Republic of the Philippines

BATANGAS STATE UNIVERSITY

Pablo Borbon Main II, Alangilan, Batangas City
College of Engineering, Architecture & Fine Arts
www.batstate-u.edu.ph Tel. No. (043) 425-0139 loc. 118

Chemical and Food Engineering Department

ChE 423: EQUIPMENT DESIGN

HEAT TRANSFER
EQUIPMENT

Prepared by:

Group 12
Members:
Cantos, Jazer Mari M.
Catapang, Cathy Mae B.
De Castro, Lyniel Jan S.
De Castro, Nica Mariel M.
ChE-4201

Submitted to:

Engr. Rodolfo C. Sotto

Instructor
 Heat Transfer Equipment

Introduction
The transfer of heat to and from process fluids is an essential part of most chemical processes.
Heat transfer equipment are found to be useful in a wide range of industries. They can be broadly
defined as equipment used for transfer of heat from a hot medium to cold medium. Heat exchanger
design and structure of these equipment varies a lot depending on the application where they are
used and the heat transfer media involved. The most commonly used type of heat-transfer
equipment is heat exchanger. Heat exchangers are devices used to transfer heat between two or
more fluid streams at different temperatures. Heat exchangers find widespread use in power
generation, chemical processing, electronics cooling, air-conditioning, refrigeration, and
automotive applications.

The term heat in physics, refers to the transfer of energy from one part of a substance to another,
or from one object to another, because of a difference in temperature. Heat flows from a substance
at a higher temperature to a substance at a lower temperature, provided the volume of the objects
remains constant. Heat does not flow from a lower to a higher temperature, unless another form of
energy transfer, work, is also present.

Types of Heat
If the heat energy is added to a substance, the motion of the molecules increases creating more
heat and thereby increasing the temperature, nearly all modern chemical process, heat is either:
needed to make the reaction between the substances happen, or is produced during a chemical
reaction.
1. Latent heat is the energy absorbed by or released from a substance during a phase change
from a gas to a liquid or a solid or vice versa.
2. Sensible heat is the energy required to change the temperature of a substance with no phase
change.

Heat Transfer
It refers to the process by which energy in the form of heat is exchanged between objects, or parts
of the same object, at different temperatures. Heat is generally transferred by radiation, convection,
or conduction, processes that may occur simultaneously.
1. Conduction is the only method of heat transfer in opaque solids. The mechanism of
conduction in solids is believed to be partially due to the motion of free electrons in the
solid matter.
2. Convection is where heat travels through liquids and gases.
3. Radiation consists of invisible energy waves, which are able to pass across a space. Unlike
the aforementioned methods, it does not require any material to be present between the hot
and cold surface.

Heat Exchangers
Process equipment and streams will need to be heated or cooled. One way to reduce consumption
of utilities is to exchange heat between these streams. For example, if a product stream requires
cooling, the excess heat can be used to preheat a feed stream that requires heating by using an
appropriate heat exchanger. Here the costs of an additional heating and additional cooling unit are
eliminated, and replaced by the cost of a heat exchanger.

Heat Exchanger Classification

Due to the large number of heat exchanger configurations, a classification system was devised
based upon the basic operation, construction, heat transfer, and flow arrangements. The following
classification as outlined are:
• Recuperators and regenerators
• Transfer processes: direct contact or indirect contact
• Geometry of construction: tubes, plates, and extended surfaces
• Heat transfer mechanisms: single phase or two phase flow
• Flow Arrangement: parallel flow, counter flow, or cross flow

