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HEAT TRANSFER

AND
HEAT EXCHANGERS

Slide 1

What We Will Cover

Heat transfer theory-review


Relation of heat transfer theory to shell and tube
heat exchangers
Design of a S&T exchanger--procedure outline
Design features and parameters of shell and tube
exchangers

Slide 2

BASIC HEAT TRANSFER CONCEPTS

Flow of heat behaves like flow of fluids and flow of


electrons

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)

COMPARISON WITH FLUIDS


Fluids:

Heat:

Q
A

= K x (P2 - P1)

(Remember Section 3?)

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

BASIC HEAT TRANSFER EQUATION

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

TOTAL RESISTANCE TO HEAT FLOW - HEAT EXCHANGERS

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

INDIVIDUAL COMPONENTS OF THE TOTAL RESISTANCE


Inside Film Resistance = R io = R i
Inside Fouling Resistance = r io = r i

Ao
Ai
Ao
Ai

Tube Wall Resistance = r w = w / k w


Outside Fouling Resistance = ro
Outside Film Resistance = Ro

Rio + rio + rw + ro + Ro = RT =
w = Wall Thickness, Feet

I
U

Kw = Thermal Conductivity, Btu / Hr x Ft 2 x F


Ft
r = Resistances, Hr x Ft2 x F/Btu

Slide 7

INDIVIDUAL COMPONENTS OF THE TOTAL RESISTANCE

Slide 8

TYPICAL RESISTANCE VALUES

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)

Film Resistances (Each)


(Inverse = h)
Fouling Resistance (Each)
Inverse

Slide 9

THE CONTROLLING COEFFICIENT

Frequently One of the two film coefficients determines the value of the overall
coefficient:

Out side Coefficient,


Inside 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%

Hence h is the Controlling Coefficient, and efforts to improve exchanger


performance should concentrate on this side of the exchanger.

TEMPERATURE DROPS ACROSS THE RESISTANCES

Temperature drop across each of the resistances is


directly proportional to each resistance.
For example, If T2 = 200 and T1 = 80, then total temperature
drop = 120F, and:
Temperature Drop

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

TEMPERATURE DROPS ACROSS THE RESISTANCES

Q
A

A Useful Concept is Heat Flux =

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

= 5817 Btu , and


T across Ro = 5817 x 0.01333 = 77.6 F
Hr x Ft
as shown on that slide.
Slide 12

BACK TO BASICS

Weve looked at basic theory, and discussed Q = U x A x T. In


refinery work we usually know either Q or A, and need to calculate the
other value.
How do we do it?

Either question requires calculating U or T.

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

FLOW PATTERNS AND TEMPERATURE DRIVING FORCE

Slide 14

FLOW PATTERNS AND TEMPERATURE DRIVING FORCE

Slide 15

FLOW PATTERNS AND TEMPERATURE DRIVING FORCE

Slide 16

FLOW PATTERNS AND TEMPERATURE DRIVING FORCE

Slide 17

TEMPERATURE DRIVING FORCE

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 =

(T1 - t2) - (T2 - t1)


(T1 - t2)

LN

(T2 - t1)

This is precisely true only when the heat release curves are straight lines.
Otherwise it is an approximation.

Slide 18

TEMPERATURE DRIVING FORCE


What about mixed flow: Shell and Tube Exchangers?
The complex flow in these units was analyzed mathematically
many years ago, resulting in rigorous equations for a
Correction Factor, Fn. This is multiplied by the LMTD to give
the correct MTDe.
MTDe = Fn x LMTD
Equations are valid only when heat release curves are linear.
Similar relations are available for transverse flow (air fin
coolers, for example).

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

What exactly do we mean by shells in series or shell


passes?

Slide 20

CALCULATION OF Fn - SHELL PASSES

Slide 21

CALCULATION OF Fn - SHELL PASSES

Slide 22

CALCULATION OF Fn

Slide 23

Complex equations simplified to charts


See TEMA Section 7, or Exxon DP IX-D
Applicable only to linear heat curves

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

R n (1 Shell) = <0.8 (unreadable on chart) - Unacceptable


Fn (2 Shell) = 0.95 Use two shells
Slide 24

CALCULATION OF Fn

Since this technique is applicable only to the case of


straight-line heat release, how do we estimate number
of shells and MTDe for other cases?

