CHAPTER 1

INTRODUCTION

Shell & tube heat exchangers are used extensively throughout the process industry and as
such a basic understanding of their design, construction and performance is important to the
practising engineer. The objective of this project is to provide a concise review of the key
issues involved in their thermal design without having to refer to the extensive literature
available on this topic.
The design of a plate & frame heat exchanger involves the consideration of many interacting
design parameters which can be summarised as follows:
Process
1. Process fluid assignments.
2. Selection of stream temperature specifications.
3. Setting plate side pressure drop design limits.
4. Setting fluid velocity limits through plates.
5. Selection of heat transfer models and fouling coefficients for.
Mechanical
1. Selection of heat exchanger TEMA layout and number of passes.
2. Specification of plate parameters - size, layout and material.
3. Setting upper and lower design limits on plate length.
There are several software design and rating packages available, including Aspen BJAC,
HTFS and CC-THERM, which enable the designer to study the effects of the many
interacting design parameters and achieve an optimum thermal design. These packages are
supported by extensive component physical property databases and thermodynamic models.
It must be stressed that software convergence and optimisation routines will not necessarily
achieve a practical and economic design without the designer forcing parameters in an
intuitive way. It is recommended that the design be checked by running the model in the
rating mode. It is the intention of this paper to provide the basic information and
fundamentals in a concise format to achieve this objective. [4]

CHATER 2

LITERATURE REVIEW

Shell and Tube-type heat exchanger have wide application in nuclear industry where they
play an important role in the transfer of heat. Their cost minimization and pressure utilization
are important targets for both designers and users. In this project a computer program for
economical design of shell and tube heat exchanger using specified pressure drop is
established. The design procedure depends on using the acceptable pressure drops in order to
minimize the thermal surface area for a certain service, involving discrete decision variables.
Also the proposed method takes into account several geometric and operational constraints
typically recommended by design codes. The capability of the proposed model was verified
through two design examples. The obtained results illustrate the capacity of the proposed
approach through using of a given pressure drops to direct the optimization towards more
effective designs, considering important limitations usually ignored in the literatures. In
designing a shell & tube heat exchanger is designed many times by taking different variables.
So in this project it designed by taking variable tube length. The optimization is taken on
pressure drop which is 0.8 bar allowable. So in a computer programme MATLAB this
exchanger is again designed and calculated.

CHAPTER 3

SHELL & TUBE HEAT EXCHANGER

Heat exchangers (STHEs) are done by sophisticated computer software. However, a good
understanding of the underlying principles of exchanger design is needed to use this
software effectively.
This article explains the basics of exchanger thermal design, covering such topics as: STHE
components; classification of STHEs according to construction. And according to service;
data needed for thermal design, tube side design, shell side design, including tube layout,
baffling, shell side pressure drop, and mean temperature difference. The basic equations for
tube side and shell side heat transfer and pressure drop are well known; here we focus on the
application of these correlations for the optimum design of heat exchangers.

[9]

3.1 Components of STHEs

It is essential for the designer to have a good working knowledge of the mechanical features
of STHEs and how they influence thermal design. The principal components of an STHE
are:
1.
2.
3.
4.
5.
6.
7.
8.

Shell;
shell cover;
Tubes;
Channel;
Channel cover;
Tube sheet;
Baffles and
Nozzles;

3.2 Classification based on construction

3.2.1 Fixed tube:
Heat exchanger (Figure 1) has straight tubes that are secured at both ends to tube sheets
welded to the shell. The construction may have removable channel covers (e.g., AEL),
bonnet-type channel covers (e.g., BEM), or integral tube sheets (e.g., NEN). The principal
advantage of the fixed tube sheet tube sheet construction is its low cost because of its simple
construction. In fact, the fixed tube sheet is the least expensive construction type, as long as
no expansion joint is required. A disadvantage of this type that the bundle is fixed to the
shell and it cannot be removed. The outsides of the tubes cannot be cleaned mechanically.
Thus, its application is limited to clean services on the shell-side. However, if a satisfactory
chemical cleaning program can be employed; fixed-tube sheet construction may be selected
3

for fouling services on the shell side.

