Shell-and-Tube Heat Exchangers

The shell and tube exchanger is by far the most commonly used type of heat-transfer
equipment used in the chemical and allied industries. The advantages of this type
are:
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 procedures.

Essentially, 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, Figure below;
• Exchanger types
• The principal types of shell and tube exchanger are shown in Figures below,
• Part number
• 1. Shell
• 2. Shell cover
• 3. Floating-head cover
• 4. Floating-tube plate
• 5. Clamp ring
• 6. Fixed-tube sheet (tube plate)
• 7. Channel (end-box or header)
• 8. Channel cover
• 9. Branch (nozzle)
• 10. Tie rod and spacer
• 21. Floating-head gland (packed gland)
• 22. Floating-head gland ring
• 23. Vent connection
• 24. Drain connection
• 25. Test connection
• 26. Expansion bellows
• 27. Lifting ring
Fixed-tube plate (based on figures from BS 3274: 1960)
U-tube (based on figures from BS 3274: 1960)
Internal floating head without clamp ring (based on figures from BS 3274: 1960)
External floating head, packed gland (based on figures from BS 3274: 1960)
Kettle reboiler with U-tube bundle (based on figures from BS 3274: 1960)
• Tube arrangements
The tubes in an exchanger are usually arranged in an equilateral triangular,
square, or rotated square pattern; see Figure below.
The triangular and rotated square patterns give higher heat-transfer rates, but at
the expense of a higher pressure drop than the square pattern. A square, or
rotated square arrangement, is used for heavily fouling fluids, where it is
necessary to mechanically clean the outside of the tubes. The recommended tube
pitch (distance between tube centers) is 1.25 times the tube outside diameter; and
this will normally be used unless process requirements dictate otherwise. Where
a square pattern is used for ease of cleaning, the recommended minimum
clearance between the tubes is 0.25 in. (6.4 mm).
 Tube layouts

pitch
Triangular 30o Rotated triangular 60o Square 90o Rotated square 45o
• Tube-side passes
The fluid in the tube is usually directed to flow back and forth in
a number of "passes“ through groups of tubes arranged in parallel,
to increase the length of the flow path. The number of passes
is selected to give the required tube-side design velocity.
The arrangement of the pass partitions for 2, 4 and 6 tube passes
are shown in Figure below;
Tube arrangements, showing pass-partitions in headers
Shell-to-bundle clearance (on diameter)
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 below, which is an empirical equation
based on standard tube layouts. The constants used in this
equation, for triangular and square patterns, is given in Table
1
below;
 N t  n1
Db = d o  
where  K1 
Nt = number of tubes,
Db = bundle diameter, mm,
do = tube outside diameter, mm.
Constants for use in equation above
Baffles
Baffles are used in the shell to direct the fluid stream across the
tubes, to increase the fluid velocity and so improve the rate of heat
transfer. The most commonly used type of baffle is the a single
segmental baffle shown in Figures below. The minimum thickness
to be used for baffles and support plates are given in the standards.
The baffle spacing's used range from 0.2 to 1.0 shell diameters.
A close baffle spacing will give higher heat transfer coefficients
but at the expense of higher pressure drop. The optimum spacing
will usually be between 0.3 to 0.5 times the shell diameter.
The clearance needed will depend on the shell diameter; typical
values, and tolerances, are given in Table below;
Typical baffle clearances and tolerances
Types of baffle used in shell and tube heat exchangers,
(a) Segmental (b) Segraental and strip
Types of baffle used in shell and tube heat exchangers,
(c) Disc and doughnut (d) Orifice
 TEMA standards
• The design and construction is usually based on TEMA
8th Edition 1998
• Supplements pressure vessel codes like ASME and BS
5500
• Sets out constructional details, recommended tube sizes,
allowable clearances, terminology etc.
• Provides basis for contracts
• Tends to be followed rigidly even when not strictly
necessary
• Many users have their own additions to the standard
which suppliers must follow

© Hyprotech 2002
 TEMA terminology

Rear end
Front end Shell head
stationary head type
type
• Letters given for the front end, shell and rear end
types
• Exchanger given three letter designation Above is
AEL
 Front head type
• A-type is standard for dirty tube side
• B-type for clean tube side duties. Use if possible since
cheap and simple.

A B

Channel and removable cover Bonnet (integral cover)

 More front-end head types
• C-type with removable shell for hazardous tube-side
fluids, heavy bundles or services that need frequent
shell-side cleaning
• N-type for fixed for hazardous fluids on shell side
• D-type or welded to tube sheet bonnet for high
pressure (over 150 bar)

C N D
 Shell type
• E-type shell should be used if possible but
• F shell gives pure counter-current flow with two
tube passes (avoids very long exchangers)
Longitudinal baffle
E F

One-pass shell Two-pass shell

Note, longitudinal baffles are difficult to seal with the shell especially
when reinserting the shell after maintenance
 More shell types
• G and H shells normally only used for horizontal
thermosyphon reboilers
• J and X shells if allowable pressure drop can not be
achieved in an E shell

