Design of Shell and Tube Heat Exchanger PDF

DESIGN OF SHELL AND TUBE HEAT EXCHANGER
INSTITUTE OF TECHNOLOGY
SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING
DESIGN OF SHELL AND TUBE HEAT EXCHANGER (SINGLE

PHASE FLOW)
PREPARED
BY
TSEGAY GEBRU
UNDER THE GUIDANCE
OF
DR. MULUWORK KAHSAY
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DECLARATION
I certify that the work presented in this paper is, to the best of my knowledge
and belief, original, except as acknowledge in the text, and that the material
has not been submitted, either in whole or in part, at this or any other
university.
I acknowledge that I have read and understood the university rules,
requirements, procedures and policy relating to my seminar award. I certify
that I have completed with the rules, requirements, procedures and policy of
the university (as they may be from time to time).
1. __________________________ ________________
Name of coordinator Signature
2. __________________________ ________________
Name of advisor Signature
3. ________________________ ____________
Name of department Signature
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ACKNOWLEDGEMENT
First of all thanks to almighty GOD for giving me patience to start and
finalize this paper.
I am deeply extending my sincere appreciation to my advisor, Dr.
Muluwork K., for his valuable advice, constant support, commitment,
dedication, encouragement and precious guidance, creative suggestions and
critical comments, and for his being everlasting enthusiastic from the
beginning to the end of the seminar. Without his urge, no doubt, this work
would not have been possible at all.
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NOMENCLATURE
Symbol description unit
Q total heat transfer W
mh mass of hot fluid kg
mc mass of cold fluid kg
Cph specific heat of hot fluid kJ/kg.k
Cpc specific heat of cold fluid kJ/kg.k
Thi hot fluid temperature at inlet k
Tho hot fluid temperature at exit k
Tci cold fluid temperature at inlet k
Tco cold fluid temperature at exit k
U overall heat transfer coefficient W/m2.k
A total area of shell m2
ΔTm log mean temperature k
ΔT1 temperature difference one k
ΔT2 temperature difference two k
C Capacity coefficient -
Cmax maximum capacity coefficient -
Cmin minimum capacity coefficient -
do outer diameter of tube m
di inner diameter of tube m
L length of shell m
Pt tube pitch m
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Ds internal shell diameter m
Nt number of tubes -
hi tube side heat transfer coefficient W/m2k
ho shell side heat transfer coefficient W/m2k
Uass assumed over all heat transfer coefficient W/m2k
Uo calculated over all heat transfer coefficient W/m2k
Are required area m2
ΔPt tube side pressure drop pa
ΔPs shell side pressure drop pa
ΔPft friction loss pressure drop pa
ΔPrt return loss pressure drop pa
P pressure pa
Re renoldous number -
Pr pranditle number -
Nu nussult number -
K thermal conductivity W/mk
u velocity m/s
t thickness m
V volume m3
Cb clearance m
Db bundle diameter m
De equivalent diameter m
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PAGE INDEX
ABSTRACT .................................................................................................. ix
CHAPTER ONE ........................................................................................... 1
1.1. INTRODUCTION .................................................................................. 1
1.2. STATEMENT OF THE PROBLEM ...................................................... 3
1.3. OBJECTIVE ............................................................................................. 4
1.3.1. General Objective ....................................................................................... 4
1.3.2. Specific Objective ........................................................................................ 4
CHAPTER TWO .......................................................................................... 5
THEORY OF SHELL AND TUBE HEAT EXCHANGER ..................... 5
2.1. Classification of heat exchangers ............................................................... 5
2.2. Methods to design shell and tube heat exchanger .................................... 9
2.2.1. LMTD Method ................................................................................................. 9
2.2.2. Ɛ − NTU Method ............................................................................................ 10
CHAPTER THREE .................................................................................... 11
DESIGN CONSIDERATIONS AND ALGORISM DEVELOPMENT 11
3.1. Thermal design considerations ................................................................. 11
3.1.1. Shell ................................................................................................................. 11
3.1.2. Tube ................................................................................................................ 12
3.1.3. Tube pitch, tube-layout and tube-count ...................................................... 12
3.1.4. Tube passes..................................................................................................... 13
3.1.5. Tube sheet ....................................................................................................... 13
3.1.6. Baffles ............................................................................................................. 14
3.1.7. Fouling Considerations ................................................................................. 16
3.1.8. Selection of fluids for tube and the shell side .............................................. 17
3.2. Thermal Design Procedure (algorism development) ............................. 18
3.2.1. Process (thermal) design procedure ............................................................. 18
CHAPTER FOUR....................................................................................... 22
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DESIGN ANALYSIS .................................................................................. 22

4.1. Design problem .......................................................................................... 22
4.2. Rise out given data ..................................................................................... 22
4.3. Design procedures (Solution) .................................................................... 22
4.3.1. Duty calculation ............................................................................................. 22
4.3.2. Determine fluid properties: .......................................................................... 23
4.3.3. Over all heat transfer coefficient assumption ............................................. 24
4.3.4. Calculation of log mean temperature .......................................................... 24
4.3.4. Find heat transfer area.................................................................................. 25
4.3.5. Layout and tube size decision ....................................................................... 26
4.3.6. Calculation for number of tubes .................................................................. 26
4.3.6. Calculation of bundle and shell diameter .................................................... 27
4.3.7. Tube side heat transfer coefficient ............................................................... 27
4.3.8. Calculation of Shell side heat transfer coefficient ...................................... 28
4.3.9. Calculation of Overall heat transfer coefficients ........................................ 29
4.3.10. Check for Pressure drop ............................................................................. 29
4.4. Cost estimation ........................................................................................... 32
4.4.1. The factorial method cost estimation ........................................................... 32
CHAPTER FIVE ........................................................................................ 34
DESIGN ANALYSIS USING C++ PROGRAM ..................................... 34
5.1. Program development of shell and tube heat exchanger design ........... 34
Summary of shell and tube heat exchanger design (single phase) ......... 37
Recommendation ........................................................................................ 38
Appendix ...................................................................................................... 39
Design Summary: ............................................................................................. 39
The program developed above gives the following output when the
assumption inputs are varying. ....................................................................... 40
Reference ..................................................................................................... 46
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TABLE INDEX
Table 2.1. Features Of Shell And Tube Type Exchangers. ................................................ 6
Table 3.1. Common Tube Layouts. .................................................................................. 13
Table 3.2. Typical Values Of Fouling Coefficients And Resistances. ............................. 17
Table 3.3. Guidelines For Placing The Fluid In Order Of Priority .................................. 18
Table4.1. Physical Properties Of Fluids ........................................................................... 23
FIGURE INDEX
Figure 2.1. Fixed-Tube Heat Exchanger. ........................................................................... 7
Figure 2.2. Floating-Head Heat Exchanger (Non-Pull Through Type) ............................. 7
Figure 2.3. Removable U-Tube Heat Exchanger. .............................................................. 8
Figure 3.1. Heat Exchanger Tube-Layouts. ..................................................................... 13
Figure 3.2. Different Type Of Heat Exchanger Baffles: A). Cut-Segmental Baffle, B).
Disc And Doughnut Baffle, C). Orifice Baffle ................................................................. 16
Fig4.2. Parallel Flow Arrangement .................................................................................. 25
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ABSTRACT
Heat exchangers are systems of thermal engineering in which its

applications are occurred in different industries. Heat exchangers are the
basic or heart of once organized plant since it transfers energy to the
processing plant.
This paper describes about the thermal design of shell and tube heat
exchangers. To design Shell and tube heat exchanger there are two methods
this paper follows the log mean temperature difference method and its
procedure is based on single phase flow type. The Borland C++ software is
also used to iterate (calculate) the numerical values with different
specifications.
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CHAPTER ONE
1.1. INTRODUCTION
Shell and tube heat exchangers are used extensively throughout the process
industry and as such a basic understanding of their design, construction and
performance is important to the practicing engineer.
The objective of this paper is to provide a concise review of the key issues involved
in their thermal design without having to refer to the extensive literature available
on this topic.
The optimum thermal design of a shell and tube heat exchanger involves the
consideration of many interacting design parameters which can be summarized as
follows:
Process
 Process fluid assignments to shell side or tube side.
 Selection of stream temperature specifications.
 Setting shell side and tube side pressure drop design limits.
 Setting shell side and tube side velocity limits.
 Selection of heat transfer models and fouling coefficients for shell
side and tube side.
Mechanical
 Selection of heat exchanger TEMA layout and number of passes.
 Specification of tube parameters - size, layout, pitch and material.
 Setting upper and lower design limits on tube length.
 Specification of shell side parameters materials, baffle cut, baffle
spacing and clearances.
 Setting upper and lower design limits on shell diameter, baffle cut and
baffle spacing.
There are several software design and rating packages available, including A spen
BJAC, HTFS and CC-THERM, which enable the designer to study the effects of the
many interacting design parameters and achieve an optimum thermal design. These
packages are supported by extensive component physical property databases and
BAHIRDAR UNIVERSITY INSTITUTE OF THECHNOLOGY SMIE (THERMAL) Page 1

thermodynamic models.
It must be stressed that software convergence and optimisation routines will not
necessarily achieve a practical and economic design without the designer forcing
parameters in an intuitive way. It is recommended that the design be checked by running
the model in the rating mode..
Detailed mechanical design and construction involving tube sheet layouts, thicknesses,
clearances, tube supports and thermal expansion are not considered but the thermal
design must be consistent with the practical requirements.

1.2. STATEMENT OF THE PROBLEM
Products of crude oil are used in different application areas especially in industries
(textile industry) but from their ordinary properties the amount of energy transferred
becomes un sufficient to the required process and also the final out put product gained
from the process is also quality less.

1.3. OBJECTIVE
1.3.1. General Objective

The general objective of this paper is to know and understand design of shell and tube
heat exchanger. Hence design of shell and tube heat exchanger for single phase flow
manually and using C++ programing is the general objective.
1.3.2. Specific Objective

Based on the general objective the specific objective is considering specific activities that
build up to the general objective. Due to this the specific objective of this paper is to
know and practice the kern method (log min temperature difference method LMTD and
effectiveness method NTU) and to develop software programing capabilities (Borland
C++).

CHAPTER TWO
THEORY OF SHELL AND TUBE HEAT EXCHANGER
2.1. Classification of heat exchangers
Transfer of heat from one fluid to another is an important operation for most of the
chemical industries. The most common application of heat transfer is in designing of heat
transfer equipment for exchanging heat from one fluid to another fluid. Such devices for
efficient transfer of heat are generally called Heat Exchanger. Heat exchangers are
normally classified depending on the transfer process occurring in them.
Amongst of all type of exchangers, shell and tube exchangers are most commonly used
heat exchange equipment. The common types of shell and tube exchangers are:
Fixed tube-sheet exchanger (non-removable tube bundle): The simplest and cheapest
type of shell and tube exchanger is with fixed tube sheet design. In this type of
exchangers the tube sheet is welded to the shell and no relative movement between the
shell and tube bundle is possible (Figure 1.1).
Removable tube bundle: Tube bundle may be removed for ease of cleaning and
replacement. Removable tube bundle exchangers further can be categorized in floating-
head and U-tube exchanger.

Floating-head exchanger: It consists of a stationery tube sheet which  is
 clamped with the shell flange. At the opposite end of the bundle, the tubes
may expand into a freely riding floating-head or floating tube sheet. A
floating head cover is bolted to the tube sheet and the entire bundle can be
removed for cleaning and inspection of the interior. This type of exchanger

is shown in Figure 1.2.
U-tube exchanger: This type of exchangers consists of tubes which are bent in the form
of a „U‟ and rolled back into the tube sheet shown in the Figure 1.3. This means that it
will omit some tubes at the Centre of the tube bundle depending on the tube arrangement.
The tubes can expand freely towards the „U‟ bend end. The different operational and
constructional advantages and limitations depending on applications of shell and tube
exchangers are summarized in Table 2.1. TEMA (USA) and IS: 4503-1967 (India)
standards provide the guidelines for the mechanical design of unfired shell and tube heat
exchangers. As shown in the Table 2.1, TEMA 3-digit codes specify the types of front-

end, shell, and rear-end of shell and tube exchangers.
Table 2.1. Features of shell and tube type exchangers.
Shell and Typical Advantages Limitations

Tube TEMA code
Exchangers
Fixed tube BEM, AEM, Provides maximum heat Shell side / out side of the tubes are
sheet NEN transfer area for a given inaccessible for mechanical cleaning.
shell and tube diameter.
No provision to allow for differential thermal
Provides for single and expansion developed between the tube and
multiple tube passes to the shell side. This can be taken care by
assure proper velocity. providing expansion joint on the shell side.
Less costly than

removable bundle designs.
Floating- AEW, BEW, Floating tube sheet allows To provide the floating-head cover it is
head BEP, AEP, for differential thermal necessary to bolt it to the tube sheet. The bolt
AES, BES expansion between the circle requires the use of space where it
shell and the tube bundle. would be possible to place a large number of
tubes.
Both the tube bundle and
the shell side can be Tubes cannot expand independently so that
inspected and cleaned huge thermal shock applications should be
mechanically. avoided.
Packing materials produce limits on design

pressure and temperature.
U-tube BEU, AEU U-tube design allows for Because of U-bend some tubes are omitted at
differential thermal the centre of the tube bundle.
expansion between the
shell and the tube bundle Because of U-bend, tubes can be cleaned only
as well as for individual by chemical methods.
tubes.
Due to U-tube nesting, individual tube is
Both the tube bundle difficult to replace.
and the shell side can be
inspected and cleaned No single tube pass or true countercurrent
mechanically. flow is possible.
Less costly than floating Tube wall thickness at the U-bend is thinner
head or packed floating than at straight portion of the tubes.
head designs.

Draining of tube circuit is difficult when

positioned with the vertical position with the
head side upward.
Description for this figure is on Table 2.1[3]
Figure 2.1. Fixed-tube heat exchanger.

Figure 2.2. Floating-head heat exchanger (non-pull through type)

Figure 2.3. Removable U-tube heat exchanger.
Typical parts and connections shown in Figures 2.1, 2.2 and 2.3 (IS: 4503-1967) are
summarized below.
1. Shell 16. Tubes (U-type)
2. Shell cover 17. Tie rods and spacers
3. Shell flange (channel end) 18. Transverse (or cross) baffles or support plates
4. Shell flange (cover end) 19. Longitudinal baffles
5. Shell nozzle or branch 20. Impingement baffles
6. Floating tube sheet 21. Floating head support
7. Floating head cover 22. Pass partition
8. Floating head flange 23. Vent connection
9. Floating head gland 24. Drain connection
10. Floating head backing ring 25. Instrument connection
11. Stationary tube sheet 26. Expansion bellows
12. Channel or stationary head 27. Support saddles
13. Channel cover 28. Lifting lugs
14. Channel nozzle or branch 29. Weir
15. Tube (straight) 30. Liquid level connection

2.2. Methods to design shell and tube heat exchanger

The goal of heat exchanger design is to relate the inlet and outlet temperatures, the
overall heat transfer coefficient, and the geometry of the heat exchanger, to the rate of
heat transfer between the two fluids. The two most common heat exchanger design
problems are those of rating and sizing. We will limit ourselves to the design of
recuperators only. That is, the design of a two fluid heat exchanger used for the purposes
of recovering waste heat. We will begin first, by discussing the basic principles of heat
transfer for a heat exchanger.
( ) ( )
By conservation of energy both on hot and cold fluids are the same heat transfer. And
also using overall heat transfer method it can be determined as;
Where, ΔTm = f(Thi, Tho, Tci, Tco)

