Petroleum Refining Design and Applications Handbook, Volume 4: Heat Transfer, Pinch Analysis, and Process Safety Incidents

ISBN-13: 9781119827528 / Angielski / Twarda / 2023 / 750 str.

PhD. Coker A. Kayode

Spis treści

Preface xixAcknowledgments xxii21 Heat Transfer 121.1 Introduction 121.1.1 Types of Heat Transfer Equipment Terminology 221.2 Details of Exchange Equipment 19Assembly and Arrangement 19Construction Codes 19Thermal Rating Standards 19Details of Stationary Heads 19Exchanger Shell Types 2021.3 Factors Affecting Shell Selection 2421.3.1 Details of Rear End Heads 2521.4 Common Combinations of Shell and Tube Heat Exchangers 26AES 26BEM 26AEP 27CFU 28AKT 28AJW 28Tubes 2921.5 Bending of Tubing 56Baffles 56Tube Side Baffles (TEMA uses Pass Partition Plates) 5621.6 Shell-Side Baffles and Tube Supports 57Tie Rods 67Tubesheets 67Tube Joints in Tubesheets 69Seal Strips 72Example 21.1 Determine Outside Heat Transfer Area of Heat Exchanger Bundle 73Tubesheets Layouts 7321.7 Tube Counts in Shells 73Applications of Tube Pitch Arrangements 9321.8 Exchanger Surface Area 93Number of Tubes 93Exact Distance Between Faces of Tubesheets 94Net Effective Tube Length 94Exact Baffle Spacing 94Impingement Baffle Location 94Effective Tube Surface 94Effective Tube Length for U-Tube Heat Exchangers 10721.9 Tube Vibration 10721.9.1 Vibration Mechanisms 10921.9.2 Treatment of Vibration Problems 11021.9.3 Corrective Measures 110Example 21.2 Use of U-Tube Area Chart 111Nozzle Connections to Shell and Heads 11221.10 Types of Heat Exchange Operations 11221.10.1 Thermal Design 11221.10.2 Temperature Difference: Two Fluid Transfer 116Example 21.3 One Shell Pass, Two Tubes Passes Parallel-Counterflow Exchanger Cross, After Murty 11721.10.3 Mean Temperature Difference or Log Mean Temperature Difference 12021.10.4 Log Mean Temperature Difference Correction Factor, F 12321.10.5 Correction for Multipass Flow Through Heat Exchangers 133Example 21.4 Performance Examination for Exit Temperature of Fluids 134Example 21.5 Calculation of Weighted MTD 136Example 21.6 Calculation of LMTD and Correction 137Example 21.7 Calculate the LMTD 140Solution 140Temperature for Fluid Properties Evaluation-Caloric Temperature 142Tube Wall Temperature 142Example 21.8 Heating of Glycerin in a Multipass Heat Exchanger 145Solution 14521.11 The Effectiveness--NTU Method 148Example 21.9 Heating Water in a Counter Current Flow Heat Exchanger 148Solution 152Example 21.10 LMTD and epsilon-NTU Methods 154Solution 154Example 21.11 156Solution 15621.12 Pressure Drop, Deltap 15821.12.1 Frictional Pressure Drop 16421.12.2 Factors Affecting Pressure Drop (Deltap) 168Tube-Side Pressure Drop, Deltapf 169Shell-Side Pressure Drop Deltapf 170Shell Nozzle Pressure Drop (Deltap noz) 172Total Shell-Side Pressure Drop, Deltap total 17221.13 Heat Balance 173Heat Load or Duty 173Example 21.12 Heat Duty of a Condenser with Liquid Subcooling 17421.14 Transfer Area 174Over Surface and Over Design 17421.15 Fouling of Tube Surface 17521.15.1 Crude Oil Fouling In Pre-Heat Train Exchangers 199Crude Type 199Crude Blending 199Crude Oil Fouling Models 202Tubular Exchanger Manufacturers' Association (TEMA) and Model Approach for Fouling Resistance, Rf of Crude Oil Pre-Heat Trains 208Fouling Mitigation and Monitoring 209HIS smartPM Software 213Effect of Fouling on Exchanger Heat Transfer Performance 216Example 21.13 216Solution 216Example 21.14 217Solution 217Prevention and Control of Liquid-Side Fouling 218Prevention and Control of Gas-Side Fouling 219UnSim Design HEX Network Digital Twin Model 219Selecting Tube Pass Arrangement 220Super Clean System Technology 22121.16 Exchanger Design 22321.16.1 Overall Heat