School of Chemical Engineering and Technology

Chemical Engineering Design one (1)

Shall and Tube Heat Exchanger Design Report

Student Name : Pewee Datoo Kolubah

Department : Chemical Engineering and Technology
Major : Chemical Engineering
Grade : 2016
Email : pewee2g6@yahoo.com
Date : June 30, 2019
 DESIGN OF SHELL AND TUBE HEAT EXCHANGER

Table of Contents

General
Introduction………………………………………………………………………..….…1
Table and Figure Index…………………………………………………………….….…2

1.0 Design Outline

Design Topic…………………………………………………………….……….3
Design Task………………………………………………………………..……..3
1.1Brief Introduction of Heat Exchanger Design
Fixed tube-sheet exchanger (non-removable tube bundle)……………..........4
Removable tube bundle………………………………………….....……...…4
2.0 Design of Main Equipment……………………………………………………...……8
Tube……………………………………………..….………………………..…….9
Tube pitch, tube-layout and tube-count……………………………………….….10
Tube Passes…………………………………………………….……..……….....10
Tube sheet……………………………………………………………….……….10
Baffles…………………………………..…….……………………………...…..11
Fouling Consideration…………………………………………..……....……..…12
2.1 Design Conditions…………………………………………………........................…13
2.2 Determination of flow path……………………………………………………....…..13
2.21: Type of flow pattern for this design………………………………….………....….13
2.3 Determination of Heat Load (Q)…………………………………………………......14
2.4 Determination of inlet and outlet temperature of the fluids …………………….…...14
2.5 Determination of the characteristics temperature………………………………….....14
2.6 Determination of the physical properties of the hot fluid (Oil) and cold
fluid (water)……………………………………………………………………...…...14
2.7 Determination the mode of Heat Exchanger……………………………………….....15
2.8 Determination of Mean Temperature Difference ……………………...................…..15
2.9 Determination of Selection for overall heat transfer coefficient
(K0) and 𝑆𝑜 ……………………………………………………………………….......16
2.10 Determination of basic size and arrangement mode according to
the serial standard…………………………………………………………..….....….16
Determination of Parameters …………………………………………………....…..17
Main Attachment ………………………………………………………………..…..18
Number of the Baffles……………………………....…………………..............…....19
Selection of Material …………………………………………………………….......19
3. 0 Checking the Design……………………………………….…………….….........….19
3.1 Check overall heat transfer coefficient ……………………………...………..……....19

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 DESIGN OF SHELL AND TUBE HEAT EXCHANGER
3.2 Checking the pressure drop for shell side and tube side…………...……………….....19
4.0 Design result list………………………………………………………........……......…20
5.0 Review of Design…………………………………………………...………………….23
Nomenclature………………………………………………………………………....….…24
References…………………………………………………………………………...…......25

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 DESIGN OF SHELL AND TUBE HEAT EXCHANGER

General Introduction
Heat transfer is an important unit operation process in many industries. Heat exchanger is
generally used in processing plant to transfer heat from one component to another or to cold a
process fluid.
This design report explains the different processes leading to the design of a shell and tube heat
exchanger at a specified hot fluid inlet and outlet temperature. In this report, oil is the hot fluid
and cooling water is considered as the cold fluid. Normally, in processing plant, the desire
parameters will be determine based on the process requirement. So the chemical engineer must
be able to choose the optimum operation conditions to meet the design requirements. To
design Shell and tube heat exchanger there are two methods this paper follows the log mean
temperature difference method and its procedure is based on single phase flow type.

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 DESIGN OF SHELL AND TUBE HEAT EXCHANGER

Table Index
Table 1.0 operational and constructional advantage and limitations…………………..…..5
Table 1.1 Typical parts and connections shown in figure 1.0, 1.1, 1nd 1.2…………….…8
Table 2.1 General Guidelines for selecting fluid flow path……………………………….13
Table 2.2 Temperatures for cold and hot fluid…………………………………………….14
Table 2.3 Physical properties of oil and water…………………………………………….14
Table 2.4 Temperature range for shell and tube heat exchangers …………………………15
Table 2.5 Data for Floating-head type condenser and heat exchanger …………………….16
Table 4.1 Design result list ………………………………………………………………...20
Table 4.2 Design results for Shell and Tube……………………………………………….21

Figure Index
Figure 1.0 structure of floating head heat exchanger………………………………………6
Figure 1.1 structure of Fixed-tube heat exchanger………………………………………...7
Figure 1.2 structure of Removable U-tube heat exchanger………………………………..7
Figure 2.0 shell of a shell and tube heat exchanger………………………………………..9
Figure 2.1 tube structure of a shell and tube heat exchanger ………………………….…..9
Figure 2.2 layouts of heat exchanger tube…………………………………………………10
Figure 2.3 structure of tube sheet …………………………………………………………11
Figure 2.4 structure of baffle use in heat exchanger………………………………………11
Figure 2.5 types of baffles…………………………………………………………………12
Figure 2.6 Square Channel Cover………………………………………………………….18

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 DESIGN OF SHELL AND TUBE HEAT EXCHANGER
1.0 Design Outline

Design Topic:
The topic of the design is Design of a shell and tube Heat exchanger for hot (oil) fluid
and cold fluid (water).

