Shell and tubeheat exchanger

design
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Design of Shell and Tube Heat
Exchangers
Design strategy
Shell and tubeheat exchanger
design
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Design of a shell and tube heat exchanger is an iterative process. The
suggested steps are outlined below.
Obtain an initial configuration, using the preliminary design techniques
that you have learned.
Follow established design guidelines (see for example Serth, 5.7) and
tables to specify an initial configuration.
Rate the design, as you have learned in the rating example to
determine if the design is thermally suitable.
Use principles of hydraulics/fluid mechanics to assess if the design is
hydraulically suitable (see section 5.3 Serth and Heaslip notes for hydraulic
calculations for S&T, and section 4.3 Serth for double-pipe HEs).
Modify the design if necessary
Iterate, until an acceptable design has been obtained.
Solved example (5.1 From Serth)
Design of a shell and tube heat exchanger
45,000 lb/h of kerosene are to be cooled from 390F to 250F by heat
exchange with 150,000 lb/h of crude oil, which is at 100F. A maximum
pressure drop of 15 psi has been specified for each stream. Crude oil
exhibits significant tendency for fouling, with a fouling factor of 0.003
h.ft
2
.F/Btu. Design a shell and tube heat exchanger for this service.
Fluid properties are as follows:
Kerosene c
p
=0.59 Btu/lb
m
.F, =0.97 lbm/ft.h, k=0.079 Btu/h.ft.F, specific
gravity 0.785, Pr=7.24
Crude Oil c
p
=0.49 Btu/lb
m
.F, =8.7 lbm/ft.h, k=0.077 Btu/h.ft.F, specific
gravity 0.85, Pr=55.36
Shell and tubeheat exchanger
design
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Initial specifications
Need to consider:
i. Fluid placement (see section 5.7.1 and Table 3.4)
ii. Shell and head types (i.e. floating head vs. fixed tubesheet), Type E
shell (single pass) vs. Type F shell (two-pass) see section 5.7.5
Shell and tubeheat exchanger
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Tube bank can be removed from the shell for cleaning
Tubular Exchanger
Manufacturers Association
(TEMA)
Three columns designate design for:
(1) Front end
(2) Shell types
(3) Rear end
e.g. Shell type E is commonly used
Shell type relates to the
shell side fluid pattern
Front and rear end relate to
the tube side flow pattern
Design standards:
Serth, pg. 88
Shell and tubeheat exchanger
design
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Initial specifications
iii. Tubing (see section 5.7.2).
Outer diameters D
o
= and 1 in. are most commonly used. For water service
in., 16 BWG tubes are recommended. For oils, in. 14 BWT for non-fouling, or
1 in. 14 BWG tubes for fouling fluids. Tube length from 8-30 ft. A good starting
point is 16 or 20 ft.
iv. Tube layout
Most commonly triangular or square, with a pitch of 1 in. (for in. tubes) or 1.25
in. (for 1-in.tubes).
Shell and tubeheat exchanger
design
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Square and rotated square patterns permit mechanical cleaning of the outside of the
tubes
Tube dimensions
Shell and tubeheat exchanger
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Initial specifications
v. Baffles (see section 5.7.6)
Segmental baffles with a 20% cut are a good starting point. This corresponds to a
baffle spacing of 0.3 shell diameters (i.e. B/d
s
=0.3)
vi. Other details such as sealing strips and construction materials.
Plain steel for tubes and shell if neither fluid is corrosive, one pair of sealing strips
per 10 tube rows.
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Sealing strips are thin strips of metal that reduce the effect of the bypass flow that flows
around the tube bundle. Mainly used in floating head heat exchangers.
Estimation of heat transfer area
Follow procedure from Example 1 (3.4 Serth) on estimation of heat transfer area
(a) Use energy balances to find the heat duty and any unknown parameters
(temperatures or mass flow rate).
(b) Calculate LMTD and correction factor assuming 1-2 heat exchanger:
Shell and tubeheat exchanger
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F=0.97>0.8 therefore one shell pass is suitable.
Estimation of heat transfer area
(d) Estimate the overall heat transfer coefficient, U
D
, from tables (for example
Table 3.5 Serth).
(e) Assuming U
D
=25 Btu/h.ft
2
.F, use the heat exchanger design equation to
calculate the required area and number of tubes.
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This is your starting point!
Initial design
(a) Find the number of tube passes, keeping in mind that turbulent flow
inside the tubes is desired (ideally Re>10,000)
The allowable range for the corresponding velocity is from 3-8 ft/s
(b) Determine the actual tube count and corresponding shell inner
diameter, d
s
(Table C.5 Serth)
This concludes the initial design. Summary:
Tube-side fluid: crude oil
Shell-side fluid: kerosene
Shell: type AES d
s
=21.25- in.
Tube bundle: 156 tubes, 1-in. OD, 0.834 ID, 14 BWG, 20 ft long on 1.25-in.
square pitch, arranged for 6 passes.
Baffle spacing 0.3 d
s
Shell and tubeheat exchanger
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Thermal Rating of the design
Now we will rate our design, using the technique learned previously (see example
3.5).
Step 1: Calculate the required overall coefficient, U
req
.
Step 2: Calculate the clean overall coefficient, U
c
, for our design.
- Calculate tube side heat transfer coefficient, h
i
(for example using eq. 4.21)
- Calculate shell-side heat transfer coefficient, h
o
(for example using eq. 3.21)
- Calculate clean overall coefficient and check if U
C
>U
req
Shell and tubeheat exchanger
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Thermal Rating of the design
Now we will rate our design, using the technique learned previously (see example
3.5).
Step 1: Calculate the required overall coefficient, U
req
.
Step 2: Calculate the clean overall coefficient, U
c
, for our design.
- Calculate tube side heat transfer coefficient, h
i
(for example using eq. 4.21)
- Calculate shell-side heat transfer coefficient, h
o
(for example using eq. 3.21)
- Calculate clean overall coefficient and check if U
C
>U
req
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Thermal Rating of the design
Step 3: Obtain the required fouling factors
Step 4: Calculate the overall heat transfer coefficient, U
D
.
If U
D
>>U
req
, the heat exchanger is thermally
suitable for service
BUT OVER-SIZED
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Over-surface and over-design
Recall:
% o:cr surocc =
A - A
c
A
c
1uu
where
A=actual heat transfer surface area in the exchanger
A
c
=calculated heat-transfer area based on overall U
c
(the clean heat transfer coefficient)
In terms of overall coefficients:
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This is much higher than the 20-40% typically used!!
We must modify the configuration, perhaps by reducing the number of tubes,
passes etc.
Hydraulic calculations will further help us in this decision (to be continued)