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King Abdulaziz University

Mechanical Engineering Department

MEP 460
Heat Exchanger Design

Design and rating of Shell


and tube heat Exchangers
Bell-Delaware method

April 2018
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Bell Delaware method for heat exchangers

1-Introduction
2-Main flow streams
3-Ideal shell side heat transfer coefficient and pressure drop
4-Shell side heat transfer coefficient and correction factors
5-Shell side pressure drop and correction factors
6- Example

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1-Intoduction

Shell and tube heat exchangers are the most commonly used
heat exchangers
Use extensively in power plants, refineries and industrial and
commercial sectors
TEMA Standards of shell and tube layouts are available
Very well known analysis methods:
Simple Kern method
Bell-Delaware method

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2- Main flow streams for shell and tube heat exchanger

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Main flow streams for shell and tube heat exchanger
Stream A is the leakage between the baffle and tubes
Stream B is the main effective cross flow stream over tube bundle
Stream C is the bundle bypass between the tube bundle and the shell wall
Stream E is the leakage between the baffle edge and the shell wall
Stream F is the by pass stream in flow channel partition due to omissions of
tubes in tube pass partition

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Main flow streams for shell and tube heat exchanger

Stream E Stream A
By pass between the leakage between
baffle and the shell tubes and baffle
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Using sealing strip to reduce bundle-shell by pass

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3-Ideal shell side heat transfer coefficient and correction factors

The three common tube layout used in shell and tube heat
exchangers are:

1-Triangular pitch
2-Square pitch
3-Rotated square pitch

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3-Ideal shell side heat transfer coefficient and correction factors
Pitch angle 𝜃𝑝 = 30°

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3-Ideal shell side heat transfer coefficient and correction factors
Pitch angle 𝜃𝑝 = 45°

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3-Ideal shell side heat transfer coefficient and correction factors
Pitch angle 𝜃𝑝 = 90 °

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3-Ideal shell side heat transfer coefficient and correction factors

𝑎
1.33
Heat transfer coefficient 𝑗𝑖 = 𝑎1 𝑅𝑒𝑠 𝑎2
𝑃𝑇 𝑑𝑜

𝑎3
𝑎= 𝑎4
1 + 0.14 𝑅𝑒𝑠

𝑏
1.33 𝑏2
Friction coefficient 𝑓𝑖 = 𝑏1 𝑅𝑒𝑠
𝑃𝑇 𝑑𝑜

𝑏3
𝑏= 𝑏4
1 + 0.14 𝑅𝑒𝑠

0.14
𝑚 −2 3
𝜇𝑠
ℎ𝑖𝑑 = 𝑗𝑖 𝐶𝑝𝑠 𝑃𝑟
𝐴𝑠 𝜇𝑠,𝑤

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Ideal heat transfer and pressure drop factors

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Shell side heat transfer coefficient

ℎ𝑜 = ℎ𝑖𝑑 𝐽𝑐 𝐽𝑙 𝐽𝑏 𝐽𝑠 𝐽𝑟

Jc, Jl, Jb, Js, Jr


Correction factors

The ideal heat transfer coefficient for pure


cross flow is given by
0.14
𝑚 −2 3
𝜇𝑠
ℎ𝑖𝑑 = 𝑗𝑖 𝐶𝑝𝑠 𝑃𝑟
𝐴𝑠 𝜇𝑠,𝑤

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Heat transfer correction factors

ℎ𝑜 = ℎ𝑖𝑑 𝐽𝑐 𝐽𝑙 𝐽𝑏 𝐽𝑠 𝐽𝑟

factor Due to Typical values


Jc baffle cut and spacing (heat 0.53-1.15
transfer in the window)
Jl leakage effects (streams A &E) 0.7-0.8
Jb bundle bypass flow ( streams C 0.7-0.9
& F streams)
Js variable baffle spacing in the 0.85-1.0
inlet and outlet sections(
Jr adverse temperature gradient 1.0 for Res>100
build-up (Res<100)
𝐽𝑐 𝐽𝑙 𝐽𝑏 𝐽𝑑 𝐽𝑠 Product of all factors (for well 0.6
design HX

