Designing

Spiral-Plate
Heat Exchangers
Spiral-p,late ex~hangers offer compactness, a variety of f,low arrangements,
efficient heat transfer, and low maintenance costs. lihese
and other features are described, along with a shortcut design method.

P. E. MINTON, Union Carbide Corp.

Spirall heat exchangers have a number of advantages over conventional shell-and-tube exchangers:
centrifugal forces increase heat transfer; the compact
configuration results in a shorter undisturbed flow
lengtH; relatively easy cleaning; and resistance to fouling: These curved-flow units (spiral plate and spiral
tube") are particularly useful1 for handing viscous
or .solids-containing fluids ..

water. Electrodes may also be wound into the assem.

bly to ano.dlcally protect surfaces ag~inst: corrosion.
Spiral-plate exchangers are normally designed' for,
the full pressure of each passage. Because the turns
of the spirall are of relatively large diameter, each
turn must. contain its design pressure,, and plate thickness is somewhat restricted-for these three reasons,
the maximum design pressure is 150 psi.,. although
foX' smaller diameters the pressure. may sometimes be
higher. J.:.imitations of materials of construction gov
ern design temperature.

Spiral-Plate-Exchanger Fabrication
Flow Arrangements and Applications
A spiral-plate excHanger is fabt'icated from two
relatively long strips of plate, which, are spaced apart
and wound around an open1 split center' to form a
pair of concentric spiral 1passages. Spacing is maintained uniformly along the length of the spiral by
spacer studs welded to the. plates.
For most services, both, fluid-flow channels are
closed by alternate channels welded at both sides of
the spiral plate (Fig. 1) .. In some applications, one
of the channels is left completely open (Fig. 4) ,.
the other closed at both sides of the plate.. These
two types of construction' prevent the fluids from,
mixing.
Spiral-plate exchangers are fabricated from any
material that can' be cold worked and welded, such'
as: carbon steelj stainless steels, Hastelloy :m and: C,
nickel and nickel alloys, aluminum alloys, titanium,
and copper alloys.. Baked phenolic-resin coatings,,
among others, protecti against corrosion from cooling
Although the spiral-plate and spiral-tutJe exchangers or aimHar,
their applications. and methods of fobricaticm ore. quit different; Thi~
article i devoted wholly. to the spital-plate exchanger; an article in
tiM Ml:ly 18 i1we of Chemical fnginH,;ng wilt take up the 1-piral+tul:Je
exchanger.

For infonnation on aheU-and-tvbe exchangen, se. Ref. 8, 9,

The desion method presented is used: bf, Union Carbide Corp, for the
thermal and hydraulic det,ign of IP!irat-p ate exchangers, and, is lOme

wllot,dilfe,...nt from that used by the fabricator.

Reprinted from CHEMICAL ENGINEERING, May 4,. 1970 Copyright

The spiral assembly can' be fitted with covers to

provide three flow patterns: (:1) both fluids in spiral
flows; (2)' one fluid in spiral flow andi the other in
axial flow across the spiral; ( 3), one fluid: in spiral
flow and the other' in a combination of axial and
spiral i flow.
For spiral flow in both channels,. the spiral assem.
bly includes flat covers at both sides (Fig. 1). In
this arrangement, the fluids usually flow countercurrently., with the cold fluid entering at the periphery
and Bowing toward' the core; and the hot fluid entering at the core andi flowing toward the periphery.
11his type of exchanger can be mounted with the
axis either vertical or horizontal. It finds wide
application' in liquid-to-liquid service,. and for gases
or condensing vapors if the volumes are not too large
for. the maximum flow area of 72 sq. in.
For spiral flow in one channel, and axial flow in
the other, the spiral assembly contains conical covers,
diShed heads, or extensions with, flat covers (Fig. 2).
h1 this design, the passage for axial flow is open. on,
both sides, and the spiral flow channel is welded on
both sides.
This type of exchanger is suitable for' services in
1970' by McGtawHill I no. 330 West 42nd St New York, N.Y. 10036

2030368834

SPI,RALPLATE EXCHANGERS

SPIRAL FLOW in both channels is widely

use~ig.

which there is a large difference in the volt.unes

of the two liquids. This includes liquid-liquid service,
heating or rooling gases, condensing vapors, or as
reboilers. It may be fabricated with one or more
passes on the axial-flow side. And it can be mounted
with the axis of the spiral either vertical or horizontal (usually vertically' for condensing or boiling)'
For combiMtion flow, a conical cover dist:ibutes
the fluid into its passage (Fig. 3). Part of the spiral
is closed at the top, and the entering fluid flows
only through the center part of, the assembly; A flat
cover at the bottom forces the fluid to Bow spirally
before leaving the exchanger.
This type is most often used for condensing vapors
(mounted vertically)' Vapors &rst flow axially until I
their volume is reduced sufficiently for finali condensing and subcooling in spiral flow.
A modification of this type: the column-mounted
condenser (Fig. 4). A bottom extension is flanged
to mate with the column. flange. Vapor flows upward
through a large central tube and: then axially across
the spiral, where it is condensed. Subcooling may
be by falling~film. cooling or by controlling a level
of condensate in the channel. In the latter case, the
vent stream leaves in spiraf flow. This type is also
designed to allow condensate to dropointo an accumulator without appreciable subcooling.

FlOW is spiral in one channel, axial in other,.-Fig. 2

The spiral-plate exchanger offers many advantages

over the shell-and-tube exchanger:
(1)' Single-flow passage makes it ideal for cooling
or heating sludges or slurries. Slurries can. be proc
essed in the spiral at velocities as low as 2 ft./sec.
For some sizes and: design pressures, eliminating the
spacer studs enables the exchanger to handle liquids
having a high content. of fioers.
(2) Distribution is good because of the single-Bow
channel.
{3) The spiraHplate exchanger. generally fouls at
much lower rates tlian the shell-and-tube exchanger
because of the single-How passage and curved-How.
path. If it fouls, it can be effectively cleaned chemically because of the single-How path and reduced
bypassing. Because the spiral can also be fabricated:
with identical! passages, it is used for services in
which the switching of fluids allows one fluid to
remove the scale deposited by the other.. Also, because the maximum' plate width is 6 ft.,. it is easily
cleaned with. High-pressure water or steam.
(4). This exchanger is well suited for heating or
cooling viscous fluids because its LID' ratio is lower
than. that; of tubular exchangers. Consequently, lam
inar-flow heat .transfer is much higher for spiral plates.
When' heating or cooling a viscous fluid, the spiral
should be oriented with the axis horizontal. With

COMBINAnON FLOW is used to condense vapors-Fig. 3

the uis verticaL the viscous fluid stratifies and this

reduces heat transfer as much as 50%.
(5)' With both fluids fl.owing spirally, flow can
be countercurrent (although not truly so, because,
throughout the unit, each channel is adjoined by an
ascending and a descending turn of the other channel! and because heat-transfer areas are not equal
for each side of the channel, the diameters. being
different). A correction factor may be applied;l how~
ever, it is so small' it can generally be ignored.
Countercurrent flow and' long passages make possible clbse temperature approaches and precise temperature control.
{6) The spiral-plate exchanger avoids problems
associated with differential thennal expansion in noncyclic service.
(7) In axial flow, a large_flow area affords a low
pressure. drop, which becomes especially important
when condensing under vacuum.
(8) This exchanger is compact: 2;000 sq. ft. of
heat-transfer surface in a 58-in.-dia. unit' with a 72in.-wide plate..

Umitations Besides Pressure

In addition to the pressure limitation noted earlier,
the spiral-plate exchanger also has the followimg
disadvantages:
{1 Repairing it in the field is difficult. A leak
cannot be plugged as in a shell~and-tube exchanger
(however, the possibility of; leakage in a spiral is less
because it is fabricated from' plate generally much
thicker than tube walls). Should a spiral need I repairing, removing the covers exposes most of the welding
1

CHEMICAL ENGINEERING/MAY 4, 1970

MODifiiED combination flow serves on

colum~g. 4

of the spiral assembly. However, repairs on the inner

parts of the plates are complicated.

(2) The spiralplate exchanger is sometimes precluded from serviee in which thennal eyclmg is
frequent. When used in cycling services, its mechani-.
cal. design sometimes must be altered to provide. for
much higher stresses. Full-faced gaskets of compressed asl:lestos are not generally acceptable for
cycling services because the growth' of the spiral!
plates. cuts the gasket~ which results in' excessive
bypassing and; in some cases,. erosion of the cover.
Metal-to-metal seals are generally necessary.
( 3) This exchanger usually should not be used
when a hard deposit forms during operation, be-
cause the spacer studs prevent such' deposits hom
being easily removed by drilling. When1 as or some
pressures,. sucli studs can be omitted, this. !.imitatiOn
is not present'
( 4) For spiral-axial' flow, the temperature difference
must be corrected. The conventionali correction for
cross flow applies. Fluids are not mixed\ flows are
generally single pass. Axial B.ow may be multipass.

SHORT,tUT RATING METHOD

The shortcut rating method for spiral-plate exchangers depends on the same technique as that

2030368836

SPIRAL-PLATE EXCHANGERS

Empirical Heat-Transfer and Pressure-Drop Rel'ationshi'.p

Eq.
No. Mechanism or Restriction

EmpiricaliEquation-Heat Transfer

Spiral Flow
(l) No phase change (liquid~' N
{2) No phase change (gas),N11.

h = (11 + 3:54.D,!Du)

> N 11u

> N 11...

(3) No phase change (!liquid), NR.,

h = (11

+ 3.54 D,/D 11 }

0~023cG (NM.)- ~Pr)-' 11

0.0144 cG (D,) -.:

< N ~<

Spiral or Axial Flow

(4) Condensing vapor, vertical, Na.

< 2,100

(5,) Condensate subcooling, vertical, N.,

~6)

Axia1 Fiow
No phase change (lliquid}, N 11 ,

n>

No phase change (gas). N Re

k = 0.925 k [gcpL'IJ<ll]l' 1"

< 2,100

h = 1.225 k/B [cB!kL.~~]' 1 '

> 10,000

> 10,000

(8) Condensing vapor, horizontaH N R

h = 0.0144 c G"". (D.) -':

< 2,100

(9) Nucleate boiling, vertical

Plate
(10) Plate, sensible heat transfer

It= 12 k,./p

(11) Flate, latent heat transfer

h = 12 k.,/p

Fouling
(12) Fouling, sensible heat transfer

h =assumed

(13) Fouling, latent heat transfer

h =assumed

Eq.
No. Mechanism or Restriction

E!Tlpirical

~ [d~r Ld,1
1~-!;;5) (~r + 1.5 + ~]

< N 11 , < Nt..c

t>.P = 0001

Jl [. 1.035 Z!' (~)"." (.#-)'"

,- , 16sL [-W
d~H (d~ 0.125) z~
W
+ 1.;>
L-

< 100

t>.P =

>N

(15~,

(Hi) No phase change, N11.

11..-

> 10,000

(19) Condensing

3,38~~~,): "(i;J" (~)

Notes:
1. NR..- = 20,000(D,/D/1) 0 "
2 .. G = W.pd(Ap,,)
3. Surface-condition factor

t>.P = 0;000 5 -;

d,H

t>.P = 4 x 10-'
s d~'

(w)u
L

t>.P =

(~')

-++

-t;

L [ W ] [

(17) Condensing

AxiaJIFiow
(18) No phase change, N 11 ,

Drop

aP = 0:0011

Spiral Flow
(14) No phase change, N ~<
No phase change, 100

Equation>-~ressure

(d,

1.3

z;

/,H)\''

+ 0.125) \w ' + 1'.5 +

0.0115 z'

1'L6]

!!.. + 1 + 0.03 H
d,

d~?~-. (~)' [ Oi0115,zo' ~ + 1 + 0.03 H J

for copper and steel= LO; for stainless steel= 1.7; for pol.ished surfaces= 2.5.

MA'20~EERING

for Rating Spiral-Plate Heat Exchangers-Table I

Physical
Property Factor

:o-:"umerical
Factor

:..T,
~

= 20.6

,.....

z"M

'II

:,,
,.

W... (T;,-TL)
flT 11
W ... (T"-T,,)
flT11

= 19.6

-1 ..

.! 77,

=32.6

= 3.8

II

1.18

= 167

M'''(z,)"

M''"Z'',

11

M''"Zl'11

..,.'"
-~

... r ..

.l.

z4M"'

X
X

500

:.T,. = 278

W0'(TH-TL)

8 .....

zlMts
-C8 2

ll.T.
W(TH-TL)
ll.T11

Pto.r

P"

k..
c

h.

~~: = 3,333

W'' A

cs

k,
1

X
X
X

d,

LH
d,
LH
d,
LH"i7

-IH

HtLt

X
X

ll.T.

wA

ll.T11
W~TH-Td

ATM

WA

ll.T11
W(Tit-Td
flT11

WA

ll.T11

(See Note 1)
(See Note 1)

LH

1Ii

d,
HL
d,
H0"
Lt3Hr

(See Note 1

Mza'"

= 6,000

J.T,
J.T,.

ll.T~r

= 0.619

J.T II

ll.T
W 11 (T .. -Td

8 .,.

= 158

.r

;..!_ = 16.1

W'',A

cs

W 2' 3 (T 11 -TL}
flT 11

s"'' (,z.p.u

MecHanical
Design Factor

Work
Factor

d,"'I'

(See Notes 2 and 3)

p
_.1?._

LH
1

LH
1

LH

(See Note 1)
(See

Note

1:)

CHEMICAL ENGINEERING/MAY 4,.1970

2030368838

SPIRALPl.ATE.. EXCHANGERS

for sheU.and~tube heat exchangers (which were discussed oy Lord, Minton and Slusser&).
Primarily; the method combines into one relationship the classical' empirical equations for fihn, heattransfer coefficients with heat'-ballmce equations and
with correlations tHat describe tHe geometry of the
heat exc~ger. The resulting .overall; equation is
recast into three separate groups. that contain factors
relating to the physical properties of the fluid, the
performance or duty of the exchanger, and the
mechanical design or arrangement of the heat-transfer
surface. These groups are then multiplied tbgether'
with a numerical factor to obtain a product that is
equal: to' the fraction of the total driving force-or
log mean temperature difference (b.Tll or LMTD)that is dissipated across each element of resistance
in the. heat-How path1
When the sum of the products for the individual
resistance equa15 1, the trial design may be assumed
to be satisfactory for heat: transfer. The physical
significance is that the sum of the temperature drops.
across each resistance is equal to the total available
t!.Tll The pressure. drops for both' fluid~flow paths
must be checked: to ensure that: both are within
acceptable limits .. Usually, several trials are necessary
to get a satisfactbry balance between heat transfer
and pressure drop.
Table I summarizes the equations used with the
method for heat transfer and: pressure drop . The
columns on the left list the conditions to which each
equation applies, and the second columns. gives the
standard forms of the correlations for .6hn coefficients
that are found in texts. The remaining columns in
Table I: tabulate the numericaL physical property,
work and mechanical design factors-all of which
together. form tlie recast dimensional equation. 1'he
product of these factors gives. the fraction of total
temperature drop' or driving force ( tJ. T1/b.T11 ) across
the. resistance.
As stated, the sum of t!.Thl t!.T11 (the hot-fluid
factor), tJ.T./tJ.TM (the cold-fluid factor)', b.T,/b.TJI.
(the fouling factor), and AT..,/ti.T11 (the plate factor)
determines the adequacy of: heat transfer. Any combinations of b.T1/ b.T11 may be used, as long as the
orientation specified: by the equation matches that
of the exchanger's flowpath ..
The units in tHe pressure-drop eq1.1ations are consistent with those used for heat transfer. Pressure drop
is calculated directly in psi.

Approximations and Assumptions

For many organic liquids, thermal conductivity
data are either not available or difficult to obtain.
JSecause molecular weights ('M) are known, the
Weber equation, which, follows,. yields thermal conductivities. whose accuracies are quite satisfactory

for most design purposes:

k - 0.86 (q#'/M"')

u; on the other hand, the thermal conductivity

is lrnown, a pseudomolecular weight may be used:

M -= 0.636 (c/k)l~
In what follows, each of tHe equations in Table I'
i~ review~d, and the conditions in which each equation apphes, as well as its limitations, are given 1
Jn, several' cases, numerical factors are inserted or
appr?xim~tions made, so as to adapt the empirlcal
relationshtps to the. design of spiral-plate exchangers.
Such modifications have been made to increase the
accuracy, to simplify, or to Broaden the use of the
~ethod. Rather than by any simplifying approximations,. the accuracy of the method is limited by. that
with which fouling factors, fluid properties and fabrication tolerances can be predicted.

Eq:uations tor: Heat; Transfer-Spiral Flow

. Eq; (1):.-No Phase Change (Liquid), NR..

>

Na .--

1~ for. liquids with Reynolds numbers greater than

the critical Reynolds number. Because the term

(1 + 3.54 D,IDH) is not constant for any given
heat, exchanger, a weighted average of 1.11 has oeen
used for this method. If a design is selected with
a different value, the numerical factor can be. adjusted
to reflect the new value.
Eq. (2):..-No Phase Change ~Gas), N 11 , > NR.rc-is
for gases with Reynolds numbers greater than the
critical ReynoiCis number;. Because tlie Prandtl number
of common gases is appromately eq)Ja) to 0178: and
the viscosity enters only as l-'o.2, the relationship of
physical' properties for gases is essentially a constant.
This constant, when combined with the numerical
coefficient in Eq. (I) to eliminate the physical prop.
erty factors for gases, results ih Eq. ( 2). As in Eq. (l ).,
the term (1 + 3.54 D,/D'H) has been taken as l.L
Eq. (3)-No Phase Change (,Liquid), N 11 , < N 11 , . is for liquids in laminar Bow, at moderate ~T and
with' large kinematic viscosity (p.Lfp). The accuracy
of the correlation, decreases as the operating conditions
or the geometry of, the heat-transfer surface are
changed tQ increase the effect of natural convection.
For a spiral plate:n
(D/L)1 11 = [12 112 D,j(DHd,)"J"' = 2"' (d,/dn)"

The value of ( d,/d;, )1'6 varies from 0.4 to 0;6. A value

of o,s for (d.ldH) 1' 8 has been used for this method.

Heat Tramsfer Equations-Spirator Axial Flow

Eq. (4}-Cond.ensing Vapor,. Vertical, NR.. < 2,100
-is for film condensation of vapors on a vertical
plate with a terminal Reynolds number (41J'/~) of
less than' 2,l00. Condensate loading (or) for veftical
plates is II' = W/2L. For Reynolds numbers above
2,100,. or fbr high Ptandtl numbers, the equation
should be adjusted by means of the Dukler plot,
as discussed by Lord, Minton, andi Slusser.s To use
Eq. ( 4)' most conveniently, the constant in it should
be multiplied by the ratio of the value obtained by
the Nusselt equation to the Dukler plot.
1'he preceding only applies to the condensation

of condensable vapors. Noncondensable gases in, the

vapor decrease the &1m coefficient, the reduction
depending on the relative sizes a the gas-cooling
load and the total cooling and condensing duty.
(A method for analyzing condensing in the presence
of noncondensable g~~Ses is discussed by Lord, Minton
and Slusser.~}
Eq .. (5)-Condensate Subcooling, Vertical,. Na. <
2,100-is fbr laminar films flowing in layer form down
vertical plates. ThiS equation is used when, the. condensate from' a vertical condenser is tb be cooled
below the bubble point. In, such cases, it is convenient to treat the condenser-subcooler as two
separate heat exchangers-the first operating only as
a condenser, (no subcooling), and the second as a
liquid cooler only. Fig. 5 shows the assumptions that
must be made to determine the height of each section,
so as to calculate intermediate temperatures that will

permit in, fum the calculation of the LMTID.

Eq. ( 4) is used in combination with appropriate
expressions for other resistances to heat transfer, tb
calirulate the height of the subcooling section. In tlle
case of the subcooling section only (See Fig. 5), the
arithmetic mean temperature difference,, [ ( T hm T..,.) + CThL - T.L)]/2, of the two fluids should
be used instead of the log mean temperature difference ..

