OPTIMIZATION OF PROCESS PARAMETER FOR THE CONSTRUCTION OF

SHELL AND TUBE HEAT EXCHANGER

ABSTRACT
Engineers are continually being asked to improve processes and increase efficiency. These
requests may arise as a result of the need to increase process throughput, increase profitability, or
accommodate capital limitations. Processes which use heat transfer equipment must frequently be
improved for these reasons. This Project provides some methods for increasing shell-and-tube exchanger
performance. The methods consider whether the exchanger is performing correctly to begin with, excess
pressure drop capacity in existing exchangers, the re-evaluation of fouling factors and their effect on
exchanger calculations, and the use of augmented surfaces and enhanced heat transfer.
A simplified model for the study of thermal analysis of shell-and- tubes heat exchangers of water
and water type is proposed Shell and Tube heat exchangers are having special importance in boilers, oil
coolers, condensers, pre-heaters. They are also widely used in process applications as well as the
refrigeration and air conditioning industry. The robustness and medium weighted shape of Shell and
Tube heat exchangers make them well suited for high pressure operations. In this Project we have shown
how to do the thermal analysis by using theoretical formulae for this we have chosen a practical problem
of parallel flow shell and tube heat exchanger of water and water type, by using the data that come from
theoretical formulae we have design a model of shell and tube heat exchanger and do the thermal
analysis and increasing efficiency by using CHEMICAL CAD software and comparing the result that
obtained from Experimental formulae.







INTRODUCTION
A heat exchanger is a device in which energy is transferred from one fluid to another across a
solid surface. Exchanger analysis and design therefore involve both convection and conduction. Two
important problems in heat exchanger analysis are
(1) Rating existing heat exchangers
- Rating involves determination of the rate of heat transfer, the change in temperature of
the two fluids and the pressure drop across the heat exchanger
(2) Sizing heat exchangers for a particular application.
- Sizing involves selection of a specific heat exchanger from those currently available or
determining the dimensions for the design of a new heat exchanger, given the required
rate of heat transfer and allowable pressure drop.
The LMTD method can be readily used when the inlet and outlet temperatures of both the hot
and cold fluids are known when the outlet temperatures are not known, the LMTD can only be used in
an iterative scheme. In this case the effectiveness-NTU method can be used to simplify the analysis.
The choice of heat exchanger type directly affects the process performance and also influences
plant size, plant layout, length of pipe runs and the strength and size of supporting structures. The most
commonly used type of heat exchanger is the shell-and- tube heat exchanger, the optimal design of
which is the main objective of this study.
Computer software marketed by companies such as HTRI and HTFS are used extensively in the
thermal design and rating of HEs. These packages incorporate various design options for the heat
exchangers including the variations in the tube diameter, tube pitch, shell type, number of tube passes,
baffle spacing, baffle cut, etc.
A primary objective in the Heat Exchanger Design (HED) is the estimation of the minimum heat
transfer area required for a given heat duty, as it governs the overall cost of the HE. But there is no
concrete objective function that can be expressed explicitly as a function of the design variables and in
fact many numbers of discrete combinations of the design variables are possible as is elaborated below.
The tube diameter, tube length, shell types etc. are all standardized and are available only in certain sizes
and geometry. And so the design of a shell-and-tube heat exchanger usually involves a trial and error
procedure where for a certain combination of the design variables the heat transfer area is calculated and
then another combination is tried to check if there is any possibility of reducing the heat transfer area.
Since several discrete combinations of the design configurations are possible, the designer needs an
efficient strategy to quickly locate the design configuration having the minimum heat exchanger cost.
Thus the optimal design of heat exchanger can be posed as a large scale, discrete, combinatorial
optimization problem.
Shell-and-tube heat exchangers are used extensively in engineering applications like power
generations, refrigeration and air-conditioning, petrochemical industries etc. These heat exchangers can
be designed for almost any capacity. The main purpose in the heat exchanger design is given task for
heat transfer measurement to govern the overall cost of the heat exchanger.
The heat exchanger was introduced in the early 1900s to execute the needs in power plants for
large heat exchanger surfaces as condensers and feed water heaters capable of operating under relatively
high pressures. Both of these original applications of shell-and-tube heat exchangers continued to be
used; but the design have become highly sophisticated and specialized, subject to various specific codes
and practices. The broad industrial use of shell-and-tube heat exchangers known today also started in the
1900s to accommodate the demands of emerging oil industry.
The steadily increasing use of shell-and-tube heat exchangers and greater demands on accuracy
of performance prediction for a growing variety of process conditions resulted in the explosion of
research activities. These included not only shell side flow but also, equally important, calculations of
true mean temperature difference and strength calculations of construction elements, in particular tube
sheets.









