Process heat transfer Double pipe heat

exchanger

Discussion
Double

pipe heat exchanger

Internal parts
Diagrams
Flow arrangements
Calculations for L.M.T.D
Advantages
Limitations
Comparison with conventional shall
and tube heat exchanger
Design types
Cost estimation
Numerical problems

HEAT EXCHANGER:
Heat exchanger is a device in which two fluid streams ,
one hot & another cold are brought into thermal contact
in order to effect transfer of heat from the hot fluid
stream to the cold.
DOUBLE PIPE HEAT EXCHANGER:
A typical double pipe heat exchanger basically consists
of a tube or pipe fixed concentrically inside a larger pipe
or tube.
OR
Heat exchanger which are used when the flow rates of
the fluids and the heat duty are small (less than 500 kW)

Construction of double pipe

Hair pin: union of two legs

hairpin construction is preferred
because it requires less space
Packing & gland: The packing
and gland provides sealing to the
annulus and support the inner pipe.
Return bend: The opposite ends
are joined by a U-bend through
welded joints.
Support lugs: Support lugs may
be fitted at these ends to hold the
inner pipe position.
Flange: The outer pipes are joined
by flanges at the return ends in
order that the assembly may be
opened or dismantled for cleaning
and maintenance.
Union joint: For joining the inner
tube with U-bend.

Contd.

Nozzles: small sections of pipes welded to the shell or to the channel

which acts as the inlet or outlet of the fluids are called nozzles.
Gaskets: Gaskets are placed between the two flanges to make the joint
leak-free.
Different types of gaskets

Nitrile rubber.

Used up to 110 oC for mineral oils, dilute

mineral acids, and aliphatic hydrocarbons.

EPDM.
(ethylene-propylene-dienemonomer)

Used up to 160 oC for mineral acids, or

bases, aqeuous solutions or steam

Viton. ( copolymer of vinylidine

flouride and hexafluoro-propylene)

Used up to 100 oC for hydrocarbons and

chlorinated hydrocarbons

Double Pipe Heat Exchangers

fluid flow passages &

configuration
Basically there
are two flow
arrangements of
double pipe heat
exchanger:
Co-current
Counter current
configuration
Series & parallel
arrangement

Co-current

counter current

Counter current
max. heat transfer within minimum area due to more
L.M.T.D
Co-current
Used for viscous fluids & gives lesser value of L.M.T.D
Co & counter current gives same value of L.M.T.D if one
of the fluid stream is isothermal (e.g steam)

Series-parallel arrangement
This configuration is used when value of pressure
exceeds its limits (500psig shell side and 500 psig tube
side) .pressure drop problem can be solved by:
Reversing the location of streams
By-passing one of the fluid streams
Dividing of stream at higher pressure drop( seriesparallel arrag.)

Log Mean Temperature evaluation

TLn

COUNTER CURRENT FLOW

CO CURRENT FLOW
1

2
T3

T4

T6

T1

T1
T2

T6

Wall

T7

T2

T8
T9

T10

A
T10

T1

T4

T5

T10

T2

T1
T6

T3

T9

T8
T7

ParallelFlow

T4

T2

T5

T3

T6

T7

T8

T9

CounterCurrentFlow

T1 Thin Tcin T3 T7

T1 Thin Tcout T3 T7

T2 Thout Tcout T6 T10

T2 Thout Tcin T6 T10

T2 T1
T2

ln
T1

ADVANTAGES.

Compactness
Very high heat transfer coefficients on both sides
of the exchanger
Close approach temperatures in counter-current
flow
Ease of maintenance.
Heat transfer area can be added or subtracted
with out complete dismantling the equipment.
High pressure ranges
(30 MPa shell side , 140 MPa tube side)
High temperatures range (600 C)

CONTD..

Ease of inspection on both sides

Ease of cleaning
Low cost
No Local over heating and possibility of stagnant
zones is also reduced
Fouling tendency is less
low pressure loss
Used for small applications

LIMITATIONS

It is not as cost effective as most shell and tube

exchangers

It requires special gaskets

Limited volumetric capacity

Fouling

Contd..
Fouling :
formation of a scale or a deposit on a heat transfer
surface is called fouling
Types of fouling:
Precipitation fouling ( due to dissolved salts of Ca
& Mg )
Particulate fouling( due to suspended particles )
Corrosion fouling
Chemical reaction fouling (due to deposits formed
by chemical reactions)
Bio fouling ( due to the attachment of bio chemical
species )
Solidification fouling ( due to sub cooling of fluids )

Comparison with shell & tube heat

exchanger
shell & tube heat exchangers are:
designed to withstand the greatest temperature and
pressure condition
Ideal for large scale applications
Commonly used in petrochemical industry where
dangerous substances are present (protective
shell)
Consists of very bulky or heavy construction, baffles are
used to increase mixing
Subject to water hammer and corrosion
High pressure loses

Design types
In case of any design equipment , the design of a heat exchanger may be
divided into two parts.

Process design
(Thermal design)

Design
types

Mechanical design

Estimation of heat transfer area.

Material of construction
Determination of tube diameter.
Thickness of tubes
Number & length of tubes.
Flanges, gaskets, support design
Tube layout ( series or parallel )
Shell & tube side pressure drops.(hydraulic design)

Mechanical
design
Double pipe Heat exchangers
can be made with various
materials:
Carbon steel
Alloy steels
Copper alloys
Exotic materials (tantalum)

Cost of heat exchanger

Some of the major factors which influence the cost of heat

exchanger are :
Heat transfer area
Tube diameter and thickness
Tube length
Pressure of fluids
Materials of construction
Special design features ( finned surface,U-bends,removeable
bundles e.t.c )

DESIGN STEPS WITH SOLVED

EXAMPLE
1)Thermal design.
2) Hydraulic design.

ASSUMPTIONS

The heat exchanger operates under steady state

conditions.
No phase change occurs: both fluids are single phase
and are unmixed.
Heat losses are negligible
The temperature in the fluid streams is uniform over
the flow cross section.
There is no thermal energy source or sink in the heat
exchanger.
The fluids have constant specific heats.
The fouling resistance is negligible.

In thermal design we
tabulate physical
properties of:
hot stream(Benzene)
cold stream(Water)

Benzene(hot stream)
entering temp.= 75C
Leaving temp.=50C
average temp=62.5C
Sp.heat=1.88 kJ/kg C
Viscosity=0.37cP
density = 860 kg./m3
thermal conductivity =
0.154 W/m K.
Flow rate = 1000 Kg/hr
outer pipe spec.
i.d. = 41 mm
o.d. = 48 mm.
LMTD = ?
Uo = ?

Water(cold stream)
entering temp.= 30C
Leaving temp.=40C
average temp=35C
Sp.heat=4.187 kJ/kg C
Viscosity=0.8cP
density = 1000 kg./m3
thermal conductivity =
0.623 W/m K.
Flow rate = ?
Inner tube spec.
i.d=21mm
O.d=25.4mm
Wall thickness=2.2mm
thermal conductivity of
wall=74.5 W/m K.

Selection of tube & pipe fluid & flow

passage
type

Flow rates
Cannot be considered because water side flow rate is not
given
Flow areas
Higher mass flow rate stream is passed through greater
flow area which cannot be considered because we don't
know which stream is of higher flow rate
Tube side fluid
As we know that water causes a lot of fouling and
corrosion hence we will take water in the tube side in this
way it would cause lesser damage to the heat exchanger.
Pipe side/annulus side
Benzene will be taken on annulus side
Flow arrangement
Counter current flow is selected because it reduces the
required surface area

General design equation &

steps Q =U A (T)
o

Step 1: Calculate (T) LMTD

Step 2: Calculate heat duty Q
Step 3: Calculate overall heat transfer coefficient on the basis of outer diameter of tube
Putting all the three values will give us the
required heat transmission area of double pipe.
Such a problem in which we have to calculate
size of heat exchanger is called sizing problem

Calculation of LMTD (step

1)
benzene 75 C
water
40 C

t1=75-40=35C
L.M.T.D= (t1- t2) / Ln (t1/ t2)
LMTD =(35 20)/Ln(35/20)
= 26.8C

50 C
30 C

t2=50-30=20C

Heat duty calculations(step

2)
SOLUTION
(a) 1000 kg of benzene is cooled from 75C to 50C per hour.
Therefore,
Heat duty (Q) = m Cp (T2-T1)
= (1000 kg,/h)(1.88 kJ/kg C)(75 50)C
= 47,000 kJ/h
Heat given by the hot stream = Heat taken by the cold stream

Water is heated from 30C to 40C Therefore,

Water flow rate = Q / Cp x (t2-t1)
= 47000/(4187)(10)
=1122 kg/h

overall heat transfer coefficient(step 3)

Calculate convective heat transfer coefficient

for tube side (hi).
Calculate convective heat transfer coefficient
for shell side (ho).
Outside surface area of tube (Ao)
Inside surface area of tube (Ai )
Mean surface area (Am)
1/Uo=1/ho +(Ao/Am)x(ro-ri/kw)+Ao/Ai(1/hi)

Calculating hi( tube side water )

Velocity = volumetric flow rate / flow area
=0.9 m/sec
Reynolds number, Re = dvp/u
= (21 x 10-3)(0.9)(1000)/8 x 10-4
=23,625
Prandtl number, Pr = Cpu/k
=(4.187)(1000)(8 x 10-4)/0.623
= 5.37
Use of Dittus-Boelter equation to calculate hi,
Nu = hidi/k = 0.023(Re)0.8(Pr)0.3
= (0.023)(23,625)0.8 (5.37)0.3 =120
Thus,hi=120x(k/di)=35660W/m2C

Calculating ho( annulus side

for annulus)calculation we calculate hydraulic diameter
benzene
Flow area annulus = inner cross-section of the pipe - outer cross-section of the
tube

= Pi/4(iD2) - Pi/4(OD1)=8.13x10-4 m2

wetted perimeter= Pi(iD2+OD1)=0.2086m

hydraulic diameter of annulus dh=4 x ( flow area/wetted perimeter)
=0.0156m

Contd
Benzene mass flow rate = 1000 kg/h
Benzene volumetric flow rate = (1000)/(860) = 1.163 m 3/hr
Velocity = volumetric flow rate / flow area = 0.397 m/s
Reynolds number, Re = dvp/u
= 14395
Prandtl number,Pr = Cpu/k
= 4.51
Calculation of ho from the Dittus-Boelter equation
Nu = hodi/k = 0.023(Re)0.8(Pr)0.3
=(0.023)(14395)0.8(4.51)0.4 = 89.12

ho = (89.12 x k/dh) = 879.8W/m2C

Contd
outside area of tube = A0 = OD L = (0.0254)(L)
inside area of tube = Ai = ID L = (0.021)(L)
Am = (OD-ID) / Ln (OD/ID)
= (0.0254 - 0.021)(L)/ Ln (0.0254/0.021)
= 0.023 (L)
A0/Am = 1.098
A0/Ai = 1.21
1/Uo=1/ho +(Ao/Am)x(ro-ri/kw)+Ao/Ai(1/hi)
Uo = 662.3W/m2K

Length of double pipe

Now calculate the required area from
Q = UoAoTm
where,
Q = 1122 kg/h
Uo = 662.3W/m2K
Tm= 26.8 C
Ao = Q / UoTm= 0.74m2
Tube length necessary, L = Ao / OD1 L
= 0.74 / (0.0254)
= 9.3 m

Hydraulic design

In hydraulic design involves calculations of

pressure drop on:
The pipe side (annulus side)
The tube side

Contd

P = f G2 L / 2 g p Di
Where,
F = friction factor
G = mass velocity of the fluid
L = length of the tube
G =9.8m/s2
p = density of tube fluid
Di = inside diameter of tube
= dimensionless viscosity ratio
P =pressure drop

P( tube side ) = 1.476 x 10-4 kgf/m2

P( pipe /annulus side ) = 2.50 x 10-4 kgf/m2

Calculation on
software

Auto-cad design (2D &

3D)

DESIGN PROBLEM :
Double Pipe Heat Exchanger

Double pipe lube oil crude oil exchanger:6900lb/hr of

26 API lube oil must be cooled from 450 to 350F by
72500lb/hr of 34 API mid continent crude oil. The
crude oil will be heated from 300 to 310F.

A fouling factor of 0.003 should be provided for each

stream, and the allowable pressure drop on each
stream will be 10psi.

CONTINUED

A number of 20-ft hairpins of 3 by 2inch IPS are

available. How many must be used, and how shall they
be arranged? The viscosity of crude oil may be obtained
from graph. For the lube oil, viscosities are 1.4cp at
500F, 3.0 at 400F and 7.7 at 300F. These are enough to
introduce an error if (u/uw)0.14=1 is assumed.

GIVEN DATA:

Lube Oil:

Mass flow
rate=wL=6900lb/hr

26 API
Entering temp.=450F
Leaving temp.=350F
Viscosity =3.0cp at 400F

Crude Oil:

Mass flow
rate=wc=72500lb/hr

34 API
Entering temp.=300F
Leaving temp.=310F
Viscosity = use graph

(1)HEAT DUTY CALCULATION :

For lube oil: Q=Wcp(T1-T2)

=6900x0.62(450-350)

cp(graph) =427000Btu/hr

. For crude oil:

Q=wcp(t2-t1)
=72500x0.585(310-300)
=427000Btu/hr

cp(graph)

(2)a LMTD Calculation:

LMTD = ( t)a- ( t)b/ln ( t)a/ ( t)b

( t) = 87.5 F

It will be impossible to put the 72,500lb/hr into single pipe or

annulus, since the flow area of each is too small. Assume
it will be employed in two parallel streams.

(2)bTemperature difference (
t):
Hot fluid

Temp.

Cold fluid

Diff.

450 F

Higher temp.

310 F

140 F ( t)a

350 F

Lower temp.

300 F

50 F ( t)b

90 F
( t)a - ( t)b

Concept of caloric
temperature:

In our problem we are given with petroleum fractions so

we wont use arithematic temperatures for evaluating
physical properties. As in case of petroleum fractions,
there viscosities show sharp variations with temperature
and also overall heat transfer coefficient doesnt remain
constant. That is why we will use average caloric
temperature for evaluating physical properties like
viscosity, specific heat etc

(3)Caloric
temperatures:

( t)c/ ( t)h =50/140

= 0.357

Kc factor =0.43
caloric temp. fraction (Fc) =0.395 (graph)

Tc=350x0.395(450-350)=389.5 F
tc =300x0.395(310-300)=304 F

Basic objective:

In order to calculate clean overall heat

transfer coefficient Uc , we require two
things.
ho ( from annulus)
lube oil
hio (from inner pipe) crude oil
Since Uc=hio xho/hio +ho

Concept of outer and inner

diameter:

We will always take inner diameter of inner pipe while

calculating the flow area in tube.
In case of annulus inner diameter of outer pipe and outer
diameter of inner pipe (equivalent diameter) is
considered.. table

Flow area calculations:

Hot fluid (annulus)

D2 =3.068/12 =0.256ft
D1 =2.38/12 =0.199ft
aa = 3.14(D22-D12)/4

=0.0206ft2
Equivalent dia. De=(D22D12)/D1

= 0.13ft

Cold fluid (inner pipe)

D =2.067/12=0.172ft
ap =3.14D2/4
=0.0233ft2
Since two parallel
streams have been
assumed so half will flow
in each pipe.

Mass velocity calculations:

Ga=W/aa
=6900/0.0206
=335000lb/hrft2
At Tc=389.5F =3.0cp
=3x2.42=7.25lb/hrft
Rea=DeGa/=0.13x335000
/7.25=6000
If only two hairpins in
series are required,L/D will
be 2x40/0.13=614
Use L/D=600
jH=20.5

Ga=w/ap
=72500/
(2x0.0233)=1560000lb/hrf
t2
At tc=304F, =0.83cp
Rep=DGp/

=0.172x1560000/2.01=13
3500
jH=320

Calculation of hio and ho :

Tc=389.50F ,
C=0.615Btu/lbF (graph)
K=0.067Btu/hrft2(F/ft)
(graph)
Pr=(c/k)0.33=(0.615x7.2
5/0.067)0.33=4.05

tc =304F
c=0.585Btu/lbF (graph)
K=0.073Btu/hrft2(F/ft)
(graph)
Pr=(c/k)0.33=(0.585x2.0
1/0.073)0.33=2.52

Continued

ho=
jHxk/De(c/k)0.33xa

ho/a
=20.5x0.067x4.05/0.13
=42.7btu/hrft2F

tw=tc+ (ho/a)/(hio/p)+
(ho/a)x(Tc-tc)

hi=
jHxk/D(c/k)0.33x
p
hi/p =
320x0.073x2.52/0.172=
34btu/hrft2F
(hio/p)=(hio/p)x(ID/
OD)
=342x2.067/2.38=297

Continued.

tw=304+42.7/
(297+42.7)x(389.5-304)
=314F
w=6.6x2.42=16lb/fthr
a=(/w)0.14=0.9
ho= ho/a xe
=38.4

As tw is calculated

w=0.77x2.42=1.86

p=(/w)0.14=1.0
ho= hw/p xw
=297x1.0=297

Clean overall & design overall

co-efficient.

Uc=(hioxho)/(hio
ho)=297x38.4/
(297+38.4)=34.0btu/hrft2F

38.4

h (outside) 297

1/Ud=1/Uc+Rd
Rd

34

---

=0.003x2=0.006hrft2F/Btu
Ud=28.2

Uc
Ud

28.2

---

Surface area.

A=Q/(Udxt)=173ft2

External surface per unit ft=0.622ft

Required length=173/0.622=278lin ft
This is equivalent to more than six 20-feet hairpins or
240 lin ft. since two parallel streams are employed, use
eight hairpins or 320 lin ft. The hairpin should have the
annuli connected in series and the tubes in two parallel
banks of four exchangers. the corrected Ud will be
=24.5.the corrected dirt factor will Rd =1/Ud-1/Uc=0.0114

Pressure drop calculations :

De = D2 D1
= 0.058 ft
Rea=( De x Ga ) /u

For Rep =133500

=2680
f = 0.0035+0.264/26800.42
s =0.775 , p=62.5x0.775
= 48.4

f = 0.0035 +
0.0264/1335000.042
= 0.005375
s = 0.076 ,p = 62.5x0.76
=47.5

Continued

Fa = 4f Ga2La / 2Gp2De
=16.07 ft

V=Ga / 3600 x p

= 1.9 fps
Fl =8(v2 /2G)

=0.45 ft
Pa= (16.7 + 0.45) x 48.4
/144
=5.8 Psi
Allowable pressure drop
=10Psi

Fp = 4f Ga2La / 2Gp2De
=25.7 ft
Pp = 25.7 x47.5/144
= 8.5 Psi
Allowable pressure drop
=10Psi

Graphical interpretation:

Pressure drop description:

Designed double pipe heat

exchanger:

Configurated heat exchanger:

Double pipe heat exchange

software calculations:

Software calculations :

Continued

Continued.

Industrial setup flow sheet of

double pipe heat exchanger:

Process description:

Inner outer diameter

description:

Double pipe description:

OD of pipe

ID of pipe
OD of
tube

ID of tube

Graphical interpretation:

Pressure drop description:

Industrial setup flow sheet of

double pipe heat exchanger:

Process description:

Books references

Donald .Q. Kern (1950) ,heat transfer & applications

( 2nd Design problem )
Binay K.Datta,heat transfer principles and applications
( 1st Design problem )
Max S. Peters, Klaus D.Timmerhaus,Ronald E.West
,plant design and economics for chemical engineers (fifth
edition)
Yunus A.Cengel,Heat & Mass transfer,a practical
approach (third edition)
Y.V.C Rao , heat transfer principles
Incropera,F.P.,Dewitt D.P., Fundamentals of Heat and
Mass Transfer, 5th ed.,John Wiley & Sons Inc., NY,2000
Kaka S. Heat exchangers selection, rating & thermal
design CRC Press, Fla, 1998

Internet references

http://chentserver.uwaterloo.ca/courses/Che025Lab/perry/Chap
11.pdf
http://en.wikipedia.org/wiki/Heat_exchanger#Flow_arrangement
http://www.advantageengineering.com/fyi/110/advantageFYI110.
php
http://www.buildingdesign.co.uk/mech/guntner/dry-aircoolers.htm
http://www.engineeringpage.com/heat_exchangers/tema.html
http://www.martechsystems.com/downloads/tech_managingreb
oilerops.pdf
http://www.me.wustl.edu/ME/labs/thermal/me372b5.htm
http://www.pacificconsultant.net/compact_heat_exchanger.htm
http://www.rwholland.com/hairpin.htm
http://www.taftan.com/thermodynamics/EXCHANGE.HTM
http://www.thomasnet.com/about/exchangers-heat-shell-tube26641001.html

Any question.