-
Browse Book Series
- Adhesion and Adhesives: Fundamental and Applied Aspects
- Advances in Additive Manufacturing Technologies
- Advances in Antenna, Microwave and Communication Engineering
- Advances in Biofeedstocks and Biofuels
- Advances in Cyber Security
- Advances in Data Engineering and Machine Learning
- Advances in Disease Diagnosis, Drug Delivery and Treatment
- Advances in E-Mobility
- Advances in Hydrogen Production and Storage
- Advances in Intelligent and Scientific Computing (AISC)
- Advances in Learning Analytics for Intelligent Cloud-IoT Systems
- Advances in Membrane Processes
- Advances in Nanotechnology and Applications
- Advances in Natural Gas Engineering
- Advances in Pipes and Pipelines
- Advances in Production Engineering
- Advances in Solar Cell Materials and Storage
- Applied Functional Materials
- Artificial Intelligence and Soft Computing for Industrial Transformation
- Astrobiology Perspectives on Life in the Universe
- Bioprocessing in Food Science
- Computational Intelligence and Biomedical Engineering
- Concise Introductions to AI and Data Science
- Cyber Systems and Quantum Engineering
- Decentralized Systems and Next-Generation Internet
- Diatoms: Biology and Applications
- Digital Convergence in Engineering Systems
- Emerging Trends in Medicinal and Pharmaceutical Chemistry
- Engineering Systems Design for Sustainable Development
- Fintech in a Sustainable Digital Society
- Industry 5.0 Transformation Applications
- Infectious and Rare Diseases
- Innovations in Materials and Manufacturing
- Leading-Edge Breakthroughs in Artificial Intelligence
- Machine Learning in Biomedical Science and Healthcare Informatics
- Marine Nanoscience and Nanotechnology
- Materials Degradation and Failure
- Mathematics and Computer Science
- Next-Generation Computing and Communication Engineering
- Performability Engineering Series
- Rotating Machinery Fundamentals and Advances
- Studies in Computational Intelligence and Smart Technologies
- Sustainable Computing and Optimization
Browse Subject Areas
For Authors
Submit a ProposalPetroleum Refining Design and Applications Handbook Volume 4
 | Heat Transfer, Pinch Analysis and Process Safety Incidents Edited by A. Kayode Coker Copyright: 2023 | Status: Published ISBN: 9781119827528 | Hardcover | 1056 pages Price: $295 USD  |
One Line Description
The fourth volume of a multi-volume set of the most comprehensive and up-to-date coverage of the advances of petroleum refining designs and applications, written by one of the world’s most well-known process engineers, this is a must-have for any chemical, process, or petroleum engineer.
Audience
Petroleum, chemical, and process engineers, petroleum and chemical engineering students, engineers and technicians working in petroleum refining, other engineers and technicians in the oil and gas industry, and engineers working towards Professional Engineering qualifications
Petroleum, chemical, and process engineers, petroleum and chemical engineering students, engineers and technicians working in petroleum refining, other engineers and technicians in the oil and gas industry, and engineers working towards Professional Engineering qualifications
Description
This fourth volume in the Petroleum Refining set, this book continues the most up-to-date and comprehensive coverage of the most significant and recent changes to petroleum refining, presenting the state-of-the-art to the engineer, scientist, or student.
This book provides the design of heat exchanger equipment, crude oil fouling in pre-heat train exchangers, crude oil fouling models, fouling mitigation and monitoring, prevention and control of liquid and gas side fouling, using the Excel spreadsheet and UniSim design software for the design of shell and tube heat exchangers, double pipe heat exchangers, air-cooled exchangers, heat loss tracing for process piping, pinch analysis for hot and cold utility targets and process safety incidents involving these equipment items and pertinent industrial case studies.
Use of UniSim Design (UniSim STE) software is illustrated in further elucidation of the design of shell and tube heat exchangers, condensers, and UniSim ExchangerNet R470 for the design of heat exchanger networks using pinch analysis. This is important for determining minimum cold and hot utility requirements, composite curves of hot and cold streams, the grand composite curve, the heat exchanger network, and the relationship between operating cost index target and the capital cost index target against ΔTmin.
Useful as a textbook, this is also an excellent, handy go-to reference for the veteran engineer, a volume no chemical or process engineering library should be without. Written by one of the world’s foremost authorities, this book sets the standard for the industry and is an integral part of the petroleum refining renaissance. It is truly a must-have for any practicing engineer or student in this area.
Back to Top
This fourth volume in the Petroleum Refining set, this book continues the most up-to-date and comprehensive coverage of the most significant and recent changes to petroleum refining, presenting the state-of-the-art to the engineer, scientist, or student.
This book provides the design of heat exchanger equipment, crude oil fouling in pre-heat train exchangers, crude oil fouling models, fouling mitigation and monitoring, prevention and control of liquid and gas side fouling, using the Excel spreadsheet and UniSim design software for the design of shell and tube heat exchangers, double pipe heat exchangers, air-cooled exchangers, heat loss tracing for process piping, pinch analysis for hot and cold utility targets and process safety incidents involving these equipment items and pertinent industrial case studies.
