Course Notes on

Shell and tube Type Heat Exchangers

Prepared By

N S Thatte

Asian Academy Of Professional Training Pune

General Arrangement(s) in Shell and Tube Heat Exchanger(s)

External Appearance

2|5
 Various Parts of Shell and Tube Heat Exchanger

Typical Flow Patterns: Shell Side and Tube Side

Shell Passes Shell Passes

3|5
Typical U Tube Bundle Arrangement

Front End opened View

4|5
Front End

Rear End
Multiple Passes

5|5
 Course Notes on
Shell and tube Type Heat Exchangers

Part 2

Tables, Nomograms, Design Procedure

And
Illustrative Examples

Prepared By

N S Thatte

Asian Academy Of Professional Training Pune

1|42
 Table 1 Tube Sheet Tube Hole Count (Ref Perry’s Handbook, Ed 6)

Table 1 (a) 5/8 in OD tube on 13/16 in square pitch

Shell ID TEMA P or S TEMA U

Number of passes Number of passes
mm in 1 2 4 6 2 4 6
203 8 55 48 34 24 52 40 32
254 10 88 78 62 56 90 80 74
305 12 140 138 112 100 140 128 108
337 13 ¼ 178 172 146 136 180 164 148
387 15 ¼ 245 232 208 192 246 232 216
438 17 ¼ 320 308 274 260 330 312 292
489 19 ¼ 405 392 352 336 420 388 368
540 21 ¼ 502 484 442 424 510 488 460
591 23 ¼ 610 584 536 508 626 596 562
635 25 700 676 618 600 728 692 644
686 27 843 812 742 716 856 816 780
737 29 970 942 868 840 998 956 920
787 31 1127 1096 1014 984 1148 1108 1060
838 33 1288 1250 1172 1148 1318 1268 1222
889 35 1479 1438 1330 1308 1492 1436 1388
940 37 1647 1604 1520 1480 1684 1620 1568
991 39 1840 1794 1700 1664 1882 1816 1754
1067 42 2157 2112 2004 1968 2196 2136 2068
1143 45 2511 2458 2326 2288 2530 2464 2402
1219 48 2865 2808 2686 2656 2908 2832 2764
1372 54 3656 3600 3462 3404 3712 3624 3556
1524 60 4538 4472 4310 4256 4608 4508 4426

Table 1 (b) 3/4 in OD tubes on 15/16 – in triangular pitch

Shell ID TEMA L or M TEMA P or S TEMA U

Number of passes Number of passes Number of passes
mm in 1 2 4 6 1 2 4 6 2 4 6
114 4.5 14 14 - - - - - - - - -
152 6 30 30 24 22 - - - - - - -
203 8 64 48 34 24 34 32 16 18 32 24 24
254 10 85 72 52 50 60 62 52 44 64 52 52

2|42
 Tube Sheet Tube Hole Count (Contd.)

Table 1 (b) (Contd) 3/4 in OD tubes on 15/16 – in triangular pitch

Shell ID TEMA L or M TEMA P or S TEMA U

Number of passes Number of passes Number of passes

mm in 1 2 4 6 1 2 4 6 2 4 6
305 12 122 114 94 96 109 98 78 68 98 88 78
337 13 ¼ 151 142 124 112 126 120 106 100 126 116 108
387 15 ¼ 204 192 166 168 183 168 146 136 180 160 148
438 17 ¼ 264 254 228 220 237 228 202 192 328 224 204
489 19 ¼ 332 326 290 280 297 286 258 248 298 280 262
540 21 ¼ 417 396 364 348 372 356 324 316 370 352 334
591 23 ¼ 495 478 430 420 450 430 392 376 456 428 408
635 25 579 554 512 488 518 498 456 444 534 500 474
686 27 676 648 602 584 618 602 548 532 628 600 570
737 29 785 762 704 688 729 708 650 624 736 696 668
787 31 909 878 814 792 843 812 744 732 846 812 780
838 33 1035 1002 944 920 962 934 868 840 978 928 904
889 35 1164 1132 1062 1036 1090 1064 990 972 1100 1060 1008
940 37 1304 1270 1200 1168 1233 1196 1132 1100 1238 1200 1152
991 39 1460 1422 1338 1320 1365 1346 1266 1244 1390 1336 1290
1067 42 1703 1664 1578 1552 1611 1580 1498 1464 1632 1568 1524
1143 45 1960 1918 1830 1800 1875 1834 1736 1708 1882 1820 1770
1219 48 2242 2196 2106 2060 2132 2100 1998 1964 2152 2092 2044
1372 54 2861 2804 2682 2660 2730 2684 2574 2536 2748 2680 2628
1524 60 3527 3476 3360 3300 3395 3346 3228 3196 3420 3340 3286
1676 66 4292 4228 4088 4044
1829 72 5116 5044 4902 4868
1981 78 6034 5964 5786 5740
2134 84 7005 6934 6766 6680
2286 90 8093 7998 7832 7708
2438 96 9203 9114 8896 8844
2743 108 11696 11618 11336 11268
3048 120 14459 14378 14080 13984

3|42
 Tube Sheet Tube Hole Count (Contd.)

Table 1 (c) 3/4 in OD tubes on 1 in square pitch

Shell ID TEMA P or S TEMA U

Number of passes Number of Passes
mm In 1 2 4 6 2 4 6
152 6 12 12 - - 14 - -
203 8 28 26 16 12 28 24 12
254 10 52 48 44 24 52 44 32
305 12 80 76 66 56 78 72 70
337 13 ¼ 104 90 70 80 96 92 90
387 15 ¼ 136 128 128 114 136 132 120
438 17 ¼ 181 174 154 160 176 176 160
489 19 ¼ 222 220 204 198 224 224 224
540 21 ¼ 289 272 262 260 284 280 274
591 23 ¼ 345 332 310 308 348 336 328
635 25 398 386 366 344 408 392 378
686 27 477 456 432 424 480 468 460
737 29 554 532 510 496 562 548 530
787 31 637 624 588 576 648 636 620
838 33 730 712 682 668 748 728 718
889 35 828 812 780 760 848 820 816
940 37 937 918 882 872 952 932 918
991 39 1048 1028 996 972 1056 1044 1020
1067 42 1224 1200 1170 1140 1244 1224 1212
1143 45 1421 1394 1350 1336 1436 1408 1398
1219 48 1628 1598 1548 1536 1640 1628 1602
1372 54 2096 2048 2010 1992 2108 2084 2068
1524 60 2585 2552 2512 2476 2614 2584 2558

Table 1 (d) 3/4 in OD tubes on 1 in triangular pitch (most popular arrangement)

Shell ID TEMA L or M TEMA P or S TEMA U

Number of passes Number of passes Number of passes
mm in 1 2 4 6 1 2 4 6 2 4 6
114 4.5 14 14 - - - - - - - - -
152 6 26 26 24 22 14 14 - - 14 12 10
203 8 42 40 26 24 31 26 16 12 32 24 24
254 10 73 66 52 44 56 48 42 40 52 48 40

4|42
 Tube Sheet Tube Hole Count (Contd.)

Table 1(d)(Contd) 3/4 in OD tubes on 1 in triangular pitch (most popular arrangement)

Shell ID TEMA L or M TEMA P or S TEMA U

Number of passes Number of passes Number of passes
mm in 1 2 4 6 1 2 4 6 2 4 6
305 12 109 102 88 80 88 78 62 68 84 76 74
337 13 ¼ 136 128 112 102 121 106 94 88 110 100 98
387 15 ¼ 183 172 146 148 159 148 132 132 152 140 136
438 17 ¼ 237 228 208 192 208 198 182 180 206 188 182
489 19 ¼ 295 282 258 248 258 250 228 220 226 248 234
540 21 ¼ 361 346 318 320 320 314 290 276 330 316 296
591 23 ¼ 438 416 382 372 400 384 352 336 400 384 356
635 25 507 486 448 440 450 442 400 392 472 440 424
686 27 592 574 536 516 543 530 488 468 554 528 502
737 29 692 668 632 604 645 618 574 556 648 616 588
787 31 796 774 732 708 741 716 666 648 744 716 688
838 33 909 886 836 812 843 826 760 740 852 816 788
889 35 1023 1002 942 920 950 930 878 856 974 932 908
940 37 1155 1124 1058 1032 1070 1052 992 968 1092 1056 1008
991 39 1277 1254 1194 1164 1209 1184 1122 1096 1224 1180 1146
1067 42 1503 1466 1404 1372 1409 1378 1314 1296 1434 1388 1350
1143 45 1726 1690 1622 1588 1635 1608 1536 1504 1652 1604 1560
1219 48 1964 1936 1870 1828 1887 1842 1768 1740 1894 1844 1794
1372 54 2519 2466 2380 2352 2399 2366 2270 2244 2426 2368 2326
1524 60 3095 3058 2954 2928 2981 2940 2932 2800 3006 2944 2884
1676 66 3769 3722 3618 3576
1829 72 4502 4448 4324 4280
1981 78 5309 5252 5126 5068
2134 84 6162 6108 5954 5900
2286 90 7103 7040 6898 6800
2438 96 8093 8026 7848 7796
2743 108 10260 10206 9992 9940
3048 120 12731 12648 12450 12336

5|42
 Tube Sheet Tube Hole Count (Contd.)

Table 1 (e) 1 in OD tube on 1 ¼ in square pitch

Shell ID TEMA P or S TEMA U

Number of passes Number of passes
mm in 1 2 4 6 2 4 6
203 8 17 12 8 12 14 8 6
254 10 30 30 16 18 30 24 12
305 12 52 48 42 24 44 40 32
337 13 ¼ 61 56 52 50 60 48 44
387 15 ¼ 85 78 62 64 80 72 74
438 17 ¼ 108 108 104 96 104 100 100
489 19 ¼ 144 136 130 114 132 132 120
540 21 ¼ 173 166 154 156 172 168 148
591 23 ¼ 217 208 194 192 212 204 198
635 25 252 240 230 212 244 240 230
686 27 296 280 270 260 290 284 274
737 29 345 336 310 314 340 336 328
787 31 402 390 366 368 400 384 372
838 33 461 452 432 420 456 444 440
889 35 520 514 494 484 518 504 502
940 37 588 572 562 548 584 576 566
991 39 661 640 624 620 664 644 640
1067 42 776 756 738 724 764 748 750
1143 45 900 882 862 844 902 880 862
1219 48 1029 1016 984 972 1028 1008 1004
1372 54 1310 1296 1268 1256 1320 1296 1284
1524 60 1641 1624 1598 1576 1634 1616 1614

Table 1 (f) 1 in OD tube on 1 1/4 in triangular pitch

Shell ID TEMA L or M TEMA P or S TEMA U

Number of passes Number of passes Number of passes
mm in 1 2 4 6 1 2 4 6 2 4 6
203 8 27 26 8 12 18 14 8 12 14 12 6
254 10 42 40 34 24 33 28 16 18 28 24 24
305 12 64 66 52 44 51 48 42 44 52 40 40
337 13 ¼ 81 74 62 56 73 68 52 44 64 56 52
387 15 ¼ 106 106 88 92 93 90 78 76 90 80 78

6|42
 Tube Sheet Tube Hole Count (Contd.)

