SURFACE AREA LIMITING

HEAT TRANSFER IN A
CATALYTIC REFORMER
REACTOR FEED EFFLUENT
EXCHANGER

Eric O. Okeke
Nigerian National Petroleum Corporation
APACT 06, Oxford, 3-5 May, 2006

BROAD OVERVIEW OF PRESENTATION

Introduction,
Problem analysis,
Method of solution & evaluation Target,
Application of engineering software tools
HYSYS & STX,

Results analysis HYSYS front-end

simulation & STX evaluation,

Engineering solution
NNPC

INTRODUCTION

The Nigerian National Petroleum Corporation (refiner) is

in oil & gas upstream and downstream activities,

The Corporation has 4 refineries in 3 locations, each

having catalytic reformer,

2 of the refineries established in the 1970s, others 1980s,

Refiner experienced surface limiting heat transfer of the

catalytic reformer feed effluent exchanger characterized
by temperature unbalance in 2 earlier plants, at different
times,

After the 1st experience the refiner commissioned a

detailed technical evaluation of the problem the
objective of this study

Refiner depends
gasoline,

NNPC

on

catalytic

reformer

for quality

REFORMER REACTOR PROCESS ENVIRONMENT

Heat Exchnager

Catalytic Reformer

Effluent

Charge Heater

Feed

Feed

Effluent

Feed on the exchanger tube side heavy

naphtha and hydrogen,

Effluent catalytic reformer reactor effluent,

Charge heater increases the feed temperature to
meet reaction conditions
NNPC

REFORMER REACTOR FEED & EFFLUENT CHARACTERISTICS

Exchanger (reformer) feed supplied

from naphtha origin,

Reformer feed quality may vary for

many reasons.

Ever-changing crude feeds impact

straight-run naphtha quality.

Cut points within naphtha splitter may
vary due to an overall reformer
optimization strategy

Effluent, a gas phase product,

containing light gases
NNPC

THE PROBLEM

1. Heat exchanger train designed to recover

heat from reactor effluent to feed,

2. Performance appeared satisfactory after

installation in early 1980s due to low
capacity utilization and other upstream
facility limitations/shut downs,

3. Years later refiner began to experience

temperature unbalance on its 2 banks,

4. Tube/shell side receive fluids of specified

process conditions,

NNPC

DESIGN & ACTUAL PERFORMANCE DATA

DESIGN
S/N
1

Stream
CRU Feed
Tube-side

RXT Efflt
Shell-side

Inlet

Outlet

Pressure

Flow, kg/hr

Temp, C

Temp, C

kg/cm2

Hvy Naphtha,
Rec gas
(96%H2)

142,454

93

484

18.2

Hydrocarbon
& H2 (Reactor
products)

142,454

545

135

14.4

Inlet

Outlet

Pressure

Flow, kg/hr

Temp, C

Temp, C

kg/cm2

Hvy Naphtha,
Rec gas
(95%H2)

54,500

87

368

18

Hydrocarbon
& H2 (Reactor
products)

54,500

467

149

13

Composition

ACTUAL (Average for 6 Months)

S/N
1

Stream
CRU Feed
Tube-side

RXT Efflt
Shell-side

NNPC

Composition

TEMPERATURE UNBALANCE ON TUBE-SIDE FLOW

Actual Temp =360 C

Design Temp =484 C

Actual Temp =505 C

Design Temp =484 C
Exchanger A

Exchanger B

Hydrogen

Heavy Naphtha Feed

Actual temp 137 C
Design temp 133 C

NNPC

Tube side inlet temp =82 C

Design inlet temp = 93 C

IMPACT ON OPERATIONS

1. Inadequate heat transfer between feed and

effluent:

Limits reactor feed inlet temperature

requirement, which provides appropriate
reaction environment, phase, flow distribution
and conversion,

