Heat Exchanger Design Basis

TP - heat exchanger design.
ppt
1
Transport Processes
Overall heat transfer coefficient
- From previous studies (CPP module):
Q = U A T
LM
o o
i i o i
i i
h
1
d
d
2k
) d d ln( d
h
1
U
1
+ + =
Some typical U values (all in W/m
2
K):
steam/water: 6000 to 18000
water/water: 850 to 1700
steam condenser (water in tubes) 1000 to 6000
ammonia condenser (water in tubes) 800 to 1400
alcohol condenser (water in tubes) 250 to 700
finned tube (air outside, water inside) 25 to 50
deduce others from charts
TP - heat exchanger design.ppt
2
Transport Processes
Contains many
combinations
May need to
transpose top
and bottom
fluids
Gives rather
conservative
estimates
3
Transport Processes
Choosing right shell-and-tube type
Decision as to
TEMA code
used depends on
fluids used

Shell& tube
exchangers
Severe thermal
exapansion stresses?
Are bellows
allowed?
Is chemical cleaning
possible?
High shellside
fouling > 0.00035
m
2
K/W?
High tubeside
fouling > 0.00035
m
2
K/W?
possible?
Removable
bundle design
Fixed
tubesheet
Is interstream
leakage allowed?
Are T & P within
range for lantern ring?
Is F correction factor
< 0.75?
Are there more than
2 passes?
Are F or multi shells
allowed?
Frequency of bundle
removal
AEL
AEM
BEM
No No Yes
Yes No
AEU
AFU
AEU AFU
No No Yes
Yes No
AEP
BEP
No No Yes
Yes No
AEW
BEW
No No Yes
Yes No
AET
BET
No No Yes
Yes No
AES
BES
No No Yes
Yes No
Is tubeside fouling >
0.00035 m
2
K/W?
Do we require tube access
without disturbing connections?
Yes No
Yes
Yes
No

Yes
No
No
Yes
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Low
High
No

Yes
4
Transport Processes
Log Mean Temperature Difference
e.g. find AT
LM
for both co-current & counter-current flow
Fluid A T
in
= 120 T
out
= 90C
Fluid B t
in
= 20 t
out
= 80C
temperature
AT
1
AT
2
hot fluid
T
in
T
out
cold fluid
t
out
t
in
2 1
2 1
LM
T ln T ln
T T
T
A A
A A
= A
5
Transport Processes
i.e. less driving force with co-current
K deg 53.6
ln40 ln70
40 70
T
LM
=
= A
K deg 39.1
ln10 ln100
10 100
T
LM
=
= A
120
80
90
40
70
20
120
80
90
20
100
10
6
Transport Processes
i.e. more driving force than either of the first two
same value for both co and counter-current
K deg 65.5
ln40 ln100
40 100
T
LM
=
= A
120
80
20
100
40
Now make fluid A condensing steam.
What happens?
7
Transport Processes
Why a log mean temperature difference rather
than any other?
Consider point along heat exchanger tube:
T T dT
t + dt t
Area = dA
Heat = dQ
At this point: AT = T t
d(AT) = dT dt
also dQ = -m
h
Cp
h
dT = m
c
Cp
c
dt (sensible heat change)
( )
/ / / /
h h c c h h c c
dQ dQ 1 1
d T dQ
m Cp m Cp m Cp m Cp
( ' '
'
A = = +
(

8
Transport Processes
Hence:
( )
/ /
h h c c
d T t
dQ=
1 1
m Cp m Cp
'
(
+
(

= U(T t).dA
( )
( )
/ /
h h c c
d T t
1 1
U.dA
T t m Cp m Cp
| |
= +
|
\ .
} }
assuming constant Cp
h
& Cp
c
:
2 2
/ /
1 1 h Ph c Pc
T t 1 1
-ln UA
T t m C m C
| |
= +
|
\ .
But
/
h Ph
1 2
Q
m C
T T
'
=
/
c Pc
2 1
Q
m C
t t
'
=

9
Transport Processes
Giving
2 2 1 2 2 1
1 1
T t T T t t
-ln UA
T t Q Q
| |
= +
|
' '
\ .
( ) ( )
2 2
1 1 2 2
1 1
T t UA
ln T t T t
T t Q
( =

