Table of Contents

CHAPTER 1 ............................................................................................................................................... 1
HEAT EXCHANGER DESIGN ................................................................................................................. 1
1.1 Introducton ........................................................................................................................................ 1
1.2 Parts of Heat Exchanger Design ........................................................................................................ 1
CHAPTER 2 ............................................................................................................................................... 3
THERMAL DESIGN CONSIDERATIONS .............................................................................................. 3
1.1 Design Procedure .............................................................................................................................. 6
1.2 Bell's method .................................................................................................................................. 11
CHAPTER 2 ............................................................................................................................................. 19
MECHANICAL DESIGN OF SHELL AND TUBE HEAT EXCHANGER ............................................ 19
2.1 Design Considerations .................................................................................................................... 19
2.2 Design Components ........................................................................................................................ 20
REFERANCE ........................................................................................................................................... 26
 CHAPTER 1
HEAT EXCHANGER DESIGN
1.1 INTRODUCTON
The transfer of heat to and from process fluids is an essential part of most chemical processes.
Transfer of heat from one fluid to another is an important operation for most of the chemical
industries. Devices used for efficient transfer of heat are generally called Heat Exchanger.
Amongst of all type of exchangers, shell and tube exchangers are most commonly used heat
exchange equipment.

1.2 Parts of Heat Exchanger Design

1. Process or Thermal Design

2. Mechanical Design

Shell and Tube Heat Exchangers

Shell and tube exchangers: are most commonly used heat exchanging equipment. The common
types of shell and tube exchangers are:

 Fixed tube-sheet exchanger (non-removable tube bundle):

 Removable tube bundle (Floating-head exchanger)

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 U-tube exchanger

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 CHAPTER 2
THERMAL DESIGN CONSIDERATIONS
The design includes the determination of heat transfer area, number of tubes, tube length and
diameter, tube layout, number of shell and tube passes, type of heat exchanger (fixed tube sheet,
removable tube bundle etc.), tube pitch, number of baffles, its type and size, shell and tube side
pressure drop etc.

1. Shell

Shell diameter should be selected in such a way to give a close fit of the tube bundle. The
clearance between the tube bundle and inner shell wall depends on the type of exchanger usually
fabricated from standard steel pipe with satisfactory corrosion allowance.

2 Tubes
 Tube OD of ¾ and 1‟‟ are very common to design a compact heat exchanger Maximum
number of tubes in the shell required to increase turbulence.
 Tube thickness should be enough to withstand the internal pressure along with the
adequate corrosion allowance.
 Tube thickness is expressed in terms of BWG (Birmingham Wire Gauge) and true
outside diameter (OD). The tube length of 6, 8, 12, 16, 20 and 24 ft are preferably used.
 Longer tube reduces shell diameter at the expense of higher shell pressure drop.
 Stainless steel, admiralty brass, copper, bronze and alloys of copper-nickel are the
commonly used tube materials:

3.Tube pitch, tube-layout and tube-count.

Tube Pitch: the shortest center to center distance between the adjacent tubes

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The tube count

The number of tubes that can be accommodated in a given shell ID is called tube count.
Depends on the factors like shell ID, OD of tube, tube pitch, tube layout, number of tube passes,
type of heat exchanger and design pressure

Tube passes

 Number of passes is chosen to get the required tube side fluid velocity to obtain greater
heat transfer co-efficient and also to reduce scale formation
 The tube passes vary from 1 to 16. The tube passes of 1, 2 and 4 are common in
application. The partition built into exchanger head known as partition plate (also called
pass partition) is used to direct the tube side flow

Tube sheet

 Forms the barrier between the tube and shell fluids.

 The tube sheet thickness should be greater than the tube outside diameter to make a good
seal.

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4. Baffles

 used to increase the fluid velocity by diverting the flow across the tube bundle to obtain
higher transfer co-efficient.
 The baffle spacing of 0.2 to 1 times of the inside shell diameter is commonly used.
Baffles are held in positioned by means of baffle spacers
 In case of cut-segmental baffle, a segment (called baffle cut) is removed to form the
baffle expressed as a percentage of the baffle diameter. Baffle cuts from 15 to 45% are
normally used. A baffle cut of 20 to 25% provide a good heat-transfer with the reasonable
pressure drop. The % cut for segmental baffle refers to the cut away height from its
diameter.

Fouling Considerations

Fouling of exchanger increases the cost of

I. construction due to over sizing,

II. additional energy due to poor exchanger performance and
III. cleaning to remove deposited materials

The material deposited reduces the effective heat transfer rate due to relatively low thermal
conductivity

Selection of fluids for tube and the shell side

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1.1 DESIGN PROCEDURE
PROCESS DESIGN OF HEAT EXCHANGER FOR SINGLE PHASE HEAT
TRANSFER
Process (Thermal) Design Procedure

Shell and tube heat exchanger is designed by trial and error calculations.

