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5.1
The most common type of heat exchanger in industrial applications is shell-and-tube heat
exchangers. The exchangers exhibit more than 65% of the market share with a variety of
design experiences of about 100 years. Shell-and tube heat exchangers provide typically
the surface area density ranging from 50 to 500 m2/m3 and are easily cleaned. The design
codes and standards are available in the TEMA (1999)-Tubular Exchanger Manufacturers
Association. A simple exchanger, which involves one shell and one pass, is shown in
Figure 5.18.
Tube outlet
Shell inlet
Tube
Shell sheet
Shell
Baffles
Shell outlet
End
channel
Tube inlet
Baffles
In Figure 5.18, baffles are placed within the shell of the heat exchanger firstly to support
the tubes, preventing tube vibration and sagging, and secondly to direct the flow to have a
higher heat transfer coefficient. The distance between two baffles is baffle spacing.
Multiple Passes
Shell-and-tube heat exchangers can have multiple passes, such as 1-1, 1-2, 1-4, 1-6, and
1-8 exchangers, where the first number denotes the number of the shells and the second
number denotes the number of passes. An odd number of tube passes is seldom used
except the 1-1 exchanger. A 1-2 shell-and-tube heat exchanger is illustrated in Figure
5.19.
42
Tube outlet
Shell inlet
Tube
Pass
partition
Shell
End
channel
Baffles
Shell outlet
Tube inlet
Ds
N p = number of pass
Ds = Shell inside diameter
N b = number of baffle
B = baffle spacing
Lt
Nb +1
(5.128)
43
De =
4 Ac
Pheated
(5.129)
From Figure 5.21, the equivalent diameter for the square pitch layout is
De =
4 Pt d o 4
d o
2
(5.130a)
From Figure 5.21, the equivalent diameter for the triangular pitch layout is
3Pt 2 d o 2
4
8
De =
d o 2
(5.130b)
Ds C t B
PT
(5.131)
do
do
di
di
Flow
Ct
Ct
Pt
(a)
Pt
(b)
do
di
(5.132)
Some diameter ratios for nominal pipe sizes are illustrated in Table C.6 in Appendix C.
The tube pitch ratio Pr is defined by
44
Pr =
Pt
do
(5.133)
(5.134)
The number of tube Nt can be predicted in fair approximation with the shell inside
diameter Ds.
N t = (CTP )
Ds2 4
(5.135)
ShadeArea
where CTP is the tube count constant that accounts for the incomplete coverage of the
shell diameter by the tubes, due to necessary clearance between the shell and the outer
tube circle and tube omissions due to tube pass lanes for multiple pass design [1].
CTP = 0.93
CTP = 0.9
CTP = 0.85
ShadeArea = CL Pt 2
(5.136)
(5.137)
(5.138)
CTP Ds2
2 =
4 CL Pt
4 CL Pr2 d o2
(5.139)
(5.140)
Nt =
CTP Ds2
Ai = d i N t L
Ao = d o N t L
(5.141)
(5.142a)
(5.142b)
45
Uo =
1 Ao
d
ln o
d
1
1
+ i +
hi Ai
ho Ao
2kL
(5.143)
Tube side
Reynolds number
u m d i m& d i
=
Ac
Re D =
Ac =
(5.144)
d i2 N t
(5.144a)
4 Np
1
Laminar flow
(Re < 2300)
hd
d Re Pr 3
Nu D = i = 1.86 i
kf
L s
0.14
(5.145)
Turbulent flow
(Re > 2300)
Nu D =
hd i
( f / 2)(Re D 1000) Pr
=
12
kf
1 + 12.7( f / 2 ) Pr 2 3 1
(5.146)
Shell side
Square pitch layout
(Figure 5.21)
Triangular pitch layout
(Figure 5.21)
Reynolds number
4 Pt d o 4
De =
d o
2
3Pt 2 d o 2
4
8
De =
d o 2
DCB
Ac = s t
Pt
u D
m& De
Re D = m e =
Ac
(5.147)
(5.148a)
(5.148b)
(5.149)
(5.150)
46
Nusselt number
h D
Nu = o e = 0.36 Re 0.55 Pr 1 3
kf
s
6
2000 <Re < 1 x 10
0.14
(5.151)
-NTU Method
Heat transfer unit
(NTU)
NTU =
Capacity ratio
Cr =
(5.152)
U o Ao
(m& c p )min
(m& c )
(m& c )
p min
(5.153)
p max
Effectiveness
One shell (2, 4,.. passes)
= 21 + C r + 1 + C r 2
[ ( ) ]
)
1 exp[ NTU (1 + C ) ] (5.154)
12
1 + exp NTU 1 1 + C r2
12
2 12
r
NTU 1 = NTU N p
where E =
E 1
ln
E +1
2 (1 + C r )
NTU = 1 + C r
2 1 2
(5.155)
(1 + C )
2 12
Effectiveness
q
qmax
p min
1i
1i
1o
2i
2 p2
p min
2o
1i
T2i )
T2i ) (5.156)
(5.157)
f Lt
1
P = 4
+ 1 N p v 2
2
di
(5.158)
f = 16 Re D
(5.159)
(5.160)
47
Ds
(N b + 1) 1 v 2
De
2
f = exp(0.576 0.19 ln (Re s ))
P = f
(5.161)
(5.162)
48
( 120C + 115C)
2
= 117.5 C
Tcool :=
( 90C + 100C)
2
= 95 C
(E5.2.1)
49
Engine oil (subscript 1)-tube side
kg
1 := 828
3
m
cp1 := 2307
cp2 := 3650
kg K
W
k1 := 0.135
m K
(E5.2.2)
J
kg K
W
k2 := 0.442
m K
2 Ns
1 := 1.027 10
2 N s
2 := 0.08 10
m
Pr1 := 175
m
Pr2 := 6.6
The thermal conductivity for the tube material (Chromium alloy) is given
W
kw := 42.7
m K
(E5.2.3)
Given information:
The inlet temperatures are given as
T1i := 120C
T2i := 90C
(E5.2.4)
kg
mdot2 := 0.47
kg
s
(E.5.2.5)
The fouling factors for engine oil and 50% ethylene glycol are given as
2
3 m K
Rfi := 0.176 10
2
3 m K
Rfo := 0.353 10
(E5.2.6)
Design requirement:
The engine oil outlet temperature must be less than 115C.
