Detail Design

Chapter
Process Design of
Heat Exchangers
6.1 SHELL AND TUBE HEAT EXCHANGER
Shell and tube heat exchangers are the most widely used equipments in chemical
industy. They are mostly used as heat transfer equipments but in a few cases they
are also used as Reactors, Falling Film Absorbers, etc. Sizes of various parts of
shell and tube heat exchangers like shell, tubes, tierods are standardized. Standards
developed by Tubular Exchanger Manufacturers Association, USA (TEMA) are
universally used for design of shell and tube heat exchangers. Equivalent Indian
Standard is IS: 4503. TEMA or IS: 4503 specify standard sizes of shell, tubes,
tierods, etc. and also maximum allowable baffle spacing, minimum tube sheet
thickness, baffle thickness, numbers of tierods required, etc. For mechanical design
and fabrication, in addition to TEMA standard, ASME Code Section VIII D1V.
I is used. In TEMA standard, shell and tube heat exchangers are classified in
three catagory;
(i) Class R covers heat exchangers which are used for severe duties in petro-
leum and related industries,
(ii) Class B covers the heat exchangers which are used in chemical process
industries not involving severe duties, and
(iii) Class C covers the heat exchangers which are used in commercial and in
less important process applications.
Most popular and reliable softwares used for the design of shell and tube heat
exchangers are of:
(i) HTRI: Heat Transfer Research Institute, USA
(ii) HTFS: Heat Transfer Fluid Flow Services, UK
(iii) BJAC: USA based company
(iv) HEI: Heat Exchange Institute, USA.
Design methods and equations used by these softwares are not available in open
literature. For the design of shell and tube heat exchanger involving fluid without
phase change, methods used by these softwares are based on Tinker's flow model.
Process Design of Heat Exchangers
@0(2)0© 0000 © (36)
T*
=5
1
Q4) © 0
Internal Floating Head Heat Exchanger with Backing Ring, Type AES
(a)
32 2 3) 6 (T^
n
f
M &
Fixed Tube Sheet Heat Exchanger, Type BEM
(b)
o 19 20 21
Outside-Packed Floating Head Heat Exchanger, Type AEP

(c)
© <AX 3)0(5
yp
U Tube Heat Exchanger, Type CFU

(d)
Introduction to Process Engineering and Design
© © d ©
Kettle Type Floating Head Reboiler, Type AKT

(e)
© 12 34
34 12 34 12 34 5
Exchanger with Packed Floating Tube sheet and Lantern Ring, Type AJW
(f)
Nomenclature of Parts of Various Shell and Tube Heat Exchangers
1. Stationary Head—Channel 14. Expansion Joint 27. Tie rods and Spacers
2. Stationary Head—Bonnet 15. Floating Tube sheet 28. Transverse Baffles or Sup-
3. Stationary Head Flage— 16. Floating Head Cover port Plates
Channel or Bonnet 17. Floating Head Flange 29. Impingement Plate
4. Channel Cover 18. Floating Head Split Backing 30. Longitudinal Baffle
5. Stationary Head Nozzle Ring 31. Pass Partition
6. Stationary Tube sheet 19. Split Shear Ring 32. Vent Connection
7. Tubes 20. Slip-on Backing Flange 33. Drain Connection
8. Shell 21. Floating Head Cover— 34. Instrument Connection
9. Shell Cover External 35. Support Saddle
10. Shell Flange-Stationary 22. Floating Tube sheet Skirt 36. Lifting Lug
Head End 23. Packing Box Flange 37. Support Bracket
II. Shell Flange-Rear Head End 24. Packing 38. Weir
12. Shell Nozzle 25. Packing Gland 39. Liquid Level Connection
13. Shell Cover Flange 26. Lantern Ring
Fig. 6.1 Different Types of Shell and Tube Heat Exchangers (Fig. N-2 of T EM A 8 Edition.
Reproduced with the Permission of the Tubular Exchanger Manufactures Association Inc.,
USA)
6.2 DESIGN OF HEAT EXCHANGERS
6. 2.1 Various Parts of Shell and Tube Heat Exchangers
6.2.1.1 Shell
Shell is the costliest part of the heat exchanger. Cost of shell and tube heat
exchanger sensitively changes with change in the diameter of shell. As per the
TEMA standard, shell size ranges from 6 in (152 mm) to 60 in (1520 mm).
Standard pipes are available up to 24 in size (600 mm NB ). If shell size is greater
than 24 in, it is fabricated by rolling a plate.
Shell diameter depends on tube bundle diameter. For fixed tube sheet shell
and tube heat exchanger, the gap between shell and tube bundle is minimum,
ranging from 10 to 20 mm. For pull through floating head heat exchanger, it is
maximum, ranging from 90-100 mm.
Required shell diameter is determined by one of the following three methods:
(a) Based on the actual tube sheet layout drawing: All latest computer softwares
available for the design of heat exchangers use this method to find shell inside
diameter. Popular computer program, written in Autolips, is used to draw the
tube sheet layout. To draw the tube sheet layout or to find the tube bundle diam-
eter total six parameters are fixed, (i) Outside diameter (OD) of tube, (ii) Num-
bers of tube side passes, (iii) Tube pitch (center to center distance between adja-
cent tubes), (iv) Tube arrangement (triangular or square), (v) Total number of
tubes and (vi) Type of shell and tube heat exchanger (fixed tube sheet, U tube or
floating head).
(b) Use of standard tables: Based on actual tube sheet layout, standard tables
are prepared. These tables give the maximum number of tubes that can be accom-
modated in various standard sizes of shell ranging from 6 in (150 mm NB) to 120 in
(3000 mm NB), for the different numbers of tube side passes, different values of
tube pitch and size and for the different arrangements of tubes. Table 6.1 gives the
data on tube sheet layouts.
Table 6.1 Tube Sheet Tube Hole Count2 3
Table 6.1 (a) % in OD tubes on in square pitch
Shell ID TEMA Por S TEMA U

Number of Passes Number of Passes
mm in 1 2 4 6 2 4 6
203 8 55 48 34 24 52 40 32
254 10 88 78 62 56 90 80 74
305 12 140 138 112 100 140 128 108
337 13 X 178 172 146 136 180 164 148
387 15 X 245 232 208 192 246 232 216
438 17 X 320 308 274 260 330 312 292

489 19 X 405 392 352 336 420 388 368
(Contd.)
138 Introduction to Process Engineering and Design
Tube Sheet Tube Hole Count (Conrd.)

Table 6.1 (a) (Conld.)
Shell ID TEMA PorS TEMA U

mm in 1 2 4 6 2 4 6
540 21 X 502 484 442 424 510 488 460
591 23 X 610 584 536 508 626 596 562
635 25 700 676 618 600 728 692 644
686 27 843 812 742 716 856 816 780

737 29 970 942 868 840 998 956 920
787 31 1127 1096 1014 984 1148 1108 1060
838 33 1288 1250 1172 1148 1318 1268 1222
889 35 1479 1438 1330 1308 1492 1436 1388
940 37 1647 1604 1520 1480 1684 1620 1568

991 39 1840 1794 1700 1664 1882 1816 1754
1067 42 2157 2112 2004 1968 2196 2136 2068
1143 45 2511 2458 2326 2288 2530 2464 2402
1219 48 2865 2808 2686 2656 2908 2832 2764
1372 54 3656 3600 3462 3404 3712 3624 3556

1524 60 4538 4472 4310 4256 4608 4508 4426
Table 6.1 (b) / in OD tubes on %-in triangular pitch
Shell ID TEMA L or M TEMA P or S TEMA U

Number of passes Number of passes Number of
passes
mm in 1 2 4 6 1 2 4 6 2 4 6
114 4.5 14 14
152 6 30 30 24 22
203 8 64 48 34 24 34 32 16 18 32 24 24
254 10 85 72 52 50 60 62 52 44 64 52 52
305 12 122 114 94 96 109 98 78 68 98 88 78
337 i/
13 74 151 142 124 112 126 120 106 100 126 116 108
387 15 X 204 192 166 168 183 168 146 136 180 160 148
438 17 X 264 254 228 220 237 228 202 192 238 224 204
489 19 X 332 326 290 280 297 286 258 248 298 280 262
540 21 X 417 396 364 348 372 356 324 316 370 352 334
591 23 X 495 478 430 420 450 430 392 376 456 428 408
635 25 579 554 512 488 518 498 456 444 534 500 474
686 27 676 648 602 584 618 602 548 532 628 600 570
737 29 785 762 704 688 729 708 650 624 736 696 668
787 31 909 878 814 792 843 812 744 732 846 812 780
838 33 1035 1002 944 920 962 934 868 840 978 928 904
889 35 1164 1132 1062 1036 1090 1064 990 972 1100 1060 1008
(Contd.)
Process Design of Heat Exchangers ' 39

Table 6.1 (b) (Contd.)
Shell ID TEMA L or M TEMAP or S TEMAU

passes
mm in I 2 4 6 I 2 4 6 2 4 6
940 37 1304 1270 1200 1168 1233 1196 1132 1100 1238 1200 1152
991 39 1460 1422 1338 1320 1365 1346 1266 1244 1390 1336 1290
1067 42 1703 1664 1578 1552 1611 1580 1498 1464 1632 1568 1524
1143 45 1960 1918 1830 1800 1875 1834 1736 1708 1882 1820 1770
1219 48 2242 2196 2106 2060 2132 2100 1998 1964 2152 2092 2044
1372 54 2861 2804 2682 2660 2730 2684 2574 2536 2748 2680 2628
1524 60 3527 3476 3360 3300 3395 3346 3228 3196 3420 3340 3286
1676 66 4292 4228 4088 4044
1829 72 5116 5044 4902 4868
1981 78 6034 5964 5786 5740
2134 84 7005 6934 6766 6680

2286 90 8093 7998 7832 7708
2438 96 9203 9114 8896 8844
2743 108 11696 11618 1133611268
3048 120 1445914378 1408013984
Table 6.1 (c) % in OD tubes on I in square pitch
Shell ID TEMA P or S TEMA U

mm in 1 2 4 6 2 4 6
152 6 12 12 — — 14 — —
203 8 28 26 16 12 28 24 12
254 10 52 48 44 24 52 44 32
305 12 80 76 66 56 78 72 70
337 13 X 104 90 70 80 96 92 90
387 15 X 136 128 128 114 136 132 120
438 17 X 181 174 154 160 176 176 160

489 19 X 222 220 204 198 224 224 224
540 21 X 289 272 262 260 284 280 274
591 23 X 345 332 310 308 348 336 328
635 25 398 386 366 344 408 392 378
686 27 477 456 432 424 480 468 460

737 29 554 532 510 496 562 548 530
787 31 637 624 588 576 648 636 620
838 33 730 712 682 668 748 728 718
889 35 828 812 780 760 848 820 816
(Conrd.)

Table 6.1 (c) (Contd.)

mm in 1 2 4 6 2 4 6
940 37 937 918 882 872 952 932 918

991 39 1048 1028 996 972 1056 1044 1020
1067 42 1224 1200 1170 1140 1244 1224 1212
1143 45 1421 1394 1350 1336 1436 1408 1398
1219 48 1628 1598 1548 1536 1640 1628 1602
1372 54 2096 2048 2010 1992 2108 2084 2068

1524 60 2585 2552 2512 2476 2614 2584 2558
Table 6.1 (d) in OD tubes on I in triangular pitch

passes
mm in 1 2 4 6 I 2 4 6 2 4 6
114 4.5 14 14
152 6 26 26 24 22 14 14 — — 14 12 10
203 8 42 40 26 24 31 26 16 12 32 24 24
254 10 73 66 52 44 56 48 42 40 52 48 40
305 12 109 102 88 80 88 78 62 68 84 76 74
337 1/
13 /4 136 128 112 102 121 106 94 88 no 100 98
387 15 X 183 172 146 148 159 148 132 132 152 140 136
438 17 X 237 228 208 192 208 198 182 180 206 188 182
489 1/
19 74 295 282 258 248 258 250 228 220 226 248 234
540 1/
21 74 361 346 318 320 320 314 290 276 330 316 296
591 1/
23 74 438 416 382 372 400 384 352 336 400 384 356
635 25 507 486 448 440 450 442 400 392 472 440 424
686 27 592 574 536 516 543 530 488 468 554 528 502
737 29 692 668 632 604 645 618 574 556 648 616 588
787 31 796 774 732 708 741 716 666 648 744 716 688
838 33 909 886 836 812 843 826 760 740 852 816 788
889 35 1023 1002 942 920 950 930 878 856 974 932 908
940 37 1155 1124 1058 1032 1070 1052 992 968 1092 1056 1008
991 39 1277 1254 1194 1164 1209 1184 1122 1096 1224 1180 1146
1067 42 1503 1466 1404 1372 1409 1378 1314 1296 1434 1388 1350
1143 45 1726 1690 1622 1588 1635 1608 1536 1504 1652 1604 1560
1219 48 1964 1936 1870 1828 1887 1842 1768 1740 1894 1844 1794
1372 54 2519 2466 2380 2352 2399 2366 2270 2244 2426 2368 2326
1524 60 3095 3058 2954 2928 2981 2940 2932 2800 3006 2944 2884
1676 66 3769 3722 3618 3576
1829 72 4502 4448 4324 4280
1981 78 5309 5252 5126 5068
(Contd.)
Tube Sheet Tube Hole Count (Contd.)

Table 6.1 (d) {Contd.)

passes
mm in 1 2 4 6 1 2 4 6 2 4 6
2134 84 6162 6108 5954 5900

2286 90 7103 7040 6898 6800
2438 96 8093 8026 7848 7796
2743 108 1026010206 9992 9940
3048 120 12731 12648 1245012336
Table 6.1 (e) 1 in OD tubes on 1 / in square pitch

mm in 1 2 4 6 2 4 6
203 8 17 12 8 12 14 8 6
254 10 30 30 16 18 30 24 12
305 12 52 48 42 24 44 40 32
337 13 X 61 56 52 50 60 48 44
387 15 X 85 78 62 64 80 72 74
438 17 X 108 108 104 96 104 100 100

489 19 X 144 136 130 114 132 132 120
540 21 X 173 166 154 156 172 168 148
591 23 X 217 208 194 192 212 204 198
635 25 252 240 230 212 244 240 230
686 27 296 280 270 260 290 284 274

737 29 345 336 310 314 340 336 328
787 31 402 390 366 368 400 384 372
838 33 461 452 432 420 456 444 440
889 35 520 514 494 484 518 504 502
940 37 588 572 562 548 584 576 566

991 39 661 640 624 620 664 644 640
1067 42 776 756 738 724 764 748 750
1143 45 900 882 862 844 902 880 862

1219 48 1029 1016 984 972 1028 1008 1004
1372 54 1310 1296 1268 1256 1320 1296 1284

1524 60 1641 1624 1598 1576 1634 1616 1614
{Contd.)
| 142 Introduction to Process Engineering and Design
Tube Sheet Tube Hole Count (Contd.)
Table 6.1 (f) I in OD tubes on I / in triangular pitch

passes
mm in 1 2 4 6 1 2 4 6 2 4 6
203 8 27 26 8 12 18 14 8 12 14 12 6
254 10 42 40 34 24 33 28 16 18 28 24 24
305 12 64 66 52 44 51 48 42 44 52 40 40
337 1/
13 /4 81 74 62 56 73 68 52 44 64 56 52
387 15 1/ 106 106 88 92 93 90 78 76 90 80 78
/4
438 17 X 147 134 124 114 126 122 112 102 122 112 102
489 19 X 183 176 150 152 159 152 132 136 152 140 136
540 21 X 226 220 204 186 202 192 182 172 196 180 176
591 23 X 268 262 236 228 249 238 216 212 242 224 216
635 25 316 302 274 272 291 278 250 240 286 264 246
686 27 375 360 336 324 345 330 298 288 340 320 300
737 29 430 416 390 380 400 388 356 348 400 380 352
787 31 495 482 452 448 459 450 414 400 456 436 414
838 33 579 554 520 504 526 514 584 464 526 504 486
889 35 645 622 586 576 596 584 548 536 596 572 548
940 37 729 712 662 648 672 668 626 608 668 636 614
991 39 808 792 744 732 756 736 704 692 748 728 700
1067 42 947 918 874 868 890 878 834 808 890 856 830
1143 45 1095 1068 1022 1000 1035 1008 966 948 1028 992 972
1219 48 1241 1220 1176 1148 1181 1162 1118 1092 1180 1136 1100
1372 54 1577 1572 1510 1480 1520 1492 1436 1416 1508 1468 1442
1524 60 1964 1940 1882 1832 1884 1858 1800 1764 1886 1840 1794
1676 66 2390 2362 2282 2260
1829 72 2861 2828 2746 2708
1981 78 3368 3324 3236 3216
2134 84 3920 3882 3784 3736

2286 90 4499 4456 4370 4328
2438 96 5144 5104 4986 4936
2743 108 6546 6494 6360 6300
3048 120 8117 8038 7870 7812
In
Table 6.1 (g) I ^ tubes on I % in square pitch
Shell ID TEMA P or S TEMA U

mm in 12 4 6 2 4 6
203 8 12 12 4 0 4 4 6
254 10 21 12 8 12 12 8 12
{Contd.)