Design Task:
The design tasks for this design is to design a heat exchanger to meet the requirement of
cooling a hot fluid (oil) from 150 ℃ to 45℃ at a mass flow of 10000 kg/hr. Water should
be used as the cooling medium with an inlet temperature of 20 ℃. Please design a shell-
and-tube heat exchanger to meet the requirement. The pressure drops of tube pass and
shell pass should be less than 25 KPa. The heat loss can be neglected.

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 DESIGN OF SHELL AND TUBE HEAT EXCHANGER

1.2 Brief Introduction of Heat Exchanger Design

A heat exchanger is a unit operator that is used to effectively transfer heat from one medium to
another or to cold down a certain fluid. Heat exchangers are used extensively throughout the
chemical process industry and as such a basic understanding of their design, construction and
performance is important to the education of chemical engineering students and practicing
engineers. In the process industry, different processes use heat exchanger according to the
process product heating or cooling requirements.

Transfer of heat from one fluid to another is an important operation for most of the chemical
industries. The most common application of heat transfer is in designing of heat transfer
equipment for exchanging heat from one fluid to another fluid. Such devices for efficient
transfer of heat are generally called Heat Exchanger. Heat exchangers are normally classified
depending on the transfer process occurring in them.
Amongst of all type of exchangers, shell and tube exchangers are most commonly used heat
exchange equipment. The common types of shell and tube exchangers are:

Fixed tube-sheet exchanger (non-removable tube bundle): The simplest and cheapest type
of shell and tube exchanger is with fixed tube sheet design. In this type of exchangers, the
tube sheet is welded to the shell and no relative movement between the shell and tube bundle
is possible (Figure 1.1).

Removable tube bundle: Tube bundle may be removed for ease of cleaning and
replacement. Removable tube bundle exchangers further can be categorized in floating-head
and U-tube exchanger.
 Floating-head exchanger: It consists of a stationery tube sheet which is clamped with
the shell flange. At the opposite end of the bundle, the tubes may expand into a freely
riding floating-head or floating tube sheet. A floating head cover is bolted to the tube
sheet and the entire bundle can be removed for cleaning and inspection of the interior.
This type of exchanger is shown in Figure 1.2.

 U-tube exchanger: This type of exchangers consists of tubes which are bent in the form
of a „U‟ and rolled back into the tube sheet shown in the Figure 1.3. This means that
it will omit some tubes at the Centre of the tube bundle depending on the tube
arrangement. The tubes can expand freely towards the „U‟ bend end. The different
operational and constructional advantages and limitations depending on applications of
shell and tube exchangers are summarized in Table 1.0.

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 DESIGN OF SHELL AND TUBE HEAT EXCHANGER
Table 1.0 operational and constructional advantage and limitations.
Shell and tube Exchangers Advantages
Fixed Tube Sheet Maximum heat transfer is
provided for a given shell
and tube diameter.
Single and multiple tube
passes to assure optimum
velocity.
Less costly then the
removable bundle designs.
Floating Head The floating tube sheet
allows for differential
thermal expansion between
the shell and the tube
bundle.
Easy to clean because both
the shell side and tube side
are accessible for inspection
and cleaning.
U-tube Allows differential thermal
expansion between the shell
and the tube bundle as well
as for individual tubes.
Can be clean because both
the tube bundle and the shell
side can be inspected for
cleaning.
Less costly then floating
head or packed floating head
design.
8
Disadvantages
Difficult to clean because
shell side/ outside of the
tubes are inaccessible.
There is no provision to
allow for differential
thermal expansion
developed between the shell
side and tube side. This can
be solved by providing
expansion joint on the shell
side.
Tube sheet is bolt to provide
the floating head. The bolt
circle requires space where
is necessary to place a large
number of tube.
Tubes cannot expand
independently so that huge
thermal shock can be
avoided.
Packing material produces
limitations on design
pressure and temperature.
Some tubes are omitted at
the center of the tube bundle
because of U-bend.
Tube can be clean only by
chemical methods. Because
of the bend.
Due to nesting, individual
tube is difficult to replace.
DESIGN OF SHELL AND TUBE HEAT EXCHANGER
No single tube pass or true
countercurrent flow is
possible.

Tube wall thickness at the u-

bend is thinner than at the
straight portion of the tubes.

Draining of tube circuit is

difficult when positioned
with the vertical position
with the head side upward.

Figure 1.0 structure of floating head heat exchanger.

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DESIGN OF SHELL AND TUBE HEAT EXCHANGER

Figure 1.1 structure of Fixed-tube heat exchanger.

