Shell and Tube Sizing and Rating Calculations

Shell and Tube Heat Exchanger Calculations
Link: Heat Exchanger Calculations
This tool was developed for process engineers to quickly estimate heat exchangers (single-phase gas or
liquid) efficiencies and create preliminary designs using kern, bell Delaware and NTU methods, and
access a list of useful tables on site. As a part of a larger project to develop what is similar to Carl
Branan’s book “process engineers Pocket Handbook” these tools would allow a process engineer to
quickly calculate/estimate equipment efficiencies or sizing using standardized calculations
The aim here is to take little-known data from the field (flow, pressures, temperatures,
compositions..etc.) and use it as input for a rough estimation without having to return to the office to
use commercial software or calculations Excel sheets to validate or to calculate. Additionally, these tools
may also serve as a gathered data validation tool.
Nomenclature
T Temperature (oC) P Pressure (kg/cm2.a)

ṁ Mass Flow rate (kg/hr) R Heat capacity ratio
ρ Density (kg/m3) S Temperature efficiency
Re Reynold’s number Ft Correction factor
Di Tube inside diameter (mm) µ Viscosity (Cp)
Do Tube outside diameter (mm) K Thermal conductivity (W/m.K)
L Tube Length (m) Cp Heat Capacity (Kg/Kcal.hr. oC)
U Overall Heat transfer coefficient A Exchanger Area (m2)
W/m2.K
Q Heat Duty (W and Kcal/hr) Ds Shell Diameter
Leff Effective length (m) Nt Number of tubes
De Equivalent Diameter (mm) h Heat transfer coefficient
W/m2.K
PT pitch size (mm) LMTD Logarithmic mean temperature difference
B baffle spacing (mm) Gs cross flow mass velocity m/m2.s

Np Number of tube passes C Clearance (mm)
Nb Number of baffles
Input Required
Table 1: Note 1: Input required depending on the case
Kern & Bell Delaware Rating Calculations Kern & Bell Delaware Preliminary Calculations
Flow rates kg/hr Flow rates kg/hr
o o
Inlet/outlet temperatures C Inlet/outlet temperatures C
Inlet/outlet pressures Kg/cm2.a Inlet/outlet pressures Kg/cm2.a
Average Densities [1] Average Densities [1]
Average Heat Capacities [1] Kcal/kg. oC Average Heat Capacities [1] Kcal/kg. oC
Average Heat Thermal Conductivities[1] W/m. °C Average Heat Thermal W/m. °C
Conductivities[1]
Average Viscosities [1] cP Average Viscosities [1] cP
Alternative option: Alternative option:
Liquid/gas: Composition Liquid/gas: Composition Vol% or
Vol% or mol%
Liquid oil fraction: SG. & temperatures Liquid oil fraction: SG. & mol%
- /°C
temperatures - /°C
Fouling factors W/m. K Fouling factors W/m. K
Exchanger Geometry Desired features in the design
Tube Diameter & thickness mm Bell Delaware
Pitch type and pitch -/mm Pitch type and pitch ratio -/-
Shell diameter mm Kern
Number of tubes / number of passes Assumed Uservice W/m2. °C
Tube Length mm Length mm
Baffle spacing mm Pitch type and pitch ratio -/-
Baffle cut %
Output Obtained
Kern and Bell Delaware Calculations NTU calculations
Duty KCal/hr Q W
∆TLMTD UA W/K
Ft Cr W/K
Corrected LMTD Cmin W/K
Surface Area m² Cmax W/K
Tube Heat transfer Coef. W/m²-°C effectiveness
Shell Heat transfer Coef. W/m²-°C NTU
Uclean W/m²-°C Thi °C
Udirty W/m²-°C Tho °C
Uservice W/m²-°C Tci °C
Over Design % Tco °C
Over Surface %
Shell Reynolds Number
Tube Reynolds Number
Tube Velocity m/s
Shell Velocity m/s
Shell D mm
Baffle Spacing mm
Number of baffles
Do mm
Di mm
Length mm
Number of tubes
Number of passes
Tube pitch mm
pitch type
baffle cut %
Heat Exchangers calculations
1. Shell and tube heat exchangers’ rating
Shell and tube heat exchanger rating is an essential process in evaluating the performance and
efficiency of a shell and tube heat exchanger. Heat exchanger rating involves determining the actual
heat transfer rate, pressure drop, and overall thermal performance of the heat exchanger based on
its operating conditions and design specifications.
During the rating process, several key factors are taken into account. These include the inlet and
outlet temperatures of both the hot and cold fluids, the flow rates of the fluids, the physical
properties of the fluids (such as density, specific heat capacity, thermal conductivity, and viscosity),
and the heat exchanger's geometric and design parameters (such as tube diameter, tube length,
shell diameter, and number of tube passes).
The rating process typically involves two main calculations:
1. Heat Transfer Calculation: This calculation estimates the actual heat transfer rate occurring in
the heat exchanger.
2. Pressure Drop Calculation: This calculation determines the pressure drop experienced by the
fluids as they flow through the heat exchanger.
By performing heat transfer and pressure drop calculations, the rating process allows engineers to
evaluate the actual performance of the heat exchanger and compare it against the design
specifications.
Additionally, heat exchanger rating also provides valuable insights into the heat exchanger's thermal
performance over time, considering factors like fouling, scaling, or degradation. This information
aids in determining maintenance schedules, cleaning intervals, and potential efficiency
improvements.
Rating Procedures: [4]
1. Calculate the required overall coefficient

2. Calculate the clean overall coefficient
3. Check if Uc > Ureq (If not then the exchanger isn’t suitable)
4. Calculate the dirty overall coefficient by adding shell and tube fouling factors
5. Check if Ud > Ureq (If not then the exchanger isn’t suitable)
1.1 Heat exchangers rating (Kern’s Method)[1]
Where
T1, T2: inlet/outlet of hot stream
T1, t2: inlet/outlet of cold stream

Duty (for single-phase heat exchangers)
Hot stream = ṁ.Cp(T1-T2)
Cold stream = ṁ.Cp(t2-t1)
The logarithmic mean temperature difference

𝑇 −𝑇
R=
𝑡 −𝑡
𝑡 −𝑡
S=
𝑇 −𝑡
R: Heat capacity ratio
S: Or P, Temperature efficiency
Using Fig. 18 in reference [1]. We get the correction factor Ft or from [2]
√𝑅 + 1 ∗ ln( )
𝐹𝑡 =
( √ )
(𝑅 − 1) ∗ ln
( √ )
(𝑇1 − 𝑡2) − (𝑇2 − 𝑡1)

𝐿𝑀𝑇𝐷 = ( )
ln
( )
𝐶𝑜𝑟𝑟𝑒𝑐𝑡𝑒𝑑 𝐿𝑀𝑇𝐷 = 𝐹𝑡 ∗ 𝐿𝑀𝑇𝐷
Heat Exchanger area (m²)
Area = N ∗ πD L ∗ n
Nt: no. of tubes
Do: tube outer diameter (m)
L: tube Length (m)
n: no. of units
Overall Heat transfer coefficient (required or service)

Q calculated (Kcal / ℎ𝑟)
U (kcal / m². hr. °C) =
A (m ) ∗ corrected LMTD
Overall Heat transfer coefficient

Calculated overall heat transfer coefficient
1
𝑈=
+ 𝑟𝑜 + 𝑟𝑤 + 𝑟𝑖 ∗ +( ∗ )
U = Calculated overall heat transfer coefficient (fouled) (Kcal/h-m¹C)

ho = Shellside film coefficient (Kcal/h-m¹C)
hi = Tubeside film coefficient of fluid inside tubes (Kcal/h-m¹C)
ro= Shellside fouling resistance on outside of tubes (h-m². C/Kcal)
ri = Tubeside fouling resistance on inside of tubes (h-m². C/Kcal)
rw = Resistance of tube wall referred to outside surface of tube (h-m². C/Kcal)
Ao/Ai = Ratio of outside to inside surface tubing
Shell side heat transfer coefficient & pressure drop

Equivalent diameter
4 × 𝑓𝑟𝑒𝑒 𝑓𝑙𝑜𝑤 𝑎𝑟𝑒𝑎
𝐷 =
𝑤𝑒𝑡𝑡𝑒𝑑 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟
/
𝐷 = , for square pitch
𝐷 = , for triangular pitch

/
Bundle cross flow area

𝐷 𝐶𝐵
𝐴 =
𝑃
Ds: Shell inside diameter m C: Clearance m
PT: pitch size m B: baffle spacing m
Shell Reynold’s number & friction factor

𝑓 = exp(0.576 − 0.19 ln 𝑅𝑒)
Where
400 < 𝑅𝑒 < 1,000,000

Shell side heat transfer coefficient [1]
.
𝐷𝑒 𝐷𝑒. 𝐺𝑠 𝐶𝑝. µ µ .
ℎ ∗ = 0.36 . .( )
𝑘 µ 𝑘 µ
for
2,000 < 𝑅𝑒 < 1,000,000

ho: shell side heat transfer coefficient (W/m2.K)
De: equivalent diameter (m)
k: thermal conductivity (W/m.K)
µ: Viscosity (N.s/m2)
Gs: shell side mass velocity (kg/s.m2) 𝐺 =
̇
Cp: heat capacity (j/kg.K)

µ : viscosity at wall temperature (N.s/m2)
Shell side pressure drop
𝑓𝐺 (𝑁 + 1)𝐷
∆𝑝 = 𝑛.
2⍴𝐷 𝜙
µ𝑠 0.14
Where 𝜙 = ( ) ,𝑁 = − 1 (Number of baffles) and (𝑁 + 1) is the number
µ𝑠,𝑤
of times the shell fluid passes the tube bundle. n number of units in series.
Tube side
𝜋𝑑 𝑁
𝐴 = ×
4 𝑁
Nt: no. of tubes
Np: no. of passes
Fluid mean velocity
𝑚̇
𝑈 =
𝜌 ×𝐴
ρ: fluid density kg/m3
𝑅 = , µ in N.s/m2
µ
For laminar flow

ṁ
𝐺 = (dimensionless)
Where graetz number between 10 and 10,000

µ .
𝑁𝑢 = 2 ∗ (𝐺 ) .( )
µ
For graetz number less than 10 assume N u=4.36 for uniform surface heat flux or
3.66 for constant surface temperature [1]
For Re > 2300
(𝑓/2)(𝑅 − 1000)𝑃
𝑁𝑢 =
1 + 12.7 (𝑃 − 1)
𝑓 = (1.58 ln 𝑅 − 3.28)
Pr: Prandtl number Cpµ/k
𝑁𝑢 . 𝑘
ℎ =
𝑑
Tube side pressure drop [3]
4𝑓𝐿𝑁 ⍴𝑢
∆𝑝 = 𝑛. + 4𝑁
𝑑 2
n: number of units in series
1.2 Heat exchangers rating (Bell-Delaware Method) [note]
In Bell Delaware method, the fluid flow in the shell is divided into a number of individual
streams. Each of these streams introduces a correction factor which is used to correct heat
transfer coefficient and pressure drop across the shell. This article gives step-by-step guidance on
doing heat exchanger rating analysis based on Bell-Delware method.
Note:
This section is mostly the Che Guide article with minor clarifications Link
a. Shell Side Heat Transfer Coefficient, hs
Cross flow area, Sm in m2 is the minimum flow area in one baffle space at the center of the tube
bundle. It is calculated by following equation:
DotL = Ds - (12.5+( Ds /200))
Sm = B[(Ds - DOTL) + (DOTL - Do)(PT - Do)/PT,eff ]*10-6
where, PT is tube pitch, B is central baffle spacing, DOTL is outer tube limit diameter, Ds is shell
diameter and Do is tube outside diameter. (all units in mm)
PT,eff = PT for 30° and 90° layouts

PT,eff = 0.707*PT for 45° layout
Shell side cross flow mass velocity, GS (kg/m².s) is defined as:
GS = 𝑚 /Sm ∗ 3600
where, mS is shell side mass flow rate. Shell side Reynolds number Re S is then calculated from
ReS = Do.GS / μS *10
where, μS is the shell side fluid dynamic viscosity at average bulk temperature in cP.
Shell side Prandtl number PrS is calculated as following:
PrS = CP,S . μS*1.163 / kS ∗ 3.6 ∗ 10
where, CP,S is the shell side fluid specific heat (kcal/kg.oC) and kS is the shell side fluid thermal
conductivity (W.m/k).
Colburn j-factor for an ideal tube bank is defined as:
1.33
𝑗=𝑎 . (𝑅𝑒 )
𝑎
𝑎=
1 + 0.14(𝑅𝑒 )
where a1, a2, a3 and a4 are the correlation constants listed below.
The ideal tube bank based coefficient (W/m2.k) is calculated from –
µ .
ℎ = 1.163 ∗ 𝑗. 𝐶 , . 𝐺 . (𝑃𝑟 ) . ( )
µ,
where, μS,W is shell side fluid viscosity at wall temperature.
a.1 Correction factor for Baffle Window Flow, JC
The factor JC accounts for heat transfer in the baffle windows. It has a value of 1.0 for exchanger
with no tubes in the windows.
JC = 0.55 + 0.72FC
FC = 1 - 2FW
FW = (θCTL - Sin(θCTL))/2π
θCTL = 2cos-1(Ds(1 - 2*Bc/100)/DCTL)
DCTL = DOTL - Do
where, Bc is segemental baffle cut in %. Fc is Fraction of tubes in cross flow. Fw is Fraction of tubes in
windows flow. Dctl is central tube limit diameter in mm (the diameter of the circle that passes through the
centers of the outermost tubes in the bundle)
Figure 1: Baffle geometry used for calculating the fraction, Fw, of tubes
in one baffle window
a.2 Correction factor for Baffle Leakage, JL
The correction factor JL considers the effects of the tube-to-baffle and shell-to-baffle leakage
streams on heat transfer.
DSB = 3.1+0.004* Ds
JL = 0.44(1-rS) + (1-0.44(1-rS))exp(-2.2rL) LTB = 0.4 mm
𝑟 = Ssb /(Ssb + Stb) If the longest unsupported
𝑟 = (Ssb + Stb)/ Sm
Ssb = Ds*DSB(π - 0.5θDS)*10 tube length is < 3 ft,
Stb = (π/4)((Do+LTB)2 - Do2)Nt(1-FW)*10 otherwise: 0.8 mm
θDS = 2cos-1(1 - 2Bc/100)
Figure 2: Ssb Shell-to-baffle leakage
area.
Where, Nt is number of tubes, DSB is diametral clearance between shell & baffle and LTB is
diametral clearance between tube and baffle (mm). rS is ratio of shell-baffle to total area and rL is
ratio of leakage to cross flow. θDS is Baffle window angle, Ssb is Shell to baffle leakage area and
Stb is Tube to baffle leakage area. (m2)
a.3 Correction factor for Bundle Bypass effects, J B
Bundle bypass correction factor JB accounts for the bundle bypass stream flowing in the gap
between the outermost tubes and the shell. The number of effective rows crossed in one cross
flow section, Ntcc between the baffle tips is provided by following equation.
Ntcc = (Ds/Pp)(1 - 2Bc/100)

Pp = PT 30.5/2 for 30° layout
Pp = PT / 20.5 for 45° layout
Pp = PT for 90° layout
Ratio of sealing strips to tube rows rss is provided by 𝑁𝑡𝑐𝑐 [11]

Nss = 𝑖𝑛𝑡𝑒𝑔𝑒𝑟
6
rss = Nss/ Ntcc
where Nss is number of sealing strips (pairs) in one baffle.
The bundle bypass flow area, Sb (m2) is defined as the area between the outermost tubes and the shell
at the shell centerline in one central baffle space. It is part of the cross-flow area , Sm.
Sb = B(Ds - DOTL - Do/2)*10
where, B is central baffle spacing. Correction factor J B is then calculated as following -
JB = exp(-Cj(Sb / Sm)(1 - (2rss)1/3)) for rss < 0.5

JB = 1 for rss >= 0.5
Cj = 1.35 for ReS < 100
Cj = 1.25 for ReS >= 100
a.4 Correction factor for adverse temperature gradient, J R
The factor JR accounts for the decrease in the heat transfer coefficient with downstream distance
in laminar flow.
Ntcw = (0.8/Pp)(Ds(Bc/100) - (Ds-(DOTL-Do))/2 )
NB = 1 + int((L - 2Ls - LBIn - LBOut)/B)
NC = (Ntcw + Ntcc)(1 + NB)
JRL = (10/NC)0.18
JR = 1, ReS > 100
JR = JRL + (20-ReS)(JRL - 1)/80, ReS <= 100, ReS > 20
JR = JRL, ReS <= 20
where, L is tube length, Ls is tubesheet thickness, LBIn is inlet baffle spacing and LBOut is outlet baffle
spacing. All units in mm. Ntcw is the number of tube rows crosses, NB is number of baffles and Nc is Tube
rows crossed in entire exchanger.
Ls ~ DS √P/C (mm)
a.5 Correction factor for unequal baffle spacing, J S P : Design pressure (kPa or
Kg/cm2G) of shell or tube
n1 = 0.6, ReS >= 100 side, whichever is greater.
n1 = 1/3, ReS < 100 C : Constant (578 for kPaG,
JS = ((NB-1)+(LBIn/B)1-n1 + (LBOut/B)1-n1)/((NB-1)+(LBIn/B) + (LBOut/B)) 58.3 for Kg/cm2G)
Or whichever greater than:
Shell side heat transfer coefficient is calculated as Ls = 50 mm Ds ≥ 500mm
Ls = 0.1* Ds for Ds < 500mm
hs = hIdeal(JC.JL.JB.JS.JR)
LBIn , LBOut is assumed = B
b. Shell Side Pressure Drop, ΔPs
Friction factor for ideal tube bank is calculated as following:
1.33
𝑓=𝑏 . (𝑅𝑒 )
𝑏
𝑏=
1 + 0.14(𝑅𝑒 )
where b1, b2, b3 and b4 are correlational constants listed below.

