Heat Exchanger Design - Part 1

CB-307
Design of Heat Transfer Equipment

(Heat Exchangers)
by
Dr. Anoop Kumar Gupta
Department of Chemical and Biochemical Engineering

Indian Institute of Technology Patna
1
Introduction
• In most chemical processes: the transfer of heat to and

from process fluids.
• A heat exchanger is a device used to transfer heat
between two or more fluids.
• The fluids may be separated by a solid wall to prevent
mixing or they may be in direct contact.
• Exchangers in which process fluids are heated or
cooled by a plant service streams are called heaters
and coolers, respectively (sensible heat exchange).
2
Introduction
• If the process stream is vaporized, the exchanger is called

a vaporizer.
• A reboiler if the exchanger is used in distillation column.
• An evaporator if it is used to concentrate a solution.
• Condenser and evaporator: phase change HE
3
Introduction
• Applications: space heating, refrigeration, air conditioning
(collectively termed as HVAC, power stations, chemical
plants, petrochemical plants, petroleum refineries, natural-
gas processing, and sewage treatment.
4
5
Introduction: Basic concepts
6
Classification: based on flow configuration
7
Classification: based on fabrication
8
Design data
TEMA Inc. Standards
(Tubular Exchanger Manufacturers Association)
9
Plate and Frame Heat Exchanger
10
Double Pipe Heat Exchanger
11
Double Pipe Heat Exchanger
Heat duty:
Q  UA  Tm  mC pc (Tc ,out  Tc ,in )  mC ph (Th ,out  Th ,in )
12
Shell and tube heat exchanger
13
Components of shell and tube heat exchanger
14
Shell and tube heat exchanger (U-tube STHE)
15
Floating Head STHE
16
STHE: Baffles
Baffles serve two purposes:

• Divert (direct) the flow across the bundle to obtain a
higher heat transfer coefficient.
• Support the tubes for structural rigidity, preventing tube
vibration and sagging.
When the tube bundle employs baffles,
• The heat transfer coefficient is higher than the coefficient
for undisturbed flow around tubes without baffles.
• For a baffled heat exchanger the higher heat transfer
coefficients result from the increased turbulence.
• The velocity of fluid fluctuates because of the constricted
area between adjacent tubes across the bundle.
17
STHE: Baffles
• The baffle cut is the height

of the segment removed,
expressed as a percentage
of the baffle disc diameter.
• Baffle cuts from 15%-45%
are used giving good heat
transfer rates without
excessive pressure drop.
• A close baffle spacing will
give higher heat transfer
coefficients but at a cost of
higher pressure drop.
• An optimum spacing of 0.3-
0.5 times the shell diameter
is generally used.
18
STHE: Fluid allocation
Tube-side fluid Shell-side fluid

Corrosive Condensing vapor
Cooling water Fluid with ∆T > 40o C
Fouling fluid Viscous fluids
Less viscous fluid Low heat transfer coefficient
High pressure steam
Hotter fluid
(Pressure drop)
19
STHE: Tube Layout
20
STHE: Passes
Single pass Double pass
Triple pass
21
STHE: Passes
22
Typical steps for design procedure of STHE
1. Obtain the required thermophysical properties (density,

viscosity, thermal conductivity, etc.) of hot and cold fluids at
the reference temperature or arithmetic mean temperature.
2. Perform energy balance and find out the heat duty (Q) of the
exchanger (heat transfer rate, fluid flow rate, temperature).
3. Decide on the type of exchanger to be used.
4. Select a trial value for the overall heat transfer coefficient, U.
5. Decide tentative number of shell and tube passes.
Determine LMTD and correction factor.
6. Calculate heat transfer area required.
23
7. Select tube material, decide tube diameter (ID, OD), tube

thickness in terms of BWG (Birmingham wire guage) or Schedule
number (=1000*P/S), and tube length. (S = allowable stress)
8. Calculate no. of tubes required to provide the heat transfer area.
9. Calculate tube side fluid velocity using mass flow rate, density
and viscosity data.
10. Select the tube pitch, determine inside shell diameter that can
accommodate the calculated number of tubes. Use the standard
tube counts table for this purpose.
24
11. Assign fluid to shell side or tube side. Select the type of
baffle (segmental, doughnut etc.), its size (i.e. percentage cut,
25% baffles are widely used), spacing and number.
12. Determine the tube side film heat transfer coefficient using
the Sieder-Tate equation in laminar and turbulent flow regimes.
Estimate the shell-side film heat transfer coefficient.
13. Select the outside tube (shell side) dirt factor and inside
tube (tube side) dirt factor.
14. Calculate overall heat transfer coefficient based on the
outside tube area including dirt factors.
25
15. Calculate % overdesign. Overdesign represents extra

surface area provided beyond that required to compensate for
fouling.
16. Calculate the tube-side pressure drop: (i) pressure drop in

the straight section of the tube (frictional loss) and (ii) return
loss due to change of direction of fluid in a multi-pass
exchanger.
26

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CB-307

Design of Heat Transfer Equipment

Department of Chemical and Biochemical Engineering

• In most chemical processes: the transfer of heat to and

• If the process stream is vaporized, the exchanger is called

Baffles serve two purposes:

• The baffle cut is the height

Tube-side fluid Shell-side fluid

Single pass Double pass

1. Obtain the required thermophysical properties (density,

7. Select tube material, decide tube diameter (ID, OD), tube

15. Calculate % overdesign. Overdesign represents extra

16. Calculate the tube-side pressure drop: (i) pressure drop in

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