OBJECTIVE

The objective of the thesis is to optimization of process parameter for the construction of
shell and tube heat exchanger.
Increasing heat exchanger performance usually means transferring more duty or operating the
exchanger at a closer temperature approach. This can be accomplished without a dramatic increase in
surface area. This constraint directly translates to increasing the overall heat transfer coefficient, U.
The overall heat transfer coefficient is related to the surface area, A, duty, Q, and driving force, T.
This equation is found in nearly all heat exchanger design references.


Q = UA T


As stated in this form, U can be calculated from thermodynamic considerations alone. This
calculation results in the required U such that the heat is transferred at the stated driving force and area.
Independent of this required U based on thermodynamics, an available U can be determined from
transport considerations. For this calculation, U is a function of the heat transfer film coefficients, h, the
metal thermal conductivity, k, and any fouling considerations, f. An exchanger usually operates
correctly if the value of U available exceeds the U required.








TYPES OF HEAT EXCHANGER

SHELL AND TUBE HEAT EXCHANGER
In this type of heat exchanger one of the fluids flow through a bundle of tubes enclosed by a
shell. The outer fluid is forced through a shell and it flows over the outside surface of the tubes such an
arrangement is employed where reliability and heat transfer effectiveness. It is the most common type of
heat exchanger in oil refineries and other large chemical Processes, and is suited for higher-pressure
applications. This type of heat exchanger consists of a shell (a large pressure vessel) with a bundle of
tubes inside it. One fluid runs through the shell to transfer heat between the two fluids.
By far the most common type of heat exchangers to be encountered in the thermal applications is
shell-and-tube heat exchangers. These are available in a variety of configurations with numerous
construction features and with differing materials for specific applications. This chapter explains the
basics of exchanger thermal design, covering such topics as: shell-and-tube heat exchanger components;
classification of shell-and-tube heat exchangers according to constructions.
Constructional Details of Shell and Tube Heat Exchanger
It is essential for the designer to have a good knowledge of the mechanical features of shell-and-
tube heat exchangers and how they influence thermal design. The principal components of shell-and-
tube heat exchangers are:
- Shell
- Shell cover
- Tubes
- Channel
- Channel cover
- Tube sheet
- Baffles
- Nozzles


Other components include tie-rods and spacers pass partition plates, impingement Plate, longitudinal
baffles, sealing strips, supports, and foundation. The Tubular Exchanger Manufacturer is Association,
TEMA, has introduced a standardized nomenclature for shell-and-tube heat exchangers. A three-letter
code has been used to designate the overall configurations. The three important elements of any shell-
and-tube heat exchangers are front head, the shell and rear head design respectively.
The Standards of Tubular Exchanger Manufacturers Association (TEMA) describes the various
components of various class of shell-and-tube heat exchanger in detail.

