2f+f2007 1

A.H. LUNDBERG SYSTENS L!N!TED

SOLUT!ONS FOR THE PULP 8 PAPER !NDUSTRY
-ENG!NEER!NG
-ENERGY
-ENv!RONNENTAL
-EvAPORAT!ON
-EQU!PNENT
2f+f2007 2
HEAT EXCHANGER
EvALUAT!ON
CASE STUD!ES 8 A B!T OF THEORY
BY BRUCE DER
PRESENTED TO PAPTAC STEAN, STEAN POWER, 8 ENERGY
CONN!TTEE JO!NT NEET!NG DECENBER 6, 2006
2f+f2007 3
YOUR HEAT EXCHANGER S!TUAT!ON
- EX!ST!NG UN!T NEEDS
EvALUAT!ON
- EX!ST!NG UN!T NEEDS
UPGRADE OR
RECONF!GURAT!ON
- USED UN!T !N NEW
APPL!CAT!ON
- NEW UN!T !N NEW
APPL!CAT!ON
2f+f2007 +
EX!ST!NG HEAT EXCHANGER OPT!ONS
- RECONF!GURAT!ON - CHANGE PROCESS, CHANGE S!DES
- RETROF!T - NOD!FY UN!T: NUNBER OF PASSES, NEW
TUBE BUNDLE, ADD PLATES
- AUGNENTAT!ON - ADD SURFACE AREA
- REPLACENENT - NEW UN!T
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HEAT EXCHANGER
EvALUAT!ON - THEORY
2f+f2007 6
FOUR!ER GENERAL EQUAT!ON
Q = U A Lt
Q = HEAT FLOW, BTUfh
U = OvERALL HEAT TRANSFER COEFF!C!ENT,
BTUfhft
2
F
A = HEAT TRANSFER SURFACE, ft
2
Lt = LNTD OR LOGAR!THN!C NEAN TENPERATURE
D!FFERENCE, F
2f+f2007 7
Q = HEAT FLOW
Q = m * c
p
* (T
1
- T
2
) m = mass flow, lbfh
C
p
= specific heat, BTUflbF
T
1
= inlet hot side fluid temperature
T
2
= outlet hot side fluid temperature
2f+f2007 8
U = OvERALL HEAT TRANSFER
COEFF!C!ENT
- CAN BE U
o
(OUTS!DE) OR U
i
(!NS!DE)
- U
o
= inverse sum of resistances
= 1f(1fh
o
+ 1fh
io
+ R
w
+ R
d
)
h
o
= outside film coefficient
h
io
= inside film coefficient
R
w
= resistance of wall
R
d
= fouling resistance
2f+f2007 9
A = HEAT TRANSFER SURFACE
- CAN BE A
o
(OUTS!DE) OR A
i
(!NS!DE)
- EvAPORATORS USUALLY A
i
, SC A
o
- OTHER SERv!CES USUALLY A
o
- D!FFERENCE ON 1" x 18 ga (0.0+9") TUBE !S 1 - (1
- 2*0.0+9)f1 = 9.8
2f+f2007 10
Lt = LNTD: COUNTERCURRENT
(T
1
- t
2
) - (T
2
- t
1
)
Lt = --------------------------
ln (T
1
- t
2
) f (T
2
- t
1
)
WBL COOLER COUNTER-CURRENT
HOT S!DE (L!QUOR) 212 185
COLD S!DE (WATER) 160 110
D!FFERENCE 52 - 75 = -23
LNTD = -23 f LN (52f75) = 62.8F
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Lt = LNTD: CO-CURRENT
(T
1
- t
1
) - (T
2
- t
2
)
Lt = --------------------------
ln (T
1
- t
1
) f (T
2
- t
2
)
EXANPLE: WBL COOLER CO-CURRENT
HOT S!DE (L!QUOR) 212 185
COLD S!DE (WATER) 110 160
D!FFERENCE 102 - 25 = 77
LNTD = 77 f LN (102f25) = 5+.8F
2f+f2007 12
h
o
= OUTS!DE L!QU!D F!LN COEFF!C!ENT
a
s
= !D * C' * B f 1++ f P
T
G
S
= W f a
s
Re
S
= D
e
* G
s
f
Using Re
S
, get j
H
from Kern, Figure 28
h
o
= j
H
* k f D
e
* (c*fk)
(1f3)
* (fw)
0.1+
2f+f2007 13
h
io
= !NS!DE L!QU!D F!LN COEFF!C!ENT
a
t
= no.tubes * flow areaftube f passes
G
t
= w f a