Table 1 (f) (Contd.) 1 in OD tube on 1 1/4 in triangular pitch

Shell ID TEMA L or M TEMA P or S TEMA U

Number of passes Number of passes Number of passes
mm in 1 2 4 6 1 2 4 6 2 4 6
438 17 ¼ 147 134 124 114 126 122 112 102 122 112 102
489 19 ¼ 183 176 150 152 159 152 132 136 152 140 136
540 21 ¼ 226 220 204 186 202 192 182 172 196 180 176
591 23 ¼ 268 262 236 228 249 238 216 212 242 224 216
635 25 316 302 274 272 291 278 250 240 286 264 246
686 27 375 360 336 324 345 330 298 288 340 320 300
737 29 430 416 390 380 400 388 356 348 400 380 352
787 31 495 482 452 448 459 450 414 400 456 436 414
838 33 579 554 520 504 526 514 584 464 526 504 486
889 35 645 622 586 576 596 584 548 536 596 572 548
940 37 729 712 662 648 672 668 626 608 668 636 614
991 39 808 792 744 732 756 736 704 692 748 728 700
1067 42 947 918 874 868 890 878 834 808 890 856 830
1143 45 1095 1068 1022 1000 1035 1008 966 948 1028 992 972
1219 48 1241 1220 1176 1148 1181 1162 1118 1092 1180 1136 1100
1372 54 1577 1572 1510 1480 1520 1492 1436 1416 1508 1468 1442
1524 60 1964 1940 1882 1832 1884 1858 1800 1764 1886 1840 1794
1676 66 2390 2362 2282 2260
1829 72 2861 2828 2746 2708
1981 78 3368 3324 3236 3216
2134 84 3920 3882 3784 3736
2286 90 4499 4456 4370 4328
2438 96 5144 5104 4986 4936
2743 108 6546 6494 6360 6300
3048 120 8117 8038 7870 7812

3. Prediction Of Shell Diameter: Approximate equations are available in literature to find the shell
diameter or to find the tube bundle diameter. One of such equations3 is given as follows:
1
𝑁 𝑛
𝐷𝑏 = 𝑑𝑜 (𝑘 𝑡 ) 1 ……………………………………………………………………………………………….. (1)
1

Where, 𝐷𝑏 = Tube bundle diameter, mm

𝑑𝑜 = Tube OD, mm

𝑁𝑡 = Total number of tubes

7|42
 Pt tube pitch
k1 and n1 are constants, values of which depend on ratio (= ), arrangement of tubes and
do tube OD
number of tube side passes. Use Tables 2 and 3 for finding constants of Eq. (1)

Table 2 Constants for Eq. (1)

A. For 𝑃𝑡 /𝑑𝑜 = 1.25, Triangular Pitch

No. of tube side passes 1 2 4 6 8

𝑘1 0.319 0.249 0.175 0.0743 0.0365
𝑛1 2.142 2.207 2.285 2.499 2.675

Table 3 Constants for Eq. (1)

B. For 𝑃𝑡 /𝑑𝑜 = 1.25, Square Pitch

No. of tube side passes 1 2 4 6 8

𝑘1 0.215 0.156 0.158 0.0402 0.0331
𝑛1 2.207 2.291 2.263 2.617 2.643

Equation (6.1) can be used for fixed tube sheet type and floating head shell and tube type heat
exchangers. For U-tube exchangers, following equation can be used:
1
𝑁, 𝑛
𝐷𝑏 = 𝑑𝑜 ( 𝑡 ) 1 ……………………………………………………………………………………….. (2)
𝑘1

𝐷𝑏
Where, 𝑁𝑡, = 𝑁𝑡 +
𝑃𝑡

𝑁𝑡 = Number of tube holes on tube sheet

After finding tube bundle diameter 𝐷𝑏′ shell ID (Inside diameter); 𝐷𝑖 can be determined by following
equation:

Where, C = Diametric clearance between shell ID and 𝐷𝑏

C = 10 to 20 mm for fixed tube sheet and U – tube

C = 50 to 80 mm for split- ring floating head

C = 90 to 100 mm for pull through floating head

8|42
 Fig. 1 Nozzle Orientation Designs for Tube Side Passes

Table 4 Typical Overall Coefficients for shell & Tube Heat Exchangers

Shell Side Tube Side U, W/(m2-OC)

[A] Heat Exchanger
1 Water Water 800 – 1400
2 Organic Solvent Water 300 – 850
3 Organic Solvent Brine 200 – 500
4 Light Oil Water 350 – 900
5 Heavy Oil Water 60 – 300
6 Water Brine 600 – 1200
7 Gas Brine 15 – 250
8 Gas Gas 10 – 50
9 Gas Water 20 – 300
10 Naphtha Water 300 – 400
11 Lube Oil Water 150 – 500
12 Gasoline Water 350 – 550
13 Kerosene Water 150 – 300
14 Water 10 - 30% Caustic Soda Solution 500 – 1250

9|42
 Table 4 (Contd.) Typical Overall Coefficients for shell & Tube Heat Exchangers

Shell Side Tube Side U, W/(m2-OC)

[B] Condensers
1 Organic Vapor Water 700 – 1000
2 Organic Vapor + Gas Water or Brine 100 – 300
3 Low Boiling Hydrocarbons Vapor Mixture Water 450 – 1100
4 Naphtha Vapor Water 300 – 425
5 Steam Water 2000 – 5000
6 Alcohol Vapor Water 500 – 1000
7 Saturated Organic Vapor Water 280 – 680
[C] Vaporizers/ Reboilers
1 Light Organics Steam 800 – 1200
2 Heavy Organics Steam 600 – 900
3 Aqueous Solution Steam 1000 – 1500
4 Chlorine Steam 700 – 1500
5 Ammonia Steam 700 – 1500
6 Water Steam 1250 – 2000
7 Refrigerants Water 425 – 850

CLASICAL METHOD OF HEAT TRANSFER AND PRESSURE DROP CALCULATIONS FOR SHELL AND
TUBE HEAT EXCHANGERS

A. Calculations of tube side heat transfer coefficient

1. For heating or cooling on tube side (no phase change), tube side heat transfer coefficient is
determined by Sieder- Tate equation. If Reynolds number; Re is less than 2000.

ℎ 𝑖 𝑑𝑖 𝑑 0.33 𝜇 0.14
𝑁𝑢 = 𝑘𝑓
= 1.86 (𝑅𝑒. 𝑃𝑟. 𝐿𝑖) (𝜇 ) ……………………………………………………………… (3)
𝑤

Where, Nu = Nusselt Number

In this equation

If 𝑁𝑢 ≤ 3.5 then Nu is taken 3.5.

If Re > 4000, tube side heat transfer coefficient is determined by Dittus – Bolter equation:

ℎ 𝑖 𝑑𝑖 𝜇 0.14
𝑁𝑢 = = 𝐶 𝑅𝑒 0.8 𝑃𝑟 0.33 ( ) ………………………………………………………………………….. (4)
𝑘 𝜇𝑤

𝑑 𝑖 𝑢𝑡 𝜌 𝑑𝑖 𝐺𝑡
Re = Reynolds number = =
𝜇 𝜇

𝐶𝑝 𝜇
Pr = Prandtl number =
𝑘

10 | 4 2
ℎ𝑖 = Tube side heat transfer coefficient, 𝑊/(𝑚2 . 𝑜 𝐶)

𝑑𝑖 = Tube ID , m

L = Length of tube , m

K = Thermal conductivity of fluid, 𝑊/(𝑚2 . 𝑜 𝐶)

𝐶𝑝 = Specific heat of fluid, 𝑘𝐽(𝑘𝑔. 𝑜 𝐶)

𝜇 = Viscosity of fluid at the bulk fluid temperature, (𝑁 ∙ 𝑠)/𝑚2 𝑜𝑟 𝑃𝑎 ∙ 𝑠

𝜇𝑤 = Viscosity of fluid at tube wall temperature, (𝑁 ∙ 𝑠)/𝑚2 𝑜𝑟 𝑃𝑎 ∙ 𝑠

C = 0.021 for gases = 0.023 for non – viscous liquid = 0.027 for viscous liquid

𝐺𝑡 = Tubeside mass velocity , 𝑘𝑔 / (𝑚2 ∙ 𝑠)

𝑚̇
=𝑎
𝑡

𝑁𝑡 𝜋
Where, 𝑎𝑡 = Tube side flow area = × 𝑑𝑖2
𝑁𝑝 4

𝑚̇ = Tube side mass flow rate of fluid, kg/s

𝑁𝑡 = Number of tubes

𝑁𝑝 = Number of tube side passes

𝜇𝑡 = Tube side fluid velocity = 𝐺𝑡 /𝜌, 𝑚/𝑠

𝜌 = Density of fluid, kg/m3

To Calculate tube side heat transfer coefficient, first calculate tube side flow area (𝑎𝑡 ), next tube side
mass velocity (𝐺𝑡 ), then tube side Reynolds number (Re) and finally tube side Prrandtl number (Pr).
Depending on the value of Re, use Eq. (3) or Eq. (4) to calculate ℎ𝑖 .

For the transition region of for 2000< Re<4000, no reliable equation is available, Hence, for this region
ℎ𝑖 is found by using both Eqs. (6.18) and (6.19) and the lesser of two values is considered.

