SECTION 9

Heat Exchangers
The process engineer is frequently required to analyze heat For isothermal condensing of the hot fluid:
exchanger designs, specify heat exchanger performance, and
determine the feasibility of using heat exchangers in new serv- •
Q = mH λH Eq 9-2
ices. This section is prepared with these specific operations in
mind and is not intended as a design manual. For no phase change of the cold fluid:
•
Q = mC CpC (TC2 − TC1) Eq 9-3
FUNDAMENTALS OF HEAT TRANSFER
For isothermal boiling of the cold fluid:
The basic definitions and equations used in heat exchanger •
Q = mC λC Eq 9-4
calculations are reviewed below:

Heat Balances Basic Heat Transfer Relations

For no phase change of the hot fluid: Q = UA (LMTD) for single-pass designs Eq 9-5a
•
Q = mH CpH (TH1 − TH2) Eq 9-1 Q = UA (CMTD) for multi-pass designs Eq 9-5b

FIG. 9-1
Nomenclature

A = area, sq ft T = temperature, °F
BP = baffle spacing, in. t = temperature, °F
C = tube count factor TMTD = True Mean Temperature Difference, °F
Cp = specific heat, Btu/(lb • °F) U = overall heat transfer coefficient, Btu/(hr • sq ft • °F)
CMTD = Corrected Log Mean Temperature Difference, °F W = width, in.
D = diameter, in. WTD = weighted temperature difference, °F
F = LMTD correction factor X = weight fraction
f = ratio of one value to another λ = latent heat, Btu/lb
FD = free diameter, in. µ = viscosity, centipoise
G = mass velocity, lb/(sq ft • sec)
ρ = density, lb/cu ft
GTTD = Greatest Terminal Temperature Difference, °F
h = film coefficient, Btu/(hr • sq ft • °F) Subscripts
H = height, in.
b = boiling
k = thermal conductivity, Btu/[(hr • sq ft • °F)/ft]
C = cold fluid
L = length, in.
c = condensing
LMTD = Log Mean Temperature Difference, °F
f = fouling
LTTD = Least Terminal Temperature Difference, °F
• H = hot fluid
m = mass flowrate, lb/hr
i = inside
N = number of exchangers
Np = number of passes in = inlet
∆P = pressure drop, lb/sq in. L = liquid
P = pressure, lb/sq in. absolute m = mean value
p = temperature efficiency n = nth value
PHE = plate and frame heat exchanger o = outside
Q = heat transferred, Btu/hr out = outlet
R = heat capacity rate ratio 2Φ = two-phase
Re = Reynolds number = (123.9 DG)/µ w = wall
RC = tube rows crossed v = vapor
r = film resistance (hr • sq ft • °F)/Btu 1 = first value
SP = number of baffle spaces 2 = second value