Use of UniSim Design (UniSim STE) software is illustrated in further elucidation of the design of shell and tube heat exchangers, condensers, and UniSim ExchangerNet R470 for the design of heat exchanger networks using pinch analysis. This is important for determining minimum cold and hot utility requirements, composite curves of hot and cold streams, the grand composite curve, the heat exchanger network, and the relationship between operating cost index target and the capital cost index target against ΔTmin.
Useful as a textbook, this is also an excellent, handy go-to reference for the veteran engineer, a volume no chemical or process engineering library should be without. Written by one of the world’s foremost authorities, this book sets the standard for the industry and is an integral part of the petroleum refining renaissance. It is truly a must-have for any practicing engineer or student in this area.
Back to Top
Author / Editor Details
A. Kayode Coker PhD, is Engineering Consultant for AKC Technology, an Honorary Research Fellow at the University of Wolverhampton, U.K., a former Engineering Coordinator at Saudi Aramco Shell Refinery Company (SASREF) and Chairman of the department of Chemical Engineering Technology at Jubail Industrial College, Saudi Arabia. He has been a chartered chemical engineer for more than 30 years. He is a Fellow of the Institution of Chemical Engineers, U.K. (C. Eng., FIChemE), and a senior member of the American Institute of Chemical Engineers (AIChE). He holds a B.Sc. honors degree in Chemical Engineering, a Master of Science degree in Process Analysis and Development and Ph.D. in Chemical Engineering, all from Aston University, Birmingham, U.K., and a Teacher’s Certificate in Education at the University of London, U.K. He has directed and conducted short courses extensively throughout the world and has been a lecturer at the university level. His articles have been published in several international journals. He is an author of six books in chemical engineering, a contributor to the Encyclopedia of Chemical Processing and Design, Vol 61 and a certified train - the mentor trainer. A Technical Report Assessor and Interviewer for chartered chemical engineers (IChemE) in the U.K. He is a member of the International Biographical Centre in Cambridge, U.K. (IBC) as Leading Engineers of the World for 2008. Also, he is a member of International Who’s Who of ProfessionalsTM and Madison Who’s Who in the U.S.
A. Kayode Coker PhD, is Engineering Consultant for AKC Technology, an Honorary Research Fellow at the University of Wolverhampton, U.K., a former Engineering Coordinator at Saudi Aramco Shell Refinery Company (SASREF) and Chairman of the department of Chemical Engineering Technology at Jubail Industrial College, Saudi Arabia. He has been a chartered chemical engineer for more than 30 years. He is a Fellow of the Institution of Chemical Engineers, U.K. (C. Eng., FIChemE), and a senior member of the American Institute of Chemical Engineers (AIChE). He holds a B.Sc. honors degree in Chemical Engineering, a Master of Science degree in Process Analysis and Development and Ph.D. in Chemical Engineering, all from Aston University, Birmingham, U.K., and a Teacher’s Certificate in Education at the University of London, U.K. He has directed and conducted short courses extensively throughout the world and has been a lecturer at the university level. His articles have been published in several international journals. He is an author of six books in chemical engineering, a contributor to the Encyclopedia of Chemical Processing and Design, Vol 61 and a certified train - the mentor trainer. A Technical Report Assessor and Interviewer for chartered chemical engineers (IChemE) in the U.K. He is a member of the International Biographical Centre in Cambridge, U.K. (IBC) as Leading Engineers of the World for 2008. Also, he is a member of International Who’s Who of ProfessionalsTM and Madison Who’s Who in the U.S.
Back to Top
Table of Contents
Preface
Acknowledgments
21. Heat Transfer
21.1 Introduction
21.1.1 Types of Heat Transfer Equipment Terminology
21.2 Details of Exchange Equipment
Assembly and Arrangement
Construction Codes
Thermal Rating Standards
Details of Stationary Heads
Exchanger Shell Types
21.3 Factors Affecting Shell Selection
21.3.1 Details of Rear End Heads
21.4 Common Combinations of Shell and Tube Heat Exchangers
AES
BEM
AEP
CFU
AKT
AJW
Tubes
21.5 Bending of Tubing
Baffles
Tube Side Baffles (TEMA uses Pass Partition Plates
21.6 Shell-Side Baffles and Tube Supports
Tie Rods
Tubesheets
Tube Joints in Tubesheets
Example 21.1 Determine Outside Heat Transfer Area of Heat Exchanger Bundle
21.7 Tube Counts in Shells
Applications of Tube Pitch Arrangements
21.8 Exchanger Surface Area
Number of Tubes
Exact Distance Between Faces of Tubesheets
Net Effective Tube Length
Exact Baffle Spacing
Impingement Baffle Location
Effective Tube Surface
Effective Tube Length for U-Tube Heat Exchangers
21.9 Tube Vibration
21.9.1 Vibration Mechanisms
21.9.2 Treatment of Vibration Problems
21.9.3 Corrective Measures
Example 21.2 Use of U-Tube Area Chart
Nozzle Connections to Shell and Heads
21.10 Types of Heat Exchange Operations
21.10.1 Thermal Design
21.10.2 Temperature Difference: Two Fluid Transfer
Example 21.3 One Shell Pass, Two Tubes Passes Parallel-Counterflow Exchanger Cross, After Murty
21.10.3 Mean Temperature Difference or Log Mean Temperature Difference
21.10.4 Log Mean Temperature Difference Correction Factor, F
21.10.5 Correction for Multipass Flow Through Heat Exchangers
Example 21.4 Performance Examination for Exit Temperature of Fluids
Example 21.5 Calculation of Weighted MTD
Example 21.6 Calculation of LMTD and Correction
Example 21.7 Calculate the LMTD
Solution
Temperature for Fluid Properties Evaluation–Caloric Temperature
Tube Wall Temperature
Example 21.8 Heating of Glycerin in a Multipass Heat Exchanger
Solution
21.11 The Effectiveness—NTU Method
Example 21.9 Heating Water in a Counter Current Flow Heat Exchanger
Solution
Example 21.10 LMTD and ε-NTU Methods
Solution
Example 21.11
Solution
21.12 Pressure Drop, Δp
21.12.1 Frictional Pressure Drop
21.12.2 Factors Affecting Pressure Drop (Δp)
Tube-Side Pressure Drop, Δpf
Shell-Side Pressure Drop Δpf
Shell Nozzle Pressure Drop (Δpnoz)
Total Shell-Side Pressure Drop, Δptotal
21.13 Heat Balance
Heat Load or Duty
Example 21.12 Heat Duty of a Condenser with Liquid Subcooling
21.14 Transfer Area
Over Surface and Over Design
21.15 Fouling of Tube Surface
21.15.1 Crude Oil Fouling In Pre-Heat Train Exchangers
Crude Type
Crude Blending
Crude Oil Fouling Models
Tubular Exchanger Manufacturers' Association (TEMA) and Model Approach for Fouling Resistance, Rf of Crude Oil Pre-Heat Trains
Fouling Mitigation and Monitoring
HIS smartPM Software
Effect of Fouling on Exchanger Heat Transfer Performance
Example 21.13
Solution
Example 21.14
Solution
Prevention and Control of Liquid-Side Fouling
Prevention and Control of Gas-Side Fouling
UnSim Design HEX Network Digital Twin Model
Selecting Tube Pass Arrangement
Super Clean System Technology
21.16 Exchanger Design
21.16.1 Overall Heat Transfer Coefficients for Plain or Bare Tubes
Example 21.15 Calculation of Overall Heat Transfer Coefficient from Individual Components
Approximate Values for Overall Heat Transfer Coefficients
Simplified Equations
Film Coefficients With Fluids Outside Tubes Forced Convection
Viscosity Correction Factor (μ/μw)0.14
Heat Transfer Coefficient for Water, hi
Shell-Side Equivalent Diameter
Shell-Side Velocities
Design and Rating of Heat Exchangers
Rating of a Shell and Tube Heat Exchanger
Design of a Heat Exchanger
Design Procedure for Forced Convection Heat Transfer in Exchanger Design
Design Programs for a Shell and Tube Heat Exchanger
Example 21.16 Convection Heat Transfer Exchanger Design
Shell and Tube Heat Exchanger Design Procedure (S.I. units)
Tubes
Tube Side Pass Partition Plate
Calculations of Tube Side Heat Transfer Coefficient
Example 21.17 Design of a Shell and Tube Heat Exchanger (S.I. units) Kern's Model
Solution
Modified Design
Shell-Side Pressure Drop, Δps
The Pressure Drop for Plain Tube Exchangers
Tube Size
Tube-Side Condensation Pressure Drop
Shell-Side
Unbaffled Shells
Segmental Baffles in Shell
Alternate: Segmental Baffles Pressure Drop
A Case Study Using UniSim® Shell-Tube Exchanger (STE) Modeler
Solution
Shell and Tube Heat Exchangers: Single Phase
Effect of Manufacturing Clearances on the Shell-Side Flow
Bell-Delaware Method
Ideal Shell-Side Film Heat Transfer Coefficient
Shell-Side Film Heat Transfer Coefficient Correction Factors
Baffle Cut and Spacing, Jc
Baffle Leakage Effects, JL
Bundle and Partition Bypass Effects, Jb
Variations in Baffle Spacing, Js
Temperature Gradient for Laminar Flow Regime, Jr
Overall Heat Transfer Coefficient, U
Shell-Side Pressure (Δp)
Tube Pattern
Accuracy of Correlations Between Kern's Method and the Bell-Delaware's Method
Specification Process Data Sheet, Design, and Construction of Heat Exchangers
Rapid Design Algorithms for Shell and Tube and Compact Heat Exchangers: Polley et al. [173]
Fluids in the Annulus of Tube-in-Pipe or Double Pipe Heat Exchanger, Forced Convection
Finned Tube Exchangers
Low Finned Tubes, 16 and 19 Fins/In.
