09/01/2006 ChE4151 HX 03 1

Heat Exchanger Design

Shell-and-Tube Exchangers
Ref: McCabe, Smith, & Harriott, 7
th
ed., Chapter 15
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Learning Objectives
What is a shell-and-tube exchanger?
How to select the number of tube passes
How to select the baffle pitch
What are the temperature patterns?
How to correct the LMTD for multi-pass
How to rate an existing exchanger
How to select a standard exchanger
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Shell-and-tube Exchangers
Provide large amounts of heat transfer area-
-up to 5000 ft
2
--in relatively small space
Available in standard sizes--specified by
TEMA--of shell diameters and tube counts
Number of tubes per shell depends on shell
diameter, tube diameter, and tube pitch
Tube lengths available in multiples of 4 ft,
e.g., 8, 12, 16, 20 ft
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Shell-and-Tube Exchanger
i
m
s
m
P
D
s
Cross sectional area of tubes:
Outside heat transfer area:
L D N A
D
N
N
S
o tubes o
i
passes
tubes
i
t
t
=
=
4
2
P = baffle pitch
D
s
= shell inside diameter
D
i
= tube inside diameter
D
o
= tube outside diameter
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Selection of number of tube passes
Inside film coefficient changes with the 0.8
power of the number of tube passes
Pressure drop changes with the 2.8 power of
the number of tube passes
Example:
1 100 0.2
2 174 1.4
4 303 9.7
6 419 30.2
8 528 67.6
N
passes
h
i
Ap, psi
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Selection of baffle pitch
Shell fluid velocity is inversely proportional
to the baffle pitch (distance between baffles)
h
o
increases with velocity to the 0.6 power
Ap increases with velocity to the 2.8 power
6 500 100.0
8 421 44.7
10 368 23.9
12 330 14.4
18 259 4.6
P, inches h
o
Ap, psi
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Temperature Patterns
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Correction to LMTD
flow rent countercur assuming LMTD = A
A = A
L
L G
T
T F T
For one shell pass, 2, 4, 6, tube passes:
( )
( )
ca ha
ca cb
H
ca cb
hb ha
H
H
H
H
G
T T
T T
T T
T T
Z
Z Z
Z Z
Z Z
Z
F

=
(
(

+
+ +
|
|
.
|

\
|

(
(

+
=
q
q
q
q
q
1 1 / 2
1 1 / 2
ln
1
1
ln
1
1
2
2
2
McCabe, Smith, & Harriott,
7th ed., Figure 15.6(a), p. 447
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Correction to LMTD
flow rent countercur assuming LMTD = A
A = A
L
L G
T
T F T
For two shell passes, 4, 8, 12, tube passes:
( )
( ) ( ) ( )( )
( ) ( ) ( )( )
ca ha
ca cb
H
ca cb
hb ha
H H H H
H H H H
H
H
G
T T
T T
T T
T T
Z
Z Z Z
Z Z Z
Z Z
Z
F

=
(
(

+ +
+ + +
|
|
.
|

\
|

(
(

+
=
q
q q q q
q q q q
q
q
1 1 1 / 2 1 / 2
1 1 1 / 2 1 / 2
ln
1
1
ln
1 2
1
2
2
2
McCabe, Smith, & Harriott,
7th ed., Figure 15.6(b), p. 448
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LMTD Correction Factor F
G

When either fluid temperature is constant,
F
G
= 1
It does not matter which fluid is in the shell
and which is in the tubes
It does not matter in which direction the
shell fluid flows
For cross flow, see McCabe, Smith, &
Harriott, 7th edition, Figure 15.7, page 452.
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Rating an existing exchanger
Exchanger exists and we know:
Number of tubes and tube passes, N
t
, N
passes

Tube diameter, length, and rating, D
o
, D
i
, L, x
w

Shell diameter, baffle pitch, tube pitch, D
s
, P, p
Compute area of heat transfer:

Compute design coefficient:
L D N A
o t o
t =
T A
q
U
o
oD
A
=
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Exchanger Rating (continued)
Compute film coefficients and clean over-
all coefficient:


Compute available fouling resistance:
If fouling resistance is large enough, the
exchanger is suitable for the service
i i
o
m L
w o
o oc
h D
D
k D
x D
h U
+ + =
1 1
oc oD
f
U U
r
1 1
=
h
i
from Sieder-Tate
h
o
from Donohue
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Selecting a Standard Exchanger
Estimate the heat transfer coefficient U
(see McCabe, Smith, and Harriott, 7th ed., Table 11.2, page 343)
Calculate an estimate of the area and
number of tubes

Select an appropriate shell diameter from
TEMA tube count tables
Rate the selected exchanger.
L D
A
N
T U
q
A
o
o
t o
t
=
A
=
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Summary
Shell-and-tube heat exchangers provide
large heat transfer area in a compact space
Fluid velocities are controlled by the
number of tube passes and baffle spacing
LMTD must be corrected for the
parallel/countercurrent patterns
Select and rate exchangers by determining
the available fouling resistance