Heat Exchanger Rating: Routine feature of Process Industries

I
n daily chemical engineering practice, Heat exchanger rating is a
general feature. Actual temperature data comparison with specified
temperature data speaks about major evaluation. In fact, four
temperature data can be converted into values of approach, range & finally well
calculated log mean temperature difference(LMTD) or Mean temperature
difference(MTD) after deriving correction factor,FT ( i.e. MTD = FT*LMTD) from its
graphs available in TEMA, DQ Kern & other standard reference books of process
heat transfer. Correction factor (FT) should be preferably at unity. FT below unity
imposes severe penalty of additional surface & more erratic temperature
behavior as approach gets crossed most probably for FT at or below 0.75.

Case of suction preheater for one of our main ammonia compressor

(centrifugal & motor driven) is a good example to study of primary rating of heat
exchangers.

As specified in case-I (please, refer Table : I : Case-I), Suction preheater

is provided with ~38% excess surface & LMTD of 79.36 oC to get suction outlet
at 50 oC. Extra surface of ~38% is substantial but indicative of Ammonia
contamination. Thus, there is a chance of choking & fouling. Finally, it may not
give reliable maintenance period for which additional surface is arranged.

For Case- I (Base case)

111°C

DESIGN CASE -I
HCV
SUCTION
PREHEATER
(1)
FROM
UPSTREAM 40 °C
TOWER 50 °C
9976 KGPH
NH3 VAPOR 139.5 °C

MAIN
COMPRESSOR
(2)

139.5 °C
3345
KGPH

• Approach = 111 – 50.22 = 61 oC (Direct check)

• LMTD = 79.36 oC (Calculated check)
• Power (FKw) @ 50 oC Suction Temperature = 349 kW
• (FKW = Fluid Kilowatt, Similar to FHP = Fluid Horse Power)
 • Range of Utility = 139.5 – 111 = 28.5 oC at given flow of 3345
kgph.
• % Excess area = 37.5% (Over design).

Later on, it is realized that suction temperature is suitable at 56 oC to

decompose any carbamate formation. Case – II depicts its parameters as below:

111°C

CASE II
HCV
SUCTION
PREHEATER
(1)
FROM
UPSTREAM 40 °C 55 °C
TOWER
9976 KGPH
NH3 VAPOR 120°C

MAIN
COMPRESSOR
(2)

139.5 °C
3345
KGPH

• Approach = 77 55 = 22 oC
• LMTD = 48.81 oC (check decrease with respect to base case)
• Power FKW @ 56 oC Suction = 356 kW
o
• Range of Utility = 120 - 77 = 43 C at 3345 kgph flow
maintained.
• % Excess area =( -)50% (Under design)
Percent excess area indicates process streams have potential but process unit
(i.e. Heat exchanger) has no capacity (i.e. under design results)

To get suitable suction temperature of 56 oC, It is better to in crease utility

flow from 3345 kgph to 6500 kgph. Case-III Depicts its parameter as below:
 111°C

CASE III
HCV
SUCTION
PREHEATER
(1) 55 °C
FROM
UPSTREAM 40 °C
TOWER
9976 KGPH
NH3 VAPOR 120°C

MAIN
COMPRESSOR
(2) 6500
KGPH
139.5 °C

• Approach = 98 -55 = 43 oC
• LMTD = 60.92 oC (Check increase with respect to Case-II)
• Power FKW @ 56 oC Suction = 356 kW
• Range of Utility = 120 98 = 22 oC
• % Excess area = 2% (Over design)

Case-III represents just right size heat exchanger but it gives no latitude
for reasonable maintenance period.
This concludes that however pressure drops & Velocities permit to
alter flow and thermal profile, there is no safe margin for reasonable
maintenance period. Hence, new heat exchanger sizing is most desirable
change to last system longer and smoother.

P.S.: Calculation of electric power for compressors with respect to suction

temperature is a function of mass flow rate, compression ratio and suction
temperature itself. There is a handy formula to speak out such values in
quantities to rate the condition better as explained above & given below in
Table: 1 & 2.
TABLE :1 : COUNTER CURRENT HEAT EXCHANGER UNIT :
CASE I II III
SHELL TUBE SHELL TUBE SHELL TUBE
VAPOR NH3 FLOW,KGPH 3345 9976 3345 9976 6500 9976
TEMPERATURE °C IN 139.5 40 120 40 120 40
TEMPERATURE °C OUT 111 50.22 77 55 98 55
∆P,BAR 0.0016 0.006 0.0014 0.006 0.0053 0.0063
VELOCITY , MPS 4.31 46.61 4.02 46.95 8.04 46.95
NRE 9021 63242 9690 62743 18300 62743
LMTD , °C 79.36 48.81 60.92
EXCESS AREA,% 37.5%(OVER) -50% (UNDER) 2% (OVER)
UD,KCAL/HR/M2/K 80 80 99
HEAT DUTY,MMKCAL/HR 0.0507 0.0745 0.0745

TABLE :2 : MAIN COMPRESSOR POWER ESTIMATE :

Cp/Cv=(γ)= 1.29 4.45 0.22
COMPRESSOR SUC PR BAR 1.08 1.08 1.08
COMPRESSOR DISCH PR BAR 2.25 2.25 2.25
COMPRESSOR SUC TEMP °C 50 56 56
COMPRESSOR POWER ,FKw 349 356 356