Dr.

CCSReddy
Technology&OptimizationManager
SingaporeRefiningCompanyPrivateLimited

11th February 2016

 Classificationofheatexchangers

Reference: Shah R.K. and Sekulic D.P.,, Fundamentals of Heat Exchanger Design, John Wiley & Sons, Inc.,
Hoboken, New Jersey, 2003 2
TEMADesignationsforShellandTubeHeatExchangers

Reference:RajivM.,EffectivelyDesignShellandTubeHeatExchangers,ChemicalEngineeringProgress,February1998
3
 FeaturesofTEMAShellandTubeType
Exchangers

Reference: Serth R.W., Process Heat Transfer: Principles and Applications, 1st Edition, Elsevier Ltd., USA, 2007. 4
FixedTubesheetandFloatingHeadHeatExchangers

Reference:RajivM.,EffectivelyDesignShellandTubeHeatExchangers,ChemicalEngineeringProgress,February1998

5
 DetailsofFixedTubeHeatExchanger

Reference: Standards of the Tubular Exchanger Manufacturers Association, Tubular Exchanger Manufacturers Association,
Inc., 9th edition, 2007, New York.
6
 DetailsofFixedTubeHeatExchanger

Reference: http://www.hcheattransfer.com/shell_and_tube.html

Reference: Shah R.K. and Sekulic D.P.,, Fundamentals of Heat Exchanger Design, John Wiley & Sons, Inc.,
Hoboken, New Jersey, 2003

7
 DetailsofKettleReboiler

Reference: Standards of the Tubular Exchanger Manufacturers Association, Tubular Exchanger Manufacturers Association,
Inc., 9th edition, 2007, New York.
8
 FixedTubesheetHeatExchangers

Advantages:
Fixed tube sheet is the least expensive construction type.
The tubes can be cleaned mechanically after removal of the channel cover
or bonnet
Leakage of the shell side fluid is minimized.
Disadvantages:
Outsides of the tubes cannot be cleaned mechanically.
Limited to clean services on the shell side.
Fixedtube sheet construction with fouling services on the shell side
generally requires chemical cleaning.
Use of this type limited to temperature difference up to 50 to 600C.
Large differential temperature between the tubes and the shell will require
expansion joint, which is very expensive.

9
 UtubeHeatExchangers
Utube:
Advantages:
It has only one tube sheet.
Bundlecanexpandorcontractinresponsetostressdifferentials
Outsidesofthetubescannotbecleanedmechanically.

Disadvantages:
Additional cost is incurred for bending the tubes.
Requires slightly longer shell.
Insidesofthetubescannotbecleanedeffectively.

10
 FloatingHeadHeatExchangers
Floating head: One tube sheet is fixed relative to the shell, and the
other is free to float within the shell. There are various types of
floating head construction. The two most common are the pull
through with backing device (TEMA S) and pull through (TEMA T)
designs.
Advantages:
Bundlecanexpandorcontractinresponsetostressdifferentials.
Bothinsideandoutsidesofthetubescannotbecleanedmechanically.

Disadvantages:
Relatively costly
Requires slightly longer shell.

11
 ShellSelection
Shell
Type Detail
E Commonlyusedshelltype
Itslimitationsareshellsidepressuredroporproblemduetoflowinduced
vibrations
J SpecialcaseofEtypeshellwhereeitherentryorexitoftheshellsidefluidcanbesplit
intotwopartstoreducepressuredroporflowinducedvibrationsintheshellside.
G Gshellshavealongitudinalbaffleaxially
Gshellsareusedforamaximumtubelengthoftwicethemaximumunsupported
spanasperTEMAasthereisonefullsupportplateinthetubebundle.
Itisusedforhorizontalthermosiphonreboilersinordertoreducethepressuredropas
wellastoavoidflowmaldistribution
H Hshellshavealongitudinalbaffleaxially
Hshellsareusedforamaximumtubelengthoffourtimesofthemaximum
unsupportedspanduetopresenceof2fullsupportplatesinthetubebundle.
Itisusedforhorizontalthermosiphonreboilersinordertoreducethepressuredropas
wellastoavoidflowmaldistribution
F Thisshellisusedwhenthereisatemperaturecrossi.e.,whentheoutlettemperature
ofcoldstreamishigherthantheoutlettemperatureofthehotstream.
Fshellsarepronetoleakageacrossthelongitudinalbaffleinremovablebundle
exchangersandhencetheiruseisgenerallynotrecommended.
IfFshellisemployedinaremovabletypeexchanger,theshellsidepressuredrop
shouldbelimitedto0.35kg/cm2g.
multipleshellsinseriesaretobeemployedwhenmorenumberoftubepassesis
required.

