Chemical Engineering

Department
Processing Engineering Branch

Design of equipment
Design of shell and tube heat exchanger

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1|Page
 The Subjects pages
NO.

1- INTRODUCTION 3

2- DIFINITION 5

3- NOMENCLATURE 6

4- DESIGN PROCEDURES 7

5- CALULATIONS 9

6- MECHANICAL DESIGN 15

7- DATA SHEET 33

8- REFERENCES 34

pg. 2
INTRODUCTION

Heat exchangers are devices that facilitate the exchange of heat between two fluids
that are at different temperatures while keeping them from mixing with each other.
Heat exchangers are commonly used in practice in a wide range of applications,
from heating and air-conditioning systems in a household, to chemical processing
and power production in large plants. the most common type of heat exchanger in
industrial applications is the shell-and-tube heat exchanger, shown in Figure below
. Shell-and-tube heat exchangers contain a large number of tubes (sometimes
several hundred) packed in a shell with their axes parallel to that of the shell.

Heat transfer takes place as one fluid flows inside the tubes while the other fluid
flows outside the tubes through the shell. Baffles are commonly placed in the shell
to force the shell-side fluid to flow across the shell to enhance heat transfer and to
maintain uniform spacing between the tubes. Despite their widespread use, shell
and- tube heat exchangers are not suitable for use in automotive and aircraft
applications because of their relatively large size and weight. Note that the tubes in
a shell-and-tube heat exchanger open to some large flow areas called headers at
both ends of the shell, where the tube-side fluid accumulates before entering the
tubes and after leaving them. Shell-and-tube heat exchangers are further classified
according to the number of shell and tube passes involved. Heat exchangers in
which all the tubes make one U-turn in the shell, for example, are called one-shell-
pass and two tube- passes heat exchangers. Likewise, a heat exchanger that
involves two passes in the shell and four passes in the tubes is called a two-shell-
passes and four-tube-passes heat exchanger.

pg. 3
A heat exchanger is a device that is used to transfer thermal energy between two or
more fluids, between a solid surface and a fluid, or between solid particulates and a
fluid, at different temperatures and in thermal contact. In heat exchangers, there are
usually no external heat and work interactions. Typical applications involve
heating or cooling of a fluid stream of concern and evaporation or condensation of
single- or multicomponent fluid streams. In other applications, the objective may
be to recover or reject heat, or sterilize, pasteurize, fractionate, distill, concentrate,
crystallize, or control a process fluid. In a few heat exchangers, the fluids
exchanging heat are in direct contact. In most heat exchangers, heat transfer
between fluids takes place through a separating wall or into and out of a wall in a
transient manner. Common examples of heat exchangers are shell-and tube
exchangers, automobile radiators, condensers, evaporators, air preheaters, and
cooling towers. If no phase change occurs in any of the fluids in the exchanger, it
is sometimes referred to as a sensible heat exchanger. There could be internal
thermal energy sources in the exchangers, such as in electric heaters and nuclear
fuel elements.

The basic designs for heat exchangers are the shell-and-tube heat exchanger and
the plate heat exchanger, although many other configurations have been developed.
According to flow layout, heat exchangers are grouped in:

• Shell-and-tube heat exchanger (STHE), where one flow goes along a bunch of
tubes and the other within an outer shell, parallel to the tubes, or in cross-flow.

pg. 4
• Plate heat exchanger (PHE), where corrugated plates are held in contact and the
two fluids flow separately along adjacent channels in the corrugation.

• Open-flow heat exchanger, where one of the flows is not confined within the
equipment.

• Contact heat exchanger, where the two fluids enter into direct contact
(simultaneous heat and mass transfer takes place).

DIFINITION ……… Ref.(1)

The transfer of heat to and from process fluids is an essential part of most chemical
processes. The most commonly used type of heat-transfer equipment is the
ubiquitous shell and tube heat exchanger. The word “exchanger” really applies to
all types of equipment in which heat is exchanged but is often used specifically to
denote equipment in which heat is exchanged between two process streams.
Exchangers in which a process fluid is heated or cooled by a plant service stream
are referred to as heaters and coolers. If the process stream is vaporized the
exchanger is called a vaporizer if the stream is essentially completely vaporized; a
reboiler if associated with a distillation column; and an evaporator if used to
concentrate a solution. The term fired exchanger is used for exchangers heated by
combustion gases, such as boilers; other exchangers are referred to as “unfired
exchangers”.

The principal types of heat exchanger used in the chemical process and allied
industries, are listed below:

1. Double-pipe exchanger: the simplest type, used for cooling and heating.
2. Shell and tube exchangers: used for all applications.
3. Plate and frame exchangers (plate heat exchangers): used for heating
and cooling.

pg. 5
4. Plate-fin exchangers.
5. Spiral heat exchangers.
6. Air cooled: coolers and condensers.
7. Direct contact: cooling and quenching.
8. Agitated vessels.
9. Fired heaters.

pg. 6
pg. 7
DESIGN PROCEDURES ……… Ref.(1)

The general equation for heat transfer across a surface is:

The prime objective in the design of an exchanger is to determine the surface area
required for the specified duty (rate of heat transfer) using the temperature
differences available. The overall coefficient is the reciprocal of the overall
resistance to heat transfer, which is the sum of several individual resistances. For
heat exchange across a typical heat exchanger tube the relationship between the
overall coefficient and the individual coefficients, which are the reciprocals of the
individual resistances, is given by:

The magnitude of the individual coefficients will depend on the nature of the heat
transfer process (conduction, convection, condensation, boiling or radiation), on
the physical properties of the fluids, on the fluid flow-rates, and on the physical
arrangement of the heat-transfer surface. As the physical layout of the exchanger
cannot be determined until the area is known the design of an exchanger is of
necessity a trial and error procedure.

