Shell & Tube HE

Shell & Tube HE?

• The most versatile type of HE.
• Used in:
Process industries;
Conventional and nuclear power stations;
Steam generators;
• Provide relatively large ratios of heat transfer area to volume.
• Can be easily cleaned.
Shell & Tube HE?
• Built of tubes (round or rectangular) mounted in shells (cylindrical,
rectangular, or arbitrary).
Fixed-Tube HE
Removable U-Tube HE

Floating-Head HE
Shell Types
 Multi Shell
Multi Shell
& & Tube Passes
Tube Passes
 Baffle Types & Geometry
Segmental Cut
• Tube Support  Single & Double = Most used
 Structural rigidity, tube vibration
and sagging prevention  Optimal buffle spacing
Orifice = 40%—60% shell diameter
• Flow Divertion
 Obtaining higher heat transfer  Buffle Cut recommended
coeff. = 25%—35%

Disk and Ring  Triple = low pressure application

Orifice
 In an orifice baffle shell-
side-fluid flows through the
clearance between tube
 Directing flow radially outside diameter and
 Very effective in ΔP to HE conversion baffle-hole diameter
 Potential bundle-to-shell bypass
stream is eliminated
Number of Tubes
• The number of tubes in a HE depends on the
Fluid flowrates; Available ΔP
• The number of tubes is selected such that the
Tube side velocity (for water and alike) = 0.9—2.4 m/s
Shell-side velocity = 0.6—1.5 m/s
• The lower velocity limit corresponds to limiting the fouling, and the
upper velocity limit corresponds to limiting the rate of erosion.
• When sand and slit are present, the velocity is kept high enough to
prevent settling.
Tube Passes
• A pass = flow of liquid from end to end of HE.
Tube passes will be in multiples of two (1-2; 1-4; 2-4; etc)
1-2 = 1 shell passes, 2 tube passes; 2-4 = 2 shell passes, 2 tube passes
Odd number TP have more complicated mechanical stresses

• More TP, more: tube side velocity, heat trans. coeff., ΔP, Ppumping

• More TP, less: fouling

Tube Materials
Consider the following!
• Compatibility
• Corrosivity of working fluid
• Conductivity, weight

Example:
Stainless steel for food processing (corrosion resistance)
Tube Wall Thickness
• The wall thickness of HE tubes is standardized in terms of
Birmingham Wire Gage BWG of the tube
• Small tube diameters
= greater area to volume density (but limited for cleaning purposes
• Large tube diameters
= for condensers and boilers
Tube Outside Diameter
• Most common sizes
=(5/8 in., ¾ in., 1 in.)
• Smaller OD
= higher HTC, more compact HE
• Larger OD
= more rugged, easier to clean
For mechanical cleaning, smallest size is 19.05 mm
For chemical cleaning, smaller size can be used
Tube Length
• Longer TL = fewer tubes, smaller diameter (lower cost).
• Employed in 8 ft, 12 ft, 15 ft, and 20 ft.
• Shell-diameter-to-tube-length-ratio
= 1/5—1/15
• Max. TL is dictated by:
Architectural layouts
Transportation
Tube Length
• Tube elongation due to thermal
expansion causes:
Header plate deformation
Shell wall deformation
• Fatigue strength of tube, header
plate, and shell joint needs to be
considered when using:
Longer tubes
High operating tube side Temp.
Cylical thermal loads
Tube Layout
• 90o layout = lowest HTC, lowest ΔP
• Square Pitch
= used when jet or mechanical cleaning is necessary,
generally not used in fixed header sheet design
(cleaning not feasible)
• Triangular Pitch
= provides more compact arrangement, preferred when
difference in Poperating between two fluids is large
Tube Pitch
• Tube Pitch Selection
 Close Pitch (small Pt/do) = increased shell-side heat transfer & surface compactness
 Open Pitch (large Pt/do) = decreased shell-plugging and ease in shell-side cleaning

• Pitch Ratio Pt/do  1.25 < PT/do < 1.5

When PT/do < 1.25, header plate (tube sheet) becomes to weak for proper rolling of the
tubes and cause leaky joints.

