ChE 417 - HEN & Heat Exchanger Design

December 4, 2017

Group #8:
Aslınur Erdemoğlu
Yiğit Sarışen
Emine Ümran Asçı
Tunahan Kanbak

1
 Abstract
This is a design report regarding to the heat exchanger network and a detailed design
of one of the heat exchangers in the network. While designing a heat transfer system, it
is significant to use the energy efficiently. A heat exchanger network can be used for this
purpose in order to maximize the recovery of heat and to minimize the cost. Therefore,
throughout this project, it is objected to design this system at its optimum values. First,
to start the detailed designing, the heat exchanger network was constructed with the given
materials and properties by using Aspen Plus V8.8 and the suitable heat exchanger to be
designed was chosen among the others. For the chosen heat exchanger, with the specified
values, the Kern’s Method for designing the heat exchanger was used. In order to decide
on the tube diameter and the number of tube and shell passes, the heat transfer area,
pressure drop and velocity values (for different diameter values) were compared. By doing
so, the heat exchanger was chosen as its optimum conditions. After completing the heat
transfer part of the design, the cost of this system was considered. The heat exchanger cost
in the network was calculated and compared with the cost of the heat exchanger without
the network. From this results, the benefit of constructing a heat exchanger network was
confirmed. By representing this report, the fact that the choice of the tube diameter is an
important choice for having a reasonable heat transfer area, pressure drop, tube-side and
shell-side fluid velocity. Also, it can be concluded that, the heat exchanger network offers
high profit and efficiency when it is compared with a separate heat exchanger system.

2
Table of Content

1 Introduction 5

2 Method of Attack 7

3 Result 8
3.1 Heat Exchanger Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2 Heat Exchanger Cost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.3 Cost Calculation Without Heat Exchanger Network . . . . . . . . . . . . . . . . 11

4 Discussion 12

5 Conclusion 12

6 Recommendations 13

7 Appendices 15

8 Equations 24

3
Nomenclature

Q Heat transfer rate(W ) K1 Constant for bundle diameter equation

m Mass flowrate of fluid(kg/s) n1 Constant for bundle diameter equation

Cp Specific heat(J/kgK) Ds Bundle diameter with clearance(m)

∆T Temperature difference(K) hi Heat transfer coefficient of tube

side(W/m2 K)
∆Tlm Log mean temperature difference
di Tube inner diameter(m)
∆Tm Mean temperature
kf Thermal conductivity of the fluid(W/mK)
R Dimensionless temperature ratio
jh Heat transfer factor
S Temperature efficiency of the heat ex-
changer µ Viscosity of fluid(P a.s)

T1 Hot fluid inlet(K) ρ Density(kg/m3 )

T2 Hot fluid outlet(K) u Linear velocity of tube side fluid(m/s)

t1 Cold fluid inlet(K) ut Linear velocity of shell side fluid(m/s)

t2 Cold fluid outlet(K) pt Tube pitch(m)

A Heat transfer area(m2 ) IB Baffle spacing(m)

U Overall heat transfer coefficient(W/m2 K) de Equivalent diameter(m)

Ft Log mean temperature correction factor Np Number of passes

Db Bundle diameter(m) jf Friction factor

d0 Tube outer diameter(m) L Tube length(m)

Nt Number of tubes HEN Heat Exchanger Network

4
1 Introduction
The second design assignment was given in November 6th and the deadline was December
4th. Throughout the project, detailed pinch analysis for the given streams was carried out.
Moreover, heat exchanger networks were designed by using Aspen Plus and the best one was
selected. From the selected network, one of the heat exchanger was chosen and its design was
conducted. Finally, the cost analysis has been carried out.
For the most chemical processes, it is essential to transfer heat to and from process fluids
and many types of heat transfer equipment are used in production facilities. Certainly, the
most commonly used one is the shell-and-tube heat exchanger type. The main advantages of
this type of heat exchanger are;

• It offers well-established design procedures.

• It can be constructed from a wide range of materials.

• It can be easily cleaned.

• It has good mechanical layout which is, it has a good shape for pressure operation.

• It uses well-established fabrication techniques.

• Its configuration provides a large surface in a small volume.

Principally, a shell-and-tube heat exchanger contains a pack of tubes in an enclosed cylin-

drical shell. In order to separate the shell side and the tube side fluids of the heat exchanger,
the ends of the tubes are placed into tube sheets (plates). Moreover, baffles are used to direct
the fluid flow, increase the fluid velocity, develop the rate of heat transfer and support the
tubes. The baffles and tube plate are held together with the help of rods and spacers.

Figure 1: Heat Exchanger Model with Baffles, Spacers and Tie Rods [3]

The most common types of shell-and-tube heat exchangers in terms of fluid flowing through
the tubes are single-pass and two-pass. The two-pass type of shell-and-tube heat exchanger can
be provided by using U tubes, so that the tube-side fluid can be turned as shown in Figure 2.
Moreover, the shell-side fluid of the heat exchanger is made to flow repeatedly by using
the baffles throughout the outside of the tubes. The type shell-side flow can be divided into

5
 Figure 2: Heat Exchanger with a) Single-pass b) Two-pass [2]

two parts as; Ideal shell side flow and Non-ideal shell side flow. Theoretically, by using the
segmented baffles with the combination of ideal cross flow and ideal axial flow, ideal shell side
flow pattern can be obtained in which the cross flow gives both higher rate of heat transfer
and pressure drop than axial flow. However, in practice it is impossible to get ideal shell side
flow since there are always leakage across the tube to baffle clearance and bypassing occurring
between the tubes and shell side. Both the leakage and bypassing disturb system and tend to
reduce the amount of heat transfer rate on the shell side. In order to decrease the effects of
bypassing, sealing devices are used. [2]

Figure 3: Types of Shell-side Flow a) Ideal b) Non-ideal [2]

In this project for the design of the selected heat exchanger, it is chosen as 1 shell passes
and 8 tube passes with the assumption of ideal shell-side flow.
In addition, heat exchanger networks can be defined as a set of heat exchangers which have
connections with each other. It can be seen that in process industries, heat exchanger networks
represent a vital part of the plant structure. The purpose of the heat exchanger network is
to maximize heat recovery and so that to minimize the overall plant cost. In other words,
suitable placement and adjustment of the heat exchangers on the hot and cold streams enables
to recover maximum energy from the process streams and to decrease the demand for more hot
and and cold utilities usage in the industries.
To design the heat exchanger, the fluid allocation must be decided first. To choose which
fluid flows through the shell side and which fluid goes into the tube, the physical properties

6
of the considered fluids should be known. For this system, the flowing fluids are 90%ethylene
glycol water mixture and pure glycerol. The physical properties of these fluids are given below.

Table 1: Physical properties of %90 Ethylene Glycol-Water and Glycerol

Material Viscosity(P a.s) Density(kg/m3 )

90% Ethylene Gycol Water 1.8*10-3 1055
Glycerol 6.97*10-3 1258.2

From Eqn.13, when pressure drop values of these fluids along the heat exchanger were
compared, it was seen that the pressure drop would be higher for glycerol since it is advantageous
for its viscosity and density values. The fluid which has lower pressure drop was chosen as the
shell-side fluid because of pressure drop sensitivity. Therefore, 90% Ethylene Glycol-Water
mixture have been used as shell-side fluid and glycerol have been used as tube side fluid, in this
project.

2 Method of Attack
Pinch Point Analysis: Energy saving is an important topic for obtaining a sustainable
design. Therefore, the methodology of Pinch Point Analysis was carried out for the project due
to high cost of utilities.
Pinch point analysis is an extension of the second law of Thermodynamics to the energy
management of the plant. It deals with the optimal structure of the heat exchanger between
the process streams and the optimal use of utilities. Pinch Analysis was done to determine
the energy cost and heat exchanger network capital cost targets for the process and to find the
pinch point in which occurring a minimum temperature difference that represents a bottleneck
in heat recovery. First, the pinch analysis procedure predicts the minimum requirements of
external energy, network area and the number of units at the pinch point. Then, the possible
heat exchanger network designs that satisfy desired values were created by using Aspen Plus
and the best fitting option was selected as the actual heat exchanger network design. This
selection was done by comparing the total costs, target percentages and cost of the utilities of
entire candidate designs. Moreover, to get better solutions several changes was done to the heat
exchanger network design such as adding area, adding heat exchanger, changing the process
streams by moving one or both end of the heat exchanger.

Heat Exchanger Design: The heat transfer of the process fluids plays a critical role in
chemical processes. To provide this system, heat exchangers are used mainly. For this project,
the shell and tube heat exchanger was designed. After pinch point analysis step, a shell and tube
heat exchanger was started to be designed. From literature, several diameter, length, thickness
and number of passes are retrieved[5] in order to obtain optimum designed heat exchanger by
comparing allowed pressure drop, velocities and area of heat exchangers .
To design and define the physical layout of the heat exchanger, heat transfer surface area
must be determined first, therefore, the calculations were done by considering this fact and
similar processes considered for initial guess values. For this project, the heat duty and the
temperatures of the fluids were known, and the design was done by using Kern’s method. To
use this method, following assumptions were made;[2]

• Heat transfer areas and the overall heat transfer coefficient are constant for in each pass.

• The temperature of the shell-side fluid for each pass is constant through the cross-section.

