Heat Transfer

Shell and Tube Heat Exchanger

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Figure: Diagram of a typical (Fixed Tubesheet) shell and
tube heat exchanger.

1. Shell and shell side nozzles

2. Tube sheets
3. Tube side channel and nozzles
4. Channel covers
5. Baffles
6. Baffle spacers 2
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Fixed Tube Design

• Simplest and cheapest type.

• Tube bundle cannot be removed for cleaning.
• Cannot be used at very high temperatures
Floating head Design

• Suitable for higher temperature differentials.

• Bundles can be removed and cleaned. Suitable for fouling
liquids.
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Design of Shell and tube exchagner

• KERN’S Method
• BELL’S Method

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 Heat exchanger Tube - Selection
• Birmingham Wire Gauge (BWG).
• Available in a number of different wall thickness. TABLE-10
• Tube diameters in the range of 5/8 to 2 in.
• Most commonly used ¾ to 1 in diameter tubes.
• Small diameter tubes should be preferred, since it gives compact
and cheap exchangers.
• Large tubes for heavily fouling fluids
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 TUBE PITCH
• The shortest distance between two adjacent tubes is called
clearance.
• Tube pitch (PT) is the shortest centre to centre distance between
two tubes.

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 TUBE PITCH

Most commonly used tube pitches are:

• Square layout:
 I in sq pitch and ¾ in Tube OD
 1¼ sq pitch and 1 in Tube OD
• Triangular layout:
 15/16 in triangular pitch and ¾ in Tube OD

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 Shell Fabrication
• Shells are fabricated from steel pipes with nominal IPS diamters
12 to 24 in.
• Shell should be close fit to reduce bypassing
Baffles
• Baffles are used to support the tube bundles and to direct the
shell side fluid.
• The baffle spacing is usually not greater than a distance equal to
the inside dia of the shell and closer than a distance equal to the
one fifth the inside dia of the shell 11
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 Shell side mass velocity
• Area for cross flow will be calculated for the hypothetical row of
tubes in the shell centre.

Where,
ID is shell inside dia, is the clearance between two tubes, B is
baffle spacing, PT is the tube pitch
Ws
• Shell side mass velocity Gs 
As
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 Shell side Equivalent dia

For square pitch

For Triangular pitch

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• Relative to the shell fluid, one tube pass is
in counter flow and the other in parallel
flow.
• LMTD has different values for two
different flow patterns.
• It is necessary to develop a new equation
for calculation of the effective or true
temp difference. 15
 Tm  Ft Tlm
ΔTm is the true temperature difference
Ft is the correction factor
Ft is related to two dimensionless ratios:

(T1  T2 ) (t 2  t1 )
R S
(t 2  t1 ) (T1  t1 )

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Temp Correction Factor, Ft

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 Shell side Pressure drop
• Proportional to the number of times the fluid crosses the bundle
b/w baffles.
• It is also proportional to the distance across the bundle each time
it is crossed.

• If the tube length is 16 ft and the baffles are spaced 18 in apart,

there will be 11 crosses or 10 baffles.
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 Shell side Pressure drop
• Pressure drop of fluid being heated or cooled and including
entrance and exit losses is:

• The equivalent diameter used for calculating the pressure drop is

same as for heat transfer. 20
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 Tube side Pressure drop

• The changes of the direction introduces an additional pressure

drop called the return loss and accounted for by allowing four
velocity heads per pass.

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 Exchangers using Water
• Water is corrosive to steel, particularly when the tube wall temperature
is high and dissolved air is present.
• Since shells are usually fabricated of steel, water is best handled in the
tubes.
• As a standard practice, the use of cooling water at velocities less than 3
ft/sec should be avoided.
• Whenever high coefficients exist on both sides of the exchanger, the use
of an unnecessarily large fouling factor should be avoided.

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Flow arrangement for increased heat recovery

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 Thank You
for
Your Attention
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