Introduction to

HEAT EXCHANGERS

Joy Mukherjee
What is a Heat Exchanger?

A heat exchanger is a device which transfers heat from one medium to another.
Classification of
Heat Exchangers
Types of HE
q Double-pipe exchanger

q Shell and tube exchangers

q Plate and frame exchangers

q Plate-fin exchangers.

q Spiral heat exchangers.

q Air cooled heat exchangers

q Agitated vessels.

q Fired heaters.
Based on transfer process

q Indirect Contact – Shell & Tube Heat Exchangers

q Direct Contact – Cooling Towers

Based on phase of fluids

q Gas-Liquid exchangers

q Liquid-Liquid exchangers

q Gas-Gas heat exchangers

Based on construction

q Tubular
§ Double pipe heat exchanger
§ Shell and tube heat exchangers
§ Spiral heat exchangers
q Plate-type
§ Plate and frame heat exchangers
§ Spiral plate heat exchangers
q Extended Surface
§ Plate-fin exchanger
§ Tube-fin exchanger
Based on flow arrangements
q Parallel flow / Co-current flow

q Counter flow

q Cross flow
Heat Transfer Coefficient
q Heat transfer rate, = ∆
U = overall heat transfer coefficient, W/(m2C)
A = heat transfer surface area, m2
∆ = mean temperature difference, oC
q Overall Heat Transfer Coefficient, Uo

ho= outside fluid film coefficient, W/(m2.oC)

hi= inside fluid film coefficient, W/(m2.oC)
hod= outside dirt coefficient (fouling factor), W/(m2.oC)
hid= inside dirt coefficient, W/(m2.oC)
kw= thermal conductivity of the tube wall material, W/(m2.oC)
di= tube inside diameter, m
do= tube outside diameter, m
Temperature Profile: Co-current flow

Log Mean Temperature

Difference (LMTD)
Temperature Profile: Counter current
flow

Log Mean Temperature

Difference (LMTD)
Temperature Correction Factor (Ft)

q Mean temperature difference, ∆

∆ = ∆

q Ft depends on R & S

−
=
−

−
=
−
Temperature correction factor: one shell pass; two or more even tube passes
Components of a STHE
q Shell
q Shell cover
q Tubes
q Channel
q Channel Cover
q Tube sheet
q Baffles
q Floating-Head Cover
q Nozzles
q Tie-Rods & Spacers
q Pass Partition Plates
q Impingement Plates
q Sealing Strips & Sealing Rods
Classification by Construction

Fixed-tube-sheet heat exchanger

q Has straight tubes secured at both ends to tube-sheets

welded to the shell

q Low cost, simplest construction.

q Bundle is "fixed" to the shell so outside of the tubes

cannot be cleaned mechanically.

q Application is limited to clean services on the shell side

Fixed-tube-sheet heat exchanger
U-tube heat exchanger
q Tubes are bent in the shape of a U

q Only one tube-sheet

q Bending of tubes adds to the cost

q Tube bundle is removable, outside of tubes can be cleaned.

q Because of the U-bend, inside of the tubes can’t be cleaned

mechanically

q Can’t be used for dirty fluids inside tubes.

U-tube heat exchanger
Floating head exchanger
q Most versatile and costliest.

q One tube-sheet is fixed relative to the shell, and the other

is free to “float” within the shell.

q Cleaning of both the insides and outsides of the tubes

q Can be used for services where both the shell-side and

the tube-side fluids are dirty

Widely used in Petroleum Industry

Floating head exchanger
U-Tube Heat Exchanger
Straight-Tube ( 1-Pass )
 Straight-Tube ( 2-Pass )

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Transportation of Heat Exchanger
TEMA Types
 TEMA Types

For dirty For No Temp

tube side Cross

Fixed tube-
sheet on the
For clean rear side of the
tube side shell

For horizontal
thermosyphon
reboilers

Large temp
difference
between shell
For
& tube fluids
Hazardous
fluid

Allowable
pressure drop
on shell side is
very low
FLUID ALLOCATION
Shell Side Tube Side
— Viscous Fluids — Fluids which are prone to
fouling
— Lower Flow Rates
— Corrosive fluids
— Cleaner Fluids
— Toxic fluids to increase
containment
— High pressure streams, since
tubes are less expensive to
build strong
— Streams with low allowable
pressure drop
— Cooling water to be put on
tube side only
Tubes

