Heat Exchangers Analysis &

Design

Overview
Temperature
Co

& Counter Flow

Overall Coefficient of Heat Transfer
The Controlling Film Coefficient
Log Mean Temperature Difference
The Caloric or Average Fluid Temperature
The Pipe Wall Temperature
Equivalent Diameter
Heat Exchangers & Their Types
2

Temperature
Driving

force by which heat is transferred

from a source to the receiver

Only

inlet and outlet temperatures of hot

and cold fluids are known or can be mea
sured, and these are referred to as proc
ess temperatures

Co & Counter Flow

Co Current or Parallel Flow

t1

Cold Fluid

qc

t2

T1

Hot Fluid

qh

T2

Counter-Current Flow

t1
T2

Cold Fluid

qc

t2

Hot Fluid

qh

T1
4

Co & Counter Flow

Co Current or Parallel
Flow Temperature Profile

Counter Current Flow

Temperature Profile

T1

T1
T2
Cold Fluid

t2

Temperature

Temperature

Hot Fluid

t2

Hot Fluid

Cold Fluid

T2

t1

t1
Distance Along the Flow Path

Distance Along the Flow Path

Overall Coefficient of Heat Transfer

When

hot and cold fluids are flowing from d

ifferent sides of the wall, the resistances en
countered in heat transfer are:
Film resistance on one side of the wall
Wall resistance
Film resistance on other side of the wall

In

case of two concentric pipes, the resista

nce encountered are:
Pipe fluid film resistance
Pipe wall resistance
Annulus fluid film resistance

Overall Coefficient of Heat Transfer

Overall Heat Transfer Coefficient is the
reciprocal of the sum of all the resistances

In This Case Resistances

are in Series
Heat Transfer Rate is given by

1
1 Lm 1
R

U
hi km ho

Q UAt

qh qc mhC ph Th mc C pc Tc
7

Very

Overall Coefficient of Heat Transfer

Pipe

has different areas on its inside and

outside surfaces
hi & ho must be referred to the same heat
flow area
If the outside area A of the inner pipe is u
sed, then hi must be multiplied by Ai/A to
give the value that hi would have if origin
ally calculated on the basis of the larger
hio hi Ai A
area A instead of Ai.
8

The Controlling Film Coefficient

When the resistance of the pipe metal is small by c

omparison with the sum of the resistances of both f
ilm coefficients, and it usually is, it may be neglecte
1 1 1
d

U hi ho
If one film coefficient is small & the other very larg
e, the small coefficient provides the major resistanc
e & the overall coefficient of heat transfer for the ap
paratus is very nearly the reciprocal of the major re
sistance
e.g h 10 & h 1000
i

When a significant difference exists, the smaller

coefficient is the controlling film coefficient
9

Log Mean Temperature Difference

The

temperature difference between two strea

ms (hot & cold) is the driving force for heat tran
Q UAt
sfer
At every point (T-t) between two streams differs
LMTD is obtained from T-t Vs Q or T-t Vs L

dQ U (T t )adL
dQ WCdT wcdt

Gives

t2 t1
t LMTD
ln t2 t1
10

Log Mean Temperature Difference

For Co Current or
Parallel Flow LMTD

t1

Cold Fluid

T1

Hot Fluid

qc

t2

qh

T2

(T1 t1 ) (T2 t2 )
t LMTD
ln (T1 t1 ) (T2 t2 )
For Counter Current
Flow LMTD

t1
T2

Cold Fluid
Hot Fluid

(T1 t2 ) (T2 t1 )
t LMTD
ln (T1 t2 ) (T2 t1 )
11

qc

t2

qh

T1

The Caloric/Average Fluid Temperature

In

fluid-fluid heat exchange the hot fluid posse

sses a viscosity on entering which becomes g
reater as the fluid cools
The cold counter flow fluid enters with a viscos
ity which decreases as it is heated
All other properties varies as hot fluid is cooled
& cold fluid is heated
Values of heat transfer coefficients vary over th
e length of the pipe to produce a larger U at th
e hot terminal than at the cold terminal
12