• Tube layout and tube locations are standardized for industrial HE.
 However, these general rule of thumbs can be ‘violated’ for custom designs.
Studi Kasus
 Pendahuluan
Terdapat sebuah unit Pengolahan Gas di daerah Z. Gas dari sumur Z
mengandung 20% lebih CO2 yang harus dihilangkan sampai max 5%.
Proses penghilangan CO2 (Sweetening) di daerah Z tersebut menggunakan
solvent amine. Gas dengan CO2 yang tinggi dikontakkan dengan solvent
amine di kolom absorber. Gas yang bersih akan dijual sedangkan solvent
yang jenuh dengan CO2 akan di-recovery untuk digunakan kembali.
Sebelum menuju kolom regenerasi, solvent akan dipanaskan terlebih dahulu
agar CO2 mudah terlepas dari solvent di kolom regenerasi. Setelah solvent
terbebas dari CO2, solvent kembali dialirkan menuju kolom absorber. Namun
sebelum kolom absorber, solvent terlebih dahulu didinginkan. Proses
pemanasan dan pendinginan ini tidak lain untuk memenuhi kebutuhan
operasi proses di masing-masing kolom.
 Unit Gas Sweetening

• Lokasi Z: Jawa
Barat
 Kondisi Operasi
Kondisi Operasi dan Karakteristik fluida dari masing-masing operasi :
Proses Pemanasan Pendinginan
Suhu In/Out (oC) 76/90 67/55
Tekanan Inlet (kPa) 4238 3585
Flowrate (kg/s) 245 233
Reference Temp (oC) 90 70
Density (kg/m3) 827 1111
Viscosity (mN-s/m2) 1.92 1.92
Thermal Conductivity (W/m- 0.32 0.32
C)
Heat Capacity (kJ/kg-C) 3.30 3.3
Process Condition All Liquid All Liquid
 Pertanyaan
Rancanglah sebuah Heat Exchanger untuk keperluan pemanasan dan
pendinginan tersebut. Pilih lah jenis heat exchanger sesuai dengan
kebutuhan.

Apabila pemanasan menggunakan steam gunakanlah:

P Steam : 453 kPa
T Steam : 139oC (outlet) dan 151.1 oC (inlet)
Process Condition : Condensing
Jawaban Studi Kasus
• Hot Fluid, Steam (Tube side)
• Cold Fluid, Amine (Shell side)

• Shell Side
• ID = 21 ¼ in = 0.53975 m
• Baffle Space = 5 in = 0.127 m
• Passes =1
• Tube Side
• Number and length= 158, 16”0’ = 4.8768 m
• OD, BWG, pitch = (1 in = 0.0254 m) , 13 BWG, (1 ¼ in = 0.03175 m), square
• ID= 0.810 in =
• Passes = 2
 𝑘𝑘𝑘𝑘 𝐽𝐽
• 𝑄𝑄𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 = 245 ∗ 3300 ∗ 90 − 76 𝑜𝑜 𝐶𝐶
𝑠𝑠 𝑘𝑘𝑘𝑘.𝐶𝐶
𝐽𝐽
• 𝑄𝑄𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 = 11,319,000
𝑠𝑠

𝐽𝐽 𝐽𝐽
• 𝑄𝑄𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 = 11,319,000 = 𝑊𝑊𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 ∗ 2403.71 ∗ 151.1 − 139 𝑜𝑜 𝐶𝐶
𝑠𝑠 𝑘𝑘𝑘𝑘.𝐶𝐶
𝑘𝑘𝑘𝑘
• 𝑊𝑊𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 = 389.17
𝑠𝑠
Hot Fluid Cold Fluid Diff
151.1 Higher Temperature 90 61.1
139 Lower Temperature 76 63
12.1 Differences 14 1.9

