In The Name OF ALLAH

THE MOST MERCIFUL

AND BENIFICIENT

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TOPIC OF PRESENTATION

DESIGN OF SHELL
AND TUBE HEAT
EXCHANGER…..

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 GROUP MEMBERS
MUHAMMAD IMRAN 2006-CHEM-35
OSAMA AKRAM 2006-CHEM-39
WAQAS AHMAD 2006-CHEM-15
TAIMOOR RAI 2006-CHEM-81

SUMITTED TO:
Prof. Shah muhammad

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Shell And Tube Heat Exchanger

Main Parts
1.Tubes
2.Shell
3.Baffles
4.Tube Sheets
5.Head
6.Tube Bundle

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 Problem Statement:
Dry ammonia gas at 83 psia and
at a rate of 9872 lb/hr is to be
cooled from 245oF to 95oF using
cooling water from 85oF to 95oF.
Design a shell and tube
heat exchanger to perform
the above duty.

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Design of a Shell And Tube Exchanger:

In this presentation following

topics would be presented:
 General Design Steps.
 Thermal Design.
 Hydraulic Design.

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 Part (A)

General Design Steps of

Shell and Tube Heat
exchanger:

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General Design Steps:
Step 1.
Perform the energy balance and calculate heat
exchanger duty.
Step 2.
Obtain the necessary thermo physical properties of
hot and cold fluid streams at their mean temperature.
Step 3.
Select the tentative number of shell and tube passes.
Step 4.
Calculate the LMTD and the correction factor FT .
Step 5.
Assume a reasonable value of the overall coefficient
on outside tube area designated as Udo .

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General Design Steps:
Step 6.
Select the tube diameter, it's wall thickness (In Terms
Of BWG) and the tube length. Calculate the number
of tubes required to provide the area calculated
above.

Step 7.
Select the tube pitch. Select the shell diameter that
can accommodate the required number of tubes.

Step 8.
Select the type, size (e.g. percentage cut) number
and spacing of baffles.

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General Design Steps:
Step 9.
Estimate the shell side and tube side heat
transfer coefficients.
Step 10.
Select the dirt factors Rd applicable to the
system.
Step11.
Calculate the overall coefficient Udo
Step 12.
Calculate the area based on this Udo.

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General Design Steps:
Step13.
Compare the Udo and A values with those assumed
Step 14.
If area is in excess of 10% of that calculated then the
design is acceptable. This excess area is sometimes
required and sometimes not. If area calculations do
not agree assume a new value of Udo and proceed in
a similar way

Step 15.
Calculate the shell side and tube side pressure drops

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 Part (B)

Thermal Design of
Shell and Tube
Heat exchanger:

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Physical Properties:
Prior entering to thermal
design calculations;
Tabulating the physical properties of
Hot fluid (Ammonia)
And cold fluid (Water)

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Physical Properties for Ammonia:
Properties: Values:
Mass Flow Rate mh 9872 lb/hr
Entering Temperature T1 245 oF
Leaving Temperature T2 95 oF
Average temperature Tavg 170 oF
Specific Heat Capacity Cph 0.53 Btu/lb-oF
Viscosity Of Ammonia µh 0.027 lb/ft-hr
Thermal Conductivity kh 0.0176Btu/hr-ft-oF
Density ρh 0.02079lb/ft3

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Physical Properties for water:
Properties: Values:
Mass Flow Rate mc 78482.4 lb/hr
Entering Temperature t1 85 oF
Leaving Temperature t2 95oF
Average temperature tavg 90oF
Specific Heat Capacity Cpc 1 Btu/lb-oF
Viscosity Of water µc 1.846 lb/ft-hr
Thermal Conductivity kc 0.358 Btu/hr-ft-oF
Density ρc 62.11 lb/ft3

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How should I start ?

An obvious answer
would be from making
an overall
 Energy And
 Material Balance.

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HOW TO CALCULATE HEAT DUTY?
By using Formula Q = m Cp ∆T
Using Values Of m, Cp and ∆T
from ammonia Q = 784824 Btu/hr.
From Which Mass Flow Rate of
Water would be calculated
using
Q =m Cp ∆T
Yields m = 78482.4 lb/hr.
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Calculation of Volumetric Flow Rate of Water:

Volumetric Flow Rate of Water

q = mc /ρc

= 1263.6 ft3/hr.

