Lecture 15

Heat Exchangers
Fall (2012)

Dr. Maher Abou Al-Sood

 Chapter 6
Shell-and-Tube Heat Exchanger (STHE)

Layout of the Lecture

6.6.6 Shellside Stream Analysis (Flow Pattern)
6.6.6.1 Kern Method (Example 6.2, Example 6.3)

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6.6 SHELLSIDE DESIGN
6.6.6 Shellside Stream Analysis (Flow Pattern)
6.6.1 Kern Method
 Calculation of the shell-side heat transfer coefficient and pressure drop is more
complex than that of the tube side.
 The first calculation methods were developed in the 1930s and 1940s.
 The method that has been the most popular was proposed by Kern.
 At present, other methods are reported to be more accurate, and we can
recommend the Kern method for preliminary estimation, but not as a final
design tool.
 Kern (1950) present what is probably the earliest textbook attempts at a logical
approach to shellside calculation.
 When tube bundle employs baffles, the heat transfer coefficient is higher that
that without baffles.

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6.6 SHELLSIDE DESIGN
6.6.6 Shellside Stream Analysis (Flow Pattern)
6.6.1 Kern Method
TABLE 6.2 Flow fractions for various streams of the shellside flow pattern

6.6 SHELLSIDE DESIGN

6.6.6 Shellside Stream Analysis (Flow Pattern)
6.6.1 Kern Method
 If there is no baffles, the flow will be along the heat exchanger inside the shell
and h can be based on the equivalent diameter De as in double pipe heat
exchanger.
 For baffled heat exchanger, the higher h results from the increased turbulence
Shellside Reynolds number:
 Kern considers a flow area that corresponds with the hypothetical tube row at
the shell central plane.
 We called it hypothetical because it may happen that there is no tube row at
the central plane, but rather two tube rows shifted a certain distance up and
down the central plane.
 This hypothetical flow area is shown in the Fig. below

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6.6 SHELLSIDE DESIGN
6.6.6 Shellside Stream Analysis (Flow Pattern)
6.6.1 Kern Method
Shellside Reynolds number:
 The number of clearances existing in the central
row can be obtained approximately by dividing
the shell diameter by PT. If B is baffle spacing,
the area of any of these clearances is CB, and it
results that the shell flow area is

Ds
As   CB
PT
 The mass velocity for the shell fluid as

m
Gs 
As
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6.6 SHELLSIDE DESIGN
6.6.6 Shellside Stream Analysis (Flow Pattern)
6.6.1 Kern Method
Equivalent Diameter:
 Kern uses an equivalent diameter for the shell. The usual definition of an
equivalent diameter is
flow area
De  4  hydrualic radious  4 
wetted perimeter
 For a square pattern
4  PT2  πd o2 / 4 
De 
πd o
 For Triangular pattern
 3 2 πd o2 
4   PT  
De   4 8 
7
πd o / 2
6.6 SHELLSIDE DESIGN
6.6.6 Shellside Stream Analysis (Flow Pattern)
6.6.1 Kern Method
Heat Transfer Coefficient, ho
 Kern suggested the following correlation for shell-side heat transfer coefficient
for a baffled bundle with a fixed baffle cut 25% as

 c p    
0.55 1/ 3 0.14
ho De DG
 0.36 e     
k     k   w 
DeG
For 2000  Re   106

All fluid properties are evaluated at the bulk (average) fluid temperature
where
ho : Shell-side heat transfer coefficient (W/m2.K)
De : Shell-side equivalent diameter (m)
G : Shell fluid mass velocity (kg/s.m2)
TABLE 6.2 Flow fractions for various streams of the shellside flow pattern

6.6 SHELLSIDE DESIGN

6.6.6 Shellside Stream Analysis (Flow Pattern)
6.6.1 Kern Method
Pressure Drop
 According to Kern, the pressure drop in the shell fluid is proportional to the
number of times the fluid crosses the tube bundle.
 If Nb is the number of baffles, the shell fluid crosses the bundle (Nb + 1) times.
 The pressure drop is also proportional to the length of the path at every bundle
cross, which can be represented by the shell diameter. Thus

f N b  1Ds G 2
0.14
 w  DeG
ps    For 400  Re s   106
2 De    
Where
Nb  L / B
f  exp 0.576  0.19 ln Re s 
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TABLE 6.2 Flow fractions for various streams of the shellside flow pattern

