School of Chemical Engineering and Analytical Science The University of Manchester Heat Transfer and Process Integration Semester

2, 2012

Area targeting exercises

Problem 1. Area targets for heat exchangers in series or parallel The analysis presented in the notes for enthalpy interval assumes splitting of a stream with the larger flowing heat capacity and running the two heat exchangers in parallel. They could of course be run in series exchange between streams 1 and 2 initially, and then between streams 1 and 4. Draw the temperature-enthalpy diagrams, and calculate the required areas using both the LMTD and -NTU methods. Does this give larger or smaller required areas? Alternatively, could we exchange between streams 1 and 4 first, and then 1 and 2? Stream 1 2 4 Initial temperature (C) 30 150 150 Final temperature (C) 140 95 95 Heat duty (kW) 22000 8250 13750 Flowing heat capacity 200 150 250

If all of Stream 1 first exchanges heat with Stream 2, then with Stream 4, the heat transferred initially would be 8250 kW and the intermediate temperature would be found as follows: 8250 Tint = = 200 (Tint 30 ) 71.25C

Checking that this agrees with the required heat transfer of 13750 kW in the second heat exchanger: Q = 200 (140 71.25) = 13750 kW

The temperature-enthalpy diagrams below show the hot and cold stream conditions in the two heat exchangers:

160C

T
120C

Th1 = 150C

160C

Ch =

15 0

W/K

T
120C

Ch
Th2 = 95C

/K 0 kW = 25

Th1 = 150C Tc2 = 140C

Th2 = 95C 80C Tc2 = 71.25C 40C 80C

/K 0 kW = 20 C
c

Tc1 = 71.25C 40C

Tc1 = 30C 0C 0C

W/K 200 k c=

8250 kW

13750 kW

Area targeting by the LMTD method in heat exchanger 1:

Tlm

Th Tc T ln h T c

78.75 65 78.75 ln 65

71.655C

and in HE2: Tlm = Th Tc T ln h T c = 10 23.75 10 ln 23.75 = 15.896C

U for the two heat exchangers was calculated in the notes as 0.375 and 0.3429 kW m2 K1, respectively, leading to A1 = Q1 U 1Tlm1 Q2 U 2 Tlm 2 = 8250 0.375 71.655 13750 0.3429 15.896 = 307 m 2

A2

2523 m 2

Total area = 2830 m2, c.f. 749 + 1365 = 2114 m2 previously. So operating the heat exchangers in series rather than in parallel would require larger heat exchangers why? (Because the temperature driving forces in the first heat exchanger are larger, but in the second much smaller.) Area targeting by the -NTU method for heat exchanger 1:

(Th1 Th 2 ) (Th1 Tc1 )

Tmin = Tmax

(150 95) (150 30)

=

0.4583

C*

71.25 30 150 95

0.75

Checking: C* = Cmin Cmax = 150 200 = 0.75 1 1 0.4583 0.75 ln = 1 0.75 1 0.4583

NTU = = A1 =

1 C * 1 ln 1 C* 1
U 1 A1 Cmin 0.7675 150 = 0.375

0.7675

307 m 2

as above!

For HE2:

(Tc 2 Tc1 ) (Th1 Tc1 )

Tmin = Tmax

(140 71.25) (150 71.25)

=

0.8730 Cmin Cmax 200 250

C*

150 95 140 71.25

0 .8

0 .8

NTU = A2 =

1 C * 1 ln 1 C* 1 4.3244 200 = 0.3429

1 1 0.8730 0.8 ln 1 0.8 1 0.8730

4.3244 =

U 2 A2 Cmin

2522 m 2

again, in (close enough) agreement with the LMTD method. Note that the larger area for HE2 arises from the larger heating duty and the much smaller temperature driving forces. Note too that an NTU of 4.3 is large and probably not economic. Looking at the Heggs chart, for a C* of 0.8 and of 0.8730, only a countercurrent (1) or cross-flow design (3) could achieve the required heat transfer.

Of course, we could try to exchange heat between Streams 1 and 4 first, then between Streams 1 and 2. Then, the heat transferred initially would be 13750 kW and the intermediate temperature would be: 13750 = Tint = 200 (Tint 30 ) 98.75C

Checking that this agrees with the required heat transfer of 8250 kW in the second heat exchanger: Q = 200 (140 98.75) = 8250 kW

The temperature-enthalpy diagrams below show the hot and cold stream conditions in the two heat exchangers. From this it becomes evident that this arrangement would not be possible, because the intermediate temperature of 98.75C is now too high to allow Stream 2 to be cooled to 95C.