Pressure drop for an ideal tube bank is calculated from
ΔPIdeal = 2f(GS²/ρS)(μS/μS,W)0.14 Ntcc
b.1 Correction factor for Baffle Leakage, RL
RL = exp(-1.33(1+rS)rLp)
p = 0.8 - 0.15(1+rS)
b.2 Correction factor for Bundle Bypass effect, R B
RB = exp(-Cr(Sb / Sm)(1 - (2rss)1/3)) for rss < 0.5

RB = 1 for rss >= 0.5
Cr = 4.5 for ReS < 100
Cr = 3.7 for ReS >= 100
b.3 Correction factor for unequal baffle spacing, RS
RS = 0.5((B/LBIn)2-n + (B/LBOut)2-n)
n = 0.2, ReS >= 100
n = 1.0, ReS < 100
1. Pressure drop for window section, ΔPW
Following terms are calculated as -

SWG = (Ds²/8)(θDS - Sin(θDS))*10
SWT = Nt.FW(πDo²/4)*10
SW = SWG - SWT
GW = mS/3600*(Sm.SW)0.5
DW = 4.SW *10 /(π.Do.Nt.FW + θDS.Ds)
SWG Gross window area m2, SWT Window area occupied with tubes m2, SW Net Cross flow area m2, Gw Mass
velocity baffle window Kg/m².s, Dw Hydraulic diameter baffle window in m.
Pressure drop for laminar and turbulent flow is calculated.
ΔPW, Turb = NB.RL(2+0.6*Ntcw).GW²/(2.ρS)

26. 𝐺W. 𝐶 Ntcw 𝐵 𝐺W²
ΔPW, Laminar = NB.RL( + + )
ρS PT − D o D w ² ρS
ΔPW = ΔPW, Turb , ReS ≥ 100
ΔPW = ΔPW,Laminar , ReS < 100
2. Pressure drop in Central Baffle spaces
ΔPC = (NB - 1)ΔPIdeal.RL.RB
3. Pressure drop in entrance & exit baffle spaces
ΔPE = ΔPIdeal(1 + Ntcw/Ntcc).RB.RS
Shell side pressure drop in bar is calculated as following -
ΔPS = ΔPW + ΔPC + ΔPE
c. Tube Side Heat Transfer Coefficient, ht

vt =mt/(⍴t*at*3600)
Reynold's number and Prandtl number are calculated as following -
at = 10-6*Nt* π. ∗
ReT = 𝐷 .v.ρt/μt ∗ 10 Pn: number of passes
PrT =1.163* Cp,t.μt/kt
where, Di is tube inside diameter mm, v is velocity m/s, ρ t is density, μt is viscosity in cP, kt is
thermal conductivity W/m.K and Cp,t is specific heat for fluid on tube side kcal/kg.oC.
For laminar flow, ReT < 2300, Sieder and Tate correlation is used for Nusselt's nubmer.
Nu = 1.86(ReT.PrT.Di/Leff)1/3
Leff = L - 2*Ls , where Leff is effective tube length in mm for fixed tube sheet, see [2] for others
For turbulent flow, ReT > 10,000, following equation developed by Petukhov-Kirillov can be
used.
f = (1.58 ln(ReT) - 3.28)-2

Nu = (f/2)ReT.PrT/(1.07+12.7(f/2)0.5(PrT2/3-1))
For transient flow, Nusselt number can be interpolated from Nu Laminar & Nu Turbulent.
Heat transfer coefficient ht in (W/m2.k) is calculated as following - For floating head

Le = L – 2xTS- XLZ [1]
ht = Nu.(kt/Di*1000)(μt/μt, w)0.14 For U-Tube
Le = L –TS+XU[2] [3] [nozzle at/after U-bend]
d. Tube Side Pressure Drop, ΔPt Le = L –TS-50 mm [4] [nozzle before U-bend]
[1] XLZ: floating head dead space (for S or T
Tube side pressure drop in bar is calculated by following equation - type)
[2] XU: U-bend length
ΔPt = (4.f.Leff.Np/Di + 4.Np)ρt.v²/2 [3] the U-bend is included in the effective
length.
where, Np is number of tube passes. [4] 50 mm: distance between TL and the
last baffle
e. Overall Heat Transfer Coefficient, U UX = 1/3 Dotl
XLZ: obtained from table in ref [3] P. 15

Resistance due to tube wall m2.k/W is calculated as following
Rtube = Do*0.001/(2.ln(Do/Di).ktube)
where, ktube is thermal conductivity of tube material W/m.k. Overall clean heat transfer
coefficient, UClean is calculated as per below equation
UClean = 1/hS + Do/(Di.ht) + Rtube)
Overall dirty heat transfer coefficient, UDirty is calculated as per below expression
UDirty = 1/(1/UClean + fshell + ftube)
where, fshell & ftube are fouling factors for shell and tube side in m2.k/W.
Heat transfer coefficient required, URequired is calculated as following
URequired = Q /(A x LMTDcorrected)
where, Q is heat duty in W, A is heat transfer area and LMTD corrected is corrected logarithmic
mean temperature difference.
Over Surface, % = (UClean/URequired - 1)*100

Over Design, % = (UDirty/URequired - 1)*100
Accuracy of Correlations Between Kern’s Method and the Bell–Delaware’s Method [4]
Heat exchangers designs have been arrived at using the Kern’s, Tinker’s, or the Bell’s method. The
suitability and accuracy of these have been reviewed in the literature. Kern’s method cannot be applied
to a TEMA type T floating head heat exchanger without sealing strips or with unsealed pass partition
lanes. Whitley presented a study of the errors found in heat transfer coefficient and pressure drop
predictions obtained with the Kern and Bell methods. Palen and Taborek show that the Bell–Delaware
method allows the prediction of shell-side film coefficients in the range from 50% lower to 100% higher
than the real values. Table below shows a comparison of the Kern, Bell–Delaware, and the Tinker’s
methods.
Kern Bell-Delaware Tinker
1. Ease of use Simple More involved More involved
2. Resultant design Very conservative Not conservative Not conservative
3. Cost of equipment Very high Relatively low Relatively low
4. Does it account for
a. By pass and leakage streams No Yes Yes
b. Inlet and outlet baffle
spacing being different than
the central one No Yes Yes
c. Number of tube rows being
different in inlet and outlet zones
than in the center. No Yes No
d. Seal strips No Yes Yes
e. Different tube layouts and
baffle cuts No Yes Yes
f. Effectiveness of tube rows in
window by a separate
calculation. No Yes Yes
Original plots
extended.
Method remains Δp calculated lam Method remains
g. Laminar flow unchanged. differently. unchanged.
Accounts for it by
Assumes shell full number of tubes in Accounts for it by mean
h. Size of tube bundle of tubes cross flow bundle width.
i. Pressure drop in the nozzle. Yes No No
Yes (takes an
j. Δp due to gradual fouling of average
heat exchanger working unit) No Yes
5. Basis of Reynolds number Equivalent
calculation diameter Tube O.D. Tube O.D.
Cross-flow mass velocity
Geometric mean of multiplied by a factor
Cross flow over the cross-flow and for tubes in baffle
6. Which mass velocity used? tube bundle window flow. window.
Source: Petroleum Refining Design and applications, vol. 4, A. Kayode coker
1.3 NTU Method

The NTU (Number of Transfer Units) method is a widely used approach for rating shell and tube heat
exchangers. It is a simplified yet effective method for evaluating the heat transfer performance of such
heat exchangers.
The NTU method is based on the concept of heat transfer effectiveness, which represents the ratio of
the actual heat transfer in the heat exchanger to the maximum possible heat transfer. It takes into
account the temperature difference between the hot and cold fluids, the heat exchanger configuration,
and the fluid flow rates.
In the NTU method, the heat exchanger is typically represented as a series of heat transfer units.
Each heat transfer unit consists of a hot fluid stream and a cold fluid stream. The NTU value
represents the number of these heat transfer units in the heat exchanger
The NTU method involves the following steps:
1. Determining the NTU Value: The NTU value is calculated based on the heat exchanger geometry,
flow rates, and heat transfer characteristics. It can be determined using equations or graphical
methods.
2. Calculating the Heat Transfer Effectiveness: The effectiveness ( ε) of the heat exchanger is
determined using the NTU value and the heat exchanger configuration. The effectiveness
represents the ratio of the actual heat transfer to the maximum possible heat transfer. It is a
measure of how efficiently heat is transferred between the hot and cold fluids.
3. Estimating the Heat Transfer Rate: Once the effectiveness is known, the heat transfer rate in the
heat exchanger can be calculated. This involves multiplying the maximum possible heat transfer
rate (which is determined by the temperature difference between the hot and cold fluids) by the
effectiveness.
4. Estimating outlet temperatures by simple heat balance in shell and tube
It should be noted that the NTU method assumes certain simplifications and may not account for all
complex factors, such as fouling or non-uniform fluid flow distribution. In such cases, more detailed
analysis and modeling may be required.
Capacity ratio
ṁ
Capacity ratio=
ṁ
Number of transfer units

𝑈𝐴
NTU =
𝐶
Cmin: stream with the lowest mCp
Overall temperature range & Effectiveness
Overall temperature range = T −t
QMax = CMin.(THot In - TCold In)
Q=ε*Cmin *(Th1 -t c1 )
THot Out = THot In - Q /( ṁH.CpH)
TCold Out = TCold In + Q /( ṁC.CpC)
Heat Exchanger Rating Assessment [8][9]
Applications of rating can be for operational performance, for

changes in process conditions, or in process design. There are three fundamental
points in determining if a heat exchanger performs well for given operating
conditions or for a new service:
(1) What actual coefficient UA value can be “performed” by the two fluids as the
result of their flow rates, individual film coefficients ht and hs, and fouling
resistance?
(2) From the heat balance: Q =( ṁ .𝐶𝑝 ) (T1-T2)= ( ṁC .𝐶𝑝 )(t2-t1), for given area A,
and actual temperatures, required U value (UR) can be calculated.
(3) The operating pressure drops for the two streams passing through the existing
heat exchanger.
The criteria can be established for the suitability of an existing exchanger for
given or new services as two necessary and sufficient conditions:
(a) UA must exceed UR to give desired overdesign (%OD) so that the heat
exchanger can meet changing process conditions for a reasonable period of
service continuously. While UA denotes the capability of the exchanger based
on its dimension and geometry, UR indicates the requirement from the process heat
transfer.
(b) Operating pressure drops on both sides must be less than allowable pressure
drops.
When these two conditions are fulfilled, an existing exchanger is suitable for the
process conditions for which it was rated. When the process conditions undergo
significant changes, a rating should be performed to make sure the exchanger can perform the task
satisfactorily under the new conditions. You could also check design R f against Rf calculated to check
your current fouling resistance.
the simple U value analysis is backed up with pressure drop information to confirm that the
performance loss is fouling related.
Actual heat exchanger Pressure Drop[8]
As the tube wall thickness increases with fouling deposits, pressure drop measurement
must be conducted and used as the basis for pressure drop rating calculations. In
doing so, the tube wall thickness including fouling deposits are assumed and iterated
until the calculated pressure drops from the rating software converges with the
measured ones.
Typical fouled exchanger pressure drops are 1.3–2 times that of clean exchangers
(Barletta, 1998). For extreme cases, fouled exchanger pressure drops are much
higher than that of clean exchangers.
It is recommended that hydraulic calculations should be conducted in an
exchanger rating software (e.g., HTRI) as the rating software is more rigorous in
pressure drop calculations than flowsheet simulation software.
Instrumentation and Data Access[9]
Most refineries have sophisticated plant data historians that record detailed plant
operating conditions with high resolution. Electronically accessible temperature and
flow data are crucial for effective exchanger performance monitoring. Manual temperature
data entry for monitoring most exchangers is feasible in principle. However, a great
deal of effort is required to collect field temperature readings from local temperature
indicators or “temperature guns.” Manual monitoring is very difficult to maintain at any
meaningful frequency level. The most frequent surveys of this type that the authors have
seen were completed every 3 months, and then only when a team from a corporate
engineering support group provided the staff.
Ideally, data should be available for each exchanger’s shell-side and tube-side outlet
temperature and each fluid’s temperature as it first enters the heat exchanger network.
Inlet temperatures for all other exchangers can be set equal to the outlet of an upstream
connected exchanger without appreciable loss in accuracy. The exchanger outlet
temperatures must be adjusted for any bypasses. Exchangers can also be modeled by
grouping identical exchangers and identifying common configurations (two series/one
parallel, two series/two parallel, etc.). Note, however, that in such groupings some
resolution is lost as to the exact location of any fouling.
Exchanger grouping for monitoring may also be determined by the availability of
bypass and isolation valves to allow online exchanger isolation and removal from
service. In general, though, monitoring resolution should be determined by available
temperature instrumentation.
Crude feed, product rundown, and tower pump-around flow rates are generally well
measured. Ideally, flow rates should be corrected for flowing density versus design for
each meter and an overall mass balance check should be performed across the unit to
ensure flow meter consistency.
Flow splits are usually less well measured unless the splits are actively manipulated
by operators. Temperatures around an associated mixer can be used to estimate an
unmetered flow split. This is especially useful around a controlled bypass. Failing this,
valve position in conjunction with valve flow characteristics can sometimes be used to
estimate flow distribution between branches. However, this is complicated by the
unequal pressure resistance on different branches, particularly when fouling is involved.
Finally, in the absence of any of these, bypasses should be assumed closed and other flow
splits to have an equal distribution.
Alternatively, data reconciliation can be used to find best-fit flow split data, though
data reconciliation then becomes a more difficult nonlinear optimization exercise. This
can also introduce more uncertainty as the model now has extra optimization variables.
Rigorous calculation of film heat transfer coefficients requires thermal and physical
data about each stream. Distillation data and liquid specific gravities are sufficient to
synthesize the required liquid properties of density, heat capacity, thermal conductivity,
and viscosity at flowing conditions in each heat exchanger. The best approach is to use
rigorous physical property simulation to calculate these properties from composition or
crude assay information. However, standard shortcut methods can also be used in
spreadsheets.
If available, electronically sourced laboratory data should be used to characterize
crude and oil product properties. It is important to include all components when
characterizing the whole crude oil stream. Different distillation types and light ends
analysis can be combined in the process simulation and the result checked against the
crude unit material balance.
Data Quality and Data Reconciliation

Exchanger tube-side heat duties (Qt) and shell-side heat duties (Qs)
are calculated independently and compared for consistency. Shell- and tube-side heat
imbalances are not uncommon. It is rare that raw plant data give
reliable (±5%) heat balance closures for all exchangers, especially with larger preheat
train systems that may have up to 60 exchangers excluding product and pump-around
coolers.
With the right tools it may be possible to manually adjust exchanger outlet temperatures to come up
with acceptable heat balances across the preheat train system; however, this is not a trivial undertaking
due to the complexity of interactions between exchangers. The final solution is also subjective as it
involves a set of sequential decisions as to which exchanger to start with and whether to adjust the
tube- or shell-side temperature in order to achieve a heat balance. There are many possible heat
balance solutions. The question is: Which is the most representative solution?
Mathematical data reconciliation can effectively answer this question. It is a vital
component of any successful fouling monitoring application. Reconciliation is a least squares
optimization process where the objective function minimizes the deviation between reconciled, heat
balanced data and the raw plant data. Temperature, fluid flow, and flow split data can be included in the
data reconciliation model. The relative weight the reconciliation model places on different data types is
governed by assigning trust factors or typical errors to each plant measurement. Occasionally, though
not often, it may be necessary to include local exchanger bypasses in the reconciliation problem.
Given that local bypass flows are never measured, bypasses must be estimated and thus very low trust
factors (or high typical errors) should be assigned to these variables.
A measure of “acceptability” should be established for any optimized solution, to determine whether to
accept or reject the current data set. If reconciled plant data deviations on a particular plant
measurement are consistently higher than expected instrumentation errors, the flow meter or
temperature indicator should be checked.
Heat Exchanger fouling monitoring [10], read more on [8] [9]
To track the amount of fouling in an exchanger one can calculate Uo frequently (weekly) and plot Uo versus
time. The pattern of the fouling curve will usually repeat itself after each cleaning. 1/Uo = R= RCLEAN +RDIRT
If conditions have changed significantly from design condition, h i and ho can be adjusted to current
conditions using the equations from the Natural Gasoline Processing Handbook summarized in
Key Formulas. RCLEAN can then be recalculated. The current RDIRT can be compared to the design RDIRT.
Many heat exchange services are regulated by instrumentation to provide a stream to a downstream
process at a consistent temperature. This temperature is accomplished by bypassing part of the
exchanger feed around the exchanger and mixing this bypassed material with the exchanger effluent.
The degree of bypassing is regulated by a temperature controller which senses the downstream mixture
temperature. When the exchanger is clean, the maximum amount of feed is bypassed; and when the
exchanger is fouled to the maximum, no feed is bypassing the exchanger. By recording the clean
bypassing condition (percent of feed bypassed), you can easily estimate the amount of exchanger
fouling by observing the amount of feed bypassed with the partially fouled exchanger.
The following equations which can be readily derived from the
above and are often quoted in the literature:
Fraction dirty = rn/rd = (Ud / UN)[UC – Un ] / (UC – Ud )
where:
rd = RDIRT design
rn = RDIRT current (now)
UC = Clean U with no fouling factors
UD = Design U which includes fouling factors
Un = Current U (now)
3. Shell &Tube Preliminary sizing
The preliminary sizing stage focuses on establishing initial estimates and configurations before
proceeding to detailed design calculations. During preliminary sizing, several key parameters need to be
considered. These include the heat duty or the amount of heat to be transferred, the temperature
difference between the two fluids, the flow rates of the fluids, and the physical properties of the fluids,
such as density and specific heat capacity.
The goal of preliminary sizing is to determine the approximate size and layout of the shell and tube heat
exchanger, including the number of tubes, tube diameter, tube length, and shell diameter. This is
achieved by employing empirical correlations, design guidelines, and engineering experience to estimate
the required surface area for heat transfer.
Additionally, factors like pressure drop, fouling, material selection, and construction constraints are also
taken into account during the preliminary sizing phase.
The results obtained from preliminary sizing serve as a foundation for detailed design and analysis,
where more precise calculations and considerations are made to optimize the heat exchanger's
performance, efficiency, and cost.
In preliminary sizing of shell and tube heat exchangers, there are certain aspects and considerations that
are generally not accounted for. These may include:
1. Vibration Analysis
2. Detailed Pressure Drop Calculations.
3. Thermal Stress Analysis
While preliminary sizing may not incorporate these detailed analyses and considerations, it is important
to note that they are crucial in the subsequent stages of design and engineering to ensure the heat
exchanger's reliability, performance, and longevity.
3.1 Bell-Delaware Preliminary Design: Polley et al.[4][6]