3.2.2 U-tube:
The tubes of a U-tube heat exchanger (Figure 1) are bent in the shape of a U. There is only
one tube sheet in a U-tube heat exchanger. However, the lower cost for the single tube sheet
is offset by the additional costs incurred for the bending of the tubes and the somewhat
larger shell diameter (due to the minimum U-bend radius), making the cost of a U-tube heat
exchanger comparable to that of a fixed-tube sheet exchanger. The disadvantage of a U-tube
heat construction is that the insides of the tubes cannot be cleaned effectively, since the Ubends would require flexible-end drill shafts for cleaning. Thus, U-tube heat exchangers
should not be used for services with a dirty fluid inside tubes.
3.2.3 Floating head:
The floating type heat exchanger is the most versatile type of STHE, and also the costliest.
In this design, one tube sheet is fixed relative to the shell, and the other is free to float
within the shell. This permits free expansion of the tube bundle, as well as cleaning of both
the insides and outsides of the tubes. Thus, floating-head SHTEs can be used for services
where both the shell side and the tube side fluids are dirty making this the standard
construction type used in dirty services, such as in petroleum refineries. There is various
type of floating-head heating-head construction. The two most common are the pull-through
with backing device (TEMA S) and pull-through (TEMA T) designs.

3.3 Classification based on service

Heat exchanger: both sides single phase and process streams (that is, not a utility).
Cooler: one stream a process liquid and the other cooling water or air
Condenser: one stream a condensing vapor and the other cooling water or air.
Chiller: one stream a process fluid being condensed at sub-atmospheric

temperatures and the other a boiling refrigerant or process stream.

Reboiler: one stream a bottoms stream from a distillation column and the other a
hot utility (steam or hot oil) or a process stream. [9]

VARIOUS TYPES OF SHELL-AND-TUBE HEAT EXCHANGER

Fig 1.different type of heat exchanger [2]

CHAPTER 4

DESIGN OF HEAT EXCHANGER

4.1 Procedure of heat exchanger design

For design of heat exchanger following steps are applied.
1. Assume tube diameter and BWG, Assume tube length, L
2. Assume fouling factor based on inside and outside tubes, hdi and hdo
3. Assume material of construction for the tubes thermal conductivity?
Table no. 1 thermal conductivity of various materials [1]
Metal
Temperature (oC)
Aluminium
0
100
Brass
0
(70 Cu, 30 Zn)
100
400
Copper
0
100
Nickel
0
212
Cupro-nickel (10% Ni)
0-100
Monel
0-100
Stainless steel (18/8)
0-100
Steel
0
100
600
Titanium
0-100

kw (W/moC)
202
206
97
104
116
388
378
62
59
45
30
16
45
45
36
16

4. You have the option to assume three known temperature and find the fourth one or four
temperature values and find one of the shell or tube side flow rate. Use the heat duty
equation (mCP T)h AND (m CP T)C where subscripts c and h refer to cold and hot
streams. Then obtain the heat duty, q.
5. Based on the type of flow, calculate Log Mean Temperature Difference, LMTD. For
counter current.

Tln

Tc ,in Th Tc , out
T T
ln h c ,in
Th Tc ,out

6. Based on the exchanger configuration obtain the Temperature correction factor. For 1shell-2-tube pass exchanger.
6

S
R

Ttube,out Ttube,in
Tshell,in Ttube,in
Tshell,in Ttube,in
Ttube,out Ttube,in

t 2 t1
T1 t1
T T2
1
t 2 t1

Figure no. 2 Temperature correction factor: one shell pass; two or more even tube 'passes [1]
7. Calculate the mean temperature difference using DTm= Ft LMTD m
8. Assume overall heat transfer coefficient as initial guess from the table no. 02 given below.
Table no. 2 overall heat transfer coefficient [1]
Shell and tube exchanger
Hot fluid
Cold fluid
Heat exchanger
Water
Water
Organic solvent
Organic solvent
Light oils
Light oils
Heavy oils
Heavy oils
Gases
Gases
coolers
Organic solvents
water
Light oils
Water
Heavy oils
Water
Gases
Water
Organic solvent
Brine
Water
Brine
Gases
Brine
Heater
Steam
Water
Steam
Organic solvent
7

U (W/m2 oC)
800-1500
100-300
100-400
50-300
10-50
250-750
350-900
60-300
20-300
150-500
600-1200
15-250
1500-4000
500-1000

Steam
Steam
Steam
Condensers
Aqueous vapours
Organic vapours
Organics (some non-condensable)
Vacuum condensers
vaporisers
Steam
Steam
Steam