The Caloric/Average Fluid Temperature

Caloric Temperature
for Hot Fluid

Tc T2 Fc (T1 T2 )
Caloric Temperature
for Cold Fluid

tc t1 Fc (t2 t1 )
13

The Caloric or Average Fluid T

emperature
Kc

Fc

t1 tc
r

t2 th
14

The Caloric/Average Fluid Temperature

If an apparatus transfers heat between

two petroleum cuts, the cut giving the l
argest value of Kc is controlling and ca
n be used directly to establish Fc for bo
th streams from the fig. 17

15

The Caloric/Average Fluid Temperature

20 oAPI crude oil is cooled from 300 to 200
0
F by heating cold 60 oAPI gasoline from 8
0 to 120 0F in a counter flow apparatus. At
what fluid temperature should U be evaluat
ed?

t1 80 F
0

Cold Fluid

T2 200 F
0

Hot Fluid

qc

t2 120 0 F

qh

T1 300 F
0

16

The Caloric/Average Fluid Temperature

tc
200 80
r

0.667
th 300 120
0
t

120

80

40
F
T1 T2 300 200 100 F 1 2
0

For Hot Fluid at T1-T2=1000F

& 0API=20 Fig. 17 gives

K c 0.68
r 0.667
Fc 0.42

For Cold Fluid at t1-t2=400F &

0
API=60 Fig. 17 gives

K c 0.1
The larger value of Kc corresponds to the controlling
heat transfer coefficient which is assumed to establish
the variation of U with temperature

17

The Pipe Wall Temperature

The

temperature of the pipe wall can be

computed from the caloric temperature
when both hi & ho are known

The

temperature difference across the pi

pe metal can be neglected and consider
the entire pipe to be at the temperature o
f the outside surface of the wall tw
18

The Pipe Wall Temperature

When Hot Fluid is
outside the inner pipe

When Hot Fluid

inside the pipe

is

ho
t w tc
Tc tc
hio ho
hio
tw Tc
Tc tc
hio ho

hio
t w tc
Tc tc
hio ho
ho
tw Tc
Tc tc
hio ho
19

Equivalent Diameter (De)

When

a fluid flows in a conduit having other th

an a circular cross section, such as an annulu
s, it is convenient to express heat transfer coef
ficients and friction factors by the same type of
equations and curves used for pipes and tubes

To permit

this type of representation for for ann

ulus heat transfer it has been found advantage
ous to employ an equivalent diameter De

20

Equivalent Diameter (De)

The

equivalent diameter is four times the

hydraulic radius, and the hydraulic radiu
s is, in turn, the radius of a pipe equivale
nt to the annulus cross section

The

hydraulic radius is obtained as the r

atio of the flow area to the wetted perime
ter

21

Equivalent Diameter (De)

The

wetted perimeter for heat transfer a

nd pressure drop are different
For Heat Transfer
Wetted

perimeter is the outer circumference

of the inner pipe with diameter D1

4 Flow _ Area
De 4 rH
4
Wetted _ Perimeter

4 D22 D12
D1

22

D22 D12

D1

Equivalent Diameter (De)

For

Pressure Drop

In

pressure drop calculations the friction not

only results from the resistance of the outer
pipe but is also affected by the outer surface
of the inner pipe
The total wetted perimeter is the sum of circ
umference of out side of inner pipe and insi
de of outer pipe
De 4 rH

4 Flow _ Area
4
Wetted _ Perimeter

4 D22 D12
( D2 D1 )
23

D2 D1

Concentric Pipe

24

Concentric Pipe H. Ex.

