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Advanced Process Design Engineering Course

Lesson # 02
Heat Exchanger Design
Part 03: Air Cooled Heat Exchanger
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Air Cooled Heat Exchanger

In this example, the program will determine if there is sufficient area available to
cool a process fluid to the required temperature for a forced-draught air-cooled
heat exchanger using Aspen Air Cooled Exchanger program in the Rating/Checking
mode.
Then, the program calculation mode will be changed to “simulation” and determine
tube side outlet temperature and duty.
Process Overview
In this example, ambient air is used to cool process water in a forced draft air-
cooled heat exchanger. We wish to determine if there is sufficient area available to
cool the process fluid to the required temperature. The process conditions and
geometry attributes are provided in the tables below. You can choose to input data
in Units of your preference, but the input and results will be reproduced in SI units.
Process Conditions - SI Units
Parameter Process Side X-side
Water Dry Air
Flow rate 30500 177500 kg/h
Temperature In/Out 92 / 56 37 / C
Inlet Pressure 1.2 Atmosphere bar (abs/gauge)
Estimated pressure drop 0.18 bar
Fouling Resistance 0.00002 m2K/W
Process Conditions - US Units

Parameter Process X-side
Side
Water Dry Air
Flow rate 67241 391320 lb/h
Temperature In/Out 197.6 / 98.6 / F

132.8
Inlet Pressure 17.4 Atmosphere psia/psi
Estimated pressure drop 2.61 psi
Fouling Resistance 0.00011357 h ft2 F/Btu

Enter the geometry information from the table below for the unit type you
choose. Any data not explicitly specified here may be left to the program
defaults.
Header: SI US
Number of inlet nozzles 4 4
Inlet nozzle inside diameter 101.2 mm 4 inches
Number of outlet nozzles 4 4
Outlet nozzle inside diameter 101.2 mm 4 inches
Type of Header Box Box
Bundle: SI US
Number of passes 4 4
Number of rows 4 4
Number of tubes 160 160
Type of bundle:
Staggered – evens row to left
Tube: SI US
Effective length of tube 6020 mm 237 inches
Traverse pitch 58.4 mm 2.3 inches
Tube Inner diameter 21.32 mm 0.839 inches
Tube Outer diameter 25.4 mm 1 inches
Layout angle 30 Degree 30 Degree
Fins: SI US
G fin
Frequency 433 /m 11 inches
Tip diameter 57.16 mm 2.25 inches
Mean fin thickness 0.457 mm 0.018 inches
Accept all defaults for any data not specified above.
Launch Aspen Exchanger Design & Rating (EDR) from the Start menu.
The Aspen Exchanger Design and Rating main window appears.

Aspen Exchanger Design and Rating allows you to create a new model by
clicking File | New or restart from an existing model by navigating to the file
using the Open or recently opened cases associated with
the Recent command.
For a new model, click New, select AirCooled and click Create to start modeling a
new exchanger.
The Aspen AirCooled Exchanger application will start.

To change the units used in the program session:

1. Use the Set Units option on the Home ribbon Units group.
Choose SI from the Set Units drop-down. Note that this can also be set for each
unit field.

Tip: EDR allows you to set default Units of Measure. This can be accomplished from File | Options | General
Program Settings.
Set Rating/Checking Mode

By default, the program runs in Design with fixed outside flow mode. Change
the application mode by clicking Rating/Checking, found on the Home tab, in
the Run Mode group, or to set the calculation mode:
Navigate to the Process Data form by selecting, Set Process Data in the Model
Setup group on the Home ribbon. Enter the process data from the table
previously provided.
Enter Process Data
The process data for this exercise is listed in the process overview and below:
SI Units Process Side X-side
Water Dry Air
Flow rate 30500 177500 kg/h
Temperature In/Out 92 / 56 37 / C
Inlet Pressure 1.2 Atmosphere bar (abs/gauge)
Estimated pressure drop 0.18 bar
Fouling Resistance 0.00002 m2K/W
US Units Process Side X-side
Water Dry Air
Flow rate 67241 391320 lb/h

Temperature In/Out 197.6 / 132.8 98.6 / F
Inlet Pressure 17.4 Atmosphere psia/psi
Estimated pressure drop 2.61 psi
Fouling Resistance 0.00011357 h ft2 F/Btu
Use this data to complete the Process Data input.
By default, the input screen flow rate data has been specified in kg/s. Change the
units for the mass flow rate units and select kg/h, found on the Home tab, in
the Units group. Similarly, the Allowable pressure drop has default units of Pa,
but here we made our entry in bar.
Note: The light blue back-shading in some fields indicates data that must be entered by the user. The
shading of these fields updates in response to data provided. Selections and numbers in italic are program
defaults and need not be entered by the user. User inputs will appear as bold blue.
Select the Outside Stream tab and enter the process data for the air that is being
used to cool. Again be careful with the selection of the units.

