Introduction To Heat Exchangers: Transport Phenomenon (CH 306)

Introduction to
HEAT EXCHANGERS
Transport Phenomenon (CH 306)
Transfer of thermal energy between
 two or more fluids
 between a solid surface and a fluid
 between solid particulates and a fluid
2 Transport Phenomenon (CH 306) 17-09-2015

Classification of
Heat Exchangers

Types of HE
 Double-pipe exchanger
 Shell and tube exchangers
 Plate and frame exchangers
 Plate-fin exchangers.
 Spiral heat exchangers.
 Air cooled heat exchangers
 Agitated vessels.
 Fired heaters.

Based on transfer process
 Indirect Contact – Shell & Tube Heat Exchangers
 Direct Contact – Cooling Towers
Based on phase of fluids

 Gas-Liquid exchangers
 Liquid-Liquid exchangers
 Gas-Gas heat exchangers

Based on construction
 Tubular
 Double pipe heat exchanger
 Shell and tube heat exchangers
 Spiral heat exchangers
 Plate-type
 Plate and frame heat exchangers
 Spiral plate heat exchangers
 Extended Surface
 Plate-fin exchanger
 Tube-fin exchanger

Based on flow arrangements
 Parallel flow / Co-current flow
 Counter flow
 Cross flow

Heat Transfer Coefficient
 Heat transfer rate, 𝑞 = 𝑈𝐴∆𝑇𝑚
U = overall heat transfer coefficient, W/(m2C)
A = heat transfer surface area, m2
∆𝑇𝑚 = mean temperature difference, oC
 Overall Heat Transfer Coefficient, Uo
ho= outside fluid film coefficient, W/(m2.oC)

hi= inside fluid film coefficient, W/(m2.oC)
hod= outside dirt coefficient (fouling factor), W/(m2.oC)
hid= inside dirt coefficient, W/(m2.oC)
kw= thermal conductivity of the tube wall material, W/(m2.oC)
di= tube inside diameter, m
do= tube outside diameter, m
Temperature Profile: Co-current flow
Log Mean Temperature

Difference (LMTD)

Temperature Profile: Counter current flow

Difference (LMTD)

Temperature Correction Factor (Ft)
 Mean temperature difference, ∆𝑇𝑚
∆𝑇𝑚 = 𝐹𝑡 ∆𝑇𝑙𝑚
 Ft depends on R & S
𝑇ℎ𝑖 − 𝑇ℎ𝑜
𝑅=
𝑇𝑐𝑜 − 𝑇𝑐𝑖
𝑆=
𝑇ℎ𝑖 − 𝑇𝑐𝑖

Temperature correction factor: one shell pass; two or more even tube passes

SHELL & TUBE
HEAT EXCHANGERS
Components of a STHE
 Shell
 Shell cover
 Tubes
 Channel
 Channel Cover
 Tubesheet
 Baffles
 Floating-Head Cover
 Nozzles
 Tie-Rods & Spacers
 Pass Partition Plates
 Impingement Plates
 Sealing Strips & Sealing Rods

Classification by Construction
Fixed-tubesheet heat exchanger
 Has straight tubes secured at both ends to tubesheets
welded to the shell
 Low cost, simplest construction.
 Bundle is "fixed" to the shell so outside of the tubes
cannot be cleaned mechanically.
 Application is limited to clean services on the shell side

U-tube heat exchanger
 Tubes are bent in the shape of a U
 Only one tubesheet
 Bending of tubes adds to the cost
 Tube bundle is removable, outside of tubes can be

cleaned.
 Because of the U-bend, inside of the tubes can’t be
cleaned mechanically
 Can’t be used for dirty fluids inside tubes.

