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The Modeling and Simulation of the Convection Section of the Atmospheric Distillation Plant Heaters

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The Modeling and Simulation of the Convection Section of the Atmospheric Distillation Plant Heaters The Modeling and Simulation of the Convection Section of the Atmospheric Distillation Plant Heaters CRISTIAN PATRASCIOIU* Petroleum-Gas University of Ploiesti,39 Bucuresti Blvd., 100520, Ploiesti, Romania The paper presents the research results of the design and adaptation of the mathematical model destined to convection heater zone simulation of the crude unit plant. The paper is structured in four parts: the convection heater zone structure, the heat transfer model of inside and outside tubes, the model adaptation and numerical simulation. In the first part there is treated the system of the convection heater zone of the tubular heater. Also there have been identified the input and output variables. The convection heater mathematical model is based on thermal balance equations and newton’s law. For the model adaptation process there have been identified four constant types: heater geometrical constants, fuel constants, heated flow constants and burn gases constants. To calculate the heated flow constants there have used two methods. First method uses the empirical relations and the second method uses the Unisim Design® simulator. The comparison between the numerical simulation results and the design data there has validated the proposed model. There has been studied the crude oil properties estimation method influence to simulation results. The study has permitted the convection heater zone statically input-output characteristics prediction. Keywords: convection heater zone, thermal balance equations, Unisim Design® simulator The modeling of the tube heaters represents a complex exchangers is realized with specialized programs within problem, the models being classified by the type of these being included HTRI and Unisim Heat Exchanger [4, dynamic regime (stationary models and dynamic models) 5]. For example, within the simulator Unisim Heat and by the special distribution of the parameters (models Exchanger there is the option Unisim FPH that is used for with concentrated parameters and models with distributed the design or simulation of a tube exchanger. The inlet data parameters). refer to the focus geometry, fuel, the convection section An example of a model with parameters distributed in geometry and the heated fluids. The simulator calculates stationary regime is realized by Diaz - Mateus [1]. The model the heat transfer, the temperature and the distribution of proposed is made of two different tub-models, one for the pressures in the heating system and the parameters of the flow that passes through the tubes (the heated flow) and outlet flows. the other for the flow of the burning gases. The model of An approach based on considering the heat exchanger the heatedflow treats the process as a distributed as a system with concentrated parameters was realized parameters-system, special attention being paid to the by the author [6, 7]. The developed models allow for a fast liquid- vapours balance for the oil products. The model of estimation of the outlet temperatures of the heat exchanger, the heat transfer for the burning gases is based on being especially useful in exploiting the heat exchangers. differential relations of the heat transfer through radiation Adapting the last type of model to the convection heater that uses the temperature at the outlet defined by Hottel represents the main element of the research work [2]. The linking element between the two sub-models is presented in this article. the temperature of the tube surface. Since this variable is the inlet variable in the twosub-models, its initialization The structure of heat exchanger in the convection and recalculation are necessary, the numerical solution of section the entire model being iterative. Regarding the heat transfer, the convection section of In the paperwork [3], there is presented a dynamic the tube heater is a heat exchanger, with a circulation in model for a heat exchanger from an energetic group. crossed counter-flow, (fig. 1a). Through the model is dynamic, the exchanger is treated The hot fluid is represented by the burning gases that as a system with concentrated parameters, the relations leave the radiation section of the heater, while the cold used being the energy balance equation and Peclet’s law. fluid is defined by the feedstock (preheated crude oil). The The design and checking of certain types of industrial heat heat exchanger is characterized by four inlet values and two outlet values, (fig. 1b). The inlet values are as follows: Fig. 1 The heat exchanger associated to the convection section of the tube heater: a) structure; b) block diagram * email: [email protected]; Tel.: (+40)0244573171 REV.CHIM.