It is now clear that the problem of heat exchanger design comes down to obtaining an
expression for the mean temperature difference. Expressions for many flow
configurations, i.e. parallel flow, counter flow, and cross flow, have been obtained in the
heat transfer field. We will examine these basic expressions later. Two approaches to heat
exchanger design that will be discussed are the LMTD method and the effectiveness
NTU method. Each of these methods has particular advantages depending upon the
nature of the problem specification.
2.2.1. LMTD Method

The log mean temperature difference (LMTD) is derived in all basic heat transfer
texts. It may be written for a parallel flow or counter flow arrangement. The LMTD
has the form:
The LMTD method assumes that both inlet and outlet temperatures are known.
When this is not the case, the solution to a heat exchanger problem becomes some-
what tedious. An alternate method based upon heat exchanger effectiveness is more
appropriate for this type of analysis. If ΔT1 = ΔT2 = ΔT, then the expression for
the LMTD reduces simply to ΔT.
2.2.2. Ɛ − NTU Method

The effectiveness / number of transfer units (NTU) method was developed to simplify a
number of heat exchanger design problems. The heat exchanger effectiveness is defined
as the ratio of the actual heat transfer rate to the maximum possible heat transfer rate if
there were infinite surface area. The heat exchanger effectiveness depends upon whether
the hot fluid or cold fluid is a minimum fluid. That is the fluid which has the smaller
capacity coefficient C = m*Cp.
( )
( )

CHAPTER THREE
DESIGN CONSIDERATIONS AND ALGORISM DEVELOPMENT
The flow rates of both hot and cold streams, their terminal temperatures and fluid
properties are the primary inputs of thermal design of heat exchangers.
3.1. Thermal design considerations
Thermal design of a shell and tube heat exchanger typically includes the determination of
heat transfer area, number of tubes, tube length and diameter, tube layout, number of
shell and tube passes, type of heat exchanger (fixed tube sheet, removable tube bundle
etc), tube pitch, number of baffles, its type and size, shell and tube side pressure drop etc.
3.1.1. Shell
Shell is the container for the shell fluid and the tube bundle is placed inside the shell.
Shell diameter should be selected in such a way to give a close fit of the tube bundle. The
clearance between the tube bundle and inner shell wall depends on the type of exchanger
([2]; page 647). Shells are usually fabricated from standard steel pipe with satisfactory
corrosion allowance. 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.

3.1.2. Tube
Tube OD of ¾ and 1‟‟ are very common to design a compact heat exchanger. The most
efficient condition for heat transfer is to have the maximum number of tubes in the shell
to increase turbulence. The tube thickness should be enough to withstand the internal
pressure along with the adequate corrosion allowance. The tube thickness is expressed in
terms of BWG (Birmingham Wire Gauge) and true outside diameter (OD). 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. Finned tubes are also used when
fluid with low heat transfer coefficient flows in the shell side. Stainless steel, admiralty
brass, copper, bronze and alloys of copper-nickel are the commonly used tube materials:
3.1.3. Tube pitch, tube-layout and tube-count
Tube pitch is the shortest centre to centre distance between the adjacent tubes. The tubes
are generally placed in square or triangular patterns (pitch) as shown in the Figure 3.1.
The widely used tube layouts are illustrated in Table 3.1.
The number of tubes that can be accommodated in a given shell ID is called tube count.

The tube count depends on the factors like shell ID, OD of tube, tube pitch, tube
layout, number of tube passes, type of heat exchanger and design pressure.
3.1.4. Tube passes
The number of passes is chosen to get the required tube side fluid velocity to obtain
greater heat transfer co-efficient and also to reduce scale formation. The tube passes vary
from 1 to 16. The tube passes of 1, 2 and 4 are common in application. The partition built
into exchanger head known as partition plate (also called pass partition) is used to direct
the tube side flow.
Table 3.1. Common tube layouts.
Tube OD, in Pitch type Tube pitch, in

34 Square 1
1 114
34 Triangular 15
16
34 1
+
+ + +
Flow Flow Flow + +
+ + + + Pitch +
Pitch Pitch
a). Square b). Triangular c). Rotated square
Figure 3.1. Heat exchanger tube-layouts.
3.1.5. Tube sheet
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.
The tubes are attached to tube sheet with two or more grooves in the tube sheet wall by
„tube rolling‟. The tube metal is forced to move into the grooves forming an excellent

tight seal. This is the most common type of fixing arrangement in large industrial
exchangers. The tube sheet thickness should be greater than the tube outside diameter to
make a good seal. The recommended standards (IS:4503 or TEMA) should be followed
to select the minimum tube sheet thickness.
3.1.6. 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. The various types of baffles are
shown in Figure 3.2. 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. Figure 3.2 also shows two other types of baffles

Shell
a). Cut-segmental baffle
Shell Doughnut
Disc
b). Disc and doughnut baffle
Baffle
Orifice
c). Orifice baffle
Figure 3.2. Different type of heat exchanger baffles: a). Cut-segmental baffle, b). Disc
and doughnut baffle, c). Orifice baffle
3.1.7. Fouling Considerations
The most of the process fluids in the exchanger foul the heat transfer surface. 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.
The effect of fouling is considered in heat exchanger design by including the tube side
and shell side fouling resistances. Typical values for the fouling coefficients and
resistances are summarized in Table 3.2. The fouling resistance (fouling factor) for
petroleum fractions are available in the text book.
Table 3.2. Typical values of fouling coefficients and resistances.

-2 -1 2 -1
Fluid Coefficient (W.m .°C ) Resistance (m .°C.W )
River water 3000-12,000 0.0003-0.0001
Sea water 1000-3000 0.001-0.0003
Cooling water (towers) 3000-6000 0.0003-0.00017
Towns water (soft) 3000-5000 0.0003-0.0002
Towns water (hard) 1000-2000 0.001-0.0005
Steam condensate 1500-5000 0.00067-0.0002
Steam (oil free) 4000- 10,000 0.0025-0.0001
Steam (oil traces) 2000-5000 0.0005-0.0002
Refrigerated brine 3000-5000 0.0003-0.0002
Air and industrial gases 5000-10,000 0.0002-0.000-1
Flue gases 2000-5000 0.0005-0.0002
Organic vapors 5000 0.0002
Organic liquids 5000 0.0002
Light hydrocarbons 5000 0.0002
Heavy hydrocarbons 2000 0.0005
Boiling organics 2500 0.0004
Condensing organics 5000 0.0002
Heat transfer fluids 5000 0.0002
Aqueous salt solutions 3000-5000 0.0003-0.0002
3.1.8. Selection of fluids for tube and the shell side
The routing of the shell side and tube side fluids has considerable effects on the heat
exchanger design. Some general guidelines for positioning the fluids are given in Table
3.3. It should be understood that these guidelines are not ironclad rules and the optimal
fluid placement depends on many factors that are service specific.

Table 3.3. Guidelines for placing the fluid in order of priority

Tube-side fluid Shell-side fluid
Corrosive fluid Condensing vapor (unless corrosive)
Cooling water Fluid with large temperature difference (>40°C)
Fouling fluid
Less viscous fluid
High-pressure steam
Hotter fluid
3.2. Thermal Design Procedure (algorism development)
3.2.1. Process (thermal) design procedure

Shell and tube heat exchanger is designed by trial and error calculations. The main
design steps of the Kern method are summarized as follows:
S#1. Obtain the required thermo physical properties of hot and cold fluids.
S#2. Perform energy balance and find out the heat duty ( Q ) of the exchanger.
( ) (1)
S#3. Assume a reasonable value of overall heat transfer coefficient (Uo,assm). The value
of Uo,assm with respect to the process hot and cold fluids can be taken from the books.
S#4. Decide tentative number of shell and tube passes ( np ). Determine the LMTD and
the correction factor Ft [1] page 48 Figs. 2.7; FT normally should be greater than 0.75 for
the steady operation of the exchangers. Otherwise it is required to increase the number of
( )( )
passes to obtain higher FT values. ( )
………….(2)
( )
S#5. Calculate heat transfer area (A) required: ……………..(3)
S#6. Select tube material, decide the tube diameter (ID= di , OD = do ), its wall thickness
(in terms of BWG or SWG) and tube length ( L ). Calculate the number of tubes
A
( nt ) required to provide the heat transfer area (A): nt  ………………(4)
 do L
.
4 m ( n p / nt )
Calculate tube side fluid velocity, u  ………………(5)
d 2
i