Note: When sufficient data has been entered necessary for the program to run, the red crosses, indicating
insufficient input, will disappear from the navigation tree and form tabs.
Because we are using the program default settings, the properties of the outside
stream will be calculated automatically as those of Dry Air. We only need to provide
property information for our tube-side process stream.
Click Set Properties on the Home ribbon.
In the Compositions tab, select Aspen Properties as the Physical property

package.

It may take a few minutes for the Aspen Properties package to load.
The screen will now show the blank composition table.
Click the Search Databank button to display the Find Components form.

There are three options to search for names and text strings. Using the
default Contains, type in the first few letters of the fluid required. Type water and
click Find Now. It may take a few moments for the list of related components to
appear in the matching components area. You may have to scroll through this list,
then click and highlight your selection.
Click Add selected compounds to add it to your list of selections. Here you can
build up an extensive list of components if you require.

A single component is here. Confirm your selection by clicking Use Selected

Compounds.
Set the Composition water to 1 on the Composition tab.

For accurate properties of water, we need to select the appropriate property

method. Click the Property Methods tab and select STEAMNBS (now NIST, US
National Institute for Standards and Technology and a major source of physical
property information).
Select Tube Stream Properties from the Navigation tree, and then click Get
Properties. The program will now generate physical property data for water
between the temperatures of 56 to 92°C and at the pressure levels of 1.2 and 1.02
bar. By default, the program will generate seven temperature points at each
pressure. If required you can type your required number of points, up to a
maximum of 24.

The default pressure and temperature ranges have automatically calculated based
on the process data we specified. These can be changed if necessary, by typing
new values and again clicking the Get Properties button.
Tip: Previewing the properties before you run is optional but it is often useful to check that you understand
the property values generated and that these cover the temperature and pressure ranges you expect
within your exchanger.
You can review the property data calculated by Aspen Properties graphically on
the Property Plots tab.

The Enthalpy-Temperature plot shows the dew and bubble points have been found
and are a little above the expected temperature for the exchanger.
The viscosity vs temperature diagram indicates the small decrease in dynamic

viscosity of water over this temperature range and shows pressure has little effect.
Now the Exchanger Geometry can be entered. Use the Next button or directly
navigate to Geometry Summary Form or click Set Geometry from the Model
Setup group on the Home tab of the ribbon. Enter data for:
 Number of Tubes per bundle
 Tube rows deep
 Tube rows per pass
Note: The input form still has a red cross indicating further data are required. The blue back shading
indicates the tube length has not been entered. We will overcome this by entering the “effective tube
length” later.

When you have entered the above data you can preview your bundle layout on
the Tube Layout tab.

Tip: The Exchanger Geometry can also be entered using the interactive graphical layout which allows you
to directly specify irregular arrangements of rows and passes. For example, you may have four rows with
three passes in your exchanger to handle phase-change effects.
Navigate to Input | Exchanger Geometry | Bundle using the navigation tree. Set
the Effective tube length. to 6020 mm (or 6.02 m).
Note: The effective tube length is the total tube length minus any length that does not contribute to heat
transfer. This includes parts of the tubes within the tube sheets or covered by external tube supports.
Now that the effective length has been supplied there is sufficient information to
estimate the total tube length, so the Geometry Summary no longer has a red
cross mark.
Using the navigation tree, go to Input | Exchanger Geometry | Headers and

Nozzles.

On the Nozzles tab enter the nozzle inside diameter and the number of inlet and
outlet nozzles.
All the required data have been entered. And there are no longer any red crosses
evident. You may like to save your case at this point. This is achieved from the
ribbon File tab, then Save As. You can of course provide an appropriate file name
and folder for your location.
Tip: Aspen Exchanger Design and Rating allows you to automatically save your work at defined time
intervals. Using File -> Options- > General Program Settings.

Running the Model

At this point Aspen EDR is ready to analyze the thermal performance of the
exchanger we have specified. Click the Run button in the, Run Control Group on
the Home ribbon.
The Program Status box will appear that can be closed to reveal any Warnings &
Messages. If there are errors then actions should be taken based on the message.
Viewing Results
Any Warnings & Messages will generally appear as the first results. In this case, the
messages indicate that, as we did not specify information on the Fan geometry,
the program estimated the fan requirements.
There are many results that you may wish to explore. To get an immediate
summary of the thermal performance click the Performance button in the Results
group of the Home ribbon.