t
Re
t
= D * G
t
f
Using Re
t
, get j
H
from Kern, Figure 2+
h
i
= j
H
* k f D * (c*fk)
(1f3)
* (fw)
0.1+
h
io
= h
i
* tube !D f tube OD
2f+f2007 1+
TYP!CAL F!LN COEFF!C!ENTS
- STEAN ~ 1500 BTUfhft
2
F, L!N!TED BY HEAT FLUX
- WATER ~ 200 TO 1000 BTUfhft
2
F, DEPENDENT ON
vELOC!TY
- A!R ~ 10 BTUfhft
2
F, DEPENDENT ON
TURBULENCEfvELOC!TY
2f+f2007 15
WALL RES!STANCE
0.035 f1+7.6= 0.0002+ T!TAN!UN X 20 GAUGE
0.0+9 f 98.+ = 0.0005 316 SS X 18 GAUGE
0.0+9 f 108 = 0.000+5 30+ SS X 18 GAUGE
TfK = TH!CKNESS f
CONDUCT!v!TY
2f+f2007 16
CALCULAT!NG OvERALL U
O
EXANPLE: KANYR SEC BLACK L!QUOR COOLER
TUBE S!DE = WEAK L!QUOR
SHELL S!DE = WATER
U
o
= inverse sum of resistances
= 1f(1fh
o
+ 1fh
io
+ R
w
+ R
d
)
= (1f7+8 +1f1071 +0.000+5 +0.003)
-1
= 1 f 0.00572 = 175
2f+f2007 17
TUBE S!DE PRESSURE DROP EQUAT!ONS
f * G
t
2
* L * n + * n * v
2
* 62.+3
LP
t
= ---------------------------------- PS! LP
r
= ------------------------- PS!
5.21 X 10
10
*D *s *(fw)
0.1+
s * 2 * g' * 1++
2f+f2007 18
SHELL S!DE PRESSURE DROP EQUAT!ON
f * G
S
2
* D
S
* (N+1)
LP
S
= --------------------------------------- PS!
5.21 X 10
10
*D
e
*s *(fw)
0.1+
2f+f2007 19
RULES OF THUNB
- CONDENSERS !N SER!ES OR PARALLEL SANE
- NULT!PLE PASS L!Q TO L!Q NUST BE !N SER!ES
- NTD CORRECT!ON FACTOR > 0.80
- TR!ANGULAR P!TCH CONNON, LOW !N COST,
CANNOT CLEAN TUBES
- SQUARE TUBE P!TCH B!GGER D!ANETER, NORE
$, CAN CLEAN TUBES
- CONNON TUBES 1" X 18 GA, 1.25" X 16 GA
- LONGER TUBES GENERALLY LOWER !N COST
- SNALLER TUBES SNALLER D!ANETER, LOWER !N
COST
- NORE SHELLS NORE COST
2f+f2007 20
RULES OF THUNB
- NORE BAFFLES BETTER HEAT
TRANSFER, BETTER TUBE SUPPORT,
BUT NORE dP
- !F v < 3 FPS, D!RT 8 SL!NE FRON
N!CRO-ORGAN!C ACT!ON ADHERES TO
TUBE WALLS THAT WOULD
OTHERW!SE BE CARR!ED AWAY W!TH
H!GHER vELOC!T!ES
2f+f2007 21
HEAT EXCHANGER
EvALUAT!ON - CASE
STUD!ES
2f+f2007 22
1. SURFACE CONDENSER ADD!T!ON
!SSUES
- HEAT TREATED WATER TO DEAERATORS
- EX!ST!NG CONCENTRATOR SURF COND ADD
BEFORE OR AFTER, !N SER!ES OR !N PARALLEL?
2f+f2007 23
SC ADD!T!ON - FLOWSHEET
NEW
TREATED
WATER
HEATER
EXISTING
SURFACE
CONDENSER
140,000 LB/H
212F VAPOUR
107,000 LB/H
212F VAPOUR
640,000 LB/H
140F TW
640,000 LB/H
190F TW
2f+f2007 2+
SC ADD!T!ON
- KEY DES!GN !SSUES
- HEAT TREATED WATER TO GOOD TENP, 1+0
190F
- TOO NUCH vAPOUR BYPASSED +0 v!A BUSTLE,
BALANCED PRESSURE DROPS TO BUNDLE 8
AROUND BUSTLE
- vAPOUR L!NE PRESSURE DROP OvERS!ZED L!NE
- TUBE v!BRAT!ON ANALYS!S, SUPPORT BAFFLES
2f+f2007 25
SC ADD!T!ON - RESULTS
- Q = 32 NN BTUfH Ao = +008 FT
2
,1 SHELL
- 6 TUBE PASSES PD = 5.8 PS!
