Shelltubeexchangerdesign PDF

SHELL & TUBE
HEAT EXCHANGER DESIGN
TFD-HE13 - Shell & Tube Heat Exchager Design 1

Introduction
q Shell & tube heat exchangers are the most v
ersatile ty
pe of heat
exchangers.
§ Theyare used in process industries, in conventional and nuclear power
stations, steam generators, etc
§ Theyare used in manyalternative energyapplications including ocean,
thermal and geothermal.
q Shell & tube heat exchangers prov
ide relativ
elylarge ratios of heat
transfer area to v
olume.
q Theycan be easilycleaned.

Shell & Tube HeatExchangers
q Shell & tube ty
pe heat exchangers are built of tubes (round or rectangular
in general) mounted in shells (cy
lindrical, rectangular or arbitraryshape).
q Manyv
ariations of this basic ty
pe is av
ailable.
§ The differences lie mainlyin the detailed features of construction and provisions
for differential thermal expansion between the tubes and the shell.
Shell
inlet
Tube Tube
inlet outlet
Shell
outlet

U-Tube, baf fled, single pass

shell & tube heat exchanger
Two pass tube, baff

ledsingle pass
shell & tube heat exchanger
Two pass tube, f loatinghead, baf f

led
single pass shell & tube heat exchanger

Shell Types
q TEMA (the Tubular Exchangers
Manufacturers Association) publishes
standards defining how shell and tube
exchangers should be built. They
define a naming system that is
commonlyused.
q Shells are also typicallypurchased in
standard siz es to control costs. Inside
the shell, baffles (dividers) are
installed to direct the flow around the
tubes, increase velocity, and promote
cross flow. Theyalso help support the
tubes. The baffle cut is the ratio of the
baffle window height to the shell
diameter. Typically, baffle cut is about
20 percent. It effects both heat
transfer and pressure drop. Designers
also need to specifythe baffle spacing;
the maximum spacing depends on how
much support the tubes need.

M ultiShell & Tube Passes

Tube to Header Plate Connection
q Tubes are arranged in a bundle and held Header
in place byheaderplate (tube sheet). Plate
q The number of tubes that can be placed

within a shell depends on
§ Tube layout, tube outside diameter, pitch,
number of passes and the shell diameter.
q When the tubes are to close to each
other, the header plate becomes to weak
.
q Methods of attaching tubes to the header
plate
HeaderPlate
Tube

Baffle Type & Geom etry
q Baffles serv
e two functions:
§ Support the tubes for structural
rigidity
, prev
enting tube v
ibration
and sagging
§ Divert the f
low across the bundle
to obtain a higher heat transfer
coefficient.

Segm ental CutBaffles
Baffle Type & Geometry
q The single and double segmental baffles are most frequentlyused. They
div
ert the flow most effectiv
elyacross the tubes.
q The baffle spacing must be chosen with care.
§ Optimal baffle spacing is somewhere between 40% - 60% of the shell diameter.
§ Baffle cut of 25%-35% is usuallyrecommended.
q The triple segmental baffles are used
for low pressure applications.

Disc & Ring Baffles
q Disc and ring baffles are composed of alternating outer rings and
inner discs, which direct the flow radiallyacross the tube field.
§ The potential bundle-to-shell bypass stream is eliminated
§ This baffle type is veryeffective in pressure drop to heat transfer
conv
ersion
q Disc

Orifice Baffle
q In an orifice baffle shell-side-fluid flows through the clearance

between tube outside diameter and baffle-hole diameter.

Num ber ofTubes
q The number of tubes in an exchanger depends on the
§ Fluid flow rates
§ Available pressure drop.
q The number of tubes is selected such that the
§ Tube side velocityfor water and similar liquids ranges from
0.9 to 2.4 m/
s (3 to 8 ft/
sec)
§ Shell-side velocityfrom 0.6 to 1.5 m/
s (2 to 5 ft/
sec).
q The lower velocitylimit corresponds to limiting the fouling, and the
upper velocitylimit corresponds to limiting the rate of er
osion.
q When sand and silt are present, the v
elocityis k
ept high enough to
prev
ent settling.

