TY - JOUR

T1 - Fouling in a Steam Cracker Convection Section Part 2

T2 - Coupled Tube Bank Simulation using an Improved Hybrid CFD-1D Model

AU - Kulkarni, Shekhar R.

AU - Verhees, Pieter

AU - Akhras, Abdul R.

AU - Van Geem, Kevin M.

AU - Heynderickx, Geraldine J.

N1 - Publisher Copyright:
© 2019, © 2019 Taylor & Francis Group, LLC.

PY - 2020/10/10

Y1 - 2020/10/10

N2 - Performing an adequate fouling study for the heat exchangers in the convection section of a steam cracker requires reliable data on circumferential tube wall temperature profiles. A hybrid Computational Fluid Dynamics (CFD)-1D convection section model, developed to perform coupled flue gas/process gas side simulations of convection sections, is improved by the implementation of flue gas radiation modeling and extended to include typical tube banks. A complete naphtha cracker convection section is simulated with the improved hybrid CFD-1D model. All tubes show distinct maximum heat fluxes on the tube walls due to the high flue gas velocity. Based on the calculated circumferential heat flux profiles, the maximum heat flux value is calculated to be 1.8 times the average tube heat flux value. As computational costs associated with a hybrid CFD-1D simulation are high, a convective heat flux profile reconstruction scheme is developed. Using the scheme, circumferential heat flux profiles are reconstructed, based on the heat fluxes calculated when performing a fully 1D coupled convection section simulation. The heat flux reconstruction profile scheme enables fast retrieval of circumferential heat flux profiles and, thus, tube wall temperature profiles. Optimization and/or design of a steam cracker convection section becomes less computationally demanding.

AB - Performing an adequate fouling study for the heat exchangers in the convection section of a steam cracker requires reliable data on circumferential tube wall temperature profiles. A hybrid Computational Fluid Dynamics (CFD)-1D convection section model, developed to perform coupled flue gas/process gas side simulations of convection sections, is improved by the implementation of flue gas radiation modeling and extended to include typical tube banks. A complete naphtha cracker convection section is simulated with the improved hybrid CFD-1D model. All tubes show distinct maximum heat fluxes on the tube walls due to the high flue gas velocity. Based on the calculated circumferential heat flux profiles, the maximum heat flux value is calculated to be 1.8 times the average tube heat flux value. As computational costs associated with a hybrid CFD-1D simulation are high, a convective heat flux profile reconstruction scheme is developed. Using the scheme, circumferential heat flux profiles are reconstructed, based on the heat fluxes calculated when performing a fully 1D coupled convection section simulation. The heat flux reconstruction profile scheme enables fast retrieval of circumferential heat flux profiles and, thus, tube wall temperature profiles. Optimization and/or design of a steam cracker convection section becomes less computationally demanding.

UR - http://www.scopus.com/inward/record.url?scp=85073787055&partnerID=8YFLogxK

U2 - 10.1080/01457632.2019.1661664

DO - 10.1080/01457632.2019.1661664

M3 - Article

AN - SCOPUS:85073787055

SN - 0145-7632

VL - 41

SP - 1531

EP - 1551

JO - Heat Transfer Engineering

JF - Heat Transfer Engineering

IS - 18

ER -