(Figure 1.Fixed Tube Sheet Shell and Tube Heat Exchanger)
Use of multiple tubes because of that is increasing the heat transfer area. Reason of increasing
heat transfer area is increase the velocity of fluid and lower effective T.
There is different type of shell available, all shell are identified regarding the diameter .Basically
sizes of the shell are 8, 10, 12 inches. We find 2 inches of increment every step start from 13 inches to
25.From 25 to 39 we find 2 inches increment and after 39 to 72 we find 3 inches increment in shell.
Tube size, which type of materials and array are primary criteria of designing of tube and shell
type of mat exchanger. After done this step hydraulic design will be done on automatically. Small tube
gives less cost with good thermal conductivity and Use of multiple tubes because of that is increasing
the heat transfer area. Reason of increasing heat transfer area is increase the velocity of fluid and lower
effective T. It will create less shell area and size. Normally two arrays are available, triangular array
produces the more tube with lower cost for particular heat transfer unit. We can control the pressure
difference in square type of array so it is more preferable rather than the triangular type of array. When
the cleaning require because of mechanical work, on that time square type of array are preferable. Wide
pitch is used in this type of array and 60
o
and 90
o
arrays have a tendency to create a channeled flow.
So that ways fluids have a tendency to pass between two rows of tube so there is not need to
complete the full round of flow. This is happen in each tube so it is big gain for evaporators and
condensers for vapor distributions. With the close type of temperature, difference and tube side of
pressure difference generally start to design the heat exchanger with two or more tube passes. The way
is to established lot of heat exchanger with normal way. Front and rear end the pass particles are
installed in the tube side. For the multi-pass tube arrangement the stress are developed at high joint.
With the pressure and temperature difference, high tensile and compressive load located the tube side.
TUBES
Heat exchangers with shell diameters of 10 inches to more than 100 are typically manufactured
to industry standards. Commonly, 0.625 to 1.5" tubing used in exchangers is made from low carbon
steel, Admiralty, copper, copper-nickel, stainless steel, Hastelloy, Inconel, or titanium.
Tubes can be drawn and thus seamless, or welded. High quality electro resistance welded tubes
display good grain structure at the weld joints. Extruded tubes with fins and interior rifling are
sometimes specified for certain heat transfer applications. Often, surface enhancements are added to
increase the available surface or aid in fluid turbulence, thereby increasing the operative heat transfer
rate. Finned tubes are recommended when the shell-side fluid have a considerably lower heat transfer
coefficient than the tube-side fluid. Note, the diameter of the finned tube is slightly smaller than the un-
finned areas thus allowing the tubes to be installed easily through the baffles and tube supports during
assembly while minimizing fluid bypass.
A U-tube design finds itself in applications when the thermal difference between the fluid flows
would otherwise result in excessive thermal expansion of the tubes. Typical U-tube bundles contain less
tube surface area as traditional straight tube bundles due to the bended end radius, on the curved ends
and thus cannot be cleaned easily. Furthermore, the interior tubes on a U-tube design are difficult to
replace and often requiring the removal of additional tubes on the outer layer; typical solutions to this
are to simply plug the failed tubes.




TUBE SHEETS
Tube sheets usually constructed from a round, flattened sheet of metal. Holes for the tube ends
are teen drilled for the tube ends in a pattern relative to each other. Tube sheets are typically
manufactured from the same material as tubes, and attached with a pneumatic or hydraulic pressure
roller to the tube sheet. At this point, tube holes can both be drilled and reamed, or they are machined
grooves (this significantly increases tube joint strength) (figure A).