pg. 8
Before equation 12.1 can be used to determine the heat transfer area required for a
given duty, an estimate of the mean temperature difference ∆Tm must be made.
This will normally be calculated from the terminal temperature differences: the
difference in the fluid temperatures at the inlet and outlet of the exchanger. The
well-known “logarithmic mean” temperature difference is given by:

The steps in a typical design procedure are given below:

1. Define the duty: heat-transfer rate, fluid flow-rates, temperatures.

2. Collect together the fluid physical properties required: density, viscosity,
thermal conductivity.
3. Decide on the type of exchanger to be used.
4. Select a trial value for the overall coefficient, U.
5. Calculate the mean temperature difference, ∆Tm.
6. Calculate the area required from equation 12.1.
7. Decide the exchanger layout.
8. Calculate the individual coefficients.
9. Calculate the overall coefficient and compare with the trial value. If the
calculated value differs significantly from the estimated value, substitute the
calculated for the estimated value and return to step 6.
10. Calculate the exchanger pressure drop; if unsatisfactory return to steps 7 or 4 or
3, in that order of preference.
11. Optimize the design: repeat steps 4 to 10, as necessary, to determine the
cheapest exchanger that will satisfy the duty. Usually this will be the one with the
smallest area.

pg. 9
 `

Design of Heat Transfer Unit No. (62): Ethylene Cooler

Branch: Processes Mor. Fluid Condition Shell Side Tube Side
No. of Group: (12)
Names of Group Component Ethylene Water
Flow rate (Kg/hr) 47500 ?
1-‫مشكاة احمد‬ Temperature in (oC) 175 30
Temperature out (oC) 50 40
2-‫نذير خضير‬ Pressure (bar) 18 5

Phase of ethylene:-
(A=15.5368 ; B=1347.01 ; C= -18.15)

Ln(p) = A - B/T+C …….(The Antione equation_vol6)

P = mmHg T = K

The ethylene pressure=18 bar

760 𝑏𝑎𝑟
P=18bar* 1 𝑏𝑎𝑟
= 13680 mmHg

1347 .01
Ln p = 15.5368 - 𝑇+(−18 .15 )

1347 .01
Ln (13680 mmHg) = 15.5368 - 𝑇 +(−18 .15 )

T = 242.2 K
Tvap = -30.8 °C

pg. 10
 Ethylene gas phase and no change in phase
(Liquid)

Phase of water :-

𝑻𝒊𝒏 = 𝟑𝟎 °𝑪 ; 𝑻𝒐𝒖𝒕 = 𝟒𝟎 °𝑪

Water phase is liquid and no change in phase because temperatures

are less than B.P

Water properties:-
Mwt=18kg/kmole ; TBp=100 ℃ ; ρL=998kg/m³

λ=40683 kJ/kmol ; Tc=647.3 K ; Pc=220.5 bar

pg. 11
  Heat Capacity
A= 92.053 ; B= -3.9953 *10−2 ; C= -2.1103 *10−4 ; D= 5.3469 *10−7

𝑪𝒑𝒍𝒊𝒈 = 𝑨 + 𝑩 𝑻 + 𝑪𝑻𝟐 + 𝑫𝑻𝟑 ….. (J/mol.k) ((Ludwig’s

𝐂𝐩𝐥𝐢𝐠 = 𝟗𝟐. 𝟎𝟓𝟑 + (−𝟑. 𝟗𝟗𝟓𝟑 ∗ 𝟏𝟎−𝟐) ∗ 𝟑𝟎𝟖 + (−𝟐. 𝟏𝟏𝟎𝟑 ∗ 𝟏𝟎−𝟒 ) ∗ 𝟑𝟎𝟖𝟐 + (𝟓. 𝟑𝟒𝟔𝟗 ∗ 𝟏𝟎−𝟕 ) ∗ 𝟑𝟎𝟖𝟑

𝑱 𝒌𝒈
𝐂𝐩𝐥𝐢𝐠 = 𝟕𝟓. 𝟑𝟓 ÷ 𝟏𝟖
𝒎𝒐𝒍. 𝒌 𝒎𝒐𝒍

𝑲𝑱
𝐂𝐩𝐥𝐢𝐠 = 𝟒. 𝟏𝟖𝟔
𝒎𝒐𝒍. ℃

 VISCOSITY
A= 658.25 ; B= 283.16

Log μ = A *[ (1/T) – (1/B) ]

𝟏 𝟏
Log μ = 𝟔𝟓𝟖. 𝟐𝟓 ∗ [ 𝟑𝟎𝟖 −
𝟐𝟖𝟑.𝟏𝟔
]

Log μ = -0.187
µ = 0.65 𝑚𝑁. 𝑠/𝑚2

 Density
From App. F (Steam Tables _ Thermo.Smith)
𝑐𝑚3
At 35℃ the specific vol. for sat. liq. =1.006 𝑔
1 𝑔
So the density of water = 1.006 = 0.994 𝑐𝑚3
𝑘𝑔
𝜌 = 994
𝑚3

 Thermal Condictiviy

pg. 12
 𝐾𝐽 𝑘𝑔 𝑘𝑔
𝐶𝑝𝐿 = 4.186 ; 𝜌𝐿 = 994 ; 𝑀𝑤𝑡 = 18 … ref (1)
𝑚𝑜𝑙.℃ 𝑚3 𝑘𝑚𝑜𝑙

−5
𝜌𝐿 4 1/3
𝐾𝑙𝑖𝑞 = 3.56 ∗ 10 ∗ 𝐶𝑝𝐿 ∗ ( )
𝑀𝑤𝑡
9944 1/3
𝐾𝑙𝑖𝑞 = 3.56 ∗ 10−5 ∗ (4.186) ∗ [ ]
18
𝑊
𝐾𝑙𝑖𝑞 = 0.564
𝑚. ℃

