Heat Transfer Equipment

CHE 141
Course Objectives

 Identify the different types of heat transfer

equipment and its application in the chemical
industry.
 Identify the factors which affect the size of a
heat exchanger; and
 Design a shell and tube heat exchanger.
Heat Transfer Equation

The prime objective in the design of a heat exchanger

is to determine the surface area required for the
specified duty (rate of heat transfer) using the
temperature difference available.
Typical Procedure in Designing a Shell and
Tube Heat Exchanger
Typical Procedure in Designing a Shell and
Tube Heat Exchanger

1. Define the heat duty: heat transfer rate, fluid

flow rates and temperatures.

QH = mHCpH-AVE (T1-T2)
QC = mCCpC-AVE (t2-t1)

QH = QC; if not select higher duty and adjust

other parameters such as flow rate or temp.

If phase change occurs, include latent heats.

Typical Procedure in Designing a Shell and
Tube Heat Exchanger

2. Collect the fluid properties required: density,

viscosity, heat capacity, and thermal
conductivity.
Typical Process Specification

Fluid name Diesel Product Heavy Feed

Fluid quantity, total kg/h 698524 221156
Vapor (in/out) kg/h - - - -
Liquid (in/out) kg/h 698524 698524 221156 221156
Steam (in/out) kg/h - - - -
Temperature (in/out) °C 205 198 164 183
Vapor Molecular kg/kmol - - - -
weight
Specific heat kJ/kg.°C - - - -
Thermal Cond. W/m.°C - - - -
Density kg/m3 856.2 861.3 850.9 840.6
Liquid Viscosity cP 0.39 0.41 2.9 2.3
Specific heat kJ/kg.°C 2.075 2.054 2.297 2.362
Thermal Cond. W/m.°C 0.090 0.091 0.085 0.083
Latent heat kJ/kg - -
Inlet pressure kPa g 1220 1620
Velocity m/s - -
Pressure drop kPa Allow. 50 Calc. - Allow. 80 Calc. -
Fouling resistance m².°C/W 0.00052 0.00069
Heat exchanged MW 2.635 LMTD - °C
(corrected)
Aspen Hysys Simulation
Typical Procedure in Designing a Shell and
Tube Heat Exchanger

3. Decide the type of exchanger to be used.

• Shell and tube
• Double pipe
• Air cooled
Types of Heat Exchangers
 Shell and Tube Heat Exchanger
Types of Heat Exchangers
 Shell and Tube Heat Exchanger
Types of Heat Exchangers
 Double Pipe Heat Exchanger
Types of Heat Exchangers
 Double Pipe Heat Exchanger
Types of Heat Exchangers
 Air Coolers

Forced Draft
Induced Draft
Types of Heat Exchangers
 Air Coolers (Forced Draft)
Typical Procedure in Designing a Shell and
Tube Heat Exchanger

4. Assume (for 1st trial) and calculate (for succeeding trials)

the overall heat transfer coefficient, UD (dirty/fouled).
Overall Heat Transfer Coefficient (UD)
Overall Heat Transfer Coefficient (UD)

Towler, et. al. 2008.

Refer to Table 11-3 to Table 11-8 for other

U values in Perry’s, et. al. 7th ed.
Overall Heat Transfer Coefficient (UD)

Towler, et. al. 2008.

Fluid Film Coefficient (ho and hi)

Many correlations were developed by various authors to

estimate the convective heat transfer coefficient in various
cases including natural convection, forced convection for
internal flow and forced convection for external flow. These
empirical correlations are presented for their particular
geometry and flow conditions.

Film coefficients, just like overall coefficients, are influenced

by many parameters such as nature of the fluid, type of
heat exchanger, fluid velocity, transport properties and
temperature.

See calculation procedure under “Pressure Drops”

Relationship of UD (dirty/fouled) and UC (clean)
Fouling Factors (hod or hid)

 Most process and service fluids will foul

the heat transfer surface areas in an
exchanger to a greater or lesser extent.

 The deposited material will normally have

a relatively low thermal conductivity and will
reduce the overall heat transfer coefficient.

Thus, it is necessary to oversize an

exchanger to allow for the reduction in the
performance during operation.
Fouling Factors (hod or hid) Towler, et. al. 2008.
Stream Temperatures

The closer the temperature approach used (difference between

the temperatures of the two streams at a given point), the larger
will be the heat-transfer area required for a given duty.

