Heat Transfer Operations

Week 6

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Importance of Heat Transfer Equipment Simulation
• Significance:
Crucial for designing, optimizing, and troubleshooting heat
transfer equipment performance.
• Steps:
• Define Components and Fluid Package
• Select Heat Transfer Equipment Type
• Configure Equipment Design (Geometry)
• Define Heat Transfer Coefficients
• Run the Simulation
• Execute the simulation to analyze equipment
performance 5
 Equipment for Heat Transfer

Key Equipment

Equipment Description Applications

Heater adds heat to a stream or fluid, heat fluids in a process, such as a distillation
raising its temperature column, reactor, or fractionator.

Cooler removes heat from a stream or cool fluids in a process, such as a condenser or
fluid, lowering its temperature. a refrigeration system.

Heat transfers heat from one fluid to exchange heat between two process streams
Exchanger another without mixing

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 Equipment for Heat Transfer
Additional Equipment
Equipment Description Applications
Fired A heater that uses a fuel, such as processes that require high-temperature
Heater natural gas, to generate heat heating, such as reforming, or cracking
Air Cooler A heat exchanger that uses air as the processes that require air cooling, such as
cooling medium. refrigeration, air separation, or gas processing.

LNG A heat exchanger that uses a cryogenic processes that require cryogenic cooling, such as
Exchanger fluid, such as LNG, as the cooling natural gas liquefaction, ethylene production, or
medium refrigeration.
Plate A heat exchanger that uses thin, processes that require compact heat exchangers,
Exchanger corrugated plates to increase the heat such as in the chemical, food, and pharmaceutical
transfer area industries.

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Engineering Standards for Heat Exchanger Design
Standard Description Application
ASME American Society of Mechanical Engineers codes for pressure vessel design.
TEMA Tubular Exchanger Manufacturers Association heat exchanger design and
construction
API American Petroleum Institute heat exchangers used in the oil
and gas industry
ASTM American Society for Testing and Materials Material specifications for the
intended service
Regulations Ensure compliance with local and international regulations and codes.
Environmental Address environmental impact and emissions in accordance with regulations.
Considerations
Quality Control Implement quality assurance and quality control practices to meet design and
construction standards.

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Shell and Tube Heat Exchanger
• Application: Commonly used in diverse industries for
non-mixing heat transfer between fluids
• Structure: A shell (outer vessel) and a bundle of
tubes (inner vessel) arranged in a specific pattern.
• Shell Side Fluids: High viscosity, corrosive, high
pressure.
• Tube Side Fluids: Low viscosity, clean, high heat
transfer coefficient.
• Heat Transfer Mechanism: Heat transferred through
tube and shell walls made of high thermal
conductivity materials.
• Key Design Parameters: tube diameter, tube length,
number of tubes, baffle spacing, shell diameter

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 Heat Exchanger Models
Heat Exchanger Model Applications Limitations
Simple End Point Quick estimation of heat Assumes constant overall
exchanger performance heat transfer coefficient and
specific heats

More accurate estimation of Still assumes constant

Simple Steady State heat exchanger overall heat transfer
Rating performance than simple coefficient and specific
end point model heats

Sizing, rating, and

Rigorous Shell&Tube optimization of shell and Requires detailed geometry
tube heat exchangers and operating conditions

Takes into account the

variation of overall heat Assumes constant specific
Simple Weighted transfer coefficient with heats
temperature
Simulates the dynamic Requires detailed geometry
Dynamic Rating behavior of heat exchangers and operating conditions
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Terms
• TEMA Type: offers a standardized classification system for shell-and-
tube heat exchangers.
• Pitch: The center-to-center distance between adjacent tubes in the
bundle.
• Duty: Heat transfer between hot and cold fluids to achieve process
goals
• LMTD: Logarithmic Mean Temperature Difference, calculates the
average temperature difference between hot and cold fluids in a HE.
• Pinch Temperature: The lowest temperature at which hot and cold
fluids efficiently exchange heat in a given heat exchanger design.

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Terms
• Heat transfer coefficient: a measure of the
efficiency of heat transfer between two fluids
• Overall heat transfer coefficient: a measure of the
efficiency of heat transfer between the two fluids
and the heat exchanger walls
• Heat flux: the rate of heat transfer per unit area
• Fouling resistance: a measure of the resistance to
heat transfer caused by fouling
• Fouling thermal conductivity: a measure of the
ability of the fouling material to conduct heat
• Fouling thickness: the thickness of the fouling layer

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Practice HYSYS
Heat Transfer Equipment

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 Ex1- Single End Point Model
100 kg/h of Hot water at 250 °C & 1000 psig is used to heat a cold stream of
water in a shell & tube heat exchanger. The inlet temperature and pressure
of the cold stream is 25 °C and 130 psig, respectively. The outlet
temperatures of the cold and hot streams are 150 °C and 190 °C, respectively.
(Fluid Package: PR)
Determine the flow rate of the cold stream passing through the exchanger.

Hot 250 °C,1000 psig cold 25 °C ,130 psig

2 Tube passes
1 Shell pass

190 °C 150 °C
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 Ex1- Single End Point Model

1 2

3 4

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Ex2: Simple Steady State Rating
• An existing shell-and-tube heat exchanger is used to transfer heat to a toluene feed
stream from a styrene product stream. The toluene enters the exchanger on the tube
side at a flow rate of 125,000 lb/hr at 100 °F and 90 psia. The styrene enters on the shell
side at a flow rate of 150,000 lb/hr at 300 °F and 50 psia. The exchanger shell and tube
are carbon steel.
• The shell has an inside diameter of 39 in. and contains 1024 × 0.75 in., 14 BWG, 6-ft long
tubes on a 1-inch square pitch. 38 segmental baffles are used with a baffle cut of 25%.
• Fouling factors are estimated to be 0.002 (hr ft2 °F/Btu) on each side.
• Determine:
1. exit temperatures of two streams
2. the heat duty
3. the pressure drop.
4. Min approach temperature

Note: More design details are given in the solution

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 Ex2: Simple Steady State Rating

1 2

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Ex2: Simple Steady State Rating

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 Ex2: Simple Steady State Rating

4 5

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Ex2: Simple Steady State Rating

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Ex2: Simple Steady State Rating

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Ex2: Simple Steady State Rating
Answers

1. exit temperatures of two streams

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Ex2: Simple Steady State Rating
Answers
2. the heat duty

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Ex2: Simple Steady State Rating
Answers
3. the pressure drop

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Ex2: Simple Steady State Rating
Answers
4. Min approach temperature

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Ex3: Rigorous sizing
2000 kg/h of water at 25 °C and 5 bar is used to cool an
equimolar mixture of benzene and toluene at 92 °C and 5 bar
at a flow rate of 1000 kg/h. Pressure drop in shell or tube side
is 0.2 bar and the desired outlet temperature of the mixture is
60 °C. Using Peng-Robinson fluid package:
Develop rigorous size of the heat exchanger.

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Ex3: Rigorous sizing

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Ex3: Rigorous sizing

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