6.6 SHELLSIDE DESIGN

6.6.6 Shellside Stream Analysis (Flow Pattern)
6.6.1 Kern Method
Heat Exchangers with 2-4 Configuration
 For heat exchangers with two shell passes in a single shell with a longitudinal
baffle (TEMA type F), such as that shown in Fig below, it must be considered
that the flow area for the mass velocity calculation is half that of a heat
exchanger with the same shell diameter without a longitudinal baffle.
 The number of bundle crosses to calculate the pressure drop will be twice the
number in a heat exchanger with the same baffle spacing and no longitudinal
baffle

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TABLE 6.2 Flow fractions for various streams of the shellside flow pattern

6.6 SHELLSIDE DESIGN

6.6.6 Shellside Stream Analysis (Flow Pattern)
6.6.1 Kern Method
Example 6.2
A Shell-and-tube heat exchanger has the following data:
Shell inside diameter Ds = 0.39 m
Number of tubes Nt = 124
Tube outside diameter do = 19 mm
Tube inside diameter di = 19 mm
Tube pitch (square) PT = 0.024 m
Tube material k = 60 W/m.K
Baffle spacing B = 0.25 m
Baffle cut BC = 25%
Number of tube passes Np = 2
Inlet temperature of the shell fluid Th,i= 67 oC
Inlet temperature of the tube fluid Tc,i= 17 oC
Exit temperature of the tube fluid Tc,o= 40 oC
Maximum tube length Lmax= 4 m
Maximum pressure drop in shellside ∆pmax,s= 5 psi
Heat exchanger duty Q = 801.6 kW
Total fouling resistance Rft = 0.000176 m2.K /W
Use the Kern method to re-rate this heat exchanger.
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TABLE 6.2 Flow fractions for various streams of the shellside flow pattern

6.6 SHELLSIDE DESIGN

6.6.6 Shellside Stream Analysis (Flow Pattern)
6.6.2 Bell or Delaware Method
 In 1950 at Delaware University, a research program in shell-and-tube heat
exchangers was developed with the sponsorship (TEMA) and (ASME).
 Many researchers worked in this program and published their conclusions in
several reports over that decade.
 The final synthesis of the study was published as a heat exchanger design
method by Kenneth Bell in 1963. This is now known as Bell or Delaware
method.
 The Delaware method utilizes empirical correlations for the heat transfer
coefficient and friction factor in flow perpendicular to banks of tubes; these are
referred to as ideal tube bank correlations.

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TABLE 6.2 Flow fractions for various streams of the shellside flow pattern

6.6 SHELLSIDE DESIGN

6.6.6 Shellside Stream Analysis (Flow Pattern)
6.6.2 Bell or Delaware Method
 In baffled heat exchangers, this type of flow is approximated in the regions
between the baffle tips.
 Furthermore, only part of the shell-side fluid follows the main flow path
through the exchanger due to the presence of leakage and bypass streams in
the shell.
 These deviations from ideal tube bank conditions are accounted for by a set of
empirical correction factors for heat transfer and pressure drop.
 The correction factors for leakage and bypass flows are correlated in terms of
the flow areas for the leakage, bypass, and main cross-flow streams.
 There are slightly different versions of the Delaware method. The presentation
in this chapter is based on the version given by Taborek.
 Consideration is restricted to exchangers with standard type E shells, single-cut
segmental baffles, and un-finned tubes.
 The extension of the method to other configurations is discussed in literature.
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TABLE 6.2 Flow fractions for various streams of the shellside flow pattern

6.6 SHELLSIDE DESIGN

6.6.6 Shellside Stream Analysis (Flow Pattern)
6.6.2 Bell or Delaware Method

Ideal tube bank correlation

 The flow perpendicular to banks of tubes has been widely studied

 A number of different correlations for heat transfer and pressure drop are
available in the literature.
 Any of these correlations can, in principle, be used with the Delaware method.
 The correlation originally used in the development of the Delaware method has
been recommended by Taborek, and is used herein.
 The correlation is in the form of three graphs (Figs. 6.11–6.13),

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TABLE 6.2 Flow fractions for various streams of the shellside flow pattern

6.6 SHELLSIDE DESIGN

6.6.6 Shellside Stream Analysis (Flow Pattern)
6.6.2 Bell or Delaware Method

Ideal tube bank correlation

 Nomenclature for Figs. 6.11–6.13 is as follows:

F = Fanning friction factor, dimensionless,
h Pr 2 / 3
j  = dimensionless
c p G

h = heat-transfer coefficient, ( W/m2·K)

cp = heat capacity of shellside fluid, ( J/kg · K)

m mass velocity (kg/s ·m2

G 
Sm
m = total mass flow rate of shellside fluid, kg/s
15
Sm = crossflow area at shell centerline, m2
6.6 SHELLSIDE DESIGN
6.6.6 Shellside Stream Analysis (Flow Pattern)
6.6.2 Bell or Delaware Method

Ideal tube bank correlation

 nomenclature for Figs. 6.11–6.13 is as follows:

Pr = Prandtl number, dimensionless
 = viscosity correction factor ((µ/µw)0.14 , dimensionless)
PT = tube pitch, (m)
do = tube OD, m
Re = DoG/μ, dimensionless
µ = viscosity of shellside fluid, Pa.s
 Note that the Reynolds number is based on the tube OD rather than the
equivalent diameter used in the Simplified Delaware method.
 The crossflow area, Sm, used to calculate the mass flux is approximated by the
area, as, used in the Simplified Delaware method.
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6.6 SHELLSIDE DESIGN
6.6.6 Shellside Stream Analysis (Flow Pattern)
6.6.2 Bell or Delaware Method

Ideal tube bank correlation

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6.6 SHELLSIDE DESIGN
6.6.6 Shellside Stream Analysis (Flow Pattern)
6.6.2 Bell or Delaware Method

Ideal tube bank correlation

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6.6 SHELLSIDE DESIGN
6.6.6 Shellside Stream Analysis (Flow Pattern)
6.6.2 Bell or Delaware Method

Ideal tube bank correlation

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6.6 SHELLSIDE DESIGN
6.6.6 Shellside Stream Analysis (Flow Pattern)
6.6.2 Bell or Delaware Method

Ideal tube bank correlation

 Approximate curve fits for previous charts are as follows

b
 1.33 
a
 1.33 
 Re b2
2/3
 Re a2
h Pr f  b1 
j  a1 
c p G  PT / d o   PT / d o 
Where

a3
a
1  0.14Re  4
a

b3
b
1  0.14Re  4
b
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6.6 SHELLSIDE DESIGN
6.6.6 Shellside Stream Analysis (Flow Pattern)
6.6.2 Bell or Delaware Method
Ideal tube bank correlation
angle Re a1 a2 a3 a4 b1 b2 b3 b4
30o 105-104 0.321 -0.388 1.450 0.519 0.372 -0.123 7.00 0.500
104-103 0.321 -0.388 0.486 -0.152
103-102 0.593 -0.477 0.570 -0.476
102-10 1.360 -0.657 45.100 -0.973
<10 1.400 -0.667 48.000 -1.000

45o 105-104 0.370 -0.396 1.930 0.500 0.303 -0.126 6.59 0.520
104-103 0.370 -0.396 0.333 -0.136
103-102 0.370 -0.500 3.500 -0.476
102-10 0.498 -0.656 26.200 -0.913
<10 1.550 -0.667 32.000 -1.000

90o 105-104 0.370 -0.396 1.187 0.370 0.391 -0.148 6.30 0.378
104-103 0.107 -0.266 0.0815 +0.022
103-102 0.408 -0.460 6.0900 -0.602
102-10 0.900 -0.631 32.1000 -0.963
<10 0.970 -0.667 35.0000 -1.000 21
6.6 SHELLSIDE DESIGN
6.6.6 Shellside Stream Analysis (Flow Pattern)
6.6.2 Bell or Delaware Method
Shellside heat transfer coefficient
 The heat-transfer coefficient for an ideal tube bank is designated hideal.
 This value is obtained from the previous graph, or from previous Eqs.
 The shellside heat-transfer coefficient, ho, is obtained by multiplying hideal by a
set of correction factors that account for the non-idealities in a baffled heat
exchanger:

ho  hideal J C J L J B J R J S 
0.14
 s 
a
 1.33 
hid  j c psG Pr 2 / 3
   a1   Re a2 c psG Pr 2 / 3
 
