Advantages of D/P H.

Ex;
i. The double-pipe heat exchanger is one of the simplest and cheapest type of heat
exchangers,
ii. Flexibility in fabrication e.g. hairpin, jacketed pipe, jacketed u-tube,
and pipe-in-pipe exchangers. 
Disadvantages of D/P H.Ex :
iii. Usually inadequate for large heat duties and flow rates,
iv. Difficult to clean fouled tubes, however total disassembly may enhance clean-ability,
v. H.T. Rate depends upon velocity and material of construction, wall thickness,
vi. Multiple hairpins may cause leakages and sagginess under weight .
vii. Frequent maintenances becomes essential but difficult specially at the bends.
viii. Poor compactness (thermal density)and suitable for H.T. area is low <10m2.
Double Pipe Heat Exchanger A double pipe heat exchanger of the dimensions shown in figure is
employed to heat 5 kg/sec of Dowtherm A from 15°C to 65°C using waste hot water cooled in the
process from 95°C to 75°C. The hot water flows in the inner tube in counter flow to the Dowtherm,
which flows in the annulus. What is the total length of the heat exchanger required? Assume the
tube material to be of steel with k = 60 W/m - K .

Fluid Properties
 SHELL AND TUBE HEAT EXCHANGER

• Shell and tube heat exchanger is an

extensive class of heat exchanger 
used in chemical & petrochemical
industry industries.
The shell and tube exchanger consists of four major parts:
• One fluid runs through the tubes, and
another
Front Header—this fluid flows
is where over
the fluid the tubes i.e.
enters the tubeside of the
exchanger. It is sometimes referred to as the Stationary Header.
the shell,
Rear Header—this is where the tubeside fluid leaves the
exchanger or where it is returned to the front header in
exchangers with multiple tubeside passes.

Tube bundle—this comprises of the tubes, tube sheets, baffles

and tie rods etc. to hold the bundle together.

Shell—this contains the tube bundle.

The remainder of this section concentrates on exchangers that

are covered by the TEMA Standard.
 PARTS OF S &T H.Exs
 S &T H.Exs consist of 2 main parts, a shell with a bundle of tubes installed in the shell,
 One fluid flows through tubes and other fluid passes outside the outside the tubes i.e. (the shell side).
 Heat is transfer occurs through the tube walls depending upon the location of hot and cold streams
 The fluids can be either liquids or gases.
 Some other parts and systematic flow of streams are shown in the fallowing diagrams .
Shell & tube exchanger consists of four major parts:

• Front Header— provision for the fluids to enters in the tube-side

of the exchanger. Usually it is referred as a Stationary Header.
• Rear Header— provision for tube-side fluid exits or returned to
the front header in exchangers for multiple tube-side passes.
• Tube bundle— Comprises of the tubes, tube sheets, baffles and tie
rods etc. to hold the bundle together.
• Shell—this contains the tube bundle.
• Design and fabrication of S & T exchangers in accordance to the
TEMA, ASME , and ASTM Standard.
Tubes:
 Tubes are available in different materials to
meet specific dimensions & specifications
required by the designer and fabricator of
shell and tube heat exchangers.
i. Tubes for an heat exchanger are available in
various sizes & lengths.
ii. Common lengths of tubes for heat exchanger
construction are 8, 12, 16 & 20 ft.
 Tube Diameter & wall thickness is
characterized by BWG (Birmingham Wire
Gauge)
i. OUTER DIAMETER (OD) 0.500 - 3.00” or 12.7 - 76.2 mm
ii. WALL THICKNESS (WT) 0.035 to 0.22” or 0.89 to 5.52 mm

iii. The wall thickness depends upon diameter,

material of construction, and pressure in side
the exchanger.
Construction of shell
• To install tube bundle a cylindrical shell ,
• One fluid flows inside the tubes and other runs
through the space between the tubes and the shell .
• Shell diameters are standardized w.r.t. No. of tubes
and type of the tube pitch.
• Shell is commonly made of carbon steel.
• The minimum thickness of shell varies from 5 to 11
mm depending upon the working pressure.
• Specification covers the design, construction,
inspection and testing of cylindrical shell,
•  A shell & tube heat exchangers may be installed
vertically or horizontally,
• Tubes are installed in a shell either fixed or floating,
or pull through type tube bundle,
 
