Demonstration (Design calculations and step by

step solution procedure of heat exchangers)

October 6, 2021

Introduction of design calculations and

step by step solution procedure of heat
exchangers

Raj Saini

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Email : raj.km.saini@gmail.com
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Contents

1 Introduction 1
1.1 Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Solution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Shell - tube heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3.1 Coefficient of tube side (brackish water flowing) . . . . . . . . . . . . 3
1.3.2 Coefficient of Shell side . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3.3 Overall heat transfer coefficient (U) . . . . . . . . . . . . . . . . . . . 5
1.4 Useful graphs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4.1 Fouling factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4.2 Shell bundle clearance . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4.3 Over all heat transfer coefficient for different fluids (U ) . . . . . . . . . 6
1.4.4 Temperature correction factor (Ft ) for one-shell and two or more-even
tubes passes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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1.4.5 Temperature correction factor (Ft ) for split-flow-shell and two-tubes
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1.4.6 Temperature correction factor (Ft ) for divided-shell and two or more
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even-tubes passes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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1.4.7 Tube side friction factor (jf ) . . . . . . . . . . . . . . . . . . . . . . . 7

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1.4.8 Tube side heat transfer factor (jh ) . . . . . . . . . . . . . . . . . . . . 8

1.4.9 Shell side friction factor (jf ) . . . . . . . . . . . . . . . . . . . . . . . 8
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1.4.10 shell side heat transfer factor (jh ) . . . . . . . . . . . . . . . . . . . . 8

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1 Introduction
The purpose of this case demostration is to learn/explore for new users and to understand the
design calculations of heat exchangers [1, 2, 3, 4]. In this report, we will see the step by step
solution of a problem (i.e. demonstration purpose only).

1.1 Problem
Design a heat exchanger to sub-col condensate from a methanol condenser from 95 0 C to 40
0
C. Flow rate of methanol 100, 000 kg/h (cp = 2.84 kJ/kg 0 C). Brackish water (cp = 4.2
kJ/kg 0 C) will be used as the coolant with temperature rise from 25 0 C to 40 0 C .
[Note: please refer to the useful graph section if you need any data. ]
We choose 1-2 shell-tube heat exchanger (fig.)

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1.2 Solution
Given data: The temperatures of hot fluid-1 (methanol) and cold fluid-2 (brakish water) are
given Thi = 95 0 C ,Th0 = 40 0 C , Tci = 25 0 C and Tco = 40 0 C Flow rate of methanol=
100, 000 kg/h and (cp = 2.84 kJ/kg 0 C) and temp. 95 0 C to 40 0 C
Brackish water (cp = 4.2 kJ/kg 0 C) and tem 25 0 C to 40 0 C

• By definition of heat balance equation for methanol,q = ṁcp 4T = 4340 kW

• With the help of q, we can find out mass flow rate of water,ṁwater = 68.9 kg/s

• By definition of Two dimensional ratios, find out R or Z and S

Thi − Tho
R= = 3.67
Tco − Tci

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 Tco − Tci
S= = 0.21
Thi − Tci
• With the help of Temperature correction factor graph fig.12.19 (ppt), we can find out Ft

Ft ≈ 0.85

• By definition of Log mean temperature 4Tlm (ref-class notes)

(4T1 − 4T2 )
4Tlm =
ln[ 4T1
4T2
]
In this geometry , 4T1 = Thi − Tco and 4T2 = Tho − Tci

(Thi − Tco ) − (Tho − Tci )

4Tlm = hi −Tco
= 310 C
ln[ TTho −Tci
]

• The heat equation for the heat exchanger (Calculation based on outer tube diameter, d0 =
20 mm)

q = Uo Ao 4Tm

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• Mean difference temperature by 4Tm = Ft 4Tln = 26 0 C R
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• Ref-ppt (methanol): U0 = 600 W/m2 .K
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q
= 278, m2
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A0 =
U0 4Tm
AT

This area is for the find out number of tubes in use the exchanger. If, we will assume only
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one tube for this area, then will get a large diameter of tube which is not possible physically .
Then we have to assume multi tubes used in heat exchanger design.
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• We can assume the tube has inner dia ID=16 mm , outer dia OD=20 mm and length
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L = 6 m [material (cupro-nickel)]
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• Area of one tube a = πd0 L = 0.303 m2

• Required area Ai = 278,m2 ,

Ai
• Number of tubes we can find : Nt = a
= 918

• Estimate the bundle diameter (Triangular and squre pitch)

Nt n1
Db = d0 ( ) 1 = 826, mm
K1
Where, do −outer diameter of tube, Nt - Number of tubes, K1 = 0.249 and n1 = 2.207 are
the constants

• The shell diameter

Ds = Db + bundle − clearance

• Ref-Useful graph section, Find out bundle − clearance = 68, mm , shell diameter

Ds = 894, mm

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1.3 Shell - tube heat exchanger
1.3.1 Coefficient of tube side (brackish water flowing)
• Mean temperature of water in side the tube =30 0 C and inner dia of tube , di =16 mm

• Cross section area of one tube, 41 πd2i =201 × 10−6 m2

• In shell , there is two passes of tubes Np = 2 , Tube per pass 918/2 = 459

• Total flow area in one pass, At = T ube − per − pass × area − of − one − tube = 0.092
m2
ṁwater
• Mass flux of rate or ( water mass velocity),nwater = At
= 749 kg/m2 − s
nwater
• Water linear velocity , uwater = ρwater
= 0.75 m/s

