1

HEAT TRANSFER, HEAT EXCHANGERS, CONDENSORS AND REBOILERS, AIR COOLERS

Reyad Awwad Shawabkeh Associate Professor of Chemical Engineering King Fahd University of Petroleum & Minerals Dhahran, 31261 Kingdom of Saudi Arabia

Contents
HEAT TRANSFER LAW APPLIED TO HEAT EXCHANGERS HEAT TRANSFER BY CONDUCTION The Heat Conduction Equation HEAT TRANSFER BY CONVECTION Forced Convection Natural Convection HEAT TRANSFER BY RADIATION OVERALL HEAT TRANSFER COEFFICIENT PROBLEMS DESIGN STANDARDS FOR TUBULAR HEAT EXCHANGERS SIZE NUMBERING AND NAMING SIZING AND DIMENSION TUBE-SIDE DESIGN SHELL-SIDE DESIGN Baffle type and spacing GENERAL DESIGN CONSIDERATION THERMAL AND HYDRAULIC HEAT EXCHANGER DESIGN DESIGN OF SINGLE PHASE HEAT EXCHANGER Kerns Method Bells method Pressure drop inside the shell and tube heat exchanger DESIGN OF CONDENSERS DESIGN OF REBOILER AND VAPORIZERS DESIGN OF AIR COOLERS9 MECHANICAL DESIGN FOR HEAT EXCHANGERS10 DESIGN LOADINGS TUBE-SHEET DESIGN AS PER TEMA STANDARDS DESIGN OF CYLINDRICAL SHELL, END CLOSURES AND FORCED HEAD REFERENCES 2 3 9 12 12 14 15 18 22 23 23 27 32 33 33 35 37 37 45 49 57 65 72 85 88 88 90 91 95

HEAT TRANSFER LAW APPLIED TO HEAT EXCHANGERS

Heat Transfer by Conduction

W/m2

W/m.K

Thermal Conductivity of solids

Thermal Conductivity of liquids

Thermal conductivity of gases

Example

Calculate the heat flux within a copper rod that heated in one of its ends to a temperature of 100 oC while the other end is kept at 25 oC. The rode length is 10 m and diameter is 1 cm.

Example

An industrial freezer is designed to operate with an internal air temperature of -20 oC when external air temperature is 25 oC. The walls of the freezer are composite construction, comprising of an inner layer of plastic with thickness of 3 mm and has a thermal conductivity of 1 W/m.K. The outer layer of the freezer is stainless steel with 1 mm thickness and has a thermal conductivity of 16 W/m.K. An insulation layer is placed between the inner and outer layer with a thermal conductivity of 15 W/m.K. what will be the thickness of this insulation material that allows a heat transfer of 15 W/m2 to pass through the three layers, assuming the area normal to heat flow is 1 m2?

The Heat Conduction Equation

10

Rate of heat conduction into control volume

Rate of heat generation inside control volume

Rate of heat conduction out of control volume

Rate of energy storage inside control volume

The Heat Conduction Equation

11

Heat Transfer by Convection

12

Reynolds and Prandtl Numbers

Re < 2100 Re > 2100 Laminar flow Turbulent flow

13

Values of Prandtl number for different liquids and gases

Flow through a single smooth cylinder

14

This correlation is valid over the ranges 10 < Rel < 107 and 0.6 < Pr < 1000 where

Flow over a Flat Plate

15

Re < 5000 Re > 5000

Laminar flow Turbulent flow

Natural Convection

16

Heat Transfer by Radiation

17

q = (Th4 - Tc4) Ac
Th = hot body absolute temperature (K) Tc = cold surroundings absolute temperature (K) Ac = area of the object (m2)

= 5.6703 10-8 (W/m2K4)

The Stefan-Boltzmann Constant

Emissivity coefficient for several selected material

18

Surface Material

Emissivity Coefficient --

Aluminum Commercial sheet

Aluminum Foil Aluminum Commercial Sheet Brass Dull Plate Brass Rolled Plate Natural Surface Cadmium Carbon, not oxidized Carbon filament Concrete, rough Granite Iron polished Porcelain glazed Quartz glass Water Zink Tarnished

0.09
0.04 0.09 0.22 0.06 0.02 0.81 0.77 0.94 0.45 0.14 - 0.38 0.93 0.93 0.95 - 0.963 0.25