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Shell side Reynold’s number

𝑑 𝑜 𝑚𝑠
𝑅𝑒𝑠 =
𝜇 𝑠 𝐴𝑠

As is the minimum flow area at the


shell centerline

𝐴𝑠 = 𝐷𝑠 − 𝑁𝑇𝐶 𝑑𝑜 𝐵

𝐷𝑠
𝑁𝑇𝐶 =
𝑃𝑇

NTC number of tubes at the centerline of the shell

𝑑𝑜 𝑚𝑠
𝑅𝑒𝑠 =
𝜇 𝑠 𝐴𝑠

Notice that Reynolds number is based on the


outside diameter of the tubes
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Shell side pressure drop

Δ𝑝𝑐
Internal

Windows Δ𝑝𝑤

Entrance
Δ𝑝𝑒

Δ𝑝𝑠 = Δ𝑝𝑐 + Δ𝑝𝑤 + Δ𝑝𝑒


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Pressure drop in cross flow between baffle edges

Δ𝑝𝑐 = Δ𝑝𝑏𝑖 𝑁𝑏 − 1 𝑅𝑙 𝑅𝑏

0.14
𝐺𝑠2 𝜇𝑠,𝑤
Δ𝑝𝑏𝑖 = 4 𝑓𝑖
2𝜌𝑠 𝜇𝑠

Rl leakage correction factor due streams A and C (typical value


between 0.4 and 0.5)
Rb by pass correction factor due to stream C and F (typical value
between 0.5 and 0.8)
Nb is the number of baffles

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Pressure drop in the window
Pressure drop in windows Δ𝑝𝑤 = Δ𝑝𝑤𝑖 𝑁𝑏 𝑅𝑙

𝑚s2 (2 + 0.6 𝑁𝑐𝑤 )


Δ𝑝𝑤𝑖 = 𝑅𝑒𝑠 ≥ 100
2𝜌𝑠 𝐴𝑠 𝐴𝑤

𝜇𝑠 𝑚s 𝑁𝑐𝑤 𝐵 𝑚s
Δ𝑝𝑤𝑖 = 26 + 2 + 𝑅𝑒𝑠 < 100
𝐴𝑠 𝐴𝑤 𝜌 𝑷𝑻 − 𝑑𝑜 𝐷𝑤 𝐴𝑠 𝐴𝑤 𝜌𝑠

No of tube rows crossed from tip to tip of baffle


𝐿𝑐
𝑫𝒔 1 − 2
𝐷𝑠
𝑁𝑐 =
𝑃𝑝
PT

No. of tube rows in window

0.8𝐿𝑐
𝑁𝑐𝑤 =
𝑃𝑝
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Parallel and normal tube pitch definition

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Pressure drop at the entrance and exit

Pressure drop in entrance and exit 𝑁𝑐 + 𝑁𝑐𝑤


Δ𝑝𝑒 = 2Δ𝑝𝑏𝑖 𝑅𝑏 𝑅𝑠
𝑁𝑐

Nc is the number of tube rows crossed in the heat exchanger (baffle tip-to-tip)
Ncw is the number of tube rows crosses in the window
Rs is the correction factor entrance and exit section having different baffle
spacing than internal section due existence of inlet and outlet nozzles

Total Shell side pressure drop Δ𝑝𝑠 = Δ𝑝𝑐 + Δ𝑝𝑤 + Δ𝑝𝑒

or

𝑁𝑐𝑤
Δ𝑝𝑠 = 𝑁𝑏 − 1 Δ𝑝𝑏𝑖 𝑅𝑏 + 𝑁𝑏 Δ𝑝𝑤𝑖 𝑅𝑙 + 2Δ𝑝𝑏𝑖 1 + 𝑅𝑏 𝑅𝑠
𝑁𝑐
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Number of baffles

Number of baffles can be calculated using

𝐿 − 𝐵𝑖 − 𝐵𝑜
𝑁𝑏 = +1
𝐵

Bi and Bo are the baffle spacing at inlet and exit

If Bi=Bo=B then

𝐿
𝑁𝑏 = − 1
𝐵

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Example 9.4 continue

𝐴𝑠 = 𝐷𝑠 − 𝑁𝑇𝐶 𝑑𝑜 𝐵 𝐷𝑠
𝑁𝑇𝐶 =
𝑃𝑇

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Example 9.4 continue

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Example 9.4 continue

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Example 9.4 continue

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Example 9.4 continue

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Example 9.4 continue

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Example 9.4 continue
Shell side pressure drop using Kern procedure

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Example 9.4 continued

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Example 9.5 continue

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Example 9.5
continue

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Example 9.5 continue

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Example 9.5
continue

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Example 9.5 continue

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Example 9.5
continued

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