G. T. Polley developed rapid design algorithms for the design of both shell and tube heat exchangers and
compact heat exchangers. These algorithms are based on the full use of allowable pressure drops of
both of the streams being contacted as the design objective and a set of simultaneous equations. In the
case of a shell and tube heat exchanger, they assumed that the best shell-side performance can be
gained by making baffle window flow velocities and bundle cross-flow velocities equal. This in turn
results in a “similarity concept” that can be used for the derivation of simple performance equations
from shell-side models. They determined the exchanger geometry
from values as follows:
1. The tube-side film heat coefficient can be directly related to the tube-side velocity and thus to
the exchanger tube count.
2. From the tube count and total surface area, the tube length can be determined.
3. The shell diameter can be calculated from the tube count.
4. Finally, with the shell diameter known, and the shell-side velocity being determined from the
shell-side film coefficient, the number of baffles and baffle spacing required within the
exchanger can be determined. They inferred that the rapid design algorithm avoids the need to
evaluate much potential geometry while ensuring the full use of the allowable pressure drop.
The only restrictions are:
The pressure drop (ΔP) referred to is that associated with flow through the exchanger bundle, as no
account is taken of any nozzle or header pressure drops. Allowance for these drops must be made ahead
of design and checked after design. However, this restriction is not considered to adversely affect the
design. Kern correlations are generally considered too inaccurate for use in modern exchanger design.
Their methodology started with a consideration of the Bell-Delaware Method as described earlier and
proceeded to consider current state-of-the-art commercial methodologies.
The algorithms used in the design have been tested with data from literature, which show that in the
case of the shell and tube heat exchanger algorithm, there appears to be the first one which makes full
use of both allowable pressure drops and thereby identifies the smallest exchanger for a given duty.
Alternatively, in the case of compact heat exchangers, a major use of such an algorithm would be the
identification of the best surface combination for a specific duty. The research showed that the basic
algorithm can be applied using the Bell-Delaware method for shell and tube
exchangers, as the approach can be further extended to even more sophisticated methods through the
use of geometrical similarity (e.g., 25% baffle cut, baffle spacing equal to shell diameter).
A = area (m2)
d = tube diameter (m)
Ds = shell diameter (m)
Ft = ΔTLMTD correction factor (non-counter-current flow)
h = film heat transfer coefficient (W/m2 oK)
K = dimensional constant, solely dependent on physical properties, volumetric flow rate, and a
single
characteristic dimension.
R = fouling resistance (m2 K/W)
Δp = pressure drop (kPa)
Subscripts
i = inside surface
o = outside surface
s = shell side
t = tube side
Source 7: Rapid Design Algorithms for Shell-and-tube and Compact Heat Exchangers, G. T. Polley
Walkthrough
a. Initialization
a. Assume an exchanger with shell diameter Ds = 387 mm baffle cut = 25%, 6 m length, 2 passes, same
tube diameter and same pitch ratio and type as specified.
b. Estimate the number of tubes that could fit in your shell diameter
c. Estimate shell Reynold’s number
θDS = 2cos-1(1 - 2Bc/100)

SWG = (Ds²/8)(θDS - Sin(θDS)) *10
SW = SWG - SWT
Based on the assumption that baffle spacing is the same as baffle cut area
Sm = SW
GW = mS/3600*(Sm.SW)0.5
GS = mS/Sm
ReS = Do.GS / μS*10
d. Calculate shell heat transfer coefficient and pressure drop
Sm = B[(Ds - DOTL) + (DOTL - Do)(PT - Do)/PT,eff ]*10
PT,eff = PT for 30° and 90° layouts Di = Do – 2*thickness
PT,eff = 0.707*PT for 45° layout Ltb = 0.4
GS = mS/3600*Sm
Ls= 0.1* Ds
ReS = Do.GS / μS*10
PrS = 1.163*CP,S.μS / kS Dsb = 3.1+0.004* Ds
Leff = L- 2* Ls
Dotl= Ds - (12.5+( Ds/200))
1.33
𝑗=𝑎 . (𝑅𝑒 )
𝑃
𝐷𝑜
𝑎
𝑎=
1 + 0.14(𝑅𝑒 )
µ .
ℎ = 1.163 ∗ 𝑗. 𝐶 , . 𝐺 . (𝑃𝑟 ) . ( )
µ,

JC = 0.55 + 0.72FC
FC = 1 - 2FW
DCTL = DOTL – Do
JL = 0.44(1-rS) + (1-0.44(1-rS))exp(-2.2rL)
rS = Ssb /(Ssb + Stb)
rL = (Ssb + Stb)/ Sm
Ssb = Ds*DSB(π - 0.5θDS)*10
Stb = (π/4)((Do+LTB)2 - Do2)Nt(1-FW)*10
θDS = 2cos-1(1 - 2Bc/100)

Ntcc = (Ds/Pp)(1 - 2Bc/100)
rss = Nss/ Ntcc
Sb = B(Ds - DOTL - Do/2)*10
JB = 1 for rss >= 0.5
Cj = 1.35 for ReS < 100
Cj = 1.25 for ReS >= 100

NB = 1 + (int)(L - 2Ls - LBIn - LBOut)/B
JRL = (10/NC)0.18
JR = 1, ReS > 100
JR = JRL, ReS <= 20
a.5 Correction factor for unequal baffle spacing, J S

n1 = 0.6, ReS >= 100
n1 = 1/3, ReS < 100
JS = ((NB-1)+(LBIn/B)1-n1 + (LBOut/B)1-n1)/((NB-1)+(LBIn/B) + (LBOut/B))
Shell side heat transfer coefficient is calculated as

1.33
𝑓=𝑏 . (𝑅𝑒 )
𝑃
𝐷𝑜
𝑏
𝑏=
1 + 0.14(𝑅𝑒 )
p = 0.8 - 0.15(1+rS)
RB = 1 for rss >= 0.5
Cr = 4.5 for ReS < 100
Cr = 3.7 for ReS >= 100

n = 0.2, ReS >= 100
n = 1.0, ReS < 100
SWG = (Ds²/8)(θDS - Sin(θDS)) *10

SW = SWG - SWT
GW = mS/3600*(Sm.SW)0.5
DW = 4.SW /(π.Do.Nt.FW + θDS.Ds)
SWG Gross window area, SWT Window area occupied with tubes, SW Net Cross flow area, Gw Mass velocity baffle
window, Dw Hydraulic diameter baffle window in m.



Shell side pressure drop in bar is calculated as following -

e. Calculate tube heat transfer coefficient and pressure drop
ReT = Di.v.ρt/μt*10
PrT = 1.163*Cp,t.μt/kt
Leff = L - 2*Ls , where Leff is effective tube length 𝑖𝑛 𝑚𝑚

used.
f = (1.58 ln(ReT) - 3.28)-2

Nu = (f/2)ReT.PrT/(1.07+12.7(f/2)0.5(PrT2/3-1))
ht = Nu.(kt/Di)(μt/μt, w)0.14
a. Tube Side Pressure Drop, ΔPt

ΔPt = (4.f.Leff.Np/Di + 4.Np)ρt.v²/2
f. Calculate shell and tube constants from the following equations
.
∆𝑃 = 𝑘 ∗ 𝐴 ∗ ℎ
.
∆𝑃 = 𝑘 ∗ 𝐴 ∗ ℎ
b. Solving for the allowable pressure drops

1. Solve the following non-linear equations to obtain the desired heat transfer coefficients for both
shell and tube and the required area (hs,ht and A) that can achieve your allowable pressure drops for
both shell and tubes
𝐴= Q /( LMTDcorrected)*(1/(1/hS + Do/(Di.ht) + Rtube)) + fshell + ftube)
.
∆𝑃 = 𝑘 ∗ 𝐴 ∗ ℎ
.
∆𝑃 = 𝑘 ∗ 𝐴 ∗ ℎ
Where ∆𝑃 and ∆𝑃 are shell and tube allowable pressure drops
Solve the following equations to obtain tube Reynold’s number and friction factor
f = (1.58 ln(ReT) - 3.28)-2

Nu = (f/2)ReT.PrT/(1.07+12.7(f/2)0.5(PrT2/3-1))
where Nu = ℎ /.(kt/Di)(μt/μt, w)0.14
after obtaining Re iterate this Re till ht calculated = ht solved from the previous step.
𝑣 = Di.Re.ρt/μt
at = mt/(⍴t*vt*3600)
*
Nt = at/ π. ∗
Leff =A/(tn. π.Do*10 )
Leff = L - 2*Ls , where Leff is effective tube length
used.
Nu = (f/2)ReT.PrT/(1.07+12.7(f/2)0.5(PrT2/3-1))
f = (1.58 ln(ReT) - 3.28)-2
if ht = ht.solved stop iteration, else change Re accordingly and start over.
Now you’ve calculated Tube length, Number of baffles, Ret and Vt and tube count.
c. Iterate!
1. Estimate Shell diameter from the tube count. If it didn’t change proceed, if changed repeat from
initialization with a new shell diameter accordingly.
2. Calculate ∆𝑃 If it didn’t change from your allowable shell pressure drop proceed, if it changed repeat
from initialization with a new baffle cut accordingly.
3. If no baffle cut % achieved ∆𝑃 start from initialization with a new number of passes.
If A, ht and ∆𝑃 as assumed/calculated then hs and ∆𝑃 should match your assumptions/requirement.
3.2 Kern Preliminary Design[4]:

1. Establish physical properties of fluids at the caloric or arithmetic mean temperature, depending
upon the temperature range and order of magnitude of the properties.
2. Establish the heat duty of the exchanger.
3. Estimate or assume a specific unit and define its size and characteristics, based upon reasonable
values of overall U and ΔTLMTD.
4. Determine the ΔTLMTD with correction if needed.
5. Assume Uservice
6. Calculate the area required.
Q calculated Kcal ℎ𝑟
A (m ) =
U kcal m . hr. °C ∗ corrected LMTD
7. Calculate number of tubes from
N = Area / πDoL ∗ n
8. Calculate the tube-side velocity based upon the calculated number of tubes per pass and the
heat balance.
9. Determine the tube-side film coefficient.
𝐷
ℎ = ℎ ∗ ( )
𝐷

10. Determine the shell-side film coefficient for an assumed baffle spacing.
a. Calculate De and Gs.
b. Calculate the Reynolds number, Re, expressed as
𝑅𝑒 = 𝐷 .𝐺 S / 𝜇
c. Calculate ho from
.
𝐷𝑒 𝐷𝑒. 𝐺𝑠 𝐶𝑝. µ µ .
ℎ ∗ = 0.36 . .( )
𝑘 µ 𝑘 µ
d. If ho appears too low, assume closer baffle spacing, up to 1/5 of the shell diameter and
recalculate Gs and ho. If this second trial is obviously too low, then a larger shell size
may be indicated; therefore, return to step 3, re-evaluate the assumed U to be certain
that is attainable.
11. If the ho appears to have possibilities of satisfying the design, continue to a conclusion by
assuming the tube-side and shell-side fouling and calculate U overall.
12. Compare values calculated in steps 10 and 5. If the calculated Uoverall is too small, re-assume a
new lower U for step 5 or try closer baffle spacing in step 9 but do not get baffles closer than 1/5
the shell I.D.
13. Calculate the percent of over Design. A reasonable figure is 10–20%.
14. Calculate the shell-side pressure drop. If p is too high, reassume U (step 3).
15. Calculate the tube-side pressure drop.
If the tube-side pressure drop exceeds a critical allowable value for the process system, then recheck by
either lowering the flow rate and changing the temperature levels or reassuming a unit with fewer
passes on tube-side or more tubes per pass. The unit must then be rechecked for the effect of changes
on heat transfer performance. The following figure illustrates the influence of various geometrical
parameters on heat exchanger heat transfer and pressure drop.
Need to Increase U
Increase hi and ho Increase A
Decrease Increase Ds with Employ multiple

Increase number Increase L appropriate shells in series or
of tubes. baffle spacing
number of tubes parallel
Decrease Do or baffle cut
Increase F
Use counter flow configuration

Use multiple shell configuration
Need to reduce pressure drop
Tube side Shell side
Decrease Increase Do Decrease L Use

and Increase Increase Increase
number of Increase double or
Ds and baffle tube
tube passes
baffle cut triple
number of spacing pitch
segmental
tubes
baffles
Source 4: Petroleum refining Design and applications handbook, vol 4

Source 4: Petroleum refining Design and applications handbook, vol 4
Quick notes on Heat exchangers’ Sizing [7] Tube Design
Construction  A good design will make full use of
1. Fixed tubesheet allowable pressure drop as this
 Low cost will yield the highest heat transfer
coefficient.
 Leakage of shell-side is minimum
 h = 0.027(DGs/μ)0.8(Cp.μ)0.33(k/D)
 Bundle is fixed into shell and can’t be
removed; the outside of the tubes can’t  h α μ-0.47
be cleaned mechanically.  h α k0.67
 Limited to clean services  h α Gs0.8
 Not suitable for large temperature  ∆P α Gs2
differentials between the tubes and  Increasing mass velocity increases
shell. h but rapidly also increases ∆P
2. U-Tube  Very high velocity may lead to
 The lower cost for the single tube-sheet erosion, liquid min velocity 1 m/s
is offset by the bending of the tubes and while max. is 2.5-3 m/s.
larger shell diameter.  If number of passes is increased
 Insides of tubes can’t be cleaned from 2 to 4 (doubled), velocity
effectively. also doubles ∆P2 = ∆P1*23
 Should not be used for dirty tube  With an increase in the number of
services inside tubes tube passes, h increases but tube-
3. Floating Head side pressure drop rises steeply.
 most versatile and costliest  Other options is to increase ht is to
 permits free expansion of tubes increase number of tubes,
 can be used for both shell and tube dirty decrease tubes diameter decrease
services tube length while increasing shell
diameter and number of tubes.
 prone to leakage, limited where shell-
side is non-hazardous and non-toxic with  Tubes smaller than ¾“ shouldn’t
moderate pressure and temperatures be used for fouling services. The
use of smaller diameter ½” only
warranted for small shell areas 20-
30 m2 .
Step-wise calculations for viscous liquids arrangement where a large
temperature cross can be achieved.
 When the variation in tube-side
inlet/outlet viscosity is pronounced, a  TEMA J: a divided-flow shell
single point calculation for ht and ∆Pt wherein the shell-side fluid enters
gives unrealistic results. the shell at the center and divides
into two halves, one flowing to the
 Particularly true when variation in cases
left and the other to the right and
where a combination of turbulent and
leaving separately, they’re then
laminar flow (Re variation hence ht
combined into a single stream( J 1-2
variation).
shell). Alternatively, the stream
 In such cases it’s advised to perform
may split into two halves that enter
step-wise calculations.
the shell at the two ends, flow
Shell-side Design toward the center and leave as a
Shell selection single stream ( J 2-1 shell)
 TEMA G: shell is a split-flow shell.
 TEMA E: most common, shell-side enters
This construction is usually
from one end and leaves from the other.
employed for horizontal thermo-
 TEMA F: two-pass shell that has a syphon reboilers. There is only a
longitudinal baffle that divides shell into central support plate and no
two passes, shell-side fluid enters at one baffles.
end, traverses the entire length of the
 Can’t be used with heat exchangers
exchanger through one-half the shell
with tube lengths higher than 3 m,
cross-sectional area, turns around and
since this would exceed the
flows through the second pass, then
maximum unsupported tube length
finally leaves at the end of the second
limit specified by TEMA.
pass.
 TEMA H: When larger tube length is
 Used for temperature-cross
needed.
situations – that is, the cold stream
 Basically two G shells placed side by
leaves at a temperature higher than
side, so that there are two full
the outlet temperature. If two-pass F
support plates. Described as double
shell has only two tube passes, this
split configuration as the flow is
becomes a true countercurrent
split twice and recombined twice.
 Invariably employed for horizontal  Rotated triangular pattern offer
thermosyphon reboilers. no valuable advantage over a
 Pressure drop is drastically less and there triangular pattern
are no cross baffles for both H and G.  Square pattern is typically
 TEMA X: pure cross-flow shell where the employed for dirty services.
shell side fluid enters, flows across the  Produces less turbulence hence
tubes and exits from the opposite side of lower hs. when Re is less than 2,000
the shell. rotated square is employed as it
 Pressure drop is extremely low. offers higher turbulence
 Employed for cooling or condensing vapors
Tube pitch
at low pressure, particularly vacuum. Full
support plates can be located if needed for  For triangular pattern, minimum
structural integrity. pitch ratio recommended by
 TEMA K: employed for kettle reboilers. TEMA is 1.25.
 Has an integral vapor-disengagement  For square pattern, minimum
space embodied in an enlarged shell. pitch ratio recommended by
 Full support plates can be located if TEMA is 1.25 or pitch = OD + 6
needed for structural integrity. mm whichever larger.
 Minimizing tube pitch minimizes
Tube layout patterns shell diameter and higher tube
 Triangular (or rotated triangular) will pitch reduce shell side pressure
accommodate more tubes than square (or drop.
rotated square.
Baffling
 Triangular pattern produces more
turbulence hence higher hs. Baffle spacing
 However, at typical tube pitch ratio of 1.25  Minimum baffle spacing specified
it doesn’t permit mechanical cleaning of by TEMA is 1/5 shell diameter or
tubes, since access lanes are available. 2” (50.8 mm) whichever greater.
 Triangular pattern is limited to clean shell-  Closer baffling causes poor bundle
side services but may used for dirty shell- penetration by the shell-side fluid,
side services provided that chemical difficulty in mechanical cleaning
cleaning is suitable and effective. and poor stream distribution.
Baffle cut
 Maximum baffle spacing is shell  Baffle cut can vary between 15 -
inside diameter. Higher baffle 45 % of the shell inside diameter.
space leads to predominantly  It’s recommended to employ
longitudinal flow, which is less baffle cut between 20 and 35%.
efficient than cross flow, and  Horizontal baffle cut is
larger unsupported tube spans, recommended for single phase
which makes the exchanger prone fluids on shell-side as this
to tube failure due to flow- minimizes accumulation of
induced vibration. deposits at the bottom of the shell
 hs α v0.6-0.7 for Re > 1,000 and also prevents stratification.
 ∆P α v1.7-2.0  In case of two pass shell (TEMA F),
 hs α v0.33for Re < 1,00 a vertical cut is preferred for ease
 ∆P α v1.0 of fabrication and bundle
 When a baffle space in reduced, assembly.
higher velocity resulted leads to
Equalize cross-flow and window
reduction in pressure drop higher
velocities
than the ratio of heat transfer
increase.  The window velocity and cross-
 Optimum ration of baffle cut to velocity should be as close as
shell inside diameter is between possible – preferably within 20%
0.3 and 0.6 of each other.
 If they differ more than that ,
repeated acceleration and
deceleration take place along the
length of the tube bundle,
resulting in inefficient conversion following parameters will affect
of pressure drop to heat transfer stream analysis and therby the
shell-side performance:
Shell-side stream analysis
1. Baffle spacing and baffle cut
2. Tube layout angle and tube
pitch
3. Number of lanes in the flow
direction and lane width
4. Clearance between the tube
and the baffle hole.
5. Clearance between the shell ID
and the baffle
 Stream A: fairly efficient, because 6. Location of sealing strips and
the shell side is in contact with the sealing rods
tubes.  Very low baffle spacing (or low
 Stream B: highly effective (main baffle cut%) tends to increase the
stream) leakage and by-pass streams as it
 Stream C: Fairly efficient, as increases resistance to main
stream C is in contact with the stream B.
peripheral tubes around the
Reducing ∆Ps by modifying baffle
bundle.
design
 Stream F: Fairly efficient, as
stream F is in contact with the Single pass shell and single
tubes along the pass-partition segmental baffles
lanes.  If ∆Ps is too high even after
increasing baffle space and baffle
 Stream E: Almost encounters no
cut% to highest values
heat transfer at all since stream
recommended, double segmental
flows along the shell wall where
baffles should be considered.
there are no tubes.
 Since the flow fraction depend Single pass shell and double
strongely upon the path segmental baffles
resistances, varying any of the
 Shifting from single segmental  Offers 4% reduction of an identical
baffle to double segmental baffle single pass exchanger but also
directly reduce cross flow velocity 40% reduction in hs.
to half, because shell flow is
No-tube-in-window segmental
divided into two parallel flows,
baffle
this greatly reduces ∆Pc.
 However, ∆Pw can’t be reduced  As baffle spacing increases to
appreciably (assuming that reduce ∆Ps, the heat exchanger
maximum recommended baffle becomes more prone to tube
cut is already reached for the failure due to flow-induced
single segmental baffle cut. But vibration.
overall there is a significant  Double segmental baffles are less
reduction in ∆Ps. likely to experience such
 There will be also a reduction in hs problems.
as cross velocity decreases but a  If these problems persist, No-
reduction lower than ∆Ps. tube-in-window segmental baffle
could be used so that the
Divided-flow shell and single- unsupported span is the baffle
segmental baffles
spacing.
 If allowable ∆Ps can’t be reached  The tube-in-window requires a
even with double segmental larger shell diameter for a given
baffles. A divided flow shell (TEMA number of tubes, escalating the
J) with single segmental baffles cost by 10%.
should be considered next, it  The higher cost is offset by the
should have approx. 1/8 ∆Ps of an higher hs since pure cross flow (no
identical single pass exchanger parallel co-current) is more
(1/23). efficient.
 Offers larger reduction in ∆Ps than
double segmental baffle as
velocity is reduced both in
window and in cross flow.
Divided-flow shell and double-
segmental baffles
Cross flow shell since there are no other
parameters that can be modified.
 When ∆Ps is very low TEMA X is
used where pure cross flow is Mean Temperature difference
employed with very low velocities.
 Ft for pure countercurrent flow =1,
 Support plates will be needed to
1-2 shell and tube heat exchanger
meet TEMA requirements and
is normally lower as some of flow
prevent any induced tube
is co-current.
vibration and since they’re parallel
 Ft is recommended to be not less
to shell-side flow ∆Ps isn’t increase
than 0.8.
Increasing Tube pitch  Increasing number of shells
 As far as thermal hydraulics are increase Ft, multipule shells must
concerned, The optimum tube- be used if temperature cross
pitch-to-tube-diameter ratio for exists (cold steam outlet is higher
conversion of pressure drop to than hot stream outlet).
heat transfer is 1.25-1.35 for  It’s important to realize that LMTD
turbulent flow and 1.4 for laminar and Ft factor concept assumes
flow. that there is no significant
 Increasing tube pitch to reduce variation in the overall heat-
∆Ps isn’t generally recommended transfer coefficient along the
as: length of the shell. However,
1. It increases shell diameter there are some services where
(additional cost) this is not true (e.g.: cooling of a
2. Reducing ∆Ps by increasing viscous liquid, phase change
baffle spacing, baffle cut or applications…etc.) in this case, the
changing shell type will result simplistic overall MTD approach
in a cheaper design. “End points” will be inaccurate
and the exchanger must be
 In case of X shells, it may be
broken into several sections and
necessary to increase the tube
the calculations performed zone-
pitch above the TEMA minimum
wise “weighted average”.
to meet pressure drop limitations,
Temperature profile distortion  Since each of the shell-side
streams has a different
 effectiveness for heat transfer, an empirical equation was
and since mixing developed for δ of the form:
of these streams in the shell is
incomplete, each stream exhibits a
different temperature profile
along the exchanger.
Where,
 The cross-flow stream (B) is the
Ta = inlet temperature of shell-
most effective for heat transfer,
side fluid
and therefore its temperature
profile lies closest to that of the Tb = outlet temperature
tube-side fluid, resulting in the shellside fluid
lowest driving force Ta = inlet temperature of tube-
for heat transfer. The least side fluid
effective stream for heat transfer mE/mo = fraction of stream E
is the shell-to-baffle leakage ReB = Reynold’s number for the
stream (E), which also experiences B stream
the least amount of mixing with  Conditions favoring high
the other streams. Hence, it leakage flow rates and low
experiences the largest driving Reynolds numbers (hence,
force for heat transfer. low δ) are high shell-side fluid
 The net result of these different viscosity and small baffle
temperature profiles is that the
spacing.
mean temperature difference in
the exchanger can be less than  The effect of temperature
that calculated using the profile distortion can be
logarithmic mean temperature mitigated by using multiple
difference (LMTD) correction shells in series because the
factor, which does not take shell-side fluid becomes well
account of these effects. This mixed as it exits one shell and
phenomenon is referred to as enters the next.
temperature profile distortion.  The minimum recommended
△Tmean = δF(△Tln)cf δ is 0.75. Below this, two or
δ ranges from 0 to 1.0. more shell in series must be
Q = UAδF(△Tln)cf employed
Other factors
“β” is the baffle cut factor, which accounts for non-crossflow patterns
caused by too small or too large a baffle cut. If the baffle cut is not
adequacy, the fraction of crossflow is decreased. It is recommended that β
is more than 0.9, and it should be checked by the HTRI program.
Another two corrections hereunder are considered. Refer to HTRI Design
Manual.
(*1) tube row effect, accounts for number of tube rows in crossflow.
(*2) boundary layer overlap correction in single-phase laminar flow for
finned tubes.
Useful tables for your trials[5]
r2 = (f). r1[2] ∆P2 = (f). ∆P2[2]
Variable[1] Flow Regime
Shell (f) Tube (f) Shell (f) Tube (f)
0.27
Viscosity Turbulent (μ2 /μ1) (μ2 /μ1)0.47 (μ2 /μ1) 0.15
(μ2 /μ1)0.2
Viscosity bulk to 𝜇 𝜇 .
Streamline . (μ2 /μ1)
wall correction 𝜇 𝜇
Thermal
Turb. Or Streamline (k1 /k2)0.67 (k1 /k2)0.67
conductivity
Sp. heat Capacity Turb. Or Streamline (Cp1 /Cp2)0.33 (Cp1 /Cp2)0.33
Mass velocity or ṁ Turbulent (G1 /G2)0.6 (G1 /G2)0.8 (G2 /G1)1.85 (G2 /G1)1.8
Streamline (G1 /G2)0.6 (G1 /G2)0.33 (G2 /G1)
Density Turb. Or Streamline (ρ1/ ρ2) (ρ1/ ρ2)
Tube diameter Turbulent (Do2 / Do1)0.4 (Di2 / Di1)0.2 (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
RC2/RC1
crossed[3]
Source 9: GPSA section 9: heat exchangers
[1] Use consistent units for any one variable in both cases
[2] 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.
[3] Number of rows of tubes exposed to cross flow (as opposed to parallel flow). This
Number is determined by baffle and bundle geometry.
[4] (hi/h2) = r2/ r1
.
ℎ 𝑟 𝜇 . 𝑘 . 𝐶 𝐺 . 𝐷 .
= = . . . .
ℎ 𝑟 𝜇 𝑘 𝐶 𝐺 𝐷
. . .
∆𝑃 𝜇 𝜌 𝑁 𝐺 𝐷
== . . . .
∆𝑃 𝜇 𝜌 𝑁 𝐺 𝐷
Note: Check for the lowest h in your calculations it should be the dominating factor
and the most factor that would influence your overall U.
Methods to improve the flow fraction
To increase “B” fraction, “A”, “C”, “E” and “F” fractions should be decreased by the following methods:
Method ＼ Fraction A C E F
Enlargement of baffle spacing Effective Effective
Increasing baffle cut Effective Effective
Decreasing tube-to-baffle clearance(*1) Effective
Installation of sealing strips Effective
Installation of seal rods Effective
Change of tube passes arrangement Effective
Change of baffle cut orientation Effective
NOTE(*1): Refer to TEMA RCB-4.2 with regard to standard its clearance
The recommended limitation about flow fractions are shown hereunder:
B stream : For turbulent flow; Min. 50%, For laminar flow; Min. 40%
C stream : Max. 10%
E stream : Max. 15%
F stream : Max 20%, preferably 15% or below
Guidelines to be kept in mind
The dynamic head, ρV2(*1), is a limitation to prevent or minimize erosion of the tube bundle,
and is used as a guideline for the necessity for impingement protection devices. Impingement
protection devices should be provided when ρV2 through the inlet nozzle exceeds the
following:
Non corrosive, non-abrasive, single-phase fluid: 2230 (kg/m-sec 2)
All other liquids, including a liquid at its bubble point: 740 (kg/m-sec 2)
Note(*1): ρ is the fluid density, and V is the linear velocity of fluid. For two-phase fluid, the
mean density should be calculated assuming a homogeneous vapor-liquid mixture.
The allowable baffle cut range for each baffle style is as follows:
Segmental: 10～49% (single phase: recommended 25%, 10-15 accepted)
Double segmental: 10～30%
Triple segmental: 10～40%
Segmental NTIW: 15～30%
Minimum spacing[2]
Segmental baffles normally should not be spaced closer than 1/5 of the shell inside diameter, or
50 mm, whichever is greater. This is the design practice specified by TEMA.
Max. spacing[2]
Baffle or support plates should be spaced such that the unsupported tube span does not exceed
the values
Table: TEMA Maximum Unsupported Tube Spans
Tube materials and temperature limits (°C)

Carbon Steel / Other alloy (400) Aluminum, Aluminum alloys
Tube O.D. Low alloy (455) Copper, Copper alloys
Copper-Nickel (316) Titanium, Titanium alloy
Nickel (454), Ni-Cr-Fe Alloy (538) (at code max. allow temp.)
19.0 or 19.05mm 1,525 mm 1,320 mm
25.0 or 25.4 mm 1,880 mm 1,625 mm
The effective temperature difference △TLMTD[2]
The effective temperature difference should be greater than 5.6 "C (10°F)
Minimum temperature approach
Recommended minimum temperature approach for shell and tube exchangers is 10 oC
Cooling water (Cooling tower water and sea water) [2]
(a) Cooling water is usually routed through the tube side of an exchanger
(b) The velocity of the cooling water in the shell side should be 0.6m/sec or more. A
higher velocity is desirable, but exchangers should be designed without causing flow-
induced vibration problems.
Tube Material Cooling Tower Water (CTW) Sea Water (SW)
Carbon steel Stainless steel 0.9~ Not used
Admiralty brass Aluminum brass 0.9∼2.4 0.9∼2.4 (*1)
Aluminum bronze Not used 0.9∼3.0
Copper-nickel 70 - 30 0.9∼4.6 0.9∼2.9
Copper-nickel 90 - 10 0.9∼3.7 0.9∼2.0
Monel 1.8∼ 1.8∼
Titanium 1.2∼ 1.2∼
Table 1: Recommended Cooling Water Velocity in Tubes (m/sec)
NOTE(*1): If sea water is not treated with an effective iron ion, the maximum water
velocity should be less than the following conditions: 1.2m/sec for admiralty brass,
1.8m/sec for Aluminum brass. Engineers should confirm the sea water supply
conditions.
(c) To reduce the tendency to foul, the maximum allowable outlet temperature for
cooling water is limited as follows:
SW: 50°C
CTW: 60°C
(d) Another important criterion is the film temperature on the tube surface including a
fouling layer. If the film temperature exceeds the following conditions, severe fouling
could result.
SW: 65°C
CTW: 70°C
Slurry handling[3]
25.0 mm O.D. or larger tubes should be used to prevent plugging of the tubes with
slurry “chunks”, and not less than 12 BWG thickness because of the possibility of
erosion that may occur at the higher velocities.
Velocity limitations (m/sec)

Max. Min
2.44 1.37
Tube side velocities[3]
 Tube side velocity for most materials and services should be held between 1.3 – 2.5
m/s
 Belo 1 to 1.2 m/s fouling may be excessive, much above 2.5 m/s erosion can become
a problem
Design margin[3]
10% design margin is recommended
4. Tool assumptions
1. Flow is steady and isothermal, and fluid properties are independent of time.
2. Fluid density is dependent on the local temperature only or is treated as constant
3. The pressure at a point in the fluid is independent of direction.
4. There are no energy sinks or sources along the streamline; flow stream mechanical
energy dissipation is idealized as zero.
5. The friction factor is considered constant with passage flow length.
6. Tube wall temperature viscosity effect is negligible.
7. Single phases for both shell and tube (two phases to be added soon)
For Bell-Delaware method:
1. Leff = L - 2*Ls , where Leff is effective tube length in mm for fixed tube sheet
2. Ls = 0.1* Ds
𝑁𝑡𝑐𝑐
3. Nss = 𝑖𝑛𝑡𝑒𝑔𝑒𝑟
6
4. DSB = 3.1+0.004* Ds
5. LTB = 0.4 mm
6. DotL = Ds - (12.5+( Ds /200))
References
1. Process Heat transfer, Kern.
2. JGC standard practice “Shell & tube Exchangers” JGS 210-120-1-24E
3. TOTAL process engineering design manual
4. Petroleum Refining Design and applications, vol. 4, A. Kayode Coker
5. GPSA Engineering Data Book Section 9 (Heat exchangers)
6. Rapid Design Algorithms for Shell-and-tube and Compact Heat Exchangers, Graham
Polley.
7. Effectively design shell-and-tube heat exchanges, Rajiv Mukherjee.
8. Energy and Process Optimization for the Process Industries, Frank Zhu.
9. Energy Management and Efficiency for the Process Industries, Alan P. Rossiter, Beth P.
Jones.
10. Applied Heat Transfer and Heat Exchangers, Aramco Engineering Encyclopedia
11. Process Heat Transfer Principles and Applications, Robert W. serth.
Other Recommended Readings and resources
1. Chemical process engineering by A. Kayode Coker vol 2 (present the manual calculations
of heat exchangers in different cases and compares results with commercial software.
Overall, an excellent book, worth checking out and should be added to your library)
2. Monitoring the Thermal Efficiency of Fouled Heat Exchangers: A Simplified Method, M.
A. S. Jerónimo et al
3. Data Reconciliation and Fouling Analysis in Heat Exchanger Network, Ahmad Nuruddin
bin Abdul Aziz.
4. Optimization of operating conditions for mitigating fouling in heat exchanger networks,
C. Rodriguez and R. Smith.
Resources
1. Bell-Delaware Calculations excel sheet
2. Kern Calculations excel sheet
3. NTU calculations excel sheet
Preliminary Design Example
Kern Method [4] page: 291
Use Kern’s Method to obtain a preliminary design for the following conditions
Kerosene API 42, 25,000 kg/hr (Shell side)
Crude oil API 34, 85,000 kg/hr (Tube side)
Kerosene Inlet Average Outlet
o
Temperature C 200 145 90
o
Specific heat kJ/kg. C 2.72 2.47 2.26
Thermal conductivity W/m. oC 0.13 0.132 0.135
Density Kg/m3 690 730 770
-2
Viscosity mNsm 0.22 0.43 0.8
Crude Oil
o
Temperature C 79 59.5 40
Specific heat kJ/kg. oC 2.09 2.05 2.01
o
Thermal conductivity W/m. C 0.133 0.134 0.135
Density Kg/m3 800 820 840
-2
Viscosity mNsm 2.4 3.2 4.3
Assumptions:
Uservice = 350 W/m2. oC
Length = 5000 mm, Do = 19.05 mm, Di = 14.83 mm, triangular pitch 30o, pitch ratio = 1.25
Allowable ∆Ps = 0.9 bar, ∆Pt = 0.9 bar,
Output
Table: input for tool was only S.G and temperatures.
Parameter Units Coker’s [1] Commercial Tool Tool

