Design heat exchanger shell and tube

THERMO HYDRAULIC DESIGN PROCEDURE SHELL AND TUBE HEAT EXCHANGER

Thermo hydraulic design steps for shell and tube heat exchanger are,

 Calculation of heat duty(Q).

 Calculation of log mean temperature difference.(LMTD)

 Finding out correction factor for LMTD

 Correction of LMTD

 Assuming overall coefficient(U)

 Area calculation

 Calculation of number of tubes

 Corrected area.
 Design heat exchanger shell and tube

 Shell side calculation

 Selection of shell inside diameter

 Baffle spacing
 Pitch calculation
 Tube clearance
 Shell area
 Mass velocity
 Equivalent diameter
 Reynold’s number across shell side
 Factor for heat transfer calculation
 Prandtl’s number
 Individual heat transfer coefficient

 Tube side calculation

 Flow area per tube

 Number of tubes calculation
 Tube area calculation
 Mass velocity calculation
 Reynold’s number across tube side
 Velocity calculation
 Prandtl’s number
 Calculation of factor for heat transfer coefficient
 Calculation of individual heat transfer coefficient

 Calculation of overall clean coefficient

 Dirt factor

 Pressure drop calculations

 Pressure drop across shell side

 Pressure drop across tube side
STEP 1:-for design
We desired to design the heat exchanger (shell and tube )in the power plant nuclear .)) Note
that the available area (110 m2 ) And not to be less area of heat exhanger (90 m2 ) for
cool the process stream from (693 k) to (493 k) by the use of cooling water its has inlet temp
(298k ),outlet temp (473 k) .
 Design heat exchanger shell and tube

To complete the specification, the duty (heat transfer rate Q ) needed to be calculated. The mean
temp of process stream and water :
Tm of water =298+473/2= 385 k
Tm of steam = 493+693 /2= 593 k
Now: - For process stream duty or heat transfer rate if the mass flow rate has m=114528kg/s
q = m Cp  T
q = (114528) x 521 x (693 – 493)
q= 1.193 x1010 J

STEP 2:-
Physical Properties Of Process stream
INLET MEAN OUTLET UNITS

Temperature 693 593 493 K

Specific heat (Cp) 521 KJ/Kg K

Thermal
0.044 W/mK
conductivity (k)

Density () 800 Kg/m3

Viscosity () 6.31x10-4 kgm-1s-1

 Design heat exchanger shell and tube
For Water:-

INLET MEAN OUTLET UNITS

Temperature 298 385 473 K

Specific heat (Cp) 490 KJ/Kg K

Thermal
0.6912 W/mK
conductivity (k)

Density () 445 Kg/m3

Viscosity () 1.028x10-3 kgm-1s-1

Step 3:-
For system of water, the value of overall heat transfer (U L )lies in the range of 375-
750W/m2 K, so assume.
UL=650 W/m2 K

Step 4:-
Usually an even number of tube passes the preferred arrangement.
For 1 shell and 2 tube passes

LMTD

 T1=(Thi –Tco )=(693-473)=220 k

 T2= (Tho–Tci)=(493-298)=195k
LMTD = [  T1–  T2]/ln[(  T1)/(  T2)]
(  Tm) LMTD = [(220) – (195)]/ln[(220)/(195)]
=207.2 K
Q = UL Ao  Tm
Ao = Q / Uo  Tm
Ao = 1.193 x1010 J / (650 x 207.2)
Ao = 88.5m2
 Design heat exchanger shell and tube

Finding out correction factor for LMTD

R,S&F

R=( Thi –Tco)/( Tco –Tci)

=(693-493)/(473-298)
=1.1428
S=( Tco–Tci)/( Thi –Tho)
=(473-298)/(693-493)
=0.44

From Fig 3 to find correction factor Temp correction factor

Ft= 0.91
 Design heat exchanger shell and tube

Corrected LMTD
Corrected LMTD= =Ft * LMTD(  Tm)
= 0.91 * 207.2
=188.52K

Step 5:-
Heat Transfer Area:
Q = UL Ao  Tm
Ao = Q / Uo  Tm
Ao = 1.193 x1010 J / (650 x 188.52)
Ao = 97m2
SELECTION OF HEAT EXCHANGER
 A < 2m2 (21.5 ft2) select a coiled heat exchanger
 2 m2 < A < 50 m2 (538 ft2) select a double-pipe heat exchanger
 A > 50 m2 select a shell-and-tube heat exchanger. ( ref. Chemical process engineering
design & Economics By Harry Silla)
 As area >50m2, shell and tube heat exchanger with 1-2 shell . Tube pass to get low
pressure drop is selected.

SELECTION Floating head type Heat Exchanger

 The floating head type exchanger is more robust exchanger capable of handling both high
temperature & high pressure.
 It’s one end of tube bundle is not attached to shell & thus can move within shell to take care
of stresses from thermal expansion.
 Since its fabrication is complex so it is approx 25% more expensive than fixed tube type for
same surface area.
 The fluid is not corrosive, so plain carbon steel can be used for the shell and tubes.

Fig(3)
 Design heat exchanger shell and tube
Tubes design :
ODt = 3/4 in from TEMA std (AES) type (Tubular Exchangers Manufacturers Association)

Corresponding to BWG= 14
Tube IDt = 14.83x10-3m
Tube OD= 19.05x10-3m
Tube thickness= 0.002m
Length of tube=5m
Pitch
For design triangular pitch 1.25 in. is selected because it permits the use of more tubes & hence
results in more surface area in a given shell diameter.
(1.25xdo) triangular pitch=1.25x19.05x10-3m =23.81x10-3

Tube Side Heat Transfer Coefficient

Step 6:-
At = (area of one tube) =  do L

= 3.14 x 19.05x10-3 x 5

= 0.299m2

No. of tubes = provisional area /area of 1 tube

# of tubes = 97/ 0.299 = 324
Tubes/pass = 324/2= 162
Step 7:-

Tube cross sectional area =  / 4 (di2)

= /4 x (14.83x10-3)2
=(1.72x10x-4 )m2
Tubes per pass =324/2 =162
Total flow area = 1.72x10-4 *162=0.027 m2
 Design heat exchanger shell and tube

Mass velocity:
Gt = mass flow rate for steam /total flow area
=(114528/3600)/0.027=1178.27 kg/sec .m2

Linear velocity :
Ut = Gt /ρ
= 1178.27 /800
Ut = 1.47 m/sec (< 4 m/sec acceptable)