Light oil
Heavy oils
Gases

300-900
60-450
30-300

Water
Water
Water
Water

1000-1500
700-1000
500-700
200-500

Aqueous solution
Light organics
Heavy organics

1000-1500
900-1200
600-900

9. Calculate the provisional area

A= q/UT
10. Based on the assumed tube diameter (ID and OD at a given BWG) and tube Length, L,
calculate number of tubes:
Nt = A/dL
11. Calculate tube pitch and the bundle diameter
pt = 1.25 do
Db = do (Nt/K1)1/n1
Where Nt = no. of tubes,
Db = bundle diameter, mm
do = tube outside diameter, mm
K1 and n1 are obtained on the type of tube arrangement of triangular or square pitch.
Table no. 3 bundle diameter calculation [1]
Triangular pitch pt = 1.25 do
No. passes
1
2

K1
n1

0.319
2.142

0.249
2.207

0.175
2.285

0.0743
2.499

0.0365
2.675

Squre pitch
K1
n1

0.125
2.207

0.156
2.291

0.158
2.263

0.0402
2.617

0.0331
2.643

Figure no. 3 calculating shell diameter [1]

12. Calculate the shell diameter from figure 3
13. Calculate the baffle spacing. Bs 0.4Ds
14. Calculate the equivalent diameter
For square pitch arrangement [3]
de = 1.27(pt2-0.785 do 2)/do
for triangular pitch arrangement [3]
de = 1.10(pt2-0.917 do 2)/do
15. Calculate the shell-side Reynolds number
16. Obtain the shell-side heat transfer coefficient
Nu= jh( Re) (Pr)1/3 (/ w)0.14
Where jh is obtained from the chart bellow

Figure no. 4 jh and Re [1]

17. Calculate the pressure drop in the shell
Ps = 8jf (Ds/ de) (L/ lB) ( / w ) -0.14 (ut2/2)
Where L = tube length
lB = baffle spacing
jf may be obtained from the chart bellow

Figure no. 5 j f & Re [1]

10

18. Calculate pressure drop in tube side

Pt = Np[8jf (L/di) ( / w ) -0.14 +2.5] (ut2)/2
19. Calculate overall heat transfer coefficient (based upon inside tube flow)

Ui

1
d
d
1 1 d i ln( d o / d i )

i i
hi hdi
2k w
d o hdo d o ho

Based upon outside tube flow

Uo

1
d
1
1 d o ln( d o / d i ) d o

o
ho hdo
2k w
d i ho d i hdi

20. Compare the calculated overall heat transfer coefficient you obtained from the previous

step with that you assumed in step 8. If it is close to what you assumed, then you had a
valid assumption, and then tabulate your results such as total surface area of tubes,
number of tubes, exchanger length and diameter, heat duty and other design specification.
Otherwise, use the calculated value in step 8 and do loop until the difference between the
calculated U between two consecutive iterations is small.

4.2 DESIGN OF SHELL & TUBE HEAT EXCHANGER

Object: Design a heat exchanger for the following duty.
Fluid 1.
Hot fluid
Mass flow rate (G)
Inlet temperature
Outlet temperature
Inlet pressure
Fouling
Fluid 2.
(Cold fluid)
Mass flow rate
Inlet temperature
Inlet pressure

Kerosene
20000 Kg/hr.
2000C
900C
5 bar
0 .0003 m2 0C/W

(G)

Crude oil
70000 Kg/hr
400C
6.5 bar
11

0.0002 m2 0C/W

Fouling

Solution
Specification
Calculate duty
Duty = mCpdT
Duty= 200002.47(200-90)/3600 = 1509.4 kW
Crude oil outlet temperature
700002.01(t2-40) = 1509.4
t2= 77.90C
Table no. 4 physical properties of kerosene and crude oil
Kerosene
Temperature
Specific heat
Thermal

Inlet
200
2.72
.130

Mean
145
2.47
.132

Outlet
90
2.26
.135

conduct.
Density
Viscosity
Crude oil
Temperature
Specific heat
Thermal

690
.22
Outlet
78
2.09
.133

730
.43
Mean
59
2.05
0.134

770
.08
Inlet
40
2.01
0.135

Kg/m3
mNsm-2

conduct.
Density
Viscosity

800
2.4

820
3.2

840
4.3

Kg/m3
mNsm-2

C
KJ/Kg0C
W/m0C

C
KJ/Kg0C
W/m0C

LMTD
Tln = [(200-78) (90-40)]/Ln (122/50)
= 80.7 oC
Correction factor (Ft) = 0.88
Actual LMTD = 0.8880.7 = 71.0
Layout and tube size
Crude oil is viscous so taking purpose of cleaning of heat exchanger so take floating heat
exchanger. Fluid is non-corrosive and operating pressure is also not too high, so plain carbon
steel is used. Crude oil is taken in tube side. Tubes are taken in standard size of 19.05mm
12