If u <1 m/s, fix n p so that, Re  4 m ( n p / nt ) 10

4
……………….(6)
 di 
.
Where, m,  and  are mass flow rate, density and viscosity of tube side fluid. However,
this is subject to allowable pressure drop in the tube side of the heat exchanger.
S#7. Decide type of shell and tube exchanger (fixed tube sheet, U-tube etc.). Select the
tube pitch (PT), determine inside shell diameter ( Ds ) that can accommodate the
calculated number of tubes ( nt ). Use the standard tube counts table for this purpose.
Tube counts are available in standard text books [1] page 372 Table 9.3.
S#8. Assign fluid to shell side or tube side (a general guideline for placing the fluids is
summarized in [1] page 376). Select the type of baffle (segmental, doughnut etc.), its size
(i.e. percentage cut, 25% baffles are widely used), spacing ( B ) and number. The baffle
spacing is usually chosen to be within 0.2 Ds to Ds .
Allocation of stream:
 The most fouling fluid flows through the tube, since the tube side is easier
to clean, especially if mechanical cleaning is required.
 The high pressure fluid flows through the tubes.
 The corrosive fluid must flow through the tube.
S#9. Determine the tube side film heat transfer coefficient ( hi ) using the suitable form of
Sieder-Tate equation in laminar and turbulent flow regimes.
Estimate the shell-side film heat transfer coefficient ( ho ) from:

1 0.14
h o D e  c  3   
jH      ……………..(7)

k k   w 

You may consider, 1.0
w
Select the outside tube (shell side) dirt factor ( Rdo ) and inside tube (tube side) dirt factor
( Rdi ) [1].
Calculate overall heat transfer coefficient (Uo,cal ) based on the outside tube area (you
may neglect the tube-wall resistance) including direct factors:

S#10. If 0 < < 30%, go to the next step#11. Otherwise go to the s#5,
calculate heat transfer area (A) required using Uo , cal and repeat the calculations starting
from s#5.
If the calculated shell side heat transfer coefficient ( ho ) is too low, assume closer baffle spacing
( B ) close to 0.2 Ds and recalculate shell side heat transfer coefficient. However, this is subject
to allowable pressure drop across the heat exchanger.
S#11. Calculate % overdesign. Overdesign represents extra surface area provided beyond that
required to compensate for fouling. Typical value of 10% or less is acceptable.
A-A
100
reqd
% Overdesign = ……………..(9)
A
reqd
A = design area of heat transfer in the exchanger; Areqd = required heat transfer area.
S#12. Calculate the tube-side pressure drop ( PT ): (i) pressure drop in the straight section of the
tube (frictional loss) ( Pt ) and (ii) return loss ( Prt ) due to change of direction of fluid in a
„multi-pass exchanger‟.
Total tube side pressure drop: PT = Pt + Prt …………..(10)
S#13. Calculate shell side pressure drop ( PS ): (i) pressure drop for flow across the tube bundle
(frictional loss) ( Ps ) and (ii) return loss ( Prs ) due to change of direction of fluid.
Total shell side pressure drop: PS = Ps + Prs …………..(11)
If the tube-side pressure drop exceeds the allowable pressure drop for the process system,
decrease the number of tube passes or increase number of tubes per pass. Go back to s#6 and
repeat the calculations steps.
If the shell-side pressure drop exceeds the allowable pressure drop, go back to s#7 and repeat the
calculations steps.

Fig. flow chart of design procedure
Fig. Two pass shell and tube heat exchanger

CHAPTER FOUR
DESIGN ANALYSIS
4.1. Design problem

20000kgh-1 of kerosene (420 API*) leaves the base of kerosene side-stripping column at 2000c
and is to be cooled to 900c by exchange with 70000kgh-1 light crude oil (340API) coming from
storage at 400c. the kerosene inters the heat exchanger at a pressure of 5bar and the crude oil at
6.5bar. A pressure drop of 0.8bar the maximum permissible on both the streams, including
nozzle losses. Assuming a pressure drop of 0.1bar for shell inlet and outlets and similarly for
tube inlet and outlet nozzles. Allowance should be made for fouling by including a fouling factor
of 0.00035(wm-2k-1)-1 for the crude stream and 0.0002(wm-2k-1)-1 for the kerosene stream.
4.2. Given data

Hot fluid inlet temperature (T1)= 2000c
Hot fluid outlet temperature (T2) = 900c
Cold fluid inlet temperature (t1) = 400c
Cold fluid outlet temperature (t2) = ?
Fouling factor of hot fluid (Rk) = 0.0002 (for kerosene)
Fouling factor of cold fluid (Rco) = 0.00035 (for crude oil)
Pinlet (for hot fluid) = 5bar
Pinlet (for cold fluid) = 6.5bar
∆pmax (for hot fluid) = 0.8bar
∆pmax (for cold fluid) = 0.8bar.
Mass flow rate of cold fluid ( mco ) = 70000kgh-1
Mass flow rate of hot fluid (mk) = 20000kgh-1
(Subscripts k-for kerosene, co-for crude oil)
4.3. Design procedures (Solution)
4.3.1. Duty calculation

At mean temperature of kerosene, the specific heat capacity is 2.47kj/kg.k

Hence, Q= mk*Cp*(T1-T2)
= (20000/3600)*2.47*(200-90) = 1509.44kW
Since the out late temperature of the cold fluid is not known we can determined using
energy balance equation.
I. Find using mean temperature of the crude oil as equal to the inlet temperature;
(70000/3600)*2.01*(t2-40) = 1509.4kW
t2 = 78.60c
stream mean temperature, Tm =(78.6 +40)/2 =59.30c
II. Find using this stream mean temperature and Cp =2.05 gives; t2 = 77.90c
In the second trial the mean temperature is, Tm =58.90c
Hence, from the two iterations we take the value of t2, t2 = 780c
4.3.2. Determine fluid properties:
Table4.1. physical properties of fluids
Description Unit Shell side Tube side

Inlet Outlet Inlet Outlet
Density kg/m3 690 770 840 800
Viscosity mn/m2s 0.22 0.80 2.4 2.6
Specific Heat kJ/kgK 2.47 2.26 2.05 2.1
Overall heat transfer coefficient: 392W/m2k

Thermal conductivity, k = 0.135W/mk
Other specifications
Tube diameter (od=19mm, Id =14.83mm)
Pitch = 23.81mm
Maximum permissible tube length =7m
Pitch dia = 1.25
Maximum permissible tube side velocity = 2m/s
Maximum permissible shell side velocity = 1m/s

Material: carbon steel to both shell and tube.
4.3.3. Over all heat transfer coefficient assumption

From the given information the overall heat transfer coefficient is vary from 300-
500W/m2oc then we start with 300W/m2oc.
4.3.4. Calculation of log mean temperature

Log mean temperature is the ratio of the change of temperature on one side to the other
side. But the type of fluid flow in tube and shell side plays great value (flow is from state
number one to state number two).
Fig4.1. counter flow arrangement

Fig4.2. Parallel flow arrangement

 Find log mean temperature for counter flow as;
Delt T1= T1-t2=200-78 =122oc
Delt T2=T2-t1=90-40=50oc
TLMTD=(deltT1 – deltT2)/(ln(deltT1/deltT2)) =80.7oc
 Find log mean temperature for parallel flow as;
Delt t1=T1-t2 =200-40=160oc
Delt t2=T2-t1 = 90-78=12oc
TLMTD=(deltT1 – deltT2)/(ln(deltT1/deltT2)) =57.14oc
From those two results we can conclude that the higher value of log mean temperature difference
is better to use because it can reduce the surface area of the exchanger. Hence counter flow is
better to use.
The value of mean temperature using counter flow is;
ΔTm = f*TLMTD = 0.85*80.7=68.6oc
Where ‘f’ can be determined from temperature correction factor graph.
4.3.4. Find heat transfer area
where Uo =300W/m2.K

