CHAPTER NINE

HEAT EXCHANGERS

The implementation of heat exchanger models is different from that of most Aspen
Plus models in that some are capable of detail design using very high quality industrial
programs which are integrated into Aspen Plus. These are the Hetran and Tasc shelland-tube heat exchanger and the Aerotran air-cooled exchanger programs. They are
documented in Aspen Plus Help: EDR (Exchanger Design and Rating). Most can be
used for design as well as being used to rate existing exchangers; that is, they can be
used as sequential modular models.
To simulate a heat exchanger one must solve the primary equations
hot
q mhot cphot (Tinhot Tout
)=0

(9.1)

cold
Tincold ) = 0
q mcold cpcold (Tout

(9.2)

q U AF TLM = 0

(9.3)

TLM =

T1 T2
ln(T1 /T2 )

(9.4)

Here q is the exchanger duty; m a flow rate, cp the heat capacity; T the temperature;
T the temperature difference at an end of the exchanger; U an overall heat transfer
coefficient which depends on temperature, transport properties, and exchanger geometry; and F a correction factor for multiple tube-side and/or shell-side passes. The
factor F , derived through the work of Nagle (1933) and Underwood (1934), can be
calculated as

Teach Yourself the Basics of Aspen Plus By Ralph Schefflan

Copyright 2011 John Wiley & Sons, Inc.

111

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HEAT EXCHANGERS

F =

R 2 + 1 ln[(1 S)/(1 RS)]

2S(R+1 R 2 +1)

(R 1) ln
2
2S(R+1+

(9.5)

R +1)

where
R=

hot
Tinhot Tout
cold
Tout
Tincold

(9.6)

S=

cold T cold
Tout
in
Tinhot Tincold

(9.7)

When used in simulation mode, the state of the exchanger feeds must be specified.
Depending on the complexity of the model chosen, the heat transfer area, A, is either
specified or calculated from the heat exchanger physical layout. Heat transfer coefficients are calculated from correlations such as the Hewitt (1992) correlation prepared
by Gnielinski, which involves the Nusselt NNU = hD/k, Reynolds NRE = DG/, and
Prandtl NPR = cp /k numbers, and the Darcy friction factor, given by


hi Di
D 2/3
(fD /8)(NRE 1000)NPR
(9.8)
NNU =
1+
=

2/3
k
L
1 + 12.7 FD /8(NPR 1)
fD = (1.82 log10 NRE 1.64)2

(9.9)

Here hi is the inside pipe heat transfer coefficient, Di the inside pipe diameter, k
the thermal conductivity, G the mass flow rate, the viscosity, cp the heat capacity,
and fD the Darcy friction factor. Complete documentation of all correlations used in
Aspen Plus can be found in Help: Heatx Reference and Model Reference. Depending
on which model is chosen, U is either specified or calculated iteratively during the
convergence process. The four heat-exchange-related models can be found in the model
library under the tab Heat Exchangers.
9.1

HEATER BLOCK

An example of the primary input form of the Heater block, which shows the possible
specifications, is shown in Figure 9.1. The Heater block offers a variety of ways to
specify the output stream state, all of which result in calculation of the energy required
to heat (or cool) a stream. Alternatively, one may specify the energy added to or
removed from a heater, which is used by the block to establish the state of the output
stream.
An important capability is the use of two heaters to model a heat exchanger
bypassing the use of equations (9.3) and (9.4), as shown in Figure 9.2. Note the use
of a heat stream to connect the two heaters. The heat stream should be aligned in the
correct direction, which depends on which heater will receive the heat, either positive
or negative. Care must be taken with the sign of the heat transferred (heat added is
positive). In this example the outlet temperature of heater H2 is specified and the heat,
stream 5, flows to heater H1. This example may be found at Chapter Nine
Examples/Heaters.