Process Heat Transfer. Principles, Applications and Rules of Thumb

615 Pages·2014·49.47 MB·English

by  Robert W. Serth and Thomas Lestina (Auth.)

DEDICATION
This book is dedicated to C.C.S.
The authors would also like to dedicate this edition to all the students and engineering professionals who
providedthoughtfulfeedbackonthefirstedition,identifyingmanycorrectionsandimprovements.Wewould
especially like to thank members of HTRI who have shared their expertise and experience to further the
development ofthermal analysis methodsfor process heat exchangers.
PROCESS HEAT TRANSFER
PRINCIPLES, APPLICATIONS AND RULES
OF THUMB
Robert W. Serth
Department of Chemical and Natural Gas Engineering,
Texas A&M University-Kingsville, Kingsville, Texas, USA
Thomas G. Lestina
Vice President, Research & Engineering Services,
Heat Transfer Research, Inc.,
College Station, Texas, USA
AMSTERDAM(cid:129)BOSTON(cid:129)HEIDELBERG(cid:129)LONDON(cid:129)NEWYORK(cid:129)OXFORD
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PREFACE TO FIRST EDITION
ThisbookisbasedonacourseinprocessheattransferthatIhavetaughtformanyyears.Thecoursehasbeen
taken by seniors and first-year graduate students who have completed an introductory course in engineering
heattransfer.Althoughthisbackgroundisassumed,nearlyallstudentsneedsomereviewbeforeproceedingto
more advanced material. For this reason, and also to make the book self-contained, the first three chapters
provideareviewofessentialmaterialnormallycoveredinanintroductoryheattransfercourse.Furthermore,the
bookisintendedforusebypracticingengineersaswellasuniversitystudents,andithasbeenwrittenwiththe
aim of facilitatingself-study.
Unlike some books in this field, no attempt is made herein to cover the entire panoply of heat transfer
equipment. Instead, the book focuses on the types of equipment most widely used in the chemical process
industries, namely, shell-and-tube heat exchangers (including condensers and reboilers), air-cooled heat
exchangersanddouble-pipe (hairpin) heat exchangers. Within the confinesof asinglevolume, thisapproach
allowsanin-depthtreatmentofthematerialthatismostrelevantfromanindustrialperspective,andprovides
studentswiththedetailedknowledgeneededforengineeringpractice.Thisapproachisalsoconsistentwiththe
time available inaone-semester course.
Design of double-pipe exchangers is presented in Chapter 4. Chapters 5 to 7 comprise a unit dealing with
shell-and-tube exchangers in operations involving single-phase fluids. Design of shell-and-tube exchangers is
coveredinChapter5usingtheSimplifiedDelawaremethodforshell-sidecalculations.Forpedagogicalreasons,
more sophisticated methods for performing shell-side heat-transfer and pressure-drop calculations are pre-
sented separately in Chapter 6 (full Delaware method) and Chapter 7 (Stream Analysis method). Heat
exchangernetworksarecoveredinChapter8.Inormallypresentthistopicatthispointinthecoursetoprovide
a change of pace. However, Chapter 8 is essentially self-contained and can, therefore, be covered at any time.
Phase-changeoperationsarecoveredinChapters9to11.Chapter9presentsthebasicsofboilingheattransfer
andtwo-phaseflow.ThelatterisencounteredinbothChapter10,whichdealswiththedesignofreboilers,and
Chapter11,whichcoverscondensationandcondenserdesign.Designofair-cooledheatexchangersispresented
inChapter12.Thematerialinthischapterisessentiallyself-containedand,hence,itcanbecoveredatanytime.
Sincetheprimarygoalofboththebookandthecourseistoprovidestudentswiththeknowledgeandskills
neededformodernindustrialpractice,computerapplicationsplayanintegralrole,andthebookisintendedfor
use with one or more commercial software packages. HEXTRAN (SimSci-Esscor), HTRI Xchanger Suite (Heat
TransferResearch,Inc.)andtheHTFSSuite(AspenTechnology,Inc.)areusedinthebook,alongwithHX-Net
(AspenTechnology,Inc.)forpinchcalculations.HEXTRANaffordsthemostcompletecoverageoftopics,asit
handlesalltypesofheatexchangersandalsoperformspinchcalculationsfordesignofheatexchangernetworks.
