DESIGN OF SHELL AND

TUBE HEAT
EXCHANGER
Problem 1
Design a shell and tube heat exchanger to cool 75000kg/hr of ethylene glycol
from 1200 to 800C using toluene as coolant which is to be heated from 250C to
650C. Assume dirt factor of 2 x 10 -4 m2K/J. Given that ethylene glycol is more
corrosive.
Solution:
Given data :
Hot Fluid – Ethylene Glycol
Cold Fluid – Toluene
Inlet temperature of hot fluid (Ethylene Glycol) T1 = 1200C
Outlet Temperature of hot fluid (Ethylene Glycol) T2 = 800C
Inlet temperature of cold fluid (toluene) t1 = 250C
Outlet Temperature of cold fluid (toluene) t2 = 650C
Flowrate of hot fluid mh = 75000kg/hr
Dirt Factor = 2 x 10 -4 m2K/J
Step 1.
Routing of Fluid
Where no phase change occurs, the following factors will
determine the allocation of the fluid streams to the shell or tubes.
• Corrosion
The more corrosive fluid should be allocated to the tube-side. This
will reduce the cost of expensive alloy or clad components.
• Fouling
The fluid that has the greatest tendency to foul the heat transfer
surfaces should be placed in the tubes. This will give better control
over the design fluid velocity, and the higher allowable velocity in
the tubes will reduce fouling. Also, the tubes will be easier to clean.
• Fluid temperatures.
If the temperatures are high enough to require the use of special alloys placing
the higher temperature fluid in the tubes will reduce the overall cost.
At moderate temperatures, placing the hotter fluid in the tubes will reduce the
shell surface temperatures, and hence the need for lagging to reduce heat loss,
or for safety reasons.
• Operating pressures.
The higher pressure stream should be allocated to the tube-side. High-pressure
tubes will be cheaper than a high-pressure shell.
• Pressure drop.
For the same pressure drop, higher heat-transfer coefficients will be obtained
on the tube-side than the shell-side, and fluid with the lowest allowable
pressure drop should be allocated to the tube-side.
• Viscosity.
Generally, a higher heat-transfer coefficient will be obtained by
allocating the more viscous material to the shell-side, providing the
flow is turbulent.
If turbulent flow cannot be achieved in the shell it is better to place
the fluid in the tubes, as the tubeside heat-transfer coefficient can
be predicted with more certainty.
• Stream flow-rates. Allocating the fluids with the lowest flow-
rate to the shell-side will normally give the most economical
design.
Tube side : Ethylene glycol
Shell side : Toluene
 Step 2
Obtain the required thermophysical properties of hot and cold fluids at
the caloric temperature or arithmetic mean temperature
Fluid Inlet temp Outlet Average Cp 𝝆 µ K
K temp K Temp K J/kgK kg/m3 Pa.s W/m.K

Ethylene
glycol 393 353 373 2783.069 1055.156 0.001749 0.2589
(Hot fluid)
Toluene 298 338 318 1758.121 845 0.0004437 0.1275
(Cold fluid)

[Finding out the thermophysical properties refer lecture notes on STEP WISE PROCEDURE FOR ESTIMATION OF
THERMOPHYSICAL PROPERTIES. Ethylene glycol – Compund No. 137, Toulene - Compund No. 326]
Step 3.
Perform energy balance and find out the heat duty (Q) of the exchanger.
Assume no heat loss to the surrounding
Qh = Qc= mhCp(T1-T2) = mc Cp (t2-t1)

Flow rate of cold fluid is not known. Find mc using heat balance
mh = 75000 kg/hr
= 20.833 kg/sec
Qh = Qc = 20.833x 2783.069x(393-353) = mc x 1758.121x(338-298)
mc = 32.978 kg/sec
Q = Qh = Qc= mhCp(T1-T2) = mc Cp (t2-t1)
= 20.833x 2783.069x(393-353)
= 2319187.06 J/sec
Step 4 .
Assume a reasonable value of overall heat transfer coefficient (U o,assm ).
The value of (U o,assm ) with respect to the process hot and cold fluids can
be taken from the books From Perry 8th edition, Page 11-25, table 11.3
Organic solvents on both tube and shell side the value of U is
20 – 60 Btu /h ft2 °F.

