STHE Design

Design of Shell and
Tube Heat Exchanger

Shell and Tube Heat Exchanger
➢ Large heat transfer surface area can be
accumulated within small volume compare
that double pipe heat exchanger
➢ It not only transfer sensible heat but also
transfer latent heat –can be used as
condenser or boiler
➢ More than 85% oil-refining, chemical, power
industry uses Shell and tube heat exchanger
➢ It can be design any duties with wide range

of temperature and pressure
➢ It can be build by many materials
➢ Many supplier
➢ Design methods and mechanical codes have
been established from many year of
experience
https://savree.com/en/encyclopedia/shell-and-tube-type-heat-exchanger
Shell side – 300 bars (4500 psi)
Maximum Pressure:
Tube side – 1400 bars (20000 psi)
Operating Temperature range: -100 oC to 600 oC
Size of heat exchanger area: 10- 1000 m2
❖ Double Pipe HE: max 50 m2

Classification of Shell and Tube Heat Exchanger
➢ Fixed Tube Fixed Tube
➢ U-Tube
➢ Internal Floating
➢ External Floating
➢ U-Tube
https://doi.org/10.1016/B978-0-12-822047-4.00011-X
Internal Floating
✓ More versatile than fixed head and U-tube exchangers

✓ Suitable for high-temperature differentials
✓ Easier to clean and can be used for fouling liquids
❑ Clearance between the outermost tubes in the bundle and shell is made greater
➢ External Floating
o Floating-head joint is located outside the shell sealed with a sliding gland joint
o Danger of leaks through gland, shell side pressure limited to 20 bar
o Flammable, toxic materials can not be used on the shell side.
Tubes
➢ Round tubes in various shapes are used in shell and tube exchangers.
➢ Most common are the tube bundles with straight and U-tubes
➢ However, sine-wave bend, J-shape, L-shape or hockey sticks etc
➢ For nuclear exchanger, double wall tube are used
Tube Dimension:
Diameter: 16 mm – 50 mm (most preferred: 16 – 25 mm)

Length: 6 ft, 8 ft, 12 ft, 16 ft, 20 ft, 24 ft. ( Optimum: length to shell diameter is 5 -10)
o Tube length is decided on the basis of heat transfer area required.

o The shell diameter will decrease with increase in the tube length so decrease in
exchanger cost, so optimum length should be taken for the tube.
U-tubes: tubes on the outside of the bundle will be longer than those of the inside. Average
length needs to be estimated for the use of thermal design.
U-tube will be bent from standard tube length and cut to size.
❖ As a guide, ¾ inch (19.05 mm) is a good trial tube diameter to start the design calculation
Pitch Square Pitch
➢ Triangular Pitch ➢ Create lower turbulence

➢ Low heat transfer coefficient
➢ Square pitch
➢ Lower pressure drop
➢ Rotated square pitch ➢ Easy to clean
Triangular Pitch Rotated Square Pitch
❑ Same turbulence as triangular pitch

❑ High heat transfer coefficient
❑ High pressure drop
❑ Difficult to clean but not as difficult
as triangular pitch
o Higher heat transfer coefficient
because it create turbulence in Most commonly used tube layouts are either triangular
the shell side fluids
o Difficult to cleaning or square, with a pitch of 1.0 in (for ¾ in tube) or 1.25 in
(for 1.0 in tube)
Tube Passes
o Tube passes used to increase the length of the liquid flow as well as residence time in
the tubes.
o It is done by using pass partition plates.
o The fluid in the tube is usually directed to flow back and forth in a number of passes
through groups of tube arrangement in parallel
o The exchanger are made of one to sixteen passes (even number except single pass).
o The number of passes is selected to give the required tube-side design velocity
Tube Passes
1-2 Passes
Single Pass (1-1)
2-4 Passes
3-6 Passes
Shell
o The shell is a container for the shell fluid.
o Usually it is cylindrical in shape with a circular cross section
o For specific application like nuclear heat exchanger have a different shape depending
upon tube bundle shape.
Shell Diameter:
➢ ( 6 inch – 42 inch (150 mm – 1067 mm) - British Standard)
➢ ( 6 inch – 60 inch ( 150 mm – 1520 mm) – TEMA standard
o Up to 24 inch (610 mm) shells are normally constructed from