Tube Passes
q Apass is when liquid flows all the wayacross from one end to the
other of the exchanger. We will count shell passes and tube passes.
§ An exchanger with one shell pass and two tube passes is a 1-2
exchanger. Almost alway
s, the tube passes will be in multiples of two
(1-2, 1-4, 2-4, etc.)
§ Odd numbers of tube passes have more complicated mechanical
stresses, etc. An exception: 1-1 exchangers are sometimes used for
vaporizers and condensers.
q A large number of tube passes are used to increase the tube side
fluid v
elocityand heat transfer coefficient and minimiz
e fouling.
§ This can onlybe done when there is enough pumping power since the
increased v elocityand additional turns increases the pressure drop
significantly
.

Tube Passes - Continued
q The number of tube passes depends on the av
ailable pressure drop.
§ Higher velocities in the tube result in higher heat transfer coefficients,
at the expense of increased pressure drop.
q Therefore, if a higher pressure drop is acceptable, it is desirable to
have fewer but longer tubes (reduced flow area and increased flow
length).
§ Long tubes are accommodated in a short shell exchanger bymultiple
tube passes.
q The number of tube passes in a shell generallyrange from 1 to 10
§ The standard design has one, two, or four tube passes.
§ An odd number of passes is uncommon and mayresult in mechanical
and thermal problems in fabrication and operation.

Tube M aterials
q Mater ials selection and compatibilitybetween construction
materials and working fluids are important issues, in particular with
regard to corrosion and/ or operation at elevatedtemper atur es.
q Requirement for low cost, light weight, high conductiv ity
, and good
joining characteristics often leads to the selection of aluminum for
the heat transfer surface.
q On the other side, stainless steel is used for food processing or
fluids that require corrosion resistance.
q In general, one of the selection criteria for exchanger material
depends on the corrosiv eness of the work ing fluid.
q A summaryTable is prov
ided as a reference fo rcorrosiv
e and non-
corrosiv
e env
ironments

M aterials for Corrosive &
Noncorrosive Service

Tube W all Thickness
q The wall thick
ness of heat exchanger tubes is standardiz
ed in terms
of Birmingham Wire Gage BWG of the tube.
q Small tube diameters (8 to 15mm) are preferred for greater area to
volume densitybut are limited for the purposes of cleaning.
q L
arge tube diameters are often required for condensers and boilers.

Tube Outside Diam eter
q The most common plain tube sizes have 15.88,19.05, and 25.40 mm
(5/
8, ¾, 1 inche) tube outside diameters.
q From the heat transfer v iewpoint, smaller-diameter tubes yield
higher heat transfer coefficients and result in a more compact
exchanger.
q Howev er, larger-diameter tubes are easier to clean and more
rugged.
q The foregoing common siz
es represent a compromise.
§ For mechanical cleaning, the smallest practical size is 19.05 mm.
§ For chemical cleaning, smaller sizes can be used provided that the
tubes nev
er plug completely
.

Tube Length
q Tube length affects the cost and operation of heat exchangers.
§ Longer the tube length (for anygiven surface area),
• Fewer tubes are needed, requiring less complicated header plate with fewer
holes drilled
• Shell diameter decreases resulting in lower cost
q Ty picallytubes are employ ed in 8, 12, 15, and 20 foot lengths.
Mechanical cleaning is limited to tubes 20 ft and shorter, although
standard exchangers can be built with tubes up to 40 ft.
q There are, like with any thing limits of how long the tubes can be.
§ Shell-diameter-to-tube-length ratio should be
within limits of 1/
5 to 1/
15
q Maximum tube length is dictated by
§ Architectural layouts
§ Transportation (to about 30m.)
• The diameter of the two booster rockets is dictated bythe smallest highway
tunnel siz
e between the location of manufacturer and Florida. Scientific hah!
Tube Length
Tube & Header Plate Deformation
q Thermal expansion of tubes needs

to be tak
en into account for heat MagnifiedDisplacement ofaShell
exchangers operating at elevated & Tube Heat ExchangerElements
UnderTher mal Load
temperatures
q Tube elongation due to thermal Undef ormed Shell Wall
Shell Wall Deformation
expansion causes:
§ Header plate deformation
§ Shell wall deformation near the
header plate
q Fatigue strength of the tube,
header plate and shell joint needs
to be considered when using
§ Longer tubes
§ High operating tube side
temperatures
Undeformed Header
HeaderPlate
§ Cyclic thermal loads Defor
mation Plate Shape