Floating head exchanger
 Most versatile and costliest.
 One tubesheet is fixed relative to the shell, and the other
is free to “float” within the shell.
 Cleaning of both the insides and outsides of the tubes
 Can be used for services where both the shell-side and
the tube-side fluids are dirty
Widely used in Petroleum Industry

U-Tube Heat Exchanger

Straight-Tube ( 1-Pass )

Straight-Tube ( 2-Pass )

TEMA Types

TEMA Types
For No
For dirty Temp
tube side Cross
Fixed tube-
sheet on the
For clean rear side of the
tube side shell
For horizontal
thermosyphon
reboilers
Large temp
difference
between shell
For
& tube fluids
Hazardous
fluid
Allowable
pressure drop
on shell side is
27 very low Transport Phenomenon (CH 306) 17-09-2015
FLUID ALLOCATION
Shell Side Tube Side
 Viscous Fluids  Fluids which are prone to
fouling
 Lower Flow Rates
 Corrosive fluids
 Cleaner Fluids
 Toxic fluids to increase
containment
 High pressure streams, since
tubes are less expensive to
build strong
 Streams with low allowable
pressure drop
 Cooling water to be put on
tube side only

Tubes
Tubes should be able to withstand:
 Operating temperature and pressure on both sides
 Thermal stresses due to the differential thermal expansion
between the shell and the tube bundle
 Corrosive nature of both the shell-side and the tube-side
fluids
 TUBE PITCH RATIO:
Min 1.25 times of tube OD
1.333 times of tube OD
1.5 times of tube OD
 TUBE PASS: Based on pressure drop & velocity limit on tube
side

TUBE LAYOUT ANGLE
30o
30o Triangular 90o 90o Square
FLOW FLOW
Triangular layouts give more

tubes in a given shell Square layouts give cleaning
lanes with close pitch
60o
45o
FLOW
60o Rotated 45o Rotated
Triangular Square
FLOW

Feature Tube Layout Pattern
Lower ΔP on shell-side Square (effective only at low

Re number)
Shell-side fouling Square - easier cleaning
Horizontal shell-side Square

Boiling
Smaller shell size Fit 15% more tubes if
triangular pitch used

Tube pitch
 Shortest distance between two adjacent tubes
 TEMA specifies a minimum tube pitch of 1.25*(OD)
 Minimum tube pitch leads to smallest shell diameter for a
given number of tubes.
 To reduce shell-side pressure drop, the tube pitch may be
increased to a higher value.

Tubesheet
 Barrier between shell-side and tube-side fluids.
 Mostly circular with uniform pattern of drilled holes.
 Tubes are attached to tubesheet

Tie rods and spacers
Tie rods and spacers are used for:
 holding the baffle assembly together
 maintaining the selected baffle spacing
Sliding strips
 help the bundle to slide out from the shell
 Can also be used as tie rods to hold the bundle in
position.

Sealing strips and Seal rods
 Sealing strips prevent shell side fluid from bypassing the
bundle.
 Sealing strips block the resulting large open area at top or
bottom of the shell.
 Seal rods are also used to control the leakage streams.

TUBE PASS LAYOUT
Ribbon
Quadrant
H-Bend

TYPES OF BAFFLES
 Segmental type;
 Single – horizontal & vertical
 Double
 Triple
 No-Tubes in Window (NTIW)
 Orifice type
 Disc and doughnut type
 Rod type
 Impingement type
 Longitudinal (pass partitions)

 ORIENTATION:
 Horizontal for heating or cooling with no phase change
 Vertical for shell side condensation
 CUT:
 15 % to 45 % of shell ID for Single Segmental
 25 % to 35 % of shell ID for Double Segmental

Baffle cut
 Height of the segment that is cut in a baffle to permit the shell-
side fluid to flow across the baffle.
 Baffle cut should be set carefully because a baffle cut that is
either too large or too small can increase the possibility of
fouling in the shell, and moreover it would also lead in
inefficient shell-side heat transfer
 CUT:
 15 % to 45 % of shell ID for Single Segmental
 25 % to 35 % of shell ID for Double Segmental

Baffle/ Nozzle orientation
 The orientation of the baffle cut is important for heat exchanger
installed horizontally.
 When the shell side heat transfer is sensible heating or cooling with
no phase change, the baffle cut should be horizontal.
 For shell side condensation, the baffle cut for segmental baffles is
vertical.
 For shell side boiling, the baffle cut may be either vertical or
horizontal depending on the service.
 Positioning of inlet/ outlet nozzle is also important for the proper
functioning of exchangers.
 In cooling water services, the inlet nozzle should be at the bottom
and outlet nozzle should be at the top.
 For condensing services exit should be from the bottom nozzle.
42 Design of HC Process Equipments 17-09-2015

Shellside Flow
In
Tubeside Flow
Out
Shell
Tube Bundle
Shellside Flow
Out
Tubeside Flow
In
43 SINGLE SEGMENTAL BAFFLES - Horizontal

Transport Phenomenon (CH 306) 17-09-2015
Shell Outlet
Channel Inlet
Channel
Outlet
Shell Outlet
44
SINGLE SEGMENTAL BAFFLES - Vertical
Shell Inlet
Shell Outlet
DOUBLE SEGMENTAL TRANSVERSE BAFFLES

46
DOUGHNUT AND DISC TYPE BAFFLES
Baffle Spacing
 Baffle spacing is the longitudinal or centreline-to-
centreline distance between adjacent baffles.
 According to TEMA, the minimum baffle spacing should
be one-fifth of the shell inside diameter or 2 in.,

whichever is greater.
 The maximum baffle spacing is the shell inside diameter.

Impingement devices
 Impingement rod, Impingement plate, Nozzle Impingement baffle
are the various devices used in heat exchangers to trim down the
effects of high velocity at entry nozzles over tube bundle.

TUBE PROBLEMS
• Scaling of inside/outside of the tube surface
• Blockage of tube passage
• By passing across the baffle
• Puncture in the tube
• Leakage through the tube to tubesheet
• Leakage through gasketted joint of floating head

Bypass & Leakage streams:
TINKER FLOW MODEL
 B stream: Main heat transfer stream, follows a path around baffles and
through tube bundle
 A stream: Leakage stream, flowing through clearance between tubes and
holes in baffles
 C stream: Tube bundle bypass stream in the gap between the tube bundle
and shell wall
 E stream: Leakage stream between baffle edge and shell wall
 F stream: Bypass stream in flow channel partitions due to omissions of
tubes in tube pass partitions.

FLOW FRACTIONS ALLOWABLE LIMITS
A Stream < 10 %
B Stream > 40 %
C Stream < 10 %
E Stream < 15 %
F Stream < 10 %

Bypass & Leakage Streams
Since the flow fractions depend strongly upon the path resistances, varying any
of the following construction parameters will affect stream analysis and
thereby the shell side performance of an exchanger:
 Baffle spacing and baffle cut
 Tube layout angle and tube pitch
 Clearance between the tube and the baffle hole
 Clearance between the shell I.D. and the baffle
 Location & no. of sealing strips and sealing rods

Temperature Cross (Co-current)
 Outlet temperature of cold stream
cannot be greater than the outlet

temperature of the hot stream.
 An F shell has 2 shell passes, so if
there are 2 tube passes as well, it

represents a pure counter-current
flow

Air cooled heat exchanger

Plate and Frame heat exchanger

Spiral heat exchanger

Aims of Thermal Design
1. Achieve the specified duty at minimum overall cost
2. To achieve high heat transfer coefficient within allowable pressure

drops.
3. 10-20 % Overdesign margin (design safety)
4. Pressure drops should be in limits
5. To keep fluid velocities in limit
6. To keep shell side flow fractions in limit