Ethylene properties:-
𝟏𝟕𝟓+𝟓𝟎
𝑻𝒂𝒗𝒈 = = 𝟏𝟏𝟐. 𝟓℃ = 𝟑𝟖𝟓. 𝟓 𝒌
𝟐

𝑴𝒘𝒕 =28 kg/kmol ; 𝑻𝑩.𝑷=103.8 °C ; ρ =577 kg/m³

λ =13553 kJ/kmol ; Tc=282.4 K ; pc=50.4 bar

 Heat Capacity
A= 3.806 ; B= 15.659 *10−2 ; C= -8.348 *10−5 ; D= 17.551 *10−9
𝑪𝒑𝒈𝒂𝒔 = 𝑨 + 𝑩 𝑻 + 𝑪𝑻𝟐 + 𝑫𝑻𝟑 ….. (KJ/Kmol.k)

𝐂𝐩𝒈𝒂𝒔 = 𝟑. 𝟖𝟎𝟔 + (𝟏𝟓. 𝟔𝟓𝟗 ∗ 𝟏𝟎−𝟐 ) ∗ 𝟑𝟖𝟓. 𝟓 + (−𝟖. 𝟑𝟒𝟖 ∗ 𝟏𝟎−𝟓 ) ∗ 𝟑𝟖𝟓. 𝟓𝟐 + (𝟏𝟕. 𝟓𝟓𝟏 ∗ 𝟏𝟎−𝟗 ) ∗ 𝟑𝟖𝟓. 𝟓𝟑

𝒌𝑱 𝒌𝒈
𝐂𝐩𝐠𝐚𝐬 = 𝟓𝟐. 𝟕𝟕𝟏 ÷ 𝟐𝟖
𝒌𝒎𝒐𝒍. 𝒌 𝒌𝒎𝒐𝒍
𝑲𝑱
𝐂𝐩𝐠𝐚𝐬 = 𝟏. 𝟖𝟖𝟓
𝒎𝒐𝒍. ℃

 VISCOSITY …… ref (1)

X=9.5 & Y=15.1 …… use graph
µ = 0.012 𝑚𝑁. 𝑠/𝑚2

pg. 13
  Density
For ideal gas Z=1
𝑷 𝑴𝒘𝒕 𝟏𝟖 ∗ (𝟏𝟎𝟏. 𝟑) ∗ (𝟐𝟖)
𝝆𝒈𝒂𝒔 = = = 𝟏𝟓. 𝟗𝟑 𝒌𝒈/𝒎𝟑
𝑹𝑻 (𝟖. 𝟑𝟏𝟒) ∗ (𝟑𝟖𝟓. 𝟓)

 Thermal Condictivity ….. ref (1)

𝐾𝐽 𝑚𝑁. 𝑠 𝑘𝑔
𝐶𝑝𝐺 = 1.881 ; 𝜇 = 0.012 ; 𝑀𝑤𝑡 = 28
𝑚𝑜𝑙. ℃ 𝑚2 𝑘𝑚𝑜𝑙
𝟏𝟎. 𝟒
𝑲𝒈𝒂𝒔 = 𝝁 ∗ ( 𝑪𝒑𝑮 + )
𝑴𝒘𝒕
𝟏𝟎. 𝟒
𝑲𝒈𝒂𝒔 = 𝑶. 𝟎𝟏𝟐 ∗ ( 𝟏. 𝟖𝟖𝟓 + )
𝟐𝟖
𝑾
𝑲𝒈𝒂𝒔 = 𝟎. 𝟎𝟐𝟕
𝒎. ℃

pg. 14
Table of physical properties :-

Physic. Prop. Ethylene Water

Antoine eq. const. A=15.5368 A=18.3036
B=1347.01 B=3816.44
C= -18.15 C= - 46.13
Heat capacity 1.885 4.186
(KJ/kg.℃)
Boiling Point at atm. - 103.8 -30.8
Press. (℃ )
Density (kg/𝒎𝟑 ) 15.93 994
Thermal Conductivity 0.027 0.564
(w/m. ℃)
Viscosity (𝒎𝑵. 𝒔/𝒎𝟐 ) 0.012 0.65

pg. 15
 Water mass flow rate:-

Qsell = Qtube
For ( shell side) Ethylene
𝐾𝐽 𝑘𝑔
𝐶𝑝𝐺 = 1.881 ; 𝑚° = 47500 ; 𝑇𝑖𝑛 = 175 ℃ ; 𝑇𝑜𝑢𝑡 = 50℃
𝑚𝑜𝑙. ℃ ℎ𝑟

𝑸𝒔𝒉𝒆𝒍𝒍 = 𝒎° ∗ 𝑪𝒑𝑮 ∗ ∆𝑻
𝑸𝒔𝒉𝒆𝒍𝒍 = 𝟒𝟕𝟓𝟎𝟎 ∗ 𝟏. 𝟖𝟖𝟓 ∗ (𝟏𝟕𝟓 − 𝟓𝟎)
𝑸𝒔𝒉𝒆𝒍𝒍 = 𝟏𝟏𝟏𝟗𝟐𝟏𝟖𝟕. 𝟓 𝑲𝑱/𝒉𝒓

