CEIC3004 Design Manual for Heat Exchangers

Technical design process

Step 1: Define the Duty

The first step to designing a heat exchanger for a specific process is to define the parameters and
conditions under which the heat exchanger will operate, namely the heat-transfer rate, fluid flow rates, and
temperatures.
The general equation for heat transfer across a surface is given by:
𝑄𝑄 = 𝑈𝑈𝑈𝑈Δ𝑇𝑇𝑚𝑚
(Equation 1)
Where
Q = heat transferred per unit time, W
U = heat transfer coefficient, W/m2°C
A = heat transfer area, m2
ΔTm = mean temperature difference, °C

The fluid flow rate and temperature needed for the process also needs to be defined
before selecting the appropriate heat exchanger. Different types of heat exchangers
can accommodate different flow rates and temperatures.Step 2: Obtain Fluid Physical
Properties
The physical properties of the heat transfer fluid is important in the design of a heat exchanger. An
appropriate heat transfer fluid would match the following requirements:
• Low viscosity
• Non-corrosive
• High thermal conductivity and diffusivity
• High boiling point and low freezing point
The specific density, viscosity, and thermal conductivity of the heat transfer fluid should then be compiled
for future reference and calculations.

Step 3: Decide on the type of Heat Exchanger

The stepwise design process for heat exchangers varies depending on the type of heat exchanger. Design
considerations to aid in the selection of the heat exchanger can be found in the Important Considerations
section. Shell and tube heat exchangers are the most common type of heat exchangers found in industry.
Consequently, the following calculations will have a primary focus on shell and tube heat exchanger design.
Detailed design considerations for other types of heat exchangers can be found in Chemical Engineering
Design (Sinnott & Towler, 2009).

1
Step 4: Select a trial value for the overall coefficient, U
When the overall coefficient is unknown, it can be estimated initially to provide a base for subsequent
calculations. The actual overall coefficient can then be iterated and compared to the trial value.

Step 5: Calculate Mean Temperature Difference

The mean temperature difference is given as:
Δ𝑇𝑇𝑚𝑚 = 𝐹𝐹𝑇𝑇 Δ𝑇𝑇𝑙𝑙𝑙𝑙
Where
𝐹𝐹𝑇𝑇 = Correction Factor T
Δ𝑇𝑇𝑙𝑙𝑙𝑙 = Log Mean Temperature Difference

Step 6: Calculate Required Area

Use Equation 1 to calculate the area needed given the heat transfer coefficient, mean temperature
difference, and heat transferred per unit time.

Step 7: Decide Exchanger Layout

The layout of specific heat exchangers can have a significant impact on the performance of the heat
exchanger. For a shell and tube heat exchanger, different tube layouts affect the overall performance of the
heat exchanger (Kallannavar, 2020).

Step 8: Calculate Individual Coefficients

Determine Heat Transfer Coefficient

Tube Side Heat Transfer Coefficient
Step 1 – Determine Tube Side linear velocity, ut
Step 2 – Determine the Tube Side Reynolds Number, Re
Step 3 – Determine the ratio of tube length to tube inner diameter, L/di
Step 4 – Determine the value of jh from figure 1
Step 5 – Determine the Tube Side Prandtl Number, Pr
𝐶𝐶𝑝𝑝 𝜇𝜇
Pr =
𝑘𝑘𝑓𝑓
Where
𝐶𝐶𝑝𝑝 = specific heat capacity
μ = viscosity
𝑘𝑘𝑓𝑓 = thermal conductivity

Step 6 – Determine the Tube Side Nusselt Number, Nu

𝜇𝜇 0.14
𝑁𝑁𝑁𝑁 = 𝑗𝑗ℎ 𝑅𝑅𝑅𝑅 𝑃𝑃𝑃𝑃 0.33 � �
𝜇𝜇𝑤𝑤

2
 Step 7 – Determine the Tube Side Heat-Transfer Coefficient
ℎ𝑖𝑖 𝑑𝑑𝑖𝑖
𝑁𝑁𝑁𝑁 =
𝑘𝑘𝑓𝑓
Where
ℎ𝑖𝑖 = heat transfer coefficient
𝑑𝑑𝑖𝑖 = characteristic length
𝑘𝑘𝑓𝑓 = thermal conductivity

