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Petroleum Refining Design and Applications Handbook, Volume 4: Heat Transfer, Pinch Analysis, and Process Safety Incidents [Hardback]

A. Kayode Coker (University of Wolverhampton, UK)

Formāts: Hardback, 1088 pages, weight: 2527 g
Izdošanas datums: 16-Feb-2023
Izdevniecība: Wiley-Scrivener
ISBN-10: 1119827523
ISBN-13: 9781119827528

Citas grāmatas par šo tēmu:

Industrial chemistry - (Noliktavā: 6 punkts)
Chemical engineering
Fossil fuel technologies

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Bibliotēkām

Formāts: Hardback, 1088 pages, weight: 2527 g
Izdošanas datums: 16-Feb-2023
Izdevniecība: Wiley-Scrivener
ISBN-10: 1119827523
ISBN-13: 9781119827528

Citas grāmatas par šo tēmu:

Industrial chemistry - (Noliktavā: 6 punkts)
Chemical engineering
Fossil fuel technologies

Permanent link: https://www.kriso.lv/db/9781119827528.html

Keywords:

PETROLEUM REFINING

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 ?Tmin.

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 specifications
Has a related website that includes computer applications along with spreadsheets and concise applied process design flow charts and process data sheets
Provides 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

Preface

xix

Acknowledgments

xxii

21 Heat Transfer

(620)

21.1 Introduction

(18)

21.1.1 Types of Heat Transfer Equipment Terminology

(17)

21.2 Details of Exchange Equipment

(5)

Assembly and Arrangement

(1)

Construction Codes

(1)

Thermal Rating Standards

(1)

Details of Stationary Heads

(1)

Exchanger Shell Types

(4)

21.3 Factors Affecting Shell Selection

(2)

21.3.1 Details of Rear End Heads

(1)

21.4 Common Combinations of Shell and Tube Heat Exchangers

(30)

AES

(1)

BEM

(1)

AEP

(1)

CFU

(1)

AKT

(1)

AJW

(1)

Tubes

(27)

21.5 Bending of Tubing

(1)

Baffles

(1)

Tube Side Baffles (TEMA uses Pass Partition Plates)

(1)

21.6 Shell-Side Baffles and Tube Supports

(16)

Tie Rods

(1)

Tubesheets

(2)

Tube Joints in Tubesheets

(3)

Seal Strips

(1)

Example 21.1 Determine Outside Heat Transfer Area of Heat Exchanger Bundle

(1)

Tubesheets Layouts

(1)

21.7 Tube Counts in Shells

(20)

Applications of Tube Pitch Arrangements

(1)

21.8 Exchanger Surface Area

(14)

Number of Tubes

(1)

Exact Distance Between Faces of Tubesheets

(1)

Net Effective Tube Length

(1)

Exact Baffle Spacing

(1)

Impingement Baffle Location

(1)

Effective Tube Surface

(13)

Effective Tube Length for U-Tube Heat Exchangers

107

(1)

21.9 Tube Vibration

107

(5)

21.9.1 Vibration Mechanisms

109

(1)

21.9.2 Treatment of Vibration Problems

110

(1)

21.9.3 Corrective Measures

110

(1)

Example 21.2 Use of U-Tube Area Chart

111

(1)

Nozzle Connections to Shell and Heads

112

(1)

21.10 Types of Heat Exchange Operations

112

(36)

21.10.1 Thermal Design

112

(4)

21.10.2 Temperature Difference: Two Fluid Transfer

116

(1)

Example 21.3 One Shell Pass, Two Tubes Passes Parallel-Counterflow Exchanger Cross, After Murty

117

(3)

21.10.3 Mean Temperature Difference or Log Mean Temperature Difference

120

(3)

21.10.4 Log Mean Temperature Difference Correction Factor, F

123

(10)

21.10.5 Correction for Multipass Flow Through Heat Exchangers

133

(1)

Example 21.4 Performance Examination for Exit Temperature of Fluids

134

(2)

