Heat Exchangers: Fundamentals and Design Analysis

Tubular Heat Exchangers: Heat Transfer Coefficients

1
 Shell-and-tube Heat Exchanger

F. P. Incropera and D.P. DeWitt, Heat and Mass Transfer

2
Internal & External flow

3
Moody (or Darcy) friction factor

Friction coefficient (Fanning friction factor)

Heat Transfer and Friction Coefficient (Internal)
Laminar Flow (Re < 2300):

4
Heat Transfer and Friction Coefficient (Internal)
Turbulent Flow :
3500 < Re < 2x104

Re > 2x104

5
 External Flow: Inline Tube Arrangement

SL

ST

6
External Flow: Staggered Tube Arrangement
Minimum Velocity – Two Possibilities SL

SD

For Min at A1
ST D

For Min at A2 V

7
Heat Transfer Coefficient

.R.F. Barron, Cryogenic Heat Transfer, 1 st Ed

8
Heat Transfer Coefficient

.R.F. Barron, Cryogenic Heat Transfer, 1 st Ed

9
Heat Transfer Coefficient: Inline Tubes

Kakac, S. et al. Heat Exchangers Selection, Rating , and Thermal Design, 3rd Edition

10
Heat Transfer Coefficient: Staggered Tube

Kakac, S. et al. Heat Exchangers Selection, Rating , and Thermal Design, 3rd Edition

11
 Correction in Number of Tubes

Kakac, S. et al. Heat Exchangers Selection, Rating , and Thermal Design, 3rd Edition

12
Numerical Problem

Kakac, S. et al. Heat Exchangers Selection, Rating , and Thermal Design, 3rd Edition

13
Heat Exchangers: Fundamentals and Design Analysis
Tubular Heat Exchangers: Double Pipe

1
Double Pipe Hairpin Heat Exchanger
Counter Flow Parallel Flow

2
Double Pipe Hairpin Heat Exchanger
 Ease of cleaning
 Fluid streams (one or both) of high pressure

 Small heat transfer surface area

 Bulky and expensive per unit surface area

3
Double Pipe Hairpin Heat Exchanger
Two Hairpin in Series

Kakac, S. et al. Heat Exchangers Selection, Rating , and Thermal Design, 3rd Edition

4
Double Pipe Hair Pin Heat Exchanger
Two Hairpin in Parallel

Kakac, S. et al. Heat Exchangers Selection, Rating , and Thermal Design, 3rd Edition

5
Inner Tube: Thermo-hydraulic Analysis
Laminar Flow (Re < 2300) Turbulent Flow

3500 < Re < 2x104

Re > 2x104

6
Annulus: Thermo-hydraulic Analysis

di d o Di

7
Annulus: Thermo-hydraulic Analysis
Laminar Flow (Re < 2300)
(do/Do) Nui Nuo
di d o Di 0 3.66
0.05 17.46 4.06
0.10 11.56 4.11
0.25 7.37 4.23
0.5 5.74 4.43
1.0 4.86 4.86
F. P. Incropera and D.P. DeWitt, Heat and Mass Transfer

8
Annulus: Thermo-hydraulic Analysis
Turbulent Flow

di d o Di

Kakac, S. et al. Heat Exchangers Selection, Rating , and Thermal Design, 3rd Edition

9
Numerical Problem
Water with flow rate of 5000 kg/h is heated up from 20°C to 35°C by
hot water at 140°C. Water temperature drop of 15°C is allowed. A
number of 3.5 m hairpins of 3 in (ID = 0.0779 m) by 2 in. (ID =0.0525
m, OD = 0.0603 m) counterflow, double-pipe heat exchangers with
annuli and pipes, each connected in series, will be used. Hot water
flows through the inner tube. Assume that the pipe is made of carbon
steel (k=54 W/m.K). The heat exchanger is insulated against heat
losses.
Calculate the number of hairpins.
Kakac, S. et al. Heat Exchangers Selection, Rating , and Thermal Design, 3 Edition
rd

Indranil Ghosh
Cryogenic Engineering Centre 10
Heat Exchangers: Fundamentals and Design Analysis
Tubular Heat Exchangers: Shell & Tube

1
Shell-and-Tube Heat Exchanger
 Most versatile type of exchangers
 Process Industries, Nuclear Power Stations
 Energy applications including Ocean, Thermal, Geothermal
 Condensers, Stream Generators, Feed Water Heaters etc.
 Design Flexibility, High Pressure Operation, Cleaning Option

Standard : Tubular Exchanger Manufacturers Association (TEMA)

Kern, Q. K and Kraus A.D. Extended Surface Heat Transfer

2
Shell-and-Tube Heat Exchanger

Fixed Tubesheet Exchanger with Two Tube Passes

Kern, Q. K and Kraus A.D. Extended Surface Heat Transfer

3
Shell-and-Tube Heat Exchanger
Floating Head Removable Bundle Exchanger

Kern, Q. K and Kraus A.D. Extended Surface Heat Transfer

4
Shell-and-Tube Heat Exchanger
U-tube Removable Bundle Exchanger

Kern, Q. K and Kraus A.D. Extended Surface Heat Transfer

5
Shell-and-Tube Heat Exchanger

Standard Shell Types and Front End and End Head Types (Courtesy TEMA)

6
Baffle Types

Kakac, S. et al. Heat Exchangers Selection, Rating , and Thermal Design, 3rd Edition

7
Baffle Types

Kakac, S. et al. Heat Exchangers Selection, Rating , and Thermal Design, 3rd Edition

8
Basic Design Approach

One Tube Pass: Two Tube Passes: Three Tube Passes:

Kakac, S. et al. Heat Exchangers Selection, Rating , and Thermal Design, 3rd Edition

9
Basic Design Approach

Kakac, S. et al. Heat Exchangers Selection, Rating , and Thermal Design, 3rd Edition

10
Basic Design Approach
 Kern Method
 Bell-Delaware Method

Kakac, S. et al. Heat Exchangers Selection, Rating , and Thermal Design, 3rd Edition

11
Heat Exchangers: Fundamentals and Design Analysis
Tubular Heat Exchangers: Shell & Tube Design Approach

1
Basic Design Approach
Problem Definition / Selection of Heat
Constraints / Desired Output Exchanger Type

Rough Estimation of
Design Parameters
NO
YES
Is ∆P, Q Acceptable? Rating Problem
Performance Evaluation

2
Problem Definition
RAW WATER CONDENSED WATER

CONDENSED WATER RAW WATER

3
Basic Design Calculation

Kakac, S. et al. Heat Exchangers Selection, Rating , and Thermal Design, 3rd Edition

4
Basic Design Calculation

Kakac, S. et al. Heat Exchangers Selection, Rating , and Thermal Design, 3rd Edition

5
Basic Design Calculation

Kakac, S. et al. Heat Exchangers Selection, Rating , and Thermal Design, 3rd Edition

Indranil Ghosh
Cryogenic Engineering Centre 6
Basic Design Calculation

Kakac, S. et al. Heat Exchangers Selection, Rating , and Thermal Design, 3rd Edition

7
Basic Design Approach

One Tube Pass

Two Tube Passes

8
Basic Design Approach

Kakac, S. et al. Heat Exchangers Selection, Rating , and Thermal Design, 3rd Edition

9
Basic Design Calculation

Kakac, S. et al. Heat Exchangers Selection, Rating , and Thermal Design, 3rd Edition

10
Basic Design Approach
 Kern Method  Bell-Delaware Method

Bundle Crossflow Area Shell-side mass velocity

Kakac, S. et al. Heat Exchangers Selection, Rating , and Thermal Design, 3rd Edition

11
Basic Design Approach
Shell-side Heat Transfer Coefficient

Kakac, S. et al. Heat Exchangers Selection, Rating , and Thermal Design, 3rd Edition

12
Basic Design Approach
Shell-side Pressure Drop Calculations

Number of Baffles

Kakac, S. et al. Heat Exchangers Selection, Rating , and Thermal Design, 3rd Edition

13