EP427/BEP4023

Process Equipment Design

Chapter 5
Heat Transfer Equipment Design

(May - Aug 2023)

By: Asst Prof Dr Cheok Choon Yoong
[email protected]

1
CLO3: Design the storage vessel, heat exchanger and
distillation column including the vessel components.
(C5, PLO3)
Heat exchanger design:
•Basic design procedure and theory
•Overall heat transfer coefficient
•General design consideration
•STHX construction details (tube & shell)
•Mean temperature difference
•Tube side heat transfer coefficient and pressure drop
•Shell side heat transfer coefficient and pressure drop
 Heat Transfer Equipment
• The transfer of heat to and from process fluids is an essential
part of most chemical processes.

• The word “exchanger” applies to all types of equipment in

which heat is exchanged but is often used specifically to
denote equipment in which heat is exchanged between two
processes streams.
• Exchangers in which a process fluid is heated or cooled by a plant
service stream are referred to as heaters and coolers.

• If the process stream is vaporized, the exchanger is called a

vaporizer if the stream is essentially completely vaporized; a
reboiler if associated with a distillation column; and an evaporator
if used to concentrate a solution.

3
 Heat Transfer Equipment
• Process fluid is heated → Heater
• Process fluid is cooled → Cooler
• Process stream is vaporized → Vaporiser
• Vaporiser in distillation column → Reboiler
• Concentrate a solution → Evaporator
Heavy duty air cooler
• Heated by combustion gases → Fire Exchanger
http://www.sigmamart.com/industri
al-cooler.html

Direct Connect Process Heaters Boiler

http://www.chromalox.com/en/catalog/industrial-heaters-and-systems/ http://www.tetrakemika.com/?page_id=103 4
 Heat Transfer Equipment
The types of heat exchanger used in the chemical process and allied
industries are:
1. Double-pipe exchanger: the simplest type, used for cooling
and heating.
2. Shell and tube exchangers: used for all applications.
3. Plate and frame exchangers (plate heat exchangers): used for
heating and cooling.
4. Plate-fin exchangers.
5. Spiral heat exchangers.
6. Air cooled: used for coolers and condensers.
7. Direct contact: used for cooling and quenching.
8. Agitated vessels.
9. Fired heaters.

5
 Heat Transfer Equipment
Double-pipe exchanger
Double pipe heat exchangers are the simplest of all types. They are fabricated
from two pieces of pipe – one inside the other. One fluid flows through the inner
pipe while the second fluid flows through the annulus between the pipes.

Flow inside double pipe heat exchangers can be co-current or countercurrent.

Double-pipe exchanger (constructed for weld fittings)

6
Double-pipe exchanger
Hairpin Exchanger
A hairpin exchanger is formed by inserting one or more U-tubes into two pipe
sections welded to a large flanged end, which is then closed using a removable
bonnet.
Each straight section of the U-tubes acts as a double-pipe exchanger. True counter-
current flow is obtained if a single U-tube is used.

Hairpin exchangers are cheaper than shell and tube exchangers at very small
sizes and can be specified for areas from 7 m2 to 150 m2.
7
Air-Cooled Exchangers
Air-cooled exchangers consist of banks of finned tubes over which air is blown or
drawn by fans mounted below or above the tubes (forced or induced draft).

Air-cooled exchangers should be considered when cooling water is in short supply

or expensive.
They can be competitive with water-cooled units even when water is plentiful.
Frank (1978) suggests that in moderate climates air cooling will usually be the best
choice for minimum process temperatures above 65°C, and water cooling for
minimum processes temperatures below 50°C.
Between these temperatures a detailed economic analysis must be carried out to
decide the best coolant. Air-cooled exchangers are used for cooling and condensing.

Cooling water circuits require a humidity driving force to achieve cooling of the water.
In climates that often experience a combination of high temperature and high
humidity, air cooling will usually be cheaper than water cooling.
Air coolers are also often specified for revamps or additions to existing plants, so as to
avoid increasing the cooling tower load and obviate investments in the site utility
system.

8
Induced draft

Forced draft

9
Heat Transfer Equipment
Air cooled heat exchanger

10
Fired Heaters (Furnaces and Boilers)
When high temperatures and high flow rates are required, fired-heaters are used.
Fired heaters are directly heated by the products of combustion of a fuel. The
highest temperature at which steam is used for process heating is typically about
250 °C. Circulating heating oils are used up to about 330 °C, but hot oil loops
themselves require a fired heater as the primary heat source. Small vertical
cylindrical fired heaters are used for duties up to 45 MW, and larger cabin furnaces
are used for higher duties.
Typical applications of fired heaters are:
1. Process feed-stream heaters; such as the feed heaters for high-temperature
reactors and refinery crude columns (pipe still furnaces); in which up to 60
per cent of the feed may be vaporized.
2. Reboilers for columns, using relatively small size direct-fired units.
3. Direct-fired reactors; for example, the pyrolysis of dichloroethane to form
vinyl chloride.
4. Reformers for hydrogen production, giving outlet temperatures of 800–
900°C.
5. Steam boilers.
6. Heaters for hot oil circuits.
11
Fired heaters (Furnaces and Boilers)

