Aspen Exchanger Design & Rating Family

A family of products to model process heat exchangers —from cost optimized designs
to rating and simulation

Heat exchangers can comprise up to 30% of capital equipment and impact 90% of the energy used in
a petrochemical process. Major savings are available by implementing best practices with the Aspen
Exchanger Design & Rating (Aspen EDR) product family.

Aspen Shell & Tube Exchanger: Thermal modeling for shell & tube, double pipe,
• Reduce exchanger costs by and multi-tube hairpin exchangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4
10-30%
Aspen Plate Exchanger: Thermal modeling for gasketed plate and frame, brazed
• Improve reliability and
process uptime plate, and welded plate exchangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 5

• Improve engineering Aspen Air Cooled Exchanger: Thermal modeling for air cooled and other tubular
efficiency by up to 30%
cross flow exchangers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 6
• Superior technology backed
by Aspen HTFS research Aspen Shell & Tube Mechanical: Mechanical design for shell & tube exchangers
and basic pressure vessels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7

Aspen Plate Fin Exchanger: Thermal modeling of multi-stream plate-fin heat

exchangers made from brazed aluminum, stainless steel, or titanium . . . . . . page 8

Aspen Fired Heater: Thermal modeling of radiant and convection sections of oil or
gas fueled fired process heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 9

The Challenge: Simplifying the Engineering Lifecycle

Conventional workflow for the design of heat exchangers requires manual data transfer from process engineer to thermal and
mechanical experts to a cost estimator. The design cycle involves several iterations and is prone to data transcription errors.
This approach also excludes the process engineer’s visibility into problem details, making it difficult to investigate multiple
process scenarios to arrive at a fully optimized process.

The AspenTech® Solution: Minimize Capital Cost and Improve Process Design
The Aspen Exchanger Design & Rating (EDR) product family provides the industry’s most comprehensive suite of programs for
heat exchanger design, simplifying the engineering cycle through a single, integrated framework. Companies deploying these
solutions reduce capital equipment cost and engineering man-hours, optimizing the operation of their processes.
Aspen Exchanger Design & Rating Family

Integrated Solution Delivers Proven Results

The Aspen Exchanger Design & Rating product family integrates rigorous process models with the industry’s
most comprehensive heat exchanger modeling capabilities. Key business-enhancing benefits include:
• Optimized equipment designs results in typical savings of 10-30% on the equipment cost per heat
exchanger.
• Integration with Aspen Plus® and Aspen HYSYS®. Identifies areas to reduce energy and operational
costs, with potential savings in the millions.
• Increased engineering efficiency. Emphasizes fast-track front-end engineering through fully integrated
tools for process design.

Aspen Simulation

Air Cooled Exchanger

Shell & Tube Exchanger

Plate Exchanger
Fired Heater

Plate Fin Exchanger

Integration Reduces Errors, Engineering Manpower and Capital Equipment Costs

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Aspen Exchanger Design & Rating Family

Aspen HTFS® Research Network

Aspen HTFS Research comprises both on-going experimental study and expert analysis to develop
AspenTech’s proprietary theoretical models and correlations, ensuring your exchangers are designed to the
highest degree of accuracy. Customers may license access to the Aspen HTFS Research Network to validate
their design practice against documented methods, models and source data.

Best-in-Class Physical Properties Methods and Data

The Aspen EDR product family accesses the world’s largest database of pure component and phase equilibrium
data for conventional chemicals and electrolytes. The database is regularly updated from the U.S. National
Institute of Standards and Technology (NIST), which ensures easy access to the best available experimental
property data. Accurate transport properties and phase equilibrium data are essential to providing accurate
equipment design calculations.

Wide Range of Applications

The products facilitate the full range of practical process applications for a wide range of exchanger types
including: shell & tube, double pipe, multi-tube hairpin, air coolers, economizers, plate and frame, plate fin,
and fired heaters from conceptual design to operational troubleshooting. This flexibility allows process streams
to be single phase, boiling or condensing vapors, single component or any mixture with or without non-
condensable gases in any condition.

Common User Interface

All six products that comprise the Aspen EDR product family operate within a common user interface which
automates data transfer from one program to another, allowing engineers to compare the advantages of various
heat exchangers. Access to AspenTech’s world class property package with more than 25,000 components and
35+ vapor equilibrium methods is accessible through each program.

Aspen EDR product family uses the power and flexibility of the Microsoft® Windows environment, allowing you
to fully explore unit geometry and performance detail. It supports “drag & drop” interfacing with Microsoft
Excel® as well as high-level communication with other software and is tightly integrated with Aspen Simulation
Workbook, providing easy and robust case studies within Microsoft Excel.

Meeting the Heat Transfer Needs of Process Engineers, Thermal Experts, and Fabricators

Function Benefit
• Common Aspen EDR user interface • Ease of use reduces the need for training
• Design optimization • Reduce equipment costs by up to 30% or more
• Run-time integration with Aspen Plus and Aspen HYSYS • Overall process optimization and improved process
• Access to the world’s largest property package reliability

• Aspen HTFS Research backed methods • More dependable results and process consistency
• High degree of accuracy

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Aspen Shell & Tube Exchanger, Aspen Plate Exchanger,
and Aspen Air Cooled Exchanger
Aspen Shell & Tube Exchanger, Aspen Plate Exchanger, and Aspen Air Cooled Exchanger enables optimum design, rating and
simulation of their respective exchangers for both the expert and casual user. High level run-time integration with Aspen Plus
and/or Aspen HYSYS enable engineers to rigorously model heat exchanger operation and identify capital saving opportunities in
the context of the overall process.

Aspen Shell & Tube Exchanger

Features Output
• All TEMA style vessels • Optimization path that identifies the most economical

• Bi-directional interface with Aspen Shell & Tube design selection, possible alternative designs, and
Mechanical controlling design constraints

• Run-time integration with Aspen Plus & Aspen HYSYS • Extensive warning and error reporting identifies
potential operational problems
• Design, rating, simulation, and maximum fouling
calculation modes • Summary of exchanger thermal-hydraulic performance

• All common applications including knockback • Fully completed TEMA data sheet

condensers, pool boiling, kettles, falling film • Interactive tube layout and setting plan drawings
evaporators, thermosiphons, multi-shell feed-effluent • Comprehensive incremental output
trains
• Vibration analysis (proprietary HTFS and TEMA
• Double-pipe and multi-tube hairpin exchangers methods)
• Multi-shell capability with no practical limits on shells • Conceptual cost estimating, customized to your own
• Plain, low finned, or longitudinally finned tubes and labor and material costs
general tube side and shell side enhancement • Extensive graphing capabilities
methods
• Thermosiphon stability checks and flow pattern
• Single, double, and triple segmental baffles, no tubes evaluation
in window, rod baffles, and unbaffled exchangers
• Proper handling of
fluids with two
immiscible liquid
phases
• Background ASME
mechanical design
for more accurate
sizing, costing, and
weight calculation

Program Results Include a Setting Plan &

Interactive Graphical Tube Sheet Layout

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Aspen Shell & Tube Exchanger, Aspen Plate Exchanger,
and Aspen Air Cooled Exchanger

Aspen Plate Exchanger

Features
• Run-time integration with Aspen Plus • Double banking
• Up to 5 passes for either hot or cold streams • Conceptual cost estimate
• Co-current or counter-current flow • User supplied Colburn j and friction factors to model
• Evaluates flow maldistribution risk special proprietary plate types

• Handles non-Newtonian fluids • Database of commercially available plates from 3

leading suppliers
• Proper handling of fluids with two liquid phases

Plot Size is Shown in the Plate Exchanger Diagram

5
Aspen Shell & Tube Exchanger, Aspen Plate Exchanger,
and Aspen Air Cooled Exchanger

Aspen Air Cooled Exchanger

Features Output
• Supports three calculation modes:
– Design – optimizes the selection based on capital • Optimization path identifies the most economical
and operating costs design selection considering capital and operating cost
– Check (Rate) – determines if a given exchanger has • Extensive warning and error reporting
sufficient area to achieve a specified duty • Summary of exchanger thermal-hydraulic performance
– Simulation options – multiple simulation options for • Detailed tubeside, X-side and nozzle pressure drops
prediction of inlet/outlet temperatures, mass flows,
• Detailed tabulation of incremental calculations
or process fouling
• X-side installation and fan noise data
• Run-time integration with Aspen Plus & Aspen HYSYS
• Fully completed API-style data sheet
• Tube side condensing or boiling heat recovery,
de-humidification, air cooled and other tubular cross- • Interactive tube layout drawing and setting plan
flow exchangers, air conditioning, charge air coolers, drawings for API-type units
A-frame and V-frame configurations • Comprehensive incremental output
• X-side flow and thermal duty operating point for a • Extensive graphing capabilities
defined fan performance curve
• Multiple tube, high fin and header types
• Up to 50 passes in simple and complex arrangements
• Bundle size: Two to 100 rows,
with multiple bundles per bay
and multiple bays per unit
• Draught: forced, induced, no fans
• Fouling: standard resistance or
tubeside as a function of
velocity, temperature, quality,
phase or length; X-side as a
function of row
• Automated handling of
condensation with immiscible
liquids
• Weight and budget cost
estimates The Program Automates the Design Optimization for CAPEX and OPEX

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Aspen Shell & Tube Mechanical

Aspen Shell & Tube Mechanical provides a complete mechanical design package that greatly improves engineering efficiency in
exchanger design. It provides a two-way interface to AspenTech’s thermal design program, automating transfer of information
and minimizing costly rework. It is the only program that optimizes the design of all mechanical components, producing detailed
code calculations, customized cost estimates, detailed drawing package, and complete bill of materials.

