284 Heat Exchangers: Selection, Rating, and Thermal Design, Second Edition ERY PPR ASS he most common due to its cheap fluid enters at one end of the shel there is one pass on the shell side. The tubes passes and are supported by transverse baffiés 3 for single-phase shell fluid applications, With i I counterflow can be obtained. To increase the effective temperature differences and, hence, exchanger effectiveness, a pure counterflow arrangement is desirable for a two tube pass exchanger. This is achieved by the use of an F-sh baffle and resulting in two shell passes. It is used when u required, with each shell pass representing one unit. The pressure drop i snd one central outlet located fluid entry and Shell-and-Tube Heat Exchangers icsnmnuates | jaar anes ea | eS ey ee i . Mansfacturers Assocation) fondensers and low-pressure gases. flow shel flow G-shell has horizont | bdad shell types and front end and rear end head types. (Courtesy ofthe Tubular Exchanger Consequently, the pressure drop is extremely low. It is used for vacuum ich as the G-shell and H-shell are used for specific baffles with the ends ‘femoved; the shell nozzles are 180? apart at the midooint of hthes ‘The Cuehall284 Heat Exchangers: Selection, Rating, and Thermal Design, Second Eaton “sarenae ienaget SSG Ob FicuRE 8.1 Conetructional pars and connections: (1) stationary head — channel; 2} stationary head — bonnet: @) stationary head lange — channel or bonnet (4) channel cover; (9) eationnry head nozzle (6) stationary tube shot (7) tubes; 8) shell) shell cover (10) shill ange — er head end; (12) shell ange — wear head ene; (12) shel nozze (13) sell cover flange (18) expancigy ining, (15) floating tube sheet (16) Noating head cover; (17) floating head backing deca (08) Boating esd backing device; (1 spit shear rng: (2) slip-on backing lange (2) eating heed cover external @2) Seating beset skit (2) packing box 24) packing (5) pkg sland: (26) lantem ring: (27) ierods and spacers; (28) transverse baffle or suppor pla (29) impingement plate; (30) longitudinal bate; (31) pase patition; (22) vent connection (63) drain connection; (34) instrument connection; (35) support saddle; (6) lifting lage (27 support bracket) weir; (39) quid level connection. (Courtesy ofthe Tabular Exchange, ‘Manwfoctorers Assectation) Figure8.3 shows the most common shell types as condensers (v symbolizes the location of the vent)? The E-shell is the most common due to its cheap. ress and simplicity. In this shell, the shell uid enters at one end of the she!) and leaves at the other end, ie, there is one pass on the shell side. The tubes may havea single or multiple passes and are supported by transverse baffles This shell is the most common for single-phase shell fluid applications, With @ single tube pass, a nominal counterfiow can be obtained, ‘To increase the effective temperature differences and, hence, exchanger effectiveness, 2 pure counterflow arrangement is desirable for a two tube pass exchanger. This is achieved by the use of an F-shell with a longitudinal baffle and resulting in two shell passes. It is used when units in series are required, with each shell pass representing one unit. The pressure drop is ‘much higher than the pressure drop of a comparable E-shell. Other important shells are the J-shell and X-shell. In the divided flow F shell, fluid entry is centrally located and split into two parts. The single nozzle is at the midpoint of the tubes, and two nozzles are near the tube ends. This shell is used for low pressure drop design applications such as a condenser in a vacuum, since the