Slide 25

NON-LINEAR HEAT RELEASE - MTDe SUGGESTION FOR COMPLEX


CASES SUCH AS REFORMER FEED/EFFLUENT

Slide 26

Plot T Vs. Enthalpy


Step Off to Get Minimum Number of Shells
Calculate MTDe for Each Shell (Discuss Later)

NON-LINEAR HEAT RELEASE--MTDe


SUGGESTION FOR CONDENSERS
Plot the condensing curve
Assume cold side is linear and draw in cold side flow pattern
If two shells, assume equal duties

Slide 27

MTDe FOR CONDENSERS (Continued)

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)

Then weight the overall MTDe as follows:

MTDe (Weighted) =

Slide 28

Qtotal
Qzone1 + Qzone2 + Qzone3
LMTD1
LMTD2
LMTD3

+ Qzone4
LMTD4

HEAT TRANSFER COEFFICIENTS

Film coefficients are relatively easy to estimate:

They are a function of


Reynolds Number DV

Prandtl Number (Cp) ()


K

Slide 29

Similarly, pressure drop is a function of Reynolds number and length of


flow path.

HEAT TRANSFER COEFFICIENTS (Continued)


The handouts just examined are suitable ONLY for estimates
of coefficients.

For detailed coefficients on which to base the purchase of an


exchanger, detailed computer calculations are necessary.
Detailed computer calculations examine the effects of many
other parameters, particularly shell-side effects such as
channeling and baffle leakage.

Slide 30

Show Videotape

Slide 31

EXCHANGER DESIGN PROCEDURE


First need to know:
Permissible tube sizes - diameter, gauge, length.
(Frequently set by refinery maintenance department)
The appropriate tube material for the service
The allowable system pressure drops for each stream.

Slide 32

EXCHANGER DESIGN PROCEDURE (Continued)


(1) Assume an overall heat transfer coefficient (Uo) and calculate
tube surface area (A).

(2)

Using the required tube size and length, calculate the number
of tubes.

(3)

Using a reasonable tube-side velocity (0.6-4.5 m/s), calculate


the tubeside cross sectional area required for each tube pass:
Acs = m3/s
m/s

(4)

Determine the EVEN number of tube passes which will most


closely approximate the needed flow area.
# tubes/pass= Acs / single tube cross sectional area
# passes = (# tubes/pass) / # tubes

Slide 33

EXCHANGER DESIGN PROCEDURE (Continued)


(5) Calculate the bundle diameter.
(6) Using a reasonable value of shell-side velocity, calculate the
flow area required between shell-side baffles (gives baffle
spacing).
(7) Calculate tube-side and shell-side pressure drop. If
satisfactory, continue to step 8. If not, modify the exchanger
geometry until pressure drop requirements are met.
(8) Calculate the overall coefficient U.
(9) Compare [U(calculated) x A x MTDe ] with the required value of
Q. If it doesnt agree within about 10%, then change exchanger
geometry and repeat calculations.

Slide 34

HEAT EXCHANGER DESIGN


There are several major types of heat exchanger used in
refineries/chemical plants:
+
+
+
+

Shell-and-Tube
Air-Fin Coolers
Double-Pipe
Plate and Frame

The vast majority are S & T.


We will briefly review usage of the minor types and then
concentrate on the features of shell-and-tube exchangers.

Slide 35

AIR COOLED EXCHANGERS


Used for cooling high to medium temperature streams where
heat recovery is not practical
Consists of tube bundle and motor driven fans
Can be forced or induced draft
Can be countercurrent or cocurrent to air flow
Tubes are usually equipped with circumferential fins
Design outlet temperature is limited by ambient air temperature

Detailed design of air-fins is left to the individual vendors.


Process Designers simply provide duty specification.

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

PLATE AND FRAME

Consists of a series of alternating corrugated plates


pressed together in a compression frame
Process fluids flow on alternate sides of the plates in
channels formed by the corrugations

Units achieve true countercurrent flow

Slide 38

PLATE AND FRAME (Continued)


ADVANTAGES
True countercurrent flow
Highly compact - take up much less space than an equivalent S
&T
Much less expensive than S & T
Very small holdup of process fluids
Small probability for cross contamination of the two fluids

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

SHELL AND TUBE

Most common type in refinery service


Consists of tube bundle within external shell

Not truly cocurrent or countercurrent

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.

FLOATING HEAD COVER FLANGE


CHANNEL PARTITION PLATE
STATIONARY TUBESHEET
CHANNEL
CHANNEL COVER
CHANNEL NOZZLE
TIE RODS AND SPACERS
TRANSVERSE BAFFLES
OR SUPPORT PLATES

16.
17.
18.
19.
20.
21.
22.