Tube Layout
RotatedSquar
e
q Tube layout is characteriz
ed bythe Tr
iangular
included angle between tubes.
§ Two standard types of tube layouts
are the squar
e and the equilater
al PT
triangle.
PT
• Triangular pitch (30o lay
out) is better for
heat transfer and surface area per unit
length (greatest tube density .)
• Square pitch (45 & 90 layouts) is needed
for mechanical cleaning.
Squar
e
§ Note that the 30°,45° and 60° are
staggered, and 90° is in line. RotatedTr
iangle
q For the identical tube pitch and

flow rates, the tube layouts in
decreasing order of shell-side heat
transfer coefficient and pressure
Tr
iangular
drop are: 30°,45°,60°, 90°.
Tube Layout- Continued
q The 90° layout will hav e the lowest heat transfer coefficient and
the lowest pressure drop.
q The squar e pitch (90° or 45°) is used when jet or mechanical
cleaning is necessaryon the shell side. In that case, a minimum
cleaning lane of ¼ in. (6.35 mm) is prov ided.
§ The square pitch is generallynot used in the fixed header sheet design
because cleaning is not feasible.
q The tr iangularpitch prov ides a more compact arrangement,
usuallyresulting in smaller shell, and the strongest header sheet for
a specified shell-side flow area.
§ It is preferred when the operating pressure difference between the two
fluids is large.

Tube Pitch
q The selection oftube pitch is a compromise between a
§ Close pitch (small values of Pt/
do) for increased shell-side heat transfer
and surface compactness, and an
§ Open pitch (large values of Pt/do) for decreased shell-side plugging and
ease in shell-side cleaning.
q Tube pitch PT is chosen so that the pitch r
atio is 1.25 <PT/
do <1.5
§ When the tubes are to close to each other (Pt/
do less than 1.25) , the
header plate (tube sheet) becomes to weakfor proper rolling of the
tubes and cause leak yjoints.
q Tube lay
out and tube locations are standardiz
ed for industrial heat
exchangers.
§ However, these are general rules of thumb and can be “violated” for
custom heat exchanger designs.

Tube & Shell ExhaustGas Cooler
Atube andshell exhaust gas cooleris usedon

diesel engines to r
educe the NOxemissions.
Ar ectangularcloselypackedtube ar rangement
is usedresultingin arectangularshell.

Basic Design Procedure
q Heat exchanger must satisfythe
§ Heat transfer requirements (design or
process needs)
§ Allowable pressure drop (pumping
capacityand cost)
q Steps in designing a heat exchanger
can be listed as:
§ Identifythe problem
§ Select an heat exchanger type
§ Calculate/Select initial design
parameters
§ Rate the initial design
• Calculate thermal performance and
pressure drops for shell and tube side
§ Evaluate the design
• Is performance and cost acceptable?

Size ofHeatExchanger
The initial size (
surf
ace ar ea) of a q q
q Ao = =
heat exchanger can be estimated from U o DTm U o FDTlm ,cf
§ where
• Ao Outside tube surface area
• q Heat duty– heat exchange between tube and shell side
• Uo Overall heat transfer coefficient
• F Correction factor F=1.0 for cross flow heat exchanger
• ? Tm True mean temperature à ? Tm = F ? Tlm
• ? Tlm Log mean temperature difference (Est of true mean temperature)
§ Corr
ection FactorFis be covered in module TFD-HE4 L
og-Mean
Temperature Difference

Overall HeatTransfer Coefficient
q The over all heat transf ercoef ficient Uo based on the outside
diameter of tubes can be estimated from:
§ The individual heat transfer coefficients (h)
§ Shell wall, outside & inside tube fouling resistances (Rw, Rfo, Rfi)
§ Overall surface efficiency(? i & ? o)
1 Ao æ 1 R fi ö R fo 1
= çç + ÷÷ + Ao Rw + +
U o Ai è ηi hi η i ø η o η o ho

HeatBalance of
Shell & Tube HeatExchanger
q Heat load of a heat exchanger can be estimated from heat balance:
q = (m& c p )c (Tc ,o - Tc ,i ) = (m& c p )h (Th ,i - Th ,o )

§ If three of the temperatures are given, the fourth can be calculated
using the abov
e equation.
§ The above equation assumes no phase change in anyof the fluids.
Tc,i
Shell
inlet
Tube Tube
inlet outlet
Th,i Shell Th,o

Tc,o outlet
Other TFD M odules Supporting
q Ov
erall heat transfer coefficient is cov
ered in module TFD-HE01
q L
og-mean temperature difference is cov
q Heat transfer from finned surfaces is cov