Inner Dia. of
Outside Pipe
(D2)

Fluid in the
Annulus

Outside Dia. of
Inner Pipe (D1)

Fluid Inside
Inner Pipe

25

Double Pipe Heat Exchanger

26

Double Pipe Heat Exchanger

When arranged in two legs, as

in fig. 6.1, the unit is a hairpin
27

Double Pipe Heat Exchanger

Principal

Parts

Two sets of concentric pipes

Two connecting Tees
A return head
A return bend
The inner pipe is supported within the outer pip
e by packing glands
Tees have nozzles to permit the entry and exit o
f the annulus fluid which crosses from one leg t
o the other through the return head
The two lengths of inner pipe are connected by
a return bend which is usually exposed & does
not provide effective heat transfer surface

28

Double Pipe Heat Exchanger

Simple

in construction
Small heat transfer surface area
Occupy large space
Leakage
However, is of greatest use where the
total required heat transfer surface is
small, 100 to 200 ft2 or less

29

Film Coefficients in Pipes & Tubes

For

Laminar Flow
DG c
hi D
1.86

k

For

13

0.14

Turbulent Flow
hi D
DG
0.027

0.8

13

w
30

0.14

Film Coefficients in Pipes & Tubes

Correlations were obtained for tubes

Pipes are rougher than tubes and produce more turbulence for equa
l Reynolds numbers
Coefficients calculated from tube data correlations are actually low
er and safer than corresponding calculations based on pipe data
Same correlations can be applied only by substituting De instea
d of D when calculation for the annulus is required

31

Tube Side Heat Transfer

32

Fouling Factors

U is obtained from values of hio & ho whereas Q & t are calcu

lated from the process conditions
Surface A (Q=UALMTD) required, can be computed
This calculation of A is known as process design
Dirt & scale deposit on the inside and outside of the pipe, addi
ng two more resistances
2 new resistances reduce the original value of U the required
amount of heat is no longer transferred by original surface A
T2 & t2 below the desired outlet temperature, although hi a
nd ho remains constant
To overcome this, the dirt/scale deposition is anticipated by int
roducing a resistance Rd called dirt, scale or fouling factor
33

Fouling Factors

U obtained form hio & ho only is considered as the clean overall

coefficient Uc
U obtained by including dirt resistance is called design or dirty
overall coefficient UD
A corresponding to UD rather than UC provides the basis on wh
ich equipment is ultimately built
1
1
1

Rdi Rdo
Rd
U D UC
UC

When Rd (deposited) > Rd (allowed)

Heat exchanger no longer delivers a quantity of heat equal to t

he process requirements and must be cleaned
34

Pressure Drop in Pipes & Pipe Annuli

Pump selected for circulation of a process fluid must develop suffi
cient head at the desired capacity to overcome all the frictional los
ses (Connecting piping, fittings and HX itself)
Head developed = pressure drop in HX circuit must be minimum
Best use of available pressure is to P G 2 P=10 psi
increase G, which increases hi and
is fairly
0.8
standard
lessens the size and cost of the apparatus hi G
2
fG
L
The pressure drop in the pipes can be P
computed from the fanning equation
2 g 2 De

Entrance / exit losses for inner pipe is negligible, but for annuli it
may be significant, unless the velocity is well above 3 ft/sec
Allowance P of one velocity head, V2/2g, per hairpin is sufficient
35

Calculation of a Double Pipe Exchanger

Q WC (T1 T2 ) wc(t2 t1 )
Heat balance
LMTD, assuming counter flow
Tc and tc
. If liquid is neither a petroleum fraction nor a hydrocarbon Tc can
not be determined through the use graph presented earlier
. Kc must be found from Uh and Uc and then Fc from the graph
. Tavg and tavg may be used in place of Tc and tc for evaluating the p
hysical properties IF
. Neither of liquids is very viscous at cold terminal, say >1 cP
. Temperature ranges do not exceed 50 to 1000F
. Temperature difference is less than 500F
. For non viscous fluids (/w)0.14 may be taken as 1
1.
2.
3.

36

Determination of Film Coefficients S

tep 4 to 10

4.

5.

6.

Inner Pipe
Flow Area
2

D
ap
, ft 2
4

Mass Velocity
m&p
Gp
, lb (hr )( ft 2 )
ap
Obtain at Tav, tavOR Tc, tc
, lb ( ft )(hr ) centipoise 2.42

Re p

DG p

4.

D2 D2
aAnnulus

a
2
1
4
Flow Area
D22 D12
De
D1

Ga
5.

m&a

aa

, lb (hr )( ft 2 )

Mass Velocity

37

Steps 4-10. Film Coefficients determination

6.
7.

Obtain jH ( jH vs DGp/)

hi D
jH

k
8.

9.

c

k

1 3

0.14

From c, k, at Tav, tavOR Tc,

tc, obtain (c/k)1/3
Obtain hi from jH

10. Convert

hi to hio

Obtain at Tav, tavOR Tc, tc,

, lb ( ft )(hr ) centipoise 2.42

Re a
7.

DeGa

Obtain jH ( jH vs DeGa/)

ho De
jH

c

k

1 3

0.14

8.

From c, k, at Tav, tavOR Tc,

tc, obtain (c/k)1/3

9.

Obtain ho from jH
38

Steps. 11-13 Overall coefficients

11.

Compute UC

hio ho
1 1
UC

Btu (hr )( ft 2 ) ( 0 F )
hio ho hio ho

12.

Compute UD

1
1 Rd
UD
UC

Q U D At

If length does not correspond to an integral number of

hairpins,
a change
13. Compute
A in dirt factor will result. The recalculated
dirt factor should equal or exceed the required dirt factor by
using the next larger integral number of hair pins
39

Pressure Drop Calculations

1.
2.

Inner Pipe
Obtain f
Find head loss
2
L Gp
Pp f p
Dp 2 p

1.

Annulus
D2e
D
Obtain
e D

D1

Rea DeGa

2.

Obtain fa L G 2
a
Pa f a
Find head D
loss
e 2a

41

Pressure Drop Calculations

V2
hl
( ft / hairpin)
2g

Pa Pa , f Pl

3.

Entrance & Exit losses

42

Double Pipe Exchangers in Series

Parallel Arrangements

43

Double Pipe Exchangers in Series

Parallel Arrangements

Suppose that the calculated pressure drop were 15

or 20 psi and exceeds the available head
How then might be the heat load transferred with t
he available pressure head?
One possibility is the use of a by-pass so that only
three-quarters or two-third of the fluids flows thro
ugh the exchanger & the remainder through the b
y-pass
This does not provide an ideal solution, since

Mass velocity is reduced, and the film coefficient also

If both coefficients are same then UC reduces by nearly G0.
8

It has to be cooled over a longer range say 160 to 100 0F, s

o that upon mixing with the by-pass fluid it reaches 100 0F

44

Double Pipe Exchangers in Series

Parallel Arrangements

Suppose that the stream which is too large to be acc

ommodated in several exchangers in series is divide
d in half and each half traverses but one exchanger t
hrough the inner pipes in Fig. 6.6
Dividing a stream in half while keeping the flow area
constant produces about one-eighth of the series pr
essure drop, since delta p =f(G2L)
While the film coefficient will also be reduced , the u
nfavorable temperature difference of by-passing can
be avoided
The larger stream may be divided in three, four, or m
ore parallel streams
In larger services each parallel stream may also flow
through several exchangers in series in each parallel
bank
45

Double Pipe Exchangers in Series

Parallel Arrangements
The

term parallel streams should not

be confused with parallel flow
Parallel streams refers to the division of
the flow of one fluid
Parallel flow refers to the direction of fl
ow between two fluids

46

True Temperature Difference for S

eries Parallel Arrangements
The LMTD calculated from T1, T2, t1, and t2 for the series
arrangement will not be the same for a series parallel ar
rangement
Half of the pipe fluid enters the upper exchanger where
the annulus fluid is hot, and half enters the lower excha
nger in which the annular fluid has already been partiall
y cooled
While exchangers in series do not transfer equal quanti
ties of heat, the series parallel relationship is even mor
e adverse, the lower exchanger accounting for relativel
y less of the total heat transfer (see fig)
if the true temperature difference is called delta t, it will
not be identical with the LMTD for the process conditio
ns although both of the exchangers operate in counter
flow

t (T1 t1 )

47

True Temperature Difference for Series Parallel

Arrangements

For one series hot stream & n parallel cold streams

1n

1 P
nR
1
R 1 1
2.3
log

R 1
R
R P

T1 T2
R
n t2 t1

T2 t1
P
T1 t1

t (T1 t1 )

For one series cold stream & n parallel hot streams

1n

1 P
n
1

2.3
log 1 R R

1 R
P

T1 t2
P
T1 t1

n(T1 T2 )
R
t2 t1

t (T1 t1 )
48

Shell & Tube Heat Exchanger

49

50

Shell & Tube Heat Exchanger

51

Shell & Tube Heat Exchanger

52

53

54

Baffles Segmental Baffles

25 % cut baffles

55

Baffles Segmental Baffles

56

Baffles Segmental Baffles

25 % cut baffles
57

Baffles Segmental Baffles

25 % cut baffles
58

Baffles Segmental Baffles

50 % cut baffles
59

Baffles Disc & Doughnut Baffles

Disc & Doughnut Baffles

60

Baffles Disc & Doughnut Baffles

Disc & Doughnut Baffles

61

Baffles Orifice Baffles

Orifice Baffles
62

Baffles Orifice Baffles

Orifice Baffles
63

Baffles

Higher h if liquid is maintained in a state of turbulen

ce
Turbulence outside the tubes introduced by baffles, ca
using liquid to flow through shell at right angles to axi
s of tubes
Centre to center distance between baffles is baffle pitc
h or baffle spacing
Baffle spacing is usually between 1/5 to 1 ID of the she
ll
Mass velocity is not entirely dependent upon diameter
of the shell
Baffles are held securely by means of baffle spacers
Segmental baffles are the most common types used
64

Tube Pitch

66

Tube Pitch

67

Tube Pitch

68

Tube Pitch

69

Shell & Tube Heat Exchanger-Par

ts

1. Shell
2. Tube Sheets
3. Channels
4. Channel Cover
5. Transverse Baffles
6. Baffle Spacers

70

1-1 Shell & Tube Heat Exchanger

71

1-2 Shell & Tube Heat Exchanger

72

U-Tube Heat Exchanger

73

Number of Passes

1-2 Shell & Tube Heat Exchanger

74

Number of Passes

2- 4 Shell & Tube Heat Exchanger

75

Number of Passes

3- 6 Shell & Tube Heat Exchanger

76

True Temperature Difference in a

1-2 Exchanger

77

True Temperature Difference in a

1-2 Exchanger

Relative to the shell fluid, one tube pass is in counter fl

ow and the other in parallel flow
Higher temperature difference results when process str
eams are in counter flow and lesser for parallel flow
1-2 Exchanger is a combination of both.
LMTD for counter flow or parallel flow alone cannot repr
esent the temperature difference for a parallel flow cou
nter flow arrangement
A new equation for the effective or true temperature diff
erence to replace the standard counter flow LMTD

78

True Temperature Difference in 1-2 Exchanger

t FT LMTD
FT

will be less than one due to the fact that the tube p
asses in parallel with the shell fluid do not contribute
so effective a temperature difference as those in count
er flow with it
It is not advisable or practical to use a 1-2 Exchanger
whenever the correction factor FT is less than 0.75
Instead some other arrangement is required which m
ore closely resembles counter flow

79

True Temperature Difference in a

1-2 Exchanger

80

True Temperature Difference in a

1-2 Exchanger
In

fact it is customary in parallel flow-count

er flow equipment to call T2 - t2 the approach
and if t2 >T2, then t2-T2 is called temperature
cross

FT

R 2 1 2 R 1 ln 1 S 1 RS

ln

2 S 1 R 2 S

1 S 1 RS
2 S 1 R 2 S 1 S 1 RS

ONLY FOR

2-4 heat exchanger

81

R 2 1

R 2 1

82

83

84

Shell Side Pressure Drop

The pressure drop through the shell of an exchanger is pro

portional to the number of times the fluid crosses the bund
le between baffles
It is also proportional to the distance across the bundle eac
h time it is crossed
Distance across the bundle is taken as the inside diameter
of the shell Ds

No of times the bundle is crossed N+1, where N is no of baf

fles
No of crosses, N+1 = tube length (in) / baffle space (in)
= L/ B

85

Shell Side Pressure Drop

There should always be an odd number of crosses if

both shell nozzles are on opposite sides of the shell
and an even number if both shell nozzles are on the
same side of the shell
The equivalent diameter used for calculating the pre
ssure drop is the same as for heat transfer, the additi
onal friction of the shell itself being neglected
For pressure drop of a fluid being heated or cooled a
nd including entrance & exit losses is

fG 2 Ds ( N 1)
Ps
2 Des
86

Tube Side Pressure Drop

fGt 2 Ln
Pt
2 De t
In flowing from one pass into the next at the channel and f
loating head the fluid changes direction abruptly by 1800 ,
although the flow area provided in the channel and floatin
g head should not be less than the combined flow area of
all the tubes in a single pass
The change of direction introduces an additional pressure
drop, called the return loss, and accounted for by allowin
g four velocity heads per pass

4n V 2
Pr
( psi )
s 2g

PT Pt Pr
87

Calculation of 1-2 Exchanger

Process

conditions required

Hot Fluid T1, T2, W, c, s, , k, Rd

Cold Fluid t , t , w, c, s, , k, R
1 2
d

For

the exchanger the following data must be

known
Shell Side

Tube Side

ID

Number
and Length

Baffle
Space (B)
Passes

OD, BWG,
Pitch
Passes

88

Calculation of an Existing 1-2 Exchanger

& (T T ) mc
& (t2 t1 )
Balance Q MC
1
2
True Temperature Difference
Heat

LMTD

T1 T2
R
t2 t1

t2 t1
S
T1 t1

t LMTD FT
Caloric

Temperature Tc & tc
89

Calculation of an Existing 1-2 Exchanger

Hot

Fluid (Shell Side)

4)Flow Area, as
as ID C B 144 PT , ft 2
5)Mass Velocity

Gs W as , lb hr. ft 2

6)Re

from De

De , square
De ,triangle

4 PT2 d o2 4

do

4 0.5 PT 0.86 PT 0.5 d o2 4

0.5 d o

.Obtain

, at Tc, or Tav
Re s DeGs

Cold

Fluid (Tube Side)

4)Flow
Area,
at Flowarea / Tube
No of
Tubes
at
No of
Passes
Flow area per
tube

at N t at 144n, ft 2
5)Mass

Velocity

Gt w at , lb hr. ft

6)Re,

obtain D Obtain , at Tc, l

Rex t2.42
DGt
b/hr ft2 = cp
90

Calculation of an Existing
1-2 Exchanger
Obtain jH for fig. 28
8) Pr no.
At Tc obtain cp & k
7)

Compute (c/k)1/3
9) ho
10)

7)

Obtain jH for fig. 24

Pr no.Fig. 16 For petroleum

fractions
At tc obtain cp& k 1 3
k c
h

j
Compute
i
H(c/k)
1/3 t
De k
9) ho
8)

Tube wall temp.

13

k c
ho jH

s
De k
ho s
t w tc
Tc tc
hio t ho s

10)

hio hi ID

t t OD
91

Calculation of an Existing
1-2 Exchanger
11)Obtain

w and

11)

0.14

s
w
12)Corrected ho

ho
ho s
s

Obtain w and

t
w

12)

0.14

Corrected hio
hio
hio t

92

Calculation of an Existing
1-2 Exchanger
13)

Clean Overall Coefficient Uc

14)

Design Overall Coefficient UD

hio ho
Uc
hio ho

Obtain external surface

/ lin. ft a// from table
10
2
Q

A aLN t ( ft )

15)

Dirt Factor Rd

UD

Uc U D
Rd
U cU D

At

If Rd equals or exceeds the required dirt

factor, proceed under the pressure drop
93

Calculation of an Existing
1-2 Exchanger
1)Friction

1)Friction

factor, f
For Res obtain f, ft2/in2 fr
om Fig. 29
2)Number of Crosses
N+1 = 12 L / B
3)Shell Side Pressure Dro
p

factor, f
For Ret obtain f, ft2/in2 fro
m Fig. 26
2)Tube Losses

fGt 2 Ln
Pt
( psi )
10
5.22
10 D(Fig.27)
3)Return
Losses
e st

4n V 2 62.5
Pr
( psi )
s 2 g 144
2
fGs Ds ( N 1)
4)Tube side pressure drop
Ps
(
psi
)
10

5.22 10 De ss

PT Pt Pr
94

Exchangers Using Water

Despite its abundance, the heat transfer characteri

stic of water separate it form all other fluids
It is corrosive to steel, particularly when the tube
wall temperature is high & dissolved air is present
Many industrial plants use non ferrous tubes
Since shells are usually fabricated of steel, water i
s best handled in the tubes
When water flow in the tubes, there is no serious p
roblem of corrosion of the channel and head cove
r, since these parts are often made up of cast iron
or cast steel
95

Exchangers Using Water

When water travels slowly through a tube, dirt resultin

g from microorganic action adhere to the tubes which
would be carried away if there were greater turbulenc
e
As a standard practice, the use of cooling water at vel
ocities less than 3 fps should be avoided
Still another factor of considerable importance is the
deposition of mineral scale
When water of average mineral and air content is brou
ght to a temperature in excess of 1200F, it is found that
tube action becomes excessive, and for this reason a
n outlet water temperature above 1200F should be avoi
ded
96

Exchangers Using Water

The

high thermal conductivity of water resu

lts in relatively high film coefficients compa
red with organic fluids
The use of tube side curve (Fig. 24), howev
er, gives coefficients which are generally hi
gh
In its place for water alone (Fig. 25) is data i
s given and are recommended whenever w
ater flows in tubes
Do example 7.4
97

Solution Exchangers
Do

example 7. 6

98

Heat Exchangers Using Steam

Do

example 7.8

99

100

Flow Arrangements for Increased

Heat Recovery (Chapter # 8)

101

Flow Arrangements for Increased

Heat Recovery

102

Flow Arrangements for Increased

Heat Recovery

103

Flow Arrangements for Increased

Heat Recovery

104

Flow Arrangements for Increased

Heat Recovery

When a temperature cross occurs in a 1-2 Exchan

ger, the value of FT drops sharply, and the small ext
ent to which the shell outlet temperature can fall b
elow the tube outlet temperature eliminates them f
rom consideration for high heat recoveries
This chapter deals with shell and tube equipment a
nd the methods by which the temperature cross of
two fluid streams t2-T2 can be increased with an ac
companying increase in heat recovery
Consider an exchanger similar to 1-2 exchanger ex
cept that it is equipped with a longitudinal baffle i.
e. 2-4 Exchanger

105

Flow Arrangements for Increased

Heat Recovery
The

shell fluid may be cooled at some point t

o a temperature lower than its outlet, and tub
e fluid may be heated to a temperature above
its outlet
When the two fluids are near their outlets, th
e shell fluid, being cooled, is actually heated
& the tube fluid is actually cooled
This is called reheating
In 2-4 Exchanger the longitudinal baffle redu
ces reheating
106

Flow Arrangements for Increased

Heat Recovery
Greater

the number of shell passes in a

n exchanger the greater the cross or the
greater the heat recovery which may be
obtained
It is seen that the 2-4 exchanger is ther
mally identical with two 1-2 exchangers
in series

107

Flow Arrangements for Increased

Heat Recovery
Greater

crosses than those possible in a 24 exchanger can be achieved by using thre

e 1-2 exchangers in series (3-6 exchanger),
or two 2-4 exchangers in series (4-8 exchan
ger)
Shell side area becomes half and no of cro
sses becomes double for 2-4 exchanger ins
tead of 1-2 exchanger
Example 8.1 & 8.2
108

Gases (Chapter # 9)
Properties

of gases
Pressure drop
Density of gas
Example 9.1

109

Chapter # 11 (Designing)
Rating an exchanger
In

chapter 7 to 9, calculations were carried

out for existing exchangers
Q was determined from the heat balance
A from number, OD and length of tubes
True temperature difference form F & LMTD
T

So solution of UD

From fluid flow conditions ho, hio, Uc, and pressu

re drops were calculated
The criterion of performance R was then obtain
d
ed from UD and Uc

110

Design of an Exchanger

When there is no available exchanger and only the

process conditions are known
Q and true temperature difference are fixed by the
process conditions
Only A and UD are unknown
UD is related to Uc by a reasonable dirt factor Rd
Except where both coefficient are approximately e
qual, the lower film coefficient determines the rang
e of Uc and UD
If a trial value of UD is assumed and a trial value of
A can be calculated
For trial value of UD see Appendix Table 8
111

Design of an Exchanger
When

the value of A is combined with tube le

ngth and pitch, the tube counts in Appendix
Table 9 becomes a catalogue of all the possi
ble exchanger shells
Form which only one will usually best fulfill t
he process conditions
Having decided which fluid will flow in the tu
bes, the trial number of tube passes can be a
pproximated
The trial mass velocity should fall somewher
e between 750,000 and 1,000,000 lb/hr ft 2 for f
luids with allowable tube side pressure drop
s of 10 psi
112

Design of an Exchanger
The

assumed number of tube passes for the t

rial surface is satisfactory if it gives a value o
f hi, above UD and a pressure drop not excee
ding the allowable pressure drop of the fluid
Next proceed to the shell side by assuming tr
ial baffle spacing which can be varied with o
ut altering hi, A and true temperature differen
ce
It is always advantageous therefore to comp
ute the tube side first to validate the use of a
particular shell
113

Calculation & Design of an Excha

nger
Heat BalanceQ WC (T1 T2 ) wc (t 2 t1 )
2) True Temperature Difference
1)

LMTD

T1 T2
R
t2 t1

t2 t1
S
T1 t1

t LMTD FT ( FT _ from _ fig .18 _ to _ 23)

3)

Caloric Temperature Tc & tc

114

Calculation & Design of an Excha

nger
Trial

Assume

a tentative value of UD (Table 8)

Compute

the surface A from A=Q/UD delta(t)

It

is always better to assume UD too high th

an too low, as this practice ensures arriving
at the minimum surface
Determine the corresponding number of tu
bes using table 10
115

Calculation & Design of an Excha

nger
Assume

number of tube passes

Select an exchanger for the nearest num
ber of tubes from the tube counts of Tabl
e9
Correct the tentative U to the surface co
D
rresponding to the actual number of tube
s which may be contained in the shell

116

Calculation & Design of an Excha

nger
Do

steps 4 to 12 for tube side and the

n pressure drop calculations
If the values of Rd and pressure drop i
s in permissible limits then do for she
ll side
Do

examples 11.1, 11.2, 11.3, 11.4

117

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119

120

121

122

123

124

125

126

127

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129

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137