Design heat exchanger shell and tube
THERMO HYDRAULIC DESIGN PROCEDURE SHELL AND TUBE HEAT EXCHANGER
Thermo hydraulic design steps for shell and tube heat exchanger are,
Calculation of heat duty(Q).
Calculation of log mean temperature difference.(LMTD)
Finding out correction factor for LMTD
Correction of LMTD
Assuming overall coefficient(U)
Area calculation
Calculation of number of tubes
Corrected area.
Design heat exchanger shell and tube
Shell side calculation
Selection of shell inside diameter
Baffle spacing
Pitch calculation
Tube clearance
Shell area
Mass velocity
Equivalent diameter
Reynold’s number across shell side
Factor for heat transfer calculation
Prandtl’s number
Individual heat transfer coefficient
Tube side calculation
Flow area per tube
Number of tubes calculation
Tube area calculation
Mass velocity calculation
Reynold’s number across tube side
Velocity calculation
Prandtl’s number
Calculation of factor for heat transfer coefficient
Calculation of individual heat transfer coefficient
Calculation of overall clean coefficient
Dirt factor
Pressure drop calculations
Pressure drop across shell side
Pressure drop across tube side
STEP 1:-for design
We desired to design the heat exchanger (shell and tube )in the power plant nuclear .)) Note
that the available area (110 m2 ) And not to be less area of heat exhanger (90 m2 ) for
cool the process stream from (693 k) to (493 k) by the use of cooling water its has inlet temp
(298k ),outlet temp (473 k) .
Design heat exchanger shell and tube
To complete the specification, the duty (heat transfer rate Q ) needed to be calculated. The mean
temp of process stream and water :
Tm of water =298+473/2= 385 k
Tm of steam = 493+693 /2= 593 k
Now: - For process stream duty or heat transfer rate if the mass flow rate has m=114528kg/s
q = m Cp T
q = (114528) x 521 x (693 – 493)
q= 1.193 x1010 J
STEP 2:-
Physical Properties Of Process stream
INLET MEAN OUTLET UNITS
Temperature 693 593 493 K
Specific heat (Cp) 521 KJ/Kg K
Thermal
0.044 W/mK
conductivity (k)
Density () 800 Kg/m3
Viscosity () 6.31x10-4 kgm-1s-1
Design heat exchanger shell and tube
For Water:-
INLET MEAN OUTLET UNITS
Temperature 298 385 473 K
Specific heat (Cp) 490 KJ/Kg K
Thermal
0.6912 W/mK
conductivity (k)
Density () 445 Kg/m3
Viscosity () 1.028x10-3 kgm-1s-1
Step 3:-
For system of water, the value of overall heat transfer (U L )lies in the range of 375-
750W/m2 K, so assume.
UL=650 W/m2 K
Step 4:-
Usually an even number of tube passes the preferred arrangement.
For 1 shell and 2 tube passes
LMTD
T1=(Thi –Tco )=(693-473)=220 k
T2= (Tho–Tci)=(493-298)=195k
LMTD = [ T1– T2]/ln[( T1)/( T2)]
( Tm) LMTD = [(220) – (195)]/ln[(220)/(195)]
=207.2 K
Q = UL Ao Tm
Ao = Q / Uo Tm
Ao = 1.193 x1010 J / (650 x 207.2)
Ao = 88.5m2
Design heat exchanger shell and tube
Finding out correction factor for LMTD
R,S&F
R=( Thi –Tco)/( Tco –Tci)
=(693-493)/(473-298)
=1.1428
S=( Tco–Tci)/( Thi –Tho)
=(473-298)/(693-493)
=0.44
From Fig 3 to find correction factor Temp correction factor
Ft= 0.91
Design heat exchanger shell and tube
Corrected LMTD
Corrected LMTD= =Ft * LMTD( Tm)
= 0.91 * 207.2
=188.52K
Step 5:-
Heat Transfer Area:
Q = UL Ao Tm
Ao = Q / Uo Tm
Ao = 1.193 x1010 J / (650 x 188.52)
Ao = 97m2
SELECTION OF HEAT EXCHANGER
A < 2m2 (21.5 ft2) select a coiled heat exchanger
2 m2 < A < 50 m2 (538 ft2) select a double-pipe heat exchanger
A > 50 m2 select a shell-and-tube heat exchanger. ( ref. Chemical process engineering
design & Economics By Harry Silla)
As area >50m2, shell and tube heat exchanger with 1-2 shell . Tube pass to get low
pressure drop is selected.
SELECTION Floating head type Heat Exchanger
The floating head type exchanger is more robust exchanger capable of handling both high
temperature & high pressure.
It’s one end of tube bundle is not attached to shell & thus can move within shell to take care
of stresses from thermal expansion.
Since its fabrication is complex so it is approx 25% more expensive than fixed tube type for
same surface area.
The fluid is not corrosive, so plain carbon steel can be used for the shell and tubes.
Fig(3)
Design heat exchanger shell and tube
Tubes design :
ODt = 3/4 in from TEMA std (AES) type (Tubular Exchangers Manufacturers Association)
Corresponding to BWG= 14
Tube IDt = 14.83x10-3m
Tube OD= 19.05x10-3m
Tube thickness= 0.002m
Length of tube=5m
Pitch
For design triangular pitch 1.25 in. is selected because it permits the use of more tubes & hence
results in more surface area in a given shell diameter.
(1.25xdo) triangular pitch=1.25x19.05x10-3m =23.81x10-3
Tube Side Heat Transfer Coefficient
Step 6:-
At = (area of one tube) = do L
= 3.14 x 19.05x10-3 x 5
= 0.299m2
No. of tubes = provisional area /area of 1 tube
# of tubes = 97/ 0.299 = 324
Tubes/pass = 324/2= 162
Step 7:-
Tube cross sectional area = / 4 (di2)
= /4 x (14.83x10-3)2
=(1.72x10x-4 )m2
Tubes per pass =324/2 =162
Total flow area = 1.72x10-4 *162=0.027 m2
Design heat exchanger shell and tube
Mass velocity:
Gt = mass flow rate for steam /total flow area
=(114528/3600)/0.027=1178.27 kg/sec .m2
Linear velocity :
Ut = Gt /ρ
= 1178.27 /800
Ut = 1.47 m/sec (< 4 m/sec acceptable)
