Module 5

Heat Exchanger Design

Part 1 of 3
 1. Introduction
• Heat is transferred to and from process
streams using other process streams or heat
transfer media.
• Heat Sink- heat is transferred to them from (a)
process stream(s).
• Heat Source- heat is extracted from them to (a)
process stream(s).
• One-Sided and Two-sided heat exchanger
models in simulation programs.
• Temperature is the driving force for heat
transfer.
 2.1 Types of Heat Exchangers
The principle heat exchanger types used in the chemical process
and allied industries are listed below:

 Double-pipe exchanger: the simplest type, used for cooling and

heating
 Shell and tube exchangers: used for all applications
 Plate and frame exchangers (plate heat exchangers): used for
heating and cooling
 Plate-fin exchangers
 Spiral heat exchangers
 Air-cooled: coolers and condensers
 Direct contact: cooling and quenching
 Agitated vessels
 Fired heaters
 2.2 Classification based on service
• Single Phase: both shell-side and tube side
fluids are in the same phase
• Condensing: one side condensing and the
other single-phase
• Vaporizing: one side vaporizing and the other
side single-phase
• Condensing/Vaporizing: One side condensing
and the other side vaporizing
 Nomenclature
• Heat Exchanger: Both sides single and process streams
• Cooler: The process fluid is in one stream. The other
stream has cooling water or air
• Heater: The process fluid is in one stream. The other
stream has a hot utility
• Condenser: One stream has a condensing vapour and the
other stream has cooling water or air
• Chiller: A process fluid is condensed at sub- atmospheric
temperature in one stream. The other stream has a boiling
refrigerant or process fluid
• Reboiler: One stream has a distillation bottoms stream and
the other has a hot utility (steam or oil) or a process
stream
 2.3 Basic Design Procedure and
Theory
The general equation for heat transfer across a surface is:

Q  UATm (1)

Where:

Q: Heat transfer rate (W)

U: Overall heat transfer coefficient (W/m2.K)

A: Heat transfer area (m2)

ΔTm: Mean (average) temperature difference,

the temperature driving force (K)
• Depending on the extent of fouling of the heat
exchanger and the conditions of the streams
passing through the exchanger, the overall heat
transfer coefficient (U) can be computed from
correlations.
• The driving force depends on the following factors:
– Temperature of the entering and exiting streams
– The variation of enthalpy with temperature and
pressure of each streams
– The stream flow pattern
For heat exchange across a typical heat exchanger tube,
the relationship between the overall heat transfer
coefficient and the individual coefficients (which are the
reciprocals of the individual resistances) is given by:
 do 
d o ln  
1 1 1  di   do  1  do  1 (2)
  
U o ho hod 2k w d i hid d i hi

Where:
Uo = Overall coefficient based on the outside area of the tube (W/m2.K)
ho = Outside fluid film coefficient (W/m2.K)
hi = Inside fluid film coefficient (W/m2.K)
hod = Outside dirt coefficient (fouling factor) (W/m2.K)
hid = Inside dirt coefficient (W/m2.K)
kw = Thermal conductivity of the tube wall material (W/m2.K)
di = Tube inside diameter (m)
do = Tube outside diameter (m)
Steps in a typical heat exchanger design

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

2. Collect the required fluid physical properties: density, viscosity, thermal
conductivity.
3. Decide on the exchanger type to be used.
4. Select a trial value for the overall coefficient (U).
5. Calculate the mean temperature difference (ΔTm).
6. Calculate the area required from equation (1).
7. Decide the exchanger layout.
8. Calculate the individual coefficients (ho and hi).
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.
2.4 Overall heat transfer coefficient
Typical overall coefficients: Refer to C&R Volume 6, page
637 and 638

Refer to Chapter 18, pages 488-489 of the

recommended textbook

These values can be used for the preliminary sizing

of equipment for process evaluation, and as trial
values for starting a detailed thermal design. More
values can be found in Perry.
 Typical heat transfer coefficients for
shell and tube exchangers
Hot fluid Cold fluid U (W/m2.K)
Water Water 800-1500
Heat Exchange
Gases Gases 10-50
Water Brine 600-1200
Coolers Gases Water 20-300
Gases Brine 15-250
Steam Water 1500-4000
Heaters Steam Gases 30-300
Flue Gases Steam 30-10
 2.5 Fouling (dirt) factors
• Fouling factors are usually quoted as heat-transfer
resistances, rather than coefficients. They are difficult to
predict and are usually based on past experiences.
• Over time, dirt deposits on the shell and tube surfaces
reduce the overall heat transfer coefficient of the heat
exchanger.
• Oversize an exchanger to allow for the decreased
performance caused by fouling during operation
• Typical values for the fouling coefficients and factors for
common process and service fluids are given in Table
12.2 (page 640, C&R, volume 6 ). These values are for
shell and tube exchangers with plain (not finned) tubes.
 2.6 Construction details for shell and
tube exchangers
• Proper configuration enables a large surface area in a
small volume.
• Good mechanical layout: a good shape for pressure
operation.
• Uses well-established fabrication techniques.
• Can be constructed from a wide range of techniques.
• Easily cleaned.
• Well-established design procedure.
• C&R, volume 6, pages 640 – 654.
 2.7 Heat-exchanger standards and
codes
The TEMA standards covers three classes of
exchangers:
• Class R: covers exchangers for the generally severe
duties of the petroleum and related industries.
• Class C: covers exchangers for moderate duties in
commercial and general process applications.
• Class B: covers exchangers for use in the chemical
process industries.
The British and American standards indicate the details
of the mechanical design features, fabrication, material
of construction and testing of shell and tube
exchangers.
The standards indicate:
- The preferred shell and tube dimensions.
- The design and manufacturing tolerances.
- Corrosion allowances.
- The recommended design stresses for materials of
construction.
The shell of an exchanger is a pressure vessel and will be
designed in accordance with the appropriate national
pressure vessel code or standard.