A=1509.4/(300*68.6) = 73.34m2
From this we can determine diameter, D A=(π/4)D2  D= 9.66m
4.3.5. Layout and tube size decision

Allocation of stream:
 The most fouling fluid flows through the tube, since the tube side is easier to clean,
especially if mechanical cleaning is required.
 The high pressure fluid flows through the tubes.
 The corrosive fluid must flow through the tube.
Hence the crude is dirtier than the kerosene, so put the crude throw the tubes and the kerosene in
the shell.
Dimensional specification for tubes from standard table
From the tube lay out system lets tray to use triangular layout
Use outside diameter, do of tube =19.05mm
Internal diameter of tube14.83mm
Length of tube, Lt=5m
Triangular Pitch 23.81mm
Calculate pitch to outside diameter ratio = 23.81/19.05 = 1.25
4.3.6. Calculation for number of tubes

Using outside diameter find the area of tube as, At1 = π*do*Lt
=π*19.05*10-3*5=0.2992m2
Next find number of tubes, Nt = A/At1 =73.34/0.2992 =245, say 240 this is from standard table
Since the number of tube is changed the tube length must be find.
L = A/(π*do*Nt) =73.34/(240*19.05*10-3*π) = 5.10m
Number of tubes per pass, Ntpp = Nt/Ntp =240/2 =120
Check the tube side velocity at this state for reasonability from standards so the cross sectional
area of the tube using internal diameter is;
(π*di2 )/4 =(1/4)*π*(14.83*10-3)2 =0.000172m2
Find the tube cross sectional area per pass =A/Ntpp =0.02073m3
Volumetric flow rate V =m/ρ =(70000/3600)*1/820 =0.0237m3/s
Know using those two ratios find the tube side velocity and check if it is within the specification.

ut = 0.0237/0.02073 = 1.14m/s since this is less than 2m/s the assumption is acceptable. But
pressure drop will be checked.
4.3.6. Calculation of bundle and shell diameter

From the standard table for two tube pass and square pitch layout tube, K1 = 0.156, n1 = 0.436, Cs
= 91 mm and the bundle diameter will be;
Dbr =do*(Nt/k1)n1= 19.05(240/0.156)0.436 = 465.9mm
From the standard table for two tube pass and triangular pitch layout tube, K1 = 0.249, n1 = 2.207
and the bundle diameter will be;
Dbt =do*(Nt/k1)n1 =19.05(240/0.249)1/2.207 =428mm
Since bundle diameter of square pitch is greater than bundle diameter of triangular pitch the
smallest diameter is better to use.
With this concept the corresponding shell clearance for Db = 0.428m and split ring floating head.
For a split ring floating head exchanger the typical shell clearance is 56mm, so the shell inside
diameter is;
Ds = Dbt+C =428 + 56 = 484mm
Tubes in center raw, Nc = Db/Pt = 428/23.81 = 18
Know check the result by using length to shell diameter ratio to see it is over the reasonable limit
within the standards.
L/Ds = 5000/484 =10.3 this is within the standard limit 10.
4.3.7. Tube side heat transfer coefficient

To determine this value first determine Re L/Di, Nu and Pr.
Re =(ρ*u*di)/µ = (820*1.14*14.83*10-3)/(3.2*10-3) = 4332
Pr = (2.05*3.2*10-6)/0.134 = 48.96
L/Di = cp*µ/k = 5000/14.83 = 337 since this value is less than 500 the value is effective
comparison with the standard.
Jht = 3.5*10-3 this value is take from table (using Re and Pr it can find from graph).
Nu =Jht*Re*pr0.33 = 3.5 *10-3*4332*(48.96)1/3 = 54.8
hi = Nu*k/di =54.8*(0.134/0.01483) = 495 say 500W/m2oc
since the values are small we are obligated to increase hence it can be increase by increasing the
tube pass from 2 to 4 then the tube side velocity will be also double.

Ut = 2*1.14m/s = 2.3m/s
Now find the values again using u value 2.3m/s gives;
Re = 2*4332 = 8664 ≈8.7*103 and Jht = 4*10-3
Nu = 4*10-3*8664*(48.96)0.33 = 125.2
hi = (0.134/0.01483)*125.2 = 1131W/m2oc
4.3.8. Calculation of Shell side heat transfer coefficient

As the number of pass increase the shell diameter will also increase.
For 4 pass k1 =0.175 and n1 =2.285
Shell diameter can also obtained using bundle diameter as;
Db =19.05(240/0.175)1/2.285 = 451mm
The bundle to shell clearance is still around 56mm then shell diameter will be;
Ds = Db + Cb = 450 + 56 =507mm
Baffle spacing is, Ds/5 say 100mm this space is used for good heat transfer with out high
pressure drop.
As = (Pt-Do)*Ds*LB/Pt =
As = (23.81-19.05)*507*100/23.81 = 10136mm2
Find the equivalent diameter for the triangular pitch arrangement.
De = 4*(0.87*pt2-(π*do2/4))/(π*do) = ((23.81-0.917*19.052)/19.05) * 1.1 = 13.92mm
Volumetric flow rate on shell side Vs = (20000/3600)*1/730 = 0.0076m3/s
Shell side velocity, u = (0.076/0.01014) = 0.75m/s
The next step will be to determine the Renaldo’s number Res and prandetl number Pr on shell
side flow.
Res = (730*0.75*13.92*10-3/0.00043) = 17723
Pr = (2.47*0.43*103*10-3)/0.132 = 8.05
From the popular table use segmental baffles with a 25% cut. This should give a reasonable heat
transfer coefficient with less pressure drop.
Now using standard tables and graphs find out the heat transfer across shell side.
Take Jhs = 4.52*10-3
hs = Nu*k/De = (0.132/13.52)*103 * 4.52*10-3*17214*8.050.33 = 1505W/m2oc

4.3.9. Calculation of Overall heat transfer coefficients

Over all coefficient can be determined as;
( ) ( )
( )
Uo = 401W/m2oc
4.3.10. Check for Pressure drop

 Tube side pressure drop
ΔPt = Np*(8*Jf(L/di)+2.5)*ρ*(u2/2)
Jft =5*10-3 *Re = 8.7*10-3m = 0.25 for laminar flow, Re <2100
M = 0.14 for turbulent flow, Re > 2100.
∆Pt = 4(8*5*10-3(500/14.83) + 2.5)*(1820*2.32/2) = 138810N/m2 ≈1.4bar
Since this is greater than the given specification pressure drop (1.4 > 0.8bar) it must be
recalculate starting from step five. Hence modification of the above data’s will continue.
 Modification
The tube velocity needs to reduce. This will reduce the heat transfer coefficient so the number of
tubes must be increased to compensate. There will be a pressure drop across the inlet and out let
nozzles. Allow 0.1bar for this, a typical figure (about 15% of the total); which leaves 0.7bar
across the tubes. Pressure drop is roughly proportional to the square of the velocity and ut is
proportional to the number of tubes per pass. So the pressure drop calculated for 240 tubes can
be used to estimate the number of tubes required. Tubes needed Nt = Nt(ΔP/0.7)0.5
Nt =240(1.4/0.7)0.5 =339 say
Hence approximate to the standard value hence, Nt = 360
Retain 4 passes since the heat transfer coefficient will be too low with 2 passes. Second trial
design: 360 tubes 19.05mm outside diameter, 14.83mm internal diameter, 5m long, triangular
pitch 23.81mm.
Tube side heat transfer coefficient