Assuming higher value Uassum = 60 Btu /h ft2 °F

= 60x5.6783 = 340.698 J/m2 sec K
Step 5 .
Decide tentative number of shell and tube passes (np).
Determine the LMTD and the correction factor FT (Perry 8th edition Fig
11.4).
Assume 1- 2 pass
LMTD Calculation
∆𝑇1 −∆𝑇2
• LMTD = ∆𝑇1
𝑙𝑛
∆𝑇2

• If LMTD from above equation is zero or negative average of the

temperature difference is taken as LMTD.
ߡ 𝑇1+ߡ𝑇2
• LMTD = = 55 K
2
LMTD correction factor FT calculation (Perry 8thedition, Page 11-6, Fig
11.4).

𝑇1−𝑇2 𝑡2 −𝑡1
R= s=
𝑡2 −𝑡1 𝑇1 −𝑡1

T1 - Inlet temp. of shell side fluid

T2 - Outlet temp. of shell side fluid
t1- Inlet temp. of tube side fluid
t2- Outlet temp. of tube side fluid

25−65 80−120
R= 80−120 = 1 S= 25−120 = .421
FT = 0.92
Step 6 .
Calculate heat transfer area ( A ) required

Q= 2319187.06 J/sec

2319187.06
A= = 134.53 m2
340.698x 55x .92
Step 7 .
Select tube material, decide the tube diameter (ID= di, OD =do ), its
wall thickness (in terms of BWG or SWG) and tube length (L). (Perry 8th
edition , page 11-42, Table 11-12)
From table 11-12
Assume
Tube OD = 1 inch = 0.0254 m
BWG 8
Thickness = 0.165 inch = 0.00417 m
Tube ID = 0.670 inch = 0.017 m
Tube length = 20ft = 6.096 m
(Standard tube length are 8,10 ,12, 16 and 20 ft, with 20 ft now the
most common - Perry 8th edition Page no. 11-41)
Step 8
Calculate the number of tubes (nt) required to provide the heat transfer
area ( A ) calculated

134.53
= = 276.7 = 277
3.14x0.0254x6.096
No. of tubes should be mostly multiple of 6
So, take no of tubes as 282 next nearest no. which is multiple of 6
nt = 282
Step 8
Calculate the number of tubes per pass
n = nt /no. of passes
= 282/2 = 141

Step 9
Calculate cross flow area (S)
π d2i
S= n x
4
3.14 x 0.0172
= 141 x = 0.03198 m2
4
Step 10
Calculate mass velocity on tube side (Gt)
Gt = m/S
= 20.833/0.03198
= 651.44 kg/m2 sec

Step 11
Calculate Reynold’s No. (NRet)
Ret = Gt di/µ
= (65 x 0.017)/0.001749
= 6331.89
( If Ret <<104, the design parameters and considerations needs to be revised to meet the
Reynolds number criteria subject to allowable pressure drop in the tube side of the heat
exchanger. i.e try changing tube pass and tube length.)
Step 12
Determine the tube side film heat transfer coefficient ( hi) using the
suitable form of equation from Perry 8th edition , page 5-9.
for Ret = 6331.89
Assuming K = 1
Substituting the values
f= 8.984 x 10-3
Nu = 73.037
hi = Nu x k / di
= 73.037 x 0.2589 / 0.017
= 1112.2 W/m2K
hio= hi x (di/do)
= 1112.2 (0.017/0.0254)
= 744.38 W/m2K
Shell side Calculation
Step 13.
Shell side dimensions.
Select suitable pitch and find out the shell side dimensions
Tube arrangement
From Page No.11-7, Fig 11.5
Corresponding to tube od 1 inch ,Triangular layout
Tube pitch p’ = 1.250in = 3.175x10-2 m
pp = 1.082 in = 2.748x 10-2 m
pn = 0.625 in = 1.587x10-2m
Step 14.
Shell diameter estimation
Equation no. 11-74b as we have selected triangular pitch
2 Tube Pass: Nt = 1266. + 73.58C + 1.234C2 − .0071C3 − .0005C4
Nt = 126 substitute in the equation to get C value.
Solving gives the value of C = - 19.46
C = 0.75(D/d)-36
D= 0.3749 m
D – Bundle O.D.
d – Tube O.D.
Ds = D +2Cs
= 0.3749+0.011 m
= 0.3859 m
Ds - Shell I.D
Cs –Clearance (Page no 11.36)
Shell side design
Step 15.
Perry 8th edition , Page 11-7 Solve equation 11-7 to 11-22
Number of tube rows crossed in one cross-flow section Nc

