frictional length + 90° turns at inlet and tube passes
passes Titanium tubes to project out of
• Vapors with noncondensable to tubesheet by 3 mm and tubes to
Typical ΔP, bar
tubes, to sweep away Titanium cladding Liquid - 0.5 to 0.7. Gas - 0.1 to 0.2
Experience based trade-off Liquid velocity Min 1 ~ 2-3 m/s

p
Shellside Heat Transfer p = Pitch d = Tube OD Shellside ΔP
□ ∆
• Trial & Error. Iterations due to shell Cross and window flows. Simple M M
streams split procedure per Nelson,
• Bypass and leak stream. Poor participation Shell diameter from • M, net free gap at bundle center line
• Temperature change in main stream is higher number of tubes
than average, reducing effective MTD. • = No of tube spaces + bundle OD to shell gap
D² = N*P²/C
Weighted MTD C = 0.75 for □ 0.86 for Δ
• Flow area,
• ho = 0.22~0.36 k/d*Re0.6Pr0.33. d= 320 tubes.25 mm OD. 32
• Cross flow = M*Baffle Spacing
hydraulic dia mm □ pitch D = 660 mm. • Window flow = π/4(Shell.ID²-No.of.Tubes * Tube.OD²) *
• d = 4[0.5p*0.86p- πd²/8]/(πd/2) OR 4[p*p- Add 50 mm to get Shell Baffle.Cut
πd²/4]/(πd) ID, 710 mm
• Calculate
• 2 flows Window Flow • Reynolds No. Cross and Window Flow. Calculate ho
• Cross flow across bundle. Varies due to shell’s • Shell side ∆P
circular shape. Window flow along tubes.
Cocurrent and counter current • Cross: No.Rows.f.4VH Window: 2VH/baffle
Heat Exchanger Sizing.XLS

Heat Exchangers 12
 U, Overall Heat Transfer Coefft Typical U and Fouling Factor F
Service U Btu UW F Btu FW Service U Btu UW F1 W F2 W
• Calculate tubeside heat transfer coefft (hi)
Water Coolers 0.002 0.0004 Rich /Lean Oil 80-100 450-570 0.0002 0.0004
Convert to outside area basis hio = hi*di/do LP Gas 35-40 200-225 0.001 0.0002 C3 Liq/ C3 Liq 110-130 625-740 0.0002 0.0002
MP Gas 40-50 225-285 0.001 0.0002 MEA/ MEA 120-130 680-740 0.0004 0.0004
• Tubeside resistance, rio = 1/hio
HP Gas 60-70 340-400 0.001 0.0002 LP/ MP Gas 50-70 280-400 0.0002 0.0002
• Shellside resistance, ro and VHP Gas 80-100 450-570 0.001 0.0002 VHP/ VHP Gas 60-80 340-450 0.0002 0.0002
Kerosene 80-90 450-500 0.001 0.0002 VHP/ C3 liq 60-80 340-450 0.0002 0.0002
• Tube wall resistance, rw = tw/kw (wall thickness ÷
MEA 130-150 740-850 0.002 0.0004 Steam Reboilers 140-160 800-900 0.0001 0.0002
conductivity). rw = do/2.kw*ln(do/di) Air 20-25 110-140 0.002 0.0004 Hotoil Reboilers 90-120 510-680 0.0004 0.0002
• Select tube and shell side fouling factors Water 180-200 1000-1140 0.001 0.0002 HM Reboilers 80-110 450-625 0.0002 0.0002
Water Condensers 0.002 0.0004 Only F in (m²·°C)/W units given. Easy to guess Btu
Dirt resistance rfio = rfi*id/od and rfo C3-C4 125-135 710-765 0.001 0.0002 values. Noncondensable accumulation or gas film
Naphtha 70-80 400-450 0.001 0.0002 reduce high condensation coefft and U.
• 1/ U = ro + rio + rw + rfio + rfo Overhead 70-80 400-450 0.001 0.0002 Service U Btu UW

• Typical fouling factor and U values .. Amine 100-110 570-625 0.002 0.0004 Wellfluid Heater 70-80 400-450
U in Btu/(hr.ft².°F) or W/(m²·°C) and Fouling Factor F in Production Gas Cooler 120-130 680-740
(hr.ft².°F)/Btu or (m²·°C)/W. Refer to TEMA for more F values. TEG-TEG HX 20 115
Operating companies may have their own values based on Fuel Gas-Gas HX 50 285
site-specific observations Water-Water HX 250 1425