Itdoesnotperformmechanicaldesigncalculationsforshell-and-tubeexchangers,however,nordoesitgenerate
detailedtube layoutsor settingplans. Furthermore, themethodologyusedbyHEXTRANisbasedon publicly
availabletechnologyandisgenerallylessrefinedthanthatoftheothersoftwarepackages.TheHTRIandHTFS
packagesuseproprietarymethodsdevelopedbytheirrespectiveresearchorganizations,andaresimilarintheir
level of refinement. HTFS Suite handles all types of heat exchangers; it also performs mechanical design
calculationsanddevelopsdetailedtubelayoutsandsettingplansforshell-and-tubeexchangers.HTRIXchanger
Suitelacksamechanicaldesignfeature,andthemoduleforhairpinexchangersisnotincludedwithanacademic
license. Neither HTRInor HTFS hasthe capability to performpinch calculations.
Asofthiswriting,AspenTechnologyisnotprovidingtheTASCandACOLmodulesoftheHTFSSuiteunder
itsuniversityprogram.Instead,itisofferingtheHTFS-plusdesignpackage.Thispackagebasicallyconsistsofthe
TASCandACOLcomputationalenginescombinedwithslightlymodifiedGUI’sfromthecorrespondingBJAC
ix
x Preface tofirst edition
programs (HETRAN and AEROTRAN),and packaged with the BJAC TEAMS mechanical design program. This
packagediffersgreatlyinappearanceandtosomeextentinavailablefeaturesfromHTFSSuite.However,most
of the results presentedin the text usingTASC and ACOLcan be generated using the HTFS-pluspackage.
Software companies are continually modifying their products, making differences between the text and
currentversionsofthe software packages unavoidable.However, manymodificationsinvolveonly superficial
changesinformatthathavelittle,ifany,effectonresults.Moresubstantivechangesoccurlessfrequently,and
even then the effects tend to be relatively minor. Nevertheless, readers should expect some divergence of the
software from the versions used herein, and they should not be unduly concerned if their results differ
somewhat from those presented in the text. Indeed, even the same version of a code, when run on different
machines,can produce slightly differentresults dueto differencesin round-off errors. With thesecaveats, it is
hopedthatthedetailedcomputerexampleswillprovehelpfulinlearningtousethesoftwarepackages,aswell
as in understanding theiridiosyncrasies andlimitations.
Ihavemadeaconcertedefforttointroducethecomplexitiesofthesubjectmattergraduallythroughoutthe
bookinordertoavoidoverwhelmingthereaderwithamassiveamountofdetailatanyonetime.Asaresult,
informationonshell-and-tubeexchangersisspreadoveranumberofchapters,andsomeofthefinerdetailsare
introduced in the context of example problems, including computer examples. Although there is an obvious
downside to thisstrategy,I nevertheless believe thatit represents good pedagogy.
Both English units, which are still widely used by American industry, and SI units are used in this book.
Students in the United States need to be proficient in both sets of units, and the same is true of students in
countriesthatdoalargeamountofbusinesswithU.S.firms.Inordertominimizetheneedforunitconversion,
however,workingequationsareeithergivenindimensionlessformor,whenthisisnotpractical,theyaregiven
in both sets of units.
Iwouldliketotakethisopportunitytothankthemanystudentswhohavecontributedtothiseffortoverthe
years,bothdirectlyandindirectlythroughtheirparticipationinmycourse.Iwouldalsoliketoexpressmydeep
appreciationtomycolleaguesintheDepartmentofChemicalandNaturalGasEngineeringatTAMUK,Dr.Ali
Pilehvari and Mrs. Wanda Pounds. Without their help, encouragement, and friendship, this book would not
have been written.
PREFACE TO SECOND EDITION
Thiseditionprovidesanimproveddiscussionofpracticalindustryconsiderationsinthedesignandoperationof
processheatexchangers.ManyoftherevisionsarebasedonrecentadvancesofHTRIresearch,plustheongoing
feedbackofprocessengineersandheat-exchangerdesignersviatheHTRITechnicalSupportGroup.Anumberof
newexampleshavealsobeenincludedthatillustrateadditionalaspectsofheat-exchangerdesign.Thefollowing
is asummary ofthe most importantadditions:
l A section on radiation has been added in Chapter 2 to provide more complete coverage of heat transfer
fundamentals. Materialon mixed convection andnon-ideal heat transfer fromfinshas alsobeenadded in
thischapter.
l AsectiononplateheatexchangershasbeenaddedinChapter3toprovidemorecompletecoverageofthe
mostwidelyusedtypesofindustrialheatexchangers.Newmaterialonbafflesandshellselectioncriteriafor
shell-and-tube exchangershas also been added.
