King Abdulaziz University

Mechanical Engineering Department

MEP 460
Heat Exchanger Design

Thermal Design of Shell

and tube heat Exchanger

March 2018

1
 Contents

1-Introduction
2-Basic components
Shell types
Tube bundle types
Tube layouts
baffle types
3-Basic design procedure
Preliminary estimate of unit size
Rating of preliminary design
4 Shell side heat transfer and pressure drop
5-Bell-Delaware method for rating a shell and
tube heat exchangers
2
 1-Introduction

 Most used heat exchangers

 Can accommodate high temperature high
pressure fluids
 In some designs tubes can be replaced
 Many options to choose from
 Different designs to choose from for shell,
tube layout and tube bundle
 Require more space when compared to
plate gasketed heat exchangers

3
 1-Introduction
Main components of a shell & tube HX

A-Shell types
B- Tube bundle types
C- Tube layouts
D-Baffle types

4
 A- Shell types

TEMA
Tubular Exchanger
Manufacturers Association
Standards

Most common
shell type are:
E, F, G

5
 A- Shell types

V stands for vent

6
 A- Shell types

Kettle re-boiler shell

7
 B- Tube bundle types
U tube bundle

Tube can expand

Replacement of
tubes is not
possible except
maybe the outer
row

Tubes can have

fins

8
 B-Tube bundle types
Fixed tube sheet

Design for ease cleaning of the

inside of the tubes
Not possible to access the outer
surface of the tubes
Has limited expansion
Individual tubes can be replaced 9
 B-Tube bundle types
Floating head

pull-through floating head

Bundle can be removed and cleaned
Good for fouled fluids
10
 C-Tube layouts

Only an E-shell with one tube pass and an F-shell with two tube
passes result in nominal counterflow. All other multiple tube passes
require a temperature correction (factor F),

Tube metal is usually:

Low carbon steel
Low alloy steel
Stainless steel
Copper
Admiralty
Cupronickel
Inconel
Aluminum (in the form of alloys),
or titanium.

The wall thickness of heat exchanger tubes is standardized in

terms of the Birmingham Wire Gage (BWG) of the tube. Tables
9.1 and 9.2 give data on heat exchanger tubes
11
 C-Tubes & Tube layouts

Tube diameters (8–15 mm) are preferred for greater area/volume

density but are limited, for purposes of in-tube cleaning
Larger tube diameters are often required for condensers and
boilers.
The tubes may be either bare or have low fins on the outside. Low
fin tubes are used when the fluid on the outside of the tubes has a
substantially lower heat transfer coefficient than the fluid on the
inside of the tubes.

As the tube length is increased the heat transfer area

increased and the number of tubes decreased. Tube
length is dictated by space available and transportation
requirement.

shell-diameter-to-tube-length ratio is typically

between 1/5 to 1/15 [ Ds/L =1/5 to 1/15]
12
 C-Tubes & Tube layouts
Commercial tube data

Birmingham
Wire Gage
(BWG)

13
C-Tubes & Tube layouts
Commercial tube data

14
C-Tubes & Tube layouts

15
 C-Tube & tube layout
Pitch angle p

 

= =

= = 16
 C-Tube & tube layout

PT is the tube pitch

do is the outside diameter

P /d , is between 1.25 and 1.5.

T o

17
 C-Tube & tube layout
Tube counts for different shell diameters and tube layout

18
Tube counts for different shell
diameter and tube layout

19
Table 9.3 Tube count

20
 D-Baffle types
Baffle function:

Baffles serve two functions:

* Support the tubes for structural rigidity,
preventing tube vibration and sagging, and
* To divert the flow across the bundle to
obtain a higher heat transfer coefficient

baffle types

 Transverse and longitudinal

 Rod and plate

21
 D-Baffle types
transverse and longitudinal baffles

Transverse baffles Longitudinal baffle

22
 D-Baffle types
Rod and plate baffles

Rod baffles Plate baffles

23
 D-Baffle types

Types of plate baffles

Single segmental
Double segmental
Triple segmental
No tubes in the window
Disk and doughnut

24
D-Baffle types Types of plate baffles

25
D-Baffle types

Types of plate baffles

26
D-Baffle types

Types of plate baffles

27
D-Baffle types
Types of plate baffles

28
 D-Baffle types
Types of plate baffles
Orifice baffle

29
 D-Baffle types

Rod and ring baffle

30
 Baffle spacing and baffle cut
Optimum baffle spacing is somewhere between 0.4
and 0.6 of the shell diameter and a baffle cut of 25% to
35% is usually recommended. The