= 2.8 = 3

Ds = 0.3859m
pp = 1.082 in = 2.748x 10-2 m
lc = 0.4 Ds = 0.1544 (baffle cut ,Page No. 11-43)
ls = 0.2 Ds =0.077 (baffle spacing, Page No. 11-43)
Step 16.
Fraction of total tubes in cross-flow Fc

Fc= 0.26

D – Bundle O.D. = Dotl = 0.3749 m

Ds = 0.3859m
lc = 0.4 Ds = 0.1544 (baffle cut ,Page No. 11-43)
Step 17.
Number of effective cross-flow rows in each window Ncw

Ncw= 4.49 =5

lc = 0.4 Ds = 0.1544 (baffle cut ,Page No. 11-43)

pp = 1.082 in = 2.748x 10-2 m
Step 18.
Cross-flow area at or near centerline for one cross-flow section, Sm
For triangular layouts:

Sm= 6.229x10-3 m2

D – Bundle O.D. = Dotl = 0.3749 m

Ds = 0.3859m
lc = 0.4 Ds = 0.1544 (baffle cut ,Page No. 11-43)
p’ = 1.250in = 3.175x10-2 m
D0 - outside diameter = 0.0254 m
Step 19.
Fraction of cross-flow area available for bypass flow Fbp

Fbp=0.1359

D – Bundle O.D. = Dotl = 0.3749 m

Ds = 0.3859m
Sm= 6.229x10-3 m2
ls = 0.2 Ds =0.077
Step 20.
Tube-to-baffle leakage area for one baffle Stb.

= 5.625x 10−3

b = (6.223)(10−4)
D0 = 0.0254 m
Nt = 282
Fc= 0.26
Step 21.
Shell-to-baffle leakage area for one baffle Ssb.

From fig 11-7, lc / Ds = 0.4

Ssb. =1.129x10-3 m2
Step 22.
Area for flow through window Sw
This area is obtained as the difference between the gross window area Swg and the window
area occupied by tubes Swt

Swg from fig 11-8

= 89 in2 = 0.0574 m2
Swt= 0.0528 m2
Sw= 4.6 x10-3 m2
Step 23.
Step 24.
Number of baffles Nb

Nb= 78.16 = 78
le approximately equal to ls
ls = 0.2 Ds =0.077
L-Tube length = 20ft = 6.096 m
Step 25.
Shell-Side Heat-Transfer Coefficient Calculation
Calculate the shell-side Reynolds number (NRe)s.

= 303075.11

where W = mass flow rate and μb = viscosity at bulk temperature. The arithmetic
mean bulk shell-side fluid temperature is usually adequate to evaluate all bulk
properties of the shell-side fluid.
D0 = 0.0254 m
W= 32.978 kg/sec
μb= 0.0004437 Pa s
Sm = 6.229x10-3 m2
Calculate the shell-side heat-transfer coefficient for an ideal tube
bank hk.

hk= 8347.5 W/m2K

where c is the specific heat, k is the thermal conductivity, and μw is the viscosity evaluated at the
mean surface temperature.
Jk = 3 x10-3 , from fig 11-9 page 11-9
C= 1758.121 J/kgK
W= 32.978 kg/sec
K= 0.1275 W/mK
μb= 0.0004437 Pa s
Sm = 6.229x10-3 m2
Step 26.
Calculate the shell-side heat-transfer coefficient for the exchanger hs from

