Professional Documents
Culture Documents
Heat Exchanger Design PDF
Heat Exchanger Design PDF
With the help of this computer program, not only the shell
and tube heat exchanger can be designed without knowing the
detail design calculation but also plant engineer can modify
the currently used heat exchanger for some necessary changes,
such as blocking the blown out tubes without much effects to
operation, changes in fluid flow rate according to other
process, etc.
It is hoped that this paper will aid in classifying the many
details questions that arise during design calculation and this
will support practicing engineers to apply the formal
backgrounds in fluid flow and heat transfer to the practical
problems posed by the design, selection, testing, or installation
of the shell and tube heat exchanger.
II. DESIGN CONSIDERATION
The designer must consider several factors that influence
the shell-side heat transfer coefficient that, in turn, determine
the rate of heat transfer in the shell-side.
1. When baffles are provided, the system directs the
shell-fluid from axial flow to top-to-bottom flow or
side-to-side flow with the effect that the heat transfer
coefficient is higher than for undisturbed flow along
the axes of the tubes [2].
2. Patterns of tube layout influence turbulence and
hence heat transfer coefficient e.g. triangular pitch
gives greater turbulence than square pitch. And under
comparable conditions of flow and tube size the heat
transfer coefficient for triangular pitch are roughly
25% greater than for square pitch [3].
3. Closer the baffle spacing, greater is the number of
times the shell-fluid is to change its direction
resulting in greater turbulence [4].
4. Shell-side coefficient is also affected by tube size,
clearance and fluid-flow characteristics [5]
5. Shell-side flow area varies across the bundle diameter
with the different number of tube clearances in each
longitudinal row of tubes. Thats why there is no true
shell-side flow area by which the mass velocity of the
shell-fluid can be computed. The correlation obtained
for fluids flowing in tubes is obviously not applicable
to fluids flowing over the tube bundles punctuated
with segmental baffles [3].
6. There are some terms used in heat exchanger
specification problems and their solutions, which are
often confused. These are rating, design and
selection. Rating defines as the computational
process in which the inlet flow rates and
temperatures, the fluid properties, and the heat
exchanger parameters are taken as input and the
outlet temperatures and thermal duty (if the
exchanger length is specified) or the required length
of the heat exchanger are calculated as output [2].
604
D s 1 2 c
100
L
B c = bch .100
Ds
L sb
2
The dimensions Ds, Dotl, baffle cut (% of Ds), and Lbb and
Lsb, shown in Fig. 2, can be obtained from a tube layout
drawing of the heat exchanger [6].
B. Calculation and Checking of Heat Load for U-Tube
Design procedures of heat load check with calculation of
heat transfer coefficient of shell and tube side are as shown in
Fig. 3.
1. Calculation of Tube-side Heat Transfer Coefficient
N t = CTP
N t = CTP
D s2
4CLPt2
2
D otl
4CLPt2
(1)
(2)
605
1/ 3
hd
d
Nu =
= 1.86 Re.Pr 0.14
k
L
(6)
d 2/3
hd
= 0.116(Re2/3 125) Pr1/ 3 0.14 1 +
k
L
(7)
Nu =
hd
= 0.023 Re 0.80 . Pr 1/ 3 0.14
k
(8)
FW =
(12)
Ssb
Ssb + Stb
S + S tb
rlm = sb
Sm
rs =
(14)
(15)
(4)
an = at-a f
(5)
Where, at is tube cross flow area, af is tip area of plate fin,
an is the net flow area for one tube. To calculate tube-side flow
passage area for one pass, an is multiplied by Nt/one pass. And
then, calculate tube side mass flow rate G1.
After that, Reynold number of the flow inside tube can then
be calculated by the following equations.
606
rss =
N ss
N tcc
N tcc =
Fig. 6 Tube Length Definition for U-Tube [8]
(17)
Lbc = {1.25-2Lbi}/{Nb-1}
(18)
Js =
Sb
Sm
Sb = Lbc[(Ds-Dotl)+Lpl]
(N b - 1) + (L bi /L bc )1-n + (L bo /L bc )1-n
(N b - 1) + (L bi /L bc ) + (L bo /L bc )
10
JR=(JR)20=
Nc
(19)
Fsbp =
(23)
(24)
Where n=0.6 for turbulent flow and n=1/3 for laminar flow.
The number of baffle compartments Nb is determined from the
effective tube length and the baffle spacing [6]-[8].
In laminar flows, heat transfer is reduced by the adverse
temperature gradient formed in the boundary layer as the flow
thermally develops along the flow channel. The laminar flow
correction factor JR accounts for this effect. For laminar shellside flow JR<1.0 (i.e. for 100 Re) while for Re>100, no
correction is needed and JR=1.0.