Vertical-cylindrical, Vertical-cylindrical, Vertical-cylindrical with

all radiant helical coil convection section12
Plate Heat Exchanger
Gasketed Plate Heat Exchangers
A gasketed plate heat exchanger consists of a stack of closely spaced
thin plates clamped together in a frame. A thin gasket seals the plates
around their edges. The plates are normally between 0.5 and 3 mm
thick and the gap between them 1.5 to 5 mm. Plate surface areas
range from 0.03 to 1.5 m2, with a plate width:length ratio from 2.0 to
3.0. The size of plate heat exchangers can vary from very small, 0.03
m2, to very large, 1500 m2. The maximum flow-rate of fluid is limited
to around 2500 m3/h.

The basic layout and flow arrangement for a gasketed plate heat
exchanger is shown in Figure 5.1.
Corner ports in the plates direct the flow from plate to plate. The
plates are embossed with a pattern of ridges, which increase the
rigidity of the plate and improve the heat-transfer performance.
13
 Heat Transfer Equipment
Gasketed-plate exchanger

Figure 5.1
14
 Gasketed-plate exchanger
Advantages Disadvantages
1. Plates are attractive when material costs 1. A plate is not a good shape to
are high. resist pressure and plate heat
2. Plate heat exchangers are easier to exchangers are not suitable for
maintain. pressures greater than about
3. Low approach temps can be used, as low 30 bar, or for high differential
as 1°C, compared with 5 to 10°C for shell pressures between the two
and tube exchangers. streams
4. Plate heat exchangers are more flexible, transferring heat.
it is easy to add extra plates. 2. The selection of a suitable
5. Plate heat exchangers are more gasket is critical.
suitable for highly viscous materials. 3. The maximum operating
6. The temperature correction factor, Ft, temperature is limited to about
will normally be higher with plate heat 250°C, due to the performance
exchangers, as the flow is closer to of the
true counter-current flow. available gasket materials.
7. Fouling tends to be significantly less
in plate heat exchangers.
15
 Jacketed Vessel
The simplest way to transfer heat to a process or storage vessel is to fit an external
jacket or an internal coil. If these methods cannot provide sufficient heat-transfer
area then a stream is withdrawn from the vessel, pumped through a heat exchanger
and returned to the vessel.

16
Immersed coils heat exchanger

17
Shell & Tube Heat Exchanger

18
From MultiTherm
19
 A shell and tube exchanger consists of a bundle of tubes enclosed in
a cylindrical shell. The ends of the tubes are fitted into tube sheets,
which separate the shell-side and tube-side fluids. Baffles are
provided in the shell to direct the fluid flow and support the tubes.
The assembly of baffles and tubes is held together by support rods
and spacers.

The minimum number of tie rods

that may be installed is also
defined in the TEMA Standards
as follows:

20
 Basic Design Procedure and Theory
The general equation for heat transfer across a surface is :

(12.1)

The prime objective in the design of an exchanger is to determine the

surface area required for the specified duty (rate of heat transfer)
using the temperature differences available.

21
 The Overall Coefficient
The overall coefficient is the reciprocal of the overall resistance to heat transfer,
which is the sum of several individual resistances. For heat exchange across a
typical heat-exchanger tube the relationship between the overall coefficient and
the individual coefficients, which are the reciprocals of the individual resistances,
is given by:

(12.2)

Shell side
Tube side
Table 12.2

22
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24
25
26
27
 Shell and Tube Exchanger:
Construction Details
Shell and Tube exchanger

It’s the most commonly used type of heat-transfer equipment.

1) The configuration gives a large surface area in a small
volume.
2) Good mechanical layout: a good shape for pressure
operation.
3) Uses well-established fabrication techniques.
4) Can be constructed from a wide range of materials.
5) Easily cleaned.
6) Well-established design procedure.