Increases load on the first reactor charge heater

causing excessive furnace tube skin
temperatures

2. Temperature unbalance experienced

therefore showed exchanger malfunction
NNPC

METHOD OF SOLUTION & EVALUATION TARGET

Review Design basis, operations data,

Analyze data as input for evaluation and
rating of exchanger,

Apply HYSYS to match plant survey data &

exchanger process conditions

Apply Shell & Tube Exchange

evaluation/rating software,

Engineering solution,
Confirm solution by re-evaluation/re-design
NNPC

EXCHANGER CONFIGURATION & SPECIFICATION - 1

CATALYTIC REFORMER REACTOR FEED/EFFLUENT EXCHANGER
Type

CES

Vertical

No of Trains - 1

Fluid Name
Total Flows,
Vapour
Liquid
Temperatures
Density
Viscosity
Specific heat
Thermal conductivity
Latent Heat
Inlet pressure
Viscosity
Pressure drop
Fouling resistance required
Heat exchanged

NNPC

Shells/train - 2

kg/hr
kg/hr
kg/hr

Liquid (Vapour)
Liquid (Vapour)
Liquid (Vapour)
Liquid (Vapour)

In parallel
Shell Side
Inlet
Outlet
Effluent
H2 + HC
142,454
142,454
138,396
4,058

Tube Side
Inlet
Outlet
Feed
H2 + HC
142,454
68,998
142,454
73,456

545
135
93
C
(3.93)
727(7.19)
671(6.73)
kg/m3
(0.02) 0.269(0.012) 0.28(0.011)
cp
(1.003)
0.52(0.93)
0.58(0.91)
kcal/kgC
(0.203) 0.101(0.102) 0.106(0.112)
kcal/mmC
kcal/kg
14.4
18.2
kg/cm2G
13.8
8
m/s
0.6
0.3
kg/cm2
0.00004
0.00004
mm2C/kcal
MTD (corrected) 67.3
50,810,000 kcal/hr

484
(6.12)
(0.019)
(0.96)
(0.177)

EXCHANGER CONFIGURATION & SPECIFICATION - 2

1.

Counter-current shell & tube: 1 shell, 2 tube

passes,

2.

Shell & Tube

3.
4.

Shell - ID 1,300 mm

Baffle spacing 400 mm.

Tube - Plain with OD 19.05 mm, thickness 2.11 mm, pitch

25.4, No 1800, length 12,192 mm,

2 exchangers arranged in parallel and vertical,

Specification and design done in late 1970s hence
process/design data, correlations and methods are
not as robust/reliable as those used today,

NNPC

SHELL & TUBE EXCHANGER MODEL - 1

The exchanger model for the study based on:

Overall heat transfer coefficient
Q = UALMT

Where
U =

1
1
ho
0.023di

hi =

km

ro

diGi
i

+ rw
0.8

do

km

ri

di

Cpii

1/3

hi
i
iw

0.14

According to empirical Sieder-Tabe equation. where h is the heat transfer coefficients of

fluids, r, fouling factors, d, tube diameters, , viscosities and Cp, the specific heat of metal
tube

NNPC

SHELL & TUBE EXCHANGER MODEL - 2

Application of the UA in HYSYS Model :

From Q = UALMT (equation 1)

UA a product of the Overall Heat transfer

coefficient, U and the Total available area for heat
transfer, A

Q, the heat exchanger duty proportional to LMT

log mean temperature difference, where UA is the
proportionality constant,

UA calculated by HYSYS in different modes in the

evaluation of temperature unbalance,

HYSYS solves equation 1 for U (for extended area

cases) when target outlet temp is specified
NNPC

SHELL & TUBE EXCHANGER MODEL - 3

Where additional surface area is required, then

Q = U(A + A)LMT

If the same duty is to be serviced by enhanced heat transfer without

additional surface,
Q = UeALMT

Where A is the additional surface area, Ue enhanced U .

Thus, for heat transfer enhancement to solve the problem without
installation of new area:
UeA U(A + A)

If heat transfer enhancement is only for inside of the tubes using inserts,
equation 3 applies, and U becomes Ue , and hi, hie.
Then solving equations 2 to 6, assuming the resistance to heat transfer
across the wall is negligible hw , and the difference

between do, di, negligible so that do=di, the enhancement

ratio hie/hi will therefore be determined.