Bundle diameter, Db =Do*(Nt/k1)1/n1

Db = 19.05(360/0.175)1/2.285 = 537mm
Shell diameter, Ds = Db +Cb
Ds = 537 +59 =597mm
Cross sectional area per pass, Acp =Ac *Ntpp
Acp = (360/4)*(14.83*10-3)π/4 = 0.01555m2
Tube velocity ut =m/(Acp*ρ) = (0.0237/0.01555) = 1.524m/s
Re = (ρc*ut*Di)/Zc
Re = (820*1.524*14.83*10-3/(3.2*10-3)) = 5792 ≈5.8*103
L/Di is the same as the first trial, 337
Heat transfer factor, Jht = 3.6*10-3
Heat transfer coefficient, hi
hi = hi = Nu*k/di =((0.134/14.83*10-3)*3.6*10-3*5792*48.960.33) = 680W/m2oc
Next step is to determine the pressure drop across tube side.
Tube side pressure drop
From the standard graph using the tube side Reynolds number the friction factor, Jft = 5.5*10-3
ΔPt = Ntp[8Jft(L/Di)(Zc/Zw)-m +2.5]
ΔPt = 4*(8*5.5*10-3(5000/14.83) +2.5)*(820*1.5242)/2 = 66029N/m2 ≈0.66bar
This is below 0.8bar hence it is acceptable.
The total pressure drop is the sum of the pressure drop across the inlet and out let of the nozzle
and the pressure drop across the tube, i.e. ΔP =ΔPt +0.1bar
ΔP= 0.66+0.1 =0.76bar this is acceptable, 0.67<0.8bar.
Keep the same baffle cut and spacing.
 Shell side pressure drop
AS =(Pt-Do)*Ds *LB*As/Pt = (23.81-19.05)*597*100/23.81 = 11935mm2
us =ms /(ρ*As) = (0.0076/0.01193) = 0.637m/s *de = 13.92mm
Res = (ρh*us*De)/Zh
= (730*0.637*13.92*10-3/(0.43*10-3)) = 15057 =1.5*104Prs = 8.05 as befor
Jhs =4.8*10-3
hs = Nu*k/De= (0.132/(13.92*10-3))*0.0048*15053*8.050.33 =1366W/m2oc this is good
estimation.

Know it simply to determine the pressure drop of shell

Jfs = 4.6*10-2
ΔPs =(8*Jfs(Ds/de)*(L/LB)*(ρk*us2/2))*(Zk/Zw)0.14
Consider low viscosity then Zw = Zk
ΔPs = (8*4.6*10-2(597/13.92)*(5000/100)(730*0.6382/2)) = 117243N/m2 ≈1.2bar
Since 1.2bar> 0.8bar the design of shell side is not acceptable it must be modify.
Check the overall coefficient to see if there is to modify the shell side design.
( ) ( )
1/Uo = (1/680 +0.00035)*19.05/14.83 +(19.05*10-3*ln(19.05/14.83) /(2*55) +(1/1364) +0.0002

Uo =302W/m2oc
Uo = (Q/(Ao*ΔTin)) *A = 360*0.2992 = 107.7m2Uo = (1509.4*103/(107.7*68.6)) = 204W/m2oc
The estimated overall coefficient is well above that required for design, 302compired to
204W/m2oc which gives scope for reducing the shell side pressure drop. Allow a drop of 0.1bar
for the shell inlet and outlet nozzles leaving 0.7bar for the shell side flow. So to keep within the
specification the shell side velocity will have to be reduced by around 0.707. To achieve this
baffle spacing will need to be increased to 100/0.707 =131, say 130mm.
As =( (23.81-19.05)/23.81) *597*130 =15516mm2 ≈0.0155m2
us =(0.0076/0.0155) = 0.490m/s
Res = (ρk*us *de)*Res/Zk = (730*0.490*13.92*10-3/(0.43*10-3)) =11580 ≈1.2*104
Prs = (Cpk*Zk)*Pr/kk = (2.47*0.43*103*10-3/0.132) = 8.05
Jhs = 5.9*10-3 and Jfs = 5.9*10-2
ho = (kk/de)*Jhs*Res*Prs1/3(Zk/Zw)0.14
= (0.132*103/13.92)*5.9*10-3*1.2*104*8.050.33 =1180W/m2oc
Consider Zk = Zw
Hence, ΔPs =8*Jfs(Ds/de)*(L/LB)*(ρk*us2/2))*(Zk/Zw)0.14
= (8*2.58*10-2(596/13.52)*(5000/144)*(730*0.4552/2)) = 47000N/m2 = 0.47bar
Since the pressure drop is within the limit (0.47bar < 0.8bar) the design on shell side is
acceptable.

4.4. Cost estimation
4.4.1. The factorial method cost estimation

Capital cost estimates for chemical process plants are often based on an estimate of the purchase
cost of the major equipment items required for the process, the other cost being estimated as
factors of the equipment cost. The accuracy of this type of estimate will depend on what stage
the design has reached at the time the estimate is made, and on the reliability of the data
available on equipment costs. In the later stages of the project design, when detailed equipment
specifications are available and firm quotations have been obtained, an accurate estimation of the
capital cost of the project can be made. Therefore total cost of the product is the sum of material
cost manufacturing cost and other like transportation cost. So in this the designer obligates to set
the material cost as follows.
 Find volume of tube, V from surface area of tube, number of tube and thickness
of tube.
V = Ast*Nt*t
= 0.299237m2*360*0.002m =0.21545064m3
 Find mass of the tube, m from density of material and volume of tube.
M = ρ*V
= 7804*0.21545064 = 1681.37679kg since density of material carbon steel is 7840kg/m3
 Find total cost of tube from cost of carbon steel per ton and mass of the
tube(material cost).
Total cost of tube = m*cost of carbon steel per ton
= 1681.37679kg * 500US$/1000kg
=840.68US$
 Find volume of shell
Vs = π*D*L*t
= 0.01597m3
 find total cost of shell(material cost)

Total cost of shell = Vs*density of material*cost of carbon steel per ton
= 0.01597m3*7804kg/m3 *500US$/1000kg

= 62.3164US$
 Find total cost of the heat exchanger(material cost)
Total cost of heat exchanger = total cost of tube + total cost of shell
= 840.68 + 62.3164
= 902.9964US$

CHAPTER FIVE
DESIGN ANALYSIS USING C++ PROGRAM
5.1. Program development of shell and tube heat exchanger design
Programing for this design helps to simplify the design iteration values. It tells the correction if
there is any mistake with specifying its location point. In addition once programed it can be used
for many parade of time and by changing the parameters it helps to design for variety of input
parameters. It saves time, effort and material requirement than manual design. Generally it is
more accurate than manual calculation.
1 . #include<iostream.h>
2. #include<conio.h>
3. #include<math.h>
4. float pi = 3.1429 ;
5. int main ()
6. {
7. const float mh = 5.556 ;
8 . const float mc = 19.444 ;
9 . const float Th1 = 473.15 ;
10. const float Th2 = 363.15 ;
11. const float Tc1 = 313.15 ;
12 . const float Rfh = 0.0002 ;
13 . const float Rfc = 0.00035 ;
14 . const float cph = 2470 ;
15 . const float cpc = 2050 ;
16 . const float kw= 55 ;
17 . float Tc2 , Q ;
18 . Q =mh * cph *( Th1 - Th2 );
19 . cout << "the load or power in w. is:" << Q << endl ;
20 . Tc2 = Tc1 + Q /( mc * cpc );
21 . cout << "the outlet cold tempreture in K. is:" << Tc2 << endl ;
22.
23. const float dnh = 730 ;
24 . const float dnc = 820 ;
25 . const float sph = 0.00043 ;
26 . const float spc = 0.0032 ;
27. const float kf = 0.135 ;
28 . float detT1 , detT2 , detTlmtd , detTm ;
29 . float f = 0.85 ;
30 . detT1 = Th1 - Tc2 ;
31 . cout << "the change of Tempreture1 in K. is:" << detT1 << endl ;
32 . detT2 = Th2 - Tc1 ;
33. cout << "the change of Tempreture2 in K. is:" << detT2 << endl ;
34 . detTlmtd=( detT1 - detT2 )/( log ( detT1 / detT2 ));
35 . cout << "the Log mean Tempretuere difference in K. is:" << detTlmtd<< endl ;
36 . detTm= f * detTlmtd ;
37 . cout << "the mean Tempretuere in K. is:" << detTm<< endl ;
38 . float Ao ;
39 . int U = 500 ;
40 . //for(U=300;U<550;U++)