l Two examples involving the design of amulti-tubehairpin exchanger have been added in Chapter 4.
l An example illustrating the significance of temperature profiles in the design of shell-and-tube heat
exchangershas been added in Chapter5.
l Asectioncoveringshell-side designguidelinesbasedon stream analysishasbeen added inChapter7,and
Example 7.4hasbeen re-worked on this basis. Two new computer examples havealso been added.
l InChapter 8, acase study has been added that illustrates the application of Pinch Analysis to a real-world
process,the production ofgasolinefrom bio-ethanol.
l AnewexamplehasbeenaddedinChapter10thatillustratessomeoftheunintendedconsequencesthatcan
arise from the use of fouling factors in reboiler design.
l In Chapter 11, a section on condenser venting, draining, and subcooling has been added. A new example
comparingdifferentbaffleconfigurationsanddifferenttypesoftubingforcondensingapplicationshasalso
been added, andExample 11.10 hasbeencompletely re-worked.
l Anexampleinvolving the design of an air-cooled condenser hasbeenadded in Chapter12.
Allmaterial pertainingto HTRI Xchanger Suite hasbeenupdatedto Version7.0,the most recent release at the
timeofwriting.Wehavealsocorrectednumerouserrorsthatunfortunatelyescapedthereviewprocessforthe
firstedition.Itisoursincerehopethattheserevisionswillenhancetheutilityofthebookforbothstudentsand
practitioners of the subject.
xi
CONVERSION FACTORS
Acceleration 1m/s2¼4.2520(cid:2)107ft/h2
Area 1m2¼10.764ft2
Density 1kg/m3¼0.06243lbm/ft3
Energy 1J¼0.239cal
¼9.4787(cid:2)l0e4Btu
Force 1N¼0.22481lbf
Foulingfactor 1m2$K/W¼5.6779h$ft2$(cid:3)F/Btu
Heatcapacityflowrate 1kW/K¼1kW/(cid:3)C
¼1895.6Btu/h$(cid:3)F
Heatflux 1W/m2¼0.3171Btu/h$ft2
Heatgenerationrate 1W/m3¼0.09665Btu/h$ft3
Heattransfercoefficient 1W/m2$K¼0.17612Btu/h$ft2$(cid:3)F
Heattransferrate 1W¼3.4123Btu/h
Kinematicviscosityandthermaldiffusivity 1m2/s¼3.875(cid:2)104ft2/h
Latentheatandspecificenthalpy 1kJ/kg¼0.42995Btu/lbm
Length 1m¼3.2808ft
Mass 1kg¼2.2046lbm
Massflowrate 1kg/s¼7936.6lbm/h
Massflux 1kg/s$m2¼737.35lbm/h$ft2
Power 1kW¼3412Btu/h
¼1.341hp
Pressure(stress) 1Pa(1N/m2)¼0.020886lbf/ft2
¼1.4504(cid:2)10e4psi
¼4.015(cid:2)10e3in.H O
2
Pressure 1.01325(cid:2)105Pa¼1atm
¼14.696psi
¼760torr
¼406.8in.H O
2
Specificheat 1kJ/kg$K¼0.2389Btu/lbm$(cid:3)F
Surfacetension 1N/m¼1000dyne/cm
¼0.068523lbf/ft
Temperature K¼(cid:3)C+273.15
¼(5/9)((cid:3)F+459.67)
¼(5/9)((cid:3)R)
Temperaturedifference 1K¼1(cid:3)C
¼1.8(cid:3)F
¼1.8(cid:3)R
Thermalconductivity 1W/m$K¼0.57782Btu/h$ft$(cid:3)F
xiii
xiv Conversion Factors
Thermalresistance 1K/W¼0.52750(cid:3)F$h/Btu
Viscosity 1kg/m$s¼1000cp
¼2419lbm/ft$h
Volume 1m3¼35.314ft3
¼264.17gal
Volumetricflowrate 1m3/s¼2118.9ft3/min(cfm)
¼1.5850(cid:2)104gal/min(gpm)
lbf:poundforceandlbm:poundmass.