9-1

Shell and Tube Exchangers
For tubular heat exchangers, the heat transfer area gener-
ally referred to is the effective outside bare surface area of the
tubes, and the overall heat transfer coefficient must also be
based on this area.
Effective Temperature Difference
In most instances the local temperature difference between
the hot stream and the cold stream will not have a constant
value throughout a heat exchanger, and so an effective average
value must be used in the rate equation. The appropriate av-
erage depends on the configuration of the exchanger. For sim-
ple countercurrent and co-current exchangers (Fig. 9-2), the
Log Mean Temperature Difference (LMTD) applies.
FIG. 9-2
Countercurrent Flow and Co-current Flow
Fig. 9-3 defines LMTD in terms of Greatest Terminal Tem-
perature Difference (GTTD) and Least Terminal Temperature
Difference (LTTD), where “terminal” refers to the first or last
point of heat exchange in the heat exchanger.
For exchanger configurations with flow passes arranged to
be partially countercurrent and partially co-current, it is com-
mon practice to calculate the LMTD as though the exchanger
were in countercurrent flow, and then to apply a correction
factor to obtain the effective temperature difference.
CMTD = (LMTD) (F) = Corrected Mean Eq 9-6
Temperature Difference
The magnitude of the correction factor, F, depends on the ex-
changer configuration and the stream temperatures. Values
of F are shown in Figs. 9-4, 9-5, 9-6, and 9-7 for most common
exchanger arrangements. In general if the value obtained for
F is less than 0.8, it is a signal that the selected exchanger
configuration is not suitable, and that one more closely ap-
proaching countercurrent flow should be sought.
Heat Exchange with Non-Linear Behavior
The above Corrected Log Mean Temperature Difference
(CMTD) implicitly assumes a linear relation between duty and
stream temperature change. Some situations for which this
assumption is not applicable include process streams which
undergo a very large temperature change so that the physical
properties change significantly, multi-component condensing
or boiling with non-linear duty vs. temperature curves, and
exchangers in which the process stream undergoes both phase
change and sensible cooling or heating.
These situations may be handled by dividing the exchanger
into zones which may be treated individually with the linear
9-2
assumption. The overall exchanger performance may be rep-
resented in terms of the weighted average performance of the
zones in the overall rate equation. The following equations
may be taken as the rate equations for the overall exchanger
and for the nth zone of the exchanger.
QTo tal = Uw td ATotal (WTD) Eq 9-7
Qn = Un An (LMTD)n Eq 9-8
Then the weighted temperature difference may be defined
as:
Σ [UnAn(LMTD)n] QTotal
(WTD) = = Eq 9-9
Σ[UnAn] Σ[Qn/(LMTD)n]
And the weighted overall heat transfer coefficient becomes:
QTotal Σ[Qn/(LMTD)n]
Uwtd = = Eq 9-10
ATotal(WTD) ATotal
In multi-component, two-phase (vapor/liquid) flow regimes
undergoing heat transfer, the vapor and liquid composition
changes that occur are related to the extent of continuous con-
tact of the two phases. If the vapor phase is maintained in
contact with the liquid, the total change in enthalpy (or other
properties) that accompanies the composition change is
termed “integral.” If the vapor is continuously removed from
contact with the liquid as it is formed, the property changes
are termed “differential.” An accurate representation of tem-
perature difference and heat transfer in these cases depends
on correct consideration of the phase separation that occurs in
the heat transfer equipment.
Overall Heat Transfer Coefficient
1
Uo = Eq 9-11
 1  Ao   1   Ao 
 h +  A   h  + rw + rfo +  A  rfi
 o  i   i  i 
Metal Resistance for Plain Tubes
The metal resistance is calculated by the following equation:
 Do   Do
rw =   ln   Eq 9-12
 24kw   Di 
Values of the tube metal thermal conductivity are found in
Fig. 9-8 for several materials of construction at different metal
temperatures.
Fouling Resistances
Fouling resistances depend largely upon the types of fluid
being handled, i.e., the amount and type of suspended or dis-
solved material which may deposit on the tube walls, suscep-
tibility to thermal decomposition, etc., and the velocity and
temperature of the streams. Fouling resistance for a particu-
lar service is usually selected on the basis of experience with
similar streams. Some typical values are given in Fig. 9-9 and
in the TEMA Standards.
Film Resistances
Equations for calculating the film coefficients, ho, and hi, for
the simpler common geometries, as functions of flow rate and
fluid properties, may be found in heat transfer references and
in engineering handbooks. Some typical values of film resis-
tances are given in Fig. 9-11. Some common overall heat trans-
fer coefficients are shown in Fig. 9-9.
Film coefficients, film resistances, and overall heat transfer
coefficient are related as follows: hi = 1/ri, ho = 1/ro, and
U = 1/Σr (as in Eq 9-11).
 FIG. 9-3
LMTD Chart

9-3
 FIG. 9-4
LMTD Correction Factor (1 shell pass; 2 or more tube passes)

FIG. 9-5
LMTD Correction Factor (2 shell passes; 4 or more tube passes)

9-4
 FIG. 9-6
LMTD Correction Factor (3 shell passes; 6 or more tube passes)

FIG. 9-7
LMTD Correction Factor (4 shell passes; 8 or more tube passes)

9-5
 FIG. 9-8 and,
Typical* Metal Thermal Conductivities, kw 0.2 1.8 1.2
∆P2  µ2   G2   ρ1   Di1   Np2 
=   G  ρ   D   Np  Eq 9-14
∆P1  µ1   1  2  i2  1
Btu/[(hr • sq ft • °F)/ft]
Metal Temperature Shell side film resistance and shell side pressure drop have
Material
200°F 400°F 600°F 800°F similar arrays. In Fig. 9-10 all the variables that change in a
Aluminum, 3003 Tempered 104 106 – – vertical column apply where the flow regime is appropriate.
Carbon Steel 29 28 26 24 The stream types and flow regimes shown in Fig. 9-11 are
Carbon Moly (1⁄2%) Steel 25 25 24 22 typical for most fluids encountered in gas plants. These base
21⁄4% Cr, 1% Mo Steel 21 22 21 20 values of film resistance and pressure drop are used with the
13 Cr 16 16 16 16 relationships given in Fig. 9-10 to evaluate an exchanger de-
304 Stainless Steel 9.3 10 11 12 sign or to project the performance of an exchanger in a new
service. This can best be understood by following Example 9-1.
Admiralty 70 79 89 –
Copper 225 224 223 – Example 9-1 — The heat exchanger specification sheet, Fig.
90-10 CuNi 30 34 42 49 9-12, shows the heat transfer requirements and the mechani-
70-30 CuNi 18 21 25 30 cal design configuration for an oil-to-oil exchanger. Evaluate
Nickel 200 39 35 33 33 the indicated performance of this design.
NiFeCrMoCu (Alloy 825) 7.1 8.1 9.1 10 Solution Steps
Titanium 12 11.5 11.2 11.2
1. Check the heat balance on the data sheet. (See Fig. 9-12)
* Excerpt from TEMA Standards
•
[mHCpH(TH1 − TH2)]
QH/QC =
•
FIG. 9-9 [ mCCpC(TC2 − TC1)]
Typical Heat Transfer Coefficients, U, [475,723(0.542) (197 − 100)]
and Fouling Resistances, rf = = 1.0
[650,860(0.60) (124 − 60)]
Service and (rf) U Service and (rf) U 2. Calculate the LMTD.
Water (0.002)/
100 psi Gas (0.001) 35-40 Rich (0.001)/Lean Oil (0.002) 80-100 197 → 100
300 psi Gas (0.001) 40-50 C3 Liq/C3 Liq (0.001) 110-130 ____
124_ ← ____
60
700 psi Gas (0.001) 60-70 MEA/MEA (0.002) 120-130
1000 psi Gas (0.001) 80-100 100 psi Gas/500 psi Gas 50-70 73 40
Kerosene (0.001) 80-90 1000 psi Gas/1000 psi Gas 60-80
MEA (0.002) 130-150 1000 psi Gas/Cond. C3 (0.001) 60-80 (73 − 40)
Air (0.002) 20-25 Steam (0.0005) Reboilers 140-160 LMTD = = 54.9°F
Water (0.001) 180-200 Hot Oil (0.002) Reboilers 90-120
ln(73/40)
Condensing with Heat Transfer Fluid (0.001) Since the exchanger is countercurrent flow, the CMTD is
water (0.002)/ Reboilers 80-110
C3 or C4 (0.001) 125-135 the LMTD.
Naphtha (0.001) 70-80
3. Check the required heat transfer coefficient.
Still Overhead (0.001) 70-80
Amine (0.002) 100-110 25,000,000
U in Btu/(hr • sq ft • °F) U = = 100.6 Btu/(hr • sq ft • °F)
rf in (hr • sq ft • °F)/Btu (4525)(54.9)
4. Calculate the tube side pressure drop and resistance to
Performance Evaluation With Sensible heat transfer with the relationships shown in Fig. 9-10
Heat Transfer and the values shown in Fig. 9-11.