IMPINGEMENT BAFFLE
VENT CONNECTION
DRAIN CONNECTION
TEST CONNECTION
SUPPORT SADDLES
LIFTING RING
SPLIT RING

MAJOR TYPES OF S & T UNITS

Fixed tube sheet (uncommon)


Floating tube sheet
+ Pull-through floating head
+ Split ring floating head

U-Tube

Slide 42

SHELL & TUBE EXCHANGERS


Fixed Tube Sheet
Cleanest. Consider only when shell side fouling factor 0.004
(m2*C/W) and shell side can be chemically cleaned.

Because of thermal stresses, this type is generally unacceptable if the


average shell temperature and average tube temperature differ by more
than 10C

U-Tube
Least expensive for high tubeside design pressure. Normally used
when tubeside fouling 0.004. (except for water)

Split Ring Floating Head


This type is normally specified unless very frequent mechanical
cleaning is required

Pull-Through Floating Head


Most expensive type of S & T unit; thermally inefficient because of
shell bypassing. Use when both sides must be mechanically cleaned

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)

Maximum bundle diameter (bundle weight)

Slide 44

TUBE SIDE FLUID


Between the two streams, the stream with the higher:
Pressure
Corrosion Rate
Fouling Rate

Is usually placed on the TUBE SIDE.


When these characteristics apply to both streams, the designer
uses his judgement.

In a service where one stream is changing phase, that stream is


assigned to SHELL SIDE.
In steam-heated vaporizers/reboilers, the condensing steam is
placed in THE TUBES.
Streams with very HIGH VISCOSITY are placed on the SHELL
SIDE (better coefficient).
Slide 45

TYPICAL TUBE DIAMETERS/WALL THICKNESS


1. Oil Service - Ferrous Tubes
Severity of Service

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

Water Service-Nonferrous Tubes

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

2. General Service Alloy Tubes

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

1. Use when ro > 0.004 and shellside


must be mechanically cleaned.
2. Reboilers/Vaporizers

Rotated Square Use as square, but only when flow is


laminar or for vibration problems

Triangular 30

Slide 48

1. Use when ro 0.004


2. Cheapest, so use when applicable

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

BAFFLE ORIENTATION AND CUT


Vertical Chord - Most Common
Condensers, vaporizers and fluids containing suspended solids
Flow is side-to-side

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.

Maximum allowable pitch:


+ For no change of phase, equals shell ID
+ For change of phase
Tube Size

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

These three characteristics are each identified by a single letter


of the alphabet
The result, for example, would be the entry TEMA Type AES
in the specification for the heat exchangers. The type MUST be
specified.

Slide 53

MOST COMMON TEMA TYPES


Front End (Channel) Arrangement
A

Removable channel with removable cover plate


May be used with fixed or removable tube bundles
Tube cleaning easier since no piping disassembly required
Flanged channel end is costly and prone to leakage
Most commonly used

B Removable channel with integral cover


May be used with fixed or removable tube bundles
Used for low tube side fouling services or where chemical
cleaning is specified. Mechanical cleaning requires piping
disassembly
Less costly and less prone to leakage than type A
C Channel integral with tubesheet and with removable cover
Two types: removable bundle and fixed bundle

Slide 54

MOST COMMON TEMA TYPES (Continued)


Shell Types

One pass shell


Most common type used

Two pass shell with longitudinal baffle


Used to improve cross flow correction factor
Equivalent to two shells in series
Maximum shellside pressure drop of 10 PSI
Maximum shellside temperature range of 350 F

G/H Split flow arrangements


Use internal baffles to split the shellside flow
Used to minimize pressure drop

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

MOST COMMON TEMA TYPES (Continued)


Rear End Head
S Floating tubesheet sandwiched between split ring and tubesheet cover
Tubesheet assembly moves within shell cover to absorb expansion of the tubes
Requires removing rear shell cover and floating tubesheet cover for
bundle removal, but results in a smaller diameter shell for the same heat
transfer surface
Usually first choice for removable bundles if mechanical cleaning of shell side
will be infrequent
T Pull through floating head
Floating tubesheet cover bolted directly to floating tubesheet
Does not require rear head disassembly for bundle removal
Results in larger diameter shell for same heat transfer surface than Type S
Preferred where frequent mechanical cleaning of shellside is anticipated
U

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

TEMA HEAT EXCHANGER NOMENCLATURE


DP IX-C Figure 2

Notes:

Slide 57

1.
2.
3.
4.

Commonly referred to as channel or channel box.


Commonly referred to as bundle types.
Recommended for condensers and thermosiphons.
Recommended for thermosiphon reboilers only.

MOST COMMON TEMA TYPES (Continued)

Therefore a TEMA AES exchanger has


A = Removable channel and removable channel cover plate

E = One pass shell (one inlet nozzle and one outlet nozzle)
S = Split ring type floating tube sheet construction

Slide 58

HEAT INTEGRATION PRINCIPLES


Object is overall minimum surface/number of shells
Try to achieve maximum LMTDs
Avoid temperature crosses if possible
Incremental surface is cheaper than more shells
Do not match streams with large differences in
Heat content
Volume

Slide 59

HEAT INTEGRATION PROCEDURES

Identify all heat sources and heat sinks


Prepare T-Q curves for sources and sinks
Match sources and sinks according to
principles
Try different arrangements using typical Uos to
estimate total surface

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

Maximum Pb, Inches


Copper, Aluminum Alloys
26.0
32.0
43.5

Pressure Drop B2
0.30
0.40
0.50

Pressure Drop Fouling Factors, Fs


Fluid
Fs
Liquids
1.15
Gases or condensing vapors 1.00
TUBE SIDE
Pressure Drop Fouling Factors
Tube O.D. Inches
Ft
0.75 Steel
1.50
1.00 Steel
1.40
1.50 Steel
1.20
0.75 Copper Based
1.20
1.00 Copper Based
1.15

Slide 62

Typical Tube Pitch


Tube O.D. Inches
Pitch In
0.75 Triangular
0.9375
0.75 Square
1.0
1.0 Square
1.25
1.5 Square
1.875

TABLE 1.01
DESIGN CONSTANTS FOR SHELL AND TUBE EXCHANGER CALCULATIONS
(Continued)

TUBE SIDE (Continued)


Design Cooling Water Velocity
Permissible
Range, ft/sec (4)

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)

Fresh (inhibited or not)


Salt or brackish

6 to 8
3

3 to 10
3 to 5

Aluminum brass

Fresh (inhibited or not)


Salt or brackish

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

Type 316 alloy steel

All types

10

8 to 15

TABLE 1.02 - EXCHANGER TUBE DATA


do= O.D. of
= Wall
di = I.D. of
Internal Cross
External Surface
Tubing, In. BWG
Thickness In. (3)
Tubing, In.
Sectional Area Sq. In.
Per Foot Length Sq. Feet

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

Light Ends Liquid Coolers (Water)


Distillate Coolers (Water)
Light Ends Reboilers (Steam)
Light Ends Feed/Bottoms

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

kw L L M M NB NP NReNS NT NTC Pb Pt Q RC Rio -

Slide 68

Total exchanger are, ft2


Area/shell, ft. 2
Bundle factor for shell side heat transfer
Bundle factor for shell side pressure drop , dimensionless
Specific heat at caloric temperature, Btu/Lb -F.
Specific heat of the shell side fluid at average
film temperature, Btu/lb-F
Shell I.D., inches
Diameter of tube bundle (outer tube limit), inches
Tube I.D., inches
Tube O. D., inches
Correction factor for log mean temperature difference
(due to partially concurrent flow), dimensionless
Shell side pressure drop correction factor, dimensionless
Tube side pressure drop correction factor, dimensionless
Mass velocity, lbs/sec - ft2
Inside film coefficient corrected to outside area, Btu/hr-ft2-F.
Outside film coefficient Btu/hr-ft2 -F
Thermal conductivity at caloric temperature, Btu/hr-ft2-F/Ft.
Thermal conductivity of the tube metal at average tube
temperature, Btu/hr-ft2-F/ft
Thermal conductivity of the tube metal at average
tube temperature
Tube wall thickness, in.
Tube length, ft.
Mass rate, lbs/hr.
Density, lbs/ft3
Number of shell baffles
Number of tube passes per shell.
Reynolds number, inch-lbs/sec-ft2 - centipoise
Number of shells in series.
Number of tubes across in the bundle
Number of tubes across the center line of the bundle
Baffle pitch, inches.
Tube pitch, inches.
Rate of heat transfer, Btu/hr.
Total resistance (clean) to heat transfer (Note 1)
Inside film resistance corrected to outside area, (Note 1)

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 -

Outside film resistance to heat transfer, (Note 1).


