HEAT EXCHANGERS

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INTRODUCTION:
Shell and tube heat exchangers are one of the most
common equipment found in all plants

How it works?

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WHAT ARE THEY USED FOR?
Classification according to service .
Heat Exchanger
Both sides single phase and process stream

Cooler
One stream process fluid and the other cooling water or air

Heater
One stream process fluid and heating utility as steam

Condenser
One stream condensing vapor and the other cooling water or air

Reboiler
One stream bottom stream from a distillation column and the other a hot utility
or process stream
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DESIGN CODES:
Code
Is recommended method of doing something
ASME BPV TEMA

Standard
is the degree of excellence required
API 660-ASME B16.5ASME B36.10MASME B36.19-ASME B16.9ASME B16.11

Specifications
Is a detailed description of construction, materials, etc
Contractor or Owner specifications
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MAIN COMPONENTS

1- Channel Cover 8- Shell

2- Channel 9- Baffles
3- Channel Flange 10- Floating Head backing Device
4- Pass Partition 11- Floating Tubesheet
5- Stationary Tubesheet 12- Floating Head
6- Shell Flange 13- Floating Head Flange
7- Tube 14 Shell Cover 5
TEMA
HEAT
EXCHANGER

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TEMA HEAT EXCHANGER
Front Head Type

A - Type B - Type C - Type

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TEMA HEAT EXCHANGER
Shell Type

E - Type F - Type

J - Type 8
K - Type
TEMA HEAT EXCHANGER
Rear End Head Types

M - Type S - Type T - Type

Fixed Tubesheet Floating Head Pull-Through
Floating Head
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CLASSIFICATION:
U-Tube Heat Exchanger

Fixed Tubesheet Heat Exchanger

Floating Tubesheet Heat exchanger

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EXAMPLE

AES 11
EXAMPLE

AKT 12
HEAT EXCHANGERS MECHANICAL
DESIGN
Terminology

Design data

Material selection

Codes overview

Sample calculations

Hydrostatic test

Sample drawing
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DESIGN DATA
Heat Exchanger Data Sheet :
TEMA type
Design pressure
Design temperature
Dimensions / passes
Tubes ( dimensions, pattern)
Nozzles & Connections
Baffles (No. & Type)

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MATERIAL SELECTION
Strength

Cost
&
Material Corrosion
Resistance
Availabilit
y Selection

Fabricability
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HEAT EXCHANGERS:
DESIGN CONSIDERATIONS
TYPES

Heat Exchanger Types

Heat exchangers are used to energy conversion and utilization. They
involve heat exchange between two fluids separated by a solid and
encompass a wide range of flow configurations.

Concentric-Tube Heat Exchangers

Parallel Flow Counterflow

Simplest configuration.

Superior performance associated with counter flow.

TYPES (CONT.)

Cross-flow Heat Exchangers

Finned-Both Fluids Unfinned-One Fluid Mixed

Unmixed the Other Unmixed

For cross-flow over the tubes, fluid motion, and hence mixing, in the
transverse direction (y) is prevented for the finned tubes, but occurs
for the un-finned condition.

Heat exchanger performance is influenced by mixing.

TYPES (CONT.)

Shell-and-Tube Heat Exchangers

One Shell Pass and One Tube Pass

Baffles are used to establish a cross-flow and to induce turbulent mixing of the
shell-side fluid, both of which enhance convection.
The number of tube and shell passes may be varied, e.g.:

One Shell Pass, Two Shell Passes,

Two Tube Passes Four Tube Passes
TYPES (CONT.)

Compact Heat Exchangers

Widely used to achieve large heat rates per unit volume, particularly
when one or both fluids is a gas.
Characterized by large heat transfer surface areas per unit volume, small
flow passages, and laminar flow.

