SHELL AND TUBE HEAT

EXCHANGER DESIGN
CLB21003 PROCESS HEAT TRANSFER

WAQIUDDIN BIN MISBAH 55213114237

MUHAMMAD NAQUIB BIN MUZAMIR 55213114300
NURUL DESTI BINTI SAIFUL 55213114248
FATIN SYAFIQA BINTI MOHAMAD RODZI 55213114330

DECEMBER 13, 2015

UNIKL MICET
 SHELL AND TUBE HEAT EXCHANGER DESIGN

SECTION 1: EXECUTIVE SUMMARY

This project involved the design and construction of a suitable shell and tube heat
exchanger according to the required characteristic given. Basically, a 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. The primary aim of
the task is to create an efficient shell and tube heat exchanger in which we will consider some
parameters (such as type of fluids used, material used as element for shell and tube
construction, pressure, temperature as well as physical and chemical properties of fluid used)
that would affect the performance of shell and tube heat exchanger. So, based on our discussion
and research done, we chose to design a shell with one shell pass accompanied by counter-
current flow of fluid flow arrangement. Meanwhile, for the tube, we are decided to design a
tube of one pass with 61 tubes per pass. Firstly, for tube bank analysis, the inlet temperature is
150C and the outlet temperature is assumed to be 65C. The area of each tube bank is 1.25282
m2 and the heat transfer calculated is 6075 kW. The type of oil entered is selected to be palm
oil. The convection heat transfer coefficient, hi is found to be 468.45 W/ m2 C. On the other
hand, for shell analysis, the inlet temperature is 25C and the outlet temperature is calculated
to be 87.84C. The area of each the shell is 0.202703 m2 and the heat transfer calculated is also
6075 kW. The type of fluid entered the shell is water. The convection heat transfer coefficient,
ho is found to be 661 W/ m2 C. Besides, the overall heat transfer coefficient, U calculated is
68.8 W/ m2 C. Brass are used as material for tube construction and carbon steel used as
material for shell construction. For cost estimation, we are using formula of purchase cost, Cp
to calculate the total cost estimation for heat exchanger. At the end of calculation, the value
obtained is the total price in dollar America (USD). When we exchanged the currency to ringgit
Malaysia (MYR), the price now is RM448841.06.

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 SHELL AND TUBE HEAT EXCHANGER DESIGN

SECTION 2: INTRODUCTION
2.1 Product
Shell and Tube Heat Exchangers are one of the most popular types of exchanger due to
the flexibility the designer has to allow for a wide range of pressures and temperatures. A shell
and tube exchanger consists of a number of tubes mounted inside a cylindrical shell. Two fluids
can exchange heat, one fluid flows over the outside of the tubes (shell) while the second fluid
flows through the tubes. The essential principle of a heat exchanger is that it transfers the heat
without transferring the fluid that carries the heat.

Figure 1: Shell and Tube Exchanger

2.2 Industrial applications

a) Gas Cooling

In the chemical industry, production processes basically represent chemical reactions

on an industrial scale. The technical gases are widely used are oxygen, nitrogen, and other
gases. In large-scale chemical production, central supply facilities often provide such gases.
Turbine and piston compressors increase the pressure of these gases to the required level. After
each compression step, shell and tube heat exchangers remove the heat of compression via a
water cooling circuit. The shell and tube heat exchangers as pressure gas coolers are also widely
used in the further processing of petrochemical products, paints, coatings, and polyurethane
products.

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 SHELL AND TUBE HEAT EXCHANGER DESIGN

b) Steam Condensation

In many chemical processes, steam is required, or results from production. Typical

examples are in the manufacture of fertilizers and terephthalic acid where the latter of which is
primarily used in making PET, which goes in turn to the production of bottles. To return
exhaust steam and vaporous refrigerants to liquid form, a number of shell and tube heat
exchangers and plate heat exchangers are available for selection.
c) Separation Technology