Step #1
Obtain the required thermo physical properties of hot and cold fluids at the caloric temperature
or arithmetic mean temperature. Calculate these properties at the caloric temperature if the
variation of viscosity with temperature is large. The detailed calculation procedure of caloric
temperature available is in reference.

Step #2

Perform energy balance and find out the heat duty (Q) of the exchanger.

Step #3.

Assume a reasonable value of overall heat transfer coefficient (Uo,assm). The value of Uo,assm
with respect to the process hot and cold fluids can be taken from the books

Step #4

 Decide tentative number of shell and tube passes (np ).

Step #5

Determine the LMTD and the correction factor FT (normally should be greater than 0.75 for the
steady operation of the exchangers.) Otherwise it is required to increase the number of passes to
obtain higher FT values

Determination of FT

a) By using a formula:

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For a 1 shell: 2 tube pass exchanger or can be used for any exchanger with an even number of
tube passes

B) Reading from a chart this is for a shell side pass greater than one,divided/split flow

Step #6:

 Calculate heat transfer area (A) required

Step #7.

Select tube material, decide the tube diameter (ID= di , OD = do ), its wall thickness (in terms of
BWG or SWG) and tube length (L).Calculate the number of tubes

Calculate tube side fluid velocity

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Step#8:

This is subject to allowable pressure drop in the tube side of the heat exchanger.

Step #9:

 Decide type of shell and tube exchanger (fixed tube sheet, U-tube etc.). Select the tube
pitch (PT), determine inside shell diameter (Ds) that can accommodate the calculated
number of tubes (nt). Use the standard tube counts table for this purpose. Tube counts are
available in standard text books

To determine DS which can accommodate the given number of tubes you can use the readily
available data or the following mechanisms:

a) An estimate of the bundle diameter Db can be obtained from equation below which is an
empirical equation based on standard tube layouts

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Step #10:

Assign fluid to shell side or tube side (a general guideline for placing the fluids is summarized in
Table 1.4). Select the type of baffle (segmental, doughnut etc.), its size (i.e. percentage cut, 25%
baffles are widely used), spacing (B) and number. The baffle spacing is usually chosen to be
within 0.2 Ds to Ds

• Equivalent diameter of shell (De);

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Step #11:

Determine the tube side film heat transfer coefficient (hi) &Estimate the shell-side film heat
transfer coefficient (ho ).For tubes Equation is the same Except De and ho are Replaced by Di
&hi

Step #12:

Calculate overall heat transfer coefficient (Uocal ) based on the outside tube area (you may
neglect the tube-wall resistance) including dirt factors:

Step#13

Step #14:

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Calculate the tube-side pressure drop (ΔPT);via the following steps;

(i) pressure drop for flow across the tube bundle (frictional loss) (Ps ) and
(ii) return loss (Prs ) due to change of direction of fluid

1.2 Bell's method

In Bell's method the heat-transfer coefficient and pressure drop are estimated from correlations
for flow over ideal tube-banks, and the effects of leakage, bypassing and flow in the window
zone are allowed for by applying correction factors.

The method is not recommended when the by-pass flow area is greater than 30% of the cross-
flow area, unless sealing strips are used.

Heat-transfer coefficient

Hoc, ideal cross-flow coefficient

The heat-transfer coefficient for an ideal cross-flow tube bank can be calculated using the heat
transfer factors jh given in Figure 12.31. Figure 12.31 has been adapted from a similar figure
given by Mueller (1973). Mueller includes values for more tube arrangements than are shown in
Figure 12.31. As an alternative to Figure 12.31, the comprehensive data given in the Engineering
Sciences Data Unit report on heat transfer during cross-flow of fluids over tube banks, ESDU
No. 73031 (1973), can be used; see Butterworth (1977). The Reynolds number for cross-flow
through a tube bank is given by:

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Fn, tube row correction factor
The mean heat-transfer coefficient will depend on the number of tubes crossed. Figure 12.31 is based on
data for ten rows of tubes. For turbulent flow the correction factor Fn is close to 1.0. In laminar flow the
heat-transfer coefficient may decrease with increasing rows of tubes crossed, due to the build up of the
temperature boundary layer. The factors given below can be used for the various flow regimes; the factors
for turbulent flow are based on those given by Bell (1963). Ncv is number of constrictions crossed =
number of tube rows between the baffle tips; see Figure 12.39, and Section 12.9.5.