Qsell = Qtube =11192187.5 KJ/hr

For ( tube side) Water

𝐾𝐽
𝐶𝑝𝐿 = 4.186 ; 𝑄 = 11192187.5 ; 𝐽/ℎ𝑟 ; 𝑇𝑖𝑛 = 30℃ ; 𝑇𝑜𝑢𝑡 = 40℃
𝑚𝑜𝑙. ℃

𝑸𝒕𝒖𝒃𝒆 = 𝒎° ∗ 𝑪𝒑𝑳 ∗ ∆𝑻
𝟏𝟏𝟏𝟗𝟐𝟏𝟖𝟕. 𝟓 = 𝒎° ∗ 𝟒. 𝟏𝟖𝟔 ∗ (𝟒𝟎 − 𝟑𝟎)
𝒎°𝒘𝒂𝒕𝒆𝒓 = 𝟐𝟔𝟕𝟑𝟕𝟏. 𝟖𝟗 𝒌𝒈/𝒉𝒓

pg. 16
∆𝑻 ; 𝑻𝒉𝒆 𝒎𝒆𝒂𝒏 𝒕𝒆𝒎𝒑𝒆𝒓𝒂𝒕𝒖𝒓𝒆 𝒅𝒊𝒇𝒇𝒆𝒓𝒆𝒏𝒄𝒆 (℃)
𝑻𝟏 = 𝟏𝟕𝟓 ℃ ; 𝑻𝟐 = 𝟓𝟎 ℃
𝒕𝟏 = 𝟑𝟎 ℃ ; 𝒕𝟐 = 𝟒𝟎 ℃

(𝑻𝟏 −𝒕𝟐 )−(𝑻𝟐 −𝒕𝟏 )

∆𝑻𝑳𝒎 = (𝑻 −𝒕 ) …. Ref (1)
𝒍𝒏 𝟏 𝟐
(𝑻𝟐 −𝒕𝟏 )

(𝟏𝟕𝟓 − 𝟒𝟎) − (𝟓𝟎 − 𝟑𝟎)

∆𝑻𝑳𝒎 =
(𝟏𝟕𝟓 − 𝟒𝟎)
𝒍𝒏
(𝟓𝟎 − 𝟑𝟎)

∆𝑻𝑳𝒎 = 𝟔𝟎. 𝟐𝟐𝟒 ℃

∆𝑻𝒎 = 𝑭𝒕 ∗ ∆𝑻𝑳𝒎

pg. 17
𝐹𝑡 = 𝑇ℎ𝑒 𝑐𝑜𝑟𝑟𝑒𝑐𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟 ; ∆𝑻𝑳𝒎 = 60.224 ℃

Where :-

( 𝑻𝟏 − 𝑻𝟐 )
𝑹=
(𝒕𝟐 − 𝒕𝟏 )
(𝟏𝟕𝟓 − 𝟓𝟎 )
𝑹= = 𝟏𝟐. 𝟓
(𝟒𝟎 − 𝟑𝟎)

(𝒕𝟐 − 𝒕𝟏 )
𝑺=
(𝑻𝟏 − 𝒕𝟏 )
(40 − 30 )
𝑺= = 𝟎. 𝟎𝟔𝟗
(175 − 30)

From figure 12.19 : ( one shell pass , two tube passes ) ….. ref(1)

So 𝐹𝑡 = 0.94 ….. it is economic because 𝐹𝑡 above 0.75

∆𝑻𝒎 = 𝑭𝒕 ∗ ∆𝑻𝑳𝒎

∆𝑻𝒎 = 𝟎. 𝟗𝟒 ∗ 𝟔𝟎. 𝟐𝟐𝟒℃

∆𝑻𝒎 = 𝟓𝟔. 𝟔℃

pg. 18
Heat Transfer Area ; A ….(𝑚2 )
𝑸 = 𝑼 𝑨 ∆𝑻𝒎
𝑸
𝑨=
𝑼 ∆𝑻𝒎

𝑤ℎ𝑒𝑟𝑒 ∶
Q =Heat Transfer per unit time ; Watt
U =The Over heat- transfer Coefficient ; W/𝑚2 . ℃
A =Heat Transfer area ; 𝑚2
∆𝑇𝑚 =mean temperature difference ; ℃

Qsell = Qtube =11192187.5 KJ/hr

𝐾𝐽 ℎ𝑟 𝐾𝐽
Q =11192187.5 ℎ𝑟
∗
3600 𝑠𝑒𝑐
= 3108.941
𝑠𝑒𝑐
= 3108.941𝐾𝑊

Q=3108941 Watt
∆𝑻𝒎 = 𝟓𝟔. 𝟔℃
Ref (1) __ table (12-1) for cooler and (Gases_water) system … U=(20 _
300) 𝑾/𝒎𝟐 . ℃

Assume ; U = 160 𝑾/𝒎𝟐. ℃

3108941
𝐴= = 343.3 𝑚2
160 ∗ 56.6

Number of tube ; 𝑁𝑡

pg. 19
Ref(1) _table (12-3)) ; choose
3
𝑑= 𝑖𝑛 𝑑0 = 𝑜𝑢𝑡𝑠𝑖𝑑𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = 20𝑚𝑚 = 0.02 𝑚
4

𝑑𝑖 = 𝑖𝑛𝑠𝑖𝑑𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = 16𝑚𝑚 = 0.016 𝑚

𝐿 = 20 𝑓𝑡 = 6.1 𝑚
𝐴1 = 𝐴𝑟𝑒𝑎 𝑜𝑓 𝑜𝑛𝑒 𝑡𝑢𝑏𝑒 = 𝜋 𝑑0 𝐿
𝐴1 = 𝜋 ∗ 0.02 ∗ 6.1 = 𝟎. 𝟑𝟖𝟑𝟑 𝒎𝟐
𝑤ℎ𝑒𝑟𝑒 ∶ 𝐴 = 𝐻𝑒𝑎𝑡 − 𝑡𝑟𝑎𝑛𝑠𝑓𝑒𝑟 𝑎𝑟𝑒𝑎 = 𝟑𝟒𝟑. 𝟓 𝒎𝟐
𝐴 = 𝑁𝑡 ∗ 𝐴1
𝐴 𝐴 343.5
𝑁𝑡 = = = = 895.6
𝐴1 𝜋 𝑑0 𝐿 0.3833
𝑵𝒕 = 𝟖𝟗𝟔
Bundle diameter ; 𝐷𝑏
Ref (1) _table (12-4)) ; for Triangular pitch and