NNPC

SHELL & TUBE EXCHANGER MODEL - 4

So that
hie
hi

ho (A + A)

hoA hiA

1.

The enhancement ratio hie/hi for tube inserts can be correlated as a

function of Reynolds number ie Re = Vdi/.

2.

Different tube inserts can be compared on the basis of plots of

enhancement ratio hie/hi versus Reynolds number,

3.

The major disadvantage in using heat transfer enhancement is that it

increases pressure drop. This will be weighed in the overall context of
reactor pressure drop requirements and transfer pump capacity.
NNPC

APPLICATION OF SOFTWARE TOOLS

HYSYS evaluation to establish process

conditions:

required for total heat exchanger network

performance,
at temperature unbalance,

HTC-STX for exchanger modelling to

further HYSYS evaluation,

HYSYS using data from STX for new

exchanger network design
NNPC

EVALUATION REQUIREMENTS

Upstream (heat exchanger inlet) and downstream

(heat exchanger outlet) configurations in the main
catalytic reformer,

Simulation using HYSYS to determine all stream

conditions and process requirements.

Transfer data (process conditions from HYSYS)

simulation to the heat exchanger, rating and
evaluation using HTC-STX determine,
Reliability of original design, and,
Overall performance evaluation of the heat exchangers

NNPC

HYSYS CAPABILITIES

HYSYS does comprehensive process

simulation ranging from a simple operation
to a complete plant site evaluation,

Incorporates utilities, unit operations and

logical models, some of which were applied
here,

Shell & Tube heat exchanger, the Adjust

model for iterative determination of critical
parameters and Spreadsheet for sensitivity
analysis.
NNPC

HYSYS SOLUTION

Stage-wise approach:

Characterization of heat exchanger fluids

shell & tube sides inlet,

Configuration of exchangers (A&B), creation

and programming for comprehensive
evaluation/analysis,

Verification of design performance,

Verification of temperature unbalance conditions

Advance using STX modelling,

Evolution of new network using HYSYS
NNPC

HYSYS SOLUTION Verification Of Design Performance

Involved iteration:

Specify design conditions including

exchangers tube outlet temps (TTOTA,BDesign),

Iteratively determine (UA)calculated for design

conditions using HYSYS ADJUST so that
TTOTA,BDesign = TTOTA,BHYSYS

Apply (UA)calculated to determine TTOTA,B at

different flowrates

Evaluate results
NNPC

HYSYS SOLUTION Verification Of Temperature Unbalance

Involved iteration:

Specify the unbalance temperature TTOTA,B(unbalance

conditions) where TTOTA=505 C and TTOTB=360 C,

Iteratively determine (UA)Aunbalance and (UA)Bunbalance

for temperature unbalance conditions using HYSYS
ADJUST so that TTOTA,B(unbalance conditions) = TTOTA,BHYSYS

Apply (UA)A,Bunbalance to determine TTOTA,B(unbalance

conditions) at different flowrates

Evaluate results

NNPC

HYSYS ENVIRONMENT

NNPC

HYSYS ANALYSIS OF EXCHANGER PERFORMANCE - 1

At Varied UA Impact On LMTD & Heater Inlet

Temps

20.0000

600

300

15.0000

360
400

10.0000

450

5.0000

484

500
400
LMTD

300

TubeAtotl

200
100

27,
2
35, 50
0
37, 00
5
40, 00
0
42, 00
5
45, 00
0
47, 00
5
50, 00
0
52, 00
5
55, 00
0
71, 00
225

0.0000

Exchnager B Flowrate kg/hour

NNPC

L T M D & T u b e c o m b in e d
o u t le t T e m p

U A ( a t I n d ic a t e d T e m p s )