(Bucharest)♦67♦No. 8 ♦2016 http://www.revistadechimie.ro 1599 α Th1, Qhot - the inlet temperature and the hot fluid (burnt ps - the surface of the convection area walls, gases); T , Q - the inlet temperature and the cold fluid corresponding to a row of tubes; cl cold α (the crude oil). The outlet variables are: Th2 - the outlet is - the exposed surface of a row of tubes. temperature of the hot fluid and T - the outlet temperature The coefficient of heat transfer by the mechanism of c2 α of the cold fluid. convection, cg , is calculated with the relation The mathematical model of the convection section in the tube heater (5) The mathematical model of the heat exchanger Reynolds and Prandtl criterions having the expressions: associated to the convection section of the tube heater is conceived based on the next simplifying hypotheses: -the heat exchanger is considered a system with concentrated parameters; (6) -the heat exchanger is operated in a stationary regime; -the heat transfer with the surrounding environment is neglected. (7) The elaborated mathematical model contains a heat balance equation associated to the two material flows, The physical properties of the burning gases, the Qhot and Qcold, and as well as the expression of the transferred dynamic viscosity and the heat transfer coefficient heat flow, expression derived out of Newton’s law [7- 10]. calculated as ponderal rates of the properties of the chemical compounds that make up the burning gases, respectively, CO2, H2O, N2, O2 and CO, at the average temperature of the burning gases. The equivalent hydraulic (1) diameter used in the relation (6) has the value de of a tube diameter in the convection section, The coefficient of heat transfer by radiation from the For the heat flow transferred in the heat exchanger, the burning gases to the tubes is calculated with the relation global heat transfer coefficient has the next expression [8]: known in literature [8]: (8) According to the same source, the transfer coefficients (2) corresponding to the two chemical compounds with radiant properties have the expressions: where: α in represents the convection coefficient within the tube; (9) α out - the convection coefficient at the tube outlet; A - the heat transfer area of the heat exchanger. The mathematical models used for the calculus of the convection coefficient at the tube inlet and the outlet, respectively, are presented in the next part. (10) The mathematical model of the heat transfer at the tube the parameter significance being the following: outlets ee - the emission coefficient of the screen; The mathematical model of the heat transfer at the tube PCO2, PH2O - the partial pressures of the compounds; outlets considers the cumulated effect of the two heat s - the thickness of the gas layer calculated with the transfer mechanisms, of convection and radiation, relation respectively, and has the expression [8] (3) (11) s1 - the space between the tubes, horizontally; the significance of the variables being as follows: s – the space between the tubes, vertically. α 2 cg - the coefficient of the heat transfer by radiation, from the burning gases to the tubes screen; The value of the power in the relation (10) is calculated α rg - the coefficient of the heat transfer by convection, with the expression from the burning gases to the tubes screen; z - a term that considers the radiation of the convection (12) area walls, a term defined by the expression: The coefficient of the heat transfer from walls to tubes, through the radiation mechanism is calculated with Monrad relation, depending on the tubes temperature [11] (4) [J / m2hK] (13) The geometrical variables introduced in the relation (4) are: The mathematical model of the heat transfer within the α tubes rp- the coefficient of the heat transfer by radiation from walls to tubes; Considering the fact that the flow within the tubes is the crude oil and also viewing industrial realities, the 1600 http://www.revistadechimie.ro REV.CHIM.(Bucharest)♦67♦No. 8 ♦2016 mathematical model of the heat transfer within the tubes The adoption of the mathematical model represents the implies the next simplifying by hypotheses: operation of specificating the numerical constant values -the flowing regime is turbulent, without axial dispersion; that interfere within the structure of the mathematical -the following is just mono-phasical. model. These constant values can be classified as follows: For the type of mono-phasical flowing, without axial -the constant values that are specifically to the heater dispersion, the criterial relation [11] may be applied: geometry; -the constant values that are specifically to the used (14) fuel; -the constant values to the heater flow; -the constant values to the specific to the burning gases. The criteria Reynolds and Prandtl in the relation (14) have the expressions: The constant values specifically to the heater geometry Geometrically, the convection section of the analyzed (15) atmospheric distillation heater is described in the figure 2 and 3. In figure 2 there is presented an overall view of the section seen from above, while in figure 3 there is a side (16) section. The constructive parameters of the convection section are presented in table 1. Based on the geometrical The physical properties of the fluid within the tubes are data previously presented, there have been calculated the calculated at the average temperature of the fluid: geometrical constants specific to the heater convection section, constant values presented in table 2.
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