Types of Heat Exchangers

1. Double Pipe- one of the simplest heat exchangers utilized in industry. This exchanger's
name comes from how one fluid flows inside a pipe and the other fluid flows between that
pipe and another pipe that surrounds the first, essentially a "tube within a tube."
 Co-Current Flow- also known as parallel flow, the two fluids that are exchanging
heat are flowing in the same direction.
 Counter-Current Flow- is used for condensing, gas cooling, and liquid-liquid
applications. Here, the fluids flow against each other in opposite directions.
2. Shell-and-Tube- A bundle of tubes is passed through a shell. Heat exchange occurs
between the fluid inside the tubes (tube-side) and the fluid outside of the tubes but within
the shell (shell-side). Baffles are often used to direct the flow of the shell-side fluids as
well as to support the tube bundle.
3. Scraped-Surface- Crystallization systems and heat transfer involving viscous fluids,
fouling may occur rapidly enough to make routine cleaning impractical. In this case, a
rotating blade moves over the surface, liberating the deposited material from the surface
and allowing it to exit at the bottom of the exchanger.
4. Gasketed and Welded Plate- Plate heat exchangers consist of a stack of corrugated plates.
The corrugation of the plates improves rigidity, controls spacing of the plates, and increases
the heat-transfer area compared to a flat plate. The hot and cold streams flow counter
currently through the alternating spaces created by the plates.
5. Spiral Plate and Tube- These heat exchangers are used for small capacities with viscous,
fouling, and corrosive fluids. Spiral plates are coiled to create alternating passages for the
fluids. The cold fluid enters at the periphery and flows towards the center, while the hot
fluid enters at the center and flows outward. Introducing the cold fluid at the periphery
reduces or eliminates the need for external insulation.
6. Plate-Fin- Plate-fin heat exchangers consist of layers of corrugated metallic sheets (fins)
between flat plates to form the flow passages. The plates are sealed with metal bars on the
side. Plate-fin heat exchangers can be 9 times as compact as a shell-and-tube heat
exchanger, and weighs less.
7. Plate- Plate heat exchangers utilize metal plates to perform heat transfer between two
fluids. They are composed of a lot of thin metal plates compressed together by two pressure
plates into a "plate pack."
8. Gas-to-Gas- Gas-to-gas heat exchangers are primarily used to recover energy from
combustion gases to preheat furnace air.

Exchanger
all types of equipment in which heat is exchanged; but, often used specifically to denote equipment
in which heat is exchanged between two process streams.
 Heaters and Coolers – process fluid is heated or cooled by a plant service stream.
 Vaporizer – process stream is essentially completely vaporized
 Reboiler – heat exchanger associated with a distillation column
 Evaporator – used to concentrate a solution
 Fired Exchanger – used for exchangers heated by combustion gases
 Unfired Exchanger- prevents the corrosion of the equipment

Types of Reboilers
1. Kettle Reboilers are often used as a steam generator. Pool boiling is used in kettle
reboilers. In pool boiling, agitation occurs through bubbling and natural convection.
2. Thermosiphon Reboilers use flow boiling. In flow boiling, agitation occurs through
bubbling and forced convection at high velocities. They can be located at a height below
the column sump.
 3. Stab-in reboilers are essentially the heat exchange tube bundle fitted inside a sump. In this
case, the sump behaves in a similar capacity to a kettle reboiler, and mechanism of pooling
is again pool boiling.

Types of Condenser
1. Total Condenser- all the vapor that enters is condensed as a film on the heat transfer
surface.
2. Partial Condenser- not all of the vapor that enters is condensed. This allows for vapor-
liquid separation.

Types of Heaters
1. Fired Heaters- Fired heaters are used for heating up to high temperatures. They are able
to reach these high temperatures because they generate energy by combustion of natural
gas, fuel oil, or process off-gas.
2. Electric Heaters- heat is generated by running electricity through wires of high resistance.
Heat is exchanged with fluid passed over axially through MgO insulation.
3. Steam Generators- Often, high-pressure steam is generated in boilers. As it moves
through a plant, it can be expanded in turbines to recover energy. Most plants use more
than one level of steam.

Types of Coolers
1. Air Coolers- Advantages of air coolers are that they do not require additional
infrastructure, and air is free so that the only operating cost is the electricity for the fans.
Additionally, it is easy to add extra capacity for a higher duty.
2. Water Coolers- Water coolers require extensive infrastructure (pipes, cooling towers,
water treatment) in order to provide water for cooling. Depending on the location, cheap
water is not always available, and it is expensive to add capacity to handle an increased
duty.
3. Refrigeration- Refrigeration is used for very low temperatures (<40C).

Applications of Heat Exchangers

1. Intercoolers and preheaters;
2. Economizers and super heaters;
3. Condensers and boilers in steam plant;
4. Condensers and evaporators in refrigeration units;
5. Regenerators;
6. Automobile radiators.
7. Cooling tower.
8. Heat pipes.

Parameters Governing the Efficiency of Heat Transfer

1. Temperature difference - High temperature difference between the involved media ensures
efficient heat transfer by increasing the heat flux.
2. Nature of fluid - Fluid properties such as viscosity, conductivity, density play critical role in
heat transfer efficiency and determination of heat transfer coefficient.
3. Type of flow - Usually, the media involved in heat transfer are in continuous flow. These flows
can either be parallel to each other (co-current flow), in opposite directions to each other (counter-
current flow) or approximately perpendicular to each other (cross flow). The temperature
difference between the two media varies with location along the length of the flow. Counter current
flows offer the best efficiency by ensuring high overall temperature difference (measured by
LMTD).
4. Surface area - High surface area available for transfer of heat energy means more efficient
transfer of heat energy for the same heat flux. Enhancement in the heat transfer area can be
achieved by using fins on the heat transfer surface.
5. Turbulence - High turbulence means easier heat transfer through convection in a fluid. As heat
transfer convection is more efficient way of heat transfer than conduction, turbulence can be used
to enhance the heat transfer efficiency.
There are some other factors as well, which are not related to heat transfer but still govern the
design of heat exchangers.