J-shell has approximately 1/8 the pressure drop of comparable E-shell. When itis used for a condensing shell laid, it will have two inlets for the vapor phase and one central outlet for the condensate. The X-shell has a centrally located uid entry and outlet, ustally witha distributor dome. The two fluids are aver tha entire lanath af tha hubs Stell-and-Tube Heat Exchangers 285 vy TD) +e ui | ND remersineccane common ||| aes HoUuRE a2 Standards ypes an rn nd and ea end ad yes (Couey ofthe Tabular changer Manufacturers Association.) a a ie Consequently, the pressure drop is extremely low. It is used for vacuum condensers and low-pressure gases. ‘he split flow shells such as the Gshell and H-shell are used for specific 4pplications. The split flow G-shell has horizontal baffles with the ends _ [fmoved; the shell nozzles are 180° apart at the midpoint of tubes, Tho G-shell286 Heat Exchangers: Selection, Rating, and Thermal Design, Second Editing I ® ey oe bre 5) = ( ir E: OnePass Stat F T-Pas Set & SoitFow wntongte Bale Teer sree pee Fea] [Se] peo tL L I zi FH: Doue Sot Fon J: Croetow A: Orton (Consinet fw ‘orConente) FIGURE @.3 ‘Schematic sketches of most common TEMA sbell types, (From Butterworth, D. 1988] in Tay ‘Pas Flow Heat Exchangers: Thermal Hire Fandanertals and Design, Klusver Publishers, The "Netherlands. With permission ) flow rates. The G-shell can be used for single-phase flows but is very often ‘used aa horizontal thermosiphon reboiler. In this case, the longitudinal baifle serves to prevent flashing out ofthe lighter components of the shell fluids and provides increased mixing. The double split flow H-shell is similar to the G shell but with-two outlet nozzies and two horizontal baffles. ‘The K-shell is a kettle reboiler with the tube bundile in the bottom of the shell covering about 60% of the shell diameter. The liquid covers the tube bundle and the vapor occupies the upper space without tubes. This shell is used when a portion of a stream needs to be vaporized, typically. to a distillation column. The feed liquid enters the shell at the nozzle near the tube sheet, the nearly dry vapor exits out the top nozzle, and non-vaporized liquid overflows the end weir and exits through the right-hand nozzle. The tube bundle is commonly a U-tube configuration. 8.2.2 Tube Bundle Types The most representative tube bundle types are shown in Figures 84-86? The main design objectives here are to accommodate thermal expansion, f furnish ease of cleaning, or to provide the least expensive construction ff other features are of no importance. ‘One design variation that allows inclependent expansion of tubes and shell is the Ustube configuration (Figure 8.4). Therefore, thermal expansion is unlimited. The U-tube is the least expensive construction because only one Shell-and-Tube Heat Exchangers 287 FIGURE 8.4 {0) A bore U-tube, baffled single pass shel, shell and-tube heat exchanger (courtesy of the Patteson-Kelley Co); and (b) Srined U-tube shell and-tube heat exchanger. (Courteny of ThownFintube) FIGURE 8.3 ‘Atwo puss tube, hatfed single pase shel hell anc-tube heat exchanger designe for mechan ‘cl cleaning ofthe inside ofthe tubes. (Courtesy of the Patterson Kelley Co} fixed tube sheet configuration is shown in Figure 85. The shell is welded to the tube sheets and there is no access to the outside of the tube bundle for cleaning. This low-cost option has anlv limited thermal exnansinn which292 Heat Exchangers: Sel FIGURE 8.7 Tube layout angles F-shell has a longitudinal baffle). The transverse baffles may be classified a: plate baffles and rod