Figure 1.2 structure of Removable U-tube heat exchanger

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 DESIGN OF SHELL AND TUBE HEAT EXCHANGER

Table 1.1 Typical parts and connections shown in figure 1.0, 1.1, 1nd 1.2

2. 0 Design of Main Equipment

Thermal design of a shell and tube heat exchanger typically includes the determination of heat
transfer area, number of tubes, tube length and diameter, tube layout, number of shell and tube
passes, type of heat exchanger (fixed tube sheet, removable tube bundle etc), tube pitch,
number of baffles, its type and size, shell and tube side pressure drop etc.
Shell:
Shell is the container for the shell fluid and the tube bundle is placed inside the shell. Shell
diameter should be selected in such a way to give a close fit of the tube bundle. The clearance
between the tube bundle and inner shell wall depends on the type of exchanger.

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 DESIGN OF SHELL AND TUBE HEAT EXCHANGER

Figure 2.0 shell of a shell and tube heat exchanger

Tube:
Tube OD of ¾ and 1‟‟ are very common to design a compact heat exchanger. The most
efficient condition for heat transfer is to have the maximum number of tubes in the shell to
increase turbulence. The tube thickness should be enough to withstand the internal pressure
along with the adequate corrosion allowance. The tube thickness is expressed in terms of BWG
(Birmingham Wire Gauge) and true outside diameter (OD). The tube length of 6, 8, 12, 16, 20
and 24 ft are preferably used. Longer tube reduces shell diameter at the expense of higher shell
pressure drop. Finned tubes are also used when fluid with low heat transfer coefficient flows
in the shell side

Figure 2.1 tube structure of a shell and tube heat exchanger

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 DESIGN OF SHELL AND TUBE HEAT EXCHANGER
Tube pitch, tube-layout and tube-count:
Tube pitch is the shortest center to center distance between the adjacent tubes. The tubes are
generally placed in square or triangular patterns (pitch). The tube count depends on the factors
like shell ID, OD of tube, tube pitch, tube layout, number of tube passes, type of heat exchanger
and design pressure.

Tube Passes:
The number of passes is chosen to get the required tube side fluid velocity to obtain
greater heat transfers co-efficient and also to reduce scale formation. The tube passes vary
from 1 to 16. The tube passes of 1, 2 and 4 are common in application. The partition built
into exchanger head known as partition plate (also called pass partition) is used to direct
the tube side flow.

Figure 2.2 layouts of heat exchanger tube

Tube sheet:
The tubes are fixed with tube sheet that form the barrier between the tube and shell fluids. The
tubes can be fixed with the tube sheet using ferrule and a soft metal packing ring. The tubes
are attached to tube sheet with two or more grooves in the tube sheet wall by tube rolling‟. The
tube metal is forced to move into the grooves forming an excellent tight seal. This is the most
common type of fixing arrangement in large industrial exchangers. The tube sheet thickness
should be greater than the tube outside diameter to make a good seal.

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 DESIGN OF SHELL AND TUBE HEAT EXCHANGER

Figure 2.3 structure of tube sheet

Baffles:
Baffles are used to increase the fluid velocity by diverting the flow across the tube bundle to
obtain higher transfer co-efficient. The distance between adjacent baffles is called baffle-
spacing. The baffle spacing of 0.2 to 1 times of the inside shell diameter is commonly used.
Baffles are held in positioned by means of baffle spacers. Closer baffle spacing gives greater
transfer co-efficient by inducing higher turbulence. The pressure drop is more with closer baffle
spacing. The various types of baffles are shown in figure 2.5.

Figure 2.4 structure of baffle use in heat exchanger

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 DESIGN OF SHELL AND TUBE HEAT EXCHANGER

Figure 2.5 types of baffles

Fouling Consideration:
The most of the process fluids in the exchanger foul the heat transfer surface. The material
deposited reduces the effective heat transfer rate due to relatively low thermal conductivity.
Therefore, net heat transfer with clean surface should be higher to compensate the reduction in
performance during operation. Fouling of exchanger increases the cost of (i) construction due
to oversizing, (ii) additional energy due to poor exchanger performance and (iii) cleaning to
remove deposited materials. A spare exchanger may be considered in design for uninterrupted
services to allow cleaning of exchanger. The effect of fouling is considered in heat exchanger
design by including the tube side and shell side fouling resistances.

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 DESIGN OF SHELL AND TUBE HEAT EXCHANGER

2.1 Design Conditions

In this design, the hot fluid (oil) with a temperature of 150 ℃ should be cold to 45 ℃ using
cooling water with an initial temperature of 20 ℃. The mass flow rate of the oil is 10000 kg/h
and the pressure drops of tube pass and shell pass should be less than 25 KPa. The heat loss in
the heat exchanger can be neglected.

2.2 Determination of flow path

The routing of the shell side and tube side fluids has considerable effects on the heat exchanger
design. Some general guidelines for choosing the flow path of the cold and hot fluid must be
follow. In this design, the oil is selected as the shell pass fluid were as the cooling water is
selected as the tube pass fluid. These selections were made because the saturated steam should
pass in the shell in other to remove the condensates that will form in the shell. Additionally,
water was selected as the tube pass fluid because, it is convenient to clean and maintain. A
summary of the guidelines is given in the table below.