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Calculating LMTD …
t1 = 85 F
o t2 = 95oF

T2 = 95 F o T1= 245oF
LMTD = [(T1- t2) - (T2-t1)]
[ln(T1- t2)/(T2-t1)]

LMTD = 51.7oF
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Calculation Of Heat Transfer Area :
Assume Udo=27 Btu/hr-ft2-oF

Using the formula Q = Udo × A× LMTD

Calculate Heat Transfer Area

A = 562.235 ft2

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 Select A Suitable Size Tube:

A Iterative Selection is
3/4" and 16 BWG
Select A suitable length
L = 16 ft

Outside Diameter of Tube = O.D = 0.0625 ft

Inside Diameter of Tube = I.D = 0.0516 ft
Wall Thickness = xw = 0.005416 ft

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1 – 1 Pass Arrangement calculation:
Outer Surface Area of Tube = 3.142×O.D×L
Outer Surface Area of Tube = 3.142 ft2
No. of Tubes Required = Area/ Outside Surface Area of One Tube
Number of Tubes Required = 178.94
Flow Area = π× (I.D) 2×Number of Tubes
4
Flow Area = 0.3742 ft2

Linear Velocity within the Tubes = Volumetric flow Rate/Flow Area

Linear Velocity within the Tubes = 0.937 ft/sec
Deduction:
According to rule of thumbs and conventions it is well known that the
velocity in the tubes should be between 3-10 ft/sec.
So 1-1 pass is rejected and we go for a 1-4 pass exchanger that might
bring the velocity in the range.

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1 – 4 Pass Arrangement calculation:
Take 180 tubes
Number of tubes per pass = 180/4
Number of tubes per pass = 45

Flow Area Per Pass

= π× (I.D)2×Number Of Tubes Per Pass
4
Flow Area per Pass = 0.0941ft2
Linear Velocity within the Tube = Volumetric flow Rate/Flow Area
Linear Velocity within the Tubes = u = 3.73 ft/sec

Deduction:
This velocity is in the allowable range so we proceed further with 1-4 Pass
Exchanger.

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1 – 4 Pass Arrangement calculation:
Calculation of reynolds no for water:
NRe = (density×velocity*Di)/µ
NRe = 23302.51
Calculation of Prandtl No for water:
Npr = (Cp×µ)/k
Npr = 5.16
Calculation of L/Di = (16 ft / 0.0516 ft) =310
Calculation Of jh factor
Which from chart comes to be = 80
Using value of jh to calculate hi by using correlation
jh = [hi (Di × Npr1/3)] / k
hi = 959.115
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Summary of tube side Calculation...

Nre = 23302.51
Npr = 5.16
µ/µw = 1
Jh = 80
hi = 959.11 (Btu/hr-
ft2-oF)
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SHELL SIDE CALCULATIONS:
1. Selecting Tube Arrangement:
Triangular (0.75 inch O.D tubes on 1 inch
triangular pitch)
2. Shell Diameter:
From the tables we see that the shell
which can accommodate 180 tubes
have I.D =17.25 inches.
Inside Diameter of Shell=Ds=1.4375ft
Pitch=PT=0.0833ft
3. Selecting Baffle:
Select 25% cut segmental baffles.
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SHELL SIDE CALCULATIONS:
4. Selecting Baffle Spacing:
According to the TEMA standards the
allowed baffle spacing is 0.2Ds--------Ds
we consider
Baffle Spacing B = 0.66×Ds
Baffle Spacing = 0.95ft
5. Calculating tube clearance:
Tube Clearance=Pitch - O.D
Tube Clearance= PD = 0.0208ft

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SHELL SIDE CALCULATIONS:
6. Calculating flow area:
Flow Area = PD × B ×Ds
PT
Flow Area = 0.3409 ft2
7. Calculating mass velocity for ammonia:
Mass Velocity of Ammonia Gs
= Mass Flow Rate of Ammonia