THERMAL DESIGN
Shell & Tube Heat Exchangers
Steps in Design
1. Calculate the heat duty.
2. Select cooling/heating medium
3. Calculate utility flow-rate.
4. Collect the fluid physical properties : density, viscosity,
thermal conductivity.
5. Allocate the fluids on shell side and tube side.
6. Decide the exchanger type
7. Determine LMTD and MTD ΔTm
8. Select a trial value for the overall coefficient, U
9. Estimate the provisional area required.
10. Tube geometry : Number of tubes & number of tube
passes etc.
11. Calculate the shell diameter.
12. Determine the shell side and tube side heat transfer
coefficients.
13. Calculate the overall coefficient and compare with the
trial value.
14. Find the area provided based on U value and then
calculate % excess area.
15. Calculate the shell side and tube side pressure drop.
16. Optimize the design

Heat Duty
 Heat Duty, Q (single phase)
𝑄 = 𝑚𝐶𝑝 ∆𝑇(sensible heat)
here, m = flow rate of process fluid
Cp= specific heat of process fluid
∆𝑇 = temp diff for process fluid
 Heat Duty, Q (phase change)
𝑄 = 𝑚λ(latent heat)
here, m = flow rate of process fluid
λ= latent heat of process fluid

Selection of cooling/heating medium
Based on cost and availability
Heating medium Cooling medium
• Steam (100-180 oC) • Cooling water (35-100
• Oil (180-300 oC) oC)
• Dowtherm oils (180-400 oC) • Chilled water (< 35 oC)

• Molten Salt (400-590 oC) • Air (> 60 oC)
• Na – K alloys (500-750 oC) • Brine (< 8 oC)
• Flue gas or Hot air (750-1100 oC)

Utility Flow rate
 Utility flow rate, mw
𝑄
𝑚𝑤 =
𝐶𝑝𝑤 ∆𝑇𝑤
Here, m = flow rate of utility
Cpw= specific heat of utility
∆𝑇 = temp diff for utility

LMTD & MTD Calculation

Difference (LMTD)

LMTD & MTD Calculation

Difference (LMTD)

Temperature Correction Factor (Ft)
 Mean temperature difference, ∆𝑇𝑚
∆𝑇𝑚 = 𝐹𝑡 ∆𝑇𝑙𝑚
 Ft depends on R & S
𝑇ℎ𝑖 − 𝑇ℎ𝑜
𝑅=
𝑆=
𝑇ℎ𝑖 − 𝑇𝑐𝑖

Temperature correction factor: one shell pass; two or more even tube passes

Overall
Coefficient

Provisional area required
 Heat transfer rate, Q = 𝑈𝐴∆𝑇𝑚
U = overall heat transfer coefficient, W/(m2C)
A = heat transfer surface area, m2
∆𝑇𝑚 = mean temperature difference, oC
𝑄
𝐴𝑝𝑟𝑜 =
𝑈∆𝑇𝑚

Number of tubes
𝐴𝑝𝑟𝑜 = 𝑁𝑡 𝜋𝑑𝑜 𝐿
Here, Nt= No. of tubes
do= tube o.d.
L= Tube length
 Decide the number of passes & tube layout, pitch

Tube Passes vs Tube Side Velocity
2.5
Tube Side Velocity, m/s

2
1.35 m/s
1.5
0.5
0
2 4 6 8
No. of Passes
 Parametric study for 2, 4, 6 and 8 passes

 To avoid fouling, tube velocity is kept between 1-2 m/s
 At 2 and 4 passes, tube velocity is less than 1 m/s
 At 8 passes, tube velocity is more than 2 m/s
 Number of passes = 6
Tube Passes vs Tube Side Pressure drop
140
Tube Side Pressure drop, kPa

120
100
Allowable pressure drop = 70 kPa
80
60
40
45.06 kPa
20
0
2 4 6 8
No. of Passes

 Allowable value of Tube side pressure drop is around 70 kPa
 At 6 passes, optimum value of pressure drop is obtained, i.e. 45.06 kPa

Tube Passes vs % Overdesign
25
20
% Overdesign 15
16.03 %
10
0
2 4 6 8
No. of Passes

 % Overdesign should be between 10 to 20 %
 At 6 passes, optimum value of % overdesign is obtained, i.e. 16.03 %
Optimization of Baffle Spacing
Baffle Spacing vs B stream flow fraction