Total Num ber ofTubes
q Once the total tube outside surface area Ao is estimated a cost
effectiv
e heat exchanger configuration needs to be calculated.
q Numberoftubes Nt is dependent on tube side flow conditions. It
is related to the shell diameter( Ds), tube length ( L) and tube
diameter( do) together with the allowable pressure drop and the
total tube side flow rate hence the heat transfer coefficient.
Ao = πd o N t L

Total Num ber ofTubes
q The total number of tubes can be predicted as a function of the

shell diameter bytak ing the shell circle Ds and div
iding it bythe
projected area of the tube layout pertaining to a single tube A1
πDs2
N t = (CTP) A1 = (CL) PT2
4 A1
q CTP is the tube count constant which accounts for the incomplete
cov erage of the shell diameter bythe tubes due to necessary
clearances between the shell and the outer tube circle.
§ CTP=0.93 One tube pass CL- Tube Layout Constant
§ CTP=0.90 Two tube passes § CL=1.00 for 90 & 45 square pitch
§ CTP=0.85 Three tube passes § CL=0.87 for 30 & 60 equilateral tri pitch

Shell Diam eter
q Shell diameter in terms of main constructional diameters can be
expressed as:
2
æ CTP ö Ds
N t = 0.785ç ÷ 2
è CL ø æ PT ö 2 1
CL é Ao (PT d o ) d o ù
2 2
çç ÷÷ d o
è do ø Ds = 0.637 ê ú
CTP ë L û
Ao = πd o N t L

Rating ofthe HeatExchanger Design
q Ratingan exchangermeans to ev aluate the thermo-hy
draulic
performance of a f
ullyspecif
iedexchanger.
q Input to the rating process is heat exchanger geometr y(constructional
design parameters), pr ocess conditions (flow rate, temperature,
pressure) and mater ial/fluidpr oper ties (density
, thermal conductiv
ity)
q Fir st output from the rating process is either the outlet temperature for
fixed tube length or the tube length itself to meet the outlet temperature
requirement.
q Secondoutput from the rating process is the pressure drop for both fluid
streams hence the pumping energyrequirements and siz e.

InsufficientTherm al Rating
q If the output of the rating analy
sis is not acceptable, a geometrical
modification should be made
q If the required amount of heat cannot be transferred to satisfy
specific outlet temperature, one should find a wayto increase the
heat transfer coefficient or increase exchanger surface area
§ One can increase the tube side heat transfer coefficient byincreasing
the fluid v
elocity- Increase number of tube passes
§ One can increase the shell side heat transfer coefficient bydecreasing
baffle spacing and/
or baffle cut
§ One can increase the surface area by
• Increasing the heat exchanger length
• Increasing the shell diameter
• Multiple shells in series

InsufficientPressure Drop Rating
q If the pressure drop on the tube side is greater than the allowable
pressure drop, then
§ the number of tube passes can be decreased or
§ the tube diameter can be increased which mayresult to
• decrease the tube length – (Same surface area)
• increase the shell diameter and the number of tubes
q If the shell side pressure drop is greater than the allowable pressure
drop then baffle spacing, tube pitch, and baffle cut can be increased
or one can change the baffle ty pe.
THEREIS ALWAYS ATRADE-OFFBETWEEN

THERMAL& PRESSUREDROP RATINGS!

The Trade-Off
Between Thermal Balance & Flow Loss
q Heat transfer and fluid friction losses tend to compete with one
another.
q The total energyloss can be minimiz
ed byadjusting the siz
e of one
irrev
ersibilityagainst the other .
q These adjustments can be made byproperlyselecting phy sical
dimensions of the solid parts (fins, ducts, heat exchanger surface).
q It must be understood, howev
er, that the result is at best a
thermody namic optimum.
§ Constraints such as cost, size, and reliabilityenter into the
determination of trulyoptimal designs.

Shell Side HeatTransfer Coefficient
q There are three r atingmethods to calculate the shell side heat
transfer coefficient:
§ Kern methodis a simplified approach suitable for shell side flow without
baffles
§ Taborekmethod
§ Bell Delaware method is the most complex but accurate wayof rating a
heat exchanger with baffles

