INTERCAMBIADORES DE LIQUIDO A LIQUIDO.

1.1. DISEO MECANICO.

Se presentah aqu los principales aspectos a tener en cuenta para el
diseo mecnico y estructural de los intercambiadores de tubo y
coraza.
1.1.1. Esfuerzos en tubos.
En este apartado se realiza un anlisis de los principales esfuerzos que pueden
presentarse en intercambiadores de calor. Se ha tomado como ejemplo un
intercambiador de tubo y coraza.
Para el diseo y clculo de los tubos y la coraza se utilizan bsicamente los
cdigos TEMA y ASME seccin VIII divisin 2.

1.1.2. Esfuerzos en coraza.

1.1.3. Esfuerzos en cabezales.

Los esfuerzos en los cabezales corresponden principalmente a los
esfuerzos longitudinales descritos en el prrafo anterior. Se presentan

las principales clases de tapas cabezales utilizados en este tipo de

equipos. (tomado de ).

Sujecin tapas planas.

Figura . clases de uniones entre las tapas y la coraza.

Discontinuidad en esfuerzos tapas semiesfricas.

Figura refuerzo de penetraciones en la lmina.

Penetracin en la lmina.

Figura Mtodos para soportar recipientes a presin. (fraas ).

Manholes.

Soportes recipientes.

Figura Tipos de uniones con brida.

Uniones con flanges o bridas.

Figura Manifold.
Manifold
Esfuerzos trmicos.

tubos bifurcados.

Figura

Esfuerzos trmicos.

Figura Pandeo de tubos debido a diferente expansin entre las lminas del
cabezal.

Figura

Figura Mximo esfuerzo de corte en la camisa en funcin de la posicin axial.

1.1.4. Esfuerzos en espejos. PATRON ESPEJO (HEADER SHEET).

Figura Patrn de distribucin de los tubos en los espejos.

Figura Ensamble de los tubos en el espejo.

Figura Espejos.

Heat Exchangers - Design Specifications

EXPERT ENGINEERS AND DRAFTSMEN WITH ON-SITE MANUFACTURING.
Shell & Tube Heat Exchangers are the most common type of heat exchanger used
in the chemical process industry. As its name implies, this type of heat exchanger
consists of a shell filled with a bundle of tubes and sealed at each end by a
tubesheet isolating the tubes and the shell.
A fluid or gas flows through the tubes while another fluid or gas flows through
the shell causing heat to transfer through the tube walls. The set of tubes is
called a tube bundle and may be composed of various tube configurations: plain,
longitudinally finned, etc.
Shell & Tube Heat Exchangers are used in applications where the demands from
high temperatures and pressures are significant.

Bendel designs and fabricates all three types of Shell & Tube Heat Exchangers:
Fixed Tubesheet, U-tube and Floating Tubesheet.
Figura intercambiador con espejos flotantes.
The Fixed Tubesheet design consists of two stationary tubesheets attached to
the shell. The bundle of straight tubes are connected between the tubesheets
and contain baffles to direct the flow around the tubes in order to generate the
required heat transfer. A head assembly is attached to each tubesheet.
The U-tube design consists of straight length tubes bent into a U-shape with
both ends terminating at the tubesheet. The tube bundle is fitted with supports
or flow baffles. The tubesheet/tube bundle is placed in the shell and bolted
between the head flange and body flange. A head assembly is required to direct
the fluid into and out of the tube bundle. This configuration allows for the entire
tube bundle to be removable.
A Floating Tubesheet design is similar to the Fixed Tubesheet design except
one tubesheet is allowed to move axially within the shell while the other
tubesheet is
fixed. This configuration also allows for the tube bundle to be removable.
Bendel is here to serve you and provide the highest quality custom built Shell &
Tube Heat Exchangers to meet your application requirements. We welcome the
opportunity toprovide you a quote.
Please see our contact pageto submit your request.

Figura

Dimensiones caractersticas en un espejo.

Figura

Figura

Figura . Herramienta para expansin de tubos.

1.1.5. Esfuerzos en deflectores.

1.1.6. Boquillas.
1.1.7. Manholes y handholes.
1.1.8. Soportes.
1.2. Software para diseo de intercambiadores de tubo y coraza.
Existehn numerosos programas que se pueden utilizar para el clculo y
diseo de este tipo de intercambiadores. Incluso una solucin simple es
desarrollar su propa hoja de clculo para realizar los principales clculos.
Algunos programas incluyen el diselo trmico e hidrulico, asi como el
diseo mecnico de acuerdo con los estandarees utilizados (ASME, TEMA,
API).
Entre los programas mencionamos los siguientes:

Kamflex.
WTS shell and tube heat exchanger design.
Codecalc ( diseo mecnico)
This package contains 2 different software,
1- Gasketed Plate Heat Exchanger Design (Phex) software Demo
Version
2- VisualBasicPowerPacksSetup from Microsoft website
The Physical properties software is a separate software and can be
downloaded separately form
webbusterz.com or webbusterz.net
Normally the physical properties are generated separately and saved to
a file. The software
then links to the physical properties software and has a feature to import
the physical properties file.
INSTRUCTIONS +
INSTALL THE SOFTWARE IN THE ORDER SET ABOVE
To install please click on the setup.exe file under the software folder. The
installer will attempt to
verify if you have the correct system files to run this software. It will also
attempt to install any missing
system files or framework before installing the software.
If the installation fails then make sure that "Microsoft .Net framework 3.5"
are installed on your computer
before re-installation. Most new computers will have this requirements.
If you don't have this requirement, there is two ways of installing
"Microsoft .Net framework 3.5"
a) Run windows update

OR
b) Download this files from Microsoft website (Microsoft .Net framework
3.5 IS FREE! you don't need to pay for it)
http://www.microsoft.com/download/en/details.aspx?id=21
HEAT-LV-yeh-404

1.2.1. Kamflex.
Esta desarrollado sobre una hoja de clculo de excell.Es de licencia libre
pero tiene un nmero limitado de corridas.

1.2.2. WTS.
1.2.3. Codecalc.
1.3. Ejemplo integral de clculo.
A contiunuacin se presenta un ejercicio tomado de tsis diseo de
intercambiadores, en el cual s erealiza un diseo completo del
intercambiador, aplicando los conceptos estudiados a lo largo de este
captulo.

How to Design a Shell-and-Tube Heat Exchanger

R. Shankar Subramanian
A lot has been written about designing heat exchangers, and specifically, shell-and-tube
heat exchangers. For example, the book by Kern (1) published in 1950 details basic design
procedures for a variety of heat exchangers. Since the publication of that book, with the
advent of computers, design procedures have become sophisticated even though the basic
goals of design remain the same. Because it is possible to specify an infinite number of
different heat exchangers that would perform the given service (heat load), we have to
identify the specific heat exchanger that would do it subject to certain constraints. These
constraints can be based on allowable pressure drop considerations either on the shell-side
or on the tube-side or both, and usually include that of minimizing the overall cost. An
article in 1979 by Taborek (2) outlines how heat exchanger design techniques evolved over
the years since the appearance of the book by Kern. More recent developments are
discussed in numerous articles in the magazine Chemical Engineering.
Here is a step-by-step approach to specifying a new shell-and-tube heat exchanger. We shall
focus on sensible heat transfer, and make extensive use of Chapter 11 in Perrys Handbook
(3). From hereon, references to page numbers, table numbers, and equation numbers are
from Perrys Handbook.
Usually, the flow rates and the physical properties of the two streams involved are
specified, and the temperatures at which the fluids are available are known. If the outgoing
temperature of one of the streams is not specified, usually a constraint (e.g. the temperature
of the cooling water cannot exceed 99) is given. Then, by an energy balance, the outgoing
temperature of the second stream can be calculated along with the heat duty. C
Size
1. The heat duty Q is usually fixed by the required service. The selected heat exchanger has
to meet or exceed this requirement.
2. Make an approximate estimate of the size of the heat exchanger by using a reasonable
guess for the overall heat transfer coefficient. For typical shell-and-tube heat exchangers in
a chemical process or a refinery, Tables 11-3 and 11-4 can be used as a starting point for the
estimate. Using this estimate, calculate the heat transfer area . This will give you an idea of
the approximate size of the heat exchanger, and therefore its cost. Based on the cost, a
determination is made on how much time is worth investing in a detailed design. A
3. Select the stream that should be placed on the tube side. The tube side is used for the
fluid that is more likely to foul the walls, more toxic or more corrosive, or for the fluid with
the higher pressure. Cleaning of the inside of the tubes is easier than cleaning the outside.
When a gas or vapor is used as a heat exchange fluid, it is typically introduced on the shell
side. Also, high
1

