SIMULATION OF HEX

Presented by
5610750712 SUPHADEJ
5710755124 PACHARA
5710755520 CHATCHALITA
5710758029 NAVAPHUN
5710758037 ANYAMANEE

HEX SIMULATION METHOD 1

 PROBLEM STATEMENT
Ethanol as a shell inlet COLD STREAM
The esterification product from the reactor
tank, the mixture of Ethyl Acrylate + Water as
a tube HOT STREAM
Exchange heat in 1 tube passed HEX

HEX SIMULATION METHOD 2

HEAT EXCHANGER DIAGRAM
Cold stream (inlet): Ethanol

Th,out= ?? c = 70 kg/h, Tc,in = 25 , P = 130 psia

Tc,out= ?? Hot stream (inlet)

h = 100 kg/h, Th,in = 70 , P =280 psia

50%wt water and 50%wt Ethyl-Acrylate

HEX SIMULATION METHOD 3

HEAT EXCHANGER SPECIFICATION
TEMA type BEM Material SS 304

Shell pass 1 Tube pass 1

Shell ID 162.74 mm Tube OD (D) 19.05 mm

Shell thickness 1270 mm Tube thickness 1.65 mm

Baffle spacing
(center to center) 97.6 mm Tube pattern 30 degree
(0.4*Shell ID) triangle

Baffle cut 25%d Tube length (L) 1200 mm

Tube pitch
Baffle count 9 (1.25*Tube OD) 23.81 mm

HEX SIMULATION METHOD 4

ASPEN EXCHANGER
SIMULATED CALCULATION

HEX SIMULATION METHOD 5

 Console: Geomet

The highlighted
part is based on
problem statement

HEX SIMULATION METHOD 6

Console: Errors & Warnings

HEX SIMULATION METHOD 7

 Input:
Process
Data
Fouling resistance
is assumed to be
.00009 since the
value is so low, it
wont effect the
calculation
HEX SIMULATION METHOD 8
Hot Stream Component Cold Stream Component

Property Data

HEX SIMULATION METHOD 9

Exchanger Geometry:
Tubes

HEX SIMULATION METHOD 10

Exchanger Geometry:
Baffles

HEX SIMULATION METHOD 11

Exchanger Geometry:
Geometry Summary

HEX SIMULATION METHOD 12

Exchanger Geometry
Nozzles
The simplest Nozzles dimension was added,
to make warnings go away

HEX SIMULATION METHOD 13

HTRI PROGRAM
SIMULATED CALCULATION

HEX SIMULATION METHOD 14

HEX SIMULATION METHOD 15
HEX SIMULATION METHOD 16
HEX SIMULATION METHOD 17
HEX SIMULATION METHOD 18
HEX SIMULATION METHOD 19
HEX SIMULATION METHOD 20
HEX SIMULATION METHOD 21
HEX SIMULATION METHOD 22
HEX SIMULATION METHOD 23
HEX SIMULATION METHOD 24
HEX SIMULATION METHOD 25
HEX SIMULATION METHOD 26
 HAND
CALCULATION
NTU METHOD

HEX SIMULATION METHOD 27

 HAND CALCULATION
Cold stream (inlet): Ethanol
From problem statement..
Th,out= ?? c= 70 kg/h, Tc,in = 25 , P = 130 psia

Cold Stream : Ethanol

= 70 kg/h
Tc,inlet = 25 C
P = 130 psia

Hot Stream : 50%wt water

50%wt E-Acrylate
Tc,out= ?? Hot stream (inlet)
= 100 kg/h
h = 100 kg/h, Th,in = 70 , P =280 psia Th,inlet = 70 C
50%wt water and 50%wt Ethyl-Acrylate P = 280 psia

HEX SIMULATION METHOD 28

 HAND CALCULATION
Heat Exchanger Specification Data given from HEX
U 90 W/m2.K
TEMA type BEM Material SS 304
As 2.1 m2
Shell pass 1 Tube pass 1
Douter,tube 19.05 mm
Shell ID 162.74 mm Tube OD (D) 19.05 mm
Ltube 1.2 m
Shell thickness 1270 mm Tube thickness 1.65 mm

Baffle spacing
(center to center) Tube pattern 30 degree
(0.4*Shell ID) 97.6 mm triangle

Baffle cut 25%d Tube length (L) 1200 mm

Tube pitch
Baffle count 9 (1.25*Tube OD) 23.81 mm

HEX SIMULATION METHOD 29

 HAND CALCULATION
We apply NTU Methodto determine the outlet
temperature of both stream, heat transfer rate,
and number of tubes.
NTU Method is the determination of the heat
transfer rate and the outlet temperatures of the
hot and cold fluids.

