Heat Exchanger Design & Mechanical Validation
Ensuring TEMA and ASME compliance for critical ONA dehydration condenser service at Aarti Industries Limited.
Engineering Requirement
ChemKlub India collaborated with Aarti Industries Limited to evaluate and optimize two heat exchangers — 1-HE007 and 1-HE008 — designed for ONA dehydration condenser service.
The primary objective was to validate the thermal and mechanical design of both vertical BEM-type units. Both heat exchangers were proven to meet the required design and operational standards. The simulation demonstrated highly efficient performance with adequate safety margins, ensuring sustained reliability for the client’s critical chemical production processes.
The project scope required adherence to TEMA Class B classification and full ASME Code Section VIII Division 1 compliance throughout the mechanical design validation process.
Our Engineering Approach
A structured four-phase methodology ensured comprehensive validation with full documentation at every stage.
Data Collection & Process Definition
Gathering process fluid properties, operating conditions, fouling factors, and nozzle geometry from client datasheets.
Simulation Setup in Aspen EDR
Building the exchanger geometry in Aspen EDR, configuring shell/tube passes, baffle spacing, and thermodynamic correlations.
Thermal & Mechanical Validation
Verifying heat duty, LMTD, pressure drops, vibration analysis, and all mechanical wall thickness calculations per ASME VIII.
Reporting & Recommendations
Delivering simulation datasheets, compliance certificates, and optimization recommendations for long-term operational efficiency.
Project Deliverables
All outputs produced and validated as part of this engagement.
Validating thermal and mechanical design parameters using Aspen Exchanger Design & Rating (EDR).
Ensuring full compliance with TEMA standards (Class B) and ASME Code Section VIII Division 1.
Analyzing heat exchange capacities (up to 161,000 kcal/h) and verifying shell- and tube-side pressure drops.
Providing actionable recommendations for performance enhancement, fluid velocity optimization, and long-term efficiency.
Mechanical wall thickness calculations and nozzle reinforcement checks for all pressure-containing components.
Vibration analysis of tube bundle to confirm structural integrity under design operating conditions.
Challenges & Engineering Solutions
Key technical challenges encountered during the project and how our team resolved them.
High fouling tendency of the ONA-water vapour process fluid increased risk of tube surface degradation, potentially reducing heat transfer efficiency over time.
Conservative fouling resistance factors per TEMA standards were applied in the simulation, and tube-side velocity was optimised above 1.0 m/s to minimise deposition while staying within allowable pressure drop limits.
Vertical orientation of the BEM exchangers introduced concerns around condensate drainage and two-phase flow distribution uniformity across the tube bundle.
Baffle cut orientation and spacing were reviewed to ensure adequate drainage geometry. Simulation confirmed even flow distribution with no significant maldistribution or flooding risk at design conditions.
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Our team specialises in thermal-mechanical design, simulation, and code compliance for process equipment.