View source for DWSIM/C2/Shell-and-Tube-Heat-Exchanger/English


{| border=1
||'''Visual Cue'''
||'''Narration'''

|-
|| '''Slide Number 1
'''Title Slide'''
|| Welcome to this tutorial on Simulating a '''Shell & Tube Heat Exchanger '''in '''DWSIM.'''

|-
|| '''Slide Number 2
'''Learning Objective'''
|| In this tutorial, we will learn to:


* Simulate a''' Shell & Tube Heat Exchanger'''
* Calculate the '''Outlet stream temperatures'''
* Calculate '''Overall Heat Transfer Coefficient'''
* Calculate '''Heat Exchange Area'''
* Calculate '''Thermal Efficiency '''and''' LMTD'''

|-
|| '''Slide Number 3
'''System Requirements'''
|| To record this tutorial, I am using


* '''DWSIM 4.3 '''and
* '''Windows 7'''

The process demonstrated in this tutorial is identical in other '''OS''' also, such as-

* '''Linux''', 
* '''Mac OS X '''or 
* '''FOSSEE OS '''on '''ARM'''.

|-
|| '''Slide Number 4'''

'''Pre-requisites '''
|| To practice this tutorial, you should know how to


* add components to a '''flowsheet'''
* select '''thermodynamic '''packages and
* add '''material '''stream''' '''and specify their properties.

|-
|| '''Slide Number 5'''

'''Prerequisite Tutorials and Files'''
|| The prerequisite tutorials are mentioned on our website, '''spoken-tutorial.org'''


You can access these tutorials and all the associated files from this site.

|-
|| '''Slide Number 6'''

'''Compounds '''and''' Inlet Condition'''


Cold Stream: Water

Hot Stream: Methanol


'''Cold Inlet Stream:'''


Mass Flow: 15000 kg/h

Mole Fraction(CH<sub>3</sub>OH): 0

Mole Fraction(H<sub>2</sub>O): 1

Temperature: 10 degree C 

Pressure: 1 bar


'''Hot Inlet Stream:'''


Mass Flow: 25000kg/h

Mole Fraction(CH<sub>3</sub>OH): 1

Mole Fraction(H<sub>2</sub>O): 0

Temperature: 80 degree C 

Pressure: 5 bar
|| Here, We will develop a '''flowsheet '''to determine:

* '''Outlet stream temperatures'''
* '''Overall Heat Transfer coefficient '''and 
* '''Heat Exchange area.'''


Here we give '''Compounds '''and''' Inlet stream conditions.'''

|-
|| '''Slide Number 7'''

'''Heat Exchanger Properties'''


Flow type: Counter-Current

Cold Fluid Pressure Drop: 0.002 bar

Hot Fluid Pressure Drop: 0.025 bar

Property Package: Raoult’s Law
|| Here we give '''Heat Exchanger''' properties and '''Property package'''.

|-
|| '''Slide Number 8 & 9'''


'''Shell & Tube Exchanger Properties'''


Type of Exchanger: 2-8 Shell % Tube Heat Exchanger


Total number of tubes: 2048

Tube Spacing: 25 mm

Tube Layout: Square

Thermal Conductivity of tube: 60 W/m K

Tube Roughness: 0.05 mm

Fouling Factor (tube side): 0.00035 K m<sup>2</sup>/W

Tube Length: 5 m

External Diameter for tube: 20 mm

Tube thickness: 2.5 mm

Fouling Factor (shell side): 0.00035 K m<sup>2</sup>/W

Shell Internal Diameter: 1000 mm

Baffle Spacing : 250 mm

Baffle Cut: 25%

Fluid in Shell: Methanol
|| Here we give '''Shell & Tube Heat Exchanger''' Properties.

|-
|| 
|| I have already opened '''DWSIM '''on my machine. 

|-
|| File >>'''New Steady-state Simulation '''
|| Go to '''File '''menu and select '''New Steady-state Simulation.'''

|-
|| Point to '''Simulation Configuration Wizard '''window
|| '''Simulation Configuration Wizard '''window appears.

|-
|| Click on '''Next'''.
| | At the bottom, click on '''Next.'''

