CHAPTER

SHELL TUBE HEAT

7
EXCHANGERS
 Technical requirements
1 • Overall heat transfer coefficient

2 • Pressure drop

3 • Heat transfer area

4 • Operating under temperature and pressure design

5 • Structure and leakage

 Fluid selection
1 • Maximum of density, heat capacity, thermal conductivity, latent
heat

2 • Melting point, boiling point, phase are suitable to operation

condition

3 • Minimum viscosity

4 • Flammability, corrosion, hazard, purity

 Fluid arrangment

Gas flow Gas flow

Mixed – Unmixed flow Unmixed – Unmixed flow

 Fluid velocity
High velocity, high number, high heat transfer
coefficient also, high pressure drop as well

Fluids Appropriate velocity ⁄

Low viscosity liquids (water, alcohol…) 0.5 ÷ 3.0
High viscosity liquids (oil, glycol, glycerine…) 0.2 ÷ 1.0
Flue gas 6 ÷ 10
Air 12 ÷ 16
Compressed air 15 ÷ 30
Saturated steam 30 ÷ 50
Superheated steam 30 ÷ 75
Shell and Tube
 Configuration

Fluid in outer
tube (1 pass)
Fluid in inner
tube (1 pass)

Fluid in outer
Fluid in inner tube (1 pass)
tube (1 pass)

Double pipe heat exchanger

Shell-and-Tube Heat Exchangers
Shell-and-Tube Heat Exchangers
 Configuration

Rear header

Fluid in shell Fluid in tube

(1 pass) (2 passes)

Shell

Front header Tube bundle

Configuration
 Specifications
Large surface area in a small volume

For high pressure

Well–established fabrication techniques

A wide range of materials

Easily cleaned

Well–established design procedures

 Shell-and-Tube Heat Exchangers
One shell pass and two tube passes

1-2 Fixed Head

1-2 Floating Head

Shell-and-Tube Heat Exchangers
1-2 U-tube

2-4 Floating Head

 Quiz: Identify the following
A
C

1-1 Fixed Head

1-2 U-tube
1-2 Fixed Head
2-4 Floating Head
3-6 Fixed Head B
 Temperature-Driving Forces
The rate of heat transfer in an shell-and-tube exchanger is
computed as:
Q = mC.(HC,out – HC ,in) = mH.(HH,out – HH, in)

Assuming (1) steady-state; (2) counter- or cocurrent

(parallel) flow; (3) constant overall heat transfer
coefficient; (4) no phase changes on either side; and (5)
negligible heat losses:

Q = U.A.ΔTLM
 Temperature-Driving Forces
For multiple-pass shell-and-tube exchangers, the flow
directions of the two fluids are combinations of
countercurrent and co-current flow, reducing the
effective value of .
For a 1-2 exchanger, with assumptions 1, 3, 4 and 5:

Q = U.A.FTΔTLM
Temperature-Driving Forces
 Example
A hot stream is cooled from 200 to 140 oF by a cold stream
entering at 100 oF and exiting at 190 oF. Determine the true
ΔTLM and select the appropriate shell-and-tube configuration
Example
 GENERAL DESIGN CONSIDERATIONS
Fluid allocation: shell or tubes
Where no phase change occurs, the following factors will determine the allocation
of the fluid streams to the shell or tubes.
Corrosion. The more corrosive fluid should be allocated to the tube-side..
Fouling. The fluid that has the greatest tendency to foul the heat-transfer
surfaces should be placed in the tubes.
Fluid temperatures. reduce the shell surface temperatures, and hence the need
for lagging to reduce heat loss, or for safety reasons.
Operating pressures. The higher pressure stream should be allocated to the tube-
side.
Pressure drop. For the same pressure drop, higher heat-transfer coefficients will
be obtained on the tube-side than the shell-side, and fluid with the lowest
allowable pressure drop should be allocated to the tube-side.
Viscosity. Generally, a higher heat-transfer coefficient will be obtained by
allocating the more viscous material to the shell-side, providing the flow is
turbulent.
Stream flow-rates. Allocating the fluids with the lowest flow-rate to the shell-side
will normally give the most economical design.
 Fluid arrangment
Factors Tube side Shell side Factors Tube side Shell side
Phase Gas / Vapor Liquid Viscosity Low High
Corrosion More Less Temperature Far from amb. Close to amb.
Fouling High Low Pressure High Low
Hazardous More Less Pressure drop High Low
Flammable High Low Flow rate Low High

For the fluid in shell side:

