Preface xix Acknowledgments xxii 21 Heat Transfer 1 21.1 Introduction 1 21.1.1 Types of Heat Transfer Equipment Terminology 2 21.2 Details of Exchange Equipment 19 Assembly and Arrangement 19 Construction Codes 19 Thermal Rating Standards 19 Details of Stationary Heads 19 Exchanger Shell Types 20 21.3 Factors Affecting Shell Selection 24 21.3.1 Details of Rear End Heads 25 21.4 Common Combinations of Shell and Tube Heat Exchangers 26 AES 26 BEM 26 AEP 27 CFU 28 AKT 28 AJW 28 Tubes 29 21.5 Bending of Tubing 56 Baffles 56 Tube Side Baffles (TEMA uses Pass Partition Plates) 56 21.6 Shell-Side Baffles and Tube Supports 57 Tie Rods 67 Tubesheets 67 Tube Joints in Tubesheets 69 Seal Strips 72 Example 21.1 Determine Outside Heat Transfer Area of Heat Exchanger Bundle 73 Tubesheets Layouts 73 21.7 Tube Counts in Shells 73 Applications of Tube Pitch Arrangements 93 21.8 Exchanger Surface Area 93 Number of Tubes 93 Exact Distance Between Faces of Tubesheets 94 Net Effective Tube Length 94 Exact Baffle Spacing 94 Impingement Baffle Location 94 Effective Tube Surface 94 Effective Tube Length for U-Tube Heat Exchangers 107 21.9 Tube Vibration 107 21.9.1 Vibration Mechanisms 109 21.9.2 Treatment of Vibration Problems 110 21.9.3 Corrective Measures 110 Example 21.2 Use of U-Tube Area Chart 111 Nozzle Connections to Shell and Heads 112 21.10 Types of Heat Exchange Operations 112 21.10.1 Thermal Design 112 21.10.2 Temperature Difference: Two Fluid Transfer 116 Example 21.3 One Shell Pass, Two Tubes Passes Parallel-Counterflow Exchanger Cross, After Murty 117 21.10.3 Mean Temperature Difference or Log Mean Temperature Difference 120 21.10.4 Log Mean Temperature Difference Correction Factor, F 123 21.10.5 Correction for Multipass Flow Through Heat Exchangers 133 Example 21.4 Performance Examination for Exit Temperature of Fluids 134 Example 21.5 Calculation of Weighted MTD 136 Example 21.6 Calculation of LMTD and Correction 137 Example 21.7 Calculate the LMTD 140 Solution 140 Temperature for Fluid Properties Evaluation–Caloric Temperature 142 Tube Wall Temperature 142 Example 21.8 Heating of Glycerin in a Multipass Heat Exchanger 145 Solution 145 21.11 The Effectiveness—NTU Method 148 Example 21.9 Heating Water in a Counter Current Flow Heat Exchanger 148 Solution 152 Example 21.10 LMTD and ε-NTU Methods 154 Solution 154 Example 21.11 156 Solution 156 21.12 Pressure Drop, Δp 158 21.12.1 Frictional Pressure Drop 164 21.12.2 Factors Affecting Pressure Drop (Δp) 168 Tube-Side Pressure Drop, Δpf 169 Shell-Side Pressure Drop Δpf 170 Shell Nozzle Pressure Drop (Δp noz) 172 Total Shell-Side Pressure Drop, Δp total 172 21.13 Heat Balance 173 Heat Load or Duty 173 Example 21.12 Heat Duty of a Condenser with Liquid Subcooling 174 21.14 Transfer Area 174 Over Surface and Over Design 174 21.15 Fouling of Tube Surface 175 21.15.1 Crude Oil Fouling In Pre-Heat Train Exchangers 199 Crude Type 199 Crude Blending 199 Crude Oil Fouling Models 202 Tubular Exchanger Manufacturers’ Association (TEMA) and Model Approach for Fouling Resistance, Rf of Crude Oil Pre-Heat Trains 208 Fouling Mitigation and Monitoring 209 HIS smartPM Software 213 Effect of Fouling on Exchanger Heat Transfer Performance 216 Example 21.13 216 Solution 216 Example 21.14 217 Solution 217 Prevention and Control of Liquid-Side Fouling 218 Prevention and Control of Gas-Side Fouling 219 UnSim Design HEX Network Digital Twin Model 219 Selecting Tube Pass Arrangement 