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gas processing and power plants, as _Hyi:lrocarhori velccity,mls V _ 1 l] ._E5 U 4?
I
I] 41
well as oft-shore platforms. In loca- Surface area rec uiremerit, secs ll1arel,35,35it
-r I |_| I
' 5490
-
changers may be a preferred choice. Exchanger cost, million $ ill?- l-Cl Hot estimated
However, even there, due to vari- _[g_gproltlmale_l y
ous process constraints, air cooling Installation cost, million 5 [l.E-3 l c.s l ilix estimated
_ @_Epl‘fl-Lltl l‘l'lt':l'[E]
alone may not always suffice. so Elperating cost, mlllitln E l]-2=l
‘I
0-3
‘
Hot estimated
water cooling may also be required. laggroximalel g
Similarly, where cooling water is Total cost, million 5 1.5? 1 2.1 1 Hot estimated
plentiful, shell-and-tube coolers may lggproximatel — -r
'I'“"""' "““'“I°-I _. .5?‘-ii??? ___ ing heat with air at different tempera-
tures in different rows. This phenom-
:Flwr
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Ilwll -_ ___ __.-Ft’--ti.s.t -___ 'Passe
51.15533 get ;i_=_ir=i=ic.ss‘c
?‘1f.‘.-'?‘.‘“l enon is shown in Figure 1.
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as-itat '
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oi
To avoid such a situation, and if
"'“"*"-""“" Air llow
Flllid le111|;l-erelure in hoot header side
Fluid llerriueraturc in rear
lreaoorsido
""°“=“"-""‘“ "“I' I-In‘-'-' Process lllearchallel side the tube-skin temperature cannot
Fronlotraholsidolluidtornperaluro l'llI=tl llorr lltlltl lcmoclalurc
be achieved in conventional flow ar-
FIGURE 1. As seen by flrese two examples, the tube sl-tin temperature in an air cooler is linlteo to the rangement lhot fluid entering from
direction of the air flow
top nozzles}, a co-current arrange-
and belt; 3} dustidebrisrpollen built tube-side pressure drop, which can ment is tried out where process
up on tubes, leading to increased be justified economically because fluid enters from bottom nozzles
air pressure drop in the bundle and the increase in the operating and and moves up the bundle. Elue to
reduction of airflow (some reverse capital cost of the pump is small lower lylTD in such an arrangement,
flow also can be seen] leading to compared to surface area and cost the required surface area goes up
loss in cooling capacity; 4] corro- of air cooler saved. in general, this further. as is usually the case. this
sion of finned tubes due to salty at- design has a relatively higher surface kind of design is tube-side resis-
mosphere or mishandling by water area requirement- Adopting a deep tance contrclling, and a bare-tube
washing and so on; 5} breaitage bundle design also helps improve design instead of finned tube will be
or stuck louver or the failure of the the air-flow distribution in the bun- less expensive. Even after all these
louver positioner, causing restriction dle. Bundles should have no more alternatives are considered, if the
in air flow and reduction of cooling
capacity; and at mat-operation of
auto-variable pitch fan blades. as Process fluid is same as as stated in the Hydrocarbon cooling hjl tempered water in a shell-and-
they can get stuck and then air flow case study tulle cooler and cooling of same tempered weter cooling
cannot be adjusted by variable- in an air cooler
blade pitch angle. Type of exchanger I shell-and-tube Air cooler
_ Fluid Tgle J Eiacltwash oitf Tempered water Tempered wateri Air
Case study _ Temp. to, lrviiiii j soil-torso-so _ soieo
its an example, we discuss the chal- _ Heat duly, Irlliirl _ 12 . 4 12 4
lenges in handling a high-viscosity, _lvrro, “C _4s.s
high-fouling and low-pour-point hy- Hydrocarbon flollilrate, ltgflt 152,105 Hll
___Te@p-eretl wateLflo_wr_a_t_i_e, ltgflt I 5135.553 _5E5,Ef.‘iE _
drocarbon in an air cooler.
Ho. of bundlesishells required _ - is in series 4 i-
A residue-upgrading project in Shell-and-tutre areal air cooler care area, mi‘ i,ooo 1,5lIliIl
a petroleum refinery has a bach- IIIII|;tE!I'IlZlIlIE3 l'II.ll'l'lIIiIH' I In-III-II-II—- I‘ IIII I
wash oil cooler where hydrocarbon Exchangercost,millions[ggproximete} _ o - as o er
is cooled from 2o4 to rotc. The oil _ Installation cost, mil.ion $ lggproximate} , 11-32 lIl.El
viscosity is in the range of 1.4 to 40 _ Total installed cost, million S lggoroximate} I l]. so l 12
cF' and the pour point is 38°C. in this
project. the engineer has restricted TABLE 3. FEHFDRHIAHBE WITH GUMEIHED AIR DHULEB MID TEMFEBED WATER
the Reynolds number to a minimum SHELI.-Mil]-TIIBE GIIIILEII
of 2,000. The design ambient-air Process fluld is same as used In Hydrocarlron cooling oarfly by an alr cooler ' Cooling of same
temperature is 47°C. The location of Talrle 2 followed by tempered water in a shell-and- tempered water in
tulle cooler _ an air cooler
the refinery does not require exten- eof exclran er Pill‘ cooler shell-and-tuhe Air cooler
sive winterization for such a liquid. Huio Type Baclrwash olliltir Backwash oiliTem|:lered ' Tempered wateri
The design target for handling 1 water g Ajr
high-viscosity, high-fouling and con- _ Temp, “C, lnrout 2lIl4i11El A no-torso-so ‘Billed
gealing (low pour point} hydrocarbon Heat dtl , MW 9.01 3.4 3.4
is to achieve a tube shin temperature MTD, T E15 -l
15.2 15
of at least 15°C above pour point, Hydrocarbon flowrate, ltglh 152,1 [I15 A isaroc full
maximizing the tube velocity and the _ Tempered water flowrate, ltgrh lllil g 143,T5T 1 1irs,rsr
heat-transfer coefficient such that ..Brioole.ttsoells_asuireo__ 21- . _,_t!t_e__io.series.._ fil-
the Reynolds number lies in the tur- Elare area, m3 est soo _ is
bulent region. _ Reynolds number roses-e.ero Asst at midpoint J-
To get a reasonably high velocity Exchanger cost, million 5 o . es o . re lllfi
lggproximatel
in the tube side for such fluid re- Installation cost , million 5 0.29 0.23 o.2e
quires increasing the number of tube a roxlmatel
passes in a deep bundle of B to 12 Total installed cost. million 3 I153 0.39 I o.sa
rows. But this also leads to a higher legproximatel -l -r
of the process fluid increases as the cooler (Steps 1-3}, using a tem-
temperature of the process fluid falls pered water shell-and-tube cooler
while progressing in the tube bundle. {Step 4) and a combination of the FIGURE 3. shown here is a computer model of an
Also, if there is mal-distribution in the two (Step 5}. The results of the per- air cooler mounted on flre pipe raclt
air side of the multi-pass air cool- formance characteristics are sum-
ers, invariably the process fluid cools marized in Tables 1-3. Several l-tey Step 2. By arranging the process
more in some of tubes than in others- observations are pointed out in the fluid flow co-currently to air flow, the
This will further increase the viscos- following paragraphs: MTD goes down from diff} (coun-
ity in the cooler tubes and therefore Step 1'. The first attempt in thermal ter-current} to 57'“lS and therefore,
reduce flow through the tubes, which design, using a conventional coun- the surface area requirement goes
causes further cooling and more flow ter-current flow arrangement in an air up. The existing design of four bays
reduction. This process continues cooler, results in a Fleynolds number becomes inadequate in surface
at the outlet of soo {deep laminar area. so one more bay is added to
until ultimately, we may notice that
fluid has stooped flowing in many flow} and a tube-sltin temperature of total]. as the number of bays is in-
of the tubes, and is only flowing in 5lIl.6"’C- The design also has a high creased, the tube-side velocity goes
a very few tubes with higher veloc- tube-side pressure drop and a low down further (0.4? mist and so does
ity and turbulent flow regime. Pres- tube-side velocity, in spite of 12 tube the overall heat-transfer coefficient,
sure drop may be substantially higher passes in an eight-tube row bundle, as tube side resistance is control-
and. unless the pump can deliver the and therefore high surface area re- ling by S5‘iti. Even if the tube-st-tin
needed head, flow may stop and quirement lhigh cost}. temperature is improved, there is not
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UPTIHISE PROCESSES
First comes the experience, then the success: discover
4 SOLUT|0N$ ""'
the entire spectrum and dynamic energy of mechanical
process engineering. PfItl.ll.lTECH is the trade fair event
for built solids - and the place where process
060 F-
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hlew strategies are needed for "green chemistry"- in the
Expert Forum Chemistry, you’lI learn about sustainable
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‘l ‘F mixed reality and new processes in solids production.
