SHELL & TUBE EXCHANGER

Why shell-and-tube?
• Can be designed for almost any duty with a very wide
range of temperatures and pressures
• Can be built in many materials
• Many suppliers
• Repair can be by non-specialists
• Design methods and mechanical codes have been
established from many years of experience
 Scope of shell-and-tube
• Maximum pressure
– Shell 300 bar (4500 psia)
– Tube 1400 bar (20000 psia)
• Temperature range
– Maximum 600oC (1100oF) or even 650oC
– Minimum -100oC (-150oF)
• Fluids
– Subject to materials
– Available in a wide range of materials
• Size per unit 100 - 10000 ft2 (10 - 1000 m2)
Can be extended with special designs/materials
 Construction
• Bundle of tubes in large cylindrical shell
• Baffles used both to support the tubes and to direct into
multiple cross flow
• Gaps or clearances must be left between the baffle and the
shell and between the tubes and the baffle to enable
assembly
Shell

Tubes

Baffle
 Tube layout

pitch
Triangular Rotated Rotated
Square square
30o triangular
90o 45o
60o

• Typically, 1 in tubes on a 1.25 in pitch or 0.75 in tubes on a 1

in pitch
• Triangular layouts give more tubes in a given shell
• Square layouts give cleaning lanes with close pitch
 Allocation of fluids
• Put dirty stream on the tube side - easier to clean inside the
tubes
• Put high pressure stream in the tubes to avoid thick,
expensive shell
• When special materials required for one stream, put that one
in the tubes to avoid expensive shell
• Cross flow gives higher coefficients than in plane tubes, hence
put fluid with lowest coefficient on the shell side
• If no obvious benefit, try streams both ways and see which
gives best design
 Problems of Conventional S & T
Zigzag path on shell side leads to
• Poor use of shell-side pressure drop
• Possible vibration from cross flow
• Dead spots
– Poor heat transfer
– Allows fouling
• Recirculation zones
– Poor thermal effectiveness, 
 Shell-side axial flow
Some problems can be overcome by having axial flow
• Good heat transfer per unit pressure drop but
– for a given duty may get very long thin units
– problems in supporting the tube
RODbaffles (Phillips petroleum)
• introduced to avoid vibrations by providing additional
support for the tubes
• also found other advantages
– low pressure drop
– low fouling and easy to clean
– high thermal effectiveness
 Twisted tube (Brown Fintube)
• Tubes support each other
• Used for single phase and condensing duties in the power,
chemical and pulp and paper industries
Shell-side helical flow (ABB Lummus)
 Comparison of shell side geometries
Twisted Segmental Helical ROD
tube baffles baffles baffles
Good p Y N Y Y
High shell N Y Y N
Low fouling Y N Y Y
Easy Y With square With square Y
cleaning pitch pitch
Tube-side Included With inserts With inserts With inserts
enhance.
Can give Y N N Y
high 
Low Y With special With double Y
vibration designs helix
 Tube Passes
• A pass is when liquid flows all the way across from one end to the
other of the exchanger.
• An exchanger with one shell pass and two tube passes is a 1-2
exchanger.
• At any time halve the number of tubes present in a shell will handle
the entire flow.
• Almost always, the tube passes will be in multiples of two (1-2, 1-4,
2-4, etc.)
• Odd numbers of tube passes have more complicated mechanical
stresses, etc.
• A large number of tube passes are used to increase the tube side
fluid velocity and heat transfer coefficient and minimize fouling.
• This can only be done when there is enough pumping power since
the increased velocity and additional turns increases the pressure
drop significantly.
Different Heat exchangers flow pattern

