Shell & Tube Heat Exchanger
- Designing
Guidelines for placing fluid in order of
priority
Tube Side Shell Side
Corrosive Fluid Condensing Vapor(unless
Cooling water corrosive)
Fouling Fluid Fluid with large temp
Less viscous
diff(>40oC)
High Pressure Steam
Hotter fluid
Shell Side Coefficients
When the tube bundle employs baffles directing the shell side fluid
across the tubes from top to bottom or side to side, the heat
transfer coefficient is higher than for undisturbed fluid.
In square pitch, the velocity of the fluid undergoes continuous
fluctuations because of the constricted area between adjacent
tubes compared with the flow area between successive rows.
In triangular pitch even greater turbulence is encountered because
the fluid flowing between adjacent tubes at high velocity impinges
directly on the succeeding row.
When pressure drop and cleanability are of little consequence ,
triangular pitch is superior for attaining high heat transfer
coefficient.
The shell side coefficient can be calculated from the graph of
heat transfer factor or from the below expression
0.55 1 0.14
ℎ𝑜 𝐷𝑒 𝐷𝑒 𝐺𝑠 𝑐𝜇 3 𝜇
= 0.36
𝑘 𝜇 𝑘 𝜇𝑤
The shell side cross flow area as is given by
𝐼𝐷 𝑥 𝐶 𝑥 𝐵
𝑎𝑠 =
𝑃𝑇
Where C is the clearance
B is baffle spacing
PT is the pitch
The equivalent diameter is 𝐷𝑒 =
4 𝑥 𝑓𝑟𝑒𝑒 𝑎𝑟𝑒𝑎
𝑤𝑒𝑡𝑡𝑒𝑑 𝑝𝑒𝑟𝑖𝑚𝑒𝑡𝑒𝑟
For square pitch
𝐷𝑒 = 4 𝑥 𝑃𝑇2 − 𝜋𝑑𝑜2 /4 /(𝜋𝑑𝑜 )
For triangular pitch
𝐷𝑒
4 𝑥 1 2 𝑃𝑇 𝑥 0.86𝑃𝑇 − 1 2 𝜋𝑑𝑜2 /4
=
1
2 𝜋𝑑𝑜
For tube side coefficient, the calculations
are done in the same way as for pipes.
In 1,2 heat exchanger-
For first tube pass the flow is parallel
For second tube pass the flow is
counter
Greater temp diff is found in counter
flow than parallel flow
Hence 1,2 exchanger is a combination
of co & counter flow
Thus, LMTD is not the true temp diff
Therefore, correction factor, FT is
necessary
87500 kg/h of distilled water enters an exchanger at 40o C
and leaves at 32 oC . The heat is transferred to 1,40,000
kg/h of raw water coming from supply at 22 oC and leaving
at 27o C .
Available is 1-2 exchanger 15.25” ID exchanger having
160, ¾” OD 18 BWG tubes,16” long and laid on 15/16 “
triangular pitch. Baffles are spaces 12” apart. Will the
exchanger be suitable ?
Total dirt factor available is 0.0003
Q = MD cD∆T = MRcR ∆t
87500 x 1 x (40-32) = 140000x 1x (27-22)
= 7, 00,000 kcal/h
40 32
LMTD = (13-10)/ln(13/10) = 11.43
13
4040 10
27 22
𝑇1 −𝑇2 8
32 𝑅= 𝑡1 −𝑡2
= 5 = 1.6