Typical U - Air Cooled HX U in Btu/(hr.ft².°F) or W/(m²·°C)

HX Sizing
Service U Btu UW Service U Btu UW Shell Tube
Lean Oil Rich Oil
Condensers Liquid Cooling
Flow, kg/h 112,039 127,007
Amine Regene 100-120 570-680 Engine Jacket 130-155 740-880 Temp, °C in/out 210/65.6 32.2/ 167.8
Ammonia 105-125 600-710 Fuel Oil 20-30 115-170 ∆P allowed, kPa 113.8 69
Refrigerant 12 75-90 430-510 Platformer Liquid 85 485
Heavy Naphtha 70-90 400-510 Light Gas Oil 70-90 400-510 Mean fluid temp, °C 137.8 100
Light Naphtha 95 540 Light Hydrocarbon 90-120 510-680 Density, kg/m³ 740 750
Light Gasoline 95-105 540-600 Light Naphtha 90 510 Sp. Heat, kJ/kg.°K 2.45 2.30
Viscosity, cP 0.5 0.5
Light Hydrocarbons 80-100 450-570 Process Water 120-145 685-825
Ther con, W/m.°K 0.13 0.13
Reactor Effluent 80-100 450-570 Residuum 10-20 60-115
Fouling, W/m.°K 0.0002 0.0002
LP Steam 135-200 770-1140 Tar 5-10 30-60
Still Overhead 75-90 430-510
Gas Cooling Steps
LLP Air 10 60 1. Check/ verify heat duty 1. Duty = 112,039*2.45*(210-65.6)/3.6 = 11 MW
LP Air 20-30 115-170 Duty = 127,007*2.30*(167.8-32.2)/3.6 = 11
Ammonia Reactor 90-110 510-625
2. Select shell and ends type.
LP Hydrocarbon 30-40 170-230 No of shell and tube passes 2. No of shells 4. Tube Passes 2
MP Hydrocarbon 50-60 280-340
HP Hydrocarbon 70-90 400-510

Heat Exchangers 13
 HX Sizing Steps HX Optimization - CEP Paper Example-1
3. Estimate LMTD 3. LMTD 210.0  65.6 R = 0.94 P = 0.81 HX Duty = 6.4 MW AES Design A
167.8  32.2 F = 0.83 • Shell Tube
4. Assume U. Estimate Area 42.2 33.3 LMTD = 31.2
• Fluid Oil HGO • ΔP- Tube = 0.17 Vs 0.7 allowed
4. Assume U = 400 A = 882.7 m²
5. Assume Tube Dia x Length. 5. Assume OD = 0.75” ID = 0.58” L = 6.1m • ΔP, bar 1.2 0.7 • ΔP- Tube with 4 passes
Tubes/ Shell = 605, say 610 A = 890 m² Design A B • ΔP= 0.17*(4/2)^2.8 = 1.2 Vs 0.7 max
Calculate number of tubes, Flow Area = 0.0527 m² Velocity = 0.9 m/s • High velocity
Shell ID, mm 925 780
velocity, Re and hi. ΔP Re = 19,857 hi = 930. hio-foul = 724
Tube OD, mm 25 x 9m 20 x 9m • Overdesign 28%
f = 0.026 Eq.L = 48.8 m ΔP = 32.8 kPa
6. Estimate Shell dia 6. Shell dia = 26.5in based on pitch = 0.9375” No of Tubes 500 540 • Reduce length ~ 9/1.28 ~ 7.5 m
No Tube Passes 2 2 • ΔP = 1.2*7.5/9 = 1.0 bar
7. Assume baffle pitch x cut 7. Assume baffle pitch = 20”. Cut = 20% Area, m² 343 300 • Negotiate with system designer
8. Cross flow area = 0.11 m² V = 0.40 m/s
8. Calculate shellside Window flow area = 0.036 m² V = 1.16 m/s Tube Pitch, mm 32 x 90° 26 x 90°
velocity, Re, and ho. Shell Re = 19,059 ho = 1,154 ho-foul = 937 Baffle @, mm 450 400
Design B
ΔP = 116 kPa Baffle Cut, % 25 30
ΔP • Smaller dia. High hi and U
9. U = 409 A = 864.1 vs 890 assumed
Shell V, m/s 1.2 1.5
9. Calculate U and A. Redo if Tube V, m/s 1.4 2.2 • Smaller shell dia and area
required 10. Try decreasing baffle spacing and ΔP - Shell, bar 0.9 1.2 • Able to match tube side ΔP
increasing baffle cut to get equal velocity ΔP - Tube, bar 0.17 0.5
U, W/m².°C 415 460
From: Effectively Design Shell-and-Tube Heat Exchangers, Rajiv Mukherjee, Chemical Engineering Progress, February 1998