'
( ) ( )
2 2 1 1
2 2
1 1
T t T t
Q UA
T t
ln
T t

'
=

= UA.T
LM
Counter-current derivation also true for co-current flow
- Co-current flow rarely used in practice
10
Transport Processes
- Shell & tube exchanger NOT in true counter-
current flow if there is more than one tube-side pass
AT
LM
< AT
LM
for pure counterflow
- In this case, calculate AT
LM
as if for counterflow.
Multiply by correction factor F to give true value:
( ) ( ) | |
( ) | | ( ) | |
1 R
1 R
1 R 1 R S 2 ln 1 R 1 R S 2 ln
SR 1 ln S 1 ln
F
2
2 2

+
+ + + + +

=
tube(in) tube(out)
shell(out) shell(in)
T T
T T
R
=
tube(in) shell(in)
tube(in) tube(out)
T T
T T
S
=
11
Transport Processes
- Alternatively,
use charts to
evaluate F.
- F should be
high (0.75 to
1.0) for
efficient
operation
- If F > 0.75 inachievable, use single tube-side pass
- F then becomes 1
12
Transport Processes
Duties
- For sensible heat (i.e. no boiling or condensing)
Q
H
= m
H
C
Ph
(T
in
- T
out
)
Q
C
= m
C
C
Pc
(t
out
- t
in
)
- For latent heat (boiling and/or condensing)
Q = m
fg

- For perfect balance, Q
H
= Q
C

i.e. heat lost by hot fluid = heat gained by cold
fluid
- In reality, heat losses always occur
13
Transport Processes
Fouling
Standard formula for U assumes clean surfaces
In reality, surface fouling increases thermal
resistance
External fouling layer
Internal fouling layer
14
Transport Processes
Fouling
Occurs for a number of reasons
Slimy film through microbial
activity in water
Precipitation of dissolved salts
Reaction of fluid alone (eg.
polymerisation of hydrocarbons)
Reaction of surface with fluid
(eg. corrosion)
Freezing
Silt
15
Transport Processes
Fouling
Dynamic problem by nature
Fouling
resistance
Time
Can be held in check by
Regular cleaning
High flow velocities
Low temperatures
Use of special devices and/or chemical additives
TEMA and others usually
quote this assymptotic value
16
Transport Processes
Fouling
Fouling resistances incorporated into formula:
Designers assume static R
fo
& R
fi
. A few examples:
FLUID R
f
(m
2
K/W)
Seawater & treated boiler water (<50C) 1 10
-4

Seawater & treated boiler water (>50C) 2 10
-4

River water (<50C) 2 to 10 10
-4

Fuel oil 9 10
-4

Refrigerating liquids 2 10
-4

Steam (non-oil bearing) 1 10
-4
( )
|
|
.
|
\
|
+ + +
|
|
.
|
\
|
+ =
fo
o o
i i o i
fi
i D
R
h
1
d
d
2k
d d ln d
R
h
1
U
1
17
Transport Processes
Mechanical considerations of shell-and-tube heat exchanger
design
Tubes held in place by tube sheets
with drilled holes
Holes align the tubes in square or
triangular arrangement
Distance between centres of adjacent
tubes = tube pitch
Outer diameters:
16, 20, 25, 30, 38, 50 mm, 2mm thick
Lengths:
1.83, 2.44, 3.66, 4.88, 6.10, 7.32 metres
18
Transport Processes
Mechanical considerations of shell-and-
tube heat exchanger design
Baffle spacing: minimum = D
s
5 (but > 5 cm)
maximum = 74d
o
0.75
(but < D
s
)
Baffle cut (segment opening height D
s
) = 0.25 to 0.40
eg. segmental baffle inside 1.00 m shell
25% means segment 25cm high removed
Smaller cut leaves smaller hole
Higher shell-side film coefficient
Greater shell side pressure drop
0.25 m

