Lecture No.

9
Design of Shell and Tube
Heat Exchangers
Today's Lecture
Shell & Tube Heat Exchanger
Design Procedure

The following procedure may be followed step-by-step
for the design of a shell and tube heat exchanger.
1. Heat load or Duty

Perform energy balance and calculate the exchanger heat
duty ,Q and the missing flow rate.
Design of Shell & Tube Heat
Exchanger

2. List the properties of Hot and cold streams;
2. Take thermo-physical properties of the hot and the cold fluid stream at the mean
temperature.

Note: Take these properties at the caloric temperature of the hot and the cold
fluids, if the variation of the viscosity is large.)

The Thermo-physical properties of many fluids are available from sources

1. Perry, Hand book of chemical engineering,
2. International Critical Tables (1927), etc.

If the necessary data are not available, these may be estimated by
using suitable correlations (Reid et al., 1988).


, C, S or , , k ,Rd, P
Hot Fluid:
Hot Fluid:
, C, S or , , k ,Rd, P
Design of Shell & Tube Heat
Exchanger

3. Select the tentative number of shell and tube passes.
Calculate the LMTD and the correction factor F
T
.

S= Cold/Cold Approach
R= Hot/Cold


T
True
= LMTD FT
(From Fig.18)
) T / T ( ln
T T
. T
2 1
2 1
1m

Design of Shell & Tube Heat

Exchanger

Design of Shell & Tube Heat
Exchanger

4. Assume design overall coefficient, U
d
, on the outside
tube area basis.

The values of the overall heat transfer coefficient for the given
service may be taken from the literature .
5. Calculate the heat transfer area required:



Design of Shell & Tube Heat
Exchanger
6. Select the tube diameter, its wall thickness (in terms
of BWG OR SWG), and the tube length.
7. Calculate the number of tubes required to provide
the area, A, calculated above.
Design of Shell & Tube Heat
Exchanger
Design of Shell & Tube Heat
Exchanger
8. a. Select the tube pitch; (Triangular or square pitch)

b. Select the shell diameter that can accommodate
the required number of tubes. A tube- sheet
layout table (tube counts) is used for this
purpose (Table 9 ).
Design of Shell & Tube Heat
Exchanger
Design of Shell & Tube Heat
Exchanger
Design of Shell & Tube Heat
Exchanger
9. Select the type, size (e.g. percentage cut),
number of baffles and baffle spacing.

For example: 25 % cut ,Segmental baffle

Note : The baffle spacing is usually not greater than a distance equal to
inside diameter of the shell or closer than a distance equal to
one-fifth the inside diameter of the shell.
Design of Shell & Tube Heat
Exchanger

10. Estimate the tube-side and shell-
side coefficients.

Note: If the estimated shell-side coefficient appears to be small,
closer baffle spacing should be tried and the outside film
coefficient (and also the pressure drop) should be
recalculated.

If the tube-side coefficient is low, adjust the number of tube
passes to increase the Reynolds number, and thereby the
heat transfer coefficient. However, this is subject to
allowable pressure drop across the exchanger.
Design of Shell & Tube Heat
Exchanger
11. Tube Side Film Coefficient
Lb/hr ft
2

Design of Shell & Tube Heat
Exchanger
Obtain JH factor Fig: 24
Design of Shell & Tube Heat
Exchanger
12. Shell Side Film Coefficient
Shell Side flow area
Lb/hr ft
2

Design of Shell & Tube Heat
Exchanger
For triangular pitch

For square pitch

Design of Shell & Tube Heat
Exchanger

Shell side Reynolds's number
Shell side film coefficient

Design of Shell & Tube Heat
Exchanger

Calculate
JH factor Fig. 28
Calculate shell side coefficient, h
o
Design of Shell & Tube Heat
Exchanger
13. Calculate the, clean, overall coefficient, Uc , on
the outside tube area basis,
Design of Shell & Tube Heat
Exchanger

Select the dirt factor, R
d
for the system and service and
calculate the overall coefficient, U
d
,.


14) Calculate the area, A, based on this U
d
.
13. Calculate Design overall coefficient, U
d
,.
Design of Shell & Tube Heat
Exchanger

15. Calculate the tube-side and the shell-side
pressure drops. If a pressure drop value is
more than the corresponding allowable values,
further adjustments in the het exchanger
configuration will be necessary.
psi
Shell-side pressure drop
Design of Shell & Tube Heat
Exchanger
16. Shell-side pressure drop
psi
Design of Shell & Tube Heat
Exchanger
Soft ware Available:


ASPEN/SP, DESIGN II, HYSIM
Thanks


Questions
Thanks
Questions
Shell & Tube Heat Exchanger

11. Compare the calculated, Ud
,
and, A, values with the
values assumed in step-4 above. If the assumed
heat exchanger configuration gives about 10%
excess areas than that required, if may be
acceptable. This provide a reasonable overdesign
which may be desirable in many cases. (However
over design is not desirable in some cases).
Otherwise, a new configuration in terms of the
number and size of the tube and tube passes, shell
diameter, etc. is assumed and the calculations are
repeated starting from step three.
Statement:

Ethyl benzene is manufactured by alkylation of benzene with
ethylene. The reaction products are separated in a series of
distillation columns. Ethyl benzene is obtained as the distillate
from the last column (called the ethyl benzene column). In a 50
tpd ethyl benzene plant, the final product leaves the overhead
condenser at 135 C. This is required to be cooled to 40 C
before pumping it to the storage tank.
Cooling water is available at 30 C for cooling. Design a shell and
tube heat exchanger for this purpose.
The allowable pressure drop is 0.15 kg/cm
2
on both tube and
shell sides.

Statement:

In an electricity-generating facility, steam leaves a turbine and is piped to a condensing
unit. After condensation occurs, it is desired to further cool the distilled water by means
of a shell and tube heat exchanger. The water enters the heat exchanger at 110 F with a
flow rate of 170,000 lbm/hr. The heat will be transferred to raw water from a nearby river.
The raw water is available at 65 F, and d the mass flow rate is 150,000 lbm/hr. It is
proposed to use a heat exchanger that has a 17.25 in, ID shell and in OD, 18 BWG
TUBES THAT ARE 16 Ft long. The tubes are laid out on a 15/16 in, triangular pitch. The
tube fluid will make two passes. The shell contains baffles that are spaced 1ft apart.
Determine the outlet temperature of the both streams.
Lecture No.14
Shell and Tube Heat Exchangers
Design



1. To determine the Heat Transfer Area required for the design
duty;

2. To specify the tube diameter, length and numbers;

3. To specify the shell diameter;

4. To find the number of shell and tube passes;

5. To arrange the tubes on the tube sheet/ or to determine the
tube layout;

6. To find the type, size, number and spacing of baffles;
The important tasks in the design process of a shell and tube
heat exchanger are: