Heat Exchanger Design

Instructor: Dr. Chandra Mouli M.R.

Chemical Engineering Department

 Agenda
• Shell and tube heat exchangers-general design
aspects
• Shell and tube heat exchangers-detail design

2
 Shell & tube heat exchanger main elements

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http://www.gc3.com/techdb/images/cool1112.gif
Tubular Exchanger Manufacturers Association (TEMA)
Types

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 Connection type-operation
Fixed tube-sheet
– For clean service on shellside
Floating head
– For dirt service on both tubeside and shellside
U-tube construction
– For clean service on tubeside

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 STHE Tube arrangement
T and RT
• Accommodate more tubes
• Mechanical cleaning restrictions
• T more turbulence than RT
S and RS:
• Can be used for clean service
• RS more turbulence than R

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R. Mukherjee, Chem. Eng. Prog., Feb. 1998.
STHE baffles
Baffles are designed to:
– Provide support for tubes
– Flow redirection (maintain velocity in shell)
– Avoid tube vibration

Baffle types
– Rod
– Plate (single, double and triple segmental)

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 Rod type baffles

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R. Mukherjee, Chem. Eng. Prog., Feb. 1998.
R. Mukherjee, Chem. Eng. Prog., Feb. 1998.
Plate baffles

baffle cut

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R. Mukherjee, Chem. Eng. Prog., Feb. 1998.
Effect of baffle-cut

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 Flow streams/leakage in shell

A: Tube-to-baffle leakage
B: The actual cross flow stream
C: Bundle-to-shell bypass (main bypass)
E: Baffle-to-shell leakage
F: Pass partition stream 12
 Pass partition plate

http://www.calgavin.com/wp-content/uploads/2014/06/fig-1-cropscale521.png 13
Fluid designation
Which fluid (cold or hot) should be allocated to
shell and tube?

These variables contribute to designation:

• Heat transfer efficiency
• Cost
• Safety
• Operation/cleaning

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Fluid flow designation side-single
phase
Corrosion : the more corrosive fluid in tube side:
– Reduces the cost of expensive alloy and coatings

Fouling : the fluid with greatest tendency to foul

in tube side, because:
– Better control over design fluid velocity
– Higher velocity in tubes will reduce fouling
– Tubes easier to be cleaned

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Fluid flow designation side-single
phase
Viscosity : the more viscous fluid should be
allocated in:
– The shell side, if turbulent can be achieved (Re > 200)
– The tube side, if turbulent can not be achieved in the
shell side

Stream Flow Rates : the fluid with the lowest flow

rate should be allocated in the shell side:
– Cheaper design

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Fluid flow designation side-single
phase
Operating Pressure : higher pressure stream in
the tube side:
– High pressure tubes cheaper than high pressure
shells

Pressure Drop : fluid with the lowest allowable

pressure drop allocated in the tube side:
– For the same pressure drop, higher h is obtained in
the tube side

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Fluid flow designation side-single
phase
Fluid Temperatures : higher temperature fluid
in the tubes, because:
– Reduce the cost if special coating is required
– Reduce the heat loss from the shell
– Safety reasons

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Shell and tube velocity
perspectives
At higher velocities:  Higher h
 Lower solid settling
 Less fouling

 Higher ∆P
 More erosion

Therefore, design velocity is recommended to

optimize the operation
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 STHE−Tube arrangement
Arrangement: T, R T, S, RS
Pitch: Pt= 1.25 Do
– Pt = distance between tube centers
• For S, recommended minimum Pt – Do = 6.4 mm
Tube passes: 1, 2, 4, 6, 8,..
• Number of passes is selected to give the required
velocity inside the tubes

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 STHE−Tube sizing
Diameter:
– 16 − 50 (mm) are used
– 16 − 25 (mm) are preferred (Cheaper Exchangers)
– Larger tubes are easily to clean  heavily fouling fluids
– 19 (mm) is a good trial value to start calculation.

