Professional Documents
Culture Documents
AND
HEAT EXCHANGERS
Slide 1
Slide 2
Rate K x
Driving Force
Resistance
QK x
Pressure Drop
Resistance
I = 1.0 x
Voltage
Resistance
Temperature Difference
QK x
Resistance
Slide 3
(General)
(Fluids)
(Electricity)
(Heat)
Heat:
Q
A
= K x (P2 - P1)
fL
D
Q = 1 x (T2 - T1)
A
RT
FLUIDS
Q = Volume / Second
P2, P1 = Higher, lower pressures
A = Area available for flow
fL
4 * D = Number of fluid flow
resistance units
Slide 4
HEAT
Q = Btu / Hour
T2, T1 = Higher, lower
temperatures
RT = Total specific
resistance
A = Area available for flow
of heat
Q = 1 x (T2 - T1) = 1 x T
A
RT
RT
RT = Total Resistance, Hr x FT2 x F / Btu
I = Total Conductivity = U Btu / Hr x Ft2 x F
RT
Q = 1 x U T
A
Q = U x A x T Btu / Hr
U is Referred to as the Overall Heat Transfer Coefficient
Slide 5
There are two areas through which heat must flow: The
inside tube area and the outside tube area. Resistance
occurs at both areas.
The Industry Standard Reference Area is the Outside Tube
Area.
Slide 6
Ao
Ai
Ao
Ai
Rio + rio + rw + ro + Ro = RT =
w = Wall Thickness, Feet
I
U
Slide 7
Slide 8
Very Low
Typical
Very High
0.00050
(2000)
0.004
(250)
0.04
(25)
0.001
(1000)
0.002
(500)
0.01
(100)
Wall Resistance
Inverse
0.000030
(32,000)
0.00027
(3760)
0.00049
(2030)
Total Resistance
Inverse
0.00303
(330)
0.01227
(81)
0.10050
(10)
Slide 9
Frequently One of the two film coefficients determines the value of the overall
coefficient:
h
hio
Ro
Rio
rw + rio + ro
RT
U
Improvement
Slide 10
=
=
=
=
=
=
=
=
75
1000
0.01333
0.00100
0.00070
0.01503
66.5
Base
75
3000
0.01333
0.00033
0.00070
0.01436
69.6
+4.6%
150
1000
0.00667
0.00100
0.00070
0.00837
119.5
+80%
Ro
Rio
rw
rio+ ro
RT
Slide 11
=
=
=
=
=
0.01333
0.00500
0.00030
0.00200
0.02063
77.6
29.1
1.7
1.6
120F
0.01333
0.02063
x 120
Q
A
Btu
Hr x Ft2
Q = U x A x (T2 - T1) = U x A x T
Then T =
Q
UxA
Then Q = T =
A
RT
Q
A
* x
Flux x Resistance
120
0.02063
BACK TO BASICS
Well talk about U later, first lets discuss T, the temperature driving
force.
Note that capital letter T denotes the hot stream, while lower case t
denotes the cold stream:
T1 = Hot In
t1 = Cold In
Slide 13
T2 = Hot Out
t 2 = Cold Out
Slide 14
Slide 15
Slide 16
Slide 17
From the preceding slides, it is clear that some sort of average driving force
must be used in design calculations.
What is this average?
The average is called The Effective Mean Temperature Difference, or MTDe.
For true countercurrent and true cocurrent flow, the effective driving force
equals the log mean average of the two extreme (largest and smallest) deltas.
Te = LMTD =
LN
(T2 - t1)
This is precisely true only when the heat release curves are straight lines.
Otherwise it is an approximation.
Slide 18
Slide 19
CALCULATION OF Fn
Depends on the number of shells in series (Shell Passes)
The more shells one has in series, the closer Fn approaches 1.0
Typically the minimum acceptable value of Fn is 0.8
Slide 20
Slide 21
Slide 22
CALCULATION OF Fn
Slide 23
CALCULATION OF Fn
Example
T1 = 300
T2 = 105
t1 = 85
t2 = 115
P = j = 115 - 85 = 0.14
300 - 85
R = 300 - 105 = 6.5
115 - 85
CALCULATION OF Fn
Slide 25
Slide 26
Slide 27
Calculate the LMTD for each zone, assuming that the cold temperature
in each zone is the average of the inlet/outlet cold temperatures of the
shell in which the zone occurs (see graph)
MTDe (Weighted) =
Slide 28
Qtotal
Qzone1 + Qzone2 + Qzone3
LMTD1
LMTD2
LMTD3
+ Qzone4
LMTD4
Slide 29
Slide 30
Show Videotape
Slide 31
Slide 32
(2)
Using the required tube size and length, calculate the number
of tubes.
(3)
(4)
Slide 33
Slide 34
Shell-and-Tube
Air-Fin Coolers
Double-Pipe
Plate and Frame
Slide 35
Slide 36
DOUBLE PIPE
Consists of one or more pipes within a larger pipe
Internal pipes can be bare surface or have longitudinal fins
True cocurrent or true countercurrent flow can be achieved
Available in standard off-the-shelf sizes
Several standard units may be connected in series or in
parallel
Not usually economical where surface requirements exceed
about 500 square feet
Especially suited for high-pressure applications
Slide 37
Slide 38
DISADVANTAGES
Limited to moderate temperatures and pressures (up to about
300F / 150C and 300 psig / 21 barg)
Some hydrocarbon streams attack the interplate gasketing
Require great time in assembly/disassembly
Best suited to aqueous streams, e.g. amines, water
Slide 39
Slide 40
NOMENCLATURE
Components of Shell and Tube Exchangers
1.
2.
3.
4.
5.
6.
7.
SHELL
SHELL COVER
SHELL FLANGE
SHELL COVER END FLANGE
SHELL NOZZLE
FLOATING HEAD TUBESHEET
FLOATING HEAD COVER
Slide 41
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
IMPINGEMENT BAFFLE
VENT CONNECTION
DRAIN CONNECTION
TEST CONNECTION
SUPPORT SADDLES
LIFTING RING
SPLIT RING
U-Tube
Slide 42
U-Tube
Least expensive for high tubeside design pressure. Normally used
when tubeside fouling 0.004. (except for water)
Slide 43
PRELIMINARY DECISIONS:
DESIGN OF SHELL-AND-TUBE UNITS
Which fluid to put in the tubes
Tube nominal diameter, wall thickness and material
Tube length
Tube layout
Baffle orientation
Baffle pitch (spacing)
Slide 44
OD, In.
Layout and
Spacing, In.
Non-Fouling or Fouling
(<0.003), Mildly Corrosive
3/4
15/16
Non-Fouling or Fouling
(<0.003), Corrosive
3/4
1.00
Extremely Fouling
( 0.003), Mildly Corrosive
Extremely Fouling
( 0.003), Corrosive
BWG
Thickness, In.
14
0.083
or
12
0.109
1.25
or
12
0.109
1.25
or
10
0.134
3/4
15/16
or 1.0
16
0.065
Non-Fouling or Fouling
(<0.003)
3/4
15/16
or 1.0
16
0.065
1.25
or
14
0.083
Extremely Fouling
(0.003)
Slide 46
TUBE LENGTH
Refinery decision (local preference)
Most common length is 20 feet (6.1m)
Occasionally, 16 (4.9m) length is used
For special situations, 8 (2.4m) and 10 (3m) can be
considered
Longer tube bundles require more plot area for bundle
removal. Longer bundles are also more difficult to extract
from the shell and to handle.
Slide 47
TUBE LAYOUT
3 Main Layouts-Square
Triangular 30
Slide 48
TYPE OF BAFFLE
Segmental - Most common
Double Segmental (modified disk and donut) is used to
obtain very low shell-side pressure drop
Tube Supports Only - No real baffles. Occasionally used
in certain reboiling or condensing services.