- I J ‘l - ,',' Directly from the experts — for everyone who wants
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to matte their processes more efficient-
utirtroesets russsrt
lnei.con'll?3B51 -"I 4
toil!“
1‘ -an ggs>“"_ _fl-
gee“ inside the tubes. The swirling fluid
r%II‘1III' x
Ix rI";IIIIIIIIII promotes greater contact with the
II[':_-‘I \ "'1 5--H-‘iii 1%
3- _
tube wall {increasing shear stress
H-I'l--
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at the walls many times more} en-
tech bay tTyo.} 1‘--.-,___g__ hancing tube-side convective heat
-. III -. _lI_I_‘lI1= IIII"'- transfer efficiency. The increase in
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values of hlusselt number, F-‘reynolds
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rt- ii’
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number, Praridtl number, pressure
I I I ‘-.I i1~;I 1..-I’I_|_-.Ii1ri':t--,3, drop and friction factor will depend
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4-iltt IIIILLIAIIIIP ANALOG OUTPUT
M ALL PRODUCTS
2 MADE IN USA
LOAD CONTROLS
EINCORPORATED
lr'll'W'llll.LOADCONT ltOLS.COl'vl
Fur details rrisit acllinlc5.r:heme|'rgr:r-nline.c:crII1l"r"3S5‘I-13
1,030
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2,233
Weatherizing for colder climates.
_i3-I322 "ll MW ln some parts of the world, where
ambient conditions are such that in
The movement of tube bundles and sometimes power is required winter, air temperature dips below
in the transverse direction could for heating coils in cold climates. freezing, temperature control of the
occur only when the piping con- Normatly, the design of the cooler process streams at the air-cooler
nected to equipment nozzles gen- will be such to accommodate the outlet is required to prevent freezing
erates enough force to overcome highest expected ambient tempera- of low pour-point hydrocarbons. This
the friction at the bundle supports. ture lfor example, 50°C}, but be- leads to a more complicated design
That is why it is a common prac- cause of seasonal changes, such a for the air cooler.
tice to provide stainless steel. strategy would be wasteful during When a minimum tube-wall tem-
polytetrafluoroethylene lPTFE} or the periods when the ambient tem- perature has to be maintained in the
other type of plate at the support perature is lower {for example, 40“'C} air cooler, a recirculation system is
point to ease the movement. But — which can be as much as 50% employed whereby automatic lou-
this must be done in consultation for the year. Operating power costs vers at the top and sides of the air
with the vendor- can therefore be much lower than cooler housing (containing the entire
3. The loads created on the bundle the installed power costs by using assembly of tube bundles. ducting,
nozzle -- due to thermal expan- two-speed motors, auto-variable steam coils, plenums and fan mo-
sion, the weights of the pipe, in- pitch fans and variable frequency tors} control the extent of recircula-
sulation and fluid. and the inside drive rvrol fan-motor control to re- tion. The recirculation is possible in
pressure of piping — should be duce the air flow. In temperate cli- forced-draft air coolers, since hot ex-
less than the limits given by API. mates, as much as 50% or more haust air can be recirculated through
Sometimes the vendor allows a of the design power may be saved a duct-and-louver system.
