Faculty of Engineering

Department of Chemical Engineering

ENGINEERING PRACTICE AND

COMMUNICATION 3
ENPC031

DESIGNING A SHELL AND TUBE HEAT

EXCHANGER {E TYPE SHELL}

Surname and Initials Ziphathe E.

Student Number 22126765

Submission Date:10 APRIL 2023 LECTURER:DR S.

MSWENI

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Acknowledgements.

I would like to extend my gratitude to our lecturer Dr S.Mtsweni for converying the
knowledge to use and for helping use to go through the assignment to the extent of analysing
the assignment problem statement. My research skills and capabilities are improved due to
this assignment. I also thank Dr S. Mtsweni for taking his time to make a video on MS
TEAMS explaining the assignment and the Graduates Attribute application to the assignment.

TABLE OF CONTENTS

ACKNOLEGEMENTS…………………………………………………………………………2

DECLERATION…………………………………………………………………………………2-3

SUMMERY………………………………………………………………………………………4-6

INTRODUCTION………………………………………………………………………………….5-6

LITERATUREREVIEW……………………………………………………………………………6

METHODOLOGY……………………………………………………………………………...7-10.

CALCULATIONS…………………………………………..…………………………………..10-13

RESULTS………………………………………………………………………………………..…13-
15 DISCUSSION……………………………….…………………………………………………….15-
16

REFFERENC…………………………………………………………………………………………17

GRAPHS USE……………………………………………………………………………………..
…………….18

Declaration

the undersigned undergraduate engineering practice and communication 3 doing national

diploma at mangosuthu university of technology, located at Umlazi, Durban south Africa. I
hereby declare, that the report work is titled, the “design of the shell and tube heat exchanger”

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,that was submitted on the 10 April 2023, serves as the recorded proof of my original work,
which is done by me, under authority of Dr S. Mtsweni, lecture at mangosuthu university of
technology, In the department of chemical engineering.

This report is submitted for fulfilment of the requirements that are needed in the qualification
award. The results that are embodied in this report have not been submitted to any institution
before, I Esona Ziphathe understand the that violation of this declaration will yield bad
results on my academics and I will be punished if I copied someone’s work.

Name :E. Ziphathe

Student no:22126765

Date:10 April 2023

Signature :e.z

Place: mangosuthu university of technology

Nomenclature.

SI UNITS Quantity name and symbol

Kg/s Water flow rate, mw

Kg/s Steam mass flow rate, ms
W Heat duty, ∅
℃ Mean temperature,∆ Tlm
______ Temperature correctio factor, S
______ Temperature correctio factor, R
m
2 Area provided, Apr
W Overall HTC, ∅ t
TUBE SIDE
℃ Mean temperature
∆ Pt Area, at
Kg/s Mass velocity, Gt
m/s Velocity, ut
_____ Prandtl number, Pr
m Equivalent diameter, de
______ Reynolds number, Re
______ Heat transfer, jh
W Viscosity correction factor, hi
2
m .K

3
 W Water coefficient, hi
m2 . K
______ Friction factor, jf
Pa Pressure drop, ∆ Pt
2
m Area, as
Kg/s Mass Velocity, us
m/s velocity
m Equivalent diameter, de
____ Heat transfer factor, jh
_____ Reynolds number, Re
_____ Prandtl number, Pr
W ho
2
m .K
m Bundle diameter, DB
____ Nr
Kg/m.s Th
W hi
m2 . K
m2 Area required
m
2 Area required
W uo
m2 . K
W uo
2
m .K

summary.

We were designing the shell and tube heat exchanger for the given duty, and deciding
whether the heat exchanger used is suitable for the application and it will work or not in
appropriate manner for the specified duty. The heat exchangers are used to exchange heat of
two fluid flowing at varying temperatures. The heat exchanger are used for refrigeration and
other applications. The are many types of heat exchanger like the double pipe exchanger but
considering the shell and tube exchanger in this report. The shell and tube exchanger was
selected since it has the high efficiency.

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To determine whether the is appropriate for the given duty the mean temperature was
calculated, the heat duty, the estimation of the overall heat transfer coefficient was done, the
tube side and shell side coefficient was determined using the kern method, the overall heat
coefficient, the area required and Ao.

The increase in the surface area causes the overall heat transfer to enhance. The high velocity
prevents solids suspensions, too high velocities leads to corrosion thus giving high heat
transfer coefficient. The pressure drop was seen to be proportional to the operating costs.