1. Capital costs - Large heat exchangers can perform heat transfer for even very small temperature
differences, but they come at a higher cost.
2. Operating costs - In shell and tube exchangers, small diameter tubes can be used to increase the
surface area available for heat transfer. But, small diameter also means higher pressure drop across
the tubes leading to higher operating costs.
3. Materials - Depending on the type of fluid and its corrosiveness, a suitable material has to be
chosen for construction of a heat exchanger, even if does not assure maximum heat transfer.
4. Fluid phase - Different types of exchangers are used for different phases of fluid and even phase
changes e.g. condensers, boilers, air cooled exchangers etc.

Design Procedure
(Heat Exchanger)
How to design a heat exchanger?
For sizing a heat exchanger, several thermal phenomena should be considered first:
 Forced convection of both fluids: Convection is the transfer of heat between a wall and a
flowing fluid, both having different temperatures. In the case of heat exchangers, it is called
forced convection as it is caused by artificial circulation (pumps, turbines, fans...)
 Conduction: This is the transfer of heat which occurs naturally through the walls, plates
and tubes. This phenomenon is based on the principle of thermal agitation without
movement of material.
 Thermal radiation which could be considered as negligible
The design of a heat exchanger addresses mainly three phases:

1.The choice of technology

Selection of the optimum technology is linked to:
 The thermal program (Required temperatures, efficiency…)
 The nature of the fluids
 The application
 The constraints of installation and maintenance

2.Thermal design
2.a. Validation of the thermal program

Once the technological choices made, we will proceed to the design of the heat exchanger , i.e.
determining its power, size and geometry. It is first necessary to validate the data of the thermal
program, with the following 3 formulas:

P: Power (in KW or KCal/h)

T: temperature (in °C)
Q: Flowrate (in Kg/h)
△t: (Tin –Tout)in °C
Cp: Specific heat (in KWh/Kg/°C)

2.b. Calculation of the heating surface

First, LMDT (Logarithmic mean temperature difference) shall be calculated. The LMDT is the
logarithmic average of the temperature differences at each end of the heat exchanger:

Tin1 : Tin cold

Tin2 : Tin hot
Tout1 : Tout cold
Tout2 : Tout cold

Once LMDT and Power have been calculated, the heat exchanger calculation can be done as
per the following formula:

K: Heat Transfer Coefficient in KW/°C/m2 that is specific to each type of equipment and given by
the manufacturer.
S : Heating area in square meters.

2.c. Calculation of K and incrustation

Getting the Heat Transfer Coefficient (HTC or K) enables to find the heating area and hence
sizing the heat exchanger.

3. Calculation of the heat exchanger pressure drop

A moving fluid undergoes energy losses due to friction on the walls (regular head loss) or mishaps
(singular head losses) such as baffles, for example. This loss of energy, expressed in pressure drop
(△P) must be compensated to allow the fluid to move.