standard pipe
o Above 24 inch they are rolled from plate
Shell Diameter
Shell diameter must be selected to give as close a fit to the tube bundle to reduce by
passing around the outside of the bundle
Shell diameter = tube bundle diameter (Db) + Clearance
Clearance will depend upon type of exchanger
Bundle Diameter:
It depend not only the number of tubes but also the number of tube passes (space must
be left for the partition plate.
Shell diameter = tube
bundle diameter (Db) + Internal Head)
Clearance
Clearance
External Head)
Baffles
Tube bundle is the most important part of a tubular heat exchanger
Tube sheets, baffles or support plates, tie rods and spacers complete the bundle
Baffles:
o Baffles are used in the shell to direct the fluid stream across the tubes to
increase the fluid velocity
o It also increase the heat transfer rate
o Single segmental baffle are commonly used.
Baffles
Baffles
Baffle Cuts:
o It is the ratio of segment opening height to shell inside
diameter
o Baffle cut is the height of the segment remove from the baffle
o Baffle cuts from 15 to 45 % are used
o Optimized baffle cut of 20 – 25 %.
There will be some leakage of fluid round the baffle as a clearance must be allowed
for assembly
Baffles
Baffle Spacing
o Baffle spacing used range from 0.2 to 1.0 times the shell diameter
o A close spacing will give higher heat transfer coefficient but expanse higher pressure drop
o Optimum spacing will 0.3 to 0.5 times the shell diameter
Tube Sheet
➢ Tube sheet hold the tube and forms a barrier between the shell and tube fluids
➢ Tube sheets should not be less than 25 mm or equal to tube outside diameter
➢ Thickness of the tube will reduce the effective length of the tube slightly and
should be allowed for calculating area available for heat transfer
Problem statement:
Design a shell and tube heat exchanger (stripped heavy naptha trim cooler) to cool the
heavy naptha stream of 3 + 0.06 (G-20) kg/s at 85 + 0.5 (G -20) oC to 55 oC using water at
27 oC as the coolant.
(G = group number)
Process Requirements:
1. Design tolerance < 5 %
2. Tube side pressure drop < 10 psi
3. Overdesign area tolerance < 10 %
Shell and Tube Heat Exchanger Design
by Kern’s Method
Steps:
Define duty using energy balance to compute Estimate tube side heat transfer coefficient
unspecified flow rates or temperature
Decide baffle spacing

Fluid allocation
Estimate shell side heat transfer coefficient

Calorific Temperature determination using r, Kc,
Fc from graph
Calculate overall heat transfer coefficient
including fouling factor, U o,cal
Collect physical properties at calorific temp
No
𝑼𝒐 𝒄𝒂𝒍 𝑼𝒐 𝒂𝒔𝒔
Determine LMTD and LMTD correction factor (FT) 𝑼𝒐, 𝒂𝒔𝒔 = 𝑼𝒐, 𝒄𝒂𝒍 0< , − , < 20%
𝑼𝒐 𝒂𝒔𝒔
,
yes
Assuming Uo, ass
Estimate tube and shell pressure drops
Determine heat transfer area

No Pressure drop within
specification?
Decide type, tube size, materials layout
yes
Calculate number of tubes, shell diameter Accept design

STHE Design

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Design of Shell and

Tube Heat Exchanger

➢ It can be design any duties with wide range

Operating Temperature range: -100 oC to 600 oC

Size of heat exchanger area: 10- 1000 m2

❖ Double Pipe HE: max 50 m2

✓ More versatile than fixed head and U-tube exchangers

Diameter: 16 mm – 50 mm (most preferred: 16 – 25 mm)

o Tube length is decided on the basis of heat transfer area required.

➢ Triangular Pitch ➢ Create lower turbulence

Triangular Pitch Rotated Square Pitch

❑ Same turbulence as triangular pitch

o Up to 24 inch (610 mm) shells are normally constructed from

Decide baffle spacing

Estimate shell side heat transfer coefficient

Determine heat transfer area

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