The main objective of this work is to assess the performance of two heat exchanger units (Stripper/Gas Overhead Condenser and Methanator Effluent Cooler) operating under steady state conditions in two stages. Two different methods are employed in monitoring the heat exchanger fouling, namely dirt factor trend method and a statistical control technique where a Cumulative Sum (CuSum) chart is used to check the stability of the process. Data were obtained through steady state monitoring and direct measurements from the plant. The data were analyzed using various energy equations and a computer program to determine the overall heat transfer coefficient, heat duty, capacity ratio, corrected log-mean-temperature difference, fouling factor, temperature range of both fluids and effectiveness. The result shows that for the Stripper/Gas Overhead Condenser, the overall heat transfer coefficient was 63.13% less than the design value in stage1 and 12.59% less in stage2. For the Methanator Effluent Cooler the value of heat duty and the overall heat transfer coefficient were 51.76% and 59.62% less respectively than the design value in stage1 and 30.72% and 30.16% less respectively in stage2. This was traceable to increase in heat transfer rate as a result of injecting the tubes of the exchangers with NALCO fluid. In order to detect small changes in the heat exchanger operation and to know the actual time fouling starts to build up, a Cusum chart is used. This work made use of QI Macros software to check the stability of the heat exchanger units and to know if processes are on-target.
Bhatt, D. & Javhar, P.M. (2014).Shell-and-Tube Heat Exchanger Performance Analysis. International Journal of science and technology, 9(3), 1872 – 1881.
Christian, B., Alex, P., & Sara, B. (2002).Heat Exchange System for Reforming in an Ammonia Process.
Gudmundsson, O., Palsson, O.P., Palsson, H., & Jonsson, G.R, (2011). Comparison ofFouling Detection Between A Physical Method And Black Box Model. Proceedings of International Conference on Heat Exchanger Fouling and Cleaning-2011.
Hasanuzzanman, M. Saidu, R. & Rahim, N. A. (2011).Effectiveness enhancement of Heat Exchangers by using Nano-fluids.IEEEfrist Conference on clean Energy and technology, 25, 98 – 108.
Hindelang, M.J., Palazzolo, J., & Rebertson, M., (2012).“Condensers” Encyclopedia of Chemical Engineering Equipment, University Michigan.
Kalpesh, P. O. & Chopra, M. (2013).Performance analysis of cross counter flow shell and tube heat exchanger by experimental investigation mathematical modeling.International Journal of Engineering Research and Technology, 2,. 7, 271 – 276.
Kern, D. Q. (1965), Process Heat Transfer, 7th Edition, McGraw-Hill, Inc. New York.
Lebele-Alawa, B.T. &Ohia, I. O. (2013). Performance Evaluation of heat Exchanger, in Polyethylene Plant. International Journal of Engineering and Technology Innovation, 8(1). 49 – 57.
Nalco Company (2011). Safety data sheet Nalco(A) 7330-Lellog Registration systems..
Norrie, B. (2010). Heat Transfer: Principles & Equipment-Factors Affecting Heat Transfer.
Rajput, P.K (2003). Heat and Mass Transfer. Ram Nagar, New Delhi, S. CHAND & COMPANY LTD. Chapter 10, 563-654.
Rao V.R &Savsani, V.J (2012). Mechanical Design Optimization using Advance Optimization Tecniques. Springer London Heidelberg. Springer Publisher. DOI:10.1007/978-1-2748-2. Chapter 7.201-210.
SPC for Excel (2014), Statistical process control publications by category from SPC for Excel.
Sabri, A. (2006), Process Engineering Manual: Heat Exchanger Monitoring.
Serth, R.W (2007). Process Heat Transfer: Principles and Applicatins. Kingsville, Taxas. Elsevier Science & Technology Books – Publisher. Chapter 3.86-115.
This work is licensed under a Creative Commons Attribution 4.0 International License.
The names and email addresses entered in this journal site will be used exclusively for the stated purposes of this journal and will not be made available for any other purpose or to any other party.
Submission of the manuscript represents that the manuscript has not been published previously and is not considered for publication elsewhere.