As a general guide, the optimum temperature approach will

usually be in the range of 10 degC to 30 degC for heat exchange
between process streams.

Lower temperature approaches are used for coolers:

5 degC to 7 degC = using cooling water
3 degC to 5 degC = refrigerated brines (chilled water)

30 degC  maximum temperature rise for recirculated cooling

water.
Typical Procedure in Designing a Shell and
Tube Heat Exchanger

5. Calculate the mean temperature difference.

 Mean Temperature Difference (Shell & Tube)

If Ft < 0.75, the exchanger is

not economical. Hence, select
Refer to Perry’s for
a different configuration.
other configurations.
Conductive Heat Transfer
Typical Procedure in Designing a Shell and
Tube Heat Exchanger

6. Calculate the required heat transfer area. Add

at least 10% (typical) margin on area.
Typical Procedure in Designing a Shell and
Tube Heat Exchanger
7. Decide the heat exchanger layout.
8. Calculate the individual heat transfer coefficients (hi,
ho).
9. Calculate the overall coefficient and compare with the
trial value. If the calculated value differs significantly
from the estimated value, substitute the calculated for
the estimated value and return to step 6.
10. Calculate the exchanger pressure drop; if
unsatisfactory return to steps 7 or 4 or 3, in that order
of preference.
11. Optimize the design: repeat steps 4 to 10, as
necessary, to determine the cheapest exchanger that
will satisfy the duty. Usually this will be the one with
the smallest area that satisfies the pressure drop
constraint.
 Shell and Tube Exchangers

The mechanical design features, fabrication, materials of

construction, and testing of shell and tube exchangers are
covered by the standards of TEMA (Tubular Heat
Exchanger Manufacturers Association).

Three Classes:
1. Class R = generally severe duties of the petroleum and
related industries.
2. Class C = moderate duties in commercial and general
process applications
3. Class B = chemical process industries
Shell and Tube Exchangers

Types of TEMA Heat

Exchangers
 Identified by a three letter
code.

First Letter = tube-side

head type (front-end)

Second Letter = shell type

Third Letter = rear end

Shell and Tube Exchangers
Shell and Tube Exchangers
Shell and Tube Exchangers

BEM = Simplest and cheapest type of shell and tube exchanger with
fixed tube-sheet design; tube bundle cannot be removed for cleaning and
there is no provision for differential expansion of the shell and tubes.

BEU = widely used but is limited to relatively clean fluids as the tubes
and bundle are difficult to clean; more difficult to replace the tubes
Shell and Tube Exchangers

AET and AES = with internal floating head; more versatile than fixed-
head and U-tube exchangers
= suitable for high temperature differentials
= tubes can be rodded from end to end and the bundle can be removed
= can be used for fouling service

AKU = kettle reboiler with U-tubes used for reboilers and evaporators
that are heated with steam, as steam is a nonfouling service

BKU = widely used kettle reboiler without a removable channel

Stream Selection

Service Shell Side Tube Side

Sea or brackish water 
Cooling tower water 
Condensing process streams 
Lower allowable pressure drop 
Larger flow with similar 
properties
Higher pressure 
Corrosive fluids / alloy 
construction
High viscosity / laminar flow 
Suspended solids 
Tubes Diameter, Thickness and Length

TEMA design standard allows tube diameters between ¼” (6.4mm) and

2” (50mm) but tube diameters in the range of 5/8” (16mm) to 2” (50mm)
are most often used.

Tip: Use a common tube diameter for heat exchangers in the plant.

Tube thickness (gauge) is selected to withstand the internal and

external (shell-side) pressure with adequate corrosion allowance.
 Use tube thickness which correspond to BWG untis (Birmingham Wire
Gauge)

Preferred Lengths of Tubes

 Dependent on plot space for removable tube bundle types
 Preferred lengths of tube are 6 ft, 8 ft, 12 ft, 16 ft, 20 ft, 24 ft.
 For a given surface area, the use of longer tubes will reduce the shell
diameter but will lead to increase pressure drop and pump work.

Optimum tube length to shell diameter ratio = 5 to 10.

GPSA Engineering Databook. 2004.
Tube Arrangements

Triangular and rotated square = higher heat-transfer rate but at

the expense of a higher pressure drop than square pattern.