G H
Longitudinal
Split flow baffles Double split flow

J X

Divided flow Cross flow

 Rear head type
These fall into three general types
• fixed tube sheet (L, M, N)
• U-tube
• floating head (P, S, T, W)
Use fixed tube sheet if T below 50oC, otherwise
use other types to allow for differential thermal
expansion
You can use bellows in shell to allow for
expansion but these are special items which
have pressure limitations (max. 35 bar)
 Fixed rear head types
L

Fixed tube sheet

• L is a mirror of the A front end head

• M is a mirror of the bonnet (B) front end
• N is the mirror of the N front end
 Floating heads and U tube
Allow bundle removal and mechanical cleaning
on the shell side
• U tube is simple design but it is difficult to clean
the tube side round the bend
 Floating heads
T S

Pull through floating head Similar to T but with smaller shell/

Note large shell/bundle gap bundle gap

Split backing ring

 Other floating heads
• Not used often and then with small exchangers

P W

Outside packing to give Externally sealed floating tube sheet

smaller shell/bundle gap maximum of 2 tube passes
 Example
• BES
• Bonnet front end, single shell pass and split backing
ring floating head
 Flow Patterns
• Parallel Flow
• Counter Current Flow
• Shell and Tube with baffles
• Cross Flow
Temperature profiles (a) Counter-current flow (b) 1 : 2 exchanger (c) Temperature cross
Flow Structure

Q=U A F ΔTlm-counter

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 and S);

 (1 − S ) 
R 2 + 1 ln 
1 − RS 
( )
F=
 2 − S R +1− R2 +1 
(R − 1)ln 
(
 2 − S R + 1 + R + 1 
2
)


Thot in − Thot out Tcold out − Tcold in

R= S=
Tcold out − Tcold in Thot in − Tcold in
Temperature correction factor: one shell pass; two or more even tube 'passes
Temperature correction factor: two shell passes; four or multiples of four tube passes
Temperature correction factor: divided-flow shell; two or more even-tube passes
Temperature correction factor, split flow shell, 2 tube pass
 GENERAL DESIGN CONSIDERATIONS

Fluid allocation: shell or tubes

Where no phase change occurs, the following factors will 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 will give 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,
• Operating pressures. The higher pressure stream should be allocated to the
tube-side. High-pressure tubes will be cheaper than a high-pressure shell.
• 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 most economical design.

Note
If no obvious benefit, try streams both ways and see which gives best design
 Tube-side enhancement using inserts

Spiral wound wire and twisted tape

• Increase tube side heat transfer coefficient but at the cost of
larger pressure drop (although exchanger can be reconfigured to
allow for higher pressure drop)
• In some circumstances, they can significantly reduce fouling. In
others they may make things worse
• Can be retrofitted

Twisted tape
 Wire-wound inserts
• Both mixes the core (radial mixing) and breaks up the boundary
layer
• Available in range of wire densities for different duties
 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)
Independently developed by two groups in Norway and
Czech Republic
 Design Procedure for Shell and Tube Heat Exchanger

1. Define heat transfer, mass flowrate and temperature deference for heat exchanger

Q = mC p T

2. Collect physical properties at bulk temperature (ρ, µ, Cp, k…etc.)

3. Select a trial value for overall heat transfer coefficient table below;
4. Decide the heat exchanger layout (Number of passes for tube and shell side
5. Calculate the mean deference temperature (LTMD)
6. Calculate R and S value in order to find the correction factor (FT)
7. Calculate the heat transfer area
8. Decide the heat exchanger layout and tube size in order to calculate number of tubes,
Bundle and shell diameter
 9. Calculate the heat transfer coefficients for each stream (hi, ho)

hi Dht  0.14
Nu = = J ht Re Pr (
0.33
)
kf w
hs Dhs  0.14
Nu = = J hs Re Pr 0.33 ( )
kf w
10. Predict the fouling factor for two sides of heat exchanger (1/hiD, 1/hoD).
11. Calculate the overall heat transfer coefficient exchanger using equation below;

Do
Do ln
1 D0 1 1 Di Do 1 1
= + + + +
U Di hi ho 2K w Di hiD hoD

© Hyprotech 2002
12. Recalculate the heat transfer coefficient using equation below and compare it with
assumed value.
Q = UAFT Tlm
13. If the calculated value within (0-10)%, the calculated value is satisfied and if not return to
step No. 4
14. Calculate the pressure drop for each side of heat exchanger if the results unsatisfactory
return to steps 4 or 8.