The wind chill, which is experienced on a cold. Windy day, is related to increased heat
transfer from exposed human skin to the surrounding atmosphere. Consider a layer of
fatty tissues 3 mm thick and maintained at 360C. On a calm day convective H.T. coefficient
25 W/m2.K but during wind @ 30km/h , convective coefficient becomes 65 W/m2.K. In
both cases ambient air temperature is –150C,
a) What is a ratio of heat loss per unit area from skin for calm and windy day?
b) What will be the skin outer surface temperature on both days?
Tube pitch & Tube Layouts:
The shortest center-to-center distance between the adjacent
tubes is called as tube pitch.
Tubes arranged in a triangular or square layout, known as
triangular or square pitch.
Square pitch gives lower shell side pressure drop than
triangular pitch.
Square pitch is good for easy cleaning whereas triangular
pitch gives more number tubes for same space available
Unless shell side fluid fouls badly, triangular pitch is used.
TEMA standards specify a minimum center to center
distance 1.25 times outside diameter of the tubes for
triangular pitch and a minimum cleaning lane of ¼ inch for
square pitch.
Tube sheet:
• It is essentially a flat circular plate. A large number of holes are drilled
in the tube sheet according to the pitch requirements.

1-2 S&T Heat Exchanger

1-1 S&T Heat Exchanger
Baffles:
The baffles are installed in the shell
1) To increase the rate of heat transfer by increasing the
velocity and turbulence of the shell side fluid
2) It helps as structural supports for tubes and dampers
against vibration.
3) The baffles cause the fluid to flow through shell at
right angles to the axes of the tubes (Cross flow).

OR
Baffles promote cross flow, wakes,
eddies, and create turbulaces
To avoid the bypassing of the shell side fluid the
clearance between the baffles and shell, and baffles
and tubes must be minimum.
The centre-to-centre distance between adjacent baffles
is known as baffle spacing or baffle pitch.
The baffle space should not be greater than the inside
diameter of the shell and should not less than the one-
fifth if the inside diameter of the shell.
The optimum baffle spacing is 0.3 to 0.50 times the
shell diameter
25% cutoff baffles
 • Single pass 1-1 exchanger:
Shell & Tube
H. Exs. Can
be used for
sensible and
Latent heat
transfer
 General Design of Heat Exchange Equipment

General design practices :

The design of heat exchange equipment is based on general
principles ( discussed Ch # 11 to 14 ).
From mass and energy balance HT area is calculated.
Quantities to be evaluated are LMTD, hi, hio, ho , Uc, UD, Rdi, Rdi,
ΔP for tube side and shell side.
The final design is based on certain compromises, e.g.
i. engineering judgment to give best overall performance,
ii. Subject to considerable uncertainty,
iii. available facilities, space, funds and practices.
 Designs are accomplished in accordance with various codes &
standards ( TEMA, ASME, API etc.)
 Designing also includes material of construction, tube & shell
diameters and length, pitches, clearance, baffle spacing, number
of passes, and so forth.
 Design should fallow the fallowing rules of thumb;
i. A high fluid velocity pass through small tubes, leads to improve
HT coefficients but increase friction & pumping cost ,
ii. High pressure streams should pass through shell because of
thickness of shell walls,
iii. More fouling fluid may pass through the tubes to avoid the dirt
accumulation on the outer surface,
 Attempt to optimize the design of individual equipment by
formal procedure, to balance;
i. HT area to minimize fixed cost,
ii. Utility cost to minimize operational cost,
iii. in processing plants network of HT equipments are developed to minimize
investment and operating costs
Limitations:
It occupy more space
Cannot obtain high velocities hence low heat transfer
coefficients.
No solution for expansion problems.
 MULTI PASS HEAT EXCHANGERS:
• Unlike single pass exchangers, multi pass exchangers are used
to lengthen the time for the same H.T. area for heating or
cooling of streams .
• Number of passes refers to the tube side fluid that how many
times passes through the tubes to attain the desired
temperature;
Advantages
Multi pass construction decreases the cross section of the fluid
path but; Disadvantages:
i. increases the fluid velocity 1) Exchanger is more complicated
ii. enhance the contact time between hot and cold streams 2) Friction losses increase because
of high velocities, longer path
iii. improve corresponding HT Coefficient/s.
3) Multiple of entrance and exit
iv. Solution to expansion problems losses
Can a simple LMTD be applied in multi-pass heat
exchangers? If not, what changes are required in LMTD?
In multi-pass heat exchangers LMTD is to
be multiplied by a correction factor;
True temperature difference = Ft * LMTD
where Ft=correction factor
For 1–1 heat exchanger Ft=1.
Ft = f (R,S)
where R and S are temperature ratios.
R= (T1-T2)/(t2-t1)
S= (t2-t1)/ (T1-t1)
where,
T1 = Hot fluid inlet temp. Ft
T2 =Hot fluid outlet temp.
t1 = cold fluid inlet temp.
t2 = cold fluid outlet temp.
S
1-2 heat exchangers:
 2-4 Pass Heat exchangers
Most shell-and-tube heat exchangers are either 1, 2, or4 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.
1-2 heat exchanger has an important limitations because of
i. In parallel flow pass ,the exchanger is unable to bring the fluid
temperatures too close.
ii. 2- 4 pass H. Exchangers designs are common because the fluid can enter &
exit on the same side which makes construction simpler.
iii. The heat recovery is poor.
Therefore 2-4 pass heat exchangers are preferred due to high velocity and
large H.T. Coefficient than 1-2 Exchanger with same flow rates.
H.T. coefficients in shell & tube heat exchangers:
The shell and tube side individual or overall heat transfer coefficients
can be measured, calculated or can be taken from literature,.
Home Task
The Optimum thermal design of S&T H.Ex. Involves many interacting
parameters which are summarized as
 CHOICE OF TUBE / SHELL SIDE FLUIDS
• Several factors are important to decide which fluid should pass through the tubes
or the shell side, summarized in the fallowing table.

• If corrosion is not a problem but one of the fluid is dirty and likely to form deposits on the wall,
that fluid should be inside the tubes, since it is easier to clean inside the tubes than the outside.
• Very hot fluids are placed inside the tube for reasons of safety and heat economy.
• Finally, the decision might be based on which arrangement gives higher overall heat transfer
coefficients or lower pressure drop.
• Very viscous liquids are often passes though shell side, because flow across the tubes promotes
turbulences to give better heat transfer than to have laminar flow in tubes.
Problem 7.5
*Process Heat Transfer by D. Q Kern
Design of Shell and Tube Heat Transfer
 Cross Flow exchangers
• In some exchangers, such as air/gas heaters, the shell is rectangular and the
number of tubes in each row would be the same.
• Flow is directly across the tubes, and baffles are not needed.
• For the shell-side heat transfer coefficient in a crossflow exchanger, the
following equation is recommended.
 Heat transfer units

• One method of characterizing the heat-exchanger performance is to

determine the number of heat-transfer units NH.
• For a two fluid counter flow exchanger NH is defined as the
temperature difference, or driving force in the exchanger.

• Transfer units can be based on either streams, but generally the

streams with lower capacity is chosen.
• The temperature change is always taken as a positive number.
• When the specific heat and the overall heat transfer coefficient are constant,
the average driving force is the mean temperature difference ΔTL . If the cold
stream has the lower capacity and thus the greater change in temperature,
NH is defined as:

• To find the temperature change as a function of NH the basic equation for

heat transfer is integrated as follows:
• The effectiveness of the heat exchanger is define as the actual
temperature change divided by the maximum possible change.
• When both streams change temperature but by
different amounts
• the effectiveness is defined as the temperature
change for the stream with the lower capacity
divided by the maximum possible change, and the
effectiveness depends on the number of transfer
units and the capacity ratio Rc :
Design of Shell and Tube Heat Transfer
Problem 7.5
*Process Heat Transfer by D. Q Kern
FT