41. {
42 . //U=U+50;
43 . Ao = Q /( U * detTm );
44. cout << "The Total area of heat transfer in meter squar is:" <<Ao << endl ;
45 . }
46 . const float Do = 0.01905 ;
47. const float Di = 0.01483 ;
48 . const float L = 5 ;
49 . float At ;
50 . At =pi * Do * L ;
51. cout << "the outer area of heat transfer in meter squar is:" <<At << endl ;
52 . float Tpp ;
53 . int Np = 4 , Nt = 360 ;
54 . Tpp =Nt / Np ;
55 . cout << "The tube needed per pass is:" << Tpp << endl ;
56 . float Act ;
57 . Act =( pi / 4 )*( Di * Di );
58 . cout << "The inner tube of cross sectionl area in Meter Square is:" <<Act << endl ;
59 . float Actp ;
60 . Actp = Tpp * Act ;
61 . cout << "The tube cross sectional area per pass in Meter Square is:" <<Actp << endl ;
62 . float Vt ;
63 . Vt =mc /( dnc * Actp );
64 . cout << "The tube side velocity in meter per second is:" <<Vt << endl ;
65 . const float nr = 0.436 ;
66 . const float nt = 0.438 ;
67. const float kr = 0.156 ;
68 . const float kt = 0.175 ;
69. const float cr = 0.091 ;
70. const float ct = 0.056 ;
71. float Dbt , Dbr ;
72. float k2 =Nt / kt ;
73. float d2 =pow ( k2 , nt );
74. //const float trg=23.66366;
75. Dbt = Do * d2 ;
76 . cout << "The Bundele Diameter by triangular pich in meter is:" << Dbt << endl ;
77 . //const float reg=24.52278;
78 . float k3 =Nt / kr ;
79 . float d3 =pow ( k3 , nr );
80 . Dbr = Do * d3 ;
81. cout << "The Bundele Diameter by regtangular pich in meter is:" << Dbr << endl ;
82 . float Dst ;
83. Dst = Dbt + ct ;
84 . cout << "The shell Diameter using triangular pich in meter is:" << Dst << endl ;
85 . float Dsr ;
86 . Dsr = Dbr + cr ;
87 . cout << "The shell Diameter using square pich in meter is:" << Dsr << endl ;
88 . float Ret , Prt , Nut , hi ;
89 . Ret =( dnc * Vt * Di )/ spc ;
90. cout << "The Re in tube side is:" << Ret << endl ;
91. Prt = cpc * spc / kf ;
92. cout << "The Pr in tube side is:" << Prt << endl ;
93. const float Jht = 0.0036 ;
94 . const float pr = 0.33 ;

95 . //const float Prrt=3.61116;

96 . Nut =( Jht * Ret *( pow ( Prt , pr )));
97. cout << "The value of Nut in tube side is:" << Nut << endl ;
98. hi =Nut * kf / Di ;
99 . cout << "The convective heat transfer coffecient in tube side is:" << hi << endl ;
100 . const float Lb = 0.13 ;
101 . const float Pt = 0.02381 ;
102 . float Acs , De , Vs , Res , Prs , Nus , ho , Uo ;
103. int es = 4 ;
104 . const float bs = 0.87 ;
105. //const float pi=22/7;
106 . Acs =( Pt - Do )* Dst * Lb / Pt ;
107 . cout << "The Shell cross sectional area in meter squar is:" <<Acs << endl ;
108 . De =( es *( bs * Pt * Pt -( pi / es )* Do * Do )/( pi * Do ));
109 . cout << "The Equivalent Diameter in meter is:" << De << endl ;
110 . Vs =mh /( dnh * Acs );
111 . cout << "The Shell side Velocity in meter/second is:" <<Vs << endl ;
112 . Res =( Vs * De * dnh )/ sph ;
113 . cout << "The Re in shell side is:" << Res << endl ;
114 . Prs =( cph * sph )/ kf ;
115 . cout << "The Pr Shell side is:" << Prs << endl ;
116 . const float Jhs = 0.0059 ;
117 . Nus = Jhs * Res * pow ( Prs , pr );
118 . cout << "Nus in shell side is:" << Nus << endl ;
119 ho =( Nus * kf )/ De ;
120 cout << "The convectivity Heat Transfer Coffiecent in Shell side in W/sq.meter*K is:" << ho << endl ; 121 int
O=1;
122 . int T = 2 ;
123 . //float Rt;
124 . const float l = 0.25041 ;
125 . float G= O / hi + Rfc ;
126 . float g = Do / Di ;
127 . float G1 = Do /( T * kw );
128 . float g1 =( O / ho )+ Rfh ;
129. Uo = O /( G * g + G1 * l + g1 );
130 . //Uo=[O/[(O/hi+Rfc)*(Do/Di)+(Do/(T*kw)*l)+(O/ho+Rfh)]];
131 . cout << "The Overall Heat Transfer Coffiecent in W/sq.meter*K is:" << Uo << endl ;
132 . float deltPt , deltPs ;
133 . const float Jft = 0.0055 ;
134. int m= 8 ;
135. double i = 2.5 ;
136 . float s = dnc * Vt * Vt / T ;
137 . float s1 = L / Di ;
138 . float s2 =m* Jft ;
139 . deltPt =( Np *( s2 * s1 + i )* s );
140 . //deltPt=(Np(m*Jf*(L/Di)+i)*dnc*Vt*Vt/T);
141 .cout << "The Pressure Drop in tube side in Pascal is:" << deltPt << endl ;
142 . const float Jfs = 0.0059 ;
143 . deltPs =m* Jfs *( Dst / De )*( L / Lb )* dnh * Vs *( Vs / T );
144. cout << "The Pressure Drop in Shell side in Pascal is:" << deltPs << endl ;
145 . return 0 ;
146 . }

Summary of shell and tube heat exchanger design (single phase)
Shell and tube heat exchangers are designed based on the effective and log mean temperature
methods thus two methods are follow different procedures (algorithms) based on the designer
first assumptions. While the general and common procedures are summarize as follows:
 Specification: define duty and make energy balance if needed to calculate unspecified
flow rates or temperature
 Set physical properties: density, µ, Cp and k
 Decide number of shell and tube passes, calculate LMT, correction factor
 Assume overall coefficient, Uo,ass
 Determine heat transfer area required
 Decide type, tube size, material layout, assign fluids
 Calculate number of tubes
 Calculate shell diameter
 Estimate tube side heat transfer coefficient
 Decide baffle spacing and estimate shell side heat transfer coefficient
 Calculate overall heat transfer coefficient including direct factors, Uo,ass
 check for 0< ((Uo,cal –Uo,ass)/Uo,ass) < 30% if yes continue to next step if no turn to step
five.
 estimate tube side and shell side pressure drop.
 check the pressure drop with the given specification, if less than the given pressure drop,
the design is acceptable if not turn to step tenth and recalculate until it becomes below the
specified pressure drop.
 estimate cost of exchanger.
 optimize to reduce cost. If yes turn to step ten and recalculate. otherwise the design is
acceptable.

Recommendation
This paper covers only for single phase flow heat exchangers. Due to the consideration of those
steps other readers can design better than in efficiency, cost and size minimization. It also leads
to design for double phase heat exchangers.
In addition to this design using C++ Borland software helps to simplify for numerical iterations
hence future men can design with the aid of simulation due to the help of the developed program.