T1o 115C
(E5.2.7)
(E5.2.8)
50
Lt := 15in
Tube length
d o :=
1
8
in
Ds = 50.8mm
Lt = 381mm
(E5.2.9)
(E5.2.10)
do = 3.175 mm
(E5.2.11)
The diameter ratio (dr = do/di) is given as suggested in the problem description.
d r := 1.3
di :=
d
dr o
di = 2.442 mm
(E5.2.12)
The tube pitch ratio (Pr = Pt/do) is given as suggested in the problem description.
Pr := 1.25
(E5.2.13)
(E5.2.14)
The baffle spacing is assumed and may be iterated, and the baffle number from Equation
(5.128) is defined.
B :=
8
8
in
Lt
Nb :=
1
B
B = 25.4mm
(E5.2.15)
Nb = 14
(E5.2.16)
(E5.2.17)
Ct = 0.794 mm
(E5.2.18)
51
From Equation (5.136), the tube count calculation constants (CTP) up to three-passes are
given
CTP :=
0.93 if Np
0.9 if Np
0.85 otherwise
(E5.2.19)
From Equation (5.138), the tube layout constant (CL) for a triangular-pitch layout is
given by
CL := 0.866
(E5.2.20)
The number of tubes Nt is estimated using Equation (5.139) and rounded off in practice.
Note that the number of tubes in the shell inside diameter defined earlier indicates the
compactness of a miniature exchanger. A 253-tube exchanger in a 2.25-inch shell outside
diameter is commercially available for a 2-inch shell diameter.
D
CTP
s
Ntube ( Ds , d o , Pr) :=
4 CL 2
P d
r
Ntube Ds , d o , Pr = 138.189
(E5.2.21)
))
Nt := round Ntube Ds , d o , Pr
Nt = 138
(E5.2.22)
A c1 :=
v 1 :=
di
4
Nt
Np
mdot1
1 A c1
Re1 :=
1 v 1 d i
1
4 2
A c1 = 6.465 10
(E5.2.23)
v 1 = 0.43
m
s
(E5.2.24)
Re1 = 84.603
(E5.2.25)
The Reynolds number indicates very laminar flow. The velocity in the tubes appears
acceptable when considering a reasonable range of 0.5 1.0 m/s in Table 5.4 for the
engine oil.
52
The friction factor is determined automatically whether it is either laminar or turbulent
using the following program as
f ReD :=
otherwise
(E5.2.26)
The Nusselt number for turbulent or laminar flow is defined using Equations (5.145) and
(5.146) with assuming that changes moderately with temperature. The convection heat
transfer coefficient is then obtained.
NuD Dh , Lt , ReD , Pr :=
f ( ReD)
(ReD 1000) Pr
2
f
Re
(
)
D
Pr 3 1
1 + 12.7
2
0.5
Dh ReD Pr
1.86
Lt
otherwise
(E5.2.27)
h 1 :=
Nu1 k1
di
Nu1 = 8.484
(E5.2.28)
h 1 = 468.972
W
2
m K
(E5.2.29)
v 2 :=
Ds Ct B
Pt
mdot2
2 A c2
4 2
A c2 = 2.581 10
(E5.2.30)
v 2 = 1.786
m
s
(E5.2.31)
53
The velocity of 1.786 m/s in the shell is acceptable because the reasonable range of 1.2
2.4 m/s for the similar fluid shows in Table 5.4. The equivalent diameter for a triangular
pitch is given in Equation (5.148b) as
P 2 3 d 2
o
t
8
4
De := 4
d
o
2
Re2 :=
De = 2.295 mm
(E5.2.32)
2 v 2 De
Re2 = 5.225 10
(E5.2.33)
The Nusselt number is given in Equation (5.152) and the heat transfer coefficient is
obtained.