We know all inlet parameters***

HEX exists know area A, U, Ltube, Dtube

HEX SIMULATION METHOD 30
 STEPS OF NTU METHOD
HEX exists know area A, U, Ltube, Dtube Number of tubes

From problem statement As = nDL

Properties of fluids
Specific heat capacities

max = Crate,minTmax
Find NTU, Capacity ratio
heat transfer
effectiveness Either from graph or
formula

Tc,out ,Th,out =
HEX SIMULATION METHOD 31
 HAND CALCULATION
Assumption:
Steady state
The heat exchanger is well insulated so that heat
loss to the surroundings is negligible
Changes in the kinetic and potential energies of
fluid streams are negligible
Fluid properties are constant
Properties:
-Hot stream at 70 C , Cp,hot =???
Analysis
-Cold stream at 25 C , Cp,cold = ???
HEX SIMULATION METHOD 32
 HAND CALCULATION
To determine the specific heat capacity of Ethyl Acrylate

Cp,E-Acrylate

HEX SIMULATION METHOD 33

 HAND CALCULATION
To determine the specific heat capacity of water

Cp,water

70

HEX SIMULATION METHOD 34

 HAND CALCULATION
We
need Interpolation
to find the specific heat capacity of water at 70

Temperature Cp,water (kJ/kg.K) =

(
50
50 4.18
4.18
70 ???
70 ??? Cp,water@70 = 4.188 kJ/kg.K
75 4.19
75 4.19

HEX SIMULATION METHOD 35

 HAND CALCULATION
Calculate the specific heat capacity of mixture by
using the formula below

Cp,mixture = ; X = mass fraction

Cp,mixture = XE-AcrylateCp,E-Acrylate + XwaterCp,water
Cp,mixture = (0.5x1.96 kJ/kg.K) + (0.5*4.188 kJ/kg.K)

Cp,mixture = 3.074 kJ/kg.K

HEX SIMULATION METHOD 36

 HAND CALCULATION
To determine the specific heat capacity of ethanol

Cp,ethanol

HEX SIMULATION METHOD 37

 HAND CALCULATION ANALYSIS
Now we have
Cp,cold,ethanol = 2.46 kJ/kg.K = 70 kg/h
Cp,hot,mixture = 3.074 kJ/kg.K = 100 kg/h

Crate = mass flow rate * heat capacity

Crate,cold = * Cp,cold = 70 kg/h *(1h/3600s) * 2.46 kJ/kg.K

Crate,hot = * Cp,hot = 100 kg/h *(1h/3600s) * 3.074 kJ/kg.K

HEX SIMULATION METHOD 38

 HAND CALCULATION

Crate,hot = 0.0854 kW/K Cmax

Crate,cold = 0.0478 kW/K Cmin

Limiting of the maximum heat transfer rate

max = CminTmax ; Tmax = Thot,in Tcold,in

HEX SIMULATION METHOD 39

 HAND CALCULATION

Mass Balance: in out = 0 (steady state)

Cold stream; cold,in = cold,out = cold = 70 kg/hr
Hot stream; hot,in = hot,out = hot = 100 kg/hr

Energy Balance: in out = 0

max = CminTmax = Crate,cold*(Thot,in Tcold,in )

max = 0.0478 kW/K*(70 25)K

max = 2.151 kW
HEX SIMULATION METHOD 40
 HAND CALCULATION
Limiting of both stream from energy balance..
Energy Balance: in out = 0

max = hCh(Th,in-Th,out) = cCc(Tc,out Tc,in)

Crate,hot Crate,cold

Tc,out = Tc,in + Th,out = Th,in -

HEX SIMULATION METHOD 41

 HAND CALCULATION
Tc,out = Tc,in + = 25 +

Tc,out = 70 Temperature of cold stream not should be

more than 70

Th,out = Th,in - = 70 -

Th,out = 44.8 Temperature of hot stream not should be

lower than 44.8

HEX SIMULATION METHOD 42

 HAND CALCULATION
From given data
U 90 W/m2.K

As 2.1 m2 To find number of tubes in HEX

Douter,tube 19.05 mm
As = nDL ; n =number of tubes
Ltube 1.2 m

As = nDL
2.1 m2 = n(19.05 mm)(1.2 m)
n = 29.24 tubes 30 tubes

HEX SIMULATION METHOD 43

 HAND CALCULATION
From given data
U 90 W/m2.K
By using NTU method;
As 2.1 m2
NTU = =
Douter,tube 19.05 mm