K Usedforkettleconstructionwherethereisanenlargedshellabovethetubebundlefor
thedisengagementofthevaporfromtheboilingliquid.
ThekettletypeisaspecialapplicationoftheUtubetypeandpullthroughtypeof
construction

12
 ShellSideFlowArrangements

Reference: Shah R.K. and Sekulic D.P.,, Fundamentals of Heat Exchanger Design, John Wiley & Sons, Inc.,
Hoboken, New Jersey, 2003 13
 HeatExchangerSelection

Reference: Kuppan T., Heat Exchanger Design Handbook, 2nd edition, CRC Press, Taylor& Francis Group, New York, 2013.
14
 HeatExchangerSelection

Reference: http://www.funke.de/files/tema_funke_process_engineering_uk.pdf 15
SizingMapforShellandTubeHeatExchangers

Reference: Woods, D.R. (2007) Rules of Thumb in Engineering Practice, Wiley-VCH Verlag GMBH, Weinheim.
16
 DesignRequirements
Typeoftheheatexchanger
DesigntemperatureandPressure
Streamcharacteristics
Flowratesofbothstreams.
Inletandoutlettemperaturesofbothstreams.
Operatingpressure
Allowablepressuredrop(Forliquids,0.50.7kg/cm2 ispermittedpershell;Forgases,
generally0.050.2kg/cm2).
HeatDuty
Foulingresistances
Physicalpropertiesofboththestreams(viscosity,thermalconductivity,density,and
specificheat,overtheentireoperatingrange)
Nozzlesizes
Tubesize(3/4and1arepopular,forfoulingapplications:upto2)andtype
Tubelength(Preferredtubelengthsare6ft,8ft,12ft,16ft,20ftand24ft;optimumtube
lengthtoshelldiameterratio~5 10).
Maximumshelldiameter
Materialofconstruction
Specialconsiderations
17
 Baffles

Bafflesareusedtosupporttubes,enableadesirablevelocitytobemaintainedfortheshell
sidefluid,andpreventfailureoftubesduetoflowinducedvibration.

Reference:RajivM.,EffectivelyDesignShellandTubeHeatExchangers,ChemicalEngineeringProgress,February1998
18
 OtherBaffletypes

Reference: http://www.embaffle.com/downloads-links.html Reference: http://www.kochheattransfer.com/products/helixchanger

Reference: http://www.metalformsltd.com/#!rod-baffles/c12db

19
 HeatExchangerWithoutBaffles

Reference: http://www.kochheattransfer.com/products/twisted-tube-bundle-technology

20
ComparisonofVariousTypesofShellandTube
HeatExchangers

21
ConstructionDetails ShellBundleClearance
Shellshouldbeaclosefittothetubebundletoreducebypassing.
Shellbundleclearancewilldependontypeofheatexchanger.

Reference: Serth R.W., Process Heat Transfer: Principles and Applications, 1st Edition, Elsevier Ltd., USA, 2007.

22
 ShellSideFlowPaths

DescriptionofFlowStreams:
A.Flowthroughannulibetweentubesandbaffles.
B.Crossflowthroughbundlebetweenbaffletips.
C.Flowthroughannulusbetweenbundleandshellbetweenbaffletips
E.Flowthroughannulusbetweenbaffleandshell.
F.Flowthroughtubepasspartitionlanesparalleltocrossflowdirection.

Reference: 1. Rajiv M., Effectively Design Shell-and-Tube Heat Exchangers, Chemical Engineering Progress, February 1998
2. Towler, G. and Sinnott, R. (2012) Chemical Engineering Design: Principles, Practice and Economics 23
of Plant and Process Design, 2nd edn, Elsevier, Oxford.
TubePasses

24
 MaterialofConstruction

Reference: Shah R.K. and Sekulic D.P.,, Fundamentals of Heat Exchanger Design, John Wiley & Sons, Inc.,
Hoboken, New Jersey, 2003
25
 FluidAllocationStrategy
Placingfluidstubesideversusshellsideiddrivenbyeconomics
Equipmentcost:Betterheattransfer, Lessmetal,Cheapermechanicalcomponents
Operatingcost:Avoidcorrosionandshutdown,Sustainperformance,minimumfouling,safety

StreamPropertyCompared Shell Tube ReasonsForThisChoice

toOtherStream side side
Matchcoefficientsandpumpingpower Minimizecost.

Lowerfilmcoefficientexpected(hshell/htube <0.3) X Enhanceoutsidesurfacetoraiselimitingsidecoefficient(singlephaseonly.)

Condensing Determinedbycoolant.
Treatedcoolingtowerwater X Corrosioninhibitorseffectivetubeside.Otherwise,usealloytubes.

Viscosityabove2cP X StaggeredtubelayoutinducesgoodheattransferatlowReynoldsnumber.
Boiling X Ifhighweightfractionvapor.Avoiddrywall.
Alloyrequiredforcorrosion X Allowscheapershellsidecomponents.
VerylowsystempressureorPavailable X CanuseJorXshellstyletoshortenflowpathandreducepressuredrop.
Highsystempressure X Reducesshellthickness.However,tuberupturedesignsometimescontrols.
Largetemperaturechangeofonestreamina X ExcessiveTinstationarytubesheetifplacedontubeside.
singleheatexchanger(over200F)
Normalfouling Doesnotmatter.
Depositstoohardtohydroblast(rare) X Usefloatingrearheadforstraighttubes.
HighFluidtemperature X Lessheatloss
Highflowrate X Highheattransfer

26
 HeatExchangerApproachTemperaturesand
PressureDrops

Reference: Silla, H., Chemical Process Engineering Design and Economics, Marcel Dekker, Inc., USA, 2003

27
HeatExchangerDesignMethods
Kernmethod:
Doesnottakeintoaccountbypassandleakagestreams.
Simpletoapplyandaccurateenoughforpreliminarydesigncalculations.
Restrictedtoafixedbafflecut(25%).

BellDelawaremethod
Mostwidelyused.
Takesintoaccount:
Leakagethroughthegapsbetweentubesandbafflesandthebafflesand
shell.
Bypassingofflowaroundthegapbetweentubebundleandshell.
StreamAnalysismethod(byTinker)
Morerigorousandgeneric.
Bestsuitedforcomputercalculations;basisformostcommercialcomputer
codes.
Software:HTRI,HTFS,AspenEDRetc.

28
 DesignGuidelines

Singlesegmentalbafflesarestandardandbyfarthemostwidelyused.Thespacing
betweenbafflesshouldbebetween0.2and1.0shelldiameters(butnotlessthan2in.).

Bafflecutshouldbebetween15%and45%.Forsinglephaseflow,however,arangeof20
35%isrecommended.

Heattransfercoefficientisinverselyproportionaltoviscositytothe0.47power.Similarly,
theheattransfercoefficientisdirectlyproportionaltothermalconductivitytothe0.67
power.

Forturbulentflow,thetubesideheattransfercoefficientvariestothe0.8powerofTube
sidemassvelocity,whereastubesidepressuredropvariestothesquareofmassvelocity.

Reference: Serth R.W., Process Heat Transfer: Principles and Applications, 1st Edition, Elsevier Ltd., USA, 2007.

29
 TubeandShellSideVelocityGuidelines

For condensing steam in vacuum conditions

Reference: Stanjones D.J., Pujado P.R., Handbook of Petroleum Processing, Springer, Netherlands, 2006.
30
 DesignGuidelines
Recommended baffle cut, Be, as a function of Baffle spacing:
baffle spacing. SBC, for single-phase flow; CV,
for condensing vapours

Nozzle Sizing:
Nozzle momentum Limitations:

Reference: Serth R.W., Process Heat Transfer: Principles and Applications, 1st Edition, Elsevier Ltd., USA, 2007.
31
ImpingementProtectionDevices

32
 KeyDesignVariables

Reference: Shah R.K. and Sekulic D.P.,, Fundamentals of Heat Exchanger Design, John Wiley & Sons, Inc.,
Hoboken, New Jersey, 2003

33
TwoPhaseFlowMap

34
 DesignStrategy

Reference: Shah R.K. and Sekulic D.P.,, Fundamentals of Heat Exchanger Design, John Wiley & Sons, Inc.,
Hoboken, New Jersey, 2003 35
ReboilerDesignOutputSummary

36
DoublePipeHeatExchanger

37
FinnedTubes

38
 PlateHeatExchangers

FullyWeldedPlateheatexchanger
Platesweldedtogethertoincreasepressureandtemperature
limits
Materials:stainlessstealandnickelbasedalloys.Canbe
madewithcopper,titaniumorgraphite
OperationLimits:
temperaturelimitsdependonthematerial
cantoleratepressuresinexcessof60bar

Reference:http://www.alfalaval.com/products

39
 TypicalOperatingRangesofPHEs

Reference: Li et al., Renewable and Sustainable Energy Reviews 15 (2011) 4855 4875
40
 CompablocPlateHeatExchangers

Reference:AlfaLaval
41
 UseofPlateHeatExchangesasCondenserand
Reboiler

Reference:
http://www.alfalaval.com/globalassets/documents/microsites/compabl
oc/condensers_and_reboilers_for_the_space_age_ppi00010en.pdf
42
 SpiralHeatExchangers

Twolongstripsofplatewrappedtoform
concentricspirals
Materials:carbonsteel,stainlesssteeland
titanium
Operationlimits:
Temperaturesupto400C(dependson
gasketedmaterials)

Condenser Vaporizer Pressuresupto25bar

43
 Reboilers
Reboilersprovideenergyinputintofractionationcolumns:
Producevaportravelingupthecolumntodrivetheseparationprocess.
Singlestageflash
Usuallyreboilliquidfromthecolumnsump.
Sidereboilersareusedinsomeapplications.

Reboilerdesigns:
Thermosiphonreboilers(verticalandhorizontal)withrecirculation most
common.
Thermosiphonreboilers(oncethrough) commoninoldervenderdesigned
systems.
Kettlereboilers Usedinspecificapplicationsonly.
Forcedflowreboilers usedinapplicationswherethermosiphonsarenotpractical.
Example:heavyoilwithsmallamountoflightends.
Internal(stabin)reboiler.

44
 Reboilers

Once-through Recirculation

Kettle Type

Oncethroughreboilershavehighvaporfractioncomparingtocirculatingreboilersatthesame
duty.Kettlereboilersareoftenusedintheamineregenerationservice.

Reference:ArnethS.,StichlmairJ.,Characteristicsofthermosiphonreboilers,Int.J.Therm.Sci.
(2001)40,38539. 45
StabInBundleReboilerandWasteHeat
RecoverySteamGenerator

46
 Horizontalvs.VerticalReboiler

HorizontalThermosiphonCirculating: Highstatichead,highcirculation
rates,lowvaporfraction,highcapitalcost,easytoisolate.

Vertical Thermosiphon Circulating : Low static head (about 3 m.) low

circulation rates, high vapor fraction (could be a problem), low capital cost,
difficult to isolate.

47
 ForcedandNaturalCirculationReboilers
ForcedCirculationReboilers:
Predictablerecirculationrate
Highvelocitiesattheexpenseofpumpingcosts
Lowpercentagevaporisedpercirculation
Usedwhenweneedtosuppressvaporization
Foulingliquidwithhighviscosity
Wideboilingmixtureatlowpressure
Mixturewithsmallpercentageoflightmassfractions(e.g.vacuumapplications)
Veryhighcirculationrateisrequiredsincethereisonlysensibleheat,nolatentheat,
imparted.Behavelikeasensibleheatexchanger.
Highpressuredrops(lownaturalcirculation)

NaturalCirculationReboiler
Vaporisationintheshell
o Horizontalthermosiphonreboiler
Vaporisationinthetubes
o Verticalthermosiphonreboiler

48
 KettleReboilers
Veryhighheatfluxcanbeachievedifmaintainedinthenucleateboilingregime.
Generallyusedforfluidswithnarrowboilingrange.Forwideboilingmixtures,liquid
distributiondevicesareneededtodistributeliquid.
Forlongbundles,multiplevaporoutletsarerecommendedtoreducehorizontalvapor
velocityinthevapordisengagementzonetominimizeentrainment.
Duetopoolboiling,kettlesarerelativelyinsensitivetohydrodynamics.
Betterthanthermosiphonsforthefollowingconditions:
Whentherearefluctuationsinoperatingconditionsofthecolumn
Atverylowpressure
Atveryhighpressure(nearcritical)
LowTbetweentheheatingmediumandtheboilingliquid

Reference: Serth R.W., Process Heat Transfer: Principles and Applications, 1st Edition, Elsevier Ltd., USA, 2007.
49
 SelectionofReboiler

Reference: Ludwig E.E., Applied Process

Design for Chemical and Petrochemical
Reference: Serth R.W., Process Heat Transfer: Principles and Plants, Vol.3, 3rd Edition, Gulf
Applications, 1st Edition, Elsevier Ltd., USA, 2007. Professional Publishing, USA, 2001.
50
 ReboilersDesignHeatFlux

Reference: Serth R.W., Process Heat Transfer: Principles and Applications, 1st Edition, Elsevier Ltd., USA, 2007.
51
 ReboilersShellSelection

Reference: Ludwig E.E., Applied Process Design for Chemical and Petrochemical Plants, Vol.3, 3rd Edition, Gulf
Professional Publishing, USA, 2001.

52
 ReboilerDesignGuidelines
Recommended steam and condensate nozzle
Recommended Fouling Factors for Reboilers
sizes

No. of Feed and return nozzle pairs A rule of thumb for estimating the diameter of K-
shell is that the distance from the uppermost tube
to the top of the shell should be at least 40% of the
shell diameter. More rigorous sizing procedure for
dome segment area is based on the following
empirical equations:

Reference: Serth R.W., Process Heat Transfer: Principles and Applications, 1st Edition, Elsevier Ltd., USA, 2007.
53
 Condensers
Condensersremoveheatfromasystembyconvertingavaporintoliquid.
Fractionationcolumnoverheadcondenserspromoteseparation
processes.
Partialcondensers
Totalcondensers
Surfacecondensersreducepressure
Vacuumcolumncondensersreduceloadtoejectors
Surfacecondensersdownstreamofsteamejectorsreducetheback
pressuretotheejectorsandpreventthemfrombreaking
Turbineexhauststeamsurfacecondensersmaximizeenergyextraction
fromsteam

54
 TypeofCondensers

Horizontal shell-side condenser with split flow (type J) shell

Horizontal shell-side condenser, type AES

Horizontal tube-side condenser

Horizontal shell-side condenser with cross flow (type X)
shell

Reference: Serth R.W., Process Heat Transfer: Principles and Applications, 1st Edition, Elsevier Ltd., USA, 2007.
55
 TypeofCondensers

Vertical tube-side down flow condenser Reflux condenser

Reference: Serth R.W., Process Heat Transfer: Principles and Applications, 1st Edition, Elsevier Ltd., USA, 2007.
56
 FinFanCoolers
InducedDraft
Plenumreducessolarradiationeffects
Reducedhotairrecirculationpotential
Betterairsideflowdistribution
Limitsonairexhausttemperature.

ForcedDraft
Easiertomaintainmechanicalequipment
Easieraccesstocleanfins
Requireslesshorsepower
Fansnotexposedtohotexhaustair

Expensive,butcostefficient
Coolorcondenselowviscosityfluids
Usuallydesignedbythemanufacturer 57
 FinFanCoolerDetails
Key
1 Tubesheet
2 Removablecoverplate
3 Removablebonnet
4 Topandbottomplates
5 Tube
6 Passpartition
7 Gasket
8 Nozzle
9 Sideframe
10 Tubespacer
11 Tubesupportcrossmember
12 Tubekeeper
13 Vent
14 Drain
15 Instrumentconnection

References:
58
 FinDetails

High-fin tubing: (a) L-fin, (b) G-fin, (c) Shoulder-grooved fin,

and (d) E-fin (bimetallic).

