Shell and Tube Heat Exchanger

Part 2

Lecturer:

Ir. I Made Astina, M.Eng., Ph.D.

Associate Professor of Mechanical Engineering

1
 Content
 Tube Pitches
 Materials
 Basic Design
 Kern Method
 Bell-Delaware Method
 Mechanical Design
 Exercise

2
 Learning Objective
 Understanding of type of attachment of tube on
tube sheet, tube passes, and tube pitches
 Understanding of materials of the heat exchanger
 Understanding of basic design of the heat
exchanger
 Able to apply Kern Method
 Able to apply Bell-Delaware Method
 Able to design shell-and-tube exchanger

3
 Tube Pitches (Refer TEMA)

 Typically, 1 in tubes on a 1.25 in pitch or 0.75 in tubes on a 1 in

pitch
 Triangular layouts give more tubes in a given shell
 Square layouts give cleaning lanes with close pitch

4
 TEMA

5
 Following parameters and constraint
for typical design

 Inlet and outlet temperature

 Fluid flow rate
 Pressure of operation
 Allowable pressure loss
 Fluid properties
 Fouling resistance for the respective
streams

6
 Allocation of fluids
 Put dirty stream on the tube side - easier to clean inside
the tubes
 Put high pressure stream in the tubes to avoid thick,
expensive shell
 When special materials required for one stream, put that
one in the tubes to avoid expensive shell
 Cross flow gives higher coefficients than in plane tubes,
hence put fluid with lowest coefficient on the shell side
 If no obvious benefit, try streams both ways and see
which gives best design

7
 Materials
Standard Designs
Shells
 Shells – Steel, 304SS, 316SS, 304LSS, 316LSS up to 42-inch diameter
Bonnets/Channels
 Bonnets/channels – Steel, 304SS, 3136SS, 304LSS, 316LSS, Cast
Iron, Cast Bronze, Ductile Iron.
Tubesheets
 Tubesheets – Aluminum Bronze, 90/10 CuNi, Muntz, RNB, 304SS,
316SS, 304LSS, 316LSS Steel.
Tubes
 Tubes – Carbon Steel, Stainless Steel, Nickel and Nickel Alloys,
Titanium and other Alloys. Bare and Lo-Fin Tubing.

8
 Materials (Custom Designs)

• Stainless steel(s) (including Alloy 20, 317SS, AL6XN, 904LSS,

etc.)
• Hastelloy • Titanium • Monel
• 90/10 CuNi • 70/30 CuNi • Inconel
• Incoloy® • Avesta 254SMO

9
 Tube Materials
 Materials selection and compatibility between construction
materials and working fluids are important issues, in particular
with regard to corrosion and/or operation at elevated
temperatures.
 Requirement for low cost, light weight, high conductivity, and
good joining characteristics often leads to the selection of
aluminum for the heat transfer surface.
 On the other side, stainless steel is used for food processing or
fluids that require corrosion resistance.
 In general, one of the selection criteria for exchanger material
depends on the corrosiveness of the working fluid.

10
 Tube Wall Thickness

 The wall thickness of heat exchanger tubes is standardized in

terms of Birmingham Wire Gage BWG of the tube.
 Small tube diameters (8 to 15 mm) are preferred for greater
area to volume density but are limited for the purposes of
cleaning.
 Large tube diameters are often required for condensers and
boilers.

11
 Tube Outside Diameter
 The most common plain tube sizes have 15.88,19.05, and
25.40 mm (5/8, ¾, 1 inch) tube outside diameters.
 Smaller-diameter tubes yield higher heat transfer coefficients
and result in a more compact exchanger.
 Larger-diameter tubes are easier to clean and more rugged.
 The foregoing common sizes 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 never plug completely.

12
 Tube Length
 Tube length affects the cost and operation of heat exchangers.
 Longer the tube length (for any given surface area), fewer tubes are needed,
requiring less complicated header plate with fewer holes drilled, shell diameter
decreases resulting in lower cost
 Typically tubes are employed in 8, 12, 15, and 20 foot lengths.
 Mechanical cleaning is limited to tubes 20 feet and shorter, although standard
exchangers can be built with tubes up to 40 ft.

