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PROCESS HEAT
TRANSFER
WEEK-10
Eduardus Budi Nursanto, Ph.D
LECTURE MATERIALS of THIS WEEK 2

 Shell and Tube Heat Exchanger

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SHELL AND TUBE HEAT

EXCHANGER
KERN
Shell and Tube Heat Exchanger 4

 Consists of tube bundles enclosed in a cylindrical shell with one fluid flowing
through the tubes and the other flowing outside of the tubes
Why shell-and-tube? 5

CEC survey: S&T accounted for 85% of new exchangers supplied to oil-refining,
chemical, petrochemical and power companies in leading European countries.
Why?
 Can be designed for almost any duty with a very wide range of temperatures and
pressures
 Can be built in many materials
 Many suppliers
 Repair can be by non-specialists
 Design methods and mechanical codes have been established from many years of
experience
 Scope of shell-and-tube
6

Maximum pressure
Shell 300 bar (4500 psia)
Tube 1400 bar (20000 psia)

Temperature range
Maximum 600oC (1100oF) or even 650oC
Minimum -100oC (-150oF)

Fluids
Subject to materials
Available in a wide range of materials

Size per unit 100 - 10000 ft2 (10 - 1000 m2)

Can be extended with special designs/materials
 Construction 7

 Bundle of tubes in large cylindrical shell

 Baffles used both to support the tubes and to direct into multiple cross flow
 Gaps or clearances must be left between the baffle and the shell and between the
tubes and the baffle to enable assembly
Shell

Tubes
Baffle
Shell-side flow 8
 9
Shell
Tube layouts 10

pitch
Triangular Rotated Square Rotated
30o triangular 90o square
60o 45o
 The tube pitch (PT) is the shortest center to center distance between adjacent tubes
 Typically, 1 in tubes on a 1.25 in pitch or 0.75 in tubes on a 1 in pitch
 Triangular layouts give more tubes in a given shell
 Square layouts give cleaning lanes with close pitch
Tube layouts 11

 Square also cause lower pressure drop when fluid flows in the direction indicated in Fig
7.3a
Allocation of fluids 12

 Put dirty stream on the tube side - easier to clean inside the tubes
 Put high pressure stream in the tubes to avoid thick, expensive shell
 When special materials required for one stream, put that one in the tubes to avoid
expensive shell
 Cross flow gives higher coefficients than in plane tubes, hence put fluid with lowest
coefficient on the shell side
 If no obvious benefit, try streams both ways and see which gives best design
Fouling 13

Shell and tubes can handle fouling but it can be reduced by

 keeping velocities sufficiently high to avoid deposits
 avoiding stagnant regions where dirt will collect
 avoiding hot spots where coking or scaling might occur
 avoiding cold spots where liquids might freeze or where corrosive products may
condense for gases
Avoiding vibration 14

 Inlet support baffles - partial baffles in first few tube rows under the nozzles
 Double segmental baffles - approximately halve cross flow velocity but also reduce
heat transfer coefficients
 Patent tube-support devices
 No tubes in the window (with intermediate support baffles)
Avoiding vibration 15

Inlet support Double-segmental baffles

baffles
Intermediate baffles
Windows
with no tubes Tubes

No tubes in the window - with intermediate support baffles

Baffling 16

 Type of baffles. Baffles are used to support tubes, enable a desirable velocity to be
maintained for the shell side fluid, and prevent failure of tubes due to flow-induced
vibration. There are two types of baffles: plate and rod. Plate baffles may be single-
segmental, double-segmental, or triple-segmental.
 Baffle spacing. Baffle spacing is the centerline-to-centerline distance between
adjacent baffles. It is the most vital parameter in STHE design.
Baffling 17
Type of Shell and Tubes Heat Exchanger 18

In nuclear power plants with pressurized water

reactors, large heat exchangers called steam
generators are two-phase, shell-and-tube heat
exchangers which typically have U-tubes.
They are used to boil water recycled from a
steam turbine condenser into steam to drive
the turbine to produce power. Most shell-and-
tube heat exchangers are either 1, 2, or 4
pass designs on the tube side. This refers to
the number of times the fluid in the tubes
passes through the fluid in the shell. In a
single pass heat exchanger, the fluid goes in
one end of each tube and out the other
Type of Shell and Tubes Heat Exchanger 19

Steam turbine condensers in power plants are

often 1-pass straight-tube heat exchangers.
Two and four pass designs are common
because the fluid can enter and exit on the
same side. This makes construction much
simpler.
Heat Exchanger Networks: Shell- and -Tube Heat Exchangers
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1 shell pass and 1 tube pass

o Needs lower area than 1-2 design Ideal shell side flow

1 shell pass and 2 tube passes

o Allowance of thermal expansion
o Easy mechanical cleaning Non-ideal shell side flow
o Good heat transfer coefficient
Shell-Side Film Coefficients 21
 The heat transfer coefficients outside tube bundles are referred to as shell-side
coefficients
 When the tube bundle employs baffles directing the shell-side fluid across the tubes
from top to bottom or side to side, the heat-transfer coefficient is higher than for
undisturbed flow along the axes of the tubes.
Shell-Side Film Coefficients 22
 For values of Re from 2000 to 1,000,000, however the data are closely represented
by the equation
Shell-Side Mass Velocity 23

 The shell-side or bundle crossflow area as, is then given by:

PT = C’+OD tube

 And as before, the mass velocity is

 B= baffle spacing, baffle spacing is usually not greater than a distance equal to
inside diameter of the shell or closer than a distance equal to the one fifth the inside
diameter of the shell
Shell-Side Equivalent Diameter 24
 By definition, the hydraulic radius corresponds to the area of a circle equivalent to the
area of a noncircular flow channel and consequently in a plane at right angles to the
direction of flow
 For Square Pitch
Shell-Side Equivalent Diameter 25
 For Triangular Pitch
Exercise-Shell-Side Equivalent Diameter 26
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1-2 Shell and Tube Heat

Exchanger
PARALLEL-COUNTERFLOW
The true temperature difference 28
 There is other equation to calculate LMTD in 1-2
Shell and Tube Heat Exchangers. In 1-2
Exchanger, there is one type of fluid flow in shell
and there are two type of fluid flows in tubes.
The true temperature difference 29

FT is similar like correction factor for LMTD

Heat Transfer for 1-2 Exchanger 30
Shell Side Pressure Drop 31

N= Number of
baffles
Shell Side Pressure Drop 32
Tube Side Pressure Drop 33
Tube Side Pressure Drop 34
Number of tubes
35
Number of tubes
36
Calculation of existing 1-2 Exchangers 37
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1-2 Exchangers 40
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