𝑇𝑇1 − 𝑡𝑡2 − 𝑇𝑇2 − 𝑡𝑡1

𝐿𝐿𝐿𝐿𝐿𝐿𝐿𝐿 =
𝑙𝑙𝑙𝑙 𝑇𝑇1 − 𝑡𝑡2 / 𝑇𝑇2 − 𝑡𝑡1

151.1 − 90 − 139 − 76
𝐿𝐿𝐿𝐿𝐿𝐿𝐿𝐿 =
𝑙𝑙𝑙𝑙 151.1 − 90 / 139 − 76

𝐿𝐿𝐿𝐿𝐿𝐿𝐿𝐿 = 62.0452𝑜𝑜 𝐶𝐶
 0.9926
LMTD Correction Factor Charts
0.2

𝑇𝑇1 −𝑇𝑇2 12.1

• 𝑅𝑅 = = = 0.864 1.00
0.4

𝑡𝑡2 −𝑡𝑡1 14 0.6

𝑡𝑡2 −𝑡𝑡1 14
• 𝑆𝑆 = = = 0.186 0.90 0.8
𝑇𝑇1 −𝑡𝑡1 75.1
1.0

Correction Factor, F
0.80 1.2

• ∆𝑡𝑡 = 62.0452 ∗ 0.9926 1.5

• ∆𝑡𝑡 = 61.5874 ℃
0.70
2

0.60
8

10
0.50
0.00 0.20 0.40 0.60 0.80 1.00 0.8642857
14
P
• Tube side
• Flow rate,
• 𝑎𝑎′𝑡𝑡 = 0.515 𝑖𝑖𝑛𝑛2
𝑁𝑁𝑡𝑡 𝑎𝑎𝑡𝑡′ 0.515
• 𝑎𝑎𝑡𝑡 = = 158 ∗ = 0.283 𝑓𝑓𝑡𝑡 2 = 0,02629156
144∗2 288
𝑊𝑊𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠
• Mass Vel., 𝐺𝐺𝑇𝑇 =
𝑎𝑎𝑇𝑇
389.17 𝑘𝑘𝑘𝑘/𝑠𝑠 𝑘𝑘𝑘𝑘
• 𝐺𝐺𝑇𝑇 = = 14968.08
0.026 𝑚𝑚2 𝑠𝑠 𝑚𝑚2
 𝐷𝐷𝑒𝑒 𝐺𝐺𝑇𝑇
• Re, =
𝜇𝜇
• 𝐷𝐷𝑒𝑒 = 0.99 in = 0.0825 ft = 0.025146 m (Fig 28, pg 838))
151.1+139
• 𝑇𝑇𝑎𝑎𝑎𝑎𝑎𝑎 = = 145.05
2
• 𝜇𝜇𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 = 13.821 𝜇𝜇𝜇𝜇𝜇𝜇. 𝑠𝑠
𝑘𝑘𝑘𝑘
0.025𝑚𝑚∗14968.08
𝑠𝑠 𝑚𝑚2
• 𝑅𝑅𝑅𝑅 = = 27,074.886
13.821∗10−3 𝑚𝑚𝑚𝑚𝑚𝑚.𝑠𝑠
• Shell Side
• Flow area,
𝐶𝐶 ′ 𝐵𝐵
• 𝑎𝑎𝑠𝑠 = 𝐼𝐼𝐼𝐼 ∗ = 0.1475 𝑓𝑓𝑡𝑡 2 = 0,0137031984 𝑚𝑚2
144 𝑃𝑃𝑇𝑇
• Mass Vel
𝑊𝑊 245
• 𝐺𝐺𝑠𝑠 = = = 17,883.211
𝑎𝑎𝑠𝑠 0.0137
 𝐷𝐷𝑒𝑒 𝐺𝐺𝑆𝑆
• Re, =
𝜇𝜇
• 𝐷𝐷𝑒𝑒 = 0.99 in = 0.0825 ft = 0.025146 m (Fig 28)
76+90
• 𝑇𝑇𝑎𝑎𝑎𝑎𝑎𝑎 = = 83𝑜𝑜 𝐶𝐶
2
• 𝜇𝜇𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 = 11.6929 𝜇𝜇𝜇𝜇𝜇𝜇. 𝑠𝑠
𝑘𝑘𝑘𝑘
0.025𝑚𝑚∗17,883.211
𝑠𝑠 𝑚𝑚2
• 𝑅𝑅𝑅𝑅 = = 38,234.865
11.693∗10−3 𝑚𝑚𝑚𝑚𝑚𝑚.𝑠𝑠

• 𝑗𝑗𝐻𝐻 = 100
• C =2.02 kJ/kg C
• K= 0.0233065 W/(m C)
1
𝐶𝐶𝐶𝐶 3
• = 10.046
𝑘𝑘
1
𝑘𝑘 𝐶𝐶𝐶𝐶 3
• ℎ𝑜𝑜 = 𝑗𝑗𝐻𝐻 ∗ 𝜃𝜃𝑠𝑠
𝐷𝐷𝑒𝑒 𝑘𝑘
ℎ0
• = 100 ∗ (0.0233065/0.025146) *10.046
𝜃𝜃𝑠𝑠
• = 924.232
• Tube side
𝐵𝐵𝐵𝐵𝐵𝐵 𝑊𝑊
• ℎ𝑖𝑖𝑖𝑖 = 1500 = 8511.698868
ℎ𝑟𝑟 𝑓𝑓𝑡𝑡 2 ℉ 𝑚𝑚2 𝐶𝐶
ℎ𝑖𝑖𝑖𝑖 8511.698868
• 𝑡𝑡𝑤𝑤 =
𝑡𝑡𝑎𝑎𝑎𝑎𝑎𝑎 + 𝑇𝑇𝑎𝑎𝑎𝑎𝑎𝑎 − 𝑡𝑡𝑎𝑎𝑎𝑎𝑎𝑎 = 83 + (145.05 −
ℎ𝑖𝑖𝑖𝑖 +ℎ𝑜𝑜 8511.698868+924.232
83)
• = 138.97 ℃
• Shell side
• 𝜇𝜇𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 = 1.92 (𝑘𝑘𝑘𝑘𝑘𝑘𝑘𝑘𝑘𝑘𝑘𝑘𝑘𝑘)
0.14
𝜇𝜇
• 𝜃𝜃𝑠𝑠 = =1
𝜇𝜇𝑎𝑎𝑎𝑎𝑎𝑎
𝑊𝑊
• Corrected coeff., ℎ𝑜𝑜 = 924.232 2
𝑚𝑚 𝐶𝐶
• Clean overall coefficient
ℎ𝑖𝑖𝑖𝑖 ℎ𝑜𝑜 8511.70∗924.232 𝑊𝑊
• 𝑈𝑈𝐶𝐶 = = = 833.70 2
ℎ𝑖𝑖𝑖𝑖 +ℎ𝑜𝑜 8511.7+924.232 𝑚𝑚 𝐶𝐶