Alternatively, tube side heat transfer coefficient ℎ𝑖 can be calculated (by Kern’s equation) from the value
of “ heat transfer factor; 𝐽ℎ" , for the entire range of Reynolds number (from Re = 10 to 106). Equation
relating ℎ𝑖 𝑎𝑛𝑑 𝐽ℎ is

𝑑𝑖 𝜇 0.14
𝑁𝑢 = ℎ𝑖 𝑘
= 𝐽ℎ 𝑅𝑒 ∙ 𝑃𝑟 0.33 (𝜇 ) ……………………………………………………………………….. (5)
𝑤

Graph of 𝐽ℎ Versus Re is given in Fig. 2 for the different values of L/di.

11 | 4 2
Fig 2 Tube Side Heat Transfer Factor

12 | 4 2
2. For condensation inside the tubes: Condensation coefficient depends on the position of condenser.
For condensation, shell side condensation with horizontal position is the best which gives the maximum
value of the coefficient. But if condensation is carried out in tube side then for horizontal position, hi is
calculated by following two equations and higher of the two values is considered:

𝜌𝐿 (𝜌𝐿 −𝜌𝑣 )𝑔 1/3

(a) ℎ𝑐𝑖 = 0.76 𝑘𝐿 ( 𝜇𝐿 𝜏ℎ
) ……………………………………………………………………………………………... (6)

This equation is called Nusselt equation, valid for stratified flow.

Where, ℎ𝑐𝑖 = Condensation coefficient, 𝑊/(𝑚2 . 𝑜 𝐶)

𝑘𝐿 = Thermal conductivity of liquid condensate, 𝑊/(𝑚2 . 𝑜 𝐶)

𝜌𝐿 = Density of liquid condensate, kg/m3

𝜌𝑉 = Density of vapour, kg/m3

g = Acceleration of gravity = 9.81 m/s2

𝜇𝐿 = Viscosity of liquid condensate, (𝑁 ∙ 𝑠)/𝑚2 𝑜𝑟 𝑘𝑔/(𝑚 ∙ 𝑠) 𝑜𝑟 𝑃𝑎 ∙ 𝑠

𝜏ℎ = Horizatal tube loading or flow of condensate per unit length of tube, 𝑘𝑔/(𝑚 ∙ 𝑠)

All liquid condensate properties 𝑘𝐿 , 𝜌𝐿 𝑎𝑛𝑑 𝜇𝐿 must be determined at mean temperature of condensate
film.

𝑚̇
𝜏ℎ = 𝐿×𝑁𝑐 …………………………….…………………………………………………………………………………….……………. (7)
𝑡

Where, L = Tune length, m

𝑚̇𝑐 = Total condensate flow, kg/s

𝑁𝑡 = Total number of tubes

1+√𝜌𝐿 /𝜌𝑣
(b) ℎ𝑐𝑖 = ℎ𝑖′ [ 2
] …………………………..…………………………………………………………..…………………………. (8)

𝑘
Where, ℎ𝑖′ = 0.021 ( 𝐿 ) 𝑅𝑒𝑐0.08 𝑃𝑟𝑐0.43 …………………………………………………………………………………………. (9)
𝑑𝑖

This equation is known as Boyko-Kruzhilin equation, valid for annular flow.

4𝜏ℎ
𝑅𝑒𝑐 = Reynolds number for the condensate film = 𝜇𝐿
…………………………………………..……………………. (10)

𝐶𝑝𝐿 𝜇𝐿
𝑃𝑟𝑐 = Prandtl number of liquid condensate = 𝑘𝐿
………………………………………………………………………. (11)

𝜌𝐿 (𝜌𝐿 −𝜌𝑣 )𝑔 1/3

For vertical position, ℎ𝑐𝑖 = 0.926 𝑘𝐿 ( 𝜇𝐿 𝜏𝑣
) …………………………………….………………………………. (12)

13 | 4 2
 𝑐𝑚̇
Where, 𝜏𝑣 = 𝑁 𝜋𝑑 …………………………..…………………………………………………………..…………………………. (13)
𝑡 𝑖

𝑚̇𝑐 = Mass flow rate of liquid condensate, kg/s

4𝜏𝑣
𝑅𝑒𝑐 = …………………………..…………………………………………………………………….…..…………………………. (14)
𝜇𝐿

This equation is also Nusselt eqatuon, valid for 𝑅𝑒𝑐 ≤ 2000. 𝐹𝑜𝑟 𝑅𝑒𝑐 > 2000, use Boyko-Kruzhilin
equation. i.e., Eq.(8)

B Calculation of Tube side Pressure Drop

1. If there is no phase change in tube side fluid, then tube side pressure drop can be calculated by
following equations:

𝐿 𝜇 −𝑚 𝜌𝑢𝑡2
∆𝑃𝑡 = 𝑁𝑝 (8𝐽𝑓 (𝑑 ) (𝜇 ) + 2.5) 2
……………………………………………………….…..…………………………. (15)
𝑖 𝑤

𝑚 = 0.25 𝑓𝑜𝑟 𝑅𝑒 ≤ 2100

= 0.14 𝑓𝑜𝑟 𝑅𝑒 > 2100

Where, ∆𝑝𝑡 = Tube side friction pressure drop, 𝑁/𝑚2 or Pa

𝑁𝑝 = Number of tube side passes

𝐽𝑓 = Tube side friction factor can be obtained from Fig. (3)

𝜌 = Density of tube side fluid, kg/m3

𝜇𝑡 = Tube side fluid velocity, m/s

∆𝑝𝑡 Calculated by this equation is actually permanent pressure loss. Calculated pressure drop (loss)
should be less than maximum allowable pressure drop. In some applications, macimum allowable
pressure drop is decided by process conditions. While in other applications, maximum allowable
pressure drop is actually optimum pressure drop (loss). Heat exchanger design means the balance
between two opposite factors, heat transfer coefficients related to fixed cost and pressure drop related
to operating cost. Increase in heat transfer coefficient by modifying the heat exchanger design also
increases pressure drop/ Hence, ideally actual pressure drop should be equal to optimum pressure drop
which given the total minimum cost of heat exchanger (i.e., fixed cost + operating cost) . As a general
guideline (Table 6.8) can be used to decide the value of maximum or optimum pressure drop. As per
Kern, optimum pressure drop for gases is 2 psi (13.8 kPa) and for liquid it is 10 psi (69 kPa).

2. If condensation takes place inside the tubes then it is difficult to predict the pressure drop as vapour
mass velocity is changing thoughout the condenser. A common practice is to calculate ∆𝑝𝑡′ by Eq. (6.31)
for inlet vapour flow rate and conditions, and multiply it by factor 0.5.

∆𝑝𝑡 = 0.5 ∆𝑝𝑡′ …………………………..…………………………………………………………………….…..…………………………. (16)

14 | 4 2
Fig 3 Tube Side Friction Factor

15 | 4 2
C Calculation of Shell Side Heat Transfer Coefficient

1. For heating or cooling on shell side or for no phase change on shell side, heat transfer coefficient ℎ𝑜
can be calculated by following procedure:

(a) Calculate shell side flow area by following equation:

(𝑃𝑡 −𝑑𝑜 )𝐷𝑠 𝐵𝑠
𝐴𝑠 = 𝑃𝑡
.…………………………………………………………………….…..…………………………………. (17)

Where, 𝐴𝑠 = Shell side flow area, 𝑚2

𝑃𝑡 = Tube pitch, m

𝑑𝑜 = Outside diameter of tube, m

𝐵𝑠 = Baffle spacing, m

𝐷𝑠 = Shell inside diameter, m

(b) Calculate shell side mass velocity 𝐺𝑠 and linear velocity (𝑢𝑠 )

𝑚̇𝑠
𝐺𝑠 = .…………………………………………………………………….…..……………………………………..………. (18)
𝐴𝑠

𝐺
𝑢𝑠 = 𝜌𝑠 .………………………………………………………………………………….…..…………………………………. (19)
𝑠

Where, 𝐺𝑠 = Shell side mass velocity, 𝑘𝑔/(𝑚2 ∙ 𝑠)

𝑚̇𝑠 = shell side mass flow rate of fluid, kg/s

𝐴𝑠 = Shell side flow area

𝜌𝑠 = Density of shell side fluid, kg/m3

(c) Calculate the shell side equivalent diameter (𝑑𝑒 )

For square pitch arrangement.

4 × cross − sectional area

de =
wetted perimeter
𝜋
4 × (𝑃𝑡2 − 4 𝑑𝑒2 )
=
𝜋𝑑𝑜
1.27
= (𝑃𝑡2 − 0.785𝑑𝑜2 ).…………………………………………………………….…..…………………………………. (20)
𝑑𝑜

16 | 4 2
 For triangular pitch arrangement.

1 𝜋
4 × (2 𝑃𝑡 × 𝑃𝑡 sin 60 − 8 𝑑𝑜2 )
de =
(𝜋𝑑𝑜 /2)
1.1
= (𝑃𝑡2 − 0.907𝑑𝑜2 ) .…………………………………………………………………….…..…………………………………. (21)
𝑑𝑜

(d) Calculate shell side Reynolds number.

𝑑𝑒 𝐺𝑠
𝑅𝑒𝑜 = …………………….…………………………………………………………….…..…………………………………. (22)
𝜇

Where, 𝜇 = Viscosity of shell side fluid at average temperature, kg/(m.s)

Also calculate shell side Prandtl number

𝐶𝑝 𝜇
𝑃𝑟𝑜 =
𝑘

𝐶𝑝 , 𝜇 and k are the properties of shell side fluid at average temperature.

Calculate the shell side heat transfer coefficient by the following correlation (Ref.5)

ℎ 𝑜 𝑑𝑒 𝜇 0.14
𝑁𝑢𝑜 = 𝑘
= 0.36 𝑅𝑒 0.55 𝑃𝑟 0.33 (𝜇 ) …………………………………….…..…………………………………. (23)
𝑤

This correlation is valid for the range of Reynolds number from 2000 to 1000 000. Alternately, shell side
heat transfer, coefficient can also be found out from “ shell side heat transfer factor; 𝐽ℎ" (by Kern’s
method).

ℎ 𝑜 𝑑𝑒 𝜇 0.14
𝑁𝑢 = 𝑘
= 𝐽ℎ ∙ 𝑅𝑒 ∙ 𝑃𝑟 0.33 (𝜇 ) …………………………………….…..…………………………………. (24)
𝑤

Graph of 𝐽ℎ versus 𝑅𝑒𝑠 given in Fig. 4.