Triangular (left) and Square (right) pitch

Four Pass S & T Hx
Eight Pass S & T Hx
Partitions in End Bonnets
• The Overall Heat Exchanger Design Process
Design of heat exchangers is an iterative (trial & error) process.
Here is a set of steps for the process
1. Calculate the required heat transfer rate, Q, in Btu/hr from
specified information about fluid flow rates and
temperatures. (See more details in the next two sections.)
2. Make an initial estimate of the overall heat transfer
coefficient, U, based on the fluids involved.
3. Calculate the log mean temperature difference, ΔTlm, from
the inlet and outlet temperatures of the two fluids. (See
more details in the next two sections.)
4. Calculate the estimated heat transfer area required, using: A
= Q/(U ΔTlm).
5. Select a preliminary heat exchanger configuration.
6. Make a more detailed estimate of the overall heat
transfer coefficient, U, based on the preliminary heat
exchanger configuration.
7. Estimate the pressure drop across the heat exchanger.
If it is too high, revise the heat exchanger
configuration until the pressure drop is acceptable.
8. If the new estimate of U is significantly different than
the previous estimate, repeat steps 4 through 7 as
many times as necessary until the two estimates are
the same to the desired degree of accuracy.
 Input information needed
In order to start the heat exchanger design process,
several items of information are needed as follows:
• The two fluids involved need to be identified.
• The heat capacity of each fluid is needed.
• The required initial and final temperatures for one
of the fluids are needed.
• The design value of the initial temperature for the
other fluid is needed.
• An initial estimate for the value of the Overall Heat
Transfer Coefficient, U, is needed.
 PERHITUNGAN SHELL & TUBE
EXCHANGER

 SHELL SIDE FILM COEFFISIENTS.

Untuk Reynold Number dari 2000 – 1.000.000
dinyatakan dalam persamaan :
0 , 55 1/ 3 0 ,14
ho .De  DeGs   C.    
 0,36     
k     k   w 

Semua data dalam gambar 28 Kern untuk

aliran turbulen.
 SHELL SIDE MASS VELOCITY
Untuk setiap tube atau bagian dianggap
mempunyai C” x 1 in2 crossflow area per inchi
ruang baffle. Sehingga Shell side atau bundle
crossflow area, as dinyatakan sebagai :
ID x C" B 2
as  , ft
PT x144
dan mass velocity dinyatakan sebagai :

W lb
Gs  , 2
as j. ft
 SHELL SIDE DIAMETER EQUIVALENT

Dari pemasangan tube seperti pada gambar 7.19

Kern. Dimana PT adalah tube pitch dalam inchi
dan do adalah diametet luar tube dalam inchi.
4 xfree area
De  , ft
wetted perimeter

Maka untuk square pitch :

d 2
4 x( PT2  o )
de  4 , in
d o
Untuk triangular pitch :
1 d 2
4 x( 12 PT x0,86 PT  2 o
)
de  4
, in
1 d
2 o
 TRUE TEMPERATUR DIFFERENCE Δt

Dalam 1-2 Exchanger,

perhitungan LMTD tidak bisa
benar-benar merupakan
paralele flow atau counter-
current flow, sehingga untuk
mencari temperatur difference
dipakai Δt yang
sesungguhnya.
Hitung :
T1  T2 t2  t1
R dan S
t 2  t1 T1  t1

Kemudian dari gambar 18 Kern, diperoleh

harga FT dan hitung Δt.

t  LMTD x FT
 Latihan soal
• Example #1: Calculate a preliminary estimate of the
heat exchanger area needed to cool 55,000 lb/hr of a
light oil (specific heat = 0.74 Btu/lb-oF) from 190oF to
140oF using cooling water that is available at 50oF.
The cooling water can be allowed to heat to 90oF. An
initial estimate of the overall heat transfer coefficient
is 120 Btu/hr-ft2-oF. Also estimate the required mass
flow rate of cooling water.
• Example #2: A shell and tube heat exchanger is to be
used for the light oil cooling described in Example #1.
How many tubes of 3 inch diameter and 10 ft length
should be used?
• Example #1:
• Solution: First calculate the required heat transfer rate based on
the required light oil cooling:
• Q = (55,000 lb/hr)(0.74 Btu/lb-oF)(190 – 140)oF = 2,035,000
Btu/hr.
• Next calculate the log mean temperature difference:
• ΔTlm = [(190 – 90) – (140 – 50)]/ln[(190 – 90)/(140 – 50)] = 94.9oF
• The preliminary area estimate can now be calculated as:
• A = Q/(U ΔTlm) = 2,035,000/(120)(79.58) = 178.7 ft2 = A
• The required mass flow rate of water can be calculated from Q =
m Cp ΔT.
• Rearranging: m = Q/Cp ΔT = (2,035,000 Btu/hr)/(1 Btu/lb-oF)
(40oF) = 50,875 lb/hr
• Example #2: A shell and tube heat exchanger
is to be used for the light oil cooling described
in Example #1. How many tubes of 3 inch
diameter and 10 ft length should be used?
• Solution: The surface area per tube will be
πDL = π(3/12)(10) ft2 = 7.854 ft2. The number
of tubes required would thus be:
• n = 178.7 ft2/7.854 ft2/tube = 22.7 tubes
(round up to 23 tubes).
 LATIHAN SOAL 7.3 KERN

