PROCESS EQUIPMENT DESIGN, 7TH SEM

Chapter 2: Process design of Heat exchangers

❖ Introduction:
➢ All chemical reaction and unit operations involve heat transfer as solid, liquid and gases
require heating and cooling during operation that are performed to get desired products.
➢ Shell and tube heat exchangers are the most widely used equipments in chemical
industry.
➢ They are mostly used as heat transfer equipments but in a few cases they are also used as
Reactors, Falling Film Absorbers, etc.
➢ Sizes of various parts of shell and tube heat exchangers like shell, tubes, tierods are
standardized developed by Tubular Exchanger Manufacturers Association, USA
(TEMA). Equivalent Indian Standard is IS: 4503.
➢ Shell and tube heat exchangers are classified in three categories;
(i) Class R covers heat exchangers which are used for severe duties in petroleum and
related industries where heat exchangers tackle toxic or flammable gases or
hazardous chemicals.
(ii) Class B covers the heat exchangers which are used in chemical process industries
not involving severe duties.
(iii) Class C covers the heat exchangers which are used in commercial and in less
important process applications such as recovery of heat or energy from effluent
streams.
➢ Most popular and reliable softwares used for the design of shell and tube heat exchangers
are of:
(i) HTRI: Heat Transfer Research Institute, USA
(ii) HTFS: Heat Transfer Fluid Flow Services, UK
(iii) BJAC: USA based company
(iv) HEI: Heat Exchange Institute, USA.
➢ For the design of shell and tube heat exchanger involving fluid without phase change,
methods used by these softwares are based on Tinker's flow model.
❖ Various parts of Shell and Tube heat exchangers:
1. Shell:
➢ Shell is the costliest part of the heat exchanger.
➢ Cost of shell and tube heat exchanger sensitively changes with change in the diameter of
shell.
➢ As per the TEMA standard, shell size ranges from 6 in (152 mm) to 60 in (1520 mm).
➢ Standard pipes are available up to 24 in size (600 mm NB) so if shell size is greater than
24 in, then it is fabricated by rolling a plate.
➢ Shell diameter depends on tube bundle diameter.
➢ For fixed tube sheet shell and tube heat exchanger, the gap between shell and tube bundle
is minimum, ranging from 10 to 20 mm. For pull through floating head heat exchanger, it
is maximum, ranging from 90-100 mm.

Prepared By: Mr. Mohammedadil Shaikh Page

 PROCESS EQUIPMENT DESIGN, 7TH SEM
Chapter 2: Process design of Heat exchangers
2. Shell side pass partition plate:
➢ Single pass shell is used in the most of the cases.
➢ Two pass shell is rarely used and is recommended where shell and tube temperature
difference is unfavorable for the single pass.
➢ Shell side pass partition plate is not provided to improve shell side heat transfer
coefficient but it is provided to avoid the unfavorable temperature difference or to avoid
the cross of temperatures between hot fluid and cold fluid.
3. Baffles:
➢ There are two functions of baffles.
(i) Baffles are used in shell to direct the fluid stream across the tubes to increase the
velocity of shell side flow and thereby to improve the shell side heat transfer
coefficient.
(ii) Baffles indirectly support the tubes and thereby reduce the vibration in tubes.
➢ Different types of baffles are used in shell and tube heat exchangers; (i) Segmental baffle,
(ii) Nest baffle, (iii) Segmental and Strip baffle (iv) Disc and Doughnut baffle, (v) Orifice
baffle (vi) Dam baffle, etc.
➢ Most widely used type of baffle is segmental baffle.
➢ Other types of baffles like nest baffle, segmental and strip baffle and disc and doughnut
baffle provide less pressure drop for the same baffle spacing but provide lower heat
transfer coefficients as compared to segmental baffle.

Prepared By: Mr. Mohammedadil Shaikh Page

 PROCESS EQUIPMENT DESIGN, 7TH SEM
Chapter 2: Process design of Heat exchangers
➢ % Baffle cut ranges from 15 to 45%. If there is no phase change on shell side fluid, then
decrease in % baffle cut increases shell side heat transfer coefficient.
➢ Baffle outside diameter is always less than shell inside diameter. Certain clearance
between baffle OD and shell ID is provided to facilitate removal and insertion of tube
bundle for maintenance.
4. Tubes:
➢ Tube size range from 1/4 in (6.35 mm) to 2.5 in (63.5 mm) in shell and tube heat
exchanger.
➢ For the standard tubes, its size is equal to outer diameter of tube.
➢ Thickness of standard tubes are expressed in BWG (Birmingham Wire Gauge).
➢ Increase in the value of BWG means decrease in tube thickness.
5. Tube side pass partition plate:
➢ Tube side passes are provided to decrease the tube side flow area and to increase tube
side fluid velocity thereby to improve the tube side heat transfer coefficient, at the
expense of pressure drop.
➢ This is true only if there is no phase change on tube side so, a greater number of tube side
passes are recommended only if there is no change in the phase of tube side fluid.
6. Tie rods:
➢ Baffles are supported by tie rods.
➢ Tie rods are made from solid metal bar.
➢ Normally four or more tie rods are required to support the baffles.
➢ Diameter of tie rod is less than the diameter of tube.
7. Spacers:
➢ Spacers are used to maintain the space between baffles.
➢ Spacers are the pieces of pipes or in the most of the cases they are the pieces of extra
available tubes.
➢ Spacers are passed over the tie rods and because of them baffles do not slide over tie rods
under the effect of the force of fluid. Hence, spacers fix the location of baffles and
maintain the space between them.
➢ Length of spacer is equal to space between the baffles.

8. Tube sheet:
➢ Tubes and one end of tierods are attached to tube sheet (also called tube plate).
Prepared By: Mr. Mohammedadil Shaikh Page
 PROCESS EQUIPMENT DESIGN, 7TH SEM
Chapter 2: Process design of Heat exchangers
➢ Hence, entire load of tube bundle is transferred to one or two tube sheets.
➢ In U-tube shell and tube heat exchanger, only one tube sheet is used.
➢ While in fixed tube sheet shell and tube heat exchanger, two tube sheets are used.
➢ One surface of tube sheet is exposed to tube side fluid and other surface is exposed to
shell side fluid.
9. Expansion joint:
➢ When shell is made from two pipes, expansion joints are attached to shell wall.
➢ Expansion joints are used in fixed tube heat exchanger to permit thermal expansion or
contraction between shell and tube because of temperature difference.
10.Sealing strips:
➢ Sealing strips are attached on the inside surface of shell throughout the length of shell.
➢ There are two functions of sealing strips.
(i) Sealing strips reduce the amount of bypass stream of shell side fluid flowing
through the clearance between shell inside diameter and tube bundle diameter and
thereby improve the shell side heat transfer coefficient. (This is valid only if there
is no phase change of shell side fluid).
(ii) Sealing strips also make the removal of tube bundle from the shell easy. Hence,
they are also known as sliding strips.

❖ Advantages and Disadvantages of different type of Shell and tube heat

exchangers over each other:
• Advantages of U-tube and Floating head heat exchangers over Fixed tube heat
exchangers:
➢ Maintenance and cleaning of tube bundle is easier. In U-tube and floating head heat
exchanger entire tube bundle can be easily taken out for cleaning and maintenance.
While the same is not possible in fixed tube sheet heat exchanger.
➢ U-tube and floating head heat exchangers permit the differential thermal expansion or
contraction between shell and tube. Therefore, use of expansion joint is not required in
U-tube and floating head heat exchangers.
• Disadvantages of U-tube and Floating head heat exchangers over Fixed tube heat
exchangers:
➢ For a given heat duty, U-tube and floating head heat exchangers are costlier than fixed
tube sheet heat exchangers because of the following reasons.
Prepared By: Mr. Mohammedadil Shaikh Page
 PROCESS EQUIPMENT DESIGN, 7TH SEM
Chapter 2: Process design of Heat exchangers
(a) For the same number of tubes, tube arrangement and tube pitch, shell sizes required
by U-tube and floating head heat exchangers are higher than the same required by
fixed tube sheet heat exchangers.
(b) In case of cooling or heating of shell side fluid (no phase change) heat transfer
coefficients obtained in U-tube and floating head heat exchangers for the given
heat duty are less as compared to fixed tube sheet heat exchangers as bypassing
area is higher in U-tube or floating head as compared to fixed tube sheet heat
exchanger.
• Advantages of U-tube heat exchangers over Floating head heat exchangers:
➢ Fixed cost of U-tube heat exchanger is always less than the same of floating head heat
exchanger for the given duty.
• Disadvantages of U-tube heat exchangers over Floating head heat exchangers:
➢ In U-tube, tube material becomes weak in bending portion, hence use of U-tube heat
exchanger is not recommended for severe conditions. While for the same conditions
floating head heat exchanger can be used.
➢ In U-tube heat exchanger number of tube side passes are fixed (two). It reduces the
flexibility in design calculations.
➢ U-tube heat exchanger is not recommended to use for tube side dirty fluid. As it is
difficult to remove dirt from U-tube.
❖ General design method for shell and tube heat exchanger:
1) Calculation of heat duty
a) For cooling or heating or for no phase change, heat duty is calculated by equation,
Ø = ṁ Cp ΔT
where,
ṁ = Mass flowrate of fluid (kg/sec)
Cp = Specific heat of fluid (kJ/kg °C)
ΔT = Temperature difference to be carried out (°C)
Ø = Heat duty required (kW)
b) For condensation with subcooling,
Ø = ṁ λ + ṁ CL ΔT

where,
ṁ = Mass flowrate of vapor (kg/sec)
CL = Specific heat of condensate (kJ/kg °C)
λ = Latent heat of vaporization (kJ/kg)
c) For reboilers,
Ø = 1.05 ṁv λ (Considering 5% heat loss)
where,
ṁv = Vaporization rate (kg/sec)

Prepared By: Mr. Mohammedadil Shaikh Page

 PROCESS EQUIPMENT DESIGN, 7TH SEM
Chapter 2: Process design of Heat exchangers
2) Selection of Cooling or Heating medium:
➢ Selection of cooling or heating medium mainly depends on the temperature (inlet
temperature) at which cooling medium or heating medium is required.
➢ Other factors like heat transfer coefficient provided by cooling medium or heating
medium, cost of the medium, etc. are also considered in the final selection.
• Heating medium:
➢ If temperature of heating medium is required in between 100° to 180°C, saturated steam
is used as heating medium. (Saturated steam condenses in dropwise manner, hence it
provides very high heat transfer coefficient.)
➢ If the temperature of heating medium required is greater than 180°C, then use of saturated
steam as a heating medium is not economical.
➢ From 180° to 300°C, hot oil (thermic fluid) is preferred as heating medium. Hot oil
system is easily available at comparatively low cost.
➢ For the precise application at large scale Dowtherm E can be considered as a heating
medium. Dowtherm E is specially processed Ortho dichlorobenzene.
➢ Dowtherm A is an organic fluid of high heat stability, mixture containing 73.5 percent
diphenyl oxide and 26.5 percent diphenyl by mass.

• Cooling medium:
➢ In refrigeration terminology a brine is any liquid cooled by a refrigerant and circulated as
a heat transfer fluid.
➢ Operating temperature range is -68° to 5°C.
➢ For any fluid to be cooled below 8°C, brines are used as cooling medium.
➢ Operating range for chilled water is 7° to 12°C.
➢ For fluid below 35°C, chilled water can be used.
➢ Cooling water is the most widely used cooling medium at near ambient temperature.

Cooling medium Operating range Recommended to use for

temp.
Brine -68° to 5°C < 8°C
Chilled water 5° to 12°C < 35°C
Cooling water 32° to 60°C 35° to 100°C
Air Atmospheric temperature > 60°C

Prepared By: Mr. Mohammedadil Shaikh Page

 PROCESS EQUIPMENT DESIGN, 7TH SEM
Chapter 2: Process design of Heat exchangers
3) Fluid allocation:
• Fluid allocation in case of phase change:
➢ Condensing or vaporizing fluid is normally taken on shell side as in the shell liquid and
vapor phases are easily separated.
➢ In case of a condenser, if condensation is carried out in tube side, then the entire liquid
condensate forms a film on heat transfer surface which provides additional resistance to
heat transfer.
➢ In case of reboilers normally on both sides phase change take place and hence fluid
allocation depends on other factors.
• Fluid allocation in case of no phase change:
➢ If there is no phase change in shell side and tube side fluid, then fluid allocation depends
on the following factors.
(i) Corrosion: Corrosive fluid is allocated tube side as the cheaper material like mild steel
can be used for costly shell, baffles, etc. For example, in cooling of ethyl iodide, it
should be taken on tube side as it requires the use of special material (Hastelloy-B).
(ii) Fouling: In fixed tube sheet heat exchanger inside surface of tubes can be easily
cleaned and hence the fluid which has the greatest tendency to foul on heat transfer
surface should be placed in the tubes. For example, cooling water has a tendency to
foul. Hence normally it is passed through tubes.
(iii) Fluid Temperature: At very high temperature as well as at very low temperature use
of special alloy is required. Hence, very hot or very cold fluid is placed on tube side to
avoid the use of costlier material for the shell.
(iv) Operating Pressure: High pressure stream should be placed on tube side as high-
pressure tubes are cheaper than high pressure shell. Diameter of shell is very much
greater than diameter of tubes hence its thickness is more sensitively changed with
change in pressure as compared to that of the tubes.
(v) Fluid flowrates and Viscosity: Very low value of flow rate of fluid and high value of
viscosity of fluid gives low value of Reynolds number. Fluid which provides very low
value of Reynolds number should be placed on shell side as the dependency of shell
side heat transfer coefficient on Reynolds number is less as compared to the same of
tube side heat transfer coefficient.
4) Energy Balance or Heat duty balance
➢ Establish energy balance or heat duty balance and based on that find the mass flow rate of
heating medium or cooling medium,
Ø = ṁ Cp ΔT = mw CLw (t2 – t1)
where,
mw = mass flowrate of cooling medium (kg/sec)
CLw = heat capacity of cooling medium (kJ/kg °C)
t2 = outlet temperature of cooling medium (°C or K)