• Liquids with ⁄ < 61, along the tube (prefer to counter current flow)
• Liquids with ⁄ > 61, across the tube
• Gases with 4000 < < 40000, across the tube
 TEMA types
TEMA: Tubular Exchanger Manufacturers Association
• Size of heat exchanger is represented by the inside
diameter of shell (or bundle diameter) and the
tube length in inches
• Type and name of a heat exchanger is designed by
three letters (front header – shell – rear header)
• Front header (stationary header) is where the fluid
enters the tube side of the exchanger
• Rear header is where the tube side fluid leaves the
exchanger or is returned to the front header with
multiple passes
• Bundle comprises the tubes, tube sheets, baffles
and tie rods… to hold the bundle together
• Shell contains the tube bundle
 TEMA types
Fixed tube sheet U–tube Floating head
AEL AEU BES
AEM CEU SIZE 23–192 TYPE AES
AEN DEU SIZE 23/37–192 TYPE CKT
BEL SIZE 19–84 TYPE GBU
BEM
BEN
SIZE 33–96 TYPE AFM
SIZE 17–192 TYPE CEN
Front header types
• Easy to repair and replace
• Allow access to the tubes for cleaning or
repair without having to disturb the
pipeline
• There are two seals (tube sheet–header
and header–end plate), risk of leakage
• Higher cost than B type

• Suitable to high pressure (only one seal)

• Access to the tubes requires disturbance to
the pipeline in order to remove the header.
• Cheapest type
Front header types
• For high pressure applications > 100
• Allow access to the tube without disturbing
the pipeline
• Difficult to repair and replace (the tube
bundle is an integral part of the header)

• For very high pressures > 150

• Allow access to the tubes without
disturbing the pipeline
• Difficult to repair and replace (the tube
bundle is an integral part of the header)
• This is the most expensive type
Front header types

• Allow access to the tubes without

disturbing the pipeline
• Difficult to maintain and replace (the
header and tube sheet are an integral part
of the shell)
• Cheaper than an A type
 Shell types

• Most commonly used

• Suitable for most duties and applications

• Pure countercurrent flow is required in a two

tube side pass (two shells side passes by a
longitudinal baffle)
• Thermal and hydraulic leakage across the baffle
 Shell types
• For horizontal thermosyphon reboilers
• For applications requires the small shell side
pressure drop

• Similar applications to G type but tends to be

used when larger units are required
 Shell types

• To be used when the maximum allowable

pressure drop is exceeded in an E type, and
tube vibration is a problem
• The divided flow on the shell side reduces the
flow velocities over the tubes and hence
reduces the pressure drop and the likelihood of
tube vibration
• Two inlet and one outlet is referred to I type
 Shell types
• For reboilers only to provide a large
disengagement space in order to minimize shell
side liquid carry over
• To be used as a chiller, cool the tube side fluid
by boiling a fluid on the shell side

• For shell side condensers and gas coolers (the

maximum shell side pressure drop is exceeded
by all other shell and baffle type combinations)
Rear header types

• For fixed tube sheets only (the tube sheet is

welded to the shell), so it’s impossible to access
to the outside of the tubes is not possible
• Allow access to the inside of the tubes without
having to remove any pipeline and the bundle
to shell clearances are small
• Small thermal expansions and this limits the
operating temperature and pressure
Rear header types
• Similar to the L type but it is slightly cheaper
• The header has to be removed to gain access to
the inside of the tubes
• Small thermal expansions and this limits the
operating temperature and pressure

• Allow access the tubes without disturbing the

pipeline
• Difficult to maintain and replace (the header
and tube sheet are an integral part of the shell)
Rear header types

• Allows access to the inside of the tubes for

cleaning and also allows the bundle to be
removed for cleaning
• Large bundle to shell clearances required in
order to pull the bundle
• For low pressure nonhazardous fluids (the shell
side fluid may leak via the packing rings). Design
gauge pressure is up to 41.4 , temperature
is 316℃
• Small thermal expansions, not low cost design
Rear header types

• Allow the bundle to be removed

• Unlimited thermal expansion
• Smaller shell to bundle clearances than the
other floating head types. Difficult to dismantle
for bundle pulling and the shell diameter and
bundle to shell clearances are larger than for
fixed head type exchangers
• Most expensive
Rear header types

• Cheaper and easier to remove the bundle than

with the S type
• Unlimited thermal expansion
• Largest bundle to shell clearance
• More expensive than fixed header and U–tube
types
Rear header types
• The simplest design, unlimited thermal
expansion, not pure counter flow unless an F
type shell is used, limited to even numbers of
tube passes
• Allows the bundle to be removed to clean the
outside of the tubes, the tightest bundle to shell
clearances
• Design pressure is up to 64 , temperature is
450℃
• Cheapest of all removable bundle designs, but
slightly more expensive than a fixed tube sheet
design at low pressures
Rear header types
• Unlimited thermal expansion, allows the tube
bundle to be removed for cleaning
• The large bundle to shell clearances required to
pull the bundle, the shell and tube side fluids
can mixed if leakage occurs
• Limitation to low pressure nonhazardous fluids
(both the fluids may leak via the packing rings).
Design gauge pressure below 20.7 for
tube, and 10.3 for shell 24
• Design temperature below 191℃
• Cheapest of the floating head designs
 Construction
1 Stationary Head–Channel 21 Floating Head Cover – External
2 Stationary Head–Bonnet 22 Floating Tubesheet Skirt
3 Stationary Head Flange–Channel or Bonnet 23 Packing Box Flange
4 Channel Cover 24 Packing
5 Stationary Head Nozzle 25 Packing Gland
6 Stationary Tube sheet 26 Lantern Ring
7 Tubes 27 Tie Rods and Spacers
8 Shell 28 Transverse Baffles or Support Plates
9 Shell cover 29 Impingement Plate
10 Shell Flange–Stationary Head End 30 Longitudinal Baffle
11 Shell Flange–Rear Head End 31 Pass Partition
12 Shell Nozzle 32 Vent Connection
13 Shell Cover Flange 33 Drain Connection
14 Expansion Joint 34 Instrument Connection
15 Floating Tubesheet 35 Support Saddle
16 Floating Head Cover 36 Lifting Lug
17 Floating Head Cover Flange 37 Support Bracket
18 Floating Head Backing Device 38 Weir
19 Split Shear Ring 39 Liquid Level Connection
20 Slip-on Backing Flange 40 Floating Head Support
 Construction
• Floating head backing (AES)