Overall heat transfer coefficient

19

For a wall

For cylindrical geometry

Typical value for overall heat transfer coefficient

Shell and Tube Heat Exchangers Hot Fluid Cold Fluid U [W/m2C]

20

Heat Exchangers

Water Organic solvents Light oils Heavy oils Reduced crude Regenerated DEA Gases (p = atm) Gases (p = 200 bar)

Water Organic Solvents Light oils Heavy oils Flashed crude Foul DEA Gases (p = atm) Gases (p = 200 bar) Water Water Water Water Water

800 - 1500 100 - 300 100 - 400 50 - 300 35 - 150 450 - 650 5 - 35 100 - 300 250 - 750 350 - 700 60 - 300 75 - 200 150 - 400

Coolers

Organic solvents Light oils Heavy oils Reduced crude Gases (p = 200 bar)

Organic solvents
Water Gases

Brine
Brine Brine

150 - 500
600 - 1200 15 - 250

Heat Exchangers Hot Fluid Heaters Steam Steam Steam Steam

Cold Fluid Water Organic solvents Light oils Heavy oils

U [W/m2C] 1500 - 4000 500 - 1000 300 - 900 60 - 450 21

Steam
Heat Transfer (hot) Oil Flue gases Flue gases Condensers Aqueous vapors Organic vapors Refinery hydrocarbons Vapors with some non

Gases
Heavy oils Steam Hydrocarbon vapors Water Water Water

30 - 300
50 - 300 30 - 100 30 -100 1000 - 1500 700 - 1000 400 - 550

condensable Vacuum condensers

Water
Water

500 - 700
200 - 500

Vaporizers

Steam Steam Steam Heat Transfer (hot) oil

Aqueous solutions Light organics Heavy organics Refinery hydrocarbons

1000 - 1500 900 - 1200 600 - 900 250 - 550

DESIGN STANDARDS FOR TUBULAR HEAT EXCHANGERS

22

Size of heat exchanger is represented by the shell inside diameter or bundle diameter and the tube length

Type and naming of the heat exchanger is designed by three letters single pass shell
The first one describes the stationary head type The second one refers to the shell type The third letter shows the rear head type

TYPE AES refers to Split-ring floating head exchanger with removable channel and cover.

Heat exchanger nomenclatures

23

The standard nomenclature for shell and tube heat exchanger

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1. Stationary Head-Channel 2. Stationary Head-Bonnet

20. Slip-on Backing Flange 21. Floating Head Cover-External

30. Longitudinal Baffle 31. Pass Partition 32. Vent Connection 33. Drain Connection 34. Instrument Connection 35. Support Saddle 36. Lifting Lug 37. Support Bracket 38. Weir 39. Liquid Level Connection 40. Floating Head Support

3. Stationary Head Flange-Channel or 22. Floating Tube sheet Skirt Bonnet 4. Channel Cover 5. Stationary Head Nozzle 6. Stationary Tube sheet 7. Tubes 8. Shell 9. Shell Cover 10. Shell Flange-Stationary Head End 11. Shell Flange-Rear Head End 12. Shell Node 13. Shell Cover Flange 14. Expansion Joint 15. Floating Tube sheet 16. Floating Head Cover 17. Floating Head Cover Flange 18. Floating Head Backing Device 19. Split Shear Ring 23. Packing Box 24. Packing 25. Packing Gland 26. Lantern Ring 27. Tie-rods and Spacers 28. Support Plates 29. Impingement Plate

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Removable cover, one pass, and floating head heat exchanger

Removable cover, one pass, and outside packed floating head heat exchanger

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Channel integral removable cover, one pass, and outside packed floating head heat exchanger

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Removable kettle type reboiler with pull through floating head

Tube sizing: Birmingham Wire Gage

Gauge 00000 (5/0) 0000 (4/0) 000 (3/0) 00 (2/0) 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 (B.W.G.) (inches) 0.500 0.454 0.425 0.380 0.340 0.300 0.284 0.259 0.238 0.220 0.203 0.180 0.165 0.148 0.134 0.120 0.109 0.095 0.083 0.072 0.065 0.058 0.049 0.042 0.035 0.032 0.028 (B.W.G.) (mm) 12.7 11.5 10.8 9.7 8.6 7.6 7.2 6.6 6.0 5.6 5.2 4.6 4.2 3.8 3.4 3.0 2.8 2.4 2.1 1.8 1.7 1.5 1.2 1.1 0.9 0.8 0.7 Gauge 23 24 25 26 27 28 29 30 31 32 33 34 35 36 25 26 27 28 29 30 31 32 33 34 35 36 (B.W.G.) (inches) 0.025 0.022 0.020 0.018 0.016 0.014 0.013 0.012 0.010 0.009 0.008 0.007 0.005 0.004 0.020 0.018 0.016 0.014 0.013 0.012 0.010 0.009 0.008 0.007 0.005 0.004 0.6 0.6 0.5 0.5 0.4 0.4 0.3 0.3 0.3 0.2 0.2 0.2 0.1 0.1 0.5 0.5 0.4 0.4 0.3 0.3 0.3 0.2 0.2 0.2 0.1 0.1