2f+f2007 26
2. GREEN L!QUOR COOLER
REPLACENENT
!SSUES
- EX!ST!NG UN!T UNDERS!ZED COOL!NG WATER
TENP TOO LOW, POOR HEAT RECOvERY
- TUBE PLUGG!NG
2f+f2007 27
GLC REPLACENENT - FLOWSHEET
NEW
GREEN LIQUOR COOLER
650 GPM 188F
GREEN LIQUOR
137 GPM 80F
WATER
137 GPM 158F
WATER
650 GPM 205F
GREEN LIQUOR
EXISTING
GREEN LIQUOR COOLER
400 GPM 205F
GREEN LIQUOR
400 GPM 190F
GREEN LIQUOR
288 GPM 100F
WATER
288 GPM 80F
WATER
2f+f2007 28
GLC REPLACENENT
- KEY DES!GN !SSUES
- PLUGG!NG USE LARGER TUBES 5f8 1"
- CLEAN!NG REASONABLE LENGTH OF TUBE 1+ FT
- H!GH QUAL!TY PROC WATER EX!ST!NG 100F, NEW 158F
- D!FFERENT!AL EXPANS!ON EXPANS!ON JO!NT ADDED
2f+f2007 29
GLC REPLACENENT - RESULTS
5f8" x 18 BWG 1" x 18 BWG TUBES
1++ 553 AREA FT
2
2.8 5.3 Q NNBTUfH
EX!ST!NG NEW
2f+f2007 30
3. STR!PPER PREHEATER RECONF!GURAT!ON
!SSUES
- TUBE S!DE FOUL!NG AFTER
2 TO 3 WEEKS OPERAT!ON
LOSS OF HEAT
TRANSFER. WHEN CLEAN
38 NN Btufh, LESS THAN
1f2 WHEN FOULED
- LOSS OF TRS STR!PP!NG
EFF!C!ENCY ODOUR
- FREQUENT CLEAN!NG
DOWNT!NE,
ENv!RONNENTAL !SSUE,
NU!SANCE
2f+f2007 31
STR!PPER PREHEATER RECONF'N
- KEY DES!GN !SSUES
- REDUCE FOUL!NG N!N!NUN vELOC!TY 3 FPS
REQU!RED, CONvERT ALL + SHELLS FRON 2 PASSES
TO + PASSES
- ADD!NG 2 CHANNEL PART!T!ON PLATES LOSS OF
SURFACE AREA (+2 TUBES)
- UNEvEN TUBES PER PASS 10 D!FFERENCE
- H!GHER PRESSURE DROP EX!ST!NG PUNP OK
- WORK CONPLETED DUR!NG SHUTDOWN
2f+f2007 32
STR!PPER PREHEATER
RECONF!GURAT!ON-RESULTS
SHUTDOWN: TUBES
ARE CLEAN
W!TH!N 2
WEEKS
LOSS OF HEAT
TRANSFER
B!-ANNUALLY NONTHLY CLEAN!NG
18.8 +.0 TUBE S!DE
DELTA P PS!
+.2 1.9 TUBE vELOC!TY
FPS
+ x 10+.5 TUBES 2 x 230
TUBES
TUBE PASSES
AFTER BEFORE
2f+f2007 33
STR!PPER PREHEATER RECONF'N
- 2 ROWS
OF
TUBES
PLUGGED
OFF
2f+f2007 3+
STR!PPER PREHEATER RECONF'N
- TWO
PART!T!ON
PLATES ADDED
2f+f2007 35
+. L!QUOR COOLER
AUGNENTAT!ON
!SSUES
- UNDERS!ZED L!QUOR COOLER !NSUFF!C!ENT HEAT
RECOvERY TALK OF DOUBL!NG UP !N PARALLEL
- TOO NUCH N!LL WATER CONSUNPT!ON
- LOW OUTLET WATER TENP FOR WASHERS
- BATCH PROCESS THERNAL EXPANS!ON PRENATURE
WELD FA!LURE HAD TO ADD 2
ND
EJ
- FLOAT!NG HEAD LEAKS EXPANS!ON JO!NT
2f+f2007 36
L!QUOR COOLER AUGNENTAT!ON -
KEY DES!GN !SSUES
- UNDERS!ZED COOLER ADDED A SECOND LARGER UN!T !N SER!ES.