220 Super Clean System Technology 221 21.16 Exchanger Design 223 21.16.1 Overall Heat Transfer Coefficients for Plain or Bare Tubes 224 Example 21.15 Calculation of Overall Heat Transfer Coefficient from Individual Components 235 Approximate Values for Overall Heat Transfer Coefficients 235 Simplified Equations 247 Film Coefficients With Fluids Outside Tubes Forced Convection 253 Viscosity Correction Factor (μ/μw)0.14 Heat Transfer Coefficient for Water, hi 257 Shell-Side Equivalent Tube Diameter 258 Shell-Side Velocities 265 Design and Rating of Heat Exchangers 265 Rating of a Shell and Tube Heat Exchanger 266 Design of a Heat Exchanger 270 Design Procedure for Forced Convection Heat Transfer in Exchanger Design 272 Design Programs for a Shell and Tube Heat Exchanger 273 Example 21.16 Convection Heat Transfer Exchanger Design 274 Shell and Tube Heat Exchanger Design Procedure (S.I. units) 286 Tubes 288 Tube Side Pass Partition Plate 288 Calculations of Tube Side Heat Transfer Coefficient 288 Example 21.17 Design of a Shell and Tube Heat Exchanger (S.I. units) Kern’s Model 291 Solution 292 Modified Design 298 Shell-Side Pressure Drop, Δps 298 Pressure Drop for Plain Tube Exchangers 300 Tube Size 300 Tube-Side Condensation Pressure Drop 304 Shell-Side 305 Unbaffled Shells 305 Segmental Baffles in Shell 306 Alternate: Segmental Baffles Pressure Drop 307 A Case Study Using UniSim® Shell-Tube Exchanger (STE) Modeler 310 Solution 311 Shell and Tube Heat Exchangers: Single Phase 329 Effect of Manufacturing Clearances on the Shell-Side Flow 329 Bell-Delaware Method 331 Ideal Shell-Side Film Heat Transfer Coefficient 332 Shell-Side Film Heat Transfer Coefficient Correction Factors 333 Baffle Cut and Spacing, Jc 333 Baffle leakage Effects, JL 335 Bundle and Partition Bypass Effects, Jb 337 Variations in Baffle Spacing, Js 338 Temperature Gradient for Laminar Flow Regime, Jr 338 Overall Heat Transfer Coefficient, U 338 Shell-Side Pressure (Δp) 339 Tube Pattern 341 Accuracy of Correlations Between Kern’s Method and the Bell-Delaware’s Method 341 Specification Process Data Sheet, Design, and Construction of Heat Exchangers 341 Rapid Design Algorithms for Shell and Tube and Compact Heat Exchangers: Polley et al. [173] 344 Fluids in the Annulus of Tube-in-Pipe or Double Pipe Heat Exchanger, Forced Convection 347 Finned Tube Exchangers 348 Low Finned Tubes, 16 and 19 Fins/In. 348 Finned Surface Heat Transfer 348 Economics of Finned Tubes 353 Tubing Dimensions 353 Design for Heat Transfer Coefficients by Forced Convection Using Radial Low-Fin Tubes in Heat Exchanger Bundles 355 Pressure Drop in Exchanger Shells Using Bundles of Low Fin Tubes 357 Tube-Side Heat Transfer and Pressure Drop 358 Design Procedure for Shell-Side Condensers and Shell-Side Condensation With Gas Cooling of Condensables, Fluid–Fluid Convection Heat Exchange 358 Vertical Condensation on Low Fin Tubes 358 Nucleate Boiling Outside Horizontal or Vertical Tubes 358 Design Procedure for Boiling, Using Experimental Data 360 Double Pipe Finned Tube Heat Exchangers 362 Finned Side-Heat Transfer 364 Tube Wall Resistance 370 Tube-Side Heat Transfer and Pressure Drop 370 Fouling Factor 371 Finned Side Pressure Drop 371 Design Equations for The Rating of A Double Pipe Heat Exchanger 372 Inner Pipe 374 Annulus 375 Vapor Service 376 Shell-Side Bare Tube 376 Shell-Side (Finned Tube) 377 Tube Side Pressure Drop, Δpt 378 Annulus 378 Calculation