software kern Polley
Surface Area m2 77.64 50.2 82.85 54.84
hs coefficient 1325.69 1510.3 1237.35 1857.4
ht coefficient 1555 1543.8 901.1 2489.5
Uservice W/m2. oC 350 736.2 315.87 561.760
Uclean W/m2. oC 508.9 472.27 413.26
Udirty W/m2. oC 440 508.2 365 420.88
Over Design % 25.7 1 13.53 -1.8
Over surface % 45 49.51 33.4
∆Ps Kg/cm2 0.7 bar 0.74 0.4 0.86
∆Pt Kg/cm2 0.96 bar 0.329 0.41 0.93
Length mm 5000 4876.8 5000 7159
Number of tubes - 260 181 213 128
Tube diameter mm 19.05 19.05 25.4 19.05
Tube thickness mm 2.11 2.11 2.11 2.11
Tube pitch mm 23.81 23.81 31.75 23.81
Ds mm 522 438.15 627 348.3
Number of passes - 4 6 4 2
Baffle spacing mm 104.32 215.9 125.4 79.67
Baffle cut % 25 38.04 25 14
Q = ṁCp∆T =(25,000/3600)*247(200-90) = 1886.8 kw
∆TLMTD = = 80.34 ˚𝐶
( )
P= = 0.2437, R = = 2.82
F = 0.8673 , ∆TCMTD= F * ∆TLMTD = 69.43
Q=UA∆TCMTD , A = Q/U∆TCMTD = 1886.8 x 103/(350x69.43) = 77.64 m2
Nt = A/πDoL = 77.64/(3.14x0.01905x5) = 259.46 (Say 260)
Tube cross sectional area = Ac = πDi2/4 = π(0.01483)2/4 = 0.0001727 m2
Area per pass = Nt/pnAc =(260/2x0.0001727)= 0.02246 m2
Gs = Wh/ρ = 85,000/3600*820= 0.02879 m3/s
Tube velocity = ut = 0.02879/0.02246 = 1.28 m/s
Estimate Shell diameter
From table 8.46 for two passes K1 = 0.249 , n1 = 2.207
.
𝐷 =𝐷 ∗ = 19.05 ∗ = 444 mm
.
Clearance is between 50 to 80 mm for split-ring floating head
Choose C= 56 mm, Ds = 444 +56 = 500 mm
∗ . ∗ .
𝑅 = = = 4864
. ∗
. ∗ ∗ . ∗
Pr= Cpμ/k = =48.96
.
Re= 4864, L/di =5000/14.84 = 337, from figure 8.55 the friction factor Jh
Jh = 3.5 x 10
Nu = Jh Re Pr 0.33(μ/μw)0.14
.
= 𝐽 𝑅𝑒𝑃𝑟 .
, assume negligible μ/μw
ℎ = 3.5 x 10 (0.134/0.01483)(4864)(48.96)0.33=555.48 W/m2. oC
In order to increase hi , tube passes is doubled, this will halve cross sectional area and double
the tube velocity.
ut = 2 x 1.28 = 2.56 m/s
Re = 2 x 4864 = 9728, Jh = 4.9 x 10
hi= 4.9 x 10 (0.134/0.01483)(9728)(48.96)0.33= 1555 W/m2. oC √√
From table 8.46 for two passes K1 = 0.175 , n1 = 2.285
.
𝐷 =𝐷 ∗ = 19.05 ∗ = 465.6 mm
.
Ds = 465.6 +56 = 521.6 mm
Baffle spacing trials
B = Ds/5 = 521.6/5 = 104.32
( ) . .
Shell flow area = = 𝑥522𝑥144 = 10853.04 mm2 =0.01853 m2
.
.
Equivalent shell diameter = De = (𝑝 − 0.913𝑑 ) =13.53 mm
Gs = Wh/ρ = 25,000/3600*730= 0.00951 m3/s
Shell velocity = us = 0.00951/0.01853 = 0.51 m/s
∗ . ∗ .
𝑅 = = = 11,714
. ∗
. ∗ ∗ . ∗
Pr= Cpμ/k = = 8.17
.
-3
jh= 5.8 x 10
.
Nu = = 𝐽 𝑅𝑒𝑃𝑟 .
ho= 5.8 x 10 (0.132/0.01353)(11,714)(8.17)0.33= 1325.69 W/m2. oC

Uclean and Udirty
𝑑
1 1 𝑑 𝑑 ln 1
𝑑
= + +
𝑈 ℎ 𝑑 2𝑘 ℎ
19.05
1 1 19.05 1 19.05 0.001905 ln 1
=( + 0.00035) + + 14.83 +
𝑈 1555 14.83 ℎ 14.83 2 ∗ 55 1325.69
𝑑
1 1 𝑑 1 𝑑 𝑑 ln 1
𝑑
= + + + +𝑅
𝑈 ℎ 𝑑 ℎ 𝑑 2𝑘 ℎ
19.05
1 1 19.05 1 19.05 0.001905 ln 1
= + 0.00035 + + 14.83 + + 0.0002
𝑈 1555 14.83 ℎ 14.83 2 ∗ 55 1325.69
= 440 W/m2. oC
Over Design = ∗ 100% = 25.7%
Pressure drops
Tube pressure drop
𝐿 μ ρv
∆Pt = 𝑁 8𝐽 + 2.5
𝐷 μ 2
=4[8x4.8x10 x337.15+2.5]820x2.56 /2 =96443.9 N/m2 = 0.96 bar
-3 2
Shell pressure drop

𝐿 𝐿 ρv μ .
∆Ps = 8𝑗 8𝐽
𝐷 𝐵 2 μ
=8[4.8x10 x(522/13.75)(5000/104)(730x0.512/2)] =66537.87 N/m2 = 0.7 bar
-2
Bell Delaware (Polley’s Method) [6]
Use Bell Delaware’s Method to obtain a preliminary design for the following conditions
Parameter Unit Shellside Tubeside

Flow rate Kg/hr 22.4*3600 77.96*3600
Fluid density Kg/m3 740 1000
Heat Capacity J/kg.K 2407 4187
Viscosity cP 0.494 1
Thermal conductivity W/m.K 0.105 0.61
o
Inlet temperature C 100 7.1
o
Outlet temperature C 42.5 16.6
Allowable ∆P kPa 13.7 11.66
Dirt factor K.m2/W 0.0 0.0
Wall resistance K.m2/W 0.00003
Heat duty kW 3100
Geometry Unit Polley’s Tool

Do mm 16 15.88
Di mm 13.5 13.4
Tube layout Degree 30 30
Tube pitch mm 20.8 20.64
Baffle/shell clearance mm 5.5 5.366
Tube/baffle clearance mm 0.5 0.4 “assumed”
Bundle/shell clearance mm 10 15.33
Output
Parameter Units Polley’s Tool
Geometry
Ds mm 563 566.6067
Tube length mm 1815 1721.38016
Baffle cut % 29.3 26
Baffle spacing mm 253 190.57
No. of baffles - 6 8
No. of tubes - 574 677
No. of tube passes - 2 2
Installed area m2 52.3 58.14
Required area m2 52.3 50.55
Performance
Shellside Re - 21,398 27,211.4
Shellside ∆P kPa 13.7 15.95
Tubeside ∆P kPa 11.69 19.6
Shellside Coeff. W/m2. oC 1406 2124.5
Tubeside Coeff. W/m2. oC 6641 6380.67
Udirty W/m2. oC 1088 982
1. Initialization
Assume exchanger with shell diameter Ds = 387 m, baffle cut=25%, 6 m length, 2 passes for the
following heat exchanger:
Geometry Unit Value
Do mm 16
Di mm 13.5
Tube layout Degree 30
Tube pitch mm 20.8
Baffle/shell clearance mm 5.5
Tube/baffle clearance mm 0.5
Bundle/shell clearance mm 10
a. Estimate the number of tubes that could fit in your shell diameter
b. Estimate shell Reynold’s number
θDS = 2cos-1(1 - 2Bc/100)
SWG = (Ds²/8)(θDS - Sin(θDS))
SWT = Nt.FW(πDo²/4)
SW = SWG - SWT
Based on the assumption that baffle spacing is same as baffle cut area
Sm = SW
GW = mS/(Sm.SW)0.5
GS = mS/Sm
ReS = Do.GS / μS
c. Calculate shell heat transfer coefficient and pressure drop
Sm = B[(Ds - DOTL) + (DOTL - Do)(PT - Do)/PT,eff ] Di = Do – 2*thickness
PT,eff = PT for 30° and 90° layouts Ltb = 0.4
PT,eff = 0.707*PT for 45° layout
Ls= 0.1* Ds
GS = mS/Sm
ReS = Do.GS / μS Dsb = 3.1+0.004* Ds
PrS = CP,S.μS / kS Leff = L- 2* Ls
Dotl= Ds - (12.5+( Ds/200))
1.33
𝑗=𝑎 . (𝑅𝑒 )
𝑃
𝐷𝑜
𝑎
𝑎=
1 + 0.14(𝑅𝑒 )
µ .
ℎ = 𝑗. 𝐶 , . 𝐺 . (𝑃𝑟 ) . ( )
µ,

JC = 0.55 + 0.72FC
FC = 1 - 2FW
DCTL = DOTL - Do

JL = 0.44(1-rS) + (1-0.44(1-rS))exp(-2.2rL)
rS = Ssb /(Ssb + Stb)
rL = (Ssb + Stb)/ Sm
Ssb = Ds*DSB(π - 0.5θDS)
Stb = (π/4)((Do+LTB)2 - Do2)Nt(1-FW)
θDS = 2cos-1(1 - 2Bc/100)

Ntcc = (Ds/Pp)(1 - 2Bc/100)
rss = Nss/ Ntcc
Sb = B(Ds - DOTL - Do/2)
JB = 1 for rss >= 0.5
Cj = 1.35 for ReS < 100
Cj = 1.25 for ReS >= 100

NB = 1 + (int)(L - 2Ls - LBIn - LBOut)/B
JRL = (10/NC)0.18
JR = 1, ReS > 100
JR = JRL, ReS <= 20
a.5 Correction factor for unequal baffle spacing, J S

n1 = 0.6, ReS >= 100
n1 = 1/3, ReS < 100
JS = ((NB-1)+(LBIn/B)1-n1 + (LBOut/B)1-n1)/((NB-1)+(LBIn/B) + (LBOut/B))
Shell side heat transfer coefficient is calculated as

1.33
𝑓=𝑏 . (𝑅𝑒 )
𝑃
𝐷𝑜
𝑏
𝑏=
1 + 0.14(𝑅𝑒 )

p = 0.8 - 0.15(1+rS)

RB = 1 for rss >= 0.5
Cr = 4.5 for ReS < 100
Cr = 3.7 for ReS >= 100
n = 0.2, ReS >= 100

n = 1.0, ReS < 100
SWG = (Ds²/8)(θDS - Sin(θDS))

SWT = Nt.FW(πDo²/4)
SW = SWG - SWT
GW = mS/(Sm.SW)0.5
DW = 4.SW /(π.Do.Nt.FW + θDS.Ds)
SWG Gross window area, SWT Window area occupied with tubes, SW Net Cross flow area, Gw Mass velocity
baffle window, Dw Hydraulic diameter baffle window.



Shell side pressure drop is calculated as following

d. Calculate tube heat transfer coefficient and pressure drop
ReT = Di.v.ρt/μt
PrT = Cp,t.μt/kt
For turbulent flow, ReT > 10,000, following equation developed by Petukhov-Kirillov
can be used.
Nu = (f/2)ReT.PrT/(1.07+12.7(f/2)0.5(PrT2/3-1))
f = (1.58 ln(ReT) - 3.28)-2
a. Tube Side Pressure Drop, ΔPt
ΔPt = (4.f.Leff.Np/Di + 4.Np)ρt.v²/2
ΔPs = 0.47 Kg/cm2, ΔPt =0.5159 Kg/cm2, hs =1061 W/m².°C, ht =7071

W/m².°C, A=48.147 m2
e. Calculate shell and tube constants from the following equations

.
∆𝑃 = 𝑘 ∗ 𝐴 ∗ ℎ
.
∆𝑃 = 𝑘 ∗ 𝐴 ∗ ℎ
ks = 1.912 , kt= 0.906
1. Solving for the allowable pressure drops

1. Solve the following non-linear equations to obtain the desired heat
transfer coefficients for both shell and tube and the required area (h s,ht
and A) that can achieve your allowable pressure drops for both shell and
tubes
𝐴= Q /( LMTDcorrected)*(1/(1/hS + Do/(Di.ht) + Rtube)) + fshell + ftube)
∆𝑃 = 𝑘 ∗ ℎ .
→ 11.66 = kt*(ht )3.5→ ht = 908 W/m².°C
∆𝑃 = 𝑘 ∗ ℎ .
→ 13.7 = ks*(hs )4.412→ hs = 6335 W/m².°C
A = 64.74 m2
Where ∆𝑃 and ∆𝑃 are shell and tube allowable pressure drops

Solve the following equations to obtain tube Reynold’s number and friction
factor
Nu = (f/2)ReT.PrT/(1.07+12.7(f/2)0.5(PrT2/3-1))
f = (1.58 ln(ReT) - 3.28)-2
where Nu = ℎ /.(kt/Di)(μt/μt, w)0.14
after obtaining Re iterate this Re till ht calculated = ht solved from the
previous step.
𝑣 = Di.Re.ρt/μt
at = mt/(⍴t*vt*3600)
Nt = at/ π. ∗
Leff =A/(tn. π.Do)
For turbulent flow, ReT > 10,000, following equation developed by Petukhov-Kirillov
can be used.
Nu = (f/2)ReT.PrT/(1.07+12.7(f/2)0.5(PrT2/3-1))
f = (1.58 ln(ReT) - 3.28)-2
if ht = ht.solved stop iteration, else change Re accordingly and start over.
Re = 21866.32, ht =6376.52 W/m².°C , vt =1.631 m/s, at=0.047 m2/s,Leff =

1.72 m, Nt = 677
2. Iterate!
1. Estimate Shell diameter from the tube count. If it didn’t change proceed,
if changed repeat from initialization with a new shell diameter
accordingly.
Ds = 566.60
2. Calculate ∆𝑃 If it didn’t change from your allowable shell pressure drop
proceed, if it changed repeat from initialization with a new baffle cut
accordingly.
3. If no baffle cut % achieved ∆𝑃 start from initialization with a new
number of passes.
Baffle cut% = 26%
∆𝑃 = 0.196 Kg/cm2
NTU Method
For the previous example:
Fluid Data Hot Cold
Flowrate kg/s 22.4 78.0
Inlet Temperature °C 100.0 7.1
Specific Heat kJ/kg.°K 2.407 4.19
Exchanger Data
Heat Exchanger Type Shell & Tube - 1 Shell - 2,4, .. Tube Passes
Heat Transfer Coefficient kW/m².°K 1.09
Area m² 52.30
Solution
UA = 52.3*1.088 = 56.9 kW/°C
Cmin = 22.4*3600*2.407* 0.239006*1.163 = 53952.94 W/oC
Cmax = 78*3600*4.19*0.239006 *1.163 = 327039.1 W/ oC
Cr = Cmin/Cmax = 0.1652
NTU = UA/Cmin = 56.9/53.95 = 1.06
Qmax = Cmin(T1-t1) = (22.4*3600*2.407* 0.239006) * (100-7.1) = 4309741 kCal
2
𝜀= = 0.6177
1 + exp (−𝑁𝑇𝑈 1 + 𝐶 )
1+𝐶 + 1+𝐶
1 − exp (−𝑁𝑇𝑈 1 + 𝐶 )
Q = ε Qmax = 0.6177 * 4309741= 2662323 Kcal/hr
T2 = T1 -Q/m.Cp = 100 – 2662323/ 46391.18 = 42.6 oC
t2 = t1 +Q/m.Cp = 7.1 + 2662323/281203 = 16.6 oC
hence, exchanger would achieve the desired outlet temperatures.