7
 • There is no leakage occurring between shell passes.

• The ratio of the viscosity of the fluids to viscosity of the water was neglected in the
equations, since this ratio has a small value.

First, since the heat duty and temperatures were known, the fluid flow rates were deter-
mined(Eqn.1). The logarithmic mean temperature of the fluids was calculated(Eqn.2). Then,
the R and S values were founded and according to these values, the corresponding value of the
log mean temperature correction factor was calculated (Eqn.3, 4 & 18). The mean temperature
was found by using Ft (Eqn.5). The required area of heat transfer was calculated (Eqn.6).
After deciding on the type of the tube and finding corresponding diameter and the length, the
number of tubes were calculated by using the area of one tube. Then, the bundle diameter
was calculated by adding the bundle diametrical clearance which was found from the graph.
(Eqn.7). After these, the tube-side heat transsfer coefficient was founded by calculating the
mean temperature, tube cross-sectional area, tubes per pass total flow area, tube-side fluid
mass velocity and the linear velocity of corresponding fluid. The physical properties such as
density, viscosity, heat capacity and thermal conductivity, of the fluids were found from the lit-
erature and a correlation which includes jh (Eqn.14, 15& 16), P r, Re, N u was used to calculate
the individual heat transfer coefficient (Eqn.8, 9 & 10). To obtain the shell-side heat transfer
coefficient, the same procedure was repeated as tube-side heat transfer coefficient, however, the
area and the diameter was found by using another formula by taking the tube arrangement as
square (Eqn.11, 12 & 17). Also, for shell-side, the heat transfer factor jh was read from the
graph[1]. After finding the individual heat transfer coefficients, overall heat transfer coefficient
was calculated, and it was compared with the initial guess value of U and it was substituted
with the initial guess value until the comparison resulted in at most 3% error. This whole
procedure was computed with MATLAB.
The pressure drop across the heat exchanger was obtained with Eqn.14 by reading the
friction factor, jf with the corresponding Re from the graphs for both shell and tube side
fluids[1].

3 Result
3.1 Heat Exchanger Design
As a starting point, the pinch point analysis has been done with both hand calculation and
ASPEN Plus for given stream data. Pinch point analysis shows that the pinch point for these
streams is 132◦ C where ∆Tmin is 10◦ C. While doing the pinch point analysis, a composition
curve has been established as shown in Figure 4.

Figure 4: Composition Curve

8
 After pinch point analysis, a Heat Exchanger Network which is a vital component in factories
from the aspect of economy is designed and then optimazed by trying several options which
are discussed in Section 2.

Figure 5: Heat Exchanger Network

From the aspect of efficiency and economy, HEN systems saves a lot of utility usage as
shown in Figure 5. By designing such a system, most of the required energy is obtained from
the available energy in process streams.
When HEN design is finished, design procedure proceeds with the design of a single heat
exchanger unit with both hand calculations and ASPEN Plus. For hand calculations, a well
known algorithm is used, which is Kern’s Method. As mentioned in Section 6, this algorithm has
a serious disadvantage on pressure drop estimation. However, this design procedure is focused
on thermal design of the heat exchanger and Kern’s Method is very useful and relatively easy to
apply[1]. The algorithm is analyzed with an example and converted into a computer program
with MATLAB which can be seen in Appendix 7.1 & 7.2. The details of this algorithm is
also mentioned in Section 2. However, another weakness of Kern’s Method is that calculations
are highly depends on graphical reading. This weakness causes an error in each calculation
and slows down the calculation procedure. Therefore, only 260 diffent combinations of heat
exchanger geometry are calculated. After selecting the suitable ones according to their pressure
drop and linear velocities, same heat exchanger is designed with ASPEN Plus. The comparison
of these two designs can be examined in Table 2.

Table 2: Kern’s Method and ASPEN Plus Comparison

Methods U Area(m2 ) Nt ∆PT ube ∆PShell DShell uT ube uShell

Aspen 441.2 154.1 996 0.1132 0.0243 828.68 1.55 0.14
Kern 473.5402 164.7694 1082 0.5903 0.6834 827.9309 0.9105 0.6937

9
 From Table 2, the fact that Kern’s Method has achieved good results on estimating the
overall heat transfer coefficent with %6 percent error approximately and very poor estimations
on pressure calculations.

3.2 Heat Exchanger Cost

To calculate purchase equipment cost the following formula should be used;

Ce = a + bS n (3.1)
Purchased equipment cost is denoted as Ce , a and b are cost constants which is available in
Table7.2 from Sinnott, S is the size parameter and n is the exponent for that type of equipment
is shown by n.[1]
For shell and tube heat exchanger, a is 28000, b is 54, n equals 1.2 and heat exchanger
area is 164.77 meters square. Purchase equipment cost on a Jan 2010 CEPCI Index, that was
532.9 was calculated as 52697.2$. In these calculations, material of construction was taken as
stainless steel, since the chosen material is copper a correction is needed. By literature research,
prices of the stainless steel and copper per tone was obtained as 2509$ and 2900$, respectively.
The factor of 1.16 was used to obtain exact calculations.
By using this factor, the purchase equipment cost of heat exchanger with material of copper
was founded as 61128.74$ on Jan 2010 CEPCI basis. When calculating the final purchase
equipment cost, CEPCI Index change is needed to be considered. For the heat exchangers
CEPCI Index in March 2017 Report, the index value is 591.0, therefore;
591
(61128.74$) = 67793.37$
532.9
The insulation cost was taken as 4% of the PEC and added to the

67793.37(1.04) = 70505.1$
According to Seider, the total cost of materials installation is estimated as 71.4%.[4]

70505.1(0.714) = 50340.6$
To calculate the total cost, the founded value should be added to purchase equipment cost.
Hence, the total cost was founded as 120845.7$.
In order to find the depreciation, straight line method was applied. To apply this law, the
equipment life was taken as 10 years and salvage cost is assumed as zero. The following formula
was used;
Original Cost − Salvage Cost
Y early Depreciation = (3.2)
Eqipment Lif e
Therefore, the yearly depreciation was evaluated as 12084.6$.
Finally, the labor cost of the heat exchanger network was calculated as by considering one
engineer and six operators for three shifts working for the plant. Therefore; as an average wage
estimate of 30000 TL per shift operator position per year and 60000 TL for an engineer can be
used. The total labor cost was founded as 240000 TL anually.
After all these, the unit founded results were changed from USD to TL and the values
obtained as;

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 Final Purchase Equipment Cost: 275674.9 TL
Installation Cost: 196831.7 TL
Total Cost: 472506.6 TL
Yearly Depreciation: 47250.8 TL

3.3 Cost Calculation Without Heat Exchanger Network

In order calculate the possible cost without the heat exchanger network, it should be con-
sidered the system has four condensers and four heaters to obtain the same output values.
For copper on Jan 2010 CEPCI Index basis.

409825.6$(1.16) = 475397.7$

For copper and March 2017 CEPCI Index.

591.0
(475397.7) = 527228.5$
532.9
If this value is changed to TL unit, it is founded as 2061463.435 TL

Table 3: Purchased Equipment Cost

PEC(basis Jan2010
Areas(m2 )
Stainless Stell)
Conderser 1 271.21 72911.2 $
Condenser 2 197.0 58602.2 $
Condenser 3 193.18 57891.5 $
Condenser 4 235.19 68852.7 $
Heater 1 81.73 38647.6 $
Heater 2 108.42 42946.0 $
Heater 3 72.05 37152.8 $
Heater 4 42.23 32821.0 $
Total PEC 409825.6 $

The insulation cost was taken as 4% of the PEC and added

2061463.4(1.04) = 2143921.9$
The cost of materials installation is estimated as %71.4

2143921.9(0.714) = 1530766.7$
In addition, with the given inlet and outlet temperature, and heat load data, the annual
cost of hot and cold utility costs were calculated and founded as 4798728 TL and 144978 TL,
respectively. Since the heat exchanger components exist in one-phase and the pressure drops
are in the desired range there is no need to use utility of electricity, so that its cost was not
calculated.

Final Purchase Equipment Cost: 3674688.6 TL

Hot Utility Cost: 143961840 TL
Cold Utility Cost: 144978 TL
Total Cost: 147781506.6 TL

11
 These calculations are made to justify the importance of heat exchanger network, the area
cost of the heat exchanger network is 3474044.4 TL, the utility cost is 110074130.4 TL and
installation with insulation cost for heat exchanger 6192692.6 TL, the total cost is 1166139867.4
TL. From the comparison of these numbers, it is seen that heat exchanger network is vital in
the aspect of economics.