Flow Area
Mass Velocity of Ammonia
= 28950.45 lb/hr-ft2
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SHELL SIDE CALCULATIONS:
8.Calculating hydraulic diameter:
For Triangular Pitch hydraulic diameter
can be calculated by using formula
Hydraulic Diameter
DH = 4(0.43×PT2-.39275×O.D2)/1.571×O.D
So;
Hydraulic Diameter = 0.059 ft
9. Calculating shell side reynold's number:
Shell Side Reynold’s Number=
DH×Gs/µh = 63262.09
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SHELL SIDE CALCULATIONS:
10.Calculating shell side Prandtl number:
Shell Side Prandtl Number
= Cph×µh/kh = 0.81
11. Evaluating Colburn's Factor from
chart:
Colburn’s Factor (jh)=140
As jh= ho× (Pr) -0.33 ×DH/kh
Thus ho= jh/(Pr) -0.33 ×DH/kh
Outside Heat Transfer Coefficient
= 39.063 Btu/hr-ft-oF
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SHELL SIDE CALCULATIONS:

12. Deducing inside and outside heat

transfer Dirt co-efficient from data
tables:
Now from the tables we see that for
ammonia water systems
Inside Heat Transfer Dirt
Coefficient=hi,d=1007.516Btu/hr-ft2-oF
Outside Heat Transfer
Coefficient=ho,d=3526.306 Btu/hr-ft2-oF

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SHELL SIDE CALCULATIONS:
13. Selecting compatible Materials Of
Construction
Material selected Carbon steel.
Thermal Conductivity of Carbon Steel
= kw =29.913Btu/hr-ft-oF

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 Calculation
The overallOfheat
Overall Heat
transfer Transfercan
coefficient Coefficient:
be
calculated from the following formula
1 = O.D + O.D .
Udo ((hi ×I.D) (hi.d × I.D)

+ O.D × Xw × ln(O.D/I.D) + 1 + 1 .
[kw× (O.D-I.D)] ho ho.d

Overall Heat Transfer Dirt Coefficient

Udo = 35.03 Btu/hr-ft2-oF

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Calculation of LMTD Correction Factor
As R = (T1-T2)/(t2-t1)
R = 15
P = (t2-t1)/(T1-t1)
P = 0.0625
Now there is a well known equation
for LMTD correction factor
F= (R2+1)0.5ln (1-P/1-RP) .
(R-1) × ln [2-P(R+1-(R2+1)0.5]
2- P[R+1+ (R2+1)0.5]
F = 0.838
The value of F is acceptable as it is above 0.75.

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 AREA VERIFICATION:
Area Required AR= Q/Udo × F × LMTD
Area Required = 517.487ft2
Area Available AA
= 3.142×O.D×Length×Number Of tubes
Area Available = 565.56ft2
Percentage excess area:
% excess area
=100× (AA-AR)/AR
% excess area = 9.29%
Note:
Since an excess area of 10% is allowed
so our design is acceptable
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 Part (C)

Hydraulic Design involves:

Pressure Drop calculation
across:
Tube Side
Shell Side

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Pressure Drop Calculations across Tube side…

Using The Relation

∆Pt =f x G2t x L x n .
2 x g x p x Di x φ t
ΔPt = 3194.77 N/m2 = 0.463 lbf/in2
Where:
f = friction factor.
Gt = Mass velocity of tube side fluid.
n = no. of tube passes.
φt = Dimensionless Viscosity ratio.
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Pressure Drop Calculations across Tube side…

Return Losses Can Be Calculated As

∆Pr = 4n( V2) = 1.495 lbf/in2
2g
Total Pressure Losses:
ΔPT = ΔPt + ΔPr = 1.958 lbf/in2

Note: Pressure Drop is in allowable limit.

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Pressure Drop Calculations across shell side…

Using The Relation

∆Ps = f sx G2s x Ds x (N b+1) .
2 x g x ps x DHx φs

∆P
N
s == 352.46 Kg/m
Tube Length
2
= 0.5 lbf
- 1 = 16
/ in 2
b
Baffle Spacing
Note: This pressure drop is in allowable
limit.
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 THANK’S …

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 Any Question ?

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