(Figure 2. Machined grooves in the tube will increase joint strength)
The tube sheet comes in contact with both fluids in the exchanger, therefore it must be
constructed of corrosion resistant materials or allowances appropriate for the fluids and velocities. A
layer of alloy metal bonded to the surface of a low carbon steel tube sheet would provide an effective
corrosion resistance without the expense of manufacturing from a solid alloy.
The tube-hole pattern, often called pitch, varies the distance between tubes as well as the angle
relative to each other allowing the pressure drop and fluid velocities to be manipulated in order to
provide max turbulence and tube surface contact for effective heat transfer.
Tube and tube sheet materials are joined with weld-able metals, and often further strengthened
by applying strength or seal weld to the joint. Typically in a strength weld, a tube is recessed slightly
inside the tube hole or slightly beyond the tube sheet whereas the weld adds metal to the resulting edge.
Seal welds are specified when intermixing of tube liquids is needed, this is accomplished whereas the
tube is level with the tube sheet surface. The weld fuses the two materials together, adding no metal in
the process. When it becomes critical to avoid the intermixing of fluid, a second tube sheet is designed
in. In this case, the outer tube sheet becomes the outside the shell path, and the inner tube sheet is vented
to atmosphere, so that a fluid leak can be detected easily effectively eliminating any chance of cross
contamination.
SHELL ASSEMBLY
The shell is constructed either from pipe or rolled plate metal. For economic reasons, steel is the
most commonly used material, and when applications involving extreme temperatures and corrosion
resistance, others metals or alloys are specified. Using off-the-shelf pope reduces manufacturing costs
and lead time to deliver to the end customer. A consistent inner shell diameter or roundness is need to
minimize the baffle spacing on the outside edge, excessive space reduces performance as the fluid tends
to channel and bypasses the core. Roundness is increased typically by using a mandrel and expanding
the shell around it, or by double rolling the shell after welding the longitudinal seam. In some cases,
although extreme, the shell is cast and then bored out until the correct inner diameter is achieved.
When fluid velocity at the nozzle is high, an impingement plate is specified to distribute fluid
evenly in the tubes, thereby preventing fluid-induced erosion, vibration and cavitations. Impingement
plates effectively eliminate the need to configure a full tube bundle, which would otherwise provide less
available surface. An impingement plate can also be installed above the shell thereby allowing a full
tube count and therefore maximizing shell space (figure 3).


(Figure 3. Impingement plate distributing the fluid to the tubes preventing fluid-induced erosion,
vibration and cavitations)

BAFFLES
Baffles function in two ways, during assembly they function as tube guides, in operation they
prevent vibration from flow induced eddies, last but most importantly they direct shell-side fluids across
the bundle increasing velocity and turbulence effectively increasing the rate of heat transfer.
All baffles must have diameter slightly smaller than the shell in order to fit, however tolerances
must be tight enough to avoid a performance loss as a result of fluid bypass around the baffles. This is
where the concept of shell roundness is of up most importance in sealing off the otherwise would be
bypass around the baffle.
Baffles are usually stamped / punched, or machined drilled; such configurations vary based on
size and application. Material selection must be compatible with the shell side fluid to avoid failure as a
result of corrosion. It is not uncommon for some punched baffle designs to include a lip around the tube
hole to provide more surfaces against the tube to reduce wear on the adjoining parts. Tube holes must be
precisely manufactured to allow easy assembly and possible field tube replacement, all the while
minimizing fluid flow through the hole and against the tube wall.

(Figure 4. Heads contain pass ribs that direct flow on the tube-side fluid for one or more passes
across the tube bundle)

In typical liquid applications, baffles occupy between 20-30% of the shell diameter; whereas in a
gas application with a necessary lower pressure drop, baffles with 40-45% of shell diameter are used
(figure 4). Baffle placement requires an overlap at one or more tubes in a row to provide adequate tube
support. Additionally baffles are spaced evenly throughout the shell to aid in reducing pressure drop and
even fluid velocity.
In a 'single-segmental configuration, baffles move fluid or gas across the full tube count. When
high velocity gases are present, this configuration would result in excessive pressure loss thus calling
fourth a double-segmental layout. In a double-segmental arrangement, structural effectiveness is
retained, yet allowing gas to flow in a straighter overall direction. While this configuration takes full
advantage of the full available tube surface, a reduction in heat transfer performance should be expected.















EQUIPMENT SPECIFICATIONS

The following is a list of all pieces of equipment and their specifications for the shell-and-tube heat
exchanger.