Finned Surface Heat Transfer
Economics of Finned Tubes
Tubing Dimensions
Design for Heat Transfer Coefficients by Forced Convection Using Radial Low-Fin
Tubes in Heat Exchanger Bundles
Pressure Drop in Exchanger Shells Using Bundles of Low Fin Tubes
Tube-Side Heat Transfer and Pressure Drop
Design Procedure for Shell-Side Condensers and Shell-Side Condensation With Gas Cooling of Condensables, Fluid-Fluid Convection Heat Exchange
Vertical Condensation on Low Fin Tubes
Nucleate Boiling Outside Horizontal or Vertical Tubes
Design Procedure for Boiling, Using Experimental Data
Double Pipe Finned Tube Heat Exchangers
Finned Side-Heat Transfer
Tube Wall Resistance
Tube-Side Heat Transfer and Pressure Drop
Fouling Factor
Finned Side Pressure Drop
Design Equations for The Rating of A Double Pipe Heat Exchanger
Inner Pipe
Annulus
Vapor Service
Shell-Side Bare Tube
Shell-Side (Finned Tube)
Tube Side Pressure Drop, Δpt
Annulus
Calculation of the Pressure Drop
Effect of Pressure Drop (Δp) on the Original Design
Nomenclature
Example 21.19
Solution
Heat Balance
Pressure Drop Calculations
Tube-Side Δp
Shell-Side Δp
Plate and Frame Heat Exchangers
Design Charts for Plate and Frame Heat Exchangers
Selection
Advantages
Disadvantages
Example 21.20
Solution
Pressure Drop Calculations
Cooling Water Side Pressure Drop
Air-Cooled Heat Exchangers
Induced Draft
Forced Draft
General Application
Advantages-Air-Cooled Heat Exchangers
Disadvantages
Bid Evaluation
Design Consideration (Continuous Service)
Mean Temperature Difference
Design Procedure for Approximation
Tube Side Fluid Temperature Control
Rating Method for Air Cooler Exchangers
The Equations
The Air Side Pressure Drop, Δpa (in. H2O)
Example 21.26
Solution
Operations of Air Cooled Heat Exchangers
Monitoring of Air-Cooled Heat Exchangers
Boiling and Vaporization
Boiling
Vaporization
Vaporization During Flow
Vaporization in horizontal Shell; Natural Circulation
Pool and Nucleate Boiling—General Correlation for Heat Flux and Critical Temperature Difference
Example 21.27
Solution
Reboiler Heat Balance
Example 21.28 Reboiler Heat Duty after Kern
Solution
Kettle Horizontal Reboilers
Maximum Bundle Heat Flux
Nucleate or Alternate Designs Procedure
Kettle Reboiler—Horizontal Shells
Horizontal Kettle Reboiler Disengaging Space
Kettle Horizontal Reboilers, Alternate Design
Boiling: Nucleate Natural Circulation (Thermosyphon) Inside Vertical Tubes or Outside Horizontal Tubes
Gilmour Method Modified
Suggested Procedure for Vaporization with Sensible Heat Transfer
Procedure for Horizontal Natural Circulation Thermosyphon Reboiler
Kern Method
Vaporization Inside Vertical Tubes; Natural Thermosyphon Action
Fair's Method
Process Requirements
Preliminary Design
Circulation Rate
Heat Transfer—Stepwise Method
Heat Transfer: Simplified Method
Design Comments
Example 21.29 C3 Splitter Reboiler
Solution
Preliminary Design
Circulation Rate
Heat Transfer Rate—Stepwise Method
Heat Transfer Rate—Simplified Method
Example 21.30 Cyclohexane Column Reboiler
Solution
Preliminary Design
Circulation Rate
Heat Transfer Rate—Simplified Method
Kern's Method Stepwise
Design Considerations
Other Design Methods
Example 21.32 Vertical Thermosyphon Reboiler, Kern's Method
Solution
Calculation of Tube Side Film Coefficient
Simplified Hajek Method—Vertical Thermosyphon Reboiler
General Guides for Vertical Thermosyphon Reboilers Design
Example 21.32 Hajek's Method—Vertical Thermosyphon Reboiler
Physical Data Required
Variables to be Determined
Determine Overall Coefficient at Maximum Flux
Determine Overall ΔT at Maximum Flux
Maximum Flat
Flux at Operating Levels Below Maximum
Fouled ΔT at Maximum Flux
Fouled ΔT, To Maintain Plus for 10°F Clean ΔT
Analysis of Data in Figure 21.225
Surface Area Required
Vapor Nozzle Diameter
Liquid Inlet Nozzle Diameter
Design Notes
Reboiling Piping
Film Boiling
Vertical Tubes, Boiling Outside, Submerged
Common Reboiler Problems
Heat Exchanger Design with Computers
Functionality
Physical Properties
UniSim Heat Exchanger Model Formulations
Case Study 1: Kettle Reboiler Simulation Using UniSim STE
Nozzle Data
Process Data
Case Study 2: Thermosyphon Reboiler Simulation Using UniSim STE
Process Data (SI Units)
Solution
Troubleshooting of Shell and Tube Exchanger