  L   
−0.14
 u2
Pt = n  8 j f    + 2.5  t

  Di   w   2
−0.14
 D   L   u     2
Ps = 8J f  s     
t

 e  B 
D L 2 
 w 

15. Optimize the design calculation by repeating steps 4-10 as necessary to design cheapest
heat exchanger which satisfy ( smallest area)
 1.27
De =  pt2 − 0.785do2  Square pitch
do
1.1 2
De =  pt − 0.917do2  Triangle pitch
do
1
 Nt  n1
Db = d o  
 K1 
D s = Db + Clearance

Clearance can be found from TEMA depend on type of tube sheet and Bundle diameter

( pt − d o ) D s L B
As =
pt

L B = ( 0.2 − 1 ) D s
© Hyprotech 2002
Example: It is desired to methanol from 95°C to 40°C with flow rate 10000 Kg/hr.
Sea water used as a coolant with temperature rise from 25°C to 40 °C. Design shell and tube
heat exchanger using data below ;

◼ Methanol (Hot stream) ▪ Sea water (Cold stream)

◼ Entering temp. = 95°C ▪ Entering temp. = 25°C
◼ Leaving temp. = 40°C ▪ Leaving temp. = 40°C
◼ Specific heat = 2.84 kJ/kg °C ▪ Specific heat = 4.2 kJ/kg °C
◼ Viscosity = 0.34 m Pa.s ▪ Viscosity = 0.8 m Pa.s
◼ Density = 750 kg./m3 ▪ Density = 900 kg./m3
◼ Thermal conductivity = 0.19 W/m K. ▪ Thermal conductivity = 0.58 W/m K.
◼ Fouling coefficient = 2000 w/m2 °C ▪ Fouling coefficient = 3000 w/m2 °C
Solution

Methanol 95 °C 40 °C
Sea water 40 °C 25 °C
∆T1=95-40=55°C ∆T2=40-25=15°C

LMTD = (∆T1- ∆T2) / Ln (∆T1/ ∆T2)

LMTD = (55 - 15) / Ln(55/15)
= 31°C
Heat Duty Q = m Cp (Th1 – Th2)
= (100000 kg,/h)(2.84 kJ/kg °C)(95 – 40)°C
= 15624000 KJ/h = 4340 KW

Heat given by the hot stream = Heat taken by the cold stream

Water is heated from 25°C to 40°C Therefore,

Water flow rate = Q / Cp x (Tc2 - Tc1)
= 4340/(4.2 x 15)
=68.9 kg/s
 T1 − T2 95 − 40 t2 − t1 40 − 25
R= = = 3.67 S= = = 0.21
t2 − t1 40 − 25 T1 − t1 95 − 25

From Figure for one shell pass; two tube 'passes FT = 0.85
Tm = 31*0.85 = 26o C
Select U= 600 w/m2 °C from table

Q 4340000
A= = = 278 m2
U Tm 600  26

Select material of construction as Cupro-Nickal

Thermal conductivity = 50 W/m K.
Pipe nominal size ¾ in x 20 ft
O.D = 20 mm
I.D = 16 mm
Area of one tube = 6x20xπ/1000 = 0.372 m2

Using allowing thickness for tube sheet = 5 cm

20
L= − 0.05 = 6m
3.28
Number of tubes = 278/0.372=738

Use 1.25 triangular pitch (Shell-Side fluid is clean)

1
N  n1
Db = d o  t 
 K1 
K1=0.249 n1=2.207
 1
 738  2.207
Db = 20   = 715mm
 0.249 

Ds = 715 + 64 = 779mm
 L  6 103 
=  = 375 From Figure 1 jh = 3.9x 10-3
di  16 

Neglect the effect of viscosity

0.59
hi = −3
 3.9  10−3  18576  5.7 0.33 = 4744.46 w / m 2 c
16 10
Select baffle spacing = 0.4

L B = 0.4  D s = 0.4  779 = 311.5 mm = 312 mm

Tube pitch = 1.25x20 = 25

( pt − d o )Ds LB (25 − 20)  312  779 10−6
As = = = 0.0485m 2
pt 25

© Hyprotech 2002
Mass flux = 100000/(36000 x 0.0485) = 512.18 Kg/s. m2
Select baffle cut 45%
1.1 2 1.1
De =  pt − 0.917do2  =  252 − 0.917  252  = 14.4 10−3 m2
do 20
Re = Gde/µ=512.12 x 14.4x10-3 x/(0.34x 10-3 )

From Figure 3 jh = 2.8 x 10-3

0.19 −3
hs = −3
 2.8  10  124333.5  5.10.33
= 1539 w / m 2
c
14.4 10
do
d o ln
1 d 1 1 di do 1 1
= 0 + + + +
U d i hi ho 2K w d i hiD hoD

U = 635.1 w/m2 °C Error% = (635.1-600)/635.1X100% = 5.52%

Pressure Drop
Tube side

  L   
−0.14
 u 2
Pt = n  8 j f     + 2.5  t

  d i   w   2

From Figure 2 jf = 4.1 x 10-3

 −3  6  10
3
  900 1.0322
Pt = 2  8  4.110   + 2.5  = 14186.119 N / m 2
= 2.05 psi
  16   2
Shell side
Linear velocity = Gs/ρ = 572/750 = 0.7629 m/s
−0.14
 D s   L   u s2   
Ps = 8J f     
 e  B  2
d L 
 w 

From Figure 4 Jf = 2.8 x 10-2

 779   6 10   750  0.7629 

3 2
−2
Ps = 8  2.8 10     = 50862.034 N / m = 7.317 psi
2

 14.4  312  2 