Table 2.1 General Guidelines for selecting fluid flow path

Tube-side fluid Shell-Side Fluid
Corrosive fluid Condensing vapor (unless corrosive)
Cooling water Fluid with large temperature difference
(>40°C)
Fouling fluid
Less viscous fluid
High-pressure steam
Hotter fluid

2.21: Type of flow pattern for this design.

The type of flow pattern for this design task is countercurrent. This flow pattern was selected
based on the calculation presented below. According to principle, the highest value for the
logarithmic main temperature difference between the hot and cold fluid from the calculation
of parallel and counter flow should be chosen.

Counter Current:

(𝑇1 −𝑡2 )−(𝑇2 −𝑡1 ) (150−30)−(45−20)

∆𝑇𝑚𝑖𝑛 = 𝑇 −𝑡 = (150−30) = 60.6 °C
𝑙𝑛 1 2 𝑙𝑛
𝑇2 −𝑡1 45−20

Parallel Flow:

(𝑇1 −𝑡1 )−(𝑇2 −𝑡2 ) (150−20)−(45−30)

∆𝑇𝑚𝑖𝑛 = 𝑇 −𝑡 = (150−20) = 55.30 °C
𝑙𝑛 1 1 𝑙𝑛
𝑇2 −𝑡2 45−30

From those two results we can conclude that the higher value of log mean temperature
difference is better to use because it can reduce the surface area of the exchanger. Hence
counter flow is better to use.

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 DESIGN OF SHELL AND TUBE HEAT EXCHANGER
2.3 Determination of Heat Load (Q)
According to the design specifications, the mass flow of the hot fluid and the temperature for
the inlet and outlet of oil so we can calculate the heat load for the heat exchanger.

(10000)(2.3)(150−45)
𝑄 = 𝑊ℎ 𝐶𝑝ℎ (𝑇1 − 𝑇2 ) = = 6.708𝑋105 W
3.6

2.4 Determination of inlet and outlet temperature of the fluids

According to the design task, the inlet and outlet temperature for the oil has been specified.
The inlet temperature for the cold fluid was also specified but the outlet temperature needs to
be determine. In general, the arrange of the temperature difference is 5-10 ℃.

Table 2.2 Temperatures for cold and hot fluid

Oil Cooling Water
Inlet( ℃) Outlet (℃) Inlet (℃) Outlet (℃)
150 45 20 30

2.5 Determination of the characteristics temperature

The characteristic temperature is the average temperature between the outlet and inlet
temperature of the hot and cold fluid.
𝑇 +𝑇 150+45
𝑇̅ = 1 2 2 = = 97.5 ℃ ……………………. Hot Fluid
2

𝑡1 +𝑡2 20+30
𝑡̅ = = = 25 ℃ …………………………. Cold Fluid
2 2

2.6 Determination of the physical properties of the hot fluid (Oil) and cold
fluid (water)
The below table gives the physical properties for oil and water at 97.5 ℃ and 25 ℃
respectively.

Table 2.3 Physical properties of oil and water

Fluid Type Qualitative Specific Density Viscosity Thermal
temperature heat (kg/m3) (10-3Pa·s) conductivity
℃ (kJ/kg·℃) (W/m·℃)
Oil 97.5 2.3 810 0.91 0.13
Water 25 4.183 997.1 0.8905 0.594

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 DESIGN OF SHELL AND TUBE HEAT EXCHANGER
2.7 Determination the mode of Heat Exchanger
The mode of heat exchanger can be calculated by finding the difference between the
characteristic temperature for the cold and hot fluid. The characteristic temperatures were
calculated in section 2.5.
𝑇̅ − 𝑡̅ = 97.5 − 25 = 72.5 ℃
According to this result, the mode of the heat exchanger that will be design is floating-head
type shell and tube heat exchanger.
The table below gives a summary of the temperature range for determining the mode of heat
exchanger.

Table 2.4 Temperature range for shell and tube heat exchangers
Fixed tube sheet type Heat Fixed tube sheet type Heat U-type tube type heat
Exchanger Exchanger with expansion exchanger & Floated-head
joint type Heat Exchanger
̅
𝑇 − 𝑡 = 40 ≤ 50 ℃
̅ ̅
𝑇 − 𝑡 = 50 ≤ 70 ℃
̅ 𝑇̅ − 𝑡̅ ≥ 70 ℃

2.8 Determination of Mean Temperature Difference

(𝑇1 −𝑡2 )−(𝑇2 −𝑡1 ) (150−30)−(45−20)
∆𝑡′𝑚𝑖𝑛 = 𝑇 −𝑡 = (150−30) = 60.6 °C
𝑙𝑛 1 2 𝑙𝑛
𝑇2 −𝑡1 45−20

𝑇1 −𝑇2 150−45 𝑡2 −𝑡1 1 30−25

𝑅= = = 10.5 𝑃= = = 0.0952
𝑡2 −𝑡1 30−20 𝑇1 −𝑇2 150−45

√𝑹𝟐 +𝟏 𝒍𝒏( 𝟏−𝑷 )

𝟏−𝑹𝑷
∅=
𝟐−𝑷(𝑹+𝟏−√𝑹𝟐 +𝟏)
(𝑹−𝟏)𝒍𝒏 (
𝟐−𝑷(𝑹+𝟏+√𝑹𝟐 +𝟏)