Tubes should be able to withstand:

§ Operating temperature and pressure on both sides
§ Thermal stresses due to the differential thermal expansion
between the shell and the tube bundle
§ Corrosive nature of both the shell-side and the tube-side
fluids
Ø TUBE PITCH RATIO:
Min 1.25 times of tube OD
1.333 times of tube OD
1.5 times of tube OD
Ø TUBE PASS: Based on pressure drop & velocity limit on tube
side
TUBE LAYOUT ANGLE

30o
30o Triangular 90o 90o Square
FLOW FLOW

Triangular layouts give more

tubes in a given shell Square layouts give cleaning
lanes with close pitch
60o

45o

FLOW
60o Rotated 45o Rotated
Triangular Square
FLOW
 Feature Tube Layout Pattern

Lower ΔP on shell-side Square (effective only at low

Re number)
Shell-side fouling Square - easier cleaning

Horizontal shell-side Square

Boiling
Smaller shell size Fit 15% more tubes if
triangular pitch used
Tube pitch

q Shortest distance between two adjacent tubes.

q TEMA specifies a minimum tube pitch of 1.25*(OD)

q Minimum tube pitch leads to smallest shell diameter for a

given number of tubes.

q To reduce shell-side pressure drop, the tube pitch may be

increased to a higher value.

Tube-sheet

q Barrier between shell-side and tube-side fluids.

q Mostly circular with uniform pattern of drilled holes.

q Tubes are attached to tube-sheet

Tie rods and spacers
Tie rods and spacers are used for:

q holding the baffle assembly together

q maintaining the selected baffle spacing

Sliding strips

q help the bundle to slide out from the shell

q Can also be used as tie rods to hold the bundle in

position.
Sealing strips and Seal rods

q Sealing strips prevent shell side fluid from bypassing the

bundle.

q Sealing strips block the resulting large open area at top or

bottom of the shell.

q Seal rods are also used to control the leakage streams.

TUBE PASS LAYOUT

Ribbon

Quadrant

H-Bend
TUBE PASS LAYOUT
TYPES OF BAFFLES

q Segmental type;
§ Single – horizontal & vertical
§ Double
§ Triple
§ No-Tubes in Window (NTIW)
q Orifice type
q Disc and doughnut type
q Rod type
q Impingement type
q Longitudinal (pass partitions)
TYPES OF BAFFLES
Baffle cut
Ø ORIENTATION:
— Horizontal for heating or cooling with no phase change
— Vertical for shell side condensation
Ø CUT:
— 15 % to 45 % of shell ID for Single Segmental
— 25 % to 35 % of shell ID for Double Segmental
Baffle cut

q Height of the segment that is cut in a baffle to permit the shell-

side fluid to flow across the baffle.
q Baffle cut should be set carefully because a baffle cut that is
either too large or too small can increase the possibility of
fouling in the shell, and moreover it would also lead in
inefficient shell-side heat transfer
Ø CUT:
— 15 % to 45 % of shell ID for Single Segmental
— 25 % to 35 % of shell ID for Double Segmental
Flow Pattern depending on Baffle
Baffle/ Nozzle orientation
q The orientation of the baffle cut is important for heat exchanger
installed horizontally.
Ø When the shell side heat transfer is sensible heating or cooling with
no phase change, the baffle cut should be horizontal.
Ø For shell side condensation, the baffle cut for segmental baffles is
vertical.
Ø For shell side boiling, the baffle cut may be either vertical or
horizontal depending on the service.
q Positioning of inlet/ outlet nozzle is also important for the proper
functioning of exchangers.
Ø In cooling water services, the inlet nozzle should be at the bottom
and outlet nozzle should be at the top.
Ø For condensing services exit should be from the bottom nozzle.
SINGLE SEGMENTAL BAFFLES - Horizontal
Shellside Flow
In
Tubeside Flow
Out
Shell

