Tube bundle replacement for segmental and helical shell and tube heat exchangers: Experimental test and economic analysis |
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| Affiliation: | 1. School of Mechatronic Engineering, Xi''an Technological University, Xi''an 710021 China;2. Mechanical Engineering Department, University of Technology, Baghdad, Iraq;3. Department of Mechanical Engineering, Faculty of Engineering, University of Mohaghegh Ardabili, Ardabil, Iran;4. Department of Mechanical Engineering, College of Engineering, King Khalid University, Abha 61421, Saudi Arabia;5. Department of Civil Engineering, College of Engineering, Prince Sattam bin Abdulaziz University, Alkharj 11942, Saudi Arabia;1. School of Mechanical Engineering, Yangtze University, Jingzhou 434023, PR China;2. Sichuan BOMCO Special Vehicle Manufacturing Co., Ltd, CNPC Baoji Oilfield Machinery Company Limited, Guanghan 618399, PR China;3. Mechatronic Engineering College, Southwest Petroleum University, Chengdu 610500, PR China |
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| Abstract: | In this investigation, the second test analysis with more comprehensive evaluation with a focus on fouling mitigation, increased running-time and economic analysis are shown and then, the thermal design procedure for tube bundle replacement of critical heat exchanger of Butene-1 unit in Petrochemical Company as a case study are described. Finally, experimental data for the average heat transfer coefficient and pressure drop of shell-side in segmental and helix bundles are measured and calculated for the mass flow rate of 14.24 kg/s and then these data are compared with the data from code and EXPRESS. Moreover, additional comparison between code and EXPRESS results are provided to ensure the accuracy of calculation program in various mass flow rates. Based on the same shell in the case studies, the results showed that in addition to improved heat transfer performance of the helix bundle over segmental bundle, helix bundle achieved two to three times longer operational run times. From economic point of view, the results for replacement of segmental bundle with a helix bundle showed that initial and installation costs of helix bundle to segmental bundle could be increased, but maintenance and operating costs can be decreased in the helix bundle, 60% and 20%, respectively. Comparison between code and EXPRESS results with experimental data for the mass flow rate of 14.24 kg/s showed that the deviation in heat transfer coefficient and pressure drop are quite reliable for segmental and helix bundles. |
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| Keywords: | Helix bundle Segmental bundle Tube bundle replacement Fouling mitigation Total cost analysis |
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