Equations for Heat Transfer-Axial Flow

Eq. (6)-No Phase Change (Liquid)l NR.,

>

10;000

-is for liquids. with Reynoltls numbers greater than

Hl,OOO;.
Eq. (7)-No Phase Change (Gas),. NR., > 10,000is for. gases with Reynolds numbero greater than
10,000 .. Again, because the physical property factor
for common, gases is essentially a constant, thiS constant is combined with the numerical' factor in
Eq. (:6) to get Eq, (7).

Eq. (8)-CondenMg Vapor,. HorU:ontal, Na. <

2,100-is for &1m condensation on spiral plates ar-

ranged for horizontal axial flow witli a terminal

Reynolds number a less than 2,100. For a spiral
plate, eondensate loading (r) depends on the length
of the plate and spacing between adjacent plates.
For any given' plate length and channel spacing, the
heat-transfer area for each' 360-deg. winding of the
spiral fucreases with the diameter of, the spiral. The
number of revolutions affects the eondensate loading in two ways: ( 1) the heat-transfer area changes,.
resulting in' more condensate being formed in the
outer spirals; and (2) the effective length over which
the condensate is formed is.determiiled by the number
of revolutions and the plate width. 'Ilhe. equations
presented depend: on a value for the effective number
of spirals of: L/7. Therefore,. the eondensate loading is given by:.

r - W (1,000) 7 (12)/4HL- 21,000 W/HL

This equation can be corrected if a design is. obtained
with a significantly dilferent condensate loading.
It does not include allowances for turbulence due
to vapor-liquid sHearing or splashing of, the condensate. At high condensate loadings, the liquid
condensate on the bottom of the spiral channels may
blanket part of the exchanger,'s effective heat-transfer
surface.
Eq. (9)-Nucleate Boiling, Vertical-is for nucleate
boiling on vertical plates. In a rigorous analysis of
a thermosyphon reboiler, the calculation of heat
transfer is combined with the hydrodynamics of the
system to determine the circulating rate through the
reboiler. How.ever, for most design purposes, tliis
calculation is not necessary. For atmospheric pressure and higher, the assumption, of nucleate boiling
over the full height of the plate gives. satisfactory
results. The assumption of nucleate boiling over the
entire height of the plate in. vacuum service produces
overly optimistic results. (The mechanism of thermo-

Condensing
zone

stiBCOOUNGZONE calculations
depend on arittlmeticmean tem
perature difference of, the tWo
fluids instead of logmean tem
perature differenoes-Fig. 5
CHEMICAL ENGINEERING/MAY 4, 1970

2030368840

SPIRALPl.ATE EXCHANGERS

syphon reboilers has been already discussed by Lord,

Minton and Slt1sser.s. ')
A surface condition factor, I, appears. in the empiri
cal correlations for boiling coefficients. This. is a
measure of, the number of nucleation sites for, bubble
formation on the heated surface. The equations for
t!.Tt/tl.TII contaim,I' (the reciprocal of I), which Has
values of 1.0 for copper and steel, 1.7 for stainless
steel or chrome.nickel alloys, and 2.5 for polished
surfaces.

Nomenclature
A
B

c
c

D.

D.
D.
d,

G
g.

Equations for Heat Transfer-Plate

Eq. ~10) and (llrHeat Transfer Through the

Plate-are for calculating the plate factor. The integrated form of the Fourier equation is QlfJ
(k..,A
tl.'Pw)/X, with X the plate thickness. Expressed in
the form of a heat-transfer coefficient; hw
12k..,/p.
Eq. (10) is used whenever sensible heat transfer
i.'i involved for either fluid. Eq. (H) is usedi when
there is latent heat transfer for each fluidl

p
p

t:J'
Q
s

Equations for Heat Transfer-Fouling

Eq. (12) and (13)-Fouling-is for conduction of,
heati through scale or solids deposits.. Fouling co
efficients are selected by the designer,. based upon
his experience. Fouling coefficients of 1,000 to 500
(fouling factors ofi 0.001 to 0.002) normally require
exchangers 10 to' 30% larger than for clean service;
The selection of, a fouling factor is arbitrary because there is usually insufficient data for accurately
assessing the degree of fouling that should be assumed
for a (itiven design. Generally, fouling for a spiralplate exchanger' is considerably less than for shelland-tube exchangers. Because fouling varies with
material. velocities and temperature, the extent to
which this influences design depends on operating
conditions and, to a great degree, the design itself.
Eq. (12) iS used for sensible heat transfer for
either fluid, and Eq .. ( 13) when latent heat is transferred' on both sides ofi the. plate;

Equations for; Pressure

Dro~Spiral

Flow

Eq .. (U)-No PhDse Change Nth > N a ..-iS based

on equations proposed by Sander.4 12 'Ilerm A in
Sander's equation an be closely approximated by.
the value of 28/(d. + 0.125). Term B in Sander's
equation accounts for the spacer studs. The factor
1.5 assumes 18 studs/sq. ft. and a stud dia. of 5/16 in.
Eq. (15)-No Phase Change 100 < Na, < Na,.again is based upon the equation proposed by Sander.
For, this flow regime, the. term A can be closely
approximated' by the 'lalue of 103.5/(d, + 0.125).
As in Eq .. (14h the factor of 1.5 accounts for the
spacer studs.
Eq. (16)-No Phase Ch4nge N 2 , < JOO:..aJso is
based on the Sander eq1.1ations. For this flow regime,,
term A can be closely approximated by the value of
2,170 d 1I.'f5. For this flow regime, the studs have

u
w
r

'
I
I

~
P
I:, I:'
IT

Heat-transfer area, sq. ft.

