SHELL AND TUBE HEAT EXCHANGER DESIGN

USING HTRI SOFTWARE

Group 1
Mulyawan Haditomo 1206291720
Ghifari Syuhada 1306387802
Anantama Karis Fadila 1306387815
Luthfi Rizki Perdana 1306437334

DEPARTMENT OF MECHANICAL ENGINEERING

FACULTY OF ENGINEERING
UNIVERSITY OF INDONESIA
2017
 CONTENTS
TABLE OF FIGURES .......................................................................................................... ii
CHAPTER 1 ......................................................................................................................... 1
INTRODUCTION ................................................................................................................ 1
1.1 Background............................................................................................................. 1
1.2 HTRI Software........................................................................................................ 1
1.3 Thesis Source .......................................................................................................... 2
CHAPTER 2 ......................................................................................................................... 3
DESIGN PROCEDURE........................................................................................................ 3
2.1 Manual Calculations Input ...................................................................................... 3
2.2 HTRI Data Input ..................................................................................................... 7
CHAPTER 3 ....................................................................................................................... 12
RESULT ............................................................................................................................. 12
3.1 Comparison & Analysis ........................................................................................ 12
CHAPTER 4 ....................................................................................................................... 16
CONCLUSION ................................................................................................................... 16
REFERENCES ................................................................................................................... 17

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 TABLE OF FIGURES
Figure 1 HTRI Xchanger suite 6.0 interface .......................................................................... 2
Figure 2. Table of Corection Factor ....................................................................................... 4
Figure 3. Table of K1 and n1 constant ................................................................................... 5
Figure 4. Bundle Clearance Graph ......................................................................................... 6
Figure 5. Input summary interface ......................................................................................... 7
Figure 6. Tube geometry interface ......................................................................................... 7
Figure 7. Process of working fluids interface ......................................................................... 8
Figure 8. Kerosene component interface ................................................................................ 8
Figure 9. Inserting manual fluid properties ............................................................................ 9
Figure 10. Inserting manual Kerosene properties ................................................................... 9
Figure 11. Crude Oil Component Interface .......................................................................... 10
Figure 12. Inserting manual fluid properties ........................................................................ 10
Figure 13. Inserting manual Crude Oil properties ................................................................ 11
Figure 14 Output summary from HTRI software ................................................................. 12
Figure 15 Shell and tube design from Adis thesis ............................................................... 13
Figure 16 Shell and tube design from HTRI software .......................................................... 13
Figure 17 Tube arrangement from Adis thesis .................................................................... 14
Figure 18 Tube arrangement from HTRI software ............................................................... 14
Figure 19 Designed shell and nozzle from Adis thesis ........................................................ 15
Figure 20 Designed shell and nozzle from HTRI software ................................................... 15

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 CHAPTER 1
INTRODUCTION
1.1 Background
It has been observed that manual calculations often become lengthy and iterative. HTRI
has a rigorous and integral approach which gives more accurate results compared to manual
calculations. HTRI is the most widely used software in the industry namely heat exchanger
manufacturing industry. But it is also important to verify the results with manual calculations.
In the same way, manual design should also be verified with industrial software like HTRI. It
may happen sometimes that due to human error, manual design results may come out to be
somewhat inaccurate. So, in order to have a good and optimized design, manual and software
based calculations should be carried out simultaneously and verified with each other [1].

By using kern method for thermal calculation and number of iteration were done
manually in Adi Indras thesis, then the results are being compared and analyzed in HTRI
software. Hence, a better performance of shell and tube type heat exchanger can be obtained.
Both the design of heat exchanger done by using HTRI and Adi Indras thesis are compared.
It is predicted that many values (for example: number tubes) of the heat exchanger are
assumed to change in HTRI as compared to the tube obtained during manual calculation.

The result from this report will visualize the output of both methods and therefore the
feasibility of Adi Indras method of designing heat exchanger can be observed.

1.2 HTRI Software

The software used in this report is HTRI Xchanger Suite Version 6.0. HTRIs
calculation methods are backed by 50 years of extensive research and data collected on
industrially relevant heat transfer equipment. There are many features that can be done by
using HTRI besides including components of heat transfer for calculating the design of heat
exchangers and fired heaters. For instance, the results can also create graphs and scale
drawings in-depth visualization of calculated results. Moreover, the extensive output reports
can also provide the detailed results including local profiles of all important parameters, etc
[2].

