The transfer of heat to and from process fluids is an essential part of most chemical processes.

The most commonly used type of heat-transfer

equipment is the ubiquitous shell and tube heat exchanger; the design of which is the main subject of this chapter.
The principal types of heat exchanger used in the chemical process and allied industries, which will be discussed in this chapter, are listed below:
1. Double-pipe exchanger: the simplest type, used for cooling and heating.
2. Shell and tube exchangers: used for all applications.
3. Plate and frame exchangers (plate heat exchangers): used for heating and cooling.
4. Plate-fin exchangers.
5. Spiral heat exchangers.
6. Air cooled: coolers and condensers.
7. Direct contact: cooling and quenching.
8. Agitated vessels.
9. Fired heaters.
The word exchanger really applies to all types of equipment in which heat is exchanged but is often used specifically to denote equipment in which
heat is exchanged between two process streams. Exchangers in which a process fluid is heated or cooled by a plant service stream are referred to
as heaters and coolers. If the process stream is vaporised the exchanger is called a vaporiser if the stream is essentially completely vaporised; a
reboiler if associated with a distillation column; and an evaporator if used to concentrate a solution. The term fired exchanger is used for exchangers
heated by combustion gases, such as boilers; other exchangers are referred to as unfired exchangers.

A heat exchanger is a device used to transfer heat between a solid object and a fluid, or between two or more fluids
A shell and tube heat exchanger is a class of heat exchanger designs. It is the most common type of heat exchanger in oil refineries and other
large chemical processes, and is suited for higher-pressure applications. As its name implies, this type of heat exchanger consists of a shell (a large
pressure vessel) with a bundle of tubes inside it. One fluid runs through the tubes, and another fluid flows over the tubes (through the shell) to
transfer heat between the two fluids. The set of tubes is called a tube bundle, and may be composed of several types of tubes: plain, longitudinally
finned, etc.
Vaporizers are devices which heat and vaporize a working fluid. In many cases, they are similar to industrial boilers except that they do not build up
high pressures. Vaporizer units are most commonly used for low pressure heat transfer by incorporating the vaporized stream as the heat exchange
fluid
Reboilers are heat exchangers typically used to provide heat to the bottom of industrial distillation columns. They boil the liquid from the bottom of a
distillation column to generate vapors which are returned to the column to drive the distillation separation.
The process of evaporation is widely used to concentrate foods and chemicals as well as salvage solvents. In the concentration process, the goal of
evaporation is to vaporize most of the water from a solution which contains the desired product.
Fired Heaters
Fired heaters are used for heating up to high temperatures. They are able to reach these high temperatures because they generate energy by
combustion of natural gas, fuel oil, or process off-gas. Fox example, they are used to generate heat for hot oil loops or steam generators (boilers).
Hot oil can be used up to 600F (35C), and fired heaters provide a way to reach those temperatures. High pressure steam, used for utilities, is
approximately 480F (250C).
Because fired heaters carry out combustion, factors such as pollutant emissions and excess air feed need to be accounted for in addition to the
required heat duty. Reducing emissions can incur substantial additional costs.
Common types of fired heaters include cabin heaters, U-tube heaters, and vertical cylindrical heaters.
Basic Concept

There are three mechanisms of heat transfer: conduction, convection, and radiation. In most heat exchangers, convection will be the dominant
mechanism. Conduction and radiation will generally be negligible in large heat exchangers, but radiation will be important in fired heaters.

Heat transfer across a surface by convection is given by the equation:

A shell and tube exchanger consists of a number of tubes mounted inside a cylindrical shell. It is a typical unit that may be found in a petrochemical
plant. Two fluids can exchange heat, one fluid flows over the outside of the tubes while the second fluid flows through the tubes. The fluids can be
single or two phase and can flow in a parallel or a cross/counter flow arrangement.
Baffles - a device used to restrain the flow of a fluid, gas, or loose material or to prevent the spreading of sound or light in a
particular direction. A baffle is designed to support tube bundles and direct the flow of fluids for maximum efficiency.
Baffles are installed on the shell side to give a higher heat-transfer rate due to increased turbulence and to support the tubes thus reducing the
chance of damage due to vibration. There are a number of different baffle types, which support the tubes and promote flow across the tubes. Figure
5 shows the following baffle arrangements:
Single Segmental (this is the most common),
Double Segmental (this is used to obtain a lower shellside velocity and pressure drop),
Disc and Doughnut.

The Number of Transfer Units (NTU) Method is used to calculate the rate of heat transfer in heat exchangers (especially counter current
exchangers) when there is insufficient information to calculate the Log-Mean Temperature Difference (LMTD). In heat exchanger analysis, if the fluid
inlet and outlet temperatures are specified or can be determined by simple energy balance, the LMTD method can be used; but when these
temperatures are not available The NTU or The Effectiveness method is used.
Advantages (Shell and tube)
Can be used in systems with higher operating temperatures and pressures
Shell and tube heat exchanger
It contains tubes inside a shell which is basic and basic design of heat exchangers, it is heavy duty equipment which is widely used in process
industries it can handle higher temperature up to 900 degree centigrades even more.

Temperature of fluids are maximum at wall than the flowing stream and the heat has to redistribute evenly, baffle arrangement make the flow
somewhat turbulent for better heat transfer disturbing the boundary layer and supporting the tube also. In most cases hot fluid like steam if fed
towards tube side and cold fluid is sent into shell side of shell and tube heat exchanger.

Based on the design and pattern of flow of fluid internally it can be classified as single pass, 1-2 pass, 2-4 pass, floating head heat
exchangers(internal floating head and outside packed floating head), fixed tube sheet, U-tube types . It accomplish the duty of condenser when it
function is to cool a stream and similarly it operates as reboiler when used for changing the phase of the stream. It operates in countercurrent and
cocurrent flow pattern and their approach will differ for same equipment. SHELL AND TUBE HEAT EXCHANGER CALCULATOR
Advantages:

Can handle heavy duty and high temperature and pressures

Easy control and operate-able
Disadvantage:

Required large space

Maintenance cost is more
Application: Used as regular heat exchanger for distillation columns, chemical equipments stream cooling and heating purpose. Used internally in
reboilers and evaporators.

Advantages of Shell and Tube Heat Exchangers;

Smaller designs can be lower cost

Much easier to service
O Ring seals also make them cheap to service
A better solution for sea water coolant, or other fluids at risk of clogging in narrow spaces
Can provide better installation options (three pass, two pass header configurations etc.)
Ideal solution for hydraulic power packs, mining machinery, sea water cooled vessels and swimming pool heating.
Advantages Disadvantages
 Widely known and understood since it is the most
common type
Most versatile in terms of types of service
Less thermally efficient than other types of heat
transfer equipment
Subject to flow induced vibration which Can
lead to equipment failure

Widest range of allowable design pressures and
temperatures
Rugged mechanical construction - can withstand
more abuse (physical and process)
Not well suited for temperature cross conditions
(multiple units in series must be used)
Contains stagnant zones (dead zones) on
the shell side which can lead to corrosion
problems
Subject to flow mal-distribution especially
with two phase inlet streams

A Fixed Tube Sheet heat exchanger is the most common type of heat exchanger in all Industries. Mostly used in higher-pressure and Higher
Temperature applications.
Fixed tube Sheet heat exchangers are the one that are very much used in process chemical industries and refinery services, as there is absolutely
no chance for intermixing of fluids. This type of heat exchanger is employed where even slightest intermixing of fluids can not be tolerated. A xed-
tubesheet heat exchanger has straight tubes that are secured at bothends to tubesheets welded to the shell. The construction may have removable
channelcovers , bonnet-type channel covers , or integral tubesheets. The principal advantage of the xedtubesheet construction is its low cost
because of its simple construction. In fact,the xed tubesheet is the least expensive construction type, as long as no expansion jointis required.

