1

DESIGN OF SHELL & TUBE HEAT EXCHANGER

A Crude oil stream is to be preheated by receiving heat
from a Kerosene product in a Shell & Tube Heat Exchanger.
The flow rates, temperatures and physical properties at the
mean temperature are given below:
Physical properties
Flow rate (m3/s)
Initial temp. (0C)
Final temp. (0C)
Density, (Kg/m3)
Specific heat, Cp
(J/Kg.K)
Viscosity, (Ns/m2)
Thermal Conductivity,
K (W/mK)

Kerosene
0.037
T1 = 200
T2 = 95
730
2470

Crude Oil
0.103
t1 = 35
t2 = 75
830
2050

4 x 10-4
0.132

3.6 x 10-3
0.13

For Heat Exchanger type: 1 Shell pass 2 Tube pass

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Assuming the Fouling coefficient for Kerosene be 5000

W/m2K and for crude oil be 2000 W/m2K
SOLUTION:
Step 1: Heat Balance
Calculating the Heat balance in the Heat Exchanger, we
have to consider the Heat flow occurs in both hot and cold
fluid.
For Hot fluid,
Qh = mhCphTh
Where Qh = heat flow from hot fluid
mh = flow rate of hot fluid = 0.037 m3/s x 730 kg/m3 =
27.01 kg/s
Cph = Specific heat of hot fluid = 730 J/kg.K
Th = T1 T2 = 200 95 = 105 0C
So, Qh = 0.037x730x2470x105
Qh = 7005043.5 J/s
Similarly, For Cold section,
Qc = mcCchTc
Th = t2 t1 = 75 35 = 40 0C
So, Qc = 0.103x830x2050x40
Qc = 7010180 J/s

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Now,

Q=

Qh +Qc
2

ie, Q = (7005043.5+7010180) / 2
Q= 7007611.75 J/s
Step 2: LMTD

LMTD (Logarithmic Mean Temperature Difference)

LMTD=

( T 1t 2) (T 2t 1)
ln

So,

(T 1t 2)
(T 2t 1)

LMTD=

( 20075 )(9535)
( 20075)
ln
( 9535)

LMTD = 88.56

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Hence the Heat exchanger is having 2 tube pass LMTD

correction factor have to be considered.
Step 3: LMTD correction factor (FT)
LMTD correction factor is usually taken for the cases
when the heat exchanger is having more than 1 tube pass.
It is determined from the graph in Perrys handbook (Page:
11-6, Fig: 11-4(a))
R=

S=

(T 1T 2)
(t 2t 1)

(t 2t 1 )
(T 1t 1)

= 2.625
= 0.242

From graph, for the corresponding values of R and S, we get

FT;
FT = 0.69
Step 4: Routing through Shell and Tube
The factors taken under consideration are,
1. More corrosive fluid in Tubes
2. Fluid having less fouling factor or fouling coefficient
will be more corrosive
Here, Crude oil is having less fouling factor than Kerosene, so
it is more corrosive
Crude Oil Tubes
Kerosene Shell

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Step 5: Assuming the value of overall heat transfer

coefficient (U0)
The value of U0 can be taken from Perrys hand book (Page:
11-25, Table: 11-3 )
We take U0 = 30 Btu/0F.Ft2.h = 30 x 50678 W/m2.K
ie, U0 = 170.34 W/m2.K
Step 6: Overall Heat transfer area (A0)
A 0=

Q
U 0 . LMTD. FT

A 0=

7007611.75
170.34 x 88.56 x 0.9

A0 = 516.01 m2
Step 7: Tube size and pitch
Reference: Perrys hand book (Page: 11-42, Table: 11-12)
Assuming tube size, 14 BWG:
Outside diameter (d0)

=0.01905m

Inside diameter (di) = 0.584 = 0.0148m

Thickness (t)

= 0.083 = 0.0021m

If operating pressure is given, thickness

t=

p d0
200 fj+ p

Assuming Tube Length (L) = 16 ft = 4.876m

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Assuming Tube pitch, Triangular Tube pitch (Pt)

Pt = 1.25 d0
Pt = 1.25 x 0.01905 = 0.0238 m
Step 8: Type of Head
For T high = Split ring floating head
If Dirt factor is high = Split ring floating head
If, Tbulk > 80 = Floating ring head
If, Tbulk 80 = Fixed ring head
Here Dirt factor is high, hence assuming Floating head
Step 9: Number of Tubes
n=

A0
d0 L

n=

516.14
x 0.01905 x 4.876

= 1769.32

n 1770

So changed actual A0,

A0,actual = nd0L
A0,actual = 1770 x x 0.01905 x 4.876m= 516.598 m2
Similarly changed Actual U0,
U 0,actual =

Q
A 0,actual . LMTD . F T

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U 0,actual =

7007611.75
516.59 x 88.56 x 0.9

= 170.191 W/m2.K

Step 10: Inside Heat transfer coefficient (hi)