baffles. The most commonly used plate baffle types ar shown in Figure 8.8 and are briefly described below: The single and douile segmental baffles are most frequently used. They diver the flow most effectively across the tubes. The baffle spacing, however, must be chosen very carefully. Optimum baffle spacing is somewhere between 0.4 and 0.6 of the shell diameter and a baffle cut of 25% to 35% usually recommended. The triple and no-tubes-in-window segmental bale are used for low pressure drop applications, which are approximately D5 and 03 of the segmental value. No-tubes-in-window construction eliminates the uupported only by every second baffle, thus minimizing tube vibration. Disc-and-ring (doughnut) baffles are composed of alternating outer figs and inner discs, which direct the flow radially across the tube field, THe potential bundle-to-shell bypass stream is thus eliminated; there are some indications that the baffle type is very effective in pressure drop to heal transfer conversion. At present, these baffles are rarely used in the Uaitel States but are popular in Europe. Another type of plate baffle is the ori h the clearance between tube es that are otherwi baffle, in which shell-side fluid flows thro outside diameter and baffle-hole diameter. Rod or grid baffles are formed by a grid of rod or strip supports (Figure The flow is essentially longitudinal, resulting in very low pressure drops Because of the close baffle spacing, the tube vibration danger is virtually| Shell-and-Tube Heat Exchangers 293 292 Heat Exchangers: Seton, Rating, and Thermal Design, Second Editi TABLE 8.3 a oe or 2 u x0 %6 % mM 70 % 2 a 1/4 11 2 ns a0 wa 203 i m 16 wie 22 25 216 20 nw a6 zm mm m0 nua 34 we 28 2 5 7 2 Be Po 2D 58 48 os a 2 = 385 8 oes a 718 om 66 10 we co 8 856 ra 75 ma s Ps se oo 38 FIGURE 87 2 1074 sos we 386 = ‘ube layout angles. xs 1206 11% 1% 1109 108 5 in, OD. Tubes om 1 14ein, Triangular Pitch plate baffles and rod bafiles. The most commonly used plate baffle types are A a 2 a i shown in Figure 88 and are briefly described below. = 10 2 2 6 Er ‘The single and double segmental baiiles are most frequently used. They 2 55 2 48 6 “ ' divert the flow most effectively across the tubes. The baffle spacing, however, Bua @ 6 8 st if must be chosen very carefully. Optimum baffle spacing is somewhere ei 2 & 0 nm 2 between 0.4 and 0.6 of the shell diameter and a baffle cut of 25% 0.35% | giv i 2 16 mm a usually recommended. The triple and no-tubes-in-window segmental baffles} 11/4 ~” 188 a bed are used for low pressure drop applications, which are approximately BS | 21/4 2 mm m 2 za { and 0:3 ofthe segmental value. No-tubes-in-window construction elinaies | 25 a a 256 252 ered wise su ly by every second baile, wa a 6 the tubes that are otherwise supported only by every second baile, this Zz i EI 2 Bs 2 i minimizing tube vibration. oe F 7 ms xe i 36 1 Disc-and-ring (doughnut) baffies are composed of altesnating outer rieys S i 3 i or ! and inner discs, which direct the flow radially across the tube field. Te | es eo ay ie Ms ‘ potential bundle-to-shell bypass stream is thus eliminated; there are some ao om a 62 ou 38 | indications that the baffle type is very effective in pressure drop to heat » 766 76 70 688 en : transfer conversion. At present, these baffles are rarely used in the United kin. O.D. Tubes on Lim. Square Pilce i States but are popular in Europe. Another type of plate baffle is the orifice baffle, in which shell-side fluid flows through the clearance between {ube y 2 26 20 20 outside diameter and baffle-hole diameter. : a 2 2 ® % : Rod or grid