Figure 1: Tube-Side Heat-Transfer Factor

Shell Side Heat Transfer Coefficient

Step 1 – Determine Shell Side linear velocity, us
Step 2 – Determine the Shell Side Reynolds Number, Re
𝜌𝜌𝜇𝜇𝑠𝑠 𝑑𝑑𝑒𝑒
𝑅𝑅𝑅𝑅 =
𝜇𝜇
Where:
𝜌𝜌 = density
𝜇𝜇𝑠𝑠 = flow speed
𝑑𝑑𝑒𝑒 = characteristic length
𝜇𝜇 = dynamic viscosity
Step 3 – Determine the value of jh from figure 2
Step 4 – Determine the Shell Side Prandtl Number, Pr
𝐶𝐶𝑝𝑝 𝜇𝜇
Pr =
𝑘𝑘𝑓𝑓
Where

3
𝐶𝐶𝑝𝑝 = specific heat capacity
μ = viscosity
𝑘𝑘𝑓𝑓 = thermal conductivity
Step 5 – Determine the Tube Side Nusselt Number, Nu
𝜇𝜇 0.14
𝑁𝑁𝑁𝑁 = 𝑗𝑗ℎ 𝑅𝑅𝑅𝑅 𝑃𝑃𝑃𝑃 0.33 � �
𝜇𝜇𝑤𝑤

Step 6 – Determine the shell side Heat-Transfer Coefficient

ℎ𝑜𝑜 𝑑𝑑𝑒𝑒
𝑁𝑁𝑁𝑁 =
𝑘𝑘𝑓𝑓
Where
ℎ𝑜𝑜 = heat transfer coefficient
𝑑𝑑𝑒𝑒 = characteristic length
𝑘𝑘𝑓𝑓 = thermal conductivity

Figure 2 - Shell-Side Heat-Transfer Factors, Segmental Baffles

Determine Mean Temperature Difference

Log Mean Temperature Difference ∆𝑇𝑇𝑙𝑙𝑙𝑙

4
 Co-current Flow
(𝑇𝑇1 − 𝑡𝑡2 ) − (𝑇𝑇2 − 𝑡𝑡1 )
∆𝑇𝑇𝑙𝑙𝑙𝑙 =
𝑇𝑇 − 𝑡𝑡2
ln � 1 �
𝑇𝑇2 − 𝑡𝑡1
Where
𝑇𝑇1 = Inlet temperature of heating fluid
𝑇𝑇2 = Outlet temperature of heating fluid
𝑡𝑡1 = Inlet temperature of cooling fluid
𝑡𝑡2 = Outlet temperature of cooling fluid

Counter current Flow

(𝑇𝑇1 − 𝑡𝑡1 ) − (𝑇𝑇2 − 𝑡𝑡2 )
∆𝑇𝑇𝑙𝑙𝑙𝑙 =
𝑇𝑇 − 𝑡𝑡1
ln � 1 �
𝑇𝑇2 − 𝑡𝑡2
Where
𝑇𝑇1 = Inlet temperature of heating fluid
𝑇𝑇2 = Outlet temperature of heating fluid
𝑡𝑡1 = Inlet temperature of cooling fluid
𝑡𝑡2 = Outlet temperature of cooling fluid

Real Mean Temperature Difference ∆𝑇𝑇𝑚𝑚

Dimensionless temperature ratios R and S
𝑇𝑇1 − 𝑇𝑇2
𝑅𝑅 =
𝑡𝑡2 − 𝑡𝑡1

𝑡𝑡2 − 𝑡𝑡1
𝑆𝑆 =
𝑇𝑇1 − 𝑡𝑡1
Determine Heat Transfer Area
𝑄𝑄
𝐴𝐴 =
𝑈𝑈∆𝑇𝑇𝑚𝑚
Where
Q = Duty
U = Overall Heat Transfer Coefficient
∆𝑇𝑇𝑚𝑚 = Real mean Temperature Difference

Determine Number of Tubes

𝐴𝐴
𝑁𝑁𝑡𝑡 =
𝜋𝜋𝑑𝑑𝑜𝑜 𝐿𝐿
Where
A = Heat Transfer Area
𝑑𝑑𝑜𝑜 = Tube Outer Diameter

5
L = Tube Length

Bundle Diameter
1
𝑁𝑁𝑡𝑡 𝑛𝑛1
𝐷𝐷𝑏𝑏 = 𝑑𝑑𝑜𝑜 � �
𝐾𝐾1
Where
𝑁𝑁𝑡𝑡 = Number of Tubes
K1 and n1 found in figure 3

Figure 3 - Constants for Bundle Diameter

Shell Diameter
Shell diameter is to be selected to give a close fit to the tube bundle to reduce bypassing around the
outside of the bundle. It is determined from figure 4.