Prepared By: Mr. Mohammedadil Shaikh Page

 PROCESS EQUIPMENT DESIGN, 7TH SEM
Chapter 2: Process design of Heat exchangers
t1 = Inlet temperature of cooling medium (°C or K)
5) Mean Temperature Difference
➢ Mean temperature difference (MTD) is calculated from equation
ΔTm = Ft ΔTlm
Where, ΔTlm is
Δ𝑇2 – Δ𝑇1
ΔTlm = Δ𝑇2
ln
Δ𝑇1
➢ Here, ΔT1 and ΔT2 are terminal temperature.
➢ For 1-1 heat exchanger (one shell side pass and one tube side pass), Ft = 1
➢ When shell side passes and/or tube side passes are more than one, Ft must be determined
by
Ft = f (R, S)
𝑇1 – 𝑇2
R=
𝑡2 – 𝑡1
𝑡2 – 𝑡1
S=
𝑇1 – 𝑡 1
where,
T1= hot fluid inlet temp. (°C)
T2= hot fluid outlet temp. (°C)
t1= cold fluid inlet temp. (°C)
t2= cold fluid outlet temp. (°C)

6) Estimate Overall Heat Transfer Coefficient

➢ Assume the value of U, overall heat transfer coefficient.
Prepared By: Mr. Mohammedadil Shaikh Page
 PROCESS EQUIPMENT DESIGN, 7TH SEM
Chapter 2: Process design of Heat exchangers
➢ Find out heat transfer area based on this selected or assumed value of U.
Ø
A=
𝑈 ΔTm
➢ For the 1 trial calculation, this A is the heat transfer area provided,
st

A = Ap = Nt π do L
where,
do = Tube outside diameter (m)
L = Length of tube (m)
Nt = Total number of tubes
➢ From above equation, value of Nt is determined.
➢ Then for the first trial, number of tube side passes and shell side passes are decided. Tube
arrangement and type of heat exchanger are also decided.

7) Finding Shell Diameter

➢ First find out Tube bundle diameter,
𝑁𝑡 (1/𝑛1)
Db = do ( )
𝑘1
where,
Db= tube bundle diameter (mm)
do = tube OD (mm)
Nt = total number of tubes
Prepared By: Mr. Mohammedadil Shaikh Page
 PROCESS EQUIPMENT DESIGN, 7TH SEM
Chapter 2: Process design of Heat exchangers
𝑃𝑡 𝑇𝑢𝑏𝑒 𝑝𝑖𝑡𝑐ℎ
➢ K1 and n1 are constants which depend on ratio ( ) = ( ), arrangement of tubes
𝑑𝑜 𝑇𝑢𝑏𝑒 𝑂𝐷
and number of tube side passes.

➢ After finding tube bundle diameter Db, shell ID (Inside diameter) Di can be determined by
following equation.
Di = Db + Cl
where,
Cl = Clearance between shell ID and Db
Cl= 10 to 20 mm for fixed tube sheet and U-tube
Cl = 50 to 80 mm for split-ring floating head
Cl = 90 to 100 mm for pull through floating head
8) Finding Tube side H.T.C.
a) For no phase change, tube side heat transfer coefficient is determined by Sieder - Tate
equation. If Reynolds number; Re is less than 2000.
ℎ𝑖 𝑑𝑖 𝑑𝑖 0.33 µ 0.14
Nu = = 1.86 (𝑅𝑒 . 𝑃𝑟 . ) (µ𝑤)
𝑘𝑓 𝐿
➢ Here, if Nu ≤ 3.5 then Nu is taken 3.5.

b) If Re > 4000, tube side heat transfer coefficient is determined by Dittus - Bolter equation.
ℎ𝑖 𝑑𝑖 µ 0.14
Nu = = C Re0.8 Pr0.33 ( )
𝑘𝑓 µ𝑤
where,
ℎ𝑖 𝑑𝑖
Nu = Nusselt number =
𝑘𝑓
𝑑𝑖 𝑢𝑡 𝜌 𝑑𝑖 𝐺𝑡
Re = Reynolds number = =
µ µ
𝐶𝑝 µ
Pr = Prandtl number =
𝑘
hi = Tube side H.T.C. (W/m2 °C)
di = Tube ID (m)
L = Length of tube (m)
k = Thermal conductivity of fluid (W/m °C)
Cp = Specific heat of fluid (kJ/kg °C)

Prepared By: Mr. Mohammedadil Shaikh Page

 PROCESS EQUIPMENT DESIGN, 7TH SEM
Chapter 2: Process design of Heat exchangers
µ = Viscosity of fluid at the bulk fluid temperature (N • sec/m2)
µw = Viscosity of fluid at tube wall temperature (N • sec/m2)
C = Constant
C = 0.021 for gases, 0.023 for non-viscous liquid, 0.027 for viscous liquid
Gt = Tube side mass velocity, kg/(m2 sec)
𝑚̇
=
𝑎𝑡
𝑁𝑡 𝜋
at = Tube side flow area = × d i2
𝑁𝑝 4
ṁ = Tube side mass flow rate of fluid (kg/sec)
Nt = Number of tubes
Np = Number of tube side passes
ut = Tube side fluid velocity = Gt/ρ (m/s)
ρ = Density of fluid (kg/m3)
c) Tube side heat transfer coefficient can be calculated from the value of "heat transfer
factor”, J for the entire range of Reynolds number (from Re = 10 to 106).
ℎ𝑖 𝑑𝑖 µ 0.14
Nu = = Jh Re Pr0.33 ( )
𝑘 µ𝑤

9) Calculation of Tube side pressure drop

➢ If there is no phase change in tube side fluid then tube side pressure drop can be
calculated by.
𝐿 µ −𝑚̇ 𝜌 𝑢𝑡 2
ΔPt = Np (8 𝐽𝑓 ( ) ( ) + 2.5)
𝑑𝑖 µ𝑤 2
where,
m = 0.25 for Re ≤ 2100 and m = 0.14 for Re > 2100
ΔPt = Tube side friction pressure drop (N/m or Pa)
Np = Number of tube side passes
Jf = Tube side friction factor can be obtained from fig below

Prepared By: Mr. Mohammedadil Shaikh Page

 PROCESS EQUIPMENT DESIGN, 7TH SEM
Chapter 2: Process design of Heat exchangers
ρ = Density of tube side fluid (kg/m3)
ut = Tube side fluid velocity (m/sec)

10) Calculation of Shell side H.T.C.