43.800 Lb/jam 42oAPI Kerosen keluar dari bagian bawah

menara distilasi pada suhu 390oF dan akan didinginkan
hingga 200oF menggunakan 34oAPI Mid-continent crude
pada sebuah shell and tube exchanger yang masuk pada
suhu 100oF dan keluar pada suhu 170 oF. Pressure drop
yang diijinkan untuk kedua aliran adalah 10 psi sesuai
dengan tabel 12 dan dirt factor yang disediakan adalah
0,003. Untuk keperluan ini dipakai 21 1/4 in ID Exchanger
yang mempunyai jumlah 158 berukuran 1 in OD 13 BWG
tube dengan panjang 16” dan dipasang secara 1 1/4 in
square pitch. Bundle dirancang untuk 4 passes dan baffle
berjarak 5 in setiap bagian. Tentukan Exchanger yang
cocok untuk ini dan berapa dirt factornya.
 PERHITUNGAN 1-4 EXCHANGER
SHELL SIDE TUBE SIDE

ID = 211/4 in Jumlah tube = 158 Panjang = 16 in

Baffle space = 5 In OD = 1
Passes = 1 BWG = 13
Pitch = 11/4 in square pitch
Passes = 4

Heat Balance :
Fluida panas : Q = m.C(T1 – T2) = 43800 x 0,59 (390 – 200) = 4.909.980
Fluida dingin : Q = m.c (t2-t1) -> m cool = 4909980/ 0,49(170-100) = 143.148

T1  T2 Dari gambar 18 diperoleh FT dan Δt

LMTD   152,2 F
T1
ln dihitung dengan :
T2

T1  T2 Δt = LMTD. FT = 144,6
R t  t
 2,7 dan S  2 1  0,24
t 2  t1 T1  t1
Menghitung Tc dan tc :
t c
Dari dan Kc dai Gambar 17, diperoleh Fc untuk menghitung Tc dan tc
t h
Tc = 279,8 ,, tc = 129,4

SHELL SIDE TUBE SIDE

4’. Flow area, 4. Flow area, dari tabel10 diperoleh a’t

ID x C" B N t .at' 158 x 0,515
as   0,147 ft 2 at    0,141
PT x144 144n 144 x 4

5’. Massa velocity : 5’. Massa velocity :

W lb Wt lb
Gs   297000 2 Gt   1.050.659,5
as j. ft at j. ft 2
6’. Bilangan Reynold. 6’. Bilangan Reynold.
De .Gs 0,99 / 12 x 297000 D.Gt 0,81 / 12 x1050659,5
Re ,s    25312 Re,t  
 0,4 x 2,42  8,7
 8220
 SHELL SIDE TUBE SIDE

7’. Dari Gambar 28 dapat dicari JH = 7. Hitung L/D kemudian Dari Gambar
90 24 dapat dicari JH = 50an

8’. Pada Tc dicari c, µ dan k untuk 8. Pada tc dicari c, µ dan k untuk

menghitung : menghitung :
1/ 3
1/ 3  c. 
 C.   
   k 
 k 

9’. Hitung ho/Φs dari persamaan

1/ 3 : 9. Hitung hi/Φt dari persamaan :
k  c 
ho  j H   s k  c 
1/ 3
De  k  hi  jH   t
D k 
ho
s hi ,ohi ID
 x
t w  tc  (Tc  tc ) 10. Hitung : 
10’. Tube wall htemperature
ho : t t OD
i ,o

t s
 SHELL SIDE TUBE SIDE

11’. Pada tw dicari µw dari gambar 14 11. Pada tw dicari µw dari gambar 14
kemudian hitung : kemudian hitung :
0 ,14
 
0 ,14
 
s    t   
 w   w 

Gambar 24 insert Gambar 24 insert

12’. Hitung :  ho  12. Hitung :  hi ,o 

ho   s hi, o   t
 s   t 

Q
U D Coeffisient
13’. Clean overall : 13. Overall Coeffisient Design :
A.t Q
UD 
Dari Tabel 10 diperoleh a”
Total surface, AA.t