(one shell _ two tube passes )

𝐾1 = 0.249 ; 𝑛1 = 2.207 ; 𝑑0 = 0.02𝑚 ; 𝑁 = 896

1⁄
𝑁 𝑛1
𝐷𝑏 = 𝑏𝑢𝑛𝑑𝑙𝑒 𝑑𝑖𝑎𝑚. = 𝑑0 ( )
𝐾1
1⁄
896 2.207
𝐷𝑏 = 0.02 ( )
0.249
𝑫𝒃 = 𝟖𝟏𝟕. 𝟐 𝒎𝒎

For tube side

pg. 20
Mass velocity (G) and velocity (U)
Where :
𝑘𝑔 ℎ𝑟 𝑘𝑔
𝑚0 = 𝑚𝑎𝑠𝑠 𝑟𝑎𝑡𝑒 = 267371.89 ∗ = 74.269
ℎ𝑟 3600 𝑠𝑒𝑐 𝑠𝑒𝑐
𝝅 𝜋
𝑡𝑢𝑏𝑒 𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛 𝑎𝑟𝑒𝑎 = 𝒅𝒊 = ∗ 162 = 201.1 𝑚𝑚2
𝟒 4
𝑁𝑡 = 𝑡𝑢𝑏𝑒𝑠 𝑁𝑢𝑚𝑏𝑒𝑟𝑠 = 896
𝑵𝒕 896
𝑡𝑢𝑏𝑒 𝑝𝑒𝑟 𝑝𝑎𝑠𝑠 = = = 448
𝟐 2
𝐴𝑡𝑜𝑡 = 𝑡𝑜𝑡𝑎𝑙 𝑓𝑙𝑜𝑤 𝑎𝑟𝑒𝑎 𝑝𝑒𝑟 𝑝𝑎𝑠𝑠 = 448 ∗ (201.1 ∗ 10−6 ) = 0.09𝑚2
𝒎° 74.269 𝐾𝐽
𝐺 = 𝑀𝑎𝑠𝑠 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 = = = 825.22 2
𝑨𝒕 0.09 𝑚 . 𝑠𝑒𝑐
𝑮 825.22 𝑚
𝑢 = 𝑉𝑒𝑙𝑜𝑐𝑖𝑡𝑦 = = = 0.83
𝝆 994 𝑠𝑒𝑐

Tube Side Coefficient ; 𝒉𝒊

Where :
𝑚 𝐾𝐽 𝑚𝑁𝑠
𝑢 = 0.83 ; 𝐺 = 825.22 2 ; 𝜇𝐿 = 0.65 ; 𝑑𝑖 = 16𝑚𝑚
𝑠𝑒𝑐 𝑚 . 𝑠𝑒𝑐 𝑚2

𝝆 𝒖 𝒅𝒊 𝑮 𝒅𝒊
Reynold No. ; 𝑹𝒆 = 𝑜𝑟
𝝁𝑳 𝝁𝑳
825.22 ∗ 0.83 ∗ 0.016
𝑹𝒆 = = 𝟐𝟎𝟑𝟏𝟑. 𝟏
0.65

pg. 21
 𝑪𝒑 𝝁 4.186 ∗ 103 ∗ 0.65 ∗ 10−3
𝑎𝑛𝑑 𝑷𝒓 = = = 𝟒. 𝟖𝟐𝟒
𝑲𝒇 0.564

Ref (1) _Figure 12.23) 𝑱𝒉

At Re=20313.1 𝐽ℎ = 4 ∗ 10−3
0.14
𝜇
& ( ⁄𝜇𝑊 ) =1

Where :
𝒉𝒊 𝒅 𝒊 𝝁
= 𝑱𝒉 𝑹𝒆 𝑷𝒓 𝟎.𝟑𝟑 ( ⁄𝝁𝑾 )𝟎.𝟏𝟒
𝑲𝒇

ℎ𝑖 ∗ (16 ∗ 10−3 )
= (4 ∗ 10−3 ) ∗ (20 313.1) ∗∗ (4.824)0.33 ∗ (1)0.14
0.564
𝑾
𝒉𝒊 = 𝟒𝟖𝟏𝟒. 𝟏𝟓
𝒎𝟐 . ℃

For Shell Side :

Mass velocity (Gs) and velocity (u)

Where :

𝒎 = 𝒎𝒂𝒔𝒔 𝒓𝒂𝒕𝒆 = 𝟒𝟕𝟓𝟎𝟎

𝒌𝒈⁄
𝒉𝒓
𝒄𝒍𝒆𝒂𝒓𝒂𝒏𝒄𝒆 = 𝟔𝟕 … … . 𝒓𝒆𝒇(𝟏); 𝒇𝒊𝒈: 𝟏𝟐_𝟏𝟎
𝑫𝒃 = 𝟖𝟏𝟕. 𝟐 𝒎𝒎

pg. 22
𝑫𝒔 = 𝒔𝒉𝒆𝒍𝒍 𝒅𝒊𝒂𝒎. = (𝑫𝒃 + 𝑪𝒍𝒆𝒂𝒓𝒂𝒏𝒄𝒆)
𝑫𝒔 = (𝟖𝟏𝟕. 𝟐 + 𝟔𝟕) = 𝟖𝟖𝟒. 𝟐 𝒎𝒎
𝑫𝒔 = 𝟖𝟖𝟒. 𝟐 𝒎𝒎

𝒃𝒖𝒇𝒇𝒍𝒆 𝑵𝑶. = 𝟐 (𝑵𝒐 𝒄𝒉𝒂𝒏𝒈𝒆 𝒊𝒏 𝒑𝒉𝒂𝒔𝒆 𝒊𝒏𝒔𝒊𝒅𝒆 𝒔𝒉𝒆𝒍𝒍 𝒔𝒊𝒅𝒆)

𝑫𝒔
𝑳𝑩 = 𝒃𝒖𝒇𝒇𝒍𝒆 𝒔𝒑𝒂𝒄𝒊𝒏𝒈 = … . 𝒓𝒆𝒇(𝟏); (𝒗𝒐𝒍𝟔; 𝒄𝒉𝟏𝟐; 𝒑𝒈: 𝟔𝟕𝟕)
𝒃𝒖𝒇𝒇𝒍𝒆 𝑵𝑶.