SHELL SIDE
HEAT TRANSFER COEFFICIENT
W ITH BAFFLES

Shell Side HeatTransfer
Baffled Flow
q When the tube bundle employs baf fles, the heat transfer
coefficient is higher than the coefficient for undisturbed flow
around tubes without baffles.
q For a baffled heat exchanger
§ the higher heat transfer coefficients result from the increased
tur
bulence.
§ the velocityoff
luidf
luctuates because of the constricted area
between adjacent tubes across the bundle.
q Onlypar t ofthe f luidtakes the desir edpath through the tube
bundle (Stream B), whereas a potentiallysubstantial portion flows
through the ‘leak
age’ areas (Streams A, C, E & F)
§ However, these clearances are inherent to the manufacturing and
assemblyprocess of shell-and-tube exchangers, and the flow
distribution within the exchanger must be tak
en into account.
M ain & Leakage Flow Stream s
Baffled Heat Exchanger
q There are fiv

e different shell side flow streams in a baffled heat
exchanger
§ Stream Ais the leakage stream in the
orifice formed bythe clearance
between the baffle tube hole and the
tube wall.
§ Stream Bis the main effective cross-
flow stream, which can be related to
flow across ideal tube bank
s.
§ Stream Cis the tube bundle bypass stream in the gap between the tube
bundle and shell wall.
§ Stream Eis the leakage stream between the baffle edge and shell wall.
§ Stream Fis the bypass stream in flow channel partitions due to omissions
of tubes in tube pass partitions.

M ain & Leakage Flow Stream s
Baffled Heat Exchanger
Pass 2 Pass 1
Str
eam A
Str
eam C
Str
eam E
Str
eam F
Str
eam Fhappens in a
multiple pass (1-2, 1-4)
heat exchanger

Bell Delaware M ethod
Heat Transfer Coefficient & Correction Factors
q In the Delaware method, the fluid flow in the shell is div

ided into a
number of individual streams A through F as defined before.
q Each of the abov e streams introduces a correction factor to the
heat transfer correlation for ideal cross-flow across a bankof tubes.
2 0.14
æ m& s öæ k s ö æ µ s ö
3
ho = hideal J c J l J b J s J r hideal = ji c ps çç ÷÷ç ÷ ç
ç
÷
÷
ç ÷
è As øè c ps µ s ø è µ s ,w ø
§ hideal heat transfer coefficient for pure § ji Colburn j-factor
cross-flow in an ideal tube bank § As Cross flow area at the centerline
§ Jc for baffle cut and spacing of shell for one cross flow
§ Jl for leakage effects between two baffles
§ Jb bundle by
pass flow C& F streams § s Stands for shell
§ Js for variable baffle spacing in the § w Wall temperature
inlet and outlet sections
§ Jr for adverse temperature gradient
build-up
The combinedef fects ofall these cor
rection f
actor
sforareasonable
well-designedshell-and-tube heat exchangeris ofthe orderof0.60
Jc Correction Factor
q Jc is the correction factor for baffle cut and spacing. This factor
tak es into account the heat transfer in the window and calculates
the ov erall av
erage heat transfer coefficient for the entire heat
exchanger.
q It depends on the shell diameter and the baffle cut distance from
the baffle tip to the shell inside diameter.
§ For a large baffle cut, this value maydecrease to a value of 0.53
§ it is equal to 1.0 for a heat exchanger with no tubes in the window
§ It mayincrease to a value as high as 1.15 for small windows with a
high window v
elocity
.

Jl Correction Factor
q Jl is the correlation factor for baffle leak
age effects including tube-
to-baffle and shell-to-baffle leak age (A- and E-streams).
q If the baffles are put too close together, then the fraction of the
flow in the leak age streams increases compared with the cross flow.
q JI is a function of the
§ ratio of total leakage area per baffle to the cross flow area between
adjacent baffles
§ ratio of the shell-to-baffle leakage area to the tube-to-baffle leakage
area.
q A ty
pical v
alue of Jl is in the range of 0.7 and 0.8.

Jb Correction Factor
q Jb is the correction factor for bundle by
passing effects due to the
clearance between the outermost tubes and the shell and pass
div iders (C- and F-streams).
§ For relativelysmall clearance between the outermost tubes and the shell
for fixed tube sheet construction, Jb = 0.90.
§ For a pull-through floating head, larger clearance is required, Jb =0.7.
§ The sealing strips (see figure8.14) can increase the value of Jb
Str
eam F
Pa Pa
ss ss
2 1

Js & Jr Correction Factors
q Js is the correction factor for v ariable baffle spacing at the inlet and
outlet. Because of the noz zle spacing at the inlet and outlet and the
changes in local v elocities, the av erage heat transfer coefficient on
the shell side will change.
q The Js v
alue will usuallybe between 0.85 and 1.00.
q Jr applies if the shell-side Rey
nolds number, Res, is less than 100.
§ If Res <20, it is fullyeffective.
§ This factor is equal to 1.00 if Res>100.
The combinedef fect of

all these corr
ection factor
s
f
orawell-designedshell-and-tube heat exchanger
is ofthe orderof0. 60