Maintenance of Heat Exchangers
Disassembly for Inspection or Cleaning
Locating Tube Leaks
Hydrocarbon Leaks
Pass Partition Failure
Water Hammer
General Symptoms in Shell and Tube Heat Exchangers
Case Studies of Heat Exchanger Explosion Hazard Incidents
A Case Study (Courtesy of U.S. Chemical Safety and Hazard Investigation Board)
TESORO ANACORTES REFINERY, ANACORTES, WASHINGTON
Process Conditions of the B and E Hear Exchangers
US Chemical Safety Board (CBS) Findings
Recommendations
Maintenance Procedures
References
22. Energy Management and Pinch Technology
22.1 Introduction
22.2 Waste Heat Recovery
22.2.1 Steam Distribution
22.2.2 Design for Energy Efficiency
22.2.3 Energy Management Opportunities
22.3 Process Integration and Heat Exchanger Networks
22.3.1 Application of Process Integration
22.4 Pinch Technology
22.4.1 Heat Exchanger Network Design
22.4.2 Energy and Capital Targeting and Optimization
22.4.3 Optimization Variables
22.4.4 Optimization of the Use of Utilities (Utility Placement)
22.4.5 Heat Exchanger Network Revamp
22.5 Energy Targets
22.5.1 Heat Recovery for Multiple Systems
Example 22.1: Setting Energy Targets and Heat Exchanger Network
Solution
22.6 The Heat Recovery Pinch and Its Significance
22.7 The Significance of the Pinch
22.8 A Targeting Procedure: The Problem Table Algorithm
22.9 The Grand Composite Curve
22.9.1 Placing Utilities Using the Grand Composite Curve
22.10 Stream Matching at the Pinch
22.10.1 The Pinch Design Approach to Inventing a Network
22.11 Heat Exchanger Network Design
Example 22.2
Solution
22.11.1 Stream Splitting
Example 22.3 (Source: Seider et al., Product and Process Design Principles—Synthesis, Analysis, and Evaluation 3rd Ed. Wiley 2009 [26])
Solution
Example 22.4 [Source: Manufacture of cellulose acetate fiber by Robins Smith
(Chemical Process Design and Integration, John Wiley 2007 [34])
Solution
22.12 Heat Exchanger Area Targets
Example 22.5 (Source: R. Smith, Chemical Process Design, Mc Graw-Hill, 1995 [20])
Solution
Example 22.6
Solution
22.13 HEN Simplification
Example 22.7: Test Case 3, TC3 Linnhoff and Hindmarch
Solution
22.13.1 Heat Load Paths
22.14 Number of Shell Target
22.14.1 Implications for HEN Design
22.15 Capital Cost Targets
22.16 Energy Targeting
22.16.1 Supertargeting or ΔTmin Optimization
Example 22.8: Cost Targeting
Solution
Example 22.9: HEN for Maximum Energy Recovery (Warren D. Seider et al. [26])
Solution
22.17 Targeting and Design for Constrained Matches
22.18 Heat Engines and Heat Pumps for Optimum Integration
22.18.1 Appropriate Integration of Heat Engines
22.18.2 Appropriate Integration of Heat Pumps
22.18.3 Opportunities for Placement of Heat Pumps
22.18.4 Appropriate Placement of Compression and Expansion in Heat Recovery Systems
22.19 Pressure Drop and Heat Transfer in Process Integration
22.20 Total Site Analysis
22.21 Applications of Process Integration
22.22 Sitewide Integration
22.23 Flue Gas Emissions
22.24 Pitfalls in Process Integration
Glossary of Terms
Summary and Heuristics
Nomenclature
References
Bibliography
Appendix D
Appendix G
Appendix H
Glossary of Petroleum and Petrochemical Technical Terminologies
About the Author
Index
Back to Top
Preface
Acknowledgments
21. Heat Transfer
21.1 Introduction
21.1.1 Types of Heat Transfer Equipment Terminology
21.2 Details of Exchange Equipment
Assembly and Arrangement
Construction Codes
Thermal Rating Standards
Details of Stationary Heads
Exchanger Shell Types
21.3 Factors Affecting Shell Selection
21.3.1 Details of Rear End Heads
21.4 Common Combinations of Shell and Tube Heat Exchangers
AES
BEM
AEP
CFU
AKT
AJW
Tubes
21.5 Bending of Tubing
Baffles
Tube Side Baffles (TEMA uses Pass Partition Plates
21.6 Shell-Side Baffles and Tube Supports
Tie Rods
Tubesheets
Tube Joints in Tubesheets
Example 21.1 Determine Outside Heat Transfer Area of Heat Exchanger Bundle
21.7 Tube Counts in Shells
Applications of Tube Pitch Arrangements
21.8 Exchanger Surface Area
Number of Tubes
Exact Distance Between Faces of Tubesheets
Net Effective Tube Length
Exact Baffle Spacing
Impingement Baffle Location
Effective Tube Surface
Effective Tube Length for U-Tube Heat Exchangers
21.9 Tube Vibration
21.9.1 Vibration Mechanisms