1
0.55
h 2 :=
Pr2
(E5.2.34)
Nu2 k2
h 2 = 1.442 10
De
W
2
m K
(E5.2.35)
The total heat transfer areas for both fluids are obtained as
2
A i := d i Lt Nt
A i = 0.403m
A o := d o Lt Nt
A o = 0.524 m
(E5.2.36)
2
(E5.2.37)
The overall heat transfer coefficient is calculated using Equation (5.143) with the fouling
factors as
1
Ao
Uo :=
1
h 1 A i
Rfi
Ai
do
d i + Rfo +
W
Uo = 209.677
2
m K
ln
+
2 kw Lt
Ao
1
h 2 A o
(E5.2.38)
54
-NTU method
The heat capacities for both fluids are defined and then the minimum and maximum heat
capacities are obtained using the MathCAD built-in functions as
W
C1 = 530.61
K
C1 := mdot1 cp1
3 W
C2 = 1.716 10
K
C2 := mdot2 cp2
(E5.2.39)
Cmin := min C1 , C2
(E5.2.40)
Cmax := max C1 , C2
(E5.2.41)
Cr = 0.309
(E5.2.42)
Uo A o
NTU = 0.207
Cmin
(E5.2.43)
The effectiveness for shell-and-tube heat exchanger is give using Equation (5.154) as
NTU
NTU1 :=
Np
Since
(E5.2.44a)
0.5
2
0.5 1 + expNTU 1 + C
1
r
2
hx := 2 1 + Cr + 1 + Cr
0.5
1 expNTU1 1 + Cr
hx = 0.182
(E5.2.44b)
C1 T1i T1o
q max
C2 T2o T2i
(E5.2.45)
The outlet temperatures are rewritten for comparison with the outlet temperatures.
55
T1i = 120 C
T2i = 90 C
T1o := T1i hx
Cmin
C1
T1i T2i
T1o = 114.544C
(E5.2.46)
Cmin
T2o := T2i + hx
T1i T2i
C2
T2o = 91.687C
(E5.2.47)
The engine oil outlet temperature of 114.544C is close enough to the requirement of
105C. The heat transfer rate is obtained
q = 2.895 10 W
(E5.2.48)
The pressure drops for both fluids are obtained using Equations (5.158) and (5.161) as
f ( Re1) Lt
P 1 := 4
di
1
2
+ 1 Np 1 v 1
2
(E5.2.49)
Ds
1
2
P 2 := f Re2
Nb + 1 2 v 2
De
2
( )
P 1 = 9.325 kPa
P 2 = 5.141 kPa
(E5.2.50)
Both the pressure drops calculated are less than the requirement of 10 kPa. The iteration
between Equations (E5.2.9) and (E5.2.46) is terminated. The surface density for the
engine oil side is obtained using the relationship of the heat transfer area over the volume
of the exchanger.
1 :=
Ao
D 2
s
4 Lt
1 = 679.134
(E5.2.51)
T2i = 90 C
56
mdot1 = 0.23
kg
mdot2 = 0.47
kg
s
mass flow rate of 50% ethylene glycol
s
4
Rfi = 1.76 10
2 K
Rfo = 3.53 10
2 K
P 1 10kPa
Design obtained
Np = 1
number of passes
Ds = 50.8 mm
d o = 3.175 mm
d i = 2.442 mm
Lt = 381 mm
tube length
Nt = 138
number of tube
Ct = 0.794 mm
tube clearance
B = 25.4 mm
baffle spacing
Nb = 14
number of baffle
T1o = 114.544C
T2o = 91.687 C
q = 2.895 kW
1 = 679
surface density
P 1 = 9.325 kPa
Ds = 2 in
Lt = 15in
B = 1 in
57
P 2 = 5.141 kPa
Problems (corrected)
Shell-and-Tube Heat Exchanger
5.3 A miniature shell-and-tube heat exchanger is designed to cool glycerin with cold
water. The glycerin at a flow rate of 0.25 kg/s enters the exchanger at 60C and leaves
at 50C. The water at a rate of 0.54 kg/s enters at 18C, which is shown in Figure
P5.3. The tube material is Cr alloy (kw = 60.5 W/mK). Fouling factors of 0.253x10-3
m2K/W for water and 0.335x10-3 m2K/W for glycerin are specified. Route the
glycerin through the tubes. The permissible maximum pressure drop on each side is
30 kPa. The volume of the exchanger is required to be minimized. Since the
exchanger is custom designed, the tube size may be smaller than NPS 1/8 (DN 6 mm)
that is the smallest size in Table C.6 in Appendix C, wherein the tube pitch ratio of
1.25 and the diameter ratio of 1.3 can be applied. Design the shell-and-tube heat
exchanger.