2. If condensation takes place on shell side then its coefficient depends on the position of condenser.

Shell side condensation coefficient for horizontal position can be determined by following modified
Nusselt equation:

1/3
𝜌𝐿 (𝜌𝐿 − 𝜌𝑉 )𝑔 −1/6
ℎ𝑐𝑜 = 0.95 𝑘𝐿 [ ] 𝑁𝑟
𝜇𝐿 𝜏ℎ

Where, ℎ𝑐𝑜 = Shell side condensation coefficient, 𝑊/(𝑚2 ∙ 0 𝐶)

𝑘𝐿 = Thermal conductivity of liquid condensate, 𝑊/(𝑚2 ∙ 0 𝐶)

𝜌𝐿 = Density of liquid condensate, kg/m3

17 | 4 2
𝜌𝑉 = Vapour density, kg/m3

g = Acceleration of gravity = 9.81 m/s2

𝜇𝐿 = Viscosity of liquid condensate, 𝑁 ∙ 𝑠/𝑚2 𝑜𝑟 𝑃𝑎 ∙ 𝑠

𝜏ℎ =Horizontal tube loading or flow of condensate per unit length of tube

𝑚̇
=
𝐿𝑁𝑡

𝑁𝑟 = Average number of tubes in vertical tube row

2
𝑁𝑟 ≅ 𝑁𝑟′
3

𝑁𝑟′ = Number of tubes in central row

𝐷𝑏
=
𝑃𝑡

𝐷𝑏 = Tube bundle diameter, m

𝑃𝑡 = Tube pitch, m

For condensation outside the vertical tube bundle, shell side condensation coefficient is given by Nusselt
equation.

𝜌𝐿 (𝜌𝐿 −𝜌𝑉 )𝑔 1/3

ℎ𝑐𝑜 = 0.926 𝑘𝐿 ( 𝜇𝐿 𝜏𝑣
) ……………………………………………………………………………………………….. (12)

Where,

𝑚̇𝑐
𝜏𝑣 = 𝑁 ……………………………………………………………………………………………………………………………… (13)
𝜏 𝜋𝑑𝑜

In Nusselt equation; Eq. (6) and Eq. (26), suffixes I and o to hc denote inside and outside of tubes,
respectively.

18 | 4 2
Fig 4 Shell Side Heat Transfer factor Jh for segmented Baffles

19 | 4 2
D Calculation of Shell Side Pressure Drop

1. For no phase change on shell side or for heating or cooling on shell side, shell side pressure drop ∆𝑝𝑠
can be calculated by the following equation:

𝐷 𝐿 𝜌𝑠 𝑢𝑠2 𝜇 −0.14
∆𝑝𝑠 = 8𝐽𝑓 ( 𝑠 ) ( ) ( )( ) …………………………………………………………………………………….. (26)
𝑑𝑒 𝐵𝑠 2 𝜇𝑤

Where, ∆𝑝𝑠 = Shell side pressure drop, 𝑁/𝑚2 or Pa

𝐷𝑠 = Shell inside diameter, m

𝑑𝑒 = Shell side equivalent diameter, m

L = Tube length, m

𝐵𝑠 = Baffle spacing, m

𝜌𝑠 = Density of shell fluid, kg/ m3

𝜇𝑠 = Shell side linear velocity, m/s

𝜇 = Viscosity of fluid at the bulk fluid temperature, (𝑁 ∙ 𝑠)/𝑚2

𝜇𝑤 = Viscosity of fluid at tube wall temperature, (𝑁 ∙ 𝑠)/𝑚2

𝐽𝑓 = Shell side frication factor for the different values of % baffle cut of segmental baffle and for the
different values of Re. It can be obtained from Fig. 5.

Shell side pressure drop ∆𝑝𝑠 Should be less than maximum allowable pressure drop. Maximum
allowable pressure drop for shell side is also decided either based on process requirement or based on
economic considerations.

Following Table can be used to judge optimum pressure drop.

Optimum pressure Drop (Maximum Allowable Pressure Drop) Based on Economic Considerations

Fluid Optimum, ∆𝒑𝒕 𝒐𝒓 ∆𝒑𝒔 ,kPa

Liquids of 𝜇𝐿 < 1 𝑐𝑃 𝑜𝑟 𝑚𝑃𝑎 ∙ 𝑠 35
Liquids of 𝜇𝐿 = 1 𝑡𝑜 10 𝑐𝑃 𝑜𝑟 𝑚𝑃𝑎 ∙ 𝑠 50 to 70
Gas or vapour at 1 to 2 atm 13.8
Gas or vapour at high vacuum 0.4 to 0.8 (3 to Torr)
(up to 60 Torr absolute pressure)
Gas or vapour at high pressure > 10 atm 0.1 times operating pressure

20 | 4 2
Fig 5 Shell Side Friction Factor Jf

21 | 4 2
In the case of shell side condensation, no reliable correlation is available for predicting ∆𝑝𝑠 Hence, ∆𝑝𝑠
can be approximately calculated by following equation:

∆𝑝𝑠 = 0.5∆𝑝𝑠′ …………………………………………………………………………………………………………. (27)

Where , ∆𝑝𝑠′ = Shell side pressure drop calculated by Eq. (6.44) based on inlet vapour flow rate and inlet
conditions.

This also should be less than maximum allowable pressure drop.

Calculated pressure drops on tune side and shell side do not account for nozzle losses.

E Calculation of the Overall Heat Transfer Coefficients

1
𝑈𝑜 = 1 1 𝑑𝑜 𝐼𝑛(𝑑𝑜 /𝑑𝑖 ) 𝑑𝑜 1 𝑑𝑜 1
…………………………………………………………… (28)
+ + + × + ×
ℎ𝑜 ℎ𝑜𝑑 2𝑘𝑤 𝑑𝑖 ℎ𝑖𝑑 𝑑𝑖 ℎ𝑖

Where, 𝑈𝑜 = Overall heat transfer coefficient based on outside are of tubes. 𝑊/(𝑚2 ∙ 𝑜 𝐶)

ℎ𝑜 = Shell side heat transfer coefficient, 𝑊/(𝑚2 ∙ 𝑜 𝐶)

𝑑𝑜 = OD of tube, m

𝑑𝑖 = ID of tube, m

𝑘𝑤 = Thermal conductivity of tube wall material, 𝑊/(𝑚2 ∙ 𝑜 𝐶)

ℎ𝑖𝑑 = Fouling coefficient for tube side fluid , 𝑊/(𝑚2 ∙ 𝑜 𝐶)

ℎ𝑜𝑑 = Fouling coefficient for shell side fluid, 𝑊/(𝑚2 ∙ 𝑜 𝐶)

Fouling refers to any unwanted deposit of material on a heat transfer surface, or by extension, to any
deposit that alters the desired fluid flow pattern. Fouling creates and additional resistance to heat
transfer and increases pressure drop by narrowing flow passages.

For the various types of fluids, recommended fouling coefficients are given below

22 | 4 2
 Recommended Fouling Coefficients

Fluid Fouling coefficient Fluid Fouling coefficient

𝑾/(𝒎𝟐 ∙ 𝒐 𝑪) 𝑾/(𝒎𝟐 ∙ 𝒐 𝑪)

Cooling water 3000-6000 Light Hydrocarbon 5000

Demineralized water 8000-10 000 Heavy Hydrocarbon 3000
Soft water 5000-8000 Aqueous Organic Solution 5000
Steam 4000-10 000 Vegetable oils 3000
Steam condensate 1500-5000 Caustic Solutions 5000
Brine 3000-5000 Gasoline 5000
Air 5000-10 000 Kerosene 3000-5000
Organic vapours 10 000 Light gas oil 3000-5000
Organic Liquids 5000 Heavy gas oil 2000-3000
Heavy hydrocarbons 2000 Naphthas 5000
Aqueous salt solutions 3000-5000 Coal flue gas 1000

F Calculating the Heat Transfer Area Required

∅𝑡
𝐴𝑟 = (∅ 𝑡𝑜 𝑏𝑒 𝑖𝑛 𝑊)
𝑈𝑜 ∆𝑇𝑚 𝑡

Also calculate actual heat transfer area 𝐴𝑜 of selected heat exchanger.

𝐴𝑜 = 𝑁𝑡 𝜋 𝑑𝑜 𝐿

𝐴𝑜
≈ (1.1 𝑡𝑜 1.2)
𝐴𝑟𝑒𝑞

∆𝑝𝑡 ∆𝑝𝑠
< (0.8 𝑡𝑜 1). < (0.8 𝑡𝑜 1)
∆𝑝𝑡 𝑚𝑎𝑥 ∆𝑝𝑠 𝑚𝑎𝑥

Thus an optimum design of shell and tube heat exchanger can be obtained.

23 | 4 2
 Illustrative Example 1

A lube – oil cooler for 2 MW steam turbine is to be designed for following operating conditions: Lube –
oil, conforming to ISO VG – 46 grade, flows at the rate of 450 L/min and is to be cooled from 65oC to
45oC with cooling water.

Kinematic viscosity of lube oil = 45.5 cSt at 45oC

Density of lube oil = 2.1413 kJ/(kg. oC)

Thermal conductivity of lube oil at 55𝑜 𝐶 = 0.13 𝑊/(𝑚 ∙ 𝐾)

Viscosity of lube oil at 55𝑜 𝐶 = 15 𝑐𝑝 𝑜𝑟 𝑚𝑝𝑎 ∙ 𝑠

Cooling water inlet/ outlet temperatures = 35𝑜 𝐶/39𝑜 𝐶

Solution
Heat duty , ∅𝑡 = 𝑚̇𝑜 𝐶𝐿𝑜 ∆𝑡

Volumetric flow rate of 𝑜𝑖𝑙 = 450 𝐿/ min = 450 × 60 × 10−3 𝑚3 /ℎ = 27 𝑚3 /ℎ

𝑚̇ = 27 × 869 = 23 463 𝑘𝑔/ℎ ≡ 6.5175 𝑘𝑔/𝑠

∅𝑡 = 23 463 × 2.1413(65 − 45)

∅𝑡 = 1004 826 𝑘𝐽/ℎ ≡ 279.118 𝑘𝑊

≡ 279.118 × 103 𝑊

Heat balance

∅𝑡 = 𝑚̇𝑤 𝐶𝐿𝑤 ∆𝑡′

279.118 = 𝑚̇𝑤 × 4.1868(39 − 35)

𝑚̇𝑤 = 16.667 𝑘𝑔/𝑠(≡ 60 𝑚3 /ℎ)

∆𝑇1 = 65 − 39 = 26𝑜 𝐶

∆𝑇2 = 45 − 35 = 10𝑜 𝐶

∆𝑇1 −∆𝑇2 26 − 10
∆𝑇𝑙𝑚 = = = 16.745𝑜 𝐶
∆𝑇1 26
𝐼𝑛 (∆𝑇 ) 𝐼𝑛 (10)
2

Allocate lube oil on tube side and cooling water on shell side.