𝟏−𝟎.𝟎𝟗𝟓𝟐
√𝟏𝟎.𝟓𝟐 +𝟏 𝒍𝒏( )
𝟏−𝟏𝟎.𝟓∗𝟎.𝟎𝟗𝟓𝟐
= = 𝟎. 𝟗𝟒𝟔 ~ 𝟎. 𝟗𝟓
𝟐−𝟎.𝟎𝟗𝟓𝟐(𝟎.𝟎𝟗𝟓𝟐+𝟏−√𝟏𝟎.𝟓𝟐 +𝟏)
(𝟏𝟎.𝟓−𝟏)𝒍𝒏 (
𝟐−𝟎.𝟎𝟗𝟓𝟐(𝟏𝟎.𝟓+𝟏+√𝟏𝟎.𝟓𝟐 +𝟏)

𝑁𝑜𝑡𝑒: ∅ can also be determine using the temperature correction factor graph.

∆𝑡𝑚𝑖𝑛 = ∅∆𝑡′𝑚𝑖𝑛 = 0.95 ∗ 60.6 = 57.53 °C

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 DESIGN OF SHELL AND TUBE HEAT EXCHANGER

2.9 Determination of Selection for overall heat transfer coefficient (K0) and
𝑆𝑜
So can be determine by preliminarily choosing the outside diameter, number of tubes and the
length of the tube. The calculation is presented below.

𝑆𝑜 = 𝑛𝜋𝑑𝑜 = (𝐿 − 0.1) = (108)(0.019)(108)(3 − 0.1) = 18.68 𝑚2

𝑄 6.708𝑋105
𝐾𝑜 = 𝑆 = 18.68∗ 57.53 = 624 𝑊/𝑚2 ℃
𝑜 ∆𝑡𝑚𝑖𝑛

2.10 Determination of basic size and arrangement mode according to the serial standard
According to our assumption for length, outside diameter and total number of tubes, the
below data can be obtained from Appendix 4 (Condenser and Heat Exchanger data) the Unit
operation of chemical Engineering seventh edition by W.L. McCabe, J.C. Smith, and P.
Harriott (ISBN 978-7-122-03192-1).

Table 2.5 Data for Floating-head type condenser and heat exchanger
Nominal Number of Number of tubes Circulation Heat exchanger
diameter tube passes 2
area (m ) area (m2)
(dn) (Np)
Total Center Tube Shell L=3m
(nt) banks pass pass
of tubes (nc)

400 4 108 9 0.0005 0.0444 18.8

Diameter= ∅19mm × 2mm, do = 0.019m, di = 0.015m, b=0.002m

Note: Regular Triangular arrangement was selected.

𝐷=𝑡(𝑛𝑐−1) +2𝑏

t = 1.4 ∗ 0.019 = 0.0266 m

b = 1.3 ∗ 0.019 = 0.0247 m

nc = 1.1√n = 1.1√108 = 11.43

𝐷𝑠 = 0.0266 ∗ (11.43 − 1) ∗ 2 ∗ 0.247 = 0.326 m

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 DESIGN OF SHELL AND TUBE HEAT EXCHANGER
Determination of Parameters
In this section, the basic parameters will be calculated for the shell pass fluid and the tube
pass fluid.

Hot Fluid: Oil (shell pass side calculations)

𝑙𝑏 = 150 𝑚𝑚 = 0.15 𝑚…………. Spacing between baffles.

𝑑𝑜 0.019
𝑨𝒔 = 𝒍𝒃 𝐷𝑠 (1 − ) = 0.15 ∗ 0.326 ∗ (1 − ) = 0.0142 𝑚2
𝑡 0.0266

𝑊ℎ 10000 𝑚3 𝑚3
𝑽𝒔 = = = 12.345 = 0.00343
𝜌 810 ℎ 𝑠

𝑽𝒔 0.00343 𝑚
𝑼𝒔 = = = 0.242
𝑨𝒔 0.0142 𝑠
𝜋 𝜋
4(𝑡 2 − 4 𝑑𝑜2 ) 4(0.02662 − 4 ∗ 0.0192 )
𝑑𝑒 = = = 0.0284 𝑚
𝜋𝑑𝑜 𝜋 ∗ 0.019

𝑐𝑝𝑠 𝜇𝑠 2.3 ∗ 0.91𝑥10−3

𝑃𝑟 = = = 0.0161 ∗ 1000 = 16.1
𝜆𝑠 0.13

s d eU s  s 0.55 1/ 3
 s  0.36 * ( )( ) (Pr )
de s

0.13 0.0284 ∗ 0.242 ∗ 810 0.55 1 𝑊

𝛼𝑠 = 0.36 ∗ ∗( −3
) ∗ 16.13 = 3077
0.0284 0.91𝑋10 ℃𝑚2

𝜌𝑠 𝑈𝑠 𝑑𝑒 810 ∗ 0.242 ∗ 0.0284

𝑅𝑒 = = = 6125.6
𝜇𝑠 0.91𝑋10−3

𝑓𝑠 = 5.0 ∗ 𝑅𝑒 −0.228 = 5.0 ∗ 6125.6−0.228 = 0.685

For water cooling (Tube pass side):