884.2 𝑚𝑚
𝑳𝑩 = = 442.1 𝑚𝑚
2
𝑷𝒕 = 𝒕𝒖𝒃𝒆 𝒑𝒊𝒕𝒄𝒉 = 1.25 ∗ 𝑑0
𝑷𝒕 = 1.25 ∗ 20 𝑚𝑚
𝑷𝒕 = 25 𝑚𝑚

& for triangular

1.1 2
𝑑𝑒 = 𝑒𝑞𝑢𝑖𝑣𝑎𝑙𝑒𝑛𝑡 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = (𝑃 − 0.917 𝑑0 )
𝑑0 𝑡
𝑑𝑒 = 𝟏𝟒. 𝟐𝟎 𝒎𝒎
(𝑃𝑡 − 𝑑0 )𝐷𝑆 𝐿𝐵
𝐴 = 𝑐𝑟𝑜𝑠𝑠 𝑓𝑙𝑜𝑤 𝑎𝑟𝑒𝑎 =
𝑃𝑡
(25 − 20) ∗ 884.2 ∗ 442.1 ∗ 106
𝐴= = 0.07818
25

pg. 23
 𝑚°
𝐺𝑠 = 𝑚𝑎𝑠𝑠 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 =
𝐴𝑠
(47500 𝑘𝑟⁄ℎ𝑟 ) ÷ 3600
𝑘𝑔
𝐺𝑠 = = 168.77
0.07818 𝑚2. 𝑠𝑒𝑐
𝐺𝑠
𝑢 = 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 =
𝜌
𝑘𝑔
168.77 𝑚
𝑢= 𝑚2 . 𝑠𝑒𝑐 = 10.595
𝑘𝑔 𝑠𝑒𝑐
15.93
𝑚3

Shell Side Coefficient ;ℎ0

Where :
𝑢 = 10.595 𝑚/ 𝑠𝑒𝑐 𝐺𝑠 = 168.77 𝑘𝑔/ 𝑠𝑒𝑐. 𝑚2 ; 𝜇 = 0.012 𝑚𝑁𝑠/𝑚2

𝑊 𝐾𝐽
𝐾𝑓 = 0.027 ; 𝑑𝑒 = 14.20 𝑚𝑚 ; 𝐶𝑝 = 1.885
𝑚.℃ 𝐾𝑔.℃

𝜌 𝑢 𝑑𝑒 𝐺𝑠 ∗ 𝑑𝑒
𝑅𝑒 = =
𝜇 𝜇
168.77 ∗ 14.2 ∗ 10−3
𝑅𝑒 = = 199711.2
0.012 ∗ 10−3
𝐶𝑝 ∗ 𝜇 (1.885 ∗ 103 ) ∗ (0.012 ∗ 10−3 )
𝑃𝑟 = = = 0.838
𝐾𝑓 0.027

pg. 24
At Re = 199 711.2 & from … ref (1) ;(fig.12_29); vol6 ; ch.12
𝐽ℎ = ℎ𝑒𝑎𝑡 𝑡𝑟𝑎𝑛𝑠𝑓𝑒𝑟 𝑓𝑎𝑐𝑡𝑜𝑟 = 1.3 ∗ 10−3

For NO. change phase in Shell Side :-

ℎ0 ∗ 𝑑𝑒 1 𝜇
= 𝐽𝑓 ∗ 𝑅𝑒 ∗ 𝑃𝑟 ⁄3 ∗ ( ⁄𝜇𝑤 )0.14
𝐾𝑓
ℎ0 ∗ (14.2 ∗ 10−3 ) 1
= (1.3 ∗ 10−3 )(199711.2)(0.838) ⁄3 ∗ ( 1)0.14
0.027
𝑾
𝒉𝟎 = 𝟒𝟔𝟓. 𝟒𝟏 𝟐
𝒎 .℃

Overall heat transfer Coefficient ; 𝑈0

Where :
from …. Ref (1) ; [vol6 ; eq (12.2)]
𝑤 𝑤
ℎ𝑖 = 4841.15 2 ; ℎ0 = 465.41 2
𝑚 .℃ 𝑚 .℃

From (table: 12.6 _ vol6 ; ch.12 )

𝑤
ℎ𝑖𝑑 = 𝑖𝑛𝑠𝑖𝑑𝑒 𝑡𝑢𝑏𝑒 𝑓𝑜𝑢𝑙𝑖𝑛𝑔 𝑓𝑎𝑐𝑡𝑡𝑜𝑟 = 4500
𝑚2 . ℃
𝑤
ℎ0𝑑 = 𝑜𝑢𝑡𝑠𝑖𝑑𝑒 𝑡𝑢𝑏𝑒 𝑓𝑜𝑢𝑙𝑖𝑛𝑔 𝑓𝑎𝑐𝑡𝑡𝑜𝑟 = 5000 2
𝑚 .℃

pg. 25
From (table: 12.6 _ vol6 ; ch.12 )
𝐾𝑤 = 𝐶𝑜𝑛𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝑚𝑒𝑡𝑎𝑙𝑠 = 45 𝑤/𝑚. ℃
𝒅
𝟏 𝟏 𝟏 𝒅𝟎 𝐥𝐧 ( 𝟎⁄𝒅 ) 𝒅𝟎 𝟏 𝒅𝟎 𝟏
𝒊
= + + + ∗ + ∗
𝑼𝟎 𝒉𝟎 𝒉𝟎𝒅 𝟐 𝑲𝒘 𝒅𝒊 𝒉𝒊𝒅 𝒅𝒊 𝒉𝒊

