Single Heat Exchanger

Problem Statement

Hot water at 250 °F and 1000 psig is used to heat a cold stream of water in a shell and tube heat
exchanger. The inlet temperature and pressure of the cold stream is 125 °F and 130 psig,
respectively. The outlet temperature of the cold and hot streams are 150 °F and 195 °F,
respectively. If the flow rate of the hot stream is 100 lb/hr, determine the flow rate of the cold
stream passing through the exchanger.
 Plan of Attack

Process Description

The heat exchanger allows for heat to be transferred from a hot fluid to a cold fluid without
mixing the two fluids. Figure 1 illustrates a counter-current heat exchanger process
diagram.

Figure 1: Counter-Current Heat Exchanger Process Diagram

Basis of Calculations

100 lb/hr of hot water

Solution Outline

1. Use HYSYS' shell and tube heat exchanger to model the process.
2. Define the inlet and outlet conditions for the streams as given in the problem
statement.
3. Obtain the mass flow rate of the cold stream HYSYS.

Assumptions

1. The components behave according to the PRSV equation of state.

2. There is no heat loss to the environment.
3. The pressure drop across shell and tube is zero.
4. The cold stream flow through the shell, while the hot stream flow through the tube.
 Model Development

Figure 2 illustrate the HYSYS simulation diagram of the heat exchanger.

Figure 2: HYSYS representation of the heat exchanger

Model Description

A hot water stream named Tube in is fed to the tube side of the heat exchanger name E-
100 and its exit stream is called Tube out. The cold water stream called Shell in is fed into
shell side of the exchanger and its exit stream is called Shell out.

Selecting Components and Fluid Package

1. Open a new case in HYSYS.

2. Select PRSV for the fluid package.
3. Select H2O for the component.

Setting up the PFD

1. Enter the Simulation Environment.

2. Select from the object palette the heat exchanger icon and install it on the PFD.

3. By default the installed heat exchanger should be called E-100. Double click on E-
100.
4. Enter the names of the streams as shown in Figure 3.
Figure 3: Stream names for the heat exchanger.

5. Close the E-100 window and return to the PFD. Ensure that the streams are
connected to the exchanger.
6. To change the icon of the exchanger, select the exchanger then right click and
select Change icon from the shortcut menu.
7. In the small window that opens, select the icon that is similar to the one shown in
Figure 2.

Selecting a Unit Preference

Since the number given in the problem statement are in English units, it would be easier
work in HYSYS if the units are English.

1. Go to the Tools menu and select Preferences.

2. Click on the Variable tab.
3. In the Available Units box, scroll and select Field. (Field is similar to English units.)
4. In the Display Units box, notice that the temperature is in F, the pressure is in psia
and the flow is in lb/hr. However, in the problem statement, the pressure was given
in units of psig. To change this to psig, press the Clone button.
5. A new Available unit set should appear with the name NewUser#. Where # stands
for a number chosen by HYSYS. Click in the box next to Unit Set Name and type in
Cogen.
6. In the Display Units box, select the cell next to Pressure.
7. Go to the drop down menu located at the top of that window and scroll and select
psig from the list (see figure 4).
 Figure 4: Selecting units from drop down menu.

8. After the units of the pressure has been changed, close the preference window and
return to the PFD.

Stream Specifications

1. Double click on E-100 to open the E-100 window.

2. In the E-100 window, click on Worksheet tab.
3. On the Conditions page of the Worksheet tab, enter the condition given in the
problem statement.
4. Since we are assuming the pressure drop across the heat exchanger is zero, enter
the same pressure for the corresponding outlet stream.
5. The should be similar to that shown in figure 5.

Figure 5: Stream Conditions

6. Next click on Composition.

7. Since the only component present is water, enter 1 for the the inlet streams. After
doing this the status box at the bottom of the window should turn from yellow to
green. This green indicates that the heat exchanger has been solved.
8. Click on Conditions and view the Mass Flow of the cold stream.
 Results

Simulation Results

The stream conditions for the heat exchangers are shown in Figure 6.

Figure 6: Stream results

Answer

At the given stream conditions and a hot stream flow rate of 100 lb/hr, the flow rate of the
cold stream passing through the exchanger is approximately 220 lb/hr.

Discussion

By changing the icon will not not affect the results. The icon was change to allow you to get a better
picture of what the process would looks like.