4 Discussion
During the design and development of this project, some main steps have been followed.
First, the assignment was defined and discussed among the team members. The engineering
knowledge of the team were analysed and synthesized in order to examine the main problems
that have been identified. After understanding the task and reviewing the materials given,
a literature and technical research have been done. After this elaborate research, various
strategies were established in order to complete the required heat exchanger design. Finally,
the suitable strategies were applied and the project was completed.
For selection of heat exchanger material, stainless steel and copper were compared and it
can be clearly seen that copper has various advantages as a heat exchanger material. Moreover,
the stainless steel option was avoided since it is dangerous to use the process fluid of ethylene
glycol solutions with stainless steel as material. Copper has two main desirable properties to
obtain thermally efficient and durable heat exchangers. Copper is an excellent heat conductor
which means it has a high thermal conductivity that allows heat to pass through it rapidly. In
addition, copper has a high corrosion resistance which is a significant property for heat transfer
applications in which the fluids are considered. Although the only affordable material that has
a high corrosion resistance like copper is stainless steel, it has a lower thermal conductivity
value than copper (which is 1/30th of the latter one.) Besides that, it was chosen that the
tube arrangement of the heat exchanger as square. The reason for this selection is, although
the triangular and rotated square patterns give higher heat transfer rates, they have higher
pressure drop than the square arrangement. Moreover, the square arrangement of tubes is
also used for ease of cleaning. Finally, it is important to mention that the process fluids were
checked according to the boiling points at the specific pressures and it was determined that
they are in one-phase.
According to the calculations by using Kern’s Method and data sheet obtained (see Ap-
pendix), the findings were compared and it was founded that the optimum heat exchanger
design has the following dimensions; it has a diameter of 15.9 mm, thickness of 1.245 mm and
length as 3048 mm. Then, the design of the heat exchanger which has the same dimensions,
heat loads and inlet-outlet temperatures as the optimum one was done by using Aspen. If
the two results were compared, Aspen design has a lower value of number of tubes (1082 for
the Kern’s Method calculations and 996 for Aspen) since it has lower value of flow rate. In
addition, both designs have similar values of heat transfer coefficients.

5 Conclusion
During the design of the heat exchanger, specifications of the system were chosen in such
a way that the design resulted in optimized values. The state of the material that is flowing
through the pipes was checked and the fluids in the heat exchanger are single phase fluids which
corresponds to the flow rate of the fluids and the diameter choice of the tubes, therefore, it affects
the heat transfer area and the overall heat transfer coefficient. The optimum tube diameter
was chosen as 15.9mm with 1.245mm thickness and 3048mm length. In addition, the cost of
the heat exchanger in the network was analyzed and final purchased equipment cost(PEC) was

12
275674.9TL, installation was 196831.7TL and the total cost by taking insulation to account
was founded as 472506.6 TL with a yearly depreciation of 47250.8TL. The insulation cost
was calculated by taking 4%of the PEC. The cost of the separate heat exchangers system was
calculated to observe the benefit of the heat exchanger. The results were, 3674688.6TL for PEC
and installation cost, 143961840TL for hot utility, 144978TL for cold utility, 147781506.6TL
for total cost value with the addition of insulation cost. According to these results, it can be
obviously seen that using HEN is more cost efficient than the single heat exchanger system.
At the beginning of the project, it was aimed to design a heat exchanger with optimum
diameters, thickness, length, material and cost. According to the P&ID diagram, calculations
according to the optimum state, reasonable results for heat exchanger in the network was
obtained. The suitable equipments and materials at design constraints are available at the
market.
In conclusion, an optimized design of a heat exchanger in the network was done by applying
the basic principles of the heat transfer mechanism. The resulting values are analyzed and
they happened to be feasible in terms of area and cost of the system. After all these, the main
conclusion can be done by saying that the heat exchanger network is much more profitable and
energy efficient than using separate heat exchangers system for the same purpose.

6 Recommendations
As a known fact, Kern’s Algorithm has an important disadvantages on predicting the pres-
sure drop, because the method doesn’t consider the leakage and bypassing streams. While
designing a heat exchanger, pressure drop has a huge role due its impact on capital cost.
Therefore, an alternative method should be considered if leakage and bypassing streams are
dominant in the system in order to obtain a more realistic design. Moreover, another weak-
ness of this method is low computational power due to high dependency on graphical readings.
Several optimizations can be made for faster calculations. One of them is Butterworth Equa-
tion which eliminates the graphical reading for tube side heat transfer coefficient. Another
optimization can be made on the correction factor readings. Kern has established a numerical
approximation on F values for 1 shell and even passes[6]. For further approximations works of
R.A. Bowman[7] can be applied.
From another point of view, while considering operation of shell and tube heat exchangers,
one of the most important concern is relief device opening time. To prevent any occasional
risks, nowadays, pressure relief valves are used instead of rupture disc in the shell and tube
heat exchangers. Also, by literature research, it is seen that main dangerous situations about
pressure control control in the heat exchanger are thermal expansion, fire, tube failure and flow
lock-in . Therefore, , while installing the heat exchanger, start up and quality tests must be
conducted to be on the safe side.

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References
[1] Towler, G. P., & Sinnott, R. K. (2013). Chemical engineering design: principles, practice,
and economics of plant and process design. Amsterdam: Elsevier BH.

[2] Sinnott, R. K. (1989). An introduction to chemical engineering design. Oxford: Pergamon

Press.

[3] Smith, R. (2016). Chemical process design and integration. Chichester: Wiley

[4] Seider, W. D., Seader, J. D., & Lewin, D. R. (n.d.). Product & Process Design Principles.
Wiley.

[5] Standards of the Tubular Exchanger Manufacturers Association. (2007). Tarrytown, NY:
TEMA.

[6] Kern, D. Q. (1990). Process heat transfer. New York: McGraw-Hill.

[7] Bowman, R. (1940). Mean Temperature Difference Correction in Multipass Exchangers (Vol.
28). Industrial and Engineering Chemistry.

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7 Appendices
7.1 MATLAB Codes for Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.1.1 Configuration File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.1.2 Kern’s Algorithm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.1.3 Calculations of Heaters and Condensers without HEN . . . . . . . . . . . 18
7.2 MATLAB Codes for Functions Used . . . . . . . . . . . . . . . . . . . . . . . . 18
7.2.1 Prandtl Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.2.2 Reynolds Number in Tube Side . . . . . . . . . . . . . . . . . . . . . . . 18
7.2.3 Reynolds Number in Shell Side . . . . . . . . . . . . . . . . . . . . . . . 18
7.2.4 Log Mean Temperature Difference and F factor . . . . . . . . . . . . . . 18
7.3 Data Sheet of TEMA and Iterative Calculation . . . . . . . . . . . . . . . . . . 19

15
7.1 MATLAB Codes for Calculations
7.1.1 Configuration File
% Glycerol in tube side
% Ethylene Glycol in s h e l l side
inletTuSi = 91.89;
outletTuSi = 115;
inletShSi = 134;
outletShSi = 117.6;
hotIn = 134;
hotOut = 1 1 7 . 6 ;
coldIn = 91.89;
coldOut = 1 1 5 ;
heatCapTuSi = 2 . 4 ; %k J / kgC
heatCapShSi = 2 . 9 3 1 ;
d e n s i t y T u S i = 1 2 5 8 . 2 ; %k g /mˆ3
densityShSi = 1055;
v i s c o s i t y T u S i = 6 . 9 7 e −3; %Pa . s
v i s c o s i t y S h S i = 1 . 8 e −3;
t h e r m a l c o n d T u S i = 0 . 2 9 2 ; %W/mK
thermalcondShSi = 0 . 1 4 9 ;
numofshells = 1;
%N = numpass / n u m o f s h e l l s ; %S h e l l S i d e Tube P a s s e s
h eatLoad = 1 4 4 6 . 9 4 ; %kW
triangular = false ;
foulingShSi = 5000;
foulingTuSi = 5000;
thermalcondTube = 1 0 0 ; %W/mK

%DON’ T Change u p p e r side

numpass = 8 ;
b a f f l e r a t i o = 1 / 0 . 3 ; %r a n g e i s f r o m 0 . 2 t o 1
guessU = 2 6 3 ; %W/mˆ2C
o u t e r D i a T u b e = 2 5 . 4 ; %mm
thickness = 2.108;
i n n e r D i a T u b e =outerDiaTube−t h i c k n e s s ; %mm
l e n g t h T u b e = 3 6 5 8 / 1 0 0 0 ; %m

%DON’ T Change any i f c o n d i t i o n o r v a l u e

%K&n v a l u e s a c c o r d i n g t o number o f p a s s e s
if triangular
i f numpass == 1
K = 0.319;
n = 2.142;
e l s e i f numpass == 2
K = 0.249;
n = 2.207;
e l s e i f numpass == 4
K= 0 . 1 7 5 ;
n= 2 . 2 8 5 ;
e l s e i f numpass == 6
K= 0 . 0 . 0 7 4 3 ;
n= 2 . 4 9 9 ;
e l s e i f numpass == 8
K= 0 . 0 3 6 5 ;
n= 2 . 6 7 5 ;
end
else
i f numpass == 1
K = 0.215;
n = 2.207;
e l s e i f numpass == 2
K = 0.156;
n = 2.291;
e l s e i f numpass == 4
K= 0 . 1 5 8 ;
n= 2 . 2 6 3 ;
e l s e i f numpass == 6
K= 0 . 0 4 0 2 ;
n= 2 . 6 1 7 ;
e l s e i f numpass == 8
K= 0 . 0 3 3 1 ;
n= 2 . 6 4 3 ;
end
end
g r a p h = i m r e a d ( ’ 1 9 2 9 . png ’ ) ;
g r a p h 2 = i m r e a d ( ’ 1 9 3 0 . png ’ ) ;
graph3 = imread ( ’ 1 9 2 4 . t i f ’ ) ;
graph3 = graph3 ( : , : , 1 : 3 ) ;