Slide 49
Horizontal Chord
Sediment-free fluids being cooled through high temperature
range (200 to 300F / 90-150 C) in one shell
Flow is over-under
Baffle Cut
This is the percent of the baffle which is cut away to permit flow
Typical cut is 25% (40% for double segmental baffles).
Slide 50
BAFFLE PITCH
Minimum allowable spacing (pitch) is 20% of the shell ID or two
inches, whichever is greater.
1
1
Slide 51
Steel
30
37
50
Copper Alloys
26
32
43.5
TEMA
Tubular Exchanger Manufacturers Association
This is the basic industrial standard for shell-and-tube
exchangers
Covers heavy-duty type (TEMA R) as well as the lighter
duty (TEMA C) units
Latest edition is the eighth dated 1999
Slide 52
TEMA TYPE
TEMA Type followed by three letters refers to the type of
+ Front end (channel) arrangement
+ Shell nozzle/baffle arrangement
+ Rear end (floating head end) arrangement
Slide 53
Slide 54
Slide 55
Divided flow
Also used to minimize pressure drop
No internal baffle
Kettle types
Used for vaporizing services (reboilers, steam generators and
refrigeration services)
Cross flow
No baffles
Low pressure drop
U-tube bundle
No floating head. Tube bundle consists of U-tubes
Not recommended where mechanical cleaning of tube side is anticipated
Good for high pressure, clean services or where chemical cleaning of
tubeside is specified
Slide 56
Notes:
Slide 57
1.
2.
3.
4.
E = One pass shell (one inlet nozzle and one outlet nozzle)
S = Split ring type floating tube sheet construction
Slide 58
Slide 59
Slide 60
Problem 5A
Heat Integration
Slide 61
TABLE 1.01
DESIGN CONSTANTS FOR SHELL AND TUBE EXCHANGER CALCULATIONS
SHELL SIDE
Maximum Allowable Baffle Pitch
Tube O.D. Inches
Steel
0.75
30.0
1.00
37.0
1.50
50.0
(For no change of phase, Pb should not exceed the shell ID.
Heat Transfer & Pressure Drop Factor B1 and B2
Baffle Position
Tube Layout
Vertical to tube rows
Square
On the bias (45)
Square
Vertical to tube rows
Triangular
Transfer B1
0.50
0.55
0.70
Pressure Drop B2
0.30
0.40
0.50
Slide 62
TABLE 1.01
DESIGN CONSTANTS FOR SHELL AND TUBE EXCHANGER CALCULATIONS
(Continued)
Material
Type of Water
Carbon Steel
Fresh, non-inhibited
Fresh, inhibited
4
6 to 8
3 to 6
3 to 10
Red brass
All types
6 to 8
3 to 4
Admiralty (inhibited)
6 to 8
3
3 to 10
3 to 5
Aluminum brass
6 to 8
5
3 to 10
4 to 8
Cupronickel (70-30)
All types
7 to 8
6 to 12
7 to 8
6 to 12
Cupronickel (90-10)
Slide 63
Most Favorable
Velocity, ft/sec
All types
Monel
All types
6 to 12
All types
10
8 to 15
12
0.109
0.532
0.223
0.1963
14
0.083 (1)
0.584
0.268
0.1963
16
0.065 (2)
0.620
0.302
0.1963
18
0.049
0.652
0.334
0.1963
1
10
0.134
0.732
0.421
0.2618
1
12
0.109 (1)
0.782
0.479
0.2618
1
14
0.083 (2)
0.0834
0.546
0.2618
1
16
0.065
0.870
0.594
0.2618
1
10
0.134
1.232
1.192
0.3927
1
12
0.109
1.282
1.291
0.3927
1
14
0.083
1.334
1.397
0.3927
GAGE EQUIVALENTS
MAXIMUM RECOMMENDED NUMBER OF TUBE PASSES
Inches
BWG
Shell ID Inches
Max. Passes
0.220
5
<10
4
0.165
8
10-19
6
0.148
9
20-29
8
0.134
10
30-39
10
0.120
11
40-49
12
0.109
12
51-59 (Rare)
14
Notes:
0.095
13
(1) Typical wall thickness for carbon steel tubes.
