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A = heat-transfer area, m2
Q UATm
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Geometry
Resistances to outside
heat transfer
inside
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TRANSFER COEFFICIENTS
Uo=overall coefficient on outside area of tube, W/m2 oC
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OVERALL HEAT TRANSFER COEFFICIENT
The overall coefficient is reciprocal of the overall resistance
do
do ln
1 1 1 di d o 1 d o 1
Uo ho hod 2k w di hid di hi
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COMMENTS
Magnitude of hs depends on:
condensation, etc.)
Physical properties (density, heat capacity, viscosity, thermal
conductivity)
Fluid flow rates
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Typical design procedure
1-Define the duty: 2- Physical properties required: density,
Q, Fs, Ts viscosity, thermal conductivity
i o 1 do 1
Uo ho hod 2k w d i hid d i hi
11-Optimise: repeat steps 4-10
10-Calculate p
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To select a trial value of U
Select a trial Value of U for given fluids.
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Fouling or dirt factor
What?
Deposit of nonmetallic material on heat
transfer surface is fouling
Consequences
Heat transfer resistance is increased which
require over design of exchanger
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Shell & Tube Exchangers
Advantages
Large surface area per unit volume
Easy cleaning
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Selecting TEMA Type Heat Exchangers
Tubular Exchange Manufacturers Association
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Straight Tube, Fixed Tube-sheet, Type BEM, AEM,
NEN, Etc.
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Advantages
Less costly than removable bundle designs
Provides maximum amount of surface for a given shell and tube diameter
Provides for single and multiple tube passes to assure proper velocity
May be interchangeable with other manufacturers of the same TEMA type
Limitations
Shell side can be cleaned only by chemical methods
No provision to allow for differential thermal expansion, must use an
expansion joint
Applications
Oil Coolers, Liquid to Liquid, Vapor condensers, reboilers, gas coolers
Generally, more viscous and warmer fluids flow through the shell
Corrosive or high fouling fluids should flow inside the tubes
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Removable Bundle, Externally Sealed Floating Tube-sheet,
Type OP, AEW, BEW
This design allows for the removal, inspection and cleaning of the shell circuit
and shell interior. Special floating tube-sheet prevents intermixing of
fluids. In most cases, straight tube design is more economical than U-tube
designs.
Advantages
Floating tube-sheet allows for differential thermal expansion between the
Shell and the tube bundle.
Shell circuit can be inspected and steam or mechanically cleaned
The tube bundle can be repaired or replaced without disturbing shell pipe
Less costly than TEMA type BEP or BES which has internal floating head
Maximum surface for a given shell diameter for removable bundle design
Tubes can be cleaned in AEW models without removing
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Limitations
Fluids in both the shell and tube circuits must be nonvolatile, non-toxic
Tube side passes limited to single or two pass design
All tubes are attached to two tube-sheets. Tubes cannot expand
independently so that large thermal shock applications should be
avoided
Packing materials produce limits on design pressure and temperature
Applications
Intercoolers and after-coolers, air inside the tubes
Coolers with water inside the tubes
Jacket water coolers or other high differential temperature duty
Place hot side fluid through the shell with entry nearest the front end
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Removable Bundle, Outside Packed Head, Type
BEP, AEP, Etc
This design allows for the easy removal, inspection and cleaning
of the shell circuit and shell interior without removing the
floating head cover. Special floating tube-sheet prevents
intermixing of fluids. In most cases, straight tube removable
design is more costly than U-tube designs.
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Advantages
Floating tube-sheet allows for differential thermal expansion between
the shell and the tube bundle.
Shell circuit can be inspected and steam cleaned. If the tube bundle has a
square tube pitch, tubes can be mechanically cleaned by passing a brush
between rows of tubes.
The tube bundle can be repaired or replaced without disturbing shell
piping
On AEP design, tubes can be serviced without disturbing tubeside piping
Less costly than TEMA type BES or BET designs
Only shell fluids are exposed to packing. Toxic or volatile fluids can be
cooled in the tubeside circuit
Provides large bundle entrance area, reducing the need for entrance
domes for proper fluid distribution
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Limitations
Shell fluids limited to non volatile, non toxic materials
Packing limits shell side design temperature and pressure
All tubes are attached to two tube-sheets. Tubes cannot expand
independently so that large thermal shock applications should be
avoided
Less surface per given shell and tube diameter than AEW or BEW
Applications
Flammable or toxic liquids in the tube circuit
Good for high fouling liquids in the tube circuit
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Removable Bundle, Internal Split Ring
Floating Head, Type AES, BES, Etc. -
Ideal for applications requiring frequent tube bundle removal for
inspection and cleaning. Uses straight-tube design suitable for
large differential temperatures between the shell and tube fluids.