16
7.1.2 Kern’s Algorithm
config
%%%

f l o w r a t e T u S i = heatLoad / ( heatCapTuSi ∗abs ( o u t l e t T u S i − i n l e t T u S i ) ) ; %k g / s

f l o w r a t e S h S i = heatLoad / ( h e a t C a p S h S i ∗abs ( i n l e t S h S i − o u t l e t S h S i ) ) ; %k g / s
%Hot s t r e a m i n S h e l l S i d e
%C o l d s t r e a m i n Tube S i d e

LMTD = LMTDcorrection ( h o t I n , hotOut , c o l d I n , c o l d O u t ) ;

while t r u e
a r e a = heatLoad ∗1 e 3 / ( guessU ∗LMTD) ; %mˆ2
s i n g l e T u b e A r e a = l e n g t h T u b e ∗ o u t e r D i a T u b e ∗1 e −3∗p i ; %mˆ2
numberofTube = round ( a r e a / s i n g l e T u b e A r e a ) ;
b u n d l e D i a = o u t e r D i a T u b e ∗ ( numberofTube /K) ˆ ( 1 / n ) ; %mm
c l e a r a n c e = 10∗ b u n d l e D i a ∗1 e−3 + 8 ;
s h e l l D i a = bundleDia + c l e a r a n c e ;

%Tube S i d e C o e f f i c i e n t
c r o s s S e c t i o n a l A r e a = p i /4 ∗ i n n e r D i a T u b e ˆ 2 ; %mmˆ2
t u b e s P e r P a s s = round ( numberofTube / numpass ) ;
t o t a l F l o w A r e a = t u b e s P e r P a s s ∗ c r o s s S e c t i o n a l A r e a ∗1 e −6; %mˆ2
massVelocityTuSi = flowrateTuSi / totalFlowArea ;
l i n v e l T u S i = massVelocityTuSi / densityTuSi ;
Re = R e y n o l d s ( i n n e r D i a T u b e , v i s c o s i t y T u S i , l i n v e l T u S i , d e n s i t y T u S i ) ;
Pr = P r a n d t l ( heatCapTuSi , v i s c o s i t y T u S i , t h e r m a l c o n d T u S i ) ;
i f ( Re > 10 && Re < 1 e 6 )
E = 0 . 0 2 2 5 ∗ exp ( − 0 . 0 2 2 5 ∗ ( l o g ( Pr ) ) ˆ 2 ) ;
S t = E∗Re ˆ ( − 0 . 2 0 5 ) ∗ Pr ˆ ( − 0 . 5 0 5 ) ;
j h = S t ∗ Pr ˆ 0 . 6 7 ;
h e a t c o e f T u S i = j h ∗Re∗ Pr ˆ 0 . 3 3 ∗ t h e r m a l c o n d T u S i / ( i n n e r D i a T u b e ∗1 e − 3 ) ;
else
f p r i n t f ( ” Re < 1 0 ! Q u i t i n g . . . \ n ” )
return
end

%S h e l l S i d e C o e f f i c i e n t
b a f f l e S p a c i n g = s h e l l D i a / b a f f l e r a t i o ; %mm
n u m b e r o f B a f f f l e s = l e n g t h T u b e ∗1 e 3 / b a f f l e S p a c i n g −1;
t u b e P i t c h = 1 . 2 5 ∗ o u t e r D i a T u b e ; %mm
c r o s s F l o w A r e a = ( ( t u b e P i t c h −o u t e r D i a T u b e ) / ( t u b e P i t c h ) ) ∗ s h e l l D i a ∗ b a f f l e S p a c i n g ∗1 e −6;
m a s s v e l o c i t y = f l o w r a t e S h S i / c r o s s F l o w A r e a ; %k g /smˆ2
%E q u i v a l e n t D i a m e t e r i n mm
if triangular
e q u i v a l e n t D i a = ( 1 . 1 / o u t e r D i a T u b e ) ∗ ( t u b e P i t c h ˆ2 − 0 . 9 1 7 ∗ o u t e r D i a T u b e ˆ 2 ) ;
else
e q u i v a l e n t D i a = ( 1 . 2 7 / o u t e r D i a T u b e ) ∗ ( t u b e P i t c h ˆ2 − 0 . 7 8 5 ∗ o u t e r D i a T u b e ˆ 2 ) ;
end
Re2 = R e y n o l d s 2 ( m a s s v e l o c i t y , e q u i v a l e n t D i a , v i s c o s i t y S h S i ) ;
f p r i n t f ( ” R e y n o l d s f o r S h e l l S i d e : %. 3 f \n ” , Re2 ) ;
Pr2 = P r a n d t l ( heatCapShSi , v i s c o s i t y S h S i , t h e r m a l c o n d S h S i ) ;
prompt = ’ j h from F i g u r e 1 9 . 2 9 f o r 25% B a f f l e Cut ?\ n ’ ;
imshow ( g r a p h ) ;
j h 2 = input ( prompt ) ;
close a l l
h e a t c o e f S h S i = j h 2 ∗Re2∗ Pr2 ˆ 0 . 3 3 ∗ t h e r m a l c o n d S h S i / ( e q u i v a l e n t D i a ∗1 e − 3 ) ;

f i r s t U = 1/ h e a t c o e f S h S i ;
secondU = 1/ f o u l i n g S h S i ;
t h i r d U = ( o u t e r D i a T u b e ∗1 e −3∗ l o g ( o u t e r D i a T u b e / i n n e r D i a T u b e ) ) / ( 2 ∗ thermalcondTube ) ;
fourthU = ( outerDiaTube / innerDiaTube ) ∗ ( 1 / f o u l i n g T u S i ) ;
f i f t h U = ( outerDiaTube / innerDiaTube ) ∗ ( 1 / h e a t c o e f T u S i ) ;
U = 1 / ( f i r s t U + secondU + t h i r d U + f o u r t h U + f i f t h U ) ;
E r r o r = 1 0 0 ∗ ( (U−guessU ) / guessU ) ; %E r r o r b e t w e e n t h e i t e r a t i o n s
i f abs ( E r r o r ) < 3
break ;
end
guessU = U ;
end

%P r e s s u r e Drop
prompt = ’ j f from F i g u r e 1 9 . 3 0 25% B a f f l e Cut ?\ n ’ ;
imshow ( g r a p h 2 ) ;
j f = input ( prompt ) ;
close ( )
f p r i n t f ( ” R e y n o l d s Number f o r Tube S i d e : %. 3 f \n ” , Re ) ; %R e y n o l d s f o r t u b e s i d e
prompt = ’ j f from F i g u r e 1 9 . 2 4 ? \ n ’ ;
imshow ( g r a p h 3 ) ;
j f 2 = input ( prompt ) ;
close ( )
linvelShSi = massvelocity / densityShSi ;
% v i s c o s i t y c h a n g e i s n e g l e c t e d and \ d e l t a P i n N/mˆ2
d e l t a P S h S i = 8∗ j f ∗ ( s h e l l D i a / e q u i v a l e n t D i a ) ∗ ( l e n g t h T u b e ∗1 e 3 / b a f f l e S p a c i n g ) ∗ ( ( d e n s i t y S h S i ∗ l i n v e l S h S i ˆ 2 ) / 2 ) ;
d e l t a P T u S i = numpass ∗ ( 8 ∗ j f 2 ∗ ( l e n g t h T u b e ∗1 e 3 / i n n e r D i a T u b e ) + 2 . 5 ) ∗ ( ( d e n s i t y T u S i ∗ l i n v e l T u S i ˆ 2 ) / 2 ) ;
d e l t a P S h S i = d e l t a P S h S i ∗1 e −5;
d e l t a P T u S i = d e l t a P T u S i ∗1 e −5;

%P r i n t r e q u i r e d v a l u e s
f p r i n t f (”\n ” ) ;
f p r i n t f ( ” Data f o r E x c e l S p r e a d s h e e t \n ” ) ;
f p r i n t f ( ”U v a l u e : %. 4 f \n ” , U ) ;
f p r i n t f ( ” Area v a l u e : %. 4 f \n ” , a r e a ) ;
f p r i n t f ( ” Number o f Tubes v a l u e : %d \n ” , n u m b e r o f T u b e ) ;
f p r i n t f ( ” Tube S i d e DP v a l u e : %. 4 f \n ” , d e l t a P T u S i ) ;
f p r i n t f ( ” S h e l l S i d e DP v a l u e : %. 4 f \n ” , d e l t a P S h S i ) ;
f p r i n t f ( ” S h e l l D i a m e t e r v a l u e : %. 4 f \n ” , s h e l l D i a ) ;
f p r i n t f ( ” Tube S i d e L i n e a r V e l o c i t y v a l u e : %. 4 f \n ” , l i n v e l T u S i ) ;
f p r i n t f ( ” S h e l l S i d e L i n e a r V e l o c i t y v a l u e : %. 4 f \n ” , l i n v e l S h S i ) ;

17
7.1.3 Calculations of Heaters and Condensers without HEN
%C o n d e n s e r s
h o t I n = h o t I n V a l u e s ;%Pre−d e f i n e d v a l u e s
hotOut = h o t O u t V a l u e s ;
coldIn = 18;
coldOut = 3 8 ;
h o t D u t y C o n s t a n t = [ 9 9 . 8 8 8 . 5 85 8 8 . 5 ] ; %kW/C
h o t D u t i e s = h o t D u t y C o n s t a n t . ∗ ( h o t I n − hotOut ) ;
averageUconstants = 750;