Tube Bundle

Shellside Flow
Out
Tubeside Flow
In
SINGLE SEGMENTAL BAFFLES - Vertical
Shell Outlet

Channel Inlet

Channel
Outlet

Shell Outlet
DOUBLE SEGMENTAL TRANSVERSE BAFFLES
Shell Inlet

Shell Outlet
DOUGHNUT AND DISC TYPE BAFFLES
Baffle Spacing

q Baffle spacing is the longitudinal or centreline-to-

centreline distance between adjacent baffles.

q According to TEMA, the minimum baffle spacing should

be one-fifth of the shell inside diameter or 2 in.,

whichever is greater.

q The maximum baffle spacing is the shell inside diameter.

Baffle Spacing
 Impingement devices

q Impingement rod, Impingement plate, Nozzle Impingement baffle

are the various devices used in heat exchangers to trim down the
effects of high velocity at entry nozzles over tube bundle.
TUBE-PROBLEMS
• Scaling of inside/outside of the tube surface

• Blockage of tube passage

• By passing across the baffle

• Puncture in the tube

• Leakage through the tube to tube-sheet

• Leakage through gasketted joint of floating head

Bypass & Leakage streams:
TINKER FLOW MODEL

Ø B stream: Main heat transfer stream, follows a path around baffles and

through tube bundle

Ø A stream: Leakage stream, flowing through clearance between tubes and

holes in baffles

Ø C stream: Tube bundle bypass stream in the gap between the tube bundle

and shell wall

Ø E stream: Leakage stream between baffle edge and shell wall

Ø F stream: Bypass stream in flow channel partitions due to omissions of

tubes in tube pass partitions.

Allowable limits of leakage streams

FLOW FRACTIONS ALLOWABLE LIMITS

A Stream < 10 %
B Stream > 40 %
C Stream < 10 %
E Stream < 15 %
F Stream < 10 %
 Leakage prevention-Sealing Strip

Tubular-type heat exchangers contain both

baffle plates and sealing strips. The baffles
force the flow to pass normal to the axes of the
tubes and they serve to support the tubes. In
order to facilitate assembly of the heat
exchanger, a space exists between the tube
bundle and the retaining shell. This space
offers a hydraulic short circuit to the fluid,
thus reducing the effectiveness of the device to
exchange heat. Sealing strips, which are
metal strips mounted on the shell and running
parallel to the tubes, are introduced to
partially block this leakage flow, thereby
increasing the effectiveness of the device.
 Bypass & Leakage Streams
Since the flow fractions depend strongly upon the path resistances, varying any
of the following construction parameters will affect stream analysis and
thereby the shell side performance of an exchanger:

Ø Baffle spacing and baffle cut

Ø Tube layout angle and tube pitch

Ø Clearance between the tube and the baffle hole

Ø Clearance between the shell I.D. and the baffle

Ø Location & no. of sealing strips and sealing rods

Temperature Cross (Co-current)

q Outlet temperature of cold stream

cannot be greater than the outlet

temperature of the hot stream.

q An F shell has 2 shell passes, so if

there are 2 tube passes as well, it

represents a pure counter-current
flow
Air cooled heat exchanger
Plate and Frame heat exchanger
Spiral heat exchanger

Ideal for handling fouling fluids, viscous media,

slurries, sewage sludge, and other dirty process fluids
and effluents with suspended solids or fibres.
Examples of Fouling

Fouling is the accumulation of unwanted material on solid surfaces

to the detriment of function. The fouling materials can consist of
either living organisms (bio-fouling) or a non-living substance
(inorganic or organic). reduces thermal efficiency, decreases heat
flux, increases temperature on the hot side, decreases temperature
on the cold side, induces under-deposit corrosion, increases use of
cooling water;
Piping, flow channels – reduces flow, increases pressure drop,
increases upstream pressure, increases energy expenditure, may
cause flow oscillations, slugging in two-phase flow, cavitation; may
increase flow velocity elsewhere, may induce vibrations, may cause
flow blockage.
Aims of Thermal Design

1. Achieve the specified duty at minimum overall cost

2. To achieve high heat transfer coefficient within allowable pressure

drops.