21.9.2 Treatment of Vibration Problems
21.9.3 Corrective Measures
Example 21.2 Use of U-Tube Area Chart
Nozzle Connections to Shell and Heads
21.10 Types of Heat Exchange Operations
21.10.1 Thermal Design
21.10.2 Temperature Difference: Two Fluid Transfer
Example 21.3 One Shell Pass, Two Tubes Passes Parallel-Counterflow Exchanger Cross, After Murty
21.10.3 Mean Temperature Difference or Log Mean Temperature Difference
21.10.4 Log Mean Temperature Difference Correction Factor, F
21.10.5 Correction for Multipass Flow Through Heat Exchangers
Example 21.4 Performance Examination for Exit Temperature of Fluids
Example 21.5 Calculation of Weighted MTD
Example 21.6 Calculation of LMTD and Correction
Example 21.7 Calculate the LMTD
Solution
Temperature for Fluid Properties Evaluation–Caloric Temperature
Tube Wall Temperature
Example 21.8 Heating of Glycerin in a Multipass Heat Exchanger
Solution
21.11 The Effectiveness—NTU Method
Example 21.9 Heating Water in a Counter Current Flow Heat Exchanger
Solution
Example 21.10 LMTD and ε-NTU Methods
Solution
Example 21.11
Solution
21.12 Pressure Drop, Δp
21.12.1 Frictional Pressure Drop
21.12.2 Factors Affecting Pressure Drop (Δp)
Tube-Side Pressure Drop, Δpf
Shell-Side Pressure Drop Δpf
Shell Nozzle Pressure Drop (Δpnoz)
Total Shell-Side Pressure Drop, Δptotal
21.13 Heat Balance
Heat Load or Duty
Example 21.12 Heat Duty of a Condenser with Liquid Subcooling
21.14 Transfer Area
Over Surface and Over Design
21.15 Fouling of Tube Surface
21.15.1 Crude Oil Fouling In Pre-Heat Train Exchangers
Crude Type
Crude Blending
Crude Oil Fouling Models
Tubular Exchanger Manufacturers' Association (TEMA) and Model Approach for Fouling Resistance, Rf of Crude Oil Pre-Heat Trains
Fouling Mitigation and Monitoring
HIS smartPM Software
Effect of Fouling on Exchanger Heat Transfer Performance
Example 21.13
Solution
Example 21.14
Solution
Prevention and Control of Liquid-Side Fouling
Prevention and Control of Gas-Side Fouling
UnSim Design HEX Network Digital Twin Model
Selecting Tube Pass Arrangement
Super Clean System Technology
21.16 Exchanger Design
21.16.1 Overall Heat Transfer Coefficients for Plain or Bare Tubes
Example 21.15 Calculation of Overall Heat Transfer Coefficient from Individual Components
Approximate Values for Overall Heat Transfer Coefficients
Simplified Equations
Film Coefficients With Fluids Outside Tubes Forced Convection
Viscosity Correction Factor (μ/μw)0.14
Heat Transfer Coefficient for Water, hi
Shell-Side Equivalent Diameter
Shell-Side Velocities
Design and Rating of Heat Exchangers
Rating of a Shell and Tube Heat Exchanger
Design of a Heat Exchanger
Design Procedure for Forced Convection Heat Transfer in Exchanger Design
Design Programs for a Shell and Tube Heat Exchanger
Example 21.16 Convection Heat Transfer Exchanger Design
Shell and Tube Heat Exchanger Design Procedure (S.I. units)
Tubes
Tube Side Pass Partition Plate
Calculations of Tube Side Heat Transfer Coefficient
Example 21.17 Design of a Shell and Tube Heat Exchanger (S.I. units) Kern's Model
Solution
Modified Design
Shell-Side Pressure Drop, Δps
The Pressure Drop for Plain Tube Exchangers
Tube Size
Tube-Side Condensation Pressure Drop
Shell-Side
Unbaffled Shells
Segmental Baffles in Shell
Alternate: Segmental Baffles Pressure Drop
A Case Study Using UniSim® Shell-Tube Exchanger (STE) Modeler
Solution
Shell and Tube Heat Exchangers: Single Phase
Effect of Manufacturing Clearances on the Shell-Side Flow
Bell-Delaware Method
Ideal Shell-Side Film Heat Transfer Coefficient
Shell-Side Film Heat Transfer Coefficient Correction Factors
Baffle Cut and Spacing, Jc
Baffle Leakage Effects, JL
Bundle and Partition Bypass Effects, Jb
Variations in Baffle Spacing, Js
Temperature Gradient for Laminar Flow Regime, Jr
Overall Heat Transfer Coefficient, U
Shell-Side Pressure (Δp)
Tube Pattern
Accuracy of Correlations Between Kern's Method and the Bell-Delaware's Method
Specification Process Data Sheet, Design, and Construction of Heat Exchangers
Rapid Design Algorithms for Shell and Tube and Compact Heat Exchangers: Polley et al. [173]
Fluids in the Annulus of Tube-in-Pipe or Double Pipe Heat Exchanger, Forced Convection
Finned Tube Exchangers
Low Finned Tubes, 16 and 19 Fins/In.