For the first trial calculations, let the number of tube side passes 𝑁𝑝 = 4

24 | 4 2
 𝑡1 − 𝑡2 𝑡2′ − 𝑡1′
𝑅= 𝑆=
𝑡2′ − 𝑡1′ 𝑡1 − 𝑡1′

𝑡1 = 65𝑜 𝐶, 𝑡2 = 45𝑜 𝐶, 𝑡1′ = 35𝑜 𝐶, 𝑡2′ = 39𝑜 𝐶

65 − 45 39 − 35
𝑅= =5 𝑆= = 0.1333
39 − 35 65 − 35

Refer appropriate figure from TEMA to get Ft ≥ 0.95, For shell passes = 4, we get, 𝐹𝑡 = 0.95

Mean temperature difference,

∆𝑇𝑚 = 0.95 × 16.745 = 15.908𝑜 𝐶

Assume overall heat transfer coefficient = 400 𝑊/(𝑚2 ∙ 𝑜 𝐶) . (Ref : Table 4)

Provisional heat transfer area for the first trial calculation.

∅𝑡 279.118 × 103
𝐴= =
𝑈 ∆𝑇𝑚 400 × 15.908

𝐴 = 43.8644 𝑚2 = 𝑁𝑡 𝜋𝑑𝑜 𝐿

𝑑𝑜 = 5/8 𝑖𝑛 = 15.875 𝑚𝑚, 𝐿 = 6 𝑓𝑡 = 1.8288 𝑚

43.8644
𝑁𝑡 = = 480.93 ≅ 480
𝜋 × (0.015 875 × 1.8288)

Select BEM type heat exchange with tube pitch 𝑃𝑡 = 1.25 𝑑𝑜 = 19.8437 𝑚𝑚 and triangular pitch
arrangement.

𝑁 1/𝑛1
Tube bundle diameter 𝐷𝑏 = 𝑑𝑜 (𝑘 𝑡 )
1

From Table 6.2 for 𝑁𝑝 = 4, 𝑘1 = 0.175 , 𝑛1 = 2.285

480 1/2.285
𝐷𝑏 = 15.875 ( ) = 507.5 𝑚𝑚
0.175

Let diametric clearance between shell ID and 𝐷𝑏 , 𝐶 = 12.5 𝑚𝑚

Shell ID, 𝐷𝑖 = 𝐷𝑏 + 12.5

= 507.5 + 12.5 = 520 mm

Evaluation of ℎ𝑖 :

Tube side flow area:

𝑑𝑖 = 13.3858 𝑚𝑚 (𝑓𝑜𝑟 18 𝐵𝑊𝐺 𝑡𝑢𝑏𝑒)

25 | 4 2
 480 𝜋 2
𝑎𝑡 = × 𝑑𝑖
4 4
480 𝜋
= × (0.013 3858)2 = 0.016 887 𝑚2
4 4
𝑚̇
Tube side mass velocity 𝐺𝑡 =
𝑎𝑡

(23 463/3600)
𝐺𝑡 = = 390.57 𝑘𝑔/(𝑚2 ∙ 𝑠)
0.016 687

Viscosity of oil:

𝜇 = 15 𝑐𝑃 = 15 × 10−3 𝑘𝑔/(𝑚 ∙ 𝑠)

𝑑𝑖 𝐺𝑡 0.013 3858 × 390.57

𝑅𝑒𝑡 = = = 348.54 𝑤ℎ𝑖𝑐ℎ 𝑖𝑠 𝑙𝑜𝑤.
𝜇 15 × 10−3

To increase the Reynold number, let the number of tube side passes 𝑁𝑝 = 8

𝑘1 = 0.0365, 𝑛1 = 2.675 from Table 2

1
480 2.675
𝐷𝑏 = 15.875 ( ) = 550 𝑚𝑚
0.0365

Shell ID, 𝐷𝑏 + 12 = 562 𝑚𝑚

Evaluation of ℎ𝑖 :

480 𝜋
𝑎𝑡 = × (0.013 3858)2 = 8.4436 × 10−3 𝑚2
8 4
8
𝐺𝑡 = 390.57 × = 781.14 𝑘𝑔/(𝑚2 ∙ 𝑠)
4
𝐺𝑡 781.14
𝑢𝑡 = = = 0.9 𝑚/𝑠
𝜌 869

𝑅𝑒𝑡 = 348.54 × 2 = 697 low but can be acceptable.

𝐶𝑝 𝜇 2.1413 × 15 × 10−3 × 103

𝑃𝑟 = =
𝑘 0.13

= 247

Using Sieder – Tate equation (𝑅𝑒𝑡 < 2000)

ℎ𝑖 𝑑𝑖 𝜇 0.14
𝑁𝑢 = = 1.86(𝑅𝑒 ∙ 𝑃𝑟 ∙ 𝑑𝑖 /𝐿)0.33 ( )
𝑘 𝜇𝑤

26 | 4 2
 0.013 3858 0.33
= 1.86 (697 × 247 × ) ×1
1.8288

= 19.618 > 3.5

𝑘 19.618 × 0.13
ℎ𝑖 = 19.62 × = = 190.53 𝑊/(𝑚2 ∙ 𝑜 𝐶) (𝑡𝑜𝑜 𝑙𝑜𝑤)
𝑑𝑖 0.013 3858

To improve oil side heat transfer coefficient, allocate lube oil shell side and water on tube side. Increase
the tube length from 6 ft to 10 ft for the same value of heat transfer area provided. It will decrease the
shell side flow area and will improve the shell side heat transfer coefficient.

𝐿 = 10 × 0.3048 = 3.048 𝑚

𝐴𝑝𝑟𝑜 = 43.8644 𝑚2 = 𝑁𝑡 𝜋𝑑𝑜 𝐿 = 𝑁𝑡 × 𝜋 × 0.015 875 × 3.048

𝑁𝑡 = 288.56 ≅ 288

Let number of tube side passes 𝑁𝑝 = 4

𝑘1 = 0.175, 𝑛1 = 2.285 (ref : Table 2)

1
288 2.285
𝐷𝑏 = 15.875 ( ) = 406 𝑚𝑚
0.175

Shell ID, 𝐷𝑖 = 406 + 12 = 418 𝑚𝑚

Evaluation of ℎ𝑖 :

288 𝜋
𝑎𝑡 = × (0.013 3858)2 = 0.01 𝑚2
4 4

Tube side mass velocity ,

16.667
𝐺𝑡 = = 166.7 𝑘𝑔/(𝑚2 ∙ 𝑠)
0.01

Density of water at 370 𝐶, 𝜌 = 993.328 𝑘𝑔/𝑚3 (from steam table)

𝐺𝑡 1666.7 𝑚
𝑢𝑡 = = = 1.678
𝜌 993.328 𝑠

𝑑𝑖 𝐺𝑡
𝑅𝑒 =
𝜇

Viscosity of water at 37𝑜 𝐶, 𝜇 = 0.73 𝑐𝑃 = 0.73 × 10−3 𝑘𝑔/(𝑚 ∙ 𝑠)

0.013 3858 × 1666.7

𝑅𝑒 = = 30 561.8 > 4000
0.73 × 10−3

27 | 4 2
Thermal conductivity of water at 37𝑜 𝐶, 𝑘 = 0.628 𝑊/(𝑚 ∙ 𝑜 𝐶)

Prandtl number of water ,

𝐶𝑝 𝜇
𝑃𝑟 =
𝑘

4.1868 × 0.73 × 10−3 × 103

𝑃𝑟 = = 4.867
0.628

Using Dittus – Bolter equation

ℎ𝑖 𝑑𝑖 𝜇 0.14
𝑁𝑢 = = 0.023 𝑅𝑒 0.8 𝑃𝑟 0.33 ( )
𝑘𝑓 𝜇𝑤

0.628
ℎ𝑖 = 0.023 × × (30 561.8)0.8 × 4.8670.33
0.013 3858

= 7046.6 𝑊/(𝑚 ∙ 𝑜 𝐶)

Evaluation of oil side heat transfer coefficient (ℎ𝑜 ) :

Shell side flow area

(𝑃𝑡 − 𝑑𝑜 )
𝐴𝑠 = × 𝐷𝑖 × 𝐵𝑠
𝑃𝑡

𝑃𝑡 /𝑑𝑜 = 1.25, 𝐷𝑖 = 418 𝑚𝑚,

𝐷𝑖 418
𝐵𝑠 = = = 83.6 𝑚𝑚
5 5

1.25𝑑𝑜 − 𝑑𝑜
𝐴𝑠 = × 0.418 × 0.0836 = 6.989 × 10−3 𝑚2
(1.25𝑑𝑜 )
𝑚̇
Shell side mass velocity, 𝐺𝑠 = 𝐴
𝑠

23 463/3600
𝐺𝑠 = = 932.537 𝑘𝑔/𝑚2 ∙ 𝑠
6.989 × 10−3
𝐺𝑠 932.537
𝑢𝑠 = = = 1.073 𝑚/𝑠
𝜌𝑠 869

Acceptable velocity

Shell side equivalent diameter for triangular pitch

28 | 4 2
 1.1 2
𝑑𝑒 = (𝑃 − 0.907𝑑𝑜2 )
𝑑𝑜 𝑡

1.1
𝑑𝑒 = [19.84372 − 0.907 × (15.875)2 ]
15.875

= 11.4465 mm

Shell side Reynolds number

𝑑𝑒 𝐺𝑠
𝑅𝑒𝑠 =
𝜇

0.011 4465 × 932.537

= = 711.62 (𝑟𝑎𝑡ℎ𝑒𝑟 𝑝𝑜𝑜𝑟)
15 × 10−3

𝐶𝑝 𝜇 2.1413 × (15 × 10−3 ) × 103

𝑃𝑟 = =
𝑘 0.13

= 247

For 𝑅𝑒 = 711.62. 𝐽ℎ = 2 × 10−2 (𝐹𝑟𝑜𝑚 𝐹𝑖𝑔. 6.14 𝑓𝑜𝑟 25% 𝑏𝑎𝑓𝑓𝑙𝑒 𝑐𝑢𝑡)