Oil fractions’ properties [Notes] Valid in the range of 50-300 F, otherwise
1. Density you may take viscosity at point 37.38 C and
Liquid [4] use the following one-point approximation
ρ = sg*1000*(1-α*((t*1.8+32)-60)) 2. From 1 viscosity point [7]
α: Thermal expansion coefficient c = -0.8696
API α ( oC-1) b= log10(µ37.38 ˚C; 1 atm )-c
14.9 0.00035 s = 0.2008*b+1.6180
34.9 0.0004 Log(µ) = (b/(1+((T-Tanalysis)/310.93))**s)+c
50.9 0.0005 µ: Viscosity in c.St
63.9 0.0006
3. From 2 viscosity points
78.9 0.0007
Solve the two points using the logarithmic
88.9 0.0008
93.9 0.00085 function
100 0.0009 A = (z2 – z1) / (x2 – x1)
Vapor B = z1 – a * x1
Molecular weight [1] x1, x2: temperature points
1⁄𝑀 = 0.0001644 ∗ 𝐴𝑃𝐼 − 0.000972 z1, z2: log of viscosity points
16.018463 ∗ 𝑚_𝑤𝑡 ∗ 𝑝 ∗ 14.7 µ = 10a (t+273.15) +b
⍴=
10.732 ∗ 𝑧 ∗ (𝑡 + 459.67) Vapor [7]
P: atm. ,t in o F ⍴: kg/m3 µOg=-0.0092696 +T0.5(0.001383-5.9712x10-5M0.5)+1.1249x10-5M
2. Heat Capacity, Latent Heat & Thermal T: temperature in oK
conductivity [Note 1] Note: The reliability of this equation is about 6%
Cp = (1/ 𝑠𝑔))*(0.388+0.00045*(t*1.8+32)) µg=10-4A[exp(B x ρC)]

Cv = Cp-(0.09/sg) A = [(12.6 + 0.021M) T 1.5] / (116 + 10.6M + T)
HLatent = (1/sg)*(110.9-0.09*(t*1.8+32)) * B = 3.45 + 0.01M+ ((548/T)
0.555927 C = 2.4 -0.2 B
k = (0.813/sg)*(1-0.0003*((t*1.8+32)-32)) ρ: Density in kg/m3
*0.1442279 Hydrocarbon mixtures
-
kgas =( -0.000500777+1.0906*10 1. Density
5
*(t*1.8+32)+0.061137256/√M.wt + liquid
0.000158966*(t*1.8+32)/√M.wt)*1.730735 GPSA (page 23-24) [2]
Cp and Cv in Kcal/kg.oC 1. Calculate C3+ Density using table
HLatent in Kcal/Kg
23-16
k and kgas in W/m.oC
2. Calculate wt% C2 in mixture in C2+
3. Viscosity
3. Calculate Density of CO2+
Liquid
4. Calculate wt% in total
1. From no viscosity points[5]
5. Use fig 23.14 for pseudo-density
API Equation
mixture at 60F and 14.7 psia
34 3.518-0.01591*t+1.734*10-5t2
30 5.804-0.029831*t+1.2485*10-5*t2 6. Use fig. 23-15 for pressure
20 9.21-0.0469*t+3.167*10-5*t2 correction
10 18.919-0.1322*t+2.431*10-5*t2 7. Use fig 23-17 for temperature
correction
8. Calculate density at operating 2. Soave-Redlich-Kwong
pressure and temperature 3. Peng-Robinson
⍴= , [6] where: 2. Viscosity of liquids/gases
∑
⍴ Liquid
⍴: Density of the mixture [kg/m3]  The Orrick-Erbar and Letsou-Stiel methods
⍴ : Density of component i are recommended for estimating the liquid
𝑤 : Weight fraction of component i viscosity. [4] [Notes]
Elbro et al [6] [Notes] Ludwig’s [3] [Notes]
µG = A+ BT + CT2
𝑉 = 𝑛 .△𝑉
Simple Methods [6]
△ 𝑉 = 𝐴 + 𝐵 ∗ 𝑇 + 𝐶 ∗ 𝑇 , Where: Method 1: If only one viscosity datum is
Vm is the molar volume of liquid, ni is the available, viscosity at other temperatures
number of group i, and △Vi is the molar can be approximately extrapolated by the
group volume equation:
Example: µµ0tt233
Estimate the liquid density of isopropyl Method 2: If two pairs of temperature-
viscosity data are available, it is often a
acetate at 20C.
good approximation to assume
µ1 is linear, reciprocal to absolute
temperature:
ln µL = ln A + B/T
Liquid mixtures[6]
Vm = V (CH3COO) + V (CH) + 2V (CH3)
At 20C, or 293.15 oK µ = ∑𝑥 .µ , for liquid hydrocarbons mixtures
V (CH3COO) = 42.820 - 20.50×10-3 (293.15) +
16.42×10-5 (293.15)2 = 50.92 ln µ = ∑ 𝑥 . ln µ , for liquid non-hydrocarbons
V (CH) = 6.297 - 21.92×10-3 (293.15) = -0.13 mixtures , xi is weight fraction
V (CH3) = 18.960 + 45.58×10-3 (293.15) = 32.32 Vapor viscosity
Vm = 50.92 - 0.13 + 2 (32.32) = 115.44 cm3/mol  The Reichenberg method is recommended.[4][Notes]
The molecular weight is 102.133, then
Ludwig’s [3]
⍴= 102.133/115.44 = 0.885 g/cm3
µG = (A + BT + CT2) x 10 -4
Ludwig’s [3]
Gas mixtures[6] (Herning Zipperer)
⍴ = 𝐴𝐵 ( )
∑ .µ .
A, B & n: constants µ = ∑
, yi is mole fraction
.
Hydrocarbon gas density Saturated Liquid viscosity
Ludwig’s [3] Ludwig’s [3]
ρideal = Mwt *Vm=Mwt.P/RT Log µL = A + (B/T) + CT + DT2
ρ = Mwt *Vm=Mwt.P/ZRT µL : cP, T: oK
where Vm is the molar volume L/g.mol GPSA
R: Universal gas const. 8.314 Use previous documentation (Line sizing)
kPa.dm3/mol.k Use fig. 23-21 to 23-29
P: Gas pressure in kPa 3. Thermal conductivity
T: Gas temperature in oK Gas Thermal conductivity
Other methods (EOS) [2] : Ludwig’s [3] [Notes]
1. Van der Waals Kgas = A+ BT + CT2
Kgas: W/m.K ∑ . .( )
𝑘 = , for gas mixtures
Stiel-Thodos Method[Notes] ∑ .( )
𝜔 = 𝑦𝜔 GPSA[2]
Using Charts
𝑍 = 0.291 − 0.08𝜔
1. Use fig 23-31 at operating
𝑀 = 𝑦𝑀 temperature to find KA
𝑇 =𝑇 2. Calculate Tr and Pr
3. Use fig. 23-32 to find thermal
𝑇 = (𝑇 𝑇 )
conductivity ratio
𝑉 =𝑉
4. K = ratio * KA
(𝑉+𝑉 )  Stiel and thodos Method is recommended
𝑉 =
8 For mixtures of simple gases, it doesn’t
∑ ∑ 𝑦𝑦𝑉 𝑇 apply to mixtures containing high CO2[2]
𝑇 =
𝑉  Miscellaneous gases can be obtained from
𝑉 = 𝑦𝑦𝑉 fig 23-33 and hydrocarbon gases from fig
23-34
𝑃 =𝑍 𝑅𝑇 /𝑉
/ Liquid Thermal conductivity
𝑇 𝑀 Ludwig’s [3] [Notes]
𝛤 = 210
𝑃 KL = A+ BT + CT2
𝑃 = 𝑉 /𝑉 KL: µcal/s.cm.oC
For organic compounds, the correlation for thermal
if ρrm<0.5: conductivity of
liquid as a function of temperature is [2]:
(λ−λ∘)ΓZcm5=1.22×10−2[exp(0.535ρr)−1] log10 kliq
if 0.5< ρrm <2.0: Thermal conductivity for liquid mixtures
(λ−λ∘)ΓZcm5=1.14×10−2[exp(0.67ρrm)−1.069] ∑ . .
if 2.0< ρrm <2.8: = ∑
or = ∑𝑤 , where
.
(λ−λ∘)ΓZcm5=2.6×10−3[exp(1.155ρrm)−2.016] Xi: Mole fraction of component i
Wi: weight fraction of component i
Tcm, Pcm, Zcm, Vcm are critical temperature, Mi: molecular weight of component i
pressure, compressibility factor and specific From graph 23-35 liquid paraffin
volume of mixture in oK, bar, -, cm3/mol hydrocarbons
Vm, Mm, λ, λ∘ are specific volume at 1 atm,  The Sato-Riedel and Missenard methods
molecular weight of mixture g/mol, are-recommended.[6] [Notes]
thermal conductivity and thermal Missenard method
conductivity at 1 atm in W/m.k k/k∗=1+QPr0.7
yi, yj are mol. Fractions of mixture k*: k at low pressure (W/m.K)
components
𝛤 is the reduced, inverse thermal
conductivity in [W/m.K]-1
Thermal conductivity for gas mixtures

Sato-Riedel Method [Notes] R: gas constant 8.3145 J mol-1 K-1
1.1053 3 + 20(1 − 𝑇𝑟) / CPL: J mol-1 K-1
𝑘= k is total the number of different kinds of
√𝑀𝑊 3 + 20(1 − 𝑇𝑏𝑟) / groups
Tr: reduced temperature oK
Tbr: reduced boiling temperature oK at 1 Vapor Heat capacity Cpv
atm Ludwig’s [3]
Kgas: W/m.K Cp = A + BT + CT2 + DT3+ET4
4. Heat capacity Cp Cp: joule/mol. K
Liquid Heat Capacity Benson method is recommended for ideal
Ludwig’s [3] [Notes] gas Cp [6]
Cp = A + BT + CT2 + DT3 Harrison-Seaton method, is much simpler
Cp: joule/mol. K than Benson method and gives only slightly
GPSA inferior results. [6]
Use table (fig 23-2) in P. 23-2 for specific Heat Capacity for gas or liquid mixtures
heats at 60 oF and 14.696 psia for gases and Cp = 𝑥 . Cp
liquid
xi is components weight fraction
 The Chueh-Swanson method is
References
recommended for estimation of liquid heat
[1] Bureau of standards report 1929: Thermal
capacity at 20C, and for temperature
dependency the Missenard method is properties of petroleum products
recommended. [6] [Notes] [2] GPSA Engineering Databook, Section 23.
The assumption is made that various groups [3] Ludwig’s applied process design for
in a molecule contribute a definite value to chemical and petrochemical plants, vol. 1
the total molar heat capacity. (chapter 3 and Appendix C)
Example:
[4] Petroleum Refinery Engineering, W. L.
Estimate the liquid heat capacity of 1,4-
pentadiene at 20C. Nelson
[5] Petroleum Refining Design and applications,
vol. 1, A. Kayode coker
[6] JGS 210-120-1-11E “Estimation of physical
properties”
[7] Prediction of the viscosity of crude oil
CpL = 2 (CH2=) + 2 (-CH=) + (-CH2-) +
fractions from a single measurement, A.
corrections noted in Table 4.2.3
= 2 (5.20) + 2 (5.10) + 7.26 + 4.5 + 2.5 Miadonye and V.R. Puttagunta
= 34.9 cal/mol･K Notes
The observed value is 35.1cal/mol･K. 1. It’s worth mentioning that the most
accurate method to obtain oil fractions
Method of Ruzicka and Domalski[Notes] properties is oil characterization
𝑇 𝑇 calculations if ASTM assay or Tb are
𝐶 =𝑅 𝐴+𝐵 +𝐷
100 100 available. For more on that topic the
following references are recommended:
𝐴= 𝑛 .𝑎 ,𝐵 = 𝑛 .𝑏 ,𝐷 = 𝑛 .𝑑
A. Characterization and Properties of
T: temperature in oK Petroleum Fractions, M. R. Riazi
B. Petroleum Refining Design and liquids, Bruce E. Poling et al, fifth edition P.
Applications Handbook, Volume 1, 6.19 and its constants in P. 6.20
chapter 3 10.The Chueh-Swanson method and Missenard
C. Petroleum Refinery Engineering, method are described in The properties of
Nelson, chapter 5 gases and liquids, Bruce E. Poling et al,
D. Petroleum Refinery Process fourth edition P. 137 and its constants in P.
Modeling: Integrated Optimization 138-13
Tools and Applications, Y A Liu, Ai- 11.Reichenberg method is described in The
Fu Chang, Chapter 1. properties of gases and liquids, Bruce E.
2. kgas equation was obtained through regressing Poling et al, fifth edition P. 9.12
Maxwell databook chart “Thermal conductivity
of hydrocarbons” P. 215 Section 12 Flow of Heat
Or from fig 23-36
3. Ludwig’s equation constants can be found
in reference [3] Appendix C pages 827-862
4. For Elbro Method constants A, B and C,
refer to The properties of gases and liquids,
Bruce E. Poling et al, fifth edition P. 4.41
5. Orrick and Erbar Method is described in
Viscosity of Liquids, Theory, Estimation,
Experiment and Data P. 315
𝜂 𝐵
ln =𝐴+
𝜌𝑀 𝑇
η: Liquid viscosity in cP
ρ: density at 20 oC
M: molecular weight
T: absolute temperature in oK
A and B are constants in table 4.30 P. 315 As
mentioned above.
6. Missenard Method is described in The
properties of gases and liquids, Bruce E.
Poling et al, fifth edition P. 10.54
7. Sato- Riedel Method is described in The
Poling et al, fourth edition P. 550
8. Stiel and thodos method is described in The
Poling et al, fifth edition P. 10.35 and its
constants in Apenddix A
9. Method of Ruzicka and Domalski is
described in The properties of gases and
Examples
Calculate water properties (Density, Viscosity, Thermal conductivity and heat capacity) at 50 oC
Ludwig’s
Substituting the coefficients (As, Bs, Cs, Ds, and Es) from Appendix C
𝒏
⍴𝑳 = 𝑨𝑩 (𝟏 𝑻𝒓 )
A = 0.347, B = 0.274, n = 0.286, Tc = 647.4 oK (from table C-1 in appendix C)
Tr = (273+50)/647.4 = 0.498
ρ = 0.347*0.286-(1-0.498)^0.286=1004 kg/m3
Log µL = A + (B/T) + CT + DT2
A = -10.73 , B =18.28, C=0.01966, D= -0.00001466 (from table C-3 in appendix C)
Log µL = -10.73 +(18.28/323) +0.01966*323 -0.00001466*3232
KL = A+ BT + CT2
A = -916.62, B = 12.547 and C = -0.015212
KL = -916.62 + 12.547*(50+273) -0.015212*3232 =1549.54 µcal/s.cm.oC
Cp = A + BT + CT2 + DT3
A = 0.6741, B=0.002825, C=-0.000008371, D =8.601*10-9 (from table C-5 in appendix C)
Cp = 0.6741+0.002825*323 -0.000008371*323 2 +8.601*10-9*3233 = 1.003 Kcal/kg.oC
heat capacity of 1-butene at a temperature of 200 oC (473.15 K).
using coefficients from table C-4 in appendix C
Cp = 24.915+ (0.20348*473.15)+(5.9828*10-5*473.152)+(-1.4166*10-7*473.153)+(
4.7053*10-11*473.154)=123.36 j/mol. K
Example 23-2 - Calculate the density of the following gas mixture at:
Temperature=100o F
Pressure =1000 psia
Component yi [%] Tci [R] Tpc [R] Pci [psia] Pci [psia] MW
CH4 83.19% 343.0 285.3 666.4 554.4 16.043
C2H6 8.48% 549.6 46.6 706.5 59.9 30.070
C3H8 4.37% 665.7 29.1 616.0 26.9 44.097
i-C4H10 0.76% 734.1 5.6 527.9 4.0 58.123
n-C4H10 1.68% 765.3 12.9 550.6 9.3 58.123
i-C5H12 0.57% 828.8 4.7 490.4 2.8 72.150
n-C5H12 0.32% 845.5 2.7 488.6 1.6 72.150
C6H14 0.63% 913.3 5.8 436.9 2.8 86.177
100.00% 392.7 661.6 20.426
Tr (100+459.67)/392.7=1.425
Pr 1000/661.6=1.512
Z-factor 0.86 (from Fig.23-4 with Pr and Tr)
Density 20.426*1000/10.732/0.86/559.67=3.95 lbm/ft 3
Example 23-2 - Calculate the density of the following liquid mixture at:
Temperature=120o F
Pressure =1760 psia
Density
Volume
Component Mole fraction Mol wt Weight, lb (60F),
, cu ft
lb/cf
Methane 0.20896 16.043 3.352 - -
Carbon dioxide 0.39730 44.010 17.485 51.016 0.3427
Ethane 0.01886 30.070 0.567 - -
Propane 0.02387 44.097 1.053 31.619 0.0333
n-Butane 0.03586 58.123 2.084 36.423 0.0572
n-Pentane 0.02447 72.150 1.766 39.36 0.0449
n-Hexane 0.01844 86.177 1.589 41.4 0.0384
n-Heptane 0.02983 100.204 2.989 42.92 0.0696
n-Octane 0.02995 114.231 3.421 44.09 0.0776
n-Decane 0.18208 142.285 25.907 45.79 0.5658
n-Tetradecane 0.03038 198.394 6.027 47.85 0.1260
Total 1.00000 66.241
Calculate density of C3+ = 44.836/1.0128=44.275 lbm/ft3

Weight % C2 in C2+ = 100*0.567/(0.567+44.836)=1.25% Wt %
Density of CO2+ = (45.403+17.485)/(45.403/44+0.3427)=45.75 lbm/ft3
Wt % CH4 in Total = 100*3.352/66.241=5.1% Wt %
(at 60F and 14.7
Pseudo-density of mixture = 42.9 lbm/ft3
psia, Fig 23-14)
Pressure correction = 0.7 lbm/ft3 (from Fig 23-15)
Density at 60F and 1,760
= 42.9+0.7=43.6 lbm/ft3
psia
Temp correction to 120F
= -1.8 lbm/ft3
from Fig. 23-17
Density at 60F and 1,760
= 43.6-1.8=41.8 lbm/ft3
psia
Viscosity
Example 23-9/10 Calculation of gas mixture viscosity.
Given:
Pressure = 1,000 psia
Temperature = 100 degF
MW = 22.0 lb/lb-mole
Tc = 409 deg R
Pc = 665 psia
Gid = 22/28.9625=0.760 dimensionless
μA = 0.0105 cP (from Fig. 23-22 at 100
deg F)
Tr = (100+459.7)/409=1.37 dimensionless
Pr = 1000/665=1.50 dimensionless
μ/μA = 1.21 dimensionless (from Fig. 23-24)
μ = 1.21*0.0105=0.0127 cP
Given:
Pressure = 300 psia
Temperature = 50 deg F
Methane = 80 mol %
Nitrogen = 15 mol %
Carbon dioxide = 5 mol %
Component yi MW Pci, Tci, deg R Vci, ft3/lb Vci • MWi • yi Zci • yi