6
Figure 4

Tube Side Pressure Drop

Shell Side Pressure Drop

Important considerations
Objective of heat exchangers
The objective of heat exchangers are to heat or cool a process fluid to a certain temperature by allowing for
heat transfer between two fluids that are at different temperatures. They are common in chemical

7
engineering, for example acting as evaporators, condensers and air preheaters, and are also utilised as a
waste heat recovery measure (Balaji et al., 2021).

Design Considerations
1. Selecting Heat Exchanger Type
The following factors should be considered:
• Operating conditions, thermal duty, required approach temperature, any phase changes
• Stream quality/purity (clean, dirty, will it easily foul the heat exchanger) and maintenance
requirements
• Maximum design pressure and temperature
• The application
• Requirements on materials e.g corrosive fluids etc.
From these, selection for the best heat exchanger type can be made, the selection guides by Hall are
particularly useful for this (Hall, 2012).
2. Fluid Allocation: Shell or Tubes
In instances where there is no phase change, the fluid allocation to shell or tubes may be determined by the
factors:
• Corrosion: the tube side should contain the more corrosive fluid to reduce costs of expensive alloy
or clad components (Hall, 2012; Towler & Sinnott, 2013)
• Fouling: the tube side should contain the fluid that fouls heat-transfer surfaces the easiest. This is
to reduce costs incurred by fouling and its cleaning, but also by providing better control of the fluid
velocity, which would reduce fouling (Hall, 2012; Towler & Sinnott, 2013).
• Fluid temperatures: The hotter fluid should be placed in the tubes. For high temperatures that
require special alloys to be used, this reduces overall costs. At moderate temperatures, this is safer
and reduces heat loss to the atmosphere (Towler & Sinnott, 2013).
• Operating pressures: The tube-side should contain the higher pressure stream, as high-pressure
tubes are cheaper than high-pressure shells. Furthermore, the required tube thickness for a high
internal pressure is less than for external pressures, which would further reduce costs (Hall, 2012;
Towler & Sinnott, 2013).
• Pressure drop: The tube side should contain the fluid with the lowest allowable pressure drop.
However, for the same pressure drop, the tube side should contain the fluid with the higher heat-
transfer coefficient (Hall, 2012; Towler & Sinnott, 2013).
• Viscosity: The more viscous fluid should be contained in the shell-side (if turbulent flow is possible)
so that heat transfer is maximised. However if turbulent flow is unattainable, the more viscous fluid
should be contained in the tube to allow for easier and more certain prediction of the tube-side heat
transfer coefficient (Towler & Sinnott, 2013).
• Stream flow rates: The shell side should contain the fluid with the lowest flow rate to minimise
costs (Towler & Sinnott, 2013).

3. Fluid Flowrate
• Tube Bundle Vibration: Tube vibration can cause the baffles to wear out or fatigue when flow rates
or pressure drop is high, and commonly occurs in cross-flow. This impacts design as attention to

8
 the bundle area at the inlet nozzle requires attention. Details for addressing this consideration are
covered in the TEMA Standards.
TEMA Standards for Mechanical Design
After the size of the heat exchanger is determined through an analysis of the thermal design, a mechanical
design of the exchanger can be performed. Shell and tube heat exchangers are very versatile in regards to
their arrangement and are thus able to be configured dependant on the thermal requirements, available
footprint, maintenance requirements and financial budgets. The Tubular Exchanger Manufacturers
Association (TEMA) publishes standards that define the classes of and configurations of different styles of
exchangers specific to tubular heat exchangers (Fanaritis and Bevevino, 1976).