ℎ𝑠 𝑑𝑒 𝜇 0.14
𝑁𝑢 = = 𝐽ℎ 𝑅𝑒 𝑃𝑟1/3 ( )
𝑘𝑓 𝜇𝑤

0.13
ℎ𝑠 = 2 × 10−2 × × 711.62 × (247)1/3 × 1
0.11 4465

= 1014.18 𝑊/(𝑚2 ∙ 𝑜 𝐶)

Overall heat transfer coefficient by Eq. (28):

From Table of Fouling Coefficient

ℎ𝑜𝑑 = 3000 𝑊/(𝑚2 ∙ 𝑜 𝐶), ℎ𝑖𝑑 = 5000 𝑊/(𝑚2 ∙ 𝑜 𝐶),

Tube material: steel or cupronickel

Thermal conductivity of tube material 𝑘𝑤 = 50 𝑊/(𝑚 ∙ 𝑜 𝐶),

15.875
1 1 1 0.015 875 𝐼𝑛 ( ) 15.875 1 15.875 1
= + + 13.3858 + × + ×
𝑈𝑜 1014.18 3000 2 × 50 13.3858 5000 13.3858 7046.6

𝑈𝑜 = 570.8 𝑊/(𝑚2 ∙ 𝑜 𝐶)
∅𝑡
Heat transfer area required, 𝐴𝑟 = 𝑈
𝑜 ∆𝑇𝑚

29 | 4 2
279.118 × 103
= 30.739 𝑚2
570.8 × 15.908
𝐴𝑝𝑟𝑜
% Excess heat transfer area = ( 𝐴𝑟
− 1) × 100

43.8644
=( − 1) × 100 = 42.7%(𝑠𝑢𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡𝑙𝑦 ℎ𝑖𝑔ℎ)
30.739

Shell side pressure drop:

𝐷𝑠 𝐿 𝜌𝑠 𝑢𝑠2 𝜇 −0.14
∆𝑝𝑠 = 8𝐽𝑓 ( )( ) ( )
𝑑𝑒 𝐵𝑠 2 𝜇𝑤

𝐷𝑠 = 0.418 𝑚, 𝑑𝑒 = 0.011 4465 𝑚, 𝐿 = 3.048 𝑚

𝐵𝑠 = 0.0836 𝑚, 𝑢𝑠 = 1.073 𝑚/𝑠, 𝜌𝑠 = 869 𝑘𝑔/𝑚3

For 𝑅𝑒𝑠 = 711.62, 𝐽𝑓 = 7.7 × 10−2

0.418 3.048 869 × 1.0732

∆𝑝𝑠 = 8 × 7.7 × 10−2 ( )( )×
0.011 4465 0.0836 2

= 410 281.7 Pa = 410.282 kPa (too high)

To decrease the shell side pressure drop, baffles spacing can be increased from 83.6 mm to 160 mm.

Revised value of 𝐵𝑠 = 160 𝑚𝑚 = 0.16 𝑚

Shell side flow area,

0.16
𝐴𝑠 = 6.989 × 10−3 × = 0.013 376 𝑚2
0.0836

Shell side mass velocity,

6.989 × 10−3
𝐺𝑠 = 932.537 × = 487.25 𝑘𝑔/(𝑚2 ∙ 𝑠)
0.013 376
𝐺𝑠 487.25
𝑢𝑠 = = = 0.56 𝑚/𝑠(𝑟𝑎𝑡ℎ𝑒𝑟 𝑝𝑜𝑜𝑟)
𝜌𝑠 869

0.011 4465 × 487.25

𝑅𝑒 = = 371.82
15 × 10−3

For 𝑅𝑒 = 371.82, 𝐽ℎ = 2.7 × 10−2 (𝑓𝑟𝑜𝑚 𝐹𝑖𝑔. 4)

ℎ𝑠 𝑑𝑒
𝑁𝑢 = = 2.7 × 10−2 × 371.82 × (247)1/3 = 62.989
𝑘𝑓

30 | 4 2
 0.13
ℎ𝑠 = 62.989 × = 715.37 𝑊/(𝑚2 ∙ 𝑜 𝐶)
0.011 4465
1 1 1 1
= − +
𝑈𝑜 570.8 1014.18 715.37

𝑈𝑜 = 462.15 𝑊/(𝑚2 ∙ 𝑜 𝐶)

∅𝑡 279.118 × 103
𝐴𝑟 = = = 37.96 𝑚2
𝑈𝑜 ∆𝑇𝑚 462.15 × 15.908

% Excess heat transfer area

43.8644
=( − 1) × 100 = 15.55%(𝑎𝑑𝑒𝑞𝑢𝑎𝑡𝑒)
37.96

Revised shell side pressure drop:

For 𝐷𝑠 = 0.418 𝑚, 𝐵𝑠 = 0.16 𝑚, 𝑑𝑒 = 0.11 4465 𝑚, 𝐿 = 3.048 𝑚, 𝑢𝑠 = 0.56 𝑚/𝑠 𝜌𝑠 = 869 𝑘𝑔/𝑚3

𝐷𝑠 𝐿 𝜌𝑠 𝜇𝑠2 𝜇 −0.14
∆𝑝𝑠 = 8𝐽𝑓 ( )( ) ( )
𝑑𝑒 𝐵𝑠 2 𝜇𝑤

For 𝑅𝑒𝑠 = 371.82, 𝐽𝑓 = 9.26 × 10−2 (From Fig. 6.15)

0.418 3.048 869 × 0.562 × 1

∆𝑝𝑠 = 8 × 9.26 × 10−2 ( )( )×
0.011 4465 0.16 2

∆𝑝𝑠 = 70 220.7 𝑃𝑎 = 70.22 𝑘𝑃𝑎 (𝑎𝑐𝑐𝑒𝑝𝑡𝑎𝑏𝑙𝑒)

Tube side pressure drop:

𝐿 𝜇 −𝑚 𝜌𝜇𝑡2
∆𝑝𝑡 = 𝑁𝑝 (8𝐽𝑓 ( ) ( ) + 2.5) ×
𝑑𝑖 𝜇𝑤 2

𝑁𝑝 = 4, 𝐿 = 3.048 𝑚, 𝑑𝑖 = 0.013 3858 𝑚, 𝑢𝑡 = 1.678 𝑚/𝑠

𝜌 = 993.328 𝑘𝑔/𝑚3 , 𝜇/𝜇𝑤 = 1

For 𝑅𝑒𝑡 = 30 561.8 𝐽𝑓 = 3.6 × 10−3 (From Fig. 6.13)

3.048 993.328 × 1.6782

∆𝑝𝑡 = 4 (8 × 3.6 × 10−3 × ( ) × 1 + 2.5) ×
0.013 3858 2

∆𝑝𝑡 = 50 668 𝑃𝑎 = 50.668 𝑘𝑃𝑎 (acceptable)

31 | 4 2
 Illustrative Example 2

10,900 kg/h of nearly pure saturated methyl ethyl ketone vapour at 13.73 kPa g is be condensed and
cooled to 60𝑜 𝐶 by cooling water which is available in plant at 32oC. Consider pressure drop of 13.7 kPa
for vapour and 68.7 kPa for the water as permissible. Design the suitable shell and tube heat exchanger
for the heat duty.

Solution
Heat duty calculation

∅𝑡 = 𝑚̇𝜆 + 𝑚̇𝐶𝐿 ∆𝑡 = ∅𝑐 + ∅𝑠𝑢𝑏

Where, ∅𝑐 = 𝑚̇𝜆 = heat duty for condensation

∅𝑠𝑢𝑏 = 𝑚̇𝐶𝐿 ∆𝑡 = heat duty for subcooling

𝑚̇ = 10 900 𝑘𝑔/ℎ = 3.0278 𝑘𝑔/𝑠

𝜆 = Latent heat of vaporization of methyl ethyl ketone (MEK) at condensation temperature

At condensation temperature of pure MEK vapour

𝑝𝑣 = 𝑝𝑡 = 13.73 𝑘𝑃𝑎 𝑔 = 115.055 𝑘𝑃𝑎 = 863 𝑇𝑜𝑟𝑟 𝑎

Antoine equation for methyl ethyl ketone

3150.42
ln (𝑝𝑣 ) = 16.5986 − 𝑇−36.65

Where, 𝑝𝑣 is in Torr and T in Deg K

𝑝𝑣 = 𝑝𝑡 = 863 𝑇𝑜𝑟𝑟, 𝑇 = 356.87 𝐾 𝑡 = 83.87 𝑜 𝐶

From Perry’s Hand Book,

𝜆𝑀𝐸𝐾 𝑎𝑡 78.2 𝑜 𝐶 = 105.93 𝑘𝑐𝑎𝑙/𝑘𝑔 = 443.5 𝑘𝐽/𝑘𝑔

Value of 𝜆𝑀𝐸𝐾 is required at 83.87 𝑜 𝐶

Using Watson relation,

1 − 𝑇𝑟2 0.38
𝜆2 = 𝜆1 ( )
1 − 𝑇𝑟1

𝑇𝑟 = reduced temperature = 𝑇/𝑇𝑐

𝑇𝑐 of MEK = 535.6 K

32 | 4 2
 (83.87 + 273.15) 0.38
1−
𝜆 𝑎𝑡 83.87 𝑜 𝐶 = 𝜆782𝑜 𝐶 ( 535.6 )
(78.2 + 273.15)
535.6

𝜆83.87𝑜 𝐶 = 443.5 × 0.9882 = 438.27 𝑘𝐽/𝑘𝑔

∅𝑐 = 𝑚̇𝜆 = 3.0278 × 738.27 = 1327 𝑘𝑊

Specific heat of MEK liquid at

(83.87 + 60)
= 72𝑜 𝐶
2

𝐶𝐿 = 2.298 𝑘𝐽/(𝑘𝑔. 𝑜𝐶 ) (From Table 3-184 of Ref.2)

∅𝑠𝑢𝑏 = 3.0278 × 2.298 × (83.87 − 60) = 166 𝑘𝑊

∅𝑡 = ∅𝑐 + ∅𝑠𝑢𝑏 = 1327 + 166 = 1493 𝑘𝑊

Energy balance

F∅ = 𝑚̇𝑤 𝐶𝑝𝑤 (𝑡𝑜′ − 32)

Fixing the outlet temperature of cooling water (𝑡𝑜′ ) 𝑎𝑠 40𝑜 𝐶,

Mass flow rate of cooling water required

∅𝑡 1493
𝑚̇𝑤 = = = 44.5746 𝑘𝑔/𝑠 = 160.5 𝑚3 /ℎ
(𝐶𝑝𝑤 ∙ ∆𝑡′) (4.1868 × 8)

First trial calculations:

Using Table 4, let overall heat transfer coefficients be

For condensation 𝑈𝑐 = 800 𝑊/(𝑚2 ∙ 𝑜 𝐶)

For subcooling 𝑈𝑠𝑢𝑏 = 200 𝑊/(𝑚2 ∙ 𝑜 𝐶)

Assume that entire flow of cooling water is first utilized for subcooling and then for condensation.

