Heat exchanger design

using bell’s method

U16CH045
U16CH046
U16CH048
In Bell’s method the heat-transfer coefficient and pressure drop are estimated from correlations for
 flow over ideal tube-banks, and
 the effects of leakage, bypassing and flow in the window zone are allowed for by applying
correction factors.

Advantages
 More satisfactory predictions of the heat-transfer coefficient and pressure drop than Kern’s
method.
 As it takes into account the effects of leakage and bypassing, can be used to investigate the effects
of constructional tolerances and the use of sealing strips.
Limitations
 not recommended when the by-pass flow area is greater than 30% of the cross-flow area, unless
sealing strips are used.
 HEAT-TRANSFER COEFFICIENT
The shell-side heat transfer coefficient is given by:
hs = hoc Fn Fw Fb FL

Where hoc = heat transfer coefficient calculated for cross-flow over an ideal tube bank, no leakage
or bypassing.
Fn = correction factor to allow for the effect of the number of vertical tube rows,
Fw = window effect correction factor,
Fb = bypass stream correction factor,
FL = leakage correction factor.

The total correction will vary from 0.6 for a poorly designed exchanger with large clearances to 0.9
for a well-designed exchanger.
Ideal cross-flow Coefficient (hoc )
can be calculated using the heat transfer
factors jh given in Figure below (Adapted
from a similar figure given by Mueller)
The Reynolds number for cross-flow through a tube bank is given by:
Re= Gs do/ 𝜇
where Gs = mass flow rate per unit area, based on the total flow and free area at the bundle
equator. This is the same as Gs calculated for Kern’s method,
do = tube outside diameter

The heat-transfer coefficient is given by:

1
ℎ𝑜𝑐 𝑑𝑜 𝜇 0.14
=𝑗ℎ 𝑅𝑒𝑃𝑟 ( )
3
𝑘𝑓 𝜇𝑤
Tube Row Correction Factor(Fn)
The mean heat-transfer coefficient will depend on the number of tubes crossed.
For turbulent flow the correction factor Fn is close to 1.0.
In laminar flow the heat-transfer coefficient may decrease with increasing rows of tubes
crossed, due to the build up of the temperature boundary layer.
1. Re > 2000, turbulent; take Fn from graph
2. Re > 100 to 2000, transition region, take Fn = 1;
3. Re < 100, laminar region, Fn ∝ N’c-0.18
Where N’c is the number of rows crossed in series from end to end of the shell, and depends
on the number of baffles.
The correction factor in the laminar region is not well established
Window Correction Factor(Fw)
This factor corrects for the effect of flow through the baffle window, and is a function of
the heat-transfer area in the window zones and the total heat-transfer area. The correction
factor is shown in Figure, plotted versus Rw, the ratio of the number of tubes in the
window zones to the total number in the bundle, determined from the tube layout diagram.
Bypass Correction factor (Fb)
This factor corrects for the main bypass stream, the flow
between the tube bundle and the shell wall, and is a
function of the shell to bundle clearance, and whether
sealing strips are used:
𝐴𝑏 2𝑁𝑠 1
𝐹𝑏 = exp[−𝛼 (1 − )3 ]
𝐴𝑠 𝑁𝑐𝑣
Where, 𝛼 = 1.5 for laminar flow, Re < 100,
𝛼 = 1.35 for transitional and turbulent flow Re > 100
Ab= clearance area between the bundle and the shell,
As = maximum area for cross-flow,
Ns = number of sealing strips encountered by the
bypass stream in the cross-flow zone
Ncv = the number of constrictions, tube rows,
encountered in the cross-flow section.
Leakage Correction Factor (FL)
This factor corrects for the leakage through the
tube-to-baffle clearance and the baffle-to shell
clearance.
(𝐴𝑡𝑏 +2𝐴𝑠𝑏 )
𝐹𝐿 = 1 − 𝛽𝐿 [ ]
𝐴𝐿

Where, 𝛽𝐿 = a factor obtained from Figure 12.35,

Atb = the tube to baffle clearance area, per baffle
Asb = shell-to-baffle clearance area, per baffle.
AL = total leakage area = (Atb + Asb)
 PRESSURE DROP
The pressure drops in the cross-flow and window zones are determined separately, and summed to give the total shell-side
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.
∆𝑃𝐶 = ∆𝑃𝑖 𝐹′𝑏 𝐹′𝐿
Where,
∆𝑃𝑐 = the pressure drop in a cross-flow zone between the baffle tips, corrected for by-passing and leakage,
∆𝑃𝑖 = the pressure drop calculated for an equivalent ideal tube bank,
𝐹′𝑏 = by-pass correction factor,
𝐹′𝐿 =leakage correction factor.
Ideal tube bank pressure drop (∆Pi)
the pressure drop across the ideal tube bank is given by:
𝜌𝑢𝑠2 𝜇 -0.14
∆𝑃𝑖 = 8𝑗𝑓 𝑁𝑐𝑣 2 (𝜇 )
𝑤

where Ncv = number of tube rows crossed (in the cross-

flow region),
us = shell side velocity, based on the clearance
area at the bundle equator
jf = friction factor obtained from Figure 12.36, at
the appropriate Reynolds number
Bypass correction factor for pressure
drop (Fb’)
Bypassing will affect the pressure drop only in the cross-
flow zones. The correction factor is calculated from the
equation used to calculate the bypass correction factor for
heat transfer, but with the following values for the
constant.
Laminar region, Re < 100, 𝛼 = 5.0
Transition and turbulent region, Re > 100, 𝛼 = 4.0
The correction factor for exchangers without sealing
strips is shown in Figure 12.37.
WINDOW-ZONE PRESSURE DROP
the window drop for turbulent flow is given by:
𝜌𝑢𝑧2
∆𝑃𝑤 = 𝐹′ 𝐿 (2 + 0.6𝑁𝑤𝑣 )
2
Where, 𝑢𝑧 = the geometric mean velocity,
𝑢𝑧 = √(𝑢𝑤 𝑢𝑠 )
uw = the velocity in the window zone, based on the window area less the area occupied
by the tubes Aw
𝑊𝑠
𝑢𝑤 = 𝐴
𝑤𝜌

Ws = shell-side fluid mass flow, kg/s,

Nwv = number of restrictions for cross-flow in window zone, approximately equal to the
number of tube rows.
END ZONE PRESSURE DROP
There will be no leakage paths in an end zone (the zone between tube sheet and baffle). Also,
there will only be one baffle window in these zones; so the total number of restrictions in the
cross-flow zone will be 𝑁𝑤𝑣 + 𝑁𝑐𝑣 . The end zone pressure drop will therefore be given by:
(𝑁𝑤𝑣 +𝑁𝑐𝑣 )
∆𝑃𝑒 = ∆𝑃𝑖 [ 𝑁𝑐𝑣
]F’b

TOTAL SHELL SIDE PRESSURE DROP

Summing the pressure drops over all the zones in series from inlet to outlet gives:
∆𝑃𝑠 = 2∆𝑃𝑒 + ∆𝑃𝑐 𝑁𝑏 − 1 + 𝑁𝑏 ∆𝑃𝑤
where Nb is the number of baffles = [(L/lb) – 1]
An estimate of the pressure loss incurred in the shell inlet and outlet nozzles must be added to
that calculated by equation given above.
End Zone Lengths
The spacing in the end zones will often be increased to provide more flow area at the inlet
and outlet nozzles. The velocity in these zones will then be lower and the heat transfer and
pressure drop will be reduced slightly. The effect on pressure drop will be more marked
than on heat transfer, and can be estimated by using the actual spacing in the end zone
when calculating the cross-flow velocity in those zones.
Shell and Bundle Geometry
With reference to Figures
Hc = baffle cut height = Ds × Bc, where Bc is the baffle cut as a fraction,
Hb = height from the baffle chord to the top of the tube bundle,
Bb = “bundle cut” = Hb/Db
Өb = angle subtended by the baffle chord, rads,
Db = bundle diameter.
Then,