Aspen Shell & Tube Mechanical

Features
• Calculation modes: Design, rating • Expansion joints: Flanged only, flanged and flued,

• Codes and standards supported: ASME Section VIII, various types of bellows
Div. 1, EN13445, CODAP, AD Merkblätter, ASTM, DIN, • Graphics: Fully dimensioned setting plan, tubesheet
AFNOR, TEMA Classes B, C, & R layout, and detailed component drawings
• Material databases: ASME, DIN, CODAP, EN, JIS • Supplemental calculations: Vertical and horizontal

• Customized costing databases: Company operating, vessel support analysis (Zick), minimum design metal
material, and welding standards, labor efficiencies, temperatures, simultaneous internal/external pressure
material costs design, analysis of thermal expansion operature cases,
nozzle loads per WRC 107/537, HEI and TEMA-RGP-
• Incorporates all TEMA exchanger types
RCB-10.7, maximum allowable working pressures,
material cladding, wind and seismic loads
• Handles up to 13 simultaneous load cases

Bi-directional Integration Allows for Simultaneous

Optimization of Both Thermal & Mechanical Designs

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Aspen Plate Fin Exchanger

Plate-fin heat exchangers are critical to many cryogenic gas separation processes and are increasingly found in many processing
plants. Significant capital and operational savings can be realized with the high thermal effectiveness provided by this
technology. Plate-fin exchangers can handle many process streams in a single exchanger, providing a high degree of thermal
integration. This minimizes consumption of primary energy and benefits modular construction and plant layout. The materials of
construction used for plate-fin exchangers are lightweight, provide highly efficient heat transfer, and permit low-temperature
operating conditions. Aspen Plate Fin Exchanger draws on AspenTech’s deep heritage and leading technology to offer precise and
flexible modeling of today’s most challenging exchanger configurations.

Aspen Plate Fin Exchanger

Features Thermal Output

• Run-time integration with Aspen HYSYS • Summary of exchanger performance
• Simple layer-based geometry specification • Exchanger diagram and temperature graphs
• Calculation modes include design, stream-by-stream • Temperature and vapor quality profiles along the
simulation, layer-by-layer simulation, or checking exchanger for all process streams
• Up to 20 process streams • Comprehensive information on pressure drop including
• Co-current and counter-current flow with any details of losses in nozzles, headers, and distributors
complexity of exchanger inlet and outlet geometry • Fin performance data calculated by the program
• Simple and multi-pass cross flow • Extensive calculation of metal temperatures
• Core-in-shell (kettle type) • Longitudinal thermal conduction
• Single-phase and two-phase calculations • Detailed summary of thermosiphon calculations
• Checks for flow maldistribution • Extensive analytical graphics for longitudinal, cross-
• Vertical or horizontal exchanger orientation layer and inter-layer material temperatures

• Plain, wavy, serrated,

perforated and
hardway fins
• Exchanger, distributor,
header, and nozzle
pressure drop
calculations
• Multiple exchangers in
series/parallel

New Graphics Assist in Uncovering Potential Equipment Failures

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Aspen Fired Heater

The sophisticated modeling of Aspen Fired Heater allows designers to explore a wide range of heater configurations. Aspen Fired
Heater brings modeling flexibility and ease-of-use with full integration of firebox and convection section heat transfer combined
with draft calculations. It offers the reliability and robustness of Aspen HTFS models for process heat transfer and pressure drop
along with the well-stirred or long-furnace models for firebox radiation. Aspen Fired Heater simulations provide heater operators
with insight into local process conditions, facilitating optimal operations and maximizing throughput and energy efficiency
without compromising safety or reliability. It also allows users to examine local heat flux and tube metal temperatures in the
firebox and convection section, thereby avoiding unstable flow regimes in two-phase.

Aspen Fired Heater

Features Thermal Output

• Run-time integration with Aspen HYSYS • Overall heater thermal performance summary,

• Combined modeling of firebox and convection section including details of the heat load and the thermal
efficiency of the unit
• Up to 10 process streams in a single heater
• Extensive warning and error reporting identifies
• Handles cylindrical and cabin fireboxes
potential operational problems
• Firebox well-stirred and long-furnace radiation models
• Overviews of thermal performance of each part of the
• Firebox wall tubes (vertical horizontal and helical coil) heater, firebox, and convection section tube banks
• Central tubes and cell-type fireboxes • Thermal overview of each stream in the heater
• Up to 9 convection tube banks and process streams • Combustion information and fuel details, including
• Supports plain or finned tubes calculated flue gas composition for individual fuels and
fuel mixtures
• Convection section tubes with high round fins, serrated
fins, circular or rectangular cross section studs • Comprehensive incremental output, including local
temperatures, pressures, and heat flux
• Full process thermal and hydraulic calculations
• Radiation information including zonal analysis
• Combustion calculations for up to 4 fuels
• Evaluation of local process conditions

Extensive Graphics Improve Ease of Use

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 Aspen Exchanger Design and Rating
Aspen Exchanger Design and Rating product family offer state-of-the-art heat exchanger simulation and
design based on over 40 years of industry-leading research. Our aim is to enhance the value of heat
transfer solutions by providing the most integrated product offering across the widest range of
technologies. This enables our customers to use the most advanced physically-based modeling, from unit
design and overall process design, through to optimization and operational monitoring.

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to enable your company to meet and exceed its business objectives. To learn more, visit [email protected]
www.aspentech.com/pro_services.

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AspenTech is a leading supplier of software that optimizes process manufacturing—for energy,
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produce products from a chemical process. With integrated aspenONE® solutions, process manufacturers
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