∅𝑠𝑢𝑏 = 𝑚̇𝑤 𝐶𝑝𝑤 (𝑡1′ − 32)

Where 𝑡1′ = intermediate temperature of cooling water

166 = 44.5746 × 4.1868 × (𝑡1′ − 32)

𝑡1′ = 32.89𝑜 𝐶

LMTD for condensation:

33 | 4 2
 ∆T1 = 83.87 − 32.89 = 50.98 𝑜 𝐶

∆T2 = 83.87 − 40 = 43.87 𝑜 𝐶

50.98 − 43.87
∆T𝑙𝑚 = = 47.336 𝑜 𝐶
50.98
𝐼𝑛 (43.87)

= ∆T𝑚𝑐

For condensation of pure component R = 0 and 𝐹𝑡 = 1, hence LMTD = MTD LMTD for subcooling:

∆T1 = 83.87 − 32.89 = 50.98 𝑜 𝐶

∆T2 = 60 − 32 = 28 𝑜 𝐶

50.98 − 28
∆T𝑙𝑚 𝑠𝑢𝑏 = = 38.349 𝑜 𝐶
50.98
𝐼𝑛 ( 28 )

= ∆T𝑚 𝑠𝑢𝑏

Assume that subcooling will take place in the prefect counter current manner.

𝐹𝑡 = 1, ℎ𝑒𝑛𝑐𝑒 𝐿𝑀𝑇𝐷 = 𝑀𝑇𝐷

Area based on assumed values of U:

For condensation:

∅𝑐 1327 × 1000
𝐴𝑐 = = = 35.042 𝑚2
𝑈𝑐 ∆𝑇𝑚𝑐 800 × 47.336

For subcooling:

∅𝑠𝑢𝑏 166 × 1000

𝐴𝑠𝑢𝑏 = = = 21.643 𝑚2
𝑈𝑐 ∆𝑇𝑚𝑠𝑢𝑏 200 × 38.349

Total area 𝐴 = 𝐴𝑐 + 𝐴𝑠𝑢𝑏 = 56.685 𝑚2

𝐴𝑠𝑢𝑏 21.643
= = 0.3818 𝑎𝑛𝑑 𝐴𝑠𝑢𝑏 < 𝐴𝑐
𝐴 56.685

Based on the selected values of overall coefficients, area required for subcooling (𝐴𝑠𝑢𝑏 ) is less than area
required for condensation (𝐴𝑐 ). Hence, to get the smaller size of heat exchanger horizontal position is
selected. Ideally in such a case, heat exchanger should be designed for both positions and the position
which requires lesser heat Area provided for the first calculation

34 | 4 2
𝐴 = 56.685 𝑚2 = 𝑁𝑡 𝜋𝑑𝑜 𝐿

Choose3/4 in OD (19.05 mm OD).6 ft (1.83 m) long tubes.

𝐴 56.685
𝑁𝑡 = = = 518
𝜋𝑑𝑜 𝐿 (𝜋 × 0.019 05 × 1.83)

Shell side fluid is a clean fluid hence, select triangular pitch arrangement.

𝑃𝑡 = 1.25 𝑑𝑜 = 23.8125 𝑚𝑚

Number of tube side passes = 2 (for first trial calculations)

Tube bundle diameter:

1
𝑁𝑡 𝑛1
𝐷𝑏 = 𝑑𝑜 ( )
𝑘1
1
518 2.207
= 19.05 ( ) (𝑢𝑠𝑖𝑛𝑔 𝑡𝑎𝑏𝑙𝑒 2)
0.249

Select a fixed tube sheet heat exchanger.

Let diametric clearance between shell ID and 𝐷𝑏 , C = 13 mm

Shell inside diameter, 𝐷𝑖 = 607 + 13 = 620 𝑚𝑚

Calculation of tube side heat transfer coefficnet:

𝑁𝑡 𝜋 2 518 𝜋
𝑎𝑡 = × 𝑑 = × (0.015 748)2 = 0.050 45 𝑚2
𝑁𝑝 4 𝑖 2 4

(Select 16 BWG tube 𝑑𝑖 = 15.748 𝑚𝑚)

Tube side mass velocity.

𝑚̇ 44.5746
𝐺𝑡 = = = 883.54 𝑘𝑔/(𝑚2 ∙ 𝑠)
𝑎𝑡 0.050 45

𝐺𝑡
𝑢𝑡 =
𝜌

883.54
= = 0.89 𝑚/𝑠 < 1 𝑚/𝑠
992.9

To avoid the excessive fouling it is recommended to keep the velocity of water greater than 1 m/s.

Increase the number of tube side passes from 2 to 4.

35 | 4 2
For 𝑁𝑝 = 4, 𝑎𝑡 = 0.025 22 𝑚2

1
518 2.285
𝐷𝑏 = 19.05 ( ) (𝑇𝑎𝑏𝑙𝑒 2)
0.175

= 630 mm

Let diametric clearance between shell ID and 𝐷𝑏′ 𝐶 = 15 𝑚𝑚

Shell inside diameter = 630 + 15 = 645 mm (revised)

44.5746
𝐺𝑡 = = 1767.43 𝑘𝑔/(𝑚2 ∙ 𝑠)
0.025 22

𝑢𝑡 = 1.78 𝑚/𝑠 𝑎𝑐𝑐𝑒𝑝𝑡𝑎𝑏𝑙𝑒

Viscosity of water at 36𝑜 𝐶, 𝜇 = 0.72 𝑐𝑃 = 0.72 × 10−3 𝑘𝑔/(𝑚 ∙ 𝑠)

0.015 748 × 1767.43

𝑅𝑒𝑡 = = 38 657.6
0.72 × 10−3

Prandtl number (Pr):

Thermal conductivity of water at 36𝑜 𝐶, 𝑘 = 0.6228 𝑊/(𝑚 ∙ 𝑠)

𝐶𝑝 𝜇 4.1868 × (0.72 × 10−3 ) 103

𝑃𝑟 = = ×
𝑘 0.6228 1

= 4.84

Using Dittus – Bolter equation

ℎ𝑖 𝑑𝑖 𝜇 0.14
= 0.023 𝑅𝑒 0.8 𝑃𝑟 0.33 ( )
𝑘 𝜇𝑤

𝜇 0.14
Considering ( ) =1
𝜇𝑤

0.023 × 0.6228
ℎ𝑖 = × (38 657.6)0.8 × (4.84)0.33
0.015 748

= 7155.5 𝑊(𝑚2 ∙ 𝑜 𝐶)

Shell side coefficient:

(a) For condensation zone, ℎ𝑐𝑜 :

Calculation for mean temperature of condensate film:

Let 𝑡𝑤 = Tabe wall temperature, 𝑜 𝐶

36 | 4 2
ℎ𝑐𝑜 = W/(𝑚2 ∙ 𝑜 𝐶) (assumed for first trial calculation)At steady state

Heat transfer rate through condensate film = overall rate of heat transfer

ℎ𝑐𝑜 𝐴𝑐 (𝑡𝑐 − 𝑡𝑤 ) = 𝑈𝑐 𝐴𝑐 (𝑡𝑐 − 𝑡𝑎𝑣 )

Where, 𝑡𝑐 = Condensation temperature of vapour on shell side, 𝑜 𝐶

𝑡𝑎𝑣 = Average tube side fluid temperature for condensaiton zone, 𝑜 𝐶

(32.89 + 40)
1500(83.87 − 𝑡𝑤 ) = 800 (83.87 − )
2

𝑡𝑤 = 58.577 𝑜 𝐶

Mean temperature of condensate film

𝑡𝑐 − 𝑡𝑤 (83.87 + 58.577)
𝑡𝑎𝑣 = = = 71.22 𝑜 𝐶
2 2

Physical properties of liquid condensate at 71.22 𝑜 𝐶 :

Viscosity of liquid MEK at 71.22 𝑜 𝐶, 𝜇𝐿 = 0.32 𝑐𝑃 = 0.32 × 10−3 𝑘𝑔/(𝑚 ∙ 𝑠)

Density of liquid MEK at 71.22 𝑜 𝐶, 𝜌𝐿 = 805 𝑘𝑔/𝑚3

Thermal conducitivity of liquid MEK at 71.22 𝑜 𝐶 , 𝑘𝐿 = 0.173 𝑊//(𝑚 ∙ 𝑜 𝐶)

Shell side condensation coefficent with horizontal position

1/3
𝜌𝐿 (𝜌𝐿 − 𝜌𝑉 )𝑔 −1/6
ℎ𝑐𝑜 = 0.95 𝑘𝐿 ( ) . 𝑁𝑟
𝜇𝐿 𝜏ℎ

Acceleration of gravity g = 9.81 m/s2

𝑃𝑀 𝑃𝑀 𝑇𝑠
Density of vapour 𝜌𝑉 = 𝑅𝑇
= 𝑇
×𝑃 (s for standard conditions)
𝑠 𝑉𝑠

863 × 72 273.15
𝜌𝑉 = ×
(273.15 + 83.87) 760 × 22.414

= 2.79 𝑘𝑔/𝑚3

𝑚̇𝑐 (10 900/3600)

𝜏ℎ = = = 3.194 × 10−3 𝑘𝑔/(𝑚 ∙ 𝑠)
𝐿𝑁𝑡 (1.83 × 518)

Average number of tubes in vertical rows

2 𝐷𝑏
𝑁𝑟 = 2/3 𝑁𝑟′ = ( )
3 𝑃𝑡

37 | 4 2
 2 630
= × = 17.64 ≅ 18
3 23.8125
1/3
805 × (805 − 2.79) × 9.81
ℎ𝑐𝑜 = 0.95 × 0.173 [ ] × (18)−1/6
0.32 × 10−3 × 3.194 × 10−3

= 1864.86 5 𝑊/(𝑚2 ∙ 𝑜 𝐶)

ℎ𝑐𝑜 is close enough to assumed value of ℎ𝑐𝑜 . Hence, correction in the value of 𝑡𝑤 is not required.

