Jump Start: Aspen Shell & Tube Exchanger V8

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1 A Brief Tutorial and Sample Case for Sizing in EDR Shell & Tube (supplement to training and online documentation) Lauren Sittler, Product Management, Aspen Technology, Inc. Tom Ralston, Director, Equipment Design and Rating, Aspen Technology, Inc.

2 Contents Introduction to Aspen Shell & Tube Exchanger Scope of this Document Tutorial Overview Step 1. Download the Aspen HYSYS File Step 2. Create a New EDR Case Step 3. Import Process Data and Specify Application Options Process and Property Data Application Options Step 4. Select Appropriate Configuration and Sizing Constraints Step 5. Save and Run Sizing Optimization Step 6. Viewing the Results Appendix A. Navigate the EDR User Interface Navigation Pane Text Coloring User Input Tabs: Geometry, Process, Errors & Warnings Appendix B. Alternative Methods to Specify Process & Property Data Manually Enter Property Data Searching the Properties Databanks Appendix C. Using a Design Template Additional Resources

3 Introduction to Aspen Shell & Tube Exchanger Aspen Exchanger Design & Rating (Aspen EDR) software provides the most comprehensive package available for designing and rating heat exchangers. EDR software is used daily for thermal, mechanical and process engineering by engineering contractors, process operators and exchanger fabricators throughout the world. Aspen Shell & Tube Exchanger can be used to design all major industrial shell & tube exchanger equipment types in any combination of processes including single phase heating or cooling and boiling or condensation. Typically, users save between 10-30% on equipment cost by effectively designing their exchangers using Aspen EDR. Given a process requirement and physical property data, the program conducts a comprehensive design search to find the optimum cost arrangement capable of satisfying the process constraints. The program provides detailed exchanger geometry and performance details as well as a specification sheet, setting plan, and tube layout drawings. Completed designs can be transferred to Aspen Shell & Tube Mechanical for complete mechanical design to the requirements of ASME or other leading international design codes. Scope of this Document This tutorial is intended as a guide to getting started using Aspen Shell & Tube Exchanger to create, evaluate, and save designs. It offers a step-by-step explanation of how an equipment designer would use the standalone program. Instructions on how to import process and property data from Aspen HYSYS and Aspen Plus are included but, for simplicity, the new automatic workflows for exchanger sizing provided in V8 simulators are covered in separate documents. The new workflows are invaluable to the process engineer conducting preliminary design of heat exchangers and as part of process revamp studies. Additional resources for a more comprehensive understanding can be found at: The AspenTech website The AspenTech support site AspenTech business consultants See the Additional Resources section of this document (page 11) for more detail. The files associated with this example are available for download on the Customer Support & Training Website. Tutorial Overview We will demonstrate the workflow by completing the design of a Shell & Tube exchanger for a crude preheat train process. We will import process and property data from an Aspen HYSYS case to size the exchanger. Explanations for each step will be provided. The appendix provides additional details on each step, as well as instructions for alternative methods of completing a step. Figure 1 shows the Aspen HYSYS process flow diagram; we are interested in Exchanger e304. 1

Figure 1. Exchanger e304 in Aspen HYSYS Preheat Train Step 1. Download the Aspen HYSYS File Download the file Preheat Train for Jump Start EDR.hsc, and save it on your desktop.

4 Figure 1. Exchanger e304 in Aspen HYSYS Preheat Train Step 1. Download the Aspen HYSYS File Download the file Preheat Train for Jump Start EDR.hsc, and save it on your desktop. We will import data from this file later so remember the location. Step 2. Create a New EDR Case On your desktop, open the Start Menu > All Programs > Aspentech > Exchanger Design and Rating V8.0 > Exchanger Design and Rating User Interface. When EDR opens, click on the File menu > New > Shell & Tube Exchanger (Shell&Tube) > OK (Figure 2). Figure 2. Open Aspen EDR Shell & Tube 2

The EDR Shell & Tube program will open in the Interactive Design Console. You will see that some default parameters have already been specified and that some input is still required.

