Class ThermalDesignCalculator

java.lang.Object
neqsim.process.mechanicaldesign.heatexchanger.ThermalDesignCalculator
public class ThermalDesignCalculator extends Object
Thermal-hydraulic design calculator for shell and tube heat exchangers.

Calculates tube-side and shell-side heat transfer coefficients, overall heat transfer coefficient U, pressure drops, and performs zone-by-zone analysis for two-phase services. Integrates correlations from HeatTransferCoefficientCalculator with shell-and-tube geometry from ShellAndTubeDesignCalculator.

Supported methods:

  • Tube side: Gnielinski (turbulent), Dittus-Boelter (fallback), plus condensation and evaporation correlations
  • Shell side: Kern method (simple), Bell-Delaware method (detailed)
  • Overall U: Resistance-in-series model including fouling and tube wall
  • Pressure drops: Fanning/Kern correlations
  • Zone analysis: Divide into sensible/condensing/boiling zones
Version:
1.0
Author:
NeqSim Development Team
See Also:

  • Field Details

    • tubeODm

      private double tubeODm

    • tubeIDm

      private double tubeIDm

    • tubeLengthm

      private double tubeLengthm

    • tubeCount

      private int tubeCount

    • tubePasses

      private int tubePasses

    • tubePitchm

      private double tubePitchm

    • triangularPitch

      private boolean triangularPitch

    • shellIDm

      private double shellIDm

    • baffleSpacingm

      private double baffleSpacingm

    • baffleCount

      private int baffleCount

    • baffleCut

      private double baffleCut

    • tubeWallConductivity

      private double tubeWallConductivity

    • tubeDensity

      private double tubeDensity

    • tubeViscosity

      private double tubeViscosity

    • tubeCp

      private double tubeCp

    • tubeConductivity

      private double tubeConductivity

    • tubeMassFlowRate

      private double tubeMassFlowRate

    • tubeHeating

      private boolean tubeHeating

    • shellDensity

      private double shellDensity

    • shellViscosity

      private double shellViscosity

    • shellCp

      private double shellCp

    • shellConductivity

      private double shellConductivity

    • shellMassFlowRate

      private double shellMassFlowRate

    • shellViscosityWall

      private double shellViscosityWall

    • foulingTube

      private double foulingTube

    • foulingShell

      private double foulingShell

    • tubeSideHTC

      private double tubeSideHTC

    • shellSideHTC

      private double shellSideHTC

    • overallU

      private double overallU

    • tubeSidePressureDrop

      private double tubeSidePressureDrop

    • shellSidePressureDrop

      private double shellSidePressureDrop

    • tubeSideVelocity

      private double tubeSideVelocity

    • shellSideVelocity

      private double shellSideVelocity

    • tubeSideRe

      private double tubeSideRe

    • shellSideRe

      private double shellSideRe

    • Jc

      private double Jc

    • Jl

      private double Jl

    • Jb

      private double Jb

    • Js

      private double Js

    • Jr

      private double Jr

    • shellSideMethod

      private ThermalDesignCalculator.ShellSideMethod shellSideMethod

    • tubeToBaffleClearance

      private double tubeToBaffleClearance

    • shellToBaffleClearance

      private double shellToBaffleClearance

    • bypassArea

      private double bypassArea

    • hasSealing

      private boolean hasSealing

    • sealingPairs

      private int sealingPairs

  • Constructor Details

    • ThermalDesignCalculator

      public ThermalDesignCalculator()
      Creates a new ThermalDesignCalculator with default parameters.

  • Method Details

    • calculate

      public void calculate()
      Performs the full thermal-hydraulic calculation.

      Calculates tube-side HTC, shell-side HTC, overall U, and pressure drops.

    • calculateTubeSide

      private void calculateTubeSide()
      Calculates tube-side heat transfer coefficient using Gnielinski or Dittus-Boelter correlation.

    • calculateShellSide

      private void calculateShellSide()
      Calculates shell-side heat transfer coefficient using the selected method.

    • calculateShellSideKern

      private void calculateShellSideKern()
      Calculates shell-side HTC using the Kern method.

    • calculateShellSideBellDelaware

      private void calculateShellSideBellDelaware()
      Calculates shell-side HTC using the Bell-Delaware method with correction factors.