Ltube 1.2 m
Crate,cold = 0.0478 kW/K

NTU =

NTU = 3.95

HEX SIMULATION METHOD 44

 HAND CALCULATION
To determine heat transfer effectiveness
0.56 =

NTU = 3.95

Capacity ratio c =

c = 0.56
NTU
So, = 0.93
HEX SIMULATION METHOD 45
 HAND CALCULATION
Or the other method to determine the heat
transfer effectiveness
From relation in case of 1 tube pass and 1 shell
pass with counter flow,

NTU = 3.95
c = 0.56

0.92 Nearly with the effectiveness value

from the graph from the previous slide
HEX SIMULATION METHOD 46
 HAND CALCULATION
The definition of the heat transfer effectiveness..

= 0.93

max = 2.151 kW
=

= 0.93 * 2.151 kW
= 2 kW

HEX SIMULATION METHOD 47

 HAND CALCULATION
Again, from the energy balance
Energy Balance: in out = 0

actual = hCh(Th,in-Th,out) = cCc(Tc,out Tc,in)

Crate,hot Crate,cold

Tc,out = Tc,in + Th,out = Th,in -

HEX SIMULATION METHOD 48

 HAND CALCULATION
Tc,out = Tc,in + = 25 +

Tc,out = 66.8 Temperature of cold stream not

more than 70

Th,out = Th,in - = 70 -

Temperature of hot stream not

Th,out = 46.58 lower than 44.8

HEX SIMULATION METHOD 49

HAND CALCULATION SUMMARY

Cp,cold,ethanol = 2.46 kJ/kg.K

= 2 kW

Th,out = 46.58
Tc,out = 66.8
n = 29.24 tubes 30 tubes

HEX SIMULATION METHOD 50

 RESULTS
COMPARISON
SUMMARY

HEX SIMULATION METHOD 51

 HEAT EXCHANGER
Why we have to use NTU method?
- Know Area A, Good when heat exchangers are available but need to
determine flow conditions, Simulation method
Fluid allocation: Which fluid should be on the tube/shell side
Why?
- Tube side: High pressure stream, fluid special metallurgy (both are
economic reason/construction), Stream exhibiting highest fouling (avoid low
flow for prevent solid participate)
- Shell side: More viscous fluid (Economic for operating cost), Lower flow
rate (Easy to clean than tube side)
Why 30 degrees triangular pattern? (Tube layout
pattern)
- A triangular pattern produces high turbulence and therefore a high heat-
transfer coefficient.

HEX SIMULATION METHOD 52

 RESULTS COMPARISON
Results Aspen Exchanger Hand calculation HTRI
Number of tubes 31 30 30
Temperature Out (Hot) 46.06C 44.58C 39.5C
Temperature Out (Cold) 64.43 C 66.8C 65.44C
Specific Heat (Hot) 3.116 kJ/kgC 3.074 kJ/kgC 3.074 kJ/kgC

Specific Heat (Cold) 2.463 kJ/kgC 2.46 kJ/kgC 2.46 kJ/kgC

Actual heat transfer rate 2.1 kW 2 kW 2.5 kW

Overall Transfer Heat 89.9 W/mK 90 W/mK 90 W/mK
Coefficient

HEX SIMULATION METHOD 53

 RESULTS COMPARISON
- Due to the different references. HTRI and
Aspen Exchanger are different program
which their own company so that make a
ll data have a slightly difference.
- The hand calculation might be differ from
those 2 programs as the heat capacity to
use from book references. Also we round
up and down decimal values.

HEX SIMULATION METHOD 54

 RESULTS COMPARISON
- From our results there are not much
different for all data
- Those 2 programs would give the overall
heat transfer coefficient as the results..
- The total heat transfer coefficient (U) that
we used to calculate other parameters:
we got it from design and its value does n
ot different much with the results from ot
her two programs
HEX SIMULATION METHOD 55
 THANK YOU
FOR
YOUR ATTENTIONS!
HEX SIMULATION METHOD 56