|-
|| Type '''Methanol '''in the '''Search '''tab
|| Now, in the '''Compounds Search '''tab, type '''Methanol.'''

|-
|| '''ChemSep '''database >>'''Methanol'''
|| Select '''Methanol '''from '''ChemSep '''database.

|-
|| '''Type Water '''in the '''Search '''tab
|| Similarly, add '''Water'''.

|-
|| Click on '''Next.'''
|| At the bottom, click on '''Next'''

|-
|| Point to''' Property Packages'''
|| Now comes '''Property Packages.'''

|-
|| '''Property Packages'''>> '''Available Property Package'''


Double click on '''Raoult’s Law'''
|| From the '''Available Property Packages''', double-click on '''Raoult’s Law.'''

|-
|| Click on''' Next.'''
|| Then click on '''Next''' button. 

|-
|| Point to''' Flash Algorithm'''
|| We are moved to a new window named '''Flash Algorithm'''.

|-
|| '''Default Flash Algorithm '''>>'''Nested Loops (VLE)'''
|| From '''Default Flash Algorithm '''select '''Nested Loops(VLE)'''

|-
|| Click '''Next'''
|| Click on '''Next '''button'''.'''

|-
|| Point to''' System of Units'''
|| Next option is '''System of Units.'''

|-
|| '''System of Units >> C5'''
|| Under '''System of Units''', select '''C5'''.

|-
|| Click on''' Finish'''
|| At the bottom, click on '''Finish '''button.

|-
|| 
|| Let us maximize the simulation window for better visibility.

|-
|| 
|| Now let’s insert two material streams that enter the '''Heat Exchanger'''.

|-
|| Point to '''Flowsheet Objects.'''
|| On the right hand side of the main simulation window, go to '''Flowsheet Objects.'''

|-
|| In the''' Filter List '''tab, type '''Material Stream'''
|| In the '''Filter List '''tab, type '''Material Stream.'''

|-
|| Click and drag '''Material Stream '''to the flowsheet
|| From the displayed list, drag and drop a '''Material Stream '''to the '''Flowsheet'''.

|-
|| Click on '''MSTR-000'''
|| Click on '''MSTR-000 '''to view its properties.

|-
|| Type '''Water In'''
|| Let’s change the name of this '''stream '''to '''Water In.'''

|-
|| 
|| Now we will specify the '''Water In stream '''properties.

|-
|| '''Input Data>>Flash Spec>>Temperature and Pressure(TP)'''
|| Go to '''Input Data.'''


Select '''Flash Spec '''as '''Temperature and Pressure (TP), '''if not already selected.


By default, '''Temperature and Pressure '''are already selected as '''Flash Spec.'''

|-
|| '''Input Data >>Temperature >>10C'''

Press '''Enter'''
|| Change '''Temperature '''to '''10 degC '''and press '''Enter.'''

|-
|| '''Input Data >>Pressure >>1bar'''

Press '''Enter'''
|| Change '''Pressure '''to '''1 bar '''and press '''Enter'''.

|-
|| '''Input Data >>Mass Flow >>15000kg/h'''

Press '''Enter'''
|| Change '''Mass Flow '''to '''15000 kg/h '''and press '''Enter'''.

|-
|| 
|| Now let us specify the '''feed stream '''compositions.

|-
|| '''Composition >>Basis >>Mole Fractions'''
|| Under '''Composition''', choose the '''Basis '''as '''Mole Fractions, '''if not already selected'''.'''


By default, '''Mole Fractions '''is selected as '''Basis.'''

|-
|| '''Methanol: 0'''

|| Now for '''Methanol''', enter the '''Amount '''as '''0 '''and press '''Enter.'''

|-
|| '''Water: 1'''
|| Similarly, for '''Water''', enter it as '''1 '''and press '''Enter.'''

|-
|| Click '''Accept Changes'''
|| On the right, click on this green tick to '''Accept Changes.'''

|-
|| 
|| Now drag and drop another '''Material Stream '''to the flowsheet.

|-
|| Click on '''MSTR-000'''
|| Click on '''Material Stream '''“'''MSTR-001” '''to view its properties.

|-
|| Type '''Methanol In'''
|| Let’s change the name of this '''stream '''to '''Methanol In.'''

|-
|| 
|| Now we will specify the '''Methanol In '''stream properties.

|-
|| '''Input Data>>Flash Spec>>Temperature and Pressure(TP)'''
|| Go to '''Input Data.'''


