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Rigorous Simulation of Heat Exchanger Networks: PRO/II® - HTRI®

September 24, 2014

Linking Third Party Software Heat Exchanger Network Simulation – 2014

3

Process Heat Transfer Modeling - Perspective

1941- 1962 Fouling Factors Established; Kern, McAdams, Tinker, Bell-Delaware

First TEMA® design methods are published to members

HTRI® Founded

Delaware Research Project issued Final Report

HTRI® Publishes Stream Analysis Method (Tinker)

Programmable, electronic desktop calculators become affordable

Apple® Computer Introduces Apple® I personal computer (4K memory)

Most PC’s provide 32K chip memory allowing program design methods

HTRI® releases first PC version of Shell & Tube software

Property Generation from a stream in PRO/II® to HTRI®

HEXTRAN® makes it possible to analyze complex heat exchanger Networks

1962 - 1963

1967

1977 - 1981

1987

1990’s

2000 - 2014

2015 – (?)

Process Simulators linked to 3rd Party Specialty software

Specialty 3rd Party Software embedded in Process simulators to permit rigorous modeling of

process equipment

4

Process Data

Design Conditions

Materials of Construction

The heat exchanger design process

Design is based on specified process conditions, materials, fouling factors, etc.

‘As-Built’ hardware is expected to meet / exceed duty within hydraulic limits

Each service designed as a discrete unit operation – MANUAL Steps to move Data

No check of impact to the overall system through rigorous flowsheet modeling of

vendor supplied equipment – No FEEDBACK Mechanism

Unexpected performance may result from ‘as-built’ accumulative overdesign

and variance from ‘design’ temperature / pressure profiles

Heat Transfer Data Sheet Setting Plan

Mat’l Requisition

Installation Startup

Operation Troubleshoot

5

HTRI® (Heat Transfer Research Inc.)

Design, Rate, and Simulate Heat Transfer Equipment

Rigorous Heat Transfer and Pressure Drop Calculations

Interfaces to Process Simulators, Physical Property Banks, Mechanical Design

Programs, Microsoft Excel®, etc.

CAPE-OPEN Compliant Applications

6

Simulating Heat Exchanger Networks - Linking PRO/II® to HTRI®

PRO/II® simulates process conditions (H&MB)

HTRI® designs and simulates (nearly) all types of heat exchangers

HTRI® provides a variety of CAPE-OPEN compliant exchanger types

CAPE-OPEN is an industry software standard which allows different

3rd party process/equipment modeling software to ‘talk’ to each other

PRO/II® Implementation of HTRI

CAPE-OPEN will interface to 7 unique HTRI® modules

In addition, the COM Server provides a seamless interface for PRO/II® to

communicate with Xist® (Shell & Tube) and Xace® (Air Coolers)

PRO/II® HTRI® LINK

COM Server (Xist® & Xace®)

CAPE-OPEN

9

Linking PRO/II® with HTRI®

• Com Server Interface (Preferred)

Full functionality of HTRI® for S&T® (Xist®) and Air Coolers (Xace®)

Seamlessly flanges PRO/II® to HTRI®

Improved stability, fewer issues with inconsistencies

• CAPE-OPEN Interface

Permits linking to other HTRI® supported Unit Operations

May not provide 100% of the HTRI® functionality

Simple Heat Exchanger Network

PRO/II® ~ 2-3 seconds

HTRI® embedded > 1 minute

Slightly More Complex Exchanger Systems Cold End Modeling using HTRI® Xpfe® via CAPE-OPEN Interface

Rigorous Model in lieu of LNG Block H&MB

CAPE-OPEN links PRO/II® to Xpfe

®

Cold Box Simulation

Xpfe® Simulation checks profiles, integration effectiveness

13

PRO/II® - HTRI® (Xpfe®) Integration (This is Significant)

Stand-alone modeling of a single unit operation

PRO/II® links Xpfe® via CAPE-OPEN

Xpfe® is not connected to other flowsheet elements; does not

exchange data or contribute to the main flowsheet solution

CAPE-OPEN Unit Operations calc’s occur after flowsheet solves

Stand-alone modeling of a Cold Box exchanger train looks promising

Still in early stages of testing, implementation, and validation

SIGNIFICANT time savings for engineers

14

PRO/II® - HTRI® (Xpfe®) Integration (This is More Significant)