psia
CH4 0.80 16.043 667.0 343.0 0.0988 1.27 0.2306
N2 0.15 28.013 492.5 227.2 0.0510 0.21 0.0434
CO2 0.05 44.010 1,069. 547.4 0.0342 0.08 0.0137
5
Mixture 1.00 19.237 335.9 1.558 0.2877
Solution
Steps
Tcm = 335.9 deg R (from Table above)
3
Vcm = 1.558 ft /lb (from Table above)
Pcm = 0.2877*10.73*335.9/1.558=665.6 psia
Zcm = 0.2877 dimensionless
5.4402*(335.9)0.1666/(665.60.6666)/(19.23)0.5
ξ = dimensionless (from Eq. 23-20)
=0.043
Tr = 1.518 dimensionless
ξμA = 0.000489 dimensionless (from Eq. 23-21)
μA = 0.000489/0.043=0.014 cP (from Eq. 23-22)
Thermal Conductivity
Example 23-12 Find the thermal conductivity of a natural gas.
Given:
Pressure = 700 psia
Temperature = 300 deg F
Tc = 440 deg R
Pc = 660 psia
Solution Steps
kA = 0.0248 Btu/[(hr-sq.ft.-deg (from Fig.23-35)
F)/ft]
Tr = (300+459.67)/440=1.73 dimensionless
Pr = 700/660=1.06 dimensionless
k/kA = 1.15 dimensionless (from Fig.23-36)
k = 1.15*0.0248=0.0285 Btu/[(hr-sq.ft.-deg
F)/ft]
Example 23-13 -- Find the thermal conductivity of the gaseous mixture shown in Fig. 23-41 at
200°F and one atmosphere.
Given:
Component Mole Thermal conductivity, MW MW-3 (yi)MW-3 (yi)(ki)MW-3
Fraction Btu/(hr-ft-degF)
CO2 0.10 0.0127 44.01 3.530 0.3530 0.00448
H2S 0.20 0.0136 34.076 3.242 0.6483 0.00882
N2 0.05 0.0175 28.013 3.037 0.1518 0.00266
CH4 0.60 0.0258 16.043 2.522 1.5131 0.03904
C2H6 0.05 0.0176 30.07 3.109 0.1555 0.00274
Total 1.00 2.8218 0.05773
Solution
km = 0.05773/2.8218=0.0205 Btu/[(hr-sq.ft.-degF)/ft]
Calculate Naphtha properties (S.G =0.727) at 25oC and vapor naphtha at 2 kg/cm2.a & 150o C
density 0.727*1000*(1-0.0005*((25*1.8+32)-60)) 720.8 Kg/m3
Cp = (1/ 𝑠𝑔))*(0.388+0.00045*(t*1.8+32)) 0.49569 Kcal/kg.C
Cv Cp-(0.09/sg) 0.3719 Kcal/kg.C
thermal conductivity = (0.813/sg)*(1-0.0003*((t*1.8+32)-32)) *0.1442279 0.15911 W/m.k
viscosity 3.518-0.01591*t+1.734*10-5t2 2.39574 cP
Mol. Weight 1/(0.0001644 ∗ 𝐴𝑃𝐼 − 0.000972) 106.29846 -
16.018463 ∗ 𝑚_𝑤𝑡 ∗ 𝑝 ∗ 14.7 5.92723 Kg/m3
Gas Density =
10.732 ∗ 𝑧 ∗ (𝑡 + 459.67)
Gas thermal ( -0.000500777+1.0906*10-5*(t*1.8+32)+0.061137256/√M.wt + 0.02316 W/m.k
conductivity 0.000158966*(t*1.8+32)/√M.wt)*1.730735
=-0.0092696 +T0.5(0.001383-5.9712x10-5M0.5) 0.00771 cP
Gas Viscosity +1.1249x10-5M
Source 1: Bureau of standards report
Report Conclusions
Specific volume of vapor: The data given in Table 9 for products of gravity 50°
to 150° A. P. I. appear to be sufficiently reliable for most industrial purposes. The
data given for products of gravity 20° to 50° A. P. I. are admittedly approximate and
are included mainly for the benefit of those users of petroleum products who have no
information at hand as to the source or the volatility of these products. Additional
experimental data on molecular weights of products of gravity 10° to 40° A. P. I.
appear desirable.
Thermal conductivity: The data given in Table 10 appear to be sufficient for all
practical uses of such data.
Specific heat: The data given in Tables 12 and 13 appear to be sufficiently
reliable for all practical applications wherein only moderate pressures (less than 50
lbs. /in.2) are involved. Additional experimental data on petroleum vapors and also
on petroleum liquids at high temperatures and pressures are desirable.
Heat content: The data given in Tables 16 to 19 should provide simplicity and
convenience in calculations of the quantities of heat involved in the heating and
cooling of petroleum products.
Figure 23-15: Density
correction for
compressibility of
hydrocarbon liquids
Figure 23-14: Pseudo Density of mixtures
Figure 23-17: Density Correction for Thermal Expansion of Hydrocarbon Liquids
FIG. 23-33
of Miscellaneous
Gases
at One Atmosphere
FIG. 23-32 Thermal Conductivity Ratio for Gases
FIG. 23-34
of H.Cs Gases
at One Atmosphere
Figure 23-4: Standing-Katz Chart
Figure 23-4: Standing-Katz Chart
Supplementary Material
Metal Composition(%) Properties sat 293 K(20◦C)

Cp k α × 105
(J/kg·K) (W/m·K) (m2 /s)
Aluminum 94-96A1,3-
Duralumin 5Cu,traceMg 833 164 6.676
Silumin
Copper 87A1,13Si 871 164 7.099
Aluminum 95Cu,5A1 410 83 2.330
bronze
Bronze 75Cu,25Sn 343 26 0.859
Red brass 85Cu,9Sn,5Zn 385 61 1.804
Brass 70Cu,30Zn 385 111 3.412
German silver 62Cu,15Ni,22Zn 394 24.9 0.733
Constantan
Iron 60Cu,40Ni 410 22.7 0.612
Castiron ∼4C 420 52 1.702
Wrought iron
Steel 460 59 1.626
Carbon steel 1C 473 43 1.172
1.5C 486 36 0.970
Chromesteel 1Cr 460 61 1.665
5Cr 460 40 1.110
10Cr 460 31 0.867
Chrome-nickel 15Cr,10Ni 460 19 0.526
steel 20Cr,15Ni 460 15.1 0.415
Nickel steel 10Ni 460 26 0.720
20Ni 460 19 0.526
40Ni 460 10 0.279
60Ni 460 19 0.493
Nickel-chrome 80Ni,15Cr 460 17 0.444
steel 60Ni,15Cr 460 12.8 0.333
40Ni,15Cr 460 11.6 0.305
20Ni,15Cr 460 14.0 0.390
Manganese 1Mn 460 50 1.388
steel 5Mn 460 22 0.637
Silicon steel 1Si 460 42 1.164
5Si 460 19 0.555
Stainless steel Type304 461 14.4 0.387
Type347 461 14.3 0.387
Tungsten steel 1W 448 66 1.858
5W 435 54 1.525
Source: Process Heat Transfer Principles and Applica ons
Fluids U (W/m2 K)
Water to water 1300-2500
Ammonia to water 1000-2500
Gases to water 10-250
Water to compressed air 50-170
Water to lubricating oil 110-340
Light organics (µ < 5 X 10^-4 Ns/m2) to water 370-750
Medium organics (5 x 10^-4 < µ < 10x10^-4 Ns/m2 to
240-650
water
Heavy organics (µ > 10 X 10^-4 Ns/m2 to lubricating oil 25-400
Steam to water 2200-3500
Steam to ammonia 1000-3400
Water to condensing ammonia 850-1500
Water to boiling Freon-12 280-1000
Steam to gases 25-240
Steam to light organics 490-1000
Steam to medium organics 250-500
Steam to heavy organics 30-300
Light organics to light organics 200-350
Medium organics to medium organics 100-300
Heavy organics to heavy organics 50-200
Light organics to heavy organics 50-200
Heavy organics to light organics 150-300
Crude oil to gas oil 130-320
Plate heat exchangers: water to water 3000-4000
Evaporators: steam/water 1500-6000
Evaporators: steam/other fluids 300-2000
Evaporators of refrigeration 300-1000
Condensers: steam/water 1000-4000
Condensers: steam/other fluids 300-1000
Gas boiler 10-50
Oil bath for heating 30-550
Source: Petroleum Refining Design and applica ons, vol. 4, A. Kayode coker
Typical film heat
Fluid Fluid condition transfer coefficients
(W/m2.K)
Water Liquid 5,000-7,500
Ammonia Liquid 6,000-8,000
Light organics Liquid 1,500-2,000
Medium organics Liquid 750-1,500
Heavy organics Liquid

Heating 250-750
Cooling 150-400
Very heavy
Liquid
organics
Heating 100-300
Cooling 60-150
Gas 1-2 bar abs 80-125
Gas 10 bar abs 250-400
Gas 100 bar abs 500-800
Condensing Heat
Transfer
Steam, ammonia No noncondensable 8,000-12,000
Pure component, 0.1 bar abs, no
Light organics 2,000-5,000
noncondensable
Light organics 0.1 bar, 4% noncontensable 750-1,000
Medium organics Pure or narrow condensing range, 1 bar abs 1,500-4,000
Heavy organics Narrow condensing range, 1 bar abs 600-2,000 .
Light
multicomponent
Medium condensing range, 1 bar abs 1,000-2,500
mixture, all
condensable
Medium
multicomponent
Medium condensing range, 1 bar abs 600-1,500
mixture, all
condensable
Heavy
multicomponent
Medium condensing range, 1 bar abs 300-600
mixture, all
condensable
Vaporizing Heat
Transfer
Water Pressure <5 bar abs, dT = 25 K 5,000-10,000
Water Pressure 5-100 bar abs, dT = 20 K 4,000-15,000
Ammonia Pressure <30 bar abs, dT = 20 K 3,000-5,000
Pure component, pressure < 30 bar abs, dT = 20

Light organics 2,000-4,000
K
Narrow bolling range, pressure 20-150 bar abs,

Light organics 750-3,000
dT at 15-20
Narrow boiling range, pressure < 20 bar

Medium organics 600-2,500
abs,dTmax = 15 K
Narrrow boiling range, pressure <20 bar abs,

