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Design of Shell Tube Heat Exchanger by Kern Method
Design of Shell Tube Heat Exchanger by Kern Method
FLOW CONDITION
[Type of flow] Counter flow
[Design Fouling Factor] 0.000176 m2- K/W
ESSENTIAL VARIABLES
[Tube materials] WATER
[Velocity of fluid inside Tubes] 2 m/s
[Tube Outside Diameter] 19 mm
[Tube Inside Diameter] 16 mm
[Thermal Conductivity of Tubes] 42.3 W/m-K
TUBE ORIENTATION & GEOMETRY
[Number of Passes] 3
[Tube Pitch] 0.0254 mm
[Tube layout] Square Layout
[Tube Count Layout] 45 deg.
[Baffle Spacing - baffle cut at 25%] 0.5 m
Step #3: Check the % surface design of heat exchanger due to fouling effects
Computed value of = 61%
If the value is too high , Set value for desired surface design then enter 30%
Step #4: Evaluate computed length of tube of heat exchanger, Note that standard length is in
20 ft and it is recommended to use it out of the its length
Computed Length = 1.89 m
Enter, the effective length of tubes should not < computed length 4.00
Step #5: Evaluate the re-calculated shell diameter on the new length of HX, Inside diameter
should referred to available shell to be used ( can be pipe or rolled plate)
Computed Shell ID = 0.68 m
FINISH
Check the result in the next sheet, Carefully evaluate and proceed next iteration
if needed. The areas for iteration will be size, tube layout, flow conditions, geometry
length of tubes ,baffle spacing and tube materials.
DEVELOPED IN EXCEL BY: REY FIEDACAN - MECHANICAL ENGINEER ,11.07.2010
1
ENGINEERING CALCULATION Designed by Rey Fiedacan
THERMAL CALCULATION OF HEAT EXCHANGER Date 11.07.2010
TYPE: SHELL & TUBES Doc. No. HX - 01 -09
DEVELOPED USING EXCEL BY REY FIEDACAN,MECHANICAL ENGINEER, 11.07.2010 -fiedrey@yahoo.com Revision 1
1.0 Temperature of outlet fluid - Cold fluid ( Predicted from energy and mass balance)
msCps(Ts1-Ts2)
Ts2 = mtCpct = 295.3 K
2.0 Log mean temperature difference across the heat exchanger (LMTD)
4.0 HEAT DUTY OF HEAT EXCHANGER based on the temperature difference between hot fluids inlet
and outlet condition.
5.0 NUMBER OF TUBES - based on the mass flowrate of cold fluid inside the tubes and recommended
velocity on the specified number of passes.
Nt = 4mtNp/ρtvtπdi2 = 1,121 tubes
374 per pass
II. TUBE SIDE CALCULATION:
1.0 TUBE SIDE HEAT TRANSFER
Nutkt where:
ht =
di Nut = Nusselt number of fluid inside the tubes
Kt = Thermal conductivity of fluid inside the tubes
di = Inside diameter of tubes
2.0 NUSSELT NUMBER ( CORRELATION FROM Petukhov - Kirililov for Turbulent flows )
which predicts results in the range of 10 4< Ret < 5 x106 and 0.5 < Prt < 200
(f/2)RetPrt
Nut =
1.07+12.7(f/2)1/2(Prt2/3 -1)
ENGINEERING CALCULATION Designed by Rey Fiedacan
THERMAL CALCULATION OF HEAT EXCHANGER Date 11.07.2010
TYPE: SHELL & TUBES Doc. No. HX - 01 -09
DEVELOPED USING EXCEL BY REY FIEDACAN,MECHANICAL ENGINEER, 11.07.2010 -fiedrey@yahoo.com Revision 1
2.2 Reynold number at tube side Ret = ρtvtdi/µt = 32,488.20 the flow is turbulent
-2
2.3 Friction factor at given Re Ft = (1.58lnRet - 3.28) = 0.005797
(f/2)RetPrt
Nut = = 225.72
1.07+12.7(f/2)1/2(Prt2/3 -1)
-1
do
1 do 1 do ln( di )
Uc = + d h + kt = 1,869.27 W/m2-K
ho i i 2
1.1 Surface area of heat exchanger for clean condition ( No fouling Effect )
Ac = Q = 97.11 m2
UcΔTm
Use: Uc = 2263.2
2.0 Outer surface area - Fouled heat transfer coefficient
do -1
1 do 1 do ln( di )
Uf = + d h + kt + Rft = 1,406.54 W/m2-K
ho i i 2
2.1 Surface area of heat exchanger for clean condition ( with fouling Effect )
Af = Q = 156.25 m2
UfΔTm
2.2 Check for % surface design
Af
Os = = 61%
Ac
Use: Os = 30 %
2.3 Surface design area of heat exchanger at certain 30 % more allowance for fouling effect
A' = 126.24 m2
Use: L = 4.00 m
V. PRESSURE DROP - This is used to determined the pumping power required to handle the fluid in tubes and shell.
1.0 TUBE SIDE PRESSURE DROP
ENGINEERING CALCULATION Designed by Rey Fiedacan
THERMAL CALCULATION OF HEAT EXCHANGER Date 11.07.2010
TYPE: SHELL & TUBES Doc. No. HX - 01 -09
DEVELOPED USING EXCEL BY REY FIEDACAN,MECHANICAL ENGINEER, 11.07.2010 -fiedrey@yahoo.com Revision 1
-2
1.1 Tube side friction factor ft = (1.5ln(Ret) - 3.28) = 0.005797
2.0 SHELL PRESSURE DROP The shell-side fluid experiences a pressure drop as it passes through the exchanger,
over the tubes, and around the baffles.
fsG2s(Nb+1)D's
ΔPs =
2ρsDeΦs
2.1 Shell side friction factor fs = exp(0.576 -0.19ln(Res)) = 0.300
therefore: fsG2s(Nb+1)D's
ΔPs = 2ρsDeΦs
= 6.4 Kpa , head required to pump the fluid into the shell
= 0.9 psi
ENGINEERING CALCULATION Designed by Rey Fiedacan
THERMAL CALCULATION OF HEAT EXCHANGER Date 11.07.2010
TYPE: SHELL & TUBES Doc. No. HX - 01 -09
DEVELOPED USING EXCEL BY REY FIEDACAN,MECHANICAL ENGINEER, 11.07.2010 -fiedrey@yahoo.com Revision 1