In order to recover valuable substances (for example, iodine in pharmaceutical

production) or to prevent pollution of the environment (for example, with inert gases in storage
tanks), desublimators have proved highly effective. In this process of thermal substance
separation, as referred to an example from nature, desublimation which works like natural
crystallization when hoarfrost develops. Unlike chemical scrubbing, this solution eliminates
the need for disposing of solvents. Desublimation also enables greater product purity and
higher degrees of separation.
2.3 Function
Heat exchanger is used as component of air conditioning and cooling systems or of
heating systems. Many industrial processes call for a certain degree of heat to function.
However, great care must be taken to keep these processes from getting too hot. Within
industrial plants and factories heat exchangers are required to keep machinery, chemicals,
water, gas, and other substances within a safe operating temperature. Heat exchangers may also
be used to capture and transfer steam or heat exhaust that is released as a byproduct of a process
or operation so that the steam or heat can be put to better use elsewhere, thereby increasing
efficiency and saving the plant money.
2.4 Type
Shell and tube type heat exchanger is an indirect contact type heat exchanger. It consists
of a series of tubes, where the fluids will run through while the shell is the container for the
shell fluid. Generally, the shell is cylindrical in shape with a circular cross section. A shell is
the most commonly used due to its low cost and simplicity, and has the highest log-mean
temperature-difference (LMTD) correction factor. The tubes have a single pass, and flow in a
counter-current flow arrangement, the hot and cold fluids enter the heat exchanger from
opposite sides and flow toward each other. There is one pass on the shell side, while the other
fluid flows within the shell over the tubes to be heated or cooled. The tube side and shell side
fluids are separated by a tube sheet.

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 SHELL AND TUBE HEAT EXCHANGER DESIGN

2.5 Calculation Method of Equipment

a) Tube Bank Analysis
b) Shell Analysis
c) Overall Heat Transfer Coefficient Analysis

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 SHELL AND TUBE HEAT EXCHANGER DESIGN

SECTION 3: TUBE BANK ANALYSIS

For the first step in calculating the heat transfer in the shell and tube heat exchanger,
the fluid for the tube side and shell side are determine with each physical properties for the
calculation needed througout designing the heat exchanger. It is decided from the description
given. Hot fluid (palm oil) enter the tube side and the cold fluid (water) enter the shell side.
The properties needed are in the Table 1.

Tube Side Shell

Palm Oil Fluid Name Water
35.000 Flow (M), Kg/s 23.0
150 Temp. in, C 25
65 Temp. out, C 87.84
3
857.25 r, Kg/m 966.7
2
8.521 m, mNs/m 0.321
2.042 cp, kJ/kgC 4.2035
6,075 Q, kW 6,075
0.1670 k, W/mC 0.6740
0.0001 R,m C/W 0.00015
Table 1: Thermophysical Properties for Water and Palm Oil

The Q, rate of heat transfer for both side of shell and tube are calculated and to be equal with
each other. The Th,out, temperature out for hot fluid are estimated in order to calculate the Qh,
rate of heat transfer of hot fluid.

The rate of heat transfer in hot fluid (palm oil) is:

Qh = mhCp,hTh
Where,
Qh = rate of heat transfer (kJ/s)
m = mass flowrate of the substance (kg/s)
Cp = specific heat capacity of the substance (kJ/kg C)
T = temperature difference of the substance (C)

Qh = mhCp,h(Th,in-Th,out)

= 35 (2.042) (150-65) C
.

= 6074.95

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 SHELL AND TUBE HEAT EXCHANGER DESIGN

In order to get the Tc,out the following step is calculated.

To calculate Tc,out in cold fluid (water), assume Qh = Qc

Qc = mcCp,cTc
Where,
Qc = rate of heat transfer (kJ/s)
m = mass flowrate of the substance (kg/s)
Cp = specific heat capacity of the substance (kJ/kg C )
T = temperature difference of the substance (C)

Qc = mcCp,c(Tc,out-Tc,in)

6074.95 = 23 (4.2035) (Tc,out-25) C
.
(Tc,out-25) = 62.84 C
Tc,out = 87.84 C

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 SHELL AND TUBE HEAT EXCHANGER DESIGN

TUBE BANK CALCULATION

The tubes in the tube bank are arranged in-line with square pattern. The information needed
for calculating hi, heat transfer coefficient for flow across tube banks are given below.

Tube pitch, St (m) 0.20625

Outer Diameter of Tube, OD (m) 0.1650
Velocity (m/s) 1.9877

The maximum velocity is:

Vmax = (V)

Where,
ST = tube pitch (m)
OD = outer diameter of tube (m)
V = velocity of hot fluid (m/s)

.
Vmax = (1.9877 )
..