36 4 3 34 5 31 6 34 12 29 7 8 27 28 18 36 32

36

15

16

33
17
1 5 34 3 10 35 35 12 34 11 13
 Construction
• Floating head backing (longitudinal baffle)
 Construction
• Packed floating tubesheet & lantern ring (AJW)
 Construction
• Externally sealed floating tubesheet (BEW)
 Construction
• Outside–packed floating head (AEP)
 Construction
• Pull through floating head (BET)
 Construction
Floating head exchangers
Spec Advantages Disadvantages
The tubesheet at the rear header is not welded to
Packing materials produce
the shell, allows to move or float. The tubesheet at
limits on design pressure and
the front header is a larger diameter than the shell
temperature. More expensive
and is sealed in a similar manner to that used in
(typically of order of 25% for
the fixed tubesheet design. The tubesheet at the
carbon steel construction)
rear header end of the shell is of slightly smaller
P, S, T, W than the equivalent fixed
diameter than the shell, allowing the bundle to be
rear header pulled through the shell. tubesheet exchanger.
(S more
Allows differential thermal expansion between the Tubes can not expand
popular)
shell and the tube bundle. Both the tube bundle independently so that huge
and the shell side can be inspected and cleaned thermal sock applications
mechanically should be avoided
A floating head exchanger is suitable for the The floating head cover is bolt
rigorous duties associated with high temperatures to the tube sheet, so it
and pressures requires the use of space.
 Construction
• Fixed tubesheet exchangers (BEM)
 Construction
Fixed tube sheet exchangers
Spec Advantages Disadvantages
The tubesheet is welded to the shell. This
Provides maximum heat transfer area results the shell side and out side of the
for a given shell & tube diameter tubes are inaccessible for mechanical
cleaning
Provides for single and multiple tube No provision to allow for differential
Normally passes to assure proper velocity thermal expansion developed between
use L, M, N the tube and the shell side. This can be
rear header Less costly then removable bundle taken care by providing expansion join on
designs the shell side
Design pressure is up to 40 bars
(below 1000mm diameter), and 25
bars (above 1200mm diameter)
Design temperature is up to 350oC
 Construction
• U–tube exchangers (CFU)
 Construction
• Tank suction heater
 Construction
U–tube exchangers
Spec Advantages Disadvantages
Because of U–bend, some tubes are omitted at the
Allows differential thermal centre of the tube bundle, tubes can be cleaned only
expansion between the shell by chemical methods (difficult for mechanical
and the tube bundle as well cleaning), so tube side fluids should be clean
as for individual tubes
Due to U–nesting, individual tube is difficult to replace
Normally
use M, U Both the tube bundle and Mixed counter and parallel flow
type the shell side can be
inspected and cleaned Tube wall thickness at the U–bend is thinner than at
mechanically straight portion of the tubes
Less costly than floating head
Draining of tube circuit is difficult when positioned
or packed floating head
with the vertical position with the head side upward
designs
 Construction
• Kettle floating head reboiler (AKT)
 Construction
• Kettle floating head reboiler (AKT)
 Construction
• Reboiler with vapor disengagement
 Construction
• Two exchangers in series
 Construction
Internal Outside– Pull–
Packed lantern
Fixed tube floating head packed through
Type of design U–tube ring floating
sheet (split backing floating floating
head
ring) head head
Rear head type L, M, N U W S P T
Relative cost from A
(cheapest) to E (most B A C E D E
expensive)

Provision for differential Expansion Individual tubes free Floating Floating Floating
expansion
Floating head
join in shell to expand head head head
Removable bundle No Yes Yes Yes Yes Yes
Replacement bundle
possible
No Yes Yes Yes Yes Yes

Individual tubes Only those in outside

replaceable
Yes Yes Yes Yes Yes
row
Tube cleaning by
chemicals inside and Yes Yes Yes Yes Yes Yes
outside
Interior tube cleaning
mechanically
Yes Special tools required Yes Yes Yes Yes
 Construction
Internal Outside– Pull–
Packed lantern
Fixed tube floating head packed through
Type of design U–tube ring floating
sheet (split backing floating floating
head
ring) head head

