SHELL AND TUBE DESIGN INVOLVING TWO PHASE HEAT TRANSFER

1.0. CONDENSERS
Condensers are heat exchangers that cool vapours to liquid. This phenomenon is called
condensation. The condensation of vapour to liquid occur the saturation temperature of a pure fluid
at a given pressure. The industrial practice of condensation occurs at almost constant pressure;
therefore the phase change occurs isothermally. Condensation occurs by two different physical
mechanisms i.e. drop-wise condensation and film condensation.
The nature of the condensation depends upon whether the condensate wets or does not wet the
solid surface. If the condensate wets the surface and flows on the surface in the form of a film, it is
called film condensation. When the condensate does not wet the solid surface and the condensate is
accumulated in the form of droplets, is drop-wise condensation. Heat transfer coefficient is about 4
to 8 times higher for drop wise condensation. The condensate forms a liquid film on the bare-surface
in case of film condensation. The heat transfer coefficient is lower for film condensation due to the
resistance of this liquid film. Drop-wise condensation occurs usually on new, clean and polished
surfaces. In industrial condensers, film condensation normally occurs.
1.1. TYPES OF CONDENSERS
Condensers are of two types;
VERTICAL CONDENSER: it has the following two configurations
Downflow vertical condenser: The vapour enters at the top of condenser and flows down inside
tubes. The condensate drains from the tubes by gravity and vapour induced shear.
Upflow vertical condenser: In case of upflow condenser, the vapour enters at the bottom and flows
upwards inside the tubes. The condensate drains down the tubes by gravity only.
Condensation inside vertical tubes follows essentially the same mechanism as condensation outside
vertical tubes if the interference of the shell baffle is neglected.
HORIZONTAL CONDENSER: The condensation may occur inside or outside the horizontal tubes.
Condensation normally occurs on the tube (i.e. shell side). But in cases where the condensate is
corrosive or it is needed to recover the latent heat from the vapour by using it to preheat the feed to
a column.
1.3. COMPARISON OF HORIZONTAL AND VERTICAL CONDENSERS IN A DISTILLATION COLUMN
1. Horizontal condenser is well suited for gravity return of condensate than vertical condenser
since maintenance and structural support for the vertical condenser may be costly and
considerably more difficult.
2. If it is desired not only to condense the overhead vapour, but also to subcool the
condensate, the vertical condenser is most suitable (subcooling is the operation of cooling
the condensate below its saturation temperature, and this is done very frequently when the
overhead product is a volatile liquid to be sent to storage.(the combination of condensation
and subcooling in a single unit eliminates the need for a separate overhead product cooler)
2.0. DESIGN CONSIDERATION OF CONDENSERS
1. Horizontal shell-side and vertical tube-side are the most commonly used types of condenser.
2. Condensers usually use wider baffle spacing of approximately shell inner diameter as the
allowable pressure drop in shell side vapour is usually less (ie if condensation is in shell side)
3. Vertical cut-segmental baffles are generally used in horizontal condensers while horizontal
cut is used for vertical condenser.
4. Opening at the bottom of the baffles is provided to allow draining of condensate
5. Water is the most widely used coolant because of it availability and cheap cost
6. Shell nozzles should be as wide as possible to avoid high pressure drop in the shell side

7. Condensing film heat transfer coefficient is assumed within the range of 500
to

(i.e. film coefficient of condensing hydrocarbons generally varies in this

range). But air-free condensing steam has a coefficient of

.
8. For the condensation of exhaust steam from turbines with vacuum discharge the condenser
surface is usually very great from 10000 to 60000ft2 per shell and tube up to 26 ft long are
employed. Large condensers are designed with overall transfer coefficient as high as

(
) Condensers as these are installed horizontally to
facilitate the distribution of the vapour and removal of the condensate.
3.0. ESTIMATION OF CONDENSING FILM HEAT TRANSFER COEFFICIENT
3.1. CONDENSATION ON HORIZONTAL TUBES
3.1.1. CONDENSATION OUTSIDE HORIZONTAL TUBE (Shell SIDE)
Based on results from commercial exchangers, Using Kerns method, the mean coefficient for a tube
bundle is given by:
(
)
[
]
Where;
Mean condensation film coefficient
Condensate thermal conductivity,
Condensate density,
,
Vapour density,
,
Condensate viscosity,
,
Gravitational acceleration, 9.81

Tubes loading, the condensate flow per unit length of tube,

Total condensate flow
Effective length of tube
Total number of tubes in the bundle,
Bundle diameter
Tube pitch
3.1.2. CONDENSATION INSIDE HORIZONTAL TUBE (TUBE SIDE)
i.

The mean coefficient for stratified flow can be estimated from:

(
)
[
]

ii.

The mean coefficient for annular flow can be estimated from Boyko-Kruzhilin equation;

( )
[
]

Where;

This equation is based on the assumption that in a condenser the inlet stream will normally be
saturated vapour and the vapour will be totally condensed.
For condenser design, the mean coefficient should be evaluated using the correlations for both
annular and stratified flow and the higher value selected.
3.2. CONDENSATION ON VERTICAL TUBES
3.2.1. CONDENSATION INSIDE AND OUTSIDE VERTICAL TUBES
(
)
[
]
Where;

This equation above applies for

and its use of the equation above 30 however will give
conservative (safe) estimate.
Above a Reynolds number of around 2000, the condensate film becomes turbulent. The effect of
turbulence in the condensate film for condenser design, can be evaluated using (Figure1) in
collaboration with the Prandtl ( ) and Reynolds number ( ) for the condensate film to give an
estimated value of;
( )[

Figure1: Condensation coefficient for vertical tubes

Note: For inside the vertical tubes however, addition verification is carried out using BoykoKruzhilin equation;

( )
[
]

Where;

Again for vertical condenser design, the mean coefficient should be evaluated with both methods
and the higher value selected.
4.0. PROCEDURES FOR DESIGNING CONDENSER
Part A:
The heat duty Q is usually fixed by the required service. It is calculated using the following
expression;
1. If the fluid to condense enters at saturated vapour and leaves as saturated liquid still at its
saturated temperature, the heat duty is given as;
2. If the fluid to condense enters as a saturated vapour at its saturated temperature and then
leaves at a lower temperature, the heat duty is given as;
(
)
Where:
Enthalpy of fluid vapour
Enthalpy of fluid liquid
3. If the fluid to condense enters as superheated vapour and then leaves as saturated liquid at
its saturated temperature, the heat duty is given as;
(
)
Where
= Saturated temperature
4. If the fluid to condense enters as superheated vapour and then leaves as saturated liquid
below its saturated temperature, the heat duty is given as;
(
)
(
)
Where:
Enthalpy of fluid vapour
Enthalpy of fluid liquid
Saturated temperature
Mass flow rate of fluid to be condensed
Specific heat capacity of vapour and liquid
Latent heat
Temperature of fluid to be condensed
Subscript 1 and 2 implies inlet and outlet condition while Subscript S implies saturated condition
Note: the heat duty calculated from above is equal to the heat absorbed by coolant. Therefore;
(
)
Specific heat capacity of coolant
Mass flow rate of coolant
=Temperature of inlet and out condition of coolant
Part B:
Make an approximate estimate of the size of the heat exchanger by using a reasonable guess for the
overall heat transfer coefficient. For typical shell-and-tube heat exchangers in a chemical process or
a refinery, data from figure1 (book1) or http://www.engineeringpage.com/ can be used as a starting

point for the estimate. Using this estimate, calculate the heat transfer area (A). This will give an idea
of the approximate size of the heat exchanger, and therefore its cost. The can be determined from
the equation below:

Where:
= Estimated overall heat transfer coefficient
= Heat transfer Area
= Mean temperature difference=
(

= Log mean temperature difference=

) (
(
(

)
)
)

=temperature correction factor (Determined from R and S values using figure 2

(book1) based on the Tube and Shell passes chosen)
(

R=

)
(

and S= (

are the inlet and outlet temperature of the condensing fluid

are the inlet and outlet temperature of the coolant
Part C
a. Fix velocity or velocity range of tube side ( )
b. For liquid: choose 2m/s or 1m/s ( ) 3m/s For gases: choose 0.3m/s or 0.1m/s
( ) 0.3m/s
c. Fix diameter of tube based on standard tube available
d. Fix the effective length of tube ( ) desired
e. Calculate the number of tubes ( ) from;
f. Calculate number of tubes per pass (N) from;

g. Calculate the tube pass ( ) from;

i.
ii.
iii.
iv.

