2/27/2015
Department of Chemical Engineering
College of Engineering
University of the Philippines Diliman
Second Semester, AY 2014-2015
ChE 142: Chemical
Engineering Plant Design
Detailed Design of
Static Equipment (HEx and AFC)
Heat Exchanger Types
Devore et al recommend the
following heat exchanger types:
Outline of Lecture
Introduction
Heat Exchanger Types
Design Calculations
P&ID Representation
Cost Estimation
Heat Exchanger Types
Spiral Heat Exchanger
Spiral heat exchanger if area is
less than 2 m2.
Double-pipe heat exchanger if
area is between 2 and 50 m2.
Shell-and-tube heat exchanger
if area is greater than 50 m2.
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Heat Exchanger Types
Heat Exchanger Types
Double Pipe Heat Exchanger
Shell and Tube Heat Exchanger
Shell and tube heat exchangers are
broadly classified into two: removable
and non-removable tube bundle.
Of the two classifications, the cheapest
options are the U-tube heat exchanger
and the fixed tubesheet heat exchanger
respectively.
Heat Exchanger Types
Heat Exchanger Types
Shell and Tube Heat Exchanger
Shell and Tube Heat Exchanger
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Heat Exchanger Types
Heat Exchanger Types
Shell and Tube Heat Exchanger
Shell and Tube Heat Exchanger
Heat Exchanger Types
Heat Exchanger Types
Shell and Tube Heat Exchanger
Shell and Tube Heat Exchanger
Costlier for the same heat transfer
area, but can clean shell side.
Cheaper for the same heat transfer
area, but cant clean shell side.
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Heat Exchanger Types
Heat Exchanger Types
Shell and Tube Heat Exchanger
Shell and Tube Heat Exchanger
Design Calculations
Design Calculations
Problem Statement
Design and draw the P&ID representation of
a shell-and-tube heat exchanger with the
following information:
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Design Calculations
Design Calculations
Initial Specifications
Initial Specifications
Fluid Placement
Place the fluid on the tube side if it is:
(arranged in order of priority)
1.
2.
3.
4.
5.
6.
Corrosive
Cooling water
More fouling
Less viscous
More pressurized
Hotter
Fluid Placement
Fouling factors (refer to Table 3.3)
Crude oil
= 0.004-0.005 hr-ft2-F/Btu
Kerosene
= 0.001-0.003 hr-ft2-F/Btu
Place the crude oil and kerosene in tube
side and shell side respectively.
Design Calculations
Design Calculations
Initial Specifications
Initial Specifications
Shell and Head Type
Tube and Tubing Layout
The following guidelines are
observed in the selection of tube
dimensions and layout:
14 BWG tubes with 1
triangular pitch for straight tubes
1 14 BWG tubes with 1
square pitch for U-tubes
What shell and tube heat exchanger type
is suitable for this service, BEU or BEM?
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Design Calculations
Design Calculations
Initial Specifications
Initial Specifications
Tube and Tubing Layout
Tube and Tubing Layout
The preferred straight tube lengths are 16 ft
and 20 ft. For the same heat transfer area,
which is more economical?
Longer but thinner
heat exchanger?
Shorter but fatter
heat exchanger?
What are the advantages and disadvantages
of triangular pitch over square pitch?
Design Calculations
Design Calculations
Initial Specifications
Initial Specifications
Baffle Dimensions
Baffle Dimensions
The baffle spacing is recommended to
be between 20% and 100% of the
shell diameter. The default is 20%.
The baffle cut is recommended to be
between 15% and 45%. The default is 20%.
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Design Calculations
Design Calculations
Maximum Pressure Drop
Maximum Pressure Drop
Allowable pressure drop for shell and tube
exchangers and air coolers in pumped liquid
service may be considered as follows:
Pressure (psig)
Allowable Pressure Drop (psi)
Shell Side
Tube Side
Up to 50
2.5 per shell
Less than 1.0
5.0
10
50 and above
5.0 per shell
1.0 to 5.0
7.5
10
Viscosity (cP)
Allowable Pressure Drop (psi)
Allowable pressure drop for shell and tube
exchangers and air coolers in condensing
service may be considered as follows:
5.0 to 15.0
10
15
15.0 to 25.0
15
20
25.0 to 50.0
15
25
Design Calculations
Design Calculations
Initial Specifications
Initial Specifications
The initial specifications are as follows:
Kerosene at shell, crude oil at tube
o Kerosene
= 0.003 hr-ft2-F/Btu
o Crude oil
= 0.005 hr-ft2-F/Btu
Heat exchanger type BEU
1 14 BWG tubes with 1 square pitch
o Outer diameter (Do) = 1.000 in
o Inner diameter (Di) = 0.834 in
o Tube pitch (PT)
= 1.250 in
o Clearance (C)
= 0.250 in
Tube length of 20 ft
Baffle spacing of 20% of shell diameter
Baffle cut of 20%
Maximum shell-side P
= 5.0 psi
Maximum tube-side P
= 10.0 psi
The initial specifications are as follows:
Kerosene at shell, crude oil at tube
o Kerosene
= 5.248 x 10-4 m2-K/W
o Crude oil
= 8.806 x 10-4 m2-K/W
Heat exchanger type BEU
1 14 BWG tubes with 1 square pitch
o Outer diameter (Do) = 0.02540 m
o Inner diameter (Di) = 0.02118 m
o Tube pitch (PT)
= 0.03175 m
o Clearance (C)
= 0.00635 m
Tube length of 6.096 m
Baffle spacing of 20% of shell diameter
Baffle cut of 20%
Maximum shell-side P
= 34.46 kPa
Maximum tube-side P
= 68.93 kPa
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Design Calculations
Design Calculations
Number of Shell Passes
Number of Shell Passes
Assume that only one shell pass will suffice.
Calculate the LMTD correction factor (F).
Assume that only one shell pass will suffice.
Calculate the LMTD correction factor (F).
Design Calculations
Design Calculations
Number of Shell Passes
Estimated Area
If calculated F is less than 0.80, set the
number of shell passes to two.
Calculate the area using the equation
Q = UAFTlm
Estimate the overall heat transfer
coefficient using the individual heat
transfer coefficients (should have been
done during ChE 141).
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Design Calculations
Design Calculations
Minimum Number of Tubes
Maximum Number of Tube Passes
The heat exchanger area is equal to the
surface area of each tube multiplied by
the number of tubes:
The tube-side fluid loses pressure as it
expands at the inlet nozzle, flows inside the
tubes, and contracts at the outlet nozzle.
A = nt x (DoL)
Assume that nozzle losses are negligible.
How can the maximum number of tube
passes be calculated using the equation
above?
Design Calculations
Design Calculations
Shell Diameter
Required Overall Heat Transfer Coefficient
Given the heat exchanger type and the tubeside details, a shell diameter can be selected:
Given the selected tube length and
the tube count on the selected shell
diameter, calculate the area available
for heat exchange:
A = nt x (DoL)
Calculate the required overall heat
transfer coefficient:
Ureq = Q/AFTlm
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Design Calculations
Design Calculations
Inside Heat Transfer Coefficient
Outside Heat Transfer Coefficient
The tube-side heat transfer coefficient is
calculated using the Seider-Tate and Hausen
equations. Viscosity correction is neglected:
The shell-side heat transfer coefficient is
calculated using the following correlation.
Viscosity correction is neglected:
Design Calculations
Design Calculations
Overall Heat Transfer Coefficient
Tube-Side Pressure Drop
Calculate the overall heat transfer coefficient
using the equation below. Metal resistance is
neglected:
The tube-side fluid loses pressure as it
expands at the inlet nozzle, flows inside the
tubes, and contracts at the outlet nozzle.
Assume that nozzle losses are negligible.
The magnitude of oversize is based on the
required overall heat transfer coefficient.
10
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Design Calculations
Design Calculations
Shell-Side Pressure Drop
Design Assessment
The shell-side fluid loses pressure as it
expands at the inlet nozzle, flows outside the
tubes, and contracts at the outlet nozzle.
Assume that nozzle losses are negligible.
P&ID Representation
What adjustments need to be done?
Case
Is overall HTC
greater than
required?
Is tube-side
P less than
maximum?
Is shell-side
P less than
maximum?
YES
YES
YES
YES
YES
NO
YES
NO
YES
NO
YES
YES
P&ID Representation
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P&ID Representation
P&ID Representation
P&ID Representation
Cost Estimation
Towler and Sinnott (2008) expressed the
January 2006 purchased cost of heat
exchangers as a function of area.
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Air Fin Coolers
Air Fin Coolers
Because of low heat
transfer coefficient on
the air side, the tubes
are finned to increase
the area available for
heat transfer.
Air Fin Coolers
Air fin coolers are second only to shelland-tube heat exchangers in frequency
of occurrence in chemical and
petroleum processing operations.
Air Fin Coolers
Forced Draft Air Fin Coolers
Assuming no process restrictions,
when is air cooling economically
advantageous over water cooling?
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Air Fin Coolers
Air Fin Coolers
Induced Draft Air Fin Coolers
Forced vs. Induced Draft Air Fin Coolers
Differentiate the two configurations in
terms of:
1. Accessibility of tubes and fan parts
2. Fan power consumption for the same
mass flowrate of air
3. Area for the same air fin cooler duty
Air Fin Coolers
Air Fin Coolers
Forced vs. Induced Draft Air Fin Coolers
Forced vs. Induced Draft Air Fin Coolers
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Air Fin Coolers
Air Fin Coolers
Forced vs. Induced Draft Air Fin Coolers
Tube Dimensions
For inlet process fluids above 350F,
use forced draft configuration.
Tube lengths are typically from 6 ft to 50 ft,
with 40 ft commonly used. Tubes are
typically stacked from three to eight rows,
with six rows commonly used.
Air Fin Coolers
Air Fin Coolers
Tube Dimensions
Bay Dimensions
Bay widths are typically from 4 ft to 30 ft, with
14 ft commonly used. Axial-flow fans with four
or six blades and diameters of 6 ft to 18 ft are
typically employed.
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Department of Chemical Engineering
College of Engineering
University of the Philippines Diliman
Second Semester, AY 2014-2015
ChE 142: Chemical
Engineering Plant Design
Detailed Design of
Static Equipment (HEx and AFC)
16