LMTDhot = LMTDcorrection ( h o t I n , hotOut , c o l d I n , c o l d O u t ) ;

c o n d e n s e r A r e a s = ( h o t D u t i e s ∗1 e 3 ) . / ( LMTDhot . ∗ a v e r a g e U c o n s t a n t s ) ;
c o l d u t i l i t y C P = 4 . 1 8 7 ; %k J / kgK
c o l d u t i l i t y F l o w s = ( h o t D u t y C o n s t a n t . / c o l d u t i l i t y C P ) ∗ 3 6 0 0 ; %k g / h
c o l d u t i l i t i e s = sum( c o l d u t i l i t y F l o w s ) / 1 0 0 0 ; %t o n / h
f p r i n t f ( ’ Cold u t i l i t y amount i s : %.3 f t o n /h \n ’ , c o l d u t i l i t i e s ) ;

%H e a t e r s
hotIn = 229;
hotOut = 2 1 9 ;
c o l d I n = c o l d I n V a l u e s ;%Pre−d e f i n e d v a l u e s
coldOut = coldOutValues ;
c o l d D u t y C o n s t a n t = [ 6 2 . 6 8 2 . 6 8 6 . 2 8 5 . 5 ] ; %kW/C
c o l d D u t i e s = coldDutyConstant . ∗ ( coldOut − c o l d I n ) ;
averageUconstants = (250+750)/2;

LMTDcold = LMTDcorrection ( h o t I n , hotOut , c o l d I n , c o l d O u t ) ;

h e a t e r A r e a s = ( c o l d D u t i e s . ∗ 1 e 3 ) . / ( LMTDcold∗ a v e r a g e U c o n s t a n t s ) ;
h o t u t i l i t y C P = 2 . 0 8 2 5 1 ; %k J / kgK
h o t u t i l i t y F l o w s = ( c o l d D u t y C o n s t a n t . / h o t u t i l i t y C P ) ∗ 3 6 0 0 ; %k g / h
h o t u t i l i t i e s = sum( h o t u t i l i t y F l o w s ) / 1 0 0 0 ; %t o n / h
f p r i n t f ( ’ Hot u t i l i t y amount i s : %.3 f t o n /h \n ’ , h o t u t i l i t i e s ) ;

7.2 MATLAB Codes for Functions Used

7.2.1 Prandtl Number
function [ Pr ] = P r a n d t l ( h e a t c a p , v i s c o s i t y , thermalcond )
%P r a n d t l Number
Pr = ( h e a t c a p ∗1 e 3 ∗ v i s c o s i t y ) / t h e r m a l c o n d ;
end

7.2.2 Reynolds Number in Tube Side

function [ Re ] = R e y n o l d s ( d i a m e t e r , v i s c o s i t y , v e l o c i t y , density )
%R e y n o l d s Number
Re = ( d i a m e t e r ∗1 e −3∗ v e l o c i t y ∗ d e n s i t y ) / v i s c o s i t y ;
end

7.2.3 Reynolds Number in Shell Side

function [ Re ] = R e y n o l d s 2 ( Ge , de , viscosity )
%R e y n o l d s Number f o r S h e l l S i d e
Re = ( Ge∗ de ∗1 e −3)/ v i s c o s i t y ;
end

7.2.4 Log Mean Temperature Difference and F factor

function [ LMTDcorrected ] = LMTDcorrection ( h o t I n , hotOut , coldIn , coldOut )
%LMTD Summary o f t h i s f u n c t i o n g o e s h e r e
% Detailed explanation goes here

LMTD = ( ( h o t I n −c o l d O u t ) −( hotOut−c o l d I n ) ) . / l o g ( ( ( h o t I n −c o l d O u t ) ) . / ( ( hotOut−c o l d I n ) ) ) ;

R = ( h o t I n −hotOut ) . / ( coldOut−c o l d I n ) ;
P = ( coldOut−c o l d I n ) . / ( h o t I n −c o l d I n ) ;
numF = s q r t (R. ˆ 2 + 1 ) . ∗ l o g ((1 −P) . / ( 1 −R. ∗ P ) ) ;
denumF = (R− 1 ) . ∗ l o g ((2 −P . ∗ ( R+1−s q r t (R. ˆ 2 + 1 ) ) ) . / ( 2 −P . ∗ ( R+1+s q r t (R. ˆ 2 + 1 ) ) ) ) ;
F = numF . / denumF ;
LMTDcorrected = LMTD. ∗ F ;

end

18
7.3 Data Sheet of TEMA and Iterative Calculation
In following pages result of the trials with different thickness, diameter, length and number
of passes combinations can be seen. Moreover, a TEMA Sheet can be examined in following
pages.