0.083
14 (2) Typical wall thickness for copper alloy tubes.
0.072
15 (3) Average wall thickness is typically 10% greater than the minimum wall thickness.
Tubes may be specified (and purchased) on either an average wall or minimum wall
0.065
16 basis. (Exxon normally specifies minimum wall.)
0.058
17
18
Slide 64 0.049
0.035
20
TABLE 1.03
THERMAL CONDUCTIVITIES OF METALS AT TYPICAL HEAT EXCHANGER TEMPERATURES
Material
Admiralty
Type 316 Stainless Steel
Type 304 Stainless Steel
Brass
Red Brass
Aluminum Brass
Cupro-Nickel
Cupro-Nickel
Monel
Inconel
Aluminum
Carbon Steel
Carbon-Moly Steel
Copper
Lead
Nickel
Titanium
Chrome-Moly Steel
Slide 65
Composition
(71 Cu - 28 Zn - 1 Sn)
(17 Cr - 12 Ni - 2 Mo)
(18 Cr - 8 Ni)
(70 Cu - 30 Zn)
(85 Cu 15 Zn)
(76 Cu - 22 Zn - 2 Al)
(90 Cu - 10 Ni)
(70 Cu - 30 Ni)
(67 Ni - 30 Cu - 1.4 Fe)
(0.5 Mo)
(1 Cr - 0.5 Mo)
(2-1/4 Cr - 0.5 Mo)
(5 Cr - 0.5 Mo)
(12 Cr - 1 Mo)
Thermal Conductivity, k,
64
9
9
57
92
58
41
17
15
11
117
26
25
223
20
36
11
24
22
20
16
TABLE 1.04
TYPICAL FOULING FACTORS - CUSTOMARY
Stream Type
Vapor Overheads
Virgin Distillate liquids to tankage
Virgin Distillate liquids from tankage
Cracked distillate liquids from tankage
Reduced Crudes
Tar, bitumen
Cracked Tar
Crudes
Steam
BFW
Cooling Water, Fresh
Cooling Water, Salt
Slide 66
Typical ri or ro
0.001
0.001
0.002
0.002
0.004
0.005
0.010
0.0102-0.004
0.001
0.001
0.0015 - 0.0025
0.0025 -0.0035
TABLE 1.05
SOME TYPICAL OVERALL COEFFICIENTS - CUSTOMARY
Type of Source
Slide 67
Typical Uo
120
70-90
80
100
Crudes/distillates
Condensers (Tower overheads)
25-50
90
NOMENCLATURE
A
As
B1
B2
C
Cf
D
Dt
di
do
Fn
Fs
Ft
G
hio
ho
k
kf
Slide 68
Ro
Rt
rio
ro
rw
S
TDS
TDT
TM
T1
T2
t1
t2
tf
ts
tt
tw
Uc
Uo
V
VN
W
Ysh
Ysp
Yth
Ytp
z
zf
zw
Ptf
Ptr
Pt
Psf
Psr
PN
Ps
te
tew -
Slide 69
Slide 70
Slide 71
FIGURE 2.01
FRICTIONAL PRESSURE DROP FOR FLUIDS FLOWING IN TUBES
Slide 72
FIGURE 2.02
HEAT TRANSFER COEFFICIENT FOR FLUIDS IN TUBES
Slide 73
FIGURE 5.01
FRICITONAL PRESSURE DROP FLUIDS FLOWING ACROSS TUBE BANKS
Slide 74
FIGURE 5.02
HEAT TRANSFER COEFFICIENT FLUIDS FLOWING ACROSS TUBE BANKS
Slide 75
FIGURE 5.01
VALUES OF THE THERMAL FUNCTION k(PRANDTL NO.)1/3 FOR LIQUID HYDROCARBONS
Slide 76
FIGURE 5.02
VALUES OF THE THERMAL FUNCTION K(PRANDTL NO.)1/3 FOR HYDROCARBON VAPORS
Slide 77
ADDENDUM 5.02
FOR FLOW INSIDE TUBES APPROXIMATE EFFECT OF VARIABLES IN THE TRANSFER OF MOMENTUM AND
HEAT
To Find P2
Multiply P1 By:
Property Changed
NRe > 10,000 (Note 1)
Turbulent Flow
Linear Velocity
(V2/V1)1.8
(V2/V1)0.8
(D1/D2)1.2
(D1/D2)0.2
Viscosity
(2/1)0.2
(2/1)0.5
(2/1)0.8
(2/1)0.8
Linear Velocity
V2/V1
(V2/V1)0.33
(D1/D2)2
(D1/D2)0.33
(D1/D2)4
D1/D2
Laminar Flow*
No dependence
Tube Length
Note 1: This is dimensionless Reynolds Number.