When the heat exchanger is designed, the heat exchanger pressure drop can be calculated with
different correlations determined by the characteristics of the exchange surfaces.
 Types of Heat Exchangers
Nomenclature
 Design Procedure for Shell and Tube Heat Exchanger
Shell and tube heat exchanger is designed by trial and error calculations. The main steps of design following
the Kern method are summarized as follows:
Step #1. Obtain the required thermophysical properties of hot and cold fluids at the caloric temperature or
arithmetic mean temperature. Calculate these properties at the caloric temperature if the variation of
viscosity with temperature is large.
Step #2. Perform energy balance and find out the heat duty ( Q ) of the exchanger.
Step #3. Assume a reasonable value of overall heat transfer coefficient (Uo, assm).
Step #4. Decide tentative number of shell and tube passes ( p n ). Determine the LMTD and the correction
factor FT. FT normally should be greater than 0.75 for the steady operation of the exchangers. Otherwise it
is required to increase the number of passes to obtain higher FT values.
Step #5. Calculate heat transfer area (A) required:
Step #6. Select tube material, decide the tube diameter its wall thickness (in terms of
BWG or SWG) and tube length (L). Calculate the number of tubes (nt) required to provide the heat transfer
area (A):
Step #7. Decide type of shell and tube exchanger (fixed tube sheet, U-tube etc.). Select the tube pitch (PT),
determine inside shell diameter (Ds) that can accommodate the calculated number of tubes (nt). Use the
standard tube counts table for this purpose.
Step #8. Assign fluid to shell side or tube. Select the type of baffle (segmental, doughnut etc.), its size (i.e.
percentage cut, 25% baffles are widely used), spacing (B) and number. The baffle spacing is usually chosen
to be within 0.2 Ds to Ds.
Step #9. Determine the tube side film heat transfer coefficient (hi) using the suitable form of Sieder-Tate
equation in laminar and turbulent flow regimes.
Step #10. If go the next step # 11. Otherwise go to step #5, calculate heat transfer area
(A) required using Uo,cal , and repeat the calculations starting from step #5.
Step #11. Calculate % overdesign. Overdesign represents extra surface area provided beyond that required
to compensate for fouling. Typical value of 10% or less is acceptable.
A = design area of heat transfer in the exchanger; Areqd = required heat transfer area.

Step #12. Calculate the tube-side pressure drop ( PT ): (i) pressure drop in the straight section of the tube
(frictional loss) ( Pt ) and (ii) return loss ( Prt ) due to change of direction of fluid in a „multi-pass
exchanger‟. Total tube side pressure drop: PT = Pt + Prt..

Step #13. Calculate shell side pressure drop ( PS ): (i) pressure drop for flow across the tube bundle
(frictional loss) ( Ps ) and (ii) return loss ( Prs ) due to change of direction of fluid. Total shell side pressure
drop: PS = P s + P rs (1.9) If the tube-side pressure drop exceeds the allowable pressure drop for the
process system, decrease the number of tube passes or increase number of tubes per pass. Go back to step
#6 and repeat the calculations steps. If the shell-side pressure drop exceeds the allowable pressure drop, go
back to step #7 and repeat the calculations steps.
Step #14. Upon fulfillment of pressure drop criteria, go mechanical design.

SELECTION GUIDE FOR SHELL AND TUBE HEAT EXCHANGER

Evaporator

Single effect calculations

Single effect evaporator calculations are pretty straight forward. The latent heat of condensation
of the steam is transferred through the heating surface to vaporize water from a boiling solution.
Therefore, two enthalpy balance equations are required to in order to calculate the rate of solvent
vaporization and the rate of required input heat.

Generally, it is possible to solve the energy and the material balance equations analytically by a
sequential approach. The following assumptions are made to develop the mass and energy balance
equations: -

• there is no leakage or entrainment

• the flow of non-condensable is negligible

• heat loss from the evaporator system is negligible

From the enthalpy data of the solutions, steam and condensate, the rate of heat input or the rate of
steam flow can be calculated.

Calculate the tube-side and shell-side pressure drop using the method discussed during design of
shell & tube exchanger from specified values of the tube length, diameter and the tube layout. If
the pressure drop value is more than the corresponding allowable pressure drop, further
adjustments in the heat exchanger configuration will be required.

Multiple effect calculations

Typically, multiple effect evaporator calculations require a trial-and-error approach as many of the
necessary properties depend on unknown intermediate temperatures. Often the heat transfer areas
in all effects are considered to be equal. Use of equal size evaporator in all effects, reduces the cost
of equipment significantly. In a typical evaporator problem, you are provided with the supply
pressure and temperature of steam, the operating pressure of the final effect, the feed and
concentrations. The designer is often required to have trial estimates of overall heat transfer
coefficients. The overall strategy is to estimate intermediate temperatures. The energy and material
balance equations are solved sequentially to determine the heat transferred in each effect and the
heat transfer area. If the areas are not equal, the calculation is repeated to revise the intermediate
temperatures and the procedure is repeated till the heat transfer area in all effects are equal.