(a) For subcooling zone, ℎ𝑜𝑠𝑢𝑏 :

With horizontal position, subcooling is taking place via natural convection only for which reliable
correlations are not available. Based on Kern’s recommendation,

ℎ𝑜𝑠𝑢𝑏 = 50 𝐵𝑡𝑢/(ℎ ∙ 𝑓𝑡 2 ∙ 𝑜 𝐹)

= 283.77 𝑊/(𝑚2 ∙ 𝑜 𝐶)

Overall Heat Transfer Coefficient for Condensation Eq. (28):

From Table 4,

For organic vapours, ℎ𝑜𝑑 = 10 000 𝑊/(𝑚2 ∙ 𝑜 𝐶)

For Cooling water, ℎ𝑖𝑑 = 4000 𝑊/(𝑚2 ∙ 𝑜 𝐶)

With methyl enthl ketone and cooling water, stainless steel – 304 is a suitable material for the tube.

Thermal conductivity of SS-304 material, 𝑘𝑤 = 16.3 𝑊/(𝑚 ∙ 𝑜 𝐶)

19.05
1 1 1 0.019 05 𝐼𝑛 ( ) 19.05 1 19.05 1
= + + 15.748 + × + ×
𝑈𝑜𝑐 1864.86 10 000 2 × 16.3 15.748 7155.5 15.748 4000

𝑈𝑜𝑐 = 820.38 𝑊/(𝑚2 ∙ 𝑜 𝐶)

Heat transfer area required for condensation

∅𝑐𝑜𝑛𝑑 1327 × 1000

𝐴𝑐𝑟 = =
𝑈𝑜𝑐 × ∆𝑇𝑚𝑐 820.38 × 47.336

𝐴𝑐𝑟 = 34.17 𝑚2

Overall heat transfer coefficient for subcooling:

1
𝑈𝑜𝑠𝑢𝑏 =
1 1 0.019 05 𝐼𝑛(19.05/15.748) 19.05 1 19.05
[283.77 + 10 000 + 2 × 16.3 + × +
15.748 4000 15.748 × 7155.5]

38 | 4 2
𝑈𝑜𝑠𝑢𝑏 = 237.72 𝑊/(𝑚2 ∙ 𝑜 𝐶)

Heat tansfer area required for subcooling,

∅𝑠𝑢𝑏 166 × 1000

𝐴𝑠𝑢𝑏𝑟 = = = 18.21 𝑚2
𝑈𝑜𝑠𝑢𝑏 × ∆𝑇𝑚𝑠𝑢𝑏 237.72 × 38.349

Total heat transfer area required

𝐴𝑡𝑟 = 𝐴𝑐𝑟 + 𝐴𝑠𝑢𝑏𝑟 = 34.17 + 18.21 = 52.38 𝑚2

𝐴𝑟𝑝𝑟𝑜 56.685
= = 1.082
𝐴𝑡𝑟𝑒𝑞 52.38

Or Excess heat transfer area = (1.082 − 1) × 100 = 8.2%

% Excess heat transfer area should be at least 10%. Hence, to increase the value of heat transfer area,
increase the tube length. New value of tube length is

1.15
𝐿 ≅ 1.82 × = 1.95 𝑚
1.082

Let new or revised tube length 𝐿 = 2 m with same number of tubes

Heat transfer area provided

2
𝐴𝑝𝑟𝑜 = × 56.685 = 61.95 𝑚2
1.83

Revised value of shell side condensation coefficient

ℎ𝑜𝑐 ∝ 𝐿1/3

2 1/3
ℎ𝑜𝑐 = ( ) × 1864.86 = 1920.9 𝑊/(𝑚2 ∙ 𝑜 𝐶)
1.83

New value of 𝑈∝

1 1 1 1
= − +
𝑈∝ 820.38 1864.86 1920.9

𝑈∝ = 831 𝑊/(𝑚2 ∙ 𝑜 𝐶)

1327 × 1000
𝐴∝ = = 33.73 𝑚2
831 × 47.336

𝐴𝑠𝑢𝑏 = 18.21 𝑚2

𝐴𝑟𝑒𝑞 = 33.73 + 18.21 = 51.94 𝑚2

39 | 4 2
𝐴𝑡𝑝𝑟𝑜 61.95
= = 1.1927
𝐴𝑡𝑟𝑒𝑞 51.94

Excess heat transfer area = (1.1927 − 1) × 100 = 19.27%

If the equal percentage of excess heat transfer are (19.27%) in both zones are provided then.

Heat transfer area provided for condensation:

𝐴𝑐𝑝𝑟𝑜 = 33.73 × 1.1927 = 40.23 𝑚2

Heat transfer are provided for sub cooling:

𝐴𝑠𝑢𝑏𝑝𝑟𝑜 = 18.21 × 1.1927 = 21.72 𝑚2

𝐴𝑠𝑢𝑏 21.72
= = 0.3506
𝐴𝑡𝑝𝑟𝑜 61.95

Hence, 35.06% of total heat transfer area should be provided for subcooling.Assuming that tube will be
uniformly distributed in the cross section of shell

𝐴𝑠𝑢𝑏𝑝𝑟𝑜 Area of segment of cross section utilized for subcooling

=
𝐴𝑡𝑝𝑟𝑜 Total cross − sectional area of shell

𝑥 𝐷𝑖2
0.3506 = 𝜋
2
4 𝐷𝑖
𝜋
𝑥= × 0.3506 = 0.2754
4

From Table 1.19b of Ref.2, for 𝑥 = 0.2754, ℎ/𝐷𝑖 = 0.382

Hence, 38.2% of shell inside diameter should be submerged in the pool of condensate to facilitate
subcooling.

This can be achieved by providing inverted U- seal (as shown in figure below) height of inverted U-seal
from the base of shell ID.

ℎ = 0.382 × 645 = 246.4 𝑚𝑚

40 | 4 2
Shell side pressure drop ∆𝑝𝑠 :

Shell side flow area

(𝑃𝑡 − 𝑑𝑜 )𝐵𝑠 𝐷𝑠
𝐴′𝑠 = × 𝑥′
𝑃𝑡

Where

ℎ
𝑥′ = 1 − = 1 − 0.382 = 0.618
𝑑𝑖

Let baffle spacing 𝐵𝑠 = Shell ID = 645 mm

(23.8125 − 19.05)
𝐴𝑠 = × 0.645 × 0.645 × 0.618 = 0.51 42 𝑚2
23.8125

Shell side mass velocity ,

𝑚̇ 3.0278
𝐺𝑠 = =
𝐴𝑠 0.05142

𝐺𝑠 = 58.884 𝑘𝑔/(𝑚2 ∙ 𝑠)

58.884
𝑢𝑠 = (𝐺𝑠 /𝜌𝑣 ) = = 21.105 𝑚/𝑠
2.79

Equivalent diameter for triangular pitch arrangement

1.1 2
𝑑𝑒 = (𝑃 − 0.907 𝑑𝑜2 )
𝑑𝑜 𝑡

1.1
= (23.81252 − 0.907 × 19.052 ) = 13.736 𝑚𝑚
19.05
0.013 736 × 58.884
𝑅𝑒𝑠 = = 73 530
1100 × 10−7 × 10−1
41 | 4 2
(Viscosity of MEK vapour at 83.87𝑜 𝐶 = 1100 × 10−7 𝑃𝑜𝑖𝑠𝑒) From Fig. 6.15, for 25% cut segmental
baffle Shell side friction factor, 𝐽𝑓 = 0.0358 𝑓𝑜𝑟 𝑅𝑒 = 73 530

𝐷𝑠 𝐿 𝜌𝑣 𝑢𝑠2 𝜇 −0.14
∆𝑝𝑠 = 0.5 × 8 × 𝐽𝑓 ( )( ) ( )
𝑑𝑒 𝐵𝑠 2 𝜇𝑤

645 2000 2.79 × 21.1052

= 0.5 × 8 × 0.0358 ( )( )×
13.736 645 2

= 129 56 𝑃𝑎 = 12.956 𝑘𝑃𝑎 < ∆𝑝𝑠 𝑚𝑎𝑥 (13.73 𝑘𝑃𝑎)

To decrease the shell side pressure drop further increase the % baffle cut from 25% to 35%. Then from
35% cut segmental baffle

𝐽𝑓 = 0.03

0.03
∆𝑝𝑠 = × 12.956 = 10.86 𝑘𝑃𝑎 < ∆𝑝𝑠𝑚𝑎𝑥 (13.73 𝑘𝑃𝑎)
0.0358

Tube side pressure drop, ∆𝑝𝑟 :

𝐿 𝜇 −𝑚 𝜌𝑢𝑡2
∆𝑝𝑡 = 𝑁𝑝 (8𝐽𝑓 ( ) ( ) + 2.5) ×
𝑑𝑖 𝜇𝑤 2

𝐿 = 2000 𝑚𝑚, 𝑁𝑝 = 4, 𝑑𝑖 = 15.748 𝑚𝑚, 𝜌 = 993.684 𝑘𝑔/𝑚3

𝑢𝑡 = 1.78 𝑚/𝑠

𝑅𝑒𝑠 = 38.657.6, 𝐽𝑓 = 3.41 × 10−3 (𝑓𝑟𝑜𝑚 𝐹𝑖𝑔 .6.13)

2000 993.684 × 1.782

∆𝑝𝑡 = 4 × (8 × 3.41 × 10−3 × ( ) × 1 + 2.5) ×
15.748 2

∆𝑝𝑡 = 37 558 𝑃𝑎 = 37.558 𝑘𝑃𝑎 < ∆𝑝𝑚𝑎𝑥 (68.6 𝑘𝑃𝑎)

Resulting Heat Exchanger Specifications:

1-4, fixed tube sheet shell and tube heat exchanger (BEM type)

Shell ID = 645 mm, Baffles: 35% cut segmental,

Baffle spacing = 645 mm,

Tube OD = 19.05 mm, 16 BWG, Tube length = 2000 mm,

∆ Pitch arrangment , Pt = 1.25 do Number of tubes, Nt = 518

42 | 4 2
 Course Notes on
Shell and tube Type Heat Exchangers

Part 3
Extracts Of TEMA