Appendix
Design Summary:
R.no Variables to determined Numerical value unit
1 Load or power 1.50957x106 watt
2 Out late cold temperature 351.021 kelvin
3 Change of temperature one 122.129 kelvin
4 Change of temperature two 50 kelvin
5 Log mean temperature difference 80.7664 kelvin
6 The mean temperature 68.6515 kelvin
7 Total area of heat transfer 73.2961 Square meter
8 Outer area of heat transfer 0.299361 Square meter
9 Tube need per pass 60 -
10 Inner tube of cross sectional area 0.000172804 Square meter
11 Tube cross sectional area per tube 0.0103682 Square meter
12 Tube side velocity 2.28701 Meter per sec
13 Bundle diameter by triangular pitch 0.450793 meter
14 Bundle diameter by rectangular pitch 0.467159 meter
15 Shell diameter using triangular pitch 0.506793 meter
16 Shell diameter using square pitch 0.558159 meter
17 Reynolds’s number in tube side 8691.06 -
18 Prenditle number in tube side 48.5926 -
19 Value of Nut in tube side 125.228 -
20 Convective heat transfer coefficient in tube side 1139.97 Watt per sq.
meter kelvin
21 Shell cross sectional area 0.0101316 Sq. meter
22 Equivalent diameter 0.013901 meter
23 Shell side velocity 0.75121 Meter per sec
24 Reynalds number in shell side 17728.5 -
25 [prenditle number in shell side 7.867 -
26 Nussult number in shell side 157.583 -
27 Convective heat transfer coefficient in shell side 1530.34 Watt per sq.
meter kelvin
28 Calculated over all heat transfer coefficient 404.327 Watt per sq.
meter kelvin
29 Pressure drop in tube side 137127 Pascal
30 Pressure drop in shell side 138168 Pascal

The program developed above gives the following output when the assumption inputs are
varying.
The iterated outputs are set step by step as follows;
 Since the convective heat transfer in tube side is small(500W/m2K) then it must be
increased the tube side heat transfer coefficient by increasing tube velocity and tube
velocity can also increase by increasing the number of tube pass. The output for four
number of pass is as follow:


 In this output also the pressure drop in tube and shell side is greater than the given
limit(1.4bar>0.8bar tube side). Therefore it can be reduced by increasing the number of
tubes. The output for number of tubes 360 is as follows:
 From the output the shell side pressure drop is until greater than the given limit
(1.2bar>0.8bar). This pressure drop can be reduced by increasing baffle spacing. From
the numerical calculation it can set the baffle spacing 130mm and the output is as
follows.

 Know all outputs are acceptable within the given specification limits but this is with the
assumption of overall heat transfer coefficient 300W/m2K. hence to select which one is
the optimum design we will iterate with 350, 400, 450, and 500W/m2K as follows.

Iteration two when Uo = 350W/m2K:
Iteration three when Uo=400W/m2K;
Iteration four when Uo=450W/m2K;
Iteration five when Uo=500W/m2K;

From all iterations we can conclude that as the assumption of overall heat transfer area increase
the total area required will be decreased in similar manner number of tubes and tube pass will
also decrease. Due to this reason the velocity of the fluid flow will be decreased due to this heat
transfer coefficient will also decrease. So the required output may be inconvenient. Hence the
optimum design is with the assumption of 300W/m2K.

Reference
[1] Selection, rating, and thermal design, third edition sadik kakac, hongtan liu,
anchasa pramuanjaroenkij
[2] Term paper on design procedure for shell and tube heat exchangers,
prepared by Dr. Muluwork Kahsay.
[3] http://www-
unix.ecs.umass.edu/~rlaurenc/Courses/che333/Reference/exchanger.pdf
[4] http://www.chemstations.com/content/documents/technical_articles/shel
l.pdf
[5] http://www.wlv.com/products/databook/ch1_4.pdf
[6] http://www.wlv.com/products/databook/databook.pdf
[7] http://userpages.umbc.edu/~dfrey1/ench445/heat_exch_design.pdf
[8] http://www.ewp.rpi.edu/hartford/~ernesto/F2008/EP/Materials4Student
s/Halko/Kara.pdf
[9] http://www.wmich.edu/mae/Faculty/Lee/ME539/Section%205.4%20She
ll-and-tube%20heat%20exchanger_corrected.pdf
[10] http://people.clarkson.edu/~wwilcox/Design/hxdesign.pdf

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DESIGN OF SHELL AND TUBE HEAT EXCHANGER

SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING

DESIGN OF SHELL AND TUBE HEAT EXCHANGER (SINGLE

UNDER THE GUIDANCE

DR. MULUWORK KAHSAY

BAHIRDAR UNIVERSITY INSTITUTE OF THECHNOLOGY SMIE (THERMAL) Page i

BAHIRDAR UNIVERSITY INSTITUTE OF THECHNOLOGY SMIE (THERMAL) Page ii

BAHIRDAR UNIVERSITY INSTITUTE OF THECHNOLOGY SMIE (THERMAL) Page iii

mh mass of hot fluid kg

mc mass of cold fluid kg

Cph specific heat of hot fluid kJ/kg.k

Cpc specific heat of cold fluid kJ/kg.k

Thi hot fluid temperature at inlet k

Tho hot fluid temperature at exit k

Tci cold fluid temperature at inlet k

Tco cold fluid temperature at exit k

U overall heat transfer coefficient W/m2.k

A total area of shell m2

ΔTm log mean temperature k

ΔT1 temperature difference one k

ΔT2 temperature difference two k

Cmax maximum capacity coefficient -

Cmin minimum capacity coefficient -

do outer diameter of tube m

di inner diameter of tube m

Ds internal shell diameter m

hi tube side heat transfer coefficient W/m2k

ho shell side heat transfer coefficient W/m2k

Uass assumed over all heat transfer coefficient W/m2k

Uo calculated over all heat transfer coefficient W/m2k

Are required area m2

ΔPt tube side pressure drop pa

ΔPs shell side pressure drop pa

ΔPft friction loss pressure drop pa

ΔPrt return loss pressure drop pa

K thermal conductivity W/mk

BAHIRDAR UNIVERSITY INSTITUTE OF THECHNOLOGY SMIE (THERMAL) Page v

BAHIRDAR UNIVERSITY INSTITUTE OF THECHNOLOGY SMIE (THERMAL) Page vi

DESIGN ANALYSIS .................................................................................. 22

BAHIRDAR UNIVERSITY INSTITUTE OF THECHNOLOGY SMIE (THERMAL) Page vii

Table 3.1. Common Tube Layouts. .................................................................................. 13

Table 3.2. Typical Values Of Fouling Coefficients And Resistances. ............................. 17

Table4.1. Physical Properties Of Fluids ........................................................................... 23

Figure 2.1. Fixed-Tube Heat Exchanger. ........................................................................... 7

Figure 2.2. Floating-Head Heat Exchanger (Non-Pull Through Type) ............................. 7

Figure 2.3. Removable U-Tube Heat Exchanger. .............................................................. 8

Figure 3.1. Heat Exchanger Tube-Layouts. ..................................................................... 13

Fig4.2. Parallel Flow Arrangement .................................................................................. 25

BAHIRDAR UNIVERSITY INSTITUTE OF THECHNOLOGY SMIE (THERMAL) Page viii

Heat exchangers are systems of thermal engineering in which its

BAHIRDAR UNIVERSITY INSTITUTE OF THECHNOLOGY SMIE (THERMAL) Page ix

BAHIRDAR UNIVERSITY INSTITUTE OF THECHNOLOGY SMIE (THERMAL) Page 1

BAHIRDAR UNIVERSITY INSTITUTE OF THECHNOLOGY SMIE (THERMAL) Page 2

1.2. STATEMENT OF THE PROBLEM

BAHIRDAR UNIVERSITY INSTITUTE OF THECHNOLOGY SMIE (THERMAL) Page 3

1.3.1. General Objective

1.3.2. Specific Objective

BAHIRDAR UNIVERSITY INSTITUTE OF THECHNOLOGY SMIE (THERMAL) Page 4

Table 2.1. Features of shell and tube type exchangers.

Shell and Typical Advantages Limitations

Less costly than

Packing materials produce limits on design

BAHIRDAR UNIVERSITY INSTITUTE OF THECHNOLOGY SMIE (THERMAL) Page 6