Example 21.5 Calculation of Weighted MTD

136

(1)

Example 21.6 Calculation of LMTD and Correction

137

(3)

Example 21.7 Calculate the LMTD

140

(1)

Solution

140

(2)

Temperature for Fluid Properties Evaluation-Caloric Temperature

142

(1)

Tube Wall Temperature

142

(3)

Example 21.8 Heating of Glycerin in a Multipass Heat Exchanger

145

(1)

Solution

145

(3)

21.11 The Effectiveness---NTU Method

148

(10)

Example 21.9 Heating Water in a Counter Current Flow Heat Exchanger

148

(4)

Solution

152

(2)

Example 21.10 LMTD and e-NTU Methods

154

(1)

Solution

154

(2)

Example 21.11

156

(1)

Solution

156

(2)

21.12 Pressure Drop, Δp

158

(15)

21.12.1 Frictional Pressure Drop

164

(4)

21.12.2 Factors Affecting Pressure Drop (Δp)

168

(1)

Tube-Side Pressure Drop, Δpf

169

(1)

Shell-Side Pressure Drop Δpf

170

(2)

Shell Nozzle Pressure Drop (Δpno2)

172

(1)

Total Shell-Side Pressure Drop, Δptotal

172

(1)

21.13 Heat Balance

173

(1)

Heat Load or Duty

173

(1)

Example 21.12 Heat Duty of a Condenser with Liquid Subcooling

174

(1)

21.14 Transfer Area

174

(1)

Over Surface and Over Design

174

(1)

21.15 Fouling of Tube Surface

175

(48)

21.15.1 Crude Oil Fouling In Pre-Heat Train Exchangers

199

(1)

Crude Type

199

(1)

Crude Blending

199

(3)

Crude Oil Fouling Models

202

(6)

Tubular Exchanger Manufacturers' Association (TEMA) and Model Approach for Fouling Resistance, Rf of Crude Oil Pre-Heat Trains

208

(1)

Fouling Mitigation and Monitoring

209

(4)

HIS smartPM Software

213

(3)

Effect of Fouling on Exchanger Heat Transfer Performance

216

(1)

Example 21.13

216

(1)

Solution

216

(1)

Example 21.14

217

(1)

Solution

217

(1)

Prevention and Control of Liquid-Side Fouling

218

(1)

Prevention and Control of Gas-Side Fouling

219

(1)

UnSim Design HEX Network Digital Twin Model

219

(1)

Selecting Tube Pass Arrangement

220

(1)

Super Clean System Technology

221

(2)

21.16 Exchanger Design

223

(130)

21.16.1 Overall Heat Transfer Coefficients for Plain or Bare Tubes

224

(11)

Example 21.15 Calculation of Overall Heat Transfer Coefficient from Individual Components

235

(1)

Approximate Values for Overall Heat Transfer Coefficients

235

(12)

Simplified Equations

247

(6)

Film Coefficients With Fluids Outside Tubes Forced Convection

253

(2)

Viscosity Correction Factor (μ/μw)0.14

255

(2)

Heat Transfer Coefficient for Water, hi

257

(1)

Shell-Side Equivalent Tube Diameter

258

(7)

Shell-Side Velocities

265

(1)

Design and Rating of Heat Exchangers

265

(1)

Rating of a Shell and Tube Heat Exchanger

266

(4)

Design of a Heat Exchanger

270

(2)

Design Procedure for Forced Convection Heat Transfer in Exchanger Design

272

(1)

Design Programs for a Shell and Tube Heat Exchanger

273

(1)

Example 21.16 Convection Heat Transfer Exchanger Design

274

(12)

Shell and Tube Heat Exchanger Design Procedure (S.I. units)

286

(2)

Tubes

288

(1)

Tube Side Pass Partition Plate

288

(1)

Calculations of Tube Side Heat Transfer Coefficient

288

(3)

Example 21.17 Design of a Shell and Tube Heat Exchanger (S.I. units) Kern's Model

291

(1)

Solution

292

(6)

Modified Design

298

(1)

Shell-Side Pressure Drop, Δps

298

(2)

Pressure Drop for Plain Tube Exchangers

300

(1)

Tube Size

300

(4)

Tube-Side Condensation Pressure Drop

304

(1)

Shell-Side

305

(1)

Unbaffled Shells

305

(1)

Segmental Baffles in Shell

306

(1)

Alternate: Segmental Baffles Pressure Drop

307

(3)

A Case Study Using UniSim® Shell-Tube Exchanger (STE) Modeler

310

(1)

Solution

311

(18)

Shell and Tube Heat Exchangers: Single Phase

329

(1)

Effect of Manufacturing Clearances on the Shell-Side Flow

329

(2)

Bell-Delaware Method

331

(1)

Ideal Shell-Side Film Heat Transfer Coefficient

332

(1)

Shell-Side Film Heat Transfer Coefficient Correction Factors

333

(1)

Baffle Cut and Spacing, Jc

333

(2)

Baffle Leakage Effects, JL

335

(2)

Bundle and Partition Bypass Effects, Jb

337

(1)

Variations in Baffle Spacing, Js

338

(1)

Temperature Gradient for Laminar Flow Regime, Jr

338

(1)

Overall Heat Transfer Coefficient, U

338

(1)

Shell-Side Pressure (Δp)

339

(2)

Tube Pattern

341

(1)

Accuracy of Correlations Between Kern's Method and the Bell-Delaware's Method

341

(1)

Specification Process Data Sheet, Design, and Construction of Heat Exchangers

341

(3)

Rapid Design Algorithms for Shell and Tube and Compact Heat Exchangers: Policy et al. [ 173]

344

(3)

Fluids in the Annulus of Tube-in-Pipe or Double Pipe Heat Exchanger, Forced Convection

347

(1)

Finned Tube Exchangers

348

(1)

Low Finned Tubes, 16 and 19 Fins/In.

348

(1)

Finned Surface Heat Transfer

348

(5)

Economics of Finned Tubes

353

(1)

Tubing Dimensions

353

(47)

Design for Heat Transfer Coefficients by Forced Convection Using Radial Low-Fin Tubes in Heat Exchanger Bundles

355

(2)

Pressure Drop in Exchanger Shells Using Bundles of Low Fin Tubes

357

(1)

Tube-Side Heat Transfer and Pressure Drop

358

(1)

Design Procedure for Shell-Side Condensers and Shell-Side Condensation With Gas Cooling of Condensables, Fluid-Fluid Convection Heat Exchange

358

(1)

Vertical Condensation on Low Fin Tubes

358

(1)

Nucleate Boiling Outside Horizontal or Vertical Tubes

358

(2)

Design Procedure for Boiling, Using Experimental Data

360

(2)

Double Pipe Finned Tube Heat Exchangers

362

(2)

Finned Side-Heat Transfer

364

(6)

Tube Wall Resistance

370

(1)

Tube-Side Heat Transfer and Pressure Drop

370

(1)

Fouling Factor

371

(1)

Finned Side Pressure Drop

371

(1)

Design Equations for The Rating of A Double Pipe Heat Exchanger

372

(2)

Irmer Pipe

374

(1)

Annulus

375

(1)

Vapor Service

376

(1)

Shell-Side Bare Tube

376

(1)

Shell-Side (Finned Tube)

377

(1)

Tube Side Pressure Drop, Δpt

378

(1)

Annulus

378

(1)

Calculation of the Pressure Drop

379

(1)

Effect of Pressure Drop (Δp) on the Original Design

380

(1)

Nomenclature

381

(1)

Example 21.19

382

(1)

Solution

383

(1)

Heat Balance

383

(6)

Pressure Drop Calculations

389

(1)

Tube-Side Δp

390

(1)

Shell-Side Δp

390

(3)

Plate and Frame Heat Exchangers

393

(4)