Heat Transfer Coefficient - Colburn j-factor
q Colburn-j factor is used in heat transfer in general and free and
forced conv ection calculations in particular.
§ It is equivalent to (St.Pr2/3) where St is Stanton number
where Stanton Number is defined as
h h h § G is the mass velocity

St = = =
Gc p (ρVmax)c p m&
cp
§ Amin is the min free flow x-sec
Amin area regardless where it occurs
q Colburn j-factor is a function of:

§ Shell side Reynolds numberbased on the
d o m& s
outside tube diameter and on the minimum cross Res =
section flow area at the shell diameter
µ s As
§ Tube layout
§ Pitch size
Numerical Formsof Colburn (j)& Friction (f)Factors
q Although the ideal v

alues of j and f are av ailable in graphical forms,
for computer analy sis, a set of curv
e-fit correlations are obtained in
the following forms:
Colbur
nj-f
actor
a
æ 1.33 ö
ji = a1 çç ÷÷ (Res )a2
è PT d o ø
a3
a=
1 + 0.14(Res ) 4
a
Fr
iction f
actor
b
æ 1.33 ö
f = b1 çç ÷÷ (Res )b2
è PT d o ø
b3
b=
1 + 0.14(Res ) 4
b

SHELL SIDE
HEAT TRANSFER COEFFICIENT
W ITHOUT BAFFLES
SHEL
L-and-TUBE HEAT EXCHANGER

Shell Side HeatTransfer Coefficient
W ithout Baffles– Flow Alongthe Tube Axis
q The heat transfer coefficient outside the tube bundle is referred to

as the shell-side heat transfer coefficient.
q If there are no baffles, the flow will be along the heat exchanger
inside the shell. Then, the heat transfer coefficient can be based on
the equiv alent diameter, De (Same as a double-pipe heat exchanger)
0.14
ho De éµ ù
= 0.36 Re0.55 Pr1/ 3 ê b ú q De Equiv
alent shell diameter
k ë µw û q Gs Shell side mass velocity
0.55 1/ 3 0.14 q b Bulkfluid temperature
ho De éD G ù é c p µ ù é µb ù
= 0.36ê e s ú ê ú ê ú
q w Wall temperature
k ë µ û ë k û ë µw û
DeGs
2 ´103 < Res = < 106
µ

EquivalentShell Diam eter - De
q The equiv alent diameter of the shell is
taken as four times the net flow area as 4´ freefl
ow area
De =
lay
out on the tube sheet (for mypitch wet t
edperimeter
lay
out) div ided bythe wetted perimeter:
RectangularPitch
4( PT2 - πd o2 / 4)
De =
πd o
Tr
iangularPitch
4( PT2 3 - πd o2 / 8)
De =
πd o / 2

Shell Side M ass Velocity - Gs
q There is no free-flow area on the shell side bywhich the shell-side
mass v elocity, Gs, can be calculated.
q For this reason, fictional v
alues of Gs can be defined based on the
bundle cross flow area at the hy pothetical tube row possessing the
maximum flow area corresponding to the center of the shell.
q Variables that affect the velocityare:
§ Shell diameter (Ds) Clearance between adjacent tubes (
C);
Pitch siz
e(PT) Baffle spacing (
B)
q The width of the flow area at the tubes located at center of the shell
is (Ds/
PT) Cand the length of the flow area is tak en as the baffle
spacing, B.
Ds CB
§ Therefore, the bundle cross flow area As, As =
PT
at the center of the shell is
m&
q Shell side mass v
elocityis Gs =
As
Shell Side Pressure Drop
q The shell-side pressure drop depends on the number of tubes the
fluid passes through in the tube bundle between the baffles as well
as the length of each crossing.
§ If the length of a bundle is divided byfour baffles, for example, all the
fluid trav
els across the bundle fiv
e times.
q A correlation has been obtained using
ìæ L ö ü
the product of distance across the fGs2 íç - 1÷ + 1ý Ds
bundle, tak en as the inside diameter
Dp s = îè B ø þ
2 ρDe (µb µ w )
0.14
of the shell, Ds and the number of
times the bundle is crossed.
§ Lis the heat exchanger length, Bis the
baffle spacing
q Shell side f riction coef
ficient f
f = exp{0.576 - 0.19l
n(Res )}
includes the entrance and exit losses
TUBE SIDE
HEAT TRANSFER COEFFICENT
&
FRICTION FACTOR
SHEL
L-and-TUBE HEAT EXCHAGER