5 The EDR Shell & Tube program will open in the Interactive Design Console. You will see that some default parameters have already been specified and that some input is still required. Appendix A explains the EDR user interface. Take a minute to familiarize yourself with the navigation and the meanings of symbols, text coloring, etc. Step 3. Import Process Data and Specify Application Options Process and Property Data Process and property data can be entered in three ways: (1) manually, (2) by using the physical property databanks provided within the program, or (3) by importing from a simulation case. In this tutorial we will use the 3rd option and import data from an Aspen HYSYS case file. The alternative methods are explained in Appendix B. Import data from Aspen HYSYS Click on the File menu > Import From > Aspen HYSYS V8.0. In the file browser locate the file Preheat Train for Jump Start EDR.hsc and click Open. From the Exchanger List choose e304 and click OK (Figure 3). Figure 3. Select Exchanger e304 in the Aspen HYSYS Case 3

Another dialogue box Import PSF data will appear. Click OK again to import the case data. Now you can see that our Input folder is fully specified, all red incomplete marks have disappeared.

6 Another dialogue box Import PSF data will appear. Click OK again to import the case data. Now you can see that our Input folder is fully specified, all red incomplete marks have disappeared. To better model the real process conditions let s adjust the fouling resistance of our streams. Open the Process Data form. This can be found in the Console Process tab or Input > Problem Definition > Process Data. Set the following. Hot Stream Cold Stream Fouling Resistance hf/btu hf/btu Application Options Let s set the application options for this example. From the navigation pane, expand the Problem Definition folder and open the Application Options form. Click on Input > Problem Definition > Application Options. Figure 4 shows the desired specifications. Figure 4. Set Application Options 4

Location of hot fluid Select geometry Shell side SI Step 4. Select Appropriate Configuration and Sizing Constraints Click on the Console from the navigation pane.

7 Location of hot fluid Select geometry Shell side SI Step 4. Select Appropriate Configuration and Sizing Constraints Click on the Console from the navigation pane. Our exchanger general geometric constraints have been fully specified with default values. We are going to change some of them to get a more appropriate design for our process. Since this exchanger is used in a crude application, we are going to change the TEMA type to a one pass shell with a removable cover and floating head with backing device, and set the tube pattern to 90 square. These selections allow for disassembly and cleaning of the unit (Figure 5). TEMA Type Hot Side Tube Pattern AES Shell side 90-Square Figure 5. Set Configuration Options 5

Step 5. Save and Run Sizing Optimization Now that required input is complete, save the case. Run the sizing (full Shell & Tube design optimization logic) by clicking the Run button on the Console.

8 Step 5. Save and Run Sizing Optimization Now that required input is complete, save the case. Run the sizing (full Shell & Tube design optimization logic) by clicking the Run button on the Console. A Program Status window will appear showing the designs being evaluated. When the run is complete, close the window. We can see that there are a couple of warnings with this design, but no errors. Step 6. Viewing the Results Open the design Console from the navigation pane. On the Geometry tab we can see the setting plan, tube layout, and stream temperature profiles. We can also see basic geometry data such as the number of shells and tubes and the dimensions of both. For this design, we have 2 shells in series with 2 tube passes and 26 baffles. Our oversurface % is 2 and our pressure drop ratio is 0.88\0.48. The overall cost is $212,656 (Figure 6). If we change one of the parameters and run the design again, we can see the results of the new design side-by-side with our first design. This makes it easy to tell whether or not a given change improves the exchanger cost or performance. Figure 6. Design Console Results 6

Jump Start: Aspen Shell & Tube Exchanger V8 Expand the Results folder to see more design specifics including performance calculations, and mechanical drawings for the setting plan and tubesheet

9 Jump Start: Aspen Shell & Tube Exchanger V8 Expand the Results folder to see more design specifics including performance calculations, and mechanical drawings for the setting plan and tubesheet layout (Figure 7). Figure 7. Results Summary To compare your results with the expected results of this exchanger sizing, view the solution file EDR Jump Start e304 Solution Aspen Technology, Inc. AspenTech, aspenone, the Aspen leaf logo, the aspenone logo, and OPTIMIZE are trademarks of Aspen Technology, Inc. All rights reserved

Appendix A. Navigate the EDR User Interface Navigation Pane The navigation pane provides access to data input and design specifications, program options, and results.