HYSYS Evaluation of Existging Network At Varied

ExchnagerB Outlet Temp

0
300.00 360.00 400.00 450.00 484.00
Targeted ExchangerB Tube Outlet Temp. C

HYSYS ANALYSIS OF EXCHANGER PERFORMANCE - 2

HYSYS Evaluation of Existging Network At Varied

ExchnagerB Outlet Temp: Tube Side Outlet Temp
510.00
505.00
500.00
495.00
490.00
485.00
480.00
475.00
470.00

120.00
T em p era tu res C

T em p era tu res C

115.00
110.00
105.00
100.00
95.00

27
,2 5
35 0
,0 0
37 0
,5 0
40 0
,0 0
42 0
,5 0
45 0
,0 0
47 0
,5 0
50 0
,0 0
52 0
,5 0
55 0
,0 0
71 0
,2 2
5

27,
25
35, 0
00
37, 0
50
40, 0
00
42, 0
50
45, 0
000
47,
500
50,
000
52,
500
55,
000
71,
225

90.00

ExchangerB Flowrate, kg/hr

NNPC

HYSYS Evaluation of Existging Network At Varied

ExchnagerB Outlet Temp: Shell Side Outlet Temp

ExchangerB Flowrate, kg/hr

HYSYS EVALUATION OF TEMPERATURE UNBALANCE CONDITIONS

Shell Side Temperature Profiles Showing Unbalance

Identified By HYSYS

Tube Side Temperature Profiles Showing Unbalance

Identified By HYSYS

440.0

T u b e s sid e T e m p s, C

540.0
490.0
440.0
390.0
340.0
290.0
240.0

TubeA
TubeB
TubeAB

340.0

ShellA

290.0

ShellB

240.0

ShellAB

190.0
140.0
2 7 ,2 5 0
3 5 ,0 0 0
3 7 ,5 0 0
4 0 ,0 0 0
4 2 ,5 0 0
4 5 ,0 0 0
4 7 ,5 0 0
5 0 ,0 0 0
5 2 ,5 0 0
5 5 ,0 0 0
7 1 ,2 2 5

2 7,
3 5 ,2 5 0
3 7 ,0 0 0
5
4 0, 00
4 2 ,0 0 0
4 5 ,5 0 0
4 7 ,0 0 0
5 0 ,5 0 0
0
5 2, 00
5 5 ,5 0 0
7 1 ,0 0 0
2 25

90.0

Exchangers A,B Flows Kg/hour

NNPC

S h e ll- sid e T e m p s, C

390.0

Exchangers A,B Flows, Kg/hour

STX CAPABILITIES

STX handles sensible heat, condensing or boiling

problems.

The tube vibration routine checks for possible

damaging tube vibrations and warns when damage
is predicted based on the bundle entrance and exit
velocities.

STX design can allow maximum geometric flexibility

in specifying the exchanger configuration - shell
nozzles located beyond the U-bends, shell inlet and
outlet nozzles on the same or opposite sides of the
shell, the use of vapor belts, symmetrical and nonsymmetrical bundles, use of internal mechanical
calculations and tube counting routines assure
accurate sizes with adequate allowances for
impingement plates, nozzles, internal bolting, pass
partitions,
NNPC

STX APPROACH & MODEL

Study applied STX in the Design, Rating & Evaluation

modes:

Design, verified the original design and analysis

of surface area requirements

Rating, determined the performance of these heat

exchangers for a fully specified set of process
conditions.

Evaluation, determined the performance of these

heat exchangers for given conditions.

Sensitivity study on Rating and Evaluation basis

for a varied heat exchanger inlet feed flow to
determine process and mechanical conditions
NNPC

ESTABLISHING DESIGN & RELIABILITY

Two stage applied to establish design &

reliability of original licensor specification:

Carry out STX Design mode to specify

geometric configuration to meet flowrate,
other process requirements and
downstream limitations,

Fine-tune result and confirm with STX

Rating mode to give full control on the
reliable or otherwise of original licensor
specification.
NNPC

SENSITIVITY ANALYSIS

Apply data from Design case verification,

Rating and Evaluation cases,
Feed rate from the actual 54,500 kg/m3 to
design flow 142,454,