𝐷𝑏
𝐻𝑏 = − 𝐷𝑠 0.5 − 𝐵𝑐
2

𝐷𝑏 − 2𝐻𝑏
𝑁𝑐𝑣 =
𝑃′ 𝑡
 Nw = Hb/ p’t
where p’t is the vertical tube pitch
p’t = pt for square pitch,
p’t = 0.87 pt for equilateral triangular pitch.
The number of tubes in a window zone Nw is given by:
Nw = Nt × R’a
where R’a is the ratio of the bundle cross-sectional area in the window zone to the
total bundle cross-sectional area, R’a a can be obtained from Figure 12.41, for the
appropriate “bundle cut”, Bb.
The number of tubes in a cross-flow zone Nc is given by
Nc = Nt - 2Nw
and Rw = 2Nw / Nt
𝜋 𝜋
𝐴𝑤 = ∗ 𝐷𝑆 2 ∗ 𝑅𝑎 − 𝑁𝑤 ∗ ∗ 𝑑𝑜 2
4 4
Ra is obtained from Figure 12.41, for the appropriate baffle cut Bc
𝑐𝑡 𝜋𝑑𝑜
𝐴𝑡𝑏 = 𝑁𝑡 − 𝑁𝑤
2
Where, Ct is the diametrical tube to baffle clearance typically 0.8mm

𝑐𝑠 𝑑𝑠
𝐴𝑠𝑏 = 2𝜋 − 𝜗𝑏
2
Where, Cs is the baffle to shell clearance

𝐴𝑏 = 𝑙𝐵 𝐷 − 𝐷
𝑠 𝑏
Where lb is the baffle spacing
Effect of fouling on pressure drop
Bell’s method gives an estimate of the shell-side pressure drop for the exchanger in the
clean condition. In service, the clearances will tend to plug up, particularly the small
clearance between the tubes and baffle, and this will increase the pressure drop. Devore
(1961) has estimated the effect of fouling on pressure drop by calculating the pressure drop
in an exchange in the clean condition and with the clearance reduced by fouling, using
Tinker’s method. He presented his results as ratios of the fouled to clean pressure drop for
various fouling factors and baffle spacings.
The ratios given in Table 12.7, which are adapted from Devore’s figures, can be used to
make a rough estimate of the effect of fouling on pressure drop.
Pressure-drop limitations
Though Bell’s method will give a better estimate of the shell-side pressure drop than
Kern’s, it is not sufficiently accurate for the design of exchangers where the allowable
pressure drop is the overriding consideration. For such designs, a divided-flow model based
on Tinker’s work should be used. If a proprietary computer program is not available, the
ESDU Design Guide, ESDU 83038 (1984) is recommended. Devore’s method can also be
considered, providing the exchanger layout conforms with those covered in his work.
FORMULAE
 HEAT TRANSFER COEFFICIENT

ℎ𝑠 = ℎ𝑜𝑐 𝐹𝑛 𝐹𝑤 𝐹𝑏 𝐹𝐿
IDEAL CROSS-FLOW COEFFICIENT (hoc)
1
ℎ𝑜𝑐 𝑑𝑜 𝜇
=𝑗ℎ 𝑅𝑒𝑃𝑟 3 ( )0.14
𝑘𝑓 𝜇𝑤

TUBE ROW CORRECTION FACTOR(Fn)

from graph
WINDOW CORRECTION FACTOR(Fw)
from graph
BYPASS CORRECTION FACTOR(Fb)
𝐴𝑏 2𝑁𝑠 1
𝐹𝑏 = exp[−𝛼 (1 − )3 ]
𝐴𝑠 𝑁𝑐𝑣
LEAKAGE CORRECTION FACTOR(FL)
(𝐴𝑡𝑏 +2𝐴𝑠𝑏 )
𝐹𝐿 = 1 − 𝛽𝐿 [ ]
𝐴𝐿
 PRESSURE DROP

CROSS –FLOW ZONES

∆𝑃𝐶 = ∆𝑃𝑖 𝐹′𝑏 𝐹′𝐿

Ideal tube bank pressure drop(∆Pi)