Exterior tube cleaning

mechanically:
Triangular pitch
No No No No No No
Square pitch
No Yes Yes Yes Yes Yes
Hydraulic–jet
cleaning:
Tube interior Yes Special tools required Yes Yes Yes Yes
Tube exterior No Yes Yes Yes Yes Yes
Double tube sheet
Yes Yes No No Yes No
feasible
Number of tube No practical Any even number Limited to one No practical No practical No practical
passes limitations possible or two passes limitations limitations limitations
Internal gaskets
Yes Yes Yes No Yes No
eliminated
 Tubes
• Tube diameter: ÷ 2 (normally ÷ 1). Large tubes are used
for fouling fluids
• Standard tube lengths: 6; 8; 10; 12; 16; 20; 24 . The long tubes
reduce the shell diameter and capital cost (especially high
pressure)
• Liquid velocity in tube
⁄ℎ
⁄ = ×
ℎ
4
=
• Exchanger surface (area) is in terms of total external square feet of
tubes
=
 Tube arrangement
• Triangular

= 1,25 • : bundle outside diameter

• : tube outside diameter
= 0,75 − 36 • : number of tube
• : tube pitch
= −24 ÷ 24
More tubes in a given space

1 : = 1298 + 74,86 + 1,283 − 0,0078 − 0,0006

2 : = 1266 + 73,58 + 1,234 − 0,0071 − 0,0005
4 : = 1196 + 70,79 + 1,180 − 0,0059 − 0,0004
6 : = 1166 + 70,72 + 1,269 − 0,0074 − 0,0006
 Tube arrangement
• Square / Rotated square

= 1,25 • : bundle outside diameter

• : tube outside diameter
= − 36 • : number of tube
• : tube pitch
= −24 ÷ 24
For mechanical cleaning