baffles are formed by a grid of rod or strip supports (Figures: | 31/4 o 0 2 % a ‘The flow is essentially longitudinal, resulting in very low pressure Si iw 2 16 i a Recatise of the close baffle soacine. the tube vibration danger is virtually a we 166, 158 150) rss294 Heat Exchangers: Selection, Rating, and Thermal Design, Second Edi and-Tube Heat Exchangers a 295 TABLE 8.3 (CONTINUED) | J TABLE 8.3 (CONTINUED) ‘Tube Sell Layout Tube Counts) "Tube Shell Layouls (Tube Counts) Shell 1D (a5 _________ in) ww a oe ee 1 a ap or ap fbn, OD, Tubes on Tn. Square Pitch ‘bin, O.D. Tubes on 1 9/16-in. Square Pitch ava ” 2 Ms 20 Ey 2/8 oat mm 203 a2 = » 2s a3 at a” 6 3 2B 6 6 2 s “ ra a0 % » 2 2 2 5 56 40 ss % 2 4s a at 657 640 600 550 36 a 48 “a 3 79 718 688 6 6s a ao 56 % os m m0 26 7 % 2 x 9 2 sie 85 7 105 1 6 % 108 1 om 6 2 2 1s i Me ue DT on 11/6 Spare Ph i i ig 8 a 6 “ ae a 3 Fa 2 2 Ps 24 i zs Be h * s re FA Fa 28 3 ae a 5 2 « ais Ee Es Bua st % & « wi 2 m 5 50 wis 5 12 rr @ ae rd 166 16s 132 Bus 213 28 1 ie 2% 250 BY 28 26 Zz 500 2s ms as 2 an 3 ito se a 406 3s 0 38 S 4 so 2 = s m2 8 8 & 2 36 m4 se oi s os ou a ia tn OD, Tabes on 156m Tengu Pith 8 4% 2 6 2 rd @ Fa ao a 2 108 ss & 2 ave 7 a oe ° B14 ” 10 10 Bs is a 2a we 18 Bis so 2 252 2 na 3a 32 su 06 nua ao 2 586 os 5 502 50s as M6 Zz o oa 0 5 ® mt 2 eo 0 a a 2 16 mm 3 m 228 om oS 8 nea we EsDesign, Second Eaton TABLE 8.3 (CONTINUED) ‘Tube Shell Layouts (Tube Counts) ap or or Shell and-Tube Heat Exchangers BL 2B z 1m 2 m2 a 5 33 38 zs 3 37 315 2 a7 37 8 49 7 From Kern, D @ (950) Process Heat Tans, McGraw Hil, New York. With permis, 8.2.6 Allocation of Streams A decision must be made as to which fluid will flow through the tubes ad which will flow through the shell. In general, the following, considerations apply: ‘+ Themore seriously 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. Because of thelr small diameter, normal thickness tubes are available to withstand higher pressures and onl ibe-side channels and other connec: tions need to be designed to withstand high pressure + The corrosive fluid must flow through the tubes; otherwise, both the shell and tubes will be corroded. Special alloys are used to resist corrosion, and itis much less expensive to provide special alloy tube: ‘than to provide both special tubes and a special Singie-segmortal bafile $8, 833838 Bato 2 97298 Heat Exchangers: Selection, Rating, and Thermal Design, Second Edition Shell-and-Tube Heat Exchangers 299 Problem Identification Tho Elemonts Win this Boxtay oe Dorey { Hard ar Computer Selection of a Basle Heat Exchanger Typo Selection of a Tentative Set ‘of Exchanger Design Parameters Moatiation atthe Basign Paramotere of the Design: ‘Thermal Performance Pressure Drops Evaluation of the Design: Q, aP Acceptable? ‘up suppor by tour rods {60 angi around pergheny psesrarie » @ Mechanical Design, Costing, Eto, “$i loge structure for process h ‘hoger: Thema Hydric Funda exchanger design. (Based on Bel nd Design, Taylor and Frat engineer must be discussed in detail. The main duty of the process 4s to supply all the information to the heat exchanger designer. At this point in the design process, the basic configuration of the heat changer must be tentatively selected, ie., whether itis to be U-tube, baffled ile-pass shell, a tube pass, baffled single-pass shell with fixed tubes, or a lLand-tube heat exchanger with a floating head to accommodate difer- thermal expansion between the tube and the shell, if one is not uncon- step is to select a tentative set of exchanger inary estimate of the heat exchanger size can be m 8.3.1 