 Anything limits of how long the tubes:

 Shell-diameter-to-tube-length ratio should be within limits of 1/5 to 1/15
 Maximum tube length is dictated by
 Architectural layouts
 Transportation (to about 30 m.)
 The diameter of the two booster rockets is dictated by the smallest highway tunnel
size between the location of manufacturer and the site

13
 Design

For certain specification, basic design equation:

q  UAT
Specific configuration, U can be evaluated and sum of fouling
resistance can be estimated.

 D1  1 D1 D1 1 D1
RA  RB     ln  
 D2  U 2k w D2 hA hB D2
14
 Cont ’d

The configuration being evaluated is also evaluated against the specific

constraints:
1. Tube side pressure drop
2. Shell side pressure drop

It also evaluates further constraints:

1. Maximum tube side velocity (too high velocity  erosion)
2. Minimum tube side velocity (too low velocity  fouling)
3. Property of tube vibration (many failures may occurs due to
vibration. Sources: instability, large amplitude)

15
 Basic Mechanical Feature

Shell Type
Tube Bundle
Tube Diameter
Tube Length
Tube Layout and Pitch
Baffle Design

16
 Kern Method
Based on data from industrial heat transfer operations
and for fixed baffle cut of 25%, the equation was
provided as:

0.55 1/ 3 0.34
hDe  De m s   cp  
 0.36     
k     k   s 

Baffle with cut of 25%

17
 Bell-Delaware Method
A method with correction factors were introduced for
the following elements:
1. Leakage thought the gaps between the tube and the
baffles and the baffles and the shell, respectively.
2. Bypass of the flow around the gap between the tube
bundle and the shell.
3. Effect of the baffle configurations (i.e. recognition of
the fact that only a fraction of the tube are in pure
cross flow.
4. Effect of adverse temperature gradient on the heat
transfer in laminar flow.

18
Bell-Delaware: Heat Transfer Calculation
Reynolds number is defined
Vmax Do
Re 

Vmax is defined as the maximum velocity between the tubes near
the centerline of the flow.

Vmax is given by
m T
Vmax 
S m

Where Sm is the flow area near the centerline.

19
 Bell-Delaware: Cont’d
 D  Do 
Square pitch: S m  LB  Ds  DOTL  OTL ( PT  Do )
 PT 

Rotated square pitch:  D  Do 

S m  LB  Ds  DOTL  OTL ( PT  Do )
 0.707 PT 
 D  Do 
Triangular pitch: S m  LB  Ds  DOTL  OTL ( PT  Do )
 PT 

Rotated triangular pitch:  D  Do 

S m  LB  Ds  DOTL  OTL ( PT  Do )
 0.5 PT 
LB = The distance between baffles
Ds = The shell diameter
DOTL = the tube bundle diameter
20 PT = the tube pitch
 Bell-Delaware: Cont’d (Correction factor)

Ideal convection heat transfer coefficient is calculated from

Nu  a Rem Pr 0.34 F1F2

F1, F2 : correction factor

The shell-side heat transfer coefficient

ho  hc J C J L J B

21
 Bell-Delaware: Cont’d (Correction factor)

Correction for baffle configuration (Jc) is expressed as a function of the

fraction (Fc) of the tube in the cross flow

J c  0.55  0.72 Fc

1 2( Ds  2 Lc )  1 Ds  2 Lc  D  2 Lc 
Fc     sin  cos   2 cos 1 s 
  DOTL DOTL  D
  OTL  

Lc = baffle cut distance

22
 Bell-Delaware: Cont’d

JL = correction factor for leakage that is related to

the shell-to-baffle and tube-to-baffle.
JB = correction for bypass in the bundle-shell gap

JB is given function of Fbp

( Ds  DOTL ) LB
Fbp 
Sm

23
 Pressure Drop Calculation

Ideal cross flow pressure drop

pc  N c K 1
f 2 Vmax 2

Pressure drop across the shell is given by

 N cw 
ps  ( N  1)pc RB  Npw RL  2pc RB 1  
 Nc 

24
Hydraulic Analysis for Shell-Side
 The shell-side fluid experiences a pressure drop as it passes through
the exchanger, over the tubes, and around the baffles.
 If the shell fluid nozzles (inlet and outlet ports) are on the same side of
the heat exchanger, then the shell-side fluid makes an even number of
the tube bundle crossings, but if they are on opposite sides, then it
makes an odd number of the bundle crossings.
 The number of bundle crossings therefore influences the pressure
drop.
Based on experiments, the pressure drop experienced by the shell-
side fluid is calculated by