viscosity liquids, for which the pressure drop for flow through the tubes might be
prohibitively large, can be introduced on the shell side.
4. The next step is to determine the approximate number of tubes needed to do the job.
Because we have an idea of the approximate heat transfer area, we can write tN
()toANDL=
where is the OD of a tube, and is its length. Both of these are only available in discrete
increments. For example, the length is selected as 8, 10, 12, 16, or 20 feet. Likewise, the
OD is specified as oDL1 131531,,,,,1,1,482844or 1inch. The tubes are typically specified to
be 14 BWG. The most common tube lengths are 16 and 20 feet and the most common tube
OD values are 3/4 and 1 inch. So, selecting one of the values in each set will get you started
in estimating the approximate number of tubes. Check the velocity through a single tube; it
should not exceed roughly 10 ft/s for liquids, to keep the pressure drop under reasonable
constraints, but it should be at least 1 to 3 ft/s (the specific choice depends on the viscosity
as well) to maintain turbulent flow, and minimize fouling. If necessary, adjust the number
of tube passes to get the velocity to fall in this range. You can learn more about tubes and
the tube-side construction from pages 11-40 to 11-41.
5. Determine the shell size. To do this, once the number of tubes is known, select a pitch
and the number of passes. Typical initial guesses are 1 or 2 tube passes. A square pitch is
chosen for reasons of convenience in cleaning the outside of the tubes; when the tubes are
in-line, cleaning is relatively straightforward. The standard choice is a pitch equal to 1.25
inches for 1-inch OD tubes, and a pitch of 1 inch for 3/4 inch OD tubes. Tubes on a
triangular pitch cannot be cleaned by tools, but rather by passing a chemical solution
through on the shell-side. Because triangular pitches allow for the packing of more tubes
into a given space, they are more common when cleaning the outside is not a major issue.
Rectangular pitches are uncommon. Knowing the number of tubes to be used and the
number of passes, you can select the required shell size. You can use the tube count table I
have posted on the course web page for settling on a suitable Shell size. Note that you
cannot find exactly the number of tubes you estimated in this table; so, you should use the
next higher discrete number that is available for the tube count.
An alternative approach is to use the method discussed in Perrys Handbook. For this, you
need to know about the clearance that must be allowed between the tube bundle and the
shell inside diameter. The values of this clearance for different ranges of shell ID values are
discussed in page 11-36. Then, you can use Equations (11.75a-d) on page 11-41 for a
square pitch, or Equations (11.74a-d) on the same page for a triangular pitch. In either case,
you need to specify the number of tube-side passes.
A 1-pass shell is the most common in use, but sometimes a 2-pass shell can be specified to
improve thermal effectiveness. Shells are made from commercial steel pipes up to an
outside diameter of 24 inches. Shells with a larger OD are made by rolling steel plate and
welding.
2

6. You need to estimate the number of baffles to be used and the spacing among them. You
can read about baffles from pages 11-42 and 11-43. Normally, baffles are equally spaced.
The minimum baffle spacing is one-fifth of the shell diameter, but not less than 2 inches,
and the maximum is determined by considerations involving supporting the tube bundle. A
simple formula from Perry for estimating the maximum is inches, where is the OD of a tube
measured in inches. The number of baffles is 0.7574oD/BaffleLoD()Spacing1, where
stands for tube length; the number of baffles must, of course, be an integer. L
7. Now, we are ready to check the thermal performance of the selected heat exchanger.
Calculate the tube-side and shell-side heat transfer coefficients, the tube wall contribution
to the resistance, and the appropriate fouling resistances. See if the calculated matches the
required that you used for estimating the heat transfer area. If it is too small, start all over
again! If it is too large, then the heat exchanger is over-specified for the required thermal
duty. oUoU
If the calculated is too small, you need to examine whether the tube-side or the shell-side
resistance is controlling (sometimes they are comparable). Remember that the smaller the
heat transfer coefficient, the larger the resistance to heat transfer. If you want to improve the
shell-side heat transfer, try adjusting the baffle spacing and shell diameter to increase the
shell-side mass velocity and therefore the Reynolds number. Also, for a given , the pitch
will play a role in influencing the Nusselt number. On the tube-side, the number of tubes
and passes and the inside diameter can be varied to influence the Reynolds number and
therefore the heat transfer coefficient. oUoD
Cost
This topic is discussed in my notes on Shell-and-tube Heat Exchangers. Follow the
procedure outlined there to evaluate the capital cost. Then, evaluate the pressure drop on
the tube-side and that on the shell-side and work out the operating cost. You can use a
figure of $ 0.06/KWH for the cost of electricity needed. By writing off the capital cost over
a reasonable lifetime for a heat exchanger, you can then work out a combined yearly cost
and compare your alternate designs on a cost-basis.
References
1. Kern, D.Q. , Process Heat Transfer, McGraw-Hill, New York, 1950.
2. Taborek, J., Evolution of heat exchanger design techniques, Heat Transfer Eng. 1, No. 1,
15-29 (1979).
3. Perry, R.H., Green, D.W., Eds. Perrys Chemical Engineers Handbook, 7th Edition,
McGraw-Hill, New York, 1997.
4. Phadke, P.S., Determining tube counts for shell-and-tube exchangers, Chemical
Engineering, September 3, 1984, pp. 65-68.