Introduction.

The transfer of heat from the process fluid and to the process fluid is most used in the
chemical industries. The heat exchanger is the equipment used to make the exchange of heat
between two fluids that are at different temperatures. The term “exchanger” applies to the
equipment to which heat is exchanged, but it denotes the equipment in which heat is
exchanged between the process streams[1]. Heat exchangers are used in preheating, in
cooling the hot fluid or gas product to a temperature that the product could be stored safely
[3].

The are many types of heat exchangers that are used in the chemical industries, such as the
double-pipe heat exchangers that are simple and they are used for cooling and heating in the
process. The shell and tube exchanger that are used in applications. The plate and frame
exchanger is used for heating and cooling. The air cooled that are used for coolers and
condensers. The direct contact exchanger that are used for cooling and extinguishing. The
plate and fin used for cooling and heating. The fired heat exchanger and lastly the agitated
vessels. The heat exchangers are widely used for refrigeration, air cooling, space heating. The
design limitations of heat exchanger are the cost, efficiency, space, material, maintenance and
the ease of construction. [2]

In this report with regards the heat exchangers, I will be investigating whether the heat the
shell and tube heat exchanger is good enough to for heating water by steam, doing the design
of the E type shell and tube and I will be determining whether the shell and tube exchanger is
good enough for the given duty by means of assumptions.

Literature review.

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Heat exchanger is the equipment that allows heat to be transferred between two fluids that
have varying temperatures. Heat exchangers are used in industries because of their different
types of constructions and application in heat exchange processes for yielding conventional
energy such as steam generator, condenser and heaters. They provide more surface for heat
exchange to occur. Their mechanical and thermal characteristics allows high pressure and
high temperature processes. Most of the heat exchangers are used for cooling and for heating,
in chemical processes and electrical generation. [4]

The E type shell and tube exchanger are commonly used and they are suitable for most
applications and duties. The shell and tube exchanger have the bundle of tubes inside shell
(cylindrical). Tube sheets are made by fitting the end of the tubes, which causes the
separation of the tube side and the shell side of the fluid. The baffles are in the shell to direct
the flow of the fluid and give support to the tubes. The baffles enhances the velocity of a fluid
and improve the rate of heat transfer, and they are connected together by roads and the
spacers. The shell and tubes are used for cooling and heating large quantities of fluids. The
task of the shell and tube heat exchanger is cooling by circulating a hot fluid in the tubes that
contain the cooler liquid.[6]

Disadvantages and advantages of shell and tube exchanger.[7]

disadvantages advantages
The efficiency of heat exchange is less. Easy to clean.
It difficult to maintain and to clean. Well established design procedures.
capacity of tube cooler cannot be increased. Can be made from different materials.
They need more space. Superior mechanical layout.
Smalls thermal expansion are allowed. Uses well established fabrication
techniques.
Tube bundles are not removable for The configuration gives a huge surface area
cleaning. in a small volume.
Their use is restricted to low shell pressure. Short time of dismantling.
They will always be a danger of leakage in Less expensive.
internal flanges.

METHODOLOGY.

The approach of the design.

1. Deciding on the duty.

-heat transfer rate

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 -water flow rate
-the temperatures

2. the collection of the physical properties.

-density

-viscosity

-heat capacity

-thermal conductivity

3. taking decision on the type of heat exchanger to be used.

4. selection of trial values for the overall coefficient.

5. calculation of the mean temperature difference.

6.calculation of the area required.

7. deciding on the layout of the heat exchanger.

8. calculation of the shell side and the tube side coefficients.

9. calculation of the overall coefficient.

10. the calculation of the pressure drop of the exchanger.

11. optimizing the design.

The equations used.

1. Calculation of the heat duty

-for no change in phase.
∅=mcp ∆ t … … … … … … … … … … … … ..(chemical design hand book 2 nd . ad towler page 1048)

2. Energy balance

-to find to find the flow rate of water or steam.

∅=mcp ∆ t=mwclw ( ∆ t ) … … … … … … … … … … … … … … … . ¿

c)mean temperature difference.