Design Charts for Plate and Frame Heat Exchangers

397

(3)

Selection

400

(1)

Advantages

400

(1)

Disadvantages

400

(1)

Example 21.20

401

(1)

Solution

401

(7)

Pressure Drop Calculations

408

(2)

Cooling Water Side Pressure Drop

410

(2)

Air-Cooled Heat Exchangers

412

(1)

Induced Draft

412

(1)

Forced Draft

413

(9)

General Application

422

(1)

Advantages-Air-Cooled Heat Exchangers

422

(1)

Disadvantages

423

(1)

Bid Evaluation

424

(4)

Design Consideration (Continuous Service)

428

(5)

Mean Temperature Difference

433

(2)

Design Procedure for Approximation

435

(5)

Tube Side Fluid Temperature Control

440

(1)

Rating Method for Air Cooler Exchangers

441

(1)

The Equations

441

(6)

The Air Side Pressure Drop, Δpa (in. H2O)

447

(1)

Example 21.26

448

(1)

Solution

448

(1)

Operations of Air Cooled Heat Exchangers

448

(2)

Monitoring of Air-Cooled Heat Exchangers

450

(1)

Boiling and Vaporization

450

(22)

Boiling

450

(5)

Vaporization

455

(1)

Vaporization During Flow

455

(15)

Vaporization in Horizontal Shell; Natural Circulation

470

(2)

Pool and Nucleate Boiling---General Correlation for Heat Flux and Critical Temperature Difference

472

(2)

Example 21.27

474

(1)

Solution

475

(5)

Reboiler Heat Balance

480

(1)

Example 21.28 Reboiler Heat Duty after Kern

480

(1)

Solution

481

(1)

Kettle Horizontal Reboilers

482

(1)

Maximum Bundle Heat Flux

483

(6)

Nucleate or Alternate Designs Procedure

489

(1)

Kettle Reboiler---Horizontal Shells

490

(1)

Horizontal Kettle Reboiler Disengaging Space

491

(1)

Kettle Horizontal Reboilers, Alternate Design

491

(2)

Boiling: Nucleate Natural Circulation (Thermosyphon) Inside Vertical Tubes or Outside Horizontal Tubes

493

(1)

Gilmour Method Modified

493

(3)

Suggested Procedure for Vaporization with Sensible Heat Transfer

496

(3)

Procedure for Horizontal Natural Circulation Thermosyphon Reboiler

499

(1)

Kern Method

499

(1)

Vaporization Inside Vertical Tubes; Natural Thermosyphon Action

499

(1)

Fair's Method

500

(7)

Process Requirements

505

(1)

Preliminary Design

506

(1)

Circulation Rate

506

(1)

Heat Transfer---Stepwise Method

507

(3)

Circulation Rate

510

(6)

Heat Transfer: Simplified Method

516

(1)

Design Comments

516

(2)

Example 21.29 C3 Splitter Reboiler

518

(1)

Solution

519

(1)

Preliminary Design

519

(1)

Circulation Rate

519

(1)

Heat Transfer Rate---Stepwise Method

520

(2)

Heat Transfer Rate---Simplified Method

522

(1)

Example 21.30 Cyclohexane Column Reboiler

522

(1)

Solution

523

(1)

Preliminary Design

523

(1)

Circulation Rate

523

(1)

Heat Transfer Rate---Simplified Method

524

(1)

Kern's Method Stepwise

525

(2)

Design Considerations

527

(3)

Other Design Methods

530

(1)

Example 21.31 Vertical Thermosyphon Reboiler, Kern's Method

530

(1)

Solution

531

(7)

Calculation of Tube Side Film Coefficient

538

(1)

Simplified Hajek Method---Vertical Thermosyphon Reboiler

539

(1)

General Guides for Vertical Thermosyphon Reboilers Design

540

(2)

Example 21.32 Hajek's Method---Vertical Thermosyphon Reboiler

542

(1)

Physical Data Required

542

(1)

