Heat Exchangers PDF

Heat Exchangers
Dr. Rakesh Kumar

Double-Pipe Heat Exchanger
ε-NTU Method
Shell and Tube Heat Exchanger
• The tubes are fixed with tube sheet that form the barrier between the tube and shell
fluids. The tubes can be fixed with the tube sheet using ferrule and a soft metal
packing ring.
Typical parts of S&T HX
• Shell: It is the container for the shell fluid and the tube bundle is placed
inside the shell. Shells are usually fabricated from standard steel pipe. The
shell thickness of 3/8 inch for the shell ID of 12-24 inch can be
satisfactorily used up to 300 psi of operating pressure.
• Tube: Tube OD of ¾ and 1’’ are very common to design a compact heat
exchanger. The tube length of 6, 8, 12, 16, 20 and 24 ft are preferably used.
Longer tube reduces shell diameter at the expense of higher shell pressure
drop. It is desirable to have the maximum number of tubes in the shell to
increase turbulence and high heat transfer. Stainless steel, copper, bronze and
alloys of copper-nickel are the commonly used tube materials.
Baffles
• Baffles are used to increase the fluid velocity by diverting the flow across the
tube bundle to obtain higher transfer co-efficient. The distance between
adjacent baffles is called baffle-spacing. The baffle spacing of 0.2 to 1 times
of the inside shell diameter is commonly used. Baffles are held in positioned
by means of baffle spacers. Closer baffle spacing gives greater transfer co-
efficient by inducing higher turbulence. The pressure drop is more with
closer baffle spacing.
Types of Baffles
• In case of cut-segmental baffle, a

segment (called baffle cut) is
removed to form the baffle
expressed as a percentage of the
baffle diameter. Baffle cuts from 15
to 45% are normally used. A baffle
cut of 20 to 25% provide a good
heat-transfer with the reasonable
pressure drop. The % cut for
segmental baffle refers to the cut
away height from its diameter
Tube pitch and layout
• Tube pitch is the shortest centre

to centre distance between the
adjacent tubes. The tubes are
generally placed in square or
triangular patterns. The number
of tubes that can be
accommodated in a given shell
ID is called tube count
Types of S&T HX
Some videos
Selection of fluids for tube and the shell side
Fouling
• The material deposited reduces the effective heat transfer rate due to
relatively low thermal conductivity. Therefore, net heat transfer with clean
surface should be higher to compensate the reduction in performance during
operation.
• Fouling of exchanger increases the cost of (i) construction due to oversizing,
(ii) additional energy due to poor exchanger performance and (iii) cleaning to
remove deposited materials. A spare exchanger may be considered in design
for uninterrupted services to allow cleaning of exchanger.
Fouling Factor
• Fouling factors must be obtained experimentally by determining the values
of U for both clean and dirty conditions in the heat exchanger
Typical values of fouling coefficients/ resistances
Heat exchanger correction factor 1-2 S&T
• Q = UAFΔTLMTD
• ΔTLMTD is based on
counter current flow
• F is correction factor
2 -shell pass and twice even number of tube
passes
Correction factor for single pass cross-flow
Types of Shell and Tube Heat Exchangers
• Fixed tube design
– Simplest and cheapest type.
– Tube bundle cannot be removed for cleaning.
– No provision for differential expansion of shell and
tubes.
– Use of this type limited to temperature difference
upto 800C.
• Floating head design
– More versatile than fixed head exchangers.
– Suitable for higher temperature differentials.
– Bundles can be removed and cleaned (fouling liquids)
Design of Shell and Tube Heat Exchangers
• Kern method:
– Does not take into account bypass and leakage streams.
– Simple to apply and accurate enough for preliminary design calculations.
– Restricted to a fixed baffle cut (25%).
• Bell-Delaware method
– Most widely used.
– Takes into account:
• Leakage through the gaps between tubes and baffles and the baffles and shell.
• Bypassing of flow around the gap between tube bundle and shell.
• Stream Analysis method (by Tinker)
– More rigorous and generic.
– Best suited for computer calculations; basis for most commercial computer codes.
Construction Details – Tube Dimensions
• Tube diameters in the range 5/8 inch (16 mm) to 2 inch (50 mm).
• Smaller diameters (5/8 to 1 inch) preferred since this gives
compact and cheap heat exchangers.
• Larger tubes for heavily fouling fluids.
• Steel tubes – BS 3606; Other tubes – BS 3274.
• Preferred tube lengths are 6 ft, 8 ft, 12 ft, 16 ft, 20 ft and 24 ft;
optimum tube length to shell diameter ratio ~ 5 – 10.
• ¾ in (19 mm) is a good starting trial tube diameter.
Construction Details - Shells
• Shell should be a close

fit to the tube bundle to
reduce bypassing.
• Shell-bundle clearance
will depend on type of
heat exchanger.
Construction Details – Tube Count
• Bundle diameter depends not only on number of tubes but also number of tube passes.
• Nt is the number of tubes