Slide 78
To Find h2
Multiply h1 By:
L2/L1
(2/1)0.33
(L1/L2)0.33
Section
I X-B
Page
Date
TABLE 1
TYPICAL OVERALL HEAT TRANSFER COEFFICIENTS - Uo
U0(1)
BTU
U0(1)
W
Hr ft2 F
m2 C
Slide 79
Crude
Crude
Crude
Crude
Flashed Crude
Fat Oil
Hydrocracker Feed
Hydrogenation Reactor Feed
Hydrofiner Feed
Debutanizer Feed
Powerformer Feed
Acetylene Converter Effluent
Foul DEA
Gas Oil Feed
Gas Oil
Rerun Still Feed
Debutanizer Feed
60 - 70
48 - 58
55 - 85
26 45
25
60
75
51 55
50 68
70
50 80
22 30
110
40
30
50
55
340 - 400
270 - 330
310 480
150 - 260
140
340
430
290 310
280 390
400
280 450
120 170
630
230
170
280
310
Section
I X-B
Page
Date
TABLE 1 - (Continued)
Fluid Being Cooled
U0(1)
BTU
U0(1)
W
Hr ft2 F
m2 C
Coolers
Water
Brine
Debutanizer Bottoms
Debutanizer Overhead Products
Debutanizer Bottom Products
Vacuum P/S Bottoms
Absorber Oil
Lean Oil
Heavy Gas Oil
Regenerated DEA
Reduced Crude
Water
Sour Water
Water
Water
Water
Water
Water
Water
Water
Water
Water
850 - 1190
570 650
390 430
480 - 510
240
110 - 140
450
400
230
630
160 180
Gas Coolers
Air, 27 psig (186 kPa gage)
105 psig (724 kPa gage)
320 psig (2206 kPa gage)
Primary Fractionator Gas
Hydrocarbon Vapors (30 M.W.)
Hydrocarbon Vapors (25 M.W.)