Variables to be Determined

542

(1)

Determine Overall Coefficient at Maximum Flux

543

(1)

Determine Overall ΔT at Maximum Flux

543

(2)

Maximum Flat

545

(1)

Flux at Operating Levels Below Maximum

545

(2)

Fouled ΔT at Maximum Flux

547

(1)

Fouled ΔT, To Maintain Plus for 10°F Clean ΔT

548

(1)

Analysis of Data in Figure 21.225

548

(1)

Surface Area Required

548

(1)

Vapor Nozzle Diameter

549

(1)

Liquid Inlet Nozzle Diameter

549

(1)

Design Notes

549

(1)

Reboiling Piping

550

(1)

Film Boiling

550

(1)

Vertical Tubes, Boiling Outside, Submerged

550

(1)

Horizontal Tubes: Boiling Outside, Submerged

550

(4)

Common Reboiler Problems

554

(1)

Heat Exchanger Design with Computers

555

(2)

Functionality

557

(1)

Physical Properties

558

(1)

UniSim Heat Exchanger Model Formulations

559

(1)

Case Study 1 Kettle Reboiler Simulation Using UniSim STE

559

(5)

Nozzle Data

564

(48)

Process Data

564

(8)

Case Study 2 Thermosyphon Reboiler Simulation Using UniSim STE

572

(2)

Process Data (SI Units)

574

(6)

Solution

580

(1)

Troubleshooting of Shell and Tube Exchanger

580

(1)

Maintenance of Heat Exchangers

580

(1)

Disassembly for Inspection or Cleaning

580

(1)

Locating Tube Leaks

580

(16)

Hydrocarbon Leaks

596

(1)

Pass Partition Failure

596

(1)

Water Hammer

596

(2)

General Symptoms in Shell and Tube Heat Exchangers

598

(1)

Case Studies of Heat Exchanger Explosion Hazard Incidents

599

(1)

A Case Study (Courtesy of U.S. Chemical Safety and Hazard Investigation Board)

599

(1)

Tesoro Anacortes Refinery, Anacortes, Washington

599

(3)

Process Conditions of the B and E Heat Exchangers

602

(1)

US Chemical Safety Board (CBS) Findings

602

(4)

Recommendations

606

(1)

Maintenance Procedures

607

(5)

References

612

(9)

22 Energy Management and Pinch Technology

621

(180)

22.1 Introduction

621

(3)

22.2 Waste Heat Recovery

624

(7)

22.2.1 Steam Distribution

625

(1)

22.2.2 Design for Energy Efficiency

626

(2)

22.2.3 Energy Management Opportunities

628

(3)

22.3 Process Integration and Heat Exchanger Networks

631

(8)

22.3.1 Application of Process Integration

638

(1)

22.4 Pinch Technology

639

(10)

22.4.1 Heat Exchanger Network Design

640

(3)

22.4.2 Energy and Capital Targeting and Optimization

643

(1)

22.4.3 Optimization Variables

643

(2)

22.4.4 Optimization of the Use of Utilities (Utility Placement)

645

(1)

22.4.5 Heat Exchanger Network Revamp

645

(4)

22.5 Energy Targets

649

(1)

22.5.1 Heat Recovery for Multiple Systems

650

(1)

Example 22.1 Setting Energy Targets and Heat Exchanger Network

650

(5)

Solution

650

(5)

22.6 The Heat Recovery Pinch and Its Significance

655

(1)

22.7 The Significance of the Pinch

656

(2)

22.8 A Targeting Procedure: The Problem Table Algorithm

658

(3)

22.9 The Grand Composite Curve

661

(4)

22.9.1 Placing Utilities Using the Grand Composite Curve

663

(2)

22.10 Stream Matching at the Pinch

665

(1)

22.10.1 The Pinch Design Approach to Inventing a Network

666

(1)

22.11 Heat Exchanger Network Design

666

(27)

Example 22.2

673

(1)

Solution

673

(5)