Square and rotated square = for heavily fouling fluids (for

mechanical cleaning)

Recommended pitch (Pt) = 1.25 x OD of tube

High Pressure Water Jet Cleaning
Tube Passes

The number of tube

passes is selected to
give the required tube-
side design velocity.
Tube Passes
Tube-sheet Layout (Tube Count)

The bundle diameter depends not only on the number of tubes but also
on the number of tube passes, as spaces must be left in the pattern of
tubes on the tube sheet to accommodate the pass partition plates.
Towler, et. al. 2008.

Alternatively, the table from

TEMA can be used to
estimate the shell ID.
Shell Diameter
Towler, et. al. 2008.
Up to 24” (610mm), shells
are normally constructed
from standard pipe
Above 24” (610mm), shells
are constructed by rolling a
plate.

Standard Shell ID (mm):

203, 254, 305, 337, 387,
438, 489, 540, 591, 635,
686, 737, 787, 838, 889,
940, 991, 1067, 1143, 1219,
1372, 1524, 1676, 1829,
1981, 2134, 2286, 2438,
2743, 3048
Shell Diameter
 Baffles
Baffles are used in the shell to direct the fluid stream across the
tubes, to increase fluid velocity and so improve the rate of heat
transfer.

Vertical Cut
Baffle Cut = height of the segment
removed to form the baffle, expressed as
% of the baffle disc diameter.
Typically, 15% to 45% (20-25%
optimum).
Spacing = 0.2-1.0x of shell ID Horizontal Cut
Baffles
Shell and Header Nozzles

Exchanger nozzles are generally sized to match the line sizes

(same pressure drop criteria).

As a rough rule of thumb, the total pressure drop in the nozzles

should not exceed 10-15% of the total allowable pressure drop.

To avoid erosion, limit the nozzle v^2 to 4000 lb/ft s^2 (TEMA
maximum for shell entrance).

Provide impingement baffle at shell

nozzle entrance for erosive fluid or
v^2 > 500 .
Shell and Tube Fluid Velocities

Liquids:
Tube side, process fluids = 1-2 m/s, maximum 4
m/s if required to reduce fouling;
water 1.5-2.5 m/s
Shell side = 0.3 to 1 m/s

Vapors:
 Should be below the maximum allowable
Pressure Drops pressure drop based on system hydraulics.

Typical

Tube side pressure drop = calculated similar to pipe pressure drop

calculation; flow in each tube = total flow / number of tubes per pass.
Shell side pressure drop = refer to Towler & Sinnott. Chemical
Engineering Design Principles, Practice and Economics of Plant and
Process Design, 2nd Edition.page 1086-1089.
Pressure Drop and Heat Transfer Coefficient
(Tube Side, Single Phase)
Pressure Drop and Heat Transfer Coefficient
(Tube Side, Single Phase)
Pressure Drop and Heat Transfer Coefficient
(Tube Side, Single Phase)
Pressure Drop and Heat Transfer Coefficient
(Tube Side, Single Phase)
Pressure Drop and Heat Transfer Coefficient
(Tube Side, Single Phase)
Pressure Drop and Heat Transfer Coefficient
(Tube Side, Single Phase)
Pressure Drop and Heat Transfer Coefficient
(Tube Side, Single Phase)
Pressure Drop and Heat Transfer Coefficient
(Tube Side, Single Phase)
Pressure Drop and Heat Transfer Coefficient
(Tube Side, Single Phase)
Pressure Drop and Heat Transfer Coefficient
(Tube Side, Single Phase)
Pressure Drop and Heat Transfer Coefficient
(Tube Side, Single Phase)
Pressure Drop and Heat Transfer Coefficient
(Tube Side, Single Phase)
Pressure Drop and Heat Transfer Coefficient
(Tube Side, Single Phase)
Pressure Drop and Heat Transfer Coefficient
(Tube Side, Single Phase)
Pressure Drop and Heat Transfer Coefficient
(Shell Side, Single Phase)
Pressure Drop and Heat Transfer Coefficient
(Shell Side, Single Phase)
Pressure Drop and Heat Transfer Coefficient
(Shell Side, Single Phase)
Pressure Drop and Heat Transfer Coefficient
(Shell Side, Single Phase)
Pressure Drop and Heat Transfer Coefficient
(Shell Side, Single Phase)
Pressure Drop and Heat Transfer Coefficient
(Shell Side, Single Phase)
 Shell and Tube HE Design Specification

• Refer to a sample PROCESS SPECIFICATION

SHEET

• Refer to a sample THERMAL DESIGN

SPECIFICATION SHEET