1) Shell-and-Tube Heat Exchanger
- Shell
Material : Stainless Steel
Length : 1.0 meter
Inside Diameter : 8.0 in
Outside Diameter : 6.60 in
Incoming pipe diameter : 3/4 in, Schedule 40 stainless steel
Outlet pipe diameter : 1 1/4 in, Schedule 40 stainless steel
- Tubes
Number of Tubes : 26
Number of Passes : 1-2, straight configuration
Material : Stainless Steel
Length : 0.6 meter
Inside Diameter : 5/8 in
Outside Diameter : 3/4 in
Pitch : 1 in, Square pitch
Incoming pipe diameter : 1 1/4 in, Schedule 40 stainless steel
Outlet pipe diameter : 1 1/4 in, Schedule 40 stainless steel

- Baffling

Number of Baffles : 2
Baffle spacing : 30 5/8 in from tube side
50 3/4 in from tube side
- Holding Tank
2) Pump

Manufactured by : Worthington Pump Incorporated
Mode l : Worthington D520
Size : 1.2X1X5
Impeller Diameter : 5.25 in
Operating Pressure : 21 psi
Incoming pipe diameter : 1 1/2 in, Schedule 40 stainless steel
Outlet pipe diameter : 1 1/4 in, Schedule 40 stainless steel
3) Valves
- Gate Valves
Manufactured by : Stockham
- Ball Valves
Manufactured by : Watts Regulator
- Computer Controlled Valves
Manufactured by : Honeywell
Model : Modulating Valve Actuator ML7984
Operating Temperature : 0 to 55C

Tube Valve Discharge Coefficient : 29.3
Shell Valve Discharge
Coefficient : 11.7
P (for shell-and-tube) : 5.0
I (for shell-and-tube) : 2.0
D (for shell-and-tube) : 0.000

4) Flow meters
Manufactured by : Brooks Instruments
Model : MT 3810
Accuracy : 5% full scale from 100% to 10% of
scale reading
Repeatability : 0.25% full scale
Operating Temperature : -29 to 215C
Flow Range : 3.52 to 35.2 gpm for shell side flow meter
8.80 to 88.0 gpm for tube side flow meter
5) Thermocouples
Manufactured by : Omega
Model : Type T
Range : -60 to 100C
Accuracy :1.0C or 0.75% above 0C (whichever is greater)
1.0C or 1.5% below 0C (whichever is greater)


6) Low Pressure Steam
Pressure : 15 psi
Temperature : 100C

7) Computer
Manufactured by : Dell Systems
Operating System : Windows NT
Software : Opto-22 electronics and computer based
software, Version R3.16. Copyright 1996-
2000 Opto-22.













Design Methods of Shell and Tube Heat Exchangers
In terms of energy flow for heat exchanger, we can use this equation First step in designing of heat
exchanger, there is two way to design heat exchanger.
1. LMTD
2. NTU Method.
General equation of heat exchanger is
LM T
T F UA Q A =
0

Where T is the Temperature difference between hot and cold fluid
In terms of energy flow for heat exchanger, we can use this equation for hot fluid,
h p
T C M Q A =
.

Where T is the Temperature difference between hot fluids
for cold fluid,

c p
T C M Q A =
.

Where T is the Temperature difference between hot fluids

Log Mean Temperature Difference Method
Heat flows between the hot and cold streams due to the temperature difference across the tube acting as
a driving force. The difference will vary with axial location. Average temperature or effective
temperature difference for either parallel or counter flow may be written as:


|
|
.
|

\
|
A
A
A A
= = A
2
1
2 1
ln
T
T
T T
LMTD T
LM


Effectiveness-NTU Method
In the thermal analysis of shell-and-tube heat exchangers by the LMTD method, an equation
(3.1) has been used. This equation is simple and can be used when all the terminal temperatures are
known. The difficulty arises if the temperatures of the fluids leaving the exchanger are not known. In
such cases, it is preferably to utilize an altogether different method known as the effectiveness-NTU
method. Effectiveness of shell-and-tube heat exchanger is defined as:
( )
( )
( )
( )
Ti Si
Ti To T
Ti Si
So Si S
T T C
T T C
T T C
T T C

