Professional Documents
Culture Documents
1
2002 Hyprotech Ltd. All Rights Reserved 1.3.9 Rating Heat Exchangers.pdf
Workshop
A heat exchanger is a vessel that transfers heat energy from one process stream to another. Until now, we have not considered the physical parameters of the heat exchangers we have modeled. In this module we will be entering this additional information regarding our shell and tube heat exchanger and allowing HYSYS to determine whether or not it will suit our needs.
Learning Objectives
In this workshop you will learn how to: Use the Heat Exchanger Dynamic Rating Method in HYSYS for heat exchanger design. Determine if an existing heat exchanger will meet the process specifications.
Prerequisites
We ignore the adjust so that it doesnt interfere with out calculations.
Before beginning this workshop you need to have completed the previous modules.
Process Overview
First Part
Process Overview
Second Part
The Cooler/Heater operations are single-sided unit operations where only one process stream passes through the operation. The LNG Exchanger allows for multiple (more than two) process streams. A shell and tube heat exchanger is a two-sided unit operation that permits two process streams to exchange heat. In this module, a shell and tube exchanger of given dimensions will be rated to see if it will meet the requirements of the process.
(M
cold
(H
out
(1)
where:
M = Fluid mass flow rate H = Enthalpy Q leak = Heat Leak Q loss = Heat Loss
The Balance Error is a Heat Exchanger Specification which, for most applications, will equal zero. The subscripts "hot" and "cold" designate the hot and cold fluids, while "in" and "out" refer to the inlet and outlet. The Heat Exchanger duty may also be defined in terms of the overall heat transfer coefficient, the area available for heat exchange and the log mean temperature difference:
(2)
where:
U = Overall heat transfer coefficient A = Surface area available for heat transfer LMTD = Log mean temperature difference Ft = LMTD correction factor
T T 1 2 LMTD = -----------------------------------Ln ( T T ) 1 2
where: T 1 = T hot ,out T col d,in T 2 = T hot ,in T cold ,out
(3)
The LMTD can be either terminal or weighted. This means that it can be calculate over the exchanger as a whole (terminal) or over sections of the exchanger (weighted). The need for this type of calculation is shown on the next page. The following plot is a heat loss curve for a single phase stream. It compares the temperatures of the process streams with the heat flow over the entire length of the exchanger. For single phase streams, these plots are linear.
Figure 1
The following curve represents a superheated vapour being cooled and then condensed. Note that it is not linear because of the condensation that takes places inside the exchanger.
Figure 2
If the LMTD is calculated using the hot fluid temperatures at points A and C, the result would be incorrect because the heat transfer is not constant over the length of the exchanger. To calculate the weighted LMTD: 1. 2. 3. Break the heat loss curve into regions at point B. Calculate the terminal LMTD for each region. Sum all of the LMTDs to find the overall LMTD.
HYSYS will do this automatically if the Heat Exchanger model is chosen as Weighted. Therefore, if condensation or vaporization is expected to occur in the exchanger, it is important that Weighted is chosen as the model.
The basics of each model: End Point Model. This model is based on Q = UAFt(LMTD). The main assumptions behind this model are the overall heat transfer coefficient U is constant the specific heats of the streams at both exchanger sides are constant. The heat curves of both shell and tube side are linear. The heat exchanger geometry is not taken into account in this model. Weighted Model. This model is particular powerful in dealing with non-linear heat curve problems such as phase change of pure components in one or both heat exchanger sides. The heat curves are divided into a number of intervals and energy balance is performed in each interval. This model can only be used for energy and material balance. The heat exchanger geometry is not taken into account in this model. Steady State Rating Model. This model makes the same assumptions as the End Point Model. It simply an extension of the End Point model which incorporates a rating calculation. If detailed geometry information is provided, the exchanger can be rated using this model. For linear or nearly linear heat curve problems, this model is a good choice because it is much faster than the dynamic rating-detailed model. Dynamic Basic Model. The Basic Model is based on Q = UAFt(LMTD) and makes the same assumptions as the End Point model. This model was originally developed for dynamic mode but was extended for rating in steady state. This model is somewhat oversimplified in that geometry configurations are not taken into account. Therefore, this model has limited functionality. When using this model, both pressure drops and the overall UA must be specified. Dynamic Detailed Model. The Detailed Model divides the entire heat exchanger into a number of heat zones. In each heat zone there is a shell hold-up and one or more tube hold-ups, according to the number of tube passes per shell pass. It is a good counterpart to the Weighted Model. The Dynamic Detailed Model is used both in steady state and in dynamic operation and is designed to solve any linear and non-linear heat curve problems.
10
1. 2. 3.