Heavy organics 400-1,500
dTmax = 15 K
Source: Petroleum Refining Design and applica ons, vol. 4, A. Kayode coker
Stream fouling factors
Natural gas 0.0002–0.0004
Column verhead products 0.0002
Lean oil 0.0004
Rich oil 0.0002
Natural gasoline and liquefied petroleum gases 0.0002
Atmospheric tower overhead vapors 0.0002
Light Naphtha 0.0004
Vacuum overhead vapors 0.0008
SALT Crude oil 0 to 120°C velocity m/s <0.6 0.0005
SALT Crude oil 0 to 120°C velocity m/s 0.6-1.2 0.0004
SALT Crude oil 0 to 120°C velocity m/s <1.2 0.0004
SALT Crude oil 120°C to 180°C velocity m/s <0.6 0.0009
SALT Crude oil 120°C to 180°C velocity m/s 0.6-1.2 0.0007
DRY Crude oil 0 to 120°C velocity m/s <0.6 0.0005
DRY Crude oil 0 to 120°C velocity m/s 0.6-1.2 0.0004
DRY Crude oil 0 to 120°C velocity m/s <1.2 0.0004
DRY Crude oil 120°C to 180°C velocity m/s <0.6 0.0005
DRY Crude oil 120°C to 180°C velocity m/s 0.6-1.2 0.0004
SALT Crude oil 180°C to 230°C velocity m/s 0.6-1.2 0.0009
SALT Crude oil 230°C and more velocity m/s <0.6 0.0012
SALT Crude oil 230°C and more velocity m/s 0.6-1.2 0.001
SALT Crude oil 230°C and more velocity m/s <1.2 0.001
DRY Crude oil 180°C to 230°C velocity m/s 0.6-1.2 0.0005
DRY Crude oil 230°C and more velocity m/s <0.6 0.0009
DRY Crude oil 230°C and more velocity m/s 0.6-1.2 0.0007
DRY Crude oil 230°C and more velocity m/s <1.2 0.0007
Gasoline 0.0004
Naphtha and light distillates 0.0005
Kerosene 0.0005
Light gas oil 0.0005
Heavy gas oil 0.0005–0.0008
Heavy fuel oils 0.0008–0.0012
Vacuum tower bottoms 0.002
Atmosphere tower bottoms 0.0014
Cracking and coking units - Overhead vapors 0.0004
Cracking and coking units - Light cycle oil 0.0004
Cracking and coking units - Heavy cycle oil 0.0005–0.0007
Fuel oil no. 2 0.0004
Fuel oil no. 6 0.0009
Transformer oil 0.0002
Engine lube oil 0.0002
Quench oil 0.0007
Refrigerant liquids 0.0002
Hydraulic fluids 0.0002
Industrial organic heat transfer media 0.0002
Molten salts 0.00009
Ammonia, liquid 0.0002
Ammonia, liquid (or bearing) 0.0005
Calcium chloride solutions 0.0005
Manufactured gas 0.002
Diesel engine exhaust gas 0.002
Steam (nonoil bearing) 0.00009
Exhaust team (oil bearing) 0.004
Compressed air 0.002
Refrigerant vapors in refrigerant cycle condensers 0.004
Ammonia vapor 0.0002
CO vapor 2 0.0002
Chlorine vapor 0.0004
Coal fuel gas 0.002
Natural gas flue gas 0.0009
MEA and DEA solutions 0.0004
DEG and TEG solutions 0.0009
Stable side draw and bottom products 0.0002
Caustic solutions 0.0004
Vegetable oils 0.0005
Acid gases 0.0004
Solvent vapors 0.0002
Stable overhead products 0.0002
Crude and vapor unit gases and vapors 0.0002
Atmospheric tower overhead vapors 0.0002
Overhead vapors - Cracking and coking unit streams 0.0004
Light-cycle oil - Cracking and coking unit streams 0.0004
Heavy-cycle oil - Cracking and coking unit streams 0.0005–0.0007
Light coker gas oil - Cracking and coking unit streams 0.0005–0.0007
Heavy coker gas oil - Cracking and coking unit streams 0.0007–0.0009
Bottom slurry oil (minimum 4.5 ft/s) - Cracking and coking unit
streams 0.0005
Light liquid products - Cracking and coking unit streams 0.0005
Feed - Naphtha hydrotreater 0.0005
Effluent - Naphtha hydrotreater 0.0004
Naphtha - Naphtha hydrotreater 0.0004
Overhead vapors - Naphtha hydrotreater 0.0003
Overhead vapor- Visbreaker 0.0005
Visbreaker bottoms- Visbreaker 0.0020
Source: Petroleum Refining Design and applica ons, vol. 4, A. Kayode coker & TEMA 9th edi on
Tubesheet type and no. of
passes tube size and pitch 8 10 12 13¼ 15¼ 17¼ 19¼ 21¼ 23¼ 25 27 29 31 33 35 37
Fixed Tubes One-Pass ¾ in. on 15/ 16 in ∆ 33 69 105 135 193 247 307 391 481 553 663 763 881 1019 1143 1,269
Fixed Tubes One-Pass ¾ in. on 1in. ∆ 33 57 91 117 157 217 277 343 423 493 577 667 765 889 1007 1,127
Fixed Tubes One-Pass ¾ in. on 1in ◽ 33 53 85 101 139 183 235 287 355 419 495 587 665 765 865 965
Fixed Tubes One-Pass 1 in. on ¼ in. ∆ 15 33 57 73 103 133 163 205 247 307 361 427 481 551 633 699
Fixed Tubes One-Pass 1 in. on 1 ¼ in ◽ 17 33 45 65 83 111 139 179 215 255 303 359 413 477 545 595
Fixed Tubes Two-Pass ¾ in. on 15/ 16 in ∆ 32 58 94 124 166 228 300 370 452 528 626 734 846 964 1088 1,242
Fixed Tubes Two-Pass ¾ in. on 1 in. ∆ 28 56 90 110 154 208 264 326 398 468 556 646 746 858 972 1,088
Fixed Tubes Two-Pass ¾ in. on 1 in ◽ 26 48 78 94 126 172 222 280 346 408 486 560 644 746 840 946
Fixed Tubes Two-Pass 1 in. on 1 ¼ in ∆ 16 32 52 62 92 126 162 204 244 292 346 410 462 530 608 688
Fixed Tubes Two-Pass 1 in. on 1 ¼ in ◽ 12 26 40 56 76 106 136 172 218 248 298 348 402 460 522 584
U Tubes Two-Pass ¾ in. on 15/ 16 in ∆ 8 34 64 94 134 180 234 304 398 460 558 648 768 882 1008 1,126
U Tubes Two-Pass ¾ in. on 1in. ∆ 8 26 60 72 108 158 212 270 336 406 484 566 674 772 882 1,000
U Tubes Two-Pass ¾ in. on 1in ◽ 12 30 52 72 100 142 188 242 304 362 436 506 586 688 778 884
U Tubes Two-Pass 1 in. on 1 ¼ in ∆ XX 8 26 42 58 84 120 154 192 234 284 340 396 466 532 610
U Tubes Two-Pass 1 in. on 1 ¼ in ◽ XX 12 22 38 58 76 100 134 180 214 256 304 356 406 464 526
Fixed Tubes Four-Pass ¾ in. on 15/ 16 in ∆ XX 48 84 108 154 196 266 332 412 484 576 680 788 904 1024 1,072
Fixed Tubes Four-Pass ¾ in. on 1in. ∆ XX 44 72 96 134 180 232 292 360 424 508 596 692 802 912 1,024
Fixed Tubes Four-Pass ¾ in. on 1in ◽ XX 48 72 88 126 142 192 242 308 366 440 510 590 688 778 880
Fixed Tubes Four-Pass 1 in. on 1 ¼ in ∆ XX 24 44 60 78 104 138 176 212 258 308 368 422 486 560 638
Fixed Tubes Four-Pass 1 in. on 1 ¼ in ◽ XX 24 40 48 74 84 110 142 188 214 260 310 360 414 476 534
U Tubes Four-Pass ¾ in. on 15/ 16 in ∆ XX 28 56 84 122 166 218 286 378 438 534 622 740 852 976 1,092
U Tubes Four-Pass ¾ in. on 1in. ∆ XX 20 52 64 98 146 198 254 318 386 462 542 648 744 852 968
U Tubes Four-Pass ¾ in. on 1in ◽ XX 24 44 64 90 130 174 226 286 342 414 482 560 660 748 852
U Tubes Four-Pass 1 in. on 1 ¼ in ∆ XX XX 20 36 50 74 110 142 178 218 266 322 376 444 508 584
U Tubes Four-Pass 1 in. on 1 ¼ in ◽ XX XX 16 32 50 66 90 122 166 198 238 286 336 384 440 500
Fixed Tubes Six-Pass ¾ in. on 15/ 16 in ∆ XX XX XX 80 116 174 230 294 372 440 532 632 732 844 964 1,106
Fixed Tubes Six-Pass ¾ in. on 1in. ∆ XX XX XX 66 104 156 202 258 322 388 464 548 640 744 852 964
Fixed Tubes Six-Pass ¾ in. on 1in ◽ XX XX XX 54 78 116 158 212 266 324 394 460 536 634 224 818
Fixed Tubes Six-Pass 1 in. on 1 ¼ in ∆ XX XX XX 34 56 82 112 150 182 226 274 338 382 442 514 586
Fixed Tubes Six-Pass 1 in. on 1 ¼ in ◽ XX XX XX XX 44 66 88 116 154 184 226 268 318 368 430 484
U Tubes Six-Pass ¾ in. on 15/ 16 in ∆ XX XX XX 74 110 156 206 272 358 416 510 596 716 826 944 1,058
U Tubes Six-Pass ¾ in. on 1in. ∆ XX XX XX 56 88 134 184 238 300 366 440 518 626 720 826 940
U Tubes Six-Pass ¾ in. on 1in ◽ XX XX XX 56 80 118 160 210 268 322 392 458 534 632 718 820
U Tubes Six-Pass 1 in. on 1 ¼ in ∆ XX XX XX 30 42 68 100 130 168 206 252 304 356 426 488 562
U Tubes Six-Pass 1 in. on 1 ¼ in ◽ XX XX XX XX 42 60 80 110 152 182 224 268 316 362 420 478
Fixed Tubes eight-Pass ¾ in. on 15/ 16 in ∆ XX XX XX XX 94 140 198 258 332 398 484 576 682 790 902 1,040
Fixed Tubes eight-Pass ¾ in. on 1in. ∆ XX XX XX XX 82 124 170 224 286 344 422 496 588 694 798 902
Fixed Tubes eight-Pass ¾ in. on 1in ◽ XX XX XX XX XX 94 132 174 228 286 352 414 490 576 662 760
Fixed Tubes eight-Pass 1 in. on 1 ¼ in ∆ XX XX XX XX XX 66 90 120 154 190 240 298 342 400 466 542
Fixed Tubes eight-Pass 1 in. on 1 ¼ in ◽ XX XX XX XX XX XX 74 94 128 150 192 230 280 334 388 438
U Tubes eight-Pass ¾ in. on 15/ 16 in ∆ XX XX XX 68 102 142 190 254 342 398 490 578 688 796 916 1,032
U Tubes eight-Pass ¾ in. on 1in. ∆ XX XX XX 52 82 122 170 226 286 350 422 498 600 692 796 908
U Tubes eight-Pass ¾ in. on 1in ◽ XX XX XX 48 70 106 146 194 254 306 374 438 512 608 692 792
U Tubes eight-Pass 1 in. on 1 ¼ in ∆ XX XX XX 24 38 58 90 118 154 190 238 290 340 404 464 540
U Tubes eight-Pass 1 in. on 1 ¼ in ◽ XX XX XX XX 34 50 70 98 142 170 206 254 300 344 396 456
TEMA P or S One-Pass 1.25 in. on 1 9/16 in ◽ 12 21 29 38 52 70 85 108 136 154 184 217 252 289 329 372
TEMA P or S Two-Pass 1.25 in. on 1 9/16 in ◽ 12 12 28 34 48 66 84 108 128 154 180 212 248 276 316 368
TEMA P or S Four-Pass 1.25 in. on 1 9/16 in ◽ 4 8 16 34 44 56 70 100 128 142 158 204 234 270 310 354
Tubesheet type and no.
of passes tube size and pitch 8 10 12 13¼ 15¼ 17¼ 19¼ 21¼ 23¼ 25 27 29 31 33 35 37
TEMA P or S Six-Pass 1.25 in. on 1 9/16 in ◽ 0 12 18 24 48 50 80 96 114 136 172 198 236 264 304 340
U Tubes Two-Pass 1.25 in. on 1 9/16 in ◽ 4 12 26 36 44 60 82 100 128 154 176 212 242 280 324 358
U Tubes Four-Pass 1.25 in. on 1 9/16 in ◽ 4 8 20 28 44 60 76 100 120 148 172 204 240 280 312 352
U Tubes Six-Pass 1.25 in. on 1 9/16 in ◽ 6 12 12 15 32 56 79 100 120 130 160 198 234 274 308 350
TEMA L or M One-
Pass 1.25 in. on 1 9/16 in ∆ 15 27 38 55 66 88 117 136 170 198 237 268 312 357 417 446
TEMA L or M Two-
Pass 1.25 in. on 1 9/16 in ∆ 10 22 36 44 64 82 106 134 164 188 228 266 304 346 396 446
TEMA L or M Four-
Pass 1.25 in. on 1 9/16 in ∆ 8 16 26 42 52 78 98 124 146 166 208 242 284 322 372 422
TEMA L or M Six-Pass 1.25 in. on 1 9/16 in ∆ 12 12 24 40 50 68 96 108 148 168 192 236 276 324 364 408
TEMA P or S One-
Pass 1.25 in. on 1 9/16 in ∆ 13 18 33 38 57 81 100 126 159 183 208 249 291 333 372 425
TEMA P or S Two-
Pass 1.25 in. on 1 9/16 in ∆ 10 20 26 44 58 72 94 120 146 172 206 238 282 326 368 412
TEMA P or S Four-
Pass 1.25 in. on 1 9/16 in ∆ 4 8 26 34 48 62 86 116 132 150 190 224 262 298 344 394
TEMA P or S Six-Pass 1.25 in. on 1 9/16 in ∆ 0 12 18 24 44 68 80 102 132 148 180 220 256 296 336 384
U Tubes Two-Pass 1.25 in. on 1 9/16 in ∆ 6 14 28 34 52 72 90 118 148 172 200 242 282 326 362 416
U Tubes Four-Pass 1.25 in. on 1 9/16 in ∆ 4 12 20 28 48 68 84 112 132 160 188 228 264 308 344 396
U Tubes Six-Pass 1.25 in. on 1 9/16 in ∆ 6 12 18 30 40 64 78 102 120 152 180 216 250 292 336 384
TEMA P or S One-
Pass 5/8 in. on 13/16 in ◽ 55 88 140 178 245 320 405 502 610 700 843 970 1127 1288 1479 1647
TEMA P or S Two-
Pass 5/8 in. on 13/16 in ◽ 48 78 138 172 232 308 392 484 584 676 812 942 1096 1250 1438 1604
TEMA P or S Four-
Pass 5/8 in. on 13/16 in ◽ 34 62 112 146 208 274 352 442 536 618 742 868 1014 1172 1330 1520
TEMA P or S Six-Pass 5/8 in. on 13/16 in ◽ 24 56 100 136 192 260 336 424 508 600 716 840 984 1148 1308 1480
U Tubes Two-Pass 5/8 in. on 13/16 in ◽ 52 90 140 180 246 330 420 510 626 728 856 998 1148 1318 1492 1684
U Tubes Four-Pass 5/8 in. on 13/16 in ◽ 40 80 128 164 232 312 388 488 596 692 816 956 1108 1268 1436 1620
U Tubes Six-Pass 5/8 in. on 13/16 in ◽ 32 74 108 148 216 292 368 460 562 644 780 920 1060 1222 1388 1568
TEMA L or M One-
Pass 3/4 in. on 15/16 in ∆ 64 85 122 151 204 264 332 417 495 579 676 785 909 1035 1164 1304
TEMA L or M Two-
Pass 3/4 in. on 15/16 in ∆ 48 72 114 142 192 254 326 396 478 554 648 762 878 1002 1132 1270
TEMA L or M Four-
Pass 3/4 in. on 15/16 in ∆ 34 52 94 124 166 228 290 364 430 512 602 704 814 944 1062 1200
TEMA L or M Six-Pass 3/4 in. on 15/16 in ∆ 24 50 96 112 168 220 280 348 420 488 584 688 792 920 1036 1168
TEMA P or S One-
Pass 3/4 in. on 15/16 in ∆ 34 60 109 126 183 237 297 372 450 518 618 729 843 962 1090 1233
TEMA P or S Two-Pass 3/4 in. on 15/16 in ∆ 32 62 98 120 168 228 286 356 430 498 602 708 812 934 1064 1196
TEMA P or S Four-Pass 3/4 in. on 15/16 in ∆ 16 52 78 106 146 202 258 324 392 456 548 650 744 868 990 1132
TEMA P or S Six-Pass 3/4 in. on 15/16 in ∆ 18 44 68 100 136 192 248 316 376 444 532 624 732 840 972 1100
U Tubes Two-Pass 3/4 in. on 15/16 in ∆ 32 64 98 126 180 238 298 370 456 534 628 736 846 978 1100 1238
U Tubes Four-Pass 3/4 in. on 15/16 in ∆ 24 52 88 116 160 224 280 352 428 500 600 696 812 928 1060 1200
U Tubes Six-Pass 3/4 in. on 15/16 in ∆ 24 52 78 108 148 204 262 334 408 474 570 668 780 904 1008 1152
TEMA P or S One-Pass 3/4 in. on 1 in ◽ 28 52 80 104 136 181 222 289 345 398 477 554 637 730 828 937
TEMA P or S Two-Pass 3/4 in. on 1 in ◽ 26 48 76 90 128 174 220 272 332 386 456 532 624 712 812 918
TEMA P or S Four-Pass 3/4 in. on 1 in ◽ 16 44 66 70 128 154 204 262 310 366 432 510 588 682 780 882
TEMA P or S Six-Pass 3/4 in. on 1 in ◽ 12 24 56 80 114 160 198 260 308 344 424 496 576 668 760 872
U Tubes Two-Pass 3/4 in. on 1 in ◽ 28 52 78 96 136 176 224 284 348 408 480 562 648 748 848 952
U Tubes Four-Pass 3/4 in. on 1 in ◽ 24 44 72 92 132 176 224 280 336 392 468 548 636 728 820 932
U Tubes Six-Pass 3/4 in. on 1 in ◽ 12 32 70 90 120 160 224 274 328 378 460 530 620 718 816 918
TEMA L or M One-Pass 3/4 in. on 1 in ∆ 42 73 109 136 183 237 295 361 438 507 592 692 796 909 1023 1155
TEMA L or M Two-
Pass 3/4 in. on 1 in ∆ 40 66 102 128 172 228 282 346 416 486 574 668 774 886 1002 1124
TEMA L or M Four-
Pass 3/4 in. on 1 in ∆ 26 52 88 112 146 208 258 318 382 448 536 632 732 836 942 1058
TEMA L or M Six-Pass 3/4 in. on 1 in ∆ 24 44 80 102 148 192 248 320 372 440 516 604 708 812 920 1032
TEMA P or S One-
Pass 3/4 in. on 1 in ∆ 31 56 88 121 159 208 258 320 400 450 543 645 741 843 950 1070
TEMA P or S Two-
Pass 3/4 in. on 1 in ∆ 26 48 78 106 148 198 250 314 384 442 530 618 716 826 930 1052
TEMA P or S Four-
Pass 3/4 in. on 1 in ∆ 16 42 62 94 132 182 228 290 352 400 488 574 666 760 878 992
TEMA P or S Six-Pass 3/4 in. on 1 in ∆ 12 40 68 88 132 180 220 276 336 392 468 556 648 740 856 968
U Tubes Two-Pass 3/4 in. on 1 in ∆ 32 52 84 110 152 206 266 330 400 472 554 648 744 852 974 1092
U Tubes Four-Pass 3/4 in. on 1 in ∆ 24 48 76 100 140 188 248 316 384 440 528 616 716 816 932 1056
U Tubes Six-Pass 3/4 in. on 1 in ∆ 24 40 74 98 136 182 234 296 356 424 502 588 688 788 908 1008
TEMA P or S One-
Pass 1 in. on 1.25 in ◽ 17 30 52 61 85 108 144 173 217 252 296 345 402 461 520 588
TEMA P or S Two-
Pass 1 in. on 1.25 in ◽ 12 30 48 56 78 108 136 166 208 240 280 336 390 452 514 572
TEMA P or S Four-Pass 1 in. on 1.25 in ◽ 8 16 42 52 62 104 130 154 194 230 270 310 366 432 494 562
TEMA P or S Six-Pass 1 in. on 1.25 in ◽ 12 18 24 50 64 96 114 156 192 212 260 314 368 420 484 548
U Tubes Two-Pass 1 in. on 1.25 in ◽ 14 30 44 60 80 104 132 172 212 244 290 340 400 456 518 584
U Tubes Four-Pass 1 in. on 1.25 in ◽ 8 24 40 48 72 100 132 168 204 240 284 336 384 444 504 576
U Tubes Six-Pass 1 in. on 1.25 in ◽ 6 12 32 44 74 100 120 148 198 230 274 328 372 440 502 566
TEMA L or M One-Pass 1 in. on 1.25 in ∆ 27 42 64 81 106 147 183 226 268 316 375 430 495 579 645 729
TEMA L or M Two-Pass 1 in. on 1.25 in ∆ 26 40 66 74 106 134 176 220 262 302 360 416 482 554 622 712
TEMA L or M Four-Pass 1 in. on 1.25 in ∆ 8 34 52 62 88 124 150 204 236 274 336 390 452 520 586 662
TEMA L or M Six-Pass 1 in. on 1.25 in ∆ 12 24 44 56 92 114 152 186 228 272 324 380 448 504 576 648
TEMA P or S One-Pass 1 in. on 1.25 in ∆ 18 33 51 73 93 126 159 202 249 291 345 400 459 526 596 672
TEMA P or S Two-Pass 1 in. on 1.25 in ∆ 14 28 48 68 90 122 152 192 238 278 330 388 450 514 584 668
TEMA P or S Four-Pass 1 in. on 1.25 in ∆ 8 16 42 52 78 112 132 182 216 250 298 356 414 484 548 626
TEMA P or S Six-Pass 1 in. on 1.25 in ∆ 12 18 44 44 76 102 136 172 212 240 288 348 400 464 536 608
U Tubes Two-Pass 1 in. on 1.25 in ∆ 14 28 52 64 90 122 152 196 242 286 340 400 456 526 596 668
U Tubes Four-Pass 1 in. on 1.25 in ∆ 12 24 40 56 80 112 140 180 224 264 320 380 436 504 572 636
U Tubes Six-Pass 1 in. on 1.25 in ∆ 6 24 40 52 78 102 136 176 216 246 300 352 414 486 548 614
Source : Source: Process Heat Transfer Principles and Applica ons & Petroleum Refining Design and applica ons, vol. 4, A. Kayode coker
Birmingham Wire Gage (inches) (mm)
BWG
7 0.180 4.572
8 0.165 4.191
9 0.148 3.759
10 0.134 3.404
11 0.120 3.048
12 0.109 2.769
13 0.095 2.413
14 0.083 2.108
15 0.072 1.829
16 0.065 1.651
17 0.058 1.473
18 0.049 1.245
19 0.042 1.067
20 0.035 0.889
21 0.032 0.813
22 0.028 0.711
23 0.025 0.635
24 0.022 0.559
25 0.020 0.508
26 0.018
27 0.016
28 0.014
29 0.013
30 0.012
31 0.010
32 0.009
33 0.008
34 0.007
35 0.005
36 0.004
Source: Heat Exchangers: Selec on, Ra ng, and Thermal Design
Source: Heat Exchangers: Selec on, Ra ng, and Thermal Design

Shell and Tube Sizing and Rating Calculations

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Shell and Tube Sizing and Rating Calculations

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Shell and Tube Heat Exchanger Calculations

Link: Heat Exchanger Calculations

T Temperature (oC) P Pressure (kg/cm2.a)

B baffle spacing (mm) Gs cross flow mass velocity m/m2.s

Kern and Bell Delaware Calculations NTU calculations

1. Shell and tube heat exchangers’ rating

The rating process typically involves two main calculations:

Rating Procedures: [4]

1. Calculate the required overall coefficient

T1, T2: inlet/outlet of hot stream

T1, t2: inlet/outlet of cold stream

Cold stream = ṁ.Cp(t2-t1)

The logarithmic mean temperature difference

(𝑇1 − 𝑡2) − (𝑇2 − 𝑡1)

Do: tube outer diameter (m)

L: tube Length (m)

Overall Heat transfer coefficient (required or service)

Overall Heat transfer coefficient

U = Calculated overall heat transfer coefficient (fouled) (Kcal/h-m¹C)

Shell side heat transfer coefficient & pressure drop

𝐷 = , for triangular pitch

Bundle cross flow area

PT: pitch size m B: baffle spacing m

Shell Reynold’s number & friction factor

400 < 𝑅𝑒 < 1,000,000

2,000 < 𝑅𝑒 < 1,000,000

Cp: heat capacity (j/kg.K)

For laminar flow

Where graetz number between 10 and 10,000

a. Shell Side Heat Transfer Coefficient, hs

PT,eff = PT for 30° and 90° layouts

Shell side cross flow mass velocity, GS (kg/m².s) is defined as:

Shell side Prandtl number PrS is calculated as following:

PrS = CP,S . μS*1.163 / kS ∗ 3.6 ∗ 10

Colburn j-factor for an ideal tube bank is defined as:

where, μS,W is shell side fluid viscosity at wall temperature.

a.1 Correction factor for Baffle Window Flow, JC

a.3 Correction factor for Bundle Bypass effects, J B

Ntcc = (Ds/Pp)(1 - 2Bc/100)

Ratio of sealing strips to tube rows rss is provided by 𝑁𝑡𝑐𝑐 [11]

where Nss is number of sealing strips (pairs) in one baffle.

where, B is central baffle spacing. Correction factor J B is then calculated as following -

JB = exp(-Cj(Sb / Sm)(1 - (2rss)1/3)) for rss < 0.5

a.4 Correction factor for adverse temperature gradient, J R

Friction factor for ideal tube bank is calculated as following:

where b1, b2, b3 and b4 are correlational constants listed below.

ΔPIdeal = 2f(GS²/ρS)(μS/μS,W)0.14 Ntcc

b.1 Correction factor for Baffle Leakage, RL

b.2 Correction factor for Bundle Bypass effect, R B

RB = exp(-Cr(Sb / Sm)(1 - (2rss)1/3)) for rss < 0.5

b.3 Correction factor for unequal baffle spacing, RS

1. Pressure drop for window section, ΔPW

Following terms are calculated as -

Pressure drop for laminar and turbulent flow is calculated.

ΔPW, Turb = NB.RL(2+0.6*Ntcw).GW²/(2.ρS)

2. Pressure drop in Central Baffle spaces

ΔPC = (NB - 1)ΔPIdeal.RL.RB

3. Pressure drop in entrance & exit baffle spaces

ΔPE = ΔPIdeal(1 + Ntcw/Ntcc).RB.RS

Shell side pressure drop in bar is calculated as following -

ΔPS = ΔPW + ΔPC + ΔPE

c. Tube Side Heat Transfer Coefficient, ht

f = (1.58 ln(ReT) - 3.28)-2

Heat transfer coefficient ht in (W/m2.k) is calculated as following - For floating head