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service
Heating and cooling
Agitated vessel
Fired heaters
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BASIC THEORY
General equation for heat transfer across a surface is
Q = heat transferred per unit time, W
U = the overall heat transfer coefficient, W/m2oC
A = heat-transfer area, m2
Tm= the mean temperature difference, oC
Q UATm
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Geometry
Resistances to
heat transfer
outside
inside
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TRANSFER COEFFICIENTS
Uo=overall coefficient on outside area of tube, W/m2 oC
ho=outside film coefficient, W/m2 oC
hi =inside film coefficient, W/m2 oC
hod=outside dirt coefficient, W/m2 oC
hid=inside dirt coefficient, W/m2 oC
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Uo
7
ho
hod
2k w
di hid
di hi
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COMMENTS
Magnitude of hs depends on:
nature of the process (conduction, convection, radiation,
condensation, etc.)
Physical properties (density, heat capacity, viscosity, thermal
conductivity)
Fluid flow rates
Physical arrangement of exchanger
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4-trial value of
OHTC (U)
3- Type of
exchanger
7-Exchanger
layout
8-hi and ho
Uo
ho
hod
i o 1 do 1
2k w
d i hid d i hi
10-Calculate p
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Consequences
Heat transfer resistance is increased which
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Advantages
Less costly than removable bundle designs
Provides maximum amount of surface for a given shell and tube diameter
Provides for single and multiple tube passes to assure proper velocity
May be interchangeable with other manufacturers of the same TEMA type
Limitations
Shell side can be cleaned only by chemical methods
No provision to allow for differential thermal expansion, must use an
expansion joint
Applications
Oil Coolers, Liquid to Liquid, Vapor condensers, reboilers, gas coolers
Generally, more viscous and warmer fluids flow through the shell
Corrosive or high fouling fluids should flow inside the tubes
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Advantages
Floating tube-sheet allows for differential thermal expansion between the
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Limitations
Fluids in both the shell and tube circuits must be nonvolatile, non-toxic
Tube side passes limited to single or two pass design
All tubes are attached to two tube-sheets. Tubes cannot expand
Applications
Intercoolers and after-coolers, air inside the tubes
Coolers with water inside the tubes
Jacket water coolers or other high differential temperature duty
Place hot side fluid through the shell with entry nearest the front end
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Advantages
Floating tube-sheet allows for differential thermal expansion between
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Limitations
Shell fluids limited to non volatile, non toxic materials
Applications
Flammable or toxic liquids in the tube circuit
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Advantages
Floating head design allows for differential thermal expansion between the shell
Limitations
Shell cover, split ring and floating head cover must be removed to remove the tube
Applications
Chemical processing applications for toxic fluids
Special intercoolers and after-coolers
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Limitations
For a given set of conditions, this TEMA style is the most expensive
design
Less surface per given shell and tube diameter than other
removable designs
Applications
Chemical processing applications for toxic fluids
Hydrocarbon fluid condensers
General industrial applications requiring frequent cleaning
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Advantages
U-tube design allows for differential thermal expansion between the shell and the tube
Limitations
Applications
Oil, chemical and water heating applications
Excellent in steam to liquid applications
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TUBES DIMENSIONS
Range: 16 mm to 50 mm
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TUBE ARRANGEMENTS
A.
Equilateral triangular
B.
Square
C.
Rotated square
P1
P1
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1 / n1
Nt
Db d o
K1
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Baffles
Purpose:
Direct flow across the tubes
Increase heat transfer
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Temperature
T1
t2
T2
t2
t1
t1
shell
T2
tubes
Heat transferred
Heat transferred
t2
T2
t2
t1
t1
T1
T1
Tlm
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T2
T1 t2 T2 t1
T t
ln 1 2
T2 t1
Counter-current
Tlm
T1 t1 T2 t2
T t
ln 1 1
T2 t 2
Co-current
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LMTD
tm Ft tlm
Ft f ( R, S )
T1 T2
t2 t1
R
,S
t2 t1
T1 t1
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Corrosion
The more corrosive fluid should be allocated
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Fouling
The fluid that has the greatest tendency to foul the heattransfer surfaces should be placed in the tubes.
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Fluid Temperatures
If the temperatures are high enough to require the use of
special alloys placing the higher temperature fluid in the
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Operating Pressure
The higher pressure stream should be allocated to the
tube-side. High-pressure tubes will be cheaper than a
high-pressure shell.
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Pressure Drop
For the same pressure drop, higher heat-transfer
coefficients will be obtained on the tube-side than the
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Viscosity
Generally, a higher heat-transfer coefficient will be obtained by
allocating the more viscous material to the shell-side, providing the
achieved in the shell it is better to place the fluid in the tubes, as the
tube-side heat-transfer coefficient can be predicted with more
certainty.
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design.
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Vapors
Vacuum
50-70 m/s
Atmospheric pressure
10-30 m/s
Shell side
0.3-1 m/s
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PRESSURE DROP
Liquids
p = 35 kN/m2
Viscosity is 1 to 10
mN s/m2
p = 50-70 kN/m2
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High vacuum
p = 0.4-0.8 kN/m2
Medium vacuum
p = 0.1 x absolute pressure
1 to 2 bar
p = 0.5 x system gauge
pressure
Above 10 bar
p = 0.1 x system gauge pressure
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where
Nu = Nusselt number = (hide/kf),
Re = Reynolds number = (utde/) = (Gtde/),
Pr = Prandtl number = (Cp/kf)
hi = inside coefficient, W/m2C,
perimeter )
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= di for tubes,
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Now,
a = 0.8.
b = 0.3 for cooling
= 0.4 for heating.
c = 0.14 for flow in tubes.
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E = 0.0225exp(-0.0225(ln Pr)2)
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the hydraulic mean diameter may be used in place of the pipe diameter
and the formulae for circular pipes can then be applied without
introducing a large error. This method of approach is entirely
empirical.
The hydraulic mean diameter DH is defined as four times
the hydraulic mean radius rH. Hydraulic mean radius is defined as the
flow cross-sectional area divided by the wetted perimeter:
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Laminar flow
Below a Reynolds number of about 2000 the flow in pipes will be
laminar.
Providing the natural convection effects are small, which will
normally be so in forced convection, to estimate the film heattransfer coefficient given equation will be used:
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The use of the jh factor enables data for laminar and turbulent flow
to be represented on the same graph.
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DESIGN METHODS
Kern Method
Bell or Bell-Delware Method
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KERN'S METHOD
The shell equivalent diameter is calculated using the flow area
between the tubes taken in the axial direction (parallel to the tubes)
and the wetted perimeter of the tubes;
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Procedure
1. Calculate the area for cross-flow As for the hypothetical row of
tubes at the shell equator, given by:
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2. Calculate the shell-side mass velocity Gs and the linear velocity us:
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De
4 PT2 do2 / 4
De
do
square
4 PT2 3 / 4 do2 / 8
De
do / 2
triangular
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5. For the calculated Reynolds number, read the value of jh, from
graph for the selected baffle cut and tube arrangement, and
calculate the shell-side heat transfer coefficient hs from:
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Bells method
In Bells method the heat-transfer coefficient and pressure
drop are estimated from correlations for flow over ideal tubebanks, and the effects of leakage, bypassing and flow in the
window zone are allowed for by applying correction factors.
Heat-transfer coefficient
The total correction will vary from 0.6 for a poorly designed
exchanger with large clearances to 0.9 for a well-designed
exchanger.
Figure
Pressure drop
Cross-flow zones
The pressure drop in the cross-flow zones between the baffle
tips is calculated from correlations for ideal tube banks, and
corrected for leakage and bypassing.
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