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 There are different types of component that HTRI can simulate; a total of 9 components
can undergo various simulations. To name some, a Xace can simulate, rate and design an air
cooler or economizer. Whereas Xfh can simulate the performance of cylindrical and box
heaters. In our case, a Xist component is used to design the shell-and-tube heat exchanger
with known values of temperature inputs, flow rate, geometry of tube, shell, and baffles, etc
[2].

Figure 1 HTRI Xchanger suite 6.0 interface

1.3 Thesis Source

The manual calculations are done in thesis of Adi Indra Winata with the title of
Designing Shell and Tube Heat Exchanger of Fixed Head Type Using 3D Template Design
the thesis was done as one the prerequisites of completing the mechanical engineering
bachelor degree in Universitas Indonesia. The thesis was done in 2008 with the objective of
creating a method of automatic design integrated with the manual calculations from VBA
Microsoft excel to output a CAD drawing of the heat exchanger.
By creating the method of automatic 3D design template, the goal is to create a designed
heat exchanger in its optimum manner with a relatively quick process.

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 CHAPTER 2
DESIGN PROCEDURE
2.1 Manual Calculations Input
Based on the thesis of Adi Indra the fluids that are used for designing the heat exchanger
are crude oil and kerosene. The specifications for the design are stated below
Table 1. Fluids Temperature

Hot Fluid Kerosene

Temperature Inlet (Th1) 200oC
Temperature Outlet (Th2) 90oC
Flow Rate (mh) 20000 kg/hr

Cold Fluid Crude Oil

Temperature Inlet (Tc1) 40oC
Flow Rate (mc) 70000 kg/hr

Then we can calculate the Temperature Outlet (T c2) for the cold fluid by using

Mean temperature of kerosene = (200 + 90)/2 = 145oC

Cp = 2.47 KJ/kgoC

From the temperature above the mechanical properties of the fluids are
Table 2. Fluids Properties

Fluids Properties Kerosene (Hot Fluid) Crude Oil (Cold Fluid)

Inle / Outlet Temp(C) 200 90 40 78

Flow Rate (Kg/hr) 20000 70000
Cp (KJ/kg.C) 0.027 0.0023 2.09 2.01
Thermal cond. (W/m.C) 0.13 0.135 0.133 0.135
Viscosity (mN-s/m2) 2.2001 8.0003 0.2402 0.4299
Density (kg/m2) 690 770 690 690

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From the known temperature, we can try to calculate the LMTD for the heat exchanger

( )
( )

Temperature correction factor

Figure 2. Table of Corection Factor

From the table of correction factor, we can get the value (Ft) = 0.87

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 It has been determined that the shell and tube heat exchanger used is a fixed head type.
And because the crude oil is dirtier than kerosene, then it is determined that the crude oil will
be inside the tubes while the kerosene inside the shell. Layout and the tube dimension are
determined as follows:
Tube diameter (do) = 19.05mm (3.4 inch)
Tube thickness (t) = 2.11mm
Tube length (L) = 5m
Tube pass = 2
Shell pass = 1
Layout = Triangular
We can calculate the pitch by using

We can calculate the number of tubes by using

After calculating the number of tubes we can use the value to calculate diameter bundle
(Db) which then will be used to find the shell diameter

From the table, we can get the value

Figure 3. Table of K1 and n1 constant

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Inserting the value to the equation

To calculate the shell diameter, we can use

Ds = Db + BDC

Where BDC is bundle diameter clearance from graph

Figure 4. Bundle Clearance Graph

In this case, we use the fixed and U-tube type which give the BDC = 12 mm

Ds = 428 + 12 = 440mm

From the calculation above we can input the data to HTRI

Table 3. Parameter

Shell ID (mm) 440

Baffle Type Single segmental
Baffle cut (% ID) 25
Tube Length (m) 5
Tube OD (mm) 19.05
Pitch (mm) 23.81
Wall thickness (mm) 2.108
Tube passes 2
Shell passes 1
Layout Triangular (30o)

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2.2 HTRI Data Input
In designing heat exchanger with HTRI software, initial data is needed to be input. Some
has to be determined first, and some will be calculated. To begin with the data input, select
the case mode to determine whether the case is designing or rating a heat exchanger. Input
the process conditions in the input summary tab from the data available beforehand. Then,
input the shell geometry and tube geometry, as well as baffle geometry.