• Density of water at 30 0 C , ρwater =995 kg/m3 , µwater = 0.8 m Pa-s and kf = 0.59
W/m −0 C

– Using the emperical corelation (Ref-any book)

hi di µ

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= jh Re P r0.33 ( )0.14

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kf µf
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where, hi - heat transfer coefficient W/m20 C , µ- viscosity , P a − s , kf − conductivity,
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W/m −0 C and di −dia. of tube mm. ( µµf ) -it can be neglecting

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AT

– L
di
ratio , Ref-ppt, jh = 3.9 × 10−3
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nwater d
– Re = = 14925
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µ
cp µ
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– Pr = kf
= 5.7
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– Heat transfer coiffecient, hi = 3812 W/m20 C

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– Pressure drop , 4P
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L µ ρu2
4Ptube = Np [8jf ( )( )−m + 2.5] water
di µf 2
where, Np -number of tubes passes, L−length of tube, m
– from fig.12.24, jf = 4.3 × 10−3
– Substitutting all values , we can get 4Ptube = 7211 Pa or 7.2 kPa

1.3.2 Coefficient of Shell side

• Pitch is a distance between two tubes, and the recommended tube pitch is 1.25 times of
outer diameter of tube.

pt = 1.25 × d0

pt = 25, mm

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 – Baffle spacing Baffle

Ds
wbaf f le−space =
number − of − shell − partitions
– we assumed number of shell partition=5
– Baffle spacing , wbaf f le−space = 178 mm
– Cross flow area of shell
(pt − ODtube )
As = Ds wbaf f le−space = 0.032, m2
pt
mass−f low−rate−in−shell
– flux rate or( methanol mass velocity),nmethanol = Cross−section−f low−area−shell
=
ṁmathanol
As
= 868 kg/m2 − s
– Equivalent diameter

1.1 2
de = (pt − 0.917d2o ) = 14.4, mm
d0
– Mean temperature of water in side the tube =68 0 C
nmethanol
– Methanol linear velocity, shell side , umethanol = = 1.16 m/s

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ρmethanol

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– Density of water at 68 0 C , ρmethanol =750 kg/m3 , µmethanol = 0.34 m Pa-s and
kf = 0.19 W/m −0 C
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nmethanol de
– Re = = 36762
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µ
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cp µ
– Pr = = 5.1
AT

kf

– From empirical correlation (Ref-any book):

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hs de µ
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= jh Re P r0.33 ( )0.14
kf µf
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– We choose 25 % baffle -cut (ref-ppt) , jh = 3.3 × 10−3

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– Substituting all values, heat transfer coefficient, hs = 2740 W/m20 C

– Pressure drop , 4P

L µ ρu2
4Pshell = [8jf ( )( )−m ] methanol
di µf 2
– from fig.12.30, jf = 4.3 × 10−3
– Substituting all values , we can get 4Pshell = 272000 Pa or 272 kPa

[ Write a comment on this pressure drop (4Pshell ) is sutabile or not.]

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1.3.3 Overall heat transfer coefficient (U)
• Thermal conductivity of tube material, ktube−material = 50 W/m0 C

– Fouling coefficients for both fluids

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* Methanol, hf −methaol = 5000 W/m C
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* Brackish water, hf −brackish−water = 3000 W/m C
– We know that expression for overall heat transfer coefficient (U)

1 1 1 ln( dd0i ) d0 1 d0 1 d0
= + + ( )+ ( )+ ( )
U hs hf −methaol ktube−material 2 hi di hf −brackish−water di

– After substituting all values, U = 738 W/m20 C

– Initially we assumed U = 600 W/m20 C , the calculated value is more of U = 738
W/m20 C

[ This is one design and there could be many other design]

Shel-tube heat exchanger picture (physical appearance)

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1.4 Useful graphs

1.4.1 Fouling factors

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1.4.2 Shell bundle clearance

1.4.3 Over all heat transfer coefficient for different fluids (U )

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1.4.4 Temperature correction factor (Ft ) for one-shell and two or more-
even tubes passes

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1.4.5 Temperature correction factor (Ft ) for split-flow-shell and two-tubes
passes

1.4.6 Temperature correction factor (Ft ) for divided-shell and two or more
even-tubes passes

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1.4.7 Tube side friction factor (jf )

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1.4.8 Tube side heat transfer factor (jh )

1.4.9 Shell side friction factor (jf )

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1.4.10 shell side heat transfer factor (jh )

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References
1. M. Darwish, F. Moukalled, A unified formulation of the segregated class of algorithms for
fluid flow at all speeds. Numerical Heat Transfer: Part B: Fundamentals, 2000.

2. P. J. P. Robert W. Fox, Alan T. McDonald, Introduction to Fluid Mechanics (8th ed), 8th ed.,
2011.

3. J. B. B. Rao and V. R. Raju, “Numerical and heat transfer analysis of shell and tube
heat exchanger with circular and elliptical tubes,” International Journal of Mechanical and
Materials Engineering, vol. 11, no. 1, p. 6, 2016.

4. N. Afsar and M. I. Inam, “Cfd analysis of shell and tube heat exchanger with different baffle
orientation and baffle cut,” AIP Conference Proceedings, vol. 1980, no. 1, p. 050006, 2018.

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