To predict the performance of a particular exchanger in a The total cross sectional flow area
new service or to compare different designs for a given service,
it is useful to understand the effects of changes in the variables [784 π (Di)2]
= = (784) (0.3019) = 237 sq in.
on film resistance to heat transfer and pressure drop. If vari- 4
ables (subscripted “1") are used for a reference basis (as those
(650,860)
values given in Fig. 9-11 are intended to be) a proration to a G = = 109.8 lb/(sq ft • sec )
new condition (subscripted ”2") can be applied based on ra- [(3600)(237/144)]
tioing the correlation of the variable at the new condition to
(123.9)(0.62)(109.8)
the reference condition. For film coefficients and pressure drop Re = = 40,200
determinations, Fig. 9-10 summarizes these ratios for the ap- 0.21
plicable variables. If tube side film resistance and pressure Therefore, it is turbulent flow since Re > 2000.
drop at new conditions involving turbulent flow were desired,
the variable arrays would be: From Fig. 9-10 (see Note †), the ratio of the second to the
first resistance is:
0.47 0.67 0.33 0.8 0.2
hi r2  µ2   k1   Cp1   G1   Di2 
= =   k   Cp  G   D  Eq 9-13 (ri)2 = (f) (ri)1
h2 r1  µ1  2  2  2  i1 

9-6
 FIG. 9-10
Variables in Exchanger Performance

r2 = (f) • (r1)† ∆P2 = (f) • (∆P1)†

Variable* Flow Regime
Shell (f) Tube (f) Shell (f) Tube (f)
Viscosity Turbulent (µ2/µ1)0.27 (µ2/µ1)0.47 (µ2/µ1)0.15 (µ2/µ1)0.2
0.14
Viscosity – bulk to wall  µ1 µw 2
correction Streamline  •  (µ2/µ1)
 µ2 µw1 
Thermal conductivity Turb. or Streamline (k1/k2)0.67 (k1/k2) 0.67

Sp. heat capacity Turb. or Streamline (Cp1/Cp2)0.33 (Cp1/Cp2)0.33

Mass velocity Turbulent (G1/G2)0.6 (G1/G2)0.8 (G2/G1)1.85 (G2/G1)1.8
(or mass flowrate) Streamline (G1/G2)0.33 (G2/G1)
Density Turb. or Streamline (ρ1/ρ2) ρ1/ρ2
0.4 0.2
Tube diameter Turbulent (Do2/Do1) (Di2/Di1) (Do1/Do2)0.15 (Di1/Di2)1.2
Tube diameter Streamline (Di2/Di1)0.33 (Di1/Di2)2
Tube length Streamline (L2/L1)0.33
Tube passes Turb. or Streamline (Np2/Np1)
No. baffle spaces Turb. or Streamline SP2/SP1
No. tube rows crossed‡ RC2/RC1

* Use consistent units for any one variable in both cases.

† f is the ratio of the new value to the old value for a given variable. The overall f is the product of the individual fs.
‡ Number of rows of tubes exposed to cross flow (as opposed to parallel flow). This number is determined by baffle and
bundle geometry

FIG. 9-11
Base Values for Use with Fig. 9-10(1)

Flow Tubeside (One Pass)

Fluid Local r
Regime k Cp ρ ∆P/ft µ(2) Gi Di
Water Turbulent 0.0009 0.358 1.0 62.1 0.068 0.764 265 0.62
HC Oil Turbulent 0.0038 0.0788 0.5 46.9 0.061 0.726 185 0.495
Methane Turbulent 0.0058 0.02 0.54 0.27 0.137 0.0113 31.2 0.62
HC Oil Streamline 0.049 0.0716 0.526 51.3 (4) (3) 42.3 0.834
Shellside
k Cp ρ ∆P(6) µ(5) Go(7) Do
Water Turbulent 0.0005 0.395 1.007 59.8 0.23 0.282 156.7 0.625
HC Oil Turbulent 0.0028 0.0762 0.557 46.8 0.25 0.549 132.4 0.625
Methane Turbulent 0.0038 0.037 0.655 0.23 0.09 0.0182 6.19 0.625

(1) Symbols and units are defined in Fig. 9-1

(2) Bulk average viscosity
(3) 6.62 and Wall viscosity is 27.75
(4) 0.14 psi for a 17 ft tube
(5) Average film viscosity
(6) Crossflow ∆P/baffle space/10 tube rows crossed between centroids of cut openings.
(7) Average crossflow mass velocity (see crossflow area calculation in Fig 9-13)