1. Re > 2000, turbulent; take

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2. Fn from Figure 12.32

where N'c is the number of rows crossed in series from end to end of the shell, and depends on
the number of baffles. The correction factor in the laminar region is not well established, and
Bell's paper, or the summary given by Mueller (1973), should be consulted if the design falls in
this region.

Fw, window correction factor

This factor corrects for the effect of flow through the baffle window, and is a function of the
heat-transfer area in the window zones and the total heat-transfer area. The. correction factor is
shown in Figure 12.33 plotted versus Rw, the ratio of the number of tubes in the window zones
to the total number in the bundle, determined from the tube layout diagram. For preliminary
calculations Rw can be estimated from the bundle and window crosssectional areas, see Section
12.9.5.

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Fj,, bypass correction factor

This factor corrects for the main bypass stream, the flow between the tube bundle and the shell
wall, and is a function of the shell to bundle clearance, and whether sealing strips are used:

where a — 1.5 for laminar flow, Re < 100,

a = 1.35 for transitional and turbulent flow Re > 100,

Ah — clearance area between the bundle and the shell, see Figure 12.39 and Section 12.9.5,

AH = maximum area for cross-flow, equation 12.21,

Ns — number of sealing strips encountered by the bypass stream in the cross-flow zone,
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Ncv — the number of constrictions, tube rows, encountered in the cross-flow section. Equation
12.30 applies for Ns < Ncv/2. Where no sealing strips are used, Fb can be obtained from Figure
12.34

FL, Leakage correction factor

This factor corrects for the leakage through the tube-to-baffle clearance and the baffle-toshell

where fa = a factor obtained from Figure 12.35,

Atb — the tube to baffle clearance area, per baffle, see Figure 12.39 and Section 12.9.5,

Asb = shell-to-baffle clearance area, per baffle, see Figure 12.39 and Section 12.9.5,

AL = total leakage area = (Atb + As/>). Typical values for the clearances are given in the
standards, and are discussed in Section 12.5.6. The clearances and tolerances required in
practical exchangers are discussed by Rubin (1968

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Pressure drop

The pressure drops in the cross-flow and window zones are determined separately, and summed
to give the total shell-side pressure drop.

Cross-flow zones

The pressure drop in the cross-flow zones between the baffle tips is calculated from correlations
for ideal tube banks, and corrected for leakage and bypassing

Where APC = the pressure drop in a cross-flow zone between the baffle tips, corrected for by-passing and
leakage,

AP; = the pressure drop calculated for an equivalent ideal tube bank

, F'b — by-pass correction factor,

F'L = leakage correction factor.

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AP/ ideal tube bank pressure drop

The number of tube rows has little effect on the friction factor and is ignored. Any suitable
correlation for the cross-flow friction factor can be used; for that given in Figure 12,36, the
pressure drop across the ideal tube bank is given by:

where N(:,,, = number of tube rows crossed (in the cross-flow region),

MS = shell side velocity, based on the clearance area at the bundle equator, equation 12.21,

jf = friction factor obtained from Figure 12.36, at the appropriate Reynolds number,

Re = (pusdt)//j,).

F'b, bypass correction factor for pressure drop

Bypassing will affect the pressure drop only in the cross-flow zones. The correction factor is
calculated from the equation used to calculate the bypass correction factor for heat transfer,
equation 12.30, but with the following values for the constant a.

Laminar region, Re < 100, a = 5.0

Transition and turbulent region, Re > 100,

a 4.0 The correction factor for exchangers without sealing strips is shown in Figure 12.37.

F'L, leakage factor for pressure drop

Leakages will affect the pressure drop in both the cross-flow and window zones. The factor is
calculated using the equation for the heat-transfer leakage-correction factor, equation 12.31, with
the values for the coefficient {}[ taken from Figure 12.38.

Window-zone pressure drop

Any suitable method can be used to determine the pressure drop in the window area; see
Butterworth (1977). Bell used a method proposed by Colburn. Corrected for leakage, the window
drop for turbulent flow is given by:

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Where uz = the geometric mean velocity,
uz, = (uwus)1/2
uw - the velocity in the window zone, based on the window area less the area Occupied by the
tubes Aw, see Section 12.9.5,

Ws = shell-side fluid mass flow, kg/s,

Nwv =number of restrictions for cross-flow in window zone, approximately equal to the number
of tube rows.

End zone pressure drop

There will be no leakage paths in an end zone (the zone between tube sheet and baffle). Also,
there will only be one baffle window in these zones; so the total number of restrictions in the
cross-flow zone will be Ncv + Nwv. The end zone pressure drop AP^ will therefore be given by:

Total shell-side pressure drop

Summing the pressure drops over all the zones in series from inlet to outlet gives:

Where Nh is the number of baffles = [(L/lb) — 1].