Select '''Flash Spec '''as '''Temperature and Pressure (TP).'''


By default, '''Temperature and Pressure '''are again already selected as '''Flash Spec.'''

|-
|| '''Input Data >>Temperature >> 80 degC'''

Press '''Enter'''
|| Change '''Temperature '''to '''80 degC '''and press '''Enter.'''

|-
|| '''Input Data >>Pressure >>5 bar'''

Press '''Enter'''
|| Change '''Pressure '''to '''5 bar '''and press '''Enter'''.

|-
|| '''Input Data >>Mass Flow >>25000 kg/h'''

Press '''Enter'''
|| Change '''Mass Flow '''to '''25000 kg/h '''and press '''Enter'''.

|-
|| 
|| Now let us specify the '''Methanol In stream compositions'''.

|-
|| '''Composition >>Basis >>Mole Fractions'''
|| Under '''Composition''', choose the '''Basis '''as '''Mole Fractions, '''if not already selected'''.'''


By default, '''Mole Fractions '''is selected as '''Basis.'''

|-
|| '''Methanol: 1'''

|| Now for '''Methanol''', enter the '''Amount '''as '''1 '''and press '''Enter.'''

|-
|| '''Water: 0'''
|| Similarly, for '''Water''', enter it as '''0 '''and press '''Enter.'''

|-
|| Click '''Accept Changes'''
|| On the right, click on this green tick to '''Accept Changes.'''

|-
|| 
|| Now let’s insert two more material streams that exit the '''Heat Exchanger'''.

|-
|| Click and Drag '''Material Stream '''to the flowsheet
|| To do that, let us drag one '''Material Stream.'''

|-
|| 
|| Let us now arrange it.

|-
|| 
|| Leave that stream as unspecified.

|-
|| Type '''Water Out'''
|| We will change the name of this '''stream '''to '''Water Out.'''

|-
|| Click and drag''' Material Stream '''to the flowsheet
|| Next, we will insert another '''Material Stream.'''

|-
|| 
|| Let us once again arrange it.

|-
|| 
|| Leave that stream as unspecified.

|-
|| Type''' Methanol Out'''
|| And name this '''stream '''as '''Methanol Out.'''

|-
|| 
|| Now let us insert a '''Heat Exchanger '''into the '''flowsheet'''.

|-
|| Go to '''Flowsheet Objects'''
|| Go to '''Flowsheet Objects'''.

|-
|| In the '''Filter list '''tab, type '''Heat Exchanger.'''
|| In the '''Filter list '''tab, type '''Heat Exchanger.'''

|-
|| Click and drag '''Heat Exchanger '''to the flowsheet
|| Click on the '''Heat Exchanger '''displayed.


Drag and drop it to the '''flowsheet.'''


|-
|| Click on '''Heat Exchanger'''
|| Let us now arrange it as required for better visibility.


Let's click on it.

|-
|| 
|| On the left, we can see a tab called''' Property Editor Window.'''

|-
|| Go to''' Connections'''


Click on drop down arrow against''' Inlet Stream 1'''


Select '''Methanol In.'''
|| Under '''Connections, '''click on the drop-down against '''Inlet Stream 1.'''


And select '''Methanol In.'''

|-
|| Click on drop down arrow against''' Outlet Stream 1'''


Select '''Methanol Out.'''
|| Next, click on the drop-down against '''Outlet Stream 1.'''


And select '''Methanol Out.'''

|-
|| Click on the drop down against''' Inlet Stream 2'''


Select '''Water In.'''
|| Then click on the drop-down against '''Inlet Stream 2. '''


And select '''Water In.'''

|-
|| Click on the drop down against''' Outlet Stream 2'''


Select '''Water Out.'''
|| Then click on the drop-down against '''Outlet Stream 2. '''


And select '''Water Out.'''

|-
|| Hover mouse at''' Calculation Parameters'''
|| Now go to the next section- '''Calculation Parameters.'''

|-
|| 
|| Here, the first option is '''Calculation Type.'''

|-
|| Click drop down against '''Calculation Type'''
|| Click on the drop-down against '''Calculation Type.'''

|-
|| Select '''Shell and Tubes Exchanger Ratings'''
|| Select '''Shell and Tubes Exchanger Ratings.'''

|-
|| Click drop down against '''Flow Direction.'''