outer diameter and 14.83mm inner diameter. Taking standard i.e. 5m long and triangular pitch
of 23.81mm.
Shell & tube specification
Tube outer diameter do = 19.05mm
Tube inner diameter di = 14.83mm
Number of tubes Nt = 360
Number of pass Np = 4 (always take even no. of pass)
Tube cross-sectional area = (14.8310-3)/4 = 0.0001727m2
Area per pass = 0.0001727360/4 = 0.01555 m2
Volumetric flow = 70000/(3600820) = 0.0237 m3/s
Tube side velocity ut = 0.0237/0.01555 = 1.524 m/s
Bundle diameter Db = do (Nt/K1)1/ n1
K1 = 0.175 & n1 = 2.285 (by table 3)
So Db = 537mm
Shell diameter Ds = 537+59 = 596mm (fig. 3)
Baffle spacing = Ds/5 = 119.2
Shell side area
As = [(pt-do) Ds lB]/pt
pt = tube pitch = 23.81mm
do = tube outer diameter = 19.05mm
Ds = shell diameter = 596mm
lB = baffle spacing = 100mm
so

As = 0.167 m2

Heat transfer coefficient

Tube side
Nu= jh( Re) (Pr)1/3 (/ w)0.14
Re= (.u.dh)/
= (8201.52414.8310-3)/3.210-2
= 5792
L/d = 5000/14.83 = 337
13

jh = 3.510-3 (by figure 4)

Nu = h dh / k
So

h = 680 W/m2 0C

Shell side
Volumetric flow rate on shell side = 20000/(3600730)=0.0076m2
us = 0.0076/ As = 0.455 m/s
de = 13.52mm
Re= (u dh)/
= (730 0.45513.5210-3)/0.4310-3 = 14644
Pr = Cp /k
= 8.05
jh = 4.810-3 (by figure 4)
Nu = h dh / k
So

h = 1177 W/m2 0C

Overall heat transfer coefficient

U = 288 W/m2 0C.
It is in range of allowable limit so we can take this specification.
Pressure drop calculation
Tube side
Pt = Np[8jf (L/di) ( / w ) -0.14 +2.5] (ut2)/2
jf = 5.510-3 (figure 5)
Pt = 66029 N/m2 = 0.66 bar
Shell side
Ps = 8jf (Ds/ de) (L/ lB) ( / w ) -0.14 (ut2/2)
jf = 4.610-2
Ps = 0.47 bar
It is in allowable limit so we can take this specification.

14

CHAPTER 5

ECONOMIC OPTIMIZATION OF SHELL

& TUBE HEAT EXCHANGER

Shell and Tube-type heat exchanger have wide application in various industries where they
play an important role in the transfer of heat from core to the heat sink; their cost
minimization is an important target for both designers and users. In this project a computer
program for economical design of shell and tube heat exchanger using specified pressure
drop is established to minimize the cost of the equipment. The design procedure depends on
using the acceptable pressure drops in order to minimize the thermal surface area for a certain
service, involving discrete decision variables. Also the proposed method takes into account
several geometric and operational constraints typically recommended by design codes, and
may provide global optimum solutions as opposed to local optimum solutions that are
typically obtained with many other optimization methods. While fulfilling heat transfer
requirements, it has anticipated to estimate the minimum heat transfer area and resultant
minimum cost for a heat exchanger for given pressure drops. The capability of the proposed
model was verified through two design examples. The obtained results illustrate the capacity
of the proposed approach through using of a given pressure drops to direct the optimization
towards more effective designs, considering important limitations usually ignored in the
literatures.
Cost minimization of Shell-and-tube heat exchangers is a key objective. Traditional design
approaches besides being time consuming, do not guarantee the reach of an economically
optimal solution. So, in this project, a new shell and tube heat exchanger optimization design
approach is developed based on a computer programme MATLAB. The MATLAB algorithm
has some good features in reaching to the global minimum in comparison to other
evolutionary algorithms. In this study technique has been applied to minimize the total cost of
the equipment shell and tube heat exchanger by varying various design variables such as tube
length, tube outer diameter, pitch size, baffle spacing, etc. Based on proposed method, a full
computer code was developed for optimal design of shell and tube heat exchangers
For our key objective economic cost optimization of shell and tube heat exchanger for a
given pressure constant for both tube and shell side. We are going to develop a computer
program for different designs of shell and tube heat exchangers.
From this program we get a design of heat exchanger for the same condition and varying tube
length and the new design is given below