28
PRINCIPAL COMPONENTS OF A SHELL-AND-TUBE HEAT EXCHANGER

29
Fixed tubesheet heat exchanger, type BEM

Disadvantages
➢ cannot be disassembled for cleaning or
inspection.
➢ If the temperature difference between the
fluids is high or the linear thermal
expansion coefficients of the tube and shell
materials are very different, when the
exchanger comes into operation,
differential expansion between shell and
tubes creates forces acting on the tube-to-
tubesheet joints that can damage the unit.
30
31
Front head types

(e) Special design for

high pressure
(1) Closure
(2) Backing ring
(3) Pass partition

32
Double pass fixed tubesheet heat exchanger, type BEM

33
 Pull through floating head heat exchanger, type BET

Removable bundle constituted of tubesheet, tubes, baffles, and

floating head.
To remove the bundle, the procedure is
1. The flanged joint of the fixed head is disassembled.
2. The removable bundle is withdrawn from the left side. During
this operation, the floating head passes through the shell. This is
why it is called a pull-through floating head. Access to the
Not fixed to the
exterior of the tubes then is possible.
shell 34
 Pull through floating head heat exchanger, type BET
Disadvantages
1. Not very suitable for single-pass heat exchangers. Because it is
necessary to install special flanges through the shell cover. The
flange a is screwed to the outlet nozzle and can be removed.
Then the packing gland is loosened, and the bundle can be pulled
through to the left. This can add considerably to the cost and adds
a potential source of leaking. Also, the advantage of free
expansion is lost.

2. The location of the floating-head flanges requires that the

tube circle diameter d1 be considerably smaller than the shell
diameter Ds.
This leaves an empty peripheral lane where the shell-
side fluid may canalize. This stream is called a bypass 3. A third problem is that the floating-
stream. head flange gasket is a hidden gasket.
Any damage to this gasket will not be
detected and may cause the higher-
pressure fluid to contaminate the other
fluid. If this cannot be tolerated
because of chemical compatibility,
toxicity, etc., other designs sometimes
are
preferred.
35
Split-ring floating-head heat exchanger, type AES

Designed to solve second problem of pull

through: the existence of a bypass region
between the shell and the tube circle.

36
Comparison between pull-through and split-ring

pull-through split-ring

37
 U-tube heat exchanger, type BEU

To solve the differential expansion

problem. Minimal used of gaskets makes
the design particularly attractive in high-
pressure service.
Limitations
1. It is not possible to clean the interior of the tubes because it is not possible to pass a cleaning rod
through them.
2. This construction cannot be used for single-pass exchangers.
3. With the exception of the outermost tubes, individual tubes cannot be replaced. Any leaking tube must be
plugged.
4. In very large diameters, support of the tubes is difficult. (The U-tube bundle becomes
38
susceptible to vibration hazards.)
 Outside-packed floating-head heat exchanger, type AEP

The floating head can move axially, and the shell side is sealed by a
packing (26) that is compressed by means of a packing gland (28).
The floating tubesheet skirt (29) diameter is smaller than that of the
shell. It thus can be removed to the left, passing through the shell,
when the unit is disassembled. The slip-on backing flange (30) is a
loose flange that can be removed to the right after removal of the
split shear ring (31).

Design pressure must be lower than 40 bar, and design

temperature must be lower than 590 K. 39
Impingement Plate 13

40
 Externally sealed floating-tubesheet heat exchanger, type BEW

In this design, an outside-packed lantern ring provides the seal

between the shell-side and tube-side fluids as the tubesheet moves
back and forth with expansion and contraction of tubes. Weep holes in
thering vent any seepage to the atmosphere.

Advantages:
No bypass area and maintenance is relatively simple
Disadvantages:
Limited use for water, steam, air, lubricating oil, or similar services in
41
conditions less severe than 2106 N/m2 and 423 K.
Advantages and disadvantages of the different types of heat exchangers

42
 Fluid Allocation: Shell or Tubes
Factors determine the allocation of the fluid streams to the
shell or tubes:
Corrosion
The more corrosive fluid should be allocated to the tube side. This will reduce the
cost of expensive alloy or clad components.
Fouling
The fluid that has the greatest tendency to foul the heat-transfer surfaces should
be placed in the tubes. This gives better control over the design fluid velocity, and
the higher allowable velocity in the tubes will reduce fouling. Also, the tubes will be
easier to clean.
Fluid temperatures
If the temperatures are high enough to require the use of special alloys, placing the
higher temperature fluid in the tubes will reduce the overall cost. At moderate
temperatures, placing the hotter fluid in the tubes will reduce the shell surface
temperatures, and hence the need for lagging to reduce heat loss, or for safety
reasons.
43
 Fluid Allocation: Shell or Tubes
Operating pressures
The higher pressure stream should be allocated to the tube side. High-pressure tubes
will be cheaper than a high-pressure shell. The required tube thickness is less for high
internal pressure than high external pressure and an expensive high-pressure shell
may be avoided.
Pressure drop
For the same pressure drop, higher heat-transfer coefficients will be obtained on
the tube side than the shell side, and fluid with the lowest allowable pressure drop
should be allocated to the tube side.
Viscosity
Generally, a higher heat-transfer coefficient will be obtained by allocating the
more viscous material to the shell side, providing the flow is turbulent. The critical
Reynolds number for turbulent flow in the shell is in the region of 200. If turbulent
flow cannot be achieved in the shell, it is better to place the fluid in the tubes, as
the tube-side heat-transfer coefficient can be predicted with more certainty.