The TEMA standards are designated a 3 letter code:

• 1st Letter = Tube-side head type
• 2nd Letter = Shell type
• 3rd Letter = Rear end

Dependant on the thermal design of the exchanger, the components contained in each of the designation
groups can be ‘mixed and matched’ to meet the design criteria. This includes considerations such as the
number of passes, pressure and the available footprint.

Further, the standards also outline several other important mechanical design constraints such as:
- Preferred shell and tube dimensions
- Manufacturing and design tolerances
- Design stresses of materials used in construction
- Corrosion allowances

The below figure outlines the different combinations of the front end, shell type and rear end as designated
by TEMA,

9
 Figure5: TEMA designations for shell and tube heat exchangers (Fanaritis and Bevevino, 1976)

Assumptions
Some common assumptions for designing heat exchangers are:
• Consider the heat exchanger as isobaric in the first approximation (Gicquel, n.d.)
• No heat exchange with the atmosphere (globally adiabatic) (Gicquel, n.d.)

10
 • Constant values for the heat transfer coefficients and thermophysical fluid properties (Gicquel, n.d.;
Hall, 2012)
• Each tube pass has an equal heat transfer area and constant overall heat-transfer coefficient
(Towler & Sinnott, 2013)
• The shell-side fluid’s temperature in any is constant across all cross-sections (Towler & Sinnott,
2013)
• There are no fluid leakages between shell passes (Hall, 2012; Towler & Sinnott, 2013)
• Use an additional safety factor of 10% when calculating total duty (Hall, 2012)
• At initial design, using your constant heat transfer coefficient, and assuming a tube diameter for the
calculation of the total length of tubes and required surface area to achieve that heat transfer
coefficient, you can then iterate these calculations until parameters such as tube diameter are
reasonable and make sense (Hall, 2012)
• Heat capacity is constant (Hall, 2012)
• Design pressure is usually ~172kPa greater than the operating pressure (Shilling et al., 2019)
• Design temperature is usually 14oC greater than the operating temperature (Shilling et al., 2019)

• Relevant references or text books.Branan's Rules of Thumb for Chemical Engineers (Fifth Edition) –
Chapter 2 focusses on heat exchangers including how to select heat exchangers and step-by-step
guidance on designing them including questions for consideration (Hall, 2012)

Towler and Sinnot Textbook 2013 version (Towler & Sinnott, 2013)
Balaji, C., Srinivasan, B., & Gedupudi, S. (2021). Chapter 7 - Heat exchangers. In C. Balaji, B. Srinivasan, & S.
Gedupudi (Eds.), Heat Transfer Engineering (pp. 199-231). Academic Press.
https://doi.org/https://doi.org/10.1016/B978-0-12-818503-2.00007-1
Gicquel, R. (n.d.). Heat exchangers. Thermoptim. Retrieved April 12 from https://direns.mines-
paristech.fr/Sites/Thopt/en/co/echangeurs.html
Hall, S. (2012). 2 - Heat Exchangers. In S. Hall (Ed.), Branan's Rules of Thumb for Chemical Engineers (Fifth
Edition) (pp. 27-57). Butterworth-Heinemann. https://doi.org/https://doi.org/10.1016/B978-0-12-
387785-7.00002-5
Shilling, R. L., Bernhagen, P. M., Murphy, W. E., Hrnjak, P. S., & Johnson, D. (2019). TEMA-STYLE SHELL-
AND-TUBE HEAT EXCHANGERS. In D. W. Green & M. Z. Southard (Eds.), Perry's Chemical Engineers'
Handbook (9th edition. ed.). McGraw-Hill Education.
https://www.accessengineeringlibrary.com/content/book/9780071834087/toc-
chapter/chapter11/section/section17
Towler, G., & Sinnott, R. (2013). Chapter 19 - Heat-Transfer Equipment. In G. Towler & R. Sinnott (Eds.),
Chemical Engineering Design (Second Edition) (pp. 1047-1205). Butterworth-Heinemann.
https://doi.org/https://doi.org/10.1016/B978-0-08-096659-5.00019-5

Fanaritis, J. and Bevevino, J., 1976. The Tubular Exchanger Manufacturers Association and
Industry. Journal of Pressure Vessel Technology, 98(2), pp.185-187.

11