15

5.1 New design

KEROSENE
flow rate Kg/h
inlet temp 0C
outlet temp0C
inlet pressure
allowable pr. Drop (bar)
fouling factor
CRUDE OIL
flow rate Kg/h
inlet temp 0C
outlet temp0C
inlet pressure (bar)
allowable pr. Drop (bar)
fouling factor

20000
200
90
5
0.8
0.0002
70000
40
6.5
0.8
0.0003

mean temp of kerosene

duty
crude outlet temp0C
mean temp 0C

145
1509.444444
78.62117982
59.31058991

heat transfer area

70.86

layout and tube size

tube outer diameter mm
19.05
tube inner diameter mm
14.83
tube length meter (change parameter)
7
triangular pitch mm
23.81
pitch/dia
1.249868766
area of one tube
no of tubes
no of passes
tube side cross sectional area
tube per pass
area per pass
volumertic flow rate
tube side velocity

0.41885235
280
2
0.000172644
140
0.024170186
0.023712737
0.981073833

bundle and shell diameter

2 tube pass
k1
n1
bundle diameter (mm)
clearence from diagram
shell diameter

0.249
2.207
459.510917
56
515.510917

heat transfer coefficient tube side

16

reynold no.
prendtl no.
L/di
jh from figure
nussult no.
hi

3729
48.96
472
0.027
363.5832041
3285.242707

heat transfer coefficient shell side

baffle spacing mm
area
equivalent diameter
shell side volumetric flow rate
shell side velocity
reynold no.
prendtl no.

160
0.016489421
13.51957786
0.00761035
0.461529248
10592.94613
8.05

baffle cut
jh from figure
Nussult no.
hs

25%
0.0021
44.5828696
435.2901288

overall heat transfer coefficient

1/U
U

0.00338129
295.7451384

pressure drop
Tube side
Re
Jf from figure
pt
p in bar

3729
0.021
64560.03225
0.645600323

Shell side
jf from figure
Re
ps
p in bar

0.066
10592.94613
68482.25238
0.684822524

17

CHAPTER 6

CONCLUSION

Table no. 5 comparisons between present and previous work

Calculated results
Previous work
Present work
AREA (m2)

70.86

70.86

Heat transfer coefficient

(W/m2 oc)
Number of tubes

268

302

280

360

Number of tube passes

Inside tube diameter (mm)

14.83

14.83

Outside tube diameter (mm)

19.05

19.05

Number of baffles

32

42

shell diameter (mm)

515.51

596

tube length (m)

Baffle spacing (mm)

160

119.2

Pressure (tube side) (bar)

0.645

0.66

Pressure (shell side) (bar)

0.685

0.47

In this work, an optimization model for the design of a shell and tube heat exchanger has
been proposed. The optimization strategy based upon the presented analytical optimization
analysis is developed as a computer aided design package. Important additional constraints,
usually ignored in previous optimization schemes, are included in order to approximate the
solution to the design practice. Two cases for optimal design of shell and tubes heat
exchanger based upon the devised computer program were presented. In case study one the
obtained results in the present work are consistent with the corresponding values. In case two
the comparison showed that the proposed model is more efficient in terms of providing
excellent optimum solutions than standard optimization method. Also the result of the study
cases ends up with the final conclusion that the use of the model provides the best solutions
with higher quality together with short duration of real time.

18

CHAPTER 7

REFERENCES

1. Sinnott, R.K. (1993) Coulson & Richardsons Chemical Engineering Vol. 6, 3rd
edition. Page No. 634-779
2. HEAT EXCHANGER selection, rating, and thermal design by Sadik kaka, hongtan
Liu (department of mechanical engineering university of miami). Page 249-278, 323348.
3. Roy G. K. Fundamental of Heat and mass transfer operation Page No. 37-82.
4. Hewitt, G.F. et al (1994) Process Heat Transfer, (CRC Press)
5. Perry ,R.H. and Green, D. (1984) Perrys Chemical Engineers Handbook, 6th edition
6.
7.
8.
9.

(McGraw Hill)
Kern, D.Q. (1950) Process Heat Transfer (McGraw Hill)
Chemstations, Inc. CHEMCAD THERM Version 5.1 User Guide
Schlunder, E.U. (1993) VDI Heat Atlas (Woodhead Publishing)
Seider, D.S., Seader, J.D.Seader and Lewin, R.L. Process Design Principles, (John

Wiley & Sons, Inc.)

10.
Lee, Jin-Jong and others, Reduce revamp costs by optimizing design and
operations, Hydrocarbon Processing, April 2007.

19