Optimize Gas Flow in TLE using CFD Case Study

Problem

An OEM of a Transfer Line Exchanger (TLE) had problems optimizing gas flow due to erosion. They hired KHE to develop a conceptual design for the inlet cone and connected piping to improve the performance of the system.

Solution

In order to complete the design, KHE performed the work in two phases. First, KHE measured the pressure drop of the inlet piping and selected an optimum pipe size. Second, we developed a CFD model to determine a desirable inlet cone design. An optimum TLE inlet cone design should have a low-pressure drop and should diffuse the flow entering the cone. Bearing that in mind, KHE evaluated the pressure drop, flow distribution entering the tube bundle, and radial tube velocities at the inlet tubesheet when comparing cone designs. Consequently, we determined that the best design had a low-pressure drop, an even flow distribution through the tubes, and a low radial velocity at the inlet face tubesheet. We then compared and analyzed a 10-inch diameter and a 12-inch diameter inlet cone and ultimately found that the 12 inch diameter inlet cone with specific modifications was the optimal design.

Results

The OEM developed a more efficient cone design with greatly reduced erosion across the tubesheet without having to resort to costly trial and error with multiple prototypes and testing.