∆ Tm=Ft . ∆ TLm

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 ∆ T 2−∆ T 1
∆ TLm=
∆T 2
ln ⁡( )
∆T 1

T 1−T 2 t 2−t 1
R= and S= ………………….
t 2−t 1 T 1−t 1
(chemical design 2nd .add page 1069-1070)

3. Estimation of overall heat transfer coefficient.

∅t
A=
U × ∆ Tm
A=NtπdoL…………….process equipment
design Harsh A. Panchal)
Type equation here .
4. Tube side area.
Nt π 2
at= × × d i … … … … … … … … . chemical design 2nd add page 1089
Np 4

5. Mass velocity at the tube side.

m
¿= ………………………….. chemical design 2nd add page 1089
at
6. The velocity at the tube side.

ut= ¿ ……………………………. chemical design 2nd add page 1089

ρ
7. Prandtl number on tube side.
ρutd e
ℜ= …………………………… chemical design 2nd add page 1089
μ
kf 0.33 μ 0.14
8. hi= jhRePr ( ) ………………………. chemical design 2nd add page 1079
di μw
9. coefficient of water.
0.8
4200 ( 1.35+0.02 t ) ut
hi= … … … … … … … … … chemical design2 nd add page 1 080.
di 0.2
10. pressure drop.

( )( )
−m
L μ ρut 2
∆ Pt =Np[8 jf +2.5] ………………………………. chemical design 2nd
di μw 2
add page 1081
11. Bundle diameter and shell diameter.
Ds=DB +Cl

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 1
Nt
) (
K 1 ……………………………….chemical design 2nd add page 1062
DB=do
n1

12. Tube side heat transfer coefficient.

-no change of phase
-determined by sieda-tate equation.
-if Re is less than 2000
0.33 0.14
hidi di μ
Nu= =1.86( ℜ . Pr . ) ( ) ……………………………………… chemical
kf L μw
design 2nd add page 1078
ρutde Gtde
ℜ= = …………………….. chemical design 2nd add page 1089
μ μ
cpμ
Pr= …………………………………………. chemical design 2nd add page 1089
kf

( μwμ )
0.14
0.33
If Re is greater than 4000 0.8 Pr ……….(process equipment design
Nu=CR e ❑
Harsh A.Panchal)

13. Calculation of the pressure drop tube side

( )( )
−m
L μ ρut 2
∆ Pt =Np[8 jf +2.5] ………….(chemical design 2nd add page 1081)
di μw 2
Type equation here .
14. Shell side heat transfer coefficient.

( pt−do ) DslB
As=
Pt

15. Shell side mass velocity

Gs Ws
Us= Gs= …………..(chemical design 2nd add page 1086)
ρ As
Type equation here .
16. Shell side equivalent diameter for triangular pitch

( )
2
pt do
de=4 × 0.87 pt−0.5 π ¿ ¿
2 4 πdo …………………(chemical design 2nd add page
2
1089)

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 J) Re number shell side

Gsde usdeρ
ℜ= = …………………chemical design 2nd add page 1089)
μ μ

k) Shell side coefficient.

0.14
hsde 0.33 μ
Nu= = jhRePr ( ) …… ………..10(
kf μw

l) shell side pressure drop.

( )( ) ( )
2 −0.14
Ds L ρu s μ
∆ Ps=8 jf … … … … chemical design2 nd add page 1089 … … … .
de lB 2 μw

m)overall heat transfer coefficient.

1
Uo=
do
doln ……………………………………..
1 1 di do 1 do 1
+ + + × + ×
ho hod 2 kw di hid di hi
(chemical design 2nd add page 1048)

n)heat transfer area required.

∅t
Ar=
uo ∆ Tm

Ao=Nt ∆ doL ………………………….(chemical design 2nd add page 1080)

Calculations.
Heat duty.
Kg Kg
m ( water )=50 × 997.2=49860 =13.85
h s
∅ ( water ) =∅ ( steam )
mwcp ∆ T =ms ×lamda

49860 × 4.296 × ( 70−10 )=ms× 2135

Kg
ms=5879.5 =1.63 Kg/s
h
Mean temperature difference.

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 ( 130−70 )−(130−10)
∆ Tlm=
130−70
ln ⁡( )
130−10
¿ 86.6 ℃
R=2∧S=0.5 Ft =1

∆ Tm=Ft × ∆ Tlm
86.6 ℃
Estimating overall HTC.