➢ For no phase change shell side heat transfer coefficient can be calculated by following
procedure.
a) Calculate shell side flow area by following equation.
(𝑃𝑡 − 𝑑𝑜) 𝐵𝑠 𝐷𝑖
AS =
𝑃𝑡
where,
AS = Shell side flow area (m²)
Pt = Tube pitch (m)
do = Outside diameter of tube (m)
BS = Baffle spacing (m)
Di = Shell inside diameter (m)
b) Calculate shell side velocity by
𝑚̇𝑠 𝑚̇𝑠
uS = and GS =
𝐴𝑠 𝜌𝑠 𝐴𝑠
where,
uS = Shell side velocity (m/sec)
ms = Shell side mass flow rate of fluid (kg/sec)
AS = Shell side flow area (m2)
c) Calculate the shell side equivalent diameter,
4 x 𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎
de =
𝑤𝑒𝑡𝑡𝑒𝑑 𝑝𝑒𝑟𝑖𝑚̇𝑒𝑡𝑒𝑟
➢ For square pitch arrangement,
1.27
de = (Pt2 – 0.785do2)
𝑑𝑜

Prepared By: Mr. Mohammedadil Shaikh Page

 PROCESS EQUIPMENT DESIGN, 7TH SEM
Chapter 2: Process design of Heat exchangers
➢ For triangular pitch arrangement,
1.1
de = (Pt2 – 0.907do2)
𝑑𝑜
d) Calculate Shell side Reynolds and Prandtl number,
𝑑𝑒 𝐺𝑠
Re =
µ
𝐶𝑝 µ
Pr =
𝑘
where,
Cp, µ and k are the properties of shell side fluid at average temperature.
e) Calculate the shell side heat transfer coefficient by following correlation,
ℎ𝑜 𝑑𝑒 µ 0.14
Nu = = 0.36 Re0.55 Pr0.33 ( )
𝑘 µ𝑤
➢ This correlation is valid for the range of Reynolds number from 2000 to 1000000.
➢ Shell side heat transfer, coefficient can be found out from "shell side heat transfer factor,
J h"
ℎ𝑜 𝑑𝑒 µ 0.14
Nu = = Jh Re Pr0.33 ( )
𝑘 µ𝑤
➢ Graph of Jh versus Re is given below,

11) Calculation of Shell side pressure drop

➢ If there is no phase change in shell side fluid then shell side pressure drop can be
calculated by.
𝐷𝑖 𝐿 𝜌𝑠 𝑢𝑠2 µ −𝑚̇
ΔPs = (8 Jf ( ) ( ) ( ) (µ𝑤) )
𝑑𝑒 𝐵𝑠 2
where,

Prepared By: Mr. Mohammedadil Shaikh Page

 PROCESS EQUIPMENT DESIGN, 7TH SEM
Chapter 2: Process design of Heat exchangers
ΔPs = Shell side pressure drop (N/m2 or Pa)
Di = Shell inside diameter (m)
de = Shell side equivalent diameter (m)
L = Tube length (m)
BS = Baffle spacing (m)
ρS = Density of shell fluid (kg/m3)
uS = Shell side linear velocity (m/s)
Jf = Shell side friction factor

12) Calculation of Overall H.T.C.

1
Uo = 1 1 𝑑𝑜 𝑙𝑛 (𝑑𝑜/𝑑𝑖) 𝑑𝑜 1 𝑑𝑜 1
+ + + 𝑥 + 𝑥
ℎ𝑜 ℎ𝑜𝑑 2 𝑘𝑤 𝑑𝑖 ℎ𝑖 𝑑𝑖 ℎ𝑖𝑑
where,
Uo = Overall heat transfer coefficient based on outside area of tubes, W/(m2 °C)
ho = Shell side heat transfer coefficient, W/(m2 °C)
do = OD of tube, m
di = 10 of tube, m
kw = Thermal conductivity of tube wall material, W/(m °C)
hid = Fouling coefficient for tube side fluid, W/(m2 °C)
hod = Fouling coefficient for shell side fluid, W/(m2 °C)

Prepared By: Mr. Mohammedadil Shaikh Page

 PROCESS EQUIPMENT DESIGN, 7TH SEM
Chapter 2: Process design of Heat exchangers

13) Calculating heat transfer area required

➢ Area required,

Ø
Ar =
𝑈𝑜 ΔTm
➢ Actual area provided,
Ap = Nt π do L
➢ For optimum design of shell and tube heat exchanger,
Ap
ϵ {1.1 to 1.2}
𝐴𝑟
ΔPt
ϵ {0.8 to 1}
Δ𝑃𝑡,𝑚̇𝑎𝑥
ΔPs
ϵ {0.8 to 1}
Δ𝑃𝑠,𝑚̇𝑎𝑥

Ex. – 1: Gas oil at 200°C is to be cooled at 40°C. The oil flowrate is 22500 kg/hr. Cooling
water is available at 30°C and temp. rise is to be limited to 20°C. The Pressure drop
allowance is 100 kN/m2. Design suitable heat exchanger.

Properties Gas oil Water

Cp, kJ/kg °C 2.28 4.18
K, W/m °C 0.125 0.631
µ, mN/m2 s 0.17 0.671
ρ, kg/m3 850 992.8

Temperature correction factor = 0.94

Base your design on overall heat transfer coefficient = 500 W/m2 °C

Tube OD = 20 mm, Tube ID = 16 mm, Tube length = 4 m, Triangular pitch Pt = 1.25 do

Prepared By: Mr. Mohammedadil Shaikh Page

 PROCESS EQUIPMENT DESIGN, 7TH SEM
Chapter 2: Process design of Heat exchangers
Number of tube side passes = 4

Shell diameter = 667 mm, baffle spacing = 133 mm, Take water on tube side.

Oil side H.T.C. = 5000 W/m2 °C

Water side H.T.C. = 4000 W/m2 °C

Thermal conductivity of tube wall material = 45 W/m °C

Assume pressure drop are within permissible limit.

Shell side H.T.C.:

ℎ𝑜 𝑑𝑒
= Jh Re Pr0.33
𝑘

and
1.1
de = (Pt2 – 0.907do2)
𝑑𝑜
Tube side H.T.C. for water:
4200 (1.35 + 0.02𝑡)
hi = Ut0.8
𝑑𝑖0.2

ANS:

1. Heat duty,
Ø = ṁ Cp ΔT
22500
= x 2.28 x (200 – 40)
3600
= 2280 kW
2. Heat duty balance,
Ø = mw CLw (t2 – t1)
2280 = mw x 4.18 x (50 – 30)
mw = 27.273 kg/sec
3. MTD,
Δ𝑇1 – Δ𝑇2
ΔTlm = Δ𝑇1
ln
Δ𝑇2
➢ For countercurrent flow.
ΔT1 = T1 – t2 = 200 – 50 = 150°C
ΔT2 = T2 – t1 = 40 – 30 = 10°C
150 – 10
ΔTlm = 150 = 51.7°C
ln
10
➢ Now,
ΔTm = Ft ΔTlm