20 ∗ 10−3 ∗ ln (20⁄16)
1 1 1 20 1 20 1
= + + + ∗ + ∗
𝑈0 465.41 5000 2 (45) 16 4500 16 4814.15

𝒘
𝑼𝟎 = 𝟑𝟒𝟎. 𝟔𝟒
𝒎𝟐 . ℃

pg. 26
Second trial
𝑤
Assume :- U = 340.64
𝑚2 .℃

& 𝐴 = 161.25𝑚2 ; 𝑁𝑡 = 422 ; 𝐷𝑏 = 581 𝑚𝑚

For tube side :-
Tube per pass =(Nt/2)=211
At =0.0424 𝑚2
G =1750.33 kg/sec 𝑚2
u = 1.76 m/sec
Re =43085.05
Pr = 4.824
𝒘
𝐽ℎ = 3.3 ∗ 10−3 𝒉𝒊 = 𝟖𝟒𝟐𝟒. 𝟏
𝒎𝟐 . ℃

For Shell Side :-

Clearance = 61 mm
Ds = 642 mm
𝐿𝐵 = 321 𝑚𝑚
As = 0.0412 𝑚2
Gs = 320.25 kg/sec . 𝑚2
u = 20.1 m/sec
Re = 378962.5
Pr = 0.838
𝒘
𝐽ℎ = 9 ∗ 10−4 𝒉𝟎 = 𝟔𝟏𝟏. 𝟒𝟏
𝒎𝟐 . ℃

pg. 27
 𝒘
𝑼𝟎 = 𝟒𝟑𝟐. 𝟔𝟓
𝒎𝟐 .℃

Third trial
𝑤
Assume :- U = 432.65
𝑚2 .℃

& 𝐴 = 126.96 𝑚2 ; 𝑁𝑡 = 332 ; 𝐷𝑏 = 521.1 𝑚𝑚

For tube side :-
Tube per pass =(Nt/2)= 166
At = 0.0334 𝑚2
G = 2 223.65 kg/sec 𝑚2
u = 2.24m/sec
Re = 54736.0
Pr = 4.824
𝒘
𝐽ℎ = 3.2 ∗ 10−3 𝒉𝒊 = 𝟏𝟎𝟑𝟕𝟕. 𝟖
𝒎𝟐 . ℃

For Shell Side :-

Clearance = 58 mm
Ds = 579.1 mm
𝐿𝐵 = 289.6 𝑚𝑚
As = 0.03354 𝑚2
Gs = 393.45 kg/sec . 𝑚2
u = 24.7 m/sec
Re = 465 582.5
Pr = 0.838
𝒘
𝐽ℎ = 8.3 ∗ 10−4 𝒉𝟎 = 𝟔𝟗𝟐. 𝟕𝟑
𝒎𝟐 .℃

pg. 28
 𝒘
𝑼𝟎 = 𝟒𝟕𝟏. 𝟑𝟕
𝒎𝟐 .℃

For third trial ; the checking

471.37−432.65
𝐸𝑟𝑟𝑜𝑟 = ∗ 100%
432.65

𝐸𝑟𝑟𝑜𝑟 = 8.9%

Where :
𝒘
𝑈𝑎𝑠𝑠𝑢𝑚𝑒𝑑 = 432.65
𝒎𝟐 .℃
𝒘
𝑈𝑐𝑎𝑙𝑐𝑢𝑙𝑎𝑡𝑒𝑑 = 𝑈0 = 471.37
𝒎𝟐 . ℃

∴ 𝑎𝑐𝑐𝑖𝑝𝑡𝑎𝑏𝑙𝑒 → 𝑒𝑟𝑟𝑜𝑟% < 10%

∴ 𝑇ℎ𝑒 𝑡ℎ𝑖𝑟𝑑 𝑡𝑟𝑖𝑎𝑙 𝑖𝑠 𝑐𝑜𝑟𝑟𝑒𝑐𝑡

pg. 29
Pressure drop for ( tube side )…..ref(1) ;(vol6 ; ch.12)

Where :
𝑁𝑝 = 𝑛𝑜. 𝑜𝑓 𝑝𝑎𝑠𝑠𝑒𝑠 𝑡𝑢𝑏𝑒𝑠 = 2 𝑝𝑎𝑠𝑠𝑒𝑠
𝑘𝑔
𝜌 = 𝑓𝑙𝑢𝑖𝑑 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 = 994 3
𝑚
𝑢𝑡 = 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑖𝑛𝑠𝑖𝑑𝑒 𝑡𝑢𝑏𝑒𝑠 = 2.24 𝑚/𝑠𝑒𝑐
𝑑𝑖 = 16 𝑚𝑚 ; 𝐿 = 6.1 𝑚

& from ref (1) ; (fig.12_24 ; vol6 ; ch.12)

At Re = 54736.0 𝐽𝑓 = 3.2 ∗ 10−3
−𝑚
𝜇 𝜌 𝑈𝑡 2
∆𝑃𝑡 = 𝑁𝑝 [ 8 𝐽𝑓 (𝐿⁄𝑑 ) ( ⁄𝜇𝑤 ) + 2.5 ]
𝑖 2