𝜌𝑢𝑠2 𝜇 -0.14
∆𝑃𝑖 = 8𝑗𝑓 𝑁𝑐𝑣 ( )
2 𝜇𝑤
Bypass correction factor for pressure drop (Fb’)
from graph
Leakage factor for pressure drop (F’L)
from the equation of FL with the values for coefficient 𝛽′L
WINDOW-ZONE PRESSURE DROP
𝜌𝑢𝑧2
∆𝑃𝑤 = 𝐹 ′ 𝐿 2 + 0.6𝑁𝑤𝑣
2
𝑢 𝑧 = 𝑢𝑤 𝑢𝑠
𝑊𝑠
𝑢𝑤 =
𝐴𝑤 𝜌

END ZONE PRESSURE DROP

(𝑁𝑤𝑣 +𝑁𝑐𝑣 )
∆𝑃𝑒 = ∆𝑃𝑖 [ ]F’b
𝑁𝑐𝑣

SHELL SIDE TOTAL PRESSURE DROP(∆𝑃𝑠 )

∆𝑃𝑠 = 2∆𝑃𝑒 + ∆𝑃𝑐 𝑁𝑏 − 1 + 𝑁𝑏 ∆𝑃𝑤

 PROBLEM
Design data of an exchanger to sub-cool condensate from a methanol condenser from 950C to 400C where flow-rate of
methanol is 100,000 kg/h and brackish water is used as the coolant, with a temperature rise from 250C to 400C is given
below. Using Bell’s method, calculate the shell-side heat transfer coefficient and pressure drop for the exchanger.
Number of tubes = 918
Shell i.d. = 894 mm
Bundle diameter = 826 mm
Tube o.d. = 20 mm
Pitch 1.25∆ = 25 mm
Tube length = 4830 mm
Baffle pitch = 356 mm
IDEAL CROSS-FLOW COEFFICIENT (hoc)
25−20
AS= 25
∗ 894 ∗ 356 ∗ 10−6 = 0.062𝑚2

100000 1 𝑘𝑔 2
Gs= ∗ = 448 𝑚
3600 0.062 𝑠

𝐺𝑠 𝑑0 448∗0.02
Re = 𝜇
= 0.00034
= 26353

From graph, jh= 5.3*10-3 Pr= 5.1

Neglect viscosity correction factor

1
ℎ𝑜𝑐 𝑑𝑜 𝜇 0.14
𝑘𝑓
=𝑗ℎ 𝑅𝑒𝑃𝑟 3(
𝜇𝑤
)

1
0.19 −3
ℎ𝑜𝑐 = 20∗10−3
∗ 5.3 ∗ 10 ∗ 26353 ∗ 5.1 = 𝟐𝟐𝟕𝟐 𝑾/𝒎𝟐 ℃
3
TUBE ROW CORRECTION FACTOR(Fn)

Tube vertical pitch, 𝑝′𝑡 = 0.87 ∗ 25 = 21.8𝑚𝑚

Baffle cut height,𝐻𝑐 = 0.25 ∗ 894 = 224𝑚𝑚

Height between baffle tips = 894 − 2 ∗ 224 = 446𝑚𝑚

446
𝑁𝑐𝑣 = = 20
21.8
From graph, Fn= 1.03
WINDOW CORRECTION FACTOR(Fw)
826
𝐻𝑏 = − 894 0.5 − 0.25 = 190𝑚𝑚
2

“Bundle cut”= 190/826 =0.23

From figure at cut of 0.23

R’a= 0.18

Tubes in one window area, Nw= 918*0.18 =165

Tubes in cross-flow area, Nc = 918- 2*165 =588

2∗165
𝑅𝑤 = = 0.36
918

From figure Fw= 1.02

BYPASS CORRECTION FACTOR(Fb)

𝐴𝑏 = 894 − 826 356 ∗ 10−6 = 0.024𝑚2

𝐴𝑏 0.024
= = 0.39
𝐴𝑠 0.062

𝐴𝑏 2𝑁𝑠 1/3
𝐹𝑏 = 𝑒𝑥𝑝[−𝛼 (1 − ( ) )]
𝐴𝑠 𝑁𝑐𝑣

Fb = 0.87
Leakage Correction Factor(FL)

