Rating Heat Exchangers 1

Rating Heat Exchangers

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1.3.9 Rating Heat Exchangers.pdf
2 Rating Heat Exchangers
We ignore the adjust so that
it doesn’t interfere with out
calculations.
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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
Before beginning this workshop you need to have completed the
previous modules.
Process Overview
First Part
Process Overview
Second Part
 Rating Heat Exchangers 5

Building the Simulation

We will be modifying the heat exchanger modeled in the Heat
Integration module. Open the case saved at the end of module and
ignore the Adjust operation.

Modeling Heat Exchangers

In this workshop, we will examine a heat exchanger from the Pre-Heat
Train. Heat exchangers are modelled in HYSYS using one of three
configurations:

• Shell and Tube

• Cooler/Heater
• Liquified Natural Gas (LNG) exchanger

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.

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Heat Exchanger Calculations

The calculations performed by the Heat Exchanger are based on energy
balances for the hot and cold fluids. The following general relation
defines the heat balance of an exchanger.

(1)
(M (H –H ) –Q ) – (M (H – H ) –Q ) = Balan ceError
cold out in cold leak hot in out hot loss

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:

Q = UA ( LM TD )F = M ( H – H ) –Q = M (H –H ) –Q
(2)
t hot in out hot loss cold out in cold leak

where: U = Overall heat transfer coefficient

A = Surface area available for heat transfer

LMTD = Log mean temperature difference

Ft = LMTD correction factor

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Log Mean Temperature Difference (LMTD)

The LMTD is calculated in terms of the temperature approaches
(terminal temperature differences) in the exchanger using the following
equation:

∆T – ∆T (3)
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

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

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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. Break the heat loss curve into regions at point B.

2. Calculate the terminal LMTD for each region.
3. 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.

Available Heat Exchanger Models

There are five shell and tube heat exchanger models available in HYSYS.
The End Point and Weighted models can be used for material and
energy balance for any two-sided heat exchangers. They can also be
used for shell and tube exchanger’s material and energy balance. Steady-
State Rating model is used for rating in steady-state mode as well as in
dynamic simulation.

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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.

Heat Exchanger Rating

Providing detailed heat exchanger to a HYSYS heat exchanger with the
Shell and Tube inlet streams fully defined, HYSYS can calculate the
conditions of the outlet streams. HYSYS iterates on the outlet
temperatures until the heat balance is satisfied. Pressure drops are
determined from the geometry.

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We need to break the Kerosene_PA return connection to the Heat

Exchanger.

When using the Rating mode the Duty can not be fixed, that means that
the Streams entering the Heat Exchanger can not be fixed by the
Column, as they are when exporting the Pump Around.

1. Break the connection of the Kerosene_PA Return stream to the Heat

Exchanger.
2. Go to the Property View of the Heat Exchanger and complete the
Outlet Shell with a stream called Kerosene Out.
3. 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.
4. 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

Some of the physical design specifications of an exchanger must be

supplied on the Sizing page of the Rating tab.

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The Rating tab has the following aspect.

Figure 4

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.

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TEMA - Front End Stationary Head Types

TEMA Types Description
A Channel and Removable Cover
B Bonnet (Integral Cover)
C Channel Integral with TubeSheet and Removable
Cover (removable tube bundle only)
N Channel Integral with TubeSheet and Removable
Cover
D Special High Pressure Closure

TEMA - Shell Types

TEMA Description
E One Pass Shell
F Two Pass Shell with Longitudinal Baffle
G Split Flow
H Double Split Flow
J Divided Flow
K Kettle Type Reboiler
X Cross Flow

TEMA - Rear End Head Types

TEMA Types Description
L Fixed TubeSheet like "A" Stationary Head
M Fixed TubeSheet like "B" Stationary Head
N Fixed Tubesheet like "N" Stationary Head
P Outside Packed Floating Head
S Floating Head with Backing Device
T Pull Through Floating Head
U U-Tube Bundle
W Externally Sealed Floating TubeSheet

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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.