Transfer Coefficients for Plain or Bare Tubes 224Example 21.15 Calculation of Overall Heat Transfer Coefficient from Individual Components 235Approximate Values for Overall Heat Transfer Coefficients 235Simplified Equations 247Film Coefficients With Fluids Outside Tubes Forced Convection 253Viscosity Correction Factor (mu/muw)¯0.14Heat Transfer Coefficient for Water, hi 257Shell-Side Equivalent Tube Diameter 258Shell-Side Velocities 265Design and Rating of Heat Exchangers 265Rating of a Shell and Tube Heat Exchanger 266Design of a Heat Exchanger 270Design Procedure for Forced Convection Heat Transfer in Exchanger Design 272Design Programs for a Shell and Tube Heat Exchanger 273Example 21.16 Convection Heat Transfer Exchanger Design 274Shell and Tube Heat Exchanger Design Procedure (S.I. units) 286Tubes 288Tube Side Pass Partition Plate 288Calculations of Tube Side Heat Transfer Coefficient 288Example 21.17 Design of a Shell and Tube Heat Exchanger (S.I. units) Kern's Model 291Solution 292Modified Design 298Shell-Side Pressure Drop, Deltaps 298Pressure Drop for Plain Tube Exchangers 300Tube Size 300Tube-Side Condensation Pressure Drop 304Shell-Side 305Unbaffled Shells 305Segmental Baffles in Shell 306Alternate: Segmental Baffles Pressure Drop 307A Case Study Using UniSim(r) Shell-Tube Exchanger (STE) Modeler 310Solution 311Shell and Tube Heat Exchangers: Single Phase 329Effect of Manufacturing Clearances on the Shell-Side Flow 329Bell-Delaware Method 331Ideal Shell-Side Film Heat Transfer Coefficient 332Shell-Side Film Heat Transfer Coefficient Correction Factors 333Baffle Cut and Spacing, Jc 333Baffle leakage Effects, JL 335Bundle and Partition Bypass Effects, Jb 337Variations in Baffle Spacing, Js 338Temperature Gradient for Laminar Flow Regime, Jr 338Overall Heat Transfer Coefficient, U 338Shell-Side Pressure (Deltap) 339Tube Pattern 341Accuracy of Correlations Between Kern's Method and the Bell-Delaware's Method 341Specification Process Data Sheet, Design, and Construction of Heat Exchangers 341Rapid Design Algorithms for Shell and Tube and Compact Heat Exchangers: Polley et al. [173] 344Fluids in the Annulus of Tube-in-Pipe or Double Pipe Heat Exchanger, Forced Convection 347Finned Tube Exchangers 348Low Finned Tubes, 16 and 19 Fins/In. 348Finned Surface Heat Transfer 348Economics of Finned Tubes 353Tubing Dimensions 353Design for Heat Transfer Coefficients by Forced Convection Using Radial Low-Fin Tubes in Heat Exchanger Bundles 355Pressure Drop in Exchanger Shells Using Bundles of Low Fin Tubes 357Tube-Side Heat Transfer and Pressure Drop 358Design Procedure for Shell-Side Condensers and Shell-Side Condensation With Gas Cooling of Condensables, Fluid-Fluid Convection Heat Exchange 358Vertical Condensation on Low Fin Tubes 358Nucleate Boiling Outside Horizontal or Vertical Tubes 358Design Procedure for Boiling, Using Experimental Data 360Double Pipe Finned Tube Heat Exchangers 362Finned Side-Heat Transfer 364Tube Wall Resistance 370Tube-Side Heat Transfer and Pressure Drop 370Fouling Factor 371Finned Side Pressure Drop 371Design Equations for The Rating of A Double Pipe Heat Exchanger 372Inner Pipe 374Annulus 375Vapor Service 376Shell-Side Bare Tube 376Shell-Side (Finned Tube) 377Tube Side Pressure Drop, Deltapt 378Annulus 378Calculation of the Pressure Drop 379Effect of Pressure Drop (Deltap) on the Original Design 380Nomenclature 381Example 21.19 382Solution 383Heat Balance 383Pressure Drop Calculations 389Tube-Side Deltap 390Shell-Side Deltap 390Plate and Frame Heat Exchangers 393Design Charts for Plate and Frame Heat Exchangers 397Selection 400Advantages 400Disadvantages 400Example 21.20 401Solution 401Pressure Drop