9-7
 Use base values from Fig. 9-11 for (ri)1 conditions. 0.15 1.85 0.15
 µ2   G2   ρ1   Do1  SP2   RC2 
0.47 0.67 0.33 0.8 0.2 f =   G    D   SP   RC 
 µ2 
f =  
 k1 
k 
 Cp1 
 Cp 
 G1 
G 
 Di2 
D   µ1   1  ρ2   o2   1   1
 µ1   2  2  2  i1 0.15 1.85 0.15
 0.34   121.4  46.8   0.625  19  23 
 0.21 
0.47
 0.0788
0.67
 0.50 
0.33
 185 
0.8
 0.62 
0.2 =    132.4  41.2   0.750  1   10 
=    0.078   0.600   109.8   0.495   0.549         
 0.726         
= 38.3
= 0.840
Basis: (Inside Area) (∆Po)2 = (f) (∆Po)1 = (38.3) (0.25) = 9.58 psi
6. Calculate the tube metal resistance.
(ri)2 = f(ri)1 and (ri)1 = 0.0038 from Fig. 9-11
Do = 0.75 in.
= (0.840) (0.0038)
Di = 0.62 in.
= 0.0032 (hr • sq ft • °F)/Btu
kw = 30 Btu/[(hr • sq ft • °F)/ft] , from Fig. 9-8.
From Fig. 9-10 (see Note †), the ratio of the second to the
first pressure drop is: Do   Do  0.75   0.75  
rw = =
24 kw   Di  (24)(30)   0.62  
ln ln
(∆Pi)2 = (f) (∆Pi)1
Use base values from Fig. 9-11 for (∆Pi)1 conditions. = 0.0002 (hr • sq ft • °F)/Btu
0.2 1.8 1.2
 µ2   G2  ρ1  Di1   Np2  7. Calculate the overall heat transfer coefficient.
f =   G    D   Np   Ao   Ao 
 µ1   1  ρ2  i2  1 Σr = ri   + ro + rw + rfo + rfi  A 
A
 i  i 
0.2 1.8 1.2
 0.21   109.8  46.9   0.495   1
=    185   38.3   0.62  1  0.1963 
 0.726         = 0.0032   + 0.0028 + 0.0002 + 0.0020
 0.1623 
= 0.285  0.1963
+ 0.001   = 0.0101
(∆Pi)2 = (f) (∆Pi)1 = (0.285) (0.061) = 0.017 psi/ft  0.1623 
For a 30 ft tube length the total ∆P is 30(0.017) = 0.51 psi 1 1
U = = = 99.0 Btu/(hr • sq ft • °F)
Σr 0.0101
5. Calculate the shell side pressure drop and resistance to 8. Compare the required heat transfer coefficient calcu-
heat transfer with the relationships shown in Fig. 9-10, lated in step 3 to the value calculated in step 7. (Available
the values shown in Fig. 9-11, and the data shown in U = 99.0; required U = 100.6) The available value is
Fig. 9-13. 1.6% less than the required value, and the calculated
(475,723) pressure drops are less than the pressure drops allowed
G = = 121.4 lb/(sq ft • sec) in Fig. 9-12. Therefore, by these calculations, the unit
(3600)(156.8/144)
will perform adequately.
From Fig. 9-10 (see Note †), the ratio of the new to the
old resistance is:
(ro)2 = (f) (ro)1
CONDENSERS
Use base values from Fig. 9-11 for (ro)1 conditions. The purpose of a condenser is to change a fluid stream from
0.27 0.67 0.33 0.6 0.4 the vapor state to the liquid state by removing the heat of
 µ2   k1  Cp1   G1  Do2  vaporization. The fluid stream may be a pure component or a
f =   k  Cp  G  D 
 µ1   2  2  2  o1 mixture of components. Condensation may occur on the shell
0.27 0.67 0.33 0.6 0.4 side or the tube side of an exchanger oriented vertically or
 0.34   0.0762  0.577  132.4   0.75  horizontally.
=    0.077   0.542  121.4   0.625 
 0.549         
Condensing the overhead vapors of a distillation column is
= 0.998 an example of condensing a mixed vapor stream. A vertical
exchanger flanged directly to the top of the column might be
(ro)2 = (f)(ro)1 = (0.998)(0.0028) = 0.0028 (hr • sq ft • °F)/Btu used. The condensed liquid drains back into the column coun-
From Fig. 9-10 (see Note †), the ratio of the new to the tercurrent to the vapor entering the condenser. The major con-
old pressure drop is: cerns in designing this type exchanger are keeping the vapor
velocity sufficiently low to prevent flooding the exchanger and
(∆Po)2 = (f) (∆Po)1
evaluating an appropriate temperature profile at the condens-
Use base values from Fig. 9-11 for (∆Po)1 conditions. Ob- ing surface to determine an effective temperature difference.
tain tube rows crossed between baffle window centroids The technical literature addresses criteria for flooding deter-
from Fig. 9-13. mination1 and special flow characteristics of falling liquid
RC2 = 23 (RC1 = 10 per note on Fig. 9-11) films. A useful estimate for determining an effective tempera-
ture difference can be made by assuming an isothermal con-
Obtain the number of crossflow spaces, which is one more densate film at the saturation temperature of the last
than the number of baffles, from Fig. 9-12. condensate formed. If the condensing temperature range ex-
SP2 = 19 [ SP1 = 1 per note on Fig. 9-11 since (∆Po)1 ceeds 10°F, consulting a specialist is recommended for a more
is for one baffle space.] rigorous calculation procedure.