Where,
Gs : Shell side mass velocity

N b : Number of baffles
0.14
 b 
 s    : Variable property correction.
 w 
f s : Shell side friction factor
Roadmap to Increase Heat Transfer
 Increase heat transfer coefficient
 Tube Side
 Increase number of tubes
 Decrease tube outside diameter
 Shell Side
 Decrease the baffle spacing
 Decrease baffle cut
 Increase surface area
 Increase tube length
 Increase shell diameter à increased number of tubes
 Employ multiple shells in series or parallel
 Increase LMTD correction factor and heat exchanger
effectiveness
 Use counter flow configuration
 Use multiple shell configuration
 Roadmap to Reduce Pressure Drop

 Tube side
 Decrease number of tube passes
 Increase tube diameter
 Decrease tube length and increase shell diameter and number
of tubes
 Shell side
 Increase the baffle cut
 Increase the baffle spacing
 Increase tube pitch
 Use double or triple segmental baffles
 Rating and Design

What is the difference?

Rating calculation is conducting analysis of available heat

exchanger to get information of heat rate, or ability of heat
exchanger to cool or heat of the working fluid

Design procedure consists of systematically changing between

configurations and checking each one until the most economic
configurations that satisfies the requirement and constraints is
identified
29
 Example 1
A shell and tube heat exchanger has the following geometry:

Use the kern method to calculate the shell side heat transfer coefficient and pressure drop for flow
of a light hydrocarbon with the following specifications (at bulk temperature)

30
 Example 2
Hot oil at 100oC is used to heat air in a shell and tube heat
exchanger. The oil makes 6 tube passes and the air makes 1 shell
pass. 2.0 kg/s of air (specific heat of 1009 J/kgoC) is to be heated
from 20 to 80oC. The specific heat of the oil is 2100 J/kgoC and its
flow rate is 3.0 kg/s. Calculate the area required.

31
 Example 3
Design debutaniser overhead condenser with using the
following operation and condition data

Hot side Cold side

Fluid Light hydrocarbon Cooling water

Corrosive No No
Pressure(bar) 4.9 5.0
Temp. In/Out (oC) 46 / 42 20 / 30
Vapour fraction In/Out 1/0 0/0
Fouling res. (m2K/W) 0.00009 0.00018
32
 Example 4
Design a crude tank outlet heater with the following data

Cold side Hot side

Fluid Crude oil Steam

Corrosive No No
Pressure(bar) 2.0 10
Temp. In/Out (oC) 10 / 75 180 / 180
Vap. fract. In/Out 0/0 1/0
Fouling res. (m2K/W) 0.0005 0.0001

33
 Rule of Thumb on Costing
 Price increases strongly with shell diameter/number of tubes
because of shell thickness and tube/tube-sheet fixing
 Price increases little with tube length
 Hence, long thin exchangers are usually best
 Consider two exchangers with the same area: fixed tubesheet, 30
bar both side, carbon steel, area 6060 ft2 (564 m2), 3/4 in (19 mm)
tubes

Length Diameter Tubes Cost

10ft 60 in 3139 $112,000
60ft 25 in 523 $54,000

34
 Shell Thickness
t
Ds p p
t
p is the gauge pressure in the shell
t is the shell wall thickness
 is the stress in the shell
From a force balance
pDs
2t  pDs hence t
2
35
 Typical Maximum Exchanger Sizes

Floating Head Fixed head & U tube

Diameter 60 in (1524 mm) 80 in (2000 mm)

Length 30 ft (9 m) 40 ft (12 m)
Area 13 650 ft2 (1270 m2) 46 400 ft2 (4310 m2)

Note that, to remove bundle, you need to allow at least

as much length as the length of the bundle

36
 Fouling Consideration

Shell and tubes can handle fouling but it can be reduced by

 keeping velocities sufficiently high to avoid deposits
 avoiding stagnant regions where dirt will collect
 avoiding hot spots where coking or scaling might occur
 avoiding cold spots where liquids might freeze or where corrosive
products may condense for gases

High fouling resistances are a self-fulfilling prophecy

37
 Flow-Induced Vibration
Two types - Resonance and Instability
 Resonance occurs when the natural frequency coincides with a
resonant frequency
 Fluid elastic instability
Both depend on span length and velocity

38
 Avoiding Vibration

 Inlet support baffles - partial baffles in first few tube

rows under the nozzles
 Double segmental baffles - approximately halve cross
flow velocity but also reduce heat transfer coefficients
 Patent tube-support devices
 No tubes in the window (with intermediate support
baffles)
 J-Shell - velocity is halved for same baffle spacing as an E
shell but decreased heat transfer coefficients