Prepared By: Mr. Mohammedadil Shaikh Page

 PROCESS EQUIPMENT DESIGN, 7TH SEM
Chapter 2: Process design of Heat exchangers
= 0.94 x 51.7
= 48.6°C
4. Area provided based on U,
➢ Value of U = 500 W/m2 °C (Given)
Ø
A=
𝑈 ΔTm
2280 x 1000
= = 93.83 m2
500 𝑥 48.6
➢ Now, number of tubes
A = Ap = Nt π do L
93.83 = Nt x π x 0.020 x 4
Nt = 373.34 ≈ 376 (As no of tube side passes are 4)
5. Shell diameter,
Di = 667 mm (Given)
6. Tube side H.T.C.,
➢ Tube side flow area,
𝑁𝑡 𝜋
at = × d i2
𝑁𝑝 4
376 𝜋
= × (0.016)2
4 4
= 0.019 m2
➢ Tube side velocity,
𝑚̇
Ut = 𝑤
𝑎𝑡 𝜌𝑡
27.273
=
0.019 𝑥 992.8
= 1.45 m/sec
➢ Now,
4200 (1.35 + 0.02𝑡)
hi = Ut0.8
𝑑𝑖0.2
4200 (1.35 + 0.02𝑥40)
= (1.45)0.8
(16)0.2
= 6981.65 W/m2 °C
7. Shell side H.T.C.,
➢ Shell side flow area,
(𝑃𝑡 − 𝑑𝑜) 𝐵𝑠 𝐷𝑖
AS =
𝑃𝑡
(1.25𝑑𝑜 − 𝑑𝑜) 𝑥 0.133 𝑥 0.667
=
1.25 𝑑𝑜
= 0.01774 m2
➢ Shell side velocity,
𝑚̇
uS = 𝑠
𝐴𝑠 𝜌𝑠
22500
=
3600 𝑥 0.01774 𝑥 850
= 0.4145 m/sec
Prepared By: Mr. Mohammedadil Shaikh Page
 PROCESS EQUIPMENT DESIGN, 7TH SEM
Chapter 2: Process design of Heat exchangers
➢ Shell side equivalent diameter,
1.1
de = (Pt2 – 0.907do2)
𝑑𝑜
1.1
= [(0.025)2 – 0.907(0.020)2]
0.020
= 0.01442 m
➢ Now,
𝑑𝑒 𝐺𝑠 𝑑𝑒 𝑢𝑠 𝜌𝑠
Reo = =
µ µ
0.01442 𝑥 0.4145 𝑥 850
=
0.17 𝑥 10−3
= 29885.45
𝐶𝑝 µ
Pr =
𝑘
2.28 𝑥 103 𝑥 0.17 𝑥 10−3
=
0.125
= 3.1008
➢ Value of Jh from graph for Reo = 29885.45, Jh = 3.6 x 10–3
➢ Now,
ℎ𝑜 𝑑𝑒
= Jh Re Pr0.33
𝑘
ℎ𝑜 𝑥 0.01442
= (3.6 x 10–3) (29885.45) (3.1008)0.33
0.125
ho = 1354.857 W/m2 °C
8. Overall H.T.C.,
1
Uo = 1 1 𝑑𝑜 𝑙𝑛 (𝑑𝑜/𝑑𝑖) 𝑑𝑜 1 𝑑𝑜 1
+ + + 𝑥 + 𝑥
ℎ𝑜 ℎ𝑜𝑑 2 𝑘𝑤 𝑑𝑖 ℎ𝑖 𝑑𝑖 ℎ𝑖𝑑
1
= 1 1 0.02 𝑥 𝑙𝑛 (20/16) 20 1 20 1
+ + + 𝑥 + 𝑥
1354.857 5000 2 𝑥 45 16 6981.65 16 4000
Uo = 676.035 W/m2 °C
9. Area required,
Ø
Ar =
𝑈𝑜 ΔTm
2280 x 1000
=
676.035 𝑥 48.6
= 69.3952 m2
➢ Now, for optimum design of heat exchanger,
Ap 93.83
= = 1.3521 (35.21% excess area is high)
𝐴𝑟 69.3952
➢ So now increasing baffle spacing from 0.133 m to 0.18 m.
➢ Revised Bs = 0.185 m
0.185
➢ As = 0.01774 x = 0.02468 m2
0.133
0.01774
➢ us = 0.4145 x = 0.2979 m/s
0.02468
0.01442 𝑥 0.2979 𝑥 850
➢ Re = = 21478.59
0.17 𝑥 10−3

Prepared By: Mr. Mohammedadil Shaikh Page

 PROCESS EQUIPMENT DESIGN, 7TH SEM
Chapter 2: Process design of Heat exchangers
➢ Value of Jh from graph for Re = 21478.59, Jh = 4 x 10–3
ℎ𝑜 𝑥 0.01442
➢ = (4 x 10–3) (21478.59) (3.1008)0.33
0.125
ho = 1086.013 W/m2 °C
1
➢ Uo = 1 1 1 = 601.711 W/m2 °C
– +
676.035 1354.857 1086.013
Ø
Ar =
𝑈𝑜 ΔTm
2280 x 1000
=
601.711 𝑥 48.6
= 77.97 m2
Ap 93.83
= = 1.2034 (20.34% excess area is satisfactory)
𝐴𝑟 77.97

❖ Criteria of selection between Horizontal and Vertical Condenser:

(i) For film wise condensation only,
➢ Horizontal position gives higher condensation coefficient than vertical position.
➢ In film wise condensation, thickness of condensate film over heat transfer surface decides
the value of condensation coefficient.
➢ With horizontal position and shell side condensation, the condensate travels less distance
over heat transfer surface before falling down by gravity compared to vertical position.
➢ With vertical position, condensate travels over the entire tube length before falling down
by gravity.
➢ Hence, average condensate film thickness obtained with horizontal position is less than
the same with vertical position and hence, it can provide higher condensation coefficient.
(ii) For condensation with subcooling,
➢ In case of condensation with subcooling in a shell and tube heat exchanger, condensation
coefficient is higher with horizontal position while subcooling coefficient is higher with
vertical position.
➢ In case of subcooling with horizontal position, small fraction of gravitational force is
acting on the pool of condensate and hence condensate is flowing with almost no
turbulence. So, subcooling with horizontal position is natural convection heat transfer.
➢ While in subcooling with vertical position, entire gravitational force is acting on pool of
condensate. Hence, it creates turbulence in pool of condensate and provides higher
subcooling coefficient. Subcooling with vertical position can be considered as forced
convection heat transfer.
➢ Therefore, in the case of condensation with subcooling, shell and tube heat exchanger is
designed for both positions (horizontal and vertical) and the position that gives higher
value of overall coefficient is selected.
(iii) For condensation with non-condensables,
➢ Selection of position depends on the % of non-condensables present in inlet vapors.