Select '''Counter Current'''
|| Next, click on the drop-down against '''Flow Direction'''


Select '''Counter Current.'''

|-
|| '''Cold Fluid Pressure Drop'''>>'''0.002 bar'''


Press '''Enter'''
|| Then click on the field against '''Cold Fluid Pressure Drop '''and enter '''0.002 bar.'''


Then press '''Enter.'''

|-
|| '''Hot Fluid Pressure Drop>>0.025bar'''



|| Click on the field against '''Hot Fluid Pressure Drop '''and enter it as '''0.025 bar.'''

|-
|| Press '''Enter'''
|| Then press '''Enter.'''

|-
|| Click '''Edit Shell and Tube Heat Exchanger Properties'''
|| Now we will enter the properties of '''Shell & Tube Exchanger'''.


Click on '''Edit Shell and Tube Heat Exchanger Properties.'''

|-
|| 
|| '''Shell and Tube Exchanger Properties''' window opens.

|-
|| Point to '''Shell and Tube Exchanger Properties '''window
|| Here, we can see the by default values for Shell and Tube side configurations.

|-
|| 
|| First we will edit the Shell Side Configuration.

|-
|| '''Shell in Series>>1'''
|| Click on the field against '''Shell in Series''' and enter it as '''1'''

|-
|| '''Shell Passes>>2'''
|| Click on the field against '''Shell Passes''' and enter it as '''2'''

|-
|| '''Internal Diameter>>1000 mm'''
|| Click on the field against '''Internal Diameter''' and enter it as '''1000'''

|-
|| '''Fouling Factor>>0.00035 K m<sup>2</sup>/W'''
|| Click on the field against '''Fouling Factor''' and enter it as '''0.00035'''

|-
|| '''Baffle Spacing >>250 mm'''
|| Click on the field against '''Baffle Spacing''' and enter it as '''250'''

|-
|| '''Baffle Cut(% diameter)>>25%'''
|| Click on the field against '''Baffle Cut(% diameter)''' and enter it as '''25'''

|-
|| 
|| This completes the '''Shell Side''' Configuration.

|-
|| 
|| Now we will edit the '''Tube Side''' Configuration.

|-
|| '''Internal Diameter>>15 mm'''
|| Click on the field against '''Internal Diameter''' and enter it as '''15'''

|-
|| '''External Diameter>>20 mm'''
|| Click on the field against '''External Diameter''' and enter it as '''20'''

|-
|| '''Length>>5 m'''
|| Click on the field against '''Length''' and enter it as '''5'''

|-
|| '''Fouling Factor>>0.00035 K m<sup>2</sup>/W'''
|| Click on the field against '''Fouling Factor''' and enter it as '''0.00035'''

|-
|| '''Roughness>>0.05 mm'''
|| Click on the field against '''Roughness''' and enter it as '''0.05'''

|-
|| '''Thermal Conductivity>>60 W/m K'''
|| Click on the field against '''Thermal Conductivity''' and enter it as '''60'''

|-
|| '''Passes per Shell>>4'''
|| Click on the field against '''Passes per Shell''' and enter it as '''4'''

|-
|| '''Tubes per Shell>>1024'''
|| Click on the field against '''Tubes per Shell''' and enter it as '''1024'''

|-
|| '''Tube Spacing>>25 mm'''
|| Click on the field against '''Tube Spacing''' and enter it as '''25'''

|-
|| '''Tube Layout>>Square'''
|| Click on the drop down against '''Tube Layout''' and select '''Square'''

|-
|| '''Fluid in Tubes>>Cold'''
|| Select the option '''Cold''' against '''Fluid in Tubes'''

|-
|| 
|| Now all the '''Shell & Tube Exchanger Properties''' are specified.

|-
|| 
|| Close the '''Shell and Tube Exchanger Properties''' window by clicking red cross mark on the top right of the window.

|-
|| 
|| Now we will run the '''simulation.'''