The two results of most overall significance are shown with red outlines.
The area ratio is 1.2. This means that the exchanger has 20% more surface than is
required to perform the thermal duty in cooling our process water from 92°C to
56°C. The program has also calculated accurately the heat transfer coefficients
which will occur on the external surface, cooled by air and on the internal surface
of the tubes exposed to the hot water.
An additional key result is the calculated tube-side pressured drop which we can
see is 0.068 bar, significantly less than our allowable pressure drop of 0.18 bar.
These results show that our exchanger is adequately designed to meet our process
requirement of 1279kW of cooling.
The resistance diagram beneath the Performance table gives a diagrammatic

representation of the relative magnitude of resistances to heat transfer. To make a
representative comparison, all of the resistances have been referred to a common
heat transfer area. In this case that is the area of the bare tube outside surface.
Here we can see that the yellow bar representing the outside heat transfer
resistance is the largest. If we wanted to increase the thermal performance of the

unit, it would be most effective to concentrate on measures which might reduce

this controlling resistance.
You may want to review an API-style specification sheet for your resulting model.
Click Review Spec Sheet in the Results group of the Home ribbon.
You may also like to look at a general arrangement drawing for your model, click
Verify Geometry in the Results group of the Home ribbon.

You may also want to explore the variation of process parameters inside the
exchanger. Some of the most important are revealed if you click Review Profiles
in the Results group on the Home ribbon.
As the unit has excess surface, it could achieve more duty. To check the duty it
could achieve, we can switch to simulation mode. On the ribbon you will find
Simulation as one of the options in the Run Mode group.
Click Simulation and then Run the program again.
Clicking Review Performance in the Results group of the Home ribbon, we

see the following.
The red boxes enclose two of the most important results of the simulation
calculation.

The air-cooled exchanger as specified can cool the process water to 53.35°C
and the cooling duty increases to 1372 kW. This is 7% higher than our required
duty.
Note: The Rating/Checking calculation we performed initially suggested that the exchanger was 20%
over surface.
Contrasting the results of the Simulation and the Rating/Checking calculation is

an illustration that in a crossflow exchanger we do not have a linear relationship
between surface area and duty. This is despite the fact that the heat transfer
coefficients are relatively constant on air-side and tube-side.
The variation in temperature difference along tubes and between tube rows is
the reason we see this behavior. In this case 20% extra surface can only be
expected to give 7% higher duty. This result illustrates the value of a fully
rigorous incremental calculation to correctly evaluate exchanger performance.

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Advanced Process Design Engineering Course

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Air Cooled Heat Exchanger

Water Dry Air

Flow rate 30500 177500 kg/h

Inlet Pressure 1.2 Atmosphere bar (abs/gauge)

Estimated pressure drop 0.18 bar

Fouling Resistance 0.00002 m2K/W

Process Conditions - US Units

Water Dry Air

Flow rate 67241 391320 lb/h

Temperature In/Out 197.6 / 98.6 / F

Inlet Pressure 17.4 Atmosphere psia/psi

Estimated pressure drop 2.61 psi

Fouling Resistance 0.00011357 h ft2 F/Btu

Email: admin@omesolglobal.com Website: www.omesolglobal.com

Number of inlet nozzles 4 4

Inlet nozzle inside diameter 101.2 mm 4 inches

Number of outlet nozzles 4 4

Outlet nozzle inside diameter 101.2 mm 4 inches

Type of Header Box Box

Number of tubes 160 160

Effective length of tube 6020 mm 237 inches

Traverse pitch 58.4 mm 2.3 inches

Tube Inner diameter 21.32 mm 0.839 inches

Tube Outer diameter 25.4 mm 1 inches

Layout angle 30 Degree 30 Degree

Frequency 433 /m 11 inches

Tip diameter 57.16 mm 2.25 inches

Mean fin thickness 0.457 mm 0.018 inches

Accept all defaults for any data not specified above.

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The Aspen AirCooled Exchanger application will start.

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To change the units used in the program session:

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Set Rating/Checking Mode

Water Dry Air

Flow rate 30500 177500 kg/h

Inlet Pressure 1.2 Atmosphere bar (abs/gauge)

Estimated pressure drop 0.18 bar

Fouling Resistance 0.00002 m2K/W

US Units Process Side X-side

Water Dry Air

Flow rate 67241 391320 lb/h

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Temperature In/Out 197.6 / 132.8 98.6 / F

Inlet Pressure 17.4 Atmosphere psia/psi

Estimated pressure drop 2.61 psi

Fouling Resistance 0.00011357 h ft2 F/Btu

Use this data to complete the Process Data input.

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Click Set Properties on the Home ribbon.

In the Compositions tab, select Aspen Properties as the Physical property

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The screen will now show the blank composition table.

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A single component is here. Confirm your selection by clicking Use Selected