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Abstract
A procedure is presented for evaluating the shell side pressure drop in shell-and-tube heat exchangers with segmental baffles.
The procedure is based on correlations for calculating the pressure drop in an ideal tube bank coupled with correction factors,
which take into account the influence of leakage and bypass streams, and on equations for calculating the pressure drop in a
window section from the Delaware method. The proposed equations were checked by comparing experimental measurements
available in the literature with the theoretical predictions. The ranges of the geometrical and operational parameters, for which
the deviations between the experimental measurements and the theoretical predictions were within & 35%, are presented in the
paper.
Kurzfassung
Em Verfahren fiir die Berechnung des Druckverlusts im AuSenraum von Rohrbfindel-Warmetibertragern mit Segment-Um-
lenkblechen wird dargestellt. Das Verfahren basiert auf Gleichungen fur die Berechnung des Druckverlusts in einem idealen
Rohrbiindel gekoppelt mit Korrekturfaktoren, die den EinfluD der Leek- und der Bypassstromungen beriicksichtigen, und auf
Gleichungen fur die Berechnung des Druckverlusts in einer Fensterzone nach der Delaware-Methode. Zur Uberprtifung der
Gleichungen wurden MeBwerte aus dem Schrifttum herangezogen und mit den theoretischen Berechnungen verglichen. Die
Bereiche der geometrischen und der betrieblichen Parameter, fiir die die Abweichungen zwischen den gemessenen und den
berechneten Werten innerhalb & 35% lagen, werden angegeben. 0 1997 Elsevier Science S.A.
*AbE
1. Introduction +
nu AP,
The flow in the shell side of a shell-and-tube heat
exchanger with segmental baffles is very complex. The +
baffles lead to a stream inside the shell, as shown in Fig.
1, which is partly perpendicular and partly parallel to the .Aps
tube bank. The gaps between the tubes and the holes in
the baffles and the gap between a baffle and the shell Fig. 2. Dividing the shell side of a shell-and-tube heat exchanger into
cause leakage streams S,, which may modify the main sections.
stream S, significantly. Since the tubes of the heat
exchanger can not be placed very near to the shell, dures have been checked in [6] against a large number
bypass streams S, may be formed, which influence also of experimental measurements on small units and on
the main stream. The flow direction of the main stream industrial scale heat exchangers. According to [6], the
relative to the tubes is different in the window sections methods of Tinker [3,4] and of Delaware [5] gave the
created by the baffle cut from that in the cross flow best results compared with the other methods available
sections existing between the segmental baffles. This in the open literature. The method of Tinker [3,4] has
necessitates the use of different equations to calculate the been frequently criticized because it is relatively compli-
pressure drop in the window sections to those used in the cated. The procedure presented in this paper for calcu-
cross flow sections. The spacing between the tube plates lating the shell side pressure drop is based principally
and the tist and the last baffle, which is mostly dictated on the Delaware method [5]. However, instead of using
by the diameter of the inlet and oulet nozzles, differs in diagrams-as in the Delaware method-to calculate
many cases from the spacing between two adjacent the pressure drop in the ideal tube bank, the present
baffles and some of the aforementioned streams are not authors use equations previously presented in [7,8].
present in the first and in the last heat exchanger Correction factors are then used-as in the Delaware
sections. This adds to the complexity of the problem. method-to take into consideration the deviatation of
A lot of publications appeared in the last few decades the flow inside the shell of the heat exchanger from that
(e.g. [l-5]), which describe methods to calculate the in the ideal case of a tube bank. Pressure drops ob-
pressure drop in the shell of a shell-and-tube heat tained experimentally by different investigators from
exchanger with baffles. A critical review is given by measurements on a number of shell-and-tube heat ex-
Palen and Taborek [6]. The different calculation proce- changers were compared with those calculated by this
procedure. In the paper, the comparison is presented
and discussed and the validity ranges of the equations
are given. This procedure forms the basis for the com-
putational procedure in the German handbook ‘VDI-
Wgrmeatlas’ [15] and in the English translation of that
handbook ‘VDI Heat Atlas’ [16].