Finned Surface Heat Transfer
Economics of Finned Tubes
Tubing Dimensions
Design for Heat Transfer Coefficients by Forced Convection Using Radial Low-Fin
Tubes in Heat Exchanger Bundles
Pressure Drop in Exchanger Shells Using Bundles of Low Fin Tubes
Tube-Side Heat Transfer and Pressure Drop
Design Procedure for Shell-Side Condensers and Shell-Side Condensation With Gas Cooling of Condensables, Fluid-Fluid Convection Heat Exchange
Vertical Condensation on Low Fin Tubes
Nucleate Boiling Outside Horizontal or Vertical Tubes
Design Procedure for Boiling, Using Experimental Data
Double Pipe Finned Tube Heat Exchangers
Finned Side-Heat Transfer
Tube Wall Resistance
Tube-Side Heat Transfer and Pressure Drop
Fouling Factor
Finned Side Pressure Drop
Design Equations for The Rating of A Double Pipe Heat Exchanger
Inner Pipe
Annulus
Vapor Service
Shell-Side Bare Tube
Shell-Side (Finned Tube)
Tube Side Pressure Drop, Δpt
Annulus
Calculation of the Pressure Drop
Effect of Pressure Drop (Δp) on the Original Design
Nomenclature
Example 21.19
Solution
Heat Balance
Pressure Drop Calculations
Tube-Side Δp
Shell-Side Δp
Plate and Frame Heat Exchangers
Design Charts for Plate and Frame Heat Exchangers
Selection
Advantages
Disadvantages
Example 21.20
Solution
Pressure Drop Calculations
Cooling Water Side Pressure Drop
Air-Cooled Heat Exchangers
Induced Draft
Forced Draft
General Application
Advantages-Air-Cooled Heat Exchangers
Disadvantages
Bid Evaluation
Design Consideration (Continuous Service)
Mean Temperature Difference
Design Procedure for Approximation
Tube Side Fluid Temperature Control
Rating Method for Air Cooler Exchangers
The Equations
The Air Side Pressure Drop, Δpa (in. H2O)
Example 21.26
Solution
Operations of Air Cooled Heat Exchangers
Monitoring of Air-Cooled Heat Exchangers
Boiling and Vaporization
Boiling
Vaporization
Vaporization During Flow
Vaporization in horizontal Shell; Natural Circulation
Pool and Nucleate Boiling—General Correlation for Heat Flux and Critical Temperature Difference
Example 21.27
Solution
Reboiler Heat Balance
Example 21.28 Reboiler Heat Duty after Kern
Solution
Kettle Horizontal Reboilers
Maximum Bundle Heat Flux
Nucleate or Alternate Designs Procedure
Kettle Reboiler—Horizontal Shells
Horizontal Kettle Reboiler Disengaging Space
Kettle Horizontal Reboilers, Alternate Design
Boiling: Nucleate Natural Circulation (Thermosyphon) Inside Vertical Tubes or Outside Horizontal Tubes
Gilmour Method Modified
Suggested Procedure for Vaporization with Sensible Heat Transfer
Procedure for Horizontal Natural Circulation Thermosyphon Reboiler
Kern Method
Vaporization Inside Vertical Tubes; Natural Thermosyphon Action
Fair's Method
Process Requirements
Preliminary Design
Circulation Rate
Heat Transfer—Stepwise Method
Heat Transfer: Simplified Method
Design Comments
Example 21.29 C3 Splitter Reboiler
Solution
Preliminary Design
Circulation Rate
Heat Transfer Rate—Stepwise Method
Heat Transfer Rate—Simplified Method
Example 21.30 Cyclohexane Column Reboiler
Solution
Preliminary Design
Circulation Rate
Heat Transfer Rate—Simplified Method
Kern's Method Stepwise
Design Considerations
Other Design Methods
Example 21.32 Vertical Thermosyphon Reboiler, Kern's Method
Solution
Calculation of Tube Side Film Coefficient
Simplified Hajek Method—Vertical Thermosyphon Reboiler
General Guides for Vertical Thermosyphon Reboilers Design
Example 21.32 Hajek's Method—Vertical Thermosyphon Reboiler
Physical Data Required
Variables to be Determined
Determine Overall Coefficient at Maximum Flux
Determine Overall ΔT at Maximum Flux
Maximum Flat
Flux at Operating Levels Below Maximum
Fouled ΔT at Maximum Flux
Fouled ΔT, To Maintain Plus for 10°F Clean ΔT
Analysis of Data in Figure 21.225