Integrated modeling

PRO/II® links Xpfe® via CAPE-OPEN (same as stand-alone)

Xpfe® is fully connected to other flowsheet elements

Xpfe® Unit Operations calc’s occur as flowsheet solves

Integrated modeling of Cold Box exchanger train is challenged

Fails to solve in some cases

Could be operator error but robustness / stability should be

investigated by software vendors to improve

Opportunity for SIGNIFICANT time savings for engineers

Quick (or not so quick) DEMO

16

PRO/II® - HTRI ® Integration - What are the Benefits?

Energy / Margin Credits (% OPEX, CIT, other)

Process Optimization and Improved Integration of Exchanger Networks

Species Targets (H2, other)

“U” x Surface Area (UA) = Opportunity

Property Generation is freaky fast

Facilitates ‘what if’ analysis

Analysis for Fouling Modeling / Reduction

Benefits from combination of integration / rigorous modeling

17

Optimize Heat Exchanger Design in the Network

Basic design – know the parameters!

Q = UA (f) LMTD Q = duty

U = overall heat transfer coefficient

A = surface area

LMTD = Log Mean Temperature Difference

Pressure Drop Inside tube heat transfer coefficient (ℎ𝑖) for

turbulent flow inside tube varies ~ 𝑚 0.8

Δ𝑃 𝑣𝑎𝑟𝑖𝑒𝑠 ~ 𝑚 2

A realistic pressure drop should be determined

at this stage to avoid re-work

Fouling predictive models may include

pressure drop as one of the mitigating

parameters; i.e. fluid shear, temperature, etc.

𝑳𝑴𝑻𝑫 = (𝑮𝑻𝑻𝑫 − 𝑳𝑻𝑻𝑫)

𝐥𝐧𝑮𝑻𝑻𝑫𝑳𝑻𝑻𝑫

U = 𝟏

[𝟏

𝒉𝒐

𝟏

𝑬𝒇+ 𝒓𝒘+ 𝒓𝒊

𝑨𝒐𝑨𝒊

+ 𝟏

𝒉𝒐

𝑨𝒐𝑨𝒊

]

Benefits

Conceptualization, FEED, Revamps, and

EPC – get it right from the start

Rigorous modeling will lead to valuable

collaboration w/Specialists

Accurate Heat Transfer (U), Pressure

Drop (P), and Vibration Analysis

Benefit / Cost for margin, energy,

reliability, cost, maintenance (basis)

Identify ‘Enhanced’ Heat Transfer

Opportunities

Benefits

Acceptable modifications for revamp

exchangers

Specialty Exchangers – model these

using CAPE-OPEN / HTRI Module

Identify TEMA Type constraints when

considering possible modifications

Start of Run, End of Run, Turndown

conditions can highlight possible pitfalls /

avoid rework in the next phase of

engineering

Benefits

Screen for damaging flow-induced tube vibration or acoustic resonance at higher flowrates, different feeds, other

Dynamic pressure impact to equipment (rho-V2 i.e. erosion)

Identify unacceptable temperature profiles / temperature approaches

Integrated reporting (All Unit Ops / H&MB) in one place

Thermodynamic models and data seamlessly match up with ‘as-built’ geometry and process conditions

21

Provide Feedback to the Software Vendor(s)

Rigorous Simulation – Go Faster!

Stability Improvements needed for complex flowsheets Provide hidden workaround when HTRI unit operation encounters fatal error

Simplicity for invoking HTRI® (toggle back and forth)

Kettles / Thermosyphon (flowsheet communication, detailed piping, etc.)

Enhanced Graphing capability in Networks across multiple exchangers

Implement HEXTRAN® Functionality in PRO/II®

HTRI® Design Mode

Heat Integration / Pinch Analysis

Monitoring (data acquisition, conditioning, reconciliation, fouling trends)

Where do we go from here?

Questions?

Thank you