Tube Side HeatTransfer Correlations
q Extensive exper imental andtheor etical effor ts have been made to
obtain the solutions for turbulent forced conv ection heat transfer and flow
friction problems in ducts because of their frequent occurrence and
application in heat transfer engineering.
q There are a large numberofcor relations available in the literature for
the fullydev eloped (hy
dro-dy namicallyand thermally ) turbulent flow of
single-phase Newtonian fluids in smooth, straight, circular ducts with
constant and temperature-dependent phy sical properties.
q The objective of this section is to highlight some ofthe existing
correlations to be used in the design of heat exchange equipment and to
emphasize the conditions orlimitations imposed on the applicabilityof
these correlations.
q Extensive efforts hav e been made to obtain empirical correlations that
represent a best-fit curve to experimental data or to adjust coefficients in
the theoretical equations to best fit the experimental data.

Flow M aldistribution& Header Design
q One of the common assumptions in basic heat exchanger design

theoryis that fluid be distributed uniformlyat the inlet of the
exchanger on each fluid side and throughout the core.
§ However, in practice, flow maldistribution is more common and can
significantlyreduce the desired heat exchanger performance.
q Flow maldistribution can be induced byheat exchanger
§ Geometry- mechanical design features such as the basic geometry,
manufacturing imperfections, and tolerances
§ Operating conditions - viscosityor densityinduced mal distribution,
multi phase flow, and fouling phenomena

Tube-to-Tube Velocity Variation
q In most cases, geometric flow Flow velocitydistribution over the header
plate before tube entrance for a
entry& exit conditions to the
rectangular x-sec heat exchanger
headers promote a tube-2-tube
velocityvariation
X-sectional areaofthe inlet

pipe to the headerplate may
be smallercompar edto the
headerplate area
Header Plate
q Nusselt correlations pr
esented
90degr ee flow tur n creates in this module assume an
non-unif orm velocity
distribution inside the tubes
equallydistributedf low
between tubes
TFD-HE13 - Shell & Tube Heat Exchager Design
§ Same velocityin each tube!
58
Tube Side HeatTransfer Coefficient
q Petukhov& Popov’s theoretical calculations for the case of fully
developed turbulent flow with constant properties in a circular tube
with constant heat flux boundaryconditions fielded a correlation,
which was based on the three-lay er turbulent boundarylay er model
with constants adjusted to match the experimental data.
§ Petukhovalso gave a simplified form of this correlation as
Nub =
( f / 2 ) Reb Prb
1.07 + 12.7( f / 2) (Pr2 3 - 1)
0.5
f = (1.58 l
nReb - 3.28 )
-2
Where the friction factor f is defined as:
q This equation predicts results in the range of

§ 104 <Re <5x106 & 0.5 <Pr <200 with 6% error
§ 104 <Re <5x106 & 0.5 <Pr <2000 with 10% error

Tube Side Pressure Drop
q The tube-side pr
essur
e dr
opcan be calculated byk
nowing the
§ Number of tube passes, Np
§ Length of the heat exchanger, L
§ Mean fluid velocityinside the tube, um
2
LN p LN p Gtube
Dpt = 4 f ´ 1 ρu 2
Dpt = 4 f ´
di 2 m
di 2ρ
q The change of direction in the passes introduces

an additional pressure drop, ? Pr due to sudden
expansions and contractions that the tube fluid Dpr = 4 N r ´ 1 ρum2
2
experiences during a return
§ This is accounted with four velocityheads per pass
é LN p ù
q Total pressure drop than becomes Dptotal = ê4 f + 4 N p ú ´ 1 ρum2
di 2
ë û
Roadm ap To Increase HeatTransfer
q Increase heat transfer coefficent
§ Tube Side
• Increase number of tubes
• Decrease tube outside diameter
§ Shell Side
• Decrease the baffle spacing
• Decrease baffle cut
q Increase surface area

§ Increase tube length
§ Increase shell diameter à increased number of tubes
§ Employmultiple shells in series or parallel
q Increase L
MTD correction factor and heat exchanger effectiv
eness
§ Use counterflow configuration
§ Use multiple shell configuration
Roadm ap To Reduce Pressure Drop
q Tube side
§ Decrease number of tube passes
§ Increase tube diameter
§ Decrease tube length and increase shell diameter and number of tubes
q Shell side
§ Increase the baffle cut
§ Increase the baffle spacing
§ Increase tube pitch
§ Use double or triple segmental baffles