19
x D(mm) & y L(mm) Thickness(mm) U Area Number of Tubes Tube Side DP Shell Side DP Shell Diameter Tube Side Linear Velocity Shell Side Linear Velocity
15.9 & 2438 0.889
2 pass 31.2262 2334.0741 19166 0.0006 0.0076 2682.2182 0.0122 0.0661
4 pass 150.7988 509.0825 4180 0.0111 0.0664 1453.4106 0.1121 0.2251
6 pass 261.6221 304.5754 2501 0.0462 0.2037 1098.2952 0.281 0.3942
8 pass 338.0111 221.1336 1816 0.1816 0.2901 1005.3914 0.5161 0.4705
1.245
2 pass 33.9865 2142.7998 17595 0.0007 0.0089 2584.2299 0.014 0.0712
4 pass 150.5407 509.0825 4180 0.012 0.0664 1453.4106 0.1176 0.2251
6 pass 272.0962 292.4665 2402 0.0521 0.2166 1081.5976 0.3073 0.4065
8 pass 363.5922 213.0817 1750 0.2106 0.2658 991.5183 0.5613 0.4837
1.651
2 pass 35.4527 2073.6416 17028 0.0009 0.0094 2547.6581 0.0153 0.0733
4 pass 153.1084 508.1103 4172 0.0133 0.0678 1452.1875 0.1247 0.2255
6 pass 290.7301 269.8061 2215 0.0695 0.237 1048.8575 0.3524 0.4323
8 pass 373.0384 210.6615 1730 0.2453 0.286 987.2503 0.602 0.4879
15.9 & 3048 0.889
2 pass 51.1624 1527.2475 10031 0.0015 0.0285 2023.8641 0.0234 0.1161
4 pass 219.3825 355.2808 2334 0.0256 0.2272 1125.2733 0.2006 0.3756
6 pass 373.8834 204.9287 1346 0.16 0.5645 868.4555 0.523 0.6305
8 pass 460.0481 170.8466 1122 0.4889 0.6473 839.2703 0.8369 0.6751
1.245
2 pass 53.3926 1467.8029 9641 0.0017 0.0276 1989.2713 0.0255 0.1202
4 pass 228.0989 342.5596 2250 0.0309 0.2423 1107.3228 0.2183 0.3878
6 pass 384.3618 200.0187 1314 0.188 0.5742 860.5806 0.5613 0.6421
8 pass 473.5402 164.7694 1082 0.5903 0.6834 827.9309 0.9105 0.6937
1.651
2 pass 58.195 1347.9864 8854 0.0019 0.032 1916.9801 0.0294 0.1294
4 pass 235.8539 328.1471 2155 0.0362 0.2614 1086.5649 0.2412 0.4028
6 pass 390.2278 198.4963 1304 0.2194 0.5923 858.0954 0.5992 0.6458
8 pass 481.8337 161.5329 1061 2.5898 0.7038 821.8731 0.9776 0.704
15.9 & 3658 0.889
2 pass 84.1793 919.0576 5030 0.0038 0.0894 1499.4604 0.0466 0.2115
4 pass 304.6049 255.576 1399 0.0565 0.5897 899.1164 0.3347 0.5882
6 pass 461.6432 167.8044 918 0.379 1.1858 751.3951 0.7658 0.8423
8 pass 549.6306 140.224 767 1.1373 1.3205 727.8442 1.2204 0.8977
1.245
2 pass 85.4851 919.2939 5031 0.004 0.0894 1499.5898 0.0489 0.2115
4 pass 307.846 255.3944 1398 0.0635 0.6132 898.8348 0.3512 0.5886
6 pass 474.7543 162.1246 887 0.4394 1.249 741.7006 0.8306 0.8644
8 pass 554.8894 139.4892 763 1.3043 1.3308 726.4215 1.2939 0.9012
1.651
2 pass 109.5742 690.3481 3378 0.0063 0.1446 1324.2952 0.0688 0.2712
4 pass 325.7374 239.2238 1039 0.0835 0.6626 873.3134 0.3976 0.6235
6 pass 477.9414 161.2281 882 0.4984 1.235 740.1174 0.8845 0.8681
8 pass 561.943 138.6692 759 1.4943 1.3413 724.9942 1.3687 0.9047
15.9 & 4877 0.889
2 pass 167.6825 469.0084 1925 0.0116 0.5998 988.6979 0.1217 0.4865
4 pass 451.9813 173.2792 711 0.2539 1.3713 668.7563 0.6582 1.0633
6 pass 620.701 123.9743 509 1.3349 3.7013 601.4034 1.3784 1.3148
8 pass 710.5623 108.8937 447 3.8716 3.8674 594.8379 2.0921 1.344
1.245
2 pass 177.0226 440.1003 1807 0.0142 0.6577 961.9897 0.136 0.5139
4 pass 505.1253 149.1403 612 0.352 3.145 626.3953 0.8034 1.212
6 pass 639.7188 120.0259 493 1.5895 3.329 594.2053 1.499 1.3468
8 pass 747.8613 103.2596 424 4.5687 4.0993 583.2253 2.3193 1.398
1.651
2 pass 186.9714 417.1616 1712 0.0174 0.6968 939.7643 0.1519 0.5385
4 pass 482.889 161.1015 661 0.36 2.8055 647.8047 0.788 1.1332
6 pass 639.5773 119.6526 491 1.7965 4.6255 593.2954 1.5857 1.351
8 pass 735.6403 102.9646 423 5.1533 4.1138 582.7117 2.4533 1.4005
15.9 & 6096 0.889
2 pass 261.6488 299.5073 984 0.0296 2.0629 739.6886 0.2381 0.8691
4 pass 600.2118 130.9038 430 0.7379 7.1245 537.0927 1.0848 1.6485
6 pass 769.0493 101.308 333 3.5263 8.5878 512.5869 2.0921 1.8099
8 pass 841.3679 91.5901 301 8.812 8.363 513.2875 3.0832 1.805
1.245
2 pass 270.1247 289.1246 949 0.0358 2.1961 728.2127 0.2588 0.8967
4 pass 617.2735 126.5969 416 0.8366 7.5471 529.4102 1.1819 1.6967
6 pass 783.2763 99.1548 326 4.0687 8.682 508.5072 2.2763 1.839
8 pass 849.1167 91.4898 300 10.0788 8.4046 512.6517 3.2348 1.8094
1.651
2 pass 299.0088 254.5413 836 0.0414 2.7333 689.4401 0.3111 1.0004
4 pass 626.0762 123.48 406 1.0119 7.8736 523.8339 1.2748 1.733
6 pass 768.0344 101.8165 334 4.583 8.371 513.1654 2.3219 1.8058
8 pass 864.9291 89.8381 295 12.1901 8.8011 509.4528 3.5142 1.8322
x D(mm) & y L(mm) Thickness(mm) U Area Number of Tubes Tube Side DP Shell Side DP Shell Diameter Tube Side Linear Velocity Shell Side Linear Velocity
19.1 & 2438 0.8890
2 pass 14.5490 5171.3479 35350.0000 0.0002 0.0016 4204.4068 0.0045 0.0069
4 pass 97.0461 754.2080 5156.0000 0.0044 0.0215 1913.0218 0.0618 0.1299
6 pass 188.7167 411.6462 2814.0000 0.0202 0.0684 1378.0888 0.1697 0.2504
8 pass 269.4272 274.3050 1875.0000 0.0707 0.1259 1220.7060 0.3402 0.3191
1.2450
2 pass 14.3613 5111.9977 34944.0000 0.0017 0.0013 4183.3010 0.0047 0.0272
4 pass 94.4248 780.3162 5334.0000 0.0045 0.0202 1941.8086 0.0621 0.1261
6 pass 207.4789 364.9589 2495.0000 0.0278 0.0821 1316.5242 0.1991 0.2744
8 pass 273.8895 269.3975 1842.0000 0.0804 0.112 1212.5859 0.3600 0.3234
1.6510
2 pass 15.8011 4597.2759 31426.0000 0.0002 0.0016 3994.3256 0.0055 0.0298
4 pass 104.5843 765.6960 5234.0000 0.005 0.0508 1925.7034 0.0662 0.1282
6 pass 218.5881 335.9805 2297.0000 0.0308 0.0931 1275.8273 0.2264 0.2921
8 pass 274.3208 268.0016 1832.0000 0.0906 0.1036 1210.1074 0.3786 0.3247
19.1 & 3048 0.8890
2 pass 28.7717 2533.7260 13854.0000 0.0005 0.0073 2796.0912 0.0115 0.0608
4 pass 156.2982 478.1815 2615.0000 0.0153 0.076 1419.2768 0.1217 0.2361
6 pass 273.1543 271.2949 1483.0000 0.057 0.2073 1080.6309 0.3223 0.4072
8 pass 338.8155 229.3247 1254.0000 0.1709 0.2297 1049.4897 0.5070 0.4317
1.2450
2 pass 31.6618 2354.6129 12874.0000 0.0006 0.0083 2708.2232 0.0129 0.0648
4 pass 171.7046 428.6451 2344.0000 0.0194 0.0921 1352.6713 0.1413 0.2599
6 pass 277.7201 268.1772 1466.0000 0.0643 0.211 1075.9157 0.3394 0.4108
8 pass 335.1469 237.1431 1297.0000 0.1765 0.2175 1062.8606 0.5112 0.4210
1.6510
2 pass 32.7530 2223.9929 12160.0000 0.0007 0.0079 2641.8040 0.0143 0.0681
4 pass 172.2350 426.6514 2333.0000 0.0146 0.0929 1349.8791 0.1487 0.2610
6 pass 288.3971 254.5413 1392.0000 0.0788 0.2241 1054.9872 0.3737 0.4273
8 pass 337.7756 234.3634 1281.0000 0.1976 0.2216 1057.9180 0.5419 0.4249
19.1 & 3658 0.8890
2 pass 51.7042 1413.3182 6439.0000 0.0012 0.0264 2003.5462 0.0247 0.1185
4 pass 211.5436 347.9105 1585.0000 0.0257 0.2088 1139.1658 0.2010 0.3664
6 pass 308.3358 254.5413 1160.0000 0.1062 0.348 984.5284 0.4125 0.4906
8 pass 425.6019 183.2788 835.0000 0.4054 0.501 900.9616 0.7654 0.5858
1.2450
2 pass 53.5992 1363.6484 6213.0000 0.0013 0.0281 1972.6660 0.0267 0.1222
4 pass 211.2423 353.1078 1609.0000 0.0052 0.2095 1146.7028 0.2060 0.3616
6 pass 335.5228 231.2186 1053.0000 0.1366 0.416 949.0759 0.4705 0.5279
8 pass 432.6433 178.4461 813.0000 1.8771 0.5166 891.9860 0.8119 0.5977
1.6510
2 pass 56.3106 1320.6275 6017.0000 0.0016 0.0302 1945.3683 0.0288 0.1257
4 pass 218.1076 343.2893 1564.0000 0.029 0.2588 1132.5185 0.2218 0.3708
6 pass 344.9845 227.8924 1038.0000 0.1541 0.4173 943.9306 0.5012 0.5337
8 pass 432.9098 178.7918 815.0000 0.5112 0.5244 892.8081 0.8501 0.5966
19.1 & 4877 0.8890
2 pass 107.3396 696.3304 2379.0000 0.0045 0.2404 1300.1495 0.0669 0.2813
4 pass 315.4739 246.8225 843.0000 0.0772 0.7684 863.7737 0.3773 0.6374
6 pass 454.9257 172.3797 589.0000 0.4288 1.2217 761.7226 0.8123 0.8196
8 pass 533.8890 146.8949 502.0000 1.2338 1.2846 744.5839 1.2635 0.8577
1.2450
2 pass 110.0201 683.5796 2336.0000 0.0051 0.252 1289.9027 0.0709 0.2858
4 pass 308.5638 254.5413 870.0000 0.0797 0.7411 875.7791 0.3799 0.6200
6 pass 458.0027 171.5631 586.0000 0.4678 1.2312 760.2533 0.8450 0.8228
8 pass 615.6872 126.5936 433.0000 1.7959 1.6696 704.5073 1.5335 0.9581
1.6510
2 pass 114.0153 654.4703 2236.0000 0.0059 0.1882 1265.6543 0.0776 0.2969
4 pass 323.1633 241.5970 826.0000 0.1068 0.7963 856.1043 0.4189 0.6488
6 pass 464.2821 168.0263 574.0000 4.7589 1.2703 754.3294 0.9032 0.8357
8 pass 606.1670 124.1291 424.0000 2.1439 2.412 698.9940 1.6360 0.9733
19.1 & 6096 0.8890
2 pass 176.1163 422.4354 1155.0000 0.0127 0.0655 950.6198 0.1377 0.5262
4 pass 428.5085 180.3135 493.0000 0.2042 2.2658 683.1602 0.6472 1.0189
6 pass 584.1915 133.8340 366.0000 1.1935 2.9457 636.4245 1.3050 1.1741
8 pass 692.4276 112.6679 308.0000 3.5001 3.3339 620.2833 2.0411 1.2360
1.2450
2 pass 181.7254 410.5508 1122.0000 0.0134 0.7281 938.7682 0.1476 0.5396
4 pass 438.0349 177.9030 486.0000 0.257 2.3231 678.9071 0.6788 1.0317
6 pass 611.8309 128.3734 351.0000 1.4045 4.5864 626.4556 1.4036 1.2117
8 pass 687.0132 114.0779 312.0000 3.8519 4.5647 623.2799 2.1233 1.2241
1.6510
2 pass 187.0819 401.7290 1098.0000 0.0148 0.7421 930.0249 0.1579 0.5498
4 pass 452.7870 173.2649 474.0000 0.3022 2.5279 671.5358 0.7286 1.0545
6 pass 548.6317 142.1771 389.0000 1.2943 2.7725 651.2313 1.3340 1.1213
8 pass 705.1175 110.0526 301.0000 4.3901 3.4145 614.9806 2.2818 1.2574
x D(mm) & y LThickness(mmU Area Number of Tubes Tube Side DP Shell Side DP Shell Diameter Tube Side Linear Velocity Shell Side Linear Velocity
22.2 & 2438 1.245
2 pass Not Feasible Not Feasible Not Feasible Not Feasible Not Feasible Not Feasible Not Feasible Not Feasible
4 pass 55.0046 1326.9376 7804 0.0017 0.005 2667.2668 0.0308 0.0668
6 pass 130.7557 564.8203 3322 0.009 0.026 1704.7178 0.1085 0.1636
8 pass 174.4953 455.0819 2676 0.0222 0.0318 1620.5964 0.1795 0.1811
1.651
2 pass Not Feasible Not Feasible Not Feasible Not Feasible Not Feasible Not Feasible Not Feasible Not Feasible
4 pass 57.4282 1268.5039 7460 0.0019 0.0054 2614.816 0.0335 0.0696