of the Pressure Drop 379 Effect of Pressure Drop (Δp) on the Original Design 380 Nomenclature 381 Example 21.19 382 Solution 383 Heat Balance 383 Pressure Drop Calculations 389 Tube-Side Δp 390 Shell-Side Δp 390 Plate and Frame Heat Exchangers 393 Design Charts for Plate and Frame Heat Exchangers 397 Selection 400 Advantages 400 Disadvantages 400 Example 21.20 401 Solution 401 Pressure Drop Calculations 408 Cooling Water Side Pressure Drop 410 Air-Cooled Heat Exchangers 412 Induced Draft 412 Forced Draft 413 General Application 422 Advantages-Air-Cooled Heat Exchangers 422 Disadvantages 423 Bid Evaluation 424 Design Consideration (Continuous Service) 428 Mean Temperature Difference 433 Design Procedure for Approximation 435 Tube Side Fluid Temperature Control 440 Rating Method for Air Cooler Exchangers 441 The Equations 441 The Air Side Pressure Drop, Δpa (in. H 2 O) 447 Example 21.26 448 Solution 448 Operations of Air Cooled Heat Exchangers 448 Monitoring of Air-Cooled Heat Exchangers 450 Boiling and Vaporization 450 Boiling 450 Vaporization 455 Vaporization During Flow 455 Vaporization in Horizontal Shell; Natural Circulation 470 Pool and Nucleate Boiling—General Correlation for Heat Flux and Critical Temperature Difference 472 Example 21.27 474 Solution 475 Reboiler Heat Balance 480 Example 21.28 Reboiler Heat Duty after Kern 480 Solution 481 Kettle Horizontal Reboilers 482 Maximum Bundle Heat Flux 483 Nucleate or Alternate Designs Procedure 489 Kettle Reboiler—Horizontal Shells 490 Horizontal Kettle Reboiler Disengaging Space 491 Kettle Horizontal Reboilers, Alternate Design 491 Boiling: Nucleate Natural Circulation (Thermosyphon) Inside Vertical Tubes or Outside Horizontal Tubes 493 Gilmour Method Modified 493 Suggested Procedure for Vaporization with Sensible Heat Transfer 496 Procedure for Horizontal Natural Circulation Thermosyphon Reboiler 499 Kern Method 499 Vaporization Inside Vertical Tubes; Natural Thermosyphon Action 499 Fair’s Method 500 Process Requirements 505 Preliminary Design 506 Circulation Rate 506 Heat Transfer—Stepwise Method 507 Circulation Rate 510 Heat Transfer: Simplified Method 516 Design Comments 516 Example 21.29 C3 Splitter Reboiler 518 Solution 519 Preliminary Design 519 Circulation Rate 519 Heat Transfer Rate—Stepwise Method 520 Heat Transfer Rate—Simplified Method 522 Example 21.30 Cyclohexane Column Reboiler 522 Solution 523 Preliminary Design 523 Circulation Rate 523 Heat Transfer Rate—Simplified Method 524 Kern’s Method Stepwise 525 Design Considerations 527 Other Design Methods 530 Example 21.31 Vertical Thermosyphon Reboiler, Kern’s Method 530 Solution 531 Calculation of Tube Side Film Coefficient 538 Simplified Hajek Method—Vertical Thermosyphon Reboiler 539 General Guides for Vertical Thermosyphon Reboilers Design 540 Example 21.32 Hajek’s Method—Vertical Thermosyphon Reboiler 542 Physical Data Required 542 Variables to be Determined 542 Determine Overall Coefficient at Maximum Flux 543 Determine Overall ΔT at Maximum Flux 543 Maximum Flat 545 Flux at Operating Levels Below Maximum 545 Fouled ΔT at Maximum Flux 547 Fouled ΔT, To Maintain Plus for 10°F Clean ΔT 548 Analysis of Data in Figure 21.225 548 Surface Area Required 548 Vapor Nozzle Diameter 549 Liquid Inlet Nozzle Diameter 549 Design Notes 549 Reboiling Piping 550 Film Boiling 550 Vertical Tubes, Boiling Outside, Submerged 550 Horizontal Tubes: Boiling Outside, Submerged 550 Common Reboiler