B
31
Baffle cut

32
33
34
Procedure for
designing heat
exchangers

Select type of
shell & tube HX

Preliminary
sizing of key
parameters
Kern method
Bell Delaware
method

35
Preliminary procedure to size a unit

1-Calculate LMTD and estimate the correction

factor F
2-Estimate the overall heat transfer coefficient U
(use table 9.4 and table 9.5 for individual h)
3-Calculate q from the known mass flow rates and
the temperatures
4-Calculate approximately the heat transfer area Ao
using 𝐴𝑜 = 𝑞 𝑈𝑜 𝐿𝑀𝑇𝐷𝑐𝑓 𝐹
5-From the calculate Ao one can estimate the
number of tubes

36
Preliminary calculation for sizing shell and tube
heat exchangers

The size of a heat exchanger can be found using

𝑞
𝐴𝑜 =
𝑈𝑜 𝐿𝑀𝑇𝐷𝑐𝑓 𝐹

Provided all temperatures are known and an

approximate value of Uo is available

An estimate for Uo can be found based on

individual thermal resistances

1 1 𝑅𝑓𝑖 1
= + + 𝐴𝑜 𝑅𝑤 + 𝑅𝑓𝑜 +
𝑈𝑜 ℎ𝑖 (𝐴𝑖 𝐴𝑜 ) (𝐴𝑖 𝐴𝑜 ) ℎ𝑜

37
Preliminary procedure
to size Shell & tube HX

Estimating the individual

heat transfer coefficient h

38
Preliminary procedure
to size a unit

Typical U value for

some heat
exchangers

39
 Symbols and their meanings
L Length of the tube [m]
De Equivalent diameter [m] used in calculating Res by Kern method
do Outside diameter of the tube [m]
di Inside diameter of the tube [m]
Ds Shell inside diameter[m]
Nt No. of tubes
A1 Area taken by single tube [m2]
CL Tube layout constant. CL=1 for 90 and 45 layout, CL=0.87 for others
CTP Tube count calculation constant. One tube pass=0.93, two tube
passes=0.9, Three tube passes=0.85
Np No of tube passes
B Baffle spacing [m]
Bc Baffle cut [m]
PT Tube pitch [m]
PT/do Pitch outside diameter ratio [-]
As Min. flow area at the shell center line [m2]
Gs 𝑚𝑠
Mass velocity [kg/(m2.s)] 40
𝐴𝑠
 Preliminary procedure to size a unit
𝑞 = 𝑚𝑐 𝐶𝑝𝑐 (𝑇𝑐𝑜 − 𝑇𝑐𝑖 ) (1)
𝐶𝑇𝑃 𝐷𝑠2
𝑞 = 𝑚ℎ 𝐶𝑝ℎ (𝑇ℎ𝑖 − 𝑇ℎ𝑜 ) (2) 𝑁𝑡 = 0.785 (8)
𝐶𝐿 𝑃𝑅2 𝑑𝑜2
𝑞 = 𝑈𝑜 𝐴𝑜 𝐿𝑀𝑇𝐷 𝐹 (3)

𝑞 (4)
𝐴𝑜 =
𝑈𝑜 𝐿𝑀𝑇𝐷 𝐹 1 2
𝐶𝐿 𝐴𝑜 𝑃𝑅2 𝑑𝑜
(5) 𝐷𝑠 = 0.637 (9)
𝐴𝑜 = 𝜋𝑑𝑜 𝑁𝑡 𝐿 𝐶𝑇𝑃 𝐿

𝜋𝐷𝑠2 (6) PR=tube pitch ratio=PT/do (10)

𝑁𝑡 = 𝐶𝑇𝑃
4𝐴1
(7)
𝐴1 = 𝐶𝐿 𝑃𝑇2
1-From Eq. (4) Ao can be estimated
CL =1 For 90 and 45 2-Assume a typical commonly used
shell and tube layout estimate CTP,
CL=0.87 For 30 and 60 CL, PT and do
3-Use Eq. (9) to estimate shell
One tube pass CTP=0.93 inside diameter Ds
Two tube pass CTP=0.9 4-Use Eq. (8) to get the number of
tubes Nt 41
Three tube passes CTP=0.85
Example 9.1 on preliminary sizing of a shell and
tube heat exchangers

42
 Example 9.1 continue

Rf=0.000176 m2 .K/W
Thi= 67 C
Baffle spacing B=0.6 Ds mh=5000 kg/hr
Water condensate
Tubes: do=19 mm, di=16 mm 40 C

heat exchanger length L<5 m

Tho

Baffle cut= 25% city Water

mc=30,000 kg/hr
17 C
Δ𝑃𝑠 < 5 𝑝𝑠𝑖
kt=60 W/(m.K)