 s ,w   PT / d o 
a3
a
1  0.14Re  4
a
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6.6 SHELLSIDE DESIGN
6.6.6 Shellside Stream Analysis (Flow Pattern)
6.6.2 Bell or Delaware Method
Shellside heat transfer coefficient
 The factor JC accounts for heat transfer in the baffle windows.
 It has a value of 1.0 for exchangers with no tubes in the windows.
 For other exchangers, it ranges from about 0.65 for very large baffle cuts to
about 1.15 for small baffle cuts.
 For well-designed exchangers, the value of JC is usually close to 1.0.
 The JL correction factor accounts for both the tube-to-baffle and shell-to-
baffle leakage streams
 The practical range of JL is from about 0.2 to 1.0, with values of 0.7–0.8 being
typical.
 For a well-designed exchanger, JL should not be less than about 0.6.
 The JB correction factor accounts for the bundle bypass stream flows around
the periphery of the tube bundle from one baffle window to the next in the
gap between the outermost tubes and the shell.
 typically has values in the range of 0.7–0.9 23
6.6 SHELLSIDE DESIGN
6.6.6 Shellside Stream Analysis (Flow Pattern)
6.6.2 Bell or Delaware Method
Shellside heat transfer coefficient
 The JS factor accounts for the baffle spacing in the inlet and outlet sections
which is often larger than in the remainder of the exchanger to accommodate
the nozzles and, in the case of U-tube exchangers, the return bends.
 Iis usually in the range of 0.85–1.0.
 If the baffle spacing is the same throughout the exchanger, JS equals 1.0
 The factor JR accounts for the decrease in the heat-transfer coefficient with
downstream distance in laminar flow.
 The effect is analogous to the (L)−1/3 dependence of the tubeside coefficient
as expressed in the Seider–Tate equation for laminar flow.
 The range of JR is from about 0.4 to 1.0, and it is equal to 1.0 for Re≥100.
 For well-designed heat exchangers, the product of all the correction factors
should not be less than about 0.5.
 Correlations for calculating the correction factors are given in literature and
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will not be discussed here.
6.6 SHELLSIDE DESIGN
6.6.6 Shellside Stream Analysis (Flow Pattern)
6.6.2 Bell or Delaware Method
Shellside pressure drop

 The nozzle-to-nozzle pressure drop in a type E shell is composed of three

parts:
ps  pc  pw  pe
where
∆pc = pressure drop in all central baffle spaces
∆ pw = pressure drop in all baffle windows
∆ pe = pressure drop in the entrance and exit baffle spaces

 The three regions of the shell corresponding to pc, pw, and pe are shown
schematically in the following Fig.

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6.6 SHELLSIDE DESIGN
6.6.6 Shellside Stream Analysis (Flow Pattern)
6.6.2 Bell or Delaware Method
Shellside pressure drop

Flow regions considered for shell-side pressure drop. (a) Cross-flow region
between baffle tips in the central baffle spaces, (b) window-flow region and (c)
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cross-flow region for inlet and outlet baffle spaces
6.6 SHELLSIDE DESIGN
6.6.6 Shellside Stream Analysis (Flow Pattern)
6.6.2 Bell or Delaware Method
Shellside pressure drop
Calculation of pc:

2 f ideal N cG 2
pc  ( Nb  1) Δpbideal R|L RB pideal 
 s
D s 1  2 BC 
Nc 
PT
where
fideal = ideal tube bank friction factor, dimensionless
Nc = number of tube rows crossed between baffle tips
RL =leakage correction factor it ranges from 0.1 to 1.0 ( typical 0.4-0.6)
RB = bypass correction factor . it ranges from 0.3 to 1.0 ( typical 0.4-0.7)
P’T = PT for square tube layout
= PT cos  for triangular ( =30o) and rotated square ( =45o) layouts
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6.6 SHELLSIDE DESIGN
6.6.6 Shellside Stream Analysis (Flow Pattern)
6.6.2 Bell or Delaware Method
Shellside pressure drop
Calculation of pw:
pw  Nb RL Δpwideal
 m s2 2  0.6 N cw 
 for Re  100
 2 s Sm S w
pwideal  
26 m  N B D  
m 2
s
 cw
 C 2 s   s
for Re  100
  S S  PT  d o Dw   s S m S w
 s m w

4S w
Dw 
d 0 N t  0.5 1  Fc   Ds ds
where
Fc = fraction of tubes in cross flow between baffle tips 28
 = baffle window angle (rad).
6.6 SHELLSIDE DESIGN
6.6.6 Shellside Stream Analysis (Flow Pattern)
6.6.2 Bell or Delaware Method
Shellside pressure drop
Calculation of pe:

 N 
pe  2 Δpbideal1  cw  RB RS
 Nc 

where RS is s correction factor for unequal baffle spacing.

The practical range of RS is from about 0.3 to 1.0.
When the baffle spacing is uniform throughout the shell, the value of RS is 1.0.
Summary:
 N cw 
p f  N b  1Δpideal RB  N b Δpw,bideal RL  2Δpideal 1   RB RS
 Nc 
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TABLE 6.2 Flow fractions for various streams of the shellside flow pattern

6.6 SHELLSIDE DESIGN

6.6.6 Shellside Stream Analysis (Flow Pattern)
6.6.1 Bell or Delaware Method
Example 6.4

It is desired to heat up 38.88 kg/s of a liquid A from 40 to 61°C using process hot
stream B, available at 104°C with a flow rate of 33.33 kg/s. The intention is to use an
existing heat exchanger whose characteristics are indicated below. A 0.0009 (m2 ·
K)/W fouling resistance is anticipated. Verify if the unit is suitable for the service, and
calculate the fluid pressure drops by using Kern and Delaware methods
Fluids Data

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