Stream flow rates

Allocating the fluids with the lowest flow rate to the shell side will normally give the
44
most economical design.
 Tubes - dimensions

Tubular Exchanger Manufactures Association (TEMA)

Diameter:
Length: ≤ 𝟔 𝒎 45
46
 Tubes - Arrangements
Triangular and rotated square patterns give higher heat-transfer
rates, but higher pressure drop than the square pattern. The
recommended tube pitch is 1.25 times the tube outside
diameter.

47
FIGURE 12.12
Shell-bundle
clearance

48
 Tube-sheet layout (tube count)
The bundle diameter will depend not only on the number of tubes but also on
the number of tube passes, as spaces must be left in the pattern of tubes on the
tube sheet to accommodate the pass partition plates.
An estimate of the bundle diameter 𝐷𝑏 can be obtained from equation

The constants for use in this equation, for triangular and square patterns, are
given in Table 12.4.
49
50
 Shells - Thickness
For pressure applications the shell thickness would be sized according
to the pressure vessel design standard.
Minimum shell thickness (mm)

51
 Figure 12.12. Shell types (pass arrangements)

(a) One-pass shell (E shell) (d) Two-pass shell with

longitudinal baffle (F shell)

(b) Split flow (G shell) (e) Double split flow (H shell)

(c) Divided flow (J shell) 52

One method of sealing the longitudinal shell-side baffle
Heat exchanger with
longitudinal baffle

53
Shells - Baffles site view Cross sectional view

A close baffle
Segmental
spacing will give
higher heat-transfer
coefficients, but at
the expense of Segmental and
higher pressure strip
drop.
The optimum
spacing will usually Disc and
be between 0.3 to doughnut
0.5 times the shell
diameter.
Orifice

Figure 12.13. Types of baffle used in shell and tube heat exchangers
54
 Disc and
doughnut
baffles

55
 Baffle Spacing
✓ Reduce baffle spacing - increase heat transfer coefficient.
However, there is a lower limit for the baffle spacing, set by the
TEMA Standards, of one-fifth the shell diameter and never less
than 2 in (51 mm).

✓ Spacing higher than the shell diameter is not common.

✓ If higher spacing is employed, the effect may be similar to that
seen in Figure below with poor heat transfer coefficients

Large cut or small spacing 56

 Effect of Baffling

✓ The most common baffle cut is about 25 percent of the diameter - the height of
the baffle window is 25 percent of the shell diameter.

57
 Mean Temperature Difference
The well-known “logarithmic mean” temperature difference is
only applicable to sensible heat transfer in true co-current or
counter-current flow, For counter-current flow, it is given:

∆𝑻𝟏 − ∆𝑻𝟐 Figure 12.19

∆𝑻𝒍𝒎 = Figure 12.20
∆𝑻𝟏
𝒍𝒏( ) Figure 12.21
∆𝑻𝟐
Figure 12.22

𝑇1 = 𝐼𝑛𝑙𝑒𝑡 𝑓𝑙𝑢𝑖𝑑 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑡𝑜 𝑠ℎ𝑒𝑙𝑙 𝑠𝑖𝑑𝑒

𝑇2 = 𝑂𝑢𝑡𝑙𝑒𝑡 𝑓𝑙𝑢𝑖𝑑 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑓𝑟𝑜𝑚 𝑠ℎ𝑒𝑙𝑙 𝑠𝑖𝑑𝑒
𝑡1 = 𝐼𝑛𝑙𝑒𝑡 𝑓𝑙𝑢𝑖𝑑 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑡𝑜 𝑡𝑢𝑏𝑒 𝑠𝑖𝑑𝑒
58
𝑡2 = 𝑂𝑢𝑡𝑙𝑒𝑡 𝑓𝑙𝑢𝑖𝑑 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑓𝑟𝑜𝑚 𝑡𝑢𝑏𝑒 𝑠𝑖𝑑𝑒
∆𝑇2 ∆𝑇1

∆𝑇1
∆𝑇2
Figure 12.19 Figure 12.20

∆𝑇1 ∆𝑇2

∆𝑇2 ∆𝑇1

Figure 12.21 Figure 12.22

59
 Mean Temperature Difference

(a) Counter-current flow (b) one shell pass and two tube passes
(1 : 2 exchanger)

Figure 12.18. Temperature profiles 60

 True Temperature Difference
The usual practice in the design of shell and tube exchanger is
to estimate the “true temperature difference” from the logarithmic
mean temperature by applying a correction factor to allow for the
departure from true counter-current flow:

where

61
 Correction Factor
The correction factor is a function of the shell and tube fluid
temperatures, and the number of tube and shell passes. It is
normally correlated as a function of two dimensionless
temperature ratios:

R is equal to the shell-side fluid flow-rate times the fluid mean specific
heat; divided by the tube-side fluid flow-rate times the tube-side fluid
specific heat.
S is a measure of the temperature efficiency of the exchanger

62
 Correction Factor
For a 1 shell : 2 tube pass exchanger, the correction factor is
given by:

63
64
Pass partitions One shell Pass partitions
Front Rear

Two passes

65
Pass partitions Pass partitions
Front Rear

66
67
68
69
 Tube Side Heat Transfer Coefficient
Heat transfer data for turbulent flow inside conduits of uniform
cross-section are usually correlated by an equation of the form:

For turbulent flow

70
 Tube Side Heat Transfer Coefficient
The index for the Reynolds number, a, is generally taken as 0.8. That for
the Prandtl number, b, can range from 0.3 for cooling to 0.4 for heating.
The index for the viscosity factor, c, is normally taken as 0.14 for flow in
tubes, from the work of Sieder and Tate (1936), but some workers report
higher values. A general equation that can be used for exchanger design is:

71
 Tube Side Heat Transfer Coefficient
To estimate the film heat-transfer coefficient:

For lamilar flow (Re ≤ 2000)

Where L is the length of the tube in metres

Heat transfer factor, 𝒋𝒉

Figure 12.23. Tube-side heat-transfer factor 73

 Tube Side Heat Transfer Coefficient
Viscosity correction factor
The viscosity correction factor will normally only be significant for viscous
liquids.

Coefficients for water

74
 Tube Side Pressure Drop
For isothermal flow in pipes:

The flow in a heat exchanger will clearly not be isothermal, and

this is allowed for by including an empirical correction factor to
account for the change in physical properties with temperature.
Normally only the change in viscosity is considered:

75
5. Heat Transfer Equipment Design

Figure 12.24. Tube-side friction factors

76
 Shell Side Heat Transfer and Pressure Drop
Flow pattern
This is used to optimize overall design of shell and tube
heat exchanger.
There are five main streams and two of it is used to optimize the
design:
Stream A is the tube-to-baffle leakage stream. The fluid flowing through the
clearance between the tube outside diameter and the tube hole in the baffle.

Stream B is the actual cross-flow stream

Stream C is the bundle-to-shell bypass stream. The fluid flowing in the clearance
area between the outer tubes in the bundle (bundle diameter) and the shell.

Stream E is the baffle-to-shell leakage stream. The fluid flowing through the
clearance between the edge of a baffle and the shell wall.
Stream F is the pass-partition stream. The fluid flowing through the gap in the
tube arrangement due to the pass partition plates. Where the gap is vertical it
will provide a low-pressure drop path for fluid flow.
77
Flow pattern

Figure 12.26. Shell-side leakage and by-pass paths 78

 Design Method – Kern’s Method

This method was based on experimental work on commercial

exchangers with standard tolerance and will give a reasonably
satisfactory prediction of the heat-transfer coefficient for
standard design.

The procedure for calculating the shell-side heat-transfer

coefficient and pressure drop for a single shell pass exchanger
is given below:

79
 Design Procedure
Calculate the area for cross-flow As for the hypothetical row of
tubes at the shell equator, given by:

The term (pt – do) / pt is the ratio Figure 12.28. Equivalent diameter, cross-
of the clearance between tubes sectional areas and wetted perimeters
and the total distance between
tube centres.

80
 Design Procedure
Calculate the shell-side mass velocity Gs and the linear
velocity us;

81
 Design Procedure
Calculate the shell-side equivalent diameter (hydraulic diameter),
Figure 12.28. for a square pitch arrangement:

For an equilateral triangular pitch arrangement:

82
 Design Procedure
Calculate the shell-side Reynolds number, given by:

For the calculated Reynolds number, read the value of jh from

Figure 12.29 for the selected baffle cut and tube arrangement,
and calculate the shell-side heat transfer coefficient hs from:

𝐶𝑝 ∙ 𝜇
𝑃𝑟 =
𝑘𝑓
The tube wall temperature (𝑡𝑤 ) can be estimated using the
method given for the tube-side: (only for viscous liquids)

83
Figure 12.29. Shell-side heat-transfer factor (𝑗ℎ ), segmental baffles 84
 Calculate tube side coefficient:

Either

Figure 12.23. 𝜌 ∙ 𝑢 𝑡 ∙ 𝑑𝑖 𝐶𝑝 ∙ 𝜇
Tube-side heat- 𝑅𝑒 = 𝑃𝑟 =
transfer factor
𝜇 𝑘𝑓
85
Figure 12.23. Tube-side heat-transfer factor

86
 Substitute all the coefficients calculated into this
equation to obtain 𝑼𝟎 :

(12.2)

If the 𝑼𝟎 calculated value differs significantly from

the estimated value, substitute the calculated for
the estimated value and return to step 6.

