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Example: Feed/effluent heat exchanger – condensate stripper The following example is based on a heat exchanger specification from a condensate treatment stripper. An existing shell-and-tube heat exchanger is replaced with a Compabloc welded plate heat exchanger, which increases heat recovery by 3.8 MW (13 MMBtu/h). It is assumed that 85% of the recovered heat translates into saved steam and, in turn, fuel savings or increased electricity generation. The two diagrams on the next page show the payback period for the investment. Figure 3.3 Condensate treatment stripper before and after revamp. Before American 13 MMBtu/h 5.4°F Steam 25 bar(a) (363 psia) Feed solution 170°C (338°F) Effluent solution 225°C (437°F) Effluent solution 100°C (212°F) Feed solution 210°C (410°F) Results Increased heat recovery Reduced cooling water temperature, fixed flow of 1,000 m3/h (4,400 gpm) Reduced cooling water flow, fixed ∆T = 10°C (18°F) Reduced CO2 emissions Assumptions • 8,400 operating hours per year SI 3.8 MW 3°C 300 m3/h 5,600 metric tons/year Feed solution 40°C (104°F) After Steam 25 bar(a) (363 psia) Effluent solution 225°C (437°F) Effluent solution 55°C (131°F) • Overall pressure drop increases by approximately 1 bar, but no new pump is needed (only operating costs increase) • Physical properties on both sides are similar to water • Installation factor = 3, i.e. the heat exchanger represents 33% of the total project cost • Cold side flow rate 75 m3/h and hot side 90 m3/h • Boiler efficiency 90% (boiler case) • Turbine isentropic efficiency 80% (electricity case) Feed solution 40°C (104°F) 1319 gpm 33 3.8 MW (13 MMBtu/h ) recovered heatPDF Image | Waste heat recovery Optimizing
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