𝜋 𝜋
𝐴 = 𝑛 𝑑𝑖2 = 108 ∗ ( ) ∗ 0.0152 = 0.0191 𝑚2
4 4

𝑊𝑠 𝐶𝑝𝑠 (𝑇1 −𝑇2 ) 10000∗2.3∗(150−45) 𝑘𝑔

𝑊𝑖 = = = 57734
𝐶𝑝𝑖 (𝑡2 −𝑡1 ) 4.183∗(30−20) ℎ

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 DESIGN OF SHELL AND TUBE HEAT EXCHANGER

57734 𝑚3
𝑉𝑖 = ( )/ (3600) = 0.0161
997.1 𝑠
𝑉𝑖 0.0161 𝑚
𝑼𝒊 = = 0.0191 = 0.843
𝐴 𝑠

𝑐𝑝𝑖 𝜇𝑖 4.183∗0.8905𝑋10−3
𝑃𝑟 = = = 6.271
𝜆𝑖 0.594

 dU 
 i  0.23 * ( i )( i i i ) 0.8 Pr n
di i

0.594 0.015 * 0.843 * 997.1 0.8

 i  0.23 * ( )( 3
) * 6.2710.3  3307.6w / m 2 oC
0.015 0.8905 X 10
𝜌𝑖 𝑈𝑖 𝑑𝑖 997.1∗0.843∗0.015
𝑅𝑒 = = = 14161.46………. Renold Number
𝜇𝑖 0.8905𝑋10−3

0.125 0.125
𝑓𝑖 = 0.0014 + 0.32
= 0.0014 + = 0.00727
𝑅𝑒 14161.460.32

𝜆 = 4𝑓𝑖 = 4 ∗ 0.00727 = 0.0291………. Corrected Thermal Conductivity

Main Attachment
Because the shell diameter is less than 400 mm, square channel cover can be selected.
Therefore, the diameter of the connector tube will be:

4𝑉 4∗0.0343
𝑑 = √ 𝜋𝑢𝑠 = √𝜋∗0.0242 = 0.134 𝑚 = 134 𝑚𝑚

Figure 2.6 Square Channel Cover

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 DESIGN OF SHELL AND TUBE HEAT EXCHANGER
Number of the Baffles
The spacing between each baffle is 150 mm therefore Zt = 0.15 m. Number of baffles can be
calculated as shown below;
𝐿 3
𝑁𝐵 = 𝑍 = 0.15 = 20 𝐵𝑎𝑓𝑓𝑙𝑒𝑠
𝑡

Selection of Material
The selection of material for the design of shell and tube heat exchanger depends on operating
pressure, temperature and corrosiveness of fluid and heat resistance, high strength, corrosion
resistance of the material. Due to the high temperature of the oil, Stainless steel can be used for
fabricating the heat exchanger. Austenitic stainless steel can be used because of it cryogenic
and high temperature resistance.

3. 0 Checking the Design

According to reference material, the thermal conductivity of steel at 100 ℃ is 50.2W/m. K.
The mean diameter for the require area is ∅19mm × 2mm, 𝑑𝑜 = 0.019𝑚, 𝑑𝑖 = 0.015𝑚 d𝑚 =
0.017. It can be assumed that the cooling water for this design is tab water. Additionally, the
fouling thermal resistance for oil and water can be determine from chemical engineering hand
book to be 𝑅𝑠𝑖 1.7197 x 10-4 (𝑚2. ℃) / and 𝑅𝑠𝑜 3.4393 x 10-4 (𝑚2. ℃) / 𝑊 respectively.

3.1 Check overall heat transfer coefficient

Preliminarily, the overall heat transfer was calculated to be 624 𝑊/𝑚2 ℃

1 𝑑𝑜 𝑑𝑜 𝑏𝑑0 1
= + 𝑅𝑠𝑖 + + 𝑅𝑠𝑜 +
𝐾𝑜 𝛼𝑖 𝑑𝑖 𝑑𝑖 𝜆𝑚𝑒𝑡𝑎𝑙 𝑑𝑚 αo

0.019 0.019 0.002 ∗ 0.019 1

= + 1.7197𝑋10−4 ∗ + + 3.4393𝑋10−4 +
3307.6 ∗ 0.015 0.015 50.2 ∗ 0.017 3076.9

𝐾𝑜 = 754.52 𝑊/𝑚2 ℃

𝐾𝑜 754.52
= = 1.209
𝐾𝑜′ 624
𝟏. 𝟏𝟓 ≤ 𝟏. 𝟐𝟎𝟗 ≤ 𝟏. 𝟐𝟓 : Therefore, the Overall heat transfer area meets the design
requirement.