Calculations 408Cooling Water Side Pressure Drop 410Air-Cooled Heat Exchangers 412Induced Draft 412Forced Draft 413General Application 422Advantages-Air-Cooled Heat Exchangers 422Disadvantages 423Bid Evaluation 424Design Consideration (Continuous Service) 428Mean Temperature Difference 433Design Procedure for Approximation 435Tube Side Fluid Temperature Control 440Rating Method for Air Cooler Exchangers 441The Equations 441The Air Side Pressure Drop, Deltapa (in. H 2 O) 447Example 21.26 448Solution 448Operations of Air Cooled Heat Exchangers 448Monitoring of Air-Cooled Heat Exchangers 450Boiling and Vaporization 450Boiling 450Vaporization 455Vaporization During Flow 455Vaporization in Horizontal Shell; Natural Circulation 470Pool and Nucleate Boiling--General Correlation for Heat Flux and Critical Temperature Difference 472Example 21.27 474Solution 475Reboiler Heat Balance 480Example 21.28 Reboiler Heat Duty after Kern 480Solution 481Kettle Horizontal Reboilers 482Maximum Bundle Heat Flux 483Nucleate or Alternate Designs Procedure 489Kettle Reboiler--Horizontal Shells 490Horizontal Kettle Reboiler Disengaging Space 491Kettle Horizontal Reboilers, Alternate Design 491Boiling: Nucleate Natural Circulation (Thermosyphon) Inside Vertical Tubes or Outside Horizontal Tubes 493Gilmour Method Modified 493Suggested Procedure for Vaporization with Sensible Heat Transfer 496Procedure for Horizontal Natural Circulation Thermosyphon Reboiler 499Kern Method 499Vaporization Inside Vertical Tubes; Natural Thermosyphon Action 499Fair's Method 500Process Requirements 505Preliminary Design 506Circulation Rate 506Heat Transfer--Stepwise Method 507Circulation Rate 510Heat Transfer: Simplified Method 516Design Comments 516Example 21.29 C3 Splitter Reboiler 518Solution 519Preliminary Design 519Circulation Rate 519Heat Transfer Rate--Stepwise Method 520Heat Transfer Rate--Simplified Method 522Example 21.30 Cyclohexane Column Reboiler 522Solution 523Preliminary Design 523Circulation Rate 523Heat Transfer Rate--Simplified Method 524Kern's Method Stepwise 525Design Considerations 527Other Design Methods 530Example 21.31 Vertical Thermosyphon Reboiler, Kern's Method 530Solution 531Calculation of Tube Side Film Coefficient 538Simplified Hajek Method--Vertical Thermosyphon Reboiler 539General Guides for Vertical Thermosyphon Reboilers Design 540Example 21.32 Hajek's Method--Vertical Thermosyphon Reboiler 542Physical Data Required 542Variables to be Determined 542Determine Overall Coefficient at Maximum Flux 543Determine Overall DeltaT at Maximum Flux 543Maximum Flat 545Flux at Operating Levels Below Maximum 545Fouled DeltaT at Maximum Flux 547Fouled DeltaT, To Maintain Plus for 10°F Clean DeltaT 548Analysis of Data in Figure 21.225 548Surface Area Required 548Vapor Nozzle Diameter 549Liquid Inlet Nozzle Diameter 549Design Notes 549Reboiling Piping 550Film Boiling 550Vertical Tubes, Boiling Outside, Submerged 550Horizontal Tubes: Boiling Outside, Submerged 550Common Reboiler Problems 554Heat Exchanger Design with Computers 555Functionality 557Physical Properties 558UniSim Heat Exchanger Model Formulations 559Case Study 1: Kettle Reboiler Simulation Using UniSim STE 559Nozzle Data 564Process Data 564Case Study 2: Thermosyphon Reboiler Simulation Using UniSim STE 572Process Data (SI Units) 574Solution 580Troubleshooting of Shell and Tube Exchanger 580Maintenance of Heat Exchangers 580Disassembly for Inspection or Cleaning 580Locating Tube Leaks 580Hydrocarbon Leaks 596Pass Partition Failure 596Water Hammer 596General Symptoms in Shell and Tube Heat Exchangers 598Case Studies of Heat Exchanger Explosion Hazard Incidents 599A Case Study (Courtesy of U.S. Chemical