6 pass 145.7975 500.3819 2943 2943 0.0307 1627.9689 0.1273 0.1794
8 pass 157.4573 509.0825 2994 0.0195 0.0269 1690.5833 0.1672 0.1664
2.108
2 pass Not Feasible Not Feasible Not Feasible Not Feasible Not Feasible Not Feasible Not Feasible Not Feasible
4 pass 60.5418 1209.37 7113 0.0023 0.0058 2560.5215 0.0368 0.0725
6 pass 144.4911 509.0825 2994 0.0123 0.0299 1638.6391 0.1311 0.1771
8 pass 185.0634 428.4123 2520 0.0265 0.0342 1584.3622 0.2076 0.1894
2.769
2 pass 9.4935 7671.785 45119 0.0001 0.0001 5433.6543 0.0031 0.0161
4 pass 67.7401 1073.2544 6312 0.0029 0.0071 2429.2605 0.0443 0.0806
6 pass 147.0455 509.0825 2994 0.0141 0.0299 1638.6391 0.1401 0.1771
8 pass 210.9891 360.034 2117 0.0408 0.0438 1483.7813 0.2639 0.216
22.2 & 3048 1.245
2 pass 15.8502 4590.2418 21593 0.0002 0.0016 3941.2797 0.0056 0.0306
4 pass 102.3764 714.9757 3363 0.0048 0.025 1841.2036 0.0715 0.1403
6 pass 177.3247 441.2547 2076 0.0188 0.0642 1425.7248 0.1738 0.2339
8 pass 262.9704 280.4488 1319 0.0828 0.106 1241.8959 0.3644 0.3083
1.651
2 pass 16.7065 4359.8923 20510 0.0002 0.0018 3853.9217 0.0061 0.032
4 pass 104.1105 705.2157 3317 0.0053 0.0256 1830.0806 0.0754 0.142
6 pass 176.1172 445.1392 2094 0.0203 0.0634 1430.4094 0.1791 0.2324
8 pass 239.2355 331.7454 1561 0.0676 0.0852 1323.099 0.3206 0.2716
2.108
2 pass 17.9624 4058.308 19091 0.0002 0.002 3735.4295 0.0069 0.0341
4 pass 106.0348 694.2034 3266 0.006 0.0263 1817.6474 0.08 0.1439
6 pass 184.7099 424.2354 1996 0.0231 0.0682 1404.5948 0.1964 0.241
8 pass 252.2743 314.2485 1478 0.0833 0.0909 1296.192 0.3535 0.283
2.769
2 pass 19.248 3818.1188 17961 0.0003 0.0022 3637.4702 0.0078 0.0359
4 pass 126.9574 573.3236 2697 0.0082 0.0352 1670.8659 0.1037 0.1703
6 pass 194.2024 401.9072 1891 0.028 0.0728 1376.0517 0.222 0.2511
8 pass 262.7446 293.7014 1382 0.1062 0.1005 1263.8717 0.4042 0.2977
22.2 & 3658 1.245
2 pass 28.1216 2599.5906 10190 0.0004 0.0063 2841.9899 0.0118 0.0589
4 pass 138.1102 545.4455 2138 0.009 0.0615 1508.6597 0.1124 0.2089
6 pass 231.8658 342.6491 1343 0.041 0.1444 1208.3669 0.2684 0.3257
8 pass 313.5596 246.3302 966 0.1695 0.1782 1104.728 0.4969 0.3897
1.651
2 pass 29.9712 2435.0197 9545 0.0005 0.0068 2762.246 0.0131 0.0623
4 pass 142.1856 526.6371 2064 0.0101 0.0654 1485.4819 0.1212 0.2155
6 pass 250.0414 305.4495 1197 0.056 0.1675 1156.7224 0.3126 0.3554
8 pass 327.7414 231.4011 907 0.2031 0.2155 1078.8862 0.5533 0.4085
2.108
2 pass 31.8009 2304.6906 9034 0.0006 0.0072 2696.8862 0.0145 0.0654
4 pass 149.8749 492.6605 1931 0.0126 0.0735 1442.6283 0.1354 0.2285
6 pass 261.4157 288.1599 1130 0.07 0.1845 1131.7149 0.3479 0.3713
8 pass 341.9172 218.1782 855 0.2469 0.2355 1055.2293 0.6112 0.4271
2.769
2 pass 35.7331 2036.2874 7982 0.0008 0.0088 2555.4346 0.0175 0.0728
4 pass 158.1571 462.8023 1814 0.015 0.0814 1403.5463 0.154 0.2414
6 pass 267.0786 282.8236 1109 0.0845 0.0845 1123.6888 0.378 0.3766
8 pass 348.5779 212.1177 831 0.3036 0.2413 1044.0086 0.6723 0.4363
22.2 & 4877 1.245
2 pass 52.8884 1497.9766 4404 0.0014 0.0308 1973.0475 0.0273 0.1222
4 pass 213.1337 372.6127 1095 0.0236 0.2478 1124.5327 0.2194 0.376
6 pass 348.4732 226.0426 665 0.1823 0.4965 925.6375 0.5416 0.555
8 pass 428.7201 181.4503 533 0.5842 0.5894 883.7659 0.8973 0.6089
1.651
2 pass 60.6686 1272.7063 3742 0.0019 0.0397 1838.1815 0.0334 0.1407
4 pass 228.2618 339.3883 998 0.0308 0.2864 1079.6932 0.2501 0.4079
6 pass 360.8815 212.1177 624 0.218 0.5414 903.5927 0.6012 0.5824
8 pass 446.8813 171.6008 505 0.7262 0.6415 866.0664 0.9924 0.634
2.108
2 pass 72.3655 1018.165 2993 0.0028 0.0557 1668.1826 0.0437 0.1709
4 pass 240.5865 318.1766 935 0.0393 0.3211 1049.2538 0.2795 0.4319
6 pass 373.1557 203.633 599 0.2598 0.576 889.7085 0.654 0.6007
8 pass 449.3087 167.8294 493 0.8141 0.6651 858.294 1.0548 0.6455
2.769
2 pass 81.1141 898.3809 2641 0.0035 0.0681 1579.9462 0.0529 0.1905
4 pass 249.727 305.4495 898 0.05 0.3447 1030.8405 0.3108 0.4475
6 pass 385.0218 195.801 576 0.3315 0.6112 876.6151 0.7283 0.6188
8 pass 453.4792 166.0052 488 0.9752 0.6753 855.0209 1.1463 0.6505
22.2 & 6096 1.245
2 pass 101.6215 763.6238 1796 0.0045 0.1636 1336.4404 0.0669 0.2662
4 pass 310.3746 255.1867 600 0.0863 0.802 863.8973 0.4008 0.6372
6 pass 454.3151 172.6765 406 0.5201 1.2717 767.9502 0.8841 0.8063
8 pass 538.5185 146.8507 345 1.5511 1.3914 750.8705 1.3982 0.8434
1.651
2 pass 113.0896 664.0207 1562 0.0052 0.2049 1257.9127 0.0801 0.3005
4 pass 324.9209 238.6324 561 0.109 0.9022 838.8518 0.4466 0.6758
6 pass 470.1997 162.4731 382 0.6372 1.3666 750.4604 0.9769 0.8444
8 pass 550.2927 138.0875 325 1.8479 1.4911 734.2734 1.5249 0.882
2.108
2 pass 124.9557 587.4029 1382 0.0064 0.2447 1192.8686 0.0946 0.3342
4 pass 337.0955 224.5952 528 0.1339 0.9933 816.8892 0.4954 0.7126
6 pass 477.9248 159.0883 374 0.7472 1.411 744.4801 1.0548 0.858
8 pass 555.9311 135.1546 318 2.1322 1.5405 728.3147 1.6349 0.8965
2.769
2 pass 132.3931 553.3506 1302 0.008 0.2762 1162.4267 0.1074 0.3519
4 pass 348.5204 218.1782 513 0.162 1.0447 806.6529 0.5463 0.7308
6 pass 483.3501 156.4803 368 0.8708 1.446 739.9427 1.1463 0.8685
8 pass 564.3099 133.9691 315 2.5969 1.5626 725.7361 1.7929 0.9029
x D(mm) & y LThickness(mmU Area Number of Tubes Tube Side DP Shell Side DP Shell Diameter Tube Side Linear Velocity Shell Side Linear Velocity
25.4 & 2438 1.245
2 pass Not Feasible Not Feasible Not Feasible Not Feasible Not Feasible Not Feasible Not Feasible Not Feasible
4 pass 31.254 2374.863 12207 0.0005 0.0013 3715.6477 0.0148 0.0344
6 pass 91.3979 819.164 4211 0.0038 0.0113 2133.4109 0.0645 0.1045
8 pass 146.8042 505.9421 2601 0.0123 0.017 1833.3045 0.1392 0.1415
1.651
2 pass Not Feasible Not Feasible Not Feasible Not Feasible Not Feasible Not Feasible Not Feasible Not Feasible
4 pass 32.3721 2297.4075 11809 0.0006 0.0014 3661.7353 0.0159 0.0355
6 pass 90.8878 826.2759 4247 0.0042 0.0099 2140.3358 0.0661 0.1038
8 pass 148.0354 506.4346 2603 0.0129 0.0172 1833.8354 0.144 0.1414
2.108
2 pass Not Feasible Not Feasible Not Feasible Not Feasible Not Feasible Not Feasible Not Feasible Not Feasible
4 pass 33.8381 2200.2318 11310 0.0007 0.0015 3592.6882 0.0172 0.0368
6 pass 94.29 786.0063 4040 0.0048 0.0107 2100.0079 0.0723 0.1078
8 pass 151.7982 489.2542 2515 0.0152 0.0179 1810.2308 0.155 0.1451
25.4 & 3048 1.245
2 pass 7.9573 9366.4097 38510 0.0001 0.0005 5801.0655 0.0023 0.0141
4 pass 59.0827 1257.6758 5171 0.0018 0.0065 0.0065 0.0065 0.0734
6 pass 142.7927 520.7311 2141 0.0107 0.0319 1649.3037 0.1267 0.1748
8 pass 186.5867 397.5977 1635 0.0287 0.0413 1539.2631 0.2218 0.2007
1.651
2 pass 8.4448 8815.2086 36244 0.0001 0.0005 5649.7315 0.0026 0.0149
4 pass 59.4117 1255.8576 5163 0.002 0.0065 2542.8991 0.0363 0.0735
6 pass 143.8687 528.4352 2173 0.0113 0.0312 1658.6346 0.1293 0.1729
8 pass 188.7187 394.7555 1623 0.0314 0.0418 1535.0011 0.2306 0.2018
2.108
2 pass 9.0379 8227.0713 33826 0.0001 0.0006 5482.2425 0.0029 0.0158
4 pass 65.0689 1139.3902 4685 0.0024 0.0076 2436.3773 0.0416 0.0801
6 pass 149.2732 503.2707 2069 0.0129 0.0336 1627.9893 0.141 0.1794
8 pass 195.0232 381.8119 1570 0.037 0.0439 1515.9393 0.2483 0.2069
25.4 & 3658 1.245
2 pass 14.818 5009.0133 17160 0.0002 0.0015 4078.7618 0.0053 0.0286
4 pass 82.1585 954.5297 3270 0.0032 0.0161 2079.6177 0.0553 0.11
6 pass 171.9829 449.1905 1539 0.0171 0.0601 1454.7776 0.1761 0.2247
8 pass 233.132 332.0103 1137 0.0654 0.0828 1342.6307 0.3186 0.2638
1.651
2 pass 15.5259 4797.2741 16435 0.0002 0.0016 4002.777 0.0057 0.0297
4 pass 93.7415 803.8145 2754 0.0042 0.0215 1928.223 0.0679 0.1279
6 pass 185.2982 401.9072 1377 0.0209 0.0711 1394.5762 0.2035 0.2445
8 pass 246.5242 305.4495 1046 0.081 0.0923 1301.1641 0.3573 0.2809
2.108
2 pass 16.6069 4471.2944 15318 0.0002 0.0017 3881.9147 0.0064 0.0316
4 pass 116.7293 670.48 2297 0.0057 0.0286 1780.2677 0.0848 0.15
6 pass 187.4974 399.3205 1368 0.0237 0.0719 1391.1062 0.2134 0.2457
8 pass 255.524 290.3512 995 0.0973 0.0995 1276.9369 0.3924 0.2916
25.4 & 4877 1.245
2 pass 30.7677 2545.413 6541 0.0006 0.0085 2680.031 0.0138 0.0662
4 pass 149.288 522.8275 1343 0.0115 0.0934 1406.077 0.1347 0.2405
6 pass 261.002 298.5352 767 0.0735 0.2187 1116.749 0.3535 0.3813
8 pass 328.87 235.8766 606 0.2463 0.2549 1059.866 0.5953 0.4233
1.651
2 pass 39.2164 1901.585 4886 0.0007 0.0137 2360.568 0.0192 0.0853
4 pass 153.757 509.0825 1308 0.0123 0.1144 1389.858 0.1431 0.2462
6 pass 261.79 297.7941 765 0.0798 0.2156 1115.643 0.3657 0.3821
8 pass 346.707 218.1782 561 0.3076 0.2862 1029.602 0.6687 0.4486
2.108
2 pass 41.2064 1828.918 4700 0.0008 0.0147 2321.049 0.0207 0.0883
4 pass 162.615 477.2649 1226 0.0143 0.1077 1350.884 0.1585 0.2606
6 pass 280.512 272.7228 701 0.1038 0.2462 1079.275 0.4159 0.4082
8 pass 348.616 218.1782 561 0.3378 0.2917 1029.602 0.6952 0.4486
25.4 & 6096 1.245
2 pass 59.3275 1310.114 2693 0.0017 0.0428 1821.905 0.0336 0.1433
4 pass 226.497 339.5263 698 0.0348 0.3183 1054.976 0.2586 0.4273
6 pass 341.455 223.5637 460 0.2168 0.5397 919.9873 0.5876 0.5619
8 pass 409.835 190.9059 392 0.6271 0.5891 900.0316 0.9234 0.587
1.651
2 pass 65.6891 1174.806 2415 0.0023 0.0517 1737.658 0.0387 0.1575
4 pass 250.641 299.6967 616 0.0478 0.3963 998.7247 0.3039 0.4768
6 pass 349.155 218.1782 449 0.2481 0.5598 911.5916 0.6241 0.5723
8 pass 426.102 181.8152 374 0.7398 0.6322 884.307 0.9959 0.6081
2.108
2 pass 69.5716 1122.976 2309 0.0023 0.055 1704.101 0.0421 0.1638
4 pass 252.779 299.4603 616 0.052 0.3963 998.7247 0.316 0.4768
6 pass 354.598 215.1053 442 0.2766 0.5733 906.1825 0.6576 0.5791
8 pass 428.311 177.5869 365 0.8483 0.6557 876.2678 1.0579 0.6193
8 Equations
Heat Load Equation;
Q
m= (1)
Cp ∆T
Log Mean Temperature Formula;

(Thot1 − Tcold2 ) − (Thot2 − Tcold1 )

∆Tlm =   (2)
Thot1 − Tcold2
ln
Thot2 − Tcold1

Dimensionless Temperature Ratio;

Thot1 − Thot2
R= (3)
Tcold2 − Tcold1
Dimensionless Temperature Ratio;
Tcold2 − Tcold1
S= (4)
Thot1 − Tcold1
The Correlation Between Log Mean Temperature and Mean Temperature;

∆Tm = Ft ∆Tlm (5)

Newton’s Law of Cooling;

Q
A= (6)
U ∆Tlm
Bundle Diameter ;
 1
Nt n1
Db = do (7)
K1
Heat Transfer Coefficient Correlation;
 0.14
hi di µ
= jh ReP r0.33 (8)
kf µw

Reynolds Number ;
ρudi
Re = (9)
µ
Prandtl Number ;
Cp µ
Pr = (10)
kf
Shell Area;
(pt − d0 )Ds IB
As = (11)
pt
Shell Side Equivalent Diameter for Square Pitch;
 2
pt − πd2o

4
πdo
de = (12)
πdo

24
Tube Side Pressure Drop;
   −m !
L µ ρu2t
∆Pt = Np 8jf + 2.5 (13)
di µw 2

Butterworth Correlation;
St = ERe−0.205 P r−0.505 (14)
Constant for Butterworth Correlation;

E = 0.0225exp −0.0225(lnP r)2

(15)

Heat Transfer Factor Correlation for Tube Side Fluid ;

 −0.14
0.67 µ
jh = StP r (16)
µw

Shell Side Equivalent Diameter for Triangular Pinch Arrangenment;

1 d2o
 
pt
4 0.87pt − π
2 2 4
de = (17)
πdo
2
The Log Mean Temperature Correction Factor for 1 Shell 2 Tube Passes;
√
 
2
1−S
( R + 1)ln
1 − RS
Ft = " √
# (18)
2 − S R + 1 − R2 + 1
(R − 1)ln √

2 − S R + 1 + R2 + 1

25