Condenser
Condenser design
The design of condenser is similar to a typical shell and tube exchangers. A condenser must have
a vent for removal of non-condensable gas. The non-condensable gas decreases the heat transfer
rate. Condenser usually use a wider baffle spacing of B D s (ID of shell) as the allowable pressure
drop in shell side vapor is usually less. Vertical cut-segmental baffles are generally used in
condensers for side-to-side vapor flow and not for top to bottom. An opening at the bottom of the
baffles is provided to allow draining of condensate.
Mean temperature difference
The condensation occurs almost at a fixed temperature (isothermally) at constant pressure for a
pure saturated vapor compound. The logarithmic mean temperature difference can be used for
condenser design.
Calculation of heat transfer co-efficient during condensation
Calculation of tube side heat transfer co-efficient (hi): The calculation of heat transfer co-efficient
for the cold fluid (coolant) can be performed similarly as discussed in design of shell and tube heat
exchanger (heat transfer without phase change). Here it is assumed that the coolant flows the in
tube side and the condensing saturated vapor flows in the shell side. If the condensation occurs in
the tube.
Miscellaneous Rules of Thumb
1. For fixed tubesheet design of shell and tube heat exchangers don’t allow too high a temperature
difference between tubeside and shellside without providing a shellside expansion joint. The
author has seen 70°F (one company) and 100°F (another company) used as this limit. An easy way
to calculate the maximum stress is as follows:
a. Assume the tubes are at tubeside bulk temperature and the shell is at shellside bulk
temperature.
b. Calculate the elongation of tubes, if unhampered, and shell, if unhampered, starting at
70°F and using the respective coefficients of expansion.
 c. If the tubes would have grown more or less than the shell, the difference will set up stress
in both members, one in tension and the other in compression.
d. Assume the deformation (strain) in each member is inversely proportional to its cross-
sectional area. In other words, the fraction of the total strain in inched inch of length will
be proportionally more for the member (tubes or shell) having the smallest cross section.
e. For each member, multiply its strain by Young’s modulus (Modulus of Elasticity) in
consistent units to get stress. Strain is dimensionless so Young’s modulus in lb/in’ will
yield stress in Ib/in’.
f. Compare this with the maximum allowable stress for the material used.
g. The tensile and compressive modules for steel are essentially the same.

2. Typical handling of design parameters.

DP = MOP + 10% but not less than MOP + 3Opsi
DP for vacuum use 15 psi external pressure for cases having atmospheric pressure on the other
side.
DT Below 32°F DT = minimum operating temperature
Above 32°F DT = MOT + 25°F but not less than 150°F where
DP = Design pressure
DT = Design temperature
MOP = Max. operating pressure
MOT = Max. operating temperature
4. 40% baffle cut = 40% open area is a good rule of thumb maximum for shell and tube heat
exchangers.
SAMPLE PROBLEM
An exhaust pipe 75mm outside diameter is cooled by surrounding it by an annular space
containing water. The hot gas enters the exhaust pipe at 350⁰C gas flow rate being 200 kg/h,
mean specific heat capacity at constant pressure 1.13 kJ/kgK, and comes out at 100⁰C. Water
enters the main at 25⁰C , flow rate 1400 kg/h, mean specific heat capacity 4.19kJ/kgK. The
heat transfer coefficient for gasses and water may be taken as 0.3 and 1.5 kW/m2 and pipe
thickness may be taken as negligible. Calculate the required pipe length for parallel flow.
Given:
D= 0.075m
T1= 350 ⁰C T2= 100 ⁰C t1= 25 ⁰C t`2= ?
QH =200kg/h Cp= 1.13kJ/kgK Qc= 1400kg/h Cpw= 4.19kJ/kgK
hg= 0.3 kW/m2 hw= 1.5 kW/m2

Solution:
-(mCp∆T)gas = (mCp∆T)H2O
-(200kg/h)(1h/3600s)(1.3kJ/kgK)(100-350) = 1400kg/h(1h/3600s)(4.19kJ/kgK)(t2-25)
 t2 = 34.63 ⁰C

A = ∏dL
Q = UA∆TLM

∆TLM = (∆T1- ∆T2)/ln⁡〖(∆T1/∆T2)〗 = (325-65.3)/(ln⁡(325/65.3)) = 162⁰C

1/U = 1/h1 + 1/h2 = 1/0.3 + 1/1.5 = 0.25

Q = UA∆TLM = -200(1/3600)(1.13)(100-350) = 0.25[∏(0.075)L] (162)
L = 1.64m

DESIGN PROBLEM:

The above design procedure is elaborated through the calculation of the following
example

Problem Statement:

150000 lb per hour of kerosene will be heated from 75 to 120°F by cooling a gasoline stream from 160
to 120°F. Inlet pressure will be 50 psia for each stream and the maximum pressure drop of 7 psi for
gasoline and 10 psi for kerosene are permissible. Published fouling factors for oil refinery streams
should be used for this application. Design a shell and tube heat exchanger for this service.