Break the connection of the Kerosene_PA Return stream to the Heat Exchanger. Go to the Property View of the Heat Exchanger and complete the Outlet Shell with a stream called Kerosene Out. Go to the Parameters tab. See that the pressure drop from the shell side has been deleted. Remove the one from the tubes because, rating a Heat Exchanger, HYSYS, uses its own correlation to calculate this value. The Rating option can be chosen by selecting Dynamic Rating from the Heat Exchanger Model drop-down menu on the Parameters page on the Design tab. Note that once this model is chosen, all information on this page disappears. This is because with this type of model the required information must be specified elsewhere.
Figure 3
4.
Some of the physical design specifications of an exchanger must be supplied on the Sizing page of the Rating tab.
10
11
The radio button selection in the Sizing Data group will dictate the type of information shown at any given moment. Each parameter will be defined later on in this module. The radio buttons in the Sizing Data group include; Overall. Required information about the entire exchanger. Most of the information entered here is used only in dynamic simulations. Shell. Required information concerning the shell side of the exchanger. All variables must be specified. Tube. Required information concerning the tube side of the exchanger. All variables must be specified.
The TEMA Type is selected as part of the Overall sizing data. There are three drop-down lists which allow you to specify the geometry of the front end stationary head type, the shell type and the rear end head type for the exchanger. The following tables provide brief descriptions for each designated TEMA Type letter. Drawings of the various TEMA types can be found on page 11-4 of Perry's Chemical Engineers Handbook, Sixth Edition.
11
12
12
13
Rating Parameters
Brief explanations are provided below for each Simple Rating parameter. The parameters are categorized according to the radio buttons in the Sizing Data group box. Most of these parameters are only available when the mode is chosen as Detailed as opposed to Basic.
Overall Information:
Tube Volume per Shell. The volume inside the tubes, used only in dynamic simulations Shell Volume per Shell. The volume inside the shell, used only in dynamic simulations Heat Trans. Area per Shell. The total area available for heat transfer, calculated from the specified geometry. Elevation. The height of the base of the exchanger, used only in dynamic simulations. Tube Passes per Shell. The number of tube passes per shell. Orientation. The orientation of the exchanger, used only in dynamic simulations. Number of Shells in Series. The number of shells in series. Number of Shells in Parallel. The number of shells in parallel. TEMA Type. Described earlier.
13
14
If you want HYSYS to use general correlations to determine the shell and tube side pressure drops and heat transfer coefficients, select the Detailed model on the Parameters page. This will allow HYSYS to calculate the desired terms.
The Rating model in HYSYS uses generalized correlations for heat transfer coefficients and pressure drop. These correlations are suitable for approximate results in most cases but may not be valid for every exchanger. For more accuracy, a rigorous model may be required. Please contact your Hyprotech representative for a list of available third party heat exchanger packages that are compatible with HYSYS through OLE Extensibility.
We are going to use some of the values provided by HYSYS by default and change others. 5. Introduce the following data where it corresponds:
Enter... 1 25 21 30 Double
In this cell... Tube Passes per Shell OD (mm) ID (mm) Tube Pitch (mm) Baffle Type
6.
Go to the Parameters tab and check the Detailed radio button. Note that the data needed for the simulation changes.
14
15
Make sure that both pressure drop cells are empty, as we said before, HYSYS calculates the values.
What is the new temperature of stream To Desalter? ______________________
4. 5.
6.
15
16
7. 8. 9.
Add a Recycle unit and connect the Kerosene Out as the Inlet stream and the Kerosene_PA Return as the Outlet. In the Numerical page of the Parameters tab, change the Maximum Iterations to 20. You need to provide the Outlet Recycle stream with an initial guess, so that all the streams entering the Column are defined, define it from the Kerosene_PA Return Copy you previously created.
Exercise 1
In the previous module, we learned where to place Recycles. It is also important to minimize the number of recycles used in the flowsheet.
Tip: A helpful way of doing this is to place the Recycle mentally in different locations and imagine the HYSYS calculation sequence.
Look at your simulation and decide where to place a single recycle to converge the case.
16
17
Exercise 2
You are asked to find a heat exchanger to replace the existing one. However, since you are on a very restricted budget, you can only consider used equipment. A heat exchanger has been found in a nearby plant. If the critical process parameter is to maintain the To Desalter temperature of at least 85C (185F), can this heat exchanger be used? The TEMA definition of this exchanger is A.E.L. The dimensions are given here:
Tube length (m) Number of Tubes Baffle Type 5 150 single
Previous experience has shown you that after about six months in operation, the exchanger becomes fouled and the fouling factor for both shell-side and tube-side is 0.0001C-h-m2/kJ.
What will the temperature of To Desalter be after 6 months of service? ______ Will this exchanger be adequate after 6 months of service? _______________
17
18
18