Reference: Serth R.W., Process Heat Transfer: Principles and Applications, 1st Edition, Elsevier Ltd., USA, 2007.
59
 FinFanCoolers

Reference: Serth R.W., Process Heat Transfer: Principles and Applications, 1st Edition, Elsevier Ltd., USA, 2007.
60
DesignGuidelinesforFinFanCoolers
Mostaircooledheatexchangersforindustrialapplications,inpetroleumrefineriesandelsewhere,are
manufacturedinaccordancewithAPIStandard661,AircooledHeatExchangersforGeneralRefinery
Services.
Anaircooledheatexchangermustbedesignedtooperateatsummertimeconditions.Therefore,theusual
practiceistouseanairtemperaturecorrespondingtothe97thor98thpercentile,i.e.,atemperaturethat
isexceededonly23%ofthetime.
Inordertoobtainanevendistributionofairflowacrossthetubebundle,thefanareashouldbeatleast
40%ofthebundlefacearea
Fortwofanbays,theratiooftubelengthtobundlewidthshouldbeintherangeof33.5.Itisalso
desirabletohaveaminimumoffourtuberows.
Forinduceddraftoperation,theoutletairtemperatureshouldbelimitedtoabout2200Finorderto
preventdamagetofanbladesandbeatings.Forceddraftoperationshouldbeconsideredifthetubeside
fluidtemperatureisgreaterthan3500F
Theairvelocitybasedonbundlefaceareaandairatstandardconditionsisusuallybetween400and800
ft/min,withavalueof500700ft/minbeingtypicalforunitswithfourtosixtuberows.

Reference: Serth R.W., Process Heat Transfer: Principles and Applications, 1st Edition, Elsevier Ltd., USA, 2007.

61
 Fouling

Reference:PowerRB.,SteamJetEjectorsfortheProcessIndustries,2nd edition,McGraw Hill(2005).

62
 FoulingandCorrosion

Reference: Shah R.K. and Sekulic D.P.,, Fundamentals of Heat Exchanger Design, John Wiley & Sons, Inc.,
Hoboken, New Jersey, 2003

63
 Fouling
Problem Susceptible Avoid By
Service
Particulate or Any stream - liquid, Maintain sufficient velocity to keep from settling. Tube
solids deposition gas, or two-phase side velocity of 6.6 ft/s (2 m/s). This velocity limit is
applicable for tubes with outside diameters of 0.75 in.
(19.05 mm) and 1 in. (25.4 mm). Increase velocity to 7.2
ft/s (2.2 m/s) for diameters 1.25 in. (31.75 mm) and 1.5
in. (38.1 mm) to maintain shear stress
Salt crystallization Stream containing Manage concentration, skin and bulk temperatures, and
or insolubility water phase pH.
Polymerization, Heavy hydrocarbon Keep temperature below activation or control exponential
coking, or reaction liquids and streams reaction rate.
to solid contaminated with
catalyst
Man-made Any liquid or two-phase Avoid.
additives streams
Biological growth Water or water Kill or control rate of growth. This is materials,
contaminated streams temperature, and velocity dependent.
Corrosion Practically any stream Adjust process to prevent corrosion and select
appropriate materials to resist corrosion.
Reference: Nesta J., Bennett C.A., Reduce Fouling in Shell and Tube Heat Exchangers, Hydrocarbon Processing, pp.77-82,
July 2004. 64
 SafetyConsiderations

Reference: CCPS, Design Solutions for Process Equipment Failures, American Institute of Chemical Engineers, New York,
65
1998
 SafetyConsiderations

Reference: CCPS, Design Solutions for Process Equipment Failures, American Institute of Chemical Engineers, New York,
1998 66
 HeatExchangersCost

Reference: W. D. Seider, J. D. Seader, D.R. Lewin, Product and Process Design Principles: Synthesis, Analysis and Evaluation
(3rd ed.), John Wiley: 2010.
67
Thank You

68