• Db is the bundle diameter (mm)
• D0 is tube outside diameter (mm)
• n1 and K1 are constants

Basic Design Procedure
• General equation for heat transfer is: Q = UA Tm
where Q is the rate of heat transfer (duty),

U is the overall heat transfer coefficient,
A is the area for heat transfer
ΔTm is the mean temperature difference
• We are not doing a mechanical design, only a thermal design.
Overall Heat Transfer Coefficient
• Overall coefficient given by:
 d0 
d 0 ln  
1
=
1
+
1
+  di  + d0 1 + d0 1
U 0 h0 hod 2k w d i hid d i hi
h0 (hi) is outside (inside) film coefficient
hod (hid) is outside (inside) dirt coefficient
kw is the tube wall conductivity
do (di) is outside (inside) tube diameters
Individual Film Coefficients
• Magnitude of individual coefficients will depend on:
– Nature of transfer processes (conduction, convection, radiation, etc.)
– Physical properties of fluids
– Fluid flow rates
– Physical layout of heat transfer surface
• Physical layout cannot be determined until area is known; hence design
is a trial-and-error procedure.
Typical Overall Coefficients
Typical Overall Coefficients
Shell and Tube Fluid Velocities
• High velocities give high heat-transfer coefficients but also high pressure drop.
• Velocity must be high enough to prevent settling of solids, but not so high as to cause
erosion.
• High velocities will reduce fouling
• For liquids, the velocities should be as follows:
– Tube side: Process liquid 1-2m/s
Maximum 4m/s if required to reduce fouling
Water 1.5 – 2.5 m/s
– Shell side: 0.3 – 1 m/s
Tube-side Heat Transfer Coefficient
• For turbulent flow inside conduits of uniform cross-section, Sieder-Tate
equation is applicable:
0.14
0.33   
Nu = C Re Pr 
0.8

 w 
Nu =
hi d e u d
Re = t e Pr =
Cp
kf  kf
C=0.021 for gases
=0.023 for low viscosity liquids
=0.027 for viscous liquids
μ= fluid viscosity at bulk fluid temperature
μw=fluid viscosity at the wall
Heat Transfer Factor, jh
• “j” factor similar to friction factor used for pressure drop:

0.14
hi d i 0.33   
= jh Re Pr  
kf  w 
• This equation is valid for both laminar and turbulent flows.

Tube Side Heat Transfer Factor
Heat Transfer Coefficients for Water
• Many equations for hi have developed specifically for water. One such equation is:
4200(1.35 + 0.02t )ut0.8
hi =
d i0.2
where hi is the inside coefficient (W/m2 0C)

t is the water temperature (0C)
ut is water velocity (m/s)
dt is tube inside diameter (mm)
Tube-side Pressure Drop
  L    − m  u 2
Pt = N p 8 j f    + 2.5 t
  d i   w   2
where ΔP is tube-side pressure drop (N/m2)

Np is number of tube-side passes
ut is tube-side velocity (m/s)
L is the length of one tube
m is 0.25 for laminar and 0.14 for turbulent
jf is dimensionless friction factor for heat exchanger tubes
Tube Side Friction Factor
• Calculate the shell side equivalent diameter (hydraulic diameter).
– For a square pitch arrangement:
 pt2 − d 02 
4
 

de =  4 
d 0
 pt 1 d 02 
– For a triangular pitch arrangement 4  0.87 pt −  
de = 
2 2 4 
d 0
2
Tube Pattern Applications
• Triangular and rotated square patterns give higher heat transfer rates,
but at the expense of a higher pressure drop than the square pattern.
• A square, or rotated square arrangement, is used for heavily fouling
fluids, where it is necessary to mechanically clean the outside of the
tubes.
• The recommended tube pitch is 1.25 times the tube outside diameter;
and this will normally be used unless process requirements dictate
otherwise.
Shell-side Reynolds Number
• The shell-side Reynolds number is given by:
Gs d e us de 
Re = =
 
• The coefficient hs is given by: 0.14
hs d e   
Nu = = jh Re Pr1 / 3  
kf  w 
where jh is given by the following chart
Shell Side Heat Transfer Factor
Shell-side Pressure Drop
• The shell-side pressure drop is given by:
−0.14
 Ds  L  u 2
  
Ps = 8 j f    s
 
 de   B  2  w 
where jf is the friction factor given by following chart.

Shell Side Friction Factor

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Heat Exchangers

Dr. Rakesh Kumar

• In case of cut-segmental baffle, a

• Tube pitch is the shortest centre

• Shell should be a close

• Nt is the number of tubes

• n1 and K1 are constants

where Q is the rate of heat transfer (duty),

• “j” factor similar to friction factor used for pressure drop:

• This equation is valid for both laminar and turbulent flows.

where hi is the inside coefficient (W/m2 0C)

where ΔP is tube-side pressure drop (N/m2)

where jf is the friction factor given by following chart.

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