1 : = 593,6 + 33,52 + 0,3782 − 0,0012 − 0,0001

2 : = 578,8 + 33,36 + 0,3847 − 0,0013 − 0,0001
4 : = 562,0 + 33,04 + 0,3661 − 0,0016 − 0,0002
6 : = 550,4 + 32,49 + 0,3873 − 0,0013 − 0,0001
 Standard tube dimensions
Weight, low carbon
Thickness Internal area External surface Internal surface
steel, 0,2836 lb/in3
(in) (in) (in) (in2) (ft2/ft) (ft2/ft)
(lb/ft)
0,194 0,028 0,0296 0,0654 0,0508 0,066 46
1 0,206 0,022 0,0333 0,0654 0,0539 0,054 52
4 0,214 0,018 0,0360 0,0654 0,0560 0,045 56
0,218 0,016 0,0373 0,0654 0,0571 0,040 58
0,277 0,049 0,0603 0,0982 0,0725 0,171 94
3 0,305 0,035 0,0731 0,0982 0,0798 0,127 114
8 0,319 0,028 0,0799 0,0982 0,0835 0,104 125
0,331 0,022 0,0860 0,0982 0,0867 0,083 134
0,370 0,065 0,1075 0,1309 0,0969 0,302 168
1 0,402 0,049 0,1269 0,1309 0,1052 0,236 198
2 0,430 0,035 0,1452 0,1309 0,1126 0,174 227
0,444 0,028 0,1548 0,1309 0,1162 0,141 241
 Standard tube dimensions
Weight, low carbon
Thickness Internal area External surface Internal surface
steel, 0,2836 lb/in3
(in) (in) (in) (in2) (ft2/ft) (ft2/ft)
(lb/ft)
0,407 0,109 0,1301 0,1636 0,1066 0,601 203
0,435 0,095 0,1486 0,1636 0,1139 0,538 232
0,459 0,083 0,1655 0,1636 0,1202 0,481 258
0,481 0,072 0,1817 0,1636 0,1259 0,426 283
5
0,495 0,065 0,1924 0,1636 0,1296 0,389 300
8
0,509 0,058 0,2035 0,1636 0,1333 0,352 317
0,527 0,049 0,2181 0,1636 0,1380 0,302 340
0,541 0,042 0,2299 0,1636 0,1416 0,262 359
0,555 0,035 0,2419 0,1636 0,1453 0,221 377
 Standard tube dimensions
Weight, low carbon
Thickness Internal area External surface Internal surface
steel, 0,2836 lb/in3
(in) (in) (in) (in2) (ft2/ft) (ft2/ft)
(lb/ft)
0,482 0,134 0,1825 0,1963 0,1262 0,833 285
0,510 0,120 0,2043 0,1963 0,1335 0,808 319
0,532 0,109 0,2223 0,1963 0,1393 0,747 347
0,560 0,095 0,2463 0,1963 0,1466 0,665 384
3 0,584 0,083 0,2679 0,1963 0,1529 0,592 418
4 0,606 0,072 0,2884 0,1963 0,1587 0,522 450
0,620 0,065 0,3019 0,1963 0,1623 0,476 471
0,634 0,058 0,3157 0,1963 0,1660 0,429 492
0,652 0,049 0,3339 0,1963 0,1707 0,367 521
0,680 0,035 0,3632 0,1963 0,1780 0,268 567
 Standard tube dimensions
Weight, low carbon
Thickness Internal area External surface Internal surface
steel, 0,2836 lb/in3
(in) (in) (in) (in2) (ft2/ft) (ft2/ft)
(lb/ft)
0,607 0,134 0,2894 0,2291 0,1589 1,062 451
0,635 0,120 0,3167 0,2291 0,1662 0,969 494
0,657 0,109 0,3390 0,2291 0,1720 0,893 529
0,685 0,095 0,3685 0,2291 0,1793 0,792 575
7 0,709 0,083 0,3948 0,2291 0,1856 0,703 616
8 0,731 0,072 0,4197 0,2291 0,1914 0,618 655
0,745 0,065 0,4359 0,2291 0,1950 0,563 680
0,759 0,058 0,4525 0,2291 0,1987 0,507 706
0,777 0,049 0,4742 0,2291 0,2034 0,433 740
0,805 0,035 0,5090 0,2291 0,2107 0,314 794
 Standard tube dimensions
Weight, low carbon
Thickness Internal area External surface Internal surface
steel, 0,2836 lb/in3
(in) (in) (in) (in2) (ft2/ft) (ft2/ft)
(lb/ft)
0,670 0,165 0,3526 0,2618 0,1754 1,473 550
0,732 0,134 0,4208 0,2618 0,1916 1,241 656
0,760 0,120 0,4536 0,2618 0,1990 1,129 708
0,782 0,109 0,4803 0,2618 0,2047 1,038 749
0,810 0,095 0,5153 0,2618 0,2121 0,919 804
1
0,834 0,083 0,5463 0,2618 0,2183 0,814 852
0,856 0,072 0,5755 0,2618 0,2241 0,714 898
0,870 0,065 0,5945 0,2618 0,2278 0,650 927
0,902 0,049 0,6390 0,2618 0,2361 0,498 997
0,930 0,035 0,6793 0,2618 0,2435 0,361 1060
 Standard tube dimensions
Weight, low carbon
Thickness Internal area External surface Internal surface
steel, 0,2836 lb/in3
(in) (in) (in) (in2) (ft2/ft) (ft2/ft)
(lb/ft)
0,890 0,180 0,6221 0,3272 0,2330 2,059 970
0,920 0,165 0,6648 0,3272 0,2409 1,914 1037
0,982 0,134 0,7574 0,3272 0,2571 1,599 1182
1,010 0,120 0,8012 0,3272 0,2644 1,450 1250
1,032 0,109 0,8365 0,3272 0,2702 1,330 1305
1
1,060 0,095 0,8825 0,3272 0,2775 1,173 1377
1,084 0,083 0,9229 0,3272 0,2838 1,036 1440
1,120 0,065 0,9852 0,3272 0,2932 0,824 1537
1,152 0,049 1,0423 0,3272 0,3016 0,629 1626
1,180 0,035 1,0936 0,3272 0,3089 0,455 1706
 Standard tube dimensions
Weight, low carbon
Thickness Internal area External surface Internal surface
steel, 0,2836 lb/in3
(in) (in) (in) (in2) (ft2/ft) (ft2/ft)
(lb/ft)
1,232 0,134 1,1921 0,3927 0,3225 1,957 1860
1,282 0,109 1,2908 0,3927 0,3356 1,621 2014
1
1,334 0,083 1,3977 0,3927 0,3492 1,257 2180
1,370 0,065 1,4741 0,3927 0,3587 0,997 2300
1,760 0,120 2,4328 0,5236 0,4608 2,412 3795
1,782 0,109 2,4941 0,5236 0,4665 2,204 3891
2
1,810 0,095 2,5730 0,5236 0,4739 1,935 4014
1,834 0,083 2,6417 0,5236 0,4801 1,701 4121
 Finned tube
• Height at 11 ⁄ , or

• Height (from outside diameter) at 19 ⁄

• Height inch at 28 ⁄
 Tubesheet

(mm) 16 20 25 38 57
Tubesheet thickness (mm) 21 26 32 48 70
Tube – tubesheet joint

Grooved Grooved and flared

Weld
Tube bundle
Tube bundle
 Shells

• Shell diameter: = 6 ÷ 20 (normally  24)

Minimum thickness Shell diameter

Material < 500 600 800 > 1000
Carbon steel 5 6 6 6
Alloy 3 4 4 6
Shells
 Nozzles & Impingements
Limitation of fluid velocity in nozzle ⁄

9000
Shell side nozzles <

2230
Tube side nozzles, noncorrosive and nonabrasive single phase fluids <

740
Tube side nozzles, other fluids <

• Impingement protection is required for gases, vapor,

two phases mixtures, corrosive or abrasive
 Expansion joint

Flat plates Flanged only heads Flared shell or Formed heads Toroidal
pipe segments

Bellows with reinforcing High pressure

Flanged & flued heads Bellows rings & insulation cover toroidal bellows
 Expansion joint