Problems 554 Heat Exchanger Design with Computers 555 Functionality 557 Physical Properties 558 UniSim Heat Exchanger Model Formulations 559 Case Study 1: Kettle Reboiler Simulation Using UniSim STE 559 Nozzle Data 564 Process Data 564 Case Study 2: Thermosyphon Reboiler Simulation Using UniSim STE 572 Process Data (SI Units) 574 Solution 580 Troubleshooting of Shell and Tube Exchanger 580 Maintenance of Heat Exchangers 580 Disassembly for Inspection or Cleaning 580 Locating Tube Leaks 580 Hydrocarbon Leaks 596 Pass Partition Failure 596 Water Hammer 596 General Symptoms in Shell and Tube Heat Exchangers 598 Case Studies of Heat Exchanger Explosion Hazard Incidents 599 A Case Study (Courtesy of U.S. Chemical Safety and Hazard Investigation Board) 599 TESORO ANACORTES REFINERY, ANACORTES, WASHINGTON 599 Process Conditions of the B and E Heat Exchangers 602 US Chemical Safety Board (CBS) Findings 602 Recommendations 606 Maintenance Procedures 607 References 612 22 Energy Management and Pinch Technology 621 22.1 Introduction 621 22.2 Waste Heat Recovery 624 22.2.1 Steam Distribution 625 22.2.2 Design for Energy Efficiency 626 22.2.3 Energy Management Opportunities 628 22.3 Process Integration and Heat Exchanger Networks 631 22.3.1 Application of Process Integration 638 22.4 Pinch Technology 639 22.4.1 Heat Exchanger Network Design 640 22.4.2 Energy and Capital Targeting and Optimization 643 22.4.3 Optimization Variables 643 22.4.4 Optimization of the Use of Utilities (Utility Placement) 645 22.4.5 Heat Exchanger Network Revamp 645 22.5 Energy Targets 649 22.5.1 Heat Recovery for Multiple Systems 650 Example 22.1: Setting Energy Targets and Heat Exchanger Network 650 Solution 650 22.6 The Heat Recovery Pinch and Its Significance 655 22.7 The Significance of the Pinch 656 22.8 A Targeting Procedure: The Problem Table Algorithm 658 22.9 The Grand Composite Curve 661 22.9.1 Placing Utilities Using the Grand Composite Curve 663 22.10 Stream Matching at the Pinch 665 22.10.1 The Pinch Design Approach to Inventing a Network 666 22.11 Heat Exchanger Network Design 666 Example 22.2 673 Solution 673 22.11.1 Stream Splitting 678 Example 22.3 (Source: Seider et al., Product and Process Design Principles—Synthesis, Analysis, and Evaluation 3rd Ed. Wiley 2009 [26]) 679 Solution 680 Example 22.4 [Source: Manufacture of cellulose acetate fiber by Robins Smith (Chemical Process Design and Integration, John Wiley 2007 [34])] 681 Solution 687 22.12 Heat Exchanger Area Targets 693 Example 22.5 (Source: R. Smith, Chemical Process Design, Mc Graw-Hill, 1995 [20]) 695 Solution 696 Example 22.6 703 Solution 703 22.13 HEN Simplification 703 Example 22.7: Test Case 3, TC3 Linnhoff and Hindmarch 703 Solution 704 22.13.1 Heat Load Paths 709 22.14 Number of Shell Target 710 22.14.1 Implications for HEN Design 711 22.15 Capital Cost Targets 712 22.16 Energy Targeting 714 22.16.1 Supertargeting or ∆Tmin Optimization 714 Example 22.8: Cost Targeting 714 Solution 715 Example 22.9: HEN for Maximum Energy Recovery (Warren D. Seider et al. [26]) 722 Solution 722 22.17 Targeting and Design for Constrained Matches 725 22.18 Heat Engines and Heat Pumps for Optimum Integration 726 22.18.1 Appropriate Integration of Heat Engines 729 22.18.2 Appropriate Integration of Heat Pumps 731 22.18.3 Opportunities for Placement of Heat Pumps 731 22.18.4 Appropriate Placement of Compression and Expansion in Heat Recovery Systems 732 22.19 Pressure Drop and Heat Transfer in Process Integration 732 22.20 Total Site Analysis 732 22.21 Applications of Process Integration 736 22.22 Sitewide Integration 741 22.23 Flue Gas Emissions 741 22.24 Pitfalls in Process Integration 744 Glossary of Terms 789 Summary and Heuristics 795 Nomenclature 796 References 796 Bibliography 800 Appendix D 801 Appendix G 877 Appendix H 919 Glossary of Petroleum and Petrochemical Technical Terminologies 927 About the Author 1053 Index 1055

