Shell and tubeheat exchanger

design
Chee 331/332/333 1
Design of Shell and Tube Heat
Exchangers Hydraulic
calculations
Design strategy
Shell and tubeheat exchanger
design
Chee 331/332/333 2
Design of a shell and tube heat exchanger is an iterative process. The
suggested steps are outlined below.
Obtain an initial configuration, using the preliminary design techniques
that you have learned.
Follow established design guidelines (see for example Serth, 5.7) and
tables to specify an initial configuration.
Rate the design, as you have learned in the rating example to
determine if the design is thermally suitable.
Use principles of hydraulics/fluid mechanics to assess if the design is
hydraulically suitable (see section 5.3 Serth and Heaslip notes for hydraulic
calculations for S&T, and section 4.3 Serth for double-pipe HEs).
Modify the design if necessary
Iterate, until an acceptable design has been obtained.
Solved example (5.1 From Serth) contd
Design of a shell and tube heat exchanger
45,000 lb/h of kerosene are to be cooled from 390F to 250F by heat exchange with
150,000 lb/h of crude oil, which is at 100F. A maximum pressure drop of 15 psi has been
specified for each stream. Crude oil exhibits significant tendency for fouling, with a fouling
factor of 0.003 h.ft
2
.F/Btu. Design a shell and tube heat exchanger for this service.
Previously we found that the H.E. that we considered was oversized.
A further consideration is that the pressure losses must stay within
specifications, while still achieving good heat transfer.
An over-sized H.E. may suffer from big pressure drops.
Design parameters may need to be adjusted to control tube-side and
shell-side pressure drop.
These calculations may assist us in choosing an improved
configuration.
We must consider tube-side and shell-side pressure drop.
Shell and tubeheat exchanger
design
Chee 331/332/333 3
Pressure drop
Tube-side pressure drop
The pressure drop is a strong function of both the tube length, L, and the
number of tube passes, n
p
:
Shell-side pressure drop
The main easily controllable factor to control the shell-side pressure
drop is the baffle spacing, B. Increasing B increases the flow area across
the tube bundle, thus decreasing P.
Shell and tubeheat exchanger
design
Chee 331/332/333 4
Heat Exchangers Chee 331/332/333 5
Tube Side Pressure Drop

The tubeside pressure drop is the sum of the pressure drop through the tubes plus the pressure
drop through the channels:


P
t
= f G
t
2
L

n + 4n V
2
lbs/in
2

5.22 x 10
10
D
e
s
t
s 2g'

Where: Pt =Pressure drop across the tubeside, lbs/ft
2

f =Friction factor, ft
2
/in
2

Gt =Tube mass velocity, lb/hr-ft
2

L =Tube length, ft
n =Number of tube passes
De =Equivalent diameter, ft
s =Specific gravity =density, lbs/ft
3
/ 62.4
s =The viscosity ratio (/w)
0.14

g' =Acceleration due to gravity =32.2 ft/sec
2

(Fanning friction factor)
Shell and tubeheat exchanger
design
Chee 331/332/333 6
Tube-side Fanning Friction Factors (Heaslipp. 68)
Tube-side P
Alternative calculation, using eq. 5.1 Serth:
Shell and tubeheat exchanger
design
Chee 331/332/333 7
laminar turbulent
To account for minor losses:
Heat Exchangers Chee 331/332/333 8
Shell Side Pressure Drop

The pressure drop through the shell of an exchanger is proportional to the the number of times the
fluid crosses the bundle between baffles. It is also proportional to the distance across the bundle
each time it is crossed.