2. Calculation procedure
pressure drop in an end cross flow section, Ap, is the a window section counts onIy as a half restriction. Fig.
pressure drop in a window section, Aps is the pressure 3 illustrates the rules for evaluating n,.
drop in both inlet and outlet heat exchanger nozzles The velocity is calculated from
and n, is the number of segmental baffles. F
It is assumed in Eq. (1) that the pressure drop w, = - (4)
components, are constant in the corresponding sections A,
along the heat exchanger length. The change in the with
physical properties in the different sections is thus
A, = SL,, (5)
ignored and the mean value can be used. The assump-
tion of a constant window pressure drop in all window where A, is the flow area defined by Eq. (5), k is the
sections implies that the difference in the length of the fluid volumetric flow rate in the heat exchanger shell, S
Crst and the last window sections as compared with is the baffle spacing and L, is the sum of the shortest
that of the intermediate window sections is not signifi- distances connecting neighbouring tubes and the short-
cant and is thus ignored. est distances between the outermost tubes and the shell
measured in the tube row on or near to the shell
2.1. Pressure drop in a crossJiow section diameter parallel to the edge of the baffle cuts.
Fig. 4 shows the lengthes LE, e and e,. Tie rods
A cross flow section is that part of the heat exchanger connecting the baffles together and furing the baffle
shell, which lies between two adjacent baffles and is spacing, which influence the length L,, should be con-
bounded from the top and the bottom by the planes sidered in evaluating LE.
that touch the upper and lower edges of the baffle cuts. The following equations correlate the pressure drop
The pressure drop in a cross flow section may be coefficient 5 to the Reynolds number and the geometry
calculated from the following equation: of the tube bank [7,8]:
For an in-line layout:
APQ = APQ,O~L~B. (4
The first term in Eq. (2) is the pressure drop in an ideal
tube bank in the abscence of bypass and leakage
streams. To account for the influence of leakage
4 = U,l + t&t
[
1 - exp - Re2;;;00
c II 9 (6)
Apa,o = hv 9,
(11) (18)
and
(12)
A
Fig. 6. Arrangement of sealing strips (n, = 2 in the figure).
where
where AF is the flow area and U, the wetted perimeter
for a window section. AF and U, can be evaluated from
A, = A,, - A,,, (51) i” \vs and d, are the nozzle pressure drop coefficient
fti both nozzles, the nozzle velocity and the nozzle
AFG= sin(;)], (52) diameter respectively. The inlet and outlet nozzle di-
ameters have been assumed to be equal.
The nozzle pressure drop coefficient 4s is the summa-
(53) tion of the nozzle pressure drop coefficient <s,rN for the
inlet nozzle and the nozzle pressure drop coefficient
and
4 s,oN for the outlet nozzle. Since the flow area at the
outlet of the inlet nozzle is usually much larger than the
flow area based on the nozzle diameter, ts,TN M 1 (sud-
den enlargement of flow area corresponding to the case
A ro is the cross-sectional area of a window section of a tube connected to a large vessel). The nozzle
including the area of the window tubes and A,, is the pressure drop coefficient 5s,oN for the outlet nozzle
cross-sectional area of the window tubes. In evaluating depends on the Reynolds number Re, for the flow
the equivalent diameter d,, the wetted area of the edge through the outlet nozzle (Res = wsdsp/v) and on the
of the baffle has been ignored. The characteristic veloc- ratio of the flow areas before and after the sudden
ity w, in Eq. (47) Eq. (48) is evaluated from contraction. If the flow area before the sudden contrac-
w, = (w,wp, (55) tion is much larger than the flow area after the contrac-
tion (flow area of the nozzle) rS,oN M 1 for laminar flow
where and koN < 0.6 for turbulent flow [14]. Thus, assuming
P ls z 2 for both laminar and turbulent flow will be on
wp = -. (56) the safe side.