Table 6.1 (g) (Conld.)

mm in i 2 4 6 2 4 6
305 12 29 28 16 18 26 20 12
337 13 X 38 34 34 24 36 28 15
387 15 % 52 48 44 48 44 44 32
438 17 K 70 66 56 50 60 60 56
489 19 % 85 84 70 80 82 76 79
540 21 % 108 108 100 96 100 100 100
591 23 K 136 128 128 114 128 120 120
635 25 154 154 142 136 154 148 130
686 27 184 180 158 172 176 172 160

737 29 217 212 204 198 212 204 198
787 31 252 248 234 236 242 240 234
838 33 289 276 270 264 280 280 274
889 35 329 316 310 304 324 312 308
940 37 372 368 354 340 358 352 350

991 39 420 402 402 392 408 400 392
1067 42 485 476 468 464 480 476 464
1143 45 565 554 546 544 558 548 550
1219 48 653 636 628 620 644 628 632
1372 54 837 820 812 804 824 808 808

1524 60 1036 1028 1012 1008 1028 1016 1008
Table 6.1 (h) I j/^ in OD tubes on I ^ in triangular pitch

Number of Passes Number of Passes Number of
Passes
mm in 1 2 4 6 1 2 4 6 2 4 6
203 8 15 10 8 12 13 10 4 0 6 4 6
254 10 27 22 16 12 18 20 8 12 14 12 12
305 12 38 36 26 24 33 26 26 18 28 20 18
337 13 1/ 55 44 42 40 38 44 34 24 34 28 30
/4
387 15 1/ 66 64 52 50 57 58 48 44 52 48 40
/4
438 17 1/ 88 82 78 68 81 72 62 68 72 68 64
/4
489 19 1/ 117 106 98 96 100 94 86 80 90 84 78
74
540 21 1/ 136 134 124 108 126 120 116 102 118 112 102
74
591 23 1/ 170 164 146 148 159 146 132 132 148 132 120
74
635 25 198 188 166 168 183 172 150 148 172 160 152
(Conrd.)

Table 6.1 (h) (Conrd.)
Shell ID TEMA L or M TEMA P or S TEMAU

Number of Passes Number of Passes Number of
Passes
mm in 12 4 6 12 4 6 2 4 6
686 27 237 228 208 192 208 206 190 180 200 188 180
737 29 268 266 242 236 249 238 224 220 242 228 216
787 31 312 304 284 276 291 282 262 256 282 264 250
838 33 357 346 322 324 333 326 298 296 326 308 292
889 35 417 396 372 364 372 368 344 336 362 344 336
940 37 446 446 422 408 425 412 394 384 416 396 384
991 39 506 490 472 464 478 468 442 432 472 444 428
1067 42 592 584 552 544 558 546 520 512 554 524 510
1143 45 680 676 646 632 646 634 606 596 636 624 592
1219 48 788 774 736 732 748 732 704 696 736 708 692
1372 54 1003 980 952 928 962 952 912 892 946 916 890
1524 60 1237 1228 1188 1152 1194 1182 1144 1116 1176 1148 1116
1676 66 1520 1496 1448 1424
1829 72 1814 1786 1736 1724
1981 78 2141 2116 2068 2044
2134 84 2507 2470 2392 2372

2286 90 2861 2840 2764 2744
2438 96 3275 3246 3158 3156
2743 108 4172 4136 4046 4020
3048 120 5164 5128 5038 5000
(Reproduced with the Permission of McGraw-Hill Education. USA)
(c) Use of approximate equations: Approximate equations are available in

literature to find the shell diameter or to find the tube bundle diameter. One of
such equations4 is given as follows:
N, "i
Db = d0 (6.1)
c
i
where, Db = Tube bundle diameter, mm

d0 = Tube OD, mm
A, = Total number of tubes
tube pitch
kj and tij are constants, values of which depend on ratio
d„ tube OD
arrangement of tubes and number of tube side passes.
Use Tables 6.2 and 6.3 for finding constants of Eq. (6.1).
Table 6.2 Constants for Eq. (6.1)
A. For P/d,, = 1.25. Triangular Pitch
No. of tube side passes 1 2 4 6 8

k, 0.319 0.249 0.175 0.0743 0.0365
n, 2.142 2.207 2.285 2.499 2.675
Table 6.3 Constants for Eq. (6.1)
B. For P,/d0 = 1.25, Square Pitch
No. of tube side passes 1 2 4 6 8

it, 0.215 0.156 0.158 0.0402 0.0331
n, 2.207 2.291 2.263 2.617 2.643
Equation (6.1) can be used for fixed tube sheet type and floating head shell and
tube type heat exchangers.
But for U-tube heat exchangers, following equation can be used.
Np-
Db - d0\ (6.2)
q /
Dh
where, N, = N, (6.3)
Pi
TV, = Number of lube holes on lube sheet
After finding tube bundle diameter shell ID (Inside diameter) D, can be deter-
mined by following equation.
A = Db + C (6.4)
where, C = Clearance between shell ID and Dh
C = 10 to 20 mm for fixed tube sheet and U-tube
C = 50 to 80 mm for split-ring floating head
C = 90 to 100 mm for pull through floating head
6.2.1.2 Shell Side Pass Partition Plate

Single pass shell is used in the most of the cases. Two pass shell is rarely used
and is recommended where shell and tube temperature difference is unfavorable
for the single pass. For such cases normally two or more heat exchangers, con-
nected in series, are recommended. Shell side pass partition plate is not provided
to improve shell side heat transfer coefficient but it is provided to avoid the unfa-
vourable temperature difference or to avoid the cross of temperatures between
hot fluid and cold fluid.
Example 6.0
Hot oil is to be cooled from 450C to 370C by cooling water. Cooling water will enter at
320C and leave at 40oC. Minimum driving force required for heat transfer in shell and
tube heat exchanger is 3 to 5 0C. Hence, for this case 1-1 shell and tube heat exchanger
can be selected. But it will provide poor heat transfer coefficient and may require large
heat transfer area. 1-2 shell and tube heat exchanger cannot be selected for this case
because of the occurrence of hypothetical temperature cross between hot and cold
fluids. 2-2 shell and tube heat exchanger can be selected. 2-2 heat exchanger will
provide higher heat transfer coefficient than 1-1 heat exchanger.
6.2.1.3 Baffles
There are two functions of baffles.

(i) Baffles are used in shell to direct the fluid stream across the tubes to in-
crease the velocity of shell side flow and thereby to improve the shell side
heat transfer coefficient. In other words baffles are used in shell to increase
the turbulence in shell side fluid.
Note: This function is useful only if there is no phase change in shell side
fluid
(ii) Baffles indirectly support the lubes and thereby reduce the vibration in tubes.
If shell side liquid velocity is higher; say more than 3 m/s, vibration analy-
sis calculations should be carried out to check whether baffle spacing is
sufficient or not. Similarly, for very high velocity of gas or vapour and also
for the higher baffle spacing (higher than shell ID), vibration analysis cal-
culation must be carried out to check the baffle spacing. Vibration analysis
calculations are given in TEMA standard.
Different types of baffles are used in shell and tube heat exchangers; (i) Seg-
mental baffle, (ii) Nest baffle, (iii) Segmental and Strip baffle (iv) Disc and
Doughnut baffle, (v) Orifice baffle (vi) Dam baffle, etc. Figure 6.2 shows vari-
ous types of baffles.
Most widely used type of baffle is segmental baffle. Other types of baffles like
nest baffle, segmental and strip baffle and disc and doughnut baffle provide less
pressure drop for the same baffle spacing but provide lower heat transfer coeffi-
cients as compared to segmental baffle. Examples: Situation when other types of
baffles might be used.
(a) For shell and tube heat exchangers shell side pressure drop controls the
overall design. For example, intercoolers of compressors and heat exchang-
ers used in very high vacuum system. In intercoolers of compressors maxi-
mum allowable shell side pressure drop may be as low as 3.45 kPa. For
such cases different types of shells are also used. Split flow (G shell) or
divided flow (J shell) designs provide low shell side pressure drop com-
pared to commonly used single pass ( E shell). Refer Fig. 6.3
(b) For shell and tube heat exchanger in which boiling or condensation is car-
ried out on shell side. In such a case baffles are required only to reduce the
vibrations in tubes.
For other type of baffles (other than segmental baffle) correlations for finding
heat transfer coefficient and pressure drop are not easily available in open litera-
ture.
oo
'ooooooN
OOOOOO \l oooooo
loooo oooo oooooo oo)
(oooo oooo \ooooooool
OOOOOO/\oooooo,
\000 000/
Without Trim Base

(a) Segmental Baffles with Horizontal Cut
00
'000 000
oooooo \ 000 000
00000000)
,00000000
oooooo / oooooo
>000000,
00
(b) Segmental and Strip Baffles
000 000
00
0 (oooo)
v „ \0000J
000 000
(e) Disc and Doughnut Baffles

ÔO
OOOOO Tubes
OOOOOO A h
00 00 o o o
00 00 oo 00
OOOOOO/
\p o o o 0 9/ \ i
T o o^
(d) Orifice Baffles (e) Nest Baffle
o
o
qOOQ- 0° OQ
OOO OOO qOOQ 0 0000
'0oO foooo oooo) \ O 00
S00 lOOOO 00001 0000 0
O 00
0
O
OoOTTQ OOOOOO 0000 \o 0 0
O /
sOOO OOO/ 0000 0/ 0000
0000
- o or- 0000 0000
o
(f) Dam Baffle (g) Horizontal Cut (h) Segmental with Vertical Cut
with Trim Base
(f), (g), and (h); Baffles for Condensers
Fig. 6.2 Different Types of Baffles used in Shell and Tube Heat Exchangers2
(Reproduced with the Permission of McGraw-Hill Education, USA)
Segmental baffle is made by cutting the circular metal disc. Segmental baffles
are specified in terms of % baffle cut.
% Baffle cut = h/d x 100 (6.5)
where, h = Height of segment removed
D = Diameter of circular metal disc from which segment is removed
= ID of shell - 2 x Clearance
% Baffle cut ranges from 15 to 45%. If there is no phase change on shell side
fluid, then decrease in % baffle cut increases shell side heat transfer coefficient.
Decrease in window area results in increase in window velocity but at the ex-
pense of pressure drop. 20 to 25% Baffle cut is found to be common in use.
(b)
(c)
Fig. 6.3 (a) One Pass Shell (E Shall) (b) Split Flow (G Shell) (c) Divided Flow (J Shell)
Baffle outside diameter is always less than shell inside diameter. Certain clear-
ance between baffle OD and shell ID is provided to facilitate removal and inser-
tion of lube bundle for maintenance. Recommended clearance between shell ID
and baffle OD is as follows.
Table 6.4 Clearance Between Shell and Segmental Baffle
Shell ID Clearance (Shell ID - Baffle OD)

Standard pipe shell 6 in to 24 in (150 mm to 600 mm) 1.6 mm
Plate shell 6 in to 25 in (150 mm to 625 mm) 3.2 mm
Plate shell 27 in to 42 in (675 mm to 1050 mm) 4.8 mm
If shell is fabricated from plate then it may not be a perfect cylinder. Hence, for
plate shell, more clearance is permitted. For heat exchanger without phase change,
increase in clearance between shell ID and baffle OD could mean decrease in
shell side heat transfer coefficient due to leakage. Fraction of shell side fluid
flowing through this clearance is not utilized for heat transfer. Hence this clear-
ance, if it is more than recommended value, is undesirable.
In kettle type reboiler, full baffle (with 0% baffle cut) is used, as in this type of
heat exchanger extra space is available for the flow of shell side liquid.
In case of horizontal inclined condenser, segmental baffles with horizontal cut

should not be used as they create resistance to the flow of condensate. Hence, in
this case there are two options; (i) Use segmental baffles with vertical cut
(Fig. 6.2 (h)) or (ii) Use segmental baffles with horizontal cut but their base must
be trimmed (Fig. 6.2 (g)).
Tube holes are made in baffle. Diameter of tube hole in baffle is kept higher
than tube OD. Normally this clearance is less than 0.8 mm.
Thickness of baffle depends on size of shell and spacing between baffles. For
the given size of shell, thickness of baffle increases with increase in baffle spac-
ing. It can be determined from the table given in TEMA standard. As per Kern5,
baffle spacing ranges from 0.2 to 1 limes shell ID. Lesser baffle spacing gives
higher heat transfer coefficient but at the expense of higher pressure drop. Opti-
mum baffle spacing is in between 0.3 to 0.5 times shell inside diameter.
6.2.1.4 Tube
Tube size range from 1/4 in (6.35 mm) to 2.5 in (63.5 mm ) in shell and tube heat
exchanger. Data for standard tubes are given in TEMA standard and Table 11.2
of Ref. 2. For the standard tubes, its size is equal to outer diameter of tube. Thick-
ness of standard tubes are expressed in BWG (Birmingham Wire Gauge). In-
crease in the value of BWG means decrease in tube thickness. For no phase
change heat exchangers and for condensers, 3/4 in (19.05 mm OD) tube is widely
used in practice. While for reboiler I in (25.4 mm OD) tube size is common.
Tubes are available in standard lengths like 6 ft (1.83 m), 8 ft (2.44 m), 12 ft (3.66
m), 16 ft (4.88 m) and 6 m.
6.2.1.5 Tube Side Pass Partition Plate