below, Then the initial design will be rated; the thermal performance and the pressure drops for both streams x exchanger must satisfy the process requ rvable presore crops unt the newt shel de gical structure of the process heat exchanger de cedure is shown in Figure 8.10. ae eatin net etae scone pte like flow rates and compositions (condensation or boiling), inletand smperatures, and pressures ofboth streams, but also the exact req ments of the process engineer and the additional information needed fProblem 3.10 a i il isi i molds number of 1000. Gder the laminar flow of an oil inside a duct with a Reyn ol ith of the duct is 2.5m and the diameter is 2 em. The duct is heated electrically By the ee of its walls as an electrical resistance. Properties of the oil at the average oi temperature are: p=870 kg/m’, j1=0.004 N.sim’, and ¢,=1959 ‘Ikg,K, and k=0.128 W/m.K. Obtain the local Nusselt number at the end of the duct. GIVEN Oil flows through a duet -Reynolds number (Re) = 1000 Length of duct (L.) = 2.5m Diameter of duct (@ FIND Local Nusselt number at the end of the duct LUTK Properties of the Oil: p=870kg/ a? k= 0.128 W/(mn-K) COA Pas = 1959 J/kg. K _ Slt _ (495902004) Peese’ ais =6122 Pectet number: Pe =Re-Pr= (1000)(61.22) = 61220 Be-d (61220000) _ 99 76 c 25 : Pe-d ig: la Pee stant heat Using the Nusselt and Gractz correlation for laminar flow and —j~> 10"; co oft) Nu =(1.953)(489.76)¥ = 15.39 flux: Nu= Problem 3.11 Ina crossflow heat exchanger, hot air at atmosphere with an average velocity of 3m/s flows| across a bank of tubes in an array with X;= X,= Sem (see Figure 3.2) . The tube diameter is 2.5em. The array has 20 rows in the direction of flow. The tube wall temperature is 30° C, jand the average air temperature in the bundle is assumed to be 300°C. Calculate the! average heat transfer coefficient and repeat the calculation if the array bas six rows in the flow direction. GIVEN, Tube wall temperature (P,) = 30°C -Average air temperature in the bundle (T,) = 300°C -Face velocity U.= 3 ms, In-tube arrangement x, 05 m FIND Average heat transfer coefficient h. SOLUTION From Appendix B (Table B.1), the properties of dry air at t =300 °C and atmosphere pressure p= 0.6157 kgm? k= 0.045 Witm-K) = 2.95x10" ms, Pr = 0.68 c, =1047 kg. K At wall temperature T, = 30°C, Pry = 0.708 For calculating Reynolds number, we must determine the smallest flow section 1-1, According to mass conservation equation PULA face = PUA min Uy =u, Ae. = 3x 9% mis Ania 05— 0025 Thus Re = YodoPs _ 6% 0.025 x0.6157 3130.68 By 2.95 x10 So we can use Equation (3.42c) to calculate Nuy 9=20, C,=1.0 ( n>16) =0.27%1x313068 x0.68"%x{ 2.68 07708, =37.0«Nu, _ 0.045 x37.0 Problem 3.12 [Repeat Problem 3.1 a hheat exchanger employs a bank of Staggered bare tubes with a longitudinal pitch of dem and transverse Situation I: (n=6) Feom Figure 3.3, it can be seen C,=0.95 s GIVEN, 02s -X, =0.04m, X, = 0.05 m, Staggered-tubes 27€, Reg wna fe } 1 Nu sozrragsatsocerexanie( 9) =35.8 . 4 EN 0.045x35.8 DONS SSS = 64.4 Wim? -K d, 2.5107 FIND Average heat transfer coefficient b. Air thermal properties are similar to Problem 3.11 AC first, we need to determine the maximum velocity across the tube-bank, the area of section 1-1 in Figure 3.2 is 2 XP (x, 2) dy = 0.04? + 0.025? ~0.025 - 0.022 The minimum flow area at front face is % =X, —d, =0.05~0.025 = 0.025 Because of2x.x, =0.044>0.025, the minimum cross-sectional area and maximum velocity are at Ay, PUA face = PUOA min Uy =U, Meet = 3x 3 095 gens a a Re, = ela _ 6T72x0025%06 _ aygy : x 2.95x10" { For staggered bundles at Reynolds number = 3082, we