9-8
 FIG. 9-12
Heat Exchanger Specification Sheet

1 Job No.
2 Customer Reference No.
3 Address Proposal No.
4 Plant Location Date Rev.
5 Service of Unit Lean Oil to Rich Oil Exchanger Item No.
6 Size 30-360 Type NEN (Hor/Vert) Connected In Parallel Series
7 Surf./Unit (Gross/Eff.) 4525 Sq Ft: Shells/Unit One Surf/Shell (Gross/Eff.) 4525 SqFt
8 PERFORMANCE OF ONE UNIT
9 Fluid Allocation Shell Side Tube Side
10 Fluid Name Lean Oil Rich Oil
11 Fluid Quantity, Total Lb/Hr 475,723 650,860
12 Vapor (In/Out)
13 Liquid 475,723 475,723 650,860 650,860
14 Steam
15 Water
16 Noncondensable
17 Temperature (In/Out) °F 197 100 60 124
18 Specific Gravity (#/ft3) AVG. 41.2 38.3
19 Viscosity, Liquid (AVG.) 0.34 0.21
20 Molecular Weight, Vapor
21 Molecular Weight, Noncondensable
22 Specific Heat (AVG.) Btu/Lb °F 0.542 0.600
23 Thermal Conductivity * 0.077 (AVG.) 0.078 (AVG.)
24 Latent Heat Btu/Lb @ °F
25 Inlet Pressure Psig 110 435
26 Velocity Ft/S
27 Pressure Drop, Allow./Calc. PSI 12 / 9.58 10 / 0.51
28 Fouling Resistance (Min.) 0.0020 0.0010
29 Heat Exchanged 25,000,000 Btu/Hr: MTD (Corrected) 54.9 °F
30 Transfer Rate, Service 100.6 Clean 148.4 Btu/Hr Sq Ft °F
31 CONSTRUCTION OF ONE SHELL Sketch (Bundle/Nozzle Orientation)
32 Shell Side Tube Side
33 Design/Test Pressure Psig 185 /Code 500 /Code
34 Design Temperature °F 650 650
35 No. Passes per Shell One One
36 Corrosion Allowance In. 0.0625 0.0625
37 Connections In 10" 14"
Size &
38
Rating
Out 10" 14"
39 Intermediate
40 Tube No. 784 OD 0.75 In.; Thk (Min/Avg) 0.065 In.; Length 30 Ft; Pitch 0.9375 In. X ▼30 ▲60 ■90 ◆45
41 Tube Type SA-214 (welded steel) Material
42 Shell SA-516-70 ID 30 OD In. Shell Cover (Integ.) (Remov.)
43 Channel or Bonnet (2) SA-516-70 (Int.) Channel Cover (2) SA-516-70 (Rem.)
44 Tubesheet-Stationary (2) SA-516-70 Tubesheet -Floating
45 Floating Head Cover Impingement Protection
46 Baffles-Cross SA-283-C Type Segmented % Cut (Diam/Area) 34 Spacing: c/c 18-5/8 In.
47 Baffles-Long Seal Type
48 Supports-Tube SA-283-C U-Bend Type
49 Bypass Seal Arrangement Spacers Tube-Tubesheet Joint
50 Expansion Joint NONE Type
51 ρv2-Inlet Nozzle 1717 Bundle Entrance 2220 Bundle Exit 1210
52 Gaskets-Shell Side Tube Side
53 -Floating Head
54 Code Requirements ASME Sec. VIII Div 1 (with Stamp) TEMA Class “C”
55 Weight/Shell 20,600 Filled with Water 29,900 Bundle Lb.
56 Remarks
57 *Btu/[(hr • sq ft • °F)/ft]
58
59
60
61