10 Appendix A. Navigate the EDR User Interface Navigation Pane The navigation pane provides access to data input and design specifications, program options, and results. All folders marked with a red X indicate that information is missing and must be specified before the calculation can be run. Input fields marked in light blue shading must be completed in order to run the case. Note that many of the forms, including all those in the Exchanger Design folder and the Program Options, folder are automatically populated with default parameters and will be marked complete upon opening a new design file. It is useful to check that the specified information in these folders is appropriate for a particular case. All results forms will be greyed-out before the calculation is run, indicating that results are not yet available. Text Coloring Default parameters appear in red. Many of these may be interdependent and you may see them change as you change other entries and selections. User specified information is always black. Figure 8 shows the Design Console interface. Figure 8. The Design Console User Interface 8

User Input Tabs: Geometry, Process, Errors & Warnings Geometry The Geometry tab contains all user-specified information pertaining to exchanger configuration, shell and tube dimensions, and the

11 User Input Tabs: Geometry, Process, Errors & Warnings Geometry The Geometry tab contains all user-specified information pertaining to exchanger configuration, shell and tube dimensions, and the overall results of the simulation after the case is run. Process The Process tab contains data regarding the physical conditions of the process streams, pressure drop, and fouling resistance of the fluids. Errors & Warnings Check the Errors & Warnings tab after running the optimization to identify operational and performance risks that were identified with the design. Appendix B. Alternative Methods to Specify Process & Property Data Manually Enter Property Data Open the Property Data folder and click on Hot Stream Composition. On the Composition tab, click the down arrow in the dropdown box next to Physical Property Package. Choose User Specified properties. Open Input > Property Data > Hot Stream Properties. Here you can type in property data for a range of temperatures and pressures or you can Copy/Paste data from Excel. Repeat for the Cold Stream Composition (Figure 9). Figure 9. Manually Specify Property Data 9

Searching the Properties Databanks In the Property Data folder, on the Hot Stream Composition form, click on the dropdown box next to Physical Property Package and choose one of the databases (Aspen

12 Searching the Properties Databanks In the Property Data folder, on the Hot Stream Composition form, click on the dropdown box next to Physical Property Package and choose one of the databases (Aspen Properties, COMThermo, BJAC). Click the Search Databank button. Enter the compound name, select the component to add, and click the add button. Repeat until your component list is complete click ok (Figure 9). Figure 10. Search for Compounds from the Properties Databank Appendix C. Using a Design Template When you open a new case, instead of choosing New, click on the Templates Tab and choose from either the default EDR design templates or a template saved on your desktop. When the file is opened it will already contain geometry and design specifications preselected for that exchanger type. You can prepare your own templates to impose company design standards or process pressure drop or fouling resistance constraints. You need to explicitly save your template files as.edt. You will typically find the standard design templates provided with your installation in: C:\Program Files (x86)\aspentech\aspen Exchanger Design and Rating V8.0\Data\Template. 10

Additional Resources Check out other training materials specifically for this product: Public Website www.aspentech.com/products/aspen-edr.aspx www.aspentech.com/products/aspen-tascplus.

13 Additional Resources Check out other training materials specifically for this product: Public Website Online Training Video Tutorials Autosizing Shell & Tube Exchangers in Aspen HYSYS V8.0 New Interactive Sizing in Aspen Plus Jump Start Tutorial Getting Started in Aspen Shell & Tube Exchanger V7.0 Jump Start: Sizing EDR Shell & Tube Exchangers in Aspen Plus Help Menu 11

14 About AspenTech AspenTech is a leading supplier of software that optimizes process manufacturing for energy, chemicals, engineering and construction, and other industries that manufacture and produce products from a chemical process. With integrated aspenone solutions, process manufacturers can implement best practices for optimizing their engineering, manufacturing, and supply chain operations. As a result, AspenTech customers are better able to increase capacity, improve margins, reduce costs, and become more energy efficient. To see how the world s leading process manufacturers rely on AspenTech to achieve their operational excellence goals, visit Worldwide Headquarters Aspen Technology, Inc. 200 Wheeler Road Burlington, MA United States phone: fax: info@aspentech.com 2013 Aspen Technology, Inc. AspenTech, aspenone, the Aspen leaf logo, the aspenone logo, and OPTIMIZE are trademarks of Aspen Technology, Inc. All rights reserved Regional Headquarters Houston, TX USA phone: São Paulo Brazil phone: Reading United Kingdom phone: +44 (0) Singapore Republic of Singapore phone: Manama Bahrain phone: For a complete list of offices, please visit

Jump Start: Rigorous Shell & Tube Exchanger Sizing in Aspen HYSYS V8

Jump Start: Rigorous Shell & Tube Exchanger Sizing in Aspen HYSYS V8 A Brief Tutorial for Autosizing and Interactive Sizing in Aspen HYSYS V8 Lauren Sittler, Product Management, Aspen Technology, Inc.