An estimate of the pressure loss incurred in the shell inlet and outlet nozzles must be added to
that calculated by equation 12.37; see Section 12.9.3.

End zone lengths

The spacing in the end zones will often be increased to provide more flow area at the inlet and outlet nozzles. The
velocity in these zones will then be lower and the heat transfer and pressure drop will be reduced slightly. The
effect on pressure drop will be more marked than on heat transfer, and can be estimated by using the actual spacing
in the end zone when calculating the cross-flow velocity in those zones.

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 CHAPTER 2
MECHANICAL DESIGN OF SHELL AND TUBE HEAT
EXCHANGER
Mechanical design of heat exchangers includes design of various pressure and non-pressure
Parts. The structural rigidity and satisfactory service of heat exchangers depends on the
appropriate mechanical design. The TEMA standards are applicable for the maximum shell ID
and wall thickness of 60 and 2 inch, a maximum design pressure of 3000 psi and a maximum
nominal diameter (inch) × design pressure (psi) of 60000 lb/in, respectively.

2.1 DESIGN CONSIDERATIONS

Design Pressure and Temperature
Design pressure of a heat exchanger is the gage pressure at the top of the vessel. The IS: 4503
specified that the design pressure should at least 5% greater than the maximum allowable
working pressure usually a 10% higher value is used.

Materials of construction

 All materials used construction of shell and heat exchangers for pressure parts must have
the appropriate specification as given in IS: 4503.
 The materials of construction should be compatible with process fluids and others parts
of materials and also should be cost effective.
 High chrome-Mo-Ni alloys (Cr content 12- 27%) can be used for high temperature
services up to 2100ºC.
 Use of any carbon or low alloy steel is not recommended for the construction of heat
Exchangers for the service below 0ºC.

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2.2 DESIGN COMPONENTS
The major mechanical design components of shell and tube heat exchangers are: shell and tube-
sheet thickness, shell cover, flanges, nozzles, gaskets, stress calculations and design of supports.

Shell cover
There is different types shell covers used in shell and tube heat exchangers: flat, tori spherical,
hemispherical, conical and ellipsoidal. Out of various types of head covers, tori spherical head is
the most widely used in chemical industries for operating pressure up to 200psi.According the
IS: 4503, the minimum thickness of the shell cover should be at least equal to the thickness of
the shell. The required thickness of a tori spherical head ( ts) can be determined by;

Channel covers diameter and thickness

The outside diameter of the channel shall be the same as that of the shell. The thickness of the
channel shall be greater of the two values:
(i) Shell thickness
(ii) Tube thickness

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Pass partition plate
 IS: 4503, specifies that the minimum thickness of channel pass partition plates
including corrosion allowance should be 10 mm for both carbon steel and alloy up to
channel size of 600 mm.
 For higher channel size, it should be 13 mm for carbon steel and 10 mm for alloy.

Tube sheet thickness

 Tube sheet is a circular flat plate with regular pattern drilled holes according to the tube
sheet layouts.
 The open end of the tubes is connected to the tube sheet. The tube sheet is fixed with the
shell and channel to form the main barrier for shell and tube side fluids.
 The tube sheet is attached either by welding (called integral construction) or bolting
(called gasketed construction) or a combination of both types.
 The minimum tube-sheet thickness (TEMA standard) to ‘resist bending 'can be calculated
by;

 The effective pressure=Ps+Pb or P=Pt+Pb , when the tube sheet is extended as a flange
for bolting heads.

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  IS: 4503 specifies that the minimum tube sheet thickness should be between 6 and 25.4
mm based on the outside tube diameter.

Impingement plates or baffles

Impingement plates are fixed on the tube side between the tube bundle and inlet nozzle to deflect
the liquid or vapor-liquid mixture to protect the tubes from erosion.

Nozzles and branch pipes

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Gaskets

 Are used to make the metal to metal surfaces leak-proof. are elastic-plastic materials and
relatively softer than the flange materials.
 when there is no contact with oil or oil vapor, the compressed asbestos fiber, natural or
synthetic rubber or other suitable gasket and packing materials having the appropriate
mechanical and corrosion resisting properties may be used (IS:4503).
 A preliminary estimation of gaskets is done using following expression

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Bolts design
The minimum initial bolt load (𝑊𝑚1) at atmospheric pressure and temperature is given by:

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Design of flange

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 REFERANCE
 Coulson_&_Richardson's_Chemical_Engineering,_Volume_6
 Internet
 Introduction to chemical engineering Thermodynamics (sixth edition)

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