Prepared By: Mr. Mohammedadil Shaikh Page

 PROCESS EQUIPMENT DESIGN, 7TH SEM
Chapter 2: Process design of Heat exchangers
a) If non-condensables are < 0.5 % (by mass), then the presence of non-condensables is
ignored in design calculations. Heat exchanger is designed as a total condenser. For
this case, horizontal position should be selected as it provides the higher condensation
coefficient.
b) If non-condensable are > 70% (by mass), then for the entire flow rate, without phase
change correlation is applied to calculate the heat transfer coefficient. For this case,
selection of the position does not depend on heat transfer coefficient.
c) Between 0.5 to 70% non-condensables, heat transfer coefficient is determined by
considering both condensation as well as cooling of non-condensables and vapors. For
this case horizontal position should be selected as it gives higher condensation
coefficient, if condensation with cooling is carried out on shell side. If the same is
carried out on tube side, then vertical position is better.
❖ Process design of Condenser:
1) Calculation of heat duty
Ø = ṁ ΔH
where,
ΔH = Enthalpy difference between liquid and vapor
2) Tube side H.T.C.
➢ If condensation takes place on tube side, then its coefficient depends on position of
condenser.
a) For horizontal position,
𝜌𝐿 (𝜌𝐿 − 𝜌𝑉 ) 𝑔 (1/3)
hci = 0.76 kL ( )
µ𝐿 𝜏ℎ
➢ This is Nusselt equation where,
hci = Condensation coefficient, W/m2 °C
kL = Thermal conductivity of liquid condensate, W/(m °C)
ρL = Density of liquid condensate, kg/m3
ρV = Density of vapor, kg/m3
µL = Viscosity of liquid condensate, (N • s)/m or kg/(m • s)
τh = Horizontal tube loading or flow of condensate per unit length of tube, kg/(m • s)
𝑊𝑐
=
𝐿 𝑥 𝑁𝑡
WC = Total condensate flow, kg/sec
Nt = total number of tubes
L = Tube length, m
b) For vertical position,
𝜌𝐿 (𝜌𝐿 − 𝜌𝑉 ) 𝑔 (1/3)
hci = 0.926 kL ( )
µ𝐿 𝜏𝑣
where,
𝑊𝑐
τV =
𝑁𝑡 𝑥 𝜋𝑑𝑖
Prepared By: Mr. Mohammedadil Shaikh Page
 PROCESS EQUIPMENT DESIGN, 7TH SEM
Chapter 2: Process design of Heat exchangers
WC = Mass flowrate of liquid condensate, kg/sec
3) Shell side H.T.C.
➢ If condensation takes place on shell side, then its coefficient depends on position of
condenser.
a) For horizontal position,
𝜌𝐿 (𝜌𝐿 − 𝜌𝑉 ) 𝑔 (1/3) –1/6
hco = 0.95 kL ( ) Nr
µ𝐿 𝜏ℎ
➢ This is also Nusselt equation where,
hco = Shell side condensation coefficient, W/m2 °C
kL = Thermal conductivity of liquid condensate, W/(m °C)
ρL = Density of liquid condensate, kg/m3
ρV = Density of vapor, kg/m3
µL = Viscosity of liquid condensate, (N • s)/m or kg/(m • s)
τh = Horizontal tube loading or flow of condensate per unit length of tube, kg/(m • s)
𝑊𝑐
=
𝐿 𝑥 𝑁𝑡
WC = Total condensate flow, kg/sec
Nt = total number of tubes
L = Tube length, m
2 𝑥 𝑁 𝑟′
Nr = Average number of tubes in vertical tube row =
3
𝐷𝑏
Nr’ = Number of tubes in central row =
𝑃𝑡
b) For vertical position,
𝜌𝐿 (𝜌𝐿 − 𝜌𝑉 ) 𝑔 (1/3)
hco = 0.926 kL ( )
µ𝐿 𝜏𝑣
where,
𝑊𝑐
τV =
𝑁𝑡 𝑥 𝜋𝑑𝑜
4) Tube side Pressure drop
➢ If condensation takes place inside the tube, then pressure drop is given by,
ΔPtˈ = 0.5 x ΔPt
5) Shell side pressure drop
➢ If condensation takes place on shell side, then pressure drop is given by,
ΔPSˈ = 0.5 x ΔPS
❖ Tinker’s flow model:
➢ In old method like Kern’s method, it is assumed that entire shell side fluid is flowing
across tube bundle and between baffles.
➢ But actually, shell side fluid is flowing in various ways.
➢ In Tinker's flow model shell side flow is divided in five different steams.

Prepared By: Mr. Mohammedadil Shaikh Page

 PROCESS EQUIPMENT DESIGN, 7TH SEM
Chapter 2: Process design of Heat exchangers

1) Stream A:
➢ Stream A is the tube-to-baffle leakage stream or it is the fraction of shell side fluid
flowing through the clearance between tube hole in baffle and tube outside diameter.
➢ This stream does not bypass the heat transfer area (outside area of tubes) and hence it
does not create any adverse effect on the value of heat transfer coefficient.
➢ However, it makes the significant difference in pressure drop.
➢ When stream A leaves this clearance, it forms free flowing jet.
➢ Hence, boundary layer separation occurs and considerable friction loss or pressure
drop takes place.
➢ Effect of stream A must be considered in the calculation of pressure drop.
2) Stream B:
➢ Stream B is the actual cross flow stream or it is the fraction of shell side fluid which is
flowing across the tube bundle and between the baffles.
➢ In Kern's method and other old methods, it is assumed that entire shell side fluid is
flowing like stream B.
3) Stream C:
➢ Stream C is bundle to shell bypass stream or it is the fraction of shell side fluid
flowing through the clearance area between shell inside diameter and tube bundle.
➢ Stream C is the main bypass stream, (bypassing the heat transfer area).
➢ This clearance area provides low pressure drop path for the shell side fluid.
➢ Hence, % of shell side fluid bypassed through this clearance area is quite significant.
➢ It is maximum with pull through floating head heat exchanger and minimum with
fixed tube sheet heat exchanger.
➢ Amount of stream C can be reduced considerably by using sealing strips which are
attached on inside surface of shell. They provide partial blockage or the additional
resistance in the path of stream C.
➢ There is no stream designated as stream "D".
4) Stream E:
➢ Stream E is the baffle to shell leakage stream.

Prepared By: Mr. Mohammedadil Shaikh Page

 PROCESS EQUIPMENT DESIGN, 7TH SEM
Chapter 2: Process design of Heat exchangers
➢ It is a part of shell side fluid flowing through clearance between edge of baffle and
shell wall.
➢ Like stream C, this stream is also bypassing the heal transfer area and hence reduces
shell side heat transfer coefficient but amount of stream E is lesser than amount of
stream C.
➢ Normally the clearance between baffle outside diameter and shell inside diameter is in
the range of 1.6 to 4.8 mm while clearance between tube bundle and shell inside
diameter is in the range of 10 to 100 mm.
5) Stream F:
➢ Stream F is the pass-partition bypass stream.
➢ In tube sheets where pass partition plates are attached, in that portion tubes cannot be
provided.
➢ In multipass heat exchangers one can find more number of gaps in tube bundle.
➢ Stream F is the fraction of shell side fluid flowing through these gaps.
➢ Just like stream C and stream E, this stream is also bypassing the heat transfer area and
reduces shell side heat transfer coefficient.
➢ To reduce the amount of this stream, sometimes dummy tubes are used.
❖ Process design of Vertical Thermosyphon reboiler:
➢ It is installed in the perfect vertical position in which normal level of liquid in distillation
column is same as level of top tube sheet of heat exchanger.
➢ Inside the tubes liquid is partially vaporized by using the healing medium like saturated
steam or hot oil on shell side.
➢ It decreases the density of fluid (vapor - liquid mixture) in "hot" leg compared to the
density of saturated liquid in relatively "cold" leg and starts natural fluid circulation in the
anticlockwise direction.
➢ In this type of reboiler, syphoning effect is created by heating (thermally), hence it is
called thermosyphon reboiler.

