Approximate design of

Shell and tube H.E

By
M.M.Sorour
Structure of the Heat Exchanger Design
(1) -The problem must be identified

This includes data like flow rates,

pressures, temperatures and
compositions, and it also includes
qualitative information such as the
likelihood of fouling and the difficulty of
cleaning, special materials
requirements, and any unusual
conditions to be encountered during
operation
Structure of the Heat Exchanger Design

( 2) Select a tentative set of major

parameters:

Tube type, size, layout, shell diameter and

length, baffle spacing, etc.
Structure of the Heat Exchanger Design

(3) The thermal performance for the

tentative configuration is rated

That is, the overall heat transfer coefficient

is calculated for the given flow rates in the
design chosen; that value is combined with
the required heat duty and the calculated
value of the mean temperature difference
to determine the heat exchanger area
required.
Structure of the Heat Exchanger Design
( 4) Compare the area calculated with the
estimated in the chosen design.

If the calculated area is reasonably close to

the available area, heat exchangers
acceptable from a thermal point of view and
one may go on to the pressure drop
calculation.

However, if the areas do not correspond, it is

necessary to adjust the tentative configuration
parameters to increase or decrease the heat
transfer area as required, and then the new
configuration is re-rated.
Structure of the Heat Exchanger Design

(5)Calculate the pressure drop

In the pressure drop calculation, the

pressure drop of each stream must be
less than but not greatly less than the
allowable values.
If the calculated pressure drop is much
less than that allowed, it will probably
prove possible to reduce the size of the
exchanger.
Procedure for Approximate Size
Estimation
Calculation of Q.
For sensible heat
transfer on the
shell-side,

For the tube-side

by
 Procedure for Approximate
Size Estimation
Calculation of MTD.
The mean temperature difference is
the logarithmic mean temperature
difference ) LMTD) times a factor
related to the heat exchanger F

 t1  T2    t 2  T1 
LMTD=
ln  t1  T2    t1  T1  
Procedure for Approximate
Size Estimation
The value of F from the following
Figures.

For preliminary design of multiple

tube pass designs, F may be
estimated as 0.9, which is the
average between the maximum
possible value, 1.0, and the
minimum recommended value, 0.8.
 Correction Factor

.One shell pass, two or more tube passes )a(

R = (T1 − T2)/(t2 − t1) and S = (t2 − t1)/(T1 − t1).

 Correction Factor

.Two shell passes, four or more tube passes )b(

R = (T1 − T2)/(t2 − t1) and S = (t2 − t1)/(T1 − t1).

 Correction Factor

Three shell passes, six or more tube passes )c(

R = (T1 − T2)/(t2 − t1) and S = (t2 − t1)/(T1 − t1).

 Correction Factor

d) Four shell passes, eight or more tube passes

R = (T1 − T2)/(t2 − t1) and S = (t2 − t1)/(T1 − t1).

 Estimation of number of
Shells
When it is
required to use
multiple shells in
series, there is a
rapid graphical
technique for
estimating a
sufficient number
of shells in series.
Ans: 3 shells
 : Example
In this example Hot stream at 310F to be
cooled to 185F using cooled stream to
be heated from 80F to 275F.

R= ( 310-165) / ( 275-80) = 0.744

S= (275-80) /( 310 – 80) = 0. 848
From F factor corrections for 3 shells in series F=0.81
MTD= 56.4 x 0.81=
Procedure for Approximate
Size Estimation

Estimation of U0.
The step with the greatest uncertainty
in preliminary calculations is estimating
the overall heat transfer coefficient.
 Overall heat transfer coefficients
Liquid-Liquid media
Design U Tube side Shell side
BTU/hrft2 F
300-500 water Demineralized water
15-25 Water Fuel oil
10-15 Oil Fuel oil
60-100 Water Gasoline
10-40 Heavy oil Heavy oil
25-50 Water Kerosene or gas oil
20-35 Oil Kerosene or gas oil
25-50 Water Lube oil ( low viscosity(
40-60 water Lube oil ( high viscosity)
50-150 Water Organic solvents
35-90 Brine Organic solvents
20-60 Organic solvents Organic solvents
100-250 Caustic soda solution Water
(10-30%)
15-25 Water Wax distillate
13-23 Oil Wax distillate
 Overall heat transfer coefficients
.Condensing Vapor-Liquid media
Design U Tube side Shell side
BTU/hrft2 F
100-200 Water Alcohol Vapor
40-60 Dowtherm vapor Asphalt
40-50 Steam Gas plant tar
20-50 Water High boiling hydrocarbon
80-200 Water Low boiling hydrocarbon
25-40 Oil Hydrocarbon vapor (partial condenser(
100-200 Water Organic solvents A
20-60 Water or brine Organic solvents high NC,A
50-120 Water or brine Organic solvents low NC,V
30-65 Water Kerosene
20-30 Oil Kerosene
50-75 Water Naphtha
20-30 Oil Naphtha
400-1000 Feed water Steam
15-25 No 6 fuel oil Steam
60-90 No 2 fuel oil Steam
 Overall heat transfer coefficients
.Condensing Vapor-Liquid media

NC noncondensable gas present.