Toroidal Bellows

Bellows with reinforcing rings & insulation cover Flanged & flued heads
 Baffles
• Baffles installation heat transfer, fluid dynamics, vibration
• Baffles spacing is generally 0.2 ÷ 0.4

Single segmental Single segmental Single segmental

(horizontal) (vertical) (rotated)

Double segmental (low shell side velocity & pressure drop)

 Baffles

Disc and doughnut

Triple segmental
 Baffles

Helical

Longitudinal
 Baffles

Tie rod and baffles

Baffles
 Tube passes

1 tube pass 2 tube passes

 Tube passes
1 1 +
2 3 2 3 +
5 4 5 4 +
6 6

Front Rear

6 tube pass
Tube passes
Tube passes
 Shell passes

1 shell pass 2 shell passes 3 shell passes

Shell passes
 Flow arrangement

Cocurrent Counter current

1−2
2−4

1 − 1 Cross flow
1 − 2 Cross flow
GENERAL DESIGN CONSIDERATIONS
Objective: To design a shell-and-tube exchanger to
perform heat transfer from a hot stream to a cold
stream.
Specifications: Given stream physical properties,
mass flow rate, process stream source and target
temperatures, and the mass flow rate and source
temperature of the duty stream.
The mechanical design of a shell-and-tube heat
exchanger involves two main steps:
1. Computation of the heat duty
2. Shell and tube configuration
GENERAL DESIGN CONSIDERATIONS
Pressure drop
GENERAL DESIGN CONSIDERATIONS
Computation of shell-and-tube exchangers involves
iteration, since the heat transfer coefficients, pressure
drops and heat transfer area all depend on the design’s
geometric configuration, which needs to be determined.
The geometric configuration (to be determined) includes
the following:
1. Shell diameter
2. Tube diameter
3. Tube length
4. Tube packing configuration (pitch) and spacing
5. Number of tube and shell passes
Design procedure for a double-tube heat exchanger
We assume that all the process conditions previously
explained are completely defined. This means that we know
the flow rates, inlet and outlet temperatures, allowable
pressure drops in both streams, and fouling resistances.
1. Selection of Tube Diameter.
2. Calculation of the Film Coefficients.
3. Calculation of the Overall Heat Transfer Coefficient.
4. Calculation of the LMTD.
5. Calculation of the Heat Transfer Area.
6. Calculation of the Total Tube Length and Number of
Tubes.
7. Calculation of the Pressure Drop.
8. Changes to the Original Design.
 Design procedure
Decide number of shell
Assume overall coefficient
and tube passes.
and pressure drops ∆
Calculate ∆ and

Set = − Estimate pressure drops of

≤ 30% tube and shell sides, ∆
Determine heat transfer
area required,
∆ ≤∆
Decide type, tube side, Calculate overall coefficient
material layout, assign including fouling factors,
fluid to shell and tube

Yes
Cost estimation
Decide baffle spacing and
Determine number of estimate heat transfer
tubes, shell diameter coefficient of shell side, ℎ Optimization
or not?
Determine fluid velocity Estimate heat transfer
and check coefficient of tube side, ℎ Final design
Temperature for fluid properties
For hot stream: ≥ ∆ = −
For cold stream: ≤ ∆ = −
∆ ∆
Log mean temperature difference: ∆ = ∆
∆

̅= +
• ∆ >∆
= ̅+∆
̅= −∆
• ∆ <∆
= +
̅= +
• ∆ =∆ = +
∆ =∆ =∆
Heat transfer coefficient of tube side
• Single phase:

. .
≤ 2100 = 1.86

.
. .
> 2100 = 0.023 1+
Heat transfer coefficient of tube side
• Condensation:
⁄
−
ℎ = 0.76

stratified flow
1+
. .
= 0.021
2
annular flow : gravitational acceleration 9.81 ⁄
: condensate thermal conductivity, ⁄ ℃
: condensate density, ⁄
: vapor density, ⁄
: condensate dynamic viscosity, ⁄
: tube loading (condensate flow per unit length of tube), ⁄
Heat transfer coefficient of shell side
• Single phase:
.
. ⁄ .
= 0.4 + 0.06

= 0.25 ÷ 5.2
= 0.67 ÷ 300
= 40 ÷ 10

1+
• Condensation: = 0.021 . .
2
 Heat transfer coefficient
• Boiling ℎ= ℎ + ℎ
ℎ . .
= = 0.019

1−
=

ℎ : heat transfer coefficient by convaction, ⁄ ℃

: characteristic dimension,
: liquid velocity, ⁄
: liquid density, ⁄
: mass fraction of vapor
: liquid dynamic viscosity, ⁄
: liquid thermal conductivity, ⁄ ℃
 Heat transfer coefficient
• Boiling ℎ= ℎ + ℎ