Part 1: Thermal design :

Given data :

Hot fluid inlet temperature (T1)= 160°F

Hot fluid outlet temperature (T2) = 120°F

Cold fluid inlet temperature (t1) = 75°F

Cold fluid outlet temperature (t2) = 120°F

Fouling factor of hot fluid (Rdg) = 0.0005 (for gasoline)

Fouling factor of cold fluid (Rdk) = 0.001 (for kerosene)

Pinlet (for hot fluid) = 50 psia

Pinlet (for cold fluid) = 50 psia

ΔPmax (for cold fluid) = 7 psia

ΔPmax (for cold fluid) = 10 psia

Mass flow rate of cold fluid ( ) = 150000 lb.h-1

(Subscripts ‘k' for kerosene and ‘g ' for gasoline)

I. Calculation of calorific temperature

° API of hot fluid=76° ; Therefore Kc = 1; Fc = 0.456

(The calorific temperature factor, Fc with ° API as a function Kc is available from the reference)

Calorific temperature of the hot fluid,

=120+0.455×(160-120)

=138.2°F

Calorific temperature of the cold fluid,

=75+0.455×(120-75)

=95.475°F

II. Fluid properties at calorific temperature

Viscosity:

76 °API gasoline, μg =0.2cp (0.484 lb.ft -1.h-1 )

46 °API kerosene, μk =1.6 cp (3.872 lb.ft-1.h-1 )

Density:

ρg =685 kg.m-3 (42.7 lb.ft-3 )

ρk =800 kg.m-3 (49.8 lb.ft-3 )

Thermal conductivity:

kg =0.075 Btu h-1 ft-1 °F-1

kk =0.083 Btu h-1 ft-1 °F-1

Specific heat capacity:

Cg = 0.57 Btu lb-1 ft-1

Ck = 0.48 Btu lb-1 ft-1

 Specific gravity:

Sg = 0.685

Sk = 0.80

III. Energy balance

Type heat exchanger: Assume no heat loss to the surrounding

=3240000 Btu/h

⇒150000×0.48×(120-75)= ×0.57×(160-120)

⇒ = 142105 lb h-1

IV. Calculation of heat transfer area and tube numbers

Iteration #1:

The first iteration is started assuming 1 shell pass and 2 tube passes shell and tube exchanger with
following dimensions and considerations.

 • Fixed tube plate

• 1'' OD tubes ( do) (14 BWG) on 1¼'' square pitch ( P T )

• Outer diameter of tube= 1''

• Tube length ( Lt)=16'

• Tube ID ( di ) = 0.834''

• Fluid arrangement: Kerosene is placed in tube side because it has the higher fouling tendency

The log mean temperature correction factor (FT) for 1-2 shell and tube exchanger :
where, ;

= 42.75°F

Determining the heat transfer area (‘ A '):

The value of overall heat transfer coefficient ( Uo,assm ) of 60 Btu h-1 ft -1 °F -1 is assumed to initiate the
design calculation for the kerosene and gasoline heat exchanger. The approximate range of overall heat
transfer coefficient depending on the hot and cold fluid can be found out from text books ( [3] page
845).

= 1586.36 ft 2

Calculating no. of tubes ( nt ):

 (1.2)

= 502

nt = 518 is taken corresponding to the closest standard shell ID OF 35" for fixed tube sheet, 1-shell and
2-tube passes exchanger with 1" tube OD on 1¼" square pitch. You may refer to standard heat transfer
books ( [3] page 841-842 ) for the selection of suitable shell ID.

Check for fluid velocity:

(1.4)

= 2740.2<10 4

As Re<<10 4 , the design parameters and considerations needs to be retuned to meet the Reynolds
number criteria subject to allowable pressure drop in the tube side of the heat exchanger.

Iteration #2:

Assumptions:

• Fixed tube plate type

• 1" OD tubes (14 BWG) on 1¼" square pitch ( PT )

• Tube length ( Lt ) = 24′ (the tube length is increased from 16' )

• 1 shell pass-6 tube pass (tube passes is increased to 6 from 2)

• Tube ID=0.834″

• Flow area per tube=0.546 inch 2

No. of tubes:

=335

nt = 368 is taken corresponding to the closest standard shell ID of 31΄΄ for fixed tube sheet, 1-shell and 6-
tube pass exchanger with 1΄΄ tube OD on 1¼΄΄ square pitch. The tube-counts are available in heat transfer
text book ( [3] Table 9 & 10 page 841-843).
 Fluid velocity:

= 11571.4 >104 corresponding to np= 6.

= 12945.15 ft/h (3.59 ft/s)

= 1.04 m/s (so the design velocity is within the acceptable range).