The isothermal equation for pressure drop for the shellside flow of a fluid being heated or cooled and
including the entrance and exit losses is:

P
s
= f G
s
2
D
s
(N+1) lbs/in
2

5.22 x 10
10
D
e
s
s


Where: P
s
=Pressure drop across the shell, lbs/ft
2

f =Friction factor, ft
2
/in
2

Gs =Shell mass velocity, lb/hr-ft
2

D
s
=Shell inside diameter, ft
N =Number of baffles
D
e
=Equivalent diameter, ft
s =Specific gravity

s
=The viscosity ratio (/
w
)
0.14

(Fanning friction factor)
N+1 is approximated by L
tube
/B
Shell and tubeheat exchanger
design
Chee 331/332/333 9
Shell-side Fanning Friction Factors (Heaslip, p. 67)
Summary of problems .
The tube-side pressure drop is too large
The shell-side pressure drop is too small
The exchanger is over-sized.
We could reduce the number of tube passes, or reduce the length of
the tubes.
Recall
To increase the pressure drop inside the shell, we can reduce the
baffle spacing
Recall P
shell-side
~1/B
3
Shell and tubeheat exchanger
design
Chee 331/332/333 10
Choose L= 14 ft,
4 passes, n
t
=130
Corresponding to
d
s
=19 1/4
Choose B=0.2 d
s
Shell and tubeheat exchanger
design
Chee 331/332/333 11
Final design
Re-iterate until all design criteria are satisfied: The pressure drops are
acceptable, shell side and tube side heat transfer coefficients does not
vary greatly, tube side velocity is within acceptable limits.
Shell and tubeheat exchanger
design
Chee 331/332/333 12
Shell and tubeheat exchanger
design
Chee 331/332/333 13
Shell And Tube Heat Exchanger Data Sheet (TEMA)
Date
Type
Connected In Parallel Series
In
Connections Out
Size &Rating Intermediate
Tube No. O.D. Thk. (Min/Avg) Length Pitch 30 / 60 / 90 / 45
Shell I.D. O.D.
v2
Type %Cut Spacing c/c
U-Bend
ASME VIII
Div1
Expansion J oint Type
Remarks:
Materi al s of Constructi on
Code Requirements Code Stamp Yes/No TEMA Cl ass
Weights/Shell - Shipping Filled With Water Bundle
Baffles (Cross)
Baffles (Long) Seal Type
Supports - Tube Type
Bypass Seal Arrangement Tube/Tubesheet J oint Gaskets
Channel or Bonnet Channel Cover
Tube Sheet - Stationary (yes/no) Tube Sheet - Floating (yes/no)
Floating Head Cover (yes/no) Impingement Protection
Desi gn Temperature, F
No. Passes Per Shel l
Corrosi on Al l owance, In.
Tube Type Material
Shell Cover (Integ.) (Remov.)
Heat Exchanged BTU/Hr MTD Corrected F
Transfer Rate, BTU Hr Sq.Ft. F -Service Clean
Shell Side Tube Side
Desi gn/Test Pressure drop, PSIG
Operati ng Pressure - PSIG
Velocity - Ft/Sec
Press.Drop Al l ow/Cal c. PSI
Fouling Resistance (Min.)
Constructi on of One Shel l Sketch (Bundle/Nozzle Orient'n)
Non-Condensabl e - Lb/Hr
Temperature (In/Out) F
Latent Heat - BTU/LB F
Speci fi c Heat - BTU/LBF
Thermal Cond. BTU Ft/Hr Sq.Ft. F
Densi ty
Vi scosi ty, Li qui d Cp
Mol ecul ar Wei ght, Vapor
Mol . Wt., Noncondensabl e
Vapor (In/Out) - Lb/Hr
Li qui d - Lb/Hr
Steam - Lb/Hr
Water - Lb/Hr
Fl ui d Ci rcul ated
Fl ui d Quanti ty Total - Lb/Hr
Performance of One Uni t
Shell Side
(In) / (Out)
Tube Side
(In) / (Out)
Service of Unit Hori z/Vert
Size
Sq. Ft. Surf./Unit (Gross)(Eff.) Shell/Unit Sq.Ft./Shell (Gross)(Eff.)
Contact Name End User
Address
Your Company Name
Installation Location Equipment Tag No.
Deliverable 2:
Use TEMA data sheet or double-pipe
heat exchanger data sheet (available
from website) to enter the summary
of your design