19
Transport Processes
First design of a shell-and-tube heat exchanger
Calculate duty Q (add 10% to include losses and
errors)
Find appropriate fouling resistances
Choose side for each fluid (based on fouling,
corrosion and pressure)
Choose type of exchanger from TEMA tree
Calculate all temperatures AT
LM
& F
Keep things simple to start with; assume 4.88m
tubes, d
o
= 20 mm, 2 tube side passes (N
P
=2)
20
Transport Processes
Cool 5.0 kg/s of ethylene glycol from 370 to 330K with
cooling water from 283 to 323K
Ethylene glycol at 350K (average) has following
properties
k = 0.261 W/m.K Cp = 2637 J/kg.K
= 0.00342 Pa.s = 1079.0 kg/m
3
Giving Pr = (26370.00342)/0.261 = 34.6
Anticipate fouling resistance of R
f
= 0.00018 m
2
K/W
Duty is Q = 5.0 2637 (370330) = 527 400 Watts
Aim to transfer 580 140 W
21
Transport Processes
Water at 303K (average) has following properties
k = 0.618 W/m.K Cp = 4179 J/kg.K
= 0.000797 Pa.s = 995.6 kg/m
3
Giving Pr = (41790.000797)/0.618 = 5.39
Anticipate fouling resistance of R
f
= 0.0001 m
2
K/W
Water fouls less and is on shell-side
We need water flowrate
( )
in out
t t Cp
Q
m
'
=
'
( )
15506 . 3
83 2 23 3 179 4
527400
=
=
3.16 kg/s water on shell-side
22
Problem we cannot calculate a log mean
Solution a log mean is just an average after all
What is average of 47 and 47?
?
ln47 ln47
7 4 7 4
T
LM
=
= A
370
323
330
47
47
283
1
70 3 30 3
23 3 83 2
R =
=
4598 . 0
70 3 83 2
70 3 330
S =
=
T = 47, F = 0.87
Transport Processes
23
Do we have
severe
expansion
stresses?
ie. are the
temperatures
greatly
different to
ambient?
Yes
Shell& tube
exchangers
Severe thermal
Are bellows
allowed?
possible?
High shellside
fouling > 0.00035
m
2
K/W?
High tubeside
fouling > 0.00035
m
2
K/W?
possible?
Removable
bundle design
Fixed
tubesheet
Is interstream
leakage allowed?
Are T & P within
< 0.75?
Are there more than
2 passes?
allowed?
Frequency of bundle
removal
AEL
AEM
BEM
No No Yes
Yes No
AEU
AFU
AEU AFU
No No Yes
Yes No
AEP
BEP
No No Yes
Yes No
AEW
BEW
No No Yes
Yes No
AET
BET
No No Yes
Yes No
AES
BES
No No Yes
Yes No
0.00035 m
2
K/W?
Yes No
Yes
Yes
No

Yes
No
No
Yes
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Low
High
No

Yes
Transport Processes
24
Are bellows
allowed?
No reason
why not
Yes

Shell& tube
exchangers
Severe thermal
Are bellows
allowed?
possible?
High shellside
fouling > 0.00035
m
2
K/W?
High tubeside
fouling > 0.00035
m
2
K/W?
possible?
Removable
bundle design
Fixed
tubesheet
Is interstream
leakage allowed?
Are T & P within
< 0.75?
Are there more than
2 passes?
allowed?
Frequency of bundle
removal
AEL
AEM
BEM
No No Yes
Yes No
AEU
AFU
AEU AFU
No No Yes
Yes No
AEP
BEP
No No Yes
Yes No
AEW
BEW
No No Yes
Yes No
AET
BET
No No Yes
Yes No
AES
BES
No No Yes
Yes No
0.00035 m
2
K/W?
Yes No
Yes
Yes
No

Yes
No
No
Yes
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Low
High
No

Yes
Transport Processes
25
High
shellside
fouling?
0.0001 <
0.00035
m
2
K/W
No

Shell& tube
exchangers
Severe thermal
Are bellows
allowed?
possible?
High shellside
fouling > 0.00035
m
2
K/W?
High tubeside
fouling > 0.00035
m
2
K/W?
possible?
Removable
bundle design
Fixed
tubesheet
Is interstream
leakage allowed?
Are T & P within
< 0.75?
Are there more than
2 passes?
allowed?
Frequency of bundle
removal
AEL
AEM
BEM
No No Yes
Yes No
AEU
AFU
AEU AFU
No No Yes
Yes No
AEP
BEP
No No Yes
Yes No
AEW
BEW
No No Yes
Yes No
AET
BET
No No Yes
Yes No
AES
BES
No No Yes
Yes No
0.00035 m
2
K/W?
Yes No
Yes
Yes
No