➢ Design steps are as below,

1) Calculation of heat duty,
ØB = 1.05 ṁv λ
Prepared By: Mr. Mohammedadil Shaikh Page
 PROCESS EQUIPMENT DESIGN, 7TH SEM
Chapter 2: Process design of Heat exchangers
where,
ṁv = mass flowrate of vapor, kg/sec
λ = latent heat of vaporization, kJ/kg
2) Fix the value of mean temperature difference, ΔTm. It should be less than and close to
critical temperature drop. Then, average temperature of heating medium Th = ΔTm + Tb.
3) Select the suitable heating medium. Based on the energy balance, find the mass flow rate
of heating medium required.
4) Assume the value of overall heat transfer coefficient, U = 1000 W/m2 °C. Find the heat
transfer area based on assumed value of U.
ØB
A= = A p = Nt π d o L
𝑈 ΔTm
➢ Find or decide the required dimension of the heat exchanger.
5) Assume the recirculation ratio equal to 4 for the first trial.
Mass flow rate of liquid recirculated mLo
Recirculation ratio = =
𝑉𝑎𝑝𝑜𝑟𝑖𝑧𝑎𝑡𝑖𝑜𝑛 𝑟𝑎𝑡𝑒 𝑚̇𝑉𝑜
where,
mLo = mass flowrate of liquid at outlet of reboiler
mVo = mass flowrate of vapor at outlet of reboiler
6) Do the pressure balance. At steady state,
ΔPav = Pressure loss in the base of distillation column +
Pressure loss in associated piping and nozzles +
Pressure loss in reboiler (tube side)
➢ Velocity of liquid through the shell of distillation column is very low compared to the
velocity of liquid through pipes. Hence, pressure loss in the base of distillation column
may be neglected.
➢ If piping arrangement is smooth and higher sizing for the pipes is provided, then pressure
loss in piping may also be neglected.
➢ Hence, ΔPav ≅ ΔPt.
➢ ΔPav is calculated by following equation,
ΔPav = L (ρL – ρav) g
where,
ΔPav = Available differential head, Pa
L = Tube length, m
ρL = Density of liquid in cold leg, kg/m3
ρav = Average density of liquid vapor mixture in hot leg, kg/m3
𝑙𝑛(𝑉𝑜/𝑉𝑖)
=
𝑉𝑜 – 𝑉𝑖
Vi = Specific volume of saturated liquid at inlet of reboiler, m3/kg = 1/ ρL
Vo = Specific volume of liquid vapor mixture at outlet of reboiler, m3/kg
(mLo/𝜌𝐿 ) + (mVo/𝜌𝑉 )
=
mLo + 𝑚̇𝑉𝑜

Prepared By: Mr. Mohammedadil Shaikh Page

 PROCESS EQUIPMENT DESIGN, 7TH SEM
Chapter 2: Process design of Heat exchangers
7) Compare the value of available differential head (ΔPav) and pressure drop in the system or
tube side pressure drop (ΔPt), obtained based on assumed value of recirculation ratio.
➢ There are five possibilities:

(i) ΔPav ≅ ΔPt

➢ It implies that the assumed value of recirculation ratio (4 for 1st trial calculation) is equal
to the actual value of recirculation ratio. Proceed for the next step of calculation.
(ii) ΔPav > ΔPt
➢ It implies that the assumed value of recirculation ratio is less than the actual recirculation
ratio. Hence, assume the higher value of recirculation ratio, repeat the calculations and
again compare the new values.
(iii) ΔPav >> ΔPt
➢ It implies that the assumed value of recirculation ratio is very much less than actual
recirculation ratio. In this case also, one can find the value of recirculation ratio for which
ΔPav ≅ ΔPt by trial-and-error calculations but very high recirculation ratio and hence very
high tube side pressure drop may be obtained which cannot be permitted.
➢ Very high tube side pressure drop will result in significant boiling point elevation inside
the tubes of the reboiler and decrease the mean temperature difference.
➢ Hence in such case one of following options can be considered.
a) Provide the control valve with flow meter in inlet line to the reboiler. Then,
pressure balance is
ΔPav = ΔPt + Pressure loss in flow meter + Pressure drop offered by control valve
b) Elevate the level of top tube sheet of reboiler above the liquid level at the base of
distillation column as shown in Fig. In this option, ΔPav = L' (ρL – ρav) g. Hence,
this modification decreases the value of available differential head ΔPav and may
equate it with ΔPt at the lower value or reasonable value of recirculation ratio.

(iv) ΔPav < ΔPt

➢ It implies that actual recirculation ratio is less as compared to assumed recirculation ratio.
➢ In this case, one of following option can be considered.
a) Increase the number of tubes and decrease the tube length. This modification will
decrease the values of both ΔPav and ΔPt, But, the percentage decrease in the value
of ΔPt will be more compared to the same in the value of ΔPav.

Prepared By: Mr. Mohammedadil Shaikh Page

 PROCESS EQUIPMENT DESIGN, 7TH SEM
Chapter 2: Process design of Heat exchangers
b) In this case actual recirculation ratio can be increased by elevating liquid level at
the base of the distillation column above the top tube sheet of reboiler as shown in
Fig. In this case equation of ΔPav is changed. ΔPav = ρgh + L (ρL – ρav) g but this
modification may increase the height of skirt support of distillation column.

(v) ΔPav << ΔPt

➢ It implies that the actual recirculation ratio is very low or very much less than minimum
recommended value (ex. - 4).
➢ This is possible when the viscosity of bottom product of distillation column is very high.
In this case use a pump in the inlet line to the reboiler to get the desired value of
circulation rate and desirable value of tube side heat transfer coefficient. But then this
reboiler becomes a forced circulation reboiler.
8) After finding the recirculation ratio for which available differential head becomes nearly
equal to pressure loss in the system, calculate the tube side heat transfer coefficient.
➢ If Reynolds number; Re is less than 2000.
ℎ𝑖 𝑑𝑖 𝑑𝑖 0.33 µ 0.14
Nu = = 1.86 (𝑅𝑒 . 𝑃𝑟 . ) (µ𝑤)
𝑘𝑓 𝐿
➢ If Re > 4000,
ℎ𝑖 𝑑𝑖 µ 0.14
Nu = = C Re0.8 Pr0.33 ( )
𝑘𝑓 µ𝑤
9) Calculate the shell side or heating medium side heat transfer coefficient. If shell side
heating medium is saturated steam, then take h'o = 6000 W/m2 °C
➢ This figure also includes fouling resistance.
➢ If hot oil is used as heating medium, then use
ℎ𝑜 𝑑𝑒 µ 0.14
Nu = = 0.36 Re0.55 Pr0.33 ( )
𝑘 µ𝑤
10) Determine the overall heat transfer coefficient.
11) Calculate the required heat transfer area.
ØB
Areq =
𝑈𝑜 ΔTm
➢ Find the % Excess heat transfer area. (It should be between 10 to 20%).
12) Find the shell side pressure drop ΔPs. It should be less than the maximum allowable
value.