higher allowable load [normally over the course of a year with auto A steam coil is generally a sepa-
two times the code value}. variable-pitch fans. rate tube bundle of one or two rows
Locating shell-and-tube coolers. Nowadays, VFD technology has having a length and width similar to
The standalone water condenser become popular and more com- the main air cooler, that is placed
and shell-and-tube trim water mon rather than auto variable-pitch below the main air cooler bundle. if
cooler can be placed above the fans, which are problematic for a an electric fan heater is to be pro-
condenser drum on a structural number of reasons. The air require- vided in place of a steam-heated
platform supported from grade. ment can be adjusted from 10 to bundle, the same is placed below
Even though a shell-and-tube water 100% through VFD control. Table each air cooler fan. Low-pressure
cooler will require less space than 4 presents the potential savings (LP) steam being inside finned tubes.
an air cooler, some area allocation that can be expected by adjusting the steam-heated bundle and lou-
is needed on the ground for on the power requirements to different ver will involve additional pressure
the platform for off-shore applica- ambient-air temperatures, for both drop in the fan design. Closing the
lions}. The pressure of the cooling a standalone air cooler, and for a louver on top of a bundle allows the
water reaching to the tube side of combination of air cooler and trim healing coil to warm the bundle dur-
condensers and trim coolers {when cooler. When the ambient tempera- ing slart up in freezing weather, so
on a platform} is very important for ture drops to below 34°C — which that the material in the bundle will
proper functioning of the condenser can occur during 5 to B months not freeze or solidify. A steam coil is
and the trim cooler. If the pressure over the year, the trim cooler may also used to temper very cold air to
drop in the cooling water circuit is not even be required at all, since the bundles in continuous operation
not properly calculated while de- the total heat duty can be handled while the fan is operating and the
signing the inletloutlet piping, the by air cooler alone. So in addition to exhaust louver is open. When two
actual cooling water flowrate will be the power savings, there will be ad- fans are operated per bay, an auto-
lower than that of the design cal- ditional savings for not using cooling variable-pitch fan or fan with l.-‘Fiji is
culation, and the performance may water, which can cost around $0.4 kept at rear end of the bundle, so
suffer as a result. millionryr. If a refinery decides to that the process fluid outlet temper-
Flexibility. The operating costs for keep both air coolers and trirn cool- ature can be controlled.
the air cooler include the electrical ers on line, power saving through C.-‘onfrolling recirculation. A part
power required to operate the fans reduction of air flow via ‘v'FD is very of the air leaving from the top of the
CHEMICAL ENGINEERING 'v'dl.h0r‘v.CHEMENGCNLlNE-CCM FEBRLJAR“r' SO19
--I: ~';_=._r,- l _ -.r =.: - l.-. L... r r -l- r |
I---- -.r
system is recirculated and mixes regulate the opening and closing .. . 1 | '!_: '
' 'lr-- =.-::-!--:-
with fresh air entering from the sides of the outlet louver. The duct sizing
so that the combined temperature is calculation and differential pres- ‘..'
:-'-::-:l'.r.
|:_'- .I.|o. ll |.|I .I'l'
._I;-:s'::'r l-'5rr':::.::.':'-.
I-I.‘-.II ||' ll:l:: I ‘II
‘ 1-ii-iii
precisely the design ambient tem- sure drop across the dampers is lf;'i:=;:r': s ;':fiil:'I-. !:':' --l;. l ll t
perature. The lower the ambient carefully done to avoid failure of -:_:" r 1 51l':_:-j_-' lI‘:;'.':r_:_ I :':" ~,'.':;_:‘_i
temperature, the greater will be the the system. The vendors scope of -II::""=i -- ' -iIiI==II-'= ==I--=':"I'==';r-II-'-
extent of recirculation. work will include the design of the -7- i:'-;r""i-l'-l_;i_iI f!:r!'l': :--;:_':if'.'..;-.'l& '=_ll".-r':;."::"r l-l-_-Iii l._:"'
For startup, when ambient tem- louvers. -n general, air-cooler tube- ‘ii-' l-'=="i-;-::-zr=t:": l":&.i Zr-.i-:1: liilil i'i5r'.'1r'-I-Iii‘. low. *"r
--..- -_'.- .- .-|.-I.-.-..-I. I" I
.::.-::'.l.. .=. ..,:. I.-,1: : . .-
perature is lower than design am- skin temperature is kept 15—20°C
bient temperature, ambient air can above the tube-side fluid pour-
be passed through a live-steam point temperature through this Author
coil, located below the bundle, elaborate system. lllahas ll lilandal is a principal
such that air approaching the bun- Aithough the cost of such an air desigll errgiileer for Fluor Elailiel
Indra Pvt. ltd. Itilh Floor, infinity
dle is heated up to the design tem- cooler is quite high, it is still pre- Tower B. 0,'ber' City. BLF Elly
perature. The recirculation of exit ferred in colder climates to prevent Phase ll, Surgeon 122 002- fiery-
air is gradually increased, which icing or frosting. I ons, lrrdia: Phone --Ell-l24-
reduces the steam requirement. Eoiled by Gerald 0ndrey 45i0r00: Fax: +B1-124-
4203-P00: Email; mantis-
Eventually, the steam supply can l rnandsl@fiuor.corrrl- He has more
be stopped altogether. Fteferences i than I-‘i4 years of experience in the
The air cooler is fitted with a duct I-_=:._; '2 tr ll l-- I :_;"r:: :-._= I .l-'|_--.:_:i l_. -1 l._. __ .r: lieltl of process heat transfer. cost optimization studies.