9-9 Revised (5-00)

 FIG. 9-13 heat is removed from the vapor at the condensate-vapor inter-
face by vaporizing (flashing) condensate so that the heat of
Heat Exchanger Detail Design Results
vaporization is equal to the sensible heat removed from the
vapor. Under this “wet wall” condition, the effective tempera-
ture of the vapor is the saturation temperature, and the effec-
tive heat transfer mechanism is condensation. The
determination of the point in the desuperheating zone of a
condenser where “drywall” conditions cease and “wet wall”
conditions begin is a trial and error procedure. A method fre-
quently employed to give a safe approximation of the required
surface is to use the condensing coefficient and the CMTD
based on the vapor saturation temperature to calculate the
surface required for both the desuperheating zone and the con-
densing zone.
The following Example 9-2 will illustrate the use of the heat
release curve to calculate the surface required and the LMTD
for each zone in a condenser for a pure component application.
Example 9-2 — A propane refrigerant condenser is required
to condense the vapor stream using the heat release curve as
shown in Fig. 9-14. This stream enters the condenser super-
heated and leaves the condenser as a subcooled liquid. Assume
that a single-tube pass, single-shell pass, counterflow ex-
changer is used so that LMTD correction factors do not apply.
Note that the propane is on the shell side. The overall heat
transfer coefficients for each zone are as follows:
Desuperheating: (180°F to 108°F)
Uv = 69.9 Btu/(hr • sq ft • °F)

hv = 111.1 Btu/(hr • sq ft • °F)

Condensing: (108°F to 108°F)
Uc = 140.0 Btu/(hr • sq ft • °F)
Leakage – use TEMA tolerances Subcooling: (108°F to 95°F )
tube hole = 576 x 0.75"π x 1/64" = 21.2 sq in
shell crack = 30"π x 0.175" x 0.60 = 9.9 sq in UL = 114.5 Btu/(hr • sq ft • °F)
31.1 sq in Solution Steps
Window flow area: 1. Calculate the surface temperature (outside wall) on the
window area = (0.237) (30")2 = 213.3 sq in vapor side at the refrigerant stream inlet using the fol-
tubes in window = (208) (0.785) (0.75")2 = 91.8 sq in lowing equation:2
121.5 sq in
leak 31.1 sq in
FIG. 9-14
152.6 sq in
Cross flow area: Propane Condensing Curve
Free area = 6.75" x 18 5/8" = 125.7 sq in
Leakage = 31.1 sq in
Net cross flow area = 156.8 sq in
BP = baffle pitch = 18 5/8"
FD = free diameter = 6.75"
Note: window area ≅ cross flow area

The condensing of a pure component occurs at a constant

temperature equal to the saturation temperature of the in-
coming vapor stream. Frequently a vapor enters a condenser
superheated and must have the sensible heat removed from
the vapor before condensation can occur. If the condensing sur-
face temperature is greater than the incoming vapor satura-
tion temperature, the superheat in the vapor is transferred to
the cold surface by a sensible heat transfer mechanism (“dry-
wall” condition). If the condensing surface temperature is less
than the saturation temperature of the incoming vapor, a con-
densate film will be formed on the cold surface. The sensible

9-10