= :
. . .
0.00122 . .
ℎ = . . . . − −

ℎ : heat transfer coefficient by boiling, ⁄ ℃ : latent heat, ⁄

: liquid thermal conductivity, ⁄ ℃ : surface tension, ⁄
: liquid density, ⁄ : wall temperature,℃
: vapor density, ⁄ : saturation temperature of liquid,℃
: liquid dynamic viscosity, ⁄ : saturation pressure relative to , ⁄
: liquid heat capacity, ⁄ ℃ : saturation pressure relative to , ⁄
 Heat transfer coefficient
• Boiling ℎ= ℎ + ℎ

= :
. .
. .
ℎ = 0.104 1.8 +4 + 10

ℎ: heat transfer coefficient, ⁄ ℃

: operating pressure,
: liquid critical pressure,
=ℎ − : heat flux, ⁄
 Heat transfer coefficient
100
8
6
5
4
3

10
8
6
5
4
3
. . .
2

1−
1
0.1 2 3 4 5 6 8 1 2 3 4 5 6 8 10 2 3 4 5 6 8 100
 Heat transfer coefficient
1.0

0.9

0.8

0.7

0.6

0.5

0.4

0.3

0.2

0.1

1
10 2 3 4 5 6 7 8 9 10 2 3 4 5 6 7 8 9 10
.
 Overall heat transfer coefficient
• For cleaning:
∆
=
1 1 1
+ ln +
ℎ 2 ℎ

1
= =
∆ 1 1
+ ln +
ℎ 2 ℎ

1
≅
1 1
+
ℎ ℎ
 Overall heat transfer coefficient
• For dirty:
1
= =
∆ 1 1
+ + ln + +
ℎ 2 ℎ

1
≅
1 1
+ + +
ℎ ℎ
 Pressure drop
Fluids Pressure drop, ∆

Low viscosity liquids <1 0.35

High viscosity liquids = 1 ÷ 10 0.5 ÷ 0.7

Gas / Vapor

High vacuum 0.004

Medium vacuum 10% system absolute pressure

1÷2 50% system gauge pressure

Above 10 10% system gauge pressure

 Pressure drop of tube side
.
Darcy equation ∆ =
145 × 10

2
“return loss” ∆ =

∆ = ∆ + ∆ : pressure drop of tube side

∆ : pressure drop in tube side
∆ : return loss (lost due to direction change)
: friction factor ⁄
: specific gravity
: density of fluid in tube ⁄
: tube velocity ⁄
: gravity acceleration 32.174 ⁄
: tube length
: number of tube passes
: tube inner diameter
 Pressure drop of tube side
⁄
Friction factor,

Reynolds number,
 Pressure drop of shell side
.
+1
Darcy equation ∆ =
145 × 10

= = 12 −
= ; triangular

4 −
− = ; square
= = −1
∆ : pressure drop of shell side : number of baffles
: friction factor ⁄ : baffle spacing
: specific gravity : cross section area of shell
: density of fluid in shell ⁄ : shell inner diameter
: shell velocity ⁄ : equivalent diameter of shell
: tube outer diameter
: tube pitch
 Pressure drop of shell side
⁄
Friction factor,

Reynolds number,
 Example of heat exchanger design
Design a shell and tube heat exchanger to preheat a stream of
30 ⁄ℎ containing ethylbenzene and styrene from 10℃ to 97℃ by
saturated steam at 0.7 . Maximum pressure drop is 0.8 .
Stream properties:
Density: 856 ⁄
Viscosity: 0.4765
Specific heat: 0.428 ⁄ ℃
Thermal conductivity: 0.133 ⁄ℎ ℃
Process fouling: 0.0002 ℎ ℃⁄
Steam fouling: 0.0001 ℎ ℃⁄
 Example of heat exchanger design
1. Fluid properties
Parameter Symbol Units Cold stream Hot stream
Fluid EB / Styrene Steam
Mass flow ⁄ℎ 30000 2111
Inlet temp. ℃ 10 115
Outlet temp. ℃ 97 115
Density ⁄ 856 0.97
Viscosity 0.4765 0.01262
Specific heat / Latent heat ⁄ ⁄ ℃ 1.792 2215.75
Thermal conductivity ⁄ ℃ 0.1546 0.02685
Fouling factor ℎ ⁄ 0.0002 0.0001

“Energy balance” = ∆ =
 Example of heat exchanger design
2. Configuration definition
Parameter Symbol Units Tube side Shell side
Fluid arrangement EB / Styrene Steam
Number of passes ⁄ 4 1
Correction factor 1 (phase change)
Overall heat transfer ⁄ ℃ 170 ÷ 340
105 − 18
Log mean temperature ∆ ℃ ∆ = = 49.33
105
ln 18

Heat duty = ∆ = = 1299

Total area = = 78 ÷ 155

∆
 Example of heat exchanger design
3. Tube selection (triangular arrangement)

Parameter Symbol Units Tube side

Outer diameter 0.0254

Inner diameter 0.0198

Tube pitch 0.03175

Tube velocity ⁄ 1.4

 Example of heat exchanger design
3. Tube selection (triangular arrangement)
Parameter Symbol Units Tube side
1
Cross section area = 3.08 × 10
4
Flow rate per tube = ⁄ 4.31 × 10