Aprovided=124 π × 0.019 ×4.094

¿ 30.3 m2

∅ t=30.0× 1500 ×86.6

6
¿ 3.936 ×10 W
Tube side.
124 π 2
at= × ×0.015
1 4
2
¿ 0.0219 m

13.85
¿=
0.0219
¿ 632.4 Kg/ s

632.4
ut=
997.2

0.6531× 10−3 ×4.196 × 103

Pr=
0.6305
¿ 4.35

997.2× 0.634 ×0.015

ℜ= −3
(de=di for the tubes)
0.6531× 10
¿ 14521

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 −3
jh=4 ×10

0.6305
hi= × 4 × 10−3 ×14521 ×4.35 0.33
0.015

W
¿ 2267.6 2
.K
m

COEFFICIENT OF WATER.

hi=4200(1.35+0.02 ( 40 )) ¿ ¿

W
¿ 14526 .℃
m2

−2 997.2× 0.63 4 2
∆ Pt =2.25[8 ×5 ×10 + 2.5] ×
2
−2
¿ 50357 Pa jf =5× 10

Shell side

( 0.024−0.019) ×0.337 × 0.106

as=
0.024
2
¿ 0.0074 m

1.63
Gs=
0.0074

¿ 220.27 Kg/s

220.27
us=
928.1

¿ 0.237 m/s

1.10
de= ¿
0.019
−2
¿ 0.0142 m jh=5× 10

0.237× 0.0142× 928.1

ℜ=
0.1905 × 10−3

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 ¿ 16396
−3 3
0.1905 ×1 0 ×4.296 × 10
Pr=
0.664

¿ 1.233

[ ]
2 −o .333
hc ml
Re greater than 30. =0.145
kl ρl ( ρl−ρv ) g

0.1905 ×1 0−3 −0.333

hc=0.145× 0.664[ ]
928.1 ( 928.1−1.908 ) 9.81

W
¿ 5938.5 2
.K
m

K1=0.319 n1=2.142

124 1
( )
0.319
DB=0.019
2.142

¿ 0.307 m

2 DB 2 0.307
nr = × = × =8.5
3 pt 3 0.024

ms 1.61 −3
Th= = =3.17∗10
cp × Nt 4.094 ×124

2
hc=20706.9 W /m

stainless steel material of construction, conductivity 53 W/m^2.K

500 W/m^2.k fouling factor assumed

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0.019 ln ⁡
1 1 1 15 19 19
= + + + +
uo 5938.5 5000 2× 53 15× 5000 15 ×2076.9

1
=7.24 ×1 0−4
uo

W
uo=1381 2
m .K

348676 2
Arequired= =3 m
1381× 86.6

13
 19
0.019 ln ⁡
1 1 1 15 19 19
= + + + +
uo 20716.9 5000 2× 53 15× 5000 15 ×2076.9

W
uo=1655 2
m .K

348676 2
Arequired= =2.4 m
1655 ×86.6

Therefore Arequired is less than the Aavailable, the heat exchanger will work for the specified duty.

Results.

Quantity name and symbol Calculated values SI UNITS

Water flow rate, mw 13.85 Kg/s

Steam mass flow rate, ms 1.63 Kg/s
Heat duty, ∅ 348676 W
Mean temperature,∆ Tlm 86.6 ℃
Temperature correctio factor, S 0.5 ______
Temperature correctio factor, R 2 ______
Area provided, Apr 30.3 m2
Overall HTC, ∅ t 3.936 ×1 0
6 W
TUBE SIDE
Mean temperature 40 ℃
Area, at 0.0219 ∆ Pt
Mass velocity, Gt 632.4 Kg/s
Velocity, ut 0.634 m/s
Prandtl number, Pr 4.35 _____
Equivalent diameter, de 0.015 m
Reynolds number, Re 14521 ______
Heat transfer, jh 4 ×1 0
−3 ______
Viscosity correction factor, hi 2267.6 W
2
m .K

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 Water coefficient, hi 14526 W
m2 . K
Friction factor, jf 5 ×1 0−2 ______
Pressure drop, ∆ Pt 50357 Pa
Shell side.
Area, as 0.0074 m
2

Mass Velocity, us 220.27 Kg/s

velocity 0.237 m/s
Equivalent diameter, de 0.0142 m
Heat transfer factor, jh 5 ×1 0
−2 ____
Reynolds number, Re 16396 _____
Prandtl number, Pr 1.233 _____
ho 5938.5 W
2
m .K
Bundle diameter, DB 0.307 m
Nr 0.5 ____
Th 3.17 ×1 0
−3 Kg/m.s
hi 20716.9 W
2
m .K
Area required 3 m
2

Area required 2.4 m

2

uo 1655 W
2
m .K
uo 1381 W
2
m .K

Design parameters selected.