hs= 8347.5x 0.73x0.48x0.93

= 2720.21 W/m2K
• Jc -the correction factor for baffle-configuration effects from Fig. 11-10.
Corresponding to Fc = 0.26, Jc 0.73
• Jl –the correction factor for baffle-leakage effects from Fig. 11-11.
(Ssb +Stb)/Sm = 1.08 ,Ssb / (Ssb +Stb)= 0.167 from fig 11-11, Jl =0.48
• Jb - the correction factor for bundle-bypassing effects from Fig. 11-12
Nss/Nc= 0.1 Fbp = 0.1359 from fig 11-12 , Jb = 0.93
• Jr-the correction factor for adverse temperature-gradient buildup at low Reynolds number
from fig 11-13,11-14
• Here as Nre is not less Jr not required
Step 27.
Calculate wall temperature

ℎ𝑠
𝑇𝑤 = 𝑡𝑚𝑒𝑎𝑛 + (𝑇𝑚𝑒𝑎𝑛 − 𝑡𝑚𝑒𝑎𝑛 )
ℎ𝑖𝑂 + ℎ𝑠

2720.21
𝑇𝑤 = 318 + (373 − 318)
744.38 + 2720.21

= 361.18K
Step 28.
Correction factor for tube side heat transfer coefficient
K= (Prb/Prw)0.11
So properties where calculated at wall temperature
K= (18.8/27.415)0.11
= 0.95935
Fluid Wall Temp Cp µ K
K J/kgK Pa.s W/m.K
Ethylene glycol
(Hot fluid) 361.18 2725.73 0.002605 0.259
Step 29.
Corrected tube side heat transfer coefficient
hio= 744.38 W/m2K
hio’= hio x K
= 744.38 x 0.95935
= 714.12 W/m2K
Step 30.
Viscosity Correction factor for shell side heat transfer coefficient
(µ/ µw)0.14
= (0.00044375/ 0.000299)0.14
= 1.056
Step 31.
Corrected Shell side heat transfer coefficient
hs’= 2720.21x 1.056
= 2856.22 W/m2K
Step 32.
Calculate the overall heat transfer coefficient

1 1 xw do 1
= + +
𝑈 hio K w dm hs

1 1 4.2x10−3 x 2.54x10−2 1
= + +
𝑈 714.12 75x 0.0212 2856.22

Kw = 75 W/mK for carbon steel

xw= do-di/2
= (0.0254-0.017)/2
= 4.2 x 10-3m
dm= do+di/2
= (0.0254+0.017)/2
= 0.0212 m
U = 550.19 W/m2K
 1 1
= + R di + R do
UD U
1 1
= + 2x2 x 10 −4
UD 550.19

UD = 450.947 W/m2K
Uassum= 340.698 W/m2sec K
Step 33.

If

go the next step. Otherwise go back calculate heat transfer area ( A ) required
using Uo,cal and repeat the calculations starting from step 6.
(450.947 -340.698)/340.698 = 0.32
Step 34.
Shell-Side Pressure-Drop Calculation
Find fk from the ideal-tube-bank friction-factor curve for the given tube layout at the calculated value of
(NRe)s, using Fig. 11-15a for triangular and rotated square arrays and Fig. 11-15b for in-line square arrays.
Calculate the pressure drop for an ideal cross-flow section.

= 4.20 kg/msec2

b = 2x10−3
Nc = 3
𝜌 = 845
(µ/ µw)0.14= 1.056
W= 32.978 kg/sec
Sm= 6.229x10-3 m2
Fk from fig 11-15 a = 0.2x 10-1
Calculate the pressure drop for an ideal window section. If (NRe)s
≥ 100,

=1122.93 kg/msec2
b = 5x10−3
Ncw= 5
𝜌 = 845
W= 32.978 kg/sec
Sm= 6.229x10-3m2
Sw= 4.6 x10-3 m2
Step 35.
Pressure drop – tube side
Calculate the pressure drop

Calculate f value from Perry 8th edition Page 6-10, Fig 6-9
Ret = 6331.89
Take ε from table 6-1
ε = 0.0457
ε/di = 0.0457 / 17 = 0.002688
corresponding f value from fig 6-9 is 0.0087
v= Gi/ ρ
= 651.44 /1055.156
= 0.617 m/sec

ߡP = 6619.33 kg/msec2