3. 10-20 % Overdesign margin (design safety)

4. Pressure drops should be in limits

5. To keep fluid velocities in limit

6. To keep shell side flow fractions in limit

Steps in Design

1. Calculate the heat duty.

2. Select cooling/heating medium
3. Calculate utility flow-rate.
4. Collect the fluid physical properties : density, viscosity,
thermal conductivity.
5. Allocate the fluids on shell side and tube side.
6. Decide the exchanger type
7. Determine LMTD and MTD ΔTm
8. Select a trial value for the overall coefficient, U
9. Estimate the provisional area required.
10. Tube geometry : Number of tubes & number of tube
passes etc.
11. Calculate the shell diameter.
12. Determine the shell side and tube side heat transfer
coefficients.
13. Calculate the overall coefficient and compare with the
trial value.
14. Find the area provided based on U value and then
calculate % excess area.
15. Calculate the shell side and tube side pressure drop.
16. Optimize the design
Heat Duty

q Heat Duty, Q (single phase)

= ∆ (sensible heat)
here, m = flow rate of process fluid
Cp= specific heat of process fluid
∆ = temp diff for process fluid
q Heat Duty, Q (phase change)
= λ(latent heat)
here, m = flow rate of process fluid
λ= latent heat of process fluid
 Selection of cooling/heating medium
Based on cost and availability
Heating medium Cooling medium
• Steam (100-180 oC) • Cooling water (35-100
• Oil (180-300 oC) oC)

• Dowtherm oils (180-400 oC) • Chilled water (< 35 oC)

• Molten Salt (400-590 oC) • Air (> 60 oC)
• Na – K alloys (500-750 oC) • Brine (< 8 oC)
• Flue gas or Hot air (750-1100 oC)

Transport
6 Phenomenon (CH 306) 23-04-
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Utility Flow rate

q Utility flow rate, mw

=
∆
Here, m = flow rate of utility
Cpw= specific heat of utility
∆ = temp diff for utility
LMTD & MTD Calculation

Log Mean Temperature

Difference (LMTD)
 LMTD & MTD Calculation

Log Mean Temperature

Difference (LMTD)

Transport
6 Phenomenon (CH 306) 23-04-
9 2018
Temperature Correction Factor (Ft)

q Mean temperature difference, ∆

∆ = ∆

q Ft depends on R & S

−
=
−

−
=
−
Temperature correction factor: one shell pass; two or more even tube passes
 Overall
Coefficient
Provisional area required

q Heat transfer rate, Q = ∆

U = overall heat transfer coefficient, W/(m2C)

A = heat transfer surface area, m2

∆ = mean temperature difference, oC

=
∆
Number of tubes

=
Here, Nt= No. of tubes
do= tube o.d.
L= Tube length
q Decide the number of passes & tube layout, pitch
 Tube Passes vs Tube Side Velocity
2.5

Tube Side Velocity, m/s

2
1.35 m/s
1.5

0.5

0
2 4 6 8
No. of Passes

§ To avoid fouling, tube velocity is kept between 1-2 m/s

§ At 2 and 4 passes, tube velocity is less than 1 m/s
§ At 8 passes, tube velocity is more than 2 m/s
§ Number of passes = 6
 Tube Passes vs Tube Side Pressure drop
140
Tube Side Pressure drop, kPa
120

100
Allowable pressure drop = 70 kPa
80

60

40
45.06 kPa
20

0
2 4 6 8

No. of Passes

§ Allowable value of Tube side pressure drop is around 70 kPa

§ At 6 passes, optimum value of pressure drop is obtained, i.e. 45.06 kPa
§ Number of passes = 6
 Tube Passes v/s % Overdesign
25

% Overdesign 20

15
16.03 %
10

0
2 4 6 8
No. of Passes

§ % Overdesign should be between 10 to 20 %

§ At 6 passes, optimum value of % overdesign is obtained, i.e. 16.03 %
§ Number of passes = 6
 Optimization of Baffle Spacing