Required: Preliminary sizing of shell and ¾” tube

tube heat exchanger PT/do=1.25
43
di=16 mm, do=19mm
Example 9.1 continue

hi =5000 W/(m^2.K)
ho=4000 W/m^2.K

44
Example 9.1 continue

45
Example 9.1 continue

46
Example 9.1 continue

47
Example 9.1 continued

48
 Rating a heat exchanger

Kern and Bell-Delaware methods

for rating shell and tube heat exchangers
49
 Shell-Side Heat Transfer and Pressure Drop (Kern)

McAdams expression for

0.55 1 3 0.14
finding the shell side ℎ𝑜 𝐷𝑒 𝐷𝑒 𝐺𝑠 𝑐𝑝 𝜇 𝜇𝑏
heat transfer coefficient = 0.36
𝑘 𝜇 𝑘 𝜇𝑤

𝐺𝑠 𝐷𝑒
2 × 103 < 𝑅𝑒𝑠 = < 1 × 106
𝜇

ho shell side heat transfer coefficient

De equivalent diameter
Gs shell side mass velocity

4𝑓𝑟𝑒𝑒 𝑓𝑙𝑜𝑤 𝑎𝑟𝑒𝑎 4𝐴𝑐

𝐷𝑒 = =
𝑊𝑒𝑡𝑡𝑒𝑑 𝑝𝑒𝑟𝑖𝑚𝑒𝑡𝑒𝑟 𝑊𝑒𝑡𝑡𝑒𝑑 𝑝𝑒𝑟𝑖𝑚𝑒𝑡𝑒𝑟

50
 Shell-Side Heat Transfer and Pressure Drop (Kern)

𝜋𝑑𝑜2
4 𝑃𝑇2− 4
𝐷𝑒 =
For square pitch 𝜋𝑑𝑜

𝑃𝑇2 3 𝜋𝑑𝑜2
4 4 − 8
For triangular pitch 𝐷𝑒 =
𝜋𝑑𝑜 2

51
 Shell-Side Heat Transfer and Pressure Drop (Kern)
The bundle cross flow area As at the centerline of the shell
depends on the shell inside diameter Ds, the tube layout pitch and
the clearance between the tubes

𝐷𝑠 𝐶𝐵
𝐴𝑠 =
𝑃𝑇

The shell side mass 𝑚𝑠

velocity is given by
𝐺𝑠 =
𝐴𝑠

52
 Shell side pressure drop

The length is taken as the shell inside diameter and

the flow make crosses over the bundle (Nb+1) times

𝑓 𝐺𝑠2 𝑁𝑏 + 1 𝐷𝑠 𝑚𝑠
Δ𝑝𝑠 = 𝐺𝑠 =
2𝜌𝐷𝑒 𝜙𝑠 𝐴𝑠

𝑓 = exp(0.576 − 0.19 ln 𝑅𝑒𝑠 )

𝐺𝑠 𝐷𝑒
400 < 𝑅𝑒𝑠 = ≤ 1 ∗ 106
𝜇

0.14
𝜇𝑏
𝜙𝑠 =
𝜇𝑤

Where Nb is the number of baffles

𝐿
𝑁𝑏 = −1
𝐵
53
B is the baffle spacing
 Tube side pressure drop
Due to friction 2
𝐿 ∗ 𝑁𝑝 𝑢𝑚 𝐿𝑁𝑝 𝐺𝑡2
Δ𝑝𝑓 = 4𝑓 𝜌 = 4𝑓
𝑑𝑖 2 𝑑𝑖 2 𝜌
Np is the number of tube passes
2
𝜌𝑢𝑚
Pressure drop due to change of Δ𝑝𝑟 = 4𝑁𝑝
2
direction of the flow
Which is taken as four velocity heads per pass

Therefore the total tube side pressure drop

𝐿𝑁𝑝 2
𝜌𝑢𝑚
Δ𝑝𝑡𝑜𝑡 = 4𝑓 + 4𝑁𝑝
𝑑𝑖 2

54
 Example 9.2 Rating of a preliminary design
It is required to rate the heat exchanger of
example 9.1

output results from example 9.1 are:

Thi= 67 C
mh=5000 kg/hr

Water condensate
40 C

Tho
Nt=117 tube city Water
mc=30,000 kg/hr

55
Correct count of tubes in a shell
according to TEMA standards

56
Example 9.2 Rating of a preliminary design

Input data for rating the heat exchanger are:

No parameter value
1 Ds 15.25 “=0.39 m
2 Nt 124 tubes
3 di 16 [mm]
4 do 19 [mm]
5 k 60 [W/(m.K)]
6 B 0.2 and baffle cut =25%
7 PT 0.0254 [m]
8 Np 2 tube passes

57
Example 9.2 continue

58
Example 9.2 continue

59
Example 9.2
continue

60
Example 9.2 continue

61
Example 9.2 continue

62
Example 9.2 continue

Calculating heat exchanger length

63
Example 9.2 continue

64
Example 9.2 continued

65