Figure 5. Input summary interface

Figure 6. Tube geometry interface

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 Figure 7. Process of working fluids interface

Next, is determining the properties of the working fluids which will be used. It is
determined that Kerosene will work as hot working fluid and Crude oil as cold working fluid.
However, since there are no properties of the working fluid available in HTRI software for
Kerosene and Crude Oil, the properties of fluids should be inserted manually to the library.

Figure 8. Kerosene component interface

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 Figure 9. Inserting manual fluid properties

Figure 10. Inserting manual Kerosene properties

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Figure 11. Crude Oil Component Interface

Figure 12. Inserting manual fluid properties

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Figure 13. Inserting manual Crude Oil properties

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 CHAPTER 3
RESULT
3.1 Comparison & Analysis

Figure 14 Output summary from HTRI software

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 Above is the output summary of the designed heat exchanger with all the data available
beforehand in Adis thesis. Compared with Adis manual calculation, the output is different.
For the TEMA type of shell geometry, based on Adis design result the TEMA type can be
categorized as BEM.

Figure 15 Shell and tube design from Adis thesis

Figure 16 Shell and tube design from HTRI software

The picture above shows the heat exchanger design from Adis thesis and HTRI software.
The upper one is Adis designed heat exchanger and the second one is from HTRI software.
In 5 meters long of designed shell, the number and spacing of the baffle is differ from each
other. It could be caused by the calculation method which is also different. In Adis thesis,
the calculation is done manually with all the formula given in text book, while in HTRI
software might have a different way of calculation that might be more accurate as well.

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 Figure 17 Tube arrangement from Adis thesis

Figure 18 Tube arrangement from HTRI software

In tube arrangement, the arrangement from those 2 sources is different. With using
triangular (300) for both of the tube arrangement, the output design differ. The pitch is
calculated differently from Adis thesis and HTRI software and concluded with different
value. The number of tube is also different, from Adis thesis calculation it is shown that it
has 240 tubes with 120 tubes in each pass, while the calculation from HTRI shown that it has
316 tubes with 158 tubes in each pass.

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 Figure 19 Designed shell and nozzle from Adis thesis

Figure 20 Designed shell and nozzle from HTRI software

Above is the picture of the output 3D design of the shell of a shell and tube heat
exchanger. From the picture, the 3D design is not significantly different, where only the
baffle spacing and number are different. Both designs are two pass shell and tube.

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 CHAPTER 4
CONCLUSION

As conclusion, HTRI software is quite easy to use if all the required data is available.
Adis thesis design calculation is based on all the formula that is in text book. The use of all
formula is depended on the type of TEMA, the flow of fluids, tube arrangement, shell and
tube geometry and etc. Adis thesis only works for particular category of shell and tube,
while HTRI software covering all the categories of heat exchanger. The manual calculation in
Adis thesis is different from HTRI. There are some variable that might be using different
formula that resulting in different value.
It is much easier to use HTRI as a software to design a shell and tube heat exchanger as it
has many variables that can be inputted to get an efficient design. And it can directly become
drawing which are exchanger drawing, tube arrangement drawing, 3D exchanger drawing,
this can help us to understand our design better.

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 REFERENCES

[1] S. Sahajpala and P. D. Shahb, Thermal Design of Ammonia Desuperheater-Condenser and

Comparative Study with HTRI, Elsevier Ltd, December 2013.

[2] Heat Transfer Research, Inc., "HTRI Xchanger Suite | HTRI," [Online]. Available:
https://www.htri.net/htri-xchanger-suite. [Accessed 20 May 2017].

[3] A. I. Winata, "Perancangan Shell And Tube Heat Exchanger Tipe Fixed Head Dengan
Menggunakan Desain 3D Template," Universitas Indonesia, Depok, 2008.

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