Bc
1 2 100
Ds
L pp
(22)
0.18
(For20 Re)
Nc = (Ntcc + Ntcw)(Nb+1)
(25)
(26)
20 - Re
J R = (J R ) 20 +
[(J R )20 1]
80
(20)
(21)
(27)
607
1.33
j1 = a 1
L tp
Dt
a=
p noz = 3
a3
1 + 0.14Re a 4
(35)
Re a2
2
Vnoz
2g c
(29)
(30)
ro 1
1 ro ro 1
1
+ ln +
+
+
r
h
h
k
r
h
h
si
so
o
i i
w i
d x3
(32)
A = (d o L1 ) + 2 nL f + f L1 N t
2
T2 T1
T
ln 2
T1
(33)
Fig. 7 Flow Chart for Pressure Drop on Shell and Tube Side
V 2
Pent = 3 i
2g c
If the calculated heat load is greater than the given heat load,
it can be said that the design is satisfied. If not, by increasing
TN, the total number of tubes, and the whole procedure may
be repeated till the above condition is satisfied.
(36)
pc = pbl (Nb-1) RB RL
608
(38)
1.33
f 1 = b1
L /D
tp t
(39)
L
R = bc
s L
bo
Re b2
(40)
2 n
L
+ bc
L bi
2n
(49)
Fluid
Inlet Temperature
(C)
Outlet Temperature
(C)
Flow rate
(m3/hr)
Heat load
(kW)
Pressure drop
(bar)
Max working
pressure (bar)
b3
b=
1 + 0.14Re b4
R =
w
(41)
-m
(42)
p
lm
R L = exp - 1.33(1 + rs )r
P = -0.15(1+rs) + 0.8
80.7
79.9
27.7
84
282
282
0.6
0.3
15
77
(44)
12000
(45)
11000
(46)
10000
9000
8000
7000
2w
0.001m
(47)
p w = N b (2 + 0.6N tcw )
R L R
2
N
p e = p bl 1 + tcw R B R S
N tcc
Shell side
water
(43)
Where pbl is the ideal bundle pressure drop for one baffle
compartment of the Nb compartments. f1 is the friction factor
and the empirical constants. R is the viscosity correction
factor and RB is the bypass correction factor. The limit of RB is
1 for rss 1/2. Use Cbp is 4.5 for laminar flow (100 Re) and
Cbh is 3.7 for transition and turbulent flows (Re>100). RL is
the leakage correction factor.
M
w =
m
Sm S w
Tube side
Hydraulic
oil
105
6000
180
200
280
300
320
340
(48)
609
11000
10000
1500
9000
1400
1300
1200
1100
1000
900
180
200
300
320
340
8000
7000
6000
5000
4000
3000
Nb=2
Nb=3
2000
Nb=4
1000
1335
1340
1345
1350
1355
1360
1365
It can be seen that in Fig. 9 and Fig. 10 shows that the Re and
ho are gradually decreased corresponding to as high as Nt.
Because of mass flow rate are constant, velocity are increase
and Re, ho are also decrease. Between total number of tube
220 and 240, there are a slight rise in heat transfer coefficient
because of changing from turbulent flow to transition flow.
32000
Heat Load (kW)
260
30000
Nb=2
Nb=3
28000
Nb=4
26000
250
240
230
24000
220
22000
210
Nb=2
Nb=3
Nb=4
200
20000
300
310
320
330
340
350
360
370
380
390
400
18000
16000
14000
1335
1340
1345
1350
1355
1360
Result
1365
Shell diameter,
m
Tube length, m
Total no. of
tubes
Tube diameter,
m
Number of
Baffle
Heat Load, kW
Tube side
pressure drop
Shell side
pressure drop
Industrial
Data
0.385
Calculated
Data
0.39
1.25
248
1.25
318
0.014
0.0127
282
0.6
283.02
0.4032
0.3
0.1652
610
[3]
[4]
[5]
[6]
[7]
[8]
Frass, A.P and M.Necatic Ozisik, 1965, Heat Exchanger Design, John
Wiley and Sons Inc.
Max S.Peters and Klaus D. Timmerhuaus, 1958, Plant Design and
Economics for Chemical Engineers, 4th ed, McGraw-Hill Book
Company.
TEMA, 1999, Standards of TEMA, 8th ed, Turbular Exchanger
Manufacturers Association, New York.
Kays, W.M and A.L.London, 1998, Compact Heat Exchangers, 3rd ed,
Krieger Publishing Malabar, FL.
E.A.Krasnoshchekov and A.S.Sukomel, 1977, Problems in Heat
Transfer, MIR Publishers, Moscow.
Professor John R.Thom, 2004, Wolverine Tube Heat Transfer Data
Book III, Wolverine Tube Inc, www.Wolverine.com.
J.P. Holman, 1963, Heat Transfer, 8th ed, McGraw-Hill Book Company.
Dr. K. J. Bell and Dr. A.C.Muller, 1984, Wolverine Tube Heat
Transfer Data Book II, Wolverine Division of UOP Inc,
www.Wolverine.com.
611