Using clearances as specified in the Standards,

tube-to-baffle 1/32 in. = 0.8mm
baffle-to-shell 3/16 in. = 4.8mm
0.8
𝐴𝑡𝑏 = ∗ 20𝜋 918 − 165 = 0.019𝑚2
2
From figure, 25% cut, 𝜗𝑏 = 2.1 𝑟𝑎𝑑𝑠.
4.8
𝐴𝑠𝑏 = ∗ 894 2𝜋 − 2.1 = 0.009𝑚2
2
𝐴𝐿 = 0.019 + 0.009 = 0.028𝑚2
𝐴𝐿
= 0.45
𝐴𝑠
From figure, 𝛽𝐿 =0.3
(0.019+2∗0.009)
𝐹𝐿 = 1 − 0.3[ ] = 0.60
0.028
SHELL SIDE HEAT TRANSFER
COEFFICIENT(hs)

ℎ𝑠 = ℎ𝑜𝑐 𝐹𝑛 𝐹𝑤 𝐹𝑏 𝐹𝐿

ℎ𝑠 = 2272 ∗ 1.03 ∗ 1.02 ∗ 0.87 ∗ 0.60 = 𝟏𝟐𝟒𝟔𝑾/𝒎𝟐 ℃

CROSS-FLOW ZONE PRESSURE DROP(∆𝑷𝒄 )

From figure, at Re = 26353, for 1.25 ∆ pitch, jf = 0.056

𝐺𝑠 448
𝑢𝑠 = = = 0.60𝑚/𝑠
𝜌 750
Neglecting viscosity term (𝜇/𝜇𝑤 )
0.62
∆𝑃𝑖 = 8 ∗ 0.056 ∗ 20 ∗ 750 ∗ = 1209.6𝑁/𝑚2
2
𝛼 = 4.0
1
2 3
𝐹′𝑏 = exp[−4.0 ∗ 0.39 1 − ] = 0.66
5
From figure, 𝛽′𝐿 = 0.52
0.019+2∗0.009
𝐹′𝐿 = 1 − 0.52 0.028
= 0.31
∆𝑃𝑐 = 1209.6 ∗ 0.66 ∗ 0.31 = 𝟐𝟒𝟖𝑵/𝒎𝟐
 WINDOW ZONE PRESSURE DROP(∆𝑷𝒘 )

From figure, for baffle cut 25%, Ra=0.19

𝜋 𝜋
𝐴𝑤 = ∗ 894 ∗ 0.19 − 165 ∗ ∗ 202 = 0.067𝑚2
2
4 4
100000 1 1
𝑢𝑤 = ∗ ∗ = 0.55𝑚/𝑠
3600 750 0.067
𝑢𝑧 = 𝑢𝑤 𝑢𝑠 = 0.57𝑚/𝑠

190
𝑁𝑤𝑣 = =8
21.8

750 ∗ 0.572
∆𝑃𝑤 = 0.31 2 + 0.6 ∗ 8 = 𝟐𝟓𝟕𝑵/𝒎𝟐
2
END ZONE PRESSURE DROP(∆𝑷𝒆 )

8 + 20
∆𝑃𝑒 = 1209.6 [ ] 0.66 = 1118N/𝒎𝟐
20
 SHELL SIDE TOTAL PRESSURE DROP(∆𝑃𝑠 )

∆𝑃𝑠 = 2∆𝑃𝑒 + ∆𝑃𝑐 𝑁𝑏 − 1 + 𝑁𝑏 ∆𝑃𝑤

4830
Number of baffles 𝑁𝑏 = − 1 = 12
356

∆𝑃𝑠 = 2 ∗ 1118 + 248 12 − 1 + 12 ∗ 257 = 𝟖𝟎𝟒𝟖 𝑵/𝒎𝟐

This is for the exchanger in the clean condition. Using the factors given in the table
to estimate the pressure drop in the fouled condition.
∆𝑃𝑠 = 1.4 ∗ 8048 = 𝟏𝟏𝟐𝟔𝟖 𝑵/𝒎𝟐