28 (B.W.G.) (mm)

Tube sizing: Birmingham Wire Gage

29

Tube-side design

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Arrangement of tubes inside the heat exchanger

Shell-side design

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(a) one-pass shell for E-type, (b) split flow of G-type, (c) divided flow of J-type, (d) two-pass shell with longitudinal baffle of F-type (e) double split flow of H-type.

types of shell passes

Shell-side design

32

Shell thickness for different diameters and material of constructions

Baffle type and spacing

33

General design consideration

Factor Corrosion Fouling Tube-side More corrosive fluid Shell-side Less corrosive fluids

34

Fluids with high fouling Low fouling and scaling and scaling

Fluid temperature Operating pressure

High temperature

Low temperature

Fluids with low pressure Fluids with high pressure drop drop

Viscosity Stream flow rate

Less viscous fluid High flow rate

More viscous fluid Low flow rate

THERMAL AND HYDRAULIC HEAT EXCHANGER DESIGN

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Design of Single phase heat exchanger Design of Condensers Design of Reboiler and Vaporizers

Design of Air Coolers

Design of Single phase heat exchanger

36

Typical values for fouling factor coefficients

37

Temperature profile for different types of heat exchangers

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For counter current

For co-current

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one shell pass; two or more even tube 'passes

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two shell passes; four or multiples of four tube passes

divided-flow shell; two or more even-tube passes

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split flow shell, 2 tube pass

cross flow heat exchanger

Shell-side heat transfer coefficient

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Shell diameter

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Bundle diameter clearance

Tube-side heat transfer coefficient

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Tube-side heat transfer factor

Shell and Tube design procedure

Kerns Method

50

This method was based on experimental work on commercial exchangers with standard tolerances and will give a reasonably satisfactory prediction of the heat-transfer coefficient for standard designs.

Bells method This method is designed to predict the local heat transfer coefficient and pressure drop by incorporating the effect of leak and by-passing inside the shell and also can be used to investigate the effect of constructional tolerance and the use of seal strip

Kerns Method

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Bells method

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Figure 34 Baffle cut geometry

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Pressure drop inside the shell

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Pressure drop inside the tubes

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Design of Condensers

61

For reactor off-gas quenching Vacuum condenser De-superheating Humidification Cooling towers

Direct contact cooler

Condensation outside horizontal tubes

For Laminar flow

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For turbulent flow,

Condensation inside horizontal tubes

63

stratified flow

annular flow

Design of Reboiler and Vaporizers

Suitable to carry viscous and heavy fluids. Pumping cost is high

64

Forced-circulation reboiler

The most economical type where there is no need for pumping of the fluid It is not suitable for viscous fluid or high vacuum operation Need to have a hydrostatic head of the fluid
Thermosyphon reboiler

It has the lower heat transfer coefficient than the other types for not having liquid circulation Used for fouling materials and vacuum operation with a rate of vaporization up to 80% of the feed
Kettle reboiler

Boiling heat transfer and pool boiling

65

Nucleate pool boiling Critical heat flux Film boiling

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Nucleate boiling heat transfer coefficient

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Critical flux heat transfer coefficient

Film boiling heat transfer coefficient

Convection boiling
Effective heat transfer coefficient encounter the effect of both convective and nucleate boiling

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Design of air cooler

71

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Mechanical Design for HE

A typical sequence of mechanical design procedures is summarized by the flowing steps Identify applied loadings. Determine applicable codes and standards. Select materials of construction (except for tube material, which is selected during the thermal design stage). Compute pressure part thickness and reinforcements. Select appropriate welding details. Establish that no thermohydraulic conditions are violated. Design nonpressure parts. Design supports. Select appropriate inspection procedure

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Design loading

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