    • calculateOverallU

      private void calculateOverallU()
      Calculates the overall heat transfer coefficient based on outside tube area.

      Resistance model: 

      1/U_o = 1/h_o + R_fo + (d_o * ln(d_o/d_i))/(2*k_w) + (d_o/d_i)*(R_fi + 1/h_i)

    • calculateTubeSidePressureDrop

      private void calculateTubeSidePressureDrop()
      Calculates tube-side pressure drop.

      Includes straight-tube friction and return losses: 

      dP_tube = N_p * (f * L / d_i * rho * v ^ 2 / 2 + 2.5 * rho * v ^ 2 / 2)

    • calculateShellSidePressureDrop

      private void calculateShellSidePressureDrop()
      Calculates shell-side pressure drop.

    • calculateShellSidePressureDropKern

      private void calculateShellSidePressureDropKern()
      Kern shell-side pressure drop calculation.

    • calculateShellSidePressureDropBellDelaware

      private void calculateShellSidePressureDropBellDelaware()
      Bell-Delaware shell-side pressure drop with correction factors.

    • calculateZones

      public ThermalDesignCalculator.ZoneResult[] calculateZones(ThermalDesignCalculator.ZoneDefinition[] zones)
      Performs zone-by-zone analysis for a phase-changing service.

      Divides the exchanger into zones based on fluid phase: desuperheating, condensing, subcooling (or preheating, boiling, superheating). Computes effective U and required area for each zone.

      Parameters:
      zones - array of zone definitions with fluid properties per zone
      Returns:
      array of zone results

    • calcDarcyFriction

      static double calcDarcyFriction(double Re)
      Calculates Darcy friction factor using Swamee-Jain for turbulent, 64/Re for laminar.
      Parameters:
      Re - Reynolds number
      Returns:
      Darcy friction factor

    • toMap

      public Map<String,Object> toMap()
      Returns all computed results as a map.
      Returns:
      map of result keys and values

    • toJson

      public String toJson()
      Converts all computed results to a JSON string.
      Returns:
      JSON string with pretty printing

    • getTubeSideHTC

      public double getTubeSideHTC()
      Gets the tube-side heat transfer coefficient.
      Returns:
      tube-side HTC (W/(m2*K))

    • getShellSideHTC

      public double getShellSideHTC()
      Gets the shell-side heat transfer coefficient.
      Returns:
      shell-side HTC (W/(m2*K))

    • getOverallU

      public double getOverallU()
      Gets the overall heat transfer coefficient based on outside area.
      Returns:
      overall U (W/(m2*K))

    • getTubeSidePressureDrop

      public double getTubeSidePressureDrop()
      Gets the tube-side pressure drop.
      Returns:
      pressure drop (Pa)

    • getTubeSidePressureDropBar

      public double getTubeSidePressureDropBar()
      Gets the tube-side pressure drop in bar.
      Returns:
      pressure drop (bar)

    • getShellSidePressureDrop

      public double getShellSidePressureDrop()
      Gets the shell-side pressure drop.
      Returns:
      pressure drop (Pa)

    • getShellSidePressureDropBar

      public double getShellSidePressureDropBar()
      Gets the shell-side pressure drop in bar.
      Returns:
      pressure drop (bar)

    • getTubeSideVelocity

      public double getTubeSideVelocity()
      Gets the tube-side velocity.
      Returns:
      velocity (m/s)

    • getShellSideVelocity

      public double getShellSideVelocity()
      Gets the shell-side velocity.
      Returns:
      velocity (m/s)

    • getTubeSideRe

      public double getTubeSideRe()
      Gets the tube-side Reynolds number.
      Returns:
      Reynolds number

    • getShellSideRe

      public double getShellSideRe()
      Gets the shell-side Reynolds number.
      Returns:
      Reynolds number

    • setTubeODm

      public void setTubeODm(double tubeODm)
      Sets tube outer diameter.
      Parameters:
      tubeODm - tube OD (m)

    • setTubeIDm

      public void setTubeIDm(double tubeIDm)
      Sets tube inner diameter.
      Parameters:
      tubeIDm - tube ID (m)

    • setTubeLengthm

      public void setTubeLengthm(double tubeLengthm)
      Sets tube length.
      Parameters:
      tubeLengthm - tube length (m)