V. Determination of heat transfer co-efficient

Tube side heat transfer co-efficient ( hi ):

j H =42 for the tube side fluid at Re=11571.4 ( [3] page 834 )

(Let 's consider = 1, μ = viscosity of the tube side fluid; μw = viscosity of tube side fluid at wall
temperature)

hi = 141.3 Btu h-1 ft -1°F-1

Shell side heat transfer co-efficient ( ho):

Assumptions:

 • 25% cut segmental baffles

• Baffles spacing ( B )= 0.5 DS = 15.5 " (half of the shell ID is selected)

Equivalent diameter for the shell side: (for square pitch)

 =0.082ft

Shell side cross flow area, (please refer to Figure 1.6 ).

C = Tube clearance

= PT - d0

= 1¼ -1=0.25″

= 0.675 ft 2

Mass velocity,

=210526 lb. h -1.ft -2

=35668

Now for the shell side,

jH =110 for the shell side fluid at Re=35668 with 25% cut segmental baffles ( [3] page 838 )

( = 1 is considered for the shell side fluid ).

ho = 155.3 Btu h -1 ft -2 °F -1

Overall heat transfer co-efficient (Uo,cal ):

Fouling factor, Rdk =0.001 h ft2 °F Btu -1 for kerosene and Rdg = 0.0005 h ft 2 °F Btu -1 for gasoline is
taken for this service.

Let select, Admirality brass as tube material with thermal conductivity, kw =70 Btu h -1 ft-1 °F-1 .

Uo,cal = 53.5 Btu h -1 ft -2 °F-1

Now,

Therefore, the calculated overall heat transfer co-efficient is well within the design criteria.

VI. Pressure drop calculation

VI.1. Tube side pressure drop:

Friction factor f = 0.00028 x 144 for Re = 0.04032 ft2 /ft2 for Re=11571.4

at = (no. of tubes)×(flow area per tube)/(no. of passes)

= 0.232 ft 2

Tube side mass velocity:

=646552 lb. h-1.ft-2

Frictional pressure drop:

= 5.81 psi
Return loss ΔPrt : (due to change in flow direction of the tube side fluid)

= 0.73 psi

Total tube side drop neglecting nozzle loss:

=5.81+0.73

=6.54 psi<10 psi

Therefore the tube side pressure drop is within the maximum allowable pressure drop of 10 psi.

VI.2. Shell side pressure drop calculation

Tube clearance, C =0.25″

Spacing, B =15.5″

as = 0.444 ft2

Mass velocity, GS = 210526 lb. h-1.ft-2

Re = 35668

No of baffles,

Friction factor, f = 0.0017 X 144= 0.2448 ft2 / ft2 with 25% cut segmental baffles

Shell side frictional pressure drop ΔPs :

=1.4 psi <7 psi

ΔPrs = 0 (in case of single shell pass flow)

Total shell side drop neglecting nozzle loss:

= 1.4 psi

Therefore the shell side pressure drop is within the maximum allowable pressure drop of 7 psi.

VII. Over surface and over design

Over surface =

The clean overall heat fransfer co-efficient:

= 141.3×0.834=117.8 Btu h-1 ft-2 °F-1

Uc = 66.98 Btu hr -1 ft-2 °F-1

% Over surface =

=20% (acceptable)

Over design:

The design area of heat transfer in the exchanger, ( nt =318) :

=π× ×24×368=2312 ft2

The required heat transfer area (where, nt =335):

= π× ×24×335=2105 ft2

% Overdesign=9.8% which is within the acceptable limit.

Part 2: Mechanical design

 The process design of shell and tube for single phase heat transfer solved in Part 1 is continued for the
mechanical design.

The minimum information required for the mechanical design of some important components of shell
and tube exchanger is summarized below:

1. a. Shell side and tube side passes: 1 shell pass and 6 tube passes.

b. Number, type, size, and layout of tubes: Number of tubes 318; tube length 20΄ (6.096 m as per IS:
4503-1967 and IS:2844-1964 standards); tube OD 1΄΄ (25.4 mm); tube ID: 0.834΄΄ (21.2 mm); square

pitch ; fixed tube sheet.

c. Shell diameter and head: Shell ID 31΄ (787.4 mm); torispherical head is selected;carbon steel for
both shell and head.

d. Corrosion allowance: Corrosion allowance of 3 mm for carbon steel is taken as per IS:4503 for the
service in the petroleum industries.

e. Design temperature and pressure: design temperature 1.1×160=176°F (80°C) (10% greater than the
highest process fluid temperature is taken); design pressure 0.38 N/mm 2(55 psia) (10% higher than the
inlet pressure of both the streams).

