HEAT TRANSFER

Heat Exchanger
 Heat exchanger is a device that
allows heat from a fluid (a liquid
or a gas) to pass to a second fluid
(another liquid or gas) without the
two fluids having to mix together
or come into direct contact
 Heat Exchanger
Essential principle of a heat exchanger is that it
transfers the heat without transferring the fluid
that carries the heat
• It is also called recuperators to distinguish from regenerators. Here,
hot and cold streams pass alternately through the same passages and
exchange heat with the mass of the equipment. It is intentionally made
with large heat capacity. It is mostly used in cryogenic services, and at
the other extreme temperature like air preheaters
• The most versatile and widely used heat exchanger are the shell and
tube types
Working Principle
Heat exchangers work because heat naturally
flows from higher temperature to lower
temperatures. Therefore if a hot fluid and a cold
fluid are separated by a heat conducting
surface, heat can be transferred from the hot
fluid to the cold fluid.

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 Working Principle
The rate of heat flow at any point (kW/m2 of transfer surface) depends on:

• Heat transfer coefficient (U), itself a function of

the properties of the fluids involved, fluid
velocity, materials of construction, geometr y
and cleanliness of the exchanger
• Temperature difference between hot and cold
streams

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 Working Principle
Total heat transferred (Q) depends on:

• Heat transfer surface area (A)

• Heat transfer coefficient
• Average temperature difference between the
streams, strictly the log mean (DTLM)

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 Compact (Plate-fin)
Plate and Frame HEX Spiral HEX
HEX

Air Cooler Double-Pipe HEX Shell and Tube HEX

TYPES OF HEAT EXCHANGER

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 PLATE AND FRAME
Plate and frame heat exchangers are made of corrugated plates on a
frame. This design creates high turbulence and high wall shear stress,
both of which lead to a high heat transfer coefficient and a high fouling
resistance. Fluids travel within the heat exchanger. The two streams flow
counter currently. The hot fluid flows down one plate while the cold
fluid flows up the other plate.
Gaskets ensure that the cold fluid and the hot fluid don’t mix.
Alternatives to the traditional gasket seal include brazing and laser
welding.
The plates are stacked in an alternating manner to cause the counter
current flow. Multiple plates are clamped together and sealed at the edges.
The design allows for the two fluids to flow in alternate directions and not
be mixed. However, heat can be transferred from one medium to the
other through the plates.
The accessibility of the heat exchange surface for cleaning makes it
particularly suitable for fouling services and where a high degree of
sanitation is required as in food and pharmaceutical processing.

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SPIRAL HEX

Hot fluid enters at the center of the spiral

element and flows to the periphery. The flow
of the cold fluid is countercurrent entering at
the periphery and leaving at the center. Spiral
types generally may be superior with highly
viscous fluid at moderate pressures.
Advantages includes: High thermal efficiency,
self cleaning passages, contercurrent or co-
current and, small footprint and easy access

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 COMPACT (PLATE-
FIN) HEX
Has similar kinds of passages for the hot and cold
fluids. It is used primarily for gas service. It is a
type of heat exchanger design that uses plates
and finned chambers to transfer heat between
fluids. It is often categorized as a compact heat
exchanger to emphasize its relatively high heat
transfer surface area to volume ratio. The large
extended surface permits about four times the
heat transfer rate per unit volume that can be
achieved with shell-and-tube-construction. It is
also designed for pressure up to 80 atm or so. It is
commercially used in cryogenic services and also
for heat recovery at high temperatures in
connection with gas turbines.

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AIR COOLERS
Process fluid flow through finned tubes and
cooling air is blown across them with fans. The
economics of application of air coolers favors
services that allow 25-40°F temperature
difference between ambient air and process
outlet. Above 10MBtu/hr, air coolers can be
economically competitive with water coolers
when water of adequate quality is available in
sufficient amount. With regards to the
installation, it requires free space around it for
the cooling air flow making it more expensive.
The pressure drop is also higher, and the
equipment is bathed in hot air which can be
deteriorating. The less solid mounting results
in a noisier operation.
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 DOUBLE PIPE HEX
It is also known as a concentric pipe, hairpin, jacked pipe
and jacketed U-tube heat exchangers that consists of a
single tube mounted inside another. One fluid flows in the
inner pipe, while a second fluid flows in the outer pipe
annuals. The straight length is only limited to a maximum of
about 20ft otherwise the center pipe will sag and cause poor
distribution in the annulus. It is customary to operate with
the high pressure, high temperature, high density and
corrosive fluid in the inner pipe and the less demanding
one in the annulus. The inner surface can be provided with
scrapers as in dewaxing of oils or crystallization from solution.
External longitudinal fins can be used to improve heat gases
with gases or viscous fluids. When greater heat transfer
surfaces are needed, several double pipes can be stacked in
any combination of series or parallel. Its process design is
practically the simplest HEX problem.

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 SHELL AND TUBE
Shell and Tube heat exchangers are most commonly used in
heating or cooling process fluids and gases. Typically found
in applications where a need to heat or cool large volumes
exist; however small volume applications are also very
common.
Shell and tube exchangers come in many variations to meet
process requirements in almost every industry or application.
They deliver reliable heat transfer performance by utilizing a
high turbulence and counter flow, making one or more
passes.
Baffle pitch or distance between baffles is normally 0.2-1.0
times the inside diameter of the shell. Heat transfer
coefficient and pressure drop depend on it. The window of
segmented baffles is about 25% which is also the parameter
in the thermal hydraulic design of the equipment. The
exchanger is mostly built with even numbers of tube passes to
simplify external piping.
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 SHELL AND TUBE
Advantages:
• Single phases, condensation or boiling can be
accommodated in either the tubes or the shell, in vertical or
horizontal positions
• Pressure range or pressure drop are virtually unlimited and
can be adjusted independently for the two fluids
• Thermal stresses can be accomodated inexpensively
• A great variety of materials of construction can be used and
may be different for the shell and tubes
• Extended surfaces for improved heat transfer can be used in
either sides
• A great range of thermal capacity is obtainable
• The equipment is readily dismantled for cleaning or repair

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RULE OF THUMB
• Take true counter current flow in a shell-and-tube exchanger as a
basis.
• Standard tubes are 3/4 in. OD,1 in. triangular spacing ,16 ft long ; a
shell 1 ft diameter accommodates 100 sq ft; 2 ft diameter,400 sq ft, 3
ft diameter,1100 sq ft.
• Tube side is for corrosive ,fouling ,scaling ,and high pressure fluids.
• Shell side is for viscous and condensing fluids.
• Pressure drops are 1.5 psi for boiling and 3–9 psi for other services.
• Minimum temperature approach is 20°F with normal coolants ,10° F or
less with refrigerants.
• Water inlet temperature is 90°F, maximum outlet 120°F.
• Heat transfer coefficients for estimating purposes ,Btu/(hr)
(sqft)(°F) :water to liquid,150 ;condensers,150 ;liquid to liquid,50; liquid
to gas,5; gas to gas,5; reboiler ,200. Max flux in reboilers, 10,000
Btu/(hr)(sqft).
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RULE OF THUMB
• Usually, the maximum heat transfer are a for a shell-and-tube heat
exchanger is in the range of 5000 ft2.
• Double-pipe exchanger is competitive at duties requiring 100–200 sq ft.
• Compact (plate and fin) exchangers have 350 sq ft/cu ft, and about 4
times the heat transfer per cu ft of shell-and-tube units.
• Plate and frame exchangers are suited to high sanitation services, and
are 25–50 % cheaper in stainless construction than shell-and-tube
units.
• Air coolers :Tubes are 0.75–1.00 in. OD, total finned surface 1520 sq
ft/sq ft bare surface, U=80–100 Btu/(hr)(sq ft bare surface) (°F),fan
power input 2–5 HP/(MBtu/hr),approach 50° For more.
• Fired heaters : radiant rate, 12,000 Btu/(hr)(sq ft); convection rate ,4000;
cold oil tube velocity, 6 ft/sec; approx equal transfers of heat in the two
sections ;thermal efficiency 70–75%;flue gas temperature 25–350°F
above feed inlet; stack gas temperature 650–950°F
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DESIGN PRINCIPLE
For specified thermal and hydraulic conditions and desired
economics, the parameters involved in the design are:
• Tube diameter
• Thickness
• Length
• Number of passes
• Pitch
• Square or Triangular
• Size of shell
• Number of shell baffles
• Baffle types, window and spacing

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DESIGN PRINCIPLE
Key Elements in Heat Exchanger Design Procedure:

• Selection of a tentative set of design parameters

• Rating of the tentative design, meaning, evaluating the
performance with the best correlations and calculations
method that are feasible
• Modification of some design parameters, then rerating
the design to meet thermal and hydraulic specifications
and economic requirements

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DESIGN PRINCIPLE
Tentative Design

1.Specify the flow rates, terminal temperatures and physical

properties
2.Calculate the LMTD and the temperature correction factor
3.Choose the simplest combination of shell and tube passes or
number of shells in series that will have a value of 0.8 or so. The
basic shell is 1-2
4.Make an estimate of the overall heat transfer coefficient
5.Choose a tube length. Normally 8, 12, 16 or 20ft
6.Standard exchanger diameters are 0.75 or 1.0 inch OD, with pitches
7.Find a shell diameter corresponding to the selections of tube
diameter, length, pitch and number of passes. Many heat exchangers
have length to shell diameter ratios between 6 and 8
8.Select the kinds and number of baffles on the shell side
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Reboiler
 Reboilers are used to generate a
flux of vapor to feed to a
distillation tower; the vapor rises
up the tower contacting a
downwards-flowing liquid stream.
It involves all the continuous
process of boiling the recycling
liquid stream in its shell side. All
types perform partial vaporization
of a stream flowing under natural
or forced circulation conditions.
 Reboiler
The name was given by the reason for boiling the same liquid
again and again . In most cases, the liquid is boiled in a shell with
the help of hot pipes (tubes) . On the external sur face of the tubes,
liquid changes its phase by obser ving heat (latent heat + sensible
heat). In -turn the required high temperature of the hot tubes are
maintained by circulating low pressure or high -pressure steam inside
the tubes. Based on the temperature sensitivity of the material and
rate of vapour formation boiling is done inside or outside of the
tubes.

• Applications involve the use as heating equipment for distillation

column and in the steam production using hot process streams
 Working Principle
Reboilers are heat exchangers typically used to provide heat to the
bottom of industrial distillation columns. They boil the liquid from
the bottom of a distillation column to generate vapors which are
returned to the column to drive the distillation separation. The
heat supplied to the column by the reboiler at the bottom of the
column is removed by the condenserat the top of the column.
Proper reboiler operation is vital to effective distillation. In a typical
classical distillation column, all the vapor driving the separation
comes from the reboiler. The reboiler receives a liquid stream from
the column bottom and may partially or completely vaporize that
stream. Steam usually provides the heat required for the vaporization.

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 HORIZONTAL SHELL VERTICAL
KETTLE REBOILER SIDE THERMOSIPHON THERMOSIPHON

FORCED CIRCULATION
REBOILER

TYPES OF REBOILER
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 KETTLE REBOILER (NATURAL
CIRCULATION)
It consists of a bundle of tubes in an oversize shell. Liquid flows from the
column into a shell in which there is a horizontal tube bundle, boiling taking
place from the outside this bundle. The vapor passes back to the column.

Open tube bundle -pitch to diameter ratio in the range of 1.5-2

Temperature in the kettle is substantially uniform
Residence time is so high that kettles are not favored for thermally sensitive
materials
Uneconomic for high pressure operation because of the large shell diameter
Deentraining mesh pads are often incorporated
Tube bundle installed directly in the tower bottom are inexpensive but the
amount of surface that can be installed is limited

Kettle reboilers are widely used in the petroleum and chemical industries;
their main problems are that of ensuring proper disentrainment of liquid
from the outgoing vapor and the problem of the collection of scale and
other solid materials in the tube bundle region over long periods of
operation. 26
 HORIZONTAL SHELL SIDE
THERMOSIPHON

Liquid from the column passes in cross flow over a tube bundle and the
liquid-vapor mixture is returned to the column. The heating fluid is inside
the tubes. This design has the advantage of preserving the natural
circulation concept while allowing a lower headroom than the vertical
thermosiphon type. However, there are more uncertainties about fouling
and about the prediction of the crossflow heat transfer rates.

Less static head difference is needed as driving force for recirculation

Circulation rate can be controlled by throttling the inlet line
There is a temperature gradient from the inlet bubblepoint to the exit
bubblepoint
Same percentage vaporization with kettles but the mean temperature
difference is greater for thermosiphon
Large surface requirement
Easier to maintain

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 VERTICAL
THERMOSIPHON

Liquid passes from the bottom of the tower into the reboiler,
with the evaporation taking place inside the tubes. The two-
phase mixture is discharged back into the tower, where the
liquid settles back to the liquid pool and the vapor passes up
the tower as shown. The heating fluid (typically condensing
steam) is on the outside of the tubes. The vertical
thermosiphon reboiler is less susceptible to fouling problems
and in general has higher heat transfer coefficients than
does the kettle reboiler. However, additional height is
required in order to mount the reboiler.

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 VERTICAL
THERMOSIPHON
• Circulation is promoted by the difference in static heads of supply liquid and the
column of partially vaporized metal
• Exit weight fraction vaporized: Hydrocarbon, 0.1-0.35; Aqueous solution, 0.02-0.1
• Circulation can be controlled by valve in a supply line
• Top tube sheet: Placed at the level of the liquid in the tower
• Flow area of the outlet piping: Made the same as that of all the tubes
• Tube diameters: 19-25 mm
• Length: 12 ft (some used 20 ft tubes)
• Greater tube lengths make less ground space but necessitate taller tower skirts
• Not suitable for low temperature difference services because of the boiling point
elevation imposed by static head
• Shell side vertical thermosiphons are sometimes applied when the heating medium
cannot be placed on the shell side

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FORCED CIRCULATION REBOILERS (LIQUID
IS PUMPED INTO THE SHELL)
The liquid is fed by means of a pump. Forced circulation reboilers with vertical or
horizontal tubes boiling may be designed. Forced circulation reboilers are similar
to vertical thermosiphon reboilers, except the pump is used for the circulation
of the liquid and the hot liquid flows inside column. To calculate the heat
transfer coefficient it is generally assumed that, heat is transferred only by forced
convection. The usual method of shell and tube exchanger design can be used.

• Either horizontal or vertical

• Since the feed liquid is at its bubblepoint, adequate NPSH must be assured for
the pump if it is a centrifugal pump
• Linear velocities in the tube: 15-20 ft/sec
• Advantage: suitable for viscous and highly fouling fluids.
• Disadvantages: Cost of pump and power and, severe maintenance
• Last resort with viscous or fouling materials, or the fraction vaporized must be
kept low

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RULE OF THUMB
Thermosiphon

• Use larger diameter pipe, minimum 22mm

• Make sure all of the pipe work slopes in the right direction as steeply
as possible (no slope reversals to clear obstacles etc).
• Ensure that there is a slope of at least 1:2 throughout the circuit, ie for
every one metre drop there are no more than two metres of
horizontal travel. It is a case of the steeper the better.
• More vertical pipe runs in one place do not compensate for more
horizontal runs elsewhere.
• Placing the collector so that one end of the manifold is a little higher
than the other is a good thing.

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DESIGN PRINCIPLE
Designing a shell type reboiler for the required process conditions
involves in making a decision about the basic options before starting
the design calculations. An engineer with his experience can choose
the type of flow in and outside of the tube, using of plain or
finned type tubes during the primary selection of the model. He
even considers the reboiler cleaning frequency, how to minimize
the startup time. Nucleate pool boiling data, knowledge of two-
phase flow theory and, heat transfer coefficients are some of
the important information required for designing.

To improve the performance of heat transfer rate, low-temperature

approach enhanced boiling tubes are used in new models which
benefits the industrial economy.

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DESIGN PRINCIPLE
Variables that influence the reboiler design are:

• Pressure drop (pressure gradient)

• Mass velocity
• Flow pattern (parallel, cross, counter types)
• Tubes orientation (vertical or horizontal)
• Critical heat flux condition
• Thermal hydraulics
• Reboiler duty

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DESIGN PRINCIPLE
Heating medium used in most reboilers:

• Low-pressure to high-pressure steam

• Commercial heat-transfer fluids (Dowtherm oil)
• Hot process streams

Thermosiphon type reboiler has similar operation procedure of a

single effect evaporator and a calandria. Its working principle
resembles the manometer model. The liquid head in the vessel of a
still/distillation column or separator maintains the flow rate of the
liquid into the reboiler.

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DESIGN PRINCIPLE
Variables affect the operation of thermosiphon reboilers are:
• Variation of temperature difference
• Operating pressure
• Liquid head
• Length and diameter of the pipes

Two design options to maintain the liquid level in reboilers:

• Using a flow control valve in the bottom of the product liquid outlet pipeline.
• Fitting a weir inside the reboiler or in the column so that it allows only the
overflow to its outlet pipe.

Control mechanisms used in reboiler controlling:

• Adjusting the steam or hot medium inlet flowrate based on vapor
temperature.
• Independent flow control of stem inlet into the reboiler.
• Cascade control of both temperature of vapor and flowrate of steam

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HEX:
Chemical Process Equipment - Selection and Design by Stanley M. Walas
Rules of Thumb for Chemical Engineers 3rd Edition by Carl Branan
www.thermopedia.com
http://www.shell-tube.com/

REBOILER:
Chemical Process Equipment - Selection and Design by Stanley M. Walas
Thermosiphon Rules of Thumb: http://www.eco-nomical.co.uk/thermosyphon.htm
Reboilers: www.thermopedia.com
Reboilers operation, design aspects and applications:
http://enggyd.blogspot.com/2013/07/reboilers-operation-design-aspects-and.html

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