Yes
No
No
Yes
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Low
High
No

Yes
Transport Processes
26
High
tubeside
fouling?
0.00018 <
0.00035
m
2
K/W
No

Shell& tube
exchangers
Severe thermal
Are bellows
allowed?
possible?
High shellside
fouling > 0.00035
m
2
K/W?
High tubeside
fouling > 0.00035
m
2
K/W?
possible?
Removable
bundle design
Fixed
tubesheet
Is interstream
leakage allowed?
Are T & P within
< 0.75?
Are there more than
2 passes?
allowed?
Frequency of bundle
removal
AEL
AEM
BEM
No No Yes
Yes No
AEU
AFU
AEU AFU
No No Yes
Yes No
AEP
BEP
No No Yes
Yes No
AEW
BEW
No No Yes
Yes No
AET
BET
No No Yes
Yes No
AES
BES
No No Yes
Yes No
0.00035 m
2
K/W?
Yes No
Yes
Yes
No

Yes
No
No
Yes
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Low
High
No

Yes
Transport Processes
27
Is tube access
required
without
dismantling?
Unlikely
unless we
had solids or
other things
that may
block
No
Shell& tube
exchangers
Severe thermal
Are bellows
allowed?
possible?
High shellside
fouling > 0.00035
m
2
K/W?
High tubeside
fouling > 0.00035
m
2
K/W?
possible?
Removable
bundle design
Fixed
tubesheet
Is interstream
leakage allowed?
Are T & P within
< 0.75?
Are there more than
2 passes?
allowed?
Frequency of bundle
removal
AEL
AEM
BEM
No No Yes
Yes No
AEU
AFU
AEU AFU
No No Yes
Yes No
AEP
BEP
No No Yes
Yes No
AEW
BEW
No No Yes
Yes No
AET
BET
No No Yes
Yes No
AES
BES
No No Yes
Yes No
0.00035 m
2
K/W?
Yes No
Yes
Yes
No

Yes
No
No
Yes
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Low
High
No

Yes
Transport Processes
28
BEM
exchanger
A fixed
tubesheet
design

Shell& tube
exchangers
Severe thermal
Are bellows
allowed?
possible?
High shellside
fouling > 0.00035
m
2
K/W?
High tubeside
fouling > 0.00035
m
2
K/W?
possible?
Removable
bundle design
Fixed
tubesheet
Is interstream
leakage allowed?
Are T & P within
< 0.75?
Are there more than
2 passes?
allowed?
Frequency of bundle
removal
AEL
AEM
BEM
No No Yes
Yes No
AEU
AFU
AEU AFU
No No Yes
Yes No
AEP
BEP
No No Yes
Yes No
AEW
BEW
No No Yes
Yes No
AET
BET
No No Yes
Yes No
AES
BES
No No Yes
Yes No
0.00035 m
2
K/W?
Yes No
Yes
Yes
No

Yes
No
No
Yes
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Low
High
No

Yes
Transport Processes
29
Transport Processes
30
Transport Processes
Choose
best
case for
each
U
suggested
=500 W/m
2
K
2
m .38 8 2
47 87 . 0 500
580140
A =

=
31
Transport Processes
Use N
T
to fix estimated coefficient as U
estimate

L = 4.88 m, d
o
= 20 mm:
Area of one tube = 4.88 0.020 = 0.3066m
2
Number of tubes needed = 28.38 0.3066 = 92.54
Obviously, should be an integer
Round up here, as 92 tubes means U>500
K W/m 6 . 497
47 87 . 0 3066 . 0 93
580140
U
2
estimate
=

=
Aim to build exchanger with U = 497.6 W/m
2
K
32
Transport Processes
Calculate tube side velocity
T
2
i t
P
/
t
t
N d
N 4m
u
t
=
Suggested ranges
Tubeside process liquids 1 to 2 m/s
(up to 4 m/s if fouling risk)
Tubeside water 1.5 to 2.5 m/s
Vacuum gases/vapours 50 to 70 m/s
Atmospheric pressure gases/vapours 10 to 30 m/s
High pressure gases/vapours 5 to 10 m/s
Note: d
i
= 0.020 2(0.002) = 0.016 m
( )
m/s 4956 . 0
3 9 016 . 0 1079
2 5.0 4
2
=

=
t
33
Transport Processes
Lower than the suggested 1 to 2 m/s
If tube side passes tripled to N
P
= 6, u
t
= 1.487 m/s
7506
00342 . 0
016 . 0 487 . 1 1079
Re
t
=

=
Use Nusselt turbulent correlation for forced
convection in tubes:
Nu = 0.036 (Re)
0.8
Pr
0.33
(d
i
L)
0.055
Nu = 0.036 (7506)
0.8
(34.6)
0.33
(0.016 4.88)
0.055
Nu = 106.6 = h
i
d
i
k
h
i
= 106.60.261 0.016 = 1739 W/m
2
K
34
Transport Processes
Find tube bundle diameter D
B
thus:
assume tube pitch (p
t
)= 1.25 d
o
N
P
1 2 4 6 8
K
1
0.215 0.156 0.158 0.0402 0.0331
n
1
2.207 2.291 2.263 2.617 2.643