87
 Design Procedure
For the calculated shell-side Reynolds number, read the friction
factor from Figure 12.30 and calculate the shell-side pressure
drop from:

The term (𝐿Τ𝑙𝐵 ) is the number of times the flow crosses the tube
bundle = (𝑁𝑏 + 1), where 𝑁𝑏 is the number of baffles.

88
Figure 12.30. Shell-side friction factor (𝑗𝑓 ), segmental baffles
89
 Shell Nozzle – Pressure Drop

The pressure loss in the shell nozzles will normally only be

significant with gases. The nozzle pressure drop can be taken as
equivalent to 1.5 velocity heads for the inlet and 0.5 for the
outlet, based on the nozzle area of the free area between the
tubes in the row immediately adjacent to the nozzle, whichever
is the least.

90
Design procedure for shell and tube heat exchanger

91
 Algorithm of Design Procedure

Heat Load = mCpΔT

Identify T1, T2, t1

and t2 for ΔTm. The value of U0 can
Obtain F from be obtained from
Figure. Figure 12.1, within
the given range.

92
Algorithm of Design Procedure

Calculate the number

of tubes.

Shell diameter
= Bundle diameter +
clearance

(Water)

(all type
of fluids)93
 Algorithm of Design Procedure
Baffle spacing range from 0.2 to 1.0 shell diameter.
Optimum spacing normally from 30% to 50% of shell
diameter.

Repeat Step 4 – Step 11 !!

94
Algorithm of Design Procedure
Shell side pressure drop can be
reduced by increasing baffle pitch.

Alternative
materials with
lower cost?
95
 Example 12-1
Design an exchanger to sub-cool condensate from a
methanol condenser from 95°C to 40°C. Flow-rate of
methanol is 100,000 kg/h. Brackish water will be used as
the coolant, with a temperature rise from 25°C to 40°C.

Solution: This example illustrates Kern’s method.

1 Fluid Allocation: Shell or Tubes
Tube – side: Brackish water (brackish water is more
Shell – side: Methanol corrosive than methanol)

2 Select type of shell and tube exchanger and define

the temperatures
Figure 12.19, Figure 12.20, Figure 12.21, Figure 12.22
96
 40 °C

25 °C
40 °C
t1 = 25°C T1 = 95°C
t2 = 40°C T2 = 40°C
95 °C
97
3 Collect the fluid physical properties
Shell-side Tube-side
Methanol Brackish water
Inlet temperature (℃) 95 25
Outlet temperature (℃) 40 40
Mean temperature (℃) 67.5 (≈ 68) 32.5 (≈ 33)
Density, ρ (kg/m3) 750 995
Thermal conductivity, 𝑘𝑓 (W/m.°C) 0.19 0.59
Viscosity, 𝜇 (kg/m.s) 0.34 × 10−3 0.8 × 10−3
Specific heat capacity, 𝐶𝑝 (kJ/kg.°C) 2.84 4.20
Fouling factor (W/m2.°C) 5000 3000

98
 Calculate log mean temperature ∆𝑻𝒍𝒎 , temperature correction
4 factor (𝑭𝒕 ) and true temperature difference ∆𝑻𝒎

Log mean temperature (∆𝑻𝒍𝒎 )

∆𝑇1 = 95 − 40 = 55℃
∆𝑇1 − ∆𝑇2 ∆𝑇2 = 40 − 25 = 15℃
∆𝑇𝑙𝑚 = 55 − 15
∆𝑇1 ∆𝑇𝑙𝑚 = = 31℃
𝑙𝑛( ) 55
∆𝑇2 ln( )
15
Temperature correction factor (𝑭𝒕 )

99
 𝑭𝒕
0.85

True temperature difference

100
If you really too free, you may use this equation to calculate:

101
5 Select a trial value for the overall coefficient, U.

From Table 12.1:

Sub-cool condensate from a methanol condenser

Take the middle value, U = 600 W/m2°C

102
From Figure 12.1

U = 600 W/m2°C

103
 6 Calculate the provision area and number of tubes required
𝑯𝒆𝒂𝒕 𝒍𝒐𝒂𝒅 𝒇𝒓𝒐𝒎 𝑴𝒆𝒕𝒉𝒂𝒏𝒐𝒍
𝟏𝟎𝟎, 𝟎𝟎𝟎 𝒌𝒈 𝟏𝒉 𝟐. 𝟖𝟒 𝒌𝑱
= × × × 𝟗𝟓 − 𝟒𝟎 ℃
𝒉 𝟑𝟔𝟎𝟎 𝒔 𝒌𝒈 ∙ ℃
Provision
= 𝟒𝟑𝟑𝟖. 𝟗 𝒌𝑾 ≈ 𝟒𝟑𝟒𝟎 𝒌𝑾
area
U = 600 W/m2°C (Capture either from Table 12.1 or Figure 12.1)

𝟒𝟑𝟒𝟎 × 𝟏𝟎𝟑
𝑨= = 𝟐𝟕𝟖 𝒎𝟐
𝟐𝟔 × 𝟔𝟎𝟎

Choose 20 mm o.d., 16 mm i.d., 4.88-m-long tubes (34 in. x 16 ft)

[Table 12.3], cupro-nickel
Allowing 5 cm for tube-sheet thickness, take 𝐿 = 4.83 𝑚
Tube
number The surface area per tube = 𝜋𝑑𝑜 𝐿
= 𝜋(20 × 10−3 )(4.83)
= 0.303 𝑚2
𝑃𝑟𝑜𝑣𝑖𝑠𝑜𝑛 𝑎𝑟𝑒𝑎 278 𝑚2
𝑵𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝒕𝒖𝒃𝒆𝒔, 𝑵𝒕 = = = 918
𝑠𝑢𝑟𝑓𝑎𝑐𝑒 𝑎𝑟𝑒𝑎 𝑝𝑒𝑟 𝑡𝑢𝑏𝑒 0.303 𝑚2
104
7 Tube-side coefficient

Heat load from methanol = heat absorb by brackish water:

4340
𝐵𝑟𝑎𝑐𝑘𝑖𝑠ℎ 𝑤𝑎𝑡𝑒𝑟 𝑓𝑙𝑜𝑤, 𝑚ሶ 𝑤𝑎𝑡𝑒𝑟 = = 68.9 𝑘𝑔/𝑠
4.2(40 − 25)

Tube passes

Water linear velocity, 𝑢𝑡

105
The coefficient can also be calculated using this equation:

𝝆𝒖𝒕 𝒅𝒊
𝑹𝒆 =
𝝁

Heat transfer factor, 𝑗ℎ

(Fig. 12.23)
𝑗ℎ = 3.9 x10-3

106
3.9 x 10-3

107
8 Calculate shell diameter
As the shell-side fluid is relatively clean use 1.25 triangular pitch

108
Use a split-ring floating head type.
From Figure 12.12, bundle diametrical clearance = 68 mm,
Shell diameter, Ds = 826 + 68 = 894 mm

68 mm

109
8 Shell-side coefficient

Baffle spacing normally is

Choose baffle spacing, 𝐼𝐵
20%-50% of shell diameter

Tube pitch, 𝑃𝑡

110
 Shell-side Tube-side
Methanol Brackish water
Inlet temperature (℃) 95 25
Outlet temperature (℃) 40 40
Mean temperature (℃) 67.5 (≈ 68) 32.5 (≈ 33)
Density, ρ (kg/m3) 750 995
Thermal conductivity, 𝑘𝑓 (W/m.°C) 0.19 0.59
Viscosity, 𝜇 (kg/m.s) 0.34 × 10−3 0.8 × 10−3
Specific heat capacity, 𝐶𝑝 (kJ/kg.°C) 2.84 4.20
Fouling factor (m2.°C/W) 0.0002 0.0002

Choose 25
percent baffle
cut, from Figure
12.29

𝒋𝒉 = 𝟑. 𝟑 × 𝟏𝟎−𝟑
111
 5. Heat Transfer Equipment Design

𝟑. 𝟑 × 𝟏𝟎−𝟑 3.67 x 104

112
Without the viscosity correction term:

Estimate wall temperature

which shows that the correction for

a low-viscosity fluid is not
significant.
113
9 Calculate the overall coefficient
Thermal conductivity of cupro-nickel alloys = 50W/m°C.

114
Pressure Drop – Tube side

Figure 12.24

neglected if the difference is small

Therefore,

low, could consider increasing the

number of tube passes. 115
5. Heat Transfer Equipment Design

𝑅𝑒 = 1.49 × 104

Figure 12.24. Tube-side friction factors

116
 Heat Transfer Equipment Design
Pressure Drop – Shell side

Figure 12.30

neglected if the difference is small

Therefore,

could be reduced by increasing the baffle pitch.