Propylene
Ethylene
Water
Water
Water
Water
Water
Water
Water
Water
13
17
23
27
38 43
55 60
50
31
70
100
130
150
220 240
310 340
280
180
Slide 80
Section
I X-B
Page
Date
TABLE 1 - (Continued)
Condensers
Atmospheric P/S Overhead
Atmospheric P/S Overhead
Atmospheric P/S Distillate
Vacuum P/S Overhead
Debutanizer Overhead
Deethanizer Overhead
Depentanizer Overhead
LPG Tower Overhead
Hydrofiner Effluent
Stabilizer Overhead
Splitter Overhead
Rerun Still Overhead
DEA Regenerator Overhead
Primary Fractionator Overhead
Primary Fractionator Overhead & Products
Powerformer Effluent
Hydrocracker Effluent
Propylene
Steam (3)
Slide 81
Water
Crude
Water
Water
Water
Water
Water
Water
Water
Water
Water
Water
Water
Water
Water
Water
Water
Water
Water
U0(1)
BTU
U0(1)
W
Hr ft2 F
m2 C
80 90
35 45
70 80
115 130
90 100
110
90 113
99
91 105
75 85
85 113
70 400
100
40 (50% cond)
60 (25% cond)
55 60
85
120
400 600
450 510
200 260
400 - 450
650 740
510 570
620
510 640
560
510 600
430 480
480 640
570
230
340
310 340
480
680
2270-3410
Section
I X-B
Page
Date
TABLE 1 - (Continued)
Fluid Being Cooled
U0(1)
BTU
U0(1)
W
Hr ft2 F
m2 C
Chillers
Ethylene (4)
Demethanizer Overhead (4)
Deethanizer Overhead (4)
Depropanizer Overhead (4)
Ethylene
Demethanizer feed
Demethanizer Feed
Propylene
Ethylene
Propylene
Propylene
Ethylene
Ethylene
Propylene
98
107
113
115
99 105
96 113
100 122
560
610
640
650
560 600
550 640
570 690
Reboilers
Steam
Lean Oil
Steam
Atmospheric P/S Top Pumparound
Steam
Steam
Atmospheric P/S Top Pumparound
Atmospheric P/S Bottoms
Steam
Steam
Steam
Steam
Demethanizer Bottoms
Demethanizer Bottoms
Deethanizer Bottoms
Deethanizer Bottoms
Depropanizer Bottoms
Debutanizer Bottoms
Debutanizer Bottoms
Debutanizer Bottoms
Depentanizer Bottoms
Debenzenizer Bottoms
Detoluenizer Bottoms
Splitter Bottoms
75
60
73 86
66
89
74 100
65
56
81
102
77
80
430
340
410 490
370
510
420 570
370
320
460
580
440
450
Slide 82
Section
I X-B
Page
Date
TABLE 1 - (Continued)
U0(1)
BTU
U0(1)
W
Hr ft2 F
m2 C
Reboilers (Continued)
Dowtherm
Steam
Steam
Steam
Dowtherm
Steam
Powerformer Effluent
Steam
Steam
Dowtherm
Splitter Bottoms
Stripper Bottoms
Stabilizer Bottoms
Rerun Tower Bottoms
Rerun Tower Bottoms
LPG Bottoms
Powerformer Stabilizer Bottoms
K3PO4 Stripper Bottoms
DEA Regenerator Bottoms
Phenol
70
82
115
74
47
70
75 77
145
240
65
400
470
650
420
270
400
430 440
820
1360
370
Preheaters
Steam
Steam
Steam
Steam
Powerformer Stabilizer Bottoms
82
80 100
110
75 89
47
520
450 570
620
430 510
270
Slide 83
Section
I X-B
Page
Date
TABLE 1 - (Continued)
Fluid Being Cooled
Steam Generators
Vacuum P/S Bottoms
Vacuum P/S Bottom Pumparound
Primary Fractionator Slurry
Flue Gas
Reformer Effluent
Feed Water
Feed Water
Feed Water
Feed Water
Feed Water
U0(1)
BTU
U0(1)
W
Hr ft2 F
m2 C
35
67 86
30 55
8 15
45 60
200
380 490
170 310
50 90
260 340
25
20
30
25
40
42
140
110
170
140
230
240
Notes:
Coefficients given represent a range of typical coefficients. Where only one coefficient given, typical
coefficients can be higher or lower than the tabulated value.
Coefficient highly dependent on fouling factors.
Steam surface condenser. Refer to Heat Exchange Institute Standards for Steam Surface Condensers.
Condensing Service.
1.
2.
3.
4.