3.2 Checking the pressure drop for shell side and tube side

Pressure drop of shell pass (oil)

∑ ∆𝑝𝑠 = (∆𝑝1′ + ∆𝑝2′ )𝐹𝑠 𝑁𝑠 𝐹𝑠 = 1.15 𝑁𝑠 = 1 𝐹 = 0.5

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 DESIGN OF SHELL AND TUBE HEAT EXCHANGER
𝜌𝑢𝑠2 810∗0.2422
∆𝑝1′ = 𝐹𝑓𝑠 𝑛𝑐 (𝑁𝐵 + 1) ( ) = 0.5 ∗ 0.685 ∗ 11.43 ∗ (20 + 1) ( ) = 1949.01 𝑝𝑎
2 2

2𝑙𝐵 𝜌𝑢𝑠2 2∗0.15 810∗0.2422

∆𝑝2′ = 𝑁𝐵 (3.5 − ) = 20 (3.5 − ) = 3229.75 𝑝𝑎
𝐷 2 0.326 2

(1949.01 + 3229.75)1.15 ∗ 1
∑ ∆𝑝𝑠 = = 3.66 𝐾𝑝𝑎
1000

3.66 𝐾𝑝𝑎 < 25 𝑘𝑝𝑎 Therefore, the shell pass passed the pressure drop check.

Pressure drop of tube pass (water)

∑ ∆𝑝𝑖 = (∆𝑝1 + ∆𝑝2 )𝐹𝑡 𝑁𝑠 𝑁𝑝

𝐹𝑡 =1.5 𝑁𝑠 =1 𝑁𝑝 =4 𝜆=0.029 L=3 m

𝐿𝜌𝑢𝑖2 3∗997.1∗0.8432
ΔP1 = λ = 0.029 ∗ = 2061.06 𝑝𝑎
2 2

𝜌𝑢𝑖2 997.1∗0.8432
∆𝑝2 = 3 ( )= 3∗ =1063.29 pa
2 2

1
∑ ∆𝑝𝑖 = ((2061.29 + 1063.29)1.5 ∗ 1 ∗ 4) = 18.75 𝑘𝑝𝑎
1000

18.75 𝑘𝑝𝑎 < 25 𝑘𝑝𝑎 𝑇ℎ𝑒𝑟𝑒𝑓𝑜𝑟𝑒, 𝑡ℎ𝑒 𝑡𝑢𝑏𝑒 𝑝𝑎𝑠𝑠 𝑝𝑎𝑠𝑠𝑒𝑑 𝑡ℎ𝑒 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑑𝑟𝑜𝑝 𝑐ℎ𝑒𝑐𝑘.

4.0 Design result list

The results for the different calculated parameters for floating-head heat exchanger that is
require to cooled oil from an inlet temperature of 150 ℃ to 45 ℃ with a mass flow of 10000
kg/h are presented in the tables below.

Table 4.1 Design result list

Parameter Value Unit
5
Heat load Q 6.708𝑋10 W
Hot fluid mass flow rate Wh 10000 Kg/h
Cold fluid mass flow rate 57733.7 Kg/h
Wc
Hot inlet temperature 150 ℃
Hot outlet temperature 45 ℃
Cold inlet temperature 20 ℃
Cold outlet temperature 30
Logarithmic mean 60.6 ℃
temperature (Δ𝑡𝑚)
Corrected Logarithmic mean 57.53
temperature

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 DESIGN OF SHELL AND TUBE HEAT EXCHANGER
Temperature Correction 0.95
Factor
Calculated Heat transfer 18.68 m2
area
Corrected Heat transfer area 15.45 m2
Estimated heat transfer 623.99 𝑊/ (𝑚2. ℃)
coefficient
Calculated heat transfer 754.52 𝑊/ (𝑚2. ℃)
coefficient
𝐾𝑜′/𝐾𝑜 1.209
Heat Exchanger Descriptions
Parameter Value Unit
Shell pass flow Oil
Tube pass flow Water
Shell pass flow velocity 0.242 m/s
Tube pass flow velocity 0.843 m/s
Temperature difference of 10 ℃
cooling water
Temperature difference of 105 ℃
Hot Fluid
Pipe diameter type ∅19mm × 2mm
Outer diameter 𝑑𝑜 0.019 m
Inner diameter 𝑑𝑖 0.015 m
Thickness b 0.002 m
Pipe length L 3 m
Arrangement Equilateral Triangle
Serial Standard Single tube pass
Spacing between Baffles lB 150 mm
Number of the baffles NB 20
Channel cover type square channel
Connector tube diameter 0.134 m
Material type Stainless Steel
Total number of Tubes 108 -
Number of tube pass 4 -
Number of shell pass 1 -
Center banks of tubes nc 11.43
Tube pass circulation area 0.0191 m
Shell pass circulation area 0.0142 m

Table 4.2 Design results for Shell and Tube

Parameter Shell Pass (Hot Fluid) Tube Pass (Cold Fluid) Unit
Volume flow 0.00340 0.0161 m3/s
Cross section 0.0142 0.0191 m2
area
Diameter 0.326 0.16 m
Fluid flow 0.242 0.843 m/s
velocity