PHYSICAL CONSTANTS
Quantity Symbol Value
Universalgasconstant R~ 0.08205atm$m3/kmol$K
0.08314bar$m3/kmol$K
8314J/kmol$K
1.986cal/mol$K
1.986Btu/lbmole$(cid:1)R
10.73psia$ft3/lbmole$(cid:1)R
1545ft$lbf/lbmole$(cid:1)R
Standardgravitationalacceleration g 9.8067m/s2
32.174ft/s2
4.1698(cid:3)108ft/h2
StefaneBoltzmanconstant sSB 5.670(cid:3)10e8W/m2$K4
1.714(cid:3)10e9Btu/h$ft2$(cid:1)R4
xv
ACKNOWLEDGMENTS
Item SpecialCreditLine
Figure3.1 Reprinted,withpermission,fromExtendedSurfaceHeatTransferbyD.Q.KernandA.D.Kraus.Copyright(cid:1)
1972byTheMcGraw-HillCompanies,Inc.
Table3.1 Reprinted,withpermission,fromPerry’sChemicalEngineers’Handbook,7thedn.,R.H.PerryandD.W.Green,
eds.Copyright(cid:1)1997byTheMcGraw-HillCompanies,Inc.
Figure3.6 Reprinted,withpermission,fromExtendedSurfaceHeatTransferbyD.Q.KernandA.D.Kraus.Copyright(cid:1)
1972byTheMcGraw-HillCompanies,Inc.
Table3.2 Reproduced,withpermission,fromJ.W.PalenandJ.Taborek,Solutionofshellsideflowpressuredropand
heattransferbystreamanalysismethod,Chem.Eng.Prog.SymposiumSeries,65,No.92,53e63,1969.
Copyright(cid:1)1969byAIChE.
Table3.5 Reprinted,withpermission,fromPerry’sChemicalEngineers’Handbook,7thedn.,R.H.PerryandD.W.Green,
eds.Copyright(cid:1)1997byTheMcGraw-HillCompanies,Inc.
Figure4.1 Copyright(cid:1)1998fromHeatExchangers:Selection,RatingandThermalDesignbyS.KakacandH.Liu.
ReproducedbypermissionofTaylor&Francis,adivisionofInformaplc.
Figure4.2 Copyright(cid:1)1998fromHeatExchangers:Selection,RatingandThermalDesignbyS.KakacandH.Liu.
ReproducedbypermissionofTaylor&Francis,adivisionofInformaplc.
Figure4.4 Reprinted,withpermission,fromExtendedSurfaceHeatTransferbyD.Q.KernandA.D.Kraus.Copyright(cid:1)
1972byTheMcGraw-HillCompanies,Inc.
Figure4.5 Reprinted,withpermission,fromExtendedSurfaceHeatTransferbyD.Q.KernandA.D.Kraus.Copyright(cid:1)
1972byTheMcGraw-HillCompanies,Inc.
Figure5.3 Copyright(cid:1)1988fromHeatExchangerDesignHandbookbyE.U.Schlünder,Editor-in-Chief.Reproducedby
permissionofTaylor&Francis,adivisionofInformaplc.
Figures6.1e6.5 Copyright(cid:1)1988fromHeatExchangerDesignHandbookbyE.U.Schlunder,Editor-in-Chief.Reproducedby
permissionofTaylor&Francis,adivisionofInformapic.
Table6.1 Copyright(cid:1)1988fromHeatExchangerDesignHandbookbyE.U.Schlünder,Editor-in-Chief.Reproducedby
permissionofTaylor&Francis,adivisionofInformaplc.
Figure6.10 Copyright(cid:1)1988fromHeatExchangerDesignHandbookbyE.U.Schlünder,Editor-in-Chief.Reproducedby
permissionofTaylor&Francis,adivisionofInformaplc.
Figure7.1 Reproduced,withpermission,fromJ.W.PalenandJ.Taborek,Solutionofshellsideflowpressuredropand
heattransferbystreamanalysismethod,Chem.Eng.Prog.SymposiumSeries,65,No.92,53e63,1969.
Copyright(cid:1)1969byAIChE.
Table,p.283 Reproduced,withpermission,fromR.Mukherjee,Effectivelydesignshell-and-tubeheatexchangers,Chem.
Eng.Prog.,94,No.2,21e37,1998.Copyright(cid:1)1998byAIChE.
Figure8.20 ReprintedfromComputersandChemicalEngineering,Vol.26,X.X.ZhuandX.R.Nie,PressureDrop
ConsiderationsforHeatExchangerNetworkGrassrootsDesign,pp.1661e1676,Copyright(cid:1)2002,with
permissionfromElsevier.
Figure9.2 Copyright(cid:1)1997fromBoilingHeatTransferandTwo-PhaseFlow,2ndedn.,byL.S.TongandY.S.Tang.
ReproducedbypermissionofTaylor&Francis,adivisionofInformaplc.
(Continued)
xvii