Total resistance (duty) to heat transfer (Note 1).
Inside fouling factor corrected to outside area, (Note 1).
Outside fouling factor (Note 1).
Resistance of tube wall metal at average wall temperature(Note 1).
Free flow area between shell baffles, in. 2
Design temperature of the shell side, F.
Design temperature of the tube side, F.
Tube sheet design temperature, F.
Inlet temperature of fluid being cooled, F.
Outlet temperature of fluid being cooled, F.
Inlet temperature of fluid being heated, F.
Outlet temperature of fluid being heated, F.
Average shell side film temperature, F.
Caloric temperature of the shell fluid, F.
Caloric temperature of the tube fluid, F.
Average tube wall temperature, F.
Over-all clean coefficient of heat transfer, Btu/hr-ft2-F.
Over-all duty coefficient of heat transfer, Btu/hr-ft2-F.
Velocity in the tubes or shell ft/sec.
Velocity in the nozzles, ft/sec.
Free width between baffles, in.
Shell side heat transfer correlation factor.
Shell side pressure drop correlation factor.
Tube side heat transfer correlation factor.
Tube side pressure drop correlation factor.
Viscosity at caloric temperature, centipoises.
Viscosity of the shell side fluid at average film temperature, centipoises.
Viscosity of the tube side fluid at tube wall temperature, centipoises.
Tube pressure drop due to friction, psi/tube pass.
Tube pressure drop due to turns, psi/tube pass.
Total tube side pressure drop, psi.
Shell side pressure drop due to friction, psi/shell.
Shell side pressure drop due to friction, psi/shell.
Nozzle Pressure drop, psi/shell.
Total shell side pressure drop, psi.
Long mean temperature difference corrected for non-ideal countercurrent
flow (Effective temperature difference) F.
Weighted effective log mean difference, F.

FIGURE 1.01 - LMTD CORRECTION FACTORS

Slide 69

FIGURE 1.02 - LMTD CORRECTION FACTORS

Slide 70

FIGURE 1.03 - LMTD CORRECTION FACTORS

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

Tube Diameter (at constant linear velocity)

(D1/D2)1.2

(D1/D2)0.2

Viscosity

(2/1)0.2

(2/1)0.5

Density (at constant linear velocity)

(2/1)0.8

(2/1)0.8

Linear Velocity

V2/V1

(V2/V1)0.33

Tube Diameter (at constant linear velocity)

(D1/D2)2

(D1/D2)0.33

Tube Diameter (at constant weight rate)

(D1/D2)4

D1/D2

NRe > 2,100 (Note 1)

Laminar Flow*

Density (at constant linear velocity

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

HEAT EXCHANGE EQUIPMENT


DESIGN CONSIDERATIONS FOR ALL
TYPES OF HEAT EXCHANGERS

Page

Date

EXXON DESIGN PRACTICES

PROPIETARY INFORMATION -For Authorized Company Use Only

TABLE 1
TYPICAL OVERALL HEAT TRANSFER COEFFICIENTS - Uo

Fluid Being Cooled

Fluid Being Heated

U0(1)
BTU

U0(1)
W

Hr ft2 F

m2 C

Shell and Tube Units with Smooth Tubes


Exchangers
Atmospheric P/S Top Pumparound
Atmospheric P/S No. 3 S/S
Atmospheric P/S Bottom Pumparound
Atmospheric P/S Bottoms
Reduced Crude
Lean Oil
Hydrocracker Effluent
Hydrogenation Reactor Effluent
Hydrofiner Effluent
Debutanizer Effluent
Powerformer Effluent
Acetylene Converter Feed
Regenerated DEA
Catalyst-Oil Slurry
Cracking Coil Vapors
Rerun Still Overhead
Splitter Overhead

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

HEAT EXCHANGE EQUIPMENT


DESIGN CONSIDERATIONS FOR ALL
TYPES OF HEAT EXCHANGERS

EXXON DESIGN PRACTICES

PROPIETARY INFORMATION -For Authorized Company Use Only

TABLE 1 - (Continued)
Fluid Being Cooled

Fluid Being Heated

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

150 210 (2)


100 115
68 75
85 90
43
20 25
80
70
40
110
29 32

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

HEAT EXCHANGE EQUIPMENT


DESIGN CONSIDERATIONS FOR ALL
TYPES OF HEAT EXCHANGERS

EXXON DESIGN PRACTICES

PROPIETARY INFORMATION -For Authorized Company Use Only

TABLE 1 - (Continued)