Shell Side Required Information:

• Shell Diameter. Can be specified or calculated from inputted
geometry.
• Number of Tubes per Shell. The number of tubes in one shell
• Tube Pitch. The shortest centre to centre distance between 2
tubes
• Tube Layout Angle. A choice between four different
configurations.
• Shell Fouling. The fouling factor on the shell side.
• Baffle Type. A choice of single, double, triple, or grid.
• Baffle Orientation. A choice between horizontal or vertical.
• Baffle Cut (% Area). The percent of the cross-sectional profile
unobstructed by the baffle.
• Baffle Spacing. The distance between adjacent baffles.

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Tube Side Required Information:

• Tube OD. The outside diameter of the tubes.
• Tube ID. The inside diameter of the tubes.
• Tube Thickness. Usually calculated from the two numbers
inputted above.
• Tube Length. The tube length per shell (one side for a U-tube).
• Tube Fouling. The tube side fouling factor.
• Tube Thermal Conductivity. The thermal conductivity of the
tubes, used in determined the overall heat transfer coefficient, U.
• Tube Wall Cp, and Tube Wall Density. Two physical properties
of the tube material, used only in dynamics.

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:

In this cell... Enter...

Tube Passes per Shell 1
OD (mm) 25
ID (mm) 21
Tube Pitch (mm) 30
Baffle Type Double

6. Go to the Parameters tab and check the Detailed radio button. Note
that the data needed for the simulation changes.

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 Rating Heat Exchangers 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? ______________________

Compare the Kerosene Out stream with the Kerosene_PA Return.

Kerosene Out Kerosene_PA Return

Temperature
Pressure

Completing the heat integration

From the previous exercise, we know that the Kerosene Out and the
Kerosene_PA Return streams have different values, this is because one is
calculated by the Heat Exchanger and the other by the Column,
respectively. To complete the heat integration and close the loop you
need to break the Pump around, since, as said before in Heat Exchange
rating, the outlet streams can not be fixed.

Once you've broken the Pumparound, the data in the Kerosene Streams
will be deleted, it's a good idea to keep the values of Kerosene_PA Return
to provide the Outlet Recycle stream with a starting point. Create a
stream called Kerosene_PA Return Copy and defined it from
Kerosene_PA Return.

1. Go to the Atmosphere Column Property View.

2. Enter the Column Environment.
3. Delete the Kerosene SS Cooler. You will be asked if you want to
delete all elements associated with the Pump Around. Answer NO.
You are also asked if you wish to delete the Kerosene Pa_Rate(Pa)
since it is not required any more. Answer YES.
4. Return to the Main Property View. Answer YES to deleting the
Kerosene PA_Q Cooler.
5. You need to change the specifications for running the column later.
Move to the Monitor page, and click in the Kerosene_PA Duty(Pa)
check box to deactivate it.
6. Add a Kerosene PA_Draw Flow spec of 300 m3/h (45,000 barrels/
day)

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7. Add a Recycle unit and connect the Kerosene Out as the Inlet stream
and the Kerosene_PA Return as the Outlet.
8. In the Numerical page of the Parameters tab, change the Maximum
Iterations to 20.
9. 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.
10. Run the Atmosphere column.

What is the Total NL-Solver Iterations? _________________________________

This data is shown in the window in the right down corner.

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 Look at your simulation and decide where to place a single recycle to
locations and imagine the converge the case.
HYSYS calculation
sequence.

How many iterations did you need? ___________________________________

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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 85°C (185°F), can this heat exchanger be used?

The TEMA definition of this exchanger is A.E.L. The dimensions are

given here:

Tube length (m) 5

Number of Tubes 150

Baffle Type single

All other parameters are the HYSYS default values

What is the temperature of To Desalter using this exchanger? _____________

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 0.0001°C-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? _______________

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