HX Viscosity Impact - CEP Paper Example-2 HX Baffle Influence - CEP Paper Example-3
Kettle Steam Generator 13 MW HVGO viscosity changes on HX Duty = 4.6 MW 25% Baffle Cut Observation
• Shell Tube • Parameter Shell Tube • Baffle cut 25% for all cases
cooling. From 1.6 to 6.36 cP • Fluid Oil HGO
• Fluid BFW HVGO • Window velocity same
• Zone calculations required • ΔP, bar 1.0 0.7 • Design A: ΔP high
• μ, cP 0.18/0.18 1.6/6.36
Design A B • Design B and C OK
Design A Design A B C • Select Design C. Low ΔP.
ΔP - Tube, bar 1.28 1.35 Baffle Spacing, mm 300 350 400
• Single viscosity based on average Hence low leak. Higher
hi, W/m².°C 404 266 Main Stream B, % 54 56 58 thermal efficiency
U, W/m².°C 284 208 temperature. HX under-surfaced Baffle hole Leak A, % 16 14 13
Overdesign, % 24 -9.1 Design B Bundle Bypass C, % 11 12 12 • Next keep baffle spacing
• 10 Zones. Re1 = 9,800 Re10 = 2,850 Baffle to Shell E, % 12 11 10 constant at 400 mm
• MTD1 = 138.5°C MTD10 = 17°C Pass-partition F, % 7 7 7 • Vary baffle cut 20 thru 35%
• Length1 = 2.3m Length10 = 45m Shellside Efficiency, % 71.3 73.4 74.9 • Higher the cut, lower is
• Reduced heat transfer in last zone velocity, ΔP and leakage.
Crossflow velocity, m/s 2.5 2.2 1.9 • 30% cut appears good for
Window velocity, m/s 2.3 2.3 2.3 this case
Use zones in such cases ΔP - Shell, bar 1.3 1 0.8 • High ΔP between baffle
U - W/m².°C 467 465 461 sections causes more leak
From: Effectively Design Shell-and-Tube Heat Exchangers, Rajiv Mukherjee, Chemical Engineering Progress, February 1998 From: Effectively Design Shell-and-Tube Heat Exchangers, Rajiv Mukherjee, Chemical Engineering Progress, February 1998

Heat Exchangers 14
 Inlet and Outlets
Piping Nozzles:
• Piping to allow bundle pull • Shellside: ρV² < 9,000 kg/m·s²
out without or minimum • Tubeside: ρV² < 2,230 kg/m·s²
disturbance for noncorrosive, nonabrasive
• Tube pulling area in plots and 750 kg/m·s² for others
• Shell/ bundle entry or exit: ρV²
< 6,000 kg/m·s²
• Provided impingement
protection: for corrosive or
abrasive gases, saturated
vapours and two phase
mixtures

Performance Fouling
• Changes in feedstock, operating conditions, • Drastically reduces performance
Corrosive Stock
throughput, controls, failure of upstream • Uclean 125 or 25. U dirty 36/17
equipment impact performance

Fouling Factor 
• Hard deposits Wet Crude

• Corrosion or fouling • Water scale, corrosion product, coke Desalted Crude

• Increases product temperature to coolers and reduce • Porous deposits Fluid Velocity 
fired heater inlet temperature. More heater duty
• Carbon deposits from heavy stocks
• Control scaling with treatment. Biocide fouling control
• Loose deposits
• Spare bundle
Cracked Overheads
• Silt, mud, coke, oxidation products
• Internal leakage or mechanical failure
• Minimum velocity

Fouling Factor 
• LP side pressurized on tube failure
• Cleaning Residues
• Poor MOC (Material of Construction) CDU Overheads
• Chemical CDU Products