Fluid Being Cooled

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

Fluid Being Heated

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

HEAT EXCHANGE EQUIPMENT


DESIGN CONSIDERATIONS FOR ALL
TYPES OF HEAT EXCHANGERS

EXXON DESIGN PRACTICES

PROPIETARY INFORMATION -For Authorized Company Use Only

TABLE 1 - (Continued)
Fluid Being Cooled

Fluid Being Heated

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

HEAT EXCHANGE EQUIPMENT


DESIGN CONSIDERATIONS FOR ALL
TYPES OF HEAT EXCHANGERS

EXXON DESIGN PRACTICES

PROPIETARY INFORMATION -For Authorized Company Use Only

TABLE 1 - (Continued)

Fluid Being Cooled

Fluid Being Heated

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

Isobutane Tower Feed


Rerun Tower Feed
Debutanizer Tower Feed
Hydrogenation Reactor Feed
Powerformer Stabilizer Feed

82
80 100
110
75 89
47

520
450 570
620
430 510
270

Slide 83

Section

I X-B

Page

Date

HEAT EXCHANGE EQUIPMENT


DESIGN CONSIDERATIONS FOR ALL
TYPES OF HEAT EXCHANGERS

EXXON DESIGN PRACTICES

PROPIETARY INFORMATION -For Authorized Company Use Only

TABLE 1 - (Continued)
Fluid Being Cooled

Steam Generators
Vacuum P/S Bottoms
Vacuum P/S Bottom Pumparound
Primary Fractionator Slurry
Flue Gas
Reformer Effluent

Fluid Being Heated

Feed Water
Feed Water
Feed Water
Feed Water
Feed Water

Longitudinal Fin Units (Coefficients based on total outside surface)


Heavy Naphtha
Water (6 ft/sec(1.8m/s) in annulus)
Water (3 ft/sec(0.9 m/s) in annulus)
Light Naphtha
Water (6 ft/sec(1.8 m/s) in annulus)
Water (3 ft/sec(0.9 m/s) in annulus)
Clean K3PO4
Water
Clean K3PO4
Foul K3PO4

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

Attachment IX - Safety Factor Selection

Slide 85

Correction Factor for Non-Condensables Calculation Procedure

Slide 86
See HEXTRAN Users Guide, located in HEXTRAN program folder

Attachment IXB - Pressure-Drop-Multiplier Selection


See also DP IX-D p. 40-41
Tubeside Pressure-Drop Multiplier (DPSCALAR)

Slide 87

Attachment IXB - Pressure-Drop-Multiplier Selection (cont.)


See also DP IX-D p. 40-41

Shellside Pressure-Drop Multiplier (DPSCALAR)


Fluid
Liquids
Gases or condensing vapors
(1)
(2)

Slide 88

This value may be increased for extremely dirty service


Use a larger number if vapors are known to be fouling.

DPSCALAR
1.15 (1)
1.0 (2)

ENHANCED HEAT TRANSFER TECHNOLOGIES (EHT)


WHAT ARE THEY?
Technologies used to improve heat transfer performance and reliability of shelland-tube (S&T) heat exchangers, or as alternates to S&TS.

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

Heat transfer enhancement is obtained by increasing heat transfer coefficient, surface


are per unit volume or temperature driving force

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

PLATE TYPE HEAT EXCHANGERS (PHE)


WHAT DOES IT DO?
It is an alternative to shell-and-tube exchangers.
Provides a compact heat exchanger because of high surface area per unit
volume
Provides true counter current flow and high heat transfer coefficients
Typical Applications - Final product cooling (close approach
Tempered water cooling
Low temperature feed/effluent exchanger
Sea water cooling (high metallurgy)
WHAT DOES IT LOOK LIKE?
Multiple streams possible

PLATE & FRAME

Slide 91

WELDED PLATE

PLATE-FIN

SPIRAL HEAT EXCHANGERS (SHE)


WHAT DOES IT DO?
It is an alternative to shell-and-tube exchangers.
Provides a compact heat exchanger because of high surface area per unit
volume
It can handle fluids with high viscosity or high solid particle content
Typical applications Final product cooling (close approach)
Overhead condensers (tower top)
Tar cooling (high viscosity)
Slurry exchangers (solids)
WHAT DOES IT LOOK LIKE?
Two plates rolled together. Spacing maintained by studs.