Tube side passes are provided to decrease the tube side flow area and to increase
tube side fluid velocity thereby to improve the tube side heat transfer coefficient,
at the expense of pressure drop. This is true only if there is no phase change on
tube side. Hence, more number of lube side passes are recommended only if
there is no change in the phase of tube side fluid.
For example, at the design stage, if the number of lube side passes are in-
creased from one to two, then for the given volumetric flow rate, flow area be-
comes half and velocity becomes double. Since, tube side heat transfer coeffi-
0 8
cient, h oc u. (where u. is tube side fluid velocity), on increasing number of
tube side passes from 1 to 2, /?, nearly becomes 1-7 times. But, A/?, oc u, , so the
pressure drop increases by 6.96 times. Increase in h/ means decrease in heat transfer
area required and decrease in fixed cost. Increase in A/?, means increase in power
required for pumping the tube side fluid and increase in operating cost. Hence,
ideally optimum number of tube side passes must be decided.
Tube side passes are very common and are advantageously used for improv-
ing tube side heat transfer coefficient. These passes can be achieved in many
ways by locating partition plates in channel covers. Figure 6.4 gives different
designs for achieving desired tube passes.
Single Pass Two Pass Four Pass Six Pass Eight Pass
V§7
Ka) 2(a) 3(a) 4(a) 5(a)
o 0 0
Kb) 2(b) 3(b) 4(b) 5(b)
O 0
1(c) 2(c) 3(c) 4(c) 5(c)
o
1(d) 2(d) 3(d) 4(d) 6(d)
o 0
1(e) 2(e) 3(e) 4(e) 6(e)
0 m
Kf) 2(f) 3(f) 4(f) 6(f)
3
F'g- 6.4 Nozzle Orientation Designs for Tube Side Passes
6.2.1.6 Tie Rods
Baffles are supported by tie rods. Tie rods are made from solid metal bar. Nor-
mally four or more tie rods are required to support the baffles. Diameter of tie rod
is less than the diameter of tube. Diameter and number of tie rods required for
given shell diameter are specified by TEMA standard and IS: 4503.
6.2.1.7 Spacers
Spacers (Fig. 6.5) are used to maintain the space between baffles. Spacers are the
pieces of pipes or in the most of the cases they are the pieces of extra available
tubes. Spacers are passed over the tie rods and because of them baffles do not
slide over tie rods under the effect of the force of fluid. Hence, spacers fix the
location of baffles and maintain the space between them. Length of spacer is
equal to space between the baffles.
Baffles
X X
0*- 0 ^
Spacer
Tie rod
Tube Plate
Fig. 6.5 Baffle Spacer Detail
6.2.1.8 Tube Sheet
Tubes and one end of tierods are attached to tube sheet (also called tube plate).
Hence, entire load of tube bundle is transferred to one or two tube sheets. In U-
tube shell and tube heat exchanger (as shown in Fig. 6.1(d), type CFU or
Fig. 6.1(e), type AKT) only one tube sheet is used. While in fixed tube sheet shell
and tube heat exchanger, two tube sheets are used. One surface of tube sheet is
exposed to tube side fluid and other surface is exposed to shell side fluid. This
point is very important in the selection of material for tube sheet and also in
determining tube sheet thickness.
Tube to tube sheet joints are two types; (a) Expanded joint and (b) Welded
joint as shown in Fig. 6.6.
Tube Sheet
Grooves Tube Wall
(a) Expanded Type (b) Welding Joint
Fig. 6.6 Tube to Tube Sheet Joint
In expanded type joint, tube holes are drilled in a tube sheet with a slightly
greater diameter than the tube OD. Two or more grooves are cut in the wall of
each hole. The tube is placed inside the tube hole and a tube roller is inserted
into the end of the tube. Roller is slightly tapered. On application of the roller,
tube expands and tube material flows into grooves and forms an extremely light
seal. Welding joint is used only for the cases where leakage of fluid can be
disasterous.
Detailed method for calculating tube sheet thickness is given in TEMA and in
IS: 4503. Minimum required tube sheet thickness is also specifed in the same.
Simplified equation is also available for calculating tube sheet thickness.
i
0.25 P
t = FG (6.6)
where, t = Effective tube sheet thickness, mm

F = constant (1 for fixed tube sheet and 1.25 for U-tube)
P = Design pressure, kPa
f= Allowable stress of tube sheet material at design temperature, kPa
G = Mean diameter of gasket, mm
Then thickness of tube sheet T is given by equation

T> {t+ depth of pass partition groove + tube side corrosion allowance +
shell side corrosion allowance)
Also T > Minimum thickness specified in the standard
6.2.1.9 Sealing Strip
It is a shell side component. Sealing strips are attached on the inside surface of
shell as shown in Fig. 6.7 throughout the length of shell.
oo
ooooo
/ ■ J •_ oooooo
':' -
-j c O G O U C_C: - o
)<:
or c
QOOOOO
Sealing Strip
Fig. 6.7 Sealing Strips
There are two functions of sealing strips.

(i) Sealing strips reduce the amount of bypass stream of shell side fluid flow-
ing through the clearance between shell inside diameter and tube bundle
diameter and thereby improve the shell side heat transfer coefficient. (This
is valid only if there is no phase change of shell side fluid).
(ii) Sealing strips also make the removal of tube bundle from the shell easy.
Hence, they are also known as sliding strips.
In Kern's method, it is assumed that entire shell side fluid is flowing across the
tube bundle and between the baffles. Actually, shell side fluid is flowing in vari-
ous ways. In all latest methods of process design, shell side fluid flow is divided
in five streams. Among these streams, one of the streams is flowing through the
clearance between shell ID and tube bundle. This clearance is significant in case
of pull through floating head heat exchanger (about 90 to 100 mm). In addition,
this clearance provides low pressure drop path for shell side fluid. Hence, actual
fraction of shell side fluid bypassed through this clearnace is considerably higher.
Sealing strip blocks the gap between bundle and shell and thereby reduce the
amount of this bypass stream considerably. In case of pull through floating head
heat exchanger, all latest computer programes, like HTRI, suggest the use of
sealing strip. Also in such programs shell side heat transfer coefficient is a func-
tion of diamension and numbers of sealing strips provided. Kern's method is not
recommended for use to predict heat transfer coefficient and pressure drop for
pull through floating head heat exchanger.
6.2.1.10 Expansion Joint
Expansion joint is attached to shell wall. In this case shell is made from two pipe
pieces. Two pipe pieces are joined together by an expansion joint as shown in
Fig. 6.8.
(a) Flat Plates (b) Flanged only Heads (c) Flared Shell or
Pipe Segments
(\
(d) Formed (e) Flanged and (t) Toroidal

Heads Fined Heads
W
UU ^J*
(g) Bellows Type (h) Bellows Type with (i) High Pressure
Reinforcing Rings Toroidal Bellows
and Insulation Cover
Fig. 6.8 Expansion Joints2
(Reproduced with the Permission of McGraw-Hill Education. USA)
Expansion joint is used in fixed tube heat exchanger to permit the differential
thermal expansion or contraction between shell and lubes which otherwise is not
permitted by fixed tube sheet heat exchanger. Differential thermal expansion be-
tween shell and tube is significant if there is a large temperature difference be-
tween temperature of shell material and temperature of tube material during op-
eration or if tube material and shell material are different. For the given case of
fixed tube sheet heat exchanger, whether an expansion joint is required or not
can be determined by calculations given in TEMA. If expansion joint is not pro-
vided in fixed tube sheet heat exchanger, then fixed tube sheet does not permit
the unequal expansion or contraction between shell and tube and it can result in
the development of thermal stress across the tube sheet. If this thermal stress is
higher than permissible value, then it may develop a crack in tube sheet, and can
result in leakage at tube to tube sheet joint. Other options, available to avoid the
development of thermal stress in the tube sheet are use of either U tube heat
exchanger or floating head heat exchanger.
6.2.2 Advantages and Disadvantages of Different Type of

Shell and Tube Heat Exchangers Over Each Other
6.2.2.1 Advantages of U-tube and Floating Head Heat

Exchangers (Figs 6.1 (a) and 6.1 (d)) Over Fixed
Tube Sheet Heat Exchangers are
(i) Maintenance and cleaning of tube bundle is easier. In U-tube and floating
head heat exchanger entire tube bundle can be easily taken out for cleaning
and maintenace. While the same is not possible in fixed tube sheet heat
exchanger.
(ii) U-tube and floating head heat exchangers permit the differential thermal
expansion or contraction between shell and tube. Therefore, use of expan-
sion joint is not required in U-tube and floating head heat exchangers.
6.2.2.2 Disadvantages of U-tube and Floating Head Heat

Exchangers Over Fixed Tube Sheet
(i) For a given heat duty, U-tube and floating head heat exchangers are costlier
than fixed tube sheet heat exchangers because of the following reasons.
(a) For the same number of tubes, tube arrangement and tube pitch, shell
sizes required by U-tube and floating head heat exchangers are higher
than the same required by fixed tube sheet heat exchangers. In U-tube
heat exchanger, minimum bend radius of U-tube is 1.5da, hence in
central portion of tube bundle, tubes cannot be provided. In floating
head heat exchanger more clearnace between shell ID and tube bundle
diameter (50 to 100 mm) is required.
(b) In case of cooling or heating of shell side fluid (no phase change) heat
transfer coefficients obtained in U-tube and floating head heat exchang-
ers for the given heat duty are less than the same obtained in fixed tube
sheet heat exchangers as bypassing area is higher in case of U-tube or
floating head as compared to fixed tube sheet heat exchanger.
6.2.2.3 Advantages and Disadvatages of U-tube Heat

Exchanger Over Floating Head Heat Exchanger
Advantage:
Fixed cost of U-tube heat exchanger is always less than the same of floating head
heat exchanger for the given duty.
Disadvatages:
(i) In U-lube, tube material becomes weak in bending portion, hence use of U-
tube heat exchanger is not recommended for severe conditions. While for
the same conditions floating head heat exchanger can be used.
(ii) In U-tube heat exchanger number of tube side passes are fixed (two). It
reduces the flexibility in design calculations.
(iii) U-tube heat exchanger is not recommended to use for tube side dirty fluid.
As it is difficult to remove dirt from U-tube. While floating head heat ex-
changer can be used where both shell side fluid and tube side fluid are dirty.
6.2.2.4 Floating Head Heat Exchangers are of Two Types
(a) Split-ring floating head heat exchanger

(b) Pull through floating head heat exchanger.
Split-ring floating head heat exchanger is widely used in the chemical process
industries (Fig. 6.1 (a)). With this type split backing ring is provided. Advantages
and disadvantages of this heat exchanger over pull through floating head heat
exchanger are as follows.
Advantage:
Compared to pull through floating head heat exchanger, less diameter is required
for shell to accommodate the same number of tubes.
Disadvatages:
More maintenance time is required. In maintenance, shell cover is removed first,
then the split backing ring, then floating head cover and finally tube bundle is
removed from the stationary end.
Pull through floating head heat exchanger is the costliest type of shell and
tube heat exchanger because it requires largest shell diameter for the given num-
bers of tubes. With this heat exchanger it is possible to remove the entire tube
bundle including floating head assembly from the stationary end.
6.2.3 Different Types of TEMA Designations
In TEMA standard different types of shell and tube heat exchangers are desig-
nated by three letters. First letter indicates type of front head, second letter indi-
cates type of shell and third indicates type of rear head. Different types of TEMA
designations are shown in Fig. 6.9.
For example, BEM shell and tube type heat exchanger means bonnet type (B
type) front head, single pass (E type) shell and stationary head with fixed tube
sheet (M type) rear head. BFL type shell and tube heat exchanger means bonnet
type front head, two pass shell with longitudinal baffle (F type shell) and station-
ary head with fixed tube sheet and removable flat cover (L type rear head).
6.3 GENERAL DESIGN METHOD FOR SHELL AND

TUBE HEAT EXCHANGER
6.3.1 Calculation of Heat Duty
(a) For cooling or heating or for no phase change, heat duty is calculated by
equation
0 = mCp At (6.7)
where, in = Mass flow rale of fluid, kg/s
0
Cp = Specific heat of fluid, in kJ/(kg • C)
At = Temperature difference to be carried out, 0C
0 = Heat duty required, kW
(b) For condensation with subcooling
0 = mA + mCL At (6.8)
Front End Rear End

Shell Types
Stationary Head Types Head Types
neJla-
Jl
L X
A Fixed Tube Sheet Like
"A" Stationary Head
One Pass Shell
"TLT8-
Channel and X
Removable Cover M
T Fixed Tube Sheet Like
Two Pass Shell "B" Stationary Head
with Longitudinal
Baffle
B
N
Fixed Tube sheet Like
G "C" Stationary Head
Bonnet
(Integral Cover) Packing
Split Flow
i
Outside Packed
Removable JE L
Tube Floating Head
C
Bundle H Packing
Only ~r x" &
Channel Integral with Double Split Flow X
Tube Sheet and
Removable Cover Floating Head
with Backing Device
Packing
T r
N Divided Flow V
T
Pull Through
Channel Integral with X Floating Head
Tube Sheet and
Removable Cover K
L XT
U tr
Kettle Type Reboiler
U-tube Bundle
D X Packing
X
J W
Special High Pressure Externally Sealed
Closure Cross Flow Floating Tube sheet
Fig. 6.9 TEMA-type Designation for Shell and Tube Heat Exchangers'. (Fig. No. N-l.2 of T£MA
8th Edition)
(Reproduced with the Permission of Tubular Exchanger Manufacturers Association. Inc.
USA.)
where, m = Mass flow rate of vapour, kg/s

CL = Specific heat of condensate, kJ/(kg ■ 0C)
A = Latent heat of vaporization, kJ/kg
(c) For reboilers
(p = mvA x 1.05 (considering 5% heat loss) (6.9)

where, my = Vaporization rate, kg/s
A = Latent heat of vaporization, kJ/kg

Actually heat duty of the reboiler is determined based on energy balance
around distillation column.
6.3.2 Selection of Cooling Medium or Heating Medium
Selection of cooling or heating medium mainly depends on the temperature (inlet

temperature) at which cooling medium or heating medium is required. Other
factors like heat transfer coefficient provided by cooling medium or heating
medium, cost of the medium, etc. are also considered in the final selection. Table
6.5 and Table 6.6 can be used as a guideline for the selection of healing medium
and cooling medium respectively.
Table 6,5 Commonly Used Heating Fluids
Heating medium Recommended temperature range
Saturated steam 100 to 180° C

Oil (Thermic Fluid) 180 to 300° C
Dowtherm E 180 to 260° C
Dowtherm A 300 to 400° C
Molten salt 400 to 590° C
Na-K alloys 590 to 750° C
Flue gas or Hot air 750 to 1100oC
Electric heating > 1100oC
Table 6.6 Commonly Used Cooling Medium
Cooling medium Operating range Recommended to use for

temperature
1. Brines -68 to 50C < 80C
Examples:
Ethanol water solution -5 to 50C < 80C
Methanol water solution -33 to -10C < 80C
Ethylene glycol -34 to 50C <80C
Aqueous solution of
calcium chloride -20 to 0oC < 80C
Aqueous solution of
sodium chloride -9.4 to 50C <80C
Methylene chloride -67.7 to -37.20C <-330C
Trichloroethylene -67.7 to -37.20C <-330C
Trichlorofluoromethane -67.7 to -37.2°C <-330C
(Con id.)
Table 6.6 (Could.)
Cooling medium Operating range Recommended to use for

temperature
2. Chilled water 5 to 120C < 350C
3. Cooling water 32 to 60oC 35 to 100oC
4. Oil -1 to 3160C < 300oC
5. Air Atmospheric temperature > 60oC
6.3.2. / Heating Mediums
If temperature of heating medium is required in between 100° to 180oC, saturated

steam is used as heating medium. Saturated steam condenses in dropwise manner,
hence it provides very high heat transfer coefficient [about 6000 W/(m2 • 0
C)].
Superheated steam is not selected as heating medium for indirect (through the
wall) heat transfer because superheating zone provides very low heat transfer
coefficient.
If the temperature of heating medium required is greater than 180oC, then use
of saturated steam as a heating medium is not economical. From 180oC to 300oC,
hot oil (thermic fluid) is preferred as heating medium. Hot oil system is easily
available at comparatively low cost. Hot oil provides low heat transfer coeffi-
cient and also properties of oil are uncertain. For the precise application at large
scale Dowtherm E can be considered as a heating medium. Downtherm E is
specially processed orthodichlorobenzene. Aluminium should not be used with
Downtherm E. Downtherm A is an organic fluid of high heat stability, an eutectic
mixture containing 73.5 percent diphenyl oxide and 26.5 percent diphenyl by
mass. Both, Downtherm A and Downtherm E were developed by Dow Chemical
Company, USA. Molten salts are a molten mixtures of inorganic salts, one of
which is an eutectic consisting 40% NaNCU, 7% NaNOj and 53% KNO3. 56%
Na and 44% K (by mass) and 22% Na-78% K (by mass) are used as sodium
potassium alloys.
6.3.2.2 Cooling Mediums
In refrigeration terminology a brine is any liquid cooled by a refrigerent and

