Académique Documents
Professionnel Documents
Culture Documents
Lecture Objectives
After this lecture, you should:
Be familiar with the major types of
available heat-exchange equipment, with
particular emphasis on shell-and-tube heat
exchangers.
o Know how to estimate overall heat
transfer coefficients for a shell-and-tube
heat exchanger.
p Know how to compute pressure drops on
both sides of a shell-and-tube heat
exchanger.
q Be able to perform mechanical design of the
most appropriate shell-and-tube heat exchanger
to meet desired duty and pressure drops.
n
7-2
Segmental baffles
Holes drilled
to tube size
7-3
Segmental baffles
Holes drilled
to tube size
7-4
7-5
7-6
7-7
http://www.tema.org
7 - 10
Steam boilers
Distillation column reboiler
Heating distillation column feed stream
Heating reactor feed stream
Heating a heating stream
Reactor (reaction inside furnace coil)
Operation principles:
Process stream flows through a c
oil
7 - 14
Convection
section
Radiation
section
Gas
burners
Dividing
wall
7 - 15
7 - 16
Temperature-Driving Forces
The rate of heat transfer in an shell-and-tube
exchanger is computed as:
Q = mc (HC ,out - HC ,in ) = mh (HH ,out - HH ,in )
Assuming (1) steady-state; (2) counter- or cocurrent flow; (3) constant overall heat transfer
coefficient; (4) no phase changes on either side; and
(5) negligible heat losses:
Q = U A TLM
where:
TLM
(T
h ,in
Th ,in -Tc
,out
ln
h ,out -Tc ,in
T
7 - 17
Temperature-Driving Forces
For multiple-pass shell-and-tube exchangers, the
flow directions of the two fluids are combinations of
countercurrent and co-current flow, reducing the
effective value of TLM . For a 1-2 exchanger, with
assumptions 1, 3, 4 and 5:
It is desirable to
Q = U A TLM
have a value of FT
FT for 1-2
of 0.85 or higher.
FT
Values below 0.75
where: FT =
are unacceptable.
ln [ (1 S ) ( 1 RS )] R 2 + 1
FT = 1 for phase
Nagle (1933)
2 S R + 1 R 2 + 1
( R 1 ) ln
2 S R + 1 + R + 1 change in duty fluid
,in
Temperature-Driving Forces
FT for 1-2 shell-and-tube exchanger.
7 - 19
Example 13.5
A hot stream is cooled from 200 to 140 oF by a cold
stream entering at 100 oF and exiting at 190 oF.
Determine the true TLM and select the appropriate
shell-and-tube configuration.
o
40 - 10 = 21.6 F
Solution:
40
FT for 1-2
FT for 4-8
R = 0.67
FT = 0.85
S = 0.9
Heat Exchanger Design
7 - 22
Class Exercise 1
A hot stream is cooled from 1,150 to 560 oF by a cold stream entering at
400 oF and exiting at 1,000 oF.
Determine the true TLM and select the appropriate
shell-and-tube configuration.
Solution:
For counter-current flow: TLM =
For multiple-pass exchangers:
Th ,in -Th ,out
=
R=
Tc ,out -Tc ,in
Tc ,out -Tc ,in
=
S=
Th ,in -Tc ,in
7 - 23
Configuration
J
H
h D C p
= I I
1 3
0.14
k k W
vs.
DI GT
W
Tube-side mass flux: GT = T ,
A
I 2
= D
4
AT
(b) for shell-side, dimensionless heat transfer coefficient:
J
H
h D C p
= O O
1 3
vs.
0.14
k k W
7 - 24
AS
deGS
=
S
d S C 'B
144PT
Heat Exchanger Design
FT
PT
PT
de =
4 ( wetted area )
wetted perimeter
4PT 2 D2O
pitch: de =
+ pitch: d =
D
O
W
Shell-side mass flux: G = S ,
S
AS
12PT 2 D2O
D
O
deS C 'B
144PT
2
WS total shell side mass flow (lb/hr), AS shell crossflow area (ft )
dS shell diameter (in),B baffle spacing (in)
7 - 25
1
1 t A A
+
F ,O
Outside
fouling
F ,O
7 - 26
+R
AI
F ,I
Internal
fouling
Wall
resistance
A = D
A
Udirty =
hO kW AM hI AI
External film
resistance
= D
A
L
I
1
1 D O
D
+ +
+ R O
F ,ID
h O hI D I
I
Internal film
resistance
L (DO DI )
= log D D
( O I)
1
Uclean =
1 DO
h + h D
O I I
0.1
4
T T
Pr = 4N v [psi]
2g
The total pressure drop is: P = Pt + Pr [psi]
7 - 27
2
fGs DS (NB + 1 )
[psi]
10
5.22 10 e D S ( w )0.14
NB number of baffles
De equivalent diameter [ft]
S specific gravity
7 - 28
7 - 30
Fluid
velocity
Heat
transfer
coefficient
Heat Exchanger Design
Shell diameter
Tube diameter
Tube length
Tube packing configuration (pitch) and spacing
Number of tube and shell passes
Class Exercise 2
Design a shell-and-tube heat exchanger to preheat
a stream of 30 T/hr containing ethylbenzene and
styrene from 10 to 97 oC.
Additional data:
Density 856 kgm-3, Viscosity 0.4765 cP,
Specific heat 0.428 kcalkg-1oC-1,
Thermal conductivity 0.133 kcalhr-1m-1oC-1
Heat supply medium Saturated steam at 10 barg.
Notes: (a) For this application, the process fluid is fed to the
tubes.
(b) Maximum P in the process side is 0.8 bar.
(c) Fouling - process: 0.0002, steam: 0.0001 hr m2/kcal
7 - 32
Cold side
Hot Side
Notes
Tube side
Shell side
EB/Styrene Sat. steam Q = mtubeCptubeT
30,000
2,113
=30,0000.428(97-10)
= 1,117,080 kcal/hr
10
115
msteam = Q/
97
115
= 528.7 kcal/kg
Units
kg/hr
Inlet Temp
Outlet Temp.
kg/m3
Density
Viscosity
cP
o
856
0.9712
0.4765
0.1262
Cp
Kcal/kg C
0.428
Kcal/hr cm
0.133
0.0002
Fouling factor
7 - 33
hr m /kcal
0.0001
Units
o
Value
18
105
LMTD
49.33
c-LMTD
49.33
T1 = Ti - to
T2 = To - ti
C. Heat Duty
1 05 1 8
T 2 T 1
=
= 4 9 .3 3
ln ( T 2 T 1 ) ln (1 0 5 1 8 )
LM T D =
c-LMTD = TLMFT
FT = 1 (phase change)
UEstimated
AEstimated
7 - 34
Kcal/hr
Notes
Units
Value
Notes
Tube passes, NT
Assumed
Shell passes, NS
Assumed
Tubing O.D., DO
0.0254
Tubing I.D., DI
0.0198
m/sec
1.4
Tube velocity, VT
Tube c-section (I.D.),AT
qT in each tube
m2
m3/hr
92
6
qT = AT VT = 4.3110-4 m3/sec
N = m/(qT )
= 30,000/(1.55856)
N NT/NS
Accepted industry standard
Value
Variable
44
Pitch
Shell I.D., ds
AAvailable
U-1
0.4382
51
Notes
A = NSNTotalLDO = 44 m2
U-pitch selected (why?)
17 shell holds 106 tubes.
A = NS 106LDO = 51 m2
Note that the available heat transfer area, 51 m2, is larger than the value
estimated previously, 23-46 m2, so can be reduced!
We shall now compute the heat transfer coefficient and the pressure drops in
the tube and shell, and compare with our targets.
7 - 36
3.0810-4
-4
c-section area/pass, AT
8.2110
GT
Kg/(hr m )
AT = ( DI2)/4
AT = AT(106/4)
3,653,462 GT = mtube/AT
ReT
42,304
Re = GTDI/
JH
130
See Item 10
Pr
5.52
Pr = Cp/K
-0.14
= (/W)
Assume = W
Kcal/(hr m2 oC)
1,538
Kcal/(hr m2 oC)
7,342
Kcal/(hr m2 oC)
UService
Kcal/(hr m2 oC)
444
Kcal/(hr m2 oC)
490-980
UEstimated
Uclean =
Udirty =
7 - 38
Kcal/(hr m2 oC)
1,033
756
UService = Q/(AAvailablec-LMTD)
1
1 D O
+
hO hI DI
RF ,O
1
1 D O
+
+
h O h ID I
D
+ RF ,I O
ID
42,304
Re = GTDI/
ft2/in2
0.000185
See Item 11
Pt, friction
psi
2.80
Pr, return
psi
5.30
bar
0.55
7 - 39
Pr = 4NTVt2/2g
= 444.592/2*g
= 5.3 psi
PTOT = Pt + Pr = 8.1 psi
in
17.25
14
in
0.72
in
0.25
NB + 1
de
C
AS
ft2
0.413
2
GS
Kg/(hr m )
Res
2
ft /in
bar
PS
Computed as de = 0.72
C = PT - DO
AS=dSCB/(PT144)
55,030
GS = msteam/AS
22,152
Re = GSde/s
0.0015
0.08
Note that the shell P is usually much lower than the tube value.
7 - 40
Units
Kcal/(hr m2 oC)
Target
490-970
Actual
444-1,033
m2
23-46
51
bar
0.8
0.55
Ptubes
Summary
After reviewing the materials in this lecture, you
should:
n Be familiar with the major types of
available
heat-exchange equipment, with particular
emphasis on shell-and-tube heat exchangers.
o Know how to estimate overall heat transfer
coefficients, including the effect of fouling.
p
7 - 42
7 - 43
130
42,300
7 - 44
0.000185
42,300
7 - 45
7 - 46
0.0015
22,195
7 - 47