Design shell and tube heat exchanger

In this design will be consider the thermal design to deal with it .before determining over all heat transfer we should

start with the logarithmic mean temperature ∆𝑇𝑙𝑚 is given by :

(𝑇1−𝑡2)−(𝑇2−𝑡1)
∆𝑇𝑙𝑚 = (𝑇1−𝑡2) (1)
𝑙𝑛
(𝑇2−𝑡1)

∆𝑇𝑙𝑚 is log mean temperature difference, T1 is hot fluid temperature, inlet, T2 is hot fluid temperature, outlet, t1 is

cold fluids temperature, inlet, and t2 is cold fluid temperature, outlet. Equation 1 can be used only when there is no

change in the specific heats, the overall heat-transfer coefficient is constant, and there are no heat losses. Ater that to

get a good value of the the mean temperature difference ∆𝑇𝑚 will deal with this equation below :

∆𝑇𝑚 = Ft ∆𝑇𝑙𝑚 (2)

Where ∆𝑇𝑚 is true temperature difference, the mean temperature difference for use in

The design and Ft is the temperature correction factor. The correction factor is a function of the number of tube and

shell passes, and the shell and tube fluid temperatures. It is ordinarily correlated as a function of two dimensionless

temperature ratio:

( 𝑇1−𝑇2 )
𝑅= (3)
( 𝑡2−𝑡1 )
 Figure 1: Temperature profiles (a) Counter-current flow (b) 1 : 2 exchanger (c) Temperature cross
Then

(𝑡2−𝑡1 )
𝑆= (4)
(𝑇1−𝑡1 )

Where R is equal to the shell-side fluid flow-rate times the fluid mean specific heat; divided by the tube-side fluid

flow-rate times the tube-side fluid specific heat. S is a measure of the temperature efficiency of the exchanger. The

correction factor is given by:

(1−𝑆 )
√( 𝑅 2 +1) ln[ ]
(1−𝑅𝑆 )
𝐹𝑡 = (5)
2−𝑆 (𝑅+1− √( 𝑅2 +1) )
(𝑅−1 ) ln[ ]
2−𝑆 (𝑅+1+ √( 𝑅2 +1) )

The equation (6) is for a 1 shell an 2 tube pass exchanger can be used for any exchanger with an even number of tube

passes, and is plotted in Figure 2. The correction factor for 2 shell passes and 4, or multiples of 4, tube passes is shown

in Figure 4, and that for divided and split flow shells in Figures 5 and 6.
Figure 2:Temperature correction factor: one shell pass; two or more even tube passes
There are some assumptions should be considered when using equation (5) are made in the derivation of the

temperature correction factor Ft, in addition to those made for the calculation of the log mean temperature

Difference: the heat transfer areas in each pass hold be equal, the overall heat-transfer coefficient should be constant,

and the temperature of the shell-side fluid in any pass is constant across any cross-section .There is no leakage of fluid

between shell passes .

Figure 3:Temperature correction factor: two shell passes; four or multiples of four tube passes
Figure 4:Temperature correction factor: divided-flow shell; two or more even-tube passes

Figure 5 :Temperature correction factor, split flow shell, 2 tube pass

TUBE-SIDE HEAT-TRANSFER COEFFICIENT AND PRESSURE DROP (SINGLE PHASE)

Heat-transfer information for turbulent flow inside conduits of uniform cross-area are mostly correlated by a

mathematical statement of the structure:

𝜇 𝑐
𝑁𝑢 = 𝐶 𝑅𝐸 𝑎 𝑃𝑏 ( ) (6)
𝜇𝑤

where Nu is Nusselt number =( hi de/ kf ), Re is Reynolds number is ( ρ ut de / µ )is ( Gt de/ µ), Pr is Prandtl number
𝑜
= ( Cp µ /kf ) and hi is inside coefficient,( 𝑊/𝑚2 𝐶 ) , de is equivalent (or hydraulic mean) diameter, (m)

4 × cross−sectional area for flow

de = = di for tubes (7)
𝑤𝑒𝑡𝑡𝑒𝑑 perimeter

where ut = fluid velocity, m/s, kf = fluid thermal conductivity, 𝑊/𝑚𝑜 𝐶, Gt = mass velocity, mass flow per unit area,

𝑘𝑔/𝑚2 𝑠, µ = fluid viscosity at the bulk fluid temperature, 𝑁𝑠/𝑚2 , µw = fluid viscosity at the wall, Cp = fluid specific

heat, heat capacity, 𝐽/𝑘𝑔𝑜 𝐶.Where Reynolds number is commonly taken as 0.8. That for the Prandtl number can be

taken 0.3 for cooling and 0.4 for heating.

µ 0.14
𝑁𝑢 = 𝐶 𝑅𝑒 0.8 𝑃𝑟 0.33 ( ) (8)
µ𝑤

Where C = 0.021 for gases = 0.021, for non-viscous liquids =0.023 , for viscous liquids =0.023 .

Next getting Stanton number St which is in the following equation:

𝑆𝑡 = 𝐸𝑅𝑒 −0.205 𝑃𝑟 −0.505 (9)

where St = Stanton number = ( Nu / Re Pr) = ( hi/ρ ut Cp ) and E = 0.0225 𝑒𝑥𝑝( 0.0225(𝑙𝑛 𝑃𝑟 2 ) .

for the Laminar flow we will use this formula :

 𝑑𝑒 0.33 µ 0.14
𝑁𝑢 = 1.86 ( 𝑅𝑒𝑃𝑟 )0.33 ( ) ( ) (10)
𝐿 µ𝑤

After that getting the Heat-transfer factor 𝑗ℎ by this equation:

ℎ𝑖 𝑑𝑖 µ 0.14
= 𝑗ℎ RePr 0.33 ( ) (11)
𝑘𝑓 µ𝑤

The utilization of the 𝑗ℎ factor enables information for laminar and turbulent flow to be spoken to on the same graph;

Figure 6. The 𝑗ℎ value got from Figure 6 can be utilized with mathematical equation (11) to evaluate the heat transfer

Figure 6: Tube-side heat-transfer factor

coefficients for heat-exchanger tubes and commercial pipes.

Tube-side pressure drop

The tube friction loss can be ascertained utilizing the well known mathematical equation for pressure-drop loss in

pipes . The essential equation for isothermal flow in pipes is:

2
𝐿′ 𝜌𝑢𝑓
△ 𝑃 = 8𝑗𝑓 ( ) (12)
𝑑𝑖 2
where 𝑗𝑓 is the dimensionless friction factor and 𝐿′ is the effective pipe length. The flow in a heat exchanger will

unmistakably not be isothermal, and this is took into account by including an empirical correction factor to account

for the change in physical properties with temperature. Ordinarily just the adjustment in viscosity is considered :

−𝑚 2
𝐿′ µ 𝜌𝑢𝑓
△ 𝑃𝑡 = 𝑁𝑝 [ 8𝑗𝑓 ( ) ( ) + 2.5 ] (13)
𝑑𝑖 µ𝑤 2

Where 𝑚 = 0.25 for laminar flow, Re < 2100, 0.14 for turbulent flow, Re > 2100. △ 𝑃𝑡 is tube-side pressure drop,

N/𝑚2 (Pa), 𝑁𝑝 is number of tube-side passes, 𝑢𝑓 tube-side velocity (m/s), L= length of one tube. Values of 𝑗𝑓 for heat

exchanger tubes can be obtained from Figure 7.

Figure 7: Tube-side friction factors

Shell-side heat-transfer coefficient and pressure drop for a single shell

( 𝑝𝑡 −𝑑𝑜 )𝐷𝑠 𝑙𝐵
𝐴𝑠 = (14)
𝑝𝑡
Where 𝑝𝑡 = tube pitch, 𝑑𝑜 = tube outside diameter, 𝐷𝑠 = shell inside diameter (m), 𝑙𝐵 = baffle spacing (m), The term

( 𝑝𝑡 −𝑑𝑜 )
= ratio of the clearance between tubes and the total distance between tube centers. Then shell-side mass
𝑝𝑡

velocity 𝐺𝑠 and the linear velocity 𝑢𝑠 :

𝐺𝑠 = 𝑊𝑠 /𝐴𝑠 (15)

𝑢𝑠 = 𝐺𝑠 /𝜌𝑠 (16)

Where 𝑊𝑠 = fluid flow-rate on the shell-side (kg/s), 𝜌𝑠 = shell-side fluid density (𝑘𝑔/𝑚3 ).After that the shell-side

equivalent diameter (hydraulic diameter), For an equilateral triangular pitch arrangement:

𝑝 𝑑2
4(( 2𝑡 ×0.87 𝑝𝑡 − 0.5 𝜋 4𝑜 ))

𝜋𝑑2
𝑜
𝑑𝑒 = (17)
2

where 𝑑𝑒 is equivalent diameter (m). Next finding the shell-side Reynolds number, given by:

(𝐺𝑠 𝑑𝑒 ) ( 𝑢𝑠 𝑑𝑒 ρ)
𝑅𝑒 = = (18)
µ µ

Then getting the value of 𝑗ℎ from Figure 8 for the selected baffle cut and tube arrangement.
Figure 8: Shell-side heat-transfer factors, segmental baffles
Figure 9:Shell-side friction factors, segmental baffles

After that finding shell-side heat transfer coefficient ℎ𝑠 from:

ℎ𝑠 𝑑𝑒 µ 0.14
𝑁𝑢 = = 𝑗𝑠 𝑅𝑒𝑃𝑟 0.33 ( ) (19)
𝑘𝑓 µ𝑤

Last thing getting the shell-side pressure drop below equation and Shell-side friction factor 𝑗𝑓 form finger 9:

2 0.14
𝐷𝑠 𝐿 𝜌𝑢𝑓 µ
∆𝑃𝑠 = 8𝑗𝑓 ( ) ( ) ( ) (20)
𝑑𝑒 𝑙𝑏 2 µ𝑤

𝐿 𝐿
where L is the tube length, is the baffle spacing. The term ( ) is the number of times the flow crosses the tube
𝑙𝑏 𝑙𝑏

bundle is the ( Nb + 1 (, where Nb is the number of baffles.