= 9.9385 m/s
Density, (kg/m3) 857.25
Dynamic viscosity, (kg/ms) 0.008521
Maximum velocity, Vmax (m/s) 9.9385
Diameter of tube (m) 0.1650

The Reynolds number is:

Re =

Where,
= density (kg/m3)
= dynamic viscosity (kg/ms)
V = maximum velocity (m/s)
Lc = diameter (m)

. (. )(.)
Re =
.
= 164976.3591

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 SHELL AND TUBE HEAT EXCHANGER DESIGN

Specific heat capacity, Cp (kJ/s) 2.042

Dynamic viscosity, (kg/ms) 0.008521
Thermal conductivity, k (W/m.) 0.1670

The Prandtl number is:

Pr =

Where,
Cp = specific heat capacity (kJ/s)
= dynamic viscosity (kg/ms)
k = thermal conductivity (W/m.C)

.. (.)
Pr =
.
.

= 104.191
Specific heat capacity, Cp (kJ/s) 2.249
Dynamic viscosity, (kg/ms) 0.003469
Thermal conductivity, k (W/m.) 0.1627

The Prandtl number at Ts= 150 is:

Prs =

Where,
Cp = specific heat capacity (kJ/s)
= dynamic viscosity (kg/ms)
k = thermal conductivity (W/m.C)

. (.)
.
Prs =
..

= 47.95

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 SHELL AND TUBE HEAT EXCHANGER DESIGN

Reynolds number, Re 164976.3591

Prandtl number, Pr 104.91
Prandtl number at surface temperature, Prs 47.95

The Nusselt number, Nu is:

0.25
Nu = 0.27 Re0.63 Pr0.36 ( )

Where,
Nu = Nusselt number
Re = Reynolds number
Pr = Prandtl number
Prs = Prandtl number at surface temperature
. 0.25
Nu = 0.27 (164976.3591)0.63 (104.191)0.36 ( )
.

= 3380.7941

To calculate heat transfer coefficient, hi:

Nusselt number, Nu 3380.7941

Diameter of tube, Lc (m) 0.1650
Thermal conductivity, k (W/m.) 0.1670

hi =

Where,
Nu = Nusselt number
L = diameter (m)
k = thermal conductivity (W/m.C)

...
hi=
.

= 3421.7734
.

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 SHELL AND TUBE HEAT EXCHANGER DESIGN

TO DETERMINE THE REQUIRED NUMBER OF TUBES

Area of one tube, Ax:

Ax= () (OD) (L)

Where,
OD = outer diameter of tube
L = tube length

Ax= 3.14 (0.1650m) (3.8m)

= 1.969 m2
Area required for heat transfer, Ay:

Ay=

Where,
LMTD = log mean temperature difference
Us = assumed overall heat transfer coefficient

Ay =
.
= 120.850 m2

No of tube, :

=

120.850
=
1.969
= 61

The total number of tube needed for shell is 61 tubes.

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 SHELL AND TUBE HEAT EXCHANGER DESIGN

SECTION 4: SHELL AND OVERALL HEAT TRANSFER COEFFICIENT

ANALYSIS
For shell side area, TEMA E single-pass shell specification were used. The shells side uid
enters the shell at one end and leaves from the other end. This is the most common shell type more
heat exchangers are built to this conguration than all other congurations combined.
The shell side contain cold fluid which is water. The thermophysical properties of
water is used to determine shell analysis. First, the Prandtl number is calculated.
Specific heat capacity, Cp (J/s) 4203.5
Dynamic viscosity, (kg/ms) 0.000321
Thermal conductivity, k (W/m.) 0.6740

The Prandtl number is:

Pr =

Where,
Cp = specific heat capacity (kJ/s)
= dynamic viscosity (kg/ms)
k = thermal conductivity (W/m.C)

.. (.)
Pr =
.
.
= 2.00

Then, the Reynold number are calculated,

Density, (kg/m3) 966.7
Dynamic viscosity, (kg/ms) 0.000321
Maximum velocity, V (m/s) 0.12
Diameter of tube (m) 0.117158

The Reynolds number is:

Re =

Where,
= density (kg/m3)
= dynamic viscosity (kg/ms)
V = velocity (m/s)
Lc = diameter (m)

. (. )(.)
Re =
.