Determine key thermodynamic parameters

and exchanger mechanical properties,

Evaluate parameters in the context of

exchanger process & thermal requirements

NNPC

VERIFY ORIGINAL DESIGN REQUIREMENT

Result showed:
0
00

0,
12

0,
11

-20.00
-25.00
-30.00
-35.00
-40.00

1.00
0.80
0.60
0.40
0.20
142,454

120,000

115,000

110,000

105,000

100,000

95,000

90,000

85,000

80,000

75,000

70,000

65,000

60,000

0.00

Flowrate kg/hr

NNPC

00

0
00
0,
10

90

,0
0

0
,0
0
80

70
,0
00

60
,0
00

54
,5
00

-15.00

Flowrate (kg/hr)

Shell & tube pressures

within allowable limits,

STX Rating mode confirmed

under sizing at varied
flowrates

-10.00

55,000

Tube vibration likely at

bundle entrance at nozzle,
first baffle chord, central
baffle space and bundle exit
at nozzle,

0.00
-5.00

54,500

Number of tube required for

specified duty will be 2,888,
whereas 1,800 used,

Vibration Index

Available surface area (%) [- means

% under- design]

5.00

EVALUATION CASE ANALYSIS - 1

Heat duty

10
0,
00
0
11
0,
00
0
12
0,
00
0

90
,0
00

80
,0
00

70
,0
00

Mean Temperature

60
,0
00

90,000
80,000
70,000
60,000
50,000
40,000
30,000
20,000
54
,5
00

Heat Duty

consistently
increase with flow
rate,

Flow Versus Heat Duty

Flowrate, kg/hr

Difference (MTD)
increase with duty

MTD
80.00

result

70.00
MTD

Similar to HYSYS

75.00
65.00
60.00
55.00
50.00

He at Duty

NNPC

65
,7
12

60
,2
36

54
,7
60

49
,2
84

43
,8
08

38
,3
32

32
,8
56

29
,8
44

45.00

EVALUATION CASE ANALYSIS - 2

100,000
80,000
60,000

SPDc

40,000

TPDc

20,000
12
0,
00
0

11
0,
00
0

10
0,
00
0

90
,0
00

80
,0
00

70
,0
00

60
,0
00

0
54
,5
00

PressureDrops- Shell/Tube

Flow Ve rs us Pre s ure Drops

Flowrates, kg/hr

1,700.00
1,500.00
1,300.00
1,100.00
900.00
700.00
500.00
300.00

SFCoef

Flowrate , kg/hr

NNPC

12
0,
00
0

11
0,
00
0

10
0,
00
0

90
,0
00

80
,0
00

70
,0
00

T FCoef

60
,0
00

54
,5
00

F
ilm
C
oefficients

Flow Ve rs us Film Coe fficie nts

EVALUATION CASE ANALYSIS - 3

1,000.00
900.00
800.00
700.00
600.00
500.00
400.00
300.00
200.00
100.00
0.00

SrateC

90
,0
00
10
0,
00
0
11
0,
00
0
12
0,
00
0

80
,0
00

70
,0
00

Srate

60
,0
00

54
,5
00

Transfer Rates

Flowrate Versus Transfer Rates (STX Parameters)

Flowrate kg/hour

NNPC

EXCHANGER VIBRATION INDICATORS

Bundle
Entrance
at Nozzle

First
Baffle
Chord

Central
Baffle
Spacing

Last
Baffle
Chord

Bundle
Exit at
Nozzle

Vibration
Index

54,500

142,450

0.8

Flowrate

1 indicates likelihood of vibration, 0 for no

vibration and the index showing the weighting of
vibration,

Results showed damaging tube vibrations.

NNPC

ENGINEERING SOLUTION

Tube vibration

Apply recommended solution

Inadequate surface area. Solution -

Application of traditional design/rating

tools - STX.