Surface Area Required
Vapor Nozzle Diameter
Liquid Inlet Nozzle Diameter
Design Notes
Reboiling Piping
Film Boiling
Vertical Tubes, Boiling Outside, Submerged
Common Reboiler Problems
Heat Exchanger Design with Computers
Functionality
Physical Properties
UniSim Heat Exchanger Model Formulations
Case Study 1: Kettle Reboiler Simulation Using UniSim STE
Nozzle Data
Process Data
Case Study 2: Thermosyphon Reboiler Simulation Using UniSim STE
Process Data (SI Units)
Solution
Troubleshooting of Shell and Tube Exchanger
Maintenance of Heat Exchangers
Disassembly for Inspection or Cleaning
Locating Tube Leaks
Hydrocarbon Leaks
Pass Partition Failure
Water Hammer
General Symptoms in Shell and Tube Heat Exchangers
Case Studies of Heat Exchanger Explosion Hazard Incidents
A Case Study (Courtesy of U.S. Chemical Safety and Hazard Investigation Board)
TESORO ANACORTES REFINERY, ANACORTES, WASHINGTON
Process Conditions of the B and E Hear Exchangers
US Chemical Safety Board (CBS) Findings
Recommendations
Maintenance Procedures
References
22. Energy Management and Pinch Technology
22.1 Introduction
22.2 Waste Heat Recovery
22.2.1 Steam Distribution
22.2.2 Design for Energy Efficiency
22.2.3 Energy Management Opportunities
22.3 Process Integration and Heat Exchanger Networks
22.3.1 Application of Process Integration
22.4 Pinch Technology
22.4.1 Heat Exchanger Network Design
22.4.2 Energy and Capital Targeting and Optimization
22.4.3 Optimization Variables
22.4.4 Optimization of the Use of Utilities (Utility Placement)
22.4.5 Heat Exchanger Network Revamp
22.5 Energy Targets
22.5.1 Heat Recovery for Multiple Systems
Example 22.1: Setting Energy Targets and Heat Exchanger Network
Solution
22.6 The Heat Recovery Pinch and Its Significance
22.7 The Significance of the Pinch
22.8 A Targeting Procedure: The Problem Table Algorithm
22.9 The Grand Composite Curve
22.9.1 Placing Utilities Using the Grand Composite Curve
22.10 Stream Matching at the Pinch
22.10.1 The Pinch Design Approach to Inventing a Network
22.11 Heat Exchanger Network Design
Example 22.2
Solution
22.11.1 Stream Splitting
Example 22.3 (Source: Seider et al., Product and Process Design Principles—Synthesis, Analysis, and Evaluation 3rd Ed. Wiley 2009 [26])
Solution
Example 22.4 [Source: Manufacture of cellulose acetate fiber by Robins Smith
(Chemical Process Design and Integration, John Wiley 2007 [34])
Solution
22.12 Heat Exchanger Area Targets
Example 22.5 (Source: R. Smith, Chemical Process Design, Mc Graw-Hill, 1995 [20])
Solution
Example 22.6
Solution
22.13 HEN Simplification
Example 22.7: Test Case 3, TC3 Linnhoff and Hindmarch
Solution
22.13.1 Heat Load Paths
22.14 Number of Shell Target
22.14.1 Implications for HEN Design
22.15 Capital Cost Targets
22.16 Energy Targeting
22.16.1 Supertargeting or ΔTmin Optimization
Example 22.8: Cost Targeting
Solution
Example 22.9: HEN for Maximum Energy Recovery (Warren D. Seider et al. [26])
Solution
22.17 Targeting and Design for Constrained Matches
22.18 Heat Engines and Heat Pumps for Optimum Integration
22.18.1 Appropriate Integration of Heat Engines
22.18.2 Appropriate Integration of Heat Pumps
22.18.3 Opportunities for Placement of Heat Pumps
22.18.4 Appropriate Placement of Compression and Expansion in Heat Recovery Systems
22.19 Pressure Drop and Heat Transfer in Process Integration
22.20 Total Site Analysis
22.21 Applications of Process Integration
22.22 Sitewide Integration
22.23 Flue Gas Emissions
22.24 Pitfalls in Process Integration
Glossary of Terms
Summary and Heuristics
Nomenclature
References
Bibliography
Appendix D
Appendix G
Appendix H
Glossary of Petroleum and Petrochemical Technical Terminologies
About the Author
Index
Back to Top