SHELL & TUBE HEAT

EXCHANGER

QAIM ALI 2005-Chem-87 1

 Heat Exchanger

Heat exchanger is the equipment used to exchange

heat between two fluids at different temperature
through a fixed wall without mixing the two fluids.

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Significance in the Process

Basic purpose of heat exchanger is to cool the

crude maleic anhydride from 400oC to 300oC
flowing at the rate of 69970 Kg/hr using
cooling water at 28oC.

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 Fluid Description

Shell Side: (Process Fluid)

§Crude Maleic Anhydride (MAN)

Tube Side: (Coolant)

§Cooling Water

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 Cooling Water
Temperature = 28 0C
Crude Maleic Pressure = 215 KPa
Anhydride Flow Rate = 6.25x105 Kg/hr
Temperature = 400 oC
Pressure = 152 KPa
Flow Rate = 69970Kg/hr

Temperature = 3000C
Pressure = 81.5 KPa

Temperature = 31 oC
Pressure = 171 KPa
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 Physical Properties
(Crude Maleic Anhydride)

Flow Rate = 69970 Kg/hr

Inlet Temp. = 400 oC
Outlet Temp. = 300 oC
Pressure = 152 kPa
Specific Heat (Cp)= 1.13 kJ/Kg.°C
Thermal conductivity (k) = 0.05 W/m.0C
Viscosity ( ) = 3.24x10-5 Kg/m.sec
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 Physical Properties
(Water)

Flow Rate = 6.25x 105Kg/hr

Inlet Temp. = 28 oC
Outlet Temp. = 31 oC
Pressure = 215kPa
Specific Heat (Cp) = 4.21 kJ/Kg.°C
Thermal conductivity (k) = 0.62 W/m.0C
Viscosity ( ) = 7.8x10-5 Kg/m.sec
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Types of Heat Exchangers

1.Double pipe
2.Shell and tube
3.Spiral type
4.Plate and frame
5.Compact heat exchanger

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Shell & Tube HE Features

i. Configuration gives large surface area in

small volume.
ii. Can be constructed from wide range of
material.
iii. Good mechanical lay out.
iv. Can be easily cleaned.

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 Types of shell & tube
Heat Exchanger
This classification is based on the type of tube
bundle fitting in the shell.

ii.Fixed tube type

iii.U-tube type
iv.Floating head type

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 Selection Criteria
(Floating head)

i. Area requirement lies within range.

ii. It eliminates differential expansion
problems.
iii. It is easy to clean tube bundle as it
can be withdrawn from channel end.

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Selection of Heat Exchanger

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 Fluid Allocation

Shell side fluid selection(Crude MAN):

i. Low viscosity fluid.
ii. Fluid which exhibit low heat transfer
coefficient.
Tube side fluid selection(Water):
i. Corrosive fluid.
ii. Fluid having high heat transfer
coefficient.
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 Shell selection

1.Shell orientation
2.Shell diameter
3.Shell passes

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 Tube Selection

1.Tube type
2.Tube length
3.Tube pattern

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Baffle Selection

1. Baffle type(segmental)
2. Baffle cut(25%)
3. Orientation (vertical)
4. Baffle spacing

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 Standard Design steps

1. Heat load
2. LMTD
3. Assume overall heat transfer coefficient
4. Calculate area required
5. Assume geometry
6. Calculate individual heat transfer coefficient
7. Calculation of overall heat transfer coefficient
8. Calculation of pressure drop in shell and tube
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 Design of 1–2 Counter Flow
Shell and Tube Heat Exchanger

Design Steps:
1. Heat Load:

Crude MAN:
Q = w Cp ∆T
= 7.9 x 106 KJ/hr
= 2198 KWatt
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2- Calculation of LMTD:

LMTD =313.5 0C
R = 10 P = 0.027
FT = 0.98
∆T = 307 0C
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(Reference: Plant Design and Economics by Timmer Hause)
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3- Heat Transfer Area:
Q = UA ∆T
A = Q / U ∆T

Assumed UD=280 W/m2.0C

(Range=50-400 W/m2 .0C)

A = 92 m2

(Ref. Heat Exchangers by Ali A. Rabah) 21

 Tube Specification

16 BWG
Outside Diameter = OD = 0.019m

Inside Diameter = ID = 0.016m

Length of Tube L = 4.88 m
Pitch = 1.25*OD =.024m
(triangular pitch)
(Ref:Process Heat Transfer by D.Q Kern ,Table 9)
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 4- No. of Tubes:
Nt = A/La = 315

Where A = total heat transfer area

L = Length of tube
a = surface area per linear foot
Nearest Tube Count = 316
ID of Shell:
=0.54m
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(Ref:Process Heat Transfer by D.Q Kern ,Table 9)
Correction of Heat transfer
Area and UD:
Corrected Area:
A = Nt x La
Ac = 92.2m2

Corrected Coefficient UD:

UD = 279 W/m2 0C
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 Shell Dimension
For Triangular Pitch:
K1 = 0.249 n1 = 2.207
Bundle diameter:
Db = Di(Nt/k1)1/n1
= 0.485 m
Ref: “Coulson & Richardson’s Chemical Engineering (Vol - 6)” Table 12.4

Shell Clearance:
= 0.054m (For split ring floating head) 25

Ref: “Coulson & Richardson’s Chemical Engineering (Vol - 6) fig 12.10

 26

(Ref. Process Heat Transfer by D.Q Kern)

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28
29
10- Clean Overall Coefficient:

Uc = hohio/(ho+hio)

= 313 W/m2 0C

11- Dirt Factor:

Rd = (UC – UD)/ UC.UD

= 0.0003 m2 0C /Watt

(Range= 0.003-0.0001 m2.0C/W) 30

(Ref. Heat Exchangers by Ali A. Rabah)

 12- Pressure Drop:
Tube Side
Shell Side

∆Ps ∆PT = ∆Pt + ∆Pr

= fGS2(N+1)Ds/5.22x1010DeΦs ∆Pt = fGt2xLn/5.22x1010DΦt

No. of crosses f = 0.00018, For Re=55693

N+1 = 12 L/B = 9 L =4.88 m , Di= 0.0157m
Ds = 0.54m ∆Pt = 5.67 psi
S = specific gravity = 0.105
For Re = 31924 , f = 0.0002 ∆Pr = (4n/s) x v2/2g
(Fig.29 Kern) v2/2g = 0.05 (Fig.27 Kern)
∆Ps = 52 kPa ΔPr = 0.4
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∆PT = 44 kPa
 Heat Exchanger
Identification: Item: Heat Exchanger
Item No. E-102
No. required: 1
Function: To cool the product from the reactor
Operation: Continuous
Type: Horizontal
Floating Head, Shell and Tube type
Duty: 2198 kWatt Heat Transfer Area: 92.2m2
Tube Side: Tubes: 0.019m outside Diam ,16 BWG
Fluid handled Cooling water 0.025m Δ Pitch
Flow rate 6.25x105Kg/hr 158 Tubes each Length 4.88m

Pressure drop 40 kPa 2 passes

Temperature 28 to 31oC Film Coefficient=1131W/m2.0C
Shell Side: Shell: 0.54m 1 Pass
Fluid handled Crude MAN Baffles 8 25% Cut
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Flow rate 69970 Kg/hr Channel baffles 1
Pressure 152 to 81.5 kPa Longitudinal baffle 0
Temperature 400 to 300oC Film Coefficient=433 W/m2.0C