Baffle Spacing vs B stream flow fraction

0.88
0.878

B stream flow fraction

0.876
0.874
0.872
0.87
0.868 0.87
0.866
0.864
0.862
0.86
200 250 300 350

Baffle Spacing, mm

§ At 250 mm, B-stream flow fraction is optimum i.e. 87 %

§ Baffle spacing = 250mm
 Baffle Spacing v/s Shell Side Pressure drop
2.5

Shell Side Pressure drop, kPa

2.25

1.75

1.5

1.25

1
200 250 300 350

Baffle Spacing, mm

§ At 250 mm, , optimum value of shell side pressure drop is obtained, i.e. 1.391 kPa
§ Baffle spacing = 250 mm
 Baffle Spacing vs % Overdesign
22

20

18
% Overdesign

16
16.03 %
14

12

10
200 250 300 350

Baffle Spacing, mm

§ % Overdesign should be between 10 to 20 %

§ At 250 mm, optimum value of % overdesign is obtained, i.e. 16.03 %
§ Baffle spacing = 250 mm
Selection of Tube Layout
Tube Layout vs No. of Tubes Tube Layout vs % Overdesign
880 40

860 35

% Overdesign
840 30
No. of Tubes

820 25

800 20

780 15

760 10
30 45 60 75 90 30 45 60 75 90
Tube Layout Tube Layout

§ Parametric study for 30o, 45o,60o and 90o layout

§ If service requires continuous cleaning lanes choose square layout only
§ 45o gives optimum number of tubes and optimum value of % overdesign
§ Tube Layout = 45o Square
Shell Diameter

q Bundle diameter, Db
Shell Diameter, Ds

= +
Tube side coefficient
q Mean utility temp, t
q Tube c/s area, At

= ×
4
Here, Np = No. of tube passes
di = tube i.d.
 Sieder-Tate Equation
Re < 2000

Dittus-Bolter Equation
Re > 4000

C = 0.021 for gases,

C = 0.023 for non-viscous liquids,
C = 0.027 for viscous liquids.

Generalized Equation
Re = 10 to 106

For Water Service

Here, de = Equivalent dia

Fluid velocity
= /
jh = tube side heat transfer factor
Shell Side Coefficient

q Choose baffle spacing, lB and tube pitch, pt

q 1/5th of the shell dia or 2 in., whichever is greater

q Cross-flow area

Here, lB is baffle spacing, m.

q Calculate mean temperature

q Decide baffle cut % (start with 25%)

Ws = shell side flow-rate, kg/s
Transport
9 Phenomenon (CH 306) 23-04-
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Shell side heat transfer coefficient, hs

jh = heat transfer factor

jh = shell side heat transfer factor
Overall Coefficient
q Overall Heat Transfer Coefficient, Uo

ho = outside fluid film coefficient, W/(m2.oC)

hi = inside fluid film coefficient, W/(m2.oC)
hod = outside dirt coefficient (fouling factor), W/(m2.oC)
hid = inside dirt coefficient, W/(m2.oC)
kw = thermal conductivity of the tube wall material, W/(m2.oC)
di = tube inside diameter, m
do = tube outside diameter, m
Dirt factor / Dirt coefficient /Fouling factor
Tube Side Pressure Drop

q Tube pressure drop

q Here, jf = friction factor for tube side

q Range of tube pressure drop is
q Gases = 14 kPa
q Liquids = 30 to 70 kPa

Fluid velocity
= ×
= /
jf = friction factor Tube side
Shell Side Pressure Drop

q Shell Side Pressure Drop

q Here, jf = friction factor for shell side

q Range of shell pressure drop is
q Liquids 48 to 60 kPa
q Gases 4 to 20 kPa
jf = friction factor shell side
To Reduce Tube Side Pressure Drop

q Tube pressure drop

Ø Decrease number of tube passes

Ø Increase tube diameter
Ø Decrease tube length
Ø Increase number of tubes & hence increase shell diameter
Fluid velocity
= ×
= /
To Reduce Shell Side Pressure Drop

q Shell Side Pressure Drop

Ø Increase the baffle cut

Ø Increase the baffle spacing
Ø Increase tube pitch
Ø Increase tube diameter
Ø Decrease shell diameter