Filln thickness (:0J00187, z r/ g, r) 111,.ft.
Core dia., in.
Specific liea.t, l3tu./ (lb.) ("F.)
Equivalent dia., ft.
Helix or spi.ral dia., R
Exchanger outside dia.,in ..
Channel spacing, in.
Fanning friction factor, dimensionless
Mass veloeity,lb./(hr.H!Iq. ft~)
Gravitational I constant, ft,./. (hr.) (4.18 x
1:0")
Channel plate wi.dtli, in.
Film coefficient of heat t:ransfer.,. Btu./
(hr.) (sq. ft.) (F.)
Thermal conductiVity, Btu./{hr.) (sq . ft.)
(F;fft.)
Plate length, ft.
Molecular weight, dimensionless
Pressure, psia.
Plate thickness; in.
Pressure drop,.psi.
Heat transferred, Btu.
Specific gravity (referred to water at
20 C.)
Logarithmic mean temperature difference
(LM'IlD), c.
Overalll heat-transfer coefficient, Btu./.
(hr.) (sq. ft.) eF.)
Flowrate, (lb./hr.) /1,000
Condensate loading, lb./. (hr.) (ft.)
Viscosity, op.
Time, hr.
Heat of vaporization, Btu./lb.
Viscosity, lb./.(hr.) (ft.)
Liquidldensity, ll:L/cu1ft.
Vapor density, lb.f.cu.ft.
Surface condition factor, dimensionli!ss
Surface tension, dynes/em.

Subscripts

11
c

. H

h
L

m
s
w

Built fluid properties

Cold stream
Film fluid properties
High temperature
Hot stream
.IJ.ow temperature
Median temperature (1see Fig. 5)
Scale or fouling material
Wall, plate material

Dimensionless Groups

N...

N
Nr.r

Reynolds number
Critical Reynolds number
Prandtl number

little effect on the pressure drop,. and any such effect

is included' in the Sander equation.
Eq; (17rCondensing-is for calculating the pressure drop for condensing vapors and is identical to
that for no phase change, except for a facto11 of
0.5 used with the condensing equation. For total
condensers, the weight rate of flow used in the
calculation should be the inlet flowrate. Because the
average Bow for partial condensers is greater than
MAY 4,.1970/CHEMICAL ENGINEERING

2030368841

far total condensers,. the multip]ymg factor should

be 0.7 instead of 0.5. Because the estimation of the
pressure drop for condensing vapors is not clear-cut,
the equation should be used only to approximate
the. pressure drop, so as to prevent the design of
exchangers with, excessive. pressure losses.

Equations for Pressure Drop--Axiali Flow

Eq .. (:18}-No Phase Change N.,

>

10,000-is an

expression of the Fanning equation for noncompressi~

ble fluids,.in which the friction factOr f. in, the Fanning
equation = 0.046/N.,u. The equation has been
revised to account for pressure lbsses in the inlet
and outlet nozzles, and the irnlet and outlet heads.
The equation also, includes the correction for the
spacer studs in the flow. eliannels.
Eq. (19}-Conden.ring-again is identical to, that
for no phase change, except for a factor of 0.5. Again.
for partial condensers,. a value of 0.7 should be used
instead of 0.5. For condensing pressure drop, only
approximate results. should: be expected, which themselves should be used only to prevent designs that
would result in excessive pressure losses.
For overhead condensers, the pressure drop in
the center tube must be added to the pressure drop
calculated from Eq. (19).

Hot side Na. (10,(!)()() X 6.225/(24 X 3.35) 714

CoiC:I aide Na, (lOiOOO X 5.925)/(24 X 8) 309

Because the ftuids willi be in lamimar flow, spiral

flow is selected for the heat exchanger design. From
Table I, the appropriate expressions for rating are:
Eq. (3)' for both fluids, Eq. (10). for the plate,
Eq, (12) for fouling and Eq. (15) far pressure drop.

Heat-Transfer Calculations
Now; substitute values:
Hot side, Eq. (3):

~T.!..
aTJI -

This example applies the rating method to the

design of a liquid~Jiquid spiral-plate heat exchanger
under the following conditions:

6
[

Coldi Side

Flowrate, lb./hr.................
6,225
5,,925
200
60
Inlet temperature, c.. . . . . . . . . . .
Outlet temperature, c.. . . . . . . . ...
I20
I 50.4
V:iscoeity, cp. . . . . . . . . . . . . . . . . . .. ..
3. 35'
. 8
Specific heat, Btu./lb.;oF.... ... . ...
0.71
0.66
Molecular, weight.................
200.4
200.4
Specific ~Vfovity............... ...
0 . 843
liL843
Allowable yressure drop, psi.. . . . . .
I
I'
Material o construction ........... stainless steel (k - Ul)
(Z,/z.)u: . . . . . . .. . . . . . . . . . . . . . .
I
I

Preliminary Calculations

Heat transferred
61225 X (200-120) X 1.8 X
0,11:
636,400 Btu./hr.

t.T11 (or LMTD) (~ - 49.4)/ln(60/4U) 54.5 C.