Prepared By: Mr. Mohammedadil Shaikh Page

 PROCESS EQUIPMENT DESIGN, 7TH SEM
Chapter 2: Process design of Heat exchangers
Ex. – 2: A horizontal condenser (1:4) is used to condense 45000 kg/hr of mixed light
hydrocarbon vapors. The condenser operates at 10 bar. The vapor will enter at 60°C and
condensation will be completed at 45°C. The avg molecular weight of vapor is 52. The
enthalpy of vapor is 596.5 kJ/kg and condensate 247 kJ/kg. Cooling water is available at
30°C and out at 40°C. Tubes require of 20 mm OD, 16.8 mm ID and 4.88 m long. Use
square pitch with Pt = 1.25do, Ft = 0.92. Assume overall H.T.C. = 900 W/m2 °C. µL = 0.16
cP, ρL = 551 kg/m3, kL = 0.13 W/m °C, Cpw = 4.18 kJ/kg °C, ρw = 993 kg/m3, kW = 0.628
W/m °C. Calculate,
1. Number of tubes, 2. Shell diameter, 3. Tube side H.T.C., 4. Shell side H.T.C.
ANS:
1. Heat duty,
Ø = ṁ Cp ΔT = ṁ ΔH
45000
= x (596.5 – 247)
3600
= 4368.75 kW
2. Heat duty balance,
Ø = mw CLw (t2 – t1)
4368.75= mw x 4.186 x (40 – 30)
mw = 104.366 kg/sec
3. MTD,
Δ𝑇1 – Δ𝑇2
ΔTlm = Δ𝑇1
ln
Δ𝑇2
➢ For countercurrent flow.
ΔT1 = T1 – t2 = 60 – 40 = 20°C
ΔT2 = T2 – t1 = 45 – 30 = 15°C
20 – 15
ΔTlm = 20 = 17.3803°C
ln
15
➢ Now,
ΔTm = Ft ΔTlm
= 0.92 x 17.3803
= 15.99°C
4. Area provided based on U,
➢ Value of U = 900 W/m2 °C (Given)
Ø
A=
𝑈 ΔTm
4368.75 x 1000
= = 303.57 m2
900 𝑥 15.99
➢ Now, number of tubes
A = Ap = Nt π do L
303.57 = Nt x π x 0.020 x 4.88
Nt = 990.05 ≈ 992 (As no of tube side passes are 4)

Prepared By: Mr. Mohammedadil Shaikh Page

 PROCESS EQUIPMENT DESIGN, 7TH SEM
Chapter 2: Process design of Heat exchangers
5. Tube side H.T.C.,
➢ Tube side flow area,
𝑁𝑡 𝜋
at = × d i2
𝑁𝑝 4
992 𝜋
= × (0.0168)2
4 4
= 0.055 m2
➢ Tube side velocity,
𝑚̇
Ut = 𝑤
𝑎𝑡 𝜌𝑡
104.366
=
0.055 𝑥 993
= 1.911 m/sec
➢ Now,
𝑑𝑖 𝑢𝑡 𝜌 0.0168 𝑥 1.911 𝑥 993
Re = = = 37486.33
µ 0.85 𝑥 10−3
𝐶𝑝 µ 4.186 𝑥 103 𝑥 0.85 𝑥 10−3
Pr = = = 5.66
𝑘 0.628
ℎ𝑖 𝑑𝑖 µ 0.14
= 0.023 Re0.8 Pr0.33 ( )
𝑘𝑓 µ𝑤
ℎ𝑖 𝑥 0.0168
= 0.023 x (37486.33)0.8 (5.66)0.33 x 1
0.628
hi = 6951.1 W/m2 °C
6. Shell side H.T.C.,
➢ Tube bundle diameter,
𝑁𝑡 (1/𝑛1)
D b = do ( )
𝑘1
992 (1/2.263)
= (0.020) ( )
0.158
= 0.9534 mm = 953.4 mm
➢ Shell inside diameter,
Di = Db + Cl
= 953.4 + 12
= 965.4 mm
➢ Shell side H.T.C.,
𝜌𝐿 (𝜌𝐿 − 𝜌𝑉 ) 𝑔 (1/3) –1/6
hco = 0.95 kL ( ) Nr
µ𝐿 𝜏ℎ
➢ Here,
𝑃𝑀 10 𝑥 52
ρV = = = 19.48 kg/m3 (T = (60+45)/2 = 52.5 °C)
𝑅𝑇 0.082 𝑥 325.5
2 𝑥 𝐷𝑏 2 𝑥 0.9534
Nr = = = 25.424 ≈ 26
3 𝑥 𝑃𝑡 3 𝑥 1.25 𝑥 0.020
𝑊𝑐 45000
τh = = = 2.582 x 10-3 kg/(m sec)
𝐿 𝑥 𝑁𝑡 3600 𝑥 4.88 𝑥 992
➢ So, shell side H.T.C. will be

Prepared By: Mr. Mohammedadil Shaikh Page

 PROCESS EQUIPMENT DESIGN, 7TH SEM
Chapter 2: Process design of Heat exchangers
𝜌𝐿 (𝜌𝐿 − 𝜌𝑉 ) 𝑔 (1/3) –1/6
hco = 0.95 kL ( ) Nr
µ𝐿 𝜏ℎ
551 (551 − 19.48) 9.81 (1/3)
= 0.95 x 0.13 x ( ) (26)–1/6
0.16 𝑥 10−3 𝑥 2.582 𝑥 10−3
= 1369.6 W/m2 °C
❖ Criteria of selection between Kettle type reboiler and Vertical
thermosyphon reboiler:
(i) Boiling fluid side (process fluid side) pressure drop in kettle type reboiler is
negligible. While the same is high and significant in thermosyphon reboiler. Hence
with vacuum distillation, kettle type reboiler is preferred. Thermosyphon reboiler is
not preferred for use with absolute pressure below 0.3 bar.
(ii) If the viscosity of bottom product of distillation column is very high, then
thermosyphon reboiler cannot be used. In such a case forced circulation reboiler is
preferred.
(iii) With atmospheric and high-pressure distillation column thermosyphon reboilers are
preferred as size and fixed cost of thermosyphon reboiler is less than the same of kettle
type reboiler. Because of the fluid circulation, thermosyphon reboiler provides higher
heat transfer coefficient than kettle type reboiler. Even for the same value of heat
transfer area, fixed cost of kettle type reboiler is higher than the same of thermosyphon
reboiler.
(iv) If the ratio of vaporization rate required to mass flow rate of residue (bottom product
of distillation column) is 0.8 or above, kettle type reboiler is preferred. Kettle type
reboilers are also use as "Vaporizers" in industry. Thermosyphon reboiler cannot be
used as vaporizer. Separation taking place in kettle type reboiler can be considered as
equivalent to one theoretical stage.
❖ Advantages and Disadvantages of Plate heat exchanger over Shell and
tube heat exchanger:
• Advantages:
1. Plate heat exchanger provides higher heat transfer coefficient as compared to shell and
tube heat exchanger.
2. Maintenance and cleaning is easier with PHE as compared to shell and tube heat
exchanger.
3. Fouling resistance is less with PHE.
4. Minimum driving force required for heat transfer is 1°C for PHE. While the same is 3 to
5°C for shell and tube heat exchanger.
5. PHE are more flexible. It is easy to increase or decrease the heat transfer area by adding
or removing the plates.
6. With highly viscous liquid, PHE is belter as it can be easily cleaned.

Prepared By: Mr. Mohammedadil Shaikh Page

 PROCESS EQUIPMENT DESIGN, 7TH SEM
Chapter 2: Process design of Heat exchangers
• Disadvantages:
1. Fixed cost of plate and hence of PHEs is higher. PHEs are not as widely used as shell and
tube heat exchangers.
2. Gasketed PHE cannot be used if operating pressure is more than 30 bar or operating
temperature is more than 250°C. While for the same case shell and tube heat exchanger
can be used.
3. Internal leakage or mixing of two fluids is more common with PHE compared to shell
and tube heat exchanger.
4. Liquid containing suspended particles tend to plug the flow area in PHE easily and so
frequent cleaning becomes necessary.

Prepared By: Mr. Mohammedadil Shaikh Page