Safety and Hazard Investigation Board) 599TESORO ANACORTES REFINERY, ANACORTES, WASHINGTON 599Process Conditions of the B and E Heat Exchangers 602US Chemical Safety Board (CBS) Findings 602Recommendations 606Maintenance Procedures 607References 61222 Energy Management and Pinch Technology 62122.1 Introduction 62122.2 Waste Heat Recovery 62422.2.1 Steam Distribution 62522.2.2 Design for Energy Efficiency 62622.2.3 Energy Management Opportunities 62822.3 Process Integration and Heat Exchanger Networks 63122.3.1 Application of Process Integration 63822.4 Pinch Technology 63922.4.1 Heat Exchanger Network Design 64022.4.2 Energy and Capital Targeting and Optimization 64322.4.3 Optimization Variables 64322.4.4 Optimization of the Use of Utilities (Utility Placement) 64522.4.5 Heat Exchanger Network Revamp 64522.5 Energy Targets 64922.5.1 Heat Recovery for Multiple Systems 650Example 22.1: Setting Energy Targets and Heat Exchanger Network 650Solution 65022.6 The Heat Recovery Pinch and Its Significance 65522.7 The Significance of the Pinch 65622.8 A Targeting Procedure: The Problem Table Algorithm 65822.9 The Grand Composite Curve 66122.9.1 Placing Utilities Using the Grand Composite Curve 66322.10 Stream Matching at the Pinch 66522.10.1 The Pinch Design Approach to Inventing a Network 66622.11 Heat Exchanger Network Design 666Example 22.2 673Solution 67322.11.1 Stream Splitting 678Example 22.3 (Source: Seider et al., Product and Process Design Principles--Synthesis, Analysis, and Evaluation 3rd Ed. Wiley 2009 [26]) 679Solution 680Example 22.4 [Source: Manufacture of cellulose acetate fiber by Robins Smith (Chemical Process Design and Integration, John Wiley 2007 [34])] 681Solution 68722.12 Heat Exchanger Area Targets 693Example 22.5 (Source: R. Smith, Chemical Process Design, Mc Graw-Hill, 1995 [20]) 695Solution 696Example 22.6 703Solution 70322.13 HEN Simplification 703Example 22.7: Test Case 3, TC3 Linnhoff and Hindmarch 703Solution 70422.13.1 Heat Load Paths 70922.14 Number of Shell Target 71022.14.1 Implications for HEN Design 71122.15 Capital Cost Targets 71222.16 Energy Targeting 71422.16.1 Supertargeting or deltaTmin Optimization 714Example 22.8: Cost Targeting 714Solution 715Example 22.9: HEN for Maximum Energy Recovery (Warren D. Seider et al. [26]) 722Solution 72222.17 Targeting and Design for Constrained Matches 72522.18 Heat Engines and Heat Pumps for Optimum Integration 72622.18.1 Appropriate Integration of Heat Engines 72922.18.2 Appropriate Integration of Heat Pumps 73122.18.3 Opportunities for Placement of Heat Pumps 73122.18.4 Appropriate Placement of Compression and Expansion in Heat Recovery Systems 73222.19 Pressure Drop and Heat Transfer in Process Integration 73222.20 Total Site Analysis 73222.21 Applications of Process Integration 73622.22 Sitewide Integration 74122.23 Flue Gas Emissions 74122.24 Pitfalls in Process Integration 744Glossary of Terms 789Summary and Heuristics 795Nomenclature 796References 796Bibliography 800Appendix D 801Appendix G 877Appendix H 919Glossary of Petroleum and Petrochemical Technical Terminologies 927About the Author 1053Index 1055

O autorze

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 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. and a senior member of the American Institute of Chemical Engineers. 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 five books in chemical engineering, a contributor to the Encyclopedia of Chemical Processing and Design. Vol 61. He was named as one of the International Biographical Centre's Leading Engineers of the World for 2008. Also, he is a member of International Who's Who of Professionals(TM) and Madison Who's Who in the U.S.