    • setTubeCount

      public void setTubeCount(int tubeCount)
      Sets tube count.
      Parameters:
      tubeCount - number of tubes

    • setTubePasses

      public void setTubePasses(int tubePasses)
      Sets number of tube passes.
      Parameters:
      tubePasses - tube passes

    • setTubePitchm

      public void setTubePitchm(double tubePitchm)
      Sets tube pitch.
      Parameters:
      tubePitchm - tube pitch (m)

    • setTriangularPitch

      public void setTriangularPitch(boolean triangularPitch)
      Sets whether tube layout is triangular.
      Parameters:
      triangularPitch - true for triangular, false for square

    • setShellIDm

      public void setShellIDm(double shellIDm)
      Sets shell inside diameter.
      Parameters:
      shellIDm - shell ID (m)

    • setBaffleSpacingm

      public void setBaffleSpacingm(double baffleSpacingm)
      Sets baffle spacing.
      Parameters:
      baffleSpacingm - baffle spacing (m)

    • setBaffleCount

      public void setBaffleCount(int baffleCount)
      Sets baffle count.
      Parameters:
      baffleCount - number of baffles

    • setBaffleCut

      public void setBaffleCut(double baffleCut)
      Sets baffle cut fraction.
      Parameters:
      baffleCut - baffle cut as fraction (e.g., 0.25)

    • setTubeWallConductivity

      public void setTubeWallConductivity(double conductivity)
      Sets tube wall thermal conductivity.
      Parameters:
      conductivity - thermal conductivity (W/(m*K))

    • setTubeSideFluid

      public void setTubeSideFluid(double density, double viscosity, double cp, double conductivity, double massFlowRate, boolean heating)
      Sets all tube-side fluid properties.
      Parameters:
      density - density (kg/m3)
      viscosity - dynamic viscosity (Pa*s)
      cp - heat capacity (J/(kg*K))
      conductivity - thermal conductivity (W/(m*K))
      massFlowRate - mass flow rate (kg/s)
      heating - true if tube fluid is being heated

    • setShellSideFluid

      public void setShellSideFluid(double density, double viscosity, double cp, double conductivity, double massFlowRate)
      Sets all shell-side fluid properties.
      Parameters:
      density - density (kg/m3)
      viscosity - dynamic viscosity (Pa*s)
      cp - heat capacity (J/(kg*K))
      conductivity - thermal conductivity (W/(m*K))
      massFlowRate - mass flow rate (kg/s)

    • setFoulingTube

      public void setFoulingTube(double fouling)
      Sets the tube-side fouling resistance.
      Parameters:
      fouling - fouling resistance (m2*K/W)

    • setFoulingShell

      public void setFoulingShell(double fouling)
      Sets the shell-side fouling resistance.
      Parameters:
      fouling - fouling resistance (m2*K/W)

    • setShellSideMethod

      public void setShellSideMethod(ThermalDesignCalculator.ShellSideMethod method)
      Sets the shell-side analysis method.
      Parameters:
      method - KERN or BELL_DELAWARE

    • getShellSideMethod

      public ThermalDesignCalculator.ShellSideMethod getShellSideMethod()
      Gets the shell-side analysis method.
      Returns:
      method KERN or BELL_DELAWARE

    • setShellViscosityWall

      public void setShellViscosityWall(double viscosity)
      Sets the shell-side viscosity at wall temperature for viscosity correction.
      Parameters:
      viscosity - viscosity at wall temperature (Pa*s), or negative to use bulk value

    • setHasSealing

      public void setHasSealing(boolean hasSealing)
      Sets whether sealing strips are installed.
      Parameters:
      hasSealing - true if sealing strips present

    • setSealingPairs

      public void setSealingPairs(int sealingPairs)
      Sets the number of sealing strip pairs.
      Parameters:
      sealingPairs - number of pairs

    • setTubeToBaffleClearance

      public void setTubeToBaffleClearance(double clearance)
      Sets the tube-to-baffle clearance.
      Parameters:
      clearance - clearance (m)

    • setShellToBaffleClearance

      public void setShellToBaffleClearance(double clearance)
      Sets the shell-to-baffle clearance.
      Parameters:
      clearance - clearance (m)

    • setBypassArea

      public void setBypassArea(double area)
      Sets the bypass area between bundle and shell.
      Parameters:
      area - bypass area (m2)