Doubling the pitch halves the shell-side
velocity, which reduces the pressure drop by a
2
factor of approximately (1Τ2)
117
 𝑅𝑒 = 3.67 × 104

Figure 12.30. Shell-side friction factor (𝑗𝑓 ), segmental baffles

118
• http://www.cheresources.com/content/article
s/heat-transfer/design-considerations-for-
shell-and-tube-heat-exchangers
• What are the allowable pressure drops and
velocities in the exchanger?
Pressure drops are very important in exchanger design (especially for gases). As
the pressure drops, so does viscosity and the fluids ability to transfer heat.
Therefore, the pressure drop and velocities must be limited. The velocity is directly
proportional to the heat transfer coefficient which is motivation to keep it high,
while erosion and material limits are motivation to keep the velocity low. Typical
liquid velocities are 1-3 m/s (3-10 ft/s). Typical gas velocities are 15-30 m/s (50-100
ft/s). Typical pressure drops are 30-60 kPa (5-8 psi) on the tubeside and 20-30 kPa
(3-5 psi) on the shellside.
119
 In order to satisfy the amount of heat to be
transferred, there are some considerations:
• Heat difference must be significant
• Process fluid & service fluid
• Loss of energy
• Design data: inlet outlet temp, flow rate o f both
streams, pressure (allowable pressure drop), physical
prop.,……..
• Material of construction
• Latest technology
120
• What is the main objective in the design of a
heat exchanger?
• The physical layout of the exchanger cannot
be determined until the heat transfer area is
known, an exchanger design is a trial and error
procedure. Agree or not? Explain your answer.

121
In an orange juice processing plant, the processes involved are juice extraction, juice
bitterness removal, treatment of the pulp and aseptic filling, pasteurization and cleaning
process, and the juice mixing process. The heat exchanger to be used in the process must be
able to maximize the quality and the taste of the juice. There is the requirement to heat 10000
kg/h of orange juice (density = 1040 kg/m3 and viscosity = 0.0003 N.s/m2) from 10 oC to 85 oC.
The specific heat of the orange juice is 3.73 kJ.kg-1oC-1 with a thermal conductivity of 0.5  10-3
W.m-1oC-1. Steam at 3 bar (133 oC) is available for the pasteurization to reduce the microbe
count and prepare the juice for packaging.
An existing heat exchanger with the specification as below:
Shell inside diameter 340 mm
Baffle 25% cut with baffle spacing of 106 mm
Tubes 15 mm inside diameter with 19 mm outside diameter
Tubes 4094 mm long with tube pitch 24 mm in triangular pitch arrangement
Numbers of tubes 124 and arranged in a single pass
Tube bundle diameter 272 mm
Material of construction, stainless steel (thermal conductivity = 45 W.m-1oC-1)
Clearance of tube-to-baffle as 0.8 mm and baffle-to-shell as 4.8 mm

You as process design engineer to check on the suitability of the existing heat exchanger. You
have decided to put the juice to flow in the tube side. You may refer to the design procedure
for shell and tube heat exchanger in Appendix B. Please state clearly the appropriate
assumption if any. Conclude your design calculation findings with justification and
recommendation.
You as a design engineer given a project to design a one shell pass and two tubes pass fixed-
tube sheet heat exchanger to heat up 112800 kg/hr of air by using 35000 kg/hr of hot steam.
Let the hot steam to flow in the tube side. The tube length to be 5 m with 16 mm inside
diameter and 20 mm outer diameter of the tube. The tube material is plain carbon steel
(thermal conductivity = 55 W/m.K) with triangular pitch arrangement. Table Q1 shows the
properties of air and hot steam. Please state clearly your assumption and justification if any.
Your preliminary design calculation and design document must include:

(a) Total heat transfer area (7 marks)

(b) Bundle and shell diameter (4 marks)
(c) Heat transfer coefficient for the tube side (9 marks)
(d) Heat transfer coefficient for the shell side (9 marks)
(e) Overall heat transfer coefficient with the lowest value of fouling factors for both streams
(2 marks)
(f) Pressure drop calculation for the tube and shell side (4 marks)
(g) The conclusion of your design based on allowable pressure drop (3 marks)
(h) Propose the suitable closures for the heat exchanger with appropriate justification (2 marks)
(i) Minimum wall thickness for the shell part if the shell side of the heat exchanger operate at
3.5 bar (3 marks)
(j) Discuss the design stage in this design project in order to achieve the optimum design of heat
exchanger (7 marks)
123
Table Q1: Properties of air and hot steam

Component and properties Inlet Mean Outlet

Air
Temperature, T (K) 384.1 418.55 453
Heat capacity, Cp (kJ/kgK) 1.011 1.0165 1.022
Density, ρ (kg/m3) 0.919 0.849 0.779
Viscosity, μ (Pa.s) 24.2610-6 24.2610-6 24.2610-6
Thermal conductivity, (W.m.K) 0.032 0.0347 0.0372

Hot steam
Temperature, T (K) 523 488.5 454
Heat capacity, Cp (kJ/kgK) 4.008 3.369 2.73
Density, ρ (kg/m3) 19.91 12.715 5.25
Viscosity, μ (Pa.s) 1.7510-5 1.62510-5 1.510-5
Thermal conductivity, (W.m.K) 0.051 0.0438 0.0366
124
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