39
 Avoiding vibration (Cont’d)

Inlet support Double-segmental baffles

baffles

Intermediate baffles

Windows
with no tubes Tubes

No tubes in the window - with intermediate support baffles

40
 Shell-Side Enhancement

 Usually done with integral, low-fin tubes

 11 to 40 fpi (fins per inch). High end for condensation
 fin heights 0.8 to 1.5 mm
 Designed with o.d. (over the fin) to fit into the a standard
shell-and-tube
 The enhancement for single phase arises from the extra
surface area (50 to 250% extra area)
 Special surfaces have been developed for boiling and
condensation

41
 Low-finned Tubes
 Flat end to go into tube sheet and intermediate flat portions
for baffle locations

 Available in variety of metals including stainless steel,

titanium and inconels

42
 Tube-side Enhancement using Inserts
Spiral wound wire and twisted tape
 Increase tube side heat transfer coefficient but at the cost of
larger pressure drop (although exchanger can be
reconfigured to allow for higher pressure drop)
 In some circumstances, they can significantly reduce fouling.
In others they may make things worse
 Can be retrofitted

43 Twisted tape
 Wire-wound Inserts (HiTRAN)
 Both mixes the core (radial mixing) and breaks up the
boundary layer
 Available in range of wire densities for different duties

44
 Problems of Conventional Shell & Tube

Zigzag path on shell side leads to

 Poor use of shell-side pressure drop
 Possible vibration from cross flow
 Dead spots
 Poor heat transfer
 Allows fouling
 Recirculation zones
 Poor thermal effectiveness, 

45
 Conventional Shell-side Flow

46
 Shell-Side Axial Flow
Some problems can be overcome by having axial flow
 Good heat transfer per unit pressure drop but
 for a given duty may get very long thin units
 problems in supporting the tube
RODbaffles (Phillips petroleum)
 introduced to avoid vibrations by providing additional
support for the tubes
 also found other advantages
 low pressure drop
 low fouling and easy to clean
 high thermal effectiveness

47
 RODbaffles
Tend to be about 10% more expensive for the same shell
diameter

48
 Twisted tube (Brown Fintube)
 Tubes support each other
 Used for single phase and condensing duties in the power,
chemical and pulp and paper industries

49
 Shell-side Helical Flow (ABB Lummus)
Independently developed by two groups in Norway and Czech
Republic

50
 Comparison of Shell side Geometries

Twisted Segmental Helical ROD

tube baffles baffles baffles
Good p Y N Y Y
High shell N Y Y N
Low fouling Y N Y Y
Easy Y With square With square Y
cleaning pitch pitch
Tube-side Included With inserts With inserts With inserts
enhance.
Can give Y N N Y
high 
Low Y With special With double Y
vibration designs helix

51
 Example 6: Double-Pipe Heat Exchanger including Pressure Drop

Seawater at 30oC flows on the inside of a 25-mm I.D. steel tube with a 0.8-mm
wall thickness at a flow rate of 0.4 kg/s. The tube forms the inside of a
double-pipe heat exchanger. Engine oil (refined lubricating oil) at 100oC
flows in the annular space with a flow rate of 0.1 kg/s. The outlet
temperature of the coil is 60oC. The material is carbon steel. The I.D. of the
outer tube is 45 mm and the I.D. and O.D. of the inner tube are 25 and 27
mm, respectively.
Calculate:
a. Heat transfer coefficient in the annulus.
b. Heat transfer coefficient inside the tube.
c. Overall heat transfer coefficient with fouling.
d. Area of the heat exchanger, and by assuming the length of a hairpin to be 4 m,
the number of hairpin.
e. Pressure drops and pumping power for both streams.
52
Hairpin Heat Exchanger
 The chemical processing industry commonly uses hairpin heat
exchangers
 Hairpins are typically rated at 500 psig shell side and 500 psig tube
side
 Fins can be added to the internal tube’s external wall to increase
heat transfer
Hairpin Heat Exchanger
A hairpin design is often more thermally efficient than a traditional shell and
tube, which results in a lower up-front cost and lower overall weight.

Note: Hairpin Heat

Exchanger is most similar
with U type Shell-and-Tube
Heat Exchanger
 Discussion

56