0.88
0.878
B stream flow fraction

0.876
0.874
0.872
0.87
0.868 0.87
0.866
0.864
0.862
0.86
200 250 300 350
Baffle Spacing, mm
 Parametric study for 200, 250, 300 and 350 mm spacing

 At 250 mm, B-stream flow fraction is optimum i.e. 87 %
 Baffle spacing = 250mm

Baffle Spacing vs Shell Side Pressure drop
2.5
Shell Side Pressure drop, kPa

2.25
1.75
1.5
1.25
1
200 250 300 350
Baffle Spacing, mm
 Parametric study for 200, 250, 300 and 350 mm spacing

 At 250 mm, , optimum value of shell side pressure drop is obtained, i.e. 1.391 kPa
 Baffle spacing = 250 mm

Baffle Spacing vs % Overdesign
22
20
18
% Overdesign 16
16.03 %
14
12
10
200 250 300 350
Baffle Spacing, mm
 Parametric study for 200, 250, 300, 350 mm spacing

 % Overdesign should be between 10 to 20 %
 At 250 mm, optimum value of % overdesign is obtained, i.e. 16.03 %
 Baffle spacing = 250 mm
Selection of Tube Layout
Tube Layout vs No. of Tubes Tube Layout vs % Overdesign

40
880
860 35
% Overdesign
840 30
No. of Tubes
820 25
800 20
780 15
760 10
30 45 60 75 90 30 45 60 75 90
Tube Layout Tube Layout
 Parametric study for 30o, 45o,60o and 90o layout

 If service requires continuous cleaning lanes choose square layout only
 45o gives optimum number of tubes and optimum value of % overdesign
 Tube Layout = 45o Square

Shell Diameter
 Bundle diameter, Db

Shell Diameter, Ds
𝑫𝒔 = 𝑫𝒃 + 𝑪𝒍𝒆𝒂𝒓𝒂𝒏𝒄𝒆

Tube side coefficient
 Mean utility temp, t
 Tube c/s area, At
𝑁𝑡 𝜋 2
𝐴𝑡 = × 𝑑𝑖
𝑁𝑝 4
Here, Np = No. of tube passes
di = tube i.d.

Sieder-Tate Equation
Re < 2000
Dittus-Bolter Equation
Re > 4000
C = 0.021 for gases,

C = 0.023 for non-viscous liquids,
C = 0.027 for viscous liquids.
Generalized Equation
Re = 10 to 106
For Water Service

Here, de = Equivalent dia
Fluid velocity
𝒖𝒕 = 𝒎𝒘 /𝑨𝒕

jh = tube side heat transfer factor

Shell Side Coefficient
 Choose baffle spacing, lB and tube pitch, pt
 1/5th of the shell dia or 2 in., whichever is greater
 Cross-flow area
Here, lB is baffle spacing, m.
 Calculate mean temperature
 Decide baffle cut % (start with 25%)

Ws = shell side flow-rate, kg/s

Shell side heat transfer coefficient, hs
jh = heat transfer factor

jh = shell side heat transfer factor
Overall Coefficient
 Overall Heat Transfer Coefficient, Uo
ho = outside fluid film coefficient, W/(m2.oC)

hi = inside fluid film coefficient, W/(m2.oC)
hod = outside dirt coefficient (fouling factor), W/(m2.oC)
hid = inside dirt coefficient, W/(m2.oC)
kw = thermal conductivity of the tube wall material, W/(m2.oC)
di = tube inside diameter, m
do = tube outside diameter, m
Dirt factor / Dirt coefficient /Fouling factor

Tube Side Pressure Drop
 Tube pressure drop
 Here, jf = friction factor for tube side

 Range of tube pressure drop is
 Gases = 14 kPa
 Liquids = 30 to 70 kPa
𝑵𝒕 𝝅 𝟐 Fluid velocity
𝑨𝒕 = × 𝒅
𝑵𝒑 𝟒 𝒊 𝒖𝒕 = 𝒎𝒘 /𝑨𝒕

jf = friction factor Tube side

Shell Side Pressure Drop
 Shell Side Pressure Drop
 Here, jf = friction factor for shell side