This fourth volume in the Petroleum Refining set, this book continues the most up-to-date and comprehensive coverage of the most significant and recent changes to petroleum refining, presenting the state-of-the-art to the engineer, scientist, or student. This book provides the design of heat exchanger equipment, crude oil fouling in pre-heat train exchangers, crude oil fouling models, fouling mitigation and monitoring, prevention and control of liquid and gas side fouling, using the Excel spreadsheet and UniSim design software for the design of shell and tube heat exchangers, double pipe heat exchangers, air-cooled exchangers, heat loss tracing for process piping, pinch analysis for hot and cold utility targets and process safety incidents involving these equipment items and pertinent industrial case studies. Use of UniSim Design (UniSim STE) software is illustrated in further elucidation of the design of shell and tube heat exchangers, condensers, and UniSim ExchangerNet R470 for the design of heat exchanger networks using pinch analysis. This is important for determining minimum cold and hot utility requirements, composite curves of hot and cold streams, the grand composite curve, the heat exchanger network, and the relationship between operating cost index target and the capital cost index target against ΔTmin. Useful as a textbook, this is also an excellent, handy go-to reference for the veteran engineer, a volume no chemical or process engineering library should be without. Written by one of the world’s foremost authorities, this book sets the standard for the industry and is an integral part of the petroleum refining renaissance. It is truly a must-have for any practicing engineer or student in this area. This groundbreaking new volume: Assists engineers in rapidly analyzing problems and finding effective design methods and select mechanical specifications Provides improved design manuals to methods and proven fundamentals of process design with related data and charts Covers a complete range of basic day–to–day petroleum refining operations topics with new materials on significant industry changes Extensive Excel spreadsheets for the design of process vessels for mechanical separation of two-phase and three-phase fluids, double-pipe heat exchanger, air-cooled exchanger, pinch analysis for hot and cold utility targets. Provides UniSim ®-based case studies for enabling simulation of key processes outlined in the book Helps achieve optimum operations and process conditions and shows how to translate design fundamentals into mechanical equipment specificationsHas a related website that includes computer applications along with spreadsheets and concise applied process design flow charts and process data sheetsProvides various case studies of process safety incidents in refineries and means of mitigating these from investigations by the US Chemical Safety Board Includes a vast Glossary of Petroleum and Technical Terminology