|-
|| Click '''Solve Flowsheet'''
|| So, from the toolbar, click on '''Solve Flowsheet '''button.

|-
|| Click '''Heat Exchanger'''
|| When the calculations are completed, click on '''Heat Exchanger '''in the '''Flowsheet'''.

|-
|| Hover mouse at''' Calculation Parameters'''
|| From the '''Property Editor Window '''of '''Heat Exchanger, '''locate '''Calculation Parameters '''section.

|-
|| 
|| Check '''Cold Fluid Outlet Temperature'''<nowiki>; It is </nowiki>'''66.15 degree C'''


Check '''Hot Fluid Outlet Temperature'''<nowiki>; It is </nowiki>'''40.95 degree C'''


Check '''Overall Heat Transfer Coefficient'''<nowiki>; It is </nowiki>'''191.83 W/m<sup>2</sup> K'''

Check '''Heat Exchange Area'''<nowiki>; It is </nowiki>'''319.12 m<sup>2'''</sup>

|-
|| Hover mouse at''' Results'''
|| From the '''Property Editor Window '''of '''Heat Exchanger, '''locate '''Results '''section.

|-
|| '''Results '''
|| Under '''Results''' section, check '''Thermal efficiency;''' it is '''79.05 %'''


Check '''Log Mean Temperature Difference;''' it is '''21.25 degree C.'''

|-
|| 
|| Now we will check the '''stream-'''wise temperature results and '''Material balance.'''

|-
|| '''Insert >>Master Property Table'''
|| Go to '''Insert '''menu and select '''Master Property Table'''.

|-
|| Double click on''' Master Property Table'''
|| Double-click on the '''Master Property Table '''to edit it.

|-
|| Point to '''Configure Master Property Table'''
|| '''Configure Master Property Table '''window opens.

|-
|| Type '''Heat Exchanger – Stream Wise Results'''
|| Enter '''Name '''as '''Heat Exchanger – Stream Wise Results'''

|-
|| '''Object Type >>Material Stream'''
|| Enter '''Object Type '''as '''Material Stream'''.


By default, '''Material Stream '''is already selected.

|-
|| 
|| So we will not change it.

|-
|| '''Object >>Methanol Out, Water Out, Methanol In and Water In.'''
|| Under '''Properties to display''', select '''Object '''as:


'''Water In, Methanol In, Water Out '''and''' Methanol Out.'''

|-
|| '''Configure Master Property Table>>Property'''
|| Under '''Property''', scroll down to see all the parameters.


Now select the properties as:


'''Temperature'''

'''Pressure'''

'''Mass Flow'''

'''Molar Flow'''

'''Molar Fraction(Mixture) / Methanol'''

'''Molar Fraction(Mixture) / Water'''

|-
|| Close this window.
|| Close this window.

|-
|| 
|| Move the '''Master Property Table '''for better visibility.


Here we can see the corresponding results for '''Inlet '''and '''Outlet streams.'''

|-
|| 
|| Now we will check the properties of '''Heat Exchanger.'''

|-
|| '''Insert >>Master Property Table'''
|| Go to '''Insert '''menu and select '''Master Property Table'''.

|-
|| Double click on''' Master Property Table'''
|| Double-click on the '''Master Property Table.'''

|-
|| Point to '''Configure Master Property Table'''
|| '''Configure Master Property Table '''window opens.

|-
|| Type '''Heat Exchanger – Results'''
|| Enter '''Name '''as '''Heat Exchanger – Results.'''

|-
|| '''Object Type >>Material Stream'''
|| Enter '''Object Type '''as '''Heat Exchanger'''.

|-
|| '''Object >>HE-004.'''
|| Under '''Properties to display''', select '''Object '''as '''HE-004'''

|-
|| '''Configure Master Property Table>>Property'''
|| Under '''Property''', scroll down to see all the parameters.


Now select the properties as:


'''Global Heat Transfer Coefficient (U)'''

'''Heat Exchange Area (A)'''

'''Heat Load'''

'''Cold fluid outlet temperature'''

'''Hot fluid outlet temperature'''

'''Logarithmic mean temperature difference LMTD''' and

'''Thermal Efficiency'''

|-
|| Close this window.
|| Close this window.

|-
|| 
|| Move the '''Master Property Table '''for better visibility.