AF
Eqs. (47) and (48) give in most cases different values for
the pressure drop in a window section at Re = 100. 3. Available experimental measurements
Therefore, Taborek [9] suggests to use intermediate
values of those values given by Eqs. (47) and (48) in the A number of investigators carried out experimental
range 50 I Re I 200 based on engineering judgment, or measurements on shell-and-tube heat exchangers with
to use the higher value as a factor of safety. In the segmental baffles and variable geometries. Tinker [ll]
present work, superposition was used and the equation examined 10 heat exchangers with different shell diame-
recommended in this work to calculate the pressure ters varying from 90 to 260 mm using oil and water as
drop ApF in a window section is given by shell-side fluid. Short [12] (B.E. Short, private commu-
nication) examined a heat exchanger with a shell diame-
(57) ter of 154 mm. Water and three different grades of oil
where covering a wide range of viscosity were used as shell
156 ES. Gaddis, V. Gnielinski/ Chemical Engineering and Processing 36 (1997) 149-159
t=J(1 3
2
2
+s21. (63)
most probably within + 35%. Since measurements with
gases as shell side fluid are not available, this procedure
should be applied only for liquids.
Fig. 9. Comparison between experimental measurements and theoretical predictions for all available experimental points.
c
_ 0 Delaware (large unit) [5]
- 0 Delaware (small unit) [5,10]
- a Short[l2]
v Short[13]
_ 0 Tinker[ll]
Fig. 10. Comparison between experimental measurements and theoretical predictions for experimental points having geometrical and operational
parameters within the ranges given in Table 2.
[5] K.J. Bell, Final Report of the Cooperative Research Program on Delaware, Engineering Experimental Station, Bulletin No. 4,
Shell and Tube Heat Exchangers, University of Delaware, Engi- 1958.
neering Experimental Station, Bulletin No. 5, 1963. [Ill T. Tinker, Shell Side Heat Transfer Characteristics of Segmen-
[6] J.W. Palen and J. Taborek, Solution of shell side flow pressure tally Baffled Shell and Tube Heat Exchangers, Preprint of paper
drop and heat transfer by stream analysis method, Chem. Eng. presented at the Annual Meeting, American Society of Mechan-
Progr. Symp. Series, 65 (1969) 53-63. ical Engineers, 1947.
[7] ES. Gaddis and V. Gnielinski, Druckverlust in querdurch- [12] B.E. Short, Heat Transfer and Pressure Drop in Heat Exchang-
striimten Rohrbiindeln, ut verfahrenstechnik, 17 (1983) 410-418. ers, The University of Texas, Publication No. 4324, 1943.
[S] ES. Gaddis and V. Gnielinski, Pressure drop in cross flow across [14] W. Kast, VDI-Warmeatlas, Section Lc, 7th edn., VDI-Verlag,
tube bundles, ht. Chem. Eng., 25 (1985) 1-15. Frankfurt, 1994.
[9] J. Taborek, Shell-and-tube heat exchangers: single-phase-flow, [15] E.S. Gaddis, VDI- Wtirmeatlas, Section Ll, 4th edn., VDI-Verlag,
Section 3.3, Heat Exchanger Design Handbook, Hemisphere, Frankfurt, 1984 and the corresponding section in the following
1983. editions.
[lo] O.P. Bergelin, M.D. Leighton, W.L. Lafferty Jr. and R.L. Pig- 1161 ES. Gaddis, VDZ Heat Atlas, Section Lm, 1st English edn.,
ford, Heat Transfer and Pressure Drop during Viscous and Turbu- VDI-Verlag, Frankfurt, 1992 (translation of the 6th german edition
lent Flow Across Baffled and Unbafjed Tube Banks, University of (1991)) and the corresponding section in the following editions.