More forgiving to thermal shock than AEW or BEW designs.
Suitable for cooling volatile or toxic fluids.
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Advantages
Floating head design allows for differential thermal expansion between the shell
and the tube bundle.
Shell circuit can be inspected and steam cleaned. If it has a square tube layout,
tubes can be mechanically cleaned
Higher surface per given shell and tube diameter than pull-through designs such
as AET, BET, etc.
Provides multi-pass tube circuit arrangement.
Limitations
Shell cover, split ring and floating head cover must be removed to remove the tube
bundle, results in higher maintenance cost than pull-through
More costly per square foot of surface than fixed tube sheet or U-tube designs
Applications
Chemical processing applications for toxic fluids
Special intercoolers and after-coolers
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Limitations
For a given set of conditions, this TEMA style is the most expensive
design
Less surface per given shell and tube diameter than other
removable designs
Applications
Chemical processing applications for toxic fluids
Hydrocarbon fluid condensers
General industrial applications requiring frequent cleaning
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Removable Bundle, U-Tube, Type BEU,
AEU, Etc.
Limitations
Because of u-bend, tubes can be cleaned only by chemical means
Because of U-tube nesting, individual tubes are difficult to replace
No single tube pass or true countercurrent flow is possible
Tube wall thickness at the U-bend is thinner than at straight portion of tubes
Draining of tube circuit is difficult when mounted with the vertical position
With the head side up.
Applications
Oil, chemical and water heating applications
Excellent in steam to liquid applications
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TUBES DIMENSIONS
Range: 16 mm to 50 mm
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TUBE ARRANGEMENTS
A. Equilateral triangular P1
B. Square
C. Rotated square P1
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TUBE SHEET LAYOUT
Tube bundle diameter depends on:
Number of tubes
Nt=number of tubes
Db=bundle diameter, mm
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1 / n1
Nt
Db d o
K1
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Baffles
Purpose:
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Mean Temperature Difference
T1 T1
Temperature
t2 shell
T2 t2 T2
t1 t1
tubes
Heat transferred
Heat transferred T2
t2
T2
t2 t1
t1 T1 T1
Tlm
T1 t2 T2 t1 Tlm
T1 t1 T2 t2
T t T t
ln 1 2 ln 1 1
T2 t1 T2 t 2
Counter-current Co-current
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LMTD
tm Ft tlm
Ft f ( R, S )
T1 T2 t2 t1
R ,S
t2 t1 T1 t1
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R = (ms X CP,f ,s / mt X CP,f,t)
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The following assumptions are made in the derivation of the
temperature correction factor Ft, in addition to those made for the
calculation of the log mean temperature difference:
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Design Considerations: STE Fluid
Allocation: Shell Or Tubes
Where no phase change occurs,
Corrosion
Fouling
Fluid Temperatures
Operating pressure
Pressure drop
Viscosity
Stream flow rates
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Corrosion
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Fouling
The fluid that has the greatest tendency to foul the heat-
transfer surfaces should be placed in the tubes.
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Pressure Drop
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Viscosity
Generally, a higher heat-transfer coefficient will be obtained by
allocating the more viscous material to the shell-side, providing the
flow is turbulent. The critical Reynolds number for turbulent flow
in the shell is in the region of 200. If turbulent flow cannot be
achieved in the shell it is better to place the fluid in the tubes, as the
tube-side heat-transfer coefficient can be predicted with more
certainty.
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Stream Flow Rates
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Design Considerations: STE Fluid Velocities
Liquids Vapors
Tube side Vacuum
Process fluids 50-70 m/s
1-2 m/s Atmospheric pressure
4 m/s maximum 10-30 m/s
Water
1.5-2.5 m/s
Shell side
0.3-1 m/s
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PRESSURE DROP
Liquids Gas and vapours
High vacuum
Viscosity <1 mN s/m2
p = 0.4-0.8 kN/m2
p = 35 kN/m2
Medium vacuum
Viscosity is 1 to 10
p = 0.1 x absolute pressure
mN s/m2 1 to 2 bar
p = 50-70 kN/m2 p = 0.5 x system gauge
pressure
Above 10 bar
p = 0.1 x system gauge pressure
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Tube-side Heat-transfer Coefficient And
Pressure Drop (Single Phase)
Heat transfer
Turbulent flow
Heat-transfer data for turbulent flow inside conduits of uniform
cross-section are correlated by an equation of the form:
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where
48
= di for tubes, 2/1/2016
ut = fluid velocity, m/s,
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A general equation that can be used for exchanger
design is:
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Butterworth (1977) gives the following equation,
the hydraulic mean diameter may be used in place of the pipe diameter
and the formulae for circular pipes can then be applied without
introducing a large error. This method of approach is entirely
empirical.
the hydraulic mean radius rH. Hydraulic mean radius is defined as the
flow cross-sectional area divided by the wetted perimeter:
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Some examples are given.