= 42338.93

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 SHELL AND TUBE HEAT EXCHANGER DESIGN

The Reynolds number and Prandtl number are needed to calculate the Nusselt number.
Reynolds number, Re 42338.93
Prandtl number, Pr 2.00

The Nusselt number, Nu is:

. / /
Nu = 0.3 + (1 + (Re/282000)5/8)4/5)
(+(./)/)/
Where,
Nu = Nusselt number
Re = Reynolds number
Pr = Prandtl number
. (.)/ (.)/
Nu = 0.3 + (1 + (42338.93/282000)5/8)4/5)
(+(./.)/)/
= 115

Nusselt number, Nu 115

Diameter of tube, Lc (m) 0.117158
Thermal conductivity, k (W/m.) 0.6740

To calculate heat transfer coefficient for shell side:

ho =

Where,
Nu = Nusselt number
L = diameter (m)
k = thermal conductivity (W/m.C)

..
ho =
.

= 661.59
.

OVERALL HEAT TRANSFER COEFFICIENT

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 SHELL AND TUBE HEAT EXCHANGER DESIGN

To calculate the overall heat transfer coefficients, using formula:

U=

Where,
hi = convection heat transfer coefficient at tube side(W/m2.C)
ho = convection heat transfer coefficient at shell side(W/m2.C)
Ai = area of inner shell (m2)
Ao = area of outer shell (m2)
Rf,t = fouling resistance (m2C/W)
Rf,o = fouling resistance (m2C/W)
, ,
RT = + + +

. .
. .

= + + +
. (. ) . . (. )
. .

= 8.5165 10-3

AT = Ai + Ao
= (1.25282 + 0.202703) m2
= 1.45555 m2

U=
. (. )

= 80.66
.

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 SHELL AND TUBE HEAT EXCHANGER DESIGN

SECTION 5: PRODUCT QUALITY ASSURANCE

Material Selection
In order to create heat exchanger, the material selection is the most crucial aspects. The
heat exchanger that created must be long lasting and low in maintenance. Other than that the
material selection is also crucial to identify and to make sure the efficiency is high. Quality
assurance includes on how to manage with the quality of materials used, products formed and
the composition as well as the inspection process done. For the design of shell tube heat
exchanger, two types of fluid substance is used which is water and oil. The oil will pass through
the tubes in shell.
Some of the problems that could arise result from improper selection of materials for
tubes are corrosion. Since the shell side are flowed with water and exposed to air that consists
oxygen. The corrosion can occur because these two things is the important element for the
formation of rust, so suitable material should be suitable in order to prevent this problem. Other
than that, penetration of oil also can occur thus leakage of oil entering the shell of heat
exchanger that is filled with water. Last but not least the inefficiency of heat transfer from hot
liquid which is oil to cold liquid which is liquid.
In order to prevent this problem some specification is identified for the heat exchanger.
The specification consists of;
High thermal conductivity
Low specific heat capacity, Cp
Corrosion resistance

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 SHELL AND TUBE HEAT EXCHANGER DESIGN

Material of Shell
For the shell side carbon steel is chosen as the material. This is because its physical
properties and mechanical properties. Steel with a low carbon content has the same properties
as iron, soft but easily formed. As carbon content rises the metal becomes harder and stronger
but less ductile and more difficult to weld. Higher carbon content lowers steel's melting point
and its temperature resistance in general. Carbon steel is a metal alloy of carbon and iron that
has a relatively low tensile strength whose surface hardness can be increased through
carburizing. The amount of carbon used is usually less than 2 percent and no other metal
elements are added. Carbon steel is the most abundantly produced of all steel products. It has
a wide range of applications in the motor and electrical appliances sector due to its
ferromagnetic nature
On the other hand it has good thermal conductivity. The thermal conductivity is high
and it absorbs the heat from the oil and cool down by water. This type of material will get hot
faster and can be cooled down faster. Next, it is impermeable. It will prevents the texture of
substance which is in this case the oil and the water to mix together even though the wall is
thin.
Lastly, due to the specific volume it can be considered as light in terms of weight. It is
way lighter than steel or iron. It can be easily designed and handle. Due to all this point it can
be conclude that this material low in maintenance and easy to replaces if there is any damages
occur.