−3 )
6.1 ∗ 10−3 (994) (2.24)2
∆𝑃𝑡 = 2 [ 8 ∗ (3.2 ∗ 10 ( ) (1) + 2.5 ]
16 2
𝑁
∆𝑃𝑡 = 61 146.68
𝑚2
∆𝑃𝑡 = 8.98 𝑝𝑠𝑖
Acceptable ∆𝑃𝑡 < 10 𝑝𝑠𝑖

pg. 30
Pressure drop for (Shell Side ) :- ..ref(1) ;(vol6 ; ch.12)

Where :
𝐷𝑠 = 𝑠ℎ𝑒𝑙𝑙 𝑑𝑖𝑎𝑚. = 579.1 𝑚𝑚
𝑘𝑔
𝜌 = 𝑓𝑙𝑢𝑖𝑑 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 = 15.93 3
𝑚
𝑢𝑠 = 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑖𝑛 𝑠ℎ𝑒𝑙𝑙 = 24.7 𝑚/𝑠𝑒𝑐
𝐿𝐵 = 𝑏𝑖𝑓𝑓𝑙𝑒 𝑠𝑝𝑎𝑐𝑖𝑛𝑔 = 289.6
𝑑𝑒 = 𝑒𝑞𝑢𝑖𝑣𝑒𝑙𝑎𝑛𝑡 𝑑𝑖𝑎𝑚. = 14.2 𝑚𝑚
𝐿 = 6.1 𝑚

& from ref (1) ; (fig.12_30 ; vol6 ; ch.12)

At Re = 465 582.5 𝐽𝑓 = 2.5 ∗ 10−3

𝑫 𝝆 𝑼𝒕 𝟐
∆𝑷𝒔 = 𝟖 𝑱𝒇 ( 𝒔⁄𝒅𝒆) (𝑳⁄𝑳 ) 𝟐
𝑩

−3 )
289.6 6.1 ∗ 103 (15.93) (24.7)2
∆𝑃𝑡 = 8 ∗ (2.5 ∗ 10 ( )( )
14.2 579.1 2
𝑁
∆𝑃𝑡 = 20 878.35
𝑚2
∆𝑃𝑡 = 3.07 𝑝𝑠𝑖

pg. 31
Nozzle Sizing
Nozzle for tube side ;
𝜋
𝑉 = 𝑢 ∗ 𝐴 = 𝑢 ∗ ( ∗ 𝑑2 )
4
Where :-
𝑘𝑔
𝑚° 267 371.89 𝑚3 𝑚3
ℎ𝑟
𝑉= = 𝑘𝑔 = 268.99 = 0.0747
𝜌 994 ℎ𝑟 𝑠𝑒𝑐
𝑚3

u= 2.5 m/sec for liquid

𝜋 2
0.0747𝑚3 / sec = (2.5 𝑚/ sec) ∗ [ ∗ 𝑑 ]
4

𝑑 = 0.0762 𝑚 = 76.2 𝑚𝑚 = 3 𝑖𝑛

Nozzle for shell side ;

𝜋
𝑉 = 𝑢 ∗ 𝐴 = 𝑢 ∗ ( ∗ 𝑑2 )
4
Where :-
𝑘𝑔
𝑚° 47 500 𝑚3 𝑚3
ℎ𝑟
𝑉= = 𝑘𝑔 = 2 981.8 = 0.828
𝜌 15.93 3 ℎ𝑟 𝑠𝑒𝑐
𝑚

u = 20 m/sec for gas

𝜋 2
0.828 𝑚3 / sec = (20 𝑚/ sec) ∗ [ ∗ 𝑑 ]
4
𝑑 = 0.115 𝑚 = 115 𝑚𝑚 = 4.5 𝑖𝑛

pg. 32
Shell thickness ;
𝑷𝒊 𝑫𝒊
𝒕=
𝟐𝑺𝑬 − 𝟏. 𝟐𝑷𝒊
Where :-
𝑁
𝑃𝑖 = 18 𝑏𝑎𝑟 ∗ 1.1 = 19.8 𝑏𝑎𝑟 = 1.98
𝑚𝑚2
𝐷𝑖 = 𝐷𝑠 = 579.1 𝑚𝑚
𝐸 = 1.0
𝑁
𝑆 = 𝑠𝑡𝑟𝑒𝑠𝑠 = 107 from ref(1) ;(table 13.2)
𝑚𝑚 2

At T=190℃

(1.98)(579.1)
𝑡𝑚𝑖𝑛 =
2(107)(1) − 1.2(1.98)
𝑡𝑚𝑖𝑛 = 5.4 𝑚𝑚

&

𝒕𝒂𝒄𝒕. = 𝒕𝒎𝒊𝒏 + 𝒄𝒐𝒓𝒓𝒐𝒔𝒊𝒐𝒏 𝒂𝒍𝒍𝒐𝒘𝒏𝒂𝒄𝒆

𝑡𝑎𝑐𝑡 = 5.4 + 2
𝑡𝑎𝑐𝑡 = 7.4 𝑚𝑚

pg. 33
pg. 34
pg. 35
 References

1- Coulson & Richardson ; Chemical Engineering Design

R K SINOTT / 2005 volume 6 - fourth edition - Chemical Engineering Series

2- Ernest E. Ludwig ; A P P L I E D PROCESS D E S I G N FOR CHEMICAL

AND PETROCHEMICAL PLANTS ;
1999 / Volume – 3 , Third Edition / Gulf Professional Publishing
Retired Consulting Engineer Baton Rouge, Louisiana

3- HEAT EXCHANGERS
http://repository.uobabylon.edu.iq/2010_2011/4_25364_730.pdf

4- Classification of Heat Exchangers

http://web.iitd.ac.in/~pmvs/courses/mel709/classification-hx.pdf

5-Smith ; Introduction to Chemical Engineering thermodynamics 6th edn ; 2005 ; Van Ness &
Abbot

pg. 36