For circular pipe:
DH = 4(/4)D2 / ( D) = D
For an annulus of outer diameter Do and inner diameter Di :
DH = 4 ( ( Do2 /4) - ( Di2 /4) ) / ( (Do + Di) ) = (Do2 - Di2)
/ (Do + Di) = Do - Di
For a duct of rectangular cross-section Da by Db :
DH = 4 DaDb / ( 2(Da + Db) = 2DaDb / (Da + Db)
For a duct of square cross-section of size Da :
DH = 4 Da2 / (4Da) = Da
For laminar flow this method is not applicable, and exact expressions
relating the pressure drop to the velocity can be obtained for ducts
of certain shapes only.
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Laminar flow
Below a Reynolds number of about 2000 the flow in pipes will be
laminar.
Providing the natural convection effects are small, which will
normally be so in forced convection, to estimate the film heat-
transfer coefficient given equation will be used:
The use of the jh factor enables data for laminar and turbulent flow
to be represented on the same graph.
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Equation can be rearranged to a more convenient form:
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Tube-side pressure drop
There are two major sources of pressure loss on the tube-side of a
shell and tube exchanger:
The friction loss in the tubes and
The losses due to the sudden contraction and expansion
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The basic equation for isothermal flow in pipes
(constant temperature) is:
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The flow in a heat exchanger will clearly not be
isothermal, and this is allowed for by including
an empirical correction factor to account for
the change in physical properties with
temperature.
Normally only the change in viscosity is considered:
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The loss in terms of velocity heads can be estimated by counting
the number of flow contractions, expansions and reversals, and
using the factors for pipe fittings to estimate the number of
velocity heads lost.
For two tube passes, there will be two contractions, two
expansions and one flow reversal.
The head loss for each of these effects is: contraction 0.5,
expansion 1.0, 180 bend 1.5; so for two passes the maximum
loss will be
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From this, it appears that Frank's recommended value of 2.5 velocity
heads per pass is the most realistic value to use.
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Viscosity Correction Factor
The viscosity correction factor will normally only be significant
for viscous liquids.
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Coefficients For Water
The equation below has been adapted from data given by
Eagle and Ferguson (1930):
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Shell-Side Heat-Transfer And Pressure
Drop (Single Phase)
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DESIGN METHODS
Kern Method
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KERN'S METHOD
The shell equivalent diameter is calculated using the flow area
between the tubes taken in the axial direction (parallel to the tubes)
and the wetted perimeter of the tubes;
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Procedure
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2. Calculate the shell-side mass velocity Gs and the linear velocity us:
De
4 PT2 do2 / 4 square
do
De
4 PT2 3 / 4 do2 / 8 triangular
do / 2
Where De = equivalent diameter in m
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4. Calculate the shell-side Reynolds number, given by:
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5. For the calculated Reynolds number, read the value of jh, from
graph for the selected baffle cut and tube arrangement, and
calculate the shell-side heat transfer coefficient hs from:
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6. For the calculated shell-side Reynolds number, read the friction
factor from graph and calculate the shell-side pressure drop
from:
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Heat Exchanger Shell Side Design
Bell Method
SHELL-SIDE HEAT-TRANSFER AND
PRESSURE DROP (SINGLE PHASE)
Flow pattern
Bells method
In Bells method the heat-transfer coefficient and pressure
drop are estimated from correlations for flow over ideal tube-
The total correction will vary from 0.6 for a poorly designed
exchanger with large clearances to 0.9 for a well-designed
exchanger.
hoc, ideal cross-flow coefficient
Fn, tube row correction factor
Fw, window correction factor
Fb, bypass correction factor
With sealing strips
Where no sealing strips are used, Fb can be obtained from
Figure
FL, Leakage correction factor
Shell and bundle geometry
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.
Pressure Drop ideal tube bank
pressure drop
The number of tube rows has little effect on the friction
factor and is ignored.
Fb , bypass correction factor for
pressure drop
Bypassing will affect the pressure drop only in the cross-flow
zones.