160C

T
120C

Th1 = 150C

160C

Ch
Th2 = 95C

/K 0 kW = 25
Tc2 = 98.75C

T
120C

Th1 = 150C

15 0 K Ch = 200 kW/ Cc = Th2 = 95C

Tc1 = 98.75C Tc2 = 71.25C

/K kW

80C

80C

40C Tc1 = 30C 0C

K kW/ 200 c=
40C

0C

13750 kW

8250 kW

Problem 2. Area targeting and identification of feasible heat exchanger designs

Table 2.1 below presents stream data for a heat recovery network that requires only cold utility. Figure 2.1 shows the balanced composite curves, which are separated into five enthalpy intervals. Table 2.1. Stream and hot and cold utility data.
Stream Number and Type Supply temperature (C) 340 180 20 100 20 Target temperature (C) 70 70 220 260 40 Required heat transfer duty (kW) 1350 1100 1000 800 650 Heat Capacity Flowrate 1 (kW K ) 5 10 5 5 32.5 Film heat transfer coefficient 2 1 (kW m K ) 0.5 1.6 0.4 0.8 1.0

1. Hot 2. Hot 3. Cold 4. Cold 5. Steam (H) 6. Cooling water (C)

350

300

250

Temperature T ( C)

200

150

100

50

0 0 500 1000 1500 2000 2500

Enthalpy H (kW)

Figure 2.1. Balanced composite curve for a four stream problem with only cold utility. Using the attached template, determine the average heat transfer coefficient and the area targets for each interval using both the LMTD and the e-NTU methods. Then, use the Heggs chart to identify suitable heat exchanger designs for each interval. Note that each enthalpy interval occurs at a change in slope for one of the two curves, at which point the temperature is easily determined (as it is the inlet or outlet temperature of one of the streams). However, the corresponding temperature of the other stream must be found by interpolation. For example, the first kink in the cold composite curve occurs at a temperature of 40C (the cooling water outlet temperature) and an accumulated duty of 750 kW (650 from the cooling water plus the 100 kW to bring stream 3 from 20 to 40C). This 750 kW is recovered from streams 1 and 2, which have a combined heat capacity of 15 kW K1 and come out at 70C; hence the inlet hot stream temperature for enthalpy interval 1 is 70 + 750 15 = 120C . This temperature is shown on the template below. To find the others, insert the stream data as illustrated below for streams 1 and 2, then perform the energy balance across each interval.

Template for calculating hot and cold stream duties in enthalpy intervals, for two hot, two cold and two utility streams.
k
Hot stream temperature (C)

Cold stream temperature (C)

Qi ,k

Qi ,k

Qi ,k

Q j ,k

Q j ,k

Q j ,k

Qi ,k hi

Qi ,k hi

Qi ,k hi

Q j ,k hi

Q j ,k hi

Q j ,k hi

Q hi i =1 i

h
j =1

Qj
j

340 300 180 140 120 70

1
CP = 5, h = 0.8

260 220 160 100 4

CP = 32.5 h=1

Total: -

200 600 200 100 250 Total: 1350 400 200 500 Total: 1100 300 300 300 100 Total: 1000

200 300 300

650 -

400 1200 400 200 500 250 125 312.5 750 750 750 250

250 375 375

400 1200 650 325 650 812.5

250 1125 1125 750 900

CP = 5, h = 0.5

2
CP = 10, h = 1.6 CP = 5, h = 0.4

40 20

Total: 800

Total: 650

Enthalpy interval k

Q hi i =1 i

h
j =1

Qj
j

J Q Q hi + h j i =1 i j =1 j I

Qk
(kW)

Uave (kW m2 K1)

Tlm (K)

Area (m2)

C*

NTU

Cmin (kW K1)

Area (m2)

Heggs chart options

400 1200 650 325 812.5

250 1125 1125 750 900

650 3325 1775 1075 1712.5

200 600 600 300 750 Total: 2450

0.3077 0.1805 0.3380 0.2791 0.4380

80.00 43.28 28.85 57.71 63.83

8.12 76.80 61.53 18.63 26.83 Total Area: 2 192 m

0.3333 0.8571 0.75 0.6 0.5

1 0.5 0.6667 0.3333 0.4

0.5 2.772 2.079 1.040 0.783

5 5 10 5 15

8.12 76.79 61.52 18.63 26.83 Total Area: 2 192 m

Any 1,3,4a,7a,9 1,3,4a,7a, 7b?,9 Any except 10b Any except 10b

Figure 5. The Heggs Chart: Asymptotic values of the maximum thermal effectiveness as NTU , for different heat exchanger types.