Thickness:
– Selected to withstand pressure drop and corrosion
– Diameters and wall thickness can be found in standard tables
– For steel tubes diameter and thickness refer to Table 12.3

Length:
– Preferred: 6, 8, 12, 16, 20, and 24 (ft).
– For same area: longer tubes  lower shell diameter
– Optimum tube length to shell diameter is from 5 to 10

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Shell and tube velocity perspective
a. Liquids
– Tube side:
• 1 – 2 (m/sec)
• Max: 4 (m/sec) to prevent fouling
– Shell Side:
• 0.3 – 1 (m/sec)
b. Va p o rs (Pressure dependent)
– Vacuum: 50 – 70 (m/sec)
– Atmospheric Pressure: 10 – 30
– High Pressure: 5 – 10
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Shell & tube pressure drop
perspective
• Liquids:
– Viscosity < 1 (mN s/m2): ΔP=35 (kN/m2)
– Viscosity 1 – 10 : 50 – 70

• Gas and Vapor:

– High Vacuum: ΔP= 0.4 – 0.8 (kN/m2)
– Medium Vacuum: 0.1 × Pabs
– 1 – 2 bar: 0.5 × Pgauge
– >10 bar : 0.1 × Pgauge
High ΔP erosion and tube vibration
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STHE−Shell design
Diameter:
• 150 −1520 (mm)
• 150 − 610 (mm)  constructed from standard pipes
• >610 (mm)  Constructed from rolling a plate
Thickness:
• Minimum shell thickness  page 646
Clearance:
• The clearance between the shell and the tube bundle
is given in Figure 12.10

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 STHE−Tube bundle design
Bundle diameter:

Nt = number of tubes
Db = bundle diameter, mm
do = tube outside diameter, mm
K1 and n 1: from Table 12.4

Pic: http://www.titanmf.com/wp-content/uploads/2014/03/Alloy-625-Shell-and-Tube-
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Heat-Exchanger-002.jpg
 Clearance

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Fig 12.10 CHE6, §12

STHE−Segmental baffle design
Diameter and tolerance:
– From Table 12.5
Spacing:
– 0.2 to 1.0 of Shell diameter
– Recommended 0.3 to 0.5 shell diameter
Cut:
– 15 to 45% of shell inside diameter
– Recommended: 20 to 35%

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Heat transfer coefficient −general

Q=UAΔTm

Otherwise obtain Ft
from graphs
Design: determine the surface area for heat transfer to
get a duty of Q based on available temperature
difference. 28
Overall heat transfer coefficient in STHE

Uo overall HTC based on do

hi tube inside fluid HTC
ho outside fluid HTC (shell)
hid,h od HTC for dirt for tube/shell
kw thermal conductivity of tube wall
di , do tube inside/outside dia
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General procedure for STHE design
1. Define the duty:
– Define the fluid flows or calculate them
– Define the temperatures
– Calculate heat load (W)
2. Collect the required physical properties.
3. Decide the heat exchanger type to be used.
4. Select a trial value for the overall coefficient, Ue :
– Table 12.1
– Figure 12.1
5. Calculate LMTD.
6. Calculate required area, Ae

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General procedure for STHE design
7. Decide the exchanger layout
8. Calculate the individual heat transfer coefficients
9. Calculate the actual overall heat transfer coefficient,
Uactual. Compare with Ue
– If Uactual ≠ Ue  go to step 6 and repeat using Uactual as
Ue
– If Uactual ≈ Ue  Continue
10. Calculate the pressure drop in the hot and cold sides.
If outside the allowable limit repeat steps 7, 4, or 3 in
that order of preference.
11. Optimise the design:
– Cheapest exchanger – smallest area

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Tube side ΔP and h
hi :
– § 8 Chem. Eng. Vol. 6,
– Also correlations in page 662 – 664 , or
– Figure 12.23 with :

∆Pt :
– Use ΔP as developed in Chapter 8, or
– Use Figure 12.24 with :

Laminar: m=0.25
Turbulent: m=0.14
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Heat transfer factor (tube-side)

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Friction factor (tube-side)

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Calculations of ΔP an h (shell-side)
• Calculations using Kern method for the shell side are
similar to those for tube side. But hypothetical shell
velocity/diameter are used.
• Cross section area for flow changes across the shell.
Linear velocity and mass velocities are calculated
based on maximum area for cross flow: @ shell
equator.
• Shell equivalent dia. base on: tube pitch, tube
diameter, shell dia and baffle spacing (hydrodynamic
dia for flow parallel to tubes).
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Area (x-flow): hypothetical row at
equator

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Kern method: Shell side ΔPs and hs
• Calculate area for cross flow, As  Eq. 12.21
• Calculate
– the shell side mass velocity, Gs = mass flow rate / As
– The shell side linear velocity, us = Gs / density
• Calculate the equivalent diameter, de
– Eq. 12.22 for Square patterns
– Eq. 12.23 for Triangle patterns
• Calculate shell side Re  Eq. 12.24
• Calculate h s  Eq. 12.25 & Fig. 12.29
• Calculate ∆P s  Eq. 12.26 & Fig. 12.30
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Design Procedure for STHE
Problem
Solution