Slide 92

ROD BAFFLEHEAT EXCHANGERS (RBE)


WHAT DOES IT DO?
It eliminates tube vibration in shell-and-tube heat exchangers
It allows debottlenecking of pressure drop limited exchangers
Typical applications - To correct known vibration problems
Compressor inter/after coolers (high velocity
gas)
Reboilers (high velocity vapor or two-phase)
WHAT DOES IT LOOK LIKE?
Rod baffles replace conventional baffles on a S&T tube bundle

Slide 93

INTEGRAL FIN TUBES (IFT)


WHAT DOES IT DO?
Provides higher heat transfer area compared to plain tubes
Enhances shell side heat transfer coefficient in two-phase applications
Typical applications - Overhead condensers
Compressor inter and after coolers
Good for single or change of phase
WHAT DOES IT LOOK LIKE?
Commonly referred to as low-fin tubes
Note that ID is smaller than plain tube of same OD and thickness
New fin geometries developed and double (inside and outside) enhanced tubes
are available.

Slide 94

NUCLEATE BOILING TUBES (NBT)


WHAT DOES IT DO?
Increases shell side heat transfer coefficient for boiling services
Typical Applications - horizontal reboilers - shell side boiling
vertical reboilers - tubeside boiling
excellent in refrigeration systems (C3 reboilers)
WHAT DOES IT LOOK LIKE?
Coating on inside or outside tube surface (UOP high flux)
special fin geometry (Wieland)

Slide 95

TURBULENCE PROMOTERS (TP)


WHAT DOES IT DO?
Increases tubeside heat transfer coefficient by the following mechanisms:
Thermal mixing through bulk or near-wall flow disturbance
Disruption of thermal boundary layer by changing bare tube surface
Impart swirl to mix flow, change flow direction or both
Typical Applications - Tar oil heating (high viscosity)
Lube oil cooling (high viscosity)
Tubeside condensers (increase HI and AI)
WHAT DOES IT LOOK LIKE?

BULK FLOW MIXERS


(LAMINAR OR TRANSITION)

Slide 96

NEAR-WALL MIXERS
(TURBULENT)

ON-LINE MECHANICAL CLEANING (OMC)


WHAT DOES IT DO?
Keep shell-and-tube heat exchangers clean, on the run
Typical Applications Crude preheat with crude on tube side
Hydrofiner feed on tube side
Cooling water on tubeside
WHAT DOES IT LOOK LIKE?
Devices are permanently installed in the bundle
SPIRELF

Slide 97

TURBOTAL

BRUSH & BASKET

LOGIC DIAGRAM TO SELECT EHT

Slide 98

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Slide 99

HEAT EXCHANGER REFERENCES

Design Practices, Section IX (Heat Exchangers) and


XIV (Fluid Flow)
Global Practices (GPs), Section 6
Heat Exchanger Specialists:
L.A. (Lou) Curcio, (281) 834-7892,
AMERICAS(LACURCI)
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(LESEREB)

Slide 100

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.

LMTD & Caloric Temperature/Properties


Shell Side, Tube Side Flowrates
Fouling
Tube Side Calculations
Shell Side Calculations
Duty & Clean Coefficients
Design Temperature of Tube Sheet
Calculation Form
Nomenclature Summary

TABLE
1.01
1.02
1.03
1.04
1.05

General Design Constants


Exchanger Tube Data
Thermal Conductivities of Metals
Typical Fouling Factors
Typical Overall Coefficients

FIGURES
1.01-1.03
2.01-2.02
3.01-3.02
4.01-4.02

Slide 101

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

SHORTCUT PROCEDURE (Continued)


2. Caloric Temperatures
a. Decide which fluid to pass through the tubes and which through the shell
b. Calculate the caloric temperatures.
For the fluid being heated, t t or t s = 0.4(t 2 - t 1 ) + t 1

For the fluid being cooled, t s or t t = 0.4(T 1

- T 2) + T 2

3. Caloric Properties of Fluids


a. Tube Side of Exchanger
1. At the caloric temperature t t, determine the following tube side fluid
properties:
For water: density, m
For hydrocarbon liquids or vapors: density, m; viscosity, z
For other fluids: density, m; viscosity, z; specific heat, c; and thermal
conductivity, k
b. Shell Side of Exchanger
1. At the caloric temperature, determine the density, m of the shell side fluid.

Slide 103

SHORTCUT PROCEDURE (Continued)


4. Shell Side and Tube Side Flow Rates
The values of the respective flow rates in lb/hr will normally be determined during the heat
and material balance calculations
5. Fouling Factors
a. Decide the tube side fouling factor r i (See Table 1.04)
b. Decide the shell side fouling factor ro (See Table 1.04)
6. Iteration, Tube Side
(1) The heat duty for the exchanger will normally be determined during the heat and
material balance calculations.
(2) Assume U, the over-all coefficient (See Table 1.05)
(3) Calculate total area
A = Q / U te
(4) Calculate the area per shell.
As = A / Ns
If necessary, the number of shells should be increased to meet the maximum
shell size limitations (typically 48). This will require recalculating Fn te, A, A s
(5) Decide the tube metal and determine tube thermal conductivity, kw (See Table
1.03).