22.11.1 Stream Splitting

678

(1)

Example 22.3 (Source: Seider et al., Product and Process Design Principles---Synthesis, Analysis, and Evaluation 3rd Ed. Wiley 2009 [ 26])

679

(1)

Solution

680

(1)

Example 22.4 [ Source: Manufacture of cellulose acetate fiber by Robins Smith (Chemical Process Design and Integration, John Wiley 2007 [ 34])]

681

(6)

Solution

687

(6)

22.12 Heat Exchanger Area Targets

693

(10)

Example 22.5 (Source: R. Smith, Chemical Process Design, Mc Graw-Hill, 1995 [ 20])

695

(1)

Solution

696

(7)

Example 22.6

703

(1)

Solution

703

(1)

22.13 HEN Simplification

703

(7)

Example 22.7 Test Case 3, TC3 Linnhoff and Hindmarch

703

(1)

Solution

704

(5)

22.13.1 Heat Load Paths

709

(1)

22.14 Number of Shell Target

710

(2)

22.14.1 Implications for HEN Design

711

(1)

22.15 Capital Cost Targets

712

(2)

22.16 Energy Targeting

714

(11)

22.16.1 Supertargeting or ΔTm.n Optimization

714

(1)

Example 22.8 Cost Targeting

714

(1)

Solution

715

(7)

Example 22.9 HEN for Maximum Energy Recovery (Warren D. Seider et al. [ 26])

722

(1)

Solution

722

(3)

22.17 Targeting and Design for Constrained Matches

725

(1)

22.18 Heat Engines and Heat Pumps for Optimum Integration

726

(6)

22.18.1 Appropriate Integration of Heat Engines

729

(2)

22.18.2 Appropriate Integration of Heat Pumps

731

(1)

22.18.3 Opportunities for Placement of Heat Pumps

731

(1)

22.18.4 Appropriate Placement of Compression and Expansion in Heat Recovery Systems

732

(1)

22.19 Pressure Drop and Heat Transfer in Process Integration

732

(1)

22.20 Total Site Analysis

732

(4)

22.21 Applications of Process Integration

736

(5)

22.22 Sitewide Integration

741

(1)

22.23 Flue Gas Emissions

741

(3)

22.24 Pitfalls in Process Integration

744

(57)

Glossary of Terms

789

(6)

Summary and Heuristics

795

(1)

Nomenclature

796

(1)

References

796

(4)

Bibliography

800

(1)

Appendix D

801

(76)

Appendix G

877

(42)

Appendix H

919

(8)

Glossary of Petroleum and Petrochemical Technical Terminologies

927

(126)

About the Author

1053

(2)

Index

1055

Kayode Coker PhD, is Engineering Consultant for AKC Technology, an Honorary Research Fellow at the University of Wolverhampton, U.K., a former Engineering Coordinator at Saudi Aramco Shell Refinery Company and Chairman of the department of Chemical Engineering Technology at Jubail Industrial College, Saudi Arabia. He has been a chartered chemical engineer for more than 30 years. He is a Fellow of the Institution of Chemical Engineers, U.K. and a senior member of the American Institute of Chemical Engineers. He holds a B.Sc. honors degree in Chemical Engineering, a Master of Science degree in Process Analysis and Development and Ph.D. in Chemical Engineering, all from Aston University, Birmingham, U.K. and a Teachers Certificate in Education at the University of London, U.K. He has directed and conducted short courses extensively throughout the world and has been a lecturer at the university level. His articles have been published in several international journals. He is an author of five books in chemical engineering, a contributor to the Encyclopedia of Chemical Processing and Design. Vol 61. He was named as one of the International Biographical Centres Leading Engineers of the World for 2008. Also, he is a member of International Whos Who of ProfessionalsTM and Madison Whos Who in the U.S.

Petroleum Refining Design and Applications Handbook, Volume 4: Heat Transfer, Pinch Analysis, and Process Safety Incidents [Hardback]

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