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 DESIGN OF SHELL AND TUBE HEAT EXCHANGER
Density 810 997.1 kg·m-3
Specific heat 2.3 4.183 kJ·kg-1·℃-1
Viscosity 0.91X10-3 0.8905X10-3 Pa·s
Thermal 0.13 0.594 W·m-1·℃-1
conductivity
Thermal 50.2 w/mk
conductivity of
steel
Equivalent 0.0284 m
diameter
Prandtl 16.1 6.27
Number
Reynolds 6125.6 14161.5
Number
Convection 3076.9 3307.6 W/m2.oC
heat transfer
coefficient
Friction 0.685 0.0073
coefficient
Fouling 3.4393𝑋10−4 1.7197𝑋10−4 𝑚2 . ℃ / 𝑊
Thermal
Resistance (Rs)
Fouling 1.15 1.5
correction
coefficient
Correction 0.5
factor of
arrangement of
tubes
Pressure drop 3.66 18.75 KPa
ΣΔ𝑝

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 DESIGN OF SHELL AND TUBE HEAT EXCHANGER

5.0 Review of Design

Shell and tube heat exchangers are designed based on the effective and log mean temperature
methods thus two methods are follow different procedures (algorithms) based on the designer
first assumptions.
The design process involved careful analysis and effective design calculation in other to obtain
the best possible parameters that will minimize process cost and equipment cost.
After all the calculation procedures, the necessary check was performed in other to determine
if the design parameters meet the process requirement.
During the calculation, the following phenomenon was observed:
1. The Flow velocity for the shell pass fluid increases with a decrease in t.
2. The heat transfer coefficient increases when t is decrease.
3. The Heat transfer area is increase with increase in t.
The below decisions were reached:
 In this design, floating head heat exchanger was selected because, the difference in the
characteristic temperature for the hot and cold fluid is greater than 70 ℃.
 A square channel cover was selected because the diameter of the shell is less than 400
mm.
 The material for the exchanger design is stainless steel because of the high temperature
of the hot fluid. Stainless steel was selected because of its ability to withstand cryogenic
and high temperature.
 From the heat transfer coefficient check, it has been observed that the heat transfer area
for the floating head heat exchanger meets the design requirements.
 The pressure drop check also shows that the design parameters meet the specify design
requirement.
Based on these results, the above design can be used to design a floating head heat exchanger
to cooled oil from 150 ℃ to 45 ℃ at a mass flow of 10000kg/h.

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 DESIGN OF SHELL AND TUBE HEAT EXCHANGER

NOMENCLATURE
Symbol Description unit
Q Total heat transfer W
Wh mass flow of hot fluid kg/h
Wc mass flow of cold fluid kg/h
Vh Volume flow of hot fluid m3/s
Vc Volume flow of cold fluid m3/s
Cph specific heat of hot fluid kJ/kg ℃
Cpc specific heat of cold fluid kJ/kg. ℃
Thi hot fluid temperature at inlet ℃
Tho hot fluid temperature at exit ℃
tci cold fluid temperature at inlet ℃
tco cold fluid temperature at exit ℃
A total area of shell m2
ΔTmin log mean temperature ℃
ΔT1 temperature difference one ℃
ΔT2 temperature difference two ℃
T Temperature ℃
do outer diameter of tube m
di inner diameter of tube m
L length of shell m
t
lb Spacing between two baffles m
Ds shell diameter m
Nt number of tubes -
𝛼i tube side heat transfer coefficient W/m2 ℃
𝛼o shell side heat transfer coefficient W/m2 ℃
Ko assumed over all heat transfer coefficient W/m2 ℃
K’o calculated over all heat transfer coefficient W/m2 ℃
Are required area m2
P pressure kpa
ΣΔ𝑝s shell Pressure Drop kpa
ΣΔ𝑝t Tube pass pressure drop kpa
Re 𝑅𝑒𝑦𝑛𝑜𝑙𝑑𝑠 number -
Pr pranditle -
Nu nussult number -
λi Water thermal conductivity W/m ℃
λo Oil thermal conductivity W/m ℃
ui velocity Water m/s
uo velocity Oil m/s
b thickness m
R Ratio of true deop in T -
P Heating Effectiveness -
μi viscosity of Water Pa·s
μo viscosity of oil Pa·s
fo friction coefficient of shell fluid -

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 DESIGN OF SHELL AND TUBE HEAT EXCHANGER
ρi Density of water kg·m-3
ρo Density of oil kg·m-3
Ft fouling correction coefficient (tube) -
Fs fouling correction coefficient (shell) -
Nb Number of baffles -
Np Number of tube passes -
Ns Number of shell passes -

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 DESIGN OF SHELL AND TUBE HEAT EXCHANGER

References
1. Unit Operation of Chemical Engineering. 7th Ed. W.L. McCabe, J. C. Smith, P.
Harriott Mc Graw Hill Education. 2008.

2. Design of Shell and Tube Heat Exchanger. T. Gebru. BAHIRDAR UNIVERSITY

INSTITUTE OF THECHNOLOGY SMIE (THERMAL). 2015

3. Chemical Engineering Design 1. Lecture notes. F. Jiang. School of Chemical Engineering and
Technology, Tianjin University. 2019.

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