References
q Fundamentals of Heat Exchanger Design
Ramesh K. Shah & Dusan Sek ulic
John Wiley& Sons, 2003
q Compact Heat Exchangers, 3rd Edition
W.M. Kays & A.L
.L ondon
q Heat Exchangers, Selection Rating & Design
SadikKak ac & Hongtan L iu
CRCPress, 2nd Edition, 2002
q Shell & Tube Heat Exchanger Design Software for Educational
Applications. Int. J. Engng. Ed. Vol. 14, No. 3, p 217-224, 1998
K.C. Leong, K.C. Toh, Y.C. L eong
q Wolv
erine Tube Heat Transfer Data Book
www.wolv erine.com

APPENDIX

Dim ensional DataFor Com m ercial Tubing

Dim ensional DataFor Com m ercial Tubing

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SHELL & TUBE

HEAT EXCHANGER DESIGN

TFD-HE13 - Shell & Tube Heat Exchager Design 1

TFD-HE13 - Shell & Tube Heat Exchager Design 2

TFD-HE13 - Shell & Tube Heat Exchager Design 3

U-Tube, baf fled, single pass

Two pass tube, baff

Two pass tube, f loatinghead, baf f

TFD-HE13 - Shell & Tube Heat Exchager Design 4

TFD-HE13 - Shell & Tube Heat Exchager Design 5

TFD-HE13 - Shell & Tube Heat Exchager Design 6

q The number of tubes that can be placed

TFD-HE13 - Shell & Tube Heat Exchager Design 7

TFD-HE13 - Shell & Tube Heat Exchager Design 8

TFD-HE13 - Shell & Tube Heat Exchager Design 9

TFD-HE13 - Shell & Tube Heat Exchager Design 10

q In an orifice baffle shell-side-fluid flows through the clearance

TFD-HE13 - Shell & Tube Heat Exchager Design 11

TFD-HE13 - Shell & Tube Heat Exchager Design 12

TFD-HE13 - Shell & Tube Heat Exchager Design 13

TFD-HE13 - Shell & Tube Heat Exchager Design 14

TFD-HE13 - Shell & Tube Heat Exchager Design 15

TFD-HE13 - Shell & Tube Heat Exchager Design 16

TFD-HE13 - Shell & Tube Heat Exchager Design 17

TFD-HE13 - Shell & Tube Heat Exchager Design 18

q Thermal expansion of tubes needs

TFD-HE13 - Shell & Tube Heat Exchager Design 20

q For the identical tube pitch and

TFD-HE13 - Shell & Tube Heat Exchager Design 22

TFD-HE13 - Shell & Tube Heat Exchager Design 23

Atube andshell exhaust gas cooleris usedon

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TFD-HE13 - Shell & Tube Heat Exchager Design 27

TFD-HE13 - Shell & Tube Heat Exchager Design 28

q = (m& c p )c (Tc ,o - Tc ,i ) = (m& c p )h (Th ,i - Th ,o )

Th,i Shell Th,o

TFD-HE13 - Shell & Tube Heat Exchager Design 30

TFD-HE13 - Shell & Tube Heat Exchager Design 31

q The total number of tubes can be predicted as a function of the

TFD-HE13 - Shell & Tube Heat Exchager Design 32

TFD-HE13 - Shell & Tube Heat Exchager Design 33

TFD-HE13 - Shell & Tube Heat Exchager Design 34

TFD-HE13 - Shell & Tube Heat Exchager Design 35

THEREIS ALWAYS ATRADE-OFFBETWEEN

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q There are fiv

TFD-HE13 - Shell & Tube Heat Exchager Design 41

TFD-HE13 - Shell & Tube Heat Exchager Design 42

q In the Delaware method, the fluid flow in the shell is div

TFD-HE13 - Shell & Tube Heat Exchager Design 44

TFD-HE13 - Shell & Tube Heat Exchager Design 45

TFD-HE13 - Shell & Tube Heat Exchager Design 46

The combinedef fect of

TFD-HE13 - Shell & Tube Heat Exchager Design 47

h h h § G is the mass velocity

q Colburn j-factor is a function of:

q Although the ideal v

TFD-HE13 - Shell & Tube Heat Exchager Design 49

TFD-HE13 - Shell & Tube Heat Exchager Design 50