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 SHELL AND TUBE HEAT EXCHANGER DESIGN

Material for Tube

For the Tube side, the material that had be chosen is brass. This is material is chosen
due to several properties which are, firstly, it has low price. In order to make tube it has many
components. So by choosing this as the material it can reduce the price. Since the tube is being
used to cool down the hot liquid which is in this case the hot oil, the material chosen must have
higher melting point. This material have higher melting point so it cannot be affected by the
temperature of the liquid.
Brass tube is used for a variety of industries; including aerospace, power generation
and automotive sectors. Brass tube is anti-corrosive, easy-to-work and has properties ideal
for water supply and plumbing components whilst its excellent visual appearance makes it a
popular choice in areas such as interior design, architecture, public art and even musical
instruments.
Common Brass can be used for a wide variety of engineering (heat exchanger tubing).
Common Brass has ductility for cold forming and can be readily joined by soft or hard
soldering.

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 SHELL AND TUBE HEAT EXCHANGER DESIGN

SECTION 6: COST ESTIMATION

Area of surface tube= 21.20 ft

Pressure shell = 9bar = 130.532psi
Pressure tube = 5.5bar = 79.7708psi
Tube length = 3.8 m = 12.467 ft

PRESSURE FACTOR, Fp
Fp shell = 0.9803 + 0.018(/100) + 0.0017(/100)
=0.9803 + 0.018(130.534/100) + 0.0017(130.534/100)
=1.0067

Fp tube = 0.9803 + 0.018(/100) + 0.0017(/100)

= 0.9803 + 0.018(79.7708/100) + 0.0017(79.7708/100)
= 0.9957

Ftotal = 1.0067 + 0.9957

= 2.0024

FLOATING HEAD,Cb
Cb = { 11.6670.8709(ln())+0.09005(ln())}
= { 11.6670.8709(ln(12.20))+0.09005(ln(12.20))}
= 23202.14

MATERIALS OF CONSTRUCTION FACTORS, Fm

Fm = + (100)
21.20
= 1.08 + ( 100 )0.05

= 2.0054
Shell = carbon steel
Tube = brass

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 SHELL AND TUBE HEAT EXCHANGER DESIGN

TUBE-LENGTH CORRECTION FACTOR, Fl

Fl = 1.12 [ (1.12-1.05) (16-12) x (12.467-12)]
= 1.11

PURCHASE COST,Cp
Cp = Fp x Fm x Fl x Cb
=(2.0024)(2.0054)(1.11)(23202.14)
= 103419.60 USD
= 448841.06 MYR

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 SHELL AND TUBE HEAT EXCHANGER DESIGN

We estimate that the cost of designing the shell and tube exchanger for the
specifications is about RM 448841.06. We estimate by using formula of purchase cost which
is :
Purchase cost = pressure factor x material factor x tube length factor x floating head
CP = Fp x Fm x Fl xCb
We design the shell with material of carbon steel and the tube by the brass. For the material
factor, we obtain the and B from the table of material construction shell and tube which the
value are 1.08 and 0.05 respectively. For the tube length factor, our tube length is 3.8 meters
which need to convert to 12.467 ft and we obtain the value of Fl by interpolate of table tube-
length correction factor between 1.12 for 12 ft and 1.05 for 16 ft which is 1.11.

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 SHELL AND TUBE HEAT EXCHANGER DESIGN

SECTION 7: REFERENCES
Blackwell, W. W. and Haydu. L. (1981) Calculating the Correct LMTD in Shell-and-Tube
Heat Exchangers, Chemical Engineering, 101-106.
Jegeda, F. O., Polley, G. T. (1992) Optimum Heat Exchanger Design, Transactions of the
Institute of Chemical Engineering, 133-141.
J.P. Holman. (2002) Heat Transfer, 9th Edition, McGraw-Hill.
Kakac, S. (1981) Heat Exchangers: Thermal-Hydraulic Fundamentals and Design,
Hemisphere Publishing Corporation, New York.
Kern, D. Q. (1950) Process Heat Transfer, McGraw Hill.
Peters, M.S., Timmerhaus, K. D., and West, R. E. (2003) Plant Design and Economics for
Chemical Engineers, McGraw-Hill, New York.
Schlunder, E. V. (1983) Heat Exchanger Design Handbook, Hemisphere Publishing
Corporation, New York.
Smith, R. (2005) Chemical Process Design and Integration, Wiley.
Taborek, J. (1983) Shell-and-Tube Heat Exchangers, Section 3.3, Heat Exchanger Design
Handbook, Hemisphere.
Tubular Exchanger Manufacturers Association, (1998) Standards of Tubular Exchanger
Manufacturers Association, 7th Edition, New York.

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APPENDIX

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