V vacuum.
A atmospheric pressure.
To convert British thermal units per
hour-square foot-degrees Fahrenheit to
joules per square meter-second-
kelvins, multiply by 5.6783
Procedure for Approximate
Size Estimation
Estimation of Ao and Key Exchanger
Parameters.
Once Q, MTD, and Uo are known, the total
outside heat transfer area Ao is readily
found from
 Exchanger dimensions
The next question is, "What set of
heat exchanger dimensions will
accommodate the heat transfer
area?" .
Size Estimate Chart
 Exchanger dimensions
Therefore, once the required area
Ao is known combinations of tube
length and shell diameter that will
provide that area in a single shell
for an exchanger of the given tube
size and layout.
The dashed lines shown in
parameter and marked 3:1, 6: 1,
etc, are ratios of tube length to
shell inside diameter..
 Exchanger dimensions
An exchanger with a length to
diameter ratio too short - say, less
than 3:1 - is likely to suffer from
poor distribution of the streams
and an excessive cost because of
the large shell diameter.
 Exchanger dimensions
An exchanger with an excessively
large length to diameter ratio is
likely to be difficult to handle
mechanically (the bundle must be
very carefully supported when
pulled, because of its springiness)
and requires a wide clearway for
pulling the bundle and retubing.
 Exchanger dimensions
An arbitrary ratio of 15:1 has been
assigned to the probable upper
limit.
Most heat exchangers fall into the
6:1 to 8:1 range, though there has
been a pronounced trend towards
higher values as pressure drop
estimation procedures have
improved
 Correction Factors
The usefulness of the figure can be
greatly extended by defining an
effective area A'o by the equation
A'o= Ao 2.56 F1 F2 F3

where A'o is the area on the ordinate of

the graph
Ao is the outside area of a tube heat
exchanger calculated from the heat
rate
Correction Factors
F1 is the correction factor for the unit
cell tube array (1.00 for 3/4 in. tubes
on a 15/16 in. triangular pitch).
F2 is the correction factor for the
number of tube passes (1.00 for one
tube pass).
F3 is the correction factor for the shell
construction/tube bundle layout type
(1.00 for fixed tube sheet).
 F1, For various unit cells
Tube
F1 Tube Layout
Pitch,in
Tube outside
Diameter, in

0.90 Triangular 13/16 5/8

1.04 Square,Rotated square 13/16 5/8
1.00 Triangular 15/16 3/4
1.16 Square,Rotated square 15/16 3/4
1.14 Triangular 1 3/4
1.31 Square,Rotated square 1 3/4
1.34 Triangular ¼1 1
¼1
1.54 Square,Rotated square 1
F2 , For various number of tube –side
passes
  F2 Inside shell
Diameter, in
  NUMBER OF TUBE-SIDE PASSES

 
8 6 4 2
  ­- 1.80 1.40 1.20 Up to 12**
  1.50 1.25 1.18 1.06 13 ¼ to 17 ¼
1.14 19 ¼ to 23 ¼
  1.35 1.19 1.04

1.20 1.16 1.12 1.03 25 to 33

1.16 1.12 1.08 1.02 35 to 45
1.12 1.08 1.05 1.02 48 to 60
1.06 1.04 1.03 1.01 Above 60
 F3 For various Tube bundle
Constructions
F3
INSIDE SHELL DIAMETER IN. TYPE OF TUBE BUNDLE
CONSTRUCTION

ABOVE 48 37-48 23 ¼ -35 ¼ 21- ¼ 13 UP TO 12

Split Backing Ring

1.04 1.06 1.09 1.15 1.30 (TEMA S)
Outside Packed
1.04 1.06 1.09 1.15 1.30 Floating Head
TEMA P

1.01 1.01 1.03 1.08 1.12 U –Tube )TEMA U)

Pull-Through Floating
1.15 1.18 1.25 1.40 Head (TEMA T)
 Example
Estimate the approximate size of an air
compressor intercooler required to cool
13,000 SCFM (58,500 Ib/hr) of air at
65 psig from 350F to125  F, using
water at80 F. The tubes are to be 3/4
in. O.D., copper, and a U-tube bundle
is desired. A tube layout on a 1 in.
triangular pitch is specified.
 Example
1- calculate the heat load:

2- Calculate the mean temperature

difference; assuming an outlet water
temperature of 110F
 Example
3- S= (110-80)/( 350-80) ,
R= (350-125)/(110-80)
F = 0.91

We estimate Uo to be about 25 Btu/hr ft2 °F.

 Example
A'o = 2.56 F1F2 F3 Ao
F1 = 1.14, noting that a 3/4 in. O.D. by 1 in
triangular pitch is specified
F2= 1.06, assuming that the shell diameter will
be in the range of 13 1/4 in. to 17 1/4 in., and two
tube passes will suffice. These assumptions
have to be checked.
F3= 1.08, correcting for the U-tube design and
that the shell diameter will be in the 13 1/4 to
21 1/4 inch range
A'o = 2.56 (1.14)( 1.06) ( 1.08 ) 1197= 4000 ft2
This area cannot be accommodated in the
specified range of shells.
 Example
Try another bigger shell size

F2 = 1.04, assuming that the shell

diameter in the range 19 1/4 to 23 1/4
F3 = 1.08, correcting for the U-tube
design and that the shell diameter
will be in the 13 1/4 to 21 1/4 inch

A'o = 2.56 (1.14)( 1.04) ( 1.08 ) 1197

= 3923 ft2
 Example
This area can be accommodated :
19 1/4 id shell by 23 ft long,
211/4 id shell 18 ft long and others
These are only that comply to the
limit of diameter taken in the
assumptions.
Since the length to diameter ratio is
within 14.3 to 10 both comply with
practice and economics and have to be
checked to other parameters.