Inside Tube, it is Crude oil. Inorder to calculate hi physical
properties of Crude oil have to be considered.
G=

mc
0.103 x 830 x 2 x 4
=
n 2 1770 x x 0.01482
d
24 i

= 561.512 kg/m2.s

Reynolds number, Re = Gdi / = 561.52 x 0.0148 / 3.6 x 10-3

Re = 2405
Prandtl Number, Pr = Cp / K = 2050 x 3.6 x 10-3 / 0.13
Pr = 56.76
Nusselt Number, Nu = 0.027 Re4/5Pr1/3(b / w)0.14 ----- Perrys
(Page: 5-9, eqn: 5-50)
Assuming (b / w)0.14 = 1
Nu = 0.027 x 24054/5 x56.731/3x1
Nu = 52.594
Now the inside heat transfer coefficient, hi = Nu.K / di =
52.594 x 0.13 / 0.0148
hi = 461.974 W/m2.K
Step 11: Shell Side (Outside) Heat Transfer coefficient

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Either of the two methods can be followed for determining

outside heat transfer coefficient,
1. Bells Method
2. Kerns Method
Here, Bells Method is followed: (Reference: Perrys hand
book)
Finding the Bundle diameter (Db)
For 2-tube pass,
Nt = 1266 + 73.58 C + 1.234 C2 0.0071 C3 0.0005 C4 ---(page 11-43, eqn:11-74b)
Neglecting the variable C4 term in above equation we get,
1770 = 1266 + 73.58 C + 1.234 C2 0.0071 C3
Equation on solving gives, C = 219.53, 6.22, -51.95
But accuracy of C is -24 C 24
Hence, C = 6.22
C=0.75

Db
36
d0

So, Db = (6.22 + 36) 0.01905 / 0.75

Bundle diameter, Db= 1.0723 m
For finding Shell inside diameter (DS)
DS = Db + 2(clearance)
Taking clearance be 0.037 m

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DS = 1.0723 + (2 x 0.037)
Shell inside diameter, DS = 1.146 m
Baffle Spacing, BS = (0.3 to 0.8) DS
Taking, BS = (0.5) DS = 0.5 x 1.146
Baffle spacing, BS = 0.573 m

BELLS METHOD STEPS

Reference: Perrys hand book Page: 11-5
1) Number of tubes Nt = 1770
2) From Figure: 11-5
Pp = 0.814 = 0.02067 m
Pn = 1.469 = 0.01191 m
D
N =
12 ( l /D ) ]
3)
------- (eqn:11-7)
P [
S

Taking lc = 0.25 (0r) (25%)

N C=

1.146
[12 ( 0.25 /1.146 ) ]
0.02067

NC = 31.25
4)

FC =

[ (

D 2 l c
D 2 l c
D 2l c
1
+2 s
sin s
2 cos1 s

Dotl
D otl
D otl

) (

)]

--------(eqn:

11-8)
Here Dotl = Db
FC =

[ (

1
1.1460.5
1.1460.5
1.1460.5
+2
sin
2 cos1

1.0723
1.0723
1.0723

) (

)]

FC = 0.717

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5)

lc
Pp

N cw=0.8

( )

N cw=0.8

0.25
0.02067

-----(eqn: 11-9)

Ncw = 9.675

S m=l s D sDotl +

6)

Here

ls

D otlD o
P

'

( P' Do )

------------(eqn: 11-10b)

'

P =Pt

= BS and

S m=0.573 1.1461.0723+

1.07230.01905
( 1.07230.01905 )
0.0238

Sm = 0.1626 m2
Fbp =( DsD otl )

7)

ls
Sm

---------------(eqn:11-11)

Fbp =( 1.1461.0723 )

0.5793
0.1626

Fbp = 0.2597
S tb=b D 0 N t (1+ F C )

8)

-------------------(eqn: 11-12)

Where b = 6.223 x 10-4

Stb = 6.223 x 10-4 x 0.01905 x 1770 (1 + 0.717)
Stb = 0.036 m2
9)

S sb =

Ds sb
2l
cos1 (1 c )
2
Ds

S sb =

1.146 x 0.037
0.5
cos1 (1
)
2
1.146

----------------(eqn: 11-13)

Ssb = 0.0459 m2
10)

Sw = Swg - Swt

---------------(eqn: 11-14)

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2 lc
Ds

2l
2l
()(1 c ) 1 1 c
Ds
Ds

---------(eqn: 11-15)

cos
D2s
Swg =
4
1
()(1

0.5
1.146

0.5
0.5 2
) 1(1
)
1.146
1.146
cos1
1.46
S wg =

Swg = 0.145 m2
S wt =

Nt
(1F c ) D20
8

S wt =

1770
( 10.717 ) x 0.019052
8

-------------(eqn: 11-16)

Swt = 0.071 m2
Sw = 0.145 0.071 = 0.074 m2
11)

Not applicable in this case

N b=

12)
N b=

L2 l e
+1
ls

-------(eqn: 11-19)

4.876(2 x 0.35)
+1
0.573

Nb = 8
Shell Side heat transfer calculations:
1) Shell Side Reynolds number
NRe = D0W / bSm
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Where W = mass flow rate (kg/s)

b = viscosity at bulk temp.
NRe =

0.01905 0.037 730

4
4 10 0.0626

NRe = 7911.13
2) Jk from fig:11-9
Jk = 9 x 10-3

3)

