Design of a heat exchangers

A device used for transferring or exchanging

energy in the form of heat between two fluids
is known as heat exchangers
 Classification
Contacting technique Indirect
contact
Direct contact

Tubular [double-pipe, shell and tube, spiral tube]

Plate [plate and frame (gasketed and welded plate),

spiral plate]
Heat Construction
H
exchangers Extended surface [plate-fin, tube-fin]

Regenerative

Single pass [parallel flow, counter-flow, cross flow]

Flow arrangement
Multi-pass [parallel flow, counter-flow, split-flow,
divided flow]

Non-compact [surface area density < 700 m2/m3]

Surface compactness

Compact [surface area density > 700 m2/m3]

Depending upon Mechanical construction

Tubular type
 Plate type

Plate and frame

Spiral Plate
Extended surface

Tube fin
Depending upon flow path
Cross flow
Depending upon pass

Single pass
Single pass

Multi pass
Divided flow
Double pipe heat exchanger
If heat duty < 500 kw or heat transfer area < 5 m2
Shell and tube heat exchanger
Shell and
Tube heat
exchanger
 Design Procedure
(1) Find out the necessary thermo physical property
at mean temperature.
(if the variation of viscosity is large then we would do
the same at the caloric temperature of hot and cold
fluid)
Caloric temperature of hot fluid
TC = T2 +FC (T1-T2)
Caloric temperature of cold fluid
tC = t1 +FC (t2-t1)

Fc = Caloric temperature factor

Caloric temperature factor (Fc)
 co td.
(2) Perform the energy balance and calculate the
exchanger heat duty =
=
Calculated flow rate of another fluid(hot or cold).

(3) Try for 1-1 pass counter current exchanger

-Calculate [LMTD]
-Assume Overall Heat Transfer coefficient (Table 8.2)
-Get area required for the service.
= =
Overall Heat
Transfer
coefficient
 co td.
(4) Tube
Selection: tube
diameter, its
wall thick
ness(in terms of
BWG or SWG)
and the tube
length.

- Find no of
tubes
required
- Calculate
tube side
velocity
- Decide for
tube Pass
co td.
(5) Trial
for multi
pass

-get actual
no of tube
-get shell
ID
-tube get
pitch
 co td.
(6) Selection of baffles
Minimum baffle spacing = Max [Shell ID/5, 5cm]

(7) Estimation of heat transfer coefficients:

(a) Tube side calculation
2
-Flow area per pass =
4
Tube side Re =
-Get corresponding jH (Colburn factor)
-Get hi
-Dettus-Boelter equation may be used
jH for tube side
 co td.
(b) Shell side calculation
-Shell side flow area


=

-Shell side Re =
-Get corresponding jH (Colburn factor)
-Get ho
-Dettus-Boelter equation may be used
jH for shell side
 co td.
(c ) Calculation of overall heat transfer coefficient (Udo)

1 1 1
= + + + +

-Get, and from Table 8.1

 Dart
factor
 co td.
(8) Calculate FT and area required based on
calculated Udo

- area required will be less than available area

 LMTD
correction
(FT )
Co td.
(9) Pressure drop calculation.
(a) Tube side and
(b) Shell side
Basic construction of shell and tube heat exchangers
 shell
It is enclosure and passage of shell side fluid
Circular x-section
Made by rolling a metal plate of suitable
dimension into a cylinder and welding along
the length.
If shell dia is around 60 cm (2 fit) then a pipe is
used.
Material of construction: Carbon steel is
common but it depends upon corrosiveness of
shell side fluid, operating temperature and
pressure.
 The tubes
The tubes provide heat transfer area in shell and tube
heat exchanger.
The fluids are brought into thermal contact through
the tube wall.
Both seamless and welded tube are used.
M/C- Wide variety of materials are used,- like Carbon
steel, SS, Cupronickel, Copper, brass, aluminium, etc.
depending upon the nature of application.
Size: / , / , , . a d . ( o i al dia). 19
mm and 25mm are commonly used
 ..contd.
For clean fluid narrow tubes are used.
Tube wall thickness are designated by BWG
(Birmingham wire gauge) or SWG (British standard
wire gauge).
Tube length- 8, , , , are co o ly used.
Other sizes- , .
Tubes arrangement- triangular or square pitch (p).
p should not be less than 1.25 of tube dia.
Square pitch preferred for easy cleaning of outer
surface.
 Tube sheets
A circular thick metal plate which hold the tubes at
the ends.
Tubes are inserted in into the holes of the tube
sheets.
Holes are slightly larger than OD of the tube.
Tube sheet lay out: arrangement of tube on the
tube sheet in a suitable pitch.
 How to joint the tubes with tube sheet
Expanded and Welded

With grooves:
Mandrel with roller
 co td.
Plain joints:
Expanded
the tube.

For this
purpose-

a) Mandrel
roller
technique

b) Hydraulic
expander

c) Detonation Belled or Welded

technique beaded joint joint
Tube bundle: the cluster of tubes so fixed into the
tube sheets is called tube bundle
Tube bundle:
The Bonnet and the Channel
 Pass partition plate, longitudinal shell pass
baffle, Baffle, Tie rod, baffle spacer
B: 6-13 mm
thick

D:
Horizontal
cut, vertical
cut, disc and
doughnut

- Provides
support
and
increase
turbulen
ce
Horizontal cut,
vertical cut,
disc and doughnut
Notch
Nozzles and impingement plate

To avoid erosion and cavitation

Hold by 2-3 narrow rods or lugs
Caloric temperature factor (Fc)
 T
u
b
e
s
e
l
e
c
ti
on
 S
i
z
e

se
lec
tion
Overall heat transfer cofficient
 Dart
factor
jH for tube side
jH for shell side
 LMTD
correction
(FT )
Data
Sheet