No. tubes per pass = 23

Total number of tubes = 92

Tube length = 10.6 ÷ 21.1

+ 36
=
Shell inner diameter 0.75 0.363
=

For 4 tube passes: = 1196 + 70.79 + 1.180 − 0.0059 − 0.0004

 Example of heat exchanger design
4. Heat transfer coefficient calculation
Parameter Symbol Units Tube side Shell side
Reynold number 63881
Prandtl number 5.523
Nusselt number 282.8
Coefficient ℎ ⁄ ℃ 2208.3 Let’s say 8517.4
Overall coefficient ⁄ ℃ 948

1
=
1 1
+ + +
ℎ ℎ
 Example of heat exchanger design
5. Pressure drop calculation

Parameter Symbol Units Tube side

Reynold number 63881

Friction factor ⁄ 0.003

Pressure drop in tube ∆ 0.03

Return loss ∆ 5.24

Pressure drop ∆ 0.363

.
2
∆ = +
145 × 10
∆ ∆
 Example of heat exchanger design
5. Pressure drop calculation
Parameter Symbol Units Shell side
Baffle spacing 0.363

Number of baffles = −1 29

−
Cross section area = 0.0263

12 −
Equivalent diameter = 0.0183

Shell velocity = ⁄ 22.9

 Example of heat exchanger design
5. Pressure drop calculation

Parameter Symbol Units Shell side

Reynold number 32411

Friction factor ⁄ 0.025

Pressure drop ∆ 0.002

.
+1
∆ =
145 × 10
Example of heat exchanger design
Summary

Total area = ; ;
Tube length = ; ; ; ;

Shell diameter = ; ; ;

Heat coefficient of tube ℎ = ;

Heat coefficient of shell ℎ = ; ; ; ; ;

Pressure drop of tube ∆ = ; ; ; ;
Pressure drop of shell ∆ = ; ; ; ; ; ;
 Data of heat exchanger design
; ;

ℎ ℎ ∆ ∆

;
 Computer programs

• Heat Transfer and Fluid Flow Service (HTFS)

• Heat Transfer Research Incorporated (HTRI)
Mechanical design
 Codes and Standards
• Boiler and Pressure Vessel Code (ASME)
Section VIII: Confined Pressure Vessles
Section II: Materials
Section V: Non Destructive Testing
• British Master Pressure Vessel Standard (BS 5500)
 Data collection
• Design pressure and temperature

= + 1.72
= + 14℃
 Tube bundle vibration
• High flow rate and pressure drop
• Avoid the cross flow
• Promote longitudinal flow
 Testing
• American Institute of Chemical Engineers’
Standard Testing Procedure for Heat Exchanger
DESIGN CONSIDERATIONS
Heat transfer

Pressure drop

Physical size

Cost
 Example 1
Water at the rate of 68 ⁄ is heated from
68℃ to 75℃ by an oil having a specific heat of
1.9 ⁄ ℃. The fluids are used in a counterflow
double pipe heat exchanger, and the oil enters
the exchanger at 110℃ and leaves at 75℃. The
overall heat transfer coefficient is 320 ⁄ ℃.
Calculate the heat exchanger area
 Example 2
Instead of the double pipe heat exchanger of
Example 1, it is desired to use a shell–and–tube
exchanger with the water making one shell pass
and the oil making two tube passes. Calculate the
area required for this exchanger, assuming that
the overall heat transfer coefficient remains at
320 ⁄ ℃
 Example 3
Water at the rate of 30000 ⁄ℎ is heated from
100℉ to 130℉ in a shell–and–tube heat exchanger.
On the shell side one pass is used with water as the
heating fluid, 15000 ⁄ℎ entering the exchanger
at 200℉ . The overall heat transfer coefficient is
250 ⁄ℎ ℉, and the average water velocity in
the diameter tubes is 1.2 ⁄ . Because of space
limitations, the tube length must not be longer than
8 . Calculate the number of tube passes, the
number of tubes per pass, and the length of tubes,
consistent with this restriction
 Example 4
A heat exchanger like that shown
as Figure is used to heat an oil in
the tubes c = 1.9 ⁄ ℃ from
15℃ to 85℃. Blowing across the
outside of the tubes is steam that Gas flow

enters at 130℃ and leaves at

110℃ with a mass flow of
5.2 ⁄ . The overall heat
transfer coefficient is
275 ⁄ ℃ and for steam is
1.86 ⁄ ℃ . Calculate the
surface area of the heat
exchanger
 Example 5
Investigate the heat transfer performance of the
exchanger in Example 4 if the oil flow rate is
reduced in half while the steam flow remains the
same. Assume remains constant at 275 ⁄ ℃.
 Example 6
Complete the Example 5 using the effectiveness
method.
 Example 7
The heat exchanger of Example 1 is used for heating
water as described in the example. Using the same
entering–fluid temperatures, calculate the exit
water temperature when only 40 ⁄ of water
is heated but the same quantity of oil is used. Also
calculate the total heat transfer under these new
conditions.
Example 8
 CHAPTER
SHELL TUBE HEAT
7
EXCHANGERS