=
min min
c
The group
min
C
UA
is called number of transfer units, NTU.
Effectiveness for shell-and-tube heat exchanger can also be expressed as:
|
|
.
|

\
|
=
max
min
min
,
C
C
C
UA
c c
Where
S
T
T
S
C
C
or
C
C
C
C
=
max
min
(depending upon their relative magnitudes).
Kays and London have given expressions for shell-and-tube heat exchangers. Some of their
relationships for effectiveness are given below:
For one shell pass, 2, 4, 6 tube passes

|
.
|

\
|
+ +
(

|
.
|

\
|
+ + +
+ + + =
2
min
2
min
2
min min 1
1 1 exp 1
1 1 exp 1
1 1 2
C NTU
C NTU
C C c

For two shell pass, any multiple of 4 tubes

1
min
2
1
min 1
2
1
min 1
2
1
1
1
1
1

(
(

|
|
.
|

\
|

(
(

|
|
.
|

\
|

= C
C C
c
c
c
c
c

It is essential that the designer of shell-and-tube heat exchangers becomes familiar with the
principles of the various correlations and methods in numerous publications, their advantages and
disadvantages, limitations and degrees of sophistication versus probable accuracy and other related
aspects. All the published methods can be logically divided into several groups:
1. The early developments based on flow over ideal tube banks or even single tubes.
2. The integral approach, which recognizes baffled cross flow modified by the presence of
window, but treats the problem on an overall basis without considerations of the modified effects
of leakage and bypass.
3. The analytical approach based on Tinkers multistream model and his simplified method.
4. The stream analysis method, which utilizes a rigorous reiterative approach based on Tinkers
model.
5. The Delaware method, which uses the principles of the Tinkers model but interprets them on an
overall basis, that is, without reiterations.
6. Numerical prediction methods.











LITERATURE REVIEW
Detailed design of shell-and-tube heat exchanger generally proceeds through the testing of a range of
potential exchanger geometries in order to find those that satisfy three major design objectives:
1. Transfer of required heat duty
2. Specified cold side pressure drop
3. Specified hot side pressure drop
The allowable pressure drops determine the operating cost of heat exchanger in the process; they also
determine the capital requirement of the installed heat exchanger surface area.
Different authors have long recognized the importance of considering pressure drops during heat
exchanger analysis.
MCADAMS [1] was one of the earliest workers to quantitatively demonstrate this. Analysis was simple
and based on tubular heat exchanger. By taking into account the cost of power and fixed cost of the
exchanger, per unit heat transferred, simple expressions for estimating the optimum mass velocities for
both inside tubes and outside tube fluids are developed. However, his equations are deriving on the basis
that each side of the exchanger can be treating independently of the other. It is assume that the streams
do not interact and the effect of opposing resistance is neglecting. This is an erroneous assumption.
JENSSEN [2] in an attempt to provide a quickly and general method for estimating the economic
power consumption in plate exchangers introduced the so-called J parameter (i.e. the specific pressure
drop per heat transfer unit parameter). He produced graphs showing economic optimum based on the
assumption that the streams on the either side the exchanger have the same flow rates and the same
physical properties. The use of such graphs in design only requires the knowledge of the ratio of the
capital cost influence to the power cost influence. The capital cost influence is given as the annual
investment increment for added unit heating surface area. The power cost influence is the annual unit
power cost. One major weakness in this work that has perhaps limited its practical application is the
assumption that the streams have identical fluid properties and identical geometries. These are highly
limiting assumptions. While the method may apply under restricted conditions to plate exchangers, its
extension to shell-and-tube heat exchangers appears too far from straightforward.