Shell and tube exchanger.

Hot fluid Cold fluid U(W/

2
m .℃¿
steam water 1500-4000
Fouling factor assumed.

Fluid Coefficient W/
W/ 2
m .℃¿ Factor resistance
m2 . ℃ ¿
Heat transfer fluid 5000 0.0002
Triangular pitch=1.25do

No. passes 1

15
 K1 0.319
n1 2.142
Tube side.

-general equation of heat exchanger

( μwμ )
0.14
0.33
Nu 0.8 Pr C=0.027 for viscus liquids
¿ CR e ❑

-de=di

Physical properties Tube side(water) Shell side( steam)

P=101325Pa 130℃ ,270*10^3 Pa
40℃
Latent heat 2407.3 2135
Thermal conductivity 0.6305 1.905(v),928.1(l)
density 997.2 0.1905
Heat capacity 0.6531 4.296

Discussion.

The calculation of the mean temperature is necessary for the collection of water physical properties. It
is necessary to change the volumetric flow rate of water to mass flow rate in order to work out the
flow rate of the steam. The estimated overall heat transfer coefficient is the one that hindered the
pressure drop on the tube side to be much lower, because the Reynolds number us is low. If the we
change the estimated value to be high within the range ,the will be an increase in the pressure drop
and the Reynolds number. The overall heat transfer coefficient is the first iteration since it has the
larger surface area compered to the two areas( shell and tube side area).when the surface area
increases, the overall heat transfer coefficient increases too, because those are directly proportional to
each other. Therefore if there is large surface area more heat transfer will be required to exchange heat
on the huge area. It important to consider the surface area when designing the heat exchanger. [ Sinot,
R.,K. Coulso and Richardson’s chemical engineering series .Amsterdam]

Moreover, The velocity must be always high to prevent any suspended solids, but no too much high as
this would cause the corrosion. The velocities obtained are low, so this will give low heat transfer
coefficient , but will give low pressure drop on the tube side. The obtained velocity is below the range
of 1.5-2.5 m/s . the closer the difference of temperatures of two streams calculated on the end of the

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exchanger, the larger the area will be needed heat duty. The pressure drop of water is in the range of
5-70KN/m^2, this will minimize the operating costs( Gavin Towler, Ray Sinnott chemical
engineering design 2nd .ed page 1074-1075). The more corrosive fluid must be on the tube side to
reduce the costs of alloy. Placing the steam on the tube, the shell surface temperature. The high-
pressure tube are cheaper than the high pressure shells. The steam is allocated on the shell side to
yield more economical design. The require is found to be greater than the area available, this means
the heat exchanger will be able to work on the appropriate manner, therefore the design is feasible.
( Evans F .L (1980) equipment design hand book 2nd ed vol 2. Gulf) .

CONCLUSIONS

The STHE is the one of the most significant process design, the design of STHE is influenced by the
pressure drop on the tube side and on the shell side. Moreover it is influenced by the overall heat
coefficient which is influenced by the fluid flow. This design included the thermodynamics and the
heat transfer modes. It is easy to design the heat exchanger although it requires more understanding
and utilization, for example on the kern method which improved the efficiency of the shell and tube
heat exchanger.

In addition, I think that, if the physical properties of water and steam were given the design would be
easy as the is confusion on the selection of the steam physical properties. The physical properties have
an impact on the overall heat transfer coefficients, the velocity and other calculated quantities. The
design would be much easier if the temperatures of the steam was given. If the factors such as jh, jf, ji
were given or the reading of their graphs were illustrated then the design would be much easier.

References.

Baloiji, C. (2021). heat transfer engineering.

encyclopedia of physical science and technology (third edition ed.). (2003).

-G. TOWLER, R. S. (2013). heat tranfer equipment (second edition ed.). london.new
york .paris.san diego.chapter 19.1047-1175

-Minton. (1970).Designing spiral plate heat exchangers. chem eng.,ny,77(May 4),103

-Ozisik,M. N(1987).Heat tranfer:A basic approach. McGraw-Hill

-Parker,D.V(1964).Plate heat exchanger.Brit. Chem Eng.,1,142

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-Saunders, E. A. D(1988).Heat Exchangers. Logmans

-Monstinski, I. L. (1963).Calculations of boiling heat transfer coefficients, based on the law

of corresponding states. Teploenergetika,4,66, English abstract in British chem eng.,8,580.

used graphs

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