f. Permissible stress, f =100.6 N/mm2 for carbon steel.

i. Shell thickness calculation (refer section 2.3.1)

Including corrosion allowance 6.72 mm, use 8 mm thickness

(This value is in accordance to IS:4503 corresponding to the shell diameter)

ii. Torispherical head (refer section 2.3.2)

Crown radius, Ri = 787.4 mm (crown radius, Ri = Ds is considered)

Knuckle radius ri =0.06 of Ri = 47.24 mm (knuckle radius ri =6% of Ds is taken)

Inside depth of the head ( hi) can be calculated as:

Effective exchanger length (Leff ) = Lt + 2 x hi = 6.096 m + 2×0.1054 m

= 6.306 m

Thickness of head ; j =1 is taken for head design

=1.77 for ri =0.06× Ri

th= 2.63 Including corrosion allowance 5.63 mm, use same thickness as for shell, i.e., 8 mm

iii. Channel cover thickness

Channel cover material: carbon steel

Dc= Outside shell diameter=803.4 mm;C1= 0.3; p =3.88 kgf/cm2 (0.38 N/mm2 )

f = 10.26 kgf/mm2 (100.6 N/mm2 )

tcc = 8.5 mm; Use 12 mm including the corrosion allowance

iv. Tube sheet thickness (refer section 2.3.5)

The tube sheet thickness is calculated based on the bending and considering the design pressure only.
It is assumed that shear does not control the design. Carbon steel is used for tube sheet material.

F=1 for fixed tube sheet; k=0.5 (square pitch)

tts =22.8 mm (satisfies the IS:4503 specification for 1΄΄outside diameter tube)

v. Impingement plate (refer section 2.3.6)

The density ( ρk) of the tube side fluid (kerosene) =0.8 g.cm3 (800 kg.m3 ); mass flow rate (mk) of
kerosene =18.91 kg/s (150000 lb.h)

Kerosene velocity,

Where, nozzle diameter, Dn = 203.2 mm=0.2032 m

The impingement parameter, ρv2 = 0.8 x 0.732 = 0.426<<125

Therefore the impingement protection is not required.

vi. Nozzle thickness (tn)

Use carbon steel for the nozzle (same material)

Considering diameter of nozzle ( Dn) to be 203.2 mm (8 inch) ( Table 2.3 ); j = 0.8

Use 6 mm thickness including the corrosion allowance.

The pressures at the entry point of both shell side and tube fluid are same. Therefore, the same
nozzle specification can be used for tube side fluid also.

vii. Design of gaskets (refer section 2.3.8)

Gasket factor m =3.75, minimum design seating stress Y= 5.35 kgf/mm2 (for flat iron jacketed,
asbestos fill) ( Table 2.4 )

viii. Bolts design (refer section 2.3.9)

The bolt load due to gasket reaction under atmospheric conditions is given:

=278515 N

The bolt load under tight pressure:

=15120 +194848=209968 N
 Therefore, Wm1 is the controlling load because Wm1> Wm2

The minimum bolt cross sectional area (bolt material carbon steel and fa = fb:

M16 nominal thread diameter with bolt circle diameter (Cb) of 860 mm, 32 bolts and 18 mm root
diameter (dbr) are selected from IS:4866-1968.

Corresponding actual bolt circle diameter,

Ab > Am; Therefore the selected bolts are suitable.

The minimum gasket width,

(compared to 35 mm selected gasket width)

ix. Flange thickness

 i. For the gasket seating condition (no internal load applied)

ii. For operating condition

(2.26)

Summation moments under operating condition

Therefore is the controlling moment .

Flange thickness (carbon steel):

References:
[1]. Indian Standard (IS: 4503-1967): Specification for Shell and Tube Type Heat Exchangers, BIS
2007, New Delhi.
[2]. Kuppan T. Heat Exchanger Design Handbook, Marcel Dekker, Inc. 2000, New York.
[3]. Standards of the Tubular Exchanger Manufacturers Association (TEMA), Inc. 18 ed., 1999,
New York.
[4]. Brownell L.E. and E.H. Young, Process Equipment Design, John Wiley and Sons, Inc. 1959.
New York.

References:

Branan, Carl R., 2002. Rules of Thumb for Chemical Engineers, Gulf Publishing Company,
Houston, TX.
Sinnott, RK., 2005. Coulson and Richardson’s Chemical Engineering: Chemical Engineering
Design, Vol. 6. 4th Ed.