Here we can see the corresponding results for '''Heat Exchanger.'''

|-
|| 
|| Let's summarize.

|-
|| '''Slide Number 10'''


'''Summary'''
|| In this tutorial, we have learnt to


* Simulate a''' Shell & Tube Heat Exchanger'''
* Calculate the''' Outlet stream temperatures'''
* Calculate '''Overall Heat Transfer Coefficient'''
* Calculate '''Heat Exchange Area'''
* Calculate''' Thermal Efficiency '''and''' LMTD'''

|-
|| '''Slide Number 11, 12, 13 &  14'''


'''Assignment'''


'''Compounds and Inlet Condition'''


Cold Stream: '''Toluene'''

Hot Stream: '''Styrene'''


'''Cold Inlet Stream:'''


Mass Flow: 50000 kg/h

Mole Fraction(C<sub>7</sub>H<sub>8</sub>): 1

Mole Fraction(C<sub>8</sub>H<sub>8</sub>): 0

Temperature: 35 degree C 

Pressure: 6.5 bar


'''Hot Inlet Stream:'''


Mass Flow: 70000kg/h

Mole Fraction(C<sub>7</sub>H<sub>8</sub>): 0

Mole Fraction(C<sub>8</sub>H<sub>8</sub>): 1

Temperature: 150 degree C 

Pressure: 3.5 bar


'''Heat Exchanger Properties'''


Flow type: Counter-Current

Cold Fluid Pressure Drop: 0.002 bar

Hot Fluid Pressure Drop: 0.025 bar

Property Package: UNIFAC


'''Shell & Tube Exchanger Properties'''


Type of Exchanger: 2-16 Shell & Tube Heat Exchanger

Total number of tubes: 1024

Tube Spacing: 75 mm

Tube Layout: Square

Thermal Conductivity of tube: 70 W/m K

Tube Roughness: 0.045 mm

Fouling Factor (tube side): 0 K m2/W

Tube Length: 5 m

External Diameter for tube: 60 mm

Tube thickness: 5 mm

Fouling Factor (shell side): 0 K m2/W

Shell Internal Diameter: 990.6 mm

Baffle Spacing : 250 mm

Baffle Cut: 25%

Fluid in Shell: Styrene

|| As an assignment,


Repeat this simulation with different '''Compounds, feed conditions '''and '''Thermodynamics'''.

|-
|| '''Slide Number 15'''

'''About the Spoken Tutorial Project'''
|| Watch the video available at following link.

'''http://spoken-tutorial.org/ '''

It summarizes the Spoken Tutorial project.

|-
|| '''Slide Number 16'''

'''Spoken Tutorial Workshops'''
|| The Spoken Tutorial Project Team

* Conducts workshops and
* Gives certificates
* For more details, please write to contact@spoken-tutorial.org

|-
|| '''Slide Number 17'''

'''Forum Slide'''


Do you have questions in this '''Spoken Tutorial?'''

Please visit this site 

Choose the minute and second where you have the question. 

Explain your question briefly. 

Someone from the FOSSEE team will answer them. 

|| Please post your times queries in this forum. 

|-
|| '''Slide Number 18
'''DWSIM Flowsheeting Project'''

|| The '''FOSSEE '''team coordinates conversion of existing flow sheets into '''DWSIM'''.

We give honorarium and certificates.

For more details, please visit this site.

|-
|| '''Slide Number 19
'''TextBook Companion Project'''
|| The '''FOSSEE '''team coordinates coding of solved examples of popular books.


We give honorarium and certificates .


For more details, please visit this site.

|-
|| '''Slide Number 20
'''Lab Migration Project'''
|| The '''FOSSEE '''team helps migrate commercial simulator labs to '''DWSIM.'''


We give honorarium and certificates.


For more details, please visit this site

|-
|| '''Slide Number 21
'''Acknowledgements'''
|| '''Spoken Tutorial '''and '''FOSSEE '''projects are funded by '''NMEICT, MHRD''', Government of India.

|-
|| '''Slide Number 22
'''Thanks'''
|| This tutorial is contributed by Kaushik Datta and Priyam Nayak.


Thanks for joining.

|}