| .I process des:gn and operalrorrs. process revamp, pro;ect
leading from the top outlet to the -'1 '-I-I::.:::=r::::- ll~;:-iii l II'."ii"=lII"""' -I-52:2-2
lII"' =:""'I |'l:'|ii:'|'-': i;‘I'. I-I"II'iII"II|
l" "Iii",-' i'Ii'I'-E!II'-".‘tI""
control and energy managemerit- Prior to l-lrior, he
bottom inlet. Louvers are placed in -| 1.. ‘I . I . ' _..
wort-red at Errginaers lntlia Ltd. Delhi anti Hindustan Pa-
ul-;- '..'r ..' ‘Jr. --ll.-.'l --'-I! I---if
the bypass duct. at the air inlet and II--I"'|:'I!.‘-ii‘ lit: =l;:':r:l:::-rI-.- ii"-r'l -.1: "r: l..-::- I
:---r-":2-l
troleum ll-Iumbai Flelinery- lvlarldaf has presented many
papers in various seminars on heal transfer. energy
at the air outlet. The temperature of -.Ii l'--::.::- .-::- I..I' -- '-..-I.-L utl "-.r-.l'. l.'-I.. =rI' I.-I-r'I:~. - -;:'I..'..-ul -.'l-:1 nlorragerrrerrt anti process irnproverrrem lvlerrtlal holds
air just below the tube bundles will “.:l..l
. ..-
'.l' .l-.- l..i:-..-:- I.---.r
. '_.... _' _ ' ' _._
a B-Tech degree tn chemical engineering from the In-
regulate the opening and closing of |
--
|
'..li:'i_l"!i-;i .'
.--r. . I
__._2':r_l l.l;_i'"zlr_r:' -l
I .- .
-.~'::;_:'= ._-:;-:;!x tliorr lnslilrrle of Teclrrrolcgy Belhi on-ti Masters tlegree
inlet and bypass louvers, whereas lI'II':-::-:'rr:e:"- r --I‘-IL l'l:.==.2 l:~-::i'za' .r -I=-:-.:;:;': ll;=r"::- ll1 lrrrarrcral nlarragerlrenl from -_li]lTlf‘lf_IlEil Bajaj lrrslilule
of lvlanagemenl Sllrrlies. l".lumhai- India-
the process outlet temperature will l.III'ir5. III.‘ l3‘..-:"' I; III:-': '--i'l"iE*i
i—r—ji
-in
_?//'1'; AFPM 2019 Annual Meeting
rt‘ Leading Industry Sustainability S innovation
lvlarr:l‘l I? — 'l‘5", .T'lfi'lSi Tilt‘? POIIS rllitttlirlg '~.viII lltj: lt‘lt':l;st'1t'l on illnnvalivtt st‘:-lillitjirls, fit'ltlt'IiTllt'I-IT, -21 nil
h.-'larriott I-?iiver"centel' cr_rrrrr"r"r,rnity. Learn the latest orn the issues you care most about and Iouilcl
San Antonio, lit strategic re ationships with over 'l,1il_ii_l industry leaders-