27 15
𝑡2 −𝑡1 5
𝑆= = = 0.278
𝑇1 −𝑡1 40−22
Ft = 0.945
Actual LMTD = 11.43 x 0.945 = 10.8oC
Hot Fluid, Distilled Water in Shell
Viscosity = 0.81cp; k = 0.5364kcal/hr m oC
𝐼𝐷 𝑥 𝐶 𝑥 𝐵
𝑎𝑠 =
𝑃𝑇
pitch = tube OD + clearance
C = 15/16 - 0.75 = 0.8175”
𝑎𝑠 = (15.25 x 0.8175 x 12)/ (15/16)
= 36.6 in2 = 0.0236 m2
4 𝑥 1 2𝑃𝑇 𝑥 0.86𝑃𝑇 −1 2 𝜋𝑑𝑜2 /4
𝐷𝑒 = 1
2 𝜋𝑑𝑜
= 0.0136m
G = w/a
= 87500/0.0236 x 3600
= 1030 kg/ m2 s
Re. No. = D G/µ
= 0.0136 x 1030/0.81 x 10 -3
= 17292
Pr= Cµ/k
= 1 x 0.81 x 10-3/(0.5364/3600)
= 5.4
0.55 1 0.14
ℎ𝑜 𝐷𝑒 𝐷𝑒 𝐺𝑠 𝑐𝜇 3 𝜇
= 0.36
𝑘 𝜇 𝑘 𝜇𝑤
= 134.52
ho = 5301 kcal/hr m2 oC
Tube Side , Raw water, viscosity =0.92cp, k = 0.5364
OD of tube = 0.75”, ID = 0.652”
Flow area of 1 tube = π x( 0.652 x 0.0254)2/ 4
= 2.15 x 10-4 m2
Total Flow Area------
No. of tubes per pass = 160/2 = 80
at= 80 x 2.15 x 10-4
= 0.0172 m2
G = w/at
= 1,40,000 / (0.0172 x 3600)
= 2261 kg/m2 s
Re. No. = D G/µ
=0.652x 0.0254x 2261 / 0.92 x 10-3
=40,700
Pr= Cµ/k
= 1 x 0.92 x 10-3/(0.5364/3600)
= 6.17
Nu= 0.027 x Re0.8 x Pr1/3
= 241.25
hi = Nu x k/d
= 7814 kcal/ hr m2 oC
hio = hi x ID/OD
= 6793 kcal/ hr m2 oC
𝑄
𝑈𝐷 =
𝐴 ∆𝑡
Uc = 2977.5 kcal/ hr m2 oC UD = 700000/( 46.7 x 10.8)
Uc = (1763.8x 1464.72)/(1763.8 + 1464.72) =
800 kcal/ hr m2 oC
UD = 1387.9 kcal/ hr m2 oC
Thus, Uc > UD
Heat Transfer Area = π D L
Rd = 0.000355
A = π x 0.75 x 0.0254 x 16 x 0.3048 x 160
A = 46.7 m2
If Rd equals or exceeds the
required Rd proceed for Pressure
Drop Calculation
Pressure Drop Calculation
For shell side Pressure Drop ∝
- Number of times the fluid crosses the bundle between baffles
- Distance across the bundle each time it crosses
𝑓 𝐺 2 𝐷𝑠 (𝑁 + 1)
∆𝑃𝑠 =
2𝑔 𝜌 𝐷𝑒 ∅𝑠
𝐿
𝑁+1=
𝐵
For tube side pressure drop has two components, along the length + drop
due to direction change
𝑓 𝐺2 𝐿 𝑛
∆𝑃𝑡 = + ∆𝑃𝑟
2𝑔 𝜌 𝐷𝑒 ∅𝑡
4𝑛 𝑣 2
∆𝑃𝑟 =
𝑠 2𝑔
Shell pressure drop
𝑓 𝐺 2 𝐷𝑠 (𝑁+1) 𝐿
∆𝑃𝑠 = 𝑁+1=
2𝑔 𝜌 𝐷𝑒 ∅𝑠 𝐵
The equivalent diameter is same as heat transfer
N+1 =12 x 16/12 = 16
0.264
𝑓 = 0.0035 + 0.42
𝑅𝑒
Re = 17,292
𝑓 = 0.0079
0.0079 𝑥 10302 𝑥 15.25 𝑥 0.0254𝑥 16
∆𝑃𝑠 =
2 𝑥 10𝑥1000𝑥 0.0136
= 190 kg/m2
= 0.27psi
Tube side pressure drop
Re = 40,700
0.264
𝑓 = 0.0035 + 0.42
𝑅𝑒
= 0.0066
𝑓 𝐺2 𝐿 𝑛
∆𝑃𝑡 = + ∆𝑃𝑟
2𝑔 𝜌 𝐷𝑒 ∅𝑡
4𝑛 𝑣 2
∆𝑃𝑟 =
𝑠 2𝑔
V = G/ 𝜌
= 2261/1000 = 2.26m/s
4𝑥 2 2.262
∆𝑃𝑟 =
1 2 𝑥10
= 2.04m
𝑓 𝐺2 𝐿 𝑛 0.0066𝑥 22612 16𝑥0.3048𝑥 2
=
2𝑔 𝜌 𝐷𝑒 ∅𝑡 2 𝑥10𝑥 1000𝑥 0.652𝑥 0.0254
= 987.54 kg/m2
= 1.4 psi
∆ Pr = 2.04𝑚 = 2.9 𝑝𝑠𝑖
Total pressure drop = 1.4 + 2.9 = 4.3 psi