K
C

----(eqn: 11-21)

W
hk =J k C

Sm

Assuming,

b 0.14
)
w

=1

0.132
2470 104

3
9 10 2470 0.037 730
hk =

0.1626

hk

= 965.029 W/m2.K

4) Jc from fig: 11-10

Jc = 1.08
5) Jl from fig: 11-11
S sb+ S tb 0.0459+0.036
=
=0.5036
Sm
0.1626

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S sb
0.0459
=
=0.5604
S sb+ S tb 0.0459+0.036

Jl = 0.52
6) Jb from fig: 11-12
Taking Nss / Nc = 0.1
Jc = 0.85
7) Taking Jr = 1
8) hS = hkJcJlJbJr --------------(eqn: 11-22)
hS = 965.029 x 1.08 x 0.52 x 0.85 x 1
hS = 460.66 W/m2.K
Step 12: Wall temperature

Tmean = (T1 + T2) / 2 = 147.5 0C

tmean = (t1 +t2) / 2 = 55 0C
t meant w t w T mean
=
1
1 d0
h
hi d i
s

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55t w
t 147.5
= w
1
0.01905
1

461.97 0.0148
460.66

Equating the above equation,

The wall temperature, tw = 106.96 0C = 379.96 K
The viscosity of Kerosene and crude oil have to be taken
corresponding to the wall temperature. And hence the shell
side heat transfer coefficient will change with this alteration.
A corrected value of hS has to be determined.
w

of Kerosene = 0.55 x 10-3 Pa.s

So, hS, corrected =

w
b

hS

hS, corrected = 440.57 W/m2.K

Similarly tube side heat transfer coefficient also changes
with respevt to the change in of Crude oil value. But in
w

this case of Crude oil is not available in Perrys hand book

and hence we take the hi value unaltered.
w

Step 13: Finding the value of U0,clean

1
U 0,clean

1
hs , correct

1 d0 xw d0
+
hi d i d m K

Where, xw = (do - di) / 2 = 0.0021

dw = (do + di) / 2 = 0.0169

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Km = 16.262 W/mK
Substituting the values,
1
U 0,clean

1
0.01905
0.021 0.01905
+
+
440.57 461.97 0.0148 0.0169 16.262

Equating and solving gives,

U0,clean = 153.605 W/m2.K
Then dirt factor have to be added along with the clean overall
heat transfer coefficient.
1
1
1
1
=
+
+
U OD U 0,clean 5000 2000

UOD = 138.69 W/m2.K

Now compare UOD and U0,actual, => 138.69 170.191
Hence UOD U0,actual; the design needs recalculation
The recalculation is done by the following methods,
1) changing number of Tubes.
2) Changing the Length of the tube.
3) Changing the diameter of the tube.
4) Changing number of passes.
The recalculation is done until UOD U0,actual
Step 14: Pressure drop calculations
1) Tube Side pressure drop:
Reference: Perrys hand book page: 6-10

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f=

D P
2
2v L

--------- (eqn: 6-32)

Then to find friction factor, f;

For smooth pipes, f depends on Re
For rough pipes, f depends on Re and /D
From figure: 6-9; f = 0.013
v=

Also,
v

Re 2405 3.6 103

=
D
830 0.01905

= 0.547 m2/s

Then,

P1 =

0.013 2 830 0.05472 4.87

0.01483

P1 = 2120.38 Pa/pass
Entrance and Exit lose:
P2=

P2 =

4 G2
2
4 561.5122
2 830

P2 = 758.406 Ps/pass
P = P1 + P2 = 2120.38 + 758.406
P = 2878.78 Pa/pass
Total number of pass is 2,
So, P = 2872.78 x 2
P = 5757.56 Pa
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2) Shell side pressure drop:

Reference: Perrys hand book
a. From figure: 11-15(a)
fK = 0.19
2

b.

0.14

bf W N
Pbk = k 2 c w
b
Sm

( )

-------------(eqn:11-25)

Where, b = 2 x 10-3
2

Pbk =

2.0 103 0.19 ( 0.037 730 ) 31.25 4 104

730 0.16262
0.55 103

0.14

Pbk = 0.4292
c.

b W 2 (2+0.6 N cw )
Pwk =
Sm Sw

Here, b =

----------------(eqn: 11-25)

5 10
4

5 10 ( 0.037 730 ) [2+ ( 0.6 9.675 ) ]

Pwk =
0.1626 0.074 730

Pwk = 0.324
d.

Ps = ( N b 1 ) Pbk R b+ N b P wk Rl +2 Pbk Rb 1+

25)
From fig: (11-17) =>

Rb=0.67

From fig: (11-16) =>

Rl=0.16

N cw
Nc

)]

---------(eqn:11-

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Ps = ( 81 ) 0.4292 0.67 +8 0.324 0.16+2 0.4292 0.16 1+

Ps

= 3.1 lbf/ft2

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9.675
31.25

)]