Evolution of new exchanger network using

HYSYS

Retrofit design
NNPC

TUBE VIBRATION

Solution applicable with further STX evaluation,

Reducing the unsupported tube span by:

Changing baffle type,
Using tube intermediate support,
Using partial tube supports (inlet/outlet spaces),

Reducing the fluid velocity by:

Changing the tube span,
Changing the tube layout,
Increase the baffle spacing,
Increase the nozzle size (inlet & outlet),
Increase the number of tubes dropped (inlet & outlet)

Can be achieved through a programme process of

re-design, engineering and installation.
NNPC

SURFACE AREA STX Design Approach

Add a shell in parallel. STX design surface

area required is 2880 tubes (current 1800 for
2 shells). HYSYS applicable for re-design of
heat exchanger network

Reduce the design fouling factor,

Change the process conditions.
NNPC

SURFACE AREA HYSYS Approach

Using data from STX, HYSYS integrated a new

exchanger C, with 1000 tubes and same
configuration with the others.

Distribute flows: Exchangers A, B to have 30% each

of total flow and Exchanger C 40%,

Carry out simulation of network and determine UA

as verification of design,

Apply the UA for simulation for the range of flows,

At low capacity utilization, Exchanger C can be bypassed Evaluation shows the need & impact of
this.
NNPC

ADDITION OF NEW EXCHANGER (SURFACE AREA) IN HYSYS

NNPC

IMPACT OF ADDITIONAL EXCHANGER ON FLUID HEAT TRANSFER CONDITIONS

145.00
135.00
125.00

ShellABC

115.00

ShellAB

71,225

55,000

52,500

50,000

47,500

45,000

42,500

40,000

37,500

95.00

35,000

105.00
27,250

A
B
C
/A
B

Shell sideT
em
psFor

Profile s Showing Impact of Exchange r C On Fluid He at

Transfe r - She ll Side

Exchangers ABC Total Flows Kg/hour

510.00
500.00
490.00

T ubeABC

480.00

T ubeAB

470.00

71
,2
25

52
,5
00

47
,5
00

42
,5
00

37
,5
00

460.00

27
,2
50

T
ubesideT
em
psForA
B
C
/A
B

Profiles S howing Impact of Exchanger C On Fluid Heat

Trans fer - Tube S ide

Exch an ge rs AB C Total Fl ows k g/h r

NNPC

SURFACE AREA Retrofit Approach - 1

The following options will apply:

1. Increase overall heat transfer coefficient.

2. Modify tube-side flow pattern to increase
number of passes, thereby increasing tubeside film coefficient,

3. On the shell-side modify baffle arrangement

to increase the shell-side film coefficients,
eg, by decreasing the baffle spacing,

NNPC

SURFACE AREA Retrofit Approach - 2

4. Change heat transfer surface from a plain

surface to a finned, ribbed or nonuniform
surface can increase the rate of heat
transfer of the tube surfaces,

5. Alternative devices can be inserted into the

inside of existing plain tubes to enhance

the inside heat transfer coefficient at the
expense of increased pressure drop. Such
devices include twisted tapes, static mixers,
coiled wires and mesh inserts.

HYSYS applied to achieve #1 above.

NNPC

CONCLUSION

Study has shown:

1.

Heat Transfer phenomenon and exchangers A & B

performances adequately illustrated by the HYSYS
& STX evaluations,

2.

Temperature unbalance caused by inadequate heat

transfer in Exchanger B with low tube-side outlet
temperature.

3.

Tube vibration indicated at flows at particular levels

up to design capacity. Prolonged application of
exchanger with vibration may have damaged tubes,

4.

HYSYS design determined new network and UA for

extended area option if required,

NNPC

RECOMMENDATION

And recommended to the Refiner as follows:

1.

Open up and inspect Exchangers A & B to determine

mechanical failures,

2.
3.

Repair/replace and clean-up exchangers tubes/shells,

4.

Provide additional surface up to about 36 percent of the

existing. HYSYS design has provided the new network
process conditions and operability.

5.

Details on the new exchanger can be done in further

evaluation STX and retrofit approaches.

6.

Re-commission exchangers, test run and re-evaluate

them for performance using engineering software tools.

Make appropriate provision to eliminate tube vibration

already specified earlier here,

NNPC

NNPC