Fixed tubesheet heat exchanger cleaning is one of the most important part during the process of heat exchanger. The two tube sheets are
supported by the heat exchanger tube, the tube sheet is thin, and the cost is low, also the inside of each tube can be cleaned. But it is
difficult to clean the shell by the mechanical method, so this kind of heat exchanger can be applied to the not easy scaling and clean fluid.
Fixed tubesheet heat exchanger is more suitable for the media temperature difference is not large, or the temperature is high but pressure of
the shell side is low, also available for the not easy to scale condition with clean media or the condition that can be cleaned chemically in the
shell side.
The fixed tubesheet heat exchanger construction is simple and low manufacturing cost, with easy tube pass cleaning process and wide
range of specifications, fixed tube sheet heat exchanger is widely used in engineering
The shell side cleaning is difficult, for the more dirty or corrosive media, fixed tubesheet heat exchanger should not be used.
Selection of Exchanger Geometry
Tube outside diameter
For the process industry, 19.05 mm (3/4") tends to be the most common.
Tube wall thickness
Reference must be made to a recognized pressure vessel code to decide this.
Tube length
For a given surface area, the longer the tube length the cheaper the exchanger, although a long thin exchanger may not be feasible.
Tube layout
45 or 90 degree layouts are chosen if mechanical cleaning is required, otherwise a 30 degree layout is often selected, because it provides a
higher heat transfer and hence smaller exchanger.
Tube pitch
The smallest allowable pitch of 1.25 times the tube outside diameter is normally used unless there is a requirement to use a larger pitch due
to mechanical cleaning or tube end welding.
Number of tube passes
This is usually one or an even number (not normally greater than 16). Increasing the number of passes increases the heat transfer
coefficient but care must be taken to ensure that the tube side v2 is not greater than about 10,000 kg/ms2.
Shell diameter
Standard pipe is normally used for shell diameters up to 610 mm (24"). Above this the shell is made from rolled plate. Typically shell
diameters range from 152 mm to 3000 mm (6" to 120").
Baffle type
Single segmental baffles are used by default but other types are considered if pressure drop constraints or vibration is a problem.
 Baffle spacing
This is decided after trying to balance the desire for increased crossflow velocity and tube support (smaller baffle pitch) and pressure drop
constraints (larger baffle pitch). TEMA provides guidance on the maximum and minimum baffle pitch.
Baffle cut
This depends on the baffle type but is typically 45% for single segmental baffles and 25% for double segmental baffles.
Materials of Construction
In general, shell and tube exchangers are made of metal, but for specialist applications (e.g., involving strong acids or pharmaceuticals), other
materials such as graphite, plastic and glass may be used.
Mechanical Design
The mechanical design of a shell and tube heat exchanger provides information on items such as shell thickness, flange thickness, etc. These
are calculated using a pressure vessel design code such as the Boiler and Pressure Vessel code from ASME (American Society of Mechanical
Engineers) and the British Master Pressure Vessel Standard, BS 5500. ASME is the most commonly used code for heat exchangers and is in 11
sections. Section VIII (Confined Pressure Vessels) of the code is the most applicable to heat exchangers but Sections IIMaterials and Section
VNon Destructive Testing are also relevant.
Both ASME and BS5500 are widely used and accepted throughout the world but some countries insist that their own national codes are used. In
order to try and simplify this the International Standards Organization is now attempting to develop a new internationally recognized code but it is
likely to be a sometime before this is accepted.
Selection Criteria
In many cases the only way of ensuring optimum selection is to do a full design based on several alternative geometries. In the first instance,
however, several important decisions have to be made concerning:
allocation of fluids to the shellside and tubeside;
selection of shell type;
selection of front end header type;
selection of rear end header type;
selection of exchanger geometry.
Fluid allocation: which fluid goes into the shell side and which into the tube?
Heat Exchanger Fluid allocation advice:

The tubeside has less metal than the shellside. Therefore, capital cost pressures favor putting corrosive fluids in the tubeside. Why?
Corrosive services tend to call for expensive, exotic metals that can withstand corrosion better than plain old carbon steel. Better to minimize
the use of the expensive material by sending corrosive services to the tubeside
Similarly, extreme pressures and temperatures (high or low) can increase the metal thickness or cost of the materials of construction
required. One would rather place extreme P/T services on the tube-side. (It is easier to make the tubes resist high pressures rather than the
entire, larger, shell)
It is easier to keep velocities higher in the tubeside. This is good for services that demand a consistently high velocity, like cooling water
For maintenance, it is easier to clean the tubeside than the shellside. Sometimes you can just open the head of the exchanger and
hydroblast each tube, instead of having to remove the entire tube bundle to get at the shell. Also the inside of tubes is an easier surface to
deal with then the complex surface of the tube bundle outsides and shell insides. Often only chemical cleaning can be reasonably performed
on the shellside. Therefore, the maintenance department would prefer that any fouling/viscous/solid-carrying/dirty streams go into the
tubeside
The shellside tends to be preferred for services with phase changes
Finned tubes can be used to increase the effective surface area the shell-side fluid sees, letting you increase the heat transfer effectiveness
on this side
Film resistance / laminar flow is more easily overcome on the shellside. The shellside tends to experience vortex shedding, and rapid
changes in direction due to tube support baffles. These factors promote mixing between layers of fluid. This means that often, from a heat
transfer perspective, you would prefer to put viscous fluids in the shell-side
There are more variables you can play with in the shellside, allowing you more options to deal with high pressure drops or low heat transfer
co-efficients and to more precisely target certain values. For example, tube baffle support spacing can be changed in small increments. This
flexibility tends to favor putting the fluid with poor heat transfer properties on the shellside. With the tubeside usually all you can do is alter
the number of tube passes to an even number (2, 4, 6, etc.). Going from 2 to 4 passes will roughly double the velocity and increase the
pressure drop by a factor of eight. (P is proportional to Length and to Velocity squared, and doubling the tube passes doubles both L and V
values)
Introduction
The choice of the allocation of the fluid to the shell side or tube side can have a significant impact on the performance, economics and maintainability
of a heat exchanger. For most design work a balanced decision is required as the considerations can lead to opposite preferences. Some general
guidelines are provided underneath:
Fouling
There are many mechanisms of fouling. Allocating the most fouling fluid to the tube side will be more favourable as mechanical cleaning of the inside
of the tubes will be much easier. As the allowable velocity in the tubes is usually higher than at the shell side and a high fluid velocity causes attrition
of the deposits, it is possible to reduce fouling by design.
A fluid with a tendency to foul generally should go on the tube side. Cleaning straight tubes normally is easier than cleaning the shell
even if a relatively large tube pitch or a square tube pattern is used to make the shell side easier to clean.

Mechanical Design Pressure

It will be more economical to put the medium with the highest maximum allowable working pressure at the tube side. If the shell side needs to be
designed for a high pressure the wall thickness will increase making the heat exchanger more expensive.
Put a high-pressure fluid on the tube side. This usually minimizes exchanger cost. The smaller tube diameter has a higher pressure rating
for the same metal thickness compared to the larger diameter shell.

Corrosion
If you need an expensive corrosion resistant material it will be more economical to place the corrosive fluid in the tubes as this will reduce the costs
of the shell material or cladding.
High Viscosity or Low Flowrates
To obtain an economic design high heat transfer coefficients are required. As heat transfer coefficients are much higher for turbulent flow this is the
most important aspect to look into. For a highly viscous medium or a low flowrate turbulent flow can be obtained easier at the shell side. If the
Reynolds number at the shell side is below 200, however, it will probably be cheaper to allocate this fluid to the tube side and use a high number of
tube passes.
Stream allocation is an important decision in heat exchanger design. This decision can impact the heat exchanger life, can also make the difference
between higher and lower maintenance costs. Can also have a high impact on the thermal performance the heat exchanger. This short article aims
to discuss the process of determining the fluid allocations in shell and tube heat exchangers. The decision is made based on the criteria below:

1- Fouling:
Check fouling factors for each fluid.
The fluid/stream with the high fouling factor should be in tubes this makes it easy to clean and prolongs the exchanger life. Placing the fouling fuild
in the tubes also allows better velocity control as increased velocities tend to reduce fouling.

2- Pressure:
Higher pressure fluid/stream is placed in Tube side. This hasan effect on the shell thickess as placing the high pressure fluid in the tubes would
mean that the shell thickness can be reduced.

3- Corrosion rate:
Higher rate fluid/stream is placed in Tube side. In general fewer corrosion resistant alloys are needed if the corrosive fluid is placed on the tube side

4- Viscosity
Fluid/Stream with higher viscosity is placed in the Shell Side as higher heat transfer rates are generally obtained using this practice.

5- Phase change
The stream with phase change is assigned to Shell Side
in steam heated vaporizers/reboilers the condensing steam is placed in Tube Side