For a flrst trial, the approximate surface can be
calculated' using an assumed overall heat-transfer
coefficient, U, of 50 :Btu./(hr.) (sq.. ft.) (F.):
A - 636,400/(50 X I.8 X 54.5) = I30 sq. ft.

Because this is a small exchanger, a plate width

of 24 in. is assumed. Therefore, L
i30/ (2 X 2).
32~5 ft. A channel spacing of % in. for both. fluids
is also assumed. The Reynolds number for spiral flow
can be calculated from the expressiont

N "' IO,OOO (JV/HZ)

Therefore:
CHEMICAL ENGINEERING/MAY 4, 1970

~5~ 80 J[ 241~~~2.5]

32.6 X3.775 X 4.967 X 0.001387, 0.848

Colli side, Eq. (3):

1 111

aT. _
[ 200.4 .
t:.TM
32.6 0.843'...
0.375
[ 24111 X 32.5,

111

][

5.925 X9C:U ]'X

.
54.5

= 32.6 X 3.775 X 5.431 X 0.001387 0.927

Foulin.g, Eq. ( 12):

t:.T, _ 6 OOO f. 0J66 J [ 5.925 X 90.4 J [

. I
J
t.TJI - ,
1,000
54.5
32.5 X 24
6,000 X 0;00066 X 9.828 X 0.001282 0.050
Flate,. Eq. (10):

E' .., 500 [~'66-J f 5.925 X 9CMJ [

t:.'/111

Hot Side

'~].

SAMPLE CALCUlATIONS

ConditiODs

200 4

32.6[ 0:843'.. , X

O.I25 ]
54.5
32.5 X 24
= 500 X 01066 X 9.828 X 0.0001603 0.052
10

Some Spi,r,ai-Piate Exchanger; Standar;ds-Table Ill

Plate

Widths,, lin.
4
6
12
12
18
18
24
24
30
36
48

Outside 018.,
Maximum, .lin.

32
32
32
58
32

Core

Dia.,ln.
8
8
8
l2
8

12
58
32
8
58
12
12
58
58
12
12
58
6C'
58
12
12
72
58
ahannel spacings, in.: 3/16 (12 in. maximum width.),
114 (48 ;n. maximum width), 5/16, %. %. %. 3f4
and: l.
Plate thiCknesses: stainless steel) 14-3 U.S. gage; car
bon steel, ~. 3/16, 114 and 5/16 in.

2o3oasss42

SPIRALPLATE EXCHANGERS

Sum of Products (SOP):

+ 0.927 + 0.050 + 0.052

SOP = 0.848

= 1.877

Because S0P is greater than 1, the assumed: heat

_xchanger is inadequate. The smface area must
be enlarged by increasing the plate width or the
plate .length. Because, in all the equations 1 L applles
directly, the follbwing new length is adopted:
1.877 X 32.5 - 61i ft.

Hot side, Eq. (15):

0;843

[-6~]

0.375 X 24

1.035 X 3.35112 X 1 X 24112

(0.375+ 0.125) 6.2251 12

t:.P - 0.07236 X 0.6917 X 9.202 =- 0J461i psi.

f 1.035 X8 X 1 X 24
16]
ti (0.375 + 1.125) 5.925112 + LS+ 61
11
:

112

Because the pressure drop is less than the allowal:lle;

the spacing can be decreased. For the second trial,
4 in. spacing for botH channels is adoptedl
Because the Heat-transfer equation for every factor
except the plate varies directly witH d,, a new SOP
can be calculated~
t:.Tl/llTM "" 0.848 (0.25/0.375)
tJ.T;/tJ.7'M = 0.927 (0;25/0.375)
t:.T,/ATII = 0.052 (0;25/0.375)
tJ.T,./tJ.TM = 0.050
SOP - 0;565 + 0.618 + 0.050 + 0.052
L = 1.285 X 32.5 = 41.8 ft.
A = 41.8 X 2 X 2 = 167 sq. ft.

The author thanks American Heat Reclaiming Corp.

for. providing figures and for permission to use certain
design.standards. He is also grateful to the Union Carbide Corp .. for permission to publish this article.

2.

3.
4:

= 0.565
= 0.618
= 0.035

5.

== 1.285

8;

6.
7.

9 ..

10.

The new pressure drop becomes:

Hot side:

J[-6~~~-]
0.25 X 24

Acknowledgements

References

t:.P = 0.07236 X 0.6583 X 13.55 = 0.645 psi.

llP- [' 0.001 X41.8

0.843

16 J

J[--5.9~]
0.375 X 24

11.
12.

13.
14.

1.035 X 3.35112 X 1 X 24 112

[ --M75 X 6.225112 --

+ 81f112

For a spiral-plate exchanger, the best design is

often that in. which the outside diameter approximately
equals the plate width.