NOT SANE S!ZE, NOT !N PARALLEL
- REDUCE WATER USAGE BOOST OUTLET TENP TO 168F
- BATCH CYCL!CAL PROCESS EJ FA!LURE DES!GN FOR 500,000 CYCLES
2f+f2007 37
L!QUOR COOLER AUGNENTAT!ON -
RESULTS
1780 GPN, +1
111F
26+0 GPN, 125
200F
WATER
2930 2930 ++172 =7101 AREA FT
2
2700 GPN, 252
200F
2700 GPN, 280
205F
L!QUOR
0.972 0.973 f 0.950 NTD CORR
FACTOR
65.8 96.9 Q NNBTUfH
BEFORE - 1 UN!T AFTER - 2 UN!TS
2f+f2007 38
L!QUOR COOLER AUGNENTAT!ON
2f+f2007 39
5. D!GESTER L!QUOR HEATER
REPLACENENT
!SSUES
- RAP!D ORGAN!Cf!NORGAN!C SCAL!NG WASH!NG
8 DR!LL!NG LOSS OF TUBE NETAL TH!CKNESS
- THERNAL EXPANS!ON EXPANS!ON JO!NT
- NO P!P!NG CHANGES TO SAvE $
- L!QUOR C!RCULAT!ON PUNP AT NAX!NUN
- L!N!TED SPACE
- EX!ST!NG SURFACE AREA OK
2f+f2007 +0
L!QUOR HEATER REPLACENENT -
KEY DES!GN !SSUES
- REDUCE FOUL!NG N!N!NUN vELOC!TY 8 FPS
REQU!RED
- THERNAL EXPANS!ON DES!GN JO!NT FOR 70,000
CYCLES
- NO P!P!NG CHANGES LESS TUBES, LONGER
TUBES DES!GNED W!TH STEAN BUSTLE
- H!GHER PRESSURE DROP EX!ST!NG PUNP
NARG!NAL
2f+f2007 +1
D!GESTER L!QUOR HEATER
REPLACENENT - RESULTS
1,675 1,66+ AREA FT
2
8.5 3.1 TUBE S!DE
DELTA P PS!
8.2 5.+ TUBE vELOC!TY
FPS
238 - 1.25"x16
BWG x 2+'
360 - 1.25"x16
BWG x 15'-9"
TUBES
ENG!NEER!NG
PHASE
NOW
2f+f2007 +2
D!GESTER L!QUOR HEATER
REPLACENENT
2f+f2007 +3
6. BLEACH CAUST!C EFFLUENT
HEAT EXCHANGER
!SSUES
- REUSE EX!ST!NG SECOND HAND UN!TS 2 SHELLS,
EACH 6016 ft
2
PROv!DED BY (766) 0.75" X 15 GA X +0
FT, 1 TUBE PASS PER SHELL
- NOT ENOUGH TUBE PASSES ACCELERATED FOUL!NG
2f+f2007 ++
BLEACH CAUST!C EFFLUENT HEAT
EXCHANGER - FLOWSHEET
2 SECOND HAND
HEAT EXCHANGERS
2300 GPM TF
B C EFFLUENT
X GPM 70F
WATER
X GPM 160F
WATER
2300 GPM 170F
B C EFFLUENT
2f+f2007 +5
BLEACH CAUST!C EFFLUENT HEAT
EXCHANGER - HEAT DUTY Q
m = 2300 gpm *500.7 lbfh fgpm *0.981
= 1,130,000 lbfh
BY !TERAT!ON, ASSUNE t
2
= 12+.3F
Q
EFFL
= 1,130,000 * 1 *(170 - 12+.3)
= 51.6 NNBTUfh
2f+f2007 +6
BLEACH CAUST!C EFFLUENT HEAT
EXCHANGER - CHECK AREA
HOT S!DE (EFFLUENT) 170 12+.3
COLD S!DE (WATER) 160 70
D!FFERENCE 10 - 5+.3 = -++.3
LNTD = -++.3 f LN (10f5+.3) = 26.2F
A = Q f (U
O
Lt)
= 12,030 ft
2
, SO CHECKS!
2f+f2007 +7
BLEACH CAUST!C EFFLUENT HEAT EXCHANGER -
PRESSURE DROPS 8 vELOC!T!ES
- LP
T
= +.0 PS!
- LP
S
= 9.8 PS!
- TUBE vELOC!TY v = 3.3 FPS
2f+f2007 +8
BLEACH CAUST!C EFFLUENT HEAT
EXCHANGER - RESULTS
1160 GPN, 70 160F WATER
2 SHELLS x 6016 AREA FT
2
2300 GPN, 170 12+F L!QUOR
51.6 Q NNBTUfH
2f+f2007 +9
CONCLUD!NG RENARKS
- WRONG: !F THE HX RUNS, LEAvE !T ALONE. R!GHT:
NON!TOR 8 OPT!N!ZE FOR NAX!NUN ENERGY
RECOvERY
- ADD!NG A HEAT EXCHANGER REQU!RES KNOWLEDGE
OF BOTH THE PULP N!LL PROCESS AND HEAT
TRANSFER HALF OF ALL HEAT EXCHANGERS ARE
SPEC!F!ED !NCORRECTLY !
- BEST TO HAvE AN ON-S!TE PROCESS ENG!NEER 8 AN
OFF-S!TE CONSULTANT TO ASS!ST
2f+f2007 50
QUEST!ONS?
CONNENTS?