can use Equation (3.43c) to calculate a Nuy cone Pe) OG)Nu, =0.35x1x3082* x0. oe = 70.6 Win (n=6) #-C0.95 (From Figure 3.3) Nu, =0.35x0.95x3082° once 37.28 0.708 mon mK 068) 0.708, 0.04 005 0.04 ' Problem 3.13 A shell-and-tube heat exchanger is to be used to cool 20 kg/s of water from 40°C to 20°C. ‘The exchanger has one shell-side pass and two tube-side passes. The hot water flows through the tubes and the cooling water flows through the shell. The cooling water enters at 15°C and leaves at 25°C. The maximum permissible pressure drop is 10 kPa. The tube wall thickness is 1.25 mm and is selected as 18 Birmingham wire gauge (BWG) copper. The length of the heat exchanger is 5 m. Assume that the pressure losses at the inlet and outlet are equal to two of a velocity head (pu,'/2). Find the number of tubes and the proper tube diameter to expand the available pressure drop. (Hint: assume a tube diameter and average velocity inside the tubes.) GIVEN ~A shell-and-tube heat exchanger, with hot flowing through tubes. “Hot water inlet temperature (Tz) = 40 °C -Hot water outlet temperature (Tp) = 20°C “Mass flow rate of hot water (it) = 20 kg/s Cooling water inlet temperature (To1) = 15 °C -Cooling water outlet temperature (T,3) = 25 °C -Maximum permissible pressure drop (Ap) = 10 kPa -Length of heat exchanger (L) = 5m Pressure losses at the inlet and outlet (Ap) = pray? -18 BWG copper tube with wall thickness of 1.25 mm FIND Number of tubes and proper tube diameter fo expand the available pressure drop. SOLUTIC Properties of water at Ty, = 204.40 =30°C: 2 9956 kg/m? =7.98x10* Pas =4179 kg. Kk =0614 W/mK 44 Assume that the average velocity Ug = 1.5 m/s, and try 3/4 I8BWG tube dimensions as: geometrical 3/4 18 BWG tube: LD. = 0.652 in; Internal area A, = 0.3339 in2; So, ring 2 PugA, — 9956%15% (0.0000 Ny 68 151603339) tea Ptah, 285%1960652°0025) 09 crud i {roxio™) Flow regime is turbulent flow.Using Blasius correlation in Table 3.4: f = 0.0791 Re” =0.0791x30992°* = 0.00596 (Lo?) eovoxassosenis = ot Niu? From force pressure, net pressure force = total shear force Ap-AG Ny =Te AQ Ne _AtyL_ 4x668x5 Bee 0.0254 x 0.652 Ap. =8067 kPa “The total pressure drop is: Ap, =Ap + Ap, = AP + Pty? =8067 + 9956%15? = 8067 +224 =10307 KPa > 10KPa Since the total pressure drop is more than permissible pressure drop, so another type of tube is tied (or reduce the average velocity Ua): W818 BWG tube: LD. = 0.777 in; Internal area A, = 0.4742 in”; _ and we following the same procedure as previous to sce if the pressure drop is less than permissible pressure drop. tty 20 N= = neg + page 9956%15% (00000645 16% 04742) Re = Pttath,_ 995.615 (0.777 0.0254) 56554 Crurbutent) “ (798x107 Flow regime is turbulent flow. Using Blasius correlation in Table 3.4 F =0.0791Re** = 0.0791x36934°* = 0.0057 }-o00sr0 5x995.6x 1.5? = 6.38 Nim? Ap:Ag Ny = ty Ag-Ny At,L_ 4x6.38%5 s = = 6.465 kPa d, — 0.0254x0.777 The total pressure drop is: Ap, = Ap + Ap, =Ap + pu,” = 6.465 +995,.6x1.57 =6.465+2.24-8.71 kPa <10kPaePrTn ToD | Q=aG a) rhe=? di, do, fh, fo, Pr Assume Viste Estimate * N’ # passes, D,, No Nr=N adjust Vy Rey > Nu; Phy AT=? A ise =? © = Anwjxe*Hd.N,) Test Mechanical @ : Design EeeeT alone? Repeat ‘NO EAP sien? Frey APuie? Shell and Tube Heat Exchanger Design--Fiow GhartG2 MeT wT eT oT 2 Rei Nui Phy Q= an a0) aT=? NO K P < hn? A surtce =? Po Assume tube mtl, size, © = Apa *Hd,N) iy dy, , ho, Pr @ Avia CAN, Assume Viahe eet roe? Test Mechanical Design Estimate ‘Ne eer [NO LAP stent? # passes, Dy, Ny fiutes APrive ? Nr=N adjust Ve Shell and Tube Asuess= 7 Heat Exchanger 7 eae Design—Flow Chart ®