+ 1.5 + 6f

Cold side, Eq .. (,15):

t:.P .. [1).(101 X 61
0.843

Ds = [15.36 X L (d,. -t+ d;, + 2p) + Q2jtl

Ds = 115,36 (4L8) [0,25 + 0:25 + 2 (0.125))
Ds-= 23.4 in.

Design summary:
Plate width.. . . . . .. . .. .. .. .
24 in.
Plate length.............. . . . 41.8 ft
Channel spacing............
1/4 in .. (both sides)
Spiral diameter.. .. . . . .. . . . . 23.4 in ..
Heat-transfer area... . . . . . .
167 sq. ft.
Hot-side pressure drop ..... 0.607 psi.
Cold~side pressure drop ..... 0. 861 psi.
U... ... . . . . . . ... . . . . . . ... . . . 38.8 Btu./(hr.)(sq.ft.)("F.)

Pr,essur;e-Drop Cal.culations

4 p .. [ 0.001 X.61 ]

The diameter of the outside spiral can now be

calculated with Table II and the following equation:

+ 1.5 +

16 ]
411:8-

15.
16.

tJ.P - 0;04958 X 1.037 X 11.80 = 0.607 psi.

Baird, M. H. I.. MoCrae, W .. Rumford. F .. and Sle--.

C. G. M.. Some Consldera.tlon" on Heat Tm.naofer In
SpLI"al Plate Heat Exchangers, Chem. Eng. Science., 7,
1 and 2, 1957, p. 112.
BLasius, H.. Dae .\hnlichkeit.sgesets bel Rlebunpvorgangzen in Flussigkeiten, Fonol&uug81&e/t. Ul, 1913.
Colbu~n,.A. P .. A Method of CoJ:TelaUng ForcedConW~e
tlon Heat TTansfer Da.ta and e. Comparison With Fluid
F'rlot.lon, A.ICI&F: TMM., !9, 1'933, p. 1174.
HargiS, A. M ... Beok.mann, A. T. and Lola.oonoa., JL J.,.
Applica.tion6 of Spiral' Plate Heat: Ex<lhangers, Chem.
Eng. Proyr .. July 1967; p .. 62.
"HeliHow Confers and Heaters," Bull. SBG; Gl"&h&m
Mfg. Co. Grea.t .:\leek, N.Y.
Ito, H .. F'rlotion F'act<>n~ for Turbulent Flow ln. Curved
Pipes. Tran8. AS&fE., 81, 2;, 1959,. p .. 123.
La.mb,. B. R., The Rosenbl.ad Spiral Heat !Exch&nger,
Trana. Inst. Cllem. Engr3. {IIJ.Ondon), June 196Z, p. A101.
Lord, R. C., Min-ton. P. E. <and Slusser, R. P., Dettlgn
Pa.l'ameters for Condensers and Reboilers, CJ1em. Eng.,
Mar.. 2'3, 1970, p. 127.
Loro, R. C:, Minton, P. E. and Slusser, R. P .. Dealgn
o! Heat Exchangers, Ghem. Eng., Jan, 26, 19-'70, p. H.
Noble, M .. A ... Kamlanl, J. S. <and McKetta, JL J., H-.t
'l'ransfer in Spiral Colla .. Petr. Eng., Apr. 1952, p. 723.
PerTy, J! H . Ed .. "OHemlcal Englneera Handbook."' 4th
ed., McGraw-Hill, New York. 1963, 10, p. 24:
Sander, J.. ( unpublf.shed). A. B. RoaenbladAI. Pa.tenter,
Stockholm .. Sweden. 1955.
"Spiral Heat Exchangers," Bull. S.A. 1UO I-ff HRSII,
Amerloan Hea.t Reclaiming Corp., New York.
Tangn, N. N. and Ja:raraman, R., Hea.t Transfer on e.
Spiral Pla.te. Hea.t Exchanger,, Tran~. In1t. Chem. Engr11.
(London), 40, 3, 1962, p, 161.
"Thermal Handbook," AI~La.va1/De!J.aval Group,
Sweden, 1969.
White, C. M., Streamline Flow Through Curved Pipes,
Proceedhtga Roval Soc. (Londonh Serlea A. 1Z3, 1929,
p. 645.

Colo side:
tJ.P _ [

o.oo~_4h8~](
0.843

D.035 X 8 112 X 1' X 24 112

5.92511- -[

--o37sx

Meet the Author

5.925_.] x
' 0.25 X 24

Paul E. Mlnfon is a project

engine~r

1. 5

16 .]

+ us

AP = 0.04958 X 0.9875X 17.59 = 0.8611

The pressure drops are less than the maximum

allowable. The plate spacing cannot be less than
4 in. for a 24!.in. plate width; decreasing the width
would result: in a higher than allowable pressure drop.
Therefore, the design is accept:able.

in

t~e

~ngineering

department at Union Carbide

Corp.'s Technical Center (P 0;
Box 8361, So. Charleston.
W. Va. 25303), where he is a
part of the heattransfO!r tech
nology group. A graduate In
chemcal engineering with a
B.S. degree from the Missouri
School of Mines and Metal
lurgy, he is a member of
AIChE.

MAY 4, 1970/HEMICAL ENGINEERING

2030368843.