Slide 104

SHORTCUT PROCEDURE (Continued)


(6) Choose the tube length, diameter, wall thickness, pitch, and layout
(See Tables 1.01 and 1.02).
(7) Determine the number of tubes as follows:
NT =

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

SHORTCUT PROCEDURE (Continued)


b. Total tube side pressure drop, P t, for water at approximately 100F.
P t = 0.020 F t N s N p

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

SHORTCUT PROCEDURE (Continued)


(13) Calculate the tube side velocity head and the nozzle velocity head.
mV 2N in the nozzles ; mV 2 in the tubes
9270
9270
(14) Calculate Ptf, the frictional pressure drop per tube pass.
Ptf = Ytp L
d

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

Slide 107

mV2 ; PN = 2
9270

mV2
9270

(two nozzles)

SHORTCUT PROCEDURE (Continued)


(16) Calculate the total tube side pressure drop, Pt
P t = F t N s N p (P tf + P tr) + PN
For : Ft , see Table 1.01.
If the pressure drop is reasonably close to the value desired, proceed to the next
step. If it seems too high or low, change number of tube passes and repeat step 9
through 16 until the pressure drop is satisfactory.
(17) From Figure 2.02, determine the heat transfer correlation factor, Y
a. Calculate the thermal function:
k

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

Slide 108

Y th
o

0.14

cz
k

io.
0.33

0.14

z
z

= 1, until tube wall temperature is calculated.

SHORTCUT PROCEDURE (Continued)


c. Estimate the average tube wall temperature, tw
t w = t t + U o (R io+ r io) (t s- t t)
d. At the average tube wall temperature, determine z w and calculate:
Z
zw

0.14

(18) Recalculate h io using this viscosity correction.


(19) Calculate the tube wall resistance, r w

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

Slide 109

SHORTCUT PROCEDURE (Continued)


(2)

(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

Slide 110

SHORTCUT PROCEDURE (Continued)


(7) Estimate the baffle pitch Pb which will give a reasonable shell-side velocity
(3-15 fps). See Table 1.01 for maximum Pb.
(8) Calculate the number of shell side baffles, N B (always a whole number).
N B = 10L/Pb
(9) Determine the free area, S, for fluid flow across the tube bundle between each pair
of baffles.
For Calculating the
Film Coefficient, h

For Calculating the


Pressure drop, P

Segmental Baffles: S = W (Pb - 0.375)


S = W (Pb - 0.375)
Modified Disc &
Donut Baffles:
S = W (Pb - 0.375)
S = 0.85 W (Pb - 0.375)
In each case, 0.375 in. represents the approximate baffle thickness.
(10) Calculate the shell side mass velocity, G.
Disc and donut baffles, G = M/50 x S; Segmental baffles, G = M/25 x S

Slide 111

SHORTCUT PROCEDURE (Continued)

(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)

(12) Calculate the shell side Reynolds number, N Re


N Re = d o G/Z f
(13) Calculate the ratio of the tube diameter to the tube spacing:
do
Pt-do
From Figure 5.01 determine the shell side pressure drop correlation factor, YSP.
Total Shell Side Pressure Drop

(14) Calculate the shell side velocity head and the nozzle velocity head.
mV 2 N in the nozzles ; mV 2
in the shell.
9270

Slide 112

9270

SHORTCUT PROCEDURE (Continued)


(15) Calculate Psf, the frictional pressure drop per shell. Table 1.01 gives values for B2.
Psf

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

For Fs, see Table 1.01.


If the pressure drop is reasonably close to the desired value, proceed to the next step. If it seems too
high or low, change the baffle pitch Pb and repeat steps 7 through 17 until the pressure drop is
satisfactory.

Slide 113

SHORTCUT PROCEDURE (Continued)


Shell Side Heat Transfer Coefficient, ho
(18)

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

See Table 1.01 for B1


8. Duty Coefficient
Calculate Uo, the over-all duty heat transfer coefficient.

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%).
Slide 114

SHORTCUT PROCEDURE (Continued)


9. Clean Coefficient
Calculate Uc, the over-all clean coefficient.
1 =R

=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.

Slide 115

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

Slide 116

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