• Mechanical, water jetting, sand blasting Fluid °API 

Heat Exchangers 15
 Fouling CDU Preheat HX Tube Corrosion
Particles Crude / Overhead Vapour HX Findings
Deposition Fouling Corrosion
• First exchanger in preheat train 1. Desalter functioning not perfect
• On tubes - inside/ outside • MOC • Crude inlet temp 30-40°C
• Crude on tube side 2. Overhead vapour corrosive. Send
Plug Fouling • Inhibitor it to tube side with lesser dead
• Horizontal Floating Head. CS
• Sacrificial anodes zones to reduce corrosion
• Large slugs of material
3. Heat crude first with other stocks
Biological Crystal In operation to 60°C. Higher metal temp
Prevention • Continuous dosing of filming amine, reduces corrosion
• Avoid stagnation. High velocity • Suitable temperature range neutralising amine and wash water
(stripped sour water reused as wash water) 4. Avoid re-used wash water from
except corrosion-erosion cases • Chemical Treatment overhead drum. High chlorides
5. A hot and cold separator (two
Particles Corrosion drum) system improves heat
• Avoid with high velocity recovery. Less corrosive due to hot
reflux in fractionator
Crystals 6. Upgrade HX metallurgy
• Avoid with inhibitors 7. Vertical instead of Horizontal HX
From: HTRI presentation “Design Margin and Fouling Factors” Biological From: eptq.com/qanda

Solvent Deasphalting Unit Typical HX P&ID

Vacuum Residue/Asphalt • Exchanger added to • Process outlet temp controls
• Cooling /heating fluid flow TIC
Exchanger improve heat recovery
• TCV on low temperature side FI
FE
TV

• Performance lower • Inlet of cooling. Outlet of heating

PG
• Aircoolers - fan on/off or speed control
than predicted TG PSV

• VR temperature rise • PG/TG on shell & tube inlets/ outlets TG PG TT PZA

LL

5°C Vs 15°C design Process

Stream In
• If HP pressure >1.3 LP design pressure PG PG TG
• Helical baffles - one • PALL/ PAHH trips to protect against TG
PSV
options for tube rupture PZA HH

improvement • Rupture Disk acts faster than RV

• PSV-thermal on cooler side

Heat Exchangers 16
 Safety Take Away
• Start-up transient condition results • 2 killed. 8 injured
• Different types to suit service • Heat Transfer Vs ΔP
in lower than design temperature, • Too many alarms appear to have
when hot fluid stops and cold fluid desensitized the operators • Sizing. Iterative calculations • Fluid allocation is key
continues to flow • Alarm Management Study
• Tubeside variables:
• Esso, Langford, Australia - LPG
• Designer has constraints • Tube dia. Length. No of passes
• Cold “rich” oil < (-)30°C heated in a
series of exchangers by hot “lean” oil at • Allowable pressure drop • Shellside variables:
230°C
• Excess condensate overflew into rich • Fluid allocation • Baffle spacing. Type. Cut. Pitch
oil and started flashing. Lean oil pump • Tube dia x length restrictions
tripped. Unheated lean oil and condy
flashing resulted in (-)30 to (-) 48°C in • Even number of passes to have
an exchanger, below MDMT inlet/outlet on the same side
• On restarting hot lean oil, thermal
shock ruptured the exchanger. Vapor
cloud reached fired heaters 170m away.
Jet fire from exchanger lasted 2 days

Heat Exchangers 17
 Condensers C3 Refrigeration Condenser
• Vapour (pure component or • Zone 2: Condensation • Duty Q = 12.2 MW • Condensing Zone
mixture) cools and • Latent heat. “Wet wall” • Qv = 2.7 + Qc = 8.8 + Ql = 0.7 • Q = 11.5 - 1.7 = 9.8 Tc = 28.4°C
56 or 42?
condenses to liquid • Hi heat transfer coefft • Heat Transfer Coefft, W/(m²·°C • LMTD = (42-33) - (42-28.4)/ln (13.6/9)
• e.g. Tower overhead or Steam • hv = 630 Uv = 400 Uc = 800 Ul = 650 = 11°C. A = 9.8e6/800/11 = 1,114 m²
• Zone 3: If subcooled,
turbine exhaust
• Sensible heat. Low transfer coefft.
• Shell or tube side “Wet wall” • Desuperheating Zone, Q = ? • Subcooling Zone
• Horizontal or vertical • Heat release curve • Tw = Tv - Uv*(Tv-Tc)/hv • Q = 0.7 MW
• Vertical: Liquid may drain • = 82 - 400*(82-34)/630 = 51.5°C • LMTD = (42-28.4) - (36-27)/ln (13.6/9)
• Temperature range > 5°C requires = 11°C. A = 0.7e6/650/11.1 = 98 m²
countercurrent to vapour. Vapour rigorous calculation • Tw > Condensing temp of 42°C.
velocity kept low to prevent Dry wall • At = 125 + 1,114 + 98 = 1,337 m²
flooding