 Range of shell pressure drop is
 Liquids 48 to 60 kPa
 Gases 4 to 20 kPa

jf = friction factor shell side
To Reduce Tube Side Pressure Drop
 Tube pressure drop
 Decrease number of tube passes

 Increase tube diameter
 Decrease tube length
 Increase number of tubes & hence increase shell diameter
𝑵𝒕 𝝅 𝟐 Fluid velocity
𝑨𝒕 = × 𝒅
𝑵𝒑 𝟒 𝒊 𝒖𝒕 = 𝒎𝒘 /𝑨𝒕

To Reduce Shell Side Pressure Drop
 Shell Side Pressure Drop
 Increase the baffle cut

 Increase the baffle spacing
 Increase tube pitch
 Increase tube diameter
 Decrease shell diameter


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Introduction To Heat Exchangers: Transport Phenomenon (CH 306)

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Introduction to

 two or more fluids

 between a solid surface and a fluid

 between solid particulates and a fluid

2 Transport Phenomenon (CH 306) 17-09-2015

3 Transport Phenomenon (CH 306) 17-09-2015

 Shell and tube exchangers

 Plate and frame exchangers

 Spiral heat exchangers.

 Air cooled heat exchangers

4 Transport Phenomenon (CH 306) 17-09-2015

 Direct Contact – Cooling Towers

Based on phase of fluids

 Gas-Gas heat exchangers

5 Transport Phenomenon (CH 306) 17-09-2015

6 Transport Phenomenon (CH 306) 17-09-2015

7 Transport Phenomenon (CH 306) 17-09-2015

ho= outside fluid film coefficient, W/(m2.oC)

Log Mean Temperature

9 Transport Phenomenon (CH 306) 17-09-2015

Log Mean Temperature

10 Transport Phenomenon (CH 306) 17-09-2015

11 Transport Phenomenon (CH 306) 17-09-2015

12 Transport Phenomenon (CH 306) 17-09-2015

15 Transport Phenomenon (CH 306) 17-09-2015

 Has straight tubes secured at both ends to tubesheets

welded to the shell

 Low cost, simplest construction.

 Bundle is "fixed" to the shell so outside of the tubes

cannot be cleaned mechanically.

 Application is limited to clean services on the shell side

16 Transport Phenomenon (CH 306) 17-09-2015

 Only one tubesheet

 Bending of tubes adds to the cost

 Tube bundle is removable, outside of tubes can be

18 Transport Phenomenon (CH 306) 17-09-2015

 Most versatile and costliest.

 One tubesheet is fixed relative to the shell, and the other

is free to “float” within the shell.

 Cleaning of both the insides and outsides of the tubes

 Can be used for services where both the shell-side and

the tube-side fluids are dirty

Widely used in Petroleum Industry

20 Transport Phenomenon (CH 306) 17-09-2015

22 Transport Phenomenon (CH 306) 17-09-2015

23 Transport Phenomenon (CH 306) 17-09-2015

24 Transport Phenomenon (CH 306) 17-09-2015

26 Transport Phenomenon (CH 306) 17-09-2015

28 Transport Phenomenon (CH 306) 17-09-2015

29 Transport Phenomenon (CH 306) 17-09-2015

Triangular layouts give more

30 Transport Phenomenon (CH 306) 17-09-2015

Lower ΔP on shell-side Square (effective only at low

Horizontal shell-side Square

31 Transport Phenomenon (CH 306) 17-09-2015

 TEMA specifies a minimum tube pitch of 1.25*(OD)

 Minimum tube pitch leads to smallest shell diameter for a

given number of tubes.

 To reduce shell-side pressure drop, the tube pitch may be

increased to a higher value.

32 Transport Phenomenon (CH 306) 17-09-2015

 Mostly circular with uniform pattern of drilled holes.