circulated as a heat transfer fluid. Operating temperature range is -680C to 50C.
For any fluid to be cooled below 80C (minimum possible temperature of chilled
water, 50C + minimum driving force required for heat transfer in shell and tube
heat exchanger, 30C), brines are used as cooling medium. Brine may be:
(a) An aqueous solutions of inorganic salts, e.g. sodium chloride solution, cal-
cium chloride solution, etc.
(b) Aqueous solutions of organic compounds such as alcohols or glycols, e.g.
ethanol, methanol, ethylene glycol, propylene glycol, etc
(c) Chlorinated or fluorinated hydrocarbons, ex. melhylene chloride, trichloro-
ethylene, trichlorofluoromethane, halogenated hydrocarbons as refrigerants.
etc.
Outlet temperature of chilled water from chilled water plant ranges from 5 to
15 C. While its return temperature is kept from 70C to 120C. When any fluid is to
0
be cooled below the temperature equal to design temperature of cooling water

from cooling tower + minimum driving force required for heat transfer in shell
and tube heat exchanger (30C), chilled water is used as cooling medium.
Cooling water is the most widely used cooling medium at near ambinent tem-
perature.
Design temperature of cooling water from cooling tower = Wet bulb tempera-
ture + Approach to the wet bulb temperature (ranges from 4 to 60C).
Cooling water can be used as cooling medium even though inlet temperature
of hot fluid is more than 100oC. But in this case extra care must be taken as at any
time cooling water can be converted into steam. In case of exothermic reaction,
oil (thermic fluid) is used for dual purpose. Initially to achieve the reaction tem-
perature, oil is used as heating medium. Then after as the reaction proceeds, the
same oil is used as cooling medium. For this, one heater and one cooling water
cooler (or economizer) are provided in oil cycle.
Oil
Expansion
M
Tank
Cooler
-0-
fx]
Fuel Fired Boiler

or
Electric Heater
Fig. 6.10 Hot Oil (Thermic Fluid) Cycle
6.3.2.3 Air Cooling
Air cooled heat exchanger has certain advantages as well as disadvantages over
cooling water cooled heat exchanger using cooling water.
Advantages:
(i) Generally operating cost of Air Cooled Heat Exchanger (ACHE) is less
than the same of Water Cooled Heat Exchanger (WCHE). Operating costs
of WCHE includes cost of make-up water for the cooling tower, power
required for the cooling tower fans and for the circulating pump, cooling
tower maintenance, etc. While operating cost of ACHE includes cost of
power consumed by fan. Day by day cost of water increases and hence the
difference in operating cost between WCHE and ACHE increases.
(ii) Inlet temperature of water to cooling tower (or outlet temperature of cool-
ing water from heat exchanger circuit) should not be greater than 60oC
otherwise it creates the scale formation and also affects the material of con-
struction of cooling tower. While for air there is no limit for temperature.
(iii) Fouling or scale formation does not take place with aircooling.
' 60 Introduction to Process Engineering and Design
Disadvantages:
(i) Fixed cost of ACHE is higher than the same of WCHE. Heat transfer coef-
ficient of air is quiet less than heat transfer coefficient provided by cooling
water and hence heat transfer area required by ACHE is more. Also design
inlet temperature of cooling water from cooling tower is always less than
design ambient temperature. It gives lesser Mean Temperature Difference
(MTD) for ACHE compared to the same for WCHE and hence it increases
heat transfer area required for ACHE.
(ii) Minimum driving force required for heat transfer, Armin is 10° to 150C for
ACHE ad 3 to 50C for WCHE. Hence minimum temperature that can be
achieved with ACHE is ambient temperature plus 10oC, while with WCHE
it is design temperature of cooling water from cooling tower plus 30C. Hence,
if the fluid is to be cooled or condensed below 550C in a tropical location,
ACHE cannot be used.
Based on atmospheric conditions, cost of heal exchangers and cost of water,
one can find out the temperature above which ACHE becomes cheaper than
WCHE.
6.3.3 Fluid Allocation
(a) Fluid allocation in case of phase change:

Condensing or vaporizing fluid is normally taken on shell side as in the
shell liquid and vapour phases are easily separated. In case of a condenser,
if condensation is carried out in tube side, then the entire liquid condensate
forms a film on heat transfer surface which provides additional resistance
to heat transfer. In case of reboilers normally on both sides phase change
take place and hence fluid allocation depends on other factors.
(b) Fluid allocation in case of no phase change:
If there is no phase change in shell side and tube side fluid, then fluid allo-
cation depends on the following factors.
(i) Corrosion: Corrosive fluid is allocated tube side as the cheaper material
like mild steel can be used for costly shell, baffles, etc. Also, other
costlier parts like tubes and tube sheets require the use of non-corrosive
or costlier material of construction in case of corrosive fluid, whether it
is on tube side or in shell side. For example, in cooling of ethyliodide,
it should be taken on lube side as it requires the use of special material
(Hastelloy-B).
(ii) Fouling: In fixed tube sheet heat exchanger inside surface of tubes can
be easily cleaned and hence the fluid which has the greatest tendancy
to foul on heat transfer surface should be placed in the tubes. For
example cooling water has a tendancy to foul. Hence normally it is
passed through tubes.
(iii) Fluid Temperature: At very high temperature as well as at very low
temperature use of special alloy is required. Hence, very hot or very
cold fluid is placed on tube side to avoid the use of costlier material for
the shell. At moderate temperature, hotter fluid is belter passed through
tubes. If it is placed on shell side more insulation is required not only to

reduce the heat loss but also for safety purpose.
(iv) Operating Pressure: High pressure stream should be placed on tube
side as high pressure tubes are cheaper than high pressure shell. Diam-
eter of shell is very much greater than diameter of tubes hence its thick-
ness is more sensitively changed with change in pressure as compared
to that of the tubes.
(v) Fluid Flow Rates and Viscosity: Very low value of flow rate of fluid
and high value of viscosity of fluid give low value of Reynolds number.
Fluid which provides very low value of Reynolds number should be
placed on shell side as the dependency of shell side heat transfer coef-
ficient on Reynolds number is less as compared to the same of tube
side heal transfer coefficient. Hence, for the lower value of Reynolds
number shell side heat transfer coefficient is higher than tube side heat
transfer coefficient. For example, in cooling of viscous oil, it is allo-
cated shell side as it provides poor Reynolds number.
6.3.4 Establish Energy Balance or Heat Duty Balance

and based on that Find the Mass Flow Rate of
Heating Medium or Cooling Medium Required
For example in case of condenser
0, = mX = mwChJt2 - /,) (6.10)

where, m = Mass flow rate of vapour condensed, kg/s
A = Latent heat of condensation kJ/kg
mw = Mass flow rate of cooling medium required kg/s

CLw = Specific heat of cooling medium kJ/(kg ■ 0C)
tj, tl = Outlet inlet temperatures of cooling medium, 0C
6.3.5 Mean Temperature Difference
Mean temperature difference (MTD) is calculated from equation

ATm = FlA^m (6.11)
0
where, = Logarithmic mean temperature difference, C
can be determined by following equation
AT2 - A'T,
(6 12)
-
In -
V Aî
where, A^ and AT^ are terminal temperature differences.

For 1-1 heat exchanger (one shell side pass and one tube side pass), F, = 1
When shell side passes and/or tube side passes are more than one, F, must be
determined.
F, =f(R, S) where R and S are temperature ratios (6.13)
R = (6.14)
h ~h
h fi_
S= (6.15)
where, ^ = Hot fluid inlet temperature

% = Hot fluid outlet temperature
tx = Cold fluid inlet temperature
t1 = Cold fluid outlet temperature
Graphs of F, vs S for the different values of /?, for the different cases are given in
Ref. 1. Figure 6.11 gives values of F, for even number of tube passes. If F, < 0.75,
economic design of shell and tube heat exchanger cannot be achieved. For such a
case alternate type of heat exchanger design should be considered. In the cases
where temperature cross is likely to occur, multiple shell pass heat exchanger or
more numbers of heal exchangers in series, should be considered.
Ft
OJ
0.6
0 0,1 0.2 0.3 0.4 0.5 0.6 0,7 0,8 0.9 1,0
Fig. 6.II Temperature Correction Factor: One Shell Pass; Even Number of Tube Passes'
(Fig. T-3.2A ofTEMA. 8th Edition)
(Reproduced with the Permission of Tubular Exchanger Manufacturers Association, Inc.
USA.)
6.3.6 Estimation of Overall Heat Transfer Coefficient
Assume the value of [/, overall heat transfer coefficient. For this, use the stand-
ard tables, in which the range of the values of U for the different cases are given.
Refer Table 6.7 for the recommended values.
Table 6.7 Typical Overcell Coefficients for Shell and Tube Heat Exchangers
Shell side Tube side U, W/(m2 • 0C)

[A] Heat exchangers
1. Water Water 800-1400

2. Organic solvent Water 300-850
3. Organic solvent Brine 200-500
4. Light oil Water 350-900
5. Heavy oil Water 60-300
6. Water Brine 600-1200
7. Gas Brine 15-250
8. Gas Gas 10-50
9. Gas Water 20-300
10. Naptha Water 300-400
11. Lube oil Water 150-500
12. Gasoline Water 350-550
13. Kerosene Water 150-300
14. Water 10 to 30% 500-1250
Caustic soda solution
[B] Condensers
1. Organic vapour Water 700-1000

2. Organic vapour + Gas Water or Brine 100-300
3. Low boiling hydrocarbons Water 450-1100
Vapour mixture
4. Naptha vapour Water 300-425
5. Steam Water 2000-5000
6. Alcohol vapour Water 500-1000
7. Saturated Organic vapour Water or Brine 280-680
[C] Vaporizers/Reboilers
1. Light organics Steam 800-1200

2. Heavy organics Steam 600-900
3. Aqueous solution Steam 1000-1500
4. Chlorine Steam 700-1500
5. Ammonia Steam 700-1500
6. Water Steam 1250-2000
7. Refrigerants Water 425-850
Find out heat transfer area based on this selected or assumed value of U.
0/
A = (6.16)
U x A'4,
For the 1st trial calculation, this A is the heat transfer area provided or actual heat
transfer area of heat exchanger.
A=Ap[0 = Nt7id0L (6.17)
where, d0 = Outside diameter of tube, m

L = Tube length, m
Nt = Total number of tubes
Values of d0 and L are decided by designer and from Eq. (6.17), value of Nt is
determined. Then for the first trial, number of tube side passes and shell side
passes are decided. Tube arrangement and type of heat exchanger are also de-
cided.
6.3.7 Finding Shell Diameter
Based on all these informations find the inside diameter of shell. Select the type
of baffle. First choice is 25% cut segmental baffle. Fix the value of baffle spac-
ing. If there is cooling or heating on shell side then for the first trial baffle spac-
ing Bs could be 0.3 to 0.5 times shell ID and if there is condensation or boiling on
shell side, Bs could be equal to shell ID for the 1st trial.
6.3.8 Calculations of Tube Side Heat Transfer Coefficient
(a) For heating or cooling on tube side (no phase change), tube side heat transfer
coefficient is determined by Sieder-Tate equation. If Re is less than 2000.
,0.33 0.14
h di d,
Nu= -^ = 1.86 Re - Pr- JL (6.18)
k pw
f
In this equation
If Nu <3.5 then Nu is taken 3.5.
If Re > 4000, tube side heat transfer coefficient is determined by Dittus-Bolter
equation;
/ \0.14
hid; 0.8 d. 0.33 _P_
Nu = = C Re™ Pr (6.19)
Pw
where, Nu = Nusselt number =

k
f
dj u, p dj Gt
Re = Reynolds number =
P P
CPP
Pr = Prandtl number -
/?, = Tube side heat transfer coefficient, W/(m""- 0C)

dj = Tube ID, m
L = Length of tube, m
k = Thermal conductivity of fluid, W/(m • 0C)
Cp = Specific heat of fluid, kJ/(kg ■ 0C)
'f
jj. = Viscosity of fluid at the bulk fluid temperature, (N • s)/m
jUw = Viscosity of fluid at tube wall temperature, (N • s)/m2
C = Constant
C = 0.021 for gases
= 0.023 for non-viscous liquid = 0.027 for viscous liquid
Gr = Tubeside mass velocity, kg/(m2 • s)
^ m
(j
i=
a,
N
t ..n ,2
where, a, = Tube side flow area = —— x —d~ (6.20)
i\p i
m = Tube side mass flow rate of fluid, kg/s

N, = Number of tubes
Np = Number of lube side passes
u, = Tube side fluid velocity = G/p, m/s
p = Density of fluid, kg/nr
To calculate tube side heat transfer coefficient, first calculate tube side flow
area (a,) then tube side mass velocity (G,), then tube side Reynolds number (Re)
and tube side Prandtl number (Pr), then depending on the value of Re, use
Eq. 6.18 or Eq. 6.19 to calculate /?,.
For the transition region or for 2000 < Re < 4000, no reliable equation is
available. Hence, for this region h-, is found by using both Eqs (6.18) and (6.19)
and the lesser of two values is considered.
Tube side heat transfer coefficient h, can be calculated from the value of "heat
transfer factor, J),", for the entire range of Reynolds number (from Re = 10 to
106). Equation relating /z, and Jh is
\0.14
P
Nt = hid]r = Jl.RePr'>* (6.21)
k vAL v y
Graph of Jh versus Re is given in Fig. 6.12 for the different values of L/dp
(b) For condensation inside the tubes.
Condensation coefficient depends on the position of condenser. For condensa-
tion, shell side condensation with horizontal position is the best which gives the
maximum value of the coefficient. But if condensation is carried out in tube side
then for horizontal position /z, is calculated by following two equations and higher
of the two values is considered.
Pl (Pz. — PL ) 8 V
(i) hci = 0.76 kL (6.22)
Pth J
v
id
<u
>
-52
UJ
c
o
5 -
OS l2
«a V—<
o lO oi
c -c
UJ £
3
• ■ z
O
175 <D
i 2 ■O
o X O)
c 0) u
>> T3 3
o "O
Z o
i-
(U •CL
-a <U
(5 a:
o
(N
-O
M
o- ocr- >o m rs o* ^cr- *c «7i 1-5 r-i

h h
'If 'JOJDB j J3JSUEJX IB3H
This equation is Nusselt equation, valid for stratified flow,

where, hci = Condensation coefficient, W/(nr • 0C)
kL = Thermal conductivity of liquid condensate, W/(m • 0C)
pL = Density of liquid condensate, kg/nr
pv = Density of vapour, kg/m3
g = Acceleration of gravity = 9.81 m/s2
P/ = Viscosity of liquid condensate, (N ■ s)/m or kg/(m • s)
Zh = Horizontal tube loading or flow of condensate per unit length of
tube, kg/(m ■ s)
All liquid condensate properties kL, pL and pL must be determined at mean tem-
perature of condensate film.
Wr
th =
LxN,
where, L = Tube length, m