(a) Fin-tube (flat tubes, continuous plate fins)

(b) Fin-tube (circular tubes, continuous plate fins)
(c) Fin-tube (circular tubes, circular fins)
(d) Plate-fin (single pass)
(e) Plate-fin (multipass)
OVERALL COEFFICIENT
Overall Heat Transfer Coefficient
An essential requirement for heat exchanger design or performance calculations.

Contributing factors include convection and conduction associated with the

two fluids and the intermediate solid, as well as the potential use of fins on
both sides and the effects of time-dependent surface fouling.

With subscripts c and h used to designate the hot and cold fluids, respectively,
the most general expression for the overall coefficient is:

1 1 1
UA UA c UA h

1 Rf , c Rf , h 1
Rw
o hAc o Ac o Ah o hAh
OVERALL COEFFICIENT

Rf Fouling factor for a unit surface area (m K/W)

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Table 11.1
Rw Wall conduction resistance (K/W)

o Overall surface efficiency of fin array (Section 3.6.5)

Af
o,c or h 1 1 f
A c or h

A At total surface area (fins and exposed base)

Af surface area of fins only

Assuming an adiabatic tip, the fin efficiency is

tanh mL
f ,c or h
mL c or h

mc or h 2U p / kwt c or h

h
partial overall coefficient
1 hR
U p , c or h
f c or h
LMTD METHOD
A Methodology for Heat Exchanger
Design Calculations
- The Log Mean Temperature Difference (LMTD) Method -
A form of Newtons Law of Cooling may be applied to heat exchangers by
using a log-mean value of the temperature difference between the two fluids:
q U A T1m
T1 T2
T1m
1n T1 / T2

Evaluation of T1 and T2 depends on the heat exchanger type.

Counter-Flow Heat Exchanger:

T1 Th,1 Tc ,1
Th,i Tc , o

T2 Th,2 Tc ,2
Th, o Tc ,i
LMTD METHOD (CONT.)

Parallel-Flow Heat Exchanger:

T1 Th,1 Tc ,1
Th,i Tc ,i

T2 Th,2 Tc,2
Th, o Tc , o

Note that Tc,o can not exceed Th,o for a PF HX, but can do so for a CF HX.
For equivalent values of UA and inlet temperatures,
T1m,CF T1m, PF

Shell-and-Tube and Cross-Flow Heat Exchangers:

T1m F T1m,CF
F Figures 11.10 - 11.13
ENERGY BALANCE
Overall Energy Balance
Application to the hot (h) and cold (c) fluids:

Assume negligible heat transfer between the exchanger and its surroundings
and negligible potential and kinetic energy changes for each fluid.
q m h ih,i ih,o

q m c ic , o ic ,i

i fluid enthalpy
Assuming no l/v phase change and constant specific heats,
q m h c p , h Th,i Th,o Ch Th,i Th,o

q m c c p , c Tc ,o Tc ,i Cc Tc ,o Tc ,i

Ch,Cc Heat capacity rates

SPECIAL CONDITIONS
Special Operating Conditions

Case (a): Ch>>Cc or h is a condensing vapor Ch .

Negligible or no change in Th Th,o Th,i .
Case (b): Cc>>Ch or c is an evaporating liquid Cc .

Negligible or no change in Tc Tc ,o Tc ,i .
Case (c): Ch=Cc.
T1 T2 T1m
PROBLEM: OCEAN THERMAL ENERGY
CONVERSION

Problem : Design of a two-pass, shell-and-tube heat exchanger to supply

vapor for the turbine of an ocean thermal energy conversion
system based on a standard (Rankine) power cycle. The power
cycle is to generate 2 MWe at an efficiency of 3%. Ocean water
enters the tubes of the exchanger at 300K, and its desired outlet
temperature is 292K. The working fluid of the power cycle is
evaporated in the tubes of the exchanger at its phase change
temperature of 290K, and the overall heat transfer coefficient is
known.

FIND: (a) Evaporator area, (b) Water flow rate.

SCHEMATIC: