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HEAT EXCHANGER
DESIGN
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Heat Transfer Equipment Types

Type Service
Double pipe exchanger Heating and cooling
Shell and tube exchanger All applications
Plate heat exchanger Heating and cooling
Plate-fin exchanger
Spiral heat exchanger
Air cooled Cooler and condensers
Direct contact Cooling and quenching
Agitated vessel Heating and cooling
Fired heaters Heating
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Double Pipe Heat Exchanger

Consists of two concentric pipes with one fluid

flowing through the inner pipe while the other
fluid flowing through the annular space
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Shell and Tube Heat Exchanger

Consists of tube bundles enclosed in a

cylindrical shell with one fluid flowing through
the tubes and the other flowing outside of the
tubes
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Heat Transfer Equipment in
Industries

 Exchanger: heat exchanged between two process

streams
 Heaters and coolers: where one stream is plant service
 Vaporiser: if a process stream is vaporised

 Reboiler: a vaporiser associated with distillation column

 Evaporator: if concentrating a solution
 Fired exchanger: if heated by combustion gases
 Unfired exchanger: not using combustion gases
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Heat Transfer Equipment in
Industries

MODES of HEAT TRANSFER

1. Conduction
 Transfer of heat from one part of a body to another part
of the same body or between two bodies in physical
contact, without significant displacement of the particles
of the two bodies
2. Convection
 Transfer of heat from one point to another within a fluid
or between a fluid and a solid or another fluid, by the
movement or mixing of the fluids involved
3. Radiation
 Transfer of heat by the absorption of radiant energy
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BASIC THEORY

General equation for heat transfer across a

surface for DPHE is:

Q  UATlm
 Q =heat transferred per unit time, W
 U=the overall heat transfer coefficient, W/m2oC
 A= heat-transfer area, m2
 Tm= the mean temperature difference,oC
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BASIC THEORY

General equation for heat transfer across a

surface for STHE is:

Q  UAYTlm
 Q =heat transferred per unit time, W
 U=the overall heat transfer coefficient, W/m2oC
 A= heat-transfer area, m2
 Tm= the mean temperature difference,oC
 Y = geometric correction factor
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Tube-Side Passes

One tube pass

Two tube pass

Three tube passes

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Geometric Correction Factor

Also refer to Figure 11-4, Perry 7th Edition

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Geometric Correction Factor

 1 X 
Z 2

1
1
2
ln   For design
Y  1  ZX 
to be
2  X Z  1  ( Z  1) 2 
 1
2
  practical,
Z  1 ln
2  X Z  1  ( Z  1) 2 
 1


2
 Y ≥ 0.85
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Logarithmic Mean
Temperature Difference

ΔT1 ΔT2

T2  T1
Tlm 
T2
ln
T1

If ΔT1 < ΔT2 and (ΔT2/ΔT1) ≤ 2, then ΔTlm

is the arithmetic mean temp difference
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Overall Heat Transfer
Coefficient
Rearranging the General Equation in terms of
driving force and total resistance:

Driving Force

Tlm
Q  UATlm Q
1
Total Resistance
UA
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Overall Heat Transfer
Coefficient
The overall coefficient is reciprocal of the overall
resistance to heat transfer, which is the sum of
several individual resistances. Individual
resistance is the reciprocal of individual HTC.

1
 Rtot
UA
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Total Resistance

the sum of several individual resistances

Individual resistance is the reciprocal of
individual HTC.
Convection
Conduction
Convection

inside

1
 Rtot  sum of individual resistance s from convection and conduction
UA
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Total Resistance

Conduction Heat Transfer is governed by Fourier’s Law!

dQ dT
 kA
dt dx
k = thermal conductivity of the Solid (BTU/hr-ft2-(OF/ft))

A = Area perpendicular to the direction of heat transfer

x = distance of heat flow

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Total Resistance

At Steady State:

dQ dT
 time invariant  kA
dt dx
dT
q  kA
dx
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Total Resistance

If k is constant:

(T1  T2 )
q  kA
( x2  x1 ) Define R = Δx/kA

(T1  T2 ) Thus, q= - ΔT/R

q
( x2  x1 )
kA
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Total Resistance

If k is not constant:

x2 dx T2
q    kdT
x1 A T1

(T1  T2 )
If k varies q
slightly with ( x2  x1 )
km A
Temp:
**km is evaluated at the mean temperature
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Total Resistance

If k is not constant:

x2 dx T2
q    kdt
x1 A T1

(T1  T2 )
If A varies q
( x2  x1 )
slightly with km Am
Thickness:
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Total Resistance

Convection Heat Transfer

q = hcA (T1 – T2)

Where:
hc- convection heat transfer coefficient, Btu/hrft2°F
-similar to k/∆x
A – Heat transfer Area
T1 – temperature at surface 1
T2 – temperature at surface 2
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Total Resistance

Convection Heat Transfer: Rearranging

q = (T1 – T2)/(1/hcA)
Where:
hc- convection heat transfer coefficient, Btu/hrft2°F
-similar to k/∆x
A – Heat transfer Area
T1 – temperature at surface 1
T2 – temperature at surface 2
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Total Resistance

Convection
Conduction
Convection

inside

1 1 1 x 1 1
 Rtot     
UA hi Ai hi ,d Ai km Am ho Ao ho,d Ao
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Total Resistance

1 1 1 1
  
in
UA U o Ao U i Ai U m Am
si
d

Ao x 1
e
1 Ao Ao 1
    
U o hi Ai hi ,d Ai km Am ho ho,d

1 1 1 Ai x Ai Ai
    
U i hi hi ,d km Am ho Ao ho,d Ao
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Typical Fouling Factor (Foust, 1980)

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Heat Transfer Without

Phase Change
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DOUBLE PIPE
HEAT EXCHANGER
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Invidual Heat Transfer
Coefficient
HT w/o Phase Change: DPHE

For Long Tubes (L/D) > 50, Tube-side

  d 0.7 
0.14
hi d i 1   
Nu   0.023N RE N Pr 3  
0.8
1    
 L 
k  w   
Applicabilty:
1. Non-metallic fluid
2. 0.5 < NPr < 100
3. NRE > 10,000
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Invidual Heat Transfer
Coefficient
HT w/o Phase Change: DPHE

For Long Tubes (L/D) > 50, Annular Space

  d 0.7 
0.14
ho d eq   
Nu   0.023N RE N Pr
0.8 1
3
  1    
 L 
k  w   
Applicabilty:
1. Non-metallic fluid
2. 0.5 < NPr < 100
3. NRE > 10,000
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Invidual Heat Transfer
Coefficient
HT w/o Phase Change: DPHE

For Short Tube (L/D < 50)

0.7
his  D
 1  
hi L
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Invidual Heat Transfer
Coefficient
HT w/o Phase Change: DPHE

Laminar Flow, Forced Convection

0.14
  
N NU  2 N GZ  
1
3

 w 
mc p
N GZ 
kL
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SHELL AND TUBE

HEAT EXCHANGER
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Invidual Heat Transfer
Coefficient
HT w/o Phase Change: STHE, ho
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Invidual Heat Transfer
Coefficient
HT w/o Phase Change: STHE, hi
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Heat Transfer WITH

Phase Change
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Invidual Heat Transfer
Coefficient
HT w/ Phase Change: STHE

Film-type Condensation on Vertical Surface

Assumptions:
1. Pure vapor is at its saturation temperature.

2. The condensate film flows in laminar regime and heat is transferred

through the film by condensation.

3. The temperature gradient through the film is linear.

4. Temperature of the condensing surface is constant.

5. The physical properties of the condensate are constant and

evaluated at a mean film temperature.

6. Negligible vapor shear exists at the interface

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Invidual Heat Transfer
Coefficient
HT w/ Phase Change: STHE

Film-type Condensation on Vertical Surface, Laminar

 kl 3l l  v H v g 

1
4

h  0.943 
 l LTv  T1  
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Invidual Heat Transfer
Coefficient
HT w/ Phase Change: STHE

Film-type Condensation on Vertical Surface, Turbulent

 kl 3l l  v H v g 

1
4

h  1.13 
 l LTv  Tl  
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Invidual Heat Transfer
Coefficient
HT w/ Phase Change: STHE

Film-type Condensation on Horizontal Surface

 kl l l   v H v g 
1
3 4

h  0.725 
 l DTv  Tl  
 If the amount of condensate is unknown

For Nre > 40, h is multiplied by 1.2

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Invidual Heat Transfer
Coefficient
HT w/ Phase Change: STHE

Film-type Condensation on Horizontal Surface

 kl l l   v gL 
1
3 3

h  0.95 
 lW 
 If the amount of condensate is known

For Nre > 40, h is multiplied by 1.2

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Invidual Heat Transfer
Coefficient
HT w/ Phase Change: STHE

Film-type Condensation on Horizontal Surface, Banks of Tubes

 kl l l   v H v g 
1
3 4

h  0.725 
 l NDTv  Tl  

For Nre > 40, h is multiplied by 1.2

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Invidual Heat Transfer
Coefficient
HT w/ Phase Change: STHE

Film-type Condensation on Horizontal Surface, Banks of Tubes

1
h N  hN 4

N1  N 2  ...  N n
 3
1
N 4

N1  N 2  ...  N n 4
3 3
4 4
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Invidual Heat Transfer
Coefficient
HT w/ Phase Change: STHE

Film-type Condensation on Horizontal Surface, Banks of Tubes

 kl l l   v H v g 
1
3 4

h  0.725 
 l NDTv  T1  

 w/o splashing
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Invidual Heat Transfer
Coefficient
HT w/ Phase Change: STHE

Film-type Condensation on Horizontal Surface, Banks of Tubes

 kl l l   v H v g 
1
3 4

h  0.725 
 l N DTv  T1  
2
3

 w/ splashing
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Invidual Heat Transfer
Coefficient
Film Temperature

Condensate Properties are evaluated at the Film Temperature

Tf = ½(Tsv + Tw) by Kern, D.Q., Process HT

Tf = Tsv - 0.75ΔT by McAdams, W.H., Heat Transmission,

3rd. Ed.
ΔT = Tsv - Tw
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Invidual Heat Transfer
Coefficient
Film Boiling on Submerged Horizontal Cylinder or Sphere

0.69 0.33
 qC pl   l 
0.31
 Pkl 
h  0.225      1
 A     v 
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Invidual Heat Transfer
Coefficient
Film Boiling on Submerged Horizontal Cylinder or Sphere

q 
 C
3

gkv  v l   v    0.4C pv Ts  Tsat  


A  v DTs  Tsat  
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Invidual Heat Transfer
Coefficient
Film Boiling on Submerged Horizontal Cylinder or Sphere

Nusselt-type Equation by Rohsenow:

0.7
 DG   C p 
2

hD
3

 Cr 
 
 
 k 

k     

Cr varies from 0.006 to 0.015

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Invidual Heat Transfer
Coefficient
Film Boiling on Submerged Horizontal Cylinder or Sphere

Nusselt-type Equation by Forster and Zuber:

 Cp 
0.62 1

 DG 
3
hD
 0.0015   
k     k 
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HE DESIGN SPECS
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TOTAL HEAT
TRANSFER AREA

Q
A
UTlm

A  NT DL
A compromise between NT and L is chosen based on (L/Dshell)
between 5 to 10
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HE DESIGN SPECIFICATION
No. of Tubes in Conventional Tubesheet Layout
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TOTAL HEAT
TRANSFER AREA

With an appropriate pitch to diameter ratio and

optimum pipe diameter chosen and the total
HT area,

Shell Diameter  NC DO  NC  1C

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HE DESIGN SPECIFICATION
LAYOUT AND PITCH ARRANGEMENT
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HE DESIGN SPECIFICATION
LAYOUT AND PITCH ARRANGEMENT
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HE DESIGN SPECIFICATION
LAYOUT AND PITCH ARRANGEMENT

• Optimum Pitch to Diameter Ratio: 1.25 to 1.50

• Suggested clearance: 6.4 mm

Tube layout normally follows symmetrical arrangement having the

largest number of tubes at the center
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HE DESIGN SPECIFICATION
BAFFLES

 Used to support tubes against sagging and vibrations

 Direct the flow of fluid and control velocities

Types:
Segmental
Disk and Doughnut Type
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HE DESIGN SPECIFICATION
BAFFLES

Segmental Baffles

Baffle Cut: 25 to 45% of disk diameter

Baffle Spacing: 20 to 100% of Shell Diameter
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HE DESIGN SPECIFICATION
BAFFLES

Disk and Doughnut Baffles

•Reduces pressure drop by 50-60%

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HE DESIGN SPECIFICATION
BAFFLES
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HE DESIGN SPECIFICATION
BAFFLES

Minimum unsupported tube span (in.) acc. to Perry = 74d0.75

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HE DESIGN SPECIFICATION
BAFFLES THICKNESS: BENDING
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HE DESIGN SPECIFICATION
BAFFLES THICKNESS: SHEARING
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HE DESIGN SPECIFICATION
BAFFLES THICKNESS
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Pressure Drop
Tube-Side Pressure Drop (Coulson and Richardson, 2005)

Basic Equation for

isothermal system

Tube friction losses

only
jf = dimensionless friction factor
L’ = effective tube length
Di = inside tube diameter
ρ = density of fluid at bulk/film temperature
ut = velocity of fluid
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Pressure Drop
Tube-Side Pressure Drop (Coulson and Richardson, 2005)

For non-isothermal
systems

Tube friction losses

only
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Pressure Drop
Tube-Side Pressure Drop (Coulson and Richardson, 2005)

W/ pressure losses due to contraction, expansion and flow reversal

Suggestions for the Estimation of these Losses:

1. Kern (1950) suggests adding 4 velocity heads per pass

2. Frank (1978) considers this to be too high, and recommends
2.5 velocity heads
3. Butterworth (1978) suggests 1.8
4. Lord et al. (1970) take the loss per pass as equivalent to a
length of tube equal to:
a. 300 tube diameters for straight tubes
b. 200 for U-tubes
5. Evans (1980) appears to add only 67 tube diameters per
pass.
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Pressure Drop
Tube-Side Pressure Drop (Coulson and Richardson, 2005)

W/ pressure losses due to contraction, expansion and flow reversal

The loss in terms of velocity heads can be estimated by:

1. counting the number of flow contractions, expansions and

reversals, and;

2. using the factors for pipe fittings to estimate the number of

velocity heads lost
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Pressure Drop
Tube-Side Pressure Drop (Coulson and Richardson, 2005)

W/ pressure losses due to contraction, expansion and flow reversal

For two tube passes, there will be:

1. two contractions (0.5)

2. two expansions (1.0)
3. one flow reversal (1.5)
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Pressure Drop
Tube-Side Pressure Drop (Coulson and Richardson, 2005)

W/ pressure losses due to contraction, expansion and flow reversal

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Pressure Drop
Shell-Side Pressure Drop (Coulson and Richardson, 2005)
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Pressure Drop
Shell-Side Pressure Drop (Coulson and Richardson, 2005)

Shell Equivalent Diameter (Hydraulic Diameter)

Square-Pitched Tube
Arrangement, de in
meter

Triangular-Pitched Tube
Arrangement, de in meter
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Pressure Drop
Shell-Side Pressure Drop (Coulson and Richardson, 2005)

Shell-Side Friction Factor???

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Pressure Drop
Shell-Side Pressure Drop (Coulson and Richardson, 2005)

Shell-Side NOZZLE Pressure Drop

1 ½ velocity heads for the inlet

½ for the outlet

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Pressure Drop
RULES OF THUMBS (Silla, 2003)
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Pressure Drop
RULES OF THUMBS (Silla, 2003)
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Pressure Drop
RULES OF THUMBS (Coulson and Richardson, 2005)
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Pressure Drop
RULES OF THUMBS (Couper, Penny, Fair & Wallas, 2010)

•vacuum condensers be limited to 0.5–1.0 psi

(25–50 Torr)

•In liquid service, pressure drops of 5–10 psi

are employed as a minimum, and up to 15% or
so of the upstream pressure
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Heat Exchanger
Temperature Limits
RULES OF THUMBS

•At high temperature, water exerts corrosive action

on steel and scaling is increased

•To minimize scale formation, water temperature

should not be more than 120ºF

•To protect against fouling and corrosion, water

temperature (outlet) should not be more than158F
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Heat Exchanger
Temperature Limits
RULES OF THUMBS

•For the cooling water, on an open circulation

systems, the temperature of the cooled water is 8-
13ºF above the wet bulb temperature

• When using cooling water to cool or condense a

process stream, assume a water inlet temperature
of 90oF (from a cooling tower) and a maximum
water outlet temperature of 120oF
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Heat Exchanger
Temperature Limits
RULES OF THUMBS

•the greatest temperature difference in an

exchanger should be at least 36 degF, and;

•the minimum temperature difference should be at

least 10 degF