Slide 84
Slide 85
Slide 86
See HEXTRAN Users Guide, located in HEXTRAN program folder
Slide 87
Slide 88
DPSCALAR
1.15 (1)
1.0 (2)
ADVANTAGES OF EHTS
Low initial cost
Low maintenance
Compact size - Save plot space, have small weight and hold-up volume
can debottleneck existing exchangers
SEVEN TYPES OF EHTS
Plate type heat exchangers (PHE)
Spiral heat exchangers (SHE)
Rod baffle exchangers (RBE)
Integral fin tubes (IFT)
Nucleate boiling tubes (NBT)
Turbulence promoters (TP)
On-line mechanical cleaning devices (OMC)
Slide 89
Q = U x A x MTD
PHE - Increase U by turbulence and MTD by countercurrency
SHE - Increase U by turbulence and MTD by countercurrency
RBE - Increase U by allowing higher flow rate
IFT - Increase A of tube surface; Increase U for condensing and vaporizing
NBT - Increase U by enhancing vaporizing heat transfer
TP - Increase U by enhancing HI
OMC - Increase U by reducing fouling; some types also increase HI
Slide 90
Slide 91
WELDED PLATE
PLATE-FIN
Slide 92
Slide 93
Slide 94
Slide 95
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NEAR-WALL MIXERS
(TURBULENT)
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TURBOTAL
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ADDENDUM 5.01
SECTION 5 - PROCESS DESIGN COURSE - HEAT EXCHANGER DESIGN
A shortcut procedure for approximate evaluation of shell and tube exchangers with no change of phase
IMPORTANT NOTE AND WARNING:
This procedure must not be used for the definitive design of heat exchangers. It is a shortcut
technique which makes many simplifying assumptions, especially with regards to shell-side
calculations
The Reynolds Number used in this addendum is dimensional.
INDEX
DESCRIPTIVE MATERIAL
1.
2.
3.
4.
5.
6.
7.
8.
9.
TABLE
1.01
1.02
1.03
1.04
1.05
FIGURES
1.01-1.03
2.01-2.02
3.01-3.02
4.01-4.02
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Fn Factors
Tube Side Correlations
Shell Side Correlations
Thermal Function K (Pr)1/3
SHORTCUT PROCEDURE
SCOPE
The following subsection presents an approximate procedure for evaluating shell and tube exchangers
in which there is no change of phase, (I.e., vapor/vapor, vapor/liquid or liquid/liquid exchangers). The
actual calculations can be made on the calculation form. Each Step of the procedure is explained in the
following paragraphs.
DETAILED PROCEDURE
1. Terminal Conditions and Effective Log Mean Temperature Difference
a. Determine the following temperatures
Inlet temperature of fluid being cooled, T 1
Outlet temperature of fluid being cooled, T 2
Inlet temperature of fluid being heated, t 1
Outlet temperature of fluid being heated, t 2
b. Determine the log mean temperature difference, tm
(T 1 - t 2) - (T 2 - t 1)
tm =
(T1 - t 2)
ln
(T2 - t 1)
c. From Figure 1.01 - 1.03, determine the minimum number of shells required
for a temperature correction factor (Fn) of at least 0.8000.
d. Determine the effective log mean temperature differences, t e
t e = Fn t m
Slide 102
- T 2) + T 2
Slide 103
Slide 104
3.82 As
(L - 0.5) do
(8) Estimate Np, the even number of tube passes per bundle which will give a reasonable tubeside velocity (3-20 fps).
(9) Calculate the linear velocity in the tubes and in the nozzles:
(d N = Nozzle ID)
Np M
V=
19.6 ;mN T d i
VN =
19.6 m dN
(10) Tube side pressure drop and heat transfer coefficient (for water).
a. Tube side heat transfer coefficient, hio for water from approximately 80F
to 180F.
1
R io
Slide 105
h io =
368
do
(Vd i) 0.7
tt
100
0.26
V 2 + 0.158L
V 1.73
+ PN
d i1.27
For PN, See Step 15 (nozzle pressure drop).
(11) For fluids other than water:
a. Calculate the tube side mass velocity, G
G = mV
b. Calculate tube side Reynolds Number, Nre (dimensional)
N Re = d i G
z
Note: At this point, check for a transition problem by calculating N Re using fluid properties
at inlet (or outlet) conditions. An Exchanger design is not valid if the type of flow conditions
changes from viscous to turbulent (or vice- versa) within the unit.
(12) From Figure 2.01 determine the tube side pressure drop correlation factor, Y tp.