1
n
1
1
T
o B
K
N
d D
|
|
.
|
\
|
=
N
T
= 93, N
P
= 6, p
t
= 1.25 0.020 = 0.025 m

m 386 . 0
0402 . 0
93
020 . 0
2.617
1
=
|
.
|
\
|
=
So tube bundle is 0.386 m in diameter, but shell
needs to be wider still

35
Transport Processes
Use graph to find
clearance between
bundle and shell
diameter D
S
12mm added so
D
S
= 0.386 + 0.012 =
0.398 m
Number of tubes at
equator n = D
B
p
t
tubes 4 . 15
025 . 0
0.386
n = =
36
Transport Processes
Find minimum baffle spacing
0.398 5 = 0.0796 m
Divide tube length by b
min
to find number of chambers
created by baffles
4.88 0.0796 = 61.3
Number of chambers should be integer i.e. round down
Actual baffle spacing b = tube length number of
chambers
b = 4.88 61 = 0.08 m
37
Transport Processes
Calculate equivalent diameter of shell-side fluid
(D
e
)
perimeter wetted
area flow 4
D
e

=
d
o
p
t
( )
( )
m 0198 . 0 020 . 0
020 . 0
0.025 4
D
2
e
= =
t
So for d
o
= 0.020 and p
t
= 0.025
o
o
2
t
o
2
o
2
t
d
d
4p
d
d
4
p 4
=
|
.
|
\
|

=
t t
t
( )
circle 1 of nce circumfere
area circle area square 4
=
38
Transport Processes
Calculate cross-section for flow (S) for
hypothetical tube row mid-shell of n tubes
D
S
b

p
t
d
o
S = b(D
S
nd
o
)
= 0.08 [0.398 15(0.02)]
= 7.8410
3
m
2
Choose tube material
if stainless steel, k = 16 W/m.K
39
Transport Processes
Calculate shell side velocities
s
/
s
s
S
m
u
=
Suggested ranges
Atmospheric pressure gases/vapours 10 to 30 m/s
Vacuum gases/vapours 50 to 70 m/s
High pressure gases/vapours 5 to 10 m/s
Shell-side liquids 0.3 to 1.0 m/s
Falls within accepted range
m/s 4048 . 0
6 . 995 00784 . 0
3.16
=
=
10013
000797 . 0
0198 . 0 4048 . 0 6 . 95 9
Re
s
=

=
40
Transport Processes
Using Grimison correlation where C = 0.348 and
n = 0.592
Nu = 1.130.348 (Re)
0.592
Pr
0.33
Nu = 0.39324 (10013)
0.592
(5.39)
0.33
Nu = 160.11 = h
o
D
e
k
h
o
= 160.110.618 0.0198 = 4997 W/m
2
K
Now have all information needed for U-value

( )
|
|
.
|
\
|
+ + +
|
|
.
|
\
|
+ =
fo
o o
i i o i
fi
i D
R
h
1
d
d
2k
d d ln d
R
h
1
U
1
41
Transport Processes
Inside
resistance
K/W m 10 550 . 7 00018 . 0
1739
1
2 4
=
|
.
|
\
|
+
( )
K/W m 10 116 . 1
16 2
0.016 0.02 ln 0.016
2 4
=
K/W m 10 401 . 2 0001 . 0

4997
1
0.02
0.016
2 4
=
|
.
|
\
|
+
Wall
resistance
Outside
resistance
Overall resistance
(7.550 + 1.116 + 2.401)10
4
= 1.106710
3
m
2
K/W
1 (1.106710
3
) = 903.6 W/m
2
K
42
Transport Processes
Here, 903.6 497.6 W/m
2
K, over 81% out
Main resistance is tubeside, so ponder options
If U
actual
U
estimate
(30%) then do any of the
following:
+ A by reducing tube length (| U
estimate
)
| A by increasing tube length/diameter (+ U
estimate
)
| number of tube-side passes (| U
actual
)
| number of shell-side baffles (| U
actual
)
If possible, alter the side where the MAIN
resistance lies

Heat Exchanger Design Basis

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K/W m 10 401 . 2 0001 . 0

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