Approximate to the nearest even whole number either upward or download

Calculate the new with the two values
Calculate from the new two
Choose the (correspondingly ) that gives velocity within the specified velocity
desired or within standard range of velocity for the fluid
Note: when calculating from approximates such that divides it into a whole
number and then use this value as the in the calculation.
Now once and has been fixed proceed to fixed tube layout
Part D: Tube Layout
a. Choose tube arrangement: e.g. 30o triangular pattern or 90o square etc.
b. Calculate or determine the tube pitch ( ) from literature
i. 30o triangular and 90o square arrangement can be have a pitch ( ) =1.25
ii. Also pitch ( ) can be chosen based on standard industrial or typical values from the
chosen tube diameter (see table )

Part E: Shell size and Average number of tubes in a vertical tube row
a. Calculate shell diameter ( ) as follows;
i.
ii.
iii.
iv.
v.

( )

Choose shell rear head type

Determine bundle diametrical clearance (
Therefore shell inner diameter,

Calculate bundle diameter (

) from; (

)(see figure7 )

Average number of tubes in a vertical tube row,

Note: This procedure of determining is used only when = 1.25 else the following method
below should be used
b. Use ,
,tube arrangement and desired standard pitch( ) to determine
(kerns
method see table )

Part F: Film coefficient calculation of condensation fluid

I.

Assume condensing film coefficient of the fluid ( ): Condensing film heat transfer

II.

coefficient is assumed within the range of

to
Calculate the mean temperature of the shell and tube side

Shell side,
Tube side,
iii.

Calculate estimate of tube wall temperature,

(

using;

= Estimated overall heat transfer coefficient

iv.

Calculate estimate mean temperature of condensate,

v.
vi.

Estimate the following physical properties @

Estimate the vapour density ( ) @ mean vapour temperature, if the condensation is

in the shell side, it is
or
if it is on tube side.

vii.

Tubes loading,

viii.

side where condensation take place.

Calculate the Condensing film heat transfer coefficient ( ) from the equations discuss

ix.

or

or

depending on the orientation and the

earlier (section 3.0) depending on the orientation of the exchanger (i.e. vertical or
horizontal) and side where the condensation takes place (i.e. shell or tube side)
If calculated
earlier assumed . Reassume and Recalculate until
calculated

assumed

or

to

apart (based on assumed

Part G: Film coefficient calculation of coolant

Based on use of Aspen plus for simulation, this will be set to be calculated using calculation
from geometry. However if the film coefficient is known it can be inputted using the
constant value option.
Note: Tube side
As a standard, if water were to be in the tube side it is preferable to use the constant value
option. For which this value is calculated from;
(
)
Where;
Inside coefficient, for water,
Water temperature,
Tube inside diameter, mm
Water velocity, m/s,

Part H: Nozzle Diameter

a. Choose shell nozzle diameter (
) based on (see table6 )
Note: Shell inlet nozzle diameter (
) = Shell outlet nozzle diameter (
b. Then calculate tube nozzle diameter ( ) from
For liquid;

)=

and for gas;

Note: Tube inlet nozzle diameter (

) = Tube outlet nozzle diameter (

)=

Part I: Baffle layout

a. Choose baffle type : segmental or ring
b. Choose baffle cut ( ): 25- 35% (optimum)
c. Calculate baffle spacing: for condensers it is reasonable to assume the following if
condensation occurs at the shell side
Tubesheet to first baffle= last baffle to tubesheet=Central baffle spacing ( ); as an
approximation let optimal =
Else;
Tubesheet to first baffle= last baffle to tubesheet=1.65
Central baffle spacing ( ); as an approximation let optimal = 0.4
d. Calculate number of baffles (

) from;