• Design overall coefficient

𝑓𝑓𝑡𝑡 2
• 𝑎𝑎′′ = 0.2618 (Table 10, pg 843)
𝑙𝑙𝑙𝑙𝑙𝑙 𝑓𝑓𝑓𝑓
• 𝐴𝐴 = 600 ∗ 16 ∗ 0.2618 = 661.83 𝑓𝑓𝑡𝑡 2 = 155,6126𝑚𝑚2
𝑄𝑄 11,319,000 𝑊𝑊
• 𝑈𝑈𝐷𝐷 = = = 787.099 2
𝐴𝐴 ∆𝑡𝑡 155.612∗61.59 𝑚𝑚 𝐶𝐶
• Dirt Factor
𝑈𝑈𝐶𝐶 −𝑈𝑈𝐷𝐷
• 𝑅𝑅𝑑𝑑 = = 7.1 ∗ 10−5
𝑈𝑈𝐶𝐶 ∗𝑈𝑈𝐷𝐷
PERANCANGAN HE DENGAN
HTRI
STEP PENGGUNAAN HTRI
• File  New Shell and Tube Exchanger
• Masuk mode Design
• Isi input summary
• Isi hot fluid properties
• Isi cold fluid properties
• Running
INPUT SUMMARY
STUDI KASUS DIKERJAKAN
DENGAN HTRI
HEAT EXCHANGER 1: PROSES
PEMANASAN
MASUK MODE DESAIN
INPUT SUMMARY
• Asumsi laju alir steam 150 kg/s
HOT FLUID PROPERTIES
• Diatur seperti di bawah, begitu juga dengan Cold Fluid Properties
FLUID PROPERTIES
• Property Package: VMGThermo_Peng Robinson
FLUID PROPERTIES
INPUT VAPOR PROPERTIES
SUMBER DATA
• https://www.irc.wisc.edu/properties/
COLD FLUID PROPERTIES
COMPONENTS
• Karena DEA tidak ada di data HTRI, yang digunakan hanya CO2
LIQUID PROPERTIES
RUNNING
• Tanda lampu merah harus sudah menunjukkan warna hijau
HASIL RUNNING – TAB DESIGN
TUBE LAYOUT
EXCHANGER DRAWING
3D DRAWING
SHELLS IN SERIES
OUTPUT SUMMARY
FINAL RESULTS
FINAL RESULTS
FINAL RESULTS
SHELLSIDE INCREMENTAL
SHELLSIDE FLOW REGION
TUBESIDE MONITOR
TUBESIDE MONITOR
VIBRATION ANALYSIS
RATING
DATA SHEET
TEMA
SPEC
SHEET
TEMA SPEC SHEET
PROPERTY MONITOR
HEAT EXCHANGER 2: PROSES
PENDINGINAN
ASUMSI
• Fluida pendingin = asumsi air tekanan 2 atm (202 kPa) 7 kg/s, karena
diasumsikan fluida pendingin diambil dari air lingkungan sekitar
INPUT SUMMARY
KOMPOSISI HOT FLUID
• Catatan: HTRI tidak menyediakan data untuk Diethanolamine
KOMPOSISI COLD FLUID
PROPERTIES
• Hot Fluid
(vapor dikosongkan)

• Cold Fluid
(vapor dikosongkan)
HASIL RUNNING
TUBE LAYOUT
OUTPUT SUMMARY
FINAL RESULTS (1)
FINAL RESULTS (2)
FINAL RESULT (3)
SHELLSIDE INCREMENTAL
SHELLSIDE INCREMENTAL
SHELLSIDE INCREMENTAL
TUBE MONITOR (1-2)
TUBE MONITOR (3-4)
VIBRATION ANALYSIS
RATING DATA
SHEET
TEMA SPEC
SHEET