100% = 12.2 MW
Zone 1:
• Trial and error, zone end Tg = 56°C 82°C Propane

Temperature, t 

Temperature, t 
• Zone 1: Vapour desuperheat Desuperheating Q = 1.7 MW Tc = 33°C Tw = 41.6°C

94% = 11.5 MW
22% = 2.7 MW
Propane • LMTD = (82-34) - (56-33)/ln (48/23)
• “Dry wall”
• Sensible heat. Low transfer 2: Condensing 3.Subcooling = 34°C. A = 1.7e6/400/34 = 125 m² 42°C
34°C
36°C
coefft Cooling Water For multicomponent condensing (i) Mol wt of vapour and Cooling Water 27°C
Heat Duty, Q  (ii) Wt% vapour vs temperature are given in data sheet Heat Duty, Q 

Floating Tubesheet -
Bundle pulled out for
inspection and cleaning
Boiling - Pool Vs Forced Convection Reboilers
• Boiling E-F-G Stable Vapor D G Kettle - 1 theoretical plate
D-E Unstable Vapor Vapor
F • Large area. High turndown. High vaporization. High vapor
• Highest heat transfer coefft E
quality
F = hΔt

• Well designed ‘pool’ in B-C-D C • Insensitive to process changes. Column need not be elevated Heating
• In E-F-G, high dry wall temperature B • Reboilers or vaporizers
B-C-D Nucleate Boiling
foul faster • Expensive. Low U
A-B Natural Convection A
• In D-E ‘erratic behavior’ Δt • Column-internal (stab-in) reboiler for small duty
High temperature Recirculating thermosiphon Feed Bottoms
differential, Δt>70° C • Flow established by density difference in inlet and outlet
• Liquid static head: Bubble point leads to high flux, vapour legs. Column elevation required
> bottom tray liquid blanketing and poor • Compact and low plot area. Vertical - simple piping
temperature unstable performance +
• Vertical tube side boiling. Vapor
high film temperature/ Horizontal shell side boiling for large area
• Slug and Mist - convective and product degradation. Liquid
• Fixed static head for recirculation. Low cost due to hi heat
nucleate boiling transfer, accurate MTD and low fouling (due to higher
At times, returning cold velocities)
• Liquid Recirculation Heating Medium is
Heating
• Limited turndown. Affected by process changes
• Max transfer. Mist and vapour film injected to reduce
avoided Heating Medium supply
temperature. Feed Bottoms
Vertical Tube: Two Phase Flow

Heat Exchangers 18
 Reboilers Reboiler Selection
Once-through
• Limited fixed flow, without recirculation
Clean Service Fouling Service
Vapor
• Low stable range Highly Viscous Heavy fouling/ Oil & Gas
Liquid
• Horizontal or vertical. Shell or tubeside • Pump thru/ Forced circulation Production plants
boiling • Pump thru/ Forced circulation
Feed Low to Moderately Viscous
Pump-through. High Capex/ Opex Bottoms
Heating
• Large area Low to Moderately Fouling
• Viscous or particulate laden liquid • Pressure > Atmospheric
• Kettle or Horizontal
• Horizontal or vertical. Shell or tube side
boiling Vapor thermosiphon • Kettle or Horizontal /
Liquid • Small to medium area Vertical thermosiphon
• Circulation under control. High U
• Usually includes recirculated liquid • Stub-in (Internal) or Vertical • Pressure < Atmospheric
• Can suppress vaporization in fouling service. thermosiphon • Pump thru or Kettle
A throttling valve required in reboiler outlet Heating
Bottoms Feed

Heat Exchangers 19