Wc = Total condensate flow, kg/s
Nj = Total number of tubes
' + V PiJPv
(ii) hci = hi' (6.23)
2
where, hf = 0.021 Re™ Pr0 43

d, j
This equation is known as Boyko-Kruzhilin equation, valid for annular flow.
4r
' /;
Rer = Reynolds number for the condensate film = (6.24)
Pl
CpL pL
Prc = Prandtl number of liquid condensate = (6.25)
where CpL, pL and icLare properties of liquid condensate which must be deter-
mined at the mean temperature of condensate film.
/ x \l/3
Pl(PL - Pv)8
For vertical position, hcj = 0.926 kL (6.26)
Wc . . 4t
where, Tv = , Wc = Mass flow rate of liquid condensate kg/s, Rec =
c
N.nd, ' Pl
This equation is also called Nusselt equation, valid for Rec < 2000. For Rec >
2000, use Boyko-Kruzhilin equation, i.e. Eq. (6.23).
6.3.9 Calculation of Tube Side Pressure Drop
(a) If their is no phase change in tube side fluid, then tube side pressure drop can
be calculated by following equation.
\—m
pwr
A/;, = N 87, + 2.5 (6.27)
w y
m = 0.25 for /^<? < 2100 and m = 0.14 for Re > 2100
,2
where, Ap, = Tube side friction pressure drop, N/m or Pa
Np = Number of tube side passes
Jf= Tube side friction factor can be obtained from Fig. (6.13)
p = Density of tube side fluid, kg/nr
u, = Tube side fluid velocity, m/s
Ap, calculated by this equation is actually permanent pressure loss. Calculated
pressure drop (loss) should be less than maximum allowable pressure drop. In
some applications, maximum allowable pressure drop is decided by process con-
ditions. While in other applications, maximum allowable pressure drop is actu-
ally optimum pressure drop (loss). Heat exchanger design means the balance
between two opposite factors, heat transfer coefficients related to fixed cost and
pressure drop related to operating cost. Increase in heat transfer coefficient by
modifying the heat exchanger design also increases pressure drop. Hence, ide-
ally actual pressure drop should be equal to optimum pressure drop which gives
the total cost of heat exchanger (i.e. fixed cost + operating cost) minimum. As a
general guideline (Table 6.8) can be used to decide the value of maximum or
optimum pressure drop. As per Kern, optimum pressure drop for gases is 2 psi
(13.8 kPa) and for liquids it is 10 psi (69 kPa) (Ref. 5).
(b) If condensation takes place inside the tube then it is difficult to predict the
pressure drop as vapour mass velocity is changing throughout the condenser. A
common practice is to calculate A/7,'by Eq. (6.27) for inlet vapour flow rate and
conditions, and multiply it by factor 0.5.
Ap, = 0.5 Ap', (6.28)
6.3.10 Calculation of Shell Side Heat Transfer Coefficient
(A) For heating or cooling on shell side or for no phase change on shell side, heat
transfer coefficient h0 can be calculated by following procedure.
(a) Calculate shell side flow area by following equation
{Pt-d^DsBs
As - (6.29)
P,
where, As = Shell side flow area, m2
p, = Tube pitch, m
d0 = Outside diameter of tube, m
Bs = Baffle spacing, m
Ds = Shell inside diameter, m
(b) Calculate shell side mass velocity Gs and linear velocity {us)
Wc
Gs = and us = (6.30)
Ac Ps
Process Design of Heat Exchangers 169
T I I—I i r -i
- t- H I
11 -|- r
H H -I- f-
+ 4 H — J- H 4 - U -I I L
X 4 4-U _l I
r • rn
4 4 4-U. -J - U -4- -J 4 4--
44 J_l_ J J _ _L 44—I—I I I L J J_l_ L
I I
— h- H 4 4 -4-1- -4- -I 4 4-1-
TT 11 I "T "I-l-rn in-i

ii i i
4-1-1-4 --I- 4 4 4-1-4 1- 4 4-1- r

444-U4 -I--I 4 4 -I- i- -
1i J _L J J L J 4 J_ L J J L J J-l-L
T Til I rn 44 1
1 4 J _ L J __L _L 4 J J _l_ L _
liJ_LJ J L i J J_ LJ J L JJJ_L_
4 4 4—1—4 4I 4I -J—
I J- -I 4- 4 4 - - i-
I
T 4 4-T 4 —r -r4 4I 4 -|- r
m <D
i ii i i O >
01
——t (-4—1 i=! -£2
+ 44—1-4 4 4 4-h uj
4 4 4—1—4 4 U -I 4I 4 4 — — t" —
4 4- - 1- c
liJ_LJ
I I I J L JJJ_LJ J L JI JI II L o c
T44-r4 4 4 -i-r 4 4 4" - •—
CJ
i-i J_l_ J J _l o
f J J L JJJ_LJ J L -D
'J JI JI JI _ II II 1 "U E
4 4 4 — 1—4 -U4 4 4-1 z
"M Co
2 QJ QJ
T 4 4-r 4 4 4 4-r 4 4I o -Q -C
,3
4)
U4—I I—1-4 -1-4 a: ro i
+ 4 4—1—4 4 I- 4-- —; Ts
14 4-1-4 4 - -U 444^L4 4- _ L 4-1- L- O
^ o QJ
+44-r4 -1-4 4 44-" M -o
1-1
I I J_L
I J J__L JJJ_LJ J--L J J_ -L_ -'--1 \L 2
II I •Q-
QJ
II I cc
1 J J _ L_ J _L 4 J J- -
+44-^4 -1-4 4 4 -I- r -

1 l I l
144-1-4-4 1- ■yq 4-1- 4- 4 1-

1JJ_I
I I I I II II LI tfJJ_LJ_J__L
I I I I I I I J_ J J _ _ L _ J__L
m-n-T-r
+ 14-1-4-4 1- ni-n-T-r II -1- -
4 4 4-1-4-4 I- 4
II I I I I I
I I I I I I
mn
ii J_I_ j_ j_ j_ _1 I I L J- J J _l_ L
I
+44-H4- -1- -1-4-4- 4 4 -I- f-
I
I I I
cocr- o wj 4 Ovccr- O */-i 4- ro a> cct-- >c m 4-
Jf 'jopej uoijouj
where, Gs = Shell side mass velocity, kg/(m2 • s)
ms = Shell side mass flow rate of fluid, kg/s

ps = Density of shell side fluid, kg/m3
(c) Calculate the shell side equivalent diameter (de) for square pitch arrange-
ment.
4 x cross sectional area

de =
wetted perimeter
TT
4x ^-^2
4
TTr/,,
1.27
(P,2 - 0.785d;) (6.31)
d,.
For triangular pitch arrangement,
4xf|p,x^sin60-|^
(nd0l2)
de=^-(Pr-0.901 dl) (6.32)

do
(d) Calculate shell side Reynolds numbers
deGs
Re = (6.33)
where, p = Viscosity of shell side fluid at average temperature, kg/(m • s)

Also calculate shell side Prandtl number
CPP
Pr = (6.34)
Cp, p and k are the properties of shell side fluid at average temperature,
(e) Calculate the shell side heat transfer coefficient by following correlation
(Ref. 5).
,0.14
h,. d„
Nu = () 55
= 0.36 Re - Pr {U3 JL (6.35)
AC
This correlation is valid for the range of Reynolds number from 2000 to
1000 000. Shell side heat transfer, coefficient can be found out from "shell
side heat transfer factor, Jh".
/ \0.14
Nu = = Jh -Re ■ Pr 0 33 JL (6.36)
Pw
Graph of A versus Re given in Fig. 6.14.
o- DC r- -c "/"> T c- cc r- >o in -T m csocr- o «n "T

i I I I
frT-r-r-r --r
t- rrn -1- -
s □ - -i- i—• I— L_ J—I I I 1
i i i " i §u -o --I-'
rt--t-1-T-T r-
g 2 t in -r I I I r-i 1
t--\ 1
-I- f- -1
TfTT'T |< Tlj
_L I ■■ 1- l >_L J_ -LI J L
i i i E i i i i i
i i i
-+- x , -f H -I- h H -I
I
II II I I I
I I I
I I I I II ■I
4 4—— I 1 -I
4 4 _l_ L J
l Li Ji _ Ll _!I i! _ "JJ_LJ_
-Ti -ii -i— r —i
_ L1 J L _
i i r-r- I !
_L
I I JI _ Il 1I II _ 1 J L J_ _ LI J I L _
i LI Ji _ LI _ II II _ 4I JI _<I L < i Ji L _
-LI
i i i I I i ii i
— I—i
i
i i i■ ill ill
i
ii i
i
i
i ti ni-i—i
i i ir — ir
rTTT-rT-n—r I I I rr
rrn
+ + H-I l-^ H
i-IJ-l I I 1_ -ULLJ_L_ . L_1 I
I I -rt-
-l- I I I I I t-t-i-r-i- 1--1 1
- h -t - ■t -t -i- - -1-
I —
-Ll-L-1 L_ ±1- i in
•n ^
- f- 4 - 4 4 —I — - H - v _ I- 4 4
_L4 4 J _ _ L _J I _ L 4 _1
_ L4 4 4 _ _ L _) I _L4
Li LJ
-n t T - - r -i- r n -1
L" Li
_ L i L-1 i' L _ L J L _! I
-4H
III
44 — H 4 HI 4-1 1
I— I— L 4 _ I I I 44 _J L L L 4 L -I I
I I I I I - -1 -1-4- 4-1
4H I f -4 4-
r
-44 4 4-1-4-1- —4 — -
oôor^ so -4 C 00 4- so -4 osoor-' so H-
'If 'JOPBJ J3JSUBJX 1B3H

(B) If condensation takes place on shell side then its coefficient depends on the
position of condenser.
Shell side condensation coefficient for horizontal position can be determined
by following modified Nusselt equation.
1/3
Pz,(Pz.-A.)g -1/6
hco - 0-95 kL N (6.37)
Pl?"/,
/■)
where, hco = Shell side condensation coefficient, W/(m • 0C)
3
kL = Thermal conductivity of liquid condensate, W/(m C)
3
p, = Density of liquid condensate, kg/m
pv = Vapour density, kg/m3
g = Acceleration of gravity = 9.81 m/s2
pL = Viscosity of liquid condensate, N • s/m2
Th = Horizontal tube loading or flow of condensate per unit lengh of
tube
LN,
where, Wc = Total condensate flow, kg/s
L = Tube length, m
Nj = Number of tubes
A,. = Average number of tubes in vertical tube row
Nr=\N; (6.38)
N ' = Number of tubes in central row
a,
n: = (6.39)
p.
Dh = Tube bundle diameter, m
P, = Tube pitch, m
For condensation outside the vertical tube bundle, shell side condensation coeffi-
cient is given by Nusselt equation.
>1/3
Pl(PL -Pv)g (6.26a)
^co ~ 0-926 kL
c
where, (6.26b)
Nt 7id,.
6.3.1 I Calculation of Shell Side Pressure Drop
(a) For no phase change on shell side or for heating or cooling on shell side, shell
side pressure drop Aps can be calculated by following equation.
\-0.14
L Ps"s P
Ap= 87, (6.40)
V ) Bs y 2 \p.w y
where, Aps = Shell side pressure drop, N/m2 or Pa

Ds = Shell inside diameter, m
de = Shell side equivalent diameter, m
L = Tube length, m
Bs = Baffle spacing, m
ps = Density of shell fluid kg/m3
us = Shell side linear velocity, m/s
fi = Viscosity of fluid at the bulk fluid temperature. (N ■ s)/m
pw = Viscosity of fluid at tube wall temperature, (N ■ s)/m
Jf = Shell side friction factor for the different values of % baffle cut
of segmental baffle and for the different values of Re, it can be
obtained from Fig. (6.15).
Shell side pressure drop Aps should be less than maximum allowable pressure
drop. Maximum allowable pressure drop for shell side is also decided either based
on process requirement or based on economic considerations.
Table 6.8 can be used to judge optimum pressure drop.
Table 6.8 Optimum Pressure Drop (Maximum Allowable Pressure Drop) based on Economic
Considerations (Ref. 4)
Fluid Optimum, Ap, or Aps, kPa

Liquids of pL < 1 cP 35
Liquids of p, = 1 to 10 cP 50 to 70
Gas or vapour at 1 to 2 atm 13.8
Gas or vapour at high vacuum 0.4 to 0.8 (3 to 6 torr)
(up to 60 torr absolute pressure)
Gas or vapour at high pressure > 10 atm 0.1 times operating pressure
(b) In case of shell side condensation no reliable correlation is available for

predicting Aps. Hence, Aps can be approximately calculated by following equa-
tion.
Aps = 0.5 Ap ' (6.41)

where Ap/ = shell side pressure drop calculated by Eq. (6.40) based on inlet
vapour flow rate and inlet conditions.
This also should be less than maximum allowable pressure drop.
6.3.12 Calculation of the Overall Heat Transfer

Coefficients by Following Equation
Uo (6 42)
~ 1 , 1 , | d0 ^ | ^ x 1 "
2k d d h
ho hot, w i Ki i i
where, U0 = Overall heat transfer coefficient based on outside area of tubes,

W/(m2 ■ 0C)
- *— h — + 1 HH- -hH
-I 1 -1-4- -hH
UI--1-I — I t 4- -l 1 -l-l- - U -I
-I- 4- -4. -I- - -4-4- - 4- -4
I I I I H H - -I
-1-4-4 -H -
-4 ■ 4 -I 1 4-1- — 4- -
rr rrr-i-r
4-i — i--1-- 1 "1 -
-r- t4 1
nn
r rTT-r-r-r
4 1-4-I - 4 -1-- 4 -i— — i — -in -in -
L L 1 J _ L _I 1 jJ
r r 4 -r -|—i -i -i
1114 r i nn
1-L4--I-L-I 4 -I 1 —i J
rrn rrr t r i nn r i
r > -i n
rm-r-r-T rrn-r-i n-i
rrjn-r-r-T ii i r r i
U 4 -I- -I | 1 -I -4
i i i i r -r r r -i
rrrT rr i
U 4 -I- -4=4-
II I I I I □^
rm-r-i rr-n -• ""
ii i i i i i = -a
ii i i i i i i = <1
rm-r-r-T rt i—i
rm-r-r-i i i
iiit ri r i i i
rm-r-r-T
rrT~i~r~r"T rr r t t -1 1
I— I— 4-4-1 1 1 1
iriii
LiJ II I I I I I I
ii ii ii ii
-4-1 4 (- -I 4-
II I I
II I I
LL1J-L-L
LL1 J_L_l_ LLL1 JJ-J_
J_ _L
-I Jl J4 _ -I-
L
LL1J_L_L. UI-1-I- LU 44 J J- _ 1 I J..U
LI LIJ
l l l _ Il _ IL LJ
rr r -11- -r-i1
LLlJ_L_L
II I I I I J J- _ 1 J__l_
LLJ.J_J L_ l_ L 44- — I 1 4 1_
rrtt m r -i
4 -4 U4
III
lit
III
I'll
'/• 'JOJOB j UOipiJj

h0 = Shell side heat transfer coefficient, W/(m2 • 0C)

d0 - OD of tube, m
^, = 10 of tube, m
kw = Thermal conductivity of tube wall material, W/(m ■ 0C)
hjd = Fouling coefficient for tube side fluid, W/(m2 • 0C)
hod = Fouling coefficient for shell side fluid, W/(m2 ■ 0C)
For the various types of fluids, recommended fouling coefficient are given in
Table 6.9.
Table 6.9 Recommended Fouling Coefficients (Ref. 4. 6 & 7j
Fluid Fouling Coefficient Fluid Fouling Coefficit

2
W/(m • "C) W/(m2 • "C)
Cooling water 3000-6000 Aqueous Organic Solution 5000
Steam 4000-10 000 Vegetable oils 3000
Steam condensate 1500-5000 Caustic Solutions 5000
Brine 3000-5000 Gasoline 5000
Air 5000-10 000 Kerosene 3000-5000
Organic vapours 10 000 Light gas oil 3000-5000
Organic liquids 5000 Heavy gas oil 2000-3000
Heavy hydrocarbons 2000 Napthas 5000
Aqueous salt solutions 3000-5000 Coal flue gas 1000
Light Hydrocarbon 5000
Heavy Hydrocarbon 3000
6.3.13 Calculating the Heat Transfer Area Required
A = — (6.43)
U0A%n
Also calculate actual heat transfer area A0.
A0 = N,Kd0L
4
{1.1 to 1.2}
4eq
An. An.
' ~ {0.8 to 1}, ——— e {0.8 to 1}
A
P, max fys max
Thus an optimum design of shell and tube heat exchanger can be obtained.
Example 6.1
A lube-oil cooler for 2 MW steam turbine is to be designed for following operating
conditions. Lube-oil, conforming to ISO VG-46 grade, flows at the rate of 450 L/min
and is to be cooled from 650C to 450C with cooling water.
Kinematic viscosity of lube oil = 45.5 cSt at 40oC.
Density of lube oil = 869 kg/m3
Specific heat of lube oil = 2.1413 kJ/(kg • 0C)
Thermal conductivity of lube oil at 550C = 0.13 W/ (m • 0C)
Viscosity of lube oil at 550C = 15 cP