KEVIN M. LUNSFORD [3], Bryan Research & Engineering, his analyzing some methods for
increasing shell-and-tube exchanger performance. The methods consider whether the exchanger is
performing correctly to begin with, excess pressure drop capacity in existing exchangers, the re-
evaluation of fouling factors and their effect on exchanger calculations, and the use of augmented
surfaces and enhanced heat transfer. Three examples are provided to show how commercial process
simulation programs and shell-and-tube exchanger rating programs may be used to evaluate these
exchanger performance issues. The last example shows how novel heat transfer enhancement can be
evaluated using basic shell-and-tube exchanger rating calculations along with vendor supplied
enhancement factors.
V.HARI HARAN, G.RAVINDRA REDDY AND B.SREEHARI [4] (ISSN: 2231-2803)
In this paper, a simplified model for the study of thermal analysis of shell-and tubes heat exchangers of
water and oil type is proposed. Shell and Tube heat exchangers are having special importance in boilers,
oil coolers, condensers, pre-heaters. They are also widely used in process applications as well as the
refrigeration and air conditioning industry. The robustness and medium weighted shape of Shell and
Tube heat exchangers make them well suited for high pressure operations. In this paper we have shown
how to done the thermal analysis by using theoretical formulae for this we have chosen a practical
problem of counter flow shell and tube heat exchanger of water and oil type, by using the data that come
from theoretical formulae we have design a model of shell and tube heat exchanger using Pro-e and
done the thermal analysis by using ANSYS software and comparing the result that obtained from
ANSYS software and theoretical formulae. For simplification of theoretical calculations we have also
done a C code which is useful for calculating the thermal analysis of a counter flow of water-oil type
shell and tube heat exchanger.
NENAD RADOJKOVI, GRADIMIR ILI, ARKO STEVANOVI [5]
Experimental investigations were done to identify influence of thermal and flow quantities and shell side
geometry on STHE's heat exchange intensity. In this paper special attention was paid to segmental baffle
cut influence on apparatus efficiency.




METHODOLOGY














































DESIGN OPTIMIZE
ESTABLISHMENT
ANALYSE
BACKGROUND
STUDY
Y
E
S

INCREASING
PERFORMANCE NO
A plan for increasing heat exchanger performance for shell and tube exchangers should consider
the following steps.




Determine that the exchanger is operating
correctly as designed. Correcting flaws in
construction and piping that may have a
detrimental effect on heat transfer and
pressure drop may be the solution
Estimate how much pressure drop is available.
For single phase heat transfer coefficients,
higher fluid velocity increases heat transfer
coefficients and pressure drop.
Estimate fouling factors that are not overstated.
Excessive fouling factors at the design state
result in oversized exchangers with low
velocities. These low velocities may exacerbate
the fouling problem. More liberal fouling
factors and periodic cleaning may increase the
heat exchangers performance.
Consider using a basic shell-and-tube exchanger
with enhancement or intensification such as
finning, tube inserts, modified tubes, or
modified baffles
One simple and obvious solution for increasing shell-and-tube heat exchanger performance
might be to switch the shell-and-tube fluids. The placement of the process fluids on the tube or shell
side is usually not dependent on the most efficient heat transfer area. A primary concern is pressure.
High-pressure fluids tend to be placed in the tubes rather than the shell, resulting in less construction
material and a less expensive exchanger. Handling phase changes may dictate where fluids are placed.
Switching the tube-and-shell side process streams may only be valid if the process streams have no
phase change and are approximately the same pressure.
For the first three steps, engineers can use operating data and commercial software with shell-
and-tube exchanger rating packages to perform the calculations and predict the resulting changes. For
the fourth criteria, engineers can use software programs for the base calculation but must obtain
additional information to account for the increases in film coefficients for a particular type of
enhancement.
The design process of shell-and-tube heat exchanger proceeds through the following steps:
Design and optimization algorithm is developed for shell-and-tube heat exchanger. A solution of core
velocity equation is a heart of such an algorithm.


Process conditions (stream compositions, flow rates,
temperatures, and pressures) must be specified.
The type of heat exchanger to be employed is chosen.
A preliminary estimate of the size of the exchanger is
made, using a heat transfer coefficient appropriate to
the fluids, the process, and the equipment.
A first design is chosen; complete in all details necessary
to carry out the design calculations