Slide 106
mV2
9720
Zw
z
0.14 or 0.25
The exponent 0.14 is for turbulent flow (N Re < 30); 0.25 is for streamline flow (N
Re<
30).
(15) Calculate the pressure drop per tube pass due to turns, Ptr, and the nozzle pressure
drop, PN.
P t = 3
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mV2 ; PN = 2
9270
mV2
9270
(two nozzles)
cz
th.
0.33
k
For hydrocarbons, refer to Figures 4.01 and 4.02.
b. Calculate the tubeside heat transfer coefficient, h
1
h io
R io
Initially assume
Z
ZW
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Y th
o
0.14
cz
k
io.
0.33
0.14
z
z
0.14
rw =
12 kw
(See Tables 1.02-1.03)
7. Iteration, Shell Side
(1) Estimate t f, the average shell side film temperature.
tf =
( t s + t t ) + (U o) (R io + r io + r w + r o) (T s- t t)
2
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(3)
At the average shell side film temperature, determine the following shell fluid properties:
a. For hydrocarbon liquids or vapors: Viscosity, z f.
b. For other fluids: Viscosity, z f; specific heat, c f; and thermal conductivity, k f.
Determine the number of tubes across the centerline of the tube bundle, NTC.
For square tube layout:
N TC = 1.19 (N T)
For triangular layout:
(4)
(5)
(6)
0.5
N TC = 1.10 (N T) 0.5
Determine the outer tube limit, D t.
D t = (N TC - 1)(P t) + d o
Determine shell I.D. as follows:
D = D t / 0.9; except for the following limitations:
1. Minimum D = D t + 1
2. Maximum D = D t + 3
Determine the free width for fluid flow normal to and around the tubes.
One shell pass, W = D - (d o N TC) ; Two shell pass, W = D - (d o NTC )
2
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(11) Calculate the shell side linear velocity, V and the shell side nozzle velocity, VN
V = G/m
Vn =
M
19.6 md2N
(d N = Nozzle ID)
(14) Calculate the shell side velocity head and the nozzle velocity head.
mV 2 N in the nozzles ; mV 2
in the shell.
9270
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9270
mV 2
9270
(Note!: For Disc & Donut baffles, divide NTC by 2.0)
(16) Calculate the pressure drop per shell due to turns, Psr, and the nozzle pressure drop, PN.
=
B 2Ysp N TC N
Psr =
(N B + 1) 3.5 - 2Pb
mV 2 ; PN =
D
9270
(17) Calculate the total shell side pressure drop, Ps.
Ps
mV 2 N
9270
Fs N s (Psr + Psf) + PN
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From Figure 5.02 determine the heat transfer correlation factor, Ysh.
A. Calculate the thermal function:
k
cfzf
1/3
kf
(For hydrocarbon liquids or vapors, refer to Figures 4.01 and 4.02)
b. Calculate the correction factor for the deviation from ideal baffle pitch.
4Pb
D
0.1
1 = h o = B 1 Ysh k
Ro
do
c fz
kf
1/3
4Pb
D
0.1
1 = R
=R
io
+r
io
+R
+r
+r
Uo
If Uo calculated does not agree with Uo assumed, repeat the calculations with a new Uo
assumed until agreement is reached (10%).
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=R
io
+r
+R
+ 0.001
Uc
10. Design Temperatures
Determine the following mechanical design features:
1. The design temperature and pressure of the shell and tube sides.
2. The nozzle size and flange rating for the inlets and outlets on both the shell
and tube sides.
3. The design temperature of the tube sheet, TM.
a.
For coolers (water on tube side), specify the higher result
of the following equations:
TM = TDT +
or
TM = TDT +
b.
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R io (TDS - TDT)
RC
(R io + rio) (TDS - TDT)
Rt
For other exchangers:
(1) When the fluid being cooled is on the tube side
TM = TDT - 0.1(TDT - TDS)
(2) When the fluid cooled is on the shell side
TM = TDT + 0.3 (TDS - TDT)
Problem 5 B-E
Heat Exchanger Design
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