Cooling water inlet temperature = 35 0C
Cooling water outlet temperature = 390C
Solution:
Heat duty, 0, = m0 CLo At
Volumetric flow rate of oil = 450 L/min = 450 x 60 x 10~3 m3/h = 27 m3/h
m = 21 x 869 = 23 463 kg/h
0, = 23 463 kg/h x 2.1413(65 - 45) LMTD
0, = 1004 826 kJ/h = 279.118 kW 650C
Heat balance
<t>,= >KCLw At
279.118= mw x 4.1868(39 - 35) 45 C
390C < 35 C
mw = 16.667 kg/s (= 60 m Vh)
A7[ = 65 - 39 = 260C
Fig. 6.16
A95 = 45 - 35 = 10oC
AT, - AT2 26-10

A^ = = 16.7450C (6.12)
^26]
In In
AT, v 10.
For the first trial calculations, let the number of tube side passes Np = A
Allocating lube oil on tube side and cooling water on shell side.
%-'h h ~l\
R = S=
h ~t\ %-h
"Tj- = 65° C, ^ = 45° C, /, = 35° C, t2 = 39° C
65-45 39-35
R = = 5, 5= = 0.1333
39-35 65 - 35
From Fig. 6.11, Ft = 0.95
Mean temperature difference. Act = F, Al{n
Arm = 0.95 x 16.745 = 15.908oC
Assume overall heat transfer coefficient U0 = 400 W/(nr- C). (Ref.: Table 6.7)
Provisional heat transfer area for the first trial calculation.
279.118 xlO3
A =
Vo AT„, 400x15.908
A = 43.8644 m2 = N,kc10L
dn = 5/8 in. = 15.875 mm, L = 6 ft = 1.8288 m
43.8644
N, = = 480.93 s 480
' TTX (0.015 875 x1.8288)
Select BEM type heat exchanger with tube pitch Pr = 1.25 d0 = 19.8437 mm and triangu-
lar pitch arrangement.
l/M,
Tube bundle diameter Dh = d0 (6.1)
k.
From Table 6.2 for Np = 4, k, = 0.175, n, = 2.285

\ 1/2.285
D/, = 15.8751 1 = 507.5 mm
0.175
Let clearance between shell ID and Dh = 12.5 mm = 520 mm
Evaluation of /i,-:
Tube side flow area:
480 k ,2
a= x—df (6.20)
4 4'
di = 13.3858 mm (for 18 BWG tube)
a, = - (0.013 3858)2 = 0.016 887 m2

r 4 4
• • 111
Tube side mass velocity C, = —
a,
1
{ 23 463 x
G. = = 390.57 kg/(mz • s)
5
' 0.016687
Viscosity of oil:
li = 15 cP = 15 xlO-3 kg/(m ■ s)
d:G. 0.013 3858x390.57

Re = = = 348.54
R 15 x 10
To increase the Reynold number, let the number of tube side passes Np = 8
K] = 0.0365,771 = 2.675 from Table 6.2
480 2.615
Db = 15.875] = 550 mm
V 0.0365
Shell ID =0,,+ 12 = 562 mm
Evaluation of hf.
a, = -(0.013 3858)2 = 8.4436 x lO"3 m2

8 4
G. = 390.57 x - = 781.14 kg/(m2 ■ s)

4
G, 781.14 no .
u, = — = = 0.9 m/s
p 869
Res = 348.54 x 2 = 697
C,,!* 2.1413x15xlO-3 xlO3

Pr =
K 0.13
= 247
Using Sieder-Tate equation (Ret < 2000)

/ \0.14
h, d: R
Nu = = I MiRe ■ Pr - dJL)0.33 (6.18)
\r~w y
>0,33
0.0133858
= 1.86 697 x 247 x X 1
1.8288
= 19.618 >3.5
k 19.618x0.13
h: = 19.62 x — = = 190.526 W/(m2 ■ 0C) (too low)
di 0.013 3858
To improve oil side heat transfer coefficient, allocate lube oil on shell side and water on
tube side. Increase the tube length from 6 ft to 10 ft for the same value of heat transfer
area provided. It will decrease the shell side flow area and will improve the shell side
heat transfer coefficient
L = 10x0.3048 = 3.048 m
Apro = 43.8644 m2 = Ntnd0L = Nlx nx 0.015 875 x 3.048
N, = 288.56 s 288
Let number of tube side passes Np = 4
k, = 0.175, n, = 2.285 (Ref.; Table 6.2)
2 8 8 ) 2.285
ZX
-7. = 15.875 175j
= 406 mm
Shell ID, D,- = 406 + 12 = 418 mm

Evaluation of /i(:
a, = —x-(0.013 3858)2 = 0.01 m2

4 4
Tube side mass velocity, G, = 1

^ ^ = '666.7 kg/(m2 ■ s)
Density of water at 340C, p = 993.328 kg/m3

(Table 3.28 of Ref. 2)
G, 1666.7
u, = = 1.678 m/s
p 993.328
d^
Re =
R
Viscosity of water at 370C, p = 0.73 cP = 0.73 x 10 3
kg/(m • s)
0.013 3858x1666.7
Re = = 30 561.8 >4000
■v-3
0.73 x 10"
Thermal conductivity of water at 370C, k = 0.628 W/(m- 0C)
CPR
Prandtl number of water, Pr =
K
4.1868 x 0.73 xl (T3 xl03

Pr = = 4.867
0.628
Using Dittus-Bolter equation
k: d, / \0.I4
08 033 P
Nu = = 0.023 Re Pi (6.19)
kf Pw
Q 628
h: = 0.023 x ' x (30 561.8)a8 X4.8670-33
0.013 3858
= 7046.6 W/(m2 ■ 0C)
Evaluation of oil side heat transfer coefficient {hn):
Shell side flow area
iP,-d0)
x Ds x Bs (6.29)
P,
PJd0 = 1.25, D9 = 418 mm, Bs = ^ = = 83.6 mm
1 -25 d0 - d0
A„ = x 0.418 x 0.0836 = 6.989 x K)"3 m2
(\.25d0)
m
Shell side mass velocity, Gs = (6.30)
a7
23 463 x
3600
G = = 932.537 kg/m2 • s
,-3
6.989x10
G
s 932.537 . n_, .
= = = 1.073 m/s
p 869
Shell side equivalent diameter for triangular pitch
de =^-(P;--0.901 d3) (6.32)

d,.
1.1
d = [19.8437 - 0.907 x (15.875)2]
15.875
= 11.4465 m
deGs
Shell side Reynolds number Re =
P
0.0114465x932.537
Re = =711.62
15x10 -3
Cpli 2.I4I3x (15 x ID-3) x 103

Pr =
k 0.13
= 247
Re =1\\ .62 =>,//( = 2 x IO"2 (From Fig. 6.14 for 25% baffle cut)
N.. = = Jh Re Prm (636)

cf
0.13
h=2x lO"2x x 711.62 x (247)l/3 x 1
0.0114465
= 1014.18 W/(m2- 0C)

Overall heat transfer coefficient
r i \
do_
d0 In
V Cl:' / d
o \ d
o 1
—+ —+ + + —x — (6.42)
U, h
o Kd 2 kw d
i Ki d
i h
i
From Table 6.9

hod = 3000 W/(m2 • 0C), hjd = 5000 W/(m2 ■ 0C)
/
15.875 "l
0.015 875 In
13.3858 7 | 15.875 1
+ + X
Un 1014.18 3000 2x50 13.3858 5000
15.875 I
+ x
13.3858 7046.6
0
Thermal conductivity of tube material kw = 50 W/(m • C)
Tube material: steel or cupronickel)
U0 = 570.8 W/(m2 • 0C)
Heat transfer area required, Ar = (6.43)

U0 ATm
279.118 xlO3
= 30.739 m2
570.8x15.908
Excess heat transfer area = -I x 100
= Kq8^4-1) X 100 = 42.7 % (sufficiently high)

Shell side Pressure Drop:
/" \ / \ -0.14
(Ds' L Ps US P
Aps = 87, (6.40)
[de . \ B,s / 2 .PW ,
Ds = 0.418 m, de = 0.011 4465 m, L = 3.048 m

Bs = 0.0836 m, us = 1.073 m/s, ps = 869 kg/m3
Jr = shell side friction factor
For Res = 711.62, Jf= 7.7 x lO"2 (From Fig. 6.15)
N
0.418 r 3.048 "l
Aps = 8 x 7.7 x lO"2 x
(0.011 4465 y 10.0836 J
= 410 281.7 Pa = 410.282 kPa (too high)

To decrease the shell side pressure drop, baffles spacing can be increased from 83.6 mm
to 160 mm.
Revised value of Bs = 160 mm = 0.16 m
Shell side flow area, As = 6.989 x lO""3 x 0 16

= 0.013 376 m2
0.0836
6.989x10 -3
Shell side mass velocity. Gs = 932.537 x = 487.25 kg/(m ■ s)
0.013 376
G
s 487.25
u, = = 0.56 m/s
Ps 869
0.0114465x487.25
Re = = 371.82
-3
15x10
hsde / \0.14
P
Nu = = Jh Re Pr,1/3 (6.36)
\Pw /
for ,-2 (from Fig. 6.14)

Re = 371.82 =^ J,, = 2.7 x lO"'
Nu = = 2.7 x lO"2 x 371.82 x(247),/3 = 62.989
0.13
/ir = 62.989 x = 715.37 W/(m2- 0C)
0.0114465
1 1
-r
U0 570.8 1014.18 715.37
U =462.15 W/(m2 • 0C)

<t>, 279.118x10'
A,= = 37.96 m2
U0ATm 462.15x15.908
43.8644
Excess heat transfer area = -1 x 100 = 15.55% (adequate)
37.96
Revised Shell side Pressure Drop:
For Ds = 0.418 m, Bs = 0.16 m, ^ = 0.011 4465 m, L = 3.048 m, us = 0.56 m/s,
pv = 869 kg/m3
Ps^s r p \
Aps = 87, {L (6.40)
U Bs J 2
For Re = 371.82, Jf= 9.26 x 102 (From Fig. 6.15)
0.418 3.048 "j 869x0.56 x

Aps = 8 x 9.26 x 10,-2
X
0.0114465 0.16
Aps = 70 220.7 Pa s 70.22 kPa (acceptable)

Tube side Pressure Drop:
/ / \ / \ —m
L p pi'i
+ 2.5 X
-r
00
&p,=K (6.27)
d
v i) . Pw ) / y
Np = 4, L = 3.048 m, 7, = 0.013 3858 m, u, = 1.678 m/s
p = 993.328 kg/m3, plf^ = I
Re, = 30 561.8 Jf= 3.6 x lO"3 (From Fig. 6.13)
-3 3.048 993.328 x 1.678

Ap,= A 8 x 3.6 x 10 x xl+ 2.5 x
\ v 0.013 3858
Ap, = 50 668 Pa = 50.668 kPa

Comments: In this case viscosity of lube oil is very high, hence it gives very poor
Reynolds number. Fluid, which provides poor Reynolds number must be allocated
shell side to get the higher heat transfer coefficient. Flere also, by changing the alloca-
tion of lube oil from tube side to shell side, lube oil side coefficient increased consid-
erably. In any (without phase change) shell and tube heat exchanger for the fixed value
of heat transfer area, increase in tube length (correspondingly decrease in number of
tubes and shell inside diameter) increases the overall heat transfer coefficient but at the
expense of pressure drop or in other words increase in tube length for the fixed value
of heat transfer area decreases the fixed cost of heat exchanger but increases its operat-
ing cost.
6.4 CRITERIA OF SELECTION BETWEEN HORIZONTAL

CONDENSER AND VERTICAL CONDENSER
(i) For only filmwise condensation, horizontal position gives higher

condensation coefficient than vertical position. In filmwise condensation,
thickness of condensate film over heat transfer surface decides the value of
condensation coefficient. With horizontal position and shellside

condensation, the condensate travels less distance over heat transfer surface
before falling down by gravity compared to vertical position. With vertical
position condensate travels over the entire tube length before falling down
by gravity. Hence, average condensate film thickness obtained with
horizontal position is less than the same with vertical position and hence it
provides higher condensation coefficient.
(ii) In case of condensation with subcooling in a shell and tube heat exchanger,
condensation coefficient is higher with horizontal position while subcooling
coefficient is higher with vertical postion. In case of subcooling with hori-
zontal position, small fraction of gravitational force is acting on the pool of
condensate and hence condensate is flowing with almost no turbulence.
Hence, subcooling with horizontal position is natural convection heat trans-
fer. While in subcooling with vertical postion, entire gravitational force is
acting on pool of condensate. Hence, it creates turbulence in pool of con-
densate and provides higher subcooling coefficient. Subcooling with verti-
cal position can be considered as forced convection heat transfer.
Therefore, in the case of condensation with subcooling, shell and tube
heat exchanger is designed for both positions (horizontal and vertical) and
the position that gives higher value of overall coefficient is selected.
(iii) In case of condensation with non-condensables, selection of position de-
pends on the % of non-condensables present in inlet vapours for which
guidelines are given by Frank5.
(a) If non-condensables are < 0.5 % (by mass), then the presence of non-
condensables is ignored in design calculations. Heat exchanger is de-
signed as a total condenser. For this case, horizontal position should be
selected as it provides the higher condensation coefficient.
(b) If non condensables are > 70% (by mass), then for the entire flow rate,
without phase change correlation is applied to calculate the heat trans-
fer coefficient. However, in calculation of heat duty (0,), condensation
is considered. For this case selection of the position does not depend
on heat transfer coefficient, as without phase change coefficient does
not depend on position of heat exchanger so in this case position is
decided by other factors like available area or available height.
(c) Between 0.5 to 70% non-condensables, heat transfer coefficient is de-
termined by considering both condensation as well as cooling of non-
condensables and vapours. For this case horizontal position should be
selected as it gives higher condensation coefficient, if condesation with
cooling is carried out on shell side. If the same is carried out on tube
side, then vertical position is better.
Example 6.2
10 900 kg/h of nearly pure saturated methyl ethyl ketone vapour at 13.73 kPa g is to be
condensed and cooled to 60oC by cooling water which is available in plant at 320C.
Consider pressure drops of 13.7 kPa for vapour and 68.7 kPa for the water as permissi-
ble. Design the suitable shell and tube heat exchanger for the heat duty.
Solution:
Heat duty calculations
<pt = ml + mCLAt = (pc + 0sub
where, <Z»(, = mX = heat duty for condensation

0sub = mCL AT = heat duty for subcooling
m = 10 900 kg/h = 3.0278 kg/s
A = Latent heat of vaporization of methyl ethyl ketone (MEK) at condensa-
tion temperature
At condensation temperature of pure MEK vapour
Py =pt= 13.73 kPa g = 115.055 kPa a = 863 torr a
Antoine equation4 for methyl ethyl ketone
i p = 16.5986
In 3150.42
v
T- 36.65
where pv is in torr and 7 in K
pv = pl = 863 torr T = 356.87 K = 83.870C
From Table 3-179 of Ref. 2,
Amek al 78.20C = 105.93 kcal/kg = 443.5 kJ/kg
Value of Amek is required at 83.870C.
Using Watson relation,
/. -p n0.38
i — ir->
A2=A|
1-7r\
Tl. = reduced temperature = 7/7c

Tc of MEK = 535.6 K
,0.38
(83.87 + 273.15)
535.6
A at 83.870C = ^ 2oC
(78.2 + 273.15)
1-
535.6
As3.87°C = 443.5 x 0.9882 = 438.27 kJ/kg

= ml = 3.0278 x 438.27 = 1327 kW
^ = mCL(83.87 - 60)
(83.87 + 60)
Specific heat of MEK liquid at = 720C:
CL = 2.298 kJ/(kg • 0C) (From Table 3-184 of Ref. 2)

0sub = 3.0278 x 2.298 x (83.87 - 60) = 166 kW
<p, = (t>c + 0sub = 1327 + 166 = 1493 kW
Energy Balance
0 = mwCpw (r0 - 32)
Fixing the outlet temperature of cooling water as 40oC,
mass flow rate of cooling water required
(p, 1493
=== 44 5746 k8/s
-
First trial calculations:

Using Table 6.7, let overall heat transfer coefficients be
for condensation Uc = 800 W/(m2 ■ 0C)
for subcooling 17sub = 200 W/(m2 • 0C)
Assuming that entire flow of cooling water is first utilized for subcooling and then for
condensation.
0suh = 'kyCpJf - 32)

where t' = intermediate temperature of cooling water
166 = 44.5746 x 4.1868 x (r' - 32)
t' = 32.890C 83.87 > 83.87
LMTD for condensation:
ATJ" = 83.87 - 32.89 = 50.98oC 40
= 83.87 -40 = 43.870C
32.89
50.98-43.87
A'4 = = 47.3360C
50.98 Fig. 6.17(a)
In
43.87
for condensation of pure component R = 0 and 4=1, hence LMTD = MTD
LMTD for subcooling:
A'TJ- = 83.87 - 32.89 = 50.98oC 83.87
= 60- 32 = 280C
60
50.98 - 28
0
A4 = = 38.349 C
50.98 32.89
In 32
28
Assuming that subcooling will take place
Fig. 6.17(b)
in the perfect counter current manner.
4 = 1, hence LMTD = MTD
Area based on assumed values of U:
For condensation:
<Pc 1327x1000
A = = 35.042 m2
£4 AT 800 x 47.336
For subcooling:
4ub 166x1000
ASub - = 21.643 m2
^sub A'4suh 200 x 38.349
Total area A = Ac + Asub = 56.685 m2
Asub 21.643
= 0.3818 and Asub < Ac
A 56.685
Based on the selected values of overall coefficients, area required for subcooling
(Asub) is less than area required for condensation (A(.). Hence to get the smaller size of
heat exchanger horizontal position is selected. Ideally in such a case heat exchanger
should be designed for both positions and the position which requires lesser heat trans-
fer area should be selected.
Area provided for the first trial calculation

A = 56.685 m2 - N,7t(](lL
Choose 3/4 on OD (19.05 mm OD), 6 ft (1.83 m) long tubes
/\ ^ 56.685
N, = = ——" =518 tubes
nd0L (^-x 0.019 05x1.83)
Shell side fluid is a clean fluid, hence, select triangular pitch arrangement
P, = 1.25 d0 = 23.8125 mm
Number of tube side passes = 2 (for lsl trial calculations)
Tube bundle diameter:
'N,-
Db = d0 (6.1)
\k\ J
= 19.051 I2'207 (Using Table 6.2)

0.249
= 607 mm
Select a fixed tube sheet heat exchanger.
Let clearance between shell ID and = 13 mm
Shell inside diameter = 620 mm
Calculation of tube side heat transfer coefficient:
o, = -^ x - J2 = — x - (0.015 748)2 = 0.050 45 m2

' Np A 2 4
(From Table 11.2, of Ref. 2 for 16 BWG tube d, = 15.748 mm)

Tube side mass velocity.
^ m 44.5746 000 C/, , 2 n

G, = — = = 883.54 kg/(mz • s)
a, 0.050 45
«,=
P
883.54
= 0.89 m/s < I m/s
992.9
To avoid the excessive fouling it is recommended to keep the velocity of water greater
than 1 m/s.
Increase the number of tube side passes from 2 to 4.
for Np = 4, a, = 0.025 22 m2
D, = 19.05 (Table 6.2)

v 0.1757
= 630 mm
Let clearance between shell ID and Dh= 15 mm
Shell inside diameter = 645 mm (revised)
44.5746 „ 2
G, = = 1767.43 kg/(m ■ s)
0.025 22
u, = 1.78 m/s
diG,
Re =
Viscosity of water at 360C, /2 = 0.72 cP = 0.72 xlO 3

kg/(m • s)
0.015 748x1767.43
Re = "\—3 = 38 657.6
0.72x10"
Prandtl number
Thermal conductivity of water at 360C, k = 0.6228 W/(m • C)
Cpu 4.1868 x (0.72 x 10-3) lu

iqS
Pr= -^- = -x
k 0.6228 1
= 4.84
Using Dittus-Bolter equation
. ^ V'-'4
0 9, 033
= 0.023 Re Pr (6.19)
k /
/ \0.I4
P
Neglecting
P /
\r-w
0.023x0.6228
h: = x (38 657.6) x (4.84)a33
0.015 748
= 7155.5 W(m2 ■ 0C)
Shell side coefficient:
(a) For condensation zone, hco:
Calculation for mean temperature of condensate film:
Let tw = Tube wall temperature, 0C
hco = 1500 W/(m2 ■ 0C) (assumed for 1st trial calculation)
At steady state
Heat transfer rate through condensate film = overall rate of heat transfer
hCoAc.(tc-tJ=UL.AL.(tc-tav)
where, tc = Condensation temperature of vapour on shell side, 0C
0
rav = Average tube side fluid temperature for condensation zone, C
(32.89 + 40)
1500(83.87-0 = 800 83.87 -
= 58.5770C
Mean temperature of condensate film
tc+tw (83.87 + 58.577)

= 71.220C
Physical properties of liquid condensate at 71.220C

Viscosity of liquid MEK at 71.22 0C, iuL = 0.32 cP = 0.32 x lO"3 kg/(m • s)
Density of liquid MEK at 71.22 0C, pL = 805 kg/m3
Thermal conductivity of liquid MEK at 71.22 0C, kL = 0A 73 W/(m • 0C)
Shell side condensation coefficient with horizontal position
1/3
Pl(Pl ~ Pv) 8 -1/6
hco = 0.95 kL N (6.37)
r
PL h
Acceleration of gravity g = 9.81 m/s2
PM PM
Density of vapour pv = x (.v for standard conditions)
RT P
'sV
y
s
863x72 273
A = x
(273 + 83.87) 760x22.414
pv = 2.97 kg/m3
W (10900/3600)
h = = 3.194 x lO"3 kg/(m • s)
LN. (1.83x518)
Average number of tubes in vertical rows
Db
Nr = 2/3 N' = —
3
2 630
= —x = 17.64 s 18
3 23.8125
1/3
805 x (805-2.79) x 9.81
A =0.95 x 0.173 -1/6
x (18)
3 -3
0.32 x 10" x 3.194 xlO
= 1864.86 W/(m2 • 0C)

hco is close enough to assume value of hc0. Hence, correction in the value of tw is not
required.
(b) For subcooling zone, //osub:
With horizontal position, subcooling is taking place via natural convection only for
which reliable correlations are not available. Based on Kern's recommendation (Ref. 5),
homb for horizontal position.
/W, = 50 Btu/(h • ft2 • 0F)
= 283.77 W/(m2 • 0C)
Overall Heat Transfer Coefficient for Condensation:
1
lJ
oc = (6.42)
d
1 + J_ + " ln(^' ldi ' +
d
o{ \
+
h.
"OC h..od 2k..
—' V
W d: \ hi /
"•( d
i h
id
From Table 6.9,
For organic vapours, hod = 10 000 W/(m2 • 0C)
For cooling water, hid = 4000 W/(m2 • 0C)
With methyl ethyl ketone and cooling water, stainless steel-304, is a suitable material for
the tube.
Thermal conductivity of SS-304 material, kw = 16.3 W/(m • 0C)
/
19.05 ^
0.019 05 In
1 1 15.748 19.05 .. 1
+ + + X
Uoc 1864.86 10 000 2x16.3 15.748 7155.5
19.05 1
+ x
15.748 4000
2 0
Uoc = 820.38 W/m • C)
Heat transfer area required for condensation
0cond 1327x1000
A,...
£T
=
Uoc x ATmc 820.38 x 47.336
Acr = 34.17 m2
Overall Heat Transfer Coefficient for Subcooling:
= <6 42)
i | i | dMdjd,) tdc \ ~d~l '
h
Ksub od 2kw d, hid di hi
1
ôsub
1 i 0.019 05 ln(19.05/15.748) 19.05 1
_j 1 x.
283.77 10000 2x16.3 15.748 4000
| 19.05
15.748x7155.5
[/„sllb = 237.72 W/(m2-0C)

Heat transfer area required for subcooling
(psuh 166x1000
ASubr = — = = 18.21 m2
ôsub x ATmsub 237.72x38.349
Total heat transfer area required
Alr = Acr + Asubr = 34.17 + 18.21 =52.38 m2
4
56 685
'P"' - = 1.082
A,req 52.38
or % Excess heat transfer area = (1.082 - 1) x 100 = 8.2%

% Excess heat transfer area should be atleast 10%. Hence, to increase the value of heat
transfer area, increase the tube length. New value of tube length is
L = 1.83 x = 1.95 m
1.082
Let new or revised tube length L = 2 m
2 ■?
Heat transfer area provided Anril = x 56.685 = 61.95 nr
pro
1.83
Revised value of shell side condensation coefficient

1/3
1^ ^ L
1/3
hoc = | — | x 1864.86 = 1920.9 W/(m2 ■ 0C)
1.83,
New value of Unc
I 1 1
+
Uoc 820.38 1864.86 1920.9
2 0
Uoc = 831 W/(m • C)
1327x1000
Alir = = 33.73 m2
831x47.336
As„b = 18.21 m2
Areci =51.94 m2
^fpro = A | OS = 1.1927
Areq 51.94
% Excess heat transfer area = (1.1927 - 1) x 100 = 19.27%

If the equal percentage of excess heat transfer area (19.27%) in both zones are provided
then.
Heat transfer area provided for condensation:
Ac,pro = 33.73 x 1.1927 = 40.23 m2
Heat transfer area provided for subcooling:
Asubpro = 18.21 x 1.1927 = 21.72 m2
= 21^2 = 0 35^
Apro 61.95
Hence, 35.06% of total heat transfer area should be provided for subcooling.
Assuming that tube will be uniformly distributed in the cross section of shell.
Aubpro Area of segment of cross section utilized for subcooling

Ajp,.,, Total cross sectional area of shell
xDf
0.3506 = —
x=- x0.3506 = 0.2754

4
From Table 1.19b of Ref. 2, for x: = 0.2754, h/D, = 0.382
Hence, 38.2% of shell inside diameter should be submerged in the pool of condensate to
faciltate subcooling.
This can be achieved by providing inverted U-seal (Fig. 6.18) height of inverted U-seal
from the base of shell ID
h = 0.382 x 645 = 246.4 mm
Shell side pressure drop Aps: Hydrocarbon

Vapours
Shell side flow area
i
/; = 246.4 mm
sOV
where x'=\- — = \- 0.382 = 0.618

di Condensate
Let baffle spacing Bs = Shell ID = 645 mm Fig. 6.18 Detail of U-Seal
(23.8125-19.05)
As = x 0.645 x 0.645 x 0.618 = 0.051 42 m2
23.8125
Shell side velocity
11 s =
Pv
Shell side mass velocity, G, = — =

Gs 0.05142
Gs = 58.884 kg/(m2 ■ s)
58,884
ms = (GVp ) = =21.105 m/s
2.79
Equivalent diameter for triangular pitch arrangement
de=^(P,2-0.901dt)
1.1
(23.81252 - 0.907 x 19.052) = 13.736 mm
19.05
0.013 736x58.884
Re = = 73 530
1100 x 10~7 x 10_l
(Viscosity of MEK vapour at 83.870C = 1100 x 10~7 Poise)

From Fig. 6.15, for 25% cut segmental baffle
Shell side friction factor, Jj-= 0.0358
\-0.14
D, L Pv".2 ' P
Aps = 0.5 x 8 x 7 (6.41)
Kde B, 2
2 79 X 2U05
= 0.5 x 8 x 0.0358 f-^-Yx -
v 13.736 A 645 ) 2
= 129 56 Pa = 12.956 kPa < Apsmax (13.73 kPa)
To decrease the shell side pressure drop, increase the % baffle cut from 25% to 35%,
then for 35% cut segmental baffle
Jf = 0.03
0.03
Ap = x 12.956 = 10.86 kPa < A psmax (13.73 kPa)
0.0358
Tube side pressure drop, Ap,:
\/ \ -m
pu;
L p
8J / ( + 2.5 X (6.27)
A y K PW J /
L = 2000 mm, Np = 4, r/,- = 15.748 mm, p = 993.684 kg/nr, m, = 1.78 m/s
Re = 38 657.6, Jf = 3.41 x H)"3 (from Fig. 6.13)
x
993.684 xl.782
Apt = 4 x 8 x 3.41 x 10"3 x f 2000
] x 1 + 2.5 x
15.748y
Ap, = 37 558 Pa = 37.558 kPa < Aptmax (68.6 kPa)
Resulting Heat Exchanger Specifications:
1-4, fixed tube sheet shell and tube heat exchanger (BEM type).
Shell ID = 645 mm. Baffles: 35% cut segmental.
Baffle spacing = 645 mm,
Tube OD = 19.05 mm, 16 BWG, Tube length = 2000 mm,
A Pitch arrangement, P, = 1.25 dn, Number of tubes, = 518
6.5 CONDENSATION WITH NON-CONDENSABLES
For the design of this type of heat exchanger, methods available are: (i) Colburn
and Hougen method and (ii) Porter and Jaffreys method. But these methods are
complex requiring trial and error calculations. These methods consider both
resistances; resistance provided by heat transfer and diffusional resistance pro-
vided by mass transfer.
Approximate methods are also available for the same. In approximate methods
only the resistance, offered by heat transfer, is considered while mass transfer
resistance is neglected. Hence in these methods it is assumed that overall rate of
heat transfer in condensation with cooling of non-condensables is totally controlled
by heat transfer resistance. One of the approximate methods is Gilmore's equa-
tion"1.
1 1
+ (6.44)
h
c8 h, 0, h K
where, hcg = Heat transfer coefficient for condensation with cooling of non-
condensables, W/(m2 • 0C)
hc = Average condensate film coefficient, determined by using single
component condensation correlations, at the average condensate
'y
composition and total condensate loading, W/(m • 0C)
/2„ = Average gas film coefficient determined for the average vapour
gas mixture flow rate, W/(nr ■ 0C)
(pg = Total sensible heat transfer from vapour-gas mixture, kW
0, = Total heat transfer, kW
0,= Latent heat of vaporization + sensible heat for cooling the gas-
vapour mixture.
For non-condensables, present in vapour, guidelines given by Frank (Sec. 6.4)
may be followed.
Process Design of Heat Exchangers 193 |
Example 6.3
Air saturated with u-hutanol vapour at 49 kPa g pressure and at 100oC temperature is to
be sent to shell and tube heat exchanger for recovering butanol. Air-butanol vapour
mixture is to be cooled to 50oC by cooling water which enters at 320C and leaves the
heat exchanger at 40oC.
Air flow rate (butanol free) = 500 NnrVh
Check that whether the shell and tube heat exchanger with following specifications is
suitable for the given duty earlier.
(i) Type of heat exchanger; BEM as per TEMA
(ii) Material of Construction of heat exchanger: SS-304
(hi) Shell ID = 387 mm
(iv) Tube OD = 19.05 mm
(v) Tube ID = 15.748 mm
(vi) Tube length = 1500 mm
(vii) Tube Pitch = 25.4 mm
(viii) Type of tube arrangement = Triangular
(ix) Number of tubes = 134
(x) Number of tube side passes = 4
(xi) Number of shell side passes = one
(xii) Baffle type = 25% cut segmental
(xiii) Baffle spacing =120 mm
Properties of fluids and material:
(a) Thermal conductivity of SS-304, kw = 16 W7(m • 0C)
(b) Antoine equation4 for butanol
3137.02
In pv = 17.2160- where pv is in torr and T is in K.
T - 94.43
(c) Latent heat of vaporization of butanol at 750C, = 642 kJ/kg
(d) Physical properties of butanol condensate at average condensate film temperature
Specific heat, CL = 2.8763 kJ/(kg ■ 0C)
Viscosity, nL = 0.95 cP = 0.95 mPa • s
Thermal conductivity, kL = 0.168 W/(m • 0C)
Density, pL = 810 kg/m3
(e) Physical properties of air-butanol vapour mixture of average composition at 750C
and at the operating pressure:
Specific heat, Cp = 1.3043 kJ/(kg ■ 0C)
Viscosity, p = 0.0174 cP or mPa • s
Thermal conductivity, k = 0.03 W/(m ■ K)
Density, p = 2.012 kg/m3
(f) Physical properties of cooling water
CLw = 4.1868 kJ/(kg • 0C)
p,,, = 0.72 cP
kw = 0.63 W/(m ■ K)
p.,, = 1000 kg/m3
(g) Fouling coefficients hod = hjd = 5000 W/(m2 ■ 0C)
Solution:
Heat duty equation for the given case
0, = ma cpa Al + mv Cpv AT + mnc A = (m(l + mv) Cpav At + mnc A
where, </), = Heat duty, kW

ma = Mass flow rate of air, kg/s
mv = Average mass flow rate of butanol vapour, kg/s
mBc = Condensation rate of butanol, kg/s
Cpa = Specific heat of air, kJ/(kg ■ 0C)
Cpv = Specific heat of butanol vapour, kJ/(kg • 0C)
A = Latent heat of vaporization of butanol, kJ/kg
C^v = Specific heat of Air-butanol vapour mixture, kJ/(kg • 0C)
Density of air at normal condition
pM pM Ts
Pair = = X (5 for standard conditions)
RT T psVs
1x29 273
Pair = X = 1.1853 kg/nr
(273 + 25) 1x22.414
ma = 500 x 1.853 = 592.65 kg/h = 0.1646 kg/s

mv = Average flow rate of butanol vapour
nivi + nix
where, mvi = Mass flow rate of butanol vapour at inlet, kg/s

mv0 = Mass flow rate of Butanol vapour at outlet, kg/s
At inlet, air is saturated with butanol vapour at 100oC temperature and at 49 kPa g
pressure.
Vapour pressure of butanol at 100oC = pv = pv
where pv = partial pressure of butanol vapour at inlet
3137.02
At 100oC In pv = 17.216-
T - 94.43
for T = 100 + 273 = 373 K, pv = 385.617 ton-
Mole fraction of butanol vapour in incoming air-butanol mixture:
Pv = 385.617
Pi Pt
p, = 49 kPa g = 49 + 101.325 = 150.325 kPa a = 1127.53 torr a
385.617
» = = 0.342
1127.53
tlr.
mvl = y,- x x molar mass of butanol (C^gOH)
{ha = molar flow rate of air)
/
' 0.1646
29
= 0.342 x x 74 = 0.2183 kg/s
1-0.342
m
v0 = yo x molar mass of butanol
i-yo
y0 = Mole fraction of butanol vapour in air-butanol vapour mixture at outlet
Pv Pv
P, P,
At the outlet also air is saturated with butanol vapour.
Pv = Pv - vapour pressure of butanol at 50oC temperature

For r= 273 + 50 = 323 K, p', = 32.8336 torr
p,' = Operating pressure of air - Vapour mixture of butanol at outlet = pl - Api
where, Aps = Shell side pressure drop.
Assume shell side pressure drop Aps =13.8 kPa (2 psi)
p,' = 150.325 - 13.8 = 136.525 kPa a = 1024 torr a
32.8336
^ = = 0.032 06
1024
0.16463
29 J
m„„ = 0.032 06 x 74 = 0.0139 kg/s
1 - 0.032 06
0.2183 + 0.0139
m„V = = 0.1161 kg/s
mBC = Condensation rate of butanol = mvi - mvo

= 0.2183 - 0.0139 = 0.2044 kg/s
(p, = (0.1646 + 0.1161) x 1.3043 (100 - 50) + 0.2044 x 642
= 149.53 kW
Heat balance: 100oC
<t>, = rnwCpw At 50 C
149.53 = mw x 4.1868 x (40 - 32)
40oC
mH, = 4.4643 kg/s = 16.07 m3/h 32 C
MTD: A'4=F,xA'4 Eq. (6.11)
ATf,, Fig. 6.19
All - AH,
A "4 = , AH = 100 - 40 = 60oC, AH = 50 - 32 = 180C
N
'AT,
In
AH,
60-18
AH, = —: = 34.880C
F, = LMTD correction factor
% -4 h ~ri
R = and S=
h ~h %-h
100-50 50 40-32 «
R = = — =6.25,5= = — =0.1176
40-32 8 100-32 68
From Fig. 6.11 for 1-4 shell and side tube heat exchanger,
' F, = 0.96
A?,, = 0.96 x 34.880C = 33.4850C
Tube side heat transfer coefficient, /?,•:
N
Tube side flow area, a, = ' x^-d} (6.20)
Np 4
134
x - (0.015 748)2 = 6.525 x K)"3 m2
4 4
ihw 4.4643
Tube side mass velocity, Gr =
a. 6.525x10 -3
= 648.2 kg/(m2 • s)
G, 684.2
Tube side linear velocity ur = — = = 0.6842 m/s
d.G, 0.015 748x684.2

Re =
P \-3
0.72x10"
= 14 965
CPF 4.1868 x (0.72 xl0_3)xl03

Pr =
0.63
Pr = 4.7849
/ nO.14
h: d: P
033
= 0.023 Re^Pr (6.19)
PW
h: = 0.023 x - — x (14 965)0"8 x (4.7849)U0.33

0 63 JJ
x 1
0.015 748
h, = 3374.9 W/(m2 • 0C)
Shell side heat transfer coefficient, h0\
1
=-L+ * 1 (6.44)
K
*0 K*
eg KC h
rl K
-g
Mean condensate film coefficient, hc:
For horizontal position, modified Nusselt's equation is applicable
1/3
Pl(PL-P\')8
hc = 0.95 kL xN. -1/6 (6.37)
Pl*i,
W m
C BC 0.2044
= 1.017 x J O"3 kg/(m - s)
LN, LN, 1.5x134
D T.Q'l
Nr = 2/3N', N' = — = = 15
P, 25.4
N,. = 10
P, +P,
M
pM
Density of vapour, pv =
RT RT
150.325 + 136.525
x 74
273
x
( 273 + 75) 101.325x22.414
pv = 3.666 kg/m3
/ \l/3
810(810-3.666) x 9.81
/? =0.95x0.168 x -1/6
-3 -3
(10)
v 0.95 x 10 x 1.017 xlO
,2 o,
hc = 2042.9 W/(m ■ 0C)
Average gas film coefficient, h^:
{Pt-d0)BsDs
Shell side flow area, A. = (6.29)
25.4-19.05
x 0.12x0.387 = 0.011 61 m2
25.4
Equivalent diameter for triangular pitch arrangement
d = —(P,2 - 0.907J 2) = ———(0.02542 - 0.907 x 0.019 052)

e
d0 0.019 05
= 0.018 247 m
Shell side mass velocity Gs:
ms (0.1646 + 0.1161)
G5 = = 24.18 kg/(m2 • s)
0.01161
deGs 0.018 247x24.18

Reynolds number, Re =
P 0.0174x10 -3
= 25 357
cpP 1.3043x0.0174x 10"3 xlO3

Pr =
k 0.03
= 0.7565
Gas film coefficient can be determined by following correlation.

0.14
d„ _R_
0 55 m
h„ = 0.36 Re Pr (6.35)
Pw /
0.03 1/3 1
hn = 0.36 x x (25 357)a55 x (0.7565)x si
0.018 247 Pw
= 142.59 W/(m2 ■ s)
_1_ = _L + ^_L- I 1
+ X (6.44)
hn h0 <pt hg 2042.9 0, 142.59
where, 0g = (ma + mv) Cp.JV At = (0.1646 + 0.1161) x 1.3043 (100 - 50) = 18.306 kW
0, = 149.53 kW
1 _ 1 18.306 v I
— i X
h.. 2042.9 149.53 142.59
2 0
/i =741.8 W/(m - C)
Overall heat transfer coefficient U.
d
1 1 | 1 | dl) In (d0!dj) | <> 1 | o 1
(6.42)
Uo h0 hod 2km di h, di hid
Thermal conductivity of tube material (SS-304), km = 16 W/(m ■ 0C)
19.05
u.uiy uo x mi
1 1 15.748) 19.05
+ H X
f/„ 741.8 5000 2x16 15.748 3374.9
19.05 1
x
15.748 5000
2 0
U0 = 442.13 W/(m • C)
Heat transfer area required, Aor:
0; 149.53 xlO3
An.. =
442.13x33.485
= 10.1 m2
Heat transfer area provided,
Aopro = N,nd0L = 134 x ^rx 0.019 05 x 1.5 = 12.0293 m2
4 pro
12 0293
Exces heat transfer area = 1 x 100= I - -1 I X 100= 19.1'
4r 10.1
Hence heat transfer area provided by heat exchanger is sufficient for the given duty.
Shell side pressure drop Aps:
/ \ / \ -0.14
'D^ L P.V«T P
Aps = 87, (6.40)
U J 4 7 2 vP.. J
Re = 253 57, Jf = 4.2 x 10" (From Fig. 6.15)

L = 1500 mm, Bs = 120 mm, Ds = 387 mm, de = 18.247 mm
ps = Density of shell side fluid (air - vapour mixture)
pM,
Ps =
RT
» +^
Average mole fraction of butanol vapour, yav =
0.342 + 0.032 06
3'av = 0.187 03
May = yav x molar mass of butonal + (1 -yav) x molar mass of air

Mav = 0.187 03 x 74 + (1 - 0.187 03) x 29 = 37.4163 kg/kmol
150.325 + 136.525
x 37.4163
pMav 273
Ps = x
RT (273 + 75) 101.325x22.414
ps = 1.8537 kg/m3
us = shell side linear velocity
(A 24.18
= 13.04 m/s
Ps 1.8537
387 V1500 "l 1.8537 x 13.04

An =8x4.2 x 10,-2 x xl
18.247 A 120
= 14 039 Pa = 14.04 kPa
Calculated shell side pressure drop (Aps= 14.04 kPa) is very close to optimum pressure
drop (APopl = 13.8 kPa). Hence it is satisfactory.
Tube side pressure drop. A/?,:
/ \
_L P_ P<
Ap, = N 87, + 2.5 (6.27)
d
\ i / , Pw
Np = 4, L= 1500 mm, d, = 15.748 mm, 1000 kg/m3- u, = 0.6842 m/s

for Re = 14 965 from Fig. 6.13 7.= 4.3 x lO"3
1500 1000 x 0.6842-'

Apt=4 8x4.3x10 -3 x 1 + 2.5 x
15.748
Ap, = 5408.4 Pa = 5.408 kPa < Ap, max (68 kPa)
Hence, tube side pressure drop is very much less than maximum or optimum pressure
drop.
Considering % excess heat transfer area, Aps and Ap,, given shell and tube
heat exchanger is suitable for the required heat transfer duty. If the given shell
and tube heat exchanger is at design stage (not fabricated), then number of tube
side passes could be increased from 4 to 8 because of the following reasons:
(i) Cooling water has a tendency to foul. To avoid the excessive fouling it is
better to keep the velocity of cooling water more than 1 m/s, preferably
near 2 m/s.
(ii) Increase in tube side passes will increase the tube side heat transfer
coefficient and overall coefficient. Consequently, it will decrease the required
heat transfer area and hence the fixed cost. However, it will increase the
operating cost for pumping the tube side fluid. Also in the given case, overall
heat transfer coefficient is controlled by shell side heat transfer coefficient
hence increase in number of tube side passes has little effect on the value of
overall heat transfer coefficient.
6.6 MULTICOMPONENT CONDENSATION
In condensation of pure component (Example: condensation of pure ethanol va-

pour), condensation is taking place in isothermal manner or at constant tempera-
ture (degree of freedom =1). While in case of multicomponent condensation,
during the condensation, temperature decreases from dew point to bubble point
temperature, except in the following cases.
(a) Condensation of the vapour mixture of two immiscible components (immis-
cible in liquid phases) Example: Vapour mixture of toluene and water
vapour.
(b) Condensation of the azeotropic vapour mixture.
For example, condensation of vapour mixture containing 89.4% (by mole)
ethanol vapour and 10.6% (by mole) steam at 1 atm pressure.
In condensation of vapour mixture of miscible components (miscible in liquid
phase), condensation starts from dew point temperature and terminates at bubble
point temperature. For the calculations of dew point, bubble point and composi-
tions of vapour phase and liquid phase in between dew point and bubble point,
vapour liquid equilibrium data at operating pressure for the given system is re-
quired.
For finding the vapour-liquid equilibrium data from dew point to bubble point
at operating pressure, there are three options.
(i) Find the VLE data by conducting the actual experiment. Particularly if the
operating pressure is atmospheric or vacuum, then determination of VLE
data via actual experiment is easier.
(ii) Find the VLE data from literature.
(iii) Find the VLE data by theoretical equation.
T/ = Kfr (6.45)
where, yi = Mole fraction of component i in vapour phase.
Xj = Mole fraction of component i in liquid phase
Ki = Equilibrium constant for component i,
Kj is a function of operating pressure, temperature as well as of composition.
For an ideal solution (i.e. the solution following Raoult's law), = f{T, p)
P,
(6.46)

Detail Design

Uploaded by

Copyright:

Available Formats

Detail Design

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Detail Design

Uploaded by

Copyright:

Available Formats

Chapter

6.1 SHELL AND TUBE HEAT EXCHANGER

@0(2)0© 0000 © (36)

Outside-Packed Floating Head Heat Exchanger, Type AEP

U Tube Heat Exchanger, Type CFU

Kettle Type Floating Head Reboiler, Type AKT

6.2 DESIGN OF HEAT EXCHANGERS

6. 2.1 Various Parts of Shell and Tube Heat Exchangers

Table 6.1 Tube Sheet Tube Hole Count2 3

Table 6.1 (a) % in OD tubes on in square pitch

Shell ID TEMA Por S TEMA U

438 17 X 320 308 274 260 330 312 292

Tube Sheet Tube Hole Count (Conrd.)

Shell ID TEMA PorS TEMA U

686 27 843 812 742 716 856 816 780

940 37 1647 1604 1520 1480 1684 1620 1568

1372 54 3656 3600 3462 3404 3712 3624 3556

Table 6.1 (b) / in OD tubes on %-in triangular pitch

Shell ID TEMA L or M TEMA P or S TEMA U

Tube Sheet Tube Hole Count (Conrd.)

Shell ID TEMA L or M TEMAP or S TEMAU

2134 84 7005 6934 6766 6680

Table 6.1 (c) % in OD tubes on I in square pitch

Shell ID TEMA P or S TEMA U

438 17 X 181 174 154 160 176 176 160

686 27 477 456 432 424 480 468 460

Tube Sheet Tube Hole Count (Conrd.)

Shell ID TEMA PorS TEMA U

940 37 937 918 882 872 952 932 918

1372 54 2096 2048 2010 1992 2108 2084 2068

Table 6.1 (d) in OD tubes on I in triangular pitch

Shell ID TEMA L or M TEMA P or S TEMA U

Tube Sheet Tube Hole Count (Contd.)

Shell ID TEMA L or M TEMA P or S TEMA U

2134 84 6162 6108 5954 5900

Table 6.1 (e) 1 in OD tubes on 1 / in square pitch

Shell ID TEMA PorS TEMA U

438 17 X 108 108 104 96 104 100 100

686 27 296 280 270 260 290 284 274

940 37 588 572 562 548 584 576 566

1143 45 900 882 862 844 902 880 862

1372 54 1310 1296 1268 1256 1320 1296 1284

Tube Sheet Tube Hole Count (Contd.)

Table 6.1 (f) I in OD tubes on I / in triangular pitch

Shell ID TEMA L or M TEMA P or S TEMA U

2134 84 3920 3882 3784 3736

Shell ID TEMA P or S TEMA U

Tube Sheet Tube Hole Count (Conrd.)

Shell ID TEMA PorS TEMA U

686 27 184 180 158 172 176 172 160

940 37 372 368 354 340 358 352 350

1372 54 837 820 812 804 824 808 808

Table 6.1 (h) I j/^ in OD tubes on I ^ in triangular pitch

Shell ID TEMA L or M TEMA P or S TEMA U

Tube Sheet Tube Hole Count (Conrd.)

Shell ID